CS Piping Fabrication

GENERAL SPECIFICATION FOR CARBON STEEL

PIPING FABRICATION

TABLE OF CONTENTS 1.0 GENERAL 1.1 Scope 1.2 Definitions

2.0 REFERENCED DOCUMENTS 3.0 FABRICATION REQUIREMENTS 3.1 General 3.2 Materials 3.3 Fabrication Tolerances 3.4 Branch Connections 3.5 Threaded Connections 3.6 Flanged Joints 3.7 Welded Attachments 3.8 Welding-General

4.0 QUALITY ASSURANCE 5.0 PREPARATION FOR SHIPMENT 5.1 Cleaning 5.2 Painting & Coating 5.3 Identification of Piping 5.4 Shipping, Handling & Storage

1

1.0

GENERAL

1.1

Scope This specification covers the fabrication, materials, examination and testing of general service carbon steel piping built in accordance with the Pressure Piping Code, ASME B31.31993, (hereinafter referred to as the Code.), for service in a chemical plant and petroleum refinery. The scope or work includes, but is not limited to the following: Providing all materials required for fabricating piping in accordance with drawings (except the items specified as furnished by others) and piping material classes. Fabrication and delivery of piping. Performing nondestructive and other examinations as specified. Fabricating and installing integral structural attachments and pads for branch connections where shown on the drawings. Supplying the required procedures and documentation.

1.2

Definitions OWNER shall mean SONATRACH its authorized representatives. CONTRACTOR shall mean the EPC CONTRACTOR designated by the OWNER to perform the Engineering, Procurement and Construction work for the Project, its sometimes referred to as CONTRACTOR or BUYER. SUBCONTRACTOR shall mean the party selected by the OWNER or CONTRACTOR, to perform the work specified in this Specification, its Subcontractors , sometimes referred to as FABRICATOR and SELLER. BUYER shall mean the party selected by the OWNER to perform the Engineering and Procurement for the Project, its authorized representatives, sometimes referred to as CONTRACTOR. SELLER shall mean the SUPPLIER selected by the OWNER or CONTRACTOR, to perform the work specified in this Specification, or to supply the material/equipment specified in this Specification, its sub-suppliers and its respective affiliates, sometimes referred to as SUBCONTRACTOR. Where "Code" is referred to in this specification, it is defined as the ASME B31 Code for Pressure Piping B31.3-Chemical Plant and Petroleum Refinery Piping.

2.0

REFERENCED DOCUMENTS The materials, design, fabrication, examination and testing shall be in accordance with the issued of the Code, as noted below, including Addenda and Code Cases. Material specifications and standards shall comply with the standards and specification listed in the Code Table and the dated edition of each standard and specification listed in the Addendum to the Code. The applicable portions of the following documents shall form a part of this specification to the extent indicated by references contained elsewhere in this specification. ASME B31.3-1993

Code for Chemical Plant and Petroleum Refinery Piping including the B31.3c-1995 Addenda

2 ASTM

American Society for Testing and Materials

PFI-ES-3

Fabrication Tolerances

PFI-ES-16

Access Holes and Plugs for Radiographic Inspection of Pipe Welds

3.0

FABRICATION REQUIREMENTS

3.1

General

3.1.1

Piping Material Class Index, and Piping Material Class Specification show the design pressure and temperature for each piping system.

3.1.2

National or local codes and standards having jurisdiction over any part of the work covered in this specification shall take precedence over this specification only if their requirements are more stringent than the requirements stated herein.

3.1.3

All discrepancies between the applicable standards, specifications and drawings shall be immediately brought to the attention of the CONTRACTOR for resolution. The decision of the CONTRACTOR shall be binding on all parties.

3.2

Materials

3.2.1

All materials shall be in accordance with the Carbon Steel Piping Material Class Specifications. SUBCONTRACTOR shall not substitute materials in regard to Class, Grade, or Type unless such substitution is submitted to the CONTRACTOR for approval and written permission given to the SUBCONTRACTOR.

3.2.2

Defective materials, including surface defects, shall be replaced.

3.3

Fabrication Tolerances

3.3.1

Dimensional tolerances of fabricated piping assemblies shall not exceed the allowance as stated in Pipe Fabrication Institute (PFI) Standard ES-3; however, the accumulated tolerances between fixed points shall not exceed + 3/8" (+ 10mm) in any direction.

3.3.2

The SUBCONTRACTOR shall be responsible for maintaining proper configuration (including slope) and dimensions of piping as indicated on the CONTRACTOR'S Issued for Construction drawings.

3.3.3

Pipe ends, risers, couplings and flanges shall be true and square for proper alignment.

3.4

Branch Connections

3.4.1

Branch connections shall be in accordance with the drawings, the Piping Material Class Specifications and the Piping Code. Substitutions by the SUBCONTRACTOR will not be permitted unless a request for such is submitted to the CONTRACTOR for approval and written permission given to the SUBCONTRACTOR or CONTRACTOR.

3.5

Threaded Connections

3.5.1

When Teflon thread tape is used, the wrapping shall start approximately two threads from the end of the pipe.

3.5.2

Teflon tape shall be applied so that it will tighten when the joint is screwed together.

3.5.3

Whenever taped joints are broken, all traces of the old tape shall be removed before applying new tape and reassembling the joint.

3.5.4

Teflon tape shall not be used in lube oil or seal oil service.

3

3.6

Flanged Joints

3.6.1

Flanged joints shall be installed so that accurate matching of bolt holes and uniform contact over the entire flange face area can be obtained prior to installing flange bolts.

3.6.2

Flange faces shall be aligned to the design plane to within 1.5 mm per foot maximum measured across any diameter, and flange bolt holes shall be aligned to within 1.5 mm maximum offset. Any damage to contact face which would prevent proper seating of the gasket shall be repaired or the flanges shall be replaced.

3.6.3

When shop installed, bolts shall be installed with an initial compression suitable to "seat" the gasket against the flange face. The initial bolt tension required to set the gasket in place shall be dictated by the flange facing and gasket material involved. Bolts shall be cleaned, free from rust and lubricated.

3.7

Welded Attachments

3.7.1

All lugs, ears, and other attachments for support, guiding and pull-up, and alignment of piping shall be supplied and welded onto the piping prior to stress relieving. Welding shall be in accordance with paragraph 3.8 below.

3.7.2

The materials used for attachment shall be in accordance with the Code and of the same chemical composition as the pipe. Location and details of attachments shall be as shown on the CONTRACTOR'S drawings.

3.7.3

Temporary attachments shall be welded in accordance with an approved welding procedure. All temporary attachments used during fabrication shall be removed flush with the pipe without undercutting. After removal, the flush area shall be examined by the same methods used when making the attachments. Flame cutting is allowed; however, the last 3/8" (10mm) of material shall be removed by grinding.

3.8

Welding-General

3.8.1

All welding, welding procedure specifications and performance qualifications shall be in accordance with the Code and the following.

3.8.2

The Bidder shall include three copies of their welding procedures with the completed bid package.

3.8.3

The SUBCONTRACTOR shall provide the CONTRACTOR with individual welder performance qualification records, if requested in writing.

3.8.4

All welds shall be of sound deposit with a straight line of fusion. The finished weld contour will be uniform, with the toe or edge of the weld merging smoothly into the base material. No undercutting or overlapping is permitted.

3.8.5

Butt welds shall have full penetration and complete fusion with a minimum of weld metal protruding on the inside of the pipe.

3.8.6

Where socket weld valves or fittings are used, the pipe shall be so spaced in the socket that no stresses will be imparted to the weld due to "bottoming" of the pipe in the socket. (Refer to ASME B31.3 Fig. 328.5.2C)

4.0

QUALITY ASSURANCE

4.1

All pipe and fittings shall be free of rejectable imperfections and defects as defined in the material specifications under which the pipe or component was furnished and shall be capable of complying with the visual examination required by the Code.

4.2

Welds shall be examined in accordance with the Code.

4 4.3

The SUBCONTRACTOR is not required to hydrostatically test pipe spool pieces; however, after field installation, piping systems will be hydrostatically tested in accordance with the applicable Piping Code. The SUBCONTRACTOR shall warrant that his work is capable of withstanding the hydrostatic test and shall repair or replace, at SUBCONTRACTOR'S expense, any item that he provided which fails to pass the hydrostatic test.

4.4

The OWNER, or OWNER'S representative, shall be permitted access to the SUBCONTRACTOR'S facility(ies) at all times during the production, shall have access to all documentation and shall be permitted to observe any testing.

5.0

PREPARATION FOR SHIPMENT

5.1

Cleaning

5.1.1

Pipe shall be cleaned internally by a suitable process and blown out with clean air.

5.1.2

Dirt, mud, loose scale, oil, weld slag and grease shall be removed from the exterior surfaces of the pipe.

5.2

Painting & Coating

5.2.1

After inspection, the SUBCONTRACTOR shall clean and paint external surfaces of piping in accordance with the General Specification for Painting and Coating .

5.2.2

Weld ends prepared for field welding shall be painted with Deoxaluminate or approved equal for a distance of four inches from the beveled ends. The Deoxaluminate coating shall be distinguishable from the coating used elsewhere.

5.3

Identification of Piping Each section of fabricated pipe, pipe assembly, or separate fitting shall be clearly marked in a durable manner with appropriate line designation data to indicate its place in the final installed assembly. This marking shall be repeated at opposite sides and ends of each piece of pipe to facilitate reading. Additionally, the pipe shall be marked with a flow arrow indicating the direction of flow.

5.4

Shipping, Handling & Storage Immediately after cleaning and inspection, openings in the pipe shall be sealed as follows:

5.4.1

All openings two inches and smaller shall be securely plugged with plastic inserts.

5.4.2

All weld ends shall be securely capped with plastic and protectors.

5.4.3

Flanged spools (including random lengths) shall have a fiberboard covering securely fastened to the flange, in order to protect the flange facing. The flange facing shall be treated with a suitable rust preventative, other than grease, before sealing.

5.4.4

All miscellaneous items shipped loose shall be suitably packed in wooden boxes having waterproof liners.