Bending and Welding Pro Spec

Fabrication and Installation of Piping

ES-14-602-01

Version No. 10.0 Page 1 of 26

Document last modified: 10 July 2009. PDF Created: 22 January 2010.

This is a Controlled Document that complies with CSBP Limited formatting and Quality

Control guidelines. Please check that this is the latest available version before use.

Title: FABRICATION AND INSTALLATION OF PIPING

Number: ES-14-602-01

Owner: David Zacher

Authoriser: David Zacher

Version Details: Owner/Authoriser changed - was Phil Talbot.

No change to document content.

TABLE OF CONTENTS

1. GENERAL................................................................................................................................. 3

1.1 SCOPE................................................................................................................................... 3

1.2 DEFINITION OF TERMS .................................................................................................... 3

2. STANDARDS ............................................................................................................................ 4

2.1 REQUIREMENTS ................................................................................................................ 4

2.2 STANDARDS ....................................................................................................................... 4

2.3 DEVIATIONS....................................................................................................................... 4

3. DESCRIPTION......................................................................................................................... 5

3.1 MATERIALS ........................................................................................................................ 5

3.2 DRAWINGS ......................................................................................................................... 5

3.3 ACCURACY......................................................................................................................... 5

4. FABRICATION REQUIREMENTS....................................................................................... 7

4.1 MARKING AND IDENTIFICATION.................................................................................. 7

4.2 TRACEABILITY OBJECTIVES.......................................................................................... 7

4.3 TRACEABILITY REQUIREMENTS .................................................................................. 7

4.4 STORAGE............................................................................................................................. 7

4.5 CUTTING AND BEVELLING............................................................................................. 7

4.6 END PREPARATION .......................................................................................................... 8

4.7 WELDING PROCEDURES, SPECIFICATIONS AND PROCEDURE QUALIFICATIONS 9

4.8 THREADING...................................................................................................................... 17

4.9 FLANGING......................................................................................................................... 17

4.10 FIT-UP................................................................................................................................. 17

4.11 BRANCH CONNECTIONS ............................................................................................... 18

4.12 PIPE BENDING.................................................................................................................. 18

4.13 STEAM TRACED PIPING................................................................................................. 18

4.14 STEAM JACKETED PIPING............................................................................................. 18

4.15 ELECTRICAL TRACING .................................................................................................. 18

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5. PROTECTION........................................................................................................................ 18

5.1 PIPE SPOOLS..................................................................................................................... 18

6. ERECTION ............................................................................................................................. 19

6.1 IDENTIFICATION ............................................................................................................. 19

6.2 STORAGE AND HANDLING ........................................................................................... 19

6.3 ASSEMBLY/INSTALLATION.......................................................................................... 20

6.4 FLANGED CONNECTIONS ............................................................................................. 20

6.5 BOLTING ........................................................................................................................... 21

6.6 CONNECTION TO EQUIPMENT..................................................................................... 22

6.7 THREADED JOINTS ......................................................................................................... 22

6.8 TEMPORARY STRAINERS.............................................................................................. 22

6.9 VALVE INSTALLATION.................................................................................................. 22

6.10 UNDERGROUND PIPING ................................................................................................ 23

6.11 INSTALLATION OF EXPANSION JOINTS .................................................................... 23

6.12 TESTING OF PIPEWORK................................................................................................. 23

7. PIPE SUPPORTS.................................................................................................................... 23

7.1 STANDARD PIPE SUPPORTS ......................................................................................... 23

7.2 SPRING HANGERS ........................................................................................................... 24

8. AS-BUILT DATA AND RECORDS...................................................................................... 24

APPENDIX 1 - TYPICAL PROCEDURE QUALIFICATION RECORD (PQR)....................... 25

APPENDIX 2 - TYPICAL WELDING PROCEDURE SPECIFICATION (WPS)...................... 26

FIGURE

Figure 1 Piping Fabrication Tolerances...................................................................................... 6

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1. GENERAL

1.1 SCOPE

This Standard covers the minimum requirements and acceptance criteria for:

a. Fabrication of piping (both in situ and/or at Workshops as assemblies/sub assemblies).

b. Installation.

c. Certification and records keeping.

It is to be used together with ASME B31.3 Chemical Plant and Petroleum Refinery Piping Code,

all Government Statutory requirements and referenced standards.

Should there be conflict between the Works, this Standard, Local Codes, Statutory Requirements or

the latest issue of the Code and other referenced standards, the Contractor shall notify the

Superintendent in writing for resolution. In general the most stringent requirement will prevail.

1.2 DEFINITION OF TERMS

Contractor/Vendor

The Company, which provides the equipment and services, needed.

Sub-Contractor

A third party to be employed by the Contractor/Vendor who has been approved by the

Superintendent in writing.

Superintendent

CSBP Limited or authorised representative. For internal works, the Superintendent shall be the

Responsible Officer.

CSBP

CSBP Limited.

Works

The scope of work that a Contractor is or may be required to execute under an agreement including

variations and remedial work.

Code

Throughout this standard, the words “The Code” shall mean ASME B31.3 Chemical Plant and

Petroleum Refinery Piping.


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2. STANDARDS

2.1 REQUIREMENTS

The Contractor shall perform the Works in accordance with the requirements of:

a. The Statutory Authorities.

b. The Code and other referenced standards.

c. This Standard

2.2 STANDARDS

Standards Association of Australia

AS1210 SAA Unfired Pressure Vessel Code including Supplement 1

AS2022 SAA Anhydrous Ammonia Code

AS2205 Methods of Destructive Testing of Welds in Metal

AS4041 Pressure Piping

American National Standards Institute (ANSI)

American Society of Mechanical Engineers (ASME)

ANSI/ASME B16.11 Forged Fittings, Socket-Welding and Threaded

ANSI/ASME B16.20 Metallic Gaskets for Pipe Flanges - Ring joint, Spiral Wounds and

Jacketed

ANSI/ASME B16.21 Non-metallic Flat Gaskets for Pipe Flanges

ANSI/ASME B16.25 Buttwelding Ends

ASME Boiler and Pressure Vessel Code

Section V Non-destructive Examination

Section VIII Boiler and Pressure Vessels - Divisions 1 & 2

Section IX Welding and Brazing Qualifications

ASME B31.3 Chemical Plant and Petroleum Refinery Piping

American Petroleum Institute

API 601 Metallic Gaskets for Refinery Piping (Double Jacketed Corrugated and

Spiral Wound)

CSBP Engineering Standards

ES-14-102-12 Protective Coatings

ES-14-102-14 Insulation of Piping and Equipment

ES-14-601-01 Basis of Design - Piping

ES-14-602-02 Inspection and Testing of Piping Systems

ES-14-602-05 Underground Piping

ES-14-603-01 Piping Material Specifications

ES-14-603-02 Valve Specifications for Process Isolation

ES-14-603-14 Steam Tracing

EP-08-030-37 Manufacturers Data Report (MDR) – Plant Projects

2.3 DEVIATIONS

There shall be no deviation from the requirements of this Standard unless previous written approval

has been obtained from the Superintendent.


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3. DESCRIPTION

3.1 MATERIALS

The piping materials covered in this Engineering Standard are Carbon Steel, Low Alloy Steel and

Stainless Steel. These are identified in the CSBP Engineering Standard Piping Material

Specifications (ES-14-603-01).

This Engineering Standard shall be used whenever it is relevant to do so for non-metallic pipework

including PVC, HDPE, ABS, Polypropylene and FRP. All such pipework shall be installed,

inspected and tested strictly in accordance with the manufacturer’s instructions and the relevant

Australian Standard.

3.2 DRAWINGS

Piping General Arrangement drawings will be provided showing equipment location and piping

configuration. These drawings shall be adhered to for the erection and installation of pipe spools.

Fabrication of pipe spools shall be in accordance with the Piping Isometric drawings which will be

provided for all lines size DN 50 and above.

Small bore piping DN 40 and below shall be field run in accordance with the General Arrangement

drawings.

Pipe support location plans may be provided for complex piping systems but generally pipe

supports will be located on General Arrangement drawings and Isometric drawings. The pipe

supports shown will be a minimum requirement. Additional supports may be required to comply

with standards and codes.

Where pipe supports need to be manufactured detail drawings will be provided.

Fabrication of pipe spools and supports shall only commence after issue of Approved for

Construction (AFC) drawings. Subsequent revisions of AFC drawings will supersede all previous

drawings and the Contractor’s procedures shall ensure all fabrication is carried out in accordance

with latest revision of each drawing.

3.3 ACCURACY

The Contractor shall verify drawing information and confirm all dimensions before commencing

fabrication.

Dimensional tolerances for completed fabricated piping shall conform to the requirements listed on

Figure 1.


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+3mm MAX FROM INDICATED DIMENSIONS

FOR FACE TO FACE, CENTRE TO FACE,

LOCATION OF ATTACHMENTS, ETC

10% MAX (FOR INTERNAL PRESSURE)

3% MAX (FOR EXTERNAL PRESSURE)

FLATTENING MEASURED AS DIFFERENCEBETWEEN THE MAXIMUM & MINIMUM O.D.

AT ANY CROSS SECTION.

+ 2mm MAX LATERAL TRANSLATION OF

BRANCHES OR CONNECTIONS

+ 1mm MAX ROTATION OF FLANGES FROM THE

INDICATED POSITION, MEASURED AS SHOWN.

1mm MAX OUT OF ALIGNMENT OF FLANGESFROM THE INDICATED POSITION MEASURED

ACROSS ANY DIAMETER.

1

2

3

4

5

Figure 1 Piping Fabrication Tolerances

The Contractor shall ensure the piping meets final assembly requirements as specified on the piping

layout drawings.

Dimensions to tie-in points shall have tolerances in accordance with the following:

a. Linear dimensions ± 1.5mm

b. Nozzles orientation and rotation ±0°30’

(Flange bolt holes shall be aligned within 3mm maximum offset)

c. Angular alignment of flange and branch welding ends 3mm per 1000mm


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4. FABRICATION REQUIREMENTS

4.1 MARKING AND IDENTIFICATION

Items shall be marked for identification and traceability in accordance with Section 4.3. Items

marked for identification shall maintain the marking through all manufacturing stages including

final assembly.

4.2 TRACEABILITY OBJECTIVES

Items and documents shall be marked to ensure means of:

a. Locating the item (traceability record).

b. Locating the quality records generated from purchasing, inspection and testing of the item.

Note: As a minimum the Contractor’s system shall enable traceability between the items and

quality records.

4.3 TRACEABILITY REQUIREMENTS

The Contractor’s fabrication procedures shall ensure that correct materials are used during

fabrication and these shall be submitted to the Superintendent for approval.

Note: Periodic audits may be carried out by the Superintendent to ensure compliance.

4.4 STORAGE

The Contractor shall be responsible for material and equipment received from the Superintendent

or warehouse stocks until the same is installed. Where Superintendent supplied materials are

delivered to the Contractor with documentation such as mill certificates, these shall be incorporated

into the Contractor’s quality records.

Materials received from the warehouse or Superintendent, are to be stored off the ground on

temporary racks or docks to prevent any deterioration until fabricated.

Pipes, fittings, valves and speciality items shall be suitably blanked to protect the ends from

damage and to prevent entry of foreign material. Flanged openings shall be protected as detailed in

Section 5.1.2.

Stainless steel material shall be kept separate from carbon steel during storage and transport.

4.5 CUTTING AND BEVELLING

Pipe shall be cut accurately to the measurements on the drawings or field fit conditions and shall be

worked into place without springing or forcing.


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Stainless steel material shall be segregated from other piping materials during all stages of

machining and fabrication to prevent surface contamination with carbon steel leading to localised

corrosion.

Cutting of pipes shall preferably be done by mechanical means. Flame cutting is acceptable within

the limits as listed below:

a. For carbon steel, flame (or arc) cutting and bevelling is acceptable only if the cut is

reasonably smooth and true and all oxides are removed from the flame-cut surface by

grinding.

b. For alloy steel, flame-cut bevels are acceptable only where machine cutting is not feasible.

After flame cutting approximately 2mm of material must be removed from the surface of

the bevel by grinding.

c. Bevelling by mechanical means (ie. shearing) requires work hardened areas to be removed

as in b. above.

d. Stainless steel and non-ferrous metals shall be prepared by machining, grinding or plasma

arc cutting and grinding.

Grinding of stainless steel and non-ferrous metals shall be done with a non-carbonaceous, iron free

non sulphur bonded grinding wheel. Chipping, filing, cutting with hacksaws or wire brushing

using carbon steel brushes is not permitted on stainless steel.

Burrs and other objectionable defects shall be removed by reaming, machining or grinding.

All cuts shall be made at right angles to the longitudinal axis of the pipe. All pipe ends shall be

remade to the full bore of the pipe.

All cuts shall be carefully bevelled and accurately matched to form a suitable groove for welding

and to permit complete penetration of the welds at all points. Reference is to be made to the

relevant section of the Code.

Defective or damaged weld ends shall be examined in order to determine the nature and extent of

damage. Any bevelled edge of pipe that has been damaged shall be machined to minimum

tolerances. All bevels shall be cleaned to bright metal finish.

Repairs shall not be made on weld preparation of pipes or fittings without written permission from

the Superintendent.

Repairs to weld preparations shall only be carried out using repair procedures which have been

reviewed and approved by the Superintendent. Repair procedures must be submitted in writing for

the Superintendent’s review and approval.

4.6 END PREPARATION

4.6.1 General

Surfaces to be welded shall be ground free of rust. Grinding is to extend 10mm past the toe of the

weld preparation and is to be done immediately prior to welding.


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4.6.2 Butt Welding

End preparation for butt-welding shall be in accordance with ANSI/ASME B16.25.

Cleaning and end preparation shall be in accordance with the Code and in accordance with this

Standard. Stainless steel materials shall be cleaned using degreasing compounds free of chlorides

and sulphur for a distance of 75mm from the prepared edge of inside and outside surfaces.

Stainless steel wire brushes shall not be used for carbon steels.

4.6.3 Fillet Welds

Pipes for insertion in slip-on flanges and for socket-weld joints shall be cut square, to within the

tolerances specified in ANSI/ASME B16.11.

Prior to welding of socket connections, the pipe shall be backed off 1.5mm from the seat of the

socket.

Socket welds and the external welds of field welded slip-on-flanges shall always be carried out

using a minimum of two passes with staggered stops and starts. Shop welded slip on flanges may

require two passes on the external weld, depending on the welding process, to ensure good root

fusion.

4.7 WELDING PROCEDURES, SPECIFICATIONS AND PROCEDURE

QUALIFICATIONS

4.7.1 General

Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR) and the

Welding Procedure Register (WPR) shall be submitted to the Superintendent and approval obtained

before any welding is begun.

The WPR shall identify all WPS necessary for the intended scope of work.

Refer to Appendix 1 and Appendix 2 for sample formats of WPS and PQR forms.

4.7.2 Welding Procedure Specification

Each WPS shall exhibit the name of the originating Contractor and shall be uniquely identified.

The WPS revision number and data shall be included. The technical requirements of this Standard

shall be adhered to in preparing WPS.

Manual, semi-automatic, or automatic electric arc welding processes shall be used on all piping.

The preparation and procedure for welding shall conform to the requirements of the Code.

Welding of carbon steel pipe shall be performed by either: Submerged Arc (SAW), Manual Metal

Arc (MMAW), Gas Tungsten Arc (GTAW), or a combination of these processes. Flux Cored Arc

(FCAW) maybe used for workshop welding only.

Welding processes other than these are prohibited.

Semi automatic and fully automatic welds shall be made with a multi pass technique.


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Weld passes thicker than 10mm are prohibited.

Welding of stainless steel or alloy shall be performed by either Gas Tungsten Arc, or Manual Metal

Arc Welding, or a combination of these processes. Root pass must be made using Gas Tungsten

Arc process with inert gas purge on inside of pipe. Flux Cored (FCAW) and GTAW wire (brand

name TGX) may be used at the discretion of the Superintendent.

Procedure for welding dissimilar metals (e.g. carbon steel to stainless steel 304L or 316L, etc) shall

be submitted to the Superintendent and approval obtained prior to any welding.

Welders qualified, as per Section 4.7.7 of this Standard shall perform all welding.

4.7.3 Qualification of Welding Procedure

All WPS shall be qualified in accordance with the Code and ASME Section IX and this Standard.

Previously qualified WPS may be submitted for the Superintendent’s approval. Qualification shall

be performed on pipe, not plate.

If a weld procedure includes PWHT, the weld procedure qualification tests shall include a hardness

survey. Acceptance criteria shall be the same as described in Section 4.7.13. The hardness survey

shall be performed using a 5-kg Vickers tester in accordance with AS2005.

4.7.4 Welding Procedure Essential Variables

In addition to the essential and supplementary essential variables listed in ASME Section IX

articles 2 and 4, the following shall be deemed essential variables:

a. For welding procedures qualified for low temperature carbon steel (impact tested carbon

steels) and low temperature low alloy steels (also impact tested) and any change in welding

consumable brand name, manufacturer, classification or country/region for base metals.

b. Any change in wire flux combination for SAW. Any decrease in preheat for material

thicknesses greater than 6mm.

c. Any change in current clarity or type (AC or DC).

d. The omission of back gouging or back grooving.

e. Variables during welding must remain same as used during procedure qualification (ie.

parameters I, V (speed) and U shall remain constant).

f. For P3 and P4 materials, hardness test on site shall be in accordance with those values

obtained or recorded during procedure qualification.

4.7.5 Impact Test Requirements

Welding procedures for all P1 Group 1 and Group 2 steels developed for use in low temperature

service (less than 0°C design minimum temperature as specified by the applicable piping class)

shall include qualification by impact test. Impact test specimens shall be tested at a calculated

temperature, using an assumed design temperature of minus (-) 46°C, whilst all other test

requirements shall be in accordance with the Code. Three specimens shall be tested from each


ES-14-602-01



sample area and the average energy value obtained from them shall be at least equivalent of 20

joules obtained from full size specimens. One specimen may show a lower equivalent value, but

this shall not be lower than 16 joules.

Impact tests for welding procedures for other materials, the assumed minimum design temperature

used for determining the impact test temperature shall be (-) 46°C or the piping minimum design

temperatures which ever is lower. Weld metal specimens shall be located as near as possible to the

pipe surface. Two specimens shall be located near the surface containing the last pass of the weld,

and one specimen near the opposite surface. The specimen location shall be identified in the

report.

Specimen sides, which are perpendicular to the base of the notch, shall be 10mm. Depth of side

containing the base of the notch shall be the greatest possible of 10mm, 7.5mm, 5mm and 2.5mm

depending on the pipe wall thickness. Test temperature of sub-size specimen shall comply with the

Code.

The notch shall be contained in the weld metal at approximately the centreline of the weld and the

base of the notch shall be perpendicular to the surface of the plate. Before machining the notch, the

specimen shall be etched to distinguish the weld metal from the parent metal and to ensure that the

notch is correctly located. Machining of the bottom of the notch shall be done with care.

The Superintendent shall witness impact testing of welding procedure qualification specimens.

4.7.6 Weld Maps

Weld maps shall be prepared for each assembly/sub-assembly fabricated identifying the welder,

date welded, nature and extent of NDE performed, defects/re-welds, re-examination, if any, results

of NDE for each weld of the assembly/sub-assembly.

Weld maps shall also contain information on hydrostatic testing viz. test pressure, medium, date

and duration of testing and the results.

All the above information shall be properly documented and up-to-date records maintained by the

Contractor. Final copies of all the above referenced documents shall be issued to the

Superintendent within seven (7) days of completion of fabrication.

4.7.7 Qualification of Welders and Operators

All welders and welding operators shall be qualified in accordance with the requirements of ASME

Section IX and this Standard prior to commencing any work including tack welds or temporary

attachments. The performance test must include 6G position. Welder qualification certificates

including evidence of re-qualification and revalidation shall be maintained for the Superintendent’s

approval and inspection.

All welder qualification tests must be carried out to an approved welding procedure specification

(WPS).

Previous qualifications may be submitted for approval provided that the holder(s) of the

qualification(s) have carried out similar work within the last six months.


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Each welder shall be assigned a unique symbol which will identify, on a weld map, all welds

performed by that welder.

4.7.8 Welding Types

All welds shall be full penetration welds except:

a. reinforcing pad, peripheral fillet welds,

b. structural attachment fillet welds and

c. socket welds, which shall be welded to the Code.

All butt welds DN 50 and below shall be made with the Gas Tungsten Arc process.

4.7.9 Welding Proximity and Location

The number of welds in the fabricated spools shall be kept to a minimum by using the longest

practical pipe lengths. The minimum distance between girth welds, shall be six times the pipe wall

thickness or 100mm, whichever is lesser.

Seam orientation of welded straight pipe to pipe and pipe to fittings shall be such that at

circumferential welds, the longitudinal welds shall be staggered, by 30 degrees left and right of the

centre line. As a minimum the circumferential distance between the staggered joints shall be

50mm or 6 times the pipe wall thickness, whichever is lesser.

Attachment welds, should be separated from pressure welds by a distance not less than 50mm,

weld toe to toe.

Welds for non-pressure attachments should not cross- existing main pressure welds. Where this is

unavoidable, the main pressure weld shall be ground back flush with the parent pipe and the area

examined for defects, using MPI/DPI inspection procedures. Subject to satisfactory acceptance of

the inspection, fabrication of the attachment weld shall be carried out in accordance with welding

procedures as approved for the main pressure weld.

Attachment welds shall not penetrate through the pressure pipe.

4.7.10 Preparation for Welding and Alignment

Earth connections shall be located as close as possible to the joint to be welded. “G” type welding

clamps shall be used for connecting pipe to earth.

The ends of pipe and fittings shall be accurately aligned and properly spaced as indicated in the

appropriate welding procedure. A pipe clamp or other device shall be used as required to obtain

accurate alignment and spacing.

The bore alignment for the butt joints shall be in accordance with the Code except that the

maximum internal trimming shall be 1:4.

Preference shall be given to the use of line-up clamps or bridge pieces for assembling components

to be welded.


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In addition to the requirements of the Code, all pipe joint preparations and welds shall be subject to

the following:

a. Backing rings are not permitted.

b. Back welds shall be examined visually for defects and, if found to be defective, shall be

removed.

Branch connection joints shall be prepared so as to permit full penetration welds of a quality

comparable to the circumferential welds in the same piping system.

When thermal cutting is performed to prepare edges, to remove attachments or defective material,

or for any other purpose, the material shall be reheated using the preheat schedules established in

the qualified welding procedures.

Welding shall not be carried out when the surfaces to be welded are wet from any cause.

Galvanised flanges, supports, clips and the like shall not be welded to or come into direct contact

with stainless steel.

All valves, piping speciality items, equipment and instruments which may be damaged by the heat

of welding shall be protected by dismantling and be re-assembled upon completion of welding and

heat treatment.

All sections of tacked or welded pipe shall be sealed prior to installation to prevent foreign matter

from entering such sections.

A qualified welder using the qualified welding procedure, which will be utilised for full welding of

the joint, shall make tack welds. Temporary tack welds shall not touch the root gap or root face and

shall not be part of a final joint weld up. Line-up clamps shall not be removed until the root pass

has been completed.

There shall be no field-welded attachments to stainless steel or alloy piping or to any vessels

without Superintendent’s approval and an approved welding procedure as described.

c. Cold spring is permitted only if it is shown on piping isometrics. If shown on piping

isometrics, this operation shall be withheld until the entire line between anchors has been

connected together in all directions up to the last closing length of pipe at the anchor and all

guides and supports are in place. The cold spring shall be pulled at one anchor with the pipe

firmly secured at the anchor on the opposite side of the section to the cold spring. Cold

springing is not permitted at rotating equipment nozzles.

d. Anchors/welded attachments on pipes shall be in accordance with Standard Pipe Support

Details and the respective piping isometrics.

Each welding bead shall be thoroughly cleaned of all scale and slag by chipping and/or grinding

and wire brushing immediately after completion of the weld and prior to the application of

succeeding beads. The width of the completed weld shall extend a minimum of 3mm greater than

the width of the original groove. For reinforcement, the bead shall extend not less than 1.5mm and

not more than 3mm above the surface of the pipe. Penetration of depth of fusion shall extend the

full depth of the pipe wall, including both the bevelled and straight portions. The bead shall be


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smooth in appearance and contain no valleys, indentations or undercut on the crest or at the edge.

The completed weld and adjacent pipe shall be cleaned of all oxide, slag and spatter to allow proper

application of protective coating.

The entire root bead shall be made with the pipe in a stationary position. Movement of the pipe

during manual welding of the root beads shall be kept to an absolute minimum.

Welding shall be a continuous operation. Welding should not be discontinued before the root run

and the next two successive passes are complete.

If welding has to be interrupted the welds area shall be covered to permit slow cooling. Before

resumption of welding on a weld cooled to ambient temperature the area shall be inspected visually

for the presence of cracks. The welds shall be subjected to magnetic particle or dye penetrant

examination to determine acceptability. Cracks shall be completely removed prior to any further

welding.

All welding necessary for in-place assembly and erection shall be in accordance with applicable

paragraphs of this Standard.

The areas from which temporary attachments have been removed shall be dressed smooth.

Stray arc strikes are forbidden.

4.7.11 Welding Consumable Control and Handling

The Contractor shall establish and implement procedures for receiving, storing, conditioning and

issuing consumables.

4.7.11.1 Receipt Storage and Identifications

All consumables shall be received and clearly identified in sealed containers.

The consumables shall be stored in sealed, moisture proof containers at a protected convenient dry

location at a temperature of not less than 20°C.

Consumables shall be identified at all times during storage, conditioning, distribution and at weld

stations. Identification shall include manufacturer, grade and batch number.

4.7.11.2 Drying of Electrodes

Prior to use, MMAW electrodes shall be dried in accordance with the manufacturer’s

recommendations.

After drying, the electrodes shall be transferred to heat storage cabinets maintained at 120°C

minimum for later use.

No electrodes shall be redried more than twice.


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4.7.12 Protection of the Welding Environment

The welding area shall be protected at all times against adverse environment conditions, water

spray, mist, drips or wind exceeding 8kph. Welding shall not proceed when the work is exposed to

such conditions.

Prefabrication areas for carbon and stainless steel shall be physically separated to prevent

contamination of stainless steels. When grinding or welding carbon steel pipe and supports

protection of any adjacent stainless steel shall be provided.

4.7.13 Heat Treatment of Welds

Heat treatment procedures, pre-heat and post-heat shall comply with the Code requirements. In the

case of Ammonia Liquid, Chlorine-Dry Liquid, Chlorine-Dry Gas, and Synthesis Gas services, heat

treatment procedures shall comply with AS4041 or the Code, whichever is more stringent. Details

shall be included in the Weld Procedures.

All welds on carbon steel and low alloy steel piping for the following services shall be heat-treated

after welding.

• Ammonia Liquid at any temperature.

• Chlorine-Dry Liquid at any temperature.

• Chlorine-Dry Gas at any temperature.

• Synthesis Gas services at any temperature.

• Ammonia Gas services where there is a possibility condensate will form under normal

operating conditions.

• Sodium Hydroxide (Caustic Soda) of 30% to 50% strength at any temperature.

• Sodium Hydroxide (Caustic Soda) less than 30% strength if the normal operating

temperature is greater than 60°C.

• 30% Sodium Cyanide Solution if the normal operating temperature is greater than 60°C.

Note: Where heat treatment is recommended for a particular service and material combinations

covered by NACE or other anti-corrosion standards, heat treatment shall be performed in

accordance with the standard.

Heat treatment shall be in accordance with the requirements of the Code clause 331.1.7 and the

following:

a. All hardness tests on stress relieved welds shall be carried out using a standard Equip tester.

A qualified metallurgist or an experienced tester approved by the Superintendent shall

perform the tests.

b. The criteria for hardness tests on local and shop stress relieved welds shall be as per the

Code plus the following:

(i) P1 materials shall not exceed 225 Brinell for ammonia and chlorine

service and 248 Brinell for other services.

(ii) For P4, P5 and P6 alloy steels, where the wall thickness is less than that

for which a maximum hardness is specified, the maximum hardness shall

be specified as for the material with the thicker walls.


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(iii) For service and material combinations covered by NACE or other anti-

corrosion standards and not covered by (i) and (ii) above, the hardness

limits in these standards shall apply.

(iv) For other materials and services not covered by (i) to (iii) above, the

maximum hardness shall not exceed 248 Brinell.

Note: For b. (iii) the hardness limit may also apply to piping and welds which are not heat

treated.

c. If heat treated in a furnace, all piping shall be properly supported in the furnace during heat

treatment to eliminate warpage and other distortion.

d. The cooling rate from the stress relieving temperature shall be in accordance with the

requirement of ASME Section VIII.

e. All machined surfaces shall be protected by a suitable paint or compound or by any other

method (eg. gasket and a counter flange for flanged surface) to prevent damage from

scaling.

f. Unless otherwise approved in writing by Superintendent, no welding, hammering or cold

forming is permitted following heat treatment.

g. All valves, piping specialties, equipment and instruments, which may be damaged by the

heat from heat treatment, shall be protected by dismantling and be re-assembled upon

completion of heat treatment.

Valve bodies (2 or 3 piece ball valves) or bonnets to be removed shall be match-marked

prior to disassembly to ensure that they are reassembled back into the same location and

orientation. Seats shall be gently lapped where necessary to remove any scale and new

bonnet/body gaskets fitted when reassembling the valves.

All welds or attachments required including pipe supports or reinforcing plates, etc, shall be made

before heat treatment. No welding is permitted after heat treatment.

4.7.14 Filler Materials

All filler materials shall deposit an alloy whose chemical, physical and corrosion resistance

properties correspond to the base material and shall satisfy requirements of the Code Standards.

Consumables for use on carbon steel lines for sodium cyanide solution shall have low sulfur

content.

4.7.15 Weld Repairs

No repair shall be undertaken without first notifying the Superintendent of the requirement to

repair, and seeking his approval of the proposed repair procedure.

Repair of welds shall be done in such a manner as not gouge, groove, or otherwise reduce the

adjacent base metal thickness.


ES-14-602-01



Repairs or replacement welds shall be performed in accordance with the original welding

procedure, including pre-heat and post weld heat treatment if originally required.

Inspection and NDT of repairs shall be as originally required for the initial welds.

A weld defect that has to be repaired shall be removed to sound metal. Repair welds shall be made

by qualified welders Welding procedures used shall be in accordance with the Code and ASME

Section IX.

4.7.16 Inspection and Testing/Welds

Non-destructive examination of welds shall be carried out in accordance with the requirements

detailed in CSBP Engineering Standard Inspection and Testing of Piping Systems (ES-14-602-02).

4.8 THREADING

The minimum pipe schedule for threading pipe shall be Sch 80. For carbon steel and low alloy steel

threaded nipples the pipe schedule shall be Sch 160 minimum. Stainless steel threaded nipples

shall be Sch 80 minimum.

Threading of steel pipe shall preferably be done after bending, forging, heat treating or welding

operations. Where post-fabrication threading is very difficult and threads are cut first, they shall be

fully protected during such operations. Threads shall be concentric with the outside pipe and shall

conform to ANSI B1.20.1 (NPT).

Screwed pipe shall be reamed after cutting and threading. The threads shall be full cut and after a

tight connection is made, no more than three threads shall remain exposed. All cutting oil and

metal chips shall be cleared off the pipe prior to assembly.

Screwed pipe joints shall be made up using a suitable tape, which has been approved in writing by

the Superintendent.

Screwed connections shall not be back welded unless specified on designs drawings, or approved

by the Superintendent. It is recommended that back welded threaded connections be replaced with

socket weld connections if possible.

4.9 FLANGING

Flange bolt holes shall straddle the principal centre lines, unless other orientation is shown on the

design drawings.

4.10 FIT-UP

Misalignment or poor fit-up in excess of the values specified in Section 3.3 is not acceptable.

For compression-type fittings, use proper tools and torques as specified by the manufacturer to

ensure a leak-tight joint. To avoid damage or distortion of the fitting, do not over-torque the fitting

nut.


ES-14-602-01



4.11 BRANCH CONNECTIONS

Lines that connect to the main line or header, including instrument connections, vents and drains

are considered branch lines. All branch connections shall be made in accordance with the

respective Piping Material Specification. All stub-ins shall meet the requirements of the Code.

4.12 PIPE BENDING

Piping shall be bent only at locations shown on isometric drawings. In all other cases welding

elbows shall be used. If the pipe to be bent contains a longitudinal weld, this weld shall be located

in the neutral zone (pipe central axis).

Pipe bending shall be in accordance with Code requirements. A minimum bend radius of five (5)

diameters shall be used. Wall thickness of completed bends shall not be less than that required for

the pressure and temperature plus any corrosion allowance. Bends are permitted provided tensile

and impact properties are not impaired by the bending operation. Butt weld joints shall not be

located in the curved section of bent pipe. Weld repair of cracks in pipe bends will not be

accepted. Cold bending of pipe DN 40 and smaller is permitted. Induction bends for larger pipes

may only be used with the approval of the Superintendent.

4.13 STEAM TRACED PIPING

Steam traced piping shall be fabricated and installed in accordance with CSBP Engineering

Standard Steam Tracing (ES-14-603-14).

4.14 STEAM JACKETED PIPING

Steam jacketed piping shall be fabricated and installed in accordance with the design drawings.

4.15 ELECTRICAL TRACING

Electrical tracing and its associated electrical supply and control shall be installed in accordance

with the design drawings and manufacturer’s instructions.

5. PROTECTION

In general, all pipes, fittings, valves, instruments and all other equipment including all accessories,

issued to the Contractor for erection shall be protected from normal weather conditions, corrosion

or damage, prior to mechanical completion

5.1 PIPE SPOOLS

.After fabrication and inspection, all pipe spools shall be protected in the following manner:

5.1.1 Pipework Painting

On completion of fabrication and workshop examination and inspection and before erection all

pipework shall be surface prepared and prime painted in accordance with the specified Painting

System. General conditions for painting and cleaning shall be as per Specification.


ES-14-602-01



Patch priming of field welds and any abraded or damaged portions shall be carried out on

completion of erection, pressure testing and any other examinations and inspections, which may be

required prior to finish coating.

Pipelines and valves shall be finish coated in accordance with the specified Painting System and

colour specific in CSBP Engineering Standard Protective Coatings (ES-14-102-12).

Cold insulated services piping shall be primed in accordance with the painting Specification.

5.1.2 Flanges

Flange faces shall be protected by coating with a removable rust preventative and blanked with

6mm thick exterior quality plywood covers, or proprietary plastic flange guard covers no smaller

than the flange OD. The flange cover shall be retained by a minimum of four bolts or by

polyethylene lock plugs.

5.1.3 Connections

Threaded connections shall be fitted with line specification steel pipe plugs or treated protectors.

Socket weld connections shall be fitted with taped polyethylene caps or plugs.

All end connections, including branch openings shall be protected with a plastic sheet, wired or

taped securely to the spool to prevent entry or dirt or moisture into the spool.

5.1.4 Stainless Steel Components

In order to minimise the possibility of stress cracking, all stainless steel valves, spools, pipe and

connections shall be stored out of contact with the ground and properly sheltered from rain.

Closures should be examined to ensure moisture cannot enter this material.

All austenitic stainless steel subject to welding or mechanical abrasion shall be passivated to

reinstate the protective oxide layer.

Stainless steel piping subject to annealing or heat treatment shall be pickled in an acid/water

solution comprising nitric and hydrofluoric acid to remove oxide scale.

6. ERECTION

6.1 IDENTIFICATION

All materials issued by Principal or supplied by the Contractor shall be identified in accordance

with the respective piping class/piping material specification, and shall be stored and handled in

such a manner as to assure proper identification.

6.2 STORAGE AND HANDLING

All fabricated pipe and equipment shall be stored off the ground until finally installed.


ES-14-602-01



Care shall be exercised, in the storage and handling of all piping materials and pre-fabricated

assemblies, so that contamination by grease, moisture or other foreign matter does not occur. End

seals of pipe, flange covers, valve covers, and similar protections shall not be removed until

necessary for fabrication or erection. The Contractor shall ensure that all piping is protected, as per

Section 4.4 at all times.

All care shall be taken when pipe sections are moved from one place to another to avoid bending or

over-straining.

6.3 ASSEMBLY/INSTALLATION

All piping shall be installed in accordance with the latest revision of the Piping drawings as per

Section 3.2.

All assembled piping shall be installed without springing or forcing. Cutting or other weakening of

structural members to facilitate piping installation shall not be permitted.

All piping shall be installed to permit free expansion and contraction without damage to joints or

supports.

A visual inspection of all pipe and pipe spools shall be made to ensure they are free of all internal

loose rust, scale, soil and debris before assembly.

A straight run of pipe shall contain the minimum number of welds. The use of off-cuts in straight

piping runs shall be avoided wherever possible.

Special precautions shall be taken during carbon steel piping erection in close vicinity of stainless

steel piping as direct contact between carbon steel and stainless steel is not permitted. Carbon steel

slings, etc, shall not be used during fabrication and installation of stainless steels. Stainless steel

piping shall be covered up with tarpaulins or similar where carbon steel piping is being erected or

worked on such that, stainless steel cannot come in contact with carbon steel. Neither shall

stainless steel or non-ferrous materials be contaminated with grinding or welding particles. Tools

shall be identified for stainless steel work only. All stainless steel piping and fittings shall be stored

away from areas where carbon steel is being worked on.

All materials used for assembly and erection must conform to the appropriate Piping Class

Specification in CSBP Engineering Standard Piping Material Specifications (ES-14-603-01).

Hydrotest vents and drains shall be installed in accordance with the Piping GA’s and Isometrics.

The Contractor shall install any additional vents and drains required for testing purposes.

6.4 FLANGED CONNECTIONS

Precautions shall be taken throughout fabrication and erection to protect the gasket face of flanges.

Flanges repaired by grinding will be rejected.

Flanged connections shall be assembled with new gaskets and stud bolts as specified in the CSBP

Engineering Standard Piping Material Specifications (ES-14-603-01). Bolts shall show at least

one, but no more than three threads beyond the nuts after assembly.


ES-14-602-01



Gaskets shall be centred on the flange faces and shall not project into the bore. Gaskets with correct

inside diameter shall be used on slip on flanges.

The clearance between flange faces shall permit the connection to be gasketed and bolted without

imposing undue strain on the piping system.

Flanged piping connections to vessels or equipment shall be correctly aligned before bolting up.

6.4.1 Protection from Leaking Flanges

In the event of a flange leak, to prevent personnel being sprayed from substances that are hazardous

because of their chemical and or physical properties, flange protection shall be provided at

locations where:

• there is a high level of Operator interface,

• flanges are adjacent to walkways or designated accessways,

• directed by the Superintendent or the applicable business unit Process/Maintenance Manager.

Hazardous substances requiring flange protection are:

• All acids

• Sodium Hydroxide (Caustic Soda)

• Ammonium Nitrate

• Sodium Cyanide Solution, and

• Other fluids, as specified by the Superintendent or the applicable business unit Process or

Maintenance Manager.

The type of flange protection to be used shall be specified by the Superintendent or the applicable

business unit Process/Maintenance Manager. Typically this will be in the form of either:

a. A ring of stainless steel cladding that is securely held in place with stainless steel banding

straps. A drainage/vent hole shall be provided in the underside of the flange guard.

or

b. Wrapping of the flange joint with Herculite. The material is to overlap itself and extend

over the pipe with sufficient material so that is can be securely held in place with 3mm

Terylene rope or another Superintendent approved method.

6.5 BOLTING

Prior to installation, all bolting shall be lubricated with an approved anti-seize compound.

Protective grease shall be removed from flange gasket faces prior to bolt-up. Flange faces shall be

parallel and aligned in horizontal and vertical planes. Non-uniform bolt loading will be rejected.

Dirt at the mating surfaces shall be removed and scratched surfaces shall be repaired.

Flange stud bolts shall be tightened evenly and sequentially to impose equal pressure on gaskets to

avoid distortion or over stressing. Hydraulically operated tensioning equipment shall be used on

stud bolts 1¼” diameter (M33) or over. These stud bolts shall be supplied one diameter overlength

to allow for bolt tensioning equipment.


ES-14-602-01



Insulating flange kits shall be installed between mating carbon steel and stainless steel piping.

Gasket compound shall not be used.

6.6 CONNECTION TO EQUIPMENT

Piping connections to equipment shall be installed such that no stresses shall be transferred from

the piping system to the equipment at the time of installation.

6.7 THREADED JOINTS

Back welding of threaded joints is not permitted unless specified on design drawings or approved

by the Superintendent. It is recommended that back welded threaded connections be replaced with

socket weld connections if possible.

Backing off of made-up threaded joints to facilitate fit-up or alignment is not permitted.

Joints shall be made using approved sealing tape and care taken to avoid over tightening.

6.8 TEMPORARY STRAINERS

Temporary strainers must be installed in the suction piping to all pumps, compressors and other

places as indicated on drawings. Break-out spools shall be installed as required for easy removal of

strainers.

6.9 VALVE INSTALLATION

Valves shall be installed as indicated on the GAs and Isometrics and in accordance with CSBP

Engineering Standard Basis for Design - Piping (ES-14-601-01). Should valve orientation not be

detailed the following guidelines should be used:

a. Valves shall be installed so that their handwheels or handles are accessible and can be

operated between full open and full closed positions without obstructions.

b. Valve location and orientation shall be such that a person can operate the valve handwheel

or handle from a safe position and in a comfortable posture. Extensions or chain wheels

shall be provided if required.

c. Valves in horizontal lines, with the exception of block valves at pressure relief valves, shall

be installed with valve stems oriented as follows, in order of preference:

1. Vertically upwards

2. Horizontally

3. Upwards at 45°

d. Gate valves installed upstream and or downstream of pressure relief valves shall be

installed with the valve spindle oriented horizontally or downwards, to prevent blockage of

the line by a disconnected gate in the valve.


ES-14-602-01



6.10 UNDERGROUND PIPING

Fabrication, laying, corrosion protection, inspection and testing of underground piping shall be in

accordance with the CSBP Engineering Standard Underground Piping (ES-14-602-05).

6.11 INSTALLATION OF EXPANSION JOINTS

Specific instructions for installing expansion joints shall be included in the Project documentation,

however the following general guidance apply:

a. Expansion joints shall be the final unit(s) installed in any piping systems.

b. Before installation of any expansion joint, all piping shall be accurately aligned without

restraints and properly anchored.

c. The space allowed in the piping for insertion of an expansion joint shall be equal to the

insertion dimension specified on drawings (plus or minus 1.5mm), including cold

springing, if specified.

d. Spacer bars supplied by the manufacturer for shipping purposes shall not be adjusted or

removed from expansion joints until after joints are in place.

e. Shipping spacer bars must be removed before testing.

f. No adjustment shall be made to tie rods provided by the manufacturer to control alignment

and end thrust; these tie rods shall remain part of the unit.

g. No attempt shall be made to correct misalignment of piping, caused by incorrect installation

of the piping or its associated equipment, by modification to any device provided to control

expansion, or the method in which that device is designed to be installed. Such

misalignment must be corrected by other means which will in no way affect the workability

of the expansion device.

6.12 TESTING OF PIPEWORK

Pressure testing of pipework shall be carried out in accordance with CSBP Engineering

Standard Inspection and Testing of Piping Systems (ES-14-602-02).

7. PIPE SUPPORTS

7.1 STANDARD PIPE SUPPORTS

All pipework shall be supported in accordance with the Code.

Support locations, type and serial number will be shown on the piping drawings. Refer to Section

3.2.

Unless otherwise indicated on piping drawings, no pipe shall be supported from another pipe.


ES-14-602-01



7.2 SPRING HANGERS

7.2.1 General

Spring hangers, as required, shall be supplied by the Contractor and shall be installed as indicated

on piping drawings.

7.2.2 Constant Support Hangers

Installation instructions are as follows:

a. Securely attach the hanger to the structure at a point where the load coupling is directly

over the desired point of attachment.

b. Make certain that the moving parts of the hanger will be unobstructed.

c. Make certain that the rod has enough thread engagement before taking up the load.

d. Turn the load coupling until the travel stop is free.

e. Prior to the final start-up/commissioning, the travel stops shall be removed

f. After the line is in operation, check the hanger for indicated hot position. If necessary,

make the adjustment by turning the load coupling to bring the indicator to the required

position. No other adjustment is normally required, since the load as calibrated at the

factory is equal to the load that has to be supported.

7.2.3 Variable Support Hangers

The installation instructions shall be as follows:

Securely attach the hanger to the structure. Turn the turnbuckle until the Variable Spring Hanger

or load column of the spring support respectively reaches the desire cold load marking. No other

adjustment is necessary. The travel stops shall be removed before the piping is put into operation

8. AS-BUILT DATA AND RECORDS

On completion of the work, the Contractor shall supply to the Superintendent, as a properly

indexed and compiled package, full details of the Welder Qualified records, fabrication records and

as-built data. This package shall be compiled in accordance with CSBP Engineering Standard

Inspection and Testing of Piping Systems (ES-14-602-02).


ES-14-602-01



APPENDIX 1 - TYPICAL PROCEDURE QUALIFICATION RECORD

(PQR)

PURCHASE ORDER No: PQR No:

WPS No:

PROCESS: MATERIAL SPEC:

MANUAL/AUTO/SEMI-AUTO HEAT No:

DATE WELDED SERIAL No:

JOINT: THICKNESS:

DIAMETER:

ELECTRODE/WIRE:

TYPE:

BATCH No:

WELDING PROCESS:

WELDING POSITION:

ELECTRODE STICKOUT:

GROOVE ANGLE: MAX. BEAD WIDTH:

INTERPASS CLEANING:

ROOT FACE: PREHEAT TEMP:

ROOT GAP: PREHEAT METHOD:

PASS No

PROCESS

POLARITY

AMPS A

VOLTS V

TRAVELSPEED MM/MIN

HEAT INPUT KJ/MM

INTERPASS TEMP ° C

ELECTRODE/WIRE GAS

NAME SIZE

MM

FLOW

RATE L/MIN

MAXIMUM THICKNESS OF

DEPOSITED WELD METAL

FOR EACH PROCESS:

TUNGSTEN TYPE AND SIZE:

GAS CUP SIZES:

GAS PERCENTAGE POSTWELD HEAT TREATMENT:

COMPOSITION

(MIXTURE)

TEMPERATURE

GAS(ES) TIME:

SHIELDING:

TRAILING:

BACKING:

OTHER:

VERIFIED BY VENDOR QC DATE:

NAME: SIGNATURE:

CSBP INSPECTOR DATE:

NAME: SIGNATURE:


ES-14-602-01



APPENDIX 2 - TYPICAL WELDING PROCEDURE SPECIFICATION

(WPS)

VENDOR: WPS No: PQR No:

REV: DATE: PAGE OF

PURCHASE ORDER No: MATERIAL SPECIFICATION:

EQUIPMENT DESCRIPTION: THICKNESS RANGE:

BASE METAL:

APPLICATION OF WPS: DIAMETER RANGE:

POSITION:

STANDARD WELD

PREPARATION:

TYPICAL WELD SEQUENCE: PROGRESSION CONSUMABLE:

TREATMENT:

EDGE PREP METHOD:

PREHEAT TEMP:

REFER ATTACHED SHEETS

FOR

VARIATIONS:

No OF PASSES MAY VERY

ACCORDING TO THICKNESS/

PREHEAT METHOD:

POSITION RETENTION TIME:

TEMP CHECK METHOD:

MAX INTERPASS TEMP:

GOUGE METHOD:

GOUGE CHECK METHOD:

MAXIMUM THICKNESS OF DEPOSITED WELD METAL FOR

EACH PROCESS:

INTERPASS CLEANING:

TACKING METHOD: MAXIMUM BEAD WIDTH:

WELD FINISH: ELECTRODE STICK OUT:

PASS No..

PROCESS

+- AMP VOLT TRAVEL SIZE MM FLUX/GAS

RANGE RANGE RANGE MM/MIN

TRADE NAME SPEC/FLOWRATE

PROCESS: TUNGSTEN TYPE & SIZE:

AWS SPEC: GAS CUP SIZES:

AWS CLASS: BACKING: TYPE:

A No: GAS: RATE:

F No: DURATION

PWHT REQUIRED: FOR VENDOR

GOVERNING CODES PREPARED BY: DATE:

CONSUMABLE TRADE NAMES: APPROVED BY: DATE:

Documents

Bending and Welding Pro Spec