Piping Inspection Handbook

INSPECTION HANDBOOK  PIPING

COMMENTARY This handbook has been developed to assist the Field Engineer and inspector in their  daily duties and provide them with the necessary data needed to make day-to-day decisions. The issuance of this handbook is not intended to replace the codes or engineering specifications, but is used as a ready reference guide in conjunction with the project requirements. It should be recognized that engineering specifications may be more restrictive than the standards used in the development of this handbook. If there are differences between this handbook and the engineering specifications, the Engineering specifications shall govern.

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CONTENTS

General...................................................... ............................................................................................................. ...................................................................... .................... .....4 G-1 CONSTRUCTION SAFETY................................................. ............... ...................... .............. ........... ....5 G-2 RECEIVING AND STORAGE...................................................... ...................................................................... ....................... .......10 10 G-3 CONCRETE EXPANSION EXPANSION ANCHORS............................................. ....... .............. ........... ....11 11 Piping.................................................. ........................................................ .................................................................... ................... ........... ....14 14 P-1 GENERAL PIPING ..................................................... ............................................................................................... ..........................................15 15 P-2 LARGE PIPING........................................................ ................................................................................................ ........................................ .....17 17 P-3 SMALL PIPING.................................................... .................................................................................................. .............................................. ...18 18 P-4 EMBEDDED PIPING................................................. ................................... ........19 19 P-5 VAL ALVES VES................................................ ............................................... ....... .............. ........... ....20 20 P-6 HANGERS AND SUPPORTS SUPPORTS........................................................ .................................................................... ................... ........... ....21 21 P-7 FLUSHING AND CLEANING CLEANING...................................................... ............................................................. .............. .............. ......... ..22 22 P-8 LEAK TESTING ............................................... ............................................... .....23 23 P-9 PROTECTIVE COATINGS COATINGS............................................... ................................ ....25 25 P-10 PIPE INSULATION INSULATION................................................. .................................. ....... .......... ...26 26

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General  No

Description

G-1 G-2 G-3

Construction Safety Receiving And Storage Concrete Expansion Anchors

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G-1 CONSTRUCTION SAFETY The following characteristics of Construction Safety shall be reviewed: GENERAL 1. Check that that workmen workmen do not not have to to work in in unsanitary unsanitary or hazardous hazardous Condition Conditionss 2. Check that that employees employees are instruc instructed ted on specifi specificc procedures procedures to follow follow when when required required to handle harmful substances 3. Check that that employees employees working working in confined confined spaces spaces are advised advised of the hazards hazards involved involved 4. Check that that protect protective ive equipme equipment nt is provided provided where where necessary necessary HOUSEKEEPING 1. 2. 3. 4.

Check that that scrap scrap with with protruding protruding nails nails is removed removed from from work work areas Check that that combustib combustible le scrap scrap and Debris Debris is is removed removed at regular regular interva intervals ls Check that that containers containers are provided provided for for waste, waste, trash trash and oily oily rags rags Check that that covers are are provided provided for Contai Containers ners with with hazardous hazardous or Flammabl Flammablee wastes

MEDICAL SERVICES AND FIRST AID 1. Check that that medical medical personnel personnel are are available available for advice advice and consultat consultation ion on occupationa occupationall health matters 2. Check that equipmen equipmentt for prompt prompt transpor transportatio tation n of injured injured to a physician physician or hospital hospital is available or that a communication system for calling an Ambulance is provided 3. Check that that the the telephone telephone numbers numbers of physicians, physicians, hospitals hospitals and ambulance ambulance service service are conspicuously posted SANITATION 1. 2. 3. 4. 5.

Check that that container containerss for drinking drinking water water shall shall be so labeled, labeled, Check that outlets outlets for for nonpota nonpotable ble water are labeled labeled Check that that there is no connection connection between between potable potable and nonpotable nonpotable water water suppli supplies es Check Check that that toilet toiletss are adequa adequate te and in in proper proper order  order  Check that adequate adequate washing washing faciliti facilities es are provided provided for employees employees using using paints, paints, coatings coatings

OCCUPATIONAL NOISE EXPOSURE 1. Check that that employees employees are given given ear protect protection ion when noise levels levels exceed exceed those those  permissible noise levels 2. Check that an effecti effective ve hearing hearing conservation conservation program program is adminis administered tered where where noise levels levels continuously exceed limits 3. Check that that devices devices for ear ear protecti protection on will will fit properly properly

G-1 Construction Safety

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ONGOING RADIATION 1. Check that person personss using x-rays x-rays or radioactiv radioactivee materials materials are qualified qualified or licensed licensed where where necessary  NONIONIZING RADIATION RADIATION 1. Check that that only qualified, qualified, trained trained person personnel nel operate operate laser laser equipme equipment nt 2. Check that that laser safety safety goggles goggles are are provided provided where power power is in in excess of of 0.005 0.005 watts and and not exposed to intensities above those shown in this section 3. Check that that areas where where laser laser equipment equipment is used are posted posted with with warning warning signs signs 4. Check Check that that laser laser is turn turned ed off off when when not in in use 5. Check that laser beam is is not directed directed at employees employees 6. Check that that the laser laser is not used used when it is is raining, raining, snowing, snowing, or when there there is heavy heavy fog or  heavy dust in the air  7. Check that that labels labels indicat indicating ing power power are are shown shown on laser equipment equipment 8. Check that laser beam is is above above heads heads where where possi possible ble GASES, VAPORS, FUMES AND MISTS 1. Check that that employees employees are not expose exposed d to amounts amounts in excess excess of “threshol “threshold d limit values” values” 2. Check that that any equipment equipment or protect protective ive measures measures instigat instigated ed to reduce reduce containments containments are are approved by a competent industrial hygienist unless, however, they can be removed by ventilation ILLUMINATION 1. Check that that illuminati illumination on in the followi following ng areas meets meets OSHA OSHA require requirements ments:: • • • • • •

Construction areas Ramps Runways Corridors Offices Shops and storage areas

VENTILATION 1. Check that that the threshold threshold limit limitss values are are not exceeded exceeded when fumes, fumes, mists, mists, dusts dusts are are removed by ventilation 2. Check that that exhaust systems systems do not draw draw harmful harmful substances substances through through work work areas 3. Check that that exhaust systems systems operate operate continually continually and and are shut down down in accordance accordance with with circumstances 4. Check that all all ventilation ventilation systems systems for dusts dusts,, fumes, mists, mists, vapors vapors or gases are are discharged discharged to outside atmosphere

G-1 Construction Safety

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HEAD PROTECTION 1. Check that that head protecti protection on for employees employees exposed exposed to to high voltage voltage is provide provided d EYE AND FACE PROTECTION 1. Check that eye and and face protection protection devices devices are are provided provided 2. Check that that adequate adequate eye and face protec protection tion equipment equipment is is provided provided to prevent prevent injury injury from  physical, chemical or radiation agents 3. Eye-wash Eye-wash devices devices are properl properly y located located adjacent to hazardous hazardous chemical chemical storage storage areas areas RESPIRATORY PROTECTION 1. 2. 3. 4.

Check that that respirato respiratorr protection protection devices devices are are approved approved by the Bureau Bureau Of Mines Mines Check that that employees employees required required to use use respirato respirators rs are trained trained in their their use use Check that respir respiratory atory equipment equipment is is inspected inspected regularly regularly and maintaine maintained d in good condition condition Check that that used respirat respiratory ory equipment equipment is cleaned cleaned and and disinfected disinfected before before reissue reissue

SAFETY BELTS, LIFELINE 1. Check that that safety safety equipment equipment is is used for for employee employee safety safety only only.. Items used otherwi otherwise se should be disposed of  2. Check that that lifelines, lifelines, safety safety belts belts have a minimum minimum breaking breaking strengt strength h of 5,400 pounds 3. Check that that safety belts lanyard lanyard is is no longer than 6 feet, feet, and made made of minimum minimum 1/2 inch inch nylon SAFETY NETS 1. Check that that safety nets are are provided provided when work work place is more than than 25 feet above above the ground, or water, and the use of platforms, scaffolds, ladders, temporary floors, safety lines, safety belts is impractical 2. Check that that nets extend 8 feet beyond beyond edge of work where where employees employees are exposed exposed 3. Check that that nets are are installed installed as close close as possible possible to to work and no more more than 25 feet feet below below working level over ground or water  HAZARDOUS MATERIALS 1. Hazard Communi Communication cation Progra Program m is availabl availablee on site site and is implem implemented ented FLAMMABLE AND COMBUSTIBLE LIQUIDS 1. Check that that only approved approved container containers, s, portable portable tanks, tanks, and metal metal safety safety cans shall shall be used used for the storage and handling of flammable liquids 2. Check that that temporary temporary building buildingss shall not not be placed placed where they they obstruct obstruct exits exits 3. Check that that temporary temporary buildi buildings ngs shall shall be placed placed in in another another building building shall shall be noncombustible or have a one hour fire Resistance rating 4. Check that that buildings buildings located located outside outside shall shall be located located not less than ten feet feet from from another  structure G-1 Construction Safety

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5. Check temporary temporary heating heating devices devices for clearance clearance to combustib combustible le material material (from (from heaters) heaters) 6. Check heaters heaters on wood wood floors floors are placed placed on noncombust noncombustible ible material material,, extending extending a minimum of two feet on all sides 7. Check that clearanc clearancee between heaters heaters and tarpauli tarpaulins, ns, canvas or simila similarr coverings coverings shall be at least ten feet. Coverings shall be securely fastened fastened to prevent contact with heater  8. Check temporary temporary heating heating devices devices are equipped equipped with with pilot and automati automaticc shut-off shut-off valve to  prevent flow of fuel if flame goes out 9. Check that that fluid fluid used in hydraulic hydraulic powere powered d tools is fire-re fire-resist sistant ant SCAFFOLDS AND LADDERS 1. Check that that portable portable ladders ladders are tied, tied, blocked blocked or otherwis otherwisee secured secured to prevent prevent displacement 2. Check that that ladders ladders placed placed in passageways passageways,, doorways doorways or in other other areas where where they may may be displaced are protected by barricades or guards 3. Check that that job made ladders ladders providi providing ng the only means means of exit exit for 25 or more more employees employees are double cleated, and not more than 24 feet in length 4. Check that that ladder cleats cleats are are inset into into side side rails 1/2 1/2 inch, or filler filler blocks are are placed  between cleats 5. Check that that standard standard guard rails rails and toe toe boards are provided provided on all all scaffolds scaffolds that that are ten ten feet or more above ground or floor. floor. Standard guard rails shall be 2”x 4" (or equivalent) 42" high (minimum) width 1” x 6” mid-rail and toe boards a minimum of 4" in height. Sizes refer to nominal or dressed dimensions. 6. Check that that scaffolds scaffolds that that must be be passed passed or worked worked under are are provided provided with screen screen from from toe board to guardrail 7. Check that that overhead overhead protection protection is is provided provided for men on on a scaffold scaffold exposed exposed to overhead overhead hazards 8. Check that that scaffold scaffold planks planks extend extend not less less than 6 inches inches nor more more than 12 inches, inches, and and are of scaffold grades material 9. Check that that floor floor openings openings are are guarded guarded with standar standard d handrails. handrails. A floor opening opening is a hole hole 12 inches or more in its least dimension through which a person can fall. 10. Check that runways are provided with with standard rails and toe boards when they are 4 feet or more above the ground 11. Check that when work is to be performed in a manhole or non vented vault, no entry shall  be made until forced ventilation is provided or the atmosphere is tested and found safe 12. Check that when work is being done in a manhole, an employee shall be available in the immediate vicinity for assistance EXCAV EXCAVATION, SHORING AND TRENCHING TRENCH ING 1. Prior to to excavation, excavation, shoring shoring and trenching trenching operations operations review review for gas lines, lines, conduit, conduit, etc., etc., or any other underground structure to be avoided 2. Atmosp Atmospher heric ic conditi conditions ons tested tested,, where necessa necessary ry 3. Adja Adjacen centt struct structur ures es shor shored ed 4. Land Land shored shored and sheat sheathed hed as needed needed for for soil soil and depth depth 5. Roads Roads and side sidewal walks ks suppo supporte rted d and prote protecte cted d 6. Banks more than than five five feet feet shored shored or sloped sloped to angle of of repose repose G-1 Construction Safety

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7. Ladders or stairs stairs provid provided ed as required required (trenches (trenches four four feet feet deep or or grates grates require require ladder  ladder  for every 25 feet of lateral travel) 8. Equipm Equipment ent ramps ramps adeq adequate uate,, slope slope not too too steep steep HOISTS, CRANES AND DERRICKS 1. Cables and sheaves sheaves free of excessi excessive ve wear wear and and abrasions abrasions 2. Slings and chains, chains, hooks hooks and eyes, eyes, have no no evidence evidence of defects, defects, excessi excessive ve wear Or  Or  damage 3. Power lines lines inactivated, inactivated, removed, removed, or at safe safe distance distance as required required by provincial provincial regulatio regulations ns 4. Area Area barrica barricaded ded or rope roped d off wher wheree necessa necessary ry

G-1 Construction Safety

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G-2 RECEIVING AND STORAGE STORAGE The following characteristics of receiving and storage shall be reviewed: 1. Check for loading loading and shipp shipping ing damage damage material material and equipment equipment is is free of damage damage caused by fire or high temperatures, excessive weather exposure, environmental damage, tie down failure or rough handling 2. Inspection Inspection of compone components nts shall shall be perform performed ed in a manner to to avoid contaminat contamination ion of  the item during inspection 3. Check that that material material and equipmen equipmentt conforms conforms to size, size, type, type, quantity quantity and configurat configuration ion as specified in the purchase order documents and detail drawings 4. Review the the supplier's supplier's documenta documentation tion for identif identificati ication on and feasibilit feasibility y to the marking marking and tagging on the received material, equipment, components and devices 5. Promptly Promptly identify identify and expedite expedite all shortage shortage items items and initiate initiate repairs repairs or or replacement replacement for damaged items 6. Avoid double double handling handling of equipment equipment and and components components by checking checking shippi shipping ng and erection schedules. Unload and transport directly to erection areas, where possible 7. Arrange Arrange storage storage so that that parts parts can be be located located easily easily.. Provide Provide full crane, truck, truck, and and rail access to storage areas. 8. Systematize Systematize and record record all storage storage location locations. s. Segregate Segregate damaged damaged or rejecte rejected d materials 9. Follow manufact manufacturer' urer'ss instructio instructions ns and/or and/or approved approved procedure proceduress when unloading, unloading, rigging, handling And transporting components from rail cars or trucks to storage (see Rigging Inspection Handbook) 10. Store instruments, electrical equipment, weld rod, insulation and other items, requiring protection from the elements indoors. Provide numbered bin storage. Provide dry storage for weld rod. Set up weld rod controls. 11. Perform user's user's acceptance, test, where required 12. Perform Perform equipment equipment maintenance, maintenance, when required 13. Check that the vendor's storage and preservation preservation requirements are followed 14. Special provisions are in place for storage of hazardous materials

G-2 Receiving and Storage

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G-3 CONCRETE EXPANSION EXPANSION ANCHORS The following characteristics of expansion anchor installation shall be reviewed: GENERAL: 1. Select the the proper proper anchor from Table Table 1 based based on the design design drawing drawing requiremen requirements ts and the thickness of the material 2. Determine Determine the hole depth depth from Table Table 1 For Hilti, Hilti, Phillips Phillips and Ramset Ramset anchors. anchors. Depth Depth of hole is measured from the surface of the fixture being anchored  Note: When the hole is measured from the concrete surface, subtract the thickness of  the fixture and any voids, grout g rout or shims beneath the fixture PRE-INST PRE-INS TALLATION SET-UP: 1. Prior to to drilling drilling for anchor instal installatio lation, n, review the the rebar placement placement drawings drawings for for the intended anchor installation 2. Using the the rebar finder finder,, scan the concrete concrete surfac surfacee and locate locate the reinforci reinforcing ng steel, steel, mark-up the bar location on the concrete surface 3. If rebar rebar will be encounte encountered red at anchor anchor location, location, contact contact discipl discipline ine engineer engineer to see if  if  the base plate or expansion anchor can be relocated 4. If base plate plate or expansion expansion anchor anchor cannot cannot be relocated, relocated, contact contact the the designated designated field field engineer to see if rebar can be cut 5. When permiss permission ion from the the designated designated Field Field Engineer Engineer is given given to cut a rebar rebar,, the depth depth of the concrete cover or the rebar should be checked and longer anchors installed, if  necessary, necessary, to ensure that the wedge wedg e of the anchors do not sit on the sides of the cut rebar  INSTALLATION: 1. All holes holes shall shall be drille drilled d with masonry masonry bits bits of the same same diameter diameter as the the anchor. anchor. If  rebar is encountered, stop further drilling and follow pre-installation instruction. 2. Blow out out loose dirt and and filing filing prior prior to installati installation on of the the anchor  3. Only after after all the the holes for for a given instal installatio lation n have been drilled drilled should should the anchors anchors  be installed 4. With With the nut on, on, and slightly slightly raised raised so so not to damage damage the threads, threads, hammer hammer the anchor  anchor  into the hole with the fixture in place before torquing, engage the nut as far as  possible. The, installation torque values are given in Table Table 1. 5. Maximum Maximum deviation deviation of the anchor anchor bolt bolt from perpen perpendicula dicularity rity with with concrete concrete surface surface should not exceed 5 degrees 6. Full thread thread engagement engagement on the nut is require required. d. Installati Installation on torque torque may be exceeded exceeded to achieve full thread engagement. 7. Minimum Minimum center to center spacing spacing and edge distance distance are are as specifie specified d on the design design drawings

G-3 Concrete Expansion Anchors

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8. If a nut bottoms bottoms out (runs out out of threads) threads) prior prior to reaching reaching proper proper torquing, torquing, additional additional steel washers may be used to maintain proper torque provided minimum embedment is maintained 9. Leveling Leveling nuts or pipe pipe shims shims shall shall not be used used on an anchor unless unless specif specified ied on the design drawing 10. Alterations to expansion anchors such as cutting, threading or machining machining is prohibited EXPANSION EXPANSION ANCHOR TEST PROCEDURE: 1. Expansion Expansion type concret concretee anchors shall shall be tested tested to the the valves in in Table Table 1 using using a calibrated torque wrench 2. Expansion Expansion anchors anchors that fail fail torque torque test shall shall be repair repaired ed as required required and re-torque re-torqued d and re-inspected 3. For shell shell type type anchors anchors (drop(drop-in) in) check check for for the following: following: • •

•

Setting plug is present Anchor setting tool of 1-3/4" minimum shank length is flush with and has full contact with the top of the anchor shell Bolts or threaded bars inserted into anchor shells have thread engagement equal to the threaded depth of the anchor shell

REPAIR OF ANCHOR FAILURES: 1. Failure Failure Due To To Concrete Concrete Breakout Breakout - anchors anchors may be reinst reinstalled alled provided provided that that the regained embedment beyond breakout depth. Concrete that is damaged shall be removed to sound concrete and repaired (see concrete repair checklist) 2. Failure Failure Due To To Anchor Anchor Breakage Breakage - anchors anchors shall be drilled drilled out, and and provided provided that the integrity of the surrounding concrete is maintained, the hole redrilled and next larger  size diameter anchor installed in the the same location. The replacement anchor  embedment length shall be at least equal to the minimum embedment for the next larger anchor. 3. Failure Failure Due To To Anchor Anchor Slippage Slippage Or Torque Torque - anchors anchors may be reoriented reoriented and retightened once for test. If the anchor cannot be torqued the anchor shall be removed, provided the integrity of the surrounding concrete maintained, the next size anchor replaced as noted in (2) above.

G-3 Concrete Expansion Anchors

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Table I Torque Value Value for Hilti, Phillips, and Ramset Expansion Anchors Anchor Size (Inches)

*Verification Torque Values (ft/lbs) 1/4" 9 3/8" 24 1/2" 45 5/8" 75 3/4" 100 1" 254 *Values include + 4% error for torque wrench calibration

Bechtel Installation Torque Torque (ft/lbs) 10 30 55 85 115 310

1. Bechtel instal installatio lation n torque values values are are to be used as guideli guidelines nes to ensure ensure that verification torque values are met. met. Installation torque values were were chosen from the recommended range of torque values that consistently pre-set the anchors to 150% of  their working loads.

G-3 Concrete Expansion Anchors

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Piping  No P-1 P-2 P-3 P-4 P-5 P-6 P-7 P-8 P-9 P-10

PIPING

Description General Piping Large Piping Small Piping Embedded Piping Valves Hangers and Supports Flushing and Cleaning Leak Testing Protective Coatings Pipe Insulation

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P-1 GENERAL PIPING The following characteristics of general piping shall be reviewed: RECEIVING 1. Check that material material is is properl properly y Prepare Prepared d and/or and/or packaged packaged 2. Check material material for for proper proper identifi identificatio cation; n; permanent permanent tags tags are fixed fixed to valves valves as specified 3. Insp Inspec ectt for for dama damage ge 4. Verify erify quantit quantities ies receiv received ed 5. Insp Inspect ect for for cle cleanl anlin ines esss 6. Verify that the the required required documents documents are received received with with shipment shipment 7. Verify that that all items items that do not conform conform to specifi specified ed requirement requirementss are properly properly segregated and/or processed STORAGE AND HANDLING 1. Review Review need need for for any any speci special al proces processin sing g 2. Check that that storage storage and handling handling is in in accordance accordance with procedur procedures, es, specific specifications ations,, and/or special instructions 3. Verify that cleanli cleanliness ness is maintai maintained ned during during storage storage FABRICATION 1. Check areas areas where materia materiall will be instal installed led for interf interference erencess and resolve resolve prior prior to fabrication (i.e., structural steel cross bracing) 2. Verify that current current revisio revision n of drawings drawings are being being used for for fabrication fabrication 3. Verify that proper proper materia materiall has been requisi requisitioned tioned from from storage storage 4. Insp Inspect ect for for cle cleanl anlin ines esss 5. Verify proper proper storage storage and identifi identification cation of of fabricated fabricated material materialss 6. Assist Assist in determini determining ng rigging rigging and material material handling handling equipme equipment nt requiremen requirements ts 7. Verify that that openings openings on vessels, vessels, tanks, tanks, etc., are proper properly ly identified identified EXCEPTIONS 1. Exceptions Exceptions identif identified ied that do do not conform conform to contract contract drawing drawing or specif specificati ication on requirements and cannot be satisfactorily resolved, should be reported on the Daily Construction Report SYSTEM PUNCH LIST 1. walk the system system or portio portion n of the system system assigned assigned to determi determine ne completion completion status, status, using appropriate system and design drawings 2. Prepar Preparee a punch punchlis listt by list listing ing all: all: • •

Items that do not conform to contract co ntract requirements Items that are not complete

P-1 General Piping

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3. Verify completion completion of punchli punchlist st items items when reporte reported d complete complete 4. Update Update and reissu reissuee as as nece necessa ssary ry

P-1 General Piping

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P-2 LARGE PIPING The following characteristics of large pipe shall be reviewed: 1. Design Design drawings have have been reviewed for construct constructabili ability ty,, interferences, interferences, problems problems for  erection, and scheduling 2. Installati Installation on preplan preplanning ning has has been been done. done. Review general piping piping checklis checklist. t. 3. Receivi Receiving ng inspec inspectio tion n has been been perfo performe rmed d 4. Materi Material al is prop properl erly y stored stored and and mainta maintaine ined d 5. Periodic Periodic material material inventori inventories es are perform performed ed and that materi material al is reordere reordered d as necessary 6. Building Building areas areas have been checked checked for for possib possible le interfer interferences ences 7. All required required wall wall and floor floor sleeves sleeves and openings openings are are provided provided prior prior to concrete concrete  placement 8. Changes are monito monitored red and and incorpor incorporated ated on the drawings drawings 9. The work is is being perform performed ed in accordance accordance with with applicabl applicablee work instruct instructions ions or   procedures 10. Exception reports are properly prepared and processed processed 11. Changes that may result in interferences interferences and/or cause delays are coordinated with other disciplines 12. Other discipline design drawings drawings are reviewed for familiarity familiarity and for possible possible interferences 13. Installed pipe pipe has been released for for testing 14. Post test punch lists lists complete and pipe pipe released for insulation, as specified 15. Completed system has been released released to startup startup

P-2 Large Piping

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P-3 SMALL PIPING The following characteristics of small pipe shall be reviewed: 1. 2. 3. 4. 5. 6. 7. 8.

Installati Installation on pre-pl pre-planning anning has been been done. done. Review general piping piping checklis checklistt Small Small pipe pipe to be field field route routed d has been been determi determined ned Small pipe pipe to be detaile detailed d on field prepar prepared ed isometrics isometrics has been determine determined d Preparation Preparation of of small pipe pipe layout layout and isometr isometric ic drawings drawings have been been completed completed Building Building areas have been been checked for interfer interferences ences prior prior to preparat preparation ion of isometric isometricss Required Required receivi receiving ng inspect inspection ion has been performed performed Pipe and and fittings fittings are proper properly ly marked, marked, identif identified ied and stored stored Required Required wall and floor floor sleeves sleeves and openin openings gs have been provid provided ed prior prior to concrete concrete  placement 9. Drawing Drawing changes changes are are monitor monitored ed and incorporated incorporated in drawings drawings 10. Required work instructions instructions or procedures have been prepared 11. Work is being performed in in accordance with work instructions on procedures 12. Exception reports are being properly properly prepared and processed 13. Other discipline design drawings drawings are reviewed for familiarity familiarity and possible interferences 14. Changes to avoid interferences interferences and possible possible delays are coordinated with other  disciplines 15. Installed piping piping has been released for for testing 16. Post test punch lists lists complete and pipe pipe released for insulation, as specified 17. Completed piping system has been turned over to startup

P-3 Small Piping

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P-4 EMBEDDED PIPING The following characteristics of embedded piping shall be reviewed: 1. Instal Installat lation ion prep preplan lannin ning g complet completed ed 2. Embedded Embedded piping piping installati installation on schedule schedule is compatibl compatiblee with concrete concrete placeme placement nt schedule 3. Material Material receivi receiving ng inspec inspections tions have been performed performed 4. Embedded Embedded pipe, fitting fittings, s, and associated associated material material is proper properly ly marked, marked, identified, identified, and stored 5. Material Material that does does not conform conform to design design requirement requirementss is properly properly segregat segregated ed and/or   processed 6. Embedded Embedded piping piping requiring requiring coating coating and and wrapping wrapping has has been determi determined ned 7. Areas have have been checked for interf interferences erences with with reinforci reinforcing ng bar, bar, structural structural steel steel and forming 8. Piping Piping is located located in plan, plan, elevation, elevation, and scope scope in accordance accordance with with the drawings drawings 9. Any installa installation tion deviati deviations ons are reflect reflected ed on "as-buil "as-built" t" drawings drawings 10. Piping is properly properly supported supported and secured against movement during embedment 11. System or partial system system has been pressure pressure tested and accepted prior to to embedment 12. Connection piping can be erected and pressure tested 13. All openings in the system system (e.g., floor drains, equipment drains, connecting piping  joints) have been sealed and any valves in the vicinity of the concrete placement or   backfill have been protected for cleanliness against damage

P-4 Embedded Pipe

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P-5 VALVES The following characteristics of valves shall be reviewed: 1. 2. 3. 4. 5.

Installati Installation on preplan preplanning ning has has been been done. done. Review general piping piping checklis checklist. t. Receivi Receiving ng inspec inspectio tion n has been been perfo performe rmed d Valves are properl properly y handled, handled, stored stored and and maintained maintained Building Building areas are checked checked for interfer interferences ences with with valves installa installation tion and operatio operation n Valves are correct correct size, size, type, pressure pressure rating rating and installed installed in their correct correct location location and orientation 6. Valve installa installation tion in-proce in-process ss inspectio inspections ns are being perform performed ed 7. Valve installa installation tion progres progresss reporting reporting system system is maintained maintained 8. Periodic Periodic valve inventor inventories ies are perfor performed med and field field purchased purchased valves valves are reorder reordered ed if  necessary 9. P&ID drawing drawing changes changes are monitor monitored ed and incorpora incorporated ted in appropr appropriate iate layout layout drawings 10. Extra valve stem packing, bonnet gaskets, pressure seals, plugs, and flange gaskets needed for repairs are available 11. Piping design drawings and vendor valve detail sheets are reviewed for compatibility compatibility including material and end preps 12. Required operating and setting setting instructions and procedures are prepared 13. Operating and setting activities activities are performed in accordance with applicable instructions, procedures and valve/operator manufacturer's instructions 14. Changes that may result in interferences interferences and/or delays are coordinated with with other  disciplines 15. Exception reports are properly prepared and processed processed 16. Required valve operator operator supports supports are installed 17. Measures are taken to protect protect valve bodies and internals from from heat effects of welding

P-5 Valves

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P-6 HANGERS AND SUPPORTS SUPPORTS The following characteristics of hangers and supports shall be reviewed: 1. Installati Installation on preplannin preplanning g has been done and is compatibl compatiblee with piping piping installat installation ion  planning 2. Receivi Receiving ng inspec inspectio tion n has been been perfo performe rmed d 3. It has been been determined determined which which hangars hangars will be field field fabricat fabricated ed and which which will be vendor supplied 4. Hanger structural structural attachm attachment ent locations locations are surveyed surveyed and identified identified 5. Installati Installation on areas areas are are checked checked for for possi possible ble interf interference erence 6. Hanger fabricat fabrication ion and installat installation ion is scheduled scheduled to precede precede piping piping installat installation ion 7. Spring Spring hangar travel travel stops stops remain remain in place place during during installat installation, ion, testing, testing, and and until system hangar checkout is performed 8. Hangers Hangers and supports supports are installed installed in in accordance accordance with detail detail drawings drawings and within within the tolerances allowed in specifications or procedures 9. The latest latest approved approved revision revision of drawings drawings are being being used for fabricat fabrication, ion, installa installation tion and checkout 10. P&ID and piping drawing changes are are monitored and incorporated on the support support drawings 11. All required exception reports reports are properly prepared and processed 12. Provisions have been established to protect protect shock suppressor suppressor intervals and reservoir  when disassembling for repair or refilling 13. Changes that may result in interferences interferences or delays are coordinated with with other  disciplines 14. Hanger and support checkout is performed in accordance with specifications specifications and/or   procedures

P-6 Hangars and Supports

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P-7 FLUSHING AND CLEANING The following characteristics of flushing and cleaning shall be reviewed: 1. Procedures Procedures are are developed developed and approved approved indicati indicating ng flushing flushing and cleaning cleaning sequence sequence steps to be performed 2. All welded welded connections connections are are complete complete and the system/s system/subsyst ubsystem em is released released for  flushing and cleaning operations 3. Flushing Flushing is not carried carried out through through any machine machinery ry or equipment equipment that that may be damaged damaged  by such flushing 4. Line debris debris is not not flushed flushed into into deadends deadends or associat associated ed vessels vessels 5. Heat exchangers exchangers are isolated isolated wherever wherever possibl possiblee until initial initial flushing flushing is complet completee 6. Orifice Orifice plates plates and flow-noz flow-nozzles zles are are removed removed from from the line 7. That if a cleaning cleaning solvent solvent is is used, mere mere are no materia materials ls in the system system that that could be be damaged by its use 8. That temporar temporary y spacers spacers or spool spool pieces pieces are provided provided where where necessary necessary to to avoid straining the pipe where items have been removed 9. All high points points are suffi sufficiently ciently vented vented to ensure ensure that the cleaning cleaning solution solution will will contact all inside surfaces of the pipe 10. Sufficient bypasses are installed to ensure the flow of the cleaning solution solution through all desired parts of the system 11. Adequate venting is provided provided to prevent vacuums forming in the system 12. Maintain surveillance of the flushing flushing and cleaning operation ensuring that that all steps of  the procedure are performed After cleaning, passivating and flushing are complete, and the system has been drained and dried: 1. Inspect Inspect all accessibl accessiblee points of the the system to to ensure that it it is free of scale, scale, rust, rust, loose  paint and film and is of correct surface appearance 2. Check that all removed removed items are correc correctly tly reinsta reinstalled lled 3. If testing testing is not to be performe performed d immediately immediately,, ensure that that the piping piping is sealed sealed 4. Make regular regular inspecti inspections ons after after cleaning cleaning to ensure ensure the piping piping is kept kept sealed sealed 5. Where specifi specified ed for critical critical components components or systems systems,, nitrogen nitrogen blanket is re-est re-establis ablished hed in accordance with manufacturer's instructions and project procedures

P-7 Flushing and Cleaning

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P-8 LEAK TESTING The following characteristics of leak testing shall be reviewed: Prerequisites 1. Pre-test Pre-test inspecti inspection on is performed performed by walking walking down the system system and verifyi verifying ng accessibility for inspection, completeness in accordance with the latest P&IDs, tightness of flanged joints and chalking of joints, as applicable 2. The test medium, medium, test test pressur pressures, es, and test test boundaries boundaries have have been establis established hed for each each test, including blind thickness determinations 3. Test boundaries boundaries are are properly properly tagged in accordance accordance with with approved approved procedures procedures and as specified 4. Test medium, medium, sampled sampled and tested tested where where specified, specified, to to determine determine if it is is acceptable/detrimental to vessel internals 5. Test gauges are calibr calibrated ated before before issuing issuing for for use use 6. Test gauges gauges are checked checked against against a master master gauge for for accuracy prior to returning returning to storage or reissuing for use 7. Test gauges gauges are calibrated calibrated by a qualif qualified ied instrume instrument nt laboratory laboratory 8. Test gauges gauges are calibrated calibrated periodical periodically ly in accordance accordance with codes, codes, procedures, procedures, and and specifications 9. Test gauges gauges have a calibrati calibration on range of not not less than than 1-1/2times 1-1/2times and not more more than 4 times the intended maximum test pressure 10. Items incapable of safely safely sustaining test pressures pressures are removed or isolated isolated from the system 11. Systems requiring lay-up after after testing have been established and the the lay-up medium to be used has been determined 12. It has been established which system will or will will not require draining after after testing 13. All required test vents and drains are installed and fill points are are established 14. The required testing equipment, relief relief valves, pressure regulators, regulators, valves, strainers and temporary pipe and fittings are available 15. All system valves are positioned as required 16. System relief valves have been gagged or removed, as required 17. The system is adequately supported for for expected loading during testing 18. Test equipment and temporary piping have been flushed prior prior to connection to system 19. Systems have been flushed flushed prior to to testing, if required 20. Required test witnesses (such as quality control, authorized code inspector, client representative, etc.) are notified in advance of scheduled test

P-8 Leak Testing

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Leak Testing 1. 2. 3. 4. 5. 6. 7. 8.

Only syst system em releas released ed for test testing ing are are tested tested Testing esting is performed performed in accordance accordance with with approved approved procedures procedures and specifi specification cationss Testing esting is performed performed by qualifi qualified ed personn personnel el Personnel Personnel safety safety is exercised exercised throughout throughout testing testing The proper proper test test medi medium um is is used used The test test medium medium is at proper proper temper temperature, ature, as applica applicable ble System pressuri pressurization zation stages are maintai maintained, ned, if required required The system system is held held at required required pressure pressure for for the specifi specified ed time before before inspecti inspecting ng for  leaks 9. Testing esting prog progres resss charts charts are maint maintain ained ed 10. Tested systems are properly vented and drained for laid-up, and/or properly properly restored for turnover to start-up 11. Documentation forms are prepared in accordance with approved procedures procedures and specifications 12. Documentation forms are completed completed and accurate 13. Documented tests are witnessed when so so required, and documentation forms bear  authorized witness signatures

P-8 Leak Testing

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P-9 PROTECTIVE PROTE CTIVE COATINGS COATINGS The following characteristics of protective coating shall be reviewed: 1. Verify proper proper storage storage of priming, priming, coating coating and and wrapping wrapping materials materials.. Materials Materials that that show evidence of deterioration or damage should not be used 2. Prior to startin starting g coating coating activities activities,, verify verify the following: following: • •

All hydrostatic and non-destructive testing specified has been performed Surface preparation performed as specified (i.e., solvent cleaning, hand tool cleaning, power tool cleaning, blast cleaning, as applicable)

Priming 1. Verify that that the specifie specified d protective protective coating coating materials materials drawn drawn from storage storage are of the correct type and quantity, are in good condition, within shelf life requirements, and are compatible with intended service (e.g., high temperature, corrosive) 2. Surface Surface is cleaned cleaned and free of moisture moisture prior prior to application application of of primer  primer  3. Primer is mixed mixed in accordance accordance with with manufactu manufacturer's rer's instructio instructions ns 4. Check that that the primer primer coat is is uniform uniform and free free of "floods, "floods, 'runs 'runs or "holidays "holidays"" 5. Verify that that the primed primed surface surface is adequately adequately protected protected when suppor supported ted by skids, skids, earthen berms, etc. 6. Where the the surface surface has been pre-p pre-primed rimed,, check the integri integrity ty of the primer primer coating coating and and initiate any necessary repairs Coating And Wrapping Wrapping 1. Check that that the primed primed surface surface is free free of any foreign foreign matter matter or moistu moisture re prior prior to application of the coating 2. Verify that weather weather and and temperatu temperature re conditions conditions are suitable suitable 3. Verify that that the applicat application ion of coating coating and wrapping wrapping material material is according according to manufacturer's directions and compatible with existing coating 4. When spiral spiral weld weld pipe pipe is used, check check that the the raised raised weld seams seams are properl properly y coated to prevent voids under the tape coating co ating 5. Verify that all valves valves and and fittings fittings are coated coated as required required by design design document documentss 6. Ensure Ensure that electri electrical cal holiday holiday testin testing g is accompli accomplished shed as required required 7. Check that that repairs repairs are made made and retested retested in accordan accordance ce with design design requireme requirements nts

P-9 Protective Coatings

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P-10 PIPE INSULATION The following characteristics of pipe insulation shall be reviewed: 1. Maintain Maintain surveilla surveillance nce of the storage storage conditi conditions ons of the the insulation insulation material materialss 2. Check that that material material drawn drawn from storage storage for for applicati application on is dry and and undamaged undamaged 3. Verify that that all required required hydrostatic hydrostatic and non-destru non-destructive ctive testing testing has been performed performed  prior to application of insulation insulation 4. Ensure Ensure any required required surface surface coating coating has been applie applied d 5. Pipe surface surface is free of moistu moisture re prior prior to applicat application ion of insulati insulation on 6. Check that that correct correct type type and and thickness thickness insulation insulation is applied applied 7. Check that that the support support fitti fittings ngs (e.g., (e.g., banding banding straps, straps, “s” and “j” “j” cups) are of the  proper material 8. Where a vapor vapor barrier barrier is require required, d, check that that it is correct correctly ly applied applied to the proper  proper  thickness and that its integrity is maintained throughout 9. Check that that protective protective metal metal coverings coverings are are applied applied in a manner manner that underly underlying ing insulation or vapor barrier is undamaged 10. Ensure that piping or equipment supports do not damage the insulation 11. To isolate the effects effects of a break-in insulation insulation or vapor barrier. barrier. The barrier should be sealed to the pipe at every fitting and supports. 12. All removable vessel heads and manways should be fitted with removable insulation 13. when abrasive insulation material such as cellular glass is used on lines or equipment subject to vibration, the inside surface should be coated to prevent damage to the lines or equipment 14. When more than one layer is to be applied, check that: that: • •

All joints of the previous layer are sealed prior to application of the next layer  All joints between one layer and another are “offset”

15. When insulation is beveled or otherwise terminated, the moisture moisture barrier should be folded over the end of the insulation and sealed 16. Where insulation abuts flanges that are not to be insulated, insulated, the insulation should be  beveled a sufficient distance from the flange to permit removal removal of flange bolts without damage to insulation

P-10 Pipe Insulation

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