10080‐1‐SS‐PP‐006
J3 Program
Dat : 07/07/20 2, Rev. 0
Piping abrication
RECO D OF REV SIONS ate 07. 7.2012
Revision Det ils Issued for Implem ntation
Revision Number
10080‐1‐SS‐PP‐006
J3 Program
Dat : 07/07/20 2, Rev. 0
Piping abrication
Contents 1.
Purpose.............................................................................................................................
2.
Scope ................................................................................................................................
3.
Cost competitive en ineering a d design........................................................................
4.
Conflicts and Deviations...................................................................................................
5.
Definitio s: .......................................................................................................................
6.
Abbrevia ions: ..................................................................................................................
7.
Codes and Standard :.......................................................................................................
8.
Basic Me hodology:..........................................................................................................
9.
Inspection and Testing: .................................................................................................. 1
10.
Preparation for ship ent:.............................................................................................. 1
11.
Vendor Data Requir ment: ............................................................................................ 1
12.
Attachm nts: .................................................................................................................. 1 i) Appe dix A – Supplementary Require ents for team and Feed Water Piping Subject to Indian B iler Regul tion Requi ements ii) FOR
III‐A ‐ Cer ificate of anufactur and Test
iii) FOR
III‐B ‐ Certificate of anufactur and Test
iv) FOR Fittings.
III‐C ‐ Certificate of Manufacture and
est of Boiler Mounti gs and
v) Appe dix B ‐ Piping alignment and Fab ication tol rances.
10080‐1‐SS‐PP‐006
J3 Program Piping abrication
Dat : 07/07/20 2, Rev. 0
1. Pu pose This specification i issued to establish a uniform procedure for the fabri ation of above g ound and undergrou d process nd utility iping, fabr icated at b th shop and site locations at the manufacturing sites of Reliance.
2. Sc pe 2.1. This specification ap lies to all the piping contained within modules, pac ages or sub‐assemblies. This specificati n does no include t e Instrum ntation, pipe‐work and tubin downstre m of the l st block valve on a pi e header. 2.2. Piping su ject to r quirements of the I dian Boil r Regulations is covered by Appendix of this specification.
3. Co t compe itive engineering and desig The engineering team shall maintain th cost focu througho t all phas s of the project. This shoul be done ithout compromisin any specification an design require ents. Fro the piping fabricati n perspective, efforts shall be ade to ensure optimizati n of pre‐ abrication at shop y maximizing the usage of automa ed facilities available t the Pipe Fabrication shop.
4. Co flicts an Deviati ns Process and utility piping shall be fabric ted in acc rdance wi h codes, drawings, and other requirements specified herein. Where conflict e ists, the rder of priority of docume ts shall follow in the ollowing sequence: (i) Local Regulatory and Statutory requirement (ii) This pecification (iii) Cod s and Standard
5. De initions: 5.1. Piping Ma erial Class s The Piping Materi l Classes pecify the material r quiremen s for pipe, fittings flanges, etc., and design d tails for ranch connections, vents, drains, and pressur ‐ temperature con ections b Service Class. Wh re special or non standar material for a par icular class is required, it will be noted on the drawings. 5.2. Supplementary Table of Wall Thickness and Branch Reinforcement The Su plementar Table of Wall Thic ness will specify by individual pipeline number the requirements of wall thickness subjec to calculation as specified in the Pipi g Material Classes. 5.3. Piping Sto k Code Index
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10080‐1‐SS‐PP‐006
J3 Program
Dat : 07/07/20 2, Rev. 0
Piping abrication
The Piping Stock C de Index i entifies and describes all piping in docu ents relat d to pipin material.
aterial item codes
6. Ab reviatio s: AWWA
American Water
orks Asso iation
NDT
Non‐D structive Testing
NDE
Non‐D structive Examination
MT
Magnetic Particle est
DPT
Dye Pe etration T st
GRE
Glass Reinforced
PMI
Positiv Material Identificati n
PWHT
Post Weld Heat Treatment
WPS
Welding Procedur Specification
PQR
Procedure Qualifi ation Record
SER
Site En ineering Request
IBR
Indian Boiler Regulation
7. Co es and S andards: 7.1. Codes 7.1.1. Local Codes or Regulations Where local regulations, ordinances, s atutes or codes tak precedence over ASME c des, such egulations, ordinances, statutes r codes shall govern. 7.1.2. Refinery Code Piping Except here spe ified otherwise, the Process Piping Code ASME B3 .3‐2010 (latest edition) gov rns fabric tion of all iping. 7.1.3. Boiler Code Pi ing The Po er piping code ASM B31.1‐ 2010 (latest dition) and the Indian Boiler Regulations 1950 governs fab ication of team and oiler feed ater piping within the battery limits f the boiler as define in the co e. For ste m and condensate lines ou side the b ttery limit of the boil r the applicable code are IBR a d ASME B31.3‐2 10. (Refer Appendix .) 7.1.4. Other Require ents GRE piping systems shall be in accordance with AWWA M4 Manual Supply ractices or ASME B31.3‐2010 as pplicable.
f Water
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J3 Program
Dat : 07/07/20 2, Rev. 0
Piping abrication
Other c des, such as refriger tion, plumbing or na ional regulations ma govern some p rts of the piping. D awings sh ll indicate the applicable codes in such cases. 7.2. Associate Referenc s 10080‐1‐SS‐PP‐X X
Piping
10080‐1‐SS‐PP‐0 2
Piping omponen s – Stock C talogue Index
10080‐1‐SS‐PP‐0 4
Piping Compone ts – Tec nical Sup ly Conditions for Pipes, ittings, Fla ges, Valve , Bolts, G skets)
10080‐1‐SS‐PP‐0 5
Piping omponen s – Colour oding
10080‐1‐SS‐PP‐0 7
Piping rection an Testing
10080‐1‐SS‐PP‐X X
Chemical Cleaning of Pipe‐works
10080‐1‐SS‐PP‐0 4
Protective coating & Painting
10080‐1‐SS‐PP‐0 6
Inducti n Bending of Pipes
10080‐1‐SS‐PP‐0 1
Extern l Liquid Ep xy Coating for Under round Piping
10080‐1‐SS‐PP‐X X
Welding, NDE and PWHT for abricated Piping
10080‐1‐ENGG‐PRA‐PP‐028
Produc ion of Spo l Drawing and Erection Isometrics
10080‐1‐ENGG‐DBD‐ST‐003
Pipe Support Stan ards
10080‐1‐ENGG‐DBD‐ST‐004
Pipe support man al of standard support drawing
10080‐1‐ENGG‐DBD‐ST‐007
aterial Cl sses
Indian oiler Regulations Standa d Fabrication Details
Notes
10080‐1‐ENGG‐DBD‐ST‐009
Indian oiler Regulation‐ Ref rence doc ment
10080‐1‐ENGG‐DBD‐ST‐010
Guideli es for supporting sm ll bore connections
10080‐1‐SS‐CI‐004
Instru ents for Measurement & Control
10080‐2‐QM00‐J P‐PP‐008
MATERIAL CONTR L DURING FABRICATION & ERECTION OF LTC /NACE PIPING MATE IALS
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10080‐1‐SS‐PP‐006
J3 Program
Dat : 07/07/20 2, Rev. 0
Piping abrication
8. Ba ic Methodology: 8.1. Extent of hop Fabri ation
8.1.1. Carbon steel iping 2" n minal bor and larger is generally shop fa ricated. Exceptions are Carbon steel piping les than 2" b re and lon straight r ns such as in ipe‐racks hich shall e field fabricated. 8.1.2. All y and stai less steel pipe, all sizes (including less th n 2”), is enerally shop abricated xcept for l ng straight runs. This is to maxi ise the sp cialised weldi g in the shop. 8.1.3. Where long traight runs of fiel piping r quire expansion lo ps, the expansion loops shall be sh p fabricat d. 8.2. Materials
8.2.1. Ma erials Sup of th piping sy issue”. Unless s suppl all temp testing, inspecti
ly: All ma erials necessary for t e fabrication and installation tems sho n on the isometrics & GA dra ings shall be “ free ecified ot erwise in the work order, the FABRICAT R shall rary materials, pipes, supports etc. requi ed for fabrication, n and tran portation.
8.2.2. Unless otherwise identifi d on piping drawings, all materi ls shall co form to 1008 ‐1‐SS‐PP‐XXX for the individual line service. Individual line class aterials and piping special items ill be identified on piping drawings and P&IDs by conventional line work and graphic symbols. ut ‐of ‐class materials will be identified by code numbers or descrip ions. FABRICATOR sh ll inspect ll piping mate ials on receipt to en ure that t e correct grade, quality, condit on, end preparations, identification and dim nsions ha e been s pplied an are in accor ance with the applicable project standards and specifi ations. 8.2.3. Ma erial Identification All materials shall e new and identifiable and shall be supplied with certification to meet project re uirements. PMI shall be performed for Alloy steel m terials bef re Fit‐up. Marking requirements and te hniques shall be in accordance 004.
ith 10080‐1‐SS‐PP‐
As an aid to preliminary recognition, ipe materials shall be Colour coded in accorda ce with 1 080‐1‐SS‐PP‐005 “Col ur Coding of Piping aterials”. Material control d ring fabrication & er ction of L CS/ NACE ipe materials shall be follo ed as given in procedure 10080‐2‐QM00‐JEP‐PP‐008. 8.2.4. Control of Materials FABRIC TOR shall submit a procedur to the UYER/CLIENT descri ing the controls to be applied to the r ceipt, storage and iss e of pipin materials.
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J3 Program
Dat : 07/07/20 2, Rev. 0
Piping abrication
The pro edure shall describe s a minimum, the foll wing:‐ i. ii. iii. iv. v. vi.
ethod of ontrols on material receipt. andling, s gregation nd storag procedures. etails of p oposed fil or stock c rd control system. Issue of ma erials proc dure. ethod of ransfer of identificati n marking on piping materials. ethod of eterminin and reporting material shortages
8.2.5. Unidentified Piping Mate ials Piping aterials t at cannot be identi ied by id ntification markings shall be placed in a storage area s parate fr m accept ble mate ial with sufficient safegua ds to pre lude the being used. PMT ay be carried out on these materials to identif y and tag alloy steel. 8.2.6. Ma erial and
eld Identi ication
Weld identification symbols hall be re orded ont fabricati n drawings with a cross re erence to ny Non Destructive E amination (NDE) report number . If at any time during installati n or fabrication, any iece of m terial is not readily identifiable, it shall be rejecte , including other components w lded thereto. 8.2.7. Da aged Mat rials Materials which h ve been d maged, g uged or found to ha e defects hall not be used except th t minor surface marks may be dressed, pr vided that the mill tolerance minimu wall thickness is not encroached upon. Dressing will require approval from the esponsible Engineer f Reliance. The Res onsible Engineer fro Reliance hall be inf rmed immediately if eceived materials are damaged and unfit for fabrication. Particul r care mu t be taken with flange faces. R dial grooves or scrat hes are not allowed. Re‐facing will require approval fr m the responsible Reliance Engineer. Edge thi kness of fl nges shall be checked after re‐facing. Damaged material shall be laced in separate storage a ea from material, with suffi ient safeg ards to pr vent its us .
ccepted
8.2.8. Dif erent piping material shall be stored in segregated areas. FAB ICATOR shall nsure tha separate batches of materials an be rel ted to the original manufacturers’ dvice note and certifi ation. Carbon steel, low temperature carbon steel, alloys and stai less steel shall be stored nd transp rted such that any possibility of cross mi ing of ma erials is prevent d. Materials destine for Indian Boiler Reg lation coded systems shall be separat d from other materials of a simil r nature.
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J3 Program Piping abrication
10080‐1‐SS‐PP‐006 Dat : 07/07/20 2, Rev. 0
All mat rials, whether loose r prefabricated, shall be stored above ground on a flat surface, on latforms or pallets, in a manner that will prev nt any deterioration from debris, gre se, paint spray or any other foreign matter. 8.3. General F brication equireme ts
In addition to the requireme ts of the governing code, the ollowing s all also apply u less other ise noted n the pipi g drawing . 8.3.1. Fabrication Ar a Fabrication of diff rent mate ials e.g. C rbon Steel, L.T. Carb n Steel, alloy steel and stainless steel etc. shall be carried out in segregated ar as to pre ent any possibility of cross ixing during cutting nd weldin . 8.3.2. Di ensions Dimensional tolerances shall e in accordance with Appendix B “Fabrica ion and Alignment Toleran es” (Based on PFI ES‐ ). 8.3.3. Bol Holes Flange olt holes re to stra dle princi al centerli es of equipment an piping, unless otherwise s own on th drawings. 8.3.4. Threaded Con ections Unless specified to the contrary on the ite Mecha threads shall be to ASME B1. 0.1 (NPT). All thread checked or chased after welding or heat treating. other i serts are to be drilled throu h the co obstruc ion.
ical contr ctor’s dra ings, all d connections must be gauge penings for thermo‐ ells and nections and be fr e from
All intermediate threaded pip joints shall be made using thre ded couplings. The use of unions is n t permitted. Threaded flanges shall be used to facilit te easy removal of valves nd in line instrument for maint nance pur oses. When 2”and 3” NPS ipes with nds threa ed BSP “T are requi ed to mat h fittings ith NPT threads, the pipe s all be cut nd thread d NPT to atch. 8.3.5. Socket Welding Care sh ll be take to ensur that a cl arance of 1.5mm re ains between the male and female ends at the bottom of the socket. Pipe for socket welding shall be squa e cut. To aintain 1. mm clearance, spring type arrangement, termed as “Gap‐O‐Let" may be provided. 8.3.6. Piping compo ents shall e in accor ance with 10080‐1‐S ‐PP‐004 “ echnical Suppl Conditions for Pipin Materials”. 8.3.7. Ori ice Runs Welding neck orifi e flanges are specifie up to 18” NPS and shall have t e same bore as the pipe. rifice runs shall not contain welds except t the flang s. Pipe
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10080‐1‐SS‐PP‐006
J3 Program Piping abrication
Dat : 07/07/20 2, Rev. 0
ends and bevels at orifice flanges must e cut such that it is perpendicul r to the axis of he pipe. elds at the orifice flanges shall be groun smooth and flush inside. Pipe tap c nnections on orifice flanges or irectly on the pipe here so specifie , shall be rilled through the pi e wall and shall be finished sm oth and flush inside. Pipe ipples to orifice flang s are thre ded and r quire seal elding. All orifice tap pipe connections and valv s to be adequately s pported/braced as per spe 10080‐1‐ S‐ST‐010 t minimise vibration nd the po ential of s al weld failure l ading to l akage. Orientation o tap and inimum straight run equired for Orifi e plate sh ll be accor ing to 10080‐1‐SS‐CI‐004. 8.3.8. Branch Conne tions Branch onnections shall be in accorda ce to 100 0‐1‐SS‐PP‐038 Branch Tables. 12" and larger pip stubs an branches shall extend to the fi st flange r to the field weld point as indicated n the piping drawings or as required for re sonable spool pi ce size. All reinf orcement ad (RF pa ) shall be pneumatic tested at 1.5 Kg/sq.cm using suitable tapped ole. Where reinfor ement pads are r quired at branch connections which are to be field weld d, they m st be fabricated by the Shop Fabricator and tack welded to the 'stub on' spool for shipment. A vent/ ell tale hole is to be drilled in each reinforcement pad or reinforcement pad sec ion. 8.3.9. Loose Piping Component Any piping components specified on piping drawings to be shipped l ose for welding on site, are to be separately acked for shipment, with the package clearly agged (see Para. 9. ) and labeled "Components f r Site Welding to Prefabricated Pipe ork". 8.3.10. Welded Pipe Support Att chments Pipe su ports shall be in accordance wit piping dr wings and with requirements of 1008 ‐1‐ENGG‐ BD‐ST‐003 “Pipe Sup ort Standards”. 8.4. Welding
8.4.1. Ge eral In addi ion to th governing code, elding sh ll confor to the tandard specific tion, 1008 ‐1‐SS‐PP‐XXX “Weldi g, PWHT a d NDE of abricated iping”. •
•
ield Welds ‐Field Welds (F.W.) ay be used at any pipe spool i terface, here pipi g dimensi ns to weld locations can be acc rately determined nd where no cutting or trimmi g of pipe ork is necessary. Field welds shall be cl sed with ut any tension in t e lines, specially t strain sensitive equipment. ield Fit W lds ‐Wher ver Field Fit Welds (F.F.W.) are indicated on piping rawings, FABRICATO shall det il and fur ish the pi e spool s ch that P ge 7 of 2
10080‐1‐SS‐PP‐006
J3 Program Piping abrication
•
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ield Const uction can trim exce s pipe and make final closing w ld. The mount of excess pip furnished shall be 1 0mm, and the pipe nd shall e square c t. loser welds/ Golden j ints ‐ In li u of press re test, th weld joint shall be tested wit Radiogra hy or Ultrasonic te t and M or PT with prior pproval of the Respo sible Engineer from R liance.
8.4.2. Sur ace Defects Surface defects c used by ishandling during fa rication shall be co sidered injuriou if the def ct extends below the mill tolera ce minimum wall thickness or is more than 1.5m in depth. Fittings, flanges or pipe with i jurious defects are d emed unacceptable or spool fabrication and shall not be used. 8.5. Bends
8.5.1. Unless other ise specified on the approval drawings and specif ications, bend in pipes hall be af ected using propriet ry manuf ctured long radius elbo s as listed. Substitution of ind ction or cold bends is only ac eptable when the geometrical requirements of the piping specificati n are met. 8.5.2. Ind ction or c ld bending shall be in accordanc with 10080‐1‐SS‐PP‐ 16. 8.5.3. If r ferenced i 10080‐1‐ NGG‐DBD PP‐001 for lines 8” N and above, mitred elbo s as per STD Drawing No EPCMD P14‐JG000‐045 may be used. 8.6. Weld Sea s
8.6.1. On welded pipe, longitudinal weld seams shall be out of hase at inline butt welds, any w lded att chments i.e. bran h conne tions, instrument conn ctions, an pipe supp rt attach ents etc. shall not bisect any seam weld. The l ngitudinal / Circumference sea s of the welded pipe should no rest on the sl eper or supports, to nable to c rry out NDT/ testing i future. 8.6.2. The minimum rotation f or welded seams sh ll be 10 times the pipe wall thickness or 90° ut of phase, whichev r is less. The minimum dist nce between circum erential butt welds, shall be 6 times the pipe wall thickness or 50 mm, whichever is greater. 8.7. Cleaning
8.7.1. All shop fabricated pipin assembli s/pipe spools shall b internally cleaned by bl wing air nly and pi e ends shall be covered with plastic end caps for sizes p to 12” NB. For sizes greater th n 12” NB, the pipe ends will be left open and the shop f abricated iping assemblies/ pipe spools shall be i ternally clean d by blowing air to remove dust and forei n matter rior to er ction at site.
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J3 Program
Dat : 07/07/20 2, Rev. 0
Piping abrication
In eithe case, wh rever flanged pipe spools/ pipin assembli s are involved, the flanged ends shall be covered with plastic flange c vers or 5 m thick pl boards cut to the size of the flanged ends so that the flange facings are fully protected. 8.7.2. If water is use in cleaning austeniti stainless teel piping assemblie , it shall not c ntain mo e than 50 ppm chlo ides. The maximum allowable limit for water quality for CS/AS pipi g for hydr ‐test shall be 250pp . 8.7.3. An special r quiremen s for cleaning of shop fabricated piping will be speci ied in the Line Design tion Table . 8.7.4. Where specifi d on the piping drawings, chemical cleaning of pipew rk shall be in ccordance with SS, 1 080‐1‐SS‐ P‐XXX. 8.7.5. Cutting should be accurate, smoot and true to template, Slag and cutting dross shall be r moved es ecially if lasma cut ing was u ed, then the slags shall e remove immediat ly after cutting so that slag rem val will be easier in the h t conditio . Similarly, holes made for SB ta ping on th header b plasma cutting also check shall be ade for re oval of sl gs immedi tely. 8.8. Alignmen and Fabri ation Tole ances
8.8.1. Alignment of ores a)
ipes with a thickne s of 6 m and greater shall not have internal isalignme t of pipe wall exceeding 1.5 m with r ot gap or 0.8 mm ithout root gap. b) ipes with a thickness less han 6 mm shall ot have internal isalignme t of pipe all exceeding 25 perc nt of the pipe wall thickness. c) hen misalignment is greater t an the ab ve, the c mponents shall be ligned by drifting, r lling or machining i accordance with the Code, nsuring that the minimum wall thickness i maintained after considering the manu acturing tolerances defined i the ap ropriate material specificatio s. 8.8.2. FA RICATOR s all be responsible for the dimen ional accu acy of fabricated pip spools. Line up clamps shall be used whe necessar to ensure that fit‐ up is within design toler nces. In a dition to he alignm nt and fa rication tol rances sp cified in the refere ced code and sta dards herein, the foll wing shall apply:
Overall linear dimen ions for li e sizes 10″ and smaller:
+ 3mm
Overall linear dimen ions for li e sizes 12″ and larger:
+ 5mm
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J3 Program
Dat : 07/07/20 2, Rev. 0
Piping abrication
Linear dimensional tolerances shall be a plicable to dimensions measure from a commo datum for the relati e locations of branches, flanged or butt‐w ld ends and shall not be cu ulative. Before bolting u , flange aces shall be aligned to the esign pla e, measured across ny diamet r within:
+ 1.5 m
Flange bolt holes shall be aligned within:
+ 2m
Specifi d angles f r bends or branches shall be within:
+ 0.25
For alig ment and abrication tolerances also refer to Appendix B. Flange f ces shall not be conc ve. 8.8.3
Fit up
a)
ipes shall e properly supported and aligned by jigs or clamps as equired in order t preclude extraneo s loads and minimize stresse during tacking. b) mall tack elds, i.e. between 12 mm and 1 mm in length, penet ating to the bottom of the groove may be used in fitting up.
9. Inspection and Testin : 9.1. Examinati n 9.1.1. All piping co ponents and work anship f r each installation hall be examined in ac ordance ith 10080 1‐SS‐PP‐025, Form 167A. FAB ICATOR shall be respo sible for non‐destructive exa ination ( adiograph , liquid penetrate, ultra onic, magnetic particle, etc.) in ccordance with the Code and to the extent specified in Form 167A. 9.1.2. Where exami ation reveals a failur to meet design or ode requirements, FABRICATOR shall make su h repairs nd carry out future examinations as are necessary to me t the design or code requirements. 9.2. Inspection 9.2.1. All inspection shall be perf rmed by FABRIC TOR's inspector. BUYE /CLIENT’s inspector retains the ight to visit FABRICA OR's place of work and carry out r ndom ins ection. B YER/CLIENT’s inspec or may re ect any mate ial, procedure or work, which, in his opi ion alone, fails to eet the requi ements of applicable codes, SSs, procedur s, drawin s, purchas orders or co tract.
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J3 Program
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9.2.2. Unless specifi d otherwise on dra ings, sho hydrostatic testing of pipe spool is not re uired. If required, all pressure testing shall be carried out in accor ance with SPECIFICA ION, 100 0‐1‐SS‐PP‐ 07. Howe er Pneumatic test for R inforcement (RF) pad shall be carried out at sho at 1.5 k /sq.cm. However hydro‐testing of spools is necessary in case of MOC/ sh t down related jobs in o der to avoid Hydro‐Test in opera ing plant. 9.2.3. Aft r installation, all fab icated assemblies will be hydr statically tested in accor ance with the applic ble Code. FABRICAT R shall gu rantee his work to be ca able of wi hstanding the hydros atic test, a d he shall repair or r place at his expense any item which fails to pass such test. 9.3. Procedures 9.3.1. Ap roval of t e following Shop FABRICATOR' procedures and activities is requi ed from R liance prio to the use of such pr cedures f r the project. a) Procedures and d tails of welding processes. b) Weld r pair procedures. c) Heat treating operations. d) Non‐destructive e amination procedures. e) Quality control pr cedures. f) Paint procedures. 9.3.2. All requests or relaxation of this SPECIFICATION, or, of the do uments refer nced in this document, shall be stated in writing for t e conside ation of BUYE . 9.3.3. Ap roval of FABRICATOR's proce ures, dra ings, etc. shall not relieve FABRICATOR of responsibility for correctness, a d compliance with a l codes, legal equirements and this SPECIFICA ION.
10.Pr paration for ship ent: 10. . Im ediately after cleani g and ins ection, fabricated piping spools shall be suitably p otected fo shipment as follows: Flange f ces, machined surfaces and threads shall b cleaned of all mill sc le, rust, etc., an coated with a corrosion preventative such s Rust Ban 324. Small b anches and small h ader atta hments s all be ad quately braced or otherwi e protected to preve t damage uring han ling, shipping and sto age. Threaded coupling and other internally hreaded c nnections shall be cl sed and protect d by wrap ing with plastic tape, or plastic c ps. Threaded nipples nd other externally t readed connections hall be closed and protect d by wrap ing with plastic tape, or plastic c ps.
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J3 Program
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Piping abrication
Weld e d prepar tions shall be protected with securely astened plastic or wooden covers an coated wi h rust pro ibited. Flange f ces shall be protecte with securely fasten d plastic o wooden c vers. Ring type joint flanges shall h ve the gro ve packed with grease prior to attaching flange protective c vers. Socket
eld ends s all be protected usin plastic plugs.
10. . All small loos pieces sh ll be boxed for prot ction duri g shipment. Each box shall be identified with a securely astened stainless steel tag bearing the purchase rder num er along with appropriate spool detail number (see p ragraph 7.1.2) to i dicate its lace in the final installed assembly. 10. . Fabricated pipe spools s all be adequately bl cked, stra ped, or o herwise held in position duri g shipment and shall be further separated by dunnag as may be necess ry to prev nt damage. Spools s all be handled using nylon straps. Chains shall not be used.
11.Ve dor Dat Require ent: 11. . The following ecords, fully identifie with the pecific material or part of the piping represented, must be a ailable for reference or examination by R liance’s Inspector. On job ompletion, they mu t be collated, indexed and bound, and forwarded to Relia ce’s offic address d for the attention of Vend r Print Control/E pediting. a) b) c) d) e) f) g) h) i) j) k) l) m) n)
ertificates attesting that all t e quality control re uirements of the pplicable code and of the engineering desig have bee met. yrometer harts and ecords of eat treatment. adiographic films. esults of agnetic particle and dye penetra t examinations. harts or other record of Brinell ardness tests. esults of ny other upplemen al types o examination test or analysis specified. elding pr cedure sp cifications (WPS) and their pro edure qualification records (PQ R). epair proc dures and approvals epair details. perators elding qualifications test results. aint proce ures. abrication drawings eld maps pproved deviations ( hall be car ied out through SERs only) if any
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11. . All ecords an reports s ated in th purchase order shall be furnished upon or prior t , the arrival of the piping at the job site. The record package shall be specificall identified as to the s ipment it epresents. 11. .
FA RICATOR s all prepar schedules to show his forecast or:‐ a) b) c) d) e) f)
aterial pr curement (as needed) aterial re uired for next 15 day . pool fabrication. pool NDT learance. pool ship ent to site. hese sche ules must be updated at regul r periods, as specified in the urchase o der, to ref lect the ac ual situati n against the original agreed schedule.
11.3.1. FA RICATOR hall prepa e and up ate every two weeks spool fa rication recor s for each plant and the overall record. 11.3.2. FA RICATOR s all provid clear legible “as built” mark‐ups of BUYER/ LIENT’s pipin isometric drawings. “As buil ” shall be issued to BUYER/CLIE T for reco d purpose within 2 eeks of notification that piping is ready for shipment. rawings s all be cle r of all revision markings, diamonds, clouds etc., and be issued on the next sequential revision as “Certifi d as Built”.
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12.Attachment :
A PENDI A SUP LEMEN ARY RE UIREME TS FOR TEAM A D FEED ATER PIIPING SU JECT TO INDIAN OILER R GULATI NS REQ IREMEN S
1.
Purpos e Appendix A is a mandatory supplement to the fab ication re uirement of this specification to en ure all st am and oiler feed systems conform t or are superior to the fabrication equireme ts of the Indian Boiler Reg lations (IBR).
2.
Piping Material Classes Only mat rials specified by th relevant piping material classes shall e used to fabric te the ste m and boiler feed s stems.
3.
Materi ls All materials purchased for use on I R syste s are s bject to specific purchas orders a d shall b segregated from all other materials of similar grade. he Fabri ator shall inspect ll materials on rec ipt to ensure the correct grade, quality, condition, nd prep ration, identificati n and dimensions have een supplied and re in acc rdance with the applicable purchas order and specific tion requirements. All materials receiv d shall be acco panied b a suppli r complet d IBR F RM IIIA, , or C (E amples attached).
4.
Weldin g and N n-Destr uctive Testing All welding config rations s all confor m to Standard Dra ing No. EPCMDP14-JG000-046 a d the req irements of specifi ation 10080-1-ENGG-XXXGAW-X X.
5.
Inspect ion All fabrication activities will be subject t IBR inspection an approval prior to installati n.
6.
Hydros tatic Te ting Hydrostatic Testing shall be p rformed f llowing c mpletion of installation with prior approval of the IBR site Inspector.
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ORM IIIC rtificate o Manufac ure and Test (R gulation (e)) Name of Part
:......................................................................................................
Maker’s Name and ddress
:......................................................................................................
Design ressure
:......................................................................................................
Design emperatur
:......................................................................................................
MATERIAL Process of Manufac ure
:......................................................................................................
Fully killed/rimmed
:......................................................................................................
Chemic l Composition
:......................................................................................................
PIPES Main Di ensions
:......................................................................................................
Toleran es
:......................................................................................................
Mode o Manufactur e
:......................................................................................................
Identification Marks
:......................................................................................................
Drawing Numbers
:......................................................................................................
Bend T st on Pipes
:......................................................................................................
Bend T st on Weld
:......................................................................................................
Flatteni g Test
:......................................................................................................
Tensile Strength
:......................................................................................................
Mode o attachment of Flanges
:......................................................................................................
Flange articulars
:......................................................................................................
Size of ranches
:......................................................................................................
Mode o attachment of Branche :...................................................................................................... Heat Tr atment
:......................................................................................................
Final H draulic Test
:......................................................................................................
NOTE:In addition, the followin information in respect of the mater ial shall be urnished in a tabular form in conformity wit the requir ments of Regulation 4( )(vi) for the note thereto, as the case may be. The information ma be given fr m the esta lished test ata or if th material is of stand rd quality an extract fro the stand rd may be f rnished ins ead.
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Metal Temp. up to C
50
275
3 0
325
375
400
425
450
475
500
525
5 50
575
60
625
Et Sc Sr
Tensile Strength at 0°C Where: Et = Yield Point at t mperature (0.2% proof tress) Sc = Average Stres to produce an elongation of 1% (c eep) in 100,000 hours t the variou working metal tem eratures. Sr = Average and lowest stres to produc rupture in 100,000 hours at the various working metal temperatu es. Temper ature range in i the table
ay extend p to the limit of applicability of the material.
The value of Sc and Sr need e furnished only in res ect of Pipes/Tubes int nded to be used for working m tal temperatures above 454°C (850°F)
Certifie that the pa ticulars ent red herein are correct.
The par iculars of fabricated co ponents ar shown in d awing No :..................................................
The pa t has been designed nd constru ted to comply with the Indian Boiler Regulati ns for a working pressure of ....................... and temperature ....................... and satisfactorily withstood a water test of .......................... on the ...........................day of .........................19 ..... in th presence of our responsible re resentative whose signature is ppended hereunder.
Maker’s Representative........................................................
Maker.................................................................................... (Name an Signature)
We have satisfied urselves th t the pipes have been constructed in accordance with Ch pter VIII. The tests onducted on the sampl s taken fro the finish d pipes ha e been witnessed by us and the particulars ntered herein are corre t.
Place. ......................................................
.................................................................
Date. ....................................................... ................................................................. (Name an Signature f Inspecting Authority).
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ORM IIIC rtificate o Manufac ure and Test (R gulation (f)) Maker’s Name
:......................................................................................................
Design ressure
:......................................................................................................
Design emperatur
:......................................................................................................
MATERIAL Process of Manufac ure
:......................................................................................................
Fully killed/rimmed
:......................................................................................................
Chemic l Composition
:......................................................................................................
TUBES Process of Manufac ure
:......................................................................................................
Main Di ensions
:......................................................................................................
Toleran es
:......................................................................................................
Bend T st
:......................................................................................................
Flatteni g Test
:......................................................................................................
Tensile Strength
:......................................................................................................
Elongation Percentage
:......................................................................................................
Crushing Test
:......................................................................................................
Flare T st
:......................................................................................................
Bend T st on Weld
:......................................................................................................
Bulging Test and Driifting Test :...................................................................................................... (for coppe and brass) Heat Tr atment
:......................................................................................................
Hydrauliic Test
:......................................................................................................
NOTE:In addition, the following inform tion in respect of the aterial shall be furnished in a tabul r form in conformity with the requirements of Regulation 4(c)(vi) for the note ther eto, as the ase may be. This i formation ay be given from the established test data o if the mat rial is of standard quality an extract from th standard ay be furnished instead. Metal Temp. up to C
50
275
3 0
325
375
400
425
450
475
500
525
5 50
575
60
625
Et Sc Sr
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Tensile Strength at 0°C where: Et = Yield Point at t mperature (0.2% proof tress) Sc = Average Stres to produce an elongation of 1% (c eep) in 100,000 hours t the variou working metal tem eratures. Sr = Average and lowest stres to produc rupture in 100,000 hours at the various working metal temperatu es.
Temper ature range in i the table
ay extend p to the limit of applicability of the material.
The value of Sc and Sr need e furnished only in res ect of Pipes/Tubes int nded to be used for working m tal temperatures above 454°C (850°F)
Certifie that the pa ticulars ent red herein are correct.
The par iculars of fabricated co ponents ar shown in d awing No:...................................................
The tubes have been manufactured to co ply with the Indian B iler Regula ions for a aximum working pr essure of ......................and temper ature of ......................... at our wor s above named an satisfactor ily withstood a water test of ......................... on he ..................... day of ..................... 19 ... in the presence of our r esponsible r epresentative whose signature is appended hereunder.
Maker’s Representative...........................................................
Maker...................................................................................... (Name an Signature)
We have satisfied ourselves that the pipes have been c nstructed in accordanc with Chapter II. The tests conducted on th samples t ken from the finished t bes have been witnessed by us and the particulars ent red herein re correct.
Place ........................................................
......................................................................
Date ......................................................... ....................................................................... (Name an Signature f Inspecting Authority)
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ORM III(Certificate of Man facture a d Test of Boiler Mo ntings and Fittings) (R gulation 69) Name of Part
:......................................................................................................
Maker’s name and ddress
:......................................................................................................
Intende Working P essure
:......................................
kg/ m² (lb./sq. i ch)
Hydrauliic Test Pres ure
:......................................
kg/ m² (lb./sq. i ch)
Main Di ensions
:......................................................................................................
Drawing Nos.
:......................................................................................................
Identification Marks
:......................................................................................................
Chemic l Composition
:......................................................................................................
Physical Test Resul s i)
Tensile Str ength
:...........................................................
ii)
Transvers Bend Test :...........................................................
iii)
Elongation
:...........................................................
Certifie that the pa ticulars ent red herein are correct.
The pa t has been designed nd constru ted to comply with the Indian Boiler Regulati ns for a maximum working pressure of ..................... and te perature f .................... and satisfactorily withstood a hydraulic test using ater and kerosene or with any suitable liquid in accordance with the provisions f Clause (a) of Regulati n 290 on the ........................ day of ...................... 19 .... in the pres nce of our esponsible epresentati e whose signature is appended hereunder.
Signatu e of Makers Representative:..................................................................................................
Signatu e of Inspecting Officer
ho witnessed the test:......................................................................
Date at ......................... the day of ................................ 19.....
Signatu e and seal f Inspecting Authority:.........................................................................................
Place..................................................................................
Date....................................................................................
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Maker’s Represen ative........................................ (Name an Signature)
10080‐1‐SS‐PP‐006 Dat : 07/07/20 2, Rev. 0
Maker..................................................................
We have satisfied ourselves that the pipes have been c nstructed in accordanc with Chapter II. The tests conducted on th samples t ken from the finished t bes have been witnessed by us and the particulars ent red herein re correct.
Place........................................................................
N me And Si nature of the Inspecting Officer w o witnesse tests.
Date.........................................................................
N me and Signature of In pecting Aut ority.
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A PPENDIX B PIPING ALIG MENT A D FABRICATION OLERAN ES (Pipe Fabric tion Instit te ES3)
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