NEW EUROPEAN PDH KALLO PROJECT

EXECUTION PLAN
PIPING PREFABRICATION WORKS

EXECUTION PLAN
PIPING PREFABRICATION WORKS

REV DATE ISSUED FOR DRAFT CHECK APPROVED

01 22/11/2019 Issued for Information S. Bovi C. Lopez A. Merella
02 24/02/2020 Issued for Information A. Sorrenti C. Lopez A. Merella
03 15/07/2020 Issued for Information S. Bovi C. Lopez A. Merella

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HOLD’s
HOLD n REF. DESCRIPTION ACTIONS
1
2
3

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INDEX

1 Purpose.............................................................................................................................................. 4
2 Definitions and Abbreviations ........................................................................................................ 5
3 Reference Documents ...................................................................................................................... 7
3.1 EPCm CONTRACTOR’s Documents ..................................................................................... 7
4 General Responsibilities .................................................................................................................. 7
5 Scope of Work .................................................................................................................................. 8
5.1 General ..................................................................................................................................... 8
5.2 Description of the WORKS ..................................................................................................... 8
5.2.1 General workflow .................................................................................................................... 8
6 Spooling Requirements .................................................................................................................... 9
6.1 Large Large Bore and Large Bore Spooling General Requirements ....................................... 9
6.2 Large Large Bore and Large Bore Piping Connected to Equipment ..................................... 10
6.3 Above Ground, Small Bore Piping in Around Equipment Area............................................ 11
6.4 Above Ground, Large Large Bore and Large Bore Piping in Pipe Rack and Sleeper Way
Area 11
6.5 Underground Piping............................................................................................................... 12
6.6 Tagging Rules for Joints and Spools ..................................................................................... 12
6.7 Welded Joints......................................................................................................................... 12
6.8 Welded Supports .................................................................................................................... 13
6.9 Spools .................................................................................................................................... 14
6.10 Flanged Joints ........................................................................................................................ 14
7 Piping Isometric Issue.................................................................................................................... 15
8 Welding Data Base Management.................................................................................................. 15
9 Deliverables..................................................................................................................................... 15
10 System Requirements .................................................................................................................... 16

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1 Purpose

The purpose of the present document is to describe the LB, LLB and SB piping spooling and
fabrication activities to be executed by FABRICATION SUPPLIER for the New European PDH
Kallo Project for Borealis Kallo N.V, located in Sint-Jansweg 2, 9130 Kallo - Kieldrecht, Belgium.

As per current SUPPLIERs strategy the mechanical works have been split into the following
packages:
# Package Brief Description
Supplier in charge of the prefabrication,
PIPING PREFABRICATION
1
WORKS LB
spooling and painting works of LB piping
(from 2” to 32”)
Supplier in charge of the prefabrication,
spooling, painting and erection works of LLB
PIPING & PAINTING
2
WORKS LLB
piping (from 34” and above), installation of
in-line valves and instruments/accessories,
pipe supports fabrication and erection
Supplier in charge of the mechanical works in
the Greenfield “Area North”: SB piping
fabrication and erection, LB piping erection
MECHANICAL & and testing, installation of in-line valves and
PAINTING WORKS instruments/accessories, static and rotating
3
GREENFIELD NORTH equipment installation (including auxiliary
AREA steel structures installation, if any), pipe
supports fabrication and erection, painting and
touch-up works, pre-commissioning activities,
assistance to commissioning
Supplier in charge of the mechanical works in
the Greenfield “Area South”: SB piping
fabrication and erection, LB piping erection
MECHANICAL & and testing, installation of in-line valves and
PAINTING WORKS instruments/accessories, static and rotating
4
GREENFIELD SOUTH equipment installation (including auxiliary
AREA steel structures installation, if any), pipe
supports fabrication and erection, painting and
touch-up works, pre-commissioning activities,
assistance to commissioning

Referring to the above SUPPLIER strategy, the present document describes the scope relevant for
the “Piping Spooling Execution Plan for LB, LLB and SB”.
Detailed description of CONSTRUCTION and FABRICATION SUPPLIER’s scope of work is
provided at Chapter 6.

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2 Definitions and Abbreviations

COMPANY means the company which awarded the CONTRACT for the execution of the WORK
to EPCm CONTRACTOR, i.e BOREALIS KALLO N.V., a company existing under the laws of
Belgium and having its offices in St.Jansweg 2, 9130 Kallo, Belgium.

EPCm CONTRACTOR means Tecnimont S.p.A. with offices located at Via Gaetano de Castillia
6A, 20124 Milan, Italy, appointed by COMPANY, through the award of the EPCm Contract, to act
on its behalf in relation to the management of the CONTRACT.

FABRICATION SUPPLIER means the company which has been awarded the EPCm
CONTRACT (by COMPANY) for the execution of the piping spooling and fabrication WORK

CONSTRUCTON SUPPLIER means the company which has been awarded the EPCm
CONTRACT (by COMPANY) for the execution of the piping erection WORK

PLANT or PROJECT means the COMPANY’s proposed new installation to be constructed in an

AREA which the WORKS forms a part i.e. 4078-Kallo Borealis Project - New European PDH
Complex in Sint Jansweg2, 9130 Kallo-Kieldecht, Belgium

AREA means the geographical location which contain’s the Project and may contain existing
COMPANY’s assets in operation i.e New European PDH Complex in Sint Jansweg2, 9130 Kallo-
Kieldecht, Belgium.

CONTRACT means the Contract Agreement, the special contract conditions (SCC) the relevant
Annexures and the General conditions (GC).

TECHNICAL INFORMATION means the work scope and relevant Attachment (Annex 4 to SCC)

WORKS SITE means the area specified in the TECHNICAL DOCUMENTATION where the
CONSTRUCTION SUPPLIER’s WORK is carried out and any other place, including but not
limited to external workshop, which the COMPANY might authorize or make available in order to
execute the WORK and any part thereof, such as COMPANY/EPCm CONTRACTOR’s warehouses
and area and warehouses for storing materials and equipment which are utilized by
CONSTRUCTION SUPPLIER.

WORK means also WORKS

WORKSHOP means the SUPPLIER’s premises where prefabrication WORKS shall be executed

WR means Works Requisition

WS means Scope of Work

NDE means Non-Destructive Examination

PWHT means Post Weld Heat Treatment

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LB means Large Bore

LLB means Large Large Bore

SB means Small Bore

TP means Test Package

EWR means Extra Work Request

MIR means Material Issue Report

ASSEMBLY WELD means a type of weld that is welded before erection

FIELD WELD means Joints welded at SITE during Erection or Installation

JOINT means the connection between two piping elements. Based on the nature of the connection
it may be welded, flanged, threaded or clamped type.

ISOMETRIC DRAWING means three-dimensional drawing providing a single line representation

of piping lines and the location of their associated components

PIPING SPOOL means section of a Piping system prefabricated together

PIPING SPOOL DRAWING means three-dimensional drawing providing a single line

representation of the prefabricated components of a Piping Isometric Drawing with the relevant
location

SHOP WELD means joints welded at WORKSHOP

FIELD FIT-WELD Joints welded at Site during Erection or Installation where an extra length of
pipe has been added for filed adjustment. The pipe end will be cut, beveled and welded on Site after
the Construction Subcontractor determines the correct dimensions and shall be compensated as
Field Weld as per 4078-XZ-SC-9000000101 specification

SPOOLING means process of splitting the engineered piping lines in SPOOLs identifying which
joints shall be carried out at WORKSHOP or at SITE. This process is carried out by the
FABRICATION SUPPLIERs based on the Project Standards, good construction practices and the
spooling criteria

EDMS means Engineering Document Management System

SD means Piping Spool Drawing

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3 Reference Documents

The below listed documents shall be subject to update and tailoring in accordance with PROJECT
requirements.

During execution of the WORK, EPCm CONTRACTOR may transmit to CONSTRUCTION

SUPPLIER, additional Quality and HSE documentations / guidelines / requirements, as applicable
to CONSTRUCTION SUPPLIER’s activities and as per requirements of the COMPANY as well as
local laws, for compliance and implementation.

3.1 EPCm CONTRACTOR’s Documents

General

EPCm CONTRACTOR COMPANY DOC NUMBER DOCUMENT TITLE

NUMBER

4078-IX-SG-9000000001 33000667-TCM-DH2-PI-SPE- PIPING SPOOLING DATA EXCHANGE

(Rev. 01) 00039 (Rev. 01) SPECIFICATION

4078-XZ-SC-9000000101 SPECIAL PREAMBLE TO PRICES AND

METHOD OF MEASUREMENT FOR
MECHANICAL WORKS

4078-XH-SG-0000000005 SPECIFICATION FOR PIPING

(Rev.02) FABRICATION AND ERECTION

4078-LZ-PC-0000000211 33000667-TCM-DH2-QA- PROCEDURE FOR MANAGEMENT OF

(Rev.03) PRC-00011 (Rev.03) PROJECT WELDING ACTIVITIES

4 General Responsibilities

Pursuant to the SUPPLIER’s general obligations, the FABRICATION SUPPLIER will assume full
responsibility about the planning, about the activities assigned and shall assure their full respect to
HSE and quality requirements and to the General Conditions of SUPPLIER and all other SUPPLIER
Documents. Remaking from mistakes, default or inadequacy of the WORKS included in
SUPPLIER’s Scope of Work are at total charge of the FABRICATION SUPPLIER.

Addition and remaking due to mistakes pointed out by EPCm CONTRACTOR and/or COMPANY
shall not be a basis for extra cost, neither shall they give the rights to extensions of the
FABRICATION SUPPLIER SCHEDULE.

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5 Scope of Work

5.1 General

The FABRICATION SUPPLIER's Scope of Work consists in the execution of piping spool works
as described in the Execution Plan and Technical documents.

FABRICATION SUPPLIER's Scope of Work includes the provision of all activities, materials,
equipment, tools and manpower, as necessary, in order to deliver and complete the works and
activities hereinafter detailed. Any part or aspect of the WORKS not expressly detailed in the
FABRICATION SUPPLIER Documents, but necessary to ensure that the facilities are fit for the
intended purpose, are deemed to be part of the FABRICATION SUPPLIER's Scope of Work.

EPCm CONTRACTOR will monitor the FABRICATION SUPPLIER’s piping spool WORKS in
order to verify that all the activities are being carried out in accordance with all specification and
schedule up to the completion of the Scope of Work.

The FABRICATION SUPPLIER shall ensure that the number of personnel shall be sufficient to
execute all ongoing piping spool WORKS and that there are adequate number of its staff, who will
be able to communicate effectively in the languages of the work force as well in reading and writing
English.

FABRICATION SUPPLIER shall not be entitled to start any demobilization activities without
COMPANY’s approval and EPCm CONTRACTOR’s written authorization.

5.2 Description of the WORKS

This Scope of Work cover all the piping spool Works for the New European PDH Kello Project for
BOREALIS Kallo N.V, to be located in Sint-Jansweg2, 9130 Kallo-Kieldrecht, Kingdom of
Belgium.

The activities forming the FABRICATION SUPPLIER’s Scope of Work are below listed and briefly
detailed in the following paragraphs:

5.2.1 General workflow

According to approved information below described FABRICATION SUPPLIER shall perform the
piping spooling WORKS.

FABRICATION SUPPLIER shall review for endorsement the spooling requirements described in
paragraph 6

FABRICATION SUPPLIER shall transmit Spool drawings IFC and all the relative documentation
officially to EPCm CONTRACTOR according to 4078-IX-SG-9000000001

In parallel with the transmission of Spool drawings IFC, FABRICATION SUPPLIER shall transmit
also to EPCm CONTRACTOR all the electronic files specified in 4078-IX-SG-9000000001 for
guarantee the alignment.

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EPCm CONTRACTOR within 15 days will transmit to FABRICATION SUPPLIER the Spool
drawings IFC

Fabrication works shall start only after the material releasing through an official MIR issued by
EPCm CONTRACTOR.

6 Spooling Requirements

As general rule, the spooling activity shall:

 Include all above ground LLB, LB and SB isometrics both inside Around Equipment and
Interconnecting areas;
 Not include lines internally lined, non-metallic lines and underground lines.

6.1 Large Large Bore and Large Bore Spooling General Requirements

The LLB and LB spooling shall be carried out considering the following general requirements, as
minimum:

 The spooling activity shall be executed with a continuous and careful view at the 3D model. The
Spooler shall have a clear understanding of the plant complexity, accessibility and constraints
that may arise during the erection activities;
 The limits of the spool’s dimensions are defined by transportation and erection constraints
whose are Project dependent. Typical spool dimensions can be anyhow considered within 12m
x 2.5m x 2.5m. Care for the dimensions has to be considered in case of container transport;
 All transmitted isometrics shall be spooled in accordance to this document;
 The spooler shall identify and properly mark with suffix “-ZZ“ each spool number of those
spools crossing more than one isometric;
 In case of joints subject to PWHT, the spools dimensions may depend on the available oven in
the prefabrication shop;
 The weight of the spool shall not be considered as a limitation during the spooling process,
except in case of extra-large size and schedule;
 No extra lengths for site adjustments shall be generally foreseen during the spooling activity
unless otherwise marked on isometric drawings. It is CONSTRUCTION SUPPLIER’s
responsibility eventually to request to the FABRICATION SUPPLIER some extra lengths to
facilitate field adjustments;
 An extra length shall be always provided for spool connecting on a TIE-IN;
 The location of the field welds shall be determined with the aim to facilitate spool erection and
minimize scaffolding and the welding execution.
o As first priority, field welds shall be located on the horizontal part of the line (5G
position).
o As second priority, field welds shall be located on the lower part of vertical line (2G
position).
o As third priority, field welds shall be located on upper part of vertical line only if
2nd priority is not possible (2G weld position).
o As last priority, field welds shall be located on the pipeline at 45° (6G position).
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-
Figure 1
 In case of two consecutive elbows, the joint between the two fittings shall not be selected as
field joint, since it may be difficult to use assembly clamps;
 In case of Piping lines with rating #1500 or #2500, or in case of NPS >24”, a detailing Piping
study shall be performed to analyze the location of the field welds and the dimensions of the
spools. Accessibility, lifting and crane positioning issues shall be considered during the
identification of the field welds. The Spooler shall ask to Contractor clarification and/or
confirmation of the assumptions made during the spooling of such lines, to avoid reworks on
site during the erection phase;
 In case of lines crossing a steel platform, a concrete slab or a grating, the field weld shall be
located above the platform/slab, so that it can be reached without the necessity of installing the
scaffolding;
 Field weld shall be considered for floor penetration / dyke wall;
 Line that is threaded Galvanized material should not include any field welds unless if seal welds
is required;
 As general guideline, pipe supports shall be welded in field to the piping lines unless differently
indicated by COMPANY/EPCm CONTRACTOR. In case of lines subject to PWHT, the support
can be welded in shop.
 For details of pipe and fittings with longitudinal weld please refer to 4078-XH-SG-0000000005
procedure, and the position for the longitudinal seam weld shall be indicated on the spool
drawings;
 As a rule, every time an isometric is revised, its spooling shall be revised by the Spooler Entity

6.2 Large Large Bore and Large Bore Piping Connected to Equipment
The last flange connecting a Piping line to a rotary machine shall be tack welded in shop and
welded in field. CONSTRUCTION SUPPLIER shall decide if an extra length on the last flange
shall be kept for field adjustments.
The last flange connecting a Piping line to a static equipment shall be tack welded.
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CONSTRUCTION SUPPLIER shall decide if an extra length on the last spool shall be kept for
field adjustments.

6.3 Above Ground, Small Bore Piping in Around Equipment Area

SB Piping shall be mainly field welded. Typical Piping arrangements, where the risk of
interference with other facilities is very remote, shall be prefabricated.
Typical arrangements to be prefabricated are:
 Piping standard assemblies (drains, vents with valve, pressure gauges, etc.)
 Control valves bypasses
 Steam and condensate manifolds arrangement
 API plans
 Sampling stations
 Lines subject to PWHT
 Trim lines
 Sprinklers lines

6.4 Above Ground, Large Large Bore and Large Bore Piping in Pipe Rack and Sleeper Way
Area
Piping lines located on the pipe rack or the sleeper way, will be mainly field welded. Each pipe
length shall be considered as a spool with two field welds. The typical length of the straight pipes
shall be assumed as follow:
Material Size Length of straight pipe
Carbon steel <= 2” 5.5 m
Carbon steel > 2” 11 m
Low alloy steel <= 2” 5.5 m
Low alloy steel > 2” 11 m
Nichel/Stainless steel <= 6” 5.5 m
Nichel/Stainless steel > 6” 11 m

Loops on the pipe rack or on the sleeper way shall instead be prefabricated. Branches on the pipe
rack shall be prefabricated up to the first weld or 500 mm from the joint between the header and
the branch.

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Figure 2
Pipe to pipe branches, at 90° or 45°, shall be welded in shop.
Olets shall be welded in shop.

6.5 Underground Piping

- Typically, underground gravity Piping lines shall all be field welded with no spooling, whereas
the pressure lines shall be spooled according the above requirements only.

6.6 Tagging Rules for Joints and Spools

During the spooling process, all joints and spools shall be numbered in accordance with the
following rules.

6.7 Welded Joints

The progressive number of welding joint per isometric after spooling will be serial from 1 to n
(with the suffix S for shop welds, F for field welds and FF for field-fit weds, see following table
for more details) moving from the first according to the direction of the flow stream including
saddles welded on the pipe body.
Example: number 18 joints in one isometric, some S some F, serial could be such as S001 to S010,
then F011, then S012 to S014, then F015, then S016 to S018.
Following table defines the numbering system and suffixes used for weld numbers for welding
done under different conditions:
Reason for
Sr. Conditions for Performance of Welding Shop Field
modification
1 Weld in normal condition S F -
See Note 1
Additional joint due to any isometric
2 See Note 2 See Note 2
revision / site modification
(A/B/C/D)
See Note 1
Same weld cut & re-welded due to any Same joint nr. Same joint nr.
3
isometric revision / site modification followed by “M” followed by “M”
(A/B/C/D)
Same joint nr. Same joint nr. See Note 1
4 Joint cut & re-welded due to repair followed by followed by
“RW” “RW” (E)
See Note 1
Same joint nr. Same joint nr.
5 Joint repaired locally due to minor defect
followed by “R” followed by “R”
(F)
See Note 1
Same joint no. Same joint no.
6 Joint welded but later eliminated
followed by “P” followed by “P”
(P)

Note 1:
S: Shop Welds (Prefabrication) F: Field Welds (Erection)
Modification type shall be mentioned in the DWR (Daily Welding Report, see Attachment 1) and
same shall be updated in the Welding Data Base as under:

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 Type A – Additional or Re-welded joint due to new revision in isometrics;

 Type B – Additional or Re-welded joint due to field modifications during erection;
 Type C – Additional or Re-welded joint due to request of Commissioning or Process;
 Type D – Additional or Re-welded joint due to Pre-fabrication mistake.
The following, rather than on DWR, shall also be updated on the Welding Data Base (the
knowledge of a defect occurs after certain time from welding date):
 Type E – Joint repaired for not acceptable defect (as a result of radiography, etc). RW1
for the first repair and RW2 for the second one.
 Type F – Joint repaired locally for not acceptable minor defect R1 for the first repair and
R2 for the second one.
 Type P (Provisory) – Joint welded but later eliminated (e.g.: a by-pass is inserted
upstream and reconnected downstream so that the intermediate of piece carrying the
given joint dismantled)

Note 2: The progressive number of welding joint on isometric in case of additional joints
introduced among the already existing will start from the last present joint number with addition
of letter “M”. In the welding database both numbers shall be kept; e.g.: S014(old) and S014M
(new).
Example: with reference to the previous example in case some more joints are requested between
joint S005 and S006 the serial will become: S001, S002, S003, S004, S005, S019M, S020M,
S006, S007, S008, S009, S010, then F011, then S012 to S014, then F015, then S016 to S018.

- Further modification: S001, S002, S003, S004, S005, S019M, S020M, S006, S007, S008, S009,
S010, then F011, then S012 to S014, then F015, then S016, S021M, S017, S018.
Weld typologies are the following:
BW Buttwelding
SW Socket welding
FT Fillet weld
THD Threaded
TW Tack welding
OL Olet

- PAD Reinforcing Pad

- SOF Slip On Flange
- SOB Stub On Branch
- SIB Stub In Branch

6.8 Welded Supports

In case of supports, which are welded to the Piping line, the welds shall be numbered with S001,
S002, etc. The numbering shall continue progressively on all the sheets of the same isometric. In
case of area change, i.e. the isometric changes, the numbering shall start again from S001. Two
support welds on the same isometric shall never have the same number, even if they are assigned
to different destinations (shop or field).

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6.9 Spools
For each isometric all spools shall be numbered progressively following the flow direction. The
first spool shall be tagged as SP01, the second SP02, and so on. The numbering shall continue
progressively on all the sheets of the same isometric. In case of area change, i.e. the isometric
changes, the numbering shall start again from SP01. Two spools on the same isometric shall never
have the same number.
All erection material, which is not part of a welded spool, shall be considered as part of a dummy
spool "SP00". All flanged valves, gaskets, bolts, flanged strainers, etc. shall be part of SP00 spool.
In case of piping material found as erection, which is logically to be fabricate, this case must be
consider as shop with approval from contractor.

6.10 Flanged Joints

For each isometric all flanged joints shall be numbered progressively following the flow direction.
The first joint shall be tagged as BT001, the second BT002, and so on. The numbering shall
continue progressively on all the sheets of the same isometric. In case of area change, i.e. the
isometric changes, the numbering shall start again from BT001. Two joints on the same isometric
shall never have the same number.
In case of isometric revision, the unaffected joints shall keep the previous numbering. The new
joint number shall be only assigned to the new or modified joints. The first available number shall
be assigned to the affected joints. Also, in case of valves or flanges reorientation, the modified
joint shall be renumbered.

Typical spooling symbols:

S001 Shop weld number

F002 Field weld number

SS/SF003 Support weld number

Shop weld symbol

Field weld symbol

SP01 Spool number

BT001 Bolted joint number

<a> Cut pipe length id

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7 Piping Isometric Issue

ISOs with the relevant BOM are issued for construction by EPCm CONTRACTOR in accordance
with the project needs and transmitted to FABRICATION SUPPLIER to produce the SD.

To optimize the number of shop welds and the entire spooling activity EPCm CONTRACTOR shall
preferably issue IFC ISOs related to complete lines inside a Construction Area.

The FABRICATION SUPPLIER shall ensure the availability of its own EDMS to manage the
received documentation and its own produced deliverables.

The entire piping spooling activity is managed and controlled by EPCm CONTRACTOR

The above requirements and additional information shall be described in the 4078-IX-SG-
9000000001

8 Welding Data Base Management

A welding database tool shall be available to track the status of all welds & flanged connections,
starting from the prefabrication workshop till the Site erection, with reference to the quality and
the progress data and certifications according to 4078-LZ-PC-0000000211, Procedure for
Management of Site Welding Activities.

The welding database tool shall be integrated with the other Contractor management systems.

9 Deliverables

The Spooling activity shall lead to the following deliverables, as minimum:

 Spooled isometric drawings with all the required information for construction both in .PDF
and .IDF/.PCF format;
 Spooled isometric drawings list;
 Spool drawings;
 Spool drawings list;
 Welding map, including welded joint details (joint number, shop/field weld, weld type,
diameter, thickness and schedule, NDT, PWHT, etc.);
 Cut pipe length list;
 Welded joint list;

COMPANY REFERENCE
REV Page
33000667-TCM-DH2-CO-PLN-00010
EPCm CONTRACTOR REFERENCE
03 15/16
4078-LZ-PL-9000000052
 NEW EUROPEAN PDH KALLO PROJECT
EXECUTION PLAN
PIPING PREFABRICATION WORKS

 Material List MTO by spools;

 Flange Map, including flange joint details;

10 System Requirements

To properly perform the spooling activity and to exchange data between all the involved actors of
the process (i.e., Contractor, FABRICATION SUPPLIER and CONSTRUCTION SUPPLIER), it’s
mandatory to define:
 The spooling software to be used in the project;
 The shape and the format of the inputs to be exchanged between Contractor and the
FABRICATOIN SUPPLIER;
 The shape and the format of the outputs to be generated by the Spooling Tool;
 The welding database to be used during the project;
 The flange database to be used during the project;
 The location where all the data shall be stored and accessed to the involved stakeholders.

The above requirements shall be described in details in the 4078-IX-SG-9000000001

COMPANY REFERENCE
REV Page
33000667-TCM-DH2-CO-PLN-00010
EPCm CONTRACTOR REFERENCE
03 16/16
4078-LZ-PL-9000000052