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THIS DOCUMENT IS INTENDED FOR USE BY ADCO AND ITS NOMINATED CONSULTANTS, CONTRACTORS,
MANUFACTURERS AND SUPPLIERS

ORIGINATOR

Engineering & Major Projects Division

Date of Issue
ADCO DOCUMENT No 31.38.01.31 -A Rev B
November 2001

GENERAL 1 PAGE 1 OF 7
DOCUMENT CLASSIFICATION
PROJECT NAME /No

———-
 REVISION RECORD

I I
REV DATE

A Dee, 2000

LE (M&W) I

B May 2001 LQCE (MD) SME(MT) HE (HS) For Implementation

LE (M&W)

DOCUMENT TITLE : ADCO DOCUMENT No. :

A Shop and Field Fabrication of Steel Piping 31.38 .01.31-A

PAGE 2 OF 7
*O Dep No :31.38.01.31. ] PROJECT NCI. REV. B DATE: NOV. 2001
I_. _ _—-–. _ 1 —

—- .
 1.1 SCOPE

1.2 REFERENcEs

1.3 MODIFICATIONS TO DEP

Attachments

Nil.

4’
DOC UMENT TITLE :
ADCO DOCUMENT No. :
Shop and Field Fabrication of Steel Piping 31.38 .01.31-A
?
—- h —r.—– ___ PAGE 3 ‘i–j=-–– - ‘“– ‘-
-o
~—.—_— ______ Jr ==P–No :31 .38.(M .31. I PROJECT No. REV. B DATE: NOV. 2001
I_____ ____ :::,

—-— .—___ -—
 Ref. Amendments I Su pplement
Section
2 PIPE FABRICATION

(add) ● All Pipe fittings, flanges, in-line, on-line and piping specialty items shall be fully in accordance
with the COMPANY specifications and Construction Drawings.

● When pieces with different inside diameters are to be butt welded, with the smaller bore shall
be internally machined so as to reduce the misalignment to less than 1.5mm, The machined
portion of the piece shall be tapered to the remaining portion of the piece, with a slope not
greater than 25% referred to the pipe internal surface. The wall thickness shall not reduce
below the design value. For details refer ASME B31.3 figure 328.4.3 for trimming and
permitted misalignment.

● Pipe spools shall be fabricated with an extra six (6) inches i.e. 150 mm of pipe at field welds,
unless noted otherwise on the spool drawings.

● When socket weld fittings are used there shall be a 1.6mm (1/1 6“) gap between the male pipe
end and the internal socket to avoid “bottoming” in the socket.

● Seal welding of screwed connections are not permitted.

● For screwed or socket weld pipe installations, CONTRACTOR shall indicate adequate unions
in the piping isometrics/ sketches to allow the convenient removal of any spool or component
without disassembly or removal of any piece of equipment or major inline instrumentation.
Contractor shall review the arrangements during installation and modify, if necessary.

● Piping installed on rotating or reciprocating equipment shall not impose any loads on the
equipment nozzles.

● All branch connections shall conform to the piping material specification and isometric
drawings and shall be joined to the header with full penetration welds. No crevices are
allowed and the bore side shall be smooth and free from any cracks.

● The CONTRACTOR shall ensure the “in process” material documentation is maintained on a
daily basis. All materials which require documentation in use during fabrication or installation
that cannot be identified with documentation shall be immediately removed from the area and
replaced at the CONTRACTOR’s expense.

2.4 Welding and welding inspection requirements shall comply with ADCO standard WS-I Rev.2

End Preps ration and Lift up

. Pipe end preparation shall be in accordance with approved welding procedure as specified in
marked up isometric, using oxy-fuel, plasma, mechanical or manual cutting/grinding tools.

. Butt weld faces to be joined shall be aligned in accordance with approved welding procedure
(WPS) as specified in marked up isometric (see also ASME B31 .3. Fig: 328.4.2 for typical butt
weld end preparation, Attachment 1)

. Socket-welding fit-up shall be in accordance with ASME B31.3 Fig: 328.5.2B and 2C,
Attachment 1.

. Branch connection fit-up shall be in accordance with ASME b31.3 Fig 328.4.4 and Fig:
328.5 .4AJ4B/4C/4D/4E, Attachment 1.

DOCUMENT TITLE : I ADCO DOCUMENT No. :

31.38 .01.31-A
Shop and Field Fabrication of Steel Piping I I
. –1
PAGE 4 OF 7
.J—
Dep No :31.38.01.31. PROJECT No. I REV. B @TE: Nov.-.ii)l ‘- ~
————— -— -. J
. Where internal misalignment exceeds 1.6mm, internal trimming shall be in accordance with
ASME b31.3 Fig 328.4.3 upon obtaining the main Contractor and/or Company approval.

● Minimum distance between longitudinal welds at pipe girth welds shall be at least 5 times the
wall thickness of the pipe or as otherwise specified, measured on the circumferential weld.

. The clear distance between edges of adjacent circumferential butt welds shall not be less
than 5 times the pipe wall thickness or 50mm (2in) which ever is greater, or as otherwise
specified.

● Pipe clamps to be used for pipe alignment shall be of the same material as the piping material.
Clamps shall be removed only after sufficient length of tack welds have been deposited.

PIPING ERECTION AND ASSE MBLY

● Pipe spools shall be installed, fully supported, where possible.

● For pipe rack, piping installation will be preferably from lower level and ongoing up to the
highest level, sequence of installation for each level shall be as follows:
> large bore field runs
> small bore field run
> large bore composite spools
} small bore composite spools

INSTALLATION O F VALVES

● Orientation of valve handle and direction of flow shall be in accordance with piping general
arrangement drawings.

● Valves shall be installed in closed position except for plug and ball valves.

. Welded type valves shall be half opened during welding & PWHT, but not fully opened.
Flanged control valves, ball valves and other soft sealed valves shall be dismantled before
PWHT and line flushing operations.

co NNECTION TO EQU IPMENT NOZZLES

● Care shall be taken so as to prevent damage to equipment nozzles caused by weight of

fabricated spools and piping components and the latter shall be supported prior to installation
on equipment nozzles.

● Pipe flanges shall be aligned with all nozzles of the rotary machinery by adjustment of pipe
support and flanged connection. The misalignment between flanges shall be within the
following limits or as otherwise specified by the equipment vendors:

● Flange face separation space required for gasket - jj).8mm

● Flange face parallelism *0. fjmm
● Rotation off-set fO.8mm
● Horz. & Vertical bolt hole off-set ~0.8mm

● Care shall be taken so that expansion or distortion resulting from welding etc. does not have
a detrimental influence on the rotary machinery.

● If rotary machine and piping misalignment is more than the specified limits rectification work
to be performed on piping components as necessary.

I
I ADCO DOCUMENT No. :
DOCUMENT TITLE :
31.38 .01.31-A
Shop and Field Fabrication of Steel Piping
.
1-- PAGE 5 OF 7

Dep No :31.38.01.31. PROJECT

“1-- No.
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A–—_—— .—— —— 1
 . After piping is connected to rotating machinery, and alignment has been established, the
rearrangement of pipe supports or re-tightening of flange bolts shall not be performed without
permission from the responsible Project Engineer.

3. INSPECTION. TESTING AND QUAL ITY CO NTROL

● COMPANY reserves the right to inspect all materials, fabrication, workmanship, welding of
materials and fabricated components for COMPANY work. COMPANY shall also reserve the
right to witness all welding procedure and welder qualification testing, including non-
destructive and destructive testing. COMPANY or its Representative shall have free entry at
all times to any part of the CONTRACTOR’s yard that concerns the manufacture of
COMPANY.

● The COMPANY reserves the right to request the CONTRACTOR to carry out NDT in addition
to that required by the scope of work. Where the additional NDT shows unacceptable
defects then the additional NDT and all remedial works for rectification shall be considered
wholly within the CONTRACTOR’s scope of work. Where the additional NDT shows no
unacceptable defects then the additional NDT will be considered as outside the
CONTRACTOR’s scope of work.

● CONTRACTOR shall submit all NDT procedures and the names and qualifications of all
proposed NDT operators to be used on the job for COMPANY review and approval. All NDT
operators shall be trained and certified in accordance with guidelines SNT-TC-1 A (Level II
minimum) of the American Society of Non-Destructive Testing. Level I and Level II
operators shall be certified by examiners who have valid ASNT level III certifications in the
relevant method. Certifications by “company appointed level Ill” examiners shall not be
acceptable. Also, the CONTRACTOR shall indicate the time lap between weld completion
and start of NDT examination in the NDT procedure.

● All NDT shall be performed after completion of PWHT as required by ASME B31.3

● COMPANY retains the right to reject any weld in its entirety that cannot be repaired to the
requirements of the Specification in two attempts.

● Random inspection acceptance criteria for piping components shall be as defined in ASME
B31.3 paragraph 341.3.4 regarding progressive examination of piping welding.

● Branch attachment welds shall be examined by dye penetrant, magnetic particle or ultrasonic
methods.

When the header thickness exceeds 16mm (5/8 inch.), this type of examination shall be made for
every 9.5mm (3/8 inch) thickness of weld build up.

. Whenever tack welds on Cr-Mo and Stainless Steel material are outside the groove, they
shall be removed and MT or PT will be applied to the areas, as applicable, after removal of
the bridge pieces and final PWHT for CrMo materials. For Carbon Steel materials, visual
inspection shall be carried out on these areas.

● For Low Temperature Carbon Steel, tack welds outside the groove are only permitted on
welds which are to be subsequently post weld heat treated. After this operation MT or PT will
be applied to the areas, as applicable.

. Hardness testing shall be carried out after PWHT (as applicable).

● Positive Material Identification (PMI) where applicable, shall be performed and recorded.

DOCUMENT TITLE : ADCO DOCUMENT No. :

31.38 .01.31-A
Shop and Field Fabrication of Steel Piping

I PAGE fjOF7 - ‘--”1

Dep No :31.38.01.31. 1 PROJECT No.

—L.——.———.—————.—
REV. B
—L.—-—.——‘“l
——
DATE: No; 2001
—
~
 Welding Inspection shall be performed by Welding Inspectors certified to CSWIP 3.1 or AWS
CWI and PCN for HT interpretation with a minimum for 5 years experience after certification.

The quality plan, inspection, NDE and testing procedures and method statements for the
scope of work shall be submitted to the Company for approval.

Each weld shall be uniquely identified with a weld number, lSO/Drawing number and piping
class numbers and the same must be represented in the weld identification/NDT drawings
and NDT reports. After completion of each weld and prior to its visual inspection and NDT,
the weld and welder identifications shall be marked adjacent to the weld at a distance of
about 50mm from the weld using paint or indelible crayons. This identification shall remain
on the pipe till the completion of all NDT for any verification by the Company Inspector.

Only wire type image Quality Indicators (IQI;s) and intensifying screens shall be used.
Radiographic sensitivity shall be 2% or better.

The radiographic density in the diagnostic area shall between 2.0 and 3.5

Ail magnetic particle examination shall be carried out by alternating current (AC) yoke
method with a white background and black magnetic ink.

All NDT instruments and accessories shall be in good working condition, and where
applicable, shall have valid calibration certificates.

Production weldment hardness testing shall be carried out with Kraut Kramer Microdur MIC 2
or MIC 10 equipment. The use of Equotip instrument shall not be acceptable. A procedure
for surface preparation and hardness testing shall be submitted for Company approval.
Hardness readings shall be made on the 12’0 clock pipe position on the weld and heat-
affected zone (HAZ) on both sides of the weld. Identifications on the HAZ shall be made
within 0.5mm from the weld toes. Three sets of readings shall be taken for each location.
Each set shall be an average of three readings. The extent of production hardness testing
shall be as follows:

i) Sour service piping welds which are locally post weld heat treated shall be 1007.
hardness tested.
ii) All other sour service piping welds (either furnace stress relieved or not post weld
heat treated) shall be 10VOhardness tested.

Inspect ion Records

a) The CONTRACTOR shall maintain weld maps throughout fabrication, recording weld
number, location and welder for all welds. Welds number shall be assigned a unique
number.

b) The CONTRACTOR shall maintain material traceability maps/drawings during the fabrication
and installation of all process piping so that the locations and the heat numbers of all weldecj
pressure retaining piping components are completely traceable,

c) At the completion of all testing, the CONTRACTOR shall prepare a bound set of all original
testing reports and containers of the original radiography films shall be transmitted to the
COMPANY along with the weld maps for their records.

DOCUMENT TITLE : ADCO DOCUMENT No. :

1
31.38 .01,31-A
Shop and Field Fabrication of Steel Piping
~
PAGE 7 OF 7

Dep No :31.38.01.31. I PROJECT No. I REV. B I DATE: Nov. 2001 ,