BES 1300-102

Petrogal MANUAL DE PROCEDIMENTOS Edição:Data:

ESPECIFICAÇÕES DE ENGENHARIARevisão:Data:

BES – Pág. 1 de 34

Mod. Q-03 Reprodução proibidaImpresso a partir da PETRONET

PIPING FABRICATION AND ERECTION

00.05.15

00.05.15

1300-102

01

00

Elaborou:J. van Eck

Verificou: Aprovou:

Petrogal MANUAL DE PROCEDIMENTOS Edição: 01Data: 00.05.15

ESPECIFICAÇÕES DE ENGENHARIARevisão: 00Data: 00.05.15

BES – 1300-102 Pág. 2 de 34


INDEX

SECTION PAGE

1. SCOPE 3

2. DEFINITIONS 3

3. CONTRACTOR'S RESPONSIBILITY 3

4. REFERENCE DOCUMENTS 4

5. DESIGN 5

6. MATERIALS 5

7. FABRICATION 7

8. INSTALLATION 14

9. INSPECTION AND TESTING 28

10. CLEANING 30

11. PAINTING/COATING 31

12. DOCUMENTATION 32

13. PREPARATION FOR SHIPMENT 33

14. ADDITIONAL REQUIREMENTS 34



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1. SCOPE

This specification covers the minimum requirements for fabrication and installation ofsteel piping, including pipe supports.

Fabrication and installation of tubing, lined pipe and nonmetallic piping are excludedfrom the scope of this specification and shall be executed in accordance withASME B31.3 and manufacturer's requirements and recommendations.

Additional or deviating requirements for duplex stainless steel piping, piping containingoxygen, underground piping, steam tracing and jacketed piping, are listed inspecifications mentioned in section 14.

2. DEFINITIONS

For this specification the following definitions are applicable:

Principal : Petróleos de Portugal S.A. (Petrogal) or the company acting onprincipal’s behalf.

Contractor : The party which carries out engineering (if applicable), supply ofmaterials, fabrication and installation/construction.

Supplier : Any manufacturer or supplier who is appointed by the principal orcontractor and responsible for the supply of materials or equipmentor services.

Shall : Is to be understood mandatory.

Should : Is to be understood as strongly recommended.

May be : Is to be understood as giving a freedom of choice.

3. CONTRACTOR'S RESPONSIBILITY

3.1 Any conflict between the requirements of this specification and reference documentsshall be referred to principal for clarification.

3.2 Contractor shall fully describe all proposed deviations from this specification andreferenced codes, standards and specifications for review and approval by principal.



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3.3 Assumptions to cover lack of information are not allowed. Contractor is obliged to obtainreliable information from principal.

3.4 Contractor shall field verify all (existing) dimensions and conditions shown on principal'sdrawings.

4. REFERENCE DOCUMENTS

4.1 CODES

DL 101/74, DL 102/74 Authority Requirements.

ASME B31.1 (...) Power Piping.

ASME B31.3 (...) Process Piping.

Note: (...) Fill in applicable issue date.

4.2 STANDARDS

The version valid on the date of contract award shall be used.

ASME B16.25 Butt-welding Ends.

4.3 SPECIFICATIONS/DRAWINGS, ETC.

BES-1300-101 Piping Materials.

BES-1300-103 Coating and Wrapping of Underground Piping.

BES-1300-104 Process and Utility Piping Design Requirements.

BES-1300-105 Pressure Testing, Flushing and Reinstatement of PipingSystems.

BES-1300-106 Steam Tracing.

BES-1300-107 Insulation of Piping and Equipment.

BES-1300-109 Welding of Carbon, Low-alloy and Austenitic StainlessSteel Piping.



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BES-1300-110 Pipe Stress and Support Design Data.

BES-1400-104 Underground Piping.

BES-2300-101 Surface Preparation and Painting.

BES-2700-102 Hot Tapping.

5. DESIGN

5.1 Contractor shall supply plan drawings and/or isometrics showing piping design.

5.2 Piping designed by contractor shall meet the requirements of ASME B31.1/B31.3(depending on selected design code) and specification BES-1300-104 "Piping DesignRequirements".

5.3 Contractor is fully responsible for all design. Principal may perform spot checks to ensurethat specifications are being properly applied.

6. MATERIALS

! All materials included in the finished piping systems (free-issue materials andmaterial purchased by contractor) shall be undamaged and fully in accordancewith the piping material class and pipe support drawings indicated on the pipingdrawing and/or P&ID. For piping material classes, see specification BES-1200-121 "Piping Materials".

! Material substitutions or deviations from the piping material classes shall not bemade without prior written approval of principal.

6.1 STORAGE/HANDLING OF MATERIALS

! Piping shall be stored in a clean, dry or well-drained area on elevated dunnage andprotected against contact with salts or salty water.

! Stainless-steel and duplex stainless steel piping shall be stored on wooden blocks,separately from carbon, alloy and galvanized carbon steel.



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! Stainless-steel and duplex stainless steel materials shall not be loaded, unloaded orhandled with hoisting devices (e.g. steel ropes and forklift trucks) containing zincor other harmful materials.

6.2 MATERIAL IDENTIFICATION

! Materials issued to contractor shall be adequately marked in accordance with therequirements of the applicable material specifications and the additionalrequirements of the purchase order requisitions and/or local codes and regulations.

! In case material identification symbols are located near the weld or on a piece ofmaterial to be cut off, material shall be restamped prior to welding or cutting toavoid loss of traceability.

! The governing principle shall be that in the installed piping systems, allcomponents can be identified and traced to their origin and completespecifications.

! Marking and remarking by contractor's representatives shall be executed by harddye stamping or engraving, whichever is applicable.

! All hard stamping shall be done by means of low stress stamps onpressure-bearing parts. Low stress stamps shall have a round nose with a radius of0.25 mm minimum.

! In case of ferrous materials with a thickness less than 5 mm and austenitic steelsless than 10 mm, marking shall be performed by engraving.

! When similar materials (e.g. carbon - low-temperature carbon steel or 304-316stainless steel) are used for the same project, materials will be supplied withadditional color coding to be able to make a quick visual identification of differenttypes of material.

Note: Color coding needs not be transferred prior to welding or cutting.



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7. FABRICATION

Fabricated metal piping shall meet local authority requirements for all piping requiringinspection and approval by local authorities.

All other fabricated metal piping shall meet the requirements of ASME B31.1/B31.3(depending on selected code).

In order to prevent corrosion of stainless steel, duplex stainless steel and other high-alloysteels, fabrication of carbon steel, galvanized carbon steel and low-alloy steel shall bedone in a separate area.

Area means different shops or two (2) areas in one (1) shop separated by suitable(temporary) walls.

For the same reason as above, tools used for fabrication of carbon steel, galvanized steeland low-alloy steel may not be used for fabrication of stainless steel, duplex stainlesssteel and other high-alloy steel. Only tools made of stainless steel are allowed forgrinding, brushing, clamping, etc.

These requirements apply to shop and field fabrication.

7.1 SHOP FABRICATION

Shop fabrication under this specification shall include all the components of the pipelineor parts thereof entering into fabricated assemblies (spools), but shall exclude all pipingspecialties other than those with welding end constructions such as bolting, gaskets,flanged valves and fittings, blind flanges, orifice plates and similar items. Contractor isresponsible for selection of piping to be shop fabricated on site or off site.

For some piping systems principal has strong preference for shop fabrication to amaximum extent possible, e.g.:

! Lined piping.

! Jacketed piping.

7.2 LOCATION OF FIELD WELDS

The size of spools and location of field welds shall be determined by contractor.



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Field welds shall be located so that the spools shall be as large as possible and consistentwith shipping limitations. Field weld locations shall be governed by the following:

! Lengths of spools shall not be limited by "match lines" that appear on drawings. Aline and its branches which appear on more than one (1) drawing is not intendedto mean that a field weld is desired at the continuation point from one drawing toanother.

! Where piping is shown passing through a wall or floor, the first weld point oneither side of the wall or floor shall be made a field weld, provided it is located atleast 150 mm away from the end of the pipe sleeve.

! Erection conditions shall be considered in determining the size of spools.

7.3 FIELD FABRICATION

Field fabrication under this specification covers, but is not necessary limited to, thefollowing operations:

! Erection of shop-fabricated piping.

! Fabrication and erection of all field-fabricated piping.

! Design, routing, fabrication and erection of all field-fabricated piping for whichno piping drawings are available.

! Fabrication and erection of all pipe supports and auxiliary steel as detailed in thepipe support drawings.

! Design, fabrication and erection of all pipe supports for small bore piping, whichshall be executed in line with the available drawings for supports.

7.4 VERIFICATION OF FIELD DIMENSIONS

Fabrication of piping and pipe supports shall be in accordance with the supplieddrawings. However, due to equipment location and fabrication tolerances, fieldverification of overall dimensions shall be made by contractor prior to erection, to ensurea proper fitup at all connections to equipment and other piping.



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7.5 MAKE-UP LENGTH

Contractor shall apply 150 mm make-up lengths in order to make adjustments, necessarydue to construction deviations. The required material shall be taken from the constructionallowances/contingencies.

7.6 TOLERANCES

7.6.1 Overall Dimensions

The dimensional tolerances of all fabricated lines shall not exceed the values givenbelow:

Less 1.5 mLength than 1.5 m and longer

Center to center }Center to flange face } ± 1.5 mm ± 3 mmFlange face to flange face }

7.6.2 Thinning of Wall Thickness and Ovality in Bends

The maximum decrease of wall thickness shall not exceed 10% of the nominal wallthickness.For tolerances on the maximum flattening, see ASME B31.1/ B31.3.

7.6.3 Flange Face Alignment

Flange faces shall be aligned to the design plane within 1 mm in 200 mm measuredacross any diameter.

7.6.4 Position of Bolt Holes for Flanged Piping

Flange bolt holes shall be aligned within 3 mm maximum offset.

Unless otherwise detailed on the drawings, flange bolt holes shall straddle the north-southcenterline when the flange face is in the horizontal position and shall straddle the verticalflange centerline when the flange is in the vertical position.



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7.7 MINIMUM DISTANCE BETWEEN WELDS

! The minimum distance between weld edges shall be 50 mm or three (3) times thewall thickness, whichever is greater.

! Welded joints, including longitudinal welds, shall not be placed less than 50 mmor three (3) times the wall thickness, whichever is greater, from openings, branchwelds, reinforcements, attachment devices, supports, etc. Principal reserves theright to specify additional requirements (such as radiography, ultrasonicinspection or postweld heat treatment) in case of deviations.

! The longitudinal welds of two (2) adjacent rings or tubes shall be staggeredapproximately 90°. Longitudinal welds shall not be situated at the bottom of thepipe.

7.8 BRANCH CONNECTIONS

Branch connection type shall be in accordance with the piping drawing or the pipingmaterial class, when no drawing is supplied.

Where openings for branches are cut in run of pipe, all materials which may drop insidethe pipe, shall be completely removed before the branch line is welded into place.

Branch connection cutouts shall be carefully bevelled and accurately matched to form asuitable groove for welding and to permit complete penetration of the welds at all points,resulting in a quality comparable with girth welds, in the same piping system.Weld details for branch welds shall be included in the welding procedure specification.Reference is made to the relevant section of ASME B31.1/ B31.3.

The centerline of the branch connections shall intersect the centerline of the header,unless otherwise specified on the piping drawing.

Nozzle joints shall be of the "set-on" type, made so that the branch connection abuts theoutside surface of the run wall.

Half couplings attached to the line shall be inserted to the inside of the run wall andwelded. Threaded couplings shall subsequently be checked with a thread gauge to ensureagainst thread damage or distortion.

Pipe to pipe branches shall be of the weld-on type unless otherwise specified on thepiping drawing.



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Welded pipe-to-pipe branch connections shall be reinforced as required by the pipingdrawings. Additional weld metal, saddles or rings shall be used for reinforcement.

Prior to welding, saddles or rings shall be drilled with one (1) ¼" NPT threaded hole fortesting and venting. Threaded hole to be sealed with compound after testing. No gaplarger than 3 mm shall exist between the OD of the pipe and ID of the ring or saddle.

7.9 GALVANIZED PIPING

Galvanized piping up to and including 2" (DN 50) nominal size shall in general beassembled from threaded galvanized components. Piping larger than 2" (DN 50) nominalsize shall be prefabricated in accordance with this specification and subsequently hot-dipgalvanized. Contractor shall take into account that after the spools have been galvanizedno welding is allowed. This implicates that field breaks shall be located at flangedconnections or connections using flexible couplings and that welded-on pipe supportsshall be welded to the spools before galvanizing.

Contractor shall consider maximum dimensions of the galvanizing facilities he intends touse, when determining spool dimensions and locations of field breaks.

Visual and dimensional inspections, nondestructive weld examinations and hydrostatictesting shall be executed before spools are hot-dip galvanized.

Threaded connections shall be reworked to clean thread depth.

7.10 END PREPARATION

7.10.1 Cutting

Cutting pipes may be done either by mechanical means (preferred) or by flame cutting orplasma cutting when the following is taken into account:

! For carbon steel, flame (or arc) cutting and bevelling is acceptable only if the cutis reasonably smooth and all oxides are removed from the surface by grinding tobright metal.

! For low and intermediate alloy steel, flame cut bevels are acceptable only wheremachine cutting is not feasible. After flame cutting approximately 2 mm ofmaterial shall be removed from the surface of the bevel by grinding.



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! For stainless steel, flame cutting is prohibited, but plasma cutting may be appliedinstead.

! Preheating during thermal cutting shall be the same as applied during welding (seespecification "Welding of Carbon, Low-alloy and Austenitic Stainless SteelPiping").

7.10.2 Bevelling

End profiles of pipes and fittings to be butt welded shall be in accordance withASME B16.25. Bevelling is not required when a make-up length is provided.

7.10.3 Tapering

Weld alignment shall be in accordance with ASME B31.1/B31.3, but with the exceptionthat the internal trimming shall be 1:4, instead of 30°.

7.10.4 Threading

The threading of pipe shall be in accordance with the applicable standard. The type ofthread is indicated on the piping drawing or in the applicable pipe class.

7.10.5 Plain Ends

Pipes for socket weld joints shall be cut square.

7.11 WELDING

The following activities shall be executed in accordance with the requirements asdescribed in specification "Welding of Carbon, Low-alloy and Austenitic Stainless SteelPiping".

! Alignment.

! Preheating.

! Tack welding.

! Welding.

! Repair welding.



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! Postweld heat treatment.

7.12 BENDING

7.12.1 General

Bending of pipes shall only be done where indicated on the isometric drawings or whenallowed by the applicable pipe class, otherwise welding elbows shall be used. The pipebending procedure shall be approved by Contractor.

If the pipe contains a longitudinal weld, this weld shall be located in the neutral zone.

At site, only cold pipe bending up to DN 80 (3 inch nominal size) is allowed, provided itis done in pipe-bending machines or presses using formers. No wrinkling, excessivethinning or flattening is allowed. Excessive scratches, gauges or die marks will begrounds for rejection.

Hot bending at site is not allowed, but shall be executed with induction pipe-bendingmachines. A pipe bending procedure shall be issued for approval by principal.

The bending radius for cold bending at site shall be as given on the isometric drawing,but shall in principle not be less than five (5) times the nominal pipe diameter. Theamount of thinning permissible is specified in paragraph 7.6.2.

7.12.2 Additional Requirements for Ferritic Steels

For ferritic steels, with the exception of the quenched and tempered grades, a normalizingheat treatment shall be applied when the hardness increase in Vickers or Brinell is morethan 100, unless local regulations are more stringent.

For quenched and tempered ferritic steels an appropriate stress-relieving heat treatmentshall be applied when the hardness increase in Vickers or Brinell is more than 100, unlesslocal regulations are more stringent. Stress relieving shall be at least 10°C below thetempering temperature.

The use of water for cooling is not permitted.



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8. INSTALLATION

Contractor is responsible for installation of all piping spools including pipe supports, allpiping components, such as bolting, gaskets, flanged valves and fittings, blind flanges,etc., and all other items, such as flow meters, control valves, orifice plates and similaritems necessary to complete final piping erection with all lines cleaned, supported,pressure tested and ready for plant operation.

Alignment of piping to equipment (machinery, vessels, exchangers, etc.) shall permitfitup without bending or springing the pipe under any circumstances. Alignment shall bechecked and approved by principal prior to bolt-up.

Where a discrepancy between drawing dimensions and field dimensions exists, sufficientmodifications shall be made to eliminate unintended cold springing and cold forcing.

Deviations from the arrangement shown on drawings shall only be made after consultingprincipal. Contractor shall submit alternative routing for review and approval byprincipal.

Alternative routing shall keep clear all access ways and equipment openings and shallmaintain accessibility of valves and instruments.

Cutting, welding and making attachments to structural members, vessels, exchangers andother equipment, not detailed in the piping and piping support drawings, shall not bepermitted without prior approval of principal.

Stainless steel, duplex stainless steel and high-alloy steel shall be suitably protectedduring installation or modification of carbon-steel, low-alloy steel and galvanized carbon-steel piping at site.

All stainless steel pipe potentially exposed to zinc dust contamination shall be protectedwith polythene sheeting. This applies in particular to piping under, or close to at the samelevel, as galvanized steel (grating/structural members/etc.). The sheeting shall be securelywrapped against tearing by wind and shall be removed upon completion of the works.

Galvanized scaffolding pipe shall be kept at a distance of at least of 20 cm from stainlesssteel pipe in order to prevent the possibility of surface contamination.

Pulling of pipe along piperacks is forbidden unless rollers are used.



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Vents, drains, condensate drip legs, pressure instrument and other connections shall beinstalled where indicated on the isometric drawings, in accordance with engineeringstandards included in specification "Piping Materials".

Protective devices on pipe ends, flanges and equipment openings shall remain in placeuntil the piping connection is ready to be made.

8.1 FLANGE ASSEMBLY

8.1.1 Tools

8.1.1.1 Use of adjustable wrenches (Bahco) or wrench hammers is prohibited.

8.1.1.2 For application of correct tool related to flange size and rating, see table I.

8.1.1.3 The calibration of torque wrenches and tensioners shall be checked againstmanufacturer's specifications upon receipt. Any tools that are out of calibration shall berejected.

A recheck of the calibration shall be made as per tool manufacturer standard. Any toolfound to be out of calibration shall immediately be taken out of service for repair.

All flanged joints secured with tools found to be defective shall be rechecked with aproperly functioning tool.

8.1.2 Flange Identification

Flanges subject to hydraulic bolt tensioning shall be numbered on the isometric or on thegeneral arrangement drawing by the contractor. Starting with the flow direction of each linenumber within one (1) unit, the flange sets shall be identified as F1, F2, F3, etc., followedby the line number, e.g. F1-P30006.

The numbering system for flanged joints at equipment not part of a piping system, e.g.manholes, etc., shall be such that each equipment flange set is identified with the nozzlenumber as shown on the equipment drawing, followed by the equipment number, e.g. M1-R1101.

The above described numbering system shall be used to relate each "assembly record" asdescribed in section 8.1.9 to the relating flange set.



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8.1.3 Torque Values

8.1.3.1 In case torque wrenches (manual or hydraulic) are used, bolts shall be tightened untiltorque values, as indicated in table II, are reached.

In case tensioning equipment is used, bolts shall be tightened until bolt force values, asindicated in table II are reached.

8.1.3.2 Listed values are NOT APPLICABLE for designed flanges over 60 inch. For theseflanges the equipment manufacturer shall indicate on his drawings the bolt torque valueused in the calculation made for the design of the flange.

8.1.3.3 For bolt material not listed in table II contact principal to obtain correct torque and boltforce values.

8.1.3.4 a. Listed values are based on the empiric bolt force in flanges according to ASMESection VIII, div. 1, Appendix S.

b. Torque moments are based on the pitch of the thread, the friction resistancebetween the thread surfaces and the bearing surfaces of the nut on the flanges.

c. Friction coefficient f = 0,12.

8.1.4 Installation

8.1.4.1 Inspection of Material

8.1.4.2 Inspect the gasket material for possible damage or defects such as bends or creases.

8.1.4.3 Inspect the mating flange facings for dirt, parallelism, flatness, surface roughness,mechanical damage and corrosion. Use a suitable solvent to clean the surfaces.

The contact area of the flanges shall be free of excessive pitting, radial tool marks andscratches.

Flange facings that are found to be damaged during construction, shall be remachined atcontractor's expense.

8.1.4.4 Inspect the studs and nuts. They should be free of dirt and corrosion and well lubricated.The studs shall be straight and the threads free of nicks, burrs and chips.



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8.1.5 Assembly of Flange Connection

8.1.5.1 Align the flanges properly. For tolerances on flange joints see specification paragraph7.6. The bolt holes shall match so that the studs can be inserted freely. Install the gasket.Gaskets shall not be lubricated.

8.1.5.2 Use four (4) studs at 0, 90, 180 and 270 degree angle as centering guides for the gasket.In the case of spiral-wound gaskets, ensure that the inner diameter of the centering ring isat all points within the outside diameter of the raised face. Clamp securely in place.

8.1.5.3 Insert the balance of the studs. Apply a suitable lubricant to the threads and the face of thenut that contacts the flange.

8.1.5.4 Hand tighten all studs and nuts. Center studs between nuts so an equal number of threadsprojects at each end. When hydraulic bolt tensioning is required, a threaded length equalto the bolt diameter should protrude at the end where the bolt tensioner is to be placed.

8.1.6 Bolt Torquing

8.1.6.1 Standard Wrench

a. Tighten bolts crosswise in at least two (2) stages. First stage to approximately 50%if the estimated value based on experience. Second stage to 100% of the estimatedvalue. Bolting shall be tightened in a sequence assuring equal distribution of boltloading.

b. Check all bolts for even distribution of required load. Steel to cast iron flangedjoints shall be made up with extreme care. In order to avoid breaking of cast ironequipment flanges, piping flanges shall be brought up flush with gasket andequipment flanges into close parallel and lateral alignment, before uniformlytightening bolts.

8.1.6.2 Manual or Hydraulic Torque Wrench

a. Tighten bolts crosswise in at least three (3) stages:

• First stage to 40% of recommended value as per table II.

• Second stage to 80% of recommended value.

• Third stage to 100% of recommended value.



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b. Check all bolts at 100% of recommended value.

8.1.7 Hydraulic Bolt Tensioning

8.1.7.1 The application of bolt-tensioning equipment shall be in strict accordance with supplier'sinstruction manual and safety procedures.

8.1.7.2 Contractor shall propose a supplier for hydraulic bolt tensioning equipment and/orservices, for approval by principal. The personnel using the equipment shall beadequately trained in the application of such equipment.

8.1.7.3 The tensioning of the bolts is carried out crosswise in a number of cycles, depending onthe number of tools that can be applied simultaneously.

As a minimum following number of tensioners shall be applied during each cycle:

NUMBER OF BOLTS NUMBER OF TENSIONERS TOUSE

32 and less 50% of bolts36 to 60 1/3 of bolts64 and up ¼ of bolts

8.1.7.4 Bolt tensioning shall be executed in two (2) steps. Contractor shall issue a tensioningprocedure for approval by principal.

8.1.7.5 After completion of bolt tensioning four (4) bolts at 90 degrees angle each shall bechecked for the break loose point. Flanges not meeting the required values shall beretensioned.

8.1.7.6 After bolt tensioning has been completed, the extended threaded part shall be greased andcovered with suitable caps to prevent damage and corrosion during operation of the plant.

8.1.7.7 Upon completion of bolt tensioning each flange shall be provided with a wire seal(s) asindicated below.



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8.1.7.8 Flange numbers as described in paragraph 8.1.2 shall be low stress dye stamped on therim of one of the flanges .

8.1.8 Leaking Flange Assemblies

8.1.8.1 Flange assemblies found to be leaking during hydrotesting shall be tightened as listedbelow:

a. Flanges assembled with standard wrenches shall be tightened with manual torquewrenches using procedure as described in subsection 8.1.6.2.

b. Flanges assembled with manual torque wrenches shall be tightened with hydraulictorque wrenches using procedure as described in subsection 8.1.6.2.

8.1.8.2 Flange assemblies tightened with hydraulic torque wrenches or hydraulic bolt tensioningequipment and found to be leaking during hydrotesting shall be disassembled, inspectedand reassembled in accordance with the requirements of this specification.

8.1.8.3 Flange assemblies still leaking after tightening as described in subsection 8.1.8.1 shallalso be disassembled, inspected and reassembled in accordance with the requirements ofthis specification.



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Reassembly shall be done with tools as described in subsection 8.1.8.1a and 8.1.8.1b. Incase of reassembly a new gasket is recommended.

8.1.8.4 Contractor shall prepare an assembly record for all flanges which are disassembled andreassembled because of leakage problems.

8.1.9 Documentation

8.1.9.1 Contractor shall prepare design calculations for all applicable flange sizes, in order todetermine the required bolt loads and, consequently, the required pressures in thehydraulic bolt tensioning equipment.

Calculations shall take into account the following design factors:

! Minimum and maximum gasket seating stress.

! Allowable bolt stress.

! Flange material.

! Design pressure.

! Hydrostatic test pressure.

! External loadings.

8.1.9.2 Contractor shall issue a hydraulic bolt tensioning procedure for approval by the principal.The procedure shall show all required information such as:

! Type of bolt tensioning equipment.

! Operation manual.

! Record preparation instructions.

! Establishment of the "break loose" pressure, based on minimum four (4)tensioners.

! Any precautions to be taken.

8.1.9.3 Contractor shall prepare an assembly record for each flange joint which needs to betensioned. These records shall be issued as part of the turn-over packages.



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Information to be shown on the assembly record shall be at least:

! Identification:

• Unit.

• Line number.

• Pipe class.

• Flange set number.

• Flange size/rating.

• Principal representative's name and signature.

! Inspection of the flange facing:

• Roughness.

• Damage: Dents, tool marks.

• Cleanliness.


! Flange fit-up:

• Gasket type.

• Gasket size.

• Bolt diameter and length.

• Number of bolts.

• Bolt material.

• Flange alignment.




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! Bolt tensioning:

• Pressure A, (the higher tool pressure, taking into account the maximumbolt stress, that is applied to obtain at least the average bolt stress).

• Pressure B, (the lower tool pressure, required to obtain the average boltstress).

• Tool number.

• "Break loose" pressure (check B pressure at four (4) bolts at 90% each) orbolt torque value.




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8.1.10 TABLE I Selection of Tools

FLANGE RATING (ANSI CLASS)150 300 600 900 1500 2500

½” 1 1 1 1 1 1¾” 1 1 1 1 1 11” 1 1 1 1 1 11½” 1 1 1 1 1 22” 1 1 1 1 1 2

F 3” 1 1 1 1 2 2L 4” 1 1 1 2 2 3A 6” 1 1 1 2 3 4N 8” 1 1 2 3 4 4G 10” 1 1 2 3 4 4E 12” 1 2 2 3 4 4

14” 1 2 3 3 4 -S 16” 1 2 3 4 4 -I 18” 2 2 4 4 4 -Z 20” 2 2 4 4 4 -E 24” 2 3 4 4 4 -

26” 2 4 - - - -28”-30” 2 4 - - - -32”-36” 3 4 - - - -38”-48” 3 4 - - - -50”-60” 4 4 - - - -above60”

4 - - - - -

LEGEND

TOOL BOLT SIZE1. Standard wrench � 1 inch

2. Torque wrench � 1¼ inch

3. Hydraulic torque wrench � 1½ inch

4. Bolt tensioning equipment > 1½ inch



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8.1.11 TABLE II Bolt Torque and Bolt Force Values

BOLT DIAMETER(INCH)

THREADS/INCH A193 B7, A193 B16 AND A320 L7, 26 IN. AND LARGER FOR 150 LB & 300 LBASME B16.47 SERIES A (MISS)

A193 B7, A193 B16 AND A320-L7, OTHERSIZES/RATINGS ASME B16.5

TORQUE VALUE IN Nm BOLT FORCE IN N (note 1) TORQUE VALUE IN NmNm

BOLT FORCE IN N(note 2)

Carbon steel Stainless steel Carbon steel(note 1)

StainlessSteel(note 3)

1/2 13 70 705/8 11 125 1253/4 10 195 1957/8 9 290 2901 8 300 200 71400 47600 400 952001 1/8 8 420 280 88940 59295 560 1185901 1/4 8 560 370 107670 71780 740 1435601 3/8 8 740 490 127640 85090 980 1701801 1/2 8 900 600 148650 99100 1200 1982001 5/8 8 1120 745 170770 113850 1490 2277001 3/4 8 1360 905 193950 129300 1810 2586001 7/8 8 1620 1080 218030 145350 2160 2907002 8 1920 1280 243000 162000 2560 3240002 1/4 8 2610 1740 295440 196960 3480 3939202 1/2 8 3420 2280 351750 234500 4560 469000

Notes: 1. 65% of empiric value to ASME Section VIII, div. 1, Appendix S2. 85% of empiric value to ASME Section VIII, div. 1, Appendix S3. 43% of empiric value to ASME Section VIII, div. 1, Appendix S



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8.2 THREADED CONNECTIONS

All threaded connections shall be seal welded, except the following:

! Connections in galvanized piping.

! Screwed plugs in valved drains and vents.

! Screwed thermowells and instrument connections.

! Screwed control valves and safety/relief valves.

Seal welding shall be executed by qualified welders and shall not be considered ascontributing to the strength of the joints. All exposed threads shall be covered by the sealweld.

Use sealing compound or teflon tape for all connections not to be seal welded.

Teflon tape is only allowed in utility services, at a design temperature of maximum200°C.

8.3 PIPE SUPPORTS

8.3.1 Temporary Supports

During erection, piping shall be adequate temporary supported until the final supports areinstalled. Temporary supports shall rest on paving, or direct or indirect on concrete orstructural beams.

Piping shall not be temporarily supported from platform grating or from scaffolding.Temporary supports shall consist of wooden blocks and/or steel hoisting ropes. Syntheticropes or strings are not acceptable as temporary supports.

Steel temporary supporting materials for stainless and duplex stainless steel materialsshall preferably be stainless steel. Galvanized temporary supporting material shall not beused.

8.3.2 General

Pipe supports shall be designed, fabricated and installed in accordance with the pipingdrawings on which the locations shall be indicated.



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Contractor shall adjust the pipe support to overcome construction measure deviations.Shims used to achieve full bearing between a pipe and/or a pipe attachment and the mainsupport member must have sufficient area to carry the load. After erection, shims shall bewelded to the main steel to prevent slippage when the pipe moves during operation.Shims shall not be welded to the pipe. Shims which are to be welded to pipe shoes shallextend the full length and width of the shoe.

Alternative supports shall only be installed after approval by principal.

Contractor shall remove fireproofing locally from steel columns and beams for a properinstallation of pipe support according to the pipe support drawings. Fireproofing shall berepaired on the main structure and need not to be installed on the additional pipe support,unless otherwise shown. Fireproofing around directional anchors from pipes which arefree to move in the transverse direction shall be kept free minimum 50 mm from the pipeanchor parts.

Where expansion bolts have to be applied in concrete members, care shall be taken not toundercut retaining bars in the concrete. Pipe supports shall be adjusted to suit the finallocation of the expansion bolts.

8.3.3 Variable Spring Supports

Installation

The spring hanger list included in the pipe support drawings shall give, for each spring:

a. The operating load.

b. The cold set load.

c. The amount and direction of travel.

When the spring is delivered, it will have been loaded to the preset load and locked intothis position by means of the cold setting stops. Depending upon the manufacturer, thecold setting stops will take the form of a plain rivet through section bar inserted aboveand below the piston plate inside the load scale slot.

The cold setting stops must remain undisturbed until the hydrostatic test on the line hasbeen satisfactorily completed, after which the following procedure shall be carried out:

a. At some time between the hydrostatic test and start-up, the cold setting stops shallbe removed. Ultimate force must not be used.



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With the cold setting stops removed, it may be noticed that the line has a tendencyto bow up or sag down. This is to be expected as when the line is cold and emptyit is obvious that it can be either oversupported or undersupported since it isdesigned to be correctly supported at the hot operating condition. Do not readjustthe spring load, but contact principal when there is doubt.

8.4 COLD SPRING

Where specified on the drawings, cold spring or fullness (cold strain) shall beaccomplished by observing the following procedures:

! Piping shall be installed while the field weld as shown on the drawings is leftunwelded until the remainder of the line is completely erected. All line anchors,guides and other supports shall be installed without using ultimate force.

! The gap between the pipe ends shall then be measured. If not equal to thespecified gap, the necessary modifications shall be made by cutting or extendingthe pipe.

! The gap shall then be closed by jacking the line and clamping and bracingsecurely in place.

! The field weld shall then be made.

8.5 EXPANSION JOINTS

Expansion joints shall be installed following thoroughly the instructions of themanufacturer regarding the removal of shipping supports and attachments, adjusting tie-rod nuts, precompressing bellows, flow direction, etc. If the joints have welding ends,protection shall be given to the bellows to prevent any injurious effects during welding.

8.6 FINAL CORRECTIONS

8.6.1 Carbon Steel, 0.3 Mo and 0.6 Mo Steel Piping

If corrections are required after fabrication, they may be carried out by a methodapproved by principal.

8.6.2 Chromium Molybdenum Steel Piping

After the final heat treatment all corrections to the piping should preferably be made inthe cold condition.



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If this is not possible the piping may be heated, for which written approval by principal isrequired. The heating shall be applied uniformly and carefully controlled, the temperatureshall not exceed the maximum temperature limit of postweld heat treatment as indicatedin ASME B31.3 and shall be minimum 10°C below the tempering temperature. Reheattreatment will then not be required.

8.6.3 Austenitic Chromium Nickel and Chromium Nickel Molybdenum Steel Piping

All corrections to the piping should preferably be made in the cold condition.

If cold correction is not possible the piping may be heated after written approval byprincipal. The heating shall be applied uniformly and carefully controlled. Thetemperature shall not exceed 400°C.

9. INSPECTION AND TESTING

9.1 GENERAL

Inspectors representing either Contractor or Principal shall have access to the Supplier’sshop or work area, with freedom to observe fabrication and inspect materials intended forfabrication.

! Test and measuring equipment used shall be calibrated every six (6) months andthis calibration shall be supported by calibration certificates.

! All inspection and testing is the responsibility of contractor. Principal shall alwayshave the right to witness inspection.

! Pipe bends manufactured by contractor shall be thoroughly visual inspected forcracks and surface laminations. If any doubt exists about the presence of cracksand laminations, contractor shall apply magnetic particle or liquid penetrantexamination to show the absence of subject surface defects.

! All cold pulled bends with service temperatures over 425°C, or ANSI ratings900 lbs and higher regardless of service temperature, shall be subjected tomagnetic particle examination or dye penetrant testing.

! Hardness of all fabricated ferritic steel bends shall be checked. Heat treatmentshall be executed as described in paragraph 7.12.2 when hardness is too high.



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The supplier shall provide records of examination as requested in ANSI B.31.3. Inaddition, he shall prepare records if any are required by ortuguese authorities(DIRECÇÃO GERAL DE ENERGIA).

! Any defects revealed by any of the examinations performed shall be reworked andretested. All assemblies indicating irremediable defects, excessive repairs,improper fabrication or not being in accordance with the requirements of thisspecification shall be subject to rejection, even if the conditions are discoveredafter acceptance at contractor's shop or revealed during field testing. All costsrelated to repairs and/or refabrication shall be for contractor's account.

9.2 POSITIVE MATERIAL IDENTIFICATION

9.2.1 Positive material identification shall be executed as follows:

a. Incoming materials in principal’s warehouse shall be examined at random byprincipal to check attached certificates.

b. Installed material shall be checked at random by contractor to eliminatepossibility of accidental material substitution.

c. All installed materials with poor readability of heat numbers or materials wheredoubt exists concerning the accuracy of the heat numbers shall be checked bycontractor.

“At random” is defined as a random check of materials per material type(independent of size, rating, wall thickness and type of piping item) up to amaximum of 1% of the total installed quantity of material.

9.2.2 PMI is only required for the following materials:

MATERIAL SERVICECr.Mo Steel All ServicesStainless Steel When IndicatedDuplex StainlessSteels

All Services

High Alloy Steels All Services

9.2.3 Contractor is responsible for execution and documentation of PMI as described underparagraph 9.2.1b. and paragraph 9.2.1c.



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9.3 WELD EXAMINATION

For weld examination requirements, see specification "Welding of Carbon, Low Alloyand Austenitic Stainless Steel Piping".

9.4 PRESSURE TESTING AND FLUSHING

! For pressure testing and flushing of completed piping systems, see specification"Pressure Testing, Flushing and Reinstatement of Piping Systems".

! Except when specifically noted on the drawings, spools shall not require shophydrostatic testing. This shall not, however, relieve contractor of the responsibilityfor any defects in materials and/or fabrication that may be revealed during fieldhydrostatic testing.

! The space between a reinforcing pad and header shall be air/soap pressure testedwith an air pressure of 1.75 barg preferably prior to erection of the line.

10. CLEANING

10.1 WELD ENDS

During weld preparation ends of all components shall be freed from any trace of oil,grease, paint, rust, scale, etc., over a distance of 50 mm minimum from the weld edge.

10.2 PIPING

10.2.1 Internal

During fabrication and installation, contractor shall prevent foreign materials such as oil,grease, sand, dirt, scale, loose particles from cutting and grinding, etc., from entering thepipe or pipe component.If foreign materials have entered the pipe or pipe component, they shall immediately beremoved before assembly of the parts by a suitable cleaning method, such as blowingthrough with air or degreasing with suitable cleaning agent or solvent.

Cleaning agents and solvents used for degreasing shall not have any properties causingcorrosion of the piping.



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10.2.2 External

Piping to be painted shall be cleaned in accordance with the requirements of specification"Surface Preparation and Painting".

Piping which needs not be painted shall be cleaned by a suitable cleaning method toremove excessive rust, scale or grease only.

Cleaning agents and solvents used for degreasing shall not have any properties causingcorrosion of the piping.

10.3 COMPLETED PIPING SYSTEMS

Unless otherwise indicated in the pipe class or on the piping drawings or P&ID's, onlyflushing as described in specification "Pressure Testing, Flushing and Reinstatement ofPiping Systems" is required.

10.4 DEGREASING

For certain services, lines need to be degreased to prevent operation problems. Thisrequirement is indicated in the pipe class or on the piping drawings or P&ID's and shallbe executed in accordance with additional specifications supplied by principal.

Cleaning agents and solvents used for decreasing shall not have any properties causingcorrosion of the piping.

10.5 CHEMICAL CLEANING

Requirements for chemical cleaning of lines shall be indicated on the piping drawingsand/or the P&ID's. If chemical cleaning is applicable, principal shall issue a chemicalcleaning procedure for approval by principal.The contractor responsible for chemical cleaning shall check whether all materialsincluded in the piping system are compatible with the intended cleaning liquid.

11. PAINTING/COATING

For painting requirements, reference is made to specification "Surface Preparation andPainting".

Underground piping shall be coated and wrapped in accordance with specification“Coating and Wrapping of Underground Piping”.



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12. DOCUMENTATION

12.1 Both shop and field fabrication include administration of material certificates, weldingoperations, destructive and nondestructive examinations and all testing operations asrequired by the applicable specifications and codes.

12.2 Contractor is responsible for planning and documenting all activities and controls whichinclude, but are not necessarily limited to, the following operations:

! Material receiving (including administration/filing of certificates).

! Cutting.

! Bending (on site and at contractors for induction bending).

! Welding.

! Heat treatment.

! Destructive and nondestructive testing.

! Hydraulic bolt tensioning and/or torquing.

! Hydrotesting.

! Flushing.

! Cleaning/chemical cleaning.

12.3 Contractor shall provide principal with two (2) copies of material test certificates for allmaterials purchased by contractor.

12.4 Documents relating to assemblies to be shipped shall be submitted to principal.

Documents shall be available to principal at all times.

12.5 For each piping system (defined as piping items welded together of same material andsame design pressure/temperature, e.g. line from a pump to a vessel) contractor shallprovide a fabrication book containing documents showing all above-listed operations,signed by a third party inspection, if required.



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13. PREPARATION FOR SHIPMENT

Before shop-fabricated assemblies are prepared for shipping, principal shall checkfollowing:

! Overall dimensions as per piping drawing.

! Required documentation as per subsections 12.2 and 12.3.

! Material identification as per subsection 6.2.

After assembly has been released by principal, contractor shall prepare material forshipping as follows:

! All assemblies shall be dry and free from water, dirt and loose or foreignmaterials.

! Flange faces, machined surfaces and threads in carbon-steel piping shall be coatedwith a corrosion preventive compound (Rust Ban 324, or equal) before applyingthe cover, cap or plug.

! Plastic caps shall be used over all plain, bevelled or threaded open ends.

! Wood, metal or plastic covers shall be bolted or strapped to open flanged ends.

! All protective coverings of piping for shipment and shipping containers shall be ofsturdy construction in order to withstand normal shipping abuse.

Provisions shall be made to prevent damage to all subassemblies during loading,unloading or shifting of the cargo in transit.

Small items shall not be shipped loose, but shall be bagged, boxed or crated. Eachcontainer shall be tagged with a description of the contents and destination.

Carbon, low-alloy and galvanized carbon steel, stainless steel and duplex stainless steelshall be shipped separately from each other.

For stainless-steel and duplex stainless steel spools, contractor shall not use steel hoistingdevices as described in subsection 6.1 and shall provide suitable transport packing toprevent spools from contacting surfaces containing zinc or other harmful materials duringthe transportation.



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13.1 SPOOL PIECE MARKING

The appropriate pipe identification, consisting of the line number and spool number, shallbe hard dye stamped into the spool. Marking shall be circled with yellow paint.

Note: When spools are shop painted the marking shall be protected against shot blastingand priming.

14. ADDITIONAL REQUIREMENTS

For additional or deviating requirements concerning fabrication and erection of steelpiping, see specifications listed below:

! "Hot Water and Steam Tracing".

! "Insulation of Piping and Equipment".

! "Underground Piping".

! "Coating and Wrapping of Underground Piping".

BES 1300-102

Documents

Transcript of BES 1300-102