F500-0000-PI-SP-5003-D2-Specification For Piping Fabrication and Erection PDF

FOROOZAN OFFSHORE COMPLEX RENOVATION
AND RECONSTRUCTION PROJECT

Contract No. 3898-86-2FGH
SPECIFICATION FOR PIPING FABRICATION AND
ERECTION
Rev. D2
Proj. Site Disc Doc. Seq. Page
F500 0000 PI SP 5003 1 of 40

SPECIFICATION FOR PIPING
FABRICATION AND ERECTION
D2 31-Jul-10 Approved For Construction A.A. J.Afkar H.Dadgar A.Jahani H.Aramideh S.Azkat
D1 18-Aug-09 Issued For Approval S.S J.Afkar H.Dadgar A.Jahani H.Aramideh S.Azkat
D0 23-May-09 Issued For Comments S.S J.Afkar H.Dadgar A.Jahani H.Aramideh S.Azkat
Rev. Date Purpose of Issue
Prep. Check. Approv. Approv. Approv.
ISI IOEC/NARDIS COMPANY

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TABLE OF CONTENT
1 INTRODUCTION ............................................................................................................................................. 5
1.1 General Description of the Project ............................................................................................................. 5
1.2 Definition ..................................................................................................................................................... 5
2 OBJECTIVE ..................................................................................................................................................... 6
3 REFERENCE DOCUMENTS .......................................................................................................................... 6
3.1 Codes and Standards ................................................................................................................................. 6
3.2 Specifications / Drawings, etc. .................................................................................................................... 6
3.3 Order of Preference .................................................................................................................................... 7
4 DESIGN ........................................................................................................................................................... 7
5 MATERIALS .................................................................................................................................................... 8
5.1 Storage / Handling of Materials .................................................................................................................. 8
5.2 Material Identification .................................................................................................................................. 9
6 FABRICATION .............................................................................................................................................. 10
6.1 Shop Fabrication ...................................................................................................................................... 10
6.2 Location of Field Welds ............................................................................................................................ 11
6.3 Field Fabrication ....................................................................................................................................... 11
6.4 Verification of Field Dimensions (New and retro-fit system) .................................................................... 11
6.5 Make-up Length ........................................................................................................................................ 12
6.6 Tolerances ................................................................................................................................................ 12
6.7 Minimum Distance between Welds .......................................................................................................... 13
6.8 Branch Connections ................................................................................................................................. 13
6.9 Galvanized Piping ..................................................................................................................................... 14
6.10 End Preparation ........................................................................................................................................ 15
6.11 Welding ..................................................................................................................................................... 16
6.12 Bending ..................................................................................................................................................... 16
7 INSTALLATION............................................................................................................................................. 17
7.1 Flange Assembly ...................................................................................................................................... 18
7.2 Threaded Connections ............................................................................................................................. 29

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7.3 Pipe Supports ........................................................................................................................................... 29
7.4 Cold Spring ............................................................................................................................................... 32
7.5 Expansion Joints ...................................................................................................................................... 32
7.6 Final Corrections ...................................................................................................................................... 32
8 INSPECTION AND TESTING ....................................................................................................................... 34
8.1 General ..................................................................................................................................................... 34
8.2 Positive Material Identification Test .......................................................................................................... 35
8.3 Weld Examination ..................................................................................................................................... 36
8.4 Pressure Testing and Flushing ................................................................................................................. 36
9 CLEANING .................................................................................................................................................... 36
9.1 Weld Ends ................................................................................................................................................ 36
9.2 Piping ........................................................................................................................................................ 36
9.3 Completed Piping Systems ...................................................................................................................... 37
9.4 Degreasing ............................................................................................................................................... 37
10 PAINTING ...................................................................................................................................................... 37
11 DOCUMENTATION ....................................................................................................................................... 37
12 PREPARATION FOR SHIPMENT ................................................................................................................ 38
12.1 Spool Piece Marking ................................................................................................................................. 39
13 ADDITIONAL REQUIREMENTS ................................................................................................................... 40

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1 INTRODUCTION
1.1 General Description of the Project

The project concerns the reconstruction and renovation of an existing oilfield in Persian Gulf. Foroozan
field is located approximately 100km southwest of Kharg Island export terminal. The field was initially
developed in the early 1970s with the first production commencing towards the end of 1975. Peak
production of about 180,000 was briefly obtained in late 1978 but in more recent years production has
experienced a continuous decline associated with increased water production.
The oil and gas produced in Foroozan field are processed at 2 main offshore production complexes, FX and

FZ.

1.2 Definition

Wherever the word "shall" has been used, its meaning is to be understood as mandatory.
Wherever the word "should" has been used, its meaning is to be understood as strongly recommended
or advised.
Wherever the wording "may be" has been used, its meaning is to be understood as a freedom of choice.
The following words and expressions shall have the meanings hereby assigned to them except where
the context of this document otherwise requires:
"Company" mean Iranian Offshore Oil (COMPANY) Company.
"EPC Contractor" mean Company mentioned in the Contract as party of the "other part" and
includes its successors and permitted assignees. (IOEC/Nardis)
" Consultant" mean the company which provided engineering design of project. The name of this
company is "Intelligent Solution Incorporation" and abbreviation is "ISI".
" Basic Consultant" mean the company which provided basic engineering design of project. The
name of this company is "Ranhill Worley Parson" and abbreviation is "RWP".
" Vendor" means anyone who provides goods or services to a company. A vendor often
manufactures and/or sells their products to a customer.
"NIOC" mean National Iranian Oil Company, a company incorporated under the laws of Iran,
whose Head Office is situated in Tehran, Iran.

Whenever terms appear in this document as capitalized terms, they shall have the meaning ascribed to them
here above.

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2 OBJECTIVE

This specification covers the minimum requirements for fabrication and installation of steel piping, including pipe
supports.
Fabrication and installation of tubing, lined pipe and nonmetallic piping are excluded from the scope of this
specification and shall be executed in accordance with ASME B31.3/ASME B31.8 and manufacturer's
requirements and recommendations.

3 REFERENCE DOCUMENTS
3.1 Codes and Standards

ASME B31.3 Process Piping.
ASME B31.8 Gas Transmission and Distribution Piping Systems.
ASME B16.25 Butt-welding Ends.
API RP 686 Machinery Installation and Installation Design

3.2 Specifications / Drawings, etc.

F500F500-0000-PI-SP-5001 Specification for Piping Materials.
F500F500-0000-PI-DB-5000 Piping Design Basis
F500F500-0000-PI-SP-5010 Piping Standard Drawings
F500F500-0000-ME-SP-4001 Surface Preparation and Painting, Coating and Corrosion
Protection
F500F500-0000-PI-SP-5005 Pressure Testing, Flushing and Reinstatement of Piping
Systems.
F500F500-0000-PI-SP-5009 Specification for Welding of Piping
F500F500-0000-PI-SP-5002 Specification for Pipe, Fittings & Flanges
F500F500-0000-PI-SP-5004 Specification for Valves

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3.3 Order of Preference

In case of conflict between regulations, codes and standards listed shall be applied in the following
priority order:

Purchase Order
Material Requisition
Data Sheets
Project Specifications and Standard Drawings
International Codes and standards
National Codes and Standards
Supplier Specifications.

Latest editions of all Codes and Standards as valid on date of Contract shall be applicable. Deviations
from applicable rules, codes and standards shall be subject to Purchasers/Owners written approval.

4 DESIGN

The Fabricator Contractor / Sub-Contractor will furnish piping detail drawings of plan and isometric. The
detail drawing will contain all the relevant dimensions for fabrication, together with a bill of materials.
The dimensions on the drawings will be true dimensions without any allowance for weld gaps.

Piping designed by Fabricator Contractor/Sub-Contractor shall meet the requirements of ASME B31.3
and where applicable, ASME B31.4/ASME B31.8.

Fabricator Contractor/Sub-Contractor shall be fully responsible for conformity between his detailed
sketches and the latest revision of drawings supplied by Design Consultant/Contractor.

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5 MATERIALS

All piping materials shall conform to the requirements of the applicable general specifications or to
requirements on the drawings, inquiry and/or purchase order.

All materials included in the finished piping systems (free-issued materials and material purchased by
Fabricator Contractor/Subcontractor) shall be undamaged and fully in accordance with the piping
material class and pipe support drawings indicated on the piping drawing and/or P&ID. For piping
material classes, see specification F500F500-0000-PI-SP-5003: Specification for Piping Materials".
Material substitutions or deviations from the piping material classes shall not be made without prior
written approval of Owners/ Authorized representative.
Fabricator Contractor shall submit a written justification for each proposed substitute materials.

Fabricator Contractor/Subcontractor shall provide a copy of the mill certificates including chemical and
physical properties for all materials.

Fabricator Contractor/Subcontractor shall be responsible for any loss or damage to free issued
materials.

Fabrication of plastic and plastic lined steel piping shall be in accordance ASME B31.3 and the
manufacturers latest recommendation.

5.1 Storage / Handling of Materials

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

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

Stainless-steel materials shall not be loaded, unloaded or handled with hoisting devices (e.g.
steel ropes and forklift trucks) containing zinc or other harmful materials.

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Storage and control procedures shall be prepared by the Fabricator Contractor/Subcontractor
to be submitted for review/approval by Owner/Authorized representatives.

Pre-fabricated pipe work shall be properly stored on level grand with 50 mm thick supports to
avoid contact with moisture.

5.2 Material Identification
Materials issued to Fabricator Contractor/Subcontractor shall be properly marked in
accordance with the requirements of the applicable material specifications and requirements of
the purchase order requisitions and/or local codes and regulations.

In an areas wherein material identification symbols are located near or along the proximity of
the weld or on a piece of material to be cut off; material shall be re-stamped prior to welding or
cutting to avoid loss of traceability.

The governing principle shall be that in the installed piping systems, all components can be
identified and traced to their origin and complete specifications.

Marking and re-marking by Fabricator Contractor/Subcontractor's representatives shall be
performed or executed by hard dye stamping or engraving, whichever is applicable.

All hard stamping shall be done by means of low stress stamps on pressure-bearing parts. Low
stress stamped shall have a round nose with a radius of 0.25 mm minimum.

Hard dye stamping or engraving is not allowed for galvanized piping.

For ferrous materials with a thickness of equal to or less than 5 mm ( 5mm) and austenitic
steel with a thickness of equal to or less than 10 mm ( 10mm), marking shall be performed by
engraving.

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

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

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6 FABRICATION
Pipe work shall be fabricated by welding, screwing, and/or flanging as specified on the design
drawing and specifications.
Fabricated metal piping shall meet local authority requirements for all piping requiring
inspection and approval by local authorities such as HSE requirement , wind or humidity.
All other fabricated metal piping shall meet the requirements of ASME B31.3 and where
applicable, ASME B31.4/ ASME B31.8.
In order to prevent corrosion of stainless steel, fabrication of carbon steel and galvanized
carbon steel shall be done 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 and galvanized steel
may not be used for fabrication of stainless steel. Only tools made of stainless steel are
allowed for grinding, brushing, clamping, etc.
These requirements apply to shop and field fabrication.
6.1 Shop Fabrication
Shop fabricated piping is define as piping components or fired heater tube assemblies (if
applicable) which are performed or welded together, in a pipe fabricating shop located offsite,
to form integral pieces ready for assembly and erection. This may include bending, forming,
threading, bevelling, welding or other operations necessary for such work and external
welded attachments where specified.
Shop fabrication under this specification shall include all the components of the pipeline or
parts thereof entering into fabricated assemblies (spools), but shall exclude all piping
specialties other than those with welding end constructions such as bolting, gaskets, flanged
valves and fittings, blind flanges, orifice plates and similar items. Fabricator
Contractor/Subcontractor will be responsible for selection of piping to be shop fabricated on
site or off site.
For some piping systems Fabricator Contractor/Subcontractor may have opt for preferential preference
for shop fabrication to a maximum extent possible, e.g.:
Lined piping.

The fabricator contractor shall keep on file the records and reports specified herein available for
examination by OWNER or its representative for at least eighteen (18) months after date of shipment.

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6.2 Location of Field Welds
The size of spools and location of field welds shall be determined by the Fabricator Contractor/
Subcontractor.
Field welds shall be located so that the spools shall be as large as possible and consistent with 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. A line and its
branches which appear on more than one (1) drawing is not intended to mean that a field weld
is desired at the continuation point from one drawing to another.
Where piping is shown passing through a wall or floor, the first weld point on either side of the
wall or floor shall be made a field weld, provided it is located at least 150 mm away from the
end of the pipe sleeve.
Erection conditions shall be considered in determining the size of spools.
6.3 Field Fabrication
All piping or fired heater tube assemblies (if applicable) which are fabricated on site, including bending,
forming, threading, bevelling, welding, assembly of shop fabricated piping, or other operations
necessary for the erection and installation of a piping system.
Field fabrication under this specification covers, but is not necessary limited to, the following 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 which no isometric
piping or piping plan drawings are available.
Fabrication and erection of all pipe supports and auxiliary steel as detailed in the pipe support
drawings.
Design, fabrication and erection of all pipe supports for small bore piping, which shall form part
and to be executed in line with the available drawings for supports.
6.4 Verification of Field Dimensions (New and retro-fit system)
Fabrication of piping and pipe supports shall be in accordance with the supplied design drawings.
However, due to equipment location and fabrication tolerances, field verification of overall dimensions
shall be made by Fabricator Contractor/Subcontractor prior to erection, to ensure a proper fit-up at all
connections to equipment and other piping.

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Fabricator Contractor/Subcontractor is required to conduct a systematic form of field measurement
including elevation and dimension of existing facilities and new related tie-in and new piping works.
The requirements of engaging third party contractor for the laser scanning works(i.e. usage of a laser
survey) to verify elevation/dimension of all tie-in works, new piping and equipment to be installed on the
existing platforms is strongly advise and recommended.
6.5 Make-up Length
Fabricator Contractor/Subcontractor shall apply 150 mm make-up lengths in order to make adjustments,
necessary due to construction deviations. The required material shall be taken from the construction
allowances/contingencies.
6.6 Tolerances

6.6.1 Overall Dimensions
The dimensional tolerances of all fabricated lines shall not exceed the values given below:
Less 1.5 m
Length than 1.5 m and longer

Center to center }
Center to flange face } 1.5 mm 3 mm
Flange face to flange face }
The angular dimensions of bends shall be within degree.
Manufacturers tolerance shall govern where forged fittings are welded and join together.

6.6.2 Thinning of Wall Thickness and Ovality in Bends
The maximum decrease of wall thickness shall not exceed 10% of the nominal wall thickness.
For tolerances on the maximum flattening, refer to ASME B31.3 and where applicable, ASME
B31.4/B31.8

6.6.3 Flange Face Alignment
For flange joints in rigid systems (free unrestrained straight length less then 10D at one or both sides of
the flange) flange faces shall be aligned to the design plane within 2.5 mm/m.
For all other flange joints flange faces shall be aligned to the design plane within 5 mm/m.
Heating of pipework to achieve alignment of flanges at equipment shall not be permitted.

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6.6.4 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-south centerline
when the flange face is in the horizontal position and shall straddle the vertical flange centerline when
the flange is in the vertical position.
6.7 Minimum Distance between Welds
The minimum distance between weld edges shall be as per requirements of specification, Specification
for Welding of Piping, document no. F500F500-0000-PI-SP-5009.
The minimum distance between welded joints, including longitudinal welds, and openings, branch
welds, reinforcements, attachment devices, supports, etc. shall be as per requirements of Para 12.9 of
Specification for Welding of Piping
Fabricator Contractor/Subcontractor shall provide and or specify additional requirements (such as
radiography, ultrasonic inspection or postweld heat treatment) in case of deviations.
The longitudinal welds of two (2) adjacent rings or tubes shall be staggered approximately 90.
Longitudinal welds shall not be situated at the bottom of the pipe.
In cases where staggering is not possible, e.g. fitting to fitting connections. The weld joint shall be
subjected to non-destructive testing.

6.8 Branch Connections

The requirements for branch reinforcements for piping shall conform to the applicable codes. Any
branch reinforcements requirements for fired heater tube assemblies will be furnished with the heater
tube assembly drawings and specifications.
Branch connection type shall be in accordance with the piping drawing or the piping material class,
when no drawing is supplied.Branch connection could be set on or set in.
Where openings for branches are cut in run of pipe, all materials which may drop inside the pipe shall
be completely removed before the branch line is welded into place.
Branch connection cut-outs shall be properly Bevelled and to accurately matched to form a suitable
groove for welding. To enable and permit complete penetration of the welds at all points, resulting in a
quality comparable with girth welds, in the same piping system.

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Weld details for branch welds shall be included in the welding procedure specification.
Reference is made to the relevant section of ASME B31.3/ASME B31.4/ASME B31.8.
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 the outside surface
of the run wall.
Threaded couplings shall subsequently be checked with a thread gauge to ensure against thread
damage or distortion.
Requirements of a 6 mm diameter vent hole in the reinforcing pad or saddle, to reveal leakage in the
weld between the branch and main run and to provide venting during welding and heat treating
operations, shall be provided. If the reinforcement pad consists of more than one piece, each piece
shall have a vent hole.
6.9 Galvanized Piping
Galvanized piping up to and including 2" (DN 50) nominal size shall in general be assembled from
threaded galvanized components.
Piping larger than 2" (DN 50) nominal size shall be pre-fabricated in accordance with this specification
and subsequently hot-dipped galvanized in accordance with ASTM A153.
Fabricator Contractor/Subcontractor shall take into account that after the spools have been galvanized
no welding will be allowed. This implies that field break shall be located at flanged connections or
connections using threaded couplings and that welded-on pipe supports shall be welded to the spools
before galvanizing.
Welding of galvanized steel to austenitic steel pressure parts is prohibited.
Subcontractor shall consider maximum dimensions of the galvanizing facilities he intends to use, when
determining spool dimensions and locations of field breaks.
Visual and dimensional inspections by Owners Authorized representative, nondestructive weld
examinations if applicable and hydrostatic testing shall be executed before spools are hot-dip
galvanized.
Threaded connections shall be reworked to clean thread depth.
Repair of galvanized piping shall be as per ASTM A780, as referenced in ASTM A153.

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6.10 End Preparation

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

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

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

Preheating during thermal cutting shall be the same as applied during welding (see
specification "Specification for Welding of Piping document no. F500F500-0000-PI-SP-5009.

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

6.10.3 Tapering
Weld alignment shall be in accordance with ASME B31.3 or ASME B31.4/ ASME B31.8.

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

6.10.5 Plain Ends
Pipes for sizes 1 shall be cut square or will be specified by schudle .

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6.11 Welding
The following activities shall be executed in accordance with the requirements as described in
specification Specification for Welding of Piping, document no. F500F500-0000-PI-SP-5009.

Alignment.

Preheating.

Tack welding.

Welding.

Repair welding.

Postweld heat treatment.

Backing ring and consumable inserts shall be prohibited unless approved in advance by OWNER.
Fields welds shall normally be butt-welded type rather than stub-in or miter type, unless otherwise
approved in writing by OWNER.

6.12 Bending

6.12.1 General
Pipe bending may be considered as an alternate to welded fabrication. This consideration shall be
made prior to piping fabrication to take advantage of possible economics.
If bending is specified, the fabricators bending procedures shall be in strict accordance with ASME
B31.3/ASME B31.8 and shall be subject to prior approval by Owner/Purchasers representative.
Bending of pipes shall only be done where indicated on the isometric drawings or when allowed by the
applicable pipe class, otherwise welding elbows shall be used.

If the pipe contains a longitudinal weld, this weld shall be located in the neutral zone.
At site, cold pipe bending is not allowed.

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Hot bending at site is not allowed, but shall be executed by Fabricator Contractor/ Subcontractors with
induction pipe-bending machines in accordance with the requirements of a bending procedure approved
by Owner.
Pipe bending shall be carried out in pipe bending machines or presses using formers. Tolerances for
thinning, flattening and wrinkling are specified in section 6.6.

6.12.2 Additional Requirements for Ferritic Steels
For feritic steels, with the exception of the quenched and tempered grades, a normalizing heat
treatment shall be applied when the hardness increase in Vickers or Brinell is more than 100, unless
local regulations are more stringent.

For quenched and tempered feritic steels an appropriate stress-relieving heat treatment shall be applied
when the hardness increase in Vickers or Brinell is more than 100, unless local regulations are more
stringent. Stress relieving shall be at least 10C below the tempering temperature.
The use of water for cooling is not permitted.

7 INSTALLATION
Fabricator Contractor/Subcontractor shall be responsible for installation of all piping spools including
pipe supports, all piping 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 similar items 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 permit fit-up without
bending or springing the pipe under any circumstances. Alignment shall be checked and approved by
Owner/Authorized representative prior to bolt-up.
API RP 686 provide proper guide lines for installation sequence and bolting up of piping connected to
machinery.
Where a discrepancy between drawing dimensions and field dimensions exists, sufficient modifications
shall be made to eliminate unintended cold springing and cold forcing.
Deviations from the arrangement shown on drawings shall only be made after approval of Owners
representative. Fabricator Contractor/ Subcontractor shall submit alternative routing for review and
approval by Owner representative.

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Alternative routing shall keep clear all access ways and equipment openings and shall maintain
accessibility of valves and instruments.
Cutting, welding and making attachments to structural members, vessels, exchangers and other
equipment, not detailed in the piping and piping support drawings, shall not be permitted without prior
approval of Owner representative.
Stainless steel shall be suitably protected during installation or modification of carbon-steel, and
galvanized carbon-steel piping at site.
All stainless steel pipe potentially exposed to zinc dust contamination shall be protected with polythene
sheeting. This requirements will apply also to piping under or close to at the same level, as galvanized
steel (grating/structural members/etc.). The sheeting shall be securely wrapped against tearing by wind
and shall be removed upon completion of the works.
Scaffolding, which is galvanized pipe, shall be kept at a distance of at least of 200 mm from stainless
steel pipe in order to prevent the possibility of surface contamination.
Pulling of pipe along piperacks is forbidden unless rollers are used.
Vents, drains, condensate drip legs, pressure instrument and other connections shall be installed where
indicated on the isometric drawings, in accordance with piping standards included in specification
"Piping Standard Drawings", doc. no. F500F500-0000-PI-SP-5008.
Protective devices on pipe ends, flanges and equipment openings shall remain in place until the piping
connection is ready to be made.
7.1 Flange Assembly
7.1.1 Tools
Usage of adjustable wrenches (Bahco) or wrench hammers is prohibited.
For application of correct tool related to flange size and rating, see table I.
The calibration of torque wrenches and tensioners shall be checked against manufacturer's
specifications upon receipt. Any tools that are out of calibration shall be rejected.
Requirement of verification and rechecking of the calibration shall be made as per tool manufacturer
standard. Any tool found to be out of calibration shall immediately be withdrawn or taken out of service for
repair.
All flanged joints secured with tools found to be defective shall be re-checked with a properly functioning
tool.

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7.1.2 Flange Identification
Flanges subject to hydraulic bolt tensioning shall be numbered on the isometric or on the general
arrangement drawing by the subcontractor. Starting with the flow direction of each line number within one
(1) unit, the flange sets shall be identified as F1, F2, F3, etc., followed by 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 nozzle number 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" as described in
section 7.1.8 and section 12.1 to the relating flange set.
7.1.3 Torque Values
In case torque wrenches (manual or hydraulic) are used, bolts shall be tightened until torque values, as
indicated in table II, are reached.
In case tensioning equipment is used, bolts shall be tightened until bolt force values, as indicated in table II
are reached.
Listed values are NOT APPLICABLE for designed flanges over 60 inches. For these flanges the
equipment manufacturer shall indicate on his drawings the bolt torque value used in the calculation
made for the design of the flange.
For bolt material not listed in table II contact EPC1 Contractor to obtain correct torque and bolt force
values.
a. Listed values are based on the empiric bolt force in flanges according to ASME Section VIII, Div.
1, Appendix S.
b. Torque moments are based on the pitch of the thread, the friction resistance between the thread
surfaces and the bearing surfaces of the nut on the flanges.
c. Friction coefficient f = 0.1

7.1.4 Installation
Inspection of Material
Inspect the gasket material for possible damage or defects such as bends or creases.
Inspect the mating flange facings for dirt, parallelism, flatness, surface roughness, mechanical damage
and corrosion. Use a suitable solvent to clean the surfaces.

ERECTION
Rev. D2
F500 0000 PI SP 5003 20 of 40

The contact area of the flanges shall be free of excessive pitting, radial tool marks and scratches.
Flange facings which are found to be damaged during construction, shall be re-machined at
subcontractor's expense.
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.
The Subcontractor shall ensure that the correct gasket material and thickness as specified in the Piping
Material Classes and on the piping drawings will be used.

7.1.5 Assembly of Flange Connection
The Fabricator Contractor/Subcontractor shall ensure that all bolting materials and types used are in
accordance with the service requirements specified on individual material specifications (piping material
classes) and detailed on the piping isometrics.
All flanges bolting shall be checked for correct grade and to ensure that they are free from damage to
the bolt/nut and any coating prior to fitting.
The Fabricator Contractor/Subcontractor shall ensure that during the installation of galvanised or PTFE
coated bolts, care will be taken that the coating is not damaged when bolt tightening. Any coating that is
damaged shall be brought to the attention of the Owner Authorized representatives.
Align the flanges properly. For tolerances on flange joints see specification section 6.6. The bolt holes
shall match so that the studs can be inserted freely. Install the gasket. Gaskets shall not be lubricated.
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 is at all points within the
outside diameter of the raised face. Clamp securely in place.
Insert the balance of the studs. Apply a suitable lubricant to the threads and the face of the nut that
contacts the flange.
Hand tightens all studs and nuts. Center studs between nuts so an equal number of threads projects at
each end. When hydraulic bolt tensioning is required, a threaded length equal to the bolt diameter
should protrude at the end where the bolt tensioner is to be placed.
For other sizes, each stud bolt shall be assembled with a projection of no more than one full thread
beyond the nut at one end.

ERECTION
Rev. D2
F500 0000 PI SP 5003 21 of 40

7.1.6 Bolt Torque
Standard Wrench
a. Tightened 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 estimated value. Bolting shall
be tightened in a sequence assuring equal distribution of bolt loading.
b. Check all bolts for even distribution of required load. Steel to cast iron flanged joints shall be
made up with extreme care. In order to avoid breaking of cast iron equipment flanges, piping
flanges shall be brought up flush with gasket and equipment flanges into close parallel and
lateral alignment, before uniformly tightening bolts.

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.

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

ERECTION
Rev. D2
F500 0000 PI SP 5003 22 of 40

7.1.7 Hydraulic Bolt Tensioning
The application of bolt-tensioning equipment shall be in strict accordance with supplier's instruction
manual and safety procedures.
Fabricator Contractor/Subcontractor shall propose a supplier/subcontractor for hydraulic bolt tensioning
equipment and/or services, for approval by Owner Authorized representative. The personnel using the
equipment shall be adequately trained in the application of such equipment.
The tensioning of the bolts is carried out crosswise in a number of cycles, depending on the 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 TO USE
32 and less 50% of bolts
36 to 60
1
/
3
of bolts
64 and up of bolts

Bolt tensioning shall be executed in two (2) steps in accordance with the tensioning procedure as
supplied by the tensioning subcontractor (see section 12) at the hydraulic pressure as calculated by
tensioning subcontractor based on information supplied by Fabricator Contractor/Subcontractor.
After completion of bolt tensioning four (4) bolts at 90 degrees angle each shall be checked for the
break loose point. Flanges not meeting the required values shall be re-tensioned.
After bolt tensioning has been completed, the extended threaded part shall be greased and covered
with suitable caps to prevent damage and corrosion during operation of the plant.
Upon completion of bolt tensioning each flange shall be provided with a wire seal(s) as indicated below.

ERECTION
Rev. D2
F500 0000 PI SP 5003 23 of 40

Flange numbers as described in paragraph 7.1.2 shall be low stress dye stamped on the rim of one of
the flanges.

7.1.8 Leaking Flange Assemblies
Flange assemblies found to be leaking during hydro-testing shall be tightened as listed below:
a. Flanges assembled with standard wrenches shall be tightened with manual torque wrenches using
procedure as described in subsection 7.1.6.
b. Flanges assembled with manual torque wrenches shall be tightened with hydraulic torque
wrenches using procedure as described in subsection 7.1.6.
Flange assemblies tightened with hydraulic torque wrenches or hydraulic bolt tensioning equipment and
found to be leaking during hydro-testing shall be dis-assembled, inspected and re-assembled in
accordance with the requirements of this specification.
Flange assemblies still leaking after tightening as described in subsection 7.1.5 shall also be dis-
assembled, inspected and re-assembled in accordance with the requirements of this specification.
Re-assembly shall be done with tools as described in subsection 7.1.6a and 7.1.6b. In case of re-
assembly a new gasket is recommended.

ERECTION
Rev. D2
F500 0000 PI SP 5003 24 of 40

Subcontractor shall prepare an assembly record for all flanges which are dis-assembled and re-
assembled because of leakage problems.
The bolt tensioning subcontractor shall prepare design calculations for all applicable flange sizes, in
order to determine the required bolt loads and, consequently, the required pressures in the hydraulic
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

The bolt tensioning fabricator contractor/sub-contractor shall issue a hydraulic bolt tensioning procedure
for approval by the Owner or Authorized representative. 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.

Fabricator Contractor/Subcontractor shall prepare an assembly record for each flange joint which needs
to be tensioned. These records shall be issued as part of the turn-over packages.
Information to be shown on the assembly record shall be at least:
Identification:
Unit.
Line number.
Pipe class.
Flange set number.
Flange size/rating.
Company representative's name and signature.

ERECTION
Rev. D2
F500 0000 PI SP 5003 25 of 40

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.
Bolt tensioning:

Pressure A, (the higher tool pressure, taking into account the maximum bolt stress, that
is applied to obtain at least the average bolt stress).
Pressure B, (the lower tool pressure, required to obtain the average bolt stress).
Tool number.
"Break loose" pressure (check B pressure at four (4) bolts at 90% each) or bolt torque
value.

ERECTION
Rev. D2
F500 0000 PI SP 5003 26 of 40

TABLE I Selection of Tools

FLANGE RATING (ANSI CLASS)
150 300 600 900 1500 2500
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 2
2 1 1 1 1 1 2
F 3 1 1 1 1 2 2
L 4 1 1 1 2 2 3
A 6 1 1 1 2 3 4
N 8 1 1 2 3 4 4
G 10 1 1 2 3 4 4
E 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 - - - -
above 60 4 - - - - -

ERECTION
Rev. D2
F500 0000 PI SP 5003 27 of 40

LEGEND

TOOL BOLT SIZE
1. Standard wrench 1 inch
2. Torque wrench 1 inch
3. Hydraulic torque wrench 1 inch (note 1)
4. Bolt tensioning equipment > 1 inch

Note 1: Manual torque wrench with multiplier is an acceptable alternative.

ERECTION
Rev. D2
F500 0000 PI SP 5003 28 of 40

TABLE II Bolt Torque and Bolt Force Values

BOLT
DIA.
(INCH)
THREADS
INCH
A193 B7, A193 B16 AND A320 L7, 26 IN. AND
LARGER FOR 150 LB & 300 LB ASME B16.47
SERIES A (MSS)
A193 B7, A193 B16 AND A320-L7,
OTHER SIZES/RATINGS ASME
B16.5
TORQUE VALUE IN
Nm
BOLT FORCE IN N
(note 1)
TORQUE
VALUE IN Nm

BOLT FORCE IN N
(note 2)
Carbon
steel
Stainless
steel
Carbon
steel
(note 1)
Stainless
Steel
(note 3)

1/2 13 70 70
5/8 11 125 125
3/4 10 195 195
7/8 9 290 290
1 8 300 200 71400 47600 400 95200
1 1/8 8 420 280 88940 59295 560 118590
1 1/4 8 560 370 107670 71780 740 143560
1 3/8 8 740 490 127640 85090 980 170180
1 1/2 8 900 600 148650 99100 1200 198200
1 5/8 8 1120 745 170770 113850 1490 227700
1 3/4 8 1360 905 193950 129300 1810 258600
1 7/8 8 1620 1080 218030 145350 2160 290700
2 8 1920 1280 243000 162000 2560 324000
2 1/4 8 2610 1740 295440 196960 3480 393920
2 1/2 8 3420 2280 351750 234500 4560 469000

Notes: 1. 65% of empirical values to ASME Section VIII, div. 1, Appendix S
2. 85% of empirical values to ASME Section VIII, div. 1, Appendix S
3. 43% of empirical values to ASME Section VIII, div. 1, Appendix S

ERECTION
Rev. D2
F500 0000 PI SP 5003 29 of 40

7.2 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.
Screwed plugs in hydrostatic test vents and drains without valves shall be seal welded after completion
of testing.
Usage of sealing compound or teflon tape for all connections which are not seal welded.
Teflon tape is only allowed in utility services, at a design temperature of maximum 200C.

7.3 Pipe Supports
7.3.1 Temporary Supports
During erection, piping shall be adequate temporary supported until the final supports are installed.
Temporary supports shall rest on structural 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.
Synthetic ropes or strings are not acceptable as temporary supports.
Steel temporary supporting materials for stainless steel materials shall preferably be stainless steel.
Usage of galvanized temporary support material is not permitted.
The use of adjacent structures or equipment as temporary supporting or lifting attachment shall not be
permitted unless authority has been obtained from the Companys Representative in writing.
Temporary attachment shall be of the same material as the parent material and shall be performed by
qualified welders.
Pipework shall not primarily be supported via control or block valves.

ERECTION
Rev. D2
F500 0000 PI SP 5003 30 of 40

7.3.2 General
Fabricator Contractor/Subcontractor 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 main
support member must have sufficient area to carry the load. After erection, shims shall be welded 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 shall extend the full length and width of the shoe.
Care shall be taken to avoid undue strain being placed on a vessel or item of equipment by unsupported
lengths of piping.
Flange connections to strain sensitive equipment shall be the last connection made on completion of a
line or interconnecting system of lines complete with permanent supports.
Alternative supports shall only be installed after approval by Owner/Authorized representative.
Pipe supports shall not be located at the weld point of piping welded construction.
Pipe support subcontractor shall remove fireproofing locally from steel columns and beams for a proper
installation of pipe support according to the pipe support drawings. Fireproofing shall be repaired on the
main structure and will not be installed on the additional pipe support, unless otherwise shown.
Any fireproofing around directional anchors from pipes which are free to move in the transverse
direction shall be kept free minimum 50 mm from the pipe anchor parts.
Should there be any expansion bolts to be installed or provided in the concrete members (if any), care
shall be taken not to undercut retaining bars in the concrete. Pipe supports shall be adjusted to suit the
final location of the expansion bolts.
Pipe supports shall not be welded to the pipe line unless specified in the design and piping drawings.
Force shall not be used to align pipes to support locations during installations.
Permanent pipe supports shall, where possible, be installed before the erection of the associated
pipework.
The Fabricator Contractor/Subcontractor shall ensure that provision of adequate support for heavy
valves and fittings before the pipework is erected or subjected to pressure test.
The burning of holes in structural steel work or component parts is strictly forbidden.
Supporting steelwork shall be set at the correct elevation, being true and level in all directions.

ERECTION
Rev. D2
F500 0000 PI SP 5003 31 of 40

Metallic surfaces of supports which will be inaccessible after erection shall be prepared and coated
before assembly of the component in accordance with the Painting, Coating and Corrosion Protection
Specification document no. F500-0000-ME-SP-4001.
Hanger rods shall be adjusted to correctly hanging after tightening of all components parts, surplus
threading may be removed.
Pipe hanger shall not be used as temporary lifting attachments.
The use of adjacent structures or equipment as temporary supporting or lifting attachments shall not be
permitted unless with approval of the Fabricator Contractor/Subcontractor in writing.

7.3.3 Variable Spring Supports
Installation
The spring hanger list included in the pipe support drawings will 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 into this position by
means of the cold setting stops. Depending upon the manufacturer, the cold setting stops will take the
form of a plain rivet through section bar inserted above and below the piston plate inside the load scale
slot.

The cold setting stops must remain undisturbed until the hydrostatic test on the line has been
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 shall be removed.
Ultimate force must not be used.

b. With the cold setting stops removed, it may be noticed that the line has a tendency to bow up or
sag down. This is to be expected as when the line is cold and empty it is obvious that it can be
either over supported or under supported since it is designed to be correctly supported at the
hot operating condition. Do not readjust the spring load, but contact Owner/Consultant
representative when there is doubt.

ERECTION
Rev. D2
F500 0000 PI SP 5003 32 of 40

7.4 Cold Spring
Cold spring or fullness (cold strain) shall not be used accomplished by any case during constrction or
fabrication.
7.5 Expansion Joints

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

7.6 Final Corrections

7.6.1 Carbon Steel Piping

If corrections are required after fabrication, they may be carried out by a method approved by
Owner/Authorized representative. Following correction method is acceptable and recommended:-
a) Local heating
b) Application of force with local heating

The following restrictions apply to the heating; forcing of piping made from carbon steel, low alloy steel or
austenitic stainless steel:
i. For carbon steel which does not require a PWHT the maximum temperature during alignment
corrections shall be 600
0
C. Temperature-indicating manometer or contact thermometers shall
be used to measure the maximum temperature. If temperature-indicating manometer are used,
a margin of 50
0
C shall be taken to allow for measurement inaccuracy (i.e. the reading with the
manometer shall not exceed 550
0
C. Forcing may be applied if necessary). For carbon steel
which requires a PWHT the maximum temperature during alignment corrections shall be the
maximum

PWHT temperature. Temperature-indicating manometer or contact thermometers
shall be used to measure the maximum temperature. If temperature-indicating crayons are
used, a

margin of 500C shall be taken to allow for measurement inaccuracy (i.e. the reading with
the crayon shall not
e
xceed the maximum PWHT temperature minus 50
0
C). Only heating with
application of local force shall be used and no quenching shall be used. The area shall either be
heated in full compliance with the PWHT procedure or the area which is heated (and corrected)
shall be post weld heat treated.

ERECTION
Rev. D2
F500 0000 PI SP 5003 33 of 40

7.6.2 Austenitic Chromium Nickel 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 w
r
itten approval by Owner/Authorized
representative. The heating shall be applied uniformly and carefully controlled. The temperature shall
not exceed 400C.

7.7 Valve

7.7.1 Wherever possible, valves should be kept near grade level. All operating valves installed 1600 mm or
more above floor, platform or other point of easy access shall be hammer blow chain wheel operated.
Hammer blow chain wheels shall have U-bolt clamps, not J-bolt clamps.

7.7.2 Hand wheels and stems shall be kept out of operating aisles, where practical, otherwise elevated to
1600 mm from grade to bottom of hand wheel.

7.7.3 Valves shall not be installed with stem below a horizontal position (90 degrees reference angle from a
vertical plane).

7.7.4 Block valves, when required, shall be installed at nozzles of pressure vessels or in lines connected to
nozzles to permit operating valves from grade or a platform. Equipment shall be capable of being
isolated if:

Operations can continue without disruption.
Depressurising associated facilities will delay maintenance on the equipment.

7.7.5 Gate valves shall be provided with an equalizing globe valve bypass with a minimum size of NPS 1 for
the following:

Class ANSI 150 - NPS 12 and larger.
Class ANSI 300 and greater - NPS 8 and larger.

ERECTION
Rev. D2
F500 0000 PI SP 5003 34 of 40

7.7.6 All valves shall have sufficient clearance to facilitate removal of the bonnets, plugs and internals.

7.7.7 Ball valves shall not be used for throttling service.

7.7.8 Valve instruments and other equipments, which may required to be monitored, adjusted or serviced
during operation shall be accessible from platform or grade.

7.7.9 Valves shall be oriented in the line as detailed on the piping isometric drawings and shall be readily
operable, and removable as required or maintainable, where specified, in-situ. Where no indication
exists on isometric or piping GA, gate, butterfly, globe and ball valves in horizontal lines shall be
installed with their stems oriented as follows in order of preference:
a) Horizontal restriction:
Downward Stem
60
O
Stem Max Orientation
315
O
Stem Max Orientation.
b) Vertical restriction:
None

7.7.10 Actuated
a) Gate, Globe (including 3 way and Y type) shall only be mounted with the stem vertically
upwards.
b) Rotary valves (butterfly, throttling, ball etc.) shall be mounted with the stem horizontal or vertical.
The Contractor shall provide for the checking of gland packings in all valves during hydrostatic
testing.

8 INSPECTION AND TESTING
8.1 General
Test and measuring equipment used shall be calibrated every six (6) months.
All inspection and testing is the responsibility of Fabricator Contractor/Subcontractor. Owner/Authorized
representatives shall always have the right to witness inspection.
Any defects revealed by any of the examinations performed shall be reworked and retested. All
assemblies indicating irremediable defects, excessive repairs, improper fabrication or not being in

ERECTION
Rev. D2
F500 0000 PI SP 5003 35 of 40

accordance with the requirements of this specification shall be subject to rejection, even if the conditions
are discovered after acceptance at Fabricator Contractor/Subcontractor's shop or revealed during field
testing. All costs related to repairs and/or re-fabrication shall be for Fabricator
Contractor/Subcontractor's account.

8.2 Positive Material Identification Test
Positive material identification (PMI) on alloy materials shall be executed with a Texas Nuclear or equal,
as follows:
a. Incoming materials in Fabricator Contractor/Subcontractor warehouse will be examined at
random by Owner authorized representative to check attached certificates. At random is
defined as a random check of materials as per material type (independent of size, rating, wall
thickness and type of piping item) up to a maximum of 1% of the total supplied quantity of
material.
b. Installed material shall be checked for 100% of installed quantity by subcontractor to eliminate
possibility of accidental material substitution.
c. All installed materials with poor readability of heat numbers or materials where doubt exists
concerning the accuracy of the heat numbers if deemed required and upon requested by the
Owner or Authorized representative shall be checked by Fabricator Contractor/Subcontractor.

PMI is only required for the following materials:

MATERIAL SERVICE

Stainless Steel All Services
Carbon Steel All Services

Fabricator Contractor/Subcontractor will be responsible for execution and documentation of PMI as
described under paragraph 8.2b. and paragraph 8.2c.

ERECTION
Rev. D2
F500 0000 PI SP 5003 36 of 40

8.3 Weld Examination

For weld examination requirements, see specification " Specification for Welding of Piping, document
no. F500-0000-PI-SP-5009.

8.4 Pressure Testing and Flushing

For pressure testing and flushing of completed piping systems, see Specification for Pressure Testing,
Flushing and Reinstatement of Piping Systems", document no. F500-0000-PI-SP-5005.
Except when specifically noted on the drawings, spools shall not require shop hydrostatic testing. This
shall not, however, relieve subcontractor of the responsibility for any defects in materials and/or
fabrication that may be revealed during field hydrostatic testing.

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

9.2 Piping
9.2.1 Internal
During fabrication and installation, Fabricator Contractor/Subcontractor shall prevent foreign materials
such as oil, grease, sand, dirt, scale, loose particles from cutting and grinding, etc., from entering the
pipe or pipe component.
Any foreign materials which may be presence or have entered the pipe or pipe component, they shall
immediately be removed before assembly of the parts by a suitable cleaning method, such as blowing
through with air or degreasing with suitable cleaning agent or solvent.
Cleaning agents and solvents used for degreasing shall not contribute or have any properties that may
cause corrosion to the piping.

ERECTION
Rev. D2
F500 0000 PI SP 5003 37 of 40

9.2.2 External
Piping to be painted shall be cleaned in accordance with the requirements of specification "Painting,
Coating and Corrosion Protection Specification" document no. F500-0000-ME-SP-4001.
Piping system whereby painting requirements is not required, piping shall be properly cleaned by a
suitable cleaning method to removed excessive rust, scale or grease only.
Cleaning agents and solvents used for degreasing shall not contribute or have any properties that may
cause corrosion to the piping.
9.3 Completed Piping Systems
Unless otherwise indicated in the pipe class or on the piping drawings or P&ID's, recommended
flushing methodology as described in Specification for Pressure Testing, Flushing and Reinstatement
of Piping Systems" document no. F500-0000-PI-SP-5005 will be adopted and implemented.
9.4 Degreasing
For certain services, lines need to be degreased to prevent operation problem. This requirement will be
address in the pipe class or on the piping drawings or P&ID's and will form part of the additional
specifications to be supplied by Fabricator Contractor/Subcontractor.
Cleaning agents and solvents used for decreasing shall not contribute or have any properties that may
cause corrosion of the piping.
10 PAINTING
For painting requirements, reference is made to specification "Painting, Coating and Corrosion
Protection Specification", document no. F500-0000-ME-SP-4001.
11 DOCUMENTATION
Both shop and field fabrication include administration of material certificates, welding operations,
destructive and non-destructive examinations and all testing operations as required by the applicable
specifications and codes.
Fabricator Contractor/Subcontractor shall be responsible for planning and documenting all activities and
controls which include, but are not necessarily limited to, the following operations:
Material receiving (including administration/filing of certificates).
Material traceability

ERECTION
Rev. D2
F500 0000 PI SP 5003 38 of 40

Cutting.
Bending (at subcontractors for induction bending).
Welding.
Welders identification
Qualification test and records of repairs
Heat treatment.
Destructive and nondestructive testing.
Hydraulic bolt tensioning and/or torquing.
Hydrotesting.
Flushing.
Cleaning.
Fabricator Contractor/Subcontractor shall provide Owner/Authorized representative with two (2) copies
of material test certificates for all materials purchased by Fabricator Contractor/Subcontractor.
Documents relating to assemblies to be shipped shall be submitted to Owner/Authorized representative
for review/approval.
Documents shall be made available to Owner/Authorized representative at all times.
For each piping system (defined as piping items welded together of same material and same design
pressure/temperature, e.g. line from a pump to a vessel) Fabricator Contractor/ Subcontractor shall
provide a fabrication book containing documents showing all above-listed operations.
12 PREPARATION FOR SHIPMENT
Before shop-fabricated assemblies are prepared for shipping, Fabricator Contractor/ Subcontractor's
inspector shall check following:
Overall dimensions as per piping drawing.
Required documentation as per subsections 11.
Material identification as per subsection 5.2.
After assembly has been released by Fabricator Contractor/Sub-contractor's representative inspector,
Fabricator Contractor/Subcontractor shall prepare material for shipping as follows:

ERECTION
Rev. D2
F500 0000 PI SP 5003 39 of 40

All assemblies shall be dry and free from water, dirt and loose or foreign materials.
Flange faces, machined surfaces and threads in carbon-steel piping shall be coated with a
corrosion preventive compound (Rust Ban 324, or equal) before applying the 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 of sturdy
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. Each container shall be
tagged with a description of the contents and destination.
Carbon, low-alloy and galvanized carbon steel, stainless steel and duplex stainless steel shall be
shipped separately from each other.
For stainless-steel and duplex stainless steel spools, subcontractor shall not use steel hoisting devices
as described in subsection 5.1 and shall provide suitable transport packing to prevent spools from
contacting surfaces containing zinc or other harmful materials during the transportation.

12.1 Spool Piece Marking
The appropriate pipe identification, consisting of the line number and spool number, shall be hard dye
stamped into the spool. Marking shall be circled with yellow paint.
Fabricator Contractor/Subcontractor shall be responsible for ensuring that throughout fabrication all pipe
spools are marked and can be identified by the numbers assigned to them by the isometric drawings.
The use of die stamping, scratching, etching or bead welding for pipe identification marking shall not be
permitted.
Pipe spool identification markings shall be clearly written on the pipe using an alkyd, brilliant white
colour paint, in two places at diametrically opposite sides and one metal tag secured to the spool piece
by multi-strand stainless steel wire or strap.
Austenitic stainless steels and Copper Nickel materials shall not be marked with crayons or paint
containing sulphur, zinc, lead, aluminium, or compound sulphur.

ERECTION
Rev. D2
F500 0000 PI SP 5003 40 of 40

All post weld heat treated (stress relieved) fabrications shall be clearly marked on both sides WELDING
PROHIBITED
In addition to the pipe spool identification, the welders identification reference shall be painted adjacent
to each weld using an approved paint / crayon.
The position chosen shall be transferred to the radiographic records for each respective weld.
This transfer shall be carried out to the satisfaction of the Owner and or Authorized Inspectors.

13 ADDITIONAL REQUIREMENTS
For additional or deviating requirements concerning fabrication and erection of steel piping, see
specifications listed below:
F500-0000-ME-SP-4005: Insulation Specification

F500-0000-PI-SP-5003-D2-Specification For Piping Fabrication and Erection PDF

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