J3Program 100801SSPP006

PipingFFabrication Datee:07/07/201
12,Rev.0

RECOR
RDOFREVIISIONS

D
Date R
RevisionDeta
ails RevisionNumber

07.0
07.2012 IssuedforImpleme
entation 0
0


J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

Con
ntents
1. Purpose..................................................................................................................................1
1
2. Scope.....................................................................................................................................1
1
3. Costcompetitiveenggineeringan
nddesign...........................................................................1
1
4. ConflictsaandDeviatiions.......................................................................................................1
1
5. Definition
ns:............................................................................................................................1
1
6. Abbreviattions:.......................................................................................................................2
2
7. Codesand
dStandardss:...........................................................................................................2
2
8. BasicMetthodology:...................
. ...........................................................................................4
4
9. InspectionandTestin
ng:......................................................................................................10
0
10. Preparationforshipm
ment:..................................................................................................11
1
11. DataRequireement:................................................................................................12
VendorD 2
12. Attachmeents:.......................................................................................................................14
4
i) Appen
ndix A Supplementary Requirem ments for Steam
S and Feed Wate
er Piping
SubjectttoIndianBo oilerRegulaationRequirrements
ii)FORM
MIIIACerttificateofM
Manufacture
eandTest
iii)FORM
MIIIBCerttificateofM
Manufacture
eandTest
iv) FORM
M IIIC Ceertificate of
o Manufacture and Test
T of Boiller Mountings and
Fittings.
v)Appen
ndixBPipingalignmentandFabrricationtoleerances.


J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

1. Purrpose
Thisspecificationississuedto establisha uniformprrocedurefoorthefabriccationof
abovegrroundandu undergroun ndprocessaandutilityppiping,fabriicatedatbo
othshop
andsitelocationsatthemanufacturingsitesofReliance.
2. Sco
ope
2.1. This speciffication app
plies to all the piping contained within mo
odules, packkages or
subassemmblies.This specificatio ondoesnottincludeth heInstrumeentation,pipework
andtubinggdownstreaamofthelaastblockvalveonapip peheader.
2.2. Piping sub
bject to reequirementss of the In ons is covered by
ndian Boileer Regulatio
AppendixAAofthisspeecification.
3. Cosstcompettitiveengiineeringaanddesign
n
Theenggineeringteamshallm maintainthe ecostfocussthroughouutallphase esofthe
project. Thisshould
dbedonew withoutcompromisingganyspecificationand ddesign
requirem
ments. From m the pipin
ng fabricatio
on perspective, effortss shall be made
m to
ensure optimizatio on of preffabrication at shop by
b maximizzing the usageu of
automattedfacilitiessavailableaatthePipeFabrication
nshop.
4. Con
nflictsand
dDeviatio
ons
Process andutility pipingshallbefabricaatedinaccoordancewitthcodes,drawings,
and othher requirements speccified here ein. Where conflict exxists, the order
o of
priorityo
ofdocumen ntsshallfollowintheffollowingseequence:
(i)LocalRegulatoryandStatu
utoryrequirement
(ii)ThisSSpecification
(iii)CodeesandStandard
5. Deffinitions:
5.1. PipingMatterialClassees
The Pipiing Materiaal Classes specify
s the material reequirementts for pipe,, fittings
flanges, etc., and design deetails for branch
b connnections, vvents, draiins, and
pressuree temperrature conn nections byy Service Class.
C Wheere special or non
standardd material for a partticular class is requirred, it will be noted on the
drawings.
5.2. SupplementaryTableofWallThiicknessand
dBranchReinforcemen
nt
The Sup
pplementaryy Table of Wall Thickkness will specify
s by individual pipeline
number the requirements of wall thickness subjectt to calculattion as spe
ecified in
thePipin
ngMaterialClasses.
5.3. PipingStocckCodeInd
dex

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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

ThePipingStockCo
odeIndexiddentifiesanddescribessallpipingm
materialitemcodes
indocum
mentsrelateedtopipinggmaterial.
6. Abb
breviation
ns:
AWWA AmericanWaterW
WorksAssocciation
NDT NonDeestructiveTesting
NDE NonDeestructiveExxamination
MT MagnetticParticleTTest
DPT DyePen
netrationTeest
GRE GlassReinforced
PMI PositiveeMaterialId
dentificatio
on
PWHT PostWeldHeatTreatment
WPS WeldingProcedureeSpecificattion
PQR Procedu
ureQualificcationRecord
SER SiteEnggineeringReequest
IBR BoilerRegulation
IndianB

7. Cod
desandSttandards:
7.1. Codes
7.1.1. LocaalCodesorRegulation
ns
Where local regulaations, ord
dinances, sttatutes or codes takee precedennce over
ASMEco
odes,suchrregulations,,ordinancess,statuteso orcodesshaallgovern.
7.1.2. RefiineryCodePiping
Except where
w speccified otherwise, the Process Piping Code ASME B31
1.32010
(latestedition)goveernsfabricaationofallp
piping.
7.1.3. BoillerCodePip
ping
The Powwer piping code
c ASMEE B31.1 20 010 (latest edition)
e and the Indiaan Boiler
Regulations1950go overnsfabrricationofssteamandb boilerfeedw waterpipin ngwithin
thebatterylimitsooftheboilerasdefined dinthecod de.Forsteaamandcon ndensate
linesouttsidethebaatterylimitoftheboile ertheapplicablecodessareIBRan ndASME
B31.320010.(ReferAppendixA A.)
7.1.4. Oth
herRequirem
ments
GRE piping systems shall be in accordan
nce with AWWA
A M45
5 Manual of
o Water
PracticesorASMEB31.32010asaapplicable.
SupplyP

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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

Other co
odes, such as refrigeraation,plum mbing or nattional regulations mayy govern
some paarts of the piping. Drrawings shaall indicate the applicable codes in such
cases.
7.2. Associated
dReferencees

100801SSPPXX
XX MaterialClaasses
PipingM

100801SSPP00
02 PipingC
ComponenttsStockCaatalogueIndex

Piping Componen nts Tech

hnical Supp ply Conditiions for
100801SSPP00
04
Pipes,FFittings,Flan
nges,Valvess,Bolts,Gaaskets)

100801SSPP00
05 PipingC
ComponenttsColourC
Coding

100801SSPP00
07 PipingEErectionand
dTesting

100801SSPPXX
XX ChemiccalCleaningofPipewo
orks

100801SSPP01
14 Protecttivecoating&Painting

100801SSPP01
16 Inductio
onBendingofPipes

100801SSPP02
21 ExternaalLiquidEpo
oxyCoatinggforUnderggroundPiping

100801SSPPXX
XX Weldingg,NDEandPWHTforFFabricatedP
Piping

100801ENGGPR
RAPP028 ProducttionofSpoo
olDrawingssandErectio
onIsometriics

100801ENGGDBDST003 PipeSupportStand
dards

100801ENGGDBDST004 Pipesupportmanu
ualofstandardsupportdrawing

IndianB
BoilerRegulations
100801ENGGDBDST007
StandarrdFabricationDetails&
&Notes

100801ENGGDBDST009 IndianB
BoilerRegulationRefeerencedocu
ument

100801ENGGDBDST010 Guidelin
nesforsupp
portingsmaallborecon
nnections

100801SSCI004 Instrum
mentsforMeasurement&Controll

MATERIALCONTRO OLDURINGFABRICATION&ERECTION
100802QM00JEEPPP008
OFLTCSS/NACEPIPINGMATER
RIALS

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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

8. BassicMetho
odology:
8.1.. ExtentofSShopFabriccation
8.1.1. Carbonsteelp piping2"no
ominalbore eandlargerisgenerallyshopfab bricated.
ExceptionsareCaarbonsteelpipinglesssthan2"bo oreandlonggstraightru
unssuch
piperacksw
asinp whichshallb
befieldfabricated.
8.1.2. Allo nless steel pipe, all sizes (including less thaan 2), is generally
oy and stain g
shopffabricatedeexceptforloongstraightruns.Thisistomaxim misethespe ecialised
weldin
ngintheshhop.
8.1.3. Where long straight
s runs of field
d piping reequire exp
pansion loo
ops, the
expan
nsionloopsshallbeshoopfabricateed.
8.2.. Materials
8.2.1. Matterials Supp ply: All matterials nece he fabricatiion and installation
essary for th
of thee piping sysstems show wn on the isometrics
i & GA draw
& wings shall be free
issue. Unless sppecified oth herwise in the work order, the FABRICATO OR shall
supplyy all tempo orary materials, pipes, supports etc. requirred for fabrication,
testing,inspectio onandtranssportation.
8.2.2. Unlessotherwiseidentifieedonpipinggdrawings,,allmateriaalsshallcon nformto
1008001SSPPXX XXfortheiindividualliineservice.Individual lineclassmmaterials
and piping
p speciial items will
w be identified on piping draw wings and P&IDs by
conveentional line work and graphic symbols. Outofclass
O s materials will be
identifiedbycodenumbers ordescripttions.FABRICATORshaallinspectaallpiping
materrials on recceipt to enssure that th
he correct grade, quality, conditiion, end
preparations, ideentification and dime ensions havve been suupplied and d are in
accorddancewiththeapplicaableprojectstandardsaandspecificcations.
8.2.3. MatterialIdentiification
Allmateerialsshallb
benewand
didentifiableandshallbesupplieedwithcerttification
tomeetprojectreq quirements..
PMIshallbeperformedforAlloysteelmaaterialsbefo
oreFitup.
Markinggrequiremeentsandtecchniquessh with100801SSPP
hallbeinacccordancew
004.
As an aid
a to preliminary reccognition, pipe
p materiials shall be Colour coded
c in
accordan ncewith10
00801SSPP005Colo ourCodingofPipingM Materials.
Materialcontroldu
uringfabricaation&ere
ectionofLTTCS/NACEp
pipemateriialsshall
befollow
wedasgiveninproced
dure100802QM00JEPPP008.
8.2.4. Con
ntrolofMatterials
FABRICAATOR shall submit a procedure e to the BUYER/CLIE
B NT describbing the
controlstobeappliiedtothereeceipt,storageandissu
ueofpipinggmaterials.

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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

Theproccedureshalldescribeaasaminimu
um,thefollo
owing:
i. Methodofccontrolsonmaterialre
M eceipt.
ii. H
Handling,seegregationaandstorage eprocedurees.
iii. D roposedfileeorstockcaardcontrolsystem.
Detailsofpr
iv. Isssueofmatterialsproceedure.
v. M
Methodoft transferofidentificatio
onmarkingssonpipingm
materials.
vi. M
Methodofd determininggandreporrtingmaterialshortages
8.2.5. UnidentifiedPiipingMaterrials
Piping materials
m thhat cannot be identiffied by ideentification markings shall be
placed in a storage area seeparate fro om acceptaable materrial with sufficient
safeguarrds to precclude themm being use ed. PMT may
m be carrried out ono these
materiallstoidentifyyandtagallloysteel.
8.2.6. MatterialandW
WeldIdentiffication
Weld identification
n symbols shall
s be reccorded onto
o fabricatio
on drawingss with a
crossrefferencetoaanyNonDestructiveExxamination(NDE)repo ortnumberss.
Ifatanyytimedurin
nginstallatio
onorfabriccation,anyp
pieceofmaaterialisnotreadily
identifiable,itshallberejected
d,includingothercomponentsweeldedtheretto.
8.2.7. Dam
magedMateerials
Materials which haave been daamaged, go
ouged or fo
ound to havve defects shall
s not
beused exceptthaatminorsurfacemarkssmaybedressed,pro ovidedthat themill
tolerancceminimum mwallthickknessisnotencroacheedupon.Dressingwilllrequire
approvalfromtherresponsibleEngineero ofReliance.
TheRespponsibleEn
ngineerfrom
mReliancesshallbeinfo
ormedimm
mediatelyifrreceived
materiallsaredamagedandunnfitforfabrication.
Particulaarcaremusstbetakenwithflangefaces.Raadialgroovesorscratcchesare
not allo
owed. Refacing will require approval fro
om the responsible Reliance
Engineer.Edgethiccknessofflaangesshallbecheckeddafterrefacing.
Damaged material shall be placed
p a separate storage arrea from accepted
in a a
materiall,withsufficcientsafegu
uardstopreeventitsusee.
8.2.8. Diffferent pipin
ng materialss shall be stored in seegregated areas. FABR
RICATOR
shall ensure
e thatt separate batches of materials canc be relaated to the original
manufacturersaadvicenoteandcertificcation.
Carbon steel, low temperature carbon steel, alloyys and stain
nless steel shall be
stored and
a transpo orted such that any possibility
p o cross mixxing of matterials is
of
preventeed.Materiaalsdestined
dforIndianBoilerRegu ulationcodedsystemsshallbe
separateedfromothhermateriallsofasimilaarnature.

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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

Allmateerials,whetherlooseoorprefabriccated,shall bestored abovegrou

undona
flat surface, on platforms
p or pallets, in a manner that will preveent any
deteriorationfromdebris,greaase,paintsprayoranyyotherforeignmatter.
8.3.. GeneralFaabricationR
Requiremen
nts
nts of the governing code, the ffollowing sh
In addition to the requiremen hall also
applyunnlessotherw wisenotedo
onthepipin ngdrawingss.
8.3.1. FabricationAreea
Fabrication of diffeerent materrials e.g. Caarbon Steel,, L.T. Carbo
on Steel, allloy steel
and stainless steel etc. shall be carried out in segregated areeas to prevvent any
possibilittyofcrossm
mixingduringcuttingaandweldingg.
8.3.2. Dim
mensions
Dimensional tolerancesshall be
b inaccorrdancewith
h Appendix B Fabricattion and
AlignmentTolerancces(BasedonPFIES3
3).
8.3.3. BolttHoles
Flange bolt
b holes are
a to strad
ddle princip
pal centerlin
nes of equipment and
d piping,
unlessotherwisesh
hownontheedrawings.
8.3.4. ThreeadedConn
nections
Unlesssspecifiedto thecontraryontheSSiteMechan nicalcontraactorsdraw
wings,all
threads shallbeto ASMEB1.220.1(NPT). Allthreadeedconnectionsmustb begauge
checkedorchased afterweldingorheat treating.O Openingsfoorthermow wellsand
nserts are to be drilled througgh the con
other in nnections aand be fre
ee from
obstructtion.
Allintermediatethreadedpipeejointsshallbemadeusingthreaadedcouplings.The
use of unions
u ot permitted. Threaded flanges shall be useed to facilitaate easy
is no
removalofvalvesaandinlineinstrumentssformainteenancepurp poses.Whe en2and
3NPSp pipeswitheendsthread dedBSPTarerequirredtomatcchfittingsw withNPT
threads,thepipesh hallbecutaandthreade
edNPTtommatch.
8.3.5. SocketWeldingg
Care shaall be taken earance of 1.5mm rem
n to ensuree that a cle mains betw
ween the
maleandfemaleendsatthe bottomoftthesocket. Pipeforsocketweldingshall
besquarrecut.Tom maintain1.5 5mmclearaance,springgtypearran ngement,te
ermedas
GapOLet"maybeeprovided.
8.3.6. Pipingcompon nentsshallbbeinaccorddancewith100801SSSPP004TTechnical
SupplyyCondition
nsforPipinggMaterials.
8.3.7. OrifficeRuns
Weldinggneckorificceflangesaarespecifieddupto18NPSandsshallhavethhesame
boreas thepipe.O
Orificerunssshallnotccontainwelddsexceptaattheflange
es.Pipe

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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

endsand dbevelsat orificeflanngesmustb becutsuch thatitispeerpendiculaartothe

axis of the
t pipe. Welds
W at th
he orifice flanges shall be groundd smooth and flush
inside. Pipe tap co
onnections on orifice flanges
f or directly
d on the pipe where
w so
specified d,shallbeddrilledthroughthepip pewallanddshallbefinishedsmo oothand
flushinsside.Pipen nipplestoorificeflange esarethreaadedandreequiresealw welding.
Allorificcetappipe connection nsandvalve estobeadequatelysu upported/bracedas
perspecc100801SSSST010to ominimise vibrationaandthepottentialofse ealweld
failureleeadingtoleeakage.Orientationofftapandm minimumstraightrunrrequired
forOrificceplateshaallbeaccord dingto100801SSCI0 004.
8.3.8. BranchConnecctions
Branch connections
c s shall be in accordan
nce to 1008
801SSPP0 038 Branch h Tables.
12" and larger pipee stubs andd branches shall exten
nd to the firrst flange or
o to the
fieldweldpointas indicatedo onthepipinngdrawingssorasrequiredforreaasonable
spoolpieecesize.
All reinfforcement Pad
P (RF pad d) shall be pneumatic tested at 1.5 Kg/sq.ccm using
suitable tapped hole.
h Where reinforccement paads are reequired at branch
connections which are to be field welde ust be fabricated by the Shop
ed, they mu
Fabricatorandtackkweldedtothe'stubon'spoolforrshipment.
A vent/ttell tale holle is to be drilled
d in each reinforcementpad
d or reinforcement
padsecttion.
8.3.9. LoosePipingCo
omponentss
Any piping components speccified on piiping drawings to be shipped lo oose for
welding on site, are to be separately
s packed
p for shipment, with the package
clearly tagged
t (seee Para. 9.2
2) and labe
eled "Components foor Site Welding to
PrefabriccatedPipewwork".
8.3.10. WeldedPipeSupportAttaachments
pportsshall beinaccordancewith
Pipesup hpipingdraawingsand withrequirements
of10080
01ENGGD DBDST003PipeSupp portStandards.
8.4.. Welding
8.4.1. Gen
neral
In addittion to thee governin
ng code, welding
w shaall conform
m to the standard
s
specificaation,1008001SSPPXXXXWeldinng,PWHTan ndNDEofFFabricatedPPiping.
FField Welds Field Wellds (F.W.) may
m be used at any piipe spool in nterface,
w
wherepipin ngdimensio onstoweld dlocationsccanbeaccu uratelydetermined
a where no cutting or trimmin
and ng of pipewwork is necessary. Fielld welds
s
shall be clo
osed withoout any tension in th he lines, eespecially at
a strain
s
sensitiveeq uipment.
F
FieldFitWeeldsWhereeverFieldFFitWelds(FF.F.W.)areiindicatedo onpiping
d
drawings, FABRICATOR R shall detaail and furn
nish the pip
pe spool su
uch that

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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

FFieldConstrructioncan trimexcessspipeand makefinallclosingwe eld.The

a
amount of excess
e pipeefurnished shall be 15
50mm, and the pipee endshall
b
besquarecu ut.
C
Closerwelds s/GoldenjoointsInlie
euofpressuuretest,theeweldjointshallbe
t
tested with
h Radiograp phy or Ultrasonic tesst and MTT or PT with prior
a
approvalof theRespon nsibleEngineerfromReeliance.
8.4.2. SurffaceDefects
Surface defects caaused by mishandling
m during fab
brication sh
hall be con
nsidered
injurioussifthedefeectextendsbelowthemilltoleran
nceminimumwallthicknessor
ismoretthan1.5mm mindepth.
Fittings, flangesor pipewithin
njuriousdefectsaredeeemedunacceptablefforspool
fabricationandshallnotbeused.
8.5.. Bends
8.5.1. Unless otherw wise specified on the e approval drawings and speciffications,
bendss in pipes shall
s be afffected using proprietaary manufaactured long radius
elbow
ws as listed. Substitutiion of induuction or cold bends is only accceptable
whenthegeometricalrequirementsofthepipingspecificatio onaremet.
8.5.2. Indu
uctionorco
oldbendinggshallbeinaccordanceewith1008
801SSPP0
016.
8.5.3. Ifreeferencedin
n100801EENGGDBDPP001forlines8NSSandabove
e,mitred
elbowwsasperSTDDrawingN NoEPCMDP14JG000045maybeused.
8.6.. WeldSeam
ms
8.6.1. On weldedpip pe,longitudinalweldseamsshall beoutofp phaseatinllinebutt
welds, any weelded attaachments i.e. brancch connecctions, instrument
conneections,anddpipesuppo mentsetc.shallnotbisectanyseaamweld.
ortattachm
Thelo
ongitudinal /Circumferenceseam msoftheweldedpipe shouldnottreston
thesleeeperorsupports,toeenabletocaarryoutNDTT/testingin
nfuture.
8.6.2. Thee minimum rotation for welded seams shaall be 10 times the pipe wall
thickn
nessor90o
outofphase,whicheve
erisless.
The min utt welds, shall be 6 times the
nimum distaancebetweeencircumfferential bu
pipewalllthicknessor50mm,whicheverisgreater.
8.7.. Cleaning
8.7.1. All shop
s es/pipe spools shall beeinternally cleaned
fabriccated pipingg assemblie
by bloowing air only
o and pip plastic end caps for
pe ends shall be coveered with p
sizesuupto12NB.Forsizessgreaterthaan12NB,thepipeen ndswillbele
eftopen
and the
t shop faabricated piping
p asse
emblies/ pipe spools shall be in nternally
cleaneedbyblowingairtoreemovedustandforeiggnmatterp priortoere
ectionat
site.

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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

Ineitherrcase,wheereverflanggedpipespo ools/pipinggassemblieesareinvolved,the
flanged endsshall becovereddwithplasticflangeco oversor5mmmthickplyyboards
cuttoth
hesizeoftheflangedeendssothatttheflangefacingsarefullyprotected.
8.7.2. Ifw
waterisuseddincleaningausteniticcstainlessssteelpipingassembliess,itshall
not co
ontain morre than 50 ppm chlorrides. The maximum allowable limit for
waterrqualityforCS/ASpipinngforhydrootestshallbe250ppm m.
8.7.3. Anyy special reequirementts for cleaning of shop fabricatted piping will be
speciffiedintheLLineDesignaationTabless.
8.7.4. Wherespecifieedonthep pipingdrawings,chemiicalcleaningofpipewo
orkshall
beinaaccordanceewithSS,10
00801SSPPPXXX.
8.7.5. Cuttting should d be accuraate, smooth h and true to template, Slag and d cutting
dross shall be reemoved esp pecially if Plasma
P cuttting was ussed, then the slags
shallb
beremoved dimmediateelyaftercutttingsothatslagremo ovalwillbeeasierin
thehootcondition n.Similarly,holesmadeforSBtap ppingontheeheaderbyyplasma
cuttingalsocheckshallbem madeforrem movalofslaagsimmediaately.
8.8.. AlignmenttandFabriccationTolerrances
8.8.1. AliggnmentofB
Bores
a) P
Pipes with a thicknesss of 6 mm m and greeater shall not have internal
m
misalignmen nt of pipe wall exceeeding 1.5 mm
m with ro oot gap or 0.8 mm
w
withoutroo tgap.
b) Pipes
P with a thickness less than
t 6 mm
m shall n
not have internal
m
misalignmen ntofpipew wallexceeding25perceentofthep pipewallthickness.
c) When
W misalignment iss greater thhan the aboove, the co
omponents shall be
a
aligned by drifting, ro
olling or machining
m n accordance with the Code,
in
e
ensuringthaattheminimumwalltthicknessissmaintaineedaftercon nsidering
t
the manuffacturing tolerances defined in n the app propriate material
s
specification
ns.
8.8.2. FAB
BRICATORsh
hallberesp
ponsibleforthedimenssionalaccurracyoffabricated
pipeespools.Lineupclam mpsshallbeusedwhen nnecessaryytoensure thatfit
up is within deesign toleraances. In ad
ddition to the
t alignmeent and fab
brication
toleerances speecified in the
t referen nced codess and stan
ndards herein, the
follo
owingshallapply:

ne sizes 10
Overall lineear dimenssions for lin +3mm
andsmalleer:
ne sizes 12
Overall lineear dimenssions for lin +5mm
andlarger:

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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

Lineardimensional tolerancesshallbeappplicableto
odimensionnsmeasureddfroma
common ndatumfortherelativvelocationssofbranch
hes,flanged
dorbuttwe
eldends
andshalllnotbecum
mulative.
Before bolting up
p, flange faces
f shall be +1.5m
mm
aligned to the design
d planne, measured
acrossaanydiameteerwithin:
Flangeb
boltholessshallbealignedwithin: +2mm
m

Specifieedanglesfo
orbendsorbranchesshall +0.25
bewith
hin:
Foralign
nmentandffabricationtolerancesalsoreferto
oAppendixxB.
Flangefaacesshallnotbeconcaave.
8.8.3 Fitup
a) P beproperlysupportedandaligned
Pipesshallb dbyjigsorclampsasrrequired
o preclude extraneou
in order to us loads and minimizze stressess during
t
tacking.
b) Smalltackw
S welds,i.e.between12mmand18 8mminlen ngth,penetrratingto
t
thebottom ofthegrooovemaybeusedinfittiingup.

9. InspectionandTestingg:
9.1. Examinatio
on
9.1.1. All piping commponents and workm manship fo or each installation shall
s be
examiined in acccordance with
w 100801SSPP025, Form 16 67A. FABRRICATOR
shall be respon nsible for nondestru uctive exam mination (rradiographyy, liquid
penettrate,ultrassonic,magn neticparticle,etc.)inaaccordance withtheCodeand
totheeextentspeecifiedinForm167A.
9.1.2. Where examinnation reveaals a failure
e to meet design or ccode requirrements,
FABRICATORshaallmakesucchrepairsaandcarryoutfutureeexamination nsasare
necessarytomeeetthedesiggnorcoderequirementts.
9.2. Inspection
n
9.2.1. All inspection shall be perfo ormed byy FABRICA ATOR's in nspector.
BUYER R/CLIENTs inspectorretainstherrighttovisitFABRICATTOR'splace ofwork
and carry
c out raandom insp
pection. BU
UYER/CLIENTs inspecttor may rejject any
materrial, proceddure or work, which, in his opin
nion alone,, fails to meet
m the
requirrements of applicable codes, SSs, procedurees, drawinggs, purchase e orders
orcon
ntract.

Pag
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J3Program 100801SSPP006
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9.2.2. Unless specifieed otherwise on draw wings, shopp hydrostatic testing of pipe
spoolss is not req
quired. If required,
r all pressure testing
t shall be carried out in
accord dance with SPECIFICATTION, 1008 801SSPP0 007. Howevver Pneumatic test
for Reeinforcemeent (RF) paad shall be e carried out
o at shop p at 1.5 kgg/sq.cm.
However hydrotesting of spools is necessary
n in case of MOC/ shu ut down
relateedjobsinorrdertoavoidHydroTestinoperattingplant.
9.2.3. Afteer installation, all fabrricated asse
emblies will be hydro
ostatically tested in
accorddancewith theapplicaableCode. FABRICATO ORshallguaaranteehis workto
becappableofwitthstandingtthehydrosttatictest,an ndheshallrepairorre eplaceat
hisexpenseanyitemwhichfailstopassssuchtest.
9.3. Procedurees
9.3.1. App
proval of th
he following Shop FABRICATOR'ss procedurees and activities is
requirredfromReeliancepriorrtotheuse
eofsuchpro ortheproject.
oceduresfo
a) Procedu
uresanddeetailsofwelldingprocessses.
b) Weldreepairprocedures.
c) Heattreeatingoperrations.
d) Nondeestructiveexxaminationproceduress.
e) Qualitycontrolpro
ocedures.
f) Paintprrocedures.
9.3.2. All requests for
f relaxation of this SPECIFICA ATION, or, of the doccuments
refereencedinthiisdocumen
nt,shallbe statedinw
writingforth
heconsiderrationof
BUYER R.
9.3.3. Appproval of FABRICATO
F R's proced dures, draw wings, etc. shall not relieve
FABRICATOR of responsibiliity for corrrectness, an
nd compliannce with all codes,
legalrrequiremen
ntsandthisSPECIFICATTION.
10.Pre
eparationforshipm
ment:
10.1
1. Immmediately after cleanin
ng and insp
pection, fab
bricated pip
ping spools shall be
suitablyprrotectedforrshipmentasfollows:
Flangefaaces,machinedsurfaceesandthre
eadsshallbeecleanedo
ofallmillscaale,rust,
etc.,and
dcoatedwitthacorrosionpreventativesuchaasRustBan324.
Small brranches an
nd small heeader attacchments sh
hall be adeequately brraced or
otherwisseprotectedtopreven ntdamaged duringhanddling,shippiingandstorrage.
Threadeedcouplingssandotherinternallytthreadedco onnections shallbeclo
osedand
protecteedbywrapp
pingwithplastictape,oorplasticcaaps.
Threadeed nipples and
a other externally
e thhreaded connections sshall be clo
osed and
protecteedbywrapp pingwithplastictape,o
orplasticcaaps.

Pag
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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

Weld en
nd preparaations shall be protected with securely ffastened pllastic or
woodencoversanddcoatedwitthrustprohhibited.
Flangefaacesshallbeprotected
dwithsecurrelyfasteneedplasticorrwoodenco
overs.
Ringtypejointflanggesshallhaavethegroo
ovepackedwithgreasepriortoattaching
flangeprotectivecoovers.
weldendssh
Socketw hallbeprottectedusinggplasticplu
ugs.
10.2
2. All small loosee pieces shaall be boxe
ed for proteection durin
ng shipmennt. Each
box shall be identifiied with a securely fastened
f stainless steel tag bearing the
purchaseo ordernumb beralongw withappropriatespool detailnum mber(seepaaragraph
7.1.2)toin
ndicateitspplaceinthefinalinstallledassembly.
10.3
3. Fabricated pipe spools sh
hall be adequately blo
ocked, strap
pped, or ottherwise
ngshipmenttandshall befurther separatedb
heldinpositiondurin bydunnage easmay
benecessaarytopreveentdamagee.Spoolssh hallbehanddledusingnylonstraps.Chains
shallnotb
beused.

11.Ven
ndorDataaRequirem
ment:
11.1
1. Theefollowingrrecords,fullyidentifieddwiththesspecificmatterialorpartofthe
piping rep
presented, must
m be avvailable for reference or examinaation by Re eliances
Inspector. On job completion,
c , they musst be collatted, indexeed and bou
und, and
forwarded d to Reliannces officee addresse ed for thee attention n of Vendoor Print
Control/Exxpediting.
a) C
Certificates attesting that all th
he quality control req quirementss of the
a
applicablec odeandoftheengineeringdesign nhavebeennmet.
b) Pyrometerc
P chartsandrrecordsofhheattreatment.
c) Radiographi
R icfilms.
d) Resultsofm
R magneticparticleanddyepenetran ntexaminattions.
e) Chartsorot
C herrecordssofBrinellh
hardnessteests.
f) Results
R of any
a other supplement
s tal types off examination test or analysis
s
specified.
g) Weldingpro
W ocedurespeecifications(WPS)and dtheirproccedurequallification
r
records(PQ QR).
h) Repairproce
R eduresandapprovals
i) Repairdetai
R ils.
j) Operatorsw
O weldingqualificationstestresults.
k) Paintproced
P dures.
l) Fabrication
F drawings
m) Weldmaps
W
n) Approvedde
A eviations(SShallbecarrriedoutthroughSERso only)ifany

Pag
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J3Program 100801SSPP006
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12,Rev.0

11.2
2. Allrrecordsand dreportssttatedinthe epurchase ordershall befurnishedupon
or prior to
o, the arrivval of the piping
p at the job site. The recorrd package shall be
specificallyyidentifiedastothesh hipmentitrrepresents.
11.3
3. FAB
BRICATORsh
hallprepareeschedulesstoshowhisforecastffor:
a) Materialpro
M ocurement(asneeded)
b) M
Materialreq
quiredforn next15dayss.
c) S
Spoolfabric ation.
d) S
SpoolNDTcclearance.
e) S
Spoolshipmmenttosite..
f) T
These scheddules must be update ed at regulaar periods, as specified in the
p
purchase orrder, to reflect the acttual situatio
on against tthe original agreed
s
schedule.
11.3.1. FAB
BRICATOR shall
s preparre and upddate every two weeks spool fab
brication
record
dsforeachplantandtheoverallrrecord.
11.3.2. FAB
BRICATORsh bleasbuiltmarkupsofBUYER/C
hallprovideeclearlegib CLIENTs
pipinggisometricd
drawings.
AsbuilttshallbeiissuedtoBUYER/CLIEN NTforrecorrdpurposesswithin2w weeksof
notificattion that piping is reaady for shipment. Drawings
D sh
hall be cleaar of all
revision markings, diamonds, clouds etcc., and be issued on tthe next sequential
revisionasCertifieedasBuilt.

Pag
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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

12.Atttachmentss:
AP
PPENDIX
XA
SUPP
PLEMENT
TARY REQ
QUIREMEN NTS FOR STEAM
S AN
ND FEED W
WATER PIIPING
SUB
BJECT TO
O INDIAN BOILER
B RE
EGULATIO
ONS REQUUIREMENT
TS
1. Purpos
se
Appendix A is a man ndatory suupplement to the fabrrication req
quirements
s of this
specification to enssure all ste
eam and boiler
b feed systems cconform to o or are
superior to the fabrication requiremen
r nts of thee Indian B Boiler Regu
ulations
(IBR).

2. Piping Material Classes

s
Only mate erials specified by the
e relevant piping ma
aterial classses shall be
b used
to fabrica
ate the stea
am and bo oiler feed sy
ystems.

3. Materia
als
All materiials purchased for use on IB BR system ms are su ubject to specific
purchasee orders annd shall bee segregate
ed from all other matterials of a similar
grade. The
T Fabriccator shall inspect all
a materials on receeipt to ens sure the
correct grade, quality, co ondition, end
e prepa
aration, id
dentificatioon and
ons have been
dimensio b supplied and are
a in acco ordance wwith the applicable
purchasee order and d specifica
ation requirements. All materials receive ed shall
be accommpanied byy a supplie er complete
ed IBR FOORM IIIA, B
B, or C (Ex xamples
attached).

4. Welding
g and No
on-Destrructive Testing
All welding configu
urations sh
hall conforrm to Standard Drawwing No. EPCMD-
E
P14-JG0000-046 an nd the requ
uirements of specificcation 1008
80-1-ENGGG-XXX-
GAW-XX XX.

5. Inspecttion
All fabrication activitties will be subject to
o IBR inspe
ection and
d approval prior to
installatio
on.

6. Hydros
static Tes
sting
Hydrostatic Testing shall
s be peerformed fo
ollowing co
ompletion o
of installation with
proval of the IBR site Inspector.
prior app

Pag
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J3Program 100801SSPP006
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F
FORM III-A
A
Ce
ertificate off Manufactture and Test
(Re
egulation 4(e))
4
Name off Part :........................................................................................................
Makers Name and address
a :........................................................................................................

Design Pressure
P :........................................................................................................
Design Temperature
T e :........................................................................................................

RIAL
MATER
Processs of Manufactture :........................................................................................................
Fully killed/rimmed :........................................................................................................
al Composition
Chemica :........................................................................................................
PIPES
Main Dim
mensions :........................................................................................................
Tolerancces :........................................................................................................
Mode off Manufacture :........................................................................................................
Identifica
ation Marks :........................................................................................................
Drawing
g Numbers :........................................................................................................
Bend Te
est on Pipes :........................................................................................................
Bend Te
est on Weld :........................................................................................................
Flattenin
ng Test :........................................................................................................
Tensile Strength :........................................................................................................
Mode off attachment of Flanges :........................................................................................................
Flange Particulars
P :........................................................................................................
Size of Branches
B :........................................................................................................
Mode off attachment of Branchess :........................................................................................................
Heat Tre
eatment :........................................................................................................
Final Hyydraulic Test :........................................................................................................

NOTE:-
In addition, the followingg information o the materrial shall be ffurnished in a tabular
n in respect of
form in conformity with h the requireements of Re e note thereto, as the
egulation 4(cc)(vi) for the
case may be. The information mayy be given fro om the estabblished test d data or if the
e material
is of standa
ard quality an extract from
m the standaard may be fu urnished insttead.

Pag
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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
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Metal Te
emp. up to C 2
250 275 30
00 325 375
5 400 425 450 475 500 525 55
50 575 600
0 625

Et
Sc
Sr

2 C
Tensile Strength at 20
Where:
Et = Yield Point at te
emperature (0.2% proof stress)
s
Sc = Avverage Stresss to produce
e an elongation of 1% (crreep) in 100,,000 hours a
at the various
s working
metal tempperatures.
Sr = Avverage and lowest stresss to produce
e rupture in 100,000 hou
urs at the va
arious workiing metal
temperaturres.
Tempera
ature range in
i the table may
m extend up
u to the limit of applicab
bility of the material.

The valu
ue of Sc and Sr need be
b furnished only in resp ended to be used for
pect of Pipes/Tubes inte
working me atures above 454C (850F)
etal tempera

Certified
d that the parrticulars ente
ered herein are
a correct.

The partticulars of fab

bricated com
mponents are
e shown in drrawing No :...................................................

The parrt has been designed anda construccted to comp ply with the Indian Boiler Regulatio ons for a
working pressure
p of ....................... and tem mperature ....................... and satiisfactorily
withstood a water test of .......................... on the ...........................day of ..........................19
e presence of our responsible rep
..... in the presentative whose sig gnature is appended
a
hereunder..

Makers Representative..........................................................

Maker.....................................................................................
(Name and d Signature)

We have satisfied ourselves

o at the pipes have been constructed in accordan
tha nce with Chaapter VIII.
The tests conducted
c on the sample es taken from ed pipes havve been witnessed by
m the finishe
us and the particulars entered
e here
ein are correc
ct.

Place. ....................................................... ..................................................................

Date. ........................................................ ..................................................................

(Name and d Signature of o Inspecting Authority).

Pag
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J3Program 100801SSPP006
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F
FORM III-B
B
Ce
ertificate off Manufactture and Test
(Re
egulation 4(f))
4

Makers Name :........................................................................................................

Design Pressure
P :........................................................................................................
Design Temperature
T e :........................................................................................................

RIAL
MATER
Processs of Manufactture :........................................................................................................
Fully killed/rimmed :........................................................................................................
al Composition
Chemica :........................................................................................................

TUBES
Processs of Manufactture :........................................................................................................
Main Dim
mensions :........................................................................................................
Tolerancces :........................................................................................................
Bend Te
est :........................................................................................................
Flattenin
ng Test :........................................................................................................
Tensile Strength :........................................................................................................
Elongatiion Percenta
age :........................................................................................................
Crushing
g Test :........................................................................................................
Flare Te
est :........................................................................................................
Bend Te
est on Weld :........................................................................................................
Bulging Test and Driifting Test :........................................................................................................
(for copperr and brass)
Heat Tre
eatment :........................................................................................................
Hydrauliic Test :........................................................................................................

NOTE:-
In addition, the follow
wing informa
ation in resppect of the material
m shall be furnishedd in a tabula
ar form in
conformity with the reqquirements off Regulation 4(c)(vi) for the
t note therreto, as the case
c may
be. This in nformation may
m be given from the established
e test data orr if the mate
erial is of
standard quality an exttract from the
e standard may
m be furnished instead.
Metal Te
emp. up to C 2
250 275 30
00 325 375
5 400 425 450 475 500 525 55
50 575 600
0 625
Et
Sc

Sr

Pag
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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

2 C
Tensile Strength at 20
where:
Et = Yield Point at te
emperature (0.2% proof stress)
s
Sc = Avverage Stresss to produce
e an elongation of 1% (crreep) in 100,,000 hours a
at the various
s working
metal tempperatures.
Sr = Avverage and lowest stresss to produce
e rupture in 100,000 hou
urs at the va
arious workiing metal
temperaturres.

Tempera
ature range in
i the table may
m extend up
u to the limit of applicab
bility of the material.

ue of Sc and Sr need be
The valu b furnished only in resp ended to be used for
pect of Pipes/Tubes inte
working me atures above 454C (850F)
etal tempera

Certified
d that the parrticulars ente
ered herein are
a correct.

The partticulars of fab

bricated com
mponents are
e shown in drrawing No:....................................................

The tub
bes have been manufacctured to com mply with th
he Indian Bo oiler Regulattions for a maximum m
working prressure of .......................and temperature of .......................... at our work ks above
named and d satisfactorily withstood d a water tes
st of .......................... on tthe ...................... day
of ...................... 19 ... in the presence of our re
esponsible representativ
r ve whose sig gnature is
appended hereunder.

Makers Representative.............................................................

Maker.......................................................................................
(Name and d Signature)

We have urselves that the pipes have

e satisfied ou h been co
onstructed in e with Chapter II. The
n accordance
tests conducted on the e samples taaken from th
he finished tu
ubes have b
been witness
sed by us
and the paarticulars ente
ered herein are
a correct.

Place ......................................................... .......................................................................

Date .......................................................... .........................................................................
(Name and d Signature of o Inspecting Authority)

Pag
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J3Program 100801SSPP006
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12,Rev.0

F
FORM III-C
C
(Certifica
ate of Manu
ufacture an
nd Test of Boiler Mou
untings and
d Fittings)
(Re
egulation 269)
2

Name off Part :........................................................................................................

Makers name and address
a :........................................................................................................

Intended
d Working Prressure :....................................... kg/ccm (lb./sq. in
nch)
Hydrauliic Test Presssure :....................................... kg/ccm (lb./sq. in
nch)
Main Dim
mensions :........................................................................................................
Drawing
g Nos. :........................................................................................................
Identifica
ation Marks :........................................................................................................
al Composition
Chemica :........................................................................................................
Physical Test Resultts
i) Tensile Strrength :............................................................

ii) e Bend Test :............................................................

Transverse

iii) Elongation :............................................................

Certified
d that the parrticulars ente
ered herein are
a correct.

The parrt has been designed and a construccted to comp ply with the Indian Boiler Regulatio ons for a
maximum working pressure of ..................... and tem mperature o of ..................... and
satisfactoriily withstood a hydraulic test using water w and kerosene or with any suita able liquid
in accordance with the provisions of on 290 on the ........................ day
o Clause (a)) of Regulatio
of ...................... 19 .... in the preseence of our responsible
r r
representativ
ve whose sig gnature is
appended hereunder.

Signaturre of Makers Representa

ative:....................................................................................................

Signaturre of Inspecting Officer who ed the test:........................................................................

w witnesse
Date at .......................... the day of ................................. 19.....

o Inspecting Authority:...........................................................................................
Signaturre and seal of

Place...................................................................................

Date......................................................................................

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J3Program 100801SSPP006
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Makers Representtative......................................... Ma
aker...................................................................
(Name and
d Signature)

We have
e satisfied ou
urselves that the pipes have
h been co
onstructed in e with Chapter II. The
n accordance
tests conducted on the e samples taaken from th
he finished tu
ubes have b
been witness
sed by us
and the paarticulars ente
ered herein are
a correct.

Place......................................................................... Na
ame And Siggnature of th
he Inspectin
ng Officer
wh
ho witnessed
d tests.

Date.......................................................................... ame and Signature of Insspecting Auth

Na hority.

Pag
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J3Program 100801SSPP006
PipingFFabrication Datee:07/07/201
12,Rev.0

A
APPENDIX B
PIPING ALIGN
NMENT AN
ND FABRICATION TOLERANC
T CES
(Pipe Fabrica
ation Institu
ute ES3)

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