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TANESCO
240 MW Combined Cycle Power Plant at Kinyerezi, Tanzania
 
 
 
 
 
 
 
 
 
 
 
 
Attachment_ X: Specifications for Prefabrication Piping 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Doc No. M-TKI1-578-11-0001


  Rev.0
PNC-TQ-XTAN4-0007 Rev.0

CONTENTS

Section No. Description Page

1 General requirements 3

2 Fabrication Requirments 9

3 Cleaning and Protection 15

4 Test and Inspection 18

5 Quality Assurance 20

6 Fabrication work schedule 22

7 Bill of Materials for Piping 24

Attachment-1 Sample of Deviation List 25

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TOSHIBA PLANT SYSTEMS & SERVICES CORPORATION
PNC-TQ-XTAN4-0007 Rev.0

1. GENERAL REQUIREMENTS

1.1 General

This specification covers the general and associated requirements for the BOP piping fabrication work.

1.2 Compliance with Specification

The Contractor shall comply with the Specification and all APPENDIX.
Any alternative offer including deviation and exception shall be proposed in accordance with the
Purchaser's form (Attachment-1) to specifically indicate such alternation to the Purchaser's approval.
Any alternation without written conception of the Purchaser shall not be accepted.
Any alternation after the placing order shall not be accepted.

1.3 Materials

All materials shall be new and unused and shall be satisfactory to the performance and reliability under
the all required conditions or reasonably inferred from the contract.

1.4 Code and Standards

Unless expressly stated to the contrary, all materials, equipment and articles furnished by the
Contractor shall comply with the applicable provisions of:

(1) The American Society of Mechanical Engineers (ASME)


B31.1 : Power Piping
B16.1 : Gray Iron Pipe, Flanges, and, Flanged Fittings
B16.5 : Pipe Flanges and Flanged Fittings
B16.9 : Factory-Made Wrought Steel Butt welding Fittings
B16.11 : Forged Steel Fittings, Socket Welded and Threaded
B16.20 : Metallic Gaskets for Pipe Flange
B16.21 : Nonmetallic Flat Gaskets for Pipe Flange
B16.24 : Cast Copper Alloy Pipe Flanges and Flanged Fittings
B16.25 : Butt welding Ends
B16.28 : Wrought Steel Butt welding Short Radius Elbows and Returns
B36.10M : Welded and Seamless Wrought Steel Pipe
B36.19M : Stainless Steel Pipe And all other applicable standards
(2) The American Society for Testing and Materials (ASTM).
(3) American Welding Society (AWS)
(4) International Organisation for Standardisation (ISO)
(5) American Standard Association (ASA)
(6) American Petroleum Institute (API)
(7) Heat Exchange Institute (HEI)
(8) National Fire Protection Association (NFPA)
(9) American Water Works Association (AWWA).
(10) Structural Steel Painting Council (SSPC).
(11) Pipe Fabrication Institute (PFI)
(12) Japan Industrial Standard (JIS)
(13) Other applicable standards and codes as listed in this Specification.

Where a standard is referred to, that standard shall be the latest published edition thereof,
unless otherwise stated.

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TOSHIBA PLANT SYSTEMS & SERVICES CORPORATION
PNC-TQ-XTAN4-0007 Rev.0

1.5 Language and Unit

All communication and documentation shall be in English and Metric unit, unless otherwise specified
i.e.;
Pressure: bar
Temperature: deg C
Dimension: m, cm, mm
Force: N
Weight: kg, ton
Mechanical Strength: Pa, kPa

1.6 Drawing and Document

1.6.1 All drawings and documents shall have a title, Drawing/Document No., Revision No. and Issued
record. The Purchaser may request to apply the standardized title block format with the
Purchaser's file numbering system.

1.6.2 The following drawings and documents shall be provided in accordance with the Purchaser's
required schedule. Any manufacturing work shall not start without the Purchaser's approval in
writing.
The Purchaser's approval and/or comments shall in no way relieve the Contractor from entire
responsibility for engineering, design, workmanship, material and all other liability under the
contract.

A - Documentation
1) Fabrication work schedule. (Refer to Section 6)
2) Sub-contractors list. ( Refer to Notes-1.)
3) Material control & traceable procedure
4) Fabrication procedure
5) Welding material control procedure
6) Welding Procedure Specification (WPS).
7) Procedure Qualification Record (PQR).
8) Qualified welder list (WPQ).
9) Welding repare procedure
10) Product identification procedure
11) Surface preparation and painting procedure.
12) Pickling procedure.
13) Pipe bending procedure.
14) Packing and transportation procedure
15) Monthly Progress Report

B - Test and Inspection


16) Material receiving inspection report
17) Marking and cutting inspection report
18) Fitup inspection report
19) Dimension inspection report
20) Welding inspection report
21) NDE inspection report (RT, UT, MT, PT)
22) Painting and Coating inspection report
23) Technical data of painting, volatile corrosion inhibitor, etc
24) Mill certificate record.
25) Visual inspection report (before/after packing)
26) Packing list

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PNC-TQ-XTAN4-0007 Rev.0

C – Drawing

27) "PIPE SPOOL" drawing


based on the Purchaser's each piping arrangement drawing,if requird by Purchaser

Cf. "PIPE SPOOL" in this specification means prefabricated


pipe in shop in order to minimize the number of site welding in
consideration of the limitation of transportation to job site.

- Notes –

(1) If the Contractor needs to use sub-contractors for manufacturing or ordering material and/or
the authority in charge of the test and inspection, such sub-contractors or authority shall be
submitted with the full name and address for the Purchaser's approval.

(2) The Contractor shall re-submit revised drawings or documents, when the Purchaser made any
comments on the submitted ones.

(3) The Contractor shall provide final drawings at the Purchaser's request.

(4) Each of two(2) photo copies and PDF data shall be submitted for all drawings and documents,
unless otherwise specified in this Specification.

1.7 Packing and Storage

1.7.1 All equipment and materials shall be boxed, crated or otherwise suitably protected during
shipment, handling and outdoor storage. The duration of site storage period is six(6) months,
unless otherwise advised by the Purchaser.

1.7.2 Any equipment which need specific storage requirements other than outdoor storage shall be
clarified by the Contractor in writing, and such storage requirements shall be accepted between
the Purchaser and the Contractor before the placing order.
The cost for any additional requirements by the Contractor unless accepted shall be borne by the
Contractor. Shipping instruction and mark to be applied will be specified during the course of the
Contract.

1.7.3 All flanges, openings and nozzles shall be given acceptable protection to prevent damage,
corrosion and entrance of foreign matter during shipment and storage.
Threaded connections and welding ends shall be closed with both plastic covers to prevent
ingress of foreign particles and prevent end damage.

1.7.4 All accessories that form a part of a main component shall necessarily be packed with the
accessory name and shall be in the same packing, unless otherwise approved by the Purchaser.

1.7.5 Any damage during transportation caused by poor packing shall be repaired satisfactorily by the
Contractor with contractor’s cost, in a suitable period for the Purchaser.

1.7.6 The Contractor shall provide, if necessary, lifting materials on the packing.

1.7.7 Large size piping, if necessary, shall be provided with structure so as to maintain, the pipe
roundness as specified and to prevent damage during transportation.

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PNC-TQ-XTAN4-0007 Rev.0

1.8 Marking

1.8.1 Each pipe spool shall be marked with UNIT NO., SPOOL NO. and FLOW DIRECTION by arrow
on the exterior surface of both ends. (in case of less than 2m spool, one point marking may be
available.) The marking paint shall be free of any metal such as tin, lead or zinc.

1.8.2 All temporary parts shall be painted yellow to distinguish from permanent parts.
(shipping parts etc..)

1.8.3 Generally 50 mm (Nominal Dia) and smaller shall be site run piping (run on site).
Such materials shall comply with the following requirements (1.8.4).

1.8.4 Each straight pipe, shall be clearly and legibly marked material PNo and material indication paint.
Each fitting shall be clearly and legibly marked material PNo., and material indication
Fittings shall be grouped together in a same bag or by another suitable means, and wired with a
rust-proof tag showing PNo, type, material specification, size and Sch. No..

1.8.5 Outer surface of priming painted material (as protection against rust and corrosion) except
Galvanized coating or lining steel, shall be painted color code marking on both end and full
length of pipes as follows. (LargeBore : DN65 or more, Small Bore: DN50 or less)

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PNC-TQ-XTAN4-0007 Rev.0

Color Code

1.9 Material

If Contractor purchase the piping material, The Contractor shall comply with below, unless otherwise
specified.

1.9.1 All pipes and fittings shall be purchased with a mill certificate record, and the manufacturer's
markings must be clearly and legibly marked. Material specification and grade must be marked
every 0.9 m along the length of pipe.(material stencil etc.)

1.9.2 All pipes and fittings shall completely comply with Codes and Standards. Substitution of any
material shall not be allowed.

1.9.3 Fittings shall be of materials equivalent to the pipe.

1.9.4 Flanged materials shall be of forging or plate equivalent to that of pipe.

1.9.5 All bolts and nuts shall be required anti-corrosive protection.

1.9.6 All gaskets shall be of asbestos free.

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PNC-TQ-XTAN4-0007 Rev.0

1.10 Scope of Works

The Contractor shall supply all of necessary materials and works to provide pre-fabricated pipe spools
and site run piping materials in accordance with the Purchaser's drawings and/or documents.
The Contractor shall provide the followings.

(1) All necessary engineering, including preparing each spool drawing, for shop fabrication based on
the Purchaser's each piping arrangement drawing (isometric drawings).

(2) Recording and submitting all information such as: Two week progress report, material order,
fabrication, heat treatment (PWHT), welding, test and inspection, cleaning, surface treatment,
painting/coating/lining, packing, transportation, etc..

(3) All application and information to Authority, Superintendent and/or the Purchaser.

(4) Non pressure parts materials such as support pad, Lug support,pipes, elbows, tees, flanges, bolts,
nuts and gasket for flanges, lining material, painting material and etc., necessary to complete the
pipe line system specified during the course of the Contract.
Any materials prepared by Purchaser shall not be need to supply by Contractor.

(5) Unloading work at the Contractor’s work shop.

(6) All manufacturing work for shop fabrication of pipe spools, including cutting, beveling, bending,
drilling, tapping, grinding, welding, heat treatment, and all other works for shop pipe fabrication.

(7) All the test and inspection work for shop fabrication and material receiving.

(8) All the painting work for shop fabrication and the raw materials of small bore piping, including
blasting, cleaning, surface treatment, primary painting and lining etc..

(9) Packing and marking work for transportation up to the unloading place.

(10) Transportation to the job site or unloading place.

(11) All painting material and consumable for shop fabrication, such as welding rods, chemicals, water,
blasting materials, electricity, compressed air, nondestructive examination materials, etc..

(12) All temporary materials for shop fabrication and shop test, such as welding bridges, welding
clamps, cover plates, blind flanges or blind plate, test pieces, etc.. (except plastic cap ref, 1.11(9))

(13) Non-pressure attachments directly welded on piping, such as Lifting wire lugs for shop and site
erection work, when specified.

(14) All touch-up paint (intermediate coat) for site repair work : (10% Qty for external surface).

(15) the transportation work from site to shop, If any defect on shop-fabrication is found by the
receiving inspection at site.

(16) Engineering work (including the 2D/3D Cad work) for making the Isometric drawing and the
Support Drawing, based on the DOW List.

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PNC-TQ-XTAN4-0007 Rev.0

1.11 Excluded Work

The following items of work do not form a part of this Contract.


But if any defect on shop-fabrication is found by the test at site, the Contractor shall bear the
responsibility and cost for modification work. Procurement of materials prepared by Purchaser.

(1) Pipe work systematic designing.

(2) Piping arrangement design.

(3) Selection of pipe size, wall thickness and material for each piping system.

(4) Major materials such as Pipes, Elbows, Tees, Reducers, Boss, Flange, Bolts, Nuts and Gasket,
etc., including engineering, design and supply. (except attachment such as non pressure parts)

(5) All support materials of pipe hanger in site use, including engineering and design for pipe hanger
and support. (except attachment such as support pad, suddle)

(6) All instrumentation equipment such as thermo couples or flow measuring orifices etc., including
engineering, design and supply.

(7) Specialties of site use, such as valves, traps, strainers, expansions etc., including engineering,
design and supply.

(8) Thermal insulation and thermal insulation cover of site use.

(9) Following Pipe-End Plastic Cap for protecting during transit and site storage.
(DN65, DN80, DN100, DN150, DN200, DN250, DN300, DN350, DN400)

(10) Erection work at site.

(11) Test and inspection at site.

(12) Third party inspection at shop.

1.13 Price Schedule

The Contractor shall submit Price Schedule of delivery with his offer that shall consist of the following
break-down item in accordance with each system of material lists. (Refer to SECTION 7.)

The Purchaser shall have the right to select his quotation either all inclusively or some of them,
depending on his prices of each piping system.

Item :
System :
1) Documentation Cost. :
2) Material Cost.(Painting etc..) :
3) Labor Cost :
Fabrication including machining,
welding cleaning, painting etc.
4) Test and Inspection Cost. :
5) Transportation fee (DDU at Job Site) :

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PNC-TQ-XTAN4-0007 Rev.0

2 Fabrication Requirments

2.1 General

This specification covers the technical general requirements for fabrication of piping.

2.2 Fabrication

2.2.1 Cutting mark position shall be made on a straight pipe surface in accordance with each spool
drawing. Before cutting, the charge number shall be stamped on the exterior surface of each
straight pipe.

2.2.2 Stamping shall be performed by a method that will not result in sharp discontinuities.
In no case shall stamping infringe on the minimum wall thickness or result in dimpling or
denting of the material being stamped.

2.2.3 Each spool number shall be painted or stamped on both end of a pipe spool.

2.2.4 Both of gas cutting and machine cutting are acceptable.

2.2.5 Beveling work for weld end preparation shall be performed by a beveling machine.
Gas cutting is not acceptable.(Refer to Fig-2.2)
All weld end preparation details shall comply with the Purchaser’s requirements, which is
basically based on ASME B16.25.

Weld end
Gas

*:Because, this range is since the


Min.50mm* metal organization has broken for heat.

Fig-2.2

2.2.6 Change in direction for Fittings shall be as indicated on the piping drawings. Elbows, Tees and
other branch line connections made with mitered joints shall be completely shop fabricated.
Reinforcements of laterals and other fittings, as required, shall be shop finished.

2.2.7 The Edge preparation shall be checked before assembly, in accordance with WPS and
applicable specifications.

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PNC-TQ-XTAN4-0007 Rev.0

2.3 Bending

In order to use a Elbow Fitting, Bending pipe is not applied in this project.
Following requirement shold be followed, If required specially.

2.3.1 Pipe bending shall meet the requirements of ASME B31.1 "Power Piping" and PFI Standerd
ES-24 “Pipe Fabrication Institute”, in addition to the requirements in this Specification.

2.3.2 Pipe bending shall be carefully controlled so that no section of the bending part shall have
excessive ovality nor wrinkles.

2.3.3 A pipe bend may be substituted by an elbow to supply an additional beveling work for weld end
preparation of pipe to connect with each end and shop weld on each end.

2.3.4 The Contractor shall guarantee that the wall thickness reduction ratio shall be less than the
value shown below.

Radius of Bend Thickness Reduction Ratio

3.0 x Pipe Diameter : 12.5 %


3.5 x Pipe Diameter : 11.5 %
4.0 x Pipe Diameter : 10.4 %
4.5 x Pipe Diameter : 9.3 %
5.0 x Pipe Diameter : 8.2 %
5.5 x Pipe Diameter : 7.1 %
6.0 x Pipe Diameter and Larger : 6.0 %

Thickness Reduction Ratio = (T-T’) / T x 100 (%)

Where:
T : Minimum Wall Thickness under the Purchaser specification
T’ : Minimum Wall Thickness after bending

Note
The Purchaser will use the above ratios to decide pipe wall thickness, therefore if the
Contractor can not guarantee these values, then the deviation shall be submitted before
the placing order.

2.3.5 The tolerance and accepted criteria for shop fabricated bends shall be in accordance with PFI
Standards ES-24. Bends shall be fabricated from whole pipe sections and shall be free of
circumferential welds.

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PNC-TQ-XTAN4-0007 Rev.0

2.4 Welding

2.4.1 Prior to commencement of any welding of the work, the Contractor shall have all welding
procedure specifications, welding equipment and operators qualified in accordance with ASME
Code Section IX "Welding Qualifications", ASME B31.1 "Power Piping" and ASME B16.25
“Buttwelding Ends”.
All welding procedure specifications shall be submitted to the Purchaser for approval. A list of the
qualified operators to be engaged must be submitted and any change to the list must be
submitted for approval by the Purchase before being implemented.

2.4.2 All welders shall be fully qualified in accordance with the test requirements of Section IX of the
ASME Boiler and Pressure Vessel Code and proof of such qualifications shall be supplied at the
Purchaser’s request.

2.4.3 The Contractor shall bear all costs to make qualification or re-qualification test, including all
consumables.

2.4.4 As-weld surfaces shall satisfy the requirements described in the following (1) to (6).

(1) Undercuts :
The depth of undercuts shall not exceed 0.03”(0.8mm) or 10% of the thickness of the base
material, whichever less. (Refer to Fig-2.4) When unacceptable undercuts is removed by
grinding or other methods, the remaining thickness of the section of the base material shall
not be reduced below the minimum thickness of design requirement.

(2) Overlap :
Overlap with lack of fusion is not acceptable, and the flank angle between weld bead and
base material, or adjacent bead shall be also 90 degree and over.

(3) Weld surface variation in height :


Surface variation in height of 1”(25mm) length of each bead, of one bead to adjacent bead,
of weld ripple of bead, of overlapped area of the preceded bead shall not exceed
0.1”(2.5mm). (Refer to Fig-2.4 )

(4) Any weld spatter, welding flux, arc strikes and the remained temporary welds are not acceptable.

(5) Reinforcement of butt weld and fillet weld size (foot length and throat thickness) of surface
finished, shall be within the tolerances specified in the applicable drawings or documents.

(6) Cracks and visible porosity are not acceptable.


The surfaces of those defective welds shall be removed by grinding.

less than
0.1”(2.5mm)
less than
0.03”
(0.8mm)

Fig-2.4 As-welded surfaces

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PNC-TQ-XTAN4-0007 Rev.0
2.5 Pre-Heat Treatment of Welding

The requirements of paragraph 131 (Welding Pre-heat) in ASME B31.1 "Power Piping" shall apply.

2.6 Post Welding Heat Treatment

2.6.1 No heat treatment is required subsequent to bending or forming operations on carbon steels
which have been heated to 900 deg.C or higher.

2.6.2 Cold bending and forming of carbon steel having a wall thickness of 19.0 mm and heavier and all
alloy pipe sizes of 100 mm ND and larger or 13.0 mm wall thickness and thicker shall be
normalized in accordance with the above.

2.6.3 Cold bending of carbon and alloy steel pipe insides and thickness less than those specified
above may be carried out without the need for post heat treatment.

2.6.4 The requirements of paragraph 132 (Post Weld Heat Treatment) in ASME B31.1 "Power Piping"
shall apply for the post weld heat treatment of pipes of various sizes, thickness and P-numbers.

2.6.5 Required heat treatment records shall be recorded as follows.


a) Actual temperature slope for heating and cooling,
b) Holding temperature and time,
c) Method of heating and cooling,

2.7 Non-Destructive Examination

Contractor shall perform Non-destructive examination in accordance with “Isometric Drawing”, and
“Pipe Line List” issued by separately.
Method and acceptance criteria for Non-destructive examination shall be complied in accordance
with ANSI/ASME Codes and ASTM Standards

2.8 Material Requirments


Major piping materials are supplied by Purchaser as mentioned “Scope of Supply”.
Following requirement shold be followed, If required specially.

2.8.1 Pipe

(1) All pipe materials shall comply with JIS or ASME, ASTM material specifications, unless otherwise
specified.

(2) Each specification number, material grade, size and total required length along with the required
hydraulic test pressure and the design conditions shall be in accordance with the Purchaser’s
piping drawings and/or documents.

(3) Permissible variations in Diameter and Wall Thickness any point in a length of pipe shall comply
with ASTM material specifications. In case of the special heavy wall thickness, permissible
variations in the wall thickness shall not vary more than 12.5% over and 10% (Max.6mm) under
the nominal wall thickness specified.

(4) Each Specification number, material grade, class, specific length, quantity, Pipe Size and
schedule No. or nominal wall thickness shall be in accordance with “Bill of Material for Piping”,
specified by Purchaser

(5) The material ASTM A312 Grade TP304, 304L,316 and 316L (or Equivalent) may be made by an
automatic welding process, unless otherwise specified.

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PNC-TQ-XTAN4-0007 Rev.0

2.8.2 Fittings

1) All fittings shall be constructed of materials equivalent to the pipe with which they are used.
The fittings shall be manufactured in accordance with ASME B16.9, ASME B16.28.

2) Forged steel fittings shall be used for all socket weld and steel threaded connections. Socket weld
and threaded fittings shall conform to ASME B16.11.

2.8.3 Flanges

Flanges shall be constructed of materials equivalent to the pipe with they are used.

2.8.4 Gaskets and Bolting

(1) Unless otherwise specified, compressed fiber gaskets will be used with flat face flanges and
slip-on raised face flanges.

(2) All gaskets shall be suitable for the design pressures and temperatures given in the Purchaser’s
drawings and/or documents.

(3) Compressed fiber gaskets shall be in accordance with ASME B16.21.

(4) Spiral would gaskets shall be made of a continuous stainless steel ribbon would into a spiral with
non asbestos filler between adjacent coils in accordance with ASME B16.20.

(5) All gaskets shall be of asbestos free.

(6) Flange bolting shall conform to the followings.


- Bolting shall conform to the requirements of ASME B16.5, B16.1 and B16.24.
- Bolting shall consist of threaded studs and two nuts for each stud.

2.9 Fabricating Tolerances

2.9.1 Shop fabricating tolerances for prefabricated piping assemblies shall meet the requirements of
PFI Standerd ES-3.

2.9.2 The tolerances on linear dimensions (intermediate or overall) apply to the face to face, face to
end, and end to end measurements of fabricated straight pipe and headers; center to end or
center to face of nozzles or other attachments; or center to face of bends; as illustrated on figure
“Application of Pipe Fabrication Torerances”. These tolerances are not accumulative.

2.9.3 Linear tolerances on “A” are as follows

3.0 mm for pipe size DN250 and under


5.0 mm for pipe size DN300 through DN600
6.0 mm for pipe size DN600 through DN900
6.0 mm for pipe size over DN900
Increasing by plus or minus 2.0 mm for each 300mm in diameter over DN900

2.9.4 Angularity tolerance across the face of flanges, weld end preparation and on rotation of flanges
are as stated on Fig-2.9 “Application of Pipe Fabrication Torerances”.

2.9.5 Bending tolerances shall conform to PFI Standerd ES-24.

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PNC-TQ-XTAN4-0007 Rev.0

Fig-2.9 - APPLICATION OF PIPE FABRICATION TOLERANCES

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PNC-TQ-XTAN4-0007 Rev.0

3 Cleaning and Protection

3.1 General

This specification covers the requirements for cleaning and protection of piping.

3.2 Procedure

3.2.1 Upon completion of shop fabrication and prior to final machining, all traces of scale, weld
spatter, sand, oil and dirt shall be removed from the inside and outside of all piping by a
pickling or blasting process, whichever is applicable.

3.2.2 After pickling, all piping shall be neutralized by immersion in a suitable solution followed by
complete drying. Large diameter piping (65 mm and larger) shall be blasted dry.

3.2.3 All Pipe spools shall be blasted to produce an acceptable surface finish.

3.2.4 the outside surface of the piping except stainless steel piping shall be painted with an
approved corrosion resisting paint for protecting during transit and site storage.

3.2.5 Internal surfaces of piping except stainless steel piping and coating piping shall be protected
from corrosion by the insertion of an approved corrosion inhibitor. (Refer to Fig-3.2.1)

A
Min.50mm Min. 2/3 x A

End of the string to be set into


Pipe the Vinyl tape.

Plastic cap (DN65 to DN400)


Vinyl tape
(More than a double volume) Arrange corrosion inhibitor
at the center of a pipe.
Hang the bag containing powder Don't contact corrosion inhibitor
with string. to a pipe inside.

Fig-3.2.1

3.2.6 All machined parts of piping(ex.weld end) except stainless steel piping shall be covered with a
rust inhibiting grease. All openings shall be adequately protected and sealed to prevent
damage to a weld-end and flange surface, and contamination of the pipe inside during
handling, shipping and storage.

3.2.7 All interior and exterior surfaces shall be thoroughly cleaned to remove all rust, scale, welding
spatters, sand and dust, and also to protect the connecting ends against damage. Surface
preparation and painting on both exterior and interior shall be carried out the same procedure
as piping spool.(Refer to Fig-3.2.2/3.2.3)

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PNC-TQ-XTAN4-0007 Rev.0

Vinyl tape
(More than 4 times volume)

Vinyl tape
(More than 3 times volume)

Hole for thermowell


or gamma plug Socket Weldlet

Fig-3.2.2 Packing procedure of hole

Metal band for packing


Or wooden frame

Cautions label
(for inhinbiter)

Pipe
Cushion
Label for Spool No.
Plastic cap
Square lumber

Fig-3.2.3 Packing procedure of pipes

3.3 Pickling

The Contractor shall submit detailed pickling procedure including chemical composition of solution,
immersion time and so on, for approval. If applicable.

3.4 Specification for Painting and Coating

3.4.1 Painting specification shall be in accordance with Painting Specification,


issued by Purchaser separately.

3.4.2 If Contractor will use any paint other than the Purchaser’s specification, Contractor shall submit
all technical data of equivalent paint for approval.

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3.5 Surface Preparation and Primer Painting

3.5.1 Before painting, all steel surface shall be prepared for painting. Oil, grease, dirt, water or all
other foreign materials shall be removed prior to painting by using a suitable solvent.

3.5.2 All works (welding, drilling, grinding, etc.) shall be completed and weld spatter, burrs or any
other detrimental particles shall be removed prior to painting.

3.5.3 All sharp edges shall be finished smooth radius particularly at concave area such as fillet welds.
All welds should be dressed to remove alkaline flux/slug deposits prior to painting.

3.5.4 Painting for one part shall be completed in the same day of which cleaning and anti-rust
treatment to be finished.

3.5.5 Before handling or re-painting, the Contractor shall confirm that the dry paint has enough
hardness.

3.5.6 As a rule, CAN paints shall be used for a short period, once it is opened.

3.5.7 The Contractor shall use the thinner which the painting manufacturer recommends, and shall
comply their mixing ratio as per the paint manufacturer’s indication.

3.5.8 The following parts shall not be painted.

(1) Screw thread.


(2) Raised face surface of flange
(3) Sliding pad.
(4) Colored steel, stainless steel and galvanized steel.

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4 Test and Inspection

4.1 General

This document covers the details of quality control requirements for piping system.
Unless otherwise specified in the applicable specifications and/or drawings, contractor shall apply
the appropriate clause of this specification.
Contractor shall take the necessary quality control activities such as in-process checking, tests or
inspections based on the specifications and drawings.
Purchaser (TPSC) and/or his Customer (Owner) and/or their representatives have the right to
witness and inspect to the purchased products at anytime during the production.
Contractor shall prepare and arrange to carry out the witness and inspection properly.

4.2 Requirment

4.2.1 Contractor shall be recorded following items and maintained in the attached sample form or
Contractor’s own form.

(1) Mill certificate


(2) Material identification & Traceability record
(3) Welding inspection report
(4) Dimension inspection record
(5) Non-destructive examination record
(6) Heat treatment record
(7) Painting inspection
(8) Packing inspection

4.2.2 Contractor shall inform above record to in replied to Purchaser’s requirement.

4.2.3 All pre-fabricated pipe spools and materials provided by the Contractor and his Subcontractor
shall be subject to inspection, test and expediting in accordance with applicable codes,
standards and this Specification in every detail.
Any alternative offer including deviation and exception shall be proposed in written form to
specifically indicate such alternation to the Purchaser’s approval.

4.2.4 The costs of all tests and inspections shall be borne by the Contractor. Furthermore,
Contractor shall not be relieved inspecting and expediting by the Purchaser for quality
assurance and delivery commitments.

4.3 Purchaser’s Witness

4.3.1 Purchaser and/or their Customer and/or their representatives have the right to witness and
inspect to the purchased products at anytime during the production.

4.3.2 Basically, the witness inspection will be carried out before packing the spools for delivery.

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4.3.3 Inspection sequence is as described below.

(a) Review of record


(b) Visual inspection for all spools.
(c) Dimensional inspection for random sampled spools.

4.3.4 The conditions of the products to be inspected are as described below.

(a) Pipe spools are set on the floor, not loaded or piled up, in order to provide easy access for
inspection.
(b) All necessary measuring instruments such as tape measures, convex rules, venire calipers,
bevel gauges, etc. which are prepared by contractor.
(c) When further detailed measurements are required, such as angular check for a spool’s bend
radius, Contractor shall prepare flat table or equivalent facilities.
(d) Contractor shall prepare and submit his internal inspection records prior to the witness
inspections.

4.3.5 The contractor shall submit the applications for the witness spool inspection and the packing
inspection to the purchaser respectively at least two(2) weeks prior to the inspection date.

4.4 Others

Any deviations from the specifications, drawings and documents, shall be submitted in written
form to Purchaser for his approval without delay.

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Inspection and Test Program

No INSPECTION AND APPLICABLE TYPE OF INSPECTION


TEST ITEMS PROCEDURE
CSTM TPSC MFCT RCRD
AND STANDARD

01 Material Inspection
a. Review of Mill Certificate Material Specification --- R R X
b. Visual / Dimensional Inspection --- M --- ---
c. Material Identification --- M M ---
02 Marking-off & Mark Transfer --- --- M X
03 Welding Inspection
a. Welding Procedure Quality Test --- R M X
b. Welder Qualification Test AWS or equiv. --- R M X
c. Fit Up Inspection --- --- M X
d. Back Chip Inspection --- --- M ---
e. Visual & Dimensional Inspection --- --- M X
f. Non-destructive Examination (NDE) --- R,S M X
04 Mo Check for Stainless Steel (if required) JIS G1518 or equiv. --- --- --- ---
05 PWHT inspection --- --- M X
06 Dimensional Inspection Piping drawings --- R,S M X
07 Visual Inspection --- R,S M X
08 Hydrostatic Test (if required) --- --- --- ---
09 Marking Inspection --- R M X
10 Cleaning Inspection --- --- M X
11 Painting Inspection Painting Specification --- R,S M X
12 Quantity Inspection --- R M X
13 Packing and Shipping Inspection Shipping and Packing --- W M X
Inspection

Abbreviation :

CSTM : CUSTOMER TPSC : TPSC (THAILAND) CO., LTD.


MFCT : MANUFACTURER RCRD : TEST RECORDS / CERTIFICATES

W : WITNESS INSPECTION (Hold Point) R : REVIEW OF TEST RECORDS / CERTIFICATES


M : MANUFACTURER’S INSPECTION AND TEST X : TO BE SUBMITTED TO TPSC
S : SPOT WITNESS INSPECTION

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5 Quality Assurance

5.1 General

This specification covers requirements for quality assurance for piping system.

5.2 Quality Assurance

5.2.1 A plan shall be submitted within two (2) weeks after Award of a Contract.
Detailed test procedures under this Contract shall be submitted for approval. These procedures
shall include details of all tests conducted in the manufacturer’s works. Detailed lists shall be
provided which shall specify applicable codes, functional and other tests to be carried out on
each item. The lists shall be supplemented with logic diagrams to show the correct plant
functional requirements.

5.2.2 The procedures, lists, and logic diagrams together with test results shall be correlated and
presented as a single bound document to form a comprehensive set of test procedures and
records of the tests. This document shall be submitted to the Purchaser.
The Contractor shall also keep all test records on his file to be made available on request.

5.2.3 Materials used under this Contract shall be subjected to ASME Codes or ASTM standard
physical and chemical tests.

5.2.4 Quality Assurance Records shall be maintained and submitted to the Purchaser to final
acceptance of the Contract.

5.2.5 Quality Assurance Records shall be compiled in accordance with the requirements in
NCA-4134.17 of ASME Boiler and Pressure Vessel Code Section III Subsection NCA.

5.2.6 The Contractor shall utilize Quality Control program ISO-9000 to verify that items and services,
including subcontracted items and services, comply with contractual requirements and
specifications.

5.3 Quality Assurance Audit

5.3.1 The Purchaser will audit the quality assurance and control system of the Contractor.
The followings are the major items of the audit.

(1) Organization of responsibilities.


(2) Manufacturing facilities and their availability.
(3) Control system of;
* Production and manufacturing facilities.
* Tools, instruments and equipment.
* Documentation.
(4) Mechanical, non-destructive testing and other special equipment for testing.
(5) Training and education system for operators.
(6) Qualification system for operators of non-destructive examination.

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(7) Welder qualification system, and qualification and control system of welding procedure and
operation.
(8) Control system of manufacturing drawing.
(9) Procurement control.

5.3.2 The result of the Purchaser’s audit, whether the Contractor’s quality assurance and control
system is judged good enough to supply the piping system or not, will be informed to the
Contractor within one (1) month.
The Contractor shall not start any manufacturing work without remedial action and the
Purchaser’s approval.

6 Fabrication Work Schedule

6.1 General

This specification covers requirements for fabrication work schedule for piping system.

6.2 Requirements

6.2.1 The Contractor shall submit his fabrication work schedule including all test and inspection for
approval. Any fabrication work shall not be started without the Purchase’s approval.

6.2.2 Fabrication work schedule shall cover every process of work to be applied onto pipe spools
and materials with the indication of witness by the Purchaser.

6.3 The Schedule for Example

6.3.1 A sample of “Fabrication Work Schedule” for Piping System is shown as follows.

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Fabrication Work Schedule for Piping System <Sample use only>

2014/ 2015/
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7

DM
PM
RM
CM
Piping System

RP
FP
WP
NDE
DT
LI
PO
PP
DP

- Abbreviation -

DM : Design for Manufacturing


PM : Purchase of Material
RM : Receive of Material
CM : Cutting of Material
FP : Fit up of Pipe
WP : Welding of Pipe
NDE : Nondestructive testing
DT : Dimensional Test
LI : Lining of pipe Inside
PO : Painting of pipe Outside
PP : Packing of Pipe spool
DP : Dispatch of Pipe spool

Actual schedule shall be described about each (an specified) piece and each (an specified)
manufacturing process in more detail adjusting actual delivery .

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7 Bill of Material for Piping

7.1 General

7.1.1 All pipe sizes are shown in nominal diameter(DN) in mm.

7.1.2 Nominal Pipe Size (DN) may be converted from “mm” to “in” as per the table below :

mm 6 8 10 15 20 25 32 40 50 65 80 90 100 125

in. 1/8 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5

mm 150 200 250 300 350 400 450 500 550 600 650 700 750 800

in. 6 8 10 12 14 16 18 20 22 24 26 28 30 32

mm 850 900 950 1000 1050 1100 1150 1200 1300 1400 1500 1600

in. 34 36 38 40 42 44 46 48 52 56 60 64

7.1.3 65mm DN and larger shall be prefabricated at the Contractor’s workshops, unless otherwise
specified.

7.1.4 Generally 50 mm DN and smaller are site run piping, except that the piping which have
quantities of “shop weld” and ”pipe bend” mentioned in the following lists are to be shop
fabricated.

7.1.5 Small stubs (50 mm DN and smaller) for connection of drain, vent and instrumentation pipe
which are shop drilled, welded and/or tapped on the main pipe shall be included in his
quotation, though these are not specifically listed in the attached “Bill of Material”.
Quantity of these stubs is very small compared with total piping weight and detail of these
stubs (location, number etc.) are not finalized at bidding stage.

7.1.6 Flange rating shall be in accordance with ASME B16.5.

7.1.7 Shop and site weld quantity mentioned in the following lists are designed in accordance with
the purchased pipe length 5.5m or 6.0m, unless otherwise specified.

7.1.8 Pipe length and quantities of fittings, flanges, pipe bends, etc. mentioned in the following lists
are for one (1) unit.

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