a Client : PT ASIAN PAINTS INDONESIA BiLFINGER Project: SEMARAK asianpaints Specification for Piping Erection Karawang, Indonesia FOR COMMENTS [Tse PT Tebodin Indonesia Menara 165, 12th Floor Jl. TB Simatupang Kav. 1 Cllandak Timur Jakarta Selatan 12560 Indonesia PT.TEBODIN INDONESIA ‘Author: Wahyu Ariasa - Telephone: +6221 2940 6840 ~ E-mail: Wahyu.Ariasa@tebodin.com April 18, 2016 Order number: 64715012 Document number: 2683100 Revision: A, always closePrevodi indonesia Speiseaan or Ping ecion ner manbar 64795012 Dosimert numer 2683100 fvtionh gee 8 BiLFINGER A_| 18/04/2016 Issued For Review WA fe) _uk Wi ee z Checked | Approved Rev. | Dat Descripti Auth ate Jescription thor i © Copyright TID Tebodin All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means without permission of the publisher.Speceatan er ang Erection cement rambar 2669100 Pears BiLFINGER TABLE OF CONTENTS: 1 SCOPE OF WORK. 4 1.1 General... 4 1.2. Abbreviations... 4 1.3 QNQC corer oi 8 1.4 Safety, Health and Environmental 5 1.5 Piping 5 1.6 Miscellaneous activities . 6 2 SCOPE OF DESIGN. eee 7 2.1. Scope of design by ENGINEER... a7 2.2 Scope of design by CONTRACTOR ean 3. SCOPE OF SUPPLY. 9 3.1 Scope of supply by the ENGINEER / OWNER. 9 3.2 Scope of supply by CONTRACTOR... sss sssessentenntnneee 9 4 MATERIALS 44 Piping 10 4.2 Pipe Classification ees et eee edt ee att seseeseee 10. 43 Pipe Fittings..... 4A GaSKEIS ceeneesnenrereen eeere 4.5 Hangers, Saddles, Anchors, and Clamps. 1 4.8 Vertical Piping Supports. 4.7 Pipe Line at Crossings 4.8 Pipe Installation 49 Valves. 5 FABRICATION 6 WELDING. dette eel 6.1 Welding Processes 13 6.2 Previous Adjustments peers = 2 14 6.3 Cuts in Piping 14 6.4 Welders’ Qualification cn 14 6.5 Electrodes and Weld Equipment. 15 7 ERECTION 8 INSPECTION AND TESTING. 9 CLEANING. 16es Seats er Pi Erecn fy) Sternmarerhene s ‘Doeamert uber 268300, 4 Revo A 14 1A 44.2 12 BiLFINGER SCOPE OF WORK General This specification covers the minimum requirements for the work to be executed by the CONTRACTOR for the supply, fabrication, erection, inspection, testing and commissioning of piping, valves and fittings. ‘Scope of piping includes: Piping for Utility System: Scopes of works / services are as follows, but not limited to Supply and Installation of piping for Utilities Piping System consisting following but not limited to a) Compress Air System Piping b) Cooling water System Piping ©) Chilled Water System Piping d) Water Distribution System Piping Piping for Part of Processing System: ‘Scope of works and /or services are as follows, but not limited to Supply and installation of piping for Part of Process Piping System, a) Solvent System Piping b) Emulsion System Piping Abbreviations EMPLOYER: Refers to Asian Paint Company is the party which initiates the project and ultimately pays for its design, supply and construction. ENGINEER: Means Tebodin, the Engineering and Consultanoy firm. CONTRACTOR: MEP Contractor selected by EMPLOYER to perform supply, fabrication, erection, inspection, testing and commissioning of piping, valves and fitings and performs duties specified by the engineer.13 14 18 Spetfetan fo Png Ertan (rer numer 6€T 36012, enue umber 2665100 Page 3/16 BiLFINGER CONSTRUCTION MANAGEMENT: Person who is appointed by the EMPLOYER to work as the EMPLOYER's agent in the construction work, preparing bidding documents and contract documents, arranging construction contracts, and managing the contractors so that all work on the project is completed on time and within budget, in accordance with contractual agreements. awac ‘The CONTRACTOR shall comply with the QA/QC agreed plan for the project ‘The Contractor may have a preference to use his own QA/QC system. If so, approval of the Construction Management and QA/QC coordinator is required. ‘The Contractor shall assign a full time QA/QC coordinator for the project. Contractor's CO-ORDINATOR shall fulfl the responsibilities and tasks which are stated in the agreed QN/QC plan, NDE (Non Destructive Examination) activities shall be executed by the CONTRACTOR under the supervision of CONSTRUCTION MANAGEMENT. Safety, Health and Environmental ‘The Contractor shall assign a full time SHE coordinator for this project, Contractor's CO-ORDINATOR shall fulfil the responsibilities and tasks which arise from this plan. Piping ‘The scope of work for the piping includes, but is not limited to ‘© Receiving of materials on SITE: ‘© Unloading, handling and SITE transportation of piping materials; ‘+ Fabrication, erection, testing, inspection and cleaning of the piping systems; ‘+ Supply and fabrication of pipe supports: ‘+ Mounting of all tems on equipment (level gauges, safely relief valves, blind flanges, etc.). This is not applicable to package units; ‘+ Mounting of on- and in-line instruments; + Supply of pining materials (if not supplied by EMPOYER); ‘+ Store keeping, administration and reporting of received materials; * Removing of protective coatings and all cleaning necessary at SITE prior to fabrication and erection ‘+ Painting of all carbon stee! piping. + Installation of pipe sleeves. * Pickling and passivating of stainless steel pipes.Pr Tevodin inoness Spacicatin far Para Erection Document umber 2683100 Revion’A BiLFINGER 1.6 Miscellaneous activities The scope of work include but is not limited to the following e.g. ‘+ Obtain all required permits on materials, construction, safety, ete.; ‘© Supply, install, maintain and remove scaffolding; ‘+ Supply of construction materials and consumables; «Supply of equipment and tools for erection; + Provide continuous clean-up of the construction area; + Remove waste materials; + Temporary facilites, storage area, shops, etc.; + Lighting of working areas in the buildings; + Administration, + Scheduling: ‘+ Co-ordination of subcontractors and with other main contractors; ‘+ Supply of quality and material control documents; + Supply of detail work schedules and progress reports + Maintain material Status Records (by computer); ‘+ Maintain all materials in good condition until the WORKS are accepted by EMPLOYER / CM; ‘+ Assistanoe during start-up: + Activities as mentioned in the General Conditions of Contract; 1.6.1 Cover plates ‘The scope of works consists of + Supply of materials, fabrication and erection of cover plates as required to seal openings/penetrations in floors and walls for piping erected by CONTRACTOR, as directed by ENGINEER. 1.6.2 Floor & Wall penetrations ‘The scope of work consists of + Marking of additional required openings on walls and floors or supply accurate dimensional sketches {for these openings for driling of holes see para. 6 + closing of the openings around the pipes on wall- or floor penetrations by means of cover plates (see 1.6) and rock woo! c.g, foam materials or sleeve plugsPr Tevodin donee BiLFINGER 2 SCOPE OF DESIGN 24 Scope of design by ENGINEER Documents supplied by ENGINEER ‘The ENGINEER will provide the following documents: ‘© Symbols and abbreviations for P&ID' ‘Piping: and instrument diagrams for process & utilities; + Equipment location plans; © Line list; + Isomettics; + Piping plans, details & sections; + Pipe supporting (partly); ‘+ Specification for piping material ‘© specification for Insulation and tracing ‘© specification for painting and labelling; 22 Scope of design by CONTRACTOR 2.2.1 General The CONTRACTOR shall prepare: * Alldocuments, not supplied by the ENGINEER but required for the correct administration, fabrication {and erection up to- and including mechanical completion, of all the piping systems, equipment and required accessories. + Detailed planning of CONTRACTOR and SUB-CONTRACTORS activities; © Meeting reports + Alldocuments, not supplied by the ENGINEER but required for the correct administration, fabrication and erection of the piping systems © Quality, Health, Safety and Environment plan QHSE. In this plan Contractor will analyse the risks and the taken precautions * QA(QC plan, including documents with equipment setting and alignment records. = QA/.QC documents ~ Manufacturing / data book.Page 616 22.2 22.3 2.2.4 BiLFINGER Documents to be supplied by the CONTRACTOR ‘As a minimum the following documents shall be submitted by the CONTRACTOR for approval by the Construction Management, and subsequently fled per piping system in proper files, + Welding procedures ‘+ Welders qualification certificates «Hydrostatic test diagrams & schedules. + ‘As built’ drawings. + Shop Drawing + Pipe support drawings. + Approval documentation as is required by the Authorities (fire, gas ete.) + Material certificates .mP As built drawings ‘The CONTRACTOR shall keep a record of all deviations from the documents supplied by ENGINEER during the execution of the WORKS. For that purpose a set of marked-up prints of drawings mentioned below shall be kept in the SITE office of the CONTRACTOR. At the end of the project these marked-up prints shall be submitted to the Construction Management for approval. Drawings to be marked-up with ‘as built’ information: + PRID's; + Piping drawings; ‘+ Equipment location plans. Colours to be used for marking-up: + Yellow = correct, no change + Red = remove, delete * Blue = addition, change + Green = remark, note Pipe Supporting Pipe supporting shall be in accordance with the Pipe Support specification prepared by CONTRACTOR.34 344 3.2.2 Pr Teboin indonese Specicabon png Econ Revs & BiLFINGER SCOPE OF SUPPLY ‘Scope of supply by the ENGINEER / OWNER Documents The following documents will be free issued by the ENGINEER to the CONTRACTOR: ‘+ Engineering documents as specified in “Scope of design by the ENGENEER’. Piping drawings will be made available during the execution of the project. ‘Scope of supply by CONTRACTOR Documents + CONTRACTOR shall supply all documents as specified in para. 2.2.2 in accordance with the requirements as specified in the CONTRACT. Materials The materials to be supplied include but are not limited to the following: * Consumables such as welding electrodes, wires, rods, gases, thread guard. + Supporting materials incl. bolts, nuts ete. to fix supporting + Spool pieces for all in line instruments and control valves, if required + Anyoother material to allow testing of al piping systems. ‘+ In general all material required for a successful execution of the work described in this specification but not free issued to CONTRACTOR. + Allbolts, nuts and gaskets. + Materials for cleaning of applicable piping systems. + Allflange insulation sets. + Allcarbon steel pipes and fitings will be supplied without a prime coatPr Tebedn indonesia 4 a4 42 43 43.4 BiLFINGER MATERIALS Piping ‘+ Piping layout as shown on the contract drawings are generally diagrammatic, and indicative, Run and arrangement of piping shall be as indicated or as in approved shop drawings. Piping shall be arranged for maximum accessibility for service and maintenance while avoiding conflict with the work of other trades. The Contractor shall be cognizant of the necessity to coordinate and cooperate with other trades to expedite the works. All pipes shall be cut accurately to actual dimensions at site, and shell be erected into place in an appropriate manner. Inside of valves, fittings and section of pipe shell be inspected and thoroughly cleaned before installation. Pipe and equipment openings shall be closed with plug, cap or other means to protect against foreign matter during installation and storage. Care shall be taken during installation to properiy ream the ends of pipe to prevent reduction in the cross sectional area of the pipe being cut. For screwed fittings, the left over pipe threads shall be painted immediately after thread engagement. Pipe lines shall be adequately supported in an approved manner. ‘+ Any material to be supplied by the CONTRACTOR shall be in accordance with the specifications and documents of this specification. If certificates cannot be made available, the CONTRACTOR shall provide small samples of all materials to the CONSTRUCTION MANAGEMENT for test & acceptance. Costs for tests are for account of the CONTRACTOR. + Incase any material supplied by employer is not in accordance with the specification or is not properly identified, the CONTRACTOR shall inform the CONSTRUCTION MANAGEMENT. immediately. + Allpiping materials required for the execution of the WORKS, shall be supplied by CONTRACTOR in accordance with ENGINEER's specs, Pipe Classification Pipe Classification shall be specified in piping material specification 2981100. Pipe Fittings Welded Fittings Elbows, tees, laterals, reducers in CS pipes shall be carbon steel butt-welded fittings or socket weld for small bore conforming to ASTM Standard A234 ANS! 816.9. Elbows, tees, laterals, reducers in SS pipes shall be stainless steel butt-welded fittings conforming to ASTM Standard A312 ANSI 816.9. Shaped ‘welded fittings for 2 sizes smaller-than-main branch take-offs under trade names of Weldolets,Speateabnior bang Econ Sear nantr ear '2 Document number: 2683100 DA Page 1116 BiLFINGER Threadolets, may be used. Horizontally installed reducers shall be of eccentric type to completely drain the pipe content, 43.2 Flanges Flanges shall be used as per piping material specification 2981 100. 4.3.3 Screwed Fittings 4a 45 Screwed fittings shall be used as per piping material specication 2981 100. Gaskets Gaskets shall be used as per piping material specification 2981100, Hangers, Saddles, Anchors, and Clamps All piping shall be securely supported. Horizontal runs of piping shall be supported by adjustable clevis type hangers and solid rods securely attached to building structure. Where several pipes run parallel, trapeze hangers may be used in lieu of separate hangers. For pipes run near the floor, pipe stanchions with base flanges and adjustable top yokes or pipe roller supports set on concrete pads may be used as appropriate. Steel brackets of approved design may be used for pipes run close to wall. A single clamp may be used for small pipes, 1 14" and smaller. Pipe hangers or supports shall be spaced not over 1.50 meter apart at heavy fittings and valves, 0.90 meter from the ends of each run out and not over 0.30 meter from each change in the direction of piping in other locations pipe supports shall be spaced as follows: Nominal Pipe Size (in} Maxi n 1 2.00m 1% 2.00m 2 2.50m 2% 2.50 3 3.00m 4 3.50. m 6 and above 600m All adjustable hangers and supports shall provide for 2 in. of vertical adjustment.46 a7 48 49 Soucstomn for Pana Ertan Ordernaoer 6¢T980'2 Docume mer 2685100 Page 12/76 BiLFINGER Vertical Piping Supports Vertical piping shall be guided or supported in the centre of each riser but not over 5.00 meter on centre and shall be supported at the base of the riser on a base elbow or tee with pipe stand. Where more than one vertical pipes is installed in close proximity to other vertical piping, approved guides may be provided. Guides and spacers of approved structural steel design shall be securely welded and anchored to place. Pipe Line at Crossings Crossings at walls, beams and ceilings Sleeves with inside diameter of no less than 1 inch larger than the outside diameter ofthe pipe shall be provided where pipes are to pass through concrete walls, beams partitions and ceilings. The space between pipe and sleeve shall be packed with elastic material and made watertight. Escutcheons of approved material and design shall be used for pipe passing through wall exposed to public area. Pipe Installation Pipe length shall be cut accurately for neat installation. Certain allowance shall be provided for positioning pipe to specific location and/or equipment. No pipe tension after connection shall be predetermined Valves Valves shall be used as per Specification Piping material 2981100. FABRICATION + For the extent of pipes to be fabricated, see the relevant P&ID's and Piping drawings for this CONTRACT. + Prior to prefabrication the CONTRACTOR shall site check dimensions, if required the findings shall be implemented in the piping plans after consult with the Construction Management. CONTRACTOR shall apply sufficient field welds and make-up length in order to allow for minor deviations in dimensions. * All carbon steel piping shall be fabricated in accordance with the requirements of specification No. 2981100. The extend of X-ray will be as follows: ~ Steam, condensate and gas piping: 10% of the welds; = Remainder of the steel welded piping: 5% of the welds; + No fabrication shall be started until shop drawings have been approved by the Construction Management.Spectcaln or Ping Erection Owier amber AT¥8912 Docamert bar 2683100, Page 19116 BiLFINGER + All material to be used for the fabrication shall be sound material, new and unused and without defects, * No production welding shall be commenced until the welding procedures proposed have been approved by the Construction Management. Filler materials, electrodes, fluxes and other significant welding materials shall be the same as those used in the procedure and qualification tests. + Welders and X-ray identifications must be clearly marked on the pipe spools and/or-pipes. All welding Con pipes shall be executed by welders in possession of a welder's qualification certificate valid for the type of weld concerned ‘© Prior to fabrication CONTRACTOR shall consult the materials status report for the availabilty of piping materials. + Degreasing Before the installation of piping, valves and in-line instruments, CONTRACTOR shall make sure that all lubricating fatty substances and conservation oils are removed from the surfaces they cover CONTRACTOR shall ensure that all piping subjected to degreasing shall be subsequently stored and ‘erected under dust free and grease free circumstances, particularly with respect to inner piping surfaces and flange contract face surfaces and flange contact face surfaces. WELDING The connections between components of the not galvanized piping (tubes and parts) will be obtained by electric welding, with inert gas or submerged arc welding, and will be executed by qualified welders; the welders can be qualified according to ASME-section IX standards Welding Processes Previous to the beginning of welding operations, a detailed description of the welding processes that will be adopted shall be presented to the management, in agreement with Section IX of the Weld Qualifications of ASME Code. For the submerged arc processes, gas or tubular electrodes, the indications established by AWS-SR-1 will be accomplished. The welding records, done for registration of the adopted welding processes, shall follow the patterns determined by the management. The qualification of the welding processes will be determined by specialized laboratories, indicated by the management, through examination of test specimen. The tests shall be executed in site, under real work conditions. The test specimen willbe supplied in all the cases, in the necessary amount, and executed in the presence of a management delegate. The tests can be repeated in any phase of the works, whenever the management judges necessary.62 63 64 Order mambar eT1S2 Docoment mmber 2685100 Page 14/76 BiLFINGER ‘The qualification doesn't impede the change of the welding process, as long as this is submitted for new approval, Previous Adjustments a) The tubes and special parts to be welded shall be positioned and dotted in order to warrant a uniform spacing over the whole circumference: the welding is not allowed to be completed on only one side, and after a while be continued at the other side. b) For position welding, the tubes can be rotated, at low speed, on pneumatic rolls, supported by the not covered locals of its extremes. ©) For the alignment of the piping the welding to an auxiliary devices tube won't be allowed, manual align must be used. The management can authorize the use of another device projected for this purpose d) The extremes of the tubes will be bevelled, and the surface of the bevel that receives the weld, must be cleaned of any paint, rust or strange particles and be inspected for battering or other harmful factors Cuts in Piping lf necessary cuts will be made in the tubes or parts, it shall be take care in order to avoid damages to the internal or external linings, all slag must be removed, and a new bevel must be made according to the established patterns. The finished surface shall become perfectly smooth, For the oxyacetylene cutting, an appropriate group of flame cutters must be at hand; the use of a gas generator Is forbidden at site. Welders’ Qualification a) Each welder must be qualified for a specific function, not considering that the manual welder ‘is necessarily, qualified as operator for automatic welding and vice-versa. b) The management will accompany the welders’ qualification that will be realized with the material to be indeed applied in the work, with an electrode of largest diameter. c) The same requirements will be applied for the operators of automatic equipment's. 4) All welders must be appropriately equipped with protection masks, aprons, suede sleeves and leggings and gloves or leather, soft and flexible. }) When the joint is x-rayed, this information must be reported.65 Revision: A a" 2 BiLFINGER Electrodes and Weld Equipment The welding electrodes and the additional materials must be to the classification ASTM-A-223, class E- 6010 and E-6011. The electrodes shall have the dimensions recommended by the tube manufacturer for each pass or according to qualified processes. For storage the elements shall be kept in dry cabinets, with 2 minimum capacity for 60 kilograms of electrodes. ‘The electrodes considered inadequate, as well as the remaining pieces, shell be pioked up in appropriate recipients and removed outside of the service places. The welding equipment must assure the indicated current for welding, ensuring the arc stability. The equipment must be provided with an instrument panel for direct reading of current and tension, and with command and control reversing switches. All feeding cables of the electrode case shail be flexible and dimensioned for the outdoor works. The respective thickness of the cable must assure that tension falls an efficient earth connection must be implanted, for the electrode case cable system, and for the earth terminal of the pieces that shall be welded. The earth cable type and the type of the electrode case feeding cables must be of the same. ERECTION © CONTRACTOR shall be aware of the fact that other contractors may be working in the same area at the same time. In order to avoid interference with others, CONTRACTOR shall make himself acquainted with the work schedule of other contractors, (See also General Conditions of Contract) + Stainless stee! piping materials shall be stored under cover and not permitted to be in contact with the ‘ground andior carbon steel piping + Hot pipes shall be installed in such a way that after erection: Pipe shoes of hot pipes, moving as a result of expansion do not fal off the supports, # Allin- and online instruments such as control valves, flow meters, orifices, thermo-wells, etc. shall be installed by the CONTRACTOR. Installation shell take place in accordance with the instructions of supplier and the Construction Management. * Burning and welding to steel structures is not allowed. Any drilling ‘approval of the Construction Management prior to execution. steel structures needs the * Driling in the concrete floors, walls etc. need the approval of the Construction Management. Holes larger than 50 mm have to be drilled by the civil CONTRACTOR for the account of the EMPLOYER. + Inall suction pipes to pumps temporary strainers shall be provided and installed by the CONTRACTOR for the start-up period, + Profiles to be used for pipe supports may be cut, provided they will be finished by means of grinding, Notches shall be obtained by two cuts ending at a drilled hole. Cutting of plates, sheets, flat bars andPr Teboin indo ‘Specfcaion or Png Ereton BiLFINGER angle profiles is permitted for bolted constructions of parts up to 16 mm thickness. Resulting burrs shall be ground fat. + Crevices and openings between foot plates etc. of pipe supports and floors shall be suitably sealed to avoid contamination + All openings in walls, ceiling and floors for piping shall be sealed. + Incase a modification is required to free issue piping material, CONTRACTOR shall submit before any change is made his proposal for the execution of the work to the Construction Management. INSPECTION AND TESTING ‘+ Inspection and testing shail be carried out in accordance with the approved Project Quality Plan and ITP + CONTRACTOR shall prepare are hydro test schedules. Construction Management shall approve test schedules prior to testing ‘+ Forall lines to be tested, the test medium and the test pressure to be applied will be indicated in the line list * CONTRACTOR shall supply all necessary hydrostatic vent and drain connections in the piping systems to be tested + Lines and systems which are open to the atmosphere such as drains and open safety valve discharge lines do not require testing. * Equipment shall be isolated from the systems to be tested by means of installing spades or blind flanges. * Control valves andlor other sensitive instruments shall be isolated from the tests, spool pieces may be installed * All required test water will be supplied by EMPLOYER. CLEANING + Nodirt or foreign matter shall be left behind within the systems + Systems shell be drained entirely after testing ‘+ Safe and efficient disposal of hydro test water shall be the responsibilty of the CONTRACTOR, and to the satisfaction of the Construction Management. ‘+ In order to avoid any possible contamination of the soil, itis required that all liquids (passivating liquids, degreaser, etc.) used during piping installation are collected and removed from SITE to an appropriate treatment facility. ‘+ Subsequent to testing and prior to commissioning, CONTRACTOR shall execute any necessary work for the satisfactory hook-up of piping within his scope to piping provided by other contractors.