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LNG Plant Project
Specification for Fabrication and Erection of
Pipework
157883-000-PI-SP-0007 Revision 1
INPUTS
Document Number Title Status
B1 Incorporation of relevant data from the above KBR document is included in this
Specification. For welding requirements refer to Welding and Non Destructive
Examination of Piping 157883-000-MW-SP-0006.
D1 General update + Client comments incorporated see bar on right side of page
D2 Abbreviations DPE and MPE changed to DPI and MPI see bar on right side of
page
0 References to Super Duplex pipe added see bar on right of page
1 Para 6.4 revised in accordance with Site request with PNLG site QC approval
Note: The latest version of this document is stored in EDM. Any prints of this document are
uncontrolled.
Contents
1. INTRODUCTION................................................................................................................... 5
1.1 Purpose....................................................................................................................... 5
1.2 Definitions .................................................................................................................. 5
1.3 General Abbreviations............................................................................................... 5
1.4 Scope .......................................................................................................................... 5
1.5 Order of Precedence.................................................................................................. 7
1.6 Codes and Standards ................................................................................................ 7
1.7 Contractors Responsibilities .................................................................................... 9
2. DESIGN DRAWINGS ........................................................................................................... 9
3. MATERIALS ....................................................................................................................... 10
3.1 Transfer of Material Identification .......................................................................... 11
3.2 Marking Technique .................................................................................................. 11
4. FABRICATION ................................................................................................................... 12
4.1 General...................................................................................................................... 12
4.2 Cleanliness of Components.................................................................................... 12
4.3 Carbon Steel/Stainless Steel Cross Contamination ............................................. 12
4.4 Spool Fabrication..................................................................................................... 12
4.5 End Preparation and Cutting .................................................................................. 12
4.6 Fabricated Lengths.................................................................................................. 13
4.7 Staggering and Spacing of Welds.......................................................................... 13
4.8 Field Fit Welds (FFW) .............................................................................................. 13
4.9 Flanges ..................................................................................................................... 14
4.10 Reinforced Branch Connections ............................................................................ 14
4.11 Tolerances (Refer to Figure 1) ................................................................................ 14
4.12 Non Pressure Attachments..................................................................................... 14
4.13 Fit Up and Alignment............................................................................................... 15
4.14 Threading.................................................................................................................. 16
4.15 Bends ........................................................................................................................ 16
4.16 Circumferential Welds ............................................................................................. 16
4.17 Fillet, Socket and Seal Welds ................................................................................. 16
4.18 Galvanizing............................................................................................................... 17
5. SUPPLEMENTARY FABRICATION REQUIREMENTS .................................................... 17
5.1 Austenitic Stainless Steel ....................................................................................... 17
6. TREATMENT AFTER FABRICATION AND ERECTION. .................................................. 18
6.1 Cleaning and Flushing ............................................................................................ 18
6.2 Flushing .................................................................................................................... 18
6.3 Pressure Testing...................................................................................................... 18
6.4 Marking ..................................................................................................................... 18
6.5 Protection for Shipping and Handling ................................................................... 19
7. FIELD RUN PIPE LINES .................................................................................................... 19
8. PAINTING AND PROTECTION.......................................................................................... 19
8.1 Painting..................................................................................................................... 19
8.2 Protection from Blast Cleaning and Painting........................................................ 20
9. INSTALLATION OF PIPEWORK ....................................................................................... 20
9.1 General Requirements............................................................................................. 20
9.2 Pre-installation and Assembly Inspection............................................................. 20
1. INTRODUCTION
1.1 Purpose
This Specification defines the minimum requirements for the fabrication and installation
of Metallic pipework for the Peru LNG Plant Project.
1.2 Definitions
For the purpose of this Specification the following definitions shall apply:
“The COMPANY” Peru LNG (Client)
"The CONTRACTOR" is CB&I .
"The VENDOR is the supplier of the equipment described in this
specification. The Vendor may or may not be the
manufacturer of all the equipment specified
The words 'will', 'may', 'should', 'shall' and 'must' have specific meanings as follows:-
'Will' is used normally in connection with an action by the Contractor
'May' is used where alternatives are equally acceptable.
'Should' is used where a provision is preferred.
'Shall' is used where a provision is mandatory.
'Must' is used only where a provision is a statutory requirement.
1.4 Scope
This Specification together with the purchase order, P&ID's, drawings and referenced
specifications, details the minimum technical requirements and working practices
required for the fabrication, installation and pressure testing of process and utility
pipework designed to ASME B31.3 which is the primary project standard, and is to be
used in its entirety except as modified by the requirements of this specification.
This Specification does not cover the requirements for welding, heat treatment, welding
inspection and NDE, these are covered by Ref Doc (2) in Sect 1.6.6.
This document shall be read in conjunction with all documents referenced in Sect 1.6.6
Drawings and documents specifying all the fabrication, installation and testing
requirements will be produced prior to commencement of fabrication.
This specification applies to work carried out at the Peru LNG Construction site location
or any remote shop facility that may be used, this applies to the following groups of
materials
• Carbon and carbon manganese steel.
• Austenitic stainless steel
• Nickel Alloy steel
• Super-Duplex Stainless Steel
Any changes to the design of pipework for whatever reason shall be agreed with the
relevant Site Engineer. The Engineering department will be consulted when necessary;
the details of the change will be recorded.
1.4.1 Inclusions
The scope of work shall be as follows:-
• Fabricate, install, and pressure and leak test all pipework shown on the piping
drawings and isometrics.
• Fabricate and install pipe supports in accordance with the pipe support
specification and all data sheets and drawings.
• Locate field welds, field fit welds and piece mark numbers.
• Locate drill and tap flanges for jackscrews, for spectacle blinds, and blinds and
spacers, where indicated on Piping Drawings and Isometrics.
• To install all special piping items.
• To install inline instrumentation such as control valves, orifice flange sets,
valves, etc.
• Flushing and cleaning all pipework in accordance with Ref Doc (4) in Sect 1.6.6
• Hydrostatically pressure test all pipework in accordance with Ref Doc (6) in Sect
1.6.6
• Pneumatically pressure test all pipework in accordance with Ref Doc (5) in Sect
1.6.6
• Surface protect and paint in accordance with Ref Doc (9) in Sect 1.6.6
Any conflicts and discrepancies between the requirements of this specification and the
related Codes, regulatory bodies and national standards found by the Contractor shall
be brought to the attention of Company representative immediately. The Company
decision regarding the resolution of any such conflict will be final.
1.4.2 Exclusions
The following piping shall be excluded from the scope of this specification;
• All instrument control piping downstream of the first or second block valve.
• All heating, ventilation, air and water services within buildings unless otherwise
2. DESIGN DRAWINGS
The Contractor’s engineering department will furnish piping detail drawings both
orthographic and Isometric type. Other drawings or standards showing typical details
will also be provided as applicable to identify the full scope of work.
The detail drawings will contain all the relevant dimensions for fabrication, together with
a matching bill of materials. The dimensions shown on the Isometric or detail drawings
will be the "actual true" dimension, with no allowance for weld gaps.
No allowance for gasket thickness is necessary, except as dimensioned on drawings.
The following abbreviations will be used on Fabrication isometrics:-
3. MATERIALS
The Contractor will furnish all materials listed in the contract documents.
The Contractor will off-load, inspect, store and control all materials.. Each specific
material type shall be stored in a separate area.
All materials supplied will be in accordance with the Piping Material Classes and
Material Data Sheets, and be fully supported with the appropriate certification. If
materials are supplied directly to site for any reason they shall also comply to project
specifications.
Substitution of materials by the Contractor shall be approved in writing by the Company
before commencement of fabrication.
The Supply of all necessary materials and equipment to enable flushing, cleaning and
pressure testing to take place shall conform to project specifications.
Carbon steel stamps shall not be used on stainless steel or Super Duplex stainless
steel materials
Paints containing metallic pigment such as zinc or aluminium shall not be used on
stainless steel and non-ferrous materials.
4. FABRICATION
4.1 General
The fabrication of pipework shall be carried out in accordance with ASME B31.3, and
this specification.
All pipework, fittings and flanges shall have the proprietary protective coating removed
to at least 50 mm from the pipe cut end prior to welding.
The weld preparation on the ends of pipe and fittings shall preferably be formed by
machining. Other methods may be used, such as thermal cutting or grinding provided
that a smooth correctly contoured surface is obtained, free from tears, slag or scale
and the end is suitable for welding.
Weld joint preparation shall be in accordance with ASME B31.3 para 328.4 or ASME
B16.25.
4.9 Flanges
Flatness of gasket faces. Flange gasket faces shall not be concave. Convexity of
flange gasket faces shall not be greater than 0.4mm across the outer diameter of the
gasket face. This should be checked prior to welding.
All flange bolt holes in vertical piping shall straddle the Plant North-South centre lines,
and all flange bolt holes in horizontal piping shall straddle the horizontal centre lines,
unless specified otherwise on the Isometric Drawing.
The fabrication of orifice flanges shall receive special attention to ensure that the
pressure tappings are positioned as shown on the Isometric Drawing, and that the pipe
bore is smooth and free from projections at the flange to pipe weld. The pipe to flange
weld in the inside of the pipe can be ground smooth and flat to the inside profile of the
pipe if necessary, but must not be under cut.
Slip on type flanges if permitted shall be fully welded inside and outside.
Flanges for shop fabricated spools that are to be supplied loose for site positioning and
welding, shall be tack welded to the end of the fabricated length.
The following procedure shall be adopted for doubler plate fillet welds crossing
circumferential or longitudinal pipe butt welds;
The longitudinal pipe seam weld should be 100% RT certified by the pipe vendor.
Documentation should be checked prior to proceeding.
Circumferential butt welds shall be RT and cleared before proceeding.
Doubler plates shall be of the same material and thickness as the pipe, and cover a
minimum of 90º of the pipe circumference. Details of typical doubler plates can be
found in the Pipe Supports Standards Ref Doc. (8)
All doubler plates shall be provided with one drilled hole. The hole shall be positioned
centrally in the plate and shall be filled with a waterproof mastic after attachment.
The doubler plate shall be located as centrally as possible over the butt welds. Mark
the positions on the pipe where the fillet welds will cross the pipe butt welds. These
areas shall be ground smooth for the width, plus 10mm each side, of the proposed fillet
welds. The grinding is only required to smooth the profile of the butt weld and to
remove all surface imperfections. Do not grind below the surface profile of the pipe.
The ground areas shall be inspected for faults using DPI or MPI.
To get the attachment plate to sit tight onto the pipe, the plate can be ground away
locally on the underside to fit over the butt weld profile. The attachment plate shall be
fillet welded in position using full fillet welds all round.
Welding preheat as required by the approved welding procedure shall be maintained
during welding of the attachment to carbon steel pipes.
On completion of welding, 100% MPI/DPI of all affected welds shall be performed,
paying particular attention to the weld crossing points.
Where miss-match of the bores results in misalignment greater than stated above, this
shall be corrected by taper or counter boring, rolling or drifting in accordance with
ASME B31.3. Care shall be taken to ensure that the wall thickness after alignment is
not reduced below the minimum wall thickness including corrosion allowance, specified
in the Piping Material Specification.
4.14 Threading
Unless specified otherwise on the design drawings, all threads shall be 'Taper' to
ASME B1.20.1 and concentric to the outside of the pipe. All threading shall be carried
out after forging or heat treatment but where this is not possible suitable thread
protection must be provided.
Where threaded flanges are specified, the pipe shall terminate 1.5mm short of the face
of the flange.
Threaded joints that are to be 'seal welded' shall be made up dry (without thread
compound or tape).
The use of worn or damaged dies for thread cutting will not be permitted. Under sized
or damaged threads shall be rejected.
Proprietary thread cutting lubricants shall be utilised.
Care shall be taken to ensure that the correct number of threads enter each fitting and
that the fitting does not bottom either on the end of the pipe or on the 'wash-out thread'.
Jointing compounds and thread sealing pastes shall be a PTFE base and the
manufacturer's temperature limitations shall be observed for these products.
PTFE tape shall not be used in threaded joints.
Any excessive wrench markings on pipe and fittings due to joint making shall be cause
for rejection.
Exposed pipe threads and acceptable wrench markings on pre-galvanised pipe and
fittings, can be repaired using cold galvanizing. The exposed threads shall be
degreased, and the damaged areas smoothed, followed by wire brushing to ISO 8501-
1 Grade St 2 followed by two coats of two pack zinc rich epoxy coating..
4.15 Bends
All changes of direction shall be made using standard bends as specified in Ref Doc
(1) in Sect 1.6.6, and as shown on design drawings.
Care shall be taken during the assembly of socket weld joints to ensure there is a
1.5mm gap between the end of the pipe and the bottom of the socket in the fitting.
Where seal welding of threaded joints is required by the Piping and Valve specification,
these shall be carried out by qualified welders using Project approved qualified
procedures. No thread compound or lubricants shall be used when assembling these
joints.
4.18 Galvanizing
Where specified in the piping specifications, pipework 2”NB and below shall be
supplied in the galvanized condition and shall be of threaded construction. All threaded
components will be galvanized un-assembled.
Galvanizing items supplied will conform to the requirements of ASTM A153 and project
document Ref Doc (9) in Sect 1.6.6. In the event of damage to the zinc coating after
galvanizing, small defects may be renovated by using cold galvanizing. This must be
carried out strictly in accordance with the requirements specified in Ref. Doc (9) in Sect
1.6.6
6.2 Flushing
Where specified on the design drawings, all erected pipework shall be flushed and
cleaned. Ref Doc (4) in Sect 1.6.6
6.4 Marking
Fabricated parts requiring trial shop assembly shall be match marked with white paint
to facilitate erection. Throughout the fabrication process each pipe shall carry the
identification marking.
All fabricated pipe spools shall be marked with the spool and area numbers assigned to
them by the isometric drawings. All markings shall be applied after the application of
any permanent protective coatings.
Pipe spool identification markings shall be clearly written on the pipe using an alkyd,
brilliant white colour paint, in two places at diametrically opposite sides and on one
tough plastic tag plate secured to the spool piece with 2 tough electrical wire ties or
straps.
The use of die-stamping, scratching, etching or bead welding for pipe identification
marking shall not be permitted. (see section 3.2)
In the event that temporary identification markings are required during cleaning,
painting or a similar operation, marking shall be die stamped on a metal tag to be
securely wired to the fabrication. The temporary tag shall be replaced with the more
permanent markings as above when the work has been completed.
Austenitic or super duplex stainless steels shall not be marked with crayons or paint
containing sulphur, zinc, lead, aluminium, or compound sulphur. Use of tin or any other
elements likely to cause intergranular penetration or cause other deleterious effects
during fabrication or at the service temperature are prohibited
All postweld heat-treated (stress relieved) spools shall be clearly marked ‘HT’ on the
identification metal tag.
On each weld on each pipe spool that has been radiographed, the radiographic zero
point shall be clearly marked.
In addition to the pipe spool identification, the welder’s identification reference shall be
marked.
8.1 Painting
Pipework shall be painted and coated in accordance with Ref Doc (9) in Sect 1.6.6
9. INSTALLATION OF PIPEWORK
In-line instruments, e.g. orifice plates, control valves, etc., shall be installed under the
direction of the Site Engineer, taking account of flushing and testing requirements.
In-line items removed for testing or other proprietary items awaiting installation shall
be protected during fabrication, in accordance with the Manufacturer's Instructions.
9.7 Bolting
Care shall be taken to ensure that all bolting materials and types used are in
accordance with the service requirements as specified on individual material
specifications the Piping Classes and as detailed on the piping isometrics.
All flange bolting shall be checked for correct grade and that they are free from damage
to the bolt/nut and any coating prior to fitting.
Nuts and studs shall be easily assembled by hand, over tight threading shall be
rejected.
All flange bolting shall be free to move through mating flanges holes in a plane at right
angles to the flange face and parallel to the pipe run.
Each stud bolt shall be assembled with a projection of between 1 and 2 1/2 full threads
beyond the nut at each end. This does not apply when bolt tensioning equipment is
being used. Refer to Ref Doc. (14)
All nut bearing faces, bolt and stud bolt threads shall be coated with colloidal
molybdenum disulphide or an equal lubricant immediately before being assembled to a
flange joint. The lubricant type must be agreed with the supplier of any bolt
torquing/tensioning equipment.
Construction shall check bolting for tightness and correct tension on completion of
pressure testing.
Bolt pre-tensioning equipment is normally be used to tighten all bolting of 1 1/8"
diameter or larger. The bolt tensioning equipment manufacturers instructions must
followed and tension loads shall be calculated using approved calculation charts and
data from the Ref Doc (14) Torque/Tensioning
The hiring of necessary pre-tensioning equipment and/or expertise for bolt tensioning
shall be determined by Construction personnel as considered necessary
Flogging up of nuts shall not be permitted and use of the correct torque equipment is
mandatory.
11.1 General
Only pipe supports of the type specified in the design and piping drawings shall be
used. See Ref Docs (7) & (8) in section 1.6.6.
11.2 Fabrication
Pipe supports shall be fabricated in accordance with the project pipe support design
specifications Ref Docs (7) & (8) in section 1.6.6.
Pipe supports shall not be welded to the pipe line unless specified in the design and
piping drawings.
Pipe support elements, which are welded directly to the pipeline during the fabrication
of the pipe or pipe spool, shall be in accordance with section 4.12 and Ref Doc (2) in
Sect 1.6.6
Non-pressure attachment fillet weld details shall be as detailed on the pipe support
drawings.
11.3 Installation
Pipe supports shall be installed in accordance with the project pipe support design
drawings.
During installation force shall not be used to align pipes to support locations, the
support shall be adjusted or packed to meet the pipe position and with the correct
clearances where specified on the support drawing.
Permanent pipe supports shall, where possible, be installed before the erection of the
associated pipework.
Care should be taken to ensure the adequate support of heavy valves and fittings
before the pipework is erected or subjected to pressure test.
13. INSPECTION
All aspects of the work at any reasonable time during fabrication, testing or on
completion should be made available for inspection by the Company, by certifying
agents or quality control representatives.
All pipework shall be fully checked against the design drawings and other related
documents to verify that all dimensions, orientations and sequence of connections or
positions of branches and instrument connections are correct and within tolerance.
Non-compliance with any requirement of this specification may result in rejection of
fabricated spools or sections of erected pipework.
A
Tangent length
B
Max out of plane for
flange face measured
A
A
A
A
X Offset 0.12”
X
A
(3mm) Max
A
measured as shown
0.06” (1.5mm)
A Section XX
A