SALAMANDER ENERGY

(BANGKANAI) LIMITED

REVISION CONTROL SHEET

Rev No Date Description

A 03-Feb-2014 Issued for Review
0 07-Mar-2014 Approved for construction
Z1 07-Jan-2015 As Built
 SALAMANDER ENERGY
(BANGKANAI) LIMITED

DOCUMENT NUMBER TITLE REV DATE PAGES

FABRICATION PROCEDURE FOR SALES GAS Z1 07-Jan-2015 3 of 25

009-BKDD06-4P-013 METERING PACKAGE

COMMENT RESPONSE SHEET

Document /
No. Comment Response Remarks
Page Ref.
 SALAMANDER ENERGY
(BANGKANAI) LIMITED

DOCUMENT NUMBER TITLE REV DATE PAGES

FABRICATION PROCEDURE FOR SALES GAS Z1 07-Jan-2015 4 of 25

009-BKDD06-4P-013 METERING PACKAGE

TABLE OF CONTENTS

1. SCOPE ....................................................................................................................... 5

2. DEFINITION ................................................................................................................. 5

3. REFERENCE DOCUMENT .............................................................................................. 5

4. ABREVIATION .............................................................................................................. 5

5. FABRICATION PROCEDURE .......................................................................................... 5

 SALAMANDER ENERGY
(BANGKANAI) LIMITED

DOCUMENT NUMBER TITLE REV DATE PAGES

FABRICATION PROCEDURE FOR SALES GAS Z1 07-Jan-2015 5 of 25

009-BKDD06-4P-013 METERING PACKAGE

1. SCOPE

This document specifies the Fabrication procedure for sales gas metering package.

2. DEFINITION

The following terms used in this document shall refer to the meanings given below:

COMPANY : Salamander Energy (Bangkanai) Limited (SEBL)

CONTRACTOR : PT. Meindo Elang Indah (MEI)
VENDOR : PT. Yokogawa Indonesia (YIN)
FABRICATOR : PT Mitrindo Dutaprakarsa

3. REFERENCE DOCUMENT
BKDD06-ME-0D-05-002 PID Sales Gas Metering Package
BKDD00-ME-1L-00-050 Piping General Specifications
BKDD00-ME-1L-00-051 Piping Material Specifications

4. ABREVIATION
None

5. FABRICATION PROCEDURE

Fabrication procedure is shown in pages 6 to25

FABRICATION & INSTALATION PROCEDURE Doc. No : 5971-MDP-QC-PR-FI-001
FOR METERING SKID PIPING Rev. No : 1
Date : 06 March 2014
Page : 1 of 20

FABRICATION AND INSTALLATION PROCEDURE

FOR METERING SKID PIPING

DOCUMENT NO.
5971-MDP-QC-PR-FI-001

Page 1 of 20

PT. Mitrindo
Contractor Client Owner
Rev. No Description DutaPrakarsa
Date
Prepared by Reviewed by Reviewed by Approval by

0 Issued for Approval 19.12.2013

1 Re-Issued for Approval 06.03.2014

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Table of Contents
1. GENERAL ......................................................................................................................................................................3
1.1. SCOPE ................................................................................................................................................................................... 3
1.2. DEFINITION OF TERMS ..................................................................................................................................................... 3
2. STANDARDS .................................................................................................................................................................3
2.1. REQUIREMENTS ................................................................................................................................................................. 3
2.2. STANDARDS ........................................................................................................................................................................ 3
2.3. DEVIATIONS ......................................................................................................................................................................... 4
3. DESCRIPTION ..............................................................................................................................................................4
3.1. MATERIALS .......................................................................................................................................................................... 4
3.2. DRAWINGS ........................................................................................................................................................................... 4
3.3. ACCURACY .......................................................................................................................................................................... 5
4. FABRICATION REQUIREMENTS .................................................................................................................................5
4.1. MARKING AND IDENTIFICATION .................................................................................................................................... 5
4.2. TRACEABILITY OBJECTIVES ........................................................................................................................................... 6
4.3. TRACEABILITY REQUIREMENTS.................................................................................................................................... 6
4.4. STORAGE ............................................................................................................................................................................. 6
4.5. CUTTING AND BEVELLING............................................................................................................................................... 6
4.6. END PREPARATION ........................................................................................................................................................... 7
4.7. WELDING PROCEDURES, SPECIFICATIONS AND PROCEDURE QUALIFICATIONS ........................................ 7
4.8. THREADING ....................................................................................................................................................................... 14
4.9. FLANGING .......................................................................................................................................................................... 14
4.10. FIT-UP .................................................................................................................................................................................. 14
4.11. BRANCH CONNECTIONS................................................................................................................................................ 15
4.12. PIPE BENDING .................................................................................................................................................................. 15
5. PROTECTION .............................................................................................................................................................15
5.1. PIPE SPOOLS .................................................................................................................................................................... 15
6. ERECTION ..................................................................................................................................................................16
6.1. IDENTIFICATION ............................................................................................................................................................... 16
6.2. STORAGE AND HANDLING ............................................................................................................................................ 16
6.3. ASSEMBLY/INSTALLATION ............................................................................................................................................ 16
6.4. FLANGED CONNECTIONS .............................................................................................................................................. 17
6.5. BOLTING ............................................................................................................................................................................. 18
6.6. CONNECTION TO EQUIPMENT ..................................................................................................................................... 18
6.7. THREADED JOINTS .......................................................................................................................................................... 18
6.8. TEMPORARY STRAINERS .............................................................................................................................................. 18
6.9. VALVE INSTALLATION ..................................................................................................................................................... 18
6.10. INSTALLATION OF EXPANSION JOINTS ..................................................................................................................... 19
6.11. TESTING OF PIPEWORK ................................................................................................................................................ 19
7. PIPE SUPPORTS ........................................................................................................................................................19
7.1. STANDARD PIPE SUPPORTS ........................................................................................................................................ 19
7.2. SPRING HANGERS ........................................................................................................................................................... 19
7.3. Variable Support Hangers ................................................................................................................................................. 20
8. AS-BUILT DATA AND RECORDS ...............................................................................................................................20
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1. GENERAL

1.1. SCOPE
This Standard covers the minimum requirements and acceptance criteria for:
• Fabrication of piping (both in situ and/or at Workshops as assemblies/sub assemblies).
• Installation.
• Certification and records keeping.

It is to be used together with ASME B31.3 Process Piping, all Government Statutory requirements and
referenced standards.

Should there be conflict between the Works, this Standard, Local Codes, Statutory Requirements or the
latest issue of the Code and other referenced standards, the fabricator shall notify the client in writing for
resolution. In general the most stringent requirement will prevail.

1.2. DEFINITION OF TERMS

Company/Client : Salamander Energy(Bangkanai) Limited (SEBL)
Contractor : PT. Meindo Elang Indah (MEI)
Vendor : PT. Yokogawa Indonesia (YIN)
Fabricator : PT. Mitrindo DutaPrakarsa (MDP)
The Code : “The Code” shall mean ASME B31.3 Process piping.

2. STANDARDS

2.1. REQUIREMENTS
The Fabricator shall perform the Works in accordance with the requirements of:
• The Statutory Authorities.
• The Code and other referenced standards.
• This Standard

2.2. STANDARDS
American National Standards Institute (ANSI)
American Society of Mechanical Engineers (ASME)
ANSI/ASME B16.11 Forged Fittings, Socket-Welding and Threaded
ANSI/ASME B16.20 Metallic Gaskets for Pipe Flanges - Ring joint, Spiral Wounds and Jacketed
ANSI/ASME B16.21 Non-metallic Flat Gaskets for Pipe Flanges
ANSI/ASME B16.25 Buttwelding Ends
ASME Boiler and Pressure Vessel Code
Section V Non-destructive Examination
Section VIII Boiler and Pressure Vessels - Divisions 1 & 2
Section IX Welding and Brazing Qualifications
ASME B31.3 Process Piping

CLIENT SPECIFICATIONS
1. BKD000-ME-IL-00-050 – Piping General Specifications
2. BKD000-ME-IL-00-051 – Piping Material Specifications
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MDP Engineering Standards

1. Protective Coatings
2. Insulation of Piping and Equipment
3. Basis of Design - Piping
4. Inspection and Testing of Piping Systems
5. Piping Material Specifications
6. Valve Specifications for Process Isolation
7. Manufacturers Data Report (MDR) – Plant Projects

2.3. DEVIATIONS
There shall be no deviation from the requirements of this Standard unless previous written approval has
been obtained from the Client

3. DESCRIPTION

3.1. MATERIALS
The piping materials covered in this Procedure are Carbon Steel, Low Alloy Steel and Stainless Steel. .

This Engineering Standard shall be used whenever it is relevant to do so for non-metallic pipework including
PVC, HDPE, ABS, Polypropylene and FRP. All such pipework shall be installed, inspected and tested
strictly in accordance with the manufacturer’s instructions and the relevant Standard.

3.2. DRAWINGS
Piping General Arrangement drawings will be provided showing equipment location and piping configuration.
These drawings shall be adhered to for the erection and installation of pipe spools.

Fabrication of pipe spools shall be in accordance with the Piping Isometric drawings which will be provided
for all lines size DN 50 and above.

Small bore piping DN 40 and below shall be field run in accordance with the General Arrangement drawings.
Pipe support location plans may be provided for complex piping systems but generally pipe supports
will be located on General Arrangement drawings and Isometric drawings. The pipe supports shown
will be a minimum requirement. Additional supports may be required to comply with standards and codes.

Where pipe supports need to be manufactured detail drawings will be provided.

Fabrication of pipe spools and supports shall only commence after issue of Approved for
Construction (AFC) drawings. Subsequent revisions of AFC drawings will supersede all previous drawings
and the Contractor’s procedures shall ensure all fabrication is carried out in accordance with latest revision
of each drawing.
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3.3. ACCURACY
The Fabricator shall verify drawing information and confirm all dimensions before commencing fabrication.

Dimensional tolerances for completed fabricated piping shall conform to the requirements listed on Figure 1.

1. 3mm MAX FROM INDICATED DIMENSIONS

FOR FACE TO FACE, CENTRE TO FACE,
LOCATION OF ATTACHMENTS, ETC
2. 10% MAX (FOR INTERNAL PRESSURE) 3%
MAX (FOR EXTERNAL PRESSURE)
FLATTENING MEASURED AS DIFFERENCE
BETWEEN THE MAXIMUM & MINIMUM O.D.
AT ANY CROSS SECTION.
3. 2mm MAX LATERAL TRANSLATION OF
BRANCHES OR CONNECTIONS
4. 1mm MAX ROTATION OF FLANGES FROM
THE INDICATED POSITION, MEASURED AS
SHOWN.
5. 1mm MAX OUT OF ALIGNMENT OF
FLANGES FROM THE INDICATED POSITION
MEASURED ACROSS ANY DIAMETER.

Figure 1 Piping Fabrication Tolerances

The Fabricator shall ensure the piping meets final assembly requirements as specified on the piping layout
drawings.
Dimensions to tie-in points shall have tolerances in accordance with the following:
A. Linear dimensions + 1.5mm
B. Nozzles orientation and rotation + 0°30’ (Flange bolt holes shall be aligned within 3mm maximum
offset)
C. Angular alignment of flange and branch welding ends 3mm per 1000mm.

4. FABRICATION REQUIREMENTS

4.1. MARKING AND IDENTIFICATION

Items shall be marked for identification and traceability in accordance with Section 4.3. Items marked for
identification shall maintain the marking through all manufacturing stages including final assembly.
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4.2. TRACEABILITY OBJECTIVES

Items and documents shall be marked to ensure means of:
A. Locating the item (traceability record).
B. Locating the quality records generated from purchasing, inspection and testing of the item.

Note:
As a minimum the Fabricator’s system shall enable traceability between the items and quality records.

4.3. TRACEABILITY REQUIREMENTS

Fabrication procedures shall ensure that correct materials are used during fabrication and these shall be
submitted to the Client for approval.

Note: Periodic inspection may be carried out by the Client to ensure compliance.

4.4. STORAGE
The Fabricator shall be responsible for material and equipment received from the Suppliers or warehouse
stocks until the same is installed. Where Vendor supplied materials are delivered to the Fabricator
with documentation such as mill certificates, these shall be incorporated into the quality records.

Materials received are to be stored off the ground on temporary racks or docks to prevent any deterioration
until fabricated.
Pipes, fittings, valves and speciality items shall be suitably blanked to protect the ends from
damage and to prevent entry of foreign material. Flanged openings shall be protected as detailed in
Section 5.1.2.

Stainless steel material shall be kept separate from carbon steel during storage and transport.

4.5. CUTTING AND BEVELLING

Pipe shall be cut accurately to the measurements on the drawings or field fit conditions and shall be worked
into place without springing or forcing.

Stainless steel material shall be segregated from other piping materials during all stages of
machining and fabrication to prevent surface contamination with carbon steel leading to localised corrosion.

Cutting of pipes shall preferably be done by mechanical means. Flame cutting is acceptable within the limits
as listed below:

A. For carbon steel, flame (or arc) cutting and bevelling is acceptable only if the cut is reasonably
smooth and true and all oxides are removed from the flame-cut surface by grinding.
B. For alloy steel, flame-cut bevels are acceptable only where machine cutting is not feasible. After flame
cutting approximately 2mm of material must be removed from the surface of the bevel by grinding.
C. Bevelling by mechanical means (ie. shearing) requires work hardened areas to be removed as in b.
above.
D. Stainless steel and non-ferrous metals shall be prepared by machining, grinding or plasma arc cutting
and grinding.

Grinding of stainless steel and non-ferrous metals shall be done with a non-carbonaceous, iron free non
sulphur bonded grinding wheel. Chipping, filing, cutting with hacksaws or wire brushing using carbon
steel brushes is not permitted on stainless steel.

Burrs and other objectionable defects shall be removed by reaming, machining or grinding.
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All cuts shall be made at right angles to the longitudinal axis of the pipe. All pipe ends shall be remade to the
full bore of the pipe.

All cuts shall be carefully bevelled and accurately matched to form a suitable groove for welding and to
permit complete penetration of the welds at all points. Reference is to be made to the relevant section of
the Code.

Defective or damaged weld ends shall be examined in order to determine the nature and extent of damage.
Any bevelled edge of pipe that has been damaged shall be machined to minimum tolerances. All
bevels shall be cleaned to bright metal finish.

Repairs shall not be made on weld preparation of pipes or fittings without written permission from the
Superintendent.

Repairs to weld preparations shall only be carried out using repair procedures which have been reviewed
and approved by the Client. Repair procedures must be submitted in writing for the Client review and
approval

4.6. END PREPARATION

4.6.1. General
Surfaces to be welded shall be ground free of rust. Grinding is to extend 10mm past the toe of the
weld preparation and is to be done immediately prior to welding.
4.6.2. Butt Welding
End preparation for butt-welding shall be in accordance with ANSI/ASME B16.25. Cleaning and end
preparation shall be in accordance with the Code and in accordance with this Standard. Stainless
steel materials shall be cleaned using degreasing compounds free of chlorides and sulphur for a
distance of 75mm from the prepared edge of inside and outside surfaces. Stainless steel wire
brushes shall not be used for carbon steels.
4.6.3. Fillet Welds
Pipes for insertion in slip-on flanges and for socket-weld joints shall be cut square, to within the
tolerances specified in ANSI/ASME B16.11.
Prior to welding of socket connections, the pipe shall be backed off 1.5mm from the seat of the
socket.
Socket welds and the external welds of field welded slip-on-flanges shall always be carried out
using a minimum of two passes with staggered stops and starts. Shop welded slip on flanges may
require two passes on the external weld, depending on the welding process, to ensure good root
fusion.

4.7. WELDING PROCEDURES, SPECIFICATIONS AND PROCEDURE QUALIFICATIONS

4.7.1. General
Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR) and the
Welding Procedure Register (WPR) shall be submitted to the Client and approval obtained before
any welding is begun.

The WPR shall identify all necessary WPS for the intended scope of work.
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4.7.2. Welding Procedure Specification : Each WPS shall exhibit the name of the originating Fabricator and
shall be uniquely identified. The WPS revision number and data shall be included. The technical
requirements of this Standard shall be adhered to in preparing WPS.

Manual, semi-automatic, or automatic electric arc welding processes shall be used on all piping. The
preparation and procedure for welding shall conform to the requirements of the Code.

Welding of carbon steel pipe shall be performed by either: Submerged Arc (SAW), Manual Metal Arc
(MMAW), Gas Tungsten Arc (GTAW), or a combination of these processes.

Welding processes other than these are prohibited.

Semi automatic and fully automatic welds shall be made with a multi pass technique.

Weld passes thicker than 10mm are prohibited.

Welding of stainless steel or alloy shall be performed by either Gas Tungsten Arc, or Manual Metal Arc
Welding, or a combination of these processes. Root pass must be made using Gas Tungsten Arc
process with inert gas purge on inside of pipe. Flux Cored (FCAW) and GTAW wire (brand name TGX)
may be used at the discretion of the Client.

Procedure for welding dissimilar metals (e.g. carbon steel to stainless steel 304L or 316L, etc) shall be
submitted to the Client and approval obtained prior to any welding.

Welders qualified, as per Section 4.7.7 of this Standard shall perform all welding.

4.7.3. Qualification of Welding Procedure

All WPS shall be qualified in accordance with the Code and ASME Section IX and this Standard.
Previously qualified WPS may be submitted for the Client approval. Qualification shall be performed on
pipe, not plate.

If a weld procedure includes PWHT, the weld procedure qualification tests shall include a hardness
survey. Acceptance criteria shall be the same as described in Section 4.7.13. The hardness survey
shall be performed using a 5-kg Vickers tester in accordance with AS2005.

4.7.4. Welding Procedure Essential Variables

In addition to the essential and supplementary essential variables listed in ASME Section IX

articles 2 and 4, the following shall be deemed essential variables:

A. For welding procedures qualified for low temperature carbon steel (impact tested carbon steels)
and low temperature low alloy steels (also impact tested) and any change in welding consumable
brand name, manufacturer, classification or country/region for base metals.
B. Any change in wire flux combination for SAW. Any decrease in preheat for material
thicknesses greater than 6mm.
C. Any change in current clarity or type (AC or DC).
D. The omission of back gouging or back grooving.
E. Variables during welding must remain same as used during procedure qualification (ie.
parameters I, V (speed) and U shall remain constant).
F. For P3 and P4 materials, hardness test on site shall be in accordance with those values
obtained or recorded during procedure qualification.
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4.7.5. Impact Test Requirements

Welding procedures for all P1 Group 1 and Group 2 steels developed for use in low temperature
service (less than 0 C design minimum temperature as specified by the applicable piping class) shall
include qualification by impact test. Impact test specimens shall be tested at a calculated temperature,
using an assumed design temperature of minus (-) 46 C, whilst all other test requirements shall
be in accordance with the Code. Three specimens shall be tested from each

sample area and the average energy value obtained from them shall be at least equivalent of 20 joules
obtained from full size specimens. One specimen may show a lower equivalent value, but this shall
not be lower than 16 joules.

Impact tests for welding procedures for other materials, the assumed minimum design temperature
used for determining the impact test temperature shall be (-) 46 C or the piping minimum design
temperatures whichever is lower. Weld metal specimens shall be located as near as possible to the
pipe surface. Two specimens shall be located near the surface containing the last pass of the weld,
and one specimen near the opposite surface. The specimen location shall be identified in the
report.

Specimen sides, which are perpendicular to the base of the notch, shall be 10mm. Depth of side
containing the base of the notch shall be the greatest possible of 10mm, 7.5mm, 5mm and 2.5mm
depending on the pipe wall thickness. Test temperature of sub-size specimen shall comply with the
Code.

The notch shall be contained in the weld metal at approximately the centreline of the weld and the base
of the notch shall be perpendicular to the surface of the plate. Before machining the notch, the
specimen shall be etched to distinguish the weld metal from the parent metal and to ensure that the
notch is correctly located. Machining of the bottom of the notch shall be done with care.

4.7.6. Weld Maps

Weld maps shall be prepared for each assembly/sub-assembly fabricated identifying the welder,
date welded, nature and extent of NDE performed, defects/re-welds, re-examination, if any, results of
NDE for each weld of the assembly/sub-assembly.

Weld maps shall also contain information on hydrostatic testing viz. test pressure, medium, date and
duration of testing and the results.

All the above information shall be properly documented and up-to-date records maintained by the
Contractor. Final copies of all the above referenced documents shall be issued to the
Superintendent within seven (7) days of completion of fabrication.

4.7.7. Qualification of Welders and Operators

All welders and welding operators shall be qualified in accordance with the requirements of ASME
Section IX and this Standard prior to commencing any work including tack welds or temporary
attachments. The performance test must include 6G position. Welder qualification certificates
including evidence of re-qualification and revalidation shall be maintained for the Client approval and
inspection.
All welder qualification tests must be carried out to an approved welding procedure specification
(WPS).

Previous qualifications may be submitted for approval provided that the holder(s) of the
qualification(s) have carried out similar work within the last six months.
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Each welder shall be assigned a unique symbol which will identify, on a weld map, all welds
performed by that welder.

4.7.8. Welding Types

All welds shall be full penetration welds except:
A. reinforcing pad, peripheral fillet welds,
B. structural attachment fillet welds and
C. socket welds, which shall be welded to the Code.
All butt welds DN 50 and below shall be made with the Gas Tungsten Arc process.

4.7.9. Welding Proximity and Location

The number of welds in the fabricated spools shall be kept to a minimum by using the longest
practical pipe lengths. The minimum distance between girth welds, shall be six times the pipe wall
thickness or 100mm, whichever is lesser.

Seam orientation of welded straight pipe to pipe and pipe to fittings shall be such that at
circumferential welds, the longitudinal welds shall be staggered, by 30 degrees left and right of the
centre line. As a minimum the circumferential distance between the staggered joints shall be
50mm or 6 times the pipe wall thickness, whichever is lesser.

Attachment welds, should be separated from pressure welds by a distance not less than 50mm,
weld toe to toe.

Welds for non-pressure attachments should not cross- existing main pressure welds. Where this is
unavoidable, the main pressure weld shall be ground back flush with the parent pipe and the area
examined for defects, using MPI/DPI inspection procedures. Subject to satisfactory acceptance of the
inspection, fabrication of the attachment weld shall be carried out in accordance with welding
procedures as approved for the main pressure weld.

Attachment welds shall not penetrate through the pressure pipe.

4.7.10. Preparation for Welding and Alignment

Earth connections shall be located as close as possible to the joint to be welded. “G” type welding
clamps shall be used for connecting pipe to earth.

The ends of pipe and fittings shall be accurately aligned and properly spaced as indicated in the
appropriate welding procedure. A pipe clamp or other device shall be used as required to obtain
accurate alignment and spacing.

The bore alignment for the butt joints shall be in accordance with the Code except that the
maximum internal trimming shall be 1:4.

Preference shall be given to the use of line-up clamps or bridge pieces for assembling components to
be welded.
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In addition to the requirements of the Code, all pipe joint preparations and welds shall be subject to the
following:
A. Backing rings are not permitted.
B. Back welds shall be examined visually for defects and, if found to be defective, shall be removed.

Branch connection joints shall be prepared so as to permit full penetration welds of a quality
comparable to the circumferential welds in the same piping system.

When thermal cutting is performed to prepare edges, to remove attachments or defective

material, or for any other purpose, the material shall be reheated using the preheat schedules
established in the qualified welding procedures.

Welding shall not be carried out when the surfaces to be welded are wet from any cause.

Galvanised flanges, supports, clips and the like shall not be welded to or come into direct contact
with stainless steel.

All valves, piping speciality items, equipment and instruments which may be damaged by the heat
of welding shall be protected by dismantling and be re-assembled upon completion of welding and
heat treatment.

All sections of tacked or welded pipe shall be sealed prior to installation to prevent foreign matter
from entering such sections.

A qualified welder using the qualified welding procedure, which will be utilised for full welding of
the joint, shall make tack welds. Temporary tack welds shall not touch the root gap or root face
and shall not be part of a final joint weld up. Line-up clamps shall not be removed until the root
pass has been completed.

There shall be no field-welded attachments to stainless steel or alloy piping or to any vessels
without Client approval and an approved welding procedure as described.

C. Cold spring is permitted only if it is shown on piping isometrics. If shown on piping

isometrics, this operation shall be withheld until the entire line between anchors has been
connected together in all directions up to the last closing length of pipe at the anchor and all
guides and supports are in place. The cold spring shall be pulled at one anchor with the pipe
firmly secured at the anchor on the opposite side of the section to the cold spring. Cold springing
is not permitted at rotating equipment nozzles.

D. Anchors/welded attachments on pipes shall be in accordance with Standard Pipe Support

Details and the respective piping isometrics.

Each welding bead shall be thoroughly cleaned of all scale and slag by chipping and/or grinding
and wire brushing immediately after completion of the weld and prior to the application of
succeeding beads. The width of the completed weld shall extend a minimum of 3mm greater than
the width of the original groove. For reinforcement, the bead shall extend not less than 1.5mm
and not more than 3mm above the surface of the pipe. Penetration of depth of fusion shall extend
the full depth of the pipe wall, including both the bevelled and straight portions. The bead shall
be smooth in appearance and contain no valleys, indentations or undercut on the crest or at the
edge. The completed weld and adjacent pipe shall be cleaned of all oxide, slag and spatter to
allow proper application of protective coating.
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The entire root bead shall be made with the pipe in a stationary position. Movement of the pipe
during manual welding of the root beads shall be kept to an absolute minimum.

Welding shall be a continuous operation. Welding should not be discontinued before the root run
and the next two successive passes are complete.

If welding has to be interrupted the welds area shall be covered to permit slow cooling. Before
resumption of welding on a weld cooled to ambient temperature the area shall be inspected
visually for the presence of cracks. The welds shall be subjected to magnetic particle or dye
penetrant examination to determine acceptability. Cracks shall be completely removed prior to
any further welding.

All welding necessary for in-place assembly and erection shall be in accordance with applicable
paragraphs of this Standard.

The areas from which temporary attachments have been removed shall be dressed smooth. Stray
arc strikes are forbidden.

4.7.11. Welding Consumable Control and Handling

The Fabricator shall establish and implement procedures for receiving, storing, conditioning and
issuing consumables.
4.7.11.1. Receipt Storage and Identifications
All consumables shall be received and clearly identified in sealed containers. The
consumables shall be stored in sealed, moisture proof containers at a protected
convenient dry location at a temperature of not less than 20 C. Consumables shall be
identified at all times during storage, conditioning, distribution and at weld stations.
Identification shall include manufacturer, grade and batch number.
4.7.11.2. Drying of Electrodes
Prior to use, MMAW electrodes shall be dried in accordance with the
manufacturer’s recommendations. After drying, the electrodes shall be transferred to
heat storage cabinets maintained at 120 C minimum for later use. No electrodes shall
be redried more than twice.

4.7.12. Protection of the Welding Environment

The welding area shall be protected at all times against adverse environment conditions, water
spray, mist, drips or wind exceeding 8kph. Welding shall not proceed when the work is exposed to
such conditions. Prefabrication areas for carbon and stainless steel shall be physically separated to
prevent contamination of stainless steels. When grinding or welding carbon steel pipe and
supports protection of any adjacent stainless steel shall be provided.

4.7.13. Heat Treatment of Welds

Heat treatment procedures, pre-heat and post-heat shall comply with the Code requirements. In the
case of Ammonia Liquid, Chlorine-Dry Liquid, Chlorine-Dry Gas, and Synthesis Gas services, heat
treatment procedures shall comply with AS4041 or the Code, whichever is more stringent. Details
shall be included in the Weld Procedures. All welds on carbon steel and low alloy steel piping for the
following services shall be heat-treated after welding. Ammonia Liquid at any temperature. Chlorine-
Dry Liquid at any temperature. Chlorine-Dry Gas at any temperature. Synthesis Gas services at any
temperature. Ammonia Gas services where there is a possibility condensate will form under
normal operating conditions.
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Sodium Hydroxide (Caustic Soda) of 30% to 50% strength at any temperature. Sodium Hydroxide
(Caustic Soda) less than 30% strength if the normal operating temperature is greater than
60°C. 30% Sodium Cyanide Solution if the normal operating temperature is greater than 60°C.

Note: Where heat treatment is recommended for a particular service and material combinations
covered by NACE or other anti-corrosion standards, heat treatment shall be performed in accordance
with the standard.

Heat treatment shall be in accordance with the requirements of the Code clause 331.1.7 and the
following:
A. All hardness tests on stress relieved welds shall be carried out using a standard Equip tester. A
qualified metallurgist or an experienced tester approved by the Superintendent shall
perform the tests.
B. The criteria for hardness tests on local and shop stress relieved welds shall be as per the Code
plus the following:
a. P1 materials shall not exceed 225 Brinell for ammonia and chlorine service and 248
Brinell for other services.
b. For P4, P5 and P6 alloy steels, where the wall thickness is less than that for which a maximum
hardness is specified, the maximum hardness shall be specified as for the material with the
thicker walls.
c. For service and material combinations covered by NACE or other anti- corrosion standards
and not covered by (i) and (ii) above, the hardness limits in these standards shall apply.
d. For other materials and services not covered by (i) to (iii) above, the maximum hardness
shall not exceed 248 Brinell.
Note: For b. (iii) the hardness limit may also apply to piping and welds which are not heat
treated.
C. If heat treated in a furnace, all piping shall be properly supported in the furnace during heat
treatment to eliminate warpage and other distortion.
D. The cooling rate from the stress relieving temperature shall be in accordance with the
requirement of ASME Section VIII.
E. All machined surfaces shall be protected by a suitable paint or compound or by any other
method (eg. gasket and a counter flange for flanged surface) to prevent damage from
scaling.
F. Unless otherwise approved in writing by Superintendent, no welding, hammering or cold
forming is permitted following heat treatment.
G. All valves, piping specialties, equipment and instruments, which may be damaged by the heat
from heat treatment, shall be protected by dismantling and be re-assembled upon completion of
heat treatment.

Valve bodies (2 or 3 piece ball valves) or bonnets to be removed shall be match-marked prior to
disassembly to ensure that they are reassembled back into the same location and orientation. Seats
shall be gently lapped where necessary to remove any scale and new bonnet/body gaskets fitted
when reassembling the valves.

All welds or attachments required including pipe supports or reinforcing plates, etc, shall be made
before heat treatment. No welding is permitted after heat treatment.

4.7.14. Filler Materials

All filler materials shall deposit an alloy whose chemical, physical and corrosion resistance
properties correspond to the base material and shall satisfy requirements of the Code Standards.
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Consumables for use on carbon steel lines for sodium cyanide solution shall have low sulfur
content.

4.7.15. Weld Repairs

No repair shall be undertaken without first notifying the Client of the requirement to repair, and
seeking his approval of the proposed repair procedure.

Repair of welds shall be done in such a manner as not gouge, groove, or otherwise reduce the
adjacent base metal thickness.

Repairs or replacement welds shall be performed in accordance with the original welding
procedure, including pre-heat and post weld heat treatment if originally required.

Inspection and NDT of repairs shall be as originally required for the initial welds.

A weld defect that has to be repaired shall be removed to sound metal. Repair welds shall be made
by qualified welders Welding procedures used shall be in accordance with the Code and ASME
Section IX.

4.7.16. Inspection and Testing/Welds

Non-destructive examination of welds shall be carried out in accordance with ASME standard and
Client Specifications.

4.8. THREADING
The minimum pipe schedule for threading pipe shall be Sch 80. For carbon steel and low alloy steel
threaded nipples the pipe schedule shall be Sch 160 minimum. Stainless steel threaded nipples shall be
Sch 80 minimum.

Threading of steel pipe shall preferably be done after bending, forging, heat treating or welding operations.
Where post-fabrication threading is very difficult and threads are cut first, they shall be fully protected during
such operations. Threads shall be concentric with the outside pipe and shall conform to
ANSI B1.20.1 (NPT).

Screwed pipe shall be reamed after cutting and threading. The threads shall be full cut and after a tight
connection is made, no more than three threads shall remain exposed. All cutting oil and metal chips shall
be cleared off the pipe prior to assembly.

Screwed pipe joints shall be made up using a suitable tape, which has been approved in writing by Client

Screwed connections shall not be back welded unless specified on designs drawings, or approved by the
Client. It is recommended that back welded threaded connections be replaced with socket weld connections
if possible.

4.9. FLANGING
Flange bolt holes shall straddle the principal centre lines, unless other orientation is shown on the design
drawings.

4.10. FIT-UP
Misalignment or poor fit-up in excess of the values specified in Section 3.3 is not acceptable.
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For compression-type fittings, use proper tools and torques as specified by the manufacturer to ensure a
leak-tight joint. To avoid damage or distortion of the fitting, do not over-torque the fitting nut.

4.11. BRANCH CONNECTIONS

Lines that connect to the main line or header, including instrument connections, vents and drains are
considered branch lines. All branch connections shall be made in accordance with the respective
Piping Material Specification. All stub-ins shall meet the requirements of the Code.

4.12. PIPE BENDING

Piping shall be bent only at locations shown on isometric drawings. In all other cases welding elbows shall
be used. If the pipe to be bent contains a longitudinal weld, this weld shall be located in the neutral zone
(pipe central axis).

Pipe bending shall be in accordance with Code requirements. A minimum bend radius of five (5) diameters
shall be used. Wall thickness of completed bends shall not be less than that required for the pressure and
temperature plus any corrosion allowance. Bends are permitted provided tensile and impact properties are
not impaired by the bending operation. Butt weld joints shall not be located in the curved section of
bent pipe. Weld repair of cracks in pipe bends will not be accepted. Cold bending of pipe DN 40
and smaller is permitted. Induction bends for larger pipes may only be used with the approval of the Client.

5. PROTECTION

In general, all pipes, fittings, valves, instruments and all other equipment including all accessories, issued to the
Contractor for erection shall be protected from normal weather conditions, corrosion or damage, prior to
mechanical completion.

5.1. PIPE SPOOLS

After fabrication and inspection, all pipe spools shall be protected in the following manner:
5.1.1. Pipework Painting
On completion of fabrication and workshop examination and inspection and before erection all
pipework shall be surface prepared and painted in accordance with the specified Painting System.
General conditions for painting and cleaning shall be as per client Specifications.

Patch priming of field welds and any abraded or damaged portions shall be carried out on
completion of erection, pressure testing and any other examinations and inspections, which may be
required prior to finish coating.

Pipelines and valves shall be finish coated in accordance with the specified Painting System and
Client Specifications. Cold insulated services piping shall be primed in accordance with the painting
Specification.

5.1.2. Flanges
Flange faces shall be protected by coating with a removable rust preventative and blanked with
6mm thick exterior quality plywood covers, or proprietary plastic flange guard covers no smaller than
the flange OD. The flange cover shall be retained by a minimum of four bolts or by
polyethylene lock plugs.

5.1.3. Connections
Threaded connections shall be fitted with line specification steel pipe plugs or treated protectors.
Socket weld connections shall be fitted with taped polyethylene caps or plugs.
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All end connections, including branch openings shall be protected with a plastic sheet, wired or
taped securely to the spool to prevent entry or dirt or moisture into the spool.

5.1.4. Stainless Steel Components

In order to minimise the possibility of stress cracking, all stainless steel valves, spools, pipe and
connections shall be stored out of contact with the ground and properly sheltered from rain.
Closures should be examined to ensure moisture cannot enter this material.

All austenitic stainless steel subject to welding or mechanical abrasion shall be passivated to
reinstate the protective oxide layer.

Stainless steel piping subject to annealing or heat treatment shall be pickled in an acid/water
solution comprising nitric and hydrofluoric acid to remove oxide scale.

6. ERECTION

6.1. IDENTIFICATION
All materials issued by the Client or supplied by the Fabricator shall be identified in accordance with the
respective piping class/piping material specification, and shall be stored and handled in such a manner as
to assure proper identification.

6.2. STORAGE AND HANDLING

All fabricated pipe and equipment shall be stored off the ground until finally installed.

Care shall be exercised, in the storage and handling of all piping materials and pre-fabricated assemblies,
so that contamination by grease, moisture or other foreign matter does not occur. End seals of pipe,
flange covers, valve covers, and similar protections shall not be removed until necessary for
fabrication or erection. The Contractor shall ensure that all piping is protected, as per Section 4.4 at all
times.

All care shall be taken when pipe sections are moved from one place to another to avoid bending or over-
straining.

6.3. ASSEMBLY/ INSTALLATION

All piping shall be installed in accordance with the latest revision of the Piping drawings as per Section 3.2.

All assembled piping shall be installed without springing or forcing. Cutting or other weakening of structural
members to facilitate piping installation shall not be permitted.

All piping shall be installed to permit free expansion and contraction without damage to joints or supports.

A visual inspection of all pipe and pipe spools shall be made to ensure they are free of all internal loose rust,
scale, soil and debris before assembly.

A straight run of pipe shall contain the minimum number of welds. The use of off-cuts in straight piping runs
shall be avoided wherever possible.
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Special precautions shall be taken during carbon steel piping erection in close vicinity of stainless steel
piping as direct contact between carbon steel and stainless steel is not permitted. Carbon steel slings, etc,
shall not be used during fabrication and installation of stainless steels. Stainless steel piping shall be
covered up with tarpaulins or similar where carbon steel piping is being erected or worked on such that,
stainless steel cannot come in contact with carbon steel. Neither shall stainless steel or non-ferrous
materials be contaminated with grinding or welding particles. Tools shall be identified for stainless steel
work only. All stainless steel piping and fittings shall be stored away from areas where carbon steel is being
worked on.

All materials used for assembly and erection must conform to the Client material specifications.

Hydrotest vents and drains shall be installed in accordance with the Piping GA’s and Isometrics.
The Fabricator shall install any additional vents and drains required for testing purposes.

6.4. FLANGED CONNECTIONS

Precautions shall be taken throughout fabrication and erection to protect the gasket face of flanges. Flanges
repaired by grinding will be rejected.

Flanged connections shall be assembled with new gaskets and stud bolts. Bolts shall show at least one, but
no more than three threads beyond the nuts after assembly.

Gaskets shall be centred on the flange faces and shall not project into the bore. Gaskets with correct inside
diameter shall be used on slip on flanges.

The clearance between flange faces shall permit the connection to be gasketed and bolted without imposing
undue strain on the piping system.

Flanged piping connections to vessels or equipment shall be correctly aligned before bolting up.

6.4.1. Protection from Leaking Flanges

In the event of a flange leak, to prevent personnel being sprayed from substances that are hazardous
because of their chemical and or physical properties, flange protection shall be provided at
locations where:

there is a high level of Operator interface, flanges are adjacent to walkways or designated
accessways, directed by the Client or the applicable business unit Process/Maintenance Manager.

Hazardous substances requiring flange protection are: All acids

Sodium Hydroxide (Caustic Soda) Ammonium Nitrate Sodium Cyanide Solution, and Other fluids,
as specified by the Client or the applicable business unit Process or Maintenance Manager.

The type of flange protection to be used shall be specified by the Client or the applicable business
unit Process/Maintenance Manager. Typically this will be in the form of either:
A. A ring of stainless steel cladding that is securely held in place with stainless steel banding
straps. A drainage/vent hole shall be provided in the underside of the flange guard.
Or
B. Wrapping of the flange joint with Herculite. The material is to overlap itself and extend over the
pipe with sufficient material so that is can be securely held in place with 3mm Terylene rope or
another Client approved method.
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6.5. BOLTING
Prior to installation, all bolting shall be lubricated with an approved anti-seize compound. Protective grease
shall be removed from flange gasket faces prior to bolt-up. Flange faces shall be parallel and aligned in
horizontal and vertical planes. Non-uniform bolt loading will be rejected. Dirt at the mating surfaces shall
be removed and scratched surfaces shall be repaired.

Flange stud bolts shall be tightened evenly and sequentially to impose equal pressure on gaskets to avoid
distortion or over stressing. Hydraulically operated tensioning equipment shall be used on stud bolts 1¼”
diameter (M33) or over. These stud bolts shall be supplied one diameter overlength to allow for bolt
tensioning equipment.

Insulating flange kits shall be installed between mating carbon steel and stainless steel piping. Gasket
compound shall not be used.

6.6. CONNECTION TO EQUIPMENT

Piping connections to equipment shall be installed such that no stresses shall be transferred from the piping
system to the equipment at the time of installation.

6.7. THREADED JOINTS

Back welding of threaded joints is not permitted unless specified on design drawings or approved by the
Client. It is recommended that back welded threaded connections be replaced with socket weld connections
if possible.

Backing off of made-up threaded joints to facilitate fit-up or alignment is not permitted. Joints shall be made
using approved sealing tape and care taken to avoid over tightening.

6.8. TEMPORARY STRAINERS

Temporary strainers must be installed in the suction piping to all pumps, compressors and other places as
indicated on drawings. Break-out spools shall be installed as required for easy removal of strainers.

6.9. VALVE INSTALLATION

Valves shall be installed as indicated on the GAs and Isometrics and in accordance with Client
Specifications.Should valve orientation not be detailed the following guidelines should be used:

A. Valves shall be installed so that their handwheels or handles are accessible and can be operated
between full open and full closed positions without obstructions.
B. Valve location and orientation shall be such that a person can operate the valve handwheel or handle
from a safe position and in a comfortable posture. Extensions or chain wheels shall be provided if
required.
C. Valves in horizontal lines, with the exception of block valves at pressure relief valves, shall be installed
with valve stems oriented as follows, in order of preference:
a. Vertically upwards
b. Horizontally
c. Upwards at 45
D. Gate valves installed upstream and or downstream of pressure relief valves shall be installed
with the valve spindle oriented horizontally or downwards, to prevent blockage of the line by a
disconnected gate in the valve.
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6.10. INSTALLATION OF EXPANSION JOINTS

Specific instructions for installing expansion joints shall be included in the Project documentation, however
the following general guidance apply:
A. Expansion joints shall be the final unit(s) installed in any piping systems.
B. Before installation of any expansion joint, all piping shall be accurately aligned without restraints and
properly anchored.
C. The space allowed in the piping for insertion of an expansion joint shall be equal to the insertion
dimension specified on drawings (plus or minus 1.5mm), including cold springing, if specified.
D. Spacer bars supplied by the manufacturer for shipping purposes shall not be adjusted or removed
from expansion joints until after joints are in place.
E. Shipping spacer bars must be removed before testing.
F. No adjustment shall be made to tie rods provided by the manufacturer to control alignment and end
thrust; these tie rods shall remain part of the unit.
G. No attempt shall be made to correct misalignment of piping, caused by incorrect installation of the piping
or its associated equipment, by modification to any device provided to control expansion, or the
method in which that device is designed to be installed. Such misalignment must be corrected
by other means which will in no way affect the workability of the expansion device.

6.11. TESTING OF PIPEWORK

Pressure testing of piping shall be carried out in accordance with the Code and Approved Procedure.

7. PIPE SUPPORTS

7.1. STANDARD PIPE SUPPORTS

All pipework shall be supported in accordance with the Code.

Support locations, type and serial number will be shown on the piping drawings. Refer to SectioN 3.2. Unless
otherwise indicated on piping drawings, no pipe shall be supported from another pipe.

7.2. SPRING HANGERS

7.2.1. General
Spring hangers, as required, shall be supplied by the Fabricator and shall be installed as indicated on
piping drawings.
7.2.2. Constant Support Hangers
Installation instructions are as follows:
A. Securely attach the hanger to the structure at a point where the load coupling is directly over
the desired point of attachment.
B. Make certain that the moving parts of the hanger will be unobstructed.
C. Make certain that the rod has enough thread engagement before taking up the load.
D. Turn the load coupling until the travel stop is free.
E. Prior to the final start-up/commissioning, the travel stops shall be removed.
F. After the line is in operation, check the hanger for indicated hot position. If necessary, make
the adjustment by turning the load coupling to bring the indicator to the required position.
No other adjustment is normally required, since the load as calibrated at the factory is
equal to the load that has to be supported.
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7.3. VARIABLE SUPPORT HANGERS

The installation instructions shall be as follows:
Securely attach the hanger to the structure. Turn the turnbuckle until the Variable Spring Hanger or load
column of the spring support respectively reaches the desire cold load marking. No other adjustment is
necessary. The travel stops shall be removed before the piping is put into operation

8. AS-BUILT DATA AND RECORDS

On completion of the work, the Fabricator shall supply , a properly indexed and compiled package, full
details of the Welder Qualified records, fabrication records and as-built data.