THPERTAL IBP3-18-1 PIPING FABRICATION Page 1 of 16 | SHOP OR FIELD BASIC PRACTICE _| Rev. 11| Dec. 1980 (Th IAP is Appropriate for Attachment to Inquiry of Purchase Document) ‘SCOPE 1.1, This Basic Practice covers mandatory requirements governing the fabrication and inspection of piping assemblies, including furnace tube assembiies. 1.2 Piping design, tayout, and material selection requirements are not covered by this Basic Practice. 1.3 The contents of this Basic Practice are arranged as follows: SECTION PAGE Scope ‘Summary of Additional Requirements Dimensional Tolerances... Bends and Miter Bends Branch Connections Seal Welding Threaded Connections Bracing Location of Connections Joints and Flanges... Welding Joints... Weld Penetration, Projection, and Depression Heat Treatment... Cleaning of Piping Inspection and Testing .. Shipment, Handling, and Storag 1.4 Amasterisk (*) indicates that a decision by the purchaser is required or that additional information is furnished by purchaser. SUMMARY OF ADDITIONAL REQUIREMENTS 24 Table 1 lists the Basic Practices, codes and standards which shall be used with this Basic Practice. "22 Table 2 lists the Basic Practices and code which shall be used with this Basic Practice as specified by tho purchaser. . TABLE 1 BASIC PRACTICES TSP 0.01 General Conditions 'BP 186-1. Impact Requirements for Matora's IBP 18-7-1 Wolang Procedures: IGP 3.10-1 Piping Erection and Testing (BP 126-100 Facies for Onetream Carosion Montring of Process Equipment IP 20-1-1 Inspecton of Equement and Matenals TBP 20.1.2 Admnistatve Procedures for Obtaining Imperial Oil Limited Inspection IP 20.2-100 Acseptabilty Standards for Nor-Destructwe Tests (CODES AND STANDARDS "ASMEZANSI Standards 81625 —_Butwelding Ends 5311 Power Piping 8313 Chemical Plant and Petrloum Refinery Piping 51201 Pipe Threads, General Purpose (Inch) ‘ASME Codes ‘Section V_Non-Desirucve Examinations Section Vill Pressure Vessels Secton IX. Welding QualificationsPag c ® 23 24 24d » 242 cat a2 1BP3-18-1 e 2 of 16 | SHOP OR FIELD fev. 11|_Dec._ 1990 | PIPING FABRICATION SUMMARY OF ADDITIONAL REQUIREMENTS (Cont) TABLE 2 BASIC PRACTICES ‘Suction and Discharge Piping for Centrifugal Pumps Ping tor Instruments LUbity Connections to Piping ana Equoment ents and Drains Flushing and Clearing Connections Piping Selection Crite Comont Lined Pipe Valve ‘Selection Criteria TBP 3.16-1 Flanges. Gaskets, Boltng and Fitings 1BP 3.17.1 Once Flanges TBP 16-21 Matenals for Hydrogen Service TBP 18-41 Postweld Heat Treatment of Equipment Handling Alkaline ‘Solutons -1Precommission Clearing of Steam Generating Equioment and Plant Pping Systems BP 1941-1 Paint & Protectivo Coating IBP 19.7.1 _Proteeton of Fabricated Stainless Stoo! ‘CODES, SPECIFICATIONS AND STANDARDS ASME Code Section 1 Power Bolers ANSI/AWS Specifications 5.1 to Flor Metal Specifications AS24 ASTM Standarde eve Controling Quality on Radiographic Testing CSA Standards W48.1 to Welding Electrode Standards waar TWPERIAL, BASIC PRACTICE Fabrication of all piping shall be per ASME 831.3, except as modified in this Basic Practice. Fabrication of boller plant piping (steam, feedwater, and blowotf) within the jurisdiction of the ASME Codes Section 1, shall comply with that code and all non-conflicting requirements of this Basic Practice. with ANSI B31.1 and all non-conficting requirements of this Basic Practice. DIMENSIONAL TOLERANCES AND LIMITATIONS Tolerances for finished fabricated piping shall conform to Figure 1 Minimum spacing of welds. The clear distance between the centarines of adjacent welds shall be as shown in Fig. 3. ‘Steam distribution piping which does not come within the jurisdiction of ASME Code, Section | shall comply Al piping shall conform to the requirements of the proper authorities of the province in which itis to be installed,THPERIAL IBP3-18-1 PIPING FABRICATION Page 3 of 16 SHOP OR FIELD BASIC PRACTICE Rev. 11] Dec. 1990 324 322 323 33 4a 42 424 © 43 8a 52 cs sa DIMENSIONAL TOLERANCES AND LIMITATIONS (Cont) TABLE 4 MINIMUM DISTANCE ‘TYPE OF JOINT BETWEEN. (LARGER OF FOLLOW ‘A__ | two longitudinal or plate seams 100 mm oF 4 ¢ A | Two ath seams on piping or tubing 25mm oat | Branen connection (w or w/o pads) and longitudinal welds 700mm or 4 | Branch connections (w or w/o pads) and girth sears 30mm or4t | Adjacent fet welds [100mm or 4 t The length and overall size of spool pleces shall be limited by shipping and erection considerations only. ‘The number of field welds shall be kept to a minimum. The location of field welds shall not be influenced by area match lines on layout drawings. Deleted. BENDS AND MITER BENDS Centertine radius of pipe bends shall be equal to at least 5 times the nominal pipe diameter. Pipe bends shall be used for small dlameter piping, 2 In. NPS (50 mm) or less, in place of welding elbows, unless impractical for layout considerations. The schedule of bends and elbows shall be equivalent to that of the pipe, unless approved otherwise by the Owner's Engineer. ‘Miter bends may be used where allowed by IBP3-16-1 and shall comply with the following: a. Bends exceeding 45 degrees shall be at least 3-piece (2 miter cuts), with not less than 4 times the pipe wall thickness between the centerlines of the welds at the crotch, or 1 in. (25 mm) whichever is greater. Bends shall have a centerline radius at least equal to the nominal pipe size. ¢. The maximum miter angle (half the change of direction) shall be 2-1/2 dagraes up to 200 psig (1980 kPa gauge) design pressure, 15 degrees up to 400 psig. (2760 kPa gauge) design pressure, and 11-1/4 degrees ‘ver 400 psig (2760 kPa gauge) design pressure. BRANCH CONNECTIONS Integrally reinforced branch welding fittings which abut the outside surface of the run wall, in sizes NPS 4 (114.3 mm OD) and larger, are not permitted under any of the following conditions: a. The A/D ratio (branch diametsr/run diameter) exceeds 0.8. 'b. The run piping wall thickness is less than schedule 40. ‘c. The run piping wall thickness is less than 0.75 in. (19 mm) where outside diameter exceeds 96 in. (914 mm). Pad reinforced branch connections are not permitted whenever the piping design temperature is 800°F (425°C) (oF greater It a forged fitting is unavailable a pad-type reinforcement may be used for ful size branch connections and it shail be of the complete encirclement type. Fabricated branch connections. Branch connections shall be directly joined to the header with full penetration is. All branch connections to headers NPS 16 (406.4 mm OD) and larger shall be visually inspected, both intemally and externally. Reinforcing pads (when required) shall be added as a subsequent fabrication step after visual inapection. Vent shall be 1/8 in. (3.2 mm) dried hole.1BP3-18-1 TWPERTAL Page 4 of 16 PIPING FABRICATION sasicrracrce | @ SHOP OR FIELD 5 Branch connections NPS 1 1/2 (48.3 mm OD) or smaller for carbon, low alloy or stainless steel and 1/8 in. corrosion allowance or less shall be made as follows: BRANCH CONNECTIONS (Cont) TABLE 4 TYPE OF CONNEGTION FOR BRANCH SIZES FLANGE RATING | MAIN LINE SIZE NPS a ey 1506 120" anc smaiier Extended Body Vaive Butt Woided To The Parent Pipe (OR Schedule XXS. Nipple 12" and smater 300 # 14" to 20" ANSI Class 6000 Rating Hal Couping-Sockst Weld 600 # [26 oF smatior eee Note: Applicable for Temperatures up to 750°F. CONNECTIONS TO PIPING 55.1 Couplings and nozzles directly attached to equipment are part of the equipment and are covered in the ‘equipment specifications. 5.5.2 Couplings and Sockolets in piping shall be as follows for: ‘a When the required corrosion allowance exceeds 1/8 in. (3.2 mm), ANSI CLASS 6000 rating half coupting socket or sockolet shall be used. oe Sa oh oa eaee aoe oeareacta ante eee eee anes ‘Schedule 160 minimum whether threaded or socket welded, with the exception of XXS for threaded nipples ‘requiring 1/8" corrosion allowance. b. Stainiess steot: Schedule 80 minimum in accordance with the Standard Piping Classes. © Pump cases: ‘Schedule 80 austenitic stainless steel minimum. Corrosive services may dictate the use of other alloys. 4. Nipples made from bar stock are prohibited. 5.5.4 The length of the pipe nipple trom the equipment connection or piping to the first valve shall be 4 in, (100 mm), ‘except where additional length is required due to insulation, jacketing, etc. 55.6 Downstream piping and fittings from the first valve shall be in accordance with the Standard Piping Classes. 557 Deleted 55.8 The minimum size of connection shall be NPS 3/4 except: ‘4. At existing connections on piping or equipment which cannot be enlarged. b. At office flanges which may be NPS 1/2. c. Small piping connected to and within 30 ft (9 mm) of a reciprocating compressor to be NPS 1 (33.4 mm OD) minimum. 55.9 Steel fittings NPS 2 (50.3 mm OD) and larger shall be seamless forged with ends bevelled for welding. 55.10 Connections NPS 2 (50.3 mm OD) and larger shall be made as follows, consistant with the requirement ofthe line classifications: ‘a. Size to size connections shall be made by straight tees.BASIC PRACTICE IBP3-18-1 PIPING FABRICATION Page 5 of 16 SHOP OR FIELD "55.11 60.1 e”* 62 63 64 BRANCH CONNECTIONS (Cont) b. Reducing type connections shall be made as shown in the following table: connec Hon nemance Unreiniorced Stuban | As por ANS! 8911 oF BOTS Reduang Tee Note 1 Renforced Stub | (a) Use reinforcing pad or waldng saddle. Note 2 ‘Sweepolets or equal | Available for main Ine sizes NPS 6 and larger ote. 2 Weidoieis or equal | No imitations on NPS 2 & 3 branch ines. For | teatrctions on izes NPS 4 and larger S00 | Notes.2'8 3. Notes: 1. As an alternate a straight tee and reducer may be used. 2. For design temperatures 800°F (525°C) or greater, tees or swoepolets shall be used. 3, IBP 3-18-1 Para, 5.1 shall apply. In hydrogen service, with an operating condition of a hydrogen partial pressure above 100 psia (689.5 kPa abs.) tho space between an attachment and the vessel shall be vented using a 1/8 in. (3 mm) diameter hole. HOT TAPPING Hot tapping of connections to lines or equipment shall be employed only when all conventional methods are impractical. Hot tapping shall be in accordance with the procedu land when approved in writing by Owner’ as outlined in the Mechanical Safe Work Practice Manual Engineer. SEAL WELDING THREADED CONNECTIONS All threaded connections within process unit limits shall be seal welded except in the following services: a Yard and instrument ai. Fresh Water. Inert gas. ‘Auxiliary piping of equipment, uniass it is the manufacturer's standard. Where equipment, steam traps, control valves, safety valves, ete. require periodic removal for maintenance, Unions or flanges shall be provided to faciitate removal. Where bronze valves are used. All threaded connections outside process unit limits shail be seal welded in the following services. Pressure storage equipment and lines. Corrosive materials. Steam (125 psi & higher pressure. Hydrogen, Lines in toxic and valuable materials services. Between tank and first block valve. Deleted Plugs and caps for drain and vent valves shall not be seal welded. ‘Seal welding of connections shall be as follows: ‘Seal welding shall be done with slectrodes not to exceed 1/8 in. (3.2 mm) in diameter, using an amperage in the low range to avoid distortion of the connection or part being welded. 1 piping assem wil be PWT sal wolding shall be gvon the necessary het eaimontas wal. However , Ped, P-5 (Group 1) and P-9 materials may be seal welded without subsequent PWHT (Except Writer required by 1BP'8-22) provided a of ine olowing roquromonts aro mot (1), The minimum preheat meets both the “required” and the "recommended preheat listed in ASME 831.31BP3-18-1 Page sof 16 | PIPING FABRICATION SHOP OR FIELD BASIC PRACTICE SEAL WELDING THREADED CONNECTIONS (Cont) (2) A temper beading technique is employed for all materials except P-1 (@) Low hydrogen electrodes or welding processes are used (4) For all alloy stoals, either low carbon electrodes with matching chemistry (.e. EB018-B2L) oF high nickel electrodes (12. ENiCrFe-3) are selected. Field seal welding on piping assemblies of air-hardening chrome materials which have been PWHT shall bbe done using matching electrodes and shall be PWHT. 4d. Field seal welding of stainless steel to air hardening chrome pump casings shall be done without PWHT provided the following is used ’) A high Ni electrode such as inconel it) A minimum preheat of 300°F ii) A maximum interpass temperature of 400°F iv) The temper bead technique. If PWHT must be carried out, it shall conform to IBP 18-2-1 or 184-1 © 65 Connections requiring seal welding shall be made up without the use of sealing compound or PTFE tape. All Cutting oil shall bo removed prior to assembly. After the joint has been tightened to full thread engagement. seal welding shall cover all exposed threads, or 1/4 in. (6 mm) minimum, ADDITIONAL REQUIREMENTS FOR FLUIDIZED SOLIDS UNITS 66 For fluidized solids units, all threaded joints of piping carrying a fluidized material shall be seal welded ADDITIONAL REQUIREMENTS FOR AUXILIARY PIPING FOR MACHINERY 6.7 Seal welding of threaded connections of auxiliary piping associated with machinery is required for: a. Pressurized lube oil piping b. Pressurized seal oil piping except at the connection to mechanical seal end plates e & Gas services under vacuum 4. Lines containing any flammable or toxic materials Union ring threads, and union bonnets of valves shall not be seal welded. ADDITIONAL REQUIREMENTS FOR PIPING FOR INSTRUMENTS © 68 — Except for the following connections, all threaded piping fitings shall be seal welded: Connections to the instruments Vent, drain, fil and rod out plugs Variable area flow meters and check valves in purge piping Union nut rings Connections to prefabricated instrument manifold blocks Instrument tubing fittings 9. Miscellaneous connections approved by Owner's Enginer 69 Thermowells shall not be seal welded. ADDITIONAL REQUIREMENTS FOR EXTERNAL STEAM TRACING SYSTEMS 6.10 Threaded pipe fittings shail be seal welded except at steam traps and for piping downstream of traps. BRACING 7.1 A.block valve shail be provided for the purpose of isolating all small piping connections ( < 1-1/2 in. NPS or ‘48.3 mm OD) in vibrating service. The vaive shall be attached in all cases as close to the piping run or equipment. ‘a8 possible so that the outlet of the valve is within 9 in. (225 mm) of the branch connection. lan extended body type valve is used for the block valve at the branch connection and the 9 in. overall dimension (pipe wall to valve outlet) is exceeded, such deviation shall be raviewed with the Owner's Engineer.e@ BASIC PRACTICE TWPERIAL IBP3-18-1 PIPING FABRICATION Page 7 of 16 SHOP OR FIELD BRACING (Cont) Oe a eee erm eae eee ces ee eee a eter eeatne reat aces eth SS ecg po peed cag Soaetunner somes 7 ear ea —| ee a pea a OS ETN FET aS ae a Sa ee Seis Ma Pe aa fends Sa Ra | Soe SS RO SG Eel aay canis Stan eT FER | a § ae GO I pam BTA Fo OT earee SER ee eh ee oa SaETy Sa aE pee ERENT Serene RU an a ne waniae cece, | omen iaste toa Sarees go 0 eee Ee ee Severin | Sa ROTLSS es aL oman eae ee RE RN Dea SR Sas RT BS BG ER TT Gaia oe = (ron gnome ont pay anon na er emanate be oe Srv aemaaa.s consents eicaae (3) Deleted. SE erga eee Rev. 11) Dec. 1990 a. Gussetting material for welded gussets shall be of the same nominal chemistry as the connected parts. Carbon steel may be used for gusseting materials with P numbers 1, 3, 4, and 5 except where the piping is in hydrogen service or where the service temperature exceeds S00*F. b. For single plane gussetting, connections shall be braced with gussets having a minimum thickness of 1/4 inch (6 mm), minimum width of 2 inches (51 mm) and maximum length of 7 in. (175 mm). For two plane ‘Qussetting, connections shall be braced with gussets having a minimum thickness of 3/16 in (5 mm), minimum width 3/4In. (20 mm) and maximum length of 7 in. (175 mm). c. Gusset and other structural attachment welds to a pressure boundary shall be PWHT whenevé 1. PWHT is required for ail welds based on service conditions. 2. PWHT is required in the alloy steel component to which the attachment is to be made based on the Heat ‘Treatment section of this Basic Practice. ‘As an alternative, gusset stubs (or pads) welded to the component prior to PWHT may be used to permit later gusset to stub (or pad) attachment without PWHT. Proposals to use special welding procedures in lieu of PWHT shall De submitted to purchaser for approval by the Owner's Engineer. 4d, Proposals to use clamped or bolted gusset designs shall be submitted to purchaser for approval by the ‘Owner's Engineer.734 on aaa 92 92a 93 c 94 941 1BP3-18-1 Page sot 16 | PIPING FABRICATION Dec. 1990 SHOP OR FIELD BASIC PRACTICE BRACING (Cont) Bracing of small piping connections NPS 1 1/2 (44.3 mm OD) inciuding pressure gauge connections, etc., on piping and on pieces of equipment (including pressure vessels, exchangers, compressors, pumps, storage tanks, ‘tc.), shall be in accordance with the following: a. Non-Vibratory Service. The first nipple and valve shall be braced with a we'-ied gusset, installed in accordance with Fig. 1.1. Connections in the following services may be excluded: 1. Yard and instrument air 2. Water 3. Inert gas 4, Stress relieved vessels associated with utility plant boilers b. Excessive Vibrations, Piping covered by par. 7.2 and where else specified by the Owner's Engineer shall be gusseted in two planes as shown in Fig. 1.1 Bracing design for piping connections NPS 1 1/2 (48.9 mm 0.0.) requiring double block vaives shall be ‘submitted to the purchaser for approval by the Owner's Engineer. LOCATION OF CONNECTIONS. ‘Ail small piping connections (< 1-1/2 in. NPS or 40 mm) shall be fabricated using a minimum length of pipe ‘between the takeoff point and valve, and without the use of elbows between the valve and takeoff point so that the outlet of the valve is within 9 in. (225 mm) of the branch connection. Deviations from this requirement for alternative piping arrangements will be specified. {All steam, instrument air, and fuel gas take-off connections shall be from the top of the supply he Condensate line connections into condensate return headers shall be at the top of the header. General Note: Bracing detail applicable to extended body type valve, oF compact Body valve pus nipple (as, Tustatec JOINTS AND FLANGES, Soft-sealed ball and plug vaives with buttwelding ends, socket-welding ends, or threaded ends requiring seal welds, shall rot be welded into the line with any soft seal materia in place. Exception to the requrement may bbe made only when the valve manufacturer certifies that removal of these materials is not necessary to prevert ther destruction due to heat of welding. Flanged vaives and check valves shall have a flanged spool piece or piping between them to allow for bolt removal and insertion. Pump discharge vaives may be exempted as por 1SP3-3-2, Fig. 1-1 ‘Taper pipe threads (NPT) per ANSI/ASME B1.20.1 shall be used for al threaded pipe joints. including thermowell, nozzles ‘Threaded connections not requiring seal welding shall be made up using sealing compounds or tapes that are sutable for the service conditions. ‘Threaded cast iron valves shall not be usod where seal welding is required. \When approved by the Owner's Enginaer slip-on flanges shal be positioned so thatthe distance from the fa flange to the pipe end shall be equal to the nominal pipe wal thickness, plus approximately 1/8" (9 mm). The welds shall be applied in a manner that wil not require refacing ofthe flange ‘Slip on flanges are not permitiad on elbows, Metering runs shall be in accordance with IBP3-6-1. Flange bolts shall straddle the established centertines (horizontal, vertical. or layout centerlines), except at equipment flanges when requited for matching orientation at equipment langes.THPERIAL [__1BP3-18-1 PIPING FABRICATION Page 9 of 16 SHOP OR FIELD e@ BASIC PRACTICE Dec._1990, 95.1 96 97 oat 10.1 10.1.1 102 ctt03 104 105 "05.1 JOINTS AND FLANGES (Cont) Bolting. The use of washers or other packing to use up excessive length of flange bolts is not acceptable. The length of machine and stub bolts shall be such that all nuts are fully engaged. Stub-ends for lap-joint flanges, if fabricated by welding, shall be made with complete penetration welds. The use of pipe unions shall be governed by the following: a. Pipe unions between process vessels, line, or equipment and the first block valve are prohibited. b. Pipe unions sizes NPS 3/4 to 1-1/2 (NPS 19-40 mm) are permitted at connection points to machinery except in lines handling toxic materials. Deleted Socket welding. Prior to welding, the pipe shall be positioned in the socket with its end 1/1 bottom of the socket. A minimum of two weld passes shall be applied at each socket joint. (2 mm) from the WELDING JOINTS. Welding end preparation. Uniess otherwise required by the piping material or welding processes to be used, welding ends shall be propared per ASME/ ANS! B16.25, except that for wall thicknesses of 3/16 to 3/4 in. (5 10, 19 mm) inclusive, the bevel angle may be reduced to not less than 30 degrees. All coatings (paint, rust inhibitor ete.) shall be removed from weld joint areas including the bevel and 1/2 in (13 mm) on ether side of the joint. Radial misalignment at the joining ends of piping components shall be limited to 1/8 in, (9.2 mm) or 1/4 the pipe wal thickness, whichever is lass. Internal radial misalignment exceeding 1/16 in. (1.6 mm) shall be taper ‘rimmed so that the adjoining internal surfaces are flush; however, the resulting thickness of the welded joint shall ‘not be less than the minimum design thickness plus corrosion ‘allowance. Backing rings may be used when approved in writing by the Owner's Engineer and for the following applications and in the following manner: a. For piping under jurisdiction of the ASME Code Section 1. For piping in clean steam and air service. Backing ring chemistry shall match the base metal chemistry. ‘Backing ring shall be fused into the joint for the entire circumference by providing a sufficiently wide root gap. For castable lined pipe. Backing rings are prohibited for the following applications: a. “Pigged'" lines. b. Auxiliary piping for machinery, including (but not limited to) piping systems such as jacket cooling water, fu lube oil, seal oil, instrument and starting air servicing compressors, turbines, engines, gears. Intake and interstage piping for reciprocating, and rotary screw compressors. Consumable inserts are not classified as backing rings, and may thus be used for all applications. Chemistry of insert shall match the base metal chemistry. Pressure welds shall be identified as follows: a. Wolds on P1, PB and Nickel Alloy materials for service above -20°F (-29°C) shall be stamped immediately adjacent to the weld with the idantication symbol of the welder or welding operator making the weld. For al alloy material (P3, P4, P5, PS, P7, P10 and P11) in service above -20°F (-29°C) the stamping of the welders or welding operators symbol shall be done with ‘Low Stress’ stamps as commercially available For service below -20°F (-29°C) any system, except metal tags, which correlates the welded joint with the welder or welding operator, other than direct stamping on the weld or pipe, may be used ADDITIONAL REQUIREMENTS FOR CEMENT-LINED CARBON STEEL PIPE AND FITTINGS 108 Butt welded pipe joints for cement-ined pipe and fittings shall be made up using any of the following procedures: 2, Butted joints. The root faces of the adjoining pipe walls shall be tightly butted (no gap for welding). No coating (or gasketing of the cement lining faces shall be done. b. Sodium silicate coated, gasketed joint. Both ends of the lining shall be coated and a 1/16 in. (1.6 mm) gaskat installed between the facings ofthe ining. The gasket shal not extnd betwoen the ends of he ine walls. ©. Epoxy cement coated joint. A uniformly applied layer of epoxy cement, approximately 1/16 in. (1.6 mm) thick, shall be applied to both ends of the cement lining. Initial set of the epoxy cement must lake place before welding1BP3-18-1_| [ae Page 10 of 16 PIPING FABRICATION SHOP OR FIELD ev. 11|_ Dec. 1990 BASIC PRACTICE 107 108 109 WELDING JOINTS (Cont) For pipe diameters < 24 in. (600 mm) the welding arc shall not come into direct contact with the cement lining ‘This shall be accomplished by the use of partial penetration welding or backing rings. To insure that a sutfciont amount of weld metal is deposited for the intagnty of the joint while stil maintaining partial penetration, a mockup test together with joint and welding details shall be submitted to the Inspector for approval prior to production welding For pipe diameters > 24 in. (600 mm) the lining shall be cut back 2 to 4 in. (60 to 100 mm) from the end prior to ‘welding to permit full penetration welding, with or without backing rings. This area shall be manually cement lined after welding is completed Deleted. ADDITIONAL REQUIREMENTS FOR CAST REFRACTORY LINED PIPE. 10.10 ean wat ‘All piping sections to be lined with castable refractory shall either be match marked and provided with truing rings (see Figure 2) prior to the installation of lining, or the lining shall terminate 8 in. (200 mm) from the pipe fend to faciltate field fitup and welding. Hammering or deforming full lined pipe (.e. lined to the end of the pipe) to effect joint fitup with other pipe is not acceptable, WELD PENETRATION, PROJECTION, AND DEPRESSIONS Penetration requirements for longitudinal, girth-butt, miter and branch connection welds shall be as follows: ‘a. Ail longitudinal welds shall have 100% penetration to the root of the joint b. Girth-butt, miter, and branch connection welds shall be as follows: TYPE OF WELDED CONNECTION Ce 1. Girtr-butt. miter, fabricated branch | Indiviual and total cumulative length of Connection, NPS 2 (60:3 mm OO) | incomplete penetration, bum-through, and and larger: ‘lag incusions shall not exceed the ‘Acceptable lenis Yor slag inclusions per ‘ASME. Code Section Vill par. UW.51 land IBP_20-2-100. 2. Branch connections NPS 2 and | Welds shall not show incomplete ‘alien enetration; cracks; or other intemal Slscontnuites such as slag of nontusion {hat extend more than 1/2 the apparent width, length, oF height of the wold {projected cross section in the radiograph fin). 3, Socket-welding connections. ‘The ond of pipe nipple or body ‘extension of extended body valves shall ‘ot be in contact wih the bottom of he socket. Maximum allowable projections of weld metal into the pipe bore at welded butt joints shall be per ASME 831.3 ‘and the following: Projections shall not exceed 1/8 in. (3 mm), except that in piping 2 In. NPS (50 mm) and smaller and “pigged" tines the maximum projection shall be 1/16 in. (1.5 mm). b, Plastic or elastomeric lined pipe. internal porous areas, cavities and pockets shall be filed with weld metal, Al internal welds shall be ground to a smooth, uniform surface. ©. Orifice tlanges and ‘meter tubes”. Welds joining orifice flanges to pipe, or "meter tubes" to pipe or fitings shall have an ID smooth and flush’ with the ID of the pipe. 4d. Internal welds of the intake and interstage piping for reciprocating, and rotary screw compressors, shail bbe ground smooth and flush with the ID of the pipe. If this cannot be done, the root pass shall be made by an inert gas welding process and the underside of the weld protected from oxidation by inert gas purging during welding Excessive weld projections on accessible joints shall be removed by grinding, Welds having excessive projections ‘on inaccessible joints shall be cut and rewolded, Concave root surface ("Suck-up” or “Suck-Back") and root undercut are acceptable it: a By visual inspection, the depth of the cavity does not exceed 1/32 in. (1 mm) ». By radiographic examination, the density (blackness) of the radiographic image is the same or lighter than that of the adjacent base metal. For this examination, the weld reinforcement shall not exceed 1/16 ja. (1.5 mm).THPERIAL [_1BP3-18-1 el PIPING FABRICATION Page 11 of 16 SHOP OR FIELD T PRACTICE Rev. 11) Dec. 1990 WELD PENETRATION, PROJECTION, AND DEPRESSIONS (Cont) c.The length of the root undercut does not exceed 2 in. in 12 in, (60 mm in 300 mm) of weld length, or 1/6 the length of the weld, whichever is smaller. 11.4 Permissible repair of root defects. On accessible joints, root defects including excessive projection may be © 124 repaired by welding or grinding or both from the root side. Root defects on inaccessible joints shall be cut out and rewelded HEAT TREATMENT Hardness of the base metal, and of the weld metal and the related heat affected zone (HAZ) ofall welds including attachment welds shall not exceed the limits given below. Tests shall be conducted with a Brinell Testing Machine, A portable hardness tester may be used, providing: a. The diameter of the indentation ball is not smaller than 7 mm and not larger than 10 mm, and b. The hardness of the reference bar is within + 12.5% of the maximum hardness required for the specific material ‘The hardness test for the HAZ shall be made with the ball centered in the HAZ to represent a composite of the weld metal, HAZ, and base metal. ‘WATERIAL | BRINELL HARDNESS PLNUMBER a Pa, @) 200 PS, PA, P5, PS | 225 e7 | 235 Pao, P12 l 225 Notes: (1) For base metal, use the lower of the value shown, or the value given in the specific ASTM standard. For weld metal and HAZ use the lower of the value shown or the value in ANSI 831.3. (2) No testing is required on the HAZ. Testing is only required on the base metal if hot forming followed by water ‘quenching is used. Examination shall be made in the presence of the Inspector to verify compliance with the above hardness valu C 122 The minimum number of welded joints to be examined to verity the specified hardness values of weld components (e., base metal, weld metal, and HAZ) shall be determined from the following: MINIMUM NUMBER OF WELDED JOINTS FOR HARDNESS TESTS PER APPROPRIATE POSTWELD HEAT TREATMENT (PHT) CATEGOR MATERIAL | WELD NUMBER | COMPONENT conaenyiy ceo 2) Category 8 Materials not Matoals which have Materials which have sequng PHHT Deen locally, PHT eon mace PAT =A woo 173 of a 776 of al welded joris waded fonts | Base Metal As required (G00 Note 2) None HAZ Nene None raz] Wold Pt | nae sem $ E50) (1/9 oa welded jets | 1/6 of a wold joints | ® wel els pwr trace tes | go P10 a Note (1) Test only welds made by the: ‘a. SMAW process using ferric filer metal other than Class E60-70XX per ANSI/AWS AS.1.IBP3-18-1 TMPERIAL Page 12 of 16 PIPING FABRICATION SHOP OR FIELD ev. 11] Dec 1990 BASIC PRACTICE 12.21 123 9 "124 125 126 127 128 1311 144 c 142 1424 HEAT TREATMENT (Cont) b. GTAW(TIG), GMAW (MIG or MAG) processes using filer metal other than ER70S-2 through ER70S-5 per ANSI/AWS A5.1 c. FCAW. (Flux-cored) CO; process using filer metal other than E7OT-1 with pure CO, or E70T-d per ANSI/AWS A5.20. 4. SAW (submerged arc) process using filer metal other than a combination of ELX or EMX wires per ANSI/AWS A5.17 and a neutral flux approved by the OWNER'S Engineer. @. SAW (submerged arc) process using ANSI/AWS AS.17 EMX filer wire and active flux or EHX filer wire and. neutral or active fx. (2) When heating and water quenching is used such as for straightening or alignment, testing is required only for Piping with nominal wall thickness greater than 3/4 in. (19 mm). All areas treated inthis manner shall be tested. (@) All areas locally heated for bending or straightening and not receiving a subsequent PWHT shall be hardness tested. ‘Seal welds made on piping having P-numbers 1, 3, 4, and § aro exempt from hardness test requirements ‘Additional hardness tests (tracer examination). For each weld component found to exceed the specified hardness, like components to two additional welded joints Selected by the inspector shall be hardness tested. These adcitional ‘examinations shall be progressive. PWHT is required for welded components of longitudinally welded carbon stee! pipe in wet HS service. The PWHT procedures outlined in ASME B31.3, par. 331.1 shall be followed. The exemptions provided in Table 331.1.1 ‘based on nominal wall thickness are not permitted. Ail welds, regardless of type oF size, that are exposed to wet HS shall be PWHT at a minimum temperature of 1150°F (620°C). External attachments, circumferential buttwelds made {rom the OD only on seamless pipe, or seal welded threaded connections on P-1 Group 1 and 2 materials do not, require PWHT, unless also in amine, caustic or carbonate service. PWHT for piping handling alkaline solutions shall be governed by the following: a. The postweld heat treatment procedure outlined in ASME B31.3, par. 331.3, shall be followed. The exemptions provided in Table 331.3.1 based on nominal wall thickness are not permitted. Socket welded and seal welded threaded connections forall pipe sizes shall also be postweld heat treated. The minimum holding time atthe full ostweld heat treatment temperature shall be 1 hour. b. Attachment of clips, brackets, or other devices requiring welding directly to the inside or outside of vessel or piping walls after postweld heat treatment is not permitted unless the heat treatment is repeated on the ‘equipment or material after welding. Materials not covered by ASME B31.3. Heat treatment requirements for welded joints or bends of materials not covered by ASME B31.3 shall be submitted to purchaser for approval by the Owner's Engineer. Exposed machined and threaded surfaces shall be protected from oxidation during heat treatment. Welding or heating, after final heat treatment, is prohibited. CLEANING OF PIPING ‘After completion of fabrication and heat treatment, all piping shall be cleaned inside and outside to remove all loose scala, weld splatter, sand, and other foreign materials. INSPECTION AND TESTING ‘The term Inspector, used in this Basic Practice, refers to the Owner's representative Inspection Standards. Inspection of ail piping shall be per ANS! B31.3, and ANS! B31.1 except as modified in this Basic Practice. Where applicable, the welding of fabricated piping shall pass the inspection of the Province in which itis to be installed. 9 NONDESTRUCTIVE EXAMINATION 43 Minimum required inspection. A minimum of 5% of the welded joints (including girth-butt, miter and branch connection welds), selected by the Inspector, shall be examined by radiography as specified below. “in-process” ‘spot MT (magnetic materials) or PT (nonmagnetic materials) examination may be substituted for branch connections where the branch diameter does not exceed 50% of the run diameter and for all integrally reinforced branch connections, Ultrasonic (UT) examination may be substituted for RT examination of branch connection welds ‘The requirements of this paragraph do not apply to welds for slip-on flanges and seal welds. a. Joints In pipe up to and including NPS 30 (762 mm OD) which are selected for examination shall be 100% radiographed.] [_1BP3-18-1 PIPING FABRICATION Page 13 of 16 SHOP OR FIELD BASIC PRACTICE Rev. 11| Dec. 1990 149.1 144 cus 145.1 INSPECTION AND TESTING (Cont) Pipe larger than NPS 30 (762 mm OD) shall be spot examined by radiographing 2 spots, atleast 90 degrees apart, per joint selected. b. AS a part of the minimum radiographic examination requirements, at loast one weld for each weld procedure and position of weld made by each welder shall be radiographically examined, A record shall be kept ff the quality and extent of each welder's work ‘The balance of the 5% minimum radiographic requirement, shall consist of random examination performed for each welder's work progressively throughout the entire job. cc. The length of each radiographic film, or the length of the UT examination, for each weld joint spot examined shall be 10 in. (250 mm) or half the pipe circumference, whichever is less. . For girth-butt welds including miter joints, the fim shall be placed on the underside of the pipe. For branch connections, film placement shall be as\ specified by the Inspector. All radiographs, spot or otherwise, shall meet the requirements of ASME Code Section Vill, par. UWS! ‘except where raqurements are speciticaly modified for girth welds and other weld flaws in par. 11.1 subpar. b land par. 11.3 respectively. The standard of weld qualily shall meet the requirements of ANS! 631.1, 831.3 latest dition and IBP 20-2-100. {. All radiographs, whether complete weld ot spot shall comply with the sensitivity requirements of ASME Code Section V, Article 2. For reinforced branch connections, sensitivity shall be based upon pipe wall thickness plus Pad thickness. 9. Wire type image quality indicators (IQ!) equal to those meeting DIN 64109 requirements, JIS-Z3104, or International Institute of Welding (IIW) requirements may be substituted for the ASME Code Section Vil Paragraph UW-51 provided the equivalent sensitivity obtained with ASME penetrameter is met. Equivalent Sensitivity shail be calculated per ASTM E142 Appendix X.1. The wire type IQ! shall be placed across the weld, fh. Fluorescent intensifying screens such as calcium tungstate shall not be used, 1. Additional examinations. When additional RT or UT examinations are required due to the detection of defective welds (Tracer Examinations), they shall be made immediately after the defective weld is found and are in addition to the minimum spot examination of 5% of the welded joints. |. Where 100% radiograph is required and the source is on the outside of the pipe, a minimum of three films per joint shall be taken, Inspection requirements for socket welds. As selected by the Inspector, a minimum of 5% of the socket welded joints from each welder shall be examined by raciographing per par. 14.3 subpar. be. and f. above. a. Additional Radiographs (tracer examination). Defective welds and improper joint fitxup (e.9. no gap between tend of pipe or tube and shoulder of socket) shall be repaired and raciographed. Two addtional weids made by the same welder shall be radiographed immediately as designated by the Inspector. These examinations are in addition to the minimum examination requirements of 5% for all welds. ‘Aagitional inspection mesting tne requirements of ASME Code Section Vil par. UWS, i required or piping ‘which is to be pneumatically field tested or which has a design pressure greater than 2500 psig, (17230 kf gauge) as follows: a. All welded longitudinal joints shall be 100% examined by either AT, UT or eddy current (ET) techniques. b. Allbutt welds shail be 100% radiographed except girth welds where the pipe is less than NPS 12 (329.9 mm (0D). All other welds shall be inspected by the liquid penetrant or magnetic particie method. For piping designed for pneumatic fleld testing, hydrostatic testing in accordance with ASME 831.3 before erection may be performed instead of the radiographic inspection specified in subpar. a. and b., above. Welds in P.3, P-4, P.5, P-6, & P-7 piping materials, excluding seal welds, shall be examined as follows a. All butt welds shall be 100% radiographed per par. 14.9 subpar. @., £, and g. above. b. All branch connection welds shall be examined visually from the inside, and by magnetic particle (A-C Yoke) method from the outside. Double welded joints shall also be MT examined prior to back welding. All branch connections to pipe walls exceeding 1/2 in. (12.7 mm) in thickness, shall also be 100% UT examined. In this latter case, MT examination from the back side is not required. Fillet weld joints, such as for slip-on flanges and socket welding fitings, shall be examined by the magnetic Particle (AC Yoke) method from the outside. 4. For branch connection and fillet welds, a minimum of 10% of the root passes, selected by the Inspector, shall be examined by the magnetic particle method. Magnetic particle examination and acceptance criteria shall be per ASME Code Section Vill, Appendix 6, In P8 materials, forthe first 10 ft. (9 m) of buttwelds, 50% of the joints shall be 100% radiographed for each welder ‘and 5% thereafter per par. 14.3 subpar. b.,e. and f. above. For other joints where radiography is not possible, the weld shall be examined by liquid dye ponetrant per ASME Section Vill Division 1 Appendix 8.IBP3-18-1 WHPERIAL Page 14 of 16 PIPING FABRICATION ‘SHOP OR FIELD fev. 11| Dec. 1990 BASIC PRACTICE e INSPECTION AND TESTING (Cont) 145.2 Welds of P-number materials as described in paragraph 14.5 made with other than matching electrodes shall be 100% radiographed per paragraph 14.3 subparagraph b.@. and f. 1459 Bhmetallic welds shai: 72 100% radiographed per paragraph 14.9 subparagraph @. and 1 14.5.4 When cast components are radiographed they shall be examined as follows: a. A minimum radiographic examination of 10% of the production from each pattern, plus magnetic particle ‘examination of 100% of the production castings, shall be accepted by the inspector. Austenitic castings shall be ‘examined by the liquid penetrant method. Alloy steel castings supplied to ASTM A-217 shall be fully radiographed The above requirements may be relaxed when the foundry supplying the castings can establish to the satisfaction of the Owner's Engineer that their standard procedure for production quality control produced sound top quality castings. 4. Radiographic quality for castings shall meet ASTM E-7t, Class 2, for castings up to 2" (51 mm thick and Class 2 of the appropriate ASTM standard for heavier thickness. © 146 Requirements for aluminum. All welded joints shall be ful radiographed for the complete length of the weld. The ingpecton shall be made in accordance with the requirements of par. 14. subpar. @. and f,, above. 14.8.1. For other non-ferrous materials, 50% of the joints for the first 10 ft. shall be 100% radiographed for each welder and 5% thereafter per par. 14.3 subpar. b., ©, and f. above. “14.7 Sectioning prohibited. Spot examination by sectioning is prohibited, except as may be specified by the Inspector to Confirm quality of a weid joint that cannot be determined by non-destructive methods of examination. Procedures. Used for sectioning and repair shall be approved by the Inspector. ULTRASONIC EXAMINATION "148 Ultrasonic examination, where specified, shall be per the ASME Code Section Vill, Appendix 12. 14.9 Where the pipe wall thickness exceeds 1-1/4 in. (32 mm) all wolds shall be 100% ultrasonically inspected in leu of radiographic examination when a single wall radiographic technique cannot be used. e 14.10 Proposals to use ultrasonic examination in lieu of radiographic examination for banch connection nozzle welds shall be submitted to purchaser for approval by Owner's Engineer. IMPACT TESTING 14.101. Piping material shall meet the impact requirements of IBP18-6-1. SHOP TEST PRESSURE TESTING REQUIREMENTS "14.11 Hydrostatic testing of individual sections of shop fabricated piping systems is not required, excopt as may be specified. If specified, the test shall be per ANS! 831.3 or ANSI B31.1, except as modified in IBP 3-19-1. 14.12 Each complete fired neater tube assembly (or coil configuration) including any flanges, fitings, couplings, etc. shall be hydrostatically tested. Hydrostatic test pressure shall be 1.5 tmes the design pressure, but not less than 200 psig {1380 KPa). SHIPMENT, HANDLING, AND STORAGE PREPARATION FOR SHIPMENT 15.1 Protection of openings, After completion of inspection, all shop fabricated piping (piping not fabricated at the job site) shall be prepared for shipment a8 follows: a. Flanges shall be protected over the entire gasket surface with metal, hardboard or wood protectors securely attached b, Piping with J-beveled ends shall be protected by firmly attached covers. ¢. Threaded-end or socket welding-end connections shall be fited with metal, wood, or plastic plugs or caps. 15.1.1. All prefabricated piping which isto be painted with the exception of 18-8 Cr-Ni steel piping, shall be given one ‘shop primer coat in accordance with IBP 19-1-1 152 Machined or threaded exterior surtaces of carbon steel, and ferrous alloys with a nominal chemistry of 12 Cr ‘and below shall be protected from corrosion during shipment and subsequent storage by coating with rust BBreventative ofa typ: (1) to provide protection during outdoor storage fora perid of twelve months exposed to a hormal industrial environment and (2) to be removable with mineral spints or any Stoddard solvent Last ERE BP reviewed — Rav. 10, March 1980TwPERIAL IBP3-18-1 PIPING FABRICATION Page 15 of 16 SHOP OR FIELD Figure 1 DIMENSIONAL TOLERANCES ‘eciac senvice (omign Temosrenare Se8a" S Hones neung > NonmaL sEnvice sna em 090 7 VB" max from indhated dimensions for face {fo facn, contr 0 faen, location & attache, pow re (es ems roma) ima er crew Smt) Fring, massed at teres betwen the ‘mosimur end naman O8 3 ay as acon, 2 max ar E16" max etre aneton {ranaurion of prancnes | Of branches o connection qo J di | = 1/16" max rotation of flanges rom the indicated ioe ciareer ax. | of Hanger tom whe indicated Gato aligneant of Rangee’| poution messed trou any from the incigate postion, | Gimenee. ‘recured soroet Boy “Aecwptaane Metre Equivien ee 1a ee mm 08. 2 eee(BP3-18-1 Page 16 of 16 PIPING FABRICATION SHOP OR FIELD Figure 2 CASTABLE LINING AND JOINT MAKE-UP DETAILS DETAR A Detall at Fleld Welded Joint For Precast Lining Lining Paces ‘after exerination ot wea Termination of ning from wala ning 1 tnitiat ining DETAL B Detall at Field-instaiieg Cast Linings or Between Precast Sections ‘wren Truing Ang Not Used Notes: vennx JE 478 i min. iote'D LUning 10 V70 In, max Tack weia Weegee 19 Pipe and Trung Ring Arter Fie. 4, lee DETAR C Lining Detail at Flanged Joint THERTAL, BASIC PRACTICE prota woises joint fiote 2 [De Pipe OD + 172 In. Remove after tela wweleed yolat complete) (1) Water resisting castable or high temperature mortar coated joint. Uniformly applied coating, about 1/16 in thick, to both ends immediately pror to welding or ange make-up (per applicable deta). (2) Pipe ends shal bo cut ~ one plane perpendicular to the axle of the pipe and beveled. Backing rings shall be installed about 5/8 in above the land at the <2 feet bevel, and paralialwith the plane of the land win #1/32 i Acceptable Metric Equivalents in a2 Gee 2 5/8 fgEEEEIOl 75100200No K SEAL WELD BAR 2" x 1/4" cur To FIT IBRAT ION GUSSETTING BAR 2" x 1/4" 7 CUT To FIT HORIZONTAL_OR VERTICAL CONNECTIONS SEAL WELD. 1/4" PLATE cur To FIT ANGULAR CONNECTION GUSSETTING FOR EXCESSIVE VIBRATION TWO_PLANE GUSSETING ORIFICE TAP CONNECTIONS (SEE NOTE 3) EOUIPMENT WALL NOTES: 1. GUSSETS SHALL BE INSTALLED AS REQUIRED By 18P 3.16.1. 2. GUSSETS SHALL BE WELDED TO VALVE. NIPPLE & PIPE OF FLANGE. 3. BRACING DETAIL APPLICABLE TO EXTENDED BODY TYPE VALVE» OR COMPACT BODY TYPE VALVE. OR COMPACT BODY VALVE PLUS NIPPLE. (AS ILLUSTRATED) IMPERIAL BASIC PRACTICE Essa) GUSSET DETAILS fore tee 3.18.1 [7]IMPERIAL BASIC PRACTICE IBP 3-19-4 PIPING ERECTION AND TESTING REV 8 JUNE’88 PAGE 1 OF 10 ‘SCOPE ‘This Basie Practice covers mandatory requirements governing the erection and field testing of piping systems, 1.2 "The tne Mashing requirements of this Basic Practice are also mandatory when spesifed inthe Job specification. 1.3. *Anastetisk (*) indicates that additional information is required. Ifa job is contracted, this additional information is furnished in the Job Specification. ‘SUMMARY OF ADDITIONAL REQUIREMENTS 21 Table 1 ists the Basic Practies, codes and standards which shal be used with this Basic Practice TABLE 1 Basie Practices 1BPO-0-1 General Conditions 1BP3.2-1, Sanitary and Industrial Sewer Systems IBPI8-6-1 Impact Requirements for Material IBP19-7-1 Stress Cracking Prevention of Fabricated Stainless Steel IBP20-1-1 Inspection of Equipment and Materials 1BP20-1-2 ‘Administrative Procedures for Obtaining Imperial Oil Limited Inspection Codes and Standards ‘ASME Codes ~ Section I Power Boilers Section V Nondestructive Examination ANSI Standard B313 Chemical Plant and Petroleum Refinery Piping BLL Power Piping ASTM Standard E427 ‘Testing for Leaks Using the Halogen Leak Detector (Alkali-on Diode) ERECTION FLANGE JOINTING PRACTICE 34 ‘Alignment tolerances of mating flanges shall be per the following: cS L ©IMPERIAL |BP 3-19-1 REV 8 JUNE'88 PIPING ERECTION AND TESTING PAGE 2 OF 10 BASIC PRACTICE ‘Total Tolerance per Flanged Joint SPECIAL SERVICE a. Design Temperature = 850°F (455°C) or Flange Rating = ANSI CLASS 900 | ITEM NORMAL SERVICE b. Where plastic or elastomeric liner (lapped over the flange faces) provides the gasket for Joint 1 | 3/32 in, per foot(1:125) (8 mm per meter) of | 1/32 in.(1 mm) max. out of parallel alignment nominal pipe diameter max. out of parallel | of flanges measured across any diameter. alignment of flanges, measured at any point on the flange periphery. 2 | 1/4 in. mm) max, translation of branches or | 1/8 in, (7 mm) max. translation of branches or connections. connections. Acceptable Metric Equivalents in, 1/32 WIG 1B 1/48SOPF. mm 1 See eee 4556C 3.2 Flange “makeup” shall be with clean gaskets. The use of gasket sealing compounds or sealing agents is prohibited, except for the anti-stick release agent or graphite supplied on compressed asbestos gaskets. 3.3. Flanged pipe joints of cement lined pipe with installed flangeless type valves. If itis necessary to grind the lining at the pipe ends to avoid interference with the action of the valve disc (or plate), the lining shall be taper ground and coated with epoxy cement. ADDITIONAL REQUIREMENTS FOR PIPING OVER NPS 3 (88.9 mm OD) CONNECTED TO ROTATING MACHINERY PIPING ERECTION AND FLANGE ALIGNMENT 4.1 A detailed piping erection procedure shall be prepared for each rotating equipment machinery category to cover: a. Piping erection sequence b. Flange alignment techniques Methodology shall cover inital and final “cold” alignment, alignment. ‘ing support adjustments, and ‘*hot”” *The procedures shall be submitted to Owner's Engineer for approval. In addition, procedures and the sequence of alignment for mult-casing compressor trains shall be mutually agreed to by contractor, machinery vendor, and Owner's Engineer 4.2 During initial flange alignment: a. Permanent spring supports shall be locked in “‘cold load” position during piping erection and hydrostatic testing, ‘No unsupported piping shall be connected to the equipment nozzles. Flange or field welded joint makeup shall be done progressively away from the equipment nozzle. 4. Piping shall be free of load-imposing temporary restraints that will result in ‘cold springing” of the piping. €. If prefabricated piping sections are used, at least two welds shall be left near the nozzle flanges for final fitting and alignment. f. Final bolt tightening of piping flanges near the equipment nozzles shall be done after initial alignment of the equipment nozzle flanges.IMPERIAL IBP 3-19-1 PIPING ERECTION AND TESTING REV 8 JUNE’88 PAGE 3 OF 10, BASIC PRACTICE 43 44 45 46 47 {8 Local heating to correct minor misalignment is permitted on piping that does not require postweld heat treating. 1h. Machined pins furnished with the mating flanges shall be used to align flange bolt holes during field erection of the mating piping. Equipment nozzle and mating flange alignment tolerances shall be within the following maximum permissible limits: a. For steam turbines and compressors other than reciprocating types, 1/64 in, (0.4 mm) for all sment categories listed in subpar. b. below. (For nozzles greater than 24 in. NPS (600 mm), the machinery vendor shall supply mating flanges] b. For centrifugal pumps and other rotating machinery: Maximum Permissible Misalignment of Flanged Joints 512 NPS S22 NPS > 24 NPS 1. Vertical bolt hole offset 18 1/16 1/64 2. Horizontal bolt hole offset V8 1/16 17/64 3: Rotational offset 18 1/6 1/64 4. Flange face paraltelism (across diam.) 1/64 1/64 1/64 5. Flange face separation, plus space required for gasket £18 £116 + 1/64 Acceptable Metric Equivalents foie 1/64 1/16 21/8) Dee 22 eee 2A) fin) O40 1:53 900/41 590/ 2000) Final support adjustment. For liquid service, final adjustments of spring support shall be made with the piping filled with process liquid. During final “cold” alignment: a. Piping and equipment nozzle flange alignment shall be verified after the equipment has been aligned and grouted. Alignment checks will be witnessed by the Owner's Enginecr. Note: If the machinery tran includes a gear unit, the level, shaft parallelism, and tooth contact pattern shall be checked prior to grouting the baseplate, Driver and driven equipment shall be aligned to the gear unit. sment method shall be used for “‘cold” alignment checks of any special tor bracket sag shall be checked and recorded; and, final readings shall, b. The reverse indicator ali purpose equipment. Indi include sag corrections. During “hot” alignment: a. Any of the following methods are acceptable for “‘hot’” alignment checks of equipment and equipment nozzle flange alignment: Dodd Bars, Essigner Bars, Optical Alignment. .. Steam turbines. A preliminary ‘hot alignment check shall be made prior to start-up of the process unit. Operating procedures, and source for steam supply and discharge will be developed by the Owner’s Engineer. Any change in alignment greater than 0.002 in. (0.5 mm) {0.004 in. 30.10 mm) in total Indicated Reading (TIR)] is unacceptable. ‘A final “hot alignment check is required for special purpose steam turbines, and on all general purpose steam turbines with design operating temperatures over 300°F or 150°C. “Cold” and “*hot” alignment checks shall be witnessed by the Owner's Engineer.IBP 3-19-1 REV 8 JUNE'88 PIPING ERECTION AND TESTING Ft PAGE 4 0F 10 |_BASIC PRACTICE e 4.8 Records of pipe flange misalignment showing the effect of the piping connections on the machinery shaft alignment shall be provided to the Owner's Engineer. The following data are required: a. Ambient temperature at which flange misalignment is measured. bb. Machine-to-driver shaft alignment: (readings before, during and after flange bolt tightening). 1, Radial alignment: (maximum dial gage runout measured perpendicular to the shaft on therim of the coupling hub). 2. Axial alignment: (maximum dial gage runout measured parallel to the shaft on the face of the ling hub near the rim). ¢. Flange misalignment: (final *‘cold”” alignment and “hot” alignment). Vertical bolt hole offset Horizontal bolt hole offset Rotational offset Flange face parallelism 5. Flange face separation 4.9 — Machinery-to-driver misalignment limits recorded during “cold alignment of piping shall be per the ‘Condition Maximum Permissible Misalignment “Cold” Alignment meskes 2 Rage wi 9 TRS eiuga ) b. During piping joint and flange | 1. Pumps and General Purpose Turbines: Change in shaft 2. Special Purpose Equipment (Unspared Equipment): Change in | { shaft alignment less than 0.002 in. (0,004 in. TIR) | c. All piping connected ‘All alignment readings are within 0.002 in. (0.004 in. TIR) “Hot” Alignment Within values recommended by the rotating machinery and coupling manufacturers, and within specified tolerances. Notes: (0) :"Cold target” values are the rotating machinery vendor’s recommended values. Q) TIR-Total Indicated Reading General Note: _. Acceptable Metric Equivalents in. 0.001 0,002 0.004 0.005 0.010 mm 0.025 0.05 0.10 0.13 0.25 ‘TESTING AND FLUSHING 5.01 Pressure testing is required in accordance with the applicable code (ANSI B31.1, B31.3 or ASME Section 1). The hydrostatic and pneumatic test procedures outlined in the applicable code shall be followed except as moditied in this Basie Practice. C a Rotating machinery, such as pumps, turbines, and compressors. Associated lube and seal ofl systems which could be impaired by the presence of water shal be tested with lube oi b. Strainers and filter elements.IMPERIAL Bp 3-19-1 PIPING ERECTION AND TESTING REV 8 JUNE'88 PAGE 5 OF 10, BASIC PRACTICE ©. Pressure relieving devices, such as rupture dises and pressure relief valves. Any equipment which does not have a specific test pressure at least as great as the piping test pressure. .. Vessels which do not satisfy impact requirements at the piping test temperature. £, Equipment lined with uncured phosphate bonded castable materials unless approved by lining ‘material manufacturer. ‘8. Piping which is normally open to the atmosphere such as drains, vents, discharge piping from pressure relieving devices, sewers, and flare piping and stack downstream of seal drum. h. Locally mounted instruments and indicating pressure gauges. Bypasses or substitution of spool pieces for the instrument, shall be used for test purposes, Spool pieces shall be provided by the Contractor. These may be fabricated from end cuts of pipe and plate flanges, and shall be subsequently turned over to the refinery. "i Pressure vessels and exchangers, unless specifically approved by the Owner's Engineer. j. Lines open to the atmosphere such as drains, vents, safety valve vents, etc. Visual inspection shall bbe made to ensure that all joints are properly connected. *k. Any other equipment designated by the Owner's Engineer 5.1.1 Two or more lines may be combined into one test system. 5.1.2 While piping is under test, care shall be taken (o ensure that excessive pressure does not occur due to an increase in ambient temperature. 5.1.3. Where repairs are necessary, lines shall be retested satisfactorily prior to acceptance. 5.2Isolation of connected lines. Piping which connects to, or is continuous with piping installed by Others shall be isolated from these lines by pipe test blanks or blinds during pressure testing and line flushing, IF iis necessary to include portions of such lines i the tes, the Owner's Engineer shall be informed. 5.3 Piping containing soft-sealed valves shall be flushed and drained before the valves are installed. 5.4 Control valves shall be excluded from pressure testing and line flushing to protect the valves from dirt, scale and foreign objects. The valves may be replaced with spool pieces or the ends of the pipe blanked off, as appropriate 5.5 All restrictions which would interfere with filling, venting, draining or flushing shall not be installed until after completion of the pressure test and line flushing operations. This includes orifice plates, flow nozzles, venturies, variable area meters, PD meters, turbine magnetic meters, strainers, and all other in-line equipment. 5.5.1 Bleed valves associated with block valves used for onstream equipment isolation and which are normally in the closed position shall be plugged. 5.5.2 Valves for low temperature service (operating temperature less than -100°F (-73°C) shall have grease and moisture removed from valve internals prior to start-up. 5.6 All piping joints (including welded joints) shall be left unpainted and uninsulated until after completion of field pressure testing. 5.7 Underground line joints shall be left exposed until after completion of field pressure and leakage CG _ testing unless partial backiiling is required for anchoring lines. Underground lines with concrete thrust blocks shall not be tested until the concrete has cured. 5.8 Temporary supports shall be used during hydrostatic testing, flushing, and solvent cleaning of piping which has not been designed to carry the weight of the piping full of water. INSTRUMENT PIPING AND SAMPLING CONNECTIONS 5.9 Instrument take-off piping and sampling system piping, up to the first block valve, shall be tested with the piping or equipment to which itis connected.- “IMPERIAL le 3:94 REV 8 JUNE'SB PIPING ERECTION AND TESTING sso) PAGE 6 OF 10 BASIC PRACTICE 5.10 Instrument lead lines, between the frst block valve and the instruments to which they are connected, shall be pressure or leak tested with the instruments disconnected, and the followin, ‘a. Instrument lead lines with a design pressure equal to or greater than 1000 psi (6900 kPa) shall be subjected to the same test pressure as the piping or equipment to which they are connected. 'b. Instrument lead lines with a design pressure less than 1000 psi shall be leak tested with air or nitrogen to a pressure of 90 to 100 psig (690 kPa). ‘Testing may be performed separately or at the same time the piping or equipment is tested. DOWTHERM PIPING $.10.1 Lines in Dowtherm service shall be leak tested following hydrostatic testing and flushing of the lines. Leak testing shall be done using one of the following medi a. Dry air and soap solution. b. Freon gas. The following test procedures and acceptance criteria shall be used. Proposals for the use of alternatives shall be approved by the Owner's Engineer. ‘A. Dry Air and Soap Solution Testing 1. Drain and dry the system using forced air. 2. Perform a pneumatic test using instrument or yard air (or dry nitrogen) at a pressure of 25 psig. A soap solution such as “Snoop” (rather than a household soap solution) shall be applied to the following points: a. All flanged joints. b. Alll socket welded joints. c. All butt welds. 4d. Valves—all body to pipe butt welds, bonnet joints, and packing. 3. The joints are acceptable if no leakage, as indicated by soap bubbles, is found. B. Freon Gas Testing 1, The Freon gas testing procedure shall be based on ASME Sec. V, Article 10 and ASTM E427. 2. The acceptance criteria based on a Freon gas concentration of 10% is as follows: L, = 1x10! ce/s Lxv FxT Leak rate (ce/s) where: L, ity L.... Measured leak rate (cc/s) v F Gas Volume on pressure side (cc) Sampling flow rate of Freon detector probe (cc/s) ‘Time allowed for accumulation (s) 4 5.10.2 Dowtherm lines shall be steam cleaned to remove any mill scale, weld spatter, weld icicles, grease and debris from the line. ‘TEST PROCEDURES Sal Sad 5.12 3.13 Calibration records for gauges used for testing shall be provided to the Owner's Engineer. Test records shall be kept by the Contractor of each line or system of lines tested on a form similar to that shown in this IBP. Gauges used for testing shall be installed as close as possible to the low point of the piping system. ng filling so that all air is All vents, and other connections which can serve as vents, shall be open di vented prior to applying test pressure.IMPERIAL, IBP 3-19-1 PIPING ERECTION AND TESTING REV 8 JUNE'88 BASIC PRACTICE PAGE 7 OF 10 5.14 *Minimum test temperature, Piping shall not be pressure tested at metal temperatures below 35°F (2°C) ‘without specific approval by the Owner’s Engineer. Note: If testing at temperatures below 35°F (2°C) must be done, the test media shall be non-freezing. The hydrotest temperature (shop or field) shall be at least 10°F (6°C) higher than the CET for components 2 in. (50 mm) of less in reference thickness, and 30°F (17°C) higher than the CET for components ‘greater than 2 in. (50 mm) in reference thickness. 5.15. *Each test of lines or systems shall be inspected and approved by the Owner's Engineer. 5.15.1 The contractor shall satisfy himself that welding has been completed and that all joints are tight under test conditions before offering any line for inspection by the inspector. VALVES: 5.15.2. Safety valves and turbine sentinel warning valves shall be shop tested by the Owner for accuracy of set pressure not more than 60 days prior to the start-up of the unit. Date of test and set pressure shall be Lie stamped on a wired-on metal tag. 5.15.3 Valves in light hydrocarbon or liquified petroleum gas service with the seats clean and dry shall be tested with air or nitrogen at 230 psig (1600 kPa gauge) for class 150 valves and 300 psig (2100 kPa gauge) for valves with higher flange ratings. HYDROSTATIC TESTING AND FLUSHING FLUIDS 5.16 Any pipe system containing high alloy steel shall be drained immediately after testing and flushing and dried by blowing air. 517 Any pipe system containing austenitic tines steel shal be tested with potable water with a maximum chlorides concentration specified in IBP19-7-1. The lines shall be immediately drained after testing and flushed, and dried by blowing with air 5.18 *Salt water may be permitted for testing non austenitic piping, provided the contractor's test procedures are approved by the Owner’s Engineer and that they include the following: 8. Methods fr isolating austenite stainless tel ping and connected equipment from contact with salt water. b, Steps to be taken to ensure complete removal of salt water from the system after testing. 5.19 A strainer shall be installed in the fill line to minimize the possibility of foreign matter being introduced into the system during the hydrostatic pressure test and line flushing operations. LEAKAGE TEST OF UNDERGROUND LINES \ 5.19.1 Deleted 5.19.2 The leakage test of underground lines with rubber ring joints shall be as follows: a, This test may be combined with the strength test. b. Certain jointing materials may sweat when water pressure is first applied, Where this type of material is used, the leakage test shall not be started until the joints have tightened. ‘The test pressure—I.5 times the maximum operating pressure shall be maintained for 30 minutes. During this period the leakage shall not exceed the amounts specified in Table 2. At any test pressure P not included in the table, the maximum permissible leakage shall be the amount allowed at 150 psi (1035 kPa) multiplied by P P for metric 150 (1035 Cd. If the leakage during a test exceeds the maximum permissible, the Contractor shall locate and make good the source or sources of excessive leakage. The line shall subsequently be re-tested until satisfactory.IMPERIAL 1gP 3.19.1 REV 8 JUNE'88 PIPING ERECTION AND TESTING PAGE 8 OF 10 BASIC PRACTICE TABLE 2 Leakage in U.S, Gallons per Joint per Inch Test Pressure Diameter of Pipe (Litres per Joint/mm Dia. of Pipe) PSI (kPa) _ Rubber Ring Joints 50 (345) 0.00191 (0.000284) 35. (515) 0.00231 (0.000344) 100 (690) 0.00271 (0.000403) 125 (860) 0.00302 (0.000449) 150. (1035) 0.00331 (0.000493) | 200 (1380) 0.00382 (0.000569) 225 (1550) 0:00405 (0.000603) PNEUMATIC TESTING 5.20 Pneumatic testing of instrument air piping and tubing shall be performed with dry instrument air. The ‘minimum test pressure shall be 90 psig (620 kPa) for supply systems and 20 psig (140 kPa) for transmission systems 5.21 *Pneumatic testing of other piping must be approved by the Owner's Engineer. If pneumatic testi C™ approved, the test procedure and the test pressure must be approved by the Owner's Engineer. If the test pressiire exceeds 100 psig (690 kPa gauge), or 25% of the MAWP of the line, the piping, valves land fittings must meet the Charpy impact requirements of Table 3 in IBP18-6-1 at the proposed metal temperature, 5.22 Pneumatic testing of spiral welded pipe is not permissible. 5.22.1 *Following the hydrostatic test a pneumatic leak test at a pressure to be specified by the Owner's Engineer shall be applied to lines in vacuum service. The pneumatic test procedure and the pipe material must be compatible so that the possibility of failure due to brittle fracture is minimized, 5.22.2. Air and other designated lines shall be pneumatically tested and checked for leakage with a soap solution. ‘TEST PRESSURES \ 5.23 Hydrostatic test pressure shall be determined per ANSI/ASME B31.3 or ANSI/ASME B31.1 . The mechanical design conditions of the piping system shall be used to calculate the hydrostatic test pressure except for underground piping employing non-welded girth joints (such as bell and spigot). 5,24 Special test pressure requirements. Test pressures for piping at steam boilers which come within the C™ jurisdiction of the ASME Code Section 1, shall be per that Code. The requirements of Provincial Authorities shall be met. 5.25 Underground pressure piping in water service and employing non-welded girth joints (such as bell and spigot) shall be hydrostatically tested at 1.5 times the system design pressure, The test pressure shall be maintained for 2 hours while the leakage rate is measured and joints are inspected for leakage.IMPERIAL BASIC PRACTICE IP 3-19-1 PIPING ERECTION AND TESTING REV 8 JUNE'88 PAGE 9 OF 10 ~ 5.25.1 5.26 ci 64 6.1 612 613 6.14 615 62 62.1 Cast iron water lines shall be hydrostatically tested to 150% of working pressure or 100 psig (690 kPa gauge) whichever is greater. Underground non pressure sewer piping shall be tested in accordance with IBP3-2-1 PIPING SYSTEMS CLEANLINESS Flushing of lines. Piping systems shall be flushed after testing until all lines are thoroughly cleared of loose seale and debris. Instruments shall not be subjected o the following procedures. Underground lines carrying product shall be pigged at least twice in each direction after hydrostatic testing. This will remove water and foreign materials from low points. Nitrogen shall be used for conveying of pig. are flushed into vessels, this flushing shall be done prior to the cleaning of the In addition to flushing, all steam lines shall be blown before traps are installed. All lines tested pneumatically shall be blown with air until clear of all foreign material. Precommission cleaning by chemical or mechanical means is required for the following piping on ‘steam generating equipment and machinery: a. Boiler feedwater piping downstream of the deaerator. b. Piping systems for machinery. 1. Lube and Seal Oil Systems Centrifugal and Axial Compressor suction piping 3. Reciprocating and Rotary Compressor suction and interstage piping (including vessels, exchangers and pulsation supression devices) 4. Positive Displacement Pump suction piping 5. Steam Turbine inlet piping “Details of proposed cleaning procedures shall be approved by the Owner's Engineer. Last ERE BP reviewed—Rev. 9, January 1986(BP 3-19-1 REV 8 JUNE’8S PAGE 10 0F 10 Refinery Unit Nature of Examination Ready for Examination PIPING ERECTION AND TESTING Equipment = _ Dwg. No. Test Pressure Contractor's Engineer IMPERIAL BASIC PRACTICE Time Held 7 i Design Press. Flange | Approx. Length No.of | ‘Temp. tes Pot Line Welds Rating | Remarks: Signatures: Contractor IMPERIAL OIL LIMITED ___—