RUWAIS LNG PROJECT
SPECIFICATION FOR PIPE FABRICATION AND ERECTION
COMPANY DOCUMENT REF.
RLNG-000-MT-SP-6301
CONTRACTOR DOC. REF.
215122C-000-JSS-6300-0001
REVISION: 1A
PAGE 1 OF 7
ADNOC GAS
SPECIFICATION FOR PIPE FABRICATION AND ERECTION
COMPANY Contract No.
4700022871
JV TJN RUWAIS Contract No
215122C
Document Class
Document Category (for Class 1)
Class 2
N/A
OPERATING CENTER Contract No.
OPERATING CENTER Doc Ref.
1A
IFC – Issued for Construction
29-Aug-2024
RBO
RBO 2024.08.30 08:02:14 +02’00’
1
0
IFC – Issued for Construction
01-Aug-2024
RBO
ICR – Issued for Client Review
17-Jul-2024
RBO
Takuya Tsutsui
f
W Takuya Tsutsui
^
:
œt : 2024.09.04
10:20:51 +01’00’
Alessio Raccanello 2024.08.30 16:20:51 +02’00’
A. Raccanello T. Tsutsui R. Vedala
A. Raccanello T. Tsutsui R. Vedala
N. Chebil T. Tsutsui R. Vedala
S. Deilles K. Fujii
S. Deilles K. Fujii
S. Deilles K. Fujii
Rev.
Revision Purpose
Date
Prepared by
Checked by
Approved by
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR PIPE FABRICATION AND ERECTION
COMPANY DOCUMENT REF.
RLNG-000-MT-SP-6301
CONTRACTOR DOC. REF.
215122C-000-JSS-6300-0001
REVISION: 1A
PAGE 2 OF 7
Table of Contents Contents Page INTRODUCTION … 4 1.0 Scope of the Document … 4 1.1 Holds List … 4 1.2 References … 4 1.3 Definitions and Abbreviations … 5 1.4 AMENDMENTS TO GASCO DESIGN GENERAL SPECIFICATION DGS-1300-185… 6 APPENDIX … 7 APPENDIX 1 DGS-1300-185 - FABRICATION, HANDLING AND INSTALLATION OF 3.1 PROCESS AND UTILITY PIPING … 7
2.0 3.0
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR PIPE FABRICATION AND ERECTION
COMPANY DOCUMENT REF.
RLNG-000-MT-SP-6301
CONTRACTOR DOC. REF.
215122C-000-JSS-6300-0001
REVISION: 1A
PAGE 3 OF 7
Table of Changes compared to previous revision (for Procedures and Job Specifications only)
Paragraph
Modification description
Remarks / Origin
Update of some Project Document Titles
Section 13 - Clause 13.18.2
Remove “b.” (cid:206) acceptance criteria are from Paragraph 323.3.5 in ASME B31.3.
CPY’s comment on rev 1 and Contractor Document register (RLNG-000-PM-NM- 1105_0)
CPY’s comment on rev 1
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR PIPE FABRICATION AND ERECTION
COMPANY DOCUMENT REF.
RLNG-000-MT-SP-6301
CONTRACTOR DOC. REF.
215122C-000-JSS-6300-0001
REVISION: 1A
PAGE 4 OF 7
1.0
INTRODUCTION
The ADNOC Ruwais LNG Project is a two train, near net-zero electrically driven LNG facility, targeting international markets. The feed gas for the project is supplied from the Habshan Gas Processing Plant via a new export gas pipeline. The plant will have two 4.8 MTPA (nominal capacity) electric driven LNG Trains with associated LNG storage/marine export facilities and utilities.
Figure 1 – Project Context
The ADNOC Ruwais LNG Project foresees the following main components at the facility:
(cid:120) Onshore LNG Liquefaction facilities for 2 x 4.8 MTPA electrically driven LNG Trains (9.6MTPA total)
(cid:120) Common facilities including inlet receiving facilities, LNG storage, BOG handling, flare, refrigerant
storage and support buildings.
(cid:120) Utilities to support the facilities including import power from the national grid.
(cid:120) Marine facilities for LNG export and bunkering.
1.1
Scope of the Document
This specification amends GASCO Design General Specification DGS-1300-185 which is attached hereto in Appendix 1. Section 2 of this document identifies the amendments to this DGS.
1.2
Holds List
HOLD
DESCRIPTION
1
1.3
References
[1] DGS-1300-185
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY
PIPING (Revision 1)
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR PIPE FABRICATION AND ERECTION
COMPANY DOCUMENT REF.
RLNG-000-MT-SP-6301
CONTRACTOR DOC. REF.
215122C-000-JSS-6300-0001
REVISION: 1A
PAGE 5 OF 7
1.4
Definitions and Abbreviations
COMPANY
CONTRACTOR
EPC ADOC POC YOC
ABU DHABI NATIONAL OIL COMPANY (ADNOC) P.J.S.C. TJN Ruwais, Joint Venture of Technip Energies France-Abu Dhabi, JGC Corporation and National Marines Dredging Company (NMDC) Engineering Procurement Construction Abu Dhabi Operating center - National Marines Dredging Company Paris Operating Center - Technip Energies Yokohama Operating center - JGC Corporation
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR PIPE FABRICATION AND ERECTION
COMPANY DOCUMENT REF.
RLNG-000-MT-SP-6301
CONTRACTOR DOC. REF.
215122C-000-JSS-6300-0001
REVISION: 1A
PAGE 6 OF 7
2.0
AMENDMENTS TO GASCO DESIGN GENERAL SPECIFICATION DGS-1300-185
Instructions contained below such as “Add”, “Substitute”, “Revised”, or “New” shall be interpreted as follows:
-
Add: Requirements shall be a continuation of the paragraph in the referenced specification.
-
Substitute: The requirement of the referenced specification shall be replaced in its entirety by the
requirements below.
- Revised: The requirement of the referenced specification shall be revised by the specific wording
below.
-
New: A new requirement as described below.
-
CODES AND STANDARDS (Add)
The following codes and standards shall be added:
NFPA 59A
Standard for the Production, Storage, and Handling of Liquefied Natural Gas (LNG)
- REFERENCE DOCUMENTS
The following DGS references are substituted with Project documents as detailed below:
DGS Reference
Project Document No.
Project Document Title
DGS-1300-015
RLNG-000-PI-SP-1003
Specification for Metallic Pipes, Flanges & Fittings
DGS-1300-016
RLNG-000-PI-SP-1011
Specification for Color Code for Piping Material Identification
DGS-1300-070
RLNG-000-PI-SP-0010
General Specification for Pipe Supports
DGS-0000-001
RLNG-000-MT-SP-6303
Positive Material Identification of Equipment and Piping
DGS-1300-160
RLNG-000-PI-SP-1013
DGS-6600-010
RLNG-000-MT-SP-2301
DGS-6300-001
RLNG-000-MT-SP-6302
Job Specification for Design - Bolts Torquing - and Tensioning
Specification for Protective Coating of Equipment, Piping & Structures
Specification for Welding and NDE of Pressure Vessels and Heat Exchangers
DGS-1300-010
RLNG-000-PI-SP-1022
Specification for Piping Material Classes
RLNG-000-PM-PP-2004
Criticality Rating Procedure
DGS-1470-009
RLNG-000-PI-SP-5101
Job Specification for Supply for GRE Pipe and Piping Components
DGS-6500-010
RLNG-000-MT-SP-2201
Specification for Thermal and Acoustic Insulation
DGS-6500-020
RLNG-000-MT-SP-2201
Specification for Thermal and Acoustic Insulation
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR PIPE FABRICATION AND ERECTION
COMPANY DOCUMENT REF.
RLNG-000-MT-SP-6301
CONTRACTOR DOC. REF.
215122C-000-JSS-6300-0001
REVISION: 1A
PAGE 7 OF 7
Section 13 FABRICATION/HANDLING/INSTALLATION
Clause 13.7 Stub-in Branch Connections – Revise the paragraph to:
Stub-in connections shall be per ASME B31.3 Figure 328.5.4; A, B, C, and Figure 328.5.4D, item (b) or (d) unless otherwise noted.
Clause 13.18 (New) Additional Requirements for Cryogenic Service – Add the new following clauses:
The following requirements apply to stainless steel Shop & Field Fabrication used in cryogenic service, which shall be defined as any service that is colder than -101°C.
13.18.1 Weld metal deposits shall be impact tested at -196°C or colder in accordance with Paragraph 323.2.2 and Table 323.2.2 of ASME B31.3. Welding procedures shall be qualified at -196°C or colder in accordance with the requirements of Paragraph 323.3 of ASME B31.3. Impact tests that meet the requirements of Table 323.3.1 which are performed as part of the weld procedure qualification will satisfy all requirements of Paragraph 323.2.2 and do not need to be repeated for the production welds.
13.18.2 To ensure acceptable impact properties of austenitic stainless steel welding consumables used, each heat, lot, or batch of filler metal or filler metal/flux combination shall be impact tested at -196°C or colder. Impact testing shall be in accordance with Welding Material Specification using the methods specified in ASTM A370 and the acceptance criteria of Paragraph 323.3.5 in ASME B31.3.
3.0
3.1
APPENDIX
APPENDIX 1 DGS-1300-185 - FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
DGS
1300
185
1
Rev.
Page 2/25
ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
TABLE OF CONTENTS
- GENERAL … 4
1.1 INTRODUCTION … 4 1.2 PURPOSE … 4 1.3 DEFINITIONS … 4
-
CODES AND STANDARDS … 5
-
REFERENCE DOCUMENTS … 6
-
DOCUMENT PRECEDENCE … 6
-
SPECIFICATION DEVIATION/CONCESSION CONTROL … 7
-
QUALITY ASSURANCE/QUALITY CONTROL … 7
6.1 QUALITY ASSURANCE MANUAL … 7 6.2 QUALITY ASSURANCE - FIELD FABRICATION … 8 6.3 QUALITY-ASSURANCE-SHOP FABRICATION … 8
- DOCUMENTATION … 8
7.1 MANUFACTURER/VENDOR MANUFACTURING PROCEDURES … 8 7.2 REPORTS … 9 7.3 MANUFACTURER/VENDOR WELDING PROCEDURES … 9 7.4 MANUFACTURER/VENDOR NONDESTRUCTIVE EXAMINATION PROCEDURES … 9 7.5 MANUFACTURER/VENDOR HOT AND COLD BENDING PROCEDURES … 9 7.6 MANUFACTURER/VENDOR DRAWINGS … 9 7.7 SPECIAL (NON-STOCK) PURCHASE ORDERS … 9 7.8 PRODUCTION SCHEDULES AND STATUS REPORTS … 9 7.9 REVISIONS … 10 7.10 WELDING REPAIR, ALTERATION RECORDS… 10 7.11 PRESSURE TEST RECORDS … 10
-
SUBCONTRACTORS/SUBVENDORS … 10
-
ENGINEERING DATA REQUIREMENTS … 10
-
MATERIALS … 10
-
MATERIAL RECEIVING AND STORAGE … 11
-
PREFABRICATION CLEANING … 11
DGS 1300-185 Rev 1
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ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
- FABRICATION/HANDLING/INSTALLATION … 11
13.1 PIPING … 11 13.2 INTERNAL MISALIGNMENT … 12 13.3 FLANGES … 12 13.4 REINFORCING PADS … 12 13.5 NONPRESSURE ATTACHMENTS … 13 13.6 BENDING … 13 13.7 STUB-IN BRANCH CONNECTIONS … 15 13.8 FABRICATION TOLERANCES … 15 13.9 FINAL FABRICATION CORRECTIONS … 16 13.10 SURFACE PREPARATION AND PAINTING … 16 13.11 PREPARATION … 17 13.12 PROTECTION, PRESERVATION AND STORAGE … 17 13.13 PREPARATION FOR SHIPPING … 17 13.14 INSTALLATION … 17 13.15 PRESSURE TESTING… 20 13.16 EXAMINATION AND TESTS … 20 13.17 WELD SPACING … 20
- APPENDICES/ATTACHMENTS … 22
ATTACHMENT 1- ACCPTANCE CRITERIA - EVALUATION OF FLANGE FACING DAMAGE … 21 ATTACHMENT 2 - FABRICATING TOLERANCES … 23 ATTACHMENT 3 - PROXIMITY OF WELDS………………………………………………………………………….25
DGS 1300-185 Rev 1
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ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
GENERAL
1.1
Introduction
This specification gives minimum requirements for the fabrication, handling and the installation of Process and Utility Piping for the ABU DHABI GAS INDUSTRIES LTD. (GASCO) facilities.
This specification does not cover the requirements for GRE/GRP piping; for these requirements refer to DGS 1470-009.
1.2
Purpose
The purpose of this specification is to provide the methods and procedures for the fabrication, handling and installation of Process and Utility Piping.
1.3
Definitions
Where used in this specification, the following terms shall have the meanings indicated below unless otherwise clearly indicated by context of their use.
COMPANY – ABU DHABI GAS INDUSTRIES LTD. (GASCO)
CONCESSION REQUEST – A deviation requested by the CONTRACTOR or VENDOR, usually after receiving the contract package or purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim, or release materials, components or equipment already in progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.
CONTRACTOR – The party(s) which carries out all or part of the design, engineering, procurement, construction, commissioning or management of the PROJECT.
DRAWINGS – Drawings provided by the CONTRACTOR/VENDOR.
MANUFACTURER/VENDOR/SUPPLIER – The party which manufactures and/or supplies the material/equipment, and provides technical documents/drawings and services to perform the duties specified by COMPANY/CONTRACTOR.
PROJECT – (To be defined) SHALL and SHOULD - The word ‘Shall’ is to be understood as a mandatory and the word ‘Should’ as strongly recommended to comply with the requirements of this document.
SUBCONTRACTOR/SUBVENDORS - The party(s) which carries out all or part of the design, procurement, the MANUFACTURER/VENDOR.
the System(s),
installation
specified
testing
and
as
by
of
FABRICATOR documents/drawings and services to perform the duties specified by COMPANY/CONTRACTOR.
- The party which manufactures and/or supplies equipment,
technical
FIELD ASSEMBLY ITEMS - Items that include bolt-on or bolt-in components to fabricated pieces such as vents, drains, instrument connections, valves, gaskets, bolts, and in-line instruments or other devices that are not welded-in” by the fabricator.
FIELD FABRICATED - Piping fabrication performed at the jobsite, either in a “shop”-type facility or at the installation site area.
FIELD WELD(ED) - Welding performed at the location where the component is to reside in its final installed location.
DGS 1300-185 Rev 1
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ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
HARD COPY - A copy on paper or other media of a computer modeled electronic file (formerly referred to as a “Piping Plan Drawing”, or “Piping Elevation Drawing” or, “Piping Isometric Drawing”; an isometric view of an individual line, or part thereof).
INSTALLER/INSTALLATION CONTRACTOR - The party which installs or erects equipment/piping systems and its components at the final location at the job-site.
INTERGRAPH PDS - Computer software manufactured by “Intergraph Corporation”, used to create an electronic model of the facilities. “Hard copies” of plan, elevation and isometric views of the facilities and its piping systems are extracted from the electronic files for use by fabricators, engineers, constructors, etc.
SHOP FABRICATE - Piping fabrication performed in or at MANUFACTURER/VENDOR’S shop, normally remote from the jobsite, but not limited to a remote site.
TECHNICAL DEVIATION - A deviation requested by the CONTRACTOR(S). Often, if refers to the authorization to deviate from COMPANY requirements prior to issuing the Contract Package. A Technical Deviation is subject to COMPANY approval.
CODES AND STANDARDS
The following codes and standards, to the extent specified herein, form a part of this specification. When an edition date is not indicated for a code or standard, the latest edition in force at the time of contract award shall apply.
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)
ASME B 31.3
ASME B16.5
ASMEB16.25
Process Piping
Pipe flanges and flanged fittings NPS ½ through NPS 24
Butt-welding ends
Boiler and Pressure Vessel Code
Section V
Section IX
Nondestructive Examination
Welding and Brazing Qualifications
AMERICAN SOCIETY FOR NON-DESTRUCTIVE TESTING (ASNT)
ASNT-TC-1A
Recommended Practice
NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE)
NACE MR0175/ISO15156-1 Petroleum and Natural Gas Industries Materials for use in H2S containing Environments in Oil and Gas Production – Part 1. General Principles for Selection of Cracking Resistant Materials
NACE MR0175/ISO15156-2 Petroleum and Natural Gas Industries Materials for use in H2S containing Environments in Oil and Gas Production – Part 2. Cracking Resistant Carbon and Low Alloy Steels
NACE MR0175/ISO15156-3 Petroleum and Natural Gas Industries Materials for use in H2S containing Environments in Oil and Gas Production – Part 3. Cracking Resistant CRA’s (Corrosion Resistant Alloys) and other Alloys
PIPE FABRICATION INSTITUTE (PFI) Standard ES3 Standard ES24
Fabricating Tolerances Pipe Bending Methods, Tolerances, Process and Material Requirements
DGS 1300-185 Rev 1
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ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
INTERNATIONAL STANDARDS ORGANIZATION (ISO) ISO 9001-2008 ISO 9004-2000
Quality Management Systems – Requirements Quality Management Systems – Guidelines for Performance Improvement
REFERENCE DOCUMENTS
The following reference documents, to the extent specified herein, form a part of this specification. Where a specific edition date is not indicated for a document, the latest edition in force at the time of VENDOR’S proposal submitted shall apply.
Design General Specifications
DGS 0000-001 DGS 0000-003 DGS 1300-010 DGS 1300-015 DGS 1300-016 DGS 1300-030 DGS 1300-040 DGS 1300-070 DGS 1300-100 DGS 1300-160 DGS 1300-165 DGS 1300-175 DGS 1300-190 DGS 1470-009 DGS 6300-001 DGS 6500-010 DGS 6500-020 DGS 6600-010 DGS 6710-001
STANDARDS STD-1300-001
STD-1381-010
Positive Material Identification of Equipment & Piping Minimum Shop Inspection and Certification Requirement Piping Systems (Piping Classes) Pipes and Piping Components Color Code for Piping Material Identification Process and Utility Field/Shop Pressure Testing Process and Utility Design, Layout and Drawings Pipe Supports Piping Tie-ins Bolt Torquing/Tensioning Procedure for Flanged Connections Internal Cleaning of Piping Galvanizing Traceability of Shop & Field Fabricated Piping Materials Requirement for Fiber Reinforced Plastics (FRP) Pipes & Fittings Welding and NDE of Piping System Hot Insulation for Piping and Equipment Cold Insulation for Piping and Equipment Painting Preservation and Export Packing
Piping Design Standards Drawings Piping Support Standard Drawings
DOCUMENT PRECEDENCE
It shall be the CONTRACTOR’S responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.
The CONTRACTOR shall notify the COMPANY of any apparent conflict between this specification, national and/or local regulations, the Codes and Standards, and any other specifications noted herein. Resolution and/or interpretation of precedence shall be obtained from the COMPANY in writing before proceeding with the design/manufacturing.
In case of conflict, the order of precedence shall be: • National and/or Local Regulations • This Specification • Project Specifications and Standards
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ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
•
Industry Codes and Standards
If some of the requirements which exist in national and /or local regulations, which are be more stringent than in this specification, the CONTRACTOR/VENDOR/ SUBCONTRACTOR shall determine, by careful scrutiny, which of the requirements are more stringent and which combination of requirements will be acceptable, in regard to safety, economic and legal aspects.
SPECIFICATION DEVIATION/CONCESSION CONTROL
Deviations from this specification are only acceptable where the CONTRACTOR has listed in his quotation the requirements he cannot, nor does not wish to comply with, and the COMPANY has accepted in writing the deviations before the order is placed.
In the absence of a list of deviations, it will be assumed that the CONTRACTOR complies fully with this specification.
Any technical deviations to the Purchase Order and its attachments including, but not limited to, the Piping Drawings and Project Specifications shall be sought by the VENDOR only through CONCESSION REQUEST format. CONCESSION REQUESTS require CONTRACTOR’S and COMPANY’S review/approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.
QUALITY ASSURANCE/QUALITY CONTROL
CONTRACTOR’S proposed quality system shall fully satisfy all the elements of ISO 9001-2008 “Quality Management Systems – Requirements’ and ISO 9004-2000 “Quality Management Systems – Guidelines for Performance Improvement”. The quality system shall provide for the planned and systematic control of all quality related activities performed during design.
The VENDOR shall have in effect at all times, a QA/QC Program which clearly establishes the authority and responsibility of those responsible for the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements, initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action.
A copy of the VENDOR’S QA/QC program shall be submitted to the CONTRACTOR with its quotation for CONTRACTOR’S review and concurrence prior to award. If VENDOR’S QA/QC program is ISO 9000 certified, then only a copy of the VENDOR’S ISO 9000 certificate is required. In addition, if VENDOR’S facility is ISO certified, CONTRACTOR’S QA audit requirements will be waived in favor of ISO 9000 registrar audits, unless the CONTRACTOR’S trend analysis program indicates areas of concern.
The VENDOR shall identify in documents to its SUBVENDOR(S) all applicable QA/QC requirements imposed by the CONTRACTOR, and shall ensure compliance thereto. On request, VENDOR shall provide objective evidence of its QA/QC surveillance of its SUBVENDOR activities.
The VENDOR shall submit certified reports of production tests as soon as the tests are completed satisfactorily.
The COMPANY/CONTRACTOR reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests. The VENDOR, 30 days after award but prior to the pre inspection meeting, shall provide the CONTRACTOR with a copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory COMPANY/CONTRACTOR witness points.
6.1
Quality Assurance Manual
A QA manual shall be submitted to the CONTRACTOR/COMPANY for review and comment. The manual shall include the procedures, instructions, and quality control systems to ensure that all assigned fabrication, handling, installation, workmanship, and other related services conform to the
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ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
specified code, approved design engineering specifications, design drawings, and other contractual, jurisdictional, and legal requirements.
The quality control system shall include the quality control requirements as defined in the contract documents, the applicable referenced specifications and Section 6 of this specification.
6.2
Quality Assurance - Field Fabrication
The specifications for fabrication, welding, and material, as shown in Section 3.0, shall be used. The CONTRACTOR/SUBCONTRACTOR will monitor and review the activities of the fabrication to ensure that applicable codes, standards, and procedures are being followed. The CONTRACTOR will monitor and review the activities of the SUBCONTRACTOR.
The CONTRACTOR shall examine and inspect in-process work and the final product to ensure that quality criteria have been met.
The CONTRACTOR shall examine and inspect all piping components for damage and improper manufacturing prior to beginning fabrication, in accordance with ASME B31.3, paragraph 341. After fabrication has been completed, all components shall be re-examined and reinspected for possible damage. Repairs shall be made and, if required, for the original material, retested and accepted by COMPANY before installation.
The CONTRACTOR is responsible for fabrication accuracy and completeness.
6.3
Quality Assurance - Shop Fabrication
the CONTRACTOR’S piping engineers should monitor and MANUFACTURER/VENDOR’S shop(s) to ensure that applicable codes, standards, and procedures are being followed to meet quality goals.
the activities of
review
The MANUFACTURER/VENDOR’S inspectors shall examine and inspect the final product to ensure that Project quality criteria have been met. The COMPANY/CONTRACTOR inspectors could also examine and inspect the MANUFACTURER/VENDOR’s inspectors work.
The MANUFACTURER/VENDOR shall examine and inspect all piping components for damage and improper manufacturing prior to beginning fabrication, in accordance with ASME B31.3 paragraph 341. After fabrication has been completed, all components shall be re-examined and reinspected for possible damage. Repairs shall be made before shipping.
The MANUFACTURER/VENDOR shall be responsible for fabrication accuracy; each piece is subject to check by COMPANY/CONTRACTOR. The release of pipe fabrications from the shop by the COMPANY/CONTRACTOR inspector does not relieve the MANUFACTURER/VENDOR of responsibility.
DOCUMENTATION
All documents produced by the MANUFACTURER/VENDOR to produce, control, and manage this work are subject to review or approval by the CONTRACTOR/COMPANY.
7.1
MANUFACTURER/VENDOR Manufacturing Procedures
MANUFACTURER/VENDOR Manufacturing Procedures to be used on this work shall be submitted to the CONTRACTOR for review and approval prior to start of fabrication.
Any document produced by the MANUFACTURER/VENDOR’s engineering group as instructions to the shop floor shall be submitted to the CONTRACTOR for review and approved to ensure proper interpretation of relevant technical requirements.
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ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
7.2
Reports
7.2.1
Material Test Reports Material Test Reports (MTRs), or Certificates of Compliance (COCs), showing physical and chemical analysis as required by the applicable ASTM material specifications shall be furnished to COMPANY upon request, prior to starting piping fabrication. CONTRACTOR shall provide full traceability for each item to the material certification, during fabrication.
7.2.2
Required Code Certification Documents
Any documentation requirements for certification of piping or components other than ASME B31.3 (such as ASME B31.1, B31.4 or 8) shall be furnished to COMPANY prior to start of fabrication.
7.2.3
Chemical Analysis Certification
Chemical analysis certification for the filler material shall be furnished to COMPANY, upon request, prior to the start of welding of piping.
7.3
MANUFACTURER/VENDOR Welding Procedures
MANUFACTURER/VENDOR Welding Procedure Specifications (WPS) to be used on this work shall be submitted to the CONTRACTOR for review and approval in accordance with DGS 6300- 001.
7.4
MANUFACTURER/VENDOR Nondestructive Examination Procedures
NDE (non-destructive examination) procedures to be used by the MANUFACTURER/VENDOR for this work shall be submitted to the CONTRACTOR for review and approval in accordance with DGS 6300-001.
Personnel performing NDE acceptance evaluations shall be qualified in accordance with ASNT Recommended Practice ASNT-TC-1A. Interpretation shall be made by Level II or III personnel. An alternative is the MANUFACTURER/VENDOR’s own certification program that has been authorized by the CONTRACTOR.
7.5
MANUFACTURER/VENDOR Hot and Cold Bending Procedures
MANUFACTURER/VENDOR shall submit their hot and cold bending procedures for review and approval by CONTRACTOR prior to bending.
7.6
MANUFACTURER/VENDOR Drawings
Isometric shop drawings produced by the MANUFACTURER/ VENDOR from the CONTRACTOR’S data and intended for the MANUFACTURER’s/VENDOR’s use in the fabrication process shall be submitted to the CONTRACTOR at the same time they are released to the shop floor. This submittal shall not imply that fabrication is to be delayed in any way. The purpose is to allow the CONTRACTOR the option and ability to perform spot checks as a form of quality assurance.
7.7
Special (non-stock) Purchase Orders
Purchase orders for materials that are considered special (not normally carried as shop stock) shall be submitted to the CONTRACTOR.
7.8
Production Schedules and Status Reports
Prior to the initiation of the work, the MANUFACTURER/VENDOR shall produce and submit to CONTRACTOR a realistic production schedule. Throughout the duration of the work, the MANUFACTURER/VENDOR shall prepare and submit weekly status reports and schedule updates.
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7.9
Revisions
in drawings/documents shall be brought
Any errors or necessary changes discovered by the MANUFACTURER/VENDOR in the piping 3D the model or CONTRACTOR/COMPANY and the CONTRACTOR. In the interest of avoiding delays in work, such approval could be agreed upon verbally between the MANUFACTURER/ VENDOR and the CONTRACTOR, however, the MANUFACTURER/VENDOR shall submit a written request for approval of such changes within five working days of the date of the verbal request.
immediate attention of formally corrected with prior approval of
the data
the
to
7.10
Welding Repair, Alteration Records
Welding repair, alteration and NDE records shall be kept in accordance with DGS 6300-001.
7.11
Pressure Test Records
Keep test records according to ASME B31.3, Paragraph 345.2.7, and DGS 1300-030. Test records are subject to review by CONTRACTOR.
SUBCONTRACTORS/SUBVENDORS
The MANUFACTURER/VENDOR shall assume unit responsibility and overall guarantee for the compliance to this specification.
The MANUFACTURER/VENDOR shall transmit all relevant documents and specifications to his SUBCONTRACTORS.
It is the MANUFACTURER/VENDOR responsibility to enforce all Specification requirements on SUBCONTRACTORS.
The MANUFACTURER/VENDOR shall submit all relevant drawings and engineering data from his SUBCONTRACTORS to the CONTRACTOR.
The MANUFACTURER/VENDOR shall obtain and transmit all warranties to the CONTRACTOR in addition to the system warranty.
ENGINEERING DATA REQUIREMENTS
All aboveground and underground piping systems are generated using the “Piping 3D model”. A “hard copy” of any particular geographic area, either as a plan or elevation view should be extracted to assist in the construction/installation of the facilities. To assist in fabrication or erection, any part of any piping system can also be extracted as an isometric view “hard copy” from the Piping 3D model. The electronic file shall be used by the piping fabricator/installer to extract the necessary data to fabricate and install the piping systems. Typically deliverables generated shall include in addition to the “hard copy” are Material take-off/ Bill Of Materials, Tie-in drawings/schedule and other document /drawings as per the project requirements.
MATERIALS
Piping materials shall be in accordance with DGS 1300-010. Any deviations shall be notified to CONTRACTOR/COMPANY for review/approval.
Substitutions, including thicker wall materials, are not permitted without prior written authorization from CONTRACTOR.
Particular note shall be made of DUAL GRADE 316/316L Stainless Steel materials. Where Dual Grade material is used, single grade material shall not be accepted as an alternative. In addition special provision shall be made to segregate single grade material from dual grade and to prevent inadvertent use of single grade where dual grade is specified.
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MATERIAL RECEIVING AND STORAGE
All material purchased for the project, shall be stored in an area specifically assigned to the project where exposure to heat, dirt, and contamination are avoided. CONTRACTOR shall provide the procedure for handling and storing materials at the job site.
Bulk materials, pipe and fittings shall be segregated by material type and schedule within the storage area.
Stainless steel and Aluminum piping shall be stored under cover and clear of the ground. Contact with ferritic steel is not permitted. Contamination from ferritic sources is not acceptable. Stainless steel material shall not come into contact with zinc coating such as galvanized materials. All slings and hooks shall be protected by a plastic insulation or nylon. Storage banding for pipe shall be of a non-contaminating and compatible material.
CONTRACTOR shall visually inspect every pipe and component and reject items that contain an injurious defect. Injurious defects are internal or external surface gouges, scars, scratches, blisters, or discontinuities that produce a notch effect or reduce the specified wall thickness by 5 percent or more.
The end caps shall be kept in place during transport and storage in order to prevent dust, dirt, foreign matter etc., from entering the pipe.
For loading and unloading of very heavy pipes, it is recommended to use slings with cushion pads or a suitable fork-arrangement placed at the center of the joints. Hooks or other devices which insert into the ends of the pipe shall not be used. A flat-bed trailer provides the best support for the lined pipes during transport. During loading or unloading lined pipes shall not be dropped on to or off of the transporting vehicle.
To prevent bending of the pipes which can cause damage to the lining, supports shall be used during storage and shipping. The distance between the supports shall not exceed 3.0 m.
Pipes shall be stored in supported tiers. The height of the tiers depends on the diameter of the pipes and shall not be more than 10 pipes for NPS 6; 6 pipes for NPS 8 to NPS16; 4 pipes for NPS 20 to NPS 36.
PREFABRICATION CLEANING
All piping and fittings shall be cleaned free from debris, grease, oil, and loose foreign material prior to fabrication or installation.
Each weld lane shall be cleaned before the weld is started. The weld cleaning shall be accomplished by wire brushing or grinding. The cleaned area shall be free from rust, scale, or mill coating. Stainless steel piping shall be fabricated within a separate area free from ferric contamination. Tools, such as flapper wheels, grinders, saws, and other abrasives that have been previously used on carbon steel shall not be used on stainless steel.
Welds of branch connections shall be completed and the fabricated piping shall be cleaned of all foreign materials before it is flanged or welded into, the main line.
FABRICATION/HANDLING/INSTALLATION
13.1
Piping
Welding, weld examination, and weld heat treatment shall be in strict accordance with DGS 6300- 001.
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The MANUFACTURER/VENDOR shall shape or bevel the ends of piping to be field welded in accordance with ASME B16.25.
Adjacent sections of longitudinally welded pipe that are joined by butt welding shall have the longitudinal weld seams positioned so that they are at least 30 degrees apart from the horizontal centerline.
The MANUFACTURER/VENDOR shall not position the longitudinal weld seam on the top or bottom of the line so that branch connections are not located on the seam.
The area of header welds where subsequent branch connections will be made shall be examined by Radiography (RT). In addition, the weld edges of the branch weld shall be examined by Magnetic Particle (MT) [or Liquid Penetrant (PT) for nonmagnetic steels]. Unacceptable defects shall be removed and repaired. This inspection supplements the existing requirements for final inspection performed on each weld.
13.2
Internal Misalignment
Misalignment criteria shall be governed by ASME B31.3 and DGS 6300-001. If the deviation factors are exceeded, one of the following procedures shall be used: a. Rotate the pipe or fittings to reduce misalignment to the acceptable tolerances (before
attempting any of the following methods).
b. Use spreaders or internal or external lineup clamps to correct moderate out-of-round condition.
c. The end with the larger internal diameter may be built up internally by depositing weld metal to
improve alignment.
d. Taper the wall of the component internally after obtaining approval from COMPANY for the proposed method and ensure wall thickness is not reduced below the minimum required by the ASME B31.3 code.
e.
If allowable deviations are exceeded beyond repair methods, the fabrication shall be redone.
13.3
Flanges
Flange bolt holes are to be oriented as follows, unless otherwise indicated in the electronic files: a. Flange face vertical - bolt holes to straddle vertical centerline.
b. Flange face horizontal - bolt holes to straddle north-south centerline.
c. Where line taps are called for, the hole shall be drilled square to the axial centerline, clean, sharp, free from burrs, wire edges, or other irregularities. The hole shall be drilled after first attaching the connection fitting.
Where slip-on flanges are called for, they shall be welded inside and outside (See Figure 328.5.2B of ASME B31.3). The weld shall be applied so that the flange face shall be free of weld spatter and does not require facing.
Orifice flanges shall be installed with the taps in the exact orientation shown in the Isometric. The sections of pipe to which the orifice flanges are attached may be standard mill run pipe, but shall be choice selected pieces and shall be round, smooth and free from blisters and scale. The interior of the pipe, at welds, shall be ground smooth. Welds to be performed on site shall be kept at a maximum distance back from the face of the orifice flange.
13.4
Reinforcing Pads
Reinforcing pads shall be installed only where called for in the isometric. Basic material shall be the same as the pipe material unless otherwise authorized by the COMPANY. The isometric will specify size and pad thickness. It is preferable to have pad shapes circular, but the pad size may
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be altered, provided an equivalent cross-sectional area is maintained and ASME requirements are met. Each pad or each piece, if the pad is made from more than one piece, shall have 1/8 NPS weep hole drilled and tapped NPT (American National Taper Pipe Thread) prior to installation (at the side and not at the crotch) of the pad. Branch connection weld shall be 100% complete and subjected to the required examination (including visual) prior to installation of reinforcing pads. Reinforcing pad to be air tested at 1 kg/cm2 by the MANUFACTURER/VENDOR. After test, the vent shall be seal welded.
13.5
Nonpressure Attachments
Nonpressure attachments shall be installed in accordance with the isometric and any supplemental data provided by CONTRACTOR.
Piping requiring post weld heat treatment shall have all welded-on nonpressure attachments installed by the shop fabricator. Piping not requiring post-weld heat treatment may have the welded-on nonpressure attachments installed by the installation CONTRACTOR. If field welding is required on post weld heat treated piping, then localized field post weld heat treating shall be done after welding.
Post weld heat treatment requirements are specified in DGS 6300-001.
Pipe shoes which are field welded to pipe shall be centered over pipe supports in the cold position. Shoes shall preferably be located and attached after the line is completely installed, but may be welded to pipe prior to installation, provided they are centered over pipe supports when the pipe is installed.
13.6
Bending
13.6.1 General
Bending of pipes shall only be done where indicated in the isometric and only with COMPANY’S approval, otherwise welding elbows shall be used. Prior to bending, MANUFACTURER/VENDOR shall submit their hot and cold bending procedures to the CONTRACTOR for approval. All bending shall conform to the requirements of PFI-ES24 and as modified herein.
If the pipe contains a longitudinal weld, this weld shall be located in the neutral zone.
Pipe bending, normally up to 4 NPS shall be done in pipe bending machines or presses using formers. No wrinkling, excessive thinning or flattening is allowed. Excessive scratches, gouges or die marks will be grounds for rejection.
Bending tolerances are given in section 13.8.2.
Local heating by manually operated gas torches shall only be applied after written authorization of the COMPANY has been obtained. Water cooling at any time during bending is strictly prohibited, except for induction bending where water cooling is required.
Information on the application of heat for bending and the required heat treatment after bending is given below for different materials.
13.6.2 Carbon Steel, Fine Grain Steel, 0.3 Mo and 0.5 Mo Steel Piping
Pipes made of these materials may be bent in the hot or cold condition.
a. Cold Bending
Definition: Cold bending is bending below the tempering temperature for quenched and tempered materials or below the post weld heat treatment temperature for other materials. The temperature shall apply even if the pipe does not require PWHT.
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After cold bending no additional heat treatment is required if all of the following requirements are met: (cid:131) The service does not contribute to stress corrosion cracking of the applicable material.
(cid:131) Hardness (cid:31) 248 HV 10
(cid:131) Rm (cid:33) 1.3 DO
In which: Rm = bending radius
DO = outer diameter pipe
If these requirements are not met, the following heat treatment shall be carried out:
-
A normalizing treatment for normalized steels
-
An austenising quench (oil, water) and temper treatment (Q+T) for quenched and tempered steels
NOTE: The above heat treatments may be replaced by a stress relief heat treatment at a temperature above the post weld heat treatment temperature if it can be shown that there has been no deterioration of the mechanical and physical properties (e.g. grain growth).
b. Hot Bending
If for normalized steels the hot bending takes place between 830 – 9500C additional heat treatment is not required. If for normalized steels the hot bending has been carried out outside the above-mentioned temperature limits an additional normalizing treatment must be carried out.
For Q+T materials, an austenizing quench (oil, water) + temper heat treatment must be carried out, similar to the original specification.
All materials shall be stress relieved after induction bending.
13.6.3 Chromium-Molybdenum Steel Piping
Cr-Mo steel piping may be bent in the hot or cold condition.
a. Cold Bending
For definition see Section 13.6.2
After cold bending no additional heat treatment is required if the following requirements are met.
(cid:131) Hardness (cid:31) 248 HV 10 (cid:131) Rm (cid:33) 1.3 Do If these requirements cannot be met the following additional heat treatment shall be carried out:
(cid:131) A stress relief treatment for normalized and Q+T steels if it can be shown that for similar type of material no deterioration of the mechanical and physical properties has taken place.
(cid:131)
If this is not acceptable an austenizing quench (air) and temper treatment for both normalized and Q+T steels shall be carried out. The tempering shall be selected in such a way that the specified mechanical values can be met.
b. Hot Bending
If hot bending is applied, austenizing quench (air) and tempering treatment shall be carried out for Q+T and normalized steels. For normalized steels a normalized + air cooled heat treatment may replace Q+T. The specified mechanical values shall be met after any heat treatment process.
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13.6.4 Austenitic Stainless Steel Piping
a. Cold Bending
After cold bending, for service operations considered to cause stress corrosion cracking, austenitic stainless steel shall be solution annealed (1050-1150(cid:113)C), and after solution annealing a rapid water quench shall be carried out.
For austenitic stainless steel applied for non-corrosive and general refinery service no additional heat treatment is required if the deformation of the steel is below 20%. If the deformation is over 20% a solution annealing treatment (1050-1150(cid:113)C) and a rapid water quench is required, as stated in paragraph above.
b. Hot Bending
For the non-stabilized types austenitic stainless steel e.g., AISI 304, 316, hot bending shall be carried out in the temperature range of 1050-1150(cid:113)C (solution annealing) and a rapid water quench. For the stabilized types, i.e., AISI 316 Ti, 321, 347, hot bending can be carried out at the homogenizing temperature (850-950(cid:113)C) followed by cooling in still air. Also, a heat treatment at 1050-1150(cid:113)C and then lowering the temperature to 950-1000°C, followed by cooling in still air may be applied.
13.6.5
Inspection
After bending, the bent items shall be subjected to non-destructive testing, i.e., visual examination and dye penetrant and/or magnetic particle examination. Cracks and crack like defects are not allowed.
13.7
Stub-in Branch Connections
Stub-in connections shall be per ASME B31.3 Figure 328.5.4; A, B, C, and Figure 328.5.4D, item (2) or (4) unless otherwise noted.
13.8
Fabrication Tolerances
13.8.1 Pipe
fabrication
tolerances
shall
be
in
accordance
with
PFI-ES3
and
Attachment 2.
13.8.2
Thinning of Wall Thickness and Quality in Bends
The maximum decrease of wall thickness shall not exceed 10% of the nominal wall thickness as specified in the line classes and in any case shall not be less than that required by the design.
The tolerances for the maximum flattening of a bend shall be per ASME B31.3, section 332.2.
13.8.3
Flange Face Alignment
Flange Face Alignment tolerances shall be in accordance with PFI-ES3 and Attachment 2.
13.8.4 Position of Bolt Holes for Flanged Piping
The maximum deviation allowed from the required position as measured along the bolt circle is 1.5mm.
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13.8.5 Vent and Drain Connection
Fabrication tolerances may be exceeded to a maximum 13 mm for vent and drain connections locations, dummy support lengths, temperature connection, or pressure tap locations, providing the deviation does not affect an in-line item.
13.8.6
Field-Fit Weld
Where the requirement is called for in the isometric, a field-fit weld is used when the exact piping dimension cannot be predetermined, to allow the installation CONTRACTOR adjustability of two spool pieces. The MANUFACTURER/VENDOR shall add 150mm to the calculated length of one of the spools. The installation CONTRACTOR is to verify the dimension before trimming and beveling. The isometric will indicate only the calculated length.
13.8.7 Alignment of piping to equipment (vessels, exchangers, pumps, etc.) shall permit fit-up without
bending or springing the pipe under any circumstance.
13.8.8 Pup-pieces installed to make up a spool length shall be a minimum of (2) pipe diameters long or
150mm long, unless authorized by the COMPANY.
13.9
Final Fabrication Corrections
13.9.1 General
If final corrections are required, these corrections should be made as much as possible by cutting and for corrections with CONTRACTOR’S/COMPANY’S approval.
techniques may be submitted
However, other
rewelding.
13.9.2 Carbon Steel, 0.3 Mo and 0.5 Mo Steel Piping
If corrections are required after fabrication they should be carried out by any suitable method before any required normalizing heat treatment. After normalizing only cold work may be applied.
13.9.3 Chromium-Molybdenum Steel Piping
After the final heat treatment all corrections to the piping should preferable is made using cold work.
If this is not possible the piping may be heated. The heating shall be applied uniformly and carefully controlled; the temperature shall not exceed the maximum temperature limit of post-weld heat treatment. Reheat treatment will then not be required. Or, if desired, cutting and rewelding may be performed.
13.9.4 Austenitic Chromium- Nickel and Chromium-Nickel-Molybdenum Steel Piping
After the final heat treatment all corrections to the piping should preferable is made in the cold condition.
If this not possible the piping may be heated. The heating shall be applied uniformly and carefully controlled; the temperature shall not exceed 400(cid:113)C.
13.10
Surface Preparation and Painting
Applicable surface preparation and painting shall be in accordance with DGS 6600-010.
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13.11
Preparation
Cleaning
Pipe requiring special cleaning either at the MANUFACTURER/VENDOR’s site or jobsite, and protection shall be noted on the P&ID, and shall be in accordance with DGS 1300-165.
13.12
Protection, Preservation and Storage
Piping shall be protected as follows: a. After fabrication, flange faces shall be cleaned, coated with rust preventative and protected with nonmetallic flange covers secured to the flange prior to erection/installation/shipment. Other methods and products for flange protection may be acceptable, subject to COMPANY approval.
b. Threaded or socket-weld connections shall be cleaned and plugged, or capped with metal or
plastic protectors.
c. The open ends of pipe shall be protected with metal or plastic caps.
d. A metal cap secured by a steel strap around the pipe shall be used to protect open end “O-lets.”
e. Austenitic stainless and nickel alloy pipe shall not be exposed to salt or salt spray.
f. Fabricated spool pieces shall be carefully loaded with the proper amount of dunnage and ample tie-downs to protect each piece during shipping. Tie-downs shall be nylon straps; chains or cable are prohibited.
g. After required examination and inspection, all shop fabricated carbon, alloy, and stainless steel
pipe for shipment shall be protected in accordance with DGS 6710-001.
h. Adequate protection shall be provided to prevent mechanical damage and atmospheric
corrosion in transit and at the jobsite.
i. Fabricated spool pieces and materials shall be protected to withstand ocean transit and extended period of storage at the jobsite for a minimum period of 18 months. Fabricated spool pieces and piping components shall be protected to safeguard against all adverse environments, such as: humidity, moisture, rain, dust, dirt, sand, mud, salt air, salt spray, and seawater.
13.13
Preparation for shipping
Shipping envelope size
If the fabricated spool pieces require shipment from the MANUFACTURER/VENDOR’s facilities, they shall be fabricated to fit easily into a shipping envelope based upon the type of shipment (truck, sea van, or other).
Each fabricated spool piece is to be identified by a code based upon the ultimate destination of the spool piece. The CONTRACTOR shall determine the piece marking details during the detailed engineering phase.
13.14
Installation
13.14.1 General
Except where shown otherwise, piping shall: a. Be run level and plumb
b. Be run on the North-South and East-West axis
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c. All piping shall be fabricated and installed to the configurations as shown in the isometric. Spool piece identification mark numbers or field welds are not indicated for field fabricated small bore piping systems. The INSTALLATION CONTRACTOR shall sectionalize as required for fabrication, handling, and installation, and shall supply spool piece installation mark numbers as required. No changes shall be made without prior approval of the COMPANY.
d. Pipe work shall be erected on permanent supports designated for the line. Temporary supports shall be kept to an absolute minimum, but to an extent sufficient to protect nozzles and adjacent piping from excessive loads during the erection.
e. Straight sections of pipe should contain the minimum number of welds. The use of off-cuts in
straight piping runs shall be avoided.
13.14.2 Flange Bolting
a. Use a logical sequence of bolt tightening to ensure even gasket compression, as indicated in
ASME B16.5.
b. Bolt tensioning shall be in accordance with DGS 1300-160.
c. Prior to bolt up, inspect flange faces. Flange faces shall be in “as-new” condition and shall be wiped clean of any debris, excess oil or grease and dirt. Restore damaged flange faces to the acceptance criteria per Attachment 1. Do not perform weld repairs on flange faces or flanges unless previously authorized by the COMPANY.
d. Do not use washers or spacers to make up bolt length. Bolt lengths are specified to prevent
oversizing.
e. Apply lubricant to bolts.
f. Stud bolt lengths shall be in accordance with the Piping Material Classes, and shall be installed so as to leave approximately an equal number of threads exposed from the nuts on each side of the flange assembly. In all cases the nut threads shall be fully engaged with the stud.
g. All fasteners (bolts and nuts) shall be coated in accordance with DGS 6600-010.
13.14.3 Joints
a. For threaded connections use thread compound per DGS 1300-010. Threaded joints to be seal
welded shall be made without thread compound.
b. Leave underground piping joints exposed until after completion of field pressure and leakage testing unless partial backfilling is required for anchoring lines. Do not test underground piping with concrete thrust blocks until the concrete has cured. Any deviation to these requirements shall be approved by the COMPANY.
c. Do not apply insulation over any joints until testing has been completed.
d. Gaskets on flanged joints shall be used only once.
e. Gaskets shall be selected in accordance with DGS 1300-010.
13.14.4 Pipe Supports
a. Piping shall be supported, guided and anchored as specified on the relevant piping drawings.
b. Install pipe supports in accordance with DGS 1300-070.
c. Welding of supports shall be indicated in the data provided by CONTRACTOR.
d. No temporary supports shall be used for hydrotest loads. Permanent supports shall be installed
to sustain hydrotest loads.
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13.14.5 Cleanliness of Piping
a. Open end and flange protection shall be used throughout installation. Protect open pipes at all
times when work on them is not actually taking place.
b. Inspect individual pipe section, prefabricated spools and pipeline items internally during
installation and remove any foreign matter before final welding or bolting.
c. The internal cleaning of piping after fabrication or installation shall comply with DGS 1300-165.
d. Piping contiguous with special equipment or piping within a packaged, VENDOR provided “skid”, which requires cleaning in accordance with the equipment MANUFACTURER’s procedures, shall be inspected by, and have cleaning supervised by the MANUFACTURER’s representative.
13.14.6
Installation Procedure for Socket-Welded Small Bore Valves
As well as complying with all applicable code requirements for quality and strength of the weld, it is necessary to avoid damage to soft seats and distortion of “small bore” valve bodies by excessive heat input.
a. Process
The process to be used shall be manual metal arc, metal inert gas or CO2 with preference for the lower heat input high deposition (dip transfer) processes. Gas welding shall not be used because of its excessive heat input.
b. Preparation
(cid:120) Ensure that the valve is in the open position. (cid:120) Correctly locate and align the pipe in the valve socket with a clearance of approximately
1.6mm (1/16 inch) between the end of the pipe and the bottom of the socket.
(cid:120) To ensure this 1.6mm gap, CONTRACTOR to carryout profile RT on all socket welds.
c. Procedure
(cid:120) Deposit the first run of weld metal around the pipe. (cid:120) Deposit metal by making additional runs as required, ensuring that each run of weld metal is cleaned and any visible defects such as cracks, cavities or other faults are removed before deposition of further weld metal. For detailed welding configuration see ASME B31.3, Figure 328.5.2C.
13.14.7 Valve and Equipment Flange Connections
Flange covers shall be retained on all flange connections to valves or equipment, until ready to connect the mating piping flanges.
Flanges connecting to strain sensitive mechanical equipment, e.g., pumps, compressors, turbines, etc. shall be fitted-up in close parallel and lateral alignment prior to tightening the bolting.
In general, flange connections to equipment shall be the last connection made on completion of a line or interconnecting system of lines. With the piping flange fitted and prior to bolting up the joint, the following tolerances shall be maintained:
(cid:120) Bolting shall move freely through accompanying bolt holes at right angle to the flange faces. (cid:120) There shall be a clear gap between two flange faces before gasket installation. There shall
be sufficient flexibility to install and replace gaskets.
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13.15
Pressure Testing
Testing of piping systems shall be in accordance with DGS 1300-030.
13.16
Examination and Tests Extent of Nondestructive Examination (NDE) shall be per DGS 6300-001.
Flanges with special finish facing, as required by DGS 1300-010, shall be within the groove depth range from 3.2 to 6.3 Ra. Use 3.2 Ra and 6.3 Ra plastic scratch gages to determine the special finish requirements.
A visual examination of each special finish flange surface shall take place before coating with rust preventative and before the protective flange cover is attached. Restore damaged flange faces to the acceptance criteria per Attachment 1.
13.17 Weld Spacing
Circumferential butt welds shall be separated by the maximum possible distance. However, between piping fittings, short pipe lengths may be required, the proximity of welds is defined in Attachment 3. Circumferential butt-welds closer than these limits shall be brought to the attention of the COMPANY and may require post weld heat treatment.
Non-pressure containing attachment welds, such as pipe support welds shall be minimum of 50 mm from any pressure containing welds.
APPENDICES/ATTACHMENTS
Attachment 1 – Acceptance Criteria – Evaluation of Flange Facing Damage Attachment 2 – Fabricating Tolerances Attachment 3 – Proximity of Welds
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ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
ACCEPTANCE CRITERIA - EVALUATION OF FLANGE FACING DAMAGE (AN UNAIDED VISUAL INSPECTION)
ATTACHMENT 1 (Page 1 of 2)
SIZE
FREQUENCY
Using the distance between two adjacent bolt holes, a maximum of two anomalies are permitted within this distance measured anywhere along the periphery of the sealing surface width. The maximum number of anomalies for a flange shall not exceed for pipe sizes 2” and smaller, 4; for pipe sizes 3” and larger, the nominal pipe size plus 2 (e.g., 10” pipe size allows 12 anomalies)
Not permitted within the sealing surface width
Not permitted within the serration width
TYPE OF DAMAGE (ANOMALIES)
Lineal: Scratches, scuffs abrasions, cuts & gouges
Depth: Shall not exceed depth of serration - Projected length: *(See Fig. 1) The projected length (PL) of individual anomalies shall not exceed 33% of the sealing surface width shown in Table 1, (page 22/25).
Pitting, punch marks
Diameter: Maximum 2.38 mm
Arc strike drags or sand blasting
Weld spatter or other protrusions above serrations
General rusting or scaling due to atmospheric exposure
Shall not reduce the serration height by more than 25%
DGS 1300-185 Rev 1
DGS
1300
185
1
Rev.
Page 22/25
ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
ATTACHMENT 1 (Page 2 of 2) )
TABLE 1
SIZE (NPS)
GASKET OUTSIDE DIA.
SEALING SURFACE WIDTH (MIN.)
ASME PRESSURE CLASS
½
¾
1
1¼
1½
2
2½
3
4
5
6
8
10
12
14
16
18
20
24
150
6.35
7.14
7.95
6.35
7.95
7.95
7.95
9.53
11.13
11.13
13.49
15.09
15.09
17.48
17.48
20.65
26.16
26.16
28.58
300
6.35
7.14
7.95
6.35
7.95
7.95
7.95
9.53
11.13
11.13
13.49
15.09
15.09
17.48
17.48
20.65
26.16
26.16
28.58
400
—
—
—
—
—
—
—
—
14.30
15.09
17.48
19.05
21.41
23.83
22.56
25.40
28.58
28.58
28.58
600
6.35
7.14
7.95
6.35
7.95
7.95
7.95
9.53
14.30
15.09
17.48
19.05
21.41
23.83
22.56
25.40
28.58
28.58
28.58
900
—
—
—
—
—
—
—
12.70
14.30
15.09
17.48
19.05
21.41
23.83
22.56
25.40
31.75
31.75
34.93
32
40
48
60
70
86
98
121
124
178
210
257
318
375
406
464
527
578
686
DGS 1300-185 Rev 1
DGS
1300
185
1
Rev.
Page 23/25
ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
ATTACHMENT 2
FABRICATING TOLERANCES
METRIC CONVERSIONS (PFI Standard ES-3)
The conversion of quantities between systems of units involves a determination of the number of significant digits to be retained. All conversions depend upon the intended precision of the original quantity and are rounded to the appropriate accuracy.
Pipe sizes together with applicable wall thicknesses are not shown with metric equivalents. The SI (metric) values where included with the customary U.S. values in this Standard are the rounded equivalents of the U.S. values and are for reference only.
Metric units were derived utilizing the following conversion factor:
Conversion
Factor
inches to millimetre
25.4
- Scope
1.1 This standard covers general pipe shop for prefabricated piping assemblies.
tolerances
fabricating
- Linear Tolerances
2.1 The tolerances on linear dimensions (intermediate or overall) apply to the face to face, face to end, and end to end measurements of fabricated straight pipe and headers; center to end or center to face of nozzles or other attachments; or center to face of bends; as illustrated on Fig.1. These not accumulative.
tolerances
are
2.2 Linear tolerances on “A” are ± 1/8” (3.0mm) for sizes 10” and under, ± 3/16” (5.0mm) for sizes 12” through 24” and ± 1/4” (6.0mm) for sizes over 24” through 36”.
2.3 Linear tolerance on “A” for sizes over 36” are subject to tolerances of ± 1/4” (6.0mm), increasing by ± 1/16” (2.0mm) for each 12” in diameter over 36”.
DGS 1300-185 Rev 1
2.4 Due to the cumulative effects of tolerances on fittings or flanges, when joined without intervening pipe segments, deviations in excess of those specified in paragraph 2.2 and 2.3 may occur.
- Angularity and Rotation Tolerance
3.1 Angularity tolerance across the face of flanges, weld end preparation and on rotation of flanges are as stated on Fig.1 of Attachment 2.
- Closer Tolerances
4.1 When closer tolerances than those given in paragraphs 2.2, 2.3 and 2.4 are they shall be absolutely necessary, subject the Purchaser and Fabricator.
to agreement between
DGS
1300
185
1
Rev.
Page 24/25
ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
ATTACHMENT 2 (Continued)
DGS 1300-185 Rev 1
DGS
1300
185
1
Rev.
Page 25/25
ABU DHABI GAS INDUSTRIES LTD. (GASCO)
FABRICATION, HANDLING AND INSTALLATION OF PROCESS AND UTILITY PIPING
DGS 1300-185 Rev 1
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