gen p es 003 fabricated piping

FABRICATED PIPINGDoc. No : GEN-P-ES-003

Rev 0 of 8

Rev Date : 23 Mar 2011

JOINT OPERATING BODYPERTAMINA- MEDCO E&P TOMORI SULAWESI

STANDARD SPECIFICATION FOR

FABRICATED PIPING

0 23 Mar 11 Original Issue BUD ARI BSA

REV. DATE REVISION ORIGIN. CHECKER APPROVED

GEN-P-ES-003, Standard Specification For Fabricated Piping, rev 0, 23 Mar 2011


Rev 0 of 8


TABLE OF CONTENTS

Page

1 SCOPE 3

2 APPLICABLE CODES, STANDARDS & SPECIFICATIONS 3

3 FABRICATION 4

4 INSPECTION AND TESTING 5

5 MATERIAL ACCOUNTABILITY 7

6 COATING OF FABRICATED PIPING 8

7 PREPARATION FOR SHIPMENT 8

1 SCOPE



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This specification defines the minimum requirements for the fabrication and inspection of carbon and alloy steel piping.

Throughout this Specification, the term "COMPANY" shall refer to JOB Pertamina - Medco E&P Tomori Sulawesi and all Subsidiary Operating Companies. The term "CONTRACTOR" shall collectively refer to the CONTRACTOR and all his SUB-CONTRACTORs, if any, engaged by COMPANY for the fabrication and inspection of steel piping systems.

2 APPLICABLE CODES, STANDARDS AND SPECIFICATIONS

The requirements of the latest editions of the following codes, standards and specifications shall form a part of this specification, except where specifically modified herein:

ASME - American Society of Mechanical Engineers

ASME – B31.3 Petroleum Refinery and Chemical Plant PipingASME – B16.5 Steel Pipe Flanges, Flanged Valves and FittingsASME – Section, VIII Div. 1 Unfired Pressure Vessel CodeASME – Section, II Parts A and C, Material SpecificationsASME – Section, V Non Destructive Examination ASME – Section, IX, Welding Qualification

API - American Petroleum Institute

API - 5L Specification for Line Pipe

COMPANY Specifications

GEN-P-ES-008 Standard Specification for Hydrostatic testing of In Plant PipingGEN-P-ES-009 Precommission Cleaning of Piping SystemsGEN-P-ES-010 Welding of Steel PipingGEN-G-ES-008 Standard Specification for Surface Preparation, Painting and

GalvanizingGEN-G-ES-010 Storage, Handling and Transportation of Steel Pipe

CONTRACTOR shall also be responsible to ensure that all work conforms to the latest requirements of the Responsible Government Authorities, MIGAS, BPMIGAS and others with jurisdiction over Fabrication and Inspection of piping systems.

3 FABRICATION

3.1 General

a) All fabrication shall comply with the requirements of ASME B31.3, this Specification and COMPANY's drawings. If there is a conflict between ASME B31.3 and the other applicable COMPANY documents, CONTRACTOR shall immediately notify COMPANY in writing of the conflict and shall not proceed with any work affected by the conflict until COMPANY resolves it.



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b). All pipe shall be handled, stored and transported in accordance with COMPANY Specification GEN-G-ES-010.

c) All branch connections shall be joined to the header with full penetration welds.

d) No bends of any kind shall be used without prior written approval of COMPANY. Under no circumstances will cold bends be permitted.

e) Fabrication involving welding shall not be sublet to others without prior written approval of COMPANY.

3.2 Welding

All welding shall be done per the requirements of Specification GEN-P-ES-010.

3.3 Tolerances

a) CONTRACTOR shall be responsible for the correctness of the dimensional requirements as detailed on COMPANY's drawings, and for any costs incurred in rectifying dimensional errors in the shop or at field erection.

b) Dimensions for inlets and outlets from a packaged, skid mounted unit shall be referenced from a single point on the skid corner, and be identical to the approved-for-construction piping plan and elevations dimensions.

3.4 Heat Treatment

a) Preheat and post weld heat treatment (stress relieving) shall be done in accordance with ASME B31.3 for carbon steel with a nominal thickness of more than 3/4 inch. After heat treatment, the metal shall be cooled down to 600oF at a rate not to exceed 500oF per hour divided by the thickness of the base metal, in inches.

b) Flanges and other exposed machined and threaded surfaces shall be protected against oxidation during heat treatment.

3.5 Screwed Piping

a) When screwed piping is required by the Drawings, screwed threads shall be clean cut with no burrs or stripping, and shall be according to ASME B31.3. Dies shall be new, sharp, and properly designed for the piping material. Immediately before fabrication, the piping, all threads of pipe and fittings shall be thoroughly cleaned of cuttings, dirt, oil, or other foreign matter. The male threads shall be liberally coated with thread tape and the piping made up sufficiently for the threads to seize.

b) Where seal welding is required by the drawings, screwed steel fittings shall be thoroughly cleaned and made up dry, using no thread sealant. After being made



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tight, a seal bead shall be welded around each joint.

3.6 Cleanliness

a) Cleanliness shall be maintained during all phases of fabrication. All stubs, electrodes, flux, slag and other foreign materials shall be removed from the fabrication.

b) Prior to welding, the pipe bevel and all surfaces adjacent thereto shall be thoroughly cleaned of all scale, rust, grease, oil, and other foreign material. Flux, weld spatter and slag shall be removed from each weld bead prior to depositing the next pass. All stub, rods, flux, slag, and other foreign material shall be removed from inside and outside the pipe, between each pass and after completion of the final pass.

c) All tools and equipment shall be kept free of oil, grease and other contaminants detrimental to fabrication. Wire brush material shall be compatible with the pipe and weld materials. Grinding wheels shall be resin bonded.

d) Upon completion of fabrication, but prior to hydrostatic testing and preparation for shipment, all piping shall either be blown out using compressed air or flushed using clean fresh corrosion inhibited water.

4 INSPECTION AND TESTING

4.1 General

a) Inspection of all piping shall be in accordance with the requirements of ASME B31.3, and this Specification.

b) CONTRACTOR shall be responsible for craft supervision and for the quality of work during fabrication and erection. COMPANY will make inspections and tests as required to check the progress and quality of the work, qualifications of CONTRACTOR's employees, and verify that work meets the Drawings and specifications.

c) Approval of testing and inspection by COMPANY will not relieve CONTRACTOR of his responsibilities and guarantees.

d) All non-destructive testing (NDT) shall be performed in accordance with written procedures that comply with the ASME Code (Section V) requirements and the requirements of this Specification. CONTRACTOR shall submit procedures for all required NDT to COMPANY for approval, prior to use.

e) All NDT shall be performed by personnel qualified in accordance with the ASME Code. The individual qualifications of all personnel proposed to perform NDT work shall be submitted to COMPANY for approval prior to beginning NDT work.

f) CONTRACTOR shall submit to COMPANY certified test reports specifying the



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chemical analysis of an undiluted weld metal deposit from each heat of weld metal used in qualification and in fabrication.

g) CONTRACTOR shall visually inspect all welds after completion before submission to COMPANY. Any indications of defects, undercutting, penetration roughness, poor contour and dimensions, etc. shall be repaired prior to any heat treatment operation.

h) Welds deposited by procedures differing from those properly qualified and approved by COMPANY shall be rejected and the weld will be completely removed by and at the expense of CONTRACTOR.

I) All prepared surfaces shall be visually inspected prior to welding. Any indications of defects shall be further examined using NDT methods.

4.2 Radiography

The radiography shall be performed as required by COMPANY Specification GEN-P-ES-010.

4.3 Ultrasonic Examination

a) In areas where radiographic examination cannot be obtained or the results thereof would be unreliable, ultrasonic examination in accordance with ASME B31.3, and ASME Code, Section V. shall be used. COMPANY written approval is required prior to substituting ultrasonic examination for radiographic examination.

b) Interpretation and acceptance criteria for ultrasonic tests shall be in accordance with ANSI-B31.3 and the ASME Code, Section V.

4.4 Liquid Penetrant and Magnetic Particle Inspection

a) Liquid Penetrant and/or magnetic particle inspection will be performed at the discretion of COMPANY, when radiography cannot be successfully employed.

b) Interpretation and acceptance criteria for liquid Penetrant and magnetic particle inspection shall be in accordance with ASME B31.3 and ASME Code, Section V.

c) Magnetic particle inspection of a fillet weld shall not be performed until at least 24 hours after the weld was completed.

d) Branch connection attachment welds shall be examined by magnetic or dye Penetrant methods when a single radiographic technique is not satisfactory. When the header thickness exceeds 5/8 inch, this type of examination shall be made for every 3/8-inch thickness of weld build-up.

4.5 Hydrostatic Testing



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a) A preliminary pneumatic check of all reinforcing pads shall be made on completion of the pipe spool at not more than 25 psig or less than 12 psig. Pressure shall be increased gradually and a soapsuds leak test carried out on the outside (and inside if accessible) of the weld between the branch and main run piping. COMPANY’s Quality Control Representative will witness this test.

b) Unless otherwise specified by COMPANY, all piping, spools, etc. fabricated by CONTRACTOR shall be hydrostaticly tested by CONTRACTOR in his fabrication facility. All hydrostatic testing shall comply with the requirements of COMPANY Specification MEP-P-ES-008. CONTRACTOR shall furnish all equipment, supplies, accessories and personnel required for hydrostatic testing.

c) No piping shall be coated or painted by CONTRACTOR prior to hydrostatic testing. If CONTRACTOR has received shop coated pipe material, the coating shall not be removed.

d) COMPANY ‘s Quality Control representative shall witness all hydrostatic testing of piping systems.

5 MATERIAL ACCOUNTABILITY

5.1 Before Coating

a) Upon receipt of material, CONTRACTOR shall mark and store all materials in such a manner that the material specifications and method of manufacture (for pipe, seamless, ERW, fittings etc.) will be clearly discernable at any time up to and including time of fabrication.

b) If at any time before, during and after piping fabrication, any piece of pipe or material is not readily identifiable, it will be subject either to outright rejection or arbitrary down grading to the lowest grade of material which has been received by CONTRACTOR to that date. The decision will be made by COMPANY’s Quality Control representative and shall be final and binding.

c) No surface preparation or external coatings will be permitted until COMPANY has verified that the proper materials have been used.

5.2 After Coating

Immediately after the piping and/or pipe spools have been externally coated, each piping spool shall be marked with stenciled paint compatible with the external coating system, with the mark numbers indicated on the appropriate piping isometric drawing. The paint or dye used for marking shall be white or some other conspicuous color.

6 COATING OF FABRICATED PIPING



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6.1 Above Ground Piping

CONTRACTOR shall coat all piping and pipe spools for above ground installation in strict accordance with COMPANY Specifications GEN-G-ES-008.

7 PREPARATION FOR SHIPMENT OR INSTALLATION

7.1 After all inspection and coating procedures have been completed, CONTRACTOR shall prepare all fabricated pipe for shipment or installation in accordance with the following:

a) The inside of all piping shall be drained and blown dry to prevent corrosion.

b) Flange faces shall be cleaned, coated with a rust preventive and protected with bolted or steel strapped exterior grade plywood covers the same diameter as the flange outside diameter. Unpainted steel shall not be used where rust could discolor coated pipe surfaces.

c) Threaded or socket weld connections shall be cleaned and plugged, or capped with metal or plastic protectors.

d) The open ends of pipe shall be protected with metal caps.

e) A metal cap, secured by a steel strap around the pipe shall be used to protect weld-o-lets.

7.2 CONTRACTOR shall adequately support pipe spools for transit. Particular attention shall be applied to spools, which are susceptible to damage during transit.


gen p es 003 fabricated piping

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