BES 1300-102

Petrogal

MANUAL DE PROCEDIMENTOS

ESPECIFICAÇÕES DE ENGENHARIA

BES – 1300-102

Edição: 01 Data: 00.05.15 Revisão: 00 Data: 00.05.15 Pág. 1 de 34

PIPING FABRICATION AND ERECTION

Elaborou: J. van Eck

Verificou:

Aprovou:

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Reprodução proibida Impresso a partir da PETRONET

Petrogal




BES – 1300-102 INDEX SECTION

PAGE

1.

SCOPE

3

2.

DEFINITIONS

3

3.

CONTRACTOR'S RESPONSIBILITY

3

4.

REFERENCE DOCUMENTS

4

5.

DESIGN

5

6.

MATERIALS

5

7.

FABRICATION

7

8.

INSTALLATION

14

9.

INSPECTION AND TESTING

28

10.

CLEANING

30

11.

PAINTING/COATING

31

12.

DOCUMENTATION

32

13.

PREPARATION FOR SHIPMENT

33

14.

ADDITIONAL REQUIREMENTS

34

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BES – 1300-102 1.

Edição: 01 Data: 00.05.15 Revisão: 00 Data: 00.05.15

SCOPE This specification covers the minimum requirements for fabrication and installation of steel piping, including pipe supports. Fabrication and installation of tubing, lined pipe and nonmetallic piping are excluded from the scope of this specification and shall be executed in accordance with ASME B31.3 and manufacturer's requirements and recommendations. Additional or deviating requirements for duplex stainless steel piping, piping containing oxygen, underground piping, steam tracing and jacketed piping, are listed in specifications mentioned in section 14.

2.

DEFINITIONS For this specification the following definitions are applicable: Principal

:

Petróleos de Portugal S.A. (Petrogal) or the company acting on principal’s behalf.

Contractor

:

The party which carries out engineering (if applicable), supply of materials, fabrication and installation/construction.

Supplier

:

Any manufacturer or supplier who is appointed by the principal or contractor and responsible for the supply of materials or equipment or services.

Shall

:

Is to be understood mandatory.

Should

:

Is to be understood as strongly recommended.

May be

:

Is to be understood as giving a freedom of choice.

3.

CONTRACTOR'S RESPONSIBILITY

3.1

Any conflict between the requirements of this specification and reference documents shall be referred to principal for clarification.

3.2

Contractor shall fully describe all proposed deviations from this specification and referenced codes, standards and specifications for review and approval by principal.

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BES – 1300-102 3.3

Assumptions to cover lack of information are not allowed. Contractor is obliged to obtain reliable information from principal.

3.4

Contractor shall field verify all (existing) dimensions and conditions shown on principal's drawings.

4.

REFERENCE DOCUMENTS

4.1

CODES

4.2

DL 101/74, DL 102/74

Authority Requirements.

ASME B31.1 (...)

Power Piping.

ASME B31.3 (...)

Process Piping.

Note: (...)

Fill in applicable issue date.

STANDARDS The version valid on the date of contract award shall be used. ASME B16.25

4.3

Butt-welding Ends.

SPECIFICATIONS/DRAWINGS, ETC. BES-1300-101

Piping Materials.

BES-1300-103

Coating and Wrapping of Underground Piping.

BES-1300-104

Process and Utility Piping Design Requirements.

BES-1300-105

Pressure Testing, Flushing and Reinstatement of Piping Systems.

BES-1300-106

Steam Tracing.

BES-1300-107

Insulation of Piping and Equipment.

BES-1300-109

Welding of Carbon, Low-alloy and Austenitic Stainless Steel Piping.

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BES – 1300-102 BES-1300-110

Pipe Stress and Support Design Data.

BES-1400-104

Underground Piping.

BES-2300-101

Surface Preparation and Painting.

BES-2700-102

Hot Tapping.

5.

DESIGN

5.1

Contractor shall supply plan drawings and/or isometrics showing piping design.

5.2

Piping designed by contractor shall meet the requirements of ASME B31.1/B31.3 (depending on selected design code) and specification BES-1300-104 "Piping Design Requirements".

5.3

Contractor is fully responsible for all design. Principal may perform spot checks to ensure that specifications are being properly applied.

6.

MATERIALS

6.1

!

All materials included in the finished piping systems (free-issue materials and material purchased by contractor) shall be undamaged and fully in accordance with the piping material class and pipe support drawings indicated on the piping drawing and/or P&ID. For piping material classes, see specification BES-1200121 "Piping Materials".

!

Material substitutions or deviations from the piping material classes shall not be made without prior written approval of principal.

STORAGE/HANDLING OF MATERIALS !

Piping shall be stored in a clean, dry or well-drained area on elevated dunnage and protected against contact with salts or salty water.

!

Stainless-steel and duplex stainless steel piping shall be stored on wooden blocks, separately from carbon, alloy and galvanized carbon steel.

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BES – 1300-102 !

6.2


Stainless-steel and duplex stainless steel materials shall not be loaded, unloaded or handled with hoisting devices (e.g. steel ropes and forklift trucks) containing zinc or other harmful materials.

MATERIAL IDENTIFICATION !

Materials issued to contractor shall be adequately marked in accordance with the requirements of the applicable material specifications and the additional requirements of the purchase order requisitions and/or local codes and regulations.

!

In case material identification symbols are located near the weld or on a piece of material to be cut off, material shall be restamped prior to welding or cutting to avoid loss of traceability.

!

The governing principle shall be that in the installed piping systems, all components can be identified and traced to their origin and complete specifications.

!

Marking and remarking by contractor's representatives shall be executed by hard dye stamping or engraving, whichever is applicable.

!

All hard stamping shall be done by means of low stress stamps on pressure-bearing parts. Low stress stamps shall have a round nose with a radius of 0.25 mm minimum.

!

In case of ferrous materials with a thickness less than 5 mm and austenitic steels less than 10 mm, marking shall be performed by engraving.

!

When similar materials (e.g. carbon - low-temperature carbon steel or 304-316 stainless steel) are used for the same project, materials will be supplied with additional color coding to be able to make a quick visual identification of different types of material. Note: Color coding needs not be transferred prior to welding or cutting.

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BES – 1300-102 7.


FABRICATION Fabricated metal piping shall meet local authority requirements for all piping requiring inspection and approval by local authorities. All other fabricated metal piping shall meet the requirements of ASME B31.1/B31.3 (depending on selected code). In order to prevent corrosion of stainless steel, duplex stainless steel and other high-alloy steels, fabrication of carbon steel, galvanized carbon steel and low-alloy steel shall be done in a separate area. Area means different shops or two (2) areas in one (1) shop separated by suitable (temporary) walls. For the same reason as above, tools used for fabrication of carbon steel, galvanized steel and low-alloy steel may not be used for fabrication of stainless steel, duplex stainless steel and other high-alloy steel. Only tools made of stainless steel are allowed for grinding, brushing, clamping, etc. These requirements apply to shop and field fabrication.

7.1

SHOP FABRICATION Shop fabrication under this specification shall include all the components of the pipeline or parts thereof entering into fabricated assemblies (spools), but shall exclude all piping specialties other than those with welding end constructions such as bolting, gaskets, flanged valves and fittings, blind flanges, orifice plates and similar items. Contractor is responsible for selection of piping to be shop fabricated on site or off site. For some piping systems principal has strong preference for shop fabrication to a maximum extent possible, e.g.:

7.2

!

Lined piping.

!

Jacketed piping.

LOCATION OF FIELD WELDS The size of spools and location of field welds shall be determined by contractor.

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BES – 1300-102

Field welds shall be located so that the spools shall be as large as possible and consistent with shipping limitations. Field weld locations shall be governed by the following:

7.3

!

Lengths of spools shall not be limited by "match lines" that appear on drawings. A line and its branches which appear on more than one (1) drawing is not intended to mean that a field weld is desired at the continuation point from one drawing to another.

!

Where piping is shown passing through a wall or floor, the first weld point on either side of the wall or floor shall be made a field weld, provided it is located at least 150 mm away from the end of the pipe sleeve.

!

Erection conditions shall be considered in determining the size of spools.

FIELD FABRICATION Field fabrication under this specification covers, but is not necessary limited to, the following operations:

7.4

!

Erection of shop-fabricated piping.

!

Fabrication and erection of all field-fabricated piping.

!

Design, routing, fabrication and erection of all field-fabricated piping for which no piping drawings are available.

!

Fabrication and erection of all pipe supports and auxiliary steel as detailed in the pipe support drawings.

!

Design, fabrication and erection of all pipe supports for small bore piping, which shall be executed in line with the available drawings for supports.

VERIFICATION OF FIELD DIMENSIONS Fabrication of piping and pipe supports shall be in accordance with the supplied drawings. However, due to equipment location and fabrication tolerances, field verification of overall dimensions shall be made by contractor prior to erection, to ensure a proper fitup at all connections to equipment and other piping.

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BES – 1300-102 7.5


MAKE-UP LENGTH Contractor shall apply 150 mm make-up lengths in order to make adjustments, necessary due to construction deviations. The required material shall be taken from the construction allowances/contingencies.

7.6

TOLERANCES

7.6.1

Overall Dimensions The dimensional tolerances of all fabricated lines shall not exceed the values given below:

Length Center to center Center to flange face Flange face to flange face 7.6.2

} } }

Less than 1.5 m

1.5 m and longer

± 1.5 mm

± 3 mm

Thinning of Wall Thickness and Ovality in Bends The maximum decrease of wall thickness shall not exceed 10% of the nominal wall thickness. For tolerances on the maximum flattening, see ASME B31.1/ B31.3.

7.6.3

Flange Face Alignment Flange faces shall be aligned to the design plane within 1 mm in 200 mm measured across any diameter.

7.6.4

Position of Bolt Holes for Flanged Piping Flange bolt holes shall be aligned within 3 mm maximum offset. Unless otherwise detailed on the drawings, flange bolt holes shall straddle the north-south centerline when the flange face is in the horizontal position and shall straddle the vertical flange centerline when the flange is in the vertical position.

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BES – 1300-102 7.7

7.8


MINIMUM DISTANCE BETWEEN WELDS !

The minimum distance between weld edges shall be 50 mm or three (3) times the wall thickness, whichever is greater.

!

Welded joints, including longitudinal welds, shall not be placed less than 50 mm or three (3) times the wall thickness, whichever is greater, from openings, branch welds, reinforcements, attachment devices, supports, etc. Principal reserves the right to specify additional requirements (such as radiography, ultrasonic inspection or postweld heat treatment) in case of deviations.

!

The longitudinal welds of two (2) adjacent rings or tubes shall be staggered approximately 90°. Longitudinal welds shall not be situated at the bottom of the pipe.

BRANCH CONNECTIONS Branch connection type shall be in accordance with the piping drawing or the piping material class, when no drawing is supplied. Where openings for branches are cut in run of pipe, all materials which may drop inside the pipe, shall be completely removed before the branch line is welded into place. Branch connection cutouts shall be carefully bevelled and accurately matched to form a suitable groove for welding and to permit complete penetration of the welds at all points, resulting in a quality comparable with girth welds, in the same piping system. Weld details for branch welds shall be included in the welding procedure specification. Reference is made to the relevant section of ASME B31.1/ B31.3. The centerline of the branch connections shall intersect the centerline of the header, unless otherwise specified on the piping drawing. Nozzle joints shall be of the "set-on" type, made so that the branch connection abuts the outside surface of the run wall. Half couplings attached to the line shall be inserted to the inside of the run wall and welded. Threaded couplings shall subsequently be checked with a thread gauge to ensure against thread damage or distortion. Pipe to pipe branches shall be of the weld-on type unless otherwise specified on the piping drawing.

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BES – 1300-102

Welded pipe-to-pipe branch connections shall be reinforced as required by the piping drawings. Additional weld metal, saddles or rings shall be used for reinforcement. Prior to welding, saddles or rings shall be drilled with one (1) ¼" NPT threaded hole for testing and venting. Threaded hole to be sealed with compound after testing. No gap larger than 3 mm shall exist between the OD of the pipe and ID of the ring or saddle. 7.9

GALVANIZED PIPING Galvanized piping up to and including 2" (DN 50) nominal size shall in general be assembled from threaded galvanized components. Piping larger than 2" (DN 50) nominal size shall be prefabricated in accordance with this specification and subsequently hot-dip galvanized. Contractor shall take into account that after the spools have been galvanized no welding is allowed. This implicates that field breaks shall be located at flanged connections or connections using flexible couplings and that welded-on pipe supports shall be welded to the spools before galvanizing. Contractor shall consider maximum dimensions of the galvanizing facilities he intends to use, when determining spool dimensions and locations of field breaks. Visual and dimensional inspections, nondestructive weld examinations and hydrostatic testing shall be executed before spools are hot-dip galvanized. Threaded connections shall be reworked to clean thread depth.

7.10

END PREPARATION

7.10.1

Cutting Cutting pipes may be done either by mechanical means (preferred) or by flame cutting or plasma cutting when the following is taken into account: !

For carbon steel, flame (or arc) cutting and bevelling is acceptable only if the cut is reasonably smooth and all oxides are removed from the surface by grinding to bright metal.

!

For low and intermediate alloy steel, flame cut bevels are acceptable only where machine cutting is not feasible. After flame cutting approximately 2 mm of material shall be removed from the surface of the bevel by grinding.

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BES – 1300-102

7.10.2


!

For stainless steel, flame cutting is prohibited, but plasma cutting may be applied instead.

!

Preheating during thermal cutting shall be the same as applied during welding (see specification "Welding of Carbon, Low-alloy and Austenitic Stainless Steel Piping").

Bevelling End profiles of pipes and fittings to be butt welded shall be in accordance with ASME B16.25. Bevelling is not required when a make-up length is provided.

7.10.3

Tapering Weld alignment shall be in accordance with ASME B31.1/B31.3, but with the exception that the internal trimming shall be 1:4, instead of 30°.

7.10.4

Threading The threading of pipe shall be in accordance with the applicable standard. The type of thread is indicated on the piping drawing or in the applicable pipe class.

7.10.5

Plain Ends Pipes for socket weld joints shall be cut square.

7.11

WELDING The following activities shall be executed in accordance with the requirements as described in specification "Welding of Carbon, Low-alloy and Austenitic Stainless Steel Piping". !

Alignment.

!

Preheating.

!

Tack welding.

!

Welding.

!

Repair welding.

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BES – 1300-102 !


Postweld heat treatment.

7.12

BENDING

7.12.1

General Bending of pipes shall only be done where indicated on the isometric drawings or when allowed by the applicable pipe class, otherwise welding elbows shall be used. The pipe bending procedure shall be approved by Contractor. If the pipe contains a longitudinal weld, this weld shall be located in the neutral zone. At site, only cold pipe bending up to DN 80 (3 inch nominal size) is allowed, provided it is done in pipe-bending machines or presses using formers. No wrinkling, excessive thinning or flattening is allowed. Excessive scratches, gauges or die marks will be grounds for rejection. Hot bending at site is not allowed, but shall be executed with induction pipe-bending machines. A pipe bending procedure shall be issued for approval by principal. The bending radius for cold bending at site shall be as given on the isometric drawing, but shall in principle not be less than five (5) times the nominal pipe diameter. The amount of thinning permissible is specified in paragraph 7.6.2.

7.12.2

Additional Requirements for Ferritic Steels For ferritic steels, with the exception of the quenched and tempered grades, a normalizing heat treatment shall be applied when the hardness increase in Vickers or Brinell is more than 100, unless local regulations are more stringent. For quenched and tempered ferritic steels an appropriate stress-relieving heat treatment shall be applied when the hardness increase in Vickers or Brinell is more than 100, unless local regulations are more stringent. Stress relieving shall be at least 10°C below the tempering temperature. The use of water for cooling is not permitted.

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BES – 1300-102 8.


INSTALLATION Contractor is responsible for installation of all piping spools including pipe supports, all piping components, such as bolting, gaskets, flanged valves and fittings, blind flanges, etc., and all other items, such as flow meters, control valves, orifice plates and similar items necessary to complete final piping erection with all lines cleaned, supported, pressure tested and ready for plant operation. Alignment of piping to equipment (machinery, vessels, exchangers, etc.) shall permit fitup without bending or springing the pipe under any circumstances. Alignment shall be checked and approved by principal prior to bolt-up. Where a discrepancy between drawing dimensions and field dimensions exists, sufficient modifications shall be made to eliminate unintended cold springing and cold forcing. Deviations from the arrangement shown on drawings shall only be made after consulting principal. Contractor shall submit alternative routing for review and approval by principal. Alternative routing shall keep clear all access ways and equipment openings and shall maintain accessibility of valves and instruments. Cutting, welding and making attachments to structural members, vessels, exchangers and other equipment, not detailed in the piping and piping support drawings, shall not be permitted without prior approval of principal. Stainless steel, duplex stainless steel and high-alloy steel shall be suitably protected during installation or modification of carbon-steel, low-alloy steel and galvanized carbonsteel piping at site. All stainless steel pipe potentially exposed to zinc dust contamination shall be protected with polythene sheeting. This applies in particular to piping under, or close to at the same level, as galvanized steel (grating/structural members/etc.). The sheeting shall be securely wrapped against tearing by wind and shall be removed upon completion of the works. Galvanized scaffolding pipe shall be kept at a distance of at least of 20 cm from stainless steel pipe in order to prevent the possibility of surface contamination. Pulling of pipe along piperacks is forbidden unless rollers are used.

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BES – 1300-102

Vents, drains, condensate drip legs, pressure instrument and other connections shall be installed where indicated on the isometric drawings, in accordance with engineering standards included in specification "Piping Materials". Protective devices on pipe ends, flanges and equipment openings shall remain in place until the piping connection is ready to be made. 8.1

FLANGE ASSEMBLY

8.1.1

Tools

8.1.1.1

Use of adjustable wrenches (Bahco) or wrench hammers is prohibited.

8.1.1.2

For application of correct tool related to flange size and rating, see table I.

8.1.1.3

The calibration of torque wrenches and tensioners shall be checked against manufacturer's specifications upon receipt. Any tools that are out of calibration shall be rejected. A recheck of the calibration shall be made as per tool manufacturer standard. Any tool found to be out of calibration shall immediately be taken out of service for repair. All flanged joints secured with tools found to be defective shall be rechecked with a properly functioning tool.

8.1.2

Flange Identification Flanges subject to hydraulic bolt tensioning shall be numbered on the isometric or on the general arrangement drawing by the contractor. Starting with the flow direction of each line number within one (1) unit, the flange sets shall be identified as F1, F2, F3, etc., followed by the line number, e.g. F1-P30006. The numbering system for flanged joints at equipment not part of a piping system, e.g. manholes, etc., shall be such that each equipment flange set is identified with the nozzle number as shown on the equipment drawing, followed by the equipment number, e.g. M1R1101. The above described numbering system shall be used to relate each "assembly record" as described in section 8.1.9 to the relating flange set.

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BES – 1300-102 8.1.3

Torque Values

8.1.3.1

In case torque wrenches (manual or hydraulic) are used, bolts shall be tightened until torque values, as indicated in table II, are reached. In case tensioning equipment is used, bolts shall be tightened until bolt force values, as indicated in table II are reached.

8.1.3.2

Listed values are NOT APPLICABLE for designed flanges over 60 inch. For these flanges the equipment manufacturer shall indicate on his drawings the bolt torque value used in the calculation made for the design of the flange.

8.1.3.3

For bolt material not listed in table II contact principal to obtain correct torque and bolt force values.

8.1.3.4

a.

Listed values are based on the empiric bolt force in flanges according to ASME Section VIII, div. 1, Appendix S.

b.

Torque moments are based on the pitch of the thread, the friction resistance between the thread surfaces and the bearing surfaces of the nut on the flanges.

c.

Friction coefficient f = 0,12.

8.1.4

Installation

8.1.4.1

Inspection of Material

8.1.4.2

Inspect the gasket material for possible damage or defects such as bends or creases.

8.1.4.3

Inspect the mating flange facings for dirt, parallelism, flatness, surface roughness, mechanical damage and corrosion. Use a suitable solvent to clean the surfaces. The contact area of the flanges shall be free of excessive pitting, radial tool marks and scratches. Flange facings that are found to be damaged during construction, shall be remachined at contractor's expense.

8.1.4.4

Inspect the studs and nuts. They should be free of dirt and corrosion and well lubricated. The studs shall be straight and the threads free of nicks, burrs and chips.

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BES – 1300-102 8.1.5

Assembly of Flange Connection

8.1.5.1

Align the flanges properly. For tolerances on flange joints see specification paragraph 7.6. The bolt holes shall match so that the studs can be inserted freely. Install the gasket. Gaskets shall not be lubricated.

8.1.5.2

Use four (4) studs at 0, 90, 180 and 270 degree angle as centering guides for the gasket. In the case of spiral-wound gaskets, ensure that the inner diameter of the centering ring is at all points within the outside diameter of the raised face. Clamp securely in place.

8.1.5.3

Insert the balance of the studs. Apply a suitable lubricant to the threads and the face of the nut that contacts the flange.

8.1.5.4

Hand tighten all studs and nuts. Center studs between nuts so an equal number of threads projects at each end. When hydraulic bolt tensioning is required, a threaded length equal to the bolt diameter should protrude at the end where the bolt tensioner is to be placed.

8.1.6

Bolt Torquing

8.1.6.1

Standard Wrench

8.1.6.2

a.

Tighten bolts crosswise in at least two (2) stages. First stage to approximately 50% if the estimated value based on experience. Second stage to 100% of the estimated value. Bolting shall be tightened in a sequence assuring equal distribution of bolt loading.

b.

Check all bolts for even distribution of required load. Steel to cast iron flanged joints shall be made up with extreme care. In order to avoid breaking of cast iron equipment flanges, piping flanges shall be brought up flush with gasket and equipment flanges into close parallel and lateral alignment, before uniformly tightening bolts.

Manual or Hydraulic Torque Wrench a.

Tighten bolts crosswise in at least three (3) stages: •

First stage to 40% of recommended value as per table II.

•

Second stage to 80% of recommended value.

•

Third stage to 100% of recommended value.

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BES – 1300-102 b.


Check all bolts at 100% of recommended value.

8.1.7

Hydraulic Bolt Tensioning

8.1.7.1

The application of bolt-tensioning equipment shall be in strict accordance with supplier's instruction manual and safety procedures.

8.1.7.2

Contractor shall propose a supplier for hydraulic bolt tensioning equipment and/or services, for approval by principal. The personnel using the equipment shall be adequately trained in the application of such equipment.

8.1.7.3

The tensioning of the bolts is carried out crosswise in a number of cycles, depending on the number of tools that can be applied simultaneously. As a minimum following number of tensioners shall be applied during each cycle: NUMBER OF BOLTS 32 and less 36 to 60 64 and up

NUMBER OF TENSIONERS TO USE 50% of bolts 1 /3 of bolts ¼ of bolts

8.1.7.4

Bolt tensioning shall be executed in two (2) steps. Contractor shall issue a tensioning procedure for approval by principal.

8.1.7.5

After completion of bolt tensioning four (4) bolts at 90 degrees angle each shall be checked for the break loose point. Flanges not meeting the required values shall be retensioned.

8.1.7.6

After bolt tensioning has been completed, the extended threaded part shall be greased and covered with suitable caps to prevent damage and corrosion during operation of the plant.

8.1.7.7

Upon completion of bolt tensioning each flange shall be provided with a wire seal(s) as indicated below.

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BES – 1300-102

8.1.7.8

Flange numbers as described in paragraph 8.1.2 shall be low stress dye stamped on the rim of one of the flanges .

8.1.8

Leaking Flange Assemblies

8.1.8.1

Flange assemblies found to be leaking during hydrotesting shall be tightened as listed below: a.

Flanges assembled with standard wrenches shall be tightened with manual torque wrenches using procedure as described in subsection 8.1.6.2.

b.

Flanges assembled with manual torque wrenches shall be tightened with hydraulic torque wrenches using procedure as described in subsection 8.1.6.2.

8.1.8.2

Flange assemblies tightened with hydraulic torque wrenches or hydraulic bolt tensioning equipment and found to be leaking during hydrotesting shall be disassembled, inspected and reassembled in accordance with the requirements of this specification.

8.1.8.3

Flange assemblies still leaking after tightening as described in subsection 8.1.8.1 shall also be disassembled, inspected and reassembled in accordance with the requirements of this specification.

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BES – 1300-102

Reassembly shall be done with tools as described in subsection 8.1.8.1a and 8.1.8.1b. In case of reassembly a new gasket is recommended. 8.1.8.4

Contractor shall prepare an assembly record for all flanges which are disassembled and reassembled because of leakage problems.

8.1.9

Documentation

8.1.9.1

Contractor shall prepare design calculations for all applicable flange sizes, in order to determine the required bolt loads and, consequently, the required pressures in the hydraulic bolt tensioning equipment. Calculations shall take into account the following design factors:

8.1.9.2

8.1.9.3

!

Minimum and maximum gasket seating stress.

!

Allowable bolt stress.

!

Flange material.

!

Design pressure.

!

Hydrostatic test pressure.

!

External loadings.

Contractor shall issue a hydraulic bolt tensioning procedure for approval by the principal. The procedure shall show all required information such as: !

Type of bolt tensioning equipment.

!

Operation manual.

!

Record preparation instructions.

!

Establishment of the "break loose" pressure, based on minimum four (4) tensioners.

!

Any precautions to be taken.

Contractor shall prepare an assembly record for each flange joint which needs to be tensioned. These records shall be issued as part of the turn-over packages.

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BES – 1300-102 Information to be shown on the assembly record shall be at least: !

!

!

Identification: •

Unit.

•

Line number.

•

Pipe class.

•

Flange set number.

•

Flange size/rating.

•

Principal representative's name and signature.

Inspection of the flange facing: •

Roughness.

•

Damage: Dents, tool marks.

•

Cleanliness.

•


Flange fit-up: •

Gasket type.

•

Gasket size.

•

Bolt diameter and length.

•

Number of bolts.

•

Bolt material.

•

Flange alignment.

•


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BES – 1300-102 !


Bolt tensioning: •

Pressure A, (the higher tool pressure, taking into account the maximum bolt stress, that is applied to obtain at least the average bolt stress).

•

Pressure B, (the lower tool pressure, required to obtain the average bolt stress).

•

Tool number.

•

"Break loose" pressure (check B pressure at four (4) bolts at 90% each) or bolt torque value.

•


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BES – 1300-102 8.1.10

TABLE I


Selection of Tools

FLANGE RATING (ANSI CLASS) 150 ½” 1 ¾” 1 1” 1 1½” 1 2” 1 F 3” 1 L 4” 1 A 6” 1 N 8” 1 G 10” 1 E 12” 1 14” 1 S 16” 1 I 18” 2 Z 20” 2 E 24” 2 26” 2 28”-30” 2 32”-36” 3 38”-48” 3 50”-60” 4 above 4 60”

300 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 3 4 4 4 4 4 -

600 1 1 1 1 1 1 1 1 2 2 2 3 3 4 4 4 -

900 1 1 1 1 1 1 2 2 3 3 3 3 4 4 4 4 -

1500 1 1 1 1 1 2 2 3 4 4 4 4 4 4 4 4 -

2500 1 1 1 2 2 2 3 4 4 4 4 -

LEGEND TOOL 1. Standard wrench

BOLT SIZE 1 inch

2. Torque wrench

1¼ inch

3. Hydraulic torque wrench

1½ inch

4. Bolt tensioning equipment

> 1½ inch

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MANUAL DE PROCEDIMENTOS ESPECIFICAÇÕES DE ENGENHARIA

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BES – 1300-102 8.1.11

TABLE II

BOLT DIAMETER (INCH)

Bolt Torque and Bolt Force Values

THREADS/INCH

A193 B7, A193 B16 AND A320 L7, 26 IN. AND LARGER FOR 150 LB & 300 LB ASME B16.47 SERIES A (MISS) TORQUE VALUE IN Nm BOLT FORCE IN N (note 1) Carbon steel

1/2 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 1 5/8 1 3/4 1 7/8 2 2 1/4 2 1/2

Notes:

13 11 10 9 8 8 8 8 8 8 8 8 8 8 8

1. 2. 3.

70 125 195 290 300 420 560 740 900 1120 1360 1620 1920 2610 3420

Stainless steel

200 280 370 490 600 745 905 1080 1280 1740 2280

Carbon steel (note 1)

71400 88940 107670 127640 148650 170770 193950 218030 243000 295440 351750

A193 B7, A193 B16 AND A320-L7, OTHER SIZES/RATINGS ASME B16.5 TORQUE VALUE IN Nm BOLT FORCE IN N Nm (note 2)

Stainless Steel (note 3)

47600 59295 71780 85090 99100 113850 129300 145350 162000 196960 234500

70 125 195 290 400 560 740 980 1200 1490 1810 2160 2560 3480 4560

95200 118590 143560 170180 198200 227700 258600 290700 324000 393920 469000

65% of empiric value to ASME Section VIII, div. 1, Appendix S 85% of empiric value to ASME Section VIII, div. 1, Appendix S 43% of empiric value to ASME Section VIII, div. 1, Appendix S

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BES – 1300-102 8.2


THREADED CONNECTIONS All threaded connections shall be seal welded, except the following: !

Connections in galvanized piping.

!

Screwed plugs in valved drains and vents.

!

Screwed thermowells and instrument connections.

!

Screwed control valves and safety/relief valves.

Seal welding shall be executed by qualified welders and shall not be considered as contributing to the strength of the joints. All exposed threads shall be covered by the seal weld. Use sealing compound or teflon tape for all connections not to be seal welded. Teflon tape is only allowed in utility services, at a design temperature of maximum 200°C. 8.3

PIPE SUPPORTS

8.3.1

Temporary Supports During erection, piping shall be adequate temporary supported until the final supports are installed. Temporary supports shall rest on paving, or direct or indirect on concrete or structural beams. Piping shall not be temporarily supported from platform grating or from scaffolding. Temporary supports shall consist of wooden blocks and/or steel hoisting ropes. Synthetic ropes or strings are not acceptable as temporary supports. Steel temporary supporting materials for stainless and duplex stainless steel materials shall preferably be stainless steel. Galvanized temporary supporting material shall not be used.

8.3.2

General Pipe supports shall be designed, fabricated and installed in accordance with the piping drawings on which the locations shall be indicated.

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Contractor shall adjust the pipe support to overcome construction measure deviations. Shims used to achieve full bearing between a pipe and/or a pipe attachment and the main support member must have sufficient area to carry the load. After erection, shims shall be welded to the main steel to prevent slippage when the pipe moves during operation. Shims shall not be welded to the pipe. Shims which are to be welded to pipe shoes shall extend the full length and width of the shoe. Alternative supports shall only be installed after approval by principal. Contractor shall remove fireproofing locally from steel columns and beams for a proper installation of pipe support according to the pipe support drawings. Fireproofing shall be repaired on the main structure and need not to be installed on the additional pipe support, unless otherwise shown. Fireproofing around directional anchors from pipes which are free to move in the transverse direction shall be kept free minimum 50 mm from the pipe anchor parts. Where expansion bolts have to be applied in concrete members, care shall be taken not to undercut retaining bars in the concrete. Pipe supports shall be adjusted to suit the final location of the expansion bolts. 8.3.3

Variable Spring Supports Installation The spring hanger list included in the pipe support drawings shall give, for each spring: a.

The operating load.

b.

The cold set load.

c.

The amount and direction of travel.

When the spring is delivered, it will have been loaded to the preset load and locked into this position by means of the cold setting stops. Depending upon the manufacturer, the cold setting stops will take the form of a plain rivet through section bar inserted above and below the piston plate inside the load scale slot. The cold setting stops must remain undisturbed until the hydrostatic test on the line has been satisfactorily completed, after which the following procedure shall be carried out: a.

At some time between the hydrostatic test and start-up, the cold setting stops shall be removed. Ultimate force must not be used.

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With the cold setting stops removed, it may be noticed that the line has a tendency to bow up or sag down. This is to be expected as when the line is cold and empty it is obvious that it can be either oversupported or undersupported since it is designed to be correctly supported at the hot operating condition. Do not readjust the spring load, but contact principal when there is doubt. 8.4

COLD SPRING Where specified on the drawings, cold spring or fullness (cold strain) shall be accomplished by observing the following procedures:

8.5

!

Piping shall be installed while the field weld as shown on the drawings is left unwelded until the remainder of the line is completely erected. All line anchors, guides and other supports shall be installed without using ultimate force.

!

The gap between the pipe ends shall then be measured. If not equal to the specified gap, the necessary modifications shall be made by cutting or extending the pipe.

!

The gap shall then be closed by jacking the line and clamping and bracing securely in place.

!

The field weld shall then be made.

EXPANSION JOINTS Expansion joints shall be installed following thoroughly the instructions of the manufacturer regarding the removal of shipping supports and attachments, adjusting tierod nuts, precompressing bellows, flow direction, etc. If the joints have welding ends, protection shall be given to the bellows to prevent any injurious effects during welding.

8.6

FINAL CORRECTIONS

8.6.1

Carbon Steel, 0.3 Mo and 0.6 Mo Steel Piping If corrections are required after fabrication, they may be carried out by a method approved by principal.

8.6.2

Chromium Molybdenum Steel Piping After the final heat treatment all corrections to the piping should preferably be made in the cold condition.

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If this is not possible the piping may be heated, for which written approval by principal is required. The heating shall be applied uniformly and carefully controlled, the temperature shall not exceed the maximum temperature limit of postweld heat treatment as indicated in ASME B31.3 and shall be minimum 10°C below the tempering temperature. Reheat treatment will then not be required. 8.6.3

Austenitic Chromium Nickel and Chromium Nickel Molybdenum Steel Piping All corrections to the piping should preferably be made in the cold condition. If cold correction is not possible the piping may be heated after written approval by principal. The heating shall be applied uniformly and carefully controlled. The temperature shall not exceed 400°C.

9.

INSPECTION AND TESTING

9.1

GENERAL Inspectors representing either Contractor or Principal shall have access to the Supplier’s shop or work area, with freedom to observe fabrication and inspect materials intended for fabrication. !

Test and measuring equipment used shall be calibrated every six (6) months and this calibration shall be supported by calibration certificates.

!

All inspection and testing is the responsibility of contractor. Principal shall always have the right to witness inspection.

!

Pipe bends manufactured by contractor shall be thoroughly visual inspected for cracks and surface laminations. If any doubt exists about the presence of cracks and laminations, contractor shall apply magnetic particle or liquid penetrant examination to show the absence of subject surface defects.

!

All cold pulled bends with service temperatures over 425°C, or ANSI ratings 900 lbs and higher regardless of service temperature, shall be subjected to magnetic particle examination or dye penetrant testing.

!

Hardness of all fabricated ferritic steel bends shall be checked. Heat treatment shall be executed as described in paragraph 7.12.2 when hardness is too high.

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BES – 1300-102

The supplier shall provide records of examination as requested in ANSI B.31.3. In addition, he shall prepare records if any are required by ortuguese authorities (DIRECÇÃO GERAL DE ENERGIA). !

Any defects revealed by any of the examinations performed shall be reworked and retested. All assemblies indicating irremediable defects, excessive repairs, improper fabrication or not being in accordance with the requirements of this specification shall be subject to rejection, even if the conditions are discovered after acceptance at contractor's shop or revealed during field testing. All costs related to repairs and/or refabrication shall be for contractor's account.

9.2

POSITIVE MATERIAL IDENTIFICATION

9.2.1

Positive material identification shall be executed as follows: a.

Incoming materials in principal’s warehouse shall be examined at random by principal to check attached certificates.

b.

Installed material shall be checked at random by contractor to eliminate possibility of accidental material substitution.

c.

All installed materials with poor readability of heat numbers or materials where doubt exists concerning the accuracy of the heat numbers shall be checked by contractor. “At random” is defined as a random check of materials per material type (independent of size, rating, wall thickness and type of piping item) up to a maximum of 1% of the total installed quantity of material.

9.2.2

PMI is only required for the following materials: MATERIAL Cr.Mo Steel Stainless Steel Duplex Stainless Steels High Alloy Steels

9.2.3

SERVICE All Services When Indicated All Services All Services

Contractor is responsible for execution and documentation of PMI as described under paragraph 9.2.1b. and paragraph 9.2.1c.

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BES – 1300-102 9.3


WELD EXAMINATION For weld examination requirements, see specification "Welding of Carbon, Low Alloy and Austenitic Stainless Steel Piping".

9.4

PRESSURE TESTING AND FLUSHING !

For pressure testing and flushing of completed piping systems, see specification "Pressure Testing, Flushing and Reinstatement of Piping Systems".

!

Except when specifically noted on the drawings, spools shall not require shop hydrostatic testing. This shall not, however, relieve contractor of the responsibility for any defects in materials and/or fabrication that may be revealed during field hydrostatic testing.

!

The space between a reinforcing pad and header shall be air/soap pressure tested with an air pressure of 1.75 barg preferably prior to erection of the line.

10.

CLEANING

10.1

WELD ENDS During weld preparation ends of all components shall be freed from any trace of oil, grease, paint, rust, scale, etc., over a distance of 50 mm minimum from the weld edge.

10.2

PIPING

10.2.1

Internal During fabrication and installation, contractor shall prevent foreign materials such as oil, grease, sand, dirt, scale, loose particles from cutting and grinding, etc., from entering the pipe or pipe component. If foreign materials have entered the pipe or pipe component, they shall immediately be removed before assembly of the parts by a suitable cleaning method, such as blowing through with air or degreasing with suitable cleaning agent or solvent. Cleaning agents and solvents used for degreasing shall not have any properties causing corrosion of the piping.

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BES – 1300-102 10.2.2


External Piping to be painted shall be cleaned in accordance with the requirements of specification "Surface Preparation and Painting". Piping which needs not be painted shall be cleaned by a suitable cleaning method to remove excessive rust, scale or grease only. Cleaning agents and solvents used for degreasing shall not have any properties causing corrosion of the piping.

10.3

COMPLETED PIPING SYSTEMS Unless otherwise indicated in the pipe class or on the piping drawings or P&ID's, only flushing as described in specification "Pressure Testing, Flushing and Reinstatement of Piping Systems" is required.

10.4

DEGREASING For certain services, lines need to be degreased to prevent operation problems. This requirement is indicated in the pipe class or on the piping drawings or P&ID's and shall be executed in accordance with additional specifications supplied by principal. Cleaning agents and solvents used for decreasing shall not have any properties causing corrosion of the piping.

10.5

CHEMICAL CLEANING Requirements for chemical cleaning of lines shall be indicated on the piping drawings and/or the P&ID's. If chemical cleaning is applicable, principal shall issue a chemical cleaning procedure for approval by principal. The contractor responsible for chemical cleaning shall check whether all materials included in the piping system are compatible with the intended cleaning liquid.

11.

PAINTING/COATING For painting requirements, reference is made to specification "Surface Preparation and Painting". Underground piping shall be coated and wrapped in accordance with specification “Coating and Wrapping of Underground Piping”.

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BES – 1300-102 12.

DOCUMENTATION

12.1

Both shop and field fabrication include administration of material certificates, welding operations, destructive and nondestructive examinations and all testing operations as required by the applicable specifications and codes.

12.2

Contractor is responsible for planning and documenting all activities and controls which include, but are not necessarily limited to, the following operations: !

Material receiving (including administration/filing of certificates).

!

Cutting.

!

Bending (on site and at contractors for induction bending).

!

Welding.

!

Heat treatment.

!

Destructive and nondestructive testing.

!

Hydraulic bolt tensioning and/or torquing.

!

Hydrotesting.

!

Flushing.

!

Cleaning/chemical cleaning.

12.3

Contractor shall provide principal with two (2) copies of material test certificates for all materials purchased by contractor.

12.4

Documents relating to assemblies to be shipped shall be submitted to principal. Documents shall be available to principal at all times.

12.5

For each piping system (defined as piping items welded together of same material and same design pressure/temperature, e.g. line from a pump to a vessel) contractor shall provide a fabrication book containing documents showing all above-listed operations, signed by a third party inspection, if required.

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BES – 1300-102 13.


PREPARATION FOR SHIPMENT Before shop-fabricated assemblies are prepared for shipping, principal shall check following: !

Overall dimensions as per piping drawing.

!

Required documentation as per subsections 12.2 and 12.3.

!

Material identification as per subsection 6.2.

After assembly has been released by principal, contractor shall prepare material for shipping as follows: !

All assemblies shall be dry and free from water, dirt and loose or foreign materials.

!

Flange faces, machined surfaces and threads in carbon-steel piping shall be coated with a corrosion preventive compound (Rust Ban 324, or equal) before applying the cover, cap or plug.

!

Plastic caps shall be used over all plain, bevelled or threaded open ends.

!

Wood, metal or plastic covers shall be bolted or strapped to open flanged ends.

!

All protective coverings of piping for shipment and shipping containers shall be of sturdy construction in order to withstand normal shipping abuse.

Provisions shall be made to prevent damage to all subassemblies during loading, unloading or shifting of the cargo in transit. Small items shall not be shipped loose, but shall be bagged, boxed or crated. Each container shall be tagged with a description of the contents and destination. Carbon, low-alloy and galvanized carbon steel, stainless steel and duplex stainless steel shall be shipped separately from each other. For stainless-steel and duplex stainless steel spools, contractor shall not use steel hoisting devices as described in subsection 6.1 and shall provide suitable transport packing to prevent spools from contacting surfaces containing zinc or other harmful materials during the transportation.

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BES – 1300-102 13.1


SPOOL PIECE MARKING The appropriate pipe identification, consisting of the line number and spool number, shall be hard dye stamped into the spool. Marking shall be circled with yellow paint. Note: When spools are shop painted the marking shall be protected against shot blasting and priming.

14.

ADDITIONAL REQUIREMENTS For additional or deviating requirements concerning fabrication and erection of steel piping, see specifications listed below: !

"Hot Water and Steam Tracing".

!

"Insulation of Piping and Equipment".

!

"Underground Piping".

!

"Coating and Wrapping of Underground Piping".

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