FABRICATION / INSTALLATION DOC.

No:
STC PROCEDURE STC -PR-PI-01

(PIPING SYSTEM & ACCESSORIES)

CONTENTS
PAGE
1. GENERAL
1-1) PURPOSE 2
1-2) APPLICABILITY 2
1-3) SYSTEM DESCRIPTION 2
1-4) MATERIAL SUPPLY 3
1-5) PIPING FABRICATION 4
1-6) PIPING ERECTION 14
1-7) QC REQUIREMENTS 25
2. FLOW CHART OF PIPING WORK 28
3. WORK PROCEDURE 30
P-1 MATERIAL CHECKING 30
P-2 CHECKING OF BEVELLED END 30
P-3 REPAIR WELDING OF BEVELLED END 30
P-4 CLEANING OF BEVELLED END 30
P-5 LINE UP 30
P-6 FIT-UP AND TACK WELDING OF BUTT JOINTS 31
P-7 FIT-UP AND TACK WELDING OF SOCKET JOINTS 32
P-8 WELDING 32
P-9 FINISHING OF WELD SURFACE 34
P-10 INSPECTION 34
P-11 REPAIR 34
P-12 PIPE FIELD CUTTING & END PREPARATION 35
4. ADDENDUM;
ERECTION AND INSTALLATION MANUAL
(MECHANICAL EQUIPMENT)
ERECTION AND INSTALLATION MANUAL
(INSULATION AND LAGGING)
EG-M9042 INSPECTION & TEST PLAN

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 FABRICATION / INSTALLATION DOC.No:
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(PIPING SYSTEM & ACCESSORIES)

1. GENERAL
1-1) PURPOSE

The purpose of this procedure is to establish

 A common standard for piping erections
 A equal level of quality and quality control
 A common standard for the division of supply of materials and services between
DACP and erection contractor for all piping systems, erected by the variety of
pipe line erection crews from different sources, as they are typical on a large
construction site with a number of erection contractor.
This procedure describes the main points for quality control of all piping installation work at
site, including field-welded pipe.
The welder and piping fitters who are engaged in the construction will work basically in
accordance with these procedures, but alternative measures can be applied under
purchaser agreement before any irregular procedure may be used.

1-2) APPLICABILITY

This procedure is applicable for all piping erections on the project site.

Deviations to this procedure are necessary by the nature of a particular system and/or by
special conditions of the site and/or by special conditions in the E (engineering) P
(procurement) C (construction) contract of the project and/or local statuary regulations
exist, then such deviations are mentioned in the specific project erection documentation
and/or individual pipe line system description. Such deviations shall prevail this procedure.

1-3) SYSTEM DESCRIPTION

The piping systems are sub-divided in branches. The branches are identified with a line
number in the P&ID Diagrams. The P&ID Diagrams identify also the limits of the branches
and interfaces to other (Equipment) systems.

The routing of piping branches and the type and locations of connections are given in the
Isometric drawings. If piping is partly pre-fabricated, then the degree of pre-fabrications is
given in the Isometric drawings, where the number of-shop & field connections are
identified. A piping system is understood to contain all elements of a pipe line, such as (not
limited):
 Pipes: Prefabricated pipe spools and/or commercial standard pipes
 Pipe Connections: between pipes, and/or to equipment: either welded, bolted, or
with standard commercial connectors.
 Pipe Specialties: Valves, Strainers, Expansion joints, Gaskets, Flanges, etc.
 Hangers & Supports: prefabricated and/or on site field adjusted and/or on site
fabricated supports.
 Paint materials of the Piping, beyond touch-up of weld seams and damaged
areas.
 The insulation of the piping.
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(PIPING SYSTEM & ACCESSORIES)

 Tag/Labeling of Equipment and Piping.

1. GENERAL
1-4) MATERIAL SUPPLY

THI will supply piping material for the engineered piping system (that indicated in
drawings) Additional piping material, such as drains, flanges, gaskets, reducers, blind discs,
sockets, bolts, nuts washers

The piping material is delivered with commercial standard units, if not specified otherwise
hereafter.

The delivered material is marked, either with labels or with a color code for identifications
on arrival.

1-4-1) Piping Material

1-4-1-1) Large bore pipes
Large Bore Pipe Material may be delivered with pre-fabricated spools or in standard
commercial units. If the large bore pipe spools are delivered pre-fabricated, then the
prefabricated spools will be delivered:
The at least one spool with over-length and a loosely attached flange for each piping
branch, to allow proper fitting of the pipe by adjusting the length of such fitting joints.
Weldolets/Couplings for connection of small bore pipe branches and instrument tubing are
site installed. Non pre-fabricated large bore Piping will delivery in commercial standard
piping length.

1-4-1-2) Small-bore pipes

Small bore Pipe 2.0" and smaller can be of welded-, bolted-, screwed.

1-4-1-3) Valves & Pipe specialties

Valves and Pipe Specialties, such as Flanges, Gaskets, Bolts & Nuts, Orifices, Sockets,
Adapters, Reducers, etc. can be either with flanges for bolted connections or bevel prepared
for welded connections. Larger size units are delivered individually packed in wooden boxes,
while small size units are delivered in the standard commercial manufacturers packing in
bulk quantities.

1-4-1-4) Hanger & Supports

The term "Piping Supports" includes all assemblies such as hangers, floor-stands, anchors,
pipe slide, guides, brackets, sway braces, vibration dampers, and any supplementary steel
required to attach piping supports.

Piping support shall be supplied and installed as indicated on the attached drawings,
including all piping supports required for support of the suspended piping which are
securely held in place without objectionable stress and swaying.

The piping supports furnished will designed in accordance with the requirements as stated
in ANSI/ASME B31.1 "Power Piping".
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1. GENERAL
Hangers and Supports are delivered mainly of commercial standard manufacturing.
Standard Steel profiles for additional secondary support structures and additional hangers
and supports are supplied from local sources.

Supplementary support beams required for attaching supports to the building structure
shall conform to ASTM A36 or JIS SS400.

All piping supports and steel structure shall be galvanized. No paints are required for
galvanized steel surfaces.

All material to affix Hangers & Support, such as welding connections, anchor bolts and self-
drilling expansion bolts are to be supplied by THI

1-4-2) Welding Material

1-4-2-1) Filler material
All filler material is within THI scope of supply. THI will submit type and manufacturer of
the filler material and to be approved by DCAP to ensure that they are compatible to the
parent metal classification and approved WPS. All filler material to be delivery in the original
packing indicated their batch no. Loose filler materials are not accepted on site.

1-4-2-2) Protection & Pre-Heating gases

All protection and preheating Gases, which are required for welding process, are within
erection contractor's scope.

1-5) PIPING FABRICATION

The fabrication of all piping shall be in accordance with the requirements stated herein and
piping drawings to be furnished later.

1-5-1) Dimensions
The dimensions indicated on the DCAP drawings do not make allowance for welding gaps
or welding shrinkage unless otherwise specifically indicated on the drawings. Allowances
are made for gaskets in the dimensions indicated. Fabrication shall be within plus or minus
3 mm of the dimensions indicated on the drawings. Where the symbol “FC,” meaning field
check, appears on the drawings, the piping so indicated shall be fabricated approximately
150 mm longer than the dimension shown to permit cutting to fit in the field.

1-5-2) Fittings
Fittings such as tees, crosses, elbows, caps, and reducers shall be used for all changes in
direction, intersections, size changes, and end closures of piping, unless otherwise
specifically indicated on the drawings or specified herein.

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1. GENERAL
Couplings shall be used for joining straight lengths of 50 mm and smaller piping.
Branch welds shall not be used except where specifically indicated on the drawings.

Welding adapters, drilled and welded pads, and branch weld connections indicated on the
drawings shall be reinforced to meet the requirements of Paragraph 104.3 of ANSI/ASME
B31.1. Safety valve nozzles shall be additionally reinforced as required to resist thrust due
to valve operation.

1-5-3) Fabricated Sections

The length of shop-fabricated sections shall be the maximum allowable within the
limitations of handling and shipping. Other requirements of these specifications, such as
interior shot blasting, pickling, and similar operations, shall not be considered in
determining the maximum length of shop fabricated sections. The choice of field weld
locations and configuration of the sections shall be selected with consideration of the
problems of field erection. Wherever possible, field welds shall be placed in convenient
locations. Location of field welds shall be subject to the DCAP concurrence.

1-5-4) End Preparation and Fit-up

Preparation of weld ends and fit-up shall be in accordance with the requirements stated
below.

End preparation and fit-up for field welds shall be in accordance with the Pipeline List and
the butt weld end preparation details included at the end of this subsection.

Base metals for butt weld joints shall be prepared by machining or mechanized oxygen
cutting. In specific instances where the use of the above equipment is impractical,
permission shall be secured for hand oxygen cutting. All slag and irregularities shall be
removed from oxygen cut ends, and hand cut ends shall be ground smooth.

Preparation of weld ends for shop welds shall be in accordance with the fabricator’s
standard end preparation and welding procedure used.

The butt weld end preparation of the bade metals for all field weld joints in Contractor-
furnished shop fabricated piping shall be prepared in the fabricator’s shop in accordance
with the Pipeline List and the butt weld end preparation detail drawings.

Radial misalignment of inside surfaces at the joint of shop welds shall not exceed the
limitations specified in ANSI/ASME B31.1.

Pipe ends for socket weld connections shall be reamed to full inside diameter to remove all
burrs and obstructions.

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Terminals of DCAP-furnished equipment, valves, and piping accessories have been

specified to be prepared for welding in accordance with the Pipeline List and the butt weld
end preparation detail drawings. The weld end preparation used by the Contractor for the
mating end shall be designed for compatibility with those end preparations.

1. GENERAL
Control of inside diameters of weld ends of Contractor-furnished piping shall be by means
of selection of piping components, addition of weld metal and machining, or machining as
required. Machining shall be in accordance with the butt weld end preparation details.

1-5-5) Welding
All welding shall be in accordance with the following requirements.

1-5-5-1) Qualification and procedures

All welding procedures, welders and welding operators shall be qualified in accordance with
code requirements before work is begun by the individual welders and welding operators.
All welding procedures shall be submitted to the DCAP for review prior to beginning the
work. The welding procedures shall be written in conformance with the code edition and
addenda stated for the applicable code under the section entitled CODE AND STANDARDS.
The submittals shall clearly state the piping materials and wall thicknesses on which each
procedure submitted will be used. The welding procedures shall include the joint design
details and welding current and voltage values to be used. Records of the names of the
welders who make each weld shall be maintained. Certified copies of any or all of the
above records shall be furnished to the DCAP on request.

Qualification of welders shall be performed at the plant site. The Contractor shall have
prequalified each of the welders. DCAP will witness the tests and judge the result of the
tests. The Contractor shall provide an independent testing laboratory, acceptable to DCAP,
to witness the welding, perform the required tests, and report results. The Contractor shall
furnish all materials, welding equipment, testing areas and supplies for the tests, and shall
certify the results in accordance with the ASME Code. All testing and retesting expenses
shall be the responsibility of the Contractor.

1-5-5-2) Methods
All welding shall be performed using and electric arc welding process which has been
qualified in accordance with the rules of the code.

Only the following welding processes will be permitted.

 Shielded metal arc

 Gas tungsten arc

 Flux cored arc

 Gas metal arc (short-circuiting transfer mode not acceptable)

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 Submerged arc

The use of self-shielded electrodes in the flux cored arc welding process in not permitted.

All gas tungsten arc welds shall be made with the addition of filler metal.

1. GENERAL
In systems with carbon steel piping where the gas tungsten arc welding process is specified
for the root pass in the Pipeline List, the shop fabricator may, at his option, use the gas
tungsten arc process or a welding process which will result in consistent quality welds. On
systems with stainless steel and chrome alloy steel piping, the gas tungsten arc welding
process shall be used.

Field welds in piping systems so specified in the Pipeline List shall be made using the gas
tungsten arc process for the first welding pass. The remaining weld passes shall be made
using one of the processes listed above.

Backing rings shall not be used for shop or field welds in piping furnished under these
specifications.

Single welded butt joints in piping fabricated of materials with a P-Number of 5 or greater
shall have the interior of the pipe beneath the welding zone purged with an inert gas. Butt
joints in all other materials using consumable inserts shall be purged during fusing of the
insert. The inert gas shall be held at a pressure slightly above atmospheric during the
deposition of the first three layers of weld metal. P-Numbers are defined in Section IX of
the ASME Boiler and Pressure Vessel Code.

The procedure for root side purging, including the method used to determine purge gas
purify prior to welding, shall be described in detail in the welding procedure or in a
separate purging procedure submitted concurrently with the welding procedure to DCAP for
review.

Nitrogen shall not be used as a purging gas for austenitic stainless steels.

The application of heat to correct weld distortion and dimensional deviation in austenitic
stainless steels is prohibited.

Block sequence welding on austenitic stainless steel is prohibited.

Antis patter compounds used on stainless steel surfaces shall not cause corrosive or other
harmful effects and shall not contain more than 200 ppm total halogens. Total halogens
shall be determined by analysis. The Contractor shall obtain certified test reports for each
batch used. Certification records shall be submitted to the DCAP.

All nondestructive examination and testing of welds shall be performed by the Contractor in
accordance with the ASME Boiler and Pressure Vessel Code.

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1-5-5-3) Filler Metal

When low hydrogen type electrodes are specified in welding procedures, the method used
for storing, handling, baking, drying, and reconditioning shall be explained in the submitted
welding procedures or in a separate electrode control procedure submitted to the Owner
for review prior to beginning the work.

Submerged arc multipass welds in carbon steels, and all welds in alloy steels and corrosion-
resistant steels shall use essentially a neutral flux.

1. GENERAL
For the shielded metal arc welding process, all filler metal shall be of the low hydrogen
type, except non-low hydrogen electrodes may be used on root passes.

The maximum diameter electrode used for shielded metal arc welding of austenitic
stainless steels shall be 4 mm.

The maximum diameter filler rod used for gas tungsten arc welding of austenitic stainless
steel shall be 3 mm.

Filler metal, including consumable inserts, for joining austenitic stainless steels to austenitic
stainless steels shall be selected and controlled to produce a delta ferrite determination
from 5 to 20 FN (ferrite number). The requirement does not apply to Type E310 or E16-8-
2 alloys. The ferrite content of each heat of bare filler metal, used with the gas tungsten
arc process, including consumable inserts, shall be determined from the chemical analysis
of the bare material using the Schaeffer, Modified Schaeffer or DeLong Constitutional
Diagram. Delta ferrite verification shall be made for all other processes by tests using
magnetic measuring devices on undiluted weld deposits. For submerged arc welding the
ferrite determination tests shall be made for each wire-flux heat-lot combination used in
production and shall be made on a production weld or simulated production weld using a
magnetic instrument previously calibrated in accordance with AWS A4.2. All other delta
ferrite weld filler verification tests shall be made on weld pads containing undiluted layers
of weld metal. The ferrite content of covered electrode weld deposits shall be determined.
All ferrite testing and certification of filler materials used in the fabrication of austenitic
stainless steel components may be performed by the material manufacturer.

Filler metals to be used for joining carbon steel to stainless steel dissimilar metal joints shall
be as indicated below.

ASME AWS
Process Specification Classification

GTAW, SAW SFA 5.14 ERNiCr-3

SNAW SFA 5.11 ENiCrFe-3

1-5-5-4) Reinforcement Limits

The interior and exterior surfaces of double welded butt joints and the exterior surfaces of
single welded butt joints shall be sufficiently free from coarse ripples, grooves, abrupt

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ridges, and valleys to be within the maximum reinforcement limits permitted by ANSI/ASME
B31.1.

The interior reinforcement of single welded butt joints shall not exceed the limits stated
below. The reinforcement shall be determined from the higher of the abutting surfaces
involved.

1. GENERAL
Material Nominal Maximum Internal
Thickness, mm Reinforcement Thickness, mm

Up to 5, inclusive 2.5

Over 5 to 12, inclusive 3

Over 12 4

The internal reinforcement of welds not accessible for visual examination may be evaluated
by suitable nondestructive examination methods. Upon request by the DCAP, such
examinations shall be performed by the Contractor to determine the extent of internal
reinforcement. This shall not be construed as precluding the Contractor from performing
these examinations as a part of his regular quality control. All defective welds shall be
repaired, regardless of the examination method by which discovered.

Welding concavity grinding, “suck-back,” or other conditions shall not result in a weld
thickness less than the minimum wall thickness of the base metal.

Arc strikes in P-5 Group 2 material shall be confined to the area to be covered by the weld.
Arc strikes outside the weld area shall be removed by grinding to a smooth contour. The
ground area shall be visually examined for cracks, porosity, and blemishes. Any defects in
the ground areas shall be removed and/or repaired. Ground area may be left unrepaired if
minimum base metal thickness requirements have not been violated.

1-5-5-5) Preheat and Interpass Temperature

Preheat and interpass temperatures shall be maintained in accordance with the
requirements of the applicable code. Electric or gas heat sources which provide a uniform
application of heat over the weld area shall be used.

Preheat and interpass temperature shall be checked by the use of temperature indicating
crayons, thermocouples, or surface contact type pyrometers.

Preheat and interpass temperatures for austenitic stainless steels shall not exceed 177 oC.
Temperature indicating crayons used on austenitic stainless steels shall not cause corrosive
or other harmful effects and shall not contain more than 200-ppm total halogens. Total
halogens shall be determined by analysis. The Contractor shall obtain certification of these

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tests for each different crayon batch used. Certification records shall be submitted to the
EGAT.

1-5-5-6) Weld Heat Input Control

For manual welding with the gas tungsten arc and shielded metal arc welding processes,
heat input shall be limited by filler material size, weaving limitations, and welding technique
restrictions as follows.

For manual gas tungsten arc welding, the maximum filler wire 2.5 mm diameter. The
maximum weld bead width shall be the lesser of four times the filler wire diameter or
10 mm.
1. GENERAL
For the shielded metal arc welding process, the maximum covered electrode size shall be 4
mm diameter. The maximum weld bead width shall be the lesser have four times the
electrode core wire diameter or 16 mm.

The second and third layer (the root pass is the first layer) in piping welds shall be
deposited using a minimum of two welding passes per layer regardless of welding process
or position.

Heat input control for machine welding, automatic welding, and semi-automatic welding
processed shall be controlled according to the formula below and the limits specified in “a”
and “b” below.

Heat Input = Voltage (1)

(volts) x Current (2) (amperes) x 60 x 25.4
Travel speed (mm per minute) (3)

a. For piping, the heat input for any welding pass shall not exceed 2,000 joules per
mm.

b. For all other components, the heat input for any welding pass shall not exceed 3,200
joules per mm.

Note(1) : The heat input is based on the voltage at the arc. Voltage may, however, be
measured at the welding power supply. If the heat input limit is exceeded when
voltage is measured at the welding power supply, the measured voltage may be
reduced by an amount equal to the voltage drop between the power supply and the
arc.

Note(2) : For pulsing current applications, the weighted average current, according to
the formula below, shall be used to calculate the heat input.

(High Pulse Current + (Low Pulse Current

Weighted Average Current = X High Pulse Time) x Low Pulse Time)
High Pulse Time + Low Pulse Time

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Note(3) : Travel speed for semi-automatic processes may be determined from test
welds using the applicable welding procedure parameters to be applied prior to actual
pipe or component welding.

Heat input instructions for all of the welding processes described above shall be included in
the Contractor’s welding procedure submitted to the DCAP.

1-5-5-7) Postweld Heat Treatment (If require per ASME code)

Stress relief of all welds shall be performed in accordance with the requirements of the
applicable code. All welding zones, bends, and hot-formed sections shall be fully stress
relieved as required by the code.

1. GENERAL

Detailed instructions for postweld heat treatment shall be given in the applicable welding
procedure specification and in a separate heat treatment procedure submitted to the EGAT
for review prior to beginning the work. The procedure shall include in its instructions the
number and approximate location of thermocouples to be used and cycle heating and
cooling rates.

Wherever required by ASTM code, stress relieving shall be performed by slowly heating the
entire assembly to the specified temperature, holding the temperature for the required
length of time, then allowing the assembly to cool. Where this procedure is impractical,
local stress reliving may be employed.

Heating may be by means of electric induction coils electric resistance coils, suitable gas
burners, or gas or oil fired furnaces. Oxyacetylene flame heating or exothermic chemical
heating methods will not be permitted. In addition, where local stress relieving is employed
a complete record of the pipe temperatures throughout the stress relieving cycle shall be
made by means of a recording potentiometer. The record shall be made available for
review by the EGAT on request.

Gas or oil fired furnace fuels used for the heat treatment of stainless steel base materials
shall have the following limitations on sulfur content.

Gas - 0.7 gram per cubic meter

Oil - 0.5 weight percent

No stress reliving for seal welds will be required.

1-5-6) Thermowells
Thermowells shall be furnished under these specifications for installation in the piping
where indicated on the drawings.

1-5-7) Threaded Connections

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Threaded adapters for 50 mm and smaller branch connections shall be installed in

accordance with the fitting manufacturer’s recommendations. The diameter of the hole in
the main run pipe shall not be less than the inside diameter of the fitting at the weld end
preparation.

A drill or reamer shall be run through each branch connection attachment and the hole in
the main pipe after the attachment has been welded to the pipe. The drill or reamer size
shall be the same as the bore diameter of the attachment.

Threads of all branch connections shall be trued by use of a thread tap after the coupling,
pad, adapter, or other threaded attachment has been welded to the main piping.

1-5-8) Instrumentation Connections

Connections for thermowells shall utilize Bonney Forge and Tool Works Thredolets or
acceptable equal. Drilling or reaming of the pipe wall shall accommodate the thermowells
with no interference.
1. GENERAL
Pressure taps for instrumentation shall be installed in accordance with Article 4.84 of the
ASME Performance Test Code PTC 6.

1-5-9) Inspection and Testing

Inspection and testing shall be as stated herein. The requirements specified herein apply to
piping fabrication work specified in this section, and to field erection of piping specified in
section 1-6 Piping Erection, as appropriate.

Documentation of these inspections and tests shall be maintained by the Contractor. Any
defects found by these inspections and tests shall be reinspected, following repair, by the
same method and technique which originally identified the defect. Acceptance shall be
based on identical acceptance criteria.

1-5-9-1) Hydrostatic Tests

Shop hydrostatic testing of fabricated piping is not required. Hydrostatic testing shall be
done as a part of the piping erection as stipulated in section 1-6

1-5-9-2) Weld Tests

The quality of welding may be checked and tested by removal of a pipe section containing
a weld. Such section of pipe shall be removed by the Contractor if requested by DCAP.
Testing will be conducted by the Contractor’s independent testing laboratory.

1-5-9-3) Nondestructive Examinations

All shop fabricated piping furnished by the Contractor and all field welds shall be inspected
as required by the applicable code and as specified herein. Service pressure and
temperature conditions for each piping system are listed in the Pipeline List.

Personnel who perform and evaluate the examination shall be qualified to at least a level I,
in accordance in ASME Section V.
All consumables for non-destructive testing are within the scope of the appointed NDT
Contractor.

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Nondestructive testing for Contractor-furnished shop fabricated piping shall be performed

in accordance with written procedures. The procedures shall be submitted to EGAT prior to
performing the work.

All nondestructive examinations for piping field erection work, except visual examination,
shall be performed by an independent testing laboratory. The services of the testing
laboratory shall be provided by the Contractor and acceptable to DCAP. The testing
laboratory will prepare procedures, perform examinations, and interpret results. The
interpretation of the testing laboratory will be final and the Contractor shall promptly repair
all defects revealed by the examinations, as required by the applicable code.

The Contractor shall provide all rigging, scaffolding, and other facilities and services as
required to permit laboratory personnel to perform the examinations.

1. GENERAL
1-5-9-3-1) Visual Examination
The Contractor shall perform visual inspection of all shop welds in Contractor-furnished
piping and field piping welds made by the Contractor.

1-5-9-3-2) Nondestructive Tests

Nondestructive tests shall be performed by the Contractor in accordance with the following
articles.

1. Radiographic examination
In addition to the welds requiring radiographic examination under the code, the
circumferential butt welds of Contractor-furnished shop fabricated piping specified in the
Pipeline List shall be radio graphically inspected in accordance with ANSI/ASME B31.1.

After radiographic examination is complete, the Contractor shall install and seal weld the
closure plugs.

2. Marking
Upon completion of each welded joint, the welding operator shall mark his regularly
assigned identification number and the last two numbers of the year in which the work was
completed.

Inspection stamps and code symbol stamps, where required and all other necessary
information shall be applied to the piping in accordance with the governing codes.

For alloy steel piping, information shall be stamped on steel bands at least 25 mm wide
which shall be mechanically fastened to the piping. Steel stamping directly on alloy piping
will not be permitted unless “low stress” dies stamps such as interrupted dot or round nose
types are used.

3. Data Reports

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Partial data reports shall be furnished for all piping fabricated to conform to Section I of the
ASME Boiler and Pressure Vessel Code. Copies of records of welding operations shall be
submitted to the DCAP.

1-5-10) Cleaning, Painting, and Marking

The interior and exterior surfaces of all piping shall be thoroughly cleaned of all sand, mill
scale, greases, oils, dirt, and other foreign materials.

1-5-10-1) Interior Surfaces

Unless otherwise specified for “blast cleaning” in the Pipeline List, the interior surfaces of all
shop fabricated piping shall be cleaned with rotary tools or wire brushing as described in
the PFI Standard ES-5, Articles 4.2.1 and 4.2.2.

The interior surfaces of shop-fabricated piping specified for blast cleaning shall be
thoroughly blast cleaned using a nonsiliceous blasting material. After cleaning, interior
surfaces of all piping shall thoroughly air blown and sealed.

1. GENERAL

1-5-10-2) Exterior Surfaces

Piping, parts, and appurtenances shall be prepared and coated in accordance with the
following.

Surfaces to be coated shall be clean, dry, oil free, and prepared in accordance with the
coating manufacturer’s instructions.

All surfaces shall be painted except for piping internals including internal surfaces of branch
connections, stainless steel, flange faces, threaded surfaces, and external surfaces within
75 mm of field welded connections.

All machined weld end preparations for field welds on carbon and all steel piping shall be
coated with a consumable coating to prevent corrosion prior to welding.

1-5-10-3) Identifying Piece Marks

Identifying piece marks (spool numbers), consisting of the pipeline identification number as
specifies the Pipeline List, and a fabricated section piece number shall be seen both sides of
each fabricated section.

1-5-11) Protection During Shipment

Open ends and branches of all fabricated pipe shall be securely closed to protect the
interior surface and end surfaces during shipment.

Weld ends larger than 50 mm shall be protected with suitable metal lined in the end with
20 mm soft wood. The caps shall be securely attached and sealed with waterproof tape.

Openings 50 mm and smaller which are not of the flange type shall be protected as follows.
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Female openings, such as sockolets, shall be sealed using pressed-in light metal
inserts, retained with a seat of waterproof type.

Nipples shall be sealed with a light metal cap retained with a seal of waterproof tape.

Flanged openings shall be sealed with waterproof disks at least 12 mm thick bolted to the
flange. A 3 mm thick rubber gasket shall be provided for sealing. Bolts used for securing
the disk shall be at least 12 mm diameter, and at least one half the required bolting shall
be used.

Miscellaneous loose items shall be suitably packed in heavy wooden boxes with waterproof
linings to prevent the entry of dirt and moisture.

1-6) PIPING ERECTION.

1-6-1) Erection of Pipe Lines Systems

The Work includes the complete installation of the piping systems which includes, but it is

1. GENERAL
not limited to:
Site plant structures to be survey and marking of the routing of the piping. The building and
equipment position to be measures with exactly. Fitting, of all large bore and small bore /
tubing systems, including all pipe line interconnections being of welded and/or bolted
and/or connector type and connections of pipe lines to machinery equipment, being of
bolted and/or connector type and including the fitting of all delivered Hangers and
Supports. The delivery, fabrication and installation of additional Hangers and Supports as
required by the local conditions to complete the system

All piping, valves, fittings, and piping specialties shall be erected in accordance with the
requirements of this section. Any piping installation not specified herein shall be done in
accordance with good engineering practice.

The piping to be fitted locally following specific local arrangements. The major small bore
piping are indicated in the drawings, while some secondary piping for drains and vents have
to be 'field run' as local conditions dictate.

The Hanger locations are engineered to affix them directly to concrete- and/or steel beams
of the power plant structures. In rare cases, where no plant structure is available at the
location of a hanger, a secondary steel support structure is to be engineered and fabricated
on the project site.

The Supports are to be affix with self-drilling bolts to concrete floors or are to be welded on
steel structures. In some cases, additional supports are required, which are to be
engineered and fabricated on the project site.

The drawings indicate the dimensions of the major lines. These dimensions are subject to
change to accommodate the equipment, valves, and fittings actually furnished and the
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variations in equipment as actually installed. If the equipment, valves, fittings, and other
components of the piping systems actually furnished differ in dimensions from those
indicated, the piping systems shall be altered as required to accommodate these changes.
If, due to some unforeseen circumstance, the installation of the piping as indicated would
result in interference, the modifications or corrections required to install the piping free
from interferences shall be made.

The Contractor shall furnish all equipment, components, and materials required to join the
piping systems together in accordance with the drawings and specifications. This shall
include all bolts, nuts, washers, and gaskets; clamps; welding rod, solvents, glues, and all
other consumables; rags; rigging and cutting equipment; etc.

1-6-2) Welding
Field welding shall be in accordance with the requirements specified in section 1-5 Piping
Fabrication.

1-6-3) Miscellaneous Piping

All miscellaneous piping shall be installed in a neat, rectangular form. Special attention shall
be given to securing an orderly appearance. All piping shall be given to securing an orderly
appearance. All piping shall be installed perpendicular or parallel to the major

1. GENERAL

equipment, building structure, and floor levels except in special cases consented to by
DCAP.

All piping, including tubing, not located on the drawings shall be installed in accordance
with the following requirements.

All branch piping shall be provided with cap or plug at the main headers.

Valves shall be installed in such a manner that they can be operated from the main
operating floors or platforms without the use of ladders or special operating devices.

Pipe runs which require condensate drainage shall be installed so that they pitch toward
the point of drainage.

Routings shall be selected to avoid interference with planned and dimensioned locations for
lighting fixtures, electrical trays, raceways, or conduit.

Sketches of the proposed routing of all piping not located on the drawings shall be
submitted to DCAP. DCAP acceptance of all routings shall be obtained before the piping is
erected.

1-6-4) Temporary Piping

All equipment, piping, and valves of a temporary nature shall be installed in a safe and
workmanlike manner. This shall include such lines as temporary vents hydrostatic test lines,
chemical cleaning lines, and all other temporary lines required to successfully complete the
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work. When the temporary piping is no longer required, the Contractor-furnished

temporary piping shall be dismantled and removed from the site.

1-6-5) Piping in Existing Areas

Before fabrication, a field check shall be made of the routings of new piping to be installed
in existing plant areas to determine that the piping, insulation, and supports can be
installed without interference. If the piping as indicated would interfere with existing
facilities, the pipe routing shall be altered or existing miscellaneous piping shall be
relocated. All pipe routings shall be subject to acceptance by DCAP.

A field checks of all connections to existing equipment and piping for location, size, flange
drilling, and flange facing shall be made prior to ordering material or fabricating pipe for
these connections.

1-6-6) Alterations and Cut-ins

All alterations and cut-ins to existing piping and equipment indicated on the drawings shall
be made as specified herein and as required for proper installation of the new piping and
equipment.

All cut-ins shall be done by sawing or by careful flame cutting. Flame cut holes shall be
ground smooth. The interior of the piping shall be thoroughly cleaned after cutting.

1. GENERAL

Whether indicated on the drawings or not, existing miscellaneous piping shall be revised as
required to permit installation, without interference, of new piping and equipment. The

alterations to existing piping shall include any required revisions, additions, or replacements
of insulation and pipe supports.

Any piping materials and valves removed and not reused shall be disposed of as directed
by DCAP.

All alterations and cut-ins to existing systems shall be made on a time schedule acceptable
to DCAP.

1-6-7) Thermal Expansion

All piping shall be installed in accordance with the drawings so that excessive or destructive
expansion forces will not exist either in the cold condition or under conditions of maximum
temperature.

It is the responsibility of the Contractor to erect the piping systems in a stress frees
condition so that the resulting cold spring gap is dimensionally acceptable to DCAP. A stress
free cold spring gap shall mean that no forces are applied on the piping by the Contractor
to achieve the cold spring gap.

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The Contractor shall provide a detailed step-by-step procedure indicating the sequence for
erecting each cold spring piping system. The general purpose for these procedures is to
assure EGAT that the pipe is erected in its correct stress free condition, and that it remains
in this position until after the cold pull gap is checked and the pipe in match marked. These
procedures shall be submitted for review before any pipe in the cold spring systems is
erected. The procedures shall be written so as to assure that the following general
requirements are met.

1. The dimensions of all shop-fabricated sections shall be checked by field

measurement, and any errors shall be brought to the attention of DCAP before
erection begins. The check shall include recording the wall thickness at two
locations on each spool. At each location, four readings shall be taken 90 degrees
apart. The location and results of these measurements shall be submitted to DCAP.
Methods used to dimensionally check pipe bends shall be acceptable to DCAP.

2. A survey system shall be established by the Contractor and used to survey and
record the erection of all piping systems.

Bench marks shall be established from the initial reference point, as required,
throughout the building up to and including the terminations of the piping and used
to correctly position each piping spool. It is not acceptable to position piping spools
measuring off of assumed locations of structural steel. All benchmarks shall be
accurately documented and the entire survey system approved by DCAP.

1. GENERAL

One acceptable method to establish horizontal reference points in the piping chase
is to suspend wires from each corner of the chase and survey their position relative
to the initial reference point. Weights shall be suspended from the wires in a
container of fluid to dampen any movement of the wires.
The piping terminal points shall be surveyed and recorded in the space provided in
the procedures. The actual terminal point locations shall be compared to the design
dimensions. EGAT shall approve of the terminal point survey before the Contractor
may proceed with piping erection.

3. All piping shall be erected into position, fit up and lugged in place. Allowances shall
be made for welding shrinkage. All lugs attached to the piping shall be of the same
material as the piping on which they are installed. No lugs shall be field welded to
alloy steel pipe. The piping shall be supported in a plumb, level position in its
permanent pipe supports. Additional temporary supports, if required, shall be
installed. Temporary rigid horizontal restraints shall be installed as required to
maintain the pipe in its correct position.

4. A final survey of the piping shall be performed after removal of pulling equipment
and installation of guides to verify that the pipe is in the proper cold position.

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1-6-8) Cutting and Drilling Structures

All necessary drilling, cutting, and patching of structures required for proper installation of
piping or bolts shall be done, but only as indicated on the drawings, specified herein, or
with the consent of DCAP.

Holes shall be cut in structural steel, Wherever possible, clamps shall be used for
attaching erection rigging, Lugs may be welded to structural steel only with the consent of
DCAP. Lugs welded to the flanges of structural steel members shall be aligned parallel
with the web of the member. Upon completion of the work, the lugs shall be removed and
the surfaces ground smooth.

All holes cut in grating of floor plate shall be banded and reinforced in accordance with the
details. Aluminum shall be used for banding aluminum plate and steel for steel grating or
floor plate. After grands and reinforcements have been installed, all welds shall be ground
smooth and weld surfaces. Two coats of zinc rich galvanizing repair compound shall be
applied to damaged areas of galvanized metals.

If normal grating support is removed by the cutting of holes, the Contractor shall be add
miscellaneous angles or other steel as required to properly support the grating.

Holes in concrete floors shall be provided with machine cut steel pipe sleeves in accordance
with the details indicated on the drawing.
All opening in concrete shall be made by core drilling, saws, or similar clean cutting
equipment.

1. GENERAL

Where box outs are left in concrete walls for the passage of pipes, the Contractor shall
weld 6 mm thick steel seal rings on the pipes and fill the space between the pipe and the
box out with concrete.

1-6-9) Penetration Seals

Penetration seals shall be furnished and installed on piping, which passes through walls and
floors where indicated on the drawings.

Materials of pipes at the center of the concrete. 6mm-Thickness X 100 mm-Height.

Penetration seal shall be of the same.

1-6-10) Valve Installation

All valves shall be installed in accordance with the requirements stated herein.

Excessive piping strains and bending moments on valves, especially ANSI Class 150 large
steel gate valves and butterfly valves, shall be avoided. Excessive strains and moments will
result in distorted valve seats.

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Valve disks and plugs shall be off the valve seats when welding valves into the lines.

Check valves shall not be installed in vertical runs of piping unless they are specifically
designed for vertical operation.

vent and drain valves shall be provided with at all high and low points respectively, and as
required for suitable operation. Unless otherwise specified, the minimum valve size for
vents and drains shall be 20 mm and 25 mm respectively.

1-6-11) Making Flanged Connections

The faces of all flanges and gaskets shall be wiped clean when making up flanged joints.
The contact faces of all flanges shall meet squarely, and particular care shall be exercised
in pulling up flanged joints to prevent overstressing of flanges or flange bolting.

The threads of all bolting shall be painted with a suitable thread lubricant before the joint is
made. The lubricant shall be suitable for the operating temperatures involved.

1-6-12) Piping Isolation

All necessary flange isolating materials and insulated bushings, unions, and couplings shall
be installed as indicated herein, on the drawings, and as required to properly isolate the
piping. Bolting at insulated flanges shall consist of studs and nuts with sufficient stud
length to allow at least one full stud thread protruding through each nut. Sleeves shall
extend into the insulating washers. After installation, insulated flanges, bushings, unions,
and couplings shall be tested to determine that the piping is properly electrically isolated
the satisfaction of DCAP.

The Contractor shall electrically isolate the designated piping from connecting piping and
equipment, reinforcing steel, structural steel, the station grounding system, and other
buried piping.
1. GENERAL

1-6-13) Piping in Concrete Trenches

Piping to be installed in open concrete trenches shall be installed in accordance with the
drawings and as specified herein.

1-6-14) Installation procedures

All piping shall be constructed to the lines, grades, and elevations shown on the contract
drawings. The permissible horizontal or vertical deviation from the lines and grades as
shown on the plans shall be not more than 25 mm at any point.
Pipes, fittings, specials and appurtenances shall at all times be handled in a manner that
will ensure installation in sound, undamaged condition. Handling methods and equipment
used shall prevent damage to the coating and shall include the use of wide canvas slings
and wide padded skids. Bare cables, chains, hooks, metal bars, or narrow skids shall not
be used.

1-6-15) Mechanical Joint Pipe Installation

Mechanical joint pipe shall be assembled in complete accordance with the manufacturer’s
instructions and recommendations. If effective sealing is not obtained in the assembly of
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mechanical joints, the joint shall be disassembled, cleaned, and reassembled. Over
tightening blots to compensate for poor installation practice will not be permitted.

Cutting shall be performed in a neat manner, Cuts shall be straight, smooth, and at right
angles to the pipe axis.

1-6-16) Underground Piping

Direct buried underground piping shall be installed as indicated on the drawings and as
specified herein.

1. Earthwork. Excavation, embedment, and backfilling shall be in accordance with

the requirements stated below.

2. Trenching. Trenching shall include the removal of all materials regardless of

type, composition, or condition, as required for proper pipe installation as
specified herein.

If no piping elevations are indicated on the drawings, underground piping shall

be installed with a minimum of 915 mm of cover. All other underground piping
shall be installed to the lines and elevations indicated on the drawings.

Trenches shall be excavated to a width, which will provide adequate working

space and pipe clearances for proper pipe installation, jointing, and embedment.
However, excepting trenches for steel piping and encased piping, the width of
trench below an elevation 150 mm above the top of the pipe shall not be more
than 450 mm greater than the outside diameter of the pipe, unless otherwise
indicated on the drawings.

1. GENERAL

Except where otherwise required for concrete encasement, rock clearance, or

trench bottom stabilization, pipe trenches shall be excavated to minimum 100
mm below pipe subgrade to provide for the installation of pipe foundation
material.

Adequate sheeting and shoring shall be provided at all times when required to
maintain sides of excavations or to protect workmen and avoid damage to
property. Sheeting shall be pulled before backfilling or shall be left permanently
in the trench if acceptable to DCAP.

The trench excavation shall be kept dry at all times by dewatering pumps or
sump or other means acceptable to DCAP.

All excess excavated materials shall be disposed of as directed by DCAP.

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3. Stabilization. Trench bottoms which become soft, mucky, or otherwise unstable

during construction operations shall be stabilized with back fill sand.

4. Pipe Foundations. All material removed below pipe subgrade elevations shall be
replaced with back fill sand material except for encased pipe. Material removed
below encased pipe subgrade elevations shall be replaced with the same material
used for the encasement unless otherwise indicated on the drawings.
The foundation for coated pipe shall consist of natural back fill sand. The sand
shall be compacted by use of vibrating compactors or by means of inundation.
The top of the sand shall be graded to provide uniform longitudinal support for
the pipe and the pipe shall be laid directly thereon.

5. Embedment and Backfill. Pipe embedment below an elevation 1/6 of the outside
pipe diameter above the bottom of the pipe shall consist of the same material as
specified herein. The remainder of the pipe embedment and the trench backfill
shall consist of the excavated soil.

Embedment materials for coated pipe shall consist of the same back fill sand specified
under Pipe Foundations for coated pipe. The sand embedment shall completely envelop
the pipe and shall extend at maximum 300 mm above the top of the pipe. The sand shall
be placed in equal layers, not to exceed 200 mm, on each side of the pipe and shall be
compacted to give maximum support and restraint to the pipe. Sand shall be wet when
compacted.

Compaction of back fill sand shall be by use of vibrating compactors. DCAP may
permit consolidation of the sand by inundation if they determine that all
conditions are favorable and the Contractor makes all necessary provisions for
adequate water supply, drainage, and anchorage of the pipe to prevent flotation.

1. GENERAL

All tools used in the placement and compaction of the embedment of coated pipe
shall be selected and used so that the pipe coating will not be damaged. Trench
backfill shall be compacted to not less than 90 per cent of maximum density.

Backfill for trenches traversing roads and parking areas shall be deposited,
spread, and compacted in layers s not more than 200 mm in thickness. Each

layer of material shall be compacted to not less than 95 per cent of maximum
density. Surfaces over

Backfilled trenches crossing surfaced areas shall be finished flush with existing
adjoining surfaces and put in a usable condition. Final resurfacing for such areas
will be done under separate specifications.

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Replacement surfacing shall match existing surfacing and shall be finished flush
with existing adjoining surfaces.

6. Grade and Alignment. Piping and concrete pipe trenches shall be laid to the
lines and grades indicated on the drawings.

All trench excavation shall be graded to provide proper slope for prevention of
collapse.

All pipes shall be brought to the exact terminal points specified.

7. Laying Pipe. Pipe shall be protected from lateral displacement by pipe

embedment material installed as specified for trench back fill.

8. Closures. When pipe laying is stopped at the end of the day or for any other
reason, the end of the pipe shall be closed with plywood and adhesive tapes.

9. Handling. Pipe, fittings, valves, and accessories shall be handled in a manner

that will ensure installation in a sound, undamaged condition. Equipment, tools,
and methods used in unloading, reloading, hauling, and laying pipe and fittings
shall be such that the pipe and fittings are not damaged.

Particular care shall be taken to prevent damage to protective coatings and

concrete pipe joint rings. Slings shall be nonabrasive and located between the
ends of each pipe section when lifting. Bare wire rope slings or the use of hooks
to lift pipe will not be permitted.

10. Mechanical Joint Pipe Installation. (If applicable) Mechanical joint pipe shall be
assembled in complete accordance with the manufacturer’s instructions and
recommendations. If effective sealing is not obtained in the assembly of
mechanical joints, the joint shall be disassembled, cleaned, and reassembled.

1. GENERAL

Over tightening bolts to compensate for poor installation practice will not be
permitted.

Cutting shall be performed in a neat manner, without damage to the pipe. Cuts
shall be straight, smooth, and at right angles to the pipe axis. Ends of ductile
iron pipe shall be cut with a saw, abrasive wheel, or oxyacetylene torch.

The installation of mechanical joints shall be in accordance with the “Notes on

Installation of Mechanical Joints” covered in ANSI/AWWA C111 A21.11.

1-6-17) Testing

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Materials and equipment tests shall be made by the Contractor as specified herein, as
specified on the Pipeline List, and as required by code requirements and local and state
regulations.

All materials, chemicals, equipment, tools, instruments, blocking, bracing, blind flange or
bulkheads, blanking plates, and all labor required to complete the tests shall be furnished.

Tests shall be performed as many times as necessary to assure proper quality of materials
and workmanship. If any tests reveal unsatisfactory materials or workmanship such
materials or installation shall be repaired or replaced to the satisfaction of DCAP.

1. Pressure testing of piping. When a test pressure is specified for a piping system in
the Pipeline List, the specified test pressure shall be applied to the system upon
completion of erection. Where no test pressure is specified, pressure testing is not
required for that system except as specified otherwise herein.

All hydrostatic and pneumatic testing shall conform to ANSI/ASME B31.1- Code for
Pressure Piping, Paragraph 137.

Except as otherwise specified herein or in the Pipeline List for “air test,” all pressure
testing shall be done hydrostatically with cold water. The specified test pressure
shall be applied for at least 1 hour. Leaks shall be repaired and the system retested
until accepted by DCAP as satisfactory.

The test pressure shall not be applied until the components being hydrostatically
tested and the pressurizing medium are approximately at the same temperature.

Before applying the test pressure, all air shall be expelled from the piping being
hydrostatically tested. The Contractor, at the direction of DCAP shall make the
required taps at the high points of the piping systems and shall plug the taps upon
completion of the testing.

Lines to be air tested shall be given an application of a leak detection fluid, which
shall reveal the presence of leaks, by easily visible means, such as bubble formation.

1. GENERAL

The piping shall be hydrostatically tested with natural water. The low points of the
piping shall be provided with drain taps and plugs. After the piping has been
hydrostatically tested and has been accepted by Owner the piping shall be
completely dewatered.

2. Field Pressure Tests after completion of erection. All systems have to undergo a
pressure test. If not otherwise specified for a particular system, following cleaning
methods shall apply:

Fire Protection System and Service Water System

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Shall be flushed with the quality of water used for operation of the system.

Fuel Oil Systems

Shall be flushed with the natural water. The System can be used for circulating
flushing.

3. Instrument and control tubing testing. Instrument and control tubing shall be
tested as specified herein.

1-6-18) Cleaning of Pipe

The inside and outside surfaces of all pipe, tubing, valves, and fittings shall be cleaned of
all dirt, sand, loose mill scale, and other foreign materials immediately after removal from
storage and before erection. All lines shall be thoroughly flushed or blown before being
placed in device. All compressed air lines shall be air blown.

1-6-19) Touch-up Painting

Damage painting shall be touched up with the same paints as the original where damage is
deep into the base metal or where oxide forms, the spot shall be cleaned to bare metal
surface and repainted with the specified painting system.

Galvanized surface shall be touched up with zinc rich paint.

1-6-20) Color Code and Marking

Identification colors for all piping and method of application shall be according to DCAP
"Identification Colors for Equipment and Pipes Convey Fluids in Liquid or Gaseous Condition
in Land Installation and on Board Ships.

1-6-21) Field Applied Coatings

Field applied coating systems for all field installed underground piping joints and for any
underground piping specials such as fittings, valves, brass or copper pipe, and short
lengths of carbon or stainless steel pipe, which may be impractical to shop coat and which
are approved by DCAP to be field coated, shall be in accordance with this article.

Except as otherwise specified, all cleaning, coating, testing, handling, and installation of
field applied coating systems shall be in accordance with AWWA C209 or by heat
shrinkable. The coating system shall consist of two separate layers of tape, with each layer

1. GENERAL

of tape applied over a primer, and with minimum overlap. The primer shall be compatible
with the tape system and shall be chloride free if used on stainless steel.

1-6-22) Electrical Inspection

After the field coating work is complete and just prior to backfilling, 100 per cent of all
shop and field coated areas shall be inspected by the Contractor, using an electrical holiday
detector. Holiday detector voltages shall be as follows.

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Holiday Detector
Coating System Voltage Range

Shop applied coat 1250√T WHERE T = THICKNESS IN MILLS

Field applied coat 1250√T WHERE T = THICKNESS IN MILLS

Any flaws or holidays found in the coated areas shall be repaired. The pipe coating shall be
retested after repair. Testing and repair shall continue until no holidays are detected.

1-6-23) Coating Repair

The method of field repair of damaged shop applied coatings shall be in accordance with
AWWA C209 or by heat shrinkable. The repair materials shall be the same as the original
coating or as recommended by the coating applicator.

The method of field repair of damaged field applied coatings shall be in accordance with of
AWWA C209 or by heat shrinkable. The repair materials shall be the same as the original
coating or as recommended by the coating manufacturer.

1-6-24) Handling of Coated Pipe

Coated pipe shall at all times by handle so as to prevent damage to the coating. Bare
cables, chains, hooks, metal bars, or narrow skids shall not be permitted to come in contact
with the coating during handling.

Coated pipe shall be carefully backfilled with clean native soil or laid on concrete trench
supports. No organic material such as sacks or wood blocks shall be allowed in the piping
trench. No sharp objects such as stones shall be allowed to contact the coated pipe.

1-6-25) Final Adjustment

After a period of initial operation, all flange bolting shall be checked for tightness.

1-7) QC REQUIREMENTS

All erection and installation works are subject to Inspection & Test, which in compliance
with the Inspection & Test Plans.

1. GENERAL

DCAP puts at disposition a set of Inspection & Test Plans and Inspection Forms for the
Machinery, equipment, Piping and Electrical Installations.

Such proposed Inspection & Test Plans and Inspection & Tests Forms must contain all
Inspection and Test required intervention points of QC Inspectors. This proposed
Inspection & Test Plans and Inspection & Tests Forms are subject to approval by DCAP.

1-7-1) Welding
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(1) Welding Standards

The delivered piping material is in accordance with ASME/ANSI if not otherwise specified for
a specific pipeline system. Field welding shall be executed in accordance with:

 ASME Section IX
 ANSI Section B 31.1
 WPS & PQR

DCAP disposes of a set of WPS/PQR covering the material use in the piping systems. The
WPS/PQR are approved and certified by DCAP. BTE may make use of these. Otherwise,
BTE has to establish its own WPS for all types of material and combination of materials and
has to proof these WPS with a supporting PQR certified by an independent 3rd party
acceptable to DCAP at its own cost.

(2) Welder Qualification (For field erection)

All Welders shall be qualified according ASME, Section IX requirement and tested to 6G
position and/or shall be in possession of a valid Welder's certificate. Prior to production
weld, welders shall perform the WQT, which and shall be witnessed and confirmed by
DCAP.

1-7-2) Bolted Connections

Bolted connections are to be made in accordance with the specified torque contained in the
erection drawings. Where no torques indicated, the connection is to be made following
EGAT Supervisor instructions. Otherwise, will following specification of each bolt’s
manufacturer specified.

After connection of all piping, a final check of all bolt connections is to be made which
includes a report of the actually applied torques of bolt connections. Verification of such bolt
connections of the Fuel Systems is to be made in the presence of an DCAP Supervisor (Hold
Point)

1-7-3) Other Connection

Other connections, such as glued type connects are to be installed in accordance with DCAP
requirements. All personnel have to be certified by the representative of the manufacturer.

1-7-4) Connection to equipment

All piping shall be connected "stress free" to machinery equipment, unless pre-stressing are
defined in drawing. The "stress free" connections of piping are to be verified by an DCAP
Supervisor (Hold Point).

1-7-5) Erection inspection & tests

All Field Assembly Works are subject to inspections & tests, which are to be conducted by
Contractor in compliance with the Inspection & Test Plan.

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2. FLOW CHART OF PIPING WORK

Material check .....Record

Visual check Rejected

Bevelled end INSP. Repair of beveled

Accepted
Line up
Note : …...Mandatory

Tack welding
.....In case of necessary

Remove the spider at the welding joint out of the pipe

.....Large bore pipe

Backfill at the rest of the pipe except welding joint .....Underground

Internal welding / Back gouging / External welding

Repair welding joint

Finishing of welding surface

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Grinding of groove

Visual check
Rejected
INSP.

Accepted

NDE as per ITP Rejected Remove defect

NDE

Accepted
.....Record
Install the Anode (if applicable)
.....Underground

Surface cleaning (both internal &

external) as preparation for painting
(Power tool or manual)

Continue.

2. FLOW CHART OF PIPING WORK

Rejected
INSP. Re-cleaning

Accepted .....Record

Coating

Rejected
INSP. Repair coating

Accepted
.....Record

Field Pressure Tests after Rejected

completion of erection as ITP INSP. Repair welding joint

Accepted .....Record

Flushing pipeline, Tag Number

Final Inspection by
DCAP inspector Correction
PageINSP.
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Punch list

Accepted

DCAP certified …… .....Issued Erection completion

certificate Subject to DCAP

END.

3. WORK PROCEDURE
ACTIVITY MATERIAL CHECKING NO. P-1

Before aligning or fit-up, all materials such as pipe, fitting, boss, elbow, tee, etc. shall be
checked for confirmation of actual product with the drawing description.

ACTIVITY CHECKING OF BEVELLED END NO. P-2

Bevelled ends shall be checked for any damage to weld preparations. If there is any
significant damage, it shall be corrected.

ACTIVITY REPAIR WELDING OF BEVELLED END NO. P-3

Welding repairs of beveled ends shall be carried out with care to avoid further defects on
actual weld.
We recommend TIG (Tungsten Inert Gas) welding for this application for the root part
The repair-welded zone shall be inspected by NDE according to ITP after grinding the weld
run.

ACTIVITY CLEANING OF BEVELLED END NO. P-4

End surface shall be ground or wire brushed to remove rust, mill scale, grease, oxide and
any harmful contamination for welding, and these surfaces shall be reasonably smooth and
uniform.
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In principle this work shall be carried out just before installation but in case of long-term
storage, all the open holes are to be covered or capped to prevent ingress of dirt and
moisture.

ACTIVITY LINE UP NO. P-5

P-5-1) Internal checking

Just before fit-up and alignment, all pipes and fittings shall be carefully cleaned.

P-5-2) Marking.
The following reference points shall be established and marked on convenient fixed
locations.
(1) Setting up X.Y.Z. axes.
X.Y.Z. axes shall be set-up in accordance with layout drawings.
(2) Marking up terminating points of pipelines.
Terminating points shall be marked up fixed locations.
X.Y.Z. dimensions between these two points measured and any error rectified.
(3) Marking up pipeline routes.
Taking into account the design and installation procedure, location of the final
Welding joint shall be decided and reference points, which are the location shown on
the drawing, shall be marked up.
In particular the fixed points for rigid supports shall be marked up as reference points.
Also the manholes shall be marked up as reference points.
It is not necessary to mark up all piping routes, only the important points such as final
welding joint, rigid supporting point, manholes etc.

P-5-3) Line up of pipe

(1) Line up pipes.
Aligning and fitting of piping can be started from either or both ends by adjusting to
the datum marks. In case of error in dimension between terminating points, the pipe
work Bevelled ends shall be adjusted within a gradient of 3/1000 at right angles to the
pipe axis so as not to cause large stress. If the gradient becomes more than 3/1000,
other remedial measures shall be taken such as grinding, cutting, bending or adding
new pipe under BT instructions.
(2) Fitting of final weld joint.
Fitting of final weld joint shall be done after completion of all the other welding work
(weld, repair) in conjunction with loosening and/or tightening various supports; the two
final joint edges are to be fitted without any stress. After completion of fitting, both
sides of the final joint are to be adequately supported to prevent distortion during
welding.
(3) Pipe Supports.
In principle, temporary supports are not to be used for piping work. If temporary
supports are unavoidable, they shall be rigid and of a type made from “ANGLE” and /or
“CHANNEL”. No wire ropes are to be used.
(4) Installation records

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The location of the final welding joint is to be indicated on the appropriate drawing or
skeleton sheet. And if there is adjustable loose pipe in these pipelines the actual
dimension shall be measured and recorded.

ACTIVITY FIT-UP AND TACK WELDING OF BUTT NO. P-6

JOINTS
P-6-1) Visual checking
It should be checked that Bevelled ends and pipe internals are clean. Do not
unnecessarily remove protection caps.
P-6-2) Fit-Up
(1) Careful alignment is to be undertaken by reference to drawing datum point.
(2) Root gap of weld preparations
Gaps are to be the same as those detailed on drawings.
(3) High-low and offset of joint surfaces.
The discrepancies for high-low dimensions on circumference joints shall not exceed the
values given in Table –1
Table -1 High-low tolerances
Joint Thickness range Value of high-low
Circumferential T  15 mm. 1.5 mm.
15 mm < T  60 10% of pipe
mm. thickness
Ref. Standard : ASME SECT. VIII-Division 2, Af-142.1
Maximum allowable offset in welded joints thickness up to 20 mm-1/4 Thickness.
The maximum offset value is 0.5 mm.
Ref. Standard : ASME B31.1 127.3 For Power Piping Internal misalignment -2.0 mm
or less.
If the measurement for high-low and offset exceed specified values, the surface edges
can be ground within a gradient of 1/4.
However, This trimming shall not result in a piping component wall thickness the
minimum design thickness Thin.
Thin  T.; Thin: minimum design thickness.
(4) Checking of groove dimensions
Checks are to be made with an appropriate gauge or template.
(5) Preparation for back shielding gas
In the case of stainless steel, some back shield preparation is to be undertaken before
fitting the pipes together.
Water-soluble paper is available for this application.
P-6-3) Tack Welding - General
(1) Carbon and stainless steel
In the case of Cr and Mo steel pipe, tack welding can be applied directly to the weld
root or by using a suitable NUTS or Bridge Piece.
(2) NUTS and Bridge Pieces
NUTS and Bridge Pieces must be of the same grade material as the pipes to be welded,
or welded pads can made using the same grade of electrode.
(3) Material
Even for the tack welding, material shall be same as that to be used for actual welding.
P-6-4) Record of groove dimensions.
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After the completion of fitting work, the width of groove, the root gap, the offset and
high-low are to be measured and recorded if necessary.

ACTIVITY FIT-UP AND TACK WELDING OF SOCKET NO. P-7

JOINTS
P-7-1) Cutting of pipe ends.
The pipe end, which will be inserted into the socket fitting, is to be at right angles to
the longitudinal axis.
The error must be less than 0.5 mm.
P-7-2) Preparation.
The inner surfaces of fittings and the outer surfaces of pipes to be inserted into fittings
shall be ground or brushed until they will be free of any contamination that might affect
the quality of welding.
P-7-3) Insertion and tack welding
Insert the pipe end to the bottom of the fitting and mark up the pipe surfaces against
the edge of the fitting.
Then draw up the pipe about 1.5 mm. and tack weld at 3~5 points.
P-7-4) Material
Even for tack welding, material shall be same as what will be used for actual product
welding.

ACTIVITY WELDING NO. P-8

P-8-1) Welder
All welders shall be tested, qualified and approved by an authorized inspector before
beginning of work.
All welder tests, pipe set-up, NDE, hydraulic tests etc., shall be witnessed
by DCAP as stipulated in the ITP (Inspection & Test Plan).
P-8-2) Welding procedures
Welding is to be undertaken in accordance with welding procedure specification and
procedure qualification record.
(1) Consumables.
In principle, the electrode and filler metal should be selected by reference to the
following Table-2
However the electrode and the filler metal must correspond with parent pipe material
when a bracket or some similar part is to be welded to the pipe.

Table-2: Electrode.

Combination of Electrode
* Base Metal
P1 + P1 LB 52 “KOBE” or equivalent
(AWS E7016) & GOUGING

(2) Preheating
For this project, this is not required. However, when there is a possible – water
around weld band area. This metal will be pre-heated to remove the moisture where

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condensation is apparent. Preheating (if required) shall be done using a hand held heating
torch. A oxy-acetylene torch is not permitted at any time.

ACTIVITY WELDING NO. P-8

P-8-3) Welding
(1) Check around the welding groove for contamination and clean as required.
(2) If necessary, tack welding should be removed.
(3) Slag and Spatter is to be removed after each pass or layer and weld metal is to be
checked closely for defects such as cracks, blow-holes, and slag-inclusion etc.
These defects must be repaired before the next weld pass is deposited.
(4) The start point and the termination of each weld run are to be checked closely and
arc striking on the parent metal surface of the pipe in not permitted.
(5) The head of the chipping hammer must be round enough to prevent cracks in the
weld metal.
(6) The welding process is not to be stopped until the suitable number of welding
layers of weld has been completed.

0°

90°

180°

Where access is adequate, welding to be conducted by 2 welders working from the

inside first at 180° (6 o’clock position) uphill till end (0° or at 12 o’clock). The back
gouging (carbon rods) shall be done on the external and final weld shall be done in
same manner as above sketch.
- No welding shall be carried out during raining.
- Fresh weld shall not be contacted with water to prevent crack.
- During back gouging, ensure that the air is dry to prevent crack.

P-8-4) Welder’s identification.

After completion of welding work, the welder’s identification marks or numbers are to
be clearly recorded to the welding & inspection check sheet.
P-8-5) Handling of welding consumables
All welding materials must be stored adequately in good conditions. Electrodes shall be
baked in heating ovens before use at a temperature of 350 ~ 400 C ( low-hydrogen
type ) or 150 ~ 200 C (lime-titanic type) for one (1) hour.
During welding work it is preferable to keep the dried electrodes in a holding oven at
100 ~ 150 C.
Dried electrodes, which have been stored in a tin or paper carbon are to be returned to
the heating oven after exposure exceeding four (4) hours.
Table-3: Electrode.
Combination of Electrode
* Base Metal
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P1 + P1 LB 52 “KOBE” or equivalent
(AWS E7016) & GOUGING

ACTIVITY WELDING NO. P-8

P-8-6) Welding & inspection check sheet
Welding should be recorded by using a recognized format.

ACTIVITY FINISHING OF WELD SURFACE NO. P-9

P-9-1) The weld surface is to be prepared by grinding coarse ripples, overlaps and under-
cut to meet the following criteria:
(1) The weld dimensions must be in accordance with the values specified in 10-4.
(2) The weld surface shall be adequately smooth and suitable for non-destructive
examination.
(3) Care shall be taken not to reduce the weld and/or base metal below the required
minimum thickness.

ACTIVITY INSPECTION NO. P-10

P-10-1) Any necessary non-destructive inspection is to be carried out based on ASME Power
Piping Section B31.1
- In the case of work being rejected, adequate method of repair is to be executed as per
the code.
- Non- destructive examination shall be performed in accordance with code applicable.

ACTIVITY REPAIR NO. P-11

P-11-1) Arc air gouging

If a defect is found by NDE and appears to be in a deep position, arc air gouging can
be used to remove the defect.
However if the defect takes the form of a crack that method cannot be used because of
the possibility of the crack being extended.
P-11-2) Grinding
When Visual Inspection found a defect, grinder can remove it. After using arc air
gouging, the surface of the gouge area is to be ground free of scale, oxide and carbon.
P-11-3) Repairs
Repair procedures are the same as those for actual welding.
P-11-4) Inspection
After the completion of repairs, the completed weld is to be inspected by the same
method by which the defect was found.

ACTIVITY PIPE FIELD CUTTING & END NO. P-12

PREPARATION
P-12-1) Pipe field cutting
(1) For large bore pipe (>24” and larger) at direction change will have extra length of
300 mm. for field cutting & trimming to match the actual coordination.

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14-1-2) For small bore pipe (<24” and smaller) at direction change and connect to Slip-
on flange will have minimum extra length of 50 mm. for field joint & trimming to match
the actual coordination.

P-12-2) After cutting, all edge shall be beveled by using of grinding tools.
(1) For large bore pipe (>24” and larger)
 Pipe thickness at 9.5 mm. Edge shall be bevel as per WPS / Design.
 Pipe thickness at 12.0 mm. Edge shall be bevel to double-vee bevel end.
(2) For small bore pipe (<24” and smaller)
Edge shall be according to ANSI B16.5

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