P15340-cyd-pi-sp-0006_rev.1 (specification For Fabrication, Erection & Testing Of Piping System)

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 1 of 37 01/06/17 Rev. No. 1 CYD Job No. Doc. Class

3

ENGINEERING, PROCUREMENT, CONSTRUCTION AND COMMISSIONING OF REFRIGERATED GASEOUS TANK FACILITY FOR ETHYLENE & PROPYLENE (RGTF) FOR PENGERANG DEEPWATER TERMINAL 2 (PDT2) AT PENGERANG, JOHOR DARUL TA’ZIM SPECIFICATION FOR FABRICATION, ERECTION AND TESTING OF PIPING SYSTEM

ZA KS ZA KS ZA KS

1

21/02/18

ER

ER

0

01/06/17

MSM

ER

A

08/05/17

MSM

ER

REV

DATE

PREPARED BY

CHECKED BY

APPROVED BY

REVISION STATUS

REVISED AS MARKED APPROVED FOR CONSTRUCTION ISSUED FOR APPROVAL DESCRIPTION

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 2 of 37 01/06/17 Rev. No. 1

CONTENT 1.  2.  3.  4.  5.  6.  7.  8.  9.  10.  11.  12.  13.  14. 

SCOPE ........................................................................................................................ 3  DEFINITIONS.............................................................................................................. 3  REFERENCES ............................................................................................................ 3  GENERAL ................................................................................................................... 4  FABRICATION............................................................................................................ 5  WELDING ................................................................................................................... 9  ASSEMBLY .............................................................................................................. 10  PROTECTION AND STORAGE AT PREFABRICATION AND SITE INCLUDING LAY-DOWN AREA ................................................................................................... 13  ERECTION OF PIPE SUPPORTS ............................................................................ 14  PIPING ERECTION ................................................................................................... 16  INSPECTION ............................................................................................................ 25  PRESSURE TESTS AND VISUAL INSPECTION .................................................... 29  TEST RECORDS ...................................................................................................... 37  ATTACHMENTS ....................................................................................................... 37 

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

1.

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 3 of 37 01/06/17 Rev. No. 1

SCOPE This specification covers the basic requirements for field fabrication, erection, inspection and testing of piping systems for RGTF project for Dialog Plant & Services Sdn. Bhd at Johor, Malaysia.

2.

DEFINITIONS Words appearing in capital letters shall have the meaning assigned to them in the Contract. For clarification purposes, the definitions used in the present PROJECT Procedure are recalled here:

3.

• PROJECT

:

means Refrigerated Gaseous Tank Facility for Ethylene and Propylene (RGTF) of PDT2 - Pengerang Deepwater Terminal 2 at Pengerang, Johor Darul Ta'zim

• Employer

:

means DIALOG PLANT SERVICES SDN. BHD. (DPSSB) I Integrated Project Team (IPT) [Main EPCC CONSULTANT for PDT2 Project]

• EPCC Contractor

: means CHIYODA MALAYSIA SDN BHD

• Sub-contractor

:

Contractor responsible of the piping job

REFERENCES The following latest codes, standards and specifications shall form a part of this specification: 2.1

Malaysian Standards MS 761 MS 830

2.2

The storage and handling of flammable and combustible liquids Code of practice for the storage, handling and transport of liquefied petroleum gases

Codes ANSI/ASME B1.20.2 ASME B31.3

Pipe Threads, General Purpose (inch) Process Piping

ASME Boiler and Pressure Vessel Code  Section V Non-destructive Examination  Section VIII Div. 1 Pressure Vessels  Section IX Welding & Brazing Qualification

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

Document No. Date

ASME B16.25 ASME B16.5 NSI/AWWA C602

2.3

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 4 of 37 01/06/17 Rev. No. 1

Butt-welding Ends Pipe Flanges and Flanged Fittings Cement-mortar lining of Water Pipelines

Job Specifications P15340-CYD-PI-SP-0002

Specification for Piping Material Service Class

P15340-CYD-PI-SP-0007

Specification for Welding Material Control at Construction Site

P15340-CYD-PI-SP-0008

Specification for Coating & Wrapping of Underground Pipe

2.4

P15340-CYD-PI-SP-0004

Specification for Cold Insulation

P15340-CYD-QC-PE-0007

Welding & Welder Control Procedure for Field Piping

P15340-CYD-QC-PE-0008

PMI Procedure

Construction Drawings The following drawings shall be the key drawing for piping fabrication and installation.    

4.

Piping Isometric Drawing Piping General Arrangement Drawing Pipe Supports Drawing Piping Standard Drawing

GENERAL 4.1

Fabrication, installation, inspection and testing of all piping shall be in accordance with ANSI B31.3 and job specifications as referred herein, except as modified in this specification and specifically indicated in the drawing. (E.g. flue gas line & etc.)

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

5.

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 5 of 37 01/06/17 Rev. No. 1

4.2

All piping shall be TIG welded 2 layers minimum at the root run before completion with other process. Pipe diameter of 2 inched and smaller shall be completely welded with the TIG process.

4.3

Piping components for piping system shall be used in accordance with specification P15340-CYD-PI-SP-0002 – Piping Material Service Class

4.4

Coating and wrapping for underground piping shall be in accordance with job specification no. P15340-CYD-PI-SP-0008 – Coating & Wrapping of Underground Pipe.

FABRICATION 5.1

Cutting Pipe shall be cut as follows: (1)

The point where the pipe is to be cut shall be marked accurately according to the isometric drawings, or to suit a particular field installation.

(2)

When irregular cutting is required for single and multiple branch connections, or for curved and mitered segments of pipe, the pipe shall cut using jig or template.

(3)

In principle, pipe shall be cut mechanically with a pipe cutter or a high-speed cutter. Abrasive disks used shall be as specifically designated; i.e. for stainless steel pipe, carbon steel pipe, low alloy steel pipe, etc. and the original heat no. must be transfer to the remaining pipe for traceability.

(4)

When the pipe is of large diameter or heavy wall thickness, or when a pipe cutter or a high-speed cutter cannot be used, the following methods may be used:  Carbon Steel Pipe and Low Alloy Steel Pipe Carbon steel and Low Alloy steel pipe shall be cut with automatic or manual oxyacetylene, or propane gas cutting torch. 

Stainless Steel Pipe Stainless steel pipe shall be cut with machine or manually using plasma or water cutting tools.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 6 of 37 01/06/17 Rev. No. 1

● Cement Line Pipe Cement line pipe shall be cut with machine using cutting disk. Flame Cutting shall not be used.

5.2

End Preparation (1)

In principle, grooves for butt welding ends shall be profiled according to the welding procedure specification (WPS). However, butt-welded grooves must be suitable for the welding process used, and properly profiled to permit complete weld fusion and penetration throughout the joint.

(2)

Weld bevels for butt welds of pipes and fittings shall be in accordance with ASME B16.25 or as specifically shown in the drawing. (e.g. flue gas lines )

Table 1: GROOVES FOR BUTT WELDED JOINTS Pipe Wall Thickness (t)

Groove

22mm or less

Single “V” groove per Figure-1A or Single “U” groove per Figure-1C

Over 22mm

Double “V” groove per Figure-1B or Single “U” groove per Figure-1C

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

5.3

5.4

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 7 of 37 01/06/17 Rev. No. 1

End Preparation Method

(1)

All pipe and component ends preparation shall be preferable by machining. Any cracks, flaws, burrs or oxidation scale shall be removed from the surface with a grinder prior to welding. The surface shall be reasonably smooth by grinding to bright metal and free of oil, grease or any foreign matter and totally dry prior to start welding.

(2)

Shop bevelling of field welds is not required if a make-up length (extra length for field cutting to size) is provided. In these cases, bevels shall be prepared after cutting the relevant pipe spool to the required length

(3)

Pipes for socket weld joints shall be cut square and burrs removed and clean by grinding to bright metal and free of any foreign matter and dry totally prior to welding.

(4)

Cement line pipe butt jointing shall be bevelled end and free of loose particle on both end of the joint. Unless another method has been agreed, the existing cement lining shall be sealed with a priming coat consisting of adhesive and ready mixed mortar. The application of the adhesive and ready mixed mortar shall be in accordance with the Manufacturer’s specification. Alternative methods for field jointing of cement lined pipe and fitting (e.g. with impregnated gaskets etc.) are subject to approval of the Employer.

Shape of Internal Trimming and Misalignment Any radial misalignment at joints in piping components shall be such that full weld penetration can be attained. Where component ends have an internal misalignment of over 1.6mm, the component with the smaller inside diameter shall be trimmed internally to an angle of less than 30° as shown in Figure 2. However, when such trimming reduces the finished wall thickness below the required minimum wall thickness, the weld metal shall be deposited at that location on the outside of the component using a qualified welding procedure to ensure the required minimum wall thickness is realized. For Flue Gas line, specific trimming as shown on the drawing is to be followed and that the approve/qualified welding procedure is to be used as approve by the Employer.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 8 of 37 01/06/17 Rev. No. 1

Figure 2 TRIMMING AND PERMITTED MISALIGNMENT

Over 1.6mm

30° max

This portion shall be finished smoothly so as to avoid a sharp edge, which may cause miss-interpretation during radiographic examination

5.5

Assembly of piping components (1)

Fabrication Tolerances Unless otherwise specified, all tolerances used for fabrication shall comply with the requirements shown in Figure 5, refer to Attachment 1.

(2)

For butt-welding of all piping components (e.g. pipe ends, fittings and welding neck flanges), a uniform root gap shall be provided as specified in the relevant Welding Procedure Specification.

(3)

The minimum distance between the edges of two pressure-containing welds shall be twice the wall thickness of the thicker pressure part. The same requirement applies to the distance between non-pressure attachment welds and a pressure-containing weld in order to allow non-destructive inspection of the pressure-containing weld. Longitudinal welds in two adjacent pipes should be 90º or 180° apart, but in any case, it shall be separated by at least twice the wall thickness of the thicker pipe.

(4)

If the pipe contains a longitudinal weld, this weld shall not be located at the bottom of the pipe after installation; it should be located at least 45° from the bottom of the pipe.

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

(5)

(6)

5.6

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 9 of 37 01/06/17 Rev. No. 1

In order to avoid excessive shrinkage stresses during weld solidification, a gap shall be left between the end of the pipe and the stop of the socket- welding component in accordance with ASME B16.11 & ASME B31.3 Fig. 328.5.2C. Failure to include this gap can lead to premature piping failures and weld cracking. Pipes that are required to be free of scale shall be blast cleaned before the welding shop accepts them for further handling.

Bending (1)

Bending of pipes shall only be done where indicated on the isometric drawings; otherwise, welding elbows shall be used.

(2)

Cold bends shall be limited up to DN50 (2” nominal bore) and smaller and shall be done in pipe bending machines or presses using formers.

(3)

The maximum decreases of wall thickness at the thinnest point after bending shall not exceed 10% of the nominal wall thickness.

(4)

For tolerances on the maximum flattening of a bend, the difference between maximum and minimum diameters at any cross section shall not exceed 8% of nominal outside diameter.

(5)

Pipe bend shall be free from cracks, wrinkles and bulges after bending. Weld repairs of cracks in the pipe bends are not acceptable.

(6)

If the pipe contains a longitudinal weld, this weld should be located in the neutral zone of the bend. If the pipe will be installed horizontally, the longitudinal weld shall be located on the top of the pipe. If one spool is bent in various planes, the longitudinal weld shall be 45° from the top of the pipe.

.

6.

WELDING (1)

All welding requirements and welding quality control shall comply with the followings: P15340-CYD-QC-PE-0007

Welding & Welder Control Procedure for Field Piping

P15340-CYD-PI-SP-0007

Welding Material Control at Construction Site

P15340-CYD-QC-PE-0008

PMI Procedure

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

(2)

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 10 of 37 01/06/17 Rev. No. 1

Final Corrections If minor adjustments are necessary to satisfy the flange parallelism tolerances, the following correction methods are acceptable, if approved by the Employer. (a) (b)

7.

Local heating or cooling; Application of force with local heating.

ASSEMBLY 7.1

7.2

General

(1)

Fabrication of all piping shall be in accordance with ANSI B31.3, except as modified in this specification and specifically specified in the drawing. (E.g. Flue Gas line, Steam Piping and etc.)

(2)

The assembly of the various piping components, whether done in a shop or at the field, shall be made so that the erected piping conforms to the requirements of this specification.

Flanged Connection (1)

All flanged joints shall be fitted up in such a way that the gasket contact faces bear uniformly on the gasket, and then be made up with relatively uniform bolt stress.

(2)

Flange bolt-holes shall straddle the established centerline (horizontal, vertical, or layout centerlines), but shall match the orientation of the flange connections on the equipment.

(3)

In bolting gasket-flanged joints, the gasket shall be properly compressed depending on the type of gasket used.

(4)

Steel-to-cast-iron flanged joints shall be assembled with care to prevent damage to the cast iron flange. Both flanges must be flat-face.

(5)

If the flange facing is damaged, any defects shall be removed by polishing and /or machining the flange facing evenly or the flange shall be replaced with a new one.

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 11 of 37 01/06/17 Rev. No. 1

Imperfections in the flange facing shall not exceed the requirement of para.6.4.5 and Table 3 of ASME B16.5. (6)

For spiral-wound gaskets, gasket paste shall not be applied.

(7)

The thread and bearing surfaces of bolts and nuts to be used on piping at temperatures of 250 °C or higher shall be coated thinly and uniformly with a lubricant to prevent them from seizing. Thread lubricants for bolting shall be lead-free and temperature resistance.

(8)

All the bolts shall extend beyond their nuts as a minimum length and 2 or 3 threads as a target length.

(9)

Bolted flange connections shall be tightened by means of spanners, impact tools or torque wrenches. Care shall be taken so that the bolt is not overtightened or tightened unevenly. (Refer to Attachment 2)

(10)

Great care is required when tightening flange bolting since the force applied varies depend on the type of flange, gasket, and bolts used. In particular, flanges of piping for dangerous services (e.g. Benzene) shall be tightened with a torque wrench with corresponding torque-force as to the sizes of the bolts.

(11)

7.3

The flange clearance for the connections of pumps shall be measured by the use of a clearance gage, the parallelism checked, and then the bolts tightened evenly.

Flange Tightening (1)

The method of flange tightening depends on bolt size, system pressure rating, and service condition of piping system. Stud bolts shall be long enough to have 2 or 3 threads after proper tightening. Following tightening method shall generally be applied unless otherwise specified. (a) Conventional method (spanner/wrenches) (b) Torque wrenches (manual of hydraulic) (c) Hydraulic bolt tensioning

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

(2)

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 12 of 37 01/06/17 Rev. No. 1

The extent of application for flange tightening shall be as per Table 2 below.

Table 2: Bolting Method Selection Table Service

ASME Pressure Class

Tightening Method

Bolt Size “D”

Low Temperature Service (-29°C < T ≤ -46°C) and Cryogenic Service (T < -46°C)

150#, 300#

Torqueing

All

Torqueing

D < 1-1/4”

Tensioning

D ≥ 1-1/4”

Torqueing

N/A

Other Services

(3)

7.4

600# and above

All

Remarks

By Manual Tightening

Flange Management Procedure such as Torque Valve for each rating and bolt size shall be referred to Doc. No. P15340-CYD-PI-PE-0002.

Threaded Piping (1)

NPT Taper pipe threads as per ASME B1.20.1 shall be used for all threaded pipe joints, including thermowell nozzles.

(2)

Teflon tape or paste may be used in utility threaded piping system and pipe joints are not seal welded. When seal welding is required, all cutting oil, Teflon tape and paste shall be removed after the joint has been tightened to full thread engagement. Seal welding shall cover all exposed threads.

(3)

Seal welding shall be done with electrodes not to exceed 3.2mm (1/8") in diameter, using amperage in the low range to avoid distortion of the connection or part being welded. For galvanize pipe and fitting, galvanize part to be welded must be clean of galvanize deposit by grinding off up to metal white prior to welding.

(4)

Plugs in test vents for hydrostatic pressure test shall be seal welded after the test.

(5)

The following connections shall not be seal welded, unless otherwise specified: (a) Plugs in vents, drains and clean-outs (b) Connection to equipment and instruments (c) Screwed thermowells

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

8.

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 13 of 37 01/06/17 Rev. No. 1

PROTECTION AND STORAGE AT PREFABRICATION AND SITE INCLUDING LAY-DOWN AREA 8.1

Protection of Prefabricated Pipe Spools (1)

Cleaning, Temporary Storage, and Marking All prefabricated pipe spools shall be protected as follows after fabrication and inspection until they are installed: (a)

All dust, rust, weld slag, or other foreign matter inside the pipe spool shall be carefully removed by brushing or by flushing it out with compressed air, or by other suitable means. After cleaning, all openings in fabricated pipe spools shall be blanked off or cover up with pipe cap/ plastic cover in well secure manner to prevent ingress of foreign matter and liquid.

(b)

Pipe spools shall be laid on suitable sleepers or temporary supports during temporary storage, but not directly on the ground.

(c)

Different type of pipe spools ( e. g. stainless steel, carbon steel, galvanize coated steel & alloy steel ) must be keep strictly store in a separated area as per their material class in order to prevent material contamination during storage until such time for installation.

(d)

Pipe spools shall be marked with the area number (major divisions such as offsite, onsite, and utility), line number, and piece number. After cleaning the pipe spool surface, it shall be marked clearly with paint by the use of a stencil. When specified, to identify the area number, piece number, etc., the colour code shall be marked on the pipe surface, or a tag plate (die stamped to the sheet metal) shall be attached with coated steel wire. Welded grooves and flange facings shall not be painted. Welds shall not be painted until the completion of required nondestructive examination, heat treatment unless otherwise approved by Employer

(e)

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

8.2

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 14 of 37 01/06/17 Rev. No. 1

Preservation of Prefabricated Pipe Spools When prefabricated pipe spools are to be transported or are to be stored for a long duration, the interior of the pipe spool shall be checked to confirm that it is clean, and the openings at pipe ends shall be protected as follows:

9.

(a)

When the pipe ends (including fittings, such as a boss) are beveled, the ends shall be coated with rust preventive and covered with a plastic cap, etc.

(b)

When the pipe ends are flanged, the flange facing shall be coated with rust preventive and protected with a wooden or plastic cover and bolted or wired on to the flange.

(c)

When the pipe ends are threaded, the threads shall be coated with rust preventive and the threaded end connections shall be protected with wooden or plastic plugs or caps. Stainless steel pipe spools shall be strictly segregated from galvanize material / zinc painted materials to avoid zinc contamination.

(d)

Unpainted welds shall be coated with rust preventive, if it is specifically required.

(e)

Masking tape can be used instead of the above protection, subject to Employer approval.

ERECTION OF PIPE SUPPORTS 9.1

Pipe Supports The materials and dimensions of all pipe supports shall conform to the piping construction drawings, and each pipe support shall be installed accurately at the positions shown on the drawings prior to piping installation. When installing the pipe supports, particular attention shall be given to the following requirements: (a)

(b)

Each support shall be fabricated and assembled so that the piping it supports cannot dislocate during operations. If shims are required under the piping or pipe shoes, the shims of carbon steel shall be welded to the pipe supports beams to ensure they remain in position. Stanchions and pipe supports requiring foundations shall have anchor bolts to the correct size, position, projection, etc., in accordance with the applicable construction drawings.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

(c) (d) (e)

(f) (g)

(h) 9.2

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 15 of 37 01/06/17 Rev. No. 1

Before installing the pipe supports, the finished condition of the cut ends of all members and welded conditions shall be checked. Pipe support shall be made level and plumb to facilitate piping alignment during piping installation. In principle, when the main run pipe is low-alloy steel or stainless steel, either a pad plate or steel members of the same material as the main run pipe shall be used for the pipe support. Carbon steel supports shall not be welded directly to the run pipe. The same type of electrode as was used to for welding on the main run pipe shall be used to weld the pipe to the support. A qualified welder shall perform the welding in accordance with WPS. When the main run pipe requires heat treatment, the welds used to attach the pad plate or support members shall also be heat treated. Welds for anchor supports shall be in accordance with the support drawing. When welding dummy pipe and other supports (shoes, rib plates, etc.) to fittings, such as elbows, tees, caps, etc., the welding shall not melt through to the interior of the fittings. No painting surfaces shall not be remain after pipe support welding.

U-Bolts U-Bolts are used for guide or anchor support. When U-bolts are used for guides, they shall be positioned to provide a proper clearance between the pipe and the U-bolt.

9.3

Sliding Supports Sliding supports shall be assembled in accordance with the support drawings strictly so that the supported piping can move as required due to thermal expansion and contraction or other design requirements. The bearing surfaces of the sliding supports shall be completely clean to ensure unrestricted movement of the support.

9.4

Spring Supports The lock-pins or preset-pieces of spring supports (hangers) shall not be removed until pressure testing has been completed. They shall be removed to adjust the spring supports prior to initial operation. Spring supports for liquid services shall be finally checked when the piping is filled with process liquid. The position of the travel indicator shall be inspected to confirm that he spring hangers operate properly, according to temperature increases from the start of initial operation. The lock-pins or preset-pieces of the spring hangers installed on the major piping around reactors, rotary machinery, etc., shall be removed as

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 16 of 37 01/06/17 Rev. No. 1

instructed by EPCC Contractor’s piping engineer, and the indicator position shall be recorded. 9.5

Additional Supports If additional supports are required, they shall be installed as instructed by EPCC Contractor’s piping engineer.

9.6

Insulation Supports The configuration, material, and installation procedures for support rings for cold insulation of vertical piping shall comply with Specification for Cold Insulation Doc. No. P15340-CYD-PI-SP-0004.

9.7

Adjustable Supports When adjustable supports are installed, the adjustable bolts shall be sufficiently long to align the supports as per the support drawing.

10. PIPING ERECTION 10.1 General Requirements (a)

(b)

(c)

(d)

(e)

Pipes shall be segregated by material category, and stacked on sleepers with wedges or stakes between the pipe and sleepers to prevent the stack from collapsing. Planning of temporary work for all piping installations shall be made well in advance and the construction equipment, tools and materials necessary for the work shall be provided as required by the schedule. Moreover, if scaffolding is required for field erection, a check shall be made in advance to ensure that the sufficient number of scaffold materials are available when required. Scaffolding shall be provided to permit safe working conditions. Small size piping, pumps, instruments, etc., shall not be used as platforms in lieu of scaffolding. All scaffold boards shall be properly secured to the scaffold tube with metal connectors or suspended from piping or structure beams by sufficient number of steel chains. The primary cords, cables, and grounding wires of all welding equipment shall be of sufficient sizes, and any conductors with damaged insulation shall be removed. All such items shall be inspected periodically for checking of damage and to confirm that they are properly connected in accordance with applicable inspection procedure. Piping components, such as pipe spools and valves, shall be lifted with the designated wire rope slings, or nylon belts. Steel wire shall not be used.

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

(f)

(g)

(h)

(i) (j)

(k) (l) (m)

(n)

(o)

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 17 of 37 01/06/17 Rev. No. 1

Piping components shall be hauled by mechanical equipment as far as possible. Even for the short haul, the components shall be securely tied to the trailer to prevent them from falling from position. Prior to installation, pipe spools shall be checked with piping construction drawings to confirm whether the dimensions, materials, pressure (or rating) class, etc., are met or not. In principle, pipe spools for elevated lines or larger size lines shall be installed first. The precedence in which they are installed shall be determined after confirming that all related equipment has been installed and aligned, and that the steel structures and pipe racks are ready to receive the piping. Inaccessible areas of piping spools shall be painted before they are installed. In principle, underground piping shall be installed before aboveground piping. To remove the dust and foreign materials inside the pipe spools prior to installation, the pipe spools shall be suspended at one end by a crane and hammered or shall be cleaned by air blowing etc. Supports, such as stanchions, shall be checked to confirm that their position, dimensions and elevation are accurate and that they are level and plumb. Temporary piping shall not be welded onto the main run pipe. The cold spring dimensions (the gap or overlap of piping) shall be checked thoroughly against the drawings prior to assembly. After it has been confirmed that the guides and anchors have been installed at the specified locations, the piping shall then be installed. Furthermore, when there are flanged joints in the same direction requiring a cold spring, a spacer with the same thickness as the dimension of the cold spring shall be inserted between the flanges, and when the entire piping system has been assembled, the spacer shall be removed and the flanges fastened. Alignment tolerances of flange connections installed in the piping shall be within the limits specified in Figure-6. However, alignment tolerances of pipe flanges for the rotating equipment nozzle shall be per section 10.3.(f). In principle, the longitudinal welded seams (joints) of welded pipes shall be located above the horizontal centreline, if the pipes are installed horizontally. Figure-6: Alignment Tolerance of Flange Connections

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 18 of 37 01/06/17 Rev. No. 1

10.2 Piping around Columns, Drums and Heat Exchangers Piping installations around columns, drums and heat exchangers shall comply the following requirements: (a) Piping for columns shall be installed in the same order as the overhead lines and risers, instrument take-off nozzles, support, spring hangers, etc. (b) For piping to be installed at the elevated places, such as on the top of the columns, drums, etc., the assembly, non-destructive examination and pressure testing shall be performed on the ground before installation as far as possible, to minimize the work required at high elevations. When piping must be installed at an elevated location, the area below shall be fenced in with a safety rope and “MEN WORKING ABOVE” signs shall be posted in the area. (c) Essential safety data, such as weight of the piping, position of its center of gravity, crane reach, crane boom length, and other vital data shall be thoroughly studied before any piping components are lifted to high elevations by means of large crane. (d) Temporary supports shall not be anchored to equipment. (e) The welds for field adjustment shall be made after the pipe spool has been installed accurately onto the nozzle of equipment. Any blanks for temporary use for pressure testing etc., shall be removed before field welding. 10.3 Piping around Rotating Machinery Piping around rotating machinery such as pumps and compressors shall be installed as follows: (a) No unsupported piping shall be connected to the equipment nozzles. All piping, except for the connections to the nozzles of rotating machinery, shall be assembled on the ground. For field-fabricated piping, flanged of field welded joints shall be made up progressively away from the equipment nozzle. If prefabricated piping sections are used, at least two welds shall be left vacant near the nozzle flanges for final fit up and alignment. Final tightening of bolting in piping flanges near the equipment nozzles shall be done after initial alignment of the equipment nozzle flanges. Then, final alignment of the equipment nozzle flanges shall be done. (b) Before connecting piping to rotating machinery, the required heat treatment, pressure testing, interior cleaning, etc., shall be completed. (c) The protective cover placed on the nozzle of the rotating machinery shall not be removed until the piping is ready to be connected. (d) Permanent spring supports shall be locked in the cold load position during piping erection and hydrostatic testing.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

(e)

(f)

(g)

(h)

(i) (j)

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 19 of 37 01/06/17 Rev. No. 1

The preset-pieces of the spring hangers shall be removed and the spring hangers shall be adjusted before operation so that the supported piping is located accurately. The alignment of connecting rotating machinery and measurement of misalignment shall be completed before installing the related pipe work. Pipe flanges shall be aligned with all the nozzles of the rotating machinery. Alignment shall be achieved by adjusting the supports and flange connections. Unless otherwise specified, the misalignment between flanges shall be within the Table 3 limits. Any piping that is not aligned within the permissible limits specified in item (f) above shall be disconnected from any rotating machinery and shall then be realigned or supports shall be adjusted. Care shall be taken so that any expansion or distortion resulting from welding, etc., does not have a detrimental effect on the rotating machinery. Local heating at or below 650°C to correct minor misalignment is permitted on ferritic steel piping that does not required post weld heat treatment. Pipe that has been post weld heat treated shall not be heated to correct misalignment without EPCC Contractor’s approval. Austenitic stainless steel piping shall not be locally heated and shall be adjusted at the welding joint by partial removal of weld metal and rewelding or other suitable means. If the misalignment of a rotating machine exceeds specified values, the connecting pipe work shall be disconnected, the rotating machinery and pipe work realigned and then reconnected. Unless approved by EPCC Contractor, pipe supports shall not be rearranged or flange bolts retightened after piping is connected to rotating machinery. Grounding for welding machine shall not be connected to pumps, compressors and valves etc.

Table 3: Limit of Misalignment for Piping Flanges Description

Limit of Misalignment

(a) Flange face separation

Within the gasket spacing ±1.5mm Only one gasket per flange connection

(b) Flange face parallelism

<= 0.25mm for flange OD up to 10” 0.01mm/cm of flange OD: max 0.75mm

(c) Offset from the center of the bolt hole

1.5mm max

(Refer to Para. 4.6 API RP 686-2009 Piping Alignment Requirement, Chapter-6)

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 20 of 37 01/06/17 Rev. No. 1

10.4 Piping on Pipe Racks

Piping installations on pipe racks shall comply the following requirements: (a) Generally, since air-cooled heat exchangers are placed on top of the pipe rack, and pumps are placed underneath or at the side of the pipe rack, the related piping shall be installed according to the time required for installing such equipment, the number of stages of the pipe rack itself, and other important criteria. In principle, piping will be installed from the bottom level of the pipe rack, proceeding upwards. Pipe rack beams shall be inspected before the piping is installed to confirm they have been painted. Support lugs shall be installed prior to fire proofing work unless expansion bolts are used as fasteners. (b) A large size and/or long pipe spool shall be installed to meet the erection schedule of pipe racks on which the pipe spool is installed. The pipe rack erection schedule need to be adjusted for installation of the spool, if necessary. (c) Before connecting piping to other equipment, piping on pipe racks shall be laid down accurately in the places specified in the construction drawings beforehand. Slide shoes and stoppers shall then be installed accurately in accordance with the construction drawings, so that a baseline for dimensional adjustments during field installation is made. However, elbows, tees, etc., required for take-off connections outside the pipe rack maybe left in place temporarily, since adjustments maybe necessary later. (d) Each length of pipe shall be temporarily tied to the pipe rack with steel wire to prevent it from falling off, before the joints are welded. (e) The weld lines (seams) of the pipe and fittings should be located off pipe rack beams as far as possible. 10.5 Offsite Piping

Offsite piping installation shall satisfy the following requirements: (a) Piping installation inside tank dikes shall commence after a thorough study of the work schedule has been made, including the segmenting of and time required for other related work, such as access for handling tank materials, pipe way installation, insulation and coating work etc. (b) Piping installation inside tank dikes shall start after it is confirmed that the level of pipe sleepers and supports has not been changed by the water filling test of the tank. When land settlement is found, the level of the pipe sleepers and supports shall be adjusted. Permanent piping shall not be connected to the tank nozzle until after hydrostatic testing of the storage tanks is completed. (c) When laying pipe on sleepers, the sleepers shall be checked to confirm that they are at the specified elevation, level, in line, and painted.

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

(d)

(e) (f)

(g)

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 21 of 37 01/06/17 Rev. No. 1

Piping to be connected to tank nozzles shall be installed after it has been confirmed that all valves and accessories have been installed accordingly to the construction drawing. Flexible hoses or expansion joints to tank nozzles shall be installed accurately as indicated on the construction drawing. Piping shall be laid on sleepers that have been marked off. Slide shoes and stoppers shall be installed accurately according to the construction drawings. Pipe fittings and welded joints shall be carefully positioned so they are not on sleepers. The flanged, threaded, or welded joints for piping passing through dikes, shall not be embedded in the dikes.

10.6 Valves

Before installing the valves or the like, internal surfaces shall be checked that there is no damage, abnormal conditions. If there are some unacceptable conditions, such valves shall be returned to the warehouse. If support such as temporary stoppers etc., the supports shall be removed after installation. These requirements shall be also applicable to section 10.7 to 10.9 hereunder. All valves shall be installed according to the following requirements: (a) The valves shall be installed accurately so that its location and the orientation of the handle comply with the piping construction drawings. However, when the orientation of the handle is deemed inappropriate for operability or accessibility, the position of the handle shall be changed as instructed by EPCC Contractor’s Piping Engineer. (b) The valve shall be checked to confirm that its class, body material, and trim material are correct for the intended service. (c) Before installing the valve, the flange faces of the valve and the connected piping shall be checked for damage, dirt, and foreign material and that the flanges are parallel with each other. Temporary support (stopper) of check valve shall be removed if existing. (d) Valves shall be installed in the closed position. Welding for installation of butt and socket weld type valves shall be performed with the valve in the closed position, to prevent the valve seat from being damaged. In principle, plug and ball valves shall be installed in open position. (e) After the valves are installed, operation of valves shall not be done except for pressure testing. (f) For lubricant type plug and ball valves, the disc shall be left in the open position and the lubricant shall be replenished to prevent loss of sealant.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

(g) (h)

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 22 of 37 01/06/17 Rev. No. 1

Globe valves, check valves, gate valves with a disc hole and other similar valves shall be installed accordingly to the flow direction marked in the body. Stem threads and yoke nuts shall be coated with grease before installing the valve, to prevent them from rusting.

10.7 Safety Valves

Safety valves including relief valves shall be installed as follows: (a) Safety valves in principle, shall be installed during construction and shall be removed and stored in vertical position during pressure testing. For threaded safety valves, the piping shall be capped. However, the safety valve with a test gag may be installed with the piping and subjected to line pressure testing. (b) All safety valves shall be installed after the PSV testing at specified set pressure has been validated in the field if required by local regulations. (c) Any securing seal on the safety valve body shall not be removed. (d) Lever-operated safety valves shall be installed with the lever oriented as shown on the construction drawing. 10.8 Expansion Joints

Expansion joints shall be installed according to the following requirements: (a) Expansion joints shall be installed accurately at the location and dimensions shown on the piping and vendor drawings, and in accordance with any supplementary instructions issued by EPCC Contactor’s Piping Engineer. For the installation, a witness inspection by an EPCC Contractor’s Piping Supervisor shall be required and the inspection results shall be recorded. (b) The expansion joint shall be installed so that the line has been completely assembled with all anchors, guides, and stoppers installed in placed as shown on the piping construction drawings. (c) Expansion joints shall be installed after confirming that no stress is produced except in the direction intended. (d) When unrestrained expansion joints (i.e., with no tie-rods) is installed in the piping systems it shall be pressure tested under the piping system test pressure without any temporary restraints. Is shall be confirmed if the main anchors are designed to resist pressure thrust forces before the test. If the anchors are not designed to resist the pressure thrust and the pressure of piping systems exceeds the shop test pressure of the joint, the expansion joint may temporarily be removed during pressure test and reinstalled after pressure test. (e) When self-restrained expansion joints (i.e., with tie-rods) is installed in the piping system, it shall be pressure tested under the piping system test pressure (the tie-rods shall be designed to resist the pressure thrust forces). Tie-rods shall be secured tightened before the test. If the expansion joint previously

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

(f) (g) (h)

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 23 of 37 01/06/17 Rev. No. 1

shop tested may be excluded from the system to be pressure tested, it shall be installed after pressure test. Prior to installation, expansion joints with inner sleeves shall be checked to ensure that the sleeve inlet (fixed side) is on upstream side. The bellow of expansion joints shall be carefully protected against falling objects and welding tools that might strike it and cause arc damage. All shipping bolts of expansion joint shall be removed after installation and before piping system pressure test.

10.9 Installation of Instruments 10.9.1

Instruments Installed by Piping Subcontractor

The following field instruments of piping and equipment shall be installed by the Piping Subcontractor: (a) Flow meters (area type, positive displacement or turbine type, magnetic type, etc.) (b) Orifice flanges and orifice plates (c) Level meters (Displacer type, ball float type) (d) Gauge glasses (e) Pressure gauges (f) Thermowells (g) Control valves, self-control valves and safety valves (h) Other instruments installed directly on the line, including instruments up to the first valve or flange in the nozzle take-off connections for the instrument lead piping. 10.9.2

General Procedure

The general procedure for installing instruments shall be as follows: (a) All instruments shall be checked to confirm the instrument number agrees with that at the specified location on the construction drawings, and shall be installed true to level, plumb, or at the specified angle. (b) The instruments and the associated piping (excluding instrument piping) shall be supported so that problems will not occur due to distortion or vibration. (c) If instruments are installed during piping construction, they shall be protected against damage and the ingress of construction debris and other foreign matter. 10.9.3

Installation of Control Valves

All control valves shall be installed as follows: (a) Control valves shall be installed according to flow direction marked on the valve body and, except for special cases, with the actuator at the top and the valve in the vertical position.

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

(b)

(c)

10.9.4

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 24 of 37 01/06/17 Rev. No. 1

Control valves may be installed with the piping. If the spool piece is installed in lieu of the control valve, the face-to-face dimensions of the spool piece shall be checked before installation to confirm they are identical to those of the designated control valve. If the control valve is installed with the piping, the open end of the valve shall be blinded to exclude foreign matter. The blind shall be the same thickness as the main gasket. During construction, control valves shall be covered with PVC (poly vinyl chloride) sheet or other suitable material, and carefully protected against damage. During pressure testing and flushing of the line, the valve shall be removed or blanked off by a temporary blind as specified in Annex-C. Installation of Flow Meters

All flow meters shall be installed as follows: (a) Before installing an orifice flange, the straight lengths of pipe required upstream and downstream of the orifice flange shall be checked to confirm that they comply with the piping construction drawings. The upstream straight pipe section shall be one piece unless otherwise specified. If a welded joint does occur in the straight section, the distance between orifice and the welded joint shall not be less than14 times the pipe diameter. After the orifice flange is welded, the inside of the welded joint shall be finished smooth. (b) Jack screws for orifice flanges shall be installed so that they are spaced 180° apart from each other. (c) When a connection is to be tapped from a pipe, the hole for the connection shall be drilled at the location shown on the drawings, the burrs removed and the hole made smooth. Sockets shall not be embedded in the pipe. (d) The orientation for pressure differential taps shall be accurate as shown on the piping construction drawings. (e) Orifice plates shall not be installed until the pipe interior has been cleaned and permission is obtained. (f) When installing orifice plates, the orifice plate number and the flow direction shall be checked. In general, the handle points upwards and the die stamped mark at the inlet points upstream. (g) The center of the orifice plate shall coincide with the center of the pipe, and the gasket shall not protrude into the pipe. (h) Flow meters, such as area type, positive displacement or turbine type, and magnetic type, shall be installed as instructed by EPCC Contractor’s Piping Engineer. Internal cleanliness of pipe upstream of flow meter shall be checked prior to installation.

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

10.9.5

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 25 of 37 01/06/17 Rev. No. 1

Installation of Level Gauge

All level gauges shall be installed as follows: (a) Level gauges shall be installed after the nozzle center distance, flange face separation, and flange face parallelism have been confirmed. Any misalignments shall be corrected before installation to prevent breakage of the gauge and leaks. (b) Precautions shall be taken to prevent water (used for pressure test or flushing) entering the level gauge. If water does enter the level gauge, the gauge shall be checked and any dirt or sediment shall be completely removed, as instructed by EPCC Contractor’s Piping Engineer. 10.9.6

Installation of Pressure Gauges

All pressure gauges shall be installed as follows: (a) All local pressure indicators shall be installed by turning the socket to effect installation. The body shall not be turned directly. (b) Local pressure indicators shall be orientated so they can easily viewed from nearby. (c) Special pressure gauges shall be installed according to the manufacturer’s instruction. 10.9.7

Installation of Thermowells

All thermowells shall be installed as follows: (a) The dimension of the boss, the position for installing the thermowells and the diameter of the hole provided in the main run pipe shall be checked to confirm that they are accurate and in accordance with the related drawings. (b) After installation, the thermowells for thermometer shall be plugged to prevent the ingress of dust and rain. 10.10 Disposition All construction equipment used for the piping work and all surplus materials, scrap and debris shall be disposed of as instructed by EPCC Contractor’s Piping Engineer.

11. INSPECTION 11.1

Inspection of Piping Materials Piping materials of each piping system shall be checked for material identification marking (die stamp or stencil marking) before fabrication. Any discrepancies shall be captured before actual installation to ensure that the correct materials (material . specification, dimensions and/or pressure/temperature rating) are used as specified on the drawings.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 26 of 37 01/06/17 Rev. No. 1

It shall also be visually checked that there are no harmful defects or damages on the material surfaces.

11.2 Inspection of Welding (1)

General The requirements for welding and welding quality control shall be in accordance with P15340-CYD-QC-PE-0007 – Welding and Welder Control Procedure for Field Piping

(2)

Inspection Prior to and During Welding Before and during welding, visual check/monitoring shall be carried out as follows, but not limited to:

(a)

Use of correct piping material properly identified (by color code and/or marking)

(b)

Edge preparation per approved WPS, no damage on weld end surface including root face (such as gas notch), cleanliness and no detrimental contamination.

(c)

Fit-up method, alignment and tack welding, material for bridge tack piece, if applied.

(d)

Qualified welder for the material to be welded (by welder identification label, or equivalent).

(e)

Use of correct welding material (by identification marking or color code of welding rod/electrode), proper welding material handling. Proper welding-earth connection to prevent-from strays arc and arc sparking.

(f)

(g)

Protection from injurious weather condition (wind, sand storm, rain, etc).

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 27 of 37 01/06/17 Rev. No. 1

11.3 Visual Inspection of Completed Welds After welding, 100% visual inspection shall be carried out on all welds prior to any non- destructive examination or heat treatment. The acceptance criteria shall be as specified in Table 341.3.2 of ASME B31.3.

11.4 Non-destructive Examination of Welds Unless otherwise specified, the non-destructive examination on piping welds shall be as shown in Table 4 (refer to Attachment 3). (1)

The extent of the required non-destructive examination on piping welds shall be as shown in Table 4.

(2)

Non-destructive examination shall be in accordance with the requirements of ASME B31.3, ASME Code Section V and this specification.

(3)

Liquid penetrant examination (PT) procedure and Magnetic particle examination (MT) procedure shall be in accordance with ASME Code Section v, Article 6 and Article 7, and the acceptance criteria shall be in accordance with ASME Code Section VIII, Div.1, Appendix 8 and Appendix 6, respectively.

(4)

Application of NDE shall be referred to Attachment 3. Acceptance criteria shall be in accordance with ASME B31.3

(5)

In case RT is difficult for butt weld of heavy wall piping, Ultrasonic Examination (UT) or combination of RT and UT may be utilized when approved by Employer. The examination procedure and acceptance criteria shall be subject to approval by Employer.

11.5 Inspection of Piping (1)

Visual Inspection of Finished Assembly Fully assembled threaded and flanged joints shall be checked for conformance to the applicable requirements of Subsections 7.2, 7.3 and 7.4 above.

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

(2)

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 28 of 37 01/06/17 Rev. No. 1

Visual Inspection during Installation of Piping The following items shall be checked during the installation of all piping: (a) Alignment (i) Any distortion of piping to bring it into alignment for joint assembly which introduces a detrimental strain in equipment or piping components. (ii) Flanged joints

(3)

Inspection of Supports The following items shall be checked for pipe supports:

(a) All pipe supports have been fabricated and installed according to the construction drawings.

(b) Fixed ends (anchors) and sliding ends (guides, shoes, etc) of pipe supports have been installed so that the piping can expand or contract in the designated direction.

(c) Pipe insulation does not come in contact with other lines or structures on account of thermal movement.

(d) There are no temporary stops for sliding supports. (e) Temporary supports are not directly welded to pipes. (f) Welds for anchor supports are sufficiently strong. (g) Bolts of supports are tightened properly. (h) Threads of spring supports and tie-rods are thoroughly protected, and a rust preventive, such as grease, has been applied to them. (4)

Test Package For Test package Preparation and Workflow, see Attachment 4.

Document Title Project Title DIALOG PLANT SERVICES SDN BHD 

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 29 of 37 01/06/17 Rev. No. 1

12. PRESSURE TESTS AND VISUAL INSPECTION 12.1 General All pressure tests shall satisfy the following general requirements: (1)

Unless otherwise specified, pressure tests shall be performed after all installation work, welding, NDE and the line check are completed.

(2)

Prior to the pressure test, a line check shall be performed based on the P&ID diagrams and the piping construction drawings, such as the isometric drawings and support drawings. All joints may be primed and/or painted before pressure test, if Employer approves it.

(3)

Before filling the piping with a test fluid, the entire line to be pressure tested shall be examined as described in Section 8 above, and any defects shall be repaired. If repairs or additions are made following the pressure test, the affected piping shall be re-tested.

(4)

The following piping components and equipment shall not be subjected to piping system pressure testing: (a) Rotating machinery, such as pumps. (b) Pressure relieving devices, such as rupture discs and safety valves (c) Instruments (d) Any other designated equipment (e) 100% RT joint check or other suitable inspection will be acceptable when hydrostatic or pneumatic testing is not practical and approved by Employer

12.2 Types of Pressure Test In generic situations, a pressure test is understood to mean a hydrostatic test unless otherwise specified.

(a) Types of pressure test are as follows:   

Pneumatic test Hydrostatic test Service test

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 30 of 37 01/06/17 Rev. No. 1

(b) Pneumatic test maybe applied following cases and lines only when approved by Employer;  Piping that cannot safely be filled by liquid due to their design and/or strength of support structures.  Piping that cannot allow any test liquid remain in the piping system for process requirement.  Following are normally included in pneumatic pressure testing as per reasons describe above. o Flare Lines o Large Vapor and Gas Service Lines o Cryogenic Service Lines (e.g. Ethylene Lines, Propylene Lines, etc.)

(c) The following lines may be Service tested:    

Firefighting lines(fire water except fire main ring header, air foam, deluge and water spray),except those underground CW supply/return line, except those underground Plant air lines Other piping specified by Employer.

12.3 Test Fluid The test fluid shall be as follows:

(a)

Water, shall be used free from silt or un-dissolved solids of any description, for hydrostatic testing unless otherwise specified. Hydrostatic testing for Austenitic Stainless steel surfaces shall be carried out with potable quality water having a maximum chloride of 30ppm. After testing, all water shall be drained immediately.

(b)

The air to be used for pneumatic testing shall be compressed air from potable compressor. However, for instrument air lines or where specifically specified, oil-free dry compressed air or an inert gas is preferable. When air compressor(s) are used for pneumatic testing, precautions against combustion shall be taken by blowing the oil separator thoroughly clean so that no lubricant enters the compressed air.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 31 of 37 01/06/17 Rev. No. 1

12.4 Test Pressures (1)

Hydrostatic Testing (a) The test pressure used for piping subject to internal pressure shall be as follows: (i) Not less than 1.5 times the design pressure (ii) For design temperature above the test temperature, the minimum test pressure shall be calculated by the following formula, except that the value of ST/S shall not exceed 6.5: PT = 1.5PST / S Where, PT = minimum test gage pressure P = internal design gage pressure ST = stress value at test temperature S = stress value at design temperature (iii)

(b)

If the test pressure as defined in Item (ii) above would produce a stress in excess of the yield strength at the test temperature, the test pressure may be reduced to the maximum pressure that will not exceed the yield strength at test temperature.

Hydrostatic Test of Piping with Vessels as a System Where the test pressure of piping attached to a vessel is the same as or less than the test pressure for the vessel, the piping may be tested with the vessel at the piping test pressure. Where the test pressure of the piping exceeds the vessel test pressure, and it is not considered practicable to isolate the piping from the vessel, the piping and the vessel may be tested together at the vessel test pressure, provided the vessel test pressure is not less than 77 % of the piping test pressure calculated according to Item (ii) of Subsection 9.4. (1), above.

(2)

Pneumatic Testing (a)

The test pressure shall be 1.1 times the design pressure.

(b)

Each reinforcing pad (or segment thereof) for pressure openings shall be tested with air at a pressure of 1.0 Barg for a minimum of 10 minutes.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

(c)

<1>

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 32 of 37 01/06/17 Rev. No. 1

Personnel exclusion zones of pneumatic test shall be considered based on ASME PCC-2. Alternatively, Subcontractor may propose other calculation method subject to EPCC Contactor approval.

12.5 Preparation for Pressure Test (1)

General (a) All joints, including welds, are to be left uninsulated for examination during testing, except those joints previously tested in accordance with this standard may be insulated or covered. (b)

Equipment, which is not to be tested, shall be either disconnected from the piping or isolated by blinds or other means during the test. A valve may be used provided the valve (including its closure mechanism) is suitable for the test pressure.

(c)

If a pressure test is to be maintained for a certain period and the test liquid in the system is subject to thermal expansion, precautions shall be taken to avoid excessive pressure. In particular, for hydrostatic testing, care shall be taken to ensure that the water will not be subject to thermal expansion so that the piping is not damaged during the test.

(d)

Any restrictions that would interfere with filling, venting, draining or flushing of a piping system shall not be installed until after pressure testing and line flushing operations are completed. This includes orifice plates, flow nozzles, variable area meters, Turbine magnetic meters, filter elements.

(e)

In principle, pressure tests shall be performed for each piping system.

(f)

However, when design conditions do not permit testing in such a manner, the system may be tested in individual sections.

(g)

Test blinds shall have a handle extending out from the flange. Test blinds shall be of approved thickness, or as shown on the drawings.

(h)

Test blinds shall be installed and removed of as and when instructed by Employer. The number of test blinds used and where they were inserted shall be recorded at all times.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 33 of 37 01/06/17 Rev. No. 1

(i)

Test pressure gages shall have graduations up to two times the prescribed test pressure but in no case shall the range be less than 1 ½ nor more than 4 times that pressure. Calibrations of the pressure gages shall be checked by periodic inspections.

(j)

Two or more pressure gages shall be installed to facilitate easy monitoring of the test and checking the reliability of the pressure gages. When the piping system to be tested has a vertical offset, pressure gages shall be installed at both the lowest and the highest points.

(k)

During pressure testing of piping, operation of any valves in the system shall be prohibited and the valves shall be clearly marked with such instructions.

(l)

All valves, orifice plates, short pieces of pipe, and other items removed or installed for the test shall be restored with the prescribed gaskets in the correct position

(m)

Test blinds and temporary piping for the test shall be removed after completion of pressure test upon instruction from the Employer.

(n)

Status of Instruments during hydrostatic pressure test as per Table 5.

Table 5 : Status of Instruments during Hydrostatic Test Instruments

Block & Vent

Remove

1.

Control Valves (General)

2.

Control Valves (Butterfly & Ball Type)

3.

Control Valves (Low Noise)

X

4.

Orifice Plates

X

5.

Flow Instruments (D/P Cell)

6.

Flow Instruments (Metal Tube Rotameter)

7.

Flow Instruments (PD

Blind Off

Include in Test

Refer to Notes

X or X X

2

X X

X

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 34 of 37 01/06/17 Rev. No. 1

Meter) 8.

Flow Instruments (Turbine Meter)

X

9.

Flow Instruments (Vortex or Thermal)

X

10.

Level Instruments (Displacer)

11.

Level Instruments (D/P Cell)

12.

Level Instruments (Float Type)

13.

Level Gauges

X

14.

Pressure Instruments

X

15.

Pressure Gauges

X

16.

Safety Relief Valves

17.

Safety Relief Valves (Screwed Connection)

18.

Analyzer Sampling Taps

19.

Thermowells

X

1

X

1

X

3 X or X X

X

4 X

Notes: 1. Pressure rating of displacers and level switches should be verified before testing 2. Orifice plates should be installed after completion of the line flushing. 3. Pressure gauges should not be installed prior to hydrostatic pressure testing. 4. Special sampling probes, such as the capillary tube type, should be installed after line flushing is completed. 12.6 Hydrostatic Test (1)

Piping designed for vapor or gas service shall be provided with additional temporary supports, if necessary, to support the weight of the test liquid.

(2)

Prior to hydrostatic testing, the piping shall be checked to confirm that it is free from air pockets, and if necessary, temporary vents shall be provided to remove any air pockets during testing.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 35 of 37 01/06/17 Rev. No. 1

12.7 Testing Method (1)

General (a) For piping systems with a check valve, the test pressure shall be applied from upstream of the valve. If this is impractical, the check valve shall be removed with blinds. The check valve is not advisable to reverse as human factors may cause the check valves to remain in reversed issue position post testing. Also any pressure drop in the pipe-line may not be detected (depending on the direction of the check valves and the location of the gauges installed) if the check valve is used.

(2)

(3)

(b)

The piping system shall be inspected visually for evidence of leaks, after the prescribed test pressure has been maintained for at least 10 minutes. All connections and welded joints shall be inspected thoroughly.

(c)

On completion of the pressure testing, the line shall be checked to confirm that there is no residual pressure within the line, and the line shall then be drained. All test blinds shall be removed upon instruction from the Employer.

Hydrostatic Testing (a) Vents in piping to be hydrostatically tested shall be opened to remove any air when filling the piping with water.

(b)

With the test gage pressure at not less than 5MpaG, the pressure shall be increased gradually in three steps to the specified holding pressure.

(c)

The test pressure during a pressure increase shall be read by the pressure gage installed at the lowest point of the piping relative to water head pressure.

(d)

After pressure testing, all water shall be drained immediately from the line to prevent the piping system from being damaged by thermal expansion. Also, to prevent a vacuum from forming in the piping, the vents shall be opened when the water is being drained.

Pneumatic Testing (a) The pressure test shall be gradually increased until a gauge pressure which is lesser of one-half the specified test pressure or 1.8 Barg is

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 36 of 37 01/06/17 Rev. No. 1

attained, at which time is preliminary check shall be made. Thereafter, the pressure shall be gradually increased in steps until the test pressure is reached, holding the pressure at each step long enough to equalized piping strains. The pressure shall then be reduced to the design pressure before examining piping system for leakage in accordance with section 12.7 (1b). <1>

(b)

A bubble test solution shall be applied to inspect all welds.

(c)

When pneumatic testing is required, the stored energy shall be minimized and should not be greater than 200 million ft.-lbs. if the calculated energy is greater than 200 million ft.-lbs, one of the mitigation measures stipulated in ASME PCC-2, Part 5, Article 5.1, <1> Section 6.2 (e) shall be followed. Alternatively, Subcontractor may propose other calculation method subject to EPCC Contactor approval. “:

12.8 Repair of Defects (1)

Repair of Defects

(a)

Defects found during the test and inspection of piping systems shall be repaired as follows. In principle, Employer or Employer Representative shall witness all repairs.

(b)

Repair welding shall be performed after the piping system is depressurized and testing fluid remaining in the pipe has been completely removed.

(c)

The defective weld to be repair, the weld shall be removed completely with a grinder, etc.

(d)

The defective weld after repair shall be inspected by magnetic particle or liquid penetrant examination and retested to confirm the defect has been completely removed. The welding, heat treatment, tests and inspections shall be the same as required for the initial welding, and shall be performed according to the applicable provisions of this specification.

(e)

(f)

In principle, the same defect shall not be repair welded more than twice.

Document Title Project Title Document No. Date

DIALOG PLANT SERVICES SDN BHD 

Piping that is repaired or modified after a pressure test shall be retest, except where the Employer agrees to 100% radiographic examination for butt weld and 100% magnetic particle or liquid penetrant examination for other pressure retaining welds in lieu of retest.

(g)

(2)

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 37 of 37 01/06/17 Rev. No. 1

Materials such as bolting etc, damaged during test and flushing shall be replaced. All gaskets, irrespective if they are damaged or not shall be replaced during each bolt up and unbolting.

12.9 Visual Inspections The following lines may be checked visually: Piping which is normally open to the atmosphere, such as drains/vents without screwed caps, and discharge piping from pressure relieving devices.

13. TEST RECORDS Employer & Employer Rep. Inspector shall approve each test of a line or system. 10.1

A test package shall be drawn out. Test Package shall include the following:  Date of test  Identification of piping (e.g. ISO/P&ID/Weld Maps)  Test fluid  Test pressure  Test Duration,  Location of Pressure gauges  NDT Reports  Weld Traceability  Approval by inspector (Employer or Employer Rep. )

13.2 Records shall also include a check of supports, installation against the P & I and piping drawings, materials, bolting, valve (type, gaskets, bolts, material, packing), and remarks (repairs, required, etc.)

14. ATTACHMENTS The following attachments are part of this specification: Attachment No 1 2 3 4

Title Dimensional Tolerance for Fabricated Piping Procedure for Flange Bolt Up Table 4 : Inspection Requirements Test Package Flow Chart

Refer to Section 5.5 Section 7.2 (9) Section 11.4 Section 11.5(4)

Document Title

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 1 of 1 ( ATTACHMENT 1) 01/06/17 Rev. No. 1

Project Title Document No.

DIALOG PLANT SERVICES SDN BHD 

Date

Figure 5 : Dimensional Tolerances for Fabricated Piping

1

2 Special Services

1

Item

Normal Service

a.

Design Temperature > – 850°F or Flange Rating –> ASME Class 900

b.

Where plastic or elastomeric liner (lapped over the flange faces) provides the gasket for the joint.

c.

Piping over NPS 3 to be connected to rotating machinery.

3 1

± 1/8 in. maximum from indicated dimensions for face to face, center to face, location of attachments, etc.

2

Bend flattening tolerance shall be in accordance with the applicable Code.

3

± 1/8 in. maximum lateral translation of branches or connections.

4

± 1/16 in. maximum rotation of flanges from the indicated position, measured as shown.

4

± 1/16 in. maximum lateral translation of branches or connections.

± 1/64 in. for piping over NPS 3 to be connected to rotating machinery. 5

Per the applicable Code.

± 1/16 in. maximum out of alignment of flanges from the indicated position, measured across any diameter.

Conversion Equivalents 1

1

1 1

5

in.

1/64

1/16

1/8

850°F

NPS 3

mm

0.4

1.5

3

454°C

80

Document Title Project Title

DIALOG PLANT SERVICES SDN BHD 

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 1 of 2 (ATTACHMENT 2) 01/06/17 Rev. No. 1

PROCEDURE FOR FLANGE BOLT UP 1.

CONFIRMATION PRIOR TO BOLT UP The following items shall be confirmed prior to bolt up; (1) (2) (3)

2.

The proper gasket has been inserted and centered. Bolts have been inserted and are finger tight. There are at least two threads extending beyond the nut on either side.

PROCEDURE FOR BOLT UP The procedure for flange bolt up shall be as follows (Figure 1); (1) (2) (3)

(4)

3.

Hand tightens bolts with a short wrench according to the sequence shown in Figure 1. Tighten bolts with a spanner or wrench and light hammer, again by the procedure shown Figure 1. Continue tightening gradually by the procedure shown in Figure 1, using a heavy hammer, until the bolts are completely drawn tight. This may take two or three additional rounds by the same procedure. For bolts larger than 1" in diameter, a final round or two with a heavier hammer is recommended to reach the correct bolt tension.

PRECAUTIONS The following special precautions shall be taken: (1) (2) (3) (4)

Never draw up tight on only one or two bolts. This will cause local gasket crushing or pinching, which will result in leaks. After each round of tightening, measuring the distance between the flange faces may check the alignment. The bolts should be gradually and evenly tightened with a wrench and hammer begins to "bounce" with a distinct ring.

Document Title Project Title

DIALOG PLANT SERVICES SDN BHD 

Document No. Date

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 2 of 2 (ATTACHMENT 2) 01/06/17 Rev. No. 1

Figure 1 TIGHTING SEQUENCE

1 1

8

4 5

4

3

6

2

3

2

7

Figure 1A 4 Bolting

Figure 1B 8 Bolting

1

12

5

8

9

4

3

10

6

7 11

2

Figure 1C 12 and above Bolting

Document Title

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 1 of 2 (ATTACHMENT 3) 01/06/17 Rev. No. 1

Project Title

DIALOG PLANT SERVICES SDN BHD 

Document No. Date

Table 4 : INSPECTION REQUIREMENTS Non-Destructive Examination

-

5

5

0

0

0

0

100

-

-

-

2-24

A106 Gr. B

-

-

-

5

5

0

0

0

0

100

-

-

-

1/2-1-1/2

A106 Gr. B

-

-

-

5

5

0

0

0

0

100

-

-

-

2-24

A106 Gr. B

-

-

-

5

5

0

0

0

0

100

-

-

-

1/2-1-1/2

A333 Gr. 6

-

-

-

100

100

0

0

0

0

100

-

-

-

2-24

A333 Gr. 6 A671 Gr. CC60 Cl.22+S2

-

-

-

100

100

0

0

0

0

100

-

-

-

-

-

-

100

100

0

0

0

0

100

-

-

-

UTG

-

Alloy Verification (PMI) %

-

Ferrite number (FN)

A106 Gr. B

Visual %

Hardness Test %

Magnetic Particle (MT)%

1/2-1-1/2

1/2-1-1/2

A312-TP304/304L

-

-

-

100

100

0

0

0

0

100

-

100

-

2-6

A312-TP304/304L A358 Gr. 304/304L Cl.1

-

-

-

100

100

0

0

0

0

100

-

100

-

-

-

-

100

100

0

0

0

0

100

-

100

1/2-1-1/2

A312-TP304/304L

-

-

-

100

100

0

0

0

0

100

-

100

-

2-6

A312-TP304/304L A358 Gr. 304/304L Cl.1

-

-

-

100

100

0

0

0

0

100

-

100

-

-

-

-

100

100

0

0

0

0

100

-

100

-

1/2-1-1/2

A312-TP304/304L

-

-

-

10

10

0

0

0

0

100

-

100

-

2-6

A312-TP304/304L A358 Gr. 304/304L Cl.1

-

-

-

10

10

0

0

0

0

100

-

100

-

-

-

-

10

10

0

0

0

0

100

-

100

-

8-30 1D03

Magnetic Particle (MT)%

Pipe Material

8-36 1D02

Radiography (RT or UT)% (*)

Nominal Pipe Size (inch) except where noted

28-36 1D01

BRW

Liquid (PT)

1B01

BRW

Attachment Welds

1A02

CW

Outlet Welds (Weldolets)

1A01

BRW

Butt Welds

Piping Class

CW Radiography (RT or UT)% (*)

Heat Treatment

8-30

REMARKS

Document Title

Specification for Fabrication, Erection and Testing of Piping System EPCC of Refrigerated Gaseous Tank Facility for Ethylene & Propylene (RGTF) for Pengerang Deepwater Terminal 2 (PDT2) at Pengerang, Johor Darul Ta’zim P15340-CYD-PI-SP-0006 Page No. 2 of 2 (ATTACHMENT 3) 01/06/17 Rev. No. 1

Project Title

DIALOG PLANT SERVICES SDN BHD 

Document No. Date

Non-Destructive Examination

Magnetic Particle (MT)%

Ferrite number (FN)

Magnetic Particle (MT)%

-

-

5 5

5 5

0 0

0 0

0 0

0 0

100 100

-

-

-

A106 Gr. B

-

-

-

5

5

0

0

0

0

100

-

-

-

A106 Gr. B

-

-

-

5

5

0

0

0

0

100

-

-

-

UTG

-

Alloy Verification (PMI) %

A106 Gr. B A106 Gr. B

Visual %

Pipe Material

Hardness Test %

Radiography (RT or UT)% (*)

BRW

Liquid (PT)

BRW

Attachment Welds

1/2-2

CW

Outlet Welds (Weldolets)

1G01

BRW

Butt Welds

Piping Class

Nominal Pipe Size (mm) except where noted 1/2-2 3-24

CW Radiography (RT or UT)% (*)

Heat Treatment

1G02 3-16

-

-

-

5

5

0

0

0

0

100

-

-

-

1/2-1-1/2

A672 Gr. B60 Cl.22 A333 Gr. 6

-

-

-

100

100

0

0

0

0

100

-

-

-

2-24

A333 Gr. 6

-

-

-

100

100

0

0

0

0

100

-

-

-

1/2-1-1/2

A312-TP304/304L

-

-

-

100

100

0

0

0

0

100

-

100

-

2-6

A312-TP304/304L

-

-

-

100

100

0

0

0

0

100

-

100

-

8-36

A358 Gr. 304/304L Cl.1

-

-

-

100

100

0

0

0

0

100

-

100

-

A312-TP304/304L

-

-

-

10

10

0

0

0

0

100

-

100

-

18-24 3B01

3D02

1/2-1-1/2 3D03

6B01

2-6

A312-TP304/304L

-

-

-

10

10

0

0

0

0

100

-

100

-

8-24

A312-TP304/304L Cl.1

-

-

-

10

10

0

0

0

0

100

-

100

-

1/2-1-1/2

A333 Gr. 6

-

-

-

100

100

0

0

0

0

100

-

-

-

100

100

0

0

0

0

100

-

-

-

0

0

0

0

100

-

100

-

0

0

0

0

100

-

100

-

2-24

A333 Gr. 6

-

-

-

1/2-1-1/2

A312-TP304/304L

-

-

-

2-6

A312-TP304/304L

-

-

-

6D02

100

100

100

100

*Note: When RT is not feasible, PT shall apply in 1st pass (Root) and final pass (Cover)

REMARKS

CHIYODA SINGAPORE LTD.

LEO+/ SILVER PROJECT

ATTACHMENT 4

LEO+/ SILVER Test Package FLOW CHART Job No.: 42620

Rev: 0 Activity

SUB-CONTRACTOR Implementing Contractor

Engineering

Construction

EMPLOYER Shell

EPCC CONTRACTOR Chiyoda

QC

Engineering

9 February, 2014

Construction

QC

Engineering

Operation

QC

Test Block Diagram Preparation

Test Package Preparation

Test Package Review

Test Pakage Review and Approval

Line Check & Punch Clearing

NDE Requirement & Completion

QC iso and NDE documents only

QC iso and NDE documents only

NDE Review and Approval

Line Check

Line Check, Punch "A" clearing and parallel NDE clearance

Request for Inspection (RFI)

NDE review and Approval

Information about RFI

Approval of the RFI

Information about RFI

Joint Line Check by Sub-Contractor, EPCC Contractor & Employer

Joint Line Check by IC, CSL and Shell

With Punch

NDE clearance

Verification of the Punch Completion

QC iso and NDE documents only

Without Punch

Punch Clearing Works

Information on Punch Clearance Information on Punch Clearance

Compilation of QC. NDE Documents

NDE Review and Approval

NDE review and Approval

Request for Inspection (RFI)

Approval of the RFI

Information about RFI

Information about RFI (for draining/ blowing)

Pressure Test, Draining and Air Blowing Pressure Test Activity Jointly Witnessed by QC from Sub-Contractor, Pressure Test Activity Jointly Witnessed by QC from IC, CSL and SEPL EPCC Contractor & Employer

Draining and Air Blowing shall be done immediately after Pressure Testing (random witness by CSL SV/ Engineering) (random witness by EPCC Contractor SVSEPL & Employer Engineering)

Punch "B" clearance

Punch B and Reinstate ment

Handover to PRECOM

NOTE: PUNCH POINT CATEGORIES PUNCH "A" : TO BE DONE BEFORE PRESSURE TEST PUNCH "B" : TO BE DONE AFTER PRESSURE TEST, BUT BEFORE HANDOVER TO PRE-COM PUNCH "C" : TO BE DONE AFTER PRE-COM, BUT BEFORE HANDOVER TO EMPLOYER

Final Confirmation

Issue to Turn Over for PreComm Works

Flow of Original Test Package Flow of NDE clearance (without Original Test Package) RFI information