es-14-602-01 site fab and ist piping
TRANSCRIPT
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ES-14-602-01
Version No. 12.0 Page 1 of 26
Document last modified: 19 December 2012. PDF created: 23 April 2013.
This is a Controlled Document that complies with
Wesfarmers Chemicals, Energy & Fertilisers formatting and Quality Control standards.
Please check that this is the latest available version before use.
Title: FABRICATION AND INSTALLATION OF PIPING
Number: ES-14-602-01
Version Number: 12.0
Date Revised: 19 December 2012
Owner: Harish Chopra
Authoriser: Manoj Thakur
Reasons for Creating
or Amending
Document
Full Review of Document
Actual Change Details: Links updated and working
TABLE OF CONTENTS
1. GENERAL ................................................................................................................................. 3
1.1 SCOPE................................................................................................................................... 31.2 DEFINITION OF TERMS .................................................................................................... 3
2. STANDARDS ............................................................................................................................ 4
2.1 REQUIREMENTS ................................................................................................................ 42.2 STANDARDS ....................................................................................................................... 42.3 DEVIATIONS ....................................................................................................................... 4
3. DESCRIPTION ......................................................................................................................... 5
3.1 MATERIALS ........................................................................................................................ 53.2 DRAWINGS ......................................................................................................................... 53.3 ACCURACY ......................................................................................................................... 5
4. FABRICATION REQUIREMENTS ....................................................................................... 7
4.1 MARKING AND IDENTIFICATION .................................................................................. 74.2 TRACEABILITY OBJECTIVES .......................................................................................... 74.3 TRACEABILITY REQUIREMENTS .................................................................................. 74.4 STORAGE ............................................................................................................................. 74.5 CUTTING AND BEVELLING ............................................................................................. 74.6 END PREPARATION .......................................................................................................... 84.7 WELDING PROCEDURES, SPECIFICATIONS AND PROCEDURE
QUALIFICATIONS .............................................................................................................. 9
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4.8 THREADING ...................................................................................................................... 174.9 FLANGING ......................................................................................................................... 174.10 FIT-UP................................................................................................................................. 174.11 BRANCH CONNECTIONS ............................................................................................... 184.12 PIPE BENDING .................................................................................................................. 184.13 STEAM TRACED PIPING ................................................................................................. 184.14 STEAM JACKETED PIPING............................................................................................. 184.15 ELECTRICAL TRACING .................................................................................................. 18
5. PROTECTION ........................................................................................................................ 18
5.1 PIPE SPOOLS ..................................................................................................................... 18
6. ERECTION ............................................................................................................................. 19
6.1 IDENTIFICATION ............................................................................................................. 196.2 STORAGE AND HANDLING ........................................................................................... 196.3 ASSEMBLY/INSTALLATION .......................................................................................... 206.4 FLANGED CONNECTIONS ............................................................................................. 206.5 BOLTING ........................................................................................................................... 216.6 CONNECTION TO EQUIPMENT ..................................................................................... 226.7 THREADED JOINTS ......................................................................................................... 226.8 TEMPORARY STRAINERS .............................................................................................. 226.9 VALVE INSTALLATION.................................................................................................. 226.10 UNDERGROUND PIPING ................................................................................................ 236.11 INSTALLATION OF EXPANSION JOINTS .................................................................... 236.12 TESTING OF PIPEWORK ................................................................................................. 23
7. PIPE SUPPORTS .................................................................................................................... 23
7.1 STANDARD PIPE SUPPORTS ......................................................................................... 237.2 SPRING HANGERS ........................................................................................................... 24
8. AS-BUILT DATA AND RECORDS...................................................................................... 24
APPENDIX 1 - TYPICAL PROCEDURE QUALIFICATION RECORD (PQR) ............. .......... 25
APPENDIX 2 - TYPICAL WELDING PROCEDURE SPECIFICATION (WPS) ............ .......... 26
FIGURE
Figure 1 Piping Fabrication Tolerances ...................................................................................... 6
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1. GENERAL1.1 SCOPEThis Standard covers the minimum requirements and acceptance criteria for:
a. Fabrication of piping (both in situ and/or at Workshops as assemblies/sub assemblies).
b. Installation.
c. Certification and records keeping.
It is to be used together with ASME B31.3 Chemical Plant and Petroleum Refinery Piping Code,all Government Statutory requirements and referenced standards.
Should there be conflict between the Works, this Standard, Local Codes, Statutory Requirements or
the latest issue of the Code and other referenced standards, the Contractor shall notify theSuperintendent in writing for resolution. In general the most stringent requirement will prevail.
1.2 DEFINITION OF TERMSContractor/Vendor
The Company, which provides the equipment and services, needed.
Sub-Contractor
A third party to be employed by the Contractor/Vendor who has been approved by the
Superintendent in writing.
Superintendent
CSBP Limited or authorised representative. For internal works, the Superintendent shall be the
Responsible Officer.
CSBP
CSBP Limited.
Works
The scope of work that a Contractor is or may be required to execute under an agreement including
variations and remedial work.
Code
Throughout this standard, the words The Code shall mean ASME B31.3 Chemical Plant and
Petroleum Refinery Piping.
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2. STANDARDS2.1 REQUIREMENTSThe Contractor shall perform the Works in accordance with the requirements of:
a. The Statutory Authorities.b. The Code and other referenced standards.
c. This Standard
2.2 STANDARDSStandards Association of Australia
AS1210 SAA Unfired Pressure Vessel Code including Supplement 1AS2022 SAA Anhydrous Ammonia Code
AS2205 Methods of Destructive Testing of Welds in Metal
AS4041 Pressure Piping
American National Standards Institute (ANSI)
American Society of Mechanical Engineers (ASME)
ANSI/ASME B16.11 Forged Fittings, Socket-Welding and Threaded
ANSI/ASME B16.20 Metallic Gaskets for Pipe Flanges - Ring joint, Spiral Wounds andJacketed
ANSI/ASME B16.21 Non-metallic Flat Gaskets for Pipe FlangesANSI/ASME B16.25 Buttwelding Ends
ASME Boiler and Pressure Vessel CodeSection V Non-destructive Examination
Section VIII Boiler and Pressure Vessels - Divisions 1 & 2Section IX Welding and Brazing Qualifications
ASME B31.3 Chemical Plant and Petroleum Refinery PipingAmerican Petroleum Institute
API 601 Metallic Gaskets for Refinery Piping (Double Jacketed Corrugated and
Spiral Wound)
CSBP Engineering Standards
ES-14-102-12 Protective CoatingsES-14-102-14 Insulation of Piping and Equipment
ES-14-601-01 Basis of Design - Piping
ES-14-602-02 Inspection and Testing of Piping SystemsES-14-602-05 Underground Piping
ES-14-603-01 Piping Material Specifications
ES-14-603-02 Valve Specifications for Process IsolationES-14-603-14 Steam Tracing
EP-08-030-37 Manufacturers Data Report (MDR) Plant Projects
2.3 DEVIATIONSThere shall be no deviation from the requirements of this Standard unless previous written approvalhas been obtained from the Superintendent.
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3. DESCRIPTION3.1 MATERIALSThe piping materials covered in this Engineering Standard are Carbon Steel, Low Alloy Steel andStainless Steel. These are identified in the CSBP Engineering Standard Piping Material
Specifications (ES-14-603-01).
This Engineering Standard shall be used whenever it is relevant to do so for non-metallic pipework
including PVC, HDPE, ABS, Polypropylene and FRP. All such pipework shall be installed,
inspected and tested strictly in accordance with the manufacturers instructions and the relevantAustralian Standard.
3.2 DRAWINGSPiping General Arrangement drawings will be provided showing equipment location and piping
configuration. These drawings shall be adhered to for the erection and installation of pipe spools.
Fabrication of pipe spools shall be in accordance with the Piping Isometric drawings which will beprovided for all lines size DN 50 and above.
Small bore piping DN 40 and below shall be field run in accordance with the General Arrangementdrawings.
Pipe support location plans may be provided for complex piping systems but generally pipe
supports will be located on General Arrangement drawings and Isometric drawings. The pipesupports shown will be a minimum requirement. Additional supports may be required to comply
with standards and codes.
Where pipe supports need to be manufactured detail drawings will be provided.
Fabrication of pipe spools and supports shall only commence after issue of Approved for
Construction (AFC) drawings. Subsequent revisions of AFC drawings will supersede all previous
drawings and the Contractors procedures shall ensure all fabrication is carried out in accordancewith latest revision of each drawing.
3.3 ACCURACYThe Contractor shall verify drawing information and confirm all dimensions before commencing
fabrication.
Dimensional tolerances for completed fabricated piping shall conform to the requirements listed on
Figure 1.
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+3mm MAX FROM INDICATED DIMENSIONS
FOR FACE TO FACE, CENTRE TO FACE,
LOCATION OF ATTACHMENTS, ETC
10% MAX (FOR INTERNAL PRESSURE)
3% MAX (FOR EXTERNAL PRESSURE)FLATTENING MEASURED AS DIFFERENCEBETWEEN THE MAXIMUM & MINIMUM O.D.
AT ANY CROSS SECTION.
+ 2mm MAX LATERAL TRANSLATION OF
BRANCHES OR CONNECTIONS
+ 1mm MAX ROTATION OF FLANGES FROM THE
INDICATED POSITION, MEASURED AS SHOWN.
1mm MAX OUT OF ALIGNMENT OF FLANGESFROM THE INDICATED POSITION MEASURED
ACROSS ANY DIAMETER.
1
2
3
4
5
Figure 1 Piping Fabrication Tolerances
The Contractor shall ensure the piping meets final assembly requirements as specified on the pipinglayout drawings.
Dimensions to tie-in points shall have tolerances in accordance with the following:
a. Linear dimensions 1.5mm
b. Nozzles orientation and rotation 030
(Flange bolt holes shall be aligned within 3mm maximum offset)
c. Angular alignment of flange and branch welding ends 3mm per 1000mm
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4. FABRICATION REQUIREMENTS4.1 MARKING AND IDENTIFICATIONItems shall be marked for identification and traceability in accordance with Section 4.3. Items
marked for identification shall maintain the marking through all manufacturing stages including
final assembly.
4.2 TRACEABILITY OBJECTIVESItems and documents shall be marked to ensure means of:
a. Locating the item (traceability record).
b. Locating the quality records generated from purchasing, inspection and testing of the item.
Note: As a minimum the Contractors system shall enable traceability between the items andquality records.
4.3 TRACEABILITY REQUIREMENTSThe Contractors fabrication procedures shall ensure that correct materials are used duringfabrication and these shall be submitted to the Superintendent for approval.
Note: Periodic audits may be carried out by the Superintendent to ensure compliance.4.4 STORAGEThe Contractor shall be responsible for material and equipment received from the Superintendentor warehouse stocks until the same is installed. Where Superintendent supplied materials aredelivered to the Contractor with documentation such as mill certificates, these shall be incorporated
into the Contractors quality records.
Materials received from the warehouse or Superintendent, are to be stored off the ground on
temporary racks or docks to prevent any deterioration until fabricated.
Pipes, fittings, valves and speciality items shall be suitably blanked to protect the ends from
damage and to prevent entry of foreign material. Flanged openings shall be protected as detailed inSection 5.1.2.
Stainless steel material shall be kept separate from carbon steel during storage and transport.
4.5 CUTTING AND BEVELLINGPipe shall be cut accurately to the measurements on the drawings or field fit conditions and shall beworked into place without springing or forcing.
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Stainless steel material shall be segregated from other piping materials during all stages of
machining and fabrication to prevent surface contamination with carbon steel leading to localised
corrosion.
Cutting of pipes shall preferably be done by mechanical means. Flame cutting is acceptable withinthe limits as listed below:
a. For carbon steel, flame (or arc) cutting and bevelling is acceptable only if the cut isreasonably smooth and true and all oxides are removed from the flame-cut surface by
grinding.
b. For alloy steel, flame-cut bevels are acceptable only where machine cutting is not feasible.
After flame cutting approximately 2mm of material must be removed from the surface ofthe bevel by grinding.
c. Bevelling by mechanical means (ie. shearing) requires work hardened areas to be removedas in b. above.
d. Stainless steel and non-ferrous metals shall be prepared by machining, grinding or plasma
arc cutting and grinding.
Grinding of stainless steel and non-ferrous metals shall be done with a non-carbonaceous, iron free
non sulphur bonded grinding wheel. Chipping, filing, cutting with hacksaws or wire brushingusing carbon steel brushes is not permitted on stainless steel.
Burrs and other objectionable defects shall be removed by reaming, machining or grinding.
All cuts shall be made at right angles to the longitudinal axis of the pipe. All pipe ends shall beremade to the full bore of the pipe.
All cuts shall be carefully bevelled and accurately matched to form a suitable groove for weldingand to permit complete penetration of the welds at all points. Reference is to be made to the
relevant section of the Code.
Defective or damaged weld ends shall be examined in order to determine the nature and extent ofdamage. Any bevelled edge of pipe that has been damaged shall be machined to minimum
tolerances. All bevels shall be cleaned to bright metal finish.
Repairs shall not be made on weld preparation of pipes or fittings without written permission from
the Superintendent.
Repairs to weld preparations shall only be carried out using repair procedures which have beenreviewed and approved by the Superintendent. Repair procedures must be submitted in writing for
the Superintendents review and approval.
4.6 END PREPARATION4.6.1 GeneralSurfaces to be welded shall be ground free of rust. Grinding is to extend 10mm past the toe of theweld preparation and is to be done immediately prior to welding.
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4.6.2 Butt WeldingEnd preparation for butt-welding shall be in accordance with ANSI/ASME B16.25.
Cleaning and end preparation shall be in accordance with the Code and in accordance with thisStandard. Stainless steel materials shall be cleaned using degreasing compounds free of chlorides
and sulphur for a distance of 75mm from the prepared edge of inside and outside surfaces.
Stainless steel wire brushes shall not be used for carbon steels.
4.6.3 Fillet WeldsPipes for insertion in slip-on flanges and for socket-weld joints shall be cut square, to within thetolerances specified in ANSI/ASME B16.11.
Prior to welding of socket connections, the pipe shall be backed off 1.5mm from the seat of the
socket.
Socket welds and the external welds of field welded slip-on-flanges shall always be carried outusing a minimum of two passes with staggered stops and starts. Shop welded slip on flanges may
require two passes on the external weld, depending on the welding process, to ensure good root
fusion.
4.7 WELDING PROCEDURES, SPECIFICATIONS AND PROCEDUREQUALIFICATIONS
4.7.1 GeneralWelding Procedure Specifications (WPS), Procedure Qualification Records (PQR) and the
Welding Procedure Register (WPR) shall be submitted to the Superintendent and approval obtainedbefore any welding is begun.
The WPR shall identify all WPS necessary for the intended scope of work.
Refer to Appendix 1 and Appendix 2 for sample formats of WPS and PQR forms.
4.7.2 Welding Procedure SpecificationEach WPS shall exhibit the name of the originating Contractor and shall be uniquely identified.
The WPS revision number and data shall be included. The technical requirements of this Standardshall be adhered to in preparing WPS.
Manual, semi-automatic, or automatic electric arc welding processes shall be used on all piping.
The preparation and procedure for welding shall conform to the requirements of the Code.
Welding of carbon steel pipe shall be performed by either: Submerged Arc (SAW), Manual Metal
Arc (MMAW), Gas Tungsten Arc (GTAW), or a combination of these processes. Flux Cored Arc(FCAW) maybe used for workshop welding only.
Welding processes other than these are prohibited.
Semi automatic and fully automatic welds shall be made with a multi pass technique.
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Weld passes thicker than 10mm are prohibited.
Welding of stainless steel or alloy shall be performed by either Gas Tungsten Arc, or Manual Metal
Arc Welding, or a combination of these processes. Root pass must be made using Gas Tungsten
Arc process with inert gas purge on inside of pipe. Flux Cored (FCAW) and GTAW wire (brandname TGX) may be used at the discretion of the Superintendent.
Procedure for welding dissimilar metals (e.g. carbon steel to stainless steel 304L or 316L, etc) shallbe submitted to the Superintendent and approval obtained prior to any welding.
Welders qualified, as per Section 4.7.7of this Standard shall perform all welding.
4.7.3 Qualification of Welding ProcedureAll WPS shall be qualified in accordance with the Code and ASME Section IX and this Standard.
Previously qualified WPS may be submitted for the Superintendents approval. Qualification shall
be performed on pipe, not plate.
If a weld procedure includes PWHT, the weld procedure qualification tests shall include a hardness
survey. Acceptance criteria shall be the same as described in Section 4.7.13. The hardness survey
shall be performed using a 5-kg Vickers tester in accordance with AS2005.
4.7.4 Welding Procedure Essential VariablesIn addition to the essential and supplementary essential variables listed in ASME Section IX
articles 2 and 4, the following shall be deemed essential variables:
a. For welding procedures qualified for low temperature carbon steel (impact tested carbon
steels) and low temperature low alloy steels (also impact tested) and any change in welding
consumable brand name, manufacturer, classification or country/region for base metals.
b. Any change in wire flux combination for SAW. Any decrease in preheat for material
thicknesses greater than 6mm.
c. Any change in current clarity or type (AC or DC).
d. The omission of back gouging or back grooving.
e. Variables during welding must remain same as used during procedure qualification (ie.
parameters I, V (speed) and U shall remain constant).
f. For P3 and P4 materials, hardness test on site shall be in accordance with those values
obtained or recorded during procedure qualification.
4.7.5 Impact Test RequirementsWelding procedures for all P1Group 1 and Group 2 steels developed for use in low temperature
service (less than 0C design minimum temperature as specified by the applicable piping class)shall include qualification by impact test. Impact test specimens shall be tested at a calculated
temperature, using an assumed design temperature of minus (-) 46C, whilst all other testrequirements shall be in accordance with the Code. Three specimens shall be tested from each
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sample area and the average energy value obtained from them shall be at least equivalent of 20
joules obtained from full size specimens. One specimen may show a lower equivalent value, but
this shall not be lower than 16 joules.
Impact tests for welding procedures for other materials, the assumed minimum design temperatureused for determining the impact test temperature shall be (-) 46C or the piping minimum design
temperatures whichever is lower. Weld metal specimens shall be located as near as possible to the
pipe surface. Two specimens shall be located near the surface containing the last pass of the weld,and one specimen near the opposite surface. The specimen location shall be identified in thereport.
Specimen sides, which are perpendicular to the base of the notch, shall be 10mm. Depth of sidecontaining the base of the notch shall be the greatest possible of 10mm, 7.5mm, 5mm and 2.5mm
depending on the pipe wall thickness. Test temperature of sub-size specimen shall comply with the
Code.
The notch shall be contained in the weld metal at approximately the centreline of the weld and the
base of the notch shall be perpendicular to the surface of the plate. Before machining the notch, thespecimen shall be etched to distinguish the weld metal from the parent metal and to ensure that the
notch is correctly located. Machining of the bottom of the notch shall be done with care.
The Superintendent shall witness impact testing of welding procedure qualification specimens.
4.7.6 Weld MapsWeld maps shall be prepared for each assembly/sub-assembly fabricated identifying the welder,date welded, nature and extent of NDE performed, defects/re-welds, re-examination, if any, results
of NDE for each weld of the assembly/sub-assembly.
Weld maps shall also contain information on hydrostatic testing viz. test pressure, medium, date
and duration of testing and the results.
All the above information shall be properly documented and up-to-date records maintained by theContractor. Final copies of all the above referenced documents shall be issued to the
Superintendent within seven (7) days of completion of fabrication.
4.7.7 Qualification of Welders and OperatorsAll welders and welding operators shall be qualified in accordance with the requirements of ASMESection IX and this Standard prior to commencing any work including tack welds or temporaryattachments. The performance test must include 6G position. Welder qualification certificates
including evidence of re-qualification and revalidation shall be maintained for the Superintendentsapproval and inspection.
All welder qualification tests must be carried out to an approved welding procedure specification(WPS).
Previous qualifications may be submitted for approval provided that the holder(s) of the
qualification(s) have carried out similar work within the last six months.
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Each welder shall be assigned a unique symbol which will identify, on a weld map, all welds
performed by that welder.
4.7.8 Welding TypesAll welds shall be full penetration welds except:
a. reinforcing pad, peripheral fillet welds,
b. structural attachment fillet welds and
c. socket welds, which shall be welded to the Code.
All butt welds DN 50 and below shall be made with the Gas Tungsten Arc process.
4.7.9 Welding Proximity and LocationThe number of welds in the fabricated spools shall be kept to a minimum by using the longest
practical pipe lengths. The minimum distance between girth welds, shall be six times the pipe wall
thickness or 100mm, whichever is lesser.
Seam orientation of welded straight pipe to pipe and pipe to fittings shall be such that at
circumferential welds, the longitudinal welds shall be staggered, by 30 degrees left and right of thecentre line. As a minimum the circumferential distance between the staggered joints shall be50mm or 6 times the pipe wall thickness, whichever is lesser.
Attachment welds, should be separated from pressure welds by a distance not less than 50mm,
weld toe to toe.
Welds for non-pressure attachments should not cross- existing main pressure welds. Where this isunavoidable, the main pressure weld shall be ground back flush with the parent pipe and the area
examined for defects, using MPI/DPI inspection procedures. Subject to satisfactory acceptance ofthe inspection, fabrication of the attachment weld shall be carried out in accordance with welding
procedures as approved for the main pressure weld.
Attachment welds shall not penetrate through the pressure pipe.
4.7.10 Preparation for Welding and AlignmentEarth connections shall be located as close as possible to the joint to be welded. G type welding
clamps shall be used for connecting pipe to earth.
The ends of pipe and fittings shall be accurately aligned and properly spaced as indicated in the
appropriate welding procedure. A pipe clamp or other device shall be used as required to obtainaccurate alignment and spacing.
The bore alignment for the butt joints shall be in accordance with the Code except that the
maximum internal trimming shall be 1:4.
Preference shall be given to the use of line-up clamps or bridge pieces for assembling components
to be welded.
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In addition to the requirements of the Code, all pipe joint preparations and welds shall be subject to
the following:
a. Backing rings are not permitted.
b. Back welds shall be examined visually for defects and, if found to be defective, shall be
removed.
Branch connection joints shall be prepared so as to permit full penetration welds of a qualitycomparable to the circumferential welds in the same piping system.
When thermal cutting is performed to prepare edges, to remove attachments or defective material,or for any other purpose, the material shall be reheated using the preheat schedules established in
the qualified welding procedures.
Welding shall not be carried out when the surfaces to be welded are wet from any cause.
Galvanised flanges, supports, clips and the like shall not be welded to or come into direct contactwith stainless steel.
All valves, piping speciality items, equipment and instruments which may be damaged by the heat
of welding shall be protected by dismantling and be re-assembled upon completion of welding andheat treatment.
All sections of tacked or welded pipe shall be sealed prior to installation to prevent foreign matter
from entering such sections.
A qualified welder using the qualified welding procedure, which will be utilised for full welding of
the joint, shall make tack welds. Temporary tack welds shall not touch the root gap or root face and
shall not be part of a final joint weld up. Line-up clamps shall not be removed until the root pass
has been completed.
There shall be no field-welded attachments to stainless steel or alloy piping or to any vessels
without Superintendents approval and an approved welding procedure as described.
c. Cold spring is permitted only if it is shown on piping isometrics. If shown on pipingisometrics, this operation shall be withheld until the entire line between anchors has been
connected together in all directions up to the last closing length of pipe at the anchor and allguides and supports are in place. The cold spring shall be pulled at one anchor with the pipe
firmly secured at the anchor on the opposite side of the section to the cold spring. Cold
springing is not permitted at rotating equipment nozzles.
d. Anchors/welded attachments on pipes shall be in accordance with Standard Pipe Support
Details and the respective piping isometrics.
Each welding bead shall be thoroughly cleaned of all scale and slag by chipping and/or grinding
and wire brushing immediately after completion of the weld and prior to the application of
succeeding beads. The width of the completed weld shall extend a minimum of 3mm greater thanthe width of the original groove. For reinforcement, the bead shall extend not less than 1.5mm and
not more than 3mm above the surface of the pipe. Penetration of depth of fusion shall extend thefull depth of the pipe wall, including both the bevelled and straight portions. The bead shall be
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smooth in appearance and contain no valleys, indentations or undercut on the crest or at the edge.
The completed weld and adjacent pipe shall be cleaned of all oxide, slag and spatter to allow proper
application of protective coating.
The entire root bead shall be made with the pipe in a stationary position. Movement of the pipeduring manual welding of the root beads shall be kept to an absolute minimum.
Welding shall be a continuous operation. Welding should not be discontinued before the root runand the next two successive passes are complete.
If welding has to be interrupted the welds area shall be covered to permit slow cooling. Beforeresumption of welding on a weld cooled to ambient temperature the area shall be inspected visually
for the presence of cracks. The welds shall be subjected to magnetic particle or dye penetrantexamination to determine acceptability. Cracks shall be completely removed prior to any further
welding.
All welding necessary for in-place assembly and erection shall be in accordance with applicable
paragraphs of this Standard.
The areas from which temporary attachments have been removed shall be dressed smooth.
Stray arc strikes are forbidden.
4.7.11 Welding Consumable Control and HandlingThe Contractor shall establish and implement procedures for receiving, storing, conditioning andissuing consumables.
4.7.11.1 Receipt Storage and Identifications
All consumables shall be received and clearly identified in sealed containers.
The consumables shall be stored in sealed, moisture proof containers at a protected convenient dry
location at a temperature of not less than 20C.
Consumables shall be identified at all times during storage, conditioning, distribution and at weld
stations. Identification shall include manufacturer, grade and batch number.
4.7.11.2 Drying of Electrodes
Prior to use, MMAW electrodes shall be dried in accordance with the manufacturersrecommendations.
After drying, the electrodes shall be transferred to heat storage cabinets maintained at 120C
minimum for later use.
No electrodes shall be redried more than twice.
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4.7.12 Protection of the Welding EnvironmentThe welding area shall be protected at all times against adverse environment conditions, water
spray, mist, drips or wind exceeding 8kph. Welding shall not proceed when the work is exposed to
such conditions.
Prefabrication areas for carbon and stainless steel shall be physically separated to prevent
contamination of stainless steels. When grinding or welding carbon steel pipe and supportsprotection of any adjacent stainless steel shall be provided.
4.7.13 Heat Treatment of WeldsHeat treatment procedures, pre-heat and post-heat shall comply with the Code requirements. In the
case of Ammonia Liquid, Chlorine-Dry Liquid, Chlorine-Dry Gas, and Synthesis Gas services, heat
treatment procedures shall comply with AS4041 or the Code, whichever is more stringent. Details
shall be included in the Weld Procedures.
All welds on carbon steel and low alloy steel piping for the following services shall be heat-treatedafter welding.
Ammonia Liquid at any temperature.
Chlorine-Dry Liquid at any temperature.
Chlorine-Dry Gas at any temperature.
Synthesis Gas services at any temperature.
Ammonia Gas services where there is a possibility condensate will form under normal
operating conditions.
Sodium Hydroxide (Caustic Soda) of 30% to 50% strength at any temperature.
Sodium Hydroxide (Caustic Soda) less than 30% strength if the normal operating
temperature is greater than 60C.
30% Sodium Cyanide Solution if the normal operating temperature is greater than 60C.
Note: Where heat treatment is recommended for a particular service and material combinationscovered by NACE or other anti-corrosion standards, heat treatment shall be performed in
accordance with the standard.
Heat treatment shall be in accordance with the requirements of the Code clause 331.1.7 and thefollowing:
a. All hardness tests on stress relieved welds shall be carried out using a standard Equip tester.
A qualified metallurgist or an experienced tester approved by the Superintendent shallperform the tests.
b. The criteria for hardness tests on local and shop stress relieved welds shall be as per the
Code plus the following:
(i) P1 materials shall not exceed 225 Brinell for ammonia and chlorine
service and 248 Brinell for other services.
(ii) For P4, P5 and P6 alloy steels, where the wall thickness is less than that
for which a maximum hardness is specified, the maximum hardness shallbe specified as for the material with the thicker walls.
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(iii) For service and material combinations covered by NACE or other anti-
corrosion standards and not covered by (i) and (ii) above, the hardness
limits in these standards shall apply.
(iv)
For other materials and services not covered by (i) to (iii) above, themaximum hardness shall not exceed 248 Brinell.
Note: For b. (iii) the hardness limit may also apply to piping and welds which are not heattreated.
c. If heat treated in a furnace, all piping shall be properly supported in the furnace during heat
treatment to eliminate warpage and other distortion.
d. The cooling rate from the stress relieving temperature shall be in accordance with therequirement of ASME Section VIII.
e. All machined surfaces shall be protected by a suitable paint or compound or by any other
method (eg. gasket and a counter flange for flanged surface) to prevent damage fromscaling.
f. Unless otherwise approved in writing by Superintendent, no welding, hammering or cold
forming is permitted following heat treatment.
g. All valves, piping specialties, equipment and instruments, which may be damaged by theheat from heat treatment, shall be protected by dismantling and be re-assembled upon
completion of heat treatment.
Valve bodies (2 or 3 piece ball valves) or bonnets to be removed shall be match-marked
prior to disassembly to ensure that they are reassembled back into the same location and
orientation. Seats shall be gently lapped where necessary to remove any scale and new
bonnet/body gaskets fitted when reassembling the valves.
All welds or attachments required including pipe supports or reinforcing plates, etc, shall be madebefore heat treatment. No welding is permitted after heat treatment.
4.7.14 Filler MaterialsAll filler materials shall deposit an alloy whose chemical, physical and corrosion resistance
properties correspond to the base material and shall satisfy requirements of the Code Standards.
Consumables for use on carbon steel lines for sodium cyanide solution shall have low sulfurcontent.
4.7.15 Weld RepairsNo repair shall be undertaken without first notifying the Superintendent of the requirement torepair, and seeking his approval of the proposed repair procedure.
Repair of welds shall be done in such a manner as not gouge, groove, or otherwise reduce theadjacent base metal thickness.
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Repairs or replacement welds shall be performed in accordance with the original welding
procedure, including pre-heat and post weld heat treatment if originally required.
Inspection and NDT of repairs shall be as originally required for the initial welds.
A weld defect that has to be repaired shall be removed to sound metal. Repair welds shall be made
by qualified welders Welding procedures used shall be in accordance with the Code and ASME
Section IX.
4.7.16 Inspection and Testing/WeldsNon-destructive examination of welds shall be carried out in accordance with the requirementsdetailed in CSBP Engineering Standard Inspection and Testing of Piping Systems (ES-14-602-02).
4.8 THREADINGThe minimum pipe schedule for threading pipe shall be Sch 80. For carbon steel and low alloy steel
threaded nipples the pipe schedule shall be Sch 160 minimum. Stainless steel threaded nipplesshall be Sch 80 minimum.
Threading of steel pipe shall preferably be done after bending, forging, heat treating or welding
operations. Where post-fabrication threading is very difficult and threads are cut first, they shall befully protected during such operations. Threads shall be concentric with the outside pipe and shallconform to ANSI B1.20.1 (NPT).
Screwed pipe shall be reamed after cutting and threading. The threads shall be full cut and after atight connection is made, no more than three threads shall remain exposed. All cutting oil and
metal chips shall be cleared off the pipe prior to assembly.
Screwed pipe joints shall be made up using a suitable tape, which has been approved in writing by
the Superintendent.
Screwed connections shall not be back welded unless specified on designs drawings, or approvedby the Superintendent. It is recommended that back welded threaded connections be replaced with
socket weld connections if possible.
4.9 FLANGINGFlange bolt holes shall straddle the principal centre lines, unless other orientation is shown on thedesign drawings.
4.10 FIT-UPMisalignment or poor fit-up in excess of the values specified in Section 3.3 is not acceptable.
For compression-type fittings, use proper tools and torques as specified by the manufacturer to
ensure a leak-tight joint. To avoid damage or distortion of the fitting, do not over-torque the fitting
nut.
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4.11 BRANCH CONNECTIONSLines that connect to the main line or header, including instrument connections, vents and drains
are considered branch lines. All branch connections shall be made in accordance with the
respective Piping Material Specification. All stub-ins shall meet the requirements of the Code.
4.12 PIPE BENDINGPiping shall be bent only at locations shown on isometric drawings. In all other cases welding
elbows shall be used. If the pipe to be bent contains a longitudinal weld, this weld shall be located
in the neutral zone (pipe central axis).
Pipe bending shall be in accordance with Code requirements. A minimum bend radius of five (5)
diameters shall be used. Wall thickness of completed bends shall not be less than that required forthe pressure and temperature plus any corrosion allowance. Bends are permitted provided tensile
and impact properties are not impaired by the bending operation. Butt weld joints shall not be
located in the curved section of bent pipe. Weld repair of cracks in pipe bends will not be
accepted. Cold bending of pipe DN 40 and smaller is permitted. Induction bends for larger pipesmay only be used with the approval of the Superintendent.
4.13 STEAM TRACED PIPINGSteam traced piping shall be fabricated and installed in accordance with CSBP Engineering
Standard Steam Tracing (ES-14-603-14).
4.14 STEAM JACKETED PIPINGSteam jacketed piping shall be fabricated and installed in accordance with the design drawings.
4.15 ELECTRICAL TRACINGElectrical tracing and its associated electrical supply and control shall be installed in accordance
with the design drawings and manufacturers instructions.
5. PROTECTIONIn general, all pipes, fittings, valves, instruments and all other equipment including all accessories,issued to the Contractor for erection shall be protected from normal weather conditions, corrosionor damage, prior to mechanical completion
5.1 PIPE SPOOLS.After fabrication and inspection, all pipe spools shall be protected in the following manner:
5.1.1 Pipework PaintingOn completion of fabrication and workshop examination and inspection and before erection allpipework shall be surface prepared and prime painted in accordance with the specified Painting
System. General conditions for painting and cleaning shall be as per Specification.
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Patch priming of field welds and any abraded or damaged portions shall be carried out on
completion of erection, pressure testing and any other examinations and inspections, which may be
required prior to finish coating.
Pipelines and valves shall be finish coated in accordance with the specified Painting System andcolour specific in CSBP Engineering Standard Protective Coatings (ES-14-102-12).
Cold insulated services piping shall be primed in accordance with the painting Specification.
5.1.2 FlangesFlange faces shall be protected by coating with a removable rust preventative and blanked with6mm thick exterior quality plywood covers, or proprietary plastic flange guard covers no smaller
than the flange OD. The flange cover shall be retained by a minimum of four bolts or by
polyethylene lock plugs.
5.1.3 ConnectionsThreaded connections shall be fitted with line specification steel pipe plugs or treated protectors.
Socket weld connections shall be fitted with taped polyethylene caps or plugs.
All end connections, including branch openings shall be protected with a plastic sheet, wired ortaped securely to the spool to prevent entry or dirt or moisture into the spool.
5.1.4 Stainless Steel ComponentsIn order to minimise the possibility of stress cracking, all stainless steel valves, spools, pipe and
connections shall be stored out of contact with the ground and properly sheltered from rain.Closures should be examined to ensure moisture cannot enter this material.
All austenitic stainless steel subject to welding or mechanical abrasion shall be passivated toreinstate the protective oxide layer.
Stainless steel piping subject to annealing or heat treatment shall be pickled in an acid/water
solution comprising nitric and hydrofluoric acid to remove oxide scale.
6. ERECTION6.1 IDENTIFICATIONAll materials issued by Principal or supplied by the Contractor shall be identified in accordance
with the respective piping class/piping material specification, and shall be stored and handled in
such a manner as to assure proper identification.
6.2 STORAGE AND HANDLINGAll fabricated pipe and equipment shall be stored off the ground until finally installed.
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Care shall be exercised, in the storage and handling of all piping materials and pre-fabricated
assemblies, so that contamination by grease, moisture or other foreign matter does not occur. End
seals of pipe, flange covers, valve covers, and similar protections shall not be removed untilnecessary for fabrication or erection. The Contractor shall ensure that all piping is protected, as per
Section 4.4 at all times.
All care shall be taken when pipe sections are moved from one place to another to avoid bending or
over-straining.
6.3 ASSEMBLY/INSTALLATIONAll piping shall be installed in accordance with the latest revision of the Piping drawings as per
Section 3.2.
All assembled piping shall be installed without springing or forcing. Cutting or other weakening of
structural members to facilitate piping installation shall not be permitted.
All piping shall be installed to permit free expansion and contraction without damage to joints orsupports.
A visual inspection of all pipe and pipe spools shall be made to ensure they are free of all internalloose rust, scale, soil and debris before assembly.
A straight run of pipe shall contain the minimum number of welds. The use of off-cuts in straight
piping runs shall be avoided wherever possible.
Special precautions shall be taken during carbon steel piping erection in close vicinity of stainless
steel piping as direct contact between carbon steel and stainless steel is not permitted. Carbon steelslings, etc, shall not be used during fabrication and installation of stainless steels. Stainless steel
piping shall be covered up with tarpaulins or similar where carbon steel piping is being erected or
worked on such that, stainless steel cannot come in contact with carbon steel. Neither shallstainless steel or non-ferrous materials be contaminated with grinding or welding particles. Tools
shall be identified for stainless steel work only. All stainless steel piping and fittings shall be storedaway from areas where carbon steel is being worked on.
All materials used for assembly and erection must conform to the appropriate Piping Class
Specification in CSBP Engineering Standard Piping Material Specifications (ES-14-603-01).
Hydrotest vents and drains shall be installed in accordance with the Piping GAs and Isometrics.The Contractor shall install any additional vents and drains required for testing purposes.
6.4 FLANGED CONNECTIONSPrecautions shall be taken throughout fabrication and erection to protect the gasket face of flanges.Flanges repaired by grinding will be rejected.
Flanged connections shall be assembled with new gaskets and stud bolts as specified in the CSBPEngineering Standard Piping Material Specifications (ES-14-603-01). Bolts shall show at least
one, but no more than three threads beyond the nuts after assembly.
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Gaskets shall be centred on the flange faces and shall not project into the bore. Gaskets with correct
inside diameter shall be used on slip on flanges.
The clearance between flange faces shall permit the connection to be gasketed and bolted without
imposing undue strain on the piping system.
Flanged piping connections to vessels or equipment shall be correctly aligned before bolting up.
6.4.1 Protection from Leaking FlangesIn the event of a flange leak, to prevent personnel being sprayed from substances that are hazardous
because of their chemical and or physical properties, flange protection shall be provided atlocations where:
there is a high level of Operator interface,
flanges are adjacent to walkways or designated accessways,
directed by the Superintendent or the applicable business unit Process/Maintenance Manager.
Hazardous substances requiring flange protection are:
All acids
Sodium Hydroxide (Caustic Soda)
Ammonium Nitrate
Sodium Cyanide Solution, and
Other fluids, as specified by the Superintendent or the applicable business unit Process or
Maintenance Manager.
The type of flange protection to be used shall be specified by the Superintendent or the applicable
business unit Process/Maintenance Manager. Typically this will be in the form of either:
a.
A ring of stainless steel cladding that is securely held in place with stainless steel bandingstraps. A drainage/vent hole shall be provided in the underside of the flange guard.
or
b. Wrapping of the flange joint with Herculite. The material is to overlap itself and extendover the pipe with sufficient material so that is can be securely held in place with 3mm
Terylene rope or another Superintendent approved method.
6.5 BOLTINGPrior to installation, all bolting shall be lubricated with an approved anti-seize compound.
Protective grease shall be removed from flange gasket faces prior to bolt-up. Flange faces shall be
parallel and aligned in horizontal and vertical planes. Non-uniform bolt loading will be rejected.
Dirt at the mating surfaces shall be removed and scratched surfaces shall be repaired.
Flange stud bolts shall be tightened evenly and sequentially to impose equal pressure on gaskets to
avoid distortion or over stressing. Hydraulically operated tensioning equipment shall be used onstud bolts 1 diameter (M33) or over. These stud bolts shall be supplied one diameter overlength
to allow for bolt tensioning equipment.
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Insulating flange kits shall be installed between mating carbon steel and stainless steel piping.
Gasket compound shall not be used.
6.6
CONNECTION TO EQUIPMENT
Piping connections to equipment shall be installed such that no stresses shall be transferred fromthe piping system to the equipment at the time of installation.
6.7 THREADED JOINTSBack welding of threaded joints is not permitted unless specified on design drawings or approved
by the Superintendent. It is recommended that back welded threaded connections be replaced withsocket weld connections if possible.
Backing off of made-up threaded joints to facilitate fit-up or alignment is not permitted.
Joints shall be made using approved sealing tape and care taken to avoid over tightening.
6.8 TEMPORARY STRAINERSTemporary strainers must be installed in the suction piping to all pumps, compressors and otherplaces as indicated on drawings. Break-out spools shall be installed as required for easy removal of
strainers.
6.9 VALVE INSTALLATIONValves shall be installed as indicated on the GAs and Isometrics and in accordance with CSBPEngineering Standard Basis for Design - Piping (ES-14-601-01). Should valve orientation not be
detailed the following guidelines should be used:
a. Valves shall be installed so that their handwheels or handles are accessible and can be
operated between full open and full closed positions without obstructions.
b. Valve location and orientation shall be such that a person can operate the valve handwheel
or handle from a safe position and in a comfortable posture. Extensions or chain wheelsshall be provided if required.
c. Valves in horizontal lines, with the exception of block valves at pressure relief valves, shall
be installed with valve stems oriented as follows, in order of preference:
1. Vertically upwards
2.
Horizontally
3. Upwards at 45
d. Gate valves installed upstream and or downstream of pressure relief valves shall be
installed with the valve spindle oriented horizontally or downwards, to prevent blockage ofthe line by a disconnected gate in the valve.
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6.10 UNDERGROUND PIPINGFabrication, laying, corrosion protection, inspection and testing of underground piping shall be in
accordance with the CSBP Engineering Standard Underground Piping (ES-14-602-05).
6.11 INSTALLATION OF EXPANSION JOINTSSpecific instructions for installing expansion joints shall be included in the Project documentation,however the following general guidance apply:
a. Expansion joints shall be the final unit(s) installed in any piping systems.
b. Before installation of any expansion joint, all piping shall be accurately aligned withoutrestraints and properly anchored.
c. The space allowed in the piping for insertion of an expansion joint shall be equal to the
insertion dimension specified on drawings (plus or minus 1.5mm), including cold
springing, if specified.
d. Spacer bars supplied by the manufacturer for shipping purposes shall not be adjusted or
removed from expansion joints until after joints are in place.
e. Shipping spacer bars must be removed before testing.
f. No adjustment shall be made to tie rods provided by the manufacturer to control alignmentand end thrust; these tie rods shall remain part of the unit.
g. No attempt shall be made to correct misalignment of piping, caused by incorrect installationof the piping or its associated equipment, by modification to any device provided to control
expansion, or the method in which that device is designed to be installed. Such
misalignment must be corrected by other means which will in no way affect the workabilityof the expansion device.
6.12 TESTING OF PIPEWORKPressure testing of pipework shall be carried out in accordance with CSBP Engineering
Standard Inspection and Testing of Piping Systems (ES-14-602-02).
7. PIPE SUPPORTS7.1 STANDARD PIPE SUPPORTSAll pipework shall be supported in accordance with the Code.
Support locations, type and serial number will be shown on the piping drawings. Refer to Section3.2.
Unless otherwise indicated on piping drawings, no pipe shall be supported from another pipe.
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7.2 SPRING HANGERS7.2.1 GeneralSpring hangers, as required, shall be supplied by the Contractor and shall be installed as indicatedon piping drawings.
7.2.2 Constant Support HangersInstallation instructions are as follows:
a. Securely attach the hanger to the structure at a point where the load coupling is directly
over the desired point of attachment.
b. Make certain that the moving parts of the hanger will be unobstructed.
c. Make certain that the rod has enough thread engagement before taking up the load.
d. Turn the load coupling until the travel stop is free.
e. Prior to the final start-up/commissioning, the travel stops shall be removed
f. After the line is in operation, check the hanger for indicated hot position. If necessary,make the adjustment by turning the load coupling to bring the indicator to the required
position. No other adjustment is normally required, since the load as calibrated at the
factory is equal to the load that has to be supported.
7.2.3 Variable Support HangersThe installation instructions shall be as follows:
Securely attach the hanger to the structure. Turn the turnbuckle until the Variable Spring Hangeror load column of the spring support respectively reaches the desire cold load marking. No other
adjustment is necessary. The travel stops shall be removed before the piping is put into operation
8. AS-BUILT DATA AND RECORDSOn completion of the work, the Contractor shall supply to the Superintendent, as a properlyindexed and compiled package, full details of the Welder Qualified records, fabrication records and
as-built data. This package shall be compiled in accordance with CSBP Engineering Standard
Inspection and Testing of Piping Systems (ES-14-602-02).
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APPENDIX 1 - TYPICAL PROCEDURE QUALIFICATION RECORD
(PQR)
PURCHASE ORDER No: PQR No:WPS No:
PROCESS: MATERIAL SPEC:
MANUAL/AUTO/SEMI-AUTO HEAT No:
DATE WELDED SERIAL No:
JOINT: THICKNESS:
DIAMETER:
ELECTRODE/WIRE:
TYPE:
BATCH No:
WELDING PROCESS:
WELDING POSITION:
ELECTRODE STICKOUT:
GROOVE ANGLE: MAX. BEAD WIDTH:
INTERPASS CLEANING:
ROOT FACE: PREHEAT TEMP:
ROOT GAP: PREHEAT METHOD:
PASSNo
PROCESS
POLARITY
AMPSA
VOLTSV
TRAVELSPEED
MM/MIN
HEATINPUT
KJ/MM
INTERPASS
TEMP C
ELECTRODE/WIRE GAS
NAME SIZE
MM
FLOW
RATE
L/MIN
MAXIMUM THICKNESS OF
DEPOSITED WELD METAL
FOR EACH PROCESS:
TUNGSTEN TYPEAND SIZE:
GAS CUP SIZES:
GAS PERCENTAGE POSTWELD HEAT TREATMENT:
COMPOSITION
(MIXTURE)
TEMPERATURE
GAS(ES) TIME:
SHIELDIN
G:
TRAILING:
BACKING:
OTHER:
VERIFIED BY VENDOR QC DATE:
NAME: SIGNATURE:
CSBP INSPECTOR DATE:
NAME: SIGNATURE:
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APPENDIX 2 - TYPICAL WELDING PROCEDURE SPECIFICATION
(WPS)VENDOR: WPS No: PQR No:
REV: DATE: PAGE OF
PURCHASE ORDER No: MATERIAL SPECIFICATION:
EQUIPMENT DESCRIPTION: THICKNESS RANGE:
BASE METAL:
APPLICATION OF WPS: DIAMETER RANGE:
POSITION:
STANDARD WELDPREPARATION:
TYPICAL WELD SEQUENCE: PROGRESSION CONSUMABLE:
TREATMENT:
EDGE PREP METHOD:
PREHEAT TEMP:
REFER ATTACHED SHEETS
FOR
VARIATIONS:
No OF PASSES MAY VERY
ACCORDING TO THICKNESS/
PREHEAT METHOD:
POSITION RETENTION TIME:
TEMP CHECK METHOD:
MAX INTERPASS TEMP:
GOUGE METHOD:
GOUGE CHECK METHOD:
MAXIMUM THICKNESS OF DEPOSITED WELD METAL FOR
EACH PROCESS:
INTERPASS CLEANING:
TACKING METHOD: MAXIMUM BEAD WIDTH:
WELD FINISH: ELECTRODE STICK OUT:
PASSNo..
PROCESS
+- AMP VOLT TRAVEL SIZE MM FLUX/GAS
RANGE RANGE RANGE
MM/MIN
TRADE NAME SPEC/FLOWRATE
PROCESS: TUNGSTEN TYPE & SIZE:
AWS SPEC: GAS CUP SIZES:
AWS CLASS: BACKING: TYPE:
A No: GAS: RATE:
F No: DURATION
PWHT REQUIRED: FOR VENDOR
GOVERNING CODES PREPARED BY: DATE:
CONSUMABLE TRADE NAMES: APPROVED BY: DATE: