Carbon Steel Pipe Fabrication

PIM-SU-2505-NCARBON STEEL PIPING FABRICATION APPLICATION: ONSHORE This document is the confidential property of Chevron U.S.A. Inc. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Chevron U.S.A. Inc. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording, or otherwise) without the prior written consent of Chevron U.S.A. Inc. Rev Date Author Sponsor K 04/1999 General revision ZRomoda ZRomoda L 11/06 General revision RSHC RSHC M 05/08 General revision RSHC RSHC N 09/10 General revision RGQP LNSK September 2010 Description © 1999–2010 Chevron U.S.A. Inc. All rights reserved. 1 of 12 ........................................................................................................................................Purchaser Documents ........................................................................................................................................5 6......................Preheat ...........................................................................................4 ................................Fabrication Requirements .....................................0 Scope ............2 .......10 9..................................................Radiography ...............0 Examination and Testing ...............6 6................................................................ All rights reserved.......................................................8 6..............10 9....................Method ......................................................................2 ..................................................S...5 ................3 ..................0 General ..............................Heat Treatment ...............................Carbon Steel Piping Fabrication PIM-SU-2505-N CONTENTS 1.... Inc.........................................Positive Material Identification ...........................................................................7 6....................0 Welding ....................................5 6...............................6 ........4 4.......0 References ..........3 2.......................................................................................................................1 ...............................................10 9......................................................................................................0 Material ................................................................4 5...............................................................................................................1 ..........Industry Codes and Standards .............8 8..........3 .............1 ..... 2 of 12 .................................8 7.................................9 8.................................................................................................0 Repairs .0 Bends ..........................12 September 2010 © 1999–2010 Chevron U.......................11 11........................................................................0 Packing for Shipment .......................................................................Hardness Testing ..................Filler Metals .............3 2....Specific Process Limits ...................................................................................0 Documentation ...............Hydrotesting ......Miscellaneous Requirements ..............................................................................................................2 .....................................11 10...........................................10 9.........................................................................................3 ......................................3 2..................................................3 3..9 8......5 6........0 Acronyms ...................................................................8 6.........................General ............................................11 12.....................................0 Preheat and Heat Treatment .................................................4 ......................................2 ..9 8.......................A.........1 .....Visual ...............9 9. Nondestructive Examination Section IX. 2. 3. This specification covers the fabrication and examination of carbon steel piping. Refer to PIM-SU-4770 and PIM-SU-4772. Qualification Standard for Welding and Brazing Procedures. carbon-moly. This specification supplements the fabrication requirements of ASME B31. Brazers. and Welding and Brazing Operators September 2010 © 1999–2010 Chevron U.3. This specification does not cover stainless steel. 3 of 12 . for those materials.0 PIM-SU-2505-N SCOPE 1.1 2. All rights reserved.1 Power Piping B31. Inc. 2.1 and ASME B31. The following documents are referenced herein and are considered part of this specification. respectively.3 Process Piping SFA-5. or chrome-moly piping fabrication.S.A.1 Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding SFA-5. Rules for Construction of Power Boilers Section V. Welders.17 Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc Welding SFA-5.0 REFERENCES 1.18 Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding SFA-5. 2. 2.20 Specification for Carbon Steel Electrodes for Flux Cored Arc Welding Boiler and Pressure Vessel Code (BPVC) Section I. Use the latest edition of each document referenced below unless otherwise specified.Carbon Steel Piping Fabrication 1.2 Purchaser Documents PIM-SU-3541 Hydrotesting of Onshore Piping Systems PIM-SU-4770 Stainless Steel Piping Fabrication PIM-SU-4772 Low Alloy Steel Piping Fabrication PIM-SU-5112 Piping Material Line Classes PIM-DU-5138 Piping Design PPL-SU-4737 Induction Bending [PIM] GC-L34496 Standard Pipe Details and Construction Notes [PIM] GD-L1057 Root Valve Installation Industry Codes and Standards American Society of Mechanical Engineers (ASME) B31. All rights reserved. inspection. 4. the more restrictive document shall apply.1. Figure 100.2(A) of ASME B31. Purchase orders for ASME BPVC Section I piping materials shall indicate that data reports. inspection. b.A.2(A) and Paragraph 123. Piping shall comply with this specification and with the latest edition of ASME B31. unless specified otherwise.0 GENERAL 1. In case of conflict between the applicable ASME codes and this specification. and stamping are required.2. Short Circuit Arc GTAW—Gas Tungsten Arc Welding NDE—Nondestructive Examination PMI—Positive Material Identification PQR—Procedure Qualification Records PWHT—Post Weld Heat Treatment SAW—Submerged Arc Welding SMAW—Shielded Metal Arc Welding UNS—Unified Numbering System WPQ—Welder Performance Qualification WPS—Welding Procedure Specification 4.1 requires that piping comply with the requirements of Section I of ASME BPVC. a.1 or ASME B31. 2. 3.1. Supplied materials shall also conform to ASME B31.2.0 ES3 Fabricating Tolerances ES49 Guidelines for Installation of Integrally Reinforced Branch Connection Outlet Fitting ACRONYMS AWS—American Welding Society CMTR—Certified Material Test Report ERW—Electric Resistance Welding FCAW-G—Gas-Shielded Flux-Cored Arc Welding FCAW-S—Self-Shielded Flux-Cored Arc Welding GMAW—Gas Metal Arc Welding GMAW-S—Gas Metal Arc Welding.Carbon Steel Piping Fabrication PIM-SU-2505-N Pipe Fabrication Institute (PFI) 3. Inc. When Figure 100. September 2010 © 1999–2010 Chevron U.3 (as applicable). materials purchased shall be accompanied by data reports.S. shall be in accordance with GC-L34496. and stamping. 4 of 12 .1. Fabrication tolerances and piping details. Purchaser shall be notified of such conflicts. A marking system accepted by Purchaser shall be used to maintain material traceability. tolerances for dimensions of fabricated pipe sections shall be in accordance with PFI ES-3. whether removed or left in place. 5. Electric resistance welding (ERW). shall be provided to Purchaser. All rights reserved. when snow is falling on the surfaces to be welded. they shall be removed and visually inspected to ensure all defects have been removed. 4.S. 8. 7. and pressure welding shall not be used. 6. 3. shall be permitted only with Purchaser’s written acceptance. Degree of piping misalignment allowed shall be corrected and heating methods shall be part of formal plan submitted to Purchaser. 6. September 2010 © 1999–2010 Chevron U. 5 of 12 . No welding shall be done when surfaces are wet or covered with ice. 3. If arc strikes occur. Inc.A. Use of the word “Code” in this specification shall mean ASME B31. Turbine steam supply and other piping requiring special cleaning shall have the root pass deposited by GTAW. shall be made by a qualified welder following the procedure detailed in ASME BPVC. Unless otherwise specified. gas metal arc welding (GMAW). 4. 9. including thicker wall materials. submerged arc welding (SAW). Section IX. 10. 2. Opportunity to witness all or part of the work. Piping shall be in accordance with line class specifications. 6. including access to facilities to verify the results. Heating may be used by field fabricator or erector to correct piping misalignment after formal plan is accepted by Purchaser.1 or ASME B31. or during periods of high wind. Tack welds. Installation of root valves shall comply with GD-L1057. 5. Repairs to pipe and fitting surfaces shall not reduce the wall thickness below the minimum required.1 General 1.0 WELDING 6. welder performance qualifications (WPQ). Section IX. and gasshielded flux-cored arc (FCAW-G) welding. gas tungsten arc welding (GTAW). flash welding. Weld procedures and welders shall be qualified in accordance with the rules of ASME BPVC. Pipe support systems shall be in accordance with PIM-DU-5138. unless the welders or welding operators are properly protected. Acceptable welding processes shall be shielded metal arc welding (SMAW). 8.Carbon Steel Piping Fabrication PIM-SU-2505-N 5. Substitutions shall be permitted only with Purchaser’s written acceptance.3 as specified by Purchaser. 7. Material substitutions. Welding procedure specifications (WPS). Arc strikes on pipe and fitting surfaces shall be avoided. and procedure qualification records (PQR) shall be reviewed and accepted by Purchaser before any welding is started.0 MATERIAL 1. 2. Cast fittings shall not be used. 9. 4. 5. When seam-welded pipes are joined by butt welding.3 and ASME B31. the distance between the centerline of longitudinal weld seams shall be 2 inches (50 mm) or three times the nominal thickness of the materials being joined.4 Seal Welding 1.S. Intersection of branch welds with longitudinal seams shall be avoided. Exposed threads shall be covered by the weld metal.2B(1) and Figure 127. 2.2. Use of slip-on flanges in space-restricted locations requires Purchaser acceptance for other services.4.2.2 PIM-SU-2505-N Fabrication Requirements 6. while maintaining weld edge distance requirements with branch connections. Field butt-weld joints in shop-fabricated piping shall be prepared in accordance with the appropriate figure shown in GC-L34496. 6 of 12 . 6.5.Carbon Steel Piping Fabrication 6. both weld passes shall be visible for inspection.A. 3. 5.3 for definition of Category D services. Use of slip-on flanges shall be restricted to Category D services.4(B)(a). Longitudinal welds shall be located at least 30 degrees above the bottom of the pipe and as high above the centerline as possible. 6. 5. Refer to GC-L34496 for details.1. Where painting of welds is required prior to hydrotest. Seal welds are considered to be pressure-containing and shall meet GC-L34496 Note 4 requirements. Pressure-containing fillet welds shall have two passes minimum. 2. 2. Inc.5 mm to 5 mm) back from the face of the flange. For field welding and heat treatment.2. whichever is greater. 3. 3. Seal welds shall be PWHT as required by Code per material or per process services. The toe of the inside fillet weld shall be 1/16 inch to 3/16 inch (1. Seal welding of threaded joints shall be permitted only if specified by Purchaser. 2. Flange face shall be protected from weld spatter. September 2010 © 1999–2010 Chevron U. Both male and female threads shall be free of oil and joint sealant.2.3 Slip-On Flanges 1. locate butt welds where there is adequate clearance. 4. Figure 328. Refer to GC-L34496 for details.2 Butt Welds 1. 4. 6. All rights reserved. See ASME B31. and the threads shall be fully engaged. Slip-on flanges shall be double welded in accordance with ASME B31.1 Fillet Welds 1. Welding neck orifice flanges shall have the same bore as the pipe. 2. Self-shielded flux cored arc welding (FCAW-S) shall not be used. 4. short-circuiting transfer) GMAW-S process may be used for butt welds and shall not be used for weldolets and other attachments. FCAW-G electrodes shall meet an H-4 or less diffusible hydrogen content.7 Orifice Runs 1. the type of 90-degree branch connections shall be in accordance with the branch connection chart in the applicable piping material specification. Electrode diameter shall not exceed 1/8 inch (3. The interrupted-arc GMAW process may be used for root pass only for any qualified base metal thickness. Unless otherwise specified.2.2 Gas-Shielded Flux Cored Arc Welding 1. 6. welding of unreinforced stub-ins shall be in accordance with the Code.1 Interrupted-Arc Gas Metal Arc Welding-Short Circuit Arc 1.2. 3.S.3 Specific Process Limits 6.3. 2. Horizontal flange faces: A pair of bolt holes shall straddle the plant north-south centerline. Root passes may be made in any direction. Inc. 6. September 2010 © 1999–2010 Chevron U. 5.Carbon Steel Piping Fabrication 6. 6.. Figure 328.A. 6. 2. Welds at orifice flanges shall be ground or machined smooth and flush on the inside of the pipe. Refer to standard drawing GC-L34496 and PFI ES49. bolt holes of fixed flanges shall be oriented as follows: 1. Wind velocity shall not exceed 5 mph (8 kph) in the weld area. 6. Sloping flange faces: A pair of bolt holes shall straddle the plane defined by the centerline of the pipe and a vertical line. The interrupted-arc GMAW-S process shall be limited to groove welding base metal thickness of 3/8 inch (10 mm) or less.e. 4. Vertical downhill welding shall not be acceptable. 3.3. FCAW-G shall be used only with gas-shielded electrodes.5 PIM-SU-2505-N Branch Connections 1. 3. All rights reserved.5.2 mm).4D(2). 2. Orifice runs shall not contain welds except at the flanges. unless the weld is sheltered from the wind. Attachment of integrally reinforced branch connections shall be by a full-penetration weld and shall be filled out to the edge of the fitting weld bevel. Unless otherwise specified. 7 of 12 . but filler and capping passes shall not be made in the downhill direction below the 2 o’clock position. 3. 2. The interrupted-arc (i. 3. Vertical flange faces: A pair of bolt holes shall straddle the vertical centerline.6 Flanges Unless otherwise specified.2. 8 of 12 .Carbon Steel Piping Fabrication 6.GTAW & GMAW ASME Section II C SFA 5. 4. 4. and free from dirt. 2. and other loose foreign materials prior to welding and assembly. At least 10 percent of production welds in each furnace heat-treated batch and 100 percent of those that are locally heat treated shall be hardness tested.FCAW-G electrodes that need to be accepted on a caseby-case basis.A.SAW Electrodes and Fluxes Table 1 Chemical Composition Requirements for Solid Electrodes Table 2 Chemical Composition Requirements for Composite Electrode Weld Metal Table 1 Chemical Composition Requirements for Solid Electrodes and Rods Table 2 Chemical Composition Requirements for Weld Metal from Composite Electrodes Table 6 Base Metal for Test Assemblies Table 1 Chemical Composition Requirements for Solid Electrodes and Rods Table 2 Chemical Composition Requirements for Weld Metal from Composite Electrodes Table 6 Base Metal for Test Assemblies ASME Section II C SFA-5.18 .4 PIM-SU-2505-N Filler Metals Table 1 shall be used to for determining American Welding Society (AWS) class and Unified Numbering System (UNS) numbers.20 . slag. Bending procedures shall be submitted to Purchaser for review and acceptance prior to fabrication. All rights reserved. 6. 2.1 . Hardness tests shall be made with a Telebrineller-type portable hardness tester. Table 1: AWS Classes with Matching UNS Numbers Specification Reference ASME Table Title ASME Section II C SFA-5. Induction bends shall be made in accordance with PPL-SU-4737.5 Hardness Testing 1.17 . 2. or Purchaseraccepted alternative. 6.0 BENDS 1. The maximum Brinell hardness of carbon steel shall be 200 BHN. Backup strips or rings shall not be used. At least 10 percent of the production welds shall be hardness tested. 7.6 Miscellaneous Requirements 1. Components shall be clean. Any weld not identified by the welder’s identification stamp shall be rejected unless it is shown to be of acceptable quality by radiographic inspection at the Supplier’s expense. Inc. Root gap inserts that are completely melted and fused in the weld bead shall be acceptable provided they have the same nominal composition as the filler metal. September 2010 © 1999–2010 Chevron U.S.SMAW Table 7 Chemical Composition Requirements for Weld Metals ASME Section II C SFA-5. 3. 3. dry. but for not less than one hour. 50°F (10°C) minimum for nominal wall thickness less than one inch. 8.Carbon Steel Piping Fabrication 8.1 Preheat PIM-SU-2505-N 1. Thermocouples may be attached by bolting or welding of thermocouple pad when accepted by Purchaser. when specified.3 requirements: a.S. induction heating coils. All rights reserved. peening. Preheat shall be required when pipe is wet or when the ambient temperature is less than 50°F (10°C). Preheat may be applied by electrical resistance heating pads. If heating by the torch method. Cooling from the heat treatment temperature shall be in still air outside the furnace. PWHT shall be accomplished by furnace. Exothermic stress-relieving kits shall not be used without written Purchaser acceptance. or oxy-fuel “rosebud” heating torches. Welds. 3. or welding of a thermocouple pad.2 Heat Treatment 1. shall be at 1. Butt weld valves shall not be subject to furnace post weld heat treatment (PWHT) without Purchaser acceptance. 175°F (79°C) minimum for nominal wall thickness one inch and larger. Thermocouples sufficient to monitor PWHT temperatures shall be attached to representative welds by direct spot or resistance welding. 3.0 PREHEAT AND HEAT TREATMENT 8.3 Method 8.1 and ASME B31. local electrical resistance heating elements. 2. 9 of 12 . Socket weld valves may undergo furnace PWHT in accordance with documented procedures provided by the manufacturer under a cover letter referencing the project for which the valves have been supplied. Inc. Welds shall be heat treated when specified by Purchaser or ASME B31. Flame residue shall be removed by solvent and cloth wipes prior to welding. b. a. care shall be taken not to locally overheat the material. Heat treatment. 2.2 Post Weld Heat Treatment 1. September 2010 © 1999–2010 Chevron U.3. 5. 8. bolting. 4.1 Preheat 1. Flames shall not impinge on the metal surface.200°F (593 to 648°C) for one hour per inch of nominal wall thickness.3. and hot bends shall be heat treated in accordance with this specification. Preheat shall be per the following ASME B31. cold bends with a radius less than five times the pipe outside diameter.A. 4. 2.100 to 1. Preheat shall be measured with contact pyrometers or temperature indicators.3. or induction heating equipment. 8. b. 2. S. f. 9. Visual examination. i. 9. Inc. impact-tested. but may need to rely on the Certified Material Test Report (CMTR) because these parameters cannot be measured by typical alloy analyzers.A.Carbon Steel Piping Fabrication PIM-SU-2505-N 5. As a minimum. 10 of 12 . All rights reserved. Calibration procedures used to ensure the maximum specified temperature differential throughout the working zone. holding times. EXAMINATION AND TESTING 1. and the Owner agrees.2 Visual 1. Special heat-treated. ultrasonic examination may be substituted for radiography. b. If the ASME Code permits. 4. c. 2. 2. and paint. Fabricator shall submit a furnace PWHT procedure for Purchaser review and acceptance.3. Heating procedures. shall be performed and repairs made before any other examinations are performed. 3. Purchaser shall retain the right to designate which piping shall be randomly tested. Loading and spacing procedures. and cooling procedures for each material type. Maximum period between calibration to recognized industry standards. 2. 9. 2) Three months for controlling and recording instruments and thermocouples. as follows: 1) One year for furnace. Dimensions of the temperature-calibrated working zone defining maximum load size. 2. Visual examination shall be in accordance with the applicable ASME Code and specific line classes in PIM SU-5112. External and accessible internal surfaces of joints and components to be examined shall be free of rust.0 Protection of flange faces to prevent scaling. Thermocouple placement requirements. e. the procedure shall address the following: a. September 2010 © 1999–2010 Chevron U. Surfaces shall be ground.3 Radiography 1. if necessary. 9. d. Operating temperature range. Description of furnace. Qualification of inspection personnel shall be per ASME B31. Carbon steels not listed above do not require positive material identification (PMI). including any in-process examination. or low temperature carbon steel requires verification. h. g. Radiography shall be performed in accordance with ASME Code and specific line classes in PIM-SU-5112.1 Positive Material Identification 1. to eliminate irregularities that can obscure or confuse the interpretation of imperfections. scale. weld flux or spatter. All rights reserved. 2. Damaged machined surfaces shall be repaired.4 Hydrotesting 1. Hydrotesting procedures shall be specified in accordance with PIM-SU-3541.3. Acceptance criteria for radiography shall be in accordance with the appropriate ASME Code. repairs shall be limited to three attempted weld repairs and two PWHTs. or the component shall be replaced. 4. 2. Copies of certifications and records required by the applicable ASME Code shall be furnished to Purchaser’s inspector. Documentation shall include a description of the location and nature of repairs made as a result of nondestructive examination (NDE) as well as testing results. 9. the first two welds for each welder shall be radiographed in addition to 5 percent of the order (or other specified percentage). Piping shall be completely drained and blown dry following testing. Progressive examination shall be in accordance with the ASME Code. 9.1 Acceptance Criteria 1. c. 2.3. Re-tested with the same method that detected the defect. Repaired promptly and reinspected at fabricator’s expense. Final radiography for acceptance shall be done following post weld heat treatment. Supplier shall maintain the following documentation and make it available to Purchaser for review: a. 4. Rejected welds shall be treated as follows: a. 9. 11. During the course of fabrication. “As-built” dimensional data and material substitutions on piping.A. 3. Inc. Spool drawings documenting heat numbers and other similar component identification numbers. to provide full material traceability. Additional radiography resulting from rejected welds shall be at fabricator’s expense and shall not be included in the 5 percent (or other specified percentage). b. b. Only potable water shall be used when hydrotesting is being performed. 2. 3. Concurrence of Purchaser inspector shall be required in the interpretation of radiographs.2 Technique Fluorescent intensifying screens shall not be used.Carbon Steel Piping Fabrication PIM-SU-2505-N 3. 9. Mill test reports and other similar certifications for materials of construction. 10. For each procedure change requiring a separate welder qualification.3 Progressive Examination 1.S.0 REPAIRS 1. 11 of 12 . Unless otherwise accepted by Purchaser. September 2010 © 1999–2010 Chevron U.0 DOCUMENTATION 1. 2.3. Exposed flange faces shall be protected against corrosion and damage by applying suitable grease.A. All rights reserved. 12 of 12 . Hardness test results. 3. Paint. and results. with characters at least 1/2 inch (13 mm) high. and prior to shipment of the applicable piping. on opposite sides.S. Plastic snap-in end covers shall be acceptable. b. Marking shall be waterproof and clearly readable. or other metals. c. 2. sulfur. 3. ink. September 2010 © 1999–2010 Chevron U. Supplier shall provide Purchaser with a complete quality control package for the piping. g. d. Threaded connections shall be protected by thread protectors. Beveled ends shall be protected by snug-fitting end protectors. lead. and other inspection records and charts. 5. Proposals to use bar coding shall be submitted for review and acceptance. Examiner certifications.0 PACKING FOR SHIPMENT 1. Inc. Each section of fabricated piping shall be plainly marked with the order and spool number. including both a hard copy and an electronic copy of the documentation listed in item 2. to identify the location of each weld. test certificates. and marking material shall not contain chlorides. Markings shall be made once on each end of the spool. reports. 4. 12.Carbon Steel Piping Fabrication PIM-SU-2505-N d. and by bolting wood or steel covers with at least four bolts. NDE. Other documentation required by project specifications. PWHT data from furnace recorder. Weld records coded to correspond with spool drawings. Pressure test procedures. Upon completion of testing. and WPQ documents. i. h. f. a. PQR. WPS. e.