Piping Design Guide Volume 3 Practice 045 250 0020 17 March 2022 PIPING DESIGN GUIDE PIPING DESIGN GUIDE CHAPTERS: 0. Piping design guide - Index 1. Dimension Tables 2. General design information, work instructions and executions 3. Specification for piping design 4. Plot development 5. Off sites - Plant Arrangement 6. Equipment Studies: Pumps and turbines 7. Equipment Studies: Compressors 8. Equipment Studies: Exchangers 9. Equipment Studies: Vessels 10. Equipment Studies: Fired equipment 11. Piping Project Activity Model (PAM), piping Activity Plan (AP) and reference practices 12. Miscellaneous Piping Details 13. Material Control 14. Instrumentation 15. Piping Plans 16. Stress 17. Isometrics 18. Supports 19. Modules 20. Material Handling 21. Miscellaneous Practices and Guidelines Page 1 of 12 Practice 045 250 0020 17 March 2022 DESIGN GUIDE DISCLAIMER OR OWNER RESPONSIBLITIES This design guide is current as of the time of issue. It is the owner’s responsibility to maintain it and keep it current with the latest information and practices With any of the Practices check with the Quality Requirements System (QRS) and for Guidelines check with Knowledge Online (KOL) to ensure that you have the latest copy. Page 2 of 12 Practice 045 250 0020 17 March 2022 PIPING DESIGN GUIDE - INDEX 0. 0-001 1. Index 045.250.0020 Index Piping design guide Dimension Tables 1-001 245.250.9801 Dimensional Chart - Overall Dimensions Weld Fittings 1-002 000.250.9801 Att 02 Dimensional Chart - Dimensions For Valves 1-003 000.250.9801 Att 03 Dimensional Chart - Control And Relief Valves For Layout Purpose 1-004 000.250.9801 Att 08 Dimensional Chart - Branch Outlet Fittings 1-005 1-005 Dimensional Chart - Flange Dimensions Class 150-2500 1-006 000.250.9801 Att 10 Dimensional Chart - Ring Joint Weld Neck Flange Class 150-2500 1-007 1-007 Dimensional Chart - Overall Dimensions Of Sw. And Scr'D Fitting Combinations 1-008 1-008 Dimensional Chart - Reducing Tee Dimensions 1-009 1-009 Dimensional Chart - Branch Dimensions Class 150 And 300 Insulated And UnInsulated Lines 1-010 000.250.9801 Att 11 Dimensional Charts - Large Diameter Fabricated Type Reducers 1-011 000.250.9801 Att 12 Dimensional Chart - Welded Mitered Elbows 1-012 000.250.9801 Att 13 Dimensional Chart - Cutting And Dimensioning Pipe At ODD Angles Of ANSI And DIN Pipe 1-013 000.250.9820 Att 01-07 Dimensional Chart - Spectacle Blinds 1-014 1-014 Dimensions of Lap Joint Stub Ends 1-015 000.250.9809 Dimensional Chart - Nominal Wall Thickness For Pipe 1-016 000.250.9801 Att 14 Dimensional Chart - Pipeline Spacing 1-017 1-017 Dimensional Charts - Reinforcing Pad Requirements 1-018 1-018 Dimensional Chart - Trigometric Functions 1-019 1-019 Dimensional Chart - Allowable Pipe Spans 1-020 245.250.9826 Dimensional Chart - Standard Welding Symbols 1-021 000.250.3824 Att 02 & Bolt Length Calculation 03 1-022 000.250.9821 Table Of Weights - Pipe Components Page 3 of 12 Practice 045 250 0020 17 March 2022 1-023 000.250.9822 Att 01 Dimensions And Properties Of Pipe & 02 1-024 000.250.9823 Coefficient Of Expansion Tables 1-025 000.250.9835 Fabrication Tolerances 2 General Design Guidelines, Work Instructions, Executions and Activity Plans, 2-001 000.000.0072 Activity Plan Preparation 2-002 000.250.F0072 Activity Plan Piping Engineering 2-003 000.100.1400 Project Activity Model (PAM) 2-004 000.100.F1400 PAM Workbook 2-005 000.250.0764 Piping Eng Graphic Activities Overview 2-006 000.250.0764 Phased Engineering-Piping Engineering Section 2-007 000.300.6702 ABS Discipline Mapping to SAP Cost Elements 2-008 000 200 1050 Standard Drawing Guidelines 2-009 000.200.1037 Engineering Document Production and Checking 2-010 000.250.1037 Drawing Checking 2-011 000.250.1038 Drawing Checking - Piping Plan Corrections 2-012 000.250.1060 Piping Operations - Supplier Drawing and Data Review for Piping 2-013 000.042.F1010 Discipline Checking Matrix - Piping 2-014 000.250.9856 Piping Codes and Standards 2-015 000.200.0600 Construction Work Areas and Work Packages 2-016 000.200.0926 Electronic 3D Model Review 2-017 2-017 3D Model Review Flow Chart 2-018 000.250.0600 Piping Design - 3D Modeling for Piping – Setup Execution and Close-Out 2-019 000.250.2025 Piping Design - Piping Layout Studies 2-020 000.250.6665 Piping Progress Rules of Credit MPSU 3 Specification for piping design 3-001 000.250.50001 Process and utility piping design, layout, and drawing Page 4 of 12 Practice 045 250 0020 17 March 2022 PIPING DESIGN GUIDE - INDEX 4 Plant Arrangement - Plot Plan Development, 4-001 000.250.2005 Plant Arrangement - Plot Plan Development - Instructions 4-002 000.250.2010 Plant Arrangement - Flow Diagram Transposition Instruction 4-003 000.250.2035 Piping Design - Piping Drawing Generation 4-004 000.200.F0916 Plot Plan Review Checklist 4-005 4-005 Canadian Operations (Alberta) Equipment Spacing Guidelines 4-006 4-006 PIP Equipment Spacing 4-007 4-007 Rail Road Clearances Design Data 4-008 4-008 Truck Dimensions 4-009 4-009 Docking Dimensions for Motor Trucks 4-010 4-010 Truck Size and Turning Radius 4-011 4-011 Typical Road Constructions 4-012 4-012 Building Plot Development 5 Off sites Plant Arrangement 5-001 000.250.2005 Att 11 Offsites - Refinery Plot Plans 5-002 000.250.2005 Att 12 Offsites - Tank Spacing 5-003 000.250.2005 Att 13 Offsites - Atmospheric Storage Tank Piping Layout Guide 5-004 000.250.2111: Sleeve through dike Page 5 of 12 Practice 045 250 0020 17 March 2022 PIPING DESIGN GUIDE - INDEX 6 Equipment Studies: Pump Turbine 6-001 000.250.1062 Supplier Drawing and Data Review - Pump and Turbines 6-002 245.250.2350 Typical Piping Arrangement Centrifugal Pumps 6-003 000.250.2350 Att 02 Pumps and Turbines - Reduction at Pump Suction 6-004 000.250.2350 Att 03 Pumps and Turbines - Pump Piping (Steam) Turbines and Reciprocating Pumps 6-005 000.250.2350 Att 04 Pumps and Turbines - Misc. Pump Piping - Coolant, Flush Oil. Vent and Drain 6-006 000.250.2350 Att 05 Pumps and Turbines - Strainer, Pump Section, Conical 6-007 6-007 Pumps and Turbines - Strainer, Pump Section, T-Strainers 6-008 6-008 Pumps and Turbines - Strainer, Pump Section, Y-Strainers 6-009 6-009 API Pump Seal Plan 6-010 6-010 Pump Support Chocks 6-011 6-011 Pump Support on Steel 7 Equipment Studies: Compressors 7-001 000.250.1063 Supplier Drawing and Data Review - Reciprocating Compressors 7-002 000.250.2470 Compressor Piping - Reciprocating and Centrifugal Compressors - Piping and Arrangement 7-003 7-001 Compressor Building Layout ,,, 8 Equipment Studies: Exchangers, 8-001 000.250.1061 Supplier drawing and data review - Exchangers 8-002 000.250.2600 Att 1 Exchangers - TEMA Nomenclature 8-003 000.250.2600 Att 2 Exchangers - Equipment Location and Piping Layout Shell and Tube Heat Exchangers 8-004 000.250.2600 Att 3 Exchangers - Forced Draft and Induced Draft Air Cooler Arrangements 8-005 000.250.2600 Att 4 Exchangers - Double Pipe Exchangers Piping Arrangements 8-006 8-006 Exchanger handling facilities · Page 6 of 12 Practice 045 250 0020 17 March 2022 PIPING DESIGN GUIDE - INDEX 9 Equipment Studies: Vessels 9-001 000.250.2660 Vessel Layout and Orientation - Classification, Piping, Trays 9-002 000.258.1104 Ladder and Platform Design Criteria 9-003 000.258.4104 Ladder and Platform Details 9-004 000.258.4107 Equipment Pipe Guide Details 9-005 000.258.4108 Equipment Pipe Support Details 9-006 000.258.4155 Vertical Vessel Support - Skirt Details 9-007 ST-2-40003 Vertical Vessel Support - Skirt Base Details 9-008 ST-2-40006 Support Leg and Base Plate Detail 9-009 ST-2-40009 Saddle Details for Horizontal Vessels (Supported on Concrete) 9-010 ST-2-40047 Saddle Details for Horizontal Vessels (Supported on Steel) 9-011 000.258.4021 Mist Eliminator Details 9-012 ST-2-40021 Name Plate Bracket Detail 9-013 ST-2-40011 Hinge and Davit for Manholes 9-014 9-005 Column Davit Details 9-015 9-006 Vessel Internal Rungs 9-016 ST-2-40015 Vortex Breakers 9-017 ST-2-40013 Pad-Type Inspection Openings 9-018 9-002 Nozzle Projection Top Platform 9-019 9-001 Nozzle Projection Chart 9-020 9-003 Vessel Support for Bridles 9-021 ST-2-40035 Bolt Position of Flanges 9-022 ST-2-40036 Allowable Fabrication Tolerances for Horizontal and Vertical Pressure Vessels 9-023 9-004 Piping and Vessel Interface (L&P and PS&G) Page 7 of 12 Practice 045 250 0020 17 March 2022 PIPING DESIGN GUIDE - INDEX 10 Equipment Studies: Fired Equipment 10-001 000.250.2520 Fired Equipment Piping: Plot, Piping Design, Burner Piping, L&P's 10-002 000.250.2520 Att. 06, Heater Squad Checking - Fired Equipment Piping 07 10-003 10-003 General Heater Information and Layout Examples 10-004 10-004 Types of Fired Process Heaters 10-005 10-005 Heater Glossary 10-006 10-006 Decoking Heater Tubes 10-007 10-007 Squad Check List boiler Vendor Drawings 10-008 10-008 Boiler Glossary 11. Undergrounds 11-001 245.250.50070 Underground Piping Design 11-002 000.200.0723 Underground Service Eng. - Discipline Interface (CUP) 11-003 000.250.2939 Checklist for Combined Underground Piping (CUP) 11-004 11-004 Underground Piping - Drain and Sewer Details 11-005 11-005 Underground Piping - Firewater Details 11-006 11-006 Underground Firewater PIV Standard 11-007 11-007 Underground Mainway and Catch Basin Standard 11-008 11-008 Underground Piping and Trenching Details Page 8 of 12 Practice 045 250 0020 17 March 2022 PIPING DESIGN GUIDE - INDEX 12. Miscellaneous Piping Details 12-001 000.250.9820 Spectacle Blind Installation and Handling Guide 12-002 12-002 Utility Station Standard 12-003 12-003 Vent and Drain Standard 12-004 12-004 Handwheel Extension Stems 12-005 12-005 Drip Pot and Steam Trap Piping 12-006 12-006 Safety Shower & Eyewash Details 12-007 12-007 Pipe Sleeve Details 12-008 12-008 Underground Piping - Firewater Details 12-009 12-009 Underground Piping - Drain and Sewer Detail 12-010 12-010 Analyzer Sample Connections 12-011 12-011 Sample Connections 13. Material Control 13-001 000.250.2190 Preparation and Handling of Manual Material Take-offs 13-002 000.250.2191 Material Sketching: Material Sketching Instructions 13-003 000.250.3820 Identification of Material Requirements from Plot Plan an Flow Diagrams 13-004 000.250.3818 Takeoff Philosophy and Guidelines 13-005 000.250.3823 Sketch Takeoff 13-006 000.250.3824 Isometric Takeoff 13-007 000.250.3827 Bulk Material Takeoff Procedure 14. Instrumentation 14-001 000.250.2710 Piping Design - Instrument Piping Guidelines 14-002 000.250.2710 Att 1 Flow Meters - Required Upstream and Downstream 14-003 000.250.2710 Att 2 Instrument Piping - Control Valve Manifold Clearances and Layout Guide 14-004 000.250.2710 Att 3 Instrument Piping - Control Valve Manifold Arrangement and Layout Guide 14-005 000.250.2710 Att 4 Instrument Piping - Orifice Flange Tap Piping 14-006 000.250.2710 Att 5 Instrument Piping - Pressure Instrument Branch Connection and Layout Clearances 14-007 000.250.2710 Att 6 Instrument Piping - Thermowell Details Selection Chart Page 9 of 12 Practice 045 250 0020 17 March 2022 14-008 000.250.2710 Att 7 Instrument Piping - Level Instrument Piping Layout Guidelines 14-009 000.250.2710 Att 8 Instrument Piping - Relief Valve Piping and Configurations 14-010 26.7 Safety Relief Valve Dimensions 14-011 000.250.2710 Att 9 Floating Rotameter Piping 14-012 000.250.2710 Att 10 Process Connections for Flanged Instruments 14-013 14-013 Instrument Air Heaters and IA Manifolds 15. Piping Plans 15-001 00.250.2050 Piping Plans - Aboveground Piping Plan Instruction 15-002 000.250.2021 Pipe Way Interface Control Chart and Procedure 15-003 000.250.F3600 Piping Interface Control Chart 15-004 000.250.2928 Checklist for Aboveground Piping Plans 15-005 000.250.2035 Piping Drawing Generation 16. Stress 16-001 000.250.1200 Piping Stress Analysis - General Operating Practices 16-002 000.250.2210 Stress Design - Responsibilities 16-003 000.250.2220 Stress Design - Sketch Procedure 16-004 000.250.2221 Stress Design - Sketch Information 16-005 000.250.2231 Stress Layout Aids for Exch, Vessels and Other Eqp 16-006 000.250.2232 Stress Layout Aids for Pipeway 16-007 000.250.9823 Coefficient of Expansion Tables 16-008 000.250.9840 Layout Aids for Flexibility and Supporting 16-009 16-009 Piping Span Charts - Fluor Canada 16-010 16-010 Vessel Guide Spacing 16-011 000.250.2926 Stress Sketch Checklist for Piping Design Page 10 of 12 Practice 045 250 0020 17 March 2022 PIPING DESIGN GUIDE - INDEX 17. Isometrics 17-001 000.250.2916 Piping Design - Isometric Readiness Checklist 17-002 000.250.2080 Piping Isometrics - Piping Isometric Drawing Instructions 17-003 000.250.2079 Piping Design - Piping Isometric Procedure 17-004 000.250.2929 Piping Design - Piping Isometric Checklist 18. Supports 18-001 DWG-001 Base Supports - C.S and S.S >= 40S Lines 18-002 DWG-002 Base Supports - Thin Wall (10S) S.S Lines 18-003 DWG-003 Base Anchors and Guides - C.S and S.S >= 40S Lines 18-004 DWG-004 Shoe and Load Distribution Pad - C.S, S.S and Cr-Mo Piping 18-005 DWG-005 Guides 18-006 DWG-006 Directional Anchors 18-007 DWG-007 Field Support-U Bolts 18-008 DWG-009 Hanger Rods 18-009 DWG-010 Support Trunnions and Riser Clamps 18-010 DWG-011 Dummy Supports 18-011 DWG-012 Support Lugs and Steel Plate and Isolation Pad for SS Lines 18-012 DWG-013 Gusset Supports 18-013 DWG-014 Hold Downs 18-014 DWG-015 Hold Downs 18-015 000.250.2158 Supports - Structural Steel (Sizing for Piping Layouts Only) 18-016 000.250.2159 Supports - Concrete (Sizing for Piping Layouts Only) 18-017 000.250.2155 Cold Piping Supports 19. Modules 19-001 19-001 Modular Piping Design Instructions 19-002 19-002 Module Transportation Envelope Design Criteria 19-003 000.200.1061 Application on Module Boundaries on P&IDs Page 11 of 12 Practice 045 250 0020 17 March 2022 PIPING DESIGN GUIDE - INDEX 20. Material Handling 20-001 000.200.1067 Material Handling Strategy 20-002 20-002 Typical Material Handling Devices 21. Miscellaneous Practices and Guidelines 21-001 000 250 50028 Internal Cleaning of Piping Systems 21-002 000.250.50050 Piping Pressure Testing 21-003 000 250 50300 Heat Tracing for Piping/ Equipment And Instruments 21-004 000 250 4300 Steam Tracing Details 21-005 000.250.1600 Piping Design - Fluid Heat Tracing Execution Requirements 21-006 000.250.2300 Piping Design - Revamp, Brownfield and Tie-Ins 21-007 000 250 2301 Tie-In General Guidelines 21-008 000 250 50027 Tie In Package 21-009 000.250.3705 Piping Materials Engineering - Line Numbering and Line List 21-010 21-010 Definitions Page 12 of 12 ® 21. Plant Arrangement - Plot Plan Development Miscellaneous 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 1 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. Date Originator's Name & Initials APPROVALS Reviewed/Checked By Name & Initials SIGNATURES Pages DATE Lead Engineer: Project Manager: Client Representative: ISSUED FOR : Design Copyright © 2007, Fluor Corporation. All Rights Reserved. Construction Other Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 2 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS Record of Revisions Rev. No. Date Copyright © 2007, Fluor Corporation. All Rights Reserved. Description Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 3 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS Table of Contents Section 1.0 GENERAL .....................................................................................................................................................4 2.0 PRODUCTS...................................................................................................................................................7 3.0 EXECUTION.................................................................................................................................................8 4.0 ATTACHMENTS........................................................................................................................................10 Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 4 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS 1.0 GENERAL 1.1 Summary A. Scope of Specification This specification prescribes the requirements for internal cleaning procedures of piping systems, including the following: • • • • B. Cleaning contractor requirements Precleaned material requirements Field flushing and cleaning requirements Field passivation of stainless steel piping systems Work Not Included Not included in this specification are the flushing, cleaning, passivation, and sterilization of stainless steel hygienic piping systems for biotech, pharmaceutical and micro electronics facilities. C. Related Specifications The following specifications prescribe items of related Work: • • • 000.250.50003 000.250.50025 000.250.50026 Piping - Material Specification Line Class – Process and Utility Piping Shop Fabrication and Handling – Process and Utility Piping Field Fabrication and Installation – Process and Utility Piping Coordinate Work prescribed by this specification with Work prescribed by the above listed specifications. D. Related Technical Requirements 1. 2. E. Complete service index and assigned cleaning procedure. Individual cleaning procedures. Terminology 1. Blowout: Blowing of a vapor such as air, nitrogen, or steam at sufficient velocity to remove all foreign matter from piping systems. 2. Chemical Cleaning: Cleaning which involves the use of chemical agents to dissolve and remove the contaminants. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 5 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS 3. Cleaning: The process of removing deposits, scales, corrosion products, or other foulants which restrict flow, impair heat transfer, or contaminate product being conveyed in the piping systems. 4. Degree of Cleaning: A detailed description of exactly to what extent contaminants shall be removed from the piping system. 5. Disinfecting: Removal of contaminants harmful to human health if contained in potable water. 6. Field Cleaning: Any cleaning procedure performed on piping systems after field installation. 7. Flushing: Circulating flushing fluid at sufficient velocity to remove all foreign matter. 8. Mechanical Cleaning: Cleaning accomplished by hand, power tool, or abrasive cleaning. 9. Hydro-blasting: Internal cleaning of assembled piping accomplished by blasting with high pressure water without additives using nozzles attached to the end of remote guided rotating hose. 10. Neutralization: Reaction between hydrogen ion from an acid and hydroxyl ion from a base to produce pH neutral water. 11. Paint Stripping: Removal of mill applied varnishes or other paint. 12. Passivation: Formation of a protective oxide film by pickling or other processes for resistance to corrosive attacks on the material. 13. Pickling: Soaking or flushing with an acid solution to remove rust, mill scale, or to form an oxide film on the internal or external surfaces. 14. Pre-cleaned Products: Materials that have been chemically cleaned, mechanically cleaned, paint stripped, disinfected, passivated, rinsed, pickled, or protected from corrosion by shop fabricator or manufacturer before installation. 15. Rinsing: Removal of residual cleaning agents or chlorides for stainless steel by washing out with fresh, de-ionized, or de-mineralized water. 1.2 References The publications listed below form part of this specification. Each publication shall be the latest revision and addendum in effect on the date this specification is issued for construction unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, Work included in this specification shall conform to the applicable provisions of these publications. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 6 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS A. ASME (American Society of Mechanical Engineers) 1. 2. B. Cleaning Equipment for Oxygen Service Pamphlet 6. Piping Systems for Dry Chloride NACE No. 2 Near-White Metal Blast Cleaning SSPC (Steel Structures Painting Council) 1. 2. 1.3 G4.1. NACE (National Association of Corrosion Engineers) 1. F. Disinfecting Water Mains Chlorine Institute 1. E. C651 CGA (Compressed Gas Association, Inc.) 1. D. Power Piping Process Piping AWWA (American Water Works Association) 1. C. B31.1 B31.3 SSPC-SP-10 Near-White Metal Blast Cleaning SSPC-VIS-1 Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning Submittals A. Cleaning Contractor Requirements Alternative cleaning procedures not specified in this document may be prepared and submitted to Owner for approval. Special cleaning procedures that are normally subcontracted to and performed by cleaning contractors such as Oxygen Cleaning and proprietary cleaning procedures such as hydro-blasting shall be submitted to the Owner approval. These procedures shall include the following: • • • • • • Detailed steps of the cleaning or passivating procedure Chemicals and equipment to be used Required time for each step Process temperatures Disposal or recovery procedures Facility Support Requirements Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 7 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS • • 1.4 Inspection and Quality Assurance Safety Precautions Quality Assurance A. General 1. 2. Cleaning Procedures a. All cleaning procedures will be specified with a degree of cleaning required and an inspection procedure to ensure the degree of cleanliness has been achieved. b. For chemically and mechanically cleaned surfaces, an inspection record will be filled out by the cleaning contractor. Refer to Attachment 14. Pre-cleaned Material Upon delivery of pre-cleaned material to the jobsite, inspection, storage, and installation procedures will be done in accordance with Project Specification 000.250.50026. B. 2.0 Qualifications 1. Cleaning procedures will be performed by a reputable cleaning contractor approved by the Owner. 2. Utilize personnel who are trained in the cleaning, protection techniques, and safety rules. PRODUCTS 2.1 General This section includes products to be pre-cleaned and delivered to the construction site with appropriate protection, identification, and tagging. 2.2 Materials A. Manufacturer Cleaning Requirements Pre-cleaned materials to be supplied by the manufacturer or supplier are specified in Project Specification 000.250.50003. B. Shop Fabricator Cleaning Requirements 1. Pre-cleaned materials to be supplied by the shop fabricator will be noted on the piping drawings in accordance with Project Specification 000.250.50025. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 8 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS C. 2. Completely remove weld slag, flux, debris, grease, oil, and any foreign matter on the surfaces. 3. Protect cleaned surfaces. Specialized Cleaning Procedures before Installation Refer to Section 4.0 of this specification, for a complete list of cleaning procedures. 3.0 EXECUTION 3.1 General This section includes the requirements and procedures for field cleaning and protection of all process and utility piping after installation and before commissioning. A. B. Field Cleaning Requirements 1. Completely remove weld slag, flux, debris, grease, oil, and any foreign matter on the surfaces of field fabricated items. 2. Re-clean all pre-cleaned surfaces as specified in accordance with this specification. 3. Protect cleaned surfaces in accordance with this specification. General Preparation for Cleaning 1. All cleaning will be done after pressure testing. 2. Schedule field cleaning as close to the commissioning of the equipment as possible. 3. Protect threaded connections, flange faces, and valves to prevent damage by abrasives. 4. Block off, disconnect, or remove the following items from the piping system to be cleaned: • • • • • • • • Filters and strainer screens Exposed instruments, gages, and cylinders Orifice plates Oil reservoirs Relief valves, control valves, and plug cocks Expansion joints Reciprocating compressor pulsation bottles Exchangers Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 9 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS • Materials that may become damaged by cleaning solutions or procedures such as items with organic seals 5. Do not allow aluminum, copper, galvanized steel, magnesium, or zinc surfaces to come in contact with solutions having a pH of less than 4.0 or a pH of more than 10. 6. Do not allow austenitic stainless steel to come in contact with the following materials: a) Acid solutions containing halides or chemicals such as hydrochloric acid. Alternative solvents are acceptable provided the diluted chloride content does not exceed 25 ppm (25 cm3/m3.) b) Caustic soda (NaOH) solutions. c) If degreasing is required, sodium carbonate and trisodium phosphate solutions may be used, provided the chloride content does not exceed 50 ppm (50 cm3/m3.) d) Rinse water that is not clean or exceeds 50 ppm (50 cm3/m3) chloride. 3.2 7. Do not introduce chemical solution into piping unless high point vents and low point drains (supplied by piping contractor) are available to ensure proper filling and complete removal of solutions. 8. Do not apply heat directly to piping containing acid solutions. Cleaning Procedures after Installation A. B. Service Index 1. Each service utilized in the process and utility piping is listed in the service index found in Attachment 01. 2. A particular cleaning procedure is assigned for all piping systems which utilize this service. Cleaning Procedures 1. C. Refer to Section 4.0, of this specification, for a complete list of cleaning procedures. Identification of Cleaned Item 1. Provide and install metal tag for cleaned items at all valves and connections to avoid subsequent contamination and to identify potential hazard. Tag will read as follows: WARNING: Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 10 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS INTERNALLY CLEANED AND PRESSURIZED; KEEP SEALED UNTIL COMMISSIONING. (DATE) 2. 4.0 Tag will be yellow with black letters and at least 8 inches (200 mm) by 10 inches (250 mm), secured with 14 gage stainless steel wire. ATTACHMENTS Attachment 01 Service Index with Assigned Cleaning Procedures (15Aug2007) Attachment 02 Cleaning Procedures before Installation: Cleaning Procedure No 1: Near-White Metal Blast Cleaning of Internal Carbon Steel Piping (15Aug2007) Attachment 03 Cleaning Procedures after Installation: Cleaning Procedure No 2: Cleaning and Water Flushing (15Aug2007) Attachment 04 Cleaning Procedures after Installation: Cleaning Procedure No 3: Air, Nitrogen, and Steam Cleaning (15Aug2007) Attachment 05 Cleaning Procedures after Installation: Cleaning Procedure No 4: Water Flushing and Disinfection (15Aug2007) Attachment 06 Cleaning Procedures after Installation: Cleaning Procedure No 5: Water Flush of Precleaned Systems (15Aug2007) Attachment 07 Cleaning Procedures after Installation: Cleaning Procedure No 6: Passivation of Stainless Steel (15Aug2007) Attachment 08 Cleaning Procedures after Installation: Cleaning Procedure No 7: Alkaline Detergent Wash for Oil and Grease Removal – Carbon Steel Pipe Only (15Aug2007) Attachment 09 Cleaning Procedures after Installation: Cleaning Procedure No 8: Alkaline Detergent Wash for Oil and Grease Removal – Stainless Steel Pipe Only (15Aug2007) Attachment 10 Cleaning Procedures after Installation: Cleaning Procedure No 9: Solvent Cleaning for Rust and Mill Scale Removal (Pickling) – Carbon Steel Pipe Only (15Aug2007) Attachment 11 Cleaning Procedures after Installation: Cleaning Procedure No 10: Post-Cleaning Passivation – Carbon Steel Pipe Only (15Aug2007) Attachment 12 Cleaning Procedures after Installation: Cleaning Procedure No 11: High Pressure Water – Carbon Steel Pipe Only (15Aug2007) Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Page 11 of 11 ® INTERNAL CLEANING OF PIPING SYSTEMS Attachment 13 Cleaning Procedures after Installation: Cleaning Procedure No 12: Chemical Cleaning for Oxygen Service (15Aug2007) Attachment 14 Pipe Cleaning Inspection Record (15Aug2007) End of Specification Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 01 - Page 1 of 1 ® INTERNAL CLEANING OF PIPING SYSTEMS Service Index with Assigned Cleaning Procedures Service Material Cleaning Procedure Boiler feed water CS / SS 2 Cooling water supply / return CS / SS 2 Condensate (Class 150, 300, 600) CS / SS 2 Nitrogen, Air CS / SS 3 Steam relief valves CS / SS 3 Steam (Class 15, 150, 300, 600) CS / SS 3 Potable water CS 4 Lube and seal oil systems CS 2, 7, 9, 10 Lube and seal oil systems SS 2, 8 Centrifugal and axial compressor suction CS 1 Reciprocating and rotary compressor suction and interstage CS 2, 7, 9, 10 Positive displacement pump suction CS 2, 7, 9, 10 Steam turbine inlet > 625 psig CS 2, 7, 9, 10 Steam turbine inlet < 625 psig CS 3 Chlorine (Refer to Note 1.) CS 2, 7, 9, 10 Oxygen (Refer to Note 2.) CS 1, 2, 7, 9, 10, 12 CS = SS = CARBON STEEL STAINLESS STEEL Note 1: Cleaning will be done in accordance with Chlorine Institute Pamphlet 6 (1, 1, 1, Trichloroethane will be used as solvent for Procedure 9. Care will be taken to remove all solvent.). Note 2: Cleaning will be done in accordance with CGA G4.1 Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 02 - Page 1 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures before Installation: Cleaning Procedure No 1: Near-White Metal Blast Cleaning of Internal Carbon Steel Piping A. B. Scope of Procedure 1. This specification covers the requirements for internal cleaning of carbon steel piping by sandblasting to white metal and internal protection of pipe spools from corrosion during shipment and temporary storage before installation. This is sometimes referred to as MSF (Mill Scale Free) Piping. 2. Where internal cleaning is required, piping spools shall refer to this specification, and a list of these spools by line number shall be attached to this specification. Preparation for Cleaning 1. Clean piping after shop pressure testing. 2. Protect threaded connections and flange faces to prevent damage by abrasives. 3. Block off, disconnect, or remove from the piping system to be cleaned, the following items: • • • • • • • • • • • • Bearings Cylinders Filters Instruments Mechanical equipment Vessels Oil reservoirs Orifice plates Plug cocks Relief valves Screens Valves 4. Take special care when selecting blast cleaning abrasives. Use properly graded abrasives to obtain the specified surface profile. 5. When blast cleaning with steel grit or a mixture of steel shot, select the pressure and blast angle to obtain a uniform surface profile. 6. Do not blast clean when the surface temperature is less the 5F (-15°C) above the atmospheric due point or the relative humidity is greater than 85 percent. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 02 - Page 2 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures before Installation: Cleaning Procedure No 1: Near-White Metal Blast Cleaning of Internal Carbon Steel Piping 7. C. D. E. Where it is not practical to internally clean a spool due to configuration, components may, with prior Owner’s approval, be internally cleaned prior to welding and subsequently welded using the GTAW root method with inert internal purge. Materials 1. Use abrasives which are sharp, clean, and neutral pH; silica sand, chilled iron grit, or shot sized to give a maximum 2 mils (50.8 microns) in height of surface profile. 2. Copper slag abrasive is not permitted. 3. Clean all recycled abrasives. 4. For corrosion protection, use Oakite special protective oil supplied in the original and sealed Oakite containers, or alternate corrosion protection materials approved by Cleaning Procedure 1. Prior to blast cleaning, remove weld slag, flux, debris, grease, oil, and other foreign materials from surfaces of piping. 2. Blast clean internal surfaces of piping in accordance with NACE No. 2 and SSPC-SP-10. 3. Following the blast cleaning, blow off internal surfaces with clean, dry, compressed air or by vacuum to remove all traces of blast products. 4. Straight pipe lengths of 20 foot (6 meters) maximum are recommended to ensure that proper cleaning and removal of sand can be accomplished. 5. In order to ensure a clean completed spool, where practical, each weld will be cleaned internally after it is made. Cleaning of the weld area will be by sandblasting, wire brushing, or grinding. Degree of Cleaning The removal of mill scale, rust, weld spatter, oil, and grease. F. Inspection 1. Work performed under this specification will be subject to examination and inspection by the Owner. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 02 - Page 3 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures before Installation: Cleaning Procedure No 1: Near-White Metal Blast Cleaning of Internal Carbon Steel Piping 2. The Owner or its authorized representative shall have reasonable access to the Contractor's work place to inspect the work during each phase of operation. 3. The following items shall be subject to inspection and approval: • • • • • G. Type and cleanliness of abrasives Cleaning method used prior to blast cleaning Humidity / dew point Thickness of protective coating Internal surfaces cleanliness in Corrosion Protection 1. Immediately following the internal blast cleaning, spray the inside of the pipe with Oakite special protective oil using a low pressure non-atomizing solid spray to obtain an internal protective coverage of 1400 to 1900 ft2/gal (34 to 47 m2/litre) or use corrosion protection approved by the Owner. The following approved alternate methods may be used: a. Immediately following the internal cleaning, the inside of the pipe shall be sprayed with a 4 percent solution of Shell Oil Company's VPI No. 250 or equal. This product is a vapor phase inhibitor sold by Shell Oil Company in crystalline powder form. The solution is prepared as follows: • • • 1 lb VPI No. 250 2-1/2 gallons (9.5 litres) Isopropyl alcohol * 1/2 gallon (2 litres) water Note: * Flammable; avoid prolonged breathing Interior surfaces shall be thoroughly wetted with the solution. A minimum of 2 gallons (8 litres) for each 100 cubic feet (3 cubic meters) of internal volume shall be used. b. VPI No. 250 may be applied in the crystalline powder form, as purchased. This method requires blowing equipment to distribute it uniformly on the inside surface of the pipe spool, applied in such a manner that no unprotected surface is more than 12 inches (305 mm) from the powder. A minimum of 2 to 3 grams for every cubic foot of internal volume (71 to 106 grams for every cubic meter) shall be used. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 02 - Page 4 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures before Installation: Cleaning Procedure No 1: Near-White Metal Blast Cleaning of Internal Carbon Steel Piping H. Preparation for Shipment 1. I. All openings will be completely sealed off to prevent any exchange of atmosphere. This will be done as rapidly as possible, after interior surfaces are treated with the protective coating. a. Flanged openings having provisions for bolting shall be sealed with at least 1/4 inch (6 mm) steel covers, with 1/8 inch (3 mm) flat neoprene gasket material. The cover and gasket will be held securely in place by full bolting for flanges with 6 bolt holes or less; secure with 50 percent bolting for more than 6 bolt holes. Bolts will be 1/8 of an inch (3 mm) smaller in diameter (minimum) than flange bolt hole diameter. b. Threaded or socketweld connections will be cleaned and plugged, or capped with metal or plastic protectors securely sealed at the joints with waterproof cloth tape. c. The open ends of pipe shall be protected with metal caps securely sealed at the joints with waterproof cloth tape. Identification and Tagging 1. Identify piping, fittings or components which are mill scale free by marking each item with MSF painted in white along its full length and covered ends. Space the MSF no more than 5 feet (1.5) apart, with letters no less than 1-1/2 inches (38 mm) high. 2. Tag components with stainless steel tags marked with the symbol, MSF. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 03 - Page 1 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 2: Cleaning and Water Flushing A. Scope of Procedure This procedure covers flushing and cleaning of piping systems after assembly and erection. B. C. Preparation for Cleaning Procedure 1. All pipe runs and joints will be visually inspected for proper installation and continuity. 2. Equipment with restricted flow passages or inaccessible areas where sediment could collect shall either be bypassed or furnished with adequately sized temporary protection strainers. 3. If system pumps are to be used for flushing and do not have a permanent suction strainer, they will then have a temporary strainer installed between the suction valve and the pump. The temporary strainer will be in accordance with Project Specification 000.250.50003. 4. Where flushing water is re-circulated and not wasted to sewers, temporary strainers and/or baskets will be installed at all sumps, tanks, and other accessible areas where extraneous material flushed from the piping system can be collected and removed. 5. To prevent contamination of instruments, all instrumentation lines will be disconnected during the flushing operation. These lines will be cleaned separately by blowing out with air or flushing with water. All instrumentation lines are to be reconnected after completion of the cleaning operation. Materials Fresh, clean water will be used as the flushing and cleaning agent. D. Equipment Not applicable. E. Cleaning Procedure 1. All pipelines shall be flushed at no less than their design flow rate. Consider a minimum flush velocity of 2.5 m/s (8.2 ft/s) to adequately remove rust. Where possible, piping systems should be sectionalized, and full system flow rates provided through individual sections. Large diameter lines where design flow rates are not practical will have flow rates specified by client. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 03 - Page 2 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 2: Cleaning and Water Flushing 2. F. Strainers and baskets should be inspected frequently during the flushing operation and cleaned if necessary. Chemical Solutions and Rinse Not applicable. G. Degree of Cleaning Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment. H. Inspection Flushing operations shall continue until extraneous material is no longer collected at strainers and baskets. Flushing can be considered complete when, flushing at the required velocity; no visible dirt is removed from the system for at least 2 minutes. Check a sample collected in a water bottle for sediments 5 minutes after sampling. I. Post-Cleaning Procedure Upon completion of flushing, all temporary strainers and baskets will be removed from the piping system unless otherwise specified by Client. Tanks and sumps are to be drained and thoroughly cleaned. Equipment and piping will be returned to their pre-flush condition. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 04 - Page 1 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 3: Air, Nitrogen, and Steam Cleaning A. Scope of Procedure This procedure covers the blowing-out of piping systems after assembly and erection. B. C. Preparation for Cleaning Procedure 1. All pipe runs and joints will be visually inspected for proper installation and continuity. 2. Equipment that has restricted flow passages or inaccessible areas where scale or particles could collect shall either be bypassed or removed and replaced by a spool piece. 3. To prevent contamination of the instruments, all instrumentation lines will be disconnected during the blowing out operation. These lines will be blown out separately and reconnected at the conclusion of the cleaning operation. 4. All low points and dirt legs must have blow-off valves. Materials 1. Blowing agent will be one of the following (as determined by Owner): • • • D. Oil free air Nitrogen Steam Equipment Not applicable. E. Cleaning Procedure All pipelines will be thoroughly blown through to ensure complete cleansing of all foreign matter. Care will be taken that the discharge point of the pipeline is in a safe location and so arranged that the discharge stream is dissipated harmlessly. All personnel will be kept clear of the discharge area during the blowing out operation. 1. For air blowing, systems are cleaned by pressurizing the piping system and then opening a temporary quick-acting valve at the end of a header to allow depressurization to atmosphere (a silencer may be required). In general, a number of blows for each system Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 04 - Page 2 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 3: Air, Nitrogen, and Steam Cleaning will be necessary to ensure cleanliness, which shall be proven with a white paper or cloth target. 2. F. For steam blowing, lines shall have a warm-up period to allow gradual warm-up and expansion before high volume blow-out is commenced. Each system shall be blown with the type of steam (e.g. low, medium, or high-pressure steam) it will carry during normal operation. Volumetric steam rate during blowing shall be at least 3 times the maximum operating volumetric flow rate. The system shall be blown initially at pressures near to atmosphere in order to expel large objects from the system. Gradually raise the pressure during later blows to the maximum operating pressure. The lines are to be blown for more than 10 minutes and steam should only be blown from a clean piping system into unclean systems. There shall be a minimum of 3 blows conducted. Between the blows there should be a cool down period of at least 60 minutes for un-insulated piping systems and 240 minutes for insulated piping systems or until the pipe surface temperature has reached 212F (100°C). Additional requirement for steam lines to turbines include a minimum of 15 blows shall be conducted. Use target plates of polished aluminium or copper to determine cleanliness. Target plate recommended minimum size is 3 x 3 inches (75 x 75 mm). Chemical Solution and Rinse Disposal Not applicable. G. Degree of Cleaning Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment. H. Inspection Procedure Following blow-through, all low points and drip legs are to be blown down until all residual matter is removed. I. Post-Cleaning Procedure All piping and equipment will be returned to their pre-blowout condition. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 05 - Page 1 of 3 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 4: Water Flushing and Disinfection A. B. C. Scope of Procedure 1. This procedure covers flushing and disinfecting of above and below ground potable water piping systems after assembly and erection. 2. This procedure requires compliance with all federal, state, and local laws and regulations that may be applicable. Preparation for Cleaning Procedure 1. All pipe runs and joints will be visually examined for proper installation and continuity. 2. Equipment that has restricted flow passages or inaccessible areas where sediment could collect will either be bypassed or removed and replaced by a spool piece. Materials 1. Flushing Procedure - Potable Water 2. Disinfecting Procedure a. Forms of chlorine can be calcium hypochlorite, sodium hypochlorite, or liquid chlorine packaged in steel cylinders. Note: Liquid chlorine must be used in conjunction with a chlorinator. D. b. Solution strength will be in accordance with AWWA C651, latest edition. c. Due to its hazardous nature, adequate safety precautions and instruction will be employed when handling any form of chlorine. Equipment Requirements will be dependent on the system to be disinfected. E. Cleaning Procedure 1. Flushing Procedure Prior to Disinfecting Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 05 - Page 2 of 3 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 4: Water Flushing and Disinfection 2. a. All pipelines will be flushed with potable water before disinfecting. Minimum flushing velocity should be 2.5 feet per second (0.8 m/s) for water mains. b. Flushing operations will continue until water discharges are clear and free from turbidity and extraneous materials. c. Upon completion of the flushing operation, systems will be drained and all items previously removed, bypassed, or disassembled will be reinstalled, reassembled, and made ready for the disinfecting procedure. Disinfecting Procedure Piping systems will be filled with a chlorine solution and left standing for an adequate contact period. Note: Contact time will be in accordance with AWWA C651, latest edition. a. 3. Chlorine Application (1) For large systems, a concentrated chlorine solution feed can be proportioned with the incoming potable water filling the system. (2) On small systems, the chlorine solution can be mixed in a container to the required concentration and fed into the piping by gravity feed or pump. Post-Flushing Procedure After the applicable contact period, the heavily chlorinated water will be flushed from the system with potable water until the chlorine concentration in the water leaving the system is no higher than that in the incoming potable water, or less than 1 ppm. F. Chemical Solution and Rinse Disposal 1. Outlet pipes or nozzles at flushing discharges will be directed to a safe location where chance of damage from disposal of flushing water is minimal. 2. All spent chemical solutions and rinses must be disposed of in an environmentally acceptable manner. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 05 - Page 3 of 3 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 4: Water Flushing and Disinfection 3. G. H. If any liquid effluent streams are discharged to a sewer system connected to a public sewage treatment plant, they must comply with the applicable state, provincial and local pretreatment regulations. Degree of Cleaning 1. Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment. 2. Disinfection of contaminants harmful to human health if consumed. Inspection Procedure Inspection will be in accordance with AWWA C651, latest edition. I. Post-Cleaning Procedure Reassembly procedures will be in accordance with Section E.1.c before disinfecting procedure. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 06 - Page 1 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 5: Water Flushing of Pre-cleaned Systems A. Scope of Procedure This procedure covers flushing of pre-cleaned piping systems after assembly, erection, and testing. B. C. Preparation for Flushing Procedure 1. Before installation, all piping spools will be swabbed clean and flushed so that the erected piping will be clean and free from foreign material. 2. If applicable, special cleaning procedures other than swabbing clean and flushing before installation are specified in the cleaning procedures before installation section. 3. Hydrostatic testing requirements must be completed before flushing. Materials Hydrostatic test fluid D. Equipment Not applicable. E. Cleaning Procedure Flushing will be accomplished after completion of pressure testing and all necessary corrections have been made. The extent of flushing will be the drawing off of the water used for hydrostatic testing of the piping. F. Chemical Solution and Rinse Disposal Not applicable. G. Degree of Cleaning Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 06 - Page 2 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 5: Water Flushing of Pre-cleaned Systems H. Inspection Procedure Piping spools will be clean and free from foreign material before installation. Care will be taken to ensure cleanliness during installation. I. Post-Cleaning Procedures Not applicable. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 07 - Page 1 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 6: Passivation of Stainless Steel A. Scope of Procedure This procedure covers the flushing, cleaning, and passivation of stainless steel piping systems after assembly and erection. B. C. Preparation for Cleaning Procedure 1. Using P&IDs and other suitable piping diagrams, a detailed step-by-step plan will be developed which describes the procedure for passivating the system. Particular care should be exercised that the planning considers the heating of the solutions, acid addition techniques, neutralization, and waste acid storage. This plan will be submitted to the Owner for approval prior to the start of passivation. 2. All pipe runs and joints will be visually inspected for proper installation and continuity. 3. Equipment with restricted flow passages or inaccessible area where sediment could collect shall either be bypassed or furnished with adequately sized temporary protection strainers. 4. If system pumps are to be used for flushing and do not have a permanent suction strainer, they shall then have a temporary strainer installed between the suction valve and the pump. The temporary strainer shall be as specified in Project Specification 000.250.50003, according to individual line class. 5. Where flushing water is re-circulated and not wasted to sewers, temporary strainers and/or baskets will be installed at all sumps, tanks, and other accessible areas where extraneous material flushed from the piping system can be collected and removed. 6. To prevent contamination of instruments, all instrumentation lines shall be disconnected during the flushing operation. These lines will be cleaned separately by blowing out with air or flushing with water. All instrumentation lines are to be reconnected after completion of the cleaning operation. 7. Pressure testing will be done prior to the cleaning procedure. Materials 1. The following criteria will be followed for water used as a flushing agent: • Water containing more than 200 ppm chlorides will not be used. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 07 - Page 2 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 6: Passivation of Stainless Steel 2. D. • Water containing more than 50 but less than 200 chlorides shall be treated with an inhibitor of 1.5 percent soda ash and 0.5 percent sodium nitrate. The chloride content of the soda ash and sodium nitrate will not exceed 500 ppm. These percentages are by weight. • Water containing less then 50 ppm chloride does not require inhibitor treatment. The nitric acid used shall be reagent grade material purchased specifically for this procedure. Recycled material from a previous job is not acceptable. Acid may, however, be reused for more than one system within the facility if appropriate acid solution quality is maintained. Equipment In order to facilitate the passivation procedure, an outside 300 series stainless steel tank and pump may be used to circulate passivation solutions. System tanks and pumps should be used, if available. E. Cleaning Procedure 1. All pipe lines will be flushed with water of specified criteria at no less than their design flow rate. Where possible, piping systems should be sectionalized, and full system flow rates provided through individual sections. Large diameter lines where design flow rates are not practical shall have flow rates specified by Owner. 2. Strainers and/or baskets should be inspected frequently during the flushing operation and cleaned if necessary. 3. During the flushing operation check all mechanical joints (temporary and permanent) for any leaks that may have developed since the pressure test. Do not introduce passivation chemicals until making sure there are no leaks. 4. The passivation procedure will be as follows: a. A 10 to 15 weight percent nitric acid solution is introduced into the system and recirculated for a minimum of 30 minutes at a temperature between 115 F (46°C) and 130 F (54°C). The solution should be circulated at a minimum linear bulk velocity of 2 ft/s (0.6 m/s). A linear bulk velocity of 5 ft/s (1.5 m/s) is preferred. Care should be exercised that none of the system is exposed to nitric acid of a concentration greater than 20 weight percent or to a temperature greater than 130 F (54°C ). Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 07 - Page 3 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 6: Passivation of Stainless Steel 5. F. G. b. Record the passivation conditions, including start time, finish time, temperatures, and linear bulk velocity. c. After passivation is completed, caustic should be added very slowly to bring the pH into the 4 to 6 range. The amount of caustic should be estimated based on the amount of acid used to make the acid solution in the system. Care should be used to ensure that the pH does not go above 6. d. Waste neutral solution to designated drain. e. To minimize staining, do not allow surfaces to dry between successive steps of the passivation and rinsing procedure. The rinsing procedure shall now be done with de-mineralized water. Heat water to 180 F (82°C) and re-circulate throughout system for final rinse. Chemical Solution and Rinse Disposal 1. In some cases, acid may be pumped to another system for passivation without neutralization. In these cases, the acid is rinsed from the system by water with the pH checked to ensure adequate neutralization. 2. The acid solution should be removed and placed in drums. If plastic lined metal drums are used, additional caustic may be added to the drums to bring the pH above 9, to protect the metal drums from acid attack. Arrangements for the removal and proper disposal of waste acid drums shall be approved by Owner prior to use. 3. Disposal of waste materials shall be in accordance with applicable local, state and federal laws and regulations. Degree of Cleaning 1. Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment. 2. Removal of all oil and greases. 3. Protection of surface to prevent rust bloom following cleaning and prior to start-up. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 07 - Page 4 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 6: Passivation of Stainless Steel H. I. Inspection Procedure 1. Following the final rinse, visually inspect the representative portions of system for evidence of gross contamination. Adequate lighting must be provided. This includes oil, grease, welding flux or slag, metal particles, and dirt. Inspection should be supplemented with borescopes or mirrors, as necessary to access surfaces that are difficult to see. There shall be no evidence of any foreign materials, nor shall the system be etched, pitted, or stained. 2. Rub representative surfaces with a clean lint-free white cotton cloth and black cotton cloth, and observe for contamination wiped off on the cloth. A smudge on the cloth is evidence of contamination. Post-Cleaning Procedures Upon completion of flushing, all temporary strainers and/or baskets will be removed from the piping system unless otherwise specified by Owner. Tanks and sumps are to be drained and thoroughly cleaned. Equipment and piping will be returned to their pre-flush condition. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 08 - Page 1 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 7: Alkaline Detergent Wash for Oil and Grease Removal – Carbon Steel Pipe Only A. Scope of Procedure This procedure covers the removal of oil, grease, and protective coatings from piping system after assembly and erection of carbon steel pipe. B. C. Preparation for Cleaning Procedure 1. Follow Cleaning Procedure 2, Cleaning and Water Flushing, except do not reconnect piping to pre-flush condition until final cleaning has been accomplished. 2. Provisions to isolate the equipment to be cleaned. 3. Provide vents at all high points and drains at all low points so that the system can be filled and drained completely. Materials Alkaline solution containing 3 percent NaOH, 1 percent sodium metasilicate, 1 percent trisodium phosphate, and 0.1 percent nonionic detergent. D. Equipment Tank and circulation equipment used for cleaning pipelines. E. F. Cleaning Procedure 1. Fill piping system with alkaline solution. 2. Heat solution to 170 F to 200 F (77°C to 93° C) and circulate intermittently for at least 6 hours. 3. Drain system and flush with fresh water until the effluent pH is less than 8. Chemical Solution and Rinse Disposal Federal, state, and local safety and water pollution control regulations should be consulted, particularly when large volumes of chemical solutions must be disposed of. Controlled release of large volumes of rinse water may be necessary to avoid damaging sewers or stream beds. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 08 - Page 2 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 7: Alkaline Detergent Wash for Oil and Grease Removal – Carbon Steel Pipe Only G. Degree of Cleaning Removal of all oil, grease, and protective coatings. H. I. Inspection Procedure 1. Visual inspection will be made of piping to determine degree of removal of contaminants following cleaning. 2. Points in the system chosen for inspection will be those sections least likely to be completely cleaned. 3. Inspection points are to be selected so that inspections can be carried out quickly and efficiently such as at flanged joints or openings, and full bore valves. 4. There will be no traces of oils, greases, paints, and similar contaminants. 5. Any contaminants which are judged to show insufficient cleaning will be considered reason for rejection. The necessary steps will be repeated until inspection passes. Post-Cleaning Procedure Upon completion of flushing, all temporary strainers and/or baskets will be removed from the piping system unless otherwise specified by Client. Tanks and sumps are to be drained and thoroughly cleaned. Equipment and piping will be returned to their pre-flush condition. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 09 - Page 1 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 8: Alkaline Detergent Wash for Oil and Grease Removal – Stainless Steel Pipe Only A. Scope of Procedure This procedure covers the removal of oil, grease, and protective coating from piping systems after assembly and erection of stainless steel pipe. B. C. Preparation for Cleaning Procedure 1. Follow Cleaning Procedure 2, Cleaning and Water Flushing, except do not reconnect piping to pre-flush condition until final cleaning has been accomplished. 2. Provisions to isolate the equipment to be cleaned. 3. Provide vents at all high points and drains at all low points, so that the system can be filled and drained completely. Materials Low chloride cleaning solution (25 ppm or less dissolved chlorides) D. Equipment Tank and circulation equipment used for cleaning pipelines. E. F. Cleaning Procedure 1. Fill piping system with cleaning solution specified above. 2. Rinse with low chloride water. 3. Drain system and purge with dry compressed air. Chemical Solution and Rinse Disposal Disposal must comply with federal, state, and local safety and water pollution control regulations. Controlled release of large volumes of rinse water may be necessary to avoid damaging sewers or stream beds. G. Degree of Cleaning Removal of all oil, grease, and protective coatings. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 09 - Page 2 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 8: Alkaline Detergent Wash for Oil and Grease Removal – Stainless Steel Pipe Only H. I. Inspection Procedure 1. Visual inspection will be made of piping to determine degree of removal of contaminants following cleaning. 2. Points in the system chosen for inspection will be those sections least likely to be completely cleaned. 3. Inspection points are to be selected so that inspections can be carried out quickly and efficiently such as at flanged joints or openings, and full bore valves. 4. There will be no traces of oils, greases, paints, and similar contaminants. 5. Any contaminants which are judged to show insufficient cleaning shall be considered reason for rejection. The necessary steps shall be repeated until inspection passes. Post-Cleaning Procedure Upon completion of flushing, all temporary strainers and/or baskets will be removed from the piping system unless otherwise specified by Owner. Tanks and sumps are to be drained and thoroughly cleaned. Equipment and piping will be returned to their pre-flush condition. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 10 - Page 1 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 9: Solvent Cleaning for Rust and Mill Scale Removal (Pickling) – Carbon Steel Pipe Only A. Scope of Procedure This procedure covers the removal of adherent rust and mill scale to leave bare metal in piping system after assembly and erection of carbon steel pipe. B. C. D. Preparation for Cleaning Procedure 1. Follow Cleaning Procedure 2, Cleaning and Water Flushing, except do not reconnect piping to pre-flush condition until final cleaning has been accomplished. 2. Follow Cleaning Procedure 7, Alkaline Detergent Wash for Oil and Grease Removal. 3. Provisions to isolate the equipment to be cleaned. 4. Provide vents at all high points and drains at all low points, so that the system can be filled and drained completely. Materials 1. Six percent hydrochloric acid containing 0.25 percent ammonium bifluoride inhibited with 2 gallons per 1000 gallons (2 liters per 1000 liters) Armohib 28 Rhodine 213 or equivalent approved by Client. 2. Inorganic acids such as phosphoric, nitric, and sulfuric acids are also widely used to remove rust and scale. These acids are highly toxic and require special handling. Organic acids such as citric, formic, hydroxy-acetic and sulfamic acid are gaining more popularity because of their relatively less toxic properties. 3. When acids are used for cleaning, they must be inhibited to reduce their corrosive action on the base metals. Various inhibitors are commercially available. The most familiar inhibitors are Rodine inhibitors made by Amchem Products. When inhibitors are added to the cleaning solutions, the rate of corrosion drops to as little as 0.001 pounds per square foot (0.005 kg/m2) per 24 hours. Equipment Tank and circulation equipment used for cleaning pipelines. E. Cleaning Procedure 1. Fill piping system with acid specified in Section C of this procedure. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 10 - Page 2 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 9: Solvent Cleaning for Rust and Mill Scale Removal (Pickling) – Carbon Steel Pipe Only 2. Heat solution to 160 F (71°C) and circulate for at least 15 minutes each hour for a minimum of 6 hours or until reaction is complete. 3. Take samples at least once per hour following circulation and test for acid strength and total iron concentration. If acid circulation drops below 3 percent, add acid to bring concentration to 5 percent. Continue cleaning until iron and acid concentrations reach equilibrium. 4. Drain system and flush with potable water (to which 0.1 percent citric acid may be added to reduce rusting). 5. Neutralize and passivate system according to Cleaning Procedure 10, Post-Cleaning Passivation – Carbon Steel Pipe Only. Note: If ammoniated citric acid or chelating agents are used as cleaning agent, further passivation is not required. 6. Drain system, open, and inspect. The cleaning procedure shall be dependent on the type of chemical cleaning agent specified. Time of chemical contact and temperature are dependent on the chemical cleaning agent and the degree of cleanliness required for the pipe service. F. G. Chemical Solution and Rinse Disposal 1. Disposal must comply with federal, state, and local safety and water pollution control regulations Controlled release of large volumes of rinse water may be necessary to avoid damaging sewers or stream beds. 2. Preferably, spent acid solution should be collected and stored prior to transfer to a scavenger contractor for disposal offsite. This solution will contain heavy metals whose discharge is strictly regulated. Degree of Cleaning Removal of all rust and mill scale. H. Inspection Procedure 1. During cleaning with hydrochloric acid, the solution will be analyzed at least once per hour for ferric iron and total iron. Ferric iron content greater than 0.4 percent and/or total Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 10 - Page 3 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 9: Solvent Cleaning for Rust and Mill Scale Removal (Pickling) – Carbon Steel Pipe Only iron content greater than 1.5 percent, with an increasing slope on the curve when iron is plotted versus time, indicates excessive corrosion and solutions should be dumped as fast as possible. 2. Carbon steel test pieces will be exposed in the piping, or if present, in the steam drum during cleaning using a pre-measured test coupon 1 inch by 1 inch by 1/8 of an inch (25 mm by 25 mm by 3 mm) minimum to obtain actual corrosion rate. Corrosion rate will be less than 0.02 mils (0.5 microns) per hour. 3. Visual inspection will be made of piping to determine degree of removal of contaminants following cleaning. 4. Points in the system chosen for inspection will be those sections least likely to be completely cleaned. 5. Inspection points are to be selected so that inspections can be carried out quickly and efficiently such as at flanged joints or openings, and full bore valves. 6. Cleaned surfaces will be visually examined under a lighting level, including both general and supplementary lighting of 250 foot candles (2700 Lm / m2) on the surfaces being examined. A lighting level of 70 foot candles (760 Lm / m2) may be used upon approval. Visual examination shall be supplemented with borescopes, mirrors, and other aids, as necessary, to properly examine inaccessible or difficult to see surfaces. Lights shall be positioned to prevent glare on the surfaces being examined. 7. There will be no scale, rust, or loose weld metal. Very light superficial rust, which is normal after cleaning, is allowed. 8. Any contaminants which are judged to show insufficient cleaning will be considered reasons for rejection. The necessary steps will be repeated until inspection passes. 9. Where usual examination is not practical, a clean-lint free white cotton cloth or filter paper, moistened but not saturated with high purity isopropyl alcohol (rubbing alcohol), may be rubbed against the surfaces at all openings. The presence of a smudge on the cloth or filter paper is evidence of incomplete cleaning and the cleaning will be repeated. 10. Removal of solids will be confirmed by the use of target plates during steam blowing. 11. Cleaning contractor to record cleaning results according to Attachment 14, Pipe Cleaning Inspection Record. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 10 - Page 4 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 9: Solvent Cleaning for Rust and Mill Scale Removal (Pickling) – Carbon Steel Pipe Only I. Post-Cleaning Procedure 1. Upon completion of flushing, all temporary strainers and/or baskets will be removed from the piping system unless otherwise specified by Client. Tanks and sumps are to be drained and thoroughly cleaned. Equipment and piping will be returned to their pre-flush condition. 2. Cleaned items will be tagged with a tag as specified in Section 3.2.C of the main body of this specification. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 11 - Page 1 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 10: Post-Cleaning Passivation – Carbon Steel Pipe Only A. Scope of Procedure This procedure covers the prevention of after-rusting of cleaned surfaces by chemical treatment for piping systems after assembly and erection of carbon steel pipe. B. C. Preparation for Cleaning Procedure 1. Follow Procedure 9, Solvent Cleaning for Rust and Mill Scale Removal (Pickling) – Carbon Steel Only, except do not reconnect piping to pre-flush condition until final cleaning has been accomplished. 2. Provisions to isolate the equipment to be cleaned. 3. Provide vents at all high points and drains at all low points so that the system can be filled and drained completely. Materials One of the following: D. 1. Solution of 2 to 5 percent phosphoric acid. 2. Solution of 1 percent caustic and 0.5 percent sodium nitrite. Equipment Tank and circulation equipment used for cleaning pipelines. E. Cleaning Procedure 1. Fill piping system with passivation agent specified above. 2. Heat solution to 180 F (82°C)and circulate for at least 2 hours. 3. Drain the system and air dry. 4. When the time between cleaning and start-up exceeds 10 days, Steps 1 and 2 will be used, followed by plugging all openings and pressurizing at 5 to 10 psig (34 to 69 kPag) of nitrogen. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 11 - Page 2 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 10: Post-Cleaning Passivation – Carbon Steel Pipe Only F. G. Chemical Solution and Rinse Disposal 1. Federal, state, and local safety and water pollution control regulations should be consulted, particularly when large volumes of chemical solutions must be disposed of. Controlled release of large volumes of rinse water may be necessary to avoid damaging sewers or stream beds. 2. Preferably, spent acid solution should be collected and stored prior to transfer to a scavenger contractor for disposal offsite. This solution contains heavy metals whose discharge is strictly regulated. Degree of Cleaning Passivation protection against after-rust and flushing free of alkaline deposits. H. Inspection Procedure During passivation, total pickup of particulate matter in compressor suction piping above 0.4 mils (10 microns) size by the flushing solution shall remain constant for at least one hour. I. Post-Cleaning Procedure Upon completion of flushing, all temporary strainers or baskets will be removed from the piping system unless otherwise specified by Owner. Tanks and sumps are to be drained and thoroughly cleaned. Equipment and piping will be returned to their pre-flush condition. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 12 - Page 1 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 11: High Pressure Water – Carbon Steel Pipe Only A. Scope of Procedure This procedure covers cleaning of piping using high pressure water. B. C. Preparation for Cleaning Procedure 1. All pipe runs and joints will be visually inspected for proper installation and continuity. 2. Equipment with restricted flow passages or inaccessible areas where sediment could collect shall either be bypassed or furnished with adequately sized temporary protection strainers. 3. Where water is re-circulated and not wasted to sewers, temporary strainers and/or baskets will be installed at all sumps, tanks, and other accessible areas where extraneous material flushed from the piping system can be collected and removed. 4. To prevent contamination of instruments, all instrumentation lines will be disconnected during the flushing operation. These lines will be cleaned separately by blowing out with air or flushing with water. All instrumentation lines are to be reconnected after completion of the cleaning operation. Materials Fresh, clean water, as per the High Pressure Water Contractor, will be used as the cleaning agent. D. Equipment The High Pressure Water Contractor will provide all equipment needed. E. Cleaning Procedure 1. All pipelines shall be flushed at no less than their design flow rate. Where possible, piping systems should be sectionalized, and full system flow rates provided through individual sections. Large diameter lines where design flow rates are not practical will have flow rates specified by client. 2. Strainers and baskets should be inspected frequently during the flushing operation and cleaned if necessary. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 12 - Page 2 of 2 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 11: High Pressure Water – Carbon Steel Pipe Only F. Chemical Solution and Rinse Disposal Not applicable. G. Degree of Cleaning Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment. Degree of cleaning shall be established by the owner. H. Inspection Procedure Inspection procedure shall be as per the High Pressure Water Cleaning contractor and approved by the owner. I. Post-Cleaning Procedure Upon completion of flushing, all temporary strainers and baskets will be removed from the piping system unless otherwise specified by Client. Tanks and sumps are to be drained and thoroughly cleaned. Equipment and piping will be returned to their pre-flush condition. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 13 - Page 1 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 12: Chemical Cleaning for Oxygen Service A. Scope of Procedure This procedure briefly discusses chemical cleaning, drying and purging of oxygen piping systems after assembly, erection and pre-cleaning testing. Cleaning methods, procedures, inspection, and packaging shall meet standard CGA G-4.1 “Cleaning Equipment for Oxygen Service”. Cleaning of the system shall be accomplished by flushing with chemicals at sufficient temperature, concentration, velocity and contact time to remove all contaminants, passivating and drying. The following procurement and erection procedures have been followed: B. 1. All pipe, tubing, fittings and valves purchased for the system have been pre-cleaned by the manufacturer or supplier. 2. All pipe, tubing, fittings and valves have been capped and sealed during shipping and storage to preclude rust and contamination. 3. All pipe, tubing, fittings and valves have been tungsten inert gas (TIG) welded on the first sealing pass. 4. Piping system has been kept clean and rust free during fabrication and erection, contamination kept to a minimum. Preparation for Cleaning Procedure 1. All pipe runs and joints shall be visually inspected for proper installation and continuity. 2. Adequate drains shall be provided at low points and vents at high points. 3. Pre-cleaned components, valves, filters, regulators and any other equipment that may be damaged or contaminated during the cleaning operation shall either not be installed until after the cleaning operation is completed or be by-passed. Spool pieces and jumpers along with required unions or flanges shall be provided and installed by the piping contractor. Inline socketweld valves subjected to chemical cleaning shall require valve manufacturer's approval of the cleaning procedures and the valve must be in its full open position during the cleaning operation. 4. Before cleaning with spool pieces in place, the system shall be hydrostatically tested in accordance with Project Specification 000.250.50050. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 13 - Page 2 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 12: Chemical Cleaning for Oxygen Service C. Materials Water connections will be available in some areas of the plant. Contractor is to contact field representative for availability and pressure. Contractor shall supply nitrogen and water when not available on site. D. Equipment Cleaning equipment and all mixing and blending equipment shall be provided by contractor and shall be located in a safe designated working area. E. Cleaning Procedure 1. Chemical cleaning is a highly specialized service and shall be done by a reputable cleaning contractor. 2. Cleaning procedures shall be prepared by contractor and submitted to engineer for review and approval. 3. Provide necessary safety ropes or isolation barricades to enclose all working area possible. 4. Supply water connections to wash down any chemicals spilled during cleaning. 5. Unauthorized personnel, as determined by the field engineer, are not permitted in the cleaning area during hazardous cleaning operations. 6. Drain, vents and temporary effluent piping shall be piped to ground level, use only gate valves on these lines. These drop lines should be posted and/or barricaded to keep out unauthorized personnel. 7. The cleaning and flushing operation shall be witnessed and approved by a representative of the owner. It is the responsibility of the contractor to continue the flush and clean operation until the owner approves of the final condition. 8. The contractor is to take all steps necessary to insure an acceptable flush to include but not limited to removal and replacement of any associated work in place. This is at no additional cost or schedule impact to the owner. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 13 - Page 3 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 12: Chemical Cleaning for Oxygen Service F. G. H. Chemical Solution and Rinse Disposal 1. Outlet pipes or nozzles at flushing discharges shall be directed to a safe location where chance of damage from disposal of flushing water is minimal. 2. All spent chemical solutions and rinses must be disposed of in an environmentally acceptable manner. Confirm offsite disposal of waste chemicals. 3. If any liquid effluent streams are discharged to a sewer system connected to a public sewage treatment plant, they must comply with the applicable provincial and local pretreatment regulations. Degree of Cleaning 1. Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment. 2. Removal of all traces of hydrocarbons in the system. Inspection Procedure The following tests shall be performed on interior of line while spool pieces are being removed and on interior of valves and equipment being installed to insure cleanliness of the system. I. 1. Fluorescent test: Random surfaces shall be examined with ultraviolet light ("black light") for traces of hydrocarbons. Any trace of hydrocarbons shall be reason for rejection. Filter paper may be used to wipe areas inaccessible to fluorescent test. Use hard filter paper to avoid leaving paper fibres behind. 2. Water break test: For use on small parts – Clean water poured on a metal surface should form a thin, unbroken film. Formation of droplets shall be considered evidence of contamination. 3. Visual examination: Shall show no mill scale or rust. Any mill scale or rust shall be considered reason for rejection. Post-Cleaning Procedure 1. Remove all spools, contaminated gaskets and jumpers used in the cleaning operations and install all pre-cleaned components. Inspect each component before installation into the Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 13 - Page 4 of 4 ® INTERNAL CLEANING OF PIPING SYSTEMS Cleaning Procedures after Installation: Cleaning Procedure No 12: Chemical Cleaning for Oxygen Service clean system. Any component that is contaminated or suspected of being contaminated must be re-cleaned. 2. After cleaning is completed and system is assembled and ready for operation, the system will be pneumatically tested using oil free nitrogen in accordance with Project Specification 000.250.50050. 3. After testing is completed, the system shall be purged with oil free nitrogen and maintained under pressure until ready for placement into service. Copyright © 2007, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-001 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50028 Date 15Aug2007 Attachment 14 - Page 1 of 1 ® INTERNAL CLEANING OF PIPING SYSTEMS Pipe Cleaning Inspection Record DATE: CONTRACT NO.: REV.: PO NO.: BY: REVIEWED: Cleaning Contractor: INITIAL AND DATE Cleaning Contractor Owner 1. Piping pressure tests completed for the system to be cleaned. Pipe lines included: 2. Piping system prepared for cleaning, including the protection of affected hardware, check of reactions to the piping materials, flushing, and temporary supports. 3. Piping system cleaned in accordance with the specification. The following processes were used: Mechanical: Detergent: Acid: Other: 4. Cleaning materials used on this pipe system were: 5. Test performed to verify cleanliness were satisfactory. These tests were: 6. Piping system passivated after cleaning with: 7. Piping system restored after cleaning. 8. Post-cleaning protection program instituted. 9. Cleaned piping system has been properly tagged and identified. DISTRIBUTION: Copyright © 2007, Fluor Corporation. All Rights Reserved. Cleaning Contractor Date Owner Date Construction Management Date Piping Engineering & Design 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 1 of 26 ® PIPING PRESSURE TESTING This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. Date Originator's Name & Initials APPROVALS Reviewed/Checked By Name & Initials SIGNATURES Pages DATE Lead Engineer: Project Manager: Client Representative: ISSUED FOR : Design Copyright © 2018, Fluor Corporation. All Rights Reserved. Construction Other Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 2 of 26 ® PIPING PRESSURE TESTING Record of Revisions Rev. No. Date Copyright © 2018, Fluor Corporation. All Rights Reserved. Description Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 3 of 26 ® PIPING PRESSURE TESTING Table of Contents Section 1.0 GENERAL ..................................................................................................................................................... 4 2.0 PRODUCTS ................................................................................................................................................... 7 3.0 EXECUTION ............................................................................................................................................... 10 4.0 REFERENCES ............................................................................................................................................ 26 5.0 ATTACHMENTS........................................................................................................................................ 26 Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 4 of 26 ® PIPING PRESSURE TESTING 1.0 GENERAL 1.1 Summary A. Scope of Specification This specification prescribes the methods, tasks, scope, and criteria for testing installed piping systems. Any deviation from this specification requires written authorization from Fluor Engineering. B. Work Not Included The following are excluded from the requirements of this specification: C. 1. Any package unit previously tested by the Manufacturer in accordance with the applicable codes. 2. Drain and sewer systems with Atmospheric design. 3. Plumbing systems, which are tested in accordance with the applicable plumbing codes. 4. Instrument piping lead lines between the root valve at the process or utility line and the connected instrument and control piping used to connect air or hydraulically operated control apparatus. 5. Liquid petroleum transportation piping systems under the jurisdiction of ASME B31.4. 6. Gas transmission and distribution piping systems under the jurisdiction of ASME B31.8. 7. Non-metallic systems, which shall be tested per manufacturer’s recommendation. 8. Existing Systems that are being re-rated. 9. Olets used for hot tap purpose. Terminology 1. Category D Fluid Service (ASME B31.3): Owner’s designation for a fluid service in which all the following apply: a. The fluid handled is nonflammable, nontoxic, and not damaging to the human tissues. b. The design gage pressure does not exceed 150 psi (1035kPa). Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 5 of 26 ® PIPING PRESSURE TESTING c. The design temperature is not greater than 366 degrees F (186 degrees C). The design temperature is not greater than 366 degrees F (186 degrees C). d. The fluid temperature caused by anything other than atmospheric conditions is not less than -20 degrees F (-29 degrees C). 2. Category M Fluid Service (ASME B31.3): Owner’s designation for a fluid service in which the potential for personnel exposure is judged to be significant, and in which a single exposure to a very small quantity of a toxic fluid, caused by leakage, can produce serious irreversible harm to persons on breathing or bodily contact, even when prompt restorative measures are taken. 3. Damaging To Human Tissues (ASME B31.3): A fluid which, under expected operating conditions, can harm skin, eyes, or exposed mucous membranes so that irreversible damage may be done unless prompt restorative measures are taken. (Restorative measures may include flushing with water, administration of antidotes, and medication.) 4. Calculated Test Pressure: The test pressure determined in accordance with Section 3.3, of this specification. 5. Minimum Test Pressure: The lowest allowable test pressure gage reading. (calculated test pressure plus the additional pressure resulting from the static head of the test fluid.) 6. Maximum Test Pressure: The highest allowable test pressure gage reading. (pressure test rating of the weakest component in the test system.) 7. Piping system: The process or utility piping labeled with a line number on the PID’s with the same Line Class Identifier, Fluid Code, Pipe Class and process conditions. 8. Test system: A system containing several Piping systems with identical or different process design conditions, which may and can be Pressure tested together because the required test conditions are identical or within required limits 9. Test Temperature: The minimum temperature occurring during the test period of either the metal temperature of the piping being tested (including any vessels or equipment included in the test) or the test fluid temperature. 10. System Test: The testing of a Test system as defined in 1.1.C 8 above, using a single test procedure and pressure. 11. Pressure Test Blind/Spade: A circular plate with an outside diameter that matches the flange raised face outer diameter, which is trapped between two flanges for the purpose of test pressure retaining isolation. Minimum thickness as per Attachment 03. System Test: The testing of a Test system as defined in 1.1.C 8 above, using a single test procedure and pressure. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 6 of 26 ® PIPING PRESSURE TESTING 1.2 12. Blind Flange: A machined flange without a bore to be used to close off a flanged open end by bolting to the existing flange. System Test: The testing of a Test system as defined in 1.1.C 8 above, using a single test procedure and pressure. 13. Temporary Support: A support such as a sandbag, a railway sleeper, a proprietary rated or certified lad bearing device or a structure fabricated in accordance with approved engineering fabrication drawings with specified load bearing capacity that has been designed and approved by an engineer. References The publications listed below form part of this specification. Each publication shall be the latest revision and addendum in effect on the date this specification is issued for construction unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, work included in this specification shall conform to the applicable provisions of these publications. A. API (American Petroleum Institute) • • B. ASME B16.5 ASME B16.21 ASME B16.34 ASME B31.1 ASME PCC-2 Pipe Flanges and Flanged Fittings Nonmetallic Flat Gaskets for Pipe Flanges Valves - Flanged, Threaded, and Welded End Power Piping Repair of Pressure Equipment and Piping ASME Boiler and Pressure Vessel Code • 1.3 Steel Gate Valves - Flanged and Butt-Welding Ends Compact Steel Gate Values ASME (American Society of Mechanical Engineers) • • • • • C. API 600 API 602 Section V Nondestructive Examination Pressure Testing A. The pressure test shall be performed after the completion of all required examination and before the internal cleaning of the pipe. B. The calculated test pressure for each line shall be specified in the Pipe Line List. Additional data, as listed below, shall be provided by Fluor Piping Engineering: • Equipment test pressures • Test pressures of special piping components such as ball valves and butterfly valves Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 7 of 26 ® PIPING PRESSURE TESTING • 1.4 Special testing instructions and cautionary notes Special Provisions for Testing A. Piping Components and subassemblies may be tested either separately or as assembled piping. B. Flanged joints used to connect piping components and subassemblies that have previously been tested, and flanged joints at which a blank or blind used to isolate equipment or other piping during a test, need not be leak tested. C. Closure welds. The final weld connecting piping systems or components which have been successfully leak tested, need not be leak tested provided the weld is examined i-process and passes with 100% radiographic examination or 100% ultrasonic examination. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 8 of 26 ® PIPING PRESSURE TESTING 2.0 PRODUCTS 2.1 2.2 Temporary Welded End Closures A. The use of plate for temporary welded on end closures is not allowed. B. Materials used for welded on end closures such as caps or blinded flanges must be per project approved piping material (line class) specifications. Project approved welding procedures and welding requirements must be adhered to. Exceptions or deviations to the approved specifications must be approved by the home office piping engineer. Temporary Non Welded End Closures When required, non welded temporary end closures, such as test plugs, must be selected and used per manufacturer’s recommendations and requirements. 2.3 Temporary spool pieces Where in-line instruments or valves have to be removed during the test, temporary spool pieces may have to be provided with temporary gaskets and bolting. Spool pieces shall be able to withstand the intended test pressure and be fabricated of material per approved piping material specifications. 2.4 Pressure Test Blinds A. Plain test blanks with 1/16 of an inch flat non-asbestos full face or ring type gaskets shall be used for blanking flat face, raised face, male and female, and tongue and groove type flanges. Provide full face blanks and gaskets at 125# CI connections. However, where permanent operational blinds are installed, they may be used for field pressure testing. (Listed material should be used for this purpose.) B. A field procedure must be established and care taken to ensure the installation and removal of material specified for testing. The following is one method for identifying test material: Plate material, extra length bolts, and gaskets for testing shall be furnished by the field unless dictated otherwise by contract requirements. The outer periphery (edge) of each test gasket shall be dabbed with a spot of fluorescent yellow paint in 4 spots (90 degree equidistant) prior to installation. End points of studs and heads of bolts shall be dabbed with a spot of fluorescent yellow paint. Refer to Attachment 03 for maximum test pressures at various blank thicknesses. 2.5 Solutions A. Corrosion Inhibitor A suitable non-toxic rust inhibitor for hydrotesting of clean lines, and / or harden inhibitor in lines with stainless steel components. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 9 of 26 ® PIPING PRESSURE TESTING B. Soap Solution A suitable soap solution for determining leaks during the pneumatic testing of systems. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 10 of 26 ® PIPING PRESSURE TESTING 3.0 EXECUTION 3.1 Preparation A. General 1. Prior to initial operation, all installed piping shall be pressure tested except where otherwise qualified in this specification. 2. The test shall be hydrostatic using water unless there is a possibility of damage due to freezing; or, if the operating fluid or piping material would be adversely affected by water, any other suitable liquid may be used. Testing of ferritic piping, however, is limited to the temperature restrictions in Section 3.6C, of this specification. 3. 4. a. If a flammable liquid is used, its flash point shall be no less than 120 degrees F and consideration shall be given to the test environment. b. If testing with glycol water mixtures to prevent freezing, the disposal problem of the test fluid shall be considered. c. The volume of water required for the pressure test, must be addressed during the preparation for the pressure test. The following systems may be tested pneumatically (with authorization from the Owner of the installation). a. The weight of the hydrotest liquid would overstress supporting structures or pipe wall in a gas, steam, or vapor lines. b. Lined pipe that could be damaged by the hydrotest liquid. c. The instrument air headers shall be tested with dry air. A commodity test as described in Section 3.3.G of this specification and paragraph 4 below, may be used if it is Category D Fluid Service, the system is complete and the instrument air compressor is operational. d. The process or piping material would be adversely affected by water. In circumstances when neither hydrostatic nor pneumatic tests are considered practical, an alternative test per section 3.3H may be employed, subject to Owner and Construction Authorization and if all of the following applies: a. A hydrostatic test would do the following: (1) Damage linings or internal insulation. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 11 of 26 ® PIPING PRESSURE TESTING b. B. (2) Contaminate a process which would be hazardous, corrosive, or inoperative in the presence of moisture. (3) Require significant support modifications for the hydrostatic test load. (4) Present a danger of brittle fracture from low metal temperature during test. A pneumatic test would do the following: (1) Introduce considerable hazard due to possible release of stored energy in the system (2) Present a danger of brittle fracture from low metal temperature during test. 5. For aboveground Fluid Category D piping an Initial Service Leak Test (Commodity Test) may be performed if approved by the Owner. See also section 3.3G. 6. Piping identified as Category M Fluid Service shall, in addition to the Hydrostatic Leak test or Pneumatic test, be subjected to a sensitive leak test in accordance with Section 3.3H., of this specification. 7. Where it is required, additional testing procedures shall be prepared for testing in the range of 350 to 3,500 Barg (5000 to 50,000 psi) to supplement this specification. 8. Calculation of safety distance for pressure testing should be addressed. See paragraph 3.5.w. Vessels and Equipment 1. 2. 3. The following shall be excluded from hydrostatic tests: a. Vessels or equipment supported by other vessels or equipment or by a support structure or foundation, not capable of supporting the hydrotest load. b. Vessels or equipment not capable of sustaining the hydrotest load, and those with internals or linings that would be damaged by the test fluid. The following shall be excluded from all pressure tests: a. Pumps, compressors, and turbines. b. Equipment and Supplier furnished piping specifically recommended by the Manufacturer not to be tested. The pressure on any point in vessels or equipment included in the pressure test shall not be greater than the shop test pressure for that equipment as stated on the vessel drawing, Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 12 of 26 ® PIPING PRESSURE TESTING Supplier's equipment drawing, or datasheets. In the event the piping test pressure is greater than the vessel or equipment test pressure, the piping shall be disconnected, blinded, and tested separately. If the piping cannot be disconnected (welded connection), 1 of the following shall be implemented: C. a. The appropriate Mechanical Equipment Engineer shall request written approval from the Supplier to test at the required piping test pressure. Refer to Section 3.3.A.3, of this specification. b. Reduce piping test pressure as necessary after review and approval of the Owner. Refer to Section 3.3.A.4, of this specification. 4. Certain types of exchangers are specifically designed for a low allowable differential pressure between shell and tubes, as stated on the Supplier drawings and datasheets. These should be checked; and, if necessary, test both shell and tubes simultaneously as one system, with the same pressure or exclude both sides from the test. 5. Pressure vessels with 2 or more pressure chambers are specifically designed for a low allowable differential pressure between pressure chambers as stated on the Manufacturers' drawings. These should be checked; and if necessary, test all adjacent pressure chambers simultaneously as one system, with the same pressure or exclude all pressure chambers from the test. Instruments Instruments shall be protected from damage when hydrotesting process and utility piping systems. Attachment 02 outlines the status of instruments during testing to ensure protection. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 13 of 26 ® PIPING PRESSURE TESTING 3.2 Test Medium Criteria A. Care shall be taken to ensure the use of clean water for these tests. A suitable filter should be provided in the filling line, should foreign matter such as sand, rust, or other particles be in evidence in the proposed test water. The use of seawater is prohibited. B. All water sources used for hydrostatic testing need to be tested for MIC (Microbiologically Influenced Corrosion Causing Bacteria) by an accredited Biological Testing Laboratory. If MIC is detected, contact Home Office Mechanical Engineering Metallurgist for proper steps to eliminate the bacteria prior to use. The bacteria analysis from the lab is required for proper diagnosis. C. Water used for hydrostatic testing of austenitic stainless steel piping, vessels, and equipment including those with austenitic stainless steel claddings, linings, or internals shall be tested for chlorides and shall conform to the requirements listed below. These requirements also apply to 12 chrome claddings or linings that are welded with austenitic stainless steel weld filler, as well as, medium and high nickel alloys and ferritic chromium stainless steel where pitting corrosion is a risk. 1. Water containing more than 200 ppm (Parts Per Million) chlorides shall not be used. 2. Water containing more than 50 ppm but less than 200 ppm chlorides shall be treated with an inhibitor of 1.5 percent soda ash and 0.5 percent sodium nitrate. The chloride content of the soda ash and sodium nitrate shall not exceed 500 ppm. These percentages are by weight. Systems containing water with up to 200 ppm chlorides should be flushed with condensate or demineralized water immediately after testing. 3. Water containing fewer than 50 ppm chloride does not require chloride inhibitor treatment. 4. Steam Condensate and Demineralized water that meet the requirements of 3.2B.3. is preferred water. 5. Piping, vessels, and equipment must be drained thoroughly after testing. Where complete drainage is impossible, when other than demineralized water or steam condensate has been used, the system shall be flushed free of all test water using boiler condensate or demineralized water containing 200 ppm hydrogen peroxide with less than 1 ppm chlorides, alcohol, petroleum distillate, or another suitable flushing solution. Hot air drying is not acceptable in lieu of flushing, but water may be blown out of pockets using instrument air or other dust filtered air. 6. It should be noted that risk of pitting corrosion is considerably diminished if the time between pressure testing and startup is as short as possible. When other than steam condensate or demineralized water has been used and the time is anticipated to be longer than five (5) days, flushing with condensate or demineralized water containing 200 ppm hydrogen peroxide is recommended. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 14 of 26 ® PIPING PRESSURE TESTING D. Piping that has been internally cleaned by sandblasting shall be tested after installation using a water solution containing a suitable rust inhibitor. After piping has been tested, it shall be drained and blown dry with air or nitrogen. A suitable corrosion inhibitor not objectionable to process stream shall be used. E. Piping that is to be chemically cleaned after installation shall be tested and all repairs made prior to cleaning. F. Systems that will be pneumatically tested because the pipeline in service will contain hydrogen cyanide or similar services contaminated by water shall be tested as follows: 1. Testing shall be performed using filtered, non-lubricated dry air only. Air provided directly from the plant compressor shall not be acceptable. Bottled dry compressed air or dry nitrogen may be used as an alternative. Note!!! Under no circumstances shall water be used in pressure testing of the system. G. 3.3 2. Unidirectional valves that are supplied with vent holes should be tested so the vent hole shall be located toward the upstream (high pressure) end when the plug is in the closed position. 3. After final test, all valves shall be wiped clean once more with clean, lint free rags and trichloromethane solvent. This cleaning shall include all accessible surfaces. Do not submerge the valve in the solvent. No trace of trichloromethane must remain or be trapped inside the valve. Environmental Management: All Requirements dealing with any environmental matter directly concerned with hydrotesting, shall be complied with during the preparation and actual testing. These requirements can be as a result of legislation, environmental impact studies or assessments that were conducted or from Record of Decision (ROD) that may have been issued by any Government Department concerned with each project. Test Methods and Pressures For ASME B31.3 Piping Systems A. Hydrostatic Testing of Piping Designed for Internal Pressure 1. The hydrostatic test pressure at every point in the system shall be as follows: a. When the design temperature is greater than the test temperature, the minimum test pressure, at the point under consideration, shall be calculated by Equation 1. When the piping system contains more than one material or more than one design temperature, Equation 1 shall be used for every combination, excluding pipe supporting elements and bolting, and the maximum calculated value of Pt is the minimum test gage pressure. Pt = Copyright © 2018, Fluor Corporation. All Rights Reserved. 1.5 PRr Equation 1 Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 15 of 26 ® PIPING PRESSURE TESTING Pt = pressure Rr = = St = S = 2. = Internal design gage ratio of St/S for pipe or components without established ratings, but shall not exceed 6.5 ratio of the component pressure rating at the test temperature to the component pressure rating at the component design temperature for components with established ratings, but shall not exceed 6.5. Allowable stress at test temperature Allowable stress value at component design temperature (Refer to Table 1, A-1, ASME B31.3) Where the test pressure as defined above would produce a stress in excess of the yield strength at test temperature or a pressure more than 1.5 times the component rating at test temperature, the test pressure shall be reduced to the maximum pressure that will not exceed the lesser of the yield strength (Equation 2) or 1.5 times the component ratings at test temperature. Pm = Pm Y T D B. Minimum test gage pressure P 2YT D = = = = Equation 2 Maximum Test Pressure (psig) Minimum Specified Yield Strength (psi) Specified Pipe Wall Thickness Minus Mill Tolerance (in) Outside Diameter (in) 3. If the design conditions of piping attached to a vessel are the same as those of the vessel, the piping and vessel may be tested together at the test pressure of the vessel. However, if the piping may be subject to higher design conditions; if it requires a higher test than the connected equipment; or if the piping is designed for lesser operating conditions than the connected equipment and could be overstressed by a system test, it shall be isolated and tested separately. 4. Where the test pressure of the piping exceeds the vessel test pressure and it is not considered practical to isolate the piping from the vessel, the piping and the vessel may be tested together at the vessel test pressure, provided the Owner approves and the vessel test pressure is not less than 77 percent of the piping test pressure calculated in accordance with Equation 1. Hydrostatic Testing of Piping Designed for External Pressure 1. Lines in external pressure service shall be subjected to an internal test pressure of 1-1/2 times the external differential design pressure but no less than a gage pressure of 15 psi. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 16 of 26 ® PIPING PRESSURE TESTING C. 2. In jacketed lines, the internal line shall be pressure tested on the basis of the internal or external design pressure, whichever is more critical. This test must be performed before completion of the jacket to provide visual access to the joints of the internal line. 3. The jacket shall be pressure tested on the basis of the jacket design pressure. Care must be taken to prevent damage to the internal line when testing the jacket. Pneumatic Testing If the piping is tested pneumatically, the test pressure shall be 110 percent of the design pressure. The test procedure shall be in accordance with section 3.7 of this specification. D. Hydrostatic-Pneumatic Testing A combination hydrostatic-pneumatic test is permissible. The pneumatic test pressure shall be in accordance with Section 3.3.F, of this specification. The pressure in the liquid filled portion of the piping shall not exceed that given in Section 3.3.A, of this specification. E. Sensitive Leak Test Piping required to have a sensitive leak test shall be tested by the Gas and Bubble Formation Testing Method specified in Article 10, Section V, of the ASME Code. Sensitive leak test shall be performed after hydrostatic test. F. Tightness Test 1. Except for piping systems identified as Category M Fluid Service, piping systems designed for internal gage pressures at or above 0 but less than 15 psig shall be tested for tightness in accordance with one of the following methods: a. Hydrostatic Fill with water to highest point in system and check all joints for leakage. See Attachment 04 - Hydro Test Connection Diagram. b. Pneumatic Pressurize system to 5 psi with air or other nonflammable gas and check all joints for leakage using a bubble forming solution. See Attachment 05 – Pneumatic Test Connection Diagram. 2. The fluid handled shall be nontoxic and not damaging to human tissue and have a design temperature within the range of minus 20 degrees F to 366 degrees F, inclusive. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 17 of 26 ® PIPING PRESSURE TESTING G. H. Initial Service Leak Test for Category D Fluid Service Only (ASME B31.3) 1. A piping system used only for Category D Fluid Service, not previously hydrostatic or pneumatic tested in accordance with this specification, may be tested at the normal operation conditions of the system during or prior to initial operation by examining for leaks at every joint. Commodity testing shall require Owner's authorization. 2. A preliminary check shall be made at no more than 25 psig pressure when the contained fluid is a gas or vapor. The pressure shall be increased gradually in steps providing sufficient time to allow the piping to equalize strains and to check leaks. Alternative Tests (Owner Approval is Required) in services other than Category D Fluid Service Under the conditions stated in Section 3.1A.4, of this specification, the following Alternate Leak Test shall be applied: 1. 3.4 Welds, including those welds used in the manufacture of welding pipe and fittings, which have not been subjected to hydrostatic or pneumatic leak tests in accordance with this specification shall be nondestructively examined as follows: a. Butt welds shall be 100 percent radiographed or 100 percent ultrasonically examined. b. All welds, including structural attachment welds, not covered in (a) above, shall be liquid penetrant examined. If the material is magnetic, magnetic particle examination may be used in lieu of liquid penetrant examination. c. When heat treatment is required, the above examinations shall be performed after heat treatment. 2. The system or joints to be tested shall be subjected to a sensitive leak test in accordance with Section 3.3.E, of this specification. Joints that have not been hydrostatic or pneumatic tested in accordance with this specification shall be examined for leakage. 3. A flexibility analysis of the piping system shall have been made in accordance with the requirements of ASME B31.3. Test Methods And Pressures For ASME B31.1 Piping Systems A. Hydrostatic Testing of Boiler External Piping (ASME B31.1) Boiler external piping shall be hydrostatically tested in accordance with PG-99, Section 1, of the ASME Boiler and Pressure Vessel Code. The test shall be conducted in the presence of the authorized inspector. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 18 of 26 ® PIPING PRESSURE TESTING B. Hydrostatic Testing of Non-boiler External Piping 1. The hydrostatic test pressure at every point in the piping system shall be no less than 1-1/2 times the design pressure. The minimum test pressure shall be as calculated by the following equation: Equation 3 Pt = 1.5P Pt = Minimum hydrostatic gage pressure (psi) P = Internal design gage pressure (psi) 2. At no time during the pressure test shall any part of the piping system be subjected to a stress greater than 90 percent of its yield strength (0.2 percent offset) at test temperature. 3. The maximum test pressure at which the stress produced in the piping shall not exceed 90 percent of the yield strength of the piping material at test temperature shall be calculated by the following equation: Pm = 2(0.9Y)T D Equation 4 Pm = Maximum test pressure (psig) 0.9Y = 90 percent of the minimum specified yield strength of the piping material (0.2 percent offset). T = Specified pipe wall thickness minus mill tolerance (in.) D = Outside diameter (in.) C. Pneumatic Testing The pneumatic test pressure shall be no less than 120 percent or more than 150 percent times the design pressure of the piping system. D. 3.5 Initial Service Test 1. When authorized by the Owner, an initial service test and examination is acceptable when other types of tests are not practical or when leak tightness is demonstrable due to the nature of the service. 2. When performing an initial service test, the piping system shall be brought up to normal operating pressure and continuously held for 10 minutes minimum. The piping system shall show no visual evidence of weeping or leaking. Test Preparation - Field Procedure A. Joints, including welds, shall be left non-insulated and exposed for examination during the test, except that joints previously tested in accordance with this specification may be insulated or covered. If a sensitive leak test is required (according to Section 3.3H., of this specification), all joints mentioned above also shall be left unprimed and unpainted. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 19 of 26 ® PIPING PRESSURE TESTING B. Underground portions of piping systems may be tested and covered before testing aboveground portions. C. Piping designed for vapor or gas shall be provided with additional temporary supports, if necessary to support the weight of the test liquid. Where it is required, temporary supports shall be specified in the pressure test documents. D. Lines that are counterweight supported shall be temporarily blocked during testing in order to sustain the weight of the test fluid. Spring hangers that have been provided with stops for carrying the test load normally do not require additional temporary supports; if this is not the case, temporary support must be provided before filling the system. E. Before testing, the following procedures shall be carried out: 1. Verify that any required heat treatment has been performed. 2. Piping systems shall have been completely checked (punched out). 3. Lines, vessels, and equipment shall be checked to ensure that the entire system can be completely drained after testing. 4. Vents or other high point connections shall be opened to eliminate air from lines that are to receive a hydrostatic test. All air shall be vented prior to start of the pressure test. 5. System shall be purged of air before hydrostatic test pressure is applied. F. Field personnel shall review all vessels and internals in order to determine best method to prevent air entrapment when filling and to prevent vacuum when draining. G. Short pieces of piping that must be removed to permit installation of a blind or blank shall be tested separately. H. Flanged joints at which a blank is inserted to isolate other equipment during a test need not be tested after blank is removed. I. Lines containing check valves shall have the source of pressure located in the piping upstream of the check valve so that the pressure is applied under the seat. If this is not possible, remove or jack up the check valve closure mechanism or remove check valve completely, and provide necessary filler piece or blinds. J. When conducting tests at freezing temperatures, the test shall not take more than 4 hours, and special precautions such as warming the line test water shall be observed to avoid freezing damage. Follow precautions to minimize the risk of brittle fracture as noted in Section 3.6.G, of this specification. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 20 of 26 ® PIPING PRESSURE TESTING K. Systems that include expansion joints shall be investigated to refer to that any required temporary restraints, anchors, or guides are installed or removed prior to test. L. When a pressure test is required to be maintained for a period of time during which the testing medium in the system would be subject to thermal expansion, provision shall be made for relief of any pressure greater than the maximum test pressure. M. Where it is possible, systems or sections shall be tested at a flanged isolation using a blind flange or hydrostatic test blind. For required thickness of Test Blanks see Attachment 03. N. Where a suitable flanged isolation is not available, vessels, equipment, or other piping not included in the system pressure test shall be either disconnected from the system or isolated by blinds or other means during the test. O. Rising stem values shall be fully opened and back seated. Although not recommended, Piping, or sections of piping, to be tested may be isolated by closed valves in exceptional cases and only provided the valve closure is suitable for the test pressure. P. Unidirectional valves that are supplied with vent holes should be tested so the vent hole shall be located toward the upstream (high pressure) end when the plug is in the closed position. Q. All components which might be damaged by the test pressure, such as traps, instruments, diaphragm valves, relief valves, pumps, vessels, etc, shall be blanked or removed from the Piping systems. For welded-in control valves their internals have to be removed and stored carefully. Valves and other in-line piping components for which the operating temperature is below 0 degrees C shall be removed prior to hydrostatic test, unless drying out can be properly achieved. Test pumps shall be disconnected from the test system prior to line inspection. All piping shall be thoroughly cleaned by flushing with water, or by blowing out with air or steam, if pneumatically tested. It shall be verified if all lines, vessels and equipment can be completely drained after testing. R. Vessels, heat exchangers and equipment, which have to be excluded from pressure testing, shall be physically disconnected and, unless otherwise stated, flushing with water shall not be done through these items. If there is a need to pressure test through equipment with 2 or more pressure chambers (e.g. welded-in heat exchanger) special care is required for allowable differential pressure between pressure chambers as stated on the Manufacturers' drawings. If necessary, test all adjacent pressure chambers simultaneously as one system with the same pressure or exclude all pressure chambers from the test. This applies also for de-pressurizing the system after test completion. For these specific pressure tests a field procedure shall be prepared and is subject to approval by Construction. S. In cases where a pipe line being tested extends beyond the battery limit without flanges, it shall be tested to the first block valve or set of flanges outside the battery limit. Care shall be taken to see that lines beyond limits are tested in accordance with pressure specified on Offsite Field Pressure Test Flow Diagrams. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 21 of 26 ® PIPING PRESSURE TESTING T. Piping which connects to, or is continuous with, piping installed by others shall be isolated from these lines by pipe test blanks or blinds during pressure testing and flushing. Where it is necessary to include portions of such lines in the test, testing shall be performed up to the first possible blinds and test blanks in the system provided by others. U. The normal locations for the pressure test gage are at grade near the pressure test pump. Readings may be made at higher points providing the gage pressure reading and the static head (0.433 psi/ft) between grade and the point of measurement do not exceed the maximum test pressure. Gages shall be tagged with the date last calibrated, and this activity shall be recorded. Gauge pressure line must be separate from pressure fill line. V. In order to hydrostatic test as much piping as possible at one time, a systems test may be employed. This test shall include one or more lines and, if possible, connected to vessels and equipment. Pressure test P&ID’s shall be developed for identifying test packages. Test packages shall be by Test Systems / circuits. W. Barricading and Accessing to Testing Area 1. Prior to a pressure testing taking place, the surrounding area must be barricaded off and clearly demarcated as a danger zone. These measures shall stay in place until the pressure test is completed. The barricades shall maintain a safe distance from the items being tested. 2. Pneumatic leak test consideration should be given to the risk associated with the release of stored energy and to the establishment of the minimum safe distance between personnel and the equipment being tested. Equations and considerations are available in the ASME PCC-2, Article 5.1. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 22 of 26 ® PIPING PRESSURE TESTING 3.6 Hydrostatic Test Procedure A. The minimum test pressure for a system test shall be such that each line in the system is subjected to a test pressure in accordance with Section 3.3, of this specification. B. The maximum system test pressure shall not exceed the pressure test rating of any piping component, or the shop test pressure of any vessels or equipment included in the test system. Maximum test pressures for flanges and valves conforming to ASME B16.5 and ASME B16.34 are given in Attachment 01. C. Hydrostatic test pressure shall not be applied until the vessel or equipment and its contents are at approximately the same temperature. To minimize the risk of brittle fracture, pressure tests through vessels and equipment shall not be conducted when the test liquid or metal temperature is below 60 degrees F (16 degrees C). Pressure tests in ferritic piping systems that do not include vessels or equipment may be conducted below 60 degrees F but shall not be conducted when the test liquid or metal temperature is below 40 degrees F (5 degrees C). D. Hydrostatic test pressure shall be maintained for a sufficient length of time to visually determine whether there are any leaks, but no less than 10 minutes. Contractor is not required to maintain test pressure in excess of 2 hours after notification of the Owner's authorized inspector. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 23 of 26 ® PIPING PRESSURE TESTING 3.7 Pneumatic Test Procedure A. Minimum Metal Temperature At time of testing, the minimum pipe metal temperature shall be as listed below: Minimum Temperature Nominal Wall Thickness 60 degrees F (16 degrees C) Carbon steel 1-1/2 inches and less 60 degrees F (16 degrees C) Post heat treated ferritic 1 inch and less 40 degrees F (5 degrees C) Austenitic steels 1 inch and less Note: Minimum temperatures for materials not listed above shall be determined by Piping Engineering when required by field construction. B. Clear the test area before bringing the line up to test pressure. It may be desirable to conduct pneumatic tests during weekends when fewer personnel are present. C. A pressure relief device shall be provided, having a set pressure no higher than the test pressure plus the lesser of 50 psi or 10 percent of the test pressure. D. When pneumatic testing at over 15 psig, a preliminary check at 15 psig shall be made to locate major leaks. The pressure shall be increased in gradual steps of 5 psig or 10 percent of the test pressure, whichever is greater. E. For flanged joint testing during pneumatic testing, the flange joint shall be hermetically sealed by means of adhesive paper tape, and a pin hole made in the tape, to permit easy detection of leaks. F. When the system has been brought up to the test overload shown on the piping pressure test system record, the pressure shall then be reduced to the design pressure before being examined for leakage. Joints and welds shall be covered with soap solution in order to detect any leakage. Soap shall be a commercial preparation made specifically for leak detection. G. Before soaping the joints, the entire line should be walked to determine whether there is any audible evidence of leakage. Any leaks found at the time shall be marked and repaired after first depressurizing the line. Sizeable leaks will be noticeable prior to walking. H. Bolting shall not be tightened while systems being tested are pressured above 30 psig. I. Pneumatic test pressure shall be maintained for a sufficient length of time to permit thorough visual inspection of all joint and weld seams but no less than 10 minutes. The contractor is not Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 24 of 26 ® PIPING PRESSURE TESTING required to maintain test pressure in excess of 2 hours after notification of Owner's authorized inspector. Pressure shall be reduced gradually when depressurizing. Air form lines of pneumatic systems, can present hazards to operators and others. To reduce noise an air silencer can be installed. See Attachment 05. 3.8 Sensitive Leak Test Procedure For the Sensitive Leak Test, reference is made to ASME B31.3 para. 345.8(b) 3.9 Tightness test Procedure For tightness testing the system shall be filled with water or pressurized with air or other nonflammable gas and then all joints are to be checked for leaks. When testing with air or gas the joints shall be checked using a bubble forming solution. 3.10 Initial Service Leak Test Procedure For the Initial Service Leak Test the test pressure shall be applied in increments of approx. 20% allowing time between increments for the piping system to equalize strains and to observe the leaks. However, for compressed gas systems the initial increment shall not exceed 170 kPag. Application of the test fluid to the piping system shall be through a valve opened slightly to minimize damage in the event of a piping failure. The pressure shall be maintained for sufficient time to determine if there are any leaks but not less than 10 minutes. Release pressure, repair any leaks, and retest. 3.11 Test Records A. Records shall be made of each piping system test utilizing Template 000.509.F75201, Pressure Test Report. Forms, when completed, shall be retained in the Field QC file as a permanent record. These records shall include the following information: • • • • • • • • • • B. Date of test Identification of piping system and any vessels or equipment tested with the piping system Test medium Test pressure Minimum ambient temperature Test medium temperature Certification by examiner Test results Name of test operator Minimum metal temperature (if applicable) Upon completion of the piping installation, the only retained records shall be a letter of certification by Owner's authorized inspector that all piping has been pressure tested as required by these procedures. Upon completion of the project, these records may be sent to the home office as specified in the Job Closeout Procedure. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 25 of 26 ® PIPING PRESSURE TESTING 3.12 Test Completion A. Pressure tests are successful if no leaks, no cracks and no deformations are detected. If leaks are found, their location shall be marked the pressure shall be gradually released, and the piping shall be drained or vented. All vents have to be opened and kept open in order that no vacuum is generated. Huge amounts of water have to be drained directly to sewer inlet (e.g. by hose) in order not to flood ground. B. If leaks are found on flanged, threaded, plugged or welded joints, the system pressure shall be totally released prior to any rectification work starting appropriate repair or replacement shall be made. The affected piping shall be re-tested at the pressures originally specified for the test. Re-testing of minor repairs or additions may be waived, provided approval of Owner is obtained and the welding is nondestructively examined according to Section 3.4.A.2, of this specification. C. After completion of testing the system shall be cleaned / flushed, all temporary blanks and blinds shall be removed, all operating blinds returned to proper position, and all lines and piping components (except those tested according to Section 3.4B., of this specification) shall be completely drained. Valves, orifice plates, expansion joints, and short pieces of piping that have been removed shall be reinstalled with proper new gaskets in place. Valves that were closed during hydrotest shall be opened to ensure drainage of the bonnet cavity. Lines being drained after testing and cleaning shall have all vents open. Piping systems downstream of check valves should be inspected to ensure complete drainage. Piping containing soft-seat valves shall be flushed and drained before the valves are installed. D. Direct connected transmitters at orifice flanges must be disconnected when replacing orifice plates to avoid distorting the connections. E. Care shall be exercised in controlling the rate of drainage from vessels with respect to the inflow of air through the vent to ensure that the vessel is not subjected to vacuum. After vessels have been completely drained, vents, cyclones, and other internal closures that were opened before testing shall be closed. F. After lines have been drained, temporary supports shall be removed, and insulation and painting completed. Spring hangers provided with stops to carry the test load shall have these stops removed. G. Flanged joints at which test blinds have been removed need not be retested. H. General 1. Instruments which were removed or blocked out for test shall be reinstalled and blocks placed in the normal operating position. 2. Bolting and gaskets used for pressure testing shall be removed and replaced with bolts and gaskets specified in the Line Class. Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Page 26 of 26 ® PIPING PRESSURE TESTING 4.0 3. Gaskets used for pressure testing shall be removed and replaced with line class gaskets. 4. Check valves that were jacked open or the internals were removed for pressure testing shall be returned to their proper operating position. 5. Vessel and equipment internal closures which were opened specifically for pressure testing shall be closed. 6. Instruments and process lead lines that were subjected to the hydrostatic pressure test shall be blown out with dry air or nitrogen. 7. Vent and drain connections that were added solely for pressure testing shall be closed and seal welded as required. Drains shall have either the valve closed and plugged or, if the valve is removed, the connection plugged and seal welded as required. 8. Painting and insulation shall be completed after inspection of seal welded vents & drains. 9. Strainer screens that were be removed, prior to testing can be re-installed after testing, drawing, drying, etc., have been completed and system is ready for final reinstating and punched for start-up. REFERENCES Construction Template 000.509.F75201: 5.0 Pressure Test Report (Contained in Practice 000.509.0000, Site Quality Manual (SQM)) ATTACHMENTS Attachment 01 Maximum Hydrostatic Test Pressure (Barg) for Flanges and Valves Attachment 02 Status of Instruments during Pressure Test Attachment 03 Schedule of Maximum Allowable Hydrostatic Test Pressures for the Listed Test Blind Thicknesses Attachment 04 Hydro Test Connection Diagram Attachment 05 Pneumatic Test Connection Diagram End of Specification Copyright © 2018, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Attachment 01 - Page 1 of 1 ® PIPING PRESSURE TESTING MAXIMUM HYDROSTATIC TEST PRESSURE (BARG) FOR FLANGES AND VALVES Table 1: Maximum Hydrostatic Test Pressure (Barg) for Flanges and Valves Material Carbon Steel Flange Rating (Class) 150 Normal (1.1) C – Mo C - 1/2 Mo (1.5) Cr – Mo 1/2 - 1/2 (1.7) 1-1/4 -1/2(1.9) 2-1/4 - 1(1.10) 5 - 1/2 (1.13) 9 - 1 (1.14) Stainless Steel 304 (2.1) 316 (2.2) 321 (2.4) 347, 348 (2.5) 304L 316L (2.3) 309 (2.6) 310 (2.7) Shell Seat Shell Seat Shell Seat Shell Seat Shell Seat Shell Seat 29.4 19.6 27.6 18.4 29.7 19.8 28.5 19.0 23.9 15.9 28.5 19.0 300 76.7 51.1 72.0 48.0 77.6 51.7 74.4 49.6 62.1 41.4 74.4 49.6 400 102.2 68.1 96.0 64.0 103.4 68.9 99.3 66.2 82.8 55.2 99.3 66.2 600 153.2 102.1 144.0 96.0 155.1 103.4 149.0 99.3 124.1 82.7 149.0 99.3 800 204.3 136.2 192.0 128.0 206.8 137.9 198.6 132.4 165.5 110.3 198.6 132.4 900 229.8 153.2 216.0 144.0 232.7 155.1 223.4 148.9 186.2 124.1 223.4 148.9 1500 383.0 255.3 360.0 240.0 387.9 258.6 372.3 248.2 310.2 206.8 372.3 248.2 2500 638.3 425.5 600.0 400.0 646.4 403.9 620.6 413.7 517.1 344.7 620.6 413.7 Notes: 1. The above chart is based on ASME B16.5-2009 and ASME 16.34-2009, and provides the maximum allowable hydrotest pressures of 1/2-inch (DN 15) through 24-inch (DN 600) flanges (shell test) and flanged and standard class weld end valves (shell test, with valve open and seat test, with valve closed). Test pressure for testing piping systems against closed valves, if allowed, is based on 1 times the Valve Pressure rating, whereas the required factory seat test per ASME B16.34-2009, Paragraph 2.5.3, is based on 110% of the Valve Pressure rating. 2. For valves not conforming to ASME B16.34, API 600 or API 602, the Manufacturers' recommended test pressure limits for both shell and seat shall be used. 3. Maximum test pressures for flanges and valves over 24 inches (DN 600) and piping components not covered by this chart shall be provided by Fluor Piping Engineering as applicable. 4. The maximum test pressure for pneumatic testing shall not exceed 75 percent of the stated values. Copyright © 2014, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Attachment 02 - Page 1 of 3 ® PIPING PRESSURE TESTING STATUS OF INSTRUMENTS DURING PRESSURE TEST 1.0 2.0 General 1.1 This attachment defines additional requirements for pressure testing of instrumentation. 1.2 Pressure testing of instrument process piping after the piping root valve and control pneumatic piping are not covered by this specification. Specific Requirements 2.1 The status of instruments during pressure testing shall conform to Table 2 of this attachment. Instruments not covered in Table 2 shall not be subjected to pressure testing without Owner's authorization. 2.2 When flanged instruments are removed from the test, the flange facings shall be protected over the entire gasket seating surface with hook or plastic covers, securely attached to the instrument, to exclude dirt and other foreign matter from the interior of the instrument and to protect the flange facings. 2.3 When threaded instruments are removed from the test, the threaded ends shall be closed with metal (of the same basic metallurgy as the instrument material) or plastic protectors, to exclude dirt and other foreign matter from the interior of the instrument. NOTE: Extreme caution should be taken in regards to Stainless Steel NPT fittings. Do not cap ends with Stainless Steel caps or plugs, without proper lubricate, as galling will occur. Better to use PVC threaded caps or plugs. 2.4 If spacer plates are required to be installed during testing, to replace removed orifice plates, they shall be installed using test gaskets and test bolting. 2.5 Float type level instruments shall be excluded during hydrostatic. 2.6 The maximum allowable test pressure for displacer type level instruments shall be verified prior to inclusion in the test. If they shall not stand the test pressure, they shall be blocked from the test and drained. 2.7 Pressure instruments shall have their root valve closed and the drain valve shall be open during testing. 2.8 Analyzer tubing shall be disconnected during testing. 2.9 Do not reverse flow in rotameters during testing. (This is dependent on the type, size and placement.) Copyright © 2014, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Attachment 02 - Page 2 of 3 ® PIPING PRESSURE TESTING STATUS OF INSTRUMENTS DURING PRESSURE TEST 2.10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Instruments shall be protected from damage due to freezing. In preparation for cold weather and during cold weather, all instruments must be drained and process lead lines blown out with air or nitrogen Table 2: Status Of Instruments During Pressure Testing – Note 1 Block Remove Blank Include And For Test Off In Test Vent Analyzers X Control valves (excluding pressure regulators, X pressure balanced, and butterfly) - Note 2 Control valves (butterfly) X Flow instruments (D/P cell and bellows) X Flow instruments (metal tube rotameters) X Flow meters (positive displacement) X Flow meters (turbine) X Flow indicating switches (bellows) X Flow switches (vane) X Sight and gage glasses X Level instruments (displacer) X Level instruments (D/P cell and bellows) X Level switches (float) – Note 3 X Orifice plates X Pressure gages – Note 4 X Pressure instruments X PSV’s X PSV’s TSV’s 3/4” and 1” screwed– Note 5 X Pressure regulators X Pressure switches– Note 3 X Refer To 2.8 2.9 2.6 2.5 2.4 2.7 Note 1: Evaluate the above chart for your condition. Note 2: Not all Control valves need to be removed. Some can be locked open. Note 3: Block, vent or remove if possible. Copyright © 2014, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Attachment 02 - Page 3 of 3 ® PIPING PRESSURE TESTING STATUS OF INSTRUMENTS DURING PRESSURE TEST Note 4: Pressure gauges that are contract material, should not be installed until after systems testing. Note 5: PSVs are always removed and sent for calibration during testing. Copyright © 2014, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Attachment 03 - Page 1 of 4 ® PIPING PRESSURE TESTING SCHEDULE OF MAXIMUM ALLOWABLE TEST PRESSURE FOR THE LISTED TEST BLIND THICKNESS (NOTE: Prior to issuing attachment, delete tables of unit system not used on project!) Table 3: Schedule of Maximum allowable Hydrostatic test pressure (Barg) for the listed Test blind Thickness Plate Thickness 15 25 (mm) 1079.7 437.2 6 10 12.5 15 20 22.5 25 30 32 35 30 45 50 Diameter Nominal (DN) 40 50 80 100 150 200 250 300 350 206.7 574.1 897.0 132.3 367.4 574.1 826.7 60.1 167.0 260.9 375.7 667.9 36.6 101.8 159.0 229.0 407.1 515.2 636.1 16.9 46.9 73.2 105.4 187.5 237.2 292.9 421.8 479.9 574.1 749.8 9.9 27.6 43.1 62.1 110.3 139.6 172.4 248.2 282.4 337.8 441.2 558.5 689.4 6.4 17.7 27.7 39.9 71.0 89.8 110.9 159.7 181.7 217.4 284.0 359.4 443.7 4.5 12.6 19.7 28.3 50.4 63.8 78.7 113.4 129.0 154.3 201.6 255.1 315.0 3.8 10.4 16.3 23.5 41.7 52.8 65.2 93.9 106.9 127.8 167.0 211.3 260.9 400 450 2.9 2.3 8.0 6.3 12.5 9.9 18.1 14.2 32.1 25.3 40.6 32.1 50.2 39.6 72.2 57.0 82.2 64.9 98.3 77.6 128.4 101.3 162.5 128.2 200.6 158.3 500 600 750 900 1.8 5.1 8.0 11.5 20.5 25.9 32.0 46.1 52.5 62.8 82.0 103.8 128.1 1.3 3.6 5.6 8.0 14.2 18.0 22.2 32.0 36.4 43.5 56.9 72.0 88.9 0.8 2.3 3.6 5.1 9.1 11.5 14.2 20.5 23.3 27.9 36.4 46.1 56.9 0.6 1.6 2.5 3.6 6.3 8.0 9.9 14.2 16.2 19.4 25.3 32.1 39.6 Notes: 1. Test blind plates listed in the Plate Thickness Schedule (above) are intended for use between bolted flanges only. Use of the listed blind plates as welded-end closures is not permitted. Also see Paragraph 2.1 “Temporary Welded on End Closures”. 2. The tabulated pressures above are calculated from the following equation stated in ASME B31.1, Paragraph 104.5.3, using the following conditions: 3. d6 – gasket inner diameter per ASME B16.21. SE – Minimum Yield Strength (Structural grade Carbon steel plate with Minimum Yield Strength of 248 MPa). For plate that is identified as having a lower Minimum Yield Strength, the allowable hydrostatic pressure must be reduced in accordance with the following formula: where: Pma Y Yx = Maximum allowable test pressure = Minimum Yield Strength (=248 MPa for ASTM A36 material) = Minimum Yield Strength for material selected 4. To convert pressures from Barg to KPa, multiply pressure values in table by conversion factor 100. 5. Plate thickness values are nominal thickness. Copyright © 2014, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Attachment 03 - Page 2 of 4 ® PIPING PRESSURE TESTING SCHEDULE OF MAXIMUM ALLOWABLE TEST PRESSURE FOR THE LISTED TEST BLIND THICKNESS (NOTE: Prior to issuing attachment, delete tables of unit system not used on project!) Table 4: Schedule of Maximum allowable Pneumatic test pressure (Barg) for the listed Test blind Thickness Plate Thickness 15 (mm) 456.3 6 10 12.5 15 20 22.5 25 30 32 35 30 45 50 Diameter Nominal (DN) 25 40 50 80 100 150 200 250 300 350 400 450 500 600 750 900 184.8 513.3 802.0 87.3 242.6 379.1 545.8 970.4 55.9 155.3 242.6 349.3 621.0 786.0 25.4 70.6 110.3 158.8 282.3 357.2 441.0 635.1 722.6 15.5 43.0 67.2 96.8 172.0 217.7 268.8 387.1 440.4 526.8 688.1 7.1 19.8 30.9 44.6 79.2 100.3 123.8 178.2 202.8 242.6 316.9 401.0 495.1 4.2 11.7 18.2 26.2 46.6 59.0 72.8 104.9 119.3 142.8 186.5 236.0 291.3 2.7 7.5 11.7 16.9 30.0 38.0 46.9 67.5 76.8 91.9 120.0 151.9 187.5 1.9 5.3 8.3 12.0 21.3 27.0 33.3 47.9 54.5 65.2 85.2 107.8 133.1 1.6 4.4 6.9 9.9 17.6 22.3 27.6 39.7 45.2 54.0 70.6 89.3 110.3 1.2 3.4 5.3 7.6 13.6 17.2 21.2 30.5 34.7 41.5 54.3 68.7 84.8 1.0 2.7 4.2 6.0 10.7 13.5 16.7 24.1 27.4 32.8 42.8 54.2 66.9 0.8 2.2 3.4 4.9 8.7 11.0 13.5 19.5 22.2 26.5 34.7 43.9 54.1 0.5 1.5 2.3 3.4 6.0 7.6 9.4 13.5 15.4 18.4 24.0 30.4 37.6 0.3 1.0 1.5 2.2 3.9 4.9 6.0 8.7 9.9 11.8 15.4 19.5 24.1 0.2 0.7 1.0 1.5 2.7 3.4 4.2 6.0 6.9 8.2 10.7 13.5 16.7 Notes: 1. 2. 3. Test blind plates listed in the Plate Thickness Schedule (above) are intended for use between bolted flanges only. Use of the listed blind plates as welded-end closures is not permitted. Also see Paragraph 2.1 “Temporary Welded on End Closures”. The tabulated pressures above are calculated from the following equation stated in ASME B31.1, Paragraph 104.5.3, using the following conditions: d6 – gasket inner diameter per ASME B16.21. SE – Maximum Allowable Stress (Structural grade Carbon steel plate, with Maximum Allowable Stress of 104.8 MPa. For plate that is identified as having a lower Maximum Allowable Stress, the allowable hydrostatic pressure must be reduced in accordance with the following formula: where: Pma SE SE2 = Maximum allowable test pressure = Maximum Allowable Stress (= 104.8 MPa for ASTM A36 material) = Maximum Allowable Stress for material selected 4. To convert pressures from Barg to KPa, multiply pressure values in table by conversion factor 100. 5. Plate thickness values are nominal thickness. Copyright © 2014, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Attachment 03 - Page 3 of 4 ® PIPING PRESSURE TESTING SCHEDULE OF MAXIMUM ALLOWABLE TEST PRESSURE FOR THE LISTED TEST BLIND THICKNESS (NOTE: Prior to issuing attachment, delete tables of unit system not used on project!) Table 3: Schedule of Maximum allowable Hydrostatic test pressure (PSI) for the listed Test blind Thickness Nominal Pipe Size (NPS) Plate Thickness ½ 1 1½ 2 3 4 6 8 10 12 14 16 18 20 24 30 (inches) 17006.8 6992.6 3289.4 2118.5 979.6 592.6 273.8 161.5 103.8 73.8 61.2 46.9 37.0 30.0 20.8 13.3 1/4” 4766.6 2204.1 1333.3 616.1 363.4 233.6 166.1 137.8 105.5 83.3 67.5 46.9 30.0 3/8 3918.4 2370.4 1095.3 646.0 415.4 295.3 244.9 187.5 148.1 120.0 83.3 53.3 1/2” 3703.7 1711.4 1009.4 649.0 461.4 382.7 293.0 231.5 187.5 130.2 83.3 5/8" 5333.3 2464.4 1453.5 934.6 664.4 551.0 421.9 333.3 270.0 187.5 120.0 3/4" 3354.3 1978.3 1272.0 904.3 750.0 574.2 453.7 367.5 255.2 163.3 7/8" 4381.1 2584.0 1661.4 1181.1 979.6 750.0 592.6 480.0 333.3 213.3 1" 5544.9 3270.3 2102.8 1494.8 1239.8 949.2 750.0 607.5 421.9 270.0 1-1/8" 4037.4 2596.0 1845.4 1530.6 1171.9 925.9 750.0 520.8 333.3 1-1/4" 4885.3 3141.2 2233.0 1852.0 1418.0 1120.4 907.5 630.2 403.3 1-3/8" 5813.9 3738.2 2657.4 2204.1 1687.5 1333.3 1080.0 750.0 480.0 1-1/2" 4387.2 3118.8 2586.7 1980.5 1564.8 1267.5 880.2 563.3 1-5/8" 5088.2 3617.1 3000.0 2296.9 1814.8 1470.0 1020.8 653.3 1-3/4" 5841.0 4152.2 3443.9 2636.7 2083.3 1687.5 1171.9 750.0 1-7/8" 6645.8 4724.3 3918.4 3000.0 2370.4 1920.0 1333.3 853.3 2" Notes: 1. 2. 3. Test blind plates listed in the Plate Thickness Schedule (above) are intended for use between bolted flanges only. Use of the listed blind plates as welded-end closures is not permitted. Also see Paragraph 2.1 “Temporary Welded on End Closures”. The tabulated pressures above are calculated from the following equation stated in ASME B31.1, Paragraph 104.5.3, using the following conditions: d6 – gasket inner diameter per ASME B16.21. SE – Minimum Yield Strength (Structural grade Carbon steel plate with Minimum Yield Strength of 36 ksi). For plate that is identified as having a lower Minimum Yield Strength, the allowable hydrostatic pressure must be reduced in accordance with the following formula: Pma = where: Yx Y Pma Y Yx x Maximum Allowable Hydrostatic Test Pressure (from table above) = Maximum allowable test pressure = Minimum Yield Strength (= 36,000 psi for ASTM A36 material) = Minimum Yield Strength for material selected Copyright © 2014, Fluor Corporation. All Rights Reserved. Piping Engineering 36 9.3 20.8 37.0 57.9 83.3 113.4 148.1 187.5 231.5 280.1 333.3 391.2 453.7 520.8 592.6 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Attachment 03 - Page 4 of 4 ® PIPING PRESSURE TESTING SCHEDULE OF MAXIMUM ALLOWABLE TEST PRESSURE FOR THE LISTED TEST BLIND THICKNESS (NOTE: Prior to issuing attachment, delete tables of unit system not used on project!) Table 4: Schedule of Maximum allowable Pneumatic test pressure (PSI) for the listed Test blind Thickness Nominal Pipe Size (NPS) Plate Thickness ½ 1 1½ 2 3 4 6 8 10 12 14 16 18 (inches) 7180.7 2952.4 1388.9 894.5 413.6 250.2 115.6 68.2 43.8 31.2 25.9 19.8 15.6 1/4” 2012.6 930.6 563.0 260.1 153.4 98.6 70.1 58.2 44.5 35.2 3/8 1554.4 1000.8 462.5 272.8 175.4 124.7 103.4 79.2 62.6 1/2” 1563.8 722.6 426.2 274.0 194.8 161.6 123.7 97.7 5/8" 2251.9 1040.5 613.7 394.6 280.5 232.7 178.1 140.7 3/4" 1416.3 835.3 537.1 381.8 316.7 242.4 191.6 7/8" 1849.8 1091.0 701.5 498.7 413.6 316.7 250.2 1" 2341.2 1380.8 887.8 631.1 523.5 400.8 316.7 1-1/8" 1704.7 1096.1 779.2 646.3 494.8 390.9 1-1/4" 2062.7 1326.3 942.8 782.0 598.7 473.0 1-3/8" 2454.8 1578.4 1122.0 930.6 712.5 563.0 1-1/2" 1852.4 1316.8 1092.2 836.2 660.7 1-5/8" 2148.3 1527.2 1266.7 969.8 766.3 1-3/4" 2466.2 1753.2 1454.1 1113.3 879.6 1-7/8" 2806.0 1994.7 1654.4 1266.7 1000.8 2" 20 24 30 36 12.7 28.5 50.7 79.2 14.0 155.2 202.7 256.5 316.7 383.2 456.0 535.2 620.7 712.5 810.7 8.8 19.8 35.2 55.0 79.2 107.8 140.7 178.1 219.9 266.1 316.7 371.6 431.0 494.8 563.0 5.6 12.7 22.5 35.2 50.7 69.0 90.1 114.0 140.7 170.3 202.7 237.9 275.9 316.7 360.3 3.9 8.8 15.6 24.4 35.2 47.9 62.6 79.2 97.7 118.3 140.7 165.2 191.6 219.9 250.2 Notes: 1. 2. 3. Test blind plates listed in the Plate Thickness Schedule (above) are intended for use between bolted flanges only. Use of the listed blind plates as welded-end closures is not permitted. Also see Paragraph 2.1 “Temporary Welded on End Closures”. The tabulated pressures above are calculated from the following equation stated in ASME B31.1, Paragraph 104.5.3, using the following conditions: d6 – gasket inner diameter per ASME B16.21. SE – Maximum Allowable Stress (Structural grade Carbon steel plate, with Maximum Allowable Stress of 15.2 ksi. For plate that is identified as having a lower Maximum Allowable Stress, the allowable hydrostatic pressure must be reduced in accordance with the following formula: Pma = where: SE2 SE Pma SE SE2 x Maximum Allowable Hydrostatic Test Pressure (from table above) = Maximum allowable test pressure = Maximum Allowable Stress (= 15,200 psi for ASTM A36 material) = Maximum Allowable Stress for material selected Copyright © 2014, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Attachment 04 - Page 1 of 1 ® PIPING PRESSURE TESTING Copyright © 2014, Fluor Corporation. All Rights Reserved. Piping Engineering 21-002 [Client Name] [Project Name] Contract [XXXX] Master Specification 000.250.50050 Date 9-Mar-22 Attachment 05 - Page 1 of 1 ® PIPING PRESSURE TESTING Copyright © 2014, Fluor Corporation. All Rights Reserved. Piping Engineering 21-003 Client Name Project Name Contract Number Master Specification 000 250 50300 Date 11-Nov-13 Page 1 of 8 HEAT TRACING FOR PIPING EQUIPMENT AND INSTRUMENTS This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. Date Originator's Name & Initials APPROVALS Reviewed/Checked By Name & Initials SIGNATURES Pages DATE Lead Engineer Project Manager: Client Approval: ISSUED FOR : Construction Copyright © 2013, Fluor Corporation. All Rights Reserved. Other Piping Engineering 21-003 Client Name Project Name Contract Number Master Specification 000 250 50300 Date 11-Nov-13 Page 2 of 8 HEAT TRACING FOR PIPING EQUIPMENT AND INSTRUMENTS Record of Revisions Revision No. Date Copyright © 2013, Fluor Corporation. All Rights Reserved. Description Piping Engineering 21-003 Client Name Project Name Contract Number Master Specification 000 250 50300 Date 11-Nov-13 Page 3 of 8 HEAT TRACING FOR PIPING EQUIPMENT AND INSTRUMENTS 1.0 GENERAL 1.1 Summary A. B. Scope of Specification 1. This specification prescribes the criteria for providing process heat control, heat conservation, and winterizing for piping systems, small equipment, and in-line instruments. 2. Wherever a difference exists between this specification and the flow diagrams (P&IDs), the flow diagrams shall govern. Related Specifications The following specifications prescribe items of related Work: 000.250.50003: 000.250.50025: 000.250 50026: 000.265.65850: Piping - Material Specification Line Class Shop Fabrication And Handling - Process And Utility Piping Field Fabrication And Installation - Process And Utility Piping Heat Tracing Design, Material, And Installation Coordinate Work prescribed by this specification with Work prescribed by the above listed specifications. C. D. Related Technical Requirements Practice 000.250.1601: Heat Tracing Practices Practice 000.270.1851: Heat Tracing Guideline 000.250.4300: STM Tracing Details Terminology 1. Heat Conservation: Process piping equipment and instruments require heat conservation whenever the pour point of the fluid is above the normal operating temperature or when it is desirable to maintain certain fluid temperatures. 2. Heat Tracing: Generalized term relating to the application of radiant heat input to piping systems from tubing attached to the outside of the pipe. 3. Process Control Tracing: Heat tracing used to ensure that the system functions from a process standpoint regardless of climate conditions. 4. Winterization Tracing: Heat tracing used to prevent freezeup due to climatic conditions only. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-003 Client Name Project Name Contract Number Master Specification 000 250 50300 Date 11-Nov-13 Page 4 of 8 HEAT TRACING FOR PIPING EQUIPMENT AND INSTRUMENTS E. Instrument Application This specification is to be used by Piping for heat tracing of all in-line instruments. Piping will also provide steam supply and conditions collection manifolds for all other instruments. The break between Piping Traced Instruments and Control Systems traced instruments will match the drawing break between the two departments. 1.2 System Description Using various media such as steam, hot water, glycol, or hot oil, heat tracing is installed to protect the piping, equipment, and instruments against temperatures that would cause congealing or freezing of the process fluids, interfere with operation, or cause damage to the equipment. A. B. Design Requirements 1. The low January average temperature shall be used to select the zone number and low ambient design temperature, which then determines the degree of winterizing protection required. 2. For areas outside the United States, the daily average low temperature of the coldest month shall be used to select the low ambient design temperature. Regional Criteria Note to Specifier!!! Choose the appropriate zone based on regional requirements. 1. 2. Zone I: Low January average 30 degrees F (minus 1 degree C) or higher. a. No winterizing is required for water service except where a sustained temperature below 30 degrees F (minus 1 degree C) is often recorded for 24 hours or longer. b. Compressors, blowers, and other mechanical equipment shall be specified for operation at low ambient design temperature. Zone II: Low January average 29 degrees F (minus 2 degrees C) to 0 degrees F (minus 18 degrees C). a. Winterizing is required for water and aqueous solutions. (1) Trace to maintain temperature of approximately 75 degrees F (24 degrees C). (2) Fluids with pour points at or above the low ambient design temperature shall be traced to maintain a temperature approximately 100 degrees F (38 degrees C) above their pour point. b. Equipment Winterizing Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-003 Client Name Project Name Contract Number Master Specification 000 250 50300 Date 11-Nov-13 Page 5 of 8 HEAT TRACING FOR PIPING EQUIPMENT AND INSTRUMENTS (1) Pumps are preferably winterized with companion piping. Compressors, blowers, and other mechanical equipment shall be specified for operation at low ambient design temperature. (2) Storage tanks and vessels shall have winterized type drains. (3) Water draw off section of vessels and bottoms of air or gas receivers where water can collect shall be heat traced. 3. Zone III: Low January average below 0 degrees F (minus 18 degrees C). a. Winterizing is required for water and aqueous solutions. (1) Trace to maintain temperature of approximately 75 degrees F (24 degrees C). (2) Fluids with pour points at or above the low ambient design temperature shall be traced to maintain a temperature approximately 100 degrees F (38 degrees C) above their pour point. b. Special consideration shall be given to the following: c. Buried lines, because of the deep frost line Air intakes to boilers and other heating equipment Cooling towers and air coolers Equipment Winterizing (1) Pumps are preferably winterized with companion piping. Compressors, blowers, and other mechanical equipment shall be specified for operation at minimum ambient design temperature. (1) Storage tanks and vessels shall have winterized type drains. (2) Water drawoff section of vessels and bottoms of air or gas receivers where water can collect shall be heat traced. C. Methods of Heat Conservation 1. Where feasible, insulation shall be used for heat conservation. 2. Heat tracing, plus insulation, is the alternative method for heat conservation. 3. Heat transfer cement may be utilized when a process line required a high heat input and common methods of heat tracing are inadequate. 2. Steam jacketing is utilized in specific cases where steam tracing with heat transfer cement is inadequate. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-003 Client Name Project Name Contract Number Master Specification 000 250 50300 Date 11-Nov-13 Page 6 of 8 HEAT TRACING FOR PIPING EQUIPMENT AND INSTRUMENTS 3. D. Electric tracing is utilized when precise temperature control is required or where steam tracing is not practical. Thermostat setting for electric tracing should not be higher than fluid operating temperature. Methods for Winterization 4. Underground lines subject to freezing are buried below frost line. 5. Winterizing by circulation shall be provided where a sufficient power source is available to keep the fluid circulating. 6. Utility water and utility air lines in intermittent service shall be winterized by draining. 7. Winterizing by steam tracing is the preferred method when winterizing by circulation and draining is impracticable. 8. Winterizing by electric tracing is utilized when a precise temperature control is required or where steam tracing is not practical. Thermostat setting for electric tracing should not be higher than fluid operating temperature. 9. Steam tracing pressure requirements are as follows: Note to Specifier!!! Choose the appropriate steam tracing pressure based on regional requirements. 1.3 Zone 1: Minimum tracing steam pressure shall be 15 psig; maximum required is 150 psig. At minimum pressure, condensate shall be routed to the plant sewer system. If condensate is collected, the minimum usable pressure shall be 25 psig. Zone II: Minimum tracing steam pressure shall be 25 psig; maximum required is 150 psig. Zone III: Minimum tracing steam pressure shall be 60 psig; maximum required is 200 psig. System Description A. Tracer Size and Length 1. Required tracer size shall be determined by piping heat loss and tracer steam pressure found in the Heat Loss Chart included in Piping Engineering Practice 000.250.1601: Heat Tracing Practices. 2. Minimum tracer size shall be 3/8 of an inch OD tubing; maximum size shall be 1 inch OD tubing. For economy, where Heat Loss Chart indicates the requirements for multiple tracers, a single tracer with heat transfer cement shall be considered. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-003 Client Name Project Name Contract Number Master Specification 000 250 50300 Date 11-Nov-13 Page 7 of 8 HEAT TRACING FOR PIPING EQUIPMENT AND INSTRUMENTS 3. When using heat transfer cement, tracers of 3/8 of an inch and 1/2 of an inch OD tubing are recommended. If more tracer area is required, multiple tracers of 3/8 of an inch and 1/2 of an inch shall be used. 4. Maximum tracer length shall be based on tracer size and steam pressure as follows: Steam pressure 15 psig through 25 psig Steam pressure 50 psig through 200 psig B. 200 feet for 3/8 of an inch and 1/2 of an inch tracers 300 feet for 3/4 of an inch and 1 inch tracers 300 feet for 3/8 of an inch and 1/2 of an inch tracers 400 feet for 3/4 of an inch and 1 inch tracers Tracer lengths for tracing with heat transfer cement shall be based on recommendation of manufacturer. 5. For stainless steel lines, the tracer material shall be low carbon steel. Stainless steel instrument leads shall be traced with copper tubing. 6. Each tracer shall have its own trap. Tracer traps shall discharge to sewer. If condensate must be collected, minimum usable pressure is 25 psig. 7. Compression type fittings shall be installed outside of the insulation OD. 8. Socket type fittings may be installed inside of the insulation. 9. The steam tracers shall be pressure tested before the insulation is applied. Under emergency conditions, the insulation may be applied but the fittings shall be left exposed until the testing is complete. Tracer Pocket Depth 1. Pocket depth is the distance the tracer rises in the direction of flow from a low point to a high point. The total pocket depth is the sum of all risers of the tracer. 2. Maximum tracer total pocket depth shall be equal to 40 percent of tracing steam gage pressure expressed in feet. Example: Tracing steam 150 psig 150 x 0.40 = 60 feet total pocket depth C. Steam Tracing Details For piping tracing details, refer to Fluor Standard Drawings. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-003 Client Name Project Name Contract Number Master Specification 000 250 50300 Date 11-Nov-13 Page 8 of 8 HEAT TRACING FOR PIPING EQUIPMENT AND INSTRUMENTS 1.4 Hot Fluid Tracing (Nonsteam) HOT OIL GYCOL HOT WATER DOWTHERM 1.5 Electric Tracing Electric tracing for heat conservation, winterization, or process controls is excluded from this specification. Refer to Electrical Engineering Specification 000.265.65850: Heat Tracing Design, Material, And Installation. 2.0 PRODUCTS 2.1 3.0 General A. Steam tracing tubing materials shall be in accordance with line class BATR noted in Piping Engineering Specification 000.250.50003: Piping - Material Specification Line Class – Process and Utility Piping. B. Tracers shall be OD tubing. Soft annealed copper tubing shall be used where the temperature of the product line or tracing steam does not exceed 400 degrees F (204 degrees C). Above this temperature, dead soft annealed hydraulic quality, low carbon, seamless steel tubing shall be used where the temperature of the product line or tracing steam does not exceed 750 degrees F (399 degrees C). C. For aluminum pipe lines, carbon steel tracer material shall not be used. D. For aluminum pipe lines and all lines above 750 degrees F (399 degrees C), the tracer material shall be stainless steel. E. For conditions where the tracer could overheat lines containing acid, caustic, amine, phenolic water, or other chemicals, insulation spacer blocks shall be installed between tracer and pipe. EXECUTION Not applicable. 4.0 ATTACHMENTS Not applicable. End of Specification Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-004 Guideline 000 250 4300 Date 07 Oct 2013 Page 1 of 2 STEAM TRACING DETAILS PURPOSE This document establishes general guidelines for steam tracing design. SCOPE This guideline includes the following attachments Attachment 01 PDST4301A PDST4301B Maximum Steam Tracer Length and Pocket Depth Maximum Steam Tracer Length Using Heat Transfer Cement Attachment 02 PDST4302 Tracer Supply and Condensate Header Sizing Attachment 03 PDST4303 Maximum Instrument Tracer Length and Pocket Depth Attachment 04 PDST4304 Tracer Position Attachment 05 PDST4305A PDST4305B PDST4305C PDST4305D Tracer Expansion Loops Tracer Expansion Loops Tracer Anchor and Guide Details Tracer Insulation Spacer Blocks Attachment 06 PDST4306A PDST4306B PDST4306C PDST4306D PDST4306E PDST4306F PDST4306G Valves, Flanges, and Control Valve Manifolds Tracer at Flanged Spool Piece – Flange Tracer Jumper Traced Valve Body Traced Valve Body and Bonnet Tracer at Valved Vents and Drains – Valve Tracer Jumper Traced Control Valve Manifold Traced Control Valves PDST4307A PDST4307B PDST4307C PDST4307D Steam Jacketing Notes Steam Jacket Details (Except Liquid Sulfur) Typical Jacketed Pipe Section (Liquid Sulfur Service) Sulfur Line Jacketing Details (Liquid Sulfur Service) – Typical Jacketed Elbow Sulfur Line Jacketing Details (Liquid Sulfur Service) – Spacers for Jacketed Sections Sulfur Line Jacketing Details (Liquid Sulfur Service) – Sulfur Sump Seal Leg Sulfur Line Jacketing Details (Liquid Sulfur Service) – Internal Tracer Detail Attachment 07 PDST4307E PDST4307F PDST4307G Attachment 08 PDST4308 Copyright © 2013, Fluor Corporation. All Rights Reserved. Pump Case Tracing Piping Engineering 21-004 Guideline 000 250 4300 Date 07 Oct 2013 Page 2 of 2 STEAM TRACING DETAILS Attachment 09 PDST4309A PDST4309B PDST4309C PDST4309D PDST4309E PDST4309F PDST4309G Attachment 10 PDST4310A PDST4310B PDST4310C PDST4310D PDST4310E PDST4310F PDST4310G PDST4310H PDST4310I Attachment 11 Copyright © 2013, Fluor Corporation. All Rights Reserved. Steam Tracing – Liquid Level Instruments Steam Tracing – Liquid Level Instruments – Level Switch Steam Tracing – Liquid Level Instruments – Level Glasses Steam Tracing – Liquid Level Instruments – Multiple Level Glasses Steam Tracing – Liquid Level Instruments – Level Controller Steam Tracing – Liquid Level Instruments – Level Controller and 1 Level Glass Steam Tracing – Liquid Level Instruments – Level Controller and Multiple Level Glasses General Notes – Steam Tracing Manifolds General Notes – Steam Tracing Manifolds (Continued) Steam Supply Manifolds – Type “A” – Typical Distribution Manifold – Horizontally Mounted Steam Supply Manifolds – Type “B” – Typical Distribution Manifold – Vertically Mounted Steam Supply Manifolds – Type “C” – Typical Distribution – No Manifold / Type “D” – Elevated Distribution Condensate Return Manifolds – Type “A” – Typical Collection Manifold for Multiple Tracers – Horizontally Mounted Condensate Return Manifolds – Type “B” – Typical Collection Manifold for Multiple Tracers – Vertically Mounted Condensate Return Manifolds – Type “C” – Typical Collection -No Manifold Manifold Detail – Preferred and Alternate Support Steam Condensate Tree Assembly Piping Engineering 21-004 21-004 21-004 21-004 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 02 - Page 1 of 1 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 03 - Page 1 of 1 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 04 - Page 1 of 1 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 05 - Page 1 of 4 ® TRACER SECUREMENT (TYPICAL) REFER TO ATTACHMENT 04 FOR TRACER POSITION. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 05 - Page 2 of 4 ® TRACER SECUREMENT (TYPICAL) REFER TO ATTACHMENT 04 FOR TRACER POSITION. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 05 - Page 3 of 4 ® #16 GA x 2" LG THERMON TFK CHANNEL OR FLUOR APPROVED EQUAL. TRIM AS REQUIRED. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 05 - Page 4 of 4 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 06 - Page 1 of 7 ® GENERAL NOTES: FOR DESIGN CRITERIA, REFER TO PIPING ENGINEERING SPECIFICATION 00.250.50300: HEAT TRACING FOR PIPING EQUIPMENT, AND INSTRUMENTS. FOR TRACER SECUREMENT REFER TO ATTACHMEN 04 FOR TRACER POSITION. TUBING UNIONS WILL BE PROVIDED FOR ITEMS REQUIRING FREQUENT REMOVAL UNIONS MUST BE LOCATED OUTSIDE OF THE INSULATION. ½ OF AN INCH LOW POINT DRAINS ARE PROVIDED FOR TRACERS IN INTERMITTENT SERVICE ONLY (SUCH AS START‐ UP, SHUTDOWN, AND PUMPOUT LINES) AND AS DEFINED BY PROCESS ENGINEERS. VALVE NOTES: VALVES REQUIRING TRACING ARE INDICATED ON THE FLOW DIAGRAMS WITH THE SYMBOL TB (TRACED BODY) OR TBB (TRACED BODY AND BONNET). CONSTRUCTION WILL INVESTIGATE THE CONFIGURATION OF THE VALVE BODY AND/OR BONNET FOR MAXIMUM TRACER CONTACT WITH THE CONSIDERATION FOR THE TRACER SIZE AND MATERIAL. VALVES WITH SMALL FACE TO FACE (END TO END) DIMENTIONS SUCH AS BUTTERFLY OR WAFER CHECK VALVES CANNOT BE TRACED. PDST4306A VALVES, FLANGES, AND CONTROL VALVE MANIFOLDS Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 06 - Page 2 of 7 ® TRACER SECUREMENT REFER TO ATTACHMENT 04 FOR TRACER POSITION. TRACER SECUREMENT REFER TO ATTACHMENT 04 FOR TRACER POSITION. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 06 - Page 3 of 7 ® TRACER SECUREMENT REFER TO ATTACHMENT 04 FOR TRACER POSITION. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 06 - Page 4 of 7 ® TRACER SECUREMENT REFER TO ATTACHMENT 04 FOR TRACER POSITION. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 06 - Page 5 of 7 ® TRACER SECUREMENT REFER TO ATTACHMENT 04 FOR TRACER POSITION. TRACER SECUREMENT REFER TO ATTACHMENT 04 FOR TRACER POSITION. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 06 - Page 6 of 7 ® TRACER SECUREMENT REFER TO ATTACHMENT 04 FOR TRACER POSITION. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 06 - Page 7 of 7 ® TRACER SECUREMENT REFER TO ATTACHMENT 04 FOR TRACER POSITION. TRACER SECUREMENT REFER TO ATTACHMENT 04 FOR TRACER POSITION. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 07 - Page 1 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 07 - Page 2 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 07 - Page 3 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 07 - Page 4 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 07 - Page 5 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 07 - Page 6 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 07 - Page 7 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 08 - Page 1 of 1 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 09 - Page 1 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 09 - Page 2 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 09 - Page 3 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 09 - Page 4 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 09 - Page 5 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 09 - Page 6 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 09 - Page 7 of 7 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 10 Page 1 of 9 ® MANIFOLDS: PIPE SIZE TO BE MINIMUM OF 2 INCHES. MANIFOLD TO BE ACCESSIBLE FROM GRADE, STAIRS, OR PLATFORM. FOR MANIFOLD HEADER SIZE, REFER TO ATTACHMENT 02: TRACER SUPPLY AND CONDENSATE HEADER SIZING. LINE SIZE MAY BE ENLARGED TO MANIFOLD SIZE AS REQUIRED FOR SPAN. CHECK WITH CONTROL SYSTESM FOR NUMBER OF CONNECTIONS REQUIRED AT EACH MANIFOLD FOR TRACING INSTRUMENTS. PROVIDE SPARE CONNECTIONS. EACH MANIFOLD WILL BE TAGGED WITH AN IDENTIFICATION NUMBER. TAG IS TO BE WELDED TO MANIFOLD ON HANDWHEEL SIDE. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 10 Page 2 of 9 ® TRACING: FOR TRACER SIZE REFER TO FLOW DIAGRAM. CARBON STEEL PIPE TO BE ROUTED TO AND FROM MANIFOLD. PRE‐INSULATED TUBING IS PREFERRED METHOD OF INSTALLATION. WHEN USED FIELD IS TO SUPPORT WITH ANGLE, CONDUIT CLAMPS UNISTRUT, AND CABLE TRAY /J.S REQUIRED. (MATERIAL BULK PURCH/J.SED BY FLUOR). Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 10 Page 3 of 9 ® CONDENSATE WILL BE ROUTED TO CONDENSATE HEADER OR NEAREST DRAIN FUNNEL. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 10 Page 4 of 9 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 10 Page 5 of 9 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 10 Page 6 of 9 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 10 Page 7 of 9 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 10 Page 8 of 9 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 Guideline 000.250.4300 Date 07 Oct 2013 Attachment 10 Page 9 of 9 ® Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering & Design 21-004 3/9/2022 000.250.1600 Piping Design - Fluid Heat Tracing Execution Requirements.pdf 21-005 Practice 000.250.1600 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - FLUID HEAT TRACING EXECUTION REQUIREMENTS 1.0 PURPOSE This practice establishes the requirements for the execution of engineering and design of Fluid Heat Tracing. This practice defines the requirements for the Piping scope of work and defines the interfaces with other disciplines related to this work. 2.0 APPLICATION This practice is applicable to all projects for which fluid heat tracing is within Fluor’s scope. Fluid Heat Tracing Engineering and Design will be executed by Fluor or a sub-contracted third party; the requirements established in this practice remain equal for both forms of execution. This Practice applies to all types of Fluid Heat Tracing, except electrical heat tracing unless specifically indicated, and will be used in conjunction with Work Instruction 000.250.1930. 3.0 INTERFACING DISCIPLINES Process Engineering Electrical Engineering Control Systems Engineering Mechanical Engineering Supply Chain 4.0 DEFINITIONS Removed from the individual practices in the design guide 5.0 6.0 This section has been left intentionally blank REQUIREMENTS 6.1 The Piping Lead Engineer will prepare the Piping Heat Tracing Specification, excluding EHT. The Piping Lead Engineer is responsible for the preparation of the Piping Heat Tracing Specification which covers all design and engineering aspects required for the design, engineering, fabrication and installation of the tracing scope of the project, excluding Electrical Heat Tracing (EHT). Electrical Heat Tracing details for engineering, fabrication and installation will be created by Electrical Engineering. The Tracing Specification also covers the tracing of small equipment and instrumentation. 6.2 The Piping Design Supervisor will create and maintain the steam tracing hook-up and design details for the project. Heat Tracing hook-up and design details are used by the Fabrication and Installation Contractor for fabricating and installing the Steam Heat Tracing. © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 1/8 http://localhost:8082/PDF/000.250.1600%20Piping%20Design%20-%20Fluid%20Heat%20Tracing%20Execution%20Requirements.pdf 3/9/2022 000.250.1600 Piping Design - Fluid Heat Tracing Execution Requirements.pdf 21-005 Practice 000.250.1600 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - FLUID HEAT TRACING EXECUTION REQUIREMENTS 6.2.1 The Piping Design Supervisor will make sure that the Steam Tracing Design Guidelines and Project Requirements are included in the Piping Job Data Book for access by all project members. For reference, see Guidelines 000.250.1601 and 000.250.4300. 6.2.2 6.3 The Control Systems Engineer will create the steam tracing design details for instrumentation. The Process Engineer / Specialist will supply and maintain the Process data required for heat tracing design. The Process data includes the following: Piping to be traced Number and size of tracers, excluding EHT Type of tracing Maximum tracer length, excluding EHT Holding temperatures Allowable heat loss 6.4 The Piping Design Supervisor will prepare a Heat Tracing Transposition. The Heat Tracing Transposition is used to identify the scope of heat tracing including EHT already early in the project. It indicates where the heat traced lines will run and is the start to identify the locations of manifolds and/or tracing panels for electrical tracing. Properly maintained, it will prevent the late addition of manifolds and additional lines with tracing fluids, such as steam and is a communication tool to the other disciplines, Client and third parties involved in heat tracing design. 6.4.1 The Piping Design Supervisor will utilize the Flowsheet Transposition Step II to identify all the lines that require Heat Tracing. Refer to Practice 000.250.2010, and also to Work Instruction 000.250.1921 found in Practice 000.250.2010. 6.4.2 6.5 The Piping Design Supervisor will make sure that the Heat Tracing Transposition clearly indicates the different types of heat tracing and is used as the basis to locate and determine the number of tracing manifolds. The Piping Materials Engineer will prepare, check and issue the Piping Line Class for Tracing. Heat Tracing is either hard-piped or tubing. A dedicated pipe class for tracing materials should be prepared by the Piping Materials Engineer in Material Manager; tracing materials can be placed on Bills of Material for requisitions and material planning and issue purposes. © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 2/8 http://localhost:8082/PDF/000.250.1600%20Piping%20Design%20-%20Fluid%20Heat%20Tracing%20Execution%20Requirements.pdf 3/9/2022 000.250.1600 Piping Design - Fluid Heat Tracing Execution Requirements.pdf 21-005 Practice 000.250.1600 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - FLUID HEAT TRACING EXECUTION REQUIREMENTS 6.6 6.5.1 The Piping Materials Engineer will prepare, check and issue the Piping Line Classes required for the tracing materials on the Project. 6.5.2 The Piping Materials Engineer will, in case Client Line Classes are available, verify that the Client Line Classes are suitable for the intended tracing scope of the project. 6.5.3 The Piping Materials Engineer will include the Piping Line Class for tracing materials in the Piping Materials Specification. The Piping Area Leads will prepare the MTO of all tracing materials in the form of piping or tubing in their respective area. 6.6.1 The Piping Area Leads will prepare the initial tracing MTO on basis of the Tracing Transposition prepared for their respective area for the Project Baseline. 6.6.2 The Piping Material Controller will collect the MTOs from the Piping Area Leads and will enter these into Material Manager. 6.6.3 The Piping Area Leads will maintain the tracing MTO and will inform Piping Material Control in case there are changes to the tracing MTO. Tracing is not modeled; the tracing MTOs are prepared manually by the Piping Area Leads or their designers. The Piping Area Leads should convey all changes to the Piping Material Controller with respect to tracing materials as soon as the change has been implemented and/or approved. This should prevent late delivery of tracing materials and/or any shortage at the (module) fabrication yard and/or at the construction site. 6.6.4 The Piping Material Controller will summarize the collected Tracing MTOs for Procurement or Contracting purposes. The Piping Material Controller prepares a Purchase Requisition in Material Manager either to purchase the tracing materials by Fluor or to inform a Contractor of the tracing quantities at a certain point in the project to ensure that the Contractor can procure the tracing materials according to schedule requirements if this is part of their scope. 6.7 The Piping Design Supervisor will determine the location, quantity of connections and number of tracing manifolds. 6.7.1 The Piping Design Supervisor will maintain the number and location of the tracing manifolds, and changes will be directly processed in the 3D model and on the drawings. © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 3/8 http://localhost:8082/PDF/000.250.1600%20Piping%20Design%20-%20Fluid%20Heat%20Tracing%20Execution%20Requirements.pdf 3/9/2022 000.250.1600 Piping Design - Fluid Heat Tracing Execution Requirements.pdf 21-005 Practice 000.250.1600 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - FLUID HEAT TRACING EXECUTION REQUIREMENTS 6.7.2 The Piping Design Supervisor will create detailed fabrication drawings of the tracing manifolds. 6.7.3 The Piping Materials Engineer will, in case pre-fabricated manifolds are procured on the project, prepare the detailed Purchase Description for these items and will prepare the Purchase Requisition. Heat Tracing Manifolds can be prefabricated by the Piping Prefabrication Contractor. Piping Design should prepare detailed drawings of the Heat Tracing manifolds including a Bill of Material. The piping materials can be entered into Material Manager under the drawing number of manifold, after which the materials can be procured, received and issued to the Piping Prefabrication Contractor. Purchase of pre-fabricated manifolds from a supplier can give the project a commercial advantage. The choice whether to prefabricate the manifolds or the procure them needs to be taken on the project by Engineering, Procurement and Engineering Management. 6.7.4 The Piping Design Supervisor will create, check and issue the Manifold Location Plan. 6.7.5 The Piping Design Supervisor will assign the manifold numbers and then prepare, check and issue the Manifold Index. The Manifold Index contains all manifolds listed with their tag number completed with information about the manifold, such as location in coordinates, number of connections, spare connections, material, etc. 6.8 The Piping Design Area Leads will prepare, check and issue a Tracer Schedule for their respective design area for each tracing system. The Tracer schedule list shows as a minimum, in the sequence of the distribution manifold numbers: The traced process item numbers (line, instrument, pump) The receiving collecting manifold number The steam tracing plan drawing number. 6.9 The Piping Area Lead will prepare tracing isometrics of the tracers along the piping. 6.9.1 The Piping Area Lead will create, check and issue tracing isometrics of lead and tail lines. 6.9.2 The Piping Area Lead will prepare tracer isometrics of the tracers along the piping systems by marking-up the piping isometrics. 6.9.3 The Piping Area Lead will ensure the tracer isometrics will indicate the tag number of the steam tracing manifolds and leads/tails they are connected to. © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 4/8 http://localhost:8082/PDF/000.250.1600%20Piping%20Design%20-%20Fluid%20Heat%20Tracing%20Execution%20Requirements.pdf 3/9/2022 000.250.1600 Piping Design - Fluid Heat Tracing Execution Requirements.pdf 21-005 Practice 000.250.1600 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - FLUID HEAT TRACING EXECUTION REQUIREMENTS 6.9.4 6.10 The Piping Designer will prepare isometrics of the lead and tail lines, ensuring that leads and tails make reference to relevant distribution and collecting manifold numbers. The Piping Material Controller will provide the detailed quantities of piping with EHT to Electrical Engineering whenever a Piping MTO is performed or when requested by Electrical Engineering. Electrical Heat Tracing quantities need to be provided to Electrical Engineering in order for this discipline to determine the required power for the EHT. A late growth of EHT can cause major change (growth) for Electrical Engineering scope with effects on cable size, substation size, etc. 6.11 The Piping Lead Engineer will report the quantity of all tracing types in the monthly key quantity report. For EHT, only the quantity of piping with EHT will be reported. Forecasting the tracing quantity should be done on basis of the Tracing Transposition and the Tracing Specification. All different types of tracing used on the project should be tracked separately. 7.0 SUPPORTING RESOURCES Work Instructions Work Instructions 000.250.1930 Heat Tracing Refer to Section 9 for more information. 8.0 SUPPORTING KNOWLEDGE Other Resources Other Resources PIP PNSC0035 Steam Tracing Specification 9.0 ATTACHMENTS, ADDENDA, WORK INSTRUCTIONS Addenda Not Used © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 5/8 http://localhost:8082/PDF/000.250.1600%20Piping%20Design%20-%20Fluid%20Heat%20Tracing%20Execution%20Requirements.pdf 3/9/2022 000.250.1600 Piping Design - Fluid Heat Tracing Execution Requirements.pdf 21-005 Practice 000.250.1600 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - FLUID HEAT TRACING EXECUTION REQUIREMENTS Attachment Not Used Work Instructions Work Instructions 000.250.1930 Heat Tracing © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 6/8 http://localhost:8082/PDF/000.250.1600%20Piping%20Design%20-%20Fluid%20Heat%20Tracing%20Execution%20Requirements.pdf 3/9/2022 000.250.1600 Piping Design - Fluid Heat Tracing Execution Requirements.pdf 21-005 Practice 000.250.1600 Date 25Sep2020 Work Instructions 000.250.1930 Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - FLUID HEAT TRACING EXECUTION REQUIREMENTS 000.250.1930 HEAT TRACING Activity Responsibility 1. Refer to Project Scope Definition Documents and/or Project Requirements Checklist as applicable. Piping Engineering Lead Design Supervisor 2. Review and provide specific contract instructions for heat tracing. 3. Prepare heat-tracing documents. Steps include, but are not limited to, the Originator following: Coordinate with Process, Equipment, Electrical and Control systems and mark up a copy of the Piping and Instrumentation Diagrams (P&ID’s) identifying pipelines, instruments, and equipment that require tracing, type of tracing, and number of tracers. Route tracing runs on reproductions of the Plot Plans and locate supply and return manifolds. Mark up master P&IDs and assign manifold, supply, and return line numbers. Prepare tracing control index. Design manifolds and manifold piping on Piping Plan Drawings and/or in the Electronic 3D model. Route tubing runs on a reproduction of the isometrics (ISO’s), and indicate the start and terminal points. (The Unit Plot Plans may be used in lieu of the Piping Plan Drawings for projects where Piping Plan Drawings are not a project deliverable.) Develop the necessary ISO’s for manifold supply and return lines. Update ISO Log. Where required, generate supply and return manifold drawings indicating tracer details. (i.e. to and from details). Refer to project tracing specification. Create manifold plan using approved plot plan as background. Acceptance Criteria 000.100.F1000 000.250.1600 000.250.1601 000.250.4300 Comments 000.250.8000 000.225.1938 000.250.1600 000.250.1601 000.250.4300 000.250.50300 – Heat Tracing for Piping Equipment & Instruments Specification – Heat Tracing Design, Material, and Installation 000.225.9008 – Process Design Manual 225-008 Winterization Route tracing runs: Refer to 000.250.2010Plant arrangementFlow diagram Transposition Instructions For manifold sizing, 000.250.4300 – (PDST 4302) Trace Supply and Condensate Header Sizing 4. 5. Self-check. (see Note 1) Obtain required checks and approvals. 6. Issue in accordance with project procedures. Originator Refer to AP (Activity Plan) Design Supervisor 000.250.F0072 000.200.1037 000.250.1038 000.100.0060 Note 1: As a Fluor employee, it is your responsibility to be aware of applicable requirements and to deliver a quality work product that complies with those requirements. © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 7/8 http://localhost:8082/PDF/000.250.1600%20Piping%20Design%20-%20Fluid%20Heat%20Tracing%20Execution%20Requirements.pdf 3/9/2022 000.250.2300 Piping Design - Revamp, Brownfield and Tie-Ins.pdf 21-006 Practice 000.250.2300 Date 12Jan2022 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - REVAMP, BROWNFIELD AND TIE-INS 1.0 PURPOSE This practice specifies the requirements for the identification and development of piping tie-ins to existing piping systems. 2.0 APPLICATION This practice is to be used on all Fluor projects for all Fluor offices where the Piping Taskforce performs work for revamp projects. Revamp Work includes all engineering & design activities in existing plant facilities. 3.0 INTERFACING DISCIPLINES Construction & Fabrication Engineering Management 4.0 DEFINITIONS Removed from the individual practices in the design guide 5.0 6.0 This section has been left intentionally blank REQUIREMENTS Scope & Tie-In Approval 6.1 The Piping Lead Engineer will determine the minimum engineering scope for Revamp and Tie-In work as per the Contract, Construction and Estimate Requirements. The Piping Lead Engineer determines which deliverables and engineering data is to be developed for the development of the revamp work. During FEED, Tie-In Packages are typically not needed and only the approval of the tie-in location is needed as deliverable to the Client. For the Estimate, a routing sketch of the new line together with the type of tie-in (cold cut, hot tap, stopple, etc.) and construction phase is required. During Detailed Engineering, the IFC Tie-In Packages are issued. The Piping Lead Engineer determines as per the Contract Requirements and agreement with the Site Manager what the minimum content is. A specification for tie-in work, such as 000.250.50027, is only made when Fluor oversees third parties that perform engineering and design for tie-in work or when required to specify requirements for fabrication and installation contractors. 6.2 The Piping Design Supervisor will determine the physical location of the tie-ins to existing Piping Systems. Tie-In Locations are generally determined by Site Surveys and make use of the preliminary tie-in locations indicated by Process on the P&IDs. Refer to Guideline 000.250.2310 for specific guidelines for © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 1/10 http://localhost:8082/PDF/000.250.2300%20Piping%20Design%20-%20Revamp,%20Brownfield%20and%20Tie-Ins.pdf 3/9/2022 000.250.2300 Piping Design - Revamp, Brownfield and Tie-Ins.pdf 21-006 Practice 000.250.2300 Date 12Jan2022 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - REVAMP, BROWNFIELD AND TIE-INS determining tie-in locations. 6.3 The Piping Lead Engineer will obtain approval from the Client for the Tie-In Locations. To document the approval of the tie-in location, a simple package can be prepared which contains the minimum information for the Client to approve the locations: P&ID Photos Model Shot Indication of Tie-In on Plot Plan Tie-In List Site Surveys 6.4 The Piping Lead Engineer will determine the minimum criteria for the Site Surveys. As-Built verification is only to be performed when it is specifically part of Fluor’s Scope of Work. Otherwise, existing drawings and 3D models are to be communicated to the Client as rely-upon information. Site survey are usually costly in terms of hours and additional costs, so clear criteria per site survey are set to make them as efficient and short as possible. 6.5 The Piping Designer will perform the Site Surveys for the agreed scope which is to be surveyed in the facility. Typically, only the actual tie-in locations are surveyed in the field, preferably with the Client. Surveys of routing of new lines through existing facilities are preferably done via the laser scans in the 3D model and only verified at site when there is a need for that: Unclear laser scan Very tight lay-out Re-use of existing facilities for which the integrity needs to be verified P&IDs 6.6 The Piping Design Supervisor will mark up the P&IDs to indicate or update the locations of the Tie-Ins to Piping Systems. Refer to Work Instruction 000.250.1931 6.7 The Piping Design Supervisor will create, maintain, and issue the Demolition P&IDs based on the P&IDs with the new tie-ins. Demolition P&IDs indicate any demolition scope that is included in the project Scope of Work. To keep the P&IDs readable, the indication of demolition scope is drawn on a separate set of P&IDs. Tie-In List 6.8 The Piping Design Supervisor will create, maintain, and issue the Piping Tie-In List. © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 2/10 http://localhost:8082/PDF/000.250.2300%20Piping%20Design%20-%20Revamp,%20Brownfield%20and%20Tie-Ins.pdf 3/9/2022 000.250.2300 Piping Design - Revamp, Brownfield and Tie-Ins.pdf 21-006 Practice 000.250.2300 Date 12Jan2022 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - REVAMP, BROWNFIELD AND TIE-INS Process Data for the Tie-In List and Piping Line List is provided by the Process Engineer, refer to Practice 000.225.2470. There is no fixed format for the Piping Tie-In List. The Piping Data Manager (PDM) contains a standard format which can be used in case the Contract does not have specific requirements. The tie-in list contains, but is not limited to the following information: Tie-In Numbers Location (Area, CWP) Construction Phase (Shutdown, Post-Shutdown, etc.) Type/Method of Tie-In Reference to Drawings and other deliverables (P&IDs, Line List) Specific Line List Data* *Note: Duplication of data is to be prevented wherever possible. PDM has data integration of the Piping Line List with the Tie-In List, allowing one source of data to feed both Lists. Laser Scanning 6.9 The Project Engineering Manager will determine if Laser Scanning is to be applied on the project. Refer to Guideline 000.250.2310. Laser Scanning can reduce the effort hours required for (Piping) Engineering as site surveys can be reduced and detailed piping routing studies can be performed in the Home Office and 3D Model. Laser Scanning is considered as an alternative method of performing site surveys, specifically in hazardous locations and operating plants. Laser Scanning is: Heavy Congestion Areas Areas such as banks of exchangers, vertical or horizontal vessels, compressors, large pumps, fired heaters or heavy congestion of piping. High Elevations High elevations with limited or no conventional access require special attention. Large Diameter Piping Large diameter piping which is very difficult to conventionally measure and survey, such as Vapor Overhead lines from towers, heater ducts, etc. As-Built Verification Laser mapping can be used as a tool to verify the existing piping, equipment, etc. versus an existing 3D model or As-Built Drawings. The laser mapping model can be referenced into the 3D model and overlaid to visually show the differences and the similarities. Pipe Racks Pipe Racks, certainly multi-level congested ones, are usually not a proper scope for laser scanning. This would involve significant effort for scaffolding and platforming to be used next to a significant © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 3/10 http://localhost:8082/PDF/000.250.2300%20Piping%20Design%20-%20Revamp,%20Brownfield%20and%20Tie-Ins.pdf 3/9/2022 000.250.2300 Piping Design - Revamp, Brownfield and Tie-Ins.pdf 21-006 Practice 000.250.2300 Date 12Jan2022 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - REVAMP, BROWNFIELD AND TIE-INS number of scans to be made. Single layer, non-congested pipe racks or sleeper trackers may be considered. 6.10 The Project Engineering Manager will develop the Technical Scope of Work for the Laser Scanning Contract. The Technical Scope of Work for the Laser Scanning Contract includes items as, but not limited to: Locations, Areas, Equipment to be laser scanned Items to be scanned Quality Requirements for the Laser Scans Schedule File format of 3D Laser Scan to be supplied Other deliverables to be supplied Plant Monuments 6.11 The Project Contracts Manager will coordinate the contracting effort for the Laser Scanning Contract. 3D Modeling 6.12 The Piping Lead Engineer will determine the minimum modeling scope for brownfield areas in the 3D Model. By default, not all existing facilities are modeled in the 3D model and only the relevant existing of the facility are included in the 3D model. When a Laser Scan is available, this can be referenced in the 3D model to efficiently and correctly route new piping scope in the facility. 6.13 The Piping Designer will model the new Piping scope in the 3D model and only model the agreed existing facilities. Wall Thickness Calculations & Rerate Scope 6.14 The Piping Materials Engineer will obtain the wall thickness measurements of the tie-in locations and verify that the wall thickness is suitable for the intended tie-in. Wall Thickness measurements are typically performed by the Client after the tie-in locations are determined. In case the Client does not provide these, Fluor can prepare a Contract for these services in case this is part of the Contract Requirements or approved by the Client and thus reimbursed. 6.15 The Piping Lead Engineer will coordinate the rerating scope for Piping in case this is included in the Scope of Work for Fluor as per Work Instruction 000.250.1932. Tie-In Packages 6.16 The Piping Lead Engineer will determine the content of the IFC Tie-In Packages based on the Contract Requirements and align it with Construction & Fabrication. © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 4/10 http://localhost:8082/PDF/000.250.2300%20Piping%20Design%20-%20Revamp,%20Brownfield%20and%20Tie-Ins.pdf 3/9/2022 000.250.2300 Piping Design - Revamp, Brownfield and Tie-Ins.pdf 21-006 Practice 000.250.2300 Date 12Jan2022 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - REVAMP, BROWNFIELD AND TIE-INS The contents of the IFC Tie-In Packages vary from project to project and may be directed through the Contract Requirements (e.g., Client specifications). The Piping Lead Engineer determines the minimum content required as per the Contract Requirements and confirms the minimum requirements with the Site Manager. Certainly, when Laser Scanning is used, the need for all “paper” deliverables can be minimized, as the 3D Review Model can be used at site as well. Typical content of an IFC Tie-In Package is: P&ID Demolition P&ID Marked-up existing isometric New isometric of new line Tie-In Location Plan (plot plan background) Piping Line List Piping Tie-In List Photos Reference to Welding, Testing, Painting, and Isolation Requirements 6.17 The Piping Design Supervisor will prepare, check, and issue the Piping Tie-In Packages per Construction Phase as per Work Instruction 000.250.1931. Scope of different phases is to be specifically segregated, as the Construction Work Packages (CWPs) are different, might involve different contractors and materials have a different Required At Site (RAS) date. Typically, most tie-in work is performed outside of the plant shutdowns to the maximum extent, as plant shutdowns are very costly for the Client. The typical phases when (part of) tie-ins are installed are: Pre-Shutdown Shutdown Post-Shutdown Anytime 7.0 SUPPORTING RESOURCES Work Instructions Work Instructions 000.250.1931 Tie-In Approval and Packages Work Instructions 000.250.1932 Rerating of Existing Piping Systems Refer to Section 9 for more information. 8.0 SUPPORTING KNOWLEDGE Practices Practices 000.225.2470 Tie-In Data Guidelines Guidelines 000.250.2301 Tie-In Practices - General Design Guidelines 000.250.2310 Laser Mapping © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 5/10 http://localhost:8082/PDF/000.250.2300%20Piping%20Design%20-%20Revamp,%20Brownfield%20and%20Tie-Ins.pdf 3/9/2022 000.250.2300 Piping Design - Revamp, Brownfield and Tie-Ins.pdf 21-006 Practice 000.250.2300 Date 12Jan2022 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - REVAMP, BROWNFIELD AND TIE-INS Forms Forms 000.250.F0072 Activity Plan Piping Engineering 9.0 ATTACHMENTS, ADDENDA, WORK INSTRUCTIONS Addenda Not Used Attachment Not Used Work Instructions Work Instructions 000.250.1931 Tie-In Approval and Packages Work Instructions 000.250.1932 Rerating of Existing Piping Systems © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 6/10 http://localhost:8082/PDF/000.250.2300%20Piping%20Design%20-%20Revamp,%20Brownfield%20and%20Tie-Ins.pdf 3/9/2022 000.250.2300 Piping Design - Revamp, Brownfield and Tie-Ins.pdf 21-006 Practice 000.250.2300 Date 12Jan2022 Work Instructions 000.250.1931 Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - REVAMP, BROWNFIELD AND TIE-INS 000.250.1931 TIE-IN APPROVAL AND PACKAGES Activity 1. Responsibility The purpose of this Work Instruction is to describe the procedure to develop and issue a tie-in package. Refer to Project Scope Definition Documents and/or Project Requirements Checklist as applicable. Review and provide specific contract instructions for the tie-ins. 2. Mark up the Piping and Instrumentation Diagrams (P&IDs) with the preliminary required tie-in locations. 3. Review contract instructions, project master P&IDs and identify tie-in points via Site Survey. 4. 5. Piping Lead Engineer Piping Lead Engineer Piping Lead Engineer / Design Supervisor Process Engineering Specialist Piping Design Practice Supervisor / 000.250.2300 Piping Designer Prepare separate set of demolition P&IDs and indicate demolition scope. Assign tie-in point numbers (TPs) on P&IDs, Tie-In Location Plan and prepare Piping Design Practice Tie-In List. Supervisor / 000.250.2300 Piping Designer Determine and list tie-in type and method to be used for each line. Piping Design Supervisor / Piping Designer 6. Obtain Client approval for Tie-In Locations, Method and Timing. Piping Design Supervisor 7. Piping Design Supervisor / Lead Piping Materials Engineer / Construction & Fabrication 9. List any special remarks outside the contract instructions such as, but not limited to, the following in the tie-in package: Existing pipe material and wall thickness Welding procedures If flanged, identify size, facing and rating Testing Timing of tie-in installation to suit plant shutdown dates Special instructions for work to be performed in confined spaces or potentially hazardous areas Special safety precautions necessary Golden (closure) welds in lieu of normal butt welds, when allowed, are to be approved by Client Determine routing of new piping through the existing facilities. Use 3D Model with Laser Scan wherever possible in lieu of manual sketching with site surveys whenever possible. Send Tie-In Isometric to Stress Engineering for review, if required. 10. Prepare a new isometric and update existing isometric. 11. Send Tie-In Isometric to Stress Engineering for review, if required. 8. Acceptance Criteria Practice 000.250.2300 Form 000.100.F1000 Practice 000.250.2300 © 2022, Fluor Corporation. All rights reserved. Piping Design Supervisor Piping Design Supervisor Piping Design Supervisor Practice 000.250.2300 Comments Practice 000.225.2470 Practice 000.225.2470 Tie-in valve type to be identified in separate column in the Tie-in List Approval of locations preferably done in FEED when possible Practice 000.225.2470 Practice 000.250.1200 Practice 000.250.1200 Fluor Restricted Data. Further copying or distribution only by permission. 7/10 http://localhost:8082/PDF/000.250.2300%20Piping%20Design%20-%20Revamp,%20Brownfield%20and%20Tie-Ins.pdf 3/9/2022 000.250.2300 Piping Design - Revamp, Brownfield and Tie-Ins.pdf 21-006 Practice 000.250.2300 Date 12Jan2022 Work Instructions 000.250.1931 Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - REVAMP, BROWNFIELD AND TIE-INS 000.250.1931 TIE-IN APPROVAL AND PACKAGES Activity Responsibility 12. Provide Material Take Off needed for the Tie-In to Material Control. Piping Designer 13. Inform Design Supervisor of any changes made that will affect work already completed or in progress by other design disciplines, adjacent piping areas, specifications, supplier drawings, or significant piping material quantity. Establish blinding, purging, safety procedures and perform NDE (NonDestructive Examination) on the proposed locations. Create the Tie-In packages with agreed contents. Piping Designer 14. 15. 16. 17. Self-check. Check Tie-In package. Update Design / ISO Status Log if being utilized on project. 18. Obtain required checks and approvals (refer to Activity Plan). 19. Issue in accordance with project procedures. Acceptance Criteria Construction & Fabrication Piping Design Practice Supervisor 000.250.2300 Piping Designer Checker Practice 000.200.1037 Guideline 000.250.2301 Piping Lead Form Engineer 000.250.F0072 Piping Lead Engineer Comments When required by the contract, a Demolition Material Take Off also needs to be prepared Practice 000.200.1037 Practice 000.100.0060 or Job Bulletins Note 1: As a Fluor employee, it is your responsibility to be aware of applicable requirements and to deliver a quality work product that complies with those requirements. © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 8/10 http://localhost:8082/PDF/000.250.2300%20Piping%20Design%20-%20Revamp,%20Brownfield%20and%20Tie-Ins.pdf 3/9/2022 000.250.2300 Piping Design - Revamp, Brownfield and Tie-Ins.pdf 21-006 Practice 000.250.2300 Date 12Jan2022 Work Instructions 000.250.1932 Full Practice Printed from Quality Requirements System Global Library PIPING DESIGN - REVAMP, BROWNFIELD AND TIE-INS 000.250.1932 RERATING OF EXISTING PIPING SYSTEMS Activity Responsibility 1. The purpose of this Work Instruction is to describe the procedure to develop and issue a tie-in package. Refer to Project Scope Definition Documents and/or Project Requirements Checklist as applicable. Review and provide specific contract instructions for rerating. 2. Determine new process conditions of existing line. 3. Obtain existing drawings and other data required for rerating from Construction & Fabrication or the Client. Wall Thickness Measurements P&IDs Line List Inspection Records Perform visual inspection of the rerated piping system in the field. 4. 5. 6. 7. 8. 9. Obtain required checks and approvals (refer to Activity Plan). 11. Issue in accordance with project procedures. Comments Piping Lead Engineer Piping Lead Engineer Piping Lead Engineer / Design Supervisor Process Practice Engineering 000.225.2470 Specialist Piping Materials Engineer Construction & Fabrication, Quality & CPI, Client Determine design code to be used for rerated systems and agree with Client Piping Materials and Authorities, where required. Engineer Confirm the existing pressure relief devices are set at the appropriate Process pressure and have sufficient capacity. Engineering Specialist Perform internal pressure calculation of all piping components in the rerated Piping Materials line. Engineer Perform Stress Analysis of the rerated piping system. Piping Stress Engineer Determine testing and examination requirements for the rerated piping Piping Materials system. Engineer, Quality & CPI and Construction & Fabrication 10. Acceptance Criteria Practice 000.250.2300 Form 000.100.F1000 Practice 000.250.2300 Piping Lead Engineer Piping Lead Engineer Practice 000.250.3727 Practice 000.250.1200 Form 000.250.F0072 Requirements are based on criticality of the line, percentage of allowable stresses used and local requirements Practice 000.200.1037 Practice 000.100.0060 or Job Bulletins Note 1: As a Fluor employee, it is your responsibility to be aware of applicable requirements and to deliver a quality work product that complies with those requirements. © 2022, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 9/10 http://localhost:8082/PDF/000.250.2300%20Piping%20Design%20-%20Revamp,%20Brownfield%20and%20Tie-Ins.pdf 21-007 Guideline 000 250 2301 Date 10-May-2013 Page 1 of 9 TIE-IN PRACTICES – GENERAL GUIDELINES PURPOSE This document establishes general guidelines for various types of tie-ins. SCOPE This guideline includes the following major sections: APPLICATION RESPONSIBILITY DEFINITIONS TIE-IN GUIDELINES TESTING FORM INSTRUCTIONS ATTACHMENTS APPLICATION This document is to be used as a guideline for making piping tie-ins, including selection, location, and design of tie-in connections to existing piping and equipment. Also to be used as a guide for completing Attachment 02 and Attachment 03. RESPONSIBILITY The Lead Piping Engineering will be responsible for the physical location, design, initiation of material procurement for the tie-in, and completing the tiein forms. The Lead Process Engineer will establish tie-in process requirements. Construction will establish blinding, purging, safety procedures, and will perform NDE (Nondestructive Examination) on the proposed locations. The client will approve tie-ins, content, and locations. DEFINITIONS Tie-In: A new piping connection to any existing pipeline or piece of equipment which is made in place. Pressure Tap (hot tap): A tie-in made by drilling or cutting a line or vessel, which is either under pressure or vacuum without losing product or interruption systems operations. Stopple: A device used to isolate a section of pipe for repair or revision without depressuring or clearing the entire line. Requires a custom design fitting to be installed, and a hot tap to be performed first. TIE-IN GUIDELINES Review Requirements Use as-built P&IDs (Piping and Instrumentation Diagrams). Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-007 Guideline 000 250 2301 Date 10-May-2013 Page 2 of 9 TIE-IN PRACTICES – GENERAL GUIDELINES Check for special process requirements such as the following: - Do not pocket/Free draining/Slope lines - Vibrating service - Allowable pressure drop - Two-phase flow. With Client Operations Representative, determine hot-tap or cold-cut. Prepare tie-in list. See Attachment 02 and 03. Locate Tie-In in the Field The majority of tie-ins to existing facilities will be accomplished during a Plant shutdown. Those piping systems remaining live during a Plant shutdown and requiring tie-ins will be identified as such in the preliminary flowsheet markups. As illustrated by the following items, special care and attention will be given during the design phase, which will be effective in minimizing system shutdown requirements: Tie-in points will be tagged with a weatherproof tag indicating the job number and tie-in number, and will be fixed to the tie-in location by means of a semipermanent but removable device such as a wire. The tie-in point will be painted on the pipe or valved tie-in point with a color of paint which is acceptable to the Plant Engineer. It is good practice to photograph each tie-in after tagging in the field, for recording purposes. Tie-ins will be as shown on applicable P&IDs. Use existing connections when possible. - Valve with no connection. - Blind flange; tap off with sealed plugs for small bore. - Replace existing flanged spools with new spools incorporating a connection point. Choose locations which can be blocked by existing valves. Review and obtain approval of tie-in locations with Process, Operations, and Maintenance. Determine testing requirements. Use Attachment 02 FSR (Field Service Request) Tie-In List Instructions and Sample Forms, for manual measurements and survey data. - Determine existing reference coordinates and elevations by survey, and paint the information on the reference item in the field; for example, pipe support column coordinates and top of steel elevations. - Measure from marked columns and steel elevations. - Take pipe measurements from welds rather than from hard-to-find centerline of elbows or Tees. - On critical tie-ins, have centerline elevation and 1 set of coordinates surveyed to complement manual field measurements. - Perform UT on existing line. (Does it meet code?) - Determine type of PMI (Positive Material Identification) on the existing line. - Determine type of existing insulation or tracing. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-007 Guideline 000 250 2301 Date 10-May-2013 Page 3 of 9 TIE-IN PRACTICES – GENERAL GUIDELINES When the Fluor Piping Design team is close to completing their work, the Fluor Piping and Process Engineers will travel to the plant site and together will check the Plant Design team work from a Process and constructability standpoint. When piping tie-ins are checked by Fluor Piping and Process Engineers, they will be reviewed with the plant's Project Engineer for approval. After preliminary approval by the plant's Project Engineer, Fluor Piping will formally draw up the Piping tie-in isometrics and Piping tie-in key plans, and develop the Piping tie-in list which will be issued formally for approval. Prepare Demolition Isometric Demolition can be shown on existing isometrics or be part of the new tie-in isometric. Demolition isometrics show Construction exactly where the existing line has to be cut to install the new tie-in. Piping and process should review P&ID and isometric for alignment. Design Routing of Line from Tie-In to Destination Field check for clearances, by Piping Lead or Designee. Try to maximize the use of existing steel. (Pass the additional loads to CSA on existing steel, especially on large bore lines.) Do not block future expansions. Use 3D Laser Scanned image as reference for design, where applicable. Review Isometrics Verify constructability (such as crane access and welder access). Verify clearances for hot-tap machine (if required). Verify clearances for bolt tensioning, where applicable. Verify sketch's level of detail; does it show existing anchors, guides, and supports (for stress review)? Verify that thermal expansion has been accounted for when taking existing line field measurements. Consider flanged spools if hot work is not permitted, or limited in accordance with construction strategy. Verify that existing isolation valves are shown. Verify new loads have been passed, and agreed to by CSA, if existing structure has been used. Considered the actual available shutdown time and the time required to cool the line (if it is hot), then cut it, pre-heat for weld, welding time, post-weld heat treatment time, number of passes for welding. This is especially important if the wall thickness of the line is high. These inputs can be obtained from Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-007 Guideline 000 250 2301 Date 10-May-2013 Page 4 of 9 TIE-IN PRACTICES – GENERAL GUIDELINES construction team. If any temporary supports are required on the tapping, then their feasibility also should be studied and time required to erect these temporary supports should be accounted. Documentation In addition to data normally shown on Piping drawings, the following information will be given when hot tapping or stoppling piping or equipment: Process fluid or vapor, minimum and maximum operating pressure and temperature, and minimum and maximum design pressure and temperature. Material specifications, acceptable wall thickness (not less than calculated minimum), and corrosion allowance of equipment or pipe to be tapped. Design code (e.g. ASME B31.3, B31.4, etc). Exact location and orientation of tapping nozzle. Drill or cutter diameter. Nozzles and adapters will be according to Piping Material Specifications as shown on the drawings. For cast iron lines, tapping saddle or sleeve specifications and the exact outside R(radius) of the lines measured at the point of pressure tapping. Special welding and heat testing procedures, if required. Valve size, rating, materials, and type. Packing material for valve and tapping machine, if other than that shown in the Piping Material Specifications for the valve. Gaskets for valve, adapter, and tapping machine, if other than that shown in the Piping Material Specifications for the valve. Test fluid and pressures for testing nozzle, valve, adapter and reinforcing pad (if reinforcing is specified), and special instructions for removal of test fluid and cleaning the nozzle, if required to prevent product contamination. Special instruction for work to be performed on equipment containing toxic or potentially hazardous material, and any other special safety precautions which may be required. Precautionary notes such as those required when tapping or stoppling ethylene, butadiene, or acetylene. The minimum clear, full-round valve opening required (allow for 1/8 of an inch (3 mm) clearance in diameter), and the specific valve meeting this requirement. If reinforced connections are not commercially available or if excessive time is required to secure the commercial connections, specify the following and provide the necessary information for their fabrication: - Cast iron lines. Design according to applicable code. - Other than cast iron lines. Specify pad. Materials Valves, packing, gaskets, and other piping components will be in accordance with the Piping Material Specifications. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-007 Guideline 000 250 2301 Date 10-May-2013 Page 5 of 9 TIE-IN PRACTICES – GENERAL GUIDELINES Nozzle reinforcement material will be of the same nominal chemical composition and physical characteristics as the branch connection and the equipment being tapped. Pressure Taps Pressure taps must be approved by Owner's Engineer. Pressure taps may be used for the following: - To provide a connection into Piping or Process equipment without disrupting normal process operations. - To provide a connection into Process equipment that has been depressured but which is impractical to prepare for "hot work." An example would be connections into long underground pipelines. - To provide a connection into a pipeline for inserting a plugging or stoppling device to isolate equipment or a section of pipe. Pressure tapping of lines or vessels containing the following is not permitted unless written approval is obtained from the client, and client approved procedures are followed: - Compressed air - Caustic soda - Oxygen - Unsaturated hydrocarbons - Decomposable Pressure taps will not be used unless it is impractical to employ conventional methods. Each tap will be evaluated on its own merits considering operating conditions, material contents, and location. The following requirements will be met: - Pressure taps will not be made in equipment while it is operating at a temperature below the metal transition temperatures. - Special preheat, welding, and post heat procedures may be required for pressure taps that will be made at low temperatures (below 40 degrees F; 4 degrees C). - Pressure taps will not be specified for equipment handling amine (MEA and DEA) or caustic, if operating conditions would require stress relief. - Pressure taps will not be specified for equipment or lines containing flammables below atmospheric pressure, or containing a mixture within the flammable range and operating at any pressure. - Pressure taps will be avoided or special precautions specified when air hardening alloys are involved. - Pressure tapping of equipment containing hydrogen is permissible, provided the equipment has not operated above the Nelson curve limits. - When equipment containing hydrogen sulfide or other toxic materials is to be pressure tapped, special safety precautions for these materials will be specified. - If equipment handling ethylene, butadiene, or acetylene is to be pressure tapped, special precautions must be taken to maintain circulation and prevent overheating and thermal decomposition (with possible explosion) of the contents. Do not pressure tap pressurized piping or pressure vessels at locations where fluid flow does not exist. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-007 Guideline 000 250 2301 Date 10-May-2013 Page 6 of 9 TIE-IN PRACTICES – GENERAL GUIDELINES Pressure tapping of storage tanks will not be specified, except at locations on the shell where the liquid level can be maintained at least 3 feet (0.9 m) above the highest point of welding during welding operations. Do not pressure tap equipment upstream of rotating machinery, unless facilities exist (such as strainers) that will prevent cuttings and droppings from reaching the machinery. Bolt-on connections will be used for pressure tapping cast iron equipment. Pressure tapping of reinforced concrete pressure piping (or other internally lined equipment) is allowed; however, special tapping materials, equipment, and techniques are required. Design of pressure tap connections will be in accordance with the applicable Codes and Standards. Locate pressure tap connections according to the following: - Allow sufficient clearance to install connections and operate the tapping or plugging equipment. - Whenever possible, locate connections so welding is performed at least 2 feet (0.6 m) from flanges, threaded connections, and riveted joints. This should prevent leaks from developing in those joints. - Locate connections so that no welding is required within 2 inches (50 mm) of an existing weld. The nozzle length must be determined for the particular tapping machine that will be used in order to ensure a complete cut through the equipment wall. In addition, for flanged nozzles, the length should be adequate to permit removal of flange bolts. When practicable, the face-to-center line dimension of flanged nozzles for perpendicular connections to pipeline should be the same as the corresponding dimensions for a welding tee, and welding neck flange of the same size and rating as the tapped line. Connections will be the reinforced type using one of the following: - Pressure tap connections for size-to-size connections will be a full encirclement saddle (3-inch minimum (75 mm) width and a minimum thickness of either 1/4 of an inch (6 mm) or the header wall thickness, whichever is greater). - Pressure tap connections for other than size-to-size will be one of the following: a) Integrally reinforced welding outlet fitting (fully welded). b) Reinforcing pad (3-inch (75 mm) minimum width and a minimum thickness of either 1/4 of an inch (6 mm) or the header wall thickness, whichever is greater). c) Full encirclement, weld-on saddles (3-inch (75 mm) minimum width and a minimum thickness of either 1/4 of an inch (6 mm) or the header wall thickness, whichever is greater). d) Full encirclement, bolt-on saddles where attachment by welding is not permitted. - Pressure tapping connections for cast iron pipelines will be full encirclement, bolt-on saddle. - Stoppling connections will be full encirclement type, fitting equal to T. D. Williamson's stopple fitting. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-007 Guideline 000 250 2301 Date 10-May-2013 Page 7 of 9 TIE-IN PRACTICES – GENERAL GUIDELINES Connections will be designed to prevent buckling of the surface being tapped, due to application of test pressure to the inside of the branch connection. An acceptable method for calculating the buckling pressures in externally loaded cylinders is given in R. J. Roark's Formulas For Stress And Strain, Fourth Edition, Page 54, Item S(34). The minimum pressure tapping nozzle and valve size specified will be 1 inch NPS. Heating or purging of the tapping or stoppling connection will be specified, if the equipment contents will be solid at ambient temperatures. NOTE: All Pressure Taps should be reviewed with HSE. Bolt-On Connections When welding or other hot work is not allowed, pressure taps using bolt-on connections will be considered. When bolt-on saddles are used to pressure tap equipment within limits or in fire hazardous areas, a fireproof gasket will be specified. Valves Valves must have clear, full round openings at least 1/8 of an inch (3 mm) greater in diameter than the specified drill or cutter OD. Valves will be inspected for sufficient clearance of cutter prior to tapping. Regular-port (not tilted-port or venturi-port) gate valve with the same NPS and rating as the branch connection will be specified, except as follows: - Ball valves may be used, if port opening and material specifications are adequate. - Corporate plug cocks (3/4 of an inch NPS) may be used in water service, if the line being tapped is cast iron or steel, Schedule 40, and is 4 inch NPS or larger. - If maximum drill diameter is required for valves size 2-inch NPS and smaller, full-port valves equal to Smith Valve No. 88 (threaded or socketweld). - Flanged full-port valves will be either API 600 pattern (available in 1- 1/2 inch and 2-inch sizes) or forged body (available in any size as a special order); check availability with the Material Engineer. For valve sizes 2 inch NPS and smaller (other than full-port type), it may be necessary to use a drill diameter one size smaller than that specified in order to clear the valve seat rings. This decision must be made in the field after the valve has been selected, since inside dimensions of the smaller valves vary widely with manufacturer and style. Testing The hot tapping or stoppling connections, reinforcing pad, valve, machine, and joints will be pressure tested prior to tapping the line. Hydrostatic test shall be specified for equipment operating between 40 and 200 degrees F (4 and 95 degrees C), unless other special conditions require a Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-007 Guideline 000 250 2301 Date 10-May-2013 Page 8 of 9 TIE-IN PRACTICES – GENERAL GUIDELINES different test medium. Air, nitrogen, or another inert gas shall be specified for other temperatures. Test pressure for the valve, nozzles, and reinforcing pad (if required) will be as follows: - For tanks, test pressure will be 40 psi (275 kPa). For piping and pressure vessels, test pressure will be calculated in accordance with the applicable code and will be based on the most severe combination of design pressure and temperature (not the operating conditions), since operating conditions may change from time to time. FORM INSTRUCTIONS FSR (Field Service Request) This form is to be initiated by the Piping Engineering Lead as a request for service for data from the field. Piping Tie-In List This form is to be completed as follows: Header Section Fill in the title area with the originator's (BY) initials, Checker's (CHK) initials, contract number, unit and area numbers, sheet number, revision, and date. Revision Section Provide revision number indicating when the individual tie-in was added or last revised. Drawing Reference Section Provide Fluor tie-in number (and Client tie-in number, if required). Provide Piping line number, sheet number, and pipe size. Provide Piping plan drawing number, or Tie-In Key/Location plan number, on which the tie-in appears. Provide P&ID number and drawing section where the tie-in appears. Planning Section Tie-in line service. Provide measured wall thickness of the existing pipe. If equipment, list equipment number and put equipment name or other designator in remarks. Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-007 Guideline 000 250 2301 Date 10-May-2013 Page 9 of 9 TIE-IN PRACTICES – GENERAL GUIDELINES Provide tie-in size and facing; for example, 4"-300RF. Indicate the material status. (Is the material ready for installation?) Indicate whether Fluor or the Client will perform the tie-in. Indicate how the line will be prepared for making the tie-in; for example, blinding, purging, and cleaning. Indicate Process and Client approvals. Indicate start and finish dates of shutdown or shutdown phase period. Indicate if a hot tap is required. Yes or No. Indicate Hot work other than Hot Tap. If any example, cold cut and welding after plugging. Indicate if the Field Service Request Form was generated. Yes or No. Indicate date when the tie-in isometric went AFC. Construction Section Indicate date when tie-in is complete. Indicate date when inspection and hydrotest are complete. Remarks Section Any pertinent comment regarding a tie-in. ATTACHMENTS Attachment 01: Tie-In Examples Attachment 02: FSR (Field Service Request) Attachment 03: Piping Tie-In List Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-007 TIE-IN APPROVAL FORM 21-007 T-001 PURPOSE TIE-IN DETAIL The purpose of the Tie-in Approval Form is to document the approval and verification of the designated tie-in locations, as shown in the Tie-in Detail and referenced drawings, by Client and Fluor representatives. Verification is to be conducted during a site walk through touching & tagging of each tie-in. Model Shot / Site Photo SCOPE Tie-in No. Execution Window Tie-in Description T-001A 2016 Outage Flanged connection (North) on Inlet header horizontal spool T-001B 2016 Outage Field weld connecting flange (South) on Inlet header vertical spool TIE-IN DRAWINGS Document Number Revision Description 1 2 3 4 5 6 APPROVAL OF TIE-IN LOCATION Name Title Plant Operations Signature Date Tie-in Location Tie-in Sketch (Optional) Construction Project Engineer Engineering Manager Fluor Process Fluor Piping Revision 1A1 Description Issued for Review Date 2015-11-26 Originator AP Checked MB Approved TM 21-007 Guideline 000.250.2301 Date 10-May-2013 Page 1 of 1 Attachment 02 ® FSR (FIELD SERVICE REQUEST) DATE: CONTRACT NO.: FSR NUMBER: PROCESS APPROVAL: REV. NO.: AREA: PIPING APPROVAL: CLIENT APPROVAL: UNIT: TIE-IN DATA Service Existing Design Conditions Temp Press. Fluor Tie-in Number Existing Line Number Isometric Line Number Piping Drawing Number DRAWING DATA P&ID Drawing LDT Drawing Number Number Access Req Ladder / Scaffold Confirm Insulation Type (Yes / No) SERVICE DATA Insul Removal Insul Removal (Yes / No) (Temp / Perm) Verify Exst Matl (Yes / No) Verify Exst Wall Thickness (Yes / No) Insulation Type (Cal. Silicate) Insul Removed (Yes / No) Verify Flange Rating (Yes/No) Photo Required (Yes/No) FIELD VERIFICATION DATA Coordinates Existing and Elevations Material Existing Material Existing Wall Thickness Insul Removal (Distance) Confirm Coord's Elev (Yes / No) Confirm Existing Cond’s (Yes/No) Measured Wall Thickness Flange Rating If the tie-in is a welded connection, is there a flanged connection close by that can be utilized? (Yes / No) Are the existing guides and directional anchors clearly identified in the as-built status? (Yes / No) COMMENTS Copyright © 2013, Fluor Corporation. All Rights Reserved. Piping Engineering 21-007 Client Name: Project Name: Project Number: Guideline 000 250 2301 Date: 10-May-2013 Page 1 of 2 Attachment 03 ® PIPING TIE-IN LIST Date: Contract No: Unit: Rev: PO No: Area: By: Reviewed: Drawing Reference Rev No Tie-in No Status Priority Piping Dwg No Copyright © 2013, Fluor Corporation. All Rights Reserved. P&ID Dwg No Tie-in Location Control Plan Dwg No Tie-in WBI No Tie-in Type Line No Size Class Existing Line Tracing Y/N Tracing Type, Insul. Type and Thickness Design Presure Design Temp Line No Size Class Existing Line # and Size Tracing Y/N Existing Tracing Type, Insul. Type and Thickness Comments Design Pressure Design Temp Piping Engineering and Design 21-007 Client Name: Project Name: Project Number: Guideline 000 250 2301 Date: 10-May-2013 Page 2 of 2 Attachment 03 ® PIPING TIE-IN LIST Date: Contract No: Unit: Rev: PO No: Area: By: Reviewed: Drawing Reference Rev No Tie-in No Status Priority Piping Dwg No P&ID Dwg No Copyright © 2013, Fluor Corporation. All Rights Reserved. Tie-in Location Control Plan Dwg No Planning WBI No Commodity Existing Wall Tie-in Size & Thickness Facing Material Status Tie-in by Client or Fluor Existing Line Prepared Y / N Process Approval Construction Client Approval Shutdown & Phase Period Hot Tap Required Field Service Request Issued Comments Isometric Issued Tie-in Installed Inspection & Hydrotest Piping Engineering and Design 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 1 of 12 Revision PIPING TIE-INS This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. Date Originator's Name & Initials APPROVALS Reviewed/Checked By Name & Initials SIGNATURES Pages DATE Lead Engineer Project Manager: Client Approval: ISSUED FOR : 00025050027.doc Construction Other Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 2 of 12 Revision PIPING TIE-INS Record of Revisions Revision No. 00025050027.doc Date Description Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 3 of 12 Revision PIPING TIE-INS 1.0 GENERAL 1.1 Summary A. B. Scope of Specification 1. This specification provides guidelines for design of piping tie-ins, selection of tie-in methods, and control and coordination of piping tie-ins for the purpose of planning and safely performing tie-in work. 2. Wherever a difference exists between this specification and the drawings, the drawings shall govern. No deviation shall be made from this specification without written authorization from Fluor Daniel. Related Specifications The following specifications prescribe items of related Work: • • • • • 000.250.50003: 000.250.50026: 000.250.50050: 000.285.50028: 000.285.85002: Piping - Material Specification Line Class Field Fabrication And Installation - Process And Utility Piping Piping Pressure Testing Internal Cleaning Of Piping Systems Welding - Piping Shop / Field Fabrication Coordinate Work prescribed by this specification with Work prescribed by the above listed specifications. C. Related Technical Requirements 1. 2. D. Williamson, T. D., Stopple Fitting. Roark, R. J., Formulas for Stress and Strain, Fourth Edition. Supplied by Owner In cases when the Owner will perform connections to existing piping or equipment, the tie-in point shall be the interface point between the Owner supplied piping and Fluor Daniel's scope piping. E. 00025050027.doc Terminology 1. Cold Tap: Work to be performed with piping or equipment out of service, depressurized, and vented. 2. Hot Tap: Work to be performed with piping or equipment in service by welding or drilling. Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 4 of 12 Revision PIPING TIE-INS 1.2 3. Stoppling: A device used to isolate a section of pipe for repairs or modifications without depressurizing or clearing the entire line, by mechanical means through hottapped connections. 4. Hazardous Substances: Included, but are not limited to, those substances that are explosive, combustible, toxic, or corrosive. 5. Flammable Service: A fluid which, under expected operating conditions, is a vapor or produces vapors that can be ignited and continue to burn in air. 6. Confined Space: An enclosure with known or potential hazards and restricted means of entrance and exit. References The publications listed below form part of this specification. Each publication shall be the latest revision and addendum in effect on the date this specification is issued for construction unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, Work included in this specification shall conform to the applicable provisions of these publications. A. ANSI (American National Standards Institute) 1. B. D. ANSI/AWS F4.1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances. API (American Petroleum Institute) 1. API Publication 2009 Safe Welding and Cutting Practices in Refineries, Gas Plants, and Petrochemical Plants 2. API Publication 2201 Procedures for Welding or Hot Tapping on Equipment Containing Flammables 3. API Publication 941 Steels for Hydrogen Service at Elevated Temperatures and Pressures in Petroleum Refineries and Petrochemical Plants ASME (American Society for Mechanical Engineers) 1. 2. 3. 00025050027.doc Safety in Welding and Cutting ANSI/AWS (American National Standards Institute/American Welding Society) 1. C. ANSI Z49.1 ASME B31.1 ASME B31.3 ASME BPV Section IX Power Piping Chemical Plant and Petroleum Refinery Piping Welding and Brazing Qualifications Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 5 of 12 Revision PIPING TIE-INS E. 1.3 Where fabrication and design criteria in this specification are affected by city, county, state, or federal requirements, this specification shall be modified as necessary to ensure compliance. System Description A. Design Requirements 1. Piping tie-ins shall be approved by Fluor Daniel Lead Piping Engineer and Client Representative before any work can be done to existing piping by Fluor Daniel Construction Personnel or Contractor. 2. A piping tie-in method for each tie-in shall be established before any tie-in work can be started. 3. Tie-in methods shall be grouped in the following procedures, and the procedures strictly adhered to during piping tie-in work: 4. B. a. Cold Tap Procedure in Conjunction With Total Plant Shutdown (refer to Attachment 01). b. Cold Tap Procedure in Conjunction With System Shutdown or Isolation of Pipe (refer to Attachment 02). c. Hot Tap Procedure - Minimum Guidelines (refer to Attachment 03). d. Hot Tap Procedure by Stoppling - Minimum Guidelines (refer to Attachment 03). Procedures may also be submitted to the Fluor Daniel Lead Piping Engineer for approval (refer to Section 1.4, of this specification). However, no deviation from the minimum guidelines and safety considerations specified in this specification shall be permitted. Drawing Preparation Requirements Tie-in points shall be identified on the P&IDs (Piping and Instrumentation Diagrams) and piping drawings with the Fluor Daniel tie-in symbol and numbering system as defined on the P&ID legend key sheet. 1. P&IDs a. b. 2. Piping Plan Drawings a. 00025050027.doc Locate and tag tie-in points during the development of flow diagrams. Show sufficient detail of existing piping to identify the point of tie-in. Tie-in points shall be indicated in the piping plans, taking into consideration clearances required to perform tie-in work. Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 6 of 12 Revision PIPING TIE-INS b. 3. Field survey of tie-in location shall be done, and it is recommended early during design. Isometric Drawings In addition to data normally shown on isometric drawings, the following information shall be given when tapping or stoppling piping or equipment: a. Process fluid or vapor with maximum operating pressure and temperature. b. Material specifications, wall thickness (no less than calculated minimum) of equipment or pipe to be tapped. c. Exact location and orientation of tapping nozzle. d. Drill or cutter diameter. e. Nozzles and adapters shall be in accordance with Piping Engineering Specification 000.250.50003, as shown on the drawings. f. For cast iron lines, tapping saddle, or sleeve specification and the exact outside radius (R) of the line as measured at the point of pressure tapping. g. Special welding and preheating procedures, if required. h. Test fluid and pressures for testing nozzles, valve, adapter, and reinforcing pad (if reinforcing is specified), and special instructions for removal of test fluid and cleaning the nozzle, if required to prevent product contamination. i. Special instruction for work to be performed on equipment containing toxic or potentially hazardous material and any other special safety precautions which may be required. j. Precautionary notes such as those required when tapping or stoppling ethylene, butadiene, or acetylene. k. The minimum clear, full-round valve opening required (allow for 1/8 of an inch clearance in diameter) and the specific valve meeting this requirement. l. If reinforced connections are not commercially available or if excessive time is required to secure the commercial connections, specify the following and provide the necessary information for their fabrication: • • C. 00025050027.doc Cast Iron Lines (Design according to applicable code.) Other than Cast Iron Lines (Specify pad.) Piping Tie-In List Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 7 of 12 Revision PIPING TIE-INS A piping tie-in list shall be prepared and issued for use by Construction / Contractor. Completed tie-ins shall be initialed and dated on the tie-in list by authorized personnel responsible for performing tie-ins, Fluor Daniel personnel on site, and the Client. 1.4 Submittals A. B. 1.5 It is mandatory that in advance of any hot tap work, the following items should be prepared and submitted to Fluor Daniel for approval: 1. WPS (Weld Procedure Specification) and PQR (Procedure Qualification Record) 2. A hot tap procedure 3. A connection design and type of hot tap machine 4. Health, safety, fire protection, and other appropriate instructions, including Owner or User requirements Alternate cold tap procedures may be submitted for Fluor Daniel approval. Otherwise, the cold tap procedures specified herein shall be adhered to. Quality Assurance To ensure that the proper precautions are taken before and during tie-in work, the following safety precautions shall be taken into consideration: A. Safety Precautions 1. Piping systems that have held hazardous substances shall be prepared before tie-in work, in accordance with ANSI / AWS F4.1 and this specification. 2. Welding or hot tapping on piping containing flammables shall be done in accordance with API Publication 2201 and this specification. 3. Only qualified personnel are allowed to perform tie-in work. Qualified personnel are designated by Fluor Daniel and Client, in writing, as capable (by education or specialized training, or both) of anticipating, recognizing, and evaluating employee exposure to hazardous substances or other unsafe conditions. These personnel should be capable of specifying the necessary control or protective action, or both, for worker safety. 4. A hot work permit must be obtained from Fluor Daniel or Client Representative before any hot tapping can be performed. (Refer to Attachment 03.) 5. Welding Precautions a. 00025050027.doc Welding shall not be performed on compressed air lines or air receivers under pressure. Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 8 of 12 Revision PIPING TIE-INS 6. b. Welding shall not be performed on piping operating above its rated working pressure. c. No welding shall be performed in gas service piping unless a minimum flow is maintained to ensure dissipation of heat. d. No welding shall be performed in tanks and vessels above their liquid level. e. No welding shall be performed on piping which is operating at less than atmospheric pressure unless prior written approval is obtained from Fluor Daniel. f. No welding shall be performed on pipe operating at a temperature below 40 degrees F unless prior written approval is obtained from Fluor Daniel. Hot tapping of lines or vessels containing the following services is not permitted unless written approval from Fluor Daniel and Client is obtained: • • • • • • Flammable vapor/air mixtures Oxidizing chemicals such as oxygen, peroxide, or chlorine Unsaturated hydrocarbons Caustic soda Amines Ammonia 7. Hot tapping shall not be done on piping with cladding or linings such as glass, lead, refractory, plastic, and strip lining. 8. Hot tapping shall not be done in piping requiring PWHT (Postweld Heat Treatment). 9. Avoid hot tapping upstream of rotating equipment unless such equipment is protected from the cuttings by means of filters or strainers. 10. To ensure that hot tapping will be performed under safe conditions, a checklist is attached for consideration. Refer to Attachment 03. 11. For work above and below grade, or in congested areas, provide for easy personnel exit. To ensure that excavations are safe for entry and hot line work, tests for presence of flammable and toxic material shall be made. If either of these are present, an air mover or some other positive means of ventilation shall be provided. Air breathing equipment must be used to protect personnel from toxic atmospheres or vapors emitted as a result of welding or penetrations into lines. Refer to Section 1.6, of this specification, for site conditions. 1.6 Site Conditions A. 00025050027.doc Existing Conditions Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 9 of 12 Revision PIPING TIE-INS B. 1. Tie-in work performed in Refineries, Gas Plants, and Petrochemical Plants shall be in accordance with API Publication 2009. 2. Tie-in work locations shall be analyzed for the appropriate safeguards and types of personal protective equipment available if needed. Factors that require consideration are as follows: a. The work location must be gas free, and precautions should be taken to prevent ignition of flammable or combustible materials. b. Before welding or cutting is performed above or near oily surfaces, the area should be flushed with water, steam cleaned, or covered with clean dirt or sand, or other precautions should be taken. c. Tie-in work should not be permitted while adjacent equipment that contains flammable liquid or vapor is being opened, disassembled, steamed, ventilated, or flushed of sediment. d. Provisions should also be made to ensure that cutting or welding operations inside a confined space do not create a hazard to personnel. (Refer to ANSI Z49.1.) Sequencing and Scheduling Plant shutdown schedule should be requested from the Owner in order to prioritize and schedule tie-in activities (such as drawing issue, material purchase, and material delivery). 2.0 PRODUCTS 2.1 New Material Criteria A. Valves, packing, gaskets, and other piping components shall be in accordance with Piping Engineering Specification 000.250.50003. B. Nozzle reinforcement material shall be of the same nominal chemical composition and physical characteristics as the branch connection and the equipment being tapped. C. Branch connections shall be in accordance with Piping Engineering Specification 000.250.50003. D. Special branch reinforcing may be required for hot tapping to prevent buckling of header during pressure testing of the branch connectors. E. Hot Tap Valves 1. 00025050027.doc Valves must have clear, full, round openings at least 1/8 of an inch greater in diameter than the specified drill or cutter OD. Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 10 of 12 Revision PIPING TIE-INS 2. 3. 2.2 00025050027.doc a. Ball valves may be used if port opening and material specifications are adequate. b. Corporation plug cocks (3/4 of an inch NPS) may be used in water service if the line being tapped is cast iron or steel. Schedule 40, and 4-inch NPS or larger. c. If maximum drill diameter is required for valves sizes 2-inch NPS and smaller, full port valves equal to Crane Company's No. 3607XU (threaded) or No. 3615XU (flanged) shall be specified. For valve sizes 2-inch NPS and smaller (other than full port type), it may be necessary to use a drill diameter 1 size smaller than that specified in order to clear the valve seat rings. This decision must be made in the field after the valve has been selected since inside dimensions of the smaller valves vary widely with manufacturer and style. Existing Material Criteria A. 2.3 Regular port (not tilted port or venturi port) gate valve with the same NPS (Nominal Pipe Size) and rating as the branch connection shall be specified, except as follows: Hot Tapping 1. Some pipe systems may be unsuitable for hot tapping because the metallurgy or thickness of metal requires stress relieving, which normally cannot be done while the system is in service. Special treatment is required for high tensile strength alloy steels, and special welding electrodes must be used. Hot tap fitting and weld rod metallurgy must be compatible with piping to be welded. 2. The base metal thickness must provide support for the new connection and the hot tap machine or be properly reinforced to provide such support. Generally, a minimum base metal thickness of 3/16 of an inch is recommended for hot tapping. A minimum base metal thinner other than 3/16 of an inch shall not be hot tapped without written authorization from Fluor Daniel and Client. 3. The base metal must be free of lamination, hydrogen attack, or stress corrosion cracking. There must be no other imperfections that would prevent a solid weld from being made. 4. Stress relieving of the welded area must not be required. Hot Tap Machine Criteria A. The hot tap machine shall be of the proper size and rating to accommodate the required pipe branch connection. B. Hot tapping machines have a maximum working pressure and temperature rating which shall not be exceeded. The machine may be powered by hand, hydraulic fluids, or pneumatic drives. Electric motor drives are prohibited. Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 11 of 12 Revision PIPING TIE-INS 3.0 C. The hot tap machine shall have an accurate means by which to indicate the travel distance of the pilot bit and cutter. D. The design shall include the specification for gaskets, tapping valve, and bolts. Hot tap fitting length must accommodate the machine. Sufficient clearance for operation of the machine must be provided. E. Before hot tapping is attempted, the machine, cutter, and pilot bit shall be carefully inspected to ensure that all are in satisfactory condition. EXECUTION 3.1 Preparation Tie-in work shall not start until the following criteria have been met: 3.2 A. Design and safety considerations have been taken into account. B. Each tie-in point must have a tapping-type listed on the tie-in list. Application And Installation A. Tie-in work shall be done in accordance with referenced procedures in this specification's Attachment section, and Piping Engineering Specification 000.250.50026. B. Tie-in work procedures shall be outlined as follows: C. 4.0 1. Preparation and Safety Precautions 2. Inspection and Testing Prior to Tie-in Work 3. Cleaning Prior to Tie-in Work 4. Installation 5. Quality Control 6. Post Tie-in Work Inspection, Testing, and Cleaning Refer to Attachments 01, 02, and 03 for detailed description of procedure. ATTACHMENTS Attachment 01: (18Jan00) Cold Tap Procedure In Conjunction With Total Plant Shutdown 00025050027.doc Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Page 12 of 12 Revision PIPING TIE-INS Attachment 02: (18Jan00) Cold Tap Procedure In Conjunction With System Shutdown Or Isolation Of Pipe Attachment 03: (18Jan00) Hot Tap And Stoppling Procedure - Minimum Guidelines End of Specification 00025050027.doc Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Attachment 01 - Sheet 1 of 1 Revision PIPING TIE-INS Cold Tap Procedure In Conjunction With Total Plant Shutdown 1. 2. 3. Preparation and Safety Precautions a. Tie-in work shall be done only at specified tie-in points. b. Tie-in points shall be clearly marked with tie-in point numbers identical to tie-in list. c. Tie-ins shall be done in sequence with a schedule previously prepared by Fluor Daniel and Client to ensure tie-ins can be completed during plant shutdown. d. Special considerations shall be given to any tie-in work done on piping which has contained hazardous substances (refer to ANSI/AWS F4.1.). e. Each tie-in work area shall be prepared in accordance with Section 1.6.A, before tie-in work is performed. Inspection and Testing Prior to Tie-in Work a. Existing piping shall be inspected. b. Valves in the line should be closed and locked out. The pipe should be disconnected and drained. The open end of the pipe sections not being worked on should be blanked off. Cleaning Prior to Tie-in Work Cleaning shall be in accordance with Welding Engineering Specification 000.285.50028. 4. Installation Installation of new piping systems shall be done in accordance with Piping Engineering Specification 000.250.50026. Welding shall be done in accordance with Welding Engineering Specification 000.285.85002. 5. Quality Control After the tie-in work is completed, it shall be checked in accordance with the existing plant safety criteria and the appropriate construction QC (Quality Control) practices. 6. Post Tie-in Work Inspection, Testing, and Cleaning Testing shall be done in accordance with Piping Engineering Specification 000.250.50050. 00025050027a01.doc Piping Engineering Client Name Project Name Contract Number 21-008 Master Specification 000 250 50027 Date 18Jan00 Attachment 02 - Sheet 1 of 1 Revision PIPING TIE-INS Cold Tap Procedure In Conjunction With System Shutdown Or Isolation Of Pipe 1. 2. 3. Preparation and Safety Precautions a. Tie-in work shall be done only at specified tie-in points. b. Tie-in points shall be clearly marked with tie-in point numbers identical to tie-in list. c. Tie-ins shall be done in sequence with a schedule previously prepared by Fluor Daniel and Client to ensure tie-ins can be completed during plant shutdown. d. Special considerations shall be given to any tie-in work done on piping which has contained hazardous substances (refer to ANSI/AWS F4.1.). e. Each tie-in work area shall be prepared in accordance with Section 1.6.A, before tie-in work is performed. Inspection and Testing Prior to Tie-in Work a. Existing piping shall be inspected. b. Valves in the line should be closed and locked out. The pipe should be disconnected and drained. The open end of the pipe sections not being worked on should be blanked off. Cleaning Prior to Tie-in Work Cleaning shall be in accordance with Welding Engineering Specification 000.285.50028. 4. Installation Installation of new piping systems shall be done in accordance with Piping Engineering Specification 000.250.50026. Welding shall be done in accordance with Welding Engineering Specification 000.285.85002. 5. Quality Control After the tie-in work is completed, it shall be checked in accordance with the existing plant safety criteria and the appropriate construction QC (Quality Control) practices. 6. Post Tie-in Work Inspection, Testing, and Cleaning Testing shall be done in accordance with Piping Engineering Specification 000.285.50050. 00025050027a02.doc Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Attachment 03 - Sheet 1 of 3 Revision PIPING TIE-INS Hot Tap And Stoppling Procedure - Minimum Guidelines Each hot or stopple tap shall be evaluated on its own merits considering operating conditions, line contents, piping materials, and location. The following requirements shall be met: a. Hot taps shall not be made in equipment while it is operating at temperatures below the metal transition temperatures. b. For hot taps that will be made at low temperatures (below 40 degrees F), special preheat, welding, and postheat procedures may be required. c. Hot taps shall not be specified for equipment handling amine (MEA and DEA) or caustic, if operating conditions would require stress relief. d. Hot taps shall not be specified for equipment or lines containing flammables below atmospheric pressure or containing a mixture within the flammable range and operating at any pressure. e. Hot taps shall be avoided or special precautions specified when air-hardening alloys are involved. f. Hot tapping of equipment containing hydrogen is permissible provided the equipment had not operated above the Nelson curve limits. (Refer to API 941.) g. When equipment containing hydrogen sulfide or other toxic materials is to be hot tapped, special safety precautions (if any) for these materials shall be specified. h. If equipment handling ethylene, butadiene, or acetylene is to be hot tapped, special precautions must be taken to maintain circulation and prevent overheating and thermal decomposition (with possible explosion) of the contents. i. Do not hot tap pressurized piping or pressure vessels at locations where fluid flow does not exist. j. Hot tapping of storage tanks shall not be specified except at locations on the shell where the liquid level can be maintained at least 3 feet above the highest point of welding during welding operations. k. Do not hot tap equipment upstream of rotating machinery unless facilities exist that will prevent cuttings and droppings from reaching the machinery. l. Bolt-on connections shall be used for hot tapping cast iron equipment. m. Hot tapping of reinforced concrete pressure piping (or other internally lined equipment) is allowed; however, special tapping materials, equipment, and techniques are required. Design of hot tap connections shall be in accordance with the applicable codes and standards. Locate hot tap connections according to the following: a. Allow sufficient clearance to install connections and operate the tapping or plugging equipment. 00025050027a03.doc Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Attachment 03 - Sheet 2 of 3 Revision PIPING TIE-INS Hot Tap And Stoppling Procedure - Minimum Guidelines b. Locate connections so that welding is performed at least 2 feet from flanges, threaded connections, and riveted joints, whenever possible. This should prevent leaks from developing in those joints. c. Locate connections so that no welding is required within 2 inches of an existing weld. The nozzle length must be determined for the particular tapping machine that will be used so as to ensure a complete cut through the equipment wall. In addition, for flanged nozzles, the length should be adequate to permit removal of flange bolts. When practicable, the face-to-center line dimension of flanged nozzles for perpendicular connections to pipelines should be the same as the corresponding dimensions for a welding tee and welding neck flange of the same size and rating as the tapped line. Connections shall be the reinforced type using one of the following: a. Hot tap connections for size-to-size connections shall be a full encirclement saddle (a minimum width of 3 inches and 1/4 of an inch minimum thickness). b. Hot tap connections for other than size-to-size shall be 1 of the following: 1. Integrally reinforced welding outlet fitting (fully welded). 2. Reinforcing pad (a minimum width of 3 inches and 1/4 of an inch minimum thickness). 3. Full-encirclement, weld-on saddles (a minimum width of 3 inches and 1/4 of an inch thickness). 4. Full-encirclement, bolt-on saddles where attachment by welding is not permitted. c. Hot tapping connections for cast iron pipelines shall be full-encirclement, bolt-on saddle. d. Stoppling connections shall be full-encirclement type fitting equal to T. D. Williamson's Stopple Fitting. Connections shall be designed to prevent buckling of the surface being tapped due to application of test pressure to the inside of the branch connection. An acceptable method for calculating the buckling pressures in externally loaded cylinders is given in R. J. Roark, Formulas for Stress and Strain, Fourth Edition, Page 354, Item S(34). The minimum hot tapping nozzle and valve size specified shall be 1-inch NPS. Heating or purging of the tapping or stoppling connection shall be specified if the equipment contents will be solid at ambient temperatures. Testing The tapping or stoppling connections, reinforcing pad, valve, machine, and joints shall be pressure tested prior to tapping the line. 00025050027a03.doc Piping Engineering 21-008 Client Name Project Name Contract Number Master Specification 000 250 50027 Date 18Jan00 Attachment 03 - Sheet 3 of 3 Revision PIPING TIE-INS Hot Tap And Stoppling Procedure - Minimum Guidelines Hydrostatic test shall be specified for equipment operating between 40 degrees F and 200 degrees F, unless other special conditions require a different test medium. For other temperatures, air, nitrogen, or another inert gas shall be specified. Test pressure for the valve, nozzles, and reinforcing pad (if required) shall be as follows: a. For tanks, test pressure shall be 40 psi. b. For piping and pressure vessels, test pressure shall be calculated according to the applicable code and shall be based on the most severe combination of design pressure and temperature (not the operating conditions), since operating conditions may change from time to time. 00025050027a03.doc Piping Engineering 21-008 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 1.0 PURPOSE This practice establishes the requirements for the identification and assignment of Line Numbers for piping, which will be used on P&IDs, MFDs, UFDs, SFDs, and other project documents. It also describes how the Piping Line List will be prepared and maintained. Piping Materials Engineering has overall responsibility for implementation and execution of this practice. 2.0 APPLICATION This practice will be used by personnel on all projects involved in Line Numbering on flow diagrams and the preparation of the project Piping Line List. 3.0 INTERFACING DISCIPLINES Mechanical Engineering Process Engineering 4.0 DEFINITIONS Removed from the individual practices in the design guide 5.0 6.0 This section has been left intentionally blank REQUIREMENTS 6.1 The Process Engineer / Specialist will provide process conditions and other agreed information to the Piping Materials Engineer. Process Engineering provides process conditions and other agreed information to Piping Materials Engineering during initial development of P&IDs through "stamped” P&IDs (see Practice 000.200.0915) and other documents. 6.1.1 The Process Engineer/ Specialist will provide the process data for the Heat Tracing requirements. This includes the purpose of the heat tracing (winterization or protection from freezing) and the quantity and size of the tracers. 6.1.2 The Piping Materials Engineer will review additional process information required on stamped P&IDs, such as fugitive emissions service, chloride service, or hydrogen service. If additional information is required on the line stamps, it is to be agreed upon between Process Engineering and Piping Engineering. This information is used to allocate Piping Line Classes on the P&IDs as per Practice 000.250.3726. © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 1/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 6.2 The Lead Piping Materials Engineer will verify that the required information is available in order to begin Line Numbering on Flow Diagrams. The following documents are required as input data and need to be available prior to Line Numbers being assigned: Piping Service Index. Stamped flow diagrams as discussed above with a "condition stamp" for each line, or group of lines with identical service conditions, issued by Process Engineering. Pressure-Temperature Design Criteria for Metallic Piping, e.g. rating tables per ASME B16.5 and ASME B16.47 or other Industrial codes or standards used. Maximum allowable working pressure tables, if developed for the project. Insulation Specifications from Mechanical Engineering, such as Specification 000.285.85110 Hot Insulation, defining insulation requirements for heat conservation, personnel protection, cold service, acoustical, etc. The tables included will indicate the insulation thickness required for each line size, based on operating temperatures. Painting Specifications from Mechanical, such as Specification 000.285.85210, defining paint codes and painting requirements for coating of Piping systems. Piping Materials Specification 000.250.50003 Governmental codes and regulations as applicable for the contract and mentioned in the design criteria documents (BEDD, etc.) or the contract Scope of Work. 6.3 The Lead Piping Materials Engineer will establish the Line Numbering format to be used on the project, addressing any Client-specific requirements. Section 8.2.3 of the Practice 000.100.0060, Project Procedures Manual (PPM) indicates Fluor’s standard format for Line Numbering, or a project Job Bulletin is issued to specify Client-specific requirements. Request in advance an allocation of Client line numbers where applicable. A typical piping Line Number consists of the following parts: WBS or Unit or Area or System Indication (when required), Line Sequence Number, Piping Material Specification Line Class designation, Line Size (NPS or DN), Fluid or Commodity Code (optional) or Insulation Code. This is illustrated in Attachment 01. 6.4 The Piping Materials Engineer will provide line numbering on Flow Diagrams using Work Instruction 000.250.1909 as a basis for assigning Line Numbers. Line Numbers are provided on P&IDs, MFDs, UFDs, UDFDs, and SFDs as discussed in the Work Instruction. © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 2/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST The Piping Materials Engineer provides Line Numbering of Tie-Ins based on the information in Attachment 02. 6.5 The Lead Piping Materials Engineer will coordinate the preparation and ongoing maintenance of the Piping Line List using Work Instruction 000.250.1940. The primary functions of the Piping Line List is to describe the unique line on the flow diagram(s) so that given a Line Number, one can locate it on the drawing. It also documents certain data for each line and provides a checklist for Piping Design, Piping Material Control, Piping Stress, and others. 6.6 The Piping Materials Engineer will establish the Piping Line List structure and format based on the fields listed in Attachment 03. The Piping Line List is maintained in Piping Data Manager, refer to Practice 000.250.0710. Whatever form it takes the elements of the Piping Line List and other additional fields to consider follow Attachment 03. 6.7 The Piping Materials Engineer will prepare the Piping Line List. The Piping Materials Engineer verifies that each Line Number entry is completed within the Piping Line List. This function occurs simultaneous with the line numbering function. Other considerations in preparing the list include: Use uniform abbreviations and auxiliary designations. Reference equipment numbers as much as possible. Transfer all conditions on flow diagrams to the line list. Use line list as a means to check continuity of flow diagrams. Assign one Line Class per Line Number. Verify process conditions are within Line Class limits, or assign the required Line Class based on process conditions. Verify that the operating temperatures are within the limits of the insulation type selected, or identify the insulation type, based on operating temperatures provided. Make notes of pertinent information or decisions with regards to piping on flow diagram and/or the Piping Line List. Add the ASME Fluid Category or PED Fluid Group and Category, required Pressure test data (pressure test type, pressure and medium), coating system, cleaning category, tracing holding temperatures, etc., as required. Include notes that may influence Line Class selection and/or pipe layout. © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 3/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 6.8 The Piping Materials Engineer will check the Piping Line List with Checklist 000.250.2940. 6.9 The Piping Materials Engineer will request input from other disciplines for update of the data fields in the Piping Line List. 6.10 6.9.1 The Mechanical Materials and Welding Engineer will provide the specification for painting when required by the Piping Line List format. 6.9.2 The Mechanical Materials and Welding Engineer will provide process commodity Post Weld Heat Treatment requirements via the Material Selection Diagram. 6.9.3 The Piping Design Supervisor marks any comments or changes arising from piping Isometric production and issue on the Piping Line List and/or communicates them to the Piping Materials Engineer. The Piping Materials Engineer will review and approve any changes/revisions to the technical content of the Piping Line List prior to the re-issue of the list. The Piping Materials Engineer makes sure that all data in the Piping Line List is kept in a clear, concise, and accurate manner. The Piping Materials Engineer keeps the Piping Line List updated with input from other team members, and arranged in Line Number order. 7.0 SUPPORTING RESOURCES Attachment Attachment 01 Line Numbering Format Example Attachment 02 Tie-In Line Numbering Examples Attachment 03 Typical Piping Line List Structure and Additional Fields Work Instructions Work Instructions 000.250.1909 Piping Line Numbering Work Instructions 000.250.1940 Piping Line Lists Refer to Section 9 for more information. 8.0 9.0 SUPPORTING KNOWLEDGE ATTACHMENTS, ADDENDA, WORK INSTRUCTIONS Addenda Not Used Attachment © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 4/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Piping Engineering Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST Attachment 01 Line Numbering Format Example Attachment 02 Tie-In Line Numbering Examples Attachment 03 Typical Piping Line List Structure and Additional Fields Work Instructions Work Instructions 000.250.1909 Piping Line Numbering Work Instructions 000.250.1940 Piping Line Lists © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 5/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Attachment 01 Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 01 LINE NUMBERING FORMAT EXAMPLE The following is Fluor’s standard Line Numbering format as discussed in Section 8.2.3 of the Standard Project Procedures Manual (PPM). Client specifications and practices will be properly reviewed for applicability when developing a project-specific Line Numbering format. © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 6/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Attachment 02 Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 02 TIE-IN LINE NUMBERING EXAMPLES This is an example of a standard approach to numbering Tie-In lines. Client specifications and practices will be properly reviewed for applicability when developing project-specific Line Numbering requirements. The following are two different situations for Tie-in lines: a. Existing – New – Existing When lines are rerouted and a new line section ties into the existing line, the Line Number will stay the same with only a suffix e.g., ‘A’ will be added to the Line Number. By adding this ‘A’ to the Line Number, this part will be recognized as a “new” line for the project. Example: Existing line number is P-12001-10”-F01A New line number is P-12001A-10”-F01A3 b. Existing – New When a line is rerouted in a unit with a new destination in that unit, a new Line Number will be assigned. Example: Existing Line Number is P-12001-10”-F01A New Line Number is P-12031-10”-F01A3 © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 7/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Attachment 03 Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 03 TYPICAL PIPING LINE LIST STRUCTURE AND ADDITIONAL FIELDS 1.0 TYPICAL LINE LIST STRUCTURE The Piping Line List can be a manual form, a computer generated report or database. Whatever form it will take, the elements of the Piping Line List will include the following (the field size is normal, but will need adjustment to meet project requirements): 2.0 a. Revision (2-place alpha-numeric field) to indicate a revised line. b. WBS or Area/Unit information (3-digit numeric field). c. Line Number (Sequence Number) (3 to 5-digit field), unique within an Area or Unit d. Line Class (4-place alpha-numeric field). e. Line Size NPS or DN (4-place numeric field with fraction capabilities for NPS). Trim Line Numbers will not require size entry. f. WBS or Area/Unit information (3-digit numeric field). g. Line Number Fluid Service code. h. Steam Out requirements - Y/N (Yes / No). Process will provide design temperature and pressure during steam out. i. Service – use consistent designations as defined on the Project Service Index. j. Vapor / Liquid / Solids (3-digit field to allow for multi-phase flow) k. From (the origin of the line) and To (the terminus of the line). Use equipment numbers where possible and abbreviate consistently. l. Design and operating pressure and temperature (4 fields with 4 numeric places each). Units will be psig and °F (imperial) or MPag and °C (metric). m. Type of insulation and heat tracing (symbols as defined on flow diagram legend, in Client specifications, or Fluor Specifications - such as 000.285.85110 Specification - Hot Insulation or Cold Insulation specification if available and applicable). n. Indication of stress check required - Y/N (Yes / No) as indicated by Piping Stress Engineer per 000.250.50200 Specification for Piping Flexibility. o. PWHT (Postweld Heat Treatment) Requirements - Y/N (Yes / No). This is as required by MSD, P&ID, or ASME Code requirement. p. Field test type and pressure (psig): H for Hydrostatic Leak Test (water), P for pneumatic Leak Test (air), I for Initial Service Leak Test (Commodity test), and NA for identification for vent and drain lines unblocked and opened to the atmosphere. These lines will not require pressure testing. q. Remarks, if any, in this field will indicate any special or alternate (upset) design conditions or special requirements. ADDITIONAL LINE LIST FIELDS TO CONSIDER PME will consider the impact of any changes to the Line List in revising software and additional time to construct and maintain the Line List. a. Fluid Category, Hazard or Toxic indication. © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 8/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Attachment 03 Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 03 TYPICAL PIPING LINE LIST STRUCTURE AND ADDITIONAL FIELDS b. Insulation thickness and material. c. Alternative or Upset conditions. d. Flow rate, density, viscosity, and velocity. e. Branch reinforcement. f. Vacuum. g. Chemical Cleaning requirement. h. Pipe schedule and material code. i. Paint code (e.g. per Specification 000.285.85210: Specification for Painting). j. Test package number k. PED category l. Other (Local) Authority Requirements © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 9/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Work Instructions 000.250.1909 Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 000.250.1909 PIPING LINE NUMBERING Acceptance Criteria The purpose of this Work Instruction is to perform consistent line numbering of Piping Materials Practice P&IDs. Engineer 000.250.3705 Refer to Project Scope Definition Documents and/or Project Requirements Originator 000.100.F1000 Checklist as applicable. General Requirements for Line Numbering Verify that the proper basis exists to begin Line Numbering. Lead Piping 000.250.3705 Materials Engineer Obtain agreed Line Numbering format from Lead Piping Materials Engineer. Piping Materials 000.250.3705 Engineer 000.100.0060 Assign Line Numbers on the P&IDs such that one Line Number will extend Piping Materials from one piece of equipment to another. Engineer Activity 1. 2. 3. 4. 5. 6. Responsibility Assign the parent Line Number to sample connections, vents, drains, and other very short connections on a line. Assign Line (trim) Numbers to miscellaneous drains, vents, bridles, etc., having the same line class, and connected to equipment such as a vessel, reboiler, tank, etc. These can be tagged a common Line Number and be identified on the Flow Diagram as “Trim”. © 2020, Fluor Corporation. All rights reserved. Piping Materials Engineer Piping Materials Engineer Comments Note: New Line Numbers will be assigned at unit, area or battery limits breaks, at spec-breaks, when design conditions change, at scope breaks, and at the aboveground / underground interface. Note: If more than one Line Class is required (for example for the top or bottom of vessels), different Line (trim) Numbers will be assigned with spec-break shown on the equipment. Fluor Restricted Data. Further copying or distribution only by permission. 10/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Work Instructions 000.250.1909 Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 000.250.1909 PIPING LINE NUMBERING Activity Responsibility 7. Assign the same Line Number and piping Line Class where the pump casing Piping Materials drain is going to an open drain system, the atmospheric piece of pipe going to Engineer the funnel as the pressurized part. 8. Assign a separate Line Number for pumps with base plate drains, since these lines are open to atmosphere on both ends. Assign a single Line Number to the whole of inlets (or outlets) of multiple equipment (heat exchangers, air coolers, pumps, etc.) configurations. Determine necessity of adding a Line Number in case a single Line Number presents difficulty in layout and design. Assign Line Numbering for Tubing that is part of Piping Scope. Piping Materials Engineer Piping Materials Engineer Piping Design Supervisor Piping Materials Engineer Assign one Line Number to utility (e.g. fire water, cooling water etc.) headers/mains, including all branches up to but excluding the unit isolation valves. Assign separate Line Number for unit isolation valves and downstream piping. Relief valve inlet piping will have same line number as the header from which it originates from. Assign separate line number for relief valve outlet piping. Assign one line Number for relief valve outlet piping, where relief valve is mounted directly to an equipment nozzle. Piping Materials Engineer 9. 10. 11. 12. 13. 14. © 2020, Fluor Corporation. All rights reserved. Acceptance Criteria Comments Note: In the case where the drain is going to a closed drain system, a new Line Number (for one or multiple pumps) will be assigned. Piping from pump casing to last isolation valve will use Pump Trim Line. Note: Tubing downstream of Piping / Instrumentation break does not require line numbers. Piping Materials Engineer Piping Materials Engineer Note: Bolting and gaskets for relief valve connection to equipment nozzle will be part of equipment Trim Line Number. Fluor Restricted Data. Further copying or distribution only by permission. 11/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Work Instructions 000.250.1909 Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 000.250.1909 PIPING LINE NUMBERING Activity Responsibility 15. Assign the same Line Number upstream and downstream of control valves, except when line class changes due to a Piping Line Class break. 16. Assign the same Line Number to steam/condensate lines to and from steam Piping Materials traps as the steam supply through to the last steam trap isolation valve Engineer downstream of the steam trap. Assign Line Numbering of Tie-Ins based on the information in Attachment 02 Piping Materials in Practice 000.250.3705. Engineer Requirements for P&IDs and MFDs Start Line Numbering with the main feed and follow the major stream as Piping Materials closely as possible through the entire process system on a flow diagram. Engineer Number miscellaneous "auxiliary" process lines next, proceeding from left to Piping Materials right and top to bottom on the flow diagram, these include vessel trim Engineer numbers, long bypasses, injection lines, relief valve tailpipes attached to a header, and any other process lines not numbered with the flow. Number Utility branch lines next; each service will be grouped together and Piping Materials numbered from left to right across the flow diagram. Engineer Requirements for UFDs and UDFDs Assign Line Numbers to utility headers; they usually originate in the utility area Piping Materials and extend throughout the plant as a header. Engineer Transfer the applicable header Line Number to other utility flow diagrams. Piping Materials Engineer Transfer the applicable branch Line Number from mechanical flow diagrams, Piping Materials new branch numbers will be assigned to utility lines that do not appear on the Engineer mechanical flow diagram. Make sure that utility header and branch numbers correspond to their Piping Materials originating unit and destination unit respectively. Engineer Assign separate Line Numbers for utility branches serving utility stations for Piping Materials each service at each utility station. Engineer Requirements for SFDs Assign one Line Number for the supply and one Line Number for the return for Piping Materials Underground cooling water headers, including all underground portions of Engineer branches. Assign the Line Numbers from the unit they serve for the aboveground section Piping Materials of branches from underground lines. Engineer Approval and Issue See Note 1 Piping Materials Engineer Obtain required checks and approvals. Piping Materials Engineer 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Issue in accordance with Project procedures © 2020, Fluor Corporation. All rights reserved. Piping Materials Engineer Acceptance Criteria Comments Note: Short bypasses will be numbered as part of the lines to which they connect and will not be given separate Line Numbers. Refer to Activity Plan for requirements Piping Lead Engineer Fluor Restricted Data. Further copying or distribution only by permission. 12/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Work Instructions 000.250.1909 Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 000.250.1909 PIPING LINE NUMBERING Note 1: As a Fluor employee, it is your responsibility to be aware of applicable requirements and to deliver a quality work product that complies with those requirements. © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 13/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Work Instructions 000.250.1940 Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 000.250.1940 PIPING LINE LISTS Activity 1. 2. 3. 4. 5. 6. 7. Acceptance Criteria Piping Materials Practice Engineer 000.250.3705 Originator 000.100.F1000 Responsibility The purpose of this Work Instruction is to develop, maintain and issue the Piping Line List. Refer to Project Scope Definition Documents and /or Project Requirements Checklist as applicable. Establish content and format of line list: • Fluor Standard • Client Standard • Line numbering series Obtain copy of engineering flow diagrams indicating line sizes, Materials line classes, insulation, and break points. Request in advance an allocation of client line numbers where applicable. Use line list as a means to check continuity of flow diagrams. Add process conditions onto line list or add line stamp conditions to the flow diagrams. Ensure conditions on flow diagrams are transferred to the line list. Piping Materials 000.250.0720 Engineer 000.100.F1000 000.250.3705 Piping Materials Engineer Originator Originator Originator Process Engineer Piping Materials Engineer Piping Materials 000.250.50003 Engineer 8. Verify process conditions are within line class limits, or assign the required line class based on process conditions. 9. Add the ASME Fluid Category and/or PED Fluid Group and Category, Piping Materials required Pressure test data (Pressure test Type, Pressure and Medium), Engineer coating system, cleaning category, tracing holding temperatures (process) and all other project required data columns, as applicable/required. Include notes/remarks that may influence Line class section and/or pipe layout. Perform Line List check, see Note 1 Piping Materials Engineer / Process Engineer 10. © 2020, Fluor Corporation. All rights reserved. Comments Some data might not be available on FEED Projects. Verify that the operating temperatures are within the limits of the insulation type selected, or identify the insulation type, based on operating temperatures provided. Piping Materials Engineer to perform selfcheck on completed Line Lists. If required, Process Engineer will perform check of Line List to verify process conditions as intended on the Stamped P&IDs. Fluor Restricted Data. Further copying or distribution only by permission. 14/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf 9/25/2020 000.250.3705 Piping Materials Engineering - Line Numbering and Line List.pdf 21-009 Practice 000.250.3705 Date 25Sep2020 Work Instructions 000.250.1940 Full Practice Printed from Quality Requirements System Global Library PIPING MATERIALS ENGINEERING - LINE NUMBERING AND LINE LIST 000.250.1940 PIPING LINE LISTS Activity 11. 12. 13. 14. Responsibility Stress review of line limit to indicate lines requiring stress analysis per project Piping Stress stress spec. Engineer Obtain required checks and approvals. Refer to AP (Activity Plan) Issue in accordance with project procedures. Piping Materials Engineer Determine who holds the “Master” line list and who is responsible for changes Piping (i.e. additions, deletions and modifications of line numbers, process conditions Engineering and other data) Lead Acceptance Criteria 000.250.3722 000.250.50200 000.200.0220 000.250.F0072 Comments Note 1: As a Fluor employee, it is your responsibility to be aware of applicable requirements and to deliver a quality work product that complies with those requirements. © 2020, Fluor Corporation. All rights reserved. Fluor Restricted Data. Further copying or distribution only by permission. 15/17 http://localhost:8082/PDF/000.250.3705%20Piping%20Materials%20Engineering%20-%20Line%20Numbering%20and%20Line%20List.pdf PIPING DESIGN GUIDE - INDEX Page 1-001 1-002 1-003 1-004 1-005 1-006 1-007 1-008 1-009 1-010 1-011 1-012 1-013 1-014 1-015 1-016 1-017 1-018 1-019 1-020 1-021 1-022 1-023 1-024 1-025 2-001 2-002 2-003 2-004 2-005 2-006 2-007 2-008 2-009 2-010 2-011 2-012 2-013 2-014 2-015 2-016 2-017 2-018 2-019 2-020 3-001 4-001 4-002 4-003 4-004 4-005 4-006 4-007 4-008 4-009 4-010 4-011 4-012 5-001 5-002 5-003 5-004 6-001 6-002 6-003 6-004 6-005 6-006 6-007 6-008 6-009 6-010 6-011 7-001 7-002 7-003 8-001 8-002 8-003 8-004 8-005 8-006 9-001 9-002 9-003 9-004 9-005 Document Number 1 Dimension Tables 245.250.9801 000.250.9801 Att 02 000.250.9801 Att 03 000.250.9801 Att 08 1-005 000.250.9801 Att 10 1-007 1-008 1-009 000.250.9801 Att 11 000.250.9801 Att 12 000.250.9801 Att 13 000.250.9820 Att 01-07 1-014 000.250.9809 000.250.9801 Att 14 1-017 1-018 1-019 245.250.9826 000.250.3824 Att 02 & 03 000.250.9821 000.250.9822 Att 01 & 02 000.250.9823 000.250.9835 Title Index Title Dimensional Chart - Overall Dimensions Weld Fittings Dimensional Chart - Dimensions For Valves Dimensional Chart - Control And Relief Valves For Layout Purpose Dimensional Chart - Branch Outlet Fittings Dimensional Chart - Flange Dimensions Class 150-2500 Dimensional Chart - Ring Joint Weld Neck Flange Class 150-2500 Dimensional Chart - Overall Dimensions Of Sw. And Scr'D Fitting Combinations Dimensional Chart - Reducing Tee Dimensions Dimensional Chart - Branch Dimensions Class 150 And 300 Insulated And Un-Insulated Lines Dimensional Charts - Large Diameter Fabricated Type Reducers Dimensional Chart - Welded Mitered Elbows Dimensional Chart - Cutting And Dimensioning Pipe At ODD Angles Of ANSI And DIN Pipe Dimensional Chart - Spectacle Blinds Dimensions of Lap Joint Stub Ends Dimensional Chart - Nominal Wall Thickness For Pipe Dimensional Chart - Pipeline Spacing Dimensional Charts - Reinforcing Pad Requirements Dimensional Chart - Trigometric Functions Dimensional Chart - Allowable Pipe Spans Dimensional Chart - Standard Welding Symbols Bolt Length Calculation Table Of Weights - Pipe Components Dimensions And Properties Of Pipe Coefficient Of Expansion Tables Fabrication Tolerances Dimensional Chart - Overall Dimensions Weld Fittings - 245.250.9801 Dimensional Chart - Dimensions For Valves - 000.250.9801 Att 02 Dimensional Chart - Control And Relief Valves For Layout Purpose - 000.250.9801 Att 03 Dimensional Chart - Branch Outlet Fittings - 000.250.9801 Att 08 Dimensional Chart - Flange Dimensions Class 150-2500 - 1-005 Dimensional Chart - Ring Joint Weld Neck Flange Class 150-2500 - 000.250.9801 Att 10 Dimensional Chart - Overall Dimensions Of Sw. And Scr'D Fitting Combinations - 1-007 Dimensional Chart - Reducing Tee Dimensions Dimensional Chart - Branch Dimensions Class 150 And 300 Insulated And Un-Insulated Lines Dimensional Charts - Large Diameter Fabricated Type Reducers - 000.250.9801 Att 11 Dimensional Chart - Welded Mitered Elbows - 000.250.9801 Att 12 Dimensional Chart - Cutting And Dimensioning Pipe At ODD Angles Of ANSI And DIN Pipe - 000.250.9801 Att 13 Dimensional Chart - Spectacle Blinds - 000.250.9820 Att 01-07 Dimensions of Lap Joint Stub Ends Dimensional Chart - Nominal Wall Thickness For Pipe - 000.250.9809 Dimensional Chart - Pipeline Spacing - 000.250.9801 Att 14 Dimensional Charts - Reinforcing Pad Requirements Dimensional Chart - Trigometric Functions Dimensional Chart - Allowable Pipe Spans Dimensional Chart - Standard Welding Symbols - 245.250.9826 Bolt Length Calculation - 000.250.3824 Att 02 & 03 Table Of Weights - Pipe Components - 000.250.9821 Dimensions And Properties Of Pipe - 000.250.9822 Att 01 & 02 Coefficient Of Expansion Tables - 000.250.9823 Fabrication Tolerances - 000.250.9835 2 General Design Guidelines, Work Instructions, Executions and Activity Plans 000.000.0072 000.250.F0072 000.100.1400 000.100.F1400 000.250.0764 000.250.0764 000.300.6702 000 200 1050 000.200.1037 000.250.1037 000.250.1038 000.250.1060 000.042.F1010 000.250.9856 000.200.0600 000.200.0926 2-017 000.250.0600 000.250.2025 000.250.6665 Activity Plan Preparation Activity Plan Piping Engineering Project Activity Model (PAM) PAM Workbook Piping Eng Graphic Activities Overview Phased Engineering-Piping Engineering Section ABS Discipline Mapping to SAP Cost Elements Standard Drawing Guidelines Engineering Document Production and Checking Drawing Checking Drawing Checking - Piping Plan Corrections Piping Operations - Supplier Drawing and Data Review for Piping Discipline Checking Matrix - Piping Piping Codes and Standards Construction Work Areas and Work Packages Electronic 3D Model Review 3D Model Review Flow Chart Piping Design - 3D Modeling for Piping - Setup, Execution and Close-Out Piping Design - Piping Layout Studies Piping Progress Rules of Credit MPSU 3 Specification for Piping Design 000.250.50001 Process and Utility Piping Design, Layout and Drawing 4 Plant Arrangement - Plot Plan Development 000.250.2005 000.250.2010 000.250.2035 000.200.F0916 5 Off Site Plant Arrangement 000.250.2005 Att 11 000.250.2005 Att 12 000.250.2005 Att 13 000.250.2111 Plant Arrangement - Plot Plan Development - Instructions - 000.250.2005 Plant Arrangement - Flow Diagram Transposition Instruction - 000.250.2010 Piping Design - Piping Drawing Generation - 000.250.2035 Plot Plan Review Checklist - 000.200.F0916 Canadian Operations (Alberta) Equipment Spacing Guidelines PIP Equipment Spacing Rail Road Clearances Design Data Truck Dimensions Docking Dimensions for Motor Trucks Truck Size and Turning Radius Typical Road Constructions Building Plot Development Offsites - Refinery Plot Plans Offsites - Tank Spacing Offsites - Atmospheric Storage Tank Piping Layout Guide Sleeve Through Dike Offsites - Refinery Plot Plans - 000.250.2005 Att 11 Offsites - Tank Spacing - 000.250.2005 Att 12 Offsites - Atmospheric Storage Tank Piping Layout Guide - 000.250.2005 Att 13 Sleeve Through Dike - 000.250.2111 Supplier Drawing and Data Review - Pump and Turbines Typical Piping Arrangement Centrifugal Pumps Pumps and Turbines - Reduction at Pump Suction Pumps and Turbines - Pump Piping (Steam) Turbines and Reciprocating Pumps Pumps and Turbines - Misc. Pump Piping - Coolant, Flush Oil. Vent and Drain Pumps and Turbines - Strainer, Pump Section, Conical Pumps and Turbines - Strainer, Pump Section, T-Strainers Pumps and Turbines - Strainer, Pump Section, Y-Strainers API Pump Seal Plan Pump Support Chocks Pump Support on Steel 7 Equipment Studies: Compressors 000.250.1063 000.250.2470 7-001 Supplier Drawing and Data Review - Reciprocating Compressors Compressor Piping - Reciprocating and Centrifugal Compressors - Piping and Arrangement Compressor Building Layout 8 Equipment Studies: Exchangers 000.250.1061 000.250.2600 Att 1 000.250.2600 Att 2 000.250.2600 Att 3 000.250.2600 Att 4 8-006 Supplier drawing and data review - Exchangers Exchangers - TEMA Nomenclature Exchangers - Equipment Location and Piping Layout Shell and Tube Heat Exchangers Exchangers - Forced Draft and Induced Draft Air Cooler Arrangements Exchangers - Double Pipe Exchangers Piping Arrangements Exchanger handling facilities 9 Equipment Studies: Vessels 000.250.2660 000.258.1104 000.258.4104 000.258.4107 000.258.4108 Process and Utility Piping Design, Layout and Drawing - 000.250.50001 Plant Arrangement - Plot Plan Development - Instructions Plant Arrangement - Flow Diagram Transposition Instruction Piping Design - Piping Drawing Generation Plot Plan Review Checklist Canadian Operations (Alberta) Equipment Spacing Guidelines PIP Equipment Spacing Rail Road Clearances Design Data Truck Dimensions Docking Dimensions for Motor Trucks Truck Size and Turning Radius Typical Road Constructions Building Plot Development 6 Equipment Studies: Pump Turbine 000.250.1062 245.250.2350 000.250.2350 Att 02 000.250.2350 Att 03 000.250.2350 Att 04 000.250.2350 Att 05 6-007 6-008 6-009 6-010 6-011 Activity Plan Preparation - 000.000.0072 Activity Plan Piping Engineering - 000.250.F0072 Project Activity Model (PAM) - 000.100.1400 PAM Workbook - 000.100.F1400 Piping Eng Graphic Activities Overview - 000.250.0764 Phased Engineering-Piping Engineering Section - 000.250.0764 ABS Discipline Mapping to SAP Cost Elements - 000.300.6702 Standard Drawing Guidelines - 000 200 1050 Engineering Document Production and Checking - 000.200.1037 Drawing Checking - 000.250.1037 Drawing Checking - Piping Plan Corrections - 000.250.1038 Piping Operations - Supplier Drawing and Data Review for Piping - 000.250.1060 Discipline Checking Matrix - Piping - 000.042.F1010 Piping Codes and Standards - 000.250.9856 Construction Work Areas and Work Packages - 000.200.0600 Electronic 3D Model Review - 000.200.0926 3D Model Review Flow Chart Piping Design - 3D Modeling for Piping - Setup, Execution and Close-Out - 000.250.0600 Piping Design - Piping Layout Studies - 000.250.2025 Piping Progress Rules of Credit MPSU - 000.250.6665 Vessel Layout and Orientation - Classification, Piping, Trays Ladder and Platform Design Criteria Ladder and Platform Details Equipment Pipe Guide Details Equipment Pipe Support Details Supplier Drawing and Data Review - Pump and Turbines - 000.250.1062 Typical Piping Arrangement Centrifugal Pumps - 245.250.2350 Pumps and Turbines - Reduction at Pump Suction - 000.250.2350 Att 02 Pumps and Turbines - Pump Piping (Steam) Turbines and Reciprocating Pumps - 000.250.2350 Att 03 Pumps and Turbines - Misc. Pump Piping - Coolant, Flush Oil. Vent and Drain - 000.250.2350 Att 04 Pumps and Turbines - Strainer, Pump Section, Conical - 000.250.2350 Att 05 Pumps and Turbines - Strainer, Pump Section, T-Strainers - 6-007 Pumps and Turbines - Strainer, Pump Section, Y-Strainers - 6-008 API Pump Seal Plan Pump Support Chocks Pump Support on Steel Supplier Drawing and Data Review - Reciprocating Compressors - 000.250.1063 Compressor Piping - Reciprocating and Centrifugal Compressors - Piping and Arrangement - 000.250.2470 Compressor Building Layout Supplier drawing and data review - Exchangers - 000.250.1061 Exchangers - TEMA Nomenclature - 000.250.2600 Att 1 Exchangers - Equipment Location and Piping Layout Shell and Tube Heat Exchangers - 000.250.2600 Att 2 Exchangers - Forced Draft and Induced Draft Air Cooler Arrangements - 000.250.2600 Att 3 Exchangers - Double Pipe Exchangers Piping Arrangements - 000.250.2600 Att 4 Exchanger handling facilities Vessel Layout and Orientation - Classification, Piping, Trays - 000.250.2660 Ladder and Platform Design Criteria - 000.258.1104 Ladder and Platform Details - 000.258.4104 Equipment Pipe Guide Details - 000.258.4107 Equipment Pipe Support Details - 000.258.4108 Title AHJ Description Definition 21-010 March 17, 2022 API Authority Having Jurisdiction (AHJ) An official organization or person who has the delegated authority to determine, mandate and enforce code requirements established by jurisdictional governing bodies regulations. American Petroleum Institute ASL Approved Suppliers List AWP BOM Advanced Work Packaging (AWP) The process that aligns the different phases, disciplines and deliverables of a project through planning and execution activities in order to produce two types of work packages: CWPs and IWPs. It is a planned, executable process that encompasses the work on an EPFC project, beginning with initial planning and continuing through detailed design, construction execution, and turnover. AWP processes are an important prerequisite to an effective WFP program. Bill of Material BPV Boiler Pressure Vessel BRMF Business Risk Management Framework CA Contract Administrator CAD Computer Aided Design CadWorx CadWorx; 3D Modeling Tool CII Construction Industry Institute Client Owner or their authorized representative. CLS Control Level Schedule CMC Change Management Coordinator COC Certificate of Conformity (COC) Document prepared by the Notified Body which declares compliance to the PED of the equipment or piping considered, based on examinations performed according the applicable Conformity Assessment Procedure. Codes are a systematic arrangement or collection of rules and regulations designed to insure minimum requirements for acceptable safety, design or operations. Codes are generally enforceable and measurable. Examples of some commonly used Codes are the ASME Boiler and Pressure Vessel Code (B&PVC) and the AWS D1.1 Structural Welding Code – Steel. Center of Gravity (CoG) The point through which all weights of the body may be assumed to act, it is the point at which the sum of the moments of all the weights of the body with reference to any axis through this point, is equal to zero. It can also be referred to as Center of Mass. Criticality Rating (CR) A method of assessing the importance of an item with respect to various categories such as its design, manufacturing routines, and the consequences of failure. The criticality for equipment and materials is established on a scale of 1 to 4 with 1 being the most critical, 4 being the least critical. Form 000.200.F0077, Criticality Rating Form, has the standard categories and definitions for criticality used on Fluor projects. Civil Structural Architectural Code CoG CR CSA CUP CWA CWP Combined Underground Plan (CUP) A single drawing document, created by extracting planimetric views from project 3D model data, showing all underground facilities. Construction Work Area (CWA) A Construction Work Area (CWA) is a portion of the plot plan that has been defined jointly by Engineering and Construction that represents a logical physical envelope for the division of work. On a modularized project, each CWA would typically contain the module(s) and stick built scope within the geographical area for a sub-process unit, such as a compressor building area or a furnace structure area. The CWA is a product of the Path of Construction and integrated planning sessions that breaks down a project into manageable geographic areas and includes all Engineering disciplines. Construction Work Package (CWP) An Engineering deliverable that contains the required documents of a well- defined, logical subdivision of a CWA construction scope, by discipline. Each CWP is defined by geographic boundaries and further divided by discipline, without overlaps. CWPs facilitate sequencing according to the Path of Construction. Page 1 of 6 Title CWX DAS DCC DCLS Description Definition 21-010 March 17, 2022 Coreworx (CWX) is the approved Fluor Document Management System (DMS) and Project Collaboration System (PCS) that allow the project team to exchange files or access documents and data issued on the project Discipline Application Specialist Design Comment Creator (DCC) Desktop application that interacts with a third-party 3D model review system to create model review comments and screen shots, and to upload them to Fluor's DRCS web application so that comments can be viewed, checked, and approved by other project members. Discipline Control Level Schedule (DCLS) DDP Instrumentation Dimensional Data for Piping- module within SPI DDR DHA Document and Data Register (DDR) The initial Supplier Document and Data Register (DDR) is prepared by the Supplier when they receive the PO. It is a list of the documents and data the Supplier will submit to meet the SDDC requirements of the PO. The list contains document numbers, document titles, and the planned submittal dates. The Supplier updates the DDR as part of progress reporting or in response to a Fluor expediting request. The DDRs submitted by the Supplier are used to update the Fluor Vendor Data Archive. Dust Hazard Analysis DMC Discipline Management & Control (DMC) DMS Document Management System DN Nominal Diameter DOC Declaration of Conformity (DOC) Document prepared by the Manufacturer which declares compliance to the PED of the pressure equipment considered based on examinations performed by the Manufacturer’s Inspection/QA department and/or assigned NoBo according to the applicable Conformity Assessment Procedure. Procurement Document Tracking Report – MatMan DTR E3D EEA Everything3D (E3D) 3D Modeling Tool developed by Aveva. Can only be used after approved waiver from the Engineering KPO. European Union countries including Iceland, Norway, and Liechtenstein. EEP Estimating Execution Plan EHT Electrical Heat Tracing EI Energy Institute EOR Engineer of Record EPC Engineering, Procurement and Construction ESR Essential Safety Requirement (ESR) The Essential Safety Requirements are included in Annex I of the PED. The Manufacturer must address all design / operating and reasonably foreseeable process conditions of the pressurized equipment and demonstrate compliance to the Essential Safety requirements defined in the PED. These include requirements on Design, Materials, Manufacturing, Inspection and Testing, Operation Instructions, and Marking. Factory Acceptance Test FAT FEED FIV Front End Engineering and Design (FEED) A project planning document (UG Philosophy) produced prior to project initiation that serves as the basis for final EPC construction document development. FTC Flow Induced Vibration (FIV) Low frequency vibration (<1 Hz up to 300 Hz) of the piping system beam modes due to high turbulent energy in the process flow through a particular piping system. Forecast to Complete GRW Global Reference Warehouse GSM Global Supplier Manager HAC Hazardous Area Classification HSE Health, Safety and Environmental Page 2 of 6 Title ICP ICU Description Definition Individual Contract Plan 21-010 March 17, 2022 IEC Isometric Control Utility (ICU) A Fluor utility use by Piping to manage and control the isometric drawing issuance. International Electrotechnical Commission IFC Issued For Construction IFD Issued For Design ISO Isometric ITB Invitation To Bid IWP LCP Installation Work Package (IWP) An Installation Work Package (IWP) is a portion of scope derived from a CWP. It is comprised of an Installation Code and a Sequence number, which contains all necessary elements for a single construction crew to complete that portion of the scope of work. It includes critical documents along with a detailed execution plan. The WFP team will confirm that a released IWP will contain constraint free work that can be executed by a single foreman and crew within a practical construction timeframe (typically a 1-2 week shift). Location Control Plan LE Lead Engineer Line Class LPF Specification as defined for a Line Number on a P&ID LSE (LPE) A numerical value calculated per the Energy Institute Guideline (see References) which can be used to rank the severity of a piping system subject to a particular piping system vibration. The value cannot be linearly compared or interpolated and it does not imply an actual probability of failure. Lead Piping Stress Engineer MatMan MaterialManager® MDR MDR Master Document Register MDU MES Material Download Utility (MDU)Material Download Utility. Utility used for downloading material quantities from Cad System Miscellaneous Electrical Supports MFD Mechanical Flow Diagram MHCD Mechanical Historical Cost Database (MHCD) A historical data tool to capture technical and commercial information of previously purchased / quoted equipment on E&C and Mining & Metals projects. Materials of Construction (MOC) Materials of Construction; material type used for piping systems, such as Carbon Steel, Low Temp Carbon Steel, 1-1/4Cr, etc. MOC MPS MPSU MR MR0 MR1 Miscellaneous Pipe Support Model Progress Status Utility (MPSU) A web-based Fluor utility used by projects to track and report 3D model progress. Model Review (MR) A plant design review including all applicable Disciplines, Client and/or Licensor that uses an electronic 3D model. Model Review MR #0 (MR0) Model review held towards the end of FEED for the purpose of finalizing the estimate basis with regard to the work breakdown structure (CWAs, CWPs), overall plant layout, safety, access egress, process block/building locations, overall major equipment placement (initial constructability, maintenance and operations requirements), ROM level assessment of modularization, Overall undergrounds layout and undergrounds philosophy (incl. electrical undergrounds). It is intended to align engineering disciplines and other stakeholders and provide the basis for MTO generation in support of a Class 2/3 estimate. Model Review MR #1 (MR1) Model review, sometimes referred to as 30% model review, held early in the detailed engineering phase based on the IFD P&IDs, IFD Equipment List and IFD Plot Plan to establish final mechanical equipment major structures locations & footprints, critical pipe routings, battery limit interfaces, main electrical equipment and cable tray routings and underground piping, sewers and cable routings. Finalization of constructability and maintenance / Page 3 of 6 Title MR2 MR3 Description Definition 21-010 March 17, 2022 operation access ways is reviewed at this time. For modular projects, this Model Review is used to establish the module frame sizes and module volumes next to the items listed above. Once MR1 is completed, and approved by the Client, the plot plan is issued IFC and IFC of Civil Works can be released. Model Review MR #2 (MR2) Model review, sometimes referred to as 60% model review, held during the ‘design engineering phase', for the purpose of finalizing the overall Plant Design with regard to major mechanical equipment, major structures & pipe supports, large bore pipe (NPS 2 and up) routings instrument inline and off line equipment, electrical equipment and general cable routings, and buildings. For modular projects, all components and commodities are to be reviewed during this module review and material handling studies need to be completed. For example, all piping including small bore needs to be reviewed as IFC Isometric Issue is performed by Module and not (or much less) than by line size. Once MR2 is complete, and approved by the Client, IFC issue of Piping Isometrics can commence as well as the release of Primary and selected Secondary Steel. MRR Model Review MR #3 (MR3) Model review, sometimes referred to as 90% model review, held near completion of the ‘detail design phase,’ for the purpose of finalizing all components of the model that were not approved at the completion of MR2. For modular projects, is to validate and reconcile all comments and actions from Model Review 1 and 2 and is intended mainly for the last review items for Electrical and Control Systems. Once MR3 is complete, and approved by the Client, balance of Discipline deliverables can be issued for fabrication or construction, such as small bore isometrics, remaining steel, loop diagrams and cable schedules. Material Receiving Report MTO Material Take-Off NDE Non Destructive Examination (NDE) Non Destructive Examination; Weld Examinations performed to verify the integrity of piping welds, such as radiography, ultrasonic examination, magnetic particle examination, etc., determined by the design code and/or project requirements. NFPA National Fire Protection Association NPS Nominal Pipe Size NTE Not-to-Exceed OPL OptiPlant Online Piping Logs (OPL) A web-based Fluor Piping Utility used for handling RFIC, S3D Catalog Errors and Needs List. OptiPlant; Conceptual 3D Modeling Tool P&ID Piping & Instrumentation Diagram (P&ID) P3D PAM Plant3D (P3D) 3D Modeling Tool developed by AutoDesk. Can only be used after approved waiver from the Engineering KPO. Project Activity Model PAR Pre-Assembled Rack PAS Project Automation Specialist PAU Pre-Assembled Unit PCF Piping Component File PCM Project Contracts Manager PDM Piping Data Manager PDN Potential Deviation Notice PED Pressure Equipment Directive PEM Project Engineering Manager PEP Project Execution Plan Page 4 of 6 Title PFD PIM PIP PM PMA Description Definition Process Flow Diagram 21-010 March 17, 2022 Project Information Manager Process Industry Practices (PIP) Process Industry Practices is a process industries standards organization that issues practices suitable for purchase orders or contracts. The practices are harmonized from non-proprietary best practices from member companies. Project Manager PSR Particular Material Appraisal (PMA) A document that - for materials which are not listed in a harmonized standard nor have European approval - provides a statement that a material fulfills the requirements of the ESR and are suitable for the proposed use and conditions. It prescribes the physical and chemical properties of a material. PMA’s shall be submitted by the Manufacturer to the Notified Body for approval. Piping Materials Engineer (PME) Responsible for creating, updating and maintaining Project Commodity Catalog in MatMan. Purchase Order (PO) A PO is the Buyer's official notification to the seller of authority to manufacture, supply, ship, and invoice for the goods specified in the order and Fluor’s commitment to pay for the value of the goods ordered. It is a legal document and should clearly and precisely cover the essential elements of the order in a manner that will render misunderstandings improbable. Project Status Review PU Package Unit RAS Required at Site REQMT Requirements (REQMT) REQMT “Requirements” (REQMT) are PlaceHolder records within the Fluor Document Management System that identify documents on the SDDC that are required to be submitted by Suppliers as part of the Purchase Order but are not on the Supplier DDR. Request for Information PME PO RFI RFP ROM Request for Proposal (RFP) The Request for Proposal is assembled and prepared by the Contract Administrator, and issued to Bidders. Request for Quotation (RFQ) Taken to be synonymous with inquiry, it is the document used to obtain price and delivery on a competitive basis for the goods required for projects. Rough Order of Magnitude RPC Revamp Planning Coordinator RTP Reference Plant Type (RTP) A standard identifying attribute of a (part of) Scope of Facilities used to classify the components of a project in such a way that data can be collected and analyzed for historical data collection and for benchmarking execution and financial data. A listing of Reference Plant types to be used on Projects can be found in Practice 000.000.0500, Unison Data Standards. RFQ S3D Smart 3D SAT Site Acceptance Test SFD System Flow Diagram SFF Sonic Flow Factor (SFF) This factor is included in the estimated acoustic power level as an increase of 6 dB when there is a secondary location of choked flow in the piping system downstream of the acoustic energy source. This typically occurs in a smaller diameter tailpipe to a relief valve at the location where the tailpipe ties into a larger diameter header. Subject Matter Expert (SME) Fluor’s global expert in one or more subject matter areas, across one or more knowledge communities. SMEs are listed in Knowledge OnLine Communities under the Experts tile. SME SOC Statement of Compliance (SOC) Document prepared by the manufacturer of a product (not being the “overall” manufacturer) or their authorized representative which states compliance to the PED of the pressure equipment considered based on examinations performed by the Manufacturer’s Inspection/QA department and/or assigned Notified Body according to the applicable Conformity Assessment Procedure. Page 5 of 6 Title SOF Description Definition 21-010 March 17, 2022 SPC Scope of Facilities (SOF) The Scope of Facilities is part of the Project Baseline Scope of work. It describes the facilities that will be provided as part of the project. Scope of Services (SOS) The Scope of Services is part of the Project Baseline Scope of Work. It is a document that describes the services to be provided to complete the project. Scope of Work (SOW) The Scope of Work is the Baseline Document for the project that includes the Scope of Services (SOS) and Scope of Facilities (SOF) for the project. SmartPlant Construction SPI SmartPlant Instrumentation SPR SmartPlant Review (SPR) Fluor’s standard tool for reviewing 3D models which enables dynamic walk-through capabilities with the option to query equipment attributes, accurately measure distances and create screen snapshots. Supplier Quality Surveillance (SQS) Fluor’s Supplier Quality Surveillance group provides inspection services and reduces potential quality variances in delivered materials and services by offering cost-effective solutions for monitoring Supplier quality system performance prior to shipment. The SQS Representative oversees the inspection of equipment and materials that are produced at Suppliers’ facilities, resolves Supplier-related quality problems, and contributes to a quality ratings database for future procurement needs. Steam Tracing SOS SOW SQS ST TCP TIC The Technical Control Plan (TCP) A risk-based quality control execution plan that emphasizes the critical and challenging technical aspects of the project and demonstrates the disciplinespecific criteria for preparing, checking and approving the critical deliverables that require further validation above the standard discipline checking matrix. Total installed cost. UG Underground VBA Visual Basic for Applications VLM Very Large Module (VLM) A VLM is a module weighing more than 600 tons. Generally, above 600 tons requires nonconventional lifting / jacking and transporting methods. Transportation is often by barge or heavy transport vessel (HTV). VLMs provide an opportunity to maximize modular content. Construction of a VLM is often segregated into stages in the module yard and the WBS level – Stage – is used to define these boundaries. Work Breakdown Index WBI WBS WCM WFP Work Breakdown Structure (WBS) Work Breakdown Structure. Hierarchical framework (family tree) representing the way the project work will be defined, planned, managed, and controlled via subdividing the project scope of facilities into manageable geographically defined elements. It serves the control needs of a project by providing a structure for performing work and defining how cost and schedule data are summarized and reported. The WBS is developed from the project scope to a level of detail that defines the framework for the organization and reporting of project information, allowing for effective project control of costs and schedule. Elements of the WBS serve as the foundation for the Project Execution Plan as well as project control functions. WCM Weight Control Manager WPS Workface Planning (WFP) Workface Planning is the portion of AWP related to the support and execution of the construction phase. It is defined as the process of organizing and delivering all the elements necessary to the construction work fronts before the work is started. This proactive process enables craft workers to perform their work safely, effectively and efficiently. This is accomplished by breaking down the construction scope included in the CWPs, into IWPs, which encompass a smaller and manageable portion of the Scope of Work of a given project. Welding Procedure Specification Z+F Z+F Suppliers of high-speed accurate phase-based laser measurement and scanning systems. Page 6 of 6