Title: 03502-3 - Installation of Piping Systems

Date: September 16, 1994

Revision 0

{NOTE: This procedure was originally developed for use on the Conoco Billings Refinery
Delayed Coker Project, Job No. 20800}

INSTALLATION OF PIPING SYSTEMS

1.0 PURPOSE

This procedure provides direction to field engineering and supervision for inspecting and
documenting the installation of piping systems.

2.0 SCOPE

This procedure covers the inspection of all types of aboveground piping systems and
includes a detailed checklist of the items that are to be checked prior to testing and
turnover.

3.0 DEFINITIONS

None

4.0 REFERENCES

None

5.0 RESPONSIBILITIES

5.1 Project Field Engineer (PFE)

The PFE is responsible to:

a. Establish procedure and guidelines for inspecting piping systems.

b. Assign Quality Control Inspection Responsibilities.

c. Provide technical guidance and direction to the Area Engineer.

 d. Ensure that the field purchased piping manual quantity is sufficient.

e. Review and approve changes to this procedure.

5.2 Area Engineer

The Area Engineer is responsible to:

a. Assign and supervise field engineers to monitor and inspect the piping
systems.

b. Monitor all Quality Control documentation requirements and ensure that all
required documentation is accepted and filed in accordance with the project
procedures.

c. Notify supervision and the PFE when corrective action is required to correct
a quality problem.

5.3 Field Engineer

The Field Engineer is responsible to:

a. Inspect the piping systems to ensure quality and confirm compliance with
project documents and specifications.

b. Provide technical direction to craft and supervision.

c. Issue, obtain required approvals, and file related quality control documents.

d. Develop hydrotest packages and accept hydrotest results.

e. Develop punch list for completed systems and issue to supervision.

5.4 Welding Engineer

The Welding Engineer is responsible to:

a. Monitor and inspect field welding operations.

b. Test welders and maintain their qualification records.

c. Direct the non destructive examination subcontractor operations.

d. Direct stress relieving operations.

 e. Obtain code inspector approval as required, for welding and stress relieving
operations.

5.5 Area Superintendent

The Area Superintendent or designee is responsible to:

a. Adhere to the project drawings and specifications

b. Maintain good workmanship

c. Fulfill all safety and quality requirements pertaining to the work.

d. Direct the craft responsible for installing piping systems.

e. Coordinate and schedule activities based on project scheduling requirements.

6.0 REQUIREMENTS

6.1 Receiving, Shakeout, and Storage

6.1.1 The Area Superintendent does the following:

a. Directs the unloading of pipe spools.

b. "Shakes Out" the pipe spools using a logical method so that removal from
storage at a later date will be efficient.

6.1.2 The Field Engineer does the following:

a. Marks up piping drawings or other documents to indicate what components

and pipe spools have been received.

b. Inspects damaged spools and recommends corrective action.

c. Verifies corrective action has been completed.

6.2 Installation and Testing

6.2.1 The Field Engineer does the following:

a. Assist superintendents and craft in planning and scheduling the erection

activities.
 b. Ensures that the survey crew supplies reference elevations and center lines
for erection.

c. Checks the material and workmanship using the Aboveground Piping Field
Inspection Checklist, Attachment A, as a guide.

d. Documents errors and brings them to the attention of the superintendent.

e. Performs P&ID checks of the piping systems.

f. Develops punchlists for completed systems and follows-up to make sure the
punch list items are completed.

g. Coordinates with other disciplines to resolve interference and right-of-way

problems.

h. Develops a hydrotest program and issues hydrotest packages.

i. Witness hydrotest, initiates test records and obtains code inspector approval.

j. Performs post test inspection and develops final system punchlists.

k. Performs final inspection and accepts the system as complete.

==================================================================

ABOVEGROUND PIPING FIELD INSPECTION CHECKLIST

ATTACHMENT A

REQUIRED REFERENCES

The Inspecting Engineer must have at his disposal the following reference documents to perform a
thorough inspection of a piping system.

1. Piping and Instrumentation Diagrams (P&ID's)

2. Piping Specifications and Supplementary Tables

3. Piping Stock Code Book

4. Line Designation Tables

5. Pipe Support Details

6. Piping Drawings
 a. Isometrics

b. Spool Sheets

c. Orthographics or Model

d. Support Drawings

7. Steam Tracing Specifications and Schedules

8. Pump Trim Drawings

9. Vendor's Equipment and Control Valve Drawings

10. Instrument Data Sheets, Installation Schedules and Details

11. Instrument Location Drawings

12. Isometric/Spool Index

13. Home Office Engineering and Field Engineering Job Instructions

14. Testing P&ID's

15. Latest Codes, ANSI B31.3, 31.1, ASME Section I and VIII

16. Allowable Substitution Specifications

BOLTS AND STUDS

1. Bolts and studs are not interchanged.

2. Bolting is correct length, and thread lubricant is used if required.

3. If other than B-7 studs are required, stamp or color code is checked on end of studs. Be
sure to verify type bolts to be used on high pressure high temperature flanges.

4. All bolts or studs are in and tight. Studs are at least flush with nuts and do not have
excessive thread exposure and have equal projection beyond nuts (normal is 2 exposed
threads).

GASKETS
1. Gaskets are installed and are the correct type, material, size and rating. Establish a color
code that can be edge inspection verified.

2. Specification changes at equipment block valves are carefully checked for correct gaskets.

3. All vessel gaskets on manways and blind flanges should be checked at this time. The vessel
manufacturer usually uses an off specification gasket.

4. Temporary gaskets may be used at temporary blinds, then line specification gaskets
installed after pulling temporary blinds. Moan list should specify the right gasket. High
pressure ring gaskets should be verified oval or hex as installed.

SMALL PIPING AT PUMPS AND OTHER EQUIPMENT (PACKAGE UNITS)

1. If the trim material is supplied by vendor, ensure that material used meets Bechtel and job
specifications or has been an agreed substitution approved by Home Office Engineering.

2. Pump trim drawings and vendor prints are checked for location and routing of trim piping.
Pumps are usually tagged at each connection, but care should be taken to see that they are
connected properly. Cooling Water systems, either individual or series feed, should be
checked carefully for arrangements of piping. Verify that all required trim piping by the
equipment vendor has been designed.

3. Plugs furnished by vendors are checked for compliance with specifications. All equipment
openings are checked for requirement of a plug or blind flange. Watch for straight
machine-threaded plugs instead of tapered pipe plugs.

4. Check pickling requirements.

5. Stress relieving requirements are checked.

6. Screwed and socket weld fittings of the correct weight and type material are used (watch
out for malleable iron versus forged steel fittings).

7. Lines are properly supported and are installed level and plumb.

PIPE SUPPORTS AND EXPANSION JOINTS

1. Verify the line supported properly. Drawings must be checked to confirm that major
supports are installed. Small lines are field supported.

2. Check clearances for pipe expansion anchor locations.

3. Remove all temporary supports - wires, wooden blocks, etc.

4. Any line, but especially steam and high temperature lines may require anchors, guides, and
longer shoes to allow for expansion.

5. Check all supports for conformance with support drawings.

6. Check insulated lines for correct shoe installation. Verify the correct height shoe is installed
and is correctly welded. Some specifications call for stitch welding to pipe; some full weld.
Avoid full-welding shoes when not required.

7. Check the height of guides next to pipe shoes on insulated lines. The guide should not
interfere with the insulation.

8. Make sure shoes are properly positioned in relation to support to allow for expansion.

9. Alloy lines must be checked carefully. Any additional welded supports or temporary welds
may require stress relieving. Clamp types may be used if specifications permit.

10. Large diameter lines must be checked carefully. Gas lines and supports not designed for
hydrotest may require temporary supports, or special permission may be obtained for air
test.

11. Spring hangers should be checked for required type with manufacturer nameplate and are
set correctly.

12. Lines at pumps and other equipment should be carefully checked for undue stresses on
equipment flanges.

13. Pipe supports are straight and plumb.

14. Lines should be checked for allowances for proper expansion.

15. Lines should be checked for required slope.

16. Bellows type expansion joints should be checked for test and service pressure. Also check
that bellows are installed with tie bars correctly oriented and flow is in the correct direction.

17. All lines should be checked for the need of additional supports and guides.

18. Cold spring may be specified by the design and should be checked and witnessed during
installation.

19. Shoes or supports are not tack welded where they should be able to slide.

20. Slide plates should be checked if required.

SEAL WELDING

1. Verify seal welding is complete as required.

2. Verify threads are covered by seal weld.

3. Ensure that no pipe dope or tape is used in screwed joints to be seal welded. Craft must be
alerted to that at the start of small piping installation.

4. Specifications must be checked to determine requirements for seal welding to equipment.

Some require it and some do not allow it.

INSULATED LINES

1. Long vertical lines may require insulation support clips at specific intervals.

2. Sufficient clearance must be for insulation on steam and hot lines from conduit, structural
steel, platforms, other lines, and handrail.

3. Clearances must be provided for insulation on equipment and lines.

4. Line mounted instrument support brackets should be installed before the line is released for
insulation.

ALLOY LINES

1. Stress relieving is complete and witnessed as required, documentation has been distributed.

2. Materials are correct type. Watch for substitutions of various alloys, especially stainless
steels - 304, 304L, 310, 316 and 316L.

3. Valves and gaskets are checked carefully. Stock code description is checked against valve
nameplate data and, if necessary, to determine valve is correct, against manufacturer catalog
number.

ORIFICE RUNS

1. Orifice runs have the specified straight length of pipe (free of welds) and both upstream and
downstream of orifice flanges.

2. Orifice taps are oriented in the correct direction. Most specifications specify vertical for gas
and horizontal for liquid.
3. Jack screws are installed as required at orifice flanges or flanges with spectacle blinds.

4. Nipples and plugs installed on orifice flanges are as specified. Some specifications require
stainless, XS or XXS.

STEAM TRACING

1. Check length numbers and size of tracers and that they are adequately tagged.

2. Check number of branch lines allowed from heater.

3. Check steam trap details.

4. Check whether instruments require tracing expansion loops.

5. Check instrument/analyzer tubing for steam trace requirements.

6. During commissioning, walkdown the piping system after steam-up to make sure that none
of the joints are leaking and that all existing lines have been connected properly or are
sealed off thoroughly.

7. Check that the tracing runs close to the surface of the pipe and that the banding holding it to
the pipe is adequate.

STRESS RELIEF OF PIPING

The following items should be verified prior to hydrotesting.

1. Check what systems require stress relief.

2. Check stress relieving records and verify both the records and physical inspection with the
engineer responsible for the stress relieving.

3. Check that the Brinell hardness tests are completed and acceptable after stress relief.

4. If local stress relieving is done, look at charts to verify the proper times and temperatures
were obtained.

5. Ensure that the proper client sign-off is obtained for stress relief acceptance.

BOILER CODE PIPING

1. Obtain the code used for design of the system.

2. Obtain the mill test reports for the materials used.

3. Verify that all the steps required by the code were followed.

4. Obtain the code inspector witness signatures for fit-up and final hydrotest acceptance.

5. Verify that the proper code papers have been filled out and signed by the proper Bechtel and
code personnel.

6. Assemble piping documentation and forward to the PFE for attachment to the final boiler
certification.

MISCELLANEOUS ITEMS

1. Lines meet specifications for head room and walk areas.

2. Relief valves and pressure gauges have been checked in calibration shop if required by
specifications. These are tagged and done as early as possible prior to installation, and a list
of these items is prepared for control, including set pressure, date checked and signature of
checker. Relief valve seals should be checked during the final P&ID check.

3. Start-up or permanent suction screens are installed in pump and compressor suction lines as
required. Check for correct direction of installation. Be sure the screen can be removed
after the pipe has been completely assembled.

4. Mount the unused portion of a blind/spacer set in a convenient location to the installation
point.

5. Spectacle blinds, blinds, and spacers are installed as required and are correct thickness.
Install jack screws as required by the specifications.

6. Relief valve stacks to atmosphere have drain holes at a low point and/or weather hoods as
required.

7. Piping specifications are carried to the point specified before the instrument details take
over. Usually, the block valves must be per piping specifications.

8. Drip legs are provided at low points in steam lines.

9. Mud legs or drip legs have clearance for expansion of the main line. Proper pipe dope or
teflon tape is used on screwed connections that will not be seal welded.
10. Check that all utility stations are properly installed, that the hose rack is securely mounted,
and that the proper hose couplings are used.

11. Install spray shield "diapers" on flange and valves where required by the specifications.

12. Verify clearance exists for removal of equipment such as deep well type pumps, motors,
tube bundles, basket strainers, and thermowells, and that spare equipment can be removed
without a plant shutdown.

PREPARATION FOR TESTING

Identify on a set of P&ID's the systems to be tested. Within the system, ensure the following:

1. All lines and equipment have been completely cleared of debris by flushing with water or
air blowing as appropriate.

2. Vessels, internals of instruments, and equipment not capable of withstanding the test
pressure are removed or blinded.

3. Relief valves and rupture discs are removed, blinded, or gagged.

4. The allowable test pressure for valve bodies and valve seats is not exceeded.

5. Either the exchanger is designed for full differential pressure or tube sheets of exchangers
are pressurized on both sides.

6. Installation of any additional test vents and/or drains required.

7. As far as is practical, lines are tested in complete systems, and the test system is laid out to
require the minimum number of blinds.

8. Make up test packages of isometrics, for the personnel performing the test. These test
packages should also include:

a. Locations of test blinds

b. Special instructions such as removal of flappers from check valves, stroking

open control valves, instruments.

c. Filling locations, if critical (upstream of check valves).

d. Valves that must be left open or closed.

e. Instructions for performing the test.

9. The Pipe Test Report may be initiated at this time.

Before the test system is filled, check the following:

1. Temporary supports and blocking are installed on lines not designed for the test loads.

2. Expansion joints are restrained or isolated.

3. Provisions have been made for preventing and/or relieving excessive pressures that may be
caused by thermal expansion of the water during the tests.

4. Test gauge is calibrated and compatible with test pressure.

5. Instruments are disconnected or isolated from the test.

6. Special instructions listed on the test package have been carried out.

7. The pump or compressor used for applying the test pressure has a safety valve and that the
setting of the valve is checked and approved as required. Relief setting is typically set at
105% of the test pressure. Check that the relief valve discharge capacity is suitable for the
test system.

8. When vessels are tested with the piping, extreme care should be taken during these tests. Be
doubly sure that all vessels are properly vented before draining a test.

9. The Pipe Test Report has been signed by the Welding Engineer.

PRESSURE TESTING

1. All hydrotesting should be performed with low chloride fresh water, unless otherwise stated
in the design documents.

2. Ensure that the system is completely filled with water, all air pockets should be removed
through high point vents.

3. Ensure the pressure test is conducted according to the instructions set out in the test
package.

4. When the test system is under pressure, inspect the system for leaks. Once the system is
"tight", the inspector should check the system and sign the Pipe Test Report.

POST-TEST ACTIVITIES
After the Pipe Test Report has been signed off, ensure the following are performed to restore the
pipe to design configuration:

1. Proper venting when draining the system, to prevent vacuum conditions which may result in
collapse of vessels not designed to withstand a vacuum.

2. If required, the system is blown dry.

3. Temporary supports and blocking are removed.

4. Expansion joint restraints are removed.

5. Test blinds and gags are removed.

6. Vent valves are removed and thread-o-lets are plugged and seal welded, if required.

7. Components removed for the test are reinstalled.

POST-TEST ACTIVITIES

1. Any open ended pipes are sealed.

2. Final checking and punch listing is performed before turnover for insulation or painting.

3. Extreme care should be taken when depressuring test system that included exchangers. The
system should be depressurized slowly on both sides of the tube bundle so that the
allowable pressure on the tube bundle is not exceeded.