SPEC 17037-P4-P-0A1G-SZ-00002 - 0 - Piping Fabrication PDF

SPECIFICATION PAGE 1 of 43
NUMBER SPEC 17037-P4-P-0A1G-SZ-00002
LAMPUNUT VILLAGE, UTILITIES

PROJECT TITLE JOB No. 17037
PACKAGE ARRANGEMENT
DESCRIPTION COMMON
PIPING FABRICATION, INSTALLATION & TESTING
SPECIFICATION
OFFICE OF ORIGIN CONTROMATION ENERGY SERVICES DIR. REF 17037-1.9.1.SPEC
WRITTEN BY NISA SULASTRI DATE: 15.01.2018 CLIENT PO
REVIEWED BY MALCOLM COLLYER DATE: 15.01.2018 CLIENT REP.
TITLE OF REVIEWER ENGINEERING MANAGER
STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER
SIGNED DATE REV.
ACCEPTED .......................... .................... .............

(Alpha or Numeric)
ACCEPTED EXCEPT AS NOTED .......................... .................... .............

(Alpha)
REVISE AND RESUBMIT .......................... .................... .............

(Alpha or Numeric)
APPROVAL BY CLIENT RESPONSIBLE MANAGER

(Numeric)
.................................................................................. DATE: ................................
Rev. Date Description By Chk’d Reviewed Client

0 19.02.2018 Issued for Use
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION PAGE 1 of 43
NUMBER SPEC 17037-P4-P-0A1G-SZ-00002

PROJECT TITLE JOB No. 17037
PACKAGE ARRANGEMENT
DESCRIPTION COMMON
PIPING FABRICATION, INSTALLATION & TESTING
SPECIFICATION
OFFICE OF ORIGIN CONTROMATION ENERGY SERVICES DIR. REF 17037-1.9.1.SPEC
WRITTEN BY NISA SULASTRI DATE: 15.01.2018 CLIENT PO
REVIEWED BY MALCOLM COLLYER DATE: 15.01.2018 CLIENT REP.
TITLE OF REVIEWER ENGINEERING MANAGER
STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER
SIGNED DATE REV.
ACCEPTED .......................... .................... .............

(Alpha or Numeric)
ACCEPTED EXCEPT AS NOTED .......................... .................... .............

(Alpha)
REVISE AND RESUBMIT .......................... .................... .............

(Alpha or Numeric)
APPROVAL BY CLIENT RESPONSIBLE MANAGER

(Numeric)
.................................................................................. DATE: ................................
Rev. Date Description By Chk’d Reviewed Client

0 19.02.2018 Issued for Use NS MC MC
SPEC 17037-P4-P-0A1G-SZ-00002_0
Dir. Ref: 17037-1.9.1.SPEC PACKAGE ARRANGEMENT COMMON
Date: 19/02/18 PIPING FABRICATION, INSTALLATION &
Page: 3 of 43 TESTING
SPECIFICATION
CONTENTS
1.0 INTRODUCTION ................................................................................................ 5

1.1 Scope ...................................................................................................................5
1.2 Document Precedence ........................................................................................5
2.0 APPLICABLE CODES, STANDARDS AND SPECIFICATIONS ....................... 6
2.1 Codes and Standards ..........................................................................................6
2.2 Project Document ................................................................................................8
3.0 RESPONSIBILITIES ........................................................................................... 9
4.0 MATERIAL SPECIFICATIONS AND GENERAL REQUIREMENTS ............... 10
4.1 Piping components ............................................................................................10
4.2 Substitution and Changes ..................................................................................10
4.3 Errors and Omissions ........................................................................................10
4.4 Storage and Handling of Material ......................................................................11
4.5 Location of Field Joints ......................................................................................12
5.0 METALLIC PIPING........................................................................................... 13
5.1 General ..............................................................................................................13
5.2 Fabrication .........................................................................................................13
5.3 WELDING ..........................................................................................................17
6.0 NON METALLIC PIPING .................................................................................. 22
6.1 General ..............................................................................................................22
6.2 Preparation for Joints .........................................................................................22
7.0 IDENTIFICATION OF PIPE SPOOLS .............................................................. 24
8.0 PROCESS AND UTILITY PIPE LABELING ..................................................... 25
8.1 Label Locations ..................................................................................................25
8.2 Label Specifications ...........................................................................................25
8.3 Piping That Must Be Labelled ............................................................................26
9.0 PIPING INSTALLATION .................................................................................. 27
10.0 QUALITY ASSURANCE .................................................................................. 30
11.0 INSPECTION AND EXAMINATION ................................................................. 31
11.1 Metallic Piping ....................................................................................................31
11.2 Non Metallic Piping ............................................................................................35
12.0 CLEANING AND TESTING PIPE WORK ........................................................ 36
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
12.1 Documentation ...................................................................................................36

12.2 Cleaning Procedure ...........................................................................................36
12.3 Pipe Pressure Testing........................................................................................37
13.0 RECORDS AND REPORTS ............................................................................. 41
14.0 REFERENCES AND GLOSSARY.................................................................... 42
14.1 Glossary of Terms and Acronyms......................................................................42
LIST OF TABLES
Table 5-1 Drawing Dimensional Tolerances ............................................................ 16

Table 5-2 Drawing Dimensional Tolerances ............................................................ 16
Table 11-1 Methods for NDT ..................................................................................... 33
Table 11-2 Extent of NDT (Class Designation as per AS 4041 Table ....................... 33
Table 11-3 Traceability Requirements (Class Designation as per AS 4041, Table 1-3)
................................................................................................................. 35
Table 14-1 Terms, Acronyms and Definition ............................................................. 42
List of Figures
Figure 8-1 Pipe Labelling .......................................................................................... 25
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
1.0 INTRODUCTION
1.1 Scope
This Specification covers the minimum requirements for furnishing all labour,
consumables and services required for receipt and storage of materials and spools, site
fabrication, erection and testing of carbon steel, galvanized, and HDPE piping, pipe
supports, valves and inline equipment for the ADARO, Lampunut Development Projects.
1.2 Document Precedence

Where conflicts occur, the following order of precedence shall be observed and reflected
in the requisition:
 Statutory Codes International
 Codes and standards
 Project Documents
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
2.0 APPLICABLE CODES, STANDARDS AND

SPECIFICATIONS
The publications listed below form part of this specification and shall be complied with.
Each publication shall be the latest revision and addendum in effect on the date this
specification is issued for design 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.
2.1 Codes and Standards

American Society of Mechanical Engineers (ASME) Codes
ASME Boiler and Pressure Vessel Code (BPVC)
- Section II Material Specifications
- Section V Non-destructive Examination
- Section VIII Division 1 Pressure Vessels
- Section IX Welding and Brazing Qualifications
ASME B 16.9 Factory-Made Wrought Steel Butt welding Fittings
ASME B 16.11 Forged Steel Fittings- Socket – Welding and Threaded
ASME B 16.25 Butt welding Ends
ASME B 31.3 Process Piping
ASME B 31.4 Pipeline Transportation Systems for Liquid and Slurries
ANSI B16.5 Steel pipe flanges and flanged fittings
ANSI B16.21 Non-metallic Flat Gaskets for Pipe Flange
ANSI B16.36 Orifice Flanges
ANSI B36.10 Welded and seamless wrought steel pipe
ANSI B1.20.1 Pipe Thread General Purpose
American Society for Testing Materials (ASTM)
ASTM G28 Standard Test Methods of Detecting Susceptibility to

Intergranular Corrosion in Wrought, Nickel-Rich, Chromium-
Bearing Alloys
ASTM A53 Pipe, Steel, Black and Hot Dipped Zinc Coated Welded and
Seamless Pipe
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
ASTM A105 Forgings, Carbon Steel, for Piping Components
ASTM A106 Standard Specification for Seamless Carbon Steel Pipe for
High-Temperature Service
ASTM A182 Piping Fitting of Wrought Carbon Steel and Alloy Steel for
Moderate and Elevated Temperatures
ASTM A193 Standard Specification for Alloy-Steel and Stainless Steel

Bolting for High Temperature Service and Other Special
Purpose Applications
ASTM A194 Standard Specification for Carbon and Alloy-Steel Nut for
Bolts for High Pressure or Temperature Service, or Both
ASTM A307 Standard Specification for Carbon Steel bolts, Studs, and
Threaded Rod
Australian Standard (AS)
AS 2032 Installation of PVC Pipe Systems
AS 2033 Installation of Polyethylene Pipe Systems
AS 2129 Flanges for pipes, valves and fittings
AS 2700 Colour Standards for General Purposes
AS 3892 Pressure Equipment - Installation
AS 3992 Pressure Equipment – Welding and Brazing Qualifications
AS 4037 Pressure Equipment – Examination and Testing
AS 4041 Pressure Piping
AS 4129 Fittings for polyethylene (PE) pipes for pressure purposes
AS 4130 Polyethylene (PE) pipes for pressure application
AS 4131 Polyethylene (PE) compounds for pressure pipes and fittings
AS 4458 Pressure Equipment – Manufacture
Pipe Fabrication Institute (PFI)
PFI ES-24 Pipe Bending Methods, Tolerances, Process and Material

Requirement
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
2.2 Project Document

This Specification should be read in conjunction with the following documents:
SPEC 17037-P4-P-0A1G-SZ-00001 Piping Materials Specification
SPEC 17037-P4-P-0A1G-SZ-00003 Piping Isolation Specification
SPEC 17037-P4-P-0A1G-SZ-00004 Burried Pipeline Specification
SPEC 17037-P4-P-0A1G-SZ-00005 Valves Specification
SPEC 17037-P4-P-0A1G-SZ-00006 Piping Speciality Items Specification
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
3.0 RESPONSIBILITIES
Contractor shall be wholly responsible for the design and construction of the equipment
and their integral components. The design details shown on the data sheets and standard
drawings are the minimum design requirements.
Should conflict occur between this Specification, the data sheet, and the drawings or
attachments, it shall be the responsibility of the Contractor to call the Company’s attention
to the conflict and request a ruling or interpretation from the Company. The Contractor is
not at liberty to assume which requirement would govern.
The Company’s review of Contractor drawings, or release of equipment for shipment by

Company Inspector, shall not relieve the Contractor of his responsibility for complying with
all the requirements of the purchase order.
Company will provide basic configuration, service data, design requirements, and all other
applicable operating parameters. These will be specified on the equipment data sheet
and in this specification.
Contractor is responsible for compliance with local codes and regulations for the region
where the equipment is to be installed. Contractor shall obtain appropriate approvals of
the equipment design and construction from the Regulatory Authorities for the region
where the equipment is to be installed.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
4.0 MATERIAL SPECIFICATIONS AND GENERAL

REQUIREMENTS
4.1 Piping components
All piping materials shall be new in accordance with the project Piping Material
Specification SPEC P17037-P4-P-0A1G-SZ-0001, Technical Specification for Valves
SPEC P17037-P4-P-0A1G-SZ-0005, Piping Specialty Items, P&IDs, Instrument lists,
Piping Standard Drawings and other applicable Project Specifications.
Piping shall be installed preferably in prefabricated sections or alternatively by site

fabrication, confirming to the requirements of the piping specifications, drawings and
P&IDs. When defined in the inquiry document; Pipe, fittings, flanges, specialty items etc.
will be supplied by the client.
Consumable item such as electrodes, filler wire, flame tips, flux, gas, rags and the like will
be supplied by the Contractor/Subcontractor as will all shipping and bundling materials
including pipe end protection.
Where materials are furnished by the client, Contractor/Subcontractor shall not be

permitted to substitute other materials for those supplied without client’s prior written
approval. Any materials procured by the Contractor/Subcontractor including those for
dummy spools shall conform to the requirements of Piping Material, Pipe Support and
other relevant specifications. Materials substitutions to those specified shall not be
allowed without the approval of the Company Representative.
Contractor/Subcontractor shall carry out all rigging studies to enable safe handling of the
pipe work during fabrication and installation.
4.2 Substitution and Changes

No substitution shall be made of materials or changes to design details without the prior
written approval of the Company Representative. This includes usage of higher
thickness/higher grade materials. Should substitutions or changes be desired, submission
is required in writing in the form of a Field Change Request to the Company
Representative stating the reason for the change and shall include the copies of drawings
or sketches demonstrating the adequacy of the proposed substitutions or changes.
Work shall not progress until an approval notice (Field Change Request/Field Change
Notice) to proceed is issued.
4.3 Errors and Omissions

The contract documents including the drawings shall be checked prior to commencing any
part of the work and immediate notification to the Company Representative of any errors,
omissions and inconsistencies discovered.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
4.4 Storage and Handling of Material

All pipe line components like pipes, fittings, specialty items, valves; instruments etc
necessary to complete the works shall be free issue to the Contractor/Subcontractor.
The Contractor/Subcontractor shall be responsible for the inspection of all pipeline

components at time of receipt on site. Company Representative shall be immediately
notified of any damage detected by the Contractor/Subcontractor during the course of
inspection. Repair or replacement of the damaged components shall not occur until the
Contractor/Subcontractor receives a written instruction from Company Representative,
advising the course of action.
The Contractor/Subcontractor shall make good any markings or colour coding deficiencies
discovered on arrival of all items and thereafter maintain the identity of any materials
remaining when parts are cut off.
All piping components and pipe spools shall be stored and handled in such a manner that
no damage or mixing of materials will occur. Materials shall be stored on non-metallic
skids and not directly on the ground.
Preservation and storage procedure shall be prepared by the Contractor/Subcontractor

and submitted to the Company Representative for approval. Valves shall be stored under
cover with spindles in vertical position. Relief valves shall be stored upright in a clean area
away from the construction activity. All Special piping items like strainer, mining hoses,
expansion bellows shall be stored undercover in accordance with supplier’s
recommendations.
Flange gasket faces shall be protected from damage at all times. Covers shall be kept on
flange gasket faces during handling and transportation. Flange gasket faces shall not be
stored in direct contact with the ground. Open ends of spools, flanged or open pipes shall
be sealed until welded into final location.
The Contractor/Subcontractor shall be responsible on receipt of pipe components to load,

transport, unload and install piping components in the designated work area by approved
methods to prevent damage. Handling methods shall be subject to the following
mandatory requirements:
 Under no circumstances shall pipes or fabricated spools be lifted by unprotected metal

slings, or hooks and they must not be levered into position with lifting bars.
 Pipes or fabricated spools shall be lifted by a minimum of two slings of appropriate

SWL except if > 6 metres in length then they must be lifted using a spreader bar or
equivalent as approved by Company Representative.
 Pipes or spools shall be transported on vehicles with cradles and adequate restraining
straps.
 Pipe open ends shall remain securely capped as supplied by the manufacturer at all
times until required to be open for fabrication or testing.
 Fittings shall remain stored in original packaging or secured to pallet until ready for
use.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
 Flange faces to fabricated pipe spools or fitting assemblies shall remain protected with
bolted on plywood or pre-formed plastic covers until installation.
For carbon steel pipes and fabricated spools which are painted or have a protective
“yellow jacket” MDPE coating or equivalent; the following additional requirements shall be
met:
 Pipes and fabricated spools shall be lifted in approved flexible slings with soft non-
abrasive lining suited to the diameter of the pipe and to prevent damage during laying.
 At all times pipes and fabricated spools must be placed in position on sand bags or
padded timber dunnage and shall in no circumstances be pushed along the ground or
dropped.
HDPE, PE 100 Polyethylene fittings and fabricated assemblies shall be protected from
elevated temperatures and direct sunlight to prevent distortion. Pre-assembled fittings
containing reducers, reducing branches or flanges shall be supported on timber dunnage
a minimum of 75 mm wide and 1500 mm centres to prevent deformation and end loading.
Substandard handling techniques resulting in cuts or scores to a depth of > 10% wall
thickness of HDPE pipe or fittings shall result in that section of pipe or component being
rejected for installation. HDPE piping systems shall be stored and handled strictly in
accordance with the manufacturer’s recommendations. Pipes and fittings shall remain
stored in packs supplied and stored on level ground.
Any damage to pipeline components caused by the Contractor/Subcontractor and his

subcontractor(s) shall be made good by completing repairs in an approved manner or
where directed by Company Representative shall be replaced.
4.5 Location of Field Joints

Locations of field welds and field fit welds shall be as shown on the isometric drawings.
Where it is necessary for the pipe spool fabricator to split a spool (e.g. for transport), it
shall be informed to the Company Representative with relevant descriptions and mark-ups
on isometrics with additional field welds details
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
5.0 METALLIC PIPING

5.1 General
All metallic piping shall be fabricated, erected, inspected and tested in accordance with
AS 4041.
A straight run of pipe shall contain a minimal number of welds. Off cuts shall not be used
where a standard full length of pipe would eliminate a weld. Pipe or fittings shall not be
bent or cold pulled by a procedure which will cause wrinkling, thinning or flattening of the
pipe.
5.2 Fabrication
5.2.1 General Requirements for Layout, Cutting and Fit Ups
Plasma and machine cutting methods may be used for stainless steel. Flame cutting is not
allowed for stainless steel. Flame cutting and bevelling is acceptable for carbon steel
piping provided the cut is reasonably smooth and true and all oxides are removed from
the flame cut surfaces by grinding. Any other method requires prior written approval by the
Company Representative.
Machining/grinding should be used for butt weld edge preparation. Machining is preferred
to grinding as machining provides uniform weld gap thickness. Grinding may be used
provided special care is taken during grinding to ensure that weld edge preparation is
smooth and fits ups are uniform. Tools with grinding discs/wheels containing carbon steel
particles shall not be used on stainless steel and high alloy steels. To prevent cross
contamination, files, grinding wheels, and wire brushes shall be designated individually for
each type of material and used exclusively for the respective materials. Grinding burrs
shall be removed to ensure complete fusion and penetration. Welding areas shall be
cleaned prior to welding.
Pipe/fittings shall be machined internally to compensate for different wall thicknesses and
shall be carefully checked for roundness, and corrected using power jacks as necessary,
prior to grinding.
For butt welding of all piping components, pipe ends, fittings and weld neck flanges, the
root opening and weld bevel alignment shall be in accordance with AS 4458. Seam
orientation of welded straight pipe and pipe to fitting shall be such that, at circumferential
welds, the longitudinal welds shall be staggered over the top of the line, preferably 30° left
and 30° right of the centre line of the pipe. The longitudinal weld in a pipe or fitting shall
not be located in the bottom 120° of a spool. The minimum distance measured between
the heat affected zones of the staggered joints shall be 50 mm. Wherever an unavoidable
clash occurs, the Company Representative shall be notified for additional NDT
requirements. Care shall be taken to ensure that longitudinal welds clear branch
connections.
Backing rings and consumable inserts shall not be used. All weld end preparations and
adjacent areas for about 100 mm shall be thoroughly cleaned and degreased prior to
welding.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
Where supports such as ‘dummy legs’, base supports or lugs are required to be fabricated
and welded to pipe spools, such requirements will be detailed on the design drawings.
Such welding shall be prior to any internal or external lining or post weld heat treatment.
Defective or damaged weld ends shall be examined by the Company Representative in

order to determine the nature and extent of damage. Weld repairs shall not be made on
weld preparations of pipe and fittings without permission from the Company
Representative. Use of cold or hot hammering as a means for repair is prohibited. Valves
that are required to be welded shall be in the open position prior to commencement of
welding to avoid damage to the valve seats. Proper care shall be taken while socket
welding to avoid damage to the soft seated ball valves.
Field welding shall not be carried out when the pipe surfaces are moist or during periods
of wind in excess of 5km/hr unless protective enclosures are provided. Weather
enclosures and their suitability for protection shall be subject to prior approval by the
Fabricated branch connections shall be in accordance with AS 4041. Branch

reinforcement material shall be made from material as specified in the relevant piping
class and subject to the same specification requirements as the piping to which it is
attached. Reinforcing pads shall have a one-quarter inch (¼”) NPT threaded hole for
testing and venting, sealed after pneumatic test.
Application of heat to piping components by heating or flame straightening is prohibited.

Cold spring or forcing of piping for the purpose of joint make is not permitted.
External surfaces to pipe ends supplied with “yellow jacket” external MDPE coating shall
be mechanically cleaned with flexible discs and wire brushes to a minimum of 40 mm from
the line of the weld. Adhesive of the jacket, scale and foreign matter shall be removed
prior to tacking or welding.
5.2.2 Flanged Joints
Flange bolt holes shall straddle vertical centerlines and north/south gridlines unless
otherwise noted on the drawings. The maximum angular tolerance of flanges on pipe as
measured at the flange OD shall be +/-1 mm per 300 mm (or part thereof) of flange OD up
to a maximum of +/-3 mm.
The clearance between the outside diameter of the pipe and bore of the slip on flange
shall comply with Table 8.2 of AS 4458. Seal welding shall be carefully applied in order to
avoid re-facing the flange face.
5.2.3 Socket Welded Connections
Preparation and assembly of joints for welding shall ensure that the pipe end is parallel to
the base of fitting and there is a gap of approximately 1.5 mm between the pipe end and
fitting. Pipes for socket weld joints shall be cut square. Fit up and minimum dimensions
shall be in accordance with AS 4458. A minimum number of two (2) weld passes shall be
made for all socket-welded joints.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
5.2.4 Threaded Connections
Unless otherwise specified, all threaded connections shall be in accordance with ASME B
1.20.1. Threaded connections shall be gauge checked or chased after welding or
galvanizing. Thread engagement shall be verified in accordance with ASME B 1.20.1.
Inside ends of threaded pipes shall be de-burred by reaming. Threaded connections shall
not be seal welded unless otherwise approved in writing by the Company Representative.
5.2.5 Branch Connections
Branch connections on shop fabrications shall include appropriate fittings, or groups of

fittings, i.e. flanged thermowell connections, half couplings or pipe stubs for smaller field
fabricated branch connections. Pipe stubs of 50 mm and smaller shall extend to the first
natural weld but not more than 300 mm from the outside surface of the header or as
indicated on the isometric drawings. Larger pipe stubs (80 mm and over) and branches
shall extend to the first flange or to the field weld point as indicated on the isometric
drawings.
5.2.6 Welded Attachments
Where welded attachments need to be added to shop piping during fabrication they will be
so noted on the isometric drawings.
Dummy pipe legs attached to welded lines, for pipe support purposes, shall be fabricated
with the spool.
5.2.7 Bending
Cold / hot bending shall be avoided and needs approval from the Company
Representative for any special use.
5.2.8 Galvanized Piping
All galvanized piping systems (spec CSGA) shall be hot dip galvanized after spool
fabrication. Spool sizes shall confirm to the galvanizing bath dimensions. Flange faces
shall be protected / cleaned during galvanizing to ensure leak tight jointing at the time of
assembly. Site fabrication and use of cold galvanized paint shall not be permitted. To
avoid site fabrication / cold galvanizing, wherever required, the end spools and fit up joints
etc. shall be flanged and prepared at shop, based on site information / requirement. These
spools shall be hot dip galvanized and then shipped to site for final box-up.
5.2.9 Dimensional Tolerances
Butt welding ends shall be bevelled as per ASME B16.25.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
Table 5-1 Drawing Dimensional Tolerances

Drawing Dimension Length
Configuration <= 6 Meters > 6 Meters
Centre to Centre ± 1.0 mm ± 2 mm
Centre to End ± 1.0 mm ± 2 mm
Centre to Flange Face ± 1.0 mm ± 2 mm
Flange Face to Flange Face ± 1.0 mm ± 2 mm
The above tolerances apply to each stated drawing dimension and are not accumulative.
The straightness of a finished spool, over the specified length, shall not deviate by more
than 0.2%, measured from end to end. However, branch connections shall be within 1.5
mm of the true centerline of the run pipe.
For flange face alignment the maximum deviation from the design plane shall not exceed
the following values listed in Table 5-2
Table 5-2 Drawing Dimensional Tolerances

DN Maximum Deviation
<= 200 1.0 mm
250 to 500 1.5 mm
600 to 900 2.5 mm
> 900 3.0 mm
However, when branches are in the same plane their flange facings shall not deviate by
more than 1.0 mm from each other.
Unless otherwise indicated on the drawings, the bolt holes of all flanges shall straddle the
vertical line of the pipe and their alignment shall be in accordance with AS 4041. The
maximum deviation permitted shall not exceed 1.5 mm measured across the bolt circle.
Piping fit-ups shall not be misaligned by more than "15%" of the wall thickness of the
thinner part being joined. Wherever possible misalignment should be minimized by
rotating the pipe/fitting for best fit. Inside surfaces of components at weld ends to be
joined shall be aligned within the dimensional limits of the weld procedure specification.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
5.3 WELDING
5.3.1 Welding Procedure
Welding procedures shall be qualified to AS 3992 and shall be approved by the Company
Representative. Production welding shall not be started until welding procedures have
been approved by the Company Representative. Welding procedures shall be prominently
displayed so that they are available to the welder, welding supervisor and inspector.
In addition to the variables listed in AS 3992 the welding procedure must detail the
following:
 Joint details, bevel angle, root face, root gap, allowable misalignment and fit up
tolerances
 Method to be used for cleaning the weld joint prior to welding and between passes
 Type (root or bridge), size and spacing of tack welds
 Method for back purging and testing oxygen level of purge gas. Allowable oxygen level
in purge gas
 Method of repairing welds and limitations of number of repairs.
Separate method statements shall detail the process of handling welding consumables.
Welding procedures qualification test pieces shall be tested in accordance with AS 3992.
5.3.2 Welding Consumables
The manufacturer’s recommended practices for storage and preparation of materials shall
be followed at all times. The Company may, at its own cost, perform additional
independent verification of welding materials. Welding consumables that became wet or
contaminated shall not be used.
Welding consumables shall be used in accordance with manufacturer’s recommendation.

Consumables used for production welding shall be of the same class and manufacturer as
those used in the qualification of the weld procedure. All tests carried out on weld
procedure qualifications shall include heat treatment as used on the finished equipment.
Low-hydrogen welding electrodes shall be used for welding of carbon steel.
Electrodes shall conform to the requirements of relevant parts of ASME BPV Code
Section II part C. Welding consumables shall be in accordance with the current lists of
approved welding consumables published by American Bureau of Shipping, Det Norske
Veritas and Lloyd Register of shipping or as approved by the Company Representative.
5.3.3 Welders
All welders shall be qualified in accordance with AS3992 and welder qualification tests
shall be carried out to approve Welding Procedure Specification. In addition, as a
minimum, welders used on field welds shall be qualified for low hydrogen electrodes and
position 2G and 5G. Qualification to 6G is preferred.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
The welders must have been qualified to perform the welding process on the material, at
the thickness range and welding position of the material being joined. Welders shall have
been qualified, or shall have welded within the qualification range, within the past three
months or within the proceeding one year if written evidence is presented that the welder
has satisfactorily welded on a job using the prescribed procedure within the last three
months. Acceptance of previously qualified procedure shall be at the sole discretion of the
A microscopic examination shall be carried out during welder qualifications.
Tack welds performed in the root shall be made by qualified welders.
Welders(s) making branch connection, socket weld or welding O-let shall be qualified for
5F position using a qualified procedure in accordance with AS 3992. Each welder shall be
identified by a unique identification number or symbol. The information shall be recorded
on an identity card, complete with photograph of welder.
The Contractor shall maintain a permanent record of all welders used, showing each
welder’s name, identifying mark, qualification record, list of welding procedures each
welder is qualified and date of qualification and a record of performance of each welder.
Copies of these records shall be available to the Company Representative on request.
Re-qualification is required whenever there is a reason for the Company Representative

to question the performance of welder.
5.3.4 Welding Processes
Welding shall be carried out by one or a combination of the following processes:
 Shielded Metal-Arc Welding (SMAW)
 Gas Tungsten-Arc Welding (GTAW)
 Submerged-Arc Welding (SAW)
 Plasma Arc Welding (PAW).
A preheat of 30-40°C shall be used on weld consumables to ensure that no moisture is

present. Shielding gas is required to exclude air that would contaminate the weld pool.
Joints must be designed so that both top and bottom side of weld are shielded. Fit up
clamps shall be employed. Shielding gas shall be of high purity argon of very low dew
point (-40°C) to prevent contamination with hydrogen from moisture.
5.3.5 Cleaning
All pipe spools shall be cleaned to be free of foreign material, including but not limited to
sand, weld splatter, scale and cutting chips to the satisfaction of Company
Representative. Methods of cleaning and acceptance of same shall be in accordance with
AS 1627. A visual inspection shall be made on pipe work.
Wire brushes used on stainless steel materials must be stainless steel. All wire brushes
and other cleaning tools shall be maintained free of oil, scale and other contamination.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
After cleaning, piping spools shall be promptly sealed to prevent mud, water and other
contaminates entering the line.
Prior to welding, the area next to welds, including the inside and outside of the pipes shall
be cleaned for a distance of at least 100mm from the weld joint. The joint faces shall then
be lightly abraded to bright metal with a tungsten burr, light grinding or sanding as is
appropriate for the material. The joint shall be welded within two hours of cleaning, or
cleaning shall be repeated.
Weld passes shall be cleaned to bright metal before depositing the next pass. Chlorinated
hydrocarbons (e.g. carbon tetrachloride) shall not be used for cleaning. As well as being
environmentally hazardous and likely to cause poisonous welding fumes.
Steel wool, sand paper, emery paper or residue forming solvents are not acceptable for
cleaning. The welded area shall be protected from contamination once it has been
cleaned.
5.3.6 Heat Treatment
5.3.6.1 Preheat
The minimum preheat temperature for welding, flame and arc cutting shall be in
accordance with the Welding Procedure Specification. Application of preheat shall be by
electrical resistance methods or oxy-propane torches.
Deposition of carbon or direct flame impingement by incorrectly set or adjusted burners

shall be avoided. Electric resistance heaters are the preferred method. Preheat shall be
applied in a gradual and uniform manner.
The preheat temperature shall be established on both side of the joint preparation for a
minimum distance of 75 mm, or three times the material thickness, whichever is the
greater. The heat source shall be removed to allow for temperature equalization (1 minute
for each 25 mm of material thickness) before measuring the preheat temperature.
5.3.6.2 Interpass Temperature
The maximum interpass temperature shall not exceed that stated in the Weld Procedure
Specification.
The minimum interpass temperature shall be the preheat temperature for the material.
Measurement of interpass temperatures shall be by temperature indicating crayons,

contact pyrometer or any other approved method of temperature measurement. Chloride
free crayons shall be used on Austenitic stainless steels.
5.3.6.3 Post Weld Heat Treatment
The Contractor shall, prior to commencement, have a procedure approved by Company

Representative. Post weld heat treatment shall be carried out in accordance with AS
4458, to the extent required by the applicable codes and line list.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
Non-destructive testing (NDT) shall be carried out prior to post weld heat treatment
(PWHT) of spools, to ensure no repairs are required and again after PWHT to detect
possible cracking caused by the heat treatment process.
PWHT shall be carried out as soon as possible after completion of welding. The use of
manually operated gas torches, gas rings or exothermic kits shall not be permitted.
Wherever possible, PWHT shall be carried out in an enclosed furnace. For site or field
welds, particularly “on site” welds, local post weld heat treatment shall be conducted.
Procedures shall be developed by the Supplier and approved by Company
Representative prior to implementation.
Stress relieved spools shall be labelled, clearly visible, “STRESS RELIEVED DO NOT
WELD”.
5.3.7 Repair of Defects
5.3.7.1 General
This section covers the repair of defects or damage in piping materials and welds.
Contractor shall submit for approval, detailed procedures for any proposed repair work to
fully welded joints, defective or damaged piping material, or any other pressure retaining
parts.
Repair work shall not be carried out until written approval of the procedures has been
obtained from the Company Representative.
A record shall be maintained of the location of all repaired areas. The cause of any
defects shall be established prior to repair, and reported to the Company Representative.
5.3.7.2 Minor Surface Repairs
Surface marks or abrasions shall be cleaned and carefully examined. Minor surface
imperfections, damage to pipe materials or fittings may be removed by grinding providing
the minimum wall thickness is not reduced locally by more than 12.5% of the nominal wall
thickness.
The ground area(s) shall be carefully dressed to ensure a smooth transition with the
surrounding surface and shall have no notches. The ground areas shall be examined by
Magnetic Particle Inspection (MPI), or Dye Penetrant Inspection (DPI), as applicable.
Defects or damage to flange faces, machined or seating surfaces shall be repaired using
a repair procedure approved by the Company Representative.
5.3.7.3 Correction of Distortion
Application of heat to piping components by line heating or flame straightening is

prohibited.
5.3.7.4 Repair by Welding
All repair welds shall be completed in accordance with an appropriate procedure, as

approved by the Company Representative, and executed by qualified welders.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
Only one attempt at a repair is permitted without approval for further attempts from the
Repair welds on longitudinal and / or circumferential weld seams, when approved, shall be
separated by at least 100 mm or the complete area cut out. When a defect falls outside
the parameters of the approved repair procedures the defect shall be cut out.
The defects shall be carefully removed by machining, grinding or arc air gouging followed
by grinding. Where arc gouging is used, a qualified and approved gouging procedure
specification shall be applied. The excavation shall extend at least 25mm beyond the
extremities of the defect and shall have a smooth transition to the parent metal. The repair
weld preparation shall be smooth, with a regular contour, and shall be free from rust
grease, oil or other extraneous material.
Peening of weld runs or the finished welds shall not be permitted.
The Contractor shall make every effort to minimize residual stresses.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
6.0 NON METALLIC PIPING

6.1 General
HDPE Piping shall conform to AS 4130, AS 4131 and AS 4129.
All polyethylene (PE) piping installation shall be strictly in accordance with the latest
edition of the piping manufacturer’s published design data and recommendations and AS
2033 “Installation of Polyethylene Pipe Systems”. Company Representative shall be
notified of any conflict between the manufacturer’s recommendations and the Australian
Standards and work shall not proceed until approval is given by the Company
Representative.
6.2 Preparation for Joints

Pipe ends shall be machine trimmed to minimize residual end curvature from the
manufacturing process and protected until welded. Pipes shall be placed in the welding
machine with the manufacturing marks aligned.
6.2.1 Butt Joints
Jointing of HDPE pipes by butt fusion shall be carried out by qualified welders in
accordance with manufacturer’s recommendations, industry guidelines and AS 2033 -
Installation of Polyethylene Pipe Systems.
The Plastics Industry Pipe Association of Australia Ltd - Industry Guidelines for Butt
Fusion Jointing of PE Pipes and Fittings – Recommended Parameters (Ref POP003) shall
be used as a guide for preparing the welding procedures for jointing of the PE pipes and
fittings.
A test sample of each PN pipe joint shall be tested in accordance with ISO 13953 -
Polyethylene (PE) Pipe and Fittings, Determination of the tensile strength of test pieces
from a butt-fused joint. The test results shall be approved by the Company
Representative. In addition, based on request from the client representative, one joint in
every 50 joints (per welding machine) constructed may be randomly selected for tensile
testing and flexural beam testing.
6.2.2 Butt Joint Welding
Welding equipment shall be capable of accurately controlling the temperature and

pressure during the welding process. The pressure gauge shall be graduated in at least
10kPa increments. Heater plate temperature shall be constant over the whole plate. The
Contractor shall use a portable surface probe pyrometer measuring the plate temperature
to an accuracy of +/-1ºC. Non-depositing alcohol shall be used to clean the heater plate
before it (or the plate) is heated up.
Welding processes shall be protected from the wind and dust. Pipe shall be protected
from any variation in temperature within the pipe. Welding shall be carried out at air
temperatures above 4ºC.
Weld joints shall not be moved until after the nominated cooling time to meet the
requirement of AS/NZS 2033. Welds shall not be artificially cooled.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
The Contractor shall submit details of operator experience and competency for approval
prior to commencement of work. Prequalification of WPS and operators for nominated
pipe diameters shall be required with minimum number of test samples for destructive
testing and accreditation in accordance with manufacturer’s recommendations. Fusion
butt welding operators shall be accredited to Australian National Training Authority
(ANTA) National Competency PMB01, Competency Unit WELD 301A.
Detailed weld procedures (WPS) shall be submitted in accordance with the pipe
manufacturer’s requirements which shall include as a minimum:
 Type of weld
 Cleaning and machine preparation of pipe ends / surfaces which are to be joined
 Polymer material compatibility and wall thickness including tapering of unmatched

SDRs between pipe and fittings
 Fusion welding temperature
 Cycle time for heating and cooling fusion joint
 Interface pressure
 Type and size of welding machine proposed.
 Weld mapping code.
It shall be mandatory for all welding machines to incorporate data loggers to allow full
traceability of on-site weld procedure, material and operators.
For slurry service applications, following fusion butt welding of each length of PE pipe, the
internal bead, which is expected to be between 5 mm and 10 mm in height, shall be
removed using a cutting device to be inserted from the open end. The operation of this
device shall be tested on trial butt welded joints. All cuttings from the bead removal
process shall be extracted from the pipeline by vacuum cleaning using a small diameter
PVC pipe (40 mm or 50 mm DN) prior to joining of the next length of pipe.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
7.0 IDENTIFICATION OF PIPE SPOOLS

Where spool pieces are fabricated in site run pipe work, each fabricated spool piece shall
be identified by a unique spool piece mark number, containing the line number. If a line
has more than one spool, marking will contain the line number followed by “/” and the
serial number of spool.
Each spool piece number shall be printed in large characters at one end for spools less
than 5 m long or at both ends for spools 5 m and longer. Spools which are too short for
individual marking shall have embossed metal identification tag, bearing the spool
number, securely fastened to the spool.
The paint used for marking shall be a color contrasting with the steel and shall be
waterproof and durable for reasonable transport handling. A stamped metal tag, bearing
the spool identification, shall be securely fastened to the spool.
Stress relieved spools shall be labelled, clearly visible, “STRESS RELIEVED DO NOT
WELD”.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
8.0 PROCESS AND UTILITY PIPE LABELING

Labels shall identify the content and purpose of the pipe. All fixed plant process and utility
piping must be labeled as described below. All labels must be attached using a lanyard
arrangement which will allow for labels to be easily relocated to replacement piping.
8.1 Label Locations

Process and utility piping must be labeled next to isolation points where they enter or
leave manifolds and junctions, i.e. the label shall be attached to the pipe using a lanyard,
in a position where an operator has a choice to direct the process.
8.2 Label Specifications

The label shall be shaped in the form of an arrow, be cut in the correct hand, and attached
to piping to indicate the direction of flow.
Labels to be made of 316 stainless steel with sharp points blunted and burrs removed.
Size of label to be:
 Length – Adjust to suit process description
 Width – 60 mm
 Thickness – 1.2 mm
 10mm diameter hole in both ends
Text to be 12 mm high and fully cut through in stencil font.
Figure 8-1 Pipe Labelling
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
8.3 Piping That Must Be Labelled

All piping shall be labeled except for pipe systems indicated below which do not requiring
labeling:
 Utility piping below DN50
 Drains and vents.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
9.0 PIPING INSTALLATION

All piping shall be installed in accordance with the Piping drawings and isometrics.
Personnel working on the erection and installation of overhead piping shall work from
properly erected scaffolding platforms. Under no circumstances shall pipe work be used
as a means of support. Equipment nozzles shall not be used as a temporary support for
pipe work. The top of a motor, or any other equipment not designed for the purpose of
providing a platform, does not constitute a platform.
Piping shall be supported, guided and anchored, as shown on the piping isometric and
support detail drawings.
Pipe support and auxiliary steelwork shall be supplied and installed in accordance with AS
4041 and AS 3892. Pipe supports shall be located in accordance with the piping isometric
drawings. Temporary construction supports may be provided wherever required and the
same shall be removed after the pipe installation. Any additional supports found
necessary in the field over and above what are shown on the drawings, shall be provided
by the Contractor with the approval from design team.
Valves shall be installed with stems orientated as indicated on piping drawings. Where no
precise position is shown the valve should be orientated to give ease of operation with
due regard to the need to keep access ways clear. Globe valves shall be installed with the
line pressure under the seat, in vacuum service the negative pressure shall be over the
seat. Butterfly valves shall be installed in the open position during flange tightening to the
valve manufacturer’s recommendations. Butterfly valves to be installed with spindles in
the horizontal and shall have the discs rotating in the same direction of flow when closing
except where operator access dictates a variation to this criterion. Check valves shall be
positioned with the flow direction as indicated in the piping isometrics.
Before flanged pipe spools are connected to pressure vessels, both the Vessel and Pipe
spool shall be checked, and witnessed by the Company Representative to ascertain that
no stress is placed on equipment due to misalignment. For vessels and other stationary
equipment the mating flanged connection shall be parallel to within six 6mm/m of flange
diameter measured at the outside of the raised face across any diameter. Manipulation
heating shall not be used.
Where drain valves are operated from a platform, the discharge shall be piped to grade as
shown on the piping drawings and directed towards a sump. Where the pipe is not shown
on the drawings the following criteria shall apply, the size of the drain pipe shall be at least
one pipe size larger than the nominal pipe size of the drain valve but never less than
DN50. An atmospheric break with a tundish shall be incorporated in each drain line to
permit checks by the operator. Where possible, two or more drain discharge lines shall be
directed to a common header to run to grade. The manifold shall be sized to allow for at
least two valves at any one time to discharge into it without restricting the flow.
Pump and compressor piping shall be installed in a sequence which will avoid any
external loadings on the equipment connections or to pump shaft mechanical seals.
The following procedure shall be applied for the alignment of flanges to rotating and
reciprocating equipment:
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
 Install, bolt down on shims and grout rotating equipment level on the foundation.
Driver to equipment alignment to be set within manufacturer's tolerances.
 Align pipe-work to equipment flanges to within the manufacturer's recommendations.
 Check the coupling alignment between driver and driven equipment. Bolt up piping to
equipment flanges and torque the bolts to the specified tension.
 Recheck the coupling alignment (between the driver and driven equipment) during the
bolting and tensioning of the pipe flanges to the equipment flanges. The bolting up and
tensioning of the flanges shall not affect the coupling alignment. Note that in case of
pumps with mechanical seals, pump driver to driven equipment coupling alignment
must comply with the mechanical seal manufacturer’s tolerances. Piping loads shall
not be permitted to affect these alignment tolerances.
 When bolting flanged connections, the gasket shall be uniformly compressed. Flanged
connections shall be bolted up by gradually tightening diagonally opposite bolts in a
clockwise or anticlockwise order so that an even gasket seating results.
On large piping it may be necessary to make up flanged connections with construction

gaskets, before welding to ensure that no misalignment occurs during these operations.
All tightening shall be by torque wrench or other tightening methods which result in
uniform tightening and provide a measurement of the applied torque.
The Contractor shall re-check all bolting for tightness and correct tension on completion of
pressure testing. Impact wrenches may be used only when tightening procedure is
checked by torque measurements.
Bolts and all bearing surfaces of nuts shall be coated with heavy duty anti-seize lubricant
prior to installation. Anti-Seize Lubricant shall require Company Representative Approval
before use.
All flange stud bolts shall extend fully through their nuts and shall have a minimum of
three exposed threads.
Stud bolts shall not be cut from length of studding.
Burning of holes in structural steelwork or component parts is strictly forbidden. All field
installed holes shall be drilled.
Contractor shall fit “dummy” spools in place of inline instruments during erection to
facilitate pressure testing.
All field run lines shall be run generally in an orderly manner, consistent with good
operation, neatness of appearance, safety of personnel, economy and use of the
minimum number of fittings consistent with provisions for expansion and flexibility. Field
run lines shall follow the pipe route nominated on the drawings with supports to suit.
Supports shall be placed so as not to restrict or prevent the access or removal of other
piping and equipment.
Pipe shoes and sliding pipe support attachments shall be positioned over the concrete or
steel support beams as shown on the drawings before any field welding or bolting to the
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
pipe is carried out. The completed supports shall be clearly identified with support number
and other relevant information to completely identify the support. All fabricated pipe
supports shall have welding preparations in accordance with AS 4458 and welds shall be
performed by qualified welders and in accordance with qualified welding procedures.
All pipe openings shall be sealed before, during and after erection to prevent the ingress
of moisture and foreign matter, flanged ends shall be sealed with light metal blinds and
gaskets or purpose manufactured plastic caps. Carbon steel material shall not be used for
temporary sealing of non CS lines. Threaded ends shall be plugged and sealed by
waterproof grease tape or purpose made plastic caps or plugs.
Flange gasket faces shall be free from rust, weld spatter, scars, paint, dents, arc strikes,
and corrosion pitting and other imperfections. In the event of damage to a flange gasket
face or perceived discrepancy Contractor shall refer the matter to the client
Representative prior to proceeding with installation of the flange.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
10.0 QUALITY ASSURANCE

Contractor shall provide all equipment, including inspection and testing in accordance with
Standard Specification - Supplier Quality System Requirements and the applicable
equipment specification.
Contractor shall have in place, or implement and maintain a Quality Assurance System
which meets the requirements of this document and ISO 9001 or 9002 as appropriate.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
11.0 INSPECTION AND EXAMINATION

Contractor shall provide Company Representative free access and sufficient notification,
being a minimum of one working day, to permit material, fabrication, welder performance
qualification tests, radiographs, ultrasonic tests and hardness tests, hydrostatic tests and
installation inspections.
Contractor shall check that all lines are installed as per the latest relevant P&ID and piping
layout drawings for completeness of the installation and offer the system for Company
inspection. Those systems shall be inspected by Company Representative together with
Contractor to check for compliance with the P&IDs, Piping Isometric Drawings and
applicable specifications.
Any piping system failing an initial inspection shall be required to undergo further
inspection after rectification of the defect until the defect has been satisfactorily remedied,
all at Contractor’s cost.
11.1 Metallic Piping

Inspection of piping shall be in accordance with the requirements of AS 4041/AS 4037
and this specification prior to any painting insulation or coating being applied.
Inspection shall include 100% visual examination and any other additional examination
necessary to ensure compliance to this Specification and Piping Material Specifications.
The Contractor shall be responsible for supervision and for the quality control of work
during fabrication and erection. The Company Representative may make inspections,
audits and tests as required checking the progress and assuring quality of the work,
qualifications of Contractor's employees and that work complies with the Drawings and
Specifications.
The Company Representative shall have the right to examine all aspects of the work at
any reasonable time during fabrication, testing or on completion. Any work which, in the
opinion of the Company Representative, does not comply with the requirements of this
Specification shall be corrected by the Contractor at his own expense.
For each radiograph, or ultrasonic examination, which reveals unacceptable defects, two
additional welds welded by the same welder shall be radiographed at the Contractor’s
expense. If either of these fails, all welds made by the welder using the same welding
process shall be radiographed. Company Representative shall have the right to nominate
these additional welds.
Acceptance by the Company Representative of testing and quality control procedures

submitted by the Contractor will not relieve the Contractor of his responsibilities and/or
guarantees.
All root runs shall be 100% visually inspected by the welder prior to filling and capping.
This shall include the internal surface where accessible.
All weld passes shall be visually inspected to ensure freedom from defects and slag.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
Random hardness examinations, at weld metal, shall be performed progressively

throughout the job and for every thickness of material. At least one of each type and
welding position of weld made by each welder shall be examined.
All pipe work shall be checked against the design drawings and other related documents
to verify that it meets all the requirements of the Drawings and this Specification.
11.1.1 Non Destructive Testing
The Contractor shall submit to the Company Representative detailed Non Destructive
Testing (NDT) procedures for approval. NDT shall be carried out in accordance with the
approved procedures.
The Contractor shall co-operate fully with the Company Representative in all aspects of
NDT and shall provide all assistance and access that the Company Representative may
request.
The methods and acceptance levels for NDT referred to in this Section, shall be
conducted in accordance with Table 12.1.
Examiners, Operators and equipment shall be approved by the Company Representative.
For any testing less than 100%, the joints selected shall be at the discretion of the
The Contractor shall nominate the welds to be tested when random sampling NDT is
required.
NDT shall be scheduled and conducted so as not to disrupt any other construction
activities. In particular the execution of radiographic examination shall be coordinated with
Company Representative to ensure no disruption to other activities occur.
11.1.2 NDT Qualifications
The Contractor shall use only NDT Operators and Examiners who are qualified to ASNT
or internationally recognized standard, have experience in the examination of the weld
type to be examined, and are recognized by the local statutory authority. Operator and
Examiner qualifications shall be subject to approval by the Company Representative.
11.1.3 NDT Reports
NDT reports shall contain all the information specified in the applicable standard and NDT
procedure. This includes:
 Identification of NDT Contractor
 Report number and date of issue, date of test
 Description of item under test (traceability)
 Procedure number, equipment used including serial numbers
 Records of discontinuities detected
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
 Scale drawing showing precise location from a given datum, orientation, and size of
relevant discontinuities
 Test sensitivity/accuracy
 Acceptance criteria
 Name of technician
 Statement of compliance or otherwise
 Details of test restrictions, or deviations from NDT procedure.
11.1.4 Methods of NDT
Methods of NDT shall be as per Table 11-1
Table 11-1 Methods for NDT

Testing Activity Standard Acceptance Criteria
Visual AS 4037 AS 4037
Radiography AS 4037 Clause 3.3 AS 4037 Clause 3.3
Ultrasonic AS 4037 Clause 3.4 AS 4037 Clause 3.4
Magnetic Particle AS 4037 Clause 3.5 AS 4037 Clause 3.5
11.1.5 Extent of NDT
The NDT requirements are based on Class designation, temperature, pressure and fluid
criticality.
Table 11-2 Extent of NDT (Class Designation as per AS 4041 Table

Method Class 1 Piping Class 2 Piping Class 3 Piping
Visual 100% 100% 100%
MT (or PT for non 0-100% 0-10% and 0-10% of Not Required

ferromagnetic branch and
materials) (Note 3) attachment welds
RT (butt weld) (Note 1) 20-100% 0-10% Not Required
UT (branch welds) 20-100% 0-10% Not Required

(Note 2)
Notes:
 Or UT where allowed, in accordance with Section 10.1.8 below.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
 Not required where wall thickness for scanning surfaces are less than 10mm, and
where branch diameters are less than DN 100. Non ferritic materials need not be
examined.
 MT or PT of branch welds to be performed prior to attachment of compensating plate if

applicable.
11.1.6 Radiographic Examination
Where the double wall double image exposure technique is employed, two exposures will
be sufficient for pipe sizes below DN 50 and a minimum of three exposures for pipe sizes
between DN 50 and DN 80. Above DN 80, the double wall single image or single wall
single image technique shall be employed and sufficient exposures shall be made to
ensure that the weld seam is fully radiographed and that a minimum of 50 mm overlap
takes place.
Only fine grain high contrast film or ultra-fine grain high contrast film may be used. Wire
type image quality indicators and film sensitivity shall be equal to EN-462-1. Only lead
intensifying screens shall be used. The minimum radiographic density in the weld area
shall be 2.0. The maximum radiographic density shall be 4.2 for all areas of the weld
including parent material. Radiation source shall not be greater than Iridium 192, 60 Ci.
Use of gamma ray for examination is not permitted without prior approval by the Company
Representative.
11.1.7 Ultrasonic Examination
Ultrasonic examination may be used in place of radiography for carbon steel over 19mm
thick, if approved by the Company Representative.
UT shall not be performed on materials whose thickness is less than 10 mm or where

scanning surface pipe diameters are less than DN 100.
As a minimum requirement ultrasonic examination shall be conducted using a minimum of

three angled transducers, usually 45°, 60° and 70° operating between 2 MHz and 5 MHz.
Prior to conducting ultrasonic examination the Contractor shall ensure that the weld
deposit and surrounding area is sufficiently smooth to avoid false or misleading
indications. The maximum surface compensation factor shall be 6 decibels.
11.1.8 Magnetic Particle/Dye Penetrant Inspection
All weld areas to be examined by magnetic particle or dye-penetrant techniques shall be

sufficiently smooth to avoid false defect indications. Care shall be exercised during
magnetic particle inspection to minimize electrode or probe arc strikes.
11.1.9 Traceability Requirements
Material and weld traceability will form part of the permanent documentation to be
compiled and provided by the Contractor. The Contractor shall supply the Company
Representative with copies of the following certificates and records (number of copies to
be as stated in the contract).
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
Table 11-3 Traceability Requirements (Class Designation as per AS 4041, Table

1-3)
Class 1 Piping Class 2 Piping Class 3 Piping
Heat No./Unique ID No. of material Yes Yes -
Weld Number Yes Yes -
Weld ID Yes Yes -
WPS Yes Yes -
Consumable Batch Yes Yes -
NDT Result Yes Yes -
Weld Repairs Yes Yes -
PWHT Yes Yes -
Hydrostatic Results Yes Yes -
Pneumatic Results Yes Yes -
11.2 Non Metallic Piping

Prequalification of WPS and operators for nominated pipe diameters shall be required with
minimum number of test samples for destructive testing and accreditation in accordance
with manufacturer’s recommendations.
All weld beads shall be visually inspected and the profile gauged to verify quality. Where
specified on line list, a random batch of weld samples will be cut out and prepared for
laboratory analysis and testing. Nominally this will be 5% of each operator’s welds unless
visual inspection determines additional samples are required due to apparent substandard
bead profiles.
A sample of each PN pipe joint shall be tested in accordance with:
 ISO 13953 - Polyethylene (PE) Pipe and Fittings, Determination of the tensile strength
of test pieces from a butt-fused joint.
 ISO 3501 "Assembled Joints Between Fittings and Polyethylene (PE) Pressure Pipes-
Test of Resistance to Pull Out";
 ISO 3503 "Assembled Joints between Fittings and Polyethylene (PE) Pressure Pipes-
Test of Leak Proofness under Internal Pressure when Subject to Bending".
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
12.0 CLEANING AND TESTING PIPE WORK

The Contractor shall supply, install, store and maintain all necessary equipment required
to carry out the cleaning and testing. Equipment required to be made available by
Contractor shall include, but not be limited to, the following:
 Test pressure gauges covering the required test pressure ranges as specified in the
Piping Material Specification.
 Test spades, blanks, gaskets, Extra long bolts (conforming to the Piping Material
Specification), temporary supports and temporary spools.
 Test pressure recorder (with calibration certification) and charts, dead weight tester.
 Oil free air compressor a source of clean, oil free compressed air for all necessary
purging and testing operations.
 Medium volume, low pressure centrifugal pump for line filling. The use of alternative
types of pumps shall require prior approval from the Company Representative.
 Low volume, high pressure positive displacement pump.
 Test manifold with suitable connections and instrumentation including bleed off valve.
 Relief valve to prevent over pressurization.
 Thermometer and temperature recorder.
 Pipes, tubes, hoses, fittings, valves, test flanges, nipples, water tank and other items
sufficient to carry out the testing.
 Calibration certificates no more than six months old shall be made available to the
Company Representative for all measuring and safety devices, using NATA approved
master calibration equipment.
12.1 Documentation
All flushing and cleaning operations and all pressure tests shall be witnessed and signed
off by the Company Representative. Test equipment shall not be dismantled until test
results are signed off by the Company Representative. No pipe work shall be insulated or
concealed or painted until the pressure test has been witnessed and approved. A
complete record of Pre-test / Post-test and Pressure Test Records shall be maintained by
the Contractor and submitted to the Company Representative for final approval upon
satisfactory completion of cleaning and pressure testing.
12.2 Cleaning Procedure

All site fabricated piping and fittings shall be cleaned on completion of fabrication by blast
of high pressure air assisted where necessary by hand held wire brushes to remove
contamination of sand weld splatter, cutting chips and other foreign matter before the
spools are primed or installed in the piping work. Cleaning tools for Stainless steel shall
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
not be intermixed with those of carbon steel materials. Weld splatter and loose scale shall
be removed and the sections then cleaned with oil-free air. Wire brushes and other
cleaning tools shall be free of oil scale and other contaminants. On completion of
cleaning, all openings shall be suitably sealed to avoid ingress of foreign matter prior to
erection.
Control valves, soft seated valves, and inline devices, Orifice plates etc shall be removed
and replaced with relevant blind flanges or temporary spool pieces and piping system
shall be flushed. All lines except plant and instrument air shall be flushed and cleaned
using potable water (pH 7 to pH 8). For all austenitic and high alloy piping systems,
dematerialized water (1 ppm chlorides and pH 6 to pH 7) shall be used. Purging and
flushing shall be carried out in a manner that will ensure that dirt and debris will not be
forced into instruments or trapped in lines. The Company Representative may however
permit flushing and cleaning to be performed after hydro testing on lines greater than DN
300.
12.3 Pipe Pressure Testing

Pressure test shall be carried out after all hot work and NDT requirements are completed
and preferably within 24 hours of the system is flushed and completely drained. If this is
not practical the circuit shall be dried and protected from ingress of sand and other foreign
matter.
All pressure testing shall comply with the requirements of AS4041 and as specified herein.
Plant and Instrument Air lines shall be subjected to initial service leak test as per clause
6.8.2 and 6.8.3 of AS 4041. The test pressure shall be as per the Piping Material
Specification and test media for carbon steel, non-metallic and lined piping systems shall
be potable water (pH 7 – 8). For all austenitic and high alloy piping systems,
dematerialized water (1 ppm Chlorides and pH 6 - 7) shall be used. Vent and drain lines,
overflow lines from tanks shall not be pressure tested.
As a minimum, test records shall include Test date, time, test pack identifier, test fluid,
duration of test, test pressure, test temperature and shall be signed by the Contractor and
12.3.1 Preparations for Pressure Testing
Contractor shall submit test packs a minimum of seven days prior to the test date to the
client Representative for approval. Test packs, P&ID diagram shall show the extent of the
piping system proposed to be tested and shall show the positions of valves, location of
blanks, temporary spools ect as per the Piping Isolation Specification SPEC 17037-P4-P-
0A1G-SZ-00003.
All Instrumentation items that can come in contact with the test fluid shall be removed and
replaced with a means of isolation as per Isolation Criteria – Piping, before flushing and/or
Pressure testing. Removed items shall be enclosed completely in plastic sheeting for
protection during storage. Similarly, all mechanical items like Rotating machinery, pumps,
compressors, Pressure vessels, Filters etc. shall also be isolated from Pressure test.
Before testing, all boundary points and valves within the proposed system shall be
suitably tagged, indicating that the system is under pressure. Areas where pressure tests
are taking place are to be roped off and warning notices posted forbidding entry to un-
authorized personnel.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
Flanges shall be securely taped with a pinhole provided in the tape for leak identification.
Test and vent holes in reinforcing pads shall be open during testing, and shall be left open
for operation.
Where flanged joints are broken for the test, the joint shall be made after the test using
new, compatible gaskets.
Where such joints were fastened with bolts tightened to specific torque valves, these shall
be replaced with new, compatible bolt sets after the test.
Any repairs on the welds which are not in the scope the Contractor shall be repaired by
the Contractor only after obtaining the approval from Company representative in writing.
Lines must be drained where welding repairs are required.
All repairs shall be retested in accordance with the relevant sections of this Specification
on completion of repairs.
Should a piping system fail to pass any test, all costs associated with the rectification work
and re testing shall be to the Contractor’s account.
Any damage caused to piping or components due to over pressurization shall be rectified
at the Contractor’s expense to the satisfaction of the Company Representative.
Permanent strainers shall be only installed after all pre commissioning, testing and
flushing is completed.
On successful completion of pressure testing and only with written approval from the
Company Representative, all in-line devices removed from the pipe work system for test
purposes shall be re-installed. All in-line devices shall be re-installed with new gaskets.
Where not more than three butt welds are required to make certain field piping
connections, the Company Representative may accept 100% radiographic inspection plus
ultrasonic examination of welds in lieu of field pressure testing provided that Specific prior
approval has been obtained and the connection piece has been hydrostatically shop
tested in accordance with this Specification.
All temporary items used for pressure testing shall be specially marked, color coded by
the Contractor prior to use and removed on completion of work.
12.3.2 Hydrostatic Test Procedure
Pressure tests shall be performed only after the Company Representative has approved
the test pack.
During filling care shall be taken to ensure that all air is bled from the system and piping
work shall be filled with water and pressurized to test pressure as defined in the Piping
Material Specification.
The test pressure shall be maintained for a minimum of one hour, pressure shall be
recorded on a pressure recorder for the duration of the test. While under test pressure, the
entire pipe system shall be inspected for any small, seeping type leaks. The Company
Representative may permit manual recording of test pressures on low criticality lines.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
Leaks shall be repaired by the most appropriate method, i.e. weld repair, tightening
flanged joints, replacing gaskets, etc. The Contractor shall ensure continual attendance at
the test manifold to monitor pressure and any bleed off. There should be no loss of
pressure.
Variations of pressure and volume due to temperature changes will be taken into account
by the Company Representative in determining whether adequate pressure has been
maintained throughout the test.
On completion and acceptance of the recorded hydro test, all water shall be drained and
the line dried with oil free air. All openings shall be sealed against ingress of any dirt or
contamination.
All blanking flanges at the extremities of the successfully tested system shall be suitably
tagged to ensure that accidental opening shall not occur.
12.3.3 Pneumatic Test Procedure
Pneumatic test shall be used only when specified in the Piping Material Specification.
All pneumatic tests shall be performed in accordance with AS4037.
Pneumatic tests shall not be performed in the rain, or whilst the piping is wet unless
permitted by Company Representative. Test shall be carried out during daylight hours
unless specifically approved by the Company Representative.
The test pressure shall not be applied until the piping system and the pressurizing media
are at similar temperatures.
A limited access area and pressure control point shall be established. Signs which read
“PNEUMATIC TEST IN PROGRESS - ACCESS BY PERMISSION ONLY” shall be posted
at the perimeter of the limited access area.
One person shall be at the Pressure Control Point monitoring the gauge whenever the
system contains pressure. If tightening is required to stop leaks, isolate the immediate
work area from persons not necessary for the tightening operation.
Personnel shall remain clear of the gasket plane projection.
A visual inspection of all joints and connections at the test pressure using leak detection
fluid shall be performed. This inspection shall be witnessed by the Company
Representative.
Any bubbles observed as a result of seepage shall be considered sufficient reason for
non-acceptance of the system being tested. The system shall be retested following repair
work.
After completion and acceptance of the recorded test, the system shall be vented
progressively to each in-line isolation, moving towards the location of the test rig. On
completion of a successful pressure test, the system shall be vented and all openings
shall be sealed against the ingress of dirt, contamination or moisture.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
All blanking flanges at the extremities of the successfully tested system shall be suitably
tagged to ensure that accidental openings shall not occur.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
13.0 RECORDS AND REPORTS

The recording, reporting and document submission requirements which form the
Manufacturer’s Data Report (MDR) shall be in accordance with the Contract Document
unless otherwise specified.
As a minimum, the following records, fully identified with the specific material or part of the
piping represented, shall form the basis of the Manufacturer’s Data Report unless
otherwise specified:
 Material and component manufacturer test certificates and all other certificates
necessary to ensure that the quality control and design requirements of the applicable
standards and piping manufacturers have been met.
 Surface treatment inspection records
 Work permits issued during the course of the contract
 Daily weld report form
 NATA endorsed certifications and NDT records
 Radiographic films
 Radiographic, ultrasonic, magnetic particle and liquid penetrant examination reports
 Hydrostatic and pneumatic test reports
 Results of any other supplemental types of examination test or analysis specified or

required by the Company.
 List of welders and associated welder qualifications and welder identification symbols
 A3 “As Built” pipe spooling and pipe support marking plan prints where required for
weld traceability
 Weld maps of piping
 Weld Procedures.
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
14.0 REFERENCES AND GLOSSARY

14.1 Glossary of Terms and Acronyms
The use Terms, Acronyms and Definition shall not deviate from those listed in Table 14-1
Table 14-1 Terms, Acronyms and Definition

Terms/Acronyms Definition
ANSI American National Standards Institute
AS Australian Standard
BS British Standards
Contractor/ Tenderer, Supplier, Sub Supplier, Contractor, Subcontractor(s)

Subcontractor
CS Carbon Steel
CSGA Carbon Steel Galvanised
CSST Carbon Steel Standard Weight
CSXS Carbon Steel Extra Strong Weight
Data All drawings/documents/data/information required to be supplied by

Supplier under the Contract/Purchase Order
dB decibel
DN Nominal diameter
DP Dye Penetration
EPDM Ethylene-propylene-diene-monomer
HAZ Heat affected Zone
HDPE High Density Polyethylene
Hex Hexagonal
IOM Installation, Operating and Maintenance Manual
ISO International Organisation for Standardisation
ITP Inspection and Test Plan
MDR Manufacturers Data Report: compilation of manufacturing data,

certification, inspection and testing records prepared by the Contractor
to verify compliance with Contract requirements
SPEC 17037-P4-P-0A1G-SZ-00002_0
SPECIFICATION
Terms/Acronyms Definition
MP Magnetic Particle
NBR Nitrile-butadiene rubber
NDT Non-Destructive Examination
NPS Nominal pipe size
OD Outside Diameter (pipe)
OS&Y Outside screw and yoke
PE HDPE Poly Ethylene PE100
PN Nominal pressure (rating)
PTFE Polytetrafluoroethylene
RF Raised face
SI International system of units
Site Construction site
SN Nominal stiffness (pipe stiffness rating)
SS Stainless Steel
STD WT Standard weight
WACA Weeks After Contract Award
WAT Weeks after Testing
WBD Weeks Before Delivery
WPS Welding Procedure Specification
SPEC 17037-P4-P-0A1G-SZ-00002_0

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SPECIFICATION PAGE 1 of 43

NUMBER SPEC 17037-P4-P-0A1G-SZ-00002

LAMPUNUT VILLAGE, UTILITIES

OFFICE OF ORIGIN CONTROMATION ENERGY SERVICES DIR. REF 17037-1.9.1.SPEC

WRITTEN BY NISA SULASTRI DATE: 15.01.2018 CLIENT PO

REVIEWED BY MALCOLM COLLYER DATE: 15.01.2018 CLIENT REP.

TITLE OF REVIEWER ENGINEERING MANAGER

STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER

SIGNED DATE REV.

ACCEPTED .......................... .................... .............

ACCEPTED EXCEPT AS NOTED .......................... .................... .............

REVISE AND RESUBMIT .......................... .................... .............

APPROVAL BY CLIENT RESPONSIBLE MANAGER

.................................................................................. DATE: ................................

Rev. Date Description By Chk’d Reviewed Client

NUMBER SPEC 17037-P4-P-0A1G-SZ-00002

LAMPUNUT VILLAGE, UTILITIES

OFFICE OF ORIGIN CONTROMATION ENERGY SERVICES DIR. REF 17037-1.9.1.SPEC

WRITTEN BY NISA SULASTRI DATE: 15.01.2018 CLIENT PO

REVIEWED BY MALCOLM COLLYER DATE: 15.01.2018 CLIENT REP.

TITLE OF REVIEWER ENGINEERING MANAGER

STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER

SIGNED DATE REV.

ACCEPTED .......................... .................... .............

ACCEPTED EXCEPT AS NOTED .......................... .................... .............

REVISE AND RESUBMIT .......................... .................... .............

APPROVAL BY CLIENT RESPONSIBLE MANAGER

.................................................................................. DATE: ................................

Rev. Date Description By Chk’d Reviewed Client

1.0 INTRODUCTION ................................................................................................ 5

12.1 Documentation ...................................................................................................36

Table 5-1 Drawing Dimensional Tolerances ............................................................ 16

Figure 8-1 Pipe Labelling .......................................................................................... 25

1.2 Document Precedence

 Statutory Codes International

 Codes and standards

2.0 APPLICABLE CODES, STANDARDS AND

2.1 Codes and Standards

ASME Boiler and Pressure Vessel Code (BPVC)

- Section II Material Specifications

- Section V Non-destructive Examination

- Section VIII Division 1 Pressure Vessels

- Section IX Welding and Brazing Qualifications

ASME B 16.9 Factory-Made Wrought Steel Butt welding Fittings

ASME B 16.11 Forged Steel Fittings- Socket – Welding and Threaded

ASME B 16.25 Butt welding Ends

ASME B 31.3 Process Piping

ASME B 31.4 Pipeline Transportation Systems for Liquid and Slurries

ANSI B16.5 Steel pipe flanges and flanged fittings

ANSI B16.21 Non-metallic Flat Gaskets for Pipe Flange

ANSI B16.36 Orifice Flanges

ANSI B36.10 Welded and seamless wrought steel pipe

ANSI B1.20.1 Pipe Thread General Purpose

American Society for Testing Materials (ASTM)

ASTM G28 Standard Test Methods of Detecting Susceptibility to

ASTM A105 Forgings, Carbon Steel, for Piping Components

ASTM A193 Standard Specification for Alloy-Steel and Stainless Steel

Australian Standard (AS)

AS 2032 Installation of PVC Pipe Systems

AS 2033 Installation of Polyethylene Pipe Systems

AS 2129 Flanges for pipes, valves and fittings

AS 2700 Colour Standards for General Purposes

AS 3892 Pressure Equipment - Installation