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INTRODUCTION .................................................................................................3
01-SAMSS-010 .........................................................................................4
SAES-L-050 and SAES-L-051 ..................................................................4
DETERMINING WHETHER PIPING MEETS
FABRICATION REQUIREMENTS .......................................................................5
Material Limitations ...................................................................................5
Pipe ................................................................................................5
Material Limitations, Cont'd .......................................................................6
Pipe Nipples ...................................................................................6
Flanges...........................................................................................7
Pipe Fittings....................................................................................7
Drawings ...................................................................................................8
Fitup Tolerances .......................................................................................8
Mitered Joints ...............................................................................10
Ends for Field Welding .................................................................10
Pipe Bending...........................................................................................10
Cold Bending ................................................................................13
Hot Bending..................................................................................14
Sample Problem 1...................................................................................15
Solution ...................................................................................................17
Welding and Heat Treatment ..................................................................18
Butt-Welds....................................................................................19
Fillet Weld.....................................................................................23
Welding Steps ..............................................................................23
Inspection and Testing of Pipe Spools ....................................................26
Product Marking and Preparation for Shipment ......................................27
Identification .................................................................................27
Cleaning .......................................................................................28
Painting ........................................................................................28
Protection .....................................................................................28
DETERMINING WHETHER METALLIC PLANT PIPING
MEETS INSTALLATION REQUIREMENTS ......................................................29
Storage and Handling..............................................................................29
GLOSSARY .......................................................................................................60
INTRODUCTION
An engineer will often be asked to participate in the
design of a piping system by evaluating a contractor's
proposal, auditing a contractor's work, performing a
screening study for cost estimating purposes, or actually
designing and managing pieces of the project.
The previous module discussed the layout, support and
flexibility design of a piping system, one step in designing
the overall piping system. This module discusses
another step in putting the pieces of the system together:
the fabrication and construction of the piping system.
Portions of the piping system are prefabricated by
contractors. After these portions are fabricated, they are
assembled wherever the piping system will be located.
This assembly includes aligning, bolting up, and welding
pieces together. The engineer must ensure that the
fabricated portions of the piping system remain
consistent with the system design, and that they meet
Saudi Aramco requirements. If the pieces of the piping
system do not fit well together, the original design
assumptions may not be valid, and the piping system
may not meet expectations and could fail prematurely.
This module assumes Saudi Aramco Standards will be
used to audit a contractor's fabrication drawings, and field
erection standards, specifically: SAES-L-050, SAES-L-
051, and 01-SAMSS-010. This auditing ensures that the
fabrication and construction of the system meets design
requirements. These requirements, or quality control
items, include:
• Material limitations.
• Fitup tolerances.
• Pipe bending limitations.
• Welding and heat treatment requirements.
• Product marking and preparation for shipment
requirements.
• Flange bolt-up requirements.
• Alignment requirements for critical equipment.
This module discusses the quality control items set forth
by the standards and construction requirements for plant
piping systems and cross-country pipelines.
01-SAMSS-010
Material Limitations
Compatible materials are essential for piping fabrication.
All materials that are used for piping elements or
structural attachments must conform to a listed
specification in accordance with ASME/ANSI B31 Codes,
and shall be traceable to mill certificates. This ensures
that basic material quality conforms to recognized
specifications, and that confirming documentation is
supplied for the materials that are actually used. 01-
SAMSS-010 provides specific additional material
requirements for fabrication. These are summarized as
follows.
Pipe
• Pipe for plant applications shall be seamless or
single-longitudinal seam submerged arc-welded
(MEX 101.02) and conform to one of the following:
- API Spec 5L, Grade B through X60.
- ASTM A53, Seamless Grade B, black (not
galvanized).
- ASTM A106, Grade B.
These specifications are all readily available and
result in pipe of comparable strength.
Pipe Nipples
Flanges
Drawings
Fabrication drawings are provided to the contractor for fabrication work. These
drawings specify piping component materials, dimensions, and specific
tolerances for piping fabrication. The Saudi Aramco engineer needs to check
that the drawings conform to all fabrication requirements, and that these are also
being followed in the field.
Fitup Tolerances
Mitered Joints
• Mitered joints are changes in direction that are
obtained by welding short pipe sections together.
Mitered joints with angular offset larger than 3° are
not permitted unless specified on the buyer's
drawing.
Pipe Bending
A bend is a change in direction that is made by physically
bending a straight section of pipe, rather than by using a
wrought or forged elbow. Pipe bends are prefabricated,
or done by the contractor, and need to be checked by the
Saudi Aramco engineer. Bending is normally done when
a long, gradual change in direction is required, either
because of fluid flow considerations, the local terrain for
pipeline applications, or to permit pipe scraping.
- ± 1% on bend radius.
Notes
• (E-C) Š 0.05D at any point, 0.03D at ends
• A 5D
• B 1.5D or 600 mm (2 ft.), based on smaller value
• Bend Minimum Thickness Not Less Than Straight Pipe Minimum Allowable
Thickness
• Bend Tolerances: ±5° on angle, ±1% on radius
FIGURE 1
Cold Bending
Hot Bending
Sample Problem 1
FABRICATION DRAWING
A D
B
Connect to P-602
Suction Flange
Dimensions
A = 37'6" ±1/4"
B = 13'-4" ±1/8"
C = 22'-0" ±1/8"
D = On Pipe Centerline ±3/16"
E = 96" Bend Radius
Notes
- Pipe: A106, Gr. A, 16 in., Sch 40.
- Nipples for Vents and Drains: 3/4 in., Sch 40,
A106, Gr. B.
- Weld-Neck Flanges: ASME/ANSI B16.5, Class
300, A350 LF2.
- Butt-Weld Fittings: A234, Gr. WPB.
- 3/4 in. Forged Couplings for Vents and Drains:
ANSI B16.11, Class 2000, A105
- Conform to ASME/ANSI B31.3 and 01-
SAMSS-010
FIGURE 2
Solution
1. The fabrication drawing shows the pipe material to
be A106, Gr. A. This is not an acceptable material
per 01-SAMSS-010. It should be A106, Gr. B, or
one of the other acceptable pipe material
specifications.
2. The nipples are specified to be A106, Gr. B material,
which is acceptable. However, their wall thickness
is specified as Sch. 40. They should be Sch. 80
minimum per 01-SAMSS-010.
3. The flanges are specified to be weld-neck,
ASME/ANSI B16.5, Class 300, A350 LF2 material.
This is acceptable.
4. The butt-weld fittings are specified to be A234, Gr.
WPB. This is acceptable.
5. The forged couplings are specified to be A105
material, ANSI B16.11, Class 2000. They should be
Class 3000 per 01-SAMSS-010.
6. A note indicates that the fabrication conforms to
ASME/ANSI B31.3 and 01-SAMSS-010. Based on
previous information, this is not in conformance with
at least 01-SAMSS-010 requirements.
7. The dimensional tolerances should conform to 01-
SAMSS-010 and SAES-L-050.
Dimensions B & C conform to the required 1/8 in.
tolerance.
Dimension A has a + 1/4 in. tolerance and is not
acceptable.
Dimension D indicates the flanged branch
connection can be off the pipe centerline by 3/16 in.
It should have a 1/16 in. tolerance.
The bend radius of 96 in. is acceptable since it
exceeds the minimum of five times (Nominal Pipe
Diameter) required by 01-SAMSS-010.
8. The flange alignment tolerances generally exceed
the 1/64 in. maximum misalignment tolerance
specified in SAES-L-050, since several exceed the
maximum 1/64 in. permitted.
Solution, Cont’d
In reviewing this one fabrication drawing, a large number
of relatively serious fabrication and construction
discrepancies were found. The fabrication and erection
tolerances do not conform to Saudi Aramco
requirements. Therefore, it should not be surprising that
there are problems in the field with the installation. In
addition, several material and piping component design
deficiencies were also noted. Because of all these
deficiencies, a complete design review of the contractor's
work is warranted.
It should be noted that this review was only made on the
basis of conforming to the minimum Saudi Aramco
requirements for fabrication and erection. It was not a
design review. For example, it was tacitly assumed that
Class 300 flanges and Schedule 40 thickness for the 16
in. pipe were acceptable for the design conditions. A
complete design review would at least spot check these
items, as well, at some point during project execution.
Butt-Welds
;;;;;;;
EQUAL WALL THICKNESS
;;;;;;;
+ 2-1/2 deg. 10 deg. + 1 deg.
Rounded
t > 7/8 in. 37 1/2 deg.
7/8 in. + 2-1/2 deg.
3/4 in.
(a) Standard End Preparation (b) Standard End Preparation
of Pipe of Butt-Welding Fittings and
Optional End Preparation of 1/16 in + 1/32 in.
Pipe 7/8 in. and Thinner
( c) Suggested End Preparation,
;;
;;
Pipe and Fittings Over
7/8 in. Thickness
+ 2-1/2 deg.
37-1/2 deg.
Standard End Preparations
;;
;;;
;;;;
;;;
30 deg.
to
- 0 deg. + 2-1/2 deg.
60 deg.
- 0 deg.
+ 5 deg.
10 deg. + 1 deg.
to
+ 2-1/2 deg.
37-1/2 deg.
80 deg.
30 deg.
(d)
(e)
(f)
Source: ASME/ANSI B31.4 - 1989. With permission from American Society of Mechanical
Engineers.
FIGURE 3
; ;;;;
Piping Fabrication and Construction
; ;;;;
ACCEPTABLE BUTT-WELDED JOINT DESIGN FOR
UNEQUAL WALL THICKNESS
;; ;
t tw t tw 2 t 2
tD tw tD
1/2 t max. 30 deg. max. 1/2 t max.
3/32 in. max. 30 deg. max. to 14 deg. min. (1:4) 1
;; ;
t tw 2
tD
30 deg. max. 1/2 t max.
1/2 t max. 2
tw tD
; ; ;
t
30 deg. max. to 14 deg. min. (1:4) 1
(d) (e)
;; ;
1
30 deg. max. to 14 deg. min. (1:4)
(f) (g)
Source: ASME/ANSI B31.4 - 1989. With permission from American Society of Mechanical
Engineers.
FIGURE 4
FILLET WELDS
;; ;;;;;
Size of
Weld
; Surface of Perpendicular Member
Convex Fillet Weld
Size of
Surface of Weld
Horizontal
Member
Theoretical Throat
Equal Leg Fillet Weld
Concave
Fillet Weld Size
Fillet Weld
Size of
Weld
Surface of Perpendicular Member
Convex Filled Weld
Surface of
Horizontal
Member
Theoretical Throat
Unequal Leg Fillet Weld
Concave
Fillet Weld
;;;;;;;;;;;;;;;;;;;;
;;;;
The size of An Equal Leg fillet Weld Is the Length of the Largest The size of an Unequal Leg fillet Weld Is the Lengths of the Largest
Inscribed Isosceles Right triangle (Theoretical Throat = 0.707 X Size). Right triangle Which Can Be Inscribed Within the Weld Cross Section
(e.g. 1/2 in. x 3/4 in.)
;;
;;
1/16 in.
Approx. Gap
The Lesser of T or 1/4 in. Before Welding
(1) Front and Back Welds (2) Face and Back Welds (3) Socket Welding Flange
;;
t
cx
Minimum Welding Dimensions t = Pressure Design Thickness
for Socket Welding cx
Components Other Then Flanges
1/16 in. Approx. Gap
;;;;; ;
;;
Typical Backing Rings and Consumable Inserts
3/16 in.
;;;;;; ;;
3/4 in. (d) Square Ring or
1/8 in. to 3/16 in. Round Wire Type
(a) Butt Joint with Bored Pipe Ends
and Solid or Split Backing Ring
3/16 in.
(e) Flat Rectangular Ring
Typical
Consumable
tm Inserts
(f) Formed Ring Type
3/4 in.
1/8 in. to 3/16 in. (g) Y-Type
(b) Butt Joint with Taper-Bored Ends
and Solid Backing Ring
Source: ASME/ANSI B31.3 - 1988. With permission from American Society of Mechanical
Engineers.
FIGURE 5
Fillet Weld
The fillet weld generally requires no special preparation
of the joints. It is an angular weld bead that joins
components positioned normally at a 90° angle to each
other. Fillet welds may be concave to slightly convex in
shape. The size of a fillet weld is stated as a leg length
of the largest inscribed right isosceles triangle as shown
in Figure 5 covering typical attachment details of slip-on
flanges. In piping systems, fillet welds are only used for
slip-on flanges, socket welds, and for welding
attachments to piping components (e.g., reinforcing pads,
supports, etc.).
Welding Steps
Cleaning:
End Preparation:
Identification
Cleaning
Painting
Protection
3 3
7 5
4 Bolt 8 Bolt
1 2 1 2
Flange Flange
6 8
4 4
3 13 3 11
9 7
5 7
5 11
9 15
12 Bolt 16 Bolt
1 2 1 Flange 2
Flange
16 10
12 6
8 6
8 10 12 14
4 4
13 3 17 3 1119
9 7 2115
5 7
5 11 17 23
19 15 9 14
1 20 Bolt 2 1 24 Bolt 2
16 Flange 20 13 Flange 10
12 6 24 18
8 10 8 6
20
18 4 14 12 4 16 22
FIGURE 6
Cleaning
Buried Installation
Sample Problem 2
Solution
This crew started out doing the job right, but did not finish
the job correctly. The following items are incorrect:
Vertical Profile
• A route drawing, detailed plan drawings, a piping
and instrument diagram, a hydrostatic test diagram,
and other drawings required per SAES-L-020 shall
be issued by the Prime Engineering Office (PEO)
and shall be the basis for installing the pipeline. The
end of the pipeline, Station 0 + 00, shall be stated in
the Scope of Work, and is normally the upstream
end. A metric tape shall be used for the horizontal
survey. Profile surveying shall be in meters and
decimal fractions of a meter.
Elastic Bends
Preformed Bends
Tie-in Temperature
- Full-thrust anchor.
SUMMARY
requirements.
• MSS-SP-44 if not specified by ASME/ANSI
B16.5 or Standard Drawing.
API 5L, Gr. X42 through X65 MSS SP75, plus additional
requirements of 02-SAMSS-005
adjustment.
• Weld-end bevel 35° ± 5°.
• 1.5 mm (1/16 in.) root face.
• End-plane normal to pipe axis within 0.25°.
e. Flange-face separation,
gasket thickness: ± 0.5 mm (± 1/64 in.).
12. Bends
• For pipeline:
- Maximum localized bend at one place for
aboveground, preformed bend per SAES-L-
051.
GLOSSARY