CONSTRUCTION PROCEDURE Doc No : 7T04-CS-00-PC-013

Rev. : 14
FOR Page : 1 of 15
PIPING PREFABRICATION Date : 17.OCT, 2013

CONSTRUCTION PROCEDURE

FOR

PIPING PREFABRICATION

PROJECT NO. : 7T04

PROJECT NAME : ERC Refinery Project

COMPANY : Egyptian Refining Company (TAKRIR) S.A.E.

SITE : Mostorod, Egypt

14 17.OCT, 2013 Revised as Noted S.S.Kim B.G.Min S.M.Hong K.H.Min

13 23.JUL, 2013 Revised as Noted S.S.Kim B.G.Min S.M.Hong K.H.Min

12 15.MAY, 2013 Revised as Noted S.S.Kim B.G.Min S.M.Hong K.H.Min

11 09.APR, 2013 Revised as Noted S.S.Kim B.G.Min S.M.Hong K.H.Min

10 10.APR, 2009 Revised as Noted S.S.Kim B.G.Min H.J.Lee S.S.Ahn

0 20.MAR, 2009 For Approval S.S.Kim B.G.Min H.J.Lee S.S.Ahn

REV. DATE DESCRIPTION PREPD CHKD CHKD APPR REVD DATE

(P/M)

CONTRACTOR COMPANY

SEOUL, KOREA
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TABLE OF CONTENTS

1. GENERAL ---------------------------------------------------------- 3

2. SCOPE OF WORK ------------------------------------------------ 4

3. MATERIALS -------------------------------------------------------6

4. DESIGN -------------------------------------------------------------7

5. DRAWING --------------------------------------------------------- 7

6. CUTTING OF PIPING ------------------------------------------- 7

7. BENDING ---------------------------------------------------------- 8

8. JOINT PREPARATION AND ALIGNMENT ---------------- 8

9. WELDING ---------------------------------------------------------- 10

10. PREHEATING AND HEAT TREATMENT ------------------- 12

11. FINAL CORRECTIONS ------------------------------------------ 12

12. TOLERANCES ----------------------------------------------------- 12

13. EXMINATION AND TESTS ------------------------------------ 12

14. HANDLING AND STORE --------------------------------------- 14

15. SHIPMENT --------------------------------------------------------- 15

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1 GENERAL

1.1 Introduction

1.1.1 This Procedure together with the related specifications and drawings covers the minimum
requirements for the fabrication, inspection and test of prefabrication of piping for all process and
utility plant for the ERC Project job site Construction Mostorod, Egypt.

1.1.2 Codes and Standards supplementary in related to this procedure shall be as follows ;

- ASME B 31.3 Process Piping

- ANSI/ASME B1.20.1 Pipe threads, General Purpose
- ASME/ANSI B.16.5 Pipe Flanges and Flanged Fittings
- ASME Boiler and Pressure Vessel Code, Section v

1.1.3 This Specification / Procedure contain additional requirements applicable only to fabricators
furnishing sub-assemblies for final erection by others. Other requirements applicable to process and
utility piping systems are contained in the following specifications:

7T04-MP-00-TS-002 Piping Design-General

7T04-MP-00-TS-004 Piping Material Specification and Classes
7T04-MP-00-TS-005 Purchasing Specification for Pipes
7T04-MP-00-TS-006 Purchasing Specification for Fittings
7T04-MP-00-TS-007 Purchasing Specification for Flanges
7T04-MP-00-TS-010 Purchasing Specification for Valves
7T04-CS-00-TS-001 Painting
7T04-CS-00-TS-003 Pipe Welding and Welding Inspection
7T04-CS-00-TS-016 Field Pressure Testing of Piping
7T04-CS-00-TS-017 Coating and Wrapping of Underground Piping
7T04-CS-00-PC-008 Carbon Steel Piping
7T04-CS-00-PC-009 Piping Construction Work
7T04-CS-00-PC-011 Alloy Steel Piping
7T04-QA-00-PC-007 Field Inspection and Test Plan
14
7T04-QA-00-PC-004 Positive Material Identification (PMI) Procedure
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1.2 Definitions

- COMPANY; ERC( Egyptian Refining CO.,) and PMC (Project Management Consultancy; Worley
Parsons)

- CONTRACTOR ; GS E & C ( GS Engineering & Construction CO.,)

- SUBCONTRACTOR (or "Piping Sub-Assembly Vendor") as used herein, shall be defined as a qualified
manufacturer or fabricator who is supplying sub-assembly piping weldments for final assembly by
CONTRACTOR and/or its erection SUBCONTRACTOR, regardless of whether the fabrication is done
in the vendor's normal premises or in a fabricating shop set up at the job site.

- Field fabricated piping shall be defined as all piping sub-assemblies and completely erected piping
systems fabricated by CONTRACTOR and/or the erection SUBCONTRACTOR who has the
responsibility for the completely erected piping system. Field fabrication includes both "in-position"
welds and any fabricating operations carried out in job site field fabricating shops operated by
CONTRACTOR and/or the erection SUBCONTRACTOR who has the responsibility for the completely
erected piping system.

1.3 Submittals

The SUBCONTRACTOR shall submit the following documents prior to the start of fabrication.

- Fabrication schedule including inspection.

- Shipping schedule, If any required.
- Fabrication shop layout including shop capacity.
- List of equipments and machines to be provided.
- Organization, and manning schedule of shop fabrication.
- Welding Procedure Specification and Procedure Qualification Records
- Procedure for Welder Qualification
- Performance Qualification Record.
- Inspection report if any required by CONTRACTOR.

2 SCOPE OF WORK

Fabrication under this specification shall include all components of a piping system, or part thereof, entering
into fabricated assemblies, but shall exclude all valves, bolting, gaskets, flanged fittings, blind flanges,
orifice plates, and all specialty items.
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2.1 SUBCONTRACTOR shall furnish all labor, supervision, materials, equipment and tools to complete the
work including handling, loading and unloading, storing, sorting and normally inspection of pipe spools of
2” and larger described in the accompanying drawings, specifications and standards and "Bill of
Quantities" as referred in the Requisition.

2.2 The work shall include ;

(1) Storing, sorting, marking and segregation of raw bulk material (pipes, fittings, flanges and
valves etc.,) for fabrication.

(2) Prefabrication of required piping including piece marking, color coding and match marking as
required to aid for field erection as follow Procedure 7T04-CS-00-PC-009.

(3) Qualification, and testing of all welders, welding operator, and welding procedures as required
by the applicable Specification 7T04-CS-00-TS-003, and as directed by CONTRACTOR
including the maintenance of required records.

(4) Providing welder identification symbols and maintaining welder qualification files as required
by the codes and Specification 7T04-CS-00-TS-003.

(5) Providing and maintaining welding materials storage facilities satisfactory to CONTRACTOR
and maintain good control of all welding materials used in the work.

(6) Providing labor, tools, equipment and materials for all weld repairs determined necessary by
independent inspection and non-destructive examination. Repair methods shall comply with the
requirements of the applicable code ASME31.3 and Specification 7T04-CS-00-TS-003.

(7) Heat treatment of weldments in accordance with Specification 7T04-CS-00-TS-003 and the
reference code ASME 31.3 and Subcontractor shall submit his PWHT procedure for Contractor
and Company approval.

(8) Sorting and segregation of spool pieces for individual piping systems within the storage area to
aid for field erection.

2.3 The latest Isometric drawings and dimensional table of materials required for the correct prefabrication of
spool pieces will be supplied to SUBCONTRACTOR by CONTRACTOR.
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2.4 Materials manufactured in accordance with Specification 7T04-MP-00-TS-004 and related codes,(ASTM,
ASME, etc.) and required for prefabrication of spool pieces, which may include pipe, butt-weld fittings,
flanges and bosses, shall be supplied to SUBCONTRACTOR by CONTRACTOR, and load/unloaded by
SUBCONTRACTOR. Welding electrodes and other consumable materials for piping fabrication work
shall be provided by SUBCONTRACTOR.

2.5 Radiography examination shall be done at SUBCONTRACTOR's Shop by NDE SUBCONTRACTOR

authorized by CONTRACTOR. SUBCONTRACTOR shall furnish the area for radiography examination
and arrange spool pieces as required for the examination.

2.6 Before or after prefabrication of pipe spool, they shall be sandblasted and primer-painted at other SUB-
CONTRACTOR's shop in accordance with Specification for Painting 7T04-CS-00-TS-001.

2.7 SUBCONTRACTOR shall have responsibility of loading / unloading all prefabricated pipe spools on the
truck for transportation.

3 MATERIALS

3.1 Pipe and Fittings

The material specification and color code for each piping assembly will be indicated on CONTRACTOR’s
Drawings and/or Specification for Piping Material Specification and Classes (7T04-MP-00-TS-004) and
Purchasing Specification 7T04-MP-00-TS-005, 006, 007 and 010.

3.2 Bolting, and Gaskets

3.2.1 Threads of bolts and studs shall be doped in the field with a graphite and water mixture, before
installation to prevent galling of the threads.

3.2.2 Gaskets in high temperature and all steam services shall be dusted with graphite.

3.3 Material Test and PMI(Positive Material Identification) Reports

3.3.1 SUBCONTRACTOR shall supply CONTRACTOR with four(4) certified copies of mill test reports
for all material which they supply. For standard alloy piping materials other than pipe, such as
flanges and welding fittings, for which such reports are not always obtainable, and for all carbon
steel piping materials certified statements that the material meets all requirements of the designated
specification will be accepted.
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3.3.2 The mill test reports or certified statements shall be available for the CONTRACTOR’s Inspector
prior to the start of fabrication.

3.3.3 PMI shall be performed in accordance with PMI Procedure (7T04-QA-00-PC-004). PMI is the non-
14
destruction test method to identified the nominal composition of alloy materials, which is done in
addition to, and independent of, identification by document of material test report.

4 DESIGN

4.1 Fabricated piping shall meet the requirements of the Code for Process Piping ASME B31.3 unless
otherwise noted herein, and the layout and dimensions as indicated on CONTRACTOR’s Drawings.
When the requirements of this specification differ from those given on Contractor’s Drawings, the
drawings shall govern.

4.2 The type of flanges, fittings, and connections will be indicated on CONTRACTOR’s Drawings and/or
Specification for Piping Material Specification and Classes(7T04-MP-00-TS-004) and Piping Design
General (7T04-MP-TS-002).

5 DRAWINGS

CONTRACTOR will not check or otherwise approve detail sketches made by SUBCONRACTOR. The
responsibility for detail sketches conforming with CONTRACTOR’s Drawings shall rest with the
SUBCONTRACTOR.

6 CUTTING OF PIPING

As a rule, pipes shall be cut mechanically with a pipe cutter or a high speed cutter. However, the followings
are permissible :

(1) Carbon steel pipe which has a carbon content not exceeding 0.35 percent in the base metal may
be cut with an automatic or manual oxygen – acetylene gas torch.

(2) Only when unavoidable, stainless steel pipe may be cut by a plasma jet, a high speed cutter or
grinder. In this case, the pipe shall be applied with a covering for preventing adhesion of spatter.

(3) Flame cutting, arc cutting, or flux injection torch cutting of alloy steel will be permitted for
rough cutting only. Air hardening alloys shall be preheated and slow cooled to avoid cracking.
The edges of alloy steels so cut must be finished by machining, grinding or chipping. Arc and
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flame cut edges of 1 Cr-Mo and higher alloy materials shall be visually examined and any
cracks shall be removed. Magnetic particle or liquid penetrant inspection, whichever is
applicable, shall be used to evaluate questionable conditions.

(4) The ends of pipe to be used with socket-welding valves, flanges and fittings should be machine
cut to minimize the need for grinding.

7 BENDING

7.1 General

7.1.1 Excessive scratches, gouges and die marks from mandrels and dies of pipe bending machines will be
cause for rejection.

7.1.2 Bending to a radius less than five(5) times the diameter of the pipe will not be permitted unless
otherwise specified on applicable CONTRACTOR’s Drawings. When bends of less than 5 times
the diameter are required, the detail of the bending method shall be subject to the approval of the
CONTRACTOR’s Inspector.

7.2 Carbon Steel

Bends in carbon steel pipe may be made hot or cold (1 1/2" and smaller pipes) by any suitable procedure.
The use of gas torches and water during hot bending shall be approved by the CONTRACTOR’s Inspector.

7.3 Ferritic Alloy Steel

The portion of a ferritic steel pipe to be hot bent shall be heated uniformly, preferably in a furnace, to a
temperature of not over 1,065 . The use of gas torches or water at any time during bending is prohibited.

7.4 Chrome Nickel Austenitic Alloy Steel & Non-Ferrous Materials

Bends in austenitic stainless steel pipe and non-ferrous materials must be made cold (1" and smaller pipes).
The application of heat in any form for bending these alloys is not permitted without special approval by
CONTRACTOR’s Inspector.

8 JOINT PREPARATION AND ALIGNMENT

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8.1 Pipe joints

8.1.1 Weld bevels shall be suitable for the welding process to be used, and the contour shall permit
complete fusion throughout the joint. Weld bevels shall be in accordance with Procedure 7T04-CS-
00-PC-008 and 7T04-CS-00-PC-011, however, when not specified, they shall be prepared in
accordance with Chapter 5 of ANSI B31.3.

8.1.2 Weld bevels shall be made by machining, grinding, chipping, thermal cutting, and the surfaces shall
be reasonably smooth and true. All surfaces to be weld shall be clean and free from paint, oil, grease,
dirt, slag, scale, rust and other materials detrimental to welding.

8.1.3 Joint fit-up shall be within acceptable limits of the preferred method of ANSI B31.3 for a full
penetration weld. There shall be no more than 1.5 mm internal radial misalignment. Unequal inside
diameter shall be contoured or taper trimmed 1:3 per ANSI B16.25. However, the resulting
thickness of the welded joint shall not be less than the minimum design thickness plus corrosion
allowance.

8.1.4 The fit-up may be made by tack welding or using clamp device holder. Back-up rings shall not be
used. All fit-up and tack weld must be made to the satisfaction of the CONTRACTOR’s Inspector.

8.2 Tee and Lateral Joints

8.2.1 Branch connections shall be in accordance with Procedure 7T04-CS-00-PC-009.

8.2.2 All cuts shall be carefully beveled and accurately matches to form a good groove for weldings.
Wherever possible the contour shall have a minimum included angle of 75 to facilitate obtaining the
required complete penetration of welds at all points.

8.2.3 Branch connections in piping that is field fabricated shall be reinforced as required by
CONTRACTOR’s Drawings and Specification 7T04-MP-00-TS-004.

8.3 Flanges

The bolt holes of flanges in the vertical lines shall straddle the Plant North-South, centerlines of the pipe in
the erected position and for flanges in the horizontal lines bolt holes shall straddle the vertical centerlines
unless otherwise indicated on CONTRACTOR’s Drawings.
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9 WELDING

9.1 General

9.1.1 No production welding shall be done until the welding procedures and welder or welding operators
have been properly qualified in accordance with the procedure and performance qualification test
requirements of the designated specification and code. In addition, the requirements of all
government regulations and jurisdictional codes, within which the piping systems are to be installed,
shall be met.

9.1.2 All field welding done by SUBCONTRACTOR shall be in accordance with the applicable
CONTRACTOR’s specifications. Each welder or welding operator must successfully pass the
Performance Qualification Test Requirement in exact accordance with the details of the welding
procedures as submitted.

9.1.3 SUBCONTRACTOR shall supply CONTRACTOR with four(4) copies of each Qualified Welding
Procedures Specifications to be used. Any Piping Erection SUBCONTRACTOR doing field welding
shall submit certified Welding Procedure/Specification to CONTRACTOR for approval. The
SUBCONTRACTOR shall also be required to conduct welder or welding operator performance
qualification tests as required by CONTRACTOR and COMPANY prior to the start of production
welding.

9.1.4 Identification of all qualified welders shall be controlled in accordance with Procedure for Field
Inspection and Test Plan (7T04-QA-00-PC-007) and Specification for Pipe Welding and Welding
Inspection (7T04-CS-00-TS-003).

14 9.1.5 Longitudinal seams in adjoining lengths of welded pipe shall be staggered and shall be located to
clear openings and external attachments as per piping construction works(7T04-CS-00-PC-009)
clause 5.4.2

9.2 Welding Process

9.2.1 All welding shall be in accordance with Specification for Pipe Welding and Welding Inspection
(7T04-CS-00-TS-003), However when a not specified, in accordance with Code for Process Piping
ASME B31.3 Chapter V.
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9.2.2 Argon gas with a purity of more than 99.99% shall be used for TIG arc welding. Flow rate of
shielding gas shall be within the range of minus 10% to plus 25% of the flow rate used in the
welding procedure qualification test.

9.2.3 The field work shop for fabrication carbon steel, 304, 304L, 304H, 316 and 316L stainless steel
piping shall be separated areas, walls or other suitable facility. Also tools, grinding stone etc. shall be
separated for each material. The work to be prefabricated or welded shall be carried out on the
working table or paved area.

9.2.4 Wire brush shall be separated and marked for cleaning of carbon steel and stainless steel. Wire brush
used on carbon steel can not be used for titanium piping.

9.2.5 A welding procedure for severe cyclic conditions shall be employed which provides a smooth,
regular, fully penetrated inner surface.

9.2.6 A weld defect to be repaired shall be removed to sound metal. Repair welds shall be made using a
welding procedure qualified in accordance with ASME B31.3, recognizing that the cavity to be
repaired may differ in contour and dimensions from the original joint. Repair welds shall be made
by welders or welding operators qualified in accordance with ASME B31.3. Preheating and heat
treatment shall be as required for the original welding.

9.2.7 Weld end valves with parts susceptible to damage by heat, such as ball valves, shall have those parts
removed during welding.

9.3 Welding Electrodes

9.3.1 All welding electrodes shall be in accordance with Specification 7T04-CS-00-TS-003.

9.3.2 Electrodes and filler metals, used in all other welding processes, shall meet the requirements of
applicable AWS Specifications. The brand shall be subject to the approval of the CONTRACTOR’s
Inspector.

9.3.3 To reduce the probability of cracking, the hydrogen content of electrodes should be kept as low as
possible.
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10 PREHEATING AND HEAT TREATMENT

Preheating and Post Weld Heat Treatment shall be in accordance with Specification 7T04-CS-00-TS-003
and Procedure 7T04-CS-00-PC-008 and 7T04-CS-00-PC-011, when a not specified, in accordance with
Code for process piping ASME B31.3 Chapter V.

11 FINAL CORRECTIONS

For carbon steel pipe, if any additional bending is required after the completion of fabrication to meet
dimensional requirements, such bending or correcting may be made by any suitable method subject to the
approval of CONTRACTOR’s Inspector and COMPANY’s representative.

12 TOLERANCES

The pipe fabrication tolerances shall be in accordance with Procedure 7T04-CS-00-PC-009.

13 EXAMINATION AND TESTS

13.1 General

13.1.1 The examination and test shall be in accordance with Procedure 7T04-CS-00-PC-009.

13.1.2 The fabrication and testing of all piping ordered under this specification is subject to inspection by
CONTRACTOR. The inspection in no way, however, relieves the fabricator or erector of his
responsibility for the piping meeting all requirements of this specification.

13.2 Inspection of Welds

13.2.1 Welding inspection shall be in accordance with Specification 7T04-CS-00-TS-003.

13.2.2 All welds shall be subject to the visual inspection requirements of the ASME Code for Process
14 Piping, B31.3, Process piping. Unless otherwise indicated in the applicable Specification for
Piping Material Specification and classes(7T04-MP-00-TS-004), there are no requirements for
radiographic, penetrant oil, or sectioning tests of welds in piping fabricated under the requirements
of this specification. The Inspector may request such testing in lieu of rejection, however, when
doubt exists as to the quality of a weld. The standards of acceptability for all radiographs shall be
the ASME Code for Process Piping B31.3. All joints subject to 100% radiographic inspection shall
have complete joint penetration.
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13.2.3 For welds made with inert gas welding techniques, which are subject to radiographic inspection, the
radiographic standard of acceptability shall include additional requirements as follows :

(1) The root of the weld shall show a smooth contour and complete freedom from evidence of non-
fused land at the edges of the base metal.

(2) "Sink" or depression of the root pass shall not result in a total thickness, including weld
reinforcement, which is less than the original wall thickness of the material being welded. The
total length of depression of the root pass shall not exceed 20% of the circumference of the pipe.

13.3 Hardness Test

Hardness tests shall be done as per 7T04-QA-00-PC-020 “Post Weld Heat Treatment (PWHT) & Hardness
Testing procedure”. The hardness test shall be made on the surface of material affected by the bending or
welding operations and shall show hardness numbers not to exceed the values permitted by ASME B31.3
Table 331.1.1. and Project Specification.

13.4 Hydrostatic Pressure Test for Piping Sub-Assemblies

No shop hydrostatic testing shall be required for any piping sub-assemblies fabricated in accordance with
this specification. These sub-assemblies and field fabricated piping shall be hydrostastically tested in the
field in accordance with Specification for Field Pressure Testing of Piping (7T04-CS-00-TS-016). All cost
for repairs to the sub-assemblies due to failures revealed by the Field Pressure Test shall be paid by the
14 SUBCONTRACTOR. All jacketed pipe shall be shop hydrostactic testing in the shop for inner/outer pipe.

13.5 Dimensional Check

Before preparation for shipment, all parts and dimensions for each piece of fabricated pipe supplied by
SUBCONTRACTOR shall be checked to make sure the final fabrication meets all requirements of the
CONTRACTOR’s Drawings and this Specification.

14 HANDLING AND STORE

14.1 Protection of Openings

After completion of inspection, all shop-fabrication and field prefabricated piping requiring relatively long
storage at the pipe spool storage area shall be prepared for shipment and installation respectively as follows:
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14.1.1 Flanges for shop fabricated piping shall be protected over the entire gasket surface with metal,
hardboard or wood protectors securely attached after applying rust preventive on the flange surface.

14.1.2 Flanges and any openings for field fabricated piping shall be protected over the entire gasket surface
and the opening against entry of any foreign matter by covering with PVC sheets, plastic plugs or
caps, hardboard, wood protectors or other suitable materials securely attached after applying rust
preventive on the flange surface.

14.1.3 Piping with V-beveled ends shall be protected by firmly attached covers.

14.1.4 Threaded end connections shall be fitted with metal, wood, or plastic plugs or caps for shipment.

14.2 Storage of austenitic stainless steel

14.2.1 All piping materials and fabricated piping shall be stored so as not to be in contact with the ground
and away from painting area.

14.2.2 All openings shall be blanked to prevent entry of moisture.

14.2.3 Austenitic stainless steel shall never be exposed to salt water or salt spray or zinc environment.

14.2.4 Seamless and welded pipes shall be stored separately.

14.2.5 Austenitic stainless steel fabrication work shall be separated from other steel fabrication work.

15 SHIPMENT

15.1 Preparation for Shipment

15.1.1 All pipe shall be dry and free from all water, dirt, and loose foreign materials. All hot bends must
be turbaned or otherwise cleaned to completely remove all adherent burned-on sand. Special
cleaning, such as sandblasting and chemical cleaning shall be done only when required by the
applicable Piping Material Specification and classes, (7T04-MP-00-TS-004), and Piping Line Index.

15.1.2 All flange faces, threaded ends, and other machined surfaces of all piping of all materials shall be
coated with grease type rust preventative applied as recommended by the manufacturer. The maker
and brand of grease used must be approved by the CONTRACTOR’s Inspector.
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15.1.3 All flange faces shall be protected against damage in shipment by suitable covers of wood or plastic.
The covers shall be securely and tightly attached by at least three bolts or by wiring through at least
four bolt holes. Threaded ends shall be provided with thread protectors.

15.2 Painting and Marking

The appropriate pipe piece identifying number shall be legibly marked in paint in large block figures on
each pipe. If the fabricated piece is too small for legible paint markings, the identifying number shall be
stamped on the pipe at one end or on the edge of a flange. Steel stenciled identifying marks on ferritic
alloy steels shall be applied prior to heat treatment. Steel stencil marks are not permitted on austenitic
stainless piping or components.

15.3 Release for Shipment

No piping shall be released for shipment until it has been approved by the CONTRACTOR’s Inspector,
and until the shipping documents and invoices, required by the applicable purchase order, have been
furnished.