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SPECIFICATION FOR PROCESS AND

OTHER PIPING SPECIAL PIECES


oleh:

Hendri Utomo

1.
1.1.

PENDAHULUAN
SPECIFICATION FOR PROCESS AND OTHER PIPING SPECIAL PIECES
Dokumen yang berisi spesifikasi teknis menyangkut peraturan dan standar
untuk material, desain, fabrikasi, pengelasan, pengecatan, galvanizing,
inspeksi dan pengujian dari Process and other Piping special pieces.

1.2

ISTILAH
Istilah Piping special pieces memiliki pengertian
yang sama dengan Piping special item tergantung
pada masing masing project dalam menggunakan
istilah ini. Piping special pieces adalah materialmaterial yang tidak tercantum dalam Piping
Material Class dan harus memiliki tag number
sebagai identifikasi di P&ID.

1.3.

TUJUAN
Digunakan sebagai referensi dalam kegiatan engineering mencakup
referensi document specification, datasheet, drawing dan technical
evaluation, disamping itu sebagai referensi dalam kegiatan inspeksi,
pengujian dan pembelian.

1.4.

RUANG LINGKUP
Specification for piping special pieces berdasarkan area mencakup dalam
dua bagian berikut :

1.4.1 Process Piping Special Pieces


Menyangkut Piping special pieces yang berada di area process seperti :
(1) Strainer, (2) Rubber dan Metal Expansion Joint, (3) Sample Cooler,
(4) Static Mixer, (5) Steam Trap, (6) Flame Arrestor, (8) Sampling
Connection, (9) Vacuum Breaker ( 10) Flexible Hose & Hose Coupling
(11) Corrosion Coupon (12) Special Valves dan sebagainya.
1.4.2 Other Piping Special Pieces
Menyangkut Piping special pieces yang tidak berhubungan langsung ke
area Process seperti : (1) Safety Shower, (2) Sight Glass, (4) Insulation
Gaskets dan sebagainya

2. PIPING SPECIAL PIECES SIMBOL, SKETSA, FUNGSI DAN LOKASI


2.1 Piping Special Pieces Simbul
Beberapa simbol dari Piping special pieces yang pada umumnya tercantum dalam
P&ID sebagaimana table berikut ini.

2.2 Piping Special Pieces Sketsa


Beberapa sketsa dibawah ini yang merupakan contoh dari Piping special pieces
adalah sebagaimana berikut ini.

APPLICABLE CODE AND STANDARDS (CONTINUED)

4,2. Applicable Document

6.1.3 Strainer Element


The Manufacturer shall submit strength calculation sheet of elements for Purchases
approval. For Conical strainers, screen element shall be adequately sealed in assembly
on plate cone, at the edges and along its seam, to prevent flow by passing of screen
mesh.
6.1.3.a Open Area Ratio
The open area ratio shall not less than the value specified in the data sheet against the
cross sectional area of the inlet pipe.
6.1.3.b Mechanical Strength
Strainers elements shall be designed to suit at least 1.5 Barg in differential pressure to
withstand the pressure without collapsing or distorting screen from solids or foreign
materials. And the elements strength calculation for each strainers under 200% open
ratio for t-type, y-type and conical type, and 200 % and/or 300% open ratio for bucket
type strainer specified in Data Sheet respectively shall be submitted together with the
open ratio calculation to CONTRACTOR for approval.
6.1.4 For tees larger than 48 (not covered by ASME B16.9), Vendor shall supply these
tees which supported by strength calculation or proof testing per Section 2.2 of ASME
B16.9. Strength calculation shall be performed in accordance with the design conditions
specified on the Data Sheet, and submitted for purchasers review.

6.1.5 Vendor shall furnish Temporary mesh for pump start-up operation where
specified in the Data Sheets.
6.1.6 Flanged strainer shall have bearing surfaces for bolting that are parallel to the
flange face within 1deg. Any back facing or spot facing to accomplish parallelism shall
be in accordance with ASME B16.5 para.6.6.
6.1.7 Strainers shall be equipped with accessories and spare parts as following basis.
a) The davit or lifting eye shall be provided for strainers cover flange as follows:
- The cover flange weight 19 to 45 kg
: Lifting Eye.
- The cover flange weight 45 kg and above : Davit.
- The line size up to 4
: Lifting Eye (For bucket
Type Strainer).
- The line size 6 and above
: Davit (For Bucket Type
Strainer).
b) Drain & Vent connection shall be provided in accordance with the Data sheet
c) Vendor shall supply the spacer that will insert in space after removal of
Conical Strainer.
d) For Y-type strainers, 200% of spare gaskets for each strainer shall be supplied
together with the body.

6.1.8
Bucket type strainers shall be of the straight flow construction in inlet and
outlet
nozzles with bolted cover flange.
Davit shall have sufficient strength and guided on body so as not to twist the bucket or
out
of position during the operation.
6.1.9 Conical type strainers shall be designed for mounting between pipe flanges and
gasket contact surface of the body ring plate shall be serrated to ASME B16.5.
Conical strainers shall be provided with identification tabs that protrude from the holding
pipe flanges.
6.1.10 Flow direction for strainer shall be permanently stamped on the casing or tab by
Vendor standard.

6.3.2 Design Configuration


Basic design configuration for Insulation set (Gasket, Steel stud bolt/ nut,
Insulating washer, Insulation coating or Insulating sleeve and Steel washer) shall
be as following figure (Fig.-1).
Fig-1. Insulation Set
Each bolt shall be coated with the Vendor applied insulation coating or insulating
sleeve and shall be supplied with 2 carbon steel nuts, 2 carbon steel flat washers
and 2 washers as one set.

6.3.3
6.3.3.a

6.3.3.b

Dimensions
Non-metallic full face Insulation Gasket dimensions shall conform to the
following.
ASME B16.5 flanges
: ASME B16.21
ASME B16.47 Series A or B : Refer to the facing dimensions of ASME B16.47
Series A or B
Insulation Bolt and Nut dimensions shall conform to the following.
(1) Stud bolt / nut
Bolt : ANSI B18.2.1
Nut
: ASME / ANSI B18.2.2 Table 9
(2) Threads
ANSI B1.1 unified screw threads Bolts class 2A, Nut class 2B
Bolt diameter
1" and smaller : Coarse thread series
Bolt diameter 1-1/8" and larger : 8-pitch-thread series
(3) Specified length of stud bolt does not include the height of the points.
(4) Nuts for bolts shall be heavy hexagonal semi finished, conforming to
ASME / ANSI B18.2.2.
(5) Manufacturer shall submit the length of bolt for Purchasers approval.

6.3.4 Scope of supply


Each insulation gasket set shall be consisted of following parts. Required
number and size of bolt nut for each set shall be in accordance
with
Attachement-1. Each bolting shall be supplied with 2-insulation and 2-steel
washers fitted condition.
(a) Insulation gasket
(b) Insulation Washer
(c) Steel Washer.
(d) Insulating sleeve
6.3.5 Material Requirement
Material shall conform to the following:
(a) Gasket
: NEMA Grade G10, GRE Standard
(b) Insulating Sleeve
: GRE Full length
(c) Steel Washer
: Galvanized plated steel washer, Dimension as
per SAE
(d) Insulation washer
: GRE per SAE Standard

6.5.3 Special Design Requirements for Expansion Joint


(1) Number of cycles shall be designed by manufacturer and it shall be
submitted
to Contractor for approval. (Minimum cycles shall be 1000.)
(2) Manufacturer shall indicate reaction of the expansion joints spring rate on
manufacturer drawings or data sheet for approval.
(3) The expansion joint shall be designed with tie rods and supply by Vendor.
(4) The expansion joint shall have a construction where any extra load should
not be applied to the bellows themselves during shipping, and installation.
(5) Expansion joint elements shall be protected against axial movement beyond
design amounts by means of limit bolts across each bellows or by another
suitable method. Limit bolts or limit stops shall be designed to carry full bellows
pressure thrust at expansion joint design pressure and temperature.
(6) Expansion joint elements shall be protected against rotational
movement
beyond specified amounts.
(7) The expansion joint design shall include a provision to maintain alignment of
the center pipe along a line that extends through the center of rotation of
each
bellows element.
(8) The specified expansion joint design capacities are calculated across the
bellows. Included in these calculations is the thermal growth of the expansion

6.6

STATIC MIXER

6.6.1 Design and Fabrication


1. Static Mixers shall be designed and fabricated in accordance
with ASME B31.3, and Data Sheet. Homogeneous mixing
immediately downstream of static mixer shall be guaranteed by
the manufacturer.
2. Dimensions shall conform with following Code and Standard.
a) Overall dimensions (Face to Face) : Manufacturers standard
b) Flanges (Incl. Facing finish)
- For 24 and smaller
: ASME B16.5
- For 22
: MSS SP-44
- For 26 to 60
: ASME B16.47
(c) Pipe shall be per ASME B36.10M or B36.19M

6.7
6.7.1

STEAM TRAP
Manufacturing Basis
(1) Steam traps / Air traps shall be designed and fabricated in accordance with ASME
B31.1/B31.3, and Data Sheet
(2) Pressure and Temperature rating of the body shall be in accordance with ASME
B16.5.
(3) Steam traps shall have an integral type unless otherwise specifically noted in Data
Sheet.
(4) Air traps shall be supplied with strainer having flanged ends, not integral to the trap,
and shall have a balancing nozzle, min. 1/2 NPT, on the cover flange.
(5) The type of traps to be used shall comply with the Data Sheet that is based on the
following criteria, however, the use of disc traps shall be limited to line traps for steam
main or steam tracing:
Body size
Type
1/2 to 1
: Disc Type Trap (Thermodynamic)
1-1/2 and larger
: Free Float Type Trap (Mechanical)
(6) Dimension
End connections shall conform to the following codes and standards.
- Flanged Ends
: ASME B16.5
- Socket Weld Ends
: ASME B16.11
Face to face dimension of steam traps shall be per Manufacturers standard.

6.8
6.8.1
6.8.2

6.9
6.9.1
6.9.2

EMERGENCY SHOWER
Manufacturing Basis
Emergency Showers and Eye Washers shall be designed and manufactured in accordance
with the ASME Z358.1 and Data Sheet.
Dimensions
End connections, specified in the Data Sheet to be prepared by CONTRACTOR shall
conform to the following codes and standards..
- Flanged ends
: ASME B16.5
- Screwed ends (Threads)
: ASME B1.20.1
SIGHT GLASS
Manufacturing Basis
Sight Glasses shall be designed and fabricated in accordance with ASME B31.3, and Data
Sheet.
Dimensions
(1) End flanges shall be suitable to connect following codes and standards, accordingly.
Type of facing (RF or FF) shall be in accordance with Data Sheet. Gasket contact
surfaces shall comply with ASME B16.5. for 24 and smaller.
(2) Face to face dimensions shall be of Manufacturers standard unless otherwise
specified in Data Sheet .
(3) Pipe shall be per ASME B36.10M or B36.19M

7.

WELDING REQUIREMENT
Welding and weld inspection shall be performed in accordance with document
Welding and Weld Inspection.

8.
8.1.

MATERIAL REQUIREMENTS
Chemical restrictions
The chemical composition of carbon steels (including l ow temperature carbon
steels) shall comply with the following:
Carbon content shall not exceed 0.23%, except for forgings and castings where this
may be relaxed to 0.25%.
- One of the following carbon equivalent requirements, based on the ladle analysis,
shall be satisfied:
Ceq= C + Mn + Cr + Mo + V + Cu + Ni 0.45% 1
6
5
15
Ceq = C + Mn x 0.42 % (2)
6
Formula (2) may be used if the material standard specifies C and Mn only Otherwise
formula (1) shall be used.
Welded Pipes and Fittings
When welded pipe or fitting is used, the full length of each weld shall be
radiographically examined to achieve Weld joint quality factor of 1.0 in
accordance with ASME B31.3. And the tolerance of wall thickness shall not be more
than 0.3 mm under nominal thickness. Other tolerances which are not covered by
ASME B16.9 shall be agreed upon.

8.2

8.3.

NACE application

8.3.1

When "NACE" is defined in Data Sheet or material description, strainers shall comply
with NACE MR0175
Sulfur and phosphorus contents shall be limited to 0.005% and 0.015%, respectively.
The max. Chemical composition of unspecified elements shall be in accordance with
Table 1 of ASTM A20.
The maximum carbon content and carbon equivalent (by Formula (1)) shall be 0.23%
and 0.43%, respectively.
The raw plate material shall be made by a process that includes vacuum degassing
while molten (ASTM A20).
Through thickness tensile property of ASTM A770 (three tensile specimens tested
and meeting 35% minimum reduction of area) shall be certified by the plate
manufacturer, but the actual testing may be exempted if the plate manufacturer can
guarantee.
The raw plate material shall be ultrasonically examined per ASTM A578
The raw plate material shall be normalized and the finished fitting or pipe shall be
stress relieved after longitudinal welding. Longitudinal weld shall be fully
radiographically examined.
The max. Production weld hardness on deposit weld metal shall be 200 HB. The
frequency of actual hardness measurement shall be agreed by CONTRACTOR.
Nickel content of weld deposit shall not exceed 1.0% as per NACE MR0175.

8.3.2
8.3.3
8.3.4
8.3.5
8.3.6

8.3.7
8.3.8
8.3.9

8.4

Impact test

Impact test requirements shall be in accordance with each


applicable
ASTM standard and ASME B31.3. In addition, for welded
pipe and
fittings with longitudinal seam in low temp. cryogenic service (ASTM
A671 CC60, A420WPL6-W, A358 304L CL-1 and A403 WP-WX
TP304L), impact test for production weld shall be done as follows:
(a) For low temp. Carbon steel welded pipe and fittings, the sampling
frequency of test specimens shall be at least one set per each heat/lot of
finished products. Test temperature and acceptance criteria on weld/HAZ
shall be the same as for the base material
(b) For TP304L stainless steel welded pipe and fittings, the acceptance
criteria of weld impact tests shall be minimum lateral expansion of 15
mils (0.38mm) at 196C on the weld deposit. Absorbed energy shall
\ also be reported for information purpose. The sampling frequency of
impact test specimens shall be at l east one per each heat/lot of finished
product unless otherwise approved by CONTRACTOR.

8.5,

Asbestos material shall not be used for gasket.

8.6.

Heat Treatment
(a)
ASTM A105 forging shall be normalized.
(b)
When PWHT is defined in the Data Sheets, all welds
including support welds shall be post weld heat treated
in accordance with ASME B31.3
(c)
The wall thickness 19.05 mm and thicker carbon steel
weld shall be stress relieved in accordance with ASME
B31.3.

8.7.

Ferrite Content
Filler metals for austenitic stainless welds shall be selected to
produce weld deposits that fall within the ferrite ranges as per
ASTM

8.8

Positive Materials Identifications


Positive materials identifications shall be performed on
following parts for Stainless & Low Alloy Steel Body
Items.
Parts Ratio of Examination
a)
Body
:
100%
b)
Cover flange :
100%
c)
Element
:
100%

8.9

Galvanizing
When Galvanizing is defined in the Data Sheets, HotDip Galvanizing shall be applied after fabrication in
accordance with document for standard painting and
galvanizing material

PAINTING
Valves shall be externally painted in accordance with the requirements in accordance
with document for standard painting and galvanizing material
Manufacturer shall execute painting for not only body, but also flange rim, face (except
gasket contact surface), and bolt holes.

10

TESTS AND INSPECTIONS


The manufacturer shall conduct tests and/or inspections in accordance with the relevant
codes and standards and the additional requirements with the following:
(1) Non Destructive Examination (NDE)
(2) The manufacturer shall perform Tests and/or inspections under the manufacturers
own quality control.
(3) Hydrostatic Pressure Test shall be carried out in accordance with Data Sheets.
(4) Water used for testing of austenitic stainless steel item shall be free from chlorides
(not in excess of 50ppm).
(5) The manufacturer has the responsibility of providing the CONTRACTORs
inspector with all specified information, and the inspector shall have free access to
witness or audit the manufacturers quality control at the manufacturers facilities at
any time while work on the products is being executed, as deemed necessary.

11

MATERIAL CERTIFICATION / MARKING


(1)
Certificate
Type certificate A, B or C required in accordance
with standard for "Certification and Marking of
Materials".
(2)
The stainless steel identification plate shall be
permanently fitted on the body. Following items
shall be clearly marked on the plate.
(a)
Tag No.
(b)
Size
(c)
Rating
(d)
Material (Body, Element)
(e)
Trade Mark
(f)
Flow Direction

12
12.1
12.2
12.3

12.4
12.5
12.6

OTHERS REQUIREMENTS
This specification has priority over the others specified in the
applicable documents.
Manufacturer shall submit manufacturing, test, inspection, and
welding procedures for CONTRACTORs approval prior to
manufacturing.
All conflicts between the requirements of this specification, related
specifications, standards, codes and CONTRACTORs requisition
shall be referred to CONTRACTOR in writing for clarification before
proceeding with manufacturing.
All material shall be protected from corrosion and mechanical damage
during transportation and storage.
Both end of material connect to another piping component shall be
protected by the plastic cap or wood
Material certificate to be submitted shall include the result and record
of heat treatment together with calibration record of equipment used,
as well as result of chemical analysis and mechanical properties tests.

13. CONTOH SPECIFICATION FOR PROCESS AND OTHER PIPING SPECIAL PIECE

STRAINER

14.

TUGAS
1. Buatlah sebuah specification untuk salah satu
special pieces / special item diatas menggunakan
contoh seperti specification untuk strainer,
dimana dapat menggunakan data data yang ada
dalam handout ini.
2. Setiap peserta training diharapkan membuat sebuah
specification ini dan diserahkan ke koordinator
training paling lambat 10 hari kerja sejak tanggal
training ini

TERIMA KASIH