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ANNEX 2.1.6 2.1.6.0_NG1005_Welding_and_Testing.docm

Welding and Testing

Project : Azura Edo (Mechanical)
____________________________________________________________________________________________________________________________________________

Contents

· Requirements on the Manufacturer in the performance of welding work and the

examination of welds
· Requirements on the qualification of examination organization and auditing their
adequacy for the performance of NDTs
2.1.6.1 Principles of Cable Testing
2.1.6.2_SCHEDULE 1 - EMPLOYER'S REQUIREMENTS 4.13.6-8
2.1.6.3_SCHEDULE 1 - EMPLOYER'S REQUIREMENTS 4.11 Welding

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ANNEX 2.1.6 2.1.6.0_NG1005_Welding_and_Testing.docm

Welding and Testing

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Requirements on the Manufacturer in the Performance of

Welding Work and the Examination of Welds

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ANNEX 2.1.6 2.1.6.0_NG1005_Welding_and_Testing.docm

Welding and Testing

Project : Azura Edo (Mechanical)
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Contents Page

1 General information on the Contents and Purpose of this Document 4

2 Notes on Organization 4

3 Welder Qualification 5

4 Performance Qualification Test 5

5 Welding Procedure Qualification Test 5

6 Minimum Requirements on the Performance of Welding Work 7

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ANNEX 2.1.6 2.1.6.0_NG1005_Welding_and_Testing.docm

Welding and Testing

Project : Azura Edo (Mechanical)
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1 General Information on the Contents and Purpose of this Document

This annex shall apply to on-site welding work and shall be complied with by the Contractor taking into
account the applicable German DIN EN-standards and guidelines or comparable international standards
such as those from ANSI, ASME, etc.., so far, as they are comparable to EN-standards.
The procedures described here are based on German DIN EN-standards for the welding of pressure-
containing welds and steel structures. This document also covers all requirements laid down in
international standards.

2 Notes and Organization

The Contractor's welding department shall be headed by a welding supervisor (welding engineer or person
with equivalent training). The welding supervisor shall fulfill the requirements of EN ISO 14731 and AD
2000 HP3. Persons fulfilling the requirements of comparable international standards, shall be recognized
as welding supervisors.

The welding supervisor shall be supported by a number of welding surveillance personnel adequate
enough to ensure that both the requirements particular to welding work and the instructions given by the
welding supervisor are complied with.

The Contractor shall be in possession of all equipment and facilities necessary for the correct performance
of all intended welding work. In cases where welds are to be heat treated, equipment capable of ensuring
sufficient accuracy and evenness of temperature along the weld piece shall be available. Only trained
personnel shall be allowed to perform such work.

Complete monitoring of welders doing welding work shall be ensured by keeping an up-to-date list of
welders containing all important data such as name, identification mark, qualification, period of validity,
NDT monitoring, number of errors made, etc.. In case of frequent faults caused by a particular welder, this
welder will not be permitted to weld any further.
On construction sites the Contractor shall provide each welder with an identification card showing the
welder's name, identification mark, personal photo and qualification.

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Welding and Testing

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3 Welder Qualification

All welding work, including temporary welds and tack welds shall be performed only by qualified personnel
in possession of a valid certificate to EN 287-1 or ASME section IX or another comparable international
certificate which has to be submitted to the site management.

4 Performance Qualification Test

After the qualification certificate has been submitted, the Customer shall reserve the right to subject all
welders intended to make pressure-retaining welds or welds on other complex steel structures to a
performance qualification test taking into account on-site conditions such as welding position, material,
dimensions, preheating and post-weld heat treatment. Weld test pieces shall be tested consistent with
EN 287-1, the scope of such tests being as follows

· carbon steel: visual examination and radiographic examination

guidance on quality levels for imperfections acc. to DIN EN 25817 (ISO 5817), group B
· low and high alloy materials: visual examination, radiographic examination or ultrasonic examination
with > 12 mm and bending test according to DIN EN 910.
guidance on quality levels for imperfections acc. to DIN EN 25817 (ISO 5817), group B
· chromium nickel steels: visual examination, surface crack examination and radiographic examination.
guidance on quality levels for imperfections acc. to DIN EN 25817 (ISO 5817), group B

5 Welding Procedure Qualification Test

As regards welding of pressure-retaining components, the Contractor shall verify his proficiency in the
required welding methods by means of welding procedure qualification tests to AD HP2/1 or DIN EN ISO
15614.

The results of the welding procedure qualification tests shall be corroborated by a party authorized to do
so. Welding procedure qualification tests carried out in accordance with comparable international
standards such as ASME Boiler and Pressure Vessel Code Section IX shall be recognized.

If changes to the fabrication schedule cause welding conditions to be altered or expanded, the scope of
applicability of the welding procedure qualification test shall be changed accordingly and a production weld
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Welding and Testing

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test piece shall be prepared and tested. The results of the welding procedure qualification test and
production weld test piece shall be available prior to the commencement of fabrication. Additional or further
welding procedure qualification tests shall be agreed with the Customer.

6 Minimum Requirements on the Performance of Welding Work

The edges of the items to be welded shall be prepared so as to ensure optimum weld quality. The
tolerances laid down in EN 29692 shall not be exceeded. Prior to welding the weld area shall be cleaned of
all contaminants such as rust, paint, oil and moisture.

In the case of materials requiring preheating, the preheat temperature shall be maintained in an area at
least four times the wall thickness or 100 mm on each side of the weld until all welding work is completed .

The grounding wire shall be attached to the work piece such that it follows the shortest path to the electric
source. Only those welding materials approved and registered for the welding method in question shall be
used. Approval granted by the TÜV (German technical inspection agency), the Deutsche Bundesbahn
(German Federal Railway), AWS, API or ships' registers (Lloyd's) shall be recognized. Proper identification
of welding materials shall be ensured. Rod electrodes shall be dried according to the manufacturer's
instructions. For welding work performed on-site, heated electrode cases with covers shall be used. The
welding supervisor shall provide each welder with not more than one daily ration of welding materials.

Austenitic and ferritic materials shall be stored, mounted and welded separately. In cases where they are
to be welded to one another, care shall be taken to ensure even and continuous fusion of the base metal
and welding material.

Welds shall be tested and assessed in accordance with the requirements of the erection procedure for the
component in question. If no requirements have been laid down, the scope of testing and the assessment
group shall be established in agreement with the Customer in accordance with DIN EN 25817. Pressure-
retaining welds shall at least fulfill the requirements of AD 2000 HP5/3.

When welding austenitic materials, the string bead technique shall be applied in order to ensure that less
heat is introduced to the weld, that is, that the interpass temperature remains low. Once a weld is

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Welding and Testing

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completed, the welder shall mark it, using a steel die for components with a wall thickness > 5 mm. The
weld area shall then be cleaned of weld spatter, slag and scale.

The dimensions and tolerances specified in the erection procedures shall be complied with. Where
tolerances are not specified, the following minimum standards shall be fulfilled

· vessels/tanks and piping: EN ISO 13920 and DIN 28005

· steel structures: DIN 18 800 T1.

All NDTs shall be recorded in the test report for the component in question. Tests shall be conducted on
short notice and taking the current stage of progress in fabrication into account to ensure that fabrication
work is not delayed. The weld imperfection rate has to be calculated on the basis of rejected joints.

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Welding and Testing

Project : Azura Edo (Mechanical)
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Requirements on the Qualification on

Examination Organization and Auditing their
Adequacy for the Performance of NDTs

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ANNEX 2.1.6 2.1.6.0_NG1005_Welding_and_Testing.docm

Welding and Testing

Project : Azura Edo (Mechanical)
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Contents Page

1 General Information on the Contents and Purpose of this Document 11

2 Organization of NDTs On-Site 11

3 Qualification of Examination Supervisors and Examiners 11

4 Examination Instruments and Equipment 12

5 Performance of Examinations 12

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ANNEX 2.1.6 2.1.6.0_NG1005_Welding_and_Testing.docm

Welding and Testing

Project : Azura Edo (Mechanical)
____________________________________________________________________________________________________________________________________________

1 General Information on the Contents and Purpose of this Document

This annex shall apply to the non destructive testing on all projects and shall be complied with by the
Contractor taking into account the applicable German and EN-standards and guidelines or comparable
international standards such as those from ANSI, ASME, etc.. so far, as they are comparable to
German and EN-standards. The procedures described here are based on German and EN-standards for
the welding of pressure-retaining welds and steel structures. This document also covers the requirements
laid down in international standards.

2 Organization of NDTs On-Site

NDTs be carried out by the Contractor's independent organization or an external company contracted to
perform the examinations. The actions to be taken by the examination supervisor for each NDT shall be
recorded in written form. The requirements and tasks of the examination supervisor are described in AD
2000 HP4 and shall apply to all on-site examination work.

Using the specified scope of examinations as a guide, the examination supervisor shall select both the
examination method to be applied and the examiners best able to perform the examination. The
examination supervisor shall sign the examination reports to be prepared.

3 Qualification of Examination Supervisors and Examiners

Examination supervisors shall be in possession of a qualification to DGZFP Level III (German NDT
Society) or ASNT No. SNT-TC-1A Level III.

Examination personnel shall be in possession of a qualification to perform examinations by the method to

be applied, that is, at least Level II for ultrasonic examination, Level I for radiographic examination and
Level I for surface crack examination, these levels being specified in DGZFP or ASNT No. SNT-TC-1A.

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Welding and Testing

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4 Examination Instruments and Equipment

The firm carrying out the examinations shall ensure that all equipment necessary for the various
examination methods, including destructive methods where required, is available on-site. Examination and
measuring equipment shall be calibrated. Records of equipment calibration shall be kept.

5 Performance of Examinations

Examinations shall be performed in accordance with the requirements laid down in the component erection
documents. Where no such requirements exist, the scope and procedure for the examinations shall be
established in agreement with the Customer.

The following examination procedures shall apply

· General AD 2000 HP 5/3

· Radiographic examination to EN 444, 462-1, 1435, 12517 and 25580
· Ultrasonic examination to EN 1712, 1713, 1714 and 27963
· Surface crack examination to EN 571, 1290 and 1291
· Visual test EN 970
· Hardness test to EN 1043 and EN ISO 6507-1

Comparable international standards may be substituted for the above subject to agreement with the
Customer.
For all compulsory weld seam test, Siemens testing regulations PV 0026.0-00000 are to be applied.
An isometric diagram according to Siemens engineering procedure E 09.59-019 of manufacture has to be
provided for documentation of welding seams.
Examination shall be performed at times selected so as to preclude delays in the erection sequence.
Examination results shall be evaluated together with the Customer immediately following performance in
accordance with the requirements for the component in question.

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Principles of Cable Testing

Power Cables (Erection Contract)
A. Standards

The following essential standards contain specifications for “Cable Testing

After Installation” of high-voltage cables:

DIN VDE 0276-603 - European standard HD 603 S1 - LV cables

DIN VDE 0276-620 - European standard HD 620 S1 - MV cables
IEC – 60502-2 Power Cables 6kV-30kV (additional)

The following applies to testing after installation:

Tests after installation comprise tests carried out on a cable and its fittings to
verify their integrity.

The test voltages and test durations for installed cables that result from the
above-mentioned standards are as follows:

- according to VDE:
Table 35.1
Test voltages U and test durations t according to DIN VDE for low- and medium-voltage cable systems (extract)

Cable rated voltages Test voltages:

U0/U U= Test DC voltage
U Test AC voltage at system frequency (45-65 Hz)
ULF VLF test AC voltage (0.1 Hz)

Paper insulated PVC-insulated cable VPE-insulated cable

mass-impregnated DIN VDE 0276-603 DIN VDE 0276-603
cable and DIN VDE 0271 and DIN VDE 0276-
DIN VDE 0276-621 620
U= U ULF U= U ULF U= U ULF
kV kV kV kV kV kV kV kV kV kV
0.6/1 - - - 5.6-8 - - 5.6-8 - -
3.6/6 - - - 20-29 2 U0 3 U0 - - -
6/10 34-48 2 U0 3 U0 34-48 2 U0 3 U0 - 2 U0 3 U0
12/20 67-98 2 U0 3 U0 - - - - 2 U0 3 U0
18/36 76-108 2 U0 3 U0 - - - - 2 U0 3 U0
Test duration t 15-30 30 min 30 15-30 30 min 30 15-30 60 60 min
min min min min min min

The rated voltage of a cable is its design voltage, which serves as a means of defining the electrical tests to be
performed on it.

The rated voltage is given as a combination of the values U0/U (Un) (in kV).

U0 is the RMS value between an insulated conductor and ground (metal cable sheath).

U is the RMS value between two external conductors of a multi-core cable or a system of single-core cables.

The formula for test DC voltage for medium-voltage cables is as follows: U= is 70 to 100% of 8 x U0

Prepared by: K. Adebahr, PG W56 Page 1 of 4

05.07.2004, Rev. 1
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Principles of Cable Testing

Power Cables (Erection Contract)
The standards essentially recommend that DC voltage tests be avoided for
PE-/VPE-insulated medium-voltage cables. The reasons for this are as
follows:
1. an excessively high DC voltage test can cause damage to the cable
(polarization of insulation, possibly leading to breakdown on application of
AC voltage), and
2. the behavior of the PE/VPE insulation in a DC voltage test does not
provide meaningful results (the material properties do not allow cable
damage to be detected).

Recommended test methods for PE-/VPE-insulated medium-voltage cables

are as follows:
1. AC voltage test at system frequency (preferable)
2. AC voltage test at 0.1 Hz (sine-wave amplitude)

The pass criterion for high-voltage testing after installation is as follows:

The sole pass criterion for the voltage test given in the standards is “no
breakdown during test”. This applies to all cable types.

Test procedure (arrangement, setup, performance) for tests after installation:

No test procedures are specified in the standards.

DC cables:
According to DIN VDE 0276-603, the test requirements also apply if the
cables are deployed in a DC system (up to max. U0 = 1.8kV).

- IEC (additional):

“20.2 Insulation test

20.2.1 AC testing
By agreement between the purchaser and the contractor, an a.c. voltage test
at power frequency in accordance with item a) or b) below may be used:

a) test for 5 min with the phase-to-phase voltage of the system applied
between the conductor and the metallic screen/sheath;

b) test for 24 h with the normal operating voltage of the system.

20.2.2 DC testing
As an alternative to the a.c. test, a d.c. test voltage equal to 4 U 0 may be
applied for 15 min.
NOTE 1 A d.c. test may endanger the insulation system under test. Other test methods are under
consideration.
NOTE 2 For installations which have been in use, lower voltages and/or shorter durations may be
used. Values should be negotiated, taking into account the age, environment, history of
breakdowns and the purpose of carrying out the test.

Prepared by: K. Adebahr, PG W56 Page 2 of 4

05.07.2004, Rev. 1
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Principles of Cable Testing

Power Cables (Erection Contract)

B. Specifications for Field Tests

1. For medium-voltage cables (i.e. all cables designed for >1kV), the test voltage
and test duration should be selected from Table 35.1 according to the type of
cable installed (see product documents or erection instructions).

2. The lowest values in the ranges for test level and test duration for medium-
voltage cables specified in Table 35.1 should be selected for the field tests.

3. Low-voltage cables (cables in DC systems included)

A simplified field test should be carried out as standard for low-voltage cables.
Major damage (e.g. damage-induced short-circuit) must be identified during
such tests. This condition can be satisfied by applying a test voltage of 1kV
DC for 1 minute. All low-voltage cables (cables in DC systems included)
should therefore be tested at this voltage for this duration.

However, if a field test in accordance with DIN VDE 0276-603 - European

standard HD 603 S1 is explicitly required in the contract between Siemens AG
and the customer, the recommendation stated in Table 35.1 for cable rated
voltages U0/U 0.6 kV - 1kV must be followed. If such a requirement exists, it
must be
a) taken into consideration in calculations during the bid phase, and
b) communicated to potential electrical erection contractors.

4. Test procedure (arrangement, setup, performance):

As specified in checklists E19.1 and E19.2 (revised).

E19_1.doc E19_2.doc

The test procedure should be taken from the table on page 4 (extract from
AR043-220) and entered under 2.2 HV Test, item 5, first column in table in
Checklist E19.1 or under 3. Insulation test, item 2, , first column in table in
Checklist E19.2.

Prepared by: K. Adebahr, PG W56 Page 3 of 4

05.07.2004, Rev. 1
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Principles of Cable Testing

Power Cables (Erection Contract)

5. The erection contractor shall provide the appropriate test equipment (see Item
6).

6. Specifications in erection contract (already included):

a. “Annex I, Schedule of Services, 7710.0000, Cables MV and LV”
i. “Insulation ... checks have to be carried out ... for every cable
installed under this contract.”
ii. “Hi-pot testing of all MV cables in accordance with the relevant
standards have to be carried out.”
b. Main contract, “9. Execution of Services, 9.6”
i. The contractor shall provide the required tools, instruments, …
necessary for carrying out his services, at his own expense, …”

Prepared by: K. Adebahr, PG W56 Page 4 of 4

05.07.2004, Rev. 1
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PARSONS AZURA EPC EMPLOYER'S

REQUIREMENTS
BRINCKERHOFF
master-key facilities. Each key shall be attached to an individual durable identification
label.

Keys and locks shall be impressed with the manufacturer's serial number.

Wall mounting cabinets suitable for the accommodation of padlocks and keys while
not in use shall be provided and mounted in approved positions and shall be suitably
labelled.

All isolating valves are to be lockable.

4.11. Welding

4.11 .1. Welders and Welders Qualifications - General

Welders employed on any work under the Contract, either at works or on site, shall be
proved to be competent to carry out the type and standard of welding required prior to
commencing work. All welders shall be qualified in accordance with the governing
design code.

In the case of pressure parts and pressure part attachment welds, each approved
welder shall have a unique identification number which shall be indicated on all welds
made by him and on all permanent test records applicable to those welds including
radiographs.

All welders engaged on either shop or site welding shall be under the supervision of a
competent welding Employer who shall demonstrate, to the Employer's satisfaction, a
complete system for the control and treatment of consumables, deployment of
welders, use of approved procedures, heat treatment, non-destructive testing ,
including spectrographic material checks on weld and parent metals, repairs and
general quality control.

4.11.2. Welders Tests

Sample welds shall be carried out on specimens of similar shape, thickness and
chemical analysis to the material to be welded, as laid down by the approved
standard and in a position which shall represent as far as possible the worst
conditions under which actual welding shall take place.

The method of preparation of the test pieces, and the standards to be used in
examination of them shall be according to the agreed Standard or Codes, or as may
be agreed with the Employer. All expenses of every kind in connection with welder's
tests shall be borne by the Contractor.

4.11 .3. Welding Procedures

All welding procedures including those proposed in repai r situations shall be qualified
as required by the governing design code and all qualified procedures shall be
submitted to the Employer for approval prior to the commencement of any welding.

4.11.4. Preheating

Where necessary, the work shall be heated prior to welding in an approved manner,
and the temperature maintained and where necessary recorded throughout the

09Apr ;
AZURA EPC EMPLOYER'S REQUIREMENTS

-64-
Prepared by Parsons Brinckerhoff
for Azura Power West Africa Ltd

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PARSONS AZURA EPC EMPLOYER'S

REQUIREMENTS
BRINCKERHOFF
operation. The metal temperature shall be checked by means of suitable
thermocouples or temperature indicating crayons.

4.11.5. Post Weld Heat Treatment

Regardless of the requirements of the specific code or specifications applicable to the

design and I or construction of the plant, it is a mandatory requirement of this
Employer's Requirements that all welds shall be subject to appropriate post weld heat
treatment with the following exceptions:

a. Austenitic stainless steels.

b. Plain carbon steels containing Jess than 0.25% carbon at thicknesses up to and
including 30 mm.
c. Low alloy steels containing 0.5% molybdenum and 1.25% chromium , 0.5%
molybdenum up to and including thicknesses of 12.5 mm provided that:
i. A hardness traverse across the weld zone gives no single result greater
than 240 HV10,and
ii. No fillet weld leg is greater than 8 mm and
iii. A minimum preheat of 200 oc is used for welding.
Plain carbon steels shall contain no more than 0.25% carbon.

All post weld heat treatments of materials and components for use at temperatures in
excess of 400 oc shall be so designed as to guarantee maximum creep properties in
the parent materials and weldments.

The soaking times at the selected heat treatment temperatures shall be:

a. Low alloy steels not containing vanadium , 5 minutes per mm of thickness with a
minimum time of 120 minutes.
b. Low alloy steels containing vanadium and high (11 to 15 %) chromium steels
containing vanadium , 180 minutes regardless of thickness.

In the event that any post weld heat treatment is carried out at a temperature in
excess of the original tempering temperature of the parent materials a reassessment
of the design strength limit stresses for the materials will be required. This may, in the
absence of acceptable mechanical test data for the specific condition, require re-
determination of the relevant mechanical properties of the materials.

The requirements for post weld heat treatment do not affect or replace in any way the
requirements for maintenance of welding preheats or post welding heating for the
purposes of diffusing hydrogen from the we ldment.

4.11.6. Inspection of Welding

The extent of weld inspection, the final weld quality, and the method of examination
shall be as stated in this Employer's Requirements and I or the agreed standards or
codes. The Contractor shall maintain, both at works and on site, adequately indexed
records of all welding , weld inspection and repairs which shall be available to the
Employer, together with facilities for viewing of X-ray photographs.

AZ URA EPC EMPLOYER'S REQUI REM ENTS Prepared by Parsons Brinckerhoff

09 Apri l 201 4 for Azura Power West Africa Ltd
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PARSONS AZURA EPC EMPLOYER'S

REQUIREMENTS
BRINCICERHOFF
The views taken by X-ray shall be to a procedure and resolution agreed with the
Employer and shall incorporate the appropriate image quality indicator.

Adequate safe storage facilities and appropriate safety regulations shall be provided
for gamma-ray units, if used .

4.11.7. Weld Repairs

Where repairs on major items of plant are found to be necessary by welding ,

dimensioned sketches of the excavated areas shall be prepared and the proposed
repair procedure submitted for approval by the Employer before any repair is
commenced. Under no circumstances shall the repair be commenced until its
approval has been obtained. The areas shall be subjected to a suitable non-
destructive test and on completion of the weld will again be non-destructively tested.
In the event that the repair requires all or any part of the item to be stress-relieved,
the non-destructive tests shall be repeated on any part deemed to have been affected
by the stress relief.

In the case of weld cracking, the Employer may require a full investigation to be made
of the cause of the cracking prior to any approval of repair procedures. The cost of all
such investigations and reports is to be wholly borne by the Contractor.

Only one attempt shall be made to repa ir any defective weld , after which it shall be
replaced if still found to be defective.

All costs associated with the repair or replacement of welds shall be borne by the
Contractor, for all welds repaired or replaced at the direction of the Employer when
such welds are found to be defective. All cost of weld repair or replacement
performed at the direction of the Employer for welds that were determined to be within
the appropriate code acceptance criteria will be to the Employer's account.

Weld repair of cast iron parts is not permitted under any circumstances.

4.11.8. Welding Electrodes and Consumables

Before any welding is commenced, the Contractor shall submit a list of all electrodes
and consumables to be used to the Employer for approval.

Electrodes and consumables shall comply with the agreed National and International
Standard and shall be suitable for the materials to be joined, the quality, size and type
of weld and the welding position.

In each case the appropriate agreed International and National standard and its
applicable material testing designation and proprietary brand name shall be given .

4.12. Pressure Vessels

All pressure vessels supplied under the Contract shall be designed , manufactured
and tested according to the relevant pressure vessel, air receiver and welding
standards and Codes unless otherwise agreed with the Employer. The individual
clauses of this Employer's Requirements may lay down additional requirements or
changes from particular Standards or Codes. The Specification of all materials used
and the particular choice of material shall take into account all possible conditions to
which the material will be subjected during manufacture, transport, erection and
operation.

AZ URA EPC EMPLOYER'S REQUIREMENT S Prepared by Parsons Brinckerhoff

~;;;14 - 66 -
for Azura Power West Africa Ltd

X- ~
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Header Page 22 of 154. Type of Document: TEC ZTO004-4711-MEC020-479962
No.:
D Index:
Issued by: E F ES EN MTEC PV
Effective as of: 2014-02-15
Title: Specification for Engineering, Procurement, and Construction of BOP Pipework According to
ASME

Proj. Code Contents Code UA or DCC Reg. No. UNID Document Number

ZTO004 4711 &MEC020 479 962 481 605 138 ZTO004-4711-MEC020-479962

SG No.: Pages: 116 Appendices:
Protection class:
For internal use only

Protection Class “For internal use only”: This specification shall only be distributed in the context of offers,
inquiries, or project execution to (potential) Clients of Siemens or to (potential) Contractors and their subcon-
tractors. To involved parties outside of Siemens AG, it shall be distributed only as confidential information.
After finalization of the inquiry or project execution, this specification shall not be used further. Importantly,
this specification must not be further distributed to others or uninvolved parties.

Annex "2.1.6.2_SCHEDULE 1 - EMPLOYER'S REQUIREMENTS 4.13.6-8-

Pipe" and
Annex "2.1.6.3_SCHEDULE 1 - EMPLOYER'S REQUIREMENTS 4.11
Welding" take precedence
over this specification for project NG1005 Azura Edo
D 2014-02-05 Fuel gas piping welded piping detailed; changes as marked (e.g. should - UT)
C 2014-01-24 Revision as marked (detailing the split of contract, traceability and scope NDT)
B 2012-07-09 Revision as marked, TCC-Document numbering updated
A 2011-12-01 Initial issue
Rev.- Date Changes
Index

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Reviewed Dr. Christoph Wehinger E P ES EN ERL PLMS-P Wehinger Christoph DN: serialNumber=Z0001M5Q, givenName=Christoph, sn=Wehinger,
o=Siemens, cn=Wehinger Christoph
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Reviewed Klaus Rührseitz E P ES EN ERL PLMS-P Ruehrseitz Klaus DN: serialNumber=Z0001LEF, givenName=Klaus, sn=Ruehrseitz, o=Siemens,
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Mueller Bernhard
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Prepared: Bernhard Müller E P ES EN PLMS PV

DN: serialNumber=Z002KWWJ, givenName=Bernhard, sn=Mueller, o=Siemens, cn=Mueller Bernhard
Grund: I have reviewed this document
Ort:Erlangen
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Name Org. Unit Signature Date

Also reviewed by: Reinhard Koch E P ES EC MEEC

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Content:

1 GENERAL............................................................................................................................................... 7
1.1 Definitions and Abbreviations .............................................................................................................. 7
1.2 Scope / Applicability / Purpose ............................................................................................................ 7
1.3 Language ............................................................................................................................................ 7

2 CODES AND STANDARDS .................................................................................................................... 7

2.1 General Definition ............................................................................................................................... 7
2.2 Pipework Code .................................................................................................................................... 8
2.2.1 Steel Pipework Code ASME B31.1 ................................................................................................. 8
2.2.2 Steel Gas Piping Codes .................................................................................................................. 8
2.2.3 Plastic Piping Code (Mainly PE) ...................................................................................................... 8
2.2.4 Double-Wall Piping Design Code .................................................................................................... 8
2.2.5 Plastic Piping Code (PVC) .............................................................................................................. 8
2.2.6 Plastic Piping Code (PVDF) ............................................................................................................ 9
2.2.7 GRP Design Codes ......................................................................................................................... 9
2.2.8 Further Standards ......................................................................................................................... 11
2.2.9 Regulations and Standards ........................................................................................................... 11
2.3 Materials of Piping Components ....................................................................................................... 11
2.3.1 Steel Piping: Main Material Design Code and Material-Related Procedures ................................. 11
2.3.2 Materials of Non-Steel Piping Standards ....................................................................................... 13
2.4 Materials of Pipe Supports, Hangers, Constraints (Restraints), and Secondary Steel ....................... 16
2.4.1 Support Materials for Steel Piping ................................................................................................. 16
2.4.2 Support Materials for Plastic Piping............................................................................................... 17
2.4.3 Materials for Secondary Steel: Code Definition ............................................................................. 18

3 GENERAL DESIGN CONDITIONS ....................................................................................................... 18

4 REQUIREMENTS FOR PIPING DESIGN ............................................................................................. 19

4.1 General Piping Design ...................................................................................................................... 19
4.2 Piping Design Input Data .................................................................................................................. 19
4.3 Piping Design Rules .......................................................................................................................... 19
4.3.1 General Design Rules ................................................................................................................... 19
4.3.2 Design Requirements concerning the Slope Requirements .......................................................... 20
4.3.3 Design Requirements concerning the Clearances and Minimum Distances .................................. 20
4.3.4 Design Requirements for M-System Piping ................................................................................... 21
4.3.5 Design Requirements for Piping at Pumps .................................................................................... 21
4.3.6 Design Requirements for Vents and Drains .................................................................................. 22
4.3.7 Design Requirements for Blow-Out Lines of Safety Valves ........................................................... 23
4.3.8 Design Requirements for the Fuel Gas Piping .............................................................................. 23
4.3.9 Design Requirements for the Yard and Underground Piping ......................................................... 23
4.3.10 Design Requirements for GRP Piping ........................................................................................... 24
4.3.11 Design Requirements for the Potable Water ................................................................................. 24
4.3.12 Design Requirements for the Galvanized Piping ........................................................................... 24
4.4 Calculations ...................................................................................................................................... 24
4.4.1 Strength Calculation / Stress Analysis ........................................................................................... 24
4.4.2 Other Calculations ......................................................................................................................... 25
4.5 Piping Component Design Requirements ......................................................................................... 26
4.5.1 Design Requirements for Pipes ..................................................................................................... 26
4.5.2 Design Requirements for Steel Bends .......................................................................................... 27
4.5.3 Design Requirements for Steel Elbows ......................................................................................... 28
4.5.4 Design Requirements for Steel Branch Connections inclusive T-Pieces, Pressure-, Temperature-,
and Level Measurement Nozzles .................................................................................................................. 28
4.5.5 Design Requirements for Reducers .............................................................................................. 30
4.5.6 Design Requirements for Steel Caps ............................................................................................ 30
4.5.7 Design Requirements for Connections such as Welds / Joints / Flanges ...................................... 30
4.6 Inline Components ............................................................................................................................ 34

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4.6.1 Design Requirements for Valves in Piping Systems ...................................................................... 34

4.6.2 Design Requirements for Throttle Plates ....................................................................................... 36
4.6.3 Design Requirements for Flow Orifices ......................................................................................... 36
4.6.4 Design Requirements for Strainers ............................................................................................... 36
4.6.5 Design Requirements for Flexible Hoses and Expansion Joints .................................................... 37
4.7 Wall and Roof Penetrations............................................................................................................... 38
4.8 Cathodic Protection ........................................................................................................................... 38
4.9 Design Requirements for Insulation (inclusive Heat Tracing / Personal Protection / Heat Loss) ....... 38
4.10 Design Requirements for Splash Guard for Control-, Lube-, and Lifting Oil Piping Systems ............. 38

5 REQUIREMENTS FOR PIPE SUPPORT DESIGN AND DESIGN OF SECONDARY STEEL .............. 39
5.1 General Requirements for Pipe Support Design ............................................................................... 39
5.1.1 General Use of Pipe Clamps and U-Bolts ..................................................................................... 40
5.1.2 Supports for Steel Double-Wall Piping .......................................................................................... 40
5.1.3 Supports for Plastic Piping (General Requirements) ..................................................................... 40
5.1.4 Rigid Rod Hangers ........................................................................................................................ 41
5.1.5 Variable Spring Hangers ............................................................................................................... 41
5.1.6 Constant (Spring) Hangers ............................................................................................................ 41
5.1.7 Snubbers ....................................................................................................................................... 41
5.1.8 Rigid Restraints (Axial Stop, Guide Supports, Rigid Struts)........................................................... 42
5.1.9 Fix Point Supports ......................................................................................................................... 42
5.2 Secondary Steel ................................................................................................................................ 42
5.2.1 Secondary Steel Connection to the Main Steel Structure .............................................................. 42
5.2.2 Secondary Steel Design Rules ...................................................................................................... 42

6 INSTRUMENTATION ........................................................................................................................... 42

7 SPECIAL EARTHING REQUIREMENTS .............................................................................................. 43

8 QUALITY ASSURANCE / QUALITY CONTROL (QA / QC) FOR STEEL PIPING ................................ 43
8.1 Quality Assurance / Quality Control (QA / QC) for Steel Piping, general items ................................. 43
8.2 Qualification of the Contractor / Fabricator / Prefabricator for Steel Piping........................................ 44
8.3 Qualification of Service Provider for the Heat Treatment ................................................................... 44
8.4 Welding - Personnel Qualification for Steel Piping ............................................................................ 44
8.5 Personnel Qualification for Testing / Examination – Steel ................................................................. 44
8.6 Inspection and Testing Organization for Steel Piping ........................................................................ 45
8.7 Non-Destructive Testing (NDT) ......................................................................................................... 45
8.7.1 Visual Examination for Steel Piping............................................................................................... 45
8.7.2 Surface Crack Testing for Steel Piping .......................................................................................... 45
8.7.3 Metascope or Ferritic Check for Steel Piping (PMI) ....................................................................... 46
8.7.4 Hardness Test for Steel Piping ...................................................................................................... 46
8.7.5 Ultrasonic Testing for Steel Piping ................................................................................................ 46
8.7.6 Radiographic Testing for Steel Piping ........................................................................................... 47
8.8 Details for Extent of Testing for Steel Piping ..................................................................................... 47
8.9 Acceptance Criteria for NDT and Test Method Procedures for Steel Piping...................................... 48
8.9.1 Acceptance Criteria / NDT Standards for Visual Examination of Welds (Steel Piping) .................. 49
8.9.2 Acceptance Criteria / NDT Standards for Surface Crack Testing for Steel Piping ......................... 49
8.9.3 Acceptance Criteria / NDT Standards for Metascope or Ferritic Check for Steel Piping ................ 49
8.9.4 Acceptance Criteria / NDT Standards for Hardness Testing for Steel Piping................................. 49
8.9.5 Acceptance Criteria / NDT Standards for Radiographic Testing for Steel Piping ........................... 49
8.9.6 Acceptance Criteria / NDT Standards for Ultrasonic Testing (Steel Piping) ................................... 49
8.10 General Requirements for Pressure Testing for Steel Piping ............................................................ 49
8.10.1 Details for Pneumatic Test for Steel Piping (if applicable) ............................................................. 50
8.10.2 Leak Testing of Lube Oil and Control Fluid System for Steel Piping.............................................. 50
8.10.3 Special Leak Testing of Gas Lines in M-System Piping ................................................................ 50
8.11 Quality Plans (Such as ITP / FQP) for Steel Piping Systems ............................................................ 50
8.12 Quality Release Note and Provisional Quality (Spool) Release Certificate........................................ 50

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9 QUALITY ASSURANCE / QUALITY CONTROL (QA / QC) FOR PLASTIC PIPING / GRP .................. 51
9.1 Qualification of the Contractor / Fabricator / Prefabricator for Plastic / GRP Piping........................... 51
9.2 Personnel Qualification for Plastic / GRP Piping ............................................................................... 51
9.2.1 Thermoplastic jointer qualification recommendation (or similar national standards) ...................... 51
9.2.2 GRP piping – welder and jointer qualification ................................................................................ 52
9.2.3 Welding Personnel - Qualification for Steel Supports in Plastic / GRP Piping Systems ................. 52
9.3 Personnel Qualification for Testing – Plastic and GRP...................................................................... 52
9.4 Non-Destructive Testing: NDT for Plastic and GRP Piping ............................................................... 52
9.4.1 Non-Destructive Testing: Specials for GRP Piping Systems ......................................................... 52
9.4.2 Non-Destructive Testing: Specials for Thermoplastic Piping Systems........................................... 53
9.4.3 Acceptance Criteria: Plastic and GRP Piping Systems ................................................................. 53
9.5 Quality Plans (Such as ITP / FQP) for Plastic and GRP Piping Systems .......................................... 53

10 REQUIREMENTS FOR FABRICATION AND ERECTION DOCUMENTS, DOCUMENT

MANAGEMENT, AND DATA EXCHANGE .................................................................................................. 53
10.1 General Requirements of Documents for Fabrication and Erection, Document Management, and
Data Exchange ............................................................................................................................................. 54
10.2 Documents / Design (3D-Model) for the Contractor of the Detail Engineering................................... 54
10.2.1 Basic Isometric Drawings for the Contractor-Detail Engineering ................................................... 55
10.2.2 Basic Dimensions for Special Parts as Input for the Contractor-Detail Engineering ...................... 55
10.2.3 Basic Pipe Supports as Input for the Contractor-Detail Engineering ............................................. 55
10.2.4 Engineering Documents for the Contractor-Detail Engineering ..................................................... 55
10.2.5 3D-Model as Input for the Contractor of the Detail Engineering .................................................... 55
10.3 Documents as Output from the Detail Engineering ........................................................................... 55
10.3.1 Fabrication- and Erection Documents from the Detail Engineering (e.g. EPC-Contracts) ............. 55
10.3.2 Documents as Input for the Contractor-Construction (for C-Contracts only) .................................. 56
10.3.3 Detailed Fabrication and Erection Isometric Drawings as Input for the Contractor ........................ 56
10.3.4 Requirements for Spooling Related to Isometric Drawings as Input for the Contractor ................. 56
10.3.5 Detail Dimension Drawings for Special Parts / Pipe Supports as Input for the Contractor ............. 56
10.3.6 Pipe Support Documents from the Detail Engineering .................................................................. 56
10.3.7 Detail Engineering MTO for Piping and Supports as Input for the Contractor ................................ 56
10.3.8 Detail Design - System Overview Sketch from the Detail Engineering as Input for the Contractor 57
10.3.9 Requirements for the Piping Detail Drawings for Buried Piping as Input for the Contractor ........... 57
10.3.10 “Quality” Related Documents as Input for Shop / Site Works ........................................................ 57
10.3.11 Erection Instructions as Input for Site Works ................................................................................. 57
10.3.12 Method statements and Risk Assessment as Input for Site Works................................................ 57
10.4 Documents for Prefabrication of the Contractor ................................................................................ 57
10.5 Documents for Erection Works of the Contractor .............................................................................. 58

11 MATERIAL PROCUREMENT BY THE CONTRACTOR ....................................................................... 58

11.1 Additional Materials (for welder skill testing and other Manufacturing Requirements) ....................... 58
11.2 Supplier Monitoring / Expediting........................................................................................................ 58

12 WELDING OF STEEL PIPING SYSTEMS ............................................................................................ 58

12.1 General Welding Requirements of Steel Piping Systems .................................................................. 58
12.2 Welding Procedures and Qualification for Steel Piping Systems ....................................................... 59
12.3 Welding Process and Technique for Steel Piping .............................................................................. 59
12.3.1 Detailed Process and Technical Requirements for Steel Piping .................................................... 59
12.3.2 Welding Consumables for Steel Piping ......................................................................................... 60
12.3.3 Heat Treatment for Steel Piping .................................................................................................... 61
12.3.4 Welding Map ................................................................................................................................. 62
12.3.5 Additional Requirements for Steel Welding Procedures within M-System Piping .......................... 63

13 PLASTIC PIPING INCLUSIVE GRP - WELDING, BONDING (GLUING), LAMINATION....................... 63
13.1 Jointing for GRP piping materials ...................................................................................................... 63
13.2 Jointing for thermoplastic piping materials ........................................................................................ 63
13.2.1 Welding / Gluing Procedures and Qualifications for Thermoplastic Piping Systems ...................... 64
13.2.2 Detail Welding / Gluing Process and Technical Requirements for Thermoplastic Piping............... 64

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13.2.3 Bonding (Gluing)/Lamination Procedures and Technical Requirements for GRP Piping ............... 64
13.2.4 Welding / Jointing Map for Plastic Piping Material ......................................................................... 65

14 PROGRESS REPORTING ................................................................................................................... 66

15 SHOP FABRICATION / PREFABRICATION / PRE-ASSEMBLY OF STEEL PIPING ........................... 66

15.1 Prefabrication Requirements ............................................................................................................. 66
15.2 Prefabrication Specialties .................................................................................................................. 67
15.2.1 General Requirements for Prefabrication of Steel Spools ............................................................. 67
15.2.2 Special Requirements for Shop-/Prefabrication of HP-, IP-, and LP-Piping Systems .................... 68
15.2.3 Special Requirements for Prefabrication of M-System Piping ....................................................... 69
15.3 Measures for avoiding Contamination / Defects during Prefabrication .............................................. 69
15.4 Requirements for Prefabrication of Supports / Delivery from shop .................................................... 69

16 SHOP FABRICATION / PREFABRICATION / PRE-ASSEMBLY OF PLASTIC PIPING ....................... 70

16.1 Requirements for Prefabrication of Spools in Plastic / GRP Piping Systems ..................................... 70
16.2 Forms and Documents for Prefabrication / Shop Fabrication of the Contractor ................................. 70
16.3 Non-Conformances in Prefabrication / Shop Fabrication................................................................... 70
16.4 Review and Approval of Documentation for Prefabrication ............................................................... 70

17 SURFACE CONDITION, CORROSION PROTECTION, COATING, RUBBER LINING ........................ 71
17.1 Surface Condition for Piping.............................................................................................................. 71
17.1.1 Painting Requirements for Contractor-Prefabrication (incl. Manufacturer, if applicable) ................ 71
17.1.2 Site Works for Corrosion Protection for Contractor-Site ................................................................ 72
17.2 Coating Requirements for Prefabricator ............................................................................................ 72
17.2.1 Epoxy Internal Coating for Cooling Water Pipework ...................................................................... 73
17.2.2 External Organic Coatings for the Corrosion Protection of Buried and Immersed Piping (PE) ...... 73
17.3 Rubber Lining.................................................................................................................................... 74

18 MATERIAL CERTIFICATION FOR PIPEWORK/MATERIAL TRACEABILITY/MARKING/LABELLING 74

18.1 Requirements for Material Certification for Pipework ........................................................................ 74
18.2 Material Traceability .......................................................................................................................... 74
18.3 Material Marking ............................................................................................................................... 74
18.3.1 Marking of Spools ......................................................................................................................... 74
18.3.2 Marking of Loose Piping (in Bundles) ............................................................................................ 75
18.3.3 Marking of Loose Parts ................................................................................................................. 75
18.4 Labelling ........................................................................................................................................... 75

19 PACKING AND TRANSPORT TO SITE................................................................................................ 76

19.1 Packing of Pipework Prior to Transportation to Site .......................................................................... 76
19.2 Transportation ................................................................................................................................... 76

20 SITE (AND CLOSE-TO-SITE) WORKS ................................................................................................ 76

20.1 Site Works - General Definitions ....................................................................................................... 76
20.2 Site Works - Detail Requirements ..................................................................................................... 77
20.3 Site Works - Works Prior to Starting of the Erection Works (Not a Comprehensive List) ................... 78
20.4 Site Works - Jointing by Providing a Tight Flange Connection .......................................................... 78
20.5 Further Site Works / Requirements ................................................................................................... 79
20.6 Pressure Testing of Piping on Site .................................................................................................... 79
20.7 Site Works - Plastic Piping - Specials for GRP Piping ....................................................................... 79
20.8 Site Works - Jointing by Welding / Bonding / Lamination on Site ...................................................... 79
20.9 Site Works - Non-Conformances to Site Erection Works for Steel and Plastic Piping ....................... 79

21 PIPE CLEANING AFTER ERECTION TO CONSIDER BY CONTRACTOR-SITE ................................ 80

21.1 Chemical Cleaning ............................................................................................................................ 80
21.2 Once-Through Flushing .................................................................................................................... 80
21.3 Oil-Flushing ....................................................................................................................................... 80
21.4 Steam Blowing .................................................................................................................................. 81

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21.5 Blow-Out with Air .............................................................................................................................. 81

21.6 Purging or Air-Blasting / Pig Cleaning (Pigging) ................................................................................ 81
21.6.1 Purging or Air-Blasting (After Fine Filter UEN01) .......................................................................... 81
21.6.2 Pigging (EK in Fuel Gas System) .................................................................................................. 81

22 DOCUMENTATION OF PIPEWORK .................................................................................................... 81

22.1 General Documentation Requirements for the Contractor................................................................. 81
22.2 Design Documentation (Contractor Detail Engineering) .................................................................... 82
22.3 Prefabrication Documentation (Partial Documentation of Prefabricator – Required by Split of Scope
Prefabrication and Erection) ......................................................................................................................... 82
22.4 Site Documentation of the Contractor (Documentation of Erection and Quality) ............................... 82
22.4.1 Implementation (End) Documentation of the Contractor ................................................................ 82
22.4.2 Quality Documentation of the Contractor....................................................................................... 83

23 REFERENCES ..................................................................................................................................... 84

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1 General
1.1 Definitions and Abbreviations
Terms used in this Specification shall have the meaning as defined in the General Conditions of Contract for
Supplies and Services (GCSS). Such definitions of terms may be supplemented or amended in the Special
Conditions of Contract for Supplies and Services (SCSS), and in the Contract Order. Further abbreviations,
definitions, and explanations, see “Abbreviations, terms, definitions, and explanations” in attachment [A1].

1.2 Scope / Applicability / Purpose

This specification covers the technical requirements for the engineering, procurement, and construction of
the BOP pipework for GTPP-, CCPP-, and SPP-projects in addition to the ‘Contract Order’.

Generally, this specification is part of or an attachment to a project-specific specification or a specification of

the Owner. Further details may be described in other technical contract conditions (TCC) or as attachments
to the Contract Order.

The project-specific adaptation of this specification may be done with a project-specific coversheet of the
specification of ASME BOP Pipework. Please refer to the indications given in Attachment Checklist for Adap-
tation of the Project-specific Specification for Design, Procurement and Prefabrication of BOP Steel Pipework
according to ASME [127].

In general, this specification is applicable for all ASME/ANSI/AWWA/API piping:

x Within the WSC of the project including all necessary parts needed for connection to the terminal point
(TP)
x Within auxiliary systems such as cooling water system, fuel oil system, fuel gas system, service air /-
water piping system, and above ground drainage system of the project
x Within the steam turbine, generator systems, and gas turbine up to the defined TP of the project
Reference for the interfaces is made to the project-specific TCC S2.1-01 “Handling of BoP Pipe Connections
at Transition Points” [107]. The TCC S2.1-01 shall be considered for the interfaces by the Contractor, if ap-
plicable.
This specification is not applicable for:
x All piping within the stationary fire protection systems (KKS: SG) of the project
x All piping within the ancillary systems such as the heating, venting, and air conditioning (HVAC) systems
(KKS: SA, SB) of the project
x All piping within the chilled water systems (KKS: QK) of the project

x All boiler and boiler external piping

1.3 Language
All documents, prepared by the Contractor, shall be in English. If documents are provided in more than one
language, one language must be English.

2 Codes and Standards

2.1 General Definition
All works carried out by the Contractor shall conform to the state of the art, best practice, to the applicable
codes and standards (latest edition, if not a dated version is referenced in the design code). This definition is
not limited to the following requirements listed in this document, in effect at date of contract award. The indi-
vidual clauses of this document may specify additional requirements from the particular codes or standards.

The Contractor may offer alternative works to defined works of this specification. These alternative works
shall comply with internationally recognized national codes or standards. However, upon request by Sie-

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mens, the Contractor shall be able to demonstrate to the satisfaction of Siemens that the alternative offered
works are equal or superior to the specified codes or standards. Requirements related to national regulations
shall be considered for all pipework.

2.2 Pipework Code

2.2.1 Steel Pipework Code ASME B31.1
The main code for design, fabrication, and testing of steel pipework is ASME B31.1 [1], latest edition and
herein referenced standards and code cases 182 and 183. Other codes such as other ASME codes (such as
ASME BPVC [1a], B31.3, B31.4, B31.8), ANSI, ASTM, API, AWWA, BS, DIN/EN/ISO, SAE may be used if
ASME B31.1 cannot cover the detailed task, if defined / agreed by Siemens.

2.2.2 Steel Gas Piping Codes

The main design code for gas systems is the ASME B31.1 design code, considering ASME material in use.
For fuel gas piping also API 1104 “Welding of pipelines…” shall be considered instead of ASME B31.1, if
confirmed by Siemens. Nevertheless the national regulations and laws are ruling as far as implemented into
national gas law / rules. Further standards / code of practice, and operation manuals shall be considered if
defined project-specifically.

For generator connected gas lines, the TE-Guidelines [108] shall be considered, referencing further regula-
tions, standards, and rules. National standards need project-specific check for applicability for the range of
the gas piping code.

2.2.3 Plastic Piping Code (Mainly PE)

The main code for plastic piping (PB, PE, PP) is the harmonized standard “EN ISO 15494 Plastics Piping
Systems for Industrial Applications – Polybutylene (PB), Polyethylene (PE), and Polypropylene (PP) - Speci-
fications for Components and the System - Metric Series”. Herein referenced national rules shall be consid-
ered. National rules may refer to national standards like the German DIN 8074, DIN 8075, DIN 8076, and for
PP, for example, the German DIN 8077 / DIN 8078). These standards may be used as far as applicable.

ASTM standards for polyethylene piping based on ASTM F714 and ASME B31.1 Appendix III rules (defined
mandatory) are possible, when provided with a suitable design calculation for the material, for approval by
Siemens.

2.2.4 Double-Wall Piping Design Code

For double-wall steel piping, the ASME B31.1 shall be applicable.

For double-wall plastic piping, the DVS 2210-2 [16] is defined as state of the art. This standard is applicable
additionally to the codes for the pipe and fittings.

For hazardous medium, special national requirements shall be considered.

2.2.5 Plastic Piping Code (PVC)

The main code for plastic piping (PVC) is the standard “EN ISO 15493 Plastics piping systems for industrial
applications - Acrylonitrile-butadiene-styrene (ABS), unplasticized poly(vinyl chloride) (PVC-U), and chlorin-
ated poly(vinyl chloride) (PVC-C) - Specifications for components and the system; Metric series”. National
rules may refer to national standards like the German DIN 8061, DIN 8062, DIN 8063, and DIN 16450.

PVC-U type shall be used as far as possible. Only if medium / parameters require more strength as possible
with standard PVC-U, then PVC-C is applicable (material recommendation of supplier to consider).
Further Design standards (as far as applicable) are needed for detail design of PVC-U such as EN ISO 1452
“Plastics piping systems for water supply, and for buried, and above-ground drainage, and sewerage under
pressure - Unplasticized poly(vinyl chloride) (PVC-U)” for below ground piping.
Further manufacturer standards or national standards such as DIN 8079 / DIN 8080 / DIN 16832 for PVC-C
may be defined suitable, if approved by Siemens.

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The availability of suitable type tests can be basis for the consideration of essential quality assurance. The
quality assurance shall be accompanied by suitable calculations of supplier for strength, deflection, and du-
rability of the concerned piping. Here manufacturer standards and experience shall be considered as manda-
tory including the support conceptual design.

For the design and erection of piping, the DVS 2204 [12], DVS 2210 [16], or other similar standards shall be
considered.

2.2.6 Plastic Piping Code (PVDF)

For PVDF-Piping, the EN ISO 10931 “Plastics piping systems for industrial applications – Polyvinylidene
fluoride (PVDF) - Specifications for components and the system” shall be considered. PVDF shall be used
where PE, PVC or other standard thermoplastic materials are not possible (due to medium, or medium con-
ditions (pressure / temperature parameters).

2.2.7 GRP Design Codes

One of the following design codes shall be considered as far as applicable, including referenced standards.
For lacking contents for the main design codes such as mentioned below, further design codes or standards
shall be used. The Contractor may offer alternative works to the defined works of this specification. These
alternative works shall comply with internationally recognized national codes or standards. However, upon
request by Siemens, the Contractor shall be able to demonstrate to the satisfaction of Siemens that the al-
ternative offered works are equal or superior to the specified codes or standards. Generally the requirements
related to national regulations shall be considered for all pipework.
x EN 14364 (ISO 10467) “Plastics piping systems for drainage, and sewerage with, or without pressure –
Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP) – Specifica-
tions for pipes, fittings, and joints” is aimed for piping up to DN 3000 / 120”. Adaptation for the VE mate-
rial is not defined, but VE material requirements shall be considered as covered. For joining technique,
this standard defines a mandatory procedure qualification. For above ground piping with smaller siz-
es (< DN 1000 / 40”), this standard is defined as a second choice (in comparison to EN ISO 14692).
EN 14364 defines some dimensions for products, which not all industrial manufacturers use for their
pipework. Many manufacturers follow own internal standards. For buried cooling water piping, this
standard is defined as first choice. For above ground piping, further standards and calculations are re-
quired such as stability calculations. Qualification programs according to this standard are intended and
shall provide all design input data for respective detail engineering for the project-specific scope of appli-
cation. Relevant items for above ground piping, missing in EN 14364, shall be covered by using, as a
minimum, recognized formula (sound engineering or proven work standards given by the manufacturer),
preferred from standards such as EN ISO 14692 (e.g. for stability calculations). The design standard
AWWA M45 (2nd. Edition) together with AWWA C950 (similar to EN 14364) can be considered as fur-
ther solution, as far as applicable and furnished by evidence, for approval of Siemens.
x EN 13121 Part 1 to 4 “GRP tanks and vessels for use above ground” is defined as further choice. This
standard can also be accepted for short large piping with many connections, if adapted to the piping
needs and if confirmed by Siemens. EN13121 is intended to standardize pressure vessels, but is appli-
cable for all special and customized constructions or components made from GRP. This standard is
much weaker concerning the complete piping needs and scope of application. Main lacking contents for
sufficient compliance to the requirements: Standardized qualification tests of components, regression
analysis, type tests and stiffness tests. Fit for purpose estimation by single statements of an expert, de-
tail calculations, and stress analyses are therefore necessary. Result: Non-standardized special con-
structions shall be considered, verified by single expert documentation.
x EN ISO 14692 ““Petroleum and natural gas industries – Glass-reinforced plastics (GRP) piping - Part 1
to 4” is the most applicable complete standard for the (Epoxy-), Vinylester- (VE) or unsaturated polyes-
ter-resin based pressure GRP piping material mainly above ground up to approximate DN 1000 / 40”.
This standard needs project-specific adaptation for power plant piping, especially for buried piping, sizes
>DN1000 / 40” and need for water piping, and further detail engineering, stress calculation, construction,
erection, because these items are not included. Each joint type is defined as a component of the system,
and need qualification (according to ISO 14692-2 Point 6, and following chapters). This standard is cen-
tred on performance of its quality properties, based on type tests, and conformity assessment (verifica-

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tion of project-related product {for all inline components} to an existing type test for the scope of applica-
tion). The standard is also detailing the accompaniment of production (tests), related to results of type
tests. Further Standards, for example BS Standards (BS 7159 and BS 6464 or manufacturing stand-
ards), are additionally needed as far as they are not conflicting the EN ISO 14692. These standards de-
fine further necessary requirements, especially for buried piping (not included in this standard).

Mainly dimensioning Standards such as DIN 16965 or DIN 16966 T1 to T8) are only acceptable, if approved
project-specifically by Siemens. Further DIN standards are acceptable, if all mandatory necessary require-
ments are included (see for example EN 14364 plus adaptation). BS standards shall not be considered for
buried piping installation.
For buried piping, bi-axial restraint couplings or an approved key-locking system are allowed. Non-buried
sand-filled pipes are allowed outside building by Siemens, if all pipe joints are full laminated (without any key-
locked bell-spigot connections or similar connections) and their calculation is provided to Siemens for ap-
proval. Project-specifically this restriction may be cancelled, when confirmed by Siemens, when supplier
provides sufficient safety considerations (based on chosen standards) and measures. This calculation shall
consider the requirements of chapter 4.4 “Calculations” of this specification. Deviations are allowed if con-
firmed by Siemens project-specifically within an assessment for applicability, considering the detail require-
ments (location, scope of application, climatic conditions).

For below ground piping, the GRP cooling water pipes shall be generally provided with a stiffness class SN
of minimum 5000N/m². Higher SN shall be provided, if requested according to structural calculation or re-
quired by Siemens project-specifically.

Main influence for the quality of GRP piping:

x Primary and secondary load (external and internal loads are included)
x Vacuum
x Fix point loads (thrust block are not allowed)
x Angle point load
x Hydraulic analysis / calculations / mass flow / parameters
x Chemical resistance
x Soil report
x Qualification of engineering
x Manufacturing
x Construction / erection and testing
x Achieved stiffness
x Avoidance of interaction of piping close to each other

The necessary quality can be defined suitable if type-tests are available as basic qualification (ruling as ref-
erence to any quality assurance in the sense of conformity declaration). By following the standards, adapted
to the needs (suitable scope of qualification and testing / surveillance), the extended experience of manufac-
turer shall be used. Type-tests (according to the before mentioned standards of this chapter) are necessary,
if required by project-specific design. Further type-tests are required for special piping components. For pip-
ing, for example, on pipe bridges, river crossing, special building wall penetrations, and areas of settlement,
type-tests shall be considered.

Generally project-specific and adequate process qualification shall be used, where the manufacturer- and
personnel qualification, the methods and procedures are assessed.

For hydrostatic pressure testing for evidence of tightness and verification of the design and installation of the
pipework, a detailed pressure test procedure shall be provided for the GRP piping.

For buried piping, worksheet ATV-A127 [29], based on DIN EN 1295-1 and EN1610, inclusive stress analy-
sis shall be considered, as far as applicable and furnished by evidence.

Other national codes have to be considered, if confirmed by Siemens. If United Kingdom (BS) Standards, or
old DIN standards are used (generally for approval of Siemens), the misuse and mixing of multiple standards

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may contain incompatible approaches -> conflicts. Equivalently defined codes (for example ASTM D 2996
and all herein referenced standards, providing suitable safety and lifetime) can be accepted, if approved by
Siemens. The corresponding operations during pipe-laying and installation shall be conducted in accordance
with the acknowledged rules of technology and the guidelines of the manufacturer. Skilled site-supervision
and skilled working staff shall be considered. The ITP [116] (for GRP piping) and FQP [116] need the ap-
proval by Siemens. The check of local project situation shall be considered by the Contractor before an of-
fer/bid for pipework. BS or DIN standards are suitable in particular cases, if good approaches for single certif-
icate of special parts are needed, for approval of Siemens. Special parts shall be based on a safety concept
and not only on standard type test data.

For Fittings: If requalification is needed, the EN1796 shall be considered. For example, a bend test of key-
locked bell-spigot or similar connection shall be considered for buried piping as per EN 1119 inclusive pres-
sure and tightness verification.

2.2.8 Further Standards

For the M-System Piping [A1], special requirements shall be considered. These requirements are specified in
the “Siemens Rules and Standards, Documents” (see chapter 23 of this specification) and all herein refer-
enced standards.

2.2.9 Regulations and Standards

For the piping with possible hazards to environment, water pollution, and/or waste discharge, the national
legislation, local regulatory requirements and respective standards have to be evaluated for the applicability
project-specifically (examples for national legislation: Prevention and Control of Water Pollution Act / Water
Pollution (Prevention) Control Act / Law, Clean Water Act (CWA) / WHG / WRG).EHS is related to national
laws, rules, and regulations: The project-specific TCCs shall be followed, such as:

x TCC 3-13 “Environmental requirements for Products to be supplied to Siemens” [107], if applicable
x TCC 3-12 “Environmental, Health and Safety Manual” [107], if applicable

2.3 Materials of Piping Components

The materials shall be supplied in accordance with the following standards (not a comprehensive list) and
Codes. Further the piping data sheets and material specifications of Siemens shall be considered. The mate-
rial to be delivered shall include the additional material necessary for manufacturing the piping, supports, and
secondary steel.

2.3.1 Steel Piping: Main Material Design Code and Material-Related Procedures
For metallic piping the ASME B31.1 “Power Piping” is defined as the main code for materials, with possible
exception for gas piping materials.

For material standards used by Siemens (as approved material for main piping parts), the listed standards of
this specification shall be considered (excluding the inline components). For inline components and valves,
the corresponding component data sheets [112] and MTO [103] shall be considered.

The materials are defined for each design section in the associated PMC [A1]. The materials are specified in
detail in the material specification [111] and in the material test sheets attached to it. The requirements for
the prevention of brittle fracture have been taken into account for the materials, if project-specifically defined.
Special material certificates may be required for special medium such as fuel gas or potable water due to
national requirements.

For the special material requirements of Siemens (CSEF [A1]), the following document shall be considered:
x ZTO004-4711-MEC020-479994 [111] (for Grade 91, Grade 92, Grade C12A and dissimilar material con-
nections to these materials)

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2.3.1.1 General Steel Pipe Materials

ASME B31.1 materials and herein referenced dated standards shall be used as defined in PMC [A1]

2.3.1.2 Steel Fuel Gas Piping Materials

x ASME B31.1 materials
All national fuel gas standards shall be checked project-specifically, whether they are applicable.

2.3.1.3 Material of Steel Forgings, Steel Fittings, Steel Flanges for ASME/AWWA Piping
ASME B31.1 materials and herein referenced dated standards shall be used as defined in PMC [A1]

ASME B16.11 “Forged steel fittings, socket welding and threaded” (allowed for carbon steel piping with pres-
sure class 150 or pressure class 300 only, with maximum allowable design temperature of 300°C in general,
for sockolets a restriction of sockolet size <=2” shall be considered additionally. For generator internal piping
(such as MK), only butt welds are allowed (no socket welds are allowed, see TE Guideline 06.0-050-102).
For M-System piping, the STIMs [109] such as STIM 03.002 picture 1 shall be considered. Deviations need
the written approval by Siemens.

2.3.1.4 Materials of Press Fittings and Tube- / Tube Adaptor Fittings for ASME- / EN piping
For press fittings and tube- / tube adaptor fittings following materials shall be used:
x Swage nipples with minimum material grade equivalent to the pipe material according to MSS SP-95
< ½“ / connecting smaller piping to ½” ASME piping
x welding- and male connectors with minimum material grade 1.4571 / 316Ti (or equivalent ASTM materi-
al) (for example, company Avit)
x press fittings with material grade 1.4401 / 304L (for example, Mapress ® fittings, company Geberit) in
GKB/SCB/QFB-Systems if approved by Siemens
x press fittings with minimum material grade 304L (for example, Vicpress ® fittings, company ) in
GKB/SCB/QFB-Systems if approved by Siemens
x compression fittings 316SS (for example, “gaugeable tube fittings and adapter fittings”, company
Swagelok)
Cutting ring connections such as Ermeto ® cutting ring fittings or fittings according to DIN 2353 or similar are
not allowed.

2.3.1.5 Non-ASME/AWWA Materials of Steel Flanges if applicable

x ISO 6164 “Hydraulic fluid power - four screw, one-piece square-flange connections for use at pressures
of 25 MPa and 40 MPa (250 bar and 400 bar)”, if applicable
x ISO 6162 (SAE J518) “Hydraulic fluid power - Flange connectors with split or one-piece flange clamps
and metric or inch screws - Part 1: Flange connectors for use at pressures of 3,5 MPa (35 bar) to
35 MPa (350 bar)”, DN 13 to DN 127 special Code 61 for 3000-lbs and Code 62 for 6000-lbs pressure
rating, if applicable

x ISO 6162 “Hydraulic fluid power - Flange connectors with split or one-piece flange clamps and metric or
inch screws - Part 2: Flange connectors, ports and mounting surfaces for use at a pressure of 42 MPa
(420 bar), DN 13 to DN 76, if applicable

2.3.1.6 Bolting Material (related to steel piping)

ASME B31.1 is relevant for the bolting. For dimensional standards the chapter 4.5.7.4.1 ”Design Require-
ments for Bolting and Gaskets concerning the Dimensioning Standards” of this specification shall be consid-
ered.

x For M-System Piping [A1] (Lift-, lube-, control-oil piping): Nord-Lock ® locking devices (see
http://www.nordlock.com)

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x Following temperature / service limits are applicable for Nord-Lock ® locking devices:
¾ For design temperature <150°C:
Carbon steel (1.7182), chromate free zinc flake bonded pair of Nord-Lock ® locking washer
¾ For design temperature >150°C up to 555°C (screw temperature) and short time usage up to 595°C:
Stainless steel (1.4404), bonded pair of Nord-Lock ® locking washer

DIN 910 “Plug screw for pressure/temperature nozzle connection”

If in special cases the bolting is defined with hot dip galvanized (for example for seawater medium if re-
quired), the threading of nuts shall be adapted to the needs by the Contractor to avoid jamming if required.
2.3.1.7 Gasket Standards and Materials (Related to Steel Piping):
Generally, only asbestos free gaskets shall be used.
In the control fluid system MAX and lifting oil MAV / MBV, fluoropolymer elastomeric (FPM according to
ISO 1629) synthetic rubber seals (such as VITON) according to ISO 3601 (ISO 868, 70+5 Shore A) are re-
quired.

In the lube oil / oil vapour system MAV / MBV and waste gas system (MK), “metal-to-metal contact gaskets”
with fluoropolymer elastomer synthetic rubber seals shall be used, if applicable (FPM according to ISO 1629
shall be used, such as Viton). For example, Kempchen WN178: WL-type is suitable.

Weld ring gaskets such as Kempchen-WN134, Type A22N inclusive graphite covered layer grooved metal
gasket, Stainless steel/graphite, type B27A shall be used for flange connections in HP steam piping systems.

For potable water, oil, and gas systems the material of gasket shall be suitable for the medium, tightness,
and hygienic requirements considering national requirements for certification, if applicable.

For epoxy and rubber lined piping systems ASME/ASTM/AWWA:

x ASME <=24”: Flat ring gasket type WG, CL150, EPDM/Steel, ASME-B16.21 for AWWA C207-D, flat face
flanges
x AWWA >24”: Flat ring gasket type WL, 150PSI, EPDM/Steel, ASME-B16.21 for AWWA C207-D, flat face
flanges

DIN 7603-A “Sealing rings for compression fittings” (for DIN 910 “Plug screws, material approval by Sie-
mens)

2.3.1.8 Material of Measurement Equipment (related to Steel Piping)

DIN 43772 “Control technology - Protective tubes and extension tubes for liquid-in-glass thermometers, dial
thermometers, thermocouples, and resistance thermometers - Dimensions, materials, testing”

For devices of fluid flow gauging (according to drawing similar to DIN 19211), the material requirements de-
fined on the corresponding drawing and this specification shall be considered (for the bypass deaerator sys-
tem, for example).

2.3.1.9 Materials of Not Yet Mentioned Steel Piping Standards

The use of materials which are not included in the above mentioned list may be permitted upon a written
agreement between Siemens and the Contractor.

2.3.2 Materials of Non-Steel Piping Standards

2.3.2.1 Materials of Plastic Piping
For plastic piping material requirements, the following listed standards are applicable. Additionally, the chap-
ter 2.2.3 to 2.2.7 of this specification are applicable. For inline components and valves, see corresponding
component data sheets [112] and MTO [103].

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2.3.2.2 Materials of Plastic or loose Steel Flanges with Stub Ends

x ASME B16.5 “Pipe Flanges & Flanged Fittings” or EN 1092-1 “Flanges and their joints - Circular flanges
for pipes, valves, fittings, and accessories Part 1: Steel flanges, PN designated”
Here the borehole design is applicable for plastic flanges only. Flanges shall be suitable for stub ends, if
used. Manufacturer recommendations of stub ends shall be followed.
x For the flange design, following standards shall be considered:
¾ “DIN 16872 Pipe joints assemblies for pipelines (piping) of thermoplastics; glass fibre reinforced poly-
ester resin (UP-GF) flanges”
Or
¾ “ASTM D4024 Standard Specification for Machine Made ‘Fiberglass’ (Glass-Fiber-Reinforced Ther-
mosetting Resin) Flanges”
Or
¾ “ASTM D5421 Standard Specification for Contact Molded Fiberglass (Glass-Fiber-Reinforced Ther-
mosetting Resin) Flanges”
Or
¾ Other standards which ever are best suitable, for approval by Siemens.

2.3.2.3 Materials of Bolting for Plastic Piping

ASME / AWWA flange bore-hole design is defined as Siemens standard for plastic piping.
The bolting shall be hot dip galvanized, if used for piping with seawater medium. The threading of nuts shall
be adapted to the needs by the Contractor to avoid jamming if required.
Stud bolts ASME / AWWA (design to ASME-B16.5/B18.2.1), to be used for GRP piping: Exception, for lug
type butterfly valves, machine bolts shall be used.
ASTM A193-B7, hot dip galv., for example, if used in marine conditions
ASTM A193 Gr.B8M CL.1, if confirmed by Siemens

Bolts / screws DIN/EN, to be used for thermoplastic piping with DIN/EN flanges:
x EN ISO 898-1 “Mechanical properties of fasteners made of carbon steel and alloy steel - Part 1: Bolts,
screws, and studs with specified property classes - Coarse thread and fine pitch thread”
x DIN 267-13 “Fasteners - Technical specifications - Part 13: Parts for bolted connections with specific
mechanical properties for use at temperatures ranging from -200°C to +700°C” (overview)
x EN ISO 3506-1 “Mechanical properties of corrosion-resistant stainless steel fasteners – Part 1: Bolts,
screws, and studs”
x EN 10272 “Stainless steel bars for pressure purposes” (additional materials for bolting)

Nuts:
For ASME / AWWA: nuts, to be used for plastic piping:
Heavy hex head nut, A194-Gr.2H, ASME-B18.2.2, hot dip galv. if used in marine conditions
Heavy hex head nut, A194 Gr.8M, ASME-B18.2.2, if stainless steel is defined.
For DIN/EN nuts, to be used for thermoplastic piping with DIN/EN flanges:
x EN 20898-2 “Mechanical properties of fasteners; part 2: Nuts with specified proof load values; coarse
thread”
x EN 10269 “Steels and nickel alloys for fasteners with specified elevated and/or low temperature proper-
ties”
x EN ISO 3506-2 “Mechanical properties of corrosion-resistant stainless steel fasteners, part 2: Nuts”

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Washers:
Washers ASME / AWWA (next to EN ISO 7090), to be used for plastic piping:
Plain washer, ANSI B18.22.1, Table 1A, wide series, carbon steel, stainless steel for stainless steel piping,
hot dip galv. if used in marine condition
For EN Washers, to be used for thermoplastic piping with DIN/EN flanges:
EN ISO 7090 “Plain washers, chamfered - Normal series, Product grade A”, hot dip galv.

Note: Generally for material selection of washers, suitable material combination shall be considered to avoid
corrosion.

2.3.2.4 Gaskets Standards and Materials (related to plastic piping):

Only asbestos free gaskets shall be used. The ASME / AWWA flange borehole design is defined as Siemens
standard for plastic piping.
Gaskets for ASME/ASTM/AWWA flange connections:
x ASME <26”: Flat ring gasket type (rubber steel, steel ring surrounded on all sides by EPDM rubber) WG,
CL150, EPDM/Steel, ASME-B16.21 for AWWA C207-D, flat face flanges
x AWWA > 26”: Flat ring gasket type (rubber steel, main load gasket) WS, 150PSI, EPDM/Steel, ASME-
B16.21 for AWWA C207-D, flat face flanges
Gaskets in case of DIN/EN flange connections:
x EN 1514 “Flanges and their joints - Dimensions of gaskets for PN-designated flanges
Part 1: Non-metallic flat gaskets with or without inserts”
x EN 1514 “Flanges and their joints - Dimensions of gaskets for PN-designated flanges
Part 8: Polymeric O-Ring gaskets for grooved flanges”
x Manufacturer standards, for example, Kempchen
x The medium transported in the piping systems shall be considered for the gasket material selection
(EPDM lifetime durability). 70 + 5 Shore A hardness (ISO 868) shall be considered for the rubber-steel
gaskets made from EPDM.
x For flange sizes <DN650 / 26”, a rubber-steel gasket (steel ring surrounded on all sides by EPDM rub-
ber, for example, Kempchen WG-type)
For flange sizes >=DN1200 / 48”, “main load gasket” (EPDM rubber-steel gaskets, for example, Kemp-
chen WS-type WN182 suitable to cooling water GRP flange dimensions

x DIN 3771-3 Fluid systems; O-rings; materials, field of application (elastomer gaskets)
(for example, used for valves and screwed fittings in PVC piping systems), if applicable
2.3.2.5 Thermoplastic Piping Material (PE, mainly)
For thermoplastic piping material (PE, mainly), see chapter 2.2.3 of this specification: PE100 (HDPE) is de-
fined as the main polyethylene piping material. Other materials are possible after approval by Siemens. The
test pressure and vacuum (if applicable) shall be considered for the selection of wall thickness of piping. The
standard wall thickness of PE100 (HDPE) is defined with SDR11 for design pressure <=16 bar and maxi-
mum 20°C (by safety factor 1.25 for water). The PE material shall be suitably protected against sunlight (in-
hibitors and stabilisers or pigmented with substances that screen out or block UV-rays).

2.3.2.6 Thermoplastic Piping Material (PVC)

For plastic piping material (PVC), see chapter 2.2.5 of this specification: PVC-U is the main PVC material to
use. Suitability of defined material shall be approved by manufacturer for the specific situation. The test
pressure and Vacuum (if applicable) shall be considered for the selection of wall thickness of piping. For
thermoplastic piping, PVC-U shall be used as piping material, if PE is not possible (due to the medium). Only
if medium / parameters require more strength than possible with standard PVC-U, then PVC-C is applicable
(material recommendation of supplier to consider). National requirements shall be considered (in some coun-

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tries PVC is not allowed). The standard wall thickness of PVC is defined with SDR13.6 for design pressure
<=16 bar and maximum 20°C.

2.3.2.7 Thermoplastic Piping Material (PVDF)

For plastic piping material (PVDF), see chapter 2.2.6 of this specification: PVDF may be used where PVC-U
is not possible. Suitability of defined material shall be approved by manufacturer. The test pressure and vac-
uum (if applicable) shall be considered for the selection of wall thickness of piping.

2.3.2.8 Double-Wall Thermoplastic Piping Materials

The material of the inner piping is related to the liquid medium, considering the parameters and lifetime of the
piping system. Mainly PE100 or PVC shall be used, see further requirements in chapter 2.2.3 and 2.2.5.

The material of the outer piping is also related to the location and lifetime to ensure that in case of a leakage
of the inner piping the medium shall never reach the environment. DVS 2204 [12], and DVS 2010 Part2 [16],
or other similar international / national Standards / manufacturer standards have to be considered. A further
leakage control system if required and its type shall be defined project-specifically.

2.3.2.9 GRP Piping Material

GRP piping installed outdoor (which means: Exposed to solar radiation) shall be UV resistant.

The material at the internal surface of the GRP pipes shall consider the quality of the fluid. The GRP-
Contractor shall request the relevant water analysis from Siemens. A corrosion resistant inner liner shall
have least a thickness of 1 mm for main cooling- and 0,5 mm thickness for auxiliary cooling water systems.
The exterior layer shall be 0,3mm at least. GRP pipes shall be machine-made, which consist of a liner, a
structural wall, and a resin rich exterior layer. The design lifetime of the GRP piping shall be minimum
25 years.

For (earth) buried pipes SLW 60 shall be considered in general, considering also the results of the stress
analysis. For pipes > 40”, a stability calculation shall be provided by the Contractor to Siemens.

For further recommendations, see chapter 2.2.7 of this specification

For branch joint connection (bonding / lamination / collar / fix flange), considering Siemens standard, see
chapter 4.5.7.4.3 “Design Requirements for Flange Connections / Couplings in GRP Piping” of this specifica-
tion.
2.3.2.10 Rubber Lined and Epoxy Coated Piping Material
For rubber lined and epoxy coated piping requirements, see chapter 17 ”Surface Condition, Corrosion Pro-
tection, Coating, Rubber Lining” of this specification.

2.4 Materials of Pipe Supports, Hangers, Constraints (Restraints), and Secondary Steel
Pipe supports and secondary steel shall be designed and fabricated in accordance with the following codes
and standards (not a comprehensive list).

2.4.1 Support Materials for Steel Piping

Following regulations, design codes, standards and Siemens rules shall be considered for the support mate-
rials for steel piping:

ASME B31.1 Power Piping

AISC Manual of Steel Construction
MSS-SP-58 Pipe Hangers and Supports Materials, Design and Manufacture
MSS-SP-69 Pipe Hangers and Supports Selection and Application
AWS D1.1 Code for Welding in Building Construction
ASTM Material Specifications
e.g. DIN/EN National/European standards if approved by Siemens

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For alloy piping, the pipe clamps shall be designed with suitable alloy material. For stainless steel piping, the
pipe clamps shall be designed with ferritic material with separating layers of austenitic sheet metal.
By Siemens approved manufacturer standards, for example: LISEGA, STAUFF, GERB.
Replicas of such standards need type approval and need to be confirmed by Siemens.
For lubrication-/ lifting oil of non-insulated M-System Piping [A1] and MK-System (according to TE-Guideline)
<=2 ½”: “DIN 3015-2 Fastening clamps - Block clamps” shall be used. For example, “heavy-duty Stauff
clamps” by Stauffenberg/D-58791/Werdohl - type SPAL / Material Polyamid-A3Z or equivalent.
>2 ½”: “DIN 3567 Pipe Clamps” shall be used.

Special STAUFF heavy duty clamps for “Press fittings” (Material Polyamid-A3Z or equivalent) or equivalent
clamps, shall be used for press fitting piping in GKB/SCB/QFB-Systems according to the applicable project-
specific support catalogue / MTO. For insulated QU-Systems special STAUFF heavy duty clamps (Material
Aluminium) or equivalent clamps shall be used.
2.4.2 Support Materials for Plastic Piping
2.4.2.1 Support Materials for Thermoplastic Piping
Common practice for thermoplastic piping supports is to use suitable carbon steel supports (minimum mate-
rial quality: S235JR according to EN 10025) such as provided by Lisega or Hesterberg. The plastic piping
Contractor shall consider the detail requirements mentioned in chapter 5.1.3 “Supports for Plastic Piping
(General Requirements)” of this specification.

Special support types may be used instead of steel supports, if project-specific required. They shall be con-
firmed for the specific situation by manufacturer, for example, support system “KLIP-IT” (GF)

Material requirement of supports for outdoor location:

x Carbon steel (S235JR minimum according to EN 10025)
Or
x PE100
Or
x Black polypropylene supports, reinforced by GRP, is defined as minimum material quality of clamping
body, and for pipe clamp, PVC as material for the locking clip.

For extreme atmosphere / UV-Exposure, PVC clamp body may be suitable.

2.4.2.2 Support Material for Double-Wall Thermoplastic Piping

For supports of double-wall piping, the supplier recommended supporting systems available shall be consid-
ered, if defined applicable by Siemens. Supporting systems, such as Akatherm-Plus ((Aliaxis group) or KLIP-
IT (“contain-it Plus” double-wall piping system produced by Georg Fischer)), are suitable for double-wall pip-
ing. Polyethylene for indoor and PVC-U for outdoor location shall be considered for the plastic supports. For
piping exposed to marine conditions or heavy UV-exposure, the PVC-C is recommended by Siemens. Note:
The KLIP-IT supports are not allowed for axial stops or fix points.

2.4.2.3 Support Materials for GRP Piping

x The support material for GRP piping shall consider the materials mentioned in chapter 2.3.1 “Steel Pip-
ing: Main Material Design Code and Material-Related Procedures” of this specification
Or
x Supports shall be designed with material S235JR minimum according to EN 10025 or ASTM A36 or
similar code, which shall be defined project-specifically.

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By Siemens approved manufacturer standards, for example: LISEGA, STAUFF, GERB, and SIKLA. Replicas
of such standards needs type approval and needs to be confirmed by Siemens.

2.4.3 Materials for Secondary Steel: Code Definition

Generally the material defined in chapter 2.4.1”Support Materials for Steel Piping” of this specification is
applicable. Project-specifically this may be changed to national, European-, International- or manufacturer
standards such as:

x Eurocode 3 by means of EN 1993 - structural steel inclusive national attachments (location of plant to
consider) and related EN 1090-1/-2 “Execution of steel structures…”
x AISC “Manual of Steel Construction”
x The selection of Eurocode 3 shall be defined project-specifically.
x Further by Siemens approved manufacturer standards, for example, Hilti, Bernecker, Sikla.

3 General Design Conditions

All steel piping systems, components, and related equipment shall be designed for a 25 years (200 000 h)
service lifetime / for a minimum of 25 years lifetime (for plastic/GRP piping).

Parts subject to regular “wear and tear” like gaskets, flexible hoses, and elastomeric compensators are ex-
cluded from this requirement. Here datasheets, if applicable, shall be asked for and be followed. Furthermore
all expected and potential maintenance cases caused by regular component service, piping, or component
permitted operating period- or periodic operational surveillance shall be considered.

All piping systems shall be designed to operate under consideration of the load cases and medium tempera-
ture and following conditions (not a comprehensive list): (The project-specific data and values are defined in
the contract by Siemens)

x Ambient outdoor temperature

x Ambient indoor temperature
x Rainfall per day
x Wind speed
x Frost line (applicable for heat tracing)
x Seismic requirements
x Composition and condition of the medium for example in raw water, and cooling water (seawater/river
water, corrosives, chemicals), and atmospheric conditions (saline atmosphere, for example). The water
analysis shall be considered.
x Snow load, if defined applicable
x Humidity
x Location (for example: outside- and inside building, elevation, pipe rack)
x Soil report (plastic/GRP piping), if defined applicable
x Vibration
x Load-free connection (floating) of main steam pipes (turbine connections ) and load-free connections to
feed water and deaerator and recirculation pumps
x Blow out / flushing / chemical cleaning where applicable
x Sandstorm (if defined applicable)

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4 Requirements for Piping Design

4.1 General Piping Design
The following requirements shall be considered in the design and the routing of the piping systems by the
Contractor. Any non-conformance of the Contractor permits Siemens to reject the Contractors works unless
the Contractor can prove that the deviating works are at least equal or superior to the specifications and
standards. In addition to the specifications and standards, the “sound engineering practice” (accumulated by
the experience of the Contractor) shall be considered applicable upon a written agreement between Siemens
and the Contractor (if deviating to codes and standards). The Contractor shall provide such deviations in
tender phase only, if Siemens will receive an advantage in comparison to the specified standard. Best prac-
tice and State of the Art (for example, modularization as base input) shall be considered applicable.

4.2 Piping Design Input Data

The piping design input data (such as nominal pipe sizes, design parameters (pressure and temperature),
insulation thickness, branch connections, instrument connections, valves, terminal points, and limits of sup-
ply) are defined in the respective P&ID of the system, in the corresponding piping list, and “Checklist Scope
and Limits of supply and services for piping” [102].

The detail designer has to check all data for plausibility and has to inform the responsible party for any devia-
tion / deficiency of relevance.

4.3 Piping Design Rules

Based on the project-specific process- and operational requirements the Contractor has to design a piping
system which fulfils all related technical standards and safety regulations in the most economical way. This
approach shall be fulfilled for individual fabrication isometric drawings inclusive piping spools as well as for
the complete set of piping systems of the plant.

All relevant basic standards for design works are defined under chapter 2 “Codes and Standards” of this
specification. The following chapters determine the minimum requirements of Siemens concerning specific
design rules and tasks of piping systems including detail design standards.

4.3.1 General Design Rules

Piping material and wall thickness shall be designed in accordance with the applicable piping code for the
maximum service conditions.

The following pressure ratings shall be applicable as a guideline (not a comprehensive list):
x Class 900 and above:
For HP-piping systems like HP systems of WSC, lifting oil, control oil, or other systems
x Class 600:
For IP-piping systems like IP systems of WSC, turbine auxiliary systems, fuel systems or other systems
x Class 300:
For LP-piping systems like LP systems from WSC and turbine auxiliary systems
x Class 150:
For LP-piping systems like LP systems from WSC, turbine auxiliary systems, potable water, domestic
water, or other systems (inclusive steel cooling water piping)
x Class 150 or PN 16 / PN 10 / pressure rating considering vacuum (project-specific decision):
For LP-piping systems like cooling water, according to PMC [A1], if confirmed by Siemens and GRP
manufacturer. PN6 (only for joint / flange thickness calculation) is allowed inside GRP pipe material class
(PMC) with rating PN10 for larger flange sizes (for example, >DN 1000 / 40”, see PMC). GRP pressure
rating is based on manufacturer vacuum calculations, which have to be considered for the GRP piping
design (if a vacuum is defined).

Project-specific deviations to this guideline may be suitable.

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The Class / PN Classification for steel piping is defined according to ASME B31.1 / ISO 2944 for the steel
piping components. For plastic piping, the pressure rating is defined according to the design code for plastic
piping, see chapter 2.2.3 to 2.2.7 (Plastic Piping Code).

Measures to sustain the effect of corrosion and / or erosion shall be applicable for steel piping parts only if
expressively specified by Siemens.

The effect of vacuum shall be considered, if required by the system design (sub atmospheric pressure ac-
cording to P&ID design section).

Piping systems have to be designed to assure loads at the terminal points and interfaces within the allowable
limits.

Deadweight loads of piping at connections to equipment shall be minimized to the greatest extent consider-
ing the requirement for a safe piping system.

All piping systems, components, and equipment with a normal operating temperature above 60°C shall be
insulated, if not defined differently by Siemens (for example personal protection).

Heat tracing for piping outdoor located shall be considered where defined.

Cold pull or pre-stressing is not permitted.

Piping systems subjected to stress analysis calculations have to be analyzed in accordance with the project-
specific PDBR [104].

Support concept has to be optimized to minimize pipe loads to connected equipment.

For metallic piping, the maximum allowable deflection the requirements of ASME B31.1, chapter 122.3.8
(supports) shall be considered (for example, sagging of pipe between the supports due to dead weight of
piping + medium weight).

For evaluation of support deflection (for critical piping, with influence on the function of support), not only the
secondary structure shall be considered, but the connecting main structure as well. If necessary, suitable
reinforcement measures shall be suggested to Siemens by the Contractor in order to meet the maximum
permitted deflections.

The deflection of supports due to the design loads in the direction of the restraints shall be 3 mm for < 2” and
5 mm for > 2”. For the deflection, the main structure shall be considered.

For plastic piping, the material stiffness and wall thickness shall be considered for the support spacing, see
chapter 2.4.2 “Support Materials for Plastic Piping”. The support spacing defined in the design codes and
manufacturer recommendations shall be followed, see chapter 2.2.3 to 2.2.8 (Plastic Piping Codes).

For support spacing of steel piping, the ASME B31.1 para. 121 is suggesting the spacing of supports. These
distances are implemented into stress calculation rules for allowable spacing. For the M-System Piping [A1],
special requirements for the support spacing shall be considered. These requirements are specified respec-
tively by “Siemens internal Standards” [A1], see chapter 23 “References” of this specification.

4.3.2 Design Requirements concerning the Slope Requirements

For WSC and auxiliary systems, the Design Guideline “Slope requirements for piping systems” [128 ] shall
be applicable.

4.3.3 Design Requirements concerning the Clearances and Minimum Distances

When designing piping systems, adequate clearances must be carried out between pipe and other piping
systems, ductwork, structural steel, concrete, equipment, and cable trays. The Contractor shall ensure the
interference-free pipework erection and sufficient head clearance of workmen.

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The final spacing and clearance shall permit the maintenance, in-service inspection, and removal of any
valve, or other piece of equipment without disturbing any adjacent piping or equipment. Any required clear-
ance or removal spaces must be reserved for that purpose. Sufficient space for removing of measuring
equipment shall be considered.

Piping shall not be routed across floors, walkways, or working spaces. Piping systems shall be designed with
sufficient space for parallel lines including the assembly of supports, flanges, valves, drainage connection,
insulation, splash guard (see chapter 4.10) and thermal displacement.

For non-buried piping: A minimum of 100 mm face to face clearance shall be designed between the largest
components of piping (considering insulation). A minimum of 50 mm face to face clearance for hot position of
steel piping shall be considered.

For buried piping: ATV-A127 [29] or similar code shall be considered for minimum clearance.
For further requirements for clearance and access to valves, see chapter 4.6.1 “Design Requirements for
Valves in Piping Systems”.

For the overhead clearance to the bottom of piping or pipe rack, the following table shall be considered:

Overhead clearance

Location Overhead clearance

Inside buildings over walkways 2100 mm

Elevated piping and/or pipe racks over roadways 4500 mm

Over railroad tracks (refer to any specific local requirements if any) 6700 mm

Piping systems containing flammable medium shall be considering respective space requirements of STIM-
03.002 [109] chapter 5.2.2. For fuel gas piping, the national rules shall be considered, if applicable.

For the plastic- / GRP piping, the material stiffness and wall thickness shall be considered for the support
spacing defined in the design codes and in the stress analysis.

For maintenance and “health and safety” requirements, see attachment “man clearance for operating per-
sonnel at various positions” [A2]. The given clearance shall not be reduced without written approval by Sie-
mens. Project-related instructions shall be defined for the national needs of the project.

4.3.4 Design Requirements for M-System Piping

For the M-System Piping [A1], the specific requirements of the STIMs [109] and TE-Guidelines [108] shall be
considered.

For double-wall piping in system MAX: The Contractor shall use the isometric drawings of the inner and outer
piping as well as the overview drawing of Siemens as input. The Contractor shall provide detail prefabrication
drawings and start works on the spools after approval by Siemens.

National requirements for hazardous piping systems shall be considered (for example, special gaskets).

4.3.5 Design Requirements for Piping at Pumps

For pump connections in piping systems, the following guidelines shall be applicable (not a comprehensive
list):
x Connecting piping shall be supported independently from the pumps.
x Vertical loops or “high points” in suction lines of pumps are not permitted.
x Reducers in suction lines of pumps shall be of eccentric type and shall be designed with the flat side up.

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x All service connections to pumps (such as drain-, vent-, balancing- and cooling water piping) shall in-
clude flange connections to enable removal of pump for maintenance

4.3.6 Design Requirements for Vents and Drains

In general, all piping systems shall be designed to permit a complete venting and draining for filling activities,
start-up and shutdown activities, and maintenance services as well as for hydrostatic testing, flushing, and
chemical cleaning. High and low points in the piping system have to be provided with a vent and a drain re-
spectively. Whenever possible piping systems shall be designed with:
x One high point for vent connection
x One low point for drain connection
4.3.6.1 Design Requirements for Vents and Drains of Steam Piping
Thermal displacement shall be considered for any drain connection in steam piping. Drains and vents of hot
piping systems shall be designed that sufficient space for installation of thermal insulation and allowance for
thermal movement are obtained. The flexibility of steam / steam turbine piping drains shall be evaluated. Any
necessary change in routing or support concept has to be advised by the Contractor.

If necessary, suitable reinforcement measures to be suggested to Siemens in order to meet the maximum
permitted deflections.

Drains of steam systems shall be generally routed to condensate collection systems. Vents for steam sys-
tems shall be generally used for hydrostatic test and if applicable for chemical cleaning and flushing purpose
only.

The drain connections (any low point) of main steam, reheat steam, auxiliary steam, process steam and
extraction steam piping systems shall be provided with a drain pot according to DR 001 “Inspection nozzles
at steam line drain pots, Dimension of steam line drain pots” [110].

Any restricting device like orifices or flow nozzles in steam piping systems shall be designed with an ade-
quate drainage connection upstream of the device.

4.3.6.2 Design Requirements for Vents and Drains of Liquid Fluid Systems
All piping systems with a liquid fluid and a nominal size > 2” shall have:
x A vent connection at all high points
x A drain connection at all low points
All piping systems with a liquid fluid and a nominal pipe size of 2” and below shall have a vent connection on
the specific high point and a drain connection on the specific low point. No additional vent and drain connec-
tions of piping systems are required, if such function is fulfilled by system branch connections, equipment
vents and drains, or operating vents and drains.

All drains and vents of piping systems with a liquid fluid shall be routed to disposal points like funnels, or floor
drains or similar. Flashing drains or vents ending at funnels or floor drains shall have suitable protection to
avoid injury to personnel.

4.3.6.3 Design Requirements for Vents and Drains of Oil and Gas Systems
Drains and vents for fuel oil and fuel piping systems shall be generally used for pressure testing, purging,
and if applicable for maintenance and flushing purpose only.

Following discharge piping shall be arranged out of explosion endangered areas and with sufficient distance
to air intake facilities and via shortest possible routing:
x Vent and drain lines of fuel gas and ignition gas skids
x Vent/waste gas piping of generator
x Vent/oil vapour exhaust lines of lubrication oil system or similar vent and exhaust lines

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Such piping shall have an exhaust special tee piece construction according to DR 012 [110], with the excep-
tion of exclusions herein mentioned.

National rules for the fuel gas venting shall be considered if applicable.

4.3.6.4 Design Requirements for Vents and Drains of M-System Piping

For drains and vents of M-System Piping [A1], the specific requirements of the “MA-Guideline” [101], the
STIMs [109], and TE-Guidelines [108] shall be considered.

For the drains and vents in the MBV oil vapour exhaust line (GT terminal point 3A), the DR 003 [110] shall be
considered for multishaft configuration of combined cycle power plants.

4.3.7 Design Requirements for Blow-Out Lines of Safety Valves

The following general requirements shall be considered for the design of blow out lines of safety valves in
piping systems (not a comprehensive list):

x The blow-out lines of safety valves with a free exit to the atmosphere shall be routed to safe locations.
x The safety valve itself shall not be separately supported. The weight of the safety valve and the reaction
forces of safety valves during blow-off shall be considered in the support concept of the respective piping
system.
x Safety valve blow out lines shall be generally routed upward (with downward slope of 1% for horizon-
tal piping to the drain connecting point).
x Safety valve blow out lines shall be generally drainable in cold condition.
4.3.8 Design Requirements for the Fuel Gas Piping
Additionally to the fuel gas code requirements for the design, defined in chapter 2.2.2 “Steel Gas Piping
Codes” of this specification, the following rules shall be considered:

x Fuel gas piping systems shall be designed with a minimum pressure loss. Fuel gas piping systems shall
be designed without any reduction of the cross-sectional area to avoid an interference of the mass flow,
except where proper allowance in the piping design has been made for such devices, and where ap-
proved by third-party (defined in national regulations).
x The design of carbon steel sections of fuel gas piping systems shall be suitable for complete purging of
each section. For pig cleaning procedure, see chapter 21.6 “Purging / Pig Cleaning …” and chapter 4.5.3
“Design Requirements for Steel Elbows”.
x Fuel gas buried piping shall be cathodic protected, see chapter 4.8 “Cathodic Protection”.
x For above ground fuel gas piping, the earthing of piping shall be considered, see chapter 7 “Special
Earthing Requirements”.

4.3.9 Design Requirements for the Yard and Underground Piping

National rules and medium specific requirements (national regulations if applicable) shall be considered. The
inner and outer pressure shall be considered for stress calculations. If applicable, underground piping shall
be buried at a minimum depth of one metre. For buried steel piping, the need of cathodic protection has to
be evaluated. For cathodic protection, see chapter 4.8 “Cathodic Protection” and for earthing, see the chap-
ter 7 “Special Earthing Requirements”. Buried metallic piping shall be suitably protected by coating or wrap-
ping.

Safety against buoying lifting-off of the piping, related to the hydrostatic pressure of surrounding water level)
shall be considered for plastic piping.

For buried GRP piping with pipe size >=DN1500 / 60”, an earth cover of minimum 1,9 metres shall be con-
sidered if not otherwise mentioned.

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4.3.10 Design Requirements for GRP Piping

The Contractor / sub-supplier / manufacturer shall draw simplified isometric drawings (spool drawings), which
show the position of workshop-joints and site-joints (laminates/bonds/glued connections).

4.3.11 Design Requirements for the Potable Water

For the potable water system, the national rules/certificates may be suitable. For this system, the national
requirements shall be checked and determined separately for suitability for each project. Health and safety
requirements for potable water shall be fulfilled. Special manufacturer piping systems such as by “Geberit-
Mapress ®” for industrial stainless steel piping and fittings may be suitable after confirmation by Siemens.

4.3.12 Design Requirements for the Galvanized Piping

National requirements for galvanized piping, for example, health and safety requirements/measures have to
be considered. Screwed connection for pipe sizes <=2” is recommended. For pipe sizes >2”, a flanged con-
nection is suitable. Connection by brazing may be also possible after confirmation by Siemens.

4.4 Calculations
For steel piping, the rules of ASME B31.1 and herein defined necessary calculations are applicable.

For fuel gas piping, the design codes and design requirements shall be considered see chapter 4.3.8
“Design Requirements for the Fuel Gas Piping“.

For plastic piping, the rules of design codes shall be followed, see chapter 2.2.3 to 2.2.8 (Plastic Piping
Code).
4.4.1 Strength Calculation / Stress Analysis
The strength calculation is the basis for the minimum wall thickness determination. The stress analysis en-
sures the requirements of the design code and Siemens.

4.4.1.1 Strength Calculation

For all piping systems, a strength calculation in accordance with ASME B31.1 shall be performed by the
Contractor, to confirm the defined piping wall thickness. A respective allowance for bending and threading
shall be considered whenever applicable.

The wall thickness shall consider the design and operating data according to the relevant P&ID of the system
and the corresponding piping list for the system. For GRP and other plastic piping systems, the loads for the
hydro test pressure, vacuum (if applicable) and the lifetime of minimum 25 years shall be considered also for
the determination of wall thickness and the material. A detailed calculation for suitability of stiffness of piping
as well as the safety against buoying (lifting-off of the piping, related to the hydrostatic pressure of surround-
ing water level) shall be provided for buried plastic piping, if required project-specifically.

External or internal coatings or lining shall not be considered as adding strength.

4.4.1.2 Flexibility- and Stress Analysis

Piping systems defined in attachment of PDBR [104] shall be analyzed for flexibility and piping stresses by
the Contractor.
For steel piping, the computer-aided stress analysis shall be performed and provided with one of the follow-
ing software programs. For flexibility analysis of GRP piping, below mentioned programs are preferred by
Siemens:
x CAESAR II of COADE, Inc. (part of Intergraph family)

Or

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x ROHR2 of SIGMA Ingenieurgesellschaft mbH, Unna, Germany (see www.rohr2.de), if confirmed by

Siemens
The loads and special requirements for stress analysis defined in the PDBR shall be considered. For all pip-
ing systems, the Contractor shall demonstrate to Siemens that the flexibility (including the resulting forces
and moments) of such systems are in accordance with the technical standard. This demonstration shall in-
clude also the equipment and components.
For stress analysis of GRP piping:
x The Contractor shall consider approved software, suitable for the project-specific pipework and material
to be used.
x The stress calculation shall be provided only, if defined project-specifically.
x The stability analysis and stiffness calculation (incl. reinforcements) for pipe and fittings as well as for the
complete piping system shall be provided by the Contractor, for approval by Siemens. The long term ma-
terial data shall be considered for the calculation of deflection and buckling.
x The stress calculation shall be performed using the suitable design code see chapter 2.2.7 “GRP Design
Codes”. Verified material data of the manufacturer resulting from initial type testing (ITT) shall be used in
the calculation. The spools to be provided shall fulfil the minimum requirements of the calculation.

Soil reports and settlement calculations shall be considered for piping calculations. A static calculation
against buoying (lifting-off of piping, related to the hydrostatic pressure of surrounding water level) has to be
carried out for thermoplastic and steel piping, if defined applicable in the project.

The Contractor shall provide all calculations in SI units to the greatest extent possible. The results of calcula-
tions performed in other units than SI shall be converted to SI units.

The calculations shall be revised if the following boundary conditions have been changed significantly (not a
comprehensive list):
x Geometry or routing of piping
x Pipe size, properties, or material
x Pipe support locations
x Valve or inline component weights or dimensions
x Operating parameters such as temperature and pressure/vacuum
x Terminal point connection

Such revision shall be applicable also after an “As-Built” survey of the respective piping systems. Before
providing a revision, the Contractor shall evaluate the possible effects of any change. The Contractor shall
inform Siemens about this evaluation and Siemens will determine whether a revision of the respective calcu-
lation shall be performed or not.

4.4.1.3 Design Requirements for Cyclic Loading of Steel piping

Main steam and (as far as concerned) reheat systems shall be designed for cyclic service. Details are de-
fined in the PDBR [104].
4.4.2 Other Calculations
Other calculations shall be performed by the Contractor mentioned in the “Checklist Scope and Limits of
supply and services for piping” [102].

For dowel plate connections the Contractor shall provide static calculations, if allowable loads are not defined
by manufacturer.

No calculation documentation shall be required for standard components which are selected solely from the
supplier/manufacturer catalogue.

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4.5 Piping Component Design Requirements

All piping components excluding components inside subcontractor supplied packages, shall conform to
ASTM in accordance with Table 126.1 of ASME B31.1 and Table 423.1 of ASME B31.4. In detail the follow-
ing standards shall be applicable (not a comprehensive list). All the interface components shall also comply
with one of these standards. The chosen standard shall be fixed in the contract documents.

ASME B1.1 Unified screw threads

ASME B1.20.1 Pipe threads
ASME B18.2.1 Bolts for pipework (stud bolts only, with the exception: for lug type butterfly valves, hex
head bolts shall be used)
ASME B18.2.2 Nuts for pipework
ASME B18.22.2 Plain washers
ASME B16.5 Pipe flanges & flanged fittings
ASME B16.9 Factory-made wrought buttwelding fittings (incl. short radius elbows)
ASME B16.10 Face-to-face and end-to-end dimensions of valves.
ASME B16.11 Forged steel fittings, socket welding and threaded (for limitation, see chapter 2.3.1.3)
ASME B16.20 Metallic gaskets
ASME B16.21 Non metallic gaskets
ASME B16.25 Butt welding ends
ASME B16.34 Valves-flanged, threaded, and welding ends, as far as not covered by ASME B31.1
(i.e. outside the fence of the power plant area)
ASME B16.47 Large diameter steel flanges
ASME B31.4 Oil transportation piping
ASME B31.8 Gas transmission and distribution piping system
ASME B36.10 Wrought steel & iron pipe
ASME B36.19 Stainless steel pipe.

The use of materials which are not included in the above mentioned list will be permitted upon a written
agreement between Siemens, Contractor and the “independent inspection agency (if applicable)”.

4.5.1 Design Requirements for Pipes

In general, seamless pipes shall be used for:
Carbon steel piping <14” And >=CL400 (>CL600 for fuel gas up to 24”)
>24” for >CL400 a project-specific decision will be provided by Siemens
Alloy steel piping <14” And / Or >=CL400
Stainless steel piping MAX / MAV lifting oil / seawater resistant
Fuel gas piping**
pipe sizes <1/2”
In general, longitudinally fusion welded pipes may be used for:
Carbon steel piping >=14” And <CL400,
Alloy steel piping >=14” And <CL400, >=14” for LBC / LBQ in general
Stainless steel piping >=1/2” (without fuel gas piping**, MAX /MAV lifting oil / seawater resistant material)
Exceptions (such as spiral-welded-, electric-resistance-welded (A53B) or welded high-pressure pipes [A1] if
any) may be shown in the piping list [115] of Siemens.
No furnace butt welded pipe shall be used.
Exceptions from the material defined in the piping list shall be used only upon a written agreement between
Siemens and the Contractor.
** Note:
The use of longitudinally fusion welded pipes within the fuel gas piping system is permitted under the following
conditions:
1. Weld joint efficiency factor of 1,0 is ensured (see ASME B31.1 Table 102.4.3)
2. Seamless fittings are used
3. National standards and/or project specific requirements actually allow the use of welded pipes

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4.5.1.1 Design Requirements Concerning the Pipe Size

The pipe sizes as mentioned in attachment [A15] shall be used. Deviations from these standard sizes shall
be allowed only, if an economic advantage could be deemed or where special fabrication is required. Sizes
not covered by this specification shall be subject to a written agreement between Siemens and the Contrac-
tor.
4.5.1.2 Design Requirements Concerning the Wall Thickness of Steel Pipe Components
In general, the wall thickness of carbon steel-, alloy steel-, stainless steel- piping and fittings shall be in ac-
cordance with ASME B31.1 and ASME B36.10M for carbon / alloy steel and ASME B36.19M for stainless
steel pipe dimensions. For toxic medium table 122.8.2 (B) of ASME B31.1 shall be considered in general for
the wall thickness.

The minimum wall thickness for buried piping systems shall include an allowance for overall height and con-
sistence of the back filling. The defined traffic loads in area of street crossings and the Calculation or Defini-
tion of settlements shall be considered by defining the wall thickness.
For carbon steel:
x For <= 2”, the Schedule STD acc. to ASME B 36.10 for butt or socket welded pipework shall be
specified as the minimum schedule for the wall thickness.
x For > 2”, the minimum wall thickness of carbon steel piping shall be STD.

For carbon and alloy piping carrying wet steam or a flashing fluid, they shall be at least one schedule
higher (heavier) than the calculated nominal wall thickness.
For stainless steel, the minimum wall thickness of stainless steel piping shall be SCH10.

General requirements:
The calculations for wall thickness should include bend thinning allowance and where threading is
required, pipe schedule shall be checked to see if it is sufficient to provide the necessary wall thick-
ness for threading in accordance with ASME B1.20.1, Table 2 which specifies:
x Below 1” - 1.45 mm material reduced by threads
x 1” to 2” - 1.77 mm material reduced by threads
The thread depth and bending allowances are in addition to the mill tolerance for seamless or welded
pipe as specified in the applicable ASTM standard.

For gas piping, the minimum wall thickness is defined in ASME B31.1 design code. Minimum wall thickness
defined in national gas rules shall be considered additionally if defined applicable project-specifically.

4.5.1.3 Design Requirements Concerning the Wall Thickness of Plastic Pipe

For GRP piping, the pressure ratings (PN) and manufacturer calculations according to design codes shall be
considered, see chapter 2.2.7 “GRP Design Codes” of this specification.

For thermoplastic piping the “standard design ratings” (SDR) and manufacturer calculations according to
design codes shall be considered, see chapter 2.2.3 and 2.2.5 (Thermoplastic piping codes) of this specifica-
tion.
4.5.2 Design Requirements for Steel Bends
For mechanical-technological properties of bends, the minimum requirements defined in “material specifica-
tion and related procedures” [111] shall be applicable. For fuel gas piping, the requirements of national gas
rules shall be considered if defined applicable project-specifically.

4.5.2.1 Design Requirements to Inductive Manufactured Steel Bends (hot bending)

The ASME B31.1 requirements for inductive bending of pipes are applicable. Herein the minimum allowable
radius is restricted to the manufacturing possibilities of shape and structural quality of bends. The welding of
“welding attachments” at the area of the bending radius is prohibited.

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The designer shall consider the additional length needed for the inductive manufacturing of bends.

The ratio of the radius of the bend at neutral fibre to outside diameter of pipe shall be >= 2.5; smaller radius
only after written confirmation of the manufacturer and Siemens.

The piping shall be in accordance with ASME B31.1

For wall thickness, see ASME B31.1, Paragraphs 102.4.5 and 104.2.1
For fabrication, see ASME B31.1, Paragraph 129
Pipe bends shall be made true to the specified radius, shall curve uniformly, and shall be made in a manner
that will preclude buckling of walls and/or flattening of the pipe cross section. Welds shall not be made in
pipe bends unless reviewed and accepted by Siemens.

No induction bends shall be made without an approved bending procedure and a successfully passed pro-
cedure qualification test. Existing documents from previous jobs may be used, for approval by Siemens. For
the first qualification and production bends, the “Requirements for Induction Bends / In-Process Examination
Sheet No. 1” [A14] shall be used for reference, but it has to be updated project-specifically.

4.5.2.2 Design Requirements for Steel Cold Bending

The ASME B31.1 requirements for cold bending of pipes are applicable. The following limitations shall be
considered as well as the definitions of chapter 3.3.1 in the “Checklist Scope and Limits of supply and ser-
vices for piping” [102]:
x Cold Bending on site: For sizes <= 1 ½”
x Cold Bending in shop: For sizes 2”, 2 ½”, 3”

The radius of cold bends shall be not less than 5 times (R>=5D) the outside diameter of the pipe. Deviations
need to be approved by Siemens.

For acceptable tolerances of cold bends see chapter 8.9 “Acceptance Criteria for NDT and Test Method
Procedures for Steel Piping” of this specification.
Special care shall be taken to stainless steel bends.

4.5.3 Design Requirements for Steel Elbows

Standard elbows according to ASME B16.9 shall be considered.

Elbows with smaller radius are subject to approval (from case to case) by Siemens. Elbows with larger radius
are used only in the condensate polishing system (LDP, resin pellets transportation) for pipe size > 2”, if re-
quested.

The use of mitred elbows may be suitable for large bore main cooling water pipes (>=20”) and condensing
system (MAG for >=32”).

For special elbows (according to drawing), the attachment “Details of Siemens NDT extent for ASME steel
piping” [A10] of this specification shall be considered for testing of such fittings.

4.5.4 Design Requirements for Steel Branch Connections inclusive T-Pieces, Pressure-, Tempera-
ture-, and Level Measurement Nozzles
Standard T-pieces are defined according to ASME B16.9. The dimensions of special T-pieces (according to
ASME B31.1 calculations) are defined in special component data sheets [112] (fitting drawings).

For special T-pieces (according to drawing), the attachment “Details of Siemens NDT extent for ASME steel
piping” [A10] of this specification shall be considered for testing.

If the design of branch connections is defined according to special fittings drawings (defined in “detailed pip-
ing component drawings” [112]), the additional length for NDT (especially for UT) shall be considered.

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Siemens standard drawings of pressure, temperature, and level measurement nozzles shall be considered,
see Detailed Piping Component Drawings [112].

For the M-System Piping [A1], the specific requirements of the “MA-Guideline” [101] chapter 6, the STIMs
[109] and TE-Guidelines [108] shall be considered.

In addition to ASME B31.1, criteria for steel branch connection are shown in following guideline see pic-
ture “Branch connection guideline” (not a comprehensive list):

Picture: Branch connection guideline

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4.5.5 Design Requirements for Reducers

Standard reducers are defined according to ASME B16.9 and according to the material specification [111].

If fittings shall be used which are not defined in ASME B16.9, the following radii shall be used for transition to
conical parts:
x R >= 20 mm for <4”
x R >= 50 mm for >=4”
For special reducers (according to drawing), the attachment “Details of Siemens NDT extent for ASME steel
piping” [A10] of this specification shall be considered for testing. The maximum inclination of reducing area
shall be 15 degree.

4.5.6 Design Requirements for Steel Caps

The dimension of caps shall follow the definitions of ASME B16.9.

For special caps (according to drawing), the attachment “Details of Siemens NDT extent for ASME steel
piping” [A10] of this specification shall be considered for testing.

4.5.7 Design Requirements for Connections such as Welds / Joints / Flanges

The detail designer shall provide a detailed floating procedure for load free interface connection to steam
turbine for HP, IP, LP and cold reheat steam system incl. bypasses as defined in STIMs [109] and if required
project-specifically further connections e.g. to feed water and deaerator and recirculation pumps. The detail
designer shall provide a detailed procedure (for example on drawings) for bolt tightening for all flanged con-
nections including the required torque and tightening sequence. Especially a procedure for installation of
inline components such as HP-Steam strainers, compensators, flexible hoses and wall- / roof penetrations
shall be provided by the detail designer.

4.5.7.1 Design Requirements for Welded Connections

All welds within pressurized steel piping systems shall be done as full penetration butt welds. Piping for dos-
ing and sampling systems with pipe sizes < ½” socket welds may be used. For prefabrication and site weld-
ing to valves and components, the component drawings/interfaces shall be considered and further UT-NDT-
test length see chapter 15.2.1 “General Requirements for Prefabrication of Steel Spools” of this specification
‘DR 007 [110] for ASME’. All weld end preparations and linear misalignments shall follow to the design code
ASME B31.1 and further ASME B16.25 / ASME B16.34 if defined, specified in the WPS. The minimum wall
thickness of pressurized components such as mentioned in the design code shall be considered. For pipes
with different wall thickness, the thicker wall thickness must be reworked. The maximum allowable angle is
15°.

For acceptance criteria, see chapter 8.9.1 “Acceptance Criteria / NDT Standards for Visual Examination of
Welds (Steel Piping)” of this specification.

For fuel gas and potable water piping, the national rules shall be considered.

For critical piping systems, the internal misalignment shall not exceed 0.8 mm all around or 1.5 mm at any
point.
4.5.7.2 Design Requirements for Weld Suitability
The distance between 2 welds shall be one time pipe diameter but not less than 100 mm (as a rule of thumb,
or even more in case of different PWHT-temperatures related to the material). For small bore also a distance
of 50mm between 2 welds shall be considered.

The distance between a weld and a pipe clamp shall be not less than 50 mm.

Heat treatment (if applicable) and the weld NDT shall be possible without restrictions related to close position
of welds.

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For several cut-outs in pipes close to each other, the rules of ASME B31.1 (formulas for minimum distance)
shall be strictly respected.

4.5.7.3 Design Requirements for Threaded Joints

Threaded joints are generally not permitted in piping systems for steam, HP water, natural gas, hydrogen,
acid, and piping under vacuum. Following standards shall be considered for the threading:
ASME B1.1 Unified Screw Threads
ASME B1.20.1Pipe Thread
Threaded joints may be used in galvanized piping systems <= 2” and for connection of electrodes for catho-
dic protection (M42x2) if applicable.

The use of threaded joints in M-System Piping [A1] is defined in the respective STIMs [109].

4.5.7.4 Design Requirements for Flange Connections

In general, flange connections shall be avoided. If flange connections are necessary, the following require-
ments shall be considered:
For the ASME/AWWA flanges:
x ASME (<= 24”) / AWWA (> 24”) flanges for cold water piping / ASME B16.47 Type A for steam piping
x ASME B16.5-2003, RF FLANGES
x AWWA C207-D, FF FLANGES (= ASME B16.47 Type A up to 60” for the borehole design)
x Weld neck flanges with a raised face design shall be used. Exceptions are defined in STIMs [109] and
TE-Guidelines [108]. In addition, special requirements (flat face) may be applicable in Plastic-, GRP-,
Rubber lined-, and Epoxy coated piping systems.
x For all flange connections, which are not defined according to ASME B16.5 / B16.47, a detail drawing
shall be prepared.
x For special flanges, ASME B31.1 (Design rules for flanges) requirements shall be considered.
x The application of gasket is defined in the following “flange-to-flange connection table”:

Flange to flange connection table

Flange 1 Flange 2 Gasket necessary

Steel / Plastic Steel / Plastic YES

Steel Rubber lined / Epoxy coated YES
Rubber lined / Epoxy coated/GRP Rubber lined / Epoxy coated / GRP YES
Rubber lined / Epoxy coated Lug type butterfly valve (with internal rubber lining) / NO
Rubber Expansion joint
Rubber lined / Epoxy coated Lug type butterfly valve (without internal rubber lining) YES
Steel /GRP Rubber Expansion joint NO
Epoxy coated Steel Expansion joint YES
(“Steel” includes carbon steel, alloy steel, and stainless steel; flanges of inline components are included)

4.5.7.4.1 Design Requirements for Bolting and Gaskets concerning the Dimensioning Standards
For ASME / AWWA bolting and gaskets:
ASME B1.1 UNC-2A considering ASME B31.1 and ASME B16.5 for the stud bolts, but for Alloy
bolting > 1 1/8”: 8UN-2A
ASME B18.2.1 Hex. head bolts for Pipework (e.g. for lug type butterfly valves)
ASME B18.2.2 (Hex) Nuts for Pipework
In the PMC [A1], the details of bolting and gaskets are defined.

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For bolting length, 1 thread outstanding from nuts shall be considered and 5 threads should be considered
for maximum outstanding length.
For dimensions of gaskets, see gasket standards mentioned in chapter 2.3.1.7 (Gaskets for steel piping) and
2.3.2.4 (Gaskets for plastic piping) of this specification.

4.5.7.4.2 Design Requirements for Flange Connections in thermoplastic Piping

ASME / AWWA flange borehole design is defined as Siemens standard for plastic piping. For connections to
DIN/EN flanges, stub ends and loose flanges (EN1092-1, suitable for plastic piping stub ends) shall be used.
DVS 2210-4: “Thermoplastic industrial piping: Items and requirements of dimensioning of flange connec-
tions“ (Industrierohrleitungen aus thermoplastischen Kunststoffen: Merkmale, Anforderungen und Dimensio-
nierung von Flanschverbindungen)
4.5.7.4.3 Design Requirements for Flange Connections / Couplings in GRP Piping
Generally, a collar / lap joint connection shall be used in straight non-buried GRP piping system (bonded
collar with socket ends for <=16” and laminated collar >16”) only where explicitly required, but considering
following details:
For branch joint connection (bonding / lamination / collar / fix flange), following Siemens standard shall be
considered:
x Bonded system (socket end) Collars with lap joints <=16” for equal run / branch size
x Laminated Collars <=16” for run / reduced branch size and generally for >16”
Further, the PCB-injection nozzle shall be provided with laminated collar.
For bi-axial restraint couplings or an approved key-locking system, see chapter 2.2.7 “GRP Design Codes” of
this specification, if allowed by Siemens.

For buried piping, flanges shall be avoided.

For below ground piping, the perpendicular tolerance (offset) of the flange shall be considered (a maximum
offset of ±10 mm is allowed for flange size >48”, in correspondence to the horizontal
or vertical plain at outer edge of flanges after completion of backfill). No tolerance
(close to zero) for flatness of flanges shall be considered (a maximal allowable in-
clination angle of 0,1° of flange sealing surface/facing is allowed, when using
Kempchen WS/(WL if approved by Siemens) type gaskets, and an angle of 0,06°,
when using Kempchen WG type gaskets)
Generally, a fix flange shall be used for vent- / drain-, sampling- / dosing lines, and component connections
(valves, measurements) if applicable:
x on reducing branch side (<=4”, PN16 borehole design) and
x for pipe sizes >=40” with reducing branches e.g. for manholes (PN10 borehole design for sizes 24” and
32”) / reducing branch 6”.
x Flange connections to coated counter-flange or stainless steel flanges if applicable
x Flange connections in high corrosion situation or narrow situations, both for approval by Siemens

Lap joint flange borehole design:

<=24” Lap joint flanges according to ASME B16.5 borehole design
>24”: Lap joint flange according to AWWA C207-D borehole design.
Generally, deviations shall be subject to a written agreement between Siemens and the Contractor.

4.5.7.4.4 Design Requirements for Flange Connection for Rubber Lined / Epoxy Coated Piping
Flange connection shall consider the needs for rubber lining/epoxy coating, see following sketch:

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End of lined area End of area with prime coating

Picture: Flange ASME B16.5 / AWWA flat face connection to pipe

G = 1,2 mm (Epoxy coated); G = 3 mm (Rubber lined)

4.5.7.4.5 Design Requirements for Flange Connections in HP Steam Piping Systems:

Weld ring gaskets shall be used for drain pot flange connections in HP-steam piping systems, see DR 001
[110].

4.5.7.4.6 Design Requirements for Flange Connections in Fuel Gas Piping

For fuel gas piping systems, the material for gaskets shall be capable of withstanding the chemical constitu-
ents of the gas being conducted, without change to its chemical and physical properties. The effects of fire
exposure to the joint shall be considered in choosing material.

The flange connection shall be designed technically tight. Hence, the gaskets and torque shall be designed
correspondingly. All vents and drains shall be capped after cleaning, but before filling with fuel gas.

For isolation joints and isolation flanges (skid), the national special requirements shall be considered.

4.5.7.5 Design Requirements for Flange Connections in M-System Piping

For M-System Piping [A1], all screwed connection shall be secured against loosening, see STIM-03.002
[109], chapter 4.14.

For generator auxiliaries piping, only metal-to-metal contact gaskets (force in bypass path / off-load) such as
Kempchen lip-seal WL gaskets (Viton rubber with a steel supporting ring) are allowed, see TE-Guidelines
[108] 06.0-050-102, page 13.

For flanges within the high-pressure lift oil and control fluid piping systems, the flange standards ISO 6164
and ISO 6162 (SAE) shall be considered. The counter flange shall be defined without groove. For this flange
connection, an O-Ring gasket (ISO 3601) shall be considered.

For flanges within the lube oil and oil vapour exhaust piping systems, rubber steel gaskets like Kempchen
brand type WL shall be used for pressure ratings <=PN16. For pressure ratings >PN16, O-ring gaskets shall
be used.

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For condenser leakage detection in the evacuation line (MAJ), a flange connection with blind flange suitable
to accommodate the “leakage detection device” (Leybold type) is required. For the details, see “Detailed
Piping Component Drawings” [112] and Component data sheets [112].

Further details are mentioned in chapter 2.3.1.6 to 2.3.1.7 (flanges, bolting and gaskets) of this specification.

4.6 Inline Components

4.6.1 Design Requirements for Valves in Piping Systems
The following general requirements shall be considered for the location of valves in piping systems (not a
comprehensive list):
x Valve installations and positioning shall be in accordance with Attachment [A3] (Arrangement of valves).
x Access to valves shall be permitted by the design of the piping systems. Vertical loops or pockets shall
be avoided. A regular access to valves shall be possible if a hand operation is necessary.
x A minimum clearance of 100 mm shall be provided around all hand wheels or hand levers of valves.
x The use of chain wheel operated valves in steam, condensate, feed-water, and preheater drain systems
is not permitted. Exceptions need written approval by Siemens.
x The valves shall show the position of preferred installation direction (for example upward) on the valve
drawing, if applicable.
x Valves shall not be installed upside down.
x Sufficient space shall be provided for maintenance and service: for example, the removal of valve inter-
nals, actuators, or similar. A permanent connection at the civil structure for the lifting device for valves
with weight >25 kg shall be provided.
x For valves with horizontal arrangement of gear and actuator, the use of a spring support shall be
checked. A written confirmation of valve manufacturer shall be provided considering the supporting con-
cept, especially for the control valves.

4.6.1.1 Design requirements for Shut-off Valves

Shut-off valves of tanks shall be directly connected to the tank nozzles, see DR 016 [110]. For outside locat-
ed insulated shut-off valves, the stem of valve may be arranged horizontally.

4.6.1.2 Design requirements for Control Valves

x The requirements for control valves are defined in the “Planning Instructions for Control Valves” [105],
STIMs [109], TE-Guidelines [108], and MA-Guideline [101] shall be considered, if applicable.

4.6.1.3 Design requirements for Motor Operated Valves

For motor operated valves in piping systems the following guidelines shall be applicable (not a comprehen-
sive list):
x Motor operated valve actuators shall be designed in the vertical up-right position. In exceptional, a hori-
zontal position of the valve stem is possible, but the Contractor-Detail engineering shall check, if an addi-
tional support for the actuator is necessary, considering the requirements of the valve manufacturer. A
downward orientation of the actuator is not permitted. Specific requirements of the vendor shall be con-
sidered, if applicable.
x The final position of each actuator shall be shown in the 3D-model and on the respective piping fabrica-
tion isometric drawings.

4.6.1.4 Design Requirements for Butterfly Valves

For butterfly valves in piping systems, the following guidelines shall be applicable (not a comprehensive list):

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x In general, a horizontal orientation of the valve shaft shall be preferred. For pipe sizes >12”, a vertical
orientation of the valve shaft is not permitted.
x A free rotation of the disc in the butterfly valves shall be considered.
x A suitable orientation of the hand levers or actuators shall be selected to avoid possible collisions with
equipment such as pumps, components, branch connections, and elbows.
x If a butterfly valve is used for throttling service, a straight pipe length of minimum 3D shall be provided
upstream and downstream of the butterfly valve.

4.6.1.5 Design requirements for Safety Valves

For safety valves in piping systems, the following guidelines shall be applicable (not a comprehensive list):

x Safety valves shall be arranged in the vertical upright position only.

x In steam piping systems, safety valve connections shall be located on horizontal pipe sections only. No
additional branch connection shall be located in the area of the safety valve connection.

x They shall be located at least 8 to 10 times of the pipe nominal header diameter downstream from any
bend or elbow. This distance shall be increased, if the direction of the change of steam flow (in the up-
stream elbow) is from vertical up to horizontal. For tees or Y-fittings, the same distance shall be applica-
ble either upstream or downstream of such pieces.

x Safety valves shall be located on horizontal piping runs, only, with the valve inlet nozzle on the top cen-
treline of the header. Where a fabricated valve branch nozzle shall be used, the nozzle must not be lo-
cated less than one nominal header diameter in distance to a header run butt weld.

x No other header branch connection, for any purpose, shall be made in the same transverse header
plane containing a safety valve inlet nozzle. Such branch connections (for other than service branches or
other safety valves) shall consider a minimum distance of 300 mm along the header.

x Where more than one safety valve or a service branch is to be installed on the same header, a minimum
distance between 2 nozzles of 600 mm or 3 times the sum of the nozzle inside radii shall be provided,
whichever is greater.

x Where more than 2 safety valves are installed on the same header, the spacing between valves shall be
varied so that the distance between each 2 valves differs from the other(s) by at least a branch nozzle
diameter.

x Backpressure forces during blow-off shall be absorbed by suitable supports. Calculations are required
for this concern. The safety valve shall be supported on main line in the piping system. The inlet and
outlet piping shall be considered for the support of the piping system including the safety valve.

x Safety valve outlet lines to the atmosphere require blow-off at safe locations. A silencer for steam lines
shall be foreseen.

x Safety valve outlet lines shall be run without pockets. If necessary, drainage shall be provided; in the
case of steam outlet lines going to the atmosphere drain holes. If necessary, lines diverting the hot con-
densate to safe location shall be provided.

x If a valve is located on a tank, the safety valve shall be located directly above the tank nozzle. Other
position needs approval by Siemens.

x The necessary clearances for dismantling above the valves (and below if needed) shall be provided.

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4.6.1.6 Design requirements for Check Valves / Non-return Valves

The following guidelines shall be applicable (not a comprehensive list):
x Swing check valves in horizontal pipe section shall be designed with the cover in the upright position.
Swing check valves in vertical pipe sections shall be used only with an upward flow direction. In addition,
a straight pipe section of 3 times the pipe diameter shall be provided upstream and downstream of the
valve if possible.
x Lift check valves like plug disc, piston disc, ball types, or similar in horizontal pipe section shall be de-
signed with the cover in the upright position. In addition, a straight pipe section of 3 times of the pipe di-
ameter shall be provided upstream and downstream of the valve if possible.
x Tilting disk valves in horizontal pipe section shall be designed with the cover in the upright position. In
addition, a straight pipe section of 4 to 6 times of the pipe diameter shall be provided downstream of the
valve if possible.
x Nozzle check valves shall be designed in horizontal pipe sections or in vertical pipe sections with an up-
ward flow direction.

4.6.1.7 Design Requirements for Steam Traps

For steam traps, the manufacturer standards / requirements shall be considered.

4.6.1.8 Design Requirements for Collecting Funnels and Y-pieces

For collecting funnels and Y-pieces, Siemens drawings shall be used. Further the manufacturer standards /
add-on requirements shall be considered, which may be not implemented in the drawing.

4.6.2 Design Requirements for Throttle Plates

Clamped throttle plates according to “detailed piping component drawings” [112] shall be considered. The
bore of throttle plate shall be calculated and dimensioned according to project-related specified component
data sheet.

For M-System Piping [A1], the “MA-Guideline” [101] and STIMs [109] shall to be considered.

4.6.3 Design Requirements for Flow Orifices

For flow orifices, the manufacturer standards / requirements shall be considered, if applicable.

4.6.4 Design Requirements for Strainers

For strainers in piping systems, the following guidelines shall be applicable (not a comprehensive list):
x In accordance with the system requirements, strainers shall have a form of Y-type (preferred), basket, or
T-type.
x Y-type strainers in liquid fluid piping systems shall be designed with the strainer pocket downwards in
horizontal pipe sections or in vertical pipe sections with a downward flow direction.
x Y-type strainers in steam or gas piping systems shall be designed with the strainer pocket in a horizontal
orientation in horizontal pipe sections or in vertical pipe sections with downward flow direction.
x Basket type strainers shall be designed in horizontal piping sections only.
x Strainers shall be designed with suitable drain and vent connections.
x The necessary clearance for maintenance and dismantling of strainers shall be provided. Strainers with
a cover weight >25 kg shall have a hinge.

x For the strainer, mesh openings / perforation of 0,5mm shall be considered. This dimension may be
adapted project-specifically by Siemens.

x The effect of vacuum shall be considered for the design of the strainer basket.

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4.6.5 Design Requirements for Flexible Hoses and Expansion Joints

4.6.5.1 Design Requirements for Flexible Hoses
Flexible hoses shall be used in cold water- and air piping systems where defined in P&ID. The medium trans-
ported in piping systems shall be considered for lifetime of suitable flexible hoses.

Flexible metallic hoses in seal water and control air system with a minimum length of 1000 mm and size ½”
inclusive suitable adapter (if needed) shall be used for the connections of control air and seal-water systems.
For a typical metallic hose, see following picture:

Picture: A typical flexible metallic hose in seal water, instrument air, and control oil piping systems

4.6.5.2 Design requirements for Expansion Joints

Expansion joints are used where the experience, flexibility calculations for steel piping according to
ASME B31.1, settlement calculations, and “state of the art” considerations are forcing their usage in a piping
system. Exception: For the steel compensators, the requirements of EJMA [A1] shall be considered for pip-
ing if defined by Siemens project-specifically. Manufacturer, not considering the EJMA, may use alternative
standards to demonstrate the suitable design of compensators only after confirmation by Siemens. In cold
water systems, rubber-steel compensators according to manufacturer standards shall be used, suitable for
the medium.

For expansion joints in piping systems, the following guidelines shall be applicable (not a comprehensive
listing):

x Installation of expansion joints shall be done according to the manufacturer’s installation instructions.
Deviations will only be accepted with explicit permission of the manufacturer.
x Permanent tie rods are required for both, metallic- and rubber-bellows (type) expansion joints, using a
spherical washer and a spherical conical seat, see picture “Cut-out from a lateral restraint compensator”
as one suitable solution.

Picture: Cut-out from a lateral restraint compensator (Source: Willbrandt Gummitechnik)

x Rubber expansion joints in piping systems under vacuum conditions shall be reinforced by a closed inner
supporting ring see picture “Detail of compensator steel ring”.

Closed inner stainless steel ring

(1.4571)

Picture: Detail of compensator steel ring (Source: Willbrandt Gummitechnik)

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x Metallic bellows of expansion joints shall be provided of stainless steel material for process piping. Me-
tallic bellows type elements shall be formed from ASTM: A240, TP 304, TP 316, TP 316L or TP 321
based on design requirements.
x For expansion joints exposed to elevated flow velocities (similar to DIN EN 14917 requirements), an
internal sleeve shall be considered, if flow induced vibrations cannot be excluded. For other concerns
(such as hot friction losses, smooth flow or protection of bellows from erosion if applicable), a project-
specific decision shall be done by Siemens.
x For the M-System Piping [A1], the special requirements for compensators shall be considered (for ex-
ample, STIM 07.001) [109]

4.7 Wall and Roof Penetrations

For wall- and roof penetrations in piping systems, the following guidelines shall be applicable (not a compre-
hensive list):
x For the design of wall- and roof penetrations, the displacement of piping systems shall be considered.
x For fuel gas piping, the national requirements shall be considered.

4.8 Cathodic Protection

For buried fuel supply piping, the cathodic protection system shall comply with the principles and practices
contained in the latest edition of EN 12954, EN 14505, EN13509, BS 7361, NACE-Codes (NACE = National
Association of Corrosion Engineers).

For cooling water piping, the cathodic protection system shall comply with the principles and practices con-
tained in the latest edition of EN 12954, EN 14505, EN 12473, EN13636, and EN 12499, if applicable.

For fuel supply piping and cooling water piping, national rules shall be considered, if defined applicable pro-
ject-specifically.

For isolation joints and isolation flanges (skid), the ATEX requirements / certificates shall be considered if
applicable, considering national regulations / requirements as well.

For above ground cooling water systems, the anode supports in form of nozzles shall be considered for the
design, if required by Siemens. Weld-on attachments shall be considered as standard piping parts inclusive
all testing. Details of design requirements of cathodic protection shall be defined project-specifically.

4.9 Design Requirements for Insulation (inclusive Heat Tracing / Personal Protection / Heat
Loss)
The requirement of insulation and freeze protection is mentioned in P&ID or in the piping list or on isometric
drawings. Piping design shall take care for weight of insulation, thermal movements of insulated piping con-
sidering the enlarged shape of piping, see chapter 4.3.3 “Design Requirements concerning the Clearances
and Minimum Distances”. The project-specific TCC 2.1-13 “Minimum requirements for electrical trace heating
systems” [107] shall be considered for heat tracing, if applicable.

For SPP only for long vertical LBA-, LBB-, LBC- and LAB piping of boiler house insulation lugs shall be used.
For pipe sizes <=6”, 2 lugs opposite positioned on outside diameter of pipe shall be used. For pipe sizes >6”,
3 or 4 lugs equal positioned on outside diameter of pipe shall be used. The insulation lugs shall be consid-
ered as standard piping parts inclusive all testing (same requirements as for support lugs).

4.10 Design Requirements for Splash Guard for Control-, Lube-, and Lifting Oil Piping Systems
A splash guard for control-, lube-, and lifting oil piping systems shall be considered, if applicable.

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5 Requirements for Pipe Support Design and Design of Secondary Steel

5.1 General Requirements for Pipe Support Design
x The design and arrangement of pipe supports shall assure that the piping is adequately supported. Pipe
supports shall be economic and simple within the safe and functional requirements. The component el-
ements of the standard catalogue of the manufacturer shall be utilized where possible and practicable.
The design shall be optimized by combining supports and restraints situated at the same location, for
example, by providing common supports to closely spaced pipes. The existing structure and also the
primary steel shall be used to support the pipes wherever possible according to “best practice” and “state
of the art”. Basis for a suitable support design and arrangement are the corresponding necessary calcu-
lations, see chapter 4.4 “Calculations” of this specification.
x Supports, hangers, and anchors shall be able to be installed without any interference to the free expan-
sion and contraction of the piping between anchors, axial stops and guides. All parts of the supporting
equipment shall be designed and be able to be installed without possibility of disengagement by move-
ment of the supported piping during any plant operating condition.
x Adequate support spacing and space for installation shall be provided, see also chapter 4.3.3 “Design
Requirements concerning the Clearances and Minimum Distances” of this specification.
x For Material codes and Design standards, see chapter 2.4 “Materials of Pipe Supports, Hangers, Con-
straints (Restraints), and Secondary Steel” and attachment [A7] (Base support type abbreviations).
x Welding attachment materials shall be compatible with the pipe material.
- Shear lugs shall be used for dynamic clamps (e.g. Lisega type 36 and 37)
- Flat lugs shall be used for clamp basis (e.g. Lisega type 49) and for the vertical riser clamps (e.g.
Lisega type 45 up to 350°C)
- Trunnions shall be used for vertical riser clamps (e.g. Lisega type 48) and dynamic restraint clamps
(e.g. axial stop, snubber etc.)
Other pipe attachments and pipe weld-on parts need the approval by Siemens.
x For vertical pipe routing, riser clamps equivalent to Lisega type 45 (up to DN125) or Lisega type 48 shall
be used.
x Requirements for plastic piping: See following listed chapters of this specification:
chapter 2.4.2 “Support Materials for Plastic Piping”
chapter 4.3 “Piping Design Rules”
chapter 4.3.9 “Design Requirements for the Yard and Underground Piping”
x For M-System Piping [A1], the special requirements of the TE- Guidelines [108] and STIMs [109] shall be
considered. All supports in M-System Piping shall be designed with locking devices at bolts and nuts.
x For scope and limits of supply for support and secondary steelwork, see referenced “Checklist Scope
and Limits of supply and services for piping” [102].
x The effects of friction in sliding supports shall be checked carefully close to mechanical equipment. If
friction forces exceed the allowable limits of this equipment, low friction sliding plates or rigid hangers
may solve this task. The use of sliding plates (inclusive the friction factors) is defined in DR 009 [110].
x For “hot piping systems (>350°C)”, trunnion-based riser clamps are defined for pipe sizes >2”.
x The support design shall consider the thermal insulation of the piping. Pipe supports shall be designed in
such a way that a minimum amount of heat is transferred into the structure. The temperature of the steel
structure shall not exceed 80°C.
x Vibrations during operation shall be reduced by use of sliding supports, stops, and pipework dampers
(for example, Gerb “VISCODAMPERS®”). For lines prone to vibration, the use of approximately one
third of frictional supports (supports with sliding contact) is mandatory.
x For special support requirements due to inline components, see chapter 4.6 “Inline Components” of this
specification: (See also chapter 4.6.1.5 of this specification. Safety valve back pressure forces shall be
considered in support calculation).
x Design consideration shall be given to:

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¾The support effects on stress limitations in the piping systems

¾The related reaction effects on the terminal equipment to which the piping is connected
¾The related effects within the support assembly components
x Insulated piping shall be designed with clamp shoe or connection lug outstanding from insulation.
x Stainless steel shim-plates are required between stainless steel pipe and carbon steel supports.
x For supports attached to existing concrete, approved expansion bolts (walls and ceiling) and approved
chemical bolts (floor) shall be used. A verification calculation shall be provided. Minimum recommended
dowel size is defined with dowel diameter of 10 mm.
x The supports shall be designed to incorporate cleaning loads and pressure test loads without additional
temporary measures.
x Suitable spring travel limitation shall provide safety, if the spring support fails.
x For <1” piping (instrumentation), the smaller pipes may be supported on bigger ones, if the displacement
of the big pipe is taken into account for the support concept of the smaller pipe. For yard area also piping
<=2” may be supported on bigger ones.
x Spring and constant hangers as well as dynamic supports shall be suitable located to satisfy the needs
of adjustment and monitoring during operation.
x For pipe systems with (horizontal) movements between cold and hot position with more than 100 mm,
the hanger clamps or rods shall be preset in cold condition. The movement shall be clearly indicated in
the support drawings.
x Restraints fabricated from structural steel shall have a clearance of 2 mm in direction of the restrained
movement except for the vertical direction. The clearance shall be enlarged up to 6mm, if defined by cal-
culation of thermal expansion.

5.1.1 General Use of Pipe Clamps and U-Bolts

5.1.1.1 Pipe Clamps:
In general, pipe clamps shall be used for supporting of pipework. Exceptions are defined in chapter 5.1.1.2 of
this specification.

For the M-System Piping [A1]:

The respective STIMs [109] shall be considered. See also chapter 2.4.1 “Support Materials for Steel Piping”
of this specification and herein defined pipe clamp types.

5.1.1.2 U-Bolts:
U-Bolts may be used (instead of pipe clamps) for non-insulated pipes (without hazardous medium and for
low-pressure piping only) with pipe sizes <=10”.

U-bolts may be used for “oil vapour exhaust”, routed to above roof level (part of MAV system)

U-Bolts shall not be used for plastic piping.

Generally the U-Bolts are not foreseen for axial stops or load carrying purpose.

5.1.2 Supports for Steel Double-Wall Piping

For the control oil piping (MAX), the “MA-Guideline” [101] chapter 3.2” shall be considered for the support
design.

5.1.3 Supports for Plastic Piping (General Requirements)

All steel supports shall have rubber or PE-inlays between pipe and clamp.

For materials, see chapter 2.4.2 “Support Materials for Plastic Piping” of this specification.

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5.1.3.1 Supports for GRP Piping

Pipe clamps shall be used for the GRP piping support design.

The pipe clamps shall be adjusted to the tolerances of outside diameter of the GRP piping. The inner edges
of the clamps shall be free from any sharp contours which could damage the GRP material.

5.1.3.2 Supports for Thermoplastic Piping

The pipe support clamps shall be adjusted to the tolerances of outside diameter of the plastic piping. The
inner edges of the clamps shall be free from any sharp contours which could damage the plastic.

5.1.3.3 Supports for Thermoplastic Double-Wall Piping

For the supports, the design requirements of supplier for double-wall piping shall be considered. A calcula-
tion shall be done to achieve a suitable support concept (inclusive suitable support distances by manufactur-
er).

5.1.4 Rigid Rod Hangers

Following items shall be considered for the rigid rod hangers:
x Hanger rods shall be subject to tensile loading only.
x The maximum swing angle of rod due to horizontal pipe movement shall be less than 4 degrees from
vertical. In excess of 4 degrees, the hanger shall have a pre-setting of 2/3 of the thermal movement in
cold position, but limited to the allowable limits of the load chain.
x Hangers shall be adjustable.
x Suitable locking devices shall be used at all threaded connections of the hanger assembly.
x Every half assembly of a riser support shall be able of supporting the entire load.
x Overall rod length shall be limited to 4 m. Upon request exceptions are possible.

5.1.5 Variable Spring Hangers

x Variable spring hangers shall be in accordance to MSS-SP-58 Type 51, 52, 53 and designed according
to Siemens approved manufacturer standards, for example, Lisega.
x Swing angle of variable spring hanger shall not be in excess of 4 degrees on each side of neutral posi-
tion. Adjustment for construction tolerances after the hanger erection inclusive locking devices of the
hanger in its final position shall be considered.
x The spring shall have a load variation of maximum 25 %.

Load variation = thermal displacement x spring rate x 100 % <= 25 %

design load

5.1.6 Constant (Spring) Hangers

x Constant spring hangers shall be in accordance to MSS-SP-58 Type 54, 55, 56 and designed according
to Siemens approved manufacturer standards, for example, Lisega. The ASME requirement for maxi-
mum friction restriction shall be considered (maximum 6%)
x Swing angle of constant spring hanger shall not be in excess of 4 degrees on each side of neutral posi-
tion.
x Constant spring hangers shall be used in all piping systems where calculated movement would cause a
variability factor greater than 25 percent.

5.1.7 Snubbers
x Snubbers shall be used where the piping system is subject to shock loads.

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x If the swing angle exceeds 4 degrees and/or the total pipe movements is in excess of 50 mm, the snub-
ber assemblies shall have a pre-setting of 2/3 of the thermal movement in the cold position. But the pre-
setting is limited to the allowable limits of the load chain.
x Total possible travel of the snubber shall exceed the thermal movement by 50 mm (2 x 25 mm).

5.1.8 Rigid Restraints (Axial Stop, Guide Supports, Rigid Struts)

x Rigid restraints shall be used to restrain the movement of pipe in the direction of the restraint.
x If the swing angle of rigid struts exceeds 4 degrees and/or the total pipe movements is in excess of
50 mm, the assemblies shall have a pre-setting of 2/3 of the thermal movement in the cold position. But
the pre-setting is limited to the allowable limits of the load chain.

5.1.9 Fix Point Supports

x A fix point (such as anchor supports) shall be used where a full constraint of piping against 3 deflections
and 3 rotations is required.
x Fix points shall be avoided whenever possible.

5.2 Secondary Steel

The secondary steel shall connect the pipe clamp inclusive load chain to the main (primary) steel structure in
a reasonable, functional, and safe way with respect to the best practice and state of the art.

5.2.1 Secondary Steel Connection to the Main Steel Structure

In general, the secondary steel shall be welded to the main steel structure. Clamped and bolted connections
need the written approval by Siemens.

Welded connection directly on galvanized steel is not permitted.

5.2.2 Secondary Steel Design Rules

The secondary steel has to follow the rules defined in chapter 2.4.3 ”Materials for Secondary Steel: Code
Definition” of this specification. Manufacturer standard support systems like Hilti, Sikla, and Halfen may be
used upon written confirmation by Siemens. The design rules of the manufacturer shall be followed.
If European steel standards are used, following steel profiles shall be preferred for the design of secondary
steel:
HEA-, HEB-, U-, equal sided L-, and MSH-profiles (MSH-profiles / EN10210, if confirmed by Siemens)

Generally the steel structure shall consider the necessary stiffness to ensure a safe supporting.

6 Instrumentation
Requirements for instrumentation for GTPP-, CCPP- projects are defined in project-specific TCC 2.1-09 “In-
strumentation and Peripheral Devices” [107] and herein referenced TCCs. This includes following items (not
a comprehensive list):
x Sampling lines, up to the first shut-off valve
x Instrument lines, up to the first shut-off valve
x Flow measuring orifices and flow nozzles complete with instrument lines
x On request, the Contractor-prefabrication has to provide pieces of straight pipes for the fabrication of the
flow measuring devices. Not applicable for thermoplastic piping.
x Level switches and remote level indicators up to all required shut-off valves, applicable only if not in
scope of component supplier. In this case Siemens will inform the Contractor.
x Control valves
x Condensation chamber, according to drawing [112]

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Instrumentation for local indication in scope of supply of the Contractor-prefabrication shall be installed by
the Contractor-site. This includes following items (not a comprehensive list):
x Local thermometers
x Local pressure gauges
x Local flow indicators

All facilities required for attachment, installation, and connection of instrumentation shall be provided by the
Contractor-prefabrication. The scope includes the necessary nozzles, lugs, and flanges, plus items directly
associated with the piping. These items are directly associated with the piping including such parts as isola-
tion valves, reducers for instrument lines, signal lines for control valves and complete flanged joints with gas-
kets for all instrumentations.

For SPP-Projects, special additional requirements which are implemented in the project-specific TCC 2.1-09
[107] have to be considered.

For M-System Piping [A1], the special requirements of the TE-Guidelines [108] and STIMs [109] shall be
considered if applicable.

7 Special Earthing Requirements

Concerning work safety during electric welding works, the pipe shall be properly grounded close to the weld.
Removable pipe connections, e.g flanges, in hazard zones shall be electrically bonded prior to dismantling.
For details of permanent earthing measures for purpose of lightning and explosion protection, the project-
specific earthing concept shall be considered.

The following requirements for metallic piping apply, considering also the magnetic field effect of electric arc
(earthing close to spot welding).

Earthing of above ground outdoor pipework shall be considered, if specified. For the details of earthing re-
quirements, see DR 008 “Earthing” [110]. Weld-on lugs of same material as main pipe shall be used. For
galvanized piping, a clamped solution shall be considered if applicable.

For general requirements for cathodic protection, see chapter 4.8 “Cathodic Protection” of this specification,
and for details of cathodic protection, the project-specific requirements shall be considered. For insulated
piping, the cladding shall be considered for earthing.

For fuel gas piping, additional earthing according to gas rules / regulations / standards shall be considered, if
project-specifically defined applicable.

8 Quality Assurance / Quality Control (QA / QC) for Steel Piping

8.1 Quality Assurance / Quality Control (QA / QC) for Steel Piping, general items
The quality assurance / quality control (QA / QC) for steel piping shall apply for all works of the Contractor
detailed in the contract including inspection and tests in shop and site.

The general requirements for QA / QC defined in the project-specific TCC 3-11 "Quality Assurance and
Quality Control" [107] shall be considered.

For the scope of supply and services related to QA / QC, the “Checklist Scope and Limits of supply and ser-
vices for piping” [102] is binding. The Contractor shall provide all testing and checks defined in this specifica-
tion and in the quality control plans.

In general, examination, inspection, and testing shall be performed based on the requirements specified in
chapter VI of ASME B31.1.

Variations and additional requirements are specified in the chapter 12.2 “Welding Procedures and Qualifica-
tion for Steel Piping Systems” of this specification.

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8.2 Qualification of the Contractor / Fabricator / Prefabricator for Steel Piping

The Contractor shall be certified to ISO 9001 by a third-party.

The contractor shall ensure that the certification of hardware and works is accomplished through a quality
assurance program (including ASME requirements, such as ASME BPVC Section II SFA-5.01), by which the
manufacturer verifies that the product (incl. welding consumables) meets the requirements of this specifica-
tion.

The manufacturer shall be able to provide suitable established written practice (WP) and Welding procedure
qualification (WPS), considering the guideline SNT-TC-1A or ASNT CP-189. BPVC Section IX and V shall be
considered as far as referenced by ASME B31.1. The welding personnel shall be trained and tested and
certified according to WP. The approval of welding personnel shall be supported by examinations and
demonstration of the employer’s written practice.

The Contractor shall fulfil all environmental, health, and safety requirements of Siemens. For the details, see
the chapter 2.2.9 “Regulations and Standards“ of this specification.

For the first qualification of inductive bends, the “Requirements for Induction Bends / Siemens In-Process
Examination Sheet No. 1” [A14] shall be used for reference, but it has to be updated project-specifically.

Bending procedure qualification shall be done with available equipment and largest diameter / smallest wall
thickness for the bends, to be witnessed by Siemens.

For the fuel gas piping and potable water system, the erection company shall be qualified to national re-
quirements, if applicable.

8.3 Qualification of Service Provider for the Heat Treatment

Only qualified service providers for heat treatment (ISO 9001 certified companies with integrated heat treat-
ment procedures, educated, trained, and tested personnel for heat treatment) are allowed to perform the
heat treatment works.

8.4 Welding - Personnel Qualification for Steel Piping

For personnel qualification for welding reference is made to:
x Chapter 2 “Codes and Standards” for the design code
x Chapter 12 “Welding of Steel Piping Systems”
x The requirements of ASME B31.1 Chapter V shall be considered by means of:
Steel welder / welding operator qualification (PQR/WOPQ) according to the requirements of ASME
B31.1 para. 127.5 - for welding / 128.5.1 - for brazing. Welders shall undergo a skill test prior to the job
welding.
Generally the welders / welding operator shall be adequately trained, have sufficient skill and experience for
the job and own valid certificates for the job on power plant site.

8.5 Personnel Qualification for Testing / Examination – Steel

Generally for the ASME piping and valves, the personnel qualification must be approved by Siemens on
following basis:

by written practice based manufacturer certification such as

x SNT-TC-1A or
x ASNT CP-189 (of American Society for Nondestructive Testing)
Or
by third-party NDT personnel certification such as
x ASNT certification level or

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x ANSI/ASNT CP 106 or
x ACCP (ACCP professional) (ASNT Central Certification Program)

For expiration and renewal of qualification, the BPVC, Section IX, QW-322 shall be considered.

A vision screening test certificate (eyesight test) for all testing personal shall be available.

For visual examination (VT) [A1]:

Knowledge and experience for examination is mandatory for personnel qualification.

For Hardness testing (HT) [A1]:

Knowledge and experience for examination is mandatory for personnel qualification.

For MT / PT / UT / RT [A1]:
The minimum level II shall be considered for the testing and evaluation of results.

Generally the welders / welding operators shall be adequately trained, have sufficient skill and experience for
the job and own valid certificates for the job.

8.6 Inspection and Testing Organization for Steel Piping

Non-destructive testing carried out on piping systems (all systems) shall be performed by:
x An inspection organization of the manufacturer, which fulfils the written practice
Or
x An external contracted service provider for performing NDT. The contracted service provider shall be
accredited, qualified, and certified in accordance with EN ISO/IEC 17025 or EN/ISO/IEC 17020 or quali-
fied under the ASNT ACCP program or equivalent.

8.7 Non-Destructive Testing (NDT)

For parts manufactured in shop or on site the examination, inspection, and testing shall be performed in ac-
cordance to the minimum requirements of the design code and the testing standards. In addition, the re-
quirements of Siemens are applicable. The extent of testing to be performed shall be executed in accord-
ance with the written procedures. Additional testing is required to achieve the Siemens safety level, not yet
covered by provided testing (such as bending tests, hardness tests, impact testing, if applicable).

For fuel gas and potable water piping, national rules shall be considered.

The test requirements of coated piping (inclusive epoxy coated and rubber lined piping) shall be defined
project-specifically.

The NDT shall be performed after the final PWHT.

If the feasibility of NDT is limited by the design, individual solutions shall be suggested by the Contractor and
mutually agreed.

8.7.1 Visual Examination for Steel Piping

Visual examination of welds shall be in accordance to ASME B31.1, para. 136.4.2 (referencing BPVC, sec-
tion V, article 9) shall be considered for the methods of testing. Sufficient illumination shall secure adequate
inspection possibilities (>=500 Lux)

8.7.2 Surface Crack Testing for Steel Piping

Surface crack testing, such as magnetic particle- and liquid penetrant testing, shall be conducted and evalu-
ated in accordance with the ASME B31.1 design code considering the applying testing standards.

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The concerned area for surface crack testing shall be the top layer of the weld and 30 mm of parent material
on both sides of the weld.

For PT, ASME B31.1, para. 136.4.4 (referencing BPVC, section V, article 6) shall be considered for the
methods of testing.
For MT, ASME B31.1, para. 136.4.3 (referencing BPVC, section V, article 7) shall be considered for the
methods of testing.
8.7.3 Metascope or Ferritic Check for Steel Piping (PMI)
The material of steel piping shall be confirmed by positive material identification (PMI). The checks shall be
performed by spectroscopic analysis or X-ray fluorescence analysis (XRF / RFA). The equipment of XRF /
RFA needs certification and authorisation. For the details of metascope testing, the non-mandatory appen-
dix B of ASME BPVC Section I may be used as acceptance criteria if defined project-specifically.
8.7.4 Hardness Test for Steel Piping
The hardness shall be tested according to EN ISO 9015-1 “Destructive tests on welds in metallic materials -
Hardness testing - Part 1: Hardness test on arc welded joints”. The hardness testing shall be performed ac-
cording to EN ISO 6507-1 to -3 “Metallic materials - Vickers hardness test”. The measuring shall be provided
according to TIV (Through indenter Viewing) or to UCI (DIN 50159 Ultrasonic Contacts Impedance). For
each test series, only one method is allowed.

The widely-used testing devices from Krautkramer (GE Inspection Technologies) are MIC10 and MIC20 for
UCI and TIV (with using TIV a more exactly measuring is possible). For UCI the reference material shall be
documented (material, dimensional data, and surface conditions). For conversion of testing results into other
hardness values or into material strength, the requirements of EN ISO 18265 shall be considered. DGZfP-
Guideline MC1 for portable testing of the German association for NDT (Deutsche Gesellschaft für
Zerstörungsfreie Prüfung e.V.) or similar standards shall be considered.

Before grinding, the wall thickness of carbon and alloy piping shall be measured to check, if enough excess
material is available for the grinding. The final surface wall thickness measurement shall be taken and rec-
orded. The Contractor (for prefabrication and site works) shall ensure that the minimum required wall thick-
ness is still available. Measurements shall be taken on equally distributed angles around the circumference if
applicable. If measurements in the heat affected zones (HAZ) are agreed for P91 / P92 (9%Cr) materials,
etching is required to identify the HAZ.

Hardness measurement traverses shall be performed on both parent metals as well as on the weld metal.

8.7.5 Ultrasonic Testing for Steel Piping

Ultrasonic testing (UT) shall be in accordance with the requirements of

x EN ISO 17640: For characterization of indications of welds, the EN ISO 23279 for carbon and alloy
welds (EN ISO 22825 for stainless steel welds) is applicable.
Or
x ASME B31.1, para. 136.4.6 (Referencing also to BPVC, section V, article 4) shall be considered for the
methods of testing.

The initial testing frequency shall be 2 MHz as Siemens recommendation and shall be 4 to 5 MHz for improv-
ing the range resolution.

For all wall thicknesses > 15mm ultrasonic examinations should be performed instead of radiographic
examination.

For fuel gas piping, special requirements shall be considered, see chapter 2.2.2 “Steel Gas Piping Codes“.

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8.7.6 Radiographic Testing for Steel Piping

Radiographic testing (RT) shall be in accordance with the requirements of ASME B31.1, para. 136.4.5 (ref-
erencing BPVC, section V, article 2). Subsection B article 22 (ASTM (S)E94) shall be considered as guide for
the methods of testing.

RT of shop and field-welded joints shall be performed with X-rays or isotopes. X-rays shall be preferred. In
case of geometric inaccessibility or thicker wall thickness (if X-ray examination is not possible), isotope Ir 192
shall be used. Se75 shall be used for thin walls (as far as X-ray examination is not possible). Special care
shall be taken to choose a sensible film (reaching a sufficient film density in the base material (>2.5 to 3 for
similar wall thickness of connected parts) and for the weld, a film density according to ASME Section V,
Art.2, para. T-282). Further special requirements for RT-films shall be defined project-specifically. Stray radi-
ation shall be avoided. The contractor-prefabrication/erection (respective to the scope) shall provide a de-
tailed testing procedure (for approval by Siemens, if required project-specifically), considering also all com-
plex welding / RT-examination situations.

A film quality according to ASTM E 1815 minimum film class 1 is required. “Table X1.1 Classification” of
ASTM E 1815 can be used for comparison to other standards such as EN 584-1 with minimum film class C4.
Films such as Agfa Structurix D5 PB (SE as further suggestion), or “Kodak Industrex T200 (D5-film), or “Fuji
IX 80” or films equivalent to these films or with better quality shall be used, considering also the requirements
of the ASME Code.

For fuel gas piping, special requirements shall be considered, see chapter 2.2.2 “Steel Gas Piping Codes“.

8.8 Details for Extent of Testing for Steel Piping

The extent of NDT of steel piping is defined in the attached table “Details of Siemens NDT extent for ASME
steel piping” [A10]. This table is based on the ASME B31.1, table 136.4.

For carbon and alloy steel piping (<=2.5Cr content (P22)) without hazardous medium [A1] such as fuel oil,
fuel gas, H2 (and without all lines of part 5 of 6 of Attachment [A10] of this specification):

x If after 20% of total welds to be tested by RT or UT the weld rejection rate is below 2% (on basis of the
NDT extent as detailed in the attached table “Details of Siemens NDT extent for ASME steel piping”
[A10]), the NDT extent shall be reduced to requirements of ASME B31.1 Table 136.4.

x No new welder shall be introduced after the reduction of the NDT extent, or such welder has to be tested
at an expected 20% of his overall welds during the project with the same results as detailed before.

x If the weld rejection rate (after reduction of the NDT extend in accordance with ASME B31.1 Table
136.4) exceeds the before mentioned 2% limit, the original requirements as per attached table “Details of
Siemens NDT extent for ASME steel piping” [A10] of this specification shall apply.

The requirements of chapter 8.10 “General Requirements for Pressure Testing for Steel Piping” of this speci-
fication shall be considered. If lines cannot be hydro-tested because of “open ends” to turbine, condenser,
etc., the required extend of additional NDT has to be fixed during the detail design.

The following additional Siemens requirements shall apply:

For special fittings (according to drawing), a quality plan according to the design code is required, stating all
the testing steps required for the final approval of the item. In general, the special fittings shall consider the
NDT requirements of attachment “Details of Siemens NDT Extent for ASME steel piping” [A10] of this speci-
fication.

The extent of NDT is mandatory for shop and the field welds of the respective piping system as a designated
lot. Addition for NDT below 100%: All materials, all nominal pipe sizes, and all welders shall be considered
for a random spot examination of the welds.

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Critical welds as dissimilar welds or welds made in constraint position, etc. shall be preferably included in the
test lots.

For guarantee welds, the requirements of the design code shall apply, to be agreed upon with involved par-
ties.
For induction bends, the “Requirements for Induction Bends / Siemens In-Process Examination Sheet No. 1”
[A14] shall be considered, but it has to be updated project-specifically.
For procedure qualification of cold bends, the relevant Contractor shall consider following tests on one typical
bend for one diameter for each material:
x 100%VT [A1] for all bends, accompanied by wall thickness measurement
x For alloy bends, 100% PT/MT [A1] in the bending area
x For carbon and stainless steel bends, PT/MT [A1] in the bending area (extrados only)
x For alloy bends only, 1 test with 5 measurements on bend extrados HT [A1] see table “Hardness values
for several materials after manufacturing” defined in chapter 8.9.4 “Acceptance Criteria / NDT Standards
for Hardness Testing for Steel Piping” of this specification.
x The linear, angular and form tolerances of Pipe Fabrication Institute PFI ES -24 “Pipe bending methods,
tolerances, process and material requirements” shall be considered (see also chapter 4.5.2.2 “Design
Requirements for Steel Cold Bending” of this specification).

For productive shop and site cold bends, the relevant Contractor shall consider following tests:
x 100%VT for all bends
x For alloy bends, 50%PT/MT [A1] in the bending area
x For carbon and stainless steel bends, spot check PT/MT [A1] in the bending area (extrados only)
x The linear, angular and form tolerances of Pipe Fabrication Institute PFI ES -24 “Pipe bending methods,
tolerances, process and material requirements” shall be considered (see also chapter 4.5.2.2 “Design
Requirements for Steel Cold Bending” of this specification).
8.9 Acceptance Criteria for NDT and Test Method Procedures for Steel Piping
Generally, the ASME B31.1 chapter VI acceptance criteria are the basis of Siemens acceptance criteria.

The NDT methods shall be in accordance with written NDT procedures and, where appropriate, with NDT
instructions. For induction bends, the “Requirements for Induction Bends / Siemens In-Process Examination
Sheet No. 1” [A14] / ITP [116] shall be considered, to be adapted project-specifically. For cold bends, the
tolerances for cold bends according to ASME B31.1 (referencing PFI ES-24) shall be considered, (tolerances
for cold bending see following formula):

.Dmax – Dmin x 100 = 8 % Maximum

Dnom

D max. is the maximum outside diameter in the bend section of pipe (mm).
D min. is the minimum outside diameter in the bend section of pipe (mm).
D nom. is the average outside diameter of the straight pipe (mm).

All equipment for NDT shall be regularly maintained and calibrated, also if not explicitly required by stand-
ards. Apart from legal requirements for rechecks all machines with recording shall be recalibrated regularly
(at least once a year).
This includes following items, but is not limited to:
x Welding- and heating equipment
x Temperature recording
x Thermocouple
x Hardness testing equipment (daily calibration before starting the testing)
x UT-measurement equipment (daily calibration or more often with recording in the UT-test certificate)
x MT-equipment
x PMI-equipment

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Copies of recalibration documents shall be held available in the shop and on site.

8.9.1 Acceptance Criteria / NDT Standards for Visual Examination of Welds (Steel Piping)
In general, the acceptance criteria for visual examination of welds (steel piping) are defined in ASME B31.1,
para. 136.4.2 (A).The limits of misalignment at weld ends are defined in ASME B31.1, para. 127.3 (C).
8.9.2 Acceptance Criteria / NDT Standards for Surface Crack Testing for Steel Piping
The acceptance criteria for surface imperfections:
For MT, ASME B31.1, para. 136.4.3, shall be considered by the Contractor.
For PT, ASME B31.1, para. 136.4.4, shall be considered by the Contractor.
8.9.3 Acceptance Criteria / NDT Standards for Metascope or Ferritic Check for Steel Piping
The checks performed by spectroscopic analysis shall provide a confirmation of given material certificates.

8.9.4 Acceptance Criteria / NDT Standards for Hardness Testing for Steel Piping
The allowable hardness value in Vickers hardness (HV) is defined in the following table “Hardness values for
several materials after manufacturing” (for orientation, deviating to EN ISO 15614-1 table 2). For electron-
and laser beam welding, the requirements of EN 15614-11 and herein referenced EN ISO 9015-2 shall be
considered. If electro or laser beam welding shall be used, special requirements shall be discussed and
agreed between the Contractor and Siemens.

Basis for a weld acceptance is the correct parent material (with suitable tensile strength) and suitable weld-
ing with correct heat treatment, examination and testing. The heat treatment itself shall be documented
completely in the heat treatment documentation, see chapter 12.3.3 “Heat Treatment for Steel Piping” of
this specification. Additional hardness testing (after check of parent material certificates and check of suita-
ble preparation of testing area) shall be done, if the heat treatment documentation and/or the measured
hardness are indicating a deviation to the limits. If still a deviation to the limits is given, the required action
or alternative measures shall be agreed with Siemens.

8.9.5 Acceptance Criteria / NDT Standards for Radiographic Testing for Steel Piping
In general, the acceptance criteria for RT [A1] of welds (steel piping) are defined in ASME B31.1, para.
136.4.5.
8.9.6 Acceptance Criteria / NDT Standards for Ultrasonic Testing (Steel Piping)
In general, the acceptance criteria for UT [A1] of welds (steel piping) are defined in ASME B31.1, para.
136.4.6.
8.10 General Requirements for Pressure Testing for Steel Piping
In general, the requirements of ASME B31.1, para. 137 shall apply. For fuel gas and buried piping, the na-
tional requirements shall be considered.

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A basic pressure test concept shall be considered, see attachment “Detail Requirements for Pressure Test-
ing” [A11]. In case of deviations to the requirements for pressure testing (related to the design code and/or
Siemens requirements such as the basic pressure test concept), the Contractor-site shall inform Siemens.
Here the Contractor-site shall issue a detailed written alternative for approval by Siemens.

8.10.1 Details for Pneumatic Test for Steel Piping (if applicable)
Pneumatic testing shall be avoided. Only with written approval by Siemens pneumatic testing shall be used
in accordance to ASME B31.1, para. 137.5. Before pneumatic testing, a leakage test <0,5 barg (gauge pres-
sure) shall be done in general.

A project-specific decision shall be provided by Siemens, if gas as test medium is suitable for the fuel gas
system.

8.10.2 Leak Testing of Lube Oil and Control Fluid System for Steel Piping
According to STIMs [109] and if available marked P&ID’s the Contractor-site shall carry out a pressure leak-
age test for:
x The steam turbine lift- and lube oil system, considering requirements of STIM-07.004 [109]
x The control fluid system considering requirements of STIM-03.006 [109]
x For the generator and gas turbine piping systems in scope of BOP piping, the corresponding
TE-Guidelines shall be considered [108]. National rules shall be considered, if defined applicable project-
specifically.

8.10.3 Special Leak Testing of Gas Lines in M-System Piping

For generator connected gas lines, the TE-Guidelines [108] shall be considered for leakage testing (for ex-
ample, H2 waste gas lines the TE-Guideline 06.02-050-102 and 6.02-200-101). Generally the national rules /
regulations shall be considered for leak testing of gas lines.

The waste gas lines (inclusive hydrogen vent lines) must be individually leak tested with compressed air. The
bearing vapour exhausters must be blanked off. Blind flanges must likewise be used to seal off the ends of
the waste gas lines.

Details for Leak Testing of Waste Gas Lines (MKQ) shall be defined project-specifically.

These locations must be closely inspected, preferably by brushing with a suitable foaming agent onto the
suspected leakage. Bubbling or foaming indicates the leak.

8.11 Quality Plans (Such as ITP / FQP) for Steel Piping Systems
Project-specific ITPs and FQPs [116] shall be provided by the Contractor for the defined scope of works,
considering the formats and contents of the templates, supplied by Siemens [119]. Siemens templates shall
be used. Each quality control procedure and ITP / FQP of the Contractor needs the approval by Siemens.
Before start of site fabrication and site erection (see chapter 20 of this specification), the project-specific
“ITP- and FQP-check for preconditions” shall be prepared by the Contractor (considering sample documents
of Siemens [119]). The fulfilment of the “ITP- and FQP-check for preconditions” shall be checked, approved
and signed off by all involved parties.

Also if prefabrication and site works shall be provided by the same company, the ITP and FQP shall be pro-
vided as separate documents by the Contractor.

8.12 Quality Release Note and Provisional Quality (Spool) Release Certificate
The Quality Release Note for shipment (QRN) shall mark the end of the prefabrication activities of a sys-
tem. For divided scope of prefabrication and pipework erection, additionally a provisional quality (spool
package) release certificate or signed-off ITP [116] for the termination of prefabrication activities of a sys-
tem is required. Both types of documents shall be provided by the Contractor-prefabrication and need the
signature by Siemens and by the Contractor.

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9 Quality Assurance / Quality Control (QA / QC) for Plastic Piping / GRP
The quality assurance / quality control (QA / QC) for plastic and GRP piping shall apply for all works of the
Contractor, detailed in the contract including inspection and tests in shop and site.

The requirements of the design code, material specifications* and material data sheets inclusive special
quality-related items such as NDT shall be considered for the quality assurance, and quality control of the
plastic, and GRP pipework. For the scope of supply and services related to QA / QC, the “Checklist Scope
and Limits of supply and services for piping” [102] shall be considered.

The general requirements for QA / QC defined in the project-specific TCC 3-11 “Quality Assurance and Qual-
ity Control” [107] shall be considered.

*(see chapter 2 “Codes and Standards” of this specification)

9.1 Qualification of the Contractor / Fabricator / Prefabricator for Plastic / GRP Piping
The Contractor shall be certified to ISO 9001.

The Contractor shall consider the requirements of ISO 3834 (EN729) / ISO 14731 or equivalent ASME /
ASTM / AISC standards for welding of steel supports. The applicable standards shall be defined project-
specifically.

The Contractor shall fulfil all environmental, health, and safety requirements of Siemens (for example, suita-
ble EHS requirements described in the Contractors EHS manual or incorporated into the quality manage-
ment manual of the Contractor). For the details, see chapter 2.2.9 “Regulations and Standards“ of this speci-
fication.

9.2 Personnel Qualification for Plastic / GRP Piping

Qualified and skilled personnel shall be employed for fabrication and erection of supports in plastic / GRP
piping systems. The guidelines and recommendations provided by the material manufacturer shall be con-
sidered. Before start of the fabrication and erection activities at site, the Contractor shall demonstrate that the
workers have been trained accordingly.
Personnel qualification requirements for welding, lamination, and bonding (gluing) is based on the Design
Code**. Further the requirements of chapter 10 “Welding / Bonding (Gluing) / Lamination” of this specification
shall be considered for required personnel qualification.
** (see also chapter 2 “Codes and Standards” of this specification)

9.2.1 Thermoplastic jointer qualification recommendation (or similar national standards)

The welding personnel qualification for plastic piping depends on type, material, and system requirements.
For these needs, the Contractor shall provide the suitable jointer qualification for approval by Siemens.
Following minimum personnel qualification certificates, suitable for pipework (welding method), shall be pro-
vided by the Contractor:
x DVS 2212-1 test group I [17] (“Qualification testing of plastic welders - Qualification test groups I and II -
Hot gas welding with the torch separate from the filler rod (WF), high-speed hot gas welding (WZ), heat-
ed tool butt welding (HS), sleeve welding with an incorporated electric heating element (HM), heated tool
sleeve welding (HD), and hot gas extrusion welding (WE)”)
Or
x EN 13067 “Plastics welding personnel - Approval testing of welders -Thermoplastics welded assemblies”
accompanied with detailed description of experience of the personnel plus further manual skill tests
(welding of samples), if DVS 2212-1 certificate is not included

For PVC piping, a gluing personnel qualification like the DVS 2221 [19] certificate or similar national certifi-
cate shall be provided by the Contractor (DVS 2221 “Testing of personnel for plastic glued joints, joints for
PVC-U, PVC-C, and ABS with solvent-containing adhesives”).

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9.2.2 GRP piping – welder and jointer qualification

For GRP piping, jointing qualification like the DVS 2220 [18] or equivalent certificate shall be provided:
x DVS 2220 “Qualification testing of plastics welders - Qualification test groups – Lamination as well as
laminate-, and gluing joints for GRP (UP-GF and EP-GF)“ Here: Subgroup II-3 (jointing by lamination),
and II-4 (jointing by gluing/bonding) according to DVS 2200 (dated 1998)
x For new personal tests, the DVS 2200 (dated 2011), subgroup I-2 (jointing by lamination), and I-3 (joint-
ing by gluing/bonding) shall be considered.
x Similar national personnel qualifications for GRP are defined suitable, if approved by Siemens.
9.2.3 Welding Personnel - Qualification for Steel Supports in Plastic / GRP Piping Systems
For steel supports: For the steel welder qualification, the same requirements as mentioned in chapter 8.4
“Welding - Personnel Qualification for Steel Piping” of this specification shall apply.

Approval test certificates for all welders shall be provided by the Contractor.

9.3 Personnel Qualification for Testing – Plastic and GRP

For VT [A1] of plastic and GRP piping, the knowledge and experience for testing is mandatory for personnel
qualification.

For other NDT the testing personnel shall have knowledge, training, and experience of the applicable design
codes, standards, testing requirements and specific testing equipment. The general personnel qualifications
of jointing plastics shall be considered as mentioned in chapter 9.2 “Personnel Qualification for Plastic / GRP
Piping” of this specification.

9.4 Non-Destructive Testing: NDT for Plastic and GRP Piping

For plastic incl. GRP piping, the NDT is defined in the design code and referenced standards. Additional
testing codes are defined in chapter 2.3.2 “Materials of Non-Steel Piping Standards” of this specification.

For plastic incl. GRP piping, the visual examination for each joint and also for the complete piping system
shall be provided by the Contractor in general.

9.4.1 Non-Destructive Testing: Specials for GRP Piping Systems

For GRP piping, 1.5 times the maximum allowed working pressure shall be foreseen as hydro test pressure,
if applicable. For buried piping the test pressure shall be defined according to EN 805.

For bonded / glued plastic joints, the DVS 2204-1 or similar national standards shall be considered for NDT.
The Barcol hardness shall be measured for laminated joint of GRP piping. The Barcol hardness shall be
>=35 for all laminated joints (sample test) according to EN 59 “Glass Reinforced Plastics; Measurement of
Hardness by means of a Barcol Impressor”. 5% of all laminated joints shall be tested for hardness and be
documented by the Contractor. Deviations are allowed after confirmation by Siemens. The Contractor shall
consider the defined number of tests in table “Number of tests on joint”. For the positions, picture “Test posi-
tions” shall be considered. The hardness testing shall consider the hardness testing procedure, to be provid-
ed by the Contractor.

1
Number of tests on joint
Number of tests on joint 5 5
Pipe size in several positions
4 3
” DN150 / 6” 2 (no. 1 to 2)
DN200 / 8” – DN 700 / 28” 4 (no. 1 to 4) 6 6

• DN 800 / 32” 6 (no. 1 to 6) 2

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Picture: Test Positions

9.4.2 Non-Destructive Testing: Specials for Thermoplastic Piping Systems

For thermoplastic welded joints, the DVS 2202 [11] or similar national standards shall be considered for
NDT. For bonded / glued thermoplastic joints, the DVS 2204-1 or similar national standards shall be consid-
ered for NDT.

For thermoplastic above ground piping, the pressure test shall be performed according to the DVS 2210-1
attachment 2 [16]. For below ground piping, the same code may be considered applicable after confirmation
of the manufacturer and Siemens. For double-wall thermoplastic piping systems, the DVS 2210-2 chapter
9.2.5 to 9.2.6 shall be considered.
9.4.3 Acceptance Criteria: Plastic and GRP Piping Systems
9.4.3.1 Acceptance Criteria: Thermoplastic piping
The Contractor shall consider the DVS 2231 for PE, PP, PVC, and PVDF piping systems (thermoplastics).
The table 2 of DVS 2231 shall be considered for acceptance criteria.
For glued plastic piping connections, the DVS 3310 / DVS 2204 shall be considered.
9.4.3.2 Acceptance Criteria: GRP piping
x For GRP piping designed according to EN ISO 14692, the table 4 of EN 14692-4 is applicable for the
acceptance criterion. The frequency of testing shall be suggested by the Contractor, for approval by
Siemens. For the hardness testing, see chapter 9.4.1 of this specification.
x For ASTM orientated design codes, the ASTM D2563 shall be considered. Details shall be defined pro-
ject-specifically.
x For acceptance criteria of other design codes, the Contractor shall provide suitable acceptance criteria
for approval by Siemens.

For visual examination, the following minimum requirements are defined by Siemens:
x Dryness (without white turbidity)
x Sealing (resin on the topcoat surface)
x Shaping (no sharp transitions)
x Air inclusions (not permissible)
x De-lamination (not permissible)
In addition, the requirements of the defined design code shall apply.
9.5 Quality Plans (Such as ITP / FQP) for Plastic and GRP Piping Systems
The Contractor shall incorporate the requirements of this specification into his ITPs and FQPs [116]. Each
quality control procedure and ITP / FQP of the Contractor must be approved by Siemens.

The quality control procedures as part of the Quality plan shall include all requirements defined in:
x Site test procedures (for example, pressure / leakage test procedures)
x NDT - procedures
x Weld bevel / joint bevel and alignment procedures
x Welding / jointing organization procedures

Also if prefabrication and erection works shall be provided by the same company, the ITP and FQP [116]
shall be provided as separate documents.

10 Requirements for Fabrication and Erection Documents, Document Management, and Data
Exchange
The required documents are defined in the “Checklist Scope and Limits of Supplies and Services“[102] (not a
comprehensive list) and in this specification. Following requirements shall be considered for the documents.

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10.1 General Requirements of Documents for Fabrication and Erection, Document Management,
and Data Exchange
General requirements for quality-related documents:

The project-specific TCC 3-07 “Requirements for Electronic Document Exchange between Contractors and
Siemens PG” shall be considered incl. the use of the “PDM-Exchange” web platform (WEB-collaboration) for
the exchange of documents and data between suppliers/consortium partners and Siemens, for project-
specific decision. Herein the electronic handling of documentation is described. The Contractor will receive
the UNID number by Siemens (Siemens unique identification number) as well as drawing number range. The
drawing number range and the UNID number shall be used mandatory for the documentation by the Con-
tractor, which shall be provided to Siemens.

The attachment "Handling of Piping and Support Bill of Quantity (BOQ) / Material Take-Off (MTO)" [124]
shall be considered.

The Contractor shall provide a “drawing transmittal list” in the same format as provided by Siemens along
with each submission of drawings/documents. Siemens will also provide the same along with the submission
of drawings/documents to the Contractor.

For engineering data, the TCC 3-02 “Handling of Engineering Data – Global Plant PDM Data Management”
(SAP) or TCC 3-03 “Engineering data – Smart Plant Foundation” (SPF) [107] shall be defined project-
specifically.

Further requirements are defined in the project-specific TCC 3-07 “Planning Documentation, Operating and
Maintenance Manuals” [107]. Folder structure requirements shall be considered, if defined applicable, for
project-specific decision. The TCC is also used where no electronic form is applicable (The forms used need
the approval by Siemens).

Reference for quality-related documents is made to following chapters of this specification:

x chapter 8 “Quality Assurance / Quality Control (QA / QC) for Steel Piping”
x chapter 9 “Quality Assurance / Quality Control (QA / QC) for Plastic Piping / GRP”
x chapter 22 “Documentation of Pipework”
For progress reporting, the chapter 14 “Progress Reporting” shall be considered.
All the revised portions of drawings/documents shall be highlighted on each issuance.
One (1) Siemens-caused revision of the isometrics and /or support drawings shall be included in the quota-
tion by the Contractor (as per contract order).
For all drawings/documents, which require a format and template review, the Contractor is advised to submit
the format and templates to Siemens for approval before actual preparation works has started.

General requirements for erection-related documents:

Basic requirements for Documentation of assemblies are specified in project-specific TCC 3-05 “Preparation
of Assembly Documents and Documentation of Assembly” [107], if applicable.

10.2 Documents / Design (3D-Model) for the Contractor of the Detail Engineering
Documents, submitted by Siemens to the Contractor of the detail engineering, are defined in the “Checklist
Scope and Limits of Supplies and Services“[102] (not a comprehensive list). The DR [110] shall be consid-
ered by the Contractor of the detail engineering.

In case of conflicting or deficient information in the 3D-Model compared to the corresponding drawings, the
Contractor has to inform in a written form. Siemens will check and decide about the binding document and
update.

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10.2.1 Basic Isometric Drawings for the Contractor-Detail Engineering

Basic isometric drawings will be extracted from the 3D-model by Siemens and submitted to the Contractor
for all lines.

The basic isometric drawings shall be submitted in the following electronic formats:
x “Pdf-file”: Quality assured neutral file (contractual document)
x CAD-file in “Drawing Exchange-format (.dxf) (for information only) if required project-specifically. It shall
be noted that the conversion to other CAD formats (for example: dwg or others) is possible with addi-
tional effort (for information only).

The attached template drawing [A4] is showing the typical level of detail of basic isometric drawings.

For double-wall piping only, special input for MAX lines (part of M-System Piping [A1]), if defined by Sie-
mens.
Siemens will provide separately isometric drawings for the inner and outer piping. The Contractor shall use
these documents as input and provide detail prefabrication drawings.
10.2.2 Basic Dimensions for Special Parts as Input for the Contractor-Detail Engineering
The basic dimensions of special parts are implemented into the 3D Model. It shall be noted that a providing
of drawings for special parts (for example: pdf or Smartsketch®” -format (.sha) or others) is possible with
additional effort (for information only).

10.2.3 Basic Pipe Supports as Input for the Contractor-Detail Engineering

The basic dimensions of basic pipe supports are implemented into the 3D Model according to the “Checklist
Scope and Limits of Supplies and Services“ [102].

10.2.4 Engineering Documents for the Contractor-Detail Engineering

For further documents as input for the Contractor, see “Checklist Scope and Limits of Supplies and Services“
[102] - mainly chapter 4.1 to 4.3. Documents needed for the pipework and not yet given to the Contractor
shall be requested in written form.

In case of deficiency of information in the 3D-Model / Design concerning information of corresponding draw-
ings the Contractor has to inform in a written form. Siemens will check and decide about the binding docu-
ment and update.

10.2.5 3D-Model as Input for the Contractor of the Detail Engineering

The “3D-Review Model” will be provided regularly as electronic data files (electronic document) for
“Smartplant ® Review” – Intergraph.

10.3 Documents as Output from the Detail Engineering

The output documents from the detail engineering shall be provided as defined in chapter 22.2 “Design Doc-
umentation (Detail Engineering Contractor)“ by the EPC-Contractor [A1].

10.3.1 Fabrication- and Erection Documents from the Detail Engineering (e.g. EPC-Contracts)
Fabrication and erection documents shall be provided as mentioned in “Checklist Scope and Limits of supply
and services for piping” [102], for example by the Detail Engineering EPC-Contractor [A1], if applicable.
These documents are detailed in chapter 10.4 to 10.5 (not a comprehensive list) and are binding input for
Shop (spooling)/Site Works.

For the design-, fabrication, and erection documents reference is made to following chapters of this specifi-
cation:
Chapter 15 “Shop Fabrication / Prefabrication / Pre-assembly of Steel Piping”
Chapter 16 “Shop Fabrication / Prefabrication / Pre-assembly of Plastic Piping”

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Chapter 20 “Site (and Close-to-Site) Works”

Chapter 22 “Documentation of Pipework”
10.3.2 Documents as Input for the Contractor-Construction (for C-Contracts only)
The Contractor in C-contracts will receive documents mentioned in “Checklist Scope and Limits of supply
and services for piping” chapter 4.4 [102] (not a comprehensive list), detailed in chapters 10.4 to 10.6.

10.3.3 Detailed Fabrication and Erection Isometric Drawings as Input for the Contractor
The attached template drawing [A5] is showing the typical detailing level of a detail isometric.

10.3.4 Requirements for Spooling Related to Isometric Drawings as Input for the Contractor
Siemens approved final isometric drawings are defined as the leading documents for fabrication works.

The maximum allowable spool length is limited due to the fabrication and transport requirements as well as
the kind of lining of the spools such as epoxy coating and rubber lining.

For all piping with nominal size < 3”, no fit-up allowance (adaptation length) shall be considered in isometrics.

For all piping with nominal size >= 3”:

x For connection of piping with components, an additional fit-up allowance of 150 mm in all three coordi-
nate directions (x, y, z) shall be considered for the isometrics.
x For straight pipe with pipe lengths >15 m, an additional fit-up allowance of 150 mm shall be considered.
x For the systems LBA10, LBB, LBC, possible piping fit-up allowances are defined in the detail isometrics.
x During the prefabrication of flanged component connections, the flange shall be welded on only, if the
end of the connecting pipe is a straight pipe piece.

In general, spools pieces shall be in one plane only.

The Inline components shall not be connected during the prefabrication in the workshop.

10.3.5 Detail Dimension Drawings for Special Parts / Pipe Supports as Input for the Contractor
The detail engineering documents shall provide all technical information in a level of detail as shown on the
typical detail engineering drawings and lists (see the attached sample drawing [A9]) such as:
x Detail engineering dimensioning drawings of special parts
x Detail pipe supports large bore (>=3”)

10.3.6 Pipe Support Documents from the Detail Engineering

The pipe support documents mentioned in “Checklist Scope and Limits of supply and services for piping”
[102] shall be provided by the Detail Engineering EPC-Contractor [A1]. Details such as mentioned below
shall be provided:
x Pipe lugs- and trunnion list / typical
x Document update by any changes

The attached sample drawing [A9] is showing the typical level of detail of a pipe support detail drawing.

10.3.7 Detail Engineering MTO for Piping and Supports as Input for the Contractor
A summary (detail design) detailed MTO (binding character) shall be provided. The MTO template [A3-1]
shall be considered by the Contractor (maybe adapted project-specifically).

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10.3.8 Detail Design - System Overview Sketch from the Detail Engineering as Input for the Con-
tractor
A detail design system sketch (system isometric) shall be provided by the Contractor-Detail Engineering,
showing all lines of a system. This sketch shall be used as an overview (for information only). For example,
system LAB shall be shown in a 3 dimensional isometric view.

10.3.9 Requirements for the Piping Detail Drawings for Buried Piping as Input for the Contractor
For preparation and installation of buried fuel gas lines and other buried piping, the Contractor shall prepare
typical drawings, showing the requirements on the soil, depth, depth of coverage, shape of the trench, com-
paction, backfilling material, and the erection procedures. These typical documents shall be approved by
Siemens. The attached examples [A9] shall be considered for the typical documents as minimum contents,
adopted for project needs, if applicable.

10.3.10 “Quality” Related Documents as Input for Shop / Site Works

For ITP and FQP (inclusive PQR) [116] the special requirements for material, prefabrication-, and site activi-
ties shall be considered. All qualifications, procedures, and testing requirements (inclusive necessary docu-
ments mentioned in the “Checklist Scope and Limits of supply and services for piping” chapter 4.4 [102])
shall be provided project-specifically for application. For requirements of quality documents, the project-
specific TCC 3-11 “Quality Assurance and Quality Control” [107] shall be considered.

10.3.11 Erection Instructions as Input for Site Works

The following erection instructions shall be considered by the Contractor-site as input data (not a compre-
hensive list):
x Pressure circuits and detailed hydro test procedure. Details/changes of pressure circuits shall be harmo-
nized with the documentation. These documents shall be provided by the Contractor in cooperation with
Siemens.
x Siemens cleaning procedures as mentioned in chapter 21 “Pipe Cleaning after Erection to consider by
Contractor-Site” of this specification

10.3.12 Method statements and Risk Assessment as Input for Site Works
The Contractor-site shall provide for approval by SSM [A1]:
x Method statements for non-standard procedures, as mentioned in the TCC 3-12 “Environmental, Health
and Safety Manual” [107], if applicable
x “Risk assessment” (see also TCC 3-12”Environmental, Health and Safety Manual” [107]) for all hazards
related to erection / testing / commission related to the concerned pipework.

10.4 Documents for Prefabrication of the Contractor

The documents for prefabrication are listed in the “Checklist Scope and Limits of supply and services for
piping”, column “supply and prefabrication” in chapter 4.1, 4.2.14, 4.4, and 4.9.4 [102] (not a comprehensive
list).

The Contractor shall provide as-built prefabrication documents.

The documents shall be prepared for site completion, if works are not finalized. The documents of prefabrica-
tor are foreseen to be taken as reference during erection. They shall be completed especially regarding the
field welds, hydro test, and NDT during the erection.

The complete prefabrication documentation shall be handed over with each delivery lot by the Contractor.
Should one system be delivered in several lots, the documentations shall be revised / updated with the new /
revised sections clearly marked by the Contractor.

The Contractor shall keep all necessary supplementary documents in files (which are not yet mentioned and
required by the design code) for own documentation of shop works. On request of Siemens, these docu-
ments shall be provided to Siemens.

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10.5 Documents for Erection Works of the Contractor

The documents for erection are listed in the “Checklist Scope and Limits of Supplies and Services“, column
“erection company” in chapter 4.1.4, 4.4, 4.7, and 4.9.4 [102] (not a comprehensive list).

11 Material Procurement by the Contractor

The “Checklist Scope and Limits of Supplies and Services” [102] and herein mentioned relevant procurement
activities is defining the scope of supply of the Contractor. In general, the material standards defined in the
MTO and in this specification are the basis for material procurement. In addition, the special requirements of
Siemens for some materials (see material specification [111]) shall be considered by the Contractor.

For steel piping, the requirements of chapter 8 “Quality Assurance / Quality Control (QA / QC) for Steel Pip-
ing” shall be considered.

For GRP and thermoplastic piping, the requirements of chapter 9 “Quality Assurance / Quality Control (QA /
QC) for Plastic Piping / GRP” shall be considered.

The radioactivity of any material must in no case be harmful to human beings or technical equipment. As the
material is intended to be used anywhere in the world, the radioactivity has to be so low that it is suitable for
import and any use in any country of the world.
11.1 Additional Materials (for welder skill testing and other Manufacturing Requirements)
For additional material (welder skill testing), the following items shall be considered for each welder:

x The coupons for site welder qualification shall be provided by the Contractor-prefabrication.
x For the carbon steel coupon dimensions, pipe size 4” is defined for welder skill testing of carbon steel
welds. For alloy steel piping the requirements of the material specification [111] shall be considered by
the Contractor, especially the detailed requirements for welder skill testing of grade 91, grade 92,
grade C12A (and similar) see ZTO004-4711-MEC020-479994 [111].
x For the stainless steel coupon dimensions, pipe size 1” is defined for welder skill testing of stainless steel
welds.
x If project-specifically no suitable pipe is defined in scope of delivery, the next pipe size shall be chosen.
Siemens will determine further necessary additional material for piping inclusive secondary steel, according
to the experience (cutting scrap) and needs. The additional material shall be supplied by the Contractor (en-
suring manufacturing according to the time schedule).

11.2 Supplier Monitoring / Expediting

The Contractor shall ensure that the material is delivered as scheduled in the detailed time schedule for pipe-
work, see chapter 4.1.4 of the “Checklist Scope and Limits of Supplies and Services” [102]. The progress
reporting shall be provided regularly to Siemens as defined in chapter 14 “Progress Reporting” of this speci-
fication. These reports and the quality of the material will be checked by Siemens according to required pro-
ject-specific requirements.

For supplier monitoring and expediting, the TCC 3-11 ”Quality Assurance and Quality Control” [107] shall be
considered.

12 Welding of Steel Piping Systems

12.1 General Welding Requirements of Steel Piping Systems
For general welding requirements, reference is made to
x Chapter 2.2 ”Pipework Code”
x Chapter 2.3 “Materials of Piping Components” inclusive Siemens specifications [111]
x Chapter 8 “Quality Assurance / Quality Control (QA / QC)” for all quality-related items

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During inspection (prefabrication and site) of steel welding, the material test certificates, heat treatment certif-
icates, -reports, -charts, welding map, jointing map (flange connections), and NDT records shall be available
for the inspector. For site welding, the skill test- and test piece reports shall be available for the inspector.
12.2 Welding Procedures and Qualification for Steel Piping Systems
To meet the requirements of the ASME Code and Siemens for the ASME piping and valves,
x the Procedure Qualification Records (PQR) shall be checked for the project-specific requirements by
Siemens or competent third-party organization,
x the Welding Procedure Specifications (WPS) shall be checked and additionally approved by Siemens or
competent third-party organization,
x Chapter 8.4 “Welding - Personnel Qualification for Steel Piping“ of this specification for personnel (weld-
ing) qualification shall be considered.
x Qualification of welding procedures to be used and qualification of welders and welding operators shall
comply with the requirements of Section IX of the ASME BPVC and with other referenced Codes. Weld
procedures and procedure qualifications shall meet all of the requirements of the latest issue of ASME
BPVC Section IX as far as not modified in ASME B31.1, chapter 127.5 “Qualification”. Carbon steel pro-
cedures covering ASME P-No. 1 base material shall not include carbon steels with a carbon content
> 0.30 %.
x Further standards may be applicable project-specifically (such as STIMs, for example, STIM-03.009
[109] for M-System Piping [A1])
Before the commencement of pipework, the Contractor shall provide (not a comprehensive list):
x A project-specific list of WPS and PQR (ASME) shall be provided for all used materials, thicknesses, and
configurations to be welded.
x All welding procedures for the various pipe sizes and material groups as part of the prefabrication proce-
dures and erection manual.
12.3 Welding Process and Technique for Steel Piping
12.3.1 Detailed Process and Technical Requirements for Steel Piping
Gas Tungsten Arc Welding (GTAW), also known as tungsten inert gas (TIG) welding, process shall be used
for all root passes and thin walled piping. Filling and covering layer by manual arc welding (SMAW) shall be
preferred. For shop fabrication, the submerged arc welding (SAW) is also accepted. Other welding process-
es (such as ‘gas metal arc welding’ (GMAW or MAG/MIG) and flux-cored arc welding (FCAW) shall be ap-
proved by Siemens. For supports and secondary steel welding, the GMAW (MAG for carbon steel and MIG
process for stainless steel) is allowed for carbon and stainless steel piping (no wind / no air draft is allowed).

For butt weld end preparation, the requirements are defined in chapter 4.5.7.1 “Design Requirements for
Welded Connections” of this specification. Generally, backing rings are not allowed. The butt weld end sur-
faces shall be prepared by machining or equivalent methods.

For generator internal piping (such as MK), only butt welds are allowed (no socket welds are allowed, see TE
Guideline 06.0-050-102).For M-System piping, the STIMs [109] such as STIM 03.002 picture 1 shall be con-
sidered. Deviations need the written approval by Siemens.

The welding of P91 / P92 alloy piping requires the use of backing Argon gas. The shielding of these welds
shall be kept for minimum of 3 layers and minimum 6 mm weld deposit thickness; the maximum allowed
concentration of residual oxygen is 40 ppm. Chambers, or balloons or equivalent shall be used as proper
equipment for purging (especially for stainless steel piping). Purging foils are strictly forbidden if harmful for
later use of piping. Further requirements of the Siemens material specifications shall be considered [111].

Stainless steel welds shall be cleaned in hot condition (immediately after welding) with stainless steel wire
brushes and /or iron-free abrasive discs (area of 20 – 25 mm on both sides of the weld). For stainless steel
piping, the acid cleaning is allowed in shop. All solvents (e.g. for chemical cleaning) used for stainless steel
shall be non-halogenated.

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Oxidation (coloration due to heat influence) on stainless steel shall be avoided, or if not avoidable be re-
moved completely. To avoid oxidation on the inside surface of piping, all welds shall be sufficiently purged.
Attention shall be paid to the purity of the shielding atmosphere. Sufficient purging shall be considered after
welding during cooling down. All oxidation darker than straw yellow shall be unacceptable.

Tack welds inclusive bridge tacks shall be made according to procedures and by welders qualified in accord-
ance with ASME BPVC Section IX. For correct positioning of welding ends, suitable pipe clamps shall be
preferred to tack welding. If alignment with tack welding is required, all filler metals used for tack welds and
also bridge tacks shall be of the same composition as the filler metal for the joint. Bridge tacks shall be ap-
plied only inside the bevel. No bridge tacks are allowed at the piping surface (outer diameter) and not for
connection to main components. Tack welds, which are incorporated into the finished welds (completely re-
melted weld deposit), shall be visually inspected for defects. Generally all welding bridges shall be removed.
All defects shall be removed before covering tack welds with additional weld metal. Defect removal shall be
verified with liquid penetrant or magnetic particle inspection. For small bore piping also pure weld filler metal
may be used instead of distance pieces.

In case of repair welding (inclusive necessary heat treatment requirements), the Contractor shall provide a
repair procedure inclusive detailed inspection plan for the approval by Siemens.
12.3.2 Welding Consumables for Steel Piping
The composition of filler metals and welding consumables shall be of a chemical composition similar to the
parent material. The welding consumables shall be qualified for the welding procedure, considering the re-
quirements of ASME B31.1 chapter V, para. 12.2. Consumable inserts are not allowed. For SMAW, basic
electrodes shall be used. For relevant modified material properties of welding consumables, no F-number
shall be used, but the manufacturer designation of welding consumables. Further ASME BPVC Section IX,
QW404.12 “Requirements of filler metal classification” shall be considered. The approval of this material
shall be provided by the Contractor (PQR/WPS). Generally the A - number shall be used for procedure quali-
fication see QW442. Group number shall be used for materials with impact testing requirements.

Storage and drying of welding consumables shall be temperature and humidity controlled. The instructions
and recommendations of the consumable supplier shall be considered. A procedure for handling of consum-
ables shall be provided for the prefabrication (and as part of the erection manual).
As guideline: Often used standards for welding consumables, see following table “Standards of welding con-
sumable” as a cutout of ASME BPVC Section II, Part C, SFA-5.01 table 2:

Standards of welding consumables (not a comprehensive list)

ISO4063 Welding process Carbon steel (C-Mn-Si) Low alloy steel Stainless steel
111 SMAW ASME/AWS A5.1 ASME/AWS A5.5 ASME/AWS A5.4
141 GTAW ASME/AWS A5.18 ASME/AWS A5.28 ASME/AWS A5.9
135 GMAW (MAG/MIG) ASME/AWS A5.18 ASME/AWS A5.9
136 FCAW ASME/AWS A5.20
121 SAW ASME/AWS A5.17 ASME/AWS A5.23

Requirements for dissimilar metal welds:

x For P91 to Stainless steel piping, using a Ni-based electrode (suggestion of Siemens): ERNiCr-3 such
as Böhler Nibas 70/20-IG for GTAW using Argon shielding gas.
x For carbon steel to stainless steel welded connections <=350°C (design temperature), a 309-Filler as
minimum shall be considered (Siemens suggestion) based on an approved PQR incl. proof of resistance
against corrosion.
x For carbon steel to stainless steel welded connections >350°C (design temperature), a Ni-base electrode
shall be considered, based on an approved PQR incl. proof of resistance against corrosion.

For welding consumables of Grade 91 / P92 / C12A alloy piping the Siemens specification ZTO004-4711-
MEC020-479994, chapter 2.3.2 [111] shall be considered.

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12.3.3 Heat Treatment for Steel Piping

Preheat-, inter-pass-, and post weld heat treatment of welded joints shall be in accordance to a qualified
WPS. The applicable heat treatment plan of welds shall be referenced in the WPS (based on PQR) prepared
by the responsible Contractor according to the ASME B31.1 and recommended practices/ requirements, for
approval by Siemens, especially for the non-horizontal welding areas.

For heat treatment requirements reference is made to:

x ASME B31.1 with reference to ASME BPVC Section IX
x AWS D10.10 ”Recommended practices for local heating of welds in piping and tubing” as guideline, as
far as applicable. The number and location of thermocouples shall be defined for each heating circuit.
For preheating, the extreme hot and the extreme cold area at both sides of weld shall be considered for
the location of thermocouples (controlling and measuring thermocouples) and for PWHT, on the weld.
x As alternative, the following ISO standards are allowed as far as these standards are compliant to the
ASME requirements. The Contractor shall confirm the compliance to the ASME requirements. The num-
ber and location of thermocouples shall be defined for each heating circuit (minimum at the extreme hot
and the extreme cold location at both sides of weld for preheating. For PWHT the thermocouple shall be
located on the weld.
x EN ISO 17663 “Welding - Quality requirements for heat treatment in connection with welding and allied
processes” with correction defined in the standard FDBR N18 - Attachment B [9] as guideline: The re-
quirements of these standards shall be reflected in the project-specific WPS. The number of thermocou-
ples shall be defined according to these standards.
x EN ISO 13916 “Guidance on the measurement of preheating temperature, inter-pass temperature, and
preheat maintenance temperature” shall be considered for the heat treatment as guideline.

Generally the Siemens-related add-on requirements shall be considered (for example, CSEF-Steel proce-
dures [111]).

The heat treatment and holding time for heat treatment shall be considered for the complete weld area (vol-
ume) and heat affected zone (HAZ). For example for piping with sizes > 8”, the length of the heat input zone
shall be >= 8 x wall thickness as a minimum.

The heating rates for heat treatment of the welds shall be defined on the basis of a PQR.
For materials prone to hardness increase (for example, alloy- and thicker carbon steels): Detailed heat
treatment plans and heat treatment procedures shall be provided by the Contractor before starting the weld-
ing for approval by Siemens.

Rough temperature gradients shall be avoided. No additional thermo-residual stresses shall be produced by
heat treatment. For complex situations, the temperature gradient shall be analysed and “tested or meas-
ured”. An even temperature distribution shall be demonstrated.

Complex situations include as a minimum:

x Massive piping components (for example, such as valve bodies) welded to piping
x Welding of material with large differences of wall thickness
x Branches
Piping components shall have a minimum metal temperature of 10°C before any welding (dry condition).

Electric heat sources (heating elements / electro-magnetic source for ferritic steels) shall be used for pre-
heating and post weld heat treatment (PWHT). Temperature monitoring with temperature-indicating crayons
shall be limited to the preheating only. Flame preheating is allowed for piping <= 2” for carbon and alloy pip-
ing.

Electric heating sources, automatic temperature control, and automatic chart recorders shall be used for
PWHT. Heating and cooling rates during post weld heat treatment shall be controlled in accordance with the

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governing code and be defined in the WPS. Thermocouple (CrNi-Cr) inclusive cables according to
EN 60584-2 (Type K, class 1) shall be used. For complex situations, a separate temperature control on both
sides of the weld is recommended. The Contractor shall provide detailed procedures for complex situations
for approval by Siemens. The following table show maximum standard interpass temperatures as guideline.

Table of maximum interpass temperature

Material Maximum interpass temperature
Austenitic stainless steel components 175°C
Ni-base buffering / welding 150°C
Special UNS material (such as N08031, S31.726) 100°C
Grade P91/P92 see material specification [111]

For all carbon steel materials and all other materials, which are defined for PWHT, the NDT shall be per-
formed after the PWHT (additional to the requirements of ASME B31.1, chapter 136.4 “Nondestructive Ex-
amination”).
For the heat treatment charts following minimum entries shall be recorded:
x KKS
x Heat treatment plan number or WPS
x Consecutive unique number of chart recorder
x Weld number, repair index (if applicable)
x Date, name, start time, stamp (name) and signature of heat treatment service provider, additionally the
time at intermediate checks with stamp (name) and signature
The execution of heat treatment shall be documented in chart recorder. A confirmation shall be provided, that
requirements of heat treatment plan are met.
12.3.4 Welding Map
For the welding map, following minimum entries shall be recorded:
General entries:
Unit, system, KKS, page, revision, spool number
Welding joint:
x Weld number
x Status (respecting all repairs, if applicable)
x WPS number
x Weld type, such as BW (butt weld), SW (socket weld), FIL (fillet weld), SEAL (seal weld)
x Weld category (shop/field)
x Diameter (mm)
x Wall thickness (mm)
x Weld identification number
Base metal of both sides:
x Part identification number
x Part description
x Thickness (mm)
x Material (only material number or long text in complete map)
x Heat number
x Certificate number
Filler metal (for all welding processes):
x Filler metal (brand type) (for all welding processes)
x Heat number (for all welding processes)
x Certificate number (for all welding processes)
Welder/welding number /date:
x Welding process number (for all welding processes)
x Welder number (for all welding processes)

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x Welding date
Heat treatment
x Heat treatment Date
x Heat treatment report number
x Repair post weld heat treatment report number (if applicable)

NDT
x VT-, RT-, UT-, MT-, PT-, PMI-Test-, HT-report number [A1]
x Repair 1 examination report number
x Repair 2 examination report number
x Remark (for example, reference to non-conformance reports)
12.3.5 Additional Requirements for Steel Welding Procedures within M-System Piping
Additional to the ASME B31.1 requirements and before mentioned requirements reference is made to:
x STIMs (for example, STIM-03.009) [109] for M-System Piping [A1], especially for the heat treatment
x Within lift oil, lube oil, and control fluid piping the use of harmful inner purging foil and foam plugs is
strictly forbidden. The Contractor has to use balloons or welding chamber tools to seal openings when
flooding the pipe with inert gas for the correct welding procedure. Silicone is not allowed on such tools.

13 Plastic Piping Inclusive GRP - Welding, Bonding (Gluing), Lamination

For general plastic welding / jointing (non-detachable connection) requirements, reference is made to:
x Chapter 2.2.3 to 2.2.7 for the plastic pipework code
x Chapter 8 “Quality Assurance / Quality Control (QA / QC)” for all quality-related items
x Chapter 2.3 “Materials of Piping Components” inclusive Siemens procedures, if applicable
13.1 Jointing for GRP piping materials
Bonding (gluing) or lamination is suitable for GRP piping materials. For details see chapter 4.5.7.4.3 “Design
Requirements for Flange Connections / Couplings in GRP Piping” of this specification.

Jointing methods of GRP piping

Pipe and fitting material Jointing method
GRP <=DN 400 / 16” Bonded joints
GRP >DN 400 / 16” Laminated joints

The Contractor shall provide the selected jointing method (see table above) and limits for approval by Sie-
mens.
13.2 Jointing for thermoplastic piping materials
During inspection of plastic welding (prefabrication and site), the material test certificates, heat treatment
certificates, -reports, -charts, welding map, jointing map, and NDT records shall be available for the inspec-
tor. For site welding / jointing, the skill test- and test piece reports shall be available for the inspector.
Welding is suitable as connection method for thermoplastic materials such as PE100, PP, and PVDF.
Bonding (gluing) or lamination is suitable for GRP piping materials.
Gluing is possible for some plastic materials such as PVC. Glued connections are not allowed in case of any
kind of boiling water.

Following jointing methods are suggested by Siemens:

Thermoplastic jointing methods for thermoplastic piping materials suggested by Siemens
Pipe and fitting material Jointing method
PP Heated tool butt welding, socket welding for OD <= 63 IR (infra-red)
PE Heated tool butt welding, socket welding for OD <= 63
PE (>=OD 280) Electro fusion, heated tools butt welding
PVC Gluing method

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PVDF Heated tool butt welding, IR

Table for jointing methods for thermoplastic piping materials suggested by Siemens

The Contractor shall provide the selected jointing method and limits for approval by Siemens.

13.2.1 Welding / Gluing Procedures and Qualifications for Thermoplastic Piping Systems
Thermoplastic weld procedures shall meet all of the requirements of the latest issue of DIN (EN / ISO)
standards, mentioned in chapter 2.2.3 to 2.2.8. The Contractor shall conduct the tests required to approve
the welding procedures of the Contractor. The Contractor shall conduct the performance qualifications of
welders and welding operators who apply these procedures.

Before the commencement of installation, on request of Siemens, the Contractor shall submit welding proce-
dures for the various pipe sizes and material groups. The welding procedures shall fit to site welding capabili-
ties.

The thermoplastic welding procedures shall consider following requirements or equivalent national stand-
ards, if required by Siemens:

Rules for plastic piping with heated tool jointing:

x Rules related to DVS 2207 “Welding of thermoplastics” [13]
x Design standard defined in chapter 2.2.4 Plastic Piping Code (PE) of this specification
x DVS 2210 “Technical rule: Industrial pipelines (piping) made of thermoplastics:
Part 1: Planning and execution - Above-ground pipe systems (including as addendum)
Part 2: Design, Structure, and Installation of Two-pipe Systems (Bonding (gluing)/Lamination personal
qualification for different plastic materials)

For the rules for plastic piping with fusion jointing, the design standards are defined in chapter 2.2.3 to 2.2.7
(Plastic Piping Code) of this specification.

Furthermore, on completion of welding for plastic piping, the Contractor shall submit the test reports for the
materials used, tests mentioned in the relevant examination, and testing procedures.
13.2.2 Detail Welding / Gluing Process and Technical Requirements for Thermoplastic Piping
The installation shall be implemented via heating element butt welding, heating element socket welding, or
electro fusion welding. Therefore the design code and detailing standards such as, for example,
DVS 2207 [13], manufacturing standard and recommendations, and procedures shall be considered. All
relevant welding parameters for socket welding have to be recorded. All welding has to be executed with
equipment covering the requirements of the standards such as, for example, DVS 2208 [14].

When using heated tool jointing, the welding personnel shall consider the necessary cooling down times of
the welded parts before starting further works on the same spool / part.

The alignment of the pipe, the shaving of the surfaces of the pipe ends (for socket welding), the cleanliness,
and the matching of the plastic pipes shall be ensured before starting the welding / jointing activities.

The jointing shall be provided on dry piping material. The humidity, the temperature of pipe surface (if close
to dew-point), and the location (environment) shall be recorded.

13.2.3 Bonding (Gluing)/Lamination Procedures and Technical Requirements for GRP Piping
Bonding (gluing) / lamination procedures shall be used for the plastic pipework, related to the defined design
code, see chapter 2.2.7 (GRP Piping Code). Before the commencement of installation, the Contractor shall
submit bonding (gluing) / lamination procedures for the applicable pipe sizes and material groups (suitable
for site capabilities / considering the geographic location of plant).

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For skill tests and test pieces, the DVS 2220 “Qualification testing of plastics welders - Qualification test
groups – Lamination as well as laminate- and gluing joints for GRP” shall be considered.

Furthermore, on completion of GRP jointing work, test reports shall be submitted for the materials used. The
heat treatment certificate if applicable, NDT records mentioned in the relevant examinations and testing pro-
cedures shall be provided to Siemens by the Contractor.

When using heated tool jointing, the welding personnel shall consider the necessary cooling down times of
the welded parts before starting further works on the same spool / part.

The alignment of the pipe, the spool end preparation, the cleanliness, and the matching of the plastic pipes
shall be ensured before starting the welding / jointing activities.

The jointing shall be provided when the concerned piping for jointing is dry. The temperature of pipe surface
(if close to dew-point) and the location (environment) shall be recorded.

For buried piping, the suitable stiffness calculation of lines >DN1000 / 40” shall be provided. For
<=DN 1000 / 40”, a confirmation shall be provided by the Contractor, stating that the stiffness of piping is
suitable for the loads (inclusive road loads).

13.2.4 Welding / Jointing Map for Plastic Piping Material

For the welding / jointing map, following minimum entries shall be recorded:

General entries:
Unit, system, KKS, page, revision, spool number
Location, humidity, and temperature recorded (climate protocol)

Welding joint:
x Weld/joint number
x Status (respecting all repairs, if applicable)
x WPS number
Weld/joint type number according to
x Weld/joint category (shop/field)
x Diameter (mm)
x Wall thickness (mm)
x Weld identification number
Base metal of both sides:
x Part identification number
x Part description
x Thickness (mm)
x Material
x Certificate number
Jointing glue / adhesive bonder (if applicable):
x Jointing glue / adhesive bonder (brand type) if applicable
x Certificate number
Welder (Jointer) /welding (bonding) number /date:
x Bonding (gluing), lamination procedure number
x Welder/jointer number
x Welding / jointing date
Heat treatment (GRP with epoxy-adhesives glues/bonds)
x Heat treatment Date (if applicable)
x Heat treatment report number (if applicable)
x Repair post weld heat treatment report number (if applicable)

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NDT
x VT-, Barcol hardness (sample test) of GRP-laminated joints, HT-report number [A1] if applicable
x Repair 1 examination report number
x Repair 2 examination report number
x Remark (for example, to non-conformance reports, if applicable)

14 Progress Reporting
For progress reporting, the project-specific TCC 3-08 “Planning Specification for Major Contracts” [107] (time
schedule and progress report) shall be considered if applicable. The project schedule provided by Siemens
shall be detailed to the required needs, to be defined project-specifically by Siemens.

For all drawings/documents, which require harmonized formats, the Contractor shall follow the format pro-
vided by Siemens. In case Siemens has not provided any format for the same, the Contractor shall submit
the typical format to Siemens for approval, before actual work preparation has started.

The different progress reporting lists/tools as required in the “Checklist Scope and Limits of Supplies and
Services” [102] shall be provided (filled out/completed) by the Contractor, following the templates Siemens
will provide.

The referenced document “Quantity Based Piping Engineering (BOP), Procurement, and Prefabrication -
Progress Monitoring” [121] shall be considered, which is referring further to TCC 3-08 [107]. Herein men-
tioned “Progress report EPF (Engineering, Procurement, and Fabrication)” is a tool for progress reporting for
piping engineering, procurement, and fabrication activities in Microsoft Excel format. Siemens will define the
template and the Contractor shall fill in the required fields as far as applicable.

The referenced document “Quantity Based Piping Erection (BOP) - Progress Monitoring” [122] shall be con-
sidered, which is referencing further to TCC 3-08 [107]. Herein mentioned “Progress Report Erection” is a
tool for progress reporting for piping erection activities in Microsoft Excel basis. Siemens will define the tem-
plate. The Contractor shall fill in the required fields of the template as far as applicable.

Additionally the Contractor shall keep the correspondence list continuously up to date.

15 Shop Fabrication / Prefabrication / Pre-assembly of Steel Piping

Shop fabrication shall be provided by the Contractor-prefabrication as a process that incorporates prefabrica-
tion of steel pipe spools and pre-assembly of supports (see also attachment [A13] in a workshop remote from
the site.

Prefabrication and its documentation apply to the cutting, bending, forming, surface treatment and welding of
individual standard pipe components to each other. Prefabrication includes their subsequent heat treatment
and non-destructive testing (NDT) to form a unit (piping spool) for installation.

In addition, all non-standard parts such as non-standard T-pieces, -reducers, -branch connections, and noz-
zles shall be prefabricated.

15.1 Prefabrication Requirements

For prefabrication reference is made to:
x Chapter 2.2 (and subfolders) for piping design codes and Siemens add-on requirements such as [111]
x ASME B31.1 chapter V for steel piping (special rules for gas piping shall be considered, if applicable).
x Chapter 8 “Quality Assurance / Quality Control (QA / QC)” for quality plans / procedures / welding re-
quirements inclusive heat treatment and testing (compliance with ASME B31.1 and Siemens add-on’s)
x Chapter 10 “Requirements for Fabrication and Erection Documents” (see also chapter 22.4.1) of this
specification
x Chapter 12 “Welding”
x Chapter 14 “Progress Reporting”

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x Chapter 17 “Surface Condition, Corrosion Protection, Coating, Rubber Lining” for surface treatment of
spools
x Chapter 18 “Material Certification for Pipework/Material Traceability/Marking/Labelling”
x “Checklist Scope and Limits of supply and services for piping” [102]

15.2 Prefabrication Specialties

15.2.1 General Requirements for Prefabrication of Steel Spools
For HP- /IP- /LP-piping with pipe sizes >= 3”, a prefabrication of spools shall be provided.

Pipe spools shall be defined for less than or equal the maximum shippable length. The erection sequencing,
available access, and the manoeuvring of the spool in place shall be considered for the spool construction,
particularly for highly congested areas.

Siemens has specified the location and length of the fit-up allowances in the detail design stage in chapter
10.3.4 “Requirements for Spooling Related to Isometric Drawings as Input for the Contractor”.

Dimension tolerances of ASME B31.1 (incl. referenced standards such as ASTM) and “Pipe Fabrication Insti-
tute” standard PFI ES-3 shall be basis for dimension tolerances, defined on detailed fabrication isometric
drawings, which shall be considered by the Contractor.

The scope of prefabrication shall include as far as possible:

x Standard fittings
x Weld-in fittings (such as butt weld fittings) and weld-in nozzles
x Nozzles
x Weldolets, Sockolets
x Lugs and trunnions on alloy / carbon steel piping subject to PWHT (incl. piping attachments)
x Couplings
x Nipples for drains
x Nipples for instrument connections
Weld-end preparations shall be provided according to ASME B31.1 in general for:
x All prefabricated large bore steel spools (except spool ends with fit-up allowances)
x Straight pipe with defined length (without pipes with fit-up allowances)
x Elbows and fittings with weld end preparation for pipe sizes < 3” for IP and LP-piping systems
x For welded connections to valves and components, the following table shall be considered for ASME
piping:

Required UT/NDT-Test length in mm

Nominal Wall Thickness T 10 < T < 25 25 < T
UT/NDT-Test Length 48 2 x T + (Min{50mm;T}

x For critical piping systems, the internal misalignment shall not exceed 0.8 mm all around or 1.5 mm at
any point.
No weld-end preparation (plain ends) for:
x Straight pipes for pipe sizes <3“ for IP and LP-piping systems
x For spools with fit-up allowances, in general

After prefabrication the Contractor-prefabrication shall determine the actual weight of the fabricated pipe
spools (including straight pipes with weld ends) for the HP system feed water, main steam, hot reheat, cold
reheat. Contractor shall provide this information to Siemens via red entries (red correx) of as-built fabrication
isometric drawings.

Note for epoxy coated and rubber lined systems:

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A hydro test (1.5 times the design pressure) for prefabricated spools shall be provided before any coating /
lining. The hydro test shall be witnessed by Siemens/involved parties see project-specific ITP [116].
Project-specific special health and safety aspects or other needs for the prefabricated spools shall be given
by project and site management before start of spooling works, if applicable. (For example, special transport-
/ erection lugs, maximum length of spools).

15.2.2 Special Requirements for Shop-/Prefabrication of HP-, IP-, and LP-Piping Systems
For > 2”: If bending is performed, the induction bending method shall be used for HP-piping systems.
15.2.2.1 Requirements for Inductive (Induction) Bending (alloy steel)
The general requirements of ASME B31.1 shall be applicable for induction bending.

The “Requirements for Induction Bends / Siemens In-Process Examination Sheet No. 1” [A14] shall be con-
sidered.

In addition, the requirements of “material specification and related procedures” for inductive fabricated bends
shall be considered, see chapter 2.3.1 “Steel Piping: Main Material Design Code and Material-Related Pro-
cedures” of this specification.

Before start of inductive bending, one test bend per material type shall be performed and tested.

For heat treatment, hardness range, and testing requirements, the Contractor shall consider the inspection
plan, confirmed by the manufacturer. For inductive fabricated bends designed to be operated in the creep
range the increased testing requirements according to the contract shall be considered, if applicable.

Within the tolerances of pipes, for bends the Contractor shall select pipes within the maximum positive toler-
ance of the wall thickness of its kind.

No humidity and no tremor/vibration shall be applied to the bends during cooling down of bends after bend-
ing.

15.2.2.2 Requirements for Cold Steel Bending

The general requirements of ASME B31.1 shall be applicable for cold bending.

The limits of pipe sizes for cold bending are defined in chapter 4.5.2.2 “Design Requirements for Steel Cold
Bending” of this specification.

For wall thickness of cold bends, see ASME B31.1: Contractor shall provide confirmation that bends fulfil all
requirements of Siemens and design code such as:
x Minimum required wall thickness
x Maximum allowed “out of roundness”
The Contractor shall consider the minimum required wall thicknesses in cold bends by check with the pres-
sure design calculations of Siemens.

All bends shall be smooth and free from buckling, cracks, flattening of the pipe cross section or other evi-
dence of mechanical damage.

For cold bends made from welded pipe, the longitudinal weld shall be near the neutral axis of the bend.

Pipe shall not be bent through an arc of more than 90 degrees.

Welds shall not be made in pipe bends unless reviewed and accepted by Siemens.

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In addition, the requirements of “material specification and related procedures” for inductive fabricated bends
shall be considered, see chapter 2.3.1 “Steel Piping: Main Material Design Code and Material-Related Pro-
cedures”.

15.2.3 Special Requirements for Prefabrication of M-System Piping

In general, the requirements of the STIMs [109] shall be considered for M-System Piping [A1].

MAW10 and MAW2x: The Contractor shall take extra care for prefabrication works and cleanliness by means
of:
x Acid cleaning of the MAW system by the Contractor (Only for lines providing gland steam to the steam
turbine during operation, see also the cleaning criteria of STIM-11.004 [109]. Details shall be defined
project-specifically.)
x Providing a cleanliness procedure, considering the STIM-06.001 “Gland sealing system” [109].

15.3 Measures for avoiding Contamination / Defects during Prefabrication

Lifting and slinging operations shall be carried out using nylon slings or straps. Metal chains and wire slings
shall not be used. Contamination of the pipe surface by corrosive or other detrimental substances, particular-
ly by non-ferrous metals, halogens, and sulphur shall be avoided. No paint, markers, labels, or tools contain-
ing led, copper, zinc, or tin shall be used.

A general separation of stainless steel materials to ferrous, copper, and zinc materials shall be considered.
All tools used for stainless steel spool prefabrication shall be suitable for the stainless steel material, avoiding
any contamination (corrosion).

15.4 Requirements for Prefabrication of Supports / Delivery from shop

The supports shall be pre-assembled to the maximum extend in an economical (related to standards), rea-
sonable, functional, and safe way (safety regulations) with respect to the best practice and state of the art,
suitable for packing, transport, and installation.

For packing of primary supports, the attachment “Definition of pre-assembled load chains” [A13] shall be
considered by the Contractor. “MSS SP-89 - Pipe Hangers and Supports - Fabrication and Installation Prac-
tices” shall be considered for the prefabrication, if applicable.

The primary support shall be provided with suitable coating according to the agreed supplier standard, which
is similar to the requirements of the respective TCC 2.1-07 / 2.1-08 “Coating Instructions …” [107].
The following primary support large bore parts shall be delivered prefabricated and pre-assembled / deliv-
ered from shop:
x Clamp base as serial part (e.g. Lisega type 45 or 49)
x Traverses as serial part (e.g. Lisega type 79)
x Spring- and constant hangers (as defined in see attachment [A13]
x Threaded Rods (standard length) (e.g. Lisega type 67)
x Turnbuckles (e.g. as Lisega type 62)
x Eye nuts (e.g. as Lisega type 60)
x Clevis (e.g. as Lisega type 61)
x Other attachments (e.g. restraints)

The following small bore primary supports shall be delivered as

x pre-assembled (only for serial load chains for small bore supports)
x bulk-material according to support manufacturer standard, if the support is not part of a serial load chain.

The following secondary or intermediate steel support (secondary steel structure) shall be supplied
non- prefabricated, but blasted and prime coated according to TCC 2.1-07 “Coating Instructions (C4)” [107]

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or TCC 2.1-08 “Coating Instructions (C5)” [107], depending on which coating instruction is defined in the
contract (not a comprehensive list):
x trimmer steel/structural shapes like beams, ‘dowel plates and stiffening plates if applicable’
x girders
x dowel or similar in mill-length

16 Shop Fabrication / Prefabrication / Pre-assembly of Plastic Piping

16.1 Requirements for Prefabrication of Spools in Plastic / GRP Piping Systems
Shop fabrication shall be provided by the Contractor as a process that incorporates prefabrication of GRP
pipe spools and prefabrication/pre-assembly of supports in a workshop remote from the site.

Prefabrication and its documentation apply to the cutting, forming, and jointing (bonding / lamination) of indi-
vidual standard pipe components to each other. Prefabrication includes their subsequent heat treatment, if
applicable, and non-destructive testing (NDT) to form a unit (piping spool) for installation. The flange connec-
tions are similar to the steel connections, adapted to the material needs. All other items are similar to the
steel standards if not specially defined by GRP piping design code as mentioned in chapter 2.2.7 “GRP De-
sign Codes”.

For thermoplastic piping systems, prefabrication is generally not foreseen. Exceptionally, prefabrication is
suitable. Details shall be discussed during kick-off meeting.

16.2 Forms and Documents for Prefabrication / Shop Fabrication of the Contractor
The fabrication and inspection documents as well as the final documentation shall be prepared and handled
in accordance with the relevant documentation instruction of Siemens, see chapter 10 “Requirements for
Fabrication and Erection Documents”. The Contractor / sub-supplier may use own forms, if not restricted in
other chapters of this specification, provided that the forms are providing the same information.

16.3 Non-Conformances in Prefabrication / Shop Fabrication

In case of deviations from the stipulated requirement during the prefabrication, the Contractor shall issue a
corresponding non-conformity for approval by Siemens. The Contractor / sub-supplier shall not continue with
prefabrication before written acceptance of the Non-conformance by Siemens in case of critical deviations.
The categories for NCR (for example, critical deviations) shall be provided project-specifically. The form ac-
cording to attachment 4 of TCC 3-11 ”Quality Assurance and Quality Control” [107] shall be used.

16.4 Review and Approval of Documentation for Prefabrication

For review and approval of documentation for prefabrication, the requirements of chapter 8 (QA / QC) shall
be considered. The required scope of prefabrication documentation is defined in chapter 10 and 22.4.1 of
this specification and listed in the “Checklist scope limits of supply and services for piping” [102].

Before start of prefabrication the manufacturer shall send the following prefabrication documents to Siemens
for review and approval (not a comprehensive list):
x WPS (approval only for steel piping)
x Procedures
x Heat treatment plan
x Quality plans (ITP, FQP) [116]

Siemens will review and release the before mentioned prefabrication documents in reasonable time after
reception. The manufacturer shall only commence with fabrication, based on released fabrication docu-
ments.

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17 Surface Condition, Corrosion Protection, Coating, Rubber Lining

17.1 Surface Condition for Piping
For surface condition for inside and outside piping, the project-specific TCC “Coating Instructions” shall be
considered. In detail, the TCC 2.1-07 “Coating Instructions (C4)” [107] or TCC 2.1-08 “Coating Instructions
(C5)” [107] is applicable, depending on which coating instruction is defined in the contract. Cleanliness shall
be recorded according to cleanliness specification [126], if applicable.

All steel spools and threaded piping (incl. galv. threaded piping) shall be protected by tight caps on all open
connections suitable taped (easy handling, with-out any residues)

Prefabricated carbon and alloy piping spools with sizes >= 3” (or >=2”, if confirmed suitable by manufac-
turer) shall be cleaned on the internal and external surface by grit blasting (for details, see TCC “Coating
Instructions” [107]). No primer shall be applied to weld regions (carbon and alloy steel). Therefore a gaffer
tape (easy handling, without any residues) or similar tape shall be used also for shop welds (before priming
the spools according to TCC “Coating Instructions” [107].

Small bore carbon, stainless and alloy piping with sizes <3” (<2”, if confirmed by manufacturer) shall be
provided in clean condition, ready for usage. The particular pipes and fittings shall be free of loose particles
(scale, steel shavings, spatter, grit, salt, sand, dirt, and rust and mill furnish), free of any welding residues,
and free from organic impurities (such as greases and oils). The piping shall be dry and the inside without
any paint. No primer shall be applied to weld regions (carbon and alloy steel). Fine dust shall be removed
with an industrial vacuum cleaner. For small bore carbon, stainless and alloy piping, all openings shall be
capped and suitable taped (easy handling, without any residues, up to fit-up). Cleanliness shall be recorded.

Carbon and alloy fittings shall be blasted according to TCC “Coating Instructions” [107]. No primer shall be
applied on site neither to weld regions (carbon and alloy steel), nor to the inside surface. For small bore car-
bon and alloy fittings, the primer shall be applied by the Contractor / material supplier according to TCC
“Coating Instructions” [107]. Loose small bore fittings shall be protected against pollution / corrosion by single
plastic bags and desiccants or shall be capped and suitable taped (easy handling, without any residues).”

Prefabricated stainless steel spools shall be chemically cleaned to achieve internally and externally clean-
liness. Weld heat tints deeper in colour than a straw yellow shall be removed by mechanical dressing fol-
lowed by chemical cleaning. This requirement may be relaxed, however, where the chemical cleaning cannot
be carried out, mechanical dressing, air blasting, soft-grinding may be used if suitable for the material, by
written agreement with Siemens, as an alternative to chemical cleaning. The piping shall have a suitable
surface after chemical cleaning to avoid later corrosion. Cleanliness shall be recorded.

Prefabricated GRP piping spools shall be provided in clean and protected condition, ready for usage. The
suitable closure, especially for the flange tightening faces, pipe couplings, bell (socket) and spigots and all
straight pipe and fittings shall be defined project-specifically. The particular spools shall be free of loose par-
ticles (such as: salt, sand, dirt), free of any lamination/bonding/gluing residues, and free from organic impuri-
ties (such as greases and oils). The piping shall be dry and the inside without any paint. Fine dust shall be
removed with an industrial vacuum cleaner. Cleanliness shall be recorded.

For thermoplastic piping in potable water system, the Contractor shall consider tight caps on all open con-
nections and suitable taped (easy handling without any residues).

“Epoxy coated- or rubber lined prefabricated piping” in cooling water system shall be internally coated
according to isometrics, see respectively chapter 17.2 / chapter 17.3 of this specification.

17.1.1 Painting Requirements for Contractor-Prefabrication (incl. Manufacturer, if applicable)

Details regarding corrosion protection for the Contractor – Prefabrication are given in TCC 2.1-07 /
TCC 2.1-08 “Coating Instructions” [107] of chapter 17.1 of this specification. Additionally project-specific pro-
cedures and requirements may be applicable. The spool markings of spools shall be visible and readable at
any time. The use of a transparent varnish, compatible with the requirements of TCC “Coating Instructions”

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[107], may be considered, if the prime coating would hide the existing markings. Deferring, project-specific
procedures may be applicable if agreed with Siemens and the Contractor.

For Hot Piping >400°C (for alloyed material and M-System Piping [A1]; for detail scope, see piping list):
Insulated piping shall be treated with a temporary preservative, durable until the time of installation. This
preservative will evaporate when heated, without leaving a residue.

For supports and parts thereof:

x Prefabricated supports, also including support materials such as structural shapes, clamps, and not-
threaded rods shall receive a primer (if not galvanized).
x The primer shall be compatible with the top coat to be applied later.
x TCC 2.1-07 / TCC 2.1-08 “Coating Instructions” [107] shall be applicable for the painting.

Where necessary, a different form of corrosion protection shall be selected for clamps on hot piping; this
shall be subject to agreement with Siemens.

17.1.2 Site Works for Corrosion Protection for Contractor-Site

Details regarding corrosion protection for the Contractor-Site are given in TCC 2.1-07 / TCC 2.1-08 “Coating
Instructions” [107]. Additionally project-specific procedures and requirements may be applicable. The spool
markings of spools shall be visible and readable at any time. The use of a transparent varnish, compatible
with the requirements of TCC “Coating Instructions” [107], may be considered, if the prime coating would
hide the existing markings. Deferring, project-specific procedures may be applicable if agreed with Siemens
and the Contractor.

When receiving the material on site, all spools inclusive areas of the shop-applied coating (and generally all
other provided materials) shall be visually inspected for any damage which may have occurred during ship-
ping and handling. These damaged areas shall be recorded and sent to Siemens for decision.

All field-welded/bonded joints, flanged joints, screwed joints, mechanical joints, and other surfaces left un-
coated in the shop (only welding area), for purposes of field erection, shall be mechanically cleaned before
any field welding. The cleanliness specification [126] shall be considered by the Contractor-Site cleanliness
inspector.

The piping products shall be treated on the outside as appropriate to their intended service with a primer
according to TCC “Coating Instructions” [107] (see chapter 17.1 of this specification) (touch-up paint and
priming of welds immediately after NDT) if required project-specifically.

Supports and parts thereof:

Prefabricated supports, also including support materials such as structural shapes, clamps and rod stock
(not threaded rods) shall receive a primer as mentioned in TCC “Coating Instructions” [107] (see chapter
17.1 of this specification) and also project-specific manufacturer procedures and requirements.

Where necessary, a different form of corrosion protection shall be selected for clamps on hot piping; this
shall be subject to agreement with Siemens.

17.2 Coating Requirements for Prefabricator

Coated carbon steel piping may be used, if GRP piping material or other materials are not suitable / reason-
able. The coatings shall consider the medium for defined lifetime and service conditions. The coating must
protect steel piping system against corrosion, based on the water analysis (see attachment of inquiry). Coat-
ings on yard piping shall withstand environmental impacts, in particular UV-light, and temperatures >30°C,
due to sun exposure. The detail requirements of flanges in coated systems are described in chapter 4.5.7.4
“Design Requirements for Flange Connection for Rubber Lined / Epoxy Coated Piping” of this specification.

For fuel gas piping:

x All fuel gas pipes, which are not made of a corrosion resistant metal, shall be externally coated, see also
subsection 17.2.2. of this specification.

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x National rules for the fuel gas piping shall be considered if applicable.

17.2.1 Epoxy Internal Coating for Cooling Water Pipework

Epoxy coating may be suitable for pipe sizes >=6” for prefabricated spools. In special cases, an fit-up allow-
ance shall be considered. If confirmed by Siemens and the manufacturer, the piping shall be epoxy coated
up to 200 mm before the end of the part (weld end). For site epoxy coating, a field touch up- and repair plan
shall be defined in detail with manufacturer.

The preparation of piping to coating and coating itself shall be handled according to the requirements defined
in chapter 17.1 of this specification. All parts to be epoxy coated shall have sharp edges removed and cor-
ners radius to approximate 5 mm adapted. Weld imperfections such as weld under-run need weld prepara-
tion according to coating instructions and ITP [116].

Details for epoxy internal coating (for example, data sheet IM-PAB/Im2) the mentioned TCC 2.1-07 /
TCC 2.1-08 “Coating Instructions” [107] in chapter 17.1 of this specification shall be considered. The Con-
tractor shall provide the technical data sheet and ITP / FQP [116] of the manufacturer (if applicable) for ap-
proval 4 weeks after the contract for approval. The testing requirements such as visual service inspection,
before coating, after coating, holiday detection, pull-off test (adhesion fracture), and thickness test are de-
fined in Siemens coating instructions, see TCC “Coating Instructions” [107].

17.2.2 External Organic Coatings for the Corrosion Protection of Buried and Immersed Piping (PE)
PE coated buried fuel gas piping shall follow the manufacturer PE coating procedures. These PE-Coating
shall be also suitable for the needs of cathodic protection, electrical insulation, and maybe for salty ground-
water resistance, if required by contract. Further at welding ends a cut back of 150 mm is required for site
works.
A complete set of heat treatment procedures (for pipe and coating, temperature and duration of heat treat-
ment included) shall be provided by the Contractor.
Generally, DIN 30670-N-n shall be considered for PE-coating, with a cutback of 100 to 150 mm, or (EN/) ISO
21809-1 – A1 – cutback 100…150mm with welding primer – under consideration off the MTS with inspection
of incoming pipes, and shall be suitable for cathodic corrosion protection. Special design for 70°C (80°C in
case of ISO 21809-1) operation temperature (“S” instead of “N” or B1 instead of A1) or an increased coating
thickness (“v” instead of “n” or A2/B2 instead of A1/B1) can be agreed project-specifically. The coating shall
be certified in the style of EN 10204-3.1 including the proof of absence of porosities and the maximum tem-
peratures applied during the coating process.
The DIN 30672 “External organic coatings for the corrosion protection of buried and immersed pipelines
(piping) for continuous operating temperatures up to 50°C -Tapes and shrinkable materials” or similar na-
tional standards (if confirmed by Siemens) shall be considered for:
x Pipe connections
x Fittings
x Valves
Primer/Butyl-tape/PE-tapes or similar tape shall be used.

EN 12068 “Cathodic protection - External organic coatings for the corrosion protection of buried or immersed
steel pipelines (piping) used with cathodic protection - Tapes and shrinkable materials”: Class C and herein
related references shall be considered for PE coating on site, coating of welded connections, coating of fit-
tings, and repairing. Further requirements such as defined in, for example, data sheet IM-BUR/Im3, men-
tioned in TCC 2.1-07 / TCC 2.1-08 [107], see chapter 17.1 of this specification, shall be considered. For du-
rability of coating, required minimum and maximum temperature as well as UV resistance according to EN
12068 shall be defined project-specifically (Siemens standard recommendation for durability is >15 years).
Special care shall be taken for the backfilling of buried piping.

Special national requirements for the coating of fuel gas piping (inclusive personnel qualifications) shall be
considered project-specifically, if applicable.

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The coating, proof of absence of porosities, and the maximum temperatures applied during the coating pro-
cess shall be certified in the style of EN 10204-3.1

17.3 Rubber Lining

In special cases (project-specifically) for cooling water systems, a rubber lining may be necessary. The re-
quirements for rubber lining shall be defined project-specifically.

18 Material Certification for Pipework/Material Traceability/Marking/Labelling

18.1 Requirements for Material Certification for Pipework
The Contractor and the sub-suppliers shall submit material certificates in accordance with the requirements
of the material specifications (see also chapter 2.3 “Materials of Piping Components” and subsections of this
specification). For shop- and site fabricated parts, the Contractor shall provide the manufacturing certificates
additionally to the material certificates, according to the attached “Material traceability and certification re-
quirements” [A12]. In case of split of scope of C-contracts (extra Contractor for erection), the Contractor-Site
shall provide material certificates only for self-ordered material and generally for all welding consumables
used on site.

18.2 Material Traceability

A suitable procedure shall be established and maintained for the handling of the used parts and materials
and the respective documentation. This procedure shall cover the identifying of material from receipt, through
prefabrication and erection, up to the final test of the installed piping.
Piece-mark traceability: A permanent marking of material is required in order to ensure bottom-up and top-
down tracing from the installed piece to the material test report (MTR) and backwards. Markings of material
shall be transferred before any cut (e.g. pipe and odd angle elbows) in order to maintain the full traceability.
Additionally, all cuts shall be attested and recorded by an authorized person.
Minimum requirements for marking:
- heat number
- spool number (as per welding book)
Lot traceability: The installed materials shall be traceable lot-wise bottom-up or top-down from the installed
piece to the material test report (MTR) or backwards.
Lot traceability is the ability to trace the history, certification and location of piping components (parts) by
means of recorded identification or references to lots. Furthermore the usage of the correct material for pres-
sure equipment shall be demonstrated by this method.
Separate national rules for defined part of the fuel gas piping system shall be considered if applicable.

For materials not covered by ASME, the material traceability shall be considered as defined in this chapter.

For GRP piping, the manufacturer name, pressure class, size, material-/type identification, and unique serial
number (relation to material batch) shall be laminated on top layer of each pipe / fitting in well readable mark-
ing as minimum requirement.

For plastic piping, the requirements of the design code shall be considered.

The material traceability shall be handled and documented as described in chapter 10, 22.4.1 and attach-
ment [A12] “Material traceability and certification requirements” of this specification.
18.3 Material Marking
The material marking is a necessary add-on of Siemens to the requirements of the design code.
18.3.1 Marking of Spools
The Contractor shall clearly mark the carbon and alloy steel prefabricated spools uniquely (unambiguous) by
hard stamp including also dot markers (with low stress stamp) as shown in the following table “Marking for

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Spools”. Generally non-alloy piping shall be dye marked (chloride-free) good visible in black colour, if no hard
stamping is required by design code / regulations.

For PE-coated piping or plastic piping, another colour may be suitable. Especially for small bore piping the
Contractor shall be able to demonstrate the traceability of material, upon request of Siemens.

Following markings are acceptable for stainless steel piping if possible:

x Dye (chloride-free) marking for items with wall thickness >= 5 mm
x Vibro-etching
x Chloride-free coloured tapes for thin-walled product forms
x Cast integral numbers
The use of coloured stamping ink, felt-tip pens, or adhesive tape is not allowed for stainless steel piping.

Marking of Spools
Material Outside colour marking Additional hard stamping Additional
coating vibro-etching
Alloy steel yes KKS – spool-no. yes no
No, for material 2.2 certificate / yes, for mate-
Carbon steel yes KKS – spool-no. rial with 3.1 certificate or higher certificates
no
Stainless steel no KKS – spool-no. no yes
GRP / Plastic no KKS – spool-no. no no

For GRP piping, the marking colour shall be defined project-specifically

18.3.2 Marking of Loose Piping (in Bundles)
Piping bundles of unmodified straight piping (if not marked individually) shall be provided as required in the
Contract Order, considering all measures, that this label cannot be lost during transport and storage. Further
details are defined in the following table “Marking of loose pipes (in bundles)”.

Marking of loose pipes (in bundles)

Material Outside coating Additional longitudinal Additional hard stampling /
colour marking on site * vibro-etching
Alloy steel yes Material + Size No
Carbon steel yes Material + Size No
Stainless steel no no No
GRP / Plastic no no No
‘*A suitable procedure may replace this requirement, if demonstrated to Siemens for applicability.

18.3.3 Marking of Loose Parts

For loose parts packed in plastic sacks or boxes, each sack and each box / cardboard shall be provided with
labels (see chapter 18.4 of this specification), considering all measures, that this label cannot be lost during
transport and storage. For further marking needs (additional to design code requirements), see chapter 19
“Packing and Transport” of this specification.
18.4 Labelling
The labelling requirements described in project-specific Contract Order shall be considered. For piping
spools (bundles excluded), the spool number shall be marked directly on all primed spools and shall be ref-
erenced in the documentation. For not primed spools and plastic piping inclusive GRP, the marking and la-
belling shall be defined project-specifically. For valves, special requirements are defined in the valve specifi-
cation [125].

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19 Packing and Transport to Site

For packing and transport requirements, the project-specific TCC 3-01 “Packing and Dispatch Guidelines …”
[107], shall be considered by the Contractor if defined applicable. For packing and transport scope of supply,
the “Checklist Scope and Limits of Supplies and Services” [102] is applicable. Directly supply of material from
pipework supplier to site needs approval by Siemens in form of a quality release note (QRN). Details shall be
defined project-specifically by Siemens.
19.1 Packing of Pipework Prior to Transportation to Site
All spools shall be sealed at ends and openings as defined in chapter 17.1 ”Surface Condition for Piping”.
The protection shall not work loose during shipment and storage. Small bore steel pipes shall be provided in
bundles with caps. Tack-welding of metal covers is not acceptable.

In general, for transport, a desiccant (for example, silica gel in bags) shall be put into the steel pipes (as far
as suitable to size), prefabricated spools and plastic bags, suitable for outdoor unprotected storage. No in-
side corrosion and dirt shall be visible after removing the caps on site. For stainless steel spools and fittings,
a packing in closed plastic sheeting is suggested by Siemens when transported in wintertime if there is a
danger of corrosion attack. A metallic contact of austenitic materials to ferritic-, zinc-, or copper materials
shall be excluded.

Care shall be taken for safe packing and safe handling (if handling is scope of the Contractor) in order to
make sure, that the material is not damaged during transport. The packaging units shall be prepared for easy
handling during loading and unloading. Material used for packing shall not have an adverse influence on the
packed items. The bundling of stainless steel with carbon steel straps and adhesive tape with residues on
spools after removing the tapes shall be excluded. If piping is packed on top of each other, a suitable sepa-
ration (soft girder) and fixation shall be considered.

An inspection report (part of the partial certificate of conformity), signed by the Contractor-prefabrication (and
further concerned party / third-party, if applicable) shall be issued by the Contractor-prefabrication. Deviation
to these requirements may be project-specifically defined and needs the written approval by Siemens.

For special piping material such as GRP, other plastic piping systems and lined/coated piping the manufac-
turer recommendations for packing shall be considered.

The Contractor shall provide detailed specific information about the foreseen packing (for example, transport
handling device especially).
19.2 Transportation
A metallic contact of austenitic materials to ferritic, zinc or copper materials shall be excluded.

The coated pipes and supports shall be handled at all times with industry-approved methods. For coated
pipes and supports, the support equipment (such as wide canvas slings, padded cradles, or rubber-covered
separators) shall have been designed to prevent damage to coating. Bare cables, chains, hooks, metal bars,
or similar devices are not allowed to come in contact with the coating. Use only straps, hemp ropes, or aus-
tenitic steel ropes for transporting austenitic materials by crane or similar equipment.

Welded transport lugs on piping shall be avoided. Exceptions shall be specified project-specifically e.g. for
sizes >48” such as cooling water piping or carbon steel process steam lines. Pipe openings shall be kept
closed by the plastic caps up to the fit-up of the concerned piping material. Stainless steel spools shall re-
main packed in plastic sheeting during transportation, if possible. Transfer and installation openings in build-
ings shall be secured. If piping is transported on top of each other, a suitable separation (soft girder) and
fixation shall be considered.

20 Site (and Close-to-Site) Works

20.1 Site Works - General Definitions
On-site works shall be provided by the Contractor-site as a process that incorporates the jointing of pipe- and
pipe spools. Following works shall be considered as site works (not a comprehensive list):

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x Assembly the supports on site (support manufacturer provides pre-assembled load chains)
x Installation of pipe spools, small bore piping and supports (considering “MSS SP-89 - Pipe Hangers and
Supports - Fabrication and Installation Practices”), inclusive secondary steel incl. adaptation to the ter-
minal point location and site requirements
x Secondary steel construction for small bore piping according to typical drawings
x Secondary steel constructions for large bore piping (if project-specific needed)
x Support adaptation
x Bolt length adaptation
x Storage at site
x Offloading and intermediate transportation on site
x Performance of NDT (Scope of Contractor-Site)
x Documentation (see chapter 22 of this specification)
x Survey work (measurements) for piping

The Contractor-site shall provide site fabrication for a limited scope for the steel piping. Small bore cold
bending, jointing of spools and fabrication of secondary steel constructions for supports are mainly con-
cerned for site fabrication. The Contractor-site (inclusive sub-supplier) shall draw as-built fabrication isomet-
ric drawings. They shall document the as-built position of site-welds for review by Siemens / further con-
cerned party. All missing data shall be added to the as-built erection isometric drawings, necessary for all
steps of releasing the piping for operation.

20.2 Site Works - Detail Requirements

For site works reference is made to:
x Chapter 2.2 and subsection of this specification for requirements related to piping design codes
x Chapter 6 “Instrumentation” and Chapter 7 “Special Earthing Requirements“
x Chapter 8 and 9 “Quality Assurance / Quality Control (QA / QC)” (for example: quality plans, procedures,
testing, welding requirements inclusive heat treatment) for the quality assurance / quality control
x Chapter 12 “Welding”
x Chapter 13 “Plastic Piping Inclusive GRP - Welding, Bonding (Gluing), Lamination”
x Chapter 15.2.2.2 “Requirements for Cold Steel Bending“ for cold bending requirements
x Chapter 17.1.2 “Site Works for Corrosion Protection” shall be considered.
x Chapter 18 “Material Certification for Pipework/Material Traceability/Marking/Labelling” especially the
additionally marking of loose piping shall be provided, when receiving the material on site.
x Chapter 10,and chapter 22.4.1 (Documents) for protocols and documentation; The red marking of “as-
built” measurements of isometric drawings, “as-built” support drawings, and P&ID shall be considered.
x Chapter 16.2 “Forms and Documents for Prefabrication / Shop Fabrication of the Contractor”
x Chapter 19.2 “Transportation” for transport of material on site
x Chapter 21 “Pipe Cleaning after Erection to consider by Contractor-Site”
x Chapter 22 “Documentation of Pipework”
x Checklist scope limits of supply and services for piping [102]

Valves and inline components shall be stored by the Contractor-site. By split scope of prefabrication and
erection, the Contractor-site shall provide a written confirmation about all received material. The Contractor-
site shall be able to inform about the site warehouse keeping and stock control. Separate storage areas for
austenitic and ferritic materials shall be ensured. The Contractor-site shall be able to show Siemens the re-
ceived material and prefabricated spools, upon request of Siemens.

Random checks for cleanliness as part of the incoming goods check of piping spools shall be performed
upon on arrival on site by the responsible Contractor-site. All desiccants inside piping spools shall be re-
moved before starting any pipe pipework. A stock keeping on site shall be provided by the Contractor-site
(inclusive storage management and stock control).

Piping placed in storage shall be stored off-ground using soft girders under the uncoated ends. Suitable
wedges shall be used to preclude rolling. Pipe shall be stored on flat drained ground whenever possible.
Valves and smaller parts shall be stored weather protected (warehouse keeping or in container off-ground
safe stored (wedges or other suitable equipment)) as recommended by Siemens.

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Especially for split scope (EP / C – contracts): During receiving inspection at site any damage or deviation to
the scope and properties of received hardware has to be transmitted to SSM [A1] (written transmittal) and
need to be verified by Siemens inspector within 14 days.

Contractor-site shall consider the national health and safety- and environmental requirements and provide,
for example, method statements for this concern.

20.3 Site Works - Works Prior to Starting of the Erection Works (Not a Comprehensive List)
x The Contractor-site has to check the actual position of the coordinates of a certain line and its terminal
points.
x The Contractor-site provides a check of erection prerequisites such as drawings, lists (terminal point list),
FQP [116] / WPS, cleanliness of the material (to record on isometric drawings), lifting equipment, and all
important tools to achieve suitable working conditions (for example, tools to handle austenitic materials
are free from ferritic impurities).
x The Contractor-site shall check the piping for adequate clearance (not a comprehensive list):
¾Between hot pipes
¾To cables
¾To steel structures
x Especially a check for clearance to the piping not routed in the 3D-model (for example, the fire fighting
piping) has to be provided by Contractor-site before starting the pipework.
x The Contractor-site shall check if all necessary information for completion of valves is available.
x The Contractor-site shall inform about the amount of pressure testing medium, required for the pressure
test.
x The bending and welding procedures (inclusive related procedure) shall be available (considering re-
quirements of chapter 15.2.2.2 of this specification. Sand-filled bending is not allowed on site.
x For GRP piping, a suitability test of the jointing glue shall be provided.

x The Contractor shall check the clearance and accessibility (see also attachment [A2] and [A3]) of valves
for operation and maintenance. Especially the junction/terminal boxes or actuators shall be accessible.
The positioning indicator of valves shall be visible.

20.4 Site Works - Jointing by Providing a Tight Flange Connection

The Contractor-site has to ensure by using approved bolt tightening procedures that required tightness is
achieved, without damaging the flange connection.

For high temperature steam lines where weld ring gaskets are used, the 2 parts of weld ring gaskets shall be
seal-welded after chemical cleaning/blow-out (depending on site requirements) without removing the used
grooved metal gasket inside the weld ring gasket.
.

Flanges shall be installed flush and square, without forcing, so that the entire mating surfaces bear uniformly
on the gasket, and then tightened up with uniform bolt tension.

The flange alignment of all flange connections from pipework to components installed by other suppliers shall
be checked, measured, and recorded by the Contractor-site. The component responsible parties (component
supplier and Siemens) shall confirm this record, if defined applicable. No flange connection must be bolted
and fixed without approval by SSM [A1]. If the alignment is not considered acceptable by Siemens due to the
piping spool construction, the Contractor-site has to modify the piping accordingly.

The national requirements for tight piping flange connections (gas and hazardous medium) shall be consid-
ered if applicable.

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20.5 Further Site Works / Requirements

For fuel gas piping, the requirements are defined in ASME B31.1. National gas rules shall be considered, if
applicable. Reuse of piping material is not permitted for fuel gas piping. Defects in fuel gas pipe, or tubing, or
fittings shall not be repaired. If the defective pipe, tubing, or fittings are located in a fuel gas system, the de-
fective material shall be replaced. A reuse of piping material needs generally the approval by Siemens.

20.6 Pressure Testing of Piping on Site

Generally, the design code requirements for pressure testing shall be considered. All tools for pressure test-
ing shall be in scope of Contractor-site such as pumps, pipe hoses, blind plates, gaskets and screws for
temporary pressure testing. Special equipment such as safety valves, ball valves and compressed air tank
shall be provided separately, if defined project specifically. The attachment “Detail Requirements for Pres-
sure Testing” [A11] shall be considered by the Contractor-site. For plastic / GRP piping an project-specific
adaptation of attachment [A11] may be suitable (considering special requirements according to the refer-
enced standard if applicable).

20.7 Site Works - Plastic Piping - Specials for GRP Piping

The site fabrication is defined for a limited scope for the GRP piping. The site fabrication includes:
x Spool length adaptation (cutting of pipe end of spools, end preparation for lamination / bonding purpose
if necessary, heat treatment, NDT, coating, QA)
x Secondary steel construction for small bore piping according to typical drawings, secondary steel con-
structions for large bore piping if project-specific required
x Support adaptation may be concerned

Only in seldom cases further fabrication works (for example, bolt length adaptation) (if required by Siemens)
shall be provided.

For plastic piping, the special requirements of the project shall be considered by the Contractor-site. These
special requirements shall be checked project-specifically with manufacturer, Contractor-site, and SSM, also
with respect to the local regulations / requirements. If buried GRP piping is crossing the UMA/UMC main
gateway or the condenser pre-fabrication area, an equally distributed load of 60 kN/m² shall be considered.

20.8 Site Works - Jointing by Welding / Bonding / Lamination on Site

Each welder / laminator on site shall pass a skill test on a non-productive weld / bond for piping systems if
required project-specifically (suitable material for the welding/bonding material scope). Welders / laminators,
whose performance is already known from prefabrication of the same project or other project in the recent 3
month, do not need to pass this test (same for gluing).

The Contractor-site shall provide all site welds/laminations/glued connections as defined on isometric draw-
ings). They shall be documented in as-build isometric drawings by Contractor-site.

It is the responsibility of the Contractor-site to adjust the fitting length of the pipe spool (defined for this pur-
pose) to the actual situation. The Contractor-site shall prepare the necessary weld end /lamination /bonding
(gluing) end after cutting to a fitting length. Here all concerns for heat treatment, NDT, and QA shall be con-
sidered, see chapter 8 and 9 of this specification. Field welds shall not be hidden by other parts (for example,
parts of supports).

The supervisor of Siemens in charge has to confirm in a protocol, especially for M-System Piping [A1] (prior
the mechanical connection to the Steam Turbine interface), that the allowable forces and moments at the
nozzle / stub are not exceeded. In this protocol, each and every connection has to be listed and signed off.

20.9 Site Works - Non-Conformances to Site Erection Works for Steel and Plastic Piping
During the erection, the Contractor-site / sub-supplier / manufacturer shall bring to attention non-
conformances with the stipulated requirement. The Contractor-site shall not continue with erection of this part
before written acceptance of the non-conformance by Siemens. The form according to attachment 4 of the
TCC 3-11 “Quality Assurance and Quality Control” [107] shall be used.

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21 Pipe Cleaning after Erection to consider by Contractor-Site

After erection of piping on site, the project-specific Siemens cleaning procedures shall be considered.

The marked WSC/HRSG P&IDs (overview and detail P&IDs / heat flow diagrams if applicable) for internal
cleaning after erection, erection instructions, and method statements shall be considered, if HRSG is already
installed. In this case the HRSG cleaning shall be performed in combination with Water Steam Cycle piping.
Therefore the project-specific TCC 2.1-12 “Chemical Cleaning of the Heat Recovery Steam Generator
(HRSG) / Steam-Water-Cycle)” [107] shall be considered for the HRSG and WSC part if applicable.

Temporary piping such as special equipment for bypass and further necessary temporary piping shall be
prepared and installed. After flushing, the temporary piping shall be dismantled and restored to the final
proper configuration by the Contractor-site. Nevertheless the Contractor-site shall check, whether the already
installed temporary hydro test spools can be kept installed and used for flushing. For the generator seal oil
(MKW) system, a pre-cleaning before the pressure test and a final “control” flushing after pressure test shall
be considered by the Contractor-site as special item.

There are following cleaning methods to consider if applicable:

x Chemical cleaning (ZTA) (not in scope of Contractor-site)*
x Once-Through Flushing e.g. geodetic draining (ZTP)
x Oil flushing for oil lines (ZTM) of system MAV / MBV / MAX / MBA (HCO) and MKW (not in scope of Con-
tractor-site)*
x Steam blowing (ZTB) (not in scope of Contractor-site)* and if required:
LBG system: Steam blow-off auxiliary steam system (ZTB) (not in scope of Contractor-site)*
x Air blow-out / Purging for EKG lines downstream the fine filter (ZTE)
x Pigging by means of Pig cleaning (EKG upstream the fine filter in fuel gas system)
x Air blow-out for MAW lines (ZTM) such as sealing steam lines to the equipment

* all works for temporary piping as mentioned before and the quality documentation of cleaning shall be pro-
vided by Contractor-site (by attaching a signed cleanliness protocol).

21.1 Chemical Cleaning

The chemical cleaning (inclusive flushing) as described in the project-specific chemical cleaning procedure
shall remove all oxide products (mill scale, welding slag) as well as all organic materials. The scope of chem-
ical cleaning is defined in the P&ID “General flow diagram for chemical cleaning”. Systems already acid
cleaned during prefabrication (MAW) shall not be chemical cleaned on site.

The special requirements for M-System Piping [A1] are described in the cleaning criteria of STIM-11.004
[109], if applicable.

21.2 Once-Through Flushing

Only water flushing e.g. geodetic draining of pipe sections is applicable for such systems as P-systems,
GHC, and part of EKT.

21.3 Oil-Flushing
For the oil flushing reference is made to following documents of the MAX, MBA (HCO), MAV, MBV, and
MKW piping systems:
x STIM-11.005 “Lubrication Oil System Flushing & Cleaning procedure” [109] for the details of lube oil
system (MAV / MBV)
x STIM-11.009 “Control Fluid System Flushing and Cleaning Procedure” [109] for the details of steam
turbine control oil system inclusive acceptance criteria
x TE Guideline 03.0-200-101 “Bearing oil supply”: A bypass in the supply line shall be considered.

Generally the system shall be installed in a clean way and carefully restored after oil flushing. This installa-
tion includes also external areas and parts, which have been removed for the flushing. The additional tempo-

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rary piping material for lube- and lifting oil system is marked on P&ID. The additional material shall be pro-
vided by the Contractor-prefabrication, if confirmed by Siemens. For the generator seal oil system, no tempo-
rary piping shall be provided by the Contractor, if confirmed by Siemens.

21.4 Steam Blowing

The required temporary blowing material shall be provided by the Contractor-prefabrication. The Contractor-
site shall install the temporary pipework, considering the input data of Siemens (MTO, isometric drawings).
Suitable manpower shall be considered by the Contractor-site for the temporary pipework installation inclu-
sive the removal of inserts, dismantling, and restoring of piping after cleaning.

21.5 Blow-Out with Air

For the gland sealing system (MAW), a blow-out with air shall be considered. Here the Contractor-site shall
consider the installation and dismantling of all temporary piping as described in STIM-06.001 [109]. For ex-
ample, the installation of pressure measurement device and safety valve in the temporary Blow-out piping
shall be considered by the Contractor-site.

21.6 Purging or Air-Blasting / Pig Cleaning (Pigging)

21.6.1 Purging or Air-Blasting (After Fine Filter UEN01)
The stainless steel sections of fuel gas piping systems shall be suitable for complete purging or air-blasting
of each section, if required, due to the routing. Details are described in the purging / blasting procedure /
defined project-specifically by Siemens. Suitable manpower shall be considered by the Contractor-site for the
temporary pipework installation, dismantling, and restoring of piping after purging / blasting.

21.6.2 Pigging (EK in Fuel Gas System)

The carbon steel sections shall be cleaned after erection, considering the pig cleaning procedure. Respec-
tive connections shall be provided by the Contractor-site. If applicable, drain and vent connection on the pig
receiver shall be considered for purging to minimize the number of connections. The project-specific pigging
procedure shall be provided by Siemens. In general, the required documents for pigging shall be provided by
the Contractor-site.

The pigging process shall be done in various steps by the Contractor-site, described in pigging procedure if
available:
x After the hydrotest and draining of the piping, drying with a foam pig or by dried air shall be provided by
the Contractor-site.
x After dehydration, a foam pig shall be driven by compressed air to remove loose particles (for example,
loose rust) and any wetness.
x An air blow-out shall remove further loose particles (if possible to both directions)
x A final white foam pig shall be used for inspection (cleanliness shall be recorded).
x After the pigging of fuel gas system, a piping system ready for operation shall be installed by the Con-
tractor-site.
For the time between pigging and charging (gas-up), the system shall be filled with nitrogen for preservation
purposes by the Contractor-site (including a tightness test).

22 Documentation of Pipework
22.1 General Documentation Requirements for the Contractor
Reference for documentation of Pipework is made to:
x “Checklist scope limits of supply and services for piping” [102] (listing the required documents for docu-
mentation, not a comprehensive list),
x Chapter 8 “Quality Assurance / Quality Control (QA / QC) for Steel Piping” and chapter 9 “Quality Assur-
ance / Quality Control (QA / QC) for Plastic Piping / GRP” of this specification for welding/jointing, heat
treatment, and NDT documents,

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x Chapter 10 “Requirements for Fabrication and Erection Documents and Data Exchange” of this specifi-
cation,
x Chapter 15 “Shop Fabrication / Prefabrication / Pre-assembly of Steel Piping”,
x TCC 3-07 “Planning Documentation, Operating and Maintenance Manuals” [107] incl. “WEB-
Collaboration”, for project-decision. Generally the documentation shall be suitable for integration into the
overall power plant documentation.

The documentation requirements shall be project-specifically adapted to the contractual needs. Generally all
requirements for documentation of this specification, the design code, national rules, and regulations shall be
considered.

22.2 Design Documentation (Contractor Detail Engineering)

For the design documentation, the Contractor shall provide all documents listed in the “Checklist scope limits
of supply and services for piping” [102] in column “Detail PipeWork Designer” (not a comprehensive list).

For highly loaded systems, the results-summary sheet shall be included in the documentation. The full print-
out of the stress calculations shall not be included into the design documentation, but the Contractor shall
keep it in own documentation. Details (such as definition of highly loaded systems) shall be defined project-
specifically.
22.3 Prefabrication Documentation (Partial Documentation of Prefabricator – Required by Split of
Scope Prefabrication and Erection)
For the prefabrication documentation, the Contractor shall provide all documents listed in the “Checklist
scope limits of supply and services for piping” [102] in column “PipeWork Supplier” and column “PipeWork
Prefabricator” (not a comprehensive list).
The documentation shall be provided by Contractor in 2 parts:
x “Partial* Prefabrication Documentation of the Contractor (TQ) (Quality Documentation)
x “Final Prefabrication Documentation of the Contractor (TP)”
(*Partial - by means of “spools not pressure tested”)

Further a Prefabrication Procedure Manual (Documentation) as collection of procedures of the Contractor

(TE) shall be provided to Siemens for approval. The following documents shall be listed: Prefabrication- /
Erection Instructions / Procedures, forms of documents, EHS, ITP and FQP [116] documents.

Separate spare part documentation (list) for “spare parts- (gaskets) / wear parts” (sacrifice anodes) shall be
provided by the Contractor.

22.4 Site Documentation of the Contractor (Documentation of Erection and Quality)

For the site documentation (TE), the Contractor shall provide all documents listed in the “Checklist scope
limits of supply and services for piping” [102] in column “Erection Company” (not a comprehensive list).
The documentation shall be provided by the Contractor in 2 parts:
x “Implementation Documentation of the Contractor (TP)”
x “Quality Documentation of the Contractor”

The “Site Documentation of the Contractor” shall include all site fabrication and erection documents, but not
the documents listed in the “Quality Documentation of the Contractor”, and chapter 22.4.2 “Quality Documen-
tation of the Contractor” of this specification), if applicable.

22.4.1 Implementation (End) Documentation of the Contractor

The final implementation documentation (as-built TP) is a compilation of the design- (TD), prefabrication-
(documents with red entries /revised documents) and erection documentation.

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For the end documentation, the Contractor shall consider the applicable design code. National rules and
regulations shall be considered if defined applicable.

The scope, structure, and content of the documentation shall be agreed upon with Siemens in advance.
Therefore the structure of the documentation of a typical piping system (inclusive filled folders as far as pos-
sible) shall be provided to Siemens latest 4 weeks before the due date of the time schedule, considering the
suitable type of contract (un-spit/split scope of supply). Any changes or updates of already handed over doc-
umentation shall be provided as traceable electronic (paper version shall be defined project-specifically)
delta Documentation (inclusive marked changes), suitable for easy handling.

22.4.2 Quality Documentation of the Contractor

For documents for quality documentation reference is made to:
x “Checklist scope limits of supply and services for piping” chapter 4.8 (Final data package) [102]
x Chapter 2.2 “Pipework Code”
x Chapter 8 “Quality Assurance / Quality Control (QA / QC) for Steel Piping”
x Chapter 9 ”Quality Assurance / Quality Control (QA / QC) for Plastic Piping / GRP”

Required documents from the Contractor are the documents mentioned in “Checklist scope limits of supply
and services for piping” chapter 4.8 (Final data package) [102] and further following listed documents for
plastic / steel piping:

Contractor shall provide for all steel piping:

x Completed and signed ITP / FQP [116]
x Qualification certificates for welding and for bending incl. welder control sheet
x Procedures for special processes such as welding, heat treatment, hot bending, cold bending, NDT, pre-
sure test, cleaning, painting, coating, transportation, and erection
x Certificates according to “Material traceability and certification requirements” [A12]
x The final fabrication and erection isometric drawings (as-built)
x Red marked fabrication and erection documents if deviating to the detail design
x Test records inclusive films / charts of heat treatment, but RT films shall be documented by Contractor
x Only on request of Siemens, a handover of the films shall be provided by the Contractor. The films shall
become property of Siemens in this case
x Pressure test records and equal documents for defined scope of prefabrication
x Cleanliness records
x Documents defined in the “Checklist Scope and Limits of supply and services for piping” chapter 4.4 [102]

Contractor shall provide for all GRP piping:

x Completed and signed ITP / FQP [116], mandatory for site
x Qualification certificates for bonding and gluing
x Procedures for special processes such as bonding, gluing, heat treatment (if applicable), NDT, cleaning,
pressure test, transportation, and erection
x Certificates according to “Material traceability and certification requirements” [A12]
x Fabrication and erection isometric drawings
x Red marked fabrication and erection documents if deviating to the detail design
x Test records
x Cleanliness confirmation
x Documents defined in the “Checklist Scope and Limits of supply and services for piping” chapter 4.4 [102]
x Documents required for documentation by the design code

General final requirements for all piping systems

x Quality documents detailed in chapter 8, 9 and 10 of this specification
x Approval certificate
x All not yet mentioned examination reports

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Details for quality documentation:

The welding map shall provide overview about the executed welding and testing NDT for prefabrication. The
electronic version shall be provided to Siemens. The welding map shall be used as input data for the erection
company, showing all welds not yet provided (site welds).

National rules and regulations shall be considered for the quality documentation.

For the final detail design support documentation the approved documents mentioned in chapter 10.3.6
“Pipe Support Documents” are documented as “Final Detail Design Support Documentation.

The documentation shall be agreed upon with Siemens in advance. Therefore the structure of the documen-
tation of a typical piping system (inclusive filled folders as far as possible) shall be provided to Siemens latest
4 weeks before the due date of the time schedule. Any changes or updates of already handed over docu-
mentation shall be provided as traceable delta Documentation (inclusive marked changes), suitable for easy
handling.

23 References
Referenced design codes (not a comprehensive list):
[1] ASME B31.1 with edition and addendum to the date of the contract
[1a] ASME Boiler and Pressure Vessel Code (BPVC) as far as applicable

DVS: Deutscher Verein für Schweißen und verwandte Verfahren e.V. (German welding society)
[11] DVS 2202 “Imperfections in thermoplastic welding joints - Features, descriptions, evaluation”
[12] DVS 2204 “Gluing of thermoplastics; polystyrene and allied plastics”
[13] DVS 2207-1 “Welding of thermoplastics - Heated tool welding of pipes, piping components and sheets
made of PE-HD”
[14] DVS 2207-15 “Welding of thermoplastics - Heated tool welding of pipes, piping part and panels made of
PVDF”
[15] DVS 2208-1 “Welding of thermoplastics - Machines and devices for the heated tool welding of pipes,
piping parts and panels”
[16] DVS 2210 - Technical rule: Industrial piping made of thermoplastics –
Part 1: Planning and execution - Above-ground pipe systems (including as addendum)
Part 2: Design, Structure, and Installation of Two-pipe Systems
[17] DVS 2212-1 “Qualification testing of plastics welders - Qualification test groups I and II - Hot gas welding
with the torch separate from the filler rod (WF), high-speed hot gas welding (WZ), heated tool butt welding
(HS), sleeve welding with an incorporated electric heating element (HM), heated tool sleeve welding (HD)
and hot gas extrusion welding (WE)”
[18] DVS 2220 “Qualification testing of plastics welders - Qualification test groups I - Lamination as well as
laminate- and gluing joints for GRP (UP-GF and EP-GF) “ (Prüfung von Kunststoffklebern- Prüfgruppe II -
Laminate sowie Laminat- und Klebverbindungen aus GFK (UP-GF und EP-GF)
[19] DVS 2221 “Prüfung von Kunststoffklebern - Rohrverbindungen aus PVC-U, PVC-C und ABS mit lösen-
den Klebstoffen“ (Qualification testing of plastics welders for pipe joints for PVC-U, PVC-C and ABS …)
[19.1] DVS 2231 “Above-ground tanks, apparatus and piping made of thermoplastics - Guide to quality as-
surance”
[19.2] DVS 3310 “Quality requirements in adhesive bonding technology”

ATV: Standards of the German association for water, wastewater and waste (Deutsche Vereinigung für
Wasserwirtschaft, Abwasser und Abfall e.V.)
[29] Worksheet (leaflet) ATV-DVWK-A127 Static calculation of Drains and Sewers ducts and piping, (3. Edi-
tion; corrected reprint 4/2008)

Siemens Rules and Standards, Documents:

[101] MA-Guideline
[102] Checklist Scope and Limits of supply and services for piping “ZTO004-4781-MCC030-479931”, which
shall be adapted project-specifically, if necessary.

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[103] Typical Material take-off (MTO) if applicable

[104] PDBR
[105] Planning Instructions for Control Valves
[107] List of TCCs (see main contract)
[108] TE-Guidelines
[109] STIMs
[110] Design Request (DR)
[111] Material specification, such as
ZTO004-4711-MEC020-479995 for steel piping material (herein in Annex 4 mentioned MTS),
ZTO004-4711-MEC020-479994 for creep strength-enhanced ferritic steel grades 91 / 92,
ZTO004-4781-MEC020-478100 for insulation if applicable
[112] Component data sheets / piping component drawings, if applicable: Such as following shall be consid-
ered:
x Pressure, temperature and level measurement nozzles, see detail component drawings: For example,
EN drawings similar to ZTO004-4711-MTB069-479750 “Nozzle for a thermowell stainless steel
Class 150 – Class 2500”
x Connection to “Leybold-Leckage-Instrument for Leakage Measurement MAJ-System”
x Typical valve drawing, for example, 10LBA25AA001
x Condensation chamber Class 150 – Class 300 ZTO004-4711- MTB030-479740
x Throttle plate drawing (template, which needs adaptation for the bore hole diameter and the KKS)
[115] Piping list (=Linelist)
[116] ITP, FQP
[117] Information sheet about the atmospheric steam blowout
[118] Information sheet about the Augmented Bypass Operation (ABO)
[119] Template and sample of ITP and FQP, template of “ITP- and FQP-check for preconditions”
[121] Quantity Based Piping Engineering (BOP), Procurement, and Prefabrication - Progress Monitoring
[122] Quantity Based Piping Erection (BOP) - Progress Monitoring
[123] Sample of a method statement
[124] Handling of Piping and Support Bill of Quantity (BOQ)/ Material Take-Off (MTO)
[125] Valve specification
[126] Cleanliness requirements for BOP-piping and connected equipment/vessels with document number
ZTO004-4711-MEC020-479961
[127] Checklist for Adaptation of the Project-specific Specification for Design, Procurement, Prefabrication
and Erection of BOP Steel Pipework according to ASME (adapted to contract type)
[128] Design Guideline “Slope requirements for piping systems” ZTO004-MEC020-4711-479903

Attachments:
[A1] “Abbreviations, terms, definitions and explanations”
[A2] “Man clearance for operating personnel at various positions”
[A3] “Arrangement of valves”
[A3-1] “Cut-out of “Template of MTO”
[A4] “Template of a basic Isometric”
[A5] “Templates of a detail isometric with / without detail weld definitions”
[A6] NOT USED
[A7] “Base support type abbreviations”
[A8] “Samples of basic engineering documents” (such as basic valve drawing)
[A9] “Samples of detail engineering documents” (such as detail drawing, detail support drawing)
[A10] “Details of Siemens NDT extent for ASME steel piping”
[A11] “Detail requirements for pressure testing”
[A12] “Material traceability and certification requirements”
[A13] “Definition of pre-assembly of load chains”
[A14] “Requirements for induction bends / Siemens in-process examination sheet no. 1”
[A15] “Pipe sizes for steel piping“
[A15.1]“Pipe sizes for thermoplastic piping”
[A15.2]“Pipe sizes for GRP piping”

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Attachment [A1]: “Abbreviations, terms, definitions and explanations” (Applicable for this document)
Item/term/ ab- Definition, explanation
breviation
Contractor The person named as such in the Contract Order, its legal successors in title and per-
mitted assignees.
Equipment All parts and products needed for a power plant
Components Vessels, pumps, heat exchanger, skids, or similar
Inline Compo- Inline components are components like valves, strainers, orifices, compensators, in-
nents strumentation (inclusive locking valves), or similar, which are in the lines and support-
ed by line hangers/supports
Piping Compo- All pipe parts belonging to the pipe system (for example, pipe, elbow, t-piece, reduc-
nents ers, flanges, caps, bolting, coupling, flexible hoses: Excluding inline components, sup-
ports, secondary steel)
Piping / Pipe- All pipe parts belonging to the pipe system (Piping components + inline components +
work supports + secondary steel + insulation)
Pipe / Lines A pipe is used to convey fluids (liquids, steam and gases ) from one location to another
(synonym to pipeline, which is used also for very long piping).
Support Assembly of pipe clamping elements, load chain, and all connecting elements (inclu-
sive secondary steel) to building structure (defined as primary steel) or to the ground
EPC (contracts, (Contractor of / contract for) Engineering, Procurement, and Construction (single or
Contractor) combined solutions for engineering, procurement, and construction)
C-contracts Contracts for construction (shop and/or site)
Contractor- Contractor with scope for prefabrication works and/or site works
erection
Contractor- Contractor with scope for prefabrication works (off-site). In many contracts the pro-
prefabrication curement is included into the scope. If not, a Contractor-Procurement is defined for the
procurement of “Piping BOP” scope.
Contractor-site Contractor with scope for erection works on site. (This does not exclude further
scopes, if defined in contract)
Contractor- Contractor with scope for the Detail Design
Detail Design
ASME BPVC American Society of Mechanical Engineers
Boiler and Pressure Vessel Code (www.asme.org)
Supplier / Sub- The original equipment supplier including warehouse supplier
supplier
M-System Pip- All steam turbine internal- and generator piping in scope of this specification. The de-
ing tailed KKS are specified on the corresponding P&ID and in the piping list.
EJMA Expansion Joint Manufacturers Association
Service Piping Service air, service water
Siemens internal standards:
DR Design request: Siemens special design requirement
STIM Steam turbine information manual
TE Guidelines Generator external interface engineering and further requirements
PDBR Piping Design Basis Report (additional requirements related to stress calculation)

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Item/term/ ab- Definition, explanation

breviation
GDCSE General design criteria structural engineering
Contract-related documents:
TCC Technical contract conditions
TLV Siemens technical delivery instruction
Power Plant related abbreviations / terms:
TP Termination point is a limit / border of a scope of supply and services: (For example,
gas turbine, steam turbine / condenser, skid, or similar)
P&ID Piping and instrumentation diagram
WSC Water-Steam Cycle
PMC Pipe Material Class (pipe material basis [construction set] for the 3D Design and Iso-
metric drawings) located in the Smartplant ® Catalogue Data Base: A PMC comprises
a defined selection of piping component, flow diverter, orifice, compensator, and in-
strumentation, which satisfy the requirements for the respective pressure-temperature
ratings
SPF Smartplant ® foundation (database)
Plant Design Plant design summarizes all important technical information as basis for basic design
(BD) of the plant. It usually consists of the specification of Siemens, Bid Documenta-
tion and technical documentation of Reference Power Plants (as far as applicable).
These different documents are binding for conceptual design but may be not con-
sistent in detail.
Basic Design Basic design comprises all engineering and planning services, which are not covered
by the plant design; it summarizes all necessary technical information as basis for
execution of detailed design of the plant.
Detail Design Detail design comprises all engineering and planning services, which are not covered
by the basic engineering. It complies in detail with owner contract, owner’s specifica-
tion, consortium contract, Siemens specification and applicable regulations. It provides
the complete engineering output for purchasing, preparation of additional manufactur-
ing documents (if required by the manufacturer), manufacturing, transport, erection,
preservation, commissioning, plant commissioning inclusive testing, operation, mainte-
nance, spare parts, operation and maintenance documentation. This documentation
shall be the base for the later delivery of the final documentation.
PQR, Procedure qualification record
WPQ, Welder / Welding operator Performance Qualification
WPQR Welder / Welding operator Performance Qualification Record
PWHT Post weld heat treatment
PBHT Post bend heat treatment
ITP Inspection and Test Plan
FQP Field quality plan (Quality plan for construction works/site activities/manufacturing on site)
CSEF Creep Strength-Enhanced Ferritic Steels (such as Grade 91 / 92 / C12A)
NDT/NDE: Testing with respect to Non-Destructive Testing / Examination:
VT, PMI Visual Testing, Positive Material Identification
SCE, MT, PT, Surface Crack Examination, Magnetic Particle Testing, Liquid Penetrant Testing,
UT, RT, Ultrasonic Testing, Radiographic Testing,
HT, WPS Hardness Testing, Welding Procedure Specification
Power Plant related abbreviations / terms (continuation):
MTO “Material Take-off” is a list of material with quantity and types made manually or gen-

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Item/term/ ab- Definition, explanation

breviation
erated from 3D model that are required to build the designed item or structure. MTO
determines the quantities that are required to accomplish the design. MTO shall not
include the labour hours as a direct item but material and labour cost shall be com-
bined into single (individual) unit rates. Material handling costs (inclusive cleaning) are
included into material costs. Welding costs including testing cost are included in the
costs for welds.
BOM “Bill of Material” is a list of raw material, sub assembly, intermediate assembly, sub
component, component parts, and quantities of each required to manufacture an end
item, used mostly for dispatch and material controlling.
BOQ “Bill of Quantity” is a list used normally for erection in which materials, parts and labour
are separately itemized. BOQ shall include the labour hours as a direct item. Labour
costs are normally mentioned in erection contract.
KANLOG/ KANLOG (Kraftwerk Anlagen Logistik) is the Energy developed IT solution for handling
WEB-DE all global logistics and export processes occurring in Siemens power plant project
KANLOG business. The system ensures that all customs and export regulations as well as all
governmental declaration routines are met and cannot be violated by Siemens and/or
the Contractors. The WEB-DEKANLOG is the internet-based tool with similar function
towards logistics and export processes.
HP-, IP-, LP- High pressure- (>= 600lbs / PN63), intermediate pressure- (< 600lbs / PN63, but >
piping 150lbs / PN16), and low-pressure piping (<= 150lbs / PN16)
CS Carbon steel = CS: materials according to ASME B31.1, mandatory Appendix A, table
A-1
SS / Alloy Stainless steel = SS: Minimum chromium contents according ASME B31.1, mandato-
ry Appendix A, table A-3; Alloy steel = low and intermediate alloy steel according to
table A-2 of the same appendix
Creep (range) Creep is the tendency of, for example, steel to slowly move or deform permanently
under the influence of stresses and heat for long periods.
HRSG Heat recovery steam generator
BOP Balance of plant
GTPP Gas turbine power plant
CCPP Combined-cycle power plant
SPP Steam power plant
GT / ST Gas turbine / Steam turbine
SSM Siemens site management
For KKS-related abbreviations see
https://w9.siemens.com/cms/supply-chain-management/en/supplier-at-siemens/Pages/rhc.aspx

Abbreviations for Support

Abbreviations for Supports, see “Support type abbreviations” in attachment [A7]

General definitions:
Must Absolute requirement (no deviations are allowed)
Shall Mandatory to consider

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Item/term/ ab- Definition, explanation

breviation
May Recommendation
Can Exception from prohibition
Should Mandatory with several evasion possibilities
Consider Mandatory to consider
Shall be provid- Shall be carried out
ed
If applicable Where it is required by code / regulation/project document and practicable it must be
done
Practicable Where it can be done it must
Reasonable Balance between cost and risk
practicable
BREF Best Available Techniques Reference Document (if applicable: Technical ensured
tightness of flange connections is concerned (for hazardous medium))
EHS Environmental Health and Safety
EHSR Essential Health and Safety Requirement
Best Practice A technique, method, process, activity, incentive, or reward that is believed to be more
effective at delivering a particular outcome than any other technique, method, process,
or similar, if applied to a particular condition or circumstance. The idea is that with
proper processes, checks, and testing, a desired outcome (such as suitable pipework)
can be delivered with fewer problems and unforeseen complications.
State of the art ..technical and an economic aspect: In order to correspond to the state of the art, the
technical solutions adopted to fulfil EHSRs must employ the most effective technical
means that are available at the time for a cost which is reasonably taking account of
the total cost of the category of concerned machinery and the risk reduction required .
Hazardous me- National laws, and regulations defining the concerned substances and concentrations
dium (for example, European Regulations for Dangerous Substances Directive (DSD),
Health and Safety Directive, Integrated Pollution Prevention and Control Directive,
Classification, Labelling and Packaging of substances and mixtures (CLP)). It is an
obligation on suppliers to provide the Safety Data Sheet (SDS - with reference to
Reach). The possible hazards are described herein in detail. The exemptions of SDS
(including also Material Safety Data Sheets (MSDS)) are also to consider as hazard-
ous (for example, waste). Relevance: Technical ensured tightness (inclusive certified
gaskets, flange fitter qualification and tightness calculations) of flange connections. By
mayor hazards a double-wall piping design or other/further safety requirements are to
consider, if defined applicable.

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Attachment [A2] “Man Clearance for Operating Personnel at Various Positions”.

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Page: 91 of 116

Attachment [A3], Part 1 of 2: “Arrangement of valves”

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Page: 92 of 116

Attachment [A3], Part 2 of 2: “Arrangement of valves”

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 No.: ZTO004-4711-MEC020-479962
Index: D Attachment [A3-1]
Cutout of template of MTO
Page: 93 of 116

Footer Page 114 of 154.

Header Page 114 of 154.

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Attachment [A4]
Template of

Footer Page 115 of 154.

Basic Isometric
Header Page 115 of 154.

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Index: D
Page: 95 of 116

Attachment [A5],

Footer Page 116 of 154.

Header Page 116 of 154.

Part 1 of 2

Template of
Detail Isometric with
detailed weld defini-
tions, to consider, if
defined project-
specifically

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Page: 96 of 116

Attachment [A5],
Part 2 of 2

Footer Page 117 of 154.

Header Page 117 of 154.

Template of
Detail Isometric
without detail
weld definitions, to
consider, if defined
project-specifically

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Header Page 118 of 154. MEC020-479962
Index: D
Page: 97 of 116

Attachment [A7] “Base Support Type Abbreviations”:

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Index: D
Page: 98 of 116

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Index: D
Page: 99 of 116

Attachment [A8]: Basic engineering dimensioning drawings

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 No.: ZTO004-4711-
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Attachment [A9]: Part 1 of 2 (drawing itself):
Index: D Detail engineering dimensioning drawings of special parts
Page: 100 of 116

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 No.: ZTO004-4711-
MEC020-479962 Attachment [A9]: Part 1 of 2 (list):
Index: D Detail engineering dimensioning drawings of special parts
Page: 101 of 116

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 No.: ZTO004-4711-
MEC020-479962
Index: D Attachment [A9]: Part 2 of 2:
Samples of “detail engineering” drawings
Page: 102 of 116 (Detail pipe supports large bore)

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Index: D
Page: 103 of of 116

Attachment [A10] “Details of Siemens NDT extent for ASME steel piping”

The following tables describe the Siemens-standard NDT extend covering the usual BOP scope in a combined cycle
power plant. The NDT scope required for semi-finished piping parts and their internal welds is not part of this attach-
ment. The NDT scope given in ASME B31.1 (see table 136.4 of ASME B31.1) must be met in any case. The scope
marked as “Siemens additional NDT scope” is required to cover all special measures / additional testing that may be
required (e.g. where a hydrostatic pressure test is harmful or impractical, or for QA/QC purposes).
The mandatory extent of examination is given in per cent [%] of the total number of both, field welds and shop welds
per system. Each weld shall be tested completely, with exception of automatic welding SAW (Submerged Arc Weld-
ing), where each weld shall be tested partially to the given extent.
Volumetric testing: where a NDT scope for UT/RT is given, the most convenient method, in accordance with the
project specific requirements, shall be selected. Further requirements to be considered are given in the chapters 8.7.5
and 8.7.6 of this specification
Surface crack examination (SCE): ): where a NDT scope for SCE is given, the most convenient method (magnetic
particle testing MT or penetrant testing PT), in accordance with the project specific requirements, shall be selected.
The specific requirements to be considered are given in the chapters 8.7.2 and 8.7.3 of this specification. For ferro-
magnetic steels, MT is shall be the preferred method.
Definitions:
Buttweld: Definition as per ASME B31.1 (one solution of a butt joint) and therein also table 136.4 including Note 1.
Branchweld: The attachment (weld) of a metal branch pipe to the run of a main pipe, with or without the use of fit-
tings.
Filletweld: all Socket-, Lap joint-, T-joints-, Corner joint-, Fillet- and Attachment welds (e.g. lugs and trunnions)
Guarantee welds: final piping butt weld, which cannot be hydrotested, related to the natural force of circumstances of
location and function.
Intermediate alloy 1: within this table, all 9% Cr steels (P-No.15E),
Intermediate alloy 2: within this table all 1,25% Cr and 2,25% Cr Steels (P-No.4 and 5a)
Low alloy: within this table Grade C Materials (A106-C)

NDT-scope for butt welds

ASME B31.1 NDT-
SIEMENS ADDITIONAL NDT SCOPE* BUTTWELDS
SCOPE
MATERIAL GROUP KKS MATERIAL CONDITIONS VT UT/RT SCE HT PMI
INTERMEDIATE ALLOY 1 >2" 100 100 25 25 10
LBA10/LBB/Mxx/Nxx P91/92
(P-No. 15E) ”2" 100 25 100 10
INTERMEDIATE ALLOY 2 >2" 100 100 10 10 10
LBC/LCM/Mxx P11/22
(P-No.4/5A) ”2" 100 25 100 10
•2" & s > 19mm 100 100
LOW ALLOY LAB-HP A106-C •2" & s ” 19mm 100 25
”2" 100
a)
>2" & s < 19mm 100 100 10
FUEL GAS SYSTEMS EKG/MBP CS/SS a)
”2" 100 10 10
a)
OIL HP SYSTEMS MAV/MBA50/MBV/MAX TP321 - 100 100 10
a)
OIL PRESSURE LINES MAV/MBV/MKW TP304/316 - 100 10 10
a)
GAS HP SYSTEMS MKx/QJx TP321 - 100 100 10
CARBON STEEL DIVERSE SYSTEMS GRADE B or similar <19mm 100
STAINLESS STEEL DIVERSE SYSTEMS all <19mm 100
a) only for stainless steel

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NDT-scope for branch welds

BRANCHWELD
MATERIAL GROUP KKS MATERIAL CONDITIONS VT UT/RT SCE HT PMI
INTERMEDIATE ALLOY 1 >4" 100 100 25 25 10
LBA10/LBB/Mxx/Nxx P91/92
(P-No. 15E) ”4" 100 100 10
INTERMEDIATE ALLOY 2 >4" 100 100 10 10 10
LBC/LCM/Mxx P11/22
(P-No.4/5A) ”4" 100 100 10
>4" & s > 19mm 100 100 10
LOW ALLOY LAB-HP A106-C ”4" & s > 19mm 100 100
s ” 19mm 100 10
b) a)
>4" & s > 19mm 100 100 10 10
a)
FUEL GAS SYSTEMS EKG/MBx CS/SS ”4" & s > 19mm 100 100 10
b) a)
s ” 19mm 100 10 10
a)
OIL HP SYSTEMS MAV/MBA50/MBV/MAX TP321 - 100 100 10
a)
OIL PRESSURE LINES MAV/MBV/MKW TP304/316 - 100 10 10
a)
GAS HP SYSTEMS MKx/QJx TP321 - 100 100 10
CARBON STEEL DIVERSE SYSTEMS GRADE B or similar <19mm 100
STAINLESS STEEL DIVERSE SYSTEMS all <19mm 100
a) only for stainless steel
b) 100% only for underground piping

NDT-scope for fillet welds

FILLETWELD
MATERIAL GROUP KKS MATERIAL CONDITIONS VT UT/RT SCE HT PMI
INTERMEDIATE ALLOY 1 LBA10/LBB/LBC/ >4" 100 100 10 10
P91/92
(P-No. 15E) Mxx/Nxx ”4" 100 100 10
INTERMEDIATE ALLOY 2 >4" 100 100 10 10
Mxx P11/22
(P-No.4/5A) ”4" 100 100 10
>4" & s > 19mm 100 100
LOW ALLOY LAB-HP A106-C ”4" & s > 19mm 100 10
s ” 19mm 100 10
a)
FUEL GAS SYSTEMS EKG/MBx CS/SS - 100 10 10
a)
OIL HP SYSTEMS MAV/MBA50/MBV/MAX TP321 - 100 10 10
a)
OIL PRESSURE LINES MAV/MBV/MKW TP304/316 - 100 10 10
a)
GAS HP SYSTEMS MKx/QJx TP321 - 100 10 10
CARBON STEEL DIVERSE SYSTEMS GRADE B or similar <19mm 100
STAINLESS STEEL DIVERSE SYSTEMS all <19mm 100
a) only for stainless steel

NDT-scope for guarantee welds

BUTTWELD
SPECIAL MEASURES VT UT/RT SCE HT PMI
c) d)
Guarantee welds 100 100 100 100 100

c) Only for welds in Intermediate Alloy for >2"

d) Only for welds in Intermediate Alloy and for HP/Pressure Oil systems for >2".

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Non-destructive Testing (NDT) requirements for temporary piping of steam blow system (ZTB) for shop and field
welds
BUTTWELD

MATERIAL GROUP KKS MATERIAL CONDITIONS VT UT/RT SCE HT PMI

P11/P22/P91/92/
ALLOY STEEL AUGMENTED BYPASS [118] 100 100 100 10
A691CR1,25

A106B/A106C/ A53B
CARBON STEEL AUGMENTED BYPASS [118] 100 100 100
OR SIMILAR

P11/P22/P91/92/
ALLOY STEEL OTHER SYSTEMS [117] 100 10 100 10
A691CR1,25

A106B/A106C/ A53B
CARBON STEEL OTHER SYSTEMS [117] 100 10 100
OR SIMILAR

BRANCHWELD

MATERIAL GROUP KKS MATERIAL CONDITIONS VT UT/RT SCE HT PMI

P11/P22/P91/92/
ALLOY STEEL 100 100
A691CR1,25

CARBON STEEL A106B/A106C/ A53B 100 100

FILLETWELD

MATERIAL GROUP KKS MATERIAL CONDITIONS VT UT/RT SCE HT PMI

CARBON STEEL A106B/A106C/ A53B ”2" 100 100

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Attachment [A11]: Detail Requirements for Pressure Testing

Basis for starting the pressure testing works:

x By Siemens and other involved parties (if applicable) signed project-specific FQP / Quality plan of manufac-
turer
x List of open points closed, related to relevant pressure test issues. These relevant open points shall be not-
ed during pressure circuit walk-down and by check of the documentation by involved parties.
x Colour-marked P&IDs of pressure circuit inclusive Siemens confirmed system test pressure, incl. filling and
venting connections and location of pressure gauges.
x Prepared pressure test protocol (test data of pressure circuit like test medium /-amount, and its temperature,
test pressure, duration of pressure test)
x Calibration certificate of the pressure test gauge
x The material and equipment for temporary piping, the temporary valves, and supports shall be available for
pressure test per pressure circuit. Especially for the gland sealing system, a temporary safety valve shall be
available, see STIM-06.001, figure 13.
x Open / close position valve list
x Final check of proper vents and drains
x A check of valve positions shall be provided by the Contractor-site.
x The piping shall be secured before filling it with liquids to prevent displacement from its correct position.
Constant- and spring hangers shall be blocked during pressure test. Safety valves shall be secured for
pressure testing.
x Contractor-site shall provide measures that freezing of piping cannot occur if necessary.
x Outer surface of piping shall be dry before pressure testing.
x Neither insulation nor any painting shall cover the welds.
x All bypasses for GT components connected to the MAV/MBV system such as control block of the GT turn-
ing gear shall be installed by the Contractor-site.
x The piping shall be able to be dried after a pressure test, if any kind of water is used as medium.
x Release for pressure test by SSM [A1]. Contractor-site shall inform SSM and site-personal about the execu-
tion time and area of pressure test. The pressure test area shall be secured by the Contractor-site.

Detail requirements for performing the pressure testing (steel piping)

For pressure testing, filling of the piping shall be executed by the Contractor-site.

The Contractor-site shall consider installation and dismantling of necessary spools for leak testing.

In general, for pressure test in kind of hydro test, demineralised water with low oxygen contents provided from
the WSC, with suitable temperature shall be used. In raw water system GA and potable water system GKB,
potable water shall be used for hydro test purpose. For systems operated with domestic, river, or cooling tower
water, the normal operating medium is defined suitable for pressure test.

The test system has to be pressurized up to the maximum operating pressure and checked for leakages before
Siemens / Inspector (if applicable) / other concerned parties arrives.

By attendance of the concerned parties the pressure has to be raised according to the requirements of the de-
sign code. The test area must not be entered by pressure value above the design pressure. The indicated pres-
sure has to be observed from a safe distance and a protected place. The inspection of the pressurized system
at design pressure shall consider all necessary personnel protection devices required for pressure testing in-
spection.

The Contractor-site shall consider, in reverse order, the same procedure as during the pressure increase. Con-
tractor-site shall ensure that all vents of the pressurized system are open when pressure relieved.

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Index: D
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The pressure test is completed by the inspector if applicable and concerned parties with signing the pressure-
test protocol.

The Contractor-site shall restore all piping and ensure a system ready for operation (for example, for concerned
items: safety valves, valve open / closed positions, blocked supports, closures and temporary supports, required
only for the pressure test if applicable, not a comprehensive list).

In general, all details shall be provided by Contractor-site easy pursuable for Siemens and Site Management.
The details shall be provided in close cooperation with Siemens and for approval by Siemens.

Note: The recommendations of manufacturer for gaskets shall be considered for pressure test. The weld ring
gasket containing the inner grooved metal gasket shall be countered by temporary pressure test flange, includ-
ing a connected vent / drain connection if required.

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Index: D
Page: 108 of of 116

Attachment [A12]: Material traceability and certification requirements

In the following table the requirements regarding traceability and material certification (MTR) is described, con-
sidering the EN10204 standard for base material certificates for of piping parts / systems / components.

Project Requirements
ASME
Location
worldwide

Critical systems: LBA-HP, LBB, LBC,

LAB-HP
Pipes & Fittings (incl lugs & trunnions)

Fuel gas (e.g. EKG and related)

PIECE-MARK TRACEABILITY
HP oil (e.g. MAV/MBV/MKG/MBA50) 3.1* MTR

Control oil (MAX)

Hydrogen (e.g. MK, QJG)

Oxygen (QCL)

LOT TRACEABILITY
All other systems
2.2 MTR

Welding consumables for Systems LBA- LOT TRACEABILITY

HP, LBB, and others within creep range 3.1 MTR (3.1 for chemical composition, 2.2 for the rest)
Other parts

Other welding consumables

LOT TRACEABILITY
Non pressure retaining parts and attach- 2.2 MTR
ments
(e.g. bolts, nuts, gaskets, etc.)

Support steel (support parts) LOT TRACEABILITY

Primary steel (clamps, bases, etc.) 2.2 MTR
Supports

LOT TRACEABILITY
Support steel (shapes, plates, beams)
Secondary steel
2.1 MTR

LOT TRACEABILITY
Spring-/constant-/snubber supports
2.2 MTR (3.1* for load transferring parts of Critical systems)

* 3.2 Material test record (MTR) may be required due to manufacturer qualification or if demanded by customer, by national law or standard.

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Index: D
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Attachment [A13] Definition of Pre-assembled Load Chains

Guideline for the Pre-assembled load chains

I. Group Classification
A. Constant hangers with rods, clamps, and steelwork (traverse only)
B. Spring hangers with rods, clamps, and steelwork (traverse only)
C. Rods with clamps (Rigid hangers)
D. Rigid struts with clamps
E. Shock absorbers with clamps
F. Trapeze support system
G. For large bore piping supports only: Single parts such as clamps bases, pipe clamps, threaded clevises,
or similar.
H. Subsequent delivery or special delivery

II. Type of Shipment

A. Constant Hangers with Rods, Clamps and Steelwork

A1: Constant hangers for a load capacity for static load of max. 10 to 12kN (e.g. up to Lisega load group 4):
Every support position is in principle to be completely packed in one package unit per KKS:
x Constant hangers without rods
x Upper and lower load chain inclusive horizontal (hanging) pipe clamps up to 10” screwed together or bun-
dled
x Horizontal (hanging) pipe clamps larger than 10” and non-reinforced riser pipe clamps packed pre-
assembled as separate unit
x All single elements of reinforced riser clamps (e.g. with trunnions) and reinforced dynamic clamps to be
included in the package in the pre-packed form (not preassembled, but pre-sorted).
x Steelwork of extreme dimensions can be packed in a separate package.
A2: Constant hangers for a load capacity for static load >12kN (e.g. Lisega load group >=5):
Due to their extreme dimensions these can be split up into maximum 4 packages:
x Threaded rods or similar, shall be delivered bolted together.
x Furthermore, as up to a load capacity for static load of max. 10 to 12kN (see A1)

B. Spring Hangers with Rods, Clamps and Steelwork

B1: Spring hangers for a load capacity for static load of max. 10 to 12kN (e.g. up to Lisega load group 4):
Every support position is in principle to be completely packed in one package unit per KKS: analogue require-
ments as in A1
B2: Spring hangers for a load capacity for static load >12kN (e.g. Lisega load group >=5):
Analogue requirements as in A2
C. Rods with Pipe Clamps (Rigid Hangers)
Every support position is in principle to be completely packed in one package unit per KKS: analogue require-
ments as in A1 / A2
D. Rigid struts with clamps

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Every support position is in principle to be completely packed in one package unit per KKS:
Rigid struts inclusive bracket(s) pre-assembled and the pipe clamps to be included in the package in the pre-
packed form (not preassembled, but pre-sorted).
E. Shock absorbers with clamps
Every support position is in principle to be completely packed in one package unit per KKS
Shock absorbers (inclusive extensions) to be packed separately in principle and the pipe clamps to be included
in the package in the pre-packed form (not preassembled, but pre-sorted).

F. Trapeze support system

Every support position is in principle to be completely packed in one package unit per KKS:
x As defined in chapter A, B or C
x Trapezes and clamp bases to be allocated in the same package as the support.

G. Single Parts such as Pipe Clamps, Clamp Bases, Threaded Clevises or Similar
x For large bore piping supports, the pipe clamp halves are to be fitted into each other and bolted together.
x Clevises, threaded or welded and weld-on brackets are to be pre-assembled with screws, split pins, or lock
rings.

H. Subsequent delivery or special delivery

For subsequent delivery or special delivery (for both, written agreement between concerned parties is required),
a shipment by parcel service is allowed. The items may be supplied in several packages or without pre-
assembly. Further steelwork shall be defined project-specifically if required prefabricated.

III. Marking
Marking: Every package unit is marked by a tag at least with the position number / article number. For preas-
sembled supports as defined in A to F, the support shall be marked with the KKS.

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Attachment [A14]: Requirements for Induction Bends / Siemens In-Process Examination Sheet No. 1
Product form Induction bends
Method High frequency induction (hot) bending
Materials ASTM A335-P91, P92, P22, P11, ASTM A106C, P36 (WB36)
Examination and ASME B31.1, para. 102.4.5, para. 104.2.1 and para. 129
delivery specifications
Tests/Examinations Certification / witness by Sie-
mens / Approval of II
M S II according to
EN 10204
1. Procedure qualification test (PQT) for new inductive bending pro- x x x
cedures

1.1 No. of PQT:

One test bend for each PQT shall be carried out for the following groups:
• 1 bend of each material with the main size
For all sizes the pipe with the lowest elongation acc. to the mill certificates
shall be used.

1.2 Angle of bend:

Minimum 30° and/or minimum length required for each test bend (depend-
ing upon the machine limitations).

1.3 Mechanical testing for PQT

a) Hardness Survey for PQT:
• 3 readings (min.) around the circumference (1 reading at the outer fibre)
• allowable range: according to table “Hardness values for several materi-
als after manufacturing, see chapter 8.9.4 “Acceptance Criteria / NDT
Standards for Hardness Testing for Steel Piping”. For not listed materials,
the allowable range shall be max. 240HV10.
b) Tensile Test for PQT:
• 1 tensile test at room temperature
• 1 tensile test at elevated temperature (same temperature as for the pipe,
see “material specification” [111], with the same acceptance criteria as for
the pipe. Following table is given for information only, to be adapted pro-
ject-specifically). Sampling location: At the external radius of the bend

Material Temperature Minimum Minimum

of bends for hot tensile test Tensile strength Yield strength (0.2%)
[°C] [MPa] [MPa]
A106C 350 483 203
P36 350 510 373
P11 500 357 137
P22 500 395 173
P91 600 255 215
P92 600 328 248
c) Charpy test
1 notched - bar impact test on 3 specimens at room temperature on each
test bend

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Tests/Examinations Certification by

M S II according to
EN 10204
d) Micro Etching
1250:1 in tension and compression area
For both b) and c):
Longitudinal specimens if t >= 10 mm and OD > 100 mm
Transverse specimens if t >= 10 mm and OD > 250 mm
If not mentioned in the mill certificates, the values for b) and c) have to be
verified by testing the same pipe before PQT to obtain the properties of the
parent material.
1.4 Surface crack examination (liquid penetrant examination)
Surface check / - crack test on the test bend, as per section 3.5

2 Mechanical tests of production bends

Mechanical tests shall be done on “test coupons“ at one bend per size
category of the production bends. There shall be done at room temperature
a tensile test and a notched bar impact test. The specimens shall be taken
at the straight pipe ends after heat treatment.

3. Acceptance criteria / NDT for production bends after final heat

treatment

3.1 Certification of heat treatment including forming temperature x x 3.1

3.2 Visual examination for final acceptance x x 3.1
3.2.1 Dimensional control after final heat treatment x x 3.1
3.2.1.1 Wall thinning: max. 12,5 %
3.2.1.2 Ovality: max. 5 % at the body
max. 1 % at the ends
.
2 (ODmax - ODmin) .
formula: ODmax + ODmin 100[%]

3.2.1.3 Bend radius: +/- 50 mm

3.2.1.4 Bend angle: +/- 0.5° (based on 500 mm tangent length)
3.2.1.5 Off-plane tolerance:
3.2.1.6 Length: No minus tolerance to that specified on the bend drawings
3.2.1.7 Bulges, dents: max. height: h </= 3 % of OD
max. distance between bulges: a >/= 12 x h
3.2.2 Out-of roundness and thickness measurement x x 3.1
Scope: Each bend
Testing level: Every 22,5° bend angle, at least every 300 mm;
wall thickness measurement (Ultrasonic test) in
tension, compression, and neutral zones
Requirements - Compilation of record for specified and actual dimensions
- Identification of points at which examination is performed

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 No.: ZTO004-4711-
Header Page 134 of 154. MEC020-479962
Index: D
Page: 113 of of 116

Tests/Examinations Certification by

M S II according to
EN 10204
3.3 Material identification check, to a suitable method x x 3.1
3.4 Hardness survey x x 3.1
Hardness test on every bend, as per section 1.3 a) above
3.5 Surface condition / Surface crack examination as final acceptance x x 3.1
criteria:
Inspection of all bends, particularly for scale and wrinkling
Surface crack examination shall be performed in accordance with ASME
B31.1 and base material acceptance criteria such as mentioned below:
Scope: each bend on the outer surface in the bend region
100% for P91 and P92
20% for P36 (WB36)
10% for all other steels
Method for magnetic steels Magnetic particle examination to EN
ISO 10893-5 or
to suitable ASTM standard
or
yoke magnetization to EN ISO
10893-2 or to ASTM E309/426 or
equivalent standard
Method for non-magnetic liquid penetration to EN ISO 10893-4
steels or equivalent
standard or ASTM standard
Requirements: - Cracks shall be inadmissible
- For linear and circular indications see following criteria
Minimum acceptance criteria:
For magnetic particle, see ASME B31.1 para. 136.4.3
For surface crack examination of bends see ASME B31.1 para. 136.4.4:
For acceptance criteria of yoke magnetization acc. to EN ISO 10898-2 or
ASTM E309/426 the corresponding standard shall be applicable. Addition-
ally requirements especially for P91/P92/WB36 such as mentioned in
EN1289/1291 class 2 shall be defined project-specifically, if applicable.
4. Destructive mechanical testing (production testing)
Test lot: One per size category
Sampling location: End face of straight length
Scope of testing for each test lot:
Specimens if s t 10 mm
1 tensile test at room temperature x 3.1
1 tensile test at elevated temperature x 3.1
1 set ISO-V specimens for notched-bar impact test at x 3.1
room temperature

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 No.: ZTO004-4711-
Header Page 135 of 154. MEC020-479962
Index: D
Page: 114 of of 116

Tests/Examinations Certification by

M S II according to
EN 10204
5. Marking x x 3.1
The following shall be included in the marking of the bends (as a mini-
mum):
5.1 Bend drawing no. (hard punched)
5.2 Heat number (hard punched)
5.3 Spool number (hard punched)
5.4 Inspector stamps
• from the Contractor’s representative
• from Siemens’ representative (optional)
6. Documentation check for final acceptance x x 3.1
Documentation shall be done on bend-basis, i.e. separate documentation
for each individual bend.
6.1 For PQT
6.1.1 Parent material
a) Hardness test record
b) Tensile test record at room temperature
c) Tensile test record at design temperature
d) Charpy test record
6.1.2 After bending
a) Hardness test record
b) Tensile test record at room temperature
c) Tensile test record at design temperature
d) Charpy test record
e) Photos of micro etching (the set of documentation including the original
photos shall be handed over to Siemens)
f) Surface crack examination record
g) Dimensional check record (reference document: test bend drawing)
h) Heat treatment record (time-temperature charts)
i) Cover sheet, indicating the general information on the bend (dimen-
sions/parameters, actual versus specified).
6.2 Production bends
a) Hardness test record (parent material and after bending)
b) Heat treatment record (time-temperature charts)
c) Surface crack examination record
d) Dimensional check record (reference document: bend drawings, ap-
proved for construction)
e) As-built bend drawings
f) Mechanical test records (for „test coupons“)
6.3 Mill certificates of all pipes used for bends
6.4 All records shall be in English
6.5 The complete documentation has to be checked and approved by
the Contractor
M = Manufacturer / Contractor
S = Siemens (Surveillance)
II = Independent Inspector

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 No.: ZTO004-4711-
Header Page 136 of 154. MEC020-479962
Index: D
Page: 115 of of 116

Attachment [A15]: Pipe sizes

The following nominal steel pipe sizes (DN) and outside diameter shall be used (not a comprehensive table)
for steam and HP/IP piping (and cold water LP steel piping <=42”):

Steel pipe sizes

Outside Outside Outside Outside di-

Nominal Nominal Nominal Nominal
diameter diameter diameter ameter
Size Size Size Size
[mm] [mm] [mm] [mm]

½” 21,3 OD 4” 114,3 OD 18” 457,0 OD 40” 1016,0 OD

¾” 26,7 OD 5” * 141,3 OD 20” 508,0 OD 48” 1219,0 OD

1” 33,4 OD 6” 168,3 OD 22” 559,0 OD 56” 1422,0 OD

1 ¼”* 42,2 OD 8” 219,1 OD 24” 610,0 OD 64” 1626,0 OD

1 ½” 48,3 OD 10” 273,0 OD 28” 711,0 OD 72” 1829,0 OD

2” 60,3 OD 12” 323,9 OD 30” 762,0 OD 80” 2032,0 OD

2 ½” * 73,0 OD 14” 355,6 OD 32” 813,0 OD

3” 88,9 OD 16” 406,4 OD 36” 914,0 OD

OD: outside diameter in accordance with ASME B36.10M / ASME B36.19M *) only for M-System Piping [A1]

In exceptional cases, Siemens will specify the application of inside diameter pipes. If required, this application
shall be used for high-pressure piping system.

Further nominal diameter: For steam lines >24” and <=60” the ASME B16.47 shall be considered.

The following nominal steel pipe sizes (DN) for cold water steel piping shall be used:
<=24”: ASME B16.5 flanges
>24” :AWWA C207-D, FF flanges (= ASME B16.47 Type A up to 60” for the borehole design)
The following nominal steel pipe sizes and inside diameter shall be used (not a comprehensive table) for cold
water piping >42”, based on AWWA M11 table 4.2.

Siemens cold water LP steel big bore pipe sizes

Nominal Outside diameter Nominal Outside diameter Nominal Outside diameter

Size [mm] Size [mm] Size [mm]

48” 1219,2mm ID 63” 1600,2mm ID 87” 2209, 8mm ID

54” 1371,6mm ID 72” 1828,8mm ID 96” 2438,4mmID

57” 1447,8mm ID 78” 1981,2mm ID

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 No.: ZTO004-4711-
Header Page 137 of 154. MEC020-479962
Index: D
Page: 116 of of 116

Attachment [A15.1]: Pipe Sizes of thermoplastic piping

The following nominal pipe sizes (ID = DN) for GRP piping shall be used (not comprehensive table). The re-
spective nominal flange size is included in the table:

Nominal pipe sizes and corresponding flanges for GRP piping

Nominal Size Flange Nominal Size Flange Nominal Size Flange Nominal Size Flange
Size Size Size Size

1” (=25mm ID) 1” 6” (=150mm ID) 6” 20” (=500mm ID) 20” 56” (=1400mm ID) 60”

1 ½” (=40mm ID) 1½” 8” (=200mm ID) 8” 24” (=600mm ID) 24” 60” (=1500mm ID) 60”

2” (=50mm ID) 2” 10” (=250mm ID) 10” 28” (=700mm ID) 28” 64” (=1600mm ID) 66”

2 ½” (=65mm ID) 2½” 12” (=300mm ID) 12” 32” (=800mm ID) 32” 72” (=1800mm ID) 72”

3” (=80mm ID) 3” 14” (=350mm ID) 14” 36” (=900mm ID) 36” 80” (=2000mm ID) 84”

4” (=100mm ID) 4” 16” (=400mm ID) 16” 40” (=1000mm ID) 40”

5” (=125mm ID) 5” 18” (=450mm ID) 18” 48” (=1200mm ID) 48”
ID: inside diameter of pipe, DN: nominal pipe size
Flange boreholes are defined according to ASME B16.5 for sizes <=24”
The flange standard AWWA C207 for >=40” shall be considered for diameter of bolt circle and OD of flange. For
sizes >24” and <40” a project-specific decision for the diameter of bolt circle will be done by Siemens.

Attachment [A15.2]: Pipe Sizes of thermoplastic piping

The following OD nominal pipe sizes for thermoplastic piping shall be used (not comprehensive table). The
respective nominal flange size is included in the table:

Nominal pipe sizes and corresponding flanges for thermoplastic piping

Nominal Flange size Nominal Flange size Nominal Flange size Nominal Flange size
Size Size Size Size

OD 16 DN 10 / 3/8” OD 75 DN 65 / 2 ½” OD 200 DN 200 / 8” OD 450 DN 450 / 18”

OD 20 DN 15 / ½” OD 90 DN 80 / 3” OD 225 DN 200 / 8” OD 500 DN 500 / 20”

OD 25 DN 20 / ¾” OD 110 DN 100 / 4” OD 250 DN 250 / 10” OD 560 DN 600 / 24”

OD 32 DN 25 / 1” OD 125 DN 100 / 4” OD 280 DN 250 / 10” OD 630 DN 600 / 24”

OD 40 DN 32 / 1 1/4” OD 140 DN 125 / 5” OD 315 DN 300 / 12”

OD 50 DN 40 / 1 ½” OD 160 DN 150 / 6” OD 355 DN 350 / 14”

OD 63 DN 50 / 2” OD 180 DN 150 / 6” OD 400 DN 400 / 16”

OD: outside diameter of pipeDN: flange boreholes according to ASME B16.5 (EN 1092-1 if connection to
DIN/EN flanges)

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Header Page 138 of 154.

Annex "2.1.6.2_SCHEDULE 1 - EMPLOYER'S REQUIREMENTS

4.13.6-8- Pipe", Annex "2.1.6.3_SCHEDULE 1 - EMPLOYER'S
REQUIREMENTS 4.11 Welding" and Annex "2.1.2 Division of
Responsibilities" take precedence
over this specification for project NG1005 Azura Edo

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commented for project Azura Edo
2016-05-19

V* +V V*

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Azura Edo 2016-05-19

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