Table of Contents
| Section | Title | Page |
| Purpose | 2 | |
| Scope | 2 | |
| Related Documents | 2 | |
| Fabrication and Inspection–General | 4 | |
| Fabricator Material Control | 5 | |
| Welding | 5 | |
| Brazing and Soldering | 8 | |
| Weld Joint Examination | 10 | |
| Threaded Joints | 12 | |
| Cold Box Frame and Jacket Panels | 12 | |
| Frame Leveling, Column Orientation–Alignment with Frame, or Column Plumbness | 13 | |
| Inspection Upon Receipt of Air Products-Supplied Pressure Vessels | 15 | |
| Handling and Preservation of Air Products-Supplied Equipment | 16 | |
| Equipment Supports and Pipe Supports | 16 | |
| Pipe Work | 17 | |
| Piping Tolerances | 20 | |
| Valving and Instrumentation | 21 | |
| Cleaning of Pipe and Associated Systems | 21 | |
| Pre-Test Flow Check Review | 29 | |
| Pressure Testing | 29 | |
| Painting | 30 | |
| Miscellaneous | 30 | |
| Changes During Fabrication | 30 | |
| Jacket Penetration As-Builts | 31 | |
| Preparation for Shipment | 31 | |
| Loading Cold Box for Transportation | 32 | |
| Cold Box Insulation | 32 | |
| Fabricator Documentation Submittals to Air Products | 32 | |
| Minimum Requirements for Radiography | 11 | |
| End View–Column | 14 | |
| Front Side View from the Top of the Box | 15 | |
| Recommended Weld Geometry–Aluminum Piping | 67 | |
| Ongoing Fabricator Documentation and Quality Assurance and Inspection Book | 34 | |
| Quality Control Checklist–Cold Box Inspection | 51 | |
| Recommended Weld Filler Material, Consumables Control, and Handling | 56 | |
| Aluminum Welding | 65 | |
| Names and Addresses of Standards Organizations | 70 | |
| Names and Addresses of Suppliers | 71 |
1. PURPOSE
1.1 This global engineering specification defines the requirements for cold box fabrication in the shop or in the field, and supplements the Technical and the Commercial Job Specifications for the Fabrication of Cold Boxes identified in the Purchase Order.
2. SCOPE
2.1 This specification applies to and defines the fabrication, quality assurance, and inspection requirements for Air Separation Unit (ASU) and other types of cold boxes. It provides the common and minimum Air Products requirements for piping, structure, instrumentation, installation of cold box equipment and structure assembly, ASME weld procedures, weld qualifications, piping assembly, piping welds, weld radiography and inspection, pipe cleaning, pressure test, temperature element installation and test, flow checks, installation of pipe supports, insulation, painting, and the preparation and submittal of the contractual documentation to verify conformance to the specifications and that the inspection requirements have been accomplished.
2.2 Job-specific requirements are identified in the Commercial and the Technical Specifications for the Fabrication of Cold Boxes and in the Purchase Order.
2.3 There shall be no changes or omissions to this specification without written permission from Air Products. All requests shall be made in writing, and changes may be made only after receipt of the written approval from the Air Products Cryogenic Systems Group.
2.4 The following are not applicable for field-fabricated cold boxes: Paragraph 14.3 Piping Shipping Supports Section 25 Preparation for Shipment Section 26 Loading Cold Box for Transportation Appendix A, Form 6 Shipping Pipe Support Record Appendix A, Form 18 Cold Box Frame Leveling Report Appendix A, Form 19 Cold Box Column Leveling Report Appendix A, Form 26 Cold Box Weight
3. RELATED DOCUMENTS
3.1 The current edition, amendments, and/or addenda of the following codes, standards, and specifications at the time of contract award shall govern, except as modified in this specification. The Project Commercial and Technical Fabrication Specifications and the Purchase Order might contain additional modifications and further technical requirements. The fabricator shall comply with all contract requirements.
3.2 When the fabricator identifies a conflict between contract documents, the conflict shall be documented and submitted to Air Products in writing for resolution, before continuing with the work.
3.3 Air Products Engineering Documents 3PI55005 Pipe Thread Sealants Service Index 4ACB-683015 Cold Box/Can Expansion Joint Installation Instructions 4ACB-684001 Cold Box/Can Temperature Element Wiring Installation Procedure 4ACS-640130 Fabrication of Structural Steel 4ACS-640131 Fabrication of Miscellaneous Metals 4WCB-30001 Cold Box Penetrations Standard Details 4WCB-50001 Perlite for Cold Box Insulation 4WCB-70001 Sealing Cold Boxes for Shipment 4WEQ-1105 HyCO Plant Positive Material Identification (PMI) Requirements 4WEQ-6804 Painting and Corrosion Protection of New Construction for Design Temperatures to 649°C (1200°F) 4WMA-007018 Site Plumbness Tolerances for Erected Distillation Columns and Cold Boxes Containing Distillation Columns 4WPI-AWZ001 Specification for Piping Assemblies for Cold Boxes 4WPI-FWAB01 Aluminum Miter Bends 4WPI-FWAJ10 Transition Joint Installation 4WPI-FWZB01 Cold Pulled Bends 4WPI-SW70001 Standard Clean (Class SC) Inspection and Acceptance Requirements 4WPI-SW70002 Process Clean (Class B) Inspection and Acceptance Requirements 4WPI-SW70003 Oxygen Clean (Class AA) Inspection and Acceptance Requirements 4WPI-VALV02 Mounting Plate Installation Procedure for Fully Extractable Valves 4WPS-VALV11 Proper Handling and Weather Protection of Samson Cryogenic Globe Cold Box Valve with Bellows Seals 4WPS-VALV12 Use of Samson Shipping Covers for Pressure Testing of Cold Box Process Piping and Valve Weather Protection 4WPI-57902 Flanged Assemblies Bolting Materials 3PI55001 Piping Class Specification Application Guide 4WCB-50002 Mineral Wool for Cold Box Insulation 4WCE-600276 Packing Process Equipment Jackets with Mineral Wool (Rock WoolÔ) 4WCE-600277 Perlite Loading of Process Equipment Jackets and Field-Erected Storage Tanks 4AEQ-660500 Pictorial Representation of Allowable Rust 4WPI-EW44001 Pressure Testing of Process Piping and Equipment 4ACB-683001 Shop-Fabricated Cold Boxes Shipping Pipe Supports 4ACB-685002 pH Determination of Mineral Wool (Rockwool) 4ACB-685003 Packed Density Determination of Mineral Wool VDR Set Vendor Document Requirements
Note: All Air Products material specifications are listed in the Engineering Specification Package-Transmittal.
3.4 American Institute of Steel Construction (AISC) 316 Manual of Steel Construction – Allowable Stress Design
3.5 American Society of Mechanical Engineers (ASME) BPVC, Section II Materials – Part A – Ferrous Material Specification BPVC, Section V Nondestructive Examination BPVC, Section VIII Rules for Construction of Pressure Vessels BPVC, Section IX Welding and Brazing Qualifications B31.3 Process Piping SFA 5.8 Specification for Filler Metals for Brazing and Braze Welding SFA 5.10 Specification for Bare Aluminum and Aluminum-Alloy Welding Electrodes and Rods
3.6 American Society for Nondestructive Testing Inc. (ASNT) SNT-TC-1A Recommended Practice
3.7 American Society for Testing and Materials (ASTM)
A 312 Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes
A 403 Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings
D 2200 Standard Pictorial Surface Preparation Standards for Painting Steel Surfaces
3.8 American Welding Society (AWS)
A5.4 Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding
A5.8 Specification for Filler Metals for Brazing and Braze Welding
A5.9 Specification for Bare Stainless Steel Welding Electrodes and Rods
A5.10 Specification for Bare Aluminum and Aluminum-Alloy Welding Electrodes and Rods
D1.1 Structural Welding Code – Steel
3.9 Pipe Fabrication Institute (PFI)
ES-3 Fabricating Tolerances
ES-31 Standard for Protection of Ends of Fabricated Piping Assemblies
3.10 Steel Structures Painting Council (SSPC)
SP 6 Joint Surface Preparation Standard Commercial Blast Cleaning
3.11 Refer to Appendices E and F for the names and addresses of standards organizations and suppliers.
4. Fabrication and INSPECTION–generaL
4.1 The fabricator shall have an effective and documented fabrication and inspection system implemented that is sufficient to ensure to Air Products that at any point during the fabrication the completed work has been properly performed and inspected. The fabricator shall keep sufficient records to permit the review of each project welder’s performance. The required documentation that is listed in Appendix A shall be submitted to the Air Products representative as directed in Section 4.6.
4.2 A kick-off meeting between the fabricator and Air Products’ representatives shall be conducted before the start of fabrication to develop and confirm general agreements regarding issues such as inspection methods, review requirements, manufacturing schedule including witness points, and fabricator’s quality assurance plan.
4.2.1 Appendix A indicates the minimum major documentation verifying that the required reviews and responsibilities of the fabrication and inspection plan were satisfactorily completed. This specification defines only the minimum fabrication and inspection requirements for these cold boxes which might be modified and supplemented by those in the Commercial and the Technical Project Specifications.
4.3 In addition, minimum inspections by the fabricator shall include all items contained in Appendices A and B, and as required by ASME B31.3, Chapter VI, Section 340, except as modified herein.
4.4 All material, fabrication, and testing also will be subject to inspection by a representative of Air Products. The Air Products representative shall have the option to witness any test. The representative might approve or disapprove the test procedure, and accept or reject the test records. Upon disapproval or rejection, the fabricator shall provide a revised test procedure or test records acceptable to the Air Products representative. The Air Products representative shall have the right to reject any work based upon “lack of good workmanship” criteria, and have the right to observe work and/or documentation verifying the satisfactory correction of previously rejected work. The fabricator shall obtain all required Air Products approvals in writing before performing rework on previously rejected fabrication. Approval of the fabrication by the Air Products representative or waiver of inspection does not relieve the fabricator of the responsibility to conform to the requirements for code compliance, material, dimensional accuracy, workmanship, specification, and the Purchase Order.
4.4.1 Air Products might elect to provide either a full-time or an intermittent time inspection representative throughout the cold box fabrication process. The presence or absence of the Air Products representative shall not be construed as affecting in any way the obligation of the fabricator to satisfy all requirements contained in the Purchase Order and the accompanying contract documents.
4.5 The fabricator shall verify that all piping components are in accordance with the appropriate ASME or ASTM specification. The required component marking will be sufficient for this verification.
4.6 Quality Assurance Documents
4.6.1 The fabricator shall submit a Quality Plan before fabrication and maintain a loose-leaf “Quality Assurance and Inspection Book” that contains a complete up-to-date set of all quality control documents required by this specification and the Purchase Order. Forms for recording the results of certain required inspections are included in Appendix A. The remaining ones will be furnished by Air Products or obtained by the fabricator, as noted and agreed to.
4.6.2 The fabricator shall submit one copy of a complete set of these documents to the Air Products representative upon completion of the fabrication. A second copy shall be shipped with the completed cold box. Additional copies might be required per the Purchase Order.
5. FABRICATOR MATERIAL CONTROL
5.1 The fabricator shall have an effective material procurement and control system sufficient to identify all materials used for the cold box fabrication. Required documentation shall be available for inspection by the Air Products representative.
5.2 Material Receipt
5.2.1 The fabricator is responsible for receiving, storing, and protecting all Air Products-supplied material. The fabricator shall provide receipts to the Air Products representative for all Air Products-supplied material. These may be submitted on a weekly basis with the schedule status report. The receipt may be either a copy of the shipping papers (packing slips) or the fabricator’s receiving report providing quantities, part numbers, and a description of each item received.
5.3 Damaged or Unacceptable Materials
5.3.1 The fabricator shall immediately notify the Air Products representative by telephone or fax, whenever any of the Air Products-supplied items are received with external damage. Failure to notify the Air Products representative within one week of the receipt of the materials transfers all responsibility for repair or replacement and schedule impact to the fabricator. Upon notification, the Air Products representative will either issue a CBCO authorizing the fabricator to make the required repairs or will provide detailed instructions for returning the damaged item to the supplier. The fabricator shall repair or replace any item damaged after acceptance and until all of the work is accepted by the Air Products representative.
- WELDING
6.1 General Welding Requirements
6.1.1 Nomenclature Used in Welding Sections
FCAW Flux Cored Welding
GMAW Gas Metal Arc Welding (MIG)
GTAW Gas Tungsten Arc Welding (TIG)
SMAW Shielded Metal Arc Welding (Coated Electrode/Stick)
6.1.2 At least one pass per 3 mm (1/8 in) of wall thickness shall be made. Downhill welding using SMAW (stick) process is prohibited. Slag shall be removed before depositing succeeding layers. The finished weld shall be uniform with the toe or edge of the weld merging smoothly into the base metal. Butt welds shall have a slight, gradual reinforcement built up from toe or edge toward the center of the weld. Fillet welds may be slightly concave on the finished surface. No undercutting or overlapping is permitted.
6.1.3 If cracks or blow holes occur on the surface of any welding bead, they shall be chipped or ground out to remove the defect, and then wire brushed to present a surface from which complete fusion may be obtained with the next successive welding bead. Peening to cover defects shall not be allowed.
6.1.4 Welding by creating a heat pattern at a circumferential joint can “draw in” the weld and the base metal in the heat-affected zone, thereby creating a “belling in” and giving a reduction in the area of the pipe or tube. This belling or distortion is undesirable and is subject to the following limitations:
6.1.4.1 The belling or distortion tolerance may not exceed 1% of the actual outside diameter (OD) or 1.5 mm (1/16 in); whichever is larger. This belling or distortion can be measured by comparing the actual OD at the belled or distorted area.
6.1.5 Welds of orifice flanges shall be made without the use of backing rings. The upstream and downstream welds shall be ground internally so that the inside diameter (ID) at the weld is within 1% of the published ID for the schedule of pipe specified. Any purchased meter runs require installation in the process pipe at the upstream and downstream ends without the use of backing rings. Backing rings shall be used for aluminum welds and removed after welding unless there is sufficient access to complete a double-sided weld. In either case, the inside of the pipe shall be ground as described above.
6.1.6 All slip-on flanges shall be welded internally and externally.
6.1.7 When backing rings are permitted and they have not been supplied by Air Products, they shall be cut by the fabricator from piping material provided as contingency material by Air Products. The backing ring composition shall match the P number or the pipe base metal composition.
6.2 Qualifications Required for Welding Procedures and Welders
6.2.1 All pipe welding, including attachment welds to piping, shall be performed according to qualified procedures developed by the fabricator and by welders qualified to the procedures in accordance with ASME BPVC Section IX and as modified by ASME B31.3, paragraph 328.2. Each weld shall be completed by a single welder unless agreed otherwise with the Air Products representative.
6.2.2 Welding procedures for stainless steel as listed in ASME B31.3, Appendix A, shall be qualified to the minimum material temperature listed therein (that is, ASTM A 312, TP304 and 304L; ASTM A 403, WP304 and 304L) and shall have weld procedures qualified to -320°F (160oC).
6.2.3 Impact testing for weld procedure qualifications shall be according to ASME B31.3. For stainless steel in cryogenic service, the weld metal shall be Charpy impact tested with a minimum of 0.53 mm (0.021 in) lateral expansion for each specimen, with three specimens required per procedure qualification.
6.2.4 Fourteen calendar days before commencement of welding, the fabricator shall deliver to Air Products Engineering Services, Engineering Data Group, prepared in accordance with the purchase order, the applicable codes and the VDR Set, two copies of all welding procedure specifications (WPS) plus two copies of the weld procedure qualifications record (PQR) relating to the specifications. No welding shall be performed until Air Products has approved, in writing, the welding procedure specifications.
6.2.5 Each welder shall be qualified according to the approved WPSs, and the welder qualification (WPQ) record shall be maintained on file at the fabricator’s job site office. Welder qualifications shall be valid and within the time limits specified in the applicable code.
6.2.6 All the cost of qualifications shall be borne by the fabricator, including the provision of all necessary materials and consumables. If there are any specialty pipe materials required that cannot be procured in time to support the erection schedule, the fabricator shall notify Air Products at the time of his tender so that Air Products can procure this material for the development of PQR to support the overall fabrication schedule.
6.2.7 Indexed copies of all PQRs, WPQs, and WPSs shall be placed in the “Quality Assurance and Inspection Book.”
6.3 Filler Material
6.3.1 See Appendix C or Appendix D (for aluminum filler material).
6.4 Weld-joint Preparation
Note: See Appendix D for aluminum welding requirements.
6.4.1 The fabricator shall prepare all welding joints according to the specified code and the approved WPS.
6.4.2 Stainless steel pipe shall only be cut by mechanical or plasma cutter processes. It shall not be cut using an oxy-acetylene torch. A minimum of 1.0 mm shall be removed from the pipe by grinding to eliminate any trace of carbon that may have been deposited by plasma cutting.
6.4.3 Materials that are being welded shall be carefully fit, aligned, and retained in position during the welding operation. Adequate and proper tack welding will be considered acceptable. Tacks shall not obstruct a full-penetration weld. Before starting to weld, tacks must be thoroughly cleaned.
6.4.4 The inside surfaces of piping components to be joined by butt welding shall be aligned so that the misalignment at any point on the inside circumference does not exceed 1.5 mm (1/16 in) or 1/4 of the nominal thickness of the component with the thinner wall, whichever is smaller.
6.4.5 The longitudinal seams of welded pipe in adjoining pipe sections shall be staggered.
6.4.6 Branch connections shall not intersect the longitudinal seam of welded pipe.
6.4.7 The fabricator shall ensure that the seams of any prefabricated piping spools do not coincide with the seams in fabricated miters.
6.4.8 Fabricated tees and mitered bends DN450 and above shall be back welded on the inside of the fittings (reference Air Products document 4WPI-FWAB01).
6.4.9 Material provided for the fabrication of miters, pipe fittings, or pipe shall not be provided with any weld preparation unless specifically advised by Air Products. The fabricator shall allow for making the required weld preparation.
6.4.10 All socket-weld joints shall have a 1.5 mm (1/16 in) gap between the pipe end and socket bottom of the fitting.
6.5 Material Specific Welding Requirements
6.5.1 Welding Requirements for Carbon Steel, Stainless Steel
6.5.1.1 The fabricator shall perform all welding according to the applicable code. The following welding processes are permitted for making one-sided groove welds:
Stainless steel welded to carbon steel: For Schedules 5 and 10, only GTAW shall be used for the root bead and the balance of the weld. For heavier piping, the root bead shall be made with GTAW; the balance of the weld may be made using another Air Products-approved welding process. All welding shall be made using an internal gas purge of either argon or nitrogen gas. The use of backing rings is not permitted except for final closure welds when approved by the Air Products representative on a case-by-case basis. Final closure welds are those welds where prefabricated piping is installed to a fixed component in the piping system resulting in positional welding where the ability to obtain a uniform root pass is impaired and/or extensive purging would be required to weld successfully. Typically, these should be less than approximately 15% of the total number of welds. Locations where backing rings have had to be used must be recorded in the construction records.
Carbon steel: Root bead welding will be made by either (1) GTAW, (2) on carbon steel only, SMAW using backing rings, for girth joints (not including branch connections), (3) GMAW – short circuit if automated and rolled, (4) GMAW – short circuit semi-auto on joints that cannot be rolled, but have access for visual inspection and grinding of the internal bead, as needed. The balance of the weld may be made using another approved welding process.
Note: GMAW – short circuit is permitted only for making the root bead. If FCAW is used, supplemental gas shielding must be provided.
6.5.1.2 Piping designated for oxygen service shall have the root pass welded using the gas tungsten arc welding (GTAW) process with argon backing purge. Following the root pass, subsequent welding may be completed by another Air Products-approved process.
6.5.1.3 The use of backing rings is not permitted for carbon or stainless steel classified for oxygen service.
6.5.1.4 For carbon steel welding, each welder shall identify the welder’s specific production welds by stamping the welder’s regularly assigned identification number on the pipe adjacent to the welds made in all carbon steel material. Stamps shall be low-stress type with a round or “U”-shaped cross section.
6.5.1.5 For stainless steel welding, each welder shall identify the welder’s specific production welds by etching (with an electric pencil) the welder’s regularly assigned identification number on the pipe adjacent to the welds made in all stainless steel material.
6.5.2 Welding Requirements for Aluminum: Refer to Appendix D, Aluminum Welding.
- BRAZING AND SOLDERING
7.1 Qualifications Required for Brazing Procedures and Brazers
7.1.1 The requirements for brazing shall be according to ASME B31.3, paragraph 333.4. Silver brazing operators shall use approved techniques that will consistently produce joints of 100% penetration of full socket depth.
7.1.2 All pipe and tube brazing shall be made according to qualified procedures as developed by the fabricator and by brazers qualified to the procedures according to ASME BPVC, Section IX as required by ASME B31.3, paragraph 333.1.
7.1.3 Fourteen calendar days before commencement of brazing, the fabricator shall deliver to Air Products Engineering Services, Engineering Data Group, prepared in accordance with the purchase order, the applicable codes and the VDR Set, two copies of all brazing procedure specifications (BPS) plus two copies of the procedure qualifications record (PQR) relating to the specifications. Brazing procedures (BPSs and the PQRs) shall be approved by Air Products in writing before initiating production of brazing.
7.1.4 Brazers shall be qualified according to the approved BQP procedures. The brazer’s performance qualification record (PQR) shall be on file at the fabricator’s job site office. Qualification shall have been made within the time limits specified in the applicable code.
7.1.5 The cost of all qualifications shall be borne by the fabricator.
7.2 Joint Materials
7.2.1 Brazed joints shall only be made with cadmium-free silver brazing alloy. Soft-soldered joints are not permitted. Brazing filler materials for copper-to-copper, copper-to-stainless, and stainless-to-stainless braze joints shall meet the requirements of BAg-7 (Braze 560 or equal) of ASME SFA5.8. Brazing flux shall be an American Welding Society, Inc. (AWS) brazing flux Type 3A (Handy Harmon flux) or approved equivalent.
7.2.2 When joints are made using heavy-duty copper alloy fittings pre-loaded with brazing alloy, no additional brazing alloy shall be applied (that is, Yorkshire HD fittings).
7.3 Preparation
7.3.1 All brazed joints shall be prepared according to ASME B31.3, paragraph 333.3.
7.3.2 Fittings shall be round, true, and new. Fittings, once brazed, shall not be reused.
7.3.3 Solder joints shall be kept as far as possible from threaded joints. In all cases, the distance shall be sufficient to prevent the heat of soldering from destroying the effective sealing effect of the thread sealant in threaded joints already completed.
7.3.4 Copper pipe and tube shall be cut to the desired length with a square cut in a square-end sawing vise or with a power saw and then deburred and cleaned. Tube cutters shall not be used unless the tube is internally deburred.
7.3.5 Pipe or tube and socket shall be cleaned to bright metal immediately before brazing. The pipe or tube shall be cleaned for a distance slightly more than the depth of the fitting socket. Cleaning shall be done carefully so that the proper clearance is maintained between the pipe, or tube and fitting.
7.3.6 Flux shall be applied to both members immediately before brazing.
7.4 Inspection
7.4.1 Whenever possible, solder joints shall receive an internal visual inspection by optical inspection devices.
7.4.2 All brazed joints shall be subject to the inspection by the Air Products representative.
7.4.3 All joints that show evidence of overheating, cracking, poor penetration, or other defects of fit-up or workmanship shall be replaced as directed by the Air Products representative.
7.4.4 At the discretion of the Air Products representative, the fabricator shall periodically monitor brazing operators’ techniques by cutting brazed joints out-of-line, then sawing them in half and pulling them apart. Defective joints and their repair shall be to the fabricator’s account. Sound joints that have been destructively tested as indicated above will be paid for by Air Products.
7.4.5 If testing under other sections of these specifications reveals unsound brazed joints, the fabricator shall disassemble and replace fittings with new material or, with the Air Products representative’s approval, re-clean to a bright finish and reassemble those joints that were deemed unsatisfactory.
- Each brazing operator shall identify the operator’s specific work by marking his regularly assigned identification symbol on the tube adjacent to the joint, at the time the joint is made.
- Complete records of all silver brazing shall be kept on Form 5 and placed in the Quality Control and Inspection Book. Form 5 includes information concerning the line number, joint elevation, cleaning, brazer, brazer qualification, and completion of the joint.
- WELD JOINT EXAMINATION
The following defines the minimum requirements for nondestructive weld joint examination.
8.1 Dye Penetrant Examination
8.1.1 All support lugs, trunnions, and supports welded to a pressure pipe shall be 100% dye penetrant examined.
8.1.2 All fillet welds where instrumentation connects to a vessel or to process pipe shall be 100% dye penetrant examined.
8.2 Radiography
8.2.1 Radiography of welds shall be performed according to ASME BPVC, Section V, Article 2, and shall be judged according to ASME B31.3, “Normal Fluid Service,” unless otherwise indicated. Personnel evaluating the radiographs must be qualified according to ASNT SNT-TC-1A. A copy of personnel qualifications must be provided.
8.2.2 All welding shall be subject to radiographic examination according to ASME B31.3, Normal Fluid Service unless stated otherwise, and shall include examination by random radiography of the total quality of the welded joints, including saddle-type branch connections selected as follows:
Radiography shall be done progressively throughout the work, commencing at the start of fabrication and/or field erection welding.
Each welder’s work for each procedure used shall be represented.
The quality of each welder’s work, as evidenced by radiographic results, shall be considered in selecting welds for additional radiographic examination.
The severity of process service shall be considered.
Weld joints shall be selected at a frequency to preclude significant rework if systematic weld quality issues are discovered.
The Air Products representative shall have the privilege of selecting the welds to be examined.
8.2.3 For aluminum refer to Appendix D, Paragraph D10.
8.2.4 Minimum radiographic examination:
8.2.4.1 The minimum radiographic examination for butt welds shall be as defined in Table 1 below. Welds shall be fully examined by random radiography in accordance with ASME B31.3. The first two production welds per WPS produced by each welder shall be subjected to full radiography. These welds may not be counted in the percentage of welds that shall be fully radiographed per welder, as per Table 1. Additional production welding may not begin until the welder produces two acceptable welds per welding procedure as assessed by radiographic results.
Table 1
Minimum Requirements for Radiography
| Piping Service | Min. % of Random Radiography | Comments |
| Oxygen | 5% | 100% visual inspection
(reference Note A below) |
| Nitrogen | 5% | |
| Other | 5% | Unless otherwise specified in contract documents (reference Note B below) |
Note A: 100% of welds on pipework designated for oxygen service shall be visually examined to ensure that the internal root profile is smooth, free from overpenetration, irregular profile, weld splatter, excessive oxide formations, or other imperfections. If the root pass cannot be visually examined, that weld shall be subjected to 100% radiographic examination.
Note B: Any additional examination required because of the nature of the contents or service of the piping system will be specified on the contract drawings and specifications.
8.2.5 Full radiography shall be performed on all weld repairs.
8.2.6 For each defective weld found, two additional (tracer) joints made by the same welder shall be promptly radiographed. If one or both of these tracers show unsatisfactory welding, additional welds made by this welder shall be radiographed, examining two welds for each tracer weld found to be unsatisfactory. Welds radiographed as tracer joints are not counted as part of the 5% sampling check. The fabricator shall reimburse Air Products at the laboratory’s quoted rates for radiographic re-examinations and radiographs related to tracers.
8.2.7 Each film shall be identified per ASME Section V, Article 2 using both the line number and the joint number. Final disposition of radiographic reports shall be in accordance with ASME Section V, Article 2.
8.2.8 The minimum examination required for brazed joints shall be 5% according to ASME B31.3. The Air Products representative reserves the right to choose joints for destructive examination (see paragraph 8.2.2 above).
8.2.9 Examination by sectioning is prohibited.
8.2.10 The fabricator shall keep sufficient records to permit reviewing the performance of each welder involved in the work. Radiographic examination reader sheets shall be maintained with the radiographic film. The reader sheets and film shall be traceable to the weld and welder.
8.2.11 By marking up the specific isometric or orthographic drawing(s), the fabricator shall keep a neat and accurate weld map of field-weld locations and shall record the welder who performed each weld.
8.2.12 All welds examined shall be recorded on Form 11. The reader log contains X-ray information and the interpretation (acceptance or rejection) of each radiograph. The completed forms shall be placed in the “Quality Assurance and Inspection Book.”
9. Transition joints and THREADED JOINTS
9.1 Transition Joints
9.1.1 If any transition joint is received without a temperature indicator label, the fabricator shall not install the joint and shall notify Air Products immediately for further instruction. Any transition joint that has been installed without a temperature indicator label will require the joint to be removed and replaced.
9.1.2 The Quality Assurance Transition Joint Check Sheet (Form 28) shall be initiated before installation of all transition joints. Each joint shall be marked with a permanent waterproof marker identifying the appropriate line number next to the temperature indicator label. The fabricator shall then take a picture of the joint, which shall include the line number ID and the temperature indicator label. This picture shall become part of the Quality Assurance documentation.
9.1.3 The fabricator shall install the transition joint in the piping system in accordance with 4WPI‑FWAJ10, which defines temperature monitoring and suggested cooling methods.
9.1.4 After completion of the welding of both ends of the transition joint, another picture shall be taken that shows both welded ends as well as the line number ID and temperature indicator label. This picture shall also become part of the Quality Assurance documentation.
9.1.5 If any transition joint’s final panel on the temperature indicator label turns black as stated in 4WPI‑FWAJ10, the fabricator shall notify Air Products immediately. The overheating of the temperature indicator label either by preheating the joint or during the weld installation process will require the transition joint to be removed and replaced.
9.2 Threaded Joints
9.2.1 The fabricator shall make up all threaded piping with as few joints as possible. All threaded joints shall be made with clean-cut taper threads conforming to National Taper Pipe Thread dimensions. Piping shall be reamed of burrs and kept clean of scale, dirt, and chips. All connections shall be permanently gastight and watertight. Unions shall be provided as shown on the drawings, or as required for proper assembly and disassembly. Couplings shall not be used except where pipe is more than 5 m (16 ft) in a straight length between fittings. All threaded joints, including those for oxygen service, shall be made in accordance with 3PI55005 for oxygen service -196°C (-320°F) to +204°C (+400°F).
10. COLD BOX frame and JACKET panels
10.1 The fabricator shall build a watertight structural steel frame and jacket in accordance with the project contract drawings, these specifications, and Air Products specifications 4ACS-640130. Following the installation and welding of the jacket panels, inspection from the inside of the box shall be made to check for any light ingress around welds. If any light is seen, weld repair must be made.
10.2 All fabrication shall be in accordance with AISC specifications.
10.3 All materials shall be new, of first quality, free of defects and imperfections, and of recent manufacture.
10.4 Welding shall be executed in accordance with AWS D1.1.
10.5 All holes shall be punched, drilled, or plasma burned and shall be free of burrs. Oxyacetylene burning of holes or pilot holes in preparation for final drilling is not permitted. Plasma burning of holes in lifting lugs is not permitted.
10.6 Erection and assembly tolerances shall be in accordance with the notes given on the Air Products project structural assembly drawings. In cases when no specific tolerances are given, erection shall conform to those specified in the AISC 316.
10.7 The fabricator shall perform specific inspections to verify that the fabrication of structural assemblies is in accordance with the project drawings, including the verification that the specified materials were used for the fabrication.
10.8 The fabricator shall perform visual inspection of 100% of the field welds. Where visual inspection indicates possible deficiencies, nondestructive testing (NDT) or repair work shall be performed by the fabricator. Questionable welds shall be tested using the dye penetrant, the magnetic particle, the ultrasonic method, or a combination of these methods to the satisfaction of the fabricator’s inspector. Weld inspection and testing procedures, techniques, standards and acceptance, and methods of repair shall be in accordance with the applicable requirements of AWS D1.1. Repair and further inspection of defective field welds shall be performed to the satisfaction of the fabricators inspector and the Air Products representative.
10.9 The fabricator’s inspector shall document all visual inspections and NDT performed. Complete records of inspections shall be maintained in the “Quality Assurance and Inspection Book.”
10.10 The cold box trunnions, lifting lugs, lifting lug holes, and welds shall be reviewed to ensure they are the proper size and the welds shall be inspected for cracks using dye penetrant or magnetic particle test.
11. FRAME LEVELING, COLUMN ORIENTATION–alignment with frame, OR COLUMN PLUMBNESS
11.1 Frame Leveling: The fabricator shall abide by the following or an Air Products approved procedure:
11.1.1 Establish the layout of the front face (shipping side) of the box structure. Then, place the support members (timbers or steel beams) on the shop floor across the runners at the base, the roof area, and at the location of the column saddle, and/or equipment supports. (The fabricator shall provide additional support members when required between these locations based on the size of the box frame to provide adequate support.)
Support members shall be of sufficient height to provide adequate clearance between the box and shop floor for lifting with hydraulic jacks.
11.1.2 Set up a surveying instrument or laser, and level the support members using the shims necessary to establish a level bed to within +/- 3 mm (+/- 1/8 in).
11.1.3 Set the assembled box structure or construct the shipping face of the box on the support members.
11.1.4 Using the surveying instrument or laser, level the main runners of the shipping face. When required, adjust with shims to establish a runner level within +/- 3 mm (+/- 1/8 in). Instrument readings shall be taken at a maximum of 6 m (20 ft) intervals or at a minimum of three locations per runner. (The fabricator shall take readings at additional locations as may be required on longer boxes.)
11.1.5 Assemble the box frame maintaining the +/- 3 mm (+/- 1/8 in) levelness of the box structure and the +/- 3 mm (+/- 1/8 in) fabrication tolerances.
11.1.6 If the box was preassembled, remove the necessary rear structural elements in order to install the column and/or equipment.
11.1.7 Using the instrument, check that column saddles are level to +/- 3 mm (+/- 1/8 in) if applicable.
11.1.8 Set the column in the saddles if applicable.
11.2 Column Orientation: The fabricator shall adhere to the following or to an Air Products approved procedure:
11.2.1 Orient from the 0° (or 180°) mark on the column’s bottom head by draping two plumb bobs over the sides of the column and one plumb bob from the 0° (or 180°) orientation mark.
11.2.2 Rotate the column until equal dimensions are established between the plumb bobs draped over the side of the column and the one at 0°(or 180°) per the following sketch:
Figure 1
End View–Column
X X
11.3 Column Deviation, Horizontal Measurement: The fabricator shall abide by the following or an Air Products approved procedure:
11.3.1 Drop plumb bobs from 0° (or 180°) orientation at all final assembly closure locations (circumferential welds) along the length of the column (see Figure 2).
11.3.2 Measure from plumb bobs to the left front corner runner. At all locations, deviation shall not exceed 1.3 mm per linear meter (1/64 inch per linear foot) to a maximum over the box length of 12.7 mm (1/2 in).
11.3.3 The same criteria shall be followed along the length of the column.
11.4 Column Deviation, Vertical Measurement: The fabricator shall abide by the following or an Air Products approved procedure:
11.4.1 Set up the instrument on level, and shoot the column at the 90° (or 270°) marks at all vessel closure locations. The tolerances in paragraph 11.3.2 shall equally apply to this sequence.
11.5 When frame and column are within tolerance, inspect and document dimensions on Forms 18 and 19.
11.6 Indexed copies of Forms 18 and Form 19 shall be included in the “Quality Assurance and Inspection Book.”
11.7 The distillation column in field-fabricated boxes shall be plumbed in accordance with 4WMA-007018.
Figure 2
Front Side View from the Top of the Box
12. INSPECTION UPON RECEIPT OF AIR PRODUCTS-SUPPLIED PRESSURE VESSELS
12.1 The fabricator shall inspect each Air Products-supplied vessel upon arrival at the fabricator’s facility and before unloading. The inspection shall be to identify any indentations, score marks, external blisters and distortion, and cracking of welds on nozzles or attachments. Additionally, the shipping pressure shall be checked in pressurized vessels including heat exchangers, distillation columns, and others by attaching a pressure gauge to each circuit provided with a valve for this purpose. The pressure reading shall be recorded on Form 10. Any damage and/or vessel pressure loss shall be reviewed immediately with the Air Products representative and also reported by telephone or fax to the Air Products project engineer, requesting instructions.
12.2 Complete records of all pressure vessels shall be kept on Form 10 and placed in the “Quality Control and Inspection Book.” Form 10 includes information concerning the equipment tag number, gauge location, pressure reading, ambient temperature, and inspector’s signature/date.
- HANDLING AND PRESERVATION OF AIR PRODUCTS-SUPPLIED EQUIPMENT
13.1 Particular care shall be taken when off-loading and handling pressure vessels. Fabricator shall observe all shipping, handling, and lifting instructions. Where lifting lugs are supplied, shackles and chains, or cables, are permitted if the shackles and chains, or cables, do not contact the vessel. Otherwise, nylon (or equivalent material) slings of 65 mm (2 1/2 in) minimum width shall be used. All lifting devices shall be inspected immediately before use to ensure integrity and adequate capacity. Distillation columns shall be lifted in accordance with the shipping and lifting sketch listed in the project specification that indicates the attachment locations, the sling width, the lift weight, and other required specifications.
13.1.1 Where handling jigs are supplied for vessel assemblies, such as manifolded heat exchangers, the handling and the sequence of the jig’s removal shall be in accordance with manufacturer’s certified drawings.
13.2 Certain vessels, such as hydrocarbon adsorbers, may be received with the adsorbent installed and the vessel pressurized from 0.35 to 1.03 bar g (5 to 15 psig). End caps for these vessels shall be removed only after the vessel is installed in the cold box and before twelve hours of attaching all connecting piping to the vessel’s first block valve. The entire operation of removing end caps and connecting the piping shall only be performed in the presence of the Air Products representative. It is extremely important that the fabricator follow these instructions together with other measures that are necessary to ensure that no liquid moisture enters these vessels.
13.3 Nozzles on pressure vessels shall be cut and the edge prepared using a procedure that prevents chips and dirt from entering the vessel. Temporary covers shall be installed to prevent entrance of all foreign matter. The fabricator and/or the Air Products representative shall sign-off next to the appropriate item on Form 15 verifying for the removal of each of these temporary covers immediately before the attachment of the connecting pipe. Form 15 shall be placed in the “Quality Assurance and Inspection Book.”
13.4 Certain valves, instruments, and equipment supplied by Air Products will be in a Class AA cleaned condition. The fabricator is responsible for maintaining this cleanliness during storage and installation at the fabricator’s facility. Any valves, instruments, and other components that are inspected and identified as contaminated shall be cleaned by the fabricator as required to meet the Class AA cleaning level.
13.5 All flange facings shall be kept covered to protect the finish and removed only immediately before the final assembly.
13.6 Flanged and welded vessels and equipment shall be aligned and properly fitted in accordance with the project drawings and specifications before bolting or welding. Piping strains on equipment shall be avoided. The fabricator shall optimize weld locations in prefabricated spools to accommodate for out of tolerance nozzles.
14. EQUIPMENT supports AND PIPE SUPPORTS
14.1 Permanent Equipment and Pipe Supports
14.1.1 The fabricator shall fabricate and install all permanent equipment and pipe supports in accordance with Air Products specifications 4ACS-640130, 4ACS-640131, the contract drawings, and this specification.
14.1.2 Welding electrodes for welding stainless steel-to-stainless steel or stainless steel-to-carbon steel shall conform to AWS A5.4 and/or AWS A5.9.
14.1.3 The fabricator shall verify that the specified materials (that is, carbon steel vs. stainless steel) are used in the construction of all equipment and pipe supports as shown on the structural and pipe support drawings.
14.1.4 The fabricator shall perform 100% visual inspection of welds. Where visual inspection indicates possible deficiencies, nondestructive testing (NDT) or repair work shall be performed by the fabricator. Questionable welds shall be tested by dye penetrant, magnetic particle, ultrasonic method, or a combination of these methods to the satisfaction of the fabricator’s inspector. Weld inspection and testing procedures, techniques, standards and acceptance, and methods of repair shall be in accordance with the applicable requirements of AWS D1.1.
14.1.5 Repair and further inspection of defective welds shall be performed to the satisfaction of the fabricator’s inspector.
14.2 Temporary Equipment and Pipe Supports
14.2.1 The fabricator shall determine requirements for all temporary equipment and pipe supports necessary to fabricate and install the piping and equipment.
14.2.2 Temporary equipment and pipe supports used for equipment and pipe installation shall be removed as permanent supports are installed or before shipment of the cold box.
14.3 Piping Shipping Supports
14.3.1 Location of the piping shipping supports shall be determined by the fabricator in accordance with Air Products specification 4ACB-683001. Additional shipping supports may be required by the Air Products representative. The fabricator shall be responsible for the details, materials, and installation of the shipping supports suitable for maintaining the piping system’s structural integrity during transit. All shipping supports shall be painted yellow for easy identification and documented on Form 6 for removal in the field.
14.4 Support Records
14.4.1 Records of shipping and permanent supports shall be kept on Forms 6 and 17 in attached Appendix A. The fabricator shall pay particular attention to proper U-bolt installation as follows:
- There is no gap between the piping attachments (trunnions and lugs) and the support steel.
- The material of the U-bolts and U-bolt nuts comply with the specifications and drawings.
- Double nuts are used on the U-bolts when called for on the drawings.
- U-bolt nuts are tightened, while the gap around pipe is maintained.
14.4.2 The details contained in Forms 6 and 17 include pipe support number, location, line number supported, elevation, welding completed, U-bolt installed properly, and pipe support complete. The inspector shall initial each line to signify its successful completion.
14.5 Completed and indexed copies of Forms 6 and 17 shall be placed in the “Quality Assurance and Inspection Book.”
15. PIPE WORK
15.1 The fabricator shall perform all piping work in accordance with ASME B31.3, the Project Technical Fabrication Specification, the current edition of applicable codes, specifications, standards, and the following:
15.1.1 Unless specifically shown on the drawings, branch welding (stub-in) is prohibited.
15.1.2 All branch connections shall be contoured to match the header pipe and shall be welded in accordance with ASME B31.3, Chapter V, Figure 328.5.4D.
15.1.3 Branch connections shall not intersect the longitudinal or circumferential pipe seams.
15.1.4 Welded attachments shall not intersect the longitudinal or circumferential pipe seams.
15.1.5 The longitudinal seams of welded pipe in adjoining pipe sections shall be staggered
15.1.6 All flange bolt holes shall straddle the natural centerlines in all directions, unless otherwise specified on the piping drawings.
15.1.7 Large fabricated tees and mitered bends shall be back-welded on the inside of the fittings. For mitered bends, an extra diametrical butt weld shall be included to allow welding inside. Mitered bends shall be in accordance with the piping specifications.
15.1.8 All copper-to-copper or copper-to-stainless steel joints shall be silver brazed, unless otherwise noted.
15.1.9 All valves with soft seats (Teflon and others) shall be fully opened before they are welded or brazed into piping.
15.1.10 All flange gasketing, bolting, and bolting sequences shall conform to Air Products specifications 4WPI-57902, 3PI55001, and 4WPI-FWZK01 unless otherwise specified on drawings.
15.1.11 All valves shall be installed as indicated on piping drawings by flow arrows at the valve body (not always the same as line flow).
15.1.12 The open ends of all pipes, valves, and other components shall be kept capped at all times until final connections are made. Wood, plastic, metal, and/or rag plugs shall not be used. Metal or plastic caps are acceptable.
15.1.13 All slip-on flanges shall be welded from both sides per Figure 328.5.2B of ASME B31.3.
15.1.14 For out-of-round piping, line-up clamps or jacks shall be used, when necessary, to provide the proper fit-up when joining pipe together.
15.1.15 Pipe bending shall conform to 4WPI-FWZB01.
15.1.16 All socket weld joints shall have approximately a 1.6 mm (1/16 in) gap between the pipe end and socket bottom per Figure 328.5.2C of ASME B31.3 before welding.
15.1.17 Fillet welds shall be produced in multiple passes to keep temperatures low in order to minimize stress and prevent leaks.
15.1.18 All welded or brazed joints shall be clearly and permanently marked by the performing operator to indicate the operator’s regularly assigned identification number.
15.1.18.1 Markings shall be made adjacent to each weld and on the fittings adjacent to each brazed joint.
15.1.18.2 Markings shall be made by use of electric pencil, rubber stamp, or metal stamp as allowed by the applicable code.
15.1.19 Transition joints shall be installed in accordance with 4WPI-FWAJ10 and Section 9.1 of this specification.
15.1.20 Penetration Tolerances:
- Penetration center point location tolerance +/- 10mm.
- Pipe penetrations tolerance +/- ½ degree in both vertical and circumferential planes.
- Face of flange tolerance +/- ½ degree in both vertical and circumferential planes.
- All deviations that exceed the above must be approved by the design group.
15.1.21 When interpreting isometric drawings, the following points shall be noted:
- Weld gaps in computer-generated isometric drawings for butt welds are 0 mm (0 in).
- Weld gaps in computer-generated isometric drawings for socket welds are 1.5 mm (1/16 in).
- Solder gaps in computer-generated isometric drawings for solder joints are 0 mm (0 in).
- Cut lengths for piping isometrics where the isometric indicates a FFW (Field Fit Weld) include an additional 40 mm (1 1/2 in) of pipe for test blank installation. See Scribe Line Cut-off Detail below.
- Cut lengths for threaded ends shall be the end of the pipe, including the thread.
- Coordinates stated at the end of a line terminating in a flange reflect the face of the flange and not the gasket thickness.
- The Air Products fabrication facility shall ensure that valve handwheels, levers, and actuators are clear of adjacent lines or other interferences before welding the valve.
- Dimension for a flanged flow element includes two flange lengths, two gasket thicknesses, and the orifice plate thickness.
- Dimension for a flanged venturi is thickness of venturi mounting plate, not including gaskets.
- Dimension for welded flow element is exact with zero root gap.
- The angle identified on the isometric for all changes of direction less than 90 degrees is the acute bend angle. It is not the included angle of the fitting.
- All dimensions showing the location of pipe supports and welded attachments are approximate. See the pipe support and weld attachment drawings for actual locations.
- Piping within the cold box is located from the outside of the jacket frame (that is, inside of panel).
- Where pipe runs are longer than a random pipe or tube length, intermediate butt weld, socket welds, or solder joints are not always shown or located. These additional joints must be located by the fabricator. Cut length shown is from end of fitting to end of fitting.
- Sloping Valve Stem Indication
- Branch Orientation
- Pipe Support Symbol
- Weld Attachment Symbol
- Scribe Line Cut-off
16. PIPING TOLERANCES
16.1 Piping fabrication dimensional tolerances shall conform to PFI ES-3, unless otherwise shown on the project design drawings. The cold box fabricator shall be responsible for determining the field welds in prefabricated pipe and any random length cut-back dimension necessary to accommodate the piping, vessel, and cold box frame fabrication tolerances. Tolerance inaccuracies of nozzle locations for distillation columns may occur. The cost of all fit-ups, including made-up joints to prespools, shall be borne entirely by the fabricator.
16.2 During installation and after pressure testing, all flanged and other connections to mechanical rotating equipment (for example, expanders and companders) shall be unbolted/disconnected and checked for proper alignment. Flanged connections shall not put any strain on the equipment casings. Dial indicators shall be used to ensure strain-free piping-to-equipment casing connections.
16.3 All flex hoses and expansion joints shall be installed undisplaced and without strain, or as indicated on the project contract drawings, or as shown on 4ACB-683015. Expansion joints shall not be used to correct for misalignment of the piping.
16.4 Cold springing is not allowed for piping fit-up unless specifically specified on the project contract drawings. Improperly fitted piping shall be removed and replaced. The Air Products representative might also direct the removal of piping deemed as improperly installed.
17. Valving and INSTRUMENTATION
17.1 The fabricator shall install all manual valves as shown on the project contract drawings and listed in the project valve summary. These valves are furnished by Air Products. Plate-mounted valves shall be installed in accordance with 4WPI-VALV02.
17.2 Handling and Installation of Samson cryogenic globe valves shall be in accordance with 4WPS-VALV11.
17.3 The fabricator shall install all temperature elements and associated wiring, control valves, orifices, orifice flanges, safety valves, and flow tubes that are furnished by Air Products. In addition, the fabricator shall furnish, install, and test all associated tubing, wiring, conduits, and miscellaneous items required for a complete installation as shown on the project contract drawings and as specified herein. Instrumentation is listed on the project instrument summary.
17.4 The project contract drawings generally do not show the actual complete run for instrument tubing. The fabricator shall estimate each tubing run by locating the tie-in on the vessel or pipe spool and routing the tubing to the corresponding nozzle in the penetration panel on the box. Estimated tubing lengths and connection details are included on the Air Products-supplied project instrument schematic drawings.
17.5 Air Products reserves the right to specify the sequence of installation and testing for the instrumentation.
17.6 Installation and testing of temperature elements shall be in accordance with 4ACB-684001. The certification of testing shall be recorded on Form 8. Form 8 shall be placed in the “Quality Assurance and Inspection Book.”
17.7 Installation of instrumentation other than temperature elements shall be checked by the Air Products representative. The verification of orifice installation shall be documented on Form 16. Form 16 shall be placed in the “Quality Assurance and Inspection Book.”
18. CLEANING OF PIPE AND ASSOCIATED SYSTEMS
18.1 All pipe shall be cleaned as specified on the Piping Isometric Index by the fabricator to 4WPI‑SW70001 (Class SC), 4WPI‑SW70002 (Class B), or 4WPI-SW70003 (Class AA), as defined herein. Cleaning shall be performed after cutting and fit-up. However, cleaning shall be performed before making joints with backing rings and also before making joints that prohibit a straight-line view for inspecting internal surfaces.
18.2 All pipe, tubing, and fittings that require “AA” or “B” cleaning shall be pre-cleaned, and the required cleanliness maintained through installation, unless otherwise permitted by the Air Products representative.
18.3 There are three levels of cleaning and inspection required. The three levels are as follows:
- Class SC Cleaning (standard cleaning)
- Class B Cleaning (used for general process systems)
- Class AA Cleaning (used for oxygen and high purity products – a hydrocarbon decontamination procedure)
18.4 The fabricator or supplier shall clean all components after cutting and beveling, but before fit-up has been performed. Flanges or a single fitting may be welded to single-cut lengths before cleaning. This preassembly procedure allows for the proper cleaning and inspection of each piece before final spool fabrication.
18.5 Inspection Requirements, Cleaned Pipe: All components and pipe assemblies shall be subject to inspection and shall be considered acceptable when they pass the following:
18.5.1 Standard Cleaning (Class SC): The visual examination of the cleaned surface under a strong, white light shall indicate the following:
- Moisture allowed
- No loose rust or scale
- Thin films of oil or mill lacquer are acceptable
- No visible foreign matter such as sand, weld spatter, and cutting chips
Note: For more details, see 4WPI-SW70001.
18.5.2 Process Clean (Class B): The visual examination of the cleaned surface under a strong, white light shall indicate the following:
- No moisture
- No rust in excess of that shown in 4AEQ-660500 except that shop-fabricated piping shall be rust free at the time of shipment according to ASTM D 2200 to SA 2
- No visible films of organic materials such as oil, grease, paint, or similar materials
- No other visible foreign matter
Note: For more details, see 4WPI-SW70002.
18.5.3 Oxygen Clean or Hydrocarbon Decontaminated (Class AA): The visual examination of the direct surface under a strong, white light shall indicate:
- No moisture
- No rust in excess of that shown in 4AEQ-660500 except that shop-fabricated piping shall be rust free at the time of shipment according to ASTM D 2200 to SA 2 1/2
- No visible films of organic materials such as oil, grease, paint, or similar materials
- No other visible foreign matter
18.5.3.1 Ultraviolet (3660 angstrom (au) wavelength) inspection shall indicate:
- No hydrocarbon fluorescence
- No more than two lint particles per 25.8 cm2 (4 in2)
18.5.3.2 A wipe test examination (using Whatman No. 44 filter paper or equal) by rubbing lightly over the surface shall indicate:
- No discoloration other than that caused by oxidation of the parent metal
- No oily residue
- No other foreign matter or particles
Note: For more details, see 4WPI-SW70003.
18.6 Cleanliness Inspection
18.6.1 The fabricator shall fully assist with cleanliness inspections and shall provide documented results as required by Form 9, Cleanliness Inspection Log. Complete records kept on Form 9 shall be placed in the “Quality Control and Inspection Book.” Form 9 includes information concerning the line number, inspection method, contaminants, and areas for the fabricator and the Air Products representative to sign as completed work is accepted.
18.6.2 Valves and in-line items may be supplied to site pre-cleaned, in which case the fabricator shall be responsible for maintaining them in the cleaned condition. Any items for oxygen service requiring recleaning shall be reported to the Air Products representative, who will decide on any necessary remedial action.
18.6.3 All piping shall be inspected for cleanliness immediately before making the final closing weld. The fabricator shall maintain a record of these inspections for inclusion in the “Quality Control and Inspection Book.”
18.6.4 The fabricator will be required to demonstrate by written procedures that requirements are being met on a daily basis to ensure the required cleanliness of the installed piping is being maintained.
18.7 Pipe Preservation and Capping Procedure – Shop Supplier of Prefabricated Pipe
18.7.1 Cleaned per Class “SC”: Cap buttweld ends with metal or plastic caps (polycaps, or equal, as manufactured by Protector Products, Cleveland, OH). Cover flanges with metal, plastic, or plywood capping and prepare for shipment according to the applicable portions of PFI ES-31.
18.7.2 Prefabricated pipe spools that have been process cleaned (Class B) or oxygen cleaned (Class AA) shall have all buttweld ends or openings sealed weathertight with a polyethylene slip-on cap. Bonney Forge “O” let connections shall be sealed with nipple caps or tap-in plugs. Flange protectors shall be 6 mm (1/4 in) thick, high-density polyethylene (HDPE) full-face covers and shall be securely attached. Seal or secure caps or flanges with at least two turns of 50 mm (2 in) waterproof tape (Tuck No. 90 or equal).
18.8 Pipe Preservation and Capping Procedure – Field Installation Fabricator
18.8.1 All temporary open ends of prefabricated and erected piping and vessels shall be resealed and waterproofed, preferably with plastic pipe caps, when not being worked on. Wooden plugs or rags are not acceptable.
18.8.2 Piping systems in process and oxygen service shall be purged with oil-free dry air or dry (dew point of -40°C or lower), oil-free nitrogen. If nitrogen is used caution must be exercised to avoid asphyxiation, and piping pressurized with nitrogen must be clearly identified as to containing a nitrogen purge. The fabricator shall supply all gases, tools, and equipment necessary to achieve this.
18.8.3 The fabricator shall ensure that cleanliness of completed piping systems is maintained by sealing all open ends with welded caps, blind flanges, or similar and purging with oil-free dry air or dry, oil-free nitrogen (dew point -40°C or lower) down to a maximum of 1000 ppmv oxygen, and until the dewpoints of the inlet and exit gas are essentially the same. After the oxygen content and dewpoint have reached the required levels, the piping system shall be pressurized to 0.1 bar g (approximately 1 psi) with oil-free dry air or nitrogen. If nitrogen is used caution must be exercised to avoid asphyxiation, and piping pressurized with nitrogen must be clearly identified as to containing a nitrogen purge. The pressure shall be monitored and maintained in this condition until the piping system is placed in service.
18.9 Cleaning Methods, Pipe and Fittings
18.9.1 Standard Cleaning, Class “SC” Cleaning
All pipe and fittings shall be cleaned of all foreign material (such as scale, sand, weld spatter particles, and cutting chips) from the inside by any suitable means (such as by a mechanically driven rotary cleaning tool or a wire brush). Inspect according to paragraph 18.5.1.
Blow out with compressed air.
18.9.2 Cleaning and Hydrocarbon Decontamination of Unfabricated Carbon Steel Pipe and Fittings (Class B and AA)
18.9.2.1 The interior of all unfabricated carbon steel pipe and fittings shall be blast cleaned with Black Beauty Blast Grit, Grade BB-1240, as manufactured by H. B. Reed and Company, Hammond, IN; or SAFE-T-BLAST Mineral Aggregates, Inc., P.O. Box 14258, Tampa, FL 33609; or Green Diamond Blast from Lone Star Industries, San Mateo, CA; or equal approved by Air Products. Blasting shall be done to remove all normal mill scale, rust, varnish, paint, hydrocarbons, and other foreign matter. After it is blast cleaned, the pipe shall be blown out with dry, oil-free air or nitrogen.
18.9.2.2 Before the internal blast cleaning of unfabricated carbon steel pipe and pipe fittings, piping shall be cut to specified lengths. The ends of the pipe shall be beveled for welding and all penetrations, nozzle connections, or other openings in pipe or pipe fittings shall be cut in. Flame cutting of pipe/pipe fittings is not permitted after piping has been blast cleaned or fabricated.
18.9.2.3 Interior blast cleaning of fabricated piping is not permitted. If it is necessary to add penetrations after fabrication, penetrations shall be cut in by a drill or a hole saw.
18.9.2.4 Acceptance of blast-cleaned piping shall be according to SA 2 (Class B) and SA 2 1/2 (Class AA) (Blast Cleaning) as shown in ASTM D 2200.
18.9.2.5 As soon as possible, but in no case more than eight hours after the completion of the internal blast-cleaning operation, the unfabricated pipe and fittings shall be immersed in an unagitated rinsing solution of Oakite NRP at a concentration of 758 cm3 (25 oz) of Oakite NRP per 3.79 L (1 gal) of water. The solution shall be maintained at a temperature of approximately 71° to 82°C (160° to 180°F). The pipe shall soak in the heated solution a minimum of five minutes. The solution shall be allowed to dry down on the work to provide an alkaline-activated coating to the surface of the work to act as a temporary rust inhibitor. This step is optional for Class B cleaning.
18.9.2.6 The interior of all unfabricated, small-bore carbon steel pipe and pipe fittings (that cannot be blast cleaned) shall be cleaned according to the following directions:
Immerse the work in a solution of Oakite No. 77 at a concentration of 237 to 473 cm3/L (8 to 16 oz/gal) of water maintained at a temperature of approximately 82° to 93°C (180° to 200°F) for a period of time ranging from 30 minutes to one hour. Since the immersion time is variable because of the varying degrees of contamination buildup on the work, the actual time required must be determined by periodic inspection. To ensure the removal of all possible soils (especially a type of varnish used by pipe manufacturers as a rust retarder), Oakite Stripper Additive shall be added to the solution to a concentration of 1 1/2% by volume.
Remove work from the cleaning solution and rinse in potable water at ambient temperature. This rinse shall be moderately agitated by using oil-free, compressed air or other mechanical means to ensure the removal of any loose soil clinging to the surface of the work.
Following the rinse, the work shall immediately be immersed in a solution of Oakite No. 31 and water at a concentration of 10 to 20% by volume. This solution shall be maintained at a temperature of approximately 71° to 82°C (160° to 180°F). The required immersion time shall be determined by periodic inspection. Usual time required is 30 minutes.
Remove work from the cleaning solution and rinse in potable water at ambient temperature. This rinse shall be heavily agitated by oil-free, compressed air, or other mechanical means to ensure the removal of all scale and rust.
Following the second rinse, the work shall immediately be immersed in an unagitated, rinsing solution of Oakite NRP at a concentration of 758 cm3 (25 oz) of Oakite NRP per 3.79 L (1 gal) of water for a minimum time of five minutes. This rinse shall be maintained at a temperature of approximately 71° to 82°C (160° to 180°F). This solution shall be allowed to dry down on the work. This step is optional for Class “B” cleaning.
In the preceding cleaning procedures, the first stage is to remove varnish, coarse dirt, and scale; the second stage is to ensure complete removal of all scale and rust; and the third stage is to provide a temporary rust inhibitor.
18.9.3 Cleaning and Hydrocarbon Decontamination of Unfabricated Aluminum Pipe, Fittings, and Parts (Class B and AA)
18.9.3.1 Prepare a solution of Oakite Aluminum Cleaner No. 164 at 47 to 63 cm3/L (6 to 8 oz/gal) of water. Heat the solution to a temperature of approximately 82° to 93°C (180° to 200°F). Allow work to soak in the solution for the period of time required to completely remove all soils and contaminants.
18.9.3.2 After attaining the required cleanliness, remove work from the cleaning solution and immediately immerse in a potable water rinse at ambient temperature using a violent, oil-free air agitation of rinse water. When rinsing tubing, piping, and similar parts, an internal pressure rinse is recommended (that is, high velocity hose stream).
18.9.3.3 If necessary, the following method shall be used to remove oxides and residue from initial cleaning:
Immerse work for a period of five minutes in a solution of Oakite No. 34 at a concentration of 78 cm3/L (10 oz/gal) of water at ambient temperature [but not less than 16°C (60°F)].
18.9.3.4 Following the above process, the work shall be thoroughly rinsed in a potable water rinse at ambient temperature using a violent, oil-free air agitation of rinse water.
18.9.4 Cleaning and Hydrocarbon Decontamination of Unfabricated Stainless Steel and Copper Pipe, Fittings, and Parts (Class B and AA)
18.9.4.1 Prepare a solution of Oakite No. 77 at a concentration of 62.5 to 125 cm3/L (8 to 16 oz/gal) of water maintained at a temperature of approximately 82° to 93°C (180° to 200°F). Allow the work to soak in the solution for the period of time required to completely remove soils and contaminants.
18.9.4.2 After attaining required cleanliness, remove work from the cleaning solution and immediately immerse in a potable water rinse at ambient temperature using a violent, oil-free air agitation of rinse water.
18.9.4.3 If cleaning is necessary for stainless steel, the Air Products representative might require the following method to be used to remove stains, residue from the initial cleaning, or similar discoloration:
Immerse the work in a 10 to 20% by volume solution of Oakite No. 31 maintained at a temperature of 71° to 82°C (160° to 180°F) for the period of time required to completely remove all stains and discoloration.
18.9.4.4 Copper tube, pipe, and fittings shall be bright dipped in a 25 to 50% solution of Oakite Metal Sheen at room temperature from 10 seconds to two minutes to remove oxides, tarnish, stains, and corrosion. The dip will indicate if the part has been cleaned properly and prepare it for brazing with minimal work.
18.9.4.5 Following the removal of stains and discoloration, the work shall be thoroughly rinsed in a potable water rinse at ambient temperature using a violent, oil-free air agitation of rinse water.
18.9.5 Alternate Cleaning and Hydrocarbon Decontamination of Aluminum Pipe, Stainless Steel Pipe, Monel Pipe, Copper Tubing, and Associated Fittings (Class B and AA)
18.9.5.1 A solution of Blue Gold and water may be used for cleaning pipe and parts.
Blue Gold is a water-soluble, biodegradable, liquid concentrate used for cleaning and degreasing parts and equipment. It is manufactured by Modern Chemical Inc., P.O. Box 368, Jacksonville, TN 72076, (501) 988-1311. Blue Gold is made to mix with water (follow the manufacturer’s mixing instructions for best results).
Note: When working with Blue Gold, use safe work practices and proper personal protective equipment (PPE) as recommended by the manufacturer. Cleaning areas shall be well ventilated, and goggles and gloves shall be worn.
For cleaning unassembled pipe and fittings that have not been pre-cleaned, high pressure-steam cleaning equipment must be used producing temperatures between 100° and 115°C (212° and 240°F). A nozzle that sprays radially and reaches into the full length of pipe must be used to ensure proper cleaning. The Blue Gold/water mix is 1 part Blue Gold to 50 parts water (maximum). A thorough rinse must be made using clean, hot [100° to 115°C (212° to 240°F)] water with the radial spray nozzle. Drying shall be facilitated by blowing with nitrogen or argon.
For cleaning assembled pipe spools that have been pre-cleaned: When additional cleaning is needed on a line, a flush may be performed. Follow the requirements for unassembled pipe and fittings; however, a radial spray nozzle is not required.
Note: Serious thought shall be given before flushing a line with this solution. The concern here is that water could become trapped in the line and will be most difficult to remove in a reasonable time. Taking advantage of gravity and drains are appropriate ways to ensure that moisture is not trapped. Every precaution must be taken to keep pre-cleaned items clean, and avoid flushing lines in the field.
For spot cleaning, use Blue Gold/water mix of 1 part Blue Gold to 20 parts water. This mix can be applied at ambient temperatures, but the warmer it is, the less work it takes to remove the contamination. It can be applied by spraying from a bottle and wiping or by wiping with clean cloths soaked with the solution. Rinse using clean, warm water and dry by wiping with clean cloths.
For parts, use a dipping container with a solution of Blue Gold/water mix of 1 part Blue Gold to 20 parts water. The solution shall be heated up to a maximum of 60°C (140°F) for best results, although a lower temperature can be used. A stiff bristled brush may be used to scrub the part. Rinse using clean, warm water and dry using clean cloths, or blow dry with a hot-air gun or an inert gas such as nitrogen or argon.
Spray Solvents may be used as a convenience for small-spot cleaning. Caution is needed because a solvent might become “flammable” as it is spray-atomized. The following spray solvents are acceptable to use:
| Brand Name | Manufacturer/Distributor |
| Micro Care GENESOLV 2000
-or- Micro Care GENESOLV 2004 |
Allied Signal Inc.
Morristown, NJ 800-637-8138 FAX: 201-455-2615 |
| Distributed by:
Cumberland Electronics Harrisburg, PA 717-232-5999 |
|
| HIGH PURITY NOFLASH CLEANER | LPS Laboratories, Inc.
Tucker, GA 800-241-8334 |
18.9.6 Description of Cleaning Mediums
18.9.6.1 Oakite Stripper Additive (Neutral)
Application: Add to any regular alkaline Oakite solution. Applicable to metals which were initially determined suitable for the Oakite solution to which it is added.
Purpose: Considerably reduces cleaning time and improves the cleaning ability of an Oakite solution. Used to accomplish removal of acrylic and epoxy lacquers.
Mixing Proportions: 2 to 10% Oakite stripper additive to any alkaline Oakite solution by volume.
Operating Temperature: Do not heat in excess of 82°C (180°F).
Precautions: Never add Oakite stripper additive to an acid Oakite. A violent reaction will occur. Do not allow contact with skin or eyes.
18.9.6.2 Oakite No. 31 (Contains Acid)
Application: All metals, except aluminum.
Purpose: To remove oxides, rust, oils, and soil.
Mixing Proportions: 10 to 20% Oakite No. 31 to water by volume.
Operating Temperature: 71° to 82°C (160° to 180°F).
Precautions: Do not allow contact with skin or eyes.
18.9.6.3 Oakite No. 34 (Acid Power-type Material)
Application: For treating aluminum, brass, bronze, and copper.
Purpose: To remove oxides and brighten metal surfaces by immersion or circulation.
Mixing Proportions: 47 cm3/L (6 oz/gal) of water by spray or 78 cm3/L (10 oz/gal) of water circulation by tank immersion.
Operating Temperature: Room temperature.
Equipment: Stainless steel – Alloy 347, 316 ECL, or 304 ECL.
Precautions: Contains chromates. Do not allow contact with skin or eyes.
18.9.6.4 Oakite No. 77 (Strong Alkaline)
Application: All metals, except aluminum.
Purpose: To remove heavy deposits of soils and oils. To remove light deposits of rust and scale.
Mixing Proportions: Add the amount of Oakite No. 77 to water, as described in paragraph 18.9.2.6 (for carbon steel) and paragraph 18.9.4.1 (for stainless steel and copper).
Operating Temperature: 82° to 93°C (180° to 200°F) depending on the application in question.
Precautions: Do not use at temperatures below 60°C (40°F) or when scum forms on solution. Do not allow contact with skin or eyes.
18.9.6.5 Oakite No. 161 (Mild Alkaline Powder Material. Inhibited Against Attack to Aluminum. Contains Depressants to Prevent Excessive Foaming.)
Application: Cleaning aluminum by pressure spray or circulation method.
Purpose: To remove all types of soils other than stains and oxides.
Mixing Proportions: 23 to 31 cm3/L (3 to 4 oz/gal) of water.
Operating Temperature: 82° to 93°C (180° to 200°F).
Equipment: Material safe on all metals. Ordinary steel solution holding tanks for spray equipment are suitable.
18.9.6.6 Oakite Aluminum Cleaner No. 164 (Mild Alkaline Powder Material. Inhibited Against Attack to Aluminum. Contains Depressants to Minimize Foaming when Agitated.)
Application: Cleaning aluminum.
Purpose: To remove all types of soils other than stains and oxides.
Mixing Proportions: 47 to 63 cm3/L (6 to 8 oz/gal) of water.
Operating Temperature: 82° to 93°C (180° to 200°F).
Equipment: Safe on all metals. Ordinary steel tanks are suitable.
18.9.6.7 Oakite NRP (Highly Alkaline Industrial Product)
Application: Ferrous metals only.
Purpose: Provides for neutralizing acid residues and imparting a dry, temporary rust-inhibiting film.
Mixing Proportions: 758 cm3 (25 oz) per 3.79 L (1 gal).
Operating Temperature: 71° to 82°C (160° to 180°F).
Precautions: Avoid contact with eyes, skin, and clothing. Wear rubber gloves, safety goggles, or face shield and suitable protective clothing when handling dry powder or solutions. Wash thoroughly after handling.
– Avoid breathing dust or mist. Use with adequate ventilation. Do not take internally.
– When preparing new solutions or adding to existing solutions, slowly sprinkle product over surface of solution while stirring to avoid splattering. Do not add to hot water or hot solution warmer than 43° to 49°C (110° to 120°F).
– In Case of Contact: Immediately flush eyes or skin with plenty of water for at least 15 minutes. Remove contaminated clothing and shoes. Get medical attention for eyes. Wash clothing and shoes before reuse.
– If swallowed, wash out mouth thoroughly with water. Drink several glasses of water or milk and follow with diluted vinegar, lemon juice, or other citrus fruit juice. Contact a physician.
18.9.7 Cleaning (Miscellaneous)
18.9.7.1 The fabricator shall provide holding tanks or troughs of sufficient size for the specified Oakite solutions and rinses, and shall install a heating medium with enough capacity to allow the system to reach the required cleaning temperatures. Heating of the cleaning solutions and rinses as specified may be accompanied by closed steam coils, electric or gas immersion heaters, or any other method sufficient to maintain the required temperatures.
18.9.7.2 The fabricator shall obtain instructional literature and personal assistance from the Oakite representative as required to provide the quality of workmanship for cleaning as required by this specification. The Oakite representative located in the area of the fabrication site shall be contacted and the Oakite representative’s assistance shall be used before the start of cleaning.
18.9.7.3 Cleaning solutions shall be maintained free of excessive dirt or mill scale.
18.9.7.4 During the process of cleaning the pipe and fittings, all Oakite solutions shall be titrated daily to check and ensure the solutions are at the specified concentrations. Titration kits are available at no cost from Oakite and shall be ordered with the cleaning chemicals.
18.9.7.5 If the piping becomes contaminated while in the possession of the fabricator, the fabricator shall repeat the cleaning at his expense.
Note: Any deviation from this specification requires prior written approval from the Air Products representative.
- PRETEST FLOW/MECHANICAL CHECK REVIEW
19.1 After the installation of all piping and before the pressure testing, the cold box piping shall be mechanically verified, reviewed, and flow checked (P&ID/piping verification) by the Air Products representative with the assistance of the fabricator. The Air Products representative shall generate the “Cold Box Inspection Check List and Punch List,” which the fabricator shall use to complete all items. Items that could have an impact on pressure testing shall be completed before the pressure test. A copy of the “Cold Box Inspection Check List and Punch List” shall be included in the “Quality Assurance and Inspection Book.”
20. PRESSURE TESTING
20.1 All piping circuits of the cold box shall be pressure tested in accordance with 4WPI-EW44001 and all leaks repaired. Repaired piping circuits shall be pressure tested again. Repair of aluminum or stainless piping leaks shall be achieved by removal of the defective area followed by the addition of stringer bead welding. Overlays are not acceptable. The specific pressure test procedure with test pressures and circuits are shown in the project Technical Fabrication Specification.
20.2 Pressure testing of Samson cryogenic globe valves shall be in accordance with 4WPS-VALV12.
20.3 The pressure test procedure Forms QC-200A and QC-200B from 4WPI-EW44001 comprising Form 7 of Appendix A shall be filled in by the fabricator as tests are completed, and signed off by the Air Products representative and the fabricator’s inspector.
20.4 Pressure testing of assemblies shall be performed using dry, oil-free air at ambient temperature. Nitrogen in NOT permitted as a test medium. The degree of dryness of the pressure testing media shall be sufficient to maintain the established cleanliness. Cleaning inspection and acceptance requirements shall be applied after completion of the pressure test, unless waived by the Air Products representative. Where the cleaning, assembly, inspection, and pneumatic pressure test are witnessed and closely monitored, the inspection after test might not be deemed necessary by the Air Products representative.
20.5 Valves, piping, orifices, and accessories required for the pressure test shall be provided by the fabricator except for pressure test relief valves which will be furnished by Air Products. These valves shall be returned to Air Products upon the completion of testing.
20.6 Complete records of pressure tests and inspections shall be maintained on Form 7 (QC-200A and QC-200B). They shall be placed in the “Quality Assurance and Inspection Book.”
21. PAINTING
21.1 The fabricator shall prepare the surface and paint the cold box in accordance with the project Technical Fabrication Specification and 4WEQ-6804. It is recommended that the shipping side of the box be painted before installation of piping and equipment.
21.2 During and upon completion of painting, the fabricator shall document the painting process on the forms in 4WEQ-6804 titled Appendix B, “Record of Paint Application,” for shop-painted boxes and Appendix C, “Contractor Daily Log” for field-painted boxes comprising Form 3.
21.3 Complete records of inspections specified in paragraph 21.2 shall be maintained in the “Quality Assurance and Inspection Book.”
22. MISCELLANEOUS
22.1 All flange facings shall have a 125 to 250 microinch finish.
22.2 All studs, bolts, and nuts shall be properly marked in accordance with ASTM requirements.
- CHANGES DURING FABRICATION
23.1 The fabricator shall not make any changes or alterations to any part of the cold box design without the prior written approval of the Air Products representative. Any changes without this approval might result in a back-charge to the fabricator. Any interferences caused by Air Products drawing errors shall be identified and the fabricator shall request written design changes from Air Products.
23.2 Elbows may be used in lieu of bends if approved by the Air Products representative. If elbows are used, the additional material, installation, correction of interferences, and preparation and submittal of drawings associated with the request for substitution shall be included in the fabricator’s scope of work.
23.3 Any changes to the cold box fabrication that are required will be authorized by the Air Products representative and detailed on the “Cold Box Change Order” (CBCO) as contained in the Cold Box Commercial Specification. The fabricator shall review and accept the CBCO before initiating the change. The fabricator shall follow procedures outlined in the commercial specification if the CBCO is rejected.
23.4 All Air Products-approved changes made by the fabricator shall be documented on the project drawings. A complete set of “as-built” (“as-fabricated”) drawings shall be forwarded to Air Products upon the completion of the work in accordance with the requirements contained on the VDR Set and Form 25.
- JACKET PENETRATION AS-BUILTS
24.1 Final as-built dimensions are required for all jacket penetrations. The fabricator shall complete Form 2, which includes the nozzle identification, elevation, horizontal dimensions, and penetration or projection dimensions. This form shall be submitted as required on the VDR Set and shall be included in the “Quality Assurance and Inspection Book.”
25. PREPARATION FOR SHIPMENT
25.1 The cold box shall be prepared and sealed for shipment in accordance with 4WCB-70001.
25.2 Certain valves that are identified in the technical specifications will require disassembly before shipment of the cold box. All disassembled parts shall be marked to ensure correct reassembly. These parts shall be packaged individually to maintain cleanliness. They shall be appropriately crated for shipment and packaged for job site storage. Automatic valves shall be disassembled using procedures that maintain factory adjustments.
25.3 Samson cryogenic globe valves shall be prepared for shipment in accordance with 4WPS‑VALV12.
25.4 All machined surfaces that require maintaining their specified finish to effect leakproof joints at final installation shall be appropriately protected from damage during shipment and job site storage.
25.5 All piping terminations or openings shall be provided with adequate sealing and protection to ensure that the cleaning and decontamination is maintained during shipment and job site storage. Wood plugs or rags shall not be used. Project jacket penetration and detail drawings provide typical requirements. The fabricator shall use these to develop the project-specific details.
25.6 When defined in the technical specification, finished cold boxes shall have the piping circuits pressurized with dry, oil-free air. For these cases, all openings shall be capped, blind flanged, and gasketed as required to retain 1.7 bar g (25 psig) design pressure. A suitable, oil-free pressure gauge shall be installed in an accessible location for monitoring each circuit. Each circuit shall be pressurized with dry, oil-free air to 0.5 ± 0.07 bar g (7 ± 1 psig) for shipment. Nitrogen in NOT permitted as a shipping medium.
25.7 Permanent pipe supports shall be installed in accordance with project drawings. They shall not be modified in any manner to serve as shipping supports. The fabricator shall also install shipping supports in cold box assemblies that are to be shipped void of insulation in accordance with Air Products specification 4ACB-683001. The shipping support configurations and locations will be approved by the Air Products representative. Additional shipping supports may be required by the Air Products representative. All shipping supports shall be painted bright yellow and their locations recorded on Form 6.
25.8 The fabricator shall weigh the finished cold box assembly before loading for shipment. Weighing may be accomplished by employing load cells or hydraulic jacks with pressure gauges. Weight values shall have an accuracy of ± 2%. The resulting weight at each of the four corners of the box shall be recorded by value and location and the results sent to the Air Products project engineer within three calendar days of measurement.
26. LOADING COLD BOX FOR TRANSPORTATION
26.1 Requirements for loading and transportation are defined in the Project Commercial and Technical Fabrication Specifications and associated design drawings.
27. COLD BOX insulation
27.1 When the fabricator’s scope includes the requirement to insulate the cold box, the fabricator shall proceed in accordance with paragraphs 27.2, 27.3, and 27.4.
27.2 Mineral Wool
27.2.1 Mineral wool shall conform to 581.02 and shall be tested in accordance with 4ACB-685002 and 4ACB-685003. The fabricator shall keep the mineral wool dry and clean at all times. If this material becomes wet or contaminated, it shall be removed, disposed of, and replaced by the fabricator.
27.2.2 The fabricator shall proceed with packing the mineral wool (rock wool) in specified areas in the process equipment jacket after all pressure testing is completed, all process circuit openings have been sealed, the interior of the jacket has been cleaned of foreign material, and the Air Products representative has given approval to proceed. Packing shall be in accordance with 4WCE-600276.
CAUTION: If mineral wool becomes wet, it shall not be used.
27.3 Perlite
27.3.1 The fabricator shall proceed with packing the perlite insulation in specified areas in the process equipment jacket after the mineral wool installation has been completed. Perlite insulation properties and testing shall be in accordance with 4WCB-50001. Installation shall be in accordance with 4WCE-600277. The perlite shall be blown into the jackets until they are full. The fabricator shall ensure that there are no voids under beams, supports, equipment, and other components as this will initiate frost spots on the jacket panels.
CAUTION: If perlite becomes wet, it shall not be used.
27.4 Complete up-to-date records of inspections shall be maintained by the fabricator on Form 14 and in the “Quality Assurance and Inspection Book.”
28. fabricator documentation submittals to air products
28.1 Documentation listed on the Air Products VDR Set shall be submitted by the fabricator to Engineering Data in accordance with dates specified in the purchase order. All documentation shall also be readily available at the fabricator’s facility. The Quality Assurance and Inspection Book shall be submitted to Air Products Engineering Services, Engineering Data Group upon completion of fabrication and shipment of the cold box.
28.2 A Material Safety Data Sheet (MSDS) for each component (other than products and byproducts) associated with the equipment being assembled, sold, and furnished by the fabricator and all subcontractors shall be compiled during the purchase of the components and the fabrication of the cold box. An MSDS shall be provided for all of the following items associated with the project in the English language, as appropriate to the project scope:
- Adsorbents
- Building materials
- Catalysts
- Cleaning materials
- Dye penetrants
- Gasket materials
- Insulation
- Machinery and valve lubricants
- Paints
- Protective coatings and coverings
- Sealants
MSDS obtained from the suppliers of equipment or sub-parts shall be requested to be provided in the English language. MSDS for all applicable items shall be incorporated into the project “Quality Assurance and Inspection Book.”
Appendix A
Ongoing Fabricator Documentation and
Quality Assurance and Inspection Book
Air Products Project and Air Products Fabricator’s
Item No. ______________________ P.O. No. __________ Name and Job No.________________
Documentation listed in the index of this appendix shall be generated by the fabricator as part of fabricator’s continuing inspection program during the course of cold box manufacture. This documentation shall be accumulated by the fabricator and submitted as specified by the VDR Set to Air Products Engineering Services, Engineering Data for review and approval. It shall also be assembled in a loose-leaf binder as the “Quality Assurance and Inspection Book” and submitted to Air Products upon completion of the contract. Documentation examples are included as listed in the index. The fabricator may use the fabricator’s own documentation, if all of the information required by the examples is included. Failure to provide the necessary inspection program and ongoing records, which attest to its implementation, might be cause for stoppage of work and/or cancellation of the purchase order or other appropriate action as determined by the Air Products representative.
Index to Documents
|
Form |
Title |
Fabricator’s Inspection Supervisor |
Date |
|
| 1. | Certification of Compliance With Purchase Order Requirements | |||
| 2. | Jacket Penetration Dimensions | |||
| 3. | Record of Paint Application (see Note N1) | |||
| 4. | Piping System Check Sheet, Aluminum and Stainless Steel | |||
| 5. | Piping System Check Sheet, Copper | |||
| 6. | Shipping Pipe Support Record (see Note N2) | |||
| 7. | Pressure Test Procedure (see Note N3) | |||
| 8. | Temperature Element Test Report | |||
| 9. | Cleanliness Inspection Log | |||
| 10. | Sign-Off for Shipping Pressure Integrity of Vessels | |||
| 11. | X-ray Reader Log | |||
| 12. | Miscellaneous NDT Inspection Reports (see Note N4) | |||
| 13. | Component Nameplate Facsimiles (see Note N5) | |||
| 14. | Mineral Wool or Perlite Analysis Report (if insulation is supplied by fabricator) (see Note N6) | |||
| 15. | Sign-off for Temporary Cover Removal from Vessel Nozzles | |||
| 16. | Verification of Orifice Installation | |||
| 17. | Permanent Pipe Supports Record | |||
| 18. | Cold Box Frame Leveling Report | |||
| 19. | Cold Box Column Leveling Report | |||
Appendix A (continued)
|
Form |
Title |
Fabricator’s Inspection Supervisor |
Date |
|
| 20. | ASME WPS (see Note N7) | |||
| 21. | ASME PQR (see Note N8) | |||
| 22. | ASME BPS (see Note N9) | |||
| 23. | ASME BQR (see Note N10) | |||
| 24. | Cleaning Procedures (see Note N11) | |||
| 25. | As-Built Drawings (see Note N12) | |||
| 26. | Cold Box Weight (see Note N13) | |||
| 27. | Miscellaneous MSDS Reports (see Note N14) | |||
| 28. | Transition Joint Installation Check Sheet |
Notes:
N1. Form 3: The fabricator shall complete and attach the form contained in 4WEQ-6804, Appendix B entitled “Record of Paint Application” for shop painting and Appendix C “Contractor Daily Log” for field painting.
N2. Form 6: The fabricator shall complete and attach the form contained in 4ACB-683001,
entitled “Shipping Pipe Supports Record.”
N3. Form 7: Detailed procedure will be provided by Air Products. Fabricator shall complete and attach forms QC-200A and QC-200B contained in 4WPI-EW44001.
N4. Form 12: Examples of miscellaneous NDT reports are:
- Magnetic particle inspections report of lifting lug examination
- Various in-process inspections
- Weld maps
Fabricator shall prepare an index and attach applicable reports to the index.
N5. Form 13: The cold box fabricator shall obtain one clean and legible copy of the National Board Nameplate for each vessel installed into the cold box (Xerox copy is suitable). These copies shall become part of the “Quality Assurance and Inspection Book.”
Fabricator shall prepare an index and attach applicable nameplate facsimiles to the index.
N6. Form 14: When the fabricator’s contract includes providing the insulation of the cold box with mineral wool or perlite insulation, the reports required by 4WCB-50001, 581.02, 4WCE-600277, and 4ACB-685002 shall be provided. The required reports shall become part of the “Quality Assurance and Inspection Book.”
Fabricator shall prepare an index and attach applicable reports to the index.
N7. Form 20: Fabricator shall prepare an index and attach applicable Welding Procedure Specifications (WPS) that were approved by Air Products for this project.
N8. Form 21: Fabricator shall prepare an index and attach applicable Procedure Qualification Records (PQR) that were approved by Air Products for this project.
Appendix A (continued)
N9. Form 22: Fabricator shall prepare an index and attach applicable Brazing Procedure Specifications (BPS) that were approved by Air Products for this project.
N10. Form 23: Fabricator shall prepare an index and attach applicable Procedure Qualification Records – Brazing (BQR) that were approved by Air Products for this project.
N11. Form 24: Fabricator shall prepare an index and attach applicable cleaning procedures that were approved by Air Products for this project.
N12. Form 25: See paragraph 23.4.
N13. Form 26: Fabricator shall prepare and submit a description of the weighing procedure, and shall include the accuracy of the measuring devices, and provide a tabulation of the cold box weights at each of the four corners.
N14. Form 27: Fabricator shall submit MSDS reports as required in paragraph 28.2 including the index listing them.
N15. All reports shall have the following in their heading:
Air Products Project and Item No. ________________________
Air Products P.O. No. _________________________________
Fabricator’s Name and Job No. ______________________
Page _____ of _____
Appendix A (continued)
Form 1
Certification of Compliance with Purchase Order Requirements
Air Products Project and
Item No._____________________________________________________________
Air Products Purchase Order No.___________________________________________
Fabricator’s Name______________________________________________________
Fabricator’s Job No._____________________________________________________
_______ The equipment fabrication practices, materials, and test records for this equipment have been reviewed and found to be complete and satisfactory and in accordance with requirements of the Air Products purchase order and these specifications.
Fabricator’s Inspection Supervisor:____________________________
Fabricator’s Authorized Officer:____________________________
Date:____________________________
| Appendix A (continued)
Form 2
Jacket Penetration Dimensions |
Air Products
Project and Air Products Fabricator’s Name _____________________
Item No. _________________ P.O. No. __________________Fabricator’s Job No. _____________________ Page ____ of ____
|
Nozzle
|
Elevation |
Horizontal Dimensions |
Penetration or Projection |
Inspector’s Signature/ |
|||||||
|
Penetration |
Drawing Dimension |
As-Built Dimension |
Dev. |
Drawing Dimension |
As-Built Dimension |
Dev. |
Drawing Dimension |
As-Built Dimension |
Dev. |
End Conn. |
Date |
Dev. = Deviation
| Appendix A (continued)
Form 4
Piping System Check Sheet Aluminum and Stainless Steel |
Air Products
Project and Air Products Fabricator’s Name _____________________
Item No. _________________ P.O. No. __________________ Fabricator’s Job No. _____________________Page ____ of ____
|
Line Identification |
Joint Elevation |
Joint
Description and Identification |
Cleaning |
Edge Prep. |
Fit-Up |
Welder ID |
Welder Qualified |
Root
Pass Insp. |
Final
Weld Insp. |
WPS Utilized |
Inspector’s
Signature/ Date |
* – Dye Penetrant Test Ä – X-ray
| Appendix A (continued)
Form 5
Piping System Check Sheet Copper |
Air Products
Project and Air Products Fabricator’s Name _____________________
Item No. _________________ P.O. No. __________________ Fabricator’s Job No. _____________________ Page ____ of ____
|
Line Identification |
Joint Elevation |
Cleaning |
Brazer ID |
Brazer Qualified |
Complete |
Remarks |
Inspector’s Signature/Date |
Appendix A (continued)
Form 8
|
Temperature Element Test Report |
Air Products
Project and Air Products Fabricator’s Name ________________
Item No. ______________ P.O. No. _______________ Fabricator’s Job No. ________________
Page _____ of _____
| Temperature
Element |
Connection Wire
Meets Specification |
EMF or Temperature
Test Results |
Inspector’s
Signature
|
Date
|
Remarks |
Appendix A (continued)
Form 9
Cleanliness Inspection Log
| Air Products
Project and Item No._______________________ Fabricator’s Name _____________________ Location ________________ Purchase Order No. _______________________ Fabricator’s Job No. _____________________ Report No. _______________ Page ____ of ____ |
||||||||||||
| Inspection Method | Metal | Spool or | Fabricator’s | Air Products | ||||||||
| Black Light | White Light | Burrs | Item | List | Inspector’s | Inspector’s | ||||||
| Date | Vis. | Wipe | Vis. | Wipe | Chips | Inspection | Contaminants | Remarks | Signature/Date | Signature/Date | ||
Appendix A (continued)
Form 10
| Sign-Off for Shipping Pressure
Integrity of Vessels |
Air Products
Project and Air Products Fabricator’s Name ________________
Item No. ______________ P.O. No. _______________ Fabricator’s Job No. ________________
Page _____ of _____
| Equipment
Tag Number |
Gauge Location
(Nozzle ID) |
Pressure
Reading |
Ambient
Temperature |
Inspector’s
Signature/Date |
| Appendix A (continued)
Form 11
X-ray Reader Log |
Air Products
Project and Air Products Fabricator’s Name ________________
Item No. ______________ P.O. No. _______________ Fabricator’s Job No. ________________
Page _____ of _____
|
Customer |
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Date |
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No. Film Per Cassette |
Film Type |
Film Processing Automatic___Manual___ |
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Isotope IR 192___ CO 60_____ |
Source Serial # |
Focal Spot Size |
Curies |
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Exposure Technique SWE_____ DWE_____ |
Film Viewing SWV____ DWV____ |
Percent X-ray |
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| Spool
No |
Weld
No. |
No.
Exp |
NPS |
Wall
Thkns |
S-F-D |
Weld
Symb |
Wld
Typ |
Wld
Pro |
Acc |
Rej |
ExpoTech | Def
1 |
Def
2 |
Def
3 |
Comments |
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Technician ___________________________________ Interpretation_____________ Level________
Area_______________ Recorded______________ Authorized Inspector___________________________
Customer’s Authorized Inspector___________________________
Appendix A (continued)
Form 15
| Sign-Off for Temporary Cover
Removal from Vessel Nozzles |
Air Products
Project and Air Products Fabricator’s Name ________________
Item No. ______________ P.O. No. _______________ Fabricator’s Job No. ________________
Page _____ of _____
| Equipment
Tag Number |
Nozzle ID |
Removed |
Inspector’s
Signature |
Date |
Appendix A (continued)
Form 16
| Verification of Orifice Installation |
Air Products
Project and Air Products Fabricator’s Name ________________
Item No. ______________ P.O. No. _______________ Fabricator’s Job No. ________________
Page _____ of _____
| Orifice
Tag Number |
Process Line Number |
Elevation |
Orifice Hole
Size |
Inspector’s
Signature/Date |
Appendix A (continued)
Form 17
| Permanent Pipe Supports Record |
Air Products
Project and Air Products Fabricator’s Name ________________
Item No. ______________ P.O. No. _______________ Fabricator’s Job No. ________________
Page _____ of _____
|
Pipe Support Number |
Pipe Support Installed Per Drawings (Ö)
|
Inspector’s Signature/ Date |
Remarks |
Appendix A (continued)
Form 18
Cold Box Frame Leveling Report
Air Products
Project and Air Products Fabricator’s Name ________________
Item No. ______________ P.O. No. _______________ Fabricator’s Job No. ________________
Page _____ of _____
Cold Box Frame Levelness (See paragraph 11.1)
Distance from Horizontal Plane
Note: Maximum Allowable Deviation = +/- 3 mm (+/- 1/8 in)
A._________B.__________C.__________D.__________E.__________
F._________G.__________H.__________J.___________K.__________
Inspector_______________
__________________________________________________________________________________
Deviation of Column Centerline to Cold Box Leveling Lugs
(For Use When Lugs are Provided)
Plan View
A.__________ C.__________
B.__________ D.__________
Inspector:__________
Note: Allowable Deviation = 1.3 mm per linear meter (1/64 inch per linear foot) to a maximum over the box length of 12.7 mm (1/2 in).
Appendix A (continued)
Form 19
Cold Box Column Leveling Report
Air Products
Project and Air Products Fabricator’s Name ________________
Item No. ______________ P.O. No. _______________ Fabricator’s Job No. ________________
Column Level and Parallel to Cold Box Shipping Side
(See paragraph 11.4 – Vertical Measurement)
Deviation of Column Centerline from Horizontal Plane
Note: Maximum Allowable Deviation = +/- 3 mm (+/- 1/8 in)
A.________B.________C.________D.________E.________
Inspector___________
___________________________________________________________________________
Column Parallel to Cold Box Left Side
(See paragraph 11.3 – Horizontal Measurement)
Plan View
Distance from Vertical Plane
Column Centerline A.________B.________C.________D.________E.________
to Left Front Corner of Box:
Inspector_____________
Notes: 1. Allowable Deviation = 1.3 mm per linear meter (1/64 inch per linear foot) to a maximum over the box length of 12.7 mm (1/2 in).
- The outside edge of the left front tube steel column is used for plumbing the cold box when it is erected.
| Appendix A (continued)
Form 28
Transition Joint Check Sheet
|
Air Products
Project and Air Products Fabricator’s Name _____________________
Item No. _________________ P.O. No. __________________ Fabricator’s Job No. _____________________Page ____ of ____
| PRE-INSTALLATION | POST INSTALLATION |
| Line
Number Identification |
Temperature
Indicator Label Installed Yes No |
Photo
File Name |
Inspector’s Signature/Date |
Temperature
Indicator Label Final Panel Black Yes No |
Photo
File Name |
Inspector’s Signature/Date |
||
| 1234 | Ö | 1234.jpg | Ö | 5678.jpg | ||||
Appendix B
Quality Control Checklist–Cold Box Inspection
The following checklist is intended to serve as a basic guide for inspection of the cold box by both the Air Products representative and the fabricator. The items in this checklist are not all inclusive, nor applicable to all installations, and should be adjusted to meet any special cold box features, shop or field location, or other requirements.
B1. STRUCTURAL
B1.1 Frame
B1.1.1 Check dimensions.
B1.1.2 Check squareness.
B1.1.3 Check flatness and levelness (Form 27).
B1.1.4 Verify that external welding is complete and 100% free of porosity and gross irregularities. Check again after surface preparation and before the painting operation.
B1.1.5 Check that the lifting lugs are drilled (not burned), and that the hole sizes and locations are correct.
B1.1.6 Ensure that the trunnions and lug welds are the proper size and were checked by dye penetrant test or magnetic particle inspection.
B1.1.7 Verify that all girts and diagonals are installed correctly; weld connection completed.
B1.2 Panels
B1.2.1 Verify that panel penetrations are in the correct locations, with welding complete, and have proper gasketing (Form 2).
B1.2.2 Inspect panels for weld pickup, warpage.
B1.3 Painting
B1.3.1 Verify that surface preparation is to SSPC-SP 6.
B1.3.2 Check elapsed time before painting and condition of surfaces. Verify type of paint, dry film thickness (DFT), coverage on welds, runs.
B1.3.3 Verify paint application (Appendix B or C of 4WEQ-6804).
B1.4 Internal Equipment and Supports
B1.4.1 Verify the dimensional location and orientation, including distance from cold box wall.
B1.4.2 Check that distillation columns are aligned level and parallel to frame shipping side (front) and left side in accordance with Section 7 or plumbed in accordance with 4WMA-007018.
B1.4.3 Verify that the correct equipment support material was used (carbon steel or stainless steel).
B1.4.4 Check for the proper bolts, nuts, U-bolts, and washers (carbon steel or stainless steel).
B1.4.5 Ensure that support bolting was tightened and lock nuts installed.
Appendix B (continued)
B1.4.6 Check that required welding of built-up members was performed (including spacing and staggering).
B1.4.7 Check for proper welds, holes, slots, and bolts at connections. Verify bolt locations in slots.
B1.4.8 Verify required gaps in equipment supports and connections.
B1.4.9 Verify that yellow shipping bars on expansion joints and flexhoses have been removed before the pressure test.
B2. PIPING
B2.1 Piping Spools
B2.1.1 Check joint preparation and squareness of cutoffs on pipe and vessel nozzles.
B2.1.2 Check pipe and vessel internals for cleanliness after nozzle cutoffs and joint preparation.
B2.1.3 Ensure adsorber vessels are opened, fitted, and welded only in the presence of the Air Products representative.
B2.1.4 Check for proper material for pipe and fittings and type, size, length of bolting hardware (include certification documents, when required).
B2.1.5 Check for correct welding material sand equipment; check regularly to ensure that correct filler materials are used. In particular, be sure that no high silicon content aluminum alloy filler materials are used (for example, 4043).
B2.1.6 Ensure that individual welded and brazed pipe spools are cleaned to the required level and are protected from contamination (Form 9).
B2.1.7 Check individual spool dimensions.
B2.1.8 Ensure that radiograph identities are clearly tied to welders, dates of welding, and to tracer radiographs. It is preferred that marked-up spool sheets be used for permanently recording these items (Form 11).
B2.1.9 Ensure operator identification is adjacent to all welds and braze joints.
B2.1.10 Ensure individual lines are permanently identified and recorded on check sheet.
B2.1.11 Ensure valves are fully opened or internals are removed before brazing or welding adjacent joints.
B2.1.12 Clean and check all valve seats after brazing to ensure removal of flux and brazing alloy.
B2.1.13 Check all brazed joints for incomplete fillets or excess brazing alloy and evidence of base metal melting. Remove suspect joints. Remove isolated joints on a random basis and peel test to ensure reliability of the brazing operation.
B2.1.14 Check branch and weldolet connections to ensure 100% penetration.
B2.1.15 Check thermowells, temperature elements, and couplings.
B2.1.16 Verify that all ASME WPS, PQR, WPQ, BPS, and BPQ have been written and approved.
B2.1.17 Ensure that flange nuts and studs are torqued to the specified values.
Appendix B (continued)
B2.2 Piping Assembly (in box)
B2.2.1 Ensure that jacket penetration panels are correctly installed before piping assembly begins.
B2.2.2 Record all penetration dimensions and inform Air Products representative immediately of out-of-tolerance dimensions (Form 2).
B2.2.3 Ensure that valves and piping penetrations are centered in panel penetration holes, unless otherwise noted on drawings.
B2.2.4 Ensure that valves and instruments are in correct flow direction, except that adsorber valves must be installed per drawings.
B2.2.5 Check that flow elements and orifices are to be completely installed and recorded (Form 16).
B2.2.6 Ensure that flow meter orientations are correct per project drawing.
B2.2.7 Provide installation log for all piping (Forms 4 and 5).
B2.2.8 Record acknowledgment of cleaning (Form 9).
B2.2.9 Verify removal of each protective barrier used for preventing chips from entering vessel nozzles.
B2.2.10 Check that nozzles are square and oriented correctly.
B2.2.11 Verify that piping seal loops are at the correct elevation.
B2.2.12 Ensure copper tubing joints are checked for completeness of brazing without evidence of overheating (melting or warping).
B2.2.13 Verify that copper instrument lines are blown down during pressure test to ensure that lines are not plugged with brazing alloy or flux.
B2.2.14 Ensure instrument lines are straight, vertical or horizontal, unkinked, and that seal loops have been provided at the correct elevations.
B2.2.15 Check that flange studs are of correct material and length and tightened properly. Verify that at least one complete thread shows above the nut.
B2.2.16 Ensure that threaded joints used approved thread sealant and are properly assembled.
B2.3 Temperature Element (TE) Installation
B2.3.1 Ensure that TE wells extend midway into pipe diameter for pipe sizes up to NPS 12, unless otherwise indicated on drawings.
B2.3.2 Verify that temperature element wire is correct material and correct length.
B2.3.3 Ensure there is enough wire for element removal and replacement without excess. Ensure the wire is coiled properly in the TE head to avoid damage to the wire insulation.
B2.3.4 Check that dual temperature elements have two pairs of temperature element wires connected between temperature element and terminal box.
B2.3.5 Check that temperature element test is performed per 4ACB-684001, paragraph 8. Liquid nitrogen is required for the testing of thermocouples only but not for RTDs. (Form 8).
Appendix B (continued)
B2.3.6 Check that armored cable is intact, supported, and undamaged before and after the pressure test.
B2.4 Pipe Supports
B2.4.1 Ensure materials are correct for U-bolts, nuts, and support structure.
B2.4.2 Ensure permanent supports are completely installed. Check locations, number of supports (Form 17) and welds.
B2.4.3 Check whether U-bolts are anchors or guides and ensure that the nuts are installed and tightened correctly.
B2.4.4 Ensure that shipping supports are completely installed and painted bright yellow.
B2.4.5 Ensure that shipping support locations are recorded on erection drawings and on Form 6. Check that maximum line movement is no greater than permitted in 4ACB-683001.
B2.4.6 Ensure that all temporary supports have been removed.
B2.4.7 Check trunnions and lugs to ensure that no gap exists between them and the support steel.
B2.5 Testing
B2.5.1 Ensure that the flow check has been completed by the Air Products representative.
B2.5.2 Check that the punch and correction list has been completed and signed off.
B2.5.3 Check that the temperature element tests were completed and signed off (Form 8).
B2.5.4 Ensure that the pressure test orifices and the proper pressure test safety valves are in place before the pressure test.
B2.5.5 Witness the proof test and reduction to design pressure.
B2.5.6 Witness the soaping of lines.
B2.5.7 Ensure that valves are shut down tight by bleeding downstream lines.
B2.5.8 Check for blockage of copper lines by bleeding downstream of valves – one at a time.
B2.5.9 Ensure sign-off of pressure test (Form 7).
B3. MISCELLANEOUS
B3.1 Cleaning Box Inside
B3.1.1 Ensure all tape and flags used for identifying lines during pressure test are removed.
B3.1.2 Verify that all beams, equipment, and panels are cleaned to remove all loose debris and visible oil films.
B3.2 Insulation
B3.2.1 Ensure that perlite or mineral wool meets the Air Products specifications 4WCB-50001 or 581.02 (Form 14) before installation.
Appendix B (continued)
B3.2.2 Check that the required packing density is met and that difficult-to-pack areas have been given proper attention.
B3.3 Shipping
B3.3.1 Remove projecting valves per the project specific technical specification.
B3.3.2 Properly pack and identify loose items such as valves, instruments, and tie-down lugs to prevent damage. Check that hardware and gaskets are included for field installation.
B3.3.3 Install all nameplates.
B3.3.4 Install duplicate vessel nameplates. Copy vessel nameplates for document package.
B3.3.5 Check width, height, and length against shipping drawing requirements.
B3.3.6 Weigh box and immediately submit weights to Air Products.
B3.3.7 Ensure that piping or nozzles are capped and that, if required, a positive pressure has been applied and is being maintained.
B3.3.8 Double-check that all previous noncompliance items have been corrected.
B3.4 Review the “Quality Assurance and Inspection Book” for completeness and correctness. Discrepancies shall be rectified to the Air Products representative’s satisfaction.
Appendix C
Recommended Weld Filler Materials, Consumables Control, and Handling
C1. PURPOSE
C1.1 To define for the fabricator the minimum requirements for receipt, storage, and handling of welding consumables.
C2. related documents
C2.1 The American Society of Mechanical Engineers (ASME)
SFA-5.1 Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
SFA-5.4 Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding
SFA-5.5 Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
SFA-5.9 Specification for Bare Stainless Steel Welding Electrodes and Rods
SFA-5.10 Specification for Bare Aluminum and Aluminum Alloy Welding Electrodes and Rods
SFA-5.18 Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding
SFA-5.28 Specification for Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding
C2.2 Manufacturers
Manufacturer’s consumables catalog and specifications.
C3. Definitions
C3.1 Coated electrode is a composite filler metal electrode consisting of a core of a bare electrode to which is applied a coating sufficient to produce a metal slag on the welding. The coating might contain material that provides a protected atmosphere, deoxidizes the bath, and stabilizes the arc.
C3.2 Consumable is a material employed on the welding protection or deposition (for example, electrodes, rods, wire, consumable ring, gas, and flux).
C3.3 Critical Service is defined as any piping system in Category M Fluid Service as defined by ASME B31.3 or lethal service defined by ASME BPVC, Section VIII.
C3.4 Drying oven is equipment used to dry up the electrodes and fluxes of low hydrogen, which have a controlled heat, through electrical resistances and air renovation, through controlled convection (for example, butterfly valve). It should have at least two instruments of temperature (thermostat and thermometer) as well as shelves with holes or grating type. The drying oven shall have the temperature capacity of 400°C (752°F).
C3.5 Drying oven for maintenance is equipment that will attend the same requirements of drying oven operation, except in relation to the temperature, whose capacity must be 200°C (392°F).
C3.6 Electrode denotes filler metal in the form of a solid cylindrical rod, typically flue coated.
C3.7 Electrode core or bare electrode is a component of a coated electrode.
C3.8 Flux is a material used to prevent, dissolve, or ease the removal of oxides and other nondesirable superficial substances.
C3.9 Quill is a portable drying oven, which has heat by way of electric resistance that can follow each welder individually to the welding location. It must maintain the temperature between 60° and 100°C (140° and 212°F).
C3.10 Storage oven is a place that has lamps or other forms of heating that allow the goods to be stored in their packing on shelves or crates, whose temperature must be 50°C (90°F) above the room temperature but not less than 20°C (68°F).
Note: The storage oven must have a hygrometer and thermometers to be able to control the humidity and air temperature.
C3.11 Welding rod is an electrode used for welding or brazing that does not conduct electricity during the process.
C4. WELDING CONSUMABLES
C4.1 Filler Material
Welding filler metals shall be according to the following:
For aluminum materials see Appendix D.
Alternate materials may be used on receipt of approval from Air Products.
| Base Metal | Bare Wire**** | Coated Electrode**** | |
| CS to CS | SFA5.18 ER70S-2 | SFA5.1 E6010 (root pass only) | |
| A53 and A106 | SFA5.28 ER80S-D2 | E7018 | |
| 304 to 304 and 304L | SFA5.9 ER308 | SFA5.4 E316L-15* | |
| 304L to 304L | SFA5.9 ER308L | SFA5.4 E316L-15* | |
| 304 to 316 | SFA5.9 ER316 | SFA5.4 E316L-15* | |
| 316 to 316L | SFA5.9 ER316L | SFA5.4 E316L-15* | |
| 316 to 321 | SFA5.9 ER347 | SFA5.4 E347 | |
| 321 to 321 | |||
| 347 to 347 | |||
| CS to 300 Series SS | SFA5.9 ER309 | SFA5.4 E309 |
Notes:
* Ferrite Number 3 maximum such as Cryosan E316L-15 by Sandvik Steel or Kryokay E316L‑15 by Teledyne McKay, or approved equal when Charpy impact testing is required.
** INCO Brand: Other manufacturers’ brands are acceptable if they are the same specification/classification.
*** The “L” grade for bare wire and coated electrode is also acceptable. All socketwelds shall be dye checked and buttwelds shall be 100% radiographed.
**** For materials not listed, the Air Products representative must approve the filler metal and procedure to be used.
C4.2 Receiving and Inspecting
C4.2.1 Consumables shall be transported to the job site in appropriate conditions, preferably in clean containers and protected against humidity (for example, closed body). This applies to coated electrodes and bare wire used in performing work.
C4.2.2 The fabricator’s welding inspector shall inspect the received consumables and check the following:
C4.2.2.1 Packing shall be received closed and shall not have any defects that would cause contamination and damages to the consumables. It shall indicate without any obliterations and legibly show the trade name, specification, and classification AWS (see Section C4.1) or ASME BPVC Section II, lot number, and fabrication date.
C4.2.2.2 The coated electrode shall have individual identification of the trade name and/or AWS rating stamped next to the electrode root, as is shown in Figure C1.
C4.2.2.3 The rods shall have individual identification of the trade name and/or AWS rating (see Section C4.1) stamped either on the material or on small papers/plastic labels located on the end of the material, as shown in Figure C1. Positive Material Identification (PMI) of filler metal shall be performed according to specification 4WEQ-1105.
C4.2.2.4 Wire spools shall come with identification tags affixed, containing the trade name and AWS rating, as shown in Figure C1.
C4.2.2.5 Fluxes shall come in packing (cans, cardboard bags, or plastic) containing the identification without any obliterations, and legible trade name, specification, and AWS (see paragraph C4.1) or ASME BPVC Section II ratings stamped on the package or on the tags attached to the package, as shown in Figure C1.
C4.2.2.6 Consumables shall be provided with their respective quality certifications, indicating the standard rating required.
C4.2.2.7 Consumables shall not exhibit any signs of oxidation.
C4.2.2.8 Coated electrodes shall not have any defective coatings (for example, thickness reduction, cracks, extremity damages, nonsticking, humidity, or eccentricity).
C4.2.3 After checking, the fabricator’s certified welding inspector shall identify the acceptable and rejected consumables.
C4.2.4 Rejected consumables shall be segregated and disposed of in a proper and safe manner.
C4.3 Storage and Control
C4.3.1 Consumables, except gases, after released by the fabricator’s certified welding inspector, shall be stored according to requirements based on the AWS rating and its respective run on the ovens, on shelves or crates. Consumables used in critical systems shall be segregated according to Air Products requirements.
C4.3.2 Consumables shall be removed from storage through the use of requisitions containing quality, trade name, and/or AWS rating and size.
C4.3.3 The welder storekeeper shall perform the distributions control using the “Electrodes Distribution Control Form” as shown in Figure C2. Electrodes shall be dispersed to only welders qualified for that particular electrode. The fabricator shall have a system to properly identify and verify each welder’s qualifications. Electrodes of specific grade shall not be issued to welders who are not qualified.
C4.3.4 Removal order of consumables from storage shall be done on a first in/first out basis in the order indicated on the receivers.
C4.3.5 Consumables shall be kept in their original packing and opened only before using or drying. Leftover consumables may be returned to stock one time if they are appropriately dried in ovens designated for this purpose. Consumables shall not be returned to stock more than one time.
C4.3.6 Gas cylinders shall be stored in an isolated place that is clean, dry, and protected from the sun and heat sources. Cylinders must be carefully moved in the vertical position avoiding mechanical impacts.
C4.4 Drying and Maintenance
C4.4.1 Cellulosic Electrode
C4.4.1.1 For this type of electrode, it is not necessary to dry. It shall be removed directly from the storage ovens and put in the portable quills that protect against bad weather.
C4.4.1.2 Electrodes not used within the specified time period shall be returned to the storage oven.
C4.4.1.3 According to AWS, cellulosic electrodes are rated as the following:
- AWS E6010
- AWS E7010-G
- AWS E7010-A1
- AWS E8010-G
C4.4.2 Rutilic Electrodes, Basic and Low Hydrogen
C4.4.2.1 These electrodes must be dried and kept at temperatures according to the tables shown in Table C1.
C4.4.2.2 Electrodes must be put on the drying ovens on layers of 50 mm (2 in) at the maximum.
C4.4.2.3 The welder storekeeper shall make the drying control using the “Electrode Handling Control Form” shown in Figure C3.
C4.4.2.4 The welder storekeeper shall make the electrode drying according to the daily-forecasted consumables for the performance and plus 20% after that.
C4.4.2.5 After drying, electrodes shall be kept in the maintenance ovens on layers not higher than 150 mm (6 in) and 25 mm (1 in) of side gap.
C4.4.2.6 When not used, electrodes must be kept in portable ovens at a temperature from 60° to 150°C (140° to 302°F).
C4.4.2.7 Electrodes dried outside the maintenance ovens or that have not been used after their initial work journey shall be returned and redried. Electrodes that have been redried shall have the ends painted.
C4.4.2.8 Redried electrodes must be used during their next work journey. It is prohibited to make a second redrying.
C4.4.2.9 According to the AWS the rutilic electrodes are rated as the following:
- AWS E6013
- AWS E7014
- AWS E7024
- AWS E308-16/E308L-16
- AWS E316-16/E316L-16
- AWS E309-16/E309-16
- AWS E312-16
C4.4.2.10 According to the AWS the basic and low hydrogen electrodes are rated as the following:
- AWS E7018/E-7018-1
- AWS E7016-1
- AWS E7018-G
- AWS E502-15/E-505-15
- AWS E8018-B2
- ASW E9018-B3
- AWS E310-15
- AWS E318-15/E-308L-15
- AWS E309-15/E-309L-15
C4.4.3 Wires and Rods
C4.4.3.1 Wires and rods to be used shall be directly removed from the storage place and placed in the appropriate drying oven.
C4.4.3.2 When there are various classes of rods at the storage place, the rods shall be painted at their extremities for better identification.
Example:
| Class AWS | Color | |
| ER70S-3 | white | |
| ER80S-B2 | blue | |
| ER308 | green |
C4.4.3.3 Wire spools that are used shall be returned to the storage place with their respective plaques or identification tags in place.
C4.4.3.4 Wire spools shall be protected against humidity, dust, and others contaminants when they are outside the storage place.
C4.4.3.5 Rods shall be cleaned immediately before using.
C4.4.4 Fluxes
C4.4.4.1 Drying ovens with trays for drying or flux drying maintenance shall not be layered more than 50 mm (2 in).
C4.4.4.2 After a work journey, flux not used shall be returned to storage. It is prohibited to make a second redrying.
C4.4.5 Drying ovens shall have calibrated thermometers according to industry standards.
Figure C1
Consumables Identification
Figure C2
Electrode Distribution
Control Form
No:
Date:
Responsible:
Customer: Contract:
| Quantity
(kg or piece) |
Respon-sible for | ||||||||
|
Date |
Stamp |
Consum-able | Lot
Number |
Diameter
(mm) |
Taken |
Time |
Turned
Back |
Time |
Hot
Sterilizer |
| (1) | (2) | (3) | (4) | (5) | (6) | (7) | (8) | (9) | (10) |
(1) Consumable fabrication date (6) Quantity of consumable taken in kg or piece
(2) Qualified welder’s number (7) Time at which the consumable is taken
(3) Type of consumable (8) Quantity of consumable turned back in kg or piece
(4) Consumable fabrication lot number (9) Time at which the consumable is turned back
(5) Consumable diameter (10) Name of the person responsible for the hot sterilizer
Table C1
| Table of the Recommendable Temperatures for Consumable
Storage, Drying, and Drying Maintenance |
|||||
|
Classification |
Conditions of
Storage |
Drying |
|||
| A W S | Type | Before Unpacking | Drying | Maintenance | |
| E6010
E7010-G E7010-A1 |
Cellulosic |
Keep off floor |
Not
recommended |
Not
recommended |
|
| E6013
E7024 |
Rutilic |
Keep off floor |
Not
recommended |
Not
recommended |
|
| E7018
E7016 E7018-1 E8018-G E8018-B2 E9018-B3 |
Basic low hydrogen |
Keep off floor |
300° + 50°F
during 1 hour |
700° to 800°F |
|
| E502-15
E505-15 |
Basic |
Keep off floor |
300° + 50°F
during 1 hour |
700° to 800°F |
|
| E308L
E309L E316L etc. |
Basic |
Keep off floor |
Not |
||
| E308-L
E309-L E316-L etc. |
Basic |
Keep off floor |
Not |
||
| FLUX
F-7x F-8x |
Basic |
Keep off floor |
500° + 50°F
during 1 hour** |
250° to 300°F above dew point |
|
| Rods
Wire |
Not
applicable |
Keep off floor | Not
applicable |
Not
applicable |
|
Figure C3
Electrode Handling Control Form (Reduced Form)
| Customer: | No: | Sheet.: | |
| Contract: | Date: | ||
| Title: | Performed By: | Approved By: |
| Drying | |||||||||
| Manufacturer | Trade Name | Diameter
(mm) |
AWS
Specification |
Lot Number |
Quantity
(kg) |
Beginning
(time) |
Conclusion
(time) |
Temperature
(°C) |
Notes |
| (1) | (2) | (3) | (4) | (5) | (6) | (7) | (8) | (9) | (10) |
(1) Consumable manufacturer name (6) Quantity of consumable received
(2) Consumable trade name (7) Time of the consumable drying beginning
(3) Consumable diameter (8) Time of consumable drying conclusion
(4) Specification according to AWS standard (9) Drying temperature
(5) Lot fabrication number of the received consumable (10) Field for additional information
Appendix D
Aluminum Welding
D1. WELD PROCESSES
D1.1 Welding shall be performed using the gas tungsten arc welding (GTAW) process (using alternating current exclusively) or the gas metal arc welding (GMAW) process. The GMAW process is recommended for prefabricated heavy wall pipe diameters DN200 (8 in NPS) or larger. No single pass or filler bead shall be more than 19 mm (3/4 in) in width. Only stringer passes are acceptable. Wash-type passes are not acceptable.
D2. WELDING QUALIFICATION REQUIREMENTS
D2.1 Refer to Section 8.2 of this specification for welding qualification requirements. All pipe welds shall be performed according to qualified procedures developed by the fabricator. Welders shall be qualified to the procedures in accordance with ASME B31.3, paragraph 328.2. In addition, aluminum welders shall be qualified welding Schedule 10 pipe when Schedule 10 is specified. When allowed by code, x-ray shall be used for welder performance qualification.
D3. FILLER MATERIAL
D3.1 The types of filler metal per AWS A5.10 (ASME SFA 5.10) to be used for welding various aluminum-alloy pipe combinations are given in the following table:
| Base Metal |
Filler Metal |
| 3003 to 3003 | ER1100 or ER4043 |
| 3003 to 5083 | ER5556 |
| 3003 to 5086 | ER5556 |
| 3003 to 5086 (1/2 inch instrument lines only) | ER4043 |
| 3003 to 6061 | ER4043 |
| 5083 to 5083 | ER5556 |
| 5083 to 5086 | ER5556 |
| 5083 to 6061 | ER5556 |
| 5086 to 6061 | ER5556 |
| 6061 to 6061 | AWS A5.10 ER5556 |
D3.2 Filler material shall be purchased from Air Products-approved suppliers:
AlcoTek Wire Corporation
2750 Aero Park Drive
Traverse City, Michigan 49686
USA
Metalli Trafilati Laminati srl.
25069 Villa Carcina
Brescia
Via Veneto 30
Italia
D4. CONTROL OF CONSUMABLES
D4.1 Refer to Appendix C, Welding Consumables Storage and Handling.
D4.2 Consumables shall be kept in their original packing and opened only just before use.
D4.3 Only remove filler material from stock that can be used within a four-hour period.
D5. BACKING RINGS
D5.1 Aluminum pipe weld procedures (excluding branches and weldolets) shall include the use of backing rings. Dimensions of backing rings shall be:
| Nominal Pipe Size
DN Inches |
Ring Dimensions |
|
| 50, 65, 80 2, 2 1/2, 3 | 3 mm (1/8 in) thick x 13 mm (1/2 in) wide (for counterbored fitting to fitting) | |
| 50, 65, 80 2, 2 1/2, 3 | 3 mm (1/8 in) thick x 25 mm (1 in) wide | |
| 100 4 | 6 mm (1/4 in) thick x 13 mm (1/2 in) wide (for counterbored fitting to fitting) | |
| 100,150, 4, 6, | 6 mm (1/4 in) thick x 25 mm (1 in) wide | |
| 200 and 8 and
larger larger |
6 mm (1/4 in) thick x 38 mm (1 1/2 in) wide |
D6. WELD PREPARATION AND FIT-UP
D6.1 All edges shall be prepared for GTAW or GMAW welding with the use of proper tools and preparation methods.
D6.2 Material removal shall be by filing or routing using suitable cutters. Grinding wheels shall not be used on aluminum material.
D6.3 All surfaces to be welded shall be cleaned to remove oil, grease, and dirt. Vapor or solvent degreasing will usually be satisfactory. If heavy oxide is present on the metal surface, the metal surface shall be cleaned by mechanical means (for example, stainless steel wire brushing).
D6.4 Immediately before fit up, all fusion surfaces, backing rings, and an area within 10 mm (3/8 in) shall be cleaned free of oxide by scraping or brushing with clean stainless steel wire brushes. Brushes must be kept clean at all times and light pressure should be used in brushing (excessive pressure can cause metal folds to form trapping dirt and oxides and causing unnecessary weld porosity).
D6.5 Each weld pass shall be thoroughly cleaned by using a stainless steel wire brush before completing the succeeding pass.
D6.7 Attempts shall be made to weld joints upon fit up (within approximately four hours). Fit-up joints shall be covered before welding.
D6.8 Weld fit-up and the welding operation must be shielded from atmospheric contamination and humidity. Contractor for field welding shall provide details of proposed sheltering and humidity control in proposal.
D6.9 A recommended weld joint geometry for aluminum piping consists of a 1.6 mm (1/16 in) land, 60 degrees included angle, and a 8 mm (5/16 in) to 10 mm (3/8 in) root gap with the backing ring tacking as shown.
Figure 3
Recommended Weld Geometry–Aluminum Piping
D7. WELDER IDENTIFICATION
D7.1 Each welder shall identify the welder’s specific production welds by etching the welder’s regularly assigned identification number with an electric pencil or low stress stamps on the pipe adjacent to the welds.
D8. REQUIRED WELDING EQUIPMENT, GAS TUNGSTEN ARC WELDING ALUMINUM
D8.1 Welding Power Supply: A 300 to 500-ampere Miller Electric Mfg. Co. Synchrowave or equivalent shall be used.
D8.2 Welding Torch: A 350-ampere minimum capacity, water-cooled torch shall be used. It must be capable of accepting 3, 4, and 5 mm (1/8, 5/32, and 3/16 in) diameter electrodes. If welding is to be performed at 250 amperes or above, a 500-ampere, water-cooled torch shall be used. Welding torches shall use a remote contactor switch to make and break the arc and current control (foot pedals are not recommended for field locations).
D8.3 Water Cooler: Radiator or tank-type water coolers shall be used. Alternatively, the welding torch may be connected directly to a house water line and water run continuously while welding. (However if water temperature is cooler than ambient temperature, there will be a tendency for torch components to “sweat” when welding is not being done. Minute traces of moisture on aluminum can produce severe weld porosity. Therefore, recirculating units are recommended.)
D8.4 Electrodes: Pure tungsten electrodes or zirconiated electrodes may be used in the following sizes:
- 3 mm (1/8 in) diameter for welding currents less than 125 amperes
- 4 mm (5/32 in) diameter for welding currents of 100 to 200 amperes
- 5 mm (3/16 in) diameter for welding currents of 175 to 300 amperes
D8.5 Gas Cup Sizes:
- 10 or 8 mm (3/8 or 5/16 in) inner diameter for 3 mm (1/8 in) diameter electrodes
- 11 or 10 mm (7/16 or 3/8 in) inner diameter for 4 mm (5/32 in) diameter electrodes
- 13 or 11 mm (1/2 or 7/16 in) inner diameter for 5 mm (3/16 in) diameter electrodes
- 16 mm (5/8 in) inner diameter for 4 mm (5/32 in) or 5 mm (3/16 in) diameter electrodes preferred for field welding conditions
D8.6 Gas Supply:
- Shielding gas shall be argon or a combination of argon and helium.
- Dew point shall be -60°C (-76°F) or less. Argon purity shall be 99.999%. Helium purity shall be 99.995%. Supplier shall provide product purity certificates.
- Care must be taken to ensure that air cannot be aspirated into the gas passages. If the welding system has any leaks the gas will become contaminated. Shielding gas supply hoses used to connect cylinders to torch shall have minimum number of connections. Use of hoses of Tygon or similar material is prohibited. Supply hoses shall be kept dry. When hoses are not in use, they shall be stored in a dry area. Flowmeters shall be specified to match shielding gas requirements.
D8.7 Electrical Characteristics: All welding shall be performed using alternating current. High frequency or similar arc starting is required. Scratch starting is not allowed.
D9. REQUIRED WELDING EQUIPMENT, GAS METAL ARC WELDING ALUMINUM
D9.1 Welding Power Supply: A constant, potential power supply of 300 amperes minimum capacity shall be used.
D9.2 Wire Feeder and Gun: The wire feeder must be designed for aluminum welding. The welding gun must be water-cooled.
Note: For light duty applications requiring no more than 200 amperes, a self-contained, air-cooled feeder/gun (such as the ESAB 1-lb spool gun) may be used.
D9.3 Water Cooler: Radiator or tank-type water coolers shall be used. Alternatively, the welding torch may be connected directly to a house water line and water run continuously while welding. (However if water temperature is cooler than ambient temperature, there will be a tendency for torch components to “sweat” when welding is not being done. Minute traces of moisture on aluminum can produce severe weld porosity. Therefore recirculating units are recommended.)
D9.4 Gas Supply:
- Shielding gas shall be argon or a combination of argon and helium.
- Dew point shall be -60°C (-76°F) or less. Argon purity shall be 99.999%. Helium purity shall be 99.995%. Supplier shall provide product purity certificates.
- Care must be taken to ensure that air cannot be aspirated into the gas passages. If the welding system has any leaks, the gas will become contaminated. Argon supply hoses used to connect cylinders to torch shall have minimum number of connections. Use of hoses of Tygon material is prohibited. Supply hoses shall be kept dry. When hoses are not in use they shall be stored in a dry area.
D9.5 Filler Materials: Spooled wire (according to ASME SFA-5.10) shall be used.
D10. WELD EXAMINATION
D10.1 Weld inspection shall be in accordance with the requirements of Section 15 and this section.
D10.2 The fabricator shall not allow a backlog of welds requiring radiography greater than two day’s production.
D10.3 The first two welds per WPS produced by each welder shall be subjected to full radiography. These welds are not counted in the percentage of welds that shall be fully radiographed.
D10.4 Full radiography shall be performed on all weld repairs. In addition, all subsequent welds by the same welder shall be completely radiographed until two consecutive welds are acceptable to the Air Product’s representative.
D10.5 100% of welds on pipe work designated for oxygen service shall be visually examined to ensure that the internal root profile is smooth, free from over penetration, irregular profile, weld splatter, excessive oxide formations, or other imperfections. If the root pass cannot be visually examined, that weld shall be subjected to 100% radiographic examination.
D10.6 Not less than 5% of branch connection welds and socket welds shall be fully examined by random dye-penetrant testing. Any additional examination required because of the nature of the contents or service of the piping system will be specified on the contract drawings and specifications.
D10.7 The Air Product’s representative reserves the right, within the limitation of the above requirements, to: (a) select welds for radiography or dye-penetrant examination, and (b) choose socket weld joints for destructive or X-ray examination. Otherwise welds selected shall be at random per the code.
D10.8 Aluminum piping should be examined using X-ray techniques (not isotope). Deviations (that is, use of isotope with ultra fine grain ASTM E-1825, Class 1 film) are to be approved by Air Products on a case-by-case basis for instances where x-ray is not practical.
D10.9 The fabricator shall record details for each weld on the form contained in the attached Appendix A, Piping System Check Sheet. The details contained on the form include a listing of the Line Identification, Joint Elevation, Joint Description and Identification, Cleaning Verification, Edge Preparation, Fit Up, Welder Identification, Welder Qualification, Root Pass Inspection, Final Weld Inspection, X-ray, Dye Penetrant Testing, and necessary remarks. Completed and indexed copies of the form shall be placed in the “Quality Assurance and Inspection Book.” The fabricator’s inspector shall initial each line to signify the completion of the details on that line.
Appendix E
Names and Addresses of
Standards Organizations
AISC – American Institute of Steel Construction
1 E Wacker Drive
Suite 3100
Chicago, IL 60601-2001
312-670-2400
ANSI – American National Standards Institute, Inc.
25 West 43rd Street 4th Floor
New York, NY 10036
212-642-4900
ASME – The American Society of Mechanical Engineers
Three Park Avenue
New York, NY 10016-5990
212-591-7000 (800-843-2763)
ASTM – American Society for Testing and Materials
100 Barr Harbor Drive
West Conshohocken, PA 19428-2959
610-832-9500
AWS – American Welding Society, Inc.
550 Northwest Le Jeune Road
Miami, FL 33126
305-443-9353 (800-443-9353)
PFI – Pipe Fabrication Institute
666, Fifth Ave., #325
New York, NY 10103
514-634-3434 (866-913-3434)
SSPC – Steel Structures Painting Council
21414 68th Ave. South
Kent, WA. 98032
253-234-8050 (800-678-5664)
Appendix F
Names and Addresses of Suppliers
| Airco Industrial Gases Division of B.O.C. Group
575 Mountain Avenue Murray Hill, NJ 07974 908-464-8100 (800-262-4273) |
Handy & Harman Tube Co., Inc.
701 W. Township Line Road Norristown, PA 19403 610-539-3900 |
|
| Air Products and Chemicals, Inc.
7201 Hamilton Boulevard Allentown, PA 18195-1501 610-481-4911 |
Miller Electric Mfg. Co.
P.O. Box 1079, Department TR Appleton, WI 54912 920-734-9821 |
|
| Bel-Ray Co., Inc.
P.O. Box 526 Farmingdale, NJ 07727 732-938-2421 |
Modern Chemical Inc.
P.O. Box 368 Jacksonville, AR 72078 501-988-1311 (800-366-8109) |
|
| Federal Process Co.
4620 Richmond Road Cleveland, OH 44128 216-464-6440 (800-846-7325) |
Permacel
US Rte. 1, P.O. Box 671 New Brunswick, NJ 08903 732-418-2400 (800-755-8273) |
|