33 52 40.pdf

SECTION 33 52 40

FUEL SYSTEMS PIPING (NON-HYDRANT)

11/18, CHG 2: 11/20

PART 1 GENERAL

1.1 SUMMARY

This section defines the requirements for pipe, piping components, and valves as related to an non-hydrant, non-service station, fuel distribution system. Such systems include, but are not limited to: marine receipt, pipeline receipt, truck off-loading receipt, pump house, pump pad, truck loading, marine loading, transfer pipeline, product recovery, and other miscellaneous piping systems. Provide the entire fuel distribution system as a complete and fully operational system. Size, select, construct, and install equipment and system components to operate together as a complete system. Substitutions of functions specified herein will not be acceptable.Coordinate the work of the system manufacturer's service personnel during construction, testing, calibration, and acceptance of the system. System components and piping specified herein must be designed to handle a working pressure of 275 psig at 100 deg F. Components specified herein must be compatible with the fuel to be handled. Components to be suitable for outside, unsheltered location, and to function normally in ambient temperatures between 30 degrees F and 100 degrees F.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN PETROLEUM INSTITUTE (API)

API RP 1110 (2013; R 2018) Recommended Practice for the Pressure Testing of Steel Pipelines for the Transportation of Gas, Petroleum Gas, Hazardous Liquids, Highly Volatile Liquids, or Carbon Dioxide

API RP 2003 (2015; 8th Ed) Protection Against Ignitions Arising out of Static, Lightning, and Stray Currents

API RP 2009 (2002; R 2007; 7th Ed) Safe Welding, Cutting, and Hot Work Practices in Refineries, Gasoline Plants, and Petrochemical Plants

API RP 2200 (1999; R 2004) Electrical Installations in Petroleum Processing Plants

API STD 608 (2012) Metal Ball Valves - Flanged, Threaded, And Welding End

API Spec 6D (June 2018, 4th Ed; Errata 1 July 2018;

Errata 2 August 2018) Specification for Pipeline and Piping Valves

API Std 594 (2017) Check Valves: Flanged, Lug, Wafer and Butt-Welding

API Std 607 (2016) Fire Test for Quarter-turn Valves and Valves Equipped with Non-metallic Seats

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.1 (2024) Unified Inch Screw Threads (UN, UNR, and UNJ Thread Form)

ASME B16.5 (2020) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B16.9 (2024) Factory-Made Wrought Buttwelding Fittings

ASME B16.11 (2022) Forged Fittings, Socket-Welding and Threaded

ASME B16.34 (2021) Valves - Flanged, Threaded and Welding End

ASME B18.2.1 (2012; R 2021) Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy Hex, Hex Flange, Lobed Head, and Lag Screws (Inch Series)

ASME B18.2.2 (2022) Nuts for General Applications:

Machine Screw Nuts, and Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)

ASME B31.3 (2022; Errata 2023) Process Piping

AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA C210 (2024) Standard for Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2019) Standard Specification for Carbon Structural Steel

ASTM A182/A182M (2024) Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A193/A193M (2024a) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and

Other Special Purpose Applications

ASTM A269/A269M (2024) Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service

ASTM A312/A312M (2022a) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A358/A358M (2024) Standard Specification for Electric-Fusion-Welded Austenitic Chromium-Nickel Stainless Steel Pipe for High-Temperature Service and General Applications

ASTM A403/A403M (2022b) Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings

ASTM A961/A961M (2024b) Standard Specification for Common Requirements for Steel Flanges, Forged Fittings, Valves, and Parts for Piping Applications

ASTM B117 (2019) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM D3308 (2012; R 2017) Standard Specification for PTFE Resin Skived Tape

ASTM F436 (2011) Hardened Steel Washers

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 142 (2007; Errata 2014) Recommended Practice for Grounding of Industrial and Commercial Power Systems - IEEE Green Book

IEEE 1100 (2005) Emerald Book IEEE Recommended Practice for Powering and Grounding Electronic Equipment

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2018) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 30 (2024; TIA 24-1) Flammable and Combustible Liquids Code

NFPA 70 (2023; ERTA 1 2024; TIA 24-1) National Electrical Code

NFPA 77 (2024; ERTA 1 2023) Recommended Practice on Static Electricity

NFPA 407 (2022; TIA 24-2) Standard for Aircraft Fuel Servicing

NFPA 780 (2023) Standard for the Installation of Lightning Protection Systems

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 5/NACE No. 1 (2007) White Metal Blast Cleaning

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE AMS3275 (2009; Rev C) Sheet, Acrylonitrile Butadiene (NBR) Rubber and Non-Asbestos Fiber Fuel and Oil Resistant

SAE J514 (2012) Hydraulic Tube Fittings

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-STD-161 (2005; Rev G; Notice 1 2010) Identification Methods for Bulk Petroleum Products Systems Including Hydrocarbon Missile Fuels

1.3 SUBMITTALS

Government approval is required for submittals with a "G" classification.

Submittals not having a "G" classification are for Contractor Quality Control approval and are provided to the Government for information only.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-01 Preconstruction Submittals

Work Plan; G

Hydrotesting Plan; G

Quality Assurance Plan; G

SD-02 Shop Drawings

Grounding and Bonding

Pipe Supports; G

SD-03 Product Data

Stainless Steel Piping; G

Fittings; G

Bolts, Nuts And Washers; G

Ball Valves; G

Silent Check Valves

Globe Valve; G

Automatic Air Vent; G

SD-06 Test Reports

Pneumatic Test

Hydrostatic Test

Performance Testing

SD-07 Certificates

Water for Hydrotesting; G

Contractor Qualifications; G

System Supplier; G

Qualifications of Owner's Inspector; G

Survey Final Elevations; G

SD-10 Operation and Maintenance Data

Ball Valves; G

Globe Valve; G

Automatic Air Vent; G

1.4 QUALITY ASSURANCE

1.4.1 Contractor Qualifications

Each installation Contractor must have successfully completed at least 3 projects of the similar scope and the same size or larger within the last 6 years. Each installation Contractor must demonstrate specific installation experience in regard to the specific system installation to be performed. Each installation Contractor must have taken, if applicable, manufacturer's training courses on the installation of piping and must meet the licensing requirements in the state. Experience must include the erection of piping systems in compliance with the requirements of ASME B31.3, and NFPA 30. Submit a letter listing prior projects, the date of construction, a point of contact for each prior project, the scope of work of each prior project, and a detailed list of work performed.

Installers must submit certification from the manufacture and Oklahoma Corporation Commission (OCC).

1.4.2 System Supplier

Since the pump control system, including but not limited to pump controlpanel, transmitters, flow switches, fueling system pumps,all field instrumentation, tightness monitoring system, and control valves with all hardware and software, is an integrated system it must be furnished by a single systems supplier regularly engaged in the supplying of these system components. System Supplier must be a company whose regular, normal, and primary business is representing manufacturers in the distribution and start-up of aviation fueling facilities, and have no affiliation with the Contractor other than as a seller to the Contractor.Supplier must provide all system components and appurtenances regardlessof manufacture, be a factory authorized certified representative, and be responsible to the Contractor for satisfactory operation of the entiresystem, and must oversee the installation of the system components.Substitutions of functions specified will not be acceptable. The Contractor and the System Supplier must be present at the systemcommissioning, and must coordinate and schedule the work during construction, testing, calibration, and acceptance of the system. The System Supplier must be on-site with their mechanical and control personnel to supervise and assist the contractor during pre-commissioning check-out of the mechanical systems and control systems, initial fuelreceipt, initial filing, hydrostatic testing, pigging, flushing, cleaning,system component tests, performance testing and all training for theowner's representatives. The System Supplier must be responsible to theContractor for scheduling all Contractor, Sub-contractor, andmanufacturer's service personnel during system start-up and finalcommissioning.

1.4.3 Work Plan

Submit a comprehensive work plan that provides sufficient detail to demonstrate a thorough understanding of the project. Document that all components to be provided will function together and produce the result expected by the Government. Include any proposed dates for piping system shutdowns as well as the Contractor's ability to complete the work within the allotted shutdown periods. Show proposed dates and nature of piping system operations required of the Government. Include a list of manpower, spare piping and system component that will be on hand for each phase of the work. Describe, in detail, the means of:

a. Coordinating work with Government and third parties.

b. Preparing for safe piping repair work.

c. Pneumatic pressure testing new piping sections.

d. Hydrostatic pressure testing new piping sections.

e. Drying lines after water was introduced for hydrotesting.

f. Interrupting or isolating an existing fuel service or system.

g. Purging piping.

h. Vapor monitoring.

i. Preparations for containing and disposing of residual fuel.

j. Cutting, sealing, and welding into existing piping systems.

k. Welding tie-ins in place.

l. Examining repair section tie-in welds.

m. Collecting, storing and disposing of waste fuel generated during work.

1.4.4 Hydrotesting Plan

The Contractor must submit a detailed written plan covering all aspects of the pipeline hydrostatic testing operations, including procedures and sequencing of testing, segments of piping to be tested, fluid to be used during testing, equipment removal and isolation, hydrostatic testing pressures, safety protocols, etc.

1.4.5 Water for Hydrotesting

Submit results of water testing and amount of water required.

PART 2 PRODUCTS

2.1 ELECTRICAL WORK

2.1.1 General

Motors, manual or automatic motor control system components except where installed in motor control centers, and protective or signal devices required for the operation specified herein must be provided under this section in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.

Any wiring required for the operation specified herein, but not shown on the electrical plans, must be provided under this section in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.

2.1.2 Grounding and Bonding

Ground and bond as indicated on the drawings and in accordance with NFPA 70, NFPA 77, NFPA 407, NFPA 780, API RP 540, API RP 2003, IEEE 142, and IEEE 1100. Provide jumpers to overcome the insulating effects of gaskets, paints, or nonmetallic components.

2.2 MATERIALS

Pipe and fittings in contact with fuel must be stainless steel, interior epoxy coated carbon steel, or interior uncoated carbon steel as indicated on the drawings or as specified herein. No zinc coated metals, brass, bronze or other copper bearing alloys must be used in contact with the fuel.Identification of piping must be in accordance with MIL-STD-161 unless specified otherwise. Material for manual valves must be as specified hereinafter. Do not use aluminum valves.

2.2.1 Stainless Steel Piping

a. Piping:

(1) ASTM A358/A358M, Grade 304L, Class 1 or Class 3 with supplementary requirements of S1, S2 and S3, or ASTM A312/A312M

Type 304L, seamless (only). Any agreements between the purchaser and the manufacturer or supplier as referenced in the applicable ASTM must include the Contracting Officer as a party to the agreement. All longitudinal piping welds will receive 100 percent radiographic inspection, 100 percent liquid penetrant inspection, 100 percent visual inspection and all tests as required by the applicable ASTM Standard. All other welds must be inspected per Section 33 52 23.15 POL SERVICE PIPING WELDING.

ASTM A312/A312M seamless piping must be provided with a minimum schedule 10S wall thickness for pipe 8 inches and larger; minimum schedule 40S for pipe smaller than 8 inches (except for threaded pipe which must be minimum Schedule 80S).

(2) Pipe Ends: All Piping must be provided with beveled ends per Chapter V, ASME B31.3, and must be shipped with the ends capped.

(3) Factory Testing and Inspection Records: Per Table K341.3.2 of Chapter IX of ASME B31.3, visual, radiographic and liquid penetrant tests must be performed for each section of piping provided as all sections are subjected to cyclic conditions. All testing and inspections records must be submitted to the Contracting Officer and must indicate the pipe mark and installed location of each piping section on the project site. Observation by the Contracting Officer of the manufacturers and the fields testing and inspection procedures must be allowed under this contract. Pipe certification along with pipe markings must be submitted before the pipe arrives on the job site.

(4) Qualifications of Owner's Inspector: Provide a qualified inspector in accordance with Chapter VI of ASME B31.3. to act as the owner's inspector (for the Government) at the pipe manufacturer's facility in addition to the manufacturer's inspector.

(5) Quality Assurance Plan: Submit Quality Assurance Plan for the welding, inspecting and testing of the welded seam pipe.

b. Stainless Steel Control Tubing: Seamless, fully annealed tubing conforming to ASTM A269/A269M, Grade TP316, Rockwell hardness B80 or less. Wall thickness for 1/2-inch tubing to be a minimum of 0.049-inch.

2.2.2 Fittings

2.2.2.1 General

Welding ells, caps, tees, reducers, must be of materials compatible for welding to the pipeline in which they are installed, and wall thickness, pressure and temperature ratings of the fittings must be not less than the adjoining pipeline. Unless otherwise specified herein or required by the conditions of installation, all elbows must be the 1.5 diameter (D) type.

Miter joints are not acceptable. Make odd angle offsets with pipe bends or elbows cut to the proper angle. Butt weld fittings must be factory-made wrought fittings manufactured by forging or shaping.

Fabricated fittings will not be permitted. Welding branch fittings must be insert type suitable for radiographic inspections specified herein.

Make branch connections with butt-welded tees except where the branch is at least two pipe sizes smaller than the run, in which case the branch connection can be made with a forged or seamless branch outlet fitting.

The branch outlet fitting must be designed in such a way that the connection can be radiographed. The branch outlet fittings may be a non-radiographicable if: the piping it is connected to is aboveground, the branch outlet size is 2.5 inches or less in diameter, and the branch outlet is located in contained pumphouses, contained truck offloads, contained truck fill stands, and other visibly contained areas equipped with containment curb.

2.2.2.2 Stainless Steel Fittings

a. Fittings 2.5 inches and Larger: Butt weld stainless steel conforming to ASTM A403/A403M, Class WP, Type 304L, seamless or welded, and ASME B16.9 of the same minimum wall thickness as the adjoining pipe.

Welded fittings must be tested and inspected the same as the welded seam pipe and meet the same requirements as for the pipe.

b. Fittings 2 inches and Smaller: Forged Type 304 or 304L , butt weld, or socket welded (except flanges, see below). If specifically indicated on drawings, non-flange fittings may be threaded. Socket welded or threaded fittings must be Class 3000 conforming to ASTM A182/A182M and ASME B16.11. Threaded fittings must only be used for above grade applications. Underground and in pits, low point drain pipe, and high point vent pipe must be butt welded.

c. Unions: Conforming to ASTM A182/A182M, Grade 304 or 316.

d. Flanges. Class 150 weld neck, butt weld, forged Type 304 stainless steel flanges conforming to ASTM A182/A182M and ASME B16.5, except flange that are to be connected to pumps must match the pump flanges rating. Threaded and slip-on flanges are not allowed. Flanges to be 1/16-inch raised-face with modified spiral serrated gasket surface finish, except where required otherwise to match system components furnished. Flange face must be machined to match valves or system components furnished. Match flange face to valves or system components furnished. Flanges must be subjected to the Supplementary Requirements S56, Liquid Penetrant Examination as outlined in ASTM A961/A961M. Detectable flaws will not be acceptable. For flanges 2 inches and smaller located in contained pumphouses, contained truck offloads, contained truck fill stands, and other visibly contained areas the fitting may be forged (socket welded), Class 150, conforming to ASTM A182/A182M and ASME B16.5. In pits, vaults, on thermal relief valve piping for pipeline routes, and other uncontained locations the flanges must be radiographicable, butt welded, weld neck type.

e. Stainless Steel Tube Fittings. Flareless, 316 stainless steel fittings conforming to SAE J514.

2.2.3 Bolts, Nuts and Washers

a. Bolts and nuts for pipe flanges, flanged fittings, valves and accessories must conform to ASME B18.2.1 and ASME B18.2.2, except as otherwise specified.

b. Bolts must be of sufficient length to obtain full bearing on the nuts and must project no more than three full threads and no less than two full threads beyond the nuts with the bolts tightened to the required torque.

c. Bolts must be regular hexagonal bolts conforming to ASME B18.2.1 with material conforming to ASTM A193/A193M, Class 2, Grade B8, stainless steel, when connections are made where a stainless steel flange is involved, and Grade B7, chromium molybdenum alloy, when only carbon steel flanges are involved. Bolts and nuts chosen must have sufficient strength to seat gasket types chosen. Bolts must be threaded in accordance with ASME B1.1, Class 2A fit, Coarse Thread Series, for sizes one-inch and smaller and Eight-Pitch Thread Series for sizes larger than one-inch.

d. Nuts must conform to ASME B18.2.2, hexagonal, heavy series with material conforming to ASTM A194/A194M, Grade 8, stainless steel for stainless steel bolts, and Grade 7, chromium molybdenum allow for chromium molybdenum alloy bolts. Nuts must be threaded in accordance with ASME B1.1, Class 2B fit, Coarse Thread Series for sizes one-inch and smaller and Eight-Pitch Thread Series for sizes larger than one-inch.

e. Provide washers under bolt heads and nuts. Use chromium molybdenum alloy washers dimensioned to ASTM F436 flat circular for chromium molybdenum bolts. Stainless steel washer dimensioned similar to ASTM F436 flat circular, use material the same as the bolt.

f. Use torque wrenches to tighten all flange bolts to the torque recommended by the gasket manufacturer. Tight in the pattern recommended by the gasket manufacturer. Use anti-seize compound on stainless steel bolts.

2.3 MANUAL VALVES

All portions of a valve coming in contact with fuel in stainless steel pipelines or epoxy lined carbon steel pipelines must be of noncorrosive material. Valves in stainless steel pipelines or epoxy lined carbon steel pipelines must be Type 304 or Type 316 stainless steel or carbon steel internally plated with chromium or nickel or internally electroless nickel plated. Valves in unlined carbon steel pipelines must have carbon steel body. Stem and trim must be stainless steel for all valves. Manually operated valves 6 inches and larger must be worm-gear operated and valves smaller than 6 inches must be lever operated or handwheel operated.

Valves smaller than 2 inches must have lever-type handles. Valves installed more than 8 feet above finished floor must have chain operators and a position indicators visible from ground level. Sprocket wheel for chain operator must be aluminum.

2.3.1 Ball Valves

Ball valves must be fire tested and qualified in accordance with the requirements of API Std 607 and API STD 608. Seal material for the fire test must be graphite, seal material for the project must be as as indicated below. Ball valves must be nonlubricated valves that operate from fully open to fully closed with 90-degree rotation of the ball.

Valves 2 inches and larger must conform to applicable construction and dimension requirements of API Spec 6D, ANSI Class 150 and must have flanged ends. Valves 2 inches and larger must conform to applicable construction and dimension requirements of API Spec 6D, ANSI Class 150 and must have flanged ends. The balls in valves 10 inches and larger full port and 12 inches and larger regular port and larger must have trunnion type support bearings. Except as otherwise specified or indicated, reduced port or full port valves may be provided at the Contractor's option. Balls must be solid, not hollow cavity.

2.3.1.1 Materials

Ball must be stainless steel. Ball valves must have tetrafluoroethylene (TFE) or fluoroelastetomer (FKM), commonly referred to as Viton seats, body seals and stem seals. Valves 4 inches and smaller must have a locking mechanism.

2.3.1.2 Electric Valve Actuator

Electric valve actuator must be as indicated for Plug (Double Block and Bleed) Valves, electric valve actuator.

2.3.2 Silent Check Valves

Spring assisted, wafer/tapped lug pattern, butterfly check with or globe type FKM or PTFE seat ring, designed to prevent flow reversal slamming of valve, dual plate, and must conform to ASME B16.34, API Std 594, except face to face dimensions may deviate from standard. Valves must be suitable for installation in any orientation. Valve body and trim material must be as previously indicated herein.

2.3.3 Globe Valve

Valve must conform to ASME B16.34, Class 150.

2.4 PIPING ACCESSORIES

2.4.1 Flexible Ball Joints

Flexible ball joints must be stainless stee, capable of 360-degree rotation plus 15-degree angular flex movement, ASME B16.5, Class 150 flanged end connections. Provide pressure molded composition gaskets designed for continuous operation temperature of 275 degrees F. Joints must be designed for minimum working pressure of ANSI Class 150.

Injectable packing will not be allowed.

2.4.2 Pipe Supports

2.4.2.1 General

Pipe supports must conform to MSS SP-58. Design pipe supports to meet the applicable requirements of ANSI/ASME B31.3 or ANSI/ASME B31.4. Provide hot-dip galvanized finish on rods, nuts, bolts, washers, and supports.

Provide miscellaneous metal that conforms to ASTM A36/A36M, standard mill finished structural steel shapes, hot-dipped galvanized.

2.5 AUTOMATIC AIR VENT

Unit must have one-inch connections and automatically vent air under pressure, and prevent a vacuum when pressure drops below a positive pressure. As fuel fills the vent, a float must rise and form a drip-tight closure. The unit pressure rating must be a minimum of 275 psi. The float must be stainless steel. Body and cover be carbon steel or ductile iron and be internally epoxy coated.

2.6 MISCELLANEOUS ACCESSORIES

2.6.1 Concrete Anchor Bolts

Concrete anchors must conform to ASTM A307, Grade C, hot-dipped galvanized.

2.6.2 Coatings for Bolts, Studs, Nuts, and Washers

Carbon steel bolts, studs, nuts, and washers must be provided with a factory applied hot-dipped zinc coating that conforms to ASTM F2329.

2.6.3 Polytetrafluoroethylene (PTFE) Tape

Tape must conform to ASTM D3308.

2.7 FINISHES

2.7.1 Factory Coating

2.7.1.1 Valves

Valve surfaces must be blasted clean according to SSPC SP 5/NACE No. 1.

Valve surfaces must be primed and coated in accordance with Section

09 97 13.27 HIGH PERFORMANCE COATING FOR STEEL STRUCTURES.

2.7.1.2 Equipment and Components

Unless otherwise specified, provide equipment and components fabricated from ferrous metal with the manufacturer's standard factory finish. Each factory finish must withstand 500 hours exposure to the salt spray test specified in ASTM B117. For test acceptance, the test specimen must show no signs of blistering, wrinkling, cracking, or loss of adhesion and no sign of rust creepage beyond 1/8-inch on either side of the scratch mark immediately after completion of the test. For equipment and component surfaces subject to temperatures above 120 degrees F, the factory coating must be appropriately designed for the temperature service.

PART 3 EXECUTION

3.1 GENERAL

Installation, workmanship, fabrication, assembly, erection, examination, inspection, and testing must be in accordance with ASME B31.3 and NFPA 30, except as modified herein. Safety rules as specified in NFPA 30 and NFPA 407 must be strictly observed. Never direct bury threaded connections, socket welded connections, unions, flanges, valves, air vents, or drains. Install all work so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible.

3.2 VERIFICATION OF DIMENSIONS

After becoming familiar with details of the work, verify dimensions in the field, and advise the Contracting Officer of any discrepancy before performing any work.

3.3 CLEANING OF PIPING

Keep the interior and ends of all new piping, affected by construction operations, thoroughly cleaned of foreign matter and water before and after being installed. Piping systems must be kept clean during installation by means of plugs or other approved methods. When work is not in progress, open ends of piping and fittings must be closed so that no water or other foreign substance will enter the pipes or fittings.

Piping must be inspected before placing into position. The interior of each length of pipe must be cleaned after welding ensuring that the interior of the piping is free of foreign matter when it is connected into the system.

3.4 PIPING LAYOUT REQUIREMENTS

3.4.1 Pipe Fabrication

Fabricate piping to measurements established on the project site and position into place without springing or forcing. Make provisions for absorbing expansion and contraction without undue stress in any part of the system. The use of flexible connectors in permanently mounted pump suction and discharge lines as a method of compensating for piping misalignment is not acceptable.

3.4.2 Interferences and Measurements

Provide offsets, fittings, and accessories required to eliminate interferences and to match actual system components connection locations and arrangements. Verify measurements before commencing work. Submit discrepancies for clarification before proceeding with the installations to the Contracting Officer.

3.4.3 Space and Access

Keep piping, control tubing, which is not detailed close to structures and columns so as to take up a minimum amount of space. Ensure that access is provided for maintenance of system components, valves and gauges.

3.4.4 Location

Do not place unions in locations that will be inaccessible after the completion of the work. Place unions on each side of equipment.

3.4.5 Pipe Supports

Where provided hot dip galvanized pipe support steel must be surface prepped to SSPC SP 16, Brush-Off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels, and Non-Ferrous Metals. Once the steel is prepped, apply only the Epoxy Intermediate Coat and Polyurethane Topcoat per manufacturer's instructions.

Provide pipe supports with the maximum spacing as defined in Table 1 below, unless otherwise indicated. At the indicated locations. Provide additional pipe supports at concentrated piping loads (valves).

Table 1. Maximum Support Spacing

Nominal Pipe Size (Inches) one-inch and under

1.5-in 2-in 3-in 4-in 6-in 8-in 10-in 12-in

Maximum Support Spacing (ft)

7-ft 9-ft 10-ft 12-ft 14-ft 17-ft 19-ft 22-ft 23-ft

Provide anchors where required to absorb or transmit thrust or eliminate vibration or pulsation. Provide supports near each change of direction.

Select support components which do not restrict the movement of the pipe due to thermal expansion. Space supports uniformly and arrange symmetrically.

3.4.6 Structural Support

Provide supplementary or intermediate steel or other structural members as required for transmission of loads to members forming part of the supporting structure. Piping must not be supported from other piping.

3.4.7 Grade

Where profiles of piping lines are shown on the drawings, grade the line uniformly between changes in slope or direction. Maintain gradient to within 1/4-inch over the entire length of pipe. When backfilling has been completed to the top of the pipe, the pipe must be surveyed at each joint, and logged by station number. Submit to the Contracting Officer for approval the survey final elevations before backfilling can continue.

3.4.8 Size Changes

Make changes in pipe size with reducing fittings. Do not use bushings.

Make branch connections with butt-welded tees except where the branch is at least two pipe sizes smaller than the run, in which case the branch connection can be made with a forged or seamless branch outlet fitting.

The branch outlet fitting must be designed in such a way that the connection can be radiographed. The branch outlet fittings may be a non-radiographicable if: the piping it is connected to is aboveground, the branch outlet size is 2.5 inches or less in diameter, and the branch outlet is located either in a pump house or on a system component pad equipped with containment curb.

3.4.9 Direction Changes

Make changes in direction of pipes with 1.5 D fittings. Make odd-angle offsets with pipe bends or elbows cut to the proper angle. Make changes in direction with fittings, except that bending of pipe 4 inches and smaller will be permitted, provided a pipe bender is used and wide sweep bends are formed. Mitering or notching pipe or other similar construction to form elbows or tees will not be permitted. The centerline radius of bends must not be less than 6 diameters of the pipe if a pipe bender is used.

3.4.10 Threaded End Connections

Provide threaded end connections only on piping 2 inches in nominal size or smaller and only where indicated on the drawings. Provide threaded connections with PTFE tape or equivalent thread-joint compound applied to the male threads only. Not more than three threads must show after the joint is tightened.

3.4.11 Existing Pipe Systems

No interruptions or isolation of an existing fuel handling service or system may be performed unless the actions are appropriately documented in the approved work plan. Perform initial cutting of existing fuel pipe with a multiwheel pipe cutter, using a nonflammable lubricant. After cut is made, seal interior of piping with a gas barrier plug. Refer to API RP 2009and API RP 2200. Purge interior of piping with carbon dioxide or nitrogen prior to performing any welding process.

3.4.12 Bolted Connections

For each bolted connection of stainless steel components (e.g., pipes, piping components, valves, and system components) use stainless steel bolts or studs, nuts, and washers. For each bolted connection of carbon steel components, use carbon steel bolts or studs, nuts, and washers.

Bolts project no more than three full threads and no less than two full threads beyond the nuts with the bolts tightened to the required torque.

Prior to installing nuts, apply a compatible anti-seize compound to the male threads.

3.4.13 Flanges and Unions

Except where threaded end connections or unions are indicated, provide flanged joints in each line immediately preceding the connection to system components or material requiring maintenance such as pumps, general valves, control valves, strainers, and other similar items and as indicated. Assemble flanged joints square and tight with matched flanges, gaskets, and bolts.

3.4.14 Manual Valves

Install isolation plug or ball valves on each side of each system equipment, at the midpoint of looped mains, and at any other points indicated or required for draining, isolating, or sectionalizing purpose.

Install valves with stems vertically up unless otherwise indicated.

Provide individual supports and anchors for each valve.

3.4.15 Air Vents

Provide 1-1/2 inches air vents at all high points and where indicated to ensure adequate venting of the piping system.

3.4.16 Drains

Provide 2 inches drains at all low points and where indicated to ensure complete drainage of the piping. Drains must be schedule 120.

3.5 SEISMIC REQUIREMENTS

Support and brace piping and attach valves to resist seismic loads as specified under Sections 13 48 00 SEISMIC CONTROL FOR MISCELLANEOUS EQUIPMENT and as shown on the drawings. Structural steel required for reinforcement to properly support piping, headers, and system components but not shown must be provided under this section. Material used for support must be as specified under Section 05 12 00 STRUCTURAL STEEL.

3.6 STRUCTURAL ATTACHMENTS

Provide attachment to building structure concrete and masonry by cast-in concrete inserts, built-in anchors, or masonry anchor devices. Apply inserts and anchors with a safety factor not less than 5. Do not attach supports to metal decking. Construct masonry anchors for overhead applications of ferrous materials only. Structural steel brackets required to support piping, headers, and system components, but not shown, must be provided under this section. Material used for support must be as specified under Section 05 12 00 STRUCTURAL STEEL.

3.7 WELDING

3.7.1 General

All joints, unless indicated otherwise, in carbon steel and stainless steel piping systems must be welded. Do not weld carbon steel to stainless steel. Welding of fuel pipe joints must comply with Section

33 52 23.15 POL SERVICE PIPING WELDING.

3.8 INSTALLATION

3.8.1 Precautions

Take special care to ensure that the protective coating on buried pipe is not damaged during installation and that the completed system is free of rocks, sand, dirt, water, weld slag, and foreign objects including construction debris. Take the following steps to ensure these conditions.

a. Coated pipe must be handled only with canvas or nylon slings or padded clamps. Any coating damaged by improper handling or storage must be repaired as specified.

b. Pipe brought to the site must be stored on blocks or horses at least 18 inches above the ground and adequately supported to prevent sagging. Padded blocks or horses must be used for coated pipe. The method and height of storing coated pipe must be in accordance with the coating manufacturer's instructions. Pipe ends must be protected and capped against weather at all times, except to accommodate immediate installation.

c. Visual inspection must be made of the inside of each length of pipe to ensure that it is clear and clean prior to installation.

d. The open ends of the pipe system must be closed at the end of each day's work or when work is not in progress by use of expansion plugs and must not be opened until the work is resumed.

e. A swab, with a leather or canvas belt disc to fit the inside diameter of pipe, must be pulled through each length of pipe after welding in place.

f. Obstruction remaining in the pipe after completion of the system must be removed at the expense of the Contractor.

g. Plasma cutters and torches are not to be used to make penetrations in the pipe or to cut pipe.

3.9 INTERIOR EPOXY COATING

When internally epoxy lined pipe is cut, the lining must be ground back from the end a minimum of one-inch but not more than 1-1/2 inches.

3.10 SYSTEM COMMISSIONING

Conform to Section 33 08 55 FUEL DISTRIBUTION SYSTEM START-UP

(NON-HYDRANT).

3.11 TESTING

Piping must be tested by pneumatic and hydrostatic pressure. Testing must comply with applicable requirements of ASME B31.3, NFPA 30 and the requirements specified herein. Hydrostatic testing must be performed using water as the liquid with Service Headquarters approval. Pressure and hydrostatic testing must be performed only after welding inspection has been completed. Labor, materials, equipment, electricity, repairs, and retesting necessary for any of the tests required herein must be furnished by the Contractor. Provide provisions to prevent displacement of the piping during testing. Keep personnel clear of the piping during pneumatic testing. Only authorized personnel must be permitted in the area during pneumatic and hydrostatic testing. Isolate system components such as pumps, tanks, filter separators, and meters from the piping system during the testing. Do not exceed the pressure rating of any component in the piping system during the testing. Following satisfactory completion of each test, relieve the test pressure and seal the pipe immediately.

When water is authorized for hydrostatic testing ensure that all water is removed from the piping by a combination of pigging the piping, followed by dehydrating the line either with dehumidified air or vacuum extraction.

Verification of pipeline dehydrating must be confirmed by measuring dew point of exhausted air. Do not allow water to remain in piping for more than 48 hours after testing. Schedule hydrotesting such that the pipeline can be filled with fuel as soon as possible (no more than two weeks) after testing is complete as it is nearly impossible to assuredly remove all water and corrosion can occur if the time to fuel introduction is extended. The Contractor must submit the piping dehydration test prior to filling pipelines with fuel.

3.11.1 Pneumatic Test

Piping to be installed underground must not receive field applied protective covering at the joints or be covered by backfill until the piping has passed the pneumatic test described herein. To facilitate the tests, isolate various sections of the piping system and test each one separately. Where such sections terminate at flanged valve points, the line must be closed by means of blind flanges in lieu of relying on the valve. Furnish tapped flanges that can be attached to the end of the section of line being tested, and that will permit a direct connection between the piping and the air compressoror pressurizing pump. No taps in the permanent line will be permitted. Furnish all necessary equipment for testing; all gauges must be subject to testing and approval of the Contracting Officer. The air used for pneumatic testing must have a dew point of no more than 41 degrees F. Provide dehumidifying equipment on the suction or discharge side of the air compressor used to provide air for testing. Pressurizing pump must not exceed 10 cfm.

3.11.1.1 Pneumatic Test Procedure

Special safety measures, including the wearing of face mask, must be taken during testing under pressure. Only authorized personnel must be permitted in the area during testing. The pneumatic test pressure must be applied in increments. A preliminary 25 psig test must be applied.

Maintain the pressure while soapsuds or equivalent materials are applied to the exterior of the piping. While applying the soapsuds, visually inspect the entire run of piping, including the bottom surfaces, for leaks (bubble formations). If leaks are discovered, repair the leaks accordingly and retest. Repeat process until system is leak-free at 25 psig. The full test pressure must then be applied. Unless otherwise directed by the Contracting Officer, all piping must be tested at a pressure of 100 psig for not less than 2-hours, during which time there must be no drop in pressure, only pressure rises with temperature. The pressure source must be disconnected during the final test period. Any leaks revealed by the test must be repaired and the test repeated.

3.11.2 Hydrostatic Test

Upon completion of pneumatic testing, hydrostatically test each aboveground piping system with fuel at 275 psig in accordance with ASME B31.3 and API RP 1110, with no leakage or reduction in gauge pressure for four hours. Furnish electricity, instruments, connecting devices, and personnel for test. In cases where it is not specified, water must be potable and treated and must meet all the requirements of water used for hydrostatic testing in API 570. Defects in work must be corrected at the Contractor's expense, and the test repeated until the work is proven to be in compliance with the Contract requirements.

3.11.3 Performance Testing

After the fuel system testing is completed (including pneumatic and hydrostatic testing) the fuel system must be flushed, cleaned and performance tested as specified in Section 33 08 55 FUEL DISTRIBUTION SYSTEM START-UP (NON-HYDRANT). All control valves, both manual and automatic, must be checked for leaks (any area wetted with fuel) and proper operation and adjusted, repaired or replaced to correct any defects.

-- End of Section --