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24
Introduction
The purpose of this standard is to bring together the information relative to design, manufacture
and installation of refrigeration carbon and stainless steel pipework on all Star specified
refrigeration equipment.
The application of thin wall stainless steel (TWSS) piping and fittings for glycol and water duties
and for pressure relief discharge lines are treated as special cases and are covered in Star
Standard Specifications No. 150 and 156.
Pressure testing on vessels and packaged unit piping will be carried out in accordance with Star
Standard Specifications Nos 113 and 125.
Section Title
1.0 Steel Pipe and Fittings
1.1 Pipe Specification
1.2 Pipework Design and Allowable Pressures
1.3 Butt Weld Fittings
1.4 Socket Weld Fittings
1.5 Flanges
1.6 Saddle Bosses
1.7 Purchasing Requirements
2.0 Installation Standards, Welding Standards and Welding Processes
2.1 Installation Standards
2.2 Welding Standards
2.3 Welding Processes
2.4 Inspection
3.0 Screwed Joints and Compression Fittings
3.1 Screw Thread Joints
3.2 Compression Fittings
4.0 Refrigeration Valves and Controls
4.1 Refrigeration Stop Valves
4.2 Bore Match
1.1.1.1 The selection of material specification for carbon steel pipe will be taken from Figure 1 of
this standard.
In general, the pipe material specification used in Star installations and units will be
ASTM A106 GR.B or ERW API5L (where available).
Where we are using carbon steel and where the working conditions are such that there
will be a combination of high pressure (i.e. above 4 Bar (G)) and low temperature (i.e.
below 29.0C) the pipe material used will be ASTM A333 GR6.
Where the pressure is less than 4 Bar (G) ASME B31.3 allows the use of ASTM A106B
material down to -45C.
1.1.1.2 The pipe dimension specification for pipe from 17.1mm OD (3/8 NB) to 168.3mm OD (6
NB) will be ANSI B.36.10 Sch 40 (BS1600) with the following dimensions and weights:
For pipe 219.1mm OD (8 NB) or above, Sch 20 will be specified with the following
dimensions and weights:
1.1.1.4 To comply with the painting specification we may choose to purchase pipework in a
cleaned and primed condition. If different grades of pipework are to be used on the same
project they should be pre-primed in different colours to avoid confusion and mistakes on
site.
1.1.1.5 Mapress pipework system may be used for small bore low pressure drains.
1.1.2.1 The stainless steel material specification shall be ASTM A312 grade 316L or 304L.
1.2.1.1 Table of carbon steel pipe diameters up to 150NB and maximum allowable
pressures
1.2.1.2 Table of carbon steel pipe diameters 200NB and above maximum allowable
pressures
The designs include a 10% allowance to cover system pressure tests at 1.1 times the
allowable pressure and a further safety factor of 10%.
Where stab-in branch connections are permitted, the end of the branch pipe shall be
shaped to match the internal curvature of the header pipe and the protrusion into the
header pipe shall be 3mm all round, not significantly more. Refer to example figures
below (extract from BS 2633).
Root run to be dressed to clean metal Root run to be dressed to clean metal
then seal welded. then seal welded.
(a) Single-bevel preparation (b) Single-J preparation
g f (max.) l r
Figure
mm mm mm mm
(a) 1.0 2.5 - -
(b) 1.0 3.0 3.0 5.0
Typical preparation and assembly of stab-in branches
The selection of material specification for butt welded pipe fittings, bends, tees, reducers
and caps will be taken from Figure 1 of this standard.
In general, the material specification for carbon steel butt welded pipe fittings, bends,
tees, reducers and caps used in Star installations and units will be ASTM A234 WPB
where the pipe is ASTM A106 Gr B or ERW API 5L.
Where the working conditions are such that there will be a combination of high pressure
(i.e. above 4 Bar (G)) and low temperature (i.e. below 29.0C), the material used will be
ASTM A420 WPL6 in all cases where the pipe is ASTM A333 Gr 6.
1.3.1.1 The dimensions of all butt weld fittings will confirm to ANSI B16.9 (BS1640). For all pipe
work from 42.2mm OD (1 NB) to 168.3mm OD (6 NB) Sch 40/STD fittings for
pipework will be specified. For 219.1mm OD (8 NB) and above, Sch 20 fittings will be
specified.
In general, the material specification for stainless steel butt welded pipe fittings, bends,
tees, reducers and caps will be ASTM A403.
Socket weld fittings will be used for all pipework up to and including 48.3mm OD (1
NB) where practical. For the avoidance of doubt, it is not considered practical to use
socket weld fittings on DIN Standard pipework. The dimensions of the fittings will
conform to ANSI B16.11 (BS3799). The selection of material will be taken from Figure 1.
In general, the fitting material will be ASTM A105. The rotor oil feed pipework on Vilter
compressor packs will be a special exception and butt welded as standard. Contract
specific requests for butt weld connections will take precedence over the requirement for
socket weld fittings in this specification.
Where working conditions are such that there will be a combination of high pressure
(over 4 Bar(G)) and low temperature (below 29.0C), the material used will be ASTM
A350GR.LF2.
Note: Where the end of a pressure carrying pipe is to be sealed, a standard butt weld
or socket weld cap fitting must be used.
1.5 Flanges
1.5.1.1 All flanges will be to ASME B16.5 (equivalent to BS 1560 or its direct replacement BS EN
1759-1) Class 300 (unless higher pressure is required or DIN flange to suit line
component). The format of the flanges for pipe sizes up to and including 33.4mm OD will
be socket weld raised face and from 42.4mm OD slip on raised face.
1.5.1.2 The selection of material will be taken from Figure 1. In general, flange material will be
ASTM A105.
Where the working conditions are such that there will be a combination of high pressure
(above 4 Bar(G)) and low temperature (below 29.0C), the flange material used will be
ASTM A350 LF2.
1.5.1.3 Flange bolt hole dimensions are given in imperial units only in ASME B16.5. However,
BS 1560 and BS EN 1759-1 (equivalent to ASME B16.5) do not preclude the use of
metric bolts and provide tables of comparable imperial and metric nominal bolt sizes.
Due to better availability, Star specify metric bolting as standard.
Several similar standards are available which apply to metric bolts. Due to better
availability, Star specify metric bolting in accordance with DIN-931 M1.6 to M39
Hexagon Head Bolts, Screws and Nuts. Acceptable alternative standards are BS EN
ISO 4014 Hexagon Head Bolts (direct equivalent of DIN 931) and BS 3692 ISO
Metric Precision Hexagon Bolts, Screws and Nuts.
Bolts for use in systems with design temperatures down to -50C shall have mechanical
properties compliant with grade 8.8 of BS EN ISO 898-1 Mechanical Properties of
Fasteners Made of Carbon Steel and Alloy Steel.
Several similar standards are available which apply to metric nuts. Due to better
availability, Star specify metric nuts in accordance with DIN 934 Hexagon Nuts with
Metric Coarse and Fine Pitch Thread. Acceptable alternative standards are BS EN ISO
4032 and 8673 (direct equivalents of DIN 934) and BS 3692 ISO Metric Precision
Hexagon Bolts, Screws and Nuts.
Nuts shall have mechanical properties compliant with grade 8 of ISO 898-2 (identical
properties are also given in BS 3692).
Marking of bolts and nuts shall be in accordance with BS EN ISO 898-1 (bolts) and BS
EN ISO 898-2 (nuts). Where bolts and nuts are specified to DIN standards, the marking
requirements of DIN 267 are acceptable (similar to ISO 898 parts 1 and 2).
Bolts for use in systems with design temperatures below -50C shall have mechanical
properties compliant with grade A2 70 of BS EN ISO 3506-1 Mechanical Properties of
Corrosion Resistant Stainless Steel Fasteners, Bolts, Screws and Studs. Nuts shall have
mechanical properties in accordance with BS EN ISO 3506-2.
Imperial 1 1 1 1 1
Metric M14 M16 M20 M24 M27 M30 M33 M36 M39
The following table shows the bolt sizes to use for Class 150, 300 and 600 flanges.
Imperial sizes are also given for information.
Where use of imperial bolting is a strict customer requirement then the applicable
standard must be agreed with the customer and Stars Production Department. Where
strict compliance with ASME B16.5 is specified, then for applications with a minimum
design temperature no lower than -48C, mechanical properties shall be compliant with
ASTM A193 Grade B7 and for lower temperature applications mechanical properties
shall be compliant with ASTM A320 Grade L7. Bolts should be specified in accordance
with ASME B18.2.1 and nuts should be specified in accordance with ASME B18.2.2.
1.6.1.1 Saddle Boss fittings will be used on all pipe work where a screwed stud coupling or
threaded insert is to be fitted.
In general, the saddle fittings material specification used in Star installations and units will
be ASTM A105.
Where working conditions are such that there will be a combination of high pressure
(i.e. above 4 Bar(G)) and low temperature (i.e. below 29.0C), the material will be ASTM
A350 LF2.
1.6.1.3 The thread of the fitting will be ANSI B1.20.1 National Standard Tape Pipe Thread NPT.
1.6.1.4 If a non standard boss is required on an installation it will be manufactured from bar
material BS970 080A15.
1.7.1 All orders for the following carbon steel material grades will state our requirement for a
maximum carbon content (C MAX) of 0.25%:
1.7.3 Painting
All carbon steel pipe purchased for Star installations and units will be externally cleaned
and prime painted. The work may be carried out by the pipe stockist on our behalf.
Alternatively, the purchaser may arrange for this work to be carried out by a third party.
After cleaning, the pipe is to be capped and externally painted with one 20 micron coat of
METAGARD G250 red oxide primer for A106 pipe and grey oxide primer for A333 pipe
(W & J Leigh & Co) or alternative material agreed in writing on a contract specific basis.
The pipe will be identified with the material certificate reference number.
2.1.1 The application standards for all carbon steel pipe work on Star installations and
package units is dependent on the system design and will be as follows:
For all primary refrigerant stainless steel pipework above a system design pressure of
8 Bar (G) the application standard shall be BS EN ISO 5817-2014 (Welding fusion
welded joints in steel, nickel, titanium and their alloys quality level C). For lower
pressure primary refrigerant stainless steel pipework or for secondary fluids refer to
Star Standard Specifications 150 and 156.
2.2.1 All welding on pressure carrying pipework on Star installations and package units will
be carried out to verified procedures to BS EN288, Pt 3:1992 - Specification and
qualification of welding processes for metallic materials or its direct replacement BS
EN ISO 15614-1 : 2004. Other recognised standards may be used if it is agreed in
writing with Stars Production Department on a contract specific basis. The
procedures will cover the range and type of welds required for the pipework being
welded.
2.2.2 All welders working on pressure carrying pipework on Star installations and units will
have current verified approval to BS EN287, Pt 1:1992 (or 2001) - Qualification testing
of welders for fusion welding. The approvals will cover the range and type of welds
required for the pipework being welded.
2.2.3 Other national welding standards such as ASME VIII may be accepted, provided
welding procedures and current qualifications of the welders cover the range and type
of welds required for pipework being welded.
Where it is proposed that an alternative standard is used, this should be agreed with
the Technical Department and the accredited inspection authority where appropriate.
2.4.1.1 Visual inspection of all pipework welds to ensure conformity with the requirements of
the application standard being used.
2.4.1.2 Non destructive inspection of butt welds will be carried out. The percentage of welds
subjected to non destructive inspection will be as follows:
Application Standard
2.4.1.4 Defect limitation and any rectification work required will be in accordance with the
application standard being used for the inspected pipework.
2.4.1.5 All non destructive inspection will be carried out to approved procedures and the
interpretation of the inspection report will be by qualified personnel.
2.4.2.1 A weld identification record will be created each time a non destructive inspection is
carried out. The record will have the following information:
1. Date
2. Job number
3. Weld identification reference
4. Welder identification reference
2.4.2.3 The weld identification record and the non destructive inspection records will be filed
together and kept with the installation records by the Branch Manager or package unit
records by the Works Office.
2.4.2.4 It has been agreed with Lloyds that there is no requirement to retain a copy of the
radiograph. However, this will be retained for all petrochemical contracts.
Screw thread joints will be used in conjunction with stud couplings, gauge and
instrument valves and small bore pipework. In general, the screw thread will be ANSI
B1.20.1 NPT.
3.2.1 Use of compression fittings will be restricted to pipe sizes 42mm OD and below.
3.2.2 The fitting used will be to DIN 2353 and will be steel L Series. The preferred
compression fittings will be Ermeto EO Range L Series.
3.2.4 Metric OD pipe for use with DIN Standard L Series fitting will be to DIN2391/C material
ST35.4/ST37.4.
3.2.6 The assembly and installation of compression fittings will be in accordance with the
manufacturers recommendations.
The selection of stop valve format for welded pipework is applicable for the
DANVALVE, Robinet and other similar valve ranges.
The matching of the bore of a valve or a mating flange must be checked to ensure
that the bore variation is generally in line with the application. In some cases we may
choose to fit a transition piece so that a butt weld will conform to the requirements of
the application standard. Alternatively, the works may choose to machine the flange
to suit the pipe.
4.2.1 Typical limits for bore difference and alignment using TIG welding with a root gap:
Up to and
Over BS2633(1) BS2971(2)
including
- 100 1.0mm
100 300 1.5mm
300 - 2.5mm
- 150 3.0
150 - 5.0
(1)
Class I arc welding of ferritic steel pipework for carrying fluids use when design pressure is
greater than 17 Bar (G) (refer to section 2.1.1).
(2)
Class II arc welding of carbon steel pipework for carrying fluids use when design pressure is less
than or equal to 17 Bar (G) (refer to section 2.1.1).
30
WELDING BS2633
CLASS 1
25
Star Standard Specification No. 24
20
Pressure Bar G
0
-1
-50 -25 0 25 50 75 100 125 150 175 200 225
-45 -29 220
Low temp references ANSI B31.5 Temperature C
para. 523.2.1 PD5500 Appendix.D REFRIGERATION
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