PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

TECHNICAL SPECIFICATION

FABRICATION OF HEATER PIPING

PTS 31.24.49.31

AUGUST 2009

© 2010 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic,
mechanical, photocopying, recording or otherwise) without the permission of the copyright owner
 PTS 31.24.49.31
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PREFACE
PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication, of
PETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based on,
or reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical
plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and
economic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every requirement
or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to
allow individual operating units to adapt the information set forth in PTS to their own environment and
requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the
quality of work and the attainment of the required design and engineering standards. In particular, for
those requirements not specifically covered, it is expected of them to follow those design and
engineering practices which will achieve the same level of integrity as reflected in the PTS. If in
doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility,
consult the owner.

The right to use PTS rests with three categories of users:

1) PETRONAS and its affiliates.

2) Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users
referred to under 1) and 2) which requires that tenders for projects, materials
supplied or - generally - work performed on behalf of the said users comply with the
relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users,
PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death)
suffered by any company or person whomsoever as a result of or in connection with the use,
application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this
disclaimer shall inure in all respects to PETRONAS and/or any company affiliated to PETRONAS that
may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users
to any company or person whomsoever and the PTS shall be used exclusively for the purpose they
have been provided to the user. They shall be returned after use, including any copies which shall
only be made by users with the express prior written consent of PETRONAS.

The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody
and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain
how users implement this requirement.
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TABLE OF CONTENTS
1. INTRODUCTION ...................................................................................................... 5
1.1 SCOPE ..................................................................................................................... 5
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5
1.3 DEFINITIONS ........................................................................................................... 5
1.4 CROSS REFERENCES ........................................................................................... 6
1.5 SUMMARY OF CHANGES SINCE PREVIOUS EDITION ........................................ 6
2. GENERAL ................................................................................................................ 6
2.1 DESIGN CODE ........................................................................................................ 6
2.2 DOCUMENTATION .................................................................................................. 6
3. MATERIALS............................................................................................................. 7
3.1 GENERAL ................................................................................................................ 7
3.2 MATERIAL CERTIFICATION ................................................................................... 7
3.3 TRACEABILITY ........................................................................................................ 7
3.4 BENDS ..................................................................................................................... 7
4. FABRICATION ......................................................................................................... 8
4.1 ASSEMBLY .............................................................................................................. 8
4.2 CUTTING AND BEVELLING .................................................................................... 8
4.3 WELDING ................................................................................................................. 8
4.4 FINAL CORRECTIONS ............................................................................................ 9
4.5 TOLERANCES ......................................................................................................... 9
5. INSPECTION AND TESTING................................................................................. 10
5.1 GENERAL .............................................................................................................. 10
5.2 PRESSURE TESTING ........................................................................................... 10
5.3 HARDNESS TESTING ........................................................................................... 10
5.4 POSITIVE MATERIAL IDENTIFICATION ............................................................... 10
5.5 TUBE FINNING ...................................................................................................... 10
6. REFERENCES ....................................................................................................... 11

APPENDICES
APPENDIX 1 INSPECTION CLASSES FOR COILS ........................................................... 12
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1. INTRODUCTION

1.1 SCOPE
This PTS specifies requirements and gives recommendations for the shop and field
fabrication, inspection and testing of piping (tubing) to be used in fired heaters and waste
heat boilers. Fired steam boilers are excluded from the scope of this PTS.

This PTS is a revision of the PTS of the same number dated December 1999; a summary of
the main changes since the previous edition is given in (1.5).

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by PETRONAS, the distribution of this PTS is confined to
PETRONAS companies forming part of PETRONAS Group and to Contractors and
Manufacturers/Suppliers nominated by them.

This PTS is intended for use in oil refineries, chemical plants, gas plants and, where
applicable, in exploration and production facilities and supply/marketing installations.

If national and/or local regulations exist in which some of the requirements may be more
stringent than in this PTS, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases the Contractor shall inform the Principal of any deviation from the requirements of this
PTS which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned with the
objective being to obtain agreement to follow this PTS as closely as possible.

1.3 DEFINITIONS

1.3.1 General definitions

The Contractor is the party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.

The Manufacturer is the party which manufactures or supplies equipment and services to
perform the duties specified by the Contractor.

The Principal is the party which initiates the project and ultimately pays for its design and
construction. The Principal will generally specify the technical requirements. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the Principal.

The word shall indicate a requirement.

The word should indicate a recommendation.

1.3.2 Specific definitions

Design Code is the code or standard specified by the Principal to which the equipment shall
conform (if not already dictated by the equipment standard).

Hydrogen service refers to all process conditions with a hydrogen partial pressure greater
than 7 bar (abs)

Very Toxic substances – See PTS 01.00.01.30

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1.4 CROSS REFERENCES

Where cross-references to other parts of this PTS are made, the referenced section number
is shown in brackets. Other documents referenced by this PTS are listed in (6).

1.5 SUMMARY OF CHANGES SINCE PREVIOUS EDITION

The previous edition of this PTS was dated December 1999. Other than editorial changes,
the following are the main changes since that edition:

Old section New section Change

1.3.2 1.3.2 Definition for “very toxic” to be referred to PTS
01.00.01.30
4.1 4.1 Added requirement regarding dissimilar welds.
4.2 4.2 Added requirement for quality of water used for cutting to
be reviewed.
5.3 5.3 Added requirement for hardness measurements also after
final corrections.
Appendix 1 Appendix 1 Added requirement for measurement of ferrite number

2. GENERAL

2.1 DESIGN CODE

If not already dictated by the equipment standard, the design code shall be specified by the
Principal (e.g. ASME VIII, ASME B31.3).

2.2 DOCUMENTATION

The Principal shall provide the Manufacturer with drawings and related requisitions giving all
information on the coils to be fabricated.

In addition to the data stated on these drawings, shop drawings provided by the
Manufacturer shall state:
• details of the welded joints with reference to the welding procedure specification, pre-
and post-weld heat treatment procedures and all non destructive examinations required;
• hydrostatic test pressure.
Before the start of manufacture, all shop drawings, weld procedure specifications including
pre-and post-weld treatment procedures, welding procedure qualification records, welder
performance qualifications and non-destructive examination procedures shall have been
reviewed by the Principal.

The Manufacturer shall comply with these drawings.

Upon completion, the Manufacturer shall supply a manufacturing report containing all the
relevant documentation. The format for this report should be in accordance with
PTS 31.22.10.35, making use of all the applicable sections.
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3. MATERIALS

3.1 GENERAL

The materials shall comply with the specification given on the drawing and/or requisition.
Unless otherwise specified, only seamless pipe and fittings shall be used.
Metallic construction materials standards shall be in accordance with the design code.

3.2 MATERIAL CERTIFICATION

All materials used for pressure-containing parts shall be traceable to inspection certificates in
accordance with ISO 10474 type 3.1.B.

3.3 TRACEABILITY
The heat numbers (or other codes traceable to the heat numbers) of certified materials (see
3.2) shall be recorded on an as-built drawing of the heater piping.

3.4 BENDS
Welding return bends in accordance with ASME B16.9 shall be used in coils.
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4. FABRICATION

4.1 ASSEMBLY

The type of flanges, fittings and connections and the extent to which welded joints are
applied shall be indicated on the Principal's drawings.

No intermediate welds shall be made in the pipes used for the coils, unless approved by the
Principal. Any dissimilar welds to pressure containing parts (e.g. tube guides) shall be
subject to the approval of the Principal.

All branch welds and structural attachment welds shall be dressed to a smooth finish, free
from undercut and merging smoothly into the pipe surface, and without any sharp corners or
other stress raisers.

4.2 CUTTING AND BEVELLING

Cutting and bevelling of pipes may be done either by mechanical means or by thermal
(flame, arc or plasma) means or by water cutting. The following shall apply:

• For carbon steel, thermal cutting and bevelling may be used only if the cut is reasonably
smooth and all oxides are removed from the surface.
• For low and intermediate alloy steel, after thermal cutting, approximately 2 mm of
material shall be removed from the surface of the bevel by grinding or machining. The
dressed bevels then shall be examined by either magnetic particle or liquid penetrant
methods prior to welding, to confirm that the bevel is free from linear indications 1.6 mm
or longer.
• Stainless steel shall not be flame or arc cut. Plasma or water cutting may be applied. The
surface shall be ground to bright metal after plasma cutting. The quality of water used for
cutting shall be reviewed by the Principal prior to use.
If preheat is specified for welding, the same preheat shall be applied for thermal cutting.
Weld bevels for butt-welding shall be in accordance with ASME B16.25.

4.3 WELDING

No production welding shall be performed until the welding procedure specifications have
been approved by the Principal and the welding procedures and welders have been qualified
in accordance with the design code.

If internal trimming of butt-welded piping components is necessary to achieve the required

alignment, it shall be done by internal tapering (with a taper no steeper than one-to-four).

Backing rings shall not be used.

The following welding process restrictions shall apply:

The GTAW process shall be employed for pipes, branch fittings and flanges in sizes DN 50
and smaller.

For stainless steel piping not back-welded inside, the root pass shall be carried out by the
GTAW process with an inert gas purge which shall be maintained until at least the second
pass has been completed.
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4.4 FINAL CORRECTIONS

4.4.1 General

Final corrections are modifications to the dimensions of a fabricated coil in order to allow
stress-free installation. No final corrections shall be performed until the related correction
procedure has been reviewed by the Principal.

The following methods of correction shall be used, in order of preference:

1. cutting and re-welding;
2. local non-uniform heating or cooling;
3. application of force with local heating.

For heating, cooling and forcing of piping made from carbon steel, low alloy steel or
austenitic stainless steel the following restrictions apply:

Temperature-indicating crayons or contact thermometers shall be used to measure the

maximum temperature. If temperature-indicating crayons are used, a margin of 50 °C shall
be taken to allow for measurement inaccuracy (i.e. the reading with the crayon shall not
exceed the maximum stated temperature minus 50 °C).
4.4.2 Carbon steel which does not require a PWHT

The maximum temperature during alignment corrections shall be 600 °C. Forcing may be
applied if necessary. Cooling in still air shall be applied.
4.4.3 Carbon steel which requires a PWHT

The maximum temperature during alignment corrections shall be the maximum PWHT
temperature. Forcing may be applied if necessary. No quenching shall be used. The area
shall either be heated in full compliance with the PWHT procedure or the area which is
heated (and corrected) shall be subject to PWHT.
4.4.4 Cr-Mo steels

The maximum temperature during alignment corrections shall be the maximum PWHT
temperature. Forcing may be applied if necessary. Cooling in still air shall be applied.
Hardness measurements shall be taken on the heated and forced area and the hardness
shall not exceed 248 HV 10.
4.4.5 Austenitic stainless steel

The maximum temperature during alignment corrections shall be 500 °C. The duration of
heating shall be kept as short as possible and forcing may be applied if required.

4.5 TOLERANCES

4.5.1 Dimensions

For dimensions stated on the Principal's drawings, the following tolerances shall apply:
Length Tolerance
< 1.5 m ± 1.5 mm
≥ 1.5 m ± 3 mm

4.5.2 Flange alignment

Flange alignment shall be in accordance with PTS 31.38.01.11.

If branches are in the same plane and their flanges are also positioned in one plane, the
flange facings shall not deviate more than 1 mm from the latter plane in the same direction.
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5. INSPECTION AND TESTING

5.1 GENERAL

All inspection and testing is the responsibility of the Manufacturer. All dimensions shall be
checked to ensure that the fabrication meets the requirements of the coil drawings and this
PTS, within the specified tolerances.
The Principal shall specify whether, and to what extent, he wishes to witness the
Manufacturer’s inspection and testing.
Inspection of welds shall be carried out after final heat treatment in accordance with the
inspection classes shown in Appendix 1.
The methods to be employed for the inspection and the acceptance criteria shall be in
accordance with the design code.
NOTE: Coil service (pressure, temperature and fluid) shall be indicated on the Principal's drawings or requisition.

5.2 PRESSURE TESTING

Pressure testing shall be performed in accordance with the design code and
PTS 61.10.08.11-Gen.

5.3 HARDNESS TESTING

The hardness shall be measured on the welding procedure qualification test plates and on
10 % of the production welds. No part of the weld, HAZ or base metal shall exceed
248 HV 10.

5.3.1 Hardness measurement method

Hardness measurements for welding procedure qualification shall be performed by the

Vickers method, with hardness traverses in accordance with EN 1043-1. The series of
readings shall extend from unaffected base material on one side, across the weld to
unaffected base metal on the other side. Three traverses shall be made: one 2 mm below the
outer surface, one 2 mm below the inner surface and one across the centre. The distance
between measurements across the weld shall not exceed 2 mm.
Transverse weld hardness testing of production welds shall be carried out using a portable
Vickers or Rockwell tester in accordance with ASTM E 110 or by another method capable of
detecting a hard HAZ in a reliable and repeatable manner (e.g., Equotip, Microdur or other
equivalent if approved by the Principal). Hardness tests shall be performed on properly
ground surfaces. For each set of hardness measurements required, the average of three
measurements on the weld and on each HAZ shall be reported.
Hardness measurements shall be carried out after any PWHT and final corrections.

5.4 POSITIVE MATERIAL IDENTIFICATION

For all materials other than carbon steel, the alloying elements in materials and weld
deposits shall be verified by chemical, spectroscopic or X-ray fluorescence methods after
fabrication of the coils. The results shall be included in the manufacturing report.

5.5 TUBE FINNING

Finned tubes shall be inspected to ensure that the fins are perpendicular to the tube within
15°. The maximum discontinuity of the resistance weld shall be 64 mm in any 2500 mm of
weld.
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6. REFERENCES

In this PTS, reference is made to the following publications:

NOTES: Unless specifically designated by date, the latest edition of each publication shall be used, together with any
amendments/supplements/revisions thereto.

PETRONAS STANDARDS
Definition of temperature, pressure and toxicity levels PTS 01.00.01.30
Welding of metals (amendments/supplements to PTS 30.10.60.18
API RP 582)
Manufacturing report for pressure vessels PTS 31.22.10.35
Piping - general requirements PTS 31.38.01.11
Field inspection prior to commissioning of mechanical PTS 61.10.08.11
equipment
AMERICAN STANDARDS
ASME Boiler and Pressure Vessel Code:
Rules for construction of pressure vessels ASME VIII
Factory-made wrought buttwelding fittings ASME B16.9
Buttwelding ends ASME B16.25
Process piping ASME B31.3
Issued by:
American Society of Mechanical Engineers
ASME International
Three Park Avenue, M/S 10E
New York, NY 10016
USA

Standard test method for indentation hardness of metallic ASTM E 110

materials by portable hardness testers
Issued by:
American Society for Testing and Materials
100 Barr Harbor Drive, West Conshohocken,
PA 19428-2959
USA

EUROPEAN STANDARDS
Destructive tests on welds in metallic materials. Hardness EN 1043-1
testing. Hardness test on arc welded joints
Issued by:
Comité Européen de Normalisation
Rue de Stassart 36
B-1050 Brussels, Belgium
Copies can also be obtained from national standards organizations

INTERNATIONAL STANDARDS
Steel and steel products - Inspection documents ISO 10474
Issued by:
International Organisation for Standardisation
1, Rue de Varembé
1211 Geneva 20, Switzerland

Copies can also be obtained from national standards organizations

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APPENDIX 1 INSPECTION CLASSES FOR COILS

Coil material Service ASME Inspection levels in %

rating (see legend)
class
(A)
Radiography MT PT

(B), (C), (D) (E) (E)

Carbon steel, Utilities < 1500 10 10
including fine-
grain carbon Utilities ≥ 1500 100 10
steel
Very toxic service (1) All ratings 100 100
Hydrogen service (1) All ratings 100 100
Other services < 1500 10 10

≥ 1500 100 100

Ferritic low All services All ratings 100 100
alloy steel
Stainless Hydrogen service (1) All ratings 100 100
steels(2)
Very toxic service (1) All ratings 100 100
Other services < 600 10 10
Other services ≥ 600 100 100
NOTE: (1) "Hydrogen service" and "very toxic" are defined in (1.3.2)
(2) The ferrite number of austenitic stainless steel welds shall be measured in accordance with PTS 30.10.60.18.

Legend:

(A) The indicated percentage of welds to be inspected shall apply to all welders involved
(B) Ultrasonic examination may be applied instead of radiography if:
(i) the configuration precludes radiography
and (ii) pipe diameter > DN 100
and (iii) nominal wall thickness >10 mm

(C) Branch connections, including small nipples, shall be radiographed unless waived by the Principal

(D) Film quality requirements:

Fine grain film (Class II) for x-ray
Ultrafine grain film (Class I) for gamma ray

(E) MT = magnetic particle examination

PT = liquid penetrant examination