Chapter 10.

Piping Work
11. GAS piping work

11.1 Application scope

These specifications shall be applicable to the gas piping work like Blast Furnace Gas, Coke Oven Gas,

Linz Donawitz Gas, Finex Oven Gas, etc.

11.2 Preparation for work

(1) Inspection of gas pipes

Control Items Construction and Inspection Standards Inspection by the

Supervisor
A Centering test on Should not exceed 1/4 of pipe thickness Visual inspection
the lengthwise joint

B Centering test on Visual inspection

the Cylindrical Joint

C Roundness (Outer diameter of pipe - Nominal outer Tape measure

tolerance diameter of pipe)
< () Nominal outer diameter x 0.0015

* Check roundness twice.

D Length tolerance Length tolerance < () 50(mm) Tape measure

(-) 0 (mm)

E. FLANGE * Number of bolt holes related to pipe diameter See section on Flange in
gas pipe materials.

350mm - 1,500mm: 25 S Visual inspection;

if defective, do machining
1,800mm - 4,500mm: 50 S (W) on flange

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 Chapter 10. Piping Work

(2) Grooving

(1) GROOVING UPPER LIMIT GAUGE

ANGLE
CHECK
(Manufacturing
Upper limit
Gauge and
lower limit
gauge) LOWER LIMIT GAUGE

(see section on Grooving procedure)

TAPE MEASURE

(See section on Grooving procedure)

A. If the thickness of the bent pipes with large diameter and water-sealed valves is 8mm or more, perform

internal gouging.

B. Use carbon rod (8 mm) for gouging.

(3) Installing gas pipes

A. Assembling straight pipes

(A)

-- Weld line
Weld and connect on site

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 Chapter 10. Piping Work

(B)

Weld and connect on site

Note: (a) Assemble pipes such that the overlapped weld lines maintain an angle of 180 (indicated as T-

cross); assuming the lengthwise weld line is in the opposite direction.

(b) Perform 100% ray tests and repair the weak points (T-cross) due to welding stress and

defective bead.

B. Assembling bent pipes

(a) The angle error of piping shall not exceed 0.5.

Straight pipe

Ground welding

C. Installing flanges

Flange Bolt welding order

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 Chapter 10. Piping Work
(a) Weld the inner side of part A and outer side of part B.

(b) Turn the pipe and weld the outer side of part A and inner side of part B

(weld in a flat position).

D After assembling the gas pipes, check the straightness.

Item Standard

Measuring Check 2 points on each straight pipe

method
Measure the piano wire at an angle of 90 Piano wire

Reference value Pipe length (L) Tolerance Remarks

per pipe length
6M or less 9 mm The reference value shall be the
9M or less 12 mm deviation between the piano wire
15M or less 15 mm and pipe: Length (L) x 1.5 (mm/M)
or less tolerance

Example of In case the pipe length is 8.5(M)?

application 1) 8.5x1.5=12.8mm
2) Tolerance of not more than 9m:
12mm - Reference value

* Weld

- Bead thickness Visual inspection

Tape measure

- Number of bead Check the number of

* If T < 6mm, weld 2 or more
welding work.
outer layers.

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 Chapter 10. Piping Work

(4) General

A. Change or add gas in the presence of the Supervisor dispatched from OWNER. Drain gas sufficiently

and perform work as approved by the Supervisor.

B. In case of modifying construction, cutting the pipes with gas may cause fire due to the naphthalene

remaining inside the pipe. Work shall be performed, and safety measures, taken as instructed by the

Supervisor dispatched from OWNER.

C. Unless specifically designated otherwise, use the following flanges and packing Apply sealing agent to all

packing used.

GAS Applicable
FLANGE Pipe Diameter Shape and Size of Packing
PRESSURE Place
Low pressure Outdoor and Black 100A ASBESTOS FREE SHEET PACKING/3.0mm
indoor with 200A "
good 300A ASBESTOS FREE ROUND BRAIDED
ventilation ID 600 PACKING/3.0mm
ID 1000 "
ID 1200 "
ID 2500 "
"
Medium Outdoor and Single- Indoor with poor ventilation and outdoor vulnerable
pressure indoor side to explosion due to gas leak.
cutting Use VALQUA for packing or its equivalent

High Indoor and Single- Water column more than 0.2 Kg/M VALQUA, or its equivalent
pressure Outdoor side at normal pressure
cutting More than min. of 0.5 Kg/
at normal pressure

D. If small-caliber gas pipes are installed horizontally, allow a slope of approximately 1/200-1/400 to

facilitate the flow of drain unless there are other special specifications.

E. Install the branch pipes from the top of the pipe and the drain from the bottom of the pipe.

(5) Air tightness tests

A. Use the following meters to select gauge for measuring pressure.

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 Chapter 10. Piping Work

Test Pressure Measuring Gauge

Up to O. 1 Kg/ Water column Manometer

Up to 1.5 Kg/ Mercury manometer
More than 1.5 Kg/ Low-pressure BOURDON

(If the test takes a long time (more than 8 hours), it is desirable to use a magnetic recording probe)

B. Check the temperature every hour.

C. Avoid the time when the temperature changes drastically for tests.

D. Close all terminal valves with dummy plates or plugs.

E. Prior to conducting airtightness tests, perform adequate soap water tests on joints and valve slide parts

or blind parts.

F. Since the pressure inside the pipe changes at the initial stage, wait until the pressure stabilizes before

checking the pressure duration.

G. Below are the airtightness test time and test pressure:

Pipe Diameter Pipe Length Duration(hr) Test Pressure

50 ~ 250 mm Max. of 100 M 1

Min. of 100 M 1.5 Normal pressure
250 ~ 800 mm Max. of 100 M 2 x 1.1 times
Min. of 100 M 3
800 ~ 1500mm Max. of 100 M 4
Min. of 100 M 6
Min. of 1,500 mm Max. of 100 M 8
Min. of 100 M 24

(6) Pressure tests

A. Selecting pressure test gauges

Test Pressure GAUGE

Up to 0.1 Kg / Water pressure manometer

Up to 1.5 Kg / Mercury Manometer
Min. of 1.5 Kg / Pressure gauge

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 Chapter 10. Piping Work
B. Test duration and test pressure (by pipe diameter and length)

Pipe Diameter Pipe Length Duration(hr) Test Pressure

50-250MM Max. of 100M 1 Test at normal

Min. of 1.5 pressure x 1.5
times
or more
250-800MM Max. of 100M 2

Min. of 3

800-1,500MM Max. of 100M 4

Min. of 6
Min. of Max. of 100M 8
1,500MM Min. of 24

C. Formula for testing the residual pressure rate

Item Residual Rate (%) Example of Application

Formula Inside the gas pipe, initial temperature of N: 17

(273 + t 1 )(P a2 + P 2 2PW 2 )
final temperature: 16.5
(273 + t 2 )(P a1 + P 1 2PW 1 )
initial pressure: 3,000mmAq
= Rate of remainder final pressure: 2,795mmAq
t: Average temperature of Ninside What is the residual rate under this condition?
the pipe ()

Pa: Atmospheric pressure (mmAq) = 95.4% (PW may be ignored)

P: Npressure inside the pipe (mmAq)

Relative humidity of N inside the gas
pipe
PW: Saturated steam pressure at t

Suffix : 1. Initial measured value

2. Final measured value

Acceptance After taking the temperature and pressure, a gas residual rate of 95% or more shall be
criteria considered satisfactory.

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 Chapter 10. Piping Work

(7) GAS PIPE

A. Specifications and dimension for gas pipe, bend, flange for gas pipe, water seal valve and others shall be

accordance with POSCO E&C standard drawings.

Refer to POSCO E&C standard drawings.

B. Specifications based on the nominal diameter of bent pipes

Refer to POSCO E&C standard drawings.

C. Maximum operating pressure and pressure for the water pressure test

Maximum Operating Pressure Pressure for the Water Pressure Test

Nominal Diameter
(Kg/) (Kg/)

200 ~ 2,000 1 Normal pressure x 1.5 times

2,000 ~ 2,800 0.5 Normal pressure x 1.5 times

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 Chapter 10. Piping Work

(8) FLANGE

A. Quality of materials used according to the operating temperature

Temperature -200 ~ -20 -20 ~ 350 350 ~ 450 450 ~ 600

Material quality STS304 SS400 SF45, F-12 F - 12

B. Refer to POSCO E&C standard drawings for specification and dimension for flange

h drill n each

(9) VALVE

A BUTTERFLY VALVE

(a) Types

Gas
direction

(Open type) (13 closed type) (Back-sheet type) (Fully closed type)

(b) Specifications for closed valves based on the nominal diameter

h drill n each

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 Chapter 10. Piping Work

Nominal FLANGE LEVER Weight (Kg)

Diameter L T W H t
D C h n e f I SS FC
(d) FC SS
80 100 10 6 125 15 13 185 150 18 8 15.5 13 150 0.53 7.0
90 100 10 6 130 15 13 195 160 18 8 15.5 13 150 0.58 7.5
100 100 10 6 135 15 13 210 175 18 8 15.5 13 150 0.64 8.2
125 150 10 8 155 18 13 250 210 21 8 15.5 13 180 1.24 14.0
175 150 10 8 172 18 13 280 240 21 8 15.5 13 180 1.76 16.0
200 200 10 8 215 18 13 336 270 18 8 22.5 17 250 3.48 24.3
250 200 12 8 240 20 16 386 325 18 12 22.5 17 250 4.84 32.3
300 200 15 8 300 20 16 436 375 18 12 22.5 17 270 6.29 42.3
350 200 15 10 325 22 16 489 445 21 12 28.5 24 300 13.71 53.4
400 200 15 10 365 22 16 539 485 21 16 33.5 25 300 18.49 58.5
450 200 15 15 410 25 19 609 550 21 16 43.5 33 350 32.69 75.9
500 200 20 15 450 25 19 659 600 21 20 43.5 33 350 38.31 96.9
600 200 20 15 500 28 19 759 700 21 20 43.5 33 400 50.87 118.9
700 250 20 20 580 28 19 859 800 21 24 53.5 41 450 92.15 156.5
800 250 20 20 660 28 22 959 900 21 24 53.5 41 500 115.1 176.5
4

(c) Specifications for closed valves based on the nominal diameter

Weight (Kg) Weight (Kg) Manufacturing

Manufacturing
Drawing
SF BC Drawing Number SF BC
Number
0.84 0.16 0.71 0.45
0.87 0.16 1.14 0.86
0.89 0.16 1.14 0.86

0.99 0.16 1.14 0.86

1.06 0.16 1.94 1.31
1.88 0.19 1.94 1.31

1.88 0.19
2.23 0.19
0.51 0.33

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 Chapter 10. Piping Work
B. NK - VALVE

(a) Features

Blocks gas flow completely without any leak

Danger resulting from the unexpected discharge of toxic gas is easily eliminated, thereby

making leak prevention easy as well as facilitating the discharging of gas into the atmosphere

and performance of water-sealing work.

Fully closed Half open/closed Fully open/closed

(10) EXPANSION JOINT

A. Material quality per component based on the operating temperature
T ()
-200 ~ 20 20 ~ 350 350 ~ 450 450 ~ 600
components
FLANGE STS 304 SS400,S25C,SF440 SF440, F - 12 F - 12
PIPE STS 304 SPP,SS400,SPPS38 SPPS38, SB400 STS304, STS321
STAY BOLT STS 304 SS400 SB400, F - 12 F - 12
BELLOWS STS 304 STS 304, STS 316 STS304, STS316 STS321, STS316L
CONTROL RING STS 304 SC 360, AC-7A SC-37, SS 400 F - 12
GUIDE BOLT STS 304, AC-7A S20C - S35C SCm - 3 STS304, SCm-3
NUT STS 304 S20C - S35C SCm - 3 STS304, SCm-3
SLEEVE STS 304 STS304, SS400 STS 304 STS 321

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 Chapter 10. Piping Work
B. Specifications

D L A F TIE ROD
Nominal FLANGE Weight
Max. Appro BOLT
Diameter
ximat Qua
(d) D C T h n S STS SS
e ntity
80 80 450 270 1.6 185 150 18 18 8 W 5/8 4 0.56 12.9
90 93 450 280 2.0 195 160 18 18 8 W 5/8 4 0.89 13.8
100 105 450 290 2.0 210 175 18 18 8 W 5/8 4 0.98 15.3
125 130 450 330 2.0 250 210 20 21 8 W 5/8 4 1.24 19.5
150 155 450 380 2.0 280 240 22 21 8 W 3/4 4 1.64 22.6
200 200 450 430 3.2 335 270 16 18 8 W 3/4 4 3.42 26.4
250 250 450 490 3.2 385 325 16 18 12 W 7/8 4 4.24 39.5
300 300 450 540 3.2 435 375 16 18 12 W 7/8 4 4.50 54.8
350 350 600 600 4.0 490 445 16 21 12 W 7/8 4 6.25 63.0
400 400 600 660 4.0 540 485 16 21 16 W 1 4 9.26 71.3
450 450 600 730 4.0 610 550 19 21 16 W 1 4 14.1 106
500 500 600 780 4.8 660 600 19 21 20 W 1 5 17.2 119
600 600 600 900 4.8 760 700 19 21 20 W 11/4 5 23.2 150
700 700 600 1,000 6.4 859 800 19 21 24 W 11/4 6 28.9 168
800 800 600 1,150 6.4 959 900 22 21 24 W 11/4 6 38.1 207
1,000 1,000 600 1,350 7.2 1,162 1,100 22 21 32 W 11/4 8 61.8 263
1,200 1,200 600 1,550 7.2 1,362 1,300 22 21 36 W 11/4 9 79.3 314
1,500 1,500 600 1,850 7.2 1,662 1,600 22 21 48 W 13/8 10 97.2 390

1,800 1,800 600 2,200 7.2 1,992 1,920 25 24 60 W 13/8 10 117 557
2,000 2,000 600 2,400 8.0 2,196 2,120 25 24 64 W 13/8 12 156 647
2,200 2,200 600 2,600 8.0 2,396 2,320 25 24 64 W 13/8 12 168 757

2,500 2,500 600 2,900 8.0 2,696 2,620 25 24 83 W 13/8 14 196 759
2,800 2,800 600 3,200 8.03 2,996 2,920 25 24 80 W 13/8 16 236 860
3,000 3,000 600 3,450 8.0 3,220 3,140 28 28 88 W 13/8 16 266 1140

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 Chapter 10. Piping Work

(11) Water-sealed valves (WSV)

A. Refer to POSCO E&C standard drawings for specification and dimension for water seal valve.

(12) Explosion proof valves

A. Classification based on the nominal diameter of piping

Nominal Unit Weight (Kg)

Diameter Type Remarks
(mm) FC SS

300 ~ 600 A type 21.22 49.5

Maximum operating pressure of 0.15Kg/Cm
Pressure at explosion (0.2Kg/Cm)
Min. of 600 B type 21.22 111.2

<A type>

<B type>

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 Chapter 10. Piping Work

(13) SEAL POT

A. Refer to POSCO E&C standard drawings for specification and dimension for seal port

A type

Closed type

B type

# 1. Specifications for the closed seal pot

Pipe
Weight (Kg/)
Nominal Specifications
D T L Remarks
Number P1 P2 P3 SS SGP FC BC

#1 350 4.5 600 25A 80A 25A 87.0 1.5 5.5 0.04 2Kg/

#2 350 4.5 600 50A 80A 25A 88.1 1.9 5.5 0.04

#3 350 4.5 600 80A 80A 25A 96.2 2.1 5.5 0.04

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 Chapter 10. Piping Work
12. Oxygen piping

12.1 General

(1) These specifications are applicable to the piping for 100% dry oxygen with purity of more than 99.6%.

(2) Perform work based on high-pressure gas handling methods and high-pressure piping standard

established by Japans Ministry of Trade and Industry (established by the high-pressure gas

association).

12.2 Specifications for piping materials

Specifications Remarks

Straight pipe * For pressure pipe, use carbon steel pipe. Control valve,
- Maximum 300A : Seamless Flow meter erection territory
- More than 350A : ERW
* Straight length of pipe ahead and behind of orifice
shall be determined by orifice maker specification.
Bent pipes * Same material as for regular pipes; as a rule, min. BEND ANGLE: Max. of 60
of 1.5D BRANCH ANGLE: 45 ~ 60
- Maximum 300A : Seamless SHORTAGE ELBOW
-More than 350A : Seamless
VALVE * VALVE body: SCS13 or SCPH2 JIS 30 Kg/
* Waist part: STS 304
* VALVE SEAT: STELLITE
* Materials for valve stem : STS304
** Control valve (PCV, FCV)
- Body : SCS13
- Trim : monel(gage, plug, seat, stem)
FLANGE SS400, SC40, S25C, STS304

PACKING * Metallic packing STS (Tombow 1834R or its Oil less gasket
equivalent) or copper packing (non-combustible material)
* Gland packing: Teflon (non-combustible material)

FIRE * Adjust Fire Breaker every branch pipe that came

BREAKER into unit plant with de-Oxidize cupper pipe or STS
Welding rod * JIS D4031, D4303 (between steel pipes) Refer to WPS
* MCU, MG 990, or its equivalent
(between steel pipe and copper pipe)
* JIS - D 309 (between steel pipe and STS)
JIS - D 308 L
* JIS - D 309 (between STS)
JIS - D 308 L

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 Chapter 10. Piping Work

12.3 Procedure for oxygen piping

(1) Procedure for installing pipes after machining

(Case 1.)

Pre-installation pipe Pickling Piping erection

PT/RT

Nor oiless dry air GAS filling (0.02Kg/)

LEAK TEST Flushing inspection Flushing PRESSURE TEST

(Operating With copper or (Oil-less dry (operating pressure
Pressure X 1.1) aluminum plate) air or N) 1.5 times)
Holding time Holding time 20min

NITROGEN Oxygen filling

PURGE
(5 Kg/)

(Case 2.)

PRESSURE TEST
Piping PT/RT Pigging (operating pressure1.5)
installation (for oxygen) Holding time: 20min

LEAK TEST Flushing inspection

FLUSHING
(Operating pressure x 1.1) With copper or aluminum
Holding time: 12hr (Oil less Dry Air or N)
plate)

NITROGEN PURGE Nitrogen Injection

(5 kg/)

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 Chapter 10. Piping Work

(2) Machining

Pipe grinding and beveling

Steel wire handle

Beveling
Cutting section
Grinding
Pure cotton plug

* Prior to starting work, cover the opening with clean pure cotton plug to suppress completely the

dispersed scale due to grinding and beveling. Once work is completed, remove the scale and dust and

clean the area surrounding the pure cotton plug with proper chemical product.

(3) Welding

Perform argon welding for 1 pass or 1/3 of total pass (use TIG welding machine)

AC arc welding may also be used for 2 passes or more

The purpose of injecting N (99.6% purity) and argon (99.999% purity) is to change the air inside the
pipe to prevent oxidization during welding; hence the good back bead and absence of adhering welding

scale.

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