STANDARD

1. INTRODUCTION
The Manufacturing Instructions of Stainless Steel Piping apply to pipe materials delivery up to requirements
for pre-treatment, constructions, installation and finishing. Current instructions should be seen in correlation
with HMESC 74.00.02.010 – Pickling & Passivating of Stainless Steel Piping and the RFQ Piping Sytems.

2. DELIVERY OF PIPING COMPONENTS.

2.1 MATERIALS
Applicable pipe and components material can be found in the Pipe Specs in the RFQ / Order Spec Piping
Systems.

3. WELDING BASIC REQUIREMENTS

• Welding of SS materials shall be done not being effected by Carbon Steel materials /parts.

• During tag welding and welding the inside of the welds shall be purged with backing gas (Argon or N2
with 3.5 % H2 addition at the option of the Contractor) to minimise scaling and oxidation. Required
purity shall be sufficient to ensure that the requirements for heat tinting can be achieved .

4. WELDING PROCEDURES

4.1 QUALITY PRINCIPLES

• The Contractor avoids mistakes, quality dips and any unnecessary rework by preparing the welding
works carefully into qualified welding;

• The Contractor should conduct entrance control on pipe materials regarding the right material, the
right piping series, the right dimensioning, any deformation and shall act adequately in case deviations
and /or deformations in delivery take place.

• The Contractor is responsible for the welding quality. Any extra cost for rework and/or Pickling and
Passivating is on their account. Or else mentioned in the Order Specs.

4.2 WELDING PROCEDURE QUALIFICATION

• Welding Procedure Specification (WPS) is a document prepared by the Contractor for each weld or
group of welds presenting detailed instructions to the welders and welding machine operators on how
to perform the production welding of piping. The site works shall be well organised and coordinated.

• Each WPS shall be supported by valid qualification tests. The results of these qualification tests shall
be laid down in a detailed Welding Procedure Qualification Records (WPQR) written and signed by
the Notified Body. When the test results meet the requirements, the weld procedure is qualified.

4.3 WELDING TEAM QUALIFICATION

• Prior to the start of the work on the construction site the contractor shall name a responsible person
with whom any welding problems occurring can be discussed (Welding Coordinator).

• All welding procedures used shall be qualified in accordance with European Standard EN 15607. The
procedures shall be submitted for approval prior to the start of construction.

• All welders must be qualified for manual and/or automatic machine.

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• Each welder who is not qualified shall make welding tests, prior to construction work (and pre-
assembly) and ditto when welders are being changed. The test weld to be made is a pipe to pipe joint
in one nominal diameter in the H-L045 (G6) position. A Notified Body must witness this test.

• If the welder fails the test, 2 additional tests may to be made. If one of these additional tests does not
meet the requirements, the welder is not qualified and is not engaged in piping work for this contract.

• Each contracted welder shall be subject for individual assessment following the visual and endoscope
weld inspection pattern.
 As reference for required heat tint level of internal surface is used: Force Institute Color Chart 1 or
2. The heat tint level shall be between A and D (no significant heat discoloration) of the chart.
 Unacceptable results from 100 % radiography
 Misalignment of circumferential seams h: maximum 15 % of the nominal wall thickness of the
pipe. Higher misalignments shall be communicated with Construction Management.

5. WELD INSPECTION
5.1 INSPECTION
• During construction both in the shop and on site, when the welding is on going, the welds shall be
inspected externally (visual) and internally (endoscope) to the amount indicated in this paragraph.

• This inspection will be done by the Contractor, Construction Management or an external party (Notified
Body).

• All welds will be 100% visually inspected externally, in accordance with NEN-EN 13018
• Endoscope inspection must be done according EN ISO 5817 For the required quality level per media
see the Selection Table in the RFQ / Order Spec.

• The first 20 welds made by a Welder shall be inspected internally with an endoscope. In case no more
than two welds show unacceptable defects this may be reduced to 10 welds inspection at random for
this Welder.

• When the inspection frequency is 10 welds and more than 5% of the welds have unacceptable
defects, then 10 welds made previously and 10 welds made in subsequent welding will be inspected.
If this inspection indicates that < 5 % show defects, the inspection rate can be reduced to 10 welds
again.

• Contractor records endoscope Inspection results on digital retraceable medium. In case of doubts on
results during inspection of the inside of the welds other inspection methods can be demanded.

5.2 ACCEPTANCE CRITERIA OF ENDOSCOPE INSPECTION

For endoscope inspection the Quality acceptance in accordance with EN 13018 and the additional
exclusions listed below are applicable:

• Root concavity is not acceptable;

• Gas holes or porosity are not acceptable;

• Unacceptable results from endoscope verification with picture of the heat tint level;
As reference for required heat tint level of internal surface is used: Force Institute Color Chart 1 or
2. The heat tint level shall be between A and D (no significant heat discoloration) of the chart.
Figure 2 of the AWS D18.1 is the discoloration reference in case the AWS D18.1 AWS D8.2
welding instructions are followed with the same tint level requirements.

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• Misalignment for circumferential seams h may be maximal 15 % of the nominal wall thickness,
whereas higher misalignments should be communicated with Construction Management;

• Reinforcement higher than 15 % of the nominal wall thickness;

In cases of doubt the Inspector or the Construction Management may require additional non-destructive
inspections such as dye penetrate testing, radiography or measurement of the δ-ferrite content in
accordance with EN 473 (required same range as in WPQR).

If rejected welds are found during the additional inspections, the inspection and repair costs will be at the
expense of the Contractor.
5.3 INSPECTION NOTIFICATION
Contractor or Welding Coordinator notifies Construction Management or Delegated Inspection Agency and
Contractor’s Notified Body timely on inspection events not being bothered by:
 Restrictions and occupation of the endoscope(s);
 Unreachability of the internal side of welds in long and /or complex piping systems.

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5.4 DOCUMENTATION OF ENDOSCOPE INSPECTION

Endoscope inspection shall be documented with digital pictures taken through the endoscope.

• The pictures shall be recorded on CDROM or agreed comparable traceable medium;

• The contractor shall keep a log of weld numbers, welder identification and findings of the inspection, in
such a way that these results are traceable and the applicable image can be located;

• The CDROM or alike with the images and recorded log are part of the Contract and subsequently part
of the inspection documentation.
5.5 WELDING DRAWINGS
The Contractor shall update engineering drawings on welding information, taking into account:

• The weld numbers shall be unique for each weld;

• The weld location, its dimension as well as the weld number and welder’s unique identification shall be
registered on Piping Arrangement Drawings and Isometrics;

• The engineering drawings are to be kept to the latest status in all cases, finally resulting in the
handing-over of as-built drawings at Plant Handing-over.
5.6 REPAIR OF REJECTED WELDS
Welds not meeting the requirements as per par 7.4 /8.1 shall be repaired, whereas:

• The Contractor must repair free of charge all

• The removal of weld metal or portions of the base metal may be done by machining or grinding.

• The unacceptable portions of the weld shall be removed without substantial removal of the base metal.
This shall be done in such a way that the remaining weld or base metal is not nicked or undercut.

• The grooves shall be free from scale, shall have acceptable contours and be visually and dyes
penetrate inspected prior to rewelding to ensure the defect has been completely removed.

• When cutting out rejected welds in the piping, particular care is required to prevent sawing dust or
sparks from entering the existing system. If it is not possible to avoid this, the dust shall be removed by
blowing through dry compressed air.

• Qualified welders according to approved welding procedures shall execute all repairs.

• The Contractor shall report all repair work to the Construction Management or Delegated Inspection
Agency.

• Every possible care shall be taken with repairs to minimize welding stresses.

• Repair of manual welds. A manual weld with unacceptable defects may only be repaired once at the
same location. If the repair is not acceptable the complete weld shall be
removed and rewelded.

• Repair of orbital welds Rejected orbital welds shall be completely removed and re-welded, with the
exception of welds that have incomplete penetration. Local repair of orbital
welds usually results in inferior quality welds.

Orbital welds with incomplete penetration may be repaired (re-melted) once,

using the special procedure qualified for this purpose.

• Local repairs shall normally be inspected 100 % by the method prescribed for the original weld or by
other inspection method with due regard to confirming that the original defect has been removed.

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6. MOUNTING
6.1 PRE-ASSEMBLY
Tools: Tools may not be made of Carbon Steel.

Air filter: To avoid the welding material being contaminated by C steel particles a filter (< 200 µm)
must be installed between pressure reducer and welding set.

Piping: Pipes shall be cut with machine saws or saws with the blade circulating round the pipe
without cooling and lubricating agents. Grinding discs and thermal cutting are not allowed;

After sawing, the pipe ends shall be de-burred and thoroughly cleaned. Dry, oil-free and
clean compressed air shall be used to blow metal dust out of the piping;

Each cut pipe part shall be marked with the Charge Number of its source pipe.

Pre-assembled and cleaned piping components shall be closed with plastic caps, to
prevent the ingress of dirt and also to properly protect the weld edges. Adhesive tapes
shall not be used here (fouling by adhesive tape material).

Accessories: The welding ends of the accessories shall be pre-machined to meet the piping tolerances;

Before installation the accessories shall be inspected for damage, plane welding ends,
cleanliness and identification-numbers;

The top sections of welding-end accessories could be required to be dismantled so their

internals are not damaged. It is Contractor’s responsibility to check this subject for all in
line components (including in line instruments).
6.2 INTERMEDIATE TRANSPORT
• After pre-assembly is finished the work will be inspected by Notified Body.

• The pre-assembled components will be transported to the installation site in such a way that dirt, wet
or mechanical damage is avoided;

• In no way Stainless Carbon Steel materials may be come into contact with Carbon Steel Materials;
6.3 INSTALLATION
Precautions: Carbon Steel materials should be stored strictly separated from Stainless Steel materials
and also therefore Stainless and Carbon Steel piping should not be installed at the same
time. In all cases they are to be separated by sheeting walls or similar partition walls.

Routing: The piping shall be routed in correspondence with its design. The Contractor or Welding
Coordinator should take in account the routing of surrounding piping – existing or in
design – to avoid interference clashes and to block future pipe routes.

Communication: Regularly consults during installation is required for the various piping Contractors and
Construction Management to avoid mistakes, quality dips, future restrictions and rework.

Aligning: The ends of the piping and/or fittings must be carefully and stress free or indicated cold
spring aligned so that offsets or faulty fittings are kept as low as possible.

Tack welds: After tacking the alignment shall be checked again. Tacking is only permitted on the outer
surface of the pipe. After tacking the alignment is rechecked.

Screwing: Parts within not sanitary PN10-pressure piping class may be executed screwed when this
is more appropriate than welding. Screwing requires a proper and sustained sealing.

Field welds: During installation attention shall be paid that dirt does not enter the piping and that tools
do not damage the outer surface of the pipes. (Use of aluminium clamping jaws, contact
between clamp and pipe surface being prevented by PTFE intermediate layers.)

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7. TESTING
7.1 NOTIFICATION
• Pressure /leakage testing and all associated activities incl. safety, forms integral part of the contract.

• After finalising the installation of the piping, the Contractor shall notify the Construction Management
and the Notified Body that piping is ready for Pressure /Leakage Testing.

• Using the flow diagrams the piping will be split into test loops for the tests in accordance with
paragraph 10.2 and isolated with blind flanges. "Test System Flow Diagrams" will be prepared in
which the test medium and test pressure will be entered as an addition to the test loop.

• In any case prior to pressure /leakage testing Contractor shall be aware of the basic piping treatments
to follow i.e. degreasing, water flushing and pickling & passivating, also in case the latter activity is
covered by other Contract. Activities could be harmonised to avoid redundancy and any corrosion.

• In each contract it must be stated if substitute gaskets will be used during installation and then
replaced by the original ones after finishing activity.
7.2 PRESSURE /LEAKAGE TEST
• All testing shall be carried out by the Contractor and witnessed by Contractor’s Notified Body and
Construction Management or Delegated Inspection Agency;

• All pressure/leakage testing shall be conducted with water not being aggressive (low chloride content);

• Pressure testing shall be done in accordance with ASME B31.3;

• Leakage testing shall be done with water at piping design pressure.

8. PIPING FINISHING
When the pressure /leakage tests are concluded, the piping systems shall be further finished internally and
externally. Especially the internal finishing activities require a proper harmonisation and planning.
8.1 INTERNAL FINISHING APPLICATION FIELDS
The table below indicates Internal Finishing Application Fields to follow; see also § 11.2 and § 11.3.

Piping Application Field Treatm_1 Treatm_2 Treatm_3 Treatm_4 Reason

Fresh water and,
General Degrease Water flush Air flush P&P Corrosion; infection
(not) treated water
Brewing Warm brew water Degrease Water flush Air flush P&P Corrosion; infection
Hot wort piping Degrease Water flush Air flush P&P Corrosion; infection
Cold product piping Degrease Water flush Air flush P&P Corrosion; infection
Hot CIP piping Degrease Water flush Air flush P&P Corrosion; infection
Cellars Cold product piping Degrease Water flush Air flush P&P Corrosion; infection
Hot CIP piping Degrease Water flush Air flush P&P Corrosion; infection
Cold CIP piping Degrease Water flush Air flush P&P Corrosion; infection
CO2 Degrease Water flush Air flush Contamination; infection
Utilities Glycol Degrease Water flush Air flush Dust; dirt; mech. damages
Air Degrease Water flush Air flush Contamination; infection
Brewing Mash piping Degrease Water flush Air flush Contamination

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8.2 DEGREASING
All Piping Application Fields require being degreased and being flushed with water afterwards. The water
should be removed completely and blowing through dry air shall clean and dehydrate the piping systems.
Be aware for in any case a part of the Application Fields, that this is the last internal finishing action.

• For degreasing an industrial cleaning chemical is used, so that all dust and soil from manufacturing is
removed. To finish this cleaning the surface shall be flushed with water to remove soil and to neutralise
the pipe surface;

• Degreasing shall be done using an alkaline solution with detergents. The solution should be able to
remove all grease, oil and fat that is present on the internal piping surface;

• After degreasing flushing the stainless steel with water until the solvent has disappeared, i.e. when no
more foam is produced (or to be determined otherwise);

• All water flushing shall be conducted with water not being aggressive (low chloride content);

• After degreasing is complete, the surface shall be visually inspected for cleanliness. In case of doubt the
manufacturer /contractor may be requested to test the absence of contamination.
8.3 PICKLING & PASSIVATING
• When welds are successfully tested in accordance with paragraph 8.1, the Pickling & Passivating of
the SS piping is not required. Otherwise it should be done to be indicated by Installation Manager;

• When Piping Application Fields require to be treated by Pickling & Passivating this should be done in
accordance with HMESC 74.00.02.010 – Piping Pickling & Passivating;

• The Piping Contract covers all internal Pre & Finishing Treatments, including those from HMESC
74.00.02.010. The Contractor shall be aware of that. In case of disagreements from Contractor’s side
this should be raised during Order negotiations and mutually agreed upon alternative implementations;

• Mind the mash piping in Brewhouse, Pickling & Passivating is not needed anyhow;

• Any Pickling & Passivating should be conducted directly after degreasing treatment to avoid corrosion;

• Each contract shall clarify in advance whether gaskets used during construction, testing, degreasing
and /or Pickling & Passivating will be replaced by the original ones after final finishing treatment.
8.4 EXTERNAL FINISHING APPLICATION FIELDS
The table below indicates External Finishing Application Fields to follow; see also HMESC 83.86.00.000.

Insulation >> Mineral Wool PIR /PUR Foam Glass Synthetic Rubber
References >> HMESC 83.86.00.601 HMESC 83.86.00.602 HMESC 83.86.00.603 HMESC 83.86.00.605

Two layers Two layers

1 Sigmarite Sealer Sigmarite Sealer
Pre-treatment >> N/A ) N/A
DTF 150 µm DTF 150 µm
Sigma 7420 Sigma 7420
1
) Given a well-mounted insulation system, preventing water coming into contact with the pipe material.

• The external finishing could be covered by another Contract. Anyhow the Piping Contractor should be
aware of the requirements for external finishing as cooperating or as responsible Contractor.

• The table above reflects the minimal requirements. By project decision requirements can be added.

• The blank parts of Pre-insulated piping for elbows and tie-ins require being pre-treated according to
the table above, unless the Pre-insulation Supplier gives guarantees on not to do so.

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9. FINAL INSPECTION
Inspection scope:
• Compliance with scope of supply
• Welding procedures and workmanship
• Welders qualifications
• Materials certificates
• Documentation
• Operability of valves
• Possibility for thermal expansion
• Supports

10. DOCUMENTATION
The Contractor shall submit the following documentation:
• As-built Isometrics and Piping Arrangement Drawings, including welding information;
• Bill of materials with applicable materials certificates;
• Welding Procedure Specifications, with supporting Welding Procedure Qualifications;
• CD ROM or alike containing results of the weld inspection, including pictures taken during
endoscope inspection and recorded log;..
• Result of the leakage tests / pressure tests.

11. SAFETY AT WORK

All pertinent safety regulations must be observed and followed. These include the following points but are
not limited to them:
• Compliance with Site Regulations;
• Execution of work with required permits;
• Use of correct eye and body protection;
• Sufficient ventilation;
• Presence of an adequate fire extinguisher;
• Proper grounding of all electrical installations;
• Observation of all pertinent or government regulations for safety at work.

12. WRAP-UP OF STANDARDS

Page
AWS D18.1 Specification for Welding of Austenitic SS Tube and Pipe in Sanitary Applications 2, 6
AWS D18.2 Guide to Weld Discoloration Levels on Inside of Austenitic SS Tube 2, 6
EN 10217-7 Welded SS Tubes for pressure systems 2
DIN 11850 Requirements for pipe materials DIN series 2, 3
DIN 11852 /11867 Pipe fittings 2
ISO 1127 Requirements for piping materials ISO series (not sanitary skid-mounted units) 2
EN 10204 Material Certificates 3
P.E.D. 97/23/EC Pressure Equipment Directive 3
EN 288-2 /3 Welding Procedures spec for arc welding /Welding procedure qualifications 4, 5
EN 719 Welding Supervision - Assignments and Responsibility 5
EN 287-1 Examination of Welders - Fusion Welding 5
EN 1418 Welding Personnel – Approval of testing for welding operators 5
EN ISO 5817 Guidance on quality levels for interpretation. 5, 6
EN 13018 Non-destructive Test – Visual judgment – General principles 6
EN 473 Qualification & Certification of Personnel for the Non-destructive Test - General 6
ASME B31.3 Process Piping 9

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