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General Specification 3.03 General Piping Fabrication, Inspection and Testing
General Specification 3.03 General Piping Fabrication, Inspection and Testing
03
GENERAL PIPING FABRICATION,
INSPECTION AND TESTING
PH
8/2001
MLJ
6/2000
Rev.
By
Description
Date
Rvwd
Appvd
GS 3.03
REVISION 0
AUG 2001
TABLE OF CONTENTS
1.0
INTRODUCTION
1.1
1.2
1.3
1.4
Scope
Exclusions
Responsibilities
Conflicts and Exceptions
2.0
3.0
GENERAL REQUIREMENTS
4.0
WELDING
4.1
4.2
4.3
4.4
4.5
5.0
6.0
General
Exothermic Heat Treatment
8.0
General Piping
Pipe Supports
7.0
General
Welding Processes
Welding Procedure Qualification
Welder and Welding Operator Qualification
Production Welding
General
Radiography
General
Preparation for Testing
Hydrostatic Leak Testing
Post-Test Requirements
Leak Repair and Re-testing
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9.0
PNUEMATIC TESTING
9.1
9.2
10.0
AUG 2001
General
Pneumatic Leak Testing
General
Acid Descaling (Pickling) and Passivation
Abrasive Blasting
Hot Oil Flushing
11.0
PROTECTIVE COATINGS
12.0
13.0
14.0
DOCUMENTATION REQUIREMENTS
APPENDICES
I
II
III
IV
V
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1.0
INTRODUCTION
1.1
Scope
1.1.1
1.1.2
Piping systems constructed of duplex stainless steel materials shall meet the
additional requirements specified in Appendix II "Additional Requirements for
Duplex Stainless Steel Piping."
1.1.3
1.1.4
1.1.5
Piping systems constructed API 5L Grade X-60 materials shall meet the
additional requirements specified in Appendix V "Additional Requirements for
API 5L Grade X-60 Carbon Steel Piping."
1.1.6
This specification shall also apply to the fabrication and attachment of pipe
supports.
1.2
Exclusions
This specification does not apply to process design, line sizing, or equipment
layout; nor does it apply to piping material and component selection, or to piping
design and layout. Specific exclusions include all small bore instrument tubing,
sub-sea pipelines, risers and J-tubes.
1.3
Responsibilities
CONTRACTOR shall be solely responsible for providing complete and operable
piping systems in full accordance with all applicable Industry Codes and
Standards, Government Regulations and COMPANY Technical Requirements.
1.4
1.4.1
All conflicts between this specification, the other Technical Requirements, and
the applicable codes and standards shall be submitted in writing to COMPANY
for resolution.
1.4.2
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2.0
2.1
The primary codes governing piping systems provided under this specification
shall be API Recommended Practice 14E "Design and Installation of Offshore
Production Piping Systems" and ANSI B31.3 "Chemical Plant and Petroleum
Refinery Piping."
2.2
The most recent issue of the codes and standards listed in Appendix I
"Mandatory Codes and Standards" shall be considered as a part of this
specification.
2.3
Special design allowances outlined in any of the codes and standards may not
be used without written approval of COMPANY.
2.4
3.0
GENERAL REQUIREMENTS
3.1
3.2
3.3
3.4
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3.5
The selection of pipe, piping components and valving shall be in full accordance
with the Technical Requirements, including General Specification 3.00 "Piping
Service Classifications and Material Requirements," and in particular the
appropriate Material Class Data Sheet for the intended service. Substitution of
alternate materials or components shall require prior written approval by
COMPANY.
3.6
3.7
References in this specification to ANSI Class 150, 300, 600, 900, 1500 and
2500 flange ratings refer to ANSI B16.5 "Pipe Flanges and Flanged Fittings."
References to API 3000, 5000 and 10,000 pound flange ratings refer to API 6A
"Specification for Wellhead Equipment."
3.8
All sour service hydrocarbon piping systems shall be in accordance with NACE
MR-01-75 "Sulfide Stress Cracking Resistant Metallic Material for Oil Field
Equipment."
3.9
3.10
4.0
WELDING
4.1
General
4.1.1
All welding shall be in strict accordance with ANSI B31.3 "Chemical Plant and
Petroleum Refinery Piping," the ASME "Boiler and Pressure Vessel Code" Section IX "Welding and Brazing Qualifications" and the COMPANY Technical
Requirements. The welding processes as discussed in this section shall be
acceptable for CONTRACTORs use in the fabrication of piping and pipe
supports unless otherwise noted in the Technical Requirements.
4.1.2
4.1.3
Only welders qualified in accordance with the ASME "Boiler and Pressure
Vessel Code" shall be utilized for fabrication. Welders shall have their
qualification certificates available for COMPANY review during all stages of
fabrication. If requested by COMPANY, CONTRACTOR shall submit a list of
qualified welders and the procedures for which they have been qualified.
COMPANY may, at its option, require new qualification tests for any welder
working on piping fabrication. Should the welder fail the new qualification tests,
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then CONTRACTOR shall bear all costs for the tests and the welder shall be
removed from the work. COMPANY will reimburse CONTRACTOR reasonable
costs of new qualification tests passed by the welder in question.
4.1.4
4.1.5
COMPANY shall reject any weld that has not been made properly. Defects in
welds or fabrication, including fit-up, shall not be permitted which in the opinion
of COMPANY are detrimental to the strength of the weld. All repair procedures
shall be submitted to COMPANY for approval prior to start of repair work. The
cost of preparing repair procedures and repairing defective welds shall to the
CONTRACTORs account, not the COMPANY.
4.1.6
Any weld tampered with or caulked in any way shall be condemned whether or
not it is sound. "Doctoring" the surface of defective welds with a torch shall not
be permitted under any circumstances.
4.1.7
4.2
Welding Processes
4.2.1
General
4.2.1.1
Acceptable weld processes for welding of piping and supports shall include the
following:
Flux Core-Arc Welding (FCAW)
Gas Metal-Arc Welding (GMAW)
Gas Tungsten-Arc Welding (GTAW)
Shielded Metal-Arc Welding (SMAW)
Submerged-Arc Welding (SAW).
4.2.1.2
4.2.1.3
4.2.2
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d. Self-shielded FCAW shall not be permitted for process piping, but may be
used for pipe support fabrication.
e. Low hydrogen consumables shall be certified by the electrode
CONTRACTOR, or tested by CONTRACTOR to result in less than 10 ml of
diffusible hydrogen per 100 gm of deposited weld metal. Diffusible hydrogen
content shall be measured by the mercury displacement or gas
chromatograph method per AWS A4.3. CONTRACTOR shall provide written
evidence of compliance with this requirement. The specification sheet for the
proposed brand of filler metal from the CONTRACTOR shall be acceptable
as written evidence.
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.7.1
Electrodes, wires and fluxes shall be selected to produce welds with mechanical
properties not less than those of the base metal. Filler metal for welding similar
materials shall be of the same nominal analysis as the base metal, except E347 electrodes shall be used for SMAW welding of Type 321 material. When
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welding two steels of unequal strengths, the welding wire or electrode shall be
matched to the higher strength material.
4.2.7.2
The weld filler metal in low-temperature piping service shall meet the same
impact test requirements as the base metal.
4.2.7.3
Tensile strength of deposited weld metal shall be limited to 100 ksi maximum
and shall be verified by a hardness test of the weld material in the procedure
qualification. Weld metal hardness shall not exceed 200 Brinell.
4.2.7.4
Carbon steel electrodes for welding API 5L, Grades B and X-42 pipe shall
conform to the following ASME specifications:
SMAW
GTAW/GMAW
SAW
FCAW
4.2.7.5
ASME SFA-5.1
ASME SFA-5.18
ASME SFA-5.17
ASME SFA-5.20 Classes:
E60T-1, E60T-5, E61T-1, E61T-5
E70T-1, E70T-5, E71T-1, E71T-5
Stainless steel electrodes shall be low carbon "L" grade, and shall conform to
the following ASME specifications:
SMAW
GTAW/GMAW
FCAW-g
ASME SFA-5.4
ASME SFA-5.9
ASME SFA-5.22
4.2.7.6
Filler metals for joining carbon steels to stainless steels shall be E309L, except
in services over 600F where Inco 182 shall be used. Low carbon grades of
austenitic stainless steel shall be joined with low carbon weld metal of
corresponding composition.
4.2.7.7
4.3
4.3.1
All weld procedures shall have been qualified no more than 6 years prior to the
date of the Contract, Agreement or Purchase Order as applicable. Provided that
the Welding Procedure Specifications (WPS) and Procedure Qualification
Records (PQR) are in full accordance with the Technical Requirements,
qualification of new procedures will be waived by COMPANY.
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4.3.2
4.3.3
Procedure qualifications shall include the composition and flowrate of inert gas
backing when used.
4.3.4
For low-temperature services, i.e. 34F and below, procedure qualifications for
ferritic materials shall include impact tests of both the weld metal and the heat
affected zones, even if impact tests are not required on the base material.
SMAW welds shall only require testing if impact test are required for the base
material.
4.3.5
SAW procedure qualification test records shall show the name of the
manufacturer and the trade name of the wire and flux used to qualify the
procedure.
4.3.6
The welding procedure tests shall demonstrate that all details are satisfactory
for obtaining full penetration welds for the following types of joints:
Double-welded longitudinal and circumferential butt joints
Single-welded longitudinal and circumferential butt joints made without a
backing ring.
4.3.7
4.4
4.4.1
Welders and welding operators shall have been qualified within the 6 months
prior to beginning of fabrication in accordance with the ASME "Boiler and
Pressure Vessel Code" - Section IX "Welding and Brazing Qualifications."
4.4.2
4.4.3
4.4.4
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4.4.5
Welders shall have their qualification certificates with picture identification at the
work site during all fabrication.
4.5
Production Welding
4.5.1
4.5.1.1
Surfaces to be welded shall be clean and free from all galvanizing, paint, oil,
dirt, scale, oxides or other materials detrimental to welding.
4.5.1.2
Weld bevels shall be suitable for the welding process selected and shall
conform to the bevel in the weld procedure specification. Bevel contour shall
permit complete fusion throughout the joint.
4.5.1.3
Weld bevels shall be made by machining, grinding or thermal cutting, and shall
be reasonably smooth and true. Materials that require preheat for welding shall
be preheated in the same manner for thermal cutting or gouging.
4.5.1.4
Prior to welding, all laminations, split ends and other defects shall be called to
the attention of COMPANY and shall be cropped, repaired or removed as
directed by COMPANY.
4.5.1.5
The use of backing rings, backup strips, strong backs or welded lugs shall not
be permitted.
4.5.1.6
Line-up clamps shall be used when necessary to ensure that fit-up is within
design tolerances. Line-up clamps shall not be removed until a continuous
stringer bead equal to one quarter of the circumference of the pipe has been
completed on both sides of the pipe.
4.5.1.7
4.5.1.8
4.5.1.9
4.5.1.10
If the required taper in accordance with API 14E "Design and Installation of
Offshore Production Piping Systems" would result in a trimmed wall thickness
less than the required wall thickness (tm), then CONTRACTOR shall fabricate a
transition spool. This spool shall be fabricated from material equal in grade to
the highest grade material to be welded, and shall have a wall thickness equal
to the thicker pipe or fitting to be welded. The transition spool length shall be at
least one and one half times the nominal pipe diameter, but no less than 12" in
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length. The transition spool shall be internally tapered at one end to match the
thickness of the thinner walled pipe or fitting, and beveled for welding. The taper
angle shall be approximately 4:1, but not less than 14 degrees. CONTRACTOR
shall stencil all transition spools with the pipe size, grade and wall thickness'.
4.5.2
Preheat
4.5.2.1
All welded joints shall be preheated in accordance with the approved weld
procedures. The minimum preheat temperature for thermal cutting, tacking and
welding shall be in accordance with ANSI B31.3 "Chemical Plant and Petroleum
Refinery Piping." Preheat shall be maintained during all multi-pass welding.
4.5.2.2
4.5.2.3
All API flanges shall be preheated to minimum 400F before welding. Preheat
shall be maintained throughout the welding process.
4.5.3
Welding
4.5.3.1
COMPANY shall reject any weld that has not been properly made per the
Technical Requirements. All welds shall be made in such a manner as to reduce
residual stresses.
4.5.3.2
Welding shall not be permitted at ambient temperatures less 40F when either
the wind velocity exceeds 10 mph or the relative humidity exceeds 50%.
Welding shall not be permitted in inclement weather unless both the welder and
the work are well protected from the elements.
4.5.3.3
Electrodes, filler wires and fluxes shall be kept clean, dry and properly stored
according to the manufacturer's recommendations. Electrodes, filler wire or fluxes
that are damp, greasy or oxidized shall not be used. During welding, care shall
be taken to avoid contamination of fluxes.
4.5.3.4
Low hydrogen electrodes shall be protected from moisture and used within 2
hours of breaking the seal on their original (hermetically sealed) containers. If
the container has been open for more than 2 hours, but less than 8 hours, the
electrodes shall be placed in a heating box and held at 225F for 8 hours
minimum, and then used within 2 hours of removal from the hot box. Electrodes
exposed longer than 8 hours shall be reconditioned by heating in an oven at
650 to 750F for 1 hour minimum.
4.5.3.5
Weld beads shall be contoured to permit complete fusion at the sides of the
bevel and to minimize slag inclusions. Flux and slag shall be completely
removed from weld beads, and from the surface of completed welds and
adjoining base material. The flux shall be removed in a manner that will not
contaminate or overheat the weld or adjoining base metal.
4.5.3.6
All welds shall be thoroughly cleaned after each pass by power wire brushing to
remove all slag, scale, splatter, coatings and dirt.
4.5.3.7
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4.5.3.8
Welds on branches or reinforcing pads shall merge smoothly with the surface of
the pipe. Sharp corners on reinforcing pads shall be removed.
4.5.3.9
Welding shall not be permitted on valves without prior written approval from
COMPANY.
4.5.3.10
Seal welding of threaded joints shall cover all exposed threads and blend
smoothly into the pipe. Seal welds on threaded joints shall be made as small as
possible using low penetration electrodes. Seal welds shall be tapered
gradually.
4.5.3.11
4.5.3.12
At the completion of all fabrication work, all excess weld metal, splatter, and
other foreign material shall be removed. Welds shall be wire brush cleaned to
remove slag and weld spatter. On stainless steel piping, wire brushing shall be
done only with stainless steel brushes which have not previously been used on
ferritic materials. Edges shall be smoothed or rendered flush with the parent
surface unless otherwise approved by COMPANY.
4.5.3.13
4.5.4
Weld Repairs
4.5.4.1
Defective welds shall be plainly marked, cut out and repaired or replaced by
CONTRACTOR in accordance with the procedures specified in the ASME
"Boiler and Pressure Vessel Code" - Section IX "Welding and Brazing
Qualifications." CONTRACTOR shall advise COMPANY in writing of all required
repairs prior to the start of repair work.
4.5.4.2
4.5.4.3
All unacceptable defects in the root or fill passes shall be entirely removed by
grinding or oxygen gouging to clean, sound metal. All slag and scale shall be
removed by power brushing. Preheating of an area with a defect shall be in
accordance with the original preheat requirements for the materials and type of
weld.
4.5.4.4
External undercut shall be repaired by grinding off the weld cap in the undercut
location and recapping.
4.5.4.5
Arc burn defects shall be ground smooth provided that the depth of the defect
does not exceed 8% of the nominal wall thickness. Arc burn defects with a
depth greater than 8% but less than 33-1/2% of the nominal wall thickness may
be repaired by welding. The defect shall be thoroughly removed by grinding,
then the cavity welded and ground smooth. The weld shall be preheated in
accordance with the original preheat requirements for the materials and type of
weld. Arc burns in excess of 33-1/2% of the nominal wall thickness shall be
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Welds may be cut out and repaired in one location a maximum of two times. If
the second repair is found to be defective, then a section of the pipe no less
than 2'-0" in length (including fittings) shall be removed and replaced. All new
welds in the repaired section shall be radiographed and heat treated (if originally
required) at CONTRACTORs expense.
4.5.4.7
4.5.4.8
If the original weld required post weld heat treatment, then it shall be heat
treated after the repair using the method originally approved by COMPANY.
5.0
5.1
General Piping
5.1.1
Piping shall be neatly installed with piping runs level, straight, plumb, square,
and parallel to platform column rows unless otherwise specified by the Technical
Requirements or approved by COMPANY. Changes in direction shall generally
be made with 90o turns or rolls.
5.1.2
5.1.3
Prefabricated pipe spools shall have a sufficient number of properly located field
welds to allow flanged connections to be installed without imposing excessive
loads, moments or strain into the system.
5.1.4
5.1.5
Minimum spacing between circumferential weld joints shall be 2", or 6 times the
wall thickness of the pipe, whichever is greater, unless otherwise approved by
COMPANY.
5.1.6
Couplings or other weld-on type branch connections and fittings shall not be
located on a weld joint.
5.1.7
Flange bolt holes shall straddle normal horizontal and vertical center lines.
5.1.8
5.1.9
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5.1.10
5.1.11
Threads on threaded pipe and fittings shall be cut to ANSI B1.20.1 "Pipe
Threads (Except Dry Seal) Specifications, Dimensions, and Gaging for Taper
and Straight Pipe Threads Including Certain Special Applications."
5.1.12
Teflon tape or pipe dope shall be used on all threaded pipe joints, except for
those joints that are to be back welded. Teflon tape or pipe dope shall only be
applied to the male thread of the joint.
5.1.13
5.1.14
For piping that is designated as "sloped," the total slope shall be as uniformly
distributed as practicable throughout the entire length of the line by shimming
the pipe where necessary. After installation, shims shall be seal welded into
place to prevent displacement and loss. Pipe shall be removed or lifted in place
to permit surface preparation and coating of the shims.
5.1.15
An inert gas arc welding process (TIG or MIG) shall be used on the root pass of
welded joints on compressor suction piping that are not accessible for internal
inspection and cleaning. The remaining passes may be welded by the Shielded
Metal-Arc Welding (SMAW) process.
5.2
Pipe Supports
5.2.1
Pipe supports shall be designed, fabricated and installed in accordance with the
AISC "Manual of Steel Construction" and the AWS D1.1 "Structural Welding
Code." Pipe supports shall be designed to withstand the load conditions
specified by the Technical Requirements.
5.2.2
5.2.3
Pipe supports shall be installed such that no piping butt welds rest on the
support.
5.2.4
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5.2.5
Pipe supports shall be welded to main structural beams of the platform, deck,
module or skid. Pipe supports shall not rest upon or be supported by grating,
deck plate or other non-structural elements. Beams shall be fabricated so that
after erection any minor camber as a result of rolling or shop assembly will be
upward.
5.2.6
Holes for bolted connections shall be 1/16" larger diameter than the bolts. All
holes shall be drilled prior to the application of any protective coatings. Torch cut
holes shall not be accepted by COMPANY.
5.2.7
5.2.8
5.2.9
5.2.10
5.2.11
Stiffeners shall be fitted accurately, neatly and tightly to transmit bearing loads.
Stiffener ends shall be milled or ground smooth to conform to the geometry of
the member when fillet welds are utilized. Otherwise, stiffener ends shall be
beveled to ensure 100% fusion in the root of the weld.
5.2.12
All pipe support welding shall be full seal welds as a minimum. Seal welds shall
be placed at all contact edges of plate and on the supporting flanges of beams,
tees, etc., and the flat legs of angles. Surfaces inaccessible for coating shall be
sealed by boxing-in with plate. Skip or stitch welding shall not be acceptable
under any circumstances.
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5.2.13
Splices in structural shapes and pipe shall be full penetration welds to provide
100% joint efficiency. Splicing tolerances shall comply with the AISC "Manual of
Steel Construction."
5.2.14
Splices in structural pipe shall not be closer together than one pipe diameter, or
3'-0", whichever is greater. For beams, splices shall not be closer together than
twice the depth of the beam, or 3'-0", whichever is greater.
5.2.15
If a beam spans a support, the beam shall not be spliced in the middle quarter
of the span, in the eighth of the span nearest the support, or over the support.
5.2.16
Cantilevered beams shall not be spliced closer to the support than one-half the
cantilever span length.
5.2.17
6.0
6.1
General
6.1.1
Post weld heat treatment (PWHT) shall be in accordance with ANSI B31.3
"Chemical Plant and Petroleum Refinery Piping" except as modified by the
Technical Requirements.
6.1.2
All carbon steel piping with a wall thickness greater than 3/4" shall be post weld
heat treated at 1100 to 1200F for 1 hour per inch of nominal wall thickness, but
in no case less than 1 hour.
6.1.3
During heat treatment, all piping shall be properly supported to prevent warping
or deterioration.
6.1.4
6.1.5
Welding shall not be allowed on piping after post weld heat treatment, unless
specifically authorized in writing by COMPANY and in accordance with ANSI
B31.3 "Chemical Plant and Petroleum Refinery Piping."
6.1.6
When post weld heat treatment of stainless steel piping is required, it shall be at
1550 to 1625F for 1 hour per inch of nominal wall thickness, but with a 1 hour
minimum. Cooling from heat treatment temperatures shall be in still air outside
the furnace.
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6.2
6.2.1
6.2.2
6.2.3
The process and materials for exothermic treatment shall be subject to approval
by COMPANY.
7.0
7.1
General
7.1.1
7.1.2
7.1.3
7.1.4
7.2
Radiography
7.2.1
7.2.2
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ANSI
ANSI
ANSI
ANSI
ANSI
ANSI
API
API
API
AUG 2001
150
300
600
900
1500
2500
10%
10%
10%
20%
20%
100%
3000
5000
10000
100%
100%
100%
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
7.2.8
All radiographic film shall be identified with a weld number traceable to the weld
location. COMPANY shall not accept any radiographs and/or fabricated items
without proper identification of the weld films.
7.2.9
7.2.10
If less than 100% of the welds are examined, for each unacceptable weld the
total number of welds to be examined shall be increased by two welds, up to
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and including radiography on every weld if necessary. All costs associated with
additional radiography as a result of unacceptable welds shall be at
CONTRACTOR's expense.
8.0
8.1
General
8.1.1
8.1.2
CONTRACTOR shall ensure that all portions of the system are tested.
CONTRACTOR shall be responsible for ensuring that test pressures required by
paragraph 8.3.1 do not result in damage to any piping or system components,
including attached equipment and instrumentation.
8.1.3
All fabrication, erection and inspection work, including but not limited to welding,
nondestructive examination, heat treatment, etc. shall be completed and
accepted by COMPANY prior to flushing and hydrostatic testing. The application
of paint, insulation or any other pipe coverings shall not start until successful
completion of hydrostatic testing.
8.1.4
8.1.5
8.1.6
CONTRACTOR shall test as much of the piping system as possible at one time
without exceeding the maximum allowable test pressure of the weakest element
in the system.
8.1.7
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The test fluid normally shall be clean, fresh potable water with a suitable
corrosion inhibitor added by CONTRACTOR. Test fluid shall not contain
suspended solids which may possibly plug orifices or small lines. For stainless
steel piping systems the chloride content of the water shall not exceed 30 ppm.
Alternately, a hydrotest medium such as diesel fuel or kerosene may be
proposed for COMPANY consideration.
8.1.9
The temperature of the hydrotest fluid shall not be less than 60F. If the fluid
temperature is likely to fall to 32F during the test period, then glycol or another
COMPANY approved antifreeze shall be added to prevent freezing.
8.1.10
8.1.11
CONTRACTOR shall provide COMPANY a minimum of one week notice for all
flushing and hydrostatic testing. The piping system to be flushed and tested
shall be detailed in the notice, including the specific lines and equipment.
8.1.12
8.2
8.2.1
CONTRACTOR shall ensure that flushing and tests do not result in damage to
equipment and instrumentation. Equipment and in-line instrumentation that may
be damaged by hydrostatic testing shall be isolated by blinds or plugs, or shall
be disconnected from the piping system. This shall include, but not be limited to
turbines, pumps, compressors, safety valves, turbine flowmeters and rupture
discs. Mounted instrumentation shall be removed or isolated from the system
during flushing and testing.
8.2.2
Restrictions that interfere with flushing, filling, venting or draining, such as orifice
plates and flow nozzles shall not be installed until the completion of testing.
8.2.3
After erection and prior to hydrostatic testing, all piping shall be thoroughly
flushed to remove weld slag, blast grit, dirt, sand, trash and other debris, and
foreign materials. CONTRACTOR shall submit a detailed flushing procedure for
approval by COMPANY, which shall be in accordance with the following:
a. Carbon steel piping shall be flushed with potable water. Stainless steel
piping shall be flushed with potable or raw water with a chlorine content
below 30 parts per million (ppm). Piping shall not be flushed with seawater
without prior written approval from COMPANY.
b. Required flushing flowrates shall be determined based on pipe diameter and
flow velocities. Velocities from 8 to 12 feet per second (fps) shall be required
for lines up to 10" NPS. Larger diameter lines shall use the highest velocity
reasonably possible, which shall be approved by COMPANY. Compressed
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air may be injected into the water while flushing to increase turbulence and
velocity. Drop flushing, the filling and draining of a piping system, does not
constitute flushing and shall not be accepted.
c. Piping and piping systems which cannot be flushed with water (because the
presence of water is unacceptable) shall be blown out with high pressure,
high velocity air. This shall include instrument and utility air lines as a
minimum.
d. Control valves, positive displacement meters, turbine meters, rotameters,
and relief devices shall be removed from the piping system during flushing.
8.2.4
Valving, including ball, gate, globe, plug and butterfly valves shall be in the fully
open position during hydrotesting. Lines containing check valves shall have the
pressure source located on the upstream side, or the check valves shall be
removed from the line or blocked open for hydrotesting.
8.2.5
Expansion joints shall be hydrotested with the piping system to check the
restraining devices.
8.2.6
Control valves shall remain in the line for hydrotesting and shall be in the fully
open position. Valves that are normally closed shall be opened for hydrotesting
using clean dry air. Valves shall not be jacked or forced open by
CONTRACTOR.
8.2.7
Pressure control valves with internal passages between the process fluid and
the diaphragm shall be isolated from hydrotesting. External connections shall be
disconnected or blocked during hydrotesting, and the diaphragm pressure shall
be bled off.
8.2.8
Hydrostatic testing shall be performed with the "in service" type of gaskets, and
shall not utilize any gasket sealing compounds. New gaskets shall be installed
on all connections that are broken after completion of the hydrotesting, or that
must be reassembled after testing.
8.2.9
8.2.10
Large diameter lines that are grouped together on common supports shall not
be simultaneously hydrotested if the weight of the test medium might overstress
the supports.
8.3
8.3.1
ANSI 150
450
350
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Pipe Class
Rating:
ANSI
ANSI
ANSI
ANSI
ANSI
300
600
900
1500
2500
1,125
2,225
3,350
5,575 (Note 1)
9,275
API 3000
API 5000
API 10000
4,500 (Note 2)
7,500 (Note 2)
15,000 (Note 2)
AUG 2001
Note 1: For flanges 16" NPS and larger the test pressure shall be 4,500 psig.
Note 2: CONTRACTOR shall confirm that all components in API 6A piping
systems are suitable for the specified hydrostatic test pressure prior to
procurement. Components not suitable for the specified hydrostatic
test pressure shall not be utilized by CONTRACTOR without prior,
specific written approval of COMPANY.
Note 3: Refer to technical requirements for hydrostatic test pressure for duplex
stainless steel.
8.3.2
Hydrostatic test pressures are for the new and cold condition, with test
temperatures of 100F or less. For higher test temperatures, CONTRACTOR
shall be responsible for checking the piping system and determining the
appropriate test pressure. The test pressure shall be selected such that the test
shall not exceed 90% of the yield strength of the weakest component at the test
temperature.
8.3.3
8.3.4
All hydrostatic tests shall be maintained for a sufficient period of time to check
for small seepage leaks. Upon successful completion of the hydrostatic test
period, the piping system shall receive a final visual check for leaks.
8.3.5
Hydrostatic testing shall be performed with two separate pressure gauges and a
dual-pen (pressure and temperature) chart recorder. Pressure gauges and
recorders shall have a pressure range of approximately twice the required test
pressure.
8.3.6
All gauges and recorders shall have been dead-weight tested and certified
within 6 months of hydrostatic testing. The certifications shall be available for
COMPANY review during all hydrostatic testing.
8.3.7
All vents shall be open during filling to ensure proper venting of all air or gases.
8.3.8
Test pressure shall not be applied against any closed valve. Skillets or blinds
shall be installed to protect valves that must remain in the closed position.
8.3.9
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Recorder charts shall depict one system test only. Charts shall be signed and
dated by CONTRACTOR and COMPANY upon completion of the test to certify
that the test was performed.
8.3.11
CONTRACTOR shall collect, record and maintain all information required for
complete test records. As a minimum, test records shall include the following
information:
a.
b.
c.
d.
e.
f.
g.
h.
i.
8.3.12
Leaks found during testing shall be repaired and the piping system retested in
accordance with the Technical Requirements. COMPANY reserves the right to
require alternate pressure tests should a piping system fail the standard
pressure test.
8.4
Post-Test Requirements
8.4.1
8.4.2
After completion of hydrostatic testing and COMPANY release, the system shall
be de-pressurized by opening the de-pressuring valve on the test rig.
8.4.3
The system shall be completely vented and then drained of the hydrotest fluid.
Particular attention shall be paid to venting during draining to avoid producing a
vacuum in the system and to allow complete drainage. Special attention shall be
given to equipment, instrumentation and piping system low points where water
may be trapped, such as valve bodies or control valve stations, to ensure
complete drainage.
8.4.4
Lines and equipment shall be cleared of all debris after drainage, and then shall
be dried by blowing warm air through the system. In particular, strainers shall be
emptied and cleaned. Alternate drying methods may be employed by
CONTRACTOR if approved by COMPANY, such as vacuum drying.
8.4.5
Soft seated valves, particularly ball valves, shall not be operated until the lines
have been thoroughly cleaned and dried.
8.4.6
All vent and drain valves shall be blinded or plugged after completion of
hydrotest, cleaning and drying.
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8.5
8.5.1
8.5.2
8.5.3
Welds or portions of welds that leak during hydrostatic testing and that have not
been radiographed previously shall be radiographed at the affected areas
before being cut out and rewelded.
8.5.4
After repair, the welds or portions of welds shall be radiographed again. The
hydrostatic test shall be performed again to verify the repairs, unless specifically
approved otherwise by COMPANY in writing.
9.0
PNEUMATIC TESTING
9.1
General
9.1.1
Pneumatic testing may be substituted for hydrostatic testing only with prior
written approval by COMPANY, and if:
a. Hydrostatic testing is totally impractical, or
b. Piping or attached equipment might be damaged by water and no alternative
exists to avoid damage, or
c. Even a small amount of water left in a system could contaminate or injure
the system, such as in a refrigerant or aviation fuel system.
9.1.2
For safety reasons, the volumes of systems being pneumatically tested shall be
kept to a minimum.
9.1.3
Unless otherwise specified, pneumatic tests shall utilize clean, dry air or
nitrogen as the test medium. If air is utilized to test instrument air lines it shall
also be oil-free.
9.1.4
9.1.5
9.2
9.2.1
Pneumatic test pressures shall be in accordance with the following table, except
that the maximum hoop stress during testing shall not be greater than 50% of
the specified minimum yield strength as noted in 49 CFR 192 "Transportation of
Natural and Other Gas by Pipeline: Minimum Federal Safety Standards":
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Pipe Class
Rating:
ANSI
ANSI
ANSI
ANSI
ANSI
ANSI
9.2.2
150
300
600
900
1500
2500
AUG 2001
315
815
1,630
2,440
4,075
6,785
300
790
1585
2375
3960
6600
9.2.3
All welds and threaded connections shall be inspected for leaks with a
soapsuds test. All flanged connections shall be masked with tape and a small
pinhole punched in the tape to facilitate the identification of leaks.
9.2.4
If both hydrostatic and pneumatic pressure testing may damage the piping
system, alternate testing methods may be performed with prior written approval
of COMPANY. Alternate testing methods shall include the following:
a. Butt welds shall be 100% radiographed in accordance with ANSI B31.3
"Chemical Plant and Petroleum Refinery Piping."
b. Welds, other than butt welds shall be liquid penetrant and magnetic particle
tested in accordance with the ASME "Boiler and Pressure Vessel Code" Section V "Nondestructive Examination" - Article 6 and Article 7 respectively.
If heat treating is required, the above examinations shall be performed after
completion of heat treating. Limitations or imperfections found as a result of the
tests shall be stated as required by ANSI B31.3 "Chemical Plant and Petroleum
Refinery Piping."
10.0
10.1
General
10.1.1
CONTRACTOR shall clean, descale (pickle) and passivate carbon steel piping
systems as specified by the Technical Requirements, as well as where
recommended by equipment manufacturer's. In general, any piping service in
which scale can potentially cause damage to downstream equipment shall be
cleaned, descaled and passivated by CONTRACTOR. As a minimum, all piping
in the following services shall be cleaned, descaled and passivated:
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The cleaned, descaled and passivated pipe shall be free of all scale, rust, weld
flux, oil, grease and other foreign materials and shall be equivalent to a Steel
Structures Painting Council SP-8 "Acid Pickling" or SP-6 "Commercial Blast
Finish" surface. All weld flux, metal shavings, coatings, sand, dirt and other
foreign materials not soluble in chemical cleaning solutions shall be removed
prior to fabrication or cleaning operations.
10.1.3
10.2
10.2.1
General
10.2.1.1
10.2.1.2
10.2.1.3
Pickling solutions shall not be allowed to contact valves, check valves, relief
valves, meters, instrument tubing, strainers, or other piping components that
contain elastomer seals, chrome or nickel plating, or galvanized coatings.
10.2.2
10.2.2.1
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10.2.2.2
After removing the precleaning solution, the system shall be rinsed with clean,
potable water until the pH of the effluent rinse is within one pH of the fresh rinse
water.
10.2.3
10.2.3.1
The system shall be pickled (descaled) with one of the following solutions:
a. Sulfuric acid (10%) for 4 to 6 hours at 150F. When mixing acid with water,
CONTRACTOR shall ensure that the acid is added to the water, not water
added to acid.
b. Hydrochloric acid (7%) for 4 to 6 hours at 150F. Note that all alloy trim
valves shall be temporarily removed to avoid pitting of the trim. HCl is an
acceptable alternative when valves can be temporarily removed.
c. Inhibited ammoniated citric acid (3% to 5%) for 6 hours at 180 to 200F.
Citric acid and inhibitor shall be mixed into the water first, and the ammonia
added to adjust the pH to between 4 and 5. Use of ammoniated citric acid
allows both pickling and passivating with the same solution, eliminating the
steps required in Section 10.2.4 below.
10.2.3.2
The system shall be agitated as necessary during circulation to flush out all
loose scale. An inhibitor shall be used during pickling in accordance with the
manufacturer's instructions.
10.2.3.3
10.2.3.4
After pickling for the required time period the acid solution shall be drained
under a nitrogen purge.
10.2.3.5
The system shall then be rinsed again in accordance with Section 10.2.2.2
above. The rinse shall be removed under a nitrogen purge. When using an
ammoniated citric acid, this step may be deleted.
10.2.4
Neutralization
10.2.4.1
10.2.4.2
After neutralizing, the system shall be rinsed with water until all traces of acid
and neutralizing solution have been removed, and then drained under a
nitrogen purge. When using an ammoniated citric acid, this step may be
deleted.
10.2.5
Passivation
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10.2.5.1
AUG 2001
After rinsing, the descaled pipe shall be passivated to minimize further corrosion
by applying a phosphate coating. The passivation solution shall be circulated for
1 hour at 130 to 150F, and consist of the following:
0.25% (wt.) monosodium phosphate
0.25% (wt.) disodium phosphate
0.50% (wt.) sodium nitrite
10.2.5.2
If an ammoniated citric acid was used for descaling, the steel surfaces shall be
passivated by raising the pH to between 9 and 10 through addition of ammonia,
and then adding 0.5 % sodium nitrite and circulating for 1 to 2 hours.
10.2.5.3
After passivation, the system shall be drained and dried thoroughly with dry air
or nitrogen. The system shall not be flushed with water after passivation. After
drying, the pipe shall be closed tightly, blanketed with an inerting gas or filled
with oil to minimize corrosion.
10.2.6
Safety
10.2.6.1
All of the above acids and most of the other treating solutions are harmful in the
event of skin contact, if swallowed, or if fumes are inhaled. Material Safety Data
Sheets (MSDS) shall be available at the job site for all chemicals being
employed. All personnel shall be properly educated and protected against
exposure by safety equipment, including chemical goggles, rubber gloves and
face shields as a minimum.
10.2.6.2
During the acid treating stage of the procedure, hydrogen gas is liberated by
reaction of the acid with the metal. Suitable precautions shall be taken to
minimize any explosion danger resulting from hydrogen accumulation in holding
tanks or other areas. Holding tanks shall be located a minimum of 50' from
process equipment and nonclassified electrical equipment. Smoking shall not be
allowed in the chemical cleaning area under any circumstances.
10.2.6.3
Safety showers shall be available and ready for use at the site. Breathing
apparatus shall be available in case of exposure to toxic fumes.
10.2.6.4
All work areas shall be barricaded with yellow and black tape with "KEEP OUT"
warning signs every 50'.
10.2.6.5
Only proper equipment shall be used. Hoses shall have a minimum working
pressure of 250 psig and shall be chemically compatible with the cleaning
solutions. Hoses shall be bonded to ground to minimize static discharge
explosion hazards.
10.2.6.6
The circulating system shall be pressure tested to 1.5 times the maximum
circulating pressure, or 90 psig, whichever is greater, and all hoses and
circulation system piping and fittings checked for leaks. All leaks shall be
repaired prior to using any chemical solutions.
10.2.6.7
Should a leak develop during circulation of the system, the chemical shall be
evacuated and the piping flushed. The leak shall be repaired before restoring
circulation.
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10.2.7
Environmental
10.2.7.1
10.2.7.2
10.3
Abrasive Blasting
10.3.1
Scale may be removed by abrasive blasting. Blasting shall remove all scale,
grease, debris, etc., resulting in a Steel Structures Painting Council (SSPC) SP6 "Commercial Blast Finish" surface. After blasting the piping shall be cleaned of
all abrasives, dust and foreign material. The pipe shall be thoroughly
passivated, dried and sealed to prevent corrosion in accordance with Section
10.2.5 above.
10.3.2
The abrasive shall be new, clean and dry. Grit or slag abrasives shall be
preferred over sand. If sand is utilized, it shall be washed and clay-free.
10.4
10.4.1
CONTRACTOR shall hot oil flush all lube, seal, and control oil piping systems,
including those for drivers, pumps, compressors, and generators prior to the first
fill of oil, as specified in the Technical Requirements.
10.4.2
CONTRACTOR shall submit a detailed hot oil flushing procedure for approval by
COMPANY, which shall be in accordance with the following as a minimum:
a. All tanks, filter housings, cooler header boxes and other system components
shall be opened, inspected, and wiped clean prior to hot oil flushing.
b. All bearing and seal housings shall be isolated from for flushing, and jumper
lines installed.
c. Oil used for flushing shall be the same type of oil specified for normal
operation of the system being cleaned.
d. The oil shall be heated to between 150 and 180F and shall be circulated
throughout the system until filter screens are free of debris. The oil shall be
circulated for a minimum of 8 hours. Final acceptance criteria shall be
determined by COMPANY in conjunction with the equipment manufacturer.
10.4.3
After flushing, CONTRACTOR shall drain and properly dispose of all flushing oil
in accordance with all city, county, state and federal regulations.
11.0
PROTECTIVE COATINGS
11.1
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11.2
All coating work shall be performed after completion of all fabrication and
testing, including hydrostatic or pneumatic pressure testing.
11.3
12.0
13.0
13.1
13.2
All unpainted finished surfaces, i.e. flange gasket faces, threads, weld bevels,
blinds, etc., shall be protected against corrosion by applying a suitable rust
preventive or grease.
13.3
All exposed piping connections, i.e., flanges, couplings, beveled weld joints,
etc., shall be protected against mechanical damage during storage, transit and
installation. Protection measures shall include, but not be limited to the
following:
a. All threaded connections shall be protected by metal thread protectors.
b. All exposed flange faces shall be protected by bolting on a steel plate or
wood cover, complete with a gasket. Wood covers shall be constructed from
marine grade plywood with a 1/2" minimum thickness. Flange covers shall
be secured with a minimum of four (4) bolts, but in no case less than 50% of
the total bolting. Plastic snap-on end covers shall not be acceptable.
c. All beveled ends shall be protected by snug fitting bevel protectors.
13.4
Prefabricated piping shipped for field assembly shall be marked with the spool
piece number, drawing number and an arrow indicating the direction of flow with
white paint. Pipe pieces shall be numbered consecutively in the direction of flow.
13.5
Flanged pipe spools shall have the spool identification number stenciled on the
flange. Spool numbers shall correspond to codes on spool sheets and assembly
drawings.
13.6
Two complete sets of "as-built" spool drawings shall be shipped with pipe to be
assembled or installed by COMPANY. The drawings shall contain all information
necessary for assembly and installation of the component parts.
13.7
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and shall reference drawings or spool sheets as applicable. Each item shall be
listed separately, and an approximate weight and dimension for each shall be
provided. The material packing method shall be identified, i.e. crated, palletized,
bundled, skid-mounted, boxed, etc. as applicable.
13.8
14.0
DOCUMENTATION REQUIREMENTS
14.1
14.2
CONTRACTOR shall maintain all mill test reports and heat numbers to provide
full material traceability for all materials used in fabrication and assembly.
14.3
CONTRACTOR shall maintain records on all welds. This shall include weld
procedure, welder identification code or symbol, and NDE results as a minimum
for each weld. The weld records shall be coded to correspond with the isometric
or spool drawings so that the location of each weld is clearly identifiable.
14.4
14.5
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APPENDIX I
MANDATORY CODES AND STANDARDS
American Institute of Steel Construction (AISC)
Manual of Steel Construction
American National Standards Institute (ANSI)
A13.1
B1.20.1
B16.5
B31.3
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APPENDIX II
ADDITIONAL REQUIREMENTS FOR DUPLEX STAINLESS STEEL
A2.1.0
SCOPE
This appendix defines additional or modified requirements for fabrication,
welding and inspection of duplex stainless steel (UNS) S31803 piping
conforming to ASTM A790 "Seamless and Welded Ferritic/Austenitic Stainless
Steel Pipe."
A2.4.0
WELDING
A2.4.1
General
Unless otherwise approved in writing by COMPANY, the maximum heat input
shall be limited to 38 kilojoules/inch. The heat input used for the procedure
qualification shall be recorded on the procedure qualification.
A2.4.2
Welding Processes
A2.4.2.3
A2.4.2.4
A2.4.2.7
A2.4.3
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A2.4.3.1
AUG 2001
A2.4.3.2
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A2.4.5
Production Welds
A2.4.5.4
Weld Repairs
AUG 2001
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AUG 2001
APPENDIX III
ADDITIONAL REQUIREMENTS FOR FIBERGLASS
REINFORCED PLASTIC (FRP) PIPING
A3.1.0
SCOPE
A3.1.1
A3.1.2
A3.2.0
A3.2.1
General
A3.2.1.1
Piping and fittings shall be designed, fabricated and installed in accordance with
ANSI B31.3 "Chemical Plant and Petroleum Refinery Piping," except as
specified otherwise by the Technical Requirements. All pipe installation and
fabrication work shall be in strict accordance with the FRP pipe manufacturer's
recommendations.
A3.2.1.2
Fiberglass piping (FRP) and resins used for potable and utility service shall be
approved by the U.S. FDA for use with potable water and shall be clearly
labeled as such.
A.3.2.1.3 All joints shall be bonded or flanged. Threaded FRP joints shall not be
permitted, except for stainless steel bushings imbedded in FRP saddles which
shall be acceptable for small bore connections for instrumentation and
vent/drain connections.
A3.2.2
A3.2.2.1
Pipe and fittings shall be handled with care and at all times protected from
impact, or from being climbed on, or used to support other materials or
equipment. End protection covers shall remain on all exposed joints until
immediately before joint assembly to prevent damage or material degradation.
A3.2.2.2
Chains shall not be used for handling pipe or fittings. When lifting with hoists or
cranes, or securing for transportation, only rope or webbed slings shall be used.
A3.2.2.3
Pipe and fittings shall not be thrown or dropped, and shall be protected from
bumping or hitting during all handling work.
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A3.2.3
Bonded Joints
A3.2.3.1
Bonded bell and spigot connections, and butt and wrap connections shall be
made in strict accordance with the FRP pipe manufacturer's recommendations.
As a minimum, considerations shall include adhesives and sealing resins, curing
agents, weather conditions for pipe assembly, curing methods and times, fit-up
and joint preparation, and material handling and support.
A3.2.3.2
All tools recommended by the FRP pipe manufacturer, especially those for joint
preparation, shall be used.
A3.2.4
Flanged Connections
A3.2.4.1
Flanged connections shall generally not be allowed on FRP piping in 16" NPS
and below, except where required at skid interfaces, equipment nozzles,
valving, and in-line instrumentation, or where required for operations or
maintenance. All flanges shall be ANSI B16.5 Class 150 flat face (FF) and shall
utilize 1/8" thick full face elastomeric gaskets.
A3.2.4.2
All flanged joints shall be uniformly tightened and shall be torqued to the pipe
manufacturer's recommended limit, but not beyond.
A3.2.4.3
Butterfly valves and wafer check valves shall be installed so that the disc swings
clear of adjacent piping.
A3.2.4.4
Prefabricated skid piping shall be shipped with the flanged joints loosely bolted
to provide maximum flexibility during transportation.
A3.2.5
A3.2.5.1
The CONTRACTOR shall ensure and review all piping layouts for suitability of
piping flexibility and support. All types of supports shall be in accordance with
the pipe manufacturers recommendations. Support cradles shall provide 180
degrees of circumferential support.
A3.2.5.2
Metal supports shall be isolated from the FRP pipe by FRP saddles, elastomeric
liners or other materials approved by the pipe manufacturer.
A3.2.5.3
A3.2.5.4
A3.2.6
Coating
A3.2.6.1
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A3.2.6.2
AUG 2001
Wet Systems
-----------------------------------
---------------------------------------
2000m - FP or PSX JF
A3.2.6.3
A3.2.6.4
A3.3.0
QUALITY ASSURANCE
A3.3.1
General
CONTRACTOR shall visually inspect all piping and fittings for damage per the
visual acceptance standards detailed in API 15LR "Specification for Low
Pressure Fiberglass Line Pipe." Visual inspection shall occur upon receipt and
before any assembly. Damaged or defective material shall not be used.
Specific, written COMPANY approval to use damaged or defective material shall
be required, and must be granted on a case by case basis.
A3.3.2
A3.3.3
Pressure Testing
A3.3.3.1
All assembled piping systems shall be cyclically hydrotested at 1.5 times the
maximum operating pressure by raising the pressure to the test pressure (at a
maximum rate of 100 psig per minute), then holding pressure for 5 minutes,
releasing the pressure, and then repeating until the system has been
satisfactorily cycled up and down at least 5 times without leaking.
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A3.3.3.2
A3.4.0
REPAIRS
Defective joints or pipe shall be repaired by cutting out the defect and bonding
in new joints or pipe. CONTRACTOR may submit a wrap repair procedure for
COMPANY consideration, but submittal and approval/rejection shall be on a
case by case basis. The wrap repair procedure shall be in accordance with the
FRP pipe manufacturer's recommendations.
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AUG 2001
APPENDIX IV
ADDITIONAL REQUIREMENTS FOR CHLORINATED
POLY VINYL CHLORIDE (CPVC) PIPING
A4.1.0
SCOPE
A4.1.1
A4.2.0
A4.2.1
CPVC pipe, tubing, and fittings shall not be assembled or installed if the
ambient temperature is below 40F or above 110F.
A4.2.2
CPVC pipe, tubing, and fittings shall be handled with extreme care to avoid
damage such as abrasions, cracking or crushing.
A4.2.3
Pipe and tubing cuts shall be square and de-burred to insure a proper fit-up of
the joint being made.
A4.2.4
All joint contact surfaces between pipe and fittings shall be solvent cleaned prior
to the application of cement. Cement shall be applied to both surfaces to be
joined. The amount of cement applied shall cause a small bead of cement to
appear at the junction.
Sufficient ventilation shall be provided to remove toxic and flammable vapors.
A4.2.5
CPVC pipe, tubing, and fittings shall be cemented with CPVC solvent cement.
The cement shall be in accordance with ASTM F493 "Specification for Solvent
Cements for Chlorinated Poly Vinyl Chloride (CPVC) Plastic Pipe and Fittings."
CPVC solvent cement shall be orange in color to facilitate identification and
minimize the unintentional use of other cements.
Extreme caution shall be taken when handling, applying, and storing solvent
cement. Handling and storage of solvent cement shall be in accordance with
ASTM F402 "Practice for Safe Handling of Solvent Cements and Primers Used
for Joining Thermoplastic Pipe and Fittings."
A4.2.6
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AUG 2001
APPENDIX V
ADDITIONAL REQUIREMENTS FOR API 5L GRADE X-60 CARBON STEEL PIPING
A5.1.0
SCOPE
A5.1.1
A5.1.2
A5.2.0
WELDING REQUIREMENTS
A5.2.1
General
A5.2.1.1
Root pass and hot pass welding shall be performed using the Gas Tungsten-Arc
Welding (GTAW) process. The remainder of the weld shall be performed using
either the gas-shielded Flux Core-Arc Welding (FCAW) or Submerged-Arc
Welding (SAW) processes.
A5.2.1.2
A5.2.2
Welding Consumables
A5.2.2.1
Consumables for welding API 5L Grade X-60 pipe shall be carbon steel and
shall conform to the following ASME specifications:
GTAW
SAW ASME SFA-5.17
FCAW
ASME SFA-5.18
ASME SFA-5.20
A5.2.2.2
A5.2.3
A5.2.3.1
Charpy V-notch impact testing shall be performed as part of the weld procedure
qualification. Testing shall be in accordance with ASTM A370 "Mechanical
Testing of Steel Products" using longitudinal V-notch specimens with the notch
located in each of the following three locations: weld metal, fusion line (FL),
fusion line (FL) plus 2 mm. Three specimens shall be required at each location
for a total of nine specimens per weld. The absorbed energy shall be 20 ft-lbs
average and 15 ft-lbs minimum at a test temperature of 32F.
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A5.2.3.2
Separate weld procedure qualifications shall be performed for welding Grade X60 to Grade X-60, Grade X-60 to fittings (ASTM A860), and Grade X-60 to
flanges (ASTM A694). Impact testing shall not be required for procedures on
ASTM A860 or ASTM A694 material.
A5.2.3.3
The following additional essential variables shall apply for all Grade X-60
welding procedures. A change in an essential variable beyond the limit specified
shall require a new qualification.
a. Any change in the brand name of electrode, flux, or electrode/flux
combination used for procedure qualification.
b. Any increase in post weld heat treatment temperature greater than 50F.
c. Any increase in post weld heat treatment duration time greater than 25% of
that used during procedure qualification.
c. Any increase in carbon equivalent by more than 0.03 above the material
used for procedure qualification.
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