Standard Specs 13 STD Spec - For Piping Fab Insp Testing Rev 0

Standard Specification for
Rev: 0
Piping Fabrication, Inspection and Testing
Doc No: P6EC-STD-PP-S-1003 Page: 2 of 14
Table of Content
1.0 SCOPE ........................................................................................................................... 3

1.1 Purpose ............................................................................................................... 3
1.2 Definitions of Terms ............................................................................................. 3
2.0 ENVIRONMENTAL DESIGN CRITERIA ......................................................................... 3

2.1 Climatic Conditions .............................................................................................. 3
2.2 Design Life .......................................................................................................... 3
3.0 CODES, STANDARDS AND REFERENCE DOCUMENTS ............................................ 3

3.1 Reference Documents ......................................................................................... 3
3.2 International Codes and Standards...................................................................... 4
4.0 FABRICATION AND ERECTION REQUIREMENTS ...................................................... 5

4.1 General................................................................................................................ 5
4.2 Piping Drawings ................................................................................................... 6
4.3 Materials .............................................................................................................. 6
4.4 General Fabrication Requirements ...................................................................... 6
4.5 Threaded Connections ........................................................................................ 7
4.6 Bolting and Gaskets............................................................................................. 8
4.7 Fit-up ................................................................................................................... 8
4.8 Tolerances ........................................................................................................... 8
4.9 Shop Detail Drawings .......................................................................................... 9
4.10 Painting, Coating and Marking ............................................................................. 9
4.11 Welding ............................................................................................................. 10
4.12 Inspection & Testing .......................................................................................... 10
4.13 Certificates and Records.................................................................................... 10
APPENDIX – A - SPECIFICATION FOR WELDING ................................................................ 12
APPENDIX – B - SPECIFICATION FOR PIPING INSPECTION .............................................. 13
APPENDIX – C - SPECIFICATION FOR PIPING TESTING ..................................................... 14
TOTAL OR PARTIAL REPRODUCTION AND / OR UTILISATION OF THIS DOCUMENTATION ARE FORBIDDEN WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER
Rev: 0
1.0 SCOPE
1.1 Purpose
This specification defines the minimum requirements for the design, material procurement,
fabrication, inspection, testing of piping systems.
The requirements of this specification are to be considered as minimum requirements and
VENDOR may submit to the PURCHASER, for agreement, any possible solutions, with
supporting calculation notes that could give technical and / or economic improvement
Any omission in this requirement shall not relieve the VENDOR of his responsibility to
deliver the piping systems, which are complete, of proven design, and conforms to the
COMPANY Requirements.
1.2 Definitions of Terms
The CLIENT /COMPANY / OWNER where used in this specification shall mean the
ultimate user / owner of the plant and facilities
The CONTRACTOR / PURCHASER where used in this specification shall mean the party,
who undertake LSTK / EPC contract for the above project.
The VENDOR / SUPPLIER where used in this specification shall mean the party, who
manufactures or supplies the equipment and services specified.
The INSPECTOR / TPA where used in this specification shall mean the PURCHASER /
COMPANY or their authorized Third Party Agency for carrying out the inspection.
The ENGINEER/DEC where used in this specification shall mean the party, who perform
Design Engineering Consultancy and Project Management for COMPANY
2.0 ENVIRONMENTAL DESIGN CRITERIA
2.1 Climatic Conditions

The piping systems shall be designed for out-door location, suited to corrosive, desert /
salt laden and marine environment. Climatic conditions under which piping systems
designed / operated shall be as per Project Design Basis.
2.2 Design Life

The piping systems shall be designed and constructed for continuous operation, outdoor
and for a minimum service life of 25 years or as per Project Design Basis.
3.0 CODES, STANDARDS AND REFERENCE DOCUMENTS
3.1 Reference Documents

The latest revision of following project specification / documents shall form integral part of
this specification
Rev: 0
P6EC-STD-PP-S-1001 : Piping Material Specification
P6EC-STD-PP-S-1002 : Valve Material Specification
P6EC-STD-PP-S-1004 : Standard Specification for Piping Specialty Items
P6EC-STD-PP-S-1005 : Standard Specification for Painting and Colour Code
P6EC-STD-PP-S-1006 : Standard Specification for Insulation
P6EC-STD-PP-S-1007 : Standard Specification for Positive Material Identification
3.2 International Codes and Standards

The design, materials, fabrication, inspection, testing and preparation for piping systems
shall be in accordance with this specification and the latest edition (including addenda /
errata) of applicable codes and standards as listed below.
ASME Sec. I : ASME Boiler and Pressure Vessel Code – Power Boilers
ASME Sec. II : ASME Boiler and Pressure Vessel Code – Materials.
ASME Sec. V : ASME Boiler and Pressure Vessel Code – Nondestructive

Examination.
ASME Sec. VIII Div. 1 : ASME Boiler and Pressure Vessel Code – Rules for
Construction of Pressure Vessels.
ASME Sec. IX : ASME Boiler and Pressure Vessel Code – Welding, Brazing
and Fusing Qualifications.
ASME B 1.20.1 : Pipe Threads
ASME B16.5 : Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24
Metric/Inch Standard.
ASME B16.9 : Factory Made Wrought Steel Butt Welding Fittings
ASME B 16.11 : Forged Steel Fittings, Socket Welding and Threaded
ASME B16.20 : Metallic Gaskets for Pipe Flanges - Ring Joint, Spiral-Wound
and Jacketed
ASME B16.21 : Non-Metallic gaskets for Piping Flanges
ASME B16.25 : Butt Welding Ends
ASME B31.3 : Process Piping
ASME B36.10 : Welded and Seamless Wrought Steel Pipe
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ASME B36.19 : Stainless Steel Pipe
AWS D 1.1 : American Welding Society – Structural Welding Code-Steel
AWS A5.1 : Specification for Covered Carbon Steel Arc Welding Electrodes
AWS A5.5 : Specification for Low Alloy Steel Covered Arc Welding
Electrodes
AWS A5.9 : Specification for Corrosion Resisting Chromium and

Chromium-Nickel Steel Bare and Composite Metal Cored and
Stranded Welding Electrodes and Welding Rods
API STD 1104 : Standard for Welding Pipelines and Related Facilities
EN10204 : Materials Testing Certificates
AWS D 1.1 : American Welding Society – Structural Welding Code-Steel
EN10204 : Materials Testing Certificates
AISC : American Institute of Steel Construction
IS - 875 (Part - 3) : Codes of practice for design loads (other than earthquake) for
buildings and structures.
IS – 1893 : Criteria for earthquake resistance design of structures
OMR : Oil Mines Regulations
OISD : Oil Industries Safety Directorate regulations
DGMS : Directorate General of Mines Safety
IER : Indian Electricity Rules
CPCB : Central Pollution Control Board of India
4.0 FABRICATION AND ERECTION REQUIREMENTS
4.1 General
4.1.1 This specification covers the requirement up to final assembly or erection. Fabrication
may be performed in the shop or on site (field). For definitions of the words" Assembly",
"Fabrication" and "Inspection" refer to ASME B31.3.
4.1.2 Two (2) months prior to commencement of Piping Fabrication, CONTRACTOR shall
submit a detailed procedure covering all aspects of the work for COMPANY approval. The
procedure shall as a minimum cover material receipts, handling, storage, marking etc.;
WPS, PQRs, welder lists, allocated area for pre-fabrication; equipment, tools to be used;
Inspection, NDT, hydrotesting, sand blasting, painting, erection, final assembly and testing;
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schedule. No work will commence till approval has been obtained of this document from
COMPANY / INSPECTOR.
4.2 Piping Drawings

4.2.1 CONTRACTOR shall issue the piping systems Approved for Construction (AFC) drawings
(including isometrics) to their Fabrication team before commencement of material
preparation, cutting and fabrication.
4.2.2 These AFC drawings shall show, as a minimum, the routing, controlling dimensions and
attachments for fabrication. Other drawings or standards showing typical details shall be
included where applicable.
4.2.3 CONTRACTOR shall review the drawings and notify the COMPANY / INSPECTOR of any
apparent discrepancies and bring to COMPANY / INSPECTOR for resolution prior to start
fabrication.
4.2.4 The type and detail of materials, fittings, connections etc, shall be as shown on the
drawings and/or in the Piping Specifications.
4.3 Materials
4.3.1 The materials for the pipe work shall be as indicated on the drawings and specified in the
project specification and Piping Material Specification.
4.3.2 Substitution of materials shall not be done unless until approved by in writing by
COMPANY/ENGINEER/INSPECTOR.
4.4 General Fabrication Requirements

4.4.1 Surface marks or abrasions shall be cleaned and carefully examined. The Type of
inspection shall be proposed by CONTRACTOR and approved by COMPANY /
INSPECTOR.
4.4.2 Pulled bends shall not be used unless individually approved in writing by the COMPANY.
Bending may then be carried out only after COMPANY / INSPECTOR approval of the
bending and heat treatment procedures.
4.4.3 The wall thickness after bending shall not be less than the minimum design thickness, plus
corrosion/erosion allowances, as required by the applicable piping material class in the
Project Specification and Piping Material Specification.
4.4.4 The centerline radius of pulled bends shall be 5 nominal pipe diameters or greater.
Butt-welds in arcs or for the addition of pulling legs will not be permitted. The pipe wall
thickness at the thinnest point after bending, less corrosion allowance, shall not be less
than the calculated thickness required for pressure and temperature or the reference
thickness, whichever is greater.
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4.4.5 Unless indicated on the drawings, all flange bolt holes shall straddle the natural vertical
and horizontal center lines of the pipe. Flange faces shall be aligned in accordance with
the requirements of the specification.
4.4.6 Flanges which are supplied loose for welding on site shall be attached to their spools by
wire, or may be tack welded, in accordance with Para.5.7 to the relevant position on the
spool.
4.4.7 The loose flange shall also be wired with a sheet metal tag which shall be stamped with
the appropriate spool identification.
4.4.8 Beveled ends may be cut and shaped on pipe for welding by machining, sawing or
grinding. The edges shall have a true finish surface which is smooth enough for welding
and which is free of paint, drags, tears, slag, oxides, oil or dirt.
4.4.9 Flame cutting is only permissible for rough forming of Carbon Steel and shall not be used
on alloy materials. All pipe spools shall, where applicable, have weld end preparations
beveled for welding unless indicated as a field fit weld on the drawings. Weld preparation
for a field fit weld shall be prepared after trial fitting. Pipes, flanges and fittings shall be
beveled for welding in accordance with ASME B16.25. Any other end preparation which
complies with the approved weld procedure qualification is acceptable.
4.4.10 The number of welds in a spool shall be kept to a minimum.
4.4.11 The distance between one welded joint and the neighboring welded joint along the piping,
as a minimum, shall be minimum 1D (One Diameter) or 75mm, whichever is greater.
4.4.12 On all socket weld joints a gap of 1.5mm ~ 2 mm shall be left between the bottom of the
socket and the end of the pipe to prevent "bottoming" in the socket.
4.4.13 Where reinforcing pads are specified, e.g. for attachments for pipe supports, they shall be
accurately shaped to suit the pipe diameter and fabricated from material with similar
chemical and mechanical properties to the parent pipe.
4.4.14 The welding of the pads to the pipework shall be carried out only by fully qualified welders
and to the approved welding procedures.
4.4.15 Each pad shall have venting hole (0.25” NPT) for air leak test and shall be filled with
grease after successful welding.
4.4.16 Fabrication of Cu/Ni/Fe and Stainless Steel materials shall be performed in designated
areas to minimize the risk of cross contamination with ferrous materials.
4.5 Threaded Connections

4.5.1 All threads shall be clean cut with no burrs or stripping and shall be in accordance with
ASME B1.20.1 Threaded connections shall be protected from damage. After welding or
heat treatment they shall be gauge checked and if necessary chased.
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4.5.2 Immediately prior to joining, piping threads shall be thoroughly cleaned of cutting, dirt, oil,
or other foreign matter. The piping shall then be made up sufficiently for the threads to
seize.
4.5.3 PTFE taps may be used to ensure adequate sealing. Threaded connections to be seal
welded shall be made up dry i.e. without the use of sealing compound or tape. They shall
be tightened up sufficiently for the threads to seize and back welded. The welding shall be
sufficient to cover all exposed threads. Exposed threads beyond seal weld are not
acceptable.
4.6 Bolting and Gaskets

4.6.1 All flanged joints shall be brought up flush with the gaskets and checked for parallel and
lateral alignment. The bolts shall be tightened uniformly and opposing sequence so that
the entire flange face, or groove, bears uniformly on the gasket.
4.6.2 Care must be taken when bolting flanges of dissimilar materials, e.g. steel to cast iron or
aluminium bronze, to avoid damage to the weaker flange.
4.6.3 All flanges shall be made up with uniform bolt tension and the procedure checked by
measuring the decrease in space between flanges.
4.6.4 All bolts shall extend fully through their nuts to expose one complete thread.
4.7 Fit-up
4.7.1 To preclude extraneous loads and to minimize strains during tacking, the pipework shall be
properly supported and aligned by jigs or clamps as required. This shall be carried out in a
manner which will not be injurious to the pipework e.g. dogs shall not be used. All tack
welding shall be carried out by qualified welders to COMPANY approved standards and
procedures.
4.7.2 Tack Welds between 12 to 18mm in length are required for all fit-up work to adequately
hold the joint during deposition of the weld root and shall be subject to the same preheat
requirements as specified by the approved welding procedure for each joint. Root tacks
shall obtain full penetration and fusion. If full penetration and fusion are not obtained, or if
the root tack cracks, it shall be removed completely by grinding prior to completion of the
weld root. All tack welds which are to be included in the final weld shall be "feather-edged".
4.7.3 Immediately prior to tacking or welding of copper nickel or stainless steel materials, the
surfaces shall be scratch brushed with a clean stainless steel brush, to remove surface
oxides and then degreased with a non-flammable, non-toxic solvent. Stainless steel wire
brushes only shall be used and reserved for the applicable material.
4.8 Tolerances
4.8.1 The dimensional tolerances on completion of fabrication shall be in accordance with ASME
B31.3 and as detailed below. Linear tolerances shall not be cumulative.
Length and other linear dimensions,+3mm flattening.
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4.8.2 Flanges Face Alignment

The plane across the gasket seating surface shall be perpendicular to the theoretical
center-line of the pipe to within 5mm/m (1/4 degree).
Bolt Hole Location.
Deviation from center-line Alignment of Bores
(Line Joints) +1.5mm
• Piping with wall thickness 6mm and above. +1.5mm
• Piping with wall thickness below 6mm. +25% the pipe wall thickness
• Angular dimensions of bends and branches, +1.4 degree
4.9 Shop Detail Drawings

The CONTRACTOR is to prepare detail drawings for piping systems necessary to satisfy
the requirements of the COMPANY / INSPECTOR. Drawings must show the spool
numbers, joint number materials, dimensions, fabrication details, and the applicable codes
and procedures. The arrangement drawing number must be shown as a reference.
4.9.1 Piping Spool Numbers
As an aid to control the fabrication and ease of installation of piping system, each section
of line which is prefabricated, or loose item, shall be allocated a spool number.
Spool numbers shall be as marked in the Piping Spool drawings / ISOs and shall be
agreed between the CONTRACTOR and COMPANY.
4.9.2 Spool Marking
Identification Spool markings : each spool shall be identified with the line number and
spool number stamped, with low stress dies, on both the edge of a flange OD / Pipe OD
4.10 Painting, Coating and Marking

4.10.1 Protective Coatings
• Cleaning of piping after fabrication and heat treatment shall be performed both
externally and internally to remove all loose scale, weld spatter, sand and other
foreign matter.
• The requirements for surface preparation and protective coating of pipework shall be
in accordance with Standard Specification for Painting and Colour Code P6EC-STD-
PP-S-1005.
4.10.2 Marking
• To facilitate erection, the appropriate pipe identification, consisting of the line number
and spool number, shall be legibly painted on each pipe spool in large block letters.
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The paint used shall be resistant to saliferous atmosphere and shall not, in itself,
cause corrosion of the pipe or fittings to which it is applied.
• All marking to be applied after application of the protective coating.
4.11 Welding
4.11.1 General welding process
• All welding shall be in accordance with ASME B31.3 unless otherwise noted.
• All Butt welds shall have 100% penetration to the root of the joint. The root gap of
butt-welds shall be such as to permit consistent full penetration.
The COMPANY reserves the right to introduce dye penetrant examination of root runs for
material classes ASME 600LB and above.
• Dye penetrant tests shall be carried out on butt weld end preparations with a wall
thickness 3/4" (19mm) and above.
• Permanent backing rings shall not be used.
• The CONTRACTOR shall submit a list of welding procedures to the COMPANY to be

used for the applicable work.
• Welding Procedures from previous projects(last 2 years) can be used, provided all
test parameters and results are in conformance to the applicable codes & standards
and this document and have been witnessed and signed by independent 3rd Party
INSPECTOR.
4.11.2 Refer Appendix- A for detailed requirements on welding
4.12 Inspection & Testing

4.12.1 The INSPECTOR shall have the right to examine all aspects of the work at any reasonable
time during fabrication, testing or on completion.
4.12.2 Acceptance criteria based on visual, radiographic or other types of examination shall be in
accordance with ASME B31.3.
4.12.3 Radiography requirements for fabricated pipe work shall be as shown in the
Piping Isometric Drawings.
4.12.4 Refer Appendix- B for detailed requirements on Inspection.
4.12.5 Refer Appendix- C for detailed requirements on Testing.
4.13 Certificates and Records

4.13.1 The CONTRACTOR shall supply the COMPANY with copies of the following certificates
and records: The number of copies to be as stated in the Purchase Documentation.
• Certified mill test reports, or material certificates, for all material which they supplied
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• Fit-up records
• Weld procedure specifications (WPS) and Procedure qualification results.(PQR)
• NDT test certificates / Results / Radiography Films
• Pyrometer charts or records of heat treatment.
• Pressure test charts / certificates.
• Surface preparation / Painting records

The mill test reports, or material certificates, and weld procedure qualifications shall be
available for review by the INSPECTOR prior to the start of fabrication.
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APPENDIX – A - SPECIFICATION FOR WELDING
Piping Fabrication, Inspection and Testing Rev: 0
APPENDIX – A - Welding
Table of Content
1.0 WELDING REQUIREMENTS ..........................................................................................2

1.1 General ................................................................................................................2
1.2 Welding Procedures and Processes ....................................................................2
1.3 Joint / Edge preparation .......................................................................................4
1.4 Welding Electrodes and Consumables.................................................................4
1.5 Weld Contour and Finish......................................................................................6
1.6 Heat Treatment ....................................................................................................6
1.7 Workmanship .......................................................................................................7
2.0 QUALITY ASSURANCE PROVISIONS ..........................................................................8

2.1 Procedure Qualifications Tests ............................................................................8
2.2 Quality Conformance Inspections ........................................................................8
2.3 Repairs ................................................................................................................9
1.0 WELDING REQUIREMENTS
1.1 General
1.1.1 Piping welding (including welds attaching supports to piping) and heat treating shall
conform to this specification and ASME B31.3, Chemical Plant and Petroleum Refinery
Piping. Welding processes should be selected based on the material to be welded.
1.1.2 Alternative welding techniques may be submitted to the COMPANY for approval.
1.1.3 Welders and welding operators shall have been qualified within the 6 months prior to
beginning of welding in accordance with Qualification ASME Section IX, Welding and
Brazing Qualifications. Qualification records shall be submitted to the COMPANY for
approval.
1.1.4 Final hardness of deposited weld metal in carbon steel shall not exceed 225 Brinell. At
least five percent of all welds shall be hardness tested with a Tele brineller portable
hardness tester or COMPANY approved alternate (one test per weld and at least one
weld per spool). Should any weld metal deposit have a rejected hardness, additional
hardness tests shall be made at the CONTRACTOR's expense, until the extent of the
unacceptable weld metal is established. All unacceptable weld metal shall be reheat
treated or replaced, and then retested at the CONTRACTOR's expense.
1.2 Welding Procedures and Processes

1.2.1 General
a) Welds shall be made by the shielded metal arc (SMAW), gas tungsten arc
(GTAW), gas metal arc (GMAW), or submerged arc process (SAW), except for the
restrictions listed below.
b) Oxyacetylene welding shall not be used unless approved in writing by the
COMPANY/INSPECTOR and only for 1.5 inches and smaller carbon steel pipe
with a wall thickness less than 0.20 inch.
c) Semi-automatic or fully-automatic welds shall be made with a multi-pass
technique.
d) All other welding processes, including flux-cored processes, shall be submitted in
writing for approval by the COMPANY/INSPECTOR. If flux-cored arc welding
(FCAW) is allowed, it shall be done only with gas shielded electrodes. Additional
FCAW restrictions are that vertical downhill is not allowed, electrode diameters
shall not exceed 1/8 inch and wind velocities shall not exceed 2 m/s in the weld
area.
e) Welding processes shall be identified by number. The identification number shall
be referenced in relevant AFC drawings.
1.2.2 Welding Processes
1.2.2.1 The following processes are permitted:

a) Shielded metal-arc (SMAW)
b) Automatic submerged-arc (SAW) - Details of submerged arc welding (SAW)
procedures shall include travel speed and heat input (kJ/mm)). If submerged arc
welding is used welds shall be at least two passes.
c) Tungsten inert gas (TIG) - An internal argon purge shall be used for gas tungsten
arc root passes of steels with more than 2% Cr. If an argon purge is utilized on
carbon 1/2% Mo or 1 1/4% Cr - 1/2% Mo, the purge may be removed when
welding of the root bead has been completed. In the case of austenitic stainless
steel, a nitrogen purge may be used instead of argon.
d) Gas metal-arc (GMAW) - Gas metal-arc welding using solid wire electrodes shall
be done in the spray transfer range with the following exceptions. The short
circuiting mode is limited to:
i. All ferritic materials not exceeding 1/4 inch nominal thickness.
ii. Root pass of single sided welds in ferritic piping in the flat and rolled (FAR)
position.
iii. Tack welds, temporary attachments, double welded joints or other
applications where weld metal deposited by the GMAW short-circuiting
process is subsequently removed.
iv. Weld metal overlays made in the 1G position.
v. The short circuiting arc process may be used for root pass welding only.
vi. The short circuiting arc process should not be used on weldolets, reinforced
nozzles and branch welds, couplings, slip-on flanges, socket welds and other
attachments.
Specific applications, other than those listed above, shall be submitted to the
COMPANY. Full particulars, such as material type, thickness, joint design, weld
bead sequence, gas mixture and welding position shall be submitted with the
request to use the GMAW short-circuiting transfer process.
e) Flux cored metal arc (FCAW) -
Flux cored arc welding shall be done in the spray transfer range and for carbon
steel welding only.
f) Corrosion resistant weld overlays when welded in the flat position.
1.2.2.2 The maximum individual weld layer thickness for all processes shall not exceed:
• 3/8" (10mm) for materials less than 1 1/4" (32mm) thickness.

• 1/2" (12.5mm) for materials 1 1/4" (32mm) thickness and greater.
1.2.2.3 Processes and/or specific applications, other than those listed above, may be
submitted for review:
a) Manufacturer ability, include complete details of fabricator's preparation, welding
techniques, welding procedures for specific applications and past experience
about the in-use process.
b) Manufacturer methods to achieve and maintain weld quality with specific details on
the extent of non-destructive testing and welding supervision.
1.2.2.4 Ferrous Material
Welding of carbon steel pipe work shall be done by an electric arc welding method.
The use of metal inert gas shielded (MIG) welding for welds, shall be allowed only
upon the written permission of the COMPANY, and shall be subject to 100% ultrasonic
or eddy current testing inspection to ensure complete fusion.
1.2.2.5 Non-Ferrous and S.S. Material
All copper nickel and S.S. pipe work shall be welded using GTAW process with
backing of argon or Nitrogen.
The welding procedure shall be such as to introduce a minimum of 50% of filler wire
into the joint. Pre-heat shall not be used. To prevent any lowering of fatigue strength
the total heat input, including interpass temperature shall be kept below 150 deg.C.
Between passes the weld shall be cleaned.
1.3 Joint / Edge preparation

1.3.1 Weld bevels shall be suitable for the welding process selected. The contour shall
permit complete fusion throughout the joint. The bevels shall conform to the bevels in
the procedure qualifications tests.
1.3.2 Weld bevels shall be made by machining, grinding. The surfaces shall be reasonably
smooth and true.
1.3.3 Materials that require preheat for welding shall be preheated in the same manner for
thermal cutting or gouging.
1.3.4 Surfaces to be welded shall be clean and free from paint, oil, dirt, scale, oxides, and
other material detrimental to welding.
1.4 Welding Electrodes and Consumables

1.4.1 Welding consumables used shall only be those established by weld procedure
qualification testing.
Full details of the electrodes, such as chemical composition, physical properties,
manufacturer and electrode specification/classification shall be included in the welding
procedure.
1.4.2 Electrode equivalents shall not be used, unless included within welding procedure duly
qualified.
All welding consumables shall be compatible with the base materials being welded.
The selected consumable shall be capable of depositing weld metal with properties
equivalent to or better than the base metal. All welding consumables shall be supplied
in hermetically sealed containers and shall be stored in a dry environment.
1.4.3 All electrodes intended for production shall be stored in a holding oven at a minimum
temperature of 150 deg C for at least one hour immediately prior to issue to the welder.
A welder shall be issued with only one type of electrode although he may receive
several gauges of that type. The electrodes shall be placed in a heated quiver which
must be capable of maintaining the electrodes at a minimum temperature of 70 deg.C.
At the end of the welder shift, or sooner if required by the inspector, all surplus
electrodes shall be returned to the stores for re-heating in a baking oven.
The way of identifying reheated electrodes should be established and submitted to
COMPANY for review and approved. Two re-heating maximum are permitted.
Damaged, contaminated or unidentifiable electrodes shall be taken out of circulation.
1.4.4 Unless specifically waived, all shielded metal-arc welding is to be done using low
hydrogen type electrodes when any of the following conditions apply:
a) Steels having a carbon content above 0.3 percent or with steels having a tensile
strength above 480 MPa or SMAW weld repair of ferritic steel castings.
b) For P-1 and P-3 steel piping materials requiring the use of low-hydrogen
electrodes.
c) Electrodes classification E6012, E6013, E7014, E7020, E8013-B2 and E7024 shall
not be used for welding of pressure containing parts of piping. These electrodes,
however, may be used for non-pressure containing fillet welds of P-1 materials.
d) Austenitic stainless steel (P-8) welding materials for pressure boundary and load
bearing welds shall contain a minimum delta ferritic content of five percent based
upon the certified chemical analysis and the WRC Delta Ferritic Diagram.
1.4.5 For submerged-arc welding, alloy steel may only be welded with alloy wire and neutral
flux.
1.4.6 Shielded metal-arc welding electrodes are to have core wires of the approximate
analysis of the base materials. Major alloy additions are not to be made via the flux
coating.
1.4.7 Welding electrodes of AWS Type E309 or E309L shall be used for welding carbon or
low alloy steel to austenitic stainless steel, except in services over 260 deg.C, where
Inco 182 shall be used.
When Post Weld Heat Treatment of this joint is required, the carbon or low alloy steel
member shall be "buttered" with AWS Type E309 or E309L, and post weld heat treated
prior to welding to the austenitic stainless steel member unless otherwise agreed by
the COMPANY.
1.4.8 The physical properties of deposited weld metal shall be within the limits specified for
the material being jointed unless otherwise approved for special applications.
1.4.9 Completed welds specified to be in severe service shall not exceed the following
Brinnel Hardness (BHN). 225 BHN in P-1 carbon steel welds, 215 BHN in P-3 and P-4
steel welds, and 241 BHN in P-5 and P-6 steel welds. For welds that require post weld
heat treatment hardness tests shall be conducted on completion of heat treatment.
1.4.10 Since various international specifications for welding consumables are not freely
interchangeable, the actual weld deposit analysis and weld metal physical properties
shall be required for all alloy welding. The information shall be taken from relevant
testing. The information listed in electrodes manufacturer's catalogues is not
acceptable.
1.4.11 The storage, baking and drying of all flux covered electrodes, flux cored wires and
fluxes shall be as recommended by the manufacturers.
1.5 Weld Contour and Finish

1.5.1 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 material.
1.5.2 Weld reinforcement and finish shall be as required by the applicable code.
1.5.3 Peening is not permitted.
1.6 Heat Treatment

1.6.1 Surface Protection
Machined surfaces including flange gasket faces shall be protected by a suitable paint
or compound to prevent damage from scaling during heat treatment.
1.6.2 Supports
During heat treatment, piping shall be properly supported in the furnace to minimize
warping and other distortion.
1.6.3 Preheating Temperatures

Preheat temperature shall be in accordance with the ASME B31.3 except that
recommended code minimum preheat temperature shall be considered mandatory
under this specification. The preheat requirements shall also apply to tack welding and
to the welding of temporary attachments. The preheat requirements above shall also
apply to all thermal gouging and cutting except for P-1 steels with a carbon content up
to 0.3 percent and a tensile strength below 480 MPa.
a) In addition to governing code requirements. P-1 steels shall have a pre-heat of 80

deg.C minimum for thickness exceeding 1 1/2 inch.
b) The maximum interpass temperatures of austenitic stainless steels are 175 deg.
C.
c) Preheat and interpass temperature are to be determined by temperature indicating
crayons, contact pyrometers or other equally suitable means approved by the
COMPANY.
d) Dissimilar welds between austenitic stainless steels and ferritic steels shall be
welded with a preheat determined by the ferritic material.
e) For the welding of castings the whole castings is to be maintained within the
approved preheat and interpass temperatures during the welding operation.
1.6.4 Post Weld Heat Treatment(PWHT)
Post weld heat treatment shall be in accordance with the applicable codes and/or
specifications. PWHT procedures should be submitted for approval by by
COMPANY/INSPECTOR
a) A procedure for each method of post weld heat treatment shall be submitted to the
COMPANY for approval.
b) For P-6 materials, the post weld heat treatment temperature used shall be at least
28 deg.C below the lower critical temperature.
c) Direct impingement, by furnace burner flames is not permitted for post weld heat
treatment.
d) Sufficient thermocouples are to be properly attached to the work piece so as to
accurately indicate metal temperature reached during post weld heat treatment.
1.6.5 Exothermic Heat Treatment
a) Heat treatment may be done by the exothermic method if the exothermic materials
are designed for the application and if consideration is given to the thickness of the
piping and the configuration of components being heat treated.
b) The process and materials for exothermic treatment shall be subject to approval by
the COMPANY/INSPECTOR.
c) The vendor shall demonstrate successful past experience in using the materials on
the specified size of pipe and wall thickness.
1.7 Workmanship
1.7.1 Cleaning shall be done in a manner that will not lead to contamination of the weld or
adjoining base metal.
1.7.2 Cleanliness shall be maintained after completion of welding. Stubs, rods, flux, slag, and
foreign material shall be removed from the equipment or piping.
2.0 QUALITY ASSURANCE PROVISIONS
Quality assurance provisions shall be in accordance with the following additional

requirements.
2.1 Procedure Qualifications Tests

2.1.1 Welding procedures shall be in writing and shall be qualified in accordance with ASME
Section IX. The procedures shall be qualified no more than 2 years prior to the
purchase order date of the equipment being fabricated.
2.1.2 Procedure and operator qualification tests shall be completed duly witnessed by 3rd
Party Inspector and the certificates shall be submitted to the COMPANY / INSPECTOR
for review prior to fabrication.
2.1.3 The welding procedure tests shall demonstrate that all details are satisfactory for
obtaining full penetration welds for the following types of joints.
a) Double-welded longitudinal and circumferential butt joints.
b) Single-welded circumferential and longitudinal butt joints made without a backing
ring.
2.1.4 For inert gas tungsten arc and inert gas metal arc processes, the qualification record
shall include the composition and flowrate of inert gas backing when used.
2.1.5 The 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.
2.2 Quality Conformance Inspections

2.2.1 General
Unless additional inspection is specified in the project specifications, other General
Specifications, or data sheets, weld inspection shall comply with the following
requirements, as a minimum.
a) All welds shall be visually inspected after the work is completed.

b) All locally heat treated welds in carbon steel pipe shall be hardness tested per
4.1.4.
2.2.2 Visual Inspection
a) The fabricator shall visually inspect weld preparation, fit-up, and weld assemblies
during all phases of fabrication. Corrections shall be made in the weld preparation
to ensure that sound welds can be achieved by the welding process used.
b) Cracks and undercutting or any evidence of poor workmanship shall be cause for
rejection.
c) Weld quality based on visual examination shall otherwise meet the requirements of
ASME B31.3.
2.2.3 Branch welds, reinforcing pads, and miter bends
Welds shall merge smoothly with the surface of the pipe. Notches or undercutting are
not acceptable. Sharp corners on reinforcing pads shall be removed.
2.2.4 Radiographic Examination

a) The following minimum percentages of welds in each pipe class rating shall be
inspected radiographically and found acceptable.
 10 percent for ASME Class 150 to 300, 600(2” & below) rated piping
 100 percent for ASME Class 600(>2”),900, 1500 & above rated piping
COMPANY shall have the option to require that 100% of the welds in all hydrocarbons
containing piping be radiographically inspected, in addition to the above requirements.
a) If less than 100 percent of the welds are examined, for each unacceptable weld
the total number of welds to be examined shall be increased by 2 welds, up to 100
percent of the welds if necessary at the Fabricator's expense.
b) Welds selected for examination shall be representative of each welder and welding
procedure so that welding quality can be established at the beginning of the work.
c) The percentage of radiographed welds shall be evenly distributed among all
welders and taken while the work is being performed.
d) Radiographic examination shall be applied to 100% of all welds, including welds
other than girth butt welds, for piping in H2S service, if weld geometry permits.
Where weld geometry precludes radiographic examination, the weld shall be
examined by the magnetic particle or liquid penetrant method, as outlined in ASME
B31.3.
2.3 Repairs
2.3.1 Any welded joint that is defective shall be repaired with the procedures specified in
ASME Section IX, and shall be heat treated after the repair. The treating method shall
be approved by the COMPANY if approval was originally required. Repairs shall be
reexamined by the original method to determine if the welds are free from defects.
Repaired joints shall be retested.
2.3.2 Repairs of defects in the root and filler beads shall be made at the instruction of the
COMPANY representative. Before repairs are made, injurious defects shall be entirely
removed by grinding or oxygen gouging to the clean 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.
After repair of the weld, the entire circumference shall be radiographed again.
2.3.3 External undercut shall be repaired by grinding off the weld cap in the undercut
locations and recapping the locations.
2.3.4 Arc burn defects shall be ground smooth provided that the depth of the defect does not
exceed 8 percent of the nominal wall thickness. Arc burn defects with a depth greater
than 8 percent but less than 33-1/2 percent of the nominal wall thickness shall be
repaired by welding. The defect shall be thoroughly removed by grinding. The cavity
shall be welded and ground smooth. The weld shall be preheated in accordance with
the original preheat requirements for the materials and type of weld. All repairs shall be
made as specified by the COMPANY representative.
2.3.5 Laminations, split ends, or other defects in the pipe shall be called to the attention of
the COMPANY representative and shall be cropped, repaired, or removed from the
pipe as directed by the COMPANY representative.
2.3.6 No weld containing cracks, regardless of size or location, is acceptable. Cracked welds
shall be cut out and removed.
2.3.7 A sketch showing location, size and type of defect shall be attached to NDT report.
Rev: 0
APPENDIX – B - SPECIFICATION FOR PIPING INSPECTION
APPENDIX – B - Inspection
Table of Content
1.0 MARKING OF MATERIAL ..............................................................................................2

1.1 General ................................................................................................................2
2.0 WELDING .......................................................................................................................2

2.1 Welding Procedure Qualification Test ..................................................................2
2.2 Welding Performance Qualification Test ..............................................................2
2.3 Edge Preparation of the Welding .........................................................................2
2.4 Non-destructive Examination (NDT) .....................................................................3
2.5 During Welding ....................................................................................................4
3.0 APPEARANCE ...............................................................................................................4
4.0 DIMENSION ....................................................................................................................4

4.1 Dimensional Tolerance ........................................................................................5
5.0 PRESSURE TEST...........................................................................................................5
6.0 LINE CHECK ..................................................................................................................5
7.0 INSPECTION ITEM LIST ................................................................................................6
1.0 MARKING OF MATERIAL
1.1 General
1.1.1 Marking of material shall be conformed to cutting plan or list.
1.1.2 Before cutting, charge number shall be posted to cutting plan and /or shop drawing for
the purpose of checking up with mill certificates.
2.0 WELDING
2.1 Welding Procedure Qualification Test

This test shall be carried out in accordance with ASME Section IX and the welding
procedure shall be subject to COMPANY/INSPECTOR's approval.
In case the welding procedure qualification tests have been qualified by Third Party,
the record shall be submitted to the COMPANY / INSPECTOR for approval without
additional test, provided these have been carried out within 2 years of start of
fabrication.
2.2 Welding Performance Qualification Test

This test shall be carried out in accordance with ASME Section IX.
In case the welding performance has been qualified within last 6 months and duly
witnessed by Third Party, the welder's list shall be submitted to the COMPANY /
INSPECTOR for approval without additional test.
2.3 Edge Preparation of the Welding

2.3.1 The surfaces of weld bevels shall be ground or by mechanical means and checked
visually.
2.3.2 The surfaces of weld bevels shall be clean and free from paint, oil, dirt, scale, water
and other material detrimental to welding.
2.3.3 Bevels to be welded shall be checked visually or dimensionally by gauge, if necessary.
2.3.4 Groove angle tolerance as fit-up to be butt welded shall be according to ASME B16.25.
2.3.5 Misalignment of section at edge to be butt welded shall not exceed 1.6mm.
2.4 Non-destructive Examination (NDT)

2.4.1 Kinds of Non-destructive Examinations to be carried out shall include, but not limited
to;
a) Radiographic Test (RT)
b) Ultrasonic Flow Test (UT)
c) Magnetic Particle Test (MPT)
d) Dye Penetrant Test (DPT)
NDT shall be carried out using RT only, wherever RT is not possible, UT may be
carried out with the approval by COMPANY / INSPECTOR.
2.4.2 Minimum Extent RT shall be as follows:
ASME 150 Class to 600 Class (2” & below) - 10%
ASME 600 Class (above 2”), 900 Class & above rated - 100%
2.4.3 NDT shall be carried out as per the requirements of ASME B31.3.
2.4.4 Application of NDT
RT shall be applied for full penetration butt weld where thickness is less than 45mm.
2.4.5 RT Examination
a) Testing technique shall be in accordance to ASME Section V, Article 2.
b) Acceptance Standard shall be ASME B31.3
c) RT Film Custody:
A complete set of radiographs shall be kept by CONTRACTOR for five years after
delivery and all records signed by the Inspectors shall be submitted to COMPANY.
2.4.6 Magnetic Particle Test ( MPT)
b) Method:
• Dry power magnetic particle exam.
• Wet magnetic particle exam.

c) Sequence of operation: Continuous method.
d) Direction of magnetization
At least one crossed examination shall be carried out on each area. The second
examination shall be with the lines of magnetic flux perpendicular to those used for
the first examination in that area.
e) Surface preparation:
Wire brushing
f) Examination coverage.
Examination shall be conducted with sufficient overlap to assure 100% coverage at
the established best sensitivity.
2.4.7 Liquid Penetrant Examination (DPT)
b) Method: Solvent- removable method
2.4.8 Procedure
Pre-cleanpenetrant application  clean by solvent  dry  apply developer 
inspection post clean.
2.4.9 Surface preparation shall be done by Wire brushing
2.4.10 Repairs
Any welded joint that is defective shall be repaired and subject to retest.
2.5 During Welding

The following items at least shall be cared during welding.
• Electrode, proper baking and storing;

• Weld position;
• Pre-heat temperature;
• Welding conditions
As for the details of edge preparation (fit - up) and welding, refer to "Welding Practice"
which shall be supplied by fabricator for COMPANY approval.
3.0 APPEARANCE
The appearance inspection shall be carried out visually for the entire weld surfaces of
outside and inside, if possible, in order to check that relevant surfaces are free from
cracks and it shall look work man like finish.
In no case surface cracks are acceptable. Surface cracks if found, the same shall be
ground-off up to the root of the crack and re-welded.
4.0 DIMENSION
Throughout the construction, actual dimensions shall be monitored, to ensure that the
fabrication and assembly are carried out within the tolerance specified in the contract
documents.
4.1 Dimensional Tolerance

4.1.1 The tolerances on linear dimensions (intermediate or overall which apply to the face to
face, face to end, and end to end measurements of fabricated straight pipe and
headers; center to end or center to face of nozzles or other attachments; or center to
face of bends shall be as follows; these tolerances are not accumulative.
• linear tolerances on "A" are +/-3.2mm for pipe sizes 10" NB and below, and
+/-4.8mm for pipe sizes 12" NB through 36" NB.
• Due to the cumulative effects of tolerances on fittings or flanges, when joined

without intervening pipe segments, deviations in excess or those specified in the
above may occur.
4.1.2 Flattening of the cross section of bended pipe shall not exceed 8% of the nominal pipe
diameter.
5.0 PRESSURE TEST
Pressure test shall be carried out in accordance with Appendix - C.
6.0 LINE CHECK
A check list shall be prepared to confirm the followings and signed by representatives
of COMPANY / INSPECTOR after checking:
a) All installation needs with P&ID drawings and specifications.
b) All valves, instrument in proper place and directions, etc.
c) Pipe slope is as per drawings.
d) All pipe supports are in place.
e) All events drains properly installed.
f) All NDT / PWHT are cleaned.
g) Line flushing completed.
7.0 INSPECTION ITEM LIST
ITEM TO BE INSPECTED WITNESS OR REVIEW DOCUMENT

TO BE
COMPANY / CONTRACTOR.
SUBMITTED
INSPECTOR
1) Welding Procedure yes* yes yes
Qualification (review)
2) Welding performance yes* yes Yes
Qualification.
3) Marking of Material spot** yes Material
(Material Verification) certificates
4) Edge Preparation (Fit- spot** yes No
Up)
5) Appearance of Pre-fab. yes yes No
6) Appearance of field - yes yes yes

Assembly & Line Check
7) Radiographic Exam. yes(film yes yes
review)
8) Magnetic Particle Exam yes yes yes
or Liquid Penetrant (witness)
Exam.
9) Pressure Test yes yes yes
10) Dimension (At Field spot** yes yes

Assembly)
11) Surface Prep. for Paint yes yes yes
12) Painting yes yes yes
Notes:
* When the test has been qualified, the documents to be submitted for review.
** Spot inspection during fabrication.
Rev: 0
APPENDIX – C - SPECIFICATION FOR PIPING TESTING
Appendix – C - Testing
Table of Content
1.0 TESTING REQUIREMENTS ...........................................................................................2

1.1 Cleaning ..............................................................................................................2
1.2 Checkout before Hydrostatic Testing ...................................................................2
1.3 General Requirements for Hydrostatic Testing .....................................................3
1.4 Hydrostatic Testing ..............................................................................................5
1.5 Pneumatic Testing ...............................................................................................5
1.6 Additional Special Requirements .........................................................................6
1.7 Test Records .......................................................................................................6
1.0 TESTING REQUIREMENTS
1.1 Cleaning
1.1.1 After fabrication, all piping, vessels, tanks, and equipment shall be thoroughly cleaned
by blowing out with air or flushing with water (see Paragraph 1.3.6 & 1.6.1 for stainless
steel piping). Where equipment or process piping cannot tolerate moisture due to
process considerations, a substitute cleaning procedure will be agreed upon with the
COMPANY / INSPECTOR.
1.1.2 Temporary strainers shall be installed upstream of all pumps, compressors, and other
designated items to prevent entry of debris in accordance with the respective flow
diagrams.
1.1.3 Water flushing should be continued until clean water appears at the discharge point for
at least one minute.
1.1.4 Control valves, positive displacement meters, turbine meters, rotameter or relieving
devices shall not be flushed.
1.1.5 After flushing, temporary strainers shall be removed from the piping, cleaned, and
re-installed.
1.1.6 For cleaning of lube oil piping systems, see Paragraph 1.3.5 and 1.6.2.
1.1.7 The CONTRACTOR shall submit a cleaning system procedure and schedule to the
COMPANY/INSPECTOR for approval.
1.2 Checkout before Hydrostatic Testing

1.2.1 Inspect water supply to ensure an adequate volume of clear Potable water is available
at a temperature of at least 7 deg. C.
1.2.2 Inspect the system to be tested to ensure the following:
a) All required welding, NDT and stress relief have been completed and all supports
are in place.
b) All high point vents are open and necessary valves are installed.
c) Positive displacement Meters, Rotometers, Turbine-Type Meters, Self-Contained
Regulators Filter elements, restriction orifices, chokes, control valves and pilot
tubes have been removed.
d) All block valves and blinds are in their proper position.
e) All relief valves have been properly isolated or removed.
f) All rupture disks have been replaced with suitable blinds.
g) Instrument lines have been disconnected at the first block valve.

h) Additional temporary supports have been installed, if necessary, on vapor or gas
piping to support the additional test fluid weight.
i) All check valves are held open, and block and bleed ball valves are in the
one-half open position.
j) All Pressure Switches, Pressure Indicators / Controllers, Level Indicators /
Controllers and Level Switches are removed or blocked-off.
1.2.3 Discuss test procedure with all personnel involved so that they clearly understand their
assigned duties. Personnel not required in the immediate area should stay clear during
the test.
1.2.4 Hot and cold insulated piping shall be tested prior to apply insulation.
1.3 General Requirements for Hydrostatic Testing

1.3.1 Hydro test pressure shall be as specified in the AFC ISO.
1.3.2 Alternative tests may be applied under the conditions of ASME B31.3, Paragraph
345.9, with prior approval of the COMPANY.
1.3.3 The hydrostatic test pressure shall be a minimum of 1.5 times the design pressure.
Where the design temperature is above the test temperature, the minimum test
pressure shall be calculated by the following equation:
Pt = 1.5 PS t
Where:
Pt = minimum hydrostatic test pressure
P = internal design pressure
St = allowable stress at test temperature
S = allowable stress at design temperature
If Pt will produce a stress in excess of the yield strength at test temperature, the test
pressure shall be reduced to the maximum pressure that will not exceed the yield
strength at test temperature.
1.3.4 The fluid used for testing shall be fresh water.
1.3.5 Lube oil or hydraulic oil systems consisting of small piping or tubing may be tested with
oil.
1.3.6 Stainless steel piping vessels and equipment shall be tested with fresh water
containing less than 50 ppm of chlorides.
1.3.7 Turbines, blowers, pumps, and compressors shall not be hydrostatically tested in the
field.
1.3.8 Shop fabricated vessels, exchangers, and piping shall be hydrostatically tested in the
vendor's shop in accordance with the applicable purchase specifications. Equipment
previously tested in the shop need not be retested in the field.
1.3.9 All piping or equipment not previously tested shall be tested in the field with the
exception of equipment where the manufacturer or COMPANY / INSPECTOR requires
that it not be tested.
1.3.10 All Ball valve seats will be tested at site prior to erection on line, not withstanding that
they have been tested at the VENDOR works. Once seat tested, the valves can be
hydro tested on line in open position.
1.3.11 Isolation of piping and equipment during test shall be accomplished by using blind
flanges or insert blinds. Valves may be used to isolate piping systems only where test
pressure is below manufacturer's recommended working pressure, with
COMPANY/INSPECTOR's prior written approval.
1.3.12 Piping must be fully erected, properly supported, and all stress relief work completed
before testing. Welds and flanges shall be clean and exposed for inspection.
1.3.13 In general instrument piping shall be tested pneumatically. If instrument piping is

hydrostatically tested, it shall be tested up to the first block valve. Testing of instrument
piping beyond the first block valve shall be under the supervision of the / INSPECTOR
and shall be limited to in service testing unless otherwise agreed in advance in writing.
1.3.14 The following items must be removed or isolated from the piping system before testing.
• Positive displacement Meters and Rotometers.

• Turbine-Type Meters.
• Filter elements, restriction orifices, chokes, control valves and pilot tubes
• Self-Contained Regulators.
• Pressure Relief Valves and Rupture Disks.
• Expansion Joints.
1.3.15 Piping repaired after testing shall be retested after repair at the test pressure originally
indicated.
1.3.16 All piping system testing shall conform to the requirements of the Specifications, codes
and standards.
1.4 Hydrostatic Testing

1.4.1 Review all procedures or applicable instructions for special precautions.
1.4.2 Fill the system slowly to avoid water hammer and to adequately bleed all air from the
system.
1.4.3 Close each high point vent after steady stream of water indicates air has been
removed.
1.4.4 When system up to test pressure, pressure shall be increased gradually in steps and
carefully examine the piping system for leaks or other evidence of problems.
1.4.5 Replace packing in items such as valves when leaks cannot be stopped by normal
tightening of packing glands.
1.4.6 After system is at test pressure and without leakage, pressure shall be maintained for
at least 60 min, without leakage.
1.4.7 Record each test including date, time, system being tested, test fluid, test pressure,
and test temperature. Obtain signature of COMPANY / INSPECTOR.
1.4.8 Open vents and drain at each system after test, and take preservative measures as
agreed with the COMPANY. Exercise care to avoid drain rate which would cause large
vessels or tanks to vacuum.
1.4.9 Replace material such as gaskets, bolting, etc., damaged during testing.
1.4.10 Replace material such as gaskets where the flanges are broken.
1.5 Pneumatic Testing

1.5.1 Pneumatic testing is not recommended.
1.5.2 If hydrostatic testing is not considered practical by the COMPANY/INSPECTOR, a

pneumatic test in accordance with ASME B31.3 may be performed, using air or
another nonflammable gas.
1.5.3 A preliminary air test at not more than 1.70 kg/cm2g pressure shall be made before
Appling the required test pressure
1.5.4 The pneumatic test pressure shall be 1.1 times the design pressure of the system. The
pressure shall be increased gradually in steps, providing time to allow piping to
equalize strains.
1.5.5 All joints, welds, and connections shall be swabbed with a soap solution to facilitate the
detection of leaks. Test pressure shall be maintained for at least 15 min.
1.5.6 Replace packing in items such as valves when leaks cannot be stopped by normal
tightening of packing glands.
1.5.7 Record each test including date, time, system being tested, test fluid, test pressure,
and atmospheric temperature, Obtain signature of COMPANY's Authorized Inspector.
1.5.8 Release pressure slowly and take preservative measures as agreed with the
COMPANY.
1.5.9 Replace material such as gaskets, bolting, damaged during testing.
1.6 Additional Special Requirements

1.6.1 Stainless Steel Piping Systems
• Fresh water containing greater than 50 ppm of chlorides may be used if sodium
nitrate is added to obtain a solution containing 0.5 percent sodium nitrate by
weight.
• After testing of austenitic stainless steel materials all water shall be drained and
completely blown out with air.
1.6.2 Lube Oil and Seal Oil Piping Systems
• Carbon steel lube oil piping shall be chemically cleaned and flushed to remove all
mill scale, weld spatter, dirt and other foreign matter from the interior of the pipe.
The chemical cleaning procedure shall be approved in advance by COMPANY /
INSPECTOR. Upon completion of the cleaning, flushing, and testing procedures,
the pipe shall be passivated and filled with lube oil.
• Stainless steel lube oil piping shall be cleaned in accordance with this
specification, except that during the flushing operation the piping shall be
hammered or mechanically vibrated frequently to facilitate the removal of all
foreign matter from the interior of the pipe. The system shall be tested in
accordance specification. Upon completion of cleaning and testing, the pipe shall
be drained, air dried, and filled with lube oil.
1.7 Test Records
1.7.1 CONTRACTOR shall maintain all the records and have traceability. The records shall
include, but not limited to;
a) Date of test.
b) Identification of piping tested and test limit.
c) Test medium.
d) Test pressure.
e) Pressure/Time recorder chart.
f) Temperature/Time recorder chart.

g) Type of testing equipment used and a copy of the equipment calibration certificate.
h) Approval by the Certifying Authority and CONTRACTOR Inspectors.
1.7.2 Records for piping which require that pressure be held for a specified period of time
shall include any corrections of test pressure due to temperature variations during the
test.
1.7.3 All test records and code examiner certifications shall be prepared and maintained by
the CONTRACTOR and shall be incorporated in final record book which will be issued
to the COMPANY on job completion.
1.7.4 Test performed at package vendors works shall be witnessed and approved as
specified in the purchase order. Test records and examination certificates shall be
forwarded to the CONTRACTOR for incorporation in the final record book.

Standard Specs 13 STD Spec - For Piping Fab Insp Testing Rev 0

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Standard Specification for

Doc No: P6EC-STD-PP-S-1003 Page: 2 of 14

1.0 SCOPE ........................................................................................................................... 3

2.0 ENVIRONMENTAL DESIGN CRITERIA ......................................................................... 3

3.0 CODES, STANDARDS AND REFERENCE DOCUMENTS ............................................ 3

4.0 FABRICATION AND ERECTION REQUIREMENTS ...................................................... 5

APPENDIX – A - SPECIFICATION FOR WELDING ................................................................ 12

APPENDIX – B - SPECIFICATION FOR PIPING INSPECTION .............................................. 13

APPENDIX – C - SPECIFICATION FOR PIPING TESTING ..................................................... 14

Doc No: P6EC-STD-PP-S-1003 Page: 3 of 14

2.0 ENVIRONMENTAL DESIGN CRITERIA

2.1 Climatic Conditions

2.2 Design Life

3.0 CODES, STANDARDS AND REFERENCE DOCUMENTS

3.1 Reference Documents

Doc No: P6EC-STD-PP-S-1003 Page: 4 of 14

P6EC-STD-PP-S-1001 : Piping Material Specification

P6EC-STD-PP-S-1002 : Valve Material Specification

P6EC-STD-PP-S-1004 : Standard Specification for Piping Specialty Items

P6EC-STD-PP-S-1005 : Standard Specification for Painting and Colour Code

P6EC-STD-PP-S-1006 : Standard Specification for Insulation

P6EC-STD-PP-S-1007 : Standard Specification for Positive Material Identification

3.2 International Codes and Standards

ASME Sec. II : ASME Boiler and Pressure Vessel Code – Materials.

ASME Sec. V : ASME Boiler and Pressure Vessel Code – Nondestructive

ASME B 1.20.1 : Pipe Threads

ASME B16.9 : Factory Made Wrought Steel Butt Welding Fittings

ASME B 16.11 : Forged Steel Fittings, Socket Welding and Threaded

ASME B16.21 : Non-Metallic gaskets for Piping Flanges

ASME B16.25 : Butt Welding Ends

ASME B31.3 : Process Piping

ASME B36.10 : Welded and Seamless Wrought Steel Pipe

Doc No: P6EC-STD-PP-S-1003 Page: 5 of 14

ASME B36.19 : Stainless Steel Pipe

AWS D 1.1 : American Welding Society – Structural Welding Code-Steel

AWS A5.9 : Specification for Corrosion Resisting Chromium and

EN10204 : Materials Testing Certificates

AWS D 1.1 : American Welding Society – Structural Welding Code-Steel

EN10204 : Materials Testing Certificates

AISC : American Institute of Steel Construction

IS – 1893 : Criteria for earthquake resistance design of structures

OMR : Oil Mines Regulations

OISD : Oil Industries Safety Directorate regulations

DGMS : Directorate General of Mines Safety

IER : Indian Electricity Rules

CPCB : Central Pollution Control Board of India

4.0 FABRICATION AND ERECTION REQUIREMENTS

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4.2 Piping Drawings

4.4 General Fabrication Requirements

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4.5 Threaded Connections

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4.6 Bolting and Gaskets

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4.8.2 Flanges Face Alignment

• Piping with wall thickness 6mm and above. +1.5mm

• Angular dimensions of bends and branches, +1.4 degree

4.9 Shop Detail Drawings

4.10 Painting, Coating and Marking

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• All marking to be applied after application of the protective coating.