R and B Fabrication Welding Installation and Testing of Pipework Specification PDF

.
Project Title
BG Tunisia Project Ref. Page File Reference
Miskar Relief and Blowdown J8472A 1 of 41
Project
FABRICATION,WELDING,INSTALLATION
&
TESTING OF PIPEWORK SPECIFICATION
BGT DOCUMENT NUMBER
GOGC DOCUMENT NUMBER
A 29/6/11 Issued For IDC NP

Checked Approved
Rev No Date Description Issued By
By By
GENESIS OIL & GAS CONSULTANTS LTD
BG TUNISIA MISKAR RELIEF AND BLOWDOWN PROJECT
FACRICATION, WELDING, INSTALLATION & TESTING OF PIPEWORK
SPECIFICATION
Rev Location Of Changes Brief Description Of Change

BG TUNISIA / MISKAR RELIEF AND BLOWDOWN
FACRICATION,WELDING,INSTALLATION & TESTING OF PIPEWORK
SPECIFICATION
INDEX
1.0 INTRODUCTION .................................................................................................... 6

1.1 Scope ..................................................................................................................... 6
1.3 Definitions .................................................................................................. 6
1.4 Conflicts ..................................................................................................... 6
2.0 CODES AND STANDARDS ................................................................................... 7
2.1 References ................................................................................................ 7
2.1.1 American National Standards Institute ...................................................... 7
2.1.2 ASME Boiler and Pressure Vessel Codes ................................................ 7
2.1.3 American Petroleum Institute .................................................................... 7
2.1.4 British Standards ....................................................................................... 8
2.1.5 Project Specifications and Standards ....................................................... 8
3.0 DESIGN .................................................................................................................. 8
3.1 Drawings and Documentation ................................................................... 8
3.2 Welded Attachments and Branch Reinforcement ..................................... 9
3.3 Proximity of Welds ..................................................................................... 9
4.0 MATERIALS ........................................................................................................... 9
4.1 Material Supply .......................................................................................... 9
4.2 Material Specifications .............................................................................. 9
4.3 Austenitic and Duplex Stainless Steel..................................................... 10
4.4 Cleaning of Austenitic and Duplex Stainless Steel ................................. 10
4.5 Additional Requirements ......................................................................... 10
5.0 FABRICATION ..................................................................................................... 10
5.1 General .................................................................................................... 10
5.2 Pipe Cutting and Welding End Preparation............................................. 11
5.3 Pipe Bending ........................................................................................... 11
5.3.1 General .................................................................................................... 11
5.3.2 Hot Bending ............................................................................................. 11
5.3.3 Cold Bending ........................................................................................... 12
5.4 Fabrication Tolerances ............................................................................ 12
5.5 Post Fabrication Treatment of Fabricated Spools ................................... 12
5.5.1 Cleaning and Protection .......................................................................... 13
5.5.2 Marking .................................................................................................... 13
5.5.3 Offshore and Onshore Spools ................................................................. 13
5.5.4 Dimensional Control ................................................................................ 13
6.0 WELDING ............................................................................................................. 14
6.1 General .................................................................................................... 14
6.2 Butt Welds ............................................................................................... 14
6.3 Branch Welds .......................................................................................... 14
6.4 Fillet Welds .............................................................................................. 15
6.5 Socket Welds........................................................................................... 15
6.6 Attachments to Thin Wall Pipes .............................................................. 15
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SPECIFICATION
6.7 Alignment ................................................................................................. 15

6.8 Fit-up and Temporary Attachments ......................................................... 15
6.9 Protection from Weather ......................................................................... 16
6.10 Weld Cleaning, Back Gouging and Repair.............................................. 16
6.11 Welding Processes .................................................................................. 16
6.12 End Preparations ..................................................................................... 17
7.0 WELDING CONSUMABLES ................................................................................ 17
7.1 Specification and Selection ..................................................................... 17
7.1.1 Stainless Steel ......................................................................................... 18
7.1.2 Carbon Steel............................................................................................ 18
7.1.3 Duplex Stainless Steel ............................................................................ 18
7.2 Storage, Protection and Baking............................................................... 19
8.0 WELDING PROCEDURE AND WELDER QUALIFICATION .............................. 19
8.1 General .................................................................................................... 19
8.2 Hardness Survey ..................................................................................... 20
8.3 Repair Procedures................................................................................... 20
9.0 HEAT TREATMENT ............................................................................................. 22
9.1 Preheat and Interpass Temperatures – Carbon Steel ............................ 22
9.2 Post Weld Heat Treatment (PWHT) – Carbon Steel............................... 22
9.3 Preheat and Interpass Temperatures – Other Materials......................... 22
9.4 Post Weld Heat Treatment (PWHT) – Other Materials ........................... 22
10.0 INSPECTION AND TESTING .............................................................................. 23
10.1 General .................................................................................................... 23
10.2 Inspection ................................................................................................ 23
10.3 Inspection Techniques & Acceptance Criteria ........................................ 23
10.4 Qualification of NDT Personnel ............................................................... 24
10.5 Progressive Examination ......................................................................... 24
11.0 INSTALLATION .................................................................................................... 25
11.1 General .................................................................................................... 25
11.2 Pipework Erection.................................................................................... 25
11.3 Flanged Joints ......................................................................................... 26
11.4 Equipment Flange Conditioning .............................................................. 26
11.5 Gaskets ................................................................................................... 26
11.6 Bolting ...................................................................................................... 29
11.7 Valves ...................................................................................................... 30
11.8 Screwed Pipework ................................................................................... 30
11.9 Pipe Supports .......................................................................................... 30
11.10 Field Run Piping ...................................................................................... 31
12.0 PRESSURE TESTING & FLUSHING .................................................................. 31
12.1 General .................................................................................................... 31
12.2 Preparation for Testing ............................................................................ 31
12.2.1 General .................................................................................................... 32
12.2.2 Test Loading ............................................................................................ 32
12.2.3 Valves and Instruments ........................................................................... 32
12.2.4 Packed Equipment .................................................................................. 33
12.3 Testing Medium ....................................................................................... 33
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SPECIFICATION
12.3.1 Hydrotstatic Test...................................................................................... 33

12.4 Test Pressure and Temperature ............................................................. 34
12.4.1 Hydrostatic Test Pressure ....................................................................... 34
12.4.2 Test Temperature .................................................................................... 34
12.5 Pressure Test Procedure ........................................................................ 34
12.5.1 General .................................................................................................... 34
12.5.2 Hydrostatic Test....................................................................................... 34
12.6 Pneumatic Test........................................................................................ 35
12.7 Test Equipment ....................................................................................... 35
12.8 Test Records ........................................................................................... 36
12.9 Post Test Requirement ............................................................................ 36
13.0 QUALITY ASSURANCE AND CERTIFICATION ................................................. 36
14.0 ADDENDUM ‘A’ .................................................................................................... 38
15.0 ADDENDUM ‘B’ .................................................................................................... 39
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SPECIFICATION
1.0 INTRODUCTION
1.1 SCOPE
This defines the requirements for fabrication, installation, pressure testing and flushing, material
inspection and testing, painting, temporary supports, packaging of spools, documentation of process,
utility and safety piping systems for the Miskar Relief and Blowdown Project This specification covers
all shop and field fabricated pipe work in Carbon Steel (incl. low temperature Carbon Steel and High
Yield Carbon Steel), Austenitic and Duplex Stainless and high nickel alloys UNS N0 8825 & UNS N0
6625.
The scope of work shall be deemed to be complete when all the work outlined in this specification is
completed to the Purchaser’s satisfaction, all piping systems are commissioned and documentation
handed over.
This Specification defines minimum standards to be met by Contractor, but does not relieve the
Contractor from his responsibility for producing work of the required quality and fitness for purpose.
Where the Contactor considers deviations from this Specification would give a better engineering
product then he shall inform the Purchaser in writing. The affected work shall be held until approval
of direction is given by the Purchaser.
If any work is Sub-Contracted, by the Contractor, the Contractor shall submit full details for the
Purchaser’s approval. The full details as a minimum shall include:-
a) Name & location of Sub-Contractor.
b) Extent of work sub-contracted.
c) Interfacing of this work with the overall program.
Approval by the Purchaser to Sub-contracted work shall not relieve the contractor of his full and total
responsibilities and the contractor shall ensure that the Sub-contracted work is in accordance with
the Purchaser’s standards and specifications.
1.2 Pipe work Excluded
Excluded from the scope of this specification are:-

a) All instrument tubing and valving downstream of the first piping block valve.
b) Fabrication and Installation of Pipe supports
1.3 Definitions
The following definitions shall apply to this specification:-

‘Purchaser’ The Purchaser shall be taken to mean BG Tunisia or any agents thereof.
‘Contractor’ The Contractor shall be taken to mean the organisation(s) carrying out the
pipe work fabrication and installation.
1.4 Conflicts
All conflicts between the requirements of this specification, related contracted documents, national
standards, codes of practice and the Enquiry Document shall be referred to the Purchaser. Where
Conflicts occur the order of precedence shall be:-
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SPECIFICATION
1) Statutory Requirements
2) Contract
3) Data Sheets
4) Minimum Code/Standard Requirements
5) This Specification
2.0 CODES AND STANDARDS
All pipe work fabrication, testing, inspection, installation and mechanical completion shall meet, as a
minimum, the requirements of ASME B31.3 ‘Chemical Plant and Petroleum Refinery Piping’
Pipe work outside the jurisdiction of ASME B31.3 shall be fabricated, tested, inspected and installed
in accordance with the appropriate governing code, such as:-
• PD 8010 Part 2 Pipelines-Design and Construction.
• ASME B31.8 Gas Transmission & Distribution Piping

Any such codes will be highlighted on the drawings and related documents.
The following codes and regulations shall also apply:-
• API-RP-14E API Recommended Practice for Design And Installation of Offshore

Production Platform Piping Systems.
• API-RP-520 API Recommended Practice for Design and Installation of Pressure

Relieving Systems.
• NACE MR-0175/ISO 15156 "Materials for use in H2S containing Environments

In oil and gas production
This Specification is intended to supplement the requirements of the above codes and regulations.
2.1 References
2.1.1 American National Standards Institute
ANSI B1.20.1 Pipe threads (except Dry seal)
ASME B31.3 Chemical plant and petroleum refinery piping
ANSI/ASME B31.1 Power piping
ANSI/ASME B31.8 Gas Transmission and Distribution Piping Systems
2.1.2 ASME Boiler and Pressure Vessel Codes
Section IX Welding and brazing qualification
Section V Non Destructive Examination
2.1.3 American Petroleum Institute

API RP.14E API recommended practice for design and installation of offshore
production platform piping systems.
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SPECIFICATION
API RP. 520 Recommended practice for the design and installation of Pressure-
Relieving Systems in Refineries
API 5L Specification for Line Pipe
API 5LC Specification for CRA Line Pipe
API BUL.5A2 API bulletin on thread compounds for casing, tubing and line pipe.
API RP 1110 Recommended practice for the Pressure Testing of liquid Petroleum
pipelines
API 1104 Welding of Pipelines and Related Facilities
2.1.4 British Standards

BS CP3012 Cleaning and preparation of metal surfaces
BS 2633 Class 1 Arc Welding of Ferritic Steel Pipe work for Carrying Fluids
BS 4105 Industrial liquid carbon dioxide
BS 4364 Industrial oxygen
BS 4366 Industrial argon
BS 4366 Industrial nitrogen
BS 4515 Process of Welding of Steel Pipelines on land and Offshore
BS 5500 Unfired fusion welded pressure vessels
PD8010 Part 2 –Pipelines-Design and Construction
EN 10045/1 Charpy Impact Tests on Metallic Materials
2.1.5 Project Specifications and Standards

BGT/MI1/G/ST/10/00/6101 Coating offshore structures, piping and equipment
J8278-L-RD-14001 Piping Material Specification & Valve data sheet
J8278-L-SD-13400 Pipe Support Specification
3.0 DESIGN
3.1 Drawings and Documentation

The Purchaser shall furnish the Contractor with all drawings and documents, specifying all the
fabrication, installation and testing requirements. The following is a list typical of documents
available.
a) P & ID’s
b) General Arrangement Drawings
c) Piping Study drawings of areas or lines not covered by (b) above
d) Piping Isometrics
e) Piping Material Specifications
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SPECIFICATION
It shall be the Purchasers responsibility to produce isometric drawings for Contractor use. These
drawings shall be authorised and approved by the Purchaser and also made available during
installation and erection of pipe work.
Any changes to pipe work for whatever reason shall be approved and recorded via the site Query
System. The Contractor shall ensure that he has the necessary design approval prior to fabricating
or installing modified lines.
The Purchaser’s drawings and documents show the shape, size, class and dimensions of all pipe
work. The Contractor shall make allowances, where necessary, for weld gaps.
The Contractor shall not make allowances for any gasket thickness, except as dimensioned on
drawings.
3.2 Welded Attachments and Branch Reinforcement
The design of welded attachment joints shall generally be in accordance with ASME B31.3. Within
the guidelines of ASME B31.3 the Contractor shall employ a joint design which suits the welding
process and enables a fully fused weld to be made.
The type of branch reinforced connection shall be as specified in the Piping Material Specification
number J8469B-L-S-14000
When specified, reinforcement pad or segment thereof shall be provided with one hole (at the side
and not at the crotch) drilled and tapped ¼ inch NPT.
3.3 Proximity of Welds
The minimum distance between toes of adjacent welds shall be 50mm or six times the thickest
pipe/fitting wall thickness, whichever is the greater.
Dimensions less than those specified above are not permitted except where Purchaser agreement
has been obtained and the following additional requirements met:-
a) Dependent on material, thickness and configuration the Purchaser may require an
intermediate stress relief to be carried out.
b) Care shall be taken to minimise stress concentration Weld profiles shall be as smooth as
possible. At the discretion of the Purchaser, welds shall be dressed.
c) When branch welds cross or are located closer than allowed to main seams, such seams
shall be radiographed or ultrasonic tested for a distance on either side of the hole of not less
than the opening diameter.
d) When attachments are located closer than allowed to main seams they shall cross the seam
completely. The seam shall be radiographed to the extent which will be covered by the
attachment, plus on either side of the attachment, a distance of twice the pipe wall thickness.
4.0 MATERIALS
4.1 Material Supply

The Contractor shall supply all temporary materials, pipe, supports, etc. required for fabrication,
installation, transportation, testing and commissioning.
4.2 Material Specifications
All piping materials, pipes, flanges, fittings, valves, bolting, gaskets, etc. shall be in accordance with
the Purchaser’s Piping Material and Valve specification Doc No J8469B-L-S-14000 and any
associated procurement specifications. The Contractor shall satisfy himself that all piping items are
in accordance with these specifications.
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SPECIFICATION
Backing rings, bridge pieces, cleats, fittings and other auxiliary items welded to the pipe work either
temporarily or permanently shall be to the same or an agreed equivalent specification as the pipe or
flange material.
4.3 Austenitic and Duplex Stainless Steel and Nickel Alloys
Austenitic and Duplex Stainless Steel materials and fabricated spools must be stored separately
from carbon steel materials and separately from each other, in designated areas set aside for that
purpose.
4.4 Cleaning of Austenitic and Duplex Stainless Steel and Nickel Alloys
All surfaces and edges of austenitic and Duplex Stainless Steels and nickel alloys which are to be
heated for any purpose; e.g. Cutting, forming or welding; shall be free from all traces of contaminants
such as paint, grease, soap, sulphur containing compounds and low melting point metals including
zinc, lead and tin, etc. Cleaning shall be accomplished by grinding, wire brushing using stainless
steel brushes and/or solvent cleaning. To avoid contamination separate (clearly defined) sets of
cleaning and grinding equipment shall be maintained for each material.
Austenitic and Duplex Stainless Steel and nickel alloys shall not be allowed to come into contact with
any carbon steel materials; i.e.; wire brushes, tools etc, whilst hot.
4.5 Additional Requirements
Additional requirements for pipe work in impact tested carbon steel are specified in Addendum ‘A’.
All spools fabricated off site will be inspected, tested and hydro tested, in accordance with this
specification. All spools are to be painted, and have appropriate identification markings added, prior
to shipment to site. All spools are to be fully certified.
Any spools arriving at site not conforming to the above or without the appropriate documentation will
not be accepted.
5.0 FABRICATION
5.1 General
Longitudinal seams in seam welded pipe shall be located to clear openings and external
attachments wherever possible. Longitudinal seams in adjoining courses shall be at 90º to each
other.
Unless otherwise stated on the Isometric Drawings, all flange bolt holes shall straddle the NS centre
line when the flange Face is horizontal and the vertical flange centre line when the face is vertical or
inclined.
Flange facings shall be accordance with the Piping Material specification Doc No J8469B-L-S-14000
the type of branch reinforced connection shall be as specified in the Piping Material Specification
number: J8469B-L-S-14000. Should warping take place during fabrication the joint contact surfaces
may be restored by machining to their original accuracy provided the flange thickness dimensions
are not reduced below the minimum required by the relevant flange specification.
The fabrication of weld neck orifice flanges shall receive special attention to ensure that the pressure
tapings are positioned as shown on the drawings and that the pipe bore is smooth and free from
projections. Weld areas shall be ground or machined or achieve the required profile.
Materials found to be damaged or found to have defects shall not be used in fabrication except after
approval of the Purchaser, when minor surface marks may be dressed by grinding, providing that the
minimum wall thickness is not encroached upon. The minimum wall thickness is the nominal wall
thickness minus the manufacturing tolerance defined in the appropriate product specifications.
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SPECIFICATION
The pipe work shall be painted in accordance with the Project Painting specification Doc No.
BGT/MI1/G/ST/10/00/6101
Flow direction arrows tapes of 50mm x 250mm size shall be marked on the pipe work every 2m to
3m interval.
5.2 Pipe Cutting and Welding End Preparation
Pipes shall be cut either by mechanical means or by thermal cutting.
End bevelling shall be done by machining, hand grinding or machine flame cutting.
Where thermal cutting is employed, all slag, oxides and traces of previously melted metal shall be
removed from welding edges by grinding or machining to sound metal.
The preheat level to be used for thermal cutting shall be as required by the relevant welding
procedure.
The bevel geometry shall be the same as and within the tolerances stated in the approved welding
procedure.
The pipe end after preparation shall be visually examined. Refer to paragraph 10.2.
5.3 Pipe Bending
5.3.1 General
a) Pulled bends will only be used when specified by the Purchaser.
b) Where pipe bending is required as shown on the Purchaser’s drawings this may be
performed either in the hot or cold condition using formers or shoes which fit the desired
contour or the pipe, and shall be carried out in accordance with ASME B31.3 except as
modified below.
c) The bend centreline radius shall be 5 times the nominal pipe diameter unless otherwise
stated.
d) Pipe bends shall be fabricated so that the seam weld is on the neutral axis during bending
and that the weld seam is subject to volumetric NDE and mechanical testing (tensile, impact
and hardness tests) for bend manufacturing procedure qualification purposes.
e) Bends shall not be wrinkled; cracked, scratched, gouged, die marked or buckled and shall
be in one plane. The minimum wall thickness of the bend, plus corrosion and erosion
allowances shall not be less than the required design thickness.
The Contractor shall submit a procedure for checking the finished wall thickness for approval
by the Purchaser. See Addendum ‘A’ for tolerances.
f) Weld repair of pipe bends shall not be permitted.
g) ‘Cut and shut’, creased or corrugated bends are not permitted.
5.3.2 Hot Bending

a) Hot bending shall be carried out and completed at a metal temperature approved by the
Purchaser. Normalised carbon steel and normalised and tempered carbon steel pipe shall
be heat treated at a temperature previously approved by the Purchaser.
b) Completed bends in austenitic stainless steel pipe shall be solution annealed at 1050 to
1100 deg C. Completed bends in carbon or carbon-manganese steel pipe do not require
Page 11 of 40
SPECIFICATION
heat treatment unless the finished bend hardness exceeds 225BHN (237VPN) in which case
a normalising operation shall be carried out at 900-950ºC.
Hardness measurements shall be taken at locations previously approved by the Purchaser.
c) The temperature and furnace atmosphere shall be carefully controlled during the bending
and any subsequent heat treatment cycle to avoid excessive scaling, carburisation or de-
carburisation.
d) The bore of completed bends shall be visually examined to ensure freedom from excessive
scaling, which may be removed by pickling, blasting or mechanical means.
e) Hot bending in 22Cr or 25Cr duplex pipe is required to be solution heat treated after bending
at around 1100degC followed by rapid quenching in water.
The Fabricator must submit a procedure for hot bending which shall be subject to Company
approval. This should include the method of bending, the bending temperature, rate of
bending, and method of cooling from the bending temperature, maximum transfer time to
quenching, maximum temperature of the cooling water, post bend heat treatment and NDE
and qualification of the bending procedure for each material grade/size by means of
mechanical testing.
Completed bends in carbon steel should be subject to post bend heat treatment irrespective
of the hardness after bending. The heat treatment should be either, tempering, normalizing
or quenching and tempering.
f) Hot bends in high nickel alloy pipe shall be given a post bend annealing
Heat treatment in the range 940 to 980degC for alloy UNS NO 8825 and 925 to 1050degC
for alloy UNS NO6625, followed by air cooling
5.3.3 Cold Bending

a) Cold bending of carbon steel pipe where applied strain exceeds 5% is not permitted.
b) Cold formed bends on austenitic stainless steel pipe do not require heat treatment.
c) After cold bending with strains in excess of 5% then either a normalising or a quench
and temper heat treatment should be applied rather than stress relief.
5.4 Fabrication Tolerances

Fabrication tolerances shall be in accordance with the specified codes and standards, supplemented
by the requirements given below.
Only seamless pipe shall be used for pipe bends and the flattening of a bend, as measured by the
difference between the maximum and minimum outside diameter at any cross section, shall not
exceed 5% of the original outside diameter of the pipe for internal pressure and 3% for external
pressure. The wall thickness after bending shall not be less than the minimum wall thickness
required for design.
Flange alignment tolerances shall be as stated in Addendum ‘B’ figure 1.
The tolerances on linear dimensions involved in the relative positions of branches, bosses, flanged
ends, flow instrument tapings and changes of direction shall be as stated in Addendum B figure 2.
Also given is the figure and tolerances on pipe bending and across the land of prepared welding
ends.
All angular dimensions of bends and branches shall be maintained within plus or minus ¼ degree.
5.5 Post Fabrication Treatment of Fabricated Spools
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SPECIFICATION
5.5.1 Cleaning and Protection

a) On completion of the fabrication, the contractor shall clean the inside and outside of all
fabricated assemblies of loose scale, dirt, sand, weld spatter and swarf using any suitable
method. The assembly shall then be blown out with compressed air, dried and the inside
inspected in accordance with Purchasers approved procedure for cleanliness, immediately
prior to the sealing of ends.
b) Welding ends shall be clean and ready for welding. Unless otherwise specified, the welding
end shall be blanked off and protected from corrosion or mechanical damage. Rigid plugs or
discs of non absorbent material securely held in position shall be provided and the pipe
ends, discs or plugs shall be sealed off using ‘Denso’ paste and tape or an approved
alternative.
c) Flanged ends shall be blanked off using 10mm thick plywood or 3mm thick steel covers
secured by a minimum of four bolts. In addition the faces of carbon steel flanges shall be
protected with a hard film coating to BS 1133, Section 6, Type TP1a or agreed alternative.
d) Threaded connections shall be sealed using distinctively colour-identified plastic plugs and
caps.
e) Piping and components shall be stored under cover out of contact with the ground and shall
be regularly examined to ensure the materials do not deteriorate. A check log of these
examinations shall be maintained by the Contactor to the approval of the Purchaser.
Corrosion protection shall be renewed as necessary. Internal corrosion protection procedure
shall be agreed by the Purchaser. Pipe or piping components shall be protected from
exposure to salt water or salt spray.
f) The external surfaces of carbon steel pipe work shall be painted as stated in the
Requisition/Purchase Order.
5.5.2 Marking
a) All fabricated spool pieces shall be clearly marked and identified prior to shipment in
accordance with the following paragraphs or as otherwise agreed. All marking shall be
applied after the application of any permanent protective coatings which have been called
for.
b) Fabricated spools requiring trial shop assembly shall be match marked with lines in white
paint to facilitate erection.
c) All paints used for marking shall be guaranteed by the Contractor to be free from lead, zinc,
copper, aluminium, tin, sulphur or any other elements likely to cause inter granular
penetration or other deleterious effects during fabrication or at the service temperature.
5.5.3 Offshore and Onshore Spools
All offshore and onshore spools shall be cleaned, protected, marked in accordance with the above
sections. These spools shall then be suitably packaged for transportation offshore.
5.5.4 Dimensional Control

The Contractor shall submit for the Purchaser’s approval, procedures for the control of tolerances
during fabrication of spools. All pre-fabricated spools will be subject to the approved dimensional
control procedure.
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SPECIFICATION
6.0 WELDING
6.1 General
The Contractor shall provide adequate and systematic supervision by competent personnel to
ensure that the required quality levels are maintained. At the discretion of the Purchaser, any welder
who consistently fails to meet the standard shall be required to undergo re-training, re-testing or
shall be removed from the job completely.
All welding shall be carried out in accordance with qualified and approved weld procedures by
welders who have been qualified to the relevant testing code.
Arc strikes outside the welding bevel are not acceptable. When these occur outside of the finished
weld the arc strike shall be carefully removed by grinding, followed by a magnetic particle or dye
penetrate inspection of the ground area to confirm it is defect free. Care shall be taken to ensure the
ground area ‘Blends in’ smoothly with the surrounding material such that no sharp notch results and
the thickness is not reduced below the required minimum wall thickness. Weld repairs when
necessary to restore the required thickness shall be carried out in accordance with an approved
repair procedure.
The acceptance of arc strikes outside of the weld groove is at the sole discretion of the Purchaser
who shall be requested to inspect the damage and approve or reject the damaged material as
appropriate.
Weld stops and starts shall be staggered by 50mm minimum such that they do not coincide in
adjacent passes or layers. Weld stops and starts shall be ground or chipped prior to laying
subsequent passes.
The number of welds shall be minimised. Pipe lengths (jointers) less than 3m long shall not normally
be welded together.
Prior to commencement of welding the weld preparation and for a distance of 50mm back from the
bevel edge shall be cleaned and degreased and shall be free from moisture and excessive oxides,
scale or any other foreign matter which may affect the integrity of the weld (see section 10.2 also)
Internals of inline valves and equipment which may be damaged due to heat transfer from the
welding process shall be removed prior to welding wherever possible.
All welds shall be 50% complete before moving, lifting, etc.
Intermediate cooling is not permitted unless the weld is 30% complete. The exposed beads shall be
subjected to M.P.I or D.P.I prior to re-commencing welding. Any defects shall be ground out.
Vertical down welding is not permitted
6.2 Butt Welds
All pressure containing butt welds shall be full penetration welds. Where access permits weld both
sides. Back gouging shall only be performed by grinding.
Permanent backing strips shall not be used. Temporary backing strips may be used only when
approved by the Purchaser. The material for temporary steel backing strips shall be of the same
nominal composition as the parent material. After completion of welding the backing strips shall be
removed and the area magnetic particle inspected to confirm the absence of significant defects.
Alternative types of backing materials shall only be used where prior approval has been obtained
from the Purchaser.
6.3 Branch Welds
All welded branch connections shall be joined to the header with full penetration welds of
comparable quality to, and subject to, the same limitations (fit-up, alignment, welding process etc.)
As girth welds, unless otherwise specified.
Page 14 of 40
SPECIFICATION
Piping branch reinforcement pads shall preferably be one piece but when not practicable, pads may
be split diametrically or along the axial centreline and welded together by full thickness/full
penetration welds.
Reinforcing pads for branches and structural attachments shall be accurately shaped and fitted to
ensure that the gap between the periphery of the pad and the pipe outside diameter is no greater
than 1.5mm.
After back gouging of double sided welds the excavated area shall be subjected to a DP or MPI
check before welding from the second side.
6.4 Fillet Welds
A minimum of two runs shall be deposited for all permanent attachments to pressure parts. Where
strength requirements permit one weld run may be acceptable for welds to non-pressure containing
parts.
All fillet welds shall be continuous and their surfaces shall be free from marked irregularities. All fillet
welds shall be overlapped at the stop-start position by at least 10mm .The root gap on fit-up should
not exceed 1.5mm.
6.5 Socket Welds
Care shall be taken during the assembly of socket welds joints to ensure there is a 1.5mm gap
between the pipe end and root face of the fitting.
Welds shall be fillet welds deposited by the Manual Metal Arc (MMA) or Tungsten Inert Gas (TIG)
process, with a minimum of two runs. The weld surface shall be free from marked irregularities.
6.6 Attachments to Thin Wall Pipes
Where attachments are to be made to thin walled piping, i.e. less than 5mm thick, care shall be
taken to avoid excessive oxidation or burn through. An inert gas purge shall be applied to the bore
surface, unless it can be demonstrated that this is not necessary. Where access to the bore surface
for cleaning and inspection is not possible the inert gas purge is mandatory.
In order to demonstrate the suitability of the weld procedure the Purchaser may require a test welds
to be made on pipe or the minimum contract thickness. Similarly the Purchaser may require welders
to be tested on their ability to weld attachments to the thin wall pipes even if their qualifications
range apparently covers the thin wall situation.
6.7 Alignment
The ends of piping components to be butt welded shall be accurately aligned in accordance with the
requirements of ASME B31.3. The maximum internal misalignment at the root gap shall be 1.5mm
except that where the pipe wall thickness is less than 6mm the misalignment shall not exceed 25%
of the wall thickness.
Where mismatch of the bores results in misalignment greater than that permitted above, this shall be
corrected by taper or counter boring in accordance with ASME B31.3.
Care shall be taken to ensure that the wall thickness after machining, meets the minimum wall
thickness required for design.
6.8 Fit-up and Temporary Attachments
Parts to be welded shall be carefully aligned and held securely in position by clamps, tack welds in
the welding groove, bridge pieces or wedges.
The specific dimensions of the root gap are the dimensions after tack welding. Where difficulty is
experienced in maintaining the root gap slight modifications in the fit-up requirements may be
permitted by agreement with the Purchaser.
Page 15 of 40
SPECIFICATION
All welding of fit-up tacks and temporary attachments shall be performed by qualified welders using
qualified procedures and the preheat level specified by the procedure.
Where tack welds are to be incorporated into the main welds they shall be of a length such that they
become part of the root pass and their ends shall be ground. Defective tack welds and those which
are not to be incorporated into the root pass shall be completely removed by grinding following
completion of welding.
Temporary attachments shall be of the same nominal composition as the parent material. They shall
only be removed by cutting by mechanical means 3mm above the surface followed by grinding flush.
The area shall then be surface crack detected to confirm the absence of defects.
6.9 Protection from Weather
The welder and welding area shall always be adequately protected from the weather so that the
weld integrity is not detrimentally affected by wind, rain or snow or from the decline of the welder’s
ability when working at low temperatures or other adverse conditions. The continuation of welding in
poor weather conditions shall be at the discretion of the Purchaser.
Weld areas shall be kept dry throughout the complete welding cycle until after the weld has cooled.
Where gas shielded welding is employed, special care shall be taken to protect the welding area
form draughts.
6.10 Weld Cleaning, Back Gouging and Repair
After each welding pass the weld shall be thoroughly cleaned and all slag and foreign matter
removed before the next run is deposited.
Peening of weld runs or the finished welds shall not be permitted.
The removal of weld defects shall preferably be carried out by grinding, machining or chipping. Arc
air or oxygen gouging may also be used on carbon steel material, provided all slag and oxidation is
removed by grinding from the gouged surfaces. Prior to arc air gouging, the repair area shall be pre-
heated as per the welding procedure. Arc air or oxygen gouging is not permitted on Austenitic or
Duplex Stainless Steel and high nickel alloy material. The removal of defects shall be confirmed by
MPI for carbon and low alloy steel and DP for corrosion resistant alloys including the austenitic and
duplex stainless steels and high nickel alloys.
Welds which have been repaired and remain defective shall be cut out completely and re-welded in
accordance with the original procedure, except where the Purchaser authorises one further repair
attempt. In no case shall more than 2 repair attempts be permitted.
All weld repairs shall be performed by qualified welders using an approved repair procedure. See
Section 8.3 of this document for repair procedure requirements.
6.11 Welding Processes
Except where otherwise agreed, welds shall be made by the manual metal arc (MMA), tungsten inert
gas (TIG), metal inert gas (MIG) or submerged arc welding (SAW) processes.
Where root runs are made by the MMA process, the electrode shall not be larger than 2.5mm
diameter.
If the TIG process is proposed for carbon steel material a high frequency arc initiation unit and crater
eliminating device with a 10 second minimum delay sequence shall be used. The electrode shall be
2% thoriated tungsten, 1.5 to 3.0mm diameter. A gas lens is required.
If the TIG process is proposed for corrosion resistant alloys a high frequency arc initiation unit and
crater eliminating device with a 10 second minimum delay sequence shall be used. The electrode
shall be 2% thoriated tungsten, 1.5 to 3.0mm diameter.
The MIG process may be used to complete welds for which TIG root runs have been deposited.
Page 16 of 40
SPECIFICATION
On stainless steel, duplex and high nickel alloy fabrications an inert gas back purge is required for
TIG and MIG welding and any other welding process used for root weld runs. The underside of the
weld shall be blanked off and all air expelled before welding commences. This shall be achieved by
introducing purging gas equal to at least five times the volume of air displaced, followed by a flow
rate of 2.5 to 7 litres per minute.
The SAW process may be used for circumstantial joint filler runs on to root runs made by some other
acceptable process/method. The specified alloying elements shall be contained in the filler wire; the
flux shall contain such elements only to the extent necessary to compensate for arc losses.
Recycling of flux shall only be permitted after Purchaser approval of the Contractor’s proposed
recycling procedures.
For all materials, pipe butt joints of nominal 50mm diameter and below shall have the root made with
Gas Tungsten-Arc Welding (GTAW) process.
All low-alloy steels, stainless steels and non-ferrous alloys and in all cases when cleanliness or
corrosion resistance are of major importance, a GTAW root pass shall be included unless the bore
surface can be adequately ground and inspected after welding. When internal grinding is not
possible, the bore surface shall be suitably purged with an inert gas prior to and during welding the
root and sufficient subsequent passes that avoid oxidation or “coking” of the root bead, as
established by the approved welding procedure.
Welding procedures for 6% Mo. (UNS S31254) stainless steels shall ensure that the heat input is
limited to 1.5kJ/mm of thickness maximum and interpass temperatures should be less than 150ºC.
The oxygen content of the back-purge shall be monitored using an oxygen meter and shall not
exceed 0.5% when measured prior to commencement of welding or during welding. A procedure for
back-purging of all welds shall be approved prior to production welding.
When welding duplex and high nickel alloys the maximum interpass temperature shall not exceed
150°C.
The following heat input limits shall apply:
22Cr duplex: 0.5-2.5 kJ/mm

25Cr duplex: 0.5-1.8 kJ/mm
6.12 End Preparations
Butt weld end preparation shall comply with that qualified in the Weld Procedure Qualification Tests
and be in accordance with ANSI B16.25.
7.0 WELDING CONSUMABLES
7.1 Specification and Selection

All consumables such as coated electrodes, bare wire, fluxes and gases shall comply with the
applicable AWS or British Standard. Other consumables may also be used provided full details of
chemicals and mechanical properties, and service experience is submitted and approval obtained
from the Purchaser.
Welding electrodes and filler wires shall be selected to give a deposited weld metal similar in
composition and tensile properties in the as welded state to the parent metal. Unless otherwise
specified, austenitic welds shall have a ferrite content of between 3% and 10%. Duplex stainless
steel welds shall have ferrite content between 35% and 65%. Contractor to submit procedure for
detailing content for approval by Purchaser.
Covered electrodes for shielded metal – Arc Welding (SMAW) shall be of a basic coated low
hydrogen type to BS 639 or AWS A5.1
Page 17 of 40
SPECIFICATION
7.1.1 Stainless Steel

Filler metal and welding techniques utilised for welds between austenitic stainless steels and ferritic
steels shall be subject to agreement with the Purchaser. The filler metal will normally be of the E309,
309L type or nickel base.
The shielding gas for the TIG and MIG processes shall be argon to BS 4365. The purge gas shall be
argon to BS 4635 or nitrogen to BS 4366 type 1. Alternatively all shielding gasses shall comply with
ANSI/AWS specification A5.32 / A5.32M-97 No other gas shall be used without approval of the
Purchaser.
7.1.2 Carbon Steel
Shielding gases shall normally be one of the following, depending on the particular application:-
a) Argon to BS 4365
b) Argon/oxygen mixtures consisting of argon to BS 4365 with up to 5% oxygen to BS 4364.
Total impurities 0.075% maximum.
c) Argon/carbon dioxide mixtures consisting of argon to BS 4365 with up to 25% carbon
dioxide to BS 4105 type 1 and up to 5% oxygen (if required) to BS 4364.
Other gases may also be considered where they have been proved satisfactory by the weld
procedure qualification tests and any other tests deemed necessary by the Purchaser.
Gases for back purging shall be argon as specified above or nitrogen to BS 4366 type 1.
Alternatively all shielding gasses shall comply with ANSI/AWS specification A5.32 / A5.32M-97
7.1.3 Duplex Stainless Steel

All welding shall be supervised and records maintained to ensure that each weld can be
subsequently identified with the individual welder concerned.
Welding of butt welds between pipes and fittings shall be made using the GTAW, PAW or SMAW
processes. All root runs shall be made using GTAW or PAW. Where fillet welds are required e.g.;
slip on fittings, either GTAW or SMAW may be used.
If the design temperature of fabrication is -50 deg C, then GTAW or PAW shall be used. If the design
temperature is not lower than -30 deg C then either GTAW, SAW or SMAW may be employed.
The type of filler wire and electrodes to be used, shall comply with the recommendations of steel
manufacturer, and need not exactly matches the chemical composition of the base material. The
electrodes shall be preferably of the ‘low hydrogen’ type.
For 22Cr and 25Cr duplex stainless steels only consumables that deposit overmatching properties
of the parent metal analysis shall be used. The minimum nickel content shall be 8% for 22% Cr
duplex and 9.5% for 25% Cr duplex.
7.1.4 High Nickel Alloys

All welding shall be supervised and records maintained to ensure that each weld can be
subsequently identified to the individual welder concerned.
Welds between pipe and fittings shall be made using the GTAW, PAW or SMAW processes. All root
runs shall be made using GTAW or PAW. GTAW or SMAW may be used for fillet welds.
Page 18 of 40
SPECIFICATION
The welding consumables shall conform to AWS ENiCrMo-3 or ERNiCrMo-3 for welds in both alloys
UNS N0 6625 and UNS N0 8825.
7.2 Storage, Protection and Baking
The storage, protection and baking of all welding electrodes, filler wires and fluxes shall be in
accordance with the Manufacturer’s recommendations.
Hydrogen controlled electrodes shall be baked to achieve a potential hydrogen level of 10mL/100g
maximum. The contractor shall submit a consumable handling, storage and control procedure for
approval prior to commencement of welding.
8.0 WELDING PROCEDURE AND WELDER QUALIFICATION

8.1 General
All pressure containing welds and welds made on to pressure parts shall be made in accordance
with a procedure written and qualified in accordance with BS EN 288 or ASME Boiler Pressure
Vessel Code Section IX where the Design Code is ASME B31.3. and BS.4515 or API Std 1104
where the design code requirement is PD8010. Pre qualified welding procedures can be submitted
to the Purchaser for review and approval. Their use shall be at the discretion of the Purchaser. No
welding shall be carried out until the procedures and test results have been approved by the
Purchaser.
Each welding procedure shall be given its own unique reference number and shall be cross
referenced to construction drawings and to the applicable qualification records.
All welders shall be qualified in accordance with the requirements of BS EN 287 or ASME Boiler
Pressure Vessel Code Section IX where the design code is ASME B31.3 or BS.4515 where the code
requirement is PD8010.
For 6% molybdenum austenitic and duplex stainless steels, material weld ability and pitting corrosion
tests shall be performed. Test results shall be assessed using ASTM G48 method A. No pitting
shall be observed after 24 hours C in root or cap of welds and parent material. The tests must be
performed at 25 deg C for 22 % duplex. 35 deg C for welds in 25% duplex and 6Mo stainless steel
Each welder shall be assigned an identification number, letter or symbol, and a complete record
including results of NDT shall be kept of each weld made by each individual welder.
For all Hydrocarbon service pipe work the complete circumference of all girth welds shall be 100%
X-Rayed. The radiographs shall be retained for examination and approval by the Purchaser.
The charpy V-notch impact test temperature during procedure qualification shall be based on the
thickest production weld to be qualified. Charpy impact tests are not required for qualification of
procedures for welds in high nickel alloys.
Charpy V-notch impact tests shall be performed in accordance with BS. EN 10045/1 or ASTM A370.
The tests shall be performed on the material in the final heat treated condition, from each heat
treatment load, on the base material and secondly on the weld and heat affected zone (HAZ)
The wall thickness of the items in the heat treatment load shall not be more than 6.35mm thicker
than the items from which the test pieces were cut.
4 sets of tests shall be performed on the weld metal and the HAZ at:-
1) the weld metal centreline
2) the fusion line
3) the fusion line +2mm
Page 19 of 40
SPECIFICATION
For impact tests on the duplex steels the lateral expansion value for each specimen shall be a
minimum of 0.38mm.
Each test shall consist of breaking 3-specimen and the average value of 3, shall be 45 joules and 35
joules minimum individual value all at minus 46ºC Impact Test Temperature.
If BS 4515 applies then the following additions are necessary:
Weld procedure qualifications shall include the following tests:-
a) Tensile Tests (at both RT and the maximum design temperature for welds in carbon,
stainless and duplex steels)
b) Bend Tests
c) Macro Examination
d) Hardness Testing (except 90/10 Cupro-Nickel Alloy)
e) X-Radiography
f) Impact Testing (except 90/10 Cupro-Nickel Alloy)
g) Weld Metal Ferrite Determination (Austenitic and Duplex Stainless Steels only)
h) Pitting Corrosion Test (Duplex and 6% Molybdenum Austenitic Stainless Steels only)
j) Micro- examination (Duplex)
The ferrite content of austenitic welds may be determined using magnetic gauges. The ferrite
content of Duplex stainless steel welds shall be determined by the intercept method of ASTM E562
using 30 fields. The ferrite range shall be 35% to 65%.
8.2 Hardness Survey

Welding procedure qualification test shall include a hardness survey in accordance with BS EN ISO
8507 of the weld and heat affected zone.
Test coupons shall be ground and macro etched to reveal the various zones of the weld. The
hardness traverses shall be in accordance with Fig 2. A macro photograph up to 5% shall be
included showing the weld passes and hardness indentations. Additional sketches may be included
if necessary.
For carbon and austenitic stainless steel NACE materials the maximum hardness value shall be: for
carbon 248 HV 1- , for 22% duplex stainless steel 286 HV 10. and for 25% duplex stainless steel 318
HV 10 and for high nickel alloy 345 VHN.
The hardness surveys should be made 1mm to 2mm from the internal and external surfaces of the
weld.
8.3 Repair Procedures
All weld repairs shall be carried out in accordance with written procedures. These procedures shall
be submitted to the Purchaser for approval prior to commencement of repair.
Repair procedures outside the scope of the original weld procedure shall be subject to the
qualification requirements stated in 8.1 above.
Page 20 of 40
SPECIFICATION
Fig 2
ON WELD CENTRE LINE
0.5mm EACH SIDE OF 2t FROM FUSION
FUSION LINE LINE
1mm INTERVALS t FROM FUSION
IN VISIBLE HAZ LINE
t .12
t
VISIBLE HEAT
AFFECTED ZONE
POSITIONS FOR HARDNESS INDENTATIONS
NOTCH POSITION NOTCH POSITION

HAZ TEST FUSION LINE +2mm HAZ TEST FUSION LINE
t .12
t
NOTCH POSITION
NOTCH POSITION FOR WELD METAL
HAZ TEST FUSION TEST
LINE + 5mm
NOTCH LOCATIONS FOR CHARPY SPECIMENS
Page 21 of 40
SPECIFICATION
9.0 HEAT TREATMENT

9.1 Preheat and Interpass Temperatures – Carbon Steel
The minimum preheat temperature for welding and thermal cutting shall be as specified in BS 5135
as applicable. No welding shall be permitted below 10 deg C metal temperature.
The required preheat temperature shall be applied to the entire length of joint and shall be
maintained until the weld has been completed. Contractor to submit procedure for approval.
Application of preheat may be by electrical methods or fixed gas burner rings, provided a uniform
temperature profile along the joint is achieved. Hand held torches are not permitted except for fit-up
welds. Deposition of carbon by direct flame impingement shall be avoided.
The maximum interpass temperature shall not exceed the highest interpass temperature recorded
during the weld procedure qualification tests or 250 deg C, whichever is the highest.
9.2 Post Weld Heat Treatment (PWHT) – Carbon Steel
PWHT shall be carried out when required by the applicable Design Code, Piping Material
Specification J8469B-L-S-14000 or the approved welding procedure. The temperature and times for
the PWHT operation shall be as specified in the applicable Design Code.
Where PWHT is required it will be noted on the Piping Isometric drawing.
PWHT shall preferably be carried out in an enclosed furnace. Where this is not possible, PWHT may
be performed in sections or by local treatment of welded seams in accordance with BS 2633, with
the approval of the Purchaser. The use of gas torches, rings or exothermic processes shall not be
permitted.
The metal temperature during PWHT shall be accurately controlled and recorded via thermocouples
welded or mechanically attached. The surface of the pipe in the heat treatment zone shall be free
from all foreign matter.
The pipe work shall be adequately supported to prevent distortion during heat treatment. If distortion
does occur the Purchaser shall be consulted before any remedial action is taken.
All machined surfaces, such as flange faces, threads etc shall be suitably protected against
oxidisation during the heat treatment cycle.
After removal of welded on thermocouples, the attachment area shall be dressed and surface crack
detected by M.P.I.
9.3 Preheat and Interpass Temperatures – Other Materials
The maximum interpass temperature during welding, other than carbon steel, shall not exceed the
highest interpass temperature recorded during the weld procedure qualification tests or 150 deg C,
whichever is the highest.
The minimum permitted metal temperature shall be 10 deg C.
9.4 Post Weld Heat Treatment (PWHT) – Other Materials
Post weld heat treatment of pipe work, other than carbon steel and low alloy steels, is not required.
Page 22 of 40
SPECIFICATION
INSPECTION AND TESTING

9.5 General
The Purchaser’s Inspecting Engineer shall have free access to all parts of the Contractor’s Works
engaged in the manufacture of pipe work and shall have the right to inspect any aspect of the work
during fabrication, installation and testing up to mechanical completion. The Contractor shall afford
the Inspecting Engineer all reasonable facilities to allow these inspection functions to be fulfilled. All
tests and inspections shall be conducted at the place of fabrication unless otherwise state.
The Contractor is required to have an identification system such that each component part can be
identified against the Mill Test Certificate and that all weld seams can be identified with the welder or
welding operator and welding procedure Specifications.
Detailed non-destructive testing and inspection (NDT) procedures shall be submitted for approval by
the Purchaser.
9.6 Inspection
Piping Systems are classified on the basis of service and material. The applicable Piping Class shall
be detailed in the Piping Material Specification J8469B-L-S-14000
After pipe cutting and weld end preparation, the weld area shall be visually examined to confirm the
surface is smooth and uniform free from cracks, tears, laminations, gouges and any other
discontinuities which may affect the integrity of the weld. If there is any indication of defects the weld
preparation area shall be subjected to surface crack detection and ultrasonic examination.
For lines 900# rating and higher:-
a) All weld bevels shall be subject to 100% surface inspection (MPI/DPI). Defects such as laps,
cracks or laminations shall not be acceptable.
b) An area 50mm back from the bevel end shall be subject to 100% ultrasonic inspection for
laminations and discontinuities. The acceptance limits shall be subject to Purchasers approval.
Where any such defects are found the weld bevel shall be re-prepared and re-examined. In the case
of laminations, the material shall be ultrasonically examined to determine the extent of laminations
and the affected area shall be cut off. Welded joints shall not be made in the areas of laminations.
Following the removal of temporary attachments the attachment areas shall be examined by MPI for
carbon and low alloy steels and DP for austenitic, duplex stainless steel. And high nickel alloy.
The extent of inspection to be carried out shall be as stated in Table 10.2
The level of inspection shall be detailed in the Requisition/Purchase order or the Piping Material
Specification No. J8469B-L-S-14000
9.7 Inspection Techniques & Acceptance Criteria
The inspection technique and acceptance criteria shall be as defined in ASME B31.3 Table 341.3.2
defined for Normal Fluid Service The exception is that the acceptance criteria for welds in process
gas pipe work, from the wellhead Christmas tree thru’ the gas export and import pipe lines; including
the flow lines, test separator, production and test manifolds and pig traps; shall be considered as
severe cyclic conditions as per ASME B31.3. These lines will be detailed on the relevant piping
isometrics and drawings.
Where spot or random radiography is specified, one complete weld in a designated number shall be
100% radiography. X-radiography to ASME Article 2 shall be used. Selection of welds for random
radiography shall be by Piping Isometric with a minimum one per spool. Selection of these individual
welds shall be as directed by the Purchaser.
Gamma radiography shall not be used except with prior approval of the Purchaser.
Page 23 of 40
SPECIFICATION
9.8 Qualification of NDT Personnel

The qualifications and competence of NDT personnel used by the Contractor and his sub-
contractors shall be subject to approval by the Purchaser and shall satisfy the requirements of this
Specification. The Purchaser reserves the right to reject or retest any NDT personnel at any time. All
NDT personnel shall be qualified to a minimum of level 2 to either SNT-TC-1A or BS-EN-473.
Visual Inspectors shall be subject to approval based on Purchaser assessment of their capabilities,
experience and qualification.
9.9 Progressive Examination

If progressive examination is proposed, it shall have prior approval of the Purchaser.
For Piping Classes refer to Miskar Piping Material Specification BG-TUN-PROJ-GES-10-TCH-0001
Rev 2.
TABLE 10.2 PIPE INSPECTION LEVELS
Service Utility Lines Hydrocarbons Liquid or Gas Cryogenic Severe cyclic
Conditions Conditions
PRESSURE ≤600 ≥900 ≤300 ≥600 ≤150 ≥300 ≥150

CLASS
BUTT WELD 1 2&5 2 &5 2&5 2&5 2 2&6
&
5
SOCKET & 3 6 5 6 6 6 *
FILLET WELDS
OLETS 4 7 7 7 7 7 7
NON PRESSURE 0 3 3 3 3 3 5
CONTAINING
FILLET WELDS
(*) Socket welds are not permitted on severe cyclic conditions
1. Minimum 5% of random Radiographic testing. If the weld reject ratio per welder or welding operator
exceeds 5 %, radiographic test shall be increased to 100% and stay at 100% until the reject rate per
welder or welding operator drops below 5 % and stays there for another 14 consecutive working
days.
2. 100% Radiographic inspection
3. 5% Magnetic Particle or Dye Penetrant Inspection
4. 5% Magnetic Particle or Dye Penetrant Inspection and Ultrasonic
Page 24 of 40
SPECIFICATION
a) 100% Magnetic Particle or Dye Penetrant Inspection and Ultrasonic the welds to be scheduled for the
radiographic inspection in order to cover the work of welders and welding operators equally rated. As
a minimum, radiographic examination will be carried out on ONE WELD IN EVERY 20 WELDS made
by each welder or welder operator. This shall cover all weld types by each welder/weld operator.
b) All welds must be 100% visual inspected.
c) Non-destructive additional inspection may be required at The Company discretion.
d) 100% RT for line subject to pneumatic test
10.0 INSTALLATION
10.1 General
Pipe work shall be installed in accordance with the requirements of the Purchaser’s drawings,
specifications and schedules.
Installation of pipe work shall be carried out under conditions satisfactory to the Purchaser.
Field fabricated make up pipe lengths in piping runs shall be 150mm unless otherwise agreed.
Identified as ‘FFW’ (Field Fit Weld) on Drawings.
In-line instruments, e.g. orifice plates, control valves, etc, shall be installed under the direction of the
Purchaser’s Instrument Engineer, taking account of the requirements of section 12.0
The Contractor shall install all Purchaser supplied (free issue) piping items. These items and any
other proprietary items shall be installed and protected, during fabrication, in accordance with the
Manufacturer’s Instructions.
10.2 Pipe work Erection
All pipe work shall be inspected prior to erection to ensure it is free from dirt, scale, weld spatter and
other foreign matter.
Except where cold springing is specified on the piping drawings, all piping shall be installed in place
without springing or forcing.
Where cold springing is specified, all supports, guides and anchors shall be checked prior to
assembly to ensure they are correctly installed. The cold spring gap or overlap shall be checked by
the Purchaser’s Inspecting Engineer and corrected if necessary. The cold pull shall be maintained at
the closing butt during welding and any subsequent heat treatment and cooling. Prior to application
of cold pull all other joints should have been welded, subjected to any post-weld heat treatment,
inspected and approved.
Where possible pipe work shall be erected on permanent supports designated for the line.
During erection of pipe work suitable supports are to be provided to ensure that no undue stresses
are imposed on the pipe.
Temporary supports and assemblies used to facilitate the erection of pipe work shall meet the
approval of the Purchaser regarding safety and suitability.
Care should be taken to avoid undue strain being placed on the vessel or item of equipment etc. by
unsupported lengths of piping.
Drainage falls shall be maintained throughout as specified on drawings.
It should be noted that vessel flanges generally, are not set sufficiently true to permit prefabrication
of the mating pipe flanges without checks being made.
Where drawings show flanges loose on a closure length of piping a careful physical check shall be
made of closing distance and alignment of flange before cutting the pipe and welding on the flange.
Page 25 of 40
SPECIFICATION
Contractor shall ensure that piping connected to equipment is supported so that minor equipment,
valves etc., can be readily removed without further supporting of the pipe and with the minimum of
dismantling.
The erection of a spool incorporating ‘cut to fit’ requirements shall be carried out taking full
advantage of the inbuilt adjustment to avoid undue stresses in the completed pipeline.
10.3 Flanged Joints

All flanged joints shall be brought up flush and square to that the entire mating surfaces bear
uniformly on the gasket and then made up with uniform bolt tension.
See Addendum B Figure 1 for flange alignment tolerances.
It is recommended that the maximum differential stress between any two bolts in a flange joint shall
not exceed 20% of the lower stress.
When bolting flange joints with spiral wound gaskets, the gasket shall be compressed evenly to the
thickness of the guide ring. This would be equal to 25% to 35% compression of the original gasket
thickness (gasket compression shall be spot checked during bolt tensioning).
Steel to cast iron flanged joints shall be made with extreme care, taking up bolts uniformly after
careful lateral and parallel alignment.
Flanged faces shall be cleaned of all dirt, grease and protective coatings and shall be inspected for
defects such as scratches or dents prior to installation.
10.4 Equipment Flange Conditioning
Flange covers shall be retained on all flange connections to mechanical equipment until ready to
connect the mating piping.
Unless hydrostatic test blanks are fitted at the connections to equipment, a thin metal plate shall be
inserted to protect the equipment against ingress of internal pipe debris resulting from the continuing
erection of the piping.
Flanges connecting to strain sensitive mechanical equipment e.g., pumps, vessels, inline
instruments etc, shall be fitted up in close parallel and lateral alignment prior to tightening the bolting.
To achieve this true alignment full advantage shall be taken of the ‘cut to fit’ allowances.
Flange connections to strain sensitive equipment shall be the last connection made on completion of
a line or interconnecting system of lines complete with permanent supports.
Heating of pipe work to achieve alignment of flanges at equipment shall not be permitted.
All openings in vessels, columns and other similar equipment items shall be clean and free from
obstruction prior to being connected to pipe work.
10.5 Gaskets
The Contractor shall be responsible for purchasing the gaskets required for the testing etc,
of pipe work. The gaskets shall be purchased based on recommendations of the Purchaser.
Contractor shall ensure that the correct gasket material and thickness, as specified in the
Piping Material Specification and on piping drawings, is used.
Contractor shall ensure that correct gasket lubricant, if specified and required by the Piping
Material Specification, is used.
Page 26 of 40
SPECIFICATION
Care shall be taken to ensure that the gasket and mating flanges are clean, true and free
from defects.
Contractor shall ensure that the gasket does not, under any circumstance, protrude into the
bore of the pipe.
FIGURE 11.5 – RECOMMENDED TORQUES FOR BOLTING

Maximum Recommended Torque (1b. ft)
FLANGE FLANGE NO. OFF BOLT BOLT BOLT
RATING N.B (inch) & SIZE OF TORQUE TORQUE TORQUE
BOLTS f=0.07 f=0.10 f=0.20
150# ½ 4 x ½” 9 24 45
¾ 4 x ½” 20 26 48
1 4 x ½” 222 29 53
1 - 1½ 4 x ½” 26 35 65
2 4 x 5/8” 46 62 114
3 4 x 5/8” 58 79 147
4 8 x 5/8” 51 68 127
6 8 x ¾” 91 124 231
8 8 x ¾” 107 144 270
10 12 x 7/8” 132 178 336
300# ½ 4 x ½” 19 24 45
¾ 4 x 5/8” 34 46 87
1 4 x 5/8” 37 50 92
1-1½ 4 x ¾” 66 90 168
2 8 x 5/8” 39 52 96
3 8 x ¾” 70 95 177
4 8 x ¾” 77 104 196
6 12 x ¾” 79 107 200
8 12 x 7/8” 128 174 326
10 16 x 1” 172 233 439
600# ½ 4 x ½” 23 31 57
¾ 4 x 5/8” 36 48 90
1 4 x 5/8” 39 52 96
1-1½ 4 x ¾” 66 90 166
2 8 x 5/8” 41 54 101
3 8 x ¾” 75 101 189
4 8 x 7/8” 121 165 308
6 12 x 1” 176 239 448
8 12 x 1-1/8” 271 370 699
10 16 x 1- ¼” 350 480 912
12 20 x 1- ¼” 360 493 937
Page 27 of 40
SPECIFICATION
FLANGE FLANGE NO. OFF BOLT BOLT BOLT

RATING N.B (inch) & SIZE OF TORQUE TORQUE TORQUE
BOLTS f=0.07 f=0.10 f=0.20
14 20 x 1- 3/8” 477 657 1254
20 24 x 1- 5/8” 826 1142 2193
30 28 x 2” 1663 2311 4473
36 28 x 2-½” 2930 4094 7973
900# ½ 4 x ¾” 39 57 107
¾ 4 x ¾” 44 59 111
1 4 x 7/8” 98 132 249
1-1½ 4 x 1” 152 206 387
2 8 x 7/8” 108 147 276
3 8 x 7/8” 126 171 320
4 8 x 1-1/8” 249 339 641
6 12 x 1-1/8” 267 364 690
8 12 x 1-3/8” 496 682 1302
10 16 x 1- 3/8” 505 694 1326
12 20 x 1- 3/8” 522 716 1367
14 20 x 1- ½” 692 955 1828
16 20 x 1-5/8” 898 1241 2385
1500# ½ 4 x ¾” 48 65 121
¾ 4 x ¾” 51 68 128
1 4 x 7/8” 111 150 282
1-1½ 4 x 1” 175 239 448
2 8 x 7/8” 130 176 330
3 8 x 1-1/8” 285 388 735
4 8 x 1-¼” 405 555 1054
6 12 x 1-3/8” 516 710 1355
8 12 x 1-5/8” 906 1253 2408
10 12 x 1- 7/8” 1414 1961 3787
12 16 x 2” 1676 2330 4509
14 16 x 2-¼” 2350 3275 6360
2500# ½ 4 x ¾” 85 115 215
¾ 4 x ¾” 96 130 242
1 4 x 7/8” 151 205 385
1-1½ 4 x 1-1/8” 341 465 879
2 8 x 1” 224 306 574
3 8 x 1-¼” 431 591 1123
4 8 x 1-½” 766 1056 2024
6 8 x 2” 1902 2644 5117
NOTE 1
All values shown include 30% increase for relaxation within the bolt tensioning equipment.
Page 28 of 40
SPECIFICATION
NOTE 2
Friction factors, f, correspond to the following:
f = 0.07 MOLY based lubricant
f = 0.10 copper based lubricant
f = 0.20 dry (no lubricant)
NOTE 3
Bolting Material ASTM A193-B7 or ASTM A320-L7
The Torque Figures shown in Figure 11.6 are based on the following:-
1. Bolting material ASTM. A193-B7M or ASTM.A320-L7M with nuts to ASTM.A194-2HM, with low
temperature applications being to grade 7M and supplementary requirements S3.
2. Hydrostatic test pressure of 1½ x Design Pressure at room temperature.
3. Hydrostatic end load + load required to seat gasket or ring joint.
4. Coefficient of friction factor of 0.07 to 0.20.
5. Inclusion of 30% allowance for relaxation of tension associated with tensioning tool.
6. The flanges being bolted together are freely suspended and no additional force is required to
overcome misalignment, offsets etc. of the preassembled piping.
10.6 Bolting
The contractor shall be responsible for purchasing all the bolting materials required for the testing
etc. of pipe work. The bolting materials shall be in accordance with Piping Material Specification
No.J8469B-L-S-14000 All flanges shall be checked for correct grade and damage prior to fitting.
All flange bolting shall be free to move through mating flanges holes in a plane at right angels to the
flange face and parallel to the pipe run (misalignment of flange holes resulting in knurling of the nut
on the flanges will be rejected).
Stud bolts cut from lengths of studding shall have the material grade stamped on the cut ends.
All nut bearing faces, bolt and stud bolt threads shall be lubricated with API 5A2 or equal lubricant
prior to fitting.
Bolt tension shall be applied in three stages using the diametrical sequence, 1st stage 25%, 2nd
stage 50%, 3rd stage 100%.
For guidance the maximum theoretical torques that should be applied when tightening flange bolts
are given in Figure 11.5.
Contractor shall re-check all bolting for tightness and correct tension on completion of testing.
Hydraulic bolt tensioning equipment shall be used on stud bolts 1¼” diameter and above. All bolts
1¼” diameter and larger shall be supplied one x diameter longer than standard, with an additional
nut or thread protector to provide thread protection for the extra threaded length which has been
provided for bolt tensioning.
Actual torque values measured at the installation will be submitted to the Purchaser for approval.
If any flanged joint leaks initially on pressure test, then the bolts shall be tightened by adding 10% to
the bolt tensioning figure given in figure 11.5. If a leak occurs after this tightening, then the joint shall
be rejected, dismantled and the reason found for this problem, solved and then re-made.
Contractor shall uniquely identify each bolted joint requiring bolt tensioning on the fabrication
drawings and provide a spreadsheet showing size, rating, bolt size and tension used for acceptance.
Page 29 of 40
SPECIFICATION
10.7 Valves
Valves shall be orientated in the line so as to be readily operable, as shown on piping drawings.
Gate and globe valves in horizontal lines shall be installed with their stems orientated as shown on
the drawings. If the stem orientation is not shown, then the order preference shall be:-
1. Vertically upwards
2. Horizontal
3. Upwards @ 45º
4. Downwards @ 45º
The above shall be subject to Purchaser approval.
The contractor shall provide for the checking of gland packing in all valves for leakage during
hydrostatic testing.
All butt welded and socket welded valves shall be tack welded in the position shown on the piping
drawings and approval of position obtained before carrying out final welding.
10.8 Screwed Pipe work
Pipe ends shall be cut square, threaded, reamed and cleaned to remove cuttings from internal and
external surfaces. All threading shall be carried out after bending, forging or heat treatments but
where this is not possible suitable thread protection must be provided. All screwed connections shall
have taper threads in accordance with ANSI B1.20.1.NPT.
All joints shall be tightened using a suitable wrench; connections 2” and larger shall be tightened
using a “RIGID compound leverage pipe wrench” or equivalent. Excessive wrench markings on pipe
and fittings shall be cause for rejection of the fabrication at the discretion of the Purchaser’s
Inspecting Engineer.
The joints shall be assembled using a suitable pipe jointing compound which shall be applied to the
male thread only, taking care to ensure the compound does not reach the inside of the pipe. PTFE
tape shall not be used.
10.9 Pipe Supports
All pipe supports shall be supplied, fabricated and installed in accordance with Specification no.
J8278-L-SD-13400 and the Purchaser’s Drawings.
Where pipe supports are required to be welded to the pipe, as specified in the drawings, this shall be
carried out during the fabrication of the pipe spool and prior to heat treatment and pressure testing.
The Contractor shall ensure there is an adequate field fit margin in the pipe supports to allow the
piping to be installed without forcing.
Attachment by site drilling or welding to structural steel shall not be permitted except with the
approval of the Purchaser.
The burning of holes in structural steelwork or component parts shall not be permitted.
Pipe hangers shall not be used as temporary lifting attachments.
Adjacent structures or equipment shall not be used as temporary supporting or lifting attachments
without the permission of the Purchaser.
The installation of spring supports shall be in accordance with the Manufacturers instructions. The
preset load pins shall not be removed until completion of the hydrostatic test of the line.
Metallic surfaces of supports which will be inaccessible after erection shall receive a protective
coating before assembly.
Page 30 of 40
SPECIFICATION
All carbon steel pipe supports fitted to stainless steel pipe shall be isolated from the pipe to prevent
electrolytic corrosion.
The Contractor shall be responsible for installing any temporary pipe support necessary for erection
and hydro testing. Full Details of these supports shall be submitted to the Purchaser for approval.
10.10 Field Run Piping

The following applies only when specified by the Purchaser
Field run lines shall be restricted to pipe work of 1-1½” nominal bore and smaller in carbon steel, low
temp carbon steel And type 316L stainless. Steel and 2” and smaller cupro-nickel.
Field run lines shall be run generally in accordance with the routing indicated on the piping drawings
and to the satisfaction of the Purchaser.
All field run lines shall be installed in an orderly manner, consistent with good operation, neatness of
appearance, safety of personnel, economy and usage of the minimum number of fittings consistent
with provisions for expansion and flexibility.
All piping shall be arranged to facilitate supporting and shall be planned for ease of removal of
equipment for inspection and servicing.
Pipe supports for all field run piping are to be designed, located fabricated and installed by the
Contractor with the exception of the first support local to any rotating equipment, which will be
designed by the Purchaser.
All field run piping shall comply with the requirements of the Piping Design Specification.
11.0 PRESSURE TESTING & FLUSHING

11.1 General
This section covers pressure testing of all shop and site fabricated pipe work. This section also
covers flushing of all piping systems.
Pressure testing of piping within Packaged Units shall not be the Contractor’s responsibility.
However, this pipe work, when fully assembled as part of the whole piping system, may be included
in the System test provided the conditions of Section 12.2 are satisfied.
The Contractor shall prepare and submit for Purchaser approval, a plan, flush and test system
isometric drawings indicating how the testing is to be carried out with respect to systems, etc. This
plan shall give details of items such as test section boundaries, direction of flushing, method of
isolation, inclusion or exclusion of instruments and equipment in the test, provision of temporary
spools and supports, locations of test gauges, recorders, vents and drains, test material take-off,
duration of test, test medium and the test pressure. Check sheets shall be completed identifying
items removed and re-instated for each test.
The Contractor shall be responsible for identifying any additional vent, drains and flushing
connections that are necessary for testing. Locations and numbers of these additional elements shall
be subject to Purchaser approval, and shall be in accordance with the Piping Material Specification
J8469B-L-S-14000 upon completion these connections shall be blanked off.
Preparation for Testing
Page 31 of 40
SPECIFICATION
11.1.1 General
a) Prior to any pressure testing the piping system shall be checked by the Purchaser’s
Inspector to ensure it has been erected in accordance with the drawings and Specifications.
The Purchaser’s Inspector shall also check that the section of piping system under test has
been correctly isolated at the specified test section boundaries.
b) The Contractor shall provide adequate and safe access for inspection of mechanical joints,
welds and other points as required by the Purchaser’s Inspector.
c) Pipe work requiring insulation should be tested prior to installation of insulation and should
be completed and tested ahead of non insulated pipe. In all cases flanged, threaded and
welded joints which have not been pressure tested shall be left bare of insulation, paint and
foreign matter which could mask a leak.
d) Test medium temperature and pressure chart recorders shall be incorporated into the
system, in addition to the required visual indication gauges, to enable these parameters to
be monitored throughout the test and provide a permanent test record. The location of the
temperature and pressure sensors shall be subject to the agreement with the Purchaser.
Two pressure chart recorders shall be used for each test.
e) Piping being hydrostatic tested shall be as far as practicable in complete systems, including
all interconnecting lines able to contain the same test pressure. The systems should include
as much equipment as possible, subject to the limitations of sections 12.2.3 and 12.2.4. The
breaking of joints to insert blanks shall be minimised.
11.1.2 Test Loading
a) The piping system hydrostatic test load shall be carefully evaluated to ensure that the
support structure will not be overloaded. Note no more than two flow lines shall be tested
simultaneously.
b) Piping normally supported on springs or counterweight shall be rigidly supported to avoid
damage due to the test fluid. Setting pins shall not be removed from spring hangers until
after testing.
c) Piping designed to carry service fluids having a lower specific gravity than the test fluid shall
be provided with any temporary supports that may be necessary to take the test load.
11.1.3 Valves and Instruments

a) Valves within the system to be tested shall be in an open position but not back seated so as
to test the valve stem packing, except where otherwise specified in the following
paragraphs.
b) Ball valves of the block and bleed type (integral body bleed) shall be in the half-open
position.
c) Control valves shall be removed and suitable spool pieces or blanks installed.
d) Pressure regulating valves within sections of pipe work being tested shall have their
regulator blocked off during the test.
e) Bursting discs, relief and safety valves shall be spaded off or removed and the nozzle fitted
with a blind flange. Screwed relief and safety valves shall be removed and replaced with
caps. Test gags shall not be used.
Page 32 of 40
SPECIFICATION
f) Lines containing check valves shall have the source of pressure on the upstream side of the
valve. If this is not possible, swing checks shall be blocked open or their disc removed,
whereas ball and piston checks shall have their internals removed. All parts removed shall
be put in a sack and wired to the valve. Alternatively the valve shall be blocked off or
replaced with a spool piece.
g) Hand operated valves within a test section shall be temporarily tagged with large red
‘Caution’ tags of similar identification to avoid inadvertent operation during filling or testing.
h) In-line flow meters of all types e.g.; turbine meters, rota meters and positive displacement
meters etc, shall be isolated from the test or removed from the line and, if required, replaced
by a temporary spool piece.
i) The following instruments to be tested by the Purchaser Instrument Engineer shall be
isolated:
• Indicating pressure gauges, when the test pressure will exceed the scale range.
• External float type level shutdown devices and controllers, when the float is not rated
for the test pressure. The float should be subjected to design pressure, then the float
chamber isolated from the system.
• Glass components.
11.1.4 Packed Equipment
a) Equipment shall not be included in the system test where:-
• The equipment hydrostatic test pressure is lower than the system test pressure.
• The weight of test medium required to fill the equipment would overload its support
structure.
• The equipment internals would be damaged by the test medium.
• The volume of test medium required to fill the equipment would be excessive.
• The equipment would be difficult to vent or drain.
• The piping system is to be pneumatic tested.

b) Pumps, turbines, compressors or blowers shall not be included in the test.
c) All restrictions which interfere with filling venting and draining, for example orifice plates
shall be installed until testing is complete.
11.2 Testing Medium
11.2.1 Hydrostatic Test
The test fluid shall be in accordance with ASME B31.3 except that flammable or combustible
fluids shall not be used. All test fluids proposed shall be subject to the approval of the
Purchaser.
For austenitic and duplex stainless steel systems, the test water shall be free from suspended
solids and have a pH value that lies between 6 and 8, and the combined fluorine and chlorine
content shall not exceed 30ppm.
For all other systems the test water shall be free from suspended solids, have a pH value of 7 or
more and a maximum chloride content of 1000ppm except where otherwise specified.
Where a hydrostatic test is called for all pipe work shall be drained and thoroughly dried after
testing in accordance with paragraph 12.5.2.
Page 33 of 40
SPECIFICATION
11.3 Test Pressure and Temperature

11.3.1 Hydrostatic Test Pressure
The hydrostatic test pressures are based on ASME B31.3 unless otherwise stated.
The test pressures indicated in the line list are the minimum required hydrostatic test pressure,
measured at the highest point of the section under test. The design of the system test must
ensure that any additional static head at the lower level run or pipe work does not cause
unacceptable over-pressurisation of the system.
11.3.2 Test Temperature
When conducting the tests at temperatures below 15 degrees Centigrade, (60 degrees
Fahrenheit) the possibility of brittle fracture shall be considered, and the Purchaser shall be
given prior notice of any decisions or actions taken. Under no circumstances shall any testing
be carried out at temperatures below 7 degrees Centigrade (45 degrees Fahrenheit).
The minimum metal temperature for all components during pneumatic testing shall normally be
15 deg C.
The minimum metal temperature requirements shall also apply to tightening of bolts to seal any
flange leaks which were discovered during the test.
11.4 Pressure Test Procedure
11.4.1 General
All pressure testing shall be carried out in the presence of the Purchaser’s Inspector and shall
be to his satisfaction.
The metal temperature during the test shall meet the requirements of section 12.4.2. Where the
ambient is below the minimum test temperature, the temperature recorded shall be closely
monitored to ensure the test temperature requirements are maintained.
Piping shall be cleared of internal debris prior to pressure testing by flushing through with test
water or blowing through with steam or air. Suitable precautions shall be taken to protect
instruments, soft seat valves, control valves, equipment etc, from damage. Flushing mediums
shall comply with section 12.3.
Ball valves shall be fully open before and during flushing.
Contractor shall indicate the flushing sequence on the system piping drawings.
All leaks shall be rectified to the satisfaction of the Purchaser’s Inspector and the system
retested to the full test pressure.
Weld defects shall necessitate the complete release of pressure and rectification of the fault in
accordance with the applicable project fabrication specifications. After completion of any heat
treatment and NDT the pressure test shall be restarted from the beginning.
Small adjustments, e.g. the tightening of flange bolts, may be carried out at the stage of 1 Bar
G. After completion of adjustments the test shall be resumed from the pressure at which the
repairs or adjustments were made.
11.4.2 Hydrostatic Test
Page 34 of 40
SPECIFICATION
Where considered appropriate, a preliminary air test in accordance with ASME B31. May be
performed in order to locate major leaks.
For high pressure hydrostatic testing consideration shall be given to roping off the test area and
displaying warning notices stating “Caution High Pressure Testing” shall be displayed at all
points of access.
All vents and other high point connections shall be opened to allow the air inside the system to
be completely expelled by the test medium, prior to applying the test pressure.
When the prescribed test pressure has been achieved in the system it shall not be approached
for close examination before 15 minutes has lapsed for stabilisation.
The test duration monitored after the stabilisation period, shall be to the Purchasers
requirement.
The test pressure gauge shall preferably be located at the high point in the system. Where this
is not practicable, readings may be taken at other points provided correction is made for the
static head. See also section 12.4
As soon as possible after completion of the pressure test the test medium shall be completely
drained from the system. Vents and other high point connections in the piping system and
connected equipment shall be opened prior to commencement of draining. Particular care shall
be taken with the venting of equipment during draining to avoid damage resulting from the
creation of excessive vacuum.
Because of the possible large volume of testing fluid to be discharged on the completion of the
test, provisions must be made for satisfactory disposal of this fluid to avoid unnecessary
flooding of the work area.
Where special fluids are used for carrying out the test, these may have to be recovered or
disposed of in a certain way to avoid drainage contamination, in cooperation with local
authorities.
The piping system and connected equipment shall be blown dry using warm, dry oil free air or
nitrogen. In addition, all materials shall be sealed after drying to prevent ingress of moisture.
Flange test plugs for offshore hydro testing of flange Joints (screwed & butt or socket welds)
may be used."
11.5 Pneumatic Test
Pneumatic tests shall only be carried out where so specified on the line list and shown on the piping
drawings, Isometrics etc.
Where pneumatic tests are performed, after initial pressurising to 1.72 Bar G, soapy water leak tests
shall be performed on all joints before proceeding gradually in steps to the specified pressure. For
safety reasons, volumes of system on pneumatic test shall be kept to a minimum to restrict the
amount of stored energy in the system. Where high pressure pneumatic tests (1.1 x design
pressure) are specified this shall only be conducted after 100% radiography of all welded joints.
Access to pneumatic test area shall be restricted to those persons required to conduct the test. An
agreed safe radius (approximately 23 meters) shall be established around the system under test.
11.6 Test Equipment
Test equipment must be of good quality and be of such pressure rating as to be capable of
withstanding the conditions prevailing at the time of pressure test.
Pressure test gauges shall have a full range not greater than twice the test pressure. The minimum
face size shall be 150mm.
Page 35 of 40
SPECIFICATION
All test instruments, recorders and gauges shall be calibrated prior to commencement of testing.
Each test instrument shall be uniquely identified and a record kept of each calibration and the name
of the calibrator.
If the source of “air for testing” is at a higher pressure than the test pressure a reducing valve shall
be fitted together with a safety valve and a pressure gauge on the low pressure side.
The test manifold between hydraulic test pump and equipment to be tested shall include, as a
minimum, one isolating valve, one pressure gauge (fitted to the lowest point in the system) and one
relief valve set to relieve at 10% above test pressure. The relief valve must not be isolated from the
pressurised system thus avoiding over-pressurisation due to increase in ambient temperature or
other external causes.
All test equipment must have prior approval of Purchaser including chart size and scales.
11.7 Test Records
Test records shall be prepared for each system test in accordance with ASME B31.3.
Records shall include details of any corrections of the test pressure carried out to compensate for
variations caused by temperature changes during the test.
Records shall include details of any corrections of the test pressure carried out to compensate for
variations caused by temperature changes during the test.
All test records shall be included in the Contractor’s data books and submitted to the Purchaser.
Flushing cleanliness record sheets shall be maintained by the Contractor.
Contractor shall include a copy of the test equipment calibration certificates with the acceptance
documentation for each test.
11.8 Post Test Requirement
The contractor shall rectify all temporary modifications to the piping system which were made for the
purpose of pressure testing. This shall include but not be limited to:-
a) Remove blinds, re-connect and re-install instruments, equipment, relief valves, orifice plates
etc, ensuring that the correct gaskets and bolting are fitted and torque bolts.
b) Remove test gauges.
c) Remove temporary supports and restore spring hangers and counterweight assemblies to
their operational mode.
d) Seal vents and drains in accordance with the requirements of the Piping Material Specification
J8469B-L-S-14000
e) Remove scaffolding.
Where an appreciable amount of repair welding has been carried out to rectify welds the system
shall be re-checked for dimensional accuracy and fit.
In order to avoid possible problems resulting from residual moisture, valves in low temperature or
highly corrosive service shall be re-packed after completion of hydrostatic testing when specified by
the Purchaser.
12.0 QUALITY ASSURANCE AND CERTIFICATION
The Contractor shall maintain an approved quality system in accordance with ISO 9001:2000 and
the instructions given in the requisition/purchase order.
Contractor shall provide to Purchaser an Inspection Release Certificate (IRC) for Purchaser to
approve for each item of pre-fabricated piping prior to shipment offshore as required by the Project
Completions Manual.
Page 36 of 40
SPECIFICATION
An inspection & Test Plan shall be developed covering all stages of fabrication, installation and
testing and is to be approved by Purchaser prior to commencement of work.
The following is a list of procedures and documents which need to be submitted for review and
approval by Purchaser prior to commencement of activities.
• ISO 9000/2000 Quality Management System certificate

• Project Quality Plan and QA/QC Organisation for the work
• Inspection and Test Plan identifying Pireco inspection hold and witness points together with
those of involved third parties.
• Material Control Procedures (receiving, inspection, storage, issue for fabrication, transfer
offshore etc.)
• NDT procedures (MPI, DPI, UT, RAD)
• NDT Operator qualification certificates
• Welding Procedure Specifications (WPS)covering the work scope
• Welding Procedure Qualification Records (WPQR) for above
• Welder qualification certificates
• Identification and traceability procedures for materials, welding and inspection & test records
• Pressure Testing Procedure
• Coating Procedures
• Manufacturing Record Books (index)
• Torque tightening procedure and sequence
• Interface arrangements for Tunisian Ministry Approvals
• Health and Safety Plan
Page 37 of 40
SPECIFICATION
13.0 ADDENDUM ‘A’

ADDITIONAL REQUIREMENTS FOR IMPACT TESTED CARBON STEEL PIPEWORK
A.1 INTRODUCTION
A1.1 This Addendum specifies the additional requirements with which the Contractor shall comply
when fabricating and installing impact tested carbon steel pipe work.
A.2 MATERIALS
A.2.1 Materials of uncertain origin or which are not to the required specification shall not be used
even for apparently unimportant items.
A.2.2 Thicker materials than those specified on the relevant drawings and Pipe Material
Specification J8469B-L-S-14000 shall not be used unless agreed by the Purchaser.
A.2.3 Hard stamping of materials shall not be permitted.
A.3 PIPE BENDING

A.3.1 Hot formed bends shall be normalised at 900-950ºC for 1 Hr/in (0.04Hr/mm) of nominal wall
thickness unless it can be demonstrated that the temperature control during hot forming
results in the items having the same mechanical properties as if it was normalised.
A.4 WELDING PROCEDURE AND WELDER QUALIFICATION

A.4.1 For impact tested material 2G and 5G positions are to be separately qualified and the 5G
weld impact test-specimens taken from the 3 o’clock position.
A.4.2 The impact test temperature during procedure qualification must be based on the thickest
productions weld to be qualified.
Page 38 of 40
SPECIFICATION
15.0 ADDENDUM ‘B’
'A'
'A'
END PREPARATION FOR WELDS SHALL NOT EVIATE FROM

'R
'
THE INDICATED POSITION BY MORE THAN 0.8mm

ACROSS THE LAND.
BENDING TOLLERANCES
'A'
BENDING RADIUS 'R' SHALL BE 5 TIMES THE PIPE

DIAMETER. TOLERANCES ON THE RADIUS SHALL BE
±5mm RADII UP TO 610mm AND ±12mm FOR
'A'
'C'
BENDING RADII ABOVE 610mm.
'A' THE ANGULAR DIMENSIONS OF BENDS AND BRANCHES

SHALL BE WITHIN ±14°.
'A' LINEAR TOLERANCES

'A'
THE TOLERANCES ON LINEAR DIMENSIONS

(INTERMEDIATE OR OVERALL) APPLY TO THE FACE TO
FACE, FACE TO END, AND END MEASUREMENTS OF
'A'
FABRICATED STRAIGHT PIPES AND HEADERS: CENTRE

TO END OR CENTRE TO FACE OF NOZZLES OR OTHER
'A'
ATTACHMENTS CENTRE TO FACE OF BEND. AS SHOWN

ON DRAWING THE TOLLERANCES ARE NOT CUMULATIVE.
'A'
LINEAR TOLERANCES ON DIMENSION 'A' ARE ±3mm

FOR SIZES 10" AND BELOW AND ±5mm FOR SIZES
'A'
'A
12" THRU 36". FOR PIPE SIZES ABOVE 36" THE

'
TOLERANCES ARE 5mm PLUS OR MINUS 0.8mm FOR

EACH 12" OR DIA OVER 36".
WHERE FORGED FITTINGS ARE WELDED TOGETHER. THE

TOLLERANCES ON DIMENSION 'C' SHALL BE GOVERNED
'A'
BY THE FITTING MANUFACTURES TOLLERANCES.
Page 39 of 40
SPECIFICATION
ADDENDUM ‘B’ contd.
MISALIGNMENT OF FLANGES
DIMENSION 'A' SHALL NOT
EXCEED 1.5mm
ALIGNMENT OF FACINGS OR ENDS

SHALL NOT DEVIATE FROM THE
INDICATED POSITION MEASURE
ACROSS THE DIAMETER BY MORE
THAN 2.5mm/METRE.
Page 40 of 40

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BGT DOCUMENT NUMBER

GOGC DOCUMENT NUMBER

A 29/6/11 Issued For IDC NP

Rev Location Of Changes Brief Description Of Change

1.0 INTRODUCTION .................................................................................................... 6

6.7 Alignment ................................................................................................. 15

12.3.1 Hydrotstatic Test...................................................................................... 33

1.2 Pipe work Excluded

Excluded from the scope of this specification are:-

The following definitions shall apply to this specification:-

2.0 CODES AND STANDARDS

• PD 8010 Part 2 Pipelines-Design and Construction.

• ASME B31.8 Gas Transmission & Distribution Piping

• API-RP-14E API Recommended Practice for Design And Installation of Offshore

• API-RP-520 API Recommended Practice for Design and Installation of Pressure

• NACE MR-0175/ISO 15156 "Materials for use in H2S containing Environments

2.1.3 American Petroleum Institute

2.1.4 British Standards

2.1.5 Project Specifications and Standards

3.1 Drawings and Documentation

4.1 Material Supply

5.3.2 Hot Bending

5.3.3 Cold Bending

5.4 Fabrication Tolerances

5.5.1 Cleaning and Protection

5.5.4 Dimensional Control

The following heat input limits shall apply:

22Cr duplex: 0.5-2.5 kJ/mm

7.0 WELDING CONSUMABLES

7.1 Specification and Selection

7.1.1 Stainless Steel

7.1.3 Duplex Stainless Steel

7.1.4 High Nickel Alloys

8.0 WELDING PROCEDURE AND WELDER QUALIFICATION

8.2 Hardness Survey

POSITIONS FOR HARDNESS INDENTATIONS

NOTCH POSITION NOTCH POSITION

NOTCH LOCATIONS FOR CHARPY SPECIMENS

9.0 HEAT TREATMENT

INSPECTION AND TESTING

9.8 Qualification of NDT Personnel

9.9 Progressive Examination

PRESSURE ≤600 ≥900 ≤300 ≥600 ≤150 ≥300 ≥150

(*) Socket welds are not permitted on severe cyclic conditions

10.3 Flanged Joints

FIGURE 11.5 – RECOMMENDED TORQUES FOR BOLTING

FLANGE FLANGE NO. OFF BOLT BOLT BOLT

10.10 Field Run Piping

11.0 PRESSURE TESTING & FLUSHING

Preparation for Testing

11.1.3 Valves and Instruments

• The equipment internals would be damaged by the test medium.

• The equipment would be difficult to vent or drain.

• The piping system is to be pneumatic tested.

11.3 Test Pressure and Temperature

• ISO 9000/2000 Quality Management System certificate

13.0 ADDENDUM ‘A’

A.3 PIPE BENDING

A.4 WELDING PROCEDURE AND WELDER QUALIFICATION

15.0 ADDENDUM ‘B’

END PREPARATION FOR WELDS SHALL NOT EVIATE FROM

THE INDICATED POSITION BY MORE THAN 0.8mm