5D Bends Combine RFQ

Material Requisition Stantec Project # 110903807
110903807-ME-MR-003 Suncor Project # 02-05478
COMPONENT DESCRIPTION: 5D Bends

TAG NUMBER(S): 91SP-3078/3079/3080/3081/3082/3083/3084/3085/3086
RFQ/PO NUMBER: 110903807-003 / TBD
RAS DATE: July 1st, 2019
AFE#: 02-05478
Issued for Quotation (Rev 0A1) Purchase (Rev ) Change Order (Rev )
1.0 SCOPE OF SUPPLY

• This scope of work includes the design, supply, fabrication, assembly, testing and inspection of
the following:
COST CAD COST CAD

ITEM QTY TAG DESCRIPTION REV
(EACH) (TOTAL)
1 ½” SCH 80 CARBON STEEL $2,000 $2,000
1 1 91SP-3078 0A1
5D BEND (Estimated) (Estimated)
1 ½” SCH 80 CARBON STEEL $2,000 $2,000
2 1 91SP-3079 0A1
1 ½” SCH 80 CARBON STEEL $2,000 $2,000
3 1 91SP-3080 0A1
1 ½” SCH 80 CARBON STEEL $2,000 $2,000
4 1 91SP-3081 0A1
1 ½” SCH 80 CARBON STEEL $2,000 $2,000
5 1 91SP-3082 0A1
1 ½” SCH 80 CARBON STEEL $2,000 $2,000
6 1 91SP-3083 0A1
1 ½” SCH 80 CARBON STEEL $2,000 $2,000
7 1 91SP-3084 0A1
1 ½” SCH 80 CARBON STEEL $2,000 $2,000
8 1 91SP-3085 0A1
1 ½” SCH 80 CARBON STEEL $2,000 $2,000
9 1 91SP-3086 0A1
$18,000
TOTAL - 0A1
(Estimated)
2.0 RECOMMENDED BIDDERS SOLE SOURCE
(Vendor Quote #)
CONTACT
VENDOR NAME CONTACT CONTACT E-MAIL
NUMBER
1 Triple D Bending - (403) 255-2944 info@pipebending.com
Stantec Consulting
Suite 200, 37 Quarry Park Boulevard SE  Calgary, Alberta T2C 5H9  Ph: (403) 252-3436  Fax: (403) 252-3464
Material Requisition Stantec Project # 110903807
110903807-ME-MR-003 Suncor Project # 02-05478
3.0 TECHNICAL DOCUMENTS AND ATTACHMENTS
• Refer to Technical Documents and Attachments:

110903807-ME-TDA-003 Rev. 0A1
4.0 VENDOR DRAWING AND DOCUMENT REQUIREMENTS
• Refer to Vendor Drawing and Document Requirements:

110903807-ME-VDDR-003 Rev. 0A1
5.0 QUALITY SURVEILLANCE AND INSPECTION REQUIREMENTS
• Inspection Level: 1
• Refer to Quality Management Requirements:
110903807-ME-QMR-003 Rev. 0A1
6.0 WARRANTY REQUIREMENTS
• Refer to Suncor terms and conditions for warranty information
7.0 SPARE PARTS
• N/A
8.0 SHIPPING INSTRUCTIONS
• Packages shall be shipped to: TBD
• Shipping Contact Information

Contact: TBD
Contact Number: TBD
Contact E-Mail: TBD
9.0 SPECIAL REQUIREMENTS
• 5D Bends shall have CRN (AB).

• Vendor to handle preparation for shipment.
For MS
Stantec Author: Mustafa Siddiqui Date: 17th May,2019
Stantec Discipline Lead: Muhammad G Khan Date: 17th May,2019
Stantec PM Approver: Anna Yurko-Weston Date: 17th May,2019
Stantec Procurement Receipt: Wayne Lau Date: 17th May,2019
Stantec QC: Chris Ebel Date: 17th May,2019
Stantec Consulting
Technical Documents and Attachments Stantec Project # 110903807
110903807-ME-TDA-003 Suncor MR # 02-05478
COMPONENT DESCRIPTION: 5D Bends

TAG NUMBER(S): 91SP-3078/3079/3080/3081/3082/3083/3084/3085/3086
RFQ/PO NUMBER: 110903807-003 / TBD
REVISION: 0A1
REVISION DATE: 17-May-2019
DOCUMENT NUMBER REV. # DOCUMENT DESCRIPTION TITLE

DATA SHEETS
DS91-L-SP3078-1 0A1 5D BEND SHEET
GENERAL
VENDOR DRAWING AND DOCUMENT
110903807-ME-VDDR-003 0A1
REQUIREMENTS
QUALITY MANAGEMENT
110903807-ME-QMR-003 0A1 QUALITY MANAGEMENT REQUIREMENTS
CLIENT STANDARD DRAWINGS
N/A
CLIENT SPECIFICATIONS – GENERAL
0118 3 Manufacturer’s Record Book Requirements
Above and Below Ground Pipelines to CSA Z662 (Section
0222 2
5.2.23)
0202 23 Piping Material Specification
Piping Class Specification – CAZ – LIME SLURRY (For
0202-CAZ 19
information)
0205 9 Piping Pressure Leak Test
0205 Att.A - Pressure Leak Test Certificate
Purchasing Requirements for Pipe, Flanges, Fittings,
0227 3
Bolting and Gaskets
0903 10 Shop and Field Welding Requirements
Stantec Consulting
Technical Documents and Attachments Stantec Project # 110903807
110903807-ME-TDA-003 Suncor MR # 02-05478
ST-QM-003 2 Standard for NDE
0213 6 Positive Material Identification
REMARKS
1. The design, fabrication, and supply of materials in the Scope of Supply shall be in accordance
with the datasheets, drawings, specification, standards, technical notes, and attachments listed
above.
Stantec Consulting
VENDOR DRAWING AND DOCUMENT REQUIREMENTS
110903807-ME-VDDR-003
Document No.: RFQ/PO#: 110903807-003/TBD
91SP-3078 / 3079 / 3080 / 3081 /
Stantec Project No.: 110903807 TAG Number(s): 3082 / 3083 / 3084 /3085 / 3086
Client Project No.: 02-05478 Revision Date: 17-May-19
Component Description: 5D Bends Revision #: 0A1
E = Electronic; V = Vendor Data Book; P = Print; Q = QC Data Book
WQ= With Quote; ARO = After Receipt of Order; PTF = Prior to Fabrication; ATOT = At Time of Testing; AT = After Testing; BS = Before Shipment; WS = With Shipment; AS = After Shipment
Certified & Final Submittal

With Quotation Approval Record
Submission Schedule
Code Data Description / Definition Q A C R
DBXX - DATA BOOKS

DB01 VENDOR DATA BOOK TABLE OF CONTENTS 1E/1V 4 wks ARO
DB02 VENDOR DATA BOOK 1E/1V 2 wks AS
DB03 QC DATA BOOKS 1E/1P WS
GDXX - GENERAL & MISCELLANEOUS DATA
GD11 (NOTE 2) DATA SHEETS MARKUPS 1E 1E/1V/1Q 2 wks ARO
DMXX - MECHANICAL DRAWINGS
DM01 GENERAL ARRANGEMENT DRAWING c/w BOM 1E 1E/1V/1Q 2 wks ARO
PXX - PROCEDURES
P01 QUALITY CONTROL PROCEDURES 1E/1V 1 wk BS
P02 HYDROSTATIC TEST PROCEDURE 1E/1V 2 wks ARO
P03 NON-DESTRUCTIVE EXAMINATION (NDE) PROCEDURES 1E/1V 2 wks ARO
WELDING PROCEDURE SPECIFICATION (WPS) / PROCEDURE
1E 1E/1V 2 wks ARO
P04 QUALIFICATION RECORD (PQR)
P05 WELD REPAIR PROCEDURE (IF APPLICABLE) 1E 1 wk PTF
P14 POSITIVE MATERIAL IDENTIFICATION PROCEDURE 1E/1V 4 wks ARO
P20 PRODUCTION HARDNESS TEST PROCEDURES (If Applicable) 1E/1V 2 wks ARO
P21 PWHT PROCEDURE (If Applicable) 1E/1V 2 wks ARO
P22 GENERAL BENDING SPECIFICATION 1E 1E/1V 2 wks ARO

P23 TEMPERATURE MONITORING PROCEDURE (If Applicable) 1E/1V 2 wks ARO
P24 QUENCHING PROCEDURE (If Applicable) 1E/1V 2 wks ARO
RMXX - MECHANICAL REPORTS AND CERTIFICATES
RM09 COPY OF CRN APPROVAL LETTER 1E/1V/1Q 2 wks BS
RM12 WELDERS LOG AND QUALIFICATIONS 1E/1V 1 wk PTF
RM13 (NOTE 1) WELD MAP/WELD DETAILS 1E 1E/1V 2 wks ARO
RM14 MATERIAL TEST REPORTS (MTRs) OR MILL CERTIFICATES 1E/1V 1 wk PTF
RM17 HYDROSTATIC TEST GAUGE CERTIFICATE 1E/1V 1 wk BS
RM18 HYDROSTATIC TEST REPORT / CERTIFICATE 1E/1V/1Q 2 wks BS
RM19 PWHT REPORT AND CHARTS (If Applicable) 1E/1V 1 wk BS
RM21 COMPLETED AND SIGNED ITP 1E/1V/1Q 1 wk BS
RM26 NON-CONFORMANCE REPORT (NCR) LOG (IF APPLICABLE) 1E 1E/1V 1 wk PTF
RM27 APPROVED NON CONFORMANCE REPORTS (NCRs)(IF APPLICABLE) 1E/1V 2 wks BS
` RM29 DEFICIENCY PUNCH LIST (IF APPLICABLE) 1E 1E/1V 1 wk BS
INSPECTOR'S QUALIFICATION CERTIFICATE FOR NON-DESTRUCTIVE
1E/1V 1wk PTF
RM43 TESTING
RM45 TEST RECORDS FOR NON-DESTRUCTIVE TESTING 1E/1V 2 wks BS
RM76 POSITIVE MATERIAL IDENTIFICATION 1E/1V 1 wk PTF
RM77 PRODUCTION HARDNESS TEST REPORTS (If Applicable) 1E/1V 2 wks BS
RM79 POST BEND INSPECTION REPORT 1E/1V 2 wks BS
RM80 TEST BEND MECHANICAL PROPERTY AND INSPECTION REPORT 1E/1V 2 wks BS
RIC13 CALIBRATION CERTIFICATION FOR TESTING INSTRUMENTATION (AS APPLICABLE) 1E/1V 1 wk BS
Note 1: Weld details can be represented on General Arrangement drawings or any other documents. Issue of separate document for approval will be
not required in this case.
Note 2: Vendor to provide data in Stantec data sheet.
Page 1 of 1
FIREBAG PROGRAM – ENGINEERING
MATERIAL REQUISITION
SECTION 4
QUALITY MANAGEMENT REQUIREMENTS
Project Name: Project No. File No: MR No.: MR Rev.
Lime MagOx System Upgrade 110903807 110903807-ME-QMR-003 110903807-003 0A1
Equipment/Material: 5D Bends
1.0 QUALITY ASSURANCE
1.1 The Seller* shall have in place a Quality Management Program that will ensure that the materials,
services and equipment offered or supplied meet the requirements specified within this Requisition
and its referenced documents. The Seller’s Quality Management System shall be assessed by
Suncor against ISO 9001 and API Q1/ISO TS 2900 Standards.
The Seller shall provide copies of formal current Certification/Registrations of their Quality
Management System at their Bid Submission Stage as indicated within 110903807-ME-VDDR-001
1.2 The Seller Quality Management Program** must be approved by Suncor prior to commencement of
work on the Order. Any request by the Seller for design changes, relaxations or acceptance of
nonconformities shall be formally applied for in writing to Suncor. (Reference: 110903807-ME-VDR-
001)
2.0 CONTENT OF THE QUALITY PLAN
2.1 The Seller shall prepare a Contract Quality Plan and Inspection and Test Plan (ITP) specific to the
scope of this MRP, which shall be submitted to Suncor within the time period specified in 110903807-
ME-VDDR-001
2.2 The format and issue of this Quality Plan and ITP shall be consistent with the document control
elements of the Seller’s Quality Management Manual, as a minimum. The Quality Plan shall be
prepared in accordance with ISO 10005 and shall include the following:
2.2.1 Identification of the product, service and contract to which the plan is to be applied.
2.2.3 Location of Primary and Sub-suppliers of equipment and Material(s), by production facility c/w a copy
of their ISO 9001 Quality Management System: Registration Status and Certificate, or regulatory
organization equivalent.
2.2.4 Identification of the individuals (c/w title) responsible for controlling the activities defined in the Quality
Plan, by production facility.
2.2.5 Identification of the individuals (c/w title and contact information) with the authority to interface directly
with Suncor.
2.2.6 Identification of all subcontractors / technical services suppliers (c/w Scope of Supply).
2.2.7 Quality Plans and ITP of all subcontractors / technical service suppliers.
-
Note: * = Vendor / Supplier / Manufacturer

** = Suncor will not release material / equipment to, or approve Third Party Services performed at a subcontractor of a
Prime Seller* (Contract or Purchase Order Holder).
UNCONTROLLED DOCUMENT WHEN PRINTED (17-MAY-19) CONTROLLED DOCUMENT IN PROJECT LOCATION
Exhibit: File 100-2004-001 – 2.4.4.2 - FB-PEG-GP10-F04 Rev.: 11 Page: 1 of 8

SECTION 4
2.2.8 All logically sequenced activities for the Scope of Supply and product required and references to the
quality system procedures and work instructions, which will be applied to those activities.
2.2.9 Specific reference to, in each Quality Plan and ITP, all the quality system procedures and work
instructions covering design assurance, production assembly, test and inspection, special processes,
control of non-conforming product, handling, storage, packing, preservation, material traceability,
certification, performance testing and delivery. Suncor will indicate if procedures, etc. are required for
information or review, after Initial Assessment of this Seller Deliverable as per 110903807-ME-
VDDR-003 and 110903807-ME-QMR-003.
2.2.10 Test and inspection frequency and acceptance criteria including the upper and lower process control
limits (where statistical process control is employed).
(Note: Process control of chemical composition, dimensional parameters and test/ performance
report data is generally based upon upper and lower control levels or specification levels.)
2.2.11 The location of each Seller’s Inspection and Test Point in the processing sequence.
2.2.12 Points where the Seller* has established witnessing or verification requirements in the processes of
their suppliers, sub-vendors/subcontractors.
3.0 SELLER’s RESPONSIBILITY FOR THIRD PARTY QUALITY MANAGEMENT
3.1 The Seller/Supplier shall list all their Quality Management activities that will be provided by Third
Parties as applicable to the Scope of Supply (Reference: 110903807-ME-MR-003).


SECTION 4
4.0 SUNCOR SOURCE QUALITY SURVEILLANCE LEVELS
Suncor will conduct Quality Control / Assurance Activities on material / equipment and Technical
Service Provisions of selected Items of Supply (Reference: 110903807-ME-MR-003).
Level 0: Receiving Inspection at final destination only.
Level 1: This level includes the Initial Visit and Final Visit, prior to release of material or equipment.
The number of visits necessary will vary with the amount of material or equipment on order as well as
the lot size the Seller* presents for assessment.
Level 2: The visit level for Level 1 applies. Subsequent visits shall be made to assess quality at
established witness and hold points. The numbers of visits necessary will vary with the amount of
material or equipment on order as well as the lot size the Seller presents for assessment** and
frequency of witness and hold points as well as the number of visits for release of equipment required.
**
Level 3: The instructions for Level 2 apply; however, additional visits will be made periodically for the
purpose of performing surveillance activities required by Suncor, the Quality and/or Inspection and
Test Plan, or special instructions. If not established by the Quality and/or Inspection and Test Plan, the
performance history of the Seller may be used to determine the frequency of visits. Suncor retains the
right to modify their Source Surveillance levels of activities, at any time and with given formal notice.
For example, if during the early stages of the order, the Seller’s personnel demonstrate
comprehension of the requirements of the order and competence in performing required test and other
quality-related functions, the frequency of witnessing operations may be reduced proportionately.
Conversely, when, through surveillance, concerns are noted, the frequency of visits may be increased.
Any changes in frequency from the Quality and/or Inspection and Test Plan require concurrence by
the Project Quality and/or Expediting Contact(s). When specification requirements exceed recognized
standards such as ASME, AWS, API, IEEE, etc., special consideration may be given by Suncor to
increasing surveillance of these activities.
Level 4: This is a full time residency status for a specific assignment. Specific activities to be
accomplished in residency status will be outlined in the MRP Quality and/or Inspection and Test Plan
When Level 4 Surveillance is specified, the Seller/Supplier shall provide suitable workstation facilities
for the Suncor assigned Quality Surveillance Representative. The facilities shall include telephone,
access to fax machine and a computer with access to internet for the purposes of Email
communication.


SECTION 4
Stantec QA/QC Coordinator: Chris Ebel
780-969-2098 587-920-3447 Chris.Ebel@stantec.com

Telephone Cell Fax Email
Source Quality Surveillance Level Established: 1
Notice to Sellers:
Suncor will provide an initial “Inspection Plan” with each MRQ/MRP Package. This document will indicate
our broad intent or minimum requirements with respect to typical Suncor Source Quality Surveillance
activities that have been assessed as: “Critical-To-Quality” Key Performance Indicators.
Suncor will throughout the process of Vendor Document Review Activities indicate their specific intent on
performing Source Quality Surveillance at Seller’s, their Third Party Service Providers, or Sub-contractor’s
facilities. The Seller/Supplier* should incorporate the Review, Inspect, Witness & Hold Points noted in
110903807-ME-QMR-001, into their initial submittal of the Inspection and Test Plan (ITP).
Suncor’s Quality Surveillance Policy is to hold the Prime Seller accountable and responsible for
performing Quality Management activities at their Third Party Service Providers and/or Sub-contractors.
Seller Quality Plans or Inspection and Test Plans that do not have specific prime Seller responsibilities for
independent (of Suncor) Quality Surveillance at their suppliers; subcontractors will be assessed as
deficient and non-compliant to this MRQ/MRP.
The Seller/Supplier shall provide Suncor with 10 working days advanced written notice of all Witness and
Hold Points as noted on pages 6 and 7 of 110903807-ME-QMR-003 of this Material Requisition. The
Seller/Supplier shall provide this notice by means of the “Supplier’s Request for Quality Surveillance” form,
attached to 110903807-ME-QMR-003 of this Material Requisition, as Page 8.
The Seller/Supplier shall include in all Sub-orders, or Sub-contracts, notice of Suncor’s intent to conduct
Quality Surveillance activities at the Sub-supplier’s, or Sub-contractor’s facilities. The activities shall
consist of confirmation of Status, Review of Documentation, Inspections, and attendance to Witness, and
Hold Points.


SECTION 4
Specific Equipment/Material: 5D Bends Inspection Level: 1
DOCUMENTATION: In addition to the copies required in 110903807-ME-VDDR-003, one copy of the documents marked
(X) must be provided by the Seller to the Buyer’s Quality Representative during source Quality
Assessments.
Upon Buyer’s Quality Representative’s request, the Seller shall provide any documents listed in
110903807-ME-VDDR-003 (not marked below) during source Quality Assessments.
ASME Code Report (U-1/U-1A) Performance Test Curves
Mill and Material Test Reports Nameplate Rubbings or Facsimile
Charpy Impact Test Reports (if applicable) Certificate of Compliance (Test Run)
Post weld Heat Treatment Records, and Charts (If Certificate of Compliance (Hydro Test)
Applicable) NDE Reports
Hardness Test Reports (If Applicable) Sub-supplier’s Inspection and Test Plans (if applicable)
Hydrostatic Test Report PMI/Ferrite
Seller/Supplier’s Inspection and Test Plan
ABSA Data Reports (AB-41)
PROCEDURES: The Procedures, Documents and Qualifications marked (X) are subject to review by Buyer prior to
fabrication. (Reference 110903807-ME-VDDR-003)
High Pot Test Routine Electrical Hydrostatic Test

Motor Test Tube Rolling Noise Test
Machining Tube Cleaning and Installation Performance Test
Welding Quality Control & Testing NDE Procedures
Welding Repair (if applicable) Surface Preparation, Painting & Hardness Test Procedure (If Applicable
Sub Supplier’s ITP(if applicable) Coating per WPS/PQR)
Seller/Supplier ITP PWHT Procedure (If Applicable Positive Material Identification Procedure
Shipping & Handling per WPS/PQR)


SECTION 4
INSPECTION The following requirements shall be considered INSPECTION POINTS, monitoring and
CHECKLIST reporting on these items are required by Suncor.
W / HP Witness / Hold Point: Inspection or test for which the Buyer’s representative is notified of the timing of the inspection or test and a hold
is placed on the inspection or test until the Buyer or their representative is in attendance.
O Observe: Inspection or test where the Buyer’s representative is notified of the timing of the inspection or test and the inspection or test
is performed as scheduled, regardless of whether the Buyer or their representative is present.
I Inspect: Buyer’s representative shall routinely inspect said activity. No delay in Seller’s fabrication process shall be incurred due to said
representative’s schedule.
RV Review or Verify: Buyer’s representative shall verify completeness and validate results of documents or exhibits pertaining to said
activity. No delay in Seller’s fabrication process shall be incurred due to said representative’s schedule.
RD Record on Drawing.
SD Submit Supporting Quality Documentation.
RN Reference Note.
W/ W/
Pressure Tests O I RV RD SD RN NDE O I RV RD SD RN
HP HP
Hydrostatic Test X RT (Radiography) X
Pneumatic Test LP (Liquid Penetrant)
Proof Tests MP (Magnetic Particle) X
UT Ultrasonic Test
Pop & Set Pressure Test
(Manual)
Back Seat Tests TOFD Ultrasonic Test
Phased Array Ultrasonic
High Pressure Closure X
Test – if applicable
Low Pressure Closure Eddy Current Test
Leak Test – if applicable
for repads and wear Brinnell Hardness X
plates
Static Seal (Inert Gas) Ferrite/ PMI
Charpy Impact Test – if
applicable
W/ W/
Materials O I RV RD SD RN Other (Specify) O I RV RD SD RN
HP HP
Flange Finish, Rating, & Vendor’s QC Manual
X X
Gasket Face Condition Valid
Heat Treat Records X Performance Test
Material Identification X
Traceability Records X
Material Test Reports X
API Inspector W/
NDE MAP O I RV RD SD RN
Checklists HP
Welder Traceability X Pumps – Centrifugal
WPS registered and
accepted by Owner X Pumps – Reciprocating
Representative
Compressors –
Centrifugal
Compressors -
Reciprocating
Fired Heaters


SECTION 4
INSPECTION The following requirements shall be considered INSPECTION POINTS, monitoring and
CHECKLIST reporting on these items are required by Suncor.
W / HP Witness / Hold Point: Inspection or test for which the Buyer’s representative is notified of the timing of the inspection or test and a hold is
placed on the inspection or test until the Buyer or their representative is in attendance.
O Observe: Inspection or test where the Buyer’s representative is notified of the timing of the inspection or test and the inspection or test is
performed as scheduled, regardless of whether the Buyer or their representative is present.
I Inspect: Buyer’s representative shall routinely inspect said activity. No delay in Seller’s fabrication process shall be incurred due to said
representative’s schedule.
RV Review or Verify: Buyer’s representative shall verify completeness and validate results of documents or exhibits pertaining to said
activity. No delay in Seller’s fabrication process shall be incurred due to said representative’s schedule.
RD Record on Drawing.
SD Submit Supporting Quality Documentation.
RN Reference Note.
W/ W/
Dimensional & Visual O I RV RD SD RN Coating & Painting O I RV RD SD RN
HP HP
External Surface
Fitup & Back Gouging X Preparation and
Inspection
Welds Internal & External X External Coating System
External Dry Film
Internal Inspection
Thickness
Internal Pre-Blast
Major Weld Repairs X
Inspection
Vessel Roundness/ Surface
Straightness Preparation/Cleanliness
Nozzle Orientation /
Coating System
Elevation/ Projection
Bundle Installation &
Dry Film Thickness
Removal
Tray installation Holiday Testing
Non-Conformance
Shaft Run-out
Resolution
Rotating Part Clearance
Grout Hole & Clearance
Alignment
Coupling/Equip.
Dimensional Accuracy X
Cleaning & Painting
Preparation for Shipment X
Marking X
Final Overall Visual X
Non-Conformance
X
Resolution – if applicable
Final Inspection/Release X
Engineering Reference Notes:

1. 5D Bends shall be registered as a pressure fitting with ABSA (AB CRN).
2.


SECTION 4
SUPPLIER’S REQUEST FOR QUALITY SURVEILLANCE
ATTENDANCE TO WITNESS, OBSERVATION AND HOLD POINTS
Note: Tentative notification shall be submitted 10 working days prior to inspection/test activities for all
witness/observation and hold points per approved ITP.
PROJECT NAME:
SUNCOR PO NO: TBD Lime MagOx PROJECT No: 110903807 / 02-05478
System Upgrade
INSPECTION NOTICE NO.: INSPECTION NOTICE DATE:
SUB-SUPPLIER
PRIME SUPPLIER
(Name, Address,
(Name, Address, Contact Name EQUIPMENT TAG NO.(s)
Contact Name &
& Number)
Number)
Name: Name: N/A 91SP-
Address: Address: N/A 3078/3079/3080/3081/3082/3083/3084/3085/3086
Contact Name:
Phone:
Fax: Contact Name:
E-mail: N/A
Phone:
Fax:
E-mail:
ITP Document No: TBA
ITP Activity: TBA
Date of activity: TBA
Estimated start time of activity: TBA


1 5D Bend DATA SHEET Data Sheet No.: DS91-L-SP3078-1
2 COMPANY Suncor AREA TBD
3 COUNTRY CANADA PLANT Plant 91
4 PURCHASE ORDER NO. TBD
5 DRAWING PD91-A-3033-1
6 TAG NUMBER 91SP-3078 LINE NUMBER 91K3010
7 QUANTITY 1
8
9 CHARACTERISTICS OF 5D BEND FLUID / PIPE CHARACTERISTICS
10 TYPE Flanged Bends PIPE CLASS CAZ
11 Size NPS 1-1/2" Material A106 B
12 Bend Radius ( R) 5D or 8" max Wt Sch 80
Bend Angle 90
13 Required Pipe (mm) 640 (Note 1) Design Condition
14 Tangent Length ( C) Tangent length shall be maximum length PRES (kPag) 1034
15 C1 = 274mm TEMP (°C) 115
16 C2 = 153mm
17
18 Operating Condition
19 PRES (kPag) 360
21 TEMP (°C) 50
22
23
24
25 5D BENDS DIMENSION
26
27
28
29
30
31
32
33
34
35
36
37
38
39
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41
42
43
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45
46
47
48
49
50 NOTES
51 1.) Vendor to confirm
52
53
54
55
56
57
58 REVISIONS Stantec
59 NO. DATE BY CHK APP DESCRIPTION Calgary, Alberta, Canada
60 0A1 17-May-19 MS MGK AYW Issued For Quotation PROJECT Suncor Plant 91
61 Lime MagOx System Upgrade
62 JOB NO. 110903807 TAG NO. 91SP-3078
63 LOCATION PAGE 1 of 1
DS91-L-SP3078-1_0A1.XLS Printed Date: 5/17/2019

7 QUANTITY 1
8
Bend Angle 90
15 C1 = 77mm TEMP (°C) 115
16 C2 = 153mm
17
19 PRES (kPag) 360
21 TEMP (°C) 50
22
23
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50 NOTES
52
53
54
55
56
57
62 JOB NO. 110903807 TAG NO. 91SP-3079
DS91-L-SP3079-1_0A1.xls Printed Date: 5/17/2019

7 QUANTITY 1
8
Bend Angle 90
15 C1 = 118mm TEMP (°C) 115
16 C2 = 153mm
17
19 PRES (kPag) 360
21 TEMP (°C) 50
22
23
24
26
27
28
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30
31
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49
50 NOTES
52
53
54
55
56
57
62 JOB NO. 110903807 TAG NO. 91SP-3080

7 QUANTITY 1
8
Bend Angle 90
15 C1 = 153mm TEMP (°C) 115
16 C2 = 153mm
17
19 PRES (kPag) 360
21 TEMP (°C) 50
22
23
24
26
27
28
29
30
31
32
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62 JOB NO. 110903807 TAG NO. 91SP-3081

7 QUANTITY 1
8
Bend Angle 90
15 C1 = 118mm TEMP (°C) 115
16 C2 = 153mm
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19 PRES (kPag) 360
21 TEMP (°C) 50
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62 JOB NO. 110903807 TAG NO. 91SP-3082

7 QUANTITY 1
8
Bend Angle 90
15 C1 = 153mm TEMP (°C) 115
16 C2 = 153mm
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19 PRES (kPag) 360
21 TEMP (°C) 50
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62 JOB NO. 110903807 TAG NO. 91SP-3083

7 QUANTITY 1
8
Bend Angle 90
15 C1 = 153mm TEMP (°C) 115
16 C2 = 153mm
17
19 PRES (kPag) 360
21 TEMP (°C) 50
22
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62 JOB NO. 110903807 TAG NO. 91SP-3084

7 QUANTITY 1
8
Bend Angle 90
15 C1 = 153mm TEMP (°C) 115
16 C2 = 153mm
17
19 PRES (kPag) 360
21 TEMP (°C) 50
22
23
24
26
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28
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62 JOB NO. 110903807 TAG NO. 91SP-3085

7 QUANTITY 1
8
Bend Angle 90
15 C1 = 153mm TEMP (°C) 115
16 C2 = 153mm
17
19 PRES (kPag) 360
21 TEMP (°C) 50
22
23
24
26
27
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62 JOB NO. 110903807 TAG NO. 91SP-3086

Enterprise Technical
Suncor-Wide Standard
Original Equipment Manufacturers (OEM) Information Requirements
CTS-0118
Original Equipment Manufacturers (OEM) Information

Requirements
Effective Date: Upon date of approval

Owned by: Enterprise Technical
Reviewed every 3 years
Livelink ID: 75126081
Controlled Document
Copyright © 2015 Suncor Energy Inc. All rights reserved.
The current revision of this approved document is kept online. Printed and digital copies are uncontrolled.
CTS_0118 1 of 78 Revision: 3
Summary of Changes
This Summary shows:

• The location of each change within the document
• All changes to this document since it was last approved and published
Location of Change Summary of Change
Title Changed to reflect only manufacturer’s information
This document has been restructured to be asset centric using Suncor’s equipment
Entire Document
classes as the common equipment type definitions.
Removed statements regarding roles, responsibilities, or area specific document
Entire Document
management applications.
Appendix A Appendix A, Vendor Data Deliverables has been superseded to CTS-0126.
Appendix B Appendix B Requirements have been moved into the body of this standard.
Submittal and Review of Vendor Documentation section has been transferred moved
Submittal
to project execution procedures within ADEM.
Turnover of Vendor Data to Business Unit section is now superseded by CTS-0104
Turnover
processes
Suncor Datasheets Section on Suncor Datasheets removed as redundant with CTS-0123
Contents
Summary of Changes ....................................................................................................................................................2

Contents .........................................................................................................................................................................3
1 About this Standard ................................................................................................................................................6
Purpose .............................................................................................................................................6
Scope.................................................................................................................................................6
Target Audience ................................................................................................................................6
Conformance Expectations ................................................................................................................6
Introduction ........................................................................................................................................6
2 General Manufacturer Documentation Requirements.............................................................................................7
2.1 Original Equipment Manufacturers Information Book Requirements............................................................7

3 Manufacturer Supplied Information Requirements..................................................................................................8
3.1 ELECTRICAL EQUIPMENT REQUIREMENTS ...........................................................................................8

ELECT_COMMUNICATION (ASECC)...............................................................................................8
ELECT_SUPPLY_DISTRIB (ASEGS) ...............................................................................................8
HEATING_DRYING_EQP (ASEHH) ................................................................................................ 14
LIGHTING (ASELL) ......................................................................................................................... 14
MOTOR_AND_DRIVE (ASEMM) .................................................................................................... 14
SWITCH_ELECT (ASESS) .............................................................................................................. 16
DISTRIB_CONTROL_SYS (ASICD) ................................................................................................ 16
TRANSDUCER_CALCULATR (ASIII).............................................................................................. 16
VALVE_CONTROL_ACTUAT (ASIVV)............................................................................................ 17
ELECTRICAL PANELS AND BOXES () .......................................................................................... 17
3.2 FIRED EQUIPMENT REQUIREMENTS .................................................................................................... 17
FLARE_CHIMNEY (BSASS) ........................................................................................................... 17
BOILER_HEATER_INCINR (BSPHH) ............................................................................................. 18
3.3 HEATING, VENTILATION, AND AIR CONDITIONING EQUIPMENT REQUIREMENTS .......................... 21
HEATING_AIR_COND (CSABH) ..................................................................................................... 21
REFRIGERATION (CSABR) ............................................................................................................ 23
VENTILATION (CSABV) .................................................................................................................. 26
3.4 INSTRUMENTATION DEVICE REQUIREMENTS ..................................................................................... 28
CONTROL_SYSTEMS (ESICD) ...................................................................................................... 28
CONTROLLER (ESICZ) .................................................................................................................. 28
ANALYZER (ESILA) ........................................................................................................................ 29
INDICATOR (ESIRA) ....................................................................................................................... 30
DETECTOR_SENSOR (ESIRI) ....................................................................................................... 31
METER (ESIRR) .............................................................................................................................. 33
SWITCH (ESISS) ............................................................................................................................. 34
TRANSMITTER (ESITT) .................................................................................................................. 35
INSTRUMENTATION PANELS AND BOXES () .............................................................................. 35
3.5 MATERIAL HANDLING EQUIPMENT REQUIREMENTS .......................................................................... 35
CONVEYING_SIZING_EQP (FSCCC) ............................................................................................ 35
HOISTING_LIFTING_EQP (FSCHH) .............................................................................................. 37
3.6 MECHANICAL EQUIPMENT REQUIREMENTS ........................................................................................ 39
ACESS_DEVICES (GSAAA) ........................................................................................................... 39

STACK_VENT (GSASS).................................................................................................................. 40
EJECTOR (GSLEM) ........................................................................................................................ 41
VALVE (GSLEV) .............................................................................................................................. 42
AGITATOR_MIXING (GSMAA) ....................................................................................................... 44
CYLINDERS (GSMCC).................................................................................................................... 45
COLUMN_EDUCTOR (GSPTC) ...................................................................................................... 45
PACKAGING_EQUIPMENT (GSPZP) ............................................................................................. 45
GENERAL_PROCESS_EQP (GSPZZ) ........................................................................................... 47
EXPLOSION_PROTECTION (GSSFF) ........................................................................................... 47
WEIGHING_EQUIPMENT (GSTPP)................................................................................................ 47
3.7 MOBILE EQUIPMENT REQUIREMENTS.................................................................................................. 48
STRUCTURE_MOBILE (HSASS) .................................................................................................... 48
COMPONENTS_MOBILE (HSCEC) ................................................................................................ 48
LOADING_EXCAVATING (HSCEL) ................................................................................................ 49
UNDERCARRIAGE (HSCEU) ......................................................................................................... 50
SYSTEMS_MOBILE (HSCEY) ........................................................................................................ 50
HOISTING_LIFT_EQPMOB (HSCHH) ............................................................................................ 51
TRANSPORTATION_EQP (HSCTT) ............................................................................................... 51
ELECTRICAL_SYSTEM (HSEGS) .................................................................................................. 52
MOTOR_DRIVE_MOBILE (HSEMM) .............................................................................................. 53
PLC_MOBILE (HSICZ) .................................................................................................................... 53
VALVES_MOBILE (HSLEV) ............................................................................................................ 53
COMP_BLOWER_MOBILE (HSMFF) ............................................................................................. 53
GEARBOX_MOBILE (HSMGG) ....................................................................................................... 54
ENGINE_MOBILE (HSMMM) .......................................................................................................... 54
PUMP_MOBILE (HSMPP) ............................................................................................................... 54
TANKS_MOBILE (HSPTT) .............................................................................................................. 55
3.8 PIPING REQUIREMENTS ......................................................................................................................... 55
GENERAL_PIPING_EQP (ISLEM) .................................................................................................. 55
PIPELINE (ISLPP) ........................................................................................................................... 56
3.9 ROTATING EQUIPMENT REQUIREMENTS ............................................................................................. 57
COMPR_FAN_BLOWER (JSMFF) .................................................................................................. 57
GEARBOX (JSMGG) ....................................................................................................................... 59
LUBRICATION (JSMLL) .................................................................................................................. 59
MOTOR_ENGINE_MECH (JSMMM) ............................................................................................... 60
PUMP (JSMPP) ............................................................................................................................... 61
GOVERNOR (JSMTG) .................................................................................................................... 63
TURBINE_WINDMILL (JSMTT) ....................................................................................................... 63
GENERAL_PROCESS_EQP (JSPZZ) ............................................................................................ 63
3.10 SAFETY, PERSONAL PROTECTION, AND FIRE PROTECTION EQUIPMENT REQUIREMENTS ........ 64
FIRST_AID_EQP (KSSAA).............................................................................................................. 64
FIRE_PROTECTION (KSSFF) ........................................................................................................ 65
ELECTRICAL_SAFETY_EQUIPMENT (KSSPP) ............................................................................ 65
3.11 PRESSURE VESSEL REQUIREMENTS ................................................................................................... 66
DRYER (LSPHD) ............................................................................................................................. 66
EXCHANGER (LSPHE) ................................................................................................................... 66
COLUMN_TOWER (LSPTC) ........................................................................................................... 67
TANKS_HOPPERS (LSPTT) ........................................................................................................... 67
REACTION_SEPARATION (LSPTV)............................................................................................... 69
3.12 PRODUCTION RESOURCES EQUIPMENT AND TOOL REQUIREMENTS ............................................ 70

MAINTSHOPEQP/TOOL (PSWMZ)................................................................................................. 70
3.13 TESTING AND MEASUREMENT EQUIPMENT REQUIREMENTS .......................................................... 71
MECHANICALTESTEQP (QSTMM) ................................................................................................ 71
MISCTOOLING&TEST (QSTZZ) ..................................................................................................... 71
MAINTSHOPEQP/TOOL (QSWMM) ............................................................................................... 71
3.14 WELL AND BUILDING REQUIREMENTS ................................................................................................. 72
WELLS (USAAA) ............................................................................................................................. 72
BUILDING (USABB) ........................................................................................................................ 72
3.15 STRUCTURE OR SYSTEM REQUIREMENTS ......................................................................................... 73
AREA_POND_ROAD (WSAAA) ...................................................................................................... 73
STRUCTURE (WSASS) .................................................................................................................. 74
4 Roles and Responsibilities .................................................................................................................................... 75
Director of M&R Integration ............................................................................................................. 75

Asset Information Specialist............................................................................................................. 75
Peer Review Network members ...................................................................................................... 75
Project Manager or Leader .............................................................................................................. 75
4.1 Measurements and Verification .................................................................................................................. 75
Measure 1 ........................................................................................................................................ 75
Verification 1 .................................................................................................................................... 75
5 Terms and Definitions ........................................................................................................................................... 76
6 References ........................................................................................................................................................... 77
6.1 Essential Documents.................................................................................................................................. 77

7 Approvals .............................................................................................................................................................. 78
Signatures........................................................................................................................................ 78
1 About this Standard
Purpose This standard identifies the minimum manufacturer’s information required to effectively
manage each operating asset.
Scope This standard applies to all business areas and is based on Suncor’s equipment classes as a
common description of each type of equipment.
This standard is only intended to cover the minimum manufacturer’s information and therefore
does not include other types of mandatory asset information as described in CTS-0127 and
CTS-0126.
The information requirements within this standard shall be delivered to Suncor’s Asset
Owners, per CTS-0104 processes.
Target Audience This Standard applies to Suncor Energy Inc. and subsidiaries over which Suncor has
operational control (collectively “Suncor” or “the company” or “enterprise-wide”).
As used in this document, “Suncor personnel” includes directors, officers, employees, contract
workers, consultants and agents of Suncor.
This standard shall be applied at all North American On-shore facilities that are operated or
owned by Suncor Energy Inc.
Conformance Conformance to this standard is mandatory for all projects that have not passed Gate 2
Expectations approvals before the approval date on this document.
The deliverables for new types of equipment that are not yet defined in this standard shall be
agreed upon by the Suncor Project and be approved by the owning Business Units Cross-
Functional team (CFT) as per the CTS-0002 Technical Deviation process. All other deviations
to the content of this standard shall also follow the CTS-0002 deviation processes.
Introduction This standard identifies the minimum manufacturer’s information necessary to effectively
manage the equipment throughout their operational life at Suncor.
The information requirements within this standard are delivered to Suncor in a single Original
Equipment Manufacturers (OEM) Information Book for each commissioned asset. Each OEM
INFORMATION BOOK will be managed as a single document in Suncor’s Information
Management systems. Additional information can be included in the OEM Information Book
upon project management discretion.
One OEM INFORMATION BOOK may be used for multiple assets provided the OEM
INFORMATION BOOK states which piece of information is relate to all of the assets it is
applied to. See Section 2.1 of this standard for additional details.
Information provided by external parties is expected to be made freely available to Suncor to

use for all business purposes, including sharing with other companies and organizations which
may be contracted to supply Suncor with materials and/or labour. Any and all exceptions to
this requirement shall be stipulated in the contracts prior to procurement.
2 General Manufacturer Documentation Requirements
2.1 Original Equipment Manufacturers Information Book Requirements
2.1.1 Each piece of information required by this standard shall be included in, and submitted as a part of the
Original Equipment Manufacturers Information Book.
2.1.2 One Original Equipment Manufacturers Information Book shall be submitted for each asset supplied by the
Manufacturer.
2.1.3 Each Original Equipment Manufacturers Information Book shall include a Suncor tag index which identifies
which pages or sections are applicable to each Suncor tag.
2.1.4 The Original Equipment Manufacturers Information Book shall be submitted to Suncor as an electronic PDF
document.
2.1.5 All scanned images within the Original Equipment Manufacturers Information Book shall be a minimum of
300 Dots Per Inch (DPI) resolution
2.1.6 The Original Equipment Manufacturers Information Book shall be electronically bookmarked with all sections
and content.
2.1.7 Manufacturers’ information shall be submitted in English language, except when the asset owners have
approved French documents at the Montreal Refinery.
2.1.8 The entire content of the Original Equipment Manufacturers Information Book shall be clear and legible.
3 Manufacturer Supplied Information Requirements
Note:
For simplicity, when more than one equipment type has the same deliverables, the equipment classes are all listed in
a common heading above the information deliverables list.
3.1 ELECTRICAL EQUIPMENT REQUIREMENTS
ELECT_COMMUNICATION (ASECC)
3.1.1 RECEIVER_TRANSMITTER_RADIO ASECCR01
Electronic Catalogue F2
Maintenance Manual H8
Manufacturer’s Datasheet L37
3.1.2 SATELLITE_COMMUNICATION ASECCV01
Installation and Removal Instructions J13
3.1.3 CAMERA_CLOSED_CIRCUIT_TELEVISION ASECCV02
Bill of Materials F1
Nameplate Details D47
ELECT_SUPPLY_DISTRIB (ASEGS)
3.1.4 ARRESTOR_LIGHTNING ASEGSA01
3.1.5 BATTERY_BANK ASEGSB01
Equipment Wiring Diagram D82
General Arrangement Drawing D30
Performance Curve E2
Storage Procedure J30
3.1.6 CHARGING_SET_BATTERY ASEGSB02
Schematic Diagram D60
3.1.7 BATTERY_CRANKING ASEGSB05
3.1.8 TRAILING_CABLE ASEGSC01
3.1.9 CABLE_POWER_DISTRIBUTION ASEGSC02
3.1.10 CIRCUIT_BREAKER ASEGSC10
Detail Drawing D20
3.1.11 CAPACITOR ASEGSC30
Detail Drawing D20
3.1.12 PANEL_POWER_DISTRIBUTION ASEGSD01
Electrical Load Lists F38
Panel Layout D49
3.1.13 PANEL_DISTRIBUTION_FUSED ASEGSD02
Panel Layout D49
3.1.14 PANEL_CONTROL ASEGSD03

Detail Drawing D20
Panel Layout D49
Protection Coordination Curve E3
Testing Procedure J31
3.1.15 PANEL_PATCHING_FIBER_OPTIC ASEGSD05
3.1.16 PANEL_ANNUNCIATOR ASEGSD06
Manufacturer’s Spare parts F11
Panel Layout D49
3.1.17 PANEL_FIRE_ALARM ASEGSD07
Panel Layout D49
3.1.18 PANEL_HEAT_TRACING ASEGSD08
Detail Drawing D20
Panel Layout D49
3.1.19 PANEL_RELAY ASEGSD09
Panel Layout D49
3.1.20 DISTRIBUTION_STARTER_RACK ASEGSD10
Detail Drawing D20
3.1.21 METER_ELECT_POWER ASEGSE05

Detail Drawing D20
3.1.22 GENERATOR_INDUCTION ASEGSG01
Detail Drawing D20
3.1.23 GENERATOR_SPARK_IGNITION ASEGSG02
Detail Drawing D20
3.1.24 GENERATOR_DIESEL ASEGSG03
Detail Drawing D20
Manufacturer’s Recommended Lifecycle Spare Parts Lists F11
Manufacturer’s Recommended Start-up Spare Parts List F13
3.1.25 GENERATOR_THERMO_ELECTRIC ASEGSG04

Detail Drawing D20
3.1.26 NEUTRAL_GROUNDING_RESISTOR ASEGSG21
3.1.27 DISTRIBUTION_MOTOR_CONTROL_CENTER ASEGSM01
Detail Drawing D20
Manufacturer’s Interface Software L34
Operations Manual H9
3.1.28 RELAY_ELECT_GENERAL_PURPOSE ASEGSR02
3.1.29 REACTOR_ELECTRICAL ASEGSR03
Detail Drawing D20
3.1.30 RELAY_ELECT_MOTOR_PROTECTION ASEGSR50

3.1.31 RELAY_ELECT_SWITCHGEAR ASEGSR51
3.1.32 SURGE_SUPRESSOR ASEGSS01
Detail Drawing D20
3.1.33 DISTRIBUTION_SWITCHGEAR ASEGSS30
Configuration and Settings Manual H1
3.1.34 TRANSFORMER_DRY_TYPE ASEGST02
Detail Drawing D20
Factory Acceptance Test Procedure J11
3.1.35 TRANSFORMER_LIQUID_FILLED ASEGST03
Centre of Gravity Plane Drawing D15
Detail Drawing D20
3.1.36 UPS ASEGSU01

Detail Drawing D20
HEATING_DRYING_EQP (ASEHH)
3.1.37 ELECTRIC_HEATER ASEHHH01
Detail Drawing D20
LIGHTING (ASELL)
3.1.38 LIGHTING_GENERAL ASELLL01
3.1.39 LIGHTING_EMERGENCY ASELLL02
Installation Instructions J15
MOTOR_AND_DRIVE (ASEMM)
3.1.40 VFD_LOW_VOLTAGE_PANEL ASEMMD05
Detail Drawing D20
3.1.41 VFD_MEDIUM_VOLTAGE_PANEL ASEMMD06
Detail Drawing D20
3.1.42 MOTOR_INDUCTION ASEMMM01
Assembly Drawing D8
Certified Test Report K47
3.1.43 MOTOR_DIRECT_CURRENT ASEMMM02
3.1.44 MOTOR_SYNCHRONOUS ASEMMM04
3.1.45 MOTOR_WOUND_ROTOR ASEMMM05
3.1.46 STARTER_ELECT_MOTOR ASEMMS01
SWITCH_ELECT (ASESS)
3.1.47 SWITCH_ELECT_TRANSFER ASESSS05
Detail Drawing D20
3.1.48 SWITCH_ELECT_AIR_BREAK ASESSS06
Detail Drawing D20
DISTRIB_CONTROL_SYS (ASICD)
3.1.49 SCADA_RTU ASICDC02
3.1.50 SCADA_MASTER_STATION_OPERATOR_STATION ASICDC03
3.1.51 CONTROLLER_HEAT_TRACING ASICDC04
TRANSDUCER_CALCULATR (ASIII)
3.1.52 TRANSDUCER_CURRENT ASIIIT02
3.1.53 TRANSDUCER_HUMIDITY ASIIIT03
3.1.54 TRANSDUCER_TEMPERATURE ASIIIT04
3.1.55 TRANSDUCER_VOLTAGE ASIIIT05
Detail Drawing D20
VALVE_CONTROL_ACTUAT (ASIVV)
3.1.56 ACTUATOR_ELECT_MOV ASIVVA01
3.1.57 ACTUATOR_CONTROL_VALVE ASIVVA02
Detail Drawing D20
ELECTRICAL PANELS AND BOXES ()

3.1.58 Electrical Panels ‘--------
3.1.59 Electrical Boxes ‘--------
3.1.60 Electronic Catalogue F2
3.2 FIRED EQUIPMENT REQUIREMENTS
FLARE_CHIMNEY (BSASS)
3.2.1 CHIMNEY_STACK BSASSC01
Assembly Drawing D8
Installation Procedure J15
Manufacturer's Recommended Safety Practices L22
3.2.2 FLARE_STACK BSASSF01
Assembly Drawing D8
Detail Drawing D20
Manufacturing Procedure J19
Material Selection Basis Document B11
3.2.3 FLARE_VENT BSASSF02
3.2.4 FLARE_GROUND BSASSF03
3.2.5 FLARE_PORTABLE BSASSF04
Assembly Drawing D8
Detail Drawing D20
BOILER_HEATER_INCINR (BSPHH)
3.2.6 BURNER_GAS BSPHHB05
Assembly Drawing D8
Design Certification C3
Detail Drawing D20
Emissions Summary Report K17
Noise Level Report K37
3.2.7 BURNER_LIQUID BSPHHB06
Assembly Drawing D8
3.2.8 BURNER_SOLID BSPHHB07
Assembly Drawing D8
3.2.9 BOILER_FIRE_TUBE BSPHHB10
Assembly Drawing D8
Cleaning and Flushing Procedure J3
Detail Drawing D20
Dry-out Procedure J40

Painting and Coating Procedure J41
Refractory Lining Procedure J39
3.2.10 BOILER_WATER_TUBE BSPHHB11
Assembly Drawing D8
Detail Drawing D20
3.2.11 BOILER_OT_STEAM_GENERATOR BSPHHB12
Assembly Drawing D8
Detail Drawing D20
3.2.12 BOILER_MINIATURE BSPHHB13
Assembly Drawing D8
Detail Drawing D20

3.2.13 HEATER_PROCESS BSPHHH02
Assembly Drawing D8
Detail Drawing D20
3.2.14 INCINERATOR_PROCESS BSPHHI01
Assembly Drawing D8
Detail Drawing D20
3.2.15 INCINERATOR_WASTE BSPHHI02
Assembly Drawing D8
Detail Drawing D20
3.3 HEATING, VENTILATION, AND AIR CONDITIONING EQUIPMENT

REQUIREMENTS
HEATING_AIR_COND (CSABH)
3.3.1 AIR_CONDITIONER CSABHA01
Detail Drawing D20
Operating Manual H9
3.3.2 TERMINAL_AND_PACKAGED_AIR_CONDITIONER CSABHA02
Assembly Drawing D8
Detail Drawing D20
Operating Manual H9
3.3.3 ROOM_AIR_CONDITIONER CSABHA03
Detail Drawing D20
Operating Manual H9
3.3.4 SPLIT_SYSTEM_AIR_CONDITIONER CSABHA04

Detail Drawing D20
Operating Manual H9
3.3.5 PACKAGED_AIR_HANDLING_UNIT CSABHA10
Assembly Drawing D8
Detail Drawing D20
Operating Manual H9
3.3.6 MAKE_UP_AIR_UNIT CSABHA11
Assembly Drawing D8
Detail Drawing D20
Operating Manual H9
3.3.7 HEAT_EXCHANGER CSABHE05
Detail Drawing D20
Operating Manual H9
3.3.8 FURNACE_WARM_AIR CSABHF05
Detail Drawing D20
Operating Manual H9
3.3.9 WALL_BASEBOARD_HEATER CSABHH06
Detail Drawing D20
Operating Manual H9
3.3.10 UNIT_HEATER CSABHH07
Detail Drawing D20
3.3.11 HEATER_SPACE CSABHH08
Detail Drawing D20
REFRIGERATION (CSABR)
3.3.12 CHILLER_GLYCOL_REFRIGERATING CSABRC01
Detail Drawing D20
Depressurization Procedure J5

Refrigerant Recovery Procedure J36
Repair and Alteration Procedure J25
Rigging and Lifting Procedure J26
3.3.13 CHILLER_WATER_REFRIGERATING CSABRC02
Detail Drawing D20
3.3.14 COMPRESSOR_REFRIGERATION CSABRC05
3.3.15 COMPRESSOR_UNIT_REFRIGERATION CSABRC06
3.3.16 CONDENSER_COIL_REFRIGERATION CSABRC10
Detail Drawing D20
3.3.17 CONDENSER_REFRIGERATION CSABRC11
Assembly Drawing D8
Detail Drawing D20
3.3.18 CONTROL_TEMPERATURE_INDICATING CSABRC15
3.3.19 COOLER_UNIT_AIR CSABRC20
Detail Drawing D20
Operating Manual H9
3.3.20 COOLER_WALK_IN CSABRC21
Detail Drawing D20
Operating Manual H9
3.3.21 EVAPORATOR_COIL_REFRIGERATION CSABRE01
Assembly Drawing D8
Detail Drawing D20
3.3.22 FREEZER_LOW_TEMPERATURE CSABRF01
Operating Manual H9
3.3.23 FREEZER_WALK_IN CSABRF02
3.3.24 ICE_MAKING_MACHINE_CUBE CSABRI01
Operating Manual H9
3.3.25 REFRIGERATION_SYSTEM_MECHANICAL CSABRR01
3.3.26 REFRIGERATION_UNIT_MECHANICAL CSABRR02
Detail Drawing D20
Operating Manual H9
3.3.27 REFRIGERATOR_LABORATORY_GENERAL_PURPOS CSABRR03
E
3.3.28 REFRIGERATOR_LABORATORY_FLAM_MATL_STOR CSABRR04
VENTILATION (CSABV)
3.3.29 DAMPER_MOTORIZED CSABVD01
Maintenance Procedure J18
3.3.30 DAMPER_RELIEF CSABVD02

3.3.31 DUCT_VENTILATION CSABVD05
3.3.32 EXHAUST_UNIT_AIR CSABVE01
3.3.33 FAN_CIRCULATING_NON_PROCESS CSABVF01
3.3.34 FAN_VENTILATING CSABVF02
3.3.35 HEATER_VENTILATION_DUCT_TYPE CSABVH05
3.3.36 HUMIDIFIER_WARM_AIR_HEATING_SYSTEM CSABVH10
3.4 INSTRUMENTATION DEVICE REQUIREMENTS
CONTROL_SYSTEMS (ESICD)
3.4.1 CONTROL_UNIT_DISTRIBUTED_CONTROL_SYSTEM ESICDC01
3.4.2 COMMUNICATION_CONTROL ESICDC02
3.4.3 ACQ CONTROL_UNIT_SUPV_CONTROL_AND_DATA_ ESICDD01
CONTROLLER (ESICZ)
3.4.4 CONTROL_VOLUME_MANUAL ESICZC01
3.4.5 CONTROL_MONITOR ESICZC02
Installation Drawing D37
3.4.6 CONTROL_INDICATOR ESICZC03
3.4.7 CONTROLLER_ANTI_SURGE ESICZC04
3.4.8 CONTROLLER_SPEED ESICZC05
3.4.9 CONTROLLER_PERFORMANCE ESICZC06
3.4.10 CONTROLLER_FLOW ESICZC07
3.4.11 CONTROLLER_ANALYZER ESICZC08
3.4.12 CONTROLLER_LEVEL ESICZC09
3.4.13 CONTROLLER_PRESSURE ESICZC10
3.4.14 CONTROLLER_TEMPERATURE ESICZC11
3.4.15 CONTROLLER_MULTIVARIABLE ESICZC12
3.4.16 CONTROLLER_VIBRATION ESICZC13
3.4.17 CONTROLLER_PROGRAMMABLE_LOGIC ESICZP01
ANALYZER (ESILA)
3.4.18 ANALYZER_VIBRATION ESILAA01
3.4.19 ANALYZER_GAS ESILAA02
3.4.20 ANALYZER_OIL_CONTENT ESILAA03
3.4.21 ANALYZER_TRACE_HYDROCARBONS ESILAA04
3.4.22 ANALYZER_WATER ESILAA05
Functional Test Results Report K43
3.4.23 CHROMATOGRAPH_GAS ESILAA06
3.4.24 ANALYZER_OXYGEN ESILAA07

3.4.25 PLATE_ORIFICE_FLUID ESILAF01
INDICATOR (ESIRA)
3.4.26 ALARM_AUDIBLE_HORN_SIREN ESIRAA01
3.4.27 ALARM_VISIBLE_LIGHT_STROBE ESIRAA02
3.4.28 GAUGE_SIGHT_GLASS ESIRAG01
3.4.29 INDICATOR_ANALYZER ESIRAI01
3.4.30 INDICATOR_FLOW ESIRAI02
3.4.31 INDICATOR_CURRENT ESIRAI03

3.4.32 INDICATOR_LEVEL ESIRAI04
3.4.33 INDICATOR_PRESSURE ESIRAI05
3.4.34 INDICATOR_SPEED ESIRAI06
3.4.35 INDICATOR_TEMPERATURE ESIRAI07
3.4.36 INDICATOR_MULTIVARIABLE ESIRAI08
3.4.37 INDICATOR_POSITION ESIRAI09
3.4.38 INDICATOR_FLAME ESIRAI10
3.4.39 INDICATOR_VIBRATION ESIRAI11
DETECTOR_SENSOR (ESIRI)
3.4.40 DETECTOR_FLAME ESIRID02
3.4.41 DETECTOR_HEAT ESIRID03
3.4.42 DETECTOR_SMOKE ESIRID05

3.4.43 MONITOR_GAS_MULTI ESIRID15
3.4.44 MONITOR_GAS_SINGLE ESIRID16
3.4.45 MONITOR_FLAME ESIRID17
3.4.46 MONITOR_VIBRATION ESIRID18
3.4.47 METER_ELECTROMAGNETIC_FIELD ESIRII01
3.4.48 PITOT_TUBE ESIRIP05
3.4.49 SENSOR_FLOW ESIRIS04
3.4.50 SENSING_ELEMENT_FIRE_DETECTOR_SYSTEM ESIRIS05
3.4.51 SENSOR_RADIOACTIVE ESIRIS09
3.4.52 SENSOR_INDUCTANCE_ELECTRICAL ESIRIS10
3.4.53 SENSOR_GAS ESIRIS11
3.4.54 SENSOR_PH ESIRIS12
3.4.55 SENSOR_ANALYZER ESIRIS13
3.4.56 TEMPERATURE_ELEMENT_THERMOCOUPLE ESIRIT05

3.4.57 METER TEMPERATURE_ELEMENT_RESISTANCE_ ESIRIT06
3.4.58 THERMOWELL ESIRIW01
METER (ESIRR)
3.4.59 METER_FLOW_GAS_TURBINE_OIL_WELL ESIRRF02
3.4.60 METER_FLOW_RATE_INDICATING ESIRRF03
3.4.61 METER_MASS_OR_CORIOLIS ESIRRF04
3.4.62 METER_VOLUMETRIC_POSITIVE_DISPLACEMENT ESIRRF05
3.4.63 METER_VORTEX ESIRRF06
3.4.64 METER_VENTURI ESIRRF07
3.4.65 METER_SONIC ESIRRF08
3.4.66 METER_ULTRASONIC ESIRRF09
Assembly Drawing D8
Calibration Results Report K8
Installation Manual H5
Operating Manual H9
Repair Manual H14
3.4.67 ORIFICE_PLATE ESIRRF10
3.4.68 METER_PITOT_TUBE ESIRRF11
3.4.69 METER_ANNUBAR ESIRRF12
3.4.70 METER_MAGNETIC ESIRRF13
3.4.71 METER_THERMAL ESIRRF14
3.4.72 RECORDER_FLOW ESIRRR01
3.4.73 ROTAMETER ESIRRR02
3.4.74 RECORDER_TEMPERATURE ESIRRR03
3.4.75 RECORDER_PRESSURE ESIRRR04
Assembly Drawing D8
Calibration Results Report K8
Installation Manual H5
Operating Manual H9
Repair Manual H14
SWITCH (ESISS)
3.4.76 SWITCH_PRESSURE ESISSS02
3.4.77 SWITCH_LEVEL ESISSS03
3.4.78 SWITCH_FLOW ESISSS04
3.4.79 SWITCH_TEMPERATURE ESISSS05
3.4.80 SWITCH_VIBRATION ESISSS06
3.4.81 SWITCH_POSITION ESISSS07
3.4.82 SWITCH_DISCONNECT ESISSS09
3.4.83 SWITCH_SPEED ESISSS10
3.4.84 SWITCH_SIGNAL_PIG ESISSS14
3.4.85 SWITCH_FLOAT ESISSS15
3.4.86 SWITCH_ANALYZER ESISSS16
3.4.87 SWITCH_BURNER ESISSS17
TRANSMITTER (ESITT)
3.4.88 TRANSMITTER_ANALYZER ESITTT03
3.4.89 TRANSMITTER_FLOW ESITTT04
3.4.90 TRANSMITTER_LEVEL ESITTT05
3.4.91 TRANSMITTER_SPEED ESITTT06
3.4.92 TRANSMITTER_PRESSURE ESITTT07
3.4.93 TRANSMITTER_BURNER ESITTT08
3.4.94 TRANSMITTER_TEMPERATURE ESITTT10
3.4.95 TRANSMITTER_PH ESITTT13
3.4.96 TRANSMITTER_CONDUCTIVITY ESITTT14
3.4.97 TRANSMITTER_DENSITY ESITTT15
3.4.98 TRANSMITTER_MULTIVARIABLE ESITTT16
3.4.99 TRANSMITTER_VIBRATION ESITTT17
3.4.100 TRANSMITTER_CURRENT ESITTT18
3.4.101 TRANSMITTER_POSITION ESITTT19
3.4.102 TRANSMITTER_VOLTAGE ESITTT20
3.4.103 TRANSMITTER_WEIGHT ESITTT21
INSTRUMENTATION PANELS AND BOXES ()

3.4.104 Instrument Panels ‘--------
3.4.105 Instrument Boxes ‘--------
3.4.106 Electronic Catalogue F2
3.5 MATERIAL HANDLING EQUIPMENT REQUIREMENTS
CONVEYING_SIZING_EQP (FSCCC)
3.5.1 CONVEYOR_BELT FSCCCC01
Detail Drawing D20
3.5.2 CONVEYOR_BUCKET FSCCCC02
Detail Drawing D20
3.5.3 CONVEYOR_SCREW FSCCCC05
Detail Drawing D20
3.5.4 CONVEYOR_VIBRATING FSCCCC06
Detail Drawing D20
Vibration Calculations B19
3.5.5 FEEDER_AGGREGATE FSCCCF01
Assembly Drawing D8
Detail Drawing D20
3.5.6 FEEDER_APRON FSCCCF02
Detail Drawing D20

3.5.7 GRINDER_INLINE FSCCCG01
Detail Drawing D20
Life Expectancy Calculations B15
3.5.8 CRUSHER_JAW FSCCCG10
Detail Drawing D20
3.5.9 CRUSHING_AND_SCREENING_UNIT FSCCCG12
Assembly Drawing D8
Detail Drawing D20
3.5.10 SIZER FSCCCS01
Assembly Drawing D8
Detail Drawing D20
HOISTING_LIFTING_EQP (FSCHH)
3.5.11 CRANE_BRIDGE FSCHHC01
Assembly Drawing D8
Detail Drawing D20

3.5.12 CRANE_JIB FSCHHC02
Assembly Drawing D8
Detail Drawing D20
3.5.13 CRANE_MONORAIL FSCHHC03
Assembly Drawing D8
Detail Drawing D20
3.5.14 ELEVATOR_FREIGHT FSCHHE01
3.5.15 ELEVATOR_PERSONNEL FSCHHE02
Assembly Drawing D8
Certificate of Completion and Acceptance C1
Certificate of Registration C2
Detail Drawing D20
3.5.16 CHAIN_HOIST_SET FSCHHH01

Assembly Drawing D8
Detail Drawing D20
3.5.17 HOIST_WIRE_ROPE FSCHHH02
Assembly Drawing D8
Detail Drawing D20
3.5.18 RAMP_LOADING_VEHICLE FSCHHL01
Assembly Drawing D8
Detail Drawing D20
3.6 MECHANICAL EQUIPMENT REQUIREMENTS
ACESS_DEVICES (GSAAA)
3.6.1 GATE_BARRIER_SYSTEM GSAAAB01
Assembly Drawing D8
Detail Drawing D20

3.6.2 TURNSTILE_PERSONNEL GSAAAB02
Assembly Drawing D8
Detail Drawing D20
3.6.3 DOOR_ACCESS_GENERAL_PURPOSE GSAAAD01
3.6.4 DOOR_OVERHEAD_SECTIONAL GSAAAD02
Assembly Drawing D8
Detail Drawing D20
STACK_VENT (GSASS)
3.6.5 VENT_STACK GSASSV01
Assembly Drawing D8
EJECTOR (GSLEM)
3.6.6 FILTER_AIR GSLEMF02
Detail Drawing D20
3.6.7 FILTER_WATER_PURIFICATION GSLEMF04
Detail Drawing D20
3.6.8 FILTER_FUEL GSLEMF05
Detail Drawing D20
3.6.9 FILTER_OIL GSLEMF06
Assembly Drawing D8
Detail Drawing D20
3.6.10 TANK_CAR_AND_TRUCK_LOADING_SET_OVERHEAD GSLEML02
Detail Drawing D20

3.6.11 MUFFLER_EXHAUST GSLEMS03
Assembly Drawing D8
3.6.12 STRAINER GSLEMS06
Detail Drawing D20
3.6.13 TRAP_STEAM GSLEMT01
VALVE (GSLEV)
3.6.14 ACTUATOR_VALVE_MECHANICAL GSLEVA01
Detail Drawing D20
3.6.15 AUTO_SAMPLER GSLEVA10
Functional Test Results Report K43
3.6.16 VALVE_CONTROL GSLEVC01
3.6.17 REGULATOR_PRESSURE_REDUCING GSLEVC02
3.6.18 REGULATOR_TEMP_SENSING GSLEVC03

3.6.19 SAMPLE_POINT_MANUAL GSLEVM01
Detail Drawing D20
Safe Work Plan L29
3.6.20 VALVE_SAFETY GSLEVR01
Detail Drawing D20
3.6.21 VALVE_RELIEF_PRESSURE_AND_TEMPERATURE GSLEVR02
3.6.22 VALVE_VACUUM_RELIEF GSLEVR03
Detail Drawing D20
3.6.23 VALVE_RUPTURE_PIN GSLEVR04
3.6.24 RUPTURE_DISC_ASSEMBLY GSLEVR05
Detail Drawing D20
3.6.25 VALVE_ANGLE_GLOBE GSLEVV01

3.6.26 VALVE_BALL GSLEVV02
3.6.27 VALVE_BUTTERFLY GSLEVV03
3.6.28 VALVE_GATE GSLEVV04
3.6.29 VALVE_GLOBE GSLEVV05
3.6.30 VALVE_SLIDER GSLEVV10
3.6.31 VALVE_CHECK GSLEVV17
Detail Drawing D20
3.6.32 VALVE_DIAPHRAGM_STOP GSLEVV18
3.6.33 VALVE_KNIFE_GATE GSLEVV19
3.6.34 VALVE_PINCH GSLEVV20
3.6.35 VALVE_DART GSLEVV23
3.6.36 VALVE_PLUG GSLEVV24
AGITATOR_MIXING (GSMAA)
3.6.37 AGITATOR_HEAVY_DUTY_WATER_TREATMENT GSMAAA01
Assembly Drawing D8
Detail Drawing D20
Vibration Specification L32
Vibration Test Procedure J34
CYLINDERS (GSMCC)
3.6.38 CYLINDER_HYDRAULIC GSMCCC01
3.6.39 CYLINDER_PNEUMATIC GSMCCC02
Detail Drawing D20
Pressure Part Calculations B7
COLUMN_EDUCTOR (GSPTC)
3.6.40 EDUCTOR_AIR GSPTCE01
Detail Drawing D20
3.6.41 EDUCTOR_STEAM GSPTCE02
3.6.42 EDUCTOR_HYDROCARBON GSPTCE03
Assembly Drawing D8
Detail Drawing D20
PACKAGING_EQUIPMENT (GSPZP)
3.6.43 PALLETIZER GSPZPP01
3.6.44 FILLER GSPZPP02
3.6.45 CAPPER_CRIMPER_PRESS GSPZPP03
Assembly Drawing D8
Emergency Shut Down Procedure J9
Safe Work Plan L29
Trouble Shooting Guide J32
3.6.46 SCANNER GSPZPP04
3.6.47 DEPALLETIZER GSPZPP05
3.6.48 DECASER GSPZPP06
3.6.49 SEALER GSPZPP07
3.6.50 STRAPPER GSPZPP08
3.6.51 WRAPPER GSPZPP09
3.6.52 PACKER_CASE GSPZPP10
3.6.53 SORTER GSPZPP11
3.6.54 ERECTOR_CASE GSPZPP12
3.6.55 BALER GSPZPP13
3.6.56 DIVERTER GSPZPP14
3.6.57 UPENDER GSPZPP15
3.6.58 CHECKER_REJECTOR GSPZPP16
Assembly Drawing D8
Safe Work Plan L29
3.6.59 LABELLER GSPZPP17
GENERAL_PROCESS_EQP (GSPZZ)
3.6.60 BREAKER_ROTARY GSPZZB04
Assembly Drawing D8
Safe Work Plan L29
3.6.61 CRUSHER_ROLL GSPZZC08
3.6.62 GRIZZLY GSPZZG05
EXPLOSION_PROTECTION (GSSFF)
3.6.63 DETONATION_ARRESTOR GSSFFF14
Detail Drawing D20
WEIGHING_EQUIPMENT (GSTPP)
3.6.64 WEIGH_SCALE_CONVEYOR GSTPPW05
3.6.65 SCALE_TRUCK GSTPPW06
Assembly and Erection Procedure J1
Calibration and testing procedure J37
Detail Drawing D20

3.7 MOBILE EQUIPMENT REQUIREMENTS
STRUCTURE_MOBILE (HSASS)
3.7.1 STRUCTURE_MOBILE_LOAD_BEARING HSASSS01
3.7.2 STRUCTURE_MOBILE_WEARING HSASSS02
3.7.3 HOUSING HSASSS03
3.7.4 BEARING HSCECB01
3.7.5 BRAKE HSCECB03
COMPONENTS_MOBILE (HSCEC)
3.7.6 ALTERNATOR_TRACTION HSCECA02
3.7.7 BLADE HSCECB02
3.7.8 DUMP_BODY HSCECB04
3.7.9 DIPPER HSCECB05
3.7.10 BUCKET HSCECB06
3.7.11 WINCH HSCECB07
3.7.12 HOIST_DRUM HSCECB08
3.7.13 BOOM HSCECB09
Manufacturer’s Recommended Bolt Torque Values L21
3.7.14 CYLINDER_HYDRAULIC HSCECC01
Detail Drawing D20
3.7.15 COLLECTOR_RING HSCECC05
3.7.16 DIFFERENTIAL HSCECD01

3.7.17 FINAL_DRIVE HSCECD02
3.7.18 AIR_DRYER HSCECD03
3.7.19 GEAR HSCECG01
Exploded Parts Diagram D26
Lubrication Procedure J17
3.7.20 RADIATOR HSCECR01
Material Safety Data Sheet (MSDS) L25
3.7.21 RIPPER HSCECR02
3.7.22 SHAFT HSCECS01
3.7.23 STRUT_SUSPENSION HSCECS02
3.7.24 TRACK HSCECT01
3.7.25 TRANSMISSION HSCECT02
3.7.26 TORQUE_CONVERTER HSCECT04
3.7.27 TIRE HSCECT05
3.7.28 WHEEL_AND_RIM HSCECW01
LOADING_EXCAVATING (HSCEL)
3.7.29 BUCKET_LOADER HSCELA02
3.7.30 EXCAVATOR_MULTIPURPOSE_WHEEL_MOUNTED HSCELE01
3.7.31 EXCAVATOR_MULTIPURPOSE_CRAWLER_MOUNTED HSCELE02
3.7.32 LOADER_SKID_STEER HSCELL01
3.7.33 LOADER_WHEEL HSCELL02
Assembly Drawing D8
Detail Drawing D20

Inspection Manual H4
Lubrication Schedule L19
UNDERCARRIAGE (HSCEU)
3.7.34 UNDERCARRIAGE HSCEUT01
SYSTEMS_MOBILE (HSCEY)
3.7.35 AIR_CONDITIONING_AND_HEATING_SYSTEM HSCEYA01
Depressurizing Procedure J5
Interconnection Wiring Diagram D81
Pressure Test Procedure J24
3.7.36 CENTRALIZED_LUBRICATION_SYSTEM HSCEYC01
3.7.37 FIRE_DETECTION_AND_SUPPRESSION_SYSTEM HSCEYF01
Interconnection Wiring Diagram D81
Pressure Test Procedure J24

HOISTING_LIFT_EQPMOB (HSCHH)
3.7.38 CRANE_TRACTOR_MOUNTED HSCHHC05
3.7.39 CRANE_TRUCK_MOUNTED HSCHHC06
3.7.40 CRANE_CRAWLER_MOUNTED HSCHHC07
3.7.41 CRANE_ROUGHTERRAIN HSCHHC08
Operating Procedure J22
TRANSPORTATION_EQP (HSCTT)
3.7.42 AIRCRAFT
(Note these requirements are Suncor specific. All regulatory HSCTTA01
information required by federal law must also be managed.)
Emergency Evacuation Procedure J7
Emergency Procedure J8
Inspection Procedure J12
Orientation Manual H10
3.7.43 VEHICLE_ALL_TERRAIN_WHEELED HSCTTA05
3.7.44 VEHICLE_ALL_TERRAINED_TRACKED HSCTTA06
IMaintenance
ti P Manual
d J12
H8
3.7.45 BOAT HSCTTB03
3.7.46 BARGE HSCTTB04
Assembly Drawing D8
Detail Drawing D20
3.7.47 VEHICLE_AUTOMOBILE HSCTTC01
3.7.48 FORKLIFT_ROUGH_TERRAIN HSCTTF02

3.7.49 FORKLIFT_CONVENTIONAL HSCTTF03
3.7.50 FORKLIFT_TIRE_HANDLER HSCTTF04
3.7.51 AERIAL_LIFT_PERSONNEL HSCTTM01
3.7.52 RAILROAD_ROLLING_STOCK HSCTTR01
3.7.53 TRAILER_MAINTENANCE_BODY HSCTTT01
3.7.54 TRAILER_PERSONNEL HSCTTT02
3.7.55 TRUCK_LIGHT HSCTTT03
3.7.56 TRAILER_LOWBED HSCTTT04
3.7.57 TRAILER_CARGO_BODY HSCTTT05
Assembly Drawing D8
Detail Drawing D20
3.7.58 VEHICLE_GROUNDS_UTILITY HSCTTV02
ELECTRICAL_SYSTEM (HSEGS)
3.7.59 PANEL_POWER_DISTRIBUTION HSEGSD01
3.7.60 PANEL_CONTROL HSEGSD02
Detail Drawing D20
3.7.61 TRANSFORMER_MOBILE HSEGST01
Detail Drawing D20

MOTOR_DRIVE_MOBILE (HSEMM)
3.7.62 MOTOR_HYDRAULIC_MOBILE HSEMMM01
3.7.63 MOTOR_INDUCTION_MOBILE HSEMMM02
3.7.64 MOTOR_DIRECT_CURRENT_MOBILE HSEMMM03
3.7.65 VARIABLE_FREQUENCY_DRIVE_MOBILE HSEMMM04
Detail Drawing D20
PLC_MOBILE (HSICZ)
3.7.66 PLC HSICZP01
VALVES_MOBILE (HSLEV)
3.7.67 HYDRAULIC_VALVE HSLEVV01
Detail Drawing D20
COMP_BLOWER_MOBILE (HSMFF)
3.7.68 COMPRESSOR_MOBILE HSMFFC02

GEARBOX_MOBILE (HSMGG)
3.7.69 GEARBOX_MOBILE HSMGGG01
3.7.70 GEARBOX_MOBILE_PLANETARY HSMGGG02
Detail Drawing D20
ENGINE_MOBILE (HSMMM)
3.7.71 ENGINE_DIESEL HSMMME01
3.7.72 ENGINE_GAS HSMMME03
PUMP_MOBILE (HSMPP)
3.7.73 PUMP_PORTABLE HSMPPP01
3.7.74 PUMP_HYDRAULIC HSMPPP02
3.7.75 PUMP_HYDRAULIC_VAR_DISP_PISTON HSMPPP03
TANKS_MOBILE (HSPTT)
3.7.76 TANK_RECEIVER_MOBILE HSPTTT01
Detail Drawing D20
3.8 PIPING REQUIREMENTS
GENERAL_PIPING_EQP (ISLEM)
3.8.1 PROBE_CORROSION ISLEMA02
Detail Drawing D20
3.8.2 PROBE_COUPON ISLEMA03
Detail Drawing D20
3.8.3 BARREL_EXPANSION ISLEMB01
3.8.4 EXPANSION_JOINT_PIPE ISLEMF03
Manufacturing Procedure J19
3.8.5 HOSE_ASSEMBLY_TEXTILE_FIBER_LINED ISLEMH01

Detail Drawing D20
3.8.6 HOSE_METALLIC ISLEMH02
Detail Drawing D20
3.8.7 INJECTION_QUILL_IQ ISLEMI01
Detail Drawing D20
3.8.8 LATERAL_PIPE ISLEML03
PIPELINE (ISLPP)
3.8.9 ELBOW_PIPE ISLPPE01
3.8.10 ELBOW_SWIVEL ISLPPE02
3.8.11 MIXER_INLINE ISLPPM05
3.8.12 PIPE ISLPPP01

3.8.13 PIPE_HANGERS_AND_SUPPORTS ISLPPS01
3.8.14 STEAM_HEAT_TRACING ISLPPT05
3.8.15 GLYCOL_HEAT_TRACING ISLPPT06
3.9 ROTATING EQUIPMENT REQUIREMENTS
COMPR_FAN_BLOWER (JSMFF)
3.9.1 BLOWER JSMFFB01
3.9.2 COMPRESSOR_CENTRIFUGAL JSMFFC01
3.9.3 COMPRESSOR_RECIPROCATING JSMFFC02

3.9.4 COMPRESSOR_SCREW JSMFFC03
3.9.5 COMPRESSOR_ROTARY JSMFFC04
3.9.6 COMPRESSOR_SLIDING_VANE JSMFFC05
3.9.7 COMPRESSOR_LIQUID_RING JSMFFC06
3.9.8 FAN_VANE_AXIAL JSMFFF01
3.9.9 FAN_CENTRIFUGAL JSMFFF02
3.9.10 FAN_TUBE_AXIAL JSMFFF03
GEARBOX (JSMGG)
3.9.11 GEARBOX_FIXED_SPEED JSMGGG01
Assembly Drawing D8
Detail Drawing D20
LUBRICATION (JSMLL)
3.9.12 LUBRICATING_UNIT JSMLLL01
Assembly Drawing D8
Detail Drawing D20

3.9.13 LUBRICATING_UNIT_PUMP JSMLLL02
3.9.14 LUBRICATING_UNIT_TURBINE JSMLLL03
MOTOR_ENGINE_MECH (JSMMM)
3.9.15 ENGINE_STATIONARY_DIESEL JSMMME01
3.9.16 ENGINE_STATIONARY_GAS JSMMME02
Lubrication Schedule L19
3.9.17 MOTOR_PNEUMATIC JSMMMM01

3.9.18 MOTOR_HYDRAULIC JSMMMM02
PUMP (JSMPP)
3.9.19 PUMP_CENTRIFUGAL JSMPPP01
3.9.20 PUMP_VACUUM JSMPPP02
3.9.21 PUMP_RECIPROCATING JSMPPP10
3.9.22 PUMP_ROTARY JSMPPP11
3.9.23 PUMP_DIAPHRAGM JSMPPP12
3.9.24 PUMP_PROGRESSIVE_CAVITY JSMPPP13
3.9.25 PUMP_MODULE_(SKID) JSMPPP99

GOVERNOR (JSMTG)
3.9.26 GOVERNOR_ELECTRONIC JSMTGE01
TURBINE_WINDMILL (JSMTT)
3.9.27 TURBINE_GAS JSMTTT01
3.9.28 TURBINE_STEAM JSMTTT02
Operating Manual H9
Vibration Specification L32
GENERAL_PROCESS_EQP (JSPZZ)
3.9.29 CENTRIFUGE_BOWL JSPZZC01
3.9.30 CENTRIFUGE_SCROLL JSPZZC02
3.9.31 HOMOGENIZER JSPZZH01
3.9.32 MIXER JSPZZM01
3.9.33 MIXER_AERATOR JSPZZM02
3.9.34 AGITATOR JSPZZM03
3.9.35 MILL JSPZZM04
Detail Drawing D20
3.9.36 RAKE_SOLIDS JSPZZR01
3.9.37 SKIMMER_UNIT_OIL_RECOVERY JSPZZS01
3.10 SAFETY, PERSONAL PROTECTION, AND FIRE PROTECTION EQUIPMENT

REQUIREMENTS
FIRST_AID_EQP (KSSAA)
3.10.1 SAFETY_SHOWER KSSAAS01
Detail Drawing D20
3.10.2 SHOWER_EYE_AND_FACE_WASH_EMER_STATION KSSAAS05
Detail Drawing D20
FIRE_PROTECTION (KSSFF)
3.10.3 STATION_FIRE_ALARM_MANUAL KSSFFA05
Detail Drawing D20
3.10.4 ALARM_PERSONNEL_HAZARD KSSFFA06
3.10.5 ALARM_SMOKE_AUTOMATIC KSSFFA07
Detail Drawing D20
3.10.6 BLANKET_FIRE KSSFFB01
3.10.7 EXTINGUISHER_FIRE KSSFFE01
3.10.8 DAMPER_FIRE KSSFFF04
Detail Drawing D20
3.10.9 HYDRANT_FIRE KSSFFF08
Detail Drawing D20
3.10.10 NOZZLE_MONITOR_TYPE_FIRE_FIGHTING KSSFFN01
3.10.11 HEAD_SPRINKLER_FIRE_PROTECTION KSSFFS02
3.10.12 AIR_RELEASE_CONTROL_AUTOMATIC_SPRINKLER KSSFFS03
Detail Drawing D20
ELECTRICAL_SAFETY_EQUIPMENT (KSSPP)
3.10.13 ELECTRICAL_SAFETY_EQUIPMENT KSSPPE01

3.11 PRESSURE VESSEL REQUIREMENTS
DRYER (LSPHD)
3.11.1 DRIER_AIR-GAS_DESICCANT LSPHDD04
Catalyst Loading Drawing D12
Detail Drawing D20
EXCHANGER (LSPHE)
3.11.2 EXCHANGER_AIR_COOLED_RAD_FINFAN LSPHEH02
Assembly Drawing D8
3.11.3 EXCHANGER_PLATE_AND_FRAME LSPHEH03
Assembly Drawing D8
Detail Drawing D20
3.11.4 EXCHANGER_SHELL_AND_TUBE LSPHEH04
Assembly Drawing D8
Detail Drawing D20
3.11.5 EXCHANGER_IMMERSED_COIL LSPHEH05

3.11.6 EXCHANGER_SPIRAL LSPHEH06
3.11.7 EXCHANGER_DOUBLE_PIPE LSPHEH11
Assembly Drawing D8
Detail Drawing D20
COLUMN_TOWER (LSPTC)
3.11.8 LEVEL_COLUMN LSPTCC01
Assembly Drawing D8
3.11.9 TOWER LSPTCT01
Assembly Drawing D8
Detail Drawing D20
3.11.10 COOLING_TOWER_LIQUID LSPTCT02
Assembly Drawing D8
Detail Drawing D20
TANKS_HOPPERS (LSPTT)
3.11.11 PUMP_BOX LSPTTB05
Detail Drawing D20

3.11.12 HOPPER_MATERIAL_HANDLING LSPTTH01
Detail Drawing D20
3.11.13 CHUTE LSPTTH02
Detail Drawing D20
3.11.14 SILO LSPTTH03
Detail Drawing D20
3.11.15 RECIEVER_AIR LSPTTR01
Detail Drawing D20
3.11.16 SPHERE LSPTTT03
Detail Drawing D20
3.11.17 TANK_UNDERGROUND LSPTTT05
Assembly Drawing D8

Detail Drawing D20
3.11.18 TANK_ABOVE_GROUND LSPTTT06
Assembly Drawing D8
Detail Drawing D20
REACTION_SEPARATION (LSPTV)
3.11.19 CYCLONE LSPTVC04
Assembly Drawing D8
Detail Drawing D20
3.11.20 DRUM LSPTVD05
Assembly Drawing D8
Detail Drawing D20
3.11.21 FILTER_VESSEL LSPTVF02

Assembly Drawing D8
3.11.22 REACTOR LSPTVR01
3.11.23 SEPARATOR_OIL LSPTVS01
Assembly Drawing D8
Detail Drawing D20
3.12 PRODUCTION RESOURCES EQUIPMENT AND TOOL REQUIREMENTS
MAINTSHOPEQP/TOOL (PSWMZ)
3.12.1 LIFTING_DEVICE PSWMZL01
3.12.2 ENGINEERED_STANDS PSWMZS01
Sizing Calculations B17
3.12.3 TOOLS_JIGS_FIXTURE PSWMZT01
Operating Procedure J22
3.13 TESTING AND MEASUREMENT EQUIPMENT REQUIREMENTS
MECHANICALTESTEQP (QSTMM)
3.13.1 MAINTENANCE_TESTING_INSTRUMENT QSTMMM01
3.13.2 MAINTENANCE_MEASURING_EQUIPMENT QSTMMM02
Assembly and Erection Procedure J1
Detail Drawing D20
MISCTOOLING&TEST (QSTZZ)
3.13.3 INSTRUMENTS_AND_LABORATORY_EQUIPMENT QSTZZM01
MAINTSHOPEQP/TOOL (QSWMM)
3.13.4 GRINDING_MACHINE_ENGRAVING_TOOL QSWMMG01
3.13.5 TOOL_KIT_GENERAL_MECHANIC QSWMMK01
3.13.6 TOOL_KIT_ELECTRONIC_SYSTEM QSWMMK02
3.13.7 TOOL_KIT_ELECTRICIAN QSWMMK03
3.13.8 TOOL_KIT_PRECISION_INSTRUMENT QSWMMK04
3.13.9 TOOL_KIT_METAL_WORKER QSWMMK05
3.13.10 TOOL_KIT_MACHINIST QSWMMK06
3.13.11 CUTTER_TOOL_SET_LATHE QSWMMK07
Assembly Drawing D8
Safe Work Plan L29
3.13.12 MEASURING_TOOLS QSWMMK08
Detail Drawing D20
3.13.13 TOOL_KIT_REFRIGERATION_EQUIPMENT QSWMMK09
3.13.14 SHOP_TOOLS_MECHANICAL QSWMMM01
3.14 WELL AND BUILDING REQUIREMENTS
WELLS (USAAA)
3.14.1 WELL_STEAM USAAAW02
3.14.2 WELL_GAS USAAAW03
3.14.3 WELL_OIL USAAAW04
3.14.4 WELL_DISPOSAL USAAAW05
3.14.5 WELL_OBSERVATION USAAAW06
3.14.6 WELL_WATER USAAAW07
BUILDING (USABB)
3.14.7 BUILDING_FIXED USABBG01
Door and Window Schedule F39
Floor Finishing Schedule F5
Reflected Ceiling Plans D53
Riser Diagram D55

Wall Schedule F22
3.14.8 BUILDING_MOBILE USABBG02
3.14.9 TRAILER_MODULAR_BUILDING USABBG03
3.14.10 TENT_MODULAR USABBG04
3.14.11 BUILDING_SKID_MOUNTED USABBG05
Door and Window Schedule F39
Floor Finishing Schedule F5
Reflected Ceiling Plans D53
Riser Diagram D55
Wall Schedule F22
3.15 STRUCTURE OR SYSTEM REQUIREMENTS
AREA_POND_ROAD (WSAAA)
3.15.1 CAVERN_STORAGE WSAAAC01
3.15.2 DOCK WSAAAD01
3.15.3 POND_RETENTION WSAAAP03
Drainage Plan L12
3.15.4 ACCESS_ROAD WSAAAR03
Cross Sectional Drawing D18
Detail Drawing D20
Grading and Contour Map D31
Routing Map D56
3.15.5 RAILROAD WSAAAR04
Detail Drawing D20
Routing Map D56
3.15.6 YARD_STORAGE WSAAAY01
Layout Drawing D40

Security Map D61
STRUCTURE (WSASS)
3.15.7 DYKE WSASSD01
Drainage Plan L12
3.15.8 CONCRETE_DRAINAGE_STRUCTURE WSASSD02
Concrete Compressive Strength Record K11
Drainage Plan L12
Sizing Calculation B17
3.15.9 PIT_NON_MINING WSASSP01
3.15.10 PIPERACK WSASSS02
Layout Drawing D40
Sizing Calculation B17
4 Roles and Responsibilities
Director of M&R Responsible for the approval of this Standard and all subsequent updates
Integration
Asset
Responsible to revise and update this Standard
Information
Specialist
Peer Review Responsible for collecting and supplying local feedback and recommendations for the
Network standard back to the Asset Information Specialist
members
Project Manager Responsible for implementing this standard

or Leader
4.1 Measurements and Verification
Measure 1 This standard is used to ensure critical asset information is created and delivered to Suncor for
each asset introduced by a project.
Verification 1 This standard shall be used by the ready for operations team, or equivalent, to verify
completeness of asset information prior to project close.
5 Terms and Definitions
Term Definition
Original Equipment
Manufacturers A collection of manufacturer’s asset information documents that are required to be delivered to
(OEM) Information Suncor in book format.
Book
6 References
6.1 Essential Documents
The list below outlines the documents that need to be read with this document for full understanding:
Document Number Document Title
CTS-0002 Technical Deviations
CTS-0112 Asset Information Numbering
CTS-0119 Metadata Requirements for Asset Information
CTS-0126 Sustained Information Required for Individual Assets
CTS-0127 Sustained Information Required for Asset Location and Use
7 Approvals
This document is unapproved if it does not contain original approvers signature below.
Signatures
Dwayne Eliuk, Asset Information Specialist (Signature and Date)
Leigh Mork December 19,2016
Leigh Mork, Director M&R Integration (Signature and Date)
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CORPORATE TECHNICAL STANDARD

Number:
Department: OPERATIONAL EXCELLENCE AND TECHNICAL SERVICES 0222
Revision:
Subject: Above and Below Ground Pipelines to CSA Z662
2
ADDENDUM / REVISIONS HISTORY

Section
REV # Change
Changed
2 All Re-formatted document.

2 1.1 Sentence revised.
Deleted “Tank farms”. Simplified the other services by deleting specific services.
2 1.2.1
Added Slurries.
2 1.2.2 Deleted “Maintenance activities”.
2 1.2.3 Added clause.
Was clause 1.3. Revised diameter to size. Deleted sentence “Specific piping line
2 1.2.4 classes shall be developed for project requirements. Relocate refer to material
grades to clause 5.2.15.
2 1.2.6 New clause added.
2 1.3 New section added.
2 2.0 Revised responsibility per new format.
2 3.1 New section added
Revised drawing number for standard drawing per new format. Added reference
2 3.2
corporate standards
2 3.3 Revised list of reference publications, codes and standards.
2 4.1 Revised the list of definitions and acronyms.
2 4.3 New clause added.
2 5.2.1.1 Revised item j. Added items q, r, s and u. Item f was previous clause 5.2.1.8.
2 5.2.1.2 Replaced item f.
2 5.2.7 Was 5.3.4.1
Standard 0222 Rev 2, Above and Below Ground Pipelines to CSA Z662 Page 3 of 54
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Revised clause to combine part of previous 1.2.4. Delted reference to API 5L
2 5.2.15
grades.
2 5.2.17 Deleted reference to API 5L grade.
2 5.2.18.3 New clause added.
2 5.2.19.1 Combined the two previous clauses 5.2.4.1 and 5.2.4.2.
2 5.2.23 Was section 5.4.5
2 5.2.23.5 Removed reference to ABSA
2 5.2.23.6 Deleted item k
2 -- Deleted previous clause 5.4.5.7
Was section 5.2.10 Completely revised to limit the use of threaded connections to
2 5.2.24
specific applications only.
2 5.2.25 Was section 5.2.11.
2 5.2.25.3 Revised to disallow the use of buried flanges.
2 5.2.28.1 Previous clause 5.2.1.3. Added items a to e.
2 5.2.26.3 Was section 5.2.12
2 5.2.26.4 Was 5.2.11.3
2 5.2.27 Was section 5.2.13
2 5.2.27.2 New clause added. Replaced previous clause 5.2.13.5.
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Deleted the sentence on reference to clamped shoes and enforce the sentence on
2 5.2.27.5
the use of full encirclement reinforcement pads per Z662.
2 5.2.28 Was 5.2.14
2 5.2.29 Was 5.2.15
Added sentence “end closure shall be designed to seal with zero pressure at the
2 5.2.29.5
door.”
2 5.2.29.13 Added the words “For bi-directional traps”.
2 5.2.30 New section added.
Was 5.2.17. Deleted specific depth for Fort McMurray, Northern British Columbia,
2 5.2.31
and Sarnia.
2 5.2.32 Was 5.2.18
2. 5.2.32.2 New clause added.
2 5.4.1.2 Deleted the option of repair damaged pipes.
Added sentence “where field bends cannot meet the requirements of CSA Z662,
2 5.4.5.1
they shall be shop bent”.
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2 5.4.6 Was 5.4.7
2 5.4.7 Was 5.4.8
2 -- Deleted previous section 5.4.9
2 5.4.8 Was 5.4.10.1
2 5.5.2.5 f) Was previous clause 5.5.2.4 e)
2 -- Deleted previous clauses 5.5.8.14, 5.5.9.1, 5.5.9.4
2 5.6 New section added
2 5.7 Was 5.6
2 5.8 Was 5.7. Heading changed.
2 -- Deleted previous clauses 5.7.1.2, 5.7.1.3, 5.7.1.4
Replaced sentence “At the beginning of the project” with “If non-CSA coatings are
2 5.8.2.1
specified”.
2 -- Deleted previous clause 5.7.2.10.
2 5.8.2.8 Replaced “S-bends” with “Manufactured bends”.
2 5.8.4.4 Simplified the clause to reference to NACE RPo274 only.
2 -- Deleted previous clauses 5.7.4.7, 5.7.5.5
2 5.8.6.2 Was 5.7.6.3. Revised the second sentence.
Was 5.7.6.2. Revised “implemented as soon as practical” to “implemented at the
2 5.8.6.3
same time when the line is commissioned”.
2 - Deleted previous clause 5.7.6.4. Requirement incorporated into clause 5.8.1.1.
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2 Table 2 Notes revised.
2 5.9.3.23 Deleted reference to ISO 15156.
2 5.9.5.5 b) Deleted testing to ASTM E92.
2 5.9.5.11 Deleted sentence related to single-welded joints.
2 5.9.5.12 Revised “250 HV” to “248 HV500”
2 5.9.6.1 Revised the clause by deleting the brand name of X-ray films.
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TABLE OF CONTENTS
1.0 PURPOSE & SCOPE .................................................................................................................................. 10
1.1 PURPOSE .................................................................................................................................................. 10
1.2 SCOPE ...................................................................................................................................................... 10
1.3 PRECAUTIONS............................................................................................................................................ 11
2.0 RESPONSIBILITIES ................................................................................................................................... 11
2.1 ACCOUNTABILITY AND APPROVAL................................................................................................................ 11
2.2 REVISIONS AND UPDATES ........................................................................................................................... 11
2.3 INTERPRETATION........................................................................................................................................ 11
2.4 IMPLEMENTATION ....................................................................................................................................... 11
3.0 REFERENCES & PREREQUISITES .......................................................................................................... 12
3.1 PREREQUISITES ......................................................................................................................................... 12
3.2 SUNCOR STANDARDS AND DRAWINGS......................................................................................................... 12
3.3 RELEVANT / REFERENCED PUBLICATIONS, CODES AND STANDARDS ............................................................. 12
4.0 DEFINITIONS AND ACRONYMS ............................................................................................................... 14
4.1 DEFINITIONS .............................................................................................................................................. 14
4.2 ACRONYMS ................................................................................................................................................ 15
4.3 PIPELINE REGULATORS .............................................................................................................................. 16
5.0 STANDARD ................................................................................................................................................. 16
5.1 GENERAL................................................................................................................................................... 16
5.2 DESIGN REQUIREMENTS ............................................................................................................................. 16
5.3 MATERIALS OF CONSTRUCTION .................................................................................................................. 28
5.4 INSTALLATION ............................................................................................................................................ 30
5.5 JOINING BY ARC AND GAS WELDING ........................................................................................................... 33
5.6 FLANGE ASSEMBLY .................................................................................................................................... 40
5.7 PRESSURE TESTING, CLEANING AND BASELINING ........................................................................................ 41
5.8 CORROSION PROTECTION OF BURIED PIPELINES ......................................................................................... 42
5.9 SOUR SERVICE PIPELINES .......................................................................................................................... 46
5.10 POLYETHYLENE PIPELINES .......................................................................................................................... 52
6.0 AUXILIARY INFORMATION ....................................................................................................................... 53
6.1 APPENDICES .............................................................................................................................................. 53
6.2 ATTACHMENTS ........................................................................................................................................... 53
7.0 DOCUMENTATION AND DELIVERABLES ............................................................................................... 53
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8.0 APPROVED BY ........................................................................................................................................... 54
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1.0 PURPOSE & SCOPE
1.1 Purpose
The purpose of this standard is to define Suncor’s essential requirements for the design and construction
of above and below ground pipelines built in accordance with Canadian Standards Association (CSA)
Z662 code.
1.2 Scope
1.2.1 This standard applies to the following fluid carrying pipeline systems in Canada:
a) Liquid Hydrocarbons
b) Water
c) SAGD Steam and Emulsion gathering lines
d) Gas
e) Sour and Non-Sour applications of the above systems
f) Slurries
1.2.2 This standard does not apply to the following pipeline systems in Canada:
a) Offshore pipelines
b) Carbon Dioxide (CO2) systems
c) Gas distribution systems
d) Aluminium pipelines
e) Non-metallic pipelines other than High Density Polyethylene (HDPE) pipelines
f) Facility auxiliary piping designed to other codes
1.2.3 This standard does not cover pipeline systems outside of Canada.
1.2.4 This Standard covers pipelines with a maximum size of NPS 24 (DN 600) and pipelines with a
maximum wall thickness of 1¼ inches (31.8 millimeters). Pipelines greater than NPS 24 (DN 600) or
wall thickness greater than 1¼ inches (31.8 millimeters) shall be considered to be project specific.
The design criteria for these systems shall be developed based on the project requirements and this
Standard.
1.2.5 This Standard is intended as a supplement to CSA Z662 to establish Suncor’s minimum standards for
the design, construction and operation of oil and gas pipeline systems in Canada. Where there is
conflict between this Standard and referenced publications, codes, standards and regulations, the
most stringent requirements will apply.
1.2.6 Application of this standard for development of other technical documents (e.g. Specifications,
Guidelines etc.) is not mandatory but recommended.
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1.3 Precautions
This standard and associated template is mandated for Corporate Technical Standards. The user of this
document must have prior knowledge and understanding of corporate and legislative direction, to use
standards to promote the consistent, safe, reliable, and cost-effective management of Suncor’s
businesses in line with the Operational Excellence Management System (OEMS).
2.0 RESPONSIBILITIES
Business Unit or Project related positions are indicative of the responsibilities; these designations may vary
based on scope and execution model of technical work.
2.1 Accountability and Approval

The Director of Technical Standards is responsible for approving this document and is accountable to
ensure this standard is effectively used for projects and existing plants.
2.2 Revisions and Updates

Discipline Subject Matter Expert (SME) is responsible for updating and revising this standard in
consultation with Peer Review Network (PRN) members and Director of Technical Standards based on
Lessons Learned and for Continuous Improvement.
2.3 Interpretation
Interpretation and guidance shall be provided by the applicable Peer Review Network member for the
business unit or the applicable Suncor Project or Discipline Engineer for a project. The Subject Matter
Expert responsible for this technical standard may be consulted by the applicable personnel for any
interpretation of the requirements within this standard. Director of Technical Standards shall have the
final decision in case of conflict.
2.4 Implementation
Director of Technical Standards is responsible for ensuring that this standard is communicated to
stakeholders and for auditing the implementation.
Business Unit / Project Management or delegate has overall responsibility for implementation of this
standard. Engineering Manager, Discipline Leads or other technical specialist shall provide necessary
support in implementation.
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3.0 REFERENCES & PREREQUISITES
3.1 Prerequisites
The Codes, Specifications, Standards, and Practices listed in this Section are a part of this standard.
Unless otherwise specified herein, the latest edition of the referenced document (including any
amendments) applies.
3.2 Suncor Standards and Drawings

CTS 0126 Sustained Information Required for Individual Assets
CTS 0210 Pipe Supports
CTS 0212 High Density Polyethylene Pipe (HDPE) Design and Installation
CTS 0221 Bolted Flange Joint Assembly
CTS-SD-LPL-001-I Piping Standard Detail, Pig Trap Facilities, Imperial Unit
CTS-SD-LPL-001-M Piping Standard Detail, Pig Trap Facilities, Metric Unit
3.3 Relevant / Referenced Publications, Codes and Standards

American Petroleum Institute
API 5L Specification for Line Pipe
American Society of Mechanical Engineers
ASME B16.5 Pipe Flange and Flange Fittings NPS 1/2 Through NPS 24
ASME B16.9 Factory-Made Wrought Buttwelding Fittings
ASMEB16.49 Factory-Made, Wrought Steel, Buttwelding Induction Bends for Transportation
and Distribution Systems
ASME B31.3 Process Piping
ASME Sect VIII Div 1 Rules for Construction of Pressure Vesse3ls
ASME Sect IX Welding, Brazing, and Fusing Qualifications
ASTM International
ASTM A193/A193M Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure
Service and Other Special Purpose
ASTM A194/A194M Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature
Service, or Both
ASTM A320/A320M Alloy-Steel and Stainless Steel Bolting for Low-Temperature Service
ASTM A333/A333M Seamless and Welded Steel Pipe for Low Temperature Service and Other
Application with Required Notch Toughness
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ASTM A350/A350M Carbon and Low-Alloy Steel Forgings, Requiring Notch Toughness Testing for
Piping Components
ASTM A420/A420M Piping Fittings of Wrought Carbon Steel and Alloy Steel for Low-Temperature
Service
ASTM E21 Standard Test Methods for Elevated Temperature Tension Tests of Metallic
Materials
ASTM E384 Standard Test Method for Knoop and Vickers Hardness of Materials
ASTM E1815 Standard Test Method for Classification of Film Systems for Industrial
Radiography
American Welding Society
AWS A5.1/A5.1M Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
AWS A5.32M/A5.32 Welding Consumables - Gases and Gas Mixtures for Fusion Welding and Allied
Processes
Canadian Gas Association
OCC-1 Control of External Corrosion on Buried or Submerged Metallic Piping Systems
Canadian Standards Association
CSA Z245-1 Steel Pipe
CSA Z245-11 Steel Fittings
CSA Z245-12 Steel Flanges
CSA Z245-13 Steel Fittings
CSA Z245-15 Steel Valves
CSA Z245.20 Plant-applied External Coatings for Steel Pipe
CSA Z245-30 Field-applied External Coatings for Steel Pipeline Systems
CSA Z662 Oil and Gas Pipeline Systems
Manufactures Standardization Society
ANSI/MSS SP-25 Standard Marking System for Valves, Fittings, Flanges, and Unions
NACE International
NACE MR0175 Petroleum and natural gas industries — Materials for use in H2S-containing
environments in oil and gas production
NACE RP0105 Liquid-Epoxy Coatings for External Repair, Rehabilitation, and Weld Joints on
Buried Steel Pipelines
NACE SP0169 Control of External Corrosion on Underground or Submerged Metallic Piping
Systems
NACE SP0188 Discontinuity (Holiday) Testing of New Protective Coatings on Conductive
Substrates
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NACE SP0274 High-Voltage Electrical Inspection of Pipeline Coatings

NACE SP0286 Electrical Isolation of Cathodically Protected Pipelines
NACE SP0394 Application, Performance, and Quality Control of Plant-Applied Single-Layer
Fusion-Bonded Epoxy External Pipe Coating
NACE TM0284 Evaluation of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen-
Induced Cracking
National Energy Board
NEB Act Part III Construction and Operation of Pipelines
Note: The NEB regulations need only be considered where a pipeline crosses provincial borders.
Provincial Acts and Regulations, including Information Letters, Regulatory Directives and Bulletins and
equivalent documents as may be issued from time to time by jurisdictional authorities.
4.0 DEFINITIONS AND ACRONYMS
4.1 Definitions
“Cold spring” - means the process which stresses the piping at the installed cold condition in order to
reduce the stresses in the piping system at the operating or hot condition.
“Dead legs” - means the section of piping system where there is no or no significant flow.
“Facility Piping” – means piping including all piping and components that are part of a facility and not
within the definition of mainline piping.
“Final Tie-In Welds” – means welds that join pressure-tested pipeline sections into a continuous pipeline,
and do not normally get pressure tested during initial pipeline construction.
“Hot Pass” – means the second pass in a multi-pass groove weld, deposited in a manner that removes
the root pass crown and any slag in the wagon track.
“Industry Standard” – means Standards, recommended practices, guidelines, etc. from a recognised
Standards Developing Organization. Examples of such organizations include CSA, ASME, ASTM, API
and NACE.
“May” – means requirements are optional and may be changed at the discretion of the person
responsible.
“Mainline Piping” – means all pipe, valves, flanges, and fittings, up to and including the first valve
isolating the main line from a facility, such as a pump station, compressor station, terminal, tank farm,
receipt point, or delivery point. It includes scraper (pig) traps (barrels), crossovers, station bypasses,
relief valve bypasses, and instrument lines that are connected to the main line.
“Microalloyed steel” - means a type of alloy steel that contains small amounts of alloying elements,
including niobium, vanadium, titanium, molybdenum, zirconium, boron, and rare-earth metals, generally in
individual concentrations less than 0.15 mass percent, to enhance strength.
“Night cap” - means cap fit over and close off the end of the pipe to prevent entry of foreign materials.
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“Poorboy Welds” – means mainline welds completed by a work crew independent of the primary
mainline work crew.
“Owner” – means Suncor Energy Inc.
“Owner’s Engineer” – means a registered, professional engineer employed directly by Suncor,
responsible for the technical integrity of the project.
“Shall” – means requirements are mandatory and may not be deviated from unless approval is obtained
in advance from Owner’s Engineer.
“Tie-In Welds” – means welds that join pipeline segments into a continuous section for subsequent
pressure testing.
4.2 Acronyms
ASME American Society of Mechanical Engineers
ASTM ASTM International
AWS American Welding Society
CLR Crack Length Ratio
CRN Canadian Registration Number
CSA Canadian Standards Association
CSR Crack Surface Ratio
CTR Crack Thickness Ratio
HBW Brinell Hardness
HIC Hydrogen Induced Cracking
MOP Maximum Operating Pressure
MOT Maximum Operating Temperature
MSD Material Selection Diagram
MSR Material Selection Report
NACE NACE International
SIF Stress Intensification Factor
SMYS Specified Minimum Yield Strength
SOHIC Stress-Orientated Hydrogen Induced Cracking
SSC Sulphide Stress Cracking
TDN Technical Deviation Notice
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4.3 Pipeline Regulators

4.3.1 Federal
NEB National Energy Board
TSB Transportation Safety Board
4.3.2 Provincial
BCOGC BC Oil and Gas Commission
AER Alberta Energy Regulator
SER Saskatchewan Energy and Resources
OEB Ontario Energy Board
5.0 STANDARD
5.1 General
5.1.1 The design of pipelines constructed from steel, shall be primarily as per CSA Z662 (latest edition)
with supplemental requirements as defined in this Standard.
5.1.2 The transition from CSA Z662 Oil and Gas Pipeline Systems Standard to ASME B31.3 Process
Piping Code shall take place on the facility side of the pig trap or facility side of the first above ground
block valve if there are no pigging facilities.
5.1.3 The design of steel oil and gas pipelines to CSA Z662 – Annex C is not permitted.
5.1.4 All design and construction records shall be provided to Operations Business Unit Document
Management (Asset Information Management) as per Suncor Standards.
5.2 Design Requirements

5.2.1 Design Criteria Document
5.2.1.1 In the early stages of pipeline design, a Design Criteria Document shall be developed to enable
distribution of the pipeline design data to all involved parties and disciplines. Information on the
Design Criteria Document shall consist of the following:
a) Pipeline Code
b) Pipeline Material
c) Pipeline Grade
d) Minimum Burial Depth to Top of Pipe
e) Flange Rating
f) Fluid Properties
g) Class Location Factor
h) Minimum Bend Radius
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i) Branch Connections
j) Maximum and Minimum Design Temperatures (The minimum metal design temperature
shall be determined using site/location specific geotechnical data.)
k) Maximum Operating Pressure
l) Maximum Operating Temperature
m) Estimated Installation Temperature
n) Design Pressure
o) Corrosion Control
p) Design Life
q) Buoyancy control
r) Leak detection methodology
s) Pigging requirement
t) Any technical requirements arising from risk or environmental impact assessments
u) Any other information or comments that will enhance the design effort and ensure pipeline
integrity
5.2.1.2 It is not normally possible to obtain a soil report covering the entire routing of the pipeline but the
survey and alignment drawings shall assist in determining the type of soils that will be
encountered and the general contour of the routing. To enable pipeline stress analysis to
proceed, the Design Criteria Document shall provide the following:
a) Soil Type
b) Soil Coefficient of Friction (estimated minimum and maximum value)
c) Soil Friction Angle (estimated minimum and maximum value)
d) Soil Density
e) Clay Un-drained Shear Strength (estimated minimum and maximum value)
f) Soil draindown analysis to support valve replacement
5.2.2 The minimum pipe size for buried pipelines shall be NPS 2 (DN 50).
5.2.3 The minimum pipe size for sour gas pipelines shall be NPS 3 (DN 75).
5.2.4 Change in pipe diameter shall be made above ground at a header and on the facility side of pigging
facilities. The use of buried reducers is not permitted.
5.2.5 Sufficient emergency remote operated block valves shall be designed in order to limit maximum spill
3 3
volume to less than 70,640 ft (2,000 m ).
5.2.6 Buried valves are not permitted.
5.2.7 Valve closing and opening speed shall be selected to minimize the risk of water hammer, surging and
slugging.
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5.2.8 Pipelines designed for pigging shall utilize maximum schedule 40 risers, fittings, and flanges up to the
pig trap flange or pigging valve, unless otherwise required by the design. CSA materials with higher
grades up to a maximum of Grade 414 can be utilized as necessary.
5.2.9 The internal diameter of fittings and components butt welded to pipe shall match the inside diameter
of the pipe. Buried fittings are not permitted in a pipeline system designed for internal line inspection
tools unless it’s inside diameter matches the line pipe. Line boring of fittings is permitted to ensure a
uniform thickness is achieved.
5.2.10 Pipelines shall be tied together with above ground headers or top tee tie-ins with isolation valves.
The use of Y-laterals or buried tees is not permitted. The only exceptions are sweet dry fuel gas
pipelines less than NPS 6 (DN 150) and sweet shallow gas pipelines less than NPS 4 (DN 100).
5.2.11 Pipelines shall be designed so that there are no buried dead legs. This includes dead legs that may
be created if a branch line is shut in. This requires a sufficient number of isolation valves at midpoint
tie-in risers, or the use of top tee tie-ins.
5.2.12 When selecting a wall thickness to be used for the pipeline, consideration shall be given to ensuring
that the wall thickness is adequate for all installation handling external loads and possible over-
excavation during construction. The minimum pipe nominal wall thickness shall be 1/8 inch (3.2
millimeters).
5.2.13 Diameter-to-wall thickness ratio (D/t) for pipe diameters up to NPS 24 (DN 300) shall be less than 70
in the corroded condition. For pipe over NPS 24 (DN 600) and up to NPS 36 (DN 900), the D/t ratio
shall be less than 100 in the corroded condition.
5.2.14 The pipeline design shall utilize materials for all components with the same nominal strength or
grade. Risers and the small bore portion of pig traps shall utilize the same or higher grade of
materials as the main pipeline.
5.2.15 Generally, the highest grade of material used will be limited to Grade 448. Material grades higher
than 448 and up to 550 may be considered with economic and technical justification, subject to
project approval, and availability and acceptable welding procedures. These higher grade materials
are typically used to distribute high pressure steam to Steam Assisted Gravity Drain (SAGD) well
pads.
5.2.16 When material Grades 290 and higher are used at temperatures above 400°F (200°C), mechanical
properties and design allowable stresses must be established by testing at the specified design
temperature, as well as at ambient conditions. For welded pipe or components, weld zone
mechanical properties must also be verified by testing at the specified design temperature and
ambient temperature. Elevated temperature tension tests shall be conducted in accordance with
ASTM E21. The frequency of testing and acceptance criteria shall be agreed to between the
manufacturer and Owner. The pipe supplier shall provide data demonstrating that specified
properties are satisfied (e.g., detailed Material Test Reports) at ambient and design temperature
conditions.
5.2.17 Material Selection Diagram
5.2.17.1 A Material Selection Report (MSR) shall be prepared to document the rationale for material
selections and corrosion control. For facility piping where multiple corrosion circuits may be
present, Material Selection Diagrams (MSD’s) shall also be prepared.
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5.2.18 Pressure
5.2.18.1 Pipelines shall be designed to withstand the Maximum Operating Pressure (MOP) of the system.
Pressure design of components such as valves, instruments, etc. shall be in accordance with the
requirements of the applicable component standard or specification.
5.2.18.2 It is essential to ensure all components are suitable for the maximum operating pressure of the
pipeline. Due to the type of valve body manufacturing process and material chemical
composition, the Maximum Operating Pressure (MOP) of the system may be limited by the flange
rating of the valves.
5.2.18.3 Overpressure protection may be provided by a dedicated relief valve or automated shut down
device. Any isolation valves between the relief valve or pressure sensing device and the pipeline
shall be equipped with a locking device (e.g. chain and lock, car seal, etc.).
5.2.19 External loadings
5.2.19.1 External loadings shall be evaluated during the initial design and, where necessary, a suitable
wall thickness and/or material grade selected to ensure future pipeline integrity. Below is a list of
external loadings that should be considered:
a) Support settlement or support frost heave
b) Local support loads
c) Axial anchor loads
d) Over excavation at riser stations
e) Excessive overburden loads
f) Construction and local traffic
g) Earthquake
h) Soil slides
i) Hydraulic shock
5.2.20 Temperature
5.2.20.1 The pipeline shall be designed for the Maximum Operating Temperature (MOT) of the system.
5.2.20.2 Above ground pipelines shall consider the thermal expansion range from the maximum operating
temperature to the estimated minimum installed temperature, minimum operating temperature or
minimum exposed ambient temperature, whichever is lowest.
5.2.20.3 Underground pipelines shall consider the thermal expansion range from the maximum operating
temperature and the metal temperature at the time of restraint. In Northern climates where the
installed temperature may be well below zero, the differential temperature range may be such
that a below ground pipeline will exceed CSA Z662 allowable stress levels in the fully
compressed state (i.e. between the virtual anchor locations). If this is the case, consider the
following to reduce the axial compressive strain to acceptable levels.
a) Increase the grade of material.
b) Heat pipeline prior to backfilling.
c) Schedule to install during higher ambient temperatures.
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Other methods used to reduce axial compressive strain shall be subject to Owner’s Engineer
approval.
5.2.21 Corrosion and Erosion Allowances
5.2.21.1 Depending on the fluid service, corrosion and erosion allowance may be required to be added to
the calculated design wall thickness. The Owner’s Business Unit Metallurgist shall be consulted.
In addition, pipelines in high consequence areas and those with CSA Class location greater than
1 may warrant the addition of a corrosion allowance.
5.2.21.2 When fluid service requirements indicate the need for additional allowances to mitigate corrosion
or erosion, this allowance shall be indicated in the Material Selection Report. Reduced fluid
velocity and increased bend radii may be used to reduce the rate of erosion.
5.2.21.3 Corrosion and erosion allowances may be reduced by up to 10% when it helps to avoid going up
to the next higher schedule or next standard mill thickness.
5.2.22 Fittings
5.2.22.1 All tees shall be welding tees as per CSA Z245.11 and as per CSA Z662 Table 4.8 Sketch B.
This is to ensure the stress intensification factors (SIF’s) are at a minimum. Fabricated tees as
indicated in CSA Z662, Table 4.8, Sketches C and D shall not be permitted.
5.2.22.2 If ASME B16.9 tees are proposed, the stress intensification factors (SIF’s) shall be in accordance
with ASME B31.3, Appendix D, Note 11, and their use shall be approved by the Owner’s
Engineer.
5.2.22.3 Branch connections shall be made with tees, reducing tees, or “olets” only. Integrally reinforced
branch fittings shall be used for branch connections NPS 2 (DN 50) and smaller. When the
branch fitting material grade is less than the run pipe grade, rating of the fitting shall be verified.
5.2.22.4 All tees shall have pig bars except reducing tees where the branch size is less than 50% of the
main line size. The bar material shall be compatible with the tee material.
5.2.22.5 Bars shall be welded to the tee with welds of sufficient strength to prevent failure. This is
essential as breaking-off of bars would result in considerable damage to the inside of the pipeline
and other components.
5.2.22.6 Where barred tees are required, they shall be indicated on Piping and Instrumentation Diagrams
(P&I.D’s) and a design sketch drawn up showing the bar details. The design sketch shall be part
of the purchasing documents for the barred tees.
5.2.22.7 Shop fabricated bends are the preferred design for risers and expansion loops. The following
pipelines shall utilize shop fabricated bends:
a) All pipelines NPS 6 (DN 150) and larger
b) All sour pipelines NPS 3 (DN 75) and larger
c) All wet gas, oil emulsion or water pipelines NPS 3 (DN 75) and larger
Risers and expansion loops for all other pipelines may use 45 degree or 90 degree elbows:
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5.2.22.8 When transition pieces are required by CSA Z662 or the engineering design, a transition piece
drawing shall be generated. The transition piece drawing and design shall comply with the
applicable requirements of CSA Z662 (e.g., Figure 7.2 and its notes, and Clause 14.3.7 if used
for oilfield steam distribution), be capable of containing the maximum operating pressure and test
pressure, and shall include the following information:
a) Piping specialty item number
b) Nominal diameter
c) Wall thickness 1 (riser)
d) Wall thickness 2 (pipeline)
e) Material grade
f) Category and test temperature
g) Overall length
h) Angle of transition
i) Weld details
j) Design pressure
k) Design temperature
l) Fluid (sour or sweet)
m) Marking requirements per ANSI/MSS SP-25
5.2.22.9 Change in wall thickness greater than 1/16 inch (1.6 millimeters) shall be made with a machined
transition piece fabricated from a piece of thicker pipe as per CSA standard and shop hydro-
tested or taper bore flange.
5.2.23 Bends
5.2.23.1 Furnace hot bends are not acceptable.
5.2.23.2 When cold bends are unsuitable for the required application, induction bends shall be provided in
accordance with CSA Z245.11 and ASME B16.49. Induction bends shall be fabricated using
seamless pipe, electric resistance welded pipe, or longitudinally welded double submerged arc
welded (DSAW) pipe. Spiral welded pipe shall not be used. Longitudinal welds shall be at or
near the neutral axis of the bend, and shall not be located in the bottom quadrant of the bend in
its installed position.
5.2.23.3 All bending procedures, test bend results, and post-bend non-destructive testing (NDE) results
shall be reviewed and approved by the Owner’s Engineer.
5.2.23.4 The effects of the heating time and temperature on the mechanical properties of the bend shall be
determined by qualification of the bending procedure and preparation of test bends as described
by CSA Z245.11.
5.2.23.5 When ordering pipe bends for ASME B31.3 piping, the applicable jurisdiction shall be contacted
to determine whether bend designs require registration as a fitting. If registration is required, it
shall be the responsibility of the bending contractor in cooperation with the requisitioning
organization.
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5.2.23.6 A Bend Specification shall be generated when procuring bends. The specification shall define the
Owner’s requirements regarding pre-bending and post-bending tolerances, material
specifications, post-bending minimum wall thicknesses, hardness limits, non-destructive
examination (NDE) etc. The Specification shall also specify the bend radius, bend angle etc. for
each bend. The Supplier shall provide the following documents, procedures, specifications and
any other documentation requested by the Owner’s Engineer unless noted otherwise by the
Owner:
a) Manufacturer’s general bending specification
b) Manufacturer’s qualification records and procedures
c) Temperature monitoring procedure
d) Quench medium, quench rates and quench control method
e) Quality control inspection procedures, reports and records
f) Material test reports (MTR) for starting pipe
g) Heat treating reports and charts
h) Post bend inspection reports
i) Test bend mechanical property and inspection report
j) Canadian Registration Number (CRN) where applicable
5.2.24 Threaded Connections
5.2.24.1 Threaded connections are permitted on above ground sections only for pipe smaller than NPS 2
(DN 50) and the end connections of vents and drains downstream of the isolation valves.
5.2.24.2 Threaded connections shall be minimum schedule 80.
5.2.24.3 Threaded bushings are not permitted. Use a swage, reducing flange, or reducing valve.
5.2.25 Flanges
5.2.25.1 Both CSA flanges and ASME flanges can be used on a pipeline. However, it shall be noted that
above 100°F (38°C), ASME B16.5 flanges have lower pressure ratings than the equivalent CSA
flanges and this will limit the Maximum Operating Pressure (MOP). If CSA flange ratings are
required when using flanges designed to ASME B16.5, the flanges shall be procured with dual
stamping. This will avoid having to increase the B16.5 flange class.
5.2.25.2 For main line flanges, the flange internal diameter shall match the internal diameter of the
adjacent pipeline to allow smooth passage of pigs and eliminate any pocketing.
5.2.25.3 Buried flanged connections are not permitted.
5.2.25.4 Flange insulating gasket kits or monolithic isolation joints shall be installed on all pipelines and
located on the pipeline side of the first/last pipeline block valve and branch valve.
5.2.26 Stress Analysis
5.2.26.1 Any pipeline larger than NPS 8 (DN 200) shall have a detailed stress and flexibility analysis
completed.
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5.2.26.2 Pipelines with a temperature differential between installation and operating greater than 90°F
(50°C) shall have a detailed stress and flexibility analysis completed.
5.2.26.3 Cold springing shall not be used where the load due to the initial cold spring is transferred to a
nozzle on a piece of equipment such as a pressure vessel, pump, etc.
5.2.26.4 For underground pipelines stress analysis shall be done at sectionalizing valve riser stations.
This assessment shall include the analysis of bending moments at valve flanges. Where stress
levels and/or flange bending moments do not meet code requirements, underground bends with
soft back-fill or an above ground expansion loop shall be used to reduce these stresses to
acceptable levels.
5.2.27 Above Ground Supports
5.2.27.1 Pipelines running above ground shall be supported on elevated structural steel or sleeper ways.
5.2.27.2 Pipelines shall be support with pipe shoes installed at all support locations. Pipelines and pipe
shoes shall be electrically isolated from the support structures.
5.2.27.3 The spacing of supports should be such that the mid-span sag of the pipeline does not exceed
1/2 inch (12 millimeters) during normal operating conditions. Larger displacements are
acceptable subject to Owner’s Engineer’s approval which shall ensure the risk of excessive liquid
accumulation is addressed. Larger mid-span displacements during hydrostatic testing are
acceptable.
5.2.27.4 Stress analysis shall be performed on pipelines where there is line contact between the support
shoe and the support structure in situations where D/t is greater than 95. If the stress levels are
unacceptable, a reinforcing pad shall be installed at each point of support.
5.2.27.5 Welded attachments shall be used for support locations where the operating stress levels are
greater than 50% of the Specified Minimum Yield Strength (SMYS). Full encirclement reinforcing
pads shall be welded to the pipeline, with continuous circumferential welds, before attaching the
shoes.
5.2.28 Below Ground Supports
5.2.28.1 Before permitting backfilling at riser locations, the Owner’s Engineer shall approve that the
pipeline has been checked for local loading at the piled support and that the soil has not been
over-excavated under it. If there are indications of over-excavation, sand bags, or other means of
ensuring continuous support, shall be provided. Where support clamps are used, they shall have
a non-conductive pad between the pipe and the pipe support clamp to prevent cathodic protection
shorting to the pile.
5.2.29 Pigging
5.2.29.1 All pipelines shall be designed to accommodate maintenance pigs and in line inspection tools (i.e.
other than the risers no restrictions must be in the line) except as provided below:
a) Pipelines less than NPS 3 (DN 75)
b) Pipelines internally lined or coated
c) Sweet dry fuel gas pipelines less than NPS 6 (DN 150)
d) Sweet pipelines less than 1640 feet (500 meters) long
e) Sweet shallow gas pipelines less than NPS 6 (DN150)
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5.2.29.2 Each end of the pipeline shall be equipped with scraper trap, either permanently installed or with
piping configured to allow the connection of a temporary trap. If the transported fluid contains
solids, the system shall be designed to allow cleaning and inspection pigs to be run on a regular
basis.
5.2.29.3 Permanent pig trap facilities as per drawing CTS-SD-LPL-001 shall be installed on the following
steel pipelines to permit cleaning, control corrosion, reduce hydrates, reduce pressure drops, and
ease future discontinuation work:
a) All pipelines NPS 6 (DN 150) and larger
b) All sour service pipelines
c) All water wet gas pipelines (i.e. wet sweet gas), except sweet shallow gas pipelines less
than NPS 6 (DN 150)
d) All oil emulsion pipelines
e) All non-coated water pipelines
5.2.29.4 Pig launching and receiving barrels are classified as “components” of the pipeline system and
hence design, materials and construction shall be in accordance with CSA Z662.
5.2.29.5 End closures of barrels shall be attached to the barrel by a flange to flange connection and fitted
with safety devices. Material and design of hinged closures shall be in accordance with ASME
Section Vlll Div.1. End closure shall be designed to seal with zero pressure on the door.
5.2.29.6 Pig launcher and receiver trap major barrel diameters for pipelines shall be as per Standard
Drawing CTS-SD-LPL-001. The internal diameter of the minor barrel shall be the same as that of
the main line.
5.2.29.7 The reducer between the major and minor barrel shall be eccentric bottom flat for horizontal
launcher traps, concentric for horizontal receiving traps, and concentric for vertical traps.
5.2.29.8 Horizontal receiver barrels may be sloped at a ratio of 1:100 down towards the end closure to
improve draining liquids from the barrel. Horizontal launchers may be sloped at a ratio of 1:100
down towards the pipeline.
5.2.29.9 Riser bend dimensions shall be adequate to accommodate expected pig and/or inspection tool
train dimensions.
5.2.29.10 Bend radii shall be determined considering wall thickness and the type of pig and/or inspection
tool to be used. As part of this determination, the applicable pig and/or inspection tool supplier
shall be consulted. The extent of out-of-roundness shall be taken into consideration. Straight
lengths of at least three pipe diameters shall be allowed upstream and downstream of all riser
bends.
5.2.29.11 For launchers, the signaller on the downstream side of the pig trap valve shall be located on the
pipeline at a distance from the main tee of at least the length of the maximum length pig to be
used. This signaller will provide confirmation that the pig has successfully passed both the pig
trap valve and the main tee.
5.2.29.12 For receivers, the signaller shall be located on the minor barrel at a distance from the pig trap
valve of at least the length of the maximum length pig to be used.
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5.2.29.13 For bi-directional traps, pig signallers shall be installed on both sides of the pig trap valve. These
signallers shall provide confirmation that the pig has successfully passed through the pig trap
valves and has been successfully launched or arrived at the receiving station.
5.2.29.14 Pig signallers shall be non-intrusive.
5.2.29.15 The isolation of all pig traps shall be by double block and bleed. Either valves with integral
double block and bleed capability or multiple single block valves may be used.
5.2.29.16 Barred tees shall be installed at the branch of the bypass line off the mainline where the branch is
larger than 50% of the mainline diameter. On the mainline, the bars on the tee shall be recessed
within the tee to ensure passage of the pig.
5.2.29.17 Cathodic protection, isolation, and grounding connections shall be considered in the design.
5.2.29.18 Permanent supports shall be provided to support and restrain the pig traps. These shall be
designed to carry the weight of the trap system filled with water (or other fluids if their density is
greater than that of water) together with the weight of pig, or inspection tool if applicable.
5.2.29.19 Pig traps shall be located at least 50 feet (15 meters) away from any type of equipment, other
than adjacent pig traps. Pig trap systems should be located adjacent to each other for ease of
pigging operations.
5.2.29.20 Pig traps shall be located so that they are orientated with their end closures pointing at least 5
degrees away from personnel areas and critical items of equipment, i.e. those containing
hydrocarbons and/or toxic material or in safety service. This is to minimize the risk of damage to
adjacent facilities that might occur in the unlikely event of a pig being ejected from a pig trap.
5.2.29.21 The requirements for pig handling equipment shall be determined based on the type and weight
of pig and pipeline size. Pigs with a mass less than 65 pounds (30 kilograms) may be loaded
manually into or out of the pig traps. Pig lifting facilities, such as runway beams, cranes, pig
loading trolleys, cassettes or baskets shall be utilized for heavier pigs and these shall be
designed with suitable access for maintenance activities.
5.2.29.22 Space in accordance with Standard Drawing CTS-SD-LPL-001 shall be provided beyond the
closure door of the pig trap for pig handling and transport. Optional items shown in the standard
drawing are to be evaluated and identified on a case by case basis by the Business Unit.
5.2.29.23 Pig trap systems shall be fenced and access shall be provided for light trucks and lifting cranes,
subject to hazardous area classification constraints. Within the pig trap system plot, where buried
pipelines are less than 3 feet (1 meter) below the surface, barriers or other protective means shall
be provided to prevent vehicles damaging the pipelines.
5.2.29.24 The traps shall be installed as close to ground level as possible with sufficient room to slope drain
lines. Drain lines shall be sloped to either a closed drain system, designated open drain system
or to a portable drain system.
5.2.29.25 When a drain system is not available, a sump equipped with pumps for the disposal of the
drained liquids to a designated disposal area shall be provided. Alternatively, the sump may be
equipped with a NPS 2 (DN 50) suction point at a safe distance from other facilities for connection
to vacuum truck suction for disposal elsewhere. The volume of the sump shall be a minimum of
two and a half times that of the trap for liquid systems. For gas systems, the volume shall be
determined on an individual basis.
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5.2.29.26 In addition, a catch pit or tray shall be provided directly under the end closure with a volume equal
to at least 5 per cent of that of the trap and of sufficient surface area to prevent any oil or debris
contamination of the surrounding ground. This pit or tray may be connected to the sump, but if
not, it shall be designed such that it is safe and easy to empty. Where a tray is used, it shall have
a cover plate to keep out rain or snow. Cover plates shall be light weight and otherwise designed
so that they can be easily removed by one person.
5.2.29.27 Drain nozzles must have a corresponding vent above the nozzle location to allow for rodding the
drain if it were to become plugged.
5.2.29.28 A platform shall be provided adjacent to any valve where the centre of the hand wheel is more
than 59 inches (1500 millimeters) above grade. Similarly, a platform shall be provided adjacent to
any equipment (e.g. pig signallers) which is more than 59 inches (1500 millimeters) above grade
and which is used during pigging operations.
5.2.29.29 Chemical injection facilities shall be considered for pipelines in corrosive service. The chemical
injection facilities shall be suitably sized for the anticipated maximum production rates.
5.2.30 Corrosion Coupons
5.2.30.1 The following pipelines require corrosion coupons installed on the downstream end of each
pipeline and located on the facility side of pigging facilities or pigging valves:
a) All sour pipelines.
b) All water wet gas pipelines (i.e. wet sweet gas), except sweet shallow gas pipelines.
c) All oil emulsion pipelines.
d) All water pipelines.
5.2.30.2 Corrosion coupons and probes located such that the entire pipeline must be depressurized to
enable retrieval shall be installed with high pressure access fittings.
5.2.30.3 Corrosion coupons and probes shall be designed and installed so that they do not protrude into
pipeline portions designed for pigging.
5.2.31 Depth of Cover and Clearance
5.2.31.1 Burial depth for lines susceptible to freezing shall be below the frost line. The frost line shall be
determined using site/location specific geotechnical data.
5.2.31.2 Use of alternative designs to prevent freezing requires prior approval from the Owner’s Engineer.
5.2.32 Crossings of Roads, Pipelines, Utilities and Railways
5.2.32.1 The use of a piping casing or sleeve at road, rail or tank dike crossings is discouraged due to
corrosion concerns for the carrier piping. Corrosion of the carrier piping within the casing is
difficult to control due to shielding of cathodic protection current. Piping casings shall not be used
unless required by the right-of-way owner, environmental regulations or design.
5.2.32.2 Road crossings shall be designed uncased utilizing higher strength material instead of increased
wall thickness when required. If increased wall thickness is required it shall not exceed 120% of
the main line nominal wall thickness. Otherwise a cased crossing shall be utilized.
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5.2.32.3 Individual approval of each crossing is required from the Owner’s Engineer of the facility being
crossed or from the appropriate regulatory authority having jurisdiction.
5.2.32.4 To ensure timely approval for crossings, the following information in Table 1 shall be provided for
the approving authority.
Table 1
Crossing Type
Information Required Roads Railroads Pipeline & Utility Water
Geometry and location of X X X X
crossing
Casing details if crossing is X X
cased
Minimum depth of cover X X
between road or railroad
Construction methods X X X X
Pipeline specifications (Note1) X X X X
Cross-sectional profile X X X X
Warning signs X X X X
Relative position and X
clearance between the two
pipelines
Sour considerations X
Depth below bottom of X X
existing line or water crossing
Sag bend location X
Environmental considerations X
Bank stabilization methods X
Buoyancy control methods X
Note 1: Specification to include size, wall thickness, operating and design pressure, operating and design
temperature, class location, etc.
5.2.32.5 Casing pipe shall have a minimum 1:20 slope to ensure no liquid build up in the casing. Casing
pipe shall be installed with coated steel spacers, end seals and casing filler - a petroleum based
corrosion preventative compound used to fill the annulus of casings to prevent corrosion by
displacing the water in the casing and preventing water from re-entering the casing. When casing
includes an end closure, an open drain shall be provided at the casing low point.
5.2.32.6 Where casing is used, the design shall take into account risks related to cathodic protection. The
design shall be reviewed and approved by a cathodic protection specialist.
5.2.32.7 In the design of river crossings, consideration shall be given to environmental and operational
risks.
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5.2.32.8 At river crossings, the corridor design shall be aligned to facilitate the future addition of a parallel
pipeline if a twin pipeline was not installed. Buoyancy control per section 5.4.6 shall be added
where appropriate.
5.3 Materials of Construction

5.3.1 Materials used in construction shall be based on a Material Selection Report (MSR), with Material
Selection Diagrams (MSDs) if required (see Para 5.2.17.1). For facility piping, suitable piping
material specifications shall be selected based on the MSDs and indicated on the Piping and
Instrumentation Diagrams (P&I.Ds).
5.3.2 Material substitutions will not generally be permitted. If there is no alternative, then the substitution
will only be permitted if the substitute material is equal to or superior, based on the service, to the
material being replaced. Approval for the substitution must be confirmed in writing from the Owner’s
Engineer.
5.3.3 Reuse of materials will only be permitted when approved by the Owner’s Engineer and in accordance
with CSA Z662.
5.3.4 Reuse of previously abandoned existing pipelines will only be permitted when approved by the
Owner’s Engineer and only after a full engineering assessment of the suitability and integrity of the
material/pipeline for the new service. The assessment shall be based on CSA Z662.
5.3.5 Piping line classes complying with CSA Z662 may be assigned to pipelines. These lines classes are
specific to fluid services and location classes. Operating pressure and temperature limits are defined
within the line classes. Similar fluid services that meet the specific location class factors, and
maximum operating pressure and temperature can use the same line classes.
5.3.6 Notch Toughness Requirements
5.3.6.1 Material notch toughness category requirements shall be in accordance with the CSA Z662
Standard and Owner requirements as shown in Figure 1.
5.3.6.2 Buried materials for sour service shall be CSA Z245 Category II impact tested to 0°F (-18°C) or
lower temperature.
5.3.6.3 Above ground materials, including risers, for sour service shall be either CSA Z245 Category II or
ASTM materials, impacted tested to -49°F (-45°C).
5.3.6.4 Materials for fittings, flanges, transition pieces, valves body and other components shall match
the line pipe notch toughness category.
5.3.6.5 ASTM A333 Grade 6 seamless pipe shall be acceptable for Category III impact tested service at
a minimum design temperature not lower than -49°F (-45°C), in accordance with CSA Z662 Table
5.3 and accompanying notes. For Category III pipe, measurement of shear area during notch
toughness testing shall not be mandatory; for Category II pipe, measurement of shear area shall
be required.
5.3.6.6 ASTM A350 Grade LF2 Class 1 forgings (flanges) and ASTM A420 Grade WPL6 fittings shall be
acceptable for Category II impact tested service at a minimum design temperature not lower than
-49°F (-45°C), in accordance with CSA Z662 Table 5.3 and accompanying notes. For Category II
forgings and fittings, measurement of shear area during notch toughness testing shall not be
mandatory.
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5.4 Installation
5.4.1 General
5.4.1.1 The installation of a pipeline shall follow the requirements in CSA Z662 Clause 6.
5.4.1.2 Pipe shall not be allowed to drop when handling. Pipe with distortions, dents, flattening, gouges,
or notches exceeding the limits of CSA Z662 shall be rejected and replaced.
5.4.1.3 Adequate precautions shall be taken to prevent mill or yard coated pipe being damaged when
hauling, lifting and placing on the right of way.
5.4.1.4 Stresses imposed by construction are to be minimized. The pipe shall fit the ditch without the use
of external force to hold it in place until the backfill is completed unless specified otherwise on
drawings approved by the Owner.
5.4.1.5 Where long sections of pipe that have been welded alongside the ditch are lowered in, care shall
be exercised so as not to impose any strains that may kink or put a permanent bend in the pipe.
5.4.1.6 All work in close proximity to power lines may be subject to electrostatic and electromagnetic
induced voltages. The site contractor shall be responsible for monitoring and implementing
mitigation measures and precautions as well as those specified by the power-line owner.
5.4.2 Right of Way
5.4.2.1 Before installation can begin, all permits, licenses, crossing agreements and easements for the
pipeline must be in place.
5.4.2.2 The selection of the right of way and extra work space shall be based on the most economical
route, taking into account physical obstacles and their effect on installation costs.
5.4.2.3 After the survey of the agreed and approved right of way, the boundaries shall be staked.
5.4.3 Trenching
5.4.3.1 The trench shall be run as true and as straight as possible to minimize the requirement for bends.
5.4.3.2 Trench shall run down the centerline of the right of way as shown on the design drawings.
5.4.3.3 The ditch digging must comply with all of the local facility’s safety standards and the Occupational
Health and Safety Act.
5.4.3.4 The required ditch width and height, side slope, cover, initial fill, backfill, compaction
requirements, etc. shall be shown on a drawing.
5.4.3.5 The depth of the trench shall be measured from the average level of the original ground or grade,
whichever is lower, on the two sides of the trench. In the event sand bags are required, the
trench shall be dug sufficiently deep to obtain the required cover.
5.4.3.6 The road ditches at the pipeline crossing shall be restored to the approval of the local authorities.
5.4.4 Crossings
5.4.4.1 Where the right of way crosses or parallels previously installed pipelines, roads, railways or
underground structures and utilities, the crossings shall be as per the specifications of the facility
crossed or the governing authority.
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5.4.4.2 On punched or bored crossings, boring shall be made accurately to the line and elevations as
indicated on the alignment drawing. Where the pipe or casing does not conform to the bottom of
the ditch, it shall be adequately supported with sandbags or other approved materials.
5.4.4.3 The casing pipe shall be cleaned thoroughly inside. A sizing plate, 5/8 inch (15 millimeters) less
than the inside diameter of casing pipe shall be passed through the casing pipe to ensure no
internal obstructions.
5.4.4.4 Precautions shall be taken to avoid damaging the pipeline, insulation and coating during
installation in the casing.
5.4.4.5 All cased crossings shall be checked by the Owner’s Engineer before and after back filling the
ends to determine that the casing is electrically insulated from the carrier pipe.
5.4.4.6 On all uncased crossings, care must be taken to protect the pipe covering. On bored or punched
crossings, it is recommended to wrap the carrier pipeline with a second protective high strength
abrasion resistant overwrap
5.4.4.7 Water crossings shall be done in a manner approved by the Owner’s Engineer, the pipeline
contractor and the representative of the facility crossed or the governing authority.
5.4.4.8 Where specified on the drawing plus where defined by the installation contractor, buoyancy
weights are to be added to the line at water crossings.
5.4.4.9 The minimum cover for creeks, creek diversion ditches, flood-plain of water courses and drainage
ditches shall be 6 feet (1.8 meters) in soil and 3 feet (0.6 meter) in rock. In muskeg, the minimum
cover shall be 5 feet (1.5 meters).
5.4.4.10 Where open trenching is used for creek crossing, the following precautions shall be implemented:
a) Protection shall be provided to prevent bank erosion
b) Washed gravel shall be used as backfill
c) Washed gravel shall be used for the access road
d) Silt fence shall be used to control creek contamination
5.4.4.11 Extra depth may be required when a trench is excavated across or adjacent to foreign pipelines,
roads or road allowances, railways or railway allowances, creeks, rivers, ravines, etc. and where
the contour of the earth may necessitate it. The extra depth will be across the entire width of the
foreign right of way involved.
5.4.4.12 When a new pipeline is to be installed within 16 feet (5 meters) of an existing pipeline or cable, it
shall be exposed by hand digging or hydrovac to determine its exact location before use of
mechanical excavation methods. No machinery shall be operated within 5 feet (1.5 meters) of an
existing pipeline or cable. Plows or wheel type trenching machines shall not be allowed to trench
across existing pipelines or right of ways.
5.4.4.13 Where power or communication cables are located within the right of way of a road or railway
which will be bored for the crossing, sufficient depth shall be maintained during boring operations
to ensure that a minimum clearance of 12 inches (300 millimeters) is maintained between the
cable and the completed pipeline.
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5.4.5 Cold Bends

5.4.5.1 Cold bends may be produced in a shop or in the field. Where field bends cannot meet the
requirements of CSA Z662, they shall be shop bent.
5.4.5.2 The pipe shall be bent where the change in direction does not allow the pipe to follow the contour
of the ditch. The minimum curvature of roping is 200 times the outside pipe diameter. Required
radii less than this shall be bent using an approved bending method.
5.4.5.3 The maximum allowable bend shall be 1 degree per pipe diameter length. Bends shall not be
permitted within setback distance of the road Right of Way (ROW). Any pipe that is buckled by
the bending operation shall be rejected. Section of the buckled pipe which has been jacked or
straightened in any matter shall not be acceptable.
5.4.5.4 In general, for pipeline changes of direction, shop fabricated bends are preferable and are
mandatory where the angle of deflection is greater than 45 degrees. When shop fabricated
bends are not provided, the Pipeline Contractor shall make the required cold field bends using
Contractor’s Bending Equipment previously approved by the Owner’s Engineer. No field bending
is permitted when the pipe or the ambient temperature is -4°F (-20°C) or lower.
5.4.5.5 Field bends shall be of uniform radius and the curvature distributed throughout as great a length
as possible. Bends shall be free from buckling.
5.4.5.6 The following shall be the minimum bend radius of a field cold bend unless a tighter radius has
been approved by the Owner’s Engineer:
a) Smaller than NPS 12 (DN 300); 18 times nominal diameter
b) NPS 12 (DN 300) and greater; per CSA Z662 clause 6.2.3(a)(ii)
5.4.5.7 Cold bending shall not be performed within 6 feet (2 meters) of the end of the pipe.
5.4.5.8 The bend wall thickness after bending shall not be less than the minimum required wall thickness
unless approved by the Owner’s Engineer.
5.4.5.9 Pipe bends shall not have a difference between maximum and minimum diameters exceeding 3%
of the specified outside diameter of the pipe.
5.4.6 Buoyancy Control
5.4.6.1 The buoyancy control method shall be outlined in the “Design Criteria Document” and the
locations indicated on the pipeline construction alignment drawing.
5.4.6.2 Test holes may be required to determine where buoyancy control is necessary before ditching is
underway.
5.4.6.3 Methods of buoyancy control can be concrete coated pipe, geo-textile weights, bolt on weights,
screw anchors or piles.
5.4.6.4 During installation, care shall be taken when installing weights to ensure no damage to the
pipeline coating or pipeline.
5.4.6.5 Concrete weights shall be protected with felt padding to avoid damage to pipe and coating.
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5.4.7 Back Filling

5.4.7.1 Initial fill and backfill shall provide firm support under the pipe. The fill in contact with the pipeline
shall be free of hard lumps or rocks greater than 1 inch (25 millimeters) diameter. As an
alternative to this fill size restriction, mechanical shield material can be used to protect the
pipeline and pipeline coating from damage by the subsequent fill.
5.4.7.2 Additional backfill may be required on over-bends to ensure the pipeline remains buried. This
requirement shall be determined during stress analysis of the pipeline. At under-bends, care
shall be taken to ensure the pipe is in contact with the ditch bottom before backfilling.
5.4.7.3 The bedding material and backfill material shall be placed in lifts and compacted by mechanical
compaction equipment to achieve 95% of the maximum proctor dry density.
5.4.8 The precautions, recommendations and procedures outlined in CSA Z662, Annex G shall be taken
into consideration when welding or cutting a pipeline during construction operations.
5.5 Joining by Arc and Gas Welding

5.5.1 General
5.5.1.1 Manual or semi-automatic arc-welding processes shall be used for joining wrought pipes,
components, and non-pressure-retaining attachments to piping. Use of other joining processes
shall be approved by the Owner.
5.5.1.2 Hot tap welding and welding of split sleeves is not completely addressed by this standard. When
hot taps, split sleeves, branches, or any other attachments must be welded to a live line, the
overall design, materials, welding qualifications, NDE requirements (before and after welding),
bake-out requirements (if applicable), and required equipment shall be reviewed and approved by
the Owner’s Engineer prior to starting the work.
5.5.1.3 When ASME B31.3 or ASME Section IX codes are used, as permitted by CSA Z662, the
applicable Owner welding standard for construction to these Codes shall be used.
5.5.2 Joints and Tacking Requirements
5.5.2.1 Partial penetration butt welds are not permitted.
5.5.2.2 All pressure containing butt and branch-to-run welds shall have a minimum of two passes, and
shall be full penetration.
5.5.2.3 Branch-to-run groove weld connections may be reinforced with fillet welds, but fillet welds alone
are not permitted.
5.5.2.4 For socket welds, the following requirements shall apply.
a) Welded with a low hydrogen process, except that the root pass may be made using
cellulose coated electrodes with a preheat that considers the risk of hydrogen cold
cracking.
b) Socket welded connections shall have at least two complete weld passes.
c) After welding, the minimum gap between the end of the pipe nipple and bottom of the
socket shall be 1/16 inch (1.5 millimeters) and the minimum depth of pipe nipple insertion
into the socket shall be 1/4 inch (6.4 millimeters).
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d) After welding, when a gap or insertion measurement is required, it shall be performed by

radiography, or by an alternate physical means of measurement approved by the Owner’s
Engineer.
5.5.2.5 Where threaded connections are permitted and seal welding is approved by the Owner’s
Engineer, all the following requirements shall be met:
a) Thread compounds or tapes shall not be used.
b) Threads shall be clean of all ragged edges, cutting oils, or lubricants.
c) Low hydrogen welding procedures and practices shall be used with qualified welder.
d) All exposed threads shall be covered with weld metal.
e) Seal weld quality shall be at least equivalent to that required for socket welds.
f) A list of threaded joints shall be submitted to the Owner’s Engineer for acceptance prior to
implementation.
5.5.2.6 Tack welds shall be:
a) Made by qualified welders, in accordance with a qualified welding procedure.
b) Preheated in accordance with the qualified welding procedure.
c) Of sufficient number and size as to maintain alignment without danger of breaking.
5.5.2.7 Root tacks shall be made with filler metal having the same classification as the root bead filler
metal to be used for production welds. Root tacks incorporated in the final weld shall be sound,
with stop/starts properly transitioned to ensure full penetration and fusion of the root bead.
5.5.2.8 Bridge tacks shall be made with filler metal of the same classification as will be used for fill
passes production welds. When bridging metal other than weld metal is required, it shall be
clean, with the same P-Number and group number as the base metal being welded. Nuts, bolts,
rebar, galvanized or coated metals, wire, old welding electrode, sucker rod, and dirty or
unidentified metals shall not be used for bridge tacking or temporary attachments. Bridge tacks
shall be made within the welding groove, completely removed as welding progresses, and not
incorporated into the finished weld.
5.5.2.9 Temporary welds are not permitted on material over Grade 386, without prior acceptance by the
Owner’s Engineer for each case. When temporary welds are used, all the following requirements
shall apply:
a) The weld area shall be preheated to the minimum temperature specified on the weld
procedure prior to welding.
b) Welds shall be completely removed before post weld heat treatment (PWHT) or
hydrostatic testing in a manner that does not cause tearing or removal of the base metal.
c) The area of removal shall be made smooth without reducing thickness below the minimum
required thickness. Corrosion allowance, if specified, shall be maintained.
d) The area of weld removal shall be fully magnetic particle (MT) or liquid penetrant (PT)
examined for evidence of cracking or other discontinuities.
5.5.3 Welding Equipment
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5.5.3.1 Welding equipment, including measurement and test equipment, shall be:
a) Capable of performing work in accordance with this standard.
b) Properly instrumented and calibrated in accordance with applicable industry standards
and regulatory requirements.
c) Maintained in a safe and good working condition at all times.
5.5.4 Materials
5.5.4.1 Filler metal and flux chemical and mechanical properties shall be compatible with those of the
base materials to be joined.
5.5.4.2 Filler metal shall be used for all welds unless otherwise authorized by the Owner’s Engineer.
5.5.4.3 ASME Section IX F No. 1 and F No. 2 electrodes, such as E7024 and E7028, shall not be used
for pressure containing welds.
5.5.4.4 Filler metals listed on a welding procedure shall provide a stable arc when operated within the
parameter limits specified by the weld procedure.
5.5.4.5 Electrode and filler metal properties shall be properly controlled in the field, including drying and
re-baking ovens required to maintain the low hydrogen properties. Contractor shall have a written
procedure for controlling the purchase, receiving, storage, conditioning, issue, and return of
electrodes and filler metals.
5.5.4.6 Shielding, backing, purging, and trailing gases shall be welding grade with a dew point of -40°F (-
40°C) or colder and shall satisfy the requirements of American Welding Society AWS
A5.32M/A5.32.
5.5.4.7 Weld procedures requiring shielding or trailing gases shall state the composition and flow rate,
which shall be consistent with wire manufacturer recommendations.
5.5.5 Qualification of Welding Procedure Specifications (WPS)
5.5.5.1 Welding procedures shall comply with the latest edition of CSA Z662 (or ASME Section IX as
permitted by CSA Z662). Existing welding procedures that do not comply with latest editions may
be amended for compliance provided essential or supplementary essential changes (variables)
are not affected. If amendments do affect these changes (variables), the welding procedure shall
be re-qualified.
5.5.5.2 Contractor shall have welding procedures suitable for the following types of welds if they are in
the scope of work, as well as a weld classification and numbering system to identify the following
types of welds in quality records:
a) Mainline (ML) welds
b) Poorboy (PB) welds
c) Tie-in (TI) welds
d) Final tie-in (FTI) welds
e) Shop fabrication (SF) welds
f) Field fabrication (FF) welds
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g) Repair (R) welds

h) Cut-out (CO) and replacement welds (which are given new weld numbers)
5.5.5.3 If available weld procedures are deemed unsuitable for tie-in or final tie-in welding, then tie-in or
final tie-in welding procedures shall be qualified by the Contractor.
5.5.5.4 If available weld procedures are deemed unsuitable for repair welding or back welding, when
permitted (e.g., insufficient preheat, improper electrodes), the Contractor shall qualify suitable
repair and back weld procedures as follows:
a) A repair weld qualification shall consist of simulated through-wall repair of a previously
prepared girth weld.
b) A back welding qualification shall consist of a simulated back weld repair of a previously
prepared girth weld.
c) Repair weld and back weld simulations shall be completed using low hydrogen electrodes,
except that the root bead and hot pass of through-wall repairs may be made using
cellulose coated electrodes.
d) Repair weld and back weld simulations shall be completed using a minimum 250°F
(120°C) preheat and inter-pass temperature.
e) Each repair weld qualification shall be non-destructively tested by radiographic or
ultrasonic methods, and by magnetic particle or liquid penetrant methods.
f) Each repair weld qualification shall be destructively tested using tensile tests, nick break
tests, root and face bends (or side bends when permitted by CSA Z662), impact tests
when required, and a hardness survey.
g) Each back weld qualification shall be non-destructively tested by radiographic and
magnetic particle methods.
h) Each back weld qualification shall be destructively tested using root bends (or side bends
when permitted by CSA Z662) and at least two hardness surveys.
5.5.5.5 Fabrication shall employ low hydrogen fabrication welding procedures qualified in accordance
with CSA Z662 or ASME IX with CSA Z662 compliance, except that the root bead and hot pass
may be made using cellulose coated electrodes.
5.5.5.6 Welding information recorded on a Procedure Qualification Record (PQR) (e.g., electrical
parameters, travel speed, preheat temperature, minimum and maximum inter-pass temperature,
and PWHT temperature and time) shall be actual values measured with certified and calibrated
instruments during the preparation of the test weld.
5.5.5.7 Weld procedure qualification mechanical tests shall be performed by an independent testing
laboratory.
5.5.5.8 When required, welding procedures shall be registered with appropriate jurisdiction authorities in
the province or territories of installation.
5.5.5.9 Castings shall not be welded or weld repaired without prior agreement from the Owner’s
Engineer.
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5.5.5.10 The following additional Essential Changes (Essential Variables) shall be included:
a) For pipe over NPS 16 (DN 400) and grade over 386, a reduction of preheat or inter-pass
temperature below that used for procedure qualification weld.
b) For pipe over NPS 16 (DN 400) and grade over 386, an increase in carbon equivalent
exceeding 0.05%.
5.5.6 Testing of WPS Qualification Test Welds
5.5.6.1 For pipe size over NPS 16 (DN 400) and grades over 386, each SMAW weld procedure
qualification test coupon shall be left for at least 48 hours before final non-destructive examination
and subsequent destructive testing. After this time period each weld procedure qualification test
coupon shall be completely examined (or re-examined) by film radiographic and magnetic particle
(wet fluorescent or black and white color contrast indicating mediums) methods, and shall satisfy
the requirements of CSA Z662.
5.5.6.2 When impact tested base metals are welded, or when required by the engineering design,
Charpy impact tests shall be conducted at or below the minimum design temperature, on weld
metal and heat affected zone (HAZ) specimens removed from butt weld procedure qualification
test coupons. Welding variables shall be within the ranges prescribed by CSA Z662 and ASME
Section IX, as applicable.
5.5.7 Qualification of Welders
5.5.7.1 Welders shall pass performance qualification tests in accordance with CSA Z662 and ASME
Section IX when permitted by CSA Z662.
5.5.7.2 Welders shall only make production welds for which they are qualified. Failure to comply with a
welding procedure specification during production welding shall be cause for removal of a welder
from the work.
5.5.7.3 Welders may be allowed to adjust welding machines and make one practice weld before
completion of each required performance qualification.
5.5.7.4 After passing visual inspection, performance qualification welds shall be subjected to radiographic
inspection. After passing radiographic inspection, test welds shall be destructively tested. All
inspections shall comply with the requirements of CSA Z662, or ASME B31.3 and ASME Section
IX when permitted by CSA Z662.
5.5.7.5 Test welds failing to pass visual inspection shall not be submitted for radiographic inspection or
destructive testing, and the welders shall be deemed to have failed their qualification test. Test
welds failing to pass radiographic inspection shall not be submitted for destructive testing, and the
welders shall be deemed to have failed their qualification test.
5.5.7.6 Welders failing to meet the minimum requirements of this standard shall not be permitted to retest
for at least thirty (30) days except, if the Owner’s Engineer and Contractor agree that the test
failure was due to conditions beyond the control of the welder, that welder may be given an
immediate retest.
5.5.7.7 Welders shall identify mainline welds by marking their assigned symbol beside each weld on the
top quarter of the pipe, with a waterproof crayon or paint stick. Punch marks or die stamps are
not permitted.
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5.5.8 Production Welding

5.5.8.1 Production welding shall be performed by qualified welders using qualified welding procedure
specifications approved by the Owner.
5.5.8.2 Each day the Contractor shall remove all welding rod stubs, wire spools or other refuse produced
during field welding, from the pipe bore, Owner property, and/or right-of-way. This shall include
the removal of all waste welding materials from the pipe after internal repair or back-welding,
when permitted, and prior to non-destructive examination of the weld.
5.5.8.3 The table below specifies the minimum number of manual welders to be used for the root and hot
passes of mainline and poorboy welds. More welders than the minimum may be required in order
to comply with the minimum time lapse between passes, or to comply with minimum preheat and
inter-pass temperature requirements.
Minimum Number of
Line Size
Root and Hot Pass Welders
≤ NPS 12 (DN 300) 1
> NPS 12 (DN 300) 2
5.5.8.4 During mainline and poorboy welding the Contractor shall periodically monitor (at least once per
day) the welding essential variables listed in CSA Z662, for compliance with the welding
procedure and this specification. Any failure to comply shall be cause for rejection of affected
welds. Documentation of compliance shall be made and shall be submitted to the Owner on a
daily basis. The extent of documentation shall be agreed between the Contractor and the
Owner’s Engineer before the start of production welding.
5.5.8.5 Night caps shall be used to cover:
a) The free end of a pipe section being welded, to prevent movement of air through the pipe.
b) Open ends of partially welded pipe sections at the end of each day's work (to prevent
ingress of dirt, snow, water, debris, or small animals).
c) Open ends of completed pipe sections to be tied-in at a later date.
5.5.8.6 Night caps shall not be welded in place and shall not be removed until work is ready to resume.
5.5.8.7 The minimum length of pipe used for mainline and poorboy spreads shall be 6 feet (2 meters).
Joints 6 feet (2 meters) and longer shall be carried forward and welded into the line as they
become available.
5.5.8.8 To reduce the risk of weld-zone hydrogen cold cracking, welded mainline and poorboy sections of
pipelines shall not be moved until all welds have cooled below 140°F (60°C). Where applicable,
the metal temperature shall also be within the acceptable range for the application of protective
coatings.
5.5.8.9 Welds, including repair and replacement welds, shall be left uncoated, uncovered and accessible
for non-destructive examination for at least one full day beyond the day that the weld was
completed, or until confirmation of final acceptability has been received from the Owner.
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5.5.8.10 Any fire damage to insulation or coating (e.g., due to preheating or thermal cutting) shall be
repaired using a procedure approved by the Owner’s Engineer.
5.5.8.11 When field welding of valves is required, the requirements of the valve manufacturer shall be
obtained by the Contractor and followed to avoid damage.
5.5.8.12 When air temperatures fall below 32°F (0°C), the following requirements shall apply:
a) Welding ends shall be heated to at least 200°F (93°C), so that the preheat temperature at
the start of welding is at least 150°F (65°C).
b) After completion (or partial completion) of welding of each weld joint a dry insulating cover
of at least 6 inches (150 millimeters) wide shall be positioned over the centre of the weld,
securely fastened, and left for a minimum period of two (2) hours, or until the weld has
cooled to ambient temperature.
5.5.8.13 Pipe and components shall be supported so that welders have unobstructed access to the weld
joint, with a minimum clearance of 16 inches (400 millimeters) between the joint to be welded and
the ground.
5.5.9 Inspection and Testing of Production Welding
5.5.9.1 Production welds shall be examined in accordance with the requirements of CSA Z662 and any
requirements of the engineering design.
5.5.9.2 Arc strikes, arc burns, and cracks are not acceptable regardless of size, type or location.
5.5.9.3 For above ground piping, all welds shall be weld mapped to the appropriate piping drawings.
5.5.9.4 For buried pipelines NPS 4 (DN 100) and larger in sour service, welds shall be mapped and
Global Positioning System (GPS) locations documented.
5.5.10 Repair of Welds Containing Repairable Defect
5.5.10.1 The minimum length of any single weld repair, recap, or back weld (when permitted) shall be 2
inches (50 millimeters) for pipe larger than NPS 4 (DN 100).
5.5.10.2 Surface repairs to visually observable surface defects in the cap pass (e.g., pinholes, external
undercut, surface porosity, excess reinforcement, and low cover) may be carried out prior to non-
destructive testing. Surface defects shall be removed by grinding or filing, and the repair area
shall be re-capped if necessary, using an approved repair welding procedure specification and
minimum 250°F (120°C) preheat. Grind repairs shall merge smoothly with adjacent base or weld
metal.
5.5.10.3 For through-wall repair and partial-wall repair of buried defects from the outside surface of the
pipe, the maximum cumulative length of repair shall not exceed 30% of the weld length (pipe
circumference). Fill and root pass defects may be removed by excavating the defect with a
power grinder, preparation of a suitable groove, and re-welding according to an approved welding
procedure with a minimum 250°F (120°C) preheat.
5.5.10.4 Back welding, when permitted, shall be performed for the full weld circumference.
5.5.10.5 All weld repairs, including re-caps and back welds, when permitted, shall be completed using a
low hydrogen process, except the first two passes of through-wall repairs can be done with
cellulose coated electrodes.
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5.5.10.6 All defects shall be completely removed by grinding prior to repair welding. Oxyacetylene flame
gouging of weld defects is not permitted. Arc air gouging of defects requires Owner approval. All
slag and scale shall be removed by wire brushing or grinding.
5.5.10.7 Grinding completely through the weld thickness for a through-wall repair shall only be permitted
when the Contractor has an approved weld repair procedure that has been qualified by simulating
a through-wall repair.
5.5.10.8 Repairs completed by welding shall be wrapped with insulation and slow cooled when the
ambient temperature is less than 50°F (10°C).
5.5.10.9 No more than two weld repair attempts are permitted at the same location in a defective weld.
Welds that have been rejected after a second weld repair attempt at the same location shall be
completely cut out and replaced.
5.5.10.10 Repair of cracked welds is not permitted. Welds containing cracks shall be cut out and replaced.
5.5.10.11 When a defective weld has been removed from the pipeline, a single replacement weld shall be
used to join the two sections of pipe whenever practical. If it is not practical to pull the pipe ends
together for the single replacement weld, then a section of nominal length equal to two (2) times
the pipe diameter or 6 feet (2 meters), whichever is greater, shall be inserted into the line and
welded into place using the same welding procedure as used for the original production welds in
the section.
5.5.10.12 All repair and replacement welds shall be examined with appropriate non-destructive examination
method. Records of all repairs and replacement welds, and their subsequent examinations, shall
be maintained and shall be traceable to welds represented.
5.5.10.13 The Contractor shall provide the Owner with daily weld production and repair rates for each
spread by welder, for each day of work, at the start of work on the following day, or such other
time as may be mutually agreed. The daily repair rate shall be the number of welds requiring
repair, including cut-out of defective welds, divided by the number of joints welded by each
spread for the day.
5.5.10.14 If the average daily repair rate for all welders exceeds 10%, or if the individual daily repair rate for
any welder exceeds 15%, the following actions shall be taken to correct the deficiencies:
a) Stop production welding.
b) Take necessary actions to reduce the repair rate, such as retraining, retesting, or
dismissal of welders, or correction of equipment, process or procedure problems.
c) Prepare a minimum 20 joint test section to assess the effect of these actions.
d) 100% radiographic examine the test section.
e) Resume production welding if the test section is acceptable to the Owner. If the test
section is not acceptable to the Owner, the steps above shall be repeated until the latest
test section has been radiographed and assessed by the Owner.
5.6 Flange Assembly

5.6.1 Bolting of flanges shall be in accordance with CTS 0221 Bolted Flange Joint Assemble. External
force applied to align flanges is not permitted.
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5.7 Pressure Testing, Cleaning and Baselining

5.7.1 General
5.7.1.1 Pressure testing shall be carried out in accordance with CSA Z662 Clause 8. For above ground
oilfield steam distribution pipelines such as SAGD pipelines, Clause 14.5 shall also apply.
5.7.1.2 CSA Z662 specifies that minimum test pressures for piping incorporating a corrosion or erosion
allowance, or both, should be increased, where practical, to produce the same hoop stress as
would have been produced at the minimum pressures specified in the absence of such
allowances. By complying with this, the test pressure in most cases would exceed the one and a
half (1.5) times pressure rating on the flange of a piping class with a Maximum Operating
Pressure at the cold rating of the flange. The following options are available and one of them
shall be agreed upon with the Owner early in the project:
a) Use the next higher rating of flange.
b) De-rate the MOP of the pipeline.
c) Pressure test only to the one and a half (1.5) times flange rating.
5.7.2 Leaks and Ruptures
5.7.2.1 Before a pressure test can commence, a test fluid leak containment and environmental protection
plan shall be developed. The following shall be addressed in the plan:
a) Impact of a fluid release on the environment
b) Method for locating leaks
c) Method for containing leaks
d) Method to clean-up leaks in accordance with environmental protection requirements
5.7.3 Pressure Test Records
5.7.3.1 Records of the pressure test that qualified the pipeline for service shall be maintained for the life
of the pipeline. In addition to the requirements of CSA Z662, the following information shall be
shown on the test charts:
a) Test start time and date
b) Test completion time and date
c) Piping line class or specification
d) Maximum operating pressure
e) Test pressure
f) Test medium
g) Test duration
f) Ambient temperature
g) Serial numbers of recorders and gauges
h) Printed name and signature of witnesses (Contractor and Owner’s Engineer or designate)
i) Printed name and signatures of the pipeline contractor and the Owner’s Engineer or
designate.
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5.7.4 Cleaning During Construction

5.7.4.1 At the final stage of construction, the pipeline shall be cleaned using a cleaning pig with an
attached gauging disc 1/4 inch (6.4 millimeters) thick and at least 95% of the inside diameter of
the pipeline being cleaned. The disc shall be made from carbon steel or aluminum plate. The pig
is to be propelled by compressed air. After running the pig, the disc shall be checked for gouges,
scars, dents and deflection. If there is any damage to the gauging disc, the cause of the damage
shall be located and corrected. A further cleaning shall be performed with a new gauging disc to
ensure the pipeline is clear of any obstructions.
5.7.5 Pipe Wall Thickness Baseline
5.7.5.1 All pipelines shall be internally inspected using a metal loss and deformation smart pig during
commissioning. This inspection report and baseline wall thicknesses shall be provided to
Operations of the respective Business Unit.
5.8 Corrosion Protection of Buried Pipelines

5.8.1 General
5.8.1.1 External corrosion control on buried or submerged steel pipelines shall be managed in
accordance with CSA Z662. CSA Z662 refers to recommended practices of CGA OCC-1 for
control of external corrosion on buried or submerged metallic piping systems. Additional
guidance may be obtained from NACE SP0169.
5.8.1.2 Buried carbon and micro-alloyed steel pipelines shall be protected from external corrosion with
external coating and cathodic protection in accordance with CSA Z662.
5.8.1.3 The Maximum Operating Temperature (MOT) of the pipeline shall be determined and agreed
upon to ensure correct selection of external coating. Operating temperatures often rise during the
lifetime of a system so it is important to ensure the external coating can handle the highest
operating temperature.
5.8.2 Coatings
5.8.2.1 If non-CSA coatings are specified, the pipeline designer shall evaluate coating systems and
prepare a written recommendation to the Owner describing coating systems most suitable for the
proposed pipe diameter, maximum operating temperature, design life, pipeline terrain, backfill
quality, and any other conditions affecting coating performance. Owner’s approval is required for
selecting the coating system.
5.8.2.2 Where fusion bonded epoxy coatings are used, suitable back-fill material or rock shields shall be
used to avoid coating damage.
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5.8.2.3 To minimize cathodic protection current demand and achieve maximum pipeline corrosion
protection, field joints shall be coated. Heat shrink sleeves shall be used for field joints of
polyethylene coated pipelines. Field joints on fusion bonded epoxy coated pipelines shall be
protected using field applied liquid epoxy coating or fusion bond coating. Heat shrink sleeves
may be applied to field joints of fusion bonded epoxy coated pipelines when approved by the
Owner’s Engineer. Joint coatings shall overlap shop applied coating or adjacent joint coatings a
minimum of 3 inches (75 millimeters).
5.8.2.4 Where tape wrapping of joints has been approved by the Owner’s Engineer, a minimum of two
layers of tape shall be applied. Each layer shall have a minimum of 50% overlap.
5.8.2.5 Shop supplied coating systems shall be supplied with a 6 inches (150 millimeters) cut-back on
both ends of the pipe length.
5.8.2.6 When field coating of pipe and fittings is required, the coating surfaces shall be cleaned in
accordance with the coating manufacturer’s recommendations.
5.8.2.7 A high strength abrasion resistant overwrap shall be provided for all bored and punched
crossings.
5.8.2.8 Manufactured bends and risers shall be shop coated with liquid applied or fusion bonded epoxy.
Risers shall be coated to a minimum of 18 inches (450 millimeters) above grade level.
5.8.2.9 All shrink sleeves and tape shall be installed in strict accordance with manufacturer’s
recommendations to ensure a holiday free coating is applied. Any repairs required to the external
coating must be carried out by qualified personnel. The repairs shall meet or exceed the
specifications of the original coating.
5.8.2.10 No field coating material shall be applied to piping below the coating supplier’s minimum
recommended application temperature.
5.8.2.11 Records of the coating selected for each component of the piping system shall be maintained.
These include but are not limited to:
a) Type of coating and specific coating specification
b) Coating manufacturer and applicator
c) Date and place of application
d) Application specification and inspection data
e) Transportation and storage records
5.8.3 Storing and Handling of Coated Materials
5.8.3.1 All coated and wrapped piping shall be stored and handled in a manner that ensures no damage
to the external protective materials.
5.8.3.2 Any material that shows evidence of deterioration, due to weather or any other cause shall be
repaired or replaced.
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5.8.4 External Coating Inspection of Buried Pipelines

5.8.4.1 Pre-coated piping shall be visually inspected before shipping to site to ensure that there are no
damaged sections. After off-loading, another visual inspection shall be carried out to check that
there was no damage incurred to the coating during transportation handling.
5.8.4.2 Visual inspection shall be conducted during all field sleeve applications to check that the proper
materials are being used and that the proper surface preparation and pre-heat methods are being
applied. Sleeve surfaces shall not be wrinkled, cracked, burned, charred or excessively
discoloured. If any of the above is evidence, the sleeve shall be cut off and a new sleeve
installed.
5.8.4.3 Before burial of uninsulated piping, all coated pipe, joints and fittings shall be inspected for
holidays using a high voltage sparking device (holiday detector) to locate pin holes, voids, thin
spots and any damage to shop applied coatings.
5.8.4.4 External coatings shall be inspected in accordance with NACE RP0274.
5.8.4.5 Only a fully charged holiday detector shall be used to inspect the pipe coating.
5.8.4.6 All pipe and sections of pipe shall be properly grounded prior to running the detector over the
pipe.
5.8.4.7 During the inspection, all defects shall be properly marked.
5.8.4.8 All holidays and defective coating or wrapping disclosed by the visual and holiday detector tests
shall be repaired. The repairs shall meet or exceed the specifications of the original coating.
5.8.4.9 After the holidays or defective coating has been repaired, a recheck of the repair using the
holiday detector shall be carried out in the presence of the Owner’s Engineer.
5.8.4.10 Peel tests on shrink sleeves shall be carried out by the pipeline contractor. The frequency shall
be decided by the Owner’s Engineer but shall not be less than 1 in 50 joints. The contractor is to
provide a peel test procedure for the Owner’s Engineer approval. The procedure shall comprise
of cutting a 1 inch (25 millimeters) by 2 inches (50 millimeters) rectangle in the sleeve or tape and
removing the section smoothly and evenly. The peel test shall be acceptable when the mastic
adhesive breaks away from the polyethylene backing, such that the vast majority of the adhesive
remains on the desired surface. The peel test fails if most of the adhesive breaks easily from the
pipe or factory applied coating surface.
5.8.4.11 When a tested field joint does not meet the adhesion requirements, the test shall be repeated on
the two joints adjacent to the tested joint. If the two tested joints are acceptable then no further
testing is required. If either of the two adjacent joints fails the adhesion test then all joint coating
work shall stop until an approved corrective action plan is in place and implemented.
5.8.4.12 Defective sleeves shall be removed and replaced. Further tests shall be done until the Owner’s
Engineer is satisfied that joints are properly installed.
5.8.5 Electrical Isolation
5.8.5.1 Cathodically protected piping and pipelines shall be electrically isolated from other metallic
structures that are not cathodically protected using commercially manufactured flange isolating
kits. Commercially manufactured monolithic isolation fittings may be used if approved by the
Owner’s Engineer.
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5.8.5.2 Flange isolating kits shall contain an isolating gasket for the flange interface, full length isolating
sleeves for each stud, and isolating washers and steel backup washers for each end of each
stud. Insulation kits shall be supplied by Owner approved suppliers.
5.8.5.3 When specifying flange isolating kits the following information shall be provided:
a) Pipe nominal diameter and thickness
b) Gasket bore
c) Pipeline contents (including contaminants such as H2S)
d) Flange standard, rating, type, and facing
e) Gasket type and style
f) Gasket sealing element material
g) Sleeve and washer material
5.8.5.4 Flange isolation kits shall be suitable for the maximum pipeline operating pressure, the test
pressure and the maximum pipeline operating temperature. Supplier of the isolation kits shall
confirm these requirements in writing.
5.8.5.5 Flange isolating kits shall be installed in accordance with the installation procedure provided by
the manufacturer.
5.8.6 Cathodic Protection
5.8.6.1 Cathodic protection shall be installed on buried lines to control corrosion of metallic surfaces in
contact with electrolyte.
5.8.6.2 Provincial legislation may have additional cathodic protection requirements over and above CSA
Z662 requirements. Pipeline designers shall confirm the local authority Acts and Regulations and
provide cathodic protection accordingly.
5.8.6.3 Cathodic protection of new piping shall be implemented at the same time when the line is
commissioned, not within one year after piping installation as permitted by CSA Z662.
Temporary cathodic protection is permitted until permanent facilities are energized. Sumps shall
also be cathodically protected.
5.8.6.4 Cathodic protection shall be maintained until the piping is abandoned in accordance with CSA
Z662. Cathodic protection shall be maintained if the piping is deactivated.
5.8.6.5 As-built drawings shall be retained for each cathodic protection installation. These drawings shall
show details and location of components of the cathodic protection system with respect to the
protected structure(s) and to major physical landmarks. As-built drawings and records depending
on the type of system, should include but not be limited to the following information:
a) Location and date placed in service
b) Specifications of rectifier or other energy sources
c) Quantity, type, location and spacing of anodes
d) Type of anode backfill material
e) Point of attachment of negative lead(s)
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f) Cable size and type of insulation

g) Right-of-way information
h) Direct current interference facilities
i) Location of related test station installations
j) Identification of bonded structures
k) Bond parameters, such as resistance, current magnitude and direction or other pertinent
information
l) Identification of connected structures
m) Type of device
5.9 Sour Service Pipelines

5.9.1 Sour Service Definition
5.9.1.1 Sour service shall be defined in accordance with CSA Z662.
5.9.1.2 Local jurisdiction may have sour service definitions different from CSA Z662. Pipeline designers
shall confirm the definitions found in local authority Acts and Regulations. The most stringent
requirements shall apply.
5.9.2 Sour Service Design
5.9.2.1 Any sour service technical requirements agreed during consultations with affected individuals or
organizations, or derived from risk assessments, shall be incorporated as pipeline design criteria.
5.9.2.2 All pressure-containing welds shall be groove welds designed for full penetration and full fusion
through the total thickness of the joint. Fillet weld reinforcement over groove welds is acceptable
(e.g., for nozzle or branch connections), but fillet welds alone are not permitted.
5.9.2.3 When internals are welded directly to the pressure membrane, full penetration welds shall be
used.
5.9.2.4 Permanent backing strips, permanent backing rings, and lap-type joints on the inside (process
side) surface of pressure equipment and piping are not permitted.
5.9.2.5 Threaded connections are not permitted.
5.9.3 Sour Service Materials
5.9.3.1 When CSA Z245 series pipe and components are not available, alternative materials listed in
CSA Z662 Table 5.3 may be used for sour service, subject to the limitations listed in CSA Z662
Table 5.3, and the additional requirements listed below. Given that CSA Z662 requires that
materials comply with the provisions of the sour service clause of the applicable CSA Z245
standard, when non-CSA materials are used additional testing may be needed to validate
compliance with a CSA Z245 standard.
5.9.3.2 All steel pipe and components for sour service shall meet the chemical requirements of applicable
industry standards and Table 2 below.
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5.9.3.3 When CSA Z245.1 pipe is not available, seamless and welded pipe may be ordered to API Spec
5L, PSL 2, Grades B though X60 provided the sour service requirements of CSA Z245.1, and API
Spec 5L Annex H and Annex K are met.
5.9.3.4 Substitution of a “higher” grade material for the specified grade is not permitted without prior
approval of the Owner’s Engineer.
5.9.3.5 Specified pipe or component grade shall not exceed 60 ksi (414 MPa) specified minimum yield
strength. This requirement also applies to materials with dual or multiple certifications.
5.9.3.6 Measured pipe or component yield strength shall not exceed 80 ksi (550 MPa), as shown on
material test report or supplementary test data.
5.9.3.7 Measured yield strength of base metal, as shown on material test reports or supplementary test
records, shall not exceed 80 ksi (550 MPa) or such lower value as may be imposed by the
applicable industry material standards.
5.9.3.8 Measured tensile strength of base metal, as shown on material test reports or supplementary test
records, shall not exceed 100 ksi (690 MPa) or such lower value as may be imposed by the
applicable industry material standards.
5.9.3.9 Surface hardness of material or welds at any location tested in the field shall not exceed 200
HBW, or such lesser value as stated in applicable industry material standards.
5.9.3.10 Plates, flanges, flanged fittings and forgings for sour service shall be supplied in the normalized,
normalized and tempered, or quenched and tempered condition.
5.9.3.11 Seamless pipes and wrought fittings for sour service shall be supplied in the hot finished,
normalized, normalized and tempered, or quenched and tempered condition.
5.9.3.12 When a tempering heat treatment is used during manufacture of sour service materials, the
tempering temperature shall be at least 1200°F (650°C), and minimum mechanical property
requirements of the industry specification for the pipe or component shall be maintained at the
selected tempering temperature.
5.9.3.13 The weld seam of electric welded pipe shall be fully normalized through the thickness of the pipe
after welding, and micro-hardness shall not exceed 248 HV500.
5.9.3.14 Spiral (helical) welded pipe is not permitted for sour service.
5.9.3.15 Surface restoration or repair of base metals by weld build-up is not permitted without prior
authorization from the Owner’s Engineer, for each occurrence.
5.9.3.16 Steel shall be fully killed. If steelmaking de-oxidation practice is not stated on the mill
certification, silicon content greater than 0.10% may be accepted as evidence of fully killed steel.
5.9.3.17 In addition to compliance with industry material standards, the heat analysis of sour service
carbon steels and microalloy steels, and product analyses when provided, shall be within the
limits of Table 2 below. Chemical composition provided on certification documents shall be
sufficient to assure compliance with this standard and the applicable industry standard.
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Table 2
Chemical Composition Limits for Sour Service Carbon Steels and Microalloyed Steels
(b, c)
Element Carbon Steels Microalloyed Steels
Seamless Pipe, Welded Pipe, Seamless Pipe, Welded Pipe,
Wrought Seamless Welded Wrought Seamless Welded
Fittings, Forged Fittings, and Fittings, Forged Fittings, and
Fittings and Plate Fittings and Plate
Flanges Flanges
Carbon 0.23 0.23 0.18 0.15
Manganese 1.35 1.35 1.45 1.60
Phosphorus 0.025 0.018 0.018 0.018
(a) (a)
Sulphur 0.025 0.010 0.015 0.010
Cu+Ni+Cr+Mo 0.60 0.60 0.60 0.60
Vanadium 0.030 0.030 0.08 0.08
Niobium 0.030 0.030 0.08 0.08
Titanium 0.030 0.030 0.08 0.08
Nb+V+Ti 0.035 0.035 0.080 0.080
Boron 0.0005 0.0005 0.0005 0.0005
(d)
Carbon Equivalent 0.43 0.43 0.45 0.35
Notes:
(a) Maximum 0.003% sulphur when HIC testing is required.
(b) In the above table, limits on C, Mn, Cu, Ni, Cr, Mo, V, Nb, Ti, B and CE are aimed at reducing the
risk of sulphide stress cracking, especially for welds that will not be subjected to post weld heat
treatment. Limits on P and S, and to a lesser extent limits on C and Mn, are aimed at reducing the
risk of hydrogen induced cracking and stress-orientated hydrogen induced cracking.
(c) In the above table, sour service chemical composition restrictions represent a compromise position
that considers both experience and product availability. Although tighter controls might be
technically desirable for certain product types or sour service severity level, product availability can
be negatively affected.
(d) Carbon Equivalent shall be calculated in accordance with CSA Z662 method.
5.9.3.18 Plate, welded pipe and welded fittings for sour gas pipelines shall be HIC tested unless otherwise
specified by the Owner’s Engineer. Plate, welded pipe and welded fittings for sour liquid and
multiphase pipelines do not require HIC testing unless specified by Owner’s Engineer. Seamless
pipe, wrought seamless fittings, forgings, and castings do not require HIC testing.
5.9.3.19 When HIC testing of plate, fittings made from plate, or welded pipe is required, the maximum
sulphur content shall be 0.003% and inclusion shape control technology shall be applied during
steelmaking.
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5.9.3.20 When required, HIC testing shall be conducted in accordance with NACE TM0284 using Solution
“A”, and acceptance criteria based on the average of three sections shall be:
a) Crack Length Ratio (CLR) ≤ 15 maximum
b) Crack Thickness Ratio (CTR) ≤ 5 maximum
c) Crack Surface Ratio (CSR) ≤ 2 maximum
5.9.3.21 Flange bolting shall be considered as “exposed” to sour fluids unless otherwise stated in writing
by the Owner’s Engineer.
5.9.3.22 Low alloy steel flange bolting, and other bolting exposed to sour fluids, shall comply with the
following ASTM standards and grade selections:
a) A193 Gr. B7M and A194 Gr. 2HM, when impact tested bolting is not required.
b) A320 Gr. L7M and A194 Gr. 7M, when impact tested bolting is required.
5.9.3.23 When corrosion resistant alloy bolting is required for sour service, it shall be in accordance with
NACE MR0175, and any additional requirements stated in the Material Selection Report.
5.9.4 Sour Service Material Marking and Certification
5.9.4.1 In addition to satisfying the marking and certification requirements of applicable industry
standards, all sour service materials shall be supplied with certification or equivalent statements
attesting to compliance with CSA Z245 standards or compliance with NACE MR0175. If
acceptable compliance certifications or statements are not available, compliance with applicable
standards shall be assessed by review of test data provided on material test reports.
5.9.4.2 Material test reports for pipe and components shall be reviewed for compliance and organized
with weld maps in the final job turnover package, and delivered to the Owner on or before job
completion.
5.9.4.3 Mill certificates for mainline pipe shall be reviewed for compliance and provided to the Owner on
or before job completion.
5.9.4.4 Where a material marking or material test report has been altered by a party other than the
original base metal manufacturer, the following shall be required:
a) A copy of documentation authorizing said party to perform the alterations shall be attached
to the material test report.
b) The material test report shall clearly and legibly record the nature of the alteration and the
name of the person making the alteration.
5.9.4.5 Material that cannot be confirmed compliant as stated above shall not be used.
5.9.5 Sour Service Joining and Post Weld Heat Treatment
5.9.5.1 Mainline welds, poorboy welds, tie-in welds, and final tie-in welds shall be completed using the
manual shielded metal arc welding (SMAW) process. Root pass electrodes shall be E6010
carbon steel. Hot pass, fill pass, and cap pass electrodes shall be E6010 carbon steel or E7010-
P1 low alloy steel. Vertical welds shall be completed in the downhill progression.
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5.9.5.2 Above ground field fabrication welds shall be completed using the SMAW process. Root pass
electrodes shall be E6010 carbon steel. Hot pass electrodes shall be E7010-P1 or E7018-1. Fill
and cap passes shall be completed using E7018-1. Welding progression for vertical welds shall
be suitable for the work to be performed and the electrode classification.
5.9.5.3 All filler metals shall produce carbon steel deposits that comply with the A-No. 1 analysis limits of
ASME Section IX. Filler metals producing low alloy steel deposits shall not be used, except for
E7010-P1, which may be used for hot passes only.
5.9.5.4 Welding procedures, including repair welding procedures, shall be qualified and used in a manner
that ensures compliance with CSA Z662 and this standard. Welding procedures shall be
submitted for Owner acceptance prior to the start of welding work.
5.9.5.5 Welding procedures shall include at least one cross-sectional hardness survey for each
Procedure Qualification Record (PQR) applicable to the work. These surveys shall be conducted
on suitably prepared and etched specimens removed transverse to the weld axis, as follows;
a) For welds that will be subjected to PWHT, cross-section hardness surveys shall be
conducted using any indentation hardness test method recognized by an ASTM standard,
except Brinell.
b) For welds that will not be subjected to PWHT, cross-section hardness surveys shall be
conducted in accordance with ASTM Standard E384 using indenter loads in the 250 to
1000 grams range (microhardness).
5.9.5.6 All cross-section hardness surveys shall include measurements of weld metal, heat affected
zones, and base metal.
5.9.5.7 For welds that will not be subjected to PWHT:
a) Line hardness surveys shall be taken within 1/16 inch (1.5 millimeters) of the outside and
inside surface of each cross-section, and at mid-thickness.
b) Heat affected zone (HAZ) hardness indentations shall be made within 1/50 inch (0.5
millimeter) of the fusion line.
c) Hardness tests shall be made at sufficient and suitable locations as to determine
maximum hardness of each zone.
5.9.5.8 Mainline, poorboy, tie-in, and final tie-in welds shall be free of arc strikes and arc burns. Arc
strikes and arc burns shall be removed by cutting out as a cylinder, followed by replacement of
the cylindrical section. Grinding and etching, although permitted by CSA Z662, are not permitted
for sour service applications.
5.9.5.9 Post weld heat treatment shall be performed when required by governing codes, standards, data
sheets, applicable purchasing documents, or the remaining clauses below. When post weld heat
treatment is applied to certain high strength materials, the thermal cycle shall be compatible with
base metal properties such that they are not reduced outside of specification ranges.
5.9.5.10 Pressure welds joining carbon steel piping shall be heat treated at a temperature of 1175°F±25°F
(635°C±15°C).
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5.9.5.11 Piping systems that have been heat treated shall not be exposed to a concentrated heat source
over 500°F (250°C) without an additional heat treatment cycle. Concentrated heat sources
include thermal cutting operations, welding arcs, and heat applied for straightening or correction
of misalignment. Owner reserves the right to require additional testing to validate acceptability of
mechanical properties for materials subjected to multiple heat treatments.
5.9.5.12 Welds joining microalloyed steels within the scope of this standard shall not be post weld heat
treated. Welding procedures qualified for microalloyed steels without post weld heat treatment
shall be approved by the Owner’s Engineer, and shall demonstrate effective hardness control by
careful selection of base metals and welding parameters, and by Vickers hardness testing of at
least one weld cross-section for each procedure qualification record applicable to the work.
Maximum hardness shall be 248 HV500.
5.9.5.13 When post weld heat treatment is not applied to sour service pressure-containing welds joining
carbon or microalloyed steel base metals over 3/8 inch (9.5 millimeters) thick, the following
additional requirements shall be met for welding procedure qualifications and production welding:
a) The carbon equivalent of material for production welding shall not exceed the carbon
equivalent of the material used for procedure qualification by more than 0.02.
b) Material test reports and carbon equivalent shall be provided with supporting Procedure
Qualification Records or supplementary hardness test reports.
c) The nominal thickness of material for production welding shall not exceed 1.5 times the
nominal thickness of material used for supporting Procedure Qualification Records or for
supplementary hardness test attachment reports.
d) Minimum preheat temperature, minimum inter-pass temperature, and minimum heat input
used for production welding shall not be less than that used for supporting Procedure
Qualification Records.
e) All welding shall be completed from the outside surface of the joint. Welding from the
inside is not permitted, including back welding on the inside surface (e.g., to correct root
bead defects or internal misalignment).
5.9.5.14 Where additional hardness testing is required to verify the suitability of an existing welding
procedure for sour service, complete re-qualification of the welding procedure is not required.
Hardness tests may be conducted on cross-sections removed from a sample weld prepared in
accordance with the welding procedure and the conditions specified in this standard.
5.9.5.15 Weld repair, cold straightening, or sizing operations are not permitted after final post weld heat
treatment.
5.9.6 Sour Service NDE
5.9.6.1 Radiographic film shall be Class 1 quality film per ASTM E1815.
5.9.6.2 When ASME B31.3 is used, as permitted by CSA Z662, lack of root fusion and lack of penetration
are not permitted.
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5.10 Polyethylene pipelines
5.10.1 Polyethylene pipelines shall be designed, installed and operated in accordance with Section 13.3 of
CSA Z662 - Oil and Gas Pipeline Systems and CTS 0212 - High Density Polyethylene Pipe (HDPE)
Design and Installation.
5.10.2 Exposure to certain hydrocarbons has a cumulative effect and can reduce the pressure capability of
polyethylene pipe. Continued exposure can also cause a reduction in tensile strength and swelling
due to absorption of hydrocarbons by the pipe wall. Therefore Owner’s Engineer approval is required
when polyethylene pipelines are proposed in areas where concentrations of hydrocarbon are present
in soils.
5.10.3 Operating temperature of polyethylene pipelines shall not exceed 140°F (60°C).
5.10.4 Internal working pressure shall be calculated as per equation listed in clause 13.3.2.2 of CSA Z662
with modified Service Fluid Factors as follow:
• F= 0.50 for Dry Gas Gathering
• F= 0.25 for Wet Gas Gathering
• F= 0.25 for Multiphase
• F= 0.25 for Liquid Hydrocarbons
• F= 0.50 for Oilfield Water
5.10.5 External loading analysis is required when using polyethylene pipes below ground. Ring deflection
calculation shall be conducted to confirm the amount of ovality does not exceed 5% or the pipe
manufacturer’s recommendation. Wall buckling calculation shall be conducted to confirm the total
load does not exceed the pipe manufacturer’s rated critical buckling pressure.
5.10.6 Polyethylene Fittings shall either be molded or shop fabricated. Field fabricated mitred bends are not
permitted.
5.10.7 Joining or bonding of dissimilar polyethylene materials is not permitted.
5.10.8 Polyethylene pipe is not conductive. Static electricity due to friction and fluid flows can be built up to
the extent a spark discharge may occur. Procedures for the dissipation of static electricity shall be
developed and implemented.
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6.0 AUXILIARY INFORMATION
6.1 Appendices
None.
6.2 Attachments
None.
7.0 DOCUMENTATION AND DELIVERABLES

7.1 In addition to the deliverables as listed in CTS 0126, the following additional documents shall be
submitted to the Business Unit Operation:
a) Design criteria documents as per clause 5.2.1.1 of this standard
b) Records of coating and cathodic protection systems
c) Pressure test records
7.2 For Polyethylene pipelines, the following additional records are required:
a) In addition to the Material Test Report (MTR) required by CSA Z662, Manufacturer’s Material
Certificates, certifying that the components have been manufactured, sampled, tested, and
inspected in accordance with the applicable manufacturing specifications and have met the
requirements shall be furnished for all polyethylene materials. Supporting reports showing the test
results shall also be furnished. Each certificate shall be signed by an authorized agent of the
Manufacturer.
b) Quality Assurance (QA) Manual
c) Bonding Procedure Specification (BPS) and Bonding Procedure Qualification Records (BPQR)
d) Bonder Performance Qualifications
e) Inspection and Test Plan
f) Pressure Testing Procedures
g) Fusion Bonding Inspection Checklist
h) Fusion Bonding Equipment List
i) Data Logs
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CORPORATE TECHNICAL SPECIFICATION

Number:
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CTS-0202
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Subject: Piping Material Specifications
23
Section
REV # Change
Changed
Whole
23 Changed from Corporate Technical Standard to Corporate Technical Specification
Document
Several
23 Director of Technical Standards changed to Director of Asset Integrity
Sections
CTS-0221 Removed and replaced by MRS-GS-RRE-014 (Bolted Flanged

23 2.1
Assembly Standard)
23 2.1 and 4.3 CTS-0910 (Pipeline Welding) was added
23 2.1 and 4.6 CTS-0603 (Alloy Cladding) was added
“Responsibili
23 This Section has been removed
ties” Section
23 4.1.1.1 The whole paragraph has been rephrased
23 4.1.1.2 And minimum
23 4.1.17 New clause
23 4.2.1 CTS 0214 Included
331.1.7 Paragraph has been removed because this paragraph has been deleted in
23 4.2.3 ASME B31.3 (2016). For hardness testing CTS 0903 and CTS 0910 has to be
followed.
23 4.2.3 Added CTS 0910
23 4.2.9 “and are indicated in the piping classes” added to the first line of the paragraph
100% radiography requirement for socket welds in Hydrofluoric Acid Service

23 4.2.9.2
removed.
23 4.5.5 CTS-0910 and CTS-0904 included.
Specification CTS-0202, Rev 23, Piping Material Specifications Page 3 of 23

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23 4.6 “Weld Overlay” added.
23 4.6.2 Hard facing overlay added
23 4.6.3 Sub clauses have been removed and requirements has been referred to CTS-0223

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TABLE OF CONTENTS
1.0 PURPOSE AND SCOPE .............................................................................................................. 7
1.1 PURPOSE ....................................................................................................................................................7
1.2 SCOPE ........................................................................................................................................................7
2.0 REFERENCE DOCUMENTS ........................................................................................................ 7
2.1 SUNCOR DOCUMENTS..................................................................................................................................7
2.2 INDUSTRY CODES AND STANDARDS - LOCATIONS IN CANADA AND USA ........................................................8
2.3 NOTES ON REFERENCED DOCUMENTS..........................................................................................................9
3.0 DEFINITIONS, ACRONYMS, AND SYMBOLS ........................................................................... 10
3.1 DEFINITIONS ............................................................................................................................................. 10
3.2 ACRONYMS .............................................................................................................................................. 10
3.3 SYMBOLS ................................................................................................................................................. 10
4.0 SPECIFICATION ........................................................................................................................ 10
4.1 DESIGN NOTES AND M ATERIAL SELECTION ............................................................................................... 10
4.2 INSPECTION AND NON-DESTRUCTIVE TESTING ........................................................................................... 14
4.3 WELDING ................................................................................................................................................. 15
4.4 COLOR CODING........................................................................................................................................ 15
4.5 SOUR SERVICE ......................................................................................................................................... 15
4.6 INTERNAL LINING AND WELD OVERLAY ...................................................................................................... 16
4.7 PIPING SPECIALTY ITEMS .......................................................................................................................... 16
4.8 SUBSTITUTIONS ........................................................................................................................................ 16
5.0 LIST OF APPENDICES .............................................................................................................. 17

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6.0 LIST OF ATTACHMENTS .......................................................................................................... 17
7.0 APPROVED BY .......................................................................................................................... 17

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1.0 PURPOSE AND SCOPE

1.1 Purpose
The purpose of this specification is to provide technical direction for the use and application of piping
material components listed in the piping material line classes provided in Attachments 0202A through
0202F.
1.2 Scope
1.2.1 This specification is based on ASME standards B31.1, B31.3, B31.4, and B31.12, and is for the
use of Suncor Energy Inc. and any contractors engaged in the design, construction, and
maintenance work for Suncor Energy Inc
1.2.2 This specification does not cover Pipelines to CSA Z662. For CSA Z662 piping line design criteria,
see Suncor CTS 0222.
2.0 REFERENCE DOCUMENTS
2.1 Suncor Documents
CTS 0113 PRODUCTION AND INFRASTRUCTURE ASSET TAGGING
CTS 0123 ASSET INFORMATION FORMS AND TEMPLATES
CTS 0201 PIPING DESIGN AND PLANT LAYOUT
CTS 0203 VALVES
CTS 0206 STEAM TRAP SELECTION
CTS 0212 HDPE PIPE DESIGN AND INSTALLATION
CTS 0213 POSITIVE MATERIAL IDENTIFICATION
CTS 0214 EXTERNAL COATINGS FOR ABOVE GROUND APPLICATIONS
CTS 0215 CHEMICAL CLEANING OF PIPING SYSTEMS
CTS 0216 EXTERNAL COATINGS FOR UNDERGROUND PIPING
CTS 0223 URETHANE LINED PIPE FOR SLURRY SERVICES
CTS 0227 PURCHASING REQUIREMENTS FOR PIPE, FLANGES, FITTINGS, BOLTING
AND GASKETS
CTS 0228 COLOR CODING OF PIPE AND PIPING COMPONENTS
CTS 0229 WELD OVERLAY OF PIPING FOR ABRASIVE SERVICE
CTS 0603 ALLOY CLADDING
CTS 0903 SHOP AND FIELD WELDING REQUIREMENTS
CTS 0904 MATERIALS AND FABRICATION REQUIREMENTS FOR SOUR/WET H2S
SERVICE
CTS 0910 PIPELINE WELDING

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CTS-SD-LGP-064-1 PIPING STANDARD DETAILS DRIP LEG AT CONTROL VALVE OR

EQUIPMENT
CTS-SD-LGP-064-2 PIPING STANDARD DETAILS DRIP LEG AT LOW POINT
CTS-SD-LGP-064-3 PIPING STANDARD DETAILS DRIP LEG AT HORIZONTAL RUN
CTS-SD-LGP-064-4 PIPING STANDARD DETAILS CONDENSATE HEADER
CTS-SD-LGP-064-5 PIPING STANDARD DETAILS STEAM TRAP ASSEMBLY FOR HP STEAM
SYSTEMS
CTS-SD-LGP-064-6 PIPING STANDARD DETAILS STEAM TRAP ASSEMBLY FOR LP AND MP
SYSTEMS
CTS-SD-LGP-064-7 PIPING STANDARD DETAILS SAFETY DRAIN FOR MODULATING CONTROL
CTS-SD-LGP-064-8 PIPING STANDARD DETAILS DRIP LEG SIZES AND NOTES
CTS-SD-LGP-069 JACK SCREW DATA FOR ORIFICE FLANGE
DD00-L-1-1 PIPING STANDARD DETAILS PP/PG/PT & DP PRESSURE CONNECTIONS
DD00-L-1062-1 PIPING STANDARD DETAILS TYPICAL VESSEL BRIDLES & DIRECT
MOUNTED INSTRUMENTS
DD00-L-1063-1 PIPING STANDARD DETAILS VENT AND DRAIN CONNECTIONS
GD00-L-1003-1 GUSSETING OF BRANCHES 1-1/2” AND SMALLER
GD00-L-1035-1 FLANGED THERMOWELL NOZZLE STANDARD
GD00-L-1035-2 THREADED THERMOWELL NOZZLE STANDARD
SUN-00224/MRS-GS-RRE-014 BOLTED FLANGE JOINT ASSEMBLY STANDARD
2.2 Industry Codes and Standards - Locations in Canada and USA
Equipment and materials to be installed in Canada and the USA shall be in accordance with
applicable regulations and with the following codes and industry standards:
API RP 941 Steels for Hydrogen Service at Elevated Temperatures and Pressures in
Petroleum Refineries and Petrochemical Plants
ASME B16.5 Pipe Flanges and Flanged Fittings: NPS ½ through NPS 24
ASME B16.9 Factory-Made Wrought Steel Butt-welding Fittings
ASME B16.11 Forged Steel Fittings, Socket-Welding and Threaded
ASME B16.20 Metallic Gaskets for Pipe Flanges – Ring-Joint, Spiral-Wound, and Jacketed
ASME B16.21 Non-metallic Flat Gaskets for Pipe Flanges
ASME B16.25 Butt-welding Ends
ASME B16.36 Orifice Flanges
ASME B16.47 Large Diameter Steel Flanges: NPS 26 through NPS 60

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ASME B16.48 Line Blanks

ASME B16.49 Factory-Made, Wrought Steel, Butt-welding Induction Bends for Transportation
and Distribution Systems
ASME B31.1 Power Piping
ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries
ASME B31.12 Hydrogen Piping and Pipelines
ASME B36.10M Welded and Seamless Wrought Steel Pipe
ASME B36.19M Stainless Steel Pipe
MSS SP-6 Standard Finishes for Contact Faces of Pipe Flanges and Connecting-End
Flanges of Valves and Fittings
MSS SP-75 High Strength, Wrought Butt-Welding Fittings
MSS SP-83 Class 3000 and 6000 Pipe Unions, Socket Welding and Threaded (Carbon Steel,
Alloy Steel, Stainless Steels, and Nickel Alloys)
MSS SP-95 Swage(d) Nipples and Bull Plugs
MSS SP-97 Integrally Reinforced Forged Branch Outlet Fittings – Socket Welding, Threaded,
and Buttwelding Ends
NACE MR0103 Petroleum, Petrochemical and Natural Gas Industries - Metallic Materials
Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining
Environments
NACE MR0175 Petroleum and Natural Gas Industries – Materials for use in H2S-Containing
Environments in Oil and Gas Production
NACE SP0472 Methods and Controls to Prevent In-service Environmental Cracking of Carbon
Steel Weldments in Corrosive Petroleum Refining Environments
NSF 61 Drinking Water System Components- Health Effects
ASTM Standards as listed
2.3 Notes on Referenced Documents
2.3.1 The latest applicable versions of the listed codes, standards and specifications shall apply.
2.3.2 Seller shall identify any other applicable Codes and Standards.
2.3.3 Under no circumstances shall this specification be interpreted as reducing the requirements for
regulatory Codes and Standards.
2.3.4 In the event of a conflict between this specification and the referenced codes and standards, the
more stringent requirements shall prevail. The Seller shall bring the matter to the attention of the
Owner or Owner’s Engineer for resolution.

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3.0 DEFINITIONS, ACRONYMS, AND SYMBOLS

3.1 Definitions
“Owner” – means Suncor Energy Inc.
“Owner’s Engineer” – is defined as the Engineer representing Suncor’s interests in the application of
this specification. The Owner’s Engineer may delegate authority to a designate of his/her choice to
execute or approve decisions as related to this Suncor specification.
The “Seller” – means the entity, manufacturer, fabricator, vendor or contractor that supplies the
equipment, materials or services
3.2 Acronyms
API - American Petroleum Institute
ASME - American Society of Mechanical Engineers
ASTM - American Society for Testing and Materials
CTS - Corporate Technical Standard
MSS - Manufacturers Standardization Society
NACE - National Association of Corrosion Engineers
NPS - Nominal Pipe Size
NPT - National Pipe Thread
NSF – National Science Foundation
P&ID - Piping and Instrument Diagram
PRN - Peer Review Network
PWHT - Post Weld Heat Treatment
SME - Subject Matter Expert
3.3 Symbols
Asterisk (*): Used at the beginning of a clause to indicate that the requirements of that specific clause
may be overruled by a Class of Plant document for a project.
Subscript Footnote [S#]: Used at the end of a clause to make reference to Appendix S containing
information for Suncor use only.
4.0 SPECIFICATION
4.1 Design Notes and Material Selection
This Section provides information and direction for the correct use and application of the piping line
classes. For more complete design and piping layout requirements see Suncor CTS 0201 PIPING
DESIGN AND PLANT LAYOUT.
4.1.1 Pressure and Temperature Ratings

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4.1.1.1 When a pipe or fitting wall thickness or schedule is given in the Piping Material line Classes, it
was obtained in accordance to the relevant code. Where “calc wall” is stated, a calculation in
accordance with the relevant code is required.
4.1.1.2 For flanges the intermediate range of pressure vs. temperature shall be per ASME B16.5 or
ASME B16.47, depending on size, but the maximum and minimum temperature shall be as
limited in the Pipe Class.
4.1.1.3 For carbon steel with a letter designation in the minimum temperature column of ASME B31.3
Table A-1 or ASME B31.12 Table 1X-1A, the minimum temperature is defined by the
applicable curves and notes shown in Fig. 323.2.2 A and B of ASME B31.3 or Fig Gr-2.1.2(b)
of ASME B31.12. If a required design minimum metal temperature / thickness combination
falls below the respective curve, approval for use must be obtained from the Owner’s
Engineer.
4.1.1.4 The corrosion allowance shown in the piping line class is the minimum allowed for the service
shown.
4.1.1.5 Any proposal to reduce the assigned corrosion allowance to achieve a commercially available
wall thickness requires prior approval of the Owner’s Engineer.
4.1.2 Pipe
4.1.2.1 The piping line classes show a pipe size range, however, NPS 3/8, 1-1/4, 3-1/2, 5, 7, 22, 28,
32, 34, 38, 40, 44, 46, 52, 56, and 58 pipe sizes shall not normally be used and may not be
found in ASME dimensional standards. Approval for use must be obtained and if approved a
conversion to Industry standard piping sizes shall be made at the earliest opportunity in the
design.
4.1.2.2 Minimum nominal pipe size run shall be NPS ¾. Connection to equipment, instruments,
steam tracing, and some auxiliary services may require NPS ½ which will be indicated on the
P&IDs or Suncor standard drawings.
4.1.3 Fittings
4.1.3.1 Pipe nipples shall be maximum 6 inches (150 mm) long with a schedule defined in each line
class. Short pieces of pipe used between various piping components are not considered
nipples and shall have the same wall thickness as the pipe shown in each line class.
4.1.3.2 The use of unions shall be as dictated by the individual piping line classes.
4.1.3.3 When “Victaulic” couplings are used with a ‘VIC-Ring’, as defined by each line class, the
coupling will be required to be one NPS larger than the line size.
4.1.4 Branch Connections
4.1.4.1 Standard branch connections shall be made in accordance with the branch connection tables
shown in Appendix A. Piping Line Classes will identify the relevant branch connection table
to be applied.
4.1.4.2 Specific service conditions, such as those classified as ‘Severe cyclic service’ may require
the application of a different branch table than shown in the Piping line class. Additionally,
piping stress analysis may require a different branch connection type than that shown on the

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branch table. For direction refer to Suncor CTS 0201, ‘Stress sketches and analyses’ and
‘Severe Cyclic Service’.
4.1.4.3 Proposed changes or substitutions to the branch component type will require prior approval
of the Owner’s Engineer.
4.1.5 Small Bore Connections
4.1.5.1 Threaded connections may be used only when permitted by the Piping line Class.
4.1.5.2 For instrument connections refer to Suncor standard Drawing DD00-L-1-1.
4.1.5.3 For vessel bridle connections see Suncor standard Drawing DD00-L-1062-1.
4.1.5.4 For vent and drain details see Suncor standard Drawing DD00-L-1063-1.
4.1.6 Gusseting
4.1.6.1 The requirements for Gusseting shall be as defined by Suncor standard Drawing GD00-L-
1003-1 and Suncor CTS 0201.
4.1.7 Elbows and Pipe Bends
4.1.7.1 Cold bending of NPS 2 and smaller carbon steel pipe, with a minimum bend radius of 5D may
be used with prior approval of the Owner’s Engineer.
4.1.8 Flanges
4.1.8.1 For orifice flanges the minimum rating is Class 300 and minimum size NPS 2. Orifice tap
nipples shall be minimum Schedule 160. Schedules will be defined in the Piping line Classes.
4.1.8.2 Orifice taps in CL 150 services shall be NPS ½, threaded and seal welded or socket weld.
4.1.8.3 Orifice taps in CL 300 and CL 600 shall be NPS ½ socket weld.
4.1.8.4 Orifice taps in CL 900 and higher shall be NPS ¾ socket weld.
4.1.8.5 Jack screws are required for NPS 3 and larger, installed in accordance with ASME B16.36.
Jack screws shall be to ASTM A320 Grade L7.
4.1.8.6 Class 300 flanges shall be used in Class 150 systems as required to match instrument
connections, equipment, vessel nozzles and as indicated on P&IDs.
4.1.8.7 Steel flanges mating to cast iron flanges shall be flat faced with full faced gaskets.
4.1.8.8 Slip-on flanges may be used only when specified in the line classes.
4.1.9 Valve Selection
4.1.9.1 For valve specifications see Suncor CTS 0203.
4.1.9.2 The type and attributes for valve requirements shall be as indicated on the project P&IDs.
4.1.9.3 For location, accessibility and configuration of valve stations see Suncor CTS 0201.
4.1.10 Bleed Rings
4.1.10.1 The use of Bleed rings shall be kept to a minimum, limited to maximum Class 600 flange
rating and require Owner’s Engineer approval.

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4.1.11 Thermowell Connections

4.1.11.1 The requirement for a Thermowell will be shown on the Project P&IDs. For Thermowell
connections, see Suncor CTS 0201 for design requirements and standard drawings GD00-L-
1035-1 and GD00-L-1035-2 for installation.
4.1.12 Gaskets
4.1.12.1 Gasket types shall be in accordance with the piping material line classes. Gaskets shall be in
accordance with ASME B16.20 and ASME B16.21.
4.1.13 Blanks and Spacers
4.1.13.1 Spectacle blanks or blanks and spacers shall be specified in accordance with ASME
Standard B16.48 latest addition.
4.1.13.2 The design of Spectacle blanks or blanks and spacers to ASME B16.48 have a 0.0625 inch
corrosion allowance and are intended primarily for use as maintenance blinds. When used as
an operating process blind in a line class with a specified corrosion allowance greater than
0.0625 inch, the following shall apply:
a. Obtain Owner’s Engineer approval for use. If engineering approval is not granted;
b. Identify the spectacle blank or blank with spacer as a Piping Specialty Item and calculate
the required thickness, or;
c. Consider adding an Isolation valve.
d. Blanks and spacers not covered by ASME B16.48 shall be Piping Specialty Items, with
thickness calculations to the respective ASME code.
e. The selection of spectacle blinds, blanks and spacers must consider para. 4.1.1.3 of this
specification.
4.1.14 Strainers
4.1.14.1 Requirements for Temporary and Permanent Strainers shall be shown on P&IDs. Strainers
shall be tagged items in accordance with Suncor CTS 0113 and shall be specified on a data
sheet as per Suncor CTS 0123.
4.1.15 Positive Isolation
4.1.15.1 The requirements for positive Isolation shall be shown on P&IDs and shall follow Suncor CTS
0201.
4.1.16 Painting
4.1.16.1 The requirement for painting shall be assessed based on environmental conditions to which
piping systems are exposed. Painting requirements are detailed in Suncor CTS 0214.
4.1.17 Material Selection for Hydrogen Service
4.1.17.1 Materials selection for new designed piping in hydrogen service shall take HTHA resistance
into account. The following safety margins shall be added to operating temperature and
hydrogen partial pressure when using Fig. 1 of API RP 941(last edition).
a. For CS (welded with no PWHT), use 25 psi (172 kPa) hydrogen partial pressure and
50°F (28°C) temperature design margins for selection of materials.

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b. For CS (non-welded or welded with PWHT), 1Cr-0.5Mo, 1.25Cr-0.5Mo, 2.25Cr-1Mo,

2.25Cr-1Mo-V, and 3Cr-1Mo, use 50 psi (344 kPa) hydrogen partial pressure and 50°F
(28°C) temperature design margins for selection of materials.
4.2 Inspection and Non-Destructive Testing
4.2.1 External pipe coatings shall be tested in accordance with Suncor CTS 0214. For underground
piping, follow CTS 0216.
4.2.2 For Pipe Classes specified as “Sour Service (NACE)” see section 4.5
4.2.3 Hardness testing shall follow CTS 0903 or CTS 0910 requirements
4.2.4 Positive Material Identification (PMI) shall be performed as required by Suncor CTS 0213.
4.2.5 Ultrasonic examination may be used to substitute for radiography at the discretion of the Owner’s
Engineer. Acceptance criteria shall be as per the applicable piping code. When Time of Flight
Diffraction (TOFD) is proposed for examination of weldments, the acceptance criteria shall be
reviewed by the Owner’s Engineer.
4.2.6 All ASME B31.3 piping examination shall meet the acceptance criteria for “Normal Fluid Service”
unless specified otherwise.
4.2.7 The requirements of Progressive Sampling for Examination as defined in ASME B31.3 Para.
341.3.4, shall also be required for ASME B31.1 piping.
4.2.8 Piping pressure testing shall be completed in accordance with Suncor CTS 0205.
4.2.9 Inspection Classes have been established based on the criticality of service for all piping systems
and are indicated in the piping classes. Fluid service, corrosion allowance, piping design
temperature and pressure have been considered in the application of the required Inspection Class
and corresponding extent of examination. The examination requirements for each Inspection Class
as indicated on the individual Piping Line Classes are:
4.2.9.1 Class I or S1
• 100% visual examination shall be carried out on the welded joints and components.
• 10% random radiography and 10% MT or 100% PT is required on welds specified as
“others” on ASME B31.1 Table 136.4.
• The non-destructive examination requirements of ASME B31.1 Table 136.4 shall be met
based on the design pressure or temperatures.
• 100% RT plus 100% MT or 100% PT required on Boiler External Piping Welds as defined
in ASME B31.1
• With Owner’s Engineer approval, Ultrasonic (UT) Examination may be used in lieu of
radiography.
4.2.9.2 Class II or SII
• Visual examination shall be carried out on 100% of the welded joints and components.
• 100% radiography is required on all girth, longitudinal and mitre groove welds including
“sweep-o-let” branch welds.
• Magnetic particle or liquid penetrant examination shall be carried out on all welds not
radiographed.

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radiography.
4.2.9.3 Class III or SIII
• 10% random radiography shall be carried out on all girth and miter groove welds.
• Magnetic particle or liquid penetrant examination shall be carried out on all P3 through P8
welds, including girth and miter groove welds, not radiographed.
radiography.
4.2.9.4 Class IV or SIV
• 5% random radiography shall be carried out on all girth and miter groove welds.
radiography.
4.2.9.5 Class V or SV
• Visual examination shall be carried out on 100% of the joints and components for cuts,
gouges, and scratches.
• O.D. Surface – maximum allowable imperfection depth shall be less than 10% of wall
thickness.
• I.D. Surface – no cuts, gouges or scratches of any size permitted.
• HDPE piping shall also be installed and tested in accordance with CTS 0212, HDPE Pipe
Design and Installation.
4.2.10 For “Severe Cyclic service” additional inspection will be required. Refer to Suncor CTS 0201.
4.3 Welding
For welding requirements refer to Suncor Corporate Technical Specifications 0903 – “Shop and Field
Welding Requirements” and 0910 – “Pipeline Welding”.
4.4 Color Coding
The color coding of piping components shall be in accordance with Suncor CTS 0228.
4.5 Sour Service
4.5.1 The individual piping line classes will identify services containing H2S and requirements for the
application of specific NACE standards and their recommendations for material qualification and
selection. CTS 0904 must be considered for additional material and fabrication requirements to
those stated in the individual line classes.
4.5.2 The following NACE standards will apply, when noted, in the line classes:
4.5.2.1 NACE MR0175/ISO 15156 – Materials for use in H2S containing environments in Oil & Gas
production.
Part 1 – General principles for selection of cracking resistant materials

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Part 2 – Cracking resistant carbon and low alloy steels and the use of cast iron
Part 3 – Cracking resistant corrosion resistant alloys and other alloys
4.5.2.2 NACE MR0103 – Materials resistant to sulphide stress cracking in corrosive petroleum
refining environments.
4.5.2.3 NACE SP0472 – Methods and controls to prevent in-service environmental cracking of
carbon steel weldments in corrosive petroleum refining environments.
4.5.3 The above NACE standards address acceptable materials, their chemical compositions, and
maximum hardness and heat treatment conditions. Heat treatment and hardness values for piping
materials used in both sour and non-sour services are shown in Suncor CTS 0227 – “Purchasing
requirements for pipe, flanges, fittings, bolting and gaskets”.
4.5.4 Selected bolting grades are defined in each piping line class.
4.5.5 Prevention of sulphide stress cracking in carbon steel (P-No. 1) material weldments shall be in
accordance with CTS-0903 for piping under ASME B31.3 and CTS-0910 for piping under ASME
B31.4. For material and fabrication requirements in wet H2S/Sour service follow CTS-0904.
4.5.6 Valves suitable for use in services containing H2S are shown with the suffix ‘-N’ in the piping line
classes and detailed in Suncor CTS 0203.
4.6 Internal Lining and Weld Overlay
4.6.1 Piping line classes show the type of lining required with notes on application and jointing.
4.6.2 For details on hard facing weld overlays refer to Suncor CTS 0229.
4.6.3 For urethane lined pipe for slurry services refer to CTS 0223.
4.6.4 For corrosion resistance weld overlay refer to CTS 0603
4.7 Piping Specialty Items
4.7.1 Piping Specialty Items are engineered items not found in the piping material line classes.
4.7.2 Piping Specialty Items require an engineering data sheet for enquiry and purchase. The data sheet
will, as a minimum, include information on the design/operating conditions, flow rates, material
requirements, connection methods and other relevant data.
4.7.3 Piping Specialty Items generally fall into two categories:
4.7.3.1 Non process related where information required can be located in line designation tables and
piping material line classes.
4.7.3.2 Process related items, where additional information to that required for Category 1 above is
necessary for enquiry/purchase.
4.8 Substitutions
4.8.1 Any material or component substitution will require written approval from the Owner’s Engineer. All
approved substitutions that differ from the piping material line class shall be marked with an
asterisk (*) on the design bill of materials.

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APPENDIX A
(PAGE 1 OF 5)
BRANCH CONNECTION TABLE 1
OLET = Sockolet or Thredolet per line class

WOL = Weldolet (integrally reinforced branch fitting)
RT = Reducing tee or tee with reducer
TEE = Equal branch tee
¾ TEE
1 RT TEE
1½ RT RT TEE
2 OLET OLET OLET TEE
3 OLET OLET OLET RT TEE
4 OLET OLET OLET RT RT TEE
6 OLET OLET OLET WOL WOL RT TEE
8 OLET OLET OLET WOL WOL WOL RT TEE
10 OLET OLET OLET WOL WOL WOL WOL RT TEE
HEADER NPS
12 OLET OLET OLET WOL WOL WOL WOL RT RT TEE

14 OLET OLET OLET WOL WOL WOL WOL WOL RT RT TEE
16 OLET OLET OLET WOL WOL WOL WOL WOL WOL RT RT TEE
18 OLET OLET OLET WOL WOL WOL WOL WOL WOL WOL RT RT TEE
20 OLET OLET OLET WOL WOL WOL WOL WOL WOL WOL WOL RT RT TEE
24 OLET OLET OLET WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
30 OLET OLET OLET WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
36 OLET OLET OLET WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
42 OLET OLET OLET WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
48 OLET OLET OLET WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
60 OLET OLET OLET WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT RT TEE
72 OLET OLET OLET WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT RT RT TEE
¾ 1 1½ 2 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48 60 72
BRANCH NPS
Note 1: A stub-in with a reinforcing pad can be considered for headers NPS 30 and larger with Approval
from Owner’s Engineer.

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Number:
CTS-0202
Revision:
23
(PAGE 2 OF 5)

Note - For Threaded branch connections, follow the line class
¾ TEE
1 RT TEE
1½ RT RT TEE
2 WOL WOL RT TEE
3 WOL WOL WOL RT TEE
4 WOL WOL WOL RT RT TEE
6 WOL WOL WOL WOL WOL RT TEE
HEADER NPS
8 WOL WOL WOL WOL WOL RT RT TEE

10 WOL WOL WOL WOL WOL WOL RT RT TEE
12 WOL WOL WOL WOL WOL WOL WOL RT RT TEE
14 WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
16 WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT TEE
18 WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
20 WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT TEE
24 WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
30 WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
¾ 1 1½ 2 3 4 6 8 10 12 14 16 18 20 24 30
BRANCH NPS

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Number:
CTS-0202
Revision:
23
(PAGE 3 OF 5)
SOL = Sockolet
¾ TEE
1 RT TEE
1½ RT RT TEE
2 SOL SOL SOL TEE
3 SOL SOL SOL RT TEE
4 SOL SOL SOL RT RT TEE
6 SOL SOL SOL WOL WOL RT TEE
8 SOL SOL SOL WOL WOL WOL RT TEE
10 SOL SOL SOL WOL WOL WOL WOL RT TEE
HEADER NPS
12 SOL SOL SOL WOL WOL WOL WOL RT RT TEE

14 SOL SOL SOL WOL WOL WOL WOL RT RT RT TEE
16 SOL SOL SOL WOL WOL WOL WOL WOL RT RT RT TEE
18 SOL SOL SOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
20 SOL SOL SOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
24 SOL SOL SOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
30 SOL SOL SOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
36 SOL SOL SOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
42 SOL SOL SOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT TEE
48 SOL SOL SOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT RT TEE
60 SOL SOL SOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL WOL RT RT RT RT TEE
¾ 1 1½ 2 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48 60
BRANCH NPS

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Number:
CTS-0202
Revision:
23
(PAGE 4 OF 5)
SWL = Sweepolet (integrally reinforced contoured insert welded branch fitting)

VSL = Vesselet ((integrally reinforced contoured insert welded branch fitting)
¾ TEE
1 RT TEE
1½ RT RT TEE
2 RT RT RT TEE
3 RT RT RT RT TEE
4 VSL VSL RT RT RT TEE
6 VSL VSL SWL SWL RT RT TEE
8 VSL VSL SWL SWL SWL RT RT TEE
10 VSL VSL SWL SWL SWL SWL RT RT TEE
HEADER NPS
12 VSL VSL SWL SWL SWL SWL SWL RT RT TEE

14 VSL VSL SWL SWL SWL SWL SWL RT RT RT TEE
16 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT TEE
18 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT TEE
20 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT RT TEE
24 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT RT RT TEE
30 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT RT RT RT TEE
36 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT RT RT RT RT TEE
42 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT RT RT RT RT RT TEE
48 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT RT RT RT RT RT RT TEE
60 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT RT RT RT RT RT RT RT TEE
¾ 1 1½ 2 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48 60
BRANCH NPS

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Number:
CTS-0202
Revision:
23
(PAGE 5 of 5)
VSL* = Vesselet or equal tee with a swage

SWL = Sweepolet (integrally reinforced branch fitting with a welded outlet)
VSL = Vesselet ((integrally reinforced branch fitting with a socket weld outlet)
¾ TEE
1 RT TEE
1½ RT VSL* TEE
2 VSL VSL* RT TEE
3 VSL VSL* RT RT TEE
4 VSL VSL RT RT RT TEE
HEADER NPS
6 VSL VSL SWL SWL RT RT TEE

8 VSL VSL SWL SWL SWL RT RT TEE
10 VSL VSL SWL SWL SWL SWL RT RT TEE
12 VSL VSL SWL SWL SWL SWL SWL RT RT TEE
14 VSL VSL SWL SWL SWL SWL SWL RT RT RT TEE
16 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT TEE
18 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT TEE
20 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT RT TEE
24 VSL VSL SWL SWL SWL SWL SWL RT RT RT RT RT RT RT TEE
¾ 1 1½ 2 3 4 6 8 10 12 14 16 18 20 24
BRANCH NPS

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Number:
CTS-0202
Revision:
23
ATTACHMENT 1 – PIPING LINE CLASSES OIL SANDS & INSITU – TAR ISLAND & FIREBAG
ATTACHMENT 0202A
ATTACHMENT 2 – PIPING LINE CLASSES OIL SANDS & INSITU – MACKAY RIVER 1
ATTACHMENT 0202B
ATTACHMENT 3 – PIPING LINE CLASSES R&M – EDMONTON, MONTREAL, MISSISSAUGA,

DISTRIBUTION
ATTACHMENT 0202C
ATTACHMENT 4 – PIPING LINE CLASSES R&M SARNIA

ATTACHMENT 0202D
ATTACHMENT 5 – PIPING LINE CLASSES SEUSA/COMMERCE CITY

ATTACHMENT 0202E
ATTACHMENT 6 – PIPING LINE CLASSES SELC/PIPELINES

ATTACHMENT 0202F

Page:
1 of 2
LINE SPECIFICATION: SERVICE:
CAZ LIME SLURRY

REV: 19 DATE: 1-Feb-13
ASME CLASS: 150 RF

MATERIAL: CARBON STEEL
TEMPERATURE LIMITS: -20 ºF to 240 ºF MAX (-29 ºC to 116 ºC MAX)
PRESSURE LIMITS: ASME B16.5 (NOTE 2)
DESIGN CODE: ASME B31.3
CORROSION ALLOWANCE: 0.0625" (1.6 MM)
STRESS RELIEVING: NOT REQUIRED
INSPECTION CLASS: III
BRANCH TABLE: 1
VENT AND DRAIN DETAIL: 1
ITEM SIZE (INCH) DESCRIPTION NOTE
PIPE 0.75 - 1.5 ASTM A106 GR B, PE, SCH-80, ASME B36.10M
2 - 12 ASTM A106 GR B, SCH-STD, ASME B36.10M
FLANGES 0.75 - 1.5 ASTM A105N, CL150, SW, RF, SCH-80, ASME B16.5
2 - 12 ASTM A105N, CL150, WN, RF, SCH-STD, ASME B16.5
0.75 - 12 ASTM A105N, CL150, BLIND, RF, ASME B16.5
0.75 - 1.5 ASTM A105N, CL300, SW, RF, SCH-80, ASME B16.5
2 - 12 ASTM A105N, CL300, WN, RF, SCH-STD, ASME B16.5
0.75 - 12 ASTM A105N, CL300, BLIND, RF, ASME B16.5
ELBOWS 0.75 - 1.5 45, ASTM A105N, CL3000, SW, ASME B16.11
2 - 12 45, ASTM A234 WPB, SCH-STD, ASME B16.9
0.75 - 1.5 90, ASTM A105N, CL3000, SW, ASME B16.11
2 - 12 90, ASTM A234 WPB, SCH-STD, ASME B16.9
TEES 0.75 - 1.5 x 0.75 - 1.5 ASTM A105N, CL3000, SW, ASME B16.11
2 - 12 x 2 - 12 ASTM A234 WPB, SCH-STD, ASME B16.9
REDUCERS 3 - 12 x 2 - 10 CONCENTRIC, ASTM A234 WPB, SCH-STD, ASME B16.9

3 - 12 x 2 - 10 ECCENTRIC, ASTM A234 WPB, SCH-STD, ASME B16.9
CAPS 0.75 - 1.5 ASTM A105N, CL3000, SW, ASME B16.11

0.75 - 1.5 ASTM A105N, CL3000, THRD, ASME B16.11
2 - 12 ASTM A234 WPB, SCH-STD, ASME B16.9
NIPPLES 0.75 - 1.5 ASTM A106 GR B, PBE, SCH-160, 3 INCH LG, ASME B36.10M
0.75 - 1.5 ASTM A106 GR B, PBE, SCH-160, 6 INCH LG, ASME B36.10M
0.75 - 1.5 ASTM A106 GR B, POE/TOE, SCH-160, 3 INCH LG, ASME B36.10M
0.75 - 1.5 ASTM A106 GR B, POE/TOE, SCH-160, 6 INCH LG, ASME B36.10M
SWAGES 1 - 1.5 x 0.75 - 1 CONCENTRIC, ASTM A234 WPB, PBE, SCH-80, MSS SP-95
2 - 4 x 0.75 - 1.5 CONCENTRIC, ASTM A234 WPB, BLE/PSE, SCH-STDx80, MSS SP-95
1 - 1.5 x 0.75 - 1 ECCENTRIC, ASTM A234 WPB, PBE, SCH-80, MSS SP-95
2 - 4 x 0.75 - 1.5 ECCENTRIC, ASTM A234 WPB, BLE/PSE, SCH-STDx80, MSS SP-95
OLETS 2 - 12 x 0.75 - 1.5 SOCKOLET, ASTM A105N, CL3000, MSS SP-97

2 - 12 x 0.75 - 1.5 ELBOLET, THRD, ASTM A105N, CL3000 1
3 - 12 x 2 ELBOLET, BW, ASTM A105N, SCH-STD 1
6 - 12 x 2 - 6 WELDOLET, ASTM A105N, SCH-STD, MSS SP-97
COUPLINGS 0.75 - 1.5 ASTM A105N, CL3000, SW, ASME B16.11
UNIONS 0.75 - 1.5 ASTM A105N, CL3000, SW, MSS SP-83
PLUGS 0.75 - 1.5 ASTM A105N, ROUND HEAD, ASME B16.11
BLANKS 0.75 - 12 SPECTACLE BLANK, CL150, RF, ASTM A516 GR 70N, ASME B16.48
SUNCOR STANDARD - 0202

Page:
2 of 2
LINE SPECIFICATION: SERVICE:
CAZ LIME SLURRY

REV: 19 DATE: 1-Feb-13
ASME CLASS: 150 RF

MATERIAL: CARBON STEEL
TEMPERATURE LIMITS: -20 ºF to 240 ºF MAX (-29 ºC to 116 ºC MAX)
PRESSURE LIMITS: ASME B16.5 (NOTE 2)
DESIGN CODE: ASME B31.3
CORROSION ALLOWANCE: 0.0625" (1.6 MM)
STRESS RELIEVING: NOT REQUIRED
INSPECTION CLASS: III
BRANCH TABLE: 1
VENT AND DRAIN DETAIL: 1
ITEM SIZE (INCH) DESCRIPTION NOTE
BOLTING ALL ASTM A193 GR B7 WITH A194 GR 2H NUTS
GASKETS 0.75 - 12 316 SP WOUND, CL150, FLEX GRAPHITE, C.STL CR, 316 IR, ASME B16.20
0.75 - 12 316 SP WOUND, CL300, FLEX GRAPHITE, C.STL CR, 316 IR, ASME B16.20
VALVES
BALL 0.75 - 1.5 VBA0602-TH - CL600 THRD, FULL BORE, PTFE SEATS, LEVER OP, API 608
2-6 VBA0151-RF - CL150 RF, REDUCED BORE, RPTFE SEATS, LEVER OP, API 608
8 - 12 VBA0151-RF-GO - CL150 RF, REDUCED BORE, RPTFE SEATS, GEAR OP, API 608
2-6 VBA0153-RF - CL150 RF, REDUCED BORE, METAL SEATS, LEVER OP, API 608
8 - 12 VBA0153-RF-GO - CL150 RF, REDUCED BORE, METAL SEATS, GEAR OP, API 608
GATE 0.75 - 1.5 VGA0031#8-SW - CL800 SW, HANDWHEEL OP, API 602
0.75 - 1.5 VGA0031#8-SW/TH - CL800 SW x THRD, HANDWHEEL OP, API 602
2 - 12 VGA0041#8-RF - CL150 RF, HANDWHEEL OP, API 600
0.75 - 1.5 VGA0315#8-RF - CL300 RF, HANDWHEEL OP, API 602
2-3 VGA0054#8-RF - CL300 RF, HANDWHEEL OP, API 600
GLOBE 0.75 - 1.5 VGL0131#8-SW - CL800 SW, HANDWHEEL OP, API 602
2-6 VGL0141#8-RF - CL150 RF, HANDWHEEL OP, ASME B16.34
CHECK 0.75 - 1.5 VCH0231#8-SW - CL800 SW, PISTON TYPE, SPRING LOADED, API 602
2 - 12 VCH0241#8-RF - CL150 RF, SWING TYPE, API 594
PLUG 0.75 - 3 VPL0160-RF - CL150 RF, SHORT PATTERN, LEVER OP, GENERALLY TO API 599
PINCH 2-6 VDP0002-RF - CL150 RF, HANDWHEEL OP, ASME B16.34 2
NOTES:
1. Dimensions shall be to the selected manufacturer's standard.
2. Pinch Valves have a limited maximum working pressure and require Engineering approval for use.
SUNCOR STANDARD - 0202

2016/03/01
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Number:
Department: ENTERPRISE TECHNICAL 0205
Revision:
Subject: PIPING PRESSURE LEAK TESTS
9

Section
REV # Change
Changed
9 1.1 Deleted “vendor packages”
9 1.2.3 Added new clause
9 1.2.4 Added word “building”
9 1.3 Added phrase “and local authority regulations” to the second paragraph
9 3.1 Deleted “local regulatory regulations”
Converted corporate standards from STD to CTS. Added CTS 0060. Deleted STD
9 3.2
0212.
9 3.3 Deleted ABSA AB-522. Added API 570, ASTM E-1003, NFPA 13, NFPA 24.
Added the phrase “registered professional engineer employed directly by Suncor or
9 4.1
its designated representative” to the definition of Owner’s Engineer
Added the phrase “employed directly by Suncor or its designated representative” to
9 4.1 the definition of Owner’s Inspector. Added the definition “Minimum pressurization
temperature”. Added definition of Maximum working pressure of a component”.
9 4.2 Added acronyms ASTM and CTS
Revised “the following sources contain information pertaining to pressure testing” to
9 5.1
“information pertaining to pressure testing is contained in the following sources:”
9 5.1.4 Added second paragraph
9 5.2.1 Added word “local”
9 5.2.3 Added “(or Business Unit equivalent)”
Added sentence “Piping pressure leak tests involve the potential release of stored
9 5.2.4
energy that could cause property damages and personnel injuries.”
9 5.2.5 Revised the pressure gauge accuracy from Grade 2A (±0.5%) to Grade A (±1.0%)
9 5.2.6 Revised “a recognized authority” to ”the Owner’s Inspector”
9 5.2.7 Revised paragraph
9 5.2.10 Deleted word “only”. Replace “shall” with “but”.
9 5.2.11 Revised item d) to add rupture discs
9 5.2.12 Clarified internals to valve internals
9 5.2.13 Delete “All”. Added “if specified”.
Standard 0205 Rev 9 Piping Pressure Leak Tests Page 3 of 26

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Number:
Revision:
9
9 5.3.2 Deleted “pumps” from the list
9 5.3.3 Added the last sentence
9 5.3.6 Added new paragraph
9 5.3.7 Add new paragraph

Revised “as described in the Code for Power Piping ASME B31.1” to “at a pressure
9 5.4.2
as defined in clause 137.4.5 of the Code B31.1”
Revised “the maximum allowable working pressure of its limiting component. This
limiting component can be flange or pipe maximum allowable working pressure” to
9 5.4.3
“the lower of either the maximum working pressure of the connecting flanges or the
maximum working pressure of the limiting system component at 100°F (38°C)”
Revised “not less than 1.2 nor more than 1.5 times the design pressure of the piping
9 5.4.4
system” to “in accordance with clause 137.5.5 of the Code B31.1”
Revised “not less than 1.1 nor more than 1.33 times the design pressure” to “in
9 5.4.5
accordance with clause 345.5.4 of the Code B31.3”
9 Previous clause 5.4.6 moved to clause 5.9.1

Added sentence “Test pressure for service test shall be the maximum operating
9 5.4.6
pressure of the system.”
Added phrase “(service test package for Category D services)” and the second
9 5.5.1
sentence
Replaced “shall” with “should. Added item c “Line Designation Table”. Correct “line
9 5.5.3
welds” to “weld lines” in item g.
9 5.5.4 Replaced “shall” with “should”
9 5.6.5 Revised “STD” to “CTS”

Revise “test medium temperature” to “metal temperature”. Revise “30°F (16°C)
above the MDMT of the piping components in the system having the highest MDMT”
to “30°F (16°C) above the minimum design metal temperature (MDMT) of the piping
9 5.7.2 components in the system having the highest MDMT for pipes wall thickness of more
than 2 inches (50 millimeters), and 10°F (6°C) above for pipe wall thickness of 2
inches (50 millimeters) or less. Added the second sentence. Relocate the previous
sentence “After testing,…..enter the piping.” To clause 5.8.4.
Added phrase “as defined in ASME Code of Pressure Piping B31.3 Figure
323.2.2B”. Revised “Application of the corresponding reduction in minimum design
9 5.7.3 metal temperature as determined by ASME B31.3, Figure 323.2.2B may be done to
reduce the hydrostatic leak test temperature. The new minimum hydrostatic leak test
temperature shall be 30°F (16°C) above the temperature determined by using ASME
B31.3, Figure 323.2.2B” to “the corresponding reduction in MDMT as determined by
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Number:
Revision:
9
the same figure may be applied to reduce the hydrostatic leak test temperature. The
new minimum hydrostatic leak test temperature in accordance with paragraph 5.7.2
can be calculated using this reduced MDMT”
9 5.7.4 Added phrase “without prior approval from the Owner’s Engineer”
9 5.7.6 Added “and the local Environment, Health and Safety Advisor”
9 5.7.7 Added words “hydrostatic leak” and last sentence
9 Deleted previous clause 5.7.8.
9 5.8.4 New clause. Moved from clause 5.7.2. Added last sentence.
Relocated paragraph from previous paragraph 5.4.6. Deleted sentence “(A copy of
9 5.9.1 the formulae for both Imperial units and SI units is presented in Appendix C for
information.)”. Rounded “1,236,890 ft-lb” to “1,237,000 ft-lb”
9 5.9.2 Added phrase “Article 5.1, Mandatory Appendix III”
9 5.9.4 Added paragraph
9 5.9.5 c) Revised “held as per” to “held for a length of time as per paragraph”
9 5.10 Added section
9 5.10.2 Corrected word “testes” to” tests”
9 5.11 Added section
9 5.11.1 Corrected word “testes” to” tests”

Revised “ASME” to “ASME Boiler & Pressure Code”. Revised “B31.1” to “ASME
9 5.12.1
Code of Pressure Piping B31.1” Revised “PARA” to “section”
Revised “must” to “shall”. Revised “a maximum metal temperature of 120°F (50°C)”
9 5.12.2
to “the metal temperature shall be 120°F (50°C) maximum”
9 5.12.3 Revised “Sect. I” to “Section I”
9 5.16.3 Revised “item” to “paragraph”
9 6.1 Deleted Appendix C

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Number:
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TABLE OF CONTENTS
1.0 PURPOSE & SCOPE .....................................................................................................................................8
1.1 PURPOSE .....................................................................................................................................................8

1.2 SCOPE .........................................................................................................................................................8
1.3 PRECAUTIONS...............................................................................................................................................8
2.0 RESPONSIBILITIES ......................................................................................................................................8
2.1 ACCOUNTABILITY AND APPROVAL...................................................................................................................8

2.2 REVISIONS AND UPDATES ..............................................................................................................................8
2.3 INTERPRETATION...........................................................................................................................................9
2.4 IMPLEMENTATION ..........................................................................................................................................9
3.0 REFERENCES & PREREQUISITES .............................................................................................................9
3.1 PREREQUISITES ............................................................................................................................................9

3.2 SUNCOR STANDARDS AND DRAWINGS............................................................................................................9
3.3 RELEVANT / REFERENCED PUBLICATIONS, CODES AND STANDARDS ................................................................9
4.1 DEFINITIONS .............................................................................................................................................. 10

4.2 ACRONYMS ................................................................................................................................................ 11
5.0 STANDARD ................................................................................................................................................. 11
5.1 INFORMATION SOURCES ............................................................................................................................. 11

5.2 PRESSURE TESTING ................................................................................................................................... 11
5.3 SPECIAL CONDITIONS ................................................................................................................................. 13
5.4 TEST PRESSURE ........................................................................................................................................ 14
5.5 SYSTEM PACKAGE FOR PRESSURE LEAK TESTS .......................................................................................... 14
5.6 PREPARATION OF SYSTEMS FOR TESTING ................................................................................................... 16
5.7 TEST MEDIUM ............................................................................................................................................ 16
5.8 HYDROSTATIC LEAK TESTING GUIDELINES .................................................................................................. 17
5.9 PNEUMATIC LEAK TESTING GUIDELINES ...................................................................................................... 18
5.10 SERVICE TESTING GUIDELINES ................................................................................................................... 19
5.11 ALTERNATE LEAK TEST .............................................................................................................................. 19

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5.12 ADDITIONAL REQUIREMENTS FOR BOILER EXTERNAL PIPING ........................................................................ 19

5.13 TESTING REQUIREMENT FOR PIPELINES ...................................................................................................... 19
5.14 TESTING REQUIREMENT FOR FIRE PROTECTION PIPING ............................................................................... 19
5.15 INSPECTION ............................................................................................................................................... 20
5.16 POST TEST PROCEDURE ............................................................................................................................ 20
6.1 APPENDICES .............................................................................................................................................. 20

6.2 ATTACHMENTS ........................................................................................................................................... 20
7.0 DOCUMENTATION AND DELIVERABLES ............................................................................................... 21
7.1 REPORTS AND RECORDS ............................................................................................................................ 21
8.0 APPROVED BY ........................................................................................................................................... 21
APPENDIX A – TEST BLANK THICKNESS REQUIREMENTS ..................................................................... 22

APPENDIX B - ALTERNATIVE TESTING FOR PIPING REPAIRS, MODIFICATIONS AND TIE-INS .......... 23
ATTACHMENT A – PRESSURE TEST CERTIFICATE .................................................................................. 26

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1.0 PURPOSE & SCOPE
1.1 Purpose
The purpose of this standard is to establish uniform requirements for the pressure leak testing of above
ground and below ground piping. These requirements shall apply to shop, module, and on-site work.
1.2 Scope
1.2.1 This standard applies to all metallic process and utilities piping within a facility that is regulated by
statutory authority within the jurisdiction in which the operating facility is located.
1.2.2 This standard does not cover any non-metallic piping systems. Testing of HDPE systems shall be
conducted in accordance with CTS 0212 High Density Polyethylene Pipe (HDPE) Design and
Installation.
1.2.3 This standard does not cover any non-pressurized sewer systems piping. Testing of non-
pressurized sewer piping shall be conducted in accordance with CTS 1517 Design of Clean Water,
Industrial and Chemical Sewers Systems and Culverts.
1.2.4 This standard does not cover any building utility services piping within the perimeter of any
commercial buildings including office buildings and control rooms. Pressure testing of these piping
systems shall follow the respective Codes and Regulations.
1.2.5 Use of this standard for Business Services, International and Offshore and other Business Units
involved in development of technical standards is recommended.
1.3 Precautions
This standard and associated template is mandated for Corporate Technical Standards. The user of this
document must have prior knowledge and understanding of corporate and legislative direction, to use
standards to promote the consistent, safe, reliable, and cost-effective management of Suncor’s
Users of this Standard must adhere to all relevant Business Unit Procedures and local authority specific
regulations.

The Director of Technical Standards is responsible for approving this document and is accountable to
ensure this standard is effectively used for projects and existing plants.

Discipline Subject Matter Expert (SME) is responsible for updating and revising this standard in
consultation with Peer Review Network (PRN) members and Director of Technical Standards based on

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Number:
Revision:
9
2.3 Interpretation
Interpretation and guidance shall be provided by the applicable Peer Review Network member for the
business unit or the applicable Suncor Project or Discipline Engineer for a project. The Subject Matter
Expert responsible for this technical standard may be consulted by the applicable personnel for any
interpretation of the requirements within this standard. Director of Technical Standards shall have the
final decision in case of conflict.
2.4 Implementation
3.1 Prerequisites
Implementation of this standard requires the knowledge of the applicable Codes and Regulations, facility
specific safe work practices, and local environmental regulations where the facility is located.

CTS 0060 Fire Prevention and Protection
CTS 0202 Piping Material Specifications
CTS 0211 Installation Instructions for Spring Supports

American Petroleum Institute
API 570 Piping Inspection Code: In-service Inspection, Rating, Repair, and Alteration of Piping
Systems
American Society of Mechanical Engineers
ASME B16.48 Line Blanks
ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries
ASME B31.8 Gas Transmission and Distribution Piping Systems
ASME B40.100 Pressure Gauges and Gauge Attachments
ASME PCC-2 Repair of Pressure Equipment and Piping
ASME Section I Rules for Construction of Power Boilers
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Number:
Revision:
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ASTM International
ASTM E1003 Hydrostatic Leak Testing
Canadian Standards Association
CSA B51 Boiler, Pressure Vessel and Pressure Piping Code
CSA Z662 Oil and Gas Pipeline Systems
NACE International
NACE SP0170 Protection of Austenitic Stainless Steels and Other Austenitic Alloys from Polythionic Acid
Stress Corrosion Cracking During a Shutdown of Refinery Equipment
NFPA
NFPA 13 Installation of Sprinkler Systems
NFPA 24 Installation of Private Fire Service Mains and Their Appurtenances
Suncor Energy
SUN-00161 Minimum Pressurization Temperature for Pressure Equipment Guideline
4.1 Definitions
“Authorized Inspector” means an inspector who has been qualified by written examination under the
rules of any state of the United States or province of Canada and is employed by an ASME accredited
Authorization Inspection Agency.
“Contractor” means the organization that is conducting the pressure leak test.
“Local Authority” means the regulatory authority controlling laws, codes, rules or regulations for the
design, fabrication and testing of industrial piping in the location of the facility.
“Minimum pressurization temperature” means the lowest (coldest) permissible metal temperature for a
given material and thickness based on its resistance to brittle failure.
“Maximum working pressure of a component” means the allowable working pressure of a component
that was selected based on design pressure and is calculated from the component’s excess wall
thickness after all the required allowances have been considered.
“Owner” means Suncor Energy Inc.
“Owner’s Engineer” means the registered professional engineer employed directly by Suncor or its
designated representative responsible for the technical integrity of the facility.
“Owner’s Inspector” means the person employed directly by Suncor or its designated representative
authorized for inspection.

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4.2 Acronyms
ABSA Alberta Boilers Safety Association
ASTM ASTM International
CSA Canadian Standards Association
CTS Suncor Corporate Technical Standard
HDPE High-Density Polyethylene
MDMT Minimum Design Metal Temperature
NACE NACE International
NFPA National Fire Protection Association
5.0 STANDARD
5.1 Information Sources

In addition to the above mentioned Codes and their sub-references, information pertaining to pressure
testing is contained in the following sources:
5.1.1 Piping Drawings
Piping drawings may be orthographic arrangements and/or piping isometrics.
5.1.2 Piping and Instrumentation Diagrams (P&ID)
The Piping and Instrumentation Diagrams indicate "to and from" routing, pipe class, fluid designation
and line number for each line and, which Code or requirements apply to various parts of the piping
systems, as well as, the limits of such Code or requirement.
5.1.3 Line Designation Tables (LDT)
The mechanical data section of the Line Designation Table shows the line number, description,
piping material class, design pressure and temperature, insulation and tracing requirements and test
type and test pressure for each line.
5.1.4 Tie-in List
The piping tie-in list shows the tie-in number, existing line number, new line number, type of
connection, the organization responsible for installing and testing of the tie-in.
Metallurgical or hydrogen embrittlement is possible for piping that has been exposed to elevated
temperatures or charged with hydrogen by corrosion reactions or hydrogen services. As a result,
the minimum pressurization temperature may have shifted. Where this is possible, consult with the
Owner’s Metallurgist to evaluate the material minimum pressurization temperature.
5.2 Pressure Testing

5.2.1 Newly installed piping shall be pressure leak tested. Pressure leak testing of piping shall be in
accordance with the applicable piping Code and Regulations of the local provincial and/or state
authority having jurisdiction.

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5.2.2 Pressure leak tests of tie-ins into existing piping systems shall meet the limitations of the potentially
corroded system and shall have prior approval of the Owner's Engineer. Existing systems may have
experienced detrimental effects to their mechanical properties and integrity such as metal loss and
shifts in metal ductility transition temperatures, and may require modification to test pressure and
temperature. Local facility Inspection Department shall be consulted for existing material condition.
5.2.3 If pressure leak test for closure and tie-in welds is impractical to be conducted, alternative testing, if
permitted by the applicable Code and Regulations, can be considered. Alternative testing shall
comply with Appendix B of this standard and requires prior approval of the Owner’s Engineer, and
local authority (or Business Unit equivalent).
5.2.4 Piping pressure leak tests involve the potential release of stored energy that could cause property
damages and personnel injuries. The Contractor conducting the pressure leak test shall ensure
safety precautions and procedures are in place prior to the test and is responsible for the safe
disposal of the test medium in an environmentally acceptable manner in accordance with the local
environmental regulations.
5.2.5 Pressure gauges for system testing shall have a measurement range of 1.5 to 4 times the test
pressure with accuracy conforming to ASME B40.100 Grade A (±1.0% in middle one-half of scale) or
better in accordance with the individual facility’s quality management standards. Pressure gauges
shall be 4 inches (100 millimeters) minimum diameter. Electronic gauges with accuracy better than
±1.0% may be used. All equipment shall have the same unit of measure as the specified test
pressure and same full scale range. Only one unit of measure shall be used.
5.2.6 Pressure gauges/recorders shall be recalibrated and certified to be accurate by the Owner’s
Inspector, at a frequency mandated by the individual facility quality management standards. The
certification documents shall be a permanent part of the system pressure test package. Each gauge
shall have an identification mark or number, which shall appear on the certification documents.
5.2.7 Test gauge shall be located as near to the high point of the system being tested as practical. If the
indicating gauge is not readily visible to the operator controlling the pressure applied, an additional
indicating gauge shall be provided where it will be visible to the operator throughout the duration of
the test. The test gauges shall be orientated to minimize injury or damage if failure of the gauge
occurs.
5.2.8 All tools, equipment, test medium and additives required for piping system pressure leak tests shall
be supplied by the Contractor. A manual pump or pressure truck equipped with a relief regulator
may be used for pressurizing. The relief regulator mounted on the pump shall be set at the test
pressure prior to the test using a calibrated gauge.
5.2.9 Valves shall be in the open position but not back seated to test the packing. Flanged valves located
at the end of a system shall be blanked on the downstream side. Threaded valves located at the
end of a system, shall be plugged or capped on the downstream side.
5.2.10 With Owner’s approval, closed valves may be used in “existing piping” but shall not be relied upon to
be leak proof at the test pressure. When closed valves must be used at the end of a pressure leak
test system, the resulting pressure drop and the make-up volume of the test fluid required to restore
the test pressure shall be recorded and included in the test report. The maximum pressure that a
closed valve may be subjected to when used for isolating a pressure leak test system shall not
exceed 110% of the valve pressure rating at 100ºF (38ºC).

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5.2.11 The following items, if isolatable, shall not be included in a pressure leak test:
a) Rotating machinery such as pumps, compressors and turbines
b) Strainer baskets and filter elements
c) All instruments downstream of the first (second in double valve systems) isolation valve
d) Pressure relieving devices such as pressure relief valves and rupture discs
e) Control valves
f) Pressure transmitters & switches, pressure gauges, pressure regulator, orifice plates, flow
transmitters, flow instruments, and level instruments
g) Pressure vessels and exchangers (for exemptions see paragraph 5.3.2)
h) Components where the manufacturer’s test pressure is less than the hydrostatic leak test
pressure provided the components were manufactured in accordance with standards
recognized by the applicable piping design code
5.2.12 Lines containing check valves shall have the fill and pressure source located upstream of the check
valve. The drain shall be located downstream of the check valve. If that is not practical, then the
valve internals shall be removed or blocked open.
5.2.13 Threaded thermowells, if specified, shall be installed prior to testing.
5.2.14 Vents provided solely for test purposes shall be plugged and seal welded following the completion of
the hydrostatic leak test.
5.2.15 Prior to hydrostatic leak testing, the Contractor shall verify that the system supports, including spring
supports, were designed to and are in the condition to support the weight of a water filled system.
5.2.16 Weld joints in shop fabricated spools that have been successfully pressure leak tested elsewhere,
and for which documentation acceptable to the Owner’s Inspector is included in the test package,
need not be re-tested in a system test.
5.2.17 A system under test pressure shall never be left unattended. If a test cannot be completed before
the end of a work period, the system shall be depressurized.
5.3 Special Conditions

5.3.1 Lines in vacuum service, unless governed by specific design conditions, shall be tested internally at
1.5 times the external differential pressure or 15 psig (103 KPag), whichever is higher.
5.3.2 Pressure leak testing of connected pressure vessels, exchangers and like equipment is acceptable
only when designed for a test pressure at least equal to the required piping test pressure and only
with prior approval of the Owner’s Engineer.
5.3.3 Connected piping may be tested with pressure vessels or other equipment requiring field test
provided resulting test pressure applied to piping meets the required piping test pressure and does
not exceed the maximum allowable test pressure. Supports for vessels and other equipment shall
be checked to ensure that they can support the full weight of the equipment and test fluid.

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5.3.4 Unless limited by design, the inner and the jacket part of jacketed lines shall be pressure tested
independently. If the test pressure in the jacket is too high for the internal lines as an external
pressure, the internal line shall be pressurized to minimize the differential pressure.
5.3.5 If heat exchanger is included in a system test, the heat exchanger shall be checked to verify that the
tube sheet differential pressure is not exceeded.
5.3.6 Lines open to the atmosphere such as vents or drains downstream of the last shutoff valve or
pressure relief valve need not be pressure leak tested; except in cases where the built-up back
pressure at any portion of the line under relieving condition exceeds 15 psig (103 KPag).
5.3.7 For piping specified per ASME Code for Pressure Piping B31.3, closure weld connecting piping
systems or components that have been successfully tested in accordance with Code section 345
need not be leak tested provided the weld is examined in-process in accordance with Code section
344.7 and passes with 100% radiographic examination in accordance with Code section 344.5 or
100% ultrasonic examination in accordance with Code section 344.6.
5.4 Test Pressure

5.4.1 Facility piping pressure leak test shall be per the requirements of the Code that the system piping
was designed for.
5.4.2 Piping specified per ASME Code for Pressure Piping B31.1 and piping governed by the ASME Boiler
and Pressure Vessel Code Section I, Power Boilers, shall be hydrostatically tested at a pressure as
defined in clause 137.4.5 of the Code B31.1.
5.4.3 Piping specified per ASME Code for Pressure Piping B31.3 shall be hydrostatically tested at a
pressure of 1.5 times the lower of either the maximum working pressure of the connecting flanges or
the maximum working pressure of the limiting system component at 100°F (38°C). The hydrostatic
leak test pressure thus calculated shall be shown on the line designation tables in the test pressure
column.
5.4.4 Pneumatic leak test pressures for ASME Code for Pressure Piping B31.1 piping shall be in
accordance with clause 137.5.5 of the Code B31.1. The test pressure shall not exceed the
maximum allowable test pressure of any non-isolatable component in the system.
5.4.5 Pneumatic leak test pressure for ASME Code for Pressure Piping B31.3 piping shall be in
accordance with clause 345.5.4 of the Code B31.3. The test pressure shall not produce a nominal
pressure stress or longitudinal stress exceeding 90% of the yield strength of any non-isolatable
component in the system at the test temperature.
5.4.6 In lieu of pressure leak test, service leak tests may be applied to Category D fluid services as defined
in Appendix M of ASME Code of Pressure Piping B31.3 subject to the approval of the Owner’s
Engineer and local regulatory authority. Test pressure for service test shall be the maximum
operating pressure of the system.
5.5 System Package for Pressure Leak Tests

5.5.1 A system pressure leak test package (service test package for Category D services) shall be
prepared for each test system. With prior Owner’s inspector approval, test package can be
exempted for minor maintenance projects which involve only shop testing of piping spools.

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5.5.2 The vertical extent of test systems shall be such that the static head of the test medium does not
create a pressure greater than the maximum allowable test pressure.
5.5.3 System pressure leak test package data should include:
a) Piping Pressure Leak Test Certificate, as per Attachment A, which contains the following:
i Project number
ii Facility and unit locations
iii Test date, start time and completion time
iv Test pressure required and the actual test pressure
v Test hold time required and the actual hold time
vi Test medium and actual test medium temperature, Recorder identification number and
certification date
vii Pressure gauges identification numbers and certification dates
viii Line numbers and pressure test limits taken from the Line Designation Table (LDT’s).
Pressure limits from the LDT’s shall be listed when combining piping of different test
pressures into one test
ix Stored energy calculations for pneumatic tests
x Signatures from the testing organization, Owner’s Inspector, and , if required, Authorized
Inspector.
b) Marked up Piping and Instrumentation Diagrams (P&ID’s)
c) Marked up Line Designation Tables (LDT) including test pressure and material MDMT (or
Minimum Pressurization Temperature for in service materials).
d) Marked up piping isometric drawings when available
e) Temporary support requirements
f) Special provisions for high static head systems
g) Records of weld inspection (visual, radiographic, or otherwise) of all the circumferential and
longitudinal weld lines made from rolled plate
h) Engineering notes including filling, purging, pressurizing, draining, flushing and drying
instructions, as well as acceptance criteria
5.5.4 Piping and Instrumentation Diagrams (P&ID’s) should be marked up to identify:
a) Test medium fill point
b) Test medium vent point(s)
c) Test medium drain point(s)
d) Test blank locations
e) Pressure gauge location(s)
f) Components removed for test
g) Limits of pressure test

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5.6 Preparation of Systems for Testing

5.6.1 Temporary blind flanges and test blanks used to isolate a test system shall be of an adequate
thickness to withstand the test pressure. (Appendix A lists the formulae for calculating piping test
blank thickness requirements.) Test blanks shall include a 'T' handle, extending at least 4 inches
(100 millimeters) beyond the flange perimeter, which shall be painted primer red. Test blanks shall
be installed with proper gaskets per applicable piping class on both sides to prevent damage to
flange facings.
5.6.2 All internal parts and in-line items removed for the duration of pressure leak testing shall be labelled.
The component to which they belong or the position in the line from which they were removed shall
also be logged to the satisfaction of the Owner’s Inspector to ensure correct replacement of
components following the testing.
5.6.3 All valves, except as excluded herein, shall be included in the pressure leak tests; ball valves shall
be in the position recommended by the manufacturer and all other valves shall be open but not back-
seated.
5.6.4 Where a valve has not been included in a system test, the valve shall be subjected to a bench
hydrostatic leak test at the required test pressure of that system for a minimum duration of 10
minutes.
5.6.5 Spring supports for lines in vapour service shall be locked in position for the test using pre-set pins or
plates or by blocking up the spring. For installation of spring supports, see CTS 0211.
5.6.6 All temporary materials installed for the purpose of pressure leak testing (such as temporary
supports, spring support restraints, expansion bellow restraints, temporary spools, blinds and plugs)
shall be prominently flagged or painted primer red to ensure their removal following testing.
5.6.7 Short pieces of piping, which must be removed to permit installation of a test blank, shall be tested
separately.
5.6.8 All pressure containing joints shall be accessible during the test and shall not be primed, painted,
insulated, back-filled or otherwise covered until satisfactory completion of the pressure leak test.
5.6.9 Where the test system piping and equipment require priming and/or painting, such priming and/or
painting shall not be applied prior to pressure leak testing.
5.7 Test Medium

5.7.1 Potable water with maximum chloride content of 50 ppm is preferred. Other water used for
hydrostatic testing of piping shall be fresh, clean and free from suspended solids and other foreign
matter. Where the quality of available water is unsatisfactory for testing, a chemical inhibitor
package shall be provided, which shall include the following chemicals:
a) Oxygen scavenger to remove dissolved oxygen
b) Biocide to kill harmful organisms and sulphate producing bacteria
c) Corrosion inhibitor to minimize corrosion
Note: Proposals to use chemical inhibitors shall be agreed between Contractor and the Owner’s
Engineer or Inspector.

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5.7.2 The minimum metal temperature during hydrostatic testing shall be 30°F (16°C) above the minimum
design metal temperature (MDMT) of the piping components in the system having the highest MDMT
for pipes wall thickness of more than 2 inches (50 millimeters), and 10°F (6°C) above for pipe wall
thickness of 2 inches (50 millimeters) or less. For existing piping with potential metallurgical or
hydrogen embrittlement the above temperature margins are over the Minimum Pressurization
Temperature.
5.7.3 If the temperature determined in paragraph 5.7.2 cannot be practically achieved in the field, the line
may be stress analyzed to determine the “Stress Ratio” as defined in ASME Code of Pressure Piping
B31.3 Figure 323.2.2B. The corresponding reduction in MDMT as determined by the same figure
may be applied to reduce the hydrostatic leak test temperature. The new minimum hydrostatic leak
test temperature in accordance with paragraph 5.7.2 can be calculated using this reduced MDMT.
5.7.4 No pressure leak testing shall be performed below a metal temperature of -20°F (-29°C) without prior
approval from the Owner’s Engineer. The possibility of brittle failure shall be evaluated and the
criteria of acceptance shall be approved by the Owner’s Engineer.
5.7.5 A non-flammable anti-freeze liquid shall be used when the ambient temperature is below 40°F (4°C).
Methanol shall not be used within process facility. With Owner’s Engineer approval, use of Methanol
may be allowed for testing outside of process facility.
5.7.6 The use of liquids other than water shall have the prior approval of the Owner’s Engineer and the
local Environment, Health and Safety Advisor.
5.7.7 For hydrostatic leak testing austenitic stainless and nickel alloy steel piping, the test fluid shall not
contain more than 50 ppm chlorides. Test fluid analysis report confirming chloride contents shall be
provided for Owner’s review prior to conducting the leak test.
5.7.8 Test medium for pneumatic leak test shall be non-flammable and non-toxic such as air or inert gas.
5.7.9 Air or inert gas used for pneumatic leak tests shall be dry (dew point -40°F (-40°C) or lower), clean,
and oil free. Oil lubricated compressors shall not be used without adequate filters and dryers.
Pneumatic leak testing temperatures shall be a minimum 30°F (16°C) above the MDMT of the piping
component in the system having the highest MDMT and shall not exceed 120°F (50°C).
5.8 Hydrostatic Leak Testing Guidelines

5.8.1 Piping that requires hydrostatic leak testing shall be thoroughly flushed of foreign materials with
clean water prior to test.
5.8.2 Prior to filling the system with the test medium, the system shall be inspected by the Contractor’s and
the Owner’s Inspectors for fabrication completeness and satisfactory test preparation, including the
placement of pressure gauges and suitability of the test rig. The test package is then signed by the
Owner’s Inspector to allow commencement of the test.
5.8.3 Liquid testing medium shall be introduced at the system low point to avoid air pocket formation.
Vents at high points shall be left open and not closed until test medium flows from the outlet. All air
must be removed before test pressure is applied.
5.8.4 After testing, the piping shall be drained and thoroughly dried and maintained such that no moisture
or chloride laden deposits will enter the piping. Refer to clause 5.16.1 for guidelines.

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5.8.5 Hydrostatic leak testing shall not commence until the test fluid temperature is in equilibrium with the
piping system.
5.8.6 The pressure shall be gradually applied, at no more than 50 psi (345 KPa) per minute, up to the
required test pressure and the test pumps shall be disconnected from the system before the pipe
inspection.
5.8.7 The specified test pressure shall be held for a sufficient length of time to allow piping to equalize
strains. The test pressure shall be held until all joints (threaded, socket-welded, butt welded and
flanged) have been inspected for leaks but in no case for less than the following:
a) Shop fabricated spools 10 minutes
b) Final line hydrostatic leak test for systems 30 minutes
5.8.8 Ambient temperature changes may cause excessive pressure or vacuum in a closed system;
therefore, piping shall not be allowed to stand still filled with test liquid without being vented to
atmosphere.
5.9 Pneumatic Leak Testing Guidelines

5.9.1 Pneumatic testing involves the hazard of released energy stored in compressed gas. Particular care
must therefore be taken to minimize the chance of failure during a pneumatic leak test. The stored
energy for a pneumatic test shall be determined by using the equation in ASME PCC-2, Article 5.1,
Mandatory Appendix II. The maximum stored energy allowed for a pneumatic leak test is facility
specific and shall be confirmed with the local regulatory authority.
For example: testing using approved standard pneumatic test procedure for systems with stored
energy up to 1,237,000 ft-lb (1677 KJ) is allowed for facilities located in the province of Alberta.
Testing for systems with energy level higher than this will require special approval from ABSA.
5.9.2 The area around the system being tested, based on the minimum safe distance requirement in
ASME PCC-2 Article 5.1, Mandatory Appendix III, shall be cleared of unauthorized personnel and
warning notices posted during the time that the piping system is pressurized for the test. The
arrangements made to exclude unauthorized personnel and the perimeter of the hazard zone, shall
be approved by the Owner’s Engineer.
5.9.3 A pressure relief device with set pressure not higher than the lesser of 110% of test pressure or test
pressure plus 50 psi (345 KPa) shall be provided for the test system.
5.9.4 Piping that requires pneumatic leak testing shall be flushed free of loose materials with clean air prior
to test.
5.9.5 The pressurization and inspection sequence shall be:
a) Pressurize to the lesser of 1/2 test pressure or 25 psig (172 KPag) and hold for a sufficient
length of time to allow piping to equalize strains. All joints (threaded, socket welded, butt
welded and flanged) shall be inspected for leaks with soap suds.
b) Pressurize gradually in 10% steps of the specified test pressure and hold for a sufficient length
of time to allow piping to equalize strains (10 minutes minimum).
c) The test pressure shall be held for a length of time as per paragraph 5.8.7 with pressure source
disconnected and then reduced to design pressure, after which all joints shall be inspected for
leaks with soap suds.
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d) The soap suds shall be an approved solution compatible with the materials being tested.
Throughout the test period, the bubble formation properties of the soap suds shall be checked.
5.9.6 All defects revealed by the test shall be repaired and re-tested.
5.9.7 Depressurization shall be conducted in a controlled manner to avoid sub-cooling due to the
refrigeration effect and to equalize pipe strains.
5.10 Service Testing Guidelines
5.10.1 Service tests shall be conducted in accordance with section 345.7 of the ASME Code of Pressure
Piping B31.3 and with prior approval from the Owner’s Engineer.
5.10.2 If the service fluid is gas or vapour, the stored energy of the test system, including the existing facility
if the test system is open to the existing facility during the test, shall be considered and the
restrictions in paragraph 5.9.1shall apply.
5.11 Alternate Leak Test
5.11.1 For systems where both hydrostatic and pneumatic tests are considered impractical, and comply
with the conditions stated in clause 345.1(c) of the ASME Code of Pressure Piping B31.3, alternative
leak test can be conducted in accordance with section 345.9 of the Code B31.3 in lieu of pressure
leak test.
5.12 Additional Requirements for Boiler External Piping
5.12.1 Pressure leak testing procedures for boiler external piping designed according to ASME Boiler &
Pressure Code Section 1 and ASME Code of Pressure Piping B31.1 shall conform to the
requirements of the Code B31.1, section 137.
5.12.2 The test medium temperature shall be 70°F (20°C) minimum and the metal temperature shall be
120°F (50°C) maximum.
5.12.3 All pressure leak tests of boiler external piping shall be conducted by organization with valid
certification as defined in ASME Section I and includes the involvement of the Authorized Inspector.
5.13 Testing Requirement for Pipelines
5.13.1 Pressure testing procedures for pipelines designed in accordance with CSA Z662 shall conform to
the requirements of CSA Z662 Section 8 and local regulatory authority.
5.13.2 Pressure testing procedures for pipelines designed in accordance with ASME B31.4 shall conform to
the requirements of B31.4 Section 437 and local regulatory authority.
5.13.3 Pressure testing procedures for pipelines designed in accordance with ASME B31.8 shall conform to
the requirements of B31.8 and local regulatory authority.
5.14 Testing Requirement for Fire Protection Piping
5.14.1 Pressure testing procedures for fire protection piping designed in accordance with NFPA codes shall
conform to the requirements of respective NFPA code that the piping was designed to and local
regulatory authority.
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5.15 Inspection
5.15.1 Following the application of hydrostatic pressure during the test, all joints including flanged, threaded
or welded shall be visually examined to verify that no leaks or other defects exist.
5.15.2 All piping components shall be dry on the external surface throughout the test. If the piping surfaces
become wet during the test due to precipitation or condensation, the test shall be aborted until these
surfaces are dry.
5.15.3 When pressure/time and temperature/time charts are used, they shall be reviewed by Owner’s
Inspector and any pressure variations shall be accounted for by temperature variation or other
causes.
5.15.4 The sign-offs shall be completed when Owner Inspector and, when applicable, Authorized Inspector
are satisfied that there are no leaks or other defects.
5.15.5 Pressure leak testing shall not be considered complete and acceptable to Owner until final site
system testing has proven the system to be free from leaks or other defects and all test results
documentation is complete.
5.16 Post Test Procedure
5.16.1 Following the acceptance of a successful test, the system shall be immediately de-pressured,
drained and vented in a gradual and safe manner in accordance with the local environmental
legislation. The system shall be thoroughly drained allowing no pockets of fluid to remain, and shall
then be blown out with dry filtered air until no visible free water or to the dryness specified in the
project scope.
5.16.2 Austenitic alloy piping that has previously exposed to service temperature above 800°F (426°C) shall
maintain a nitrogen purge after air dry.
5.16.3 All items removed for the test (see paragraph 5.6.2) shall be replaced and all temporary materials
installed for the purpose of testing (see paragraph 5.6.6) shall be removed. The replacement of
piping component internals that were removed for testing shall be carefully controlled to ensure that
they are reinstalled in the correct place. Flange joints opened for these purposes shall be remade
with new gaskets.
5.16.4 The system shall be re-inspected for mechanical completeness by the Contractor’s and the Owner’s
Inspectors and signed off as complete. The signed test package shall be retained as part of the
contract documentation.
6.1 Appendices
Appendix A Test Blank Thickness Requirements
Appendix B Alternate Testing – Piping Repairs, Modifications and Tie-in
6.2 Attachments
Attachment A Pressure Leak Test Certificate
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APPENDIX A – TEST BLANK THICKNESS REQUIREMENTS

A1.0 Thickness requirement
Allowable pressure shall be calculated based on the following formula from paragraph 304.5.3 of ASME
B31.3:
𝑡𝑚 = 𝑑𝑔 √ 3𝑃
+𝐶
16𝑆𝐸𝑊
tm = blank thickness in inches (mm)

dg = inside diameter of gasket or gasket pitch diameter in inches (mm)
P= allowable pressure
S= stress value for material per Table 1 of ASME B31.3, 18300 psi (126 MPa), based on ASTM A285
Grade C, or ASTM 516 Grade 55
E= quality factor, 1 for non casting
W = Weld joint strength reduction factor, 1 for blank fabricated from plate without any welding
C = sum of mechanical allowance, 0 in the case of blank fabricated from plate
A2.0 Dimensions
The outside diameter of test blanks shall conform to the dimensions specified in ASME B16.48.
A3.0 Marking
All tests blanks shall be marked by die stamping on the 4" (100 mm) min. “T” handle, welded as an
extension, with the material specification, pipe size, test pressure and the words "FOR TESTS ONLY".
Example:
In imperial units, NPS 4 x 3/8" thick blank would have the following stamped:
ASTM A285-C NPS 4; Class 150
FOR TESTS ONLY up to 847 psig
In SI units, DN 100 X 9.5 mm thick blank would have the following stamped:
ASTM A285-C DN 100, Class 150
FOR TESTS ONLY up to 5840 KPag
A4.0 Cautions
Test blanks shall not be used as service blanks. Service blanks are designed for the particular application
including temperature, corrosion, pressure, and code.
Note: Test blanks fabricated and installed according to these requirements shall be removed from the piping
system immediately after the piping pressure test.

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APPENDIX B - ALTERNATIVE TESTING FOR PIPING REPAIRS, MODIFICATIONS AND

TIE-INS
B1.0 Purpose
The purpose of this procedure is to detail the requirements for use of alternative testing in lieu of pressure
leak testing, as required by Code and Suncor Standards for piping repairs, modifications and tie-ins.
B2.0 Scope
This procedure applies to pressure piping system repairs, modifications and tie-ins, where application of a
hydrostatic or pneumatic leak test is deemed impractical.
Alternative testing only applies to the field final tie-in weld(s) of the system being repaired or modified.
Sub-assemblies and components must be pressure leak tested before performing the tie-in weld.
Alternative testing shall not apply to equipment such as vessels and heat exchangers.
B3.0 Procedure
Temporary welded caps or closures may be required to perform this test. Although valves are hydrostatic
leak tested at the time of manufacture, they shall be re-tested prior to installation to detect packing and
bonnet gasket leaks. NDE for sub-assemblies must be performed in accordance with the relevant piping
specification per CTS 0202, Piping Materials Specifications.
B3.1 Code and Suncor Alternative Testing Requirements
It is the intent of Suncor and the Code requirements that pressure leak testing (hydrostatic or
pneumatic) be carried out whenever possible and practical. The purpose of a pressure leak test is to
ensure against leakage and to detect gross defects in the design, materials, welding and assembly.
When conditions arise where the waiving of a pressure leak test is warranted, it is important that
alternative testing be carried out to ensure the integrity of the system is maintained.
Both CSA Standard B51, Boiler, Pressure Vessel and Pressure Piping Codes and ASME piping Codes
states that where the application of a pressure leak test is difficult or impractical, alternative
procedures in lieu of the pressure leak testing may be used only after approval by the Owner’s
Engineer and followed by the approval of the regulatory authorities.
B3.2 Cases for Application of Alternative Testing
The following are examples where pressure test may not be practical:
B3.2.1 Piping shut off valves are not available for isolating a line and temporary closures are impractical.
B3.2.2 Pressure leak testing would have to be carried out against a hot valve or live system.
B3.2.3 For systems such as lube oil, recirculating process fluid, seal water, etc. While starting up
equipment such as pumps, compressors, and associated process equipment, ample opportunity
is provided for examination for leakage prior to the full scale operation.
B3.2.4 Attachment of non-pressure parts such as structural attachments or seal-welding of threaded
joints which were previously pressure leak tested.

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B3.2.5 Replacement of a single component in a system such as a valve, nipple, elbow etc. where
isolation is impractical. The single component shall be closely inspected for defects, and all
valves hydrostatic leak tested as per the applicable code that the valve was designed for.
B3.2.6 Where lack of support integrity does not allow hydrostatic test of an entire system.
B3.3 Alternative Testing Requirements
B3.3.1 Alternative testing only applies to the FINAL FIELD WELD(S).
B3.3.2 All alternative testing must be followed by an initial service leak test. The location must be left
bare of insulation for examination during the initial start-up of the system.
B3.3.3 For closure welds, the requirements of ASME B31.3 Code for process piping, clause 345.2.3 may
be applied at the discretion of the Owner’s Engineer. However, radiography, ultrasonic, or other
alternative testing in lieu of pressure leak testing shall not be applied to closure welds in critical
process services as defined in the attached table Potential Services for Alternative Testing.
B4.0 Implementation
B4.1 The Area Maintenance Supervisor and Owner’s Engineer may identify an application for alternative
testing. A drawing/sketch is provided in the job package detailing the location of the field tie-in welds
and required alternative testing.
B4.2 The Owner’s Engineer shall review applications for alternative testing for services as defined in the
attached table with consideration to safety, design, reliability and service conditions. The Owner’s
Engineer shall review and specify the alternative testing required for the application.
B4.3 The Owner’s Engieer shall obtain approval, as required, from the local regulatory authority.
B4.4 The Owner’s Inspector or designate shall review all applications, prior to start of the job, for
compliance with this procedure, Codes and Suncor standards.
The Owner’s Inspector shall ensure that all alternative testing is completed as specified.

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POTENTIAL SERVICES FOR ALTERNATE TESTING
SERVICE SHOP HYDROTEST RT MT PT UT WI

Water, Glycol, Sewage, Condensate, Slurry Valves and Piping F
All less than 366°F (186°C), 150 psig. (1035 KPag)
B31.3 Category D
General utility services Valves and Piping B B * B
Over 366°F (186°C) or 150 psig (1035 KPag) F F
General hydrocarbon and chemical services Valves and Piping B B B * B

All less than 366°F (186°C) or 150 psig (1035 KPag) F F F
General hydrocarbon and chemical services Owner’s engineer approval is required for all testing in
Over 366°F (186°C) or 150 psig (1035 KPag) lieu of pressure leak testing.
Hydrogen ≥Class 300, ≤Class 600 Pressure leak test is required.
Hydrocarbon & Chemical ≥Class 600, ≤Class 900 Waiving of pressure leak test and application of
Steam services ≥Class 600 alternative testing requires thorough review of the
Utility services ≥Class 600 system and approval by Owner’s Engineer.
° °
Temperature > 500 F (260 C)
Utility lines in cyclic service
Hydrogen ≥Class 600 Alternate testing is not allowed.
Hydrocarbon & Chemical ≥Class 900
° °
Temperature > 750 F (400 C)
Process lines in cyclic service
LEGEND
RT — 100% Radiography
MT― Magnetic Particle
PT ― Penetrant (Stainless Steels)
UT ― Shearwave Ultrasonic
WI ― In Process Visual Weld Inspection per B31.3
* ― Large Bore Branch Connections
B ― Butt Weld
F ― Fillet or Socket Weld

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ATTACHMENT A – PRESSURE TEST CERTIFICATE

Pressure Leak Test Certificate
Issued by: Project Number:
Facility Location: Unit:
Test Date Start Time Completion Time
Test Pressure Required: Actual Test Pressure:
Test Hold Time Required: Actual Hold Time:
Test Medium: Actual Test Medium Temperature:
Recorder Identification Number: Calibration Date:
Gauge Identification Number: Calibration Date Gauge Identification Number: Calibration Date:
Line # Location Hydro-Test Design Description of Repairs

Equipment # Pressure Pressure
From To
Stored energy for pneumatic testing:
Notes:
Approvals Date Contractor Owner’s Inspector

Released for Testing
Tested and Accepted
Reinstated After Test
Print name / initial

Local Authorities Approval:
(Only when required)
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OPERATIONAL EXCELLENCE AND TECHNICAL SERVICES Number:

Department:
0227
PURCHASING REQUIREMENTS FOR Revision:
Subject:
PIPE, FLANGES, FITTINGS, BOLTING AND GASKETS 3
Addendum / Revisions History
REV. Section
Change
# Changed
2 All New Standard Issued for Implementation
3 1.2.2 Added clarification to HDPE, PVC, and FRP
3 2.2 and 2.3 Re-Worded
3 3.1 Added references to CTS 0213 and CTS 0228
3 4.1 Revised definition of “Owners Engineer”
3 4.2 Added Acronyms
3 5.2.1 Adjusted colour coding requirement – not mandatory
3 5.3.2 & 5.6.3 Section 5.3.2 temperatures changed, section 5.6.3 wording revised, added
equivalent fahrenheit temperatures
3 5.5.9 Added metric equivalents
3 5.5.10 and Added equivalent fahrenheit temperature
5.6.2
3 5.6.6 Added metric equivalent
Standard 0227, Rev 3, Purchasing Requirements for Pipe, Flanges, Fittings, Bolting and Gaskets Page 3 of 9
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TABLE OF CONTENTS
1.0 PURPOSE & SCOPE................................................................................................................. 5

1.1 PURPOSE ............................................................................................................................... 5
1.2 SCOPE .................................................................................................................................... 5
2.0 RESPONSIBILITIES .................................................................................................................. 5
2.1 ACCOUNTABILITY AND APPROVAL ..................................................................................... 5
2.2 REVISIONS AND UPDATES ................................................................................................... 5
2.3 INTERPRETATION ................................................................................................................. 5
2.4 IMPLEMENTATION ................................................................................................................. 5
3.0 REFERENCES & PREREQUISITES ......................................................................................... 6
3.1 SUNCOR STANDARDS AND DRAWINGS ............................................................................. 6
3.2 RELEVANT / REFERENCED PUBLICATIONS, CODES AND STANDARDS .......................... 6
4.0 DEFINITIONS AND ACRONYMS .............................................................................................. 6
4.1 DEFINITIONS .......................................................................................................................... 6
4.2 ACRONYMS ............................................................................................................................ 6
5.0 STANDARD ............................................................................................................................... 6
5.1 COMMON COMPONENT REQUIREMENTS .......................................................................... 6
5.2 COLOUR CODING .................................................................................................................. 7
5.3 AUSTENITIC STAINLESS STEELS (300 SERIES) ................................................................. 7
5.4 CARBON STEEL ..................................................................................................................... 7
5.5 PIPE ........................................................................................................................................ 7
5.6 FLANGES................................................................................................................................ 8
5.7 FITTINGS ................................................................................................................................ 8
5.8 BOLTING AND GASKETS....................................................................................................... 9
6.0 APPROVED BY ......................................................................................................................... 9
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1.0 PURPOSE & SCOPE

1.1 Purpose
The purpose of this standard is to supplement component descriptions given in piping material requisitions
issued for enquiry and purchase of pipe, flanges, fittings, gaskets and bolting. This standard will also define
Suncor requirements where alternative methods of manufacture or testing are offered by the Industry codes
and standards listed in Suncor CTS 0202 ‘PIPING MATERIAL SPECIFICATIONS’.
1.2 Scope
1.2.1 This standard applies to the following business units that are a part of Suncor Energy Inc;
• Oil Sands & In Situ
• Refining
• Major Projects
Use of this standard for Business Services, International and Offshore and other Business Units
1.2.2 This standard does not cover Non-metallic piping materials such as HDPE (High density
polyethylene), PVC (Poly Vinyl Chloride) or FRP (Fiberglass Reinforced Polyester). Fabrication,
Installation and other standard requirements for non-metallic materials will be addressed by the
individual piping line classes.
Business Unit or Project related positions are indicative of the responsibilities; these designations may vary based
on scope and execution model of technical work.
The Director of Technical Standards is responsible for approving this document and is accountable to ensure
this standard is effectively used for projects and existing plants.
The piping discipline SME (Subject Matter Expert) is responsible for updating and revising this standard in
consultation with Peer Review Network (PRN) members and the Director of Technical Standards based on
2.3 Interpretation
Interpretation and guidance shall be provided by the applicable PRN member for the business unit or the
applicable Suncor project or discipline engineer for a project. The SME responsible for this technical
standard may be consulted by the applicable personnel for any interpretation of the requirements within this
standard. The Director of Technical Standards shall have the final decision in case of conflict.
2.4 Implementation
The Director of Technical Standards is responsible for ensuring that this standard is communicated to
The Business Unit / Project Manager or delegate has overall responsibility for implementation of this
standard. The Engineering Manager, discipline leads or other technical specialist shall provide necessary
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CTS 0202 – PIPING MATERIAL SPECIFICATIONS
CTS 0213 – POSITIVE MATERIAL IDENTIFICATION
CTS 0228 – COLOR CODING OF PIPE AND PIPING COMPONENTS
Industry codes and standards which include ASME, ASTM, API and MSS, as referenced in the individual
piping line classes contained in Suncor CTS 0202.

4.1 Definitions
“Owner” – means Suncor Energy Inc
“Owner’s Engineer” – means the person responsible for the technical integrity of the project, usually a
professional engineer registered with the relevant jurisdiction.
4.2 Acronyms
API American Petroleum Institute
ASTM American Society for Testing and Materials
CE Carbon Equivalent
CTS Corporate Technical Standard (Interchangeable with STD)
HBW Brinell scale hardness
MSS Manufacturers Standardization Society
MTR Material Test Report
PRN Peer Review Network
SME Subject Matter Expert
STD Standard
UNS Unified Numbering System
5.0 STANDARD
5.1 Common Component requirements
5.1.1 All material shall be new and free of defects, dirt, debris and imperfections as defined in the
applicable material standard.
5.1.2 Heavier schedules for pipe, flanges and fittings wall thickness requirements shall not be
substituted without prior agreement of the Owner or Owner’s Engineer.
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5.1.3 When specified, the seller shall verify Alloy material in accordance with Suncor CTS 0213
5.1.4 Any repair by welding shall require prior approval of the Owner’s Engineer.
5.1.5 A complete material test report showing results of all chemistry and physical tests will be required
for all material types and grades. The MTR shall include results of chemical analysis and
mechanical properties together with results of supplementary requirements as specified.
5.2 Colour coding
5.2.1 Colour coding of piping components is not mandatory. Suncor CTS 0228 for colour coding of
piping components shall be applied only when requested by the purchaser.
5.3 Austenitic Stainless steels (300 series)
5.3.1 Stainless steel, where available as ‘dual grade’ or ‘dual certified’ such as 304/304L and 316/316L,
shall be permanently marked accordingly.
5.3.2 Grades 321 and 347 shall be supplied in the solution annealed and stabilized condition. The
0 0 0
stabilizing heat treatment temperature shall be minimum 1600 F (870 C) and maximum 1650 F
0
(900 C) for a minimum of 2 hours.
5.3.3 Grades 321 and 347 require the grain size, as determined in accordance with ASTM E112 (one
piece per heat treatment load) shall be between 4 and 7.
5.3.4 Grades 321 and 347 supplied to ASTM A358 require one intergranular corrosion test with one
test specimen per heat.
5.3.5 All austenitic stainless steel pipe shall be supplied in solution annealed and pickled condition.
5.4 Carbon Steel
5.4.1 The Carbon equivalent, determined by the formula CE = C + Mn/6 + (Cr + Mo + V)/5 + (Ni +
Cu)/15 shall not exceed 0.45%.
5.5 Pipe
5.5.1 For Carbon steel seamless and welded pipe the hardness shall not exceed the lesser of that
imposed by the material standard or 200 HBW. Sufficient hardness tests shall be conducted on
each heat and heat treatment load, to ensure compliance with the acceptance criterion. For
welded pipe after normalizing, the hardness of the weld and heat affected zone shall not exceed
200 HBW or equivalent. Where hardness limits are not stated in material standards the following
shall apply:
• 200 HBW maximum for P-1 material
• 225 HBW maximum for P3 and P4 materials
5.5.2 Welded pipe shall not be made from grades of ASTM A515 steel. Hardness testing of weld
seams is required and the hardness shall not exceed 200 HBW.
5.5.3 ASTM A691 welded pipe shall be heat treated in accordance with the class shown in the item
description. The plate used for the manufacture of ASTM A691 shall be supplied in the
normalized and tempered condition.
5.5.4 Pipe requested as ‘threaded and coupled’ shall be supplied with taper thread couplings, with
threads to ASME B1.20.1. Threads of galvanized piping shall be free of galvanizing.
5.5.5 A grade will be included for the purchase of Pipe to ASTM B444 for temperature application and
testing. Pipe to UNS N06625 shall be supplied in the cold worked and annealed condition.
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5.5.6 Class 1 or Class 2 will be included for the purchase of Pipe to ASTM B619 for UNS N10276.
5.5.7 Pipe purchased to ASTM B165, B407 and B690 shall be supplied in the cold worked and
annealed condition.
5.5.8 Pipe to ASTM A106 GR B shall be supplied ‘Hot finished’ for all sizes.
5.5.9 ASTM A139 GR E pipe used in the fabrication of Urethane lined piping shall meet the following:
• The ovality shall be +/- 0.060 inches (+/-1.5 millimetres) for pipe NPS 12 and smaller.
• The ovality shall be +/- 0.090 inches (+/-2.3 millimetres) for pipe NPS 14 and larger.
• The straightness/total indicated runout (TIR) shall not exceed 0.31% for pipe lengths up to 40
feet (12 Meters) and 0.33% for pipe lengths between 40 feet (12 Meters) and 50 feet (15
Meters).
0 0
5.5.10 All ASTM A671 GR CC70 shall be impact tested to -50 F (-46 C) to supplement S2 of the
standard
5.6 Flanges
5.6.1 Forged flanges to ASTM A105 shall be supplied in the normalized condition and stamped
accordingly with the suffix – ‘N’
0
5.6.2 Forged flanges to ASTM A350 LF2 shall be supplied to Class 1, impact tested to -50 F (-46 C).
5.6.3 Orifice flanges purchased to ASME B16.36 shall be supplied in pairs and supplied with Jack
screws for NPS 3 and larger. Jack screws shall be to ASTM A320 GR L7. The pressure tap
connection type and size required will be specified in the component description. Substitutions
will require prior written approval of the Owner’s Engineer.
5.6.4 For Carbon steel forgings the hardness shall not exceed the lesser of that imposed by the
material standard or 200 HBW. Hardness tests shall be conducted on each heat and heat
treatment load, to ensure compliance with the acceptance criterion. Where hardness limits are
not stated in material standards the following shall apply:
• 200 HBW maximum for P-1 material
• 225 HBW maximum for P3 and P4 materials
5.6.5 Flange facing finishes shall be in accordance with ASME B16.5 & B16.47 unless otherwise
specified in the component description.
5.6.6 Flanges used in the fabrication of Urethane lined piping require a maximum inside and outside
diameter tolerance of +/- 0.040 inches (+/- 1 millimetre)
5.7 Fittings
5.7.1 The manufacturing method for wrought steel fittings of seamless and welded construction will be
identified in the component descriptions with the suffix: ‘S’, ‘W’ or ‘WX’. All welded fittings shall
be 100% radiographed; ultrasonic examination is not an acceptable alternative.
5.7.2 Forged fittings to ASTM A105 shall be supplied in the normalized condition and stamped
accordingly with the suffix – ‘N’
5.7.3 Swaged nipples shall be wrought fittings.
5.7.4 When butt welding fittings with ends internally tapered to specified schedules results in dimension
changes to the ASME standard quoted, notification shall be given in the supplier’s quotation.
5.7.5 For Carbon steel fittings the hardness shall not exceed the lesser of that imposed by the material
standard or 200 HBW. Hardness tests shall be conducted on each heat and heat treatment load,
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Number:
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Revision:
Subject: Shop and Field Welding
10
Section
REV # Change
Changed
This edition of Suncor Standard 0903 has been extensively revised, edited, and re-
formatted to incorporate comments received from Major Projects and PRNs. The
standard has also been updated to use for Lump Sum contracts. Five new clauses
All 5.4.4, 5.4.5, and 5.4.6 have been added to General Requirements for Welding
9
Consumables. Also the definitions have been standardized. The format and clause
numbering is in accordance with Suncor Standard 0001 “Development of Technical
Standards”.
10 1.2. Scope Clarifications and additions

3.0 Additions of further standards and references
4.0 Added definitions of two more services
5.1 Added further welding requirements
5.2 Added further welding procedure requirements
5.3 Added further welder performance requirements
5.4 Added reference of Suncor Wide Guideline document
5.5 Clarified and added new limitations, added new welding processes
5.7 Clarification and addition of new preheat temperature criteria
5.8 Added Inter-pass temperature for various material in Appendix B
Clarification and addition of new PWHT requirements, Include PWHT temperatures
5.10
for various services in Appendix B
5.11 Clarified radiography requirements and production hardness requirements
5.12 Clarified ferrite determination
5.13 Added Super Duplex SS and other requirements for DSS welding
5.14 Weld repair section rearranged
Added new section on Other Items- Stud welding, Backing materials, Temporary
6.0
Attachments and Fired Heater Thermocouple Attachments
7.0 Added Health and Safety
Standard 0903 Rev 10 Shop and Field Welding Page 3 of 61

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Added Normative Appendix Table 1A & Table 2A for Interpass temperature for
Appendix A
various materials
Added Normative Appendix Table 3A PWHT temperature for various materials and
Appendix A
services
Added Normative Appendix Table 1B Selection of welding consumables for various
Appendix B
materials
Added Normative Appendix Table 2B Welding consumables for Dissimilar metal
Appendix B
welding of Carbon and Low alloy steel welding
Added Normative Appendix table 3B Consumables for various Stainless Steel
Appendix B
Alloys
Appendix B Added Normative Appendix Table 4B Consumables for Duplex Stainless Steel
Added Normative Appendix Table 5B Consumables for Copper-Nickel and Nickel
Appendix B
base alloys

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TABLE OF CONTENTS
1.0 PURPOSE & SCOPE .....................................................................................................................................7

1.1 PURPOSE ........................................................................................................................................................7
1.2 SCOPE ............................................................................................................................................................7
1.3 PRECAUTIONS .................................................................................................................................................7
2.1 ACCOUNTABILITY AND APPROVAL .....................................................................................................................8
2.2 REVISIONS AND UPDATES.................................................................................................................................8
2.3 INTERPRETATION .............................................................................................................................................8
2.4 IMPLEMENTATION .............................................................................................................................................8
3.1 PREREQUISITES ...............................................................................................................................................8
3.2 3.2 SUNCOR STANDARDS AND DRAWINGS .........................................................................................................9
3.3 RELEVANT / REFERENCED PUBLICATIONS, CODES AND STANDARDS ...................................................................9
4.1 DEFINITIONS – GENERAL ............................................................................................................................... 11
4.2 DEFINITIONS – SERVICE ................................................................................................................................ 11
4.3 DEFINITIONS – MATERIAL .............................................................................................................................. 12
4.4 ACRONYMS ................................................................................................................................................... 13
5.0 WELDING .................................................................................................................................................... 14
5.1 GENERAL W ELDING REQUIREMENTS .............................................................................................................. 14
5.2 W ELDING PROCEDURE .................................................................................................................................. 19
5.3 W ELDER PERFORMANCE QUALIFICATION ....................................................................................................... 22
5.4 GENERAL REQUIREMENTS FOR W ELDING CONSUMABLES (FILLER METALS AND FLUX) ..................................... 23
5.5 W ELDING PROCESS AND FILLER METAL LIMITATIONS ...................................................................................... 24
5.6 FABRICATION AND FIT-UP .............................................................................................................................. 30
5.7 PREHEAT TEMPERATURE............................................................................................................................... 30
5.8 INTER-PASS TEMPERATURE ........................................................................................................................... 31
5.9 HYDROGEN DEGASSING (BAKE-OUT) ............................................................................................................. 32
5.10 HEAT TREATMENT ......................................................................................................................................... 32
5.11 INSPECTION .................................................................................................................................................. 34
5.12 FERRITE CONTENT OF AUSTENITIC STAINLESS STEEL W ELD METAL ................................................................ 37
5.13 DUPLEX AND SUPER DUPLEX STAINLESS STEEL MATERIAL AND WELDING REQUIREMENTS ............................... 38
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5.14 W ELD REPAIRS ............................................................................................................................................. 43

6.0 OTHER ITEMS ............................................................................................................................................ 44
6.1 STUD W ELDING............................................................................................................................................. 44
6.2 BACKING MATERIALS..................................................................................................................................... 45
6.3 PEENING ...................................................................................................................................................... 45
6.4 TEMPORARY ATTACHMENTS .......................................................................................................................... 45
6.5 HEATER TUBE SKIN THERMOCOUPLE INSTALLATION AND W ELDING ................................................................. 45
7.0 HEALTH AND SAFETY .............................................................................................................................. 47
7.1 GENERAL HEALTH AND SAFETY REQUIREMENTS............................................................................................. 47
8.0 REVIEW AND APPROVAL REQUIREMENTS FOR CONTRACTORS ..................................................... 47
8.1 GENERAL APPROVAL REQUIREMENTS ............................................................................................................. 47
9.1 APPENDICES ................................................................................................................................................. 48
9.2 ATTACHMENTS .............................................................................................................................................. 48
interpass and pwht .......................................................................................................................................... 50
selection of welding consumables ................................................................................................................... 53

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1.0 PURPOSE & SCOPE

1.1 Purpose
This standard establishes Suncor’s requirements for welding fabricated equipment, piping and
structural items attached and related to process equipment integrity as detailed in Section 1.2, Scope.
1.2 Scope
1.2.1 This standard establishes the requirements for shop and field welding, the associated heat
treatment, and inspection.
1.2.2 This standard contains the requirements for shop and field weld fabrication, erection,
alteration and repair of pressure vessels including welded internal and entire external skirts
and supports welding, all structures attached and related to process equipment, piping
systems, boilers, heaters, Flare stacks, heat transfer equipment, storage tanks and its
internals, and pressure boundaries of rotating equipment and attachments.
1.2.3 This standard also applies to other equipment or component item when referenced by an
applicable purchase document.
1.2.4 This standard is general in nature and is intended to augment the welding requirements of
ASME BPVC Section IX and similar codes, standards, specifications and practices such as
those listed in Section 3.
1.2.5 This standard does not apply to In-Service welding and Hot Tapping. Hot-tapping or In-
service welding of process piping, pressure equipment or tanks shall be performed in
accordance with Suncor Standard 0220.
1.2.6 Weld overlay and clad restoration is covered in Suncor Corporate Alloy Cladding standard
CTS 0603.
1.2.7 This standard does not apply to pipelines which are covered by CSA Z662, DOT 195,
B31.4, B31.8 or API 1104. Pipeline welding is covered by Suncor Pipeline welding standard
CTS 0910.
1.2.8 This standard does not apply to structural steel weld fabrication or erection covered by
Suncor Standard 0302 and CTS 0909.
1.2.9 This standard applies to the following Suncor Energy Inc. business units:
1.2.9.1 Oil Sands
1.2.9.2 In Situ
1.2.9.3 Exploration and Production
1.2.9.4 Refining and Marketing Major Projects
1.3 Precautions
This standard and associated template is mandated for Corporate Technical Standards. The user of
this document must have prior knowledge and understanding of corporate and legislative direction, to
use standards to promote the consistent, safe, reliable, and cost-effective management of Suncor’s
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businesses in line with the Operational Excellence Management System (OEMS). All work related to
this standard shall be in compliance with Suncor Energy Inc. corporate site specific safety standards
and local regulatory safety and environmental requirements.
Business Unit or Project related positions are indicative of the responsibilities; these designations may vary
Director of Technical Standards is responsible for approving this standard, and has overall
accountability to ensure that this standard is effectively implemented.
Discipline Subject Matter Expert (Welding SME) is responsible to update and revise this standard in
consultation with Peer Review Network (PRN) members and the Director of Technical Standards
based on “Lessons Learnt”, “Continuous Improvement”, and industry best practice.
2.3 Interpretation
PRN members within business units are responsible for interpretation of standard. The Welding SME
shall be consulted in complex cases. Director of Technical Standards shall have the final decision in
case of conflict.
2.4 Implementation
2.4.1 Director of Technical Standards is responsible for ensuring that this standard is
communicated to stakeholders and for auditing the implementation.
2.4.2 The Business Unit Engineering Manager/Director or Project Management (or delegate) has
overall responsibility for implementation of this standard. Engineering Manager/Director,
Discipline Leads, or other technical specialist shall provide necessary support in
implementation.

3.1 Prerequisites
3.1.1 The referenced documents form an integral part of this standard.

3.1.2 Any conflict between this document and the referenced documents shall be brought to the
attention of the Owner/Purchaser for resolution prior to proceeding with work.
3.1.3 All reference Industry codes and standards shall be based on the latest edition or the
edition in effect at the time of Purchase Order or Contract document.
3.1.4 All referenced Suncor Standards shall be based on the revision specified in the Purchase
Order or Contract.

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3.2 3.2 Suncor Standards and Drawings
CTS 0202 Piping Material Specifications

CTS 0204 Piping Fabrication and Installation
CTS 0213 Positive Material Identification
CTS 0220 In-Service Welding And Hot Tapping
CTS 0601 Pressure Vessels,

CTS 0801 Shell and Tube Echanger
CTS 0802 Air Cooled Exchangers
CTS 0603 Alloy Cladding
CTS 0904 Materials and Fabrication Requirements for Pressure Equipment in
Sour/Wet H2S Service
CTS 1802 Elevated Flares
CTS 2401 Welded Field Erected Storage Tanks
CTS 2402 Welded Shop Fabricated Storage Tanks
MRS –GL- TWD -001 Risk Assessment and Mitigation For Dissimilar Metal Welds
Suncor- Wide Guideline

ASME BPVC-I Rules of Construction for Power Boilers
ASME BPVC-IIA Ferrous Materials Specifications
ASME BPVC-IIB Nonferrous Material Specification

ASME BPVC-IIC Specifications for Welding Rods, Electrodes and Filler Metals
ASME BPVC-V Non Destructive Examination
ASME BPVC- VIII Div. 1 Rules for Construction of Pressure Vessels
ASME BPVC- VIII Div.2 Rules for Construction of Pressure Vessels [Alternate Rules]
ASME BPVC - IX Welding, Brazing, and Fusing Qualifications
ASTM A833 Standard Practice for Indentation Hardness of Metallic Materials by
Comparison Hardness Testers
ASTM E384 Standard Test Method For Knoop and Vickers Hardness of Materials
AWS A4.2 Standard Procedures for Calibrating Magnetic Instruments to Measure the
Delta Ferrite Content of Austenitic and Duplex Ferritic-Austenitic Stainless
Steel Weld Metal
AWS A4.3 Standard Methods for Determination of the Diffusible Hydrogen Content of
Martensitic, Bainitic, and Ferritic Steel Weld Metal Produced by Arc
Welding
AWS D.1.1 Structural Welding Code - Steel
AWS D1.6 Structural Welding Code – Stainless Steel
AWS D10.8 RP for Welding of Cr-Mo Steel Piping and Tubing
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AWS D10.10 Recommended Practices for Local Heating of Welds in Piping and Tubing
NACE MR0103/ Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum
ISO 17945 Refining Environments
NACE MR0175 / Petroleum and natural gas industries -Materials for use in H2S-containing
ISO 15156 Environments in oil and gas production
NACE SP0403 Avoiding Caustic Stress Corrosion Cracking of Carbon Steel Refinery
Equipment and Piping
NACE SP0472 Standard Recommended Practice: Methods and Controls to Prevent In-
service Environmental Cracking of Carbon Steel Weldments in Corrosive
Petroleum Refining Environments
NACE Publication 34108 Review and Survey of Alkaline Carbonate Stress Corrosion Cracking in
Refinery Sour Waters
NACE Corrosion 2002 Thick Wall Stainless Steel Piping in Hydroprocessing Units Heat
Paper No.02478 Treatment Issues
API 510 Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair,
and Alteration
API 570 Piping Inspection Code: Inspection, Repair, Alternation, and Rerating of In-
service Piping Systems
API RP 582 Welding Guidelines for Chemical, Oil, and Gas Industries.
API 617 Axial and Centrifugal Compressors and Expander-compressors for
Petroleum, Chemical, and Gas Industry Services
API 620 Design and Construction of Large, Welded Low-Pressure Storage Tanks
API STD 650 Welded Tanks for Oil Storage
API 653 Tank Inspection, Repair, Alternation and Reconstruction
API RP 934-A Materials and Fabrication of 2¼Cr-1Mo, 2¼Cr-1Mo-1/4V, 3Cr-1Mo, and
3Cr-1Mo-1/4V Steel Heavy Wall Pressure Vessels for High-temperature,
High-pressure Hydrogen Service
API 934-C Materials and Fabrication of 1-1/4CR-1/2Mo Steel Heavy Wall Pressure
Vessels for High Pressure Hydrogen Service Operating at or Below 825 °F
(441 °C)
API 938-B Use of 9Cr-1Mo-V (Grade 91) Steel in the Oil Refining Industry
API Tech. Report 938-C Use of Duplex Stainless Steels in the Oil Refining
API RP941 Steels for Hydrogen Service at Elevated Temperatures and Pressures in
Petroleum Refineries and Petrochemical Plants
API RP 939-C Guidelines for Avoiding Sulfidation (Sulfidic) Corrosion Failures in Oil
Refineries
API RP 945 Avoiding Environmental Cracking in Amine Units
CSA B51 Boiler, pressure vessel, and pressure piping code (applicable to equipment
for use in Canada)
Lean Austenitic type 16.8.2 Stainless Steel weld metal. - Authors: A W Marshall & J C M Farrar
NBIC, Part 1 Installation
NBIC Part 2 Inspection
NBIC Part 3 Repairs and Alterations
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WRC Bulletin 452 Recommended Practices for Local Heating of Welds in Pressure Vessels

4.1 Definitions – General
4.1.1 “Owner’s Engineer” means the Suncor Engineer or the designated representative for the
technical integrity of the work.
4.1.2 “Owner’s inspector” means the Inspector or the designated representative responsible for
that aspect of the work.
4.1.3 “Owner” means Suncor Energy Inc.
4.1.4 “Purchaser” means the agency that issues the Purchase Order contract of the supplier.
4.1.5 “Supplier” means the agency that supplies the service material or equipment also referred
to as the “Seller”, the “Vendor” or the “Manufacturer”.
4.1.6 Welding Specialist means an Engineer or Welding Technologist who has degree or
diploma or Technology certification in Mechanical/Welding/Metallurgy discipline and has 5
years minimum experience out of which 3 years are in reviewing and approving WPS/PQR.
With Owners approval, individual with degree/diploma/technology certification in other
relevant Engineering discipline may be considered provided he/she has relevant
credentials and extensive experience in reviewing and approving WPQ/PQR.
4.1.7 Repair Rate for piping = (number of joints rejected / no. of joints inspected) X 100%;
reported as a percentage per inspection method applied.
4.1.8 Repair Rate for equipment is reported as a percentage per inspection method applied.
total length of rejected weld deposit x 100(%)
Repair Rate (%) =
total length of weld deposit inspected
4.2 Definitions – Service
4.2.1 Hydrogen Service is defined as process streams containing greater than 50 psia (345
kPa) max operating partial pressure of hydrogen at operating temperatures greater than
400°F (204°C).
4.2.2 Polythionic Acid Stress Corrosion Cracking (PASCC) as defined in NACE RP0170, it is
the cracking of sensitized austenitic stainless steel and austenitic alloys material when
exposed to a conductive service environment. There are three primary contributing factors
required for the cracking to initiate- a) conducive polythionic acid service environment,
formed by reaction of oxygen and water with sulphide corrosion products, b) Sufficient
Tensile stress, caused by either equipment applied stress or residual stresses or both
combined, c) Susceptible material- generally sensitized austenitic materials.
4.2.3 Sulphur Service, Sulphur Environment or Sulphidation Service are defined as
hydrocarbon streams containing sulphur compounds (polysulphides, hydrogen sulphide,
mercaptans, aliphatic sulphides and disulphides) at temperatures greater than 450°F
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(232°C).
4.2.4 Environmental Cracking Service
4.2.4.1 Cracking initiated by Hydrogen charging sour service environment as defined below in
4.2.5 is any of the following:
a) Sulphide Stress Cracking (SSC)
b) Hydrogen Blistering
c) Hydrogen Induced Cracking (HIC)
d) Stress Oriented Hydrogen-Induced Cracking (SOHIC)
4.2.4.2 Alkaline Stress Cracking (ASCC) service is any of the following:
a) Caustic SCC service (CSCC) as defined by NACE RP0403,
b) Alkanolamine solutions containing CO2 and/or H2S as described by API RP 945 ,
c) Alkaline sour waters containing carbonate service as described by NACE TR 34108,
4.2.4.3 Hydrogen Stress Cracking (HSC) service is the following:
a) HF acid
4.2.5 Sour Service (also known as Wet H2S Service) Services in which environment condition
contains sufficient dissolved sulphides species that cause cracking of material by Hydrogen
charging into the steel when exposed to process environment as defined in NACE MR0103/ISO
17945 or NACE MR0175/ISO 15156. Materials and Fabrication Requirements for such services
are provided in Suncor standard CTS 0904.
4.2.6 Hydrofluoric Service HF acid is used for hydrocarbon processing such as in HF alkylation units
to further process dried isobutene and olefins with HF. HF acid in the aqueous environment can
lead to hydrogen charged stress corrosion cracking (HSC).
4.2.7 Caustic Service is when caustic used in hydrocarbon processing plants may cause caustic
Stress Corrosion Cracking of equipment and piping.
4.2.8 Cyclic Service is when the conditions applying to specific weld joints in piping or equipment shall
be subjected to the cyclic service conditions as defined in piping or pressure vessel code or other
conditions that the designer determines will produce an equivalent fatigue effect.
4.3 Definitions – Material
4.3.1 Batch = manufacturers’ designation for a heat of weld filler metal or mix of weld flux.
4.3.2 Creep Enhanced Low Alloy Steels are defined as Cr-Mo alloy steels with vanadium
additions (i.e. 2¼CrMo-V, 9CrMo-V).
4.3.3 Low Alloy Steels are defined as standard grades of chrome and/or chrome-molybdenum
alloys with up to 9 wt.% chrome (i.e. C-½Mo, 1Cr-½Mo, 1¼Cr-½Mo, 2¼Cr-1Mo, 5Cr-1Mo,
and 9Cr-1Mo). Vanadium modified CrMo grades are not included. Any Low Alloy Steel or
matching weld filler metal with a vanadium content that exceeds 0.05 wt% shall be rejected.
4.3.4 Metal Cored Arc Welding (MCAW) is a variation of GMAW or FCAW welding process with
tubular consumable that contains metal powder additions and no flux. The core may
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include some alloying elements to improve weldment properties. In the absence of flux to
produce shielding gas, the process is only operated with an auxiliary gas shielding.
4.3.5 Composite Material is a material consisting of two or more discrete materials with each
material retaining its physical identity.
4.4 Acronyms

ASTM American Society for Testing and Materials
AWS American Welding Society
BPVC Boiler and Pressure Vessel Code (ASME)
Cr Chromium
CVN Charpy V notch (impact toughness)
DMW Dissimilar Metal Weld; the weld joining two base metals of different alloy compositions
by using a filler metal that is compatible with both. It also includes the joining of base
metals of the same alloy composition with a compatible filler metal that has a different
alloy designation.
DSS Duplex stainless steel
FCAW Flux Core Arc Welding
FN Ferrite Number
GMAW Gas Metal Arc Welding
GMAW-MWSC Gas Metal Arc Welding - Modified Wave Short Circuit (is not an ASME or AWS welding
process designation) is used in this standard to refer to a form of pulsed GMAW. Typical
commercial designations are: STT (Lincoln), RMD (Miller), or CMT (Fronius).
GTAW Gas Tungsten Arc Welding
GTSM Gouge (or grind) to sound metal
HAZ Heat Affected Zone (of a weld)
HBW Brinell Hardness (tungsten indenter)
HV Vickers Hardness Number
MCAW Metal Core Arc Welding
MDMT Minimum Design Metal Temperature
Mo Molybdenum
MT Magnetic Particle Testing
NDE Non-Destructive Examination
Ni Nickel
PQR Procedure Qualification Record
PRN Peer Review Network (Suncor term)
PT Penetrant Testing
PWHT Post Weld Heat Treatment
RT Radiographic Testing
SAW Submerged Arc Welding

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SCC Stress Corrosion Cracking

SMAW Shielded Metal Arc Welding
SME Subject Matter Expert (Suncor term)
UT Ultrasonic Testing, specifically angle beam (shear wave) techniques
V Vanadium
WPQ Welder Performance Qualification
WPS Welding Procedure Specification
5.0 WELDING
5.1 General Welding Requirements
5.1.1 During welding, all welds shall be protected from weather conditions that may adversely
affect weld quality.
5.1.2 All surfaces to be welded shall be dry, and free of mill scale, rust, oil, grease, dirt, paint and
similar "contaminants".
5.1.3 Welding of austenitic stainless steels or nickel alloys to components which have been
galvanized, or painted with “zinc-rich" paints, is prohibited even if these coatings have been
removed.
5.1.4 Flame cutting shall not be permitted on alloys containing 9% Cr or higher.
5.1.5 When flame or plasma cutting is used on carbon steel with a thickness greater than 1” (25
mm) or on any thickness of 1%Cr to 12%Cr alloys, the weld bevel preparation shall be
ground to bright metal and shall be examined by MT.
5.1.6 For stainless steels and nickel alloys, flame cutting/air arc gouging is not allowed. Plasma
cutting is allowed for austenitic stainless steel and nickel alloys, in this case the gouged
surface shall be ground or machined to sound metal.
5.1.7 Unless otherwise stated in this standard, backing strips (either temporary or permanent)
shall not be used for new fabrication except when allowed by tank construction code.
5.1.8 Backing strips may be used for field maintenance welding with prior written approval of the
Owner/Purchaser. The risk associated with the use of backing strips shall be evaluated
and shall include as a minimum the following considerations:
a) Corrosion - enhanced crevice corrosion and stress corrosion cracking threat,
b) weld root quality and interference with examinations,
c) pigging applications in piping,
d) backing strips becoming detached, and
e) residual and applied stress concentration effects (cracking, fatigue & SCC).
5.1.9 Non-consumable Ceramic retainers are allowed to be used only for tank floor plates
welding upon prior approval of Owner’s welding specialist. All welders shall be qualified per
code requirements. Ceramic retainers shall not be used with FCAW 100% CO2 gas
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shielding. Ceramic retainers shall not be used in joints with wide root openings above
3/8”(10mm).
5.1.10 All pressure retaining joints, including socket welds, and Tube to Tubesheet welds shall
have a minimum of two passes; stop-starts shall be staggered.
5.1.11 Wash pass weld is not permitted, wash pass shall not be considered as a weld pass, wash
pass welding intended to remelting of the weld caps is not considered a part of strength
weld.
5.1.12 Peening shall not be used. The use of pneumatic tools for the purposes of slag removal is
not considered peening.
5.1.13 “Vertical" welding shall be in the vertical-up direction only, with the following exceptions:
a) All welders performing downhill welding shall be qualified in downhill welding to code
requirements.
b) SMAW is acceptable for welding downhill progression for fill and cap passes when
E7048 electrodes are used.
c) Gas Metal Arc Welding - Modified Wave Short Circuit (GMAW-MWSC) process may be
used for root pass in the “vertical-down” direction if qualified by weld procedure coupon
qualification testing,
d) Field maintenance weld overlays, welding in the vertical down direction shall be
subject to prior written approval of Owner’s Welding Specialist.
e) The root pass of above ground storage tanks that are subsequently removed (GTSM)
and welded from the opposite side,
f) The cap pass of above ground storage tanks that are not in contact with process fluids.
g) FCAW is not accepted for vertical downhill progression welding.
5.1.14 Each weld layer shall be completed prior to starting the next layer. Continuous multiple
pass Block welding with staggered starts and stops in which separated lengths are
completely or partially built up in cross section before intervening lengths are deposited is
permitted for welding large attachments on large pressure envelope components. PQR and
WPS shall be submitted and prior Owner’s Welding Specialist approval is required when
block welding is considered, additional NDE may be required.
5.1.15 Socket welds shall have an approximate 1/16” (1.5 mm) gap between the bottom of socket
and end of the inserted pipe prior to welding as required by piping code. Prior to the
assembly of the socket welded joint, the pipe and fitings shall be cleaned of any debris and
one of the following methods shall be used to ensure a 1/16” (1.5mm) gap is maintained
after the welding:
a) The square cut pipe to be in-service shall be inserted into the socket to maximum
depth and scribed with a soapstone and then withdrawn approximately 1/16” (1.5mm)
away from the contact between the end of the pipe and bottom of the socket then tack
welded in place.
b) Use a water soluble spacer ring of 1/16” (1.5mm) thick
5.1.16 Welder identification map shall be provided or each weld shall be marked with the welder’s
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unique symbol using indelible ink markers or low stress metal stamps. Marking materials
shall be suitable for SS and contain less than 200 ppm halogens and 200 ppm sulphur.
When requested, composition certificates of marking materials shall be provided by the
supplier.
5.1.17 Grinding wheels or wire brushes used on carbon or low alloy steels shall not be used on
stainless steel (any grade) or on nickel alloys.
5.1.18 The Supplier shall ensure that the applicable qualified WPS are available to welders when
performing production welding. Supplier and Purchaser QC/QA personnel will ensure
compliance to these requirements during quality surveillance.
5.1.19 Unless otherwise specified by the owner, all butt welds shall be full (complete) penetration
welded joints in accordance with the applicable Code of construction.
5.1.20 For maintenance welding applications, the Owner/Purchaser shall ensure that welding
related Suncor local BU facility documents and requirements that supplement or exceed
this standard are implemented. Industry recommended specific maintenance welding
practices should also be considered where requirements exceed those of this standard. In
every case, maintenance welding procedures and practices shall be approved by the
Owner/Purchaser.
5.1.21 Drawings indicating the location of weld joints with the associated WPS’s (weld maps), the
applicable welding procedure specifications (WPS) and procedure qualification records
(PQR) shall be submitted for Purchaser review and approval prior to fabrication.
5.1.22 Dissimilar Metal Welds (DMW)
5.1.22.1 Dissimilar metal welding between ferritic and austenitic materials including Alloy 400 or
between austenitic welding including Alloy 400 on ferritic base metals shall be avoided in
new fabrication for application in services where galvanic corrosion, environmental
cracking or thermal fatigue is possible without the written acceptance of the Owner’s
Welding Specialist prior to commencing of fabrication. (See paragraph 5.1.24 for
maintenance welding that involves dissimilar metal joints.)
Examples of such services include but are not limited to:
a) Corrosive services
b) sour service
c) Ammonium Bisulphide
d) Carbonic acid
e) HF service
f) Hydrogen service
g) Thermal fatigue service
h) Low temperature service below -20F
i) High Temperature service >600F
5.1.23 Corrosion-Resistant Weld Overlays on ferritic base metals are considered as Dissimilar
Metal Welds unless the entire100% surface areas of the ferritic base metal surface
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including any nozzles and attachments are covered by overlay and no area of the ferritic
base metal is exposed to the process services. All weld overlay welding shall be in
compliance with Suncor Alloy Cladding standard CTS 0603 and ASME Section IX
requirements.
5.1.24 For maintenance welding applications, all dissimilar metal joints shall be identified and the
welding procedures shall be subject to prior review and acceptance from the Owner’s
Welding Specialist.- Refer Suncor-Wide Guideline document MRS-GL-TWD-001 Risk
Assessment and Mitigation for Dissimilar Metal Welds Guideline.
5.1.25 Document review for above 5.1.22 Dissimilar Metal Welding shall include evaluation of the
following:
a) Verification of compliance to regulatory and applicable Code requirements,
b) Differential thermal expansion and resulting cyclic stresses or creep,
c) Service suitability, including galvanic corrosion or stress corrosion cracking threats,
d) Review of PQR(s) and supporting or appended test reports (hardness traverses) that
may involve multiple weld procedures with intermittent heat treatment.
5.1.26 Special Service Applications Welding
5.1.26.1 Welding for special service applications such as HF acid, where weld slag inclusions are
attacked by service exposure, following additional requirements shall be considered:
a) Root pass and hot pass to a minimum weld deposit of 3/8” (9.5 mm) shall be
performed with GTAW for piping and GTAW or GMAW-MWSC process for pressure
vessels in single sided weld construction.
b) For double sided weld joint configuration, inside weld cap exposed to service, shall be
welded using above a) criteria.
c) For fill passes when SMAW or other welding processes that contain slag are used,
welding procedures shal be qualified with interpass cleaning as an “Essential Variable”
to minimize slag in the final welds.
d) Acceptance criteria of the weld defects shall be per ASME B31.3 Severe Cyclic
Service acceptance criteria
e) When PWHT is required, final NDE shall be performed at least 24 hours after the final
PWHT after it is cooled down to ambient temperature.
5.1.27 Cyclic Services for applications welding
5.1.27.1 Fatigue due to pressure cycling, thermal cycling, and other cyclic loadings shall be
considered in the design of piping and equipment.
5.1.27.2 All welds shall have a smooth weld profile, caps to be ground smooth and flush with parent
metals:
a) 40-80 grit disks can be used to remove the weld cap to “near-flush” with the pipe or the
equipment.
b) 120 grit disks must be used to finish grinding the cap flush with the pipe or the
equipment.
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c) Grinding direction shall be longitudinal to the pipe or equipment axis.

5.1.27.3 All groove welds shall be full penetration welds. Partial penetration groove welds are not
allowed.
5.1.27.4 Permanent backing rings are not allowed. If required, consumable inserts or removable
non-metallic backing rings can be used.
5.1.27.5 Socket welds shall not be used.
5.1.27.6 Miter welds shall not be used.
5.1.27.7 Structural external and internal attachments to piping or equipment shall be designed to
minimize stress concentration.
5.1.27.8 All welding procedures shall be qualified to have a smooth, regular, fully penetrated inner
surface.
5.1.27.9 For piping welds, root pass shall be welded with GTAW process.
5.1.27.10 For pressure vessel of single sided weld construction, GTAW process shall be utilized. For
pressure vessels of double sided weld joint configuration when welding process with
coated electrodes or flux covering are used, welding procedure and production welding
shall utilize increased Interpass cleaning to remove all slag from the welding.
5.1.27.11 All craters (stop/start) shall be ground/buffed smooth.
5.1.27.12 Only filler metal classifications matching the base metal shall be used.
5.1.27.13 Temporary welds shall not be allowed.
5.1.27.14 Mechanical clamps shall be used for piping alignment. The use of welded alignment
devices (such as fit-up lugs) is not permitted.
5.1.27.15 Thickness transitioning:
a) Thickness transition shall be a smooth between offset edges at a slope of not more
than 4 in 10 with the surfaces or edge of either part.
b) The transition of thickness may be accomplished by sloping weld faces, by chamfering
the thicker part, or by a combination of the two methods.
5.1.27.16 All welds shall be 100% visually examined.
5.1.27.17 All fillet and branch connection welds that are not radiographed shall be 100% examined
by shear wave ultrasonic examination.
5.1.27.18 All circumferential butt and groove welds and applicable branch connection welds shall be
100% examined by radiography.
5.1.27.19 For piping, ASME B31.3 alternative inspection requirements for severe cyclic service as
defined in ASME B31.3 Clause 300.2 shall be stated to increase fatigue design life of
piping subjected to severe cyclic service (such as Coker blow down service piping).
5.1.27.20 All welds in piping shall be inspected as per ASME B31.3 Clause 341.4.3. Additional
Acceptance criteria for weld visual and radiographic inspection shall be in accordance with
ASME B31.3 Table 341.3.2 for severe cyclic conditions, with the following exceptions:

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a) Cap reinforcements are not allowed.

5.1.27.21 For piping welds, acceptance criteria for ultrasonic examination shall be in accordance with
ASME B31.3 Clause 344.6.2.
5.2 Welding Procedure
5.2.1 Prior to weld fabrication the applicable Supplier’s weld procedures both WPSs and PQRs
shall be submitted for review by the Owner/Purchaser’s Welding Specialist.
5.2.2 The review shall include and ensure:
a) Verification of compliance to regulatory and applicable Code requirements,
b) Material suitability – Material chemistry and Mechanical properties compatibility
c) Service suitability – Hardness, impact test and thermal treatment (such as PWHT)
requirements,
d) Compliance to applicable Suncor standards and the purchase order,
e) Review of PQR(s) and supporting or appended test reports.
5.2.3 Welding Procedure for all welds exposed to sour service environments shall be qualified
according to NACE SP0472 latest edition. The qualifications shall include preproduction
hardness control methods on weld deposit and HAZ within specified hardness limits to
prevent sulfide cracking hardness. Refer to Suncor standard CTS0904 Materials and
Fabrication Requirements for Sour/Wet H2S Service for various base metal chemistry and
welding requirements applicable to sour service severities. Thermal methods requirements
to control HAZ hardness shall be following:
5.2.3.1 Pressure Vessels: PWHT per Suncor Pressure Vessels standard CTS0601
5.2.3.2 Piping: Per Suncor Piping Specifications CTS0202
Upon prior approval of Owner’s welding specialist, HAZ hardness control requirements for
Seamless carbon steel Piping with single-sided welding maybe waived provided:
a) Multi-pass welding with tempering effect used
b) PQR and WPS qualified with Maximum Carbon Equivalent CE 0.43 and
c) all production pipes to be used in the service shall be CE ≤ 0.43 max. and
d) Preproduction weld procedure HAZ hardness comply with NACE hardness
requirements
5.2.3.3 Temper bead welding as an alternate thermal method for HAZ hardness control is not
permitted. Exception to this could be considered for Category-1 mild sour service case by
case upon prior discussion with and approval from Owner’s Welding Specialist.
5.2.4 Welding shall not begin until the welding procedures have been approved.
5.2.5 All welding shall be performed in accordance with WPS(s) that has been qualified in
accordance with the ASME BPVC Section IX, the additional requirements of the
construction Code, and the applicable additional requirements of this Standard.
5.2.6 All advanced Waveform Controlled Welding process shall be as per guideline provided in
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the latest ASME IX Appendix H. All welding procedures shall be qualified with heat-input as
per QW-409.1(c) and Appendix H- 300 for New Procedures Qualifications for waveform
controlled welding.
5.2.6.1 Welding procedures previously qualified using non-waveform controlled welding and heat
input determined by QW-409.1 (a) may continue to be used for waveform controlled
welding, provided they are amended to require heat input determination for production
welds using methods QW-409.1 (c).
5.2.6.2 Welding procedures previously qualified using non-waveform controlled welding and heat
input determined by QW-409.1 (b) continue to be applicable for waveform controlled
welding without changes to the heat input determination method.
5.2.7 The welding procedure specifications used by manufacturer/fabricators located in Canada
shall be registered with the applicable Canadian provincial regulatory authority.
5.2.8 WPS’s shall describe all essential, nonessential, and when required, supplementary
essential variables for each welding process used, the WPS and PQR shall also document
the additional requirements of this Standard that are not covered under ASME BPV Code
Section IX.
5.2.9 All welding procedures that are specified to join ASME P No’s 1 thru 7 base materials, and
that may be exposed to stress corrosion cracking (SCC) services, shall be subject to the
following additional qualification testing to control the properties of the weld heat affected
zone (HAZ). Qualification shall include cross sectional hardness testing of the weld
procedure qualification coupon and recording the coupon base metal alloy composition as
follows:
a) Record the qualification coupon base metal alloy composition. Base metal MTR shall
be attached.
b) Perform a Vickers (ASTM E384, HV10) hardness survey using a transverse cross-
section of the weld procedure qualification coupon in accordance with NACE SP0472
for carbon steel, or in accordance with ISO 15156/NACE MR0175, NACE MR0103 as
applicable for carbon steel or all other materials.
c) The hardness measured on the transverse cross section of the weld procedure
qualification coupon shall meet the hardness requirements of ANSI/NACE
MR0175/ISO 15156/ or ANSI/ISO 17945/NACE MR0103 as applicable for all other
materials.
5.2.10 Welding Procedures for Pressure Vessels that will be Post Weld Heat Treated (PWHT),
shall be qualified based on the number of cycles specified in Suncor Std.0601 and
minimum holding temperature and hold time requirements as in Table 3A in Appendix A of
this standard.
5.2.11 Unless otherwise specified by the owner the procedure qualification for tube-to-tubesheet
weldments that are exposed to Stress Corrosion Cracking service and will not be Post
Weld Heat Treated, shall be qualified by testing a mock-up of the tube-to-tubesheet joint
that is fabricated in accordance with the following requirements as provided below. All
mock-ups shall supplement the tube-to-tubesheet welding qualification requirements of
ASME Section IX.
a) It shall contain 2 rows of 5 tube-to-tubesheet welds, and shall be sectioned through all
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10 welds.
b) Each weld shall be uniquely identified on the face of the test coupon.
c) The sections shall be polished and suitably etched to reveal weld bead placement.
d) Close simulation of the production tube-to-tubesheet welded joints is required for the
mock-up and shall include the following:
e) The thickness of the mock-up tube-sheet shall be at least as thick as the production
tubesheet, but need not exceed thickness specified in ASME Sec IX, QW-193.
f) The same production materials (specification and grade).
g) The maximum carbon equivalent allowed in production shall be the carbon equivalent
of the materials used to fabricate the mock-up.
h) The same production welds preparation and joint configuration used for the mock-up.
i) The same access restrictions to the weld joint as will be present during production.
j) The minimum preheat allowed in production.
k) The minimum welding heat input allowed in production.
l) The same weld bead placement.
m) The maximum degree of cold expansion intended for production.
5.2.11.1 Mock-up cross sectional micro-hardness shall be as per NACE MR0175/ISO15156 or
NACE MR0103/ISO17945 as applicable.
5.2.11.2 Testing of the mock-up shall include Vickers micro-hardness measurements of all ten
welds, of both base metals, both heat affected zones (HAZ's), and the weld metal deposit.
a) A suitable etchant and microscopy shall be used when targeting micro-hardness test
indentations towards harder microstructures within the HAZ.
b) Visual examination at 10x magnification shall be used to check for cracks; none are
allowed.
5.2.11.3 Testing of the mock-up shall be performed by an independent third party facility,
experienced in the qualification of welding procedures and weld testing. A report detailing
all the specifics of the mock-up test including the obtained micro-hardness values shall be
provided to Owner/Purchaser’s Welding Specialist for review and approval prior to starting
of the fabrication. The report shall be suitable for submission to the authorized jurisdiction,
either as a stand-alone procedure qualification record (PQR) or as a supplement to an
existing PQR.
5.2.12 For maintenance welding applications, where PQR’s do not include tubesheet mock-up
coupon testing, the temper bead welding technique shall be used.
5.2.13 Production welders shall be trained to ensure that procedural control (i.e. specific
requirements for preheat, current, voltage, arc length, travel speed, and bead placement) is
maintained.
5.2.14 For maintenance welding applications, the user shall ensure that welding related Business

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Unit specific documents with requirements that are in addition to this standard are followed.
Industry recommended practices for maintenance welding should also be considered
where requirements exceed those of this standard.
5.3 Welder Performance Qualification
5.3.1 Welders and welding operators employed in shop fabrication, field erection, and in
alteration or repair shall be qualified to the requirements of ASME Section IX and shall hold
a valid performance evaluation and a competence certificate and any other applicable local
regulatory requirements for each welding process they are to weld.
5.3.2 All tack and temporary welds unless removed and not become part of the completed weld
shall comply with all requirements of para 5.3.1.
5.3.3 In addition to clause 5.3.1, welders using the following processes as in 5.3.3.1 and 5.3.3.2
shall pass mechanical testing in accordance with ASME QW-302 (guided-bend testing)
prior to production welding. The welder performance test coupon shall be made with
material of the same ASME P- number as used in production.
5.3.3.1 GMAW-MWSC - for all materials
5.3.3.2 FCAW/MCAW - for material other than P1
5.3.3.3 Welder who has already undergone bend testing for above processes in 5.3.3.1 & 5.3.3.2
within the past six months, need not perform bend testing again for the applicable project.
However, manufacturer/contractor shall provide documented evidence of bend testing of
respective welder to Purchaser’s Welding Specialist for review. For piping welding
application, first two production weld joints shall be RT’d as a qualifier of each welder.
Such two production welds chosen for welder qualification shall not be considered as a
part of random radiography examination calculation.
5.3.3.4 Exceptions to the above para 5.3.3.3 requirements may be considered case by case basis
upon written satisfactory acceptance from Purchaser’s/Owner’s Welding Specialist review,
following minimum documentations (but not limited to) shall be submitted for review:
a) Certificate of competency from local regulatory authority.
b) Valid company performance qualification card indicating type of pressure welding the
welder is certified and currently engaged.
c) Welder’s ASME Sec. IX Qualification record.
d) If the welder qualification is expired, welder shall have valid 6 months period extension
in compliance with the local regulatory requirements such as equivalent to AR 169 in
Alberta.
e) Welder’s Guided Bend test on groove weld using above 5.3.3.1 or 5.3.3.2 process with
acceptance certificate and validity date.
f) WQR showing owner welding inspector verification.
g) Proof of continuity in the relevant welding job beyond 6 months validly including
drawings with weld map and the jobs performed by the welder and repair rate.
h) Written procedure by the fabricating employer company that all welding jobs of the
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welder shall be tracked for inspection and if repair rate exceeds 4%, the welder shall
be removed and all welds completed shall be cut-out and removed.
5.4 General Requirements for Welding Consumables (Filler Metals and Flux)
5.4.1 All welding rods, Electrodes and Filler metals shall be as per by ASME II, Part C/AWS
Specifications and classifications. Filler metals and Fluxes shall be specified in the WPS
and PQR. Welding consumables shall be used only for the welding process applications
recommended in the ASME II, Part C/AWS filler metal specifications or by its manufacturer
(e.g. filler metals designed for “single-pass welding” shall not be used for multiple pass
applications and fluxes designed for non-PWHT applications shall not be used for PWHT
applications).
5.4.2 “G” classification electrodes chemical composition is not completely controlled by ASME
Section II, Part C. All G” classification electrodes, if used for welding, shall be separately
qualified for each manufacturer, grade, and heat of electrode so classified.
5.4.3 The storage and handling of welding consumables used in production shall be carried out
in accordance with the consumable manufacturer’s recommendations and the ASME BPV
Code Section II, Part C. Each fabricator shall have this requirement included in their quality
assurance program. Quality assurance programs are subject to review by the Purchaser.
5.4.4 Carbon steel welding consumables (ASME A-No.1) intended for SSCC service applications
shall contain no more than 1.0 wt.% Nickel.
0
5.4.5 When using 300 series stainless steel filler materials for design temperatures above 1000 F
0
(538 C), or when “H” Grade materials are specified by Suncor, high carbon
electrodes/wires with 0.040% minimum carbon shall be used.
5.4.6 When DMW is permitted by prior approval of Owner’s welding specialist, the filler metal for
welding between ferritic steels (P-1 through P-5 and P-15E) to:
5.4.6.1 Martensitic stainless steels (P-6) or Ferritic streels (P-7) or Austenitic stainless steels (P-8),
the filler metals shall be selected based on the following criteria:
0
a) Type 309 and Type 309L may be used for design temperatures not exceeding 600 F
0
(315 C)
b) Type 309Nb shall not be used when PWHT is required, except for weld overlay
applications.
0
c) Nickel base filler metals shall be used when design temperature exceeds 600 F
0
(315 C) using design conditions shown in Table 1.
5.4.6.2 For service conditions exceeding the limits provided in the Table 1, Owner’s Welding
Specialist shall be consulted.
5.4.6.3 ASME/AWS Classification ER310/E310-XX and ASME/AWS Classification ERNiCrFe-6
shall not be used.

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Table 1- Applications of Nickel-base Electrodes in Sulfidation and Non-Sulfidation Environments
Maximum Maximum Design

ASME/AWS Filler
Design Temperature Temperature (Sulfur
Material Classification
(Non-Sulfur Environnent) Environment)
ERNiCr-3, ENiCrFe-3 1000 °F (540 °C) 700 °F (370 °C)

ERNiCr-3, ENiCrFe-2 1400 °F (760 °C) 750 °F (400 °C)
ERNiCrMo-3, ENiCrMo-3 1100 °F (590 °C) 900 °F (480 °C)
5.4.7 Fe content of alloy 625 welding consumables used for weld overlaying on carbon and low
alloy steel materials shall be limited to 2% maximum.
5.4.8 Wires with micro additions of Ti and/or Boron added to enhance low temperature
toughness shall require additional hardness and impact testing after PWHT as specified by
the owner, these are to be submitted for Owner’s acceptance.
5.5 Welding Process and Filler Metal Limitations
5.5.1 Selection of Welding consumables are listed in Appendix B.

5.5.2 The following processes and filler metals are allowed, subject to the following limitations:
5.5.2.1 Shielded Metal Arc Welding (SMAW)
a) Low Hydrogen type electrodes shall be used in SMAW process. E6010 electrodes may
be used for welding the root pass and the subsequent pass in carbon steel pipe butt
0
welds, however, for low temperature applications (colder than -20 F), the hot pass
shall be welded with low hydrogen consumables.
b) E6012, E6013, E6022, and E7014 SMAW electrodes shall not be used.
c) E7024 electrodes shall not be used with the exception of tank roof and tank floor weld
fabrication only. Tank floor lap joints shall be welded with minimum two passes.
d) E6010 Electrode sizes larger than 3/16" (4.8 mm) diameters shall be restricted to the
flat or horizontal-fillet welding positions.
e) When SMAW process is applied to weld in application of Special Services (Refer to
5.1.26), following additional requirements shall apply:
i. Welding procedures shall be qualified with interpass cleaning as an “Essential
Variable” to minimize slag in the final welds.
5.5.2.2 Gas Tungsten Arc Welding (GTAW) and Pulsed GTAW (GTAW–P)
a) Autogenous welding (without filler metal) shall not be permitted.
b) Autogenous welding for proprietary equipment maybe considered on case by case
basis upon prior approval of Suncor Welding Specialist, details of the process with
weld map and PQR/WPS shall be submitted for review prior to commencing welding
work.
c) Cut solid wire filler metal shall be tagged or die-stamped at both ends. PMI per Suncor

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Standard 0213 shall be completed on one cut solid wire sample per heat lot or on one
spool wire sample per heat lot of low alloy steel or stainless steel weld filler metal.
d) Purge gases shall not be substituted with welding techniques or flux-coated wire.
e) GTAW welding process shall be used and back purge gas shall be applied for the root
pass and hot pass to a minimum weld deposit of 3/8” (9.5 mm) on pipe and tube butt-
welds for:
i. 2¼Cr-Mo and higher Cr-Mo alloys, stainless steels, nickel based alloys, or for
ii. Special Services (Refer to 5.1.26) and applications such as but not limited to:
 HF service and other such services where slag free clean weld root passes are a
prerequisite to prevent corrosion
 lube oil lines,
 hydraulic lines,
 steam inlet lines to steam turbines,
 instrument lines,
 austenitic fired heater tubes.
5.5.2.3 Gas Metal Arc Welding (GMAW) and Metal Cored Arc Welding (MCAW)
a) Applicable materials: carbon steel, low alloy steel, austenitic stainless steel (300
series), duplex stainless steel.
b) GMAW-S (short circuit mode) shall not be used. GMAW- MWSC is permitted to be
used only for root pass welding.
c) GMAW Spray mode, shall be limited to fill passes only.
d) GMAW Spray mode is permitted in Flat and Horizontal positions only
e) GMAW Globular mode is not permitted.
f) The sheliding gas shal be rich in Argon in the spray mode, maximum CO2 content shall
be limited to 15%.
g) MCAW process with composite electrodes is not permitted to fabricate pressure
equipment, vessels or piping that are made using carbon steel or low alloy steel where
the MDMT is less than -20°F (-29°C) unless production impact tests are completed on
each batch of weld consumables that are used in production. Only consumables
designated with low temperature impact toughness properties shall be considered. The
test temperature for CVN impact toughness testing shall be the MDMT or lower.
h) The design of MCAW joints used for the pressure retaining envelop shall be such that
full 100% volumetric examination can be completed. Applicable examination methods
are RT or UT (shear wave angle beam, PAUT, or TOFD).
i) See Section 5.3 of this Standard for additional welder performance testing
requirements.
j) Pipe less than NPS 4 shall be welded in the 1G position (plus/minus 15 degrees of top
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dead centre).
k) Branch connections shall be welded in the 2G position.
5.5.2.4 Gas Metal Arc Welding - Modified Wave Short Circuit (GMAW- MWSC) and Gas Metal Arc
Welding - Pulsed (GMAW-P)
a) Only inverter type welding power sources shall be used with GMAW-MWSC and
GMAW-P processes. Production welding power sources shall be of the same make
and model as those used to fabricate the weld procedure qualification test coupon.
The fabricator shall keep records verifying that welders are trained in the use of the
make and model of power sources to be used in production.
b) Production welding shall utilize the same filler metal wires (consumable manufacturer
brand and filler metal classification), shielding gas composition, shielding gas flow rate
range, and gas cup size as reported in the applicable weld PQR.
c) GMAW-MWSC shall be limited to weld root pases only.
d) GMAW-P shall be limited to weld fill passes only
e) GMAW-MWSC and GMAW-P are permitted to be used in all positions welding.
f) See Section 5.3 of this Standard for additional welder performance testing
requirements.
g) GMAW-MWSC welding process with back purge gas shall be applied for welding root
pass and hot pass to a minimum weld deposit of 3/8” (9.5 mm) for welding on pipe and
tube butt-welds for following applications:
i. 2¼ Cr-Mo and higher Cr-Mo Alloys, stainless steels, or for
ii. Special Services (Refer to 5.1.26) and applications such as but not limited to:
iii. HF service and other such services where slag free clean weld root passes are a
prerequisite to prevent corrosion
iv. lube oil lines,
v. hydraulic lines,
vi. steam inlet lines to steam turbines,
vii. instrument lines,
viii. austenitic fired heater tubes.
h) GMAW-MWSC may be used to weld austenitic stainless steels only for root pass
without backing gas subject to the following requirements:
i. Tri-mix shielding gases are used (e.g. 85% - 92% Helium, 4.5% - 10% Argon,
2.5% - 3.5% CO2), and shall be as specified by the WPS, and
ii. High silicon weld filler metal (e.g. ER-308L-Si; ER-347-Si) shall be used for
austenitic stainless steel base materials.
5.5.2.5 Flux Cored Arc Welding (FCAW)
a) Applicable to joining the base metals: carbon steel, low alloy steels, austenitic stainless
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steels, and duplex stainless steel.

b) FCAW is not permitted for joining ferritic grades of stainless steels or for high alloy
base metals.
c) Inverter type weld power sources shall be used.
d) Electrode types identified by the consumable manufacturer for multipass application
shall be used
e) FCAW process is not permitted to fabricate pressure equipment, vessels or piping that
are made using carbon steel or low alloy steel where the MDMT is less than -20°F (-
29°C) unless production impact tests are completed on each batch of weld
consumables that are used in production. Only consumables designated with low
temperature impact toughness properties shall be considered. The test temperature for
CVN impact toughness testing shall be the MDMT or lower.
f) The FCAW process shall not be used to make the root pass of single sided welded
joints.
g) Only the externally gas shielded FCAW process (i.e. FCAW-G) shall be used.
h) The FCAW process shall not be used on pipe groove welds or branch connections with
diameters less than NPS 4 unless welded in the 1G (rolled) welding position with
minimum 2 passes.
i) Consumables for welding carbon steel and low alloy steels shall be certified with
diffusible hydrogen designator shall be as per Table 2.
j) The Bismuth (Bi) content of austenitic stainless steel weld consumables shall be less
than 0.002 wt% (20ppm) for all applications when operating temperature is greater
0
than 750F (400 C) or when Post Weld Heat Treatment is required to be done above
0 0
900 F (500 C).
k) See Section 5.3 of this Standard for additional welder performance testing
requirements.
l) Welding of CrMo-V (Vanadium modified grades) steels shall not be permitted.
m) The design of FCAW joints used for the pressure retaining envelop shall be such that
full 100% volumetric examination can be completed. Applicable examination methods
are RT or UT (shear wave angle beam, PAUT, or TOFD).
n) FCAW is permitted on non-pressure welds such as internals and attachment welds.

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Table 2- Diffusible Hydrogen Limit for FCAW Consumables

Specified Minimum Tensile Strength for the Base Maximum Diffusible Hydrogen
Metal Designation (per ASME/AWS
SFA/A5.20 or SFA/A5.29)
≤ 70 Ksi (483 MPa) H16
> 70 Ksi (483 MPa) and ≤ 85 Ksi (587 MPa) H8
> 85 Ksi (587 MPa) H4
5.5.2.6 Submerged Arc Welding (SAW)

a) The semi-automated SAW process where advance of the welding is manually
controlled by hand held SAW guns with pressurized/gravity flux feed delivery shall not
be used.
b) Longitudinal weld joints shall be made using removable starting and stopping (run-on
and run-off) tabs.
c) Deliberate addition of alloying elements through the flux is prohibited. Only neutral
fluxes shall be used. Alloy, semi active, or active flux shall not be used. Fluxes that
compensate for arc losses of alloying elements are permitted.
d) Welding of alloy steel base metal shall be done with an alloy filler wire and neutral flux.
e) Flux cored filler metal is not permitted.
f) Flux from re-crushed slag shall not be used.
g) EL8, EL8K, EL12 or EM12 filler metals shall not be used when welding 70 ksi (485
MPa) tensile strength base materials which receive a post weld heat treatment and/or
a post weld normalizing heat treatment.
h) SAW wire and flux manufacturer’s trade/brand names shall be considered as essential
variables for the WPS. WPS shall be re-qualified whenever a change in flux
trade/brand names are made.
i) Wire and flux used for joining shall be from the same manufacturer (i.e. Lincoln wire
with Lincoln recommended flux), combining or mixing wire and flux from different
manufacturer is not permitted.
j) Exception to above para j) may be accepted under special ciscumstances upon prior
approval from Owner’s Welding Specialist only when the folloiwng condisions are
satisfied:
i. Certified Material Test Certificate (CMTR) of the flux/wire combination in
compliance to testing requirements and test results to AWS and ASME
specifications.
ii. Reasons and rationale for the deviation.
5.5.2.7 Electroslag Welding (ESW)
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a) Electroslag welding shall be limited to corrosion resistant weld overlay on P-1 through
P-5 base metals.
b) Welding procedures for electroslag welding shall be re-qualified whenever the welding
flux or wire is changed from one manufacturer to another or from one manufacturer’s
grade to another grade from the same manufacturer. Equivalence under ASME
Section II, Part C shall not be considered adequate for substitution without
requalification.
c) If the manufacturer proposes to use an active flux to attain the specified chemistry, the
manufacturer shall submit samples produced at both extreme limits, maximum and
minimum, of the specified heat input range. Both samples shall meet the overlay
chemistry specifications.
5.5.2.8 Electro Gas Welding (EGW)
a) Electro Gas Welding shall not be permitted for any piping or pressure equipment
welding.
b) Electro Gas welding may be permitted for fabrication of field erected storage tanks
upon prior approval of Owner’s Welding Specialist.
5.5.2.9 Plasma Arc Welding (PAW)
a) Plasma Arc Welding shall not be permitted for any piping or pressure equipment
welding.
b) Plasma Arc Welding may be permitted in special applications only upon prior approval
of Owner’s Welding Specialist. Automatic Plasma Arc Welding without addition of filler
metal is not permitted.
5.5.2.10 Low energy Capacitor Discharge (CD) welding may be used for welding temporary
attachments, e.g. thermocouples and permanent non-structural attachments without
preheat above 50F (10C) or subsequent PWHT on P-1 through P-5B and P15E materials
provided:
a) Prior Owner’s Welding Specialist approval is obtained
b) A Welding Procedure Specification is prepared in accordance with ASME Section IX,
describing the low energy capacitor Discharge (CD) equipment, the combination of
materials to be joined, and the technique of application. Qualification of the welding
procedure is not required.
c) Energy output of the welding process is limited to 125 W-Sec.
d) For P5A, P5B and P15E materials, the maximum Carbon content of the material is
0.15%
e) After thermocouples are removed, the areas shall be visually examined for evidence of
defects to be repaired.
5.5.2.11 Other weld processes (those not listed above) shall not be used without the prior written
approval of the Owner (a Welding Specialist’s review shall be obtained as part of this
approval).
5.5.2.12 Welded joints made with unapproved welding processes (those not listed above) shall be
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removed.
5.5.3 PMI Testing of Welding Consumables
5.5.3.1 PMI of welding consumables shall be performed to comply with the requirements of Suncor
standard CTS 0213
5.6 Fabrication and Fit-up
5.6.1 When weld joint alignment tolerances have not been specified in the applicable fabrication
Code or Suncor Standard, the alignment tolerances of Section VIII, Division 1 of the Boiler
and Pressure Vessel Code shall govern.
5.6.2 Before fitting up the weld joint, the profile and dimensions of the weld end preparation shall
be checked and compared to the requirements of the applicable Code of construction. If
the specified tolerances are exceeded, the joint preparation shall be corrected by grinding,
machining or any other methods subject to prior approval from Owner/Purchaser.
5.7 Preheat Temperature
5.7.1 Preheating, where required, shall apply to, thermal cutting, gouging, tack welding, including
temporary attachments and shall be in accordance with the latest applicable code and
recommended practices such as ASME B31.3 Table 330.1.1, ASME BPVC Section VIII
Division 1 Appendix R, API 934-A, API 934-C and AWS D1.1. Any recommendations or
requirements for preheat listed in the relevant codes shall be considered mandatory.
5.7.2 When using cellulose base electrodes for downhill progression welding, preheat
0 0
temperature shall be 212 F (100 C) minimum or as recommended by electrode
manufacturer for that specific electrodes. Prior approval of Owner’s Welding Specialist is
required before commencement of welding, additional NDE for identifying any Delayed
Hydrogen Cracking is required. Same electrodes and brand names shall be used for all
such production welding. Alternate method to using high preheat maybe accepted upon
case by study and subject to prior approval of Owner’s Welding Specialist.
5.7.3 For piping, pressure vessels, and pressure equipment that will be exposed to service
categories SSCC, SCC, Hydrogen, or Hydrofluoric Acid, the minimum weld preheat
temperature shall be the preheat temperature used to make the weld procedure
qualification coupon for which the relevant WPS was qualified.
5.7.4 The preheat temperature shall be applied, and maintained for the entire duration of welding
operation throughout the full thickness of the weld joint and at least 3 in.(75mm) on each
side of the weld for carbon steel heavy wall vessels/piping greater 2 inches (50mm)
thickness and for P4,5,6,7,9 and 15E materials.
5.7.5 Higher preheat temperatures shall be applied when designated in the WPS.
5.7.6 Propane gas or an equivalent “clean” heating gas shall be used. The torch tip shall be
appropriate for the work (e.g. a "rosebud", not a cutting tip). Heating shall be carried out to
ensure sufficient time and energy uniformly soaks the entire weld area.
5.7.7 Preheat temperatures shall be confirmed through the use of heat sensitive crayons, contact
pyrometers, infra-red scanners, or other equally suitable means. Electronic instruments
shall have documented proof of calibration that is no older than twelve months’ time.
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5.7.8 Preheat when required, shall be applied and maintained through the entire thickness of the
weld for a minimum of 3 inch (76 mm) or 1.5 times the greater nominal thickness either side
of the joint. The base metal temperature for tack welds shall be at or above the specified
minimum temperature for a distance not less than 1 in (25mm) in all directions from the
point of welding. Unless otherwise specified in the qualified WPS, the minimum preheat
temperature shall be maintained until the weld is complete.
5.7.9 When welding two different P No. materials, the preheat temperature shall be the higher
temperature for the material being welded.
5.7.10 For low alloys steel materials such as P Nos. 3, 4,5A, 5B, 6 and 15E, the required preheat
shall be applied and temperature shall be maintained until PWHT throughout the entire
thickness of the weld and at least 3 in (75mm) on each side of the weld.
5.7.11 When for any practical difficulties, if the above requirement in para 5.7.10 cannot be
applied, a de-hydrogenation heat treatment (DHT) shall be applied immediately after
welding is completed.
5.7.12 Preheat temperature should be lowered to below Martensite finish temperature (Mf) prior to
starting of PWHT.
5.7.13 For P-1 materials above 1 inch (25mm) thickness, the minimum preheat temperature shall
rd
be maintained after welding commences, until at least ½” (12mm) thickness or 1/3 .of the
weld groove thickness whichever is less for single groove and or one side of the double
groove joint is welded.
5.7.14 If the minimum preheat maintenance is interrupted before the weld is complete, cooling
shall be done under an insulation blanket and the partially completed weld shall be subject
to MT or PT before resumption of welding. When not practical, exceptions to the above
may be considered case by case such as when welding large tanks, or large vessels with
double side continuous welding or similar scenarios, case wise technical justifications with
details demonstrating compliance with the intent of the maintenance of continuous preheat
with full documentations shall be submitted for prior approval from Owner’s Welding
Specialist.
5.7.15 Weld joints that require preheat in excess of 150°F (65°C) shall be completed with no
intermediate cooling.
5.7.16 Where PWHT is required and cannot be carried out immediately after welding, the weld
shall be slow-cooled to room temperature under an insulation blanket. Heavy wall P1
material of thickness greater than 2 inches (50mm) shall be cooled under insulation
blanket, all other P-1 material of lower thickness fabricated in a controlled shop
environment may not require to comply with this requirement.
5.7.17 Special preheating methods such as by Induction heating or gas heating is permitted only
upon prior approval from Owner’s Welding Specialist before starting any welding related
activity.
5.8 Inter-pass Temperature
5.8.1 Inter-pass temperatures shall be as per Appendix A Table 1A and Table 2A, weld inter-
pass temperature shall be specified on the relevant WPS.

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5.9 Hydrogen Degassing (Bake-out)
5.9.1 Hydrogen bake-out (e.g. pre-weld degassing) shall be applied before thermal-cutting or
welding on carbon and low alloy steels (including vanadium modified grades) piping and
pressure components that has been operated in the following services (as defined in
Section 4.2 “Definitions”):
a) hydrogen service,
b) sour service,
c) hydrofluoric services, and
d) services where welding problems, such as porosity or cracking, have occurred.
5.9.2 Hydrogen bake-out shall be carried out using electric resistance heating pads at 400°F to
650°F (200°C to 350°C) for a minimum of 4 hours. Equipment, vessels and piping in
process circuits that have been subject to process steam-out operations that exceeds both
400°F (200°C) metal temperature and 4 hours can be considered to have been degassed
(i.e. bake-out).
5.9.3 On vessels over 1/2 inch (12.7 mm) thick, heat may be applied from both sides to assure
uniform, through-thickness heating.
5.9.4 The Owner or designate shall be consulted for specific applications of hydrogen bake-out
including any modifications and repairs to pressure vessels, piping or components.
5.10 Heat Treatment
5.10.1 Heat treatment as used in this section shall include all thermal treatments of the material
0 0
during fabrication exceeding 900 F (480 C)
5.10.2 Post Weld Heat Treatment (PWHT) Refer Appendix A Table 3A.
5.10.2.1 Post Weld Heat Treatment temperatures and holding time for various materials and service
exposure shall be per Mandatory Appendix A Table 3A. Heat treatment procedure shall be
reviewed by Purchaser’s welding specialist prior to PWHT.
5.10.2.2 PWHT for WPS of alloy steel material P No.15E shall include the following:
a) Maximum Heating Rate,
b) Holding temperature range,
c) Holding time,
d) Maximum cooling rate.
5.10.3 Special heat treating methods such as Induction heating and internally fired heating are not
permitted. Under any special conditions, when this type of heating method is necessary,
prior Owner’s Welding Specialist approval shall be obtained.
5.10.3.1 For local PWHT, fabricator shall have a written heat treatment procedure having adequate
number of control/ monitoring thermocouples so that it is possible to know with certainty
the temperature at all locations on a component throughout the heat treatment cycle.
Compliance to AWS D.10.10 / WRC Bulletin 452 is a minimum.

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5.10.3.2 A legible time/temperature chart, identifying the component or components heat-treated,

shall be signed and dated upon completion of PWHT by the heat treatment operator.
Certification shall be provided for the calibration of heat treatment equipment within the
previous 6 months.
5.10.3.3 Post weld heat treatment shall be performed in a furnace whenever practical and direct
flame impingement is not permitted.
5.10.3.4 Alternately, PWHT may be achieved by the use of electric resistance heating methods.
5.10.3.5 When Post Weld Heat Treatment immediately after welding is impractical, the welded or
hot worked material shall be suitably insulated after welding and allowed to cool slowly to
ambient temperature. This procedure does not eliminate the need for PWHT.
5.10.4 For maintenance welding, National Board Inspection Code NB-23 Part 3 rules for welding
and Post Weld Heat Treatment may apply subject to Owner’s Welding Specialist approval.
5.10.5 No stamping, grinding or welding is permitted on the process wetted surfaces of piping,
equipment or vessels after PWHT. Prior Owner’s Welding Specialist approval is required
for any exceptions when needed due to construction constraints such as Boiler Drum
internal tubing and seal plates etc. additional requirements may apply as required.
5.10.6 Stabilization Heat Treatment
5.10.6.1 Stabilizing heat treatment shall be applied to the chemically stabilized austenitic stainless
steel grades that operate at a process temperature greater than 800°F (425°C)
5.10.6.2 Chemically stabilized austenitic stainless steels (e.g. type 316Ti, 321, 347 stainless steel,
CF8C cast stainless steel, etc.) shall be purchased in the solution treated and stabilized
heat treatment condition. Other chemically stabilized alloys (alloys 825 or 625) are typically
purchased in the solution treated condition only. The welding of Alloys 825 or 625 materials
need not be followed by a stabilization post weld heat treatment if the welding inter-pass
temperature for multi-pass welded joints does not exceed 350°F (175°C)- (Refer Normative
Appendix B) If the welding inter-pass temperature of 350°F (175°C) is exceeded then the
joint shall be replaced (weld deposit and heat affected zones).
5.10.6.3 The stabilizing heat treatment thermal cycle shall be 2-4 hours at a temperature between
1600°F and 1650°F (870°C and 900°C). The time at temperature shall be measured at the
thickest section of the part being heat treated, and the measurement shall be obtained
using a thermocouple that is welded (i.e. capacitor discharge welding) to the surface.
Where possible, the temperature shall be measured on the surface that is process wetted.
The thermal stabilization heat treatment shall consist of heating to a temperature of 1650°F
(900°C), followed by a four hour hold, terminating the heating cycle, and cooling in still air.
Quenching with moving air or water is not permitted because of potential distortion
concern.
5.10.6.4 Stainless steel grades that are chemically stabilized and have not been supplied in the
stabilized heat treatment condition shall either:
a) receive a stabilization heat treatment prior to welding, or
b) receive a stabilization heat treatment after all weld fabrication is completed. In this
case, the entire weld fabricated equipment or component shall be stabilized heat
treated.
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5.10.6.5 All weld joints in fired heater; tubes made using stabilized grades of stainless steel such as
TP 321 or TP 347 materials shall be welded and thermally treated as below:
a) When the thickness is greater than or equal to 1” (25mm), a 1/8 (3mm)” to
3/16(4.5mm)” thick layer of E347-15 or ER347 weld metal shall be deposited for the
weld exposed to the product. The remaining portion of the weld shall be completed
with E16-8-2-15 or ER16-8-2. PWHT of thickness greater than or equal to 1”(25mm)
maybe considered on an individual basis.
b) When the thickness is less than 1”(25mm) and operating temperature is greater than
0 0
800 F (425 C), complete welding shall be done using E347-15 or ER347 and thermal
stabilization shall be done in accordance with paragraph 5.9.2.3
5.10.6.6 Stabilizing heat treatment is not required for materials or weld fabricated equipment,
vessels or piping that operate at process temperatures less than 800°F (425°C). However,
the use of stabilized stainless steel base materials that have been stabilize heat treated in
services less than 800°F (425°C) is acceptable.
5.10.6.7 Unless otherwise specified by the Owner/Purchaser, stabilizing heat treatment does not
apply to weld overlay or bi-metallic welded equipment, vessels or piping.
5.11 Inspection
5.11.1 When PWHT is specified, to verify the integrity of welds, all alloy steel P No.3 and above,
and P. No.1 materials wall thickness in excess of 2 inches (50mm), final NDE shall be
performed after the final PWHT. Ferrite testing shall be always performed before any
PWHT.
5.11.2 All NDE procedures and acceptance/rejection criteria shall be in full compliance with ASME
Section V applicable Code(s) and Owner’s Standard.
5.11.3 When piping is fabricated with 5% or 10% radiography, such radiography shall be
performed progressively throughout the course of fabrication and shall cover the specified
percentage per welder per piping line class. Representative sample from various welding
processes used by the same welder shall be included in the specified radiographic
coverage.
5.11.4 Arc strikes shall be removed by grinding, followed by Wet Fluorescent Magnetic Particle
Examination for materials exposed to Stress Corrosion Cracking Services, and dry powder
MT or PT for all other services.
5.11.5 Production hardness testing shall be performed and shall meet the hardness requirements
as in Table 3, under following conditions:
a) For P-1 materials in piping, pressure equipment and tanks etc. after completion of all
applicable heat treatments including post weld heat treatment when specified.
b) in the Environmental cracking service such as but are not limited to:
i. NACE sour service,
ii. Caustic,
iii. Amine,

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iv. Carbonate,
5.11.5.2 When required by governing design/fabrication code.
5.11.5.3 When required for regulatory compliance.
Table 3- Production Weld Metal Hardness Limits (Note 1)

Brinell Hardness
(ASME P-No.) Minimum (HBW) Maximum (HBW)
P-1 120 200
P-3 130 225
P-4 130 225
P-5A, P-5B Group1, P-5C 140 235
P-6 Gr-4, CA6NM Class B only (Note 2) 130 255
P-6 (all other grades) ** 120 235
P-7 (Note 2) 120 225
P-15E, formerly P-5B Group 2 (e.g. Grade 91) 210 248
Note 1: Compilation of NACE and ASME code values, with the more stringent governing.
Note 2 Heat treated in accordance with ISO 15156/NACE MR0175 or NACE MR0103 as applicable, and shall meet all
other applicable requirements of ISO 15156/NACE MR 0175 or NACE MR0103.
5.11.6 Production Hardness Testing shall be performed in the following procedure to comply with
the hardness values as provided in Table 3:
5.11.6.1 Method:
a) The hardness shall be measured in accordance with ASTM A 833, “Indentation
Hardness of Metallic Materials by Comparison Hardness Testers”. The measurements
shall be expressed as the Brinell hardness scale.
b) Where comparison hardness testing (per ASTM A 833) cannot be performed, hardness
measurements may be determined in accordance with ASTM A 1038, “Portable
Hardness Testing by the Ultrasonic Contact Impedance (UCI) Method”, with the
following requirements:
i. The reported hardness shall be the average of 10 measurements expressed as
Brinell hardness,
ii. The results shall be expressed as “xxx” HBW(UCI) 10 (10 kg force), the method
of hardness conversion to Brinell shall be stated on the hardness test report. If
ASTM E 140 “Hardness Conversion Charts” are used, all limitations stated within
ASTM E 140 shall apply.
5.11.6.2 Location: Hardness shall be measured on the cap and HAZ (as close as practicable to the
edge of the weld) on the vessel exposed to the service and preferably on the cap and HAZ
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on the piping welds exposed to the service or alternatively on the accessible surface of the
welds. Each test location shall be prepared by filing, grinding or polishing the weld cap as
required to perform the hardness measurement. Test areas shall be prepared in
accordance with ASTM A 833 or ASTM A 1038, as applicable.
5.11.6.3 Piping:
a) Production hardness testing of weld joints shall be done as per Table 3 Production
Weld Metal Hardness Limits requirements, per WPS per line class. Such production
hardness testing shall be performed progressively throughout the course of fabrication
and shall cover the specified percentage per WPS per line class. Representative
sample from various welding processes if used for the same line class, shall be
included in the specified hardness measurements coverage.
b) When locally post weld heat treated, 100% of locally heat treated weld joints shall be
tested. When furnace heat treated, 10% of the welds shall be tested.
c) The number of hardness test locations per weld joint shall be:
i. up to and including NPS 6: 1 test location, or
ii. above NPS 6: 2 testing locations (~ diametrically opposed)
d) Production hardness testing is not required when the welding of piping is performed
per NACE SP0472 Table 2 “Welding Process/Filler Metal Combinations Exempt from
Weld Deposit Hardness Testing”, provided following are satisfied:
i. Consistent Filler metals used in production welding and procedure qualification
are AWS or ASME certified.
ii. Quality Control procedures are in place to ensure that only exempt filler metals as
in Table 2 of NACE SP0472 are used in production welding.
5.11.6.4 Vessels and Equipment: Refer to Suncor Pressure Vessels standard CTS 0601.
5.11.6.5 Attachment Welds: 10% of process exposed attachment welds shall have production
hardness testing.
5.11.6.6 Tanks: Hardness measurements are required at 2 locations per vertical weld joint on both
the inner and outer surfaces of the tank. Hardness measurements are required at 10 metre
intervals on the inner surface of horizontal weld joints. Two hardness measurements of the
cap pass on the inner surface of nozzle welds are required for nozzles that are NPS 6 and
greater.
5.11.7 Non-Conforming Hardness Measurements:
a) Weld deposits found to be outside the hardness limits given in Table 3 are
unacceptable and shall be reported to the Owner for review. Unless accepted as is by
the Owner, the weld joint(s) in question shall be removed and re-welded, or, if
applicable may be heat treated to reduce the hardness to an acceptable value. If post
weld heat treating is used, the welding procedure shall be re-qualified in accordance
with the Code of construction using a weld procedure qualification coupon made with
production base metal that has been post weld heat treated to the same time &
temperature as used in production.

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b) The specific approach to be used to correct the high hardness condition shall be
subject to Owner acceptance before any corrective action is taken.
c) Regardless of the method of corrective action taken, the weld deposits shall be
retested to ensure that the corrective action has resulted in acceptable hardness
values.
d) For piping, the hardness of an additional 10% of production welded joints that were not
measured in accordance with clause 5.11.6.3 shall be measured. Any measurement
not conforming to the requirements of Table 3 shall require that all production pipe
weld joints to be hardness tested.
5.12 Ferrite Content of Austenitic Stainless Steel Weld Metal
5.12.1 Ferrite determination of type 300 series austenitic stainless steel weld metal is required for
production weld joints.
5.12.2 Ferrite determination shall be carried out before any post weld heat treatment.
5.12.3 Ferrite determination shall be performed with a properly calibrated Fischer model
Feritscope, or equivalent approved by the Owner, and the measurement expressed as
ferrite number (FN). Non-magnetic methods of determining ferrite number may be used
with the prior approval of the Owner’s Welding Specialist.
5.12.4 Production ferrite measurements of pipe welds shall be performed on a minimum of 5% of
type 300 series stainless steel joints. Each welding procedure shall be represented. A
ferrite determination that is outside the acceptable range shown below in section 5.12.8
shall be considered unacceptable and require that all (100%) of type 300 series stainless
steel pipe welds be examined. Unacceptable weld joints shall require that the joint be
removed, re-welded and re-tested.
5.12.5 Production ferrite measurements of all (100%) of type 300 series stainless steel fired heater
tube welds shall be carried out. A ferrite determination that is outside the acceptable range
shown below in clause 5.12.8 shall be considered unacceptable and are to be removed
unless further testing and acceptance criteria are accepted by the Owner.
5.12.6 For type 300 series stainless vessel or tank butt welds, a minimum of one location per
seam shall be measured on both the inner and outer surface. One ferrite determination
shall be made for each 10 feet of weld seam. In addition, one ferrite determination shall be
made on each nozzle flange-to-neck and nozzle neck-to-shell/head weld. Each welding
procedure shall be represented. A ferrite determination that is outside the acceptable range
shown below in section 5.12.8 shall be considered unacceptable and require that the weld
joint be removed, re-welded and re-tested.
5.12.7 Ferrite number determination is not required for Dissimilar Metal Welds, when permitted to
use, between Ferritic and Austenitic material.
5.12.8 The required deposited weld metal ferrite number (FN) shall be as follows:
a) type 304, 308, 309, 317 series stainless steel weld metal: 4 FN to 10 FN
b) type 310, 320 series stainless steel weld metal: 0 FN to 4 FN
c) type 316 series stainless steel weld metal (except weld overlay): 3 FN to 10 FN
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d) type 316 series stainless steel weld overlay: 1 FN to 8 FN

e) type 347 stainless steel weld metal that will be exposed to operating temperatures less
than 1000°F (538°C): 5 FN to 10 FN
f) type 347 stainless steel weld metal that will be exposed to operating temperatures
greater than or equal to 1000°F (538°C): 3 FN to 8 FN
g) E/ER 16-8-2 stainless steel weld metal: 1 FN to 5 FN
h) all other austenitic stainless steel deposited weld metal not listed above, including “L”
and “H” grades: 4 to 10 FN
5.13 Duplex and Super Duplex Stainless Steel Material and welding Requirements
5.13.1 Acceptable Duplex and Super duplex Stainless Steel Material Grades
5.13.1.1 Duplex and Super Duplex stainless steel shall be supplied in accordance with the following
specifications:
a) Plate: ASME SA-240, UNS S31803, S32205 or UNS S32750
b) Forgings: ASME SA-182 grade F51 (S31803), F55 (S32760) or F60 (UNS S32205)
c) Pipe: ASME SA-790, UNS S31803, S32205, S32750 or UNS S32760
d) Tubing: ASME SA-789, UNS S31803, S32205 or S32750
e) Casting: ASTM A995 Grade 4A UNS J92205 (CD3MN), ASTM A995 Gr 5A UNS
J93404 (CE3MN), ASTM A995 UNS Gr 6A J93380 (CD3MWCuN)
5.13.1.2 Additional Material Requirements for Duplex and Super duplex Stainless Steel Material
a) DSS materials shall be supplied in the solution annealed and bright-annealed
condition. If solution annealing is not carried out in argon atmosphere (inert), DSS
materials shall be white pickled. DSS materials shall be liquid quenched immediately
after solution annealing
b) Nitrogen content shall be 0.14% wt. Minimum for Duplex SS and 0.22% wt. for Super
Duplex SS
c) Welded tubing shall receive both hydrostatic pressure testing and the nondestructive
electric testing in accordance with ASME SA-789
d) The weld repair of tubes is not permitted.
e) Heat exchanger tubes and tube bends shall not be heat treated after bending or
straightening if the hardness of the cold worked material is less than HRC 28. The
amount of cold work for 22%Cr DSS grades shall be limited to 15 % maximum strain
which is equivalent to limiting U-bending to 3.3D bend radii minimum. For 25%Cr DSS
grades, the bend radius can be made down to 1.5D. If the hardness requirement is
exceeded, the entire tube length shall be re-solution annealed to ASME requirements
5.13.2 General Welding requirements for Duplex and Super duplex Stainless Steel Material
5.13.2.1 Duplex and Super Duplex stainless steel welding consumables shall be as per Appendix B
Table 4B of this standard.
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5.13.2.2 Maximum Recommended inter-pass temperature shall be per Mandatory Appendix A

Table 2A.
5.13.2.3 Back-gouging shall be carried out using procedures that ensure the complete removal of
oxides from plasma-cut surfaces. Carbon-arc gouging is not permitted.
5.13.2.4 When back-gouging and welding on the reverse side or when full penetration joints are not
possible, the root pass shall be made with the GTAW or GMAW process and back purged
until at least 1/4” (6 mm) of weld metal thickness has been deposited.
5.13.2.5 Back purge gas shall be a welding grade with maximum oxygen content of 2500 ppm and
composed of 95% argon and 5% nitrogen. Other purge gas mixtures require prior approval
of the Purchaser Welding Specialist. The composition and flow rate of the purge gas shall
be stated on the applicable WPS.
5.13.3 Procedure Qualification Requirements for Duplex and Super Duplex Stainless Steels
5.13.3.1 Essential variables for procedure qualification shall be in accordance with ASME Section
IX with the addition of the following as supplementary essential variables:
a) notch toughness (ASTM A923, test method B),
b) heat input: any change that exceeds 10% of the lowest heat input used to prepare the
weld procedure qualification coupon,
c) interpass temperature: any increase in the interpass temperature that is greater than
that measured during welding of the procedure qualification coupon,
d) filler metal: any change in consumable type including manufacturer, trade name and
flux. Welding procedures shall be qualified with the same weld filler metal size and
consumable manufacturer / trade names to be used in production (see Section 5.13.4,
above),
e) back purge gas composition,
f) the qualified minimum thickness shall not be less than 80% of thickness of the weld
procedure qualification coupon.
5.13.3.2 In addition, welding procedure qualification shall be supplemented by ASTM A923 Test
Method B and C as follows:
a) UTest Method B: Charpy V notch toughness testing at the following weld joint
locations:
b) 2 specimens at weld centre-line
c) 2 specimens at fusion line
d) 2 specimens at fusion line + 2.5 mm
e) 2 specimens at fusion line + 4.75 mm
Note: 1) The test temperature and CVN impact toughness acceptance criteria shall conform to the
requirements of ASTM A923 Table 2.
Note: 2) For product forms or shapes that cannot be evaluated by the Charpy V notch impact toughness
testing; Test Method C of ASTM A923 shall be used. The rapid screening tests included in ASTM A923 shall
not be used to accept material.

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f) Test Method C: Ferric Chloride Corrosion Test of 2 specimens.

5.13.3.3 The manufacturer and brand of the weld filler metal (or filler metal and flux combination)
that was used to make the weld procedure qualification coupon shall be an essential
welding variable and be stated on the WPS. Additionally wire and flux used for joining shall
be from the same manufacturer, mixing or combining wire and flux from different
manufacturer is not permitted. A change in the manufacturer or brand of the filler metal (or
flux) shall require requalification of the welding procedure. If the only essential variable to
be changed is the manufacturer or brand of the filler metal, then testing of the weld
procedure qualification coupon shall be restricted to the following:
a) Weld metal Charpy V notch impact toughness testing in accordance with ASTM A 923,
Method B, and
b) Corrosion testing of the weld (transverse cross section) in accordance with ASTM A
923, Method C.
5.13.3.4 If essential welding variables other than the manufacturer or brand of the filler metal are
changed then complete weld procedure re-qualification shall be performed.
5.13.3.5 Procedure qualifications shall be done on duplex and super duplex stainless steel base
metals of the same UNS number as to be used in production and according to the following
requirements:
5.13.3.6 Thickness and Heat Input
a) The minimum and maximum qualified weld thickness (t) shall be as follows for:
i. t ≤ 5/8” (16 mm), the minimum qualified thickness shall be the thickness of the
qualification test coupon (T) and the maximum qualified thickness shall be 2T up
to a maximum of 5/8” (16 mm).
ii. t > 5/8” (16mm) but < 1-1/8” (29mm), the minimum and maximum qualified
thickness may be qualified by qualification test coupons within this range.
iii. t ≥1-1/8” (29mm), the minimum qualified thickness is T and the maximum qualified
thickness shall be 1.2T.
b) The heat input shall not exceed the maximum used during procedure qualification.The
minimum heat input qualified shall be the higher of 0.5kJ/mm (12.7kJ/inch) or 50% of
the maximum used on the PQR.
5.13.3.7 Welding Position – For manual and semi-automatic welding, the procedure shall be
qualified in the vertical (3G) 3G, 5G, or 6G positions. Vertical weld progression shall be
upward.
5.13.3.8 Ferrite to Austenite Ratio
a) Measurement of the ferrite to austenite content in the deposited weld metal and heat
affected zone (HAZ) shall be performed according to ASTM E562 guidelines and at a
magnification of 400X or greater.The number of fields and points per sampled area
shall be in agreement with the guidance displayed in the 10% relative accuracy column
in ASTM E562, Table 3 As a guideline, magnification should be based on the initial
determination of the sample areas to be tested to ensure that the microstructure can
be clearly resolved without having adjacent grid points fall over the same constituent
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feature. A 100 point grid mapped over 10 fields in a target area (weld/HAZ) may be
considered sufficient for material with 30% or greater ferrite content.
b) The following three areas shall be evaluated for ferrite/austenite and reported in the
PQR:
i. Root pass
ii. Mid-thickness
iii. Cover pass (This is to be used as a reference for the test required on production
welds).
iv. for weld overlays, only the final weld deposit shall be tested.
Ferrite testing shall be measured in each location using both the point count method and
ferritescope. The ferritescope testing at each location shall consist of 5 readings averaged
using a ferriescope calibrated in accordnace with AWS A4.2
c) Ferrite content shall be within the following ranges:
i. Weld metal – 30 to 65 percent
ii. HAZ – 40 to 65 percent
iii. Base metal – 40 to 60 percent.
Note that ferrite content down to 25% may be acceptable for the weld metal if corrosion or other tests are
satisfactory subject to Owner’s Welding Specialist approval. When a nickel alloy consumable is used, the ferrite
content in the weld deposit is not required to be tested.
5.13.3.9 Hardness Testing

a) Weld procedure qualification shall include hardness testing. Hardness measurements
shall be taken using the Vickers 10 kg (or lighter) scale for base metal and weld metal
testing. Within the HAZ the Vickers 5 kg scale is recommended. At least eight
measurements at a depth of 2.5 mm below the inside and below the outside surfaces
shall be recorded for base metal, HAZ and weld deposit.
b) For duplex stainless steel, the average hardness shall not be above 310 HV with no
reading over 320 HV.
c) For super duplex stainless steel, the average hardness shall not be above 340 HV with
no reading over 350 HV.
5.13.3.10 Corrosion and Impact testing
Either the corrosion or impact test described below shall be performed on the PQR sample
a) Each heat of material shall be tested per ASTM A923 Test method B (Charpy V notch
impact toughness test) to ensure adequate corrosion resistance. Acceptance criteria
shall be per Table 2 of ASTM A923. For product forms that cannot be evaluated by the
Charpy V notch impact toughness test, ASTM A923 Test Method C (ferric chloride
corrosion test) shall be performed. The rapid screening test methods included in ASTM
A923 shall not be used to accept material in lieu of test methods B or C.
5.13.3.11 Dissimilar metal welds (i.e. carbon steel to duplex stainless steel, or austenitic stainless
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steel to duplex stainless steel) shall require qualification and testing to the requirements of
this specification except that the non-duplex base material and HAZ need not be subject to
CVN impact toughness or corrosion testing.
5.13.4 Duplex and Super duplex stainless steel Production Weld Requirements
5.13.4.1 All production welds (including tack welds and tube-to-tubesheet welds) shall be made with
the addition of filler metal. Autogenous welding (welding without the addition of filler metal)
is not allowed.
5.13.4.2 Ferrite to Austenite Ratio Determination
a) Whenever ferrite testing is required for production welds, the number of tests shall be
as follows:
i. For piping, each weld shall be tested and the number of tests for circumferential
welds shall be as follows: for NPS up to 24 inches, two (2) ferrite tests; for NPS 26
inches through NPS 36 inches, three (3) ferrite tests; and for NPS 38 inches and
larger, four (4) ferrite tests.
ii. For equipment, all pressure-retaining welds should be tested at least once in
every 10 ft. of linear weld. Nozzle connection welds should have one (1) test per
weld.
b) Pressure boundary welds shall have ferrite measurements made by using a Fischer
Feritscope® calibrated in accordance with AWS A4.2M. A total of three five (5)
measurements shall be taken in the center of each weld cap and, if accessible, the
root pass. Welds made from each weld procedure, welder, and heat/lot of filler metal
shall be tested. The weld cap and root pass shall be prepared as recommended by the
manufacturer of the testing instrument. The acceptance criteria shall be per 5.13.2.5
(c) above.
c) Hardness tests: weld and base metal
i. Greater of 1/3 of all welded joints or 1 spot per 50ft (15.2m) of weld
ii. For Duplex SS, the maximum allowable hardness is 320 HV10
iii. For Super Duplex SS, the maximum allowable hardness is 350 HV10.
5.13.5 Welded Tube-to-Tubesheet Joints of Duplex and Super duplex Stainless Steel Material
5.13.5.1 Where the production test requirements (ferrite testing) cannot be practically obtained, a
tube-to-tubesheet mock-up is required as a supplement to the welding procedure
qualification record. The mock up shall be done in accordance with ASME IX, QW-193 and
QW-288, and the following requirements:
a) The test assembly shall simulate all steps of the production joint including both rolling
and welding. In addition, if the production welding is to be performed through a plug
sheet, this shall be simulated in the test assembly (i.e. access hole diameter and
distance from access hole to tubesheet shall be equivalent to production distances).
b) Hardness measurements (Vickers HV10 scale) shall be taken in the heat-affected-
zone (HAZ) of the tubesheet, HAZ of the tubes and weld metal. A minimum of 9
measurements shall be taken on each quadrant. A minimum of one quadrant shall be
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tested for each welder. For Duplex stainless steel, the average hardness shall not
exceed 310 HV10, and no individual measurement shall exceed 320 HV10. For Super
Duplex stainless steel, the average hardness shall not exceed 340 HV10 and no
individual measurement shall exceed 350 HV10.
c) A quadrant section of a tube-to-tubesheet weld shall be subjected to corrosion testing
in accordance with ASTM A923, Method C. No pitting is allowed.
d) In addition to the requirements specified by ASME IX, QW-193, the microstructure and
ferrite content of one randomly selected weld section shall be assessed using the
procedure detailed above in clause 5.13.6.
5.13.6 Non-destructive Examinations of Duplex and Super duplex Stainless Steel Material
5.13.6.1 The ferrite content of all accessible production welds including weld overlay shall be
determined using a Fisher Feritscope, or equivalent approved by the Owner. A minimum of
3 ferrite determinations shall be made on each weld, and the average value of the 3
measurements shall be between 35 and 60 vol%. Testing shall be done after welding is
complete and before any grinding, cold work, or heat treatment.
5.13.6.2 All accessible DSS production welds shall be PT examined. Procedures and acceptance
criteria shall be in accordance with ASME Section VIII, Division 1, Appendix 8.
5.13.6.3 Longitudinal welds of tubes and pipe shall receive 100% RT examination after bending.
The bend surfaces of tubes and pipe shall receive 100% PT or examination.
5.14 Weld Repairs
5.14.1 General Requirements

In addition to the requirements of the construction Code and other Sections of this
Standard, the weld repairs shall require the following:
5.14.1.1 All acceptance NDE for weld repairs shall be made after any PWHT is completed.
5.14.1.2 Repair welds performed on steels exposed to services listed in section 5.9 of this standard,
that require PWHT shall be subjected to NDE testing 24 hours after the final PWHT to
detect the presence of any delayed hydrogen cracking.
5.14.1.3 Only two weld repair attempts are permitted on a location in which a rejected defect has
been identified. If a third weld repair attempt is required, a written repair procedure and a
written explanation of the cause shall be submitted to the Owner which additionally
requires Owner acceptance before the third repair may proceed. If the proposed repair
procedure is rejected or if the third repair attempt fails, any subsequent actions are to be
approved by the Owner (which may include complete weld removal and re-welding).
5.14.1.4 For all welding, if the average repair rate exceeds 4% a written evaluation of the cause for
the majority of weld repairs shall be submitted to the Owner/Purchaser. A plan to reduce
the weld repair rate to less than 4% shall be submitted to the Owner/Purchaser for
acceptance. Alternate: The fabricator shall have a written procedure for tracking and
handling weld repairs and determining a repair rate, refer to repair rate calculation in para
4.1.8 of this standard. The procedure shall include a mitigation plan to reduce repairs when
considered excessive. This written procedure shall be submitted to the Owner/Purchaser
for acceptance prior to the start of welding.
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5.14.2 Weld Repair of Castings

5.14.2.1 Repair of castings by welding shall be in accordance with the requirements of the material
specification to which the castings are supplied, except as modified herein.
5.14.2.2 The weld repair of Duplex Stainless Steel casting (i.e. as specified by SA-995) shall be
carried out in accordance with Section 5.13 of this Standard.
5.14.2.3 Weld repairs shall be considered major if:
a) A casting has leaked during pressure (hydrostatic) test,
b) The depth of the cavity prepared in the casting for welding exceeds 20% of the wall
thickness or 1 inch [25 mm] depth, whichever is smaller,
c) The extent of the cavity exceeds 10 inch2 [65 cm2],
d) The casting will be exposed to hydrogen service,
e) The weld repair is to be made on a surface that will be exposed to a Stress Corrosion
Cracking (SCC) service.
5.14.2.4 All austenitic castings supplied in accordance with SA-351/SA-351M (except Grades HK,
HT, and CT15C) which have been subjected to any weld repairs, shall receive a post weld
solution heat treatment in accordance with supplementary requirement S11.
5.14.2.5 Major weld repairs shall be subject to prior acceptance of the Owner/Purchaser.
5.14.2.6 Major weld repairs shall be documented by means of sketches or photographs showing the
location and major dimensions of the defects. Documentation shall be submitted to the
Owner/ Purchaser for prior approval.
5.14.2.7 All weld repairs shall be made using procedures and welders that are qualified in
accordance with ASME Section IX.
5.14.2.8 All weld procedure specifications (WPS) and procedure qualification records (PQR) for
major weld repairs shall be submitted to the Owner/Purchaser for review.
5.14.2.9 The cavity prepared for welding of all major weld repairs shall be inspected by either
magnetic particle inspection or liquid penetrant inspection to ensure the cavity is free from
defects.
5.14.2.10 As a minimum requirement, all completed major weld repairs shall be inspected by either
magnetic particle examination (MT) or by liquid penetrant examination (PT) but in no case
shall the type and extent of inspection be less than that used to originally identify the
defect.
6.0 OTHER ITEMS

6.1 Stud Welding
6.1.1 Automatically timed arc and resistance stud welding for attaching load-carrying studs shall
be per UW-27, UW-28 and UW-29 of ASME Section VIII, Division 1 or AWS D1.1 Section 7
for structural attachment. A production test sample of at least 5 consecutively welded studs
shall be tested at the beginning of each shift and after performing maintenance operations
on the stud welding equipment.
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6.1.2 Production welds shall be bend or hammer tested in accordance with ASME Section IX,
QW192. Joints with less than 100% fusion may be accepted case by case upon prior
approval of Welding Specialist.
6.1.3 The weld current (D.C.S.P.) and weld time shall be reported on the PQR and shall be
generally in accordance with AWS Welding Handbook, Volume 2, latest edition, Chapter 9,
Figure 9.22
6.1.4 Except when using Capacitor Discharge (CD) welding, for all other stud welding process,
only fluxed studs shall be used.
6.1.5 The base material must be free of rust, scale, paint, or any other foreign matter, prior to
commercial arc-stud welding.
6.1.6 A full fillet shall be produced around the entire stud on all production welds.
6.1.7 Preheat shall be in accordance with the ASME applicable code for pipe or pressure vessels
as well as section 5.7 of this standard.
6.1.8 Post weld heat treatment of the base metal for stud welding is not required on carbon and
low-alloy steels shall comply with all the requirements of the applicable code of construction
regarding the attachment of non-pressure fillet welded parts to pressure parts, in respect to
preheat temperatures, carbon and chromium content, thickness of pressure part, and fillet
size.
6.1.9 Carbon steel studs shall not be used on austenitic stainless steel base materials.
6.2 Backing Materials
6.2.1 When metallic backing material is permitted, the P-No., or its nominal chemical composition
shall be specified in the WPS and/or applicable fabrication drawing. For joints between
similar materials, the chemical composition of backing materials shall match the nominal
base metal chemical composition.
6.3 Peening
6.3.1 Peening is not permitted.
6.4 Temporary Attachments
6.4.1 Temporary attachments welded to the base metal shall be compatible with the base metal
and welded in accordance with qualified weld procedure. Temporary attachments shall be
removed by grinding or gouging and the base metal resorted to its original condition before
final heat treatment if required, pressure testing, and the final acceptance. The base metal
shall be inspected with MT or PT (for nonmagnetic) upon removal of the attachment.
6.5 Heater Tube Skin Thermocouple Installation and Welding
6.5.1 Thermocouples shall be installed per Suncor Gas Fired Standard CTS 0401-P3 Figure 3 or
Petro-Canada standard Fired Heaters TC Installation standard drawing D-S-252-1. The
following Installation practices shall be adopted.
6.5.1.1 Grind surface of heater tube in areas of thermocouple pad and clip attachments to remove
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rust, scale or other contaminants. Ground area at thermocouple pad location should be
approximately 3 inches (75 mm) long by 2 inches (50 mm) wide. Ground area at clip
location should be sufficient to ensure attachment welding on a clean surface.
6.5.1.2 Locate and position the thermocouple pad firmly in desired location, centering pad in
ground area.
6.5.1.3 Select welding filler material from Table 4.
6.5.1.4 Deposit root and fill passes using small diameter electrodes, stringer bead technique
should be used. Gas Tungsten Arc (GTAW) welding process using 1/16” (1.5mm) welding
rod is preferred especially for the root pass welding to ensure best weld penetration.
6.5.1.5 All welds must extend for the full length of the thermocouple pad. Locate retaining clip in
desired position and weld to furnace tube using filler material cited in Table 4:
TABLE 4: Thermocouple Materials and Welding Processes
Thermocou
ple Sheath Filler AWS/ASME Min. Interpass
Furnace Tube Welding PWHT
Material Material Filler Material Preheat Temp
Material Process (Note 3)
(Note1) Spec (Note 2) (max)
SS 310,
Carbon Steel (P Alloy
0 0
No.-1) 600,601 ERNi Cr Mo -2 GTAW/ 50 F <1 in, 600 F None
Hastelloy X ENi Cr Mo -2 SMAW (25mm),
0
200 F
>1 in
SS 310,
C-1/2 Mo (P Alloy 600 Hastelloy X ERNi Cr Mo -2 GTAW/ 0 0 None
200 F 500 F
No.-3, Group ENi Cr Mo -2 SMAW
1&2). C% ≤0.25
SS 310,
1 1/4 Cr-1/2 Mo Alloy 600, Hastelloy X ERNi Cr Mo -2 GTAW/ 0 0 None
250 F 500 F
(P No.-4, 601 ENi Cr Mo -2 SMAW
Group1)
SS 310, None
2 1/4 Cr - 1 Mo Alloy 600,
0 0
(P-5A) 601 Hastelloy X ERNi Cr Mo -2 GTAW/ 400 F 500 F
ENi Cr Mo -2 SMAW
0
5 Cr -1/2 Mo SS 310, Hastelloy X ERNi Cr Mo -2 GTAW/ 400 F 500F 1250-
0
9 Cr - 1 Mo Alloy 600, ENi Cr Mo -2 SMAW 1400 F
0
(P-5B) 601 (675-670 C)
(Note 4)
0 0
HK-40 (P-8) SS 310, Hastelloy X ERNi Cr Mo -2 GTAW/ 50 F 350 F None
Incoloy 800, 825 Alloy 600, ENi Cr Mo -2 SMAW
(P-45) 601
NOTES TO TABLE4: (Numbers in parentheses in TABLE IV refer to the following notes:)

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Note 1: An alternate filler material is Hastelloy S (ERNiCrMo-7), available in bare wire form.
Alternatively, Inconel E/ER NiCrMo-1, Inconel 82 (ERNiCr-3), or, Inconel 182 (ENiCrFe-3) may be used provided operating
temperatures do not exceed 11000F (5950C) and high sulfur is not present in the flue gas environments.
INCO-Weld-A (ENiCrFe-2) may be used for temperatures above 11000F (5950C) and up to 16000F (8700C) when flue gas
environment does not contain high sulphur, Inconel 112 (ENiCrMo-3) or Inconel 625 (ERNiCrMo-3) may be used for
temperatures above 16000F(8700C) and when flue gas environment does not contain high sulphur.
Note 2: Interpass temperatures shall be controlled in the range of 2000F (95°C) to maximum shown in Table and heat input
to the Hastelloy X material shall be minimized.
Note 3: Throat thickness of the fillet weld shall be ≤13 mm (1⁄2 in.)
Note 4:
A. Maintenance Applications: Alternative welding methods without PWHT may be applied subject to prior approval of BU Welding
Specialist.
When none is considered, following to be demonstrated and documented by BU Materials/Welding Specialist:
A.1 Comparable service experience, i.e. Same service – example Crude heater, Coker heater, powerformer heater, hydrotreater
heaters etc.
A.2 Same material of construction,
A.3 Service temperature and its effects
A.4 Frequency and intensity of thermal cycling
A.5 Flexibility stress levels
A.6 Probability of Brittle fracture failure
A.7 Other pertinent factors
A.8 Welding Procedure qualification and WPS
A.9 Follow Table 4 recommended Preheat and Interpass temperature
B. Major Projects Applications: shall follow the code PWHT requirements, however, may consider welding a
Ni alloy 625 buttering layer and perform PWHT before welding the thermocouple pad on the buttering layer. This would enable future
thermocouple maintenance welding on the same location without PWHT. Prior Suncor welding specialist review and approval
is required.
7.0 HEALTH AND SAFETY

7.1 General Health and Safety Requirements
7.1.1 All welding and welding related activities such as metal cutting, gauging, thermal treatment
and other forms of associated welding related activities shall be performed strictly under
Suncor site specific environment, health and safety rules and regulations and within local
regulatory requirements for those activities.
8.0 REVIEW AND APPROVAL REQUIREMENTS FOR CONTRACTORS

8.1 General approval requirements
8.1.1 The following review and approval requirements shall be carried out prior to proceeding
with weld fabrication:
a) In addition to compliance with specific contract specifications, contractors shall submit
Quality Assurance and Quality Control documents, repair procedure, PWHT procedure
with thermocouple layout to the Owner/Purchaser for review. Weld fabrication shall be
commenced only after obtaining the approved documents.
b) For all equipment such as vessels, exchangers, tanks, and pumps, a drawing showing
details of each joint or each class of joints with welding symbols, WPS number and
NDE shall be submitted.
c) For piping, a summary that details the welding and inspection of each welded joint, per
piping class shall be completed as per Suncor STD.0204 Piping Fabrication and
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Installation Attachment ‘A’. This form, or Owner/Purchaser approved alternate, shall be

submitted with the WPSs and their supporting PQRs.

None
9.1 Appendices
9.1.1 Appendix A: Normative Appendix for Weld Interpass and PWHT Temperature
9.1.2 Appendix B: Normative Appendix for Selection of Welding Consumables
9.2 Attachments
None

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Appendix A – Interpass & PWHT - NORMATIVE
INTERPASS AND PWHT
Table 1A- Recommended Maximum Interpass Temperature
Material Group Maximum Interpass Temperature
P-1 (carbon steel) 600F (315C)
P-3, P-4, P-5A, P-5B and P-5C (low alloy steel) 600F (315C)
P-6 (Type 410) 600F (315C)
P-6 (CA6NM) 650F (315C)
P-7 (Type 405/410S) 500F (260C)
P-8 (austenitic stainless steel) 350F (175C)
P-10H (duplex stainless steel) Refer to Table 2A
P-11A, Group 1 350F (175C)
P-15E 600F (315C)
P-41, P42 300F (150C)
P-43, P44, and P-45 350F (175C)
Source: API 582
Table 2A – Maximum Recommended Interpass temperatures for Duplex and Super Duplex Stainless Steel
Maximum Interpass Temperature
Thickness Duplex Stainless Steel (e.g. UNS S32205) Super Duplex Stainless Steel (e.g., UNS
S32750)
<1/8 in. (3mm) 120F (50C) 120F(50C)
<1/4 in. (6mm) 160F(70C) 160F(60C)
<3/8 in. (9.5mm) 210F(100C) 210F(100C)
≥3/8 in. (9.5mm) 300F (150C) 250F(120C)
Note: For P-10H material (duplex stainless steel), the production interpass temperature shall not exceed the interpass temperature used
during procedure qualification

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Table 3A – PWHT and Holding Time
P-No. Material Type Special Service Nominal or Time at Holding Temperature

Requirement Control Holding (deg F)
Thickness as Temperature (Note 2)
applicable per (hr.) (Note 1)
code
1 Carbon steel None, (Note 3) According to 1, minimum 1100-1200

code
1 Carbon steel Sour service all 1, minimum 1150 to 1200
( Note 4)
1 Carbon steel Caustic all 1, minimum 1150 to 1200
(Note 5)
1 Carbon steel Amine all 1, minimum 1150 to 1200
1 Carbon steel Carbonates all 1, minimum 1200 to 1250
1 Carbon steel HF acid all 1, minimum 1150 to 1200
1 Carbon steel Deaerator all 1, minimum 1150 to 1200
1 Carbon steel Ethanol all 1, minimum 1150 to 1200
3 C-1/2Mo None, (Note 3) According to 1, minimum 1150-1200
code
3 C-Mn-Mo None, (Note 3) According to 1, minimum 1150-1200
code
4 1Cr-1/2Mo, For maximum tempering all 1, minimum 1275-1325
1-1/4Cr-1/2Mo (Creep service)
4 1Cr-1/2Mo, For optimum high all 1, minimum 1250-1300
1-1/4Cr-1/2Mo temperature properties
(Toughness)
4 1Cr-1/2Mo, Heavy wall pressure all 1, minimum 1225 to 1275
1-1/4Cr-1/2Mo vessels for high-pressure
Hydrogen service
operating at or below
8250F (4410C)
4 1-1/4Cr-1/2Mo Pressure vessels for all 2, minimum, 1225 to 1275
service above 8250F refer API 934-
(4410C) E for more
details
5A 2-1/4Cr-1Mo For maximum Tempering( all 2, minimum 1300 to 1350
Creep)
5A 2-1/4Cr-1Mo For maximum high- all 2, minimum 1275 to 1325
temperature properties
(toughness)
5A 2-1/4Cr-1Mo Heavy wall pressure all 2, minimum, 1250-1300
vessels for high- refer API 934-
temperature, high- A for more
pressure hydrogen service details
5B 5Cr-1/2Mo None, (Note 3) According to 2, minimum 1325-1375
code
5B 9Cr-1Mo None, (Note 3) According to 2, minimum 1350-1400
code
15E 9Cr-1Mo-V None, (Note 3) According to 2, minimum, 1375-1425 (Note 6)
code refer API 938-
B for more
details
5C 2-1/4Cr-1Mo-V Heavy wall pressure According to 8 minimum 1275 to 1325
vessels for high- code See API 934-
temperature, high-pressure A for more

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hydrogen service details

6 Martensitic None, (Note 3) According to 2, minimum according to Code,
Stainless Steels code (Note 7)
7 Ferritic Stainless None, (Note 3) According to 1, minimum according to Code
Steels code
8 Austenitic None, (Note 3) According to According to according to Code
Stainless Steels code Code (Note 8)
9A 1-1/2 to 2-1/2 Ni
9B 3-1/2 Ni None, (Note 3) According to 1, minimum 1100F-1150
code
10H Duplex Stainless None, (Note 3) According to according to according to Code
Steels code Code
11A 8 Ni, 9 Ni None, (Note 3) According to 1, minimum according to Code, See

code (Note 9)
45 Alloy 800, Alloy None, (Note 3) According to according to according to Code

800H, Alloy code Code
800HT
Based on: API 582
Note 1: Greater of thickness based holding time to code compliance or as specified Minimum Holding time in column five
Note 2 - For Q&T or N&T materials, the PWHT holding temperature shall be at least 25F below the original tempering temperature of the base
metal unless the fabricator demonstrates that mechanical properties can be achieved at a higher PWHT temperature and holding time.
Note 3: When required by code or specified by Suncor standard.
Note 4 – As per Suncor Piping Classes and Suncor Pressure Vessels standard
Note 5 – As per Suncor Piping Classes and Suncor Pressure Vessels standard
Note 6 – PWHT shall NOT commence before the welds cool down to ≤ 2000F (930C) to allow ALL austenite transformation to Martensite
Note 7 - For Type CA6NM material, a double tempering heat treatment is required at 1225F to 1275F, followed by air cooling to ambient
temperature, and a second heat treatment at 1100F to 1150F and air cooling to ambient temperature.
Note 8 - For Type 321 and Type 347 materials, postweld thermal stabilization shall be as per 5.10.6
Note 9 - For 9% Ni, the entire vessel, assembly, or plate must be at the PWHT holding temperature at the same time. The cooling rate from
the holding temperature shall not be less than 300F (167C) per hour down to a temperature of 600F (315C). A local or partial PWHT cannot
be used since this results in portions of the structure being in the embrittlement range of 600F – 1000F (315C – 540C) for extended periods of
time thereby impairing material toughness

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Subject: Appendix B – Selection of Welding Consumables
NORMATIVE
SELECTION OF WELDING CONSUMABLES
Table 1B: Welding consumables for joining Similar Materials of Steel and Non Ferrous Materials
MAT'L COATED ELECTRODES WELDING RODS

INDEX BASE MATERIAL ASME PREFERRED ALTERNATIVE ASME
NO. CLASSIFICATION
SPEC ELECTRODE ELECTRODE SPEC (∆)
1 (1) SFA5.1 E70XX (10) E60XX (3) (5,6,7) -
Carbon Steel (5,6,7) E7X-T1 (18,19,20)-
2 (2) SFA5.1 E70XX (3,10) -
SFA5.20 E7XT-1MJ (21)
3 1 1/4Cr-1/2Mo SFA5.5 E8018-B2 E8016-B2 (8,15,16) -
4 Low 2 1/4Cr-1Mo SFA5.5 E9018-B3 E8018-B3L/ (8,15,16) -
Chromium E8015-B3L (4)
5 Ferritic 5Cr-1/2Mo SFA5.5 E8018-B6 E8015-B6 SFA5.28 ER80S-B6
6 Steels 9Cr-1Mo SFA5.5 E8018-B8 E8015-B8 SFA5.28 ER80S-B8
7 9Cr-1Mo-V (P/T/F91) SFA5.5 E9018-B9 (14) E9015-B9 (14) SFA5.28 ER905-B9 (14)
8 Type 405 SFA5.4 E309-15/16 (17) SFA5.9 ER309 (17)
Ferritic or
9 Martensitic Type 410S SFA5.4 E309-15/16 (17) SFA5.9 ER309 (17)
10 Stainless Type 410 SFA5.4 E309-15/16 (17) SFA5.9 ER309 (17)
Steels
11 Type 430 SFA5.4 E309-15/16 (17) SFA5.9 ER309 (17)
12 Types 304 and 304H SFA5.4 E308-16 (9) E308-15 (9) SFA5.9 ER308 (9)
13 Type 304L SFA5.4 E308L-16 E308L-15 SFA5.9 ER308L
14 Types 321, 321H, 347 SFA5.4 E347-15 (11) E347-15 (11) SFA5.9 ER347 (11)
15 Type 347H SFA5.4 E347-15 (9,11) E347-15 (9,11) SFA5.9 ER347 (9,11)
E317 and E317 and
16 Types 317 and 317L SFA5.4 SFA5.9 ER317 and ER317L
Austenitic E 317L-16 317L-15
Stainless
17 Steels Types 316 and 316H SFA5.4 E316-16 (9) E316-15 SFA5.9 ER316 (9)
18 Type 316L SFA5.4 E316L-16/17 E316L-15 SFA5.9 ER316L
19 Type 309 SFA5.4 E309-16 E309-15 SFA5.9 ER309
20 Type 310 SFA5.4 E310-16 E310-15 SFA5.9 ER310
21 ASTM A351 Gr. HK40 - (12 and 13) (12 and 13) - (12 and 13)
22 HP MOD/HP MOD LC - (12 and 13) (12 and 13) - (12 and 13)
23 Alloy 800, 800H, 800HT SFA5.11 ENiCrFe-2 - SFA5.14 ERNiCr-3
24 Non-Ferrous Alloy 400 SFA5.11 ENiCu-7 - SFA5.14 ERNiCu-7
Metal and
25 Alloy 600 and 625 SFA5.11 ENiCrMo-3 - SFA5.14 ERNiCrMo-3
Alloys
26 Alloy 825 SFA5.11 ENiCrMo-3 - SFA5.14 ERNiCrMo-3

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NOTES TO TABLE 1B: (Numbers in parentheses in TABLE 1B refer to the following note:)
∆ Prior Suncor approval shall be obtained where no ASME material specification exists for wire or rods.
1. Minimum ultimate tensile strength less than 60,000 psi (414 MN/m2).
2. Minimum ultimate tensile strength 60,000 psi (414 MN/m2) and greater.
3. The following classifications are not acceptable for use in pressure containing welds: E6012, E6013, E6022, E7014 and
E7024. However these classifications may be used for tank roof fillet welds. See Paragraph 5.5.1.1 (a) for welding permitted
with E6010 electrodes.
4. PWHT can cause the strength of these filler metals to drop below minimum requirements. Care should be taken to insure
adequate strength in the PWHT condition.
5. Gas metal arc (GMAW) and flux cored arc (FCAW) wire shall conform to ASME SFA 5.18 and SFA 5.20.
6. Submerged arc (SAW) wire and flux shall conform to ASME SFA 5.17 or SFA 5.23; however, equivalence under these
standards shall not be considered adequate for substitution between different manufacturers or between a single
manufacturer's grades without requalification.
7. For gas tungsten arc (GTAW), ASME SFA 5.18 ER70S 2 is the preferred welding wire.
8. Flux cored arc (FCAW) wire shall conform to ASME SFA 5.29.
9. For design temperatures above 1000oF (538oC), minimum 0.040% carbon is required.
10. For impact tested carbon steel with an MDMT colder than -20oF (-6.7oC) use E7018-1.
11. For welding Types 321 and 347 materials:
i. When the thickness is greater than or equal to 1”, a 1/8” to 3/16” thick layer of E347-15 or ER347 weld metal shall be
deposited for the weld exposed to the product. The remaining portion of the weld shall be completed with E16-8-2-15
or ER16-8-2. PWHT of thickness greater than or equal to 1” maybe considered on an individual basis.
ii. When the thickness is less than 1” and operating temperature is greater than 800oF (427oC), complete welding shall be
done using E347-15 or ER347 and thermal stabilization shall be done in accordance with paragraph 9.6.
12. Centrifugal casting alloys shall be welded with welding rods or electrodes depositing weld metal of equivalent chemical
composition, including carbon content.
13. Welding rods or electrodes shall be used, subject to Petro-Canada’s approval, which deposit weld metal of equivalent
mechanical properties as the base material.
14. Filler material chemistry shall meet ASME SFA-5.5, SFA-5.23, or SFA-5.28 requirements for B9 material with Ni + Mn limited to
1.5% maximum. Certified material test reports (CMTR) are required for each heat, lot and batch of welding consumables to be
used.
15. Submerged arc (SAW) wire and flux shall conform to ASME SFA 5.23. Wire and flux combinations shall deposit welds with the
same nominal chemical composition and equivalent mechanical properties as the base material. Limitations on substitution
shall be as specified in Note 6 above.
16. For gas tungsten arc (GTAW) and gas metal arc (GMAW), rods and wire shall conform to ASME SFA 5.28 and shall deposit
welds with the same nominal chemical composition and equivalent mechanical properties as the base material.
17. Refer 5.4.6.3 Type 309 and 309L shall not be used for design temperatures exceeding 6000F (3150C)
18. 100% CO2 shielding gas is not allowed
19. Dual shield process only for shop fabrication
20. Batch testing or CMTR is required for all consumables.
21. These consumables shall be used for MDMT -200F to -400F

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Table 2B Welding Consumables for joining Dis-Similar Materials for joining Carbon and Low Alloy Steel
Base Material Carbon Carbon- 1 and 1 2 ¼ Cr- 5 Cr -1/2 9 Cr -1 2 ¼ Nickel 3½ 9% Nickel

Steel Molybdenum ¼ Mo 1Mo steel Mo steel Mo steel steel Nickel steel
(Notes 1, 2, steel steel steel
and 4)
Carbon Steel Refer AC AD ADE ADEF ADEFH AJ AK

Table-1
Carbon- Refer Table-1 C CD CDE CDE * * *

Molybdenum
steel
1 and 1 ¼ Mo Refer D DE DEF DEFH

steel Table-1
2 ¼ Cr- 1Mo Refer E EF EFH

steel Table-1 (Note 3)
5 Cr -1/2 Mo Refer F FH
steel Table-1
9 Cr -1 Mo steel Refer H (Note

Table-1 3)
2 ¼ Nickel steel J JK LM
3 ½ Nickel steel K LM
9% Nickel steel LM
Key
A ASME/AWS SFA/A 5.1, Classification E70XX low hydrogen (see Note 4).
B ASME/AWS SFA/A 5.1, Classification E6010 for root pass (see Note 4).
C ASME/AWS SFA/A 5.5, Classification E70XX-A1, low hydrogen.
D ASME/AWS SFA/A 5.5, Classification E80XX-B2, low hydrogen.
E ASME/AWS SFA/A 5.5, Classification E80XX-B3L (see Note 5) or E90XX-B3, low hydrogen.
F ASME/AWS SFA/A 5.5, Classification E80XX-B6 or E80XX-B6L (see Note 5), low hydrogen.
H ASME/AWS SFA/A 5.5, Classification E80XX-B8 or E80XX-B8L (see Note 5), low hydrogen.
J ASME/AWS SFA/A 5.5, Classification E80XX-C1 or E70XX-C1L, low hydrogen.
K ASME/AWS SFA/A 5.5, Classification E80XX-C2 or E70XXC2L, low hydrogen.
L ASME/AWS SFA/A 5.11, Classification ENiCrMo-3.
M ASME/AWS SFA/A 5.11, Classification ENiCrMo-6, ENiCrFe-4, ENiCrFe-9, ENiCrMo-3, ENiCrMo-4, ENiCrMo-10, ENiMo-8,or ENiMo-9..
* An unlikely or unsuitable combination. Prior approval from Owner’s Welding Specialist is required.
NOTE 1 This table refers to coated electrodes. For bare and cored wire welding (SAW, GMAW, GTAW, FCAW), use equivalent electrode
classifications (ASME/AWS SFA/A5.14, SFA/A5.17, SFA/A5.18, SFA/A5.20, SFA/A5.23, SFA/A5.28, SFA/A5.29, SFA/A5.34). Refer to
the text for information on other processes.
NOTE 2 Higher alloy electrode specified in the table should normally be used to meet the required tensile strength or toughness after
PWHT.
The lower alloy electrode specified may be required in some applications to meet weld metal hardness requirements.
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NOTE 3 This table does not cover modified versions of Cr-Mo alloys.
NOTE 4 See 5.5.1.a)
NOTE 5 PWHT can cause the strength of these filler metals to drop below minimum requirements. Care should be taken to insure adequate
strength in the PWHT condition.
Based on: API 582

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Table 3B Welding Consumables for joining various Stainless Steel Alloys
Type Type Type Type Type Type Type Type 316 Type Type 317L Type 321 Type Type
Base 405 SS 410S 410 304 SS 304L 304H SS 310 SS. SS 316L SS SS SS 347 SS 347H
Material SS SS SS SS
(See Notes 1, 2, and
3)
carbon and low-alloy low

AB AB AB AB AB AB AB AB AB AB A AB AB
alloy steel
B
Type 405 stainless steel ABC ABC ABC AB AB AB AB AB AB AB A AB AB
B
Type 410S stainless steel ABC ABC AB AB AB AB AB AB AB A AB AB

B
Type 410 stainless steel ABC AB AB AB AB AB AB AB A AB AB

B
Type 304 stainless steel Tab DH DJ A DF DGH DI D DE DE

le-1 E
Type 304L stainless steel Tab DHJ A DF GH HI D DE DE

le-1 E
Type 304H stainless steel DGH J

Tabl A DFJ DIJ D EJ EJ
(see Note 5)
e-1 E
J
Type 310 stainless steel Tab AK A A A A A

le-1
Type 316 stainless steel Tabl FG FI E EF EF

e-1 F
Type 316L stainless steel Tabl GI E EG EG

e-1 G
Type 317L stainless steel Table- E EI EI

1 I
E
Type 321 stainless steel E E
(see Note
1)
Type 347 stainless steel Tab E

le-1
Type 347H stainless steel

Tab
(see Note 5)
le-1
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Key
A ASME/AWS SFA/A 5.4, Classification E309-XX.
B ASME/AWS SFA/A 5.11, Classification ENiCrFe-2 or -3 or ENiCrMo-3 (see Note 4).
C ASME/AWS SFA/A 5.4, Classification E410-XX (0.05 % C max.) (heat treatment at 1400 °F required).
D ASME/AWS SFA/A 5.4, Classification E308-XX.
E ASME/AWS SFA/A 5.4, Classification E347-XX.
F ASME/AWS SFA/A 5.4, Classification E316-XX.
G ASME/AWS SFA/A 5.4, Classification E316L-XX.
H ASME/AWS SFA/A 5.4, Classification E308L-XX.
I ASME/AWS SFA/A 5.4, Classification E317L-XX.
J ASME/AWS SFA/A 5.4, Classification E308H-XX.
K ASME/AWS SFA/A 5.4, Classification E310-XX.
NOTE 1 This table refers to coated electrodes. For bare wire or cored welding (SAW, GMAW, GTAW, FCAW), use equivalent electrode classifications
(ASME/AWS SFA/A 5.9, SFA/A5.14, SFA/A5.22, SFA/A5.34). Refer to the text for information on other processes. Either ER347 or ER321 may be used for
GTAW or PAW of Type 321 stainless steel.
NOTE 2 The higher alloy electrode specified in the table is normally preferred.
NOTE 3 See Section 5.12 delta ferrite requirements.
NOTE 4 See Table 1 for the temperature limitation for nickel-base filler metals.
NOTE 5 E16-8-2 is often specified when the weld deposit will be exposed to high creep strains where sigma phase may affect performance.
Based on: API 582

BUSINESS SERVICES

Number:

10
NORMATIVE
Table 4B Welding Consumables for joining Duplex Stainless Steel
Duplex Alloys Undermatched Alloys Overmatched

Alloys
Base Metals ↓ →
P8 (TP P43 (IN P45 (IN

P8 P8
S31803 254 625) 825)
UNS S32304 S32550 S32760 S32750 S39274 P1-P5 (TP (TP
S32205 SMO)
304) 316)
S32304 A-DF A-DF A-DF A-DF A-DF A-DF AEF AEF AF GH GH GH
S31803
A-D A-D A-D A-D A-D AEF AEF AF GH GH GH
S32205
S32550 B-D B-D B-D B-D ABEF ABEF ABF GH GH GH
S32760 CDGH CDGH CDGH A-DEF A-DEF A-DF GH GH GH
S32750 CDGH CDGH A-DEF A-DEF A-DF GH GH GH
S39274 CDGH A-DEF A-DEF A-DF GH GH GH

Key
A ASME SFA 5.4, Classification E2209—duplex filler material.
B ASME SFA 5.4, Classification E 2553—duplex filler material.
C ASME SFA 5.4, Classification E2594—duplex filler material.
D DP3W (unclassified)—duplex filler material.
E ASME SFA 5.4, Classification E309L—high-alloy austenitic filler material.
F ASME SFA 5.4, Classification E309LMo—high-alloy austenitic filler material.
G ASME SFA 5.11, Classification ENiCrMo-10—nickel-base filler material.
H ASME SFA 5.11, Classification ENiCrMo-14—nickel-base filler material.
NOTE 1 This table refers to coated electrodes. For bare and cored wire welding (SAW, GMAW, GTAW, FCAW), use equivalent electrode classification
(ASME/AWS SFA/A5.9, SFA/A5.14, SFA/A5.22, and SFA/A5.34). Refer to the text for information on other processes
NOTE 2 At times, ENiCrMo-10 ENiCrMo-13, and ENiCrMo-14 are used for Duplex and Super Duplex weld joints when severe corrosion is anticipated..
Source: API 582

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Number:

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Subject: Appendix C – Selection of Welding Consumables
NORMATIVE
Table 5B Welding Consumables for joining Copper- Nickel and Nickel base Alloys
70-30 & 90- Alloy 400 Nickel Alloy 800 Alloy Alloy Alloy Alloy C- Alloy Alloy B-2 Alloy Alloy G-
10 Cu-Ni (N04400) 200 (N08800), 600 625 825 22 C-276 (N10665 G-3 30
(N022 800H (N066 (N0662 (N0882 (N0602 (N102 ) (N069 (N0603
00) (N08810), 00) 5) 5) 2) 76) 85) 0)
800HT
(N08811)
Base Material (See
Note 1)
Carbon and Low Alloy BC BC C A A A A D E F G H

Steel
300-Series Stainless BC AC AC A A A A D E F G H
Steel
400-Series Stainless B B AC A A A A D E F G H
Steel
70-30 & 90-10 Cu-Ni B B C C C C C * * * * *
Alloy 400 (N04400) B BC A A A A A A F A A
Nickel 200 (N02200) C AC AC AC AC CD CE CF CG CH
Alloy 800 (N08800), K A A A DJ EJ FJ GJ HJ

800H
(N08810), 800HT
(N08811) (see Note 2)
Alloy 600 (N06600) A AJ A DJ EJ FJ GJ HJ
Alloy 625 (N06625) J J DJ EJ FJ GJ HJ
Alloy 825 (N08825) J DJ EJ FJ GJ HJ
Alloy C-22 (N06022) D EJ FJ GJ HJ
Alloy C-276 (N10276) E FJ GJ HJ
Alloy B-2 (N10665) F GJ HJ
Alloy G-3 (N06985) G HJ
Alloy G-30 (N06030) H
Key
A ASME/AWS SFA/A5.11, Classification ENiCrFe-2 or -3

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Subject: Appendix C – Selection of Welding Consumables
NORMATIVE
B ASME/AWS SFA/A5.11, Classification ENiCu-7

C ASME/AWS SFA/A5.11, Classification ENi-1
D ASME/AWS SFA/A5.11, Classification ENiCrMo-4
E ASME/AWS SFA/A5.11, Classification ENiMo-7
G ASME/AWS SFA/A5.11, Classification ENiCrMo-9
H ASME/AWS SFA/A5.11, Classification ENiCrMo-11
J ASME/AWS SFA/A5.11, Classification ENiCrMo-3
K ASME/AWS SFA/A5.11, Classification ENiCrMo-1 or matching filler metal
* An unlikely or unstable combination. Consult the pirchaser’s engineer if this comination is needed.
NOTE 1 Table A.4 refers to coated electrodes. For bareor cored wire welding (SAW, GMAW, GTAW, FCAW), use equivalent electrode
classification (ASME/AWS SFA 5.14, SFA/A5.34). Refer to the etxt for information on other processes.
Note 2 For Alloys 800, 800H, and 800HT, if sulfidation or stress relaxation cracking is a concern, use filler metals.
Source: API 582

Standard for Non-Destructive Examination (NDE)
Effective: 2015-03-31
Owned by: Director Quality Assurance, Major Projects
Major Projects Approver: Director Project Management, Major Projects
Reviewed every 3 years
Livelink ID: 264036684
Controlled Document 1 of 17 Revision: 2.0

Current revisions of approved documents are maintained online in Livelink. Printed copies are uncontrolled.
ST-QM-003
Summary of Changes
This Summary shows:
 All changes from last approved and published document

 The location within the document where the changes have been made
Location of Change Summary of Change

Section 1, Pg. 4 Update to the Target Audience wording.
Section 4, Pg. 15 Update to the Roles and Responsibilities wording.

ST-QM-003
Contents
Summary of Changes ................................................................................................................................... 2

Contents ........................................................................................................................................................ 3
1 About this Standard ................................................................................................................................ 4
Purpose ............................................................................................................................... 4
Scope .................................................................................................................................. 4
Target Audience .................................................................................................................. 4
Conformance Expectations ................................................................................................. 4
2 Requirements ......................................................................................................................................... 5
2.1 Certification And Qualification Requirements ............................................................................... 5
Non-Destructive Examination Personnel Qualification and Certification Requirements... 5
Visual Welding Inspection Personnel Qualification Requirements ..................................... 6
Non-Destructive Examination Competency Requirements................................................. 7
Level 1 Non-Destructive Examination Personnel Requirements ........................................ 7
2.2 Non Destructive Examination Procedure Requirements .............................................................. 9
Non-Destructive Examination Procedure Submittal Requirements .................................... 9
Non-Destructive Examination Procedure Review Requirements ....................................... 9
Non-Destructive Examination Procedure Acceptance Requirements .............................. 10
2.3 Requirements for Magnetic Particle Testing (MT) ..................................................................... 10
Requirements for Magnetic Particle Testing (MT) ............................................................ 10
2.4 Competency Performance Demonstration Testing (CPDT) and Job Test Requirements.......... 11
Competency Performance Demonstration Testing and Job Testing Requirements......... 11
3 Terms and Definitions .......................................................................................................................... 12
4 Roles and Responsibilities ................................................................................................................... 15
5 References ........................................................................................................................................... 16
Appendix A – Types of Compliance Audits................................................................................................. 17

ST-QM-003
1 About this Standard
Purpose The purpose of this standard is to specify the requirements of Non Destructive
Examination (NDE) on Suncor projects.
Scope This standard applies to Suncor physical asset projects.
Target Audience The target audience of this standard are those managing, sourcing or performing
Non-Destructive Examination activities on a Suncor Project
The target audience of this Standard is the person or organization responsible for
sourcing or performing Non-Destructive Examination activities on a Suncor Project or
work site.
2
For Suncor executed activities (or scope) on projects, the target audience is the
Suncor Integrated Team responsible for Non-Destructive Examination activities.
For non-Suncor executed activities (or scope) on projects, the target audience is
the contractor or third-party service provider responsible for Non-Destructive
Examination activities.
Conformance This standard is effective March 31, 2015.

Expectations

ST-QM-003
2 Requirements
2.1 Certification And Qualification Requirements
Non-Destructive The Non-Destructive Examination personnel qualification and certification

Examination requirements:
Personnel
Qualification 2.1.1 Perform Non-Destructive Examination activities in accordance with the
and Certification requirements of applicable construction Codes and Suncor project
Requirements specifications.
Note: Qualified refers to: Certified Non-Destructive Examination personnel who

has been examined by the Non-Destructive Examination Service Provider and has
demonstrated the knowledge, skills and experience required to fulfill the
requirements to properly perform a specific job in accordance with their Quality
Management system.
2.1.2 Demonstrate that Non-Destructive Examination Personnel are certified in

accordance with latest edition of one of the following certifying standards :
2.1.2.1 Recommended Practice for Personal Qualification and Certification
in Non-destructive Testing, American Society for Non-destructive
Testing SNT-TC-1A, CP-106;
2.1.2.2 Qualification and Certification of NDT Personnel CAN/CGSB
48.9712-ISO 9712; IDT;
2.1.2.3 General Requirements For Qualification and PCN Certification of
NDT Personnel, The British Institute Of Non Destructive Testing
PCN/GEN;
2.1.2.4 Certification of Personnel in Non Destructive Testing CSWIP-ISO-
NDT; and,
2.1.2.5 Qualification and Certification of NDT Personnel ISO 9712.
2.1.3 Demonstrate that Non-Destructive Examination personnel are qualified and
certified in accordance with the latest editions of:
2.1.3.1 CAN/CGSB 48.9712-ISO 9712, IDT to meet the requirements of
CAN/CSA/Z662 Oil and Gas Pipeline System and CAN/CSA-W59
Welded Steel Construction; and,
2.1.3.2 PCN or CSWIP for methods AUT, PAUT and TOFD.
Note: Certification to National or International standards other than those stated

above may be acceptable under specific and special circumstances as determined
by Suncor Project Quality and Project Services Quality.

ST-QM-003
The visual welding inspection personnel qualification requirements for boiler,

Visual Welding
pressure vessel, piping, storage tanks and pipelines:
Inspection
Personnel 2.1.4 Provide qualified and certified personnel for performing visual examinations
Qualification for acceptance of components and welds in accordance with the standards
Requirements and codes listed in Figure 1 to a minimum of a Visual Testing Level 2 of:
2.1.4.1 American Society of Non Destructive Testing SNT-TC-1A;
2.1.4.2 British Institute of Non Destructive Testing PCN;
2.1.4.3 United Kingdom Accreditation Service CSWIP;
2.1.4.4 Canadian Welding Bureau, CWB Level 2;
2.1.4.5 American Welding Society AWS-CWI;
2.1.4.6 American Petroleum Institute API-510;
2.1.4.9 ABSA In –Service Boiler and Pressure Vessel Inspector; or,
2.1.4.10 ABSA Certified Welding Examiner.
Visual Welding Examination Standards and Codes:

1. American Society of Mechanical Engineers, Boiler and Pressure
Vessel Code (ASME BPVC) Section I, IV, VIII
2. American Society of Mechanical Engineers B31.1 Power Piping Code
3. American Society of Mechanical Engineers B31.3 Process Piping
Code
4. Boiler, Pressure Vessel and Pressure Piping Code - CSA B51
5 Standard for Welded Tanks for Oil Storage API-650 Code
6 Oil and Gas Pipeline System CSA Z662 Code
Figure 1
2.1.5 Demonstrate that personnel are qualified in accordance with Suncor

Standard 0302 Furnishing of Steel Structures to perform visual inspection on
structural components.
Note: Upon receipt of a Deviation Notice (DN) from Suncor Project and accepted
by Project Services Quality, Visual Testing Level 1 personnel may perform visual
examinations independently for acceptance.

ST-QM-003
Non-Destructive The Non-Destructive Examination competency requirements:

Examination
Competency 2.1.6 Confirm that the Non-Destructive Examination service provider demonstrates
Requirements competency of Non-Destructive Examination personnel by:
2.1.6.1 Providing training to Non-Destructive Examination personnel in the
procedures intended to satisfy the scope of work;
2.1.6.2 Document the Non-Destructive Examination personnel
performance levels for the specified competency; and,
2.1.6.3 Record and maintain the competency status in the individual’s
training file.
Level 1 Non- The Level 1 Non-Destructive Examination Personnel requirements:

Destructive
Examination 2.1.7 Verify that Non-Destructive Examination Level 1 personnel are qualified and
Personnel certified to:
Requirements
2.1.7.1 Perform specific calibrations;
2.1.7.2 Perform specific Non-Destructive Examination applications in
accordance to written procedures; and,
2.1.7.3 Record test results.
2.1.8 Provide Non-Destructive Examination Level 1 personnel necessary
instruction and direct supervision from a certified Non-Destructive
Examination Level 2 or 3 Examiner.
Note: A Level 1 examiner shall not make any evaluations for acceptance or
rejection.

Destructive
Examination 2.1.9 Verify that Non Destructive Examination Level 2 personnel are qualified and
Personnel certified to:
Requirements
2.1.9.1 Set up and calibrate equipment;
2.1.9.2 Interpret and evaluate results based on the application of an
approved procedure and with respect to applicable Codes,
standards, and specifications; and,
2.1.9.3 Organize and report the results of Non-Destructive Examination
tests.
2.1.10 Verify that Non-Destructive Examination Level 2 personnel are thoroughly
familiar with the scope and limitations of the methods for which they are
qualified.

ST-QM-003

Destructive
Examination 2.1.11 Verify that Non-Destructive Examination Level 3 personnel are qualified and
Personnel certified to be capable of:
Requirements
2.1.11.1 Developing, qualifying, and approving procedures;
2.1.11.2 Establishing and approving techniques;
2.1.11.3 Interpreting codes, standards, specifications, procedures and test
results; and,
2.1.11.4 Designating the particular Non-Destructive Examination methods,
techniques, and procedures to be used.
2.1.12 Verify that Non-Destructive Examination Personnel Level 3 have sufficient
practical background in the following to establish techniques and to assist in
establishing acceptance criteria:
2.1.12.1 Applicable materials;
2.1.12.2 Fabrication; and,
2.1.12.3 Product technology.
2.1.13 Verify Non-Destructive Examination Personnel Level 3 have a basic working
knowledge of the other Non-Destructive Examination test methods.
2.1.14 Verify Non-Destructive Examination Personnel Level 3 are capable of
training and examining for competency Non-Destructive Examination
Personnel Level 1 and 2 personnel in the methods in which he or she is
certified.

ST-QM-003
2.2 Non Destructive Examination Procedure Requirements
Non-Destructive The Non Destructive Examination procedure submittal requirements:

Examination
Procedure 2.2.1 Obtain supplier or sub-supplier Non-Destructive Examination procedures and
Submittal addendums for review prior to start of any Non-Destructive Examination
Requirements activity.
Non-Destructive The Non-Destructive Examination procedure review requirements:

Examination
Procedure 2.2.2 Review supplier or sub-supplier Non-Destructive Examination procedures
Review and addendums prior to the start of Non-Destructive Examination activities.
Requirements
Note: Engineering and Procurement (EP) or Engineering, Procurement and
Construction (EPC) company designated representative or Suncor Project Quality
representative when there is no EP or EPC for the Project shall conduct procedure
reviews and acceptance.
2.2.2.1 Confirm that Non-Destructive Examination procedures and

subsequent revisions are developed and approved by a designated
Level 3 representative of the Non-Destructive Examination service
provider.
2.2.2.2 Confirm that Non-Destructive Examination procedures are in
compliance with the applicable construction Code and Suncor
project specifications.
2.2.2.3 Confirm that Non-Destructive Examination procedures identify
acceptance criteria in accordance with applicable construction
Code identified in the Scope of Work and
i. Demonstrate that Non-Destructive Examination personnel
are aware of and understand acceptance criteria.
2.2.2.4 Review Non-Destructive Examination procedures for all of the
following test methods and advanced UT applications in
accordance with the applicable construction Code:
i. Visual Testing (VT);
ii. Penetrant Testing (PT);
iii. Magnetic Particle Testing (MT);
iv. Eddy Current Testing (ET);
v. Radiographic Testing (RT);
vi. Manual Ultrasonic Testing (MUT);
vii. Automated Ultrasonic Testing Application (AUT);
viii. Phased Array Ultrasonic Testing Application (PAUT); and,
ix. Time of Flight Diffraction Application (TOFD).

ST-QM-003
Non-Destructive The Non-Destructive Examination procedure acceptance requirements:

Examination
Procedure 2.2.3 Stamp the cover page of accepted Non-Destructive Examination procedures
Acceptance with the applicable review code status in accordance with Standard 0118
Requirements Vendor Data Requirements.
2.2.3.1 Return stamped procedures to the supplier or sub-supplier for
implementation.
2.3 Requirements for Magnetic Particle Testing (MT)
Requirements The requirements for magnetic particle testing:

for Magnetic
Particle Testing 2.3.1 Use Direct Current (DC) to evaluate indication when the Magnetic Particle
(MT) Testing (MT) is the primary examination method.
2.3.2 Perform magnetic particle examinations after post weld heat treatment
(PWHT) by the indirect magnetization method (yoke or coil method) to avoid
arc strikes.
Note: Permanent magnets shall not be used to perform magnetic particle

examinations on any Suncor Project.

ST-QM-003
2.4 Competency Performance Demonstration Testing (CPDT) and Job Test

Requirements
Competency The competency performance demonstration testing and job testing requirements:
Performance
Demonstration 2.4.1 Perform a job test on Non-Destructive Examination personnel performing
Testing and Job AUT, PAUT and TOFD applications to determine their specific competency
Testing for the type of material and weld configuration to be inspected by the
Requirements applicable Non-Destructive Examination application.
2.4.2 Use a mock-up test specimen that contains artificial flaws relative to the
applicable acceptance criteria, of the type, size and location that could be
expected to occur during the construction or fabrication process.
2.4.3 Provide to Suncor a schedule and location of Non-Destructive Examination
personnel Job Tests.
2.4.4 Document and provide job test records for each Non-Destructive
Examination personnel for Suncor’s review or audit.
Note: Based on Equipment Criticality, Jobs Tests may be witnessed by Suncor

project representative as and when needed.
Suncor will perform periodic compliance audits to verify the correct implementation
of this standard. Refer to Appendix A for the different types of Compliance Audits.

ST-QM-003
3 Terms and Definitions
Term Definition
AUT Automated Ultrasonic Testing.
Procedure, used by the certification body to confirm that the qualification requirements
Certification
for a method, level and sector have been fulfilled, leading to the issuing of a
certificate.
Certified NDE personnel who are suitably qualified and trained, and have proper
Competent
experience to correctly perform NDE work in accordance with written procedures
without direct supervision.
DN Deviation Notice.
Means a supervisor who
Direct Supervision • Is personally and visually supervising the NDE personnel and
• Is able to communicate readily and clearly.
The corporate, private, or public entity which employs personnel for wages salary,
Employer
fees, or other consideration.
Work activities accomplished in a specific NDE method under the direction of qualified
Experience supervision including the performance of Non-destructive Examinations and related
activities, but not including time spent in organized training programs.
Job Test A test that is performed to ascertain the competency of NDE personnel regarding their
ability to correctly use an approved procedure and use it to evaluate flaws in a
specimen mock-up.

ST-QM-003
The term “materials” as used in this Standard, refers to any weld, component, or item
requiring some form of NDE to be performed, based on the requirements of a
Materials
referencing code, Suncor Standards, Project Specifications, or other Project Specific
Documents.
Non-Destructive Testing (NDT). also known as; Non-Destructive Evaluation or Non-

Destructive Examination (NDE), or Non-Destructive Inspection (NDI).
NDT/NDE/NDI
The development and application of technical methods to examine materials or
components in ways that do not impair future usefulness and serviceability in order to
detect, locate, measure and evaluate flaws; to assess integrity, properties and
composition; and to measure geometrical characteristics.
Is an orderly sequence of actions or steps describing how a specific NDE Technique

shall be applied to meet the requirements of a Construction Code, Standard or
Specification. The Procedure shall as a minimum, fully describe the necessary pre-
NDE Procedure
inspection material preparation, equipment calibration, inspection set-up, technique
application, acceptance Criteria, disposition, reporting, post-inspection cleaning,
marking, and safety requirements.
An NDE Procedure that has been reviewed and accepted either by; the EP/EPC
Accepted NDE
designated representative, or by Suncor Project Quality representative, for use in
Procedure
Suncor new Construction/Fabrication Projects.
An item such as Pressure Equipment and Structural when constructed fully new
New Construction based on an accepted design either in a shop or a site. A repair or alteration of the
above items in service does not constitute New Construction.
An NDE Procedure that has been physically qualified by the NDE service provider by
Qualified NDE
demonstration to the authorized qualifying organizations for a specific application, as
Procedure
specified by applicable Construction Codes.
The party who owns the facility wherein the pressure equipment including structural
Owner will be used. The owner is typically also the User and an organization, person, firm, or
corporation, legally responsible for the safe operation of any pressure equipment.

ST-QM-003
The party who establishes the pressure equipment and structural construction criteria
(e.g. selection of geometry, loads, etc.) consistent with the User criteria, defines and
Purchaser specifies the mechanical design requirements, and awards the contract to the
Supplier or Sub-supplier. The Purchaser may also be the Owner, User, or the Owner’s
or User’s Designated Agent (e.g. engineering contractor).
PAUT Phased Array Ultrasonic Testing.
QMS Quality Management System.
Demonstrated skill and knowledge and documented training and experience required
Qualification
for personnel to properly perform the duties of a specific job.
A certified NDE personnel who has been examined by the NDE Service Provider and
has demonstrated the knowledge, skills and experience required to fulfill the
Qualified NDE
requirements to properly perform a specific job in accordance with their Quality
Personnel
Management system. This acknowledgement of “qualified personnel” shall be
recorded in the individual’s training file.
Any individual or organization, who furnishes items or services, in accordance with a

Supplier procurement document. Supplier is also termed as Vendor, Seller, Contractor, Sub-
Contractor, Fabricator or Consultant depending on their role.
The party who establishes construction criteria in accordance with the philosophy of
User Code, Regulatory requirements and service hazards. The User is the operator of the
facility wherein the pressure equipment and structural will be installed.
TOFD Time of Flight Diffraction Ultrasonic Testing.
The organized program developed to impart the knowledge and skill necessary for
Training
qualification.

ST-QM-003
4 Roles and Responsibilities
Role Responsibility
Integrated The role with the overall accountability to fulfill the requirements of this standard.
Team Lead
2
Note: For Suncor, during Stage 1 to Gate 2 the Development Lead is typically the
Integrated Team Lead.
During Stage 3 and Stage 4 the Execution Lead is typically the Integrated Team Lead.
Supplier/ Sub- The Supplier/Sub-supplier is responsible to ensure that their NDE Service Providers (in
supplier house or external) are certified, qualified, competent, and that their NDE Examination
procedures meet the requirements of the applicable Construction Code(s) and relevant
Suncor Project requirements. They are also responsible to ensure the competency of all
qualified NDE personnel to be used by the NDE service providers. This shall be ensured
through an auditable and documented process by the supplier/sub-supplier. The
competency verification process of NDE personnel may include a performance
demonstration test (Job Test) as described in Section 2.5 of this standard.
NDE Service The NDE Service Provider (in house or external) is solely accountable, for providing
Provider certified and competent NDE personnel to work on Suncor Projects. As part of the due
diligence concept, the NDE Service Provider shall actively monitor and ensure that NDE
personnel are using the correct procedure on the job. It is the NDE Service Provider’s
responsibility to ensure that all certified NDE personnel are “qualified” and “competent” to
perform NDE examinations, or other duties, in accordance with the NDE Service
Provider’s Quality Management System (QMS).
Only qualified and competent Level-3 personnel, certified in the applicable Test Method,
shall approve NDE Procedures. As a representative or an agent of the NDE Service
Provider, the Level-3 by virtue of affixing his/ her signature or stamp/seal to the NDE
Procedure as “Approver”, indicates the procedure has been reviewed and is in
compliance with applicable Construction Code(s) and Suncor Project requirements.
The NDE Service Provider is responsible to supply the NDE personnel with approved
and calibrated NDE equipment in accordance with the Code requirements.
The NDE Service Provider shall provide the NDE personnel with the appropriate NDE
Reference Standards to perform static and dynamic calibrations (when required), of NDE
systems equipment, as required by the applicable Code and standard.
The NDE Service Provider is accountable and responsible to ensure that NDE Sub-
suppliers (when used) are in compliance with the NDE Service Providers QMS.

ST-QM-003
5 References
Document Number Document Title
SNT-TC-1A Recommended Practice for Personnel Qualification and Certification in Non-

destructive Testing (2011 Edition)
CAN/CGSB 48.9712-2014 “Non-Destructive Testing – Qualification and Certification of NDT Personnel
ASME B31.1 Power Piping, Latest Edition, and Addenda
ASME B31.3 Process Piping, Latest Edition, and Addenda
CSA Z662 Oil and Gas Pipeline Systems, Latest Edition and Addenda
CSA B51 Boiler, Pressure vessel and Pressure piping Code, Latest Edition and Addenda
CSA W-59 Welded Steel Construction, Latest Edition and Addenda
API-1104 Welding of Pipelines and Related facilities, Latest Edition and Addenda
WS D 1.1 Structural Welding Code- Steel, Latest Edition and Addenda
ASME BPV SECTION I ASME Boiler and Pressure Vessel Code Section I, Latest Edition and Addenda
ASME BPV SECTION IV ASME Boiler and Pressure vessel Code Section-IV, Latest edition and Addenda
ASME BPV SECTION V ASME Boiler & Pressure Vessel Code, Section V, Non-Destructive Examination
Latest Edition and Addenda
ASME BPV SECTION VIII, ASME Boiler and Pressure Code Section VIII, Div. 1 & 2, Latest Edition and Addenda
Div 1 & 2
PCN/GEN ISSUE 6 rev. B General Requirements for Qualification and PCN Certification of NDT personnel
CSWIP-ISO-NDT-11/93-R Requirements for the Certification of Personnel Engaged in Non-Destructive Testing in

accordance with requirements of EN 473 and ISO 9712
Standard 0118 Vendor Data Requirements
Standard 0302 Furnishing of Steel Structures

ST-QM-003
Appendix A – Types of Compliance Audits
On-site compliance audit description:

On-Site
Compliance
A1.1.1 Suncor Project Services Quality and/or Project Quality will perform periodic
Audit
scheduled on-site compliance audits on the main Supplier or Fabricator to
ascertain the correct implementation pertaining to the various requirements
of this standard for the Non-Destructive Examination methods based on
equipment criticality.
A1.1.2 NDE service providers whose services are engaged by the main
Supplier/Fabricator may also be subjected to such compliance audit.
Scope of The scope of compliance audits:

Compliance
Audit A1.1.3 These scheduled audits may be performed in the shop or field locations of
the main Supplier/Fabricator, including the locations of the NDE service
provider.
A1.1.4 The primary focus of the audit will be on the process of selection of the
NDE service providers by the main Supplier/Fabricator based on the
training, experience, qualification and certification of NDE personnel.
A1.1.5 The correct implementation of qualified procedure on the job shall also be a
focus of this audit.
Remote or Remote or random compliance audit description:

Random
Compliance A1.1.6 When an on-site compliance audit is not feasible, a remote audit based on
Audit the review of the Supplier/Fabricator/NDE service provider’s Quality
Control Manual, Procedure etc. will be performed.
A1.1.7 A random audit may be performed at the field locations to ascertain the
correct implementation of the requirements of this standard by the NDE
service provider’s personnel. Remote audit may also include review of NDE
Reports/data collected during inspection/test.
Specific Specific compliance audit description:

Compliance
Audit A1.1.8 At the request of Project Quality, an audit may also be performed on a
specific supplier/ sub-supplier when their performance regarding
implementation of this standard is questionable.
Accountability The description of accountability for compliance audits:

for Performance
A1.1.9 The Project Quality will be accountable for the audits requested by Project
of Compliance
Quality or jointly by Project Services Quality, Project Quality and Supply
Audit
Chain Management( SCM)

ST-QM-003
The following individuals have approved and signed this document.
UserName: Frank Randt (frandt)

Title: Dir Quality Assurance
Date: Wednesday, 18 March 2015, 09:38 AM Mountain Time
Meaning: I approve the changes to this document.
================================================
UserName: Don Smith (dlsmith)

Title: Dir Project Mgmt
Date: Wednesday, 18 March 2015, 12:37 PM Mountain Time
Meaning: I approve the changes to this document.
================================================
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CorporateTechnical Standard
Department: Number:
ENTERPRISE TECHNICAL
0221
Subject: Revision:
BOLTED FLANGE JOINT ASSEMBLY
3
Addendum / Revisions History
REV. Section
Change
# Changed
3 1.2.1 Re-worded.
3 1.2.2 Deleted “but not be limited”. “Pressure Vessel” replaced with “Static Equipment” at
second and third bullet. Added “that are in accordance with ASME B16.5 or ASME
B16.47” at fourth bullet
3 1.2.3 Added HDPE Pipe and Resilient seated Butterfly Valves. Last sentence re-worded
3 1.3 Added sentence relative to FLRA
3 3.1 Re-worded
3 3.2 Corrected titles for CTS 0205 and CTS 0220
3 3.3 Updated titles for ASME B31.1, B31.3, B31.4, ASTM A105, ASTM A182, ASTM
A193, ASTM A194, ASTM A320, ASTM A350,ASTM A453, ASTM A694, and deleted
reference to ASEM B31.11
3 4.0 Split into sections 4.1 and 4.2
3 4.1 New paragraph for Definitions, Added definitions for “Owner”, “Owner’s Engineer”
“Owner’s Inspector”, and “Suncor” – at definition for Powered Torqueing, changed
“Tightening” to “Torqueing”
3 4.2 New paragraph for Acronyms – spelling of Nunavut corrected
3 5.1 Fig. 1 Added “/studs/nuts” to “Bolt replacement” - in note 1 added “Hydraulic tensioning
requirement for bolts 2 inches and larger, added “single manual or powered torque
wrench” to Minimum equipment required in category III, and Reworded Note 2 and
Note 6.
3 5.2.2 “Suncor” replaced with “Owner’s Engineer”
3 5.3.1 In second sentence, added “and the joint is disassembled and gasket replaced”
3 5.3.2 Added section for match-marking of flanges at dissasembly
3 5.3.3 Added section
3 5.4.1-3. “Correct” replaced with “Owner’s Engineer Approved”
3 5.4.1-4. Re-worded – added reference to “Owner’s Engineer Approved”
3 5.4.2-1 Re-worded and added reference to Appendix G
3 5.5.2 Added new sentence after first sentence. In third sentence, “must” replaced with
“shall”
3 5.5.3 “Suncor” replaced with “Owner’s Engineer” – added ® for registered trade marks
3 5.6.2 Deleted reference to figures 2,3, and 4 – added acceptable variation tolerances.
Replaced “Suncor” with “Owner’s Engineer” in last sentence. Added “for resolution”
after “report to Owner’s Engineer”.
3 5.6.5 Deleted reference to figures 5, 6, and 7 – added acceptable variation tolerances.
Added reference “to Owner’s Engineer for approval” in third paragraph.
3 5.7 Added sentence at the beginning referencing ASME PCC-1 Appendix C
3 5.7.1 “should” replaced with “shall” in first sentence - replaced “joint assembly procedure
sheet” with “Bolted Flange Joint Assembly Record Data Sheet (See Appendix G)
This paragraph has been split into 5 subsections
3 5.7.6 Paragraph re-worded – previously was 5.7.2
3 5.7 Figure 8 Deleted – refer to ASME PCC-1
3 5.7 Figure 9 Deleted – refer to ASME PCC-1
3 5.8.1 The term “bolt” is replaced with “machine bolt” in the first sentence in this paragraph,
added “at every turnaround or more” before “frequently” – in last sentence changed
Standard 0221, Rev 3 Bolted Flange Joint Assembly Page 3 of 57
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“should” to “shall”
3 5.8.2 Deleted commentary after first sentence (references to bolt types) – provided
guidance relative to B7M bolt material tourque values. This paragraph has been split
into 3 subsections
3 5.8.5 Re-worded – added ® for registered trade marks- this was previously numbered as
5.8.3
3 Exhibit 1 Added title “Application of Anti-seize”
3 5.9.2 Re-worded to align with current version of ASME PCC-1.
3 5.10.2-2. Added “tool” to “(<50% coverage)”
3 5.10.2-3. Added “tool” to “(50% or 100% coverage)”
3 5.10.2-3-c. “pump” replaced with “tensioner pump”
3 5.10.3-1. Added “tool” and “<” to “(, 50% coverage)”
3 5.10.3-2. Added “tool” to “(50% or 100% coverage)”
3 5.10.3-2.c. “pump” replaced with “tensioner pump”
3 5.11 “only” replaced with “primarily”
3 5.11.1.3 “System Hold” test changed to “Sensitive Leak test”
3 5.12 “must” replaced with “shall”
3 5.12.3 “Hot Torque” replaced with “Start-up re-torque or Hot Torque” and definition re-
worded to align with ASME PCC-1-2013
3 5.12.4 Definition re-worded to align with definition in ASME PCC-1-2013
3 5.12.6 “Odd-Bolting” changed to “Half-bolting” or “Odd-Bolting” and definition re-worded to
align with ASME PCC-1-2013.
3 6.0 Modified the first sentence in this paragraph.
3 Appendix B Added the word “tool” at coverages in B.2 and B.3
3 Appendix C Deleted “general” in first sentence and ref to API 601 corrected to API 605 –
“Engineer” changed to “Owner’s Engineer” – added headings in all tables
3 Appendix E “will” replaced with “shall” in note c.- “Engineering” changed to “Owner’s Engineer”
3 Appendix F Expanded descriptions of categories – added note relative to HF and H2S services
3 Appendix G “Joint Risk Category” changed to “Risk Category”

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TABLE OF CONTENTS
1.0 PURPOSE & SCOPE.................................................................................................................. 6

1.1 PURPOSE ................................................................................................................................. 6
1.2 SCOPE ...................................................................................................................................... 6
1.3 PRECAUTIONS ......................................................................................................................... 7
2.0 RESPONSIBILITIES ................................................................................................................... 7
2.1 ACCOUNTABILITY AND APPROVAL ........................................................................................ 7
2.2 REVISIONS AND UPDATES ..................................................................................................... 7
2.3 INTERPRETATION .................................................................................................................... 7
2.4 IMPLEMENTATION ................................................................................................................... 7
3.0 REFERENCES & PREREQUISITES .......................................................................................... 7
3.1 PREREQUISITES ...................................................................................................................... 7
3.2 SUNCOR STANDARDS AND DRAWINGS ................................................................................ 7
3.3 RELEVANT / REFERENCED PUBLICATIONS, CODES AND STANDARDS ............................ 8
4.1 DEFINITIONS ............................................................................................................................ 9
4.2 ACRONYMS .............................................................................................................................. 9
5.0 STANDARD .............................................................................................................................. 10
5.1 JOINT CATEGORIES .............................................................................................................. 10
5.2 TRAINING, QUALIFICATION AND EQUIPMENT CALIBRATION ............................................ 11
5.3 JOINT DISASSEMBLY ............................................................................................................. 11
5.4 REQUIRED EQUIPMENT ........................................................................................................ 11
5.5 JOINT CLEANING ................................................................................................................... 12
5.6 JOINT INSPECTION ................................................................................................................ 12
5.7 GASKET INSTALLATION ........................................................................................................ 13
5.8 INSTALLATION OF BOLTS ..................................................................................................... 13
5.9 JOINT ALIGNMENT ................................................................................................................. 15
5.10 TIGHTENING THE JOINT ........................................................................................................ 17
5.11 LEAK TESTING THE ASSEMBLED JOINT .............................................................................. 18
5.12 MISCELLANEOUS TERMINOLOGY........................................................................................ 18
6.0 DOCUMENTATION AND DELIVERABLES ............................................................................. 20
7.0 LIST OF APPENDICES ............................................................................................................ 20
8.0 APPROVED BY ........................................................................................................................ 21
APPENDIX A – SINGLE TOOL TIGHTENING PATTERN .................................................................. 22
APPENDIX B – MULTIPLE TOOL TIGHTENING PATTERNS ............................................................ 26
APPENDIX C – ASSEMBLY BOLT LOAD.......................................................................................... 30
APPENDIX D – BOLT LOAD VERIFICATION .................................................................................... 48
APPENDIX E – TURN-OF-NUT PROCEDURE ................................................................................... 51
APPENDIX F – JOINT CATEGORY ASSESSMENT........................................................................... 55
APPENDIX G – BOLTED FLANGE JOINT ASSEMBLY RECORD DATA SHEET ............................. 56

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1.0 PURPOSE & SCOPE

1.1 Purpose
The purpose of this standard is to define the requirements for installing and tightening gasketed metallic
bolted flange connections to consistently achieve flange joint integrity for leak free operation.
1.2 Scope
1.2.1 This standard shall be applicable to standard Raised Face (RF) and Ring Type Joint (RTJ) flange
connections and custom designed Heat Exchanger girth flanges. Torque/Tension values provided in
this standard are for ASME B16.5 or ASME B16.47 flanges only. For custom designed Heat
Exchanger flanges, Torque/Tension values are to be calculated by the Owner’s Engineer as per
procedures outlined in clause CTS 801.
1.2.2 This standard shall apply to:
• ASME B16.5 and ASME B16.47 Piping flanged joints.
• Static Equipment connections to matching piping flange joints.
• Static Equipment man-way covers.
• Pressure Vessel and Shell & Tube Exchanger body or girth flanges that are in accordance with
ASME B16.5 or ASME B16.47 (both internal and external).
• Flange materials of Ductile Iron, Carbon Steel, Low Alloy Steel, Stainless Steel, and High Alloy Steel
(both ferritic and non-ferritic materials)
1.2.3 Some examples for which this standard does NOT apply:
• Flat Face Flanges
• Control Valve Bonnets
• Valve Bonnets (i.e. Gate, Globe, Check Valve Bonnets)
• Breech Lock Closures (i.e. Chiyoda, Belleli, IMB, etc.)
• Rotating Equipment casing, suction and discharge flanges
• Flame arrestors
• Rubber expansion joints
• Resilient seated Butterfly Valves
• Air Cooler Plug Sheet Plugs
• Equipment Anchor bolting
• Teflon (PTFE) lined pipe
• Fibreglass (FRP) pipe
• HDPE pipe
• Cast Iron Flanges, Cast Aluminium Flanges
Procedures for tightening of joints that are not within the scope of this document shall be determined by
the Owner’s Engineer in consideration of the equipment or component manufacturer’s procedures and
specified torque or bolt stress values.
1.2.4 This standard applies to the following Business Units that are a part of Suncor Energy Inc;
• Oil Sands & In Situ
• Refining
• Major Projects
1.2.5 Use of this standard for Business Services, Exploration and Production, and other Business Units
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1.3 Precautions
Users of this Standard must adhere to all relevant Business Unit Procedures. In all cases, the appropriate
Field Level Risk Assessment (FLRA) shall be performed prior to any of these activities taking place.
Business Unit or Project related positions are indicative of their responsibilities; these designations may vary
Director of Technical Standards is responsible for approving and has overall accountability to ensure that this
standard is effectively used for projects and existing plants.
Discipline Subject Matter Expert (SME) is responsible to update and revise this standard in consultation with
Peer Review Network (PRN) members and Director of Technical Standards based on Lessons Learnt and for
Continuous Improvement.
2.3 Interpretation
PRN members within business units are responsible for interpretation of standard. SME shall be consulted in
complex cases. Director of Technical Standards shall have the final decision in case of conflict.
2.4 Implementation

3.1 Prerequisites
Users of this Standard must adhere to relevant Business Unit Procedures and training requirements.
CTS 0201 PIPING DESIGN AND PLANT LAYOUT
CTS 0202 PIPING MATERIAL SPECIFICATIONS
CTS 0203 VALVES
CTS 0204 PIPING FABRICATION AND INSTALLATION
CTS 0205 PIPING PRESSURE LEAK TESTS
CTS 0220 ON-LINE WELDING AND HOT TAP DESIGN AND INSTALLATION REQUIREMENTS

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ASME B1.1 – UNIFIED INCH SCREW THREADS
ASME B16.5 – PIPE FLANGES AND FLANGED FITTINGS
ASME B16.36 – ORIFICE FLANGES
ASME B16.20 – METALLIC GASKETS FOR PIPE FLANGES
ASME B16.47 – LARGE DIAMETER STEEL FLANGES
ASME B31.1 – POWER PIPING
ASME B31.3 – PROCESS PIPING
ASME B31.4 – PIPELINE TRANSPORTATION SYSTEM FOR LIQUIDS AND SLURRIES
ASME B31.8 – GAS TRANSMISSION AND DISTRIBUTION PIPING SYSTEMS
ASME B31.12 – HYDROGEN PIPING AND PIPELINES
ASME B46.1 – SURFACE TEXTURE (SURFACE ROUGHNESS, WAVINESS AND LAY)
ASME PCC-1 – GUIDELINES FOR PRESSURE BOUNDARY BOLTED JOINT FLANGE ASSEMBLY
ASME SECTION VIII – BOILER AND PRESSURE VESSEL (DIVISION 1 AND 2) CODE
ASTM A105 – CARBON STEEL FLANGES FOR PIPING APPLICATIONS
ASTM A182 – FORGED OR ROLLED ALLOY AND STAINLESS STEEL PIPE FLANGES, FORGED
FITTINGS AND VALVES AND PARTS FOR HIGH-TEMPERATURE SERVICE
ASTM A 193 – ALLOY-STEEL AND STAINLESS STEEL BOLTING FOR HIGH TEMPERATURE OR HIGH
PRESSURE SERVICE AND OTHER SPECIAL PURPOSE APPLICATIONS
ASTM A194 – CARBON AND ALLOY STEEL NUTS FOR BOLTS FOR HIGH PRESSURE OR HIGH
TEMPERATURE SERVICE, OR BOTH
ASTM A320 – ALLOY-STEEL AND STAINLESS STEEL BOLTING FOR LOW TEMPERATURE SERVICE
ASTM A350 – CARBON AND LOW-ALLOY STEEL FORGINGS, REQUIRING NOTCH TOUGHNESS
TESTING FOR PIPING COMPONENTS
ASTM A453 – HIGH-TEMPERATURE BOLTING, WITH EXPANSION COEFFICIENTS COMPARABLE TO
AUSTENITIC STAINLESS STEELS.
ASTM A694 – CARBON AND ALLOY STEEL FORGINGS FOR PIPE FLANGES, FITTINGS, VALVES, AND
PARTS FOR HIGH-PRESSURE TRANSMISSION SERVICE.
CSA Z662 – OIL AND GAS PIPELINE SYSTEMS

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4.0
4.1 Definitions
Category M Fluid – A fluid service in which the potential for personnel exposure is judged to be significant
and in which a single exposure to a very small quantity of a toxic fluid, caused by leakage, can produce
serious irreversible harm to persons on breathing or bodily contact, even when prompt restorative measures
are taken.
Hydraulic Bolt Tensioning – Using hydraulic tensioning equipment to accurately tension bolts.
Joint – The complete connection including all components such as gasket, flange seating surfaces, and all
studs and nuts.
May – indicates an acceptable course of action
Owner – means Suncor Energy Inc. or its designated representative.
Owner’s Engineer – means the registered professional engineer who is employed directly by Suncor or its
designated representative and is responsible for the technical integrity of the project.
Owner’s Inspector – means the person authorized for inspection.
Powered Torqueing – Torqueing flange bolts using calibrated hydraulic, electric, or pneumatic torque.
Shall – indicates a mandatory requirement
Should – indicates a preferred course of action
Suncor – means Suncor Energy Inc.
Tightening – Tightening flange bolts using hand or impact wrenches.
Torque – The moment of a force or system of forces causing rotation. Torque methods use the inclined
plane of a thread to convert rotary motion of the nut into axial motion of the bolt.
Torqueing – Tightening flange bolts using calibrated manual torque wrenches.
4.2 Acronyms
ABSA – Alberta Boilers Safety Association.
ACI – Regulatory Authorities (Chief Inspectors) for PEI, NS, NB, NFLD/Labrador, Yukon, NWT, Nunavut
ASME – American Society of Mechanical Engineers
ASTM – American Society for Testing and Materials
BCSA – British Columbia Safety Authority
CSA – Canadian Standards Association
Manitoba Labor and Immigration Mechanical and Engineering Branch
RBQ – Regie Du Batiment Du Quebec
TSASK – Technical Safety Authority of Saskatchewan
TSSA – Technical Standards and Safety Authority – Ontario

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5.0 STANDARD
5.1 Joint Categories
The category of joint is determined by consideration of the joint service severity and consequences of joint
failure (see Appendix F). The below table outlines the required bolted joint assembly equipment and quality
assurance steps to ensure the appropriate level of technology and effort is applied.
Joint Criticality Rating: CATEGORY I CATEGORY II (Note 5) CATEGORY III (Note 5)
Description: CRITICAL SERVICE TYPICAL SERVICE NON-CRITICAL SERVICE
MINIMUM ASSEMBLY LOAD Multiple Tool Controlled Powered Single Manual or Powered Torque Single Manual or Powered
CONTROL METHOD Torque Wrench or Hydraulic Wrench (Note 1) Torque Wrench (Note 1)
REQUIRED Tensioning
OPTIONAL MORE ACCURATE Multiple Tool Controlled Powered Multiple Tool Controlled Powered N/A
ASSEMBLY LOAD CONTROL Torque Wrench or Hydraulic Torque Wrench or Hydraulic
METHOD Tensioning with Extensometer Tensioning
Verification (Note 3)
MINIMUM EQUIPMENT 2 or more calibrated Torque 1 or more calibrated wrenches Single calibrated Manual or
REQUIRED Wrenches or 50% coverage with Powered Torque Wrench
Hydraulic Tensioners
JOINT GAP MEASUREMENT Required Required Not Required

DURING ASSEMBLY
BOLT/STUD/NUT Required (Note 6) Required (Note 6) Required (Note 6)

REPLACEMENT
HARDENED WASHERS Recommended as per Note 2 Recommended as per Note 2 Recommended as per Note 2
ASSEMBLY RECORDS Required Required N/A
SUNCOR QUALITY Required – 5% of Joints (Note 4) Random Audit N/A

ASSURANCE INSPECTION
Figure 1 – Assembly Procedure Matrix

Notes:
1. Powered torque wrench(es) or Hydraulic tensioning should be used for studs 1-1/4 inch in diameter or greater. Hydraulic
bolt tensioning should be used for studs 2 inch in diameter and larger.
2. Hardened washers are recommended only on frequently opened joints (more than every turnaround) where practical.
When hydraulic tensioners are used on stud bolts, hardened washers are only to be used under the nut opposite to the
one being tensioned. Never use a hardened washer under the tensioning head.
3. Bolt tensioning requires 25% of bolts of each joint to have Ultrasonic Testing to confirm elongation.
4. % Inspection refers to the number of completed joints.
5. Equipment nozzles (including Bridles, PRVs and PVRVs) shall default to a minimum Category II.
6. Bolt, Stud, or nut replacement is required only where it is determined that the bolt, stud, or nut is damaged or has been
abused, or where the bolt cannot be identified. This applies to new bolt ups or previously bolted-up joints which are
disassembled and to be bolted up again.

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5.2 Training, Qualification and Equipment Calibration

5.2.1 All joint assemblers shall be capable of executing the requirements of this document. This document
is based on recommendations included in ASME PCC-1.
5.2.2 All contract joint assemblers shall provide a copy of their quality control procedure pertaining to bolted
joint assembly to the Owner’s Engineer for review prior to starting work.
5.2.3 All assembly equipment shall be calibrated in accordance with manufacturer recommendations, but in
no case shall the calibration interval exceed 1 year. Tools shall be uniquely identifiable and traceable
to the certification documentation.
5.3 Joint Disassembly
5.3.1 For joints that have leaked and the joint is disassembled and gasket replaced, it is often necessary to
preserve the gasket in order to determine the root cause of the leakage. In those cases, care should
be taken in order to avoid damaging the gasket during disassembly.
5.3.2 At disassembly, flanges should be match-marked in instances where those joints can be re-
assembled in more than one orientation.
5.3.3 Before any joint is disassembled, it is essential that assurance be obtained from personnel in
responsible charge of the management of the system that all pressure, including that due to a liquid
head, has been removed from the system and that proper procedures have been followed to ensure
that joints may be safely opened.
A sufficient number of loosened nuts shall be left in place until all tension has been relieved, to guard
against failing components, or pipe spring or other unanticipated movement. Due to the possibility of
residual liquid in the pipe along with any unrelieved pressure, the first bolts loosened shall be in a
location that will direct any pressure release away from the assembler. Generally, for joints in the
vertical plane, this will be at the top of the joint and then at the bottom to drain the liquid.
When significant numbers of bolts are loosened in rotational order, the elastic recovery of the clamped
parts can result in excessive loads on the relatively few remaining bolts, making further disassembly
difficult and sometimes causing galling between the nut and bolt sufficient to result in torsional failure of
the bolt as further loosening is attempted.
5.4 Required Equipment
Prior to commencing joint assembly, the following items shall be available to the assembler:
5.4.1 All Joints:
1. Correct size tightening equipment, including back-up wrench.
2. Wire brush for cleaning (Stainless for Stainless flanges).
3. Owner’s Engineer approved anti-seize product (see 5.8.3).
4. Owner’s Engineer approved adhesive for holding the gasket in place, if required.
5. Flashlight for inspecting the gasket once installed in the joint.
6. Correct PPE for the joint location.
5.4.2 Category I & II Joints:
1. Joint Assembly Record Data Sheet from Appendix G.
2. Straight edge of sufficient length to span the flange facing diameter, where practical.

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3. Feeler gauges for flange flatness measurement.

4. Vernier Callipers or Joint Gap Gauge to measure flange gap.
5.5 Joint Cleaning
The flange gasket seating surfaces should be cleaned sufficiently to allow inspection of the surface and to
ensure that no residual material remains that may be detrimental to the ability of the gasket to seal.
5.5.1 Ensure that the nut surface is clean.
5.5.2 Remove all traces of gasket or corrosion from the gasket seating surface using a wire brush or
scraper. Due care shall be taken to avoid any damage to the serrations on the flange facing. For
stainless steel flanges, the wire brush used shall be stainless steel. For graphite faced gaskets, it is
acceptable to leave traces of graphite in the valleys of the seating surface serrations.
5.5.3 Remove all product, foreign materials or adhesive from the flange gasket seating surface. Solvent or
degreaser (approved for use by the Owner’s Engineer prior to being applied) may be required in the
case of heavy greases, oils or adhesives. Pre-approved degreasing agents include “MAGNAFLUX
SPOTCHECK® SKC-S” and “CHEMETALL ARDROX® 9PR50”
5.6 Joint Inspection
The flange gasket seating surfaces require inspection to ensure that there are no imperfections that may
result in joint leakage. For new construction, flange facing acceptable criteria shall follow ASME B16.5 and
ASME B16.47 requirements. For post-construction, the following actions should be taken:
5.6.1 Inspect the flange to nut contact surfaces for the presence of excessive wear (out-of-square), burrs,
scores, galling or gouges. If damage is severe, the back of the flange will need to be spot-faced to
remove the damage, otherwise the defects may be removed using hand tools.
5.6.2 Inspect the flange surface finish in the region of the gasket sealing element for surface defects and
general flange surface finish condition. The acceptable variation in both circumferential flange seating
surface flatness and radial (across surface) flange seating surface flatness is 0.006 inch (0.15 mm).
Report any defects that appear to fail the criterion to the Owner’s Engineer for resolution before
proceeding.
5.6.3 Inspect the bolts and nuts for obvious signs of damage (even new nuts and bolts should be checked),
corrosion and galling. Prior to applying anti-seize, run the nuts at least 4 complete turns past the
point where they will tighten on the flange. For stud bolts, both ends of the bolt and both nuts should
be checked at least once. The nuts should run easily by hand. If they cannot be tightened by hand
then the bolt and nut should either be replaced or machined to remove any defects.
5.6.4 Inspect the gasket for any signs of damage during transport or handling. Do not install a gasket that
appears to have been damaged. Some gasket damage may be repairable, but in all cases, Owner’s
Engineer should be notified and the gasket manufacturer’s recommendation should be sought.
5.6.5 For Category I and Category II joints, the flatness of the flange must be inspected using a straight
edge across the flange face at 4 locations (every 45 degrees) and a feeler gauge to measure any
gaps. The acceptable variation in both circumferential flange seating surface flatness and radial
(across surface) flange seating surface flatness is 0.006 inch (0.15 mm). Report any defects to the
Owner’s Engineer for approval to proceed further. It is acceptable to gauge mating flanges that have
only one possible alignment configuration and determine that any waviness of the flange faces is
complimentary, such that the seating surfaces follow the same pattern. This is found in multi-pass
exchanger joints and is often caused by thermal distortion. In this case, it is conservative to calculate
the overall gaps between the flanges at points around the circumference and utilize the single flange
tolerances specified above to determine acceptability of the gap. This technique may also be used
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on piping flanges that are rigidly fixed in location and cannot be separated sufficiently for
measurement of individual flatness.
5.7 Gasket Installation
Recommended gasket contact surface finish for various gasket types are identified in ASME PCC-1
Appendix C. Guidelines for allowable gasket contact surface flatness and defect depth are provided in ASME
PCC-1 Appendix D.
5.7.1 The type and size of all gaskets shall be verified against the Bolted Flange Joint Assembly Record
Data Sheet (see Appendix G).
5.7.2 Gaskets that have been in service (including for hydro-test) shall never be re-used.
5.7.3 Substandard gaskets should not be used for hydrostatic test purposes, the gasket should be to
specification.
5.7.4 Gaskets shall not be removed from their shipping/handling protectors until immediately prior to flange
joint assembly and shall be clean and free of debris.
5.7.5 The gasket should be centred on the flange facing and should not project into the bore of the line.
5.7.6 The gasket shall be securely held in place during the joint assembly process; a very light dusting of
spray adhesive on the gasket (not the flange) may be used. Particular care shall be taken to avoid
adhesive chemistry that is incompatible with the process fluid which could result in stress corrosion
cracking or pitting of the flange surfaces. Do not use tape strips radially across the gasket to hold it in
position. Do not use grease.
5.7.7 The gasket should not be wet prior to installation and no gasket that is saturated with water or other
substance shall be installed, as this can cause gasket failure due to degradation or the creation of
steam.
5.8 Installation of Bolts
The following guidelines should be followed for initial joint assembly:
5.8.1 For joints that are disassembled at every turnaround or more frequently, hardened washers in
accordance with ASME PCC-1 Appendix M should be used under the nuts at both ends of stud bolts
and under the nut for a machine bolt when tightening using torque control methods. For hydraulic
tensioning, a washer may be used under the opposite nut to the one being tensioned in order to
facilitate joint disassembly. Hardened washers shall never be used under the nut being tensioned.
5.8.2 Stud bolts and nuts shall be per the Suncor Piping Line Class specification for the joint and shall be
installed with the markings facing outward and all in the same direction in order to facilitate post-
assembly inspection.
5.8.3 Assembly Torque and per bolt assembly loads are provided in Appendix C for the most commonly
used bolting materials (ASTM A193 Gr B7/B16 bolts, ASTM A193 Gr B8M CL1 bolts, and ASTM
A193 Gr B8M CL2 bolts).
5.8.4 Even though ASTM A193 Gr B7M bolts have lower yield strength, they can be assembled to the
same values as those shown for ASTM A193 Gr B7 bolts.
5.8.5 For non-coated bolts, an Owner’s Engineer approved Anti-Seize Compound shall be applied liberally
and completely (see exhibit 1 below) to the nut contact faces and to the threads on both ends of the
bolts past where the nuts will come to rest after tightening; the lubricant should be applied after the
bolts are inserted through the flange bolt holes to avoid possible contamination with solid particles
that could create unwanted reaction torque. The following are Suncor approved Anti-Seize

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Compounds which are relative to a nut factor of 0.18 for ASTM A193-B7 and ASTM A193-B16 bolts
and 0.22 for stainless steel bolts and include the following:
a) JET-LUBE 550® NONMETALLIC ANTI-SEIZE COMPOUND
b) JET-LUBE NIKAL® High Temperature Anti-Seize Compound
c) LOCTITE® Nickel Anti-Seize
Exhibit 1
Application of Anti-seize
5.8.6 The Anti-seize may be applied to one end of a stud bolt prior to inserting the bolt into the joint,
however the second end should only be lubricated once in the joint, to avoid loss of anti-seize or
contamination of the anti-seize during insertion of the bolt into the joint.
5.8.7 Bolts used for hydraulic tensioning will require a projection of one bolt diameter at the end being
tensioned. This additional length should be protected from corrosion with a cap and heavy grease
after completion of tensioning. At the other end, and for other assembly methods, at least two
complete threads should show above the nut after joint assembly (fewer threads showing may be
accepted by the Owner’s Engineer).
5.8.8 If an assembly pattern other than the Quadrant Pattern is being used, then the bolts should be
numbered in accordance with the sequence listed in Appendix A of this procedure for that pattern.
5.8.9 Strong consideration should be given to replacing bolts of any size should it be found that they have
been abused or non-lubricated during previous assemblies.

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5.9 Joint Alignment

5.9.1 Pre-Assembly Alignment
The joint shall be aligned prior to assembly. The below geometric and force limits are recommended:
1. Centreline High/Low: The tolerance is measured by placing a straight edge on the outside
diameter of one flange and extending it to or over the mating flange. This is done at four points
around the flange, approximately 90 degrees from each other. The maximum acceptable
difference between the flange centreline is 1/16 inch (1.5 mm) at any point.
1/16” max.
(1.5 mm)
2. Parallelism: The tolerance is usually derived by measuring the closest and farthest distance
between the flanges and comparing. An acceptable tolerance is a difference no greater than
1/32 inch (0.8 mm), achieved using a force of no greater than 10% of the specified assembly
torque or bolt load for any bolt.
Max. 1/32” (0.8 mm)

difference between the
widest and narrowest
points
3. Rotational – Two Hole: The tolerance is measured by observing a 90 degree angle where the
fastener passes through the flanges to ensure that the holes are aligned within 1/8 inch (3 mm).
1/8” max
(3 mm)

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1. Excessive Spacing or Gap: When no external alignment devices are used, the flanges shall be
brought into contact with the uncompressed gasket uniformly across the flange faces using less
than the equivalent of 10% of the total target assembly bolt load. When aligning the flanges no
single bolt is to be tightened above 20% of the single bolt maximum torque or target bolt load
(the combined allowance for excessive gap and parallelism tolerances). When external
alignment devices are used, the flanges shall be brought to the compressed gasket thickness
uniformly across the flange faces using an external load equivalent to less than 20% of the target
assembly bolt load.
2. In addition the following notes and cautions must be followed:

a. Out of tolerance conditions shall be corrected before the gasket is installed to avoid
damaging it.
b. Only minimal or reasonable adjustments are to be made after the gasket is installed.
c. If the flanges that are in need of aligning are connected to pumps or other rotating
equipment, great care shall be taken to prevent introducing a strain into the equipment
housing or bearings. Having a qualified rotating equipment person measure the
movement in the equipment during assembly to ensure that you do not disturb the
rotating equipment alignment is a common and necessary practice.
d. Once the flanges are aligned, install the gasket and tighten the fasteners completely,
and then release the aligning devices. Follow this rule as closely as possible. External
forces have far less effect once a joint is properly loaded.
5.9.2 Assembly Alignment
In addition to being aligned initially, the joint shall also remain in alignment during assembly.
Misalignment (indicated by uneven gasket compression) is indicative of gasket damage, gasket slippage
or undesirable contact between the flanges
The alignment during assembly should be checked per the following procedure:
Take measurements of the gaps between the flanges around the circumference at 8 equally spaced
locations (4 locations is acceptable for flanges NPS 8 and smaller) to verify that the flanges are being
brought together evenly. An acceptable tolerance is a difference no greater than 1/32 inch (0.8 mm) at
the O.D. of the sealing surface, achieved using a force of no greater than 10% of the maximum torque or
bolt load for any bolt.
When no external alignment devices are used, the flanges should be brought into contact with the
uncompressed gasket uniformly across the flange faces using less than the equivalent of 10% of the total
target assembly bolt load. When aligning, the flanges, no single bolt should be tightened above 20% of
the single bolt maximum torque or target bolt load.

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When external alignment devices are used, the flanges should be brought to the compressed gasket
thickness uniformly across the flange faces using an external load equivalent to less than 20% of the total
target assembly bolt load.
Owner’s Engineer approval is required where more force is required to bring the flange gap into
compliance.
5.10 Tightening the Joint
The following guidelines should be followed for initial joint assembly, based on criticality (see Appendix F) and
assembly technique:
5.10.1 Category III Joints
1. One of the assembly patterns listed in Appendix A of this Standard should be followed.
2. Care should be taken in the initial part of the pattern to ensure that load is being applied gradually
to ensure alignment of the joint occurs prior to 100% of the load being applied on any one bolt.
5.10.2 Category II Joints
1. Single Manual or Hydraulic Torque Wrench
a. The tightening equipment being used shall all be within calibration date.
b. One of the assembly patterns listed in Appendix A of this Standard shall be followed.
c. The assembly bolt torque for the appropriate gasket and flange size and rating in
accordance with Appendix C of this Standard shall be used.
d. The flange gap shall be measured per section 5.9.2.
2. Multiple Hydraulic Torque Wrenches (< 50% tool coverage) (It is typically more practical and
efficient to utilise hydraulic tensioning if 50% or greater tool coverage is desired.)
b. The assembly pattern listed in Appendix B of this Standard shall be followed.
3. Multiple Hydraulic Tensioners (50% or 100% tool coverage) (Typically using less than 50% tool
coverage hydraulic tensioning is less efficient and less accurate than using multiple hydraulic
torque wrenches with extensometer verification of the achieved bolt load. Less than 50%
coverage of tensioners may be used, but additional passes, per the 50% procedure, for verification
that all bolts are at the desired preload will be required.)
c. The assembly bolt load for the appropriate gasket and flange size and rating in
accordance with Appendix C of this Standard divided by the tool pressure area and
multiplied by the appropriate relaxation factor shall be used as the tensioner pump set
pressure.

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5.10.3 Category I Joints

1. Multiple Hydraulic Torque Wrenches (< 50% tool coverage)
2. Multiple Hydraulic Tensioners (50% or 100% tool coverage)
a. The tightening equipment being used must all be within calibration date.
c. The assembly bolt load for the appropriate gasket and flange size and rating in
accordance with Appendix C of this Standard divided by the tool pressure area and
multiplied by the appropriate relaxation factor shall be used as the tensioner pump
pressure.
5.11 Leak Testing the Assembled Joint
For Category I joints, a Joint Integrity Leak Test is specified. The leak test for joint integrity is primarily to tell
whether the gasket has slipped off-centre or is damaged during assembly.
5.11.1 Leak Test
One of the following will meet the minimum leak test requirements:
1. Hydrostatic test at Operating pressure
2. Pneumatic test at 15 psig (103 kPag) pressure followed by “Snoop” testing.
3. A Sensitive leak test with “Snoop” testing of the joints is typically performed for high pressure
hydrogen systems (Hydro-cracker / Hydrotreater, etc.) during start-up.
5.12 Miscellaneous Terminology
The following definitions serve to provide a standardized field terminology and procedure for various
assembly related procedures. In all cases, the appropriate Field Level Risk Assessment (FLRA) shall be
performed prior to any of these activities taking place.
5.12.1 Nut Factor
The nut factor for an Anti-Seize product determines the amount of bolt load that will be generated for an
applied torque. It is an approximate measure of the bolt friction and should be determined by test results.
For the Anti-Seize Compound used in this specification, the nut factor should be taken as 0.18 for ASTM
A193 Grade B7 and ASTM A193 Grade B16 bolting and 0.22 for Stainless Steel bolting. The relationship
used to determine the required torque is listed below:
T=F.K.D/12
Where
T = applied Torque (ft. lb) D = bolt diameter (inches)
F = Applied Load (lb) K = nut factor
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5.12.2 Make-Up Technique

Where bolts are inaccessible to the assembly equipment being used due to local restrictions such as
nozzles, the inaccessible bolts may need to be assembled using a less accurate method. The
inaccessible bolts and nuts and four other bolts and nuts shall have their ends marked in order to
measure the amount of rotation applied during assembly. The inaccessible nuts should be turned the
same amount of rotation during assembly using the less accurate method of tightening as the four
accessible nuts are turned using the accurate method of tightening. This method employs the Turn-of-
nut procedure to achieve the same approximate level of preload in the inaccessible bolts as the
accessible bolts. Every effort should be made to provide equipment of the type specified that can access
all nuts, but the make-up technique may be used in rare cases where this is simply not possible.
5.12.3 “Start-up Re-torque” or “Hot Torque”
Tightening all bolts on a joint while the unit is coming up to operating temperature in a circular pass until
the nuts no longer turn. Start-up Re-torque (also referred to as Hot Torque) is performed to increase the
residual operational stress on the gasket (to recover initial gasket relaxation), to minimize the likelihood of
leakage. It is typically performed while the unit is on line but may also be performed prior to operation
using heating pads to bring the flange up to temperature. Since this activity will only increase the load on
the gasket, the risk of leakage is significantly lower than for other activities (such as Hot Bolting). Start-up
0 0
re-torque or Hot Torque is performed when the temperature of the flange or bolts is between 300 F (149
0 0 0
C) and 450 F (232 C), or within 24 hours of unit start up if the joint temperature remains below 300 F
0
(149 C). This temperature range is selected to maximize the gasket relaxation that has occurred and
also to ensure that the lubricating oils of the anti-seize product have not evaporated.
Start-up re-torque or Hot Torqueing should be used on the following joints:
0 0
a. All joints that have an Operating Temperature greater than 700 F (371 C).
b. All Heat Exchanger joints with a Design Temperature differential between tube side and shell side
0 0
of greater than 300 F (149 C).
c. Any problematic bad actor joints at the discretion of the Maintenance Engineer in consultation with
the Process contact Engineer.
d. Any joints that experience cyclic service or two phase flow.
e. Any joints that have a history of leakage after a process upset.
f. Any specialty joints as recommended by the vendor.
5.12.4 “Turn-of-Nut” Procedure
Tightening of all bolts on a joint while the unit is in operation or during a turn around, without
disassembling the joint. Turn-of-Nut is used either to proactively increase the gasket stress to prevent
leakage (in high temperature or cyclic services) or to reseal a small stable leak. If this procedure is
performed while the unit is on line, there is a small risk of additional leakage. However, since the load on
the gasket will only increase, the risk of leakage is significantly lower than for other activities (such as Hot
Bolting). Turn-of-Nut involves tightening the joint by turning one nut on each bolt by a specific amount
(See Appendix E). Turn-of Nut does not require knowledge of the nut factor and therefore can be applied
at any stage during the life of the joint. An engineering and risk analysis of the turn-of-nut operation shall
be carried out to establish that the operation can be performed safely. For fibre-sheet gasket style, Turn-
of-nut is used only for low-pressure, non-hazardous services as that gasket type has a tendency to
degrade in service and could blow out if retightened while operating.

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5.12.5 “Hot-Bolting”
The sequential removal and replacement of bolts on flanged joints while the unit is under reduced
operating pressure. The procedure generally consists of removing one bolt at a time in a flange, re-
lubricating it, re-installing it (or a new bolt) and re-tightening it to a specified torque. Hot bolting can be
performed while the unit is on-line or once the unit is depressurized. If performed while the unit is on-line,
consideration of the risk of leakage includes the number of bolts in the flange and the hazard associated
with the contained process fluid. Hot-Bolting is used to either replace corroded or defective bolts or to
proactively increase the gasket stress to prevent leakage (in high temperature or cyclic service) or to
reseal a small stable leak.
NOTE: Hot-Bolting while the unit is on-line to increase gasket stress or seal a small stable leak is not
recommended or required if “Turn-of-Nut” tightening can be used. See Article 3.11 of ASME PCC-2. An
engineering and risk analysis of the hot-bolting operation shall be carried out to establish that the
operation can be performed safely. Refer to ASME PCC-2 for further information on joint-tightening
activities once the unit is fully operational.
5.12.6 “Half-Bolting or “Odd-Bolting”
The removal of every other bolt (so the flange is left with half the number of bolts) during plant
depressurization (the unit is off line), usually when the system is close to atmospheric pressure (the
lesser of 25% of maximum allowable pressure or 50 psig (345 kPa)). The procedure generally consists
of removing every second bolt, re-lubricating them, re-installing them and re-tightening to a specified
torque. The remaining bolts are then removed, re-lubricated, re-installed and re-tightened to a specified
torque such that all bolts have been re-installed. There is a small risk of leakage with this procedure,
particularly if the system is accidentally re-pressurized. An engineering and risk analysis of the half-
bolting or odd-bolting operation should be carried out to establish that the operation can be performed
safely. Refer to ASME PCC-2 for further information on joint tightening activities once the unit is fully
operational.
5.12.7 “Four-Bolting” or “Eight-Bolting”
The removal of every bolt except four or eight evenly spaced opposing bolts in preparation for breaking
the joint (typically for blinding or valve removal) during a shut-down. The unit is off-line to do this, as in
the requirement for half-bolting outlined in ASME PCC-2. However, as the joint is not broken, the line
may still contain process fluid. There is a small risk of leakage with this procedure. This activity is
performed to speed up blinding or valve removal during shut-down. An engineering and risk analysis of
the four-bolting or eight-bolting operation shall be carried out to establish that the operation can be
performed safely.
6.0 DOCUMENTATION AND DELIVERABLES

The joint assembly procedure sheet contained in Appendix G shall be fully completed for all applicable joints as
referred in Figure 1 of this standard. The “Front Line Supervisor” in charge of the assembly shall verify each step
has been completed and initial the form at the appropriate location indicating compliance with the requirements.
Any deviation from normal joint assembly or additional steps taken to assemble the joint (such as adjusting the
initial torque to achieve joint alignment) must be noted on the assembly procedure sheet.
7.0 LIST OF APPENDICES

Appendix A – Single Tool Tightening Pattern
Appendix B – Multiple Tool Tightening Pattern
Appendix C – Assembly Bolt Load
Appendix D – Bolt Load Verification
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APPENDIX A – SINGLE TOOL TIGHTENING PATTERN

(Page 1 of 4)
This appendix contains two single tool tightening procedures based on the alternative patterns contained in
ASME PCC-1 Appendix F.
A.1 QUADRANT METHOD
This method does not require numbering of the bolts, as the first loose bolt in the quadrant due to be
tightened is the next bolt that must be tightened. For soft gaskets (gaskets where the relative movement
between the flange faces during assembly is relatively large: e.g., PTFE, spiral wound, Ring Type Joints
and compressed sheet gaskets), a minimum of two pattern passes are required. For hard gaskets
(Kammprofile, corrugated metal and flat solid-metal gaskets), a minimum of one pattern pass is required.
For problematic joints, it is recommended that an additional pattern pass be completed above the
minimum required. After the pattern passes are complete then circular passes shall be performed until
the nuts do not turn. The procedure is as follows:
Pass #1a: Proceed in one of the following patterns, depending on the number of bolts on the flange and
tighten the first four bolts to 30% of Assembly Load. If there are more than 52 bolts on the flange then two
bolts may be grouped as one (i.e.: tighten two bolts in one quadrant prior to proceeding to the next
quadrant. For joints with more than 104 bolts, three bolts may be grouped as one.
Pass #1b: Tighten the next four bolts to 70% of Assembly Load
Pass #1c and 2: Tighten all subsequent bolts to 100% of Assembly Load until all pattern passes are complete
Pass #3 onward: Tighten in circular passes until the nuts do not turn
12 1
11 2 12 Bolt Example – Star Quadrant Sequence

(generally for joints with 16 bolts or less):
Pass 1a –30% of Assembly Load: 1, 7, 4, 10
10 3 Pass 1b –70% of Assembly Load: 2, 8, 5, 11
Pass 1c - 100% of Assembly Load: 3, 9, 6, 12
nd
Pass 2 (If 2 pattern pass specified) - 100% of
9 4 Assembly Load : 1, 7, 4, 10 – 2, 8, 5, 11 – 3, 9,
6, 12
Pass 3 onward - 100% of Assembly Load (until
8
5 nuts do not turn): 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,
12, - 1, 2, 3, etc….
7 6

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(Page 2 of 4)
24 Bolt Example – Circular Sequence (suitable only

for >16 bolt flanges):
24 1
23 2 Pass 1a – 30% of Assembly Load: 1, 7, 13, 19
22 3
21 4
Pass 1b– 70% of Assembly Load: 2, 8, 14, 20
Pass 1c - 100% of Assembly Load: 3, 9, 15, 21 -
20 5
4,10,16,22 - 5,11,17,23 - 6,12,18,24
19 6 nd
Pass 2(If 2 pattern pass specified) - 100% of
Assembly Load
18 7
1,7,13,19 - 2,8,14,20 - 3,9,15,21 - 4,10,16,22 -
17 8 5,11,17,23 - 6,12,18,24
16 9
Pass 3 onward - 100% of Assembly Load (until
15 10 nuts do not turn)
14 11 1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,
13 12
17,18,19,20,21,22,23,24 - 1,2,3, etc….

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(Page 3 of 4)
A.2 STAR PATTERN METHOD
This method requires numbering of the bolts in accordance with the table on the next page prior to
commencing assembly of the joint. The bolt numbers should be marked on the flange in a clockwise order
per the table numbering system for the number of bolts in the joint. For soft gaskets (gaskets where the
relative movement between the flange faces during assembly is relatively large; e.g. PTFE, spiral wound,
Ring Type Joints and compressed sheet gaskets), a minimum of two pattern passes are required. For
hard gaskets (Kammprofile, corrugated metal and flat solid-metal gaskets), a minimum of one pattern
pass is required. For problematic joints, it is recommended that an additional pattern pass be completed
above the minimum required. After the pattern passes are complete then circular passes shall be
performed until the nuts do not turn. The procedure is as follows:
Pass #1a: Proceed in the pattern outlined below and tighten the first four bolts to 30% of Assembly Load.
If there are more than 52 bolts on the flange then two bolts may be treated as one, as noted in the
numbering system. For joints with more than 104 bolts, three bolts may be grouped as one, as noted in
the numbering system.
Pass #1b: Tighten the next four bolts to 70% of final load
Pass #1c & 2: Tighten all subsequent bolts to 100% of final load until all pattern passes are complete
Pass #3 onward: Tighten in circular passes until the nuts no longer turn
24 Bolt Examples:
24 1
23 2 Pass 1a – 30% of Assembly Load: 1, 13,7,19
22 3
Pass 1b – 70% of Assembly Load: 4,16,10,22
21 4
20 5
Pass 1c - 100% of Assembly Load: 2, 14,8,20
- 5,17,11,23 - 3, 15,9,21 - 6,18,12,24
19 6
nd
Pass 2 (If 2 pattern pass specified) - 100% of
Assembly Load
18 7
1, 13,7,19 - 4,16,10,22 - 2, 14,8,20 -
17 8
5,17,11,23 - 3, 15,9,21 - 6,18,12,24
16 9 Pass 3 onward - 100% of Assembly Load, in

circular pattern, until nuts do not turn.
15 10
1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,
14 11
13 12 17,18,19,20,21,22,23,24 - 1,2,3, etc….

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(Page 4 of 4)
STAR PATTERN BOLT NUMBERING SEQUENCES

Instructions: Start at one bolt and number each bolt in a clockwise direction with the number
sequence listed below
4 1, 3 ,2, 4
8 1, 5, 3, 7, 2, 6, 4, 8
12 1, 5, 9, 3, 7, 11, 2, 6, 10, 4, 8, 12
16 1, 13, 5, 9, 3, 15, 7, 11, 2, 14, 6, 10, 4, 16, 8, 12
20 1, 13,5 ,17, 9, 3, 15, 7, 19, 11, 2, 14, 6, 18, 10, 4, 16, 8, 20, 12
24 1, 13, 21, 5, 17, 9, 3, 15, 23, 7, 19, 11, 2, 14, 22, 6, 18, 10, 4, 16, 24, 8, 20, 12,
28 1, 13, 21, 5, 17, 9, 25, 3, 15, 23, 7, 19, 11, 27, 2, 14, 22, 6, 18, 10, 26, 4, 16, 24, 8, 20, 12, 28
32 1, 29, 13, 21, 5, 17, 9, 25, 3, 31, 15, 23, 7, 19, 11, 27, 2, 30, 14, 22, 6, 18, 10, 26, 4, 32, 16, 24, 8,
20, 12, 28
36 1, 29, 13, 21, 5, 17, 33, 9, 25, 3, 31, 15, 23, 7, 19, 35, 11, 27, 2, 30, 14, 22, 6, 18, 34, 10, 26, 4, 32,
16, 24, 8, 20, 36, 12, 28
40 1, 29, 13, 21, 37, 5, 17, 33, 9, 25, 3, 31, 15, 23, 39, 7, 19, 35, 11, 27, 2, 30, 14, 22, 38, 6, 18, 34, 10,
26, 4, 32, 16, 24, 40, 8, 20, 36, 12, 28
44 1, 29, 13, 21, 37, 5, 17, 33, 9, 25, 41, 3, 31, 15, 23, 39, 7, 19, 35, 11, 27, 43, 2, 30, 14, 22, 38, 6, 18,
34, 10, 26, 42, 4, 32, 16, 24, 40, 8, 20, 36, 12, 28, 44
48 1, 29, 45, 13, 21, 37, 5, 17, 33, 9, 25, 41, 3, 31, 47, 15, 23, 39, 7, 19, 35, 11, 27, 43, 2, 30, 46, 14,
22, 38, 6, 18, 34, 10, 26, 42, 4, 32, 48, 16, 24, 40, 8, 20, 36, 12, 28, 44
52 1, 29, 45, 13, 21, 49, 5, 37, 17, 33, 9, 25, 41, 3, 31, 47, 15, 23, 51, 7, 39, 19, 35, 11, 27, 43, 2, 30,
46, 14, 22, 50, 6, 38, 18, 34, 10, 26, 42, 4, 32, 48, 16, 24, 52, 8, 40, 20, 36, 12, 28,44
56 Group 2 bolts together & number each bolt according to 28 bolt pattern
60 See Group Bolting Instruction: P=28, N=1, A=29, B=30, C=31, D=32
Etc….
108 Group 3 bolts together & number per the 36 bolt pattern
120 Group 3 bolts together & number per the 40 bolt pattern
Etc……
GROUP BOLT INSTRUCTION:
Number “N” bolt/s “A”, the opposite “N” bolt/s (180 degrees opposite) “B”, the “N” bolt/s 90 degrees
counter-clockwise from that “C” and the “N” bolt/s opposite that “D” then number per the “P” bolt
pattern starting at the bolt clockwise from the bolt numbered “A”, skipping the already numbered
bolts. See 60 bolt & 116 bolt examples below:
60 Number 1 bolt 29, the opposite bolt 30, the bolt 90 degrees counter-clockwise from that 31 and the
bolt opposite that 32, then number per the 28 bolt pattern starting at the bolt clockwise from the bolt
numbered 29, skipping the already numbered bolts.
116 Number two bolts 37, the opposite two bolts 38, two bolts 90 degrees counter-clockwise from that 39
and two bolts opposite that 40, then number per the 36 bolt pattern, skipping the already numbered
bolts.

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APPENDIX B – MULTIPLE TOOL TIGHTENING PATTERNS

(Page 1 0f 4)
This appendix contains two tightening procedures, which are based on the alternative patterns contained
in ASME PCC-1 Appendix F. These methods do not require numbering of the bolts, as the first loose bolt
in the quadrant due to be tightened is the next bolt that must be tightened. A minimum of 4 tightening
tools should be used for this method. More tools will result in better compression of the gasket. Multiples
of 4 tools should be used in order that the tools can be evenly spaced around the joint. For soft gaskets
(gaskets where the relative movement between the flange faces during assembly is relatively large: e.g.
PTFE, spiral wound, Ring Type Joints and compressed sheet gaskets.) in large diameter, low pressure
flanges (> 64 inches, < 200 psig) the use of a minimum of 8 tools should be considered to avoid the
potential to locally overload the gasket by “rippling” the flange. There are no pattern passes used in these
procedures, circular passes are used and the passes shall be performed until the nuts do not turn. It is
essential that the nuts are turned at the same time (simultaneously); otherwise the flange may become
misaligned.
B.1 Hydraulic Torque (> 4 Tools)
Pass #1a: Proceed in a circular pattern with the tools evenly spaced and pressure applied to each
tool simultaneously. Tighten the first set of bolts to 100% of Assembly Load, measure gaps. If
greater than 30% of bolts are being tightened simultaneously, then the load should be stopped at
50% of the load in order that the gaps can be measured, in addition to measuring the gaps again at
100% of load.
Pass #1b: Tighten the next four bolts to 100% of Assembly Load, measure gaps.
Pass #1c onward: Tighten the next four bolts and all subsequent bolts to 100% of Assembly Load
in a circular manner until at least 2 sets of nuts in a row do not turn when a pressure corresponding
to 95% of the assembly load is applied. Measure gaps after the first complete pass at 100% of
load.

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(Page 2 of 4)
24 1
24 Bolt, 4 Tool Example:
23 2
22 3 Pass 1a – 100% of Assembly Load
21 4 Simultaneously: 1, 7, 13, 19,
measure gaps
20 5
Pass 1b – 100% of Assembly Load
19 6
Simultaneously: 2, 8, 14, 20,
measure gaps
18 7
17 8 Pass 1c onward - 100% of Assembly

Load Simultaneously: 3, 9, 15, 21 and
16 9 then proceed in a clockwise circular
15 10 pattern tightening the next set of bolts
14 11 until 2 sets of nuts in a row do not
13 12 turn. Measure gaps after all bolts
have been tightened to 100% once.
24 1 Pass 1a – 50% of Assembly Load

23 2
Simultaneously: 1, 4, 7, 10, 13, 16, 19, 22,
22 3
measure gaps.
21 4
Pass 1b – 100% of Assembly Load
20 5 Simultaneously: 1, 4, 7, 10, 13, 16, 19, 22,
measure gaps
19 6
Pass 1c – 100% of Assembly Load

18 7 Simultaneously: 2, 5, 8, 11, 14, 17, 20, 23,
measure gaps
17 8
Pass 1d onward - 100% of Assembly Load
16 9
Simultaneously: 3, 6, 9, 12, 15, 18, 21, 24,
15 10 measure gaps and then proceed in a
14 11 clockwise circular pattern tightening the
13 12 next set of bolts until 2 sets of nuts in a row
do not turn

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 3 of 4)
B.2 Hydraulic Tensioning (50% Tool Coverage)
Pass #1a: Complying with manufacturer instructions, fit tensioners to bolts. Follow equipment
safety instructions, including ensuring all tensioners are fully threaded onto the bolts prior to
applying any pressure, in order to prevent injury. Ensure that each tensioner sits completely flat on
the flange, if there is any gap or if the tensioner face is not parallel with the flange then this must be
fixed prior to proceeding to tension otherwise full load will not be achieved. Tension the first set of
bolts to 70% of Assembly Load, measure gaps.
Pass #1b: Tension the same bolts to between 110% and 125% of assembly load, measure gaps.
The over-tightening on this pass is to account for the load loss due to bolt interaction once the
second set of bolts is tightened. A higher value should be used for relatively short bolts (length ≈ 10
x diameter), with the load decreasing to 110% for bolts with lengths > 20 x diameter. To minimize
relaxation, it is advisable to cycle the tensioner pressure from a minimal pressure to full load
several times, tightening the nut during each cycle until the additional nut movement is minimal
prior to removing the tensioners.
Pass #1c onward: Tension the second set of bolts to 105% of assembly load, measure gaps. The
load applied at this step is marginally higher to account for the relaxation that occurs once the load
is transferred from the tensioner to the nut. To minimize relaxation, it is advisable to cycle the
tensioner pressure from minimum to full load several times, tightening the nut during each cycle
until the additional nut movement is minimal prior to removing the tensioners.
Pass #2 onward: Place at least four tensioners onto the first set of bolts. Stroke the tensioners to
th
100% of assembly load. If the nuts turn more than 1/16 of a flat, then all of the first set of bolts
must be re-tensioned to 105% of assembly load. Repeat this on the next set of bolts until the nut
movement is less than the specified limit.
B.3 Hydraulic Tensioning (100% Tool Coverage)
Pass #1a: Complying with manufacturer instructions, fit tensioners to all bolts. Follow equipment
safety instructions, including ensuring all tensioners are fully threaded onto the bolts prior to
applying any pressure, in order to prevent injury. Ensure that each tensioner sits completely flat on
the flange, if there is any gap or if the tensioner face is not parallel with the flange then this should
be fixed prior to proceeding to tension otherwise full load will not be achieved. Tension the bolts to
70% of assembly load, measure gaps.
Pass #1b: Tension the bolts to 105% of assembly load, measure gaps. The load applied at this
step is marginally higher to account for the relaxation that occurs once the load is transferred from
the tensioner to the nut. To minimize relaxation, it is advisable to cycle the tensioner pressure to
full load several times, tightening the nut during each cycle until the additional nut movement is
th
minimal (< 1/16 of a flat) prior to removing the tensioners.

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 4 of 4)

24 1
23 2
Pass 1a – 70% of Assembly Load
22 3
Simultaneously on every second bolt, measure
21 4 gaps.
20 5 Pass 1b – 110% to 125% of Assembly Load
Simultaneously on the same bolts, measure
19 6
gaps.
18 7 Pass 1c - 105% of Assembly Load

Simultaneously on the second bolts, measure
17 8
gaps
16 9
Pass 2 onward - 100% of Assembly Load on
15 10 the next set of bolts, retension and recheck
14 11 next set of bolts if significant nut movement
13 12
occurs
24 1 24 Bolt, 24 Tool Example:

23 2
22 3
Pass 1a – 70% of Assembly Load
21 4 Simultaneously on all bolts, take gap
measurements
20 5
Pass 1b onward - 105% of Assembly Load
19 6
Simultaneously on all bolts, take gap
measurements. Repeat, without gap
18 7 measurement, until no nut movement occurs
during tightening of the nut.
17 8
16 9
15 10
14 11
13 12

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3
APPENDIX C – ASSEMBLY BOLT LOAD

(Page 1 of 18)
This Appendix contains recommendations for selection of assembly bolt torque for torque control
assembly or bolt load for hydraulic tension assembly. It contains tables of required bolt torque or load
versus joint material and gasket type for standard ASME B16.5 and ASME B16.47 Series A (MSS-SP-44)
& Series B (API 605) flanges. The method used to establish the requirements of this Appendix follow the
procedures contained in ASME PCC-1 Appendix O. Joint material combination other than those outlined
in this Appendix should be calculated in accordance with that procedure on a case-by-case basis by the
Owner’s Engineer. Where anti-seize products are used that have a different Nut Factor to the one listed
on the table, the table value should be multiplied by the ratio of the actual nut factor divided by the nut
factor listed on the table. The allowable flange loads are calculated with an assumed pipe wall thickness,
listed below in Tables C-0-1 and C-0-2. Where the side minimum wall thickness is significantly less or
more than the listed value (>15%) then the tables should be re-calculated.
TABLE C-0-1 TABLE C-0-2

ASME B16.5 ASME B16.47
Calculations – Pipe Thickness Used (in.) Calculations – Pipe Thickness Used (in.)
Flange Class Flange Class
NPS NPS
150 300 600 900 1500 2500 150 300 400 600 900
0.5 0.065 0.065 0.065 0.065 0.065 0.344 26 0.312 0.500 0.704 0.934 1.382
0.75 0.065 0.065 0.065 0.065 0.065 0.344 28 0.312 0.500 0.758 1.006 1.488
1.0 0.065 0.065 0.065 0.065 0.065 0.344 30 0.250 0.625 0.812 1.078 1.594
1.5 0.065 0.065 0.065 0.065 0.065 0.344 32 0.312 0.625 0.867 1.150 1.700
2 0.065 0.065 0.154 0.109 0.218 0.344 34 0.312 0.625 0.921 1.222 1.807
2.5 0.083 0.083 0.120 0.203 0.276 0.552 36 0.312 0.750 0.975 1.294 1.913
3 0.083 0.083 0.120 0.216 0.300 0.600 38 0.375 0.693 1.029 1.366 2.019
4 0.083 0.083 0.237 0.237 0.438 0.674 40 0.375 0.729 1.083 1.437 2.126
5 0.109 0.109 0.258 0.375 0.500 0.750 42 0.375 0.766 1.137 1.509 2.232
6 0.109 0.109 0.280 0.432 0.562 0.910 44 0.375 0.802 1.192 1.581 2.338
8 0.109 0.148 0.322 0.500 0.812 1.185 46 0.375 0.839 1.246 1.653 2.444
10 0.134 0.307 0.500 0.594 1.000 1.476 48 0.375 0.875 1.300 1.725 2.551
12 0.156 0.330 0.500 0.688 1.125 1.751 50 0.375 0.912 1.354 1.797
14 0.156 0.250 0.500 0.750 1.250 52 0.375 0.948 1.408 1.869
16 0.165 0.312 0.562 0.938 1.375 54 0.375 0.984 1.462 1.941
18 0.188 0.375 0.812 1.031 1.750 56 0.375 1.021 1.517 2.012
20 0.188 0.375 0.812 1.281 1.750 58 0.375 1.057 1.571 2.084
24 0.218 0.562 0.969 1.531 2.062 60 0.375 1.094 1.625 2.156

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 2 of 18)
TABLE C-1-1A TABLE C-1-1B

ASME B16.5 CARBON STEEL FLANGES ASME B16.5 CARBON STEEL FLANGES
ASME B16.20 SPIRAL WOUND GASKETS WITH INNER AND ASME B16.20 SPIRAL WOUND GASKETS WITH INNER AND
OUTER RINGS OUTER RINGS
ASTM A193 GR B7/B16 BOLTS ASTM A193 GR B7/B16 BOLTS
ASSEMBLY TORQUE (ft-lb) (K=0.18) PER BOLT ASSEMBLY LOAD (lb x 1000)
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 30 40 40 105 105 105 0.5 4 5 5 9 9 9
0.75 35 60 60 105 105 105 0.75 4 6 6 9 9 9
1 50 80 80 170 170 170 1 6 8 8 13 13 13
1.5 65 170 170 300 300 370 1.5 8 15 15 20 20 22
2 125 90 90 200 200 250 2 13 9 9 15 15 17
2.5 125 125 125 280 280 370 2.5 13 11 11 18 18 22
3 125 185 185 275 390 525 3 13 16 16 21 23 28
4 125 225 360 500 610 950 4 13 20 27 29 32 42
5 225 225 540 705 960 1560 5 20 20 36 37 42 59
6 225 225 510 575 760 2390 6 20 20 34 34 37 80
8 225 360 800 880 1230 2390 8 20 27 47 43 50 80
10 360 525 910 805 1945 4830 10 27 35 48 39 69 129
12 360 800 955 965 2390 6510 12 27 47 51 47 80 158
14 540 700 1075 1155 3465 14 36 41 52 51 103
16 540 1045 1525 1435 4830 16 36 56 68 59 129
18 800 1135 2120 2410 6510 18 47 60 87 86 158
20 800 1135 1945 2535 8540 20 47 60 80 84 190
24 1135 2055 2680 4830 13780 24 60 91 95 129 262

ASME B16.47 SERIES A CARBON STEEL FLANGES ASME B16.47 SERIES A CARBON STEEL FLANGES
Flange Class – Series A Flange Class – Series A
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 645 1505 2210 6510 26 34 62 79 158
28 550 1505 2525 8540 28 29 62 84 190
30 645 2185 2715 8540 30 34 83 90 190
32 1000 2385 3465 10950 32 44 85 103 225
34 950 2725 4045 13780 34 42 97 120 262
36 1000 2845 4830 13780 36 44 95 129 262
38 1165 2055 4620 16075 38 52 91 137 306
40 1000 2315 4620 13780 40 44 95 137 262
42 1165 2425 6440 16075 42 52 99 172 306
44 1040 2935 5635 17065 44 46 112 150 303
46 1165 3740 6440 20830 46 52 133 172 347
48 1165 3430 7595 20830 48 52 122 184 347
50 1560 3830 9965 50 59 128 221
52 1560 3980 9965 52 59 133 221
54 1560 5330 9965 54 59 158 221
56 1560 5515 12780 56 59 163 262
58 1565 5015 12780 58 60 148 262
60 1560 5180 16085 60 59 153 306
Note: Tensioner pump pressure (psig) is obtained by using the above bolt load multiplied by the load loss factor (1.05 to 1.25), multiplied by
1000 and divided by the tensioner pressure area (in2)

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 3 of 18)

ASME B16.47 SERIES B CARBON STEEL FLANGES ASME B16.47 SERIES B CARBON STEEL FLANGES
ASTM A193 GR B7/B16 BOLTS ASME A193 GR B7/B16 BOLTS
ASSMEBLY TORQUE (ft-lb) (K=0.18) PER BOLT ASSEMBLY LOAD (lb x 1000)
Flange Class – Series B Flange Class – Series B
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 220 945 1435 4830 26 19 50 59 129
28 225 900 1820 6510 28 20 48 69 158
30 175 1055 2270 8540 30 15 51 81 190
32 215 1380 2790 8540 32 19 61 93 190
34 320 1300 4045 10955 34 24 58 120 225
36 320 1675 4045 8540 36 24 69 120 190
38 460 1620 38 31 66
40 465 1530 40 31 63
42 465 1915 42 31 73
44 445 1800 44 29 68
46 690 2240 46 41 80
48 640 2625 48 38 93
50 655 1985 50 39 70
52 630 1945 52 37 69
54 560 2590 54 33 92
56 590 3810 56 35 113
58 755 3470 58 40 103
60 785 3500 60 42 104
Note: Tensioner pump pressure (psig) is obtained by using the above bolt load multiplied by the load loss factor (1.05 to 1.25), multiplied by
1000 and divided by the tensioner pressure area (in2).

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3
APPENDIX C – BOLT ASSEMBLY LOAD

(Page 4 of 18)

ASME B16.21 GRAPHITE SHEET GASKETS ASME B16.21 GRAPHITE SHEET GASKETS
ASSEMBLYTORQUE (ft-lb) (K=0.18) PER BOLT ASSEMBLY LOAD (lb x 1000)
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 25 25 25 0.5 3 3 3
0.75 35 50 50 0.75 4 5 5
1 45 55 55 1 5 5 5
1.5 65 125 125 1.5 8 11 11
2 125 85 2 13 9
2.5 125 120 2.5 13 10
3 125 170 3 13 15
4 125 225 4 13 20
5 225 225 5 20 20
6 225 225 6 20 20
8 225 360 8 20 27
10 360 415 10 27 28
12 360 625 12 27 37
14 540 545 14 36 32
16 540 765 16 36 41
18 800 865 18 47 46
20 800 950 20 47 51
24 1135 1475 24 60 65

ASME B16.47 SERIES A CARBON STEEL FLANGES ASME B16.47 SERIES A CARBON STEEL FLANGES
ASTM A193 GR B7/B16 BOLTS ASTM A 193 GR B7/B16 BOLTS
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 645 1505 26 34 62
28 550 1505 28 29 62
30 645 2110 30 34 80
32 1000 2385 32 44 85
34 875 2725 34 39 97
36 1000 2855 36 44 95
38 1165 1310 38 52 58
40 1000 1640 40 44 67
42 1165 1725 42 52 71
44 1040 2120 44 46 81
46 1165 2715 46 52 96
48 1165 2675 48 52 95
50 1365 3915 50 52 130
52 1450 4065 52 55 135
54 1535 6085 54 58 180
56 1485 6300 56 56 187
58 1565 5705 58 60 169
60 1525 5895 60 58 175

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 5 of 18)

ASME B16.47 SERIES B CARBON STEEL FLANGES ASME B16.47 SERIES B CARBON STEEL FLANGES
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 220 1060 26 19 56
28 225 960 28 20 51
30 175 1220 30 15 59
32 215 1665 32 19 74
34 320 1510 34 24 67
36 320 2325 36 24 95
38 460 2665 38 31 109
40 465 2575 40 31 105
42 465 3225 42 31 123
44 445 3030 44 29 115
46 690 4215 46 41 150
48 640 3970 48 38 141
50 655 3755 50 39 133
52 630 3570 52 37 127
54 560 3860 54 33 137
56 590 7085 56 35 210
58 755 7045 58 40 209
60 785 7200 60 42 213

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 6 of 18)

ASME B16.20 RTJ GASKETS ASME B16.20 RTJ GASKETS
Flange Class - RTJ Flange Class - RTJ
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 - 35 35 100 100 150 0.5 - 5 5 9 9 13
0.75 - 55 55 140 100 190 0.75 - 6 6 13 9 17
1 45 75 75 220 220 265 1 6 8 8 17 17 20
1.5 60 215 210 345 345 585 1.5 8 19 19 23 23 35
2 120 105 120 260 260 320 2 13 12 13 20 20 21
2.5 120 160 210 340 340 470 2.5 13 14 19 23 23 28
3 120 210 220 340 480 595 3 13 19 20 26 29 32
4 120 220 355 530 635 1185 4 13 20 27 31 34 53
5 220 220 535 710 945 2095 5 20 20 36 38 42 80
6 220 220 440 500 730 2875 6 20 20 30 30 35 96
8 220 355 635 780 1470 2580 8 20 27 38 38 60 86
10 355 510 635 710 2035 4825 10 27 34 34 35 72 129
12 355 675 600 710 2640 6560 12 27 40 32 35 88 159
14 535 595 725 1265 3570 14 36 35 35 56 106
16 535 740 945 1535 4825 16 36 40 42 63 129
18 735 700 1225 2515 6505 18 44 37 50 89 158
20 635 915 1225 2940 8535 20 38 49 50 98 190
24 850 1740 2175 5240 13775 24 46 77 77 140 262

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 7 of 18)

ASME B16.5 STAINLESS STEEL FLANGES ASME B16.5 STAINLESS STEEL FLANGES
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 30 30 30 105 105 105 0.5 4 4 4 9 9 9
0.75 30 60 60 105 105 105 0.75 4 6 6 9 9 9
1 40 65 65 170 170 170 1 5 7 7 13 13 13
1.5 65 170 170 300 300 370 1.5 8 15 15 20 20 22
2 120 90 90 200 200 250 2 13 9 9 15 15 17
2.5 125 125 125 280 280 370 2.5 13 11 11 18 18 22
3 125 185 185 275 390 525 3 13 16 16 21 23 28
4 105 225 360 500 610 950 4 11 20 27 29 32 42
5 200 225 540 705 960 1560 5 18 20 36 37 42 59
6 225 225 510 575 760 2390 6 20 20 34 34 37 80
8 225 360 800 880 1230 2390 8 20 27 47 43 50 80
10 350 525 910 805 1945 4830 10 26 35 48 39 69 129
12 360 775 955 965 2390 6510 12 27 46 51 47 80 158
14 525 580 1075 1155 3465 14 35 34 52 51 103
16 440 925 1525 1435 4830 16 29 49 68 59 129
18 715 1015 2120 2410 6510 18 42 54 87 86 158
20 655 1015 1945 2535 8540 20 39 54 80 84 190
24 925 1680 2680 4830 13780 24 49 74 95 129 262

ASME B16.47 SERIES A STAINLESS STEEL FLANGES ASME B16.47 SERIES A STAINLESS STEEL FLANGES
ASSEMBLEY TORQUE (ft-lb) (K=0.18) PER BOLT ASSEMBLY LOAD (lb x 1000)
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 550 1230 2210 6510 26 29 50 79 158
28 525 1290 2525 8540 28 28 53 84 190
30 550 1640 2715 8540 30 29 62 90 190
32 950 2045 3465 10950 32 42 73 103 225
34 950 2385 4045 13780 34 42 85 120 262
36 950 2510 4830 13780 36 42 84 129 262
38 950 2055 4620 16075 38 42 91 137 306
40 950 2315 4620 13780 40 42 95 137 262
42 1000 2425 6440 16075 42 44 99 172 306
44 950 2935 6440 17065 44 42 112 172 303
46 1000 3740 6440 20830 46 44 133 172 347
48 1000 3430 7595 20830 48 44 122 184 347
50 1560 3830 9965 50 59 128 221
52 1560 3980 9965 52 59 133 221
54 1560 5330 9965 54 59 158 221
56 1560 5515 12780 56 59 163 262
58 1560 5015 12780 58 59 148 262
60 1560 5180 16085 60 59 153 306

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 8 of 18)

ASME B16.47 SERIES B STAINLESS STEEL FLANGES ASME B16.47 SERIES B STAINLESS STEEL FLANGES
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 185 885 1435 4830 26 16 47 59 129
28 190 800 1820 6510 28 16 42 69 158
30 150 1020 2270 8540 30 13 49 81 190
32 180 1380 2790 8540 32 16 61 93 190
34 265 1260 4045 10955 34 20 56 120 225
36 265 1675 4045 8540 36 20 69 120 190
38 385 1620 38 26 66
40 385 1530 40 26 63
42 390 1915 42 26 73
44 370 1800 44 25 68
46 575 2240 46 34 80
48 535 2625 48 31 93
50 545 1985 50 32 70
52 525 1945 52 31 69
54 470 2590 54 28 92
56 495 3810 56 29 113
58 630 3470 58 33 103
60 655 3500 60 35 104

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 9 of 18)

NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 25 25 0.5 3 3
0.75 25 50 0.75 3 5
1 40 55 1 5 5
1.5 65 125 1.5 8 11
2 120 85 2 13 9
2.5 125 120 2.5 13 10
3 125 170 3 13 15
4 105 225 4 11 20
5 200 225 5 18 20
6 225 225 6 20 20
8 225 360 8 20 27
10 350 415 10 26 28
12 360 625 12 27 37
14 525 545 14 35 32
16 440 765 16 29 41
18 715 865 18 42 46
20 655 950 20 39 51
24 925 1475 24 49 65

NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 550 1075 26 29 44
28 460 1290 28 24 53
30 550 1640 30 29 62
32 830 2045 32 37 73
34 795 2385 34 35 85
36 830 2510 36 37 84
38 830 1310 38 37 58
40 795 1640 40 35 67
42 1000 1725 42 44 71
44 795 2120 44 35 81
46 1000 2715 46 44 96
48 1000 2675 48 44 95
50 1300 3915 50 50 130
52 1300 4065 52 50 135
54 1300 6085 54 50 180
56 1300 6300 56 50 187
58 1305 5705 58 50 169
60 1300 5895 60 50 175

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 10 of 18)

ASME B16.21 GRAPHITE SHEET GASKET ASME B16.21 GRAPHITE SHEET GASKET
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 185 885 26 16 47
28 190 800 28 16 42
30 150 1020 30 13 49
32 180 1390 32 16 62
34 265 1260 34 20 56
36 265 1940 36 20 80
38 385 2410 38 26 99
40 385 2425 40 26 99
42 390 3160 42 26 120
44 370 3030 44 25 115
46 575 3695 46 34 131
48 535 3605 48 31 128
50 545 3585 50 32 127
52 525 3570 52 31 127
54 470 3215 54 28 114
56 495 6925 56 29 205
58 630 6255 58 33 185
60 655 6405 60 35 190

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 11 of 18)

NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 - 25 25 100 100 120 0.5 - 4 4 9 9 11
0.75 - 55 55 115 115 155 0.75 - 6 6 10 10 14
1 35 60 60 180 180 230 1 5 7 7 14 14 18
1.5 60 170 170 345 345 500 1.5 8 16 15 23 23 30
2 115 85 120 260 260 320 2 13 10 13 20 20 21
2.5 120 120 175 340 340 470 2.5 13 11 16 23 23 28
3 120 175 220 340 480 595 3 13 16 20 26 29 32
4 95 220 355 530 635 1185 4 11 20 27 31 34 53
5 195 220 535 710 945 2095 5 17 20 36 38 42 80
6 220 220 440 500 730 2875 6 20 20 30 30 35 96
8 220 355 635 780 1470 2580 8 20 27 38 38 60 86
10 345 510 635 710 2035 4825 10 26 34 34 35 72 129
12 355 675 600 710 2640 6560 12 27 40 32 35 88 159
14 520 580 725 1265 3570 14 35 34 35 56 106
16 430 740 945 1535 4825 16 29 40 42 63 129
18 705 700 1225 2515 6505 18 42 37 50 89 158
20 635 915 1225 2940 8535 20 38 49 50 98 190
24 850 1655 2175 5240 13775 24 46 74 77 140 262

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 12 of 18)

ASTM A193 GR B8M CL2 BOLTS ASTM A193 GR B8M CL2 BOLTS
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 35 45 45 125 125 125 0.5 4 5 5 9 9 9
0.75 40 75 75 125 125 125 0.75 4 6 6 9 9 9
1 55 95 95 205 205 205 1 6 8 8 13 13 13
1.5 55 190 190 365 365 455 1.5 6 14 14 20 20 22
2 105 105 105 245 245 305 2 9 9 9 15 15 17
2.5 105 155 155 340 340 455 2.5 9 11 11 18 18 22
3 105 190 190 305 480 640 3 9 14 14 19 23 28
4 105 190 305 610 745 1160 4 9 14 19 29 32 42
5 190 190 455 860 1170 1905 5 14 14 25 37 42 59
6 190 190 455 680 930 2920 6 14 14 25 33 37 80
8 190 305 680 1075 1505 2920 8 14 19 33 43 50 80
10 305 455 960 985 2375 5905 10 19 25 42 39 69 129
12 305 680 960 1180 2920 7955 12 19 33 42 47 80 158
14 455 680 1310 1410 4235 14 25 33 52 51 103
16 455 960 1740 1755 5905 16 25 42 63 59 129
18 680 960 2255 2940 7955 18 33 42 76 86 158
20 680 960 2255 3100 10435 20 33 42 76 84 190
24 960 1740 3275 5905 16840 24 42 63 95 129 262

ASME B16.20 SPIRAL WOUND GASKETS WIT INNER AND ASME B16.20 SPIRAL WOUND GASKETS WITH INNER AND
ASTM A193 GR B8M CL2 BOLTS ASTM A193 GR B8M CL 2 BOLTS
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 675 1505 2700 7955 26 29 50 79 158
28 640 1580 3090 10435 28 28 53 84 190
30 675 2005 3320 10435 30 29 62 90 190
32 1160 2495 4235 13385 32 42 73 103 225
34 1160 2910 4945 16840 34 42 85 120 262
36 1160 3065 5905 16840 36 42 84 129 262
38 1160 1740 5650 19650 38 42 63 137 306
40 1160 2255 5650 16840 40 42 76 137 262
42 1220 2255 7870 19650 42 44 76 172 306
44 1160 2860 7870 20855 44 42 89 172 303
46 1220 3565 7870 25455 46 44 104 172 347
48 1220 3565 9280 25455 48 44 104 184 347
50 1910 4380 12180 50 59 119 221
52 1910 4380 12180 52 59 119 221
54 1910 6360 12180 54 59 154 221
56 1910 6360 15620 56 59 154 262
58 1910 6130 15620 58 59 148 262
60 1910 6330 19655 60 59 153 306

BUSINESS SE RVICES
Department: Number:
0221
Subject: Revision:
3

(Page 13 of 18)

ASME B16.47 SERIES B STAINLESS STEEL FLANGES ASME B16.47 SERIES B STAINLESS FLANGES
ASTM A 193 GR B8M CL2 BOLTS ASTM A 193 GR B8M CL2 BOLTS
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 190 960 1755 5905 26 14 42 59 129
28 190 960 2225 7960 28 14 42 69 158
30 180 1245 2775 10440 30 13 49 81 190
32 190 1685 3410 10440 32 14 61 93 190
34 305 1540 4945 13390 34 19 56 120 225
36 305 2045 4945 10440 36 19 69 120 190
38 455 1975 38 25 66
40 455 1865 40 25 63
42 455 2340 42 25 73
44 455 2200 44 25 68
46 680 2735 46 33 80
48 650 3210 48 31 93
50 670 2425 50 32 70
52 645 2380 52 31 69
54 570 3165 54 28 92
56 605 4660 56 29 113
58 770 4240 58 33 103
60 800 4275 60 35 104

BUSINESS SE RVICES
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(Page 14 of 18)

ASTM A193 GR B8M CL2 BOLTS ASTM A193 GR B8M CL 2 BOLTS
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 30 30 0.5 3 3
0.75 40 60 0.75 4 5
1 50 65 1 5 5
1.5 55 155 1.5 6 11
2 105 105 2 9 9
2.5 105 145 2.5 9 10
3 105 190 3 9 14
4 105 190 4 9 14
5 190 190 5 14 14
6 190 190 6 14 14
8 190 305 8 14 19
10 305 455 10 19 25
12 305 680 12 19 33
14 455 665 14 25 32
16 455 935 16 25 41
18 680 960 18 33 42
20 680 960 20 33 42
24 960 1740 24 42 63

NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 675 1315 26 29 44
28 560 1580 28 24 53
30 675 2005 30 29 62
32 1015 2495 32 37 73
34 970 2910 34 35 85
36 1015 3065 36 37 84
38 1015 1600 38 37 58
40 970 2005 40 35 67
42 1220 2105 42 44 71
44 970 2590 44 35 81
46 1220 3320 46 44 96
48 1220 3270 48 44 95
50 1590 4380 50 50 119
52 1590 4380 52 50 119
54 1590 6360 54 50 154
56 1590 6360 56 50 154
58 1595 6360 58 50 154
60 1590 6360 60 50 154

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(Page 15 of 18)

ASTM 193 GR B8M CL2 BOLTS ASTM A 193 GR B8M CL2 BOLTS
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 190 960 26 14 42
28 190 960 28 14 42
30 180 1245 30 13 49
32 190 1695 32 14 62
34 305 1540 34 19 56
36 305 2255 36 19 76
38 455 2255 38 25 76
40 455 2255 40 25 76
42 455 2860 42 25 89
44 455 2860 44 25 89
46 680 3570 46 33 104
48 650 3570 48 31 104
50 670 3570 50 32 104
52 645 3570 52 31 104
54 570 3570 54 28 104
56 605 6360 56 29 154
58 770 6360 58 33 154
60 800 6360 60 35 154

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(Page 16 of 18)

NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 - 35 35 120 120 145 0.5 - 4 4 9 9 11
0.75 - 65 65 140 140 185 0.75 - 6 6 10 10 14
1 45 75 70 220 220 280 1 5 7 7 14 14 18
1.5 50 185 185 420 420 615 1.5 6 14 14 23 23 30
2 100 100 100 300 300 390 2 9 9 9 19 19 21
2.5 100 150 185 415 415 575 2.5 9 11 14 23 23 28
3 100 185 185 300 590 730 3 9 14 14 19 29 32
4 100 185 300 645 780 1450 4 9 14 19 31 34 53
5 185 185 450 870 1155 2560 5 14 14 25 38 42 80
6 185 185 450 610 890 3515 6 14 14 25 30 35 96
8 185 300 675 950 1795 3155 8 14 19 33 38 60 86
10 300 450 780 870 2490 5900 10 19 25 34 35 72 129
12 300 675 735 870 3225 8020 12 19 33 32 35 88 159
14 450 675 885 1545 4360 14 25 33 35 56 106
16 450 905 1155 1875 5900 16 25 40 42 63 129
18 675 855 1500 3075 7950 18 33 37 50 89 158
20 675 955 1500 3590 10430 20 33 42 50 98 190
24 955 1735 2660 6405 16835 24 42 63 77 140 262

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(Page 17 of 18)

ALL GASKET TYPES ALL GASKET TYPES
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 35 35 35 125 125 125 0.5 4 4 4 9 9 9
0.75 35 70 70 125 125 125 0.75 4 6 6 9 9 9
1 35 70 70 205 205 205 1 4 6 6 13 13 13
1.5 35 125 125 305 305 455 1.5 4 9 9 17 17 22
2 70 70 70 205 205 305 2 6 6 6 13 13 17
2.5 70 125 125 305 305 455 2.5 6 9 9 17 17 22
3 70 125 125 205 455 640 3 6 9 9 13 22 28
4 70 125 205 455 640 1160 4 6 9 13 22 28 42
5 125 125 305 640 1160 1905 5 9 9 17 28 42 59
6 125 125 305 455 875 2920 6 9 9 17 22 35 80
8 125 205 455 875 1505 2920 8 9 13 22 35 50 80
10 205 305 640 875 2375 5905 10 13 17 28 35 69 129
12 205 455 640 875 2920 7955 12 13 22 28 35 80 158
14 305 455 875 1160 4235 14 17 22 35 42 103
16 305 640 1160 1505 5905 16 17 28 42 50 129
18 455 640 1505 2375 7955 18 22 28 50 69 158
20 455 640 1505 2920 10435 20 22 28 50 80 190
24 640 1160 2375 5905 16840 24 28 42 69 129 262
TABLE C-13-2-A TABLE C-13-2B

NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 640 1505 2375 7955 26 28 50 69 158
28 640 1505 2920 10435 28 28 50 80 190
30 640 1905 2920 10434 30 28 59 80 190
32 1160 2375 4235 13385 32 42 69 103 225
34 1160 2375 4235 16840 34 42 69 103 262
36 1160 2920 5905 16840 36 42 80 129 262
38 1160 1160 4235 16840 38 42 42 103 262
40 1160 1505 4235 16840 40 42 50 103 262
42 1160 1505 5905 16840 42 42 50 129 262
44 1160 1905 5905 20855 44 42 59 129 303
46 1160 2375 5905 25455 46 42 69 129 347
48 1160 2375 7955 25455 48 42 69 158 347
50 1910 2920 10440 50 59 80 190
52 1910 2920 10440 52 59 80 190
54 1910 4240 10440 54 59 103 190
56 1910 4240 13390 56 59 103 225
58 1910 4240 13390 58 59 103 225
60 1910 4240 16850 60 59 103 263

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(Page 18 of 18)

NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
26 125 640 1505 5905 26 9 28 50 129
28 125 640 1910 7960 28 9 28 59 158
30 125 875 2380 10440 30 9 35 69 190
32 125 1160 2920 10440 32 9 42 80 190
34 205 1160 4240 13390 34 13 42 103 225
36 205 1505 4240 10440 36 13 50 103 190
38 305 1505 38 17 50
40 305 1505 40 17 50
42 305 1910 42 17 59
44 305 1910 44 17 59
46 455 2380 46 22 69
48 455 2380 48 22 69
50 455 2380 50 22 69
52 455 2380 52 22 69
54 455 2380 54 22 69
56 455 4240 56 22 103
58 640 4240 58 28 103
60 640 4240 60 28 103

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APPENDIX D – BOLT LOAD VERIFICATION

(Page 1 of 3)
This Appendix outlines two possible methods for determining the residual bolt load immediately after
assembly. In addition, the use of a proprietary instrumented bolt, such as ‘RotaBolt’ or ‘Valley Forge Indicator
Bolts’ may also be used. None of the methods outlined are suitable for measuring the bolt load once the joint
0
has been placed in operation at an elevated temperature >200°F (>95 C). Only the ultrasonic and the
manual elongation measurement methods are accurate for determining the residual bolt load of high
0 0
temperature flanges >400 F (>200 C) during shut down periods, when a joint is at ambient temperature. In
both cases, the bolts must be un-tightened one-by-one in order to determine the unloaded length, since bolt
relaxation will have caused the length to change from initial assembly.
D.1 Manual Elongation Measurement
The bolt load may be determined by measuring the difference in the bolt length from the un-assembled
condition to the assembled condition. In order to ensure that the measurement is accurate, it is necessary
to center-drill the ends of the bolts and use ball bearings between the measuring caliper or micrometer
faces (see Figure D-1). The bolt stress achieved during assembly for the bolt being measured is
calculated using the below equation.
Fb = (Ab Eb ∆Lb) / Lg
Where Fb = the bolt load (/1000 lb)

∆Lb = the total amount of elongation measured
Lg = the bolt grip length (distance between nut faces + one diameter)
Ab = the bolt root area (in²)
Eb = the bolt modulus of elasticity (ksi) at the measurement temperature
= 29650 ksi for B7 & B16 @ 70°F
= 28260 ksi for B8 @ 70°F
= 28120 ksi for B8M @ 70°F
Measure ∆Lb using Vernier Calipers or
large C-shaped Micrometer
Lg = Nut to Nut distance + Bolt Dia.
Nut to Nut distance
Center-Drill & use

Hardened Ball-Bearings
Both Ends
Figure D-1 – Manual Elongation Measurement Diagram

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Subject: Revision:
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(Page 2 of 3)
D.2 Ultrasonic Elongation Measurement
The bolt load may be determined by measuring the difference in the bolt length from the un-assembled
condition to the assembled condition using ultrasonic length measurement. In order to ensure that the
measurement is accurate, it is necessary to machine both ends of the bolt flat in a lathe. The surface is
considered flat if it has a surface finish of 63 to 80 μRa (μRa = micro Roughness) and end parallelism of
±0.005 in. Care should be taken to ensure that the lathe tool height is correctly set at centerline to avoid
any central raised point on the end. The repeatability of the method is enhanced by using an end-cap
that holds the ultrasonic probe in a central position and can be tightened using the same finger pressure
each time (Figure D-2). The ultrasonic equipment manufacturer’s recommendations should be followed
to measure the applied bolt load, with consideration of the recommendations listed following the below
figures. Operator training on the use of the equipment prior to arriving at site is required and shall be
documented. Calibration of the equipment using a certified load cell (either on a tensile machine or with a
hollow canister load cell, (Figure D-3) shall be provided on the size and type of bolt being measured.
Calibration shall be performed a minimum of every 6 months on the bolt material being measured.
Plastic (Delrin, Nylon or similar) end cap,

threaded to bolt size and dimensioned to hold
the probe onto the bolt end in a central location
Figure D-2 – Ultrasonic Measurement End-Cap

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(Page 3 of 3)
Pull on Brackets with a

Certified Tensile Machine
Hollow Canister
Certified Load Cell
Min. 6in.
Min. 6in.
Steel Spacer
Option B – Certified
Option A – Hollow Tensile Machine
Canister Load Cell
Figure D-3 – Ultrasonic Equipment Calibration
The following aspects of ultrasonic bolt elongation measurement should be kept in mind:
a. The method is sensitive to stress levels in the bolt. For direct tensile stress, the equipment should
automatically adjust to the stress level. However, bending stresses in the bolt will result in
inaccuracies in the readings and possible loss of signal. Bolt elongation measurement deals with
stress levels of a higher magnitude and over a longer length than standard thickness measurement
UT, therefore the effects are more significant for bolts than for standard UT thickness measurement.
b. The method is also extremely sensitive to temperature. For every 1°F inaccuracy in temperature
measurement, the measured load will be inaccurate by about 1% of bolt yield stress. This means that
a 20°F temperature variation along the bolt length will lead to a 10% error in measurement if the
temperature probe is only mounted on one end of the bolt. Temperature probe placement and
accuracy is important. The probe must be positioned on the bolt being measured and left to stabilize
prior to taking the reading. If there is any variation in temperature along the length of the bolt, this
must also be compensated for.

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APPENDIX E – TURN-OF-NUT PROCEDURE
(Page 1 of 4)
The standard approach to turn-of-nut in order to obtain an approximate 8ksi increase in gasket stress is
outlined in Figure E-4.
Procedure:
1) Measure flange gap at eight locations evenly distributed around
flange
2) Mark each bolt end at the nut, flange and bolt end so that rotation of
Fraction of
the nut versus the bolt can be determined.
a Nut Flat
3) Start one side of the leak location and tighten each nut by the
specified amount of nut rotation, proceeding in a circular pattern around
the flange. DO NOT exceed maximum torque specified estimate
approximate torque to turn nuts (does not need to be exact). Remember
"Righty-Tighty" & "Lefty-Loosey" = right hand down to tighten.
4) Re-measure flange gap at all eight locations & record this and
approximate torrque to turn on sheet
Figure E-4 – Turn-of-Nut Procedure

Notes:
a) Turn-of-Nut should only be used for flanges constructed from ductile materials (> 10% elongation at
tensile rupture).
b) For standard piping flanges, in order to obtain a 10 ksi increase in gasket stress, tighten one nut by
the amount shown in the below table.
c) For exchanger flanges, in order to obtain an approximate 8 ksi increase in gasket stress, tighten the
nut one half of a nut flat. In cases where leakage is occurring, and the one half turn does not seal it,
then the nut can be tightened a further one half of a flat. This guideline is for typical exchanger
flanges with relatively long bolts. The amount the nut is turned should be reduced for flanges with
short, large diameter bolts and shall be calculated by the Owner’s Engineer.
d) The suggested procedure for applying Turn-of-Nut is contained n Figure E-4.
e) The maximum acceptable torque that may be applied is shown in the below table for B7 and B16
0 0
bolts at temperatures <250 F (120 C). For other materials or temperatures, the value may be
calculated from the below equation:

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(Page 2 of 4)
3
Tmax = 0.108ryD /C
Where: Tmax = Maximum Allowable Torque in ft.lb (N.m)

ry = Bolt material yield at bolt metal temperature in psi (MPa)
D = bolt diameter in inches (mm)
C = Units Conversion = 12 for Custom Units (1000 for SI Units)
Table E-1
Maximum Allowable Turn-of-Nut Torque

B7 & B16 bolts at ambient conditions
Bolt Bolt
Tmax Tmax
Diameter Yield
(ft-lb) (Nm)
(in.) (ksi)
0.500 105 118 160
0.625 105 231 312
0.750 105 399 540
0.875 105 633 858
1.000 105 945 1,281
1.125 105 1,346 1,824
1.250 105 1,846 2,502
1.375 105 2,457 3,330
1.500 105 3,189 4,324
1.625 105 4,055 5,498
1.750 105 5,065 6,866
1.875 105 6,229 8,446
2.000 105 7,560 10,250
2.250 105 10,764 14,594
2.500 95 13,359 18,113
2.750 95 17,781 24,109
3.000 95 23,085 31,300
3.250 95 29,351 39,795
3.500 95 36,658 49,703
3.750 95 45,088 61,133
4.000 95 54,720 74,192

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Department: Number:
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Subject: Revision:
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(Page 3 of 4)
Table E-2
Total Flats to turn for 10 ksi
Increase in Gasket Stress Maximum Allowable Torque (ft.lb)
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0..5 0.23 0.16 0.18 0.08 0.08 0.07 0.5 115 115 115 395 395 395
0.75 0.29 0.18 0.20 0.12 0.12 0.11 0.75 115 230 230 395 395 395
1 0.34 0.24 0.26 0.12 0.12 0.11 1 115 230 230 630 630 630
1.5 0.45 0.22 0.25 0.17 0.17 0.16 1.5 115 395 395 945 945 1,345
2 0.34 0.26 0.21 0.25 0.19 0.14 2 230 230 230 630 630 945
2.5 0.47 0.22 0.19 0.20 0.17 0.14 2.5 230 395 395 945 945 1,345
3 0.62 0.29 0.27 0.28 0.19 0.15 3 230 395 395 630 1,345 1,845
4 0.69 0.43 0.39 0.27 0.23 0.18 4 230 395 630 1,345 1,845 3,185
5 0.53 0.54 0.41 0.31 0.24 0.19 5 395 395 945 1,845 3,185 5,060
6 0.66 0.60 0.42 0.34 0.26 0.21 6 395 395 945 1,345 2,455 7,560
8 0.99 0.66 0.49 0.37 0.28 0.21 8 395 630 1,345 2,455 4,055 7,560
10 0,75 0.47 0.53 0.37 0.32 0.20 10 630 945 1,845 2,455 6,225 14,765
12 1.09 0.57 0.62 0.50 0.30 0.26 12 630 1,345 1,845 2,455 7,560 17,780
14 0.98 0.73 0.60 0.48 0.25 14 945 1,345 2,455 3,185 10,760
16 1.34 0.84 0.74 0.45 0.35 16 945 1,845 3,185 4,055 14,765
18 1.09 0.96 0.69 0.56 0.39 18 1,345 1,845 4,055 6,225 17,780
20 1.23 1.12 0.77 0.48 0.38 20 1,345 1,845 4,055 7,560 23,085
24 1.56 1.23 0.77 0.46 0.44 24 1,845 3,185 6,225 14,765 36,655
B16.47 Series A B16.47 Series A
26 2.21 1.77 0.95 0.49 26 1,845 4,055 6,225 17,780
28 2.44 1.94 0.92 0.50 28 1,845 4,055 7,560 23,085
30 2.53 1.69 0.82 0.53 30 1,845 5,060 7,560 23,085
32 2.54 1.64 0.76 0.50 32 3,185 6,225 10,760 29,350
34 2.55 1.61 0.73 0.52 34 3,185 6,225 10,760 36,655
36 2.77 1.49 0.71 0.55 36 3,185 7,560 14,765 36,655
38 3.54 1.43 0.60 0.45 38 3,185 3,185 10,760 36,655
40 3.32 1.05 0.55 0.39 40 3,185 4,055 10,760 36,655
42 3.49 1.06 0.57 0.41 42 3,185 4,055 14,765 36,655
44 4.00 0.93 0.52 0.40 44 3,185 5,060 14,765 45,085
46 3.93 1.02 0.55 0.38 46 3,185 6,225 14,765 54,720
48 4.08 1.06 0.53 0.39 48 3,185 6,225 17,780 54,720
50 3.87 0.91 0.57 50 5,060 7,560 23,085
52 4.03 0.91 0.54 52 5,060 7,560 23,085
54 4.17 0.96 0.54 54 5,060 10,760 23,085
56 4.14 0.96 0.53 56 5,060 10,760 29,350
58 4.29 0.86 0.52 58 5,060 10,760 29,350
60 4.27 0.86 0.56 60 5,060 10,760 36,655
B16.47 Series B B16.47 Series B
26 1.45 1.00 0.69 0.55 26 395 1,845 4,055 14,765
28 1.43 1.06 0.73 0.55 28 395 1,845 5.060 17,780
30 1.67 1.00 0.63 0.47 30 395 2,455 6,225 23,085
32 1.47 1.03 0.61 0.47 32 395 3,185 7,560 23,085
34 1.69 1.08 0.63 0.46 34 630 3,185 10,760 29,350
36 1.68 1.06 0.59 0.49 36 630 4,055 10,760 23,085
38 1.77 0.77 38 945 4,055
40 1.87 0.74 40 945 4,055
42 1.51 0.76 42 945 5,060
44 1.85 0.70 44 945 5,060
46 2.00 0.80 46 1,345 6,225
48 1.87 0.94 48 1,345 6,225
50 1.95 0.74 50 1,345 6,225
52 1.92 0.71 52 1,345 6,225
54 1.98 1.13 54 1,345 6,255
56 1.52 0.86 56 1,345 10,760
58 1.69 0.78 58 1,845 10,760
60 1.48 0.85 60 1,845 10,760

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Subject: Revision:
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(Page 4 of 4)
Table E-2M
Total Flats to turn for 69MPa
Increase in gasket stress Maximum allowable torque (Nm)
NPS NPS
150 300 600 900 1500 2500 150 300 600 900 1500 2500
0.5 0.23 0.16 0.18 0.08 0.08 0.07 0.5 155 155 155 535 535 535
0.75 0.29 0.18 0.20 0.12 0.12 0.11 0.75 155 310 310 535 535 535
1 0.34 0.24 0.26 0.12 0.12 0.11 1 155 310 310 850 850 850
1.5 0.45 0.22 0.25 0.17 0.17 0.16 1.5 155 535 535 1,280 1,280 1,820
2 0.34 0.26 0.21 0.25 0.19 0.14 2 310 310 310 850 850 1,280
2.5 0.47 0.22 0.19 0.20 0.17 0.14 2.5 310 535 535 1,280 1,280 1,820
3 0.62 0.29 0.27 0.28 0.19 0.15 3 310 535 535 850 1,820 2,500
4 0.69 0.43 0.39 0.27 0.23 0.18 4 310 535 850 1,820 2,500 4,315
5 0.53 0.54 0.41 0.31 0.24 0.19 5 535 535 1,280 2,500 4,315 6,860
6 0.66 0.60 0.42 0.34 0.26 0.21 6 535 535 1,280 1,820 3,325 10,245
8 0.99 0.66 0.49 0.37 0.28 0.21 8 535 850 1,820 3,325 5,495 10,245
10 0.75 0.47 0.53 0.37 0.32 0.20 10 850 1,280 2,500 3,325 8,435 20,015
12 1.09 0.57 0.62 0.50 0.30 0.26 12 850 1,820 2,500 3,325 10,245 24,105
14 0.98 0.73 0.60 0.48 0.25 14 1,280 1,820 3,325 4,315 14,585
16 1.34 0.84 0.74 0.45 0.35 16 1,280 2,500 4,315 5,495 20,015
18 1.09 0.96 0.69 0.56 0.39 18 1,820 2,500 5,495 8,435 24,105
20 1.23 1.12 0.77 0.48 0.38 20 1,820 2,500 5,495 10,245 31,295
24 1.56 1.23 0.77 0.46 0.44 24 2,500 4,315 8,435 20,015 49,695
B16.47 Series A B16.47 Series A
26 2.21 1.77 0.95 0.49 26 2,500 5,495 8,435 24,105
28 2.44 1.94 0.92 0.50 28 2,500 5,495 10,245 31,295
30 2.53 1.69 0.82 0.53 30 2,500 6,860 10,245 31,295
32 2.54 1.64 0.76 0.50 32 4,315 8,435 14,585 39,790
34 2.55 1.61 0.73 0.52 34 4,315 8,435 14,585 49,695
36 2.77 1.49 0.71 0.55 36 4,315 10,245 20,015 49,695
38 3.54 1.43 0.60 0.45 38 4,315 4,315 14,585 49,695
40 3.32 1.05 0.55 0.39 40 4,315 5,495 14,585 49,695
42 3.49 1.06 0.57 0.41 42 4,315 5,495 20,015 49,695
44 4.00 0.93 0.52 0.40 44 4,315 6,860 20,015 61,125
46 3.93 1.02 0.55 0.38 46 4,315 8,435 20,015 74,190
48 4.08 1.06 0.53 0.39 48 4,315 8,435 24,105 74,190
50 3.87 0.91 0.57 50 6,860 10,245 31,295
52 4.03 0.91 0.54 52 6,860 10,245 31,295
54 4.17 0.96 0.54 54 6,860 14,585 31,295
56 4.14 0.96 0.53 56 6,860 14,585 39,790
58 4.29 0.86 0.52 58 6,860 14,585 39,790
60 4.27 0.86 0.56 60 6,860 14,585 49,695
B16.47 Series B B16.47 Series B
26 1.45 1.00 0.69 0.31 26 535 2,500 5,495 20,015
28 1.43 1.06 0.73 0.30 28 535 2,500 6,860 26,640
30 1.67 1.00 0.63 0.25 30 535 3,325 8,435 34,590
32 1.47 1.03 0.61 0.27 32 535 4,315 10,245 34,590
34 1.69 1.08 0.63 0.26 34 850 4,315 14,585 43,980
36 1.68 1.06 0.59 0.27 36 850 5,495 14,585 34,590
38 1.77 0.77 38 1,280 5,495
40 1.87 0.74 40 1,280 5,495
42 1.51 0.76 42 1,280 6,860
44 1.85 0.70 44 1,280 6,860
46 2.00 0.80 46 1,820 8,435
48 1.87 0.94 48 1,820 8,435
50 1.95 0.74 50 1,820 8,435
52 1.92 0.71 52 1,820 8,435
54 1.98 1.13 54 1,820 8,435
56 1.52 0.86 56 1,820 14,585
58 1.69 0.78 58 2,500 14,585
60 1.48 0.85 60 2,500 14,585

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APPENDIX F – JOINT CATEGORY ASSESSMENT
(Page 1 of 1)
F1 - CATEGORY I – CRITICAL SERVICE

Hydrogen – Class 600 and higher
Natural Gas – Class 600 and higher
Hydrocarbon – Class 900 and higher
Steam – Class 1500
Utilities – Class 1500
Pipeline Code – Class 900 and higher (all services)
Irrespective of the service fluid: Floating head joints and tube sheet joints for Shell & Tube Heat Exchangers.
F2 – CATEGORY II – TYPICAL SERVICE
Hydrogen – Class 150 and Class 300
Natural Gas – Class 150 and Class 300
Pipeline Code – Class 300 and Class 600
Hydrocarbon – Class 300 and Class 600
Steam – Class 600 and 900
Utilities – Class 600 and 900
F3 – CATEGORY III – NON-CRITICAL SERVICE
Hydrogen – None
Hydrocarbon – Class 150
Steam - Class 150 and Class 300
Utilities – Class 150 and Class 300
Note:
All Suncor facilities are encouraged to develop a document to identify which Piping Line Classes fall into the
above listed categories. Special consideration should be given to HF service and H2S service.

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APPENDIX G – BOLTED FLANGE JOINT ASSEMBLY RECORD DATA SHEET
(Page 1 of 2)
Work Order No. Equipment Tag No.
ISO/Drawing No. Line Spec: Flange Size/Rating/Mat’l:
Stud/ Bolt Size: Bolting Materials: Gasket Type
Tensioning Required? Yes No Plant No. Joint No.
Reviewed by: Date

Fit Up Checklist (Print Name & Initial) (mm/dd/yyyy)
Correct Studs/ Bolts/ Nuts as per BOM
Correct Gasket as per BOM
Flange Face Free From Defects & Clean (Section 5.6)
Flange Face / Bolt Holes Aligned (Section 5.9)
Studs / Nuts Cleaned & Lubricated (Section 5.8)
Joint Tighten Complete and Thread Engagement Verified
Tightening Method Hand Torque Hydraulic Torque
U/T Requirements Not Required 10 % Random 100%
Joint Category: III II I
Tool Serial Number: Tool Calibration Due Date:
Tool Serial Number: Toll Calibration Due Date:
Final Torque / Tension Value:

Continued on page 2 of 2

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APPENDIX G – BOLTED FLANGE JOINT ASSEMBLY RECORD DATA SHEET
(Page 2 of 2)
FRONT LINE SUPERVISOR CONTRACTOR

REQUIRED SUNCOR
INSPECTION
TORQUE TRADESMAN INSPECTION
PASS IF INSPECTED
OR (Print Name) Date IF INSPECTED
Print Name Sign Name BY
TENSION (yyyy/mm/dd) BY SUNCOR
CONTRACTOR
1A 30%
1B 70%
1C 100%
2 PATTERN 100%
3 ROTATIONAL 110%
4 (IF REQ”D) 100%
5 (IF REQ”D) 100%
6 (IF REQ”D) 100%
CONTRACTOR QC:
SUNCOR QA:
Print Name Sign Name Date (yyyy/mm/dd)
COMMENTS / FEEDBACK:

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Subject: Positive Material Identification
6
Section
REV # Change
Changed
5 Format change to new Corporate Technical Standard

1.1.1 & 1.1.2 Purpose further clarified
3.1 & 3.2.1 Included reference to ASTM and API Standards
4 Added more definitions
5 PMI Requirements and Extent of PMI- Re-Written
5.1 Included PMI performed by Third Party Agency
5.2 Added Extent of PMI
5.4 Added PMI Exemptions
5.6 PMI Test Methods further elaborated
5.9 Clarified Acceptance and Rejection criteria
5.10 Further clarified Retest and Rejection
5.12 Included Marking and
5.13 Documentation further clarified
Cleaned up Appendix A Material compositions requirements
Revised all element requirements to match ASTM/ASME standards
Included Foot Notes to clarify deviation and PMI acceptance requirements
6 1.2.4 Scope to further clarify exclusion

3.1 Included
3.2 Added Suncor reference standards
3.2 Added new reference standards
4.2.1 Modified ally material definition
5.1.2.3 Added four more clarifications to PMI requirement
5.2.2 Added one more item
Standard 0213 Rev 6 Positive Material Identification Page 3 of 25

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Subject: Positive Material Identification
6
5.2.7 Added Dissimilar Metal Welds in PMI examination

Added requirements for PMI failed sample
5.3.1
And thermowells
5.4 Further added items in PMI exemptions list
Table 1 Further clarified Alloy bolts PMI requirements
5.7.1 Further clarified PMI procedure
5.9.1 Overhauled to simplify acceptance criteria
5.9.7 Added Dissimilar Metal Welds
5.13.2 Changed to simplify PMI documentation report
7.1 Added deliverable documentation requirement
Appendix A Tables for alloy identification elements simplified

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Subject: Positive Material Identification 6
TABLE OF CONTENTS
1.0 PURPOSE & SCOPE .....................................................................................................................................7

1.1 PURPOSE .....................................................................................................................................................7
1.2 SCOPE .........................................................................................................................................................7
1.3 PRECAUTIONS...............................................................................................................................................7
2.1 ACCOUNTABILITY AND APPROVAL...................................................................................................................8
2.2 REVISIONS AND UPDATES ..............................................................................................................................8
2.3 INTERPRETATION...........................................................................................................................................8
2.4 IMPLEMENTATION ..........................................................................................................................................8
3.1 PREREQUISITES ............................................................................................................................................8
3.2 SUNCOR STANDARDS AND DRAWINGS............................................................................................................8
3.3 RELEVANT / REFERENCED PUBLICATIONS, CODES AND STANDARDS ................................................................9
4.0 DEFINITIONS AND ACRONYMS ..................................................................................................................9
4.1 DEFINITIONS .................................................................................................................................................9
4.2 TERMINOLOGY DEFINITIONS ....................................................................................................................... 10
5.0 STANDARD ................................................................................................................................................. 10
5.1 PMI REQUIREMENTS .................................................................................................................................. 10
5.2 EXTENT OF PMI EXAMINATION, SAMPLING AND TESTING PROGRAMS............................................................ 11
5.3 RANDOM PMI TESTING............................................................................................................................... 13
5.4 PMI EXEMPTIONS ...................................................................................................................................... 14
5.5 TIMING OF PMI .......................................................................................................................................... 15
5.6 PMI TEST METHODS .................................................................................................................................. 16
5.7 PERSONNEL AND TRAINING......................................................................................................................... 17
5.8 ACCEPTANCE CRITERIA .............................................................................................................................. 17
5.9 RETEST AND REJECTION ............................................................................................................................ 18
5.10 MATERIAL IDENTIFICATION AND TRACEABILITY ............................................................................................. 19
5.11 MARKING ................................................................................................................................................... 19
5.12 DOCUMENTATION AND REPORT................................................................................................................... 20
5.13 POINT OF INSTALLATION PMI ..................................................................................................................... 21

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6.0 LIST OF APPENDICES............................................................................................................................... 21

6.1 APPENDIX A – COMMON ALLOY STEEL MATERIALS ...................................................................................... 21
7.0 REPORTING ............................................................................................................................................... 21
7.1 DOCUMENTS AND DELIVERABLES ................................................................................................................ 21
8.0 APPROVED BY ........................................................................................................................................... 22

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1.0 PURPOSE & SCOPE
1.1 Purpose
1.1.1 This standard establishes Suncor’s requirements for material and quality assurance system to
verify that the nominal composition of alloy components to be exposed to either pressure or
process conditions are consistent with the specified construction alloy materials.
1.1.2 Positive material identification or alloy verification is an important component of an overall
quality assurance program. It is not intended to substitute for required material test reports, or
any other material identification or verification programs. Material test reports shall not be
considered as a substitute for PMI testing.
1.1.3 Where there are different requirements within this standard or referenced Publications, Codes,
and Standards, the more stringent criteria shall be applied.
1.2 Scope
1.2.1 This standard applies to all alloy components that are intended to be exposed to pressure or
process environments. Materials may include plates, pipes, tubes, valves, flanges, fittings, bolts,
welds, weld overlays, cladding, vessel internals and instruments.
1.2.2 This standard shall apply to both new components and repair or replacement components for
plant, shop and field fabrication.
1.2.3 This standard shall be used for new facilities as well as for maintenance revamps, or
expansions of existing facilities.
1.2.4 This standard does not apply to;
1.2.4.1 Material verification programs to identify in-service materials
1.2.4.2 Carbon steel (group P-1) materials
1.2.4.3 Abrasive resistant materials (including cast and welded products) used in handling oil sand
or slurry (in Extraction)
1.2.4.4 Electrical equipment
1.3 Precautions
This standard and associated template is mandated for Corporate Technical Standards. The user of
this document must have prior knowledge and understanding of corporate and legislative direction, to
use standards to promote the consistent, safe, reliable, and cost-effective management of Suncor’s
Business Unit or Project related positions are indicative of the responsibilities; these designations
may vary based on scope and execution model of technical work.

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Director of Technical Standards is responsible for approving this standard, and has overall
accountability to ensure that this standard is effectively implemented.

Discipline Subject Matter Expert (Welding SME) is responsible to update and revise this standard in
consultation with Peer Review Network (PRN) members and the Director of Technical Standards
based on “Lessons Learnt”, “Continuous Improvement”, and industry best practice.
2.3 Interpretation
PRN members within business units are responsible for interpretation of standard. The Welding SME
shall be consulted in complex cases. Director of Technical Standards shall have the final decision in
case of conflict.
2.4 Implementation
2.4.1 Director of Technical Standards is responsible for ensuring that this standard is communicated
to stakeholders and for auditing the implementation.
2.4.2 The Business Unit Engineering Manager/Director or Project Management (or delegate) has
overall responsibility for implementation of this standard. Engineering Manager/Director,
Discipline Leads, or other technical specialist shall provide necessary support in
implementation.
3.1 Prerequisites
3.1.1 The referenced documents form an integral part of this standard.
3.1.2 Any conflict between this document and the referenced documents shall be brought to the
attention of the Owner/Purchaser for resolution prior to proceeding with work.
3.1.3 All reference Industry codes and standards shall be based on the latest edition or the edition in
effect at the time of Purchase Order or Contract document.
3.1.4 All referenced Suncor Standards shall be based on the revision specified in the Purchase Order
or Contract.

CTS 903 Shop and Field Welding
CTS 0220 In-Service Welding And Hot Tapping
CTS 0603 Alloy Cladding

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3.3.1 The latest edition/revision of the following codes and standards form an integral part of this
specification.
ASME - Materials Specifications
ASME BPVC Section II, Ferrous Materials Specifications
Part A
ASME BPVC Section II, Non Ferrous Materials Specifications
Part B
ASME BPVC Section II, Specifications for Welding Rods, Electrodes and Filler
Part C
ASME BPVC Section V Non-destructive Examination
AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM):
ASTM E350 Standard Test Method for “Chemical Analysis of Carbon Steel,
Low Alloy Steel, Silicon Electrical Steel, Ingot Iron, and
Wrought Iron
ASTM E352 Standard Test Method for “Chemical Analysis of Tool Steels
and other Similar Medium and High-Alloy Steels
ASTM E353 Standard test Method for “Chemical Analysis of Stainless, Heat-
Resisting, Maraging, and Other Similar Chromium-Nickel-Iron
Alloys
ASTM E354 Standard test Method for “Chemical Analysis of High-
Temperature, Electrical, Magentic, and Other Similar Iron,
Nickel, and Cobalt Alloys
ASTM E478 Standard Test Method for "Chemical Analysis of Copper Alloys
ASTM E527 Standard Practice for Numbering Metals and Alloys in the
Unified Numbering System (UNS)”
ASTM A 751 Standard Test Methods, Practices, and Terminology for
Chemical Analysis of Steel Products
API Standards
API RP 578 Material Verification Program for New and Existing Alloy Piping
Systems
4.1 Definitions
4.1.1 “Owner’s Engineer” means the Suncor Engineer or the designated representative for the
technical integrity of the work.
4.1.2 “Owner’s inspector” means the Inspector or the designated representative responsible for that

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aspect of the work.

4.1.3 “Owner” means Suncor Energy Inc.
4.1.4 “Purchaser” means the agency that issues the Purchase Order contract of the supplier.
4.1.5 “Supplier” means the agency that supplies the service material or equipment also referred to as
the “Seller”, the “Vendor” or the “Manufacturer”.
4.2 Terminology Definitions

4.2.1 “Alloy material” is any metallic material (including welding filler materials) that contains alloying
elements such as chromium, nickel or molybdenum, which are intentionally added to enhance
mechanical or physical properties and/or corrosion resistance. This shall include all materials
classified as group P-3 and higher (as defined in ASME IX, QW/QB-422), all as-deposited welds
produced using consumables of group A-2 and higher (as defined ASME IX, QW-442).
4.2.2 “Accessible” means no disassembly for inspection is required.
4.2.3 “Heat Number” is a unique alpha, numeric or alphanumeric designation used to identify a
specific melt of a given material produced from the same heat and therefore has consistent
chemical and physical properties.
4.2.4 “Inspection lot” is a group of identical items from a single manufacturer or supplier made up of a
single heat from which the inspection sample is taken.
4.2.5 “Batch” is a quantity of manufactured identical items, which may be comprised of more than one
inspection lot.
4.2.6 “Inspection sample” is one or more items selected at random from an inspection lot which will
be representative of the inspection lot.
4.2.7 “Material verification program” is a documented quality assurance procedure used to assess
metallic alloy materials (including weldments and attachments where specified) to verify
conformance with the selected or specified alloy material.
4.2.8 “Mill Test Report (MTR)/Certified Material Test Reports (CMTR)” a certified document that
permits each component to be identified according to the original heat of material from which it
was produced and identifies the applicable material specification (including documentation of all
test results required by the material specification).
4.2.9 “Positive Material Identification (PMI) test” is a physical evaluation or test of a material to
confirm that the material which has been or will be placed into service is consistent with the
selected or specified alloy material designated by the owner/user.
5.0 STANDARD
5.1 PMI Requirements

5.1.1 General
5.1.1.1 PMI testing is to be performed on all new alloy material components that may be exposed

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to pressure and/or process environments. PMI shall be performed on all new alloy material
components and welds comprising the pressure envelope and on all equipment internals
that may be exposed to the process environment. Final PMI Testing shall be performed in
the “completed” or “as-welded” condition.
5.1.1.2 PMI testing shall be performed on the surface to be exposed to pressure or the process
fluid. Alternatively PMI testing shall be performed on the external surface of the
component or weld when the surface to be exposed to the process fluid is not accessible
for PMI testing.
5.1.1.3 PMI shall not be considered as a substitute for required mill test reports. Mill test reports
shall not be considered as acceptable PMI.
5.1.1.4 Suppliers which apply, as part of their normal manufacturing sequence, verifiable in house
PMI programs that meet or exceed the requirements of this standard should so state in
their quotations and submit their PMI program for Purchaser/Owner’s review.
5.1.2 PMI Performed by Third-Party Agency
5.1.2.1 When PMI is performed by the Supplier or a third party agency, the Supplier shall endorse
that all PMI tests have been performed in accordance with the approved procedure by
qualified personnel, and that all PMI has been performed at the point which will ensure the
correct material has been used.
5.1.2.2 The Supplier shall ensure that all involved parties fully understand the PMI requirements,
the verification method to be used, the period during fabrication that verification will be
carried out, and the method of marking verified material.
5.1.2.3 The PMI personnel and procedures shall be subject to review by the Purchaser/Owner as
follows:
a) The Supplier or third party agency shall submit for review the PMI procedures,
including complete descriptions of the methods and equipment to be used and
personnel qualification procedures.
b) Purchaser/Owner’s inspector will review the procedures and qualifications and
reserves the right to witness sample PMI tests to the extent necessary to prove the
procedures and personnel are acceptable.
c) All tests and stages of PMI shall be subject to further witness by
Purchaser/Owner’s inspector.
d) If the conduct of any verification is unacceptable to Purchaser/Owner’s inspector,
or if any material has been incorrectly identified, all further tests shall be witnessed
and approved by Purchaser/Owner’s inspector until such time as the problem is
corrected.
5.2 Extent of PMI Examination, Sampling and Testing Programs

5.2.1 Refer to Table 1 for Extent of PMI Testing to be performed.
5.2.2 The minimum requirements for the PMI sampling and testing program shall consist of minimum

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one test point for 5.2.2.1 to 5.2.2.6 as follows:

5.2.2.1 Fabricated Alloy Static Equipment (e.g. Pressure Vessels, Heat Exchangers, Tanks, etc.)
a) Each component of pressure assembly such as shell plates, heads, nozzles and
nozzle necks and nozzle flanges etc.
b) All pressure-containing weld metals. Welding consumables shall be verified as per
para 5.2.6. For double welded joints, both weld caps, inside and outside when
accessible shall be tested.
c) Cladding and Weld Overlay - each clad componenet including clad nozzles and
WOL component such as Shell plates, heads, nozzle and nozzle necks, flanges
etc.
5.2.2.2 Shop and Field Fabricated Alloy Piping assemblies including:
a) All pressure piping and component parts such as flanges, fittings, valves (body and
bonnet), couplings, small bore components etc.
b) Expansion joints, flexible hoses, specialty piping (SP) items, ejectors, liquid drains,
etc.
c) Weld overlay and cladding- 25ft2 (2.3 m2) for straight run pipes, each piping
components separately such as flanges, fittings, reducers, elbows etc.
d) All pressure-containing weld metals. Welding consumables shall be verified as per
para 5.2.6
e) Ring Joint flange gaskets and and clamp type (e.g. Grayloc) connector flange
gaskets
5.2.2.3 Bulk Alloy Piping Components excluded from above 5.2.2.2
5.2.2.4 All pipe, flanges, fittings, forging for fabrication, specialty piping (SP) items, ejectors, liquid
drains, etc.
5.2.2.5 The body and bonnet of all valves.
5.2.2.6 Weld overlay and cladding- 25ft2 (2.3 m2) for straight run pipes, each piping components
separately such as flanges, fittings, reducers, elbows etc.
5.2.3 Alloy Mechanical Rotating Equipment (e.g. Compressors, Expanders, Pumps, centrifuges, etc.)
5.2.3.1 All pressure containing components and pressure containing components welds that are
exposed to the process fluid. Components or component welds that cannot be accessed
after final assembly shall be verified prior to completion of assembly.
5.2.3.2 PMI will not be required for non-pressure parts; however, the manufacturer’s in-house
verification program must be capable of demonstrating the specified materials have been
used.
5.2.3.3 All components including metallic linings, cladding or weld overlay including clad
restoration welds that may be exposed to service.

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5.2.4 Fired Heaters, Boilers

5.2.4.1 All alloy pressure containing components including welds.
5.2.4.2 All tube supports, tube hangers and tube sheets.
5.2.5 Instruments, Control Valves, and Pressure Relief Valves
5.2.5.1 For control valves, the alloy body and bonnet of each control valve. The trim for valves
used in safety instrumentations systems.
5.2.5.2 For flow meters, the alloy pressure containing portions of each insert type flow meter.
5.2.5.3 For level displacers, level gauges and attached alloy piping component, float switches,
alloy pressure containing chamber and head of each displacer/level gauge/alloy
component and switch.
5.2.5.4 The alloy pressure relief valves (PRV), rupture discs and pressure containing portions of
any instrument through which the process fluid flows.
5.2.5.5 Thermo-wells other than covered under para 5.3.1.2. d).
5.2.6 PMI Testing of Welding Consumables
5.2.6.1 When welding is conducted, one electrode or wire sample from each lot or package of
alloy weld rod shall be positively identified.
5.2.6.2 For Dissimilar Weld Metal Welds, one electrode or wire sample of each weld metal
combination shall be positively identified. The remainder of the lot shall be compared to
the sample to verify that the markings of the wires/electrodes are correct.
5.2.6.3 Some weld rods have the alloying elements contained in the flux, and do not meet the
alloy specification until welded. PMI testing of weld metal (e.g. deposited weld metal or
undiluted weld “buttons”) is permissible alternative to PMI testing of an electrode or wire
sample provided it is conducted immediately prior to production welding.
5.3 Random PMI Testing

5.3.1 Random PMI in lieu of 100% PMI is acceptable only where specified below;
5.3.1.1 Random PMI requires a representative sample of the inspection lot. The inspection shall
consist of one for lots of five or less or for lots greater than five units, the inspection
sample shall consist of two units or 5%, whichever is larger.
5.3.1.2 If a lot sample fails to meet the acceptance criteria, the next lot from the same
supplier/fabricator shall be 100% or to a lesser percentage as approved by the owner, PMI
tested. Alternatively, upon request from the supplier/fabricator, the failed sample may be
retested at the Owner’s option, or be retested at an Owner approved Metallurgical
laboratory at the supplier or fabricator’s expense. Upon acceptance of the retest, the
sampling percentage of the remaining lots shall be per original to 5.3.1.1.
5.3.1.3 Random PMI is acceptable in the following cases, for;
a) Heat exchanger tubes, tube to tube-sheet seal and strength welds.

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b) Nuts, bolts or fasteners.

c) All alloy vessel internals such as distributors, nozzles, piping, trays, demister pads
etc.
d) Thermowells specified to stainless steel or higher metallurgy (eg. Inconel 625,
Hastealloy, Monel etc.) for all piping/equipment of lesser metallugy such as carbon
steel and low chrome construction.
e) Flexible metal hoses.
5.4 PMI Exemptions

5.4.1 The following items are exempt from PMI testing unless specifically designated for testing by
Purchaser/Owner:
5.4.1.1 Internal instruments parts, including orifice plates.
5.4.1.2 Electrical components.
5.4.1.3 Stainless steel instrument tubing and copper tubing with an outside diameter of 3/4 of an
inch and less, when properly identified by paint stencil (exchanger tubing is not included in
this exemption).
5.4.1.4 Compression-type ferrules, fittings, and components for use with 3/4“outside diameter and
smaller tubing.
5.4.1.5 Pump seals.
5.4.1.6 Stainless steel instruments, PRV internals (disc/nozzles), pump casings and tubings
installed in carbon steel piping circuits.
5.4.1.7 Components and piping of lubricating systems or steam tracing using 300 series stainless
steel.
5.4.1.8 Solid metal gaskets and Spiral Wound gaskets except as required in 5.2.2.2. e) or
owner/Purchaser requirement based on criticality of service.
5.4.1.9 B7, B7M and B16 Bolts
5.4.1.10 Utility Hose end quick coupling connections for following services:
a) Utility water
b) Low pressure Steam
c) Utility Air
d) Nitrogen

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TABLE 1 - EXTENT OF PMI EXAMINATION

(This Table shall be read in conjunction with Section 5.2 of this specification)
Percentage
EQUIPMENT
PMI
Pressure Vessels and Heat Exchangers:

Plates, forging, nozzles (pipe), fittings 100%
Air –Cooled Exchanger tubes 100%
Shell & Tube Exchanger tubes 5%
Bulk Piping Components 100%

Valves 100%
Furnaces, Fired Heaters, Boilers:
100%
Tubes and other alloy containing parts
Expansion Joints (all pressure containing components) 100%
Shop fabricated spools (pipe, pipe fittings, flanges) 100%
Vessels and Exchangers pressure containing welds 100%
Piping welds (including socket welds) 100%
Random
Alloy Fasteners (bolts, nuts, washers) PMI –
5.3.1.3 b)
Rotating Equipment: Pressure containing casings 100%
Instrumentation: Pressure containing housing 100%
Control Valves 100%
Weld Overlay 100%
Clad Material 100%
5.5 Timing of PMI

5.5.1 Final PMI shall be performed upon completion of fabrication or assembly but prior to delivery. It
is preferable to perform “Final PMI” prior to the final hydrotest.
5.5.2 Where identical equipment or piping with differing metallurgies are installed, field PMI is
required.
5.5.3 Not all components or welds requiring PMI will be accessible for final PMI. It shall be the
Supplier’s responsibility to ensure that all items requiring PMI are tested as specified at an
appropriate time during the fabrication or assembly process. This will include such items as
vessel internals and internal welding, valve internals, instruments, pumps and other process

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equipment.
5.5.4 Wherever applicable, PMI shall be performed for all internal components before final
assembling, it is not the intent of this Standard that items be disassembled or that welds be
excavated to perform PMI testing.
5.5.5 The Purchaser/Owner or his/her designate has the right to witness any or all PMI testing and
also spot check “as-installed” items in the field at any time during the life of the component. Any
discrepancies shall be corrected by the Supplier.
5.5.6 PMI testing at receiving is considered a critical component of an overall PMI program but shall
not substitute for the final PMI required by paragraph 5.5.1.
5.5.7 PMI testing of welding consumables prior to use is considered a critical component of an overall
PMI program but shall not substitute for final PMI required by paragraph 5.5.1.
5.6 PMI Test Methods

5.6.1 PMI, where required, shall be performed by one of the following methods (listed in order of
preference):
5.6.1.1 Portable X-Ray Fluorescence (XRF),
a) The accuracy of portable analyzer instruments shall be checked by measurement
against known standards of each alloy type. Testing shall be performed according
to the alloy analyzer manufacturer's procedures.
b) Each analyzer shall be calibrated according to manufacturer requirements. At the
beginning and end of each shift, the instrument shall be checked at least three
times against a known standard for each alloy type to be inspected during the shift,
using the method to be used during the shift. This check shall be performed under
environmental conditions similar to the test location.
5.6.1.2 Portable Optical Emission Spectrometry,
a) These techniques may generate arcs and sparks a potential ignition source occurs
therefore prior to use of this technique in the field, a review shall be conducted to
determine if gas testing and hot work permits are required.
5.6.1.3 Laboratory wet Chemical Analysis.
5.6.2 Qualitative methods of alloy sorting including electromagnetic (eddy current), thermoelectric,
electrical resistivity, chemical spot testing, spark testing or triboelectric are not acceptable.
5.6.3 PMI Procedure: Any supplier or fabricator performing PMI Testing shall submit their PMI testing
procedure complying with the requirements of this standard for review and approval by the
Purchaser/Owner or his/her designate prior to use. The procedure shall cover safety, personnel
qualifications, type and manufacturer of PMI testing equipment, calibration, testing
requirements, material surface preparation, acceptance criteria, documentation requirements,
performance, marking or stamping requirements and resolution of discrepancies. The procedure
must identify how the process will be controlled, particularly in a project environment where pipe
spools may be fabricated at a fabricators shop, in the field, and also where rework may occur.

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At a minimum, this standard must be met.

5.6.4 If a failed component is detected in any one the sampled heat/lots, 100% of the components in
that lot shall be verified.
5.6.5 Implementation of a PMI program shall not release the Supplier from the responsibility of
furnishing the specified materials and documentation.
5.7 Personnel and Training

5.7.1 Personnel performing PMI testing shall have previous proven ability with PMI and shall be
qualified to the satisfaction of the Purchaser/Owner or his/her designate who will review and
approve the training and experience records. PMI technicians shall have the following
qualifications;
5.7.1.1 Proof of successful completion of PMI training course, this course could be presented in-
house, by the manufacturer or other institution but shall be generally be a minimum of one
day in duration.
5.7.1.2 Two months of documented experience performing PMI activity.
5.7.1.3 PMI operators shall ensure safe operation of all equipment.
5.7.1.4 PMI operators shall ensure PMI equipment is operated, calibrated and maintained in
accordance with manufacturer’s specifications and the submitted and approved PMI
procedure.
5.8 Acceptance Criteria

5.8.1 For materials requiring PMI, all elements specified for each material and welding category in
Table 1A and Table 2A in Appendix A shall be analysed and recorded.
5.8.2 Acceptance criteria for all materials that were PMI tested shall be as follows:
a) The measured value of alloying elements obtained on Analysis Mode Examination
shall be within 10% of the specified level or range in the applicable materials
standards (example: for 5 Cr, where the allowable range is 4–6%, the measured
value shall fall within the range 3.6 to 6.6%).
b) Alloy Identification or Alloy Matching Mode Examination instrument shall confirm
that alloys comply with the specified standard, within the accuracy given in above
paragraph 5.8.2.a).
c) All recorded elements as required by Appendix A shall meet the weight
percentages of alloying elements as specified in the relevant ASME BPVC Section
II Part A/B or ASTM material specification. A summary of alloys commonly used by
Purchaser/Owner is included as Appendix A for reference.
d) For weld deposits, all recorded elements shall meet the weight percentages of
alloy elements specified in the relevant ASME BPVC Section II Part C specification
for deposited weld metal. A summary of commonly used alloys is include Appendix

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A for reference.
5.8.3 The test methods outlined section 5.6 in this document are intended to identify alloy materials
and are not intended to establish the exact conformance of a material to a particular alloy
specification. Depending on the test method selected, the PMI test method shall identify the
nominal composition of alloy materials specified against each material category in Table 1A and
2A of Appendix A. Identification of materials by visual stamps/markings alone shall not be
considered as substitute for PMI testing but may be an important component of an overall
quality assurance program.
5.8.4 For Dissimilar Metal Welds, final weld cap composition shall match or be higher than the lower
alloy of the bi-metal metallurgy.
5.8.5 When alloy verification is required for materials not listed, the Purchaser/Owner shall be
consulted for information concerning the elements to be analyzed and the acceptable values.
This includes weld overlay and clad restoration welds where the filler metal and base metal are
different resulting in the as deposited weld to have a chemistry not listed in the above sections.
5.8.6 Additional requirements, such as confirmation of carbon content as specified for low and high
carbon grades in Appendix A of listed identification elements is required to identify these grades
from normal grade of that specific family, such as SS 316L from SS 316 grade. If required, upon
prior approval of Owner’s Engineer’s, alternative testing method may be utilized to perform test
of carbon determination.
5.9 Retest and Rejection

5.9.1 Fabricated equipment and assembled spools having components that do not meet the required
limit of the acceptance criteria as per Table1-A for materials and Table-2A for welds shall not be
accepted.
5.9.2 The Supplier may retest any unacceptable component using the more accurate wet chemical
analysis method. The results of this second test shall be considered final.
5.9.3 Materials, components or welds that are found to be not acceptable, shall be marked and
segregated pending resolution by the Supplier’s quality manager.
5.9.4 Alternate to the above requirement in 5.9.1, unacceptable materials, upon supplier/fabricator’s
formal request, may be subject to the corrective procedures approved by the owner at the
supplier/fabricator expense.
5.9.5 Weld metal which does not meet PMI acceptance criteria shall be completely removed,
rewelded and tested at the supplier, fabricator expense.
5.9.6 Samples taken by destructive means for chip analysis shall be repaired using an approved
repair procedure.
5.9.7 All weld repairs related to PMI as in 5.9.6 shall be performed prior to any required Post Weld
Heat Treatment, final hydrotest or NDE requirement.
5.9.8 A “no-match” or no reading shall be deemed to be a Non Compliance (NCR) and treated
accordingly.

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5.9.9 Purchaser/Owner shall be notified of all rejects and the details of why the rejection occurred.
5.9.10 Material found by PMI to be unacceptable, shall be rejected and replaced with a component of
correct specification. The applicable Non Conformance Report (NCR) process shall be followed
to determine the non-conformance causes, Risk associated and any preventative actions or
precautions required.
5.9.11 Only the Owner’s Engineer may accept the use of materials that have been rejected. The NCR
will still be issued and followed as to disposition.
5.9.12 Where random PMI has been performed, one rejected component will reject the entire lot. Use
of components from a rejected lot requires 100% PMI of the entire lot.
5.10 Material Identification and Traceability
5.10.1 Alloy materials are to be identified by their alloy designation (i.e. ASME/ASTM description) and
nominal composition.
5.10.2 The Supplier shall submit PMI documentation for fabricated piping and equipment supplied.
This documentation shall include all PMI test results and PMI maps that show the general
locations of all PMI tests. It is preferred that PMI maps be on the same document as the weld
maps.
5.10.3 In addition to marking or stamping of each component or item, all items checked will be
traceable to and documented on its unique drawing or other identifiable system so a
combination of physical marking and documentation will ensure traceability.
5.10.4 With the exception of small bulk items, PMI test results shall be traceable to each component
and weld. Small bulk items include nuts, bolts, valve internals.
5.11 Marking
5.11.1 Failed Components

5.11.1.1 Materials, items, and welds which are found to be unacceptable during verification testing
shall be immediately marked with a red 'R', for Rejected or any Non-Conformance
marking, removed and segregated from the lot, pending resolution by Purchaser/Owner.
5.11.2 Acceptable Components
5.11.2.1 All verified materials with acceptable analysis shall be marked with the letters "AV" (Alloy-
Verified) using a low stress stamp or other marking approved by Purchaser/Owner. In the
case of percentage PMI of a batch, or Inspection lot, only those items actually alloy
verified shall be marked with the letters "AV". Items in the same batch, or Inspection lot
covered by percentage verification, but which have not been tested, shall be marked with
the letters "AV B" (Alloy-Verified–Batch).
5.11.2.2 A permanent dye or paint may be used. The marking shall be placed as follows:
a) Pipe: Two marks, 180 degrees apart, 3 inches from each end of each length on
the outer surface of the pipe.

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b) Welds: Adjacent to the welder's mark on the weld. Alternatively, a weld map may
be used.
c) Fittings and Forging: Adjacent to the Supplier's markings.
d) Valves: Adjacent to the Supplier's markings on bodies and other pressure parts.
e) Plates: Adjacent to the heat numbers.
f) Castings: Adjacent to the Supplier's markings and heat numbers.
g) Tubes for heat transfer service: Stenciled, not stamped, approx. 3” from each end.
5.11.2.3 The marking shall be done with a water insoluble material that contains no harmful
substance, such as metallic pigments, aluminum, lead or zinc, sulfur or chlorides, which
would harmfully affect austenitic or nickel alloy steels at ambient or elevated temperatures
or which may be detrimental to the material, process and/or environment. The Supplier
shall submit analysis of marking material to Purchaser/Owner. Submittal shall
demonstrate, by chemical analysis and history of use, that material meets the
requirements. If metal stamping is utilized, the dies shall be of the low stress type.
5.11.2.4 If the material or item is too light, too small, or cannot otherwise be stamped, vibro etching
or color-coding shall be applied in conjunction with Supplier's standards and the
requirements of Section 5.12 and noted on the PMI reports.
5.12 Documentation and Report
5.12.1 PMI test results shall be recorded on a PMI Report, Refer Appendix B for example; each
Supplier/Owner site may develop/follow PMI report formats suitable to their use. The report
shall contain;
5.12.1.1 Inspection date
5.12.1.2 Inspection location
5.12.1.3 Inspection Agency
5.12.1.4 Inspection personnel
5.12.1.5 PMI equipment, model number
5.12.1.6 Date of calibration of the alloy analyzer
5.12.1.7 Purchaser’s PO# or other specific job reference #
5.12.1.8 Supplier Name (manufacturer or fabricator)
5.12.1.9 Material specification and traceability (heat number)
5.12.1.10 Recorded element percentage by weight
5.12.1.11 Signature of the inspector to verify review and acceptance of results.
5.12.1.12 PMI Procedure number and rev.

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5.12.2 All elements specified in Table 1A and Table 2A of Appendix A shall be recorded on the PMI
Report.
5.12.3 Appendix A contains a list of materials and welding consumables commonly used.
5.12.4 The completed PMI report and documentation indicating test locations along with associated
MTR’s shall be included in the test results data package and shall accompany the shipment
package. For all other work, MTR’s with PMI reports and documentation shall be included in the
appropriate job file.
5.13 Point Of Installation (POI) PMI
5.13.1 All Business Units shall develop their own PMI program for Point of Installation inspection fitting
to their own requirements in compliance with principles of this standard.
5.13.2 For all BU’s that already have an established POI PMI that are in compliance with the
philosophy of this standard may continue to use the same or may modify to include to reflect the
requirements of this corporate standard.
6.0 LIST OF APPENDICES
6.1 Appendix A – Common Alloy Steel Materials
7.0 REPORTING
7.1 Documents and Deliverables

7.1.1 At the conclusion of the project, the supplier/fabricator shall provide the Owner/Purchaser with
the documentation of a complete report of positive material identification of the required
piping/equipment material and welds, consisting of all above as in 5.12.1.

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Corporate Technical Standard
Number:
Revision:
Subject: Positive Material Identification- Appendix A 6
Table 1A – COMMON ALLOY STEELS (1), (2)
Alloy UNS Identification Alloy UNS Identification

Elements Elements
½ Cr – ½ Mo K11547 Cr, Mo SS 310 S31000 Cr, Ni
C – ½ Mo K11522 Mo SS 310S S31008 Cr, Ni, C*
1 Cr - ½ Mo K11757 Cr, Mo SS 316 S31600 Cr, Ni, Mo
1¼ Cr - ½ Mo K11789 Cr, Mo SS 316L S31603 Cr, Ni, Mo, C*
2¼ Cr - 1 Mo K21590 Cr, Mo SS 316H S31609 Cr, Ni, Mo, C*
2¼ Cr - 1 Mo – ¼ V K31835 Cr, Mo, V SS 317 S31700 Cr, Ni, Mo
3 Cr – 1Mo K31545 Cr, Mo SS 317L S31703 Cr, Ni, Mo, C*
5Cr - ½ Mo S50200 Cr, Mo SS 321 S32100 Cr, Ni, Mo, Ti
9 Cr - 1 Mo K91560 Cr , Mo SS 321H S32109 Cr, Ni, Mo, Ti, C*
SS 304 S30400 Cr, Ni SS 347 S34700 Cr, Ni, Mo, Nb (3)
SS 304L S30403 Cr, Ni, C* SS 347H S34709 Cr, Ni, Mo, Nb (3),
C*
SS 304H S30409 Cr, Ni, C* SS 405 S40500 Cr
SS 308 S30800 Cr, Ni SS 410 S41000 Cr
SS 309 S30900 Cr, Ni SS 16-8-2H S16800 Cr, Ni, Mo
SS 309S S30908 Cr, Ni, C* Duplex SS 2205 S32205 Cr, Ni, Mo

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SS 309H S30909 Cr, Ni, C* SS 430 S43000 Cr

Elements Elements
Duplex SS2507 S32750 Cr, Ni, Mo Inconel 625 N06625 Cr, Ni, Mo, Nb (3)
254SMO S31254 Cr, Ni, Mo Incoloy 800 N08800 Cr, Ni, Ti
Alloy 20Cb-3 N08020 Cr, Ni, Mo Incoloy 825 N08825 Cr, Ni, Mo, Ti
AL6XN N08367 Cr, Ni, Mo HK-40 J94204 Cr, Ni, Mn
Monel 400 N04400 Ni, Cu HP Cr, Ni
Inconel 617 N06617 Cr, Ni, Mo
Table 2A - WELD METAL / CONSUMABLE ALLOY ELEMENT

Elements Elements
A1 (C – ½ Mo) 8W1701 Mo E309 SS W30910 Cr, Ni
B1 (½ Cr – ½ Mo) W51018 Cr, Mo E310 SS W31010 Cr, Ni
B2 (1 ¼ Cr – ½ Mo ) W52018 Cr, Mo E316 SS W31610 Cr, Ni, Mo
B3 (2 ¼ Cr – 1 Mo ) W53018 Cr, Mo E317 SS W31710 Cr, Ni, Mo
B6 (5 Cr – ½ Mo) W50218 Cr, Mo E347SS W34710 Cr, Ni, Mo, Nb (3)
B8 (9 Cr – 1 Mo) W50418 Cr, Mo E410 SS W34710 Cr

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E308 SS W30810 Cr, Ni E430 SS W41010 Cr

Elements Elements
E16-8-2 W43010 Cr, Ni, Mo ENiCrMo-3 W86112 Cr, Ni, Mo, Nb (3)
(Inco 112)
E2209 (2205 Duplex W39209 Cr, Ni, Mo ENiCrCoMo-1 W86117 Cr, Mo, Co, Nb (3)
SS) (Inco 117)
Cr, Ni, Mo, Nb (3) ENiCu-7 Ni, Cu

ENiCrFe-2 (Inco A)
W86133 (Monel 400) W84190
ENiCrFe-3 (Inco 182) Cr, Ni, Nb (3) ENiCu-B Ni, Cu

W86182 W84002
ENiCrMo-1 W86007 Cr, Mo, Co, Nb E320 (Alloy W88021 Cr, Ni, Mo, Nb (3)
(3) 20Cb-3)
1) This Table is included for reference only. For actual values, refer to the applicable ASME or ASTM
Standard. The test method outlined in section 5.6 is intended to identify alloy materials and are not
intended to establish the exact conformance of a material to a particular alloy specification. Depending on
the test method selected, the PMI test method shall identify the nominal composition of alloy materials.
Identification of materials by visual stamps/markings alone shall not be considered as a substitute for PMI
testing but may be an important component of an overall quality assurance program. The precision of the
test equipment shall be consistent with the established test objectives. When the accurate match to the
component composition is desired, alternative test methods may be adopted.
2) Composition of cast materials may vary from the listed above, refer to relevant ASTM cast material spec.
3) Nb may alternatively be reported as Nb+Ta (Nb may also be Cb)
⃰ Carbon content shall satisfy the minimum and maximum limits of ASME/ASTM specification after
accounting for 10% variation as mentioned 5.9.1.1.No carbon content lesser or greater than specified
carbon content in the material spec. is acceptable.

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Material Requisition Stantec Project # 110903807

110903807-ME-MR-003 Suncor Project # 02-05478

COMPONENT DESCRIPTION: 5D Bends

1.0 SCOPE OF SUPPLY

COST CAD COST CAD

2.0 RECOMMENDED BIDDERS SOLE SOURCE

3.0 TECHNICAL DOCUMENTS AND ATTACHMENTS

• Refer to Technical Documents and Attachments:

4.0 VENDOR DRAWING AND DOCUMENT REQUIREMENTS

• Refer to Vendor Drawing and Document Requirements:

5.0 QUALITY SURVEILLANCE AND INSPECTION REQUIREMENTS

6.0 WARRANTY REQUIREMENTS

• Refer to Suncor terms and conditions for warranty information

7.0 SPARE PARTS

8.0 SHIPPING INSTRUCTIONS

• Packages shall be shipped to: TBD

• Shipping Contact Information

9.0 SPECIAL REQUIREMENTS

• 5D Bends shall have CRN (AB).

Stantec Discipline Lead: Muhammad G Khan Date: 17th May,2019

Stantec PM Approver: Anna Yurko-Weston Date: 17th May,2019

Stantec Procurement Receipt: Wayne Lau Date: 17th May,2019

Stantec QC: Chris Ebel Date: 17th May,2019

COMPONENT DESCRIPTION: 5D Bends

DOCUMENT NUMBER REV. # DOCUMENT DESCRIPTION TITLE

E = Electronic; V = Vendor Data Book; P = Print; Q = QC Data Book

Certified & Final Submittal

Code Data Description / Definition Q A C R

DBXX - DATA BOOKS

P21 PWHT PROCEDURE (If Applicable) 1E/1V 2 wks ARO

P22 GENERAL BENDING SPECIFICATION 1E 1E/1V 2 wks ARO

1.0 QUALITY ASSURANCE

2.0 CONTENT OF THE QUALITY PLAN

Note: * = Vendor / Supplier / Manufacturer

UNCONTROLLED DOCUMENT WHEN PRINTED (17-MAY-19) CONTROLLED DOCUMENT IN PROJECT LOCATION

Exhibit: File 100-2004-001 – 2.4.4.2 - FB-PEG-GP10-F04 Rev.: 11 Page: 1 of 8

3.0 SELLER’s RESPONSIBILITY FOR THIRD PARTY QUALITY MANAGEMENT

Note: * = Vendor / Supplier / Manufacturer

UNCONTROLLED DOCUMENT WHEN PRINTED (17-MAY-19) CONTROLLED DOCUMENT IN PROJECT LOCATION

Exhibit: File 100-2004-001 – 2.4.4.2 - FB-PEG-GP10-F04 Rev.: 11 Page: 2 of 8

4.0 SUNCOR SOURCE QUALITY SURVEILLANCE LEVELS

Level 0: Receiving Inspection at final destination only.

Note: * = Vendor / Supplier / Manufacturer

UNCONTROLLED DOCUMENT WHEN PRINTED (17-MAY-19) CONTROLLED DOCUMENT IN PROJECT LOCATION

Exhibit: File 100-2004-001 – 2.4.4.2 - FB-PEG-GP10-F04 Rev.: 11 Page: 3 of 8

Stantec QA/QC Coordinator: Chris Ebel

780-969-2098 587-920-3447 Chris.Ebel@stantec.com

Source Quality Surveillance Level Established: 1

Note: * = Vendor / Supplier / Manufacturer

UNCONTROLLED DOCUMENT WHEN PRINTED (17-MAY-19) CONTROLLED DOCUMENT IN PROJECT LOCATION

Exhibit: File 100-2004-001 – 2.4.4.2 - FB-PEG-GP10-F04 Rev.: 11 Page: 4 of 8

Specific Equipment/Material: 5D Bends Inspection Level: 1

High Pot Test Routine Electrical Hydrostatic Test

Note: * = Vendor / Supplier / Manufacturer

UNCONTROLLED DOCUMENT WHEN PRINTED (17-MAY-19) CONTROLLED DOCUMENT IN PROJECT LOCATION

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Note: * = Vendor / Supplier / Manufacturer

UNCONTROLLED DOCUMENT WHEN PRINTED (17-MAY-19) CONTROLLED DOCUMENT IN PROJECT LOCATION

Exhibit: File 100-2004-001 – 2.4.4.2 - FB-PEG-GP10-F04 Rev.: 11 Page: 6 of 8

Engineering Reference Notes:

Note: * = Vendor / Supplier / Manufacturer

UNCONTROLLED DOCUMENT WHEN PRINTED (17-MAY-19) CONTROLLED DOCUMENT IN PROJECT LOCATION

Exhibit: File 100-2004-001 – 2.4.4.2 - FB-PEG-GP10-F04 Rev.: 11 Page: 7 of 8

SUPPLIER’S REQUEST FOR QUALITY SURVEILLANCE