11.MKS-112-TS-TP1-SP-05 - 0 - SP For PI Fabrication Install Inspection & Testing

EXTENSION OF GAS COMPRESSION Doc.
No MKS-112-TS-TP1-SP-05
CAPACITY AT BLOCK 09-1.
INSTALL TRAIN A ON MKS Rev. No 0
FOR ALL SUB-PROJECTS
SPECIFICATION FOR PIPING FABRICATION, Page 2 of 24

INSTALLATION, INSPECTION & TESTING
TABLE OF CONTENTS
1.0 GENERAL 3
1.1 Introduction 3
1.2 Purpose of document 3
1.3 Definitions and Abbreviations 4
1.4 Documents 5
2.0 MATERIAL REQUIREMENT 6
3.0 FABRICATION REQUIREMENTS 7
3.1 General Requirements 7
3.2 Preparation 7
3.3 Welding 7
3.4 Connection 9
4.0 INSTALLATION REQUIREMENTS 10
4.1 General 10
4.2 Pipework Erection 10
4.3 Erection of Tie-Ins to Equipment 11
4.4 Installation of Valves 11
4.5 Flange Joints 12
4.6 Gaskets 12
4.7 Bolting 12
4.8 Installation of Pipe Support 12
5.0 INSPECTION AND TESTING 13
6.0 WELD REJECTION AND REPAIR 14
7.0 FLUSHING 16
8.0 HYDROSTATIC PRESSURE TEST 16
9.0 PNEUMATIC TESTS 18
10.0 ALTERNATIVE TESTING METHODS 18
11.0 TEST RECORDS 18
12.0 RETESTING 19
13.0 PROTECTIVE COATINGS AND INSULATION 19
14.0 MARKING AND IDENTIFICATION 19
15.0 DOCUMENTATION INCLUDING CERTIFICATES AND RECORDS 23
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EXTENSION OF GAS COMPRESSION Doc. No MKS-112-TS-TP1-SP-05

1.0 GENERAL
1.1 Introduction
The gas compression platform MKS was built in 1996. It is located next the oil production
platform MSP4 at White Tiger Oil Field of the Block 09-1, approximately 145 km South-
East of Vung Tau City, offshore of the Socialist Republic of Vietnam. The MKS and MSP4
platforms are connected via linking bridge. There are 04 high pressure gas compression
modules (BM100, BM200, BM300, BM400) operating on the MKS platform with 315
MSCMD each.
In order to increase gas compression capacity at block 09-1 Vietsovpetro is developing
the project “Extension of gas compression capacity at block 09-1. Install Train A on
MKS”. Project scope of work includes:
- Installation a new high pressure gas compression module Train A with capacity 1.7
MMSCMD on the MKS platform;
- Modification of structure, process and utility systems on the MKS and MSP4 platforms to
support for installation and operation of the Train A.
Before installation of Train A on the MKS platform, two existing gas compression
modules (BM300 and BM400) shall be removed. Removing of these two existing gas
compression modules is not in scope of the project “Extension of gas compression
capacity at block 09-1. Install Train A on MKS”.
Picture 1 – Location of MKS platform at White Tiger Oil Field

1.2 Purpose of document
This specification covers the minimum requirements for piping fabrication, erection,
installation, inspection and testing for piping systems on Train A, piping modification
on MSP4, MKS.
This specification is a COMPANY General specification and shall be read in
conjunction with the applicable project specific documents listed in Section 1.4.
This document does not cover the following:
- Pipelines and its fittings below the riser Shutdown valve;
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- Instrument tubing, heating, ventilation;
- Wellhead.
1.3 Definitions and Abbreviations
1.3.1 Definitions
PROJECT Extension of gas compression capacity at Block 09-1
COMPANY The party which initiates the project and ultimately pays for its
design and construction and owns the facilities. Here the
COMPANY is Vietsovpetro (Referred to as VSP)
VENDOR/ The party on which the order or contract for supply of the
SUPPLIER equipment / package/ piping material or services is placed
CONTRACTOR Any party who is responsible for and/or performs fabrication,
erection, assembly, installation, inspection and testing of piping
system.
SUB The entity engaged by the CONTRACTOR and approved by the
CONTRACTOR COMPANY to perform any activity under the CONTRACTOR’s
scope of work.
WORK The goods and services provided to the COMPANY by the
CONTRACTOR, SUB CONTRACTOR or VENDOR
THIRD PARTY The independent agency, appointed by the COMPANY, to
INSPECTOR perform design appraisals and manufacturing surveillance
(TPI) activities at SUPPLIER’s works with respect to the subject
WORK on behalf of the COMPANY.
1.3.2 Abbreviations
VSP Vietsovpetro
NPS Nominal Pipe Size
PMI Positive Material Identification
NDT Non-Destructive Testing
NDE Non Destructive Examination
HAZ Heat Affected Zone
PWHT Post Weld Heat Treatment
PO Purchase Order
WPS Welding Procedure Specification
WQR Welder Qualification Record
SMAW Shielded Metal Arc Welding
GMAW Gas Metal Arc Welding
SAW Submerged Arc Welding
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GTAW Gas Tungsten Arc Welding
PCN Personnel Certification in Non- Destructive Testing
CSWIP Certification Scheme for Welding and Inspection Personnel
ASNT The American Society for Nondestructive Testing, Inc
FCAW Flux core arc welding
IOM Installation and Operation Manual
1.4 Documents
The design of piping systems shall be in accordance with latest edition of, but not
limited to, the documents and standards list below including any applicable normative
references:
1.4.1 International Code and standard:
Code Title
ASME B31.3 Process Piping
ASME B31.8 Gas Transmission and Distribution Piping System
ASME B16.25 Butt Welding Ends
ASME VIII Pressure Vessel and Boiler Code (Div 1 & Div 2)
ASME Sec V Nondestructive Examination
ASME BPVC
Welding, Brazing, and Fusing Qualifications
Section IX
ASME Sec IX Welding and Brazing Qualifications
ASME II PART A Ferrous Material Specifications
ASME II PART B Nonferrous Material Specifications
Specifications for Welding Rods, Electrodes and Filler
ASME II PART C
Metals
Recommended Practice for Design and Installation of
API RP14E
Offshore Production Platform Piping Systems
Sizing, Selection and Installation of Pressure Relieving
API RP-520
Devices
API 1104 Welding of Pipelines and Related Facilities
API 660 Shell and Tube Heat Exchangers.
BS EN ISO 10204 Metallic Products – Types of Inspection Document
Pipe Hangers and Supports - Materials, Design,
MSS SP-58
Manufacture, Selection, Application, and Installation
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1.4.2 Project Documents
Document No. Title

MKS-112-TS-TP1-SP-01 Piping Material Class Specification
MKS-112-TS-TP1-SP-02 Specification for Manual Valves
MKS-112-TS-TP1-SP-03 Specification for Piping Special Items
MKS-112-TS-TP1-SP-04 Specification for Piping and Equipment Insulation
MKS-112-TS-TP1-GEN-01 Piping Support Standard
MKS-112-TS-TP1-GEN-02 Piping Design Standard
MKS-112-GEN-AZ7-SP-01 Specification for Painting
MKS-112-GEN-AZ7-SCH-01 Basic Painting Schedules
Painting Design Report for Piping of Module Train
MKS-112-TS-AZ7-RPT-02
A
MSP4-190-TS-AZ7-RPT-02 Painting Design Report for Modification of Piping
MKS-112-TS-TX1-LST-01 Line List
MKS-112-TS-PID P&IDs
MSP4-190-TS-PID P&IDs
MKS-112-ISO Isometric Drawings
MSP4-190- ISO Isometric Drawings
Vendor's Documents General Arrangement, IOM
2.0 MATERIAL REQUIREMENT

All material shall be new, sound and free from defects, per relevant project requirement
and supplied with the appropriate mill certificate per project specification requirement.
Material found to be damaged or to have defects shall not be used in fabrication unless
repaired in accordance with a repair procedure approved by COMPANY.
Mill Test Certification of all Materials as per specification shall be reviewed by the
Vendor/Contractor’s QA/QC personnel before use of any pipe or fittings or flanges for
fabrication. The materials shall be certified that it meets the requirement of applicable
codes. All materials received which are not compliant to the Purchase Order or which do
not have the specified certification shall be quarantined and shall not be used in the
facilities fabrication or installation.
Positive Material Identification (PMI) shall be conducted to verify alloy content for all piping
material except Carbon Steel P.No-1.
All free issue materials shall be identified and stored separately in the Contractor’s yard.
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3.0 FABRICATION REQUIREMENTS
3.1 General Requirements
Piping fabrication, welding, inspection, testing and heat-treating shall conform to this
Specification and ASME B31.3& B31.8 wherever applicable. The piping includes pipe
supports welded to the pipe.
For minimum spacing between welds, refer to “ Piping design standard” MKS-112-TS-
TP1-GEN-02.
Socket weld connection shall be restricted to small bore piping 1.1/2’’ and below. Other
than flanged connections, only approved mechanical joints shall be used. Threaded
connections are only permitted for instrument and tubing connections. Seal welding of
threaded connections is prohibited. If approved, seal welding shall be accomplished in
accordance with ASME B31.3.
Thermowells, caps and plugs on vents and drains shall not be seal welded.
Cleaning of the pipe after fabrication and heat treatment shall be performed externally and
internally to remove all loose scale, weld spatter, sand and other foreign matter.
Fabrication of stainless steel and other alloy steel material shall be performed in separate
designated area to minimise the risk of cross contamination with carbon steel and other
dissimilar materials and with tools used only for this type of fabrication.
Internals of in-line valves and equipment that could be damaged due to heat transfer shall
be removed prior to welding and/or heat treatment.
3.1.1 Fabrication Tolerance
Fabrication tolerance shall be as defined by ASME B31.3 and Appendix 1.
3.2 Preparation
Cutting and beveling of pipes and fittings may be done by mechanical or thermal method.
When oxyfuel gas cutting is used to bevel pipes and fittings, the bevel end shall be
thoroughly cleaned of carbon residue prior welding. Plasma arc cutting shall be used for
stainless steel and other high alloy steel material.
3.3 Welding
3.3.1 General
CONTRACTOR shall develop Welding Procedure Specification (WPS), Welding
Procedure Qualification Record (WPQR) and Welding Procedure Register (WPR) to cover
the full range of material to be welded and all necessary procedures needed during
fabrication, including weld repair procedures. COMPANY shall be approve the above
documents prior to commencement of fabrication. Suitable previously qualified weld
procedures and procedure qualification records, witnessed by an accredited Certifying
Authority, may be used, subject to written approval by COMPANY.
For low temperature service 0°C and below, procedure qualification for ferritic, materials
shall include impact tests of both the weld metal and the heat affected zones, even if the
impact tests are not required on the base material.
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The impact test shall be performed in accordance with ASME B31.3. The lateral
expansion shall be reported if required.
3.3.2 Qualification of Welding Procedure
Welded joints in process and service lines being constructed as per ASME B31.3 shall be
made with a qualified welding specification by welding operators or welders qualified
either in accordance with Section IX of the ASME Boiler and Pressure Vessel Code
ASME B31.3.
3.3.3 Qualification of Welders
All welds shall be made with a qualified welding procedure as specified in accordance
with Section IX of the ASME Boiler and Pressure Vessel Code and ASME B31.3. Welding
procedures shall include, where applicable, preheating of welds and / or post-weld heat
treating requirements and must be approved by COMPANY prior to fabrication. Impact
test temperature, impact energy values, test location shall be in accordance with ASME
B31.3 and relevant ASME requirement based on minimum design temperature as
specified in relevant piping class.
3.3.4 Welding Grooves
The ends of steel pipe and fittings to be butt welded shall be beveled to form a welding
groove in accordance with the approved Welding Procedure Specification.
Welding grooves for butt welded joints in pipe of unequal wall thickness shall be end
preparation and geometry internally in accordance with ASME B31.3 and shall conform to
acceptable designs for unequal wall thickness requirements of ASME B16.25. .
Surface to be welded shall be clean and free from paint, oil, dirt, scale, oxides, and other
material detrimental for a distance of 1” (25mm) from bevel.
3.3.5 Alignment
Butt weld alignment shall satisfy the requirements of ASME B31.3 and the requirements
that are qualified in the weld procedure qualification test.
Inside surface of pipe to be welded shall be aligned within the dimension limits of WPS.
3.3.6 Weld Contour and Finish
Weld beads shall be contoured to permit complete fusion at the sides of the bevel and to
minimize slag inclusions. Flux and slag shall be completely removed from weld beads and
from the surface of completed welds and adjoining base material. The flux shall be
removed in a manner that will not contaminate or overheat the weld or adjoining base
metal. Weld reinforcement and finish shall be as required by the applicable code.
3.3.7 Weld Quality
Butt welds shall have full penetration and complete fusion with a minimum of weld metal
protruding on the inside of the pipe per ASME B31.3.
All welds shall have a slight reinforcement built up gradually from the toe or edge toward
the centre of the weld per ASME B31.3. Radiography and other NDT methods shall be
required as indicated in this specification to verify the weld quality.
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3.3.8 Heat Treatment
Exposed machined and threaded surfaces shall be protected from oxidation during heat
treatment.
No welding shall be performed after heat treatment is completed.
Heat treatment requirements and hardness specifications for attachment welds of
nonpressure parts, such as gussets and trunnion attachments, shall match those
requirements specified for the nominal analyses of the attached pressure part.
Minimum pre-heat temperatures for thermal cutting, welding, and tack welding shall be as
specified in ASME B31.3 and/or applicable Welding Procedure Specification (WPS).
Post-weld heat treatment shall be as per ASME B31.3 or as required by Company.
Post Weld Heat Treatment of welds shall applied for piping carbon steel with wall
thickness above 25mm in accordance with ASME B31.3.
3.4 Connection
3.4.1 Butt welds
Butt welding of pipe and fittings shall conform to the approved Welding Procedure
Specification. Weld reinforcement shall be applied so that the weld shall have a smooth
contour that will merge gradually with the surfaces of adjacent pipe and fittings. No
external force shall be used on pipe alignment.
Butt weld 90 degree elbows shall be long radius elbows.
For a reducing fitting or reducer (large end and small end) connected to piping of different
weight designations (schedule or weight), the fitting or reducer shall be of the higher
piping weight designation.
3.4.2 Flange Connections
The wall thickness and the bore of the hubs of weld neck flanges shall match the pipe. If
the wall thickness of the flange or pipe exceeds the thickness of the other as specified in
ASME B31.3, the thicker item shall be bored or trimmed at an angle to correct the
difference. When the flange is thicker, the required modification shall be shown on the
flange description in the material list. When the pipe is thicker, the drawing shall indicate
that boring or trimming by the fabricator is required.
Flanges to mate with flat faced flanges on pumps or other machinery shall be flat faced. It
is satisfactory to machine the flat face from raised face flanges for this purpose. Full faces
gaskets shall be used with the flat face flanges.
Stud bolt lengths for flange systems shall be in accordance with the ASME B16.5. For
other cases, the minimum length shall provide for the last thread in each nut to be
completely engaged. The maximum length shall not cause the stud to extend more than
approximately 6mm beyond the nut on each end. Excessive torque shall not be applied
when installing stud bolts.
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3.4.3 Screw Thread Connections
Screwed threads shall be clean cut with no burns or stripping and shall be tapered
according to ASME B1.20.1. Immediately before erecting the piping, all threads of pipe
and fittings shall be thoroughly cleansed of cuttings, dirt, oil or other foreign matter.
The male threads shall be coated with thread sealant and the piping made up sufficiently
for the threads to seize. Thread sealant such as three bond sealant and thread locker
shall be used.
4.0 INSTALLATION REQUIREMENTS
4.1 General
The following documents and any other relevant documents related to piping material and
equipment shall be reviewed before starting of the installation at site:
 Material certificates
 NDT certificates
 Shop fabrication inspection reports
 Installation, operating and maintenance instructions
 Safety data on equipment and contained materials
As a minimum requirement, all valves shall be inspected for:
 Number, type, size, bore, body material, pressure and temperature ratings
 Face to face dimensions
 Flange face finish
 Weld end preparation (if field weld mounted)
 Nameplate details inclusive of PO No. etc
 Trim materials inclusive of seat material, stem packing material, bonnet gasket
material etc
 Arrow for flow direction (if relevant)
 Orientation of valve hand wheel / operating mechanism
 General condition
 Protective coating
4.2 Pipework Erection
All pipes shall be inspected before erection to ensure that they are free from loose
contamination.
Pipework shall be erected on permanent supports designated for the line. Temporary
supports shall be kept to an absolute minimum, but to an extent sufficient to protect
nozzles and adjacent piping from excessive loads during the erection.
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4.3 Erection of Tie-Ins to Equipment
Piping shall be erected and supported in a manner that will not put undue strain on
equipment such as compressors, engines, pumps, vessels and heat exchangers. The
following procedure shall be observed:
 After the equipment has been set the pipe shall be connected to the equipment
without making any tight connections to flanges.
 Flat face flanges and full-face gaskets shall only be used on piping connecting to
equipment with flat face flanges.
 Flanges shall be checked to ensure that no strain is placed on the equipment. If
the pipe is not in correct alignment it shall be realigned. The correction in
alignment shall not be made while the pipe is connected to the equipment.
Heating of piping to correct misalignment shall not be permitted.
The following procedure shall also be applied for the alignment of flanges to rotating
equipment:
 Align pipework to equipment flanges to within the manufacturer’s tolerances.
Adjust pipe support where necessary.
 Flange faces for flanges in pipe to equipment shall be parallel within 1.6mm
measured across any diameter.
 Bolt up piping to equipment flanges and apply torque to the bolts to achieve the
specified tension.
 Check the shaft coupling alignment during the bolting and tensioning of the pipe
flanges to the equipment flanges. The bolting up and tensioning of the flanges
shall not affect the coupling alignment between the driver and driven equipment.
 Check efficiency of pipe supports.
4.4 Installation of Valves
Spring loaded type check valves must be installed with the pin in vertical position when
flow is horizontal.
Ball valves with socket weld type, the need for disassembly or other requirements to
prevent seat damage shall be investigated. Ball valves with pre-installed pup may be
used to avoid seat damage.
Valves shall be installed with stems orientated vertically up or as indicated on piping
drawings. Split disc wafer type check valves shall be installed with the shaft in vertical
position.
All valves, including control or shut off valves, shall be installed in the correct orientation
for flow. Where incorrect installation has taken place the valve shall be removed,
inspected and correctly positioned at the Vendor/Contractor’s expense.
Valves shall be seat leak tested at site before installation.
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4.5 Flange Joints
Clean protective grease from flange gasket faces and position for bolt up. Flange faces
shall be parallel and aligned in the horizontal and vertical. Position gasket and install bolts
and nuts to hand tight.
All bolts for flanged connections require extreme attention in assembly to ensure uniform
loading on the gasket surfaces. Non uniform bolt loading, dirt at the mating surfaces or
scratched flange surfaces shall be subject to release and flange joint reassembly or
flange face redressing.
Flange alignment shall conform to the required tolerances of ASME B31.3.
4.6 Gaskets
Gaskets shall be treated in accordance with manufacturer's instruction. Gaskets shall be
replaced after opening or dismantling of flange connections.
Care shall be taken to ensure that the gasket and mating flanges are clean, true and free
from defects. RTJ gaskets are to be lightly smeared on the mating surface with a
propriety anti-friction lubricant prior to fitting between the flange grooves. Anti-friction
lubricant, compatible with the flange material and process fluid shall be used.
4.7 Bolting
Bolting shall be in accordance with the requirements in the Piping Material Class
Specification, MKS-112-TS-TP1-SP-01 and on piping isometric drawings.
All carbon steel bolt shall be fluorocarbon coated.
All bolting shall move freely through the flange bolt holes.
The Vendor/Contractor shall be responsible for all bolt torque requirements and their
applications. All actual bolt torque values shall be measured for every bolt 1¼” diameter
and larger in piping 600lb flange rating and above and submitted to the Company for
approval.
The stud bolts for flange joints pressure class 600 and above, which are subject to
tightening, hydrostatic test, dismantling and retightening, may be reused. Stud bolts,
which have been hydro-tensioned, shall not be reused. This is provided that the bolt
stress during hydrostatic test does not exceed 80% of yield stress and the threads have
not been damaged. Hydro-tensioned bolts shall be replaced.
As an alternative, the Company prefers that temporary test bolting are used for
hydrostatic testing and replaced with bolting specified in the piping material specification
after successful completion of the hydrostatic test.
Hydraulic bolt tensioning systems, approved by the Company shall be used on bolts of 1”
diameter and larger. Bolts for hydraulic tensioning shall be supplied with one additional
bolt dia length longer than standard. The extra length shall protrude on one side of the
flange only and shall be protected.
4.8 Installation of Pipe Support
Pipe support shall be accordance with the relevant pipe support detail drawings
developed for the project.
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Piping shall not be forced to fit with support locations in such a manner that additional
stress is introduced.
Where spring support are installed the spring shall locked gagged until commissioning
/start up.
All piping shall be arranged to facilitate supporting, and shall be planed for ease of
removal of equipment for inspection and servicing. Pipes shall not normally be supported
by other pipes.
5.0 INSPECTION AND TESTING
CONTRACTOR is responsible for all QA/QC services required to ensure strict compliance
with the requirements of this Specification.
COMPANY or its authorized representatives shall be permitted at all times free access to
all parts of CONTRACTOR's facilities shops that concern the fabrication and testing of the
piping system.
The approval of any work by COMPANY's representative and the release of the unit for
shipment shall in no way release the CONTRACTOR from their responsibility for carrying
out all of the provisions of these Specifications.
All welds shall be visually inspected. Any deficiency found during welding inspection shall
be recorded and shall be evaluated based on the acceptance limit provided for in ASME
B31.3.
All examinations inclusive of in-process examinations shall be carried out in full
compliance with requirements specified in ASME B31.3 and this specification and any
other requirements covered by Company General Specifications referenced herein.
All NDT shall be carried out at ABM temperature. Check welding procedure and decide
for each correct situation.
Weld examinations shall be performed in accordance with the following standards:
a) Visual ASME Section V, Article 9
b) Radiographic ASME Section V, Article 2
c) Magnetic Particle ASME Section V, Article 7
d) Liquid Penetrant ASME Section V, Article 6
e) Ultrasonic ASME Section V, Article 4
Welds that are to be examined by non-destructive methods shall be finished as required
in ASME B31.3 and the standards listed above.
Non destructive examination of piping shall be as below:
%MT/PT %RT/UT
% Acceptance Criteria -
System Abbreviation (for Fillet (for Butt
Visual Category
weld) weld)
Process Liquid ASME B31.3 - Severe
PL 100 100 100
System cyclic condition
Process Gas ASME B31.3 - Severe
PG 100 100 100
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Gaslif t Gas ASME B31.3 - Severe
GL 100 100 100
High Pressure ASME B31.3 - Severe
BH 100 100 100
Flar e System cyclic condition
Blowdown Gas ASME B31.3 - Severe
BD 100 100 100
ASME B31.3 - Severe
Fuel Gas S ystem FG 100 100 100
cyclic condition
High Pressure ASME B31.3 - Normal
VH 100 100 10
Vent S ystem Fluid condition
Low Pr essure ASME B31.3 - Normal
VL 100 100 10
Vent S ystem Fluid condition
ASME B31.3 - Normal
Close Drain System DC 100 100 10
Fluid condition
Open Hazardous ASME B31.3 - Normal
DH 100 100 10
Drain System Fluid condition
Open Non-
ASME B31.3 - Normal
Hazardous Drain DN 100 100 5
Fluid condition
System
Instrument Air ASME B31.3 - Normal
AI 100 100 10
System Fluid condition
ASME B31.3 - Normal
Utilit y Air S ystem AU 100 100 10
Fluid condition
ASME B31.3 - Normal
Nitrogen S ystem NT 100 100 10
Fluid condition
ASME B31.3 - Normal
Lube Oil System OL 100 100 10
Fluid condition
ASME B31.3 - Normal
Fire Water System FW 100 100 10
Fluid condition
ASME B31.3 - Normal
Sewage system SW 100 100 10
Fluid condition
ASME B31.3 - Normal
Drain Water System DR 100 100 5
Fluid condition
6.0 WELD REJECTION AND REPAIR
Indications or imperfections that are outside the limits of the applicable codes and
standards, this Specification, Project Specifications or other requirements stated on
Purchase Order, shall be cause for rejection and the Manufacturer shall be subject to the
Inspection Agency approval and shall be at the sole expense of the Manufacture.
Complete repair of weld shall include removal of the weld, beveling of new edges, and re-
welding.
When welding is judged to be unsatisfactory by the Inspection Agency, the welder or
welding operator responsible for the work shall be suspended from welding and all his
work examined by non-destructive means. Welding found to be unacceptable by the
Inspection Agency shall be repaired. The welder or welder operator may be re-assigned
only after additional training, the completion of satisfactory re-qualification tests , and with
the approval of the Inspection Agency.
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All repairs shall be documented and shall be include in the manufacture’s data book.
Documentation on repair shall include the following (for each repair):
 Location and layout of defect
 Nature of defect and means of detection used
 Repair work actually performed( defect removal method, WPS used)
 NDE performed and results obtained during and after repair.
Repair shall be advised to the Inspection Agency; the repair method, the welding
procedure and welder qualifications, etc.., shall be accordance with this Specification and
shall be approved by the Inspection Agency before any repair being initiated. This
approval must be based on qualification testing (PQR) supporting a specific WPS for
each type or repair.
Welds containing cracks shall be subject to additional non-destructive testing (Ultrasonic
or Magnetic Particle) and then, the extent of repair shall be decided by the Inspection
Agency. Repair welding will only be permitted after consideration of the nature and cause
of cracking.
Unacceptable defects shall be removed chipping, grinding, machining or air-arc gouging.
Where air-arc gouging is used, all carbon, cooper and other debris, including carburized
metal, shall be removed by grinding or other mechanical methods approved by the
Inspection Agency. Oxygen gouging of quenched and tempered steels or other high
strength steels is not permitted.
For partial repair, the cut-out portion shall be sufficiently deep and long to remove the
defect. At the ends and sides of the cut, there shall be a gradual taper from the base of
the cut to the surface of the weld metal. The width and profile of the cut shall provide
adequate access for re-welding.
Special care shall be taken to remove weld defects located at the root in other to obtain
an acceptable root gap.
Prior to starting the repair, the repair grooves shall be examined by dye penetrant method,
to ensure that all defects are removed.
Preheating (where required) and inter-pass temperatures shall be maintained during all
well repairs.
Repair on already post well heat treated components shall be subject to a new post well
heat treatment under the same conditions and rules.
All repaired welds shall be re-inspected in accordance with this specification at the
manufacturer’s expense. Moreover, additional radiographs of two welds previously
performed by the same welder shall be required at the Manufacture’s expense. These
additional two welds shall be selected by the Inspection Agency.
For all other welds, only two repairs shall be permitted on the same area of a given weld:
should a third repair become necessary, then the whole weld shall be cut as per above.
In any case, the WPS used for repairs shall be qualified on the same number of
succession performed.
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7.0 FLUSHING
All completed piping systems shall be flushed prior to testing. Piping system shall be
broken into sub-systems for flushing. The Company shall approve the flushing sub-
systems and the procedure. The sub-system nominated for flushing shall be securely
isolated from all other sub-systems to prevent water and debris entering the adjacent sub-
systems. Special care shall be taken to isolate rotating equipment from the flushing.
All lines two (2) inches and larger, other than instrument and utility air lines shall be
flushed with fresh clean water so as to completely clear them of any loose mill scale, rust,
or various extraneous material. All lines smaller than two (2) inches, and air lines of any
size, shall be cleaned out in a similar manner using compressed air. The flushing medium
shall be at as high a velocity as practical (minimum of 5 ft/sec) in order to flush out any
loose material in the line.
Flow shall be from high to low points. Flanges shall be opened and spool pieces shall be
removed as necessary to flush the piping thoroughly.
Main header shall be flushed for longer than 30 minutes and the branch for longer than 15
minutes.
Orifice plates, thermowells, flow straightening vanes, positive displacement (PD) and
turbine meters, vortex meters, control valves, corrosion probes, sample probes, pig
signalers, displacement type level instruments, and other vulnerable equipment, if already
installed, shall be removed and/or blinded off prior to flushing (the instrument engineer
shall define these in conjunction with the piping supervisor). All instrument leads shall be
disconnected prior to flushing but shall be reinstated and capped at the disconnected
instruments prior to hydrotest. All control valves shall be removed. Spring type supports
shall have stops installed to prevent overloading of the support.
All vessels included within a piping system being flushed are to be drained through the
vessel drain system.
All valve shall be full open during flushing process.
Fresh water used for flush stainless steel shall have chloride less than 50PPM.
A punch list shall be prepared of any repair or rework that will need to be carried out
before hydrotest and before leak testing and before final acceptance of piping.
No hydrotest or leak test may be carried out if punchlist items are outstanding which
affect the validity of such testing or where clearing the punchlist would call into question
the validity of such testing.
8.0 HYDROSTATIC PRESSURE TEST
Hydrostatic pressure testing of piping systems shall be in accordance with ASME B31.3
(latest edition). Piping test pressures shall be given on the Project Line List and also
shown on piping isometric drawings.
All piping systems shall be hydrostatic tested, except pneumatic testing with compressed
air shall be carried out for instrument air. These systems shall be tested at 1.1 x design
pressure.
______________________________________________________________________

Testing procedure, schedules and Hydrotest-Pneumatic Test Mechanical Flow Diagram
shall be submitted for COMPANY approval prior to commencement of testing.
Hydrostatic test water shall be clean, potable water with a pH of more than 6 and less
than 8. Test water shall contain a maximum of 500 ppm chloride for carbon steel piping
systems, and 100ppm for austenitic steel or high nickel alloy materials.
Prior to commencing any pressure test, Contractor shall verify with the Company
Representative that completed welding, NDT, PWHT, PMI and Hardness by Traceability
Summary Report was sighted and verified. The report form shall be approved by
Company. Upon review of the Summary Report the Company Representative shall
authorize the Contractor to proceed with the pressure testing.
The test pressure shall be maintained for an adequate time to determine small seepage
type leaks and to permit a thorough inspection. Minimum hold time of 1 hour shall apply.
Contractor shall ensure that adequate temporary support, vent, drain and blind are
provided to test in accordance with this Specification and applicable Codes. High point for
vent and low point for drain shall be specified.
Following completion of pressurization of the system, the pump shall be completely
disconnected from the subject piping system.
Testing shall not be done against closed valves. If it is impractical to test through a valve,
that valve shall be isolated by blinds or disconnected from the piping system.
All in-line ball valves shall be 50% opened, so as not to damage the valve seats. All other
valves shall be fully open.
Short pipe spools, which must be removed to permit installation of test blinds, shall be
tested separately. Where piping being tested extends beyond the scope of its module
then the pipe shall be left long blanked and tested. After testing the pipe shall be left long,
and the hydrotest blind shall remain for preservation purposes.
The following piping and equipment shall be excluded or isolated from hydrostatic testing:
 Rotating machinery, pumps, compressors, etc.
 Strainers and filter elements
 Control valves
 Pressure-relieving devices such as pressure relief valves and rupture discs.
 Vessels which do not satisfy impact requirements at piping test temperature.
 Vessels that would be overstressed at piping test pressures.
 Instruments which are not suitable for hydrotesting (the instrument engineer will
define which instruments meet this criteria) at the design pressure (as far as
practical all inline, offline and impulse lines should be included as part of the
hydrotest)
 Permanent pressure gauges.
 Expansion joints.
 Orifice plates.
______________________________________________________________________

 Corrosion Probes.
 Removable internal parts of the vessel
 Any other piping or equipment designated by Company.
9.0 PNEUMATIC TESTS
Subject to prior approval by the COMPANY, pneumatic testing may be substituted for
hydrostatic testing if the following condition apply:
- If special supports or other special arrangements would be required on large, low
pressure lines;
- If hydrostatic test are impracticable;
- If the possibility exist that piping, insulation material, or attached equipment might be
damaged by water;
- If even a small amount of water is left in a system, could be damaging to the system.
For safety, the volume of system being pneumatically tested shall be kept as small as
possible.
10.0 ALTERNATIVE TESTING METHODS
In all cases where pressure testing of hook-up spool welds and any minor changes or
additions to the piping system will entail an extensive retest, the closure/minor welds may
be alternative tested to the stipulations of this document without being subject to any
sensitivity leak test requirements.
The qualification of a weld by alternative testing fall into two categories which are
determined by service/pressure. These are as follows:
Alternative I:
Only where design pressure < 10 Barg on non toxic and non flammable utility service
All hook-up spool closure welds and any minor change/additional welds shall be NDE
tested at design conditions in accordance with ASME B31.3 Para. 345.1 and visually
inspected. But NDE shall not be less than requirement stated earlier in this specification.
Alternative II:
All hook-up spool closure welds and any minor change/additional welds shall be subject
to 100% radiography and 100% MPI or dye penetrant as applicable to material.
11.0 TEST RECORDS
Contractor shall furnish all testing equipment and recording instruments with all necessary
supplies and shall maintain accurate and permanent records. The testing and recording
equipment shall be subject to the written approval of the Company.
All records, data, and charts clearly marked with the following information shall be
furnished to the Company in the Hydrostatic Test Report.
 Company name and authorized representative.
 Testing Contractor's name and authorized representative.
______________________________________________________________________

 Line identification of piping and/or equipment tested.
 Date, start time, and stop time of test.
 Test pressure and duration.
 Test medium used.
 Ambient air temperature.
 The recorder element range.
 Explanation of any pressure discontinuities that may appear on the chart.
 Listing of items excluded from the test.
 Service test record.
 Marked up P&IDs depicting valves which passed and failed service test.
 Signature of Company's and Testing Contractor's authorized representative.
12.0 RETESTING
Should piping failure occur during testing, the Contractor or Vendor shall locate the failure.
Contractor or Vendor shall at his expense repair all defects resulting from inferior
workmanship or defective materials furnished by the Contractor or Vendor. After repairs
have been made, the Contractor or Vendor shall retest until a successful test is obtained
to the satisfaction of the Company's Representative.
13.0 PROTECTIVE COATINGS AND INSULATION
All piping shall be fully blasted and painted in accordance with “Specification for
Painting”: MKS-112-GEN-AZ7-SP-01.
Branch connections on thermally insulated lines shall be designed so that branch
connections for valves, gauges, thermowells, instrument bridle, etc., extend through the
pipe insulation a sufficient distance so that valves can be operated and equipment can be
dismantled for maintenance without removing the insulation on the pipe run.
Painting shall include:
 Painting of the installed pipe
 Painting of the piping components including valves, flanges, specialty items etc.
 Painting inspection and repair.
Insulation of Piping shall be in accordance with Specification for Piping and Equipment
Insulation MKS-112-TS-TP1-SP-04
Branch connections on thermally insulated lines shall be designed so that branch
connections for valves, gauges, thermoweels, instrument bridles, etc.., extend through the
pipe insulation a sufficient distance so that valves can be operated and equipment can be
dismantled for maintenance without removing the insulation on the pipe run.
14.0 MARKING AND IDENTIFICATION
To facilitate erection, the appropriate pipe identification, consisting of the line number and
spool number, shall be legibly painted onto secondary coating surfaces of each pipe
______________________________________________________________________

spool in large block letters or hard stamped on metal tags firmly secured to the spool if
final coating has been applied to the finished spool. The paint shall not, in itself, cause
corrosion or affect final coating of the pipe or fittings to which it is applied. Paint
containing lead, zinc, copper or tin shall not be used.
In addition, each final made-up spool shall be identified with the line number and spool
number stamped with low stress dies on the edge of a flange. If the spool contains no
flanges, the information shall be stamped, or for stainless steel or non-ferrous materials,
vibro-etched on the bevel end of the pipework.
- Inscriptions and direction identification shall be applied after finishing of painting and
insulating of piping. Direction identification is as per «Notes».
- Inscriptions are to be in Roman type. Letters height is to be as per below Table 14.1.
Dimensions of pointer indexes and marking inscriptions
Pointer index
a
a b
Table 14.1 – Dimensions of pointer indexes and marking inscriptions
(*): "b" length will be adjusted depending on painting text in Table 14.4
Nominal pipe Letter height, mm

a b
diameter,
(mm) (mm) One text string Two text strings
d, mm
< 80 26 74 19 -
From 80 To 150 52 320* 32
From 80 To 150 52 148 17
From 150 To 250 74 508* 50
From 150 To 250 74 210 50 25
Over 300 148 560* 90
Over 300 148 420 50
- Dimensions of warning color rings are to be as per below Table 14.2 .

Dimensions of warning color rings
______________________________________________________________________

d
a a
L
d
a a a a a a a a a a
L
Table 14.2 – Dimensions of warning color rings
Nominal pipe diameter d, mm L, мм а, мм

< 80 2000 40
From 80 To 150 3000 50
From 150 To 250 4000 70
Over 300 6000 100
______________________________________________________________________

- Ring colors to be as below Table 14.3:
Table 14.3 – Ring Colors
External
System Abbreviation coating Ring Color
color
Process Liquid System PL Yellow signal Red - "space" - Red (2 rings)
Process Gas System PG Yellow signal Red - "space" - Red (2 rings)
Gaslif t Gas System GL Yellow signal Red - "space" - Red (2 rings)
High Pressure Flar e System BH Yellow signal Red - "space" - Red (2 rings)
Blowdown Gas S ystem BD Yellow signal Red - "space" - Red (2 rings)
Fuel Gas S ystem FG Yellow signal Red - "space" - Red (2 rings)
High Pressure Vent S ystem VH Yellow signal Red - "space" - Red (2 rings)
Low Pr essure Vent S ystem VL Yellow signal Red - "space" - Red (2 rings)
Close Drain System DC Yellow signal Red - "space" - Red (2 rings)
Open Hazardous Drain System DH Yellow signal Red - "space" - Red (2 rings)
Open Non-Hazardous Drain Red - "space" - Red (2 rings)
DN Yellow signal
System
Instrument Air S ystem AI Grey Green - Red - Green (3 rings)
Utilit y Air S ystem AU Grey Green - Red - Green (3 rings)
Nitrogen S ystem NT Grey Green - Red - Green (3 rings)
Lube Oil System OL Grey Green - Red - Green (3 rings)
Fire Water System FW Red Signal Green - "space" - Green (2 rings)
Sewage system SW Green Yellow - "space" - Yellow (2 rings)
Drain Water System DR Green Yellow - "space" - Yellow (2 rings)
______________________________________________________________________

- Inscriptions and direction identification are applied on the identification painting coating.
Their colors are as below Table 14.4.
Table 14.4 – Inscription and Direction Colors
Combination
External Painting
System Abbreviation color of arrow
coating color Text
& letter
Process Liquid System PL Yellow signal Red on Yellow Liquid
Process Gas System PG Yellow signal Red on Yellow Gas
Gaslif t Gas System GL Yellow signal Red on Yellow GL Gas
High Pressure Flar e S ystem BH Yellow signal Red on Yellow HP Flare
Blowdown Gas S ystem BD Yellow signal Red on Yellow BD Gas
Fuel Gas S ystem FG Yellow signal Red on Yellow Fuel Gas
High Pressure Vent S ystem VH Yellow signal Red on Yellow HP Vent
Low Pr essure Vent S ystem VL Yellow signal Red on Yellow LP Vent
Red on Yellow Closed
Close Drain System DC Yellow signal
Drain
Red on Yellow Open Haz.
Open Hazardous Drain System DH Yellow signal
Drain
Open Non-Hazardous Drain Red on Yellow Open
DN Yellow signal
System Drain
Instrument Air S ystem AI Grey Black on Grey Inst. Air
Utilit y Air S ystem AU Grey Black on Grey Utilit y Air
Nitrogen S ystem NT Grey Black on Grey Nitrogen
Lube Oil System OL Grey Black on Grey Lube Oil
Fire Water System FW Red Signal White on Red Fire Water
Sewage system SW Green White on Green Sewage
White on Green Drain
Drain Water System DR Green
Water
15.0 DOCUMENTATION INCLUDING CERTIFICATES AND RECORDS

A system of documentation and identification shall be established and maintained by the
Contractor and shall be issued with the final documentation after completion of work.
The documents shall include, but not be limited to the following:
a) Welding procedure specifications
b) Welding procedure qualifications
c) Welder/welding operator qualifications
d) List of welders including processes, materials and positions for which they are
qualified
e) List of welding procedures with details
f) Post weld heat treatment procedures
g) Post weld heat treatment records
h) Non-destructive testing (NDT) procedures
______________________________________________________________________

i) NDT operator qualifications
j) NDT records
k) List of NDT operators
l) Welding consumable handling procedures
m) Flux handling and recycle procedure
n) Repair procedure
o) Spool numbering list
p) Pressure test procedure
q) Pressure test records
r) Pressure test instrument calibration records
s) Records of any agreed concessions to the specified standards
t) Mill certificates
u) Welding consumables batch number list
v) Welding and NDT traceability records
w) Painting procedure
x) Painting inspection records
y) As-built red-line mark-ups
z) As-built drawings, including fabrication isometrics (with MTO’s).
______________________________________________________________________

11.MKS-112-TS-TP1-SP-05 - 0 - SP For PI Fabrication Install Inspection & Testing

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EXTENSION OF GAS COMPRESSION Doc.

SPECIFICATION FOR PIPING FABRICATION, Page 2 of 24

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Picture 1 – Location of MKS platform at White Tiger Oil Field

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IOM Installation and Operation Manual

ASME B16.25 Butt Welding Ends

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Document No. Title

2.0 MATERIAL REQUIREMENT

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Nominal pipe Letter height, mm

- Dimensions of warning color rings are to be as per below Table 14.2 .

SPECIFICATION FOR PIPING FABRICATION, Page 21 of 24

Table 14.2 – Dimensions of warning color rings

Nominal pipe diameter d, mm L, мм а, мм

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15.0 DOCUMENTATION INCLUDING CERTIFICATES AND RECORDS

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