NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES P.10

ERECTION AND TESTING OF STEEL PIPING

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

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INDEX

SECTION TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4

2.0 DEFINITIONS 4

2.1 Technical 4
2.2 Contractual 5

3.0 DESIGN 5

3.1 Codes and Standards 5

4.0 MATERIALS 6

4.1 Piping Materials 6

4.2 Piping Cleanliness 6

5.0 ERECTION 6

5.1 Flanged Joints 6

5.2 Flanged Connections to Rotating Equipment - Additional Requirements 6
5.3 Checks Prior to Installation 7
5.4 Handling 8
5.5 Installation 8

6.0 POST-WELD HEAT TREATMENT 8

7.0 INSPECTION 8

7.1 Prior to Testing 8

8.0 TESTING 9

8.1 General 9
8.2 Pipework to be Tested 9
8.3 Piping and Equipment Not Requiring Field Pressure Testing 10
8.4 Test Medium 11
8.5 Test Instrumentation 11
8.6 Hydrostatic Testing 11
8.7 Pneumatic Testing 12
8.8 Flushing 13
8.9 Post Test Activities 13
8.10 Certificates 14
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SECTION TITLE PAGE

9.0 DOCUMENTATION 14

9.1 Introduction 14
9.2 Schedules/Reports 14
9.3 Prior to Testing 14
9.4 Following Hydrotest 14

10.0 WARRANTY 15

Figure 1 Flange Alignment Tolerance 16

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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification details the requirements for the erection and testing of pressure and process
piping. Pressure testing of piping systems and integral components is carried out to ensure that
mechanical strength and tightness meet the system design requirements.

1.1.2 All piping shall be installed, inspected and tested in accordance with the latest edition of ANSI
B31.3, plus the additional requirements of this specification.

1.1.3 This specification applies to process and utility piping for refinery, onshore oil and gas
installations and processing facilities.

1.1.4 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.5 In the event of any conflict between this specification and any applicable code or standards, the
Vendor/Contractor shall inform the Owner in writing and receive written clarification from the
Owner before proceeding with the work.

1.1.6 This General Engineering Specification will form part of the Purchase Order/Contract.

1.1.7 For the erection and testing of oil and gas transmission pipelines, refer to GES R.04.

1.2 Other NOC Specifications

Where indicated in this specification, the following additional NOC Specifications shall apply:

GES P.01 - Piping Material Specifications

GES P.02 - Plant Piping Systems

GES P.09 - Steel Piping Fabrication (Shop or Field)

GES W.01 - Welding Procedure and Welder Qualifications

GES W.06 - Storage and Control of Welding Consumables

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Erection

The complete installation of a piping system in the locations and on the supports designated by the
engineering design, including any field assembly, fabrication, examination, inspection and testing
of the system, as required by the applicable code.
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Flammable

A liquid or gas which can be ignited and will continue to burn in air.

Components

Any of the parts which are incorporated into the piping system, including piping, tubing, fittings,
flanges, gaskets, bolting and valves, and special items.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the piping system and
components.

Vendor

The company supplying the piping systems and components.

Contractor

The main Contractor for a defined piece of work.

Sub-contractor

A company awarded a Contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the piping system
and components have been designed, constructed, inspected and tested in accordance with the
requirements of this specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or assigned Inspection

Authority, who verifies that the equipment has been designed, constructed, inspected and tested in
accordance with this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

Erection and testing of all piping shall comply with the following codes and standards:

ASME B31.1 - Power Piping

ASME B31.3 - Process Piping

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4.0 MATERIALS

4.1 Piping Materials

All piping materials (including gaskets) shall be as specified in GES P.01.

Prior to erection, the Vendor/Contractor shall ensure that all materials received at site comply with
the piping material specification and all applicable drawings. Checks to be carried out shall
include, but not be limited to:

(a) pipe diameter and schedule;

(b) flange rating and facing;

(c) valve type/tagging;

(d) gaskets and gasket material;

(e) bolts - materials, length, diameter;

(f) damage which may have arisen during manufacture, or may have been due to incorrect
handling or in transit;

(g) all material certificates supplied according to Purchase Order/Contract.

4.2 Piping Cleanliness

Prior to installation, the Vendor/Contractor shall ensure that all piping is cleaned internally. This shall
be achieved by a method which will not be detrimental to the piping material and shall be approved by
the Inspector.

5.0 ERECTION

5.1 Flanged Joints

5.1.1 Contact surfaces between flanges and gaskets shall be checked before assembly. Grease, oxides, sand
and dust shall be removed prior to assembly. Assembly shall be with clean unused gaskets. The use
of gasket sealing compounds or sealing agents is prohibited.

5.1.2 Non-asbestos fibre and spiral wound gaskets shall not be re-used.

5.1.3 Ring joint gaskets may be re-used after cleaning and inspection.

5.1.4 Flanged joints shall not be made without the use of gaskets. Where there is a risk of misalignment due
to weld shrinkage, flanges shall be coupled using temporary gaskets prior to welding.

5.1.5 Flange alignment tolerances shall be within the limits shown in Figure 1.

5.2 Flanged Connections to Rotating Equipment - Additional Requirements

5.2.1 The Vendor/Contractor shall prepare a detailed erection procedure which includes the piping erection
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sequence and methods to be employed in aligning flanges connected to rotating machinery. There shall
be a separate procedure for each category of rotating equipment.

These procedures shall include initial alignment, final cold alignment, final hot alignment and
adjustment of spring supports. These procedures shall be subject to the Owners approval prior to work
commencing.

5.2.2 During piping erection, the following points shall be observed:

(a) Field welding of make-up joints or of flanged connections shall be made progressively away from
the equipment nozzle.

(b) Piping connected to equipment nozzles shall be fully supported.

(c) If pipe spools have been prefabricated, at least two welds near the nozzle flanges shall be left for
final fitting and alignment.

(d) Piping connected to equipment nozzles shall not be subjected to any form of temporary restraint
which might result in "cold spring".

(e) Spring supports shall be locked in the "cold load" position during erection and testing.

5.2.3 During initial flange alignment, the following points shall be observed:

(a) Following erection, any misalignment between the equipment flange and the piping flange shall be
checked before making the connection.

(b) If misalignment between flanges cannot be corrected in the "cold" condition, local heating may be
permitted by the Owner on piping which does not require post-weld heat treatment, providing that
this is done under supervision and in such a way that the piping material does not suffer any
detrimental effects. Reference shall be made to the applicable welding material specification for
guidance on this matter.

5.2.4 Initial alignment of equipment nozzle flanges shall be completed before any final bolt tightening of
piping flanges near the equipment nozzles is carried out.

5.2.5 During final bolt tightening of piping/equipment flanges, a dial indicator shall be used to check any
misalignment of the machine-to-driver shaft caused by this activity.

5.2.6 On completion of tightening, the machine-to-driver shaft alignment shall be within 70% of the
tolerances allowed by the machinery manufacturer when the piping is both connected and
disconnected.

5.3 Checks Prior to Installation

5.3.1 Prior to the installation of piping, the Vendor/Contractor shall ensure that:

(a) Dimensions of prefabricated items are in accordance with piping drawings.

(b) Elevations on steel support structures and of equipment nozzles (vessels, exchangers, columns,
machines, etc) comply with piping drawings.

(c) That there will be no interference between piping to be erected and previously erected equipment
(piping, vessels, machinery, steel structures, etc).
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(d) That, in the case of underground piping, the depth of the trench (i.e. base of pipe elevation) is in
accordance with piping drawings.

5.4 Handling

5.4.1 During erection, it shall be the responsibility of the piping Vendor/Contractor to ensure that no damage
occurs to piping components.

This shall include, but not be limited to:

(a) Avoidance of damage to control valves, pressure relief valves, thermowells, level indicators and
controllers, etc.

(b) Avoidance of damage to pipe coatings through the use of incorrect handling.

(c) Avoidance of damage to pipe bevel ends, flange faces, etc.

5.4.2 Where any damage is noted to piping components, it shall be the responsibility of the piping
Vendor/Contractor to rectify any such damage.

5.5 Installation

5.5.1 Where temporary supports are used to assist in the installation of piping, they shall not be welded to the
pipe.

5.5.2 When the piping has been installed in its final position, all permanent piping supports shall be installed
and welding of field fit welds undertaken.

5.5.3 All field welding, including weld end preparation, fit-up and use of temporary erection aids and post-
weld heat treatment (where specified) shall be carried out in accordance with the piping welding
procedure specifications and with GES P.09.

6.0 POST-WELD HEAT TREATMENT (PWHT)

Where PWHT, in accordance with GES P.01 is required after fabrication, this shall be carried out in
accordance with GES P.09, Section 6.0.

This procedure shall take into consideration expansion of piping in fixed positions and allowances shall
be made to permit that expansion.

7.0 INSPECTION

7.1 Prior to Testing

7.1.1 Before any pressure testing is implemented, the following checks shall be carried out:

(a) The piping shall conform with the piping and instrumentation diagram (P&ID), the piping general
arrangement and the piping isometrics.

(b) That all required inspections and non-destructive examination have been satisfactorily completed.
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Inspection and NDE of welds made during field erection shall comply with the requirements of
GES P.09.

(c) That all pipe supports have been correctly installed.

(d) That the correct gaskets have been fitted and that all flange bolts have been installed and
tightened.

(e) That all valves, except those exempt from testing have been correctly installed.

(f) That, where the piping/supports have not been designed to take account of liquid loading,
additional temporary pipe supports have been installed.

(g) That all spring supports have been gagged and recorded.

7.1.2 Authorisation to test shall only be given when all of the above checklist items have been completed.

8.0 TESTING

8.1 General

8.1.1 Pressure testing shall be carried out in accordance with the applicable code (ASME B31.1 or ASME
B31.3), except as modified by this section.

8.1.2 Written authorisation to proceed with hydrotest shall be issued by the Vendor/Contractor's Inspector,
only following satisfactory completion of all inspections as detailed in Section 7.0. No hydrotesting
shall take place until this authorisation is issued.

8.1.3 All piping joints, including welded joints, shall be left unpainted and un-insulated until after
completion of field pressure testing.

8.1.4 Underground piping joints shall be left exposed until after completion of field pressure and leak testing,
unless partial backfilling is required for underground lines.

8.1.5 One test system may contain two or more lines.

8.1.6 Pressure testing shall be carried out in daylight under dry conditions to permit thorough inspection for
leaks.

8.1.7 Pressure testing on piping requiring post-weld heat treatment shall be carried out after the heat
treatment.

8.1.8 All pressure testing shall be carried out in the presence of the Owner and/or the Inspection Authority.

8.2 Pipework to be Tested

8.2.1 All new pipework sections (except as noted under Section 8.3) whether on-site, off-site, shop
fabricated or field run, shall be pressure tested.

8.2.2 Reinforcing pads shall be air tested and checked for leaks using soap solution.

8.2.3 Pipework modifications, including field welds of new to existing pipework, shall be pressure tested.
Under exceptional circumstances, the Owner may agree to waive the test and substitute other
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inspection tests (for example, under the circumstances described in ASME B31.3, paragraph 345.1 [c]),
subject to a minimum recommended level of inspection, thus:

- Ultrasonic test prior to cutting the pipe (design pressure above 40 barg and design temperature
above 212 °F (100 °C);

- 100% radiographic inspection of the welds;

- 100% magnetic particle or dye penetrant inspection of the welds.

8.2.4 Pipework modifications, where existing lines have flanges added to bolt in new sections, shall have the
new flanges pressure tested.

8.2.5 All uprated piping systems shall be pressure tested where the revised test pressure is greater than the
original test pressure.

8.2.6 Instrument take-off and sample system piping shall be tested up to the first block valve with the piping
system to which it is connected.

8.3 Piping and Equipment not Requiring Field Pressure Testing

8.3.1 The following piping components and equipment shall not be subjected to field pressure testing:

(a) Rotating equipment such as compressors, pumps and turbines.

(b) Equipment lined with chemically bonded castable materials, unless approval is given by the lining
manufacturer.

(c) Pressure relief equipment, such as pressure relief valves and rupture discs.

(d) Pressure vessels and exchangers.

(e) Equipment where the impact toughness requirements are unsatisfactory at the piping test
temperature.

(f) Equipment where the specified test pressure is less than that specified for the piping system under
test.

(g) Control valves which shall only be installed following completion of flushing operations in order
to avoid any damage caused by dirt, scale or debris. Temporary spool pieces may be installed in
place of these valves to facilitate testing and flushing, or the pipe ends may be blanked off using
blinds sufficiently thick for the test pressure.

(h) Equipment such as filters, driers, reactors, etc. containing chemicals which would be contaminated
by coming into contact with the test medium.

(i) Instruments, including in-line flow switches, pressure indicators, pressure gauges, level displacers
and level glasses. Temporary pipe spool pieces shall be installed in place of the instruments for
the purpose of testing.

(j) Strainers and filter elements.

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(k) Piping such as atmospheric vents, drains, discharge piping from pressure relief devices, sewers,
etc., which are normally open to atmosphere. Visual inspection shall be made to ensure that all
joints are properly connected.

8.3.2 All of the above, along with other equipment which the Owner considers unsuitable for pressure
testing, shall be removed or isolated from the system under test by means of suitable blinds.

8.4 Test Medium

8.4.1 For hydrostatic/hydraulic testing, the testing medium shall normally be inhibited potable water of a
quality which will not contaminate the system through deposition or corrosion.

8.4.2 Consideration should be given to the use of corrosion inhibitors, oxygen scavengers, biocides or any
other chemicals where, because of local conditions or delayed drainage and drying after the test, there
is a possibility of an adverse reaction.

8.4.3 Any piping system containing austenitic stainless steel shall be tested with potable water with a
maximum chloride concentration of 30 ppm. The line shall immediately be drained and dried by
blowing with air.

8.4.4 Where the Owner considers that water may be unsuitable for testing in that it might be detrimental to
the piping material or be incompatible with the process fluid, an alternative test medium shall be
chosen. For example, lube and seal oil systems for rotating machinery that could be damaged by the
presence of water can be tested with lube oil. If a flammable liquid is selected, the flashpoint shall be
above 122 °F (50 °C).

8.4.5 For pneumatic testing, the test medium shall be clean, dry air or nitrogen.

8.5 Test Instrumentation

8.5.1 All indicating gauges for use in pressure testing shall be individually identified and calibrated against
either a dead weight tester or a calibrated master gauge.

8.5.2 Gauges shall be recalibrated and certified at any time when there is a reason to believe that they are in
error, but at least every six months or 10 uses, whichever is more frequent.

8.5.3 Indicating pressure gauges for use in testing shall preferably have dials graduated over a range of
approximately double the intended maximum test pressure, but in no case shall the range be less than
1.5 times that pressure.

8.5.4 Calibration records for gauges used for pressure testing shall be provided to the Inspector.

8.6 Hydrostatic Testing

8.6.1 The test gauge shall be installed at the low point of the piping system. Where this is not visible to the
test operator, an additional gauge shall be installed in a position visible to the operator.

8.6.2 All vents shall be open during filling to ensure that all air is expelled prior to applying test pressure.

8.6.3 All valves shall be in the "open" position. Testing against closed valves is not permitted.

8.6.4 During hydrotesting, the metal temperature shall not be less than 35 °F (2 °C), unless antifreeze
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solution is used. The requirements of ASME B31.3 345.2.1.c shall be adhered to.

8.6.5 The test pressure shall be in accordance with ANSI B31.3, i.e. test pressure shall be 1.5 times the
design pressure.

8.6.6 The test pressure shall be applied gradually.

8.6.7 On reaching the test pressure, it shall be held for three hours during which time all joints shall be
inspected for any sign of leakage.

8.6.8 Care shall be taken to ensure that the pressure remains constant during the test. When conditions
require that a pressure test be maintained for a period of time, during which the test medium would be
subject to thermal expansion, provision shall be made for the relief of excess pressure.

8.6.9 If any repairs are found to be necessary during or subsequent to hydrostatic testing on components
forming, or attached to pressure parts, the pressure containing component shall again be subjected to
the pressure test after any repairs and after any required post-weld heat treatment.

8.7 Pneumatic Testing

8.7.1 Pneumatic testing shall only be applied where hydrostatic testing is neither feasible nor desirable. The
potential risks associated with pneumatic testing should be understood and adequate safety precautions
taken to ensure that the agreed test pressure cannot be exceeded and that test temperature is carefully
considered, ASME B31.3 345.5.1.

8.7.2 The test pressure shall be in accordance with ASME B31.3, subject to a maximum of 1.1. times design
pressure, ASME B31.3 345.5.2/345.5.4.

8.7.3 Because of the hazardous nature of pneumatic testing, the Vendor/Contractor shall prepare and submit
a detailed test procedure to the Inspector for approval, prior to the commencement of any testing. The
test procedure shall include, but not be limited to, the following points:

(a) The test medium normally used shall be clean dry air. Nitrogen may be used where air is not
acceptable. Note that special care is needed to avoid accidental overpressure when using a source
of high pressure nitrogen.

(b) When large diameter, low pressure systems (e.g. flare rings) are to be tested, the surrounding area
must be sealed off and entry permitted only to authorised personnel.

(c) The system shall be pressurised to 25 psig (1.70 barg) and a preliminary leak test performed.

(d) The pressure shall be applied in gradual stages of no more than 10% of test pressure, allowing
sufficient time between each increase to permit equalisation of piping stresses.

(e) The pressure shall be increased until the agreed test pressure is reached and then held for 10
minutes.

(f) The pressure shall be reduced to design pressure and all joints fully inspected using soap solution
to ensure freedom from leakage.

(g) Reducing the pressure to atmospheric shall also be carried out in a gradual, controlled manner.
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8.7.4 Pneumatic testing and leak testing, using air and soap solution, shall be applied to the following items:

(a) Reinforcement plates at nozzle connections to the run pipe.

(b) Strip or panel lining of pipes.

(c) Pipeline road crossing tight sleeves.

(d) Testing of re-made flanged or screwed joints after hydrotesting.

(e) Testing of a completed component where hydrotesting is not desired or is additional to

hydrotesting.

Note:

Reinforcement plates and lining panels require that they be furnished with a drilled and tapped hole
suitable for both venting the air gap during welding and for subsequent leak testing.

8.7.5 Instrument air piping and tubing shall be pneumatically tested using clean, dry instrument air.
Hydrostatic testing is not permitted.

8.7.6 For instrument air supply lines, the minimum test pressure shall be 90 psig (620 kPag) and for
transmission systems it shall be 20 psig (138 kPag), but if possible these shall be tested to 1.1 x design
pressure.

8.7.7 Pneumatic testing of spiral welded pipe is prohibited.

8.8 Flushing

8.8.1 On completion of hydrotesting, all piping systems shall be flushed through until they are clear of all
debris and loose scale. The medium used for flushing shall generally be the same medium as that used
for testing.

8.8.2 Immediately following hydrotesting and flushing, all piping systems shall be drained and blown dry
using compressed air.

8.8.3 During hydrotesting and flushing operations, a strainer shall be fitted into the water supply line to
prevent the ingress of foreign matter being introduced into the system.

8.8.4 Where process lines are to be flushed into vessels this shall be done prior to final cleaning of vessels.

8.8.5 Prior to installation of steam traps, all steam lines shall be blown through. This is additional to
flushing.

8.8.6 Piping containing soft seated valves shall be flushed and drained before the valves are installed.

8.9 Post Test Activities

8.9.1 Following successful testing of the piping system, the following activities shall take place:

(a) remove all test blinds;

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(b) remove any approved temporary gaskets and install specification gaskets;

(c) remove any temporary spool pieces and install any valves left out for testing.

The Vendor/Contractor shall leave the tested systems in the status previously agreed with the Owner.
The reinstallation of control valves, safety valves, filters, etc., will be according to prior agreement
with the authority responsible for commissioning.

8.10 Certificates

On completion of each system test, the Vendor/Contractor shall generate a test certificate detailing all
applicable data which shall be signed by the Vendor/Contractor's employee responsible for supervising
the test, the Owner's representative and/or the Inspection Authority.

9.0 DOCUMENTATION

9.1 Introduction

This section covers the documentation requirements for erection, inspection and field testing of
pressure and process piping.

9.2 Schedules/Reports

The Vendor/Contractor shall supply with his tender a schedule showing submission of all documents
for review and approval, proposed sub-contractors and an erection programme.

The Vendor/Contractor shall submit with its tender a Quality Plan for the project.

Weekly progress reports shall be submitted to the Owner.

9.3 Prior to Testing

Prior to testing being undertaken, the following documentation is required to be supplied to the
Inspector:

(a) hydrostatic or pneumatic test procedure approved by the Owner;

(b) all documentation relating to the fabrication and erection of piping showing that all of the required
tests and inspections have been satisfactorily completed;

(c) authorisation to hydrotest;

(d) pressure gauge calibration certificates.

9.4 Following Hydrotest

During testing, records shall be made of each piping system which shall include the following
information:

(a) date of test;

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(b) identification of piping and equipment tested with the system;

(c) test medium;

(d) test pressure;

(e) minimum ambient and test medium temperature.

Following completion of testing, the Pressure Test Certificate shall be completed and signed by the
Vendor/Contractor, the Owner and/or the Inspection Authority.

10.0 WARRANTY

The Vendor/Contractor shall warrant all equipment, materials and services supplied against any defect
for a period of 12 months after commissioning or 24 months form the date of delivery to the site,
whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.

Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified by the Purchase Order/Contract.