S0442 GPS L XXX SP 0005 - 0 - Specification For Piping Fabrication and Installation

HOANG LONG JOINT OPERATING COMPANY LTD
TGT FIELD DEVELOPMENT
Document Title: SPECIFICATION FOR PIPING

FABRICATION INSTALLATION AND
TESTING
GPS Document No.: S0442-G PS-L-XXX-SP-0005
Client Document No.:
~ ., 1-
0 23-Feb-10 Approved For Construction '¥~B )f DP SLl"V

i!fV
C1 25-Feb-09 Reissued For Design TS DP JM
C 20-Feb-09 Issued For Design TS DP JM
B 13-Feb-09 Issued For Approval TS DP JM
A 30-Jan-09 Issued For IDC TS DP JM
REV DATE DESCRIPTION BY CHECKED APPROVED CLIENT

---- ---
CLIENT: CLIENT REF:
Hoang Long Joint Operating Company XXXX

CONTRACTOR: GPS REF:
Global Process Systems Pte Ltd S0442

GLOBAL PROCESS SYSTEMS PTE LTD Document No. : S0442-GPS-L-XXX-SP-0005
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SPECIFICATION FOR PIPING FABRICATION Page : 2 of 42
INSTALLATION AND TESTING
TABLE OF CONTENTS
1.0 SCOPE 4
2.0 SPECIFICATIONS, CODES, STANDARDS AND REGULATIONS 4
3.0 FABRICATION REQUIREMENTS OF PIPEWORK 5
3.1 General Requirements 5
3.1.1 Bends 6
3.1.2 GRE Piping Bonding 6
3.1.3 Fabrication Tolerance 7
3.1.4 Construction Marking 7
3.2 Welding 7
3.2.1 Welding Procedure Qualifications and Welder Qualifications 7
3.2.2 Welding Procedures and Processes 8
3.2.3 Filler Materials, Electrodes, Wire, and Flux 9
3.2.4 Fabrication and Welding Joint Preparation, Spacing and Alignment 10
3.2.5 Weld Contour and Finish 11
3.2.6 Butt Welds for Orifice Rums 11
3.2.7 Other Requirements 11
3.2.8 Heat Treatment 11
3.3 Non Destructive Testing (NDT) Requirements 12
3.3.1 General Requirements 12
3.3.2 Radiographic Tests 14
3.3.3 Acceptance Criteria 14
3.3.4 Ultrasonic Testing (UT) 14
3.3.5 Magnetic Particle Inspection (MPI) 14
3.3.6 Dye Penetrant Inspection (DPI) 15
3.3.7 Acceptance Criteria 15
3.3.8 NDE Operator Qualifications 16
3.3.9 Pressure Testing 16
4. INSTALLATION REQUiREMENTS 16
4.1 General 16
4.2 Piping Erection 17
4.3 Erection of Tie Ins to Equipment 18
4.4 Installation of Valves 18
4.5 Installation of Threaded Assemblies 19
4.6 Make Up of Flanged Assemblies 19
4.7 Insulating Flanges 20
4.8 Gaskets 20
4.9 Installation of Line Blinds, Spectacle Blinds and 20
5.0 INSPECTION AND TESTING REQUIREMENTS 21
5.1 Additional Quality Verification Inspections 21
5.1.1 General 21
5.1.2 Visual Inspection 21
5.1.3 Hardness Test 21
5.1.4 Radiographic Examination 22
5.1.5 Magnetic Particle Examination 22
5.1.6 Repairs for GRE Piping 22
5.1.7 Repairs 22
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5.1.8 Traceability Requirements 23

6.0 PROTECTIVE COATINGS 23
7.0 FLUSHING 23
7.1 General 23
8.0 HYDROSTATIC PRESSURE TEST 25
8.1 General 25
8.2 PREPARATION FOR FLUSHING AND HYDROTESTING 27
8.3 MATERIALS AND EQUIPMENT 28
8.4 HYDROTEST FLUID 28
9.0 Alternative Testing Methods 30
9.1 SYSTEM SERVICE TEST 30
9.2 OTHER TESTING 33
10.0 TEST RECORDS 33
11.0 RETESTING 33
12.0 COMPLETION OF PRESSURE TESTS 33
13.0 CHEMICAL CLEANING 34
13.1 General 34
13.2 Extent of Chemically Cleaning 34
13.3 Chemical Cleaning of Carbon Steel Piping 36
13.3.1 Degreasing 36
13.3.2 Chemical Cleaning 36
13.3.3 Neutralisation 36
13.3.4 Passivation 36
13.3.5 Water Flushing 37
13.3.6 Drying 37
13.3.7 Inspection 37
13.3.8 Protective Coating/Preservation 37
13.4 Chemical Cleaning of Stainless Piping 37
13.4.1 General 37
13.4.2 Removal of Dirt, Degreasing 37
13.4.3 Chemical Cleaning 38
13.4.4 Water Flushing 38
13.4.5 Drying 38
13.4.6 Inspection 38
13.4.7 Protective Coating / Preservation 38
13.5 Hot Oil Flushing 38
13.5.1 General 38
13.5.2 Flushing Oil 38
13.5.3 Cleanliness of Hydraulic Oil Systems 38
13.5.4 Cleanliness of Lubricating Oil Systems 39
13.5.5 Cleanliness of Seal Oil Systems 39
13.6 Hook-Up Piping 39
13.7 Relngress of Contaminants 39
14.0 PREPARATION FOR SHIPPING AND STORAGE 39
15.0 WARRANTY 40
16.0 DOCUMENTATION INCLUDING CERTIFICATES AND 40
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1.0 SCOPE
This Specification defines the minimum requirements for piping fabrication, erection
and installation and testing which shall be followed in the TGT Field Development
project.
This specification does not cover the following:

1. All instrument control piping downstream of the last piping block valve
2. Risers below the hanger flange and sub-sea pipework
3. Sanitary piping systems
4. HVAC piping within E-House.
2.0 SPECIFICATIONS, CODES, STANDARDS AND REGULATIONS
The latest edition of the below listed documents are applicable:
S0442-GPS-L-XXX-SP-0001 Specification for Piping and Valve Materials

S0442-GPS-L-XXX-SP-0002 Specification for Piping Design
S0442-GPS-L-XXX-SP-0004 Specification for Piping Supports
S0442-GPS-L-XXX-SP-0006 Specification for Insulation
S0442-GPS-M-XXX-SP-0014 Specification for Painting and Protective Coating
ASME 831.3 Process Piping
ASME 831.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other
Liquids
ASME 8 31.8 Gas Transmission and Distribution Piping Systems
ASME 816.5 Pipe Flanges and Flanged Fittings
ASME 816.47 Large Diameter Steel Flanges
API RP14E Recommended Practice for Design and Installation of Offshore
Production Platform Piping Systems
ASME VIII Pressure Vessel and 80iler Code (Div 1 & Div 2)
API-RP-2A Planning, Design and Constructing Fixed Offshore Platforms
API RP-520 Sizing, Selection and Installation of Pressure Relieving Devices in
Refineries.
API 660 Shell and Tube Heat Exchangers.
ASME 81.1 Unified Inch Screw Threads
ASME 81.20.1 Pipe Threads, General Purpose
ASME Sec V Nondestructive Examination
ASME Sec IX Welding and 8razing Qualifications
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3.0 FABRICATION REQUIREMENTS OF PIPEWORK
3.1 General Requirements
Piping fabrication, welding, inspection, testing and heat-treating shall conform to this
Specification and ASME 831.3, 831.4 & 831.8 wherever applicable. The piping
includes pipe supports welded to the pipe.
Fabrication, welding procedures, and welder qualifications shall be in accordance with

ASME 831.3, 831.4 & 831.8 whichever applicable except as modified by this
Specification.
Minimum spacing of circumferential welds between centre lines shall be minimum two
(2) pipe diameters or 6" whichever is less. In restricted circumstances minimum
spacing shall not be less than four (4) times the wall thickness or one inch (1")
whichever is the greater.
All metallic piping 1-1/2" and smaller for hydrocarbon service shall be butt welded.
Threaded and socket weld piping shall be restricted to non hydrocarbon piping
service. Other than flanged connections, only approved mechanical joints shall be
used. Threaded connections shall be gauge/checked, or chased after welding or heat
treatment. Seal welding of threaded connections is prohibited. If approved, seal
welding shall be accomplished in accordance with ASME 831.3.
Thermowells, caps and plugs on vents and drains, shall not be seal we.lded.
All small bore fitting branch welding shall be performed by Gas Tungsten Arc Welding
(GTAW).
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.
Dimensional tolerances shall be as per APPENDIX 1, "Piping Fabrication tolerances".

Piping designed for pigging operations shall have 3D radius bends, unless otherwise
specified.
Material Certification as per specification shall be reviewed by the

Vendor/Contractor's QAlQC personnel before use of any pipe or fittings or flanges for
fabrication. 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.
All free issue materials shall be identified and stored separately in the Fabricator's
yard.
All pipe spools shall be tagged as indicated in the piping isometrics and shall be
tracked at all stages of fabrication, NOT, painting etc. to its exact location in the
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fabrication yard. All pipe supports shall have a unique tag which is tracked at all
stages of fabrication and painting to its exact location in the fabrication yard.
Prefabricated pipe spools shall be cleaned, painted (if required) and preserved prior
to installation.
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 Bends
Cold-formed pipe bends are not permitted.
Hot-formed pipe bends are acceptable with the following requirements; the pipe wall
thickness at the thinnest point after bending, less the corrosion allowance, shall not
be less than the calculated thickness required for the pressure and temperature; pipe
bends shall be free from cracks, wrinkles, and bulges after bending and heat
treatment; weld repair of cracks in pipe bends is not acceptable.
Bends made to a radius less than five times the outside pipe diameter shall be made
either above 590°C for carbon steel and 930°C for stainless steel, or shall require
heat treating. After hot bending, bends shall be cooled in still air.
Galvanised pipe shall not be bent, or welded. Such piping requiring bending or
welding shall be galvanised after fabrication.
Mitre bends shall not be used unless approved by the Company.
Only 1.50 radius bends (elbows) shall be used, without prior Company approval.
Centre line radius of shop pipe bends shall be at least equal to three (3) times the
nominal pipe diameter. All pipe bends shall be accomplished in accordance with
ASME B31.3.
3.1.2 GRE Piping Bonding
General
GRE piping and fittings shall be designed, fabricated and installed according to ASME
B31.3 code, except as stated elsewhere in this Specification. All pipe installation and
fabrication must be in strict accord with the pipe manufacturer's recommendations.
Bonded Joints
All materials used in the GRE joint system shall be compatible with the service and
the piping system and shall be applied in strict accordance with the pipe
manufacturer's recommended installation procedures. As a minimum, these
considerations shall include adhesives, resins, glass and curing agents; ambient
temperatures and weather conditions for pipe assembly; curing methods and times;
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fitting up, joint preparations and assembly techniques; material handling and support;
and workmanship testing and inspection.
Tools recommended by the pipe manufacturer, especially those for pipe joint
preparation, must be used.
All pipefitters who fabricate GRE piping and fittings and flanges must be trained by
the pipe manufacturer and must be certified by the manufacturer within 1 year prior to
the pipefitting.
Fabricator shall certify all procedures by testing in accordance with ASME 831.3.
3.1.3 Fabrication Tolerance
Fabrication tolerance shall be as defined by ASME 831.3 and Appendix 1.
3.1.4 Construction Marking
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.
3.2 Welding
3.2.1 Welding Procedure Qualifications and Welder Qualifications
General
All welding procedures shall be as per ASME Section IX and shall be submitted to
Company for approval. Procedure qualifications shall be completed and submitted to
Company for Approval prior to starting fabrication.
All welding procedures shall be identified by number and shall be referenced on all
fabrication drawings. Details of welding procedures qualification tests, including test
results, shall be submitted to Company for review and approval prior to starting
fabrication. Company may choose to witness such qualification tests.
Welders and welding operators shall be qualified per ASME Section IX prior to
fabrication and records shall be made available to Company upon request.
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Cleaning shall be done in a manner that will not lead to contamination of the weld or
adjoining base metal. Cleanliness shall be maintained after completion of welding.
Stubs, rods, flux, slag and foreign material shall be removed from the equipment or
piping.
The welding procedure tests shall demonstrate that all details are satisfactory for
obtaining full penetration welds for the following types of joints:
• Double-welded longitudinal and circumferential butt joints.

• Single-welded circumferential and longitudinal butt joints made without a
backing ring.
For inert gas tungsten arc and inert gas metal arc process, the qualification record
shall include the composition and flow rate of inert gas backing when used.
The SAW procedure qualification test report shall show the name of the manufacturer
and the trade name of the wire and flux used to qualify the procedure.
Low Temperature Service Welds
For low temperature service DOC 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.
The impact test shall be performed in accordance with ASME 831.3. The lateral
expansion shall be reported if required.
3.2.2 Welding Procedures and Processes
(a) General
Welds shall be made by one of the following processes:
Shielded metal arc (SMAW)
Gas tungsten arc (GTAW)
Gas metal arc (GMAW)
Submerged arc (SAW)
Restrictions to the above are listed below.
Semi-automatic or fully automatic welds shall be made with a multi-pass technique.
All other welding processes, including flux-cored processes, shall be submitted in

writing for Company approval. If flux-cored arc welding (FCAW) is allowed, it shall be
done only with gas-shielded electrodes. Additional FCAW restrictions are that vertical
downhill is not allowed, short circuiting arc is not allowed, electrode diameters shall
not exceed 3.2mm and wind velocities shall not exceed 8km/h in the weld area.
Welding processes shall be identified by number. The identification number shall be

referenced on all fabrication drawings.
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Welders and welding operators shall have been qualified within six (6) months prior to
the start of fabrication in accordance with B&PVC Section IX, Welding and Brazing
Qualifications. Qualification records shall be submitted to the Company for approval.
Backing rings shall not be used unless specifically approved by the Company.
Consumable inserts may be used if approved by the Company prior to fabrication.
(b) Short Circuiting Arc GMAW Process
The short-circuiting arc GMAW process may be used for root pass welding only. It
shall not be used on weldolets, reinforced nozzles and branch welds, couplings, slip-
on flanges, socket welds and other attachments. Wind velocities shall not exceed
8km/h in the weld area.
(c) Gas Tungsten Arc Welding Process
If low hydrogen SMAW electrodes are unsuitable for producing a weld of acceptable
quality, the GTAW process or cellulosic SMAW electrodes shall be used for root
passes on single welded butt joints.
An internal gas purge shall be used for the root pass and second layer of autogenous
and stainless steel welds.
(d) Submerged Arc Welding
No SAW passes shall be greater than 9.5mm thick and all SAW welding shall be
multi-pass.
3.2.3 Filler Materials, Electrodes, Wire, and Flux
The deposited filler metal shall match the nominal analyses and physical properties of
the base material when similar metals are welded. Alloyed welding material
(manganese and silicon) shall not be used. When metals of different nominal
analyses or physical properties are to be joined by welding, Fabricator is to supply to
Company the welding procedure for approval prior to fabrication.
Where impact testing is required, the filler metal for welds shall meet the same impact
test requirements as the base metal.
Exceptionally high strength welds or excessively alloyed welds are not acceptable.
Filler metal for welding similar materials shall be of the same nominal analysis as the
base metal.
Low carbon grades of austenitic stainless steels shall be joined with low carbon weld
metal of corresponding composition.
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All welding consumables shall be low hydrogen consumables unless otherwise

approved. Filler metal for joining carbon steels to stainless steels shall be E390L,
except in services over 260°C, where Inco 182 shall be used.
In low temperature service, filler metal for welds shall meet the same impact test
requirements as the base metal. The composition of SAW weld wire shall match the
composition of the parent metal. Alloy agents added through the flux are not
acceptable.
Welding products shall be used within the limits recommended by the manufacturers.
For pressure containing welds, the following electrode classifications are not
acceptable:
E6012, E6013, E7014, E7020, E7024 and E8013-82.
Electrodes, filler wires and fluxes shall be kept clean, dry and properly stored
according to manufacturer's recommendation. Electrodes, filler wires or fluxes that
are damp, greasy or oxidized shall not be used.
Austenitic stainless steel weld deposits shall have a ferritic content of 3-10%. One
deposited weld metal sample shall be taken for every 30 linear meters of welding and
shall be checked for carbon, chromium, nickel, silicon, molybdenum, manganese and
niobium content. These analyses shall be used to determine the ferrite content by the
Schaeffler Diagram. When approved by the Company, the Ferritascope may be used
as an alternative method to verify ferrite content. Ferritascope must be used prior to
weld heat treatment.
3.2.4 Fabrication and Welding Joint Preparation, Spacing and Alignment
(a) Edge Preparation

Weld bevels shall be suitable for the welding process selected. The contour shall
permit complete fusion throughout the joint. The bevel shall conform to the bevels in
the procedure qualification tests.
Weld bevel shall be made by machining, grinding or thermal cutting. The surface shall
be reasonably smooth and true. Materials that require preheat for welding shall be
preheated in the same manner for thermal cutting or gouging.
Surface to be welded shall be clean and free from paint, oil, dirt, scale, oxides, and
other material detrimental to welding.
(b) Spacing and Alignment

The Vendor/Contractor shall use line-up clamps for butt welds in piping system.
Strongbacks and welded lugs are prohibited. Butt weld alignment shall satisfy the
requirements of ASME B31.3 and the requirements that are qualified in the weld
procedure qualification test.
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Misalignment shall not be corrected by cold working (i.e. deformation beyond the yield
point) unless a subsequent Company approved heat treatment procedure is applied
prior to welding.
3.2.5 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. Peening is not permitted.
3.2.6 Butt Welds for Orifice Rums
When the design of an orifice run necessitates welds, these shall be ground smooth
and flush with the inside of the pipe. Pipe-tap connections where required, shall be
drilled through the pipe wall and be smooth inside.
3.2.7 Other Requirements
No permanent backing rings shall be used. Consumable inserts are not classified as
backing rings, and thus may be used for all applications. Chemistry of the insert shall
match the base-metal chemistry.
Semi-automatic or full-automatic welds shall be made with a multi-pass technique.
GMAW welding process for other than root pass must be reviewed and approved by
Company.
Arc burns shall be removed by grinding or by cutting out a cylindrical section of pipe
and replacing with an undamaged spool. Grinding is permitted only if sufficient wall
thickness remains after grinding to sustain the pressure in the corroded condition.
The gap between the socket weld component and pipe end shall be approximately
1/16" to avoid "bottoming" which could result in excessive weld stress.
Minimum of 2 passes is required for all types of fillet welds on pressure containment
components, e.g. socket weld fittings.
All flange bolt holes shall straddle normal horizontal and vertical centre lines of the
pipe, except where connecting to equipment dictates otherwise.
3.2.8 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.
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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 831.3.
Post-weld heat treatment shall be as per ASME 831.3 or as required by Company.
Surface Protection
Machined surfaces shall be protected by a suitable compound to prevent damage
from scaling during heat treatment.
Supports
During heat treatment, piping shall be properly supported in the furnace to minimize
warping and other distortion.
Preheating Temperature
The minimum pre-heat temperatures for thermal cutting, welding and tack welding
shall be as specified in ASME 831.3.
Post Weld Heat Treatment

Post weld heat treatment shall be in accordance with ASME 831.3.
Carbon steel piping in process service that does not require post weld heat treatment
under ASME 831.3 Code shall be subject to weld metal hardness testing.
Exothermic Heat Treatment

Heat treatment may be by the exothermic method if the exothermic materials are
designed for the application and if consideration is given to the thickness of the piping
and the configuration of components being heat-treated.
The process and materials for exothermic treatment shall be subject to approval by
the Company. The Vendor/Contractor shall demonstrate successful past experience
in using the materials on the specified size of pipe and wall thickness.
3.3 Non Destructive Testing (NOT) Requirements
3.3.1 General Requirements
All examinations inclusive of in-process examinations shall be carried out in full

compliance with requirements specified in ASME 831.3 and this specification and any
other requirements covered by Company General Specifications referenced herein.
Castings shall be inspected as per ASME 831.3 and the listed standards therein.
Weld examinations shall be performed in accordance with the following standards:

a) Visual ASME Section V, Article 9
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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 AWS 01.1 Section 6.0, Part F
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:
• NOT Group 1 Non FlammablelToxic Fluids - including Open Drain

systems, fabricated from carbon steel or Austentic stainless steel materials
with a MDMT >= -29° and a maximum design temperature of 185° C,
• NOT Group 2 All Systems eXcluding Systems categorized as NOT
Group 1 for ASME flange ratings <=300LB
• NOT Group 3 All Systems for ASME flange ratings >=600LB
NOT Connection Visual Volumetric Surface

Group Type Examination (RT/UT) (MPI/DPI)
1 Buttwelded 1000/0 10% 10%
2 Buttwelded 100% 10% 100%
3 Buttwelded 100% 1000/0 1000/0
Angular branch welds shall be examined to the same degree as buttwelded

connections. Branch connections, socket welds, O'lets, shall be subject to visual and
surface NDE as above.
For 100/0 NDE, progressive examination shall be applied according to ASME B31.3
341.3.4.
The interpass temperature shall be measured within the joint level. The minimum
interpass temperature shall not be less than the specified preheat temperature. The
maximum interpass temperature shall not exceed the highest of maximum qualified or
as stated below:
0
• 250 e for carbon steels;
0
• 150 e for stainless steels
• e
1000 Nickel base alloys, Duplex & Super Duplex Stainless Steels
The weld level of O-Iets shall be completely filled up to weld line on the O-Iets.
Smooth transition between the pipe and the O-Iets is required. Notches below the
weld line shall be avoided. Prior to welding, sufficient root gap shall be ensured.
PWHT of welds shall be as per ASME B31.3.

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3.3.2 Radiographic Tests
First 2 welds by each welder shall be fully radiographed. Spot radiography shall then
be performed on a minimum of one shot on one weld in each 20 welds for each
welder on the following piping:
1) Water
2) Air
3) Atmospheric drain lines
The length of film for each weld shall be 250 mm (10") or half the pipe circumference
whichever is less.
3.3.3 Acceptance Criteria
Acceptance criteria based on visual inspection, radiography, and other types of

examination shall be per ASME 831.3, with the following modifications:
1) The internal weld protrusion on lines subject to pigging operations shall not
exceed 1/16"
2) Orifice-flange butt welds shall be internally ground smooth and flush
3) Any other Company specified criteria e.g.- severe cyclic service criteria for
specific fluid service piping
Acceptance criteria for castings and welds shall be as stated in the engineering
design and ASME 831.3 as applicable for cyclic, sever cyclic or high pressure
service.
3.3.4 Ultrasonic Testing (UT)
UT of welds shall be carried out in accordance with ASME 831.3 Section 344.6 and
ASME V article 5.
UT shall not be performed on thickness less that 12.5mm or where scanning surface
pipe diameters are less than ON 100.
On branches, weldolets and similar geometry's, scanning from the internal surface of
the branch shall be carried out wherever practical.
3.3.5 Magnetic Particle Inspection (MPI)
MPI shall be carried out in accordance with the requirements of ASME 831.3 or
ASTM E709.
The AC electromagnetic yoke technique shall be used with either black ink on white
background or UV fluorescent ink. Dry powders shall not be used.
The magnetizing field shall be applied continuously during examination. A minimum

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of 4 seconds shall be allowed for particle migration before examination.
Examination shall be carried out with the yoke both parallel and transverse to the axis
of the weld.
A.C Yokes shall be capable of lifting a carbon steel weight of 10 Ibs (4.5 kg).
The operator shall demonstrate the effectiveness of the technique being adopted on
any weldment by the use of a Penetrameter (e.g. Berthold, Setting 2/Burmah Castrol)
and portable field strength meters.
The magnetic flux density shall be 0.72 Telsa minimum.
All indications found by this examination technique shall be investigated. Light

surface grinding may be carried out before or during MPE to provide a satisfactory
surface finish on which to carry out the test or to assist the operator in the
interpretation of any possible indication.
3.3.6 Dye Penetrant Inspection (DPI)
Dye penetrant inspection shall be in accordance with ASME V article 6.
3.3.7 Acceptance Criteria
The acceptance criteria for finished welds shall be as follows:
Visual! MPI : as per ASME B31.3, Table 341.3.2A Normal Service conditions.
UT
For all classes, all indications producing a response equal to or greater than 20%
DAC (14dB), shall be investigated.
All defects classified as liner defects, lack of fusion or lack of penetration shall be
rejected.
All indications producing a response greater than 50% DAC shall be reported.
Defects, other than linear defects, lack of fusion or lack of penetration producing
responses greater than 100% DAC shall be rejected if the linear dimensions exceed a
cumulative length of t in any length of 2t.
Single Point Reflectors (Indications, which show, pattern 1 behavior in both directions
as per BS 3923 Appendix L).
• If separated by a distance of 25mm or greater - acceptable regardless of

amplitude
• If separated by a distance of less than 25mm - indications with an amplitude
greater than 100%> DAC shall be reported
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3.3.8 NDE Operator Qualifications
NOE examination personnel shall be qualified in accordance with PCN/CSWIP/ASNT

requirements. The minimum acceptable qualifications shall be :
ASNT/PCN Radiography (welds) :

• Technicians (level 2)
• Interpreters (RT interpreter level 2)
ASNT/PCN Ultrasonic Practitioner (welds) :

• Operators (level 2 for the relevant joint categories to be tested)
• Supervisors (level 3)
ASNT/PCN Magnetic Particle and Penetrant Practitioners:

• Operators (level 2)
For any testing frequency less than 100%> e.g. 1 in 10, the stated frequency shall be
applied on a per system basis, or a representative sampling method.
If at any time examination or NOE carried out in accordance with this specification
reveals the presence of cracking in a welded joint including HAZ, the applicable
welding procedure shall be withdrawn until such time as the cause has been
established and appropriate modifications made to the procedure.
All NOE shall be carried out after any applicable post weld heat treatment, and 48
hours minimum after welding.
3.3.9 Pressure Testing
On completion of fabrication and NOT, pressure testing shall be carried out as

detailed in 'Inspection and Testing Requirements'
4. 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
NOT 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
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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 Piping Erection
Pipe shall be free of all internal loose rust, scale, soil and debris before assembly.
Every precaution shall be taken during erection to prevent foreign matter from
entering the piping system. Protective covers shall not be removed until final
assembly is imminent.
Chains shall not be used for handling pipe spools, valves or associated piping
attachments. Only certified rope or webbed slings shall be used.
All piping shall be installed in accordance with approved Company drawings. The
Vendor /Contractor shall provide adequate break-out points for removal of pipe
sections in socket weld construction, even though such break-out are not shown on
the piping drawings.
Modifications to pipe routing may be necessary to avoid interference. The Company

shall approve such modifications. The modifications shall be reflected on 'as-built'
record drawings marked up by the Vendor/Contractor. Modifications to any critical
lines for stresses and/or associated supports shall be approved by the Company prior
to commencement of the modification.
Cold springing or forcing of piping for the purpose of joint make up is not permitted
unless approved by the Company.
For GRE piping the pipe manufacturer, Contractor and Company shall review and
approve all piping layouts for suitability of piping flexibility and support. All types of
supports shall be in accordance with pipe manufacturer's recommendation.
Valves and heavy components shall be independently supported or suspended at all

times to prevent excessive torque, bending and longitudinal stresses being
transmitted to or carried by the pipe system.
Where it is necessary for the pipe to move about the support, suitable slip pads shall
be provided to prevent wear.
For the site run piping system the Contractor shall submit to Company for approval
suitable sketch plan showing proposed pipe run, pipe support locations and pipe
support types proposed.
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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.
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.
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4.5 Installation of Threaded Assemblies
Threads shall be clean cut with no burrs or stripping and thread shall be per ASME
B1.20.1 tapered. Ends shall be reamed to remove burrs. Immediately before erecting
piping, pipe and fitting threads shall be thoroughly cleaned 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.
4.6 Make Up of Flanged Assemblies
Bolt tensioning equipment shall be used for bolts of diameter 1-1/2" and larger. Bolt
tensioning shall be used for hot oil service for all sizes of bolts irrespective of rating.
Gaskets once taken out from a made-up assembly shall not be reused.
Before installation of new gasket, the old gasket shall be completely removed and the
flange facings shall be thoroughly cleaned.
Colloidal molybdenum disulfide or other approved lubricant shall be applied to all

flange bolts before the joints are assembled.
Flange connections shall be made up as follows:

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.
Regardless of the scheme selected for flange joint assembly, i.e. gauge between
flanges, torque wrench or bolt elongation, it is important to tighten uniformly and not
prematurely set the gasket. Hand tighten all nuts first, and then gradually tighten
opposite nuts on the joint. Do not bring a single nut to full tightness before the others
have been carefully stepped up toward this final position.
Flange bolt and stud threads shall protrude a minimum of 6mm or two full thread
pitches, whichever is the greater, past the nut. Extremely long bolt projection will not
be accepted unless required for hydraulic tensioning. Uniformity of bolt projection
through the nuts of stud bolts shall be observed.
GRE Flange Connections

All flanged joints shall be uniformly tightened and shall be torqued no more than the
pipe manufacturer's recommended limit.
Washers shall be used at all bolted connections where all GRE flat-faced flanges
mate together or with wafer type valves. Flat-faced flanges shall not mate with raised
faced flanges unless permitted by GRE manufacturer.
Flat-faced carbon steel flanges shall be used at piping class changes interfacing with
GRE piping class with flat-faced flanges.
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Insulation
Where specified, piping, valves and associated equipment and fittings shall be
insulated in accordance with Specification for Insulation, S0442-GPS-L-XXX-SP-
0006.
4.7 Insulating Flanges

Insulating flanges or kits shall be installed at locations identified in the P&ID and
subsequently to the isometric/fabrication drawings.
4.8 Gaskets
The Vendor/Contractor shall ensure that the correct gasket material and thickness, as
specified in the Specification for Piping and Valve Materials, S0442-GPS-L-XXX-SP-
0001 and on piping drawings, is used.
Care shall be taken to ensure that the gasket and mating flanges are clean, true and
free from defects.
The Vendor/Contractor shall ensure that the correct bolting material and grade is
used as specified in the Specification for Specification for Piping and Valve Materials,
S0442-GPS-L-XXX-SP-0001 and on piping drawings.
All carbon steel bolting shall be Hot Dip Spun Galvanized.
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 1%"
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 11/2" 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.
4.9 Installation of Line Blinds, Spectacle Blinds and
Blind Flanges
Line Blinds, spectacle blinds or blind flanges shall be installed :-
• To positively isolate equipment for inspection / testing / maintenance / vessel

entry.
• To isolate systems those are not used during normal operation or are only
used during emergency operation.
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SPECIFICATION FOR PIPING FABRICATION Page : 21 of42
The number of line blinds required for pressure testing of piping system shall be
determined by the Vendor/Contractor. These line blinds shall not be shown on the
P&IDs.
5.0 INSPECTION AND TESTING REQUIREMENTS
5.1 Additional Quality Verification Inspections
5.1.1 General
The extent of welding inspection and hydrostatic testing shall be in accordance with
ASME B31.3 and the following requirements.
5.1.2 Visual Inspection
All welds shall be visually inspected after the root pass and after the work is
completed. The fabricator shall visually inspect weld preparation, fit-up and weld
assemblies during all phases of fabrication. Correction shall be made in the weld
preparation to ensure that sound welds can be achieved by welding process used.
Cracks and undercutting or any evidence of poor workmanship shall result in the
rejection of the weld. Weld quality based on visual examination shall otherwise meet
the requirement of ASME B31.3. Branch welds and reinforcing pad welds shall merge
smoothly with the surface of the pipe.
Notches or undercutting are not acceptable. Sharp corners of reinforcing pads shall
be removed.
A final visual inspection shall be carried out of all the piping and pipe supports for
integrity of installation.
A check on protective coating shall be carried out.
A P&ID line walk with a yellow line of the P&ID shall be carried out jointly by the
process engineer and piping supervisor.
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.
5.1.3 Hardness Test
All locally heat treated welds in carbon steel pipe shall be hardness tested as outlined
below.
Final hardness of deposited weld metal in carbon steel shall not exceed 200
Brinell. At least 5% of all welds shall be hardness tested with a Telebrineller
portable hardness tester or Company approved alternate (one test per weld and
at least one weld per spool). Should any weld metal deposit have a rejected
hardness, additional hardness shall be made at Vendor's/Contractor's expense,
until the extent of unacceptable weld metal is established.
All unacceptable weld metal shall be reheat treated or replaced, and then retested
at Vendor's/Contractor's expense.
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5.1.4 Radiographic Examination

Radiographic examination shall be in accordance with ASME B31.3.
If less than 1000/0 of the welds are examined, for each unacceptable weld the total
number of welds to be examined shall be increased by 2 welds, up to 100%> of the
welds if necessary at fabricator's expense.
Welds selected for examination shall be representative of each welder and welding
procedure so that welding quality can be established at the beginning of the work.
The percentage of the radiographed welds shall be evenly distributed among all
welders and taken while the work is being performed. Radiographic examination shall
be applied to 100 % of all welds selected for examination.
Where weld geometry precludes radiographic examination, the weld shall be
examined by magnetic particle or liquid penetrant methods as outlined in ASME
831.3.
Radiographic technique shall produce maximum contrast and good definition of
penetrameter holes and shall obtain a film density of 1.7 to 3.5 in the weld image.
Fluorescent intensifying screens shall not be used. All penetrameters shall be
shimmed to compensate for weld reinforcement.
When the welding of a welder or welding operator is judged unsatisfactory by the
Company, the welder or welder operator shall be removed from the work by the
Vendor/Contractor. The welding shall be inspected by non-destructive examination
and defective welding removed or repaired as directed by the Company. The welder
or welding operator may be reassigned only after additional training, the completion of
satisfactory qualification tests and approval of the Company.
5.1.5 Magnetic Particle Examination

Magnetic particle examination shall be in accordance with ASME B31.3.
5.1.6 Repairs for GRE Piping
Defective joints shall be repaired by cutting out the defective joint and bonding in a
new coupling. On a case-by-case basis the piping fabricator may submit a wrap repair
procedure for Company approval. In general these procedures shall meet the pipe
manufacturer's recommendations.
5.1.7 Repairs
Material such as gaskets and bolting that are damaged during tests shall be replaced.
Any welded joint that is defective shall be repaired with the procedures specified in
B&PVC Section IX, and shall be heat-treated after the repair. The treating method
shall be approved by the Company if approval is originally required. Repair shall be
re-examined by the original method to determine if the welds are free from defects.
Repaired joints shall be retested.
Repairs of defects in the root and filler beads shall require Company approval. Before
repairs are made, defects shall be entirely removed by grinding or oxygen gouging to
the clean metal. All slags and scales shall be removed by power brushing.
Preheating of an area with a defect shall be in accordance with the original preheat
requirements for the materials and type of weld. After repair of the weld, the entire
circumference shall be radiographed again.
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External undercut shall be repaired by grinding off the weld cap in the undercut
location and recapping the location.
Arc burn defect shall be ground smooth provided that the depth of the defect does not
exceed 8% of the nominal wall thickness. Arc burn defects with a depth greater than
8% but less than 33%> of the nominal wall thickness shall be repaired by welding. The
defect shall be thoroughly removed by grinding. The cavity shall be welded and
ground smooth. The weld shall be preheated in accordance with the original preheat
requirements for the materials and type of weld. All repair procedures shall be
approved by the Company.
Laminations, split ends or other defects in the pipe shall be brought to the attention of
the Company and shall be cropped, repaired or removed from the pipe as per
approved procedure.
No weld containing cracks, regardless of size and location, is acceptable. Cracked
welds shall be cut and removed.
Welding which is accidentally quenched e.g. rain or washdown shall be cut out.
5.1.8 Traceability Requirements

Material and weld traceability will form part of the final documentation to be compiled
and provided by the Vendor/Contractor as per section 16.0 of this document.
6.0 PROTECTIVE COATINGS

Prior to assembly all piping shall be fully painted in accordance with "Specification for
Painting and Protective Coating"; S0442-GPS-M-XXX-SP-0014, with field weld end
preparations to bare metal.
Completed field welds shall be cleaned in situ and painted in accordance with
Specification for Painting and Protective Coating.
Painting shall include:
Painting of the pre-fabricated spool pieces

Painting of the installed pipe
Painting of the piping components including valves, flanges, specialty items
etc.
Painting inspection and repair.
Marking and Identification
Pipe marking and identification shall be in accordance with specification S0442-GPS-

M-XXX-SP-OO 14.
7.0 FLUSHING
7.1 General
Prior to commencing any flushing, Contractor or Vendor shall verify with Company
Representative that all required post weld heat treatment (PWHT), non-destructive
testing (NOT) such as radiography, ultrasonic, etc., has been completed in
accordance with this specification. Upon verification of the above requirements, the
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Company Representative shall authorize, in writing, the Contractor or Vendor to

proceed with 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 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.
Flushing shall be performed until a clear stream of flushing medium exits the piping,
with a minimum flush volume being equal to five times the volume of the piping being
flushed. All flushing shall be done in the presence of the Company Representative.
Orifice plates, thermowells, flow straightening vanes, positive displacement (PO) 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 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.
Pressurized Air Shockblowing (PAS)

Pressurized Air Shockblowing (PAS) means cleaning or checking of cleanliness by
installing a quick acting valve or a rupture disk on an open flange end. Thereafter the
circuit is pressurized to predetermined pressure and then quickly open the valve or
pressurize until the rupture disk burst. A certain amount of water may be inserted in
order to improve the transport effect of debris. This method may be used as an initial
cleaning method for Instrument Air, Plant Air and as an alternative method for initial
cleaning of small bore pipe (less than 2"). This method shall be used when there are
problems to remove trapped liquid in the circuit.
The method shall be used to verify cleanliness of small bore pipe where video
inspection is impossible or inadequate due to pipe dimension or configuration.
When using PAS method for cleaning or verification the procedure shall be repeated
until cleanliness is acceptable.
The air shocking pressure shall never exceed the working pressure of the system and
shall never be more than 8 bar. Safety precautions shall be taken when this method is
used, to ensure that the discharge pipe-end is shielded, to prevent dislodged debris
from injuring personnel.
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Relngress of Contaminants
If it is determined that for any reason that there is a risk that the flushing is no longer
valid due to sloppy housekeeping practices or carelessly leaving the system open all
flushing and if applicable chemical cleaning shall be repeated. Exceptions to this rigid
rule are at the sole discretion of Company.
8.0 HYDROSTATIC PRESSURE TEST
8.1 General
Hydrostatic pressure testing of piping systems shall be in accordance with ASME
831.3 (latest edition). Piping test pressures shall be given on the Line List S0442-
GPS-P-H01-LL-0001.
For piping system with pressure rating greater than ASME Class 600, Contractor and
Vendor shall submit bolt torquing / tensioning procedures prior to conducting
hydrostatic testing.
Prior to commencing any pressure test, Contractor or Vendor shall verify with the
Company Representative that completed NOT & PWHT 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 or Vendor to proceed with the pressure testing.
Contractor or Vendor shall hydrostatically test piping, vessels and equipment for
which he has fabrication or assembly responsibility. Pipe spools shall be hydrostatic
tested prior to installations. Hydrostatic testing may be performed for completed
systems or for individual components of the system, as approved by the Company.
However, if individual components are hydrostatically tested, the Contractor or
Vendor shall flush the completed assembly prior to the system service test. Should
Contractor or Vendor desire to hydrostatically test through Company furnished
equipment, he may do so with written approval of Company Representative. When
hydrostatically testing through Company furnished equipment, Contractor or Vendor
shall exercise due caution to protect any instrumentation associated with the
Company furnished equipment.
Vents shall be open during water filling so that air is vented prior to applying pressure
to the system.
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.
The pressure for each section tested shall be contained by suitably placed spectacle
blinds, spades, skillets, blank insert chokes, blind flanges or other means of positive
closure. Contractor or Vendor shall supply calculations to Company verifying the
thickness and material specification of blinds to be used for isolation during
hydrostatic tests. Test pressure connections shall be on the upstream side of check
valves. In no case shall flappers, pistons, discs, etc. be removed from check valves in
order to facilitate flushing and/or hydrostatic testing. Thermowells shall be included in
hydrostatic tests.
A minimum of two (2) pressure gauges shall be used for pressure tests. One shall be
a pressure-temperature recorder (Foxboro 24-hour chart or equal) with a range
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suitable for recording the test pressure. The bulb of the temperature pen shall be
supplied with adequate capillary to allow attachment to the pipe. The full scale of the
other pressure gauge shall be 1.5 to 3 times of the test pressure. At the start of each
test, the pressure gauges shall be tested hydraulically utilizing a master gauge. This
.master gauge shall not be exposed to any hydrostatic testing. The pressure gauges
shall be deadweight tested after every 5 tests, regardless of test duration.
The master gauge calibration shall be carried out every six months and witnessed by
Company's representative to start the pressure tests, pressure shall be increased
step by step at 250/0, 500/0, 750/0, and 100% of the test pressure. Leaks shall be
checked between each step. The hydrostatic tests shall be held at 1000/0 of the test
pressure for a minimum of one (1) hour or beyond, for a period required to complete
full visual inspection of the test sections to the satisfaction of the Company
Representative. Fire water piping shall be hydrostatically pressure tested in
accordance with NFPA 13 for 2 hours. Readings shall be taken from the temperature
and pressure gauges at fifteen-minute intervals during the test, and recorded on the
Company approved form. During the test, the test medium may be subject to thermal
expansion. Contractor or Vendor shall take proper precautions to avoid excessive
pressure. Pressure bleeds back to test pressure shall be witnessed by a Company
Representative and noted on the test record. When practicable, piping or equipment
under test shall be shielded from direct sunlight.
All joints, including welds, are to be left uninsulated, unpainted, and exposed during
the test. Only tests with ending pressure equal to or above the test pressure will be
accepted. Contractor or Vendor should schedule tests for that portion of the day when
thermal contraction will not result in ending pressure lower than the starting pressure.
Before decreasing the pressure, the piping shall be examined for deformation and all
joints and connections shall be examined for leaks.
Vents shall be open during water draining so that air is filled to prevent pulling a
vacuum in the system.
Pressure tests on each major section of piping shall be carried out with all pressure
relief valves removed and their respective nozzles or connections blinded off or
plugged. The pressure relief valves will themselves be tested to their respective set
point pressures, by the Contractor or Vendor, in a separate test. Tests of pressure
relief valves are to be witnessed and approved by the Company's Representative.
Upon completion of piping or vessel hydrostatic test, pressure relief valves shall be
reinstalled in each system.
Systems below design pressures of 7 Barg may be soap bubble tested.
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
Pressure-relieving devices such as pressure relief valves and rupture discs.
Vessels which do not satisfy impact requirements at piping test temperature.
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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 hyd rotest)
Permanent pressure gauges.
• Expansion joints.
Orifice plates.
Corrosion Probes.
Removable internal parts of the vessel
Any other piping or equipment designated by Company.
8.2 PREPARATION FOR FLUSHING AND HYDROTESTING

Contractor or Vendor shall be responsible for properly preparing facilities for pressure
testing.
Contractor or Vendor shall review the drawings and piping to ensure that adequate
temporary supports, vents, drains, and spades (as necessary to allow testing) are
provided to test the facility in accordance with this specification. Contractor or Vendor
shall report to the Company the findings from this review. Contractor or Vendor shall
provide all high points in the piping with a vent and all low points with a drain,
regardless of whether or not they are specifically shown on the drawings.
Contractor or Vendor shall prepare, for the purpose of the pressure tests, a procedure
and schedule for testing all process and utility piping within the limits of his
responsibilities. The procedure and schedule shall be presented to the Company at
least sixty (60) days, or with mutually agreed period, prior to the scheduled start of
pressure tests. Such procedures should include, but are not limited to, details of the
following:
Mark-ups of piping and instrument diagrams (P&IDs) showing the limits of

piping and equipment to be included in each test.
Test medium to be used.
Location of all isolation blinds, high point vents, low point drains, and
temporary piping supports.
Procedures for flushing lines including fill points and equipment to be
removed for flushing.
Procedures for filling lines including addition of oxygen scavenger and
bactericide in proper quantities.
Procedures for pressurization of the system, including the location of the
injection points and specified test pressures.
The testing operations shall be conducted diligently, thoroughly, and in a safe,
workmanlike manner in accordance with accepted piping testing practices. Any work
by Contractor or Vendor, or existing conditions, which in the opinion of Company are
deemed to be unacceptable shall be corrected by Contractor or Vendor. The testing
operations may not continue until the unsafe conditions have been corrected to the
satisfaction of Company.
Contractor or Vendor shall not receive additional compensation for time lost due to
unacceptable conditions and shall make every effort to recover the schedule.
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If testing is subcontracted, Contractor or Vendor shall furnish an individual who will be

responsible for supervising testing operations. Company will witness and approve all
tests.
8.3 MATERIALS AND EQUIPMENT

Contractor or Vendor shall furnish all materials and equipment necessary to pressure
test all piping. These include, but are not limited to pumps, compressors, pressure
gages, P-T recorders, valves, filters, plugs, blinds, caps, strainers, flanges, bolts,
gaskets, all piping incidental to the filling, flushing, transferring, and disposing of the
test medium, bactericides, oxygen scavengers, dyes (if required), and the test
medium.
Contractor or Vendor shall provide a suitable pressure relieving device between the
pressurizing pump discharge nozzle and the fill point, with a validated pressure gauge
calibrated to prevent excess pressure in any of the piping and equipment being
tested.
All gauges and recorders shall be calibrated by master gauge and comparator or
dead weight tester and the master gauge and dead weight tester calibration shall be
traceable to national standards.
8.4 HYDROTEST FLUID

Except as otherwise specified, all piping shall be tested with water. The test water
shall be clean and free from suspended matter. The test water shall be analyzed by
Vendor/Contractor and may be analyzed by the Company to determine its suitability
for use in the testing operations.
Suspended matter in the fill water shall be removed before injection into the piping by
a filter, capable of removing 99 percent of all particles 92 microns in diameter and
larger, or equivalent to using a 100 x 100 wire-mesh screen.
If foreign material is pumped into the piping because of faulty equipment or careless
workmanship, Vendor/Contractor shall again flush the line with clean water. Only
potable water shall be used in piping systems containing stainless steel or duplex
components.
When air or nitrogen is specified as the testing medium, they shall have a maximum
dewpoint of -29°C.
Conditions requiring the use of oxygen scavenger and bacteria control depend on
how long the test media will remain in the system and whether potable water or
seawater will be used.
If potable water is used for hydrostatic testing, oxygen removal and bacteria control
shall be required at the following treatment rates as follows or Company approved
equal:
• Up to 1 wk No chemical required
• 1 wk - 1 month SEA TR Oil Services: Corrtreat-650 OR 300 ppm
Jetco Chemicals: Jet Cor-471 200 ppm
• 1-24 months SEA TR Oil Services: Corrtreat-650 OR 300 ppm
Jetco Chemicals: Jet Cor-471 250 ppm
If seawater is used for hydrostatic testing, the following steps shall be taken:
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Isolation of all austenitic and duplex stainless steel piping (including all components
such as valves, fittings, etc.) and connected equipment from contact with the
seawater.
Complete removal of saltwater from the system after testing including flushing with
potable water and then drying with air.
Oxygen removal and bacteria control treatment rates shall be as follows or Company
approved equal:
• Up to 1 day No chemical required

• 1 day - 1 month SEA TR Oil Services: Corrtreat-650 OR 300 ppm
Jetco Chemicals: Jet Cor-471 OR 200 ppm
Petrolite Pacific :Fludex WF-3538 500 ppm
Petrolite Pacific: Fludex WF-3538 500 ppm
Petrolite Pacific: Fludex WF-3538 750 ppm
Water used to test piping or vessels fabricated from or containing parts (including clad
or overlay) of austenitic stainless steel, duplex stainless steel, ferritic stainless or high
nickel alloy shall be free from undissolved solids and meet the following chloride
limits:
If the vessel or piping metal temperature never exceeds 65 deg C during
commissioning, operation or non-operation, water containing up to 50 ppm
chlorides may be used for the hydrostatic test.
If the vessel or piping metal temperature exceeds 65 deg C during
commissioning, operation or non-operation, and the vessel is flushed with
condensate or demineralised water immediately after testing, water
containing up to 50 ppm chlorides may be used for pressure test.
When flushing with demineralised water it is essential to ensure that all
surfaces previously wetted during the pressure test are flushed. All residual
water shall be completely removed.
commissioning, operation or non-operation, but the water can be fully
drained and completely removed immediately after testing, e.g., by mopping
up, water containing up to 50 ppm chlorides may be used for hydrostatic
testing.
commissioning, operation or non-operation, and proper drainage is not
possible, the recommended practice is to utilize water containing less than 1
ppm chlorides, i.e., condensate or demineralised water.
Instrument air lines and utility air lines shall be tested with compressed air
(maximum dewpoint of -29°C).
Lube oil and seal oil lines shall be tested with oil as approved by Company.
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
Revision :0
tested. After testing the pipe shall be left long, and the hydrotest blind shall
remain for preservation purposes.
9.0 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 NOE
tested at design conditions in accordance with ASME B31.3 Para. 345.1 and visually
inspected. But NOE 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 1000/0 MPI or dye penetrant as applicable to
material.
9.1 SYSTEM SERVICE TEST

The System Service Test is a test to prove the integrity of completed, fully assembled
piping systems including all vessels and any Company furnished items in the system.
The test shall be designed to demonstrate that systems, upon completion of
assembly, are ready to introduce hydrocarbons and are capable of operation at
pressures specified.
After completion of all recorded hydrostatic pressure tests of completed systems, or
final assembly of individually, hydrostatically tested components, each piping system
shall be given a service test at the system design pressure.
Contractor shall service test all completed platform piping systems, including
equipment which may have been previously service tested as a unit by individual
Vendors. All valves, control valves, filters, strainers, turbine meters, PO meters, flow
nozzles, level gauges, level switches, level controls, rupture discs, pressure relief
valves, and pressure gauges shall be installed for the test. All other instruments and
any rotating equipment such as pumps and compressors are excluded from the tests.
This work shall be witnessed by a Company Representative, and or his designee and
shall be fully completed in the fabrication facility prior to shipment.
The service tests are carried out in the fabrication yard once the risk of the final
product being again dismantled has been reduced to a minimum.
Service tests shall be carried out at night for safety reasons and during gas service
testing only highly trained personnel specializing in such testing are allowed on the
Facility. The service test shall apply to hydrocarbon sections of Vendor packages
also.
Revision :0
Where due to hook up or the likes completion of service tests onshore is not possible
then limited overlapping service tests shall be carried out offshore such that the entire
system has been subject to a service test prior to being placed in operation.
During the service test, the isolation valves for relief valves shall be closed and relief
valves removed. Where relief valves are equipped with isolation and vent/calibration
valves then the relief valve may be maintained in its position with the isolation valves
closed and the vent / calibration valves opened. After the service test of that portion of
the system containing the isolation valves and prior to depressurizing the test fluid the
relief valve shall be installed.
The test pressure shall be lowered to ninety percent (90°!cJ) of the relief valve and/or
rupture disc set point pressure, the vent / calibration valve closed and the block valve
opened. The purpose of this procedure is to check the connection between the block
valve and relief valve.
All temporary positive closures such as plugs, blinds, spectacles, spades, and skillets
which may have been used during hydrostatic testing, shall be removed and all piping
joints shall be made up as they would be during normal operation of functional
systems.
Any used gaskets from prior tests shall be replaced.
On liquid systems the test fluid will be water, whilst on process gas the test fluid shall
be nitrogen, and on mixed systems gas over water may be used to limit the volume of
Nitrogen's used.
For water systems the filling and venting procedures shall be the same as for
hydrostatic tests. Pressure shall be brought to system design pressure and held for
30 minutes. All connections which were not made prior to hydrostatic tests shall be
checked for leaks and tightened as necessary. During service test, every valve in the
system shall be tested by being closed and used to hold the test pressure for a period
of time necessary to determine whether each valve is in turn positively shutting off
and holding pressure. Packing shall be replaced in equipment, such as valves, when
leaks cannot be stopped by normal tightening of packing glands. Valve seat leaking
shall be determined by monitoring levels and pressures and by listening for leaks
across the seat with an ultrasonic leak detector.
When Contractor is testing systems on completed platforms, only one complete
system at a time shall be tested for safety reasons and to prevent structural failures (if
this is a risk). During testing, Contractor shall take suitable precautions to prevent
building up excessive pressures in adjacent equipment not included in the test, such
as opening vent valves in the adjacent systems, etc.
In the event that a piping system contains a piece of skidded equipment that has
already been nitrogen leak and service tested by the Vendor, the Contractor shall
carry out service testing again in the yard.
For nitrogen service test, the following procedures shall be used:
1. Prior to testing Contractor shall submit to Company three (3) sets of Piping
and Instrument Diagrams colour coded to depict individual test limits and
their corresponding test pressure. In general, these limits shall follow ASME
pressure classification.
2. All valves shall be leak tested and shall be clearly labeled on these
diagrams with an identification number. A Valve Test Schedule shall be
Revision :0
prepared by Contractor and submitted to Company for approval and shall be

utilized to record the results of each individual valve test.
3. Helium shall be utilized as the tracer gas for the purpose of detecting and
quantifying leaks. A portable mass spectrometer calibrated to detect only
helium shall be utilized. All leaks greater than 5 SCF/year (resilient seals)
and 10 SCF/year (metallic seals) shall be repaired. This detection shall be
carried out a joint at a time by puncturing tape on the joint.
4. When testing a system adjacent to a previously tested system, tape of a
different colour shall be utilized on all possible sources of leakage. Tape
shall remain following completion of any test.
5. Pressure shall be held against all valves undergoing seat leakage (service)
testing for a minimum of 5 minutes. During this period the pressure shall be
monitored for decline. In addition, during this period an ultrasonic detector
shall be utilized on each valve holding pressure to determine if seat leakage
is occurring. Results shall be recorded on the Valve Test Schedule.
6. Contractor shall sequence tests, if possible, so that nitrogen is conserved.
Sequencing is subject to the approval of Company.
7. Prior to the introduction of nitrogen into any system all reasonable steps
shall be taken to remove any pockets of water. These steps shall include
opening all drain valves and/or plugs, pressurizing/purging with air, etc. If
necessary, nitrogen may be used to pressurize a system in order to dislodge
trapped pockets of water.
8. An initial gross leak test shall be conducted at 30 to 40 psig to identify all
bad gaskets, missing plugs, open valves, etc. This test shall be conducted
prior to taping of possible leak sources. Following a successful gross leak
test, the pressure shall be brought up incrementally in steps of
approximately 20 to 25 percent of the maximum test pressure. At each step
all joints shall be tested for leakage and repaired as required.
9. Upon completion of a test the oxygen content within that system shall be
determined and recorded. After all tests are concluded a Company
representative will determine if additional reduction in oxygen content is
necessary. In any event, the oxygen content should not exceed 2%.
10. After the test is completed, pressure in the system shall be reduced in
controlled steps of 25%, from 100% to 75%, 50%, 25% with minimum of 1
minute interval in each step. Contractor shall ensure that bleed down rate of
the test pressure is carried out in sufficient time so as not to cause any
damage (shrinkage or explosive decompression) to any of the components
in the system being tested.
At the conclusion of the nitrogen test, all spectacle blinds, spades, skillets, blank
insert chokes, blind flanges and other means of positive closures that do not form
part of the permanent process system shall be removed and the piping and
insulation (if applicable) shall be re-instated. Contractor shall leave a 50 psig
nitrogen blanket in the entire tested piping system on the platform, including
vessels and skidded equipment (if recommended by the equipment Vendor).
11. Tightening leaking joints under high gas pressure shall not be carried out
and the system section shall be isolated and depressurized in order to effect
tightening.
Revision :0
12. Joints which cannot be service tested as above shall be witnessed make up
and shall be hydro tightened.
For low pressure utilities Contractor may propose to carry out an instrument air
service test subject to Company approval.
Open drain service testing shall be a liquid full test only.
9.2 OTHER TESTING

Vacuum testing of refrigerant loops is required as per the HVAC specification. Large
process refrigeration systems shall have a Helium tracer Nitrogen leak test to
minimize the chance of leakage of expensive system gas.
10.0 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.
11.0 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.
12.0 COMPLETION OF PRESSURE TESTS

Upon completion of hydrostatic tests and service tests, the Contractor or Vendor
shall:
Dispose of all test medium to a location designated by the Company,
exercising proper caution to avoid accidental creation of a vacuum during
draining of water from equipment.
Restore any equipment excluded from tests to a fully operational condition.
Revision :0
• Remove all temporary facilities installed including temporary supports and

bracing.
Remove any temporary plugs or blinds.
Replace any used gaskets or damaged nuts and bolts.
Air purge all piping and equipment, unless specifically deleted by Company
in writing, to remove low point pockets of water. Air purging shall be
performed in the presence of the Company Representative and last a
minimum of thirty (30) minutes.
Remove all stops placed in spring type supports.
Touch up any areas of paint damaged during testing per G-ES-002,
"Painting and Protective Coating."
13.0 CHEMICAL CLEANING
13.1 General
Specific equipment requires connected piping to be chemically cleaned prior to
commissioning, in order to prevent undesirable foreign matter entering the equipment.
Any requirement for chemical cleaning shall be listed in the project Line List.
13.2 Extent of Chemically Cleaning

The extent of chemical cleaning shall be as follows:
Flushing
All piping shall be flushed.
Chemical Cleaning
Chemical cleaning shall be carried out in accordance with section 13.3 on carbon
steel piping in the following systems:
All compressor suction lines and recycle lines between the suction scrubber
and the compressor suction nozzle
All compressor discharge lines up to the first discharge block valve
All compressor recycle lines upstream of the recycle control valve
All expander inlet lines between the inlet scrubber and the expander inlet
nozzle
All metering piping and inlet piping to metering skids
Fuel gas distribution piping after the main fuel gas filter coalescers
Seal gas systems after the main filter coalescers
Hot Oil system piping
Hydraulic Oil system piping
Lubrication and Seal Oil systems piping
Inert Gas distribution piping to compressors, and hot oil systems
Video Inspection
All condensate pump suction lines between the pump suction vessel/tank
and the pump suction nozzle
All hydrocarbon pump discharge lines up to the first discharge block valve
Revision :0
All compressor suction lines between the suction scrubber and the
compressor suction nozzle
All compressor discharge lines up to the first discharge block valve (only if
the control valve is prone to blockage due to small ports)
• All compressor recycle lines upstream of the recycle control valve (only if the
control valve is prone to blockage due to small ports)
All expander inlet lines between the inlet scrubber and the expander inlet
nozzle
• All metering piping and inlet piping to metering skids
All piping between the filter coalescers and the C02 removal membranes
Fuel gas distribution piping after the main fuel gas filter coalescers
Seal gas systems after the main filter coalescers
• Diesel distribution piping after the filter coalescer
Hot Oil system piping
• Hydraulic Oil system piping
Lubrication and Seal Oil systems piping
• Inert Gas distribution piping to compressors, and hot oil systems from the
last filter
Grit Blasting
Compressor suction lines.
Gas re-injection lines.
Prior to chemical cleaning the piping shall be flushed.
Any internal coating other than initial preservation oil shall also be removed prior to
chemical cleaning.
The systems to be chemical cleaned shall have high and low point vents and drains.
These shall be marked on chemical cleaning Isometrics.
Precautions to be taken to prevent the ingress of chemical cleaning fluids into
equipment shall form part of the procedures to be submitted by the Contractor for
approval.
The chemical cleaning procedure shall describe a method using only one volume
chemical cleaning fluid per system (i.e. the same volume to be used for all steps
mentioned below), adding the required amount and type of chemicals required in
order to carry-out the following steps:-
1) Degreasing
2) Descaling
3) Neutralisation
4) Passivation
When above steps are completed a second volume of fresh water shall wash out
remaining chemical fluid.
For systems where microscopic test samples are required for cleanliness verification,
i.e. compressor suction lines, lube oil lines and instrument air lines: ISO-standard
4406 shall be used for defining the solid contaminate quantities in the flushing
medium. The upper and lower limits for the number of particles which will be
permitted for the various systems are specified in Appendix C.
Finally the system shall be dried and preserved.
Revision :0
13.3 Chemical Cleaning of Carbon Steel Piping

Equivalent alternative method may be submitted for review/approval by the Principal.
13.3.1 Degreasing
Degreasing shall be achieved by the addition of suitable degreasing agents based on
emulsifiers and/or detergents compatible with the chemical cleaning, neutralization,
and passivation mediums.
Whenever protective coatings of preservatives are present on the internal surface, the
chemical cleaning fluid shall be formulated in the manner as to dissolve and remove
such contaminants.
For certain types of coatings/preservatives a two stage cleaning method may be used
if required. However, the method and procedures shall be subject to the Principal's
acceptance before application.
13.3.2 Chemical Cleaning

The purpose of the following chemical cleaning procedure is to remove oil, grease,
mill scale and rust from the piping internals. This shall be achieved by means of
circulating a mixture of chelating agents, corrosion inhibitors, degreasing agents,
solvents, etc. The cleaning solution shall be controlled to avoid excessive corrosion of
the metal and localized corrosion i.e. pitting, and stress corrosion cracking shall all be
strictly controlled through the system at a temperature of about 80°C until clear, bare
metal surfaces are exposed.
High point vents shall be opened periodically to allow trapped air in air pockets to
escape during the chemical cleaning operation.
The chemical cleaning operation shall be continuously monitored by suitable
analytical methods for chelant concentration, iron concentration, pH value,
appearance, colour and EMF (Electro Motive Force) until laboratory results indicate
the operation is completed. This is normally achieved when the chelant and iron
concentrations are stabilised.
Systems to be cleaned shall be sufficiently split-up to ensure proper contact time with
the chemicals and achievement of required velocities for particle transport.
In the liquid flow there shall be a filter unit to remove solid particles. The filtration
capability shall be sufficient to achieve cleanliness as laid down in the relevant
equipment standards and if not specified to the satisfaction of both Manufacturer and
Company.
13.3.3 Neutralisation
The chemical cleaning fluid shall be neutralised with the compatible type of alkali
(Caustic Soda, Hydrazine, Sodium Bicarbonate or Ammonia) to a pH range of 8.5-10
depending on the type of chelant used.
13.3.4 Passivation
The chemical cleaning solution shall be cooled to between 45-55°C (depending on
the type of passivating agent used), and the pre-calculated quantity of passivator
(nitrite, phosphate or peroxides) based on the level of iron concentration added.
This solution shall be circulated in the system for minimum of one (1) hour depending
on the type of passivator and temperature.
Revision :0
Passivation shall be monitored from a laboratory with competent personnel and

equipment, to prevent ferric ionic corrosion.
Passivation is normally complete within four (4) hours (depending on the type of
composition) when EMF is stabilised. At this stage the system is drained with air or
nitrogen.
13.3.5 Water Flushing

Piping shall be thoroughly flushed with clean fresh water as rapidly as possible after
the chemical cleaning operation to rid the surface or all traces of excess chelant or
iron salts. High-pressure water, high flow velocity and adequate drainage are required
to facilitate rapid flush operation. The water shall not be recirculated.
All blanked ends, including vents, drains, instrument taps etc. shall be opened long
enough to flush out all entrapped chemicals.
Rinsing shall continue for at least ten (10) minutes after the pH of the effluent water
equals the pH of the feed water.
13.3.6 Drying
Drying shall be performed immediately after completion of final water flushing.
13.3.7 Inspection
A visual inspection of internal piping surfaces by videotape, shall be performed to
ensure that piping surfaces are free from all traces of contamination and liquid.
13.3.8 Protective Coating/Preservation

When rust preventive is to be used, the internal surface shall be coated immediately
after drying and inspection. If carbon steel systems, such as, heating and cooling
medium or closed-circuit glycol, are to be internally protected, a water based
preservation medium, without any traces of solvents, shall be used. Below freezing
point, use mixtures with triethylene glycol.
Note: Systems preserved shall also be dried, when preservation operation is
completed.
13.4 Chemical Cleaning of Stainless Piping.

Equivalent alternative methods may be submitted for approval by the Company.
13.4.1 General
The cleaning operation follows to a great extent the same procedure as for chemical
cleaning of carbon steel piping, except for the following:
Cleaning agent shall be Nitric Acid. Alternatives in accordance with ASTM A380 may
be proposed.
Note: Neutralisation not required
Note: Passivation not required
Temperature shall not exceed 55°C at any time
13.4.2 Removal of Dirt, Degreasing

The piping system shall be internally cleaned and degreased using the same
procedure as stated for carbon steel.
Revision :0
13.4.3 Chemical Cleaning

When chemical cleaning is required in order to remove oxidation along pipe walls and
scale occurred as a result of welding the same procedure as per carbon steel piping
shall be used.
13.4.4 Water Flushing

Piping shall be thoroughly flushed after the chemical cleaning to the same procedure
as for carbon steel.
13.4.5 Drying
Drying shall be done as per carbon steel.
13.4.6 Inspection
This shall be as per carbon steel piping.
13.4.7 Protective Coating I Preservation

Immediately after drying and inspection, pipe and flanged ends shall be fully
protected against the ingress of foreign material using a procedure supplied by the
Contractor and approved by Company.
13.5 Hot Oil Flushing
13.5.1 General
Hydraulic oil, lube oil and seal oil systems shall be hot oil flushed to ensure the
internal piping surfaces are free from all traces of contamination.
If chemical cleaning is specified, this must be carried-out prior to hot oil flushing. The
Contractor shall develop detailed hot oil flushing procedures which shall be adjusted
to suit each type of system. Hot oil flushing on vendor packages shall in general
follow the above sequence. However, the Vendors recommended procedures and
cleanliness standard shall be submitted for approval by the Principal.
13.5.2 Flushing Oil

Whenever possible the flushing oils shall be the same grade as the operating fluid. A
different grade may be selected provided it is fully compatible with the operating fluid.
When the final flushing oil is the same grade as the operating oil, unless otherwise
specified, it shall be left in the system at the end of the flushing procedure. Any other
flushing oil must be removed.
13.5.3 Cleanliness of Hydraulic Oil Systems

Hot oil flushing shall continue until the accepted level of cleanliness has been
reached.
The cleanliness level shall be assessed by microscopic examination of the test
sample.
A system is considered clean when, using a 3~ filter absolute, the oil sample meets
the cleanliness requirements specified in the equipment standards or to the
satisfaction of the equipment manufacturers and Company.
Revision :0
13.5.4 Cleanliness of Lubricating Oil Systems

As per Hydraulic Oil Systems above, but the system is considered clean when using a
10 micron filter absolute, the oil sample meets the cleanliness requirements specified
in the equipment standards or to the satisfaction of the equipment manufacturers and
Company.
13.5.5 Cleanliness of Seal Oil Systems

As per Hydraulic Oil Systems above, but the system is considered clean when using a
1a ~ filter absolute, the oil sample meets the cleanliness requirements specified in the
equipment standards or to the satisfaction of the equipment manufacturers and
Company.
13.6 Hook-Up Piping

Hook-up piping requiring chemical cleaning shall be performed by the hook-up
Contractor. For closed-circuit systems for hydraulic, lube and seal oil, chemical
cleaning of hook-up piping shall be performed separately after hook-up closing welds
are completed, and piping has been pressure tested. Valves and break flanges shall
be installed to ensure that the existing system is isolated so that chemical re-cleaning
is not necessary.
For closed circuit systems for heating and cooling medium, chemical cleaning shall be
performed prior to final installation, and chemical cleaning of the hook-up closing
welds is not required.
13.7 Relngress of Contaminants

If it is determined that for any reason that contaminants have reentered the system
then all flushing and chemical cleaning shall be repeated. Exceptions to this rigid rule
are at the sole discretion of Company.
14.0 PREPARATION FOR SHIPPING AND STORAGE

Preparation for shipping and storage shall be in accordance with the Company
Procurement Specification, with the following additional requirements.
Prior to shipment, all piping components, flanges, valves and filters shall be protected
to prevent damage in transit and during storage at erection site.
Pipe and fittings shall be handled with care and at all times protected from impact, or
from being climbed on, or used to support other materials or equipment.
Pipe and fittings shall not be thrown or dropped and shall be protected from bumping
or hitting during any handling phase.
Chains shall not be used for handling pipe. When transporting or using mechanical
means of lifting, only rope or webbed slings shall be used.
Pipe shall not be piled directly on the ground, steel or concrete floors. The pipe shall
rest on supports properly spaced to prevent bending of the pipe or damage to the
fittings.
Prefabricated piping shipped for field assembly shall be marked with white paint
giving the spool number and an arrow indicating the direction of flow. Pipe spools
shall be numbered consecutively in the direction of flow. In addition, prefabricated
piping shall be colour coded as to service, i.e. fire water, potable water.
Revision :0
15.0 WARRANTY
The engineering Contractor shall have final and total responsibility for the fabrication
and installation of the piping as described in this Specification.
The warranty for the works shall be in accordance with the requirements of the Terms
and Conditions accompanying the Purchase Order / Contract.
16.0 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 (NOT) procedures
i) NOT operator qualifications
j) NOT records
k) List of NOT operators
I) Welding consumable handling procedures
m) Flux handling and recycle procedure
n) Repair procedure
0) 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 NOT 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).
Revision :0
APPENDICES
APPENDIX 1 Piping Fabrication Tolerances

Revision :0
APPENDIX-1
PIPING FABRICATION TOLERANCES
FLANGE
t.
NOTE 1
SECTiON . ED
Notes:
1. Tolerances on dimensions, which do not include pipe segments, are to be
based on ASME standards for fittings or flanges involved, otherwise tolerance
is3mm.
2. Rotation of flanges from the indicated position measured as shown 2mm
maximum.
3. Alignment of facings or ends shall not deviate from the indicated position
measured across any diameter more than 2mm per 300mm.
4. End preparation for weld shall not deviate from the indicated position by more
than 1mm across the diameter. For inert gas weld joints or 3mm for other
joints.

S0442 GPS L XXX SP 0005 - 0 - Specification For Piping Fabrication and Installation

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S0442 GPS L XXX SP 0005 - 0 - Specification For Piping Fabrication and Installation

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HOANG LONG JOINT OPERATING COMPANY LTD

TGT FIELD DEVELOPMENT

Document Title: SPECIFICATION FOR PIPING

GPS Document No.: S0442-G PS-L-XXX-SP-0005

Client Document No.:

0 23-Feb-10 Approved For Construction '¥~B )f DP SLl"V

C 20-Feb-09 Issued For Design TS DP JM

B 13-Feb-09 Issued For Approval TS DP JM

A 30-Jan-09 Issued For IDC TS DP JM

REV DATE DESCRIPTION BY CHECKED APPROVED CLIENT

Hoang Long Joint Operating Company XXXX

Global Process Systems Pte Ltd S0442

5.1.8 Traceability Requirements 23

This specification does not cover the following:

2.0 SPECIFICATIONS, CODES, STANDARDS AND REGULATIONS

The latest edition of the below listed documents are applicable:

S0442-GPS-L-XXX-SP-0001 Specification for Piping and Valve Materials

3.0 FABRICATION REQUIREMENTS OF PIPEWORK

3.1 General Requirements

Fabrication, welding procedures, and welder qualifications shall be in accordance with

Dimensional tolerances shall be as per APPENDIX 1, "Piping Fabrication tolerances".

Material Certification as per specification shall be reviewed by the

Cold-formed pipe bends are not permitted.

Mitre bends shall not be used unless approved by the Company.

3.1.2 GRE Piping Bonding

3.1.3 Fabrication Tolerance

Fabrication tolerance shall be as defined by ASME 831.3 and Appendix 1.

3.1.4 Construction Marking

3.2.1 Welding Procedure Qualifications and Welder Qualifications

• Double-welded longitudinal and circumferential butt joints.

Low Temperature Service Welds

3.2.2 Welding Procedures and Processes

Restrictions to the above are listed below.

Semi-automatic or fully automatic welds shall be made with a multi-pass technique.

All other welding processes, including flux-cored processes, shall be submitted in

Welding processes shall be identified by number. The identification number shall be

(b) Short Circuiting Arc GMAW Process

(c) Gas Tungsten Arc Welding Process

(d) Submerged Arc Welding

3.2.3 Filler Materials, Electrodes, Wire, and Flux

All welding consumables shall be low hydrogen consumables unless otherwise

3.2.4 Fabrication and Welding Joint Preparation, Spacing and Alignment

(a) Edge Preparation

(b) Spacing and Alignment

3.2.5 Weld Contour and Finish

3.2.6 Butt Welds for Orifice Rums

3.2.7 Other Requirements

Semi-automatic or full-automatic welds shall be made with a multi-pass technique.

3.2.8 Heat Treatment

Heat treatment requirements and hardness specifications for attachment welds of

Post-weld heat treatment shall be as per ASME 831.3 or as required by Company.

Post Weld Heat Treatment

Exothermic Heat Treatment

3.3 Non Destructive Testing (NOT) Requirements

3.3.1 General Requirements

All examinations inclusive of in-process examinations shall be carried out in full

Weld examinations shall be performed in accordance with the following standards:

b) Radiographic ASME Section V, Article 2

Welds that are to be examined by non-destructive methods shall be finished as

Non destructive examination of piping shall be as below:

• NOT Group 1 Non FlammablelToxic Fluids - including Open Drain

NOT Connection Visual Volumetric Surface

Angular branch welds shall be examined to the same degree as buttwelded