PROCEDURE Piping Chevron

GENERAL SPECIFICATION 3.
03
GENERAL PIPING FABRICATION,

INSPECTION AND TESTING
Chevron Offshore (Thailand) Ltd
0 PH Issued for Use 8/2001
A MLJ Issue for Review 6/2000
Rev. By Description Date Rvw’d Appv’d

GENERAL PIPING FABRICATION, INSPECTION GS 3.03
AND TESTING REVISION 0
CHEVRON OFFHSHORE THAILAND LTD AUG 2001
TABLE OF CONTENTS
1.0 INTRODUCTION
1.1 Scope
1.2 Exclusions
1.3 Responsibilities
1.4 Conflicts and Exceptions
2.0 MANDATORY CODES AND STANDARDS
3.0 GENERAL REQUIREMENTS
4.0 WELDING
4.1 General
4.2 Welding Processes
4.3 Welding Procedure Qualification
4.4 Welder and Welding Operator Qualification
4.5 Production Welding
5.0 FABRICATION, ASSEMBLY AND ERECTION
5.1 General Piping

5.2 Pipe Supports
6.0 POST WELD HEAT TREATMENT
6.1 General
6.2 Exothermic Heat Treatment
7.0 QUALITY ASSURANCE AND QUALITY CONTROL
7.1 General
7.2 Radiography
8.0 FLUSHING AND HYDROSTATIC TESTING
8.1 General
8.2 Preparation for Testing
8.3 Hydrostatic Leak Testing
8.4 Post-Test Requirements
8.5 Leak Repair and Re-testing
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9.0 PNUEMATIC TESTING
9.1 General
9.2 Pneumatic Leak Testing
10.0 CLEANING, DESCALING AND PASSIVATING STEEL PIPING
10.1 General
10.2 Acid Descaling (Pickling) and Passivation
10.3 Abrasive Blasting
10.4 Hot Oil Flushing
11.0 PROTECTIVE COATINGS
12.0 IDENTIFICATION AND MARKINGS
13.0 PREPARATION FOR SHIPMENT AND STORAGE
14.0 DOCUMENTATION REQUIREMENTS
APPENDICES
I Mandatory Codes and Standards

II Additional Requirements for Duplex Stainless Steel Piping
III Additional Requirements for Fiberglass Reinforced Plastic (FRP) Piping
IV Additional Requirements for Chlorinated Poly Vinyl Chloride (CPVC) Piping
V Additional Requirements for API 5L Grade X-60 Carbon Steel Piping
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1.0 INTRODUCTION
1.1 Scope
1.1.1 This specification, in conjunction with the other Technical Requirements, defines
the minimum acceptable requirements for the fabrication, assembly, welding,
erection, installation, inspection, testing, cleaning and documentation of carbon
and austenitic stainless steel piping systems used in upstream oil and gas
production facilities. This specification governs piping systems provided in
accordance with API Recommended Practice 14E "Design and Installation of
Offshore Production Piping Systems" and ANSI B31.3 "Chemical Plant and
Petroleum Refinery Piping."
1.1.2 Piping systems constructed of duplex stainless steel materials shall meet the
additional requirements specified in Appendix II "Additional Requirements for
Duplex Stainless Steel Piping."
1.1.3 Piping systems constructed of Fiberglass Reinforced Plastic (FRP) materials
shall meet the additional requirements specified in Appendix III "Additional
Requirements for Fiberglass Reinforced Plastic (FRP) Piping."
1.1.4 Piping systems constructed of Chlorinated Poly Vinyl Chloride (CPVC) materials
shall meet the additional requirements specified in Appendix IV "Additional
Requirements for Chlorinated Poly Vinyl Chloride (CPVC) Piping."
1.1.5 Piping systems constructed API 5L Grade X-60 materials shall meet the
additional requirements specified in Appendix V "Additional Requirements for
API 5L Grade X-60 Carbon Steel Piping."
1.1.6 This specification shall also apply to the fabrication and attachment of pipe
supports.
1.2 Exclusions
This specification does not apply to process design, line sizing, or equipment
layout; nor does it apply to piping material and component selection, or to piping
design and layout. Specific exclusions include all small bore instrument tubing,
sub-sea pipelines, risers and J-tubes.
1.3 Responsibilities
CONTRACTOR shall be solely responsible for providing complete and operable
piping systems in full accordance with all applicable Industry Codes and
Standards, Government Regulations and COMPANY Technical Requirements.
1.4 Conflicts and Exceptions
1.4.1 All conflicts between this specification, the other Technical Requirements, and
the applicable codes and standards shall be submitted in writing to COMPANY
for resolution.
1.4.2 Any and all exceptions to the Technical Requirements shall be submitted in
writing to COMPANY for approval.
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2.0 MANDATORY CODES AND STANDARDS

2.1 The primary codes governing piping systems provided under this specification
shall be API Recommended Practice 14E "Design and Installation of Offshore
Production Piping Systems" and ANSI B31.3 "Chemical Plant and Petroleum
Refinery Piping."
2.2 The most recent issue of the codes and standards listed in Appendix I
"Mandatory Codes and Standards" shall be considered as a part of this
specification.
2.3 Special design allowances outlined in any of the codes and standards may not
be used without written approval of COMPANY.
2.4 COMPANY "Safety in Designs" Manual (GO-590) shall be considered as part of
this specification. CONTRACTOR shall refer to COMPANY "Safety in Designs"
Manual regarding all safety concerns related to piping system design, layout,
fabrication and assembly, such as valve accessibility guidelines, overhead
clearance requirements and valve handwheel/stem position limitations.
3.0 GENERAL REQUIREMENTS

3.1 The fabrication, assembly, welding, erection, installation, inspection, testing,
cleaning and documentation of piping systems shall be in full accordance with
API RP 14E "Design and Installation of Offshore Production Piping Systems,"
ANSI B31.3 "Chemical Plant and Petroleum Refinery Piping" and COMPANY
Technical Requirements. All addenda issued through the date of the Purchase
Order, Contract or Agreement, as applicable, shall apply in full.
3.2 The fabrication, installation, inspection and testing of Polypropylene Lined (PPL)
carbon steel piping systems shall be in accordance with ASTM F492 "Propylene
and Polypropylene (PP) Plastic-Lined Ferrous Metal Pipe and Fittings," the
manufacturer's requirements and recommendations, and the Technical
Requirements. Welding and field branch connections shall not be permitted on
pre-fabricated, lined spool pieces.
3.3 The fabrication, installation, inspection and testing of Fiberglass Reinforced
Plastic (FRP) piping systems shall be in accordance with the manufacturer’s
requirements and recommendations, and the Technical Requirements.
CONTRACTOR shall note that the Technical Requirements do not include
complete, detailed piping fabrication, inspection or testing requirements specific
to the needs of FRP piping systems. CONTRACTOR shall be responsible for
developing piping fabrication, inspection or testing requirements to the mutual
satisfaction of COMPANY and the FRP piping manufacturer.
3.4 The fabrication, installation, inspection and testing of Chlorinated Poly Vinyl
Chloride (CPVC) piping systems shall be in accordance with ASTM D2846
"Specification for Chlorinated Poly Vinyl Chloride (CPVC) Plastic Hot and Cold
Water Distribution Systems," the manufacturer’s requirements and
recommendations, and the Technical Requirements.
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3.5 The selection of pipe, piping components and valving shall be in full accordance
with the Technical Requirements, including General Specification 3.00 "Piping
Service Classifications and Material Requirements," and in particular the
appropriate Material Class Data Sheet for the intended service. Substitution of
alternate materials or components shall require prior written approval by
COMPANY.
3.6 Pipe support materials shall be provided in accordance with the Technical
Requirements. As a minimum, pipe supports shall be fabricated from carbon
steel that meets the requirements of ASTM A36 or ASTM A-53, A-106-B or API
5L, Grade B pipe, unless specified otherwise.
3.7 References in this specification to ANSI Class 150, 300, 600, 900, 1500 and
2500 flange ratings refer to ANSI B16.5 "Pipe Flanges and Flanged Fittings."
References to API 3000, 5000 and 10,000 pound flange ratings refer to API 6A
"Specification for Wellhead Equipment."
3.8 All sour service hydrocarbon piping systems shall be in accordance with NACE
MR-01-75 "Sulfide Stress Cracking Resistant Metallic Material for Oil Field
Equipment."
3.9 CONTRACTOR shall not proceed with material purchasing or fabrication without
approval of COMPANY.
3.10 As a minimum, all workmanship shall be equal to standard commercial practice in
modern fabrication shops. All work shall be performed by workmen skill in their
trades. All materials and equipment shall be new and of high quality manufacture.
4.0 WELDING
4.1 General
4.1.1 All welding shall be in strict accordance with ANSI B31.3 "Chemical Plant and
Petroleum Refinery Piping," the ASME "Boiler and Pressure Vessel Code" -
Section IX "Welding and Brazing Qualifications" and the COMPANY Technical
Requirements. The welding processes as discussed in this section shall be
acceptable for CONTRACTOR’s use in the fabrication of piping and pipe
supports unless otherwise noted in the Technical Requirements.
4.1.2 All welding procedures shall be in writing and shall be qualified in accordance
with the ASME "Boiler and Pressure Vessel Code" - Section IX "Welding and
Brazing Qualifications" as modified by ANSI B31.3 "Chemical Plant and
Petroleum Refinery Piping." All Weld Procedure Specifications (WPS) and
Procedure Qualification Records (PQR) shall be submitted to COMPANY for
approval prior to any welding.
4.1.3 Only welders qualified in accordance with the ASME "Boiler and Pressure
Vessel Code" shall be utilized for fabrication. Welders shall have their
qualification certificates available for COMPANY review during all stages of
fabrication. If requested by COMPANY, CONTRACTOR shall submit a list of
qualified welders and the procedures for which they have been qualified.
COMPANY may, at it’s option, require new qualification tests for any welder
working on piping fabrication. Should the welder fail the new qualification tests,
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then CONTRACTOR shall bear all costs for the tests and the welder shall be
removed from the work. COMPANY will reimburse CONTRACTOR reasonable
costs of new qualification tests passed by the welder in question.
4.1.4 All welding processes shall be identified by number. Identification numbers shall
be referenced on all fabrication drawings. CONTRACTOR shall submit
fabrication drawings or weld maps that identify the proposed welding process
for each weld, or types of weld configurations, prior to the start of welding.
4.1.5 COMPANY shall reject any weld that has not been made properly. Defects in
welds or fabrication, including fit-up, shall not be permitted which in the opinion
of COMPANY are detrimental to the strength of the weld. All repair procedures
shall be submitted to COMPANY for approval prior to start of repair work. The
cost of preparing repair procedures and repairing defective welds shall to the
CONTRACTOR’s account, not the COMPANY.
4.1.6 Any weld tampered with or caulked in any way shall be condemned whether or
not it is sound. "Doctoring" the surface of defective welds with a torch shall not
be permitted under any circumstances.
4.1.7 All welding equipment shall be in good condition and subject to inspection by
COMPANY. Any equipment found in need of repair shall be removed from the
fabrication work until said repair is completed.
4.2 Welding Processes
4.2.1 General
4.2.1.1 Acceptable weld processes for welding of piping and supports shall include the
following:
• Flux Core-Arc Welding (FCAW)
• Gas Metal-Arc Welding (GMAW)
• Gas Tungsten-Arc Welding (GTAW)
• Shielded Metal-Arc Welding (SMAW)
• Submerged-Arc Welding (SAW).
4.2.1.2 Oxyacetylene welding shall not be permitted.

4.2.1.3 All semi-automatic or fully-automatic welds shall be made utilizing a multi-pass
technique.
4.2.2 Flux Core-Arc Welding (FCAW)

a. Wind velocities shall not exceed 5 mph in the weld area.
b. Gas shielded electrodes shall always be utilized, and the electrode diameter
shall not exceed 1/8".
c. Vertical downhill welding shall not be permitted.
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d. Self-shielded FCAW shall not be permitted for process piping, but may be
used for pipe support fabrication.
e. Low hydrogen consumables shall be certified by the electrode
CONTRACTOR, or tested by CONTRACTOR to result in less than 10 ml of
diffusible hydrogen per 100 gm of deposited weld metal. Diffusible hydrogen
content shall be measured by the mercury displacement or gas
chromatograph method per AWS A4.3. CONTRACTOR shall provide written
evidence of compliance with this requirement. The specification sheet for the
proposed brand of filler metal from the CONTRACTOR shall be acceptable
as written evidence.
4.2.3 Gas Metal-Arc Welding (GMAW)

b. Short-arc GMAW shall be used only for root pass butt welding on piping.
c. Short-arc GMAW shall not be used on weld-o-lets, reinforced nozzles and
branch welds, couplings, slip-on flanges, socket welds or other pipe
appurtenances.
4.2.4 Gas Tungsten-Arc Welding (GTAW)

b. An internal gas purge shall be provided for the root pass and the second
layer of autogenous and stainless steel welds.
4.2.5 Shielded Metal-Arc Welding (SMAW)

b. Low hydrogen electrodes shall be required.
c. If SMAW low hydrogen electrodes are unsuitable for producing acceptable
radiograph quality, then GTAW, GMAW, or cellulosic SMAW electrodes shall
be used on the root pass on single-sided butt welds.
d. Cellulosic SMAW electrodes shall not be permitted for welds on API flanges.
4.2.6 Submerged-Arc Welding (SAW)

b. All welding shall be multipass, with semi- or fully-automatic equipment.
c. Weld passes shall not be greater than 3/8" thick.
d. Addition of alloy agents through the flux shall not be acceptable.
4.2.7 Filler Metals, Electrodes, Wire and Flux

4.2.7.1 Electrodes, wires and fluxes shall be selected to produce welds with mechanical
properties not less than those of the base metal. Filler metal for welding similar
materials shall be of the same nominal analysis as the base metal, except E-
347 electrodes shall be used for SMAW welding of Type 321 material. When
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welding two steels of unequal strengths, the welding wire or electrode shall be
matched to the higher strength material.
4.2.7.2 The weld filler metal in low-temperature piping service shall meet the same
impact test requirements as the base metal.
4.2.7.3 Tensile strength of deposited weld metal shall be limited to 100 ksi maximum
and shall be verified by a hardness test of the weld material in the procedure
qualification. Weld metal hardness shall not exceed 200 Brinell.
4.2.7.4 Carbon steel electrodes for welding API 5L, Grades B and X-42 pipe shall
conform to the following ASME specifications:
• SMAW ASME SFA-5.1
• GTAW/GMAW ASME SFA-5.18
• SAW ASME SFA-5.17
• FCAW ASME SFA-5.20 Classes:
E60T-1, E60T-5, E61T-1, E61T-5
E70T-1, E70T-5, E71T-1, E71T-5
4.2.7.5 Stainless steel electrodes shall be low carbon "L" grade, and shall conform to
the following ASME specifications:
• SMAW ASME SFA-5.4
• GTAW/GMAW ASME SFA-5.9
• FCAW-g ASME SFA-5.22
4.2.7.6 Filler metals for joining carbon steels to stainless steels shall be E309L, except
in services over 600°F where Inco 182 shall be used. Low carbon grades of
austenitic stainless steel shall be joined with low carbon weld metal of
corresponding composition.
4.2.7.7 The following SMAW SFA-5.1 electrode classifications shall not be acceptable
for pressure containing welds:
• E6012
• E6013
• E6020
• E7014
• E7020
• E7024.
4.3 Welding Procedure Qualification

4.3.1 All weld procedures shall have been qualified no more than 6 years prior to the
date of the Contract, Agreement or Purchase Order as applicable. Provided that
the Welding Procedure Specifications (WPS) and Procedure Qualification
Records (PQR) are in full accordance with the Technical Requirements,
qualification of new procedures will be waived by COMPANY.
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4.3.2 If new weld procedures or new procedure qualifications are required,

CONTRACTOR shall bear all costs. All procedure qualifications shall be
performed by an independent testing laboratory suitable to COMPANY.
COMPANY shall, at its option, witness the procedure qualifications.
4.3.3 Procedure qualifications shall include the composition and flowrate of inert gas
backing when used.
4.3.4 For low-temperature services, i.e. 34°F and below, procedure qualifications for
ferritic materials shall include impact tests of both the weld metal and the heat
affected zones, even if impact tests are not required on the base material.
SMAW welds shall only require testing if impact test are required for the base
material.
4.3.5 SAW procedure qualification test records shall show the name of the
manufacturer and the trade name of the wire and flux used to qualify the
procedure.
4.3.6 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 longitudinal and circumferential butt joints made without a
backing ring.
4.3.7 Hardness testing shall be performed as part of the weld procedure qualification
for all sour service carbon steel piping. Two hardness traverses, including weld
metal, heat affected zone (HAZ), and base metal, shall be made on a polished
and etched cross-section of the weld at 1 to 2 mm below the cap pass, and 1 to
2 mm above the root pass. Readings shall be taken every 2 mm in the weld
metal and base metal, and every 1 mm in the HAZ, with a minimum of 3
readings in each zone. Maximum hardness shall not exceed Vickers 250 using a
load not exceeding 22 pounds (10 kg).
4.4 Welder and Welding Operator Qualification

4.4.1 Welders and welding operators shall have been qualified within the 6 months
prior to beginning of fabrication in accordance with the ASME "Boiler and
Pressure Vessel Code" - Section IX "Welding and Brazing Qualifications."
4.4.2 All welder qualifications and certificates with picture identification shall be
submitted to COMPANY for approval prior to any fabrication. If existing welder
qualifications are judged inadequate by COMPANY and welders must be
requalified, welder re-qualification shall be performed at CONTRACTOR’s
expense.
4.4.3 COMPANY reserves the right to witness all welder re-qualification tests.
CONTRACTOR shall notify COMPANY a minimum of two weeks prior to the
tests to allow COMPANY to witness the tests.
4.4.4 Radiographic examination of a qualification test plate (or pipe) in lieu of
mechanical testing shall not be accepted by COMPANY.
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4.4.5 Welders shall have their qualification certificates with picture identification at the
work site during all fabrication.
4.5 Production Welding

4.5.1 Joint Preparation and Fit-up
4.5.1.1 Surfaces to be welded shall be clean and free from all galvanizing, paint, oil,
dirt, scale, oxides or other materials detrimental to welding.
4.5.1.2 Weld bevels shall be suitable for the welding process selected and shall
conform to the bevel in the weld procedure specification. Bevel contour shall
permit complete fusion throughout the joint.
4.5.1.3 Weld bevels shall be made by machining, grinding or thermal cutting, and shall
be reasonably smooth and true. Materials that require preheat for welding shall
be preheated in the same manner for thermal cutting or gouging.
4.5.1.4 Prior to welding, all laminations, split ends and other defects shall be called to
the attention of COMPANY and shall be cropped, repaired or removed as
directed by COMPANY.
4.5.1.5 The use of backing rings, backup strips, strong backs or welded lugs shall not
be permitted.
4.5.1.6 Line-up clamps shall be used when necessary to ensure that fit-up is within
design tolerances. Line-up clamps shall not be removed until a continuous
stringer bead equal to one quarter of the circumference of the pipe has been
completed on both sides of the pipe.
4.5.1.7 Consumable inserts may be used only with written authorization from
COMPANY. Approval for use of consumable inserts shall be obtained prior to the
start of fabrication and included in the Procedure Qualifications as required by
ANSI B31.3 "Chemical Plant and Petroleum Refinery Piping."
4.5.1.8 If the wall thickness difference in a butt-weld joint is greater than 1/16", a
transition in accordance with API 14E "Design and Installation of Offshore
Production Piping Systems" - Appendix B "Acceptable Butt Welded Joint Design
for Unequal Wall Thicknesses" shall be required. The maximum offset shall be
1/16", not 3/32" as allowed by API 14E.
4.5.1.9 If component ends must be trimmed to correct internal misalignment in
accordance with API 14E "Design and Installation of Offshore Production Piping
Systems," the trimming shall not reduce the finished wall thickness below the
required wall thickness (tm) for the pipe or fitting. The required wall thickness (tm)
shall be defined as the design wall thickness including all mechanical, corrosion
and erosion allowances.
4.5.1.10 If the required taper in accordance with API 14E "Design and Installation of
Offshore Production Piping Systems" would result in a trimmed wall thickness
less than the required wall thickness (tm), then CONTRACTOR shall fabricate a
transition spool. This spool shall be fabricated from material equal in grade to
the highest grade material to be welded, and shall have a wall thickness equal
to the thicker pipe or fitting to be welded. The transition spool length shall be at
least one and one half times the nominal pipe diameter, but no less than 12" in
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length. The transition spool shall be internally tapered at one end to match the
thickness of the thinner walled pipe or fitting, and beveled for welding. The taper
angle shall be approximately 4:1, but not less than 14 degrees. CONTRACTOR
shall stencil all transition spools with the pipe size, grade and wall thickness'.
4.5.2 Preheat
4.5.2.1 All welded joints shall be preheated in accordance with the approved weld
procedures. The minimum preheat temperature for thermal cutting, tacking and
welding shall be in accordance with ANSI B31.3 "Chemical Plant and Petroleum
Refinery Piping." Preheat shall be maintained during all multi-pass welding.
4.5.2.2 Additionally, preheating to 100°F shall be required if the base metal is damp, if
the surface temperature is less than 40°F or if the relative humidity is above
50%.
4.5.2.3 All API flanges shall be preheated to minimum 400°F before welding. Preheat
shall be maintained throughout the welding process.
4.5.3 Welding
4.5.3.1 COMPANY shall reject any weld that has not been properly made per the
Technical Requirements. All welds shall be made in such a manner as to reduce
residual stresses.
4.5.3.2 Welding shall not be permitted at ambient temperatures less 40°F when either
the wind velocity exceeds 10 mph or the relative humidity exceeds 50%.
Welding shall not be permitted in inclement weather unless both the welder and
the work are well protected from the elements.
4.5.3.3 Electrodes, filler wires and fluxes shall be kept clean, dry and properly stored
according to the manufacturer's recommendations. Electrodes, filler wire or fluxes
that are damp, greasy or oxidized shall not be used. During welding, care shall
be taken to avoid contamination of fluxes.
4.5.3.4 Low hydrogen electrodes shall be protected from moisture and used within 2
hours of breaking the seal on their original (hermetically sealed) containers. If
the container has been open for more than 2 hours, but less than 8 hours, the
electrodes shall be placed in a heating box and held at 225°F for 8 hours
minimum, and then used within 2 hours of removal from the hot box. Electrodes
exposed longer than 8 hours shall be reconditioned by heating in an oven at
650 to 750°F for 1 hour minimum.
4.5.3.5 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.
4.5.3.6 All welds shall be thoroughly cleaned after each pass by power wire brushing to
remove all slag, scale, splatter, coatings and dirt.
4.5.3.7 Peening shall not be permitted.
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4.5.3.8 Welds on branches or reinforcing pads shall merge smoothly with the surface of
the pipe. Sharp corners on reinforcing pads shall be removed.
4.5.3.9 Welding shall not be permitted on valves without prior written approval from
COMPANY.
4.5.3.10 Seal welding of threaded joints shall cover all exposed threads and blend
smoothly into the pipe. Seal welds on threaded joints shall be made as small as
possible using low penetration electrodes. Seal welds shall be tapered
gradually.
4.5.3.11 Welds containing cracks, regardless of size or location, shall not be acceptable.
Cracks, notches, undercutting or any other evidence of poor workmanship shall
be cause for rejection.
4.5.3.12 At the completion of all fabrication work, all excess weld metal, splatter, and
other foreign material shall be removed. Welds shall be wire brush cleaned to
remove slag and weld spatter. On stainless steel piping, wire brushing shall be
done only with stainless steel brushes which have not previously been used on
ferritic materials. Edges shall be smoothed or rendered flush with the parent
surface unless otherwise approved by COMPANY.
4.5.3.13 Stainless steel piping shall be kept free of surface contamination by iron or
other foreign material. Excessive surface contamination and/or oxidation (heat
tint) of welds shall be removed using an acid pickling solution or paste, or by
blasting with iron-free grit.
4.5.4 Weld Repairs

4.5.4.1 Defective welds shall be plainly marked, cut out and repaired or replaced by
CONTRACTOR in accordance with the procedures specified in the ASME
"Boiler and Pressure Vessel Code" - Section IX "Welding and Brazing
Qualifications." CONTRACTOR shall advise COMPANY in writing of all required
repairs prior to the start of repair work.
4.5.4.2 All costs associated with repairing defective welds shall be borne by
CONTRACTOR.
4.5.4.3 All unacceptable defects in the root or fill passes shall be entirely removed by
grinding or oxygen gouging to clean, sound metal. All slag and scale 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.
4.5.4.4 External undercut shall be repaired by grinding off the weld cap in the undercut
location and recapping.
4.5.4.5 Arc burn defects 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 33-1/2% of the nominal wall thickness may
be repaired by welding. The defect shall be thoroughly removed by grinding,
then the cavity welded and ground smooth. The weld shall be preheated in
accordance with the original preheat requirements for the materials and type of
weld. Arc burns in excess of 33-1/2% of the nominal wall thickness shall be
Page 13 of 44 8/2001
removed by replacing a section of the pipe or fitting in accordance with the

following paragraph.
4.5.4.6 Welds may be cut out and repaired in one location a maximum of two times. If
the second repair is found to be defective, then a section of the pipe no less
than 2'-0" in length (including fittings) shall be removed and replaced. All new
welds in the repaired section shall be radiographed and heat treated (if originally
required) at CONTRACTOR’s expense.
4.5.4.7 After completion of the weld repair, the entire circumference shall be
radiographed using the original method and acceptance criteria to verify
acceptability of the repaired weld.
4.5.4.8 If the original weld required post weld heat treatment, then it shall be heat
treated after the repair using the method originally approved by COMPANY.
5.0 FABRICATION, ASSEMBLY AND ERECTION

5.1 General Piping
5.1.1 Piping shall be neatly installed with piping runs level, straight, plumb, square,
and parallel to platform column rows unless otherwise specified by the Technical
Requirements or approved by COMPANY. Changes in direction shall generally
be made with 90o turns or rolls.
5.1.2 Piping terminations at pressure vessels and major equipment, such as pumps or
compressors, shall be installed so that mating flanges are parallel, concentric
and in contact prior to bolting the piping in place. Flanges shall not require
"springing" to insert gaskets. Piping shall not impose loads greater than that
allowed by the equipment manufacturer, applicable code or Technical
Requirement, whichever is more conservative.
5.1.3 Prefabricated pipe spools shall have a sufficient number of properly located field
welds to allow flanged connections to be installed without imposing excessive
loads, moments or strain into the system.
5.1.4 The maximum offset allowed on pipe spools to be welded together shall be
1/16". Bolt holes in flanged joints shall have less than 1/8" offset. Hammering,
jacking or other mechanical alignment methods shall not be acceptable.
5.1.5 Minimum spacing between circumferential weld joints shall be 2", or 6 times the
wall thickness of the pipe, whichever is greater, unless otherwise approved by
COMPANY.
5.1.6 Couplings or other weld-on type branch connections and fittings shall not be
located on a weld joint.
5.1.7 Flange bolt holes shall straddle normal horizontal and vertical center lines.
5.1.8 Miter welds shall not be acceptable unless approved by COMPANY.
5.1.9 A valved drain connection shall be provided by CONTRACTOR at all piping low
points regardless of whether or not a drain connection is indicated on the
drawings. Piping drain valves shall be a minimum of 3/4" NPS and shall be
provided with plugs or blind flanges, unless specified otherwise by the Technical
Requirements.
Page 14 of 44 8/2001
5.1.10 A vent connection shall be provided by CONTRACTOR at all piping high points
where gas may be trapped, regardless of whether or not a vent connection is
indicated on the drawings. Vent connections shall be a minimum of 3/4" NPS
and shall be provided with plugs or blind flanges, unless specified otherwise by
the Technical Requirements.
5.1.11 Threads on threaded pipe and fittings shall be cut to ANSI B1.20.1 "Pipe
Threads (Except Dry Seal) Specifications, Dimensions, and Gaging for Taper
and Straight Pipe Threads Including Certain Special Applications."
5.1.12 Teflon tape or pipe dope shall be used on all threaded pipe joints, except for
those joints that are to be back welded. Teflon tape or pipe dope shall only be
applied to the male thread of the joint.
5.1.13 Piping "as-built" dimensional tolerance with regard to final end-to-end
dimensions (across the platform) and location of branches or appurtenances
shall be plus or minus 1/8" linearly and plus or minus 2 o angularly. Lines that are
designated as "sloped lines" shall maintain a positive slope in the direction
specified.
5.1.14 For piping that is designated as "sloped," the total slope shall be as uniformly
distributed as practicable throughout the entire length of the line by shimming
the pipe where necessary. After installation, shims shall be seal welded into
place to prevent displacement and loss. Pipe shall be removed or lifted in place
to permit surface preparation and coating of the shims.
5.1.15 An inert gas arc welding process (TIG or MIG) shall be used on the root pass of
welded joints on compressor suction piping that are not accessible for internal
inspection and cleaning. The remaining passes may be welded by the Shielded
Metal-Arc Welding (SMAW) process.
5.2 Pipe Supports

5.2.1 Pipe supports shall be designed, fabricated and installed in accordance with the
AISC "Manual of Steel Construction" and the AWS D1.1 "Structural Welding
Code." Pipe supports shall be designed to withstand the load conditions
specified by the Technical Requirements.
5.2.2 All piping shall be adequately supported and securely clamped to minimize
vibration and prevent unnecessary strain on the piping system, including valves,
instrumentation, meters and equipment. In general, piping shall be supported as
required by the Technical Requirements; namely the approved piping drawings.
However, during piping erection additional supports are often deemed
necessary to meet the Technical Requirements, and shall be provided by
CONTRACTOR at no additional cost to COMPANY.
5.2.3 Pipe supports shall be installed such that no piping butt welds rest on the
support.
5.2.4 Pipe support structures shall be of welded construction. Bolted construction
shall be allowed by COMPANY only if welded construction is prohibited by
shipping, handling, installation or maintenance considerations.
Page 15 of 44 8/2001
5.2.5 Pipe supports shall be welded to main structural beams of the platform, deck,
module or skid. Pipe supports shall not rest upon or be supported by grating,
deck plate or other non-structural elements. Beams shall be fabricated so that
after erection any minor camber as a result of rolling or shop assembly will be
upward.
5.2.6 Holes for bolted connections shall be 1/16" larger diameter than the bolts. All
holes shall be drilled prior to the application of any protective coatings. Torch cut
holes shall not be accepted by COMPANY.
5.2.7 Unless otherwise specified in the Technical Requirements, pipe shall be
clamped to pipe supports using bichromated cadmium plated "U" bolts complete
with rubber sleeves. Neoprene rubber pads, a minimum of 3/8" thick, shall be
provided between the pipe and support for all pipe 8" NPS and smaller. All "U"
bolts shall be double nutted with bichromated cadmium plated nuts.
COMPANY shall not accept galvanized bolting, including studs, bolts, cap
screws, jacking bolts, nuts, washers, "U" bolts, etc., on piping systems, and in
particular, not on stainless steel piping systems.
5.2.8 Where COMPANY approval has been granted to weld supports directly to
piping, the following requirements shall apply:
a. The pipe support shall be welded to the pipe in a manner that will minimize
penetration into the pipe and will minimize local stresses induced in the
piping. Recommend procedures include SMAW (in the downhill direction) or
GMAW.
b. Undercutting shall not be accepted under any circumstances.
c. The pipe support material shall be compatible with the pipe or fitting
material. Preheating, welding and heat treatment of the support to the pipe
shall be in accordance with the welding requirements for the pipe.
5.2.9 CONTRACTOR shall demonstrate the acceptability of pipe support welding
procedures prior to commencement of work. All pipe support welds shall be
subject to visual or NDE inspection and acceptance by COMPANY.
5.2.10 Unless specified otherwise by the Technical Requirements, pipe supports shall
be installed so that bolted spool pieces can be removed for maintenance
without cutting.
5.2.11 Stiffeners shall be fitted accurately, neatly and tightly to transmit bearing loads.
Stiffener ends shall be milled or ground smooth to conform to the geometry of
the member when fillet welds are utilized. Otherwise, stiffener ends shall be
beveled to ensure 100% fusion in the root of the weld.
5.2.12 All pipe support welding shall be full seal welds as a minimum. Seal welds shall
be placed at all contact edges of plate and on the supporting flanges of beams,
tees, etc., and the flat legs of angles. Surfaces inaccessible for coating shall be
sealed by boxing-in with plate. Skip or stitch welding shall not be acceptable
under any circumstances.
Page 16 of 44 8/2001
5.2.13 Splices in structural shapes and pipe shall be full penetration welds to provide
100% joint efficiency. Splicing tolerances shall comply with the AISC "Manual of
Steel Construction."
5.2.14 Splices in structural pipe shall not be closer together than one pipe diameter, or
3'-0", whichever is greater. For beams, splices shall not be closer together than
twice the depth of the beam, or 3'-0", whichever is greater.
5.2.15 If a beam spans a support, the beam shall not be spliced in the middle quarter
of the span, in the eighth of the span nearest the support, or over the support.
5.2.16 Cantilevered beams shall not be spliced closer to the support than one-half the
cantilever span length.
5.2.17 As a minimum, pipe supports fabricated as "ship loose" for installation by
COMPANY (or Others) shall be test-fitted to confirm fit-up, then coated with
primer and color-coded with paint marks to facilitate field assembly. Paint marks
shall be at least 2" high unless limited by the size of the member to be marked.
Marks shall be applied to members in a protected location where they will not be
evident upon completion of installation. Paint mark color shall be in sharp
contrast with the primer paint, and shall be compatible with the primer and finish
paints specified by the Technical Requirements. Paint shall be durable for
exposure to normal atmospheric conditions for a minimum of 6 months.
6.0 POST WELD HEAT TREATMENT

6.1 General
6.1.1 Post weld heat treatment (PWHT) shall be in accordance with ANSI B31.3
"Chemical Plant and Petroleum Refinery Piping" except as modified by the
Technical Requirements.
6.1.2 All carbon steel piping with a wall thickness greater than 3/4" shall be post weld
heat treated at 1100 to 1200°F for 1 hour per inch of nominal wall thickness, but
in no case less than 1 hour.
6.1.3 During heat treatment, all piping shall be properly supported to prevent warping
or deterioration.
6.1.4 Machined surfaces shall be protected by suitable paint or compound to prevent
damage from scaling during heat treatment.
6.1.5 Welding shall not be allowed on piping after post weld heat treatment, unless
specifically authorized in writing by COMPANY and in accordance with ANSI
B31.3 "Chemical Plant and Petroleum Refinery Piping."
6.1.6 When post weld heat treatment of stainless steel piping is required, it shall be at
1550 to 1625°F for 1 hour per inch of nominal wall thickness, but with a 1 hour
minimum. Cooling from heat treatment temperatures shall be in still air outside
the furnace.
Page 17 of 44 8/2001
6.2 Exothermic Heat Treatment

6.2.1 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.
6.2.2 CONTRACTOR shall demonstrate successful past experience in using the
materials on the specified size and wall thickness of pipe.
6.2.3 The process and materials for exothermic treatment shall be subject to approval
by COMPANY.
7.0 QUALITY ASSURANCE AND QUALITY CONTROL

7.1 General
7.1.1 CONTRACTOR shall be responsible for all aspects of quality assurance and
quality control (QA/QC) during all phases of the work, including visual inspection
of all weld preparation, joint fit-up, welding and completed assemblies.
Corrections shall be made as necessary during joint fit-up and weld preparation
to ensure that sound welds can be achieved by the welding process employed.
All welds shall be visually inspected after the work is completed.
7.1.2 COMPANY reserves the right to inspect, or for an authorized representative to
inspect the work at any time during fabrication and to have access to all test
records and results.
7.1.3 CONTRACTOR shall afford COMPANY, free of charge, all necessary and
reasonable information and use of facilities needed for determining that piping
systems are being furnished in accordance with the Technical Requirements.
COMPANY inspection shall not relieve CONTRACTOR of responsibility for all
examinations necessary to assure compliance with the Technical Requirements.
7.1.4 Should the work of a fitter, welder or welding operator be judged unsatisfactory
by COMPANY, the fitter, welder or welding operator shall be removed from the
work by CONTRACTOR. The fitter, welder or welding operator may be
reassigned only after the completion of satisfactory re-qualification tests and
approval of COMPANY.
7.2 Radiography
7.2.1 Radiographic inspection shall be performed by a qualified third party
SubContractor. Self-examination by CONTRACTOR shall not be acceptable to
COMPANY. Technicians shall be qualified to American Society of Nondestructive
Testing (ASNT) Recommended Practice No. SNT-TC-1A "Nondestructive Testing
Qualification and Certification." Inspectors responsible for grading and
interpretation of radiographs shall be Technician Level II or III certified by ASNT
SNT-TC-1A, and helpers shall be SNT-TC-1A Level I certified as a minimum.
7.2.2 Unless specified otherwise in the Technical Requirements, the following
minimum percentages of welds in each pipe class shall be radiographically
inspected:
Pipe Class Rating: Radiograph Inspection Level:
Page 18 of 44 8/2001
ANSI 150 10%

ANSI 300 10%
ANSI 600 10%
ANSI 900 20%
ANSI 1500 20%
ANSI 2500 100%
API 3000 100%
API 5000 100%
API 10000 100%
7.2.3 In addition to the above requirements, 100% of the welds in hydrocarbon

services shall be radiographically inspected. This shall include all lines classified
as process lines, instrument gas, utility gas, diesel fuel, fuel gas, blanket gas (if
hydrocarbon), utility oils, and pipelines as defined in the Technical
Requirements.
7.2.4 In addition to the above requirements, 100% of all welds in hydrogen sulfide
(H2S) services shall be radiographically inspected, including welds other than
girth butt welds if weld geometry permits. Where weld geometry precludes
radiographic examination, the weld shall be examined by the magnetic particle
or liquid penetrant method as outlined in ANSI B31.3 "Chemical Plant and
Petroleum Refinery Piping."
7.2.5 Where radiography is specified to be less than 100%, the radiography shall be a
"random examination" as opposed to a "spot examination." Welds selected to
be examined shall be evenly distributed between all pipe spools and welders in
so much as reasonably possible. Concurrence of COMPANY shall be obtained
on the selection of welds to be examined.
7.2.6 Production welding quality shall be established at the beginning of the work by
radiographic inspection. Welds selected for examination shall be representative
of each welder and welding procedure, and shall be taken shortly after
completion of the weld, but not within 24 hours. The percentage of radiographed
welds shall be evenly distributed among all welders.
7.2.7 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.
7.2.8 All radiographic film shall be identified with a weld number traceable to the weld
location. COMPANY shall not accept any radiographs and/or fabricated items
without proper identification of the weld films.
7.2.9 COMPANY reserves the right to require additional radiographs. Should
additional repairs be required, then CONTRACTOR shall bear all costs for the
additional radiographs and repairs. Should repairs not be required, then
COMPANY will reimburse CONTRACTOR reasonable costs for the additional
radiographs.
7.2.10 If less than 100% of the welds are examined, for each unacceptable weld the
total number of welds to be examined shall be increased by two welds, up to
Page 19 of 44 8/2001
and including radiography on every weld if necessary. All costs associated with
additional radiography as a result of unacceptable welds shall be at
CONTRACTOR's expense.
8.0 FLUSHING AND HYDROSTATIC TESTING

8.1 General
8.1.1 Upon completion of fabrication and inspection, each piping system shall be
flushed and then hydrostatically pressure tested in accordance with ANSI B31.3
"Chemical Plant and Petroleum Refinery Piping" to verify the integrity of the
materials and weldments prior to commissioning and placing the systems in
service. All piping systems shall be hydrostatically tested, including systems
designed for 15 psig and less without regard to the design temperature. Test
requirements may waived only by COMPANY.
8.1.2 CONTRACTOR shall ensure that all portions of the system are tested.
CONTRACTOR shall be responsible for ensuring that test pressures required by
paragraph 8.3.1 do not result in damage to any piping or system components,
including attached equipment and instrumentation.
8.1.3 All fabrication, erection and inspection work, including but not limited to welding,
nondestructive examination, heat treatment, etc. shall be completed and
accepted by COMPANY prior to flushing and hydrostatic testing. The application
of paint, insulation or any other pipe coverings shall not start until successful
completion of hydrostatic testing.
8.1.4 CONTRACTOR shall be responsible for performing flushing and hydrostatic
testing in accordance with the Technical Requirements. Use of SubContractor-
CONTRACTOR(s) shall require COMPANY approval. All tests shall be
performed at a location suitable for performing the tests. Test equipment
including pumps, gauges, recorders, and other items shall be located in the
same area, if possible. Hydrostatic testing shall not be allowed outdoors during
inclement weather conditions.
8.1.5 CONTRACTOR shall prepare detailed hydrostatic test procedures for each
hydrostatic test, including a pressure test flow diagram to define and record the
extent of each test. The procedures shall be submitted for COMPANY review
and approval a minimum of two weeks prior to hydrostatic testing. The diagrams
shall clearly detail the extent of the systems to be tested, the valves to be
opened, and the equipment and instrumentation to be removed, isolated by
blanking with blind flanges, or otherwise protected. Piping classification breaks
shall be clearly marked on all pressure test diagrams. A copy of the mechanical
flowsheets may be marked to produce the required pressure test flow diagrams.
8.1.6 CONTRACTOR shall test as much of the piping system as possible at one time
without exceeding the maximum allowable test pressure of the weakest element
in the system.
8.1.7 If a portion of a piping system cannot be hydrostatically tested because the
presence of water is unacceptable, a notation shall be made on the pressure
test flowsheets indicating that hydrostatic testing is prohibited. The affected
Page 20 of 44 8/2001
portion shall be isolated and tested pneumatically in accordance with Section

9.0 below.
8.1.8 The test fluid normally shall be clean, fresh potable water with a suitable
corrosion inhibitor added by CONTRACTOR. Test fluid shall not contain
suspended solids which may possibly plug orifices or small lines. For stainless
steel piping systems the chloride content of the water shall not exceed 30 ppm.
Alternately, a hydrotest medium such as diesel fuel or kerosene may be
proposed for COMPANY consideration.
8.1.9 The temperature of the hydrotest fluid shall not be less than 60°F. If the fluid
temperature is likely to fall to 32°F during the test period, then glycol or another
COMPANY approved antifreeze shall be added to prevent freezing.
8.1.10 A preliminary test schedule shall be submitted with CONTRACTOR’s work plan,
and updated periodically during fabrication. This schedule shall list proposed
test dates for all piping systems and note deadlines for submittal and approval
of detailed test procedures for each piping system.
8.1.11 CONTRACTOR shall provide COMPANY a minimum of one week notice for all
flushing and hydrostatic testing. The piping system to be flushed and tested
shall be detailed in the notice, including the specific lines and equipment.
8.1.12 Preliminary or unofficial tests may be performed at the discretion of
CONTRACTOR, provided that COMPANY is notified and afforded the
opportunity to witness the tests.
8.2 Preparation for Testing

8.2.1 CONTRACTOR shall ensure that flushing and tests do not result in damage to
equipment and instrumentation. Equipment and in-line instrumentation that may
be damaged by hydrostatic testing shall be isolated by blinds or plugs, or shall
be disconnected from the piping system. This shall include, but not be limited to
turbines, pumps, compressors, safety valves, turbine flowmeters and rupture
discs. Mounted instrumentation shall be removed or isolated from the system
during flushing and testing.
8.2.2 Restrictions that interfere with flushing, filling, venting or draining, such as orifice
plates and flow nozzles shall not be installed until the completion of testing.
8.2.3 After erection and prior to hydrostatic testing, all piping shall be thoroughly
flushed to remove weld slag, blast grit, dirt, sand, trash and other debris, and
foreign materials. CONTRACTOR shall submit a detailed flushing procedure for
approval by COMPANY, which shall be in accordance with the following:
a. Carbon steel piping shall be flushed with potable water. Stainless steel
piping shall be flushed with potable or raw water with a chlorine content
below 30 parts per million (ppm). Piping shall not be flushed with seawater
without prior written approval from COMPANY.
b. Required flushing flowrates shall be determined based on pipe diameter and
flow velocities. Velocities from 8 to 12 feet per second (fps) shall be required
for lines up to 10" NPS. Larger diameter lines shall use the highest velocity
reasonably possible, which shall be approved by COMPANY. Compressed
Page 21 of 44 8/2001
air may be injected into the water while flushing to increase turbulence and
velocity. Drop flushing, the filling and draining of a piping system, does not
constitute flushing and shall not be accepted.
c. Piping and piping systems which cannot be flushed with water (because the
presence of water is unacceptable) shall be blown out with high pressure,
high velocity air. This shall include instrument and utility air lines as a
minimum.
d. Control valves, positive displacement meters, turbine meters, rotameters,
and relief devices shall be removed from the piping system during flushing.
8.2.4 Valving, including ball, gate, globe, plug and butterfly valves shall be in the fully
open position during hydrotesting. Lines containing check valves shall have the
pressure source located on the upstream side, or the check valves shall be
removed from the line or blocked open for hydrotesting.
8.2.5 Expansion joints shall be hydrotested with the piping system to check the
restraining devices.
8.2.6 Control valves shall remain in the line for hydrotesting and shall be in the fully
open position. Valves that are normally closed shall be opened for hydrotesting
using clean dry air. Valves shall not be jacked or forced open by
CONTRACTOR.
8.2.7 Pressure control valves with internal passages between the process fluid and
the diaphragm shall be isolated from hydrotesting. External connections shall be
disconnected or blocked during hydrotesting, and the diaphragm pressure shall
be bled off.
8.2.8 Hydrostatic testing shall be performed with the "in service" type of gaskets, and
shall not utilize any gasket sealing compounds. New gaskets shall be installed
on all connections that are broken after completion of the hydrotesting, or that
must be reassembled after testing.
8.2.9 Temporary supports shall be installed as necessary to prevent sagging or
excessive stress on the piping system. Special consideration shall be given to
supporting partially liquid packed or gas piping systems during flushing and
hydrostatic testing. Particular attention shall be given to systems having spring or
counterweight supports, and to systems containing expansion joints or loops.
8.2.10 Large diameter lines that are grouped together on common supports shall not
be simultaneously hydrotested if the weight of the test medium might overstress
the supports.
8.3 Hydrostatic Leak Testing

8.3.1 Unless specified otherwise by the Technical Requirements, the minimum
hydrotest pressure for steel piping shall be in accordance with the following
table:
Pipe Class Carbon Steel System: Stainless Steel System:
Rating: (psig) (psig)
ANSI 150 450 350
Page 22 of 44 8/2001

ANSI 300 1,125 900
ANSI 600 2,225 1,800
ANSI 900 3,350 2,700
ANSI 1500 5,575 (Note 1) 4,500
ANSI 2500 9,275 7,500
API 3000 4,500 (Note 2) N/A
API 5000 7,500 (Note 2) 6,900 (Note 2)
API 10000 15,000 (Note 2) N/A
Note 1: For flanges 16" NPS and larger the test pressure shall be 4,500 psig.
Note 2: CONTRACTOR shall confirm that all components in API 6A piping
systems are suitable for the specified hydrostatic test pressure prior to
procurement. Components not suitable for the specified hydrostatic
test pressure shall not be utilized by CONTRACTOR without prior,
specific written approval of COMPANY.
Note 3: Refer to technical requirements for hydrostatic test pressure for duplex
stainless steel.
8.3.2 Hydrostatic test pressures are for the new and cold condition, with test
temperatures of 100°F or less. For higher test temperatures, CONTRACTOR
shall be responsible for checking the piping system and determining the
appropriate test pressure. The test pressure shall be selected such that the test
shall not exceed 90% of the yield strength of the weakest component at the test
temperature.
8.3.3 Hydrostatic testing shall be maintained for a minimum of 2 hours after
stabilization of pressure and temperature.
8.3.4 All hydrostatic tests shall be maintained for a sufficient period of time to check
for small seepage leaks. Upon successful completion of the hydrostatic test
period, the piping system shall receive a final visual check for leaks.
8.3.5 Hydrostatic testing shall be performed with two separate pressure gauges and a
dual-pen (pressure and temperature) chart recorder. Pressure gauges and
recorders shall have a pressure range of approximately twice the required test
pressure.
8.3.6 All gauges and recorders shall have been dead-weight tested and certified
within 6 months of hydrostatic testing. The certifications shall be available for
COMPANY review during all hydrostatic testing.
8.3.7 All vents shall be open during filling to ensure proper venting of all air or gases.
8.3.8 Test pressure shall not be applied against any closed valve. Skillets or blinds
shall be installed to protect valves that must remain in the closed position.
8.3.9 If the test liquid in the system is subject to thermal expansion, CONTRACTOR
shall take precautions to avoid excessive pressure. Precautions such as
Page 23 of 44 8/2001
surveillance throughout the test period by a suitably qualified person may be

considered.
8.3.10 Recorder charts shall depict one system test only. Charts shall be signed and
dated by CONTRACTOR and COMPANY upon completion of the test to certify
that the test was performed.
8.3.11 CONTRACTOR shall collect, record and maintain all information required for
complete test records. As a minimum, test records shall include the following
information:
a. Test Date with Start and Finish Times
b. Piping Line and Equipment Numbers (or pressure test flow diagram number)
c. Design Pressure and Temperature
d. Minimum Test Pressure and Hold Time
e. Test Pressure & Temperature Recording Chart
f. Water Chloride Content (stainless steel piping)
g. Test Medium (if not water)
h. Applicable Remarks Concerning Defects
i. CONTRACTOR and COMPANY Approval Signatures
8.3.12 Leaks found during testing shall be repaired and the piping system retested in
accordance with the Technical Requirements. COMPANY reserves the right to
require alternate pressure tests should a piping system fail the standard
pressure test.
8.4 Post-Test Requirements

8.4.1 All piping systems, including equipment and instrumentation included in the
testing shall be thoroughly drained, cleaned and dried upon completion of
testing.
8.4.2 After completion of hydrostatic testing and COMPANY release, the system shall
be de-pressurized by opening the de-pressuring valve on the test rig.
8.4.3 The system shall be completely vented and then drained of the hydrotest fluid.
Particular attention shall be paid to venting during draining to avoid producing a
vacuum in the system and to allow complete drainage. Special attention shall be
given to equipment, instrumentation and piping system low points where water
may be trapped, such as valve bodies or control valve stations, to ensure
complete drainage.
8.4.4 Lines and equipment shall be cleared of all debris after drainage, and then shall
be dried by blowing warm air through the system. In particular, strainers shall be
emptied and cleaned. Alternate drying methods may be employed by
CONTRACTOR if approved by COMPANY, such as vacuum drying.
8.4.5 Soft seated valves, particularly ball valves, shall not be operated until the lines
have been thoroughly cleaned and dried.
8.4.6 All vent and drain valves shall be blinded or plugged after completion of
hydrotest, cleaning and drying.
Page 24 of 44 8/2001
8.5 Leak Repair and Re-testing

8.5.1 CONTRACTOR shall be responsible for all costs associated with repair of
deficiencies resulting from CONTRACTOR’s work or CONTRACTOR-supplied
equipment or materials. Costs shall include, but not be limited to development of
repair procedures, repairs, inspection and testing, radiography, stress relief (if
applicable) and hydrostatic testing necessary to correct the deficiency to
COMPANY’s satisfaction.
8.5.2 CONTRACTOR shall advise COMPANY of all defects in writing, and shall
submit a proposal with recommended repair procedures to COMPANY for
approval prior to starting any repair work.
8.5.3 Welds or portions of welds that leak during hydrostatic testing and that have not
been radiographed previously shall be radiographed at the affected areas
before being cut out and rewelded.
8.5.4 After repair, the welds or portions of welds shall be radiographed again. The
hydrostatic test shall be performed again to verify the repairs, unless specifically
approved otherwise by COMPANY in writing.
9.0 PNEUMATIC TESTING

9.1 General
9.1.1 Pneumatic testing may be substituted for hydrostatic testing only with prior
written approval by COMPANY, and if:
a. Hydrostatic testing is totally impractical, or
b. Piping or attached equipment might be damaged by water and no alternative
exists to avoid damage, or
c. Even a small amount of water left in a system could contaminate or injure
the system, such as in a refrigerant or aviation fuel system.
9.1.2 For safety reasons, the volumes of systems being pneumatically tested shall be
kept to a minimum.
9.1.3 Unless otherwise specified, pneumatic tests shall utilize clean, dry air or
nitrogen as the test medium. If air is utilized to test instrument air lines it shall
also be oil-free.
9.1.4 If a test requires a closure joint (flanged, screwed, or welded) for blocking
purposes, the integrity of the repaired or reworked joint shall be tested as
applicable.
9.1.5 Access to pneumatic test areas shall be restricted to personnel absolutely
required to conduct the tests.
9.2 Pneumatic Leak Testing

9.2.1 Pneumatic test pressures shall be in accordance with the following table, except
that the maximum hoop stress during testing shall not be greater than 50% of
the specified minimum yield strength as noted in 49 CFR 192 "Transportation of
Natural and Other Gas by Pipeline: Minimum Federal Safety Standards":
Page 25 of 44 8/2001

ANSI 150 315 300
ANSI 300 815 790
ANSI 600 1,630 1585
ANSI 900 2,440 2375
ANSI 1500 4,075 3960
ANSI 2500 6,785 6600
9.2.2 CONTRACTOR shall be responsible for developing appropriate procedures for

pneumatic leak testing. Procedures shall be submitted for COMPANY review
and approval, and shall incorporate the following as a minimum:
a. The pneumatic test pressure shall start at 25 psig.
b. The test pressure shall be increased gradually in increments of 15 psid to
provide time for stress in the piping to equalize. The gradual increase also
provides sufficient time to check for leaks.
c. After the full test pressure has been reached and the temperature has
stabilized, all piping welds and connections shall be inspected for leaks,
after which the pressure shall maintained for a minimum of 1 hour, and the
piping welds and connections inspected for leaks again to complete the test.
9.2.3 All welds and threaded connections shall be inspected for leaks with a
soapsuds test. All flanged connections shall be masked with tape and a small
pinhole punched in the tape to facilitate the identification of leaks.
9.2.4 If both hydrostatic and pneumatic pressure testing may damage the piping
system, alternate testing methods may be performed with prior written approval
of COMPANY. Alternate testing methods shall include the following:
a. Butt welds shall be 100% radiographed in accordance with ANSI B31.3
"Chemical Plant and Petroleum Refinery Piping."
b. Welds, other than butt welds shall be liquid penetrant and magnetic particle
tested in accordance with the ASME "Boiler and Pressure Vessel Code" -
Section V "Nondestructive Examination" - Article 6 and Article 7 respectively.
If heat treating is required, the above examinations shall be performed after
completion of heat treating. Limitations or imperfections found as a result of the
tests shall be stated as required by ANSI B31.3 "Chemical Plant and Petroleum
Refinery Piping."
10.0 CLEANING, DESCALING AND PASSIVATING CARBON STEEL PIPING

10.1 General
10.1.1 CONTRACTOR shall clean, descale (pickle) and passivate carbon steel piping
systems as specified by the Technical Requirements, as well as where
recommended by equipment manufacturer's. In general, any piping service in
which scale can potentially cause damage to downstream equipment shall be
cleaned, descaled and passivated by CONTRACTOR. As a minimum, all piping
in the following services shall be cleaned, descaled and passivated:
Page 26 of 44 8/2001
• Compressor Suction Piping (from the Scrubber, Filter or K.O. Drum)

• Compressor Interstage Coolers, and Suction and Bypass Piping
• Compressor Suction Pulsation Dampeners
• Lube Oil Piping
• Seal Oil Piping
• Control Oil Piping
• Hydraulic Oil Piping
• Fuel Gas Piping to Equipment Drivers
• Diesel Fuel Piping to Equipment Drivers.
10.1.2 The cleaned, descaled and passivated pipe shall be free of all scale, rust, weld
flux, oil, grease and other foreign materials and shall be equivalent to a Steel
Structures Painting Council SP-8 "Acid Pickling" or SP-6 "Commercial Blast
Finish" surface. All weld flux, metal shavings, coatings, sand, dirt and other
foreign materials not soluble in chemical cleaning solutions shall be removed
prior to fabrication or cleaning operations.
10.1.3 CONTRACTOR shall propose the cleaning, descaling and passivation method,
unless otherwise specified by COMPANY. However, the method shall be
approved by COMPANY prior to the start of work.
10.2 Acid Pickling and Passivation

10.2.1 General
10.2.1.1 CONTRACTOR shall be responsible for acid pickling (descaling) and
passivation, including the selection of pickling solutions and inhibitors.
CONTRACTOR shall properly control the pickling solution to avoid excessive
corrosion of the metal by the pickling solution. CONTRACTOR shall ensure that
test samples (corrosion coupons) representative of all materials in the piping
system are exposed to the pickling solution. Exposure of the test coupons shall
be for the entire duration to accurately monitor the corrosive effect of the
solution on the piping system. A typical pickling procedure shall be as outlined in
the following sections.
10.2.1.2 Pickling solutions shall not be allowed to contact any parts of process
equipment or instrumentation.
10.2.1.3 Pickling solutions shall not be allowed to contact valves, check valves, relief
valves, meters, instrument tubing, strainers, or other piping components that
contain elastomer seals, chrome or nickel plating, or galvanized coatings.
10.2.2 Precleaning and Rinsing

10.2.2.1 CONTRACTOR shall circulate a 2% (wt.) trisodium phosphate solution with
wetting agent (surfactant) to remove grease and oil films from the pipe before
pickling. Solution shall be mixed in accordance with the manufacturer's
instructions, and the pipe treated for 1 to 2 hours at 140 to 160°F. All oil and
grease shall be removed before the start of pickling.
Page 27 of 44 8/2001
10.2.2.2 After removing the precleaning solution, the system shall be rinsed with clean,
potable water until the pH of the effluent rinse is within one pH of the fresh rinse
water.
10.2.3 Acid Pickling (Descaling)

10.2.3.1 The system shall be pickled (descaled) with one of the following solutions:
a. Sulfuric acid (10%) for 4 to 6 hours at 150°F. When mixing acid with water,
CONTRACTOR shall ensure that the acid is added to the water, not water
added to acid.
b. Hydrochloric acid (7%) for 4 to 6 hours at 150°F. Note that all alloy trim
valves shall be temporarily removed to avoid pitting of the trim. HCl is an
acceptable alternative when valves can be temporarily removed.
c. Inhibited ammoniated citric acid (3% to 5%) for 6 hours at 180 to 200°F.
Citric acid and inhibitor shall be mixed into the water first, and the ammonia
added to adjust the pH to between 4 and 5. Use of ammoniated citric acid
allows both pickling and passivating with the same solution, eliminating the
steps required in Section 10.2.4 below.
10.2.3.2 The system shall be agitated as necessary during circulation to flush out all
loose scale. An inhibitor shall be used during pickling in accordance with the
manufacturer's instructions.
10.2.3.3 Acceptable inhibitors shall be as follows:
• Armohib 31 for sulfuric or citric acid
• Rodine #213 or #214 for hydrochloric acid.
10.2.3.4 After pickling for the required time period the acid solution shall be drained
under a nitrogen purge.
10.2.3.5 The system shall then be rinsed again in accordance with Section 10.2.2.2
above. The rinse shall be removed under a nitrogen purge. When using an
ammoniated citric acid, this step may be deleted.
10.2.4 Neutralization
10.2.4.1 A neutralizing solution of 2% soda ash (sodium carbonate) shall be circulated to
remove all traces of acid from the system. The solution shall be circulated for a
minimum of 1 hour at 120°F, and then drained under a nitrogen purge. When
using an ammoniated citric acid, this step may be deleted.
10.2.4.2 After neutralizing, the system shall be rinsed with water until all traces of acid
and neutralizing solution have been removed, and then drained under a
nitrogen purge. When using an ammoniated citric acid, this step may be
deleted.
10.2.5 Passivation
Page 28 of 44 8/2001
10.2.5.1 After rinsing, the descaled pipe shall be passivated to minimize further corrosion
by applying a phosphate coating. The passivation solution shall be circulated for
1 hour at 130 to 150°F, and consist of the following:
• 0.25% (wt.) monosodium phosphate
• 0.25% (wt.) disodium phosphate
• 0.50% (wt.) sodium nitrite
10.2.5.2 If an ammoniated citric acid was used for descaling, the steel surfaces shall be
passivated by raising the pH to between 9 and 10 through addition of ammonia,
and then adding 0.5 % sodium nitrite and circulating for 1 to 2 hours.
10.2.5.3 After passivation, the system shall be drained and dried thoroughly with dry air
or nitrogen. The system shall not be flushed with water after passivation. After
drying, the pipe shall be closed tightly, blanketed with an inerting gas or filled
with oil to minimize corrosion.
10.2.6 Safety
10.2.6.1 All of the above acids and most of the other treating solutions are harmful in the
event of skin contact, if swallowed, or if fumes are inhaled. Material Safety Data
Sheets (MSDS) shall be available at the job site for all chemicals being
employed. All personnel shall be properly educated and protected against
exposure by safety equipment, including chemical goggles, rubber gloves and
face shields as a minimum.
10.2.6.2 During the acid treating stage of the procedure, hydrogen gas is liberated by
reaction of the acid with the metal. Suitable precautions shall be taken to
minimize any explosion danger resulting from hydrogen accumulation in holding
tanks or other areas. Holding tanks shall be located a minimum of 50' from
process equipment and nonclassified electrical equipment. Smoking shall not be
allowed in the chemical cleaning area under any circumstances.
10.2.6.3 Safety showers shall be available and ready for use at the site. Breathing
apparatus shall be available in case of exposure to toxic fumes.
10.2.6.4 All work areas shall be barricaded with yellow and black tape with "KEEP OUT"
warning signs every 50'.
10.2.6.5 Only proper equipment shall be used. Hoses shall have a minimum working
pressure of 250 psig and shall be chemically compatible with the cleaning
solutions. Hoses shall be bonded to ground to minimize static discharge
explosion hazards.
10.2.6.6 The circulating system shall be pressure tested to 1.5 times the maximum
circulating pressure, or 90 psig, whichever is greater, and all hoses and
circulation system piping and fittings checked for leaks. All leaks shall be
repaired prior to using any chemical solutions.
10.2.6.7 Should a leak develop during circulation of the system, the chemical shall be
evacuated and the piping flushed. The leak shall be repaired before restoring
circulation.
Page 29 of 44 8/2001
10.2.7 Environmental
10.2.7.1 CONTRACTOR shall develop a detailed contingency plan and shall have
equipment available to contain and clean up any chemical leaks. Storm drains
shall be sandbagged prior to the start of cleaning. Any and all chemical spills
shall be reported to COMPANY immediately.
10.2.7.2 All materials used for chemical cleaning shall be considered hazardous.
Chemical effluent shall be handled in a responsible way, and in compliance with
all city, county, state and federal regulations.
10.3 Abrasive Blasting

10.3.1 Scale may be removed by abrasive blasting. Blasting shall remove all scale,
grease, debris, etc., resulting in a Steel Structures Painting Council (SSPC) SP-
6 "Commercial Blast Finish" surface. After blasting the piping shall be cleaned of
all abrasives, dust and foreign material. The pipe shall be thoroughly
passivated, dried and sealed to prevent corrosion in accordance with Section
10.2.5 above.
10.3.2 The abrasive shall be new, clean and dry. Grit or slag abrasives shall be
preferred over sand. If sand is utilized, it shall be washed and clay-free.
10.4 Hot Oil Flushing

10.4.1 CONTRACTOR shall hot oil flush all lube, seal, and control oil piping systems,
including those for drivers, pumps, compressors, and generators prior to the first
fill of oil, as specified in the Technical Requirements.
10.4.2 CONTRACTOR shall submit a detailed hot oil flushing procedure for approval by
COMPANY, which shall be in accordance with the following as a minimum:
a. All tanks, filter housings, cooler header boxes and other system components
shall be opened, inspected, and wiped clean prior to hot oil flushing.
b. All bearing and seal housings shall be isolated from for flushing, and jumper
lines installed.
c. Oil used for flushing shall be the same type of oil specified for normal
operation of the system being cleaned.
d. The oil shall be heated to between 150 and 180°F and shall be circulated
throughout the system until filter screens are free of debris. The oil shall be
circulated for a minimum of 8 hours. Final acceptance criteria shall be
determined by COMPANY in conjunction with the equipment manufacturer.
10.4.3 After flushing, CONTRACTOR shall drain and properly dispose of all flushing oil
in accordance with all city, county, state and federal regulations.
11.0 PROTECTIVE COATINGS

11.1 CONTRACTOR shall provide protective coatings in accordance with the
Technical Requirements, including but not limited to surface preparation,
abrasive blasting, coatings, touchup and repairs, inspection, testing and
documentation records.
Page 30 of 44 8/2001
11.2 All coating work shall be performed after completion of all fabrication and
testing, including hydrostatic or pneumatic pressure testing.
11.3 The exposed portions of all blinds shall be greased to prevent corrosion.
12.0 IDENTIFICATION AND MARKINGS

All piping shall be identified by color code or piping labels in accordance with
COMPANY "Safety in Designs" Manual (GO-590) and with ANSI A13.1 "Scheme
for the Identification of Piping Systems." Piping shall be identified with painted
stencils or a COMPANY approved vinyl labeling system. Identification markings
shall be black lettering on a gray background, with 2" to 3" high letters
depending on the pipe size. Spacing of identification markings shall not exceed
40'. Flow direction arrows shall be provided with all labels.
13.0 PREPARATION FOR SHIPMENT AND STORAGE

13.1 CONTRACTOR shall be responsible for preparation for shipment and storage in
accordance with the Technical Requirements, the Commercial Terms and
Conditions, and as specified herein.
13.2 All unpainted finished surfaces, i.e. flange gasket faces, threads, weld bevels,
blinds, etc., shall be protected against corrosion by applying a suitable rust
preventive or grease.
13.3 All exposed piping connections, i.e., flanges, couplings, beveled weld joints,
etc., shall be protected against mechanical damage during storage, transit and
installation. Protection measures shall include, but not be limited to the
following:
a. All threaded connections shall be protected by metal thread protectors.
b. All exposed flange faces shall be protected by bolting on a steel plate or
wood cover, complete with a gasket. Wood covers shall be constructed from
marine grade plywood with a 1/2" minimum thickness. Flange covers shall
be secured with a minimum of four (4) bolts, but in no case less than 50% of
the total bolting. Plastic snap-on end covers shall not be acceptable.
c. All beveled ends shall be protected by snug fitting bevel protectors.
13.4 Prefabricated piping shipped for field assembly shall be marked with the spool
piece number, drawing number and an arrow indicating the direction of flow with
white paint. Pipe pieces shall be numbered consecutively in the direction of flow.
13.5 Flanged pipe spools shall have the spool identification number stenciled on the
flange. Spool numbers shall correspond to codes on spool sheets and assembly
drawings.
13.6 Two complete sets of "as-built" spool drawings shall be shipped with pipe to be
assembled or installed by COMPANY. The drawings shall contain all information
necessary for assembly and installation of the component parts.
13.7 For items to be shipped overseas, by either COMPANY or CONTRACTOR, a
complete list of all items shall be submitted to COMPANY at least 3 weeks in
advance of shipment. This list shall contain a detailed description of all items,
Page 31 of 44 8/2001
and shall reference drawings or spool sheets as applicable. Each item shall be
listed separately, and an approximate weight and dimension for each shall be
provided. The material packing method shall be identified, i.e. crated, palletized,
bundled, skid-mounted, boxed, etc. as applicable.
13.8 Related materials shall be bundled, palleted, or crated together. Ship loose
items shall be carefully inventoried and crated or palletized. A copy of the
inventory shall be included in each crate or attached to each pallet.
14.0 DOCUMENTATION REQUIREMENTS

14.1 CONTRACTOR shall be responsible for providing documentation in accordance
with the Technical Requirements. As a minimum this shall include "as-built"
dimensional data on all piping within CONTRACTOR’s scope of work.
14.2 CONTRACTOR shall maintain all mill test reports and heat numbers to provide
full material traceability for all materials used in fabrication and assembly.
14.3 CONTRACTOR shall maintain records on all welds. This shall include weld
procedure, welder identification code or symbol, and NDE results as a minimum
for each weld. The weld records shall be coded to correspond with the isometric
or spool drawings so that the location of each weld is clearly identifiable.
14.4 CONTRACTOR shall maintain records of all pressure testing. Test procedures,
reports, and test results shall be submitted to COMPANY upon completion of
tests and prior to shipment of the piping.
14.5 CONTRACTOR shall submit pickling and passivation procedure for approval by
COMPANY.
Page 32 of 44 8/2001
APPENDIX I
MANDATORY CODES AND STANDARDS
American Institute of Steel Construction (AISC)

Manual of Steel Construction
American National Standards Institute (ANSI)

A13.1 Scheme for the Identification of Piping Systems
B1.20.1 Pipe Threads (Except Dry Seal) Specifications, Dimensions, and Gaging for
Taper and Straight Pipe Threads Including Certain Special Applications
B16.5 Pipe Flanges and Flanged Fittings
B31.3 Chemical Plant and Petroleum Refinery Piping
American Petroleum Institute (API)

5L Specification for Line Pipe
6A Specification for Wellhead Equipment
RP 14E Design and Installation of Offshore Production Piping Systems
15LR Specification for Low Pressure Fiberglass Line Pipe
American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code
Section V Nondestructive Examination
Section IX Welding and Brazing Qualifications
American Society of Nondestructive Testing (ASNT)

SNT-TC-1A Nondestructive Testing Qualification and Certification
American Society for Testing and Materials (ASTM)

A36 Specification for Structural Steel
A53 Specification for Steel Pipe, Black or Hot-Dipped Zinc Coated
A106-B Specification for Carbon Steel Pipe
A325 Specification for High-Strength Bolts for Structural Steel Joints
A370 Mechanical Testing of Steel Products
A790 Seamless and Welded Ferritic/Austenitic Stainless Steel Pipe
D2846 Specification for Chlorinated Poly Vinyl Chloride (CPVC) Plastic Hot- and Cold-
Water Distribution Systems
E562 Determining Volume Fraction by Systematic Manual Point Count
F402 Practice for Safe Handling of Solvent Cements and Primers Used for Joining
Thermoplastic Pipe and Fittings
F493 Specification for Solvent Cements for Chlorinated Poly Vinyl Chloride (CPVC)
Plastic Pipe and Fittings
Page 33 of 44 8/2001
American Welding Society (AWS)

A4.2 Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta
Ferrite Content of Austenitic Stainless Steel Weld Metal
A5.1 Specification for Covered Carbon Steel Arc Welding Electrodes
A5.5 Specification for Low Alloy Steel Covered Arc Welding Electrodes
A5.9 Specification for Corrosion Resisting Chromium and Chromium-Nickel Steel
Bare and Composite Metal Cored and Stranded Welding Electrodes and
Welding Rods.
D1.1 Structural Welding Code
Manufacturers Standardization Society of the Valve Fittings Industry (MSS)

SP 58 Pipe Hangers and Support - Materials, Design and Manufacture
National Association of Corrosion Engineers (NACE)

MR-01-75 Sulfide Stress Cracking Resistant Metallic Material for Oil Field Equipment
National Fire Protection Association (NFPA)

54 National Fuel Gas Code
Steel Structures Painting Council (SSPC)

SP-6 Commercial Blast Finish
SP-8 Acid Pickling
Page 34 of 44 8/2001
APPENDIX II
ADDITIONAL REQUIREMENTS FOR DUPLEX STAINLESS STEEL
A2.1.0 SCOPE
This appendix defines additional or modified requirements for fabrication,
welding and inspection of duplex stainless steel (UNS) S31803 piping
conforming to ASTM A790 "Seamless and Welded Ferritic/Austenitic Stainless
Steel Pipe."
A2.4.0 WELDING
A2.4.1 General
Unless otherwise approved in writing by COMPANY, the maximum heat input
shall be limited to 38 kilojoules/inch. The heat input used for the procedure
qualification shall be recorded on the procedure qualification.
A2.4.2 Welding Processes
A2.4.2.3 Gas Metal-Arc Welding (GMAW)

The use of the short-arc GMAW shall not be permitted.
A2.4.2.4 Gas Tungsten-Arc Welding (GTAW)

a. Shielding gas shall be argon plus 2% nitrogen. A pure nitrogen internal gas
purge shall be used for the root pass and second layer of all GTAW welds.
b. Autogenous welding shall not be permitted, i.e. filler metal addition shall be
required.
A2.4.2.7 Filler Metals, Electrodes, Wire and Flux

a. Filler material selection shall be based on both corrosion and mechanical
property considerations. The filler material shall be of the same composition
as the base materials but with a higher nickel content to improve as-welded
properties. All welding consumables shall be subject to COMPANY approval
prior to fabrication. Submerged-arc wire and flux shall be from the same
manufacturer.
b. Duplex stainless steel weld deposits shall have a ferrite content in the range
of 30 to 60%. The ferrite content of the heat affected zone (HAZ) shall be in
the range of 40 to 60%.
A2.4.3 Welding Procedure Qualification
Page 35 of 44 8/2001
A2.4.3.1 Welding procedures shall be qualified in writing and shall be qualified in

accordance with ASME Section IX. In addition to the requirements of ASME
Section IX, the following shall be essential variables for the procedure
qualification:
a. A change from any base material used in qualification to any other

COMPANY approved material.
b. Any change in consumables manufacturer or trade name.
c. Any change in heat exceeding +/-10% of that used on the procedure

qualification test.
A2.4.3.2 The following additional requirements shall be part of the procedure

qualification:
a. A cross-section of the procedure qualification weld shall be made.

Examination shall be at a minimum of 400X. The cross-section shall show a
properly made weld. The microstructure shall be free from grain boundary
carbides, nitrides and intermetallic phases. The austenite / ferrite ratio shall
be determined and carried out according to ASTM E562 "Determining
Volume Fraction by Systematic Manual Point Count" point counting, and
shall meet the requirements of paragraph A2.4.2.7.b above.
b. A microhardness traverse shall be run across the weld metal, heat affected
zone and the base metal at a maximum of 2 mm below the cap pass. Six
equally spaced indentations shall be made in the weld metal. In the heat
affected zone, indentations shall start as close to the fusion line as possible
and shall be made along the traverse at 0.5 mm increments into unaffected
base material. The base material shall have a minimum of 3 indentations.
The maximum hardness at any location shall not exceed 285 HV10.
c. Charpy impact testing in accordance with ASTM A370 "Mechanical Testing

of Steel Products" shall be carried out on samples from the procedure
qualification test. Three sets of three specimens each shall be taken, one
set each from the base metal, weld metal and heat affected zone. The test
temperature shall be -20oF. The average of each set shall be a minimum of
25 ft-lbs, and no individual test shall be less than 20 ft-lbs based on full
sized (10 mm x 10 mm) specimens.
Page 36 of 44 8/2001
A2.4.5 Production Welds
A2.4.5.4 Weld Repairs

All defective welded joints shall be repaired by the procedure qualified in
accordance with the Technical Requirements. Any weld with an unacceptable
defect may only be repaired once. If the repair is not acceptable, the complete
weld shall be removed. Any beveled edge that has been damaged shall be
restored within tolerances required by the Weld Procedure Specification.
Restoration of beveled edges by welding shall be prohibited. Weld repairs shall
be reexamined by the original method to verify that the welds are free from
defects.
Page 37 of 44 8/2001
APPENDIX III
ADDITIONAL REQUIREMENTS FOR FIBERGLASS

REINFORCED PLASTIC (FRP) PIPING
A3.1.0 SCOPE
A3.1.1 This appendix defines additional or modified requirements for fabrication,
installation, inspection and testing of Ameron Bondstrand Fiberglass Reinforced
Plastic (FRP) piping. This specification also describes the minimum
requirements for fabrication, installation and testing of Ameron PSX L3 FRP
piping for firewater and deluge service.
A3.1.2 CONTRACTOR shall be responsible for the detailed design, installation, testing
and supply of all materials necessary to make the piping system complete and
operable.
A3.2.0 PIPE INSTALLATION AND ASSEMBLY
A3.2.1 General
A3.2.1.1 Piping and fittings shall be designed, fabricated and installed in accordance with
ANSI B31.3 "Chemical Plant and Petroleum Refinery Piping," except as
specified otherwise by the Technical Requirements. All pipe installation and
fabrication work shall be in strict accordance with the FRP pipe manufacturer's
recommendations.
A3.2.1.2 Fiberglass piping (FRP) and resins used for potable and utility service shall be
approved by the U.S. FDA for use with potable water and shall be clearly
labeled as such.
A.3.2.1.3 All joints shall be bonded or flanged. Threaded FRP joints shall not be
permitted, except for stainless steel bushings imbedded in FRP saddles which
shall be acceptable for small bore connections for instrumentation and
vent/drain connections.
A3.2.2 Handling and Storage

A3.2.2.1 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. End protection covers shall remain on all exposed joints until
immediately before joint assembly to prevent damage or material degradation.
A3.2.2.2 Chains shall not be used for handling pipe or fittings. When lifting with hoists or
cranes, or securing for transportation, only rope or webbed slings shall be used.
A3.2.2.3 Pipe and fittings shall not be thrown or dropped, and shall be protected from
bumping or hitting during all handling work.
Page 38 of 44 8/2001
A3.2.3 Bonded Joints

A3.2.3.1 Bonded bell and spigot connections, and butt and wrap connections shall be
made in strict accordance with the FRP pipe manufacturer's recommendations.
As a minimum, considerations shall include adhesives and sealing resins, curing
agents, weather conditions for pipe assembly, curing methods and times, fit-up
and joint preparation, and material handling and support.
A3.2.3.2 All tools recommended by the FRP pipe manufacturer, especially those for joint
preparation, shall be used.
A3.2.4 Flanged Connections

A3.2.4.1 Flanged connections shall generally not be allowed on FRP piping in 16" NPS
and below, except where required at skid interfaces, equipment nozzles,
valving, and in-line instrumentation, or where required for operations or
maintenance. All flanges shall be ANSI B16.5 Class 150 flat face (FF) and shall
utilize 1/8" thick full face elastomeric gaskets.
A3.2.4.2 All flanged joints shall be uniformly tightened and shall be torqued to the pipe
manufacturer's recommended limit, but not beyond.
A3.2.4.3 Butterfly valves and wafer check valves shall be installed so that the disc swings
clear of adjacent piping.
A3.2.4.4 Prefabricated skid piping shall be shipped with the flanged joints loosely bolted
to provide maximum flexibility during transportation.
A3.2.5 Flexibility, Layout, and Support
A3.2.5.1 The CONTRACTOR shall ensure and review all piping layouts for suitability of
piping flexibility and support. All types of supports shall be in accordance with
the pipe manufacturer’s recommendations. Support cradles shall provide 180
degrees of circumferential support.
A3.2.5.2 Metal supports shall be isolated from the FRP pipe by FRP saddles, elastomeric
liners or other materials approved by the pipe manufacturer.
A3.2.5.3 Valves and heavy components shall at all times be independently supported or
suspended to prevent excessive torque, bending and longitudinal stresses
being transmitted to or carried by the pipe system.
A3.2.5.4 Direction changes in close proximity to pump discharges shall be avoided to the
best extent possible
A3.2.6 Coating
A3.2.6.1 Conventional coatings for the purpose of preventing or delaying ultraviolet (UV)
damage shall not be required.
Page 39 of 44 8/2001
A3.2.6.2 Material selection for firewater pipe and fittings shall be as follows:
Dry Systems Wet Systems
----------------------------------- ---------------------------------------
2000m - FP or PSX JF 2000m w/ 5m minimum intumescent
coating at all joints and fittings or PSX63
A3.2.6.3 Fire protection for flanges in firewater systems shall be accomplished by

covering the flanges with molded, intumescent coated, half shell covers
approved by the FRP pipe manufacturer. This protection is required for all
material types listed in A3.2.5.2 above.
A3.2.6.4 Acceptable intumescent, fire protective coatings shall be limited to Pitt-Char

(PPG Industries) and Chartek (Textron Specialty Materials). Alternative coatings
shall not be accepted or approved by COMPANY after award of the Contract,
Agreement or Purchase Order, as applicable. Coatings shall be applied in strict
accordance with the FRP pipe and coating manufacturer's recommendations.
A3.3.0 QUALITY ASSURANCE
A3.3.1 General
CONTRACTOR shall visually inspect all piping and fittings for damage per the
visual acceptance standards detailed in API 15LR "Specification for Low
Pressure Fiberglass Line Pipe." Visual inspection shall occur upon receipt and
before any assembly. Damaged or defective material shall not be used.
Specific, written COMPANY approval to use damaged or defective material shall
be required, and must be granted on a case by case basis.
A3.3.2 Training and Certification

The FRP pipe manufacturer shall train and certify all CONTRACTOR workers
involved in pipe assembly and piping fabrication. Worker certification shall be in
strict accordance with the FRP pipe manufacturer's recommendations. The
CONTRACTOR shall certify all procedures by testing in accordance with ANSI
B31.3 "Chemical Plant and Petroleum Refinery Piping."
A3.3.3 Pressure Testing

A3.3.3.1 All assembled piping systems shall be cyclically hydrotested at 1.5 times the
maximum operating pressure by raising the pressure to the test pressure (at a
maximum rate of 100 psig per minute), then holding pressure for 5 minutes,
releasing the pressure, and then repeating until the system has been
satisfactorily cycled up and down at least 5 times without leaking.
Page 40 of 44 8/2001
A3.3.3.2 Following successful cyclic test, the system shall be hydrostatically pressure
tested at 1.5 times the rated design pressure (new & cold) for at least 4 hours
without leaking. The 4 hour test shall not begin until the last "leak" is repaired or
stopped. A subsequent leak after the test has begun shall cause the test to be
restarted such that there are four consecutive hours of leak-free testing.
CONTRACTOR shall verify that the hydrostatic test pressure will not exceed
FRP pipe manufacturer's allowables.
A3.4.0 REPAIRS
Defective joints or pipe shall be repaired by cutting out the defect and bonding
in new joints or pipe. CONTRACTOR may submit a wrap repair procedure for
COMPANY consideration, but submittal and approval/rejection shall be on a
case by case basis. The wrap repair procedure shall be in accordance with the
FRP pipe manufacturer's recommendations.
Page 41 of 44 8/2001
APPENDIX IV
ADDITIONAL REQUIREMENTS FOR CHLORINATED

POLY VINYL CHLORIDE (CPVC) PIPING
A4.1.0 SCOPE
A4.1.1 This appendix defines additional or modified requirements for fabrication,
installation, inspection and testing of Chlorinated Poly Vinyl Chloride (CPVC)
piping conforming to ASTM D2846 "Specification for Chlorinated Poly Vinyl
Chloride (CPVC) Plastic Hot and Cold Water Distribution Systems."
A4.2.0 PIPE INSTALLATION AND ASSEMBLY

A4.2.1 CPVC pipe, tubing, and fittings shall not be assembled or installed if the
ambient temperature is below 40°F or above 110°F.
A4.2.2 CPVC pipe, tubing, and fittings shall be handled with extreme care to avoid
damage such as abrasions, cracking or crushing.
A4.2.3 Pipe and tubing cuts shall be square and de-burred to insure a proper fit-up of
the joint being made.
A4.2.4 All joint contact surfaces between pipe and fittings shall be solvent cleaned prior
to the application of cement. Cement shall be applied to both surfaces to be
joined. The amount of cement applied shall cause a small bead of cement to
appear at the junction.
Sufficient ventilation shall be provided to remove toxic and flammable vapors.
A4.2.5 CPVC pipe, tubing, and fittings shall be cemented with CPVC solvent cement.
The cement shall be in accordance with ASTM F493 "Specification for Solvent
Cements for Chlorinated Poly Vinyl Chloride (CPVC) Plastic Pipe and Fittings."
CPVC solvent cement shall be orange in color to facilitate identification and
minimize the unintentional use of other cements.
Extreme caution shall be taken when handling, applying, and storing solvent
cement. Handling and storage of solvent cement shall be in accordance with
ASTM F402 "Practice for Safe Handling of Solvent Cements and Primers Used
for Joining Thermoplastic Pipe and Fittings."
A4.2.6 Threaded connections in CPVC piping shall not be permitted.
Page 42 of 44 8/2001
APPENDIX V
ADDITIONAL REQUIREMENTS FOR API 5L GRADE X-60 CARBON STEEL PIPING
A5.1.0 SCOPE
A5.1.1 This appendix defines additional or modified requirements for procurement,
fabrication, installation, inspection and testing of API 5L Grade X-60 carbon
steel piping systems provided in accordance with ANSI B31.3 "Chemical Plant
and Petroleum Refinery Piping."
A5.1.2 These requirements are not intended to apply to pipelines provided in

accordance with ANSI B31.4 "Liquid Transportation Systems for Hydrocarbons,
Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols" or to ANSI B31.8
"Gas Transmission and Distribution Piping Systems."
A5.2.0 WELDING REQUIREMENTS
A5.2.1 General
A5.2.1.1 Root pass and hot pass welding shall be performed using the Gas Tungsten-Arc
Welding (GTAW) process. The remainder of the weld shall be performed using
either the gas-shielded Flux Core-Arc Welding (FCAW) or Submerged-Arc
Welding (SAW) processes.
A5.2.1.2 Preheat temperature shall be 212°F minimum for all thicknesses.
A5.2.2 Welding Consumables

A5.2.2.1 Consumables for welding API 5L Grade X-60 pipe shall be carbon steel and
shall conform to the following ASME specifications:
• GTAW ASME SFA-5.18

• SAW ASME SFA-5.17
• FCAW ASME SFA-5.20
A5.2.2.2 Chemistry of all welding consumables shall be reported to COMPANY. All

consumables shall have a nickel content less than 1%.
A5.2.3 Weld Procedure Qualification

A5.2.3.1 Charpy V-notch impact testing shall be performed as part of the weld procedure
qualification. Testing shall be in accordance with ASTM A370 "Mechanical
Testing of Steel Products" using longitudinal V-notch specimens with the notch
located in each of the following three locations: weld metal, fusion line (FL),
fusion line (FL) plus 2 mm. Three specimens shall be required at each location
for a total of nine specimens per weld. The absorbed energy shall be 20 ft-lbs
average and 15 ft-lbs minimum at a test temperature of 32°F.
Page 43 of 44 8/2001
A5.2.3.2 Separate weld procedure qualifications shall be performed for welding Grade X-
60 to Grade X-60, Grade X-60 to fittings (ASTM A860), and Grade X-60 to
flanges (ASTM A694). Impact testing shall not be required for procedures on
ASTM A860 or ASTM A694 material.
A5.2.3.3 The following additional essential variables shall apply for all Grade X-60
welding procedures. A change in an essential variable beyond the limit specified
shall require a new qualification.
a. Any change in the brand name of electrode, flux, or electrode/flux

combination used for procedure qualification.
b. Any increase in post weld heat treatment temperature greater than 50°F.
c. Any increase in post weld heat treatment duration time greater than 25% of
that used during procedure qualification.
c. Any increase in carbon equivalent by more than 0.03 above the material
used for procedure qualification.
Page 44 of 44 8/2001

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GENERAL SPECIFICATION 3.

GENERAL PIPING FABRICATION,

Chevron Offshore (Thailand) Ltd

0 PH Issued for Use 8/2001

A MLJ Issue for Review 6/2000

Rev. By Description Date Rvw’d Appv’d

2.0 MANDATORY CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

5.0 FABRICATION, ASSEMBLY AND ERECTION

5.1 General Piping

6.0 POST WELD HEAT TREATMENT

7.0 QUALITY ASSURANCE AND QUALITY CONTROL

8.0 FLUSHING AND HYDROSTATIC TESTING

9.0 PNUEMATIC TESTING

10.0 CLEANING, DESCALING AND PASSIVATING STEEL PIPING

11.0 PROTECTIVE COATINGS

12.0 IDENTIFICATION AND MARKINGS

13.0 PREPARATION FOR SHIPMENT AND STORAGE

14.0 DOCUMENTATION REQUIREMENTS

I Mandatory Codes and Standards

2.0 MANDATORY CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

4.2.1.2 Oxyacetylene welding shall not be permitted.

4.2.2 Flux Core-Arc Welding (FCAW)

4.2.3 Gas Metal-Arc Welding (GMAW)

4.2.4 Gas Tungsten-Arc Welding (GTAW)

4.2.5 Shielded Metal-Arc Welding (SMAW)

4.2.6 Submerged-Arc Welding (SAW)

4.2.7 Filler Metals, Electrodes, Wire and Flux

4.3 Welding Procedure Qualification

4.3.2 If new weld procedures or new procedure qualifications are required,

4.4 Welder and Welding Operator Qualification

4.5 Production Welding

4.5.4 Weld Repairs

removed by replacing a section of the pipe or fitting in accordance with the

5.0 FABRICATION, ASSEMBLY AND ERECTION

5.2 Pipe Supports

6.0 POST WELD HEAT TREATMENT

6.2 Exothermic Heat Treatment

7.0 QUALITY ASSURANCE AND QUALITY CONTROL

ANSI 150 10%

7.2.3 In addition to the above requirements, 100% of the welds in hydrocarbon

8.0 FLUSHING AND HYDROSTATIC TESTING

portion shall be isolated and tested pneumatically in accordance with Section

8.2 Preparation for Testing

8.3 Hydrostatic Leak Testing

Pipe Class Carbon Steel System: Stainless Steel System:

surveillance throughout the test period by a suitably qualified person may be

8.4 Post-Test Requirements

8.5 Leak Repair and Re-testing

9.0 PNEUMATIC TESTING

9.2 Pneumatic Leak Testing

Pipe Class Carbon Steel System: Stainless Steel System:

9.2.2 CONTRACTOR shall be responsible for developing appropriate procedures for

10.0 CLEANING, DESCALING AND PASSIVATING CARBON STEEL PIPING

• Compressor Suction Piping (from the Scrubber, Filter or K.O. Drum)

10.2 Acid Pickling and Passivation

10.2.2 Precleaning and Rinsing

10.2.3 Acid Pickling (Descaling)

10.3 Abrasive Blasting

10.4 Hot Oil Flushing

11.0 PROTECTIVE COATINGS

12.0 IDENTIFICATION AND MARKINGS

13.0 PREPARATION FOR SHIPMENT AND STORAGE