MOM-MUR-10-PC-SP-0001!00!1 Process Piping Fabricaton, Inspection and Testing Specification

PROCESS PIPING, FABRICATION,
INSPECTION AND TESTING SPECIFICATION.
REVISION HISTORY
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MURPHY
Process Piping, Fabrication,

Installation,
Inspection
and
Testing Specification
MOM-MUR-10-PC-SP-0001-00
Revision: 1
Page 2 of 52
REVISION STATUS ISUMMARY OF CHANGES
The information provided by Mutphy is confidentiai and shaii only be used by the party to whom it is disclosed to p h e
Receiving Pa!t)i').
The Receiving Party shaii not disclose, publish, reproduce or reveal the information received to any other
third party whatsoever except with the specific prior written authorization of Murphy. The Receiving Party shaii within five (5)
days from notice from Murphy return or destroy (upon instruction of Murphy) ail confidential information furnished by Murphy.
The Receiving Party shaii also take such precautions as are reasonably necessary to protect the confidential information,
including taking measures to prevent ioss, theft and misuse.
The Receiving Party shall fully indemnify and keep Murphy at ail time fully indemnified from and against any ioss or disciose
sf confidentiai information and from all actions, proceedings, claims, demands, costs, awards and damages arising directly or
indirectly as a result of such unauthorizeddisclosure.
&RPHY
Process Piping. Fabrication.

Installation
hspecdion
and
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Table of Contents
1.0
OBJECTIVE ......................
.
.
...........................................................................................
7
2.0
SCOPE OF DOCUMENT.................................................................................................. 7
3.0
.
.
......................................................................................
7
REFERENCES.......................
9
DEFINITIONS IACRONYMS ..........................................................................................
3.1
.
....................................................................
10
RESPONSIBILITIES.............................
II
PROCEDURES ...............................................................................................................
4.0
5.0
5.1
Quality Control ...............................................................................................................

11
5.2
11
SHOP AND AS-BUILT DRAWINGS ........................... ...................................................
5.3
12
MATERIALS...................................................................................................................
5.4
.
........................................................................
12
GENERAL FABRICATION.................
5.5
Traceab~l~ty
.....................................................................................................................
13
..
5.5.1
5.5.2
Categorization of Piping and Components..............................................................
5.5.3
Second Category Piping and Components (Non Harmful Contents) TYPE 11 .........14
5.5.4
Physical Identification of Piping and Components .................................................. 14
5.5.5
Pipe Spool ldent~f~cat~on

..........................................................................................
15
5.5.6
15
Valve Identification ..................................................................................................
5.6
First Category Piping and Components (Very Harmful Contents) TYPE 1 ..............14
. . .
..
Traceablllty Requirements .............................................................................................

16
5.6.1
5.7
13
16
Limits of Pipingllnstwment Material Certification ....................................................
PIPING FABRICATION and INSTALLATION................

.
.
.........................................18
5.7.1
General....................................................................................................................
18
5.7.2
20
Pipe Alignment ........................................................................................................
5.7.3
20
Threaded and Socket Weld Piping ..........................................................................
5.7.4
Bolting .....................................................................................................................
21
5.7.5
Severe Cyclic Service .............................................................................................

22
5.7.6
...................................................................................
Tack Welds ..................... .
.
22
5.7.7
Pressure Containing Welds .....................................................................................

22
5.7.8
................................................................................
Weld Spacing ....................
.
.
22
5.8
Pipe Bends.....................................................................................................................
23
5.9
..............................................
Weld MarkinglWelder Identification ........................
.
.
.
23
5.10
5.1 1
......................................................................................................
23
Pipe Support Fablication and Installation...................................................................
24
Attachment Welds
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.......................25
5.13
In-Line Instruments.....................................................................................................
25
26
5.14
Field Run Lines...........................................................................................................
5.15
Supplementary Requirements for Duplex Stainless Steels..........................
.
........26
.
.
5.15.1
Fabr~cat~on
...........................................................................................................
26
27
5.15.2
Welding ................................................................................................................
5.16
WELDING ................................................................................................................ 30
5.16.1
General ...............................................................................................................
30
Branch Connections .................................................
5.1 2
5.16.2
30
Copper-Nickel Alloys ............................................................................................
5.16.3
Welding Procedure Qualification.......................................................................
5.16.4
Process Flow Lines ..............................................................................................

30
5.16.5
Welder and Welding Operator Qualification.........................................................

30
5.16.6
Repairs.............
.
.
............................................................................................31
30
5.17
POSTWELD HEAT TREATMENT ..............................................................................

31
5.18
INSPECTION I EXAMINATION..................................................................................31
5.18.1
General .....................
.
.
.
...................................................................................
31
5.18.2
Personnel Requirements......................................................................................
31
5.18.3
5.18.4
5.18.5
Extent of Inspection - General.............................................................................. 32

. .
Radiograph Exam~nat~on
...............................................................................
32
.
.
Ultrasonic Exam~nat~on
........................................................................................ 33
5.18.6
33
Magnetic Particle Examination.............................................................................
5.18.7
33
Liquid Penetrant Examination ..............................................................................
5.19
35
PRESSURE TESTING ...............................................................................................
.
.
..............................................................................
35
5.19.1
General .............................
5.19.2
System Preparation............................................................................................36
5.19.3
Flushing and Cleaning .............................
5.19.4
High Pressure Jet Flushing (HPJF)......................................................................38
5.19.5
Pressurised Air Shockblowing (PAS) ...................................................................

39
5.19.6
Re-Ingress of Contaminants .........................

.
.
.................................................
39
5.20
.
.
.................................................... 37
Pressure Testing ........................................................................................................

39
5.20.1
.............................................................
Water Head Testing .........................
.
.
40
5.20.2
Hydrostatic Testing ..............................................................................................

40
5.20.3
.
.
.
.........................................................
41
Pneumatic Testing ...........................
5.21
Test Documentation ....................................................
...............41
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5.21 .1
5.22

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42
Reinstatement ......................................................................................................
CHEMICAL CLEANING ..............................................................................................42
5.22.1
.
..............................................................................42
General ..............................
5.22.2
5.22.3
Extent of Chemically Cleaning .............................................................................

43
Flushing................................................................................................................
43
5.22.4
Chemical Cleaning ...............................................................................................43
5.22.5
Video Inspection...................................................................................................43
5.22.6
Grit Blasting..........................................................................................................44
.
.
...............................
45
Chemical Cleaning of Carbon Steel Piping ....................
45
5.23.1
Degreasing...........................................................................................................
5.23
5.23.2
45
Chemical Cleaning ...............................................................................................
5.23.3
Neutral~sat~on
.......................................................................................................
46
5.23.4
. .
. . ...........................................................................................................
Pass~vat~on
5.23.5
46
Water Flushing .....................................................................................................
5.23.6
47
Drying...................................................................................................................
5.23.7
47
Inspection.............................................................................................................
5.23.8
Protective CoatingIPreservation........................................................................... 47
5.24
46
Chemical Cleaning of Stainless Piping.....................................................................47
5.24.1
47
General ...............................................................................................................
5.24.2
48
Removal of Dirt. Degreasing ................................................................................
5.24.3
Chemical Cleaning ...............................................................................................

48
5.24.4
48
Water Flushing ....................................................................................................
5.24.5
48
Drying...................................................................................................................
5.24.6
48
Inspection.............................................................................................................
5.24.7
Protective Coating I Preservation.........................................................................

48
5.25
Hot Oil Flushing ..........................................................................................................

49
5.25.1
General .........................................................................................................
49
5.25.2
.
.
.....................................................................
49
Flushing Oil ..............................
5.25.3
Cleanliness of Hydraulic Oil Systems ..................................................................

49
Cleanliness of Lubricating Oil Systems ..................
...............
...............................49
5.25.5 Cleanliness of Seal Oil Systems ..........................................................................
50
.............................................................................
5.26
Hook-Up Piping .....................
.
.
50
5.27
Re-Ingress of Contaminants.......................................................................................
50
5.28
COATING ...................................................................................................................
50
5.25.4
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5.29
INSULATION ............................................................................................................
50
5.30
IDENTIFICATION AND SHIPPING ...................

.
.
..................................................
51
.......
.................................................
51
5.31
MECHANICAL COMPLETION ...................
6.0 APPENDICES ......................
.
........................................................................................
52
.
....................................................... 52
PRESSURE TESTING REQUIREMENTS........
Table of Tables
6.1
Table 3-1 References ................................................................................................................

7
..
Table 3-I-Definlt~ons.....................................................................................................................
9
Table 3-2: Acronyms .....................................................................................................................
9
Table 5-1: Requirementsfor Piping Material Traceability ...........................................................17
Table 5-2-Testing Requirements Duplex .....................
.
.
.
.
...................................................
27
Table 5-3 Inspection Class Summary .........................................................................................
34
Table 5-4-HPJF Requirements .........................
.
.
.
................................................................39
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1.0 OBJECTIVE
The objective of this document is to define the minimum technical requirements for Process and
Utility Piping Fabrication, Installation, Inspection and Testing.
Note this specification supersedes MOC specification 06001-SK-EG-QU-STD-GEN-003 Rev 3
Specification for Process Piping Fabrication, Installation lnspection and Testing.
2.0 SCOPE OF DOCUMENT
This specification covers the fabrication of metallic pipe only. All non-metallic pipes shall be
fabricated in strict accordance with the manufacturer's recommendations and specifications.
The CONTRACTOR shall obtain COMPANY written approval for any deviations from the
requirements of this document or specifications, standards and drawings referenced herein or
elsewhere in the Contract.
This document and the codes, specifications and referenced documents listed in Table 3.1
below are not intended to be all-inclusive. The requirements set forth do not relieve the
CONTRACTOR of his responsibility to perform all services in a safe manner, to meet applicable
codes and standards, to comply with government regulations or to supply a product capable of
performing its intended service.
3.0 REFERENCES
The latest editions of all applicable codes, specifications and references shall define the
minimum requirements applicable to the subject work and no statement contained in this
Specification shall be construed as limiting the work to such minimum requirements.
Wherever conflicts or omissions between codes, specifications and contract occur, the most
onerous condition shall apply. The CONTRACTOR is responsible for reviewing the list below
and informing the COMPANY of any omissions. All conflicts shall be formally brought to the
attention of the COMPANY.
Table 3-1 References
Standard No.
Title.
06001-SK-EG-MD-STD-GEN-0002
06001-SK-EG-PI-STD-GEN-0001
Testing, Precommissioning, Commissioning

and Acceptance of Works.
Specificationfor Piping Systems
06001-SK-PM-QU-STD-PQP-0002
Quality Assurance Quality Control
MURPHY
ASTM A5781A578M
ASTM E562
AWS D l .I
IS0 4406

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Passivation of Stainless Steel Parts,

Equipment, and Systems
Straight-Beam Ultrasonic Examination of Plain
and Clad Steel Plates for Special Applications
Standard Test Method for Determining Volume
Fraction by Systematic Manual Point Count
Structural Welding Code Steel (pipe supports
only)
Hydraulic fluid power -- Fluids -- Method for
coding the level of contamination by solid
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Installation,
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Title.
particles
IS0 10474
NACE MR 0175
OPER-SK-PM-MD-STD-GEN-0001
3.1
Steel and steel products - Inspection

documents
Sulfide Stress Cracking Resistant Metallic
Materials for Oilfield Equipment
Project Tagging Philosophy
DEFINITIONS IACRONYMS
Table 3-I-Definitions
Definition
Murphy Sarawak Oil Co. Ltd., as the project
developer and ultimate owner of the facility.
The COMPANY or consortium which is awarded
the Construction contract for the project including
its sub-CONTRACTORS.
The on which the order or contract for supply of
the goods or services is placed.
Any design drawings for the facilities supplied by
COMPANY
as
part of
the
contract
documentation.
This does not include
preliminary, conceptual drawings that may be
provided unless such drawings explicitly address
issues of relevance to this specification.
For the purpose of this document the definition
is:A set of related tasks with a starting date,
specific goals and conditions,
defined
responsibilities, a budget, planning, and a fixed
end date.
7
CONTRACTOR
PROJECT
L
Table 3-2: Acronyms
Abbreviation
Definition
API
American Petroleum Institute
ASNT
ASTM
American Society For Non-destructive Testing

American Society For Testing and Materials
AWS
American Welding Society
BS
British Standard
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Installation,
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Abbreviation
Definition
DIN
Deutsches Institute for Normung
DPI
Dye Penetrant Inspection
DSS
Duplex Stainless Steel
EMF
Electro Motive Force
HPJF
High Pressure Jet Flushing
HSE
HVWF
Health and Safety Executive

High Velocity Water Flushing
ITP
Inspection and Test Plan
MPI
Magnetic Particle Inspection
MDR
Manufacturer's Data Records
MSDS
Material Safety Data Sheet
MTR
Material Traceability Report
NDT
Non Destructive Testing
P& IDS
PMI
Piping and Instrument Drawings.
PMT
Project Management Team
PPE
Personal Protection Equipment
PQR
PWHT
Procedure Qualification Record

Post Weld Heat Treatment
RT
Radiographic Testing
RTJ
Ring Type Joint
UT
VDRL
Ultrasonic Testing
Vendor Document Requirement List.
WPS
Welding Procedure Specification
Revision: 1
Page 10 of 52
Positive Material Identification
4.0 RESPONSIBILITIES
It is the responsibility of all team members in the PMT groups to ensure compliance of this
document during the execution of the project.
It is the responsibility of the CONTRACTOR to read, understand and follow the requirements of
this document during the execution of the project.
*
MURPHy

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5.0 PROCEDURES
5.1
Quality Control
The CONTRACTOR shall have a quality control system and quality control manual covering all
fabrication activities. Controlled copies of the quality control manual shall be available for
COMPANY approval and for monitoring of all construction activities.
The CONTRACTOR shall establish detailed procedures for control of welding quality. The
following procedures shall be submitted for review and approved by COMPANY prior to starting
fabrication:
Welding and weld repair;
Storage, control, and identification of welding consumables;
Welder qualification records;
InspectionlNDT;
Post-weld heat treatment, if required;
Monitoring the progress and quality of welding.
The CONTRACTOR shall ensure the "in process" material documentation is maintained on a
daily basis. All materials, which require documentation in use during fabrication or installation
that cannot be identified with documentation shall be immediately removed from the area and
replaced at the CONTRACTOR'S expense. This will include partially assembled piping
assemblies if one or more components are found to be deficient or cannot be identified by
material records.
All piping components shall be fully traceable from the final position within the structure. Piping
and piping components shall be fully traceable to the material batch numberlheat number1
identification number, etc.
The CONTRACTOR shall establish and employ a Positive Material Identification (PMI) System
to enable verification and traceability of material to MTR's during any stage of supply, storage,
manufacture or final installation. The PMI shall include an Alloy Verification (AV) System, which
will have the ability to physically verify material composition using material analyzers. The
System shall meet the requirements of COMPANY specifications.
5.2
SHOP AND AS-BUILT DRAWINGS
The CONTRACTOR shall prepare piping isometrics and spool drawings for all piping. The
isometric drawings shall show all spool numbers, welded attachments, location and type of
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welds (shop or field), NDT requirements, type of pressure test and test pressure, other notes on
construction, post weld heat treatment requirements and a complete bill of materials.
The CONTRACTOR shall ensure that all positions and locations of piping components, piping
runs and terminal points are maintained.
Where the final assembly of piping systems is not within the CONTRACTOR'S yard, the
CONTRACTOR shall verify that all spools, whether built from isometrics or shop drawings, are
of a length which will enable the spool to be transported if necessaly and enable spools to be
easily installed.
The CONTRACTOR shall maintain an up to date, complete and accurate record of all changes
made to design drawings during the fabrication and erection of the piping. Upon completion of
the work, the CONTRACTOR shall incorporate all changes into the "As Built" construction
drawings. COMPANY will not consider that Work is completed until the as-built drawings are
received. The as-built mark ups shall be incorporated into CONTRACTOR drawings for issue
with final documentation.
5.3
MATERIALS
The material used for utility and process piping shall meet the requirements of COMPANY
Specification 06001SK-EG-PI-STD-GEN-0001: Specfication for Piping Systems
The CONTRACTOR shall submit to COMPANY for approval a written procedure covering
material receipt, inspection and storage. The procedure should cover but not limited to:
Defective materials
Storage and Segregation
Materials allocation
Transfer of Markings for trace ability
Preservation
MSDS and any special handling requirements
Inspection
5.4
GENERAL FABRICATION
The CONTRACTOR shall maintain "clean" fabrication areas for the fabrication of stainless steel
and nickel alloy piping to minimize the possibility of contamination.
The CONTRACTOR shall pay specific attention to the segregation of tools and the protection of
material.
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. .
fabrication, including but not limited to grinding discs, cutting tools, and wire brushes designed
for use with stainless steel andlor other high alloy materials.
The CONTRACTOR shall prepare for shipment and load all loose spools in a manner so as to
minimize damage to the spool and to keep them stable for shipment. Several spools may be
placed on a pallet or in a common shipping cargo basket or rack provided they are adequately
chocked and supported. Spools may be chocked off each other. No spool to spool contact is
permitted. Spools shall be secured by banding with a "Band-It" or equal. Each spool shall bear
a unique spool number (corresponding to the fabricationlinstallation drawing) for identification.
The CONTRACTOR shall provide padded slings or straps for handling coated pipe and nonferrous padded slings for stainless steel and alloy pipe. The CONTRACTOR shall exercise care
in lowering, assembling and installing all coated piping. Any damage to the coating caused by
the CONTRACTOR shall be repaired at CONTRACTOR'S expense to the satisfaction of
COMPANY.
Upon completion of installation and painting, CONTRACTOR shall stencil the line number and
flow armw on the piping in accordance with the requirements of COMPANY coating
specification.
5.5
5.5.1
Traceability
Categorization of Piping and Components
The piping and piping components of the work are distributed into two categories of importance,
mainly as regard of the consequence of their Hazard level which is dependent on the
harmfulness of its contents as well as pressure rating and diameter size.
Some of the categorisations are obvious however in other cases the line is more blurred and in
such cases the categoly shall be decided by COMPANY whose decision is binding.
Recommended requirements for the various systems are listed (See table 5.1), however where
a higher safety or quality assurance level is demanded, the COMPANY may specify additional
requirements.
The following categorization shall be used only for the construction of piping and piping
components for onshore and offshore facilities. In case of doubt regarding classification of
piping and piping components for categoly of importance, the decision of the COMPANY shall
be final.
6RPHY
5.5.2

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First Category Piping and Components (Very Harmful Contents) TYPE I
Failure of any of these components causes a substance to escape which, under expected
concentration and operating conditions, is classified as extremely or highly flammable, very
toxic, harmful, oxidizing, explosive, self-reactive, corrosive, or harmful to human tissue. Failure
of any of these components causes a substance to escape which, under expected
concentration and operating conditions, is classified as a combustible liquid or fluid irritant to
humans or is harmful to the environment.
The use of exotic and speciality materials, which required to be fully identifiable, shall be
classified as a Type I Category.
To simplify matters this category is deemed to include all live hydrocarbons (including chemical,
gas, condensate and oil).
5.5.3
Second Category Piping and Components (Non Harmful Contents) TYPE II
They are components other than those classified in First Category. Failure of any of these
components causes a substance to escape, which, under expected concentration and operating
conditions, is classified as normally not harmful except for pressure effects. (Including
Instrument and Utility Air, Nitrogen, Firewater, Service Water and Potable Water)
5.5.4
Physical Identification of Piping and Components
All materials shall be marked to provide unique identification. First category (Type I) piping and
components shall be die stamped using low stress stamps of a character height of approx
12mm. Second category (Type II) piping and components shall, as a minimum, be identified by
legible paint marker or stencilling. Die stamping shall be used for materials 10mm or greater,
below 10mm materials may be engraved (Type I shall be engraved) paint marked or stencilled.
Alloy piping (including stainless steel, duplex stainless steels, and copper nickel) shall be
supplied marked permanently over the entire length. The marking details shall be as per
material specifications and shall include nominal pipe size (NPS), charge or heat number and
the manufacturer's unique symbol.
The CONTRACTOR'Sor VENDOR'S (as applicable) unique numbering system shall at all times
identify the Type of pipe or component I, or II, part or piece number, spool number, unique
number and material grade.
The CONTRACTOR'S or VENDOR's (as applicable) system shall also include provision for
identifying by colour coding the grade of material on all pieces in manufacturing. Pipe lengths
shall be painted with a paint stroke of appropriate colour corresponding to the steel grade
*
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centre.
Stencil marking shall utilize water insoluble ink, the ink shall not contain any harmful metal or
metal salts such as zinc, lead or copper which cause corrosive attack on heating. Only chloride
free paint shall be used for paint marking.
All materials at all times shall be traceable back to the CONTRACTOR'S or VENDOR's (as
applicable) material management system and vice versa. Drawings shall be marked up to
identify all Type I material and include full traceability of material.
5.5.5
Pipe Spool ldentification
The completed spools, prior to dispatch for post weld heat treatment, painting, galvanizing or
chemical cleaning etc shall be identified by a hard metal stamp marking. The stamping shall be
performed on one flange rim only or where no flange is fabricated into the spool, the spool shall
be identified by engraving the face of one of the weld bevels.
Spools shall also be identified by an aluminium tag (75mm x 25mm) and wired by stainless steel
wire to each spool, the characters stamped on each tag should be approx 12mmhigh.
Marking shall consist of Isometric and Spool number.
Spools that have been post weld heat treated shall be identified by stencilling over final coating
the following text "PWHT do not weld".
5.5.6
Valve ldentification
In general Valves shall be identified as per the requirements of MSS SP-25 "Standard Marking
System for Valves, Fittings and Unions".
The manufacturer's heat or melt number shall be recorded on the valve body, bonnet and
covers. All valves shall have identification markings either on the body of the valve or on a 316
stainless steel identification plate permanently fixed to the valve. The markings on the body or
identification plate shall contain the following information: Manufacturer's name or trademark,
valve tag number, material designation, rating designation, code of compliance (816.34 Class
1500, API 598 etc), trim identification (seat, stem, disc, ball etc) and size.
In addition to the above identification, each valve shall have a 316 stainless steel tag wired with
316 stainless steel wire to the valve identifying the valve tag number (see COMPANY Tagging
Philosophy OPERSK-PM-MD-STD-GEN-0001)and valve size.
The CONTRACTOR'S or VENDOR'S (as applicable) colour coding system shall be used to
identify the grade of material of all valves.
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All valves at all times shall be traceable back to the CONTRACTOR'S material management
system and vice versa. Valves shall be traceable to material and test certification and material
traceability drawing.
5.6
Traceability Requirements
First category (Type I) piping and components shall have "Full Traceability"
Second category (Type 11) piping and components may have "No Traceability".
Specific requirements in COMPANY general and project specifications and data sheets may
increase or decrease or simply clarify the specific traceability requirements.
"Full Traceability" means the recorded and or documented manufacturing and quality history of
all identifiable materials and components (traced back to original source when required) via test
reports, material certifications, letters of conformity, etc, which have been nominated in the
approved ITP, VDRL and MDR list of contents.
These records shall be fully traceable to the relevant component or part on the finished product
and shall be included in the MDR using marked-up drawings/isometrics and separate
traceability sheets.
"No Traceability" means proof of traceability of materials and components is not required
"Product" for the definition of this document the word "Product" means materials, items,
equipment, parts, components, and assemblies.
"Certification" means material or component reports, provided by the supplier which
demonstrate or state that the product has met or exceeded all of the requirements specified in
the material specification and purchase order details refer to IS0 10474-1991 for specific
certification types.
5.6.1
Limits of Pipingllnstrurnent Material Certification
This shall apply to the following materials:

Pipe
Pipe Fittings
Pipe Flanges
Piping special pressure containing parts
In-line and On-line valve body pressure containing parts
lnline instrument pressure containing parts
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Piping Specialty Items (where applicable)

This specifically does not apply to any instrument material beyond the piping root valves, which
require ISO, 10474-1991-2.2 material certification on the pressure containing parts only.
This specifically does not apply to stud bolts and gaskets, which require IS0 10474-1991 -2.2
material certification only. Stud bolts will be tested for tensile strength on a random basis at an
independent laboratoty. Testing covering a random sample of at least 5% of total order will be
undertaken by supplier.
Table 5-1: Requirementsfor Piping Material Traceability
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5.7
5.7.1

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PIPING FABRICATION and INSTALLATION

General
Welded fabrication of piping shall be in accordance with the requirements of ASME 831.3 for
the individual material specification classes.
Miter joints shall not be used.
Pipe spools for hook up pipe work shall be fabricated with an extra 6" of pipe at field fit welds.
Piping shall be erected and supported in a manner that will not put undue strain on pumps,
vessels, or equipment. All equipment, prefabricated piping, and appurtenances shall be fitted
and assembled strain-free. The CONTRACTOR shall be prepared to demonstrate, by
disassembly of the spool, the strain-free state of all fabricated piping.
No lifting or rigging shall be allowed from existing pipework.
For rotating equipment, pipe shall be erected beginning at the piece of equipment, then moving
away from the equipment as it is assembled. Where required or specified, field welds in two
directions shall be used when installing pipe to equipment.
Valve handles and wrenches shall be modified by CONTRACTOR where necessary for proper
valve operation, and when the valve cannot be otherwise rotated to clear an obstruction
All flanged connections shall be made by tightening the flange bolts in an accepted pattern to an
even torque.
6RPHY

Installation,
Inspection
and
Bolt tensioning shall be carried out on all Class 600 and bolts 1;
Revision: I
Page 19 of 52
'
diameter and above on
flanges using COMPANY approved tensioning equipment.

Flange bolt and stud threads shall protrude a minimum of one to two full thread pitches past the
nut. Uniformity of bolt projection through the nuts of stud bolts shall be carefully observed.
To prevent the ingress of unwanted material the ends of pipewolk and associated equipment,
unless being actively worked on will be "blinded off' with material "fit for purpose". Pipe shall be
inspected prior to assembly to ensure pipe is free of all intemal loose scale, rust, soil and debris.
All flange bolting shall be hot dipped spun galvanized.
Pipework shall be installed in accordance with the codes and standards specified in Section 3
and the CONTRACTOR'S Piping General Arrangements, Support Arrangements Drawings,
Specification and Schedules.
Temporary supports, if required for hydrotesting, shall be decided and installed by the
CONTRACTOR and removed after hydrotesting is complete.
Drainage falls shall be maintained throughout as specified on the drawings.
Where drawings show flanges loose on a closure length of piping with cut to fit allowance, a
physical check shall be made of closing distance and alignment of flange before cutting the pipe
and welding on the flanges.
Pipework shall be fitted into place without springing orforcing.
Flange joints having spectacle blind or spade and spacer for ring joint flange class 900# and
above shall be furnished with two (2) jack screw bolts on one side.
Flange connections to strain sensitive equipment shall be the last connection made on
completion of a line or interconnecting system of lines complete with permanent supports. Final
connections shall be witnessed by CONTRACTOR'S Representative to ensure undue nozzle
loading is not imposed on the strain sensitive equipment.
No sealing compounds shall be applied to gaskets or flange faces.
The CONTRACTOR shall install and make good all valve accessories and attachments such as:
locking devices, interlock devices and assemblies, extension spindles and chain operators.
Valves shall be orientated in the line so as to be readily operable, and removable, either fully or
in part and all elevated valves shall be made accessible by means of permanent platforms to
allow operation and maintenance.
All valves shall be installed in the open position, unless noted otherwise on Process flow sheets,
with their stems orientated as shown on the piping drawings.
The SubCONTRACTOR shall check gland packings on all valves for leakage during hydrostatic
testing.
6RPny
5.7.2

Installation
Inspection
and
Revision: 1
Page 20 of 52
Pipe Alignment
Internal misalignment of pipe-work shall not exceed 25% of the pipe wall thickness up to a
maximum of 118 inch (3.2 mm)
Dimensional tolerances for fabrication and installation of piping shall be plus or minus 118"
(3.2mm) at equipment or skid tie-in points unless otherwise noted on the drawings. With the
exception of compressor closing spools which require far greater levels of accuracy. Tolerances
shall not be cumulative.
Flange faces shall be aligned within f %" from the square with pipe, or l m m across the face
diameter, whichever is the smaller, regardless of orientation.
Alignment of pipes to be jointed may be improved by the use of hydraulic or screw type clamps.
Hammering or heating the pipe shall not be permitted. Excessive misalignment may be
overcome by buttering of the weld preparation but only with the prior written approval of the
COMPANY representative.
Internal grinding or machining may be conducted to improve root alignment of misalignment
equal to or less than 118 inch (3.2 mm) exists. However, the taper shall be 1 in 4 minimum and
the minimum wall thickness shall be maintained.
Attempts to improve alignment shall not be carried out by cold working unless a subsequent
heat treatment is applied prior to welding and written COMPANY approval is given.
For piping connections to rotating equipment, pipe strain shall be checked by mounting dial
indicators on the coupling at zero point, vertically and horizontally, then installing the piping
flange bolts and gaskets. If attachment of the piping causes the dial indicators to move more
than 0.002 inches TIR, then the piping must be corrected to prevent undue stress on the
equipment. lnline pumps and vertical well pumps do not lend themselves to checking pipe
strain by the dial indicator method. The acceptable procedure for checking these types of
pumps is to check flange parallelism with feeler gauges. A variance across the face of the
flange of 0.025" (0.635mm) or less is acceptable.
Multiple headerslmanifolds and bridles with multiple connections shall be Jig-set to minimize
distortion during fabrication and maintain fabrication tolerances.
5.7.3
Threaded and Socket Weld Piping
The use of socket weld or threaded piping is determined by the criteria indicated in COMPANY
Specification 06001-SK-EG-PI-STD-GEN-0001. Seal welding of threaded connections shall not
be carried out.
Xk
I(JJURPHY

Installation,
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Revision: 1
Page 21 of 52
Welds carried out on socket welds or threaded seal welds will have a minimum of two runs
showing, on completion of the final passes.
Screwed threads shall be clean cut with no burrs or stripping. Dies shall be new, sharp and
properly designed for the pipe material. Immediately before erecting the piping, all pipe threads
and fittings shall be thoroughly cleaned of cuttings, dirt, oil, and other foreign matter. Teflon
tape shall not be used for screwed connections. Thread sealant shall be used for all
screwed connections.
When connecting to some equipment, it may be necessary to match a 2" or larger threaded
connection. Threaded flanges per the piping specifications or ASME 816.5 shall be used as a
companion flange.
Sufficient unions shall be provided to allow for convenient removal of any spool or component
without disassembly or removal of any piece of equipment or major inline instrumentation.
Pipe engagement in socket weld fittings during fabrication shall leave 1/16" (1.5mm) clearance
between the pipe end and the shoulder of the fitting to allow for in service expansion in
accordance with ASME 831.3 fig. 328.5.2C
5.7.4
Bolting
Flange bolt holes shall straddle horizontal and vertical centerlines unless noted othetwise on the
construction drawings.
CONTRACTOR may reuse existing bolts from a flanged connection if the bolts are free from
visible damage or corrosion, and they meet the specification requirements. CONTRACTOR
may not reuse existing rings or gaskets.
All flange bolting shall be free to move through mating flange holes in a plane at right angles to
the flange face and parallel to the pipe run (misalignment of flange holes resulting in knurling of
the nut on the flange will be rejected).
All flange machine bolts shall extend fully through their nuts and shall have all bolt heads on one
side of the joint.
All flange bolting shall be hot dipped spun galvanized.
Stud bolts shall not be cut from lengths of studding.
All nut bearing surfaces and threads of bolts shall be lubricated with an API 5A2 or equal
lubricant prior to fitting.
Bolt tensioning shall be applied in three stages using the diametrical sequence, 1st stage 25%,
2nd stage 50%, 3rd stage 100%.
4#
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Page 22 of 52
For guidance, torque values reached will be such that no leakage will occur during hydrotesting,
and the maximum bolt stresses shall not exceed these as specified in ASME 831.3 paragraph
302.3.2 (a).
All fasteners shall be hot dipped galvanized coated unless otherwise COMPANY approved in
special conditions.
5.7.5
Severe Cyclic Service
The external surface of welds intended for severe cyclic service, as defined by ANSI 831.3,
shall be ground flush with the pipe surface.
5.7.6
Tack Welds
Tack welds shall be carried out by qualified welders using approved consumables and preheat
as specified by the approved welding procedure.
5.7.7
Pressure Containing Welds
All pressure containing welds shall visibly show a minimum of two passes, with an overlap of
start and stops. This includes socket welds.
5.7.8
Weld Spacing
Circumferential butt welds shall be separated by the maximum possible distance and not less
than 1 x D without written approval from COMPANY. However, between piping fittings, etc.,
short pipe lengths may be required. In this situation, butt welds shall not be within 3 inches (75
mm) of adjacent butt welds. For pipe sizes less than 3 inches nominal bore, butt welds may be
within the greater of 4 times the wall thickness or one pipe diameter of adjacent butt welds.
Circumferential butt-welds closer than the above limits shall be brought to the attention of the
COMPANY representative for approval.
The longitudinal welds of adjacent pipes shall be staggered by at least 30 degrees or 3 inch (75
mm), whichever is greater.
Branch 1 nozzle and other pressure attachments welds shall not be closer than 3 inch (75 mm)
to adjacent pressure welds. Any cases which fail to meet these criteria shall be approved by the
COMPANY representative prior to commencement of fabrication.
Non-pressure containing attachment welds, such as pipe support welds, shall be a minimum of
2 inch (50 mm) from any pressure containing welds.
Minimum spacing shall be measured TOE to TOE and not weld centerline
##
MURPHY
5.8

Installation,
Inspection
and
Revision: 1
Page 23 of 52
Pipe Bends
Bends shall conform to ASME 831.3, Section 332 and the engineering drawings with the
following additional limitation:
Bending shall be performed in accordance with procedures submitted by the CONTRACTOR
and approved by the COMPANY prior to start of the work. Bending procedures shall include
heat treatment after bending, if required. Bending procedures shall be demonstrated by the
CONTRACTOR.
Unless project requirements specify otherwise, the minimum bend radius shall be five (5) times
the nominal pipe diameter for 6 and 8" piping and three (3) times the nominal pipe diameter for
20" and 24" piping. A greater bend radius may be required because of material grade, pipe
size, and/or nominal wall thickness.
Suitable allowance for pipe wall thinning due to the bending process shall be applied to obtain
the specified pipe wall thickness after bending.
Each bend shall have a smooth contour, free from buckling, cracks, and/or other evidence of
mechanical damage.
The difference between the maximum and minimum diameters at the ends of the completed
bend, as defined by the engineering drawings, shall not exceed the applicable ASTM or API
material specification for the straight pipe prior to bending. This requirement does not include
the extra tangent lengths that may be required for bend pulling purposes.
The weld seam(s) on pipe with longitudinal welds shall be located as near as possible to the
neutral axis of the bend.
5.9
Weld Markingwelder Identification
Each weld, on adjacent area, shall be marked with the identification symbol of the welder or
welding operator. Failure to use the symbol shall be cause for rejection of the work or piece and
removal of the weld.
5.10
Attachment Welds
Fillet welds used for attachments shall be carried out by qualified welders using COMPANY
approved welding procedures.
Cleats, bridge pieces, tacking strips or other attachments temporarily welded to pipe-work to
facilitate fabrication shall be the same material or a COMPANY approved equivalent, as the
pipe-work to which it will be attached.
M RpHy

Installation,
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Revision: 1
Page 24 of 52
Temporary attachments shall be completely and carefully removed prior to any post-weld heat
treatment that may be required. Where removal is by air-arc gouging or flame cutting, the cut
shall be made clear of the pipe-work such that 118 inch (3.2 mm) of the temporary attachment is
left for final removal by grinding. Removal by hammering or bending is not permitted. Any
surface imperfections remaining after their removal shall be repaired by welding, in accordance
with a COMPANY approved welding procedure. This shall be followed by grinding to a smooth
finish, flush with the surface of the adjacent pipe. The repaired area(s) shall be subject to
magnetic particle or dye penetrant examination.
5.11
Pipe Support Fabrication and Installation
Unless othetwise stated, CONTRACTOR shall design, fabricate, and install all pipe supports
Welding of attachments for the purposes of supports shall be carried out as part of the piping
fabrication in accordance with the applicable codes and standards. Prior to testing all other
parts shall be fabricated in accordance with AWS D1.l and the guidelines in AISC, "Manual of
Steel Const~ction".
All pipe supports shall be seal welded to prevent corrosion. Any area not able to be seal welded
shall be enclosed using %" (6mm) flat plate.
The CONTRACTOR shall purchase and install all support specialty items (such as spring
hangers) in accordance with construction drawings, COMPANY specifications, and good
engineering practice.
Unless otherwise noted, all boltholes shall be no larger than 1/16" (1.5mm) greater than bolt
diameter. Boltholes shall be punched or drilled. Boltholes may be torchfflame cut with
COMPANY approval and only if properly reamed after cutting and the holes are finished to the
proper diameter as stated above.
U-bolts shall be 316 SS and shall be double nut type. In addition, U-bolts for stainless steel
pipe shall be neoprene coated and a 118" thick strip of neoprene shall be placed between the
pipe and pipe support prior to installing the U-bolt.
All relief, blowdown and safety head discharge piping shall be securely braced for relieving
conditions.
During installation, pipework shall not be forced so as to suit the installed support and thereby
introduce undue stresses into the line.
Supporting steelwork shall be set at the correct elevation, being true and level in all respects.
Metallic surfaces of supports which will be inaccessible after erection shall receive a suitable,
permanent, protective coating before assembly of the component, in accordance with Coating
for Structures, Piping, and Equipment Specification.
xx.
MURPHY

Installation,
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Revision: 1
Page 25 of 52
Spring support units shall be installed in accordance with the manufacturer's instructions and
shall not have 'stops' removed until completion of pressure testing of the pipework. 'Stops' shall
be colour tagged by manufacturer for identification.
In the event that stoppers or guides are welded after hydrotest is completed then pipework shall
be re-hydrotested.
5.12
Branch Connections
Where reinforcement pads(doub1ers) or saddles are required they shall be of the same material
as the run pipe (unless specified otherwise) and shall be formed and contoured to provide a
good fit to both run and branch pipe.
Branch reinforcement pads and similar attachments or each segment thereof shall be provided
with two 3.0 mm drilled and tapped holes prior to fitting to the pipe, so ensuring leak detection,
venting and testing facilities one at each side at right angles to the run pipe and never in the
crotch of the branch.
Each reinforcing pad, saddle or similar attachment or each segment thereof shall be tested at a
minimum pressure of 50 psig
. - with air utilising
- a soap solution to detect air leaks. M.P.I. in lieu of
hydrotesting is acceptable. Test and vent holes shall be filled with silicon upon completion of
the test.
All integrally reinforced outlet fittings shall be fully welded out to give a smooth transition
between the fitting and header to eliminate any points of any stress concentration. In order to
avoid distortion of thin wall headers in austenitic and duplex stainless steels, titanium and 90110
Cupro-nickel, welding shall be carried out with a minimum of heat input.
To overcome possible fatigue failures of small bore branch connections 2"NB and below, all unconnected valved branch connections shall be braced back to the main run pipe in two planes.
5.13
In-Line Instruments
In-line instruments e.g., orifice plates, control valves, meters etc., shall be installed by the
CONTRACTOR under the direction and control of the CONTRACTOR'S Instrument Engineer.
Unless otherwise instructed by the CONTRACTOR'S lnstrument Engineer, in-line instruments
shall not be installed prior to pressure testing of the pipework.
As specified by Testing Specifications and procedures the CONTRACTOR shall fit "dummy"
spools in place of in-line instruments including control valves during erection to facilitate
pressure testing.
8RPHY

Installation,
Inspection
and
Revision: I
Page 26 of 52
All instruments installed shall be capable of complete or part removal for maintenance
purposes.
5.14
Field Run Lines
All field run lines shall be installed in an orderly manner, clear of access and maintenance
routes, consistent with good operation, neatness of appearance, safety of personnel, economy
and usage of the minimum number of fittings consistent with provisions for expansion and
flexibility.
All piping shall be arranged to facilitate supporting and shall be planned for ease of removal of
equipment for inspection and servicing.
5.15
Supplementary Requirements for Duplex Stainless Steels.
These supplementary requirements are for the fabrication and welding of duplex stainless steels
at site or shop.
5.15.1
Fabrication
CONTRACTOR shall maintain clean areas with dedicated tooling for the fabrication of duplex
stainless steels.
All hand tools (grinders, power brushes) and consumables (grinding disc, brushes, and flappers)
should be labeled as follows:
BLUE - All tools used on DSS material shall be colour coded blue and shall not be
interchanged, these tools shall remain assigned to the area until completion of project. Chisels,
files, hammers, wire clippers, hack saw blades, knife etc are all hardened tool steels (that are
wear resistant) that can be used in contact with either DSS or carbon steel surfaces must not be
interchanged. New consumables shall be utilized on these tools and the old consumable shall
be discarded to prevent contamination with DSS material and filler wire.
Lifling of Duplex Stainless Steel pipes and fittings shall not be done with hooks or any carbon
steel device that could come into contact with the DSS material. The acceptable way for
handling DSS material shall be with 'padded slings' (or other MOC approved slings) with eyes
looped around end of the pipes. Alternatively, forklifls can be used in yard based areas where
the forks cradle the pipe on the exterior coveredlprotected surface. Any unusual indications
should be reported to the Supervisor or the QC Inspector.
All open ends of pipe and fittings, except pipes and fittings which are being worked on will be
covered at all times, with material of sufficient strength to prevent damage to ends and entry of
deleterious material. Flange faces, including flat face and Gray Lock faces will be protected at
all times to prevent damage to RTJ faces.
6RPHY

Installation,
Inspection
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Revision: I
Page 27 of 52
Prior to fit-up, all pipe ends and weld bevels shall be examined. Surface defects, gouges,
dents, burrs and nicks shall be reported to shop supervisor and quality control representative.
The internal surface of all pipes shall be checked and shall be free of moisture and deleterious
material. Internal and external surface for a distance of 25 mm from the prepared edge shall be
dried, brushed and wiped clean with an approved solvent. Fit-up shall be as per the drawing
and relevant welding procedures.
5.15.2 Welding
Welding Procedures.
Each electrode lot shall require a separate procedure qualification(s). A lot includes changes
within the manufacturer's brand and type of consumable. Such changes include material heat,
flux batch, etc.
Welding procedures shall be qualified by separate test coupons welded at the lowest and
highest heat input to be used in production.
Welding procedures shall be on representative size specimens. Small diameter test pieces will
not qualify larger diameters. Diameter range for procedure tests shall be approved by
COMPANY Welding Engineer.
The ferritelaustenite phase balance of the weld metal shall be measured by the point count
method ASTM E 562 for the root, fill, and cap area of the weld cross section. The ferrite content
shall be 30 to 55% in the weld metal. A magnetic ferrite gage shall be used to measure the
percent ferrite on the cap of weld metal and be reported on the PQR for reference.
The heat input shall be between 0.5 - 2.5 kJlmm
The minimum number of mechanical test specimens required for a welding procedure
qualification test weld shall be in accordance with ASME Section IX, with the addition of:
Table 5-2-Testing Requirements Duplex
Test
Quantity
Charpy V-notch at -40C

Weld centerline
Fusion line
Fusion line + 2.3 mm
Fusion line + 4.5 mm
Cross section for macro-examination, photomicrographs and ferrite
measurements
Charpy impact testing shall be in accordance with ASME Section VIII, UG-84.
Acceptance standards for welding procedure qualification tests shall be as follows:
3
3
3
3
1
##
MURPHY

Installation,
Inspection
and
Revision: 1
Page 28 of 52
Charpy Tests
The average absorbed energy value obtained for a set of three full-size (10 mm x 10 mm)
specimens shall be at least 37 fl. Ibs. (50J) with no individual value less than 30 fl. Ibs. (40J).
For sub-size specimens, the absorbed energy shall be reduced in linear proportion to the
through-thickness specimen dimension. Lateral expansion measurements shall be reported for
information. In the event of failure of Charpy tests, re-test requirements shall be agreed with
COMPANY Engineer.
Ferrite Tests (Modified ASTM E562)

For ferrite assessment during procedure qualification tests, metallurgical sections shall be
polished and electrolytically etched at 7-8 V in 40% KOH to clearly reveal the two-phase
austenitelfel~itemicrostructure. The area being point counted, either parent material, weld metal
or HAZ, should be examined and photographed under a microscope at a sufficient magnification
to fill the field of view and to be able to clearly discriminate between the constituent phases. A
magnification of 400X minimum is required.
The photographs shall be overlaid with a grid of at least 100 points and the percentage ferrite
shall be calculated from the number of points that fall on the ferrite phase and the total number
of points used.
The ferrite content shall be measured on one of the metallurgical sections using the point
counting technique at the following locations:
In the parent metal, one measurement on each side of the weld at mid thickness (total of 2).
In the heat affected zone on each side of the weld, in the region of the root pass (total of 2).
In the weld metal, 3 measurements near to the vertical center line of the weld, one in the cap,
one in the root, and one at mid thickness (total of 3).
Photomicrographs and Macro-examination
Photomicrographs at 400X minimum shall be provided to the COMPANY for each of the
locations where a phase balance assessment is performed.
Photomicrographs shall show a typical austenitelferrite micro-structure.
The macro-examination shall provide evidence that the weld is sound and free from cracks and
other defects with full penetration and fusion between weld passes and parent metal.
Hardness Test
Hardness testing is required on all plate and nozzle weld procedure qualification records.
Hardness readings shall be taken in Vickers with a 10 Kg load. At least 8 readings at a depth of
d#
MURPHy

Installation,
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Page 29 of 52
0.100 inch (2.5 mm) below the inside and below the outside surfaces shall be recorded for both
base metals, heat-affected zone and weld deposit. Hardness shall not be above Hv310.
Chemical Composition
A full chemical composition shall be performed on the weld deposit and the following elements
shall be measured and reported: C-Cr-Ni-Mo-Si-Ti-Al-Mg-N-CU-Nb. The following shall apply:
cs 0.02%
Cr +3.3 Mo 232 or Cr+3.3 Mo +16N where Nitrogen is present.
Production Welding
The maximum interpass temperature shall not exceed 150C. Measurements shall be taken on
the parent metal surface, directly adjacent to the weld groove, using a contact thermometer with
an instant digital display. Temperature indicating crayons shall not be used.
All single sided welds shall be made with a GTAW root pass and back purged until at least 6mm
of weld metal thickness has been deposited. Backing gas shall be welding grade 100% argon
with a purity of at least 99.95% argon. The oxygen content of the back-purged volume shall be
less than 0.5% (5000 ppm). The Supplier shall submit details of the method and equipment to
be used for monitoring oxygen content as part of the welding procedure specification.
All duplex stainless steel welding shall be monitored 100% and heat inputs and welding
sequence agreed with COMPANY Welding Engineer prior to welding.
Production welds shall be checked on the cap along the weld with a calibrated ferrite gauge and
shall not exceed 55% ferrite. The measurement spacing along the weld length shall be the
lesser of three equidistant locations or 300mm (12"). A minimum of five (5) measurements shall
be taken at each location. The surface shall be prepared as recommended by the manufacturer
of the testing instrument. Acceptance shall be based on the average of the measurements at
each location. Of the five (5) local measurements, the highest and lowest values may be
discarded and the average of the remaining three reported as the final value.
Repair Welding of Duplex Stainless Steel

Repairs shall be carried out to a pre qualiied duplex welding procedure (WPS). A second repair
shall not be allowed and the whole DSS weld shall be removed and rewelded.
*
MURPHy
5.16
5.16.1

Installation,
Inspection
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Revision: 1
Page 30 of 52
WELDING
General
Welding processes shall comply with the requirements of ASME 831.3, ASME IX and
specification: API RP-582.
5.16.2 Copper-Nickel Alloys

Prior to welding the weld preparation and a band 2 inch (50 mm) wide on both sides shall be
cleaned by stainless steel brushing and solvent degreasing to remove oxides, dirt, grease, paint
and all other contaminants.
Attempts to reduce misalignment shall not be carried out by cold working unless subsequent
heat treatment (stress relieving at 1100F (600C)) is applied. Alternatively, hot working in the
temperature range of 1380-1830F (750C-1000C) may be used. Local hammering of weld
seams or parent pipe is not permitted.
Weld restraint shall be minimized to avoid hot cracking in the weld and heat affected zone
during welding.
5.16.3
Welding Procedure Qualification
Welding procedure qualification shall comply with ASME 831.3 and ASME IX latest editions.
Backing rings are not acceptable.
When applicable for welding procedures to meet the additional requirements of NACE MR 0175
(sour service), hardness traverses shall be conducted .The acceptance criterion is a maximum
hardness value of 248 HV5 Vickers. For pipe thicknesses of 0.40 inch (10.16 mm) and up, the
maximum external HA2 hardnesses shall be 300 HV5.
5.16.4 Process Flow Lines

Special care shall be taken with process gas flow lines to ensure weld metal potential is greater
than parent metal potential to avoid preferential weld corrosion. A minimum of 1% Nickel
content shall be present in the weld metal at the root area.
5.16.5
Welder and Welding Operator Qualification
Welders and welding operators shall be qualified in accordance with the essential variables of
ASME 831.3 and the supplemental requirements of COMPANY specification for Welding
Procedure and Welder Performance Qualification.
6RPHY
5.16.6
Process Piping,
Fabrication,
Installation,
Inspection
and
Revision: I
Page 31 of 52
Repairs
For all welding processes, written repair procedures approved by the COMPANY shall be
utilized. These may be based on COMPANY approved full penetration groove welding
procedures or specifically qualified for repairs. For carbon steel procedures based on groove
welding procedures, work piece temperature shall be a minimum of 100F (38C) higher than
the minimum preheat temperature required for the original approved welding procedure. The
number of repair attempts shall be limited to not more than two. Repairs on Carbon Steel
material shall be executed with low hydrogen processes and electrodes, cellulosic electrodes
are not to be used for any weld repairs.
5.17
POSTWELD HEAT TREATMENT
The CONTRACTOR shall submit a post-weld heat treatment (PWHT) procedure in compliance
with ASME 831.3 for COMPANY approval prior to any PWHT being conducted. Only
COMPANY approved procedures shall be used for PWHT. This shall include, but not be limited
to, the number, location and method of attachment of thermocouples to the pipe or location
within a furnace.
All threaded connections shall be chased or gauge checked after heat treatment.
Exposed machined and threaded surfaces shall be protected from oxidation during heat
treatment.
Cleaning of piping after fabrication and heat treatment shall be performed externally and
internally to remove all loose scale, weld spatter, sand and other foreign materials.
5.18
5.18.1
INSPECTION IEXAMINATION
General
The CONTRACTOR procedures for radiographic, ultrasonic, magnetic particle, and dye
penetrant examination and inspection shall comply with ASME Section V. Acceptance
standards shall be in accordance with ASME B31.3.
CONTRACTOR shall carry out NDT for the individual piping systems as per the inspection class
requirement identified in the project line list.
5.18.2
Personnel Requirements
NDT examiner certification shall comply with the CONTRACTOR written practice as described
in the ASNT SNT-TC-1A. The written practice and all NDE examiner certification shall be
submitted to the COMPANY for review and approval prior to any inspection.
*
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Page 32 of 52
All inspectors shall be qualified to ASNT Level II, minimum, in the appropriate method according
to the Written Practice and shall be approved by the COMPANY before beginning work. Level I
examiners are permitted provided they are directly supervised by a Level II examiner.
All inspectors shall be certified to an internationally recognized standard except specialty
technicians (PT, MT, UT, and RT) who shall be qualified and certified according to the
guidelines ASNT SNT-TC-1A Level II or equivalent. Additionally, all specialty technicians may
be required to demonstrate their capabilities with a practical site test for COMPANY approval.
5.18.3
Extent of lnspection -General
The extent of inspection I examination shall be in accordance with ANSI 831.3 and the
supplemental requirements below. Progressive examination, as described in 831.3 paragraph
341.3.4, applies where less than 100% inspection is specified.
100% examination shall be performed on the first 10 welds produced by each welder.
Radiographs required by this paragraph shall not be used to satisfy the requirements of the
remaining welds. The extent of examination for all remaining welds shall be as indicated below
for each inspection method and is summarised in table 6.2.
All "Golden Welds" (i.e. Process pipe tie-in welds that that for some reason are not hydrotested)
shall as a minimum have the following NDT carried out 100% radiography, 100% ultrasonic
testing and 100% dye penetrant or magnetic particle testing, No "Golden Welds" shall be made
without the written permission from COMPANY.
5.18.4
Radiograph Examination
No radiography is required on piping welds in which all of the following apply:
The fluid service is non-flammable, nontoxic, and not damaging to human tissues;
The design gauge pressure does not exceed 100 psig
The design temperature is from -20F (-29C) through 366F (186C).
Agreed by COMPANY Welding Engineer.
Twenty percent random radiography shall apply to all piping welds on P-No. 1, P-No. 3, and PNo. 8 steel as defined in ASME 831.3 for which any of the following apply. All other P-Numbers
require 100%:
The design gauge pressure exceeds 150 psig, the design absolute pressure is less
than atmospheric (vacuum), or the design external pressure is greater than
atmospheric (jacketed piping).
Piping is for hydrocarbon service;
The pressure class is 2150 lb ANSI.
tion
and
Revision: 1
Page 33 of 52
Testing specification
II
The fluid service is flammable, toxic, or damaging to human tissue;
One hundred percent radiography shall apply to all piping welds in which any of the following
apply:
Piping in vibratory service, which includes piping connected to and within 50 feet
(15.2 m) of the suction or discharge of a reciprocating pump or compressor;
Piping in a severe cyclic condition as defined by ASME 831.3;
Fluid service such that the consequences of piping failure are severe personal injury,
loss of life andlor prohibitive expense (e.g. sour service);
Pressure class is 300 lb ANSI, and higher.
The design temperature is above 366F (186C) or below -20F (-29C).
5.18.5
Ultrasonic Examination
Ultrasonic examination of welds, when directed by the COMPANY representative, shall be

performed with the supplementary requirements of 831.3 paragraph 344.6.2.
For welds employing short-circuit GMAW welds on any part of the weld, 100% ultrasonic
examination shall be performed on 5% of the welds selected by COMPANY. If non-fusion
defects are found, additional inspections or the discontinuance of GMAW may be required at the
COMPANY'Sdiscretion.
The COMPANY shall reserve the option to radiograph socket welds to confirm proper
clearances and fit-ups.
5.18.6
Magnetic Particle Examination
Magnetic particle examination shall be conducted on branch connection welds of ferrit~c

materials The yoke method wRh a white background and black ink shall be used.
5.18.7
Liquid Penetrant Examination
Dye penetrant examination shall be conducted on branch connection on nonferrous materials.

Installation,
Inspection
and
MURPHY
Revision: 1
Page 34 of 52
Table 5-3 lnspection Class Summary

Class
Sewice
Flange
Rating
Design Temp.
NDT
Requirem
(Note 4
below
100
psig
desi
on FlammableINon Tox
150psig desi
above
acuum or Jacketed S e ~ i
LPG
All
(Note 2)
Sour Service
All
100%
Note(s)
1. Applies to P No-1,3&8 Materials Only.
2. Includes All Materials Except P-1,3&8.
3. Includes Open Vent and Drain Systems in any material
4. Where 0% NDE requires random 100% Visual lnspection but no DPEIMPE.
Where 20% NDE requires random 20% Radiography plus 20% random DPEIMPE.
Where 100% NDE requires 100% Radiography plus 100% DPEIMPE.
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Installation,
Inspection
and
Revision: 1
Page 35 of 52
COMPANY reserves the right to increase NDT extent of inspection to 100% if failure rates are
above 10% by joint on any service.
5.19
5.19.1
PRESSURE TESTING
General
This specification defines the minimum requirements for flushing and pressure testing of piping.
All piping shall be subject to a water head test, a hydrostatic test, or a pneumatic test as
indicated in Appendix A of this specification. Test Pressures shall be calculated per ASME
831.3 and be indicated on the line list and isometrics.
Just prior to installation each individual valve shall be hydrotested to design pressure. Testing
shall be conducted separately against each side of the closed valve. Any leaks shall be
repaired, and testing shall be repeated afler each repair.
The CONTRACTOR shall develop procedures covering system preparation, flushing, pressure
testing, drying and preservation. The procedures shall define the methodology, materials,
safety equipment, and instrumentation for documentation, testing media, duration and disposal.
The procedures shall provide sufficient detail for the COMPANY to evaluate the work to be
performed.
The CONTRACTOR shall be responsible for ensuring the safety of all personnel engaged in the
witnessing of the tests. The safety provisions shall be clearly stated in the hydrostatic and
pneumatic testing procedures.
The CONTRACTOR shall provide all supervision, labour, equipment, materials and
consumables required for the system preparation, flushing, pressure testing, drying,
preservation and reinstatement. All test equipment and temporary materials shall be compatible
with the pressure rating and materials of the system under test. Gaskets intended for final
assembly shall not be used for temporary test purposes. The welding of temporary fittings for
test purposes shall be carlied out to the same standards as for the piping under test. No NDT
(except for welding attachments to permanent job piping) will be required by the COMPANY on
these welds unless otherwise stated by COMPANY.
The CONTRACTOR shall ensure that adequate temporary supports, vents, drains and blinds
are provided to test the facility in accordance with this specification.
The CONTRACTOR shall provide all high points in the piping with vents and all low points with
drains, regardless of whether or not they are specifically shown on the drawings.
A current calibration certificate (within previous 60 days) shall be provided for the pressure and
temperature chart recorders. The chart recorderlgauge shall be tested prior to carrying out
pressure testing, the calibration shall be traceable to a known standard. The standard test
equipment to which it is tested against i.e. dead weight tester, will be retested each year.
*
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Installation,
Inspection
and
Revision: 1
Page 36 of 52
All pressure tests shall be witnessed and accepted by the COMPANY, it's representatives or a
third party inspector authorised by the COMPANY.
Prior to hydrotesting CONTRACTOR shall invite Client to a joint line-walk to ensure adherence
to approved for construction P&ID and Isometrics.
Hydrotest water shall be clean, fresh, non-corrosive water, free of un-dissolved solids, flat, gas
free with no dissolved oxygen and available at a minimum of 50F (10C).
The CONTRACTOR shall add a non-corrosive, non-hazardous, corrosion inhibitor to the
hydrotest water in concentrations recommended by the material manufacturer.
The
CONTRACTOR shall submit the proposed inhibitor system to the COMPANY for approval.
In the case of stainless steel piping water shall not have a chloride content greater than 30
PPM.
Hydrotesting of pipework may be carried out through piping valves installed in the half open
position. No hydrotest shall be carried out against a closed valve as isolation of a system.
Depending on the location of the test rig it may be required to use two Hydrotest gauges in
circumstances where long runs of pipe work is encountered or feet head of pipe is high.
5.19.2
System Preparation
The CONTRACTOR shall prepare a procedure and schedule for testing all piping within the
limits of his responsibilities. The procedure shall follow the guidelines established by this
specification. The procedure and schedule shall be presented to the COMPANY at least thirty
(30) days prior to the scheduled start of pressure tests. The procedures shall include, but are
not limited to, the following:
Mark-ups of piping and instrument diagrams (P&ID's) showing the limits of piping
and equipment to be included in each test.
Isometric drawings marked up with test limits.
Test medium to be used.
Test pressure and duration.
Location of all isolation blinds, high point vents, low point drains, and temporary
piping supports.
Procedures for flushing lines including fill points and equipment to be removed for
flushing.
Procedures for filling lines including addition of oxygen scavenger and bactericide in
proper quantities.
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Installation,
Inspection
and
Revision: 1
Page 37 of 52
Procedures for pressurization of the system, including the location of the injection
points and specified test pressures.
The form which shall be used to record hydrostatic test data.
Where applicable HSE procedures for the handling of chemicals etc.
Prior to testing, all piping shall have been cleaned to remove mill scale, weld spatter, dirt and
other foreign matter. All welding, NDT and stress relieving shall be complete.
All in-line equipment or devices which may be damaged or hamper the test shall be removed
from the system. All sensitive in-line and on-line instrumentation items shall be removed or
isolated and this shall include, but not be limited to the following:
Pressure vessels or any mechanical equipment
Check valves or check valve flappers
Restriction orifices / orifice plates
Positive displacement meters
Turbine type meters/PD metersllnsertion Type meters.
Self regulated controllers
Relief valves
Rupture Discs
Level controls and switches
Filter elements
Diffusers
Transmitters
Corrosion probes/chemical injection quills
Control/Choke Valves.
5.19.3
Flushing and Cleaning
Prior to commencing any flushing, CONTRACTOR or VENDOR shall verify with COMPANY
Representative that all required post weld heat treatment (PWHT), non-destructive testing
(NDT) such as radiography, ultrasonic, etc., has been completed in accordance with COMPANY
Piping Design, Fabrication and Installation specifications. Upon verification of the above
requirements, the COMPANY Representative shall authorize, in writing, the CONTRACTOR or
VENDOR to proceed with flushing.
XIE
MURPHY
Process Piping,
Fabrication,
Installation,
Inspection
and
Revision: 1
Page 38 of 52
All completed piping systems shall be flushed prior to testing. Piping system shall be broken into
sub-systems for flushing. The COMPANY shall approve the flushing sub-systems and the
procedure. The sub-system nominated for flushing shall be securely isolated from all other subsystems to prevent water and debris entering the adjacent sub-systems. Special care shall be
taken to isolate rotating equipment from the flushing.
All lines two (2) inches and larger, other than instrument and utility air lines shall be flushed with
clean inhibited water so as to completely clear them of any loose mill scale, rust, or various
extraneous material. All lines smaller than two (2) inches, and air lines of any size, shall be
cleaned out in a similar manner using compressed air. The flushing medium shall be at as high
a velocity as practical (minimum of 5 meterslsec) in order to flush out any loose material in the
line. Flow shall be from high to low points. Flanges shall be opened and spool pieces shall be
removed as necessary to flush the piping thoroughly.
Flushing shall be performed until a clear stream of flushing medium exits the piping, with a
minimum flush volume being equal to five times the volume of the piping being flushed. All
flushing shall be done in the presence of the COMPANY Representative.
Orifice plates, thermowells, flow straightening vanes, positive displacement (PD) and turbine
meters, vortex meters, control valves, corrosion probes, sample probes, pig signallers,
displacement type level instruments, and other vulnerable equipment, if already installed, shall
be removed prior to flushing (the instrument engineer shall define these in conjunction with the
piping supervisor). All instrument leads shall be disconnected prior to flushing but shall be
reinstated and capped at the disconnected instruments prior to hydrotest. All control valves
shall be removed. Spring type supports shall have stops installed to prevent overloading of the
support.
All vessels included within a piping system being flushed are to be drained through the vessel
drain system.
5.19.4
High Pressure Jet Flushing (HPJF)
COMPANY will accept High pressure jet flushing (HPJF) i.e. retrojetting which requires even
cleaning of the entire pipe surface with fresh water at a pressure of minimum 600 barg, using a
rotating hose (rot-fan system). The rot-fan system shall have facilities for a controlled linear
speed and rotation of both hose and nozzle. The equipment must be safe to operate and
equipped with automatic shut-off system in case of hose failure. The rotating hose shall be
capable of operating 90" bends without a drop in performance, capable of cleaning up to 300 m
lengths at a time, additionally, the unit shall be fitted with the necessary attachments at pipe
entrance in order to collect and dispose of debris and to be able to operate cleanly and safely.
6RPHy
6 and above
Revision: 1
Page 39 of 52
Rotating hose to be used.
I Rotatino Nozzle shall be used.
2" to 4"
2" and below
5.19.5

Installation,
Inspection
and
High Velocity Water Flushing (HWVF); minimum velocity

shall be 10 mlsec.
Pressurised Air Shockblowing (PAS)
Pressurised Air Shock blowing (PAS) means cleaning or checking of cleanliness by installing a
quick acting valve or a rupture disk on an open flange end. Thereafter the circuit is pressulised
to predetermined pressure and then quickly open the valve or pressurise until the rupture disk
burst. A certain amount of water may be inserted in order to improve the transport effect of
debris. This method may be used as an initial cleaning method for Instrument Air, Plant Air and
as an alternative method for initial cleaning of small bore pipe (less than 2 ) . This method shall
be used when there are problems to remove trapped liquid in the circuit.
The method shall be used to verify cleanliness of small bore pipe where video inspection is
impossible or inadequate due to pipe dimension or configuration.
When using PAS method for cleaning or verification the procedure shall be repeated until
cleanliness is acceptable.
The air shocking pressure shall never exceed the working pressure of the system and shall
never be more than 8 barg. Safety precautions shall be taken when this method is used, to
ensure that the discharge pipe-end is shielded, to prevent dislodged debris from injuring
personnel.
5.19.6
Re-Ingress of Contaminants
If it is determined that for any reason that there is a lisk that the flushing is no longer valid due
to sloppy housekeeping practices or carelessly leaving the system open all flushing and if
applicable chemical cleaning shall be repeated. Exceptions to this rigid rule are at the sole
discretion of COMPANY.
5.20
Pressure Testing
All piping shall be subject to a water head test, a hydrostatic test or a pneumatic test. Test
pressures shall be calculated per ASME 831.3.
I
5.20.1

Installation,
Inspection
and
Revision: 1
Page 40 of 52
Water Head Testing
Where necessary, a method of isolation shall be installed and piping completely filled with
water. The piping shall be examined for leaks. For acceptance purposes no leaks are allowed.
This method is permitted only for atmospheric vents or drains.
5.20.2
Hydrostatic Testing
All piping other than instrument air or instrument gas piping shall be prepared for test in
accordance with the test flowsheet and the test procedure. This shall include isolation by blind
flanges, spectacle blinds, or plugs.
Instrument take-offs shall be tested to the outlet side of the piping block valve. The piping block
valve shall be fitted with a blind or plug, as required.
All valves shall be in the half open position for the test. Under no circumstances will hydrotest
be conducted against a closed valve; all hydrotesting shall be against flanged, spectacle blinded
or plugged connections.
The piping shall be slowly filled with water until all air is excluded. The hydrostatic vents shall
be closed and the piping shall be slowly pressurized to 50% of the test pressure and then in
increments until the test pressure is reached. When leaks are identified, the pressure shall be
reduced to the level not greater than the previous increment before flange bolts shall be torqued
to stop the leak. Flange bolts shall not be torqued over allowable stresses. Where the leak
cannot be stopped, inspection for evidence of other problems shall be carried out; this may
require depressurising and stripping.
Once the system has reached the test pressure, the test shall not start until temperatures have
equalized throughout the piping and transient strains have dissipated. A start time shall be
agreed and this time recorded. Test duration shall be for a minimum period of one hour after
leaks are stopped. Once Test pressure is reached and stable the test pump shall be
disconnected from the system under test.
The piping shall be carefully inspected for leaks and evidence of other problems at the end of
the test period and at the test pressure. For acceptance, no leaks are permitted.
The piping pressurizationsteps, test pressure and temperature at the test start time, hold period
and finish time shall be recorded on a chart recorder.
For large piping systems, the CONTRACTOR may at his discretion transfer test medium from
one system to another for test purposes providing the medium has not become contaminated in
the test process.
No testing shall be performed during periods of rain unless the entire piping system under test is
protected from the weather.
MURPHy

Installation,
Inspection
and
Revision: 1
Page 41 of 52
A recently calibrated 2-pen pressure and temperature recorder shall be utilized for the
hydrotest. The CONTRACTOR shall submit to COMPANY a copy of the calibration charts for
the pressure recorder.
Disposal of all hydrotest media shall be a responsibility of the CONTRACTOR and shall be in
accordance with applicable laws.
5.20.3
Pneumatic Testing
Only low pressure piping systems should be considered for pneumatic test and each such test
must have written approval from COMPANY.
All instrument air or instrument gas piping shall be prepared for test, as for hydrotest. In
addition, all flanges shall be wrapped with duct tape and a small hole punched through the tape
at the top of the flange.
The piping shall be pressurized to a pressure of 25 PSI with clean, dry air and gross air leaks
shall be remedied. The piping shall be slowly pressurized to 50% of the test pressure, then
increased in increments of 10% until the test pressure is reached. When leaks are identified the
pressure shall be reduced before flange bolts shall be torqued up to stop the leak. Where the
leak cannot be stopped inspection for evidence of other problems shall be carried out; this may
require depressurising and stripping.
A start time shall be agreed between the COMPANY and the CONTRACTOR and this time
recorded.
The piping under test shall be carefully inspected for leaks and evidence of other problems at
the end of the test period and at the least pressure. All joints, welds and connections shall be
swabbed with a soap solution. For acceptance no leaks are permitted.
The piping pressurization steps, test pressure and temperature at the test start time, hold period
and finish time shall be recorded on a chart recorder.
Test duration shall be for a minimum period of one hour after leaks are stopped.
No testing shall be performed during periods of rain unless the entire piping system is protected
from the weather.
Nitrogen testing, when required shall require a separate documented work instruction and be
carried out by specialist CONTRACTOR.
5.21
Test Documentation
The CONTRACTOR shall provide documentation to record each pressure test. Each pressure
test shall be given a unique test number and this test number shall be referenced on the front
sheet of the pressure test pack. A pressure test pack shall be produced for each pressure test.
$X
MURPHY

Installation,
Inspection
and
Revision: 1
Page 42 of 52
The pressure test pack shall contain the following documentation:

The test pressure and medium as specified on the line list.
All welding, NDT and PWHT is complete and piping is ready for test.
Isometric and P&IDs drawings marked up with test limits.
Test flowsheets, and flushing, testing, reinstatement procedure.
Pressure and temperature recorder chart showing pressurization, test start, hold
time, temperature fluctuations and finish time signed by the CONTRACTOR,
COMPANY and third party as applicable.
Calibration Certificates showing timeldate of calibration.
Piping hydrotest certificate on completion of the test.
If the piping fails the pressure test then no test chart will be signed off.
The
CONTRACTOR shall be responsible for all remedial work, repairs and retesting.
All rework shall be carried out in accordance with the relevant specifications and
procedures.
Piping will not be accepted unless covered by a fully signed off test chart.
5.21 .I Reinstatement
After successful hydrotest the piping shall be emptied of the test medium. Where applicable,
pressure tested piping shall be reinstated in accordance with isometric and design drawings.
The piping shall be dried internally andlor subject to preservation to ensure no deterioration
prior to system commissioning.
Temporay vent and drain valves shall be removed and replaced with blinds or plugs, as
applicable.
High point vents and low point drains added for hydro testing purposes shall be seal welded
after testing. The plugs shall be removed and cleaned of any jointing compound or tape prior to
being reinstated and welded.
5.22
5.22.1
CHEMICAL CLEANING
General
Specific equipment requires connected piping to be chemically cleaned prior to commissioning,

in order to prevent undesirable foreign matter entering the equipment. All requirements relating
to HSE, MSDS sheets, PPE and safeguards shall be documented and approved by COMPANY.
It shall be the responsibility of the individual CONTRACTOR for the disposal of fluids utilised by
any of the flushing, chemical cleaning andlor preservation of piping and equipment.
8RPnY
5.22.2
Process
Piping,
Fabrication,
~nsta~htion, ~nspection
and
Revision: I
Page 43 of 52
Extent of Chemically Cleaning
The extent of chemical cleaning shall be as follows:
5.22.3
Flushing
All piping shall be flushed.
5.22.4 Chemical Cleaning

Chemical cleaning shall be carried out in accordance with section 5.22 on identified carbon steel
piping including but not limited to the following systems:
All compressor suction lines and recycle lines between the suction scrubber and the
compressor suction nozzle
All compressor discharge lines up to the first discharge block valve
All compressor recycle lines upstream of the recycle control valve
All expander inlet lines between the inlet scrubber and the expander inlet nozzle
All metering piping and inlet piping to metering skids
Fuel gas distribution piping after the main fuel gas filter coalescers
Seal gas systems after the main filter coalescers
Hot Oil system piping
Hydraulic Oil system piping
Lubrication and Seal Oil systems piping
Inert Gas distribution piping to compressors, and hot oil systems
5.22.5
Video Inspection
All condensate pump suction lines between the pump suction vesselltank and the
pump suction nozzle
All hydrocarbon pump discharge lines up to the first discharge block valve
All compressor suction lines between the suction scrubber and the compressor
suction nozzle
Xk
MURPHY

Installation,
Inspection
and
Revision: 1
Page 44 of 52
All compressor discharge lines up to the first discharge block valve (only if the control
valve is prone to blockage due to small ports)
All compressor recycle lines upstream of the recycle control valve(only if the control
valve is prone to blockage due to small ports)
All expander inlet lines between the inlet scrubber and the expander inlet nozzle
All metering piping and inlet piping to metering skids
All piping between the filter coalescers and the C02 removal membranes
Fuel gas distribution piping after the main fuel gas filter coalescers
Seal gas systems after the main filter coalescers
Diesel distribution piping after the filter coalescer
Hot Oil system piping
Hydraulic Oil system piping
Lubrication and Seal Oil systems piping
Inert Gas distribution piping to compressors, and hot oil systems from the last filter
Inlet lines to welded plate or fusion bonded or PCME heat exchangers.
Process refrigeration lines
5.22.6 Grit Blasting

Compressor suction lines.
Gas re-injection lines.
Prior to chemical cleaning the piping shall be flushed.

Any internal coating other than initial preservation oil shall also be removed prior to chemical
cleaning.
The systems to be chemical cleaned shall have high and low point vents and drains. These
shall be marked on chemical cleaning Isometrics.
Precautions to be taken to prevent the ingress of chemical cleaning fluids into equipment shall
form part of the procedures to be submitted by the CONTRACTORfor approval.
The chemical cleaning procedure shall describe a method using only one volume chemical
cleaning fluid per system (i.e. the same volume to be used for all steps mentioned below),
adding the required amount and type of chemicals required in order to carry-out the following
steps:-
#k
MURPHY

Installation,
Inspection
and
MOM-MUR-10-PGSP-0001-00
Revision: 1
Page 45 of 52
1. Degreasing
2. Descaling
3. Neutralisation
4. Passivation
When above steps are completed a second volume of fresh water shall wash out remaining
chemical fluid.
For systems where microscopic test samples are required for cleanliness verification, i.e.
compressor suction lines, lube oil lines and instrument air lines: ISO-standard 4406 shall be
used for defining the solid contaminate quantities in the flushing medium. The upper and lower
limits for the number of particles which will be permitted for the various systems are specified in
Appendix C.
Finally the system shall be dried and preserved.
5.23
Chemical Cleaning of Carbon Steel Piping
Equivalent alternative method may be submitted for reviewlapproval by the Principal.
5.23.1
Degreasing
Degreasing shall be achieved by the addition of suitable degreasing agents based on

emulsifiers andlor detergents compatible with the chemical cleaning, neutralisation, and
passivation mediums.
Whenever protective coatings of preservatives are present on the internal surface, the chemical
cleaning fluid shall be formulated in the manner as to dissolve and remove such contaminants.
For certain types of coatings/preservatives a two stage cleaning method may be used if
required. However, the method and procedures shall be subject to the COMPANY'Sacceptance
before application.
5.23.2
Chemical Cleaning
The purpose of the following chemical cleaning procedure is to remove oil, grease, mill scale
and rust from the piping internals. This shall be achieved by means of circulating a mixture of
chelating agents, corrosion inhibitors, degreasing agents, solvents, etc. The cleaning solution
shall be controlled to avoid excessive corrosion of the metal and localised corrosion i.e. pitting,
Xk
MURPHY

Installation,
Inspection
and
Revision: 1
Page 46 of 52
and stress corrosion cracking shall all be strictly controlled. through the system at a temperature
of about 80C until clear, bare metal surfaces are exposed.
High points vents shall be opened periodically to allow trapped air in air pockets to escape
during the chemical cleaning operation.
The chemical cleaning operation shall be continuously monitored by suitable analytical methods
for chelant concentration, iron concentration, pH value, appearance, colour and EMF (Electro
Motive Force) until laboratory results indicate the operation is completed. This is normally
achieved when the chelant and iron concentrations are stabilised.
Systems to be cleaned shall be sufficiently split-up to ensure proper contact time with the
chemicals and achievement of required velocities for particle transport.
In the liquid flow there shall be a filter unit to remove solid particles. The filtration capability shall
be sufficient to achieve cleanliness as laid down in the relevant equipment standards and if not
specified to the satisfaction of both Manufacturer andCOMPANY.
5.23.3
Neutralisation
The chemical cleaning fluid shall be neutralised with the compatible type of alkali (Caustic Soda,
Hydrazine, Sodium Bicarbonate or Ammonia) to a pH range of 8.5-10 depending on the type of
chelant used.
5.23.4
Passivation
The chemical cleaning solution shall be cooled to between 45-55C (depending on the type of
passivating agent used), and the pre-calculated quantity of passivator (nitrite, phosphate or
peroxides) based on the level of iron concentration added.
This solution shall be circulated in the system for minimum of one (1) hour depending on the
type of passivator and temperature.
Passivation shall be monitored from a laboratoty with competent personnel and equipment, to
prevent ferric ionic corrosion.
Passivation is nomlally complete within four (4) hours (depending on the type of composition)
when EMF is stabilised. At this stage the system is drained with air or nitrogen.
5.23.5
Water Flushing
Piping shall be thoroughly flushed with clean fresh water as rapidly as possible after the
chemical cleaning operation to rid the surface or all traces of excess chelant or iron salts. High-
*
MURPHY

Installation,
Inspection
and
Revision: 1
Page 47 of 52
pressure water, high flow velocity and adequate drainage are required to facilitate rapid flush
operation.
The water shall not be recirculated.
All blanked ends, including vents, drains, instrument taps etc. shall be opened long enough to
flush out all entrapped chemicals.
Rinsing shall continue for at least ten (10) minutes afler the pH of the effluent water equals the
pH of the feed water.
5.23.6
Drying
Drying shall be performed immediately afler completion of final water flushing.
5.23.7
lnspection
A visual inspection of internal piping surfaces by videotape, shall be performed to ensure that
piping surfaces are free from all traces of contamination and liquid.
5.23.8
Protective CoatinglPresewation
When rust preventive is to be used, the internal surface shall be coated immediately afler drying
and inspection. If carbon steel systems, such as, heating and cooling medium or closed-circuit
glycol, are to be internally protected, a waterbased preservation medium, without any traces of
solvents, shall be used. Below freezing point, use mixtures with triethylene glycol.
Note: Systems preserved shall also be dried, when preservation operation is completed.
16.3.9 CONTRACTOR tosupply a safety procedure for handling and working with chemicals
during any chemical cleaning or hot oil flushing activities.
5.24
Chemical Cleaning of Stainless Piping.
Equivalent alternative methods may be submitted for approval by the COMPANY.
5.24.1
General
The cleaning operation follows to a great extent the same procedure as for chemical cleaning of
carbon steel piping, except for the following:
MURPHY

Installation,
Inspection
and
Revision: 1
Page 48 of 52
Cleaning agent shall be Nitric Acid. Alternatives in accordance with ASTM A380 may be
proposed.
Note : Neutralisation not required
Note : Passivation not required
Temperature shall not exceed 55C at any time
5.24.2
Removal of Dirt, Degreasing
The piping system shall be internally cleaned and degreased using the same procedure as
stated for carbon steel.
5.24.3
Chemical Cleaning
When chemical cleaning is required in order to remove oxidation along pipe walls and scale
occurred as a result of welding the same procedure as per carbon steel piping shall be used.
5.24.4
Water Flushing
Piping shall be thoroughly flushed after the chemical cleaning to the same procedure as for
carbon steel.
5.24.5
Drying
Drying shall be done as per carbon steel.
5.24.6
Inspection
This shall be as per carbon steel piping.
5.24.7
Protective Coating IPreservation
Immediately after drying and inspection, pipe and flanged ends shall be fully protected against
the ingress of foreign material using a procedure supplied by the CONTRACTOR and approved
by COMPANY.
J;k
MURPHY
5.25
5.25.1

Installation,
Inspection
and
Revision: 1
Page 49 of 52
Hot Oil Flushing

General
Hydraulic oil, lube oil and seal oil systems shall be hot oil flushed to ensure the internal piping
surfaces are free from all traces of contamination.
If chemical cleaning is specified, this must be carried-out prior to hot oil flushing.
The CONTRACTOR shall develop detailed hot oil flushing procedures which shall be adjusted
to suit each type of system. Hot oil flushing on VENDOR packages shall in general follow the
above sequence. However, the VENDORS recommended procedures and cleanliness standard
shall be submitted for approval by the Principal.
5.25.2
Flushing Oil
Whenever possible the flushing oils shall be the same grade as the operating fluid. A different
grade may be selected provided it is fully compatible with the operating fluid.
When the final flushing oil is the same grade as the operating oil, unless otherwise specified, it
shall be left in the system at the end of the flushing procedure. Any other flushing oil must be
removed.
5.25.3
Cleanliness of Hydraulic Oil Systems
Hot oil flushing shall continue until the accepted level of cleanliness has been reached. The
cleanliness level shall be assessed by microscopic examination of the test sample. A system is
considered clean when, using a 3p filter absolute, the oil sample meets the cleanliness
requirements specified in the equipment standards or to the satisfaction of the equipment
manufacturers and COMPANY.
5.25.4
Cleanliness of Lubricating Oil Systems
As per Hydraulic Oil Systems above, but the system is considered clean when using a
10 micron filter absolute, the oil sample meets the cleanliness requirements specified in the
equipment standards or to the satisfaction of the equipment manufacturers and COMPANY.
6RPHy
5.25.5

Installation,
Inspection
and
Revision: 1
Page 50 of 52
Cleanliness of Seal Oil Systems
As per Hydraulic Oil Systems above, but the system is considered clean when using a 10 wfilter
absolute, the oil sample meets the cleanliness requirements specified in the equipment
standards or to the satisfaction of the equipment manufacturers and COMPANY .
5.26
Hook-Up Piping
Hook-up piping requiring chemical cleaning shall be performed by the hook-up CONTRACTOR.
For closed-circuit systems for hydraulic, lube and seal oil, chemical cleaning of hook-up piping
shall be performed separately after hook-up closing welds are completed, and piping has been
pressure tested. Valves and break flanges shall be installed to ensure that the existing system is
isolated so that chemical re-cleaning is not necessaly.
For closed circuit systems for heating and cooling medium, chemical cleaning shall be
performed prior to final installation, and chemical cleaning of the hook-up closing welds is not
required.
5.27
Re-Ingress o f Contaminants
If it is determined that for any reason that contaminants have reentered the system then all
flushing and chemical cleaning shall be repeated. Exceptions to this rigid rule are at the sole
discretion of COMPANY.
5.28
COATING
All process piping and components shall be coated in accordance with applicable COMPANY
Coating Specification MOM-MUR-10-DC-PR-0003-00, latest revision.
In general, piping shall be blasted and painted up to the final coat of paint prior to installation on
skid packages or platform interconnections. Where this is not possible, the CONTRACTOR shall
mask adjacent piping to protect it from overspray. Gasket surfaces on flange faces shall be
protectedlmasked off to ensure sealing integrity as specified in COMPANY specification
Coatings for Structures, Piping and Equipment.
5.29
INSULATION
Insulation shall be applied in accordance with applicable COMPANY: SPECIFICATION FOR

EQUIPMENT AND PIPING INSULATION Document number: 06001-SK-EG-PI-STD-GEN-0005.
Unless otherwise specified, insulation shall be applied only afler final assembly and testing.
JX
MURPHY
5.30

Installation,
Inspection
and
Revision: 1
Page 51 of 52
IDENTIFICATION AND SHIPPING
Each shop fabricated spool piece shall be shown on a detail drawing of that spool piece only
and shall be assigned a spool piece number, which shall include the line number identifying the
individual spool piece.
A copy of the arrangement drawing(s) shall be marked by the CONTRACTOR with the
individual spool piece numbers for identification. The CONTRACTOR shall also furnish a
transparency and two blue line drawings, or computer data file of each spool piece drawing
when issued for fabrication.
Each spool piece shall be marked with its spool piece number painted or hard stencilled on a
metal tag in large letters in at least one place near one end or, in case that the spool piece
exceeds 15 feet (4.6 m) in length, then both ends shall be painted or have metal tags. Spool
pieces which are too small to have a painted spool piece number shall be identified by marking
(stencilling) the spool piece number on a metal tag wired securely to the spool piece. Paints
used on piping shall be of the type which are not harmful to the piping material, i.e., no active
metallic pigment or greater than 250 ppm chlorides on stainless steel pipe.
For shipment from the shop to the field, protection shall be given to exposed gasket surfaces,
welding bevels, and threads as specified below.
Flanges and bevelled ends shall be blanked with wood, wood fiber, plastic, or metal protective
covers securely attached by bolting, steel strap, steel clips, or suitable friction locking devices.
Tapped connections shall be fitted with threaded pipe plugs. Threaded ends shall be provided
with metal or plastic thread protectors.
All other openings shall be protected to prevent entry of extraneous materials.
All piping components shall be kept dry.
After final positioning of spectacle blinds the exposed section of the blind shall be protected
against corrosion by using Denso tape or equivalent.
Final fix gaskets to be colour coded to show the difference between the test gasket and the final
gasket.
5.31
MECHANICAL COMPLETION
In order to demonstrate mechanical completion ready for pre-commissioning the

CONTRACTOR shall carry out a 'line by line' walk to check the system and its components
have been installed in accordance with the latest revision of the P&ID's. The installed system
shall also be checked against the isometric and pipe support design drawings for compliance
and a punch list produced of outstanding items for rectification.
6RPHY

Installation.
Inspection
and
6.0
APPENDICES
6.1
PRESSURE TESTING REQUIREMENTS
End of Document.
Revision: I
Page 52 of 52

MOM-MUR-10-PC-SP-0001!00!1 Process Piping Fabricaton, Inspection and Testing Specification

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PROCESS PIPING, FABRICATION,

INSPECTION AND TESTING SPECIFICATION.

Process Piping, Fabrication,

REVISION STATUS ISUMMARY OF CHANGES

Process Piping. Fabrication.

Quality Control ...............................................................................................................

Categorization of Piping and Components..............................................................

Physical Identification of Piping and Components .................................................. 14

Pipe Spool ldent~f~cat~on

Traceablllty Requirements .............................................................................................

PIPING FABRICATION and INSTALLATION................

Severe Cyclic Service .............................................................................................

Pressure Containing Welds .....................................................................................

Process Piping. Fabrication.

Welding Procedure Qualification.......................................................................

Process Flow Lines ..............................................................................................

Welder and Welding Operator Qualification.........................................................

POSTWELD HEAT TREATMENT ..............................................................................

Extent of Inspection - General.............................................................................. 32

Flushing and Cleaning .............................

High Pressure Jet Flushing (HPJF)......................................................................38

Pressurised Air Shockblowing (PAS) ...................................................................

Re-Ingress of Contaminants .........................

Pressure Testing ........................................................................................................

Hydrostatic Testing ..............................................................................................

Test Documentation ....................................................

Process Piping. Fabrication.

CHEMICAL CLEANING ..............................................................................................42

Extent of Chemically Cleaning .............................................................................

Chemical Cleaning ...............................................................................................43

Chemical Cleaning of Stainless Piping.....................................................................47

Chemical Cleaning ...............................................................................................

Protective Coating I Preservation.........................................................................

Hot Oil Flushing ..........................................................................................................

Cleanliness of Hydraulic Oil Systems ..................................................................

Process Piping. Fabrication.

IDENTIFICATION AND SHIPPING ...................

Table 3-1 References ................................................................................................................

Process Piping, Fabrication,

Testing, Precommissioning, Commissioning

Quality Assurance Quality Control

Process Piping, Fabrication,

Passivation of Stainless Steel Parts,

Process Piping, Fabrication,

Steel and steel products - Inspection

American Petroleum Institute

American Society For Non-destructive Testing

American Welding Society

Process Piping, Fabrication,

Deutsches Institute for Normung

Dye Penetrant Inspection

Duplex Stainless Steel

Electro Motive Force

High Pressure Jet Flushing

Health and Safety Executive

Inspection and Test Plan

Magnetic Particle Inspection

Manufacturer's Data Records

Material Safety Data Sheet

Material Traceability Report

Non Destructive Testing

Piping and Instrument Drawings.

Project Management Team

Personal Protection Equipment