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03
GENERAL PIPING FABRICATION, INSPECTION, AND TESTING
CONTENTS
1.0 INTRODUCTION ..........................................................................................................3
2.0 REFERENCES .............................................................................................................3
2.1 ......Industry Standards ...........................................................................................3
2.2 ......Chevron Specifications .....................................................................................5
3.0 GENERAL REQUIREMENTS ......................................................................................5
4.0 BENDS .........................................................................................................................6
5.0 WELDING ....................................................................................................................6
5.1 ......Welding Procedure Documentation (WPS and PQR) ......................................6
5.2 ......Welder and Welding Operator Qualification .....................................................6
5.3 ......Repair Procedures ...........................................................................................7
5.4 ......Welding Processes ...........................................................................................7
5.5 ......Production Welding ..........................................................................................8
6.0 FABRICATION, ASSEMBLY AND ERECTION ........................................................12
6.1 ......General Piping ................................................................................................12
6.2 ......Pipe Supports .................................................................................................13
6.3 ......Assembly ........................................................................................................14
7.0 POST WELD HEAT TREATMENT ............................................................................14
7.1 ......Thermocouples ...............................................................................................14
8.0 QUALITY ASSURANCE, TESTING AND QUALITY CONTROL ..............................15
8.1 ......General ...........................................................................................................15
8.2 ......Weld Inspections ............................................................................................15
8.3 ......Radiography ...................................................................................................15
9.0 FLUSHING .................................................................................................................16
9.1 ......General ...........................................................................................................16
9.2 ......Preparation for Leak Testing ..........................................................................17
10.0 HYDROSTATIC LEAK TESTING ..............................................................................18
10.1 ....Post-Test Requirements .................................................................................20
10.2 ....Pneumatic Testing ..........................................................................................20
10.3 ....Leak Repair and Re-Testing ..........................................................................21
11.0 CLEANING, DESCALING AND PASSIVATING OF CARBON STEEL PIPING ......21
11.1 ....General ...........................................................................................................21
11.2 ....Cleaning by Acid Pickling ...............................................................................22
12.0 HOT OIL FLUSHING .................................................................................................24
13.0 IDENTIFICATION AND MARKINGS .........................................................................25
14.0 PREPARATION FOR SHIPMENT AND STORAGE .................................................25
15.0 DOCUMENTATION REQUIREMENTS .....................................................................26
1.0 INTRODUCTION
1. This specification, in conjunction with the other technical requirements, defines the minimum
acceptable requirements for the fabrication, assembly, welding, erection, installation, inspec-
tion, testing, cleaning and documentation of piping systems used in upstream oil and gas pro-
duction facilities.
2. This specification applies to both shop and field fabricated piping.
3. This Specification governs piping systems provided in accordance with API Recommended
Practice 14E "Design and Installation of Offshore Production Piping Systems."
4. Piping systems designed for pressures in excess of that permitted by ASME B16.5 Class 2500
shall be designed and fabricated and installed in accordance with ASME B31.3, Chapter IX
"High Pressure Piping."
a. Pipelines are specifically excluded from the scope of this specification.
b. Instrumentation tubing is subject to the additional requirements of ICM-SU-11.01.
5. This specification shall also apply to the fabrication and attachment of pipe supports.
6. Piping systems in accordance with this specification shall comply with prevailing Government
Regulations and Statutes.
7. Any and all exceptions to the technical requirements shall be submitted in writing to Company
for approval prior to fabrication.
2.0 REFERENCES
1. The most recent issue of the standards and codes listed below shall be considered as a part of
this Specification.
2. All Addenda issued through the date of the Purchase Order, Contract or Agreement, as appli-
cable, shall apply in full.
B1.20.1 Pipe Threads (Except Dry Seal) Specifications, Dimensions, and Gaging for
Taper and Straight Pipe Threads Including Certain Special Applications
Boiler and Pressure Vessel Code
Section V - Nondestructive Examination
Section IX - Welding and Brazing Qualifications
American Society of Nondestructive Testing (ASNT)
SNT-TC-1A Nondestructive Testing Qualification and Certification
American Society for Testing and Materials (ASTM)
A36 Specification for Structural Steel
A106 Specification for Carbon Steel Pipe
A193 Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Ser-
vice
A194 Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Tempera-
ture Service, or Both
A320 Alloy-Steel and Stainless Steel Bolting Materials for Low- Temperature
Service
A370 Standard Test Methods and Definitions for Mechanical Testing of Steel
Products
A694 Standard Specification for Carbon and Alloy Steel Forgings for Pipe
Flanges, Fittings, Valves, and Parts for High-Pressure Transmission Service
A860 Wrought High-Strength Low-Alloy Steel Butt-Welding Fittings
B117 Standard Practice for Operating Salt Spray (Fog) Apparatus
E562 Determining Volume Fraction by Systematic Manual Point Count
F1137 Phosphate/Oil and Phosphate/Organic Corrosion Protective Coatings for
Fasteners
F1470 Fastener Sampling for Specified Mechanical Properties and Performance
Inspection
American Welding Society (AWS)
A4.3 Standard Methods for Determination of the Diffusible Hydrogen Content of
Martensitic, Bainitic and Ferritic Steel Weld Metal Produced by Arc Weld-
ing
A5.5 Specification for Low Alloy Steel Covered Arc Welding Electrodes
Manufacturers Standardization Society of the Valve Fittings Industry (MSS)
SP-44 Steel Pipe Line Flanges
SP-75 Specification for High Test Wrought Welding Fittings
National Association of Corrosion Engineers (NACE)
MR-01-75/ISO 15156 Petroleum and Natural Gas Industries - Materials for use in H2S Containing
Environments in Oil and Gas Production
11. Tack welds shall be of the same quality and material as the completed weld and shall be fully
fused with weld beads; otherwise the tack weld shall be removed during the welding opera-
tion.
12. Arc strikes on pipe and fitting surfaces shall be removed. See Section 5.5.8 item 3.
13. Contractor shall provide protective coatings in accordance with COM-SU-2.02.
14. Hot taps to previously operated piping systems shall not be permitted without prior written
approval by Company.
15. Orifice flange taps shall not be located at the top or bottom position.
16. Valves shall not be installed with their stems located below the horizontal.
4.0 BENDS
Bends are not permitted without written approval of the Company.
5.0 WELDING
5.4.1 General
1. All semi-automatic or fully-automatic welds shall be made utilizing a multi-pass tech-
nique.
2. Vertical downhill welding shall not be permitted.
3. Low hydrogen consumables shall be certified by the electrode manufacturer, or tested
by Contractor to comply with AWS A4.3 H8 or better.
4. An internal gas purge shall be provided for the root pass and the second layer of stain-
less steel welds for any gas shielded process.
5. Acceptable weld processes for welding of piping and supports shall include the fol-
lowing:
a. Flux Core-Arc Welding (FCAW)
b. Gas Metal-Arc Welding (GMAW)
c. Gas Tungsten-Arc Welding (GTAW)
d. Shielded Metal-Arc Welding (SMAW)
e. Submerged-Arc Welding (SAW)
3. SAW procedure qualification test records shall show the name of the manufacturer
and the trade name of the wire and flux used to qualify the procedure. Flux manufac-
turer's trade name shall be an essential variable.
4. Addition of alloy agents through the flux shall not be acceptable.
5. SAW is not permitted for austenitic stainless steel.
4. Stainless steel electrodes shall be low carbon "L" grade, and shall conform to the fol-
lowing ASME specifications:
5. Electrodes, filler wires and fluxes shall be kept clean, dry and stored according to the
manufacturer's instructions.
a. Electrodes, filler wire or fluxes that are damp, greasy or oxidized shall not be
used.
b. During welding, avoid contamination of fluxes. Reuse of flux is permitted in
accordance with manufacturer's instructions.
6. Filler metals for joining carbon steels to stainless steels shall be E309L, except in ser-
vices over 600°F (315°C) where ERNiCr-3 or ENiCrFe-3 shall be used.
2. Welding shall not be permitted when the wind velocity exceeds 5 miles per hour for gas
shielded processes and 10 miles per hour for flux shielded processes unless appropriate wind
screens are used
3. The use of backing rings or backup strips is not permitted.
4. Consumable inserts may be used only with written authorization from Company.
5. Peening of welds shall not be permitted.
6. Welds on branches or reinforcing pads shall merge smoothly with the surface of the pipe.
a. On integrally reinforced fittings, welds shall fill completely to the fitting's weld line.
b. Sharp corners on reinforcing pads shall be removed.
7. At the completion of welding and prior to inspection, all excess weld metal, slag, spatter, and
other foreign material shall be removed.
8. Stainless steel piping shall be kept free of surface contamination by ferritic materials or other
foreign material.
9. An inert gas arc welding process (GTAW or GMAW) shall be used on the root pass of welded
joints on compressor suction piping. The remaining passes may be welded by the Shielded
Metal-Arc Welding (SMAW) process.
10. Any weld not identified by the welder's identification stamp or mark shall be rejected. Com-
pany may, at its option, accept the weld if the weld can be shown to be of acceptable quality by
radiography, at the Contractor's expense.
5.5.1 Buttwelds
1. When seam-welded pipes are joined by butt welding, longitudinal weld seams should
be positioned at least 1 in. (25 mm) or 30 degrees apart, whichever is larger.
2. For horizontal pipe runs, all longitudinal weld seams shall be positioned in the upper
half of the pipe run.
5.5.4 Valves
1. Welding shall not be permitted on valves without prior Company approval of Contrac-
tor's written procedure. This includes the attachment of flanges to non-flanged valves.
2. Buttweld end or socket weld end valves that have PTFE or other heat-sensitive parts
shall be protected from the heat of welding, or Post Weld Heat Treatment (PWHT), in
accordance with the manufacturer's instructions.
5.5.6 Preheating
1. Recommended preheat temperatures per ASME B31.3 Table 330.1.1 shall be required
and shall be maintained during all multi-pass welding.
2. Preheating shall be required if the base metal is damp, or if the surrounding air or
metal surface temperature is less than 50°F (10°C).
3. All API flanges and other API 6A components to be welded shall be preheated to a
minimum of 400°F (204°C) before welding. Preheat shall be maintained throughout
the welding process.
c. Pipe shall be removed or lifted in place to permit surface preparation and coating of the
shims.
14. Piping for compressor and pump installations shall comply with API RP 686 where applicable.
15. Modification or alteration of standard approved fittings is not permitted.
16. Manufactured components such as Y-laterals shall not be permitted without prior written
approval by Company. Approval, if granted, will require full compliance with ASME B31.3.
17. Cold formed fittings shall not be permitted in sour service.
6.3 Assembly
1. The cap or seal of an opening shall not be broken until ready for final assembly.
2. Minor surface defects may be removed by grinding, provided the remaining wall thickness is
not reduced below the allowable tolerances. The Company Inspector shall be informed of any
repairs, to permit the checking and approval of wall thickness tolerances.
7.1 Thermocouples
1. For furnace postweld heat treatments, sufficient thermocouples to monitor postweld heat treat-
ment temperatures shall be attached to representative welds by direct spot or resistance weld-
ing, peening, bolting, or welding of a thermocouple pad.
2. For local postweld heat treatments, thermocouples to monitor postweld heat treatment temper-
atures shall be attached to all welds by direct spot or resistance welding, peening, bolting, or
welding of a thermocouple pad.
3. Two or more thermocouples shall be used to measure and record the entire heat treating cycle.
a. A sufficient number shall be distributed on the thicker parts of weldments and pipe to
assure uniformity of temperature throughout the heat treatment batch.
b. For pipe to flange welds, at least one thermocouple shall be placed on the flange side of
the weld.
4. For Temperature Uniformity, the differential between any two thermocouples shall not exceed
100°F (56°C) for the heating period, 25°F (14°C) for the hold period, and 100°F (56°C) for the
cooling period.
5. Controlling thermocouples shall be attached to the pipe.
6. Flames shall not impinge on the metal surface. The furnace atmosphere shall be controlled to
minimize surface oxidation.
7. During heat treatment, all piping shall be properly supported, to prevent warping or deteriora-
tion.
8. Welding shall not be allowed on piping after post weld heat treatment, unless specifically
authorized in writing by Company.
9. Exothermic post weld heat treatment is not permitted without prior written Company approval.
8.1 General
1. A preliminary schedule for inspection and testing shall be submitted with Contractor's work
plan, and updated periodically during fabrication.
a. The schedule shall list proposed inspection hold points and test dates and shall note dead-
lines for the submittal and approval of detailed inspection and test procedures for each pip-
ing system.
b. Hydrostatic pressure test procedures shall be submitted for Company review and approval
a minimum of two weeks prior to hydrostatic testing.
2. Contractor shall be responsible for all aspects of quality assurance and quality control (QA/
QC) during all phases of the work.
3. Should the work of a fitter, welder or welding operator be judged unsatisfactory by Company,
the fitter, welder or welding operator shall be removed from the work by Contractor. The fitter,
welder or welding operator may be reassigned only after the completion of satisfactory re
qualification tests and approval of Company.
8.3 Radiography
1. Radiographic inspection shall be performed by a qualified third party Subcontractor. Self-
examination by Contractor shall not be acceptable to Company.
a. Technicians shall be qualified to American Society of Nondestructive Testing (ASNT)
Recommended Practice No. SNT-TC-1A.
b. Inspectors responsible for grading and interpretation of radiographs shall be Technician
Level II, minimum, certified by ASNT SNT-TC-1A, and helpers shall be SNT-TC-1A
Level I certified, as a minimum.
2. Unless specified otherwise, the following percentages of welds in each pipe class as shown in
Table 1 shall be radiographically inspected:
3. In addition to the above requirements, 100% of the butt welds in hydrocarbon services shall be
radiographically inspected.
4. In addition to the above requirements, 100% of all welds in hydrogen sulfide H2S services
shall be radiographically inspected, including welds other than girth butt welds if weld geome-
try permits. Where weld geometry precludes radiographic examination, the weld shall be
examined by the magnetic particle or liquid penetrant method as outlined in ASME B31.3.
5. Where radiography is specified to be less than 100%, the radiography shall be a "random
examination" as opposed to a "spot examination".
a. Welds selected to be examined shall be evenly distributed between all pipe spools and
welders in so much as reasonably possible.
b. Concurrence of Company shall be obtained on the selection of welds to be examined.
6. Company reserves the right to require additional radiographs.
7. If random examination is specified, progressive sampling is required.
8. Normal Fluid Service criteria shall be used unless Severe Cyclic Conditions are specified on
the piping isometrics.
9.0 FLUSHING
9.1 General
1. Contractor shall provide Company a minimum of one week notice for all cleaning and hydro-
static testing. The piping system to be cleaned and tested shall be detailed in the notice, includ-
ing the specific lines and equipment.
2. Contractor shall prepare detailed hydrostatic test procedures for each hydrostatic test, includ-
ing a pressure test flow diagram to define and record the extent of each test.
a. The diagrams shall clearly detail the extent of the systems to be tested, the valves to be
opened, and the equipment and instrumentation to be removed, isolated by blanking with
blind flanges, or otherwise protected.
b. Piping classification breaks shall be clearly marked on all pressure test diagrams.
3. The application of coatings, insulation or any other pipe coverings prior to leak testing shall
conform to the following.
a. All joints, including welds, bonds and connections, shall be unpainted, uncoated, uninsu-
lated and exposed for all specified visual, liquid penetrant, magnetic particle, radiographic
and ultrasonic examination prior to leak testing.
b. All joints, including welds, bonds and connections, shall be uninsulated and exposed for
examination during leak testing, except that joints previously leak tested may be insulated
or covered.
c. All joints, including welds, bonds and connections, may be coated with the specified
primer prior to leak testing unless a sensitive leak test in accordance with ASME B31.3,
paragraph 345.8 is required.
4. Equipment and in-line instrumentation that may be damaged by cleaning or flushing opera-
tions shall be isolated by blinds or plugs, or shall be disconnected from the piping system.
a. This shall include, but not be limited to turbines, pumps, compressors, safety valves, tur-
bine flowmeters and rupture discs.
b. Mounted instrumentation shall be removed or isolated from the system during flushing
and testing.
5. Restrictions that interfere with flushing, filling, venting or draining, such as orifice plates and
flow nozzles shall not be installed until the completion of leak testing.
6. Contractor shall be responsible for ensuring that pressure tests do not result in damage to any
piping or system components.
7. The flushing and test fluids shall be clean, fresh potable water with less than 100 ppm chlo-
rides.
8. The temperature of the hydrotest fluid shall not be less than 60°F (15°C).
3. Control valves, positive displacement meters, turbine meters, rotameters, and relief devices
shall be removed from the piping system prior to flushing.
4. Hydrotesting against closed block valves is not permitted without prior written permission
from Company. Permission will be granted only where Contractor can demonstrate the reli-
ability of the block valves to be used.
8. All vents shall be open during filling to ensure proper venting of all air or gases.
9. Contractor shall take precautions to avoid excessive pressure due to thermal expansion. Pre-
cautions such as surveillance throughout the test period by a suitably qualified person may be
considered.
10. Hydrostatic test pressures are for the new and cold condition.
a. Test pressures shall be in accordance with ASME B31.3 for Normal Service piping.
b. Test pressures exceeding 90% of the specified minimum yield strength of a component, or
greater than 175% of the maximum rating within the applicable component standard, may
result in rejection by Company of the affected components.
c. Test temperature shall be 100°F (38°C) or less.
d. For higher test temperatures, Contractor shall be responsible for determining the appropri-
ate test pressure.
11. Hydrostatic testing shall be maintained for a minimum of 2 hours after stabilization of pres-
sure and temperature. The specified test pressure shall be maintained for at least 30 minutes
prior to examination of all joints, including welds, bonds and connections, for leaks.
12. All hydrostatic tests shall be maintained for a sufficient period of time to check for small seep-
age leaks.
13. Hydrostatic testing shall be performed with two separate pressure gauges and a dual-pen (pres-
sure and temperature) chart recorder. Pressure gauges and recorders shall have a pressure
range of approximately twice the required test pressure.
14. All gauges and recorders shall have been dead-weight tested and certified within 6 months
prior to the start of hydrostatic testing. The certifications shall be available for Company
review during all hydrostatic testing.
15. Recorder charts shall depict one system test only. Charts shall be signed and dated by Contrac-
tor and Company upon completion of the test to certify that the test was performed.
16. Contractor shall collect, record and maintain all information required for complete test
records. As a minimum, test records shall include the following information:
a. Test date with start and finish times.
b. Piping line and equipment numbers (or pressure test flow diagram number).
c. Design pressure and temperature.
d. Minimum test pressure and hold time.
e. Test pressure and temperature recording chart.
f. Water chloride content (stainless steel piping).
g. Test medium (if not water).
h. Applicable remarks concerning defects.
i. Contractor and Company approval signatures.
17. Leaks found during testing shall be repaired and the piping system retested.
18. Company reserves the right to require alternate pressure tests should a piping system fail the
standard pressure test.
10.2.1 General
1. Pneumatic testing may be substituted for hydrostatic testing only with prior written
approval by Company, and if any of the following is determined:
a. Hydrostatic testing is totally impractical, or
b. Piping or attached equipment might be damaged by water and no alternative exists
to avoid damage, or
c. Even a small amount of water left in a system could contaminate or injure the sys-
tem, such as in a refrigerant or aviation fuel system.
2. Unless otherwise specified, pneumatic tests shall utilize clean, dry air or nitrogen as
the test medium.
3. If air is utilized to test instrument air lines, it shall also be oil-free.
4. If a test requires a closure joint (flanged, screwed, or welded) for blocking purposes,
the integrity of the repaired or reworked joint shall be tested as applicable.
5. Access to pneumatic test areas shall be restricted to personnel absolutely required to
conduct the tests.
6. If both hydrostatic and pneumatic pressure testing may damage the piping system,
alternate testing methods may be performed with prior written approval of Company.
Alternate testing methods shall include the following:
a. Butt welds shall be 100% radiographed in accordance with ASME B31.3.
b. Welds, other than butt welds, shall be liquid penetrant and magnetic particle tested
in accordance with the ASME "Boiler and Pressure Vessel Code" - Section V,
"Nondestructive Examination" - Article 6 and Article 7, respectively.
c. If heat treating is required, the above examinations shall be performed after com-
pletion of heat treating.
11.1 General
1. As a minimum, all carbon steel piping in the following services shall be cleaned, descaled and
passivated:
a. Compressor Suction Piping (from the Scrubber, Filter or K.O. Drum).
b. Compressor Interstage Coolers, and Suction and Bypass Piping.
11.2.1 General
1. Contractor shall propose the acid cleaning agent(s), including inhibitors.
2. Contractor shall control the pickling solution in order to avoid excessive corrosion of
metal by the pickling solution.
a. Contractor shall include test coupons in the piping to be pickled and shall ensure
that these coupons are representative of all the materials in the piping system to be
exposed to the pickling solution.
b. Exposure of the test coupons shall be for the entire duration, to accurately monitor
the corrosive effect of the solution on the piping system.
c. A typical pickling procedure shall be as outlined in the following sections.
d. Pickling solutions shall not be allowed to contact any parts of process equipment,
valves, check valves, relief valves, meters, instrumentation, instrument tubing,
strainers, or other piping components that contain elastomer seals, chrome or
nickel plating, or galvanized coatings.
11.2.4 Neutralization
1. A neutralizing solution of 2% (by weight) soda ash (sodium carbonate) shall be circu-
lated to remove all traces of acid from the system.
a. The solution shall be circulated for a minimum of one hour at 120°F (48°C) and
then drained under a nitrogen purge.
b. When using an ammoniated citric acid, this step may be deleted.
2. After neutralizing, the system shall be rinsed with water until all traces of acid and
neutralizing solution have been removed, and then drained under a nitrogen purge.
When using an ammoniated citric acid, this step may be deleted.
3. The acid-cleaned and neutralized pipe shall be equivalent to a SSPC-SP-8 "Acid Pick-
ling" surface.
4. The acid-cleaned and neutralized pipe shall be passivated, dried and sealed.
11.2.6 Passivation
1. The descaled pipe shall be passivated to minimize further corrosion by applying a
phosphate coating.
2. Acid cleaned pipe may be passivated directly after neutralization and rinsing, without
drying.
3. The passivation solution shall be circulated for one hour at 130°F (54°C) to 150°F
(65°C), and shall consist of the following:
a. 0.25% (by weight) monosodium phosphate.
b. 0.25% (by weight) disodium phosphate.
c. 0.50% (by weight) sodium nitrite.
4. If an ammoniated citric acid was used for descaling, the steel surfaces shall be passi-
vated by raising the pH to between 9 and 10 through addition of ammonia, and then
adding 0.5 % sodium nitrite and circulating for 1 to 2 hours.
5. After passivation, the system shall be drained and dried thoroughly with warm dry air
or nitrogen.
a. The system shall not be flushed with water after passivation.
b. After drying, the pipe shall be closed tightly, blanketed with an inert gas or filled
with oil to minimize corrosion.
APPENDIX A
e. Any increase in carbon equivalent (IIW) by more than 0.03 above the material used for
procedure qualification.
f. A change in the process of manufacture for the base material, outside the following
groups:
(1) Quenched and tempered steels
(2) TMCP or controlled-rolled steels
(3) Normalized or as-rolled steels
APPENDIX B
Documentation • Supplier shall provice lot number of coating used on each lot of
fasteners with material certification.
• Supplier shall provide a certificate of compliance stating that
the coated fasteners satisfy the requirements of this specifica-
tion.
• Supplier shall provide documented corrosion resistance perfor-
mance. Testing shall be by Salt Spray cabinet following ASTM
B117. Acceptance criteria will be that leass that 15% of the
sufrace shows red rust after 1500 hours.
• Supplier shall provide documentation that Whitford has quali-
fied the coating applicator.