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CONTROLLED DOCUMENT

Title: STANDARD: PIPING FABRICATION,


INSTALLATION, ERECTION AND TESTING

Controlled Ref No: W1000SX3215141 Revision: 4

Name Date

Prepared by: Garry Ralls 9/2/09

Approved by: M Hamblin 9/2/09

Custodian: M Brameld 9/2/09

Concurrence (Agreement that must be obtained if an item is prepared external to, but impacts, a department or division. If
concurrence is required, it must be noted within the body of the item).

1.

Woodside Management System Sub-processes MUST obtain concurrence endorsement from BopCom. The date of the BopCom
meeting where endorsement is granted should be indicated below.

BopCom Endorsement Meeting date when endorsement granted:

REVISION HISTORY

Revision Description Date Prepared by Approved by

1 Combined with L0000SM143503. In doing so 01/2007 B Hurtig M Brameld


a title change was also made.

2 Appendix E updated to clarify conditions 09/2007 M Brameld M Brameld


necessary for hydro test to be waived for field
welds

3 Revised to allow use on external website 10/2008 G Ralls M Hamblin

4 Updated APPENDIX B - FABRICATION 02/2009 G Ralls M Hamblin


TOLERANCES

INFORMATION SECURITY REVIEW STATUS PREPARED


CONFIDENTIALITY CLASSIFICATION (Check one box only) (Check one box only)
(Check one box only)
Unclassified Review on/by By WEL
(Shared without Restrictions) (01/09/2012):
Restricted Review Not Required For WEL
(Freely Shared within Woodside and Under PO/Contract No:
Associated Companies)

Confidential
(Shared With Selected Personnel)

Most Confidential
(Strict Need-to-Know Basis)

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
any process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.
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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

OPERATIONS / PROJECTS USE ONLY

Operating Facility:

Key TAG No’s:

DOCUMENT DISTRIBUTION

Full Name / External Organisation Name (if applicable) Electronic


Copy No. (Show Username (WOPID) to differentiate between persons with identical Hard Copy
Notification
names).

00 WEL Document Control

01 TW Doc Control

02 CAJV Doc Control

03 Gilbert Habets(10063)

04 Peter Nalepa(3019)

05 Mike Hamblin(3227)

06 Pluto Eng Coordinator(2404)

07 Sunrise Eng Manager(7521)

08 Browse Eng Coordinator(4350)

09 LNG Project Development Eng Manager(8927)

10 Clive Saxton(3606)

11 Tony Glesson – TW ENG Manager

12 Iain Denholm – CAJV Eng Manager

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
any process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.
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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

PREFACE
Woodside Energy Ltd. (WEL) has developed a suite of Engineering and Technical Standards and
Guidelines. It is intended that these reflect the most suitable engineering practices for use on all
new WEL facilities as well as the modification of existing facilities. The application of the Standards
is mandatory. The application of Guidelines is to support the implementation of the Standards, and
are considered best practice, but are not mandatory.

The Standards are based on the experience acquired by WEL personnel and contractors during
WEL’s involvement with the design, construction, operation and maintenance of WEL processing
units and facilities. Where appropriate, the Standards are based on or make reference to national
and international standards and codes of practice.

The objective of this publication is to ensure the overall integrity of engineering design and to
achieve maximum technical and economic benefits through the standardisation of engineering and
technical practices.

The use by WEL contractors or manufacturers/suppliers of the Engineering and Technical


Standards contained in this publication does not relieve them of any responsibility whatsoever for
the quality of design, materials and workmanship that they have been engaged to provide.

Where the standards to be used for a certain application are not provided for in this publication,
WEL expects that the standards that are used will achieve the same level of integrity as reflected in
this publication. If WEL contractors or manufacturers/suppliers have any doubt as to the relevant
standard to use, then they must consult WEL, however they will remain responsible at all times for
the use of the most appropriate standard. Specific requirements may be added as an addendum to
these Standards and Guidelines for various projects. Project specific requirements must not depart
from the requirements of the Engineering and Technical Standards contained in this publication.
Where changes or additions to these Standards are required, they must be raised as a deviation
and presented to the WEL Technical Authority for consideration.

WEL grants the right to use these Standards and Guidelines to WEL’s consultants, contractors and
suppliers who are contractually authorised to do so and to any tier of contractor to its consultants,
contractors and suppliers who are contractually required to comply with them.

DISCLAIMER

WEL and its joint venture partners disclaim any liability of whatsoever nature for any damage
(including injury or death) suffered by any company or person whomsoever as a result of or in
connection with the use, application or implementation of any standard, combination of standards
or any part thereof contained in this publication.

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
any process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.
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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

TABLE OF CONTENTS

1. INTRODUCTION ................................................................................ 6
1.1 SCOPE ........................................................................................................ 6
1.2 REGULATORY CONSIDERATIONS .......................................................... 6
1.3 DEFINITIONS.............................................................................................. 6
1.4 ABBREVIATIONS ....................................................................................... 7
2. STORAGE AND HANDLING OF MATERIALS ................................. 8
2.1 STAINLESS STEEL MATERIALS .............................................................. 8
2.2 CEMENT LINED MATERIALS.................................................................... 8
3. FABRICATION................................................................................... 9
3.1 WELDING.................................................................................................... 9
3.2 THREADED CONNECTION........................................................................ 9
3.3 PIPING ERECTION ................................................................................... 10
3.3.1 Flange Alignment ....................................................................................... 10
3.3.2 Insulating Flanges ...................................................................................... 10
3.3.3 Cathodic Protection Isolation Point ............................................................ 10
3.3.4 Pipe Sealing ............................................................................................... 11
3.3.5 Erection Precautions .................................................................................. 11
3.4 JOINING OF CEMENT LINED PIPE AND FITTINGS ............................... 11
3.5 ORIFICE METER RUNS ........................................................................... 12
3.6 TOLERANCES.......................................................................................... 12
3.7 PAINTING ................................................................................................. 12
3.8 GALVANISING.......................................................................................... 12
4. TESTING AND INSPECTION .......................................................... 13
4.1 FINAL INSPECTION AND SYSTEM TEST STATUS ............................... 13
5. PRESSURE TESTING ..................................................................... 14
5.1 TESTING REQUIREMENTS ..................................................................... 14
5.1.1 Field Testing............................................................................................... 14
5.2 TESTING PREPARATION ........................................................................ 14
5.2.1 Inline Items in the Testing Circuit ............................................................... 14
5.2.2 Equipment in the Testing Circuit ................................................................ 14
5.3 TEST MEDIA............................................................................................. 15
5.4 TEST EQUIPMENT ................................................................................... 15
5.5 COMPLETION OF TESTING .................................................................... 15
5.6 TEST RECORDS ...................................................................................... 15
6. CLEANING....................................................................................... 17
7. QUALITY ASSURANCE .................................................................. 18
This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
any process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.
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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

7.1 QUALITY CONTROL ................................................................................ 18


7.2 QUALITY RECORDS AND CERTIFICATION........................................... 18
7.3 MARKING AND TRACEABILITY ............................................................. 18
8. REFERENCES ................................................................................. 19
9. APPENDICES .................................................................................. 20
APPENDIX A - WELDING PROCEDURE QUALIFICATION TESTING
REQUIREMENTS...................................................................................... 21
APPENDIX B - FABRICATION TOLERANCES................................................ 23
APPENDIX C - TYPICAL INSULATING FLANGECONNECTION DETAILS.... 25
APPENDIX D - EXAMINATION GROUPS ........................................................ 26
APPENDIX E - EXTENT OF TESTING AND INSPECTION ............................ 28
APPENDIX F - REQUIREMENTS FOR HYDROTEST WATER ........................ 29
APPENDIX G – INSPECTION AND TEST PLAN.............................................. 30
APPENDIX H – PIPING FIELD TEST REPORT................................................ 31
APPENDIX I – TRACEABILITY RECORD SHEET ........................................... 31
APPENDIX I – TRACEABILITY RECORD SHEET ........................................... 32
APPENDIX J – TRACEABILITY RECORD DRAWING/ISOMETRIC SHEET... 33

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
any process (electronic or otherwise) without the specific written consent of Woodside. All rights are reserved.
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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

1. INTRODUCTION
1.1 SCOPE
This document is intended to be used as a reference to Woodside requirements concerning
the fabrication and installation of pipework in conjunction with the following documents:

AS 4458 Pressure equipment - Manufacture


AS 4041 Pressure Piping

Note: AS 4041 specifies that process piping complying with ASME B31.3 is deemed to comply with AS 4041.

This document provides clarification of, amendments to and additional requirements to AS


4458.

This standard describes the minimum requirements for fabrication, erection and testing of
process piping

The scope of this standard includes process piping on all WEL facilities. It does not apply to
pipelines, structural tubulars, or hoses or instrument tubing.

The Technical Specification for Piping Classes (W9000MX001) and all relevant piping
drawings issued by WEL, shall be used as the basis for fabrication and erection and shall be
adhered to without deviation. In the event of a discrepancy, the Contractor shall refer the
discrepancy to the TA for written instruction before proceeding with work on the affected
area.

1.2 REGULATORY CONSIDERATIONS


If international and/or regional regulations exist in which some of the requirements may be
more stringent than in this Standard an assessment shall be made to determine which of the
requirements are the more stringent and which combination of requirements will be
acceptable as regards safety, environmental, economic and legal aspects. In all cases the
Contractor shall inform the WEL Technical Authority

1.3 DEFINITIONS
The definitions below shall apply:

• The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project, or operation or
maintenance of a facility. The Principal may undertake all or part of the duties of the
contractor.
• The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
• The Principal is the party that initiates the project and ultimately pays for its design
and construction. The Principal will generally specify the technical requirements. The
Principal may also include an agent or consultant authorised to act for, and on behalf
of, the Principal.
• The words shall / must / will indicate a mandatory requirement.

This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

• The word should indicates a recommended course of action.


• The words may / can indicate one acceptable course of action.
• WEL Technical Authority (TA) in this document refers to the Materials, Inspection
and Corrosion Engineering TA. Authority to deviate from these standards is delegated
to the custodian(s) indicated on the document details page of this document.

1.4 ABBREVIATIONS
ISO International Standard Organisation
ITP Inspection and Testing Plan
LPG Liquefied Petroleum Gas
MDR Manufacturer’s Data Report
MRA Mutual Recognition Arrangement
NATA National Association of Testing Authorities
NDT Non Destructive Testing
PEFS Process Engineering Flow Scheme
QRS Quality Requirements Specifications
TA Technical Authority
UV Ultraviolet
WEL Woodside Energy Ltd.

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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

2. STORAGE AND HANDLING OF MATERIALS


The storage and control of piping materials and consumables on site shall be maintained in
accordance with AS 4041 and this standard.

To maintain the condition of metallic materials, components and fabricated spools of differing
composition, they must be stored separately from each other.

Valves shall be stored with spindles in the vertical position. Relief valves shall be stored
upright in a clean area away from construction activity.

Partly erected piping components and spools shall be protected at all times from ingress of
moisture or foreign matter by covering and where necessary, by taping.

Materials found to be defective or not in compliance with this standard shall be brought to the
attention of the TA.

2.1 STAINLESS STEEL MATERIALS


The following additional requirements shall apply for the storage and handling of stainless
steel materials;
• Stainless steel piping and components shall be stored in separate areas away from
carbon steel and other material storage areas.
• Direct contact of stainless steel with carbon steel during transportation, storage and
erection shall be avoided.
• Steel wire slings shall not be used for handling and transportation of stainless steel
pipes.

If ingress of foreign materials has occurred including water or condensation from air,
remedial action shall be undertaken immediately, the affected area cleaned, thoroughly dried
and open ends resealed.

All cleaning shall be performed in accordance with the approved material preservation and
storage procedures and Section 6 of this Standard. Stainless steel components may be
cleaned with acetone if no crevices exist in the surface of the component. The component
shall then be rinsed with demineralised water.

Piping or piping components found to be contaminated by carbon steel or other material shall
not be used until the decontamination process has been carried out and piping components
cleared by WEL.

2.2 CEMENT LINED MATERIALS


Airtight covers shall be fitted at all times to the open ends of cement lined piping, fittings and
spools to ensure a moist atmosphere inside. A small quantity of water shall be maintained at
all times on the cement lining.

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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

3. FABRICATION
3.1 WELDING
All welds shall be full penetration welds apart from the following:-

1. Slip on Flanges, which shall be welded inside and outside with a continuous fillet weld
of at least two passes.
2. Reinforced pad peripheral fillet welds (where specified).
3. Structural attachment fillet welds.

Weld procedure qualification testing shall be in accordance with the requirements of


Appendix A.

NDT Acceptance Criteria For Welds must conform to Severe cyclic conditions as stated in
ANSI B31.3, Table 341.3.2A unless otherwise specified.

Wire brushes, grinding wheels and clean-up tools shall be made from materials that are
compatible with the base materials (i.e. brass brushes for copper based materials, stainless
for stainless and duplex, etc.)

The use of hot or cold hammering as a means for repair is prohibited

Seam orientation of welded straight pipe and pipe to fittings shall be such that at
circumferential welds, the longitudinal welds shall be staggered over the top of the line,
preferably 30° left and 30° right of the centre line for the preceding element. The minimum
distance between two staggered longitudinal welds shall be 50mm or five times the pipe wall
thickness, whichever is greater. Longitudinal welds shall clear branch connections. Seam
orientation criteria shall be maintained in relation to adjacent and connecting piping spools.

For circumferential welds, the minimum inter-weld distance between them shall be 50mm or
twice the thickness of the thicker pressure-retaining part, whichever is greater.

Should an unavoidable clash occur, the Principal shall be notified for additional NDT
requirements.

Welding earth connections shall be located as close as possible to the joints to be welded.
Welding clamps shall only be used for connecting the welding earth lead to the piping.
Welding earth leads shall never be connected to parts of valves.

In the event of damage to the gasket face, the contractor shall refer the matter to the
Principal prior to proceeding with fabrication.

Valves that are required to be welded shall be in the open position prior to the
commencement of welding to avoid damage to valve seats.

Use of permanent backing rings is prohibited. Consumable inserts shall not be used.

3.2 THREADED CONNECTION


Unless otherwise specified, all threads shall be in accordance with ASME B1.20.1.

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All threaded connections shall be gauge-checked or chased after welding or galvanising.


Contractor shall verify thread engagement in accordance with ASME B1.20.1.

Inside ends of threaded pipes shall be deburred by reaming.

Threaded connections shall not be seal welded.

3.3 PIPING ERECTION


3.3.1 Flange Alignment
For the alignment of flanges to rotating and reciprocating equipment, and heat exchangers,
the requirement shall be in accordance to W1000SM3218383.

For all other flange alignments, requirements shall be in accordance to the “Flange Checklist”
found in W1000SM3131997.

The torque of the bolts shall be to the specified tension in accordance to W1000SM3131997.

All flanged connections shall be made using fully threaded stud bolts and nuts. A minimum
of one complete thread shall protrude from the nut after completion of tightening.

3.3.2 Insulating Flanges


Insulating flanges, or kits have often been installed at line specification changes where
dissimilar metals are in contact. In this application they have proven to be generally
ineffective. All dissimilar material piping connections have the potential to corrode, and the
need for corrosion mitigation shall be assessed by a competent corrosion engineer. This may
result in the installation of an insulating kit or spool into the line. Insulation flanges may also
be installed to provide electrical isolation of cathodic protection system(s). Refer to Appendix
C for typical insulating flange connection details.

Where insulating flange kits are to be installed, care shall be taken not to damage the bolt
sleeve and gaskets. The completed joint shall be tested with a High Frequency Insulation
Resistance Meter or similar device to assure electrical isolation. The insulation resistance
test shall be conducted for one minute at 100 volts with a minimum acceptable resistance
level of one M-OHM.

Epoxy coating of flange faces and pipe internal surfaces is required where any joint is fitted
with an insulating gasket. Where epoxy coating is required, the Principal shall be notified
prior to joint assembly. Epoxy coating or gasket compounds shall not be used on any other
piping joints.

3.3.3 Cathodic Protection Isolation Point


Weatherproof/UV proof signs as detailed below shall be provided at all cathodic protection
isolation points, including:-
• insulating gaskets
• tundishes
• those points where it is necessary to insulate pipework from supporting steel structures
due to the absence of an insulating flange kit in the pipe run at the above ground/below
ground interface.
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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

Signs shall be approximately 200 x 150 in size, with the words:-

CAUTION
CATHODIC PROTECTION
ISOLATION POINT

written in red letters on a white background. The signs shall be attached to the pipe
immediately adjacent to the isolating point, in a prominent position and secured with a
stainless steel band or approved equivalent.

3.3.4 Pipe Sealing


All pipe openings shall be sealed before, during and after erection to prevent the ingress of
moisture and foreign matter, flanged ends shall be sealed with light metal blinds and gaskets
or purpose manufactured plastic caps. Carbon steel material shall not be used for temporary
sealing of stainless steel lines. Threaded ends shall be plugged and sealed by waterproof
grease tape or purpose made plastic caps or plugs.

This also includes open pipe ends of piping being erected in pipe-racks or equipment in the
plant.

3.3.5 Erection Precautions


Carbon steel clamps, tools, bolts, and supports shall not be used during fabrication and
installation of stainless steel. Only Stainless steel Clamps and U-bolts shall be used for
stainless steel piping supports.

Stainless steel piping shall be covered with tarpaulins or similar when carbon steel piping is
being erected or worked on in such a manner that the stainless steel cannot come in contact
with the carbon steel nor shall it become contaminated with grinding or welding particles.
Tools shall be identified for stainless steel work only.

Stainless steel spacer strips of adequate size approved by the Principal shall be securely
installed in areas where stainless steel piping temporarily rests on carbon steel supports.

Stainless steel piping shall not come in contact with zinc from nearby cutting or welding
operations on galvanised pipe or galvanised structures.

All field welded joints and adjacent unpainted areas in austenitic stainless steel shall be
protected by taping these areas, on completion of NDT. The tape shall overlap painted
areas by a minimum of 25 mm. The tape shall remain in place until removal is required for
inspection purposes during pressure testing. On completion of pressure testing welded joints
shall again be taped or painted.

The Contractor shall ensure that taped areas provide full protection and remain undamaged.

3.4 JOINING OF CEMENT LINED PIPE AND FITTINGS


Cement lined pipe and fittings shall be joined using the split collar method. Standard tee
fittings shall be provided with cement lined extended stub ends to receive the split collar.
Allowance shall be made for a 2 mm root gap between the collar bevel end preparations for
an axial butt weld. Collars will be 90 mm in width and 10 mm in thickness.
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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

Shaping of split collars with a hammer or heating torch while the collar is fitted to the cement
lined pipe shall not be permitted.

Piping components and the cement lining shall be cut by a “cold method”, i.e. fibre disc. The
cut face of both the pipe and cement lining shall be square and flush. Piping components
shall be trial assembled to verify the gap between the parts to be joined does not exceed 2
mm.

A suitable “Araldite” product, or equivalent, shall be used as a joint compound between the
mating surfaces of the piping components. The compound shall be applied prior to welding
the split band. Sufficient compound shall be applied to completely fill the gap and to
completely and evenly cover the face of each pipe and cement end with 2 mm thick layer of
the compound, any surplus shall be cleaned out.

The Contractor shall submit the following for approval by the Principal;
• Proposed “Araldite” or equivalent compound and the recommended method of
application.
• A complete procedure for the preparation, installation and welding of cement lined
piping components.
• Repair procedure for damaged cement lining, including cracks in the lining, excessive
separation at the joint and damage caused during installation and testing.

3.5 ORIFICE METER RUNS


Orifice meter runs shall be fabricated and installed in accordance with DEP 61.38.10.10-Gen,
Shop & Field Fabrication of Orifice Meter Runs.

3.6 TOLERANCES
Fabrication tolerances shall be per AS 4458 and Appendix B.

Piping fit-ups shall not be misaligned by more than 15% of the wall thickness of the thinner
part being joined. Wherever possible, misalignment should be minimised by rotating the
pipe/fitting for best fit.

3.7 PAINTING
Painting shall be in accordance with W1000SM002.

3.8 GALVANISING
Galvanising of piping shall be in accordance with AS/NZS 4680.

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4. TESTING AND INSPECTION

The contractor shall perform inspection and testing activities in accordance with the
requirements of this standard (Appendix D and Appendix E), AS 4458, approved
ITP(s)/QRS(s), and WEL Standard W1000SQ002, whichever is more stringent.

All NDT shall be executed in accordance with AS4458, and Appendix E .

All companies issuing NDT reports shall be NATA accredited in Australia, or be part of the
NATA Mutual Recognition Arrangements (MRA) network outside Australia.

4.1 FINAL INSPECTION AND SYSTEM TEST STATUS


When the Contractor has completed all testing of a full piping system, the Principal shall
inspect the completed piping system and shall notify the Contractor of any deficiencies or
outstanding work which must be completed prior to acceptance of the system.

The Contractor shall maintain a master copy of all PEFS, isometrics and all Underground
Piping Plan Drawings (where relevant). These are to be colour coded to indicate piping
systems which have been accepted by WEL.

The Contractor shall maintain a Testing Status Report for each designated piping system
which shall include the following;
• Piping Field Test Report Number
• Date of the Company’s approval to proceed with Pressure Test
• Date Pressure Testing complete for each Test Pack
• Date Post Test “Punch-List” Items were fully completed
• Date of Company acceptance of full piping system

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STANDARD: PIPING FABRICATION, INSTALLATION, ERECTION AND TESTING

5. PRESSURE TESTING
Pressure testing shall comply with W1000SM001 and AS 4458.

5.1 TESTING REQUIREMENTS

Pressure tests of piping shall include all closing welds between different parts of the system.

Reinforcing pads shall be tested with clean and dry oil free air at a pressure of 35kPa gauge.
With the test pressure maintained at 35kPa gauge the weld surfaces on the inside and
outside shall be swabbed with a leak testing solution approved by the TA.

All testing of reinforcing pads shall be recorded by the Contractor.

The test vent hole shall be sealed off with grease or a plastic plug.

5.1.1 Field Testing

Pressure piping shall include all piping designed to convey or contain process or utility fluids
at either a positive or a negative internal pressure.

Prior to commencement of pressure testing, the Contractor or Test Engineer shall submit for
the Principal’s review and acceptance, a comprehensive punch list of outstanding items and
all required quality control records.

5.2 TESTING PREPARATION

5.2.1 Inline Items in the Testing Circuit

The piping system shall be tested prior to the installation of inline items or the connection of
instruments to the piping wherever possible to avoid needing to isolate or remove of such
items as required in W1000SM001. It is the Contractor’s responsibility to remove and re-
install the inline items, as well as sealing and plugging for the test as a result of such
removals.

Prior approval must be obtained by the TA to include inline equipment in the pressure test
circuit.

Testing of piping containing check valves shall have the pressure source located on the
upstream of the valve and the drain on the downstream side of the valve. Should it not be
possible to meet this requirement, the check valve shall have the flapper or piston removed.
A new gasket shall be installed wherever the check valve bonnet has been disturbed.

Spring supports shall be restrained or removed during hydrostatic testing. For each case the
Contractor shall seek guidance/approval from the Principal.

5.2.2 Equipment in the Testing Circuit

All equipment, other rotating machinery, vessels, and heat exchangers shall be isolated from
the pressure test. Spades shall be installed at the flanges of the equipment to provide
isolation prior to filling up the test circuit. Prior approval must be obtained by the TA to
include vessels in the pressure test circuit.
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All necessary precautions shall be taken to ensure that, where applicable, nitrogen purges in
equipment are maintained and ingress of moisture prevented. Purges shall not be released
without the Principal’s approval and shall be reinstated upon completion of required work
unless otherwise directed by the Principal.

5.3 TEST MEDIA

Appendix F outlines chloride and water inhibitor requirements during the hydrotesting of
piping.

For carbon steel piping and austenitic, duplex and super duplex stainless steel piping, the
hydrostatic testing medium shall be water at ambient temperature with a pH value between 7
and 8.

An analysis report of the water, including chloride content and pH value, shall be attached to
the test report at all times. The analysis report shall be prepared by a certified and
recognised laboratory.

5.4 TEST EQUIPMENT

Equipment to be used during testing shall have suitable capacity for the range of test
pressures required. Unless specified differently in W1000SM001, pressure gauges shall
have a full scale range between 100% and 150% of test pressure and an accuracy and
sensitivity of >2% of the full scale reading.

5.5 COMPLETION OF TESTING


Pressure tests shall be considered complete when;
• All defects and leaks have been corrected to the satisfaction of the Principal
• All documentation is complete and accepted by the Principal

• All temporary test blinds and spades have been removed, new gaskets installed and
the piping system reinstated

Sealing materials shall not be used to correct leaks in joins. Valve glands shall not be
tightened to the extent that the valve cannot be operated. If directed by the Principal, valves
shall be repacked in accordance with defined procedures.

After hydrostatic testing of the system is complete and approved by the Company, all lines
and equipment shall be completely drained of the test fluid. Protective tape shall then be
reapplied to stainless steel welded joints which are not already painted.

5.6 TEST RECORDS


Records for piping which require that pressure be held for a specified period of time shall
include any corrections of test pressure due to temperature variations between the start and
finish of the test.

Records for piping in which a specified leakage rate is permitted shall include the quantity of
water added and the time at which the addition was made.

All test records and authorised Company’s certifications shall be retained in the job records
for compilation of Manufacturer’s Data Report (MDR).
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A typical format for a Piping Field Test Report is shown in Appendix H, the Contractor may
use his own format providing all information shown in Appendix H is included.

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6. CLEANING
Completed systems shall be internally cleaned to remove all remaining dust and foreign
matter by water flushing or blowing with air. Water flushing shall not be permitted for LPG
vapour, instrument air, nitrogen or any other low temperature piping operating at minus 35°C
and below.

Flushing shall be done with clean water suitable to that permitted by hydrostatic test water
requirements, refer to W1000SM001.

All piping on isometric drawings marked “Piping to be Internally Blast Cleaned in Shop”, shall
be inspected prior to installation to ensure the internal surfaces are clean and free of rust and
scale in accordance with AS1627.4, Class Sa 1.

Where special conditions exist such as cleaning of compressor suction and lube oil piping, a
separate cleaning procedure shall be prepared for the TA’s approval.

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7. QUALITY ASSURANCE
The fabrication, installation, erection and verification of piping systems shall be conducted by
a “body” holding ISO 9001 certification for their Quality Management System, and who have
qualified mechanical and material engineers experienced in Piping Systems.

7.1 QUALITY CONTROL

Inspection and Test Plans, (ITP’s), shall be prepared and submitted to the Company to
describe all the inspections and tests to be carried out by the Contractor in conjunction with
the supply of goods or services to the Company.

The ITP’s shall include those tests, required by the Company shown in relevant Contract
documents.

A typical format for an ITP is shown in Appendix G, the Contractor may use his own format
providing all information shown in Appendix G is included.

All ITP’s shall be approved, by the Company, prior to commencement of the work.

7.2 QUALITY RECORDS AND CERTIFICATION


The contractor shall generate quality records from the inspection and test activities listed in
this specification and in accordance with the approved Inspection and Test Plan(s). As a
minimum the contractor shall maintain records of all pressure tests, records of all welding
operations, weld numbers, records of all special cleaning and all certification records.

All certification of records shall be in accordance W1000SQ002. Those records not included
in the MDR shall be available for Woodside review and thereafter retained in accordance
with industry standards.

Quality records requiring traceability as detailed in this standard shall bear an identical
marking to the item inspected or tested.

Material, welding and non destructive testing traceability shall be recorded for inclusion in the
MDR.

To standardise quality record format, Woodside may provide the contractor with proforma
documentation prior to commencement of work.

7.3 MARKING AND TRACEABILITY


The contractor shall mark all items for identification and traceability in accordance with this
standard, AS4458 and W1000SQ002.

Traceability shall be generally in accordance with W1000SQ002 in conjunction with specific


project requirements and/or Australian Standards. The Contractor shall record traceability
data throughout fabrication and installation of the piping components. Traceability records
shall be complete and available for inspection by the Principal before pressure testing can
proceed

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A typical format for a Tracability Record Sheet for piping and for Drawings/Isometrics is
shown in Appendix I and Appendix J respectively. The Contractor may use his own format
providing all information shown in Appendix I and/or Appendix J is included.

8. REFERENCES
Metal Finishing – Preparation and Pretreatment of Surfaces.
AS1627.4
Part 4: Abrasive Blast Cleaning of Steel.
AS 4458 Pressure equipment – Manufacture
AS 4041 Pressure Piping
Hot Dip Galvanized (Zinc) Coatings on Fabricated Ferrous
AS/NZ 4680
Articles
ANSI B31.3 Process Piping
DEP 61.38.10.10 Shop & Field Fabrication of Orifice Meter Runs
W1000SM001 Hydrostatic and Pneumatic Pressure Testing
W1000SM002 Protective Coatings
W1000SM3131997 Flange Bolting Standard
Erection, Inspection, Maintenance and Preservation of
W1000SM3218383
Equipment
W1000SQ002 Certification, Marking and Inspection of Engineering Products

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9. APPENDICES

APPENDIX
WELDING PROCEDURE QUALIFICATION A
TESTING REQUIREMENTS

FABRICATION TOLERANCES B
TYPICAL INSULATING FLANGE CONNECTION C
DETAILS
EXAMINATION GROUPS D
EXTENT OF TESTING AND INSPECTION E
INHIBITOR REQUIREMENTS FOR HYDROTEST F
WATER
INSPECTION AND TEST PLAN G
PIPING FIELD TEST REPORT H
TRACEABILITY RECORD SHEET I
TRACEABILITY RECORD DRAWING/ISOMETRIC J
SHEET

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APPENDIX A - WELDING PROCEDURE QUALIFICATION TESTING REQUIREMENTS


Test Test details A106 Gr B / CuNi A333 Gr 6 A333 Gr 3 304L/316L 22Cr Duplex 25Cr CrMo 6Mo Super-
Method A105 Superduplex austenitic
Tensile ASME IX R R R R R R R R R
Bends ASME IX R R R R R R R R R
Charpy ASME B31.3 . NR NR 27J average 27J average Not required 40J average of 3 50J average of NR Not required for
(Notes 1, Locations: One of 3 of 3 for lines specimens, 3 specimens, lines above
2, 3, 4) set of 3 specimens, specimens, above 101°C. 31J minimum 35J min single -101°C.
specimens to be 21J minimum 21J For cryogenic single specimen. specimen. For cryogenic
taken from each single minimum lines, 0.38mm Tested at Tested at lines, 0.38mm
of the following specimen. single minimum –50°C -46°C minimum lateral
locations: Tested at specimen. lateral expansion required
Weld metal -46°C Tested at expansion at
centreline, FL, -101°C required at MDT.
FL+2, FL+5. -196°C.
Macro X5 mag with R R R R R R R R R
photo
Hardness HV10 250 max NR 250 max 320 max 250 max 310 max 330 max 350 max NR
(22 HRC) (22 HRC) (22 HRC) (28 HRC) (32 HRC)
Corrosion ASTM G48 NR NR NR NR NR 23°C for 24h. 40°C for 24h. NR 40°C for 24h.
Method A No pitting to be No pitting to be No pitting to be
visible at x20 visible at x20 visible at x20
magnification magnification magnification
Maximum weight Maximum Maximum weight
loss 1.0 g/m2. weight loss 1.0 loss 4.0 g/m2.
g/m2.
Ferrite ASTM E562 NR NR NR NR 4 – 10% 30 – 70% 35 – 65% NR NR
Micro 400X mag with NR NR NR NR NR R Note 5 R Note 5 NR NR
photo

Notes: R = required, NR = Not required

1 For subsize Charpy specimens, impact test temperature reduction shall be per ASME B31.3 Table 323.3.4.
2 Specimens shall be cut transverse to the weld, with the axis of the notch perpendicular to the pipe surface and so that one face of the specimen is substantially parallel
to and within 2mm of the top surface of the weld.
3 For wall thickness >25mm, an additional set of 3 specimens from the weld root (centreline) is to be tested.
4 Where more than one welding process is used in a single joint, the required impact tests shall be duplicated in the different regions of the joint.
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5 Test samples shall comprise a cross section of the weld metal, heat affected zone and base metal. The micro-structure shall be suitably etched and examined at 400
X magnification and shall have grain boundary with no continuous precipitations and the inter-metallic phases, nitrides and carbides shall not in total exceed 0.5%

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APPENDIX B - FABRICATION TOLERANCES


PFI Standard ED-3
Reaffirmed September 2000

FABRICATION TOLERANCES

METRIC CONVERSIONS

The conversion of quantities between of units involves a determination of the number of significant digits to be retained.
All conversions depend up on the intended precision of the original quantity and are rounded to the appropriate accuracy.

Pipe sizes together with applicable wall thickness are not shown with metric equivalents.

The SI (metric) values where included with the customary U.S. values in the Standard are the rounded equivalents of the
U.S. values and are for reference only.

Metric units were derived utilizing the following factor:

Conversion Factor
__________ ________

inches to 25.4
millimetre

(2.0 mm) for each 12” in diameter over


1. Scope 36”.

1.1 This standard covers general pipe shop 2.4 Due to the cumulative effects of
fabrications tolerances for prefabricated tolerances on fittings or flanges, when
piping assemblies. joined without intervening pipe segments,
deviations in excess of those specified in
2. Linear Tolerances paragraphs 2.2 and 2.3 may occur.

2.1 The tolerances of linear dimensions


(intermediate or overall) apply to the face 3. Angularity and Rotation Tolerances
to face, face to end, and end to end
measurements of fabricated straight pipe 3.1 Angularity tolerance across the face of
and headers; center to end or center to flanges, weld end preparation and on
face of nozzles or other attachments; or rotation of flanges are as stated on Fig. 1.
center to face of bends; as illustrated on
Fig. 1. These tolerances are not 4. Close Tolerances
accumulative.
4.1 When closer tolerances than those given
2.2 Linear tolerances on “A” are ± 1/8” (3.0 in paragraphs 2.2, 2.3 and 2.4 are
mm) for sizes 10” and under, ± 3/16” (5.0 absolutely necessary, they shall be
mm) for sizes 12” through 24” and ± ¼” subject to agreement between the
(6.0 mm) for sizes over 24” through 36”. Purchaser and Fabricator.

2.3 Linear tolerances on “A” for sizes over 36”


are subject to tolerances of ± ¼” (6.0
mm), increasing by plus or minus 1/16”

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APPENDIX C - TYPICAL INSULATING FLANGECONNECTION DETAILS

CEMENT

RADIUS EDGES

GASKET

EPOXY

TYPICAL INSULATING FLANGE CONNECTION DETAILS

NPS Length of Pipe to be Internally Epoxy Coated each side of Flanged Connection
< 4” 300 mm
4” to 8” 375 mm If pipe bolts onto a valve then the length of pipe to be epoxy
coated shall
10” to 14” 450 mm be double the listed length.
> 14” 600 mm

NOTES:
1) Epoxy shall be Taubmans Interline 925, or equivalent, to a Dry Film Thickness of 400 microns
minimum, 500 microns maximum.

2) Steel surfaces shall be prepared for epoxy coating by mechanically cleaning to a minimum Class Sa
1 finish.

3) Surface preparation and coatings application shall be in accordance with Paint Manufacturers
instructions and the surface prepared to a length 150 mm longer than the length to be coated.

4) Company approval is required prior to joint final assembly.

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APPENDIX D - EXAMINATION GROUPS

Group 1

Where any of the following conditions apply:

(a) ANSI Class 900 Rating and above

(b) ANSI Class 150, 300 or 600 when the service or fluid content is:
- Process Hydrocarbon Liquids and/or Vapour (excluding vent and flare),
including Condensate, LPG, Natural Gas, “Wet” Gas, “Hot” Gas, Wet
natural Gas with CO2, Boil Off Gas, Compressor Vapour Return
- Fuel Gas
- Instrument Air supplying ESD Valves
- Refrigerant
- Steam
- Potable Water Supplying ESD Valves
and the computed stress exceeds 0.8 of the allowable stress range SA.

Group 2

Where any of the following conditions apply:

(a) ANSI Class 150, 300 or 600 when the service or fluid content is:
- Flare (HP & LP)
- Vent Atmosphere (where the source line is process hydrocarbon)
- Diesel Oil / Fuel Oil / Distillate Oil
- Chemicals including Caustic Soda, Oxazolidione, Sulfinol
- Lube /Seal Oil
- Seal Oil/Hydraulic Oil
- Firewater / Fire Fighting Water / Fire Fighting Seawater
- Fire Fighting Concentrated Foam
- Gasoline
- Heated Water
- Recovered Oil
- Produced Water
- Hazardous Open Drain
- Closed Drain
- Dry end condensate load line
- Slop Oil
- Sulphuric Acid (1.5 – 98%)

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Group 3

Where any of the following conditions apply:

(a) ANSI Class 150, 300 or 600 when the serve or fluid content is:
- Potable Water (Class 1 when supplying ESD Valves), Chilled Water,
Cooling Water, Demineralised Water
- Steam/steam Condensate
- Service Air, Tool Air
- Service Water
- Instrument Air (Class 1 when supplying ESD valves)
- Fresh Water
- Nitrogen/Inert Gas
- Dry End Foam, Dry Chemicals, Dry End Deluge
- Cooling Seawater
- Deballast Water
- Oily Sewer

Group 4

Where any of the following conditions apply:

(a) Piping systems open to the atmosphere but not covered under Groups 1, 2 or 3
(eg deck drains, etc)

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APPENDIX E - EXTENT OF TESTING AND INSPECTION

METHOD EXAMINATION GROUP (Note 1)


1 2 3 4
VISUAL 100% 100% 100% 100%
MT (Note 2) 100% Of branch
10% Branch, socket
(OR PT FOR NON- 100% socket & Nil
& attachment welds
FERROMAGNETIC MATERIALS) attachment welds
RT (Note 3) 100% Coverage 100% Coverage on
100% Nil
(BUTT WELD) on 1 in 10 welds 1 in 20 welds
UT (Note 4)
100% 0 0 0
(BRANCH WELDS)
ACCEPTANCE CRITERIA PER Severe cyclic Severe cyclic Severe cyclic Severe cyclic
ANSI B31.3, TABLE 341.3.2A conditions conditions conditions conditions
HYDROTEST SHOP FAB
Yes Yes Yes No
(Note 5, 7) SPOOLS
FIELD WELDS Yes Yes Yes
No
(Note 6) (Note 6) (Note 6)
MINIMUM
½ hour ½ hour ½ Hour N/A
DURATION
RECORDS Yes Yes Yes N/A

NOTES:

1 Examination groups are identified in Appendix C and are directly related to the extent of testing
performed on each category of piping.

2 MT or PT of branch welds to be performed prior to attachment of compensating plate if applicable.

3 UT may be substituted for RT on carbon steel, low alloy steel, stainless, duplex and super duplex butt
welds, where there is access to both sides of the weld, and where approval by the TA is given. The
UT operator and UT procedure shall be approved by the TA.

4 Not required where wall thickness for scanning surfaces are less than 10mm, and where branch
diameters are less than 125mm. Non-ferritic materials need not be examined.

5 Refer to piping isometrics for full hydrotest requirements. A hydrotest may only be waived with the
written approval of the Materials and Inspection Group.

6 Hydrotest of field welds may be waived in accordance with section 345.2.6 and 345.2.3(c) of ASME
B31.3. Where hydrotest is waived all field welds shall be subject to 100% RT and PT.

7 Refer to Appendix F for inhibitor requirements for hydrotest water.

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APPENDIX F - REQUIREMENTS FOR HYDROTEST WATER

WATER
MATERIAL DURATION 1 COMMENTS
QUALITY

< 1 day Corrosion inhibitor NOT REQUIRED


<200 PPM
CARBON STEEL
CHLORIDE
Corrosion inhibitor suitable for
> 1 day
duration REQUIRED

As an ALTERNATIVE, potable type


water with up to 200ppm chloride
AUSTENITIC, DUPLEX AND may be used if it can be
Demineralised all
SUPERDUPLEX STAINLESS demonstrated that the component
<10PPM chloride
STEEL can be drained and thoroughly air
dried within 24 hours of completion
of the hydrotest

COPPER BASED N/A all Ensure water does NOT contain S

NON-METALLIC N/A all Corrosion inhibitor NOT required

Note: 1. Total contact time of test medium with component

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APPENDIX G – INSPECTION AND TEST PLAN

P L A N N o .: IN S P E C T IO N A N D T E S T P L A N PAGE: OF

C o n tracto ry N u m b er: C o n tracto r:

D escrip tio n : S u b co n tracto r:

Item N o .: L o catio n :

D escrip tio n :

V e rifica tio n /W itn ess


Item N o ./ C o n tr a c to r C o d e /S ta n d a r d /
A cc e p ta n ce M D R R ep o r t/
O p e ra tio n M a n u fa c tu r in g o r In sp e c tio n D esc rip tio n In sp e c tio n o r T e st S p e c ific a tio n V endor P u r ch a se r O th er
C riter a R ec o r d T itle
S ta g e N o . P r o ce d u re N o . R e fer e n c e
A c tio n S ig n A c tio n S ig n A ctio n S ig n

R ev D a te
R eason for R evision D ra w n C h ec k ed A c tio n :
S ta t.

W W itn ess, M an d a tory H old P oin t R /A R eview a n d S ign D oc u m en tation


W /S W itn ess/In sp ec t a t R a n d om R R ev iew D oc u m en tation O n ly
W /I W itn ess In itia l th en a t R an d om

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APPENDIX H – PIPING FIELD TEST REPORT

C O N T R A C T N o .:
P IP IN G F IE L D T E S T R E P O R T
P R I O R I T Y S Y S T E M N o .:
F L O W S H E E T S (R E F . D W G ): P I P I N G T E S T N o .:
S H E E T N o .:
TEST PRESSU RE: OF
T E S T M E D IA :

L IN E N o . S IZ E IS O N o . FRO M TO IN S U . P A IN T REM ARKS

S I G N E D B Y C O M P A N Y ( P r io r to T e s tin g ) :
P I P I N G /M E C H A N I C A L E N G I N E E R NAM E DATE

W E L D IN G IN S P E C T O R NAM E DATE

T E S T W IT N E S S E D B Y : CONTRACTOR NAM E DATE

COM PANY NAM E DATE

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APPENDIX I – TRACEABILITY
ITY RECORD SHEET

TRACEABILITY RECO RD SH EET CONTRACT No.:

ISOM ETRIC No.: SPOOL:

W ELD ING INSPECTO R


PIPE U NIQU E HEAT AND /OR W ELDER CO NSUM ABLE
DESCR IPTION OF ITEM PR OCEDU RE
CLASS N UM BER TRACEABILITY NU M BERS ID BATC H N o.
No. C ONTR AC TOR COM PANY

C OM M ENTS:
CONTRACTO R
IN SPECTOR
SIGNATURE NAM E DATE

COM P ANY
IN SPECTOR
SIGNATURE NAM E DATE

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APPENDIX J – TRACEABILITY RECORD DRAWING/ISOMETRIC SHEET

T R A C E A B IL IT Y R E C O R D D R A W IN G /ISO M E T R IC SH E E T CO N T R A CT N o.:

M = M A T E R IAL/C O M P O N E N T
W = W E LD

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