Documente Academic
Documente Profesional
Documente Cultură
03
TABLE OF CONTENTS
1.0 INTRODUCTION
1.1 Scope
1.2 Exclusions
1.3 Responsibilities
1.4 Conflicts and Exceptions
4.0 WELDING
4.1 General
4.2 Welding Processes
4.3 Welding Procedure Qualification
4.4 Welder and Welding Operator Qualification
4.5 Production Welding
6.1 General
6.2 Exothermic Heat Treatment
7.1 General
7.2 Radiography
8.1 General
8.2 Preparation for Testing
8.3 Hydrostatic Leak Testing
8.4 Post-Test Requirements
8.5 Leak Repair and Re-testing
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9.1 General
9.2 Pneumatic Leak Testing
10.1 General
10.2 Acid Descaling (Pickling) and Passivation
10.3 Abrasive Blasting
10.4 Hot Oil Flushing
APPENDICES
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1.0 INTRODUCTION
1.1 Scope
1.1.1 This specification, in conjunction with the other Technical Requirements, defines
the minimum acceptable requirements for the fabrication, assembly, welding,
erection, installation, inspection, testing, cleaning and documentation of carbon
and austenitic stainless steel piping systems used in upstream oil and gas
production facilities. This specification governs piping systems provided in
accordance with API Recommended Practice 14E "Design and Installation of
Offshore Production Piping Systems" and ANSI B31.3 "Chemical Plant and
Petroleum Refinery Piping."
1.1.2 Piping systems constructed of duplex stainless steel materials shall meet the
additional requirements specified in Appendix II "Additional Requirements for
Duplex Stainless Steel Piping."
1.1.3 Piping systems constructed of Fiberglass Reinforced Plastic (FRP) materials
shall meet the additional requirements specified in Appendix III "Additional
Requirements for Fiberglass Reinforced Plastic (FRP) Piping."
1.1.4 Piping systems constructed of Chlorinated Poly Vinyl Chloride (CPVC) materials
shall meet the additional requirements specified in Appendix IV "Additional
Requirements for Chlorinated Poly Vinyl Chloride (CPVC) Piping."
1.1.5 Piping systems constructed API 5L Grade X-60 materials shall meet the
additional requirements specified in Appendix V "Additional Requirements for
API 5L Grade X-60 Carbon Steel Piping."
1.1.6 This specification shall also apply to the fabrication and attachment of pipe
supports.
1.2 Exclusions
This specification does not apply to process design, line sizing, or equipment
layout; nor does it apply to piping material and component selection, or to piping
design and layout. Specific exclusions include all small bore instrument tubing,
sub-sea pipelines, risers and J-tubes.
1.3 Responsibilities
CONTRACTOR shall be solely responsible for providing complete and operable
piping systems in full accordance with all applicable Industry Codes and
Standards, Government Regulations and COMPANY Technical Requirements.
1.4 Conflicts and Exceptions
1.4.1 All conflicts between this specification, the other Technical Requirements, and
the applicable codes and standards shall be submitted in writing to COMPANY
for resolution.
1.4.2 Any and all exceptions to the Technical Requirements shall be submitted in
writing to COMPANY for approval.
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3.5 The selection of pipe, piping components and valving shall be in full accordance
with the Technical Requirements, including General Specification 3.00 "Piping
Service Classifications and Material Requirements," and in particular the
appropriate Material Class Data Sheet for the intended service. Substitution of
alternate materials or components shall require prior written approval by
COMPANY.
3.6 Pipe support materials shall be provided in accordance with the Technical
Requirements. As a minimum, pipe supports shall be fabricated from carbon
steel that meets the requirements of ASTM A36 or ASTM A-53, A-106-B or API
5L, Grade B pipe, unless specified otherwise.
3.7 References in this specification to ANSI Class 150, 300, 600, 900, 1500 and
2500 flange ratings refer to ANSI B16.5 "Pipe Flanges and Flanged Fittings."
References to API 3000, 5000 and 10,000 pound flange ratings refer to API 6A
"Specification for Wellhead Equipment."
3.8 All sour service hydrocarbon piping systems shall be in accordance with NACE
MR-01-75 "Sulfide Stress Cracking Resistant Metallic Material for Oil Field
Equipment."
3.9 CONTRACTOR shall not proceed with material purchasing or fabrication without
approval of COMPANY.
3.10 As a minimum, all workmanship shall be equal to standard commercial practice in
modern fabrication shops. All work shall be performed by workmen skill in their
trades. All materials and equipment shall be new and of high quality manufacture.
4.0 WELDING
4.1 General
4.1.1 All welding shall be in strict accordance with ANSI B31.3 "Chemical Plant and
Petroleum Refinery Piping," the ASME "Boiler and Pressure Vessel Code" -
Section IX "Welding and Brazing Qualifications" and the COMPANY Technical
Requirements. The welding processes as discussed in this section shall be
acceptable for CONTRACTOR’s use in the fabrication of piping and pipe
supports unless otherwise noted in the Technical Requirements.
4.1.2 All welding procedures shall be in writing and shall be qualified in accordance
with the ASME "Boiler and Pressure Vessel Code" - Section IX "Welding and
Brazing Qualifications" as modified by ANSI B31.3 "Chemical Plant and
Petroleum Refinery Piping." All Weld Procedure Specifications (WPS) and
Procedure Qualification Records (PQR) shall be submitted to COMPANY for
approval prior to any welding.
4.1.3 Only welders qualified in accordance with the ASME "Boiler and Pressure
Vessel Code" shall be utilized for fabrication. Welders shall have their
qualification certificates available for COMPANY review during all stages of
fabrication. If requested by COMPANY, CONTRACTOR shall submit a list of
qualified welders and the procedures for which they have been qualified.
COMPANY may, at it’s option, require new qualification tests for any welder
working on piping fabrication. Should the welder fail the new qualification tests,
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then CONTRACTOR shall bear all costs for the tests and the welder shall be
removed from the work. COMPANY will reimburse CONTRACTOR reasonable
costs of new qualification tests passed by the welder in question.
4.1.4 All welding processes shall be identified by number. Identification numbers shall
be referenced on all fabrication drawings. CONTRACTOR shall submit
fabrication drawings or weld maps that identify the proposed welding process
for each weld, or types of weld configurations, prior to the start of welding.
4.1.5 COMPANY shall reject any weld that has not been made properly. Defects in
welds or fabrication, including fit-up, shall not be permitted which in the opinion
of COMPANY are detrimental to the strength of the weld. All repair procedures
shall be submitted to COMPANY for approval prior to start of repair work. The
cost of preparing repair procedures and repairing defective welds shall to the
CONTRACTOR’s account, not the COMPANY.
4.1.6 Any weld tampered with or caulked in any way shall be condemned whether or
not it is sound. "Doctoring" the surface of defective welds with a torch shall not
be permitted under any circumstances.
4.1.7 All welding equipment shall be in good condition and subject to inspection by
COMPANY. Any equipment found in need of repair shall be removed from the
fabrication work until said repair is completed.
4.2 Welding Processes
4.2.1 General
4.2.1.1 Acceptable weld processes for welding of piping and supports shall include the
following:
• Flux Core-Arc Welding (FCAW)
• Gas Metal-Arc Welding (GMAW)
• Gas Tungsten-Arc Welding (GTAW)
• Shielded Metal-Arc Welding (SMAW)
• Submerged-Arc Welding (SAW).
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d. Self-shielded FCAW shall not be permitted for process piping, but may be
used for pipe support fabrication.
e. Low hydrogen consumables shall be certified by the electrode
CONTRACTOR, or tested by CONTRACTOR to result in less than 10 ml of
diffusible hydrogen per 100 gm of deposited weld metal. Diffusible hydrogen
content shall be measured by the mercury displacement or gas
chromatograph method per AWS A4.3. CONTRACTOR shall provide written
evidence of compliance with this requirement. The specification sheet for the
proposed brand of filler metal from the CONTRACTOR shall be acceptable
as written evidence.
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welding two steels of unequal strengths, the welding wire or electrode shall be
matched to the higher strength material.
4.2.7.2 The weld filler metal in low-temperature piping service shall meet the same
impact test requirements as the base metal.
4.2.7.3 Tensile strength of deposited weld metal shall be limited to 100 ksi maximum
and shall be verified by a hardness test of the weld material in the procedure
qualification. Weld metal hardness shall not exceed 200 Brinell.
4.2.7.4 Carbon steel electrodes for welding API 5L, Grades B and X-42 pipe shall
conform to the following ASME specifications:
• SMAW ASME SFA-5.1
• GTAW/GMAW ASME SFA-5.18
• SAW ASME SFA-5.17
• FCAW ASME SFA-5.20 Classes:
E60T-1, E60T-5, E61T-1, E61T-5
E70T-1, E70T-5, E71T-1, E71T-5
4.2.7.5 Stainless steel electrodes shall be low carbon "L" grade, and shall conform to
the following ASME specifications:
• SMAW ASME SFA-5.4
• GTAW/GMAW ASME SFA-5.9
• FCAW-g ASME SFA-5.22
4.2.7.6 Filler metals for joining carbon steels to stainless steels shall be E309L, except
in services over 600°F where Inco 182 shall be used. Low carbon grades of
austenitic stainless steel shall be joined with low carbon weld metal of
corresponding composition.
4.2.7.7 The following SMAW SFA-5.1 electrode classifications shall not be acceptable
for pressure containing welds:
• E6012
• E6013
• E6020
• E7014
• E7020
• E7024.
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4.4.5 Welders shall have their qualification certificates with picture identification at the
work site during all fabrication.
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length. The transition spool shall be internally tapered at one end to match the
thickness of the thinner walled pipe or fitting, and beveled for welding. The taper
angle shall be approximately 4:1, but not less than 14 degrees. CONTRACTOR
shall stencil all transition spools with the pipe size, grade and wall thickness'.
4.5.2 Preheat
4.5.2.1 All welded joints shall be preheated in accordance with the approved weld
procedures. The minimum preheat temperature for thermal cutting, tacking and
welding shall be in accordance with ANSI B31.3 "Chemical Plant and Petroleum
Refinery Piping." Preheat shall be maintained during all multi-pass welding.
4.5.2.2 Additionally, preheating to 100°F shall be required if the base metal is damp, if
the surface temperature is less than 40°F or if the relative humidity is above
50%.
4.5.2.3 All API flanges shall be preheated to minimum 400°F before welding. Preheat
shall be maintained throughout the welding process.
4.5.3 Welding
4.5.3.1 COMPANY shall reject any weld that has not been properly made per the
Technical Requirements. All welds shall be made in such a manner as to reduce
residual stresses.
4.5.3.2 Welding shall not be permitted at ambient temperatures less 40°F when either
the wind velocity exceeds 10 mph or the relative humidity exceeds 50%.
Welding shall not be permitted in inclement weather unless both the welder and
the work are well protected from the elements.
4.5.3.3 Electrodes, filler wires and fluxes shall be kept clean, dry and properly stored
according to the manufacturer's recommendations. Electrodes, filler wire or fluxes
that are damp, greasy or oxidized shall not be used. During welding, care shall
be taken to avoid contamination of fluxes.
4.5.3.4 Low hydrogen electrodes shall be protected from moisture and used within 2
hours of breaking the seal on their original (hermetically sealed) containers. If
the container has been open for more than 2 hours, but less than 8 hours, the
electrodes shall be placed in a heating box and held at 225°F for 8 hours
minimum, and then used within 2 hours of removal from the hot box. Electrodes
exposed longer than 8 hours shall be reconditioned by heating in an oven at
650 to 750°F for 1 hour minimum.
4.5.3.5 Weld beads shall be contoured to permit complete fusion at the sides of the
bevel and to minimize slag inclusions. Flux and slag shall be completely
removed from weld beads, and from the surface of completed welds and
adjoining base material. The flux shall be removed in a manner that will not
contaminate or overheat the weld or adjoining base metal.
4.5.3.6 All welds shall be thoroughly cleaned after each pass by power wire brushing to
remove all slag, scale, splatter, coatings and dirt.
4.5.3.7 Peening shall not be permitted.
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4.5.3.8 Welds on branches or reinforcing pads shall merge smoothly with the surface of
the pipe. Sharp corners on reinforcing pads shall be removed.
4.5.3.9 Welding shall not be permitted on valves without prior written approval from
COMPANY.
4.5.3.10 Seal welding of threaded joints shall cover all exposed threads and blend
smoothly into the pipe. Seal welds on threaded joints shall be made as small as
possible using low penetration electrodes. Seal welds shall be tapered
gradually.
4.5.3.11 Welds containing cracks, regardless of size or location, shall not be acceptable.
Cracks, notches, undercutting or any other evidence of poor workmanship shall
be cause for rejection.
4.5.3.12 At the completion of all fabrication work, all excess weld metal, splatter, and
other foreign material shall be removed. Welds shall be wire brush cleaned to
remove slag and weld spatter. On stainless steel piping, wire brushing shall be
done only with stainless steel brushes which have not previously been used on
ferritic materials. Edges shall be smoothed or rendered flush with the parent
surface unless otherwise approved by COMPANY.
4.5.3.13 Stainless steel piping shall be kept free of surface contamination by iron or
other foreign material. Excessive surface contamination and/or oxidation (heat
tint) of welds shall be removed using an acid pickling solution or paste, or by
blasting with iron-free grit.
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5.1.10 A vent connection shall be provided by CONTRACTOR at all piping high points
where gas may be trapped, regardless of whether or not a vent connection is
indicated on the drawings. Vent connections shall be a minimum of 3/4" NPS
and shall be provided with plugs or blind flanges, unless specified otherwise by
the Technical Requirements.
5.1.11 Threads on threaded pipe and fittings shall be cut to ANSI B1.20.1 "Pipe
Threads (Except Dry Seal) Specifications, Dimensions, and Gaging for Taper
and Straight Pipe Threads Including Certain Special Applications."
5.1.12 Teflon tape or pipe dope shall be used on all threaded pipe joints, except for
those joints that are to be back welded. Teflon tape or pipe dope shall only be
applied to the male thread of the joint.
5.1.13 Piping "as-built" dimensional tolerance with regard to final end-to-end
dimensions (across the platform) and location of branches or appurtenances
shall be plus or minus 1/8" linearly and plus or minus 2 o angularly. Lines that are
designated as "sloped lines" shall maintain a positive slope in the direction
specified.
5.1.14 For piping that is designated as "sloped," the total slope shall be as uniformly
distributed as practicable throughout the entire length of the line by shimming
the pipe where necessary. After installation, shims shall be seal welded into
place to prevent displacement and loss. Pipe shall be removed or lifted in place
to permit surface preparation and coating of the shims.
5.1.15 An inert gas arc welding process (TIG or MIG) shall be used on the root pass of
welded joints on compressor suction piping that are not accessible for internal
inspection and cleaning. The remaining passes may be welded by the Shielded
Metal-Arc Welding (SMAW) process.
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5.2.5 Pipe supports shall be welded to main structural beams of the platform, deck,
module or skid. Pipe supports shall not rest upon or be supported by grating,
deck plate or other non-structural elements. Beams shall be fabricated so that
after erection any minor camber as a result of rolling or shop assembly will be
upward.
5.2.6 Holes for bolted connections shall be 1/16" larger diameter than the bolts. All
holes shall be drilled prior to the application of any protective coatings. Torch cut
holes shall not be accepted by COMPANY.
5.2.7 Unless otherwise specified in the Technical Requirements, pipe shall be
clamped to pipe supports using bichromated cadmium plated "U" bolts complete
with rubber sleeves. Neoprene rubber pads, a minimum of 3/8" thick, shall be
provided between the pipe and support for all pipe 8" NPS and smaller. All "U"
bolts shall be double nutted with bichromated cadmium plated nuts.
COMPANY shall not accept galvanized bolting, including studs, bolts, cap
screws, jacking bolts, nuts, washers, "U" bolts, etc., on piping systems, and in
particular, not on stainless steel piping systems.
5.2.8 Where COMPANY approval has been granted to weld supports directly to
piping, the following requirements shall apply:
a. The pipe support shall be welded to the pipe in a manner that will minimize
penetration into the pipe and will minimize local stresses induced in the
piping. Recommend procedures include SMAW (in the downhill direction) or
GMAW.
b. Undercutting shall not be accepted under any circumstances.
c. The pipe support material shall be compatible with the pipe or fitting
material. Preheating, welding and heat treatment of the support to the pipe
shall be in accordance with the welding requirements for the pipe.
5.2.9 CONTRACTOR shall demonstrate the acceptability of pipe support welding
procedures prior to commencement of work. All pipe support welds shall be
subject to visual or NDE inspection and acceptance by COMPANY.
5.2.10 Unless specified otherwise by the Technical Requirements, pipe supports shall
be installed so that bolted spool pieces can be removed for maintenance
without cutting.
5.2.11 Stiffeners shall be fitted accurately, neatly and tightly to transmit bearing loads.
Stiffener ends shall be milled or ground smooth to conform to the geometry of
the member when fillet welds are utilized. Otherwise, stiffener ends shall be
beveled to ensure 100% fusion in the root of the weld.
5.2.12 All pipe support welding shall be full seal welds as a minimum. Seal welds shall
be placed at all contact edges of plate and on the supporting flanges of beams,
tees, etc., and the flat legs of angles. Surfaces inaccessible for coating shall be
sealed by boxing-in with plate. Skip or stitch welding shall not be acceptable
under any circumstances.
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5.2.13 Splices in structural shapes and pipe shall be full penetration welds to provide
100% joint efficiency. Splicing tolerances shall comply with the AISC "Manual of
Steel Construction."
5.2.14 Splices in structural pipe shall not be closer together than one pipe diameter, or
3'-0", whichever is greater. For beams, splices shall not be closer together than
twice the depth of the beam, or 3'-0", whichever is greater.
5.2.15 If a beam spans a support, the beam shall not be spliced in the middle quarter
of the span, in the eighth of the span nearest the support, or over the support.
5.2.16 Cantilevered beams shall not be spliced closer to the support than one-half the
cantilever span length.
5.2.17 As a minimum, pipe supports fabricated as "ship loose" for installation by
COMPANY (or Others) shall be test-fitted to confirm fit-up, then coated with
primer and color-coded with paint marks to facilitate field assembly. Paint marks
shall be at least 2" high unless limited by the size of the member to be marked.
Marks shall be applied to members in a protected location where they will not be
evident upon completion of installation. Paint mark color shall be in sharp
contrast with the primer paint, and shall be compatible with the primer and finish
paints specified by the Technical Requirements. Paint shall be durable for
exposure to normal atmospheric conditions for a minimum of 6 months.
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7.2 Radiography
7.2.1 Radiographic inspection shall be performed by a qualified third party
SubContractor. Self-examination by CONTRACTOR shall not be acceptable to
COMPANY. Technicians shall be qualified to American Society of Nondestructive
Testing (ASNT) Recommended Practice No. SNT-TC-1A "Nondestructive Testing
Qualification and Certification." Inspectors responsible for grading and
interpretation of radiographs shall be Technician Level II or III certified by ASNT
SNT-TC-1A, and helpers shall be SNT-TC-1A Level I certified as a minimum.
7.2.2 Unless specified otherwise in the Technical Requirements, the following
minimum percentages of welds in each pipe class shall be radiographically
inspected:
Pipe Class Rating: Radiograph Inspection Level:
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and including radiography on every weld if necessary. All costs associated with
additional radiography as a result of unacceptable welds shall be at
CONTRACTOR's expense.
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air may be injected into the water while flushing to increase turbulence and
velocity. Drop flushing, the filling and draining of a piping system, does not
constitute flushing and shall not be accepted.
c. Piping and piping systems which cannot be flushed with water (because the
presence of water is unacceptable) shall be blown out with high pressure,
high velocity air. This shall include instrument and utility air lines as a
minimum.
d. Control valves, positive displacement meters, turbine meters, rotameters,
and relief devices shall be removed from the piping system during flushing.
8.2.4 Valving, including ball, gate, globe, plug and butterfly valves shall be in the fully
open position during hydrotesting. Lines containing check valves shall have the
pressure source located on the upstream side, or the check valves shall be
removed from the line or blocked open for hydrotesting.
8.2.5 Expansion joints shall be hydrotested with the piping system to check the
restraining devices.
8.2.6 Control valves shall remain in the line for hydrotesting and shall be in the fully
open position. Valves that are normally closed shall be opened for hydrotesting
using clean dry air. Valves shall not be jacked or forced open by
CONTRACTOR.
8.2.7 Pressure control valves with internal passages between the process fluid and
the diaphragm shall be isolated from hydrotesting. External connections shall be
disconnected or blocked during hydrotesting, and the diaphragm pressure shall
be bled off.
8.2.8 Hydrostatic testing shall be performed with the "in service" type of gaskets, and
shall not utilize any gasket sealing compounds. New gaskets shall be installed
on all connections that are broken after completion of the hydrotesting, or that
must be reassembled after testing.
8.2.9 Temporary supports shall be installed as necessary to prevent sagging or
excessive stress on the piping system. Special consideration shall be given to
supporting partially liquid packed or gas piping systems during flushing and
hydrostatic testing. Particular attention shall be given to systems having spring or
counterweight supports, and to systems containing expansion joints or loops.
8.2.10 Large diameter lines that are grouped together on common supports shall not
be simultaneously hydrotested if the weight of the test medium might overstress
the supports.
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Note 1: For flanges 16" NPS and larger the test pressure shall be 4,500 psig.
Note 2: CONTRACTOR shall confirm that all components in API 6A piping
systems are suitable for the specified hydrostatic test pressure prior to
procurement. Components not suitable for the specified hydrostatic
test pressure shall not be utilized by CONTRACTOR without prior,
specific written approval of COMPANY.
Note 3: Refer to technical requirements for hydrostatic test pressure for duplex
stainless steel.
8.3.2 Hydrostatic test pressures are for the new and cold condition, with test
temperatures of 100°F or less. For higher test temperatures, CONTRACTOR
shall be responsible for checking the piping system and determining the
appropriate test pressure. The test pressure shall be selected such that the test
shall not exceed 90% of the yield strength of the weakest component at the test
temperature.
8.3.3 Hydrostatic testing shall be maintained for a minimum of 2 hours after
stabilization of pressure and temperature.
8.3.4 All hydrostatic tests shall be maintained for a sufficient period of time to check
for small seepage leaks. Upon successful completion of the hydrostatic test
period, the piping system shall receive a final visual check for leaks.
8.3.5 Hydrostatic testing shall be performed with two separate pressure gauges and a
dual-pen (pressure and temperature) chart recorder. Pressure gauges and
recorders shall have a pressure range of approximately twice the required test
pressure.
8.3.6 All gauges and recorders shall have been dead-weight tested and certified
within 6 months of hydrostatic testing. The certifications shall be available for
COMPANY review during all hydrostatic testing.
8.3.7 All vents shall be open during filling to ensure proper venting of all air or gases.
8.3.8 Test pressure shall not be applied against any closed valve. Skillets or blinds
shall be installed to protect valves that must remain in the closed position.
8.3.9 If the test liquid in the system is subject to thermal expansion, CONTRACTOR
shall take precautions to avoid excessive pressure. Precautions such as
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10.1.2 The cleaned, descaled and passivated pipe shall be free of all scale, rust, weld
flux, oil, grease and other foreign materials and shall be equivalent to a Steel
Structures Painting Council SP-8 "Acid Pickling" or SP-6 "Commercial Blast
Finish" surface. All weld flux, metal shavings, coatings, sand, dirt and other
foreign materials not soluble in chemical cleaning solutions shall be removed
prior to fabrication or cleaning operations.
10.1.3 CONTRACTOR shall propose the cleaning, descaling and passivation method,
unless otherwise specified by COMPANY. However, the method shall be
approved by COMPANY prior to the start of work.
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10.2.2.2 After removing the precleaning solution, the system shall be rinsed with clean,
potable water until the pH of the effluent rinse is within one pH of the fresh rinse
water.
10.2.4 Neutralization
10.2.4.1 A neutralizing solution of 2% soda ash (sodium carbonate) shall be circulated to
remove all traces of acid from the system. The solution shall be circulated for a
minimum of 1 hour at 120°F, and then drained under a nitrogen purge. When
using an ammoniated citric acid, this step may be deleted.
10.2.4.2 After neutralizing, the system shall be rinsed with water until all traces of acid
and neutralizing solution have been removed, and then drained under a
nitrogen purge. When using an ammoniated citric acid, this step may be
deleted.
10.2.5 Passivation
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10.2.5.1 After rinsing, the descaled pipe shall be passivated to minimize further corrosion
by applying a phosphate coating. The passivation solution shall be circulated for
1 hour at 130 to 150°F, and consist of the following:
• 0.25% (wt.) monosodium phosphate
• 0.25% (wt.) disodium phosphate
• 0.50% (wt.) sodium nitrite
10.2.5.2 If an ammoniated citric acid was used for descaling, the steel surfaces shall be
passivated by raising the pH to between 9 and 10 through addition of ammonia,
and then adding 0.5 % sodium nitrite and circulating for 1 to 2 hours.
10.2.5.3 After passivation, the system shall be drained and dried thoroughly with dry air
or nitrogen. The system shall not be flushed with water after passivation. After
drying, the pipe shall be closed tightly, blanketed with an inerting gas or filled
with oil to minimize corrosion.
10.2.6 Safety
10.2.6.1 All of the above acids and most of the other treating solutions are harmful in the
event of skin contact, if swallowed, or if fumes are inhaled. Material Safety Data
Sheets (MSDS) shall be available at the job site for all chemicals being
employed. All personnel shall be properly educated and protected against
exposure by safety equipment, including chemical goggles, rubber gloves and
face shields as a minimum.
10.2.6.2 During the acid treating stage of the procedure, hydrogen gas is liberated by
reaction of the acid with the metal. Suitable precautions shall be taken to
minimize any explosion danger resulting from hydrogen accumulation in holding
tanks or other areas. Holding tanks shall be located a minimum of 50' from
process equipment and nonclassified electrical equipment. Smoking shall not be
allowed in the chemical cleaning area under any circumstances.
10.2.6.3 Safety showers shall be available and ready for use at the site. Breathing
apparatus shall be available in case of exposure to toxic fumes.
10.2.6.4 All work areas shall be barricaded with yellow and black tape with "KEEP OUT"
warning signs every 50'.
10.2.6.5 Only proper equipment shall be used. Hoses shall have a minimum working
pressure of 250 psig and shall be chemically compatible with the cleaning
solutions. Hoses shall be bonded to ground to minimize static discharge
explosion hazards.
10.2.6.6 The circulating system shall be pressure tested to 1.5 times the maximum
circulating pressure, or 90 psig, whichever is greater, and all hoses and
circulation system piping and fittings checked for leaks. All leaks shall be
repaired prior to using any chemical solutions.
10.2.6.7 Should a leak develop during circulation of the system, the chemical shall be
evacuated and the piping flushed. The leak shall be repaired before restoring
circulation.
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10.2.7 Environmental
10.2.7.1 CONTRACTOR shall develop a detailed contingency plan and shall have
equipment available to contain and clean up any chemical leaks. Storm drains
shall be sandbagged prior to the start of cleaning. Any and all chemical spills
shall be reported to COMPANY immediately.
10.2.7.2 All materials used for chemical cleaning shall be considered hazardous.
Chemical effluent shall be handled in a responsible way, and in compliance with
all city, county, state and federal regulations.
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11.2 All coating work shall be performed after completion of all fabrication and
testing, including hydrostatic or pneumatic pressure testing.
11.3 The exposed portions of all blinds shall be greased to prevent corrosion.
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and shall reference drawings or spool sheets as applicable. Each item shall be
listed separately, and an approximate weight and dimension for each shall be
provided. The material packing method shall be identified, i.e. crated, palletized,
bundled, skid-mounted, boxed, etc. as applicable.
13.8 Related materials shall be bundled, palleted, or crated together. Ship loose
items shall be carefully inventoried and crated or palletized. A copy of the
inventory shall be included in each crate or attached to each pallet.
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APPENDIX I
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APPENDIX II
A2.1.0 SCOPE
This appendix defines additional or modified requirements for fabrication,
welding and inspection of duplex stainless steel (UNS) S31803 piping
conforming to ASTM A790 "Seamless and Welded Ferritic/Austenitic Stainless
Steel Pipe."
A2.4.0 WELDING
A2.4.1 General
Unless otherwise approved in writing by COMPANY, the maximum heat input
shall be limited to 38 kilojoules/inch. The heat input used for the procedure
qualification shall be recorded on the procedure qualification.
b. Autogenous welding shall not be permitted, i.e. filler metal addition shall be
required.
b. Duplex stainless steel weld deposits shall have a ferrite content in the range
of 30 to 60%. The ferrite content of the heat affected zone (HAZ) shall be in
the range of 40 to 60%.
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b. A microhardness traverse shall be run across the weld metal, heat affected
zone and the base metal at a maximum of 2 mm below the cap pass. Six
equally spaced indentations shall be made in the weld metal. In the heat
affected zone, indentations shall start as close to the fusion line as possible
and shall be made along the traverse at 0.5 mm increments into unaffected
base material. The base material shall have a minimum of 3 indentations.
The maximum hardness at any location shall not exceed 285 HV10.
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APPENDIX III
A3.1.0 SCOPE
A3.1.1 This appendix defines additional or modified requirements for fabrication,
installation, inspection and testing of Ameron Bondstrand Fiberglass Reinforced
Plastic (FRP) piping. This specification also describes the minimum
requirements for fabrication, installation and testing of Ameron PSX L3 FRP
piping for firewater and deluge service.
A3.1.2 CONTRACTOR shall be responsible for the detailed design, installation, testing
and supply of all materials necessary to make the piping system complete and
operable.
A3.2.1 General
A3.2.1.1 Piping and fittings shall be designed, fabricated and installed in accordance with
ANSI B31.3 "Chemical Plant and Petroleum Refinery Piping," except as
specified otherwise by the Technical Requirements. All pipe installation and
fabrication work shall be in strict accordance with the FRP pipe manufacturer's
recommendations.
A3.2.1.2 Fiberglass piping (FRP) and resins used for potable and utility service shall be
approved by the U.S. FDA for use with potable water and shall be clearly
labeled as such.
A.3.2.1.3 All joints shall be bonded or flanged. Threaded FRP joints shall not be
permitted, except for stainless steel bushings imbedded in FRP saddles which
shall be acceptable for small bore connections for instrumentation and
vent/drain connections.
A3.2.2.2 Chains shall not be used for handling pipe or fittings. When lifting with hoists or
cranes, or securing for transportation, only rope or webbed slings shall be used.
A3.2.2.3 Pipe and fittings shall not be thrown or dropped, and shall be protected from
bumping or hitting during all handling work.
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A3.2.3.2 All tools recommended by the FRP pipe manufacturer, especially those for joint
preparation, shall be used.
A3.2.4.2 All flanged joints shall be uniformly tightened and shall be torqued to the pipe
manufacturer's recommended limit, but not beyond.
A3.2.4.3 Butterfly valves and wafer check valves shall be installed so that the disc swings
clear of adjacent piping.
A3.2.4.4 Prefabricated skid piping shall be shipped with the flanged joints loosely bolted
to provide maximum flexibility during transportation.
A3.2.5.1 The CONTRACTOR shall ensure and review all piping layouts for suitability of
piping flexibility and support. All types of supports shall be in accordance with
the pipe manufacturer’s recommendations. Support cradles shall provide 180
degrees of circumferential support.
A3.2.5.2 Metal supports shall be isolated from the FRP pipe by FRP saddles, elastomeric
liners or other materials approved by the pipe manufacturer.
A3.2.5.3 Valves and heavy components shall at all times be independently supported or
suspended to prevent excessive torque, bending and longitudinal stresses
being transmitted to or carried by the pipe system.
A3.2.5.4 Direction changes in close proximity to pump discharges shall be avoided to the
best extent possible
A3.2.6 Coating
A3.2.6.1 Conventional coatings for the purpose of preventing or delaying ultraviolet (UV)
damage shall not be required.
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A3.2.6.2 Material selection for firewater pipe and fittings shall be as follows:
----------------------------------- ---------------------------------------
A3.3.1 General
CONTRACTOR shall visually inspect all piping and fittings for damage per the
visual acceptance standards detailed in API 15LR "Specification for Low
Pressure Fiberglass Line Pipe." Visual inspection shall occur upon receipt and
before any assembly. Damaged or defective material shall not be used.
Specific, written COMPANY approval to use damaged or defective material shall
be required, and must be granted on a case by case basis.
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A3.3.3.2 Following successful cyclic test, the system shall be hydrostatically pressure
tested at 1.5 times the rated design pressure (new & cold) for at least 4 hours
without leaking. The 4 hour test shall not begin until the last "leak" is repaired or
stopped. A subsequent leak after the test has begun shall cause the test to be
restarted such that there are four consecutive hours of leak-free testing.
CONTRACTOR shall verify that the hydrostatic test pressure will not exceed
FRP pipe manufacturer's allowables.
A3.4.0 REPAIRS
Defective joints or pipe shall be repaired by cutting out the defect and bonding
in new joints or pipe. CONTRACTOR may submit a wrap repair procedure for
COMPANY consideration, but submittal and approval/rejection shall be on a
case by case basis. The wrap repair procedure shall be in accordance with the
FRP pipe manufacturer's recommendations.
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APPENDIX IV
A4.1.0 SCOPE
A4.1.1 This appendix defines additional or modified requirements for fabrication,
installation, inspection and testing of Chlorinated Poly Vinyl Chloride (CPVC)
piping conforming to ASTM D2846 "Specification for Chlorinated Poly Vinyl
Chloride (CPVC) Plastic Hot and Cold Water Distribution Systems."
A4.2.2 CPVC pipe, tubing, and fittings shall be handled with extreme care to avoid
damage such as abrasions, cracking or crushing.
A4.2.3 Pipe and tubing cuts shall be square and de-burred to insure a proper fit-up of
the joint being made.
A4.2.4 All joint contact surfaces between pipe and fittings shall be solvent cleaned prior
to the application of cement. Cement shall be applied to both surfaces to be
joined. The amount of cement applied shall cause a small bead of cement to
appear at the junction.
A4.2.5 CPVC pipe, tubing, and fittings shall be cemented with CPVC solvent cement.
The cement shall be in accordance with ASTM F493 "Specification for Solvent
Cements for Chlorinated Poly Vinyl Chloride (CPVC) Plastic Pipe and Fittings."
CPVC solvent cement shall be orange in color to facilitate identification and
minimize the unintentional use of other cements.
Extreme caution shall be taken when handling, applying, and storing solvent
cement. Handling and storage of solvent cement shall be in accordance with
ASTM F402 "Practice for Safe Handling of Solvent Cements and Primers Used
for Joining Thermoplastic Pipe and Fittings."
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APPENDIX V
A5.1.0 SCOPE
A5.1.1 This appendix defines additional or modified requirements for procurement,
fabrication, installation, inspection and testing of API 5L Grade X-60 carbon
steel piping systems provided in accordance with ANSI B31.3 "Chemical Plant
and Petroleum Refinery Piping."
A5.2.1 General
A5.2.1.1 Root pass and hot pass welding shall be performed using the Gas Tungsten-Arc
Welding (GTAW) process. The remainder of the weld shall be performed using
either the gas-shielded Flux Core-Arc Welding (FCAW) or Submerged-Arc
Welding (SAW) processes.
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A5.2.3.2 Separate weld procedure qualifications shall be performed for welding Grade X-
60 to Grade X-60, Grade X-60 to fittings (ASTM A860), and Grade X-60 to
flanges (ASTM A694). Impact testing shall not be required for procedures on
ASTM A860 or ASTM A694 material.
A5.2.3.3 The following additional essential variables shall apply for all Grade X-60
welding procedures. A change in an essential variable beyond the limit specified
shall require a new qualification.
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