APPENDIX A

ATTACHMENT 13
Minimum Piping Design Requirements

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APPENDIX A

PART 1

Design Requirements

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APPENDIX A

1.

SCOPE

1.1

This document outlines the minimum requirements for the design and
detailed engineering of onshore piping systems, and shall be read in
conjunction with QP Engineering Standards, ES.5.06.0008 [Piping
General Design], ES.5.06.0019 [Flange Bolting Piping-General Design],
ES.5.06.0014 [Valve Guidelines] and ES.5.14.0021 [Specification for Pipe
Supports].

1.2

This document is applicable to piping which will be designed to ASME B

31.3 Design Code. Instrument air line routed off-site shall also be
considered within the scope of ASME B 31.3. The following are not
included in the Scope of this document:

1.2.1 Instrument Piping downstream of the primary isolation valve

1.2.2 HVAC piping/ducting for building services.
1.2.3 Plumbing for building services
1.2.4 Pipelines in the scope of ASME B 31.4 and B 31.8
1.2.5 Piping within a storage tank or pressure vessel.
1.2.6 CONTRACTOR shall design the piping system based on the minimum
requirements stated hereunder. Any additional requirements not covered
herein shall be developed by the CONTRACTOR and shall be approved by
QP.

2.

REFERENCES
ES.5.06.0008:

Piping General Design

ES.5.06.0014:

Valve Selection Guide

ES.5.06.0019:

Flange Bolting Guidelines

ES.5.14.0021:

Specification for Pipe Supports

QP-STD-R-001: QP Technical Standard for Materials for Sour Service

QP-SPC-L-002: Technical Specification for Painting and Wrapping of
Metal Surfaces (New Construction and Maintenance)
2.1

In case of conflict in the interpretation of the various design guides,

requirements of this design guide shall govern, except where superseded
by more stringent local requirements. Where there is conflict between
various QP guides and ASME B 31.3, the most stringent requirements, as
decided by QP, shall apply.

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3.

MATERIALS

3.1

Except for utility service, piping and valve materials of construction for
process applications shall be suitable for sour service, and shall conform to
the requirements of latest edition of QP Specification, QP-STD-R-001 and
NACE Standard MR 0175 / ISO 15156.

3.2

Piping Specifications and Data Sheets shall be prepared. Where QP

Specifications have been supplied with, these shall be reviewed and
revised, as appropriate, to reflect the project requirements.

3.3

Austenitic stainless steel bolting shall not be used, as it is susceptible to

chloride stress-corrosion cracking (CSCC) in saliferous environments. Low
alloy high strength carbon steel bolting conforming to ASTM A 193 / A 194
or ASTM A 320 specification can be used. Selection of material grade shall
be based on service conditions (sour service, low/high temperature
applications, etc.) Low alloy carbon steel bolting shall be provided with
suitable coating for protection against corrosion. Suitable coating material
is ENP coating for sour service applications and zinc coating (hot dip
galvanization) for general service. Use of PTFE coating shall have the
approval of QP.

4.

DESIGN

4.1

General

4.1.1 Piping design shall comply with the requirements of ASME B 31.3, this
document and all relevant documents indicated in this document. There
shall be a margin between the maximum normal operating pressure and
the maximum allowable working pressure or design pressure, as indicated
in Figure 4, Section 3.20.3.3 of API RP 521.
4.1.2 Lines shall be sized as per the sizing criteria indicated in Sections 6.4, 6.5,
6.6 and 6.7 of QP Engineering Standard, ES.5.06.0008. Pump suction and
discharge lines shall be sized as per the criteria in Section 6.5, and
compressor suction and discharge lines as per the criteria in Section 6.6.
4.1.3 Pump suction piping must be designed to minimize friction losses and to
present a uniform velocity profile (steady state laminar flow) to the suction
of the impeller. Suction piping shall be as direct as possible, with minimum
number of bends. It shall be at least one or two sizes larger than the pump
nozzle. The reducer at the suction nozzle shall be of the eccentric type, flat
side on top. Pump NPSH (A) shall be calculated based on the static head,
frictional losses and vapour pressure of the liquid pumped. The sizing of
the discharge pipe shall be made with due reference to the static head and
the frictional losses. The discharge line shall never be less than the pump
discharge. Non-return valve and isolation valves shall be provided in the
discharge pipe close to the pump, as appropriate. The pump minimum recirculation line shall be sized based on proven design.
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4.1.4 Piping system shall be designed and materials selected to accommodate
all pressures, temperatures, stresses, corrosive conditions, etc., which
occur during erection, and, as a result of extreme operating conditions
during start-up, normal operation, shut-down and emergency conditions.
4.1.5 Wall thickness calculations shall be performed based on ASME B 31.3,
considering all corrosion allowances, manufacturing allowances, etc.
Calculation for GRE Piping Wall Thickness Shall be based on relevant
international and manufacturers standards.
4.1.6 In general, tap-offs (branch connections) from liquid carrying pipes shall be
from the bottom of the pipes and those from gas and vapour carrying pipes
shall be from the top, except in the case of cooling water pipes, in which
case, tap-offs shall be from the top in order to prevent ingress of dirt or
particulate matter into the heat exchanger tubes. Branch connections shall
be made in accordance with the branch schedule for each piping class.
4.1.7 In the case of brown field projects, the system shall be designed as to
facilitate easy integration with the existing facilities with minimum plant
shutdown. Tie-in Schedule and Tie-in Engineering Package, identifying the
interfaces with the existing systems and the shut-down requirements, shall
be developed for this purpose. The new piping shall be adequately
designed following the piping specification of the existing facility.
4.1.8 Pipe sizes smaller than 1 nominal size shall not be used. All instrument
connections to pressure containing systems shall be provided with isolation
valves of minimum 1 size conforming to the corresponding line
specification.
4.1.9 All utility headers shall be of minimum 2 diameter.
4.1.10 Vents and drains required for operation, inspection, maintenance,
hydrostatic testing, dewatering and commissioning shall be provided. All
test vent and drain points shall be blinded after successful testing. Dead
legs shall be provided with drain valve and blinded. All process drains
shall be manifolded to a drain header
4.1.11 All pipe-work, especially drain lines shall be properly sloped so as not to
leave any dead liquid pockets in the piping. A slope of 1 % shall be
considered for the drain lines, unless otherwise indicated in the Piping
and Instrumentation Diagram. Drain lines shall be provided with isolation
valves that are to be blinded after testing, pre-commissioning and
commissioning.
4.1.12 Pressure relief and temperature relief valves shall be provided, as
appropriate, in order to ensure safe operation. The location, connection
and support shall be selected such that vibration does not affect the
integrity of the valve and the pipe-work. Inlet lines to the relief valves shall
be self-draining back to the process equipment or piping. Pressure relief
piping shall be checked for thermal expansion and reaction forces of
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high-pressure,high-velocity streams. Relief valve discharge pipe supports
shall be capable of withstanding the calculated reaction forces.
4.1.13 In the case of packaged skid-mounted items, sufficient mass shall be
provided for the skid base in order to avoid natural frequencies resulting
in resonance, which can cause damage to the equipment and piping
system, and also to ensure that only residual vibration amplitude levels
occur under normal operating conditions of the equipment.
4.1.14 Bi-metallic piping material shall not be used in order to avoid galvanic
corrosion. In case this is un-avoidable, insulating material shall be used
in between two dissimilar material joints.
4.1.15 Buried piping shall be protected by appropriate coating and wrapping in
accordance with QP Technical Specification, QP-SPC-L-002. Cathodic
protection shall be provided for underground piping as per specifications,
as dictated by the relevant project requirements. Concrete pits shall be
provided for all valves located below grade.
4.1.16 Where piping takes off above ground from below ground, isolation joint
shall be provided at the above ground / underground interface.
4.2

PIPE JOINTS AND FITTINGS

4. 2.1 Connections shall be either flanged, butt-weld, socket-welded or

threaded, as dictated by the material type and the piping specification.
Generally, butt-weld joints and fittings shall be used for carbon steel,
stainless steel and alloy steel pipes. Socket-welded and threaded
connections are not permitted for process service. Socket-weld joints are
permissible for utility pipes of size below 2. Threaded connections are
applicable for galvanized carbon steel piping of size 3 and below,
especially for instrument air service. Connections for non-ferrous pipes
are dictated by the relevant piping specifications.
4.2.2 Socket-weld and threaded fittings, where provided, shall conform to the
requirements of ASME B 16.11. Butt-weld fittings shall conform to the
requirements of ASME B 16.9 or MSS SP-75, as applicable, with the buttweld ends being bevelled to ASME B 16.25. Integrally reinforced
(proprietary reinforced) branch connections shall be forged or wrought
and shall conform to the requirements of MSS SP-97. Fittings not
covered in any of the international standards shall be as per the
Manufacturers standard.
4.2.3 Flanges shall be forged and shall conform to the requirements of ASME B
16.5 or ASME B 16.47, Series A / MSS SP-44, as applicable. For carbon
steel, stainless steel and alloy steel flanges, the flange face shall be
either raised face or ring type joint, as indicated in the relevant piping
specification. For raised face flange, face finish shall be generally smooth
for use with spiral wound gaskets, with a finish between Ra 3.2 and Ra
6.3 microns (125 to 250 AARH), in accordance with ASME B 46.1 / MSS
SP-6 and judged visually with a comparator block. For ring joint flanges,
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the gasket groove side wall shall have a surface finish of Ra 0.4 to 1.6
microns maximum to ASME B 46.1.
4.2.4

Flanges for cast iron and non-ferrous materials like copper, aluminum, etc
shall be of flat face.

4.2.5

Flange connections 6 NPS (150 NB) and larger for hydrogen service
operating at or above self-ignition temperature shall have smothering
steam rings to extinguish a possible fire from hydrogen leak. Flanges for
hydrogen service shall not be insulated.

4.2.6

Stud bolts for flange joints shall be fully threaded with two hexagonal,
heavy series, double chamfered nuts and shall conform to the
requirements of ASME B 18.2.1 and ASME B 18.2.2 for bolts and nuts
respectively. Diameter and length of stud bolts shall be as per ASME B
16.5 or ASME B 16.47, Series A / MSS SP-44, as applicable. Threads
shall be Unified Standard, Class 2A for bolts and Class 2B for nuts, in
accordance with Unified Inch Screw Threads, ASME B 1.1. Spiral wound
and metal ring-joint gaskets shall conform to ASME B 16.20, and nonmetallic gaskets to ASME B 16.21.

4.2.7

Flanges, bolting and ring-joint gaskets for wellhead pipe work shall
conform to API 6A.

4.3

VALVES

4.3.1

Valves shall comply with the requirements of QP Valve Selection Guide

ES.5.06.0014. However, in case of conflict between ES.5.06.0014 and
this document, the clauses in this document shall take precedence.

4.3.2

Required data shall be filled in the Valve Data Sheet in the QP provided
template, or any other template, as agreed.

4.3.3

The following types of valves are recommended for auxiliary

Drains
- gate or ball valves
Vents
- globe or ball valves
Sampling
- needle or globe valves
Utilities Hose Station - globe or ball valves
Level gauge
- gate or ball valves
Level instrument
- gate or ball valves
Pressure instrument - gate or ball valves
Orifice assembly
- gate or ball valves

4.3.4

Isolation valves shall be provided at all required locations in order to

facilitate isolation of equipment and systems for maintenance. In general,
ball valves are preferred for isolation. For applications 200 deg C and
above, gate valves shall be considered. However, valve types indicated
on the P&IDs shall have precedence.

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4.3.5

For piping class 900 and above, the piping system shall be
designed
with positive isolation by incorporating a double block and bleed system
consisting of two separate valves with a bleed connection in between and
provision of spades, as per the latest revision QP Fire and safety
Philosophy, QP-PHL-S- 001.

4.3.6

Ball valves shall be of the standard size reduced bore type, unless
otherwise process conditions demand the use of full bore valves, as
indicated in the respective Piping and Instrumentation Diagrams. Ball
valves of size 2 NPS (50 NB) and larger shall have integral double block
and bleed feature in both the open and closed positions in order to
facilitate complete flushing and draining of the valve body cavity and to
check the integrity of the seat. Further, for ball valves of size 2 NPS and
larger, the ball shall be trunnion-mounted.

4.3.7

Valve body pressure-temperature rating shall correspond with ASME B

16.34 and/or the respective flange rating as per ASME B 16.5. The body
and other pressure containing parts shall be designed in compliance with
ASME Sec VIII, Div I in order to satisfy the pressure-temperature rating.
Corrosion allowance, as applicable ,shall be considered in the design.
The minimum wall thickness obtained shall not be less than that specified
in ASME B 16.34, Table3. Valves shall also be designed to withstand a
sustained internal vacuum of at least one millibar in both the open and
closed
positions.
Valve
body
shall
have
sufficient rigidity to withstand a compressive axial thrust exerted by the
connected piping, equal to the design pressure multiplied by the area of
the maximum valve bore, without permanent distortion of the body or
affecting the free movement and sealing of the valve element.

4.3.8

Valve body / bonnet shall be forged / cast, as specified. Forgings are

acceptable in place of castings, but not vice versa. Fabrication from plate
material is not permitted. Material of construction of yoke shall be
equivalent to that of body / bonnet, or superior. Body joints with threads
are not permitted for process applications. The flanged joints shall be
designed to ASME Sec VIII, Div I. Welds, wherever applicable, shall be
made by fully qualified welders and in accordance with the provisions of
ASME Sec IX; only full penetration welds are allowed. Repair by welding
is not permitted for forged body valves; however, this is permitted for cast
body valves. Repair Welding Procedure and welding operators shall be
qualified in accordance with ASME Sec IX.

4.3.9

Valve stem shall be forged or machined from forged or rolled bar. Casting
is not permitted. Stem shall be sized such that it is capable of
withstanding the maximum operating torque required to operate the valve
against the maximum differential pressure as per the appropriate class.
The combined stress due to side load and operating torque shall not
exceed the maximum allowable stresses specified in ASME Sec VIII Div
I. The design shall take into account a safety factor of 1.5 based on the

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maximum output torque of the operating mechanism. The weakest point
of the stem shall always be outside of the stem seal.
4.3.10 Valve design shall ensure repair of gland packing under full line pressure.
4.3.11 Auxiliary vent and drain connections to the valve body shall be provided:
if the valves are trunnion mounted; if specified; if mandatory, as dictated
by the relevant Piping Class; or, if recommended by the Manufacturer.
These vent and drain connections shall comply with ASME B 16.34,
Clause 6.3 for Auxiliary connections. Vents shall be at the highest
position and drains at the lowest on the valve body. Vent connections
shall have a bleed fitting of an anti blow-out design. Drain connections
shall be provided with blind flange. Any connection that could result in
crevice corrosion like socket weld joints is not allowed; the connection
shall be full butt welded to the valve body in accordance with MSS SP 45,
Paragraph 6.3 and ASME B 31.3. Sizes of vent and drain connections
shall be in accordance with the requirements of MSS SP 45; valves of
size 4 NPS (100 NB) and smaller may have a combined vent and drain
connection. For valves of sizes 16 NPS (600 NB) and larger, the valve
body shall be fitted with a bleed device that may be opened and closed
against pressure and that cannot be unscrewed from the parent plug.
4.3.12 Pressure relief arrangement, if applicable for the valve as per API 6D,
Clause 6.8, shall comply with the relevant requirements of API RP 520 /
API RP 521 and ASME Sec VIII Div I.
4.3.13 Gate and globe valves shall be of Outside Screw and Yoke (OS&Y),
rising stem and hand wheel and bolted bonnet (BB) or cover (BC)
construction. Bolt threads shall be UNC to ASME B 1.1. Valves shall be
with back seat design and the seats shall be of renewable type. The
wedge or disc, as the case may be, shall be loosely attached to the stem
and hence, renewable. The stem, which is held by the bonnet or cover,
shall be of the anti blow-out type.
4.3.14 Dual plate check valves shall not be used for abrasive services (for
instance, crude containing sediments).
4.3.15 All valves in hydrocarbon service shall be of fire-safe design. In the
case of dual plate check valves, only flanged or solid lug valves shall be
used in hydrocarbon service; wafer type valves shall not be used.
4.3.16 Valves shall be leak-tight, and shall conform to the requirements of
Tables 4 and 5 of API 598.
4.3.17 Threaded and socket welded connections are not permitted for valves in
process service. Flanged valves shall have the flanges integrally cast or
forged with the body. Where the end flanges are welded to the valve
body, if agreed to by QP, the flanges shall be cast or forged with buttwelding ends, and attached to the valve body by full penetration butt
welds. Flanged ends shall have the flange dimensions as per ASME B
16.5 for sizes 24 NPS (600 NB) and below, and as per ASME B 16.47
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Series A / MSS SP 44 for sizes above 24 NPS (600 NB). Flange face
shall be either raised face or ring type joint, as specified. For raised face
flange, face finish shall be smooth for use with spiral wound gaskets,
with a finish between Ra 3.2 and Ra 6.3 microns (125 to 250 AARH), in
accordance with ASME B 46.1 / MSS SP 6. For ring joint flanges (Class
900 and above), the gasket groove side wall shall have a surface finish of
Ra 0.4 to 1.6 microns.
4.3.18 Materials of construction of the valves shall be suitable for the process,
design and environmental conditions. Except for utility service, the
materials shall be suitable for sour service and conform to the
requirements of latest revision of NACE MR 0175 / ISO 15156 and QP
Specification QP-STD-R-001. Materials of construction shall be selected
to minimize the risk of seizure of working parts, covers or bolts due to
cryogenic temperature. Valve design shall avoid bimetallic corrosion
between carbon steel and high alloy components used in the assembly.
Suitable insulation shall be provided as required. Further, the design shall
ensure that no galling of contacting stainless steel surfaces can occur.
4.3.19 Where AISI 316 material is used for the trim in place of F316, Due
Penetrant (DP) / Liquid Penetrant (LP) tests shall be done.
4.3.20 All carbon steel castings and forgings shall be furnished in the
normalised, normalised and tempered or quenched and tempered
condition. Austenitic stainless steel shall be furnished in the solution
annealed condition. All heat treatment shall comply with the requirements
of NACE MR 0175 / ISO 15156 and QP-STD-R-001, as applicable.
4.3.21 Identification shall be maintained on materials and parts in order to
facilitate traceability, as required by documented Manufacturer
requirements. All items shall be traceable to a specific heat and heat treat
lot.
4.3.22 Stem seals, body seals and gaskets shall be of asbestos free material
suitable for the service conditions and the pressure-temperature ratings.
Acceptable seal materials are VITON Gr. B, F, GF or HNBR. VITON A
shall not be used. Stem and gland packing material shall be flexible
graphite / inhibited Grafoil or equivalent, Reinforced PTFE, PTFE
impregnated graphite, etc. While selecting seal and packing materials,
capability of the materials to withstand test pressure corresponding to the
valve rating, shall be checked, especially in the case of valves for low
temperature service.
4.3.23 Valves of sizes 8 NPS (200 NB) and above or 250 kg and heavier shall
be equipped with lifting lugs. Tapped holes and eye bolts shall not be
used for lifting. All valves 12 NPS (300 NB) and above shall be provided
with base support (support feet or ribs). Height of support feet shall be
kept minimum.

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4.3.24 Manually operated valves shall be operated by a lever, wrench or hand
wheel. The direction of operation shall be clockwise for closing the
valves. The effort required to apply the breakaway torque against the
maximum differential pressure shall not exceed 350 N. Where the effort
required to operate the valve exceeds 350 N, gear operators shall be
provided. Provision of gear operator shall be guided by QP Standard
ES.5.06.0014. The maximum output torque of the gear operator shall be
at least 1.5 times the required maximum operating torque of the valve.
Gear operator shall be heavy duty, totally enclosed, grease-filled, selflocking type, dust and weather proof to IP 55, suitable for outdoor
installation. [Where specified, the gear enclosure shall be water
proof/splash proof to IP 65.] The gear operator shall be adjustable at 45
degree increments in the field.
4.3.25 Valves shall have locking devices to lock the valve either in the full open
(Lock Open or LO) or full close (Lock Close or LC) position. It can be
suitable brackets fitted on the valve to facilitate locking using pad locks
and chains. Valves shall be supplied with mechanical interlocks, if
specified. The supply shall include interlock units, set of keys, and key
cabinet to be placed in the control room. The interlock system shall be of
Trapped Key Mechanical Interlock System, the sequence of logic being
as indicated in the Data Sheet.
4.3.26 All valves and their actuators, where fitted, shall be marked and identified
as per ASME B 16.34 / appropriate design standard. Each valve shall be
tagged with rigid stainless steel identification or tag plate, securely
attached to the body with four stainless steel screws at each corner of the
tag plate. The following information, with metric units as applicable, shall
be die stamped or deep engraved on the tag plate: Valve Manufacturers
name, Model Number and Serial Number, with year of manufacture; Body
Material, Rating and Size; Trim Size and Material; Service, Purchasers
Valve Tag Number and Purchase Order Number.
4.3.27 Inspection and Testing:
4.3.27.1 The Manufacturer shall perform all inspection and tests at his works as
per the requirements of this document, and the relevant codes, as
appropriate.
4.3.27.2 All valves shall be visually inspected as per MSS SP 55.
4.3.27.3 Dimensional check on all valves shall be carried out as per the
drawings approved by QP/Purchaser.
4.3.27.4 Chemical composition and mechanical properties, including hardness,
shall be checked as per relevant material standards for each heat of
steel used. Tension tests and hardness tests shall be carried out in
accordance with ASTM A 370. For austenitic stainless steel valves,
Inter-Granular Corrosion (IGC) Test shall be conducted as per ASTM A
262 Practice B, with the acceptance criteria being 60 mils per year for
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all types of materials (forgings, rolled stocks, wrought stocks and
castings). Alternatively, IGC shall be done as per ASTM A 262 Practice
E, with the acceptance criteria of No cracks as observed from 20 X
magnification for all material types other than castings. In addition,
microscopic structure shall be observed from 250 X magnification.
4.3.27.5 Charpy V-notch impact test shall be done, where specified, as per
ASTM A 370. Impact testing is applicable for valves if it is applicable for
the corresponding piping, as dictated by the relevant Piping Class
Specification. Normally, impact testing is done for applications below (-)
29 deg C. However, impact testing is required for valves of sizes 16
NPS (400 NB) and above, irrespective of the temperature. For impact
testing, the energy requirements shall be as per QP-STD-R-001.
4.3.27.6 Non Destructive Examination shall be carried out on individual valve
components consisting of but not limited to castings, forgings and
assembly welds. Body and bonnet or cover sections made of castings
shall be radiographically examined on 100 % of the critical areas as per
the procedures and acceptance criteria of ASME B 16.34, Annexure B.
Body and bonnet or cover sections made of forgings shall be
ultrasonically examined on 100 % of the critical areas in accordance
with the procedures and acceptance standards of Annexure E of ASME
B 16.34, or examined by radiography in accordance with the
procedures and acceptance standards of Annexure B of ASME B 16.34.
All exterior and accessible interior surfaces of castings and forgings
shall be given a surface examination on 100 % of the surfaces by Wet
Magnetic Particle Examination or Liquid Penetrant Examination.
Examination shall be done in the final machined condition. Method and
acceptance shall be as per MSS SP 53 or ASME B 16.34, Annexure C
for Magnetic Particle Examination and ASME B 16.34, Annexure D for
Liquid Penetrant Examination. Bodies and bonnets made by weld
assembly of segments of castings and forgings shall be examined by
the methods indicated above for castings and forgings, as applicable. In
addition, all fabrication welds shall receive radiography examination in
accordance with ASME Sec VIII Div I in a manner that results in a weld
joint efficiency of one (1.0). Welds, which cannot be inspected by
radiography methods, shall be inspected by ultrasonic or magnetic
particle methods, the procedures and acceptance criteria for which shall
be as per ASME Sec VIII Div I, Appendix U and Appendix VI
respectively.
4.3.27.7 Hydrostatic testing of the body and seat shall be carried out in
compliance with the requirements of API 6D, API 598 or BS 6755 Part I,
as specified in the Valve Data Sheet. During pressure testing, valves
shall not have cavities filled with sealant, grease or other foreign
material. The vent, drain and sealant lines shall be either included in the
shell pressure test, or tested independently. Valve stem packing used
for hydrostatic testing shall be of the same type or style as that
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ultimately shipped with the valve. After hydrostatic testing and
acceptance, valve test packing and traces of test fluid shall be removed
from the internal parts and all components shall be thoroughly drained,
dried and cleaned. Drying of valve internals shall be with compressed
air and lint free rags. The internal surfaces shall be coated with suitable
water dispelling anti-corrosion fluid. To ensure total coverage, the valve
shall be placed in the half open position, filled with the fluid and then
drained. The packing shall be replaced with unused dry packing and
compressed to the required packing design pressure. The quality of
water to be used for hydrostatic testing is indicated in Section 4.6.2 of
this document.
4.3.27.8 Backseat test shall be carried out on all valves as per API 598. The
backseat test shall be done immediately after the shell test, and all
packing glands shall be retightened after the backseat test.
4.3.27.8.1 A supplementary air (pneumatic) seat test shall be carried out for all
valves as per API 6D/API 602, if specified.
4.3.27.8.2 Valves shall be subject to operational torque test under a hydraulic
pressure equal to the maximum differential pressure corresponding to
the valve rating at normal ambient temperature conditions. For
manually operated valves, it shall be established that the effort
required to apply the breakaway torque or thrust shall not exceed 350
N.
4.3.27.8.3 Power actuated valves shall be tested, after assembly of the valve and
actuator, at the valve manufacturers works. At least, five open-closeopen cycles without internal pressure and five open-close-open cycles
with maximum differential pressure shall be performed on the
valve/actuator assembly. The breakaway torque as well as the time
elapsed from fully open to fully closed position shall be recorded during
testing. The actuator shall be adjusted to ensure that the opening and
closing time is within the limits stated on the Actuator Data Sheet. The
hand operator provided on the actuator shall also be checked after the
cyclic testing for satisfactory manual over-ride performance. The above
tests shall be conducted on a minimum of one valve out of a lot of five
valves of the same size, rating and actuator model/type. If the tests do
not meet the specified requirements, re-testing or rejection of the lot
shall be decided by the Inspector.
4.3.27.8.4 For valves fitted with mechanical interlocks, the sequence of the logic
shall be checked for a particular set of valves. A test report shall be
produced and submitted.
4.3.27.8.5 In the case of ball/plug valves, surface contact test shall be done. The
ball/plug shall be dressed with Engineers blue and placed into the
body so that the weight of the ball/plug presses against the ball
cavity/plug taper. If necessary, the cover may be placed in the open
position. The ball/plug shall then be operated from fully open to fully
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closed position three times. The body bore and ball/plug surface shall
be examined for surface contact. The surface contact shall be, at least,
90 % of the total area. The non-contact area must be distributed in
such a way as not to propagate leaks. The surface contact test, when
specified, shall be witnessed by a Third Party Inspector. The
witnessing may be waived if the plug and body are lapped together
and subsequently vacuum tested in dry conditions for a perfect match.
4.3.27.8.6 For valves in hydrocarbon service, fire testing shall be carried out in
accordance with the requirements of API 607, API 6FA, API 6FD or BS
6755 Part 2, as appropriate. Type test certificates endorsed by a
Third Party Inspection Agency shall be made available; or else,
individual testing shall be carried out.
4.3.27.8.7 Before commencement of manufacture, an Inspection and Test Plan
(ITP) shall be prepared and submitted for review and approval. The
ITP shall include all quality related activities, reference standards,
acceptance criteria, verification documents, Supplier responsible
persons and inspection mark-up.
4.3.27.8.8 Where Third Party Inspection (TPI) is called for, the Manufacturer
shall appoint a reputable Third Party Inspection Agency TPIA
(Lloyds, ABS, DNV, BVQI, Velosi, etc., as indicated in the Preferred
Vendors List) to carry out all inspection and tests at his works prior to
shipment. QP also reserve the right to perform stage-wise inspection
and witness the tests at the Manufacturers works. The Manufacturer
shall give a reasonable notice of time (minimum two weeks) and shall
provide, without charge, reasonable access and facilities required for
inspection. QP may, at their discretion, appoint a Third Party
Inspection Agency to carry out inspection on their behalf or together
with them.
4.3.27.8.9 Manufacturer shall submit material certificates at the time of despatch
in accordance with EN 10204 type 3.1 or type 3.2, as specified. Only
those items that have been certified as approved by QPs Inspector or
TPI shall be despatched from the Manufacturers works.
4.3.27.8.10 All valves of size 2 NPS (50 NB) and greater shall be tested in the
State of Qatar in accordance with API 598, following receipt at the
construction site. Testing shall be done by the (EPIC) Contractor as
per approved testing procedure at the Contractors own valve
testing facility approved by QP, or at an independent workshop
approved by QP. This test shall be witnessed by QP or their
authorised representative. Test certificates shall be issued for QP
approval and records.
4.4

LAYOUT

4.4.1

Plant layout design shall consider safety, operability and

inspection/maintenance aspects of the plant. Spacing and layout of the

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units shall be done in such a way that they are economical, ergonomical,
safe and in compliance with QP Fire and Safety Philosophy, QP-PHL-S001 and Hazardous Area Classification requirements. Piping layout and
pipe racks/pipe supports shall be engineered in such a way that crane
route is not blocked and all plant equipment and package units are
easily accessible for operation, maintenance and removal/replacement.
Equipment layout and piping design shall take into consideration QRA
findings as applicable, and shall also ensure drainage, venting and
isolation facilities for safe operation and maintenance of the equipment
and associated facilities as well as hydrostatic testing of the pipe-work.
4.4.2

Equipment sizes and maximum skid dimensions shall be considered

against the backdrop of site limitations in the detailed design.

4.4.3

All valves and instruments shall be located for easy operation and
maintenance. Access platforms or walkways shall be considered
wherever required for this purpose.

4.4.4

Process piping shall be avoided in closed pipe trenches in order to

avoid accumulation of hydrocarbon vapours. For piping in open
trenches, the
minimum clearance shall be 100 mm between the
underside of any piping component and the trench bottom.

4.4.5

Piping entering or leaving the plot area or a processing unit shall be

grouped together. Lines with expansion loops shall also be grouped
together, such that the heaviest and hottest pipes are located at the
sides of the pipe rack. This will facilitate provision of expansion loops
and will reduce the stresses in the beams on account of weight and
thermal expansion of the pipes. Pipes on sleepers shall also be
grouped together in similar fashion in order to facilitate provision of
expansion loops; however, where horizontal expansion loops are not
possible on account of space constraints, the loops shall be horizontal
with vertical take-offs, or completely vertical.

4.4.6

Pipes entering or leaving the process area shall have isolation valves at
the battery limits and shall be grouped together. A spectacle blind or
spade/spacer shall be installed down stream of the isolation valve, as
appropriate.

4.4.7

Minimum distance between two non-insulated pipes in the pipe

bridges/racks, sleepers or pipe trenches shall be 75 mm, measured
edge to edge, and 25 mm, measured between the outer edges of
flanges of two adjacent pipes or outer edge of flange of one pipe and
the outer edge of the adjacent pipe, as the case may be. Flanges shall
be staggered on adjacent pipes. For insulated pipes, the above
dimensions apply to the edge of insulation. Distance between the pipes
shall allow for handling of spectacle blinds or spades/spacers.

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4.4.8

4.4.8.1
4.4.8.2
4.4.8.3
4.4.8.4

Sufficient head-room shall be provided for cranes, hoists, tackles, etc.

Minimum overhead clearance to the bottom of pipe or pipe support shall
be:
5.5 m - for cranes, hoists, emergency vehicles and other tall vehicles
4.0 m - for truck access
3.0 m - for forklift and small vehicles in aisles for equipment and
machinery
2.3 m - for walkways and platforms for personnel

4.4.9

Lines crossing walkways and roads in the plant area shall be installed
below ground in culverts or buried, or installed overhead on pipe bridge,
as appropriate. The ends of the culvert shall be kept open in order to
prevent accumulation of hydrocarbon vapours. Where the line is buried,
pipe sleeve shall be used, and the pipe shall be kept centrally in the
sleeve by guide pieces welded to the pipe or fixed to the sheeting if the
line is insulated. Minimum overhead clearance to the bottom of pipe
bridge shall be 5.5 m m.

4.4.10

Cut-outs in walls and floors shall be sealed after piping installation in

order to avoid chimney draught in case of fire and to prevent liquid
dripping and falling of debris onto a lower deck. At the location of the
cut-outs, the line shall be installed in steel pipe sleeves. Openings in
bund walls at the location of pipe crossings shall be
properly sealed

4.4.11

Walk-over platforms over pipes shall have minimum clear width of 800
mm.

4.5

PIPE SUPPORTS AND STRESS ANALYSIS

4.5.1

Design, supply, fabrication and installation of supports for piping

systems shall comply with the minimum requirements specified in QP
Standard ES.5.14.0021: Specification for Pipe Supports.

4.5.2

Adequate supports shall be provided in order to cater to the static and

dynamic loads acting on the piping system, and provision for piping
expansion shall be made in order to prevent overstressing of the
system. Supports shall prevent piping from excessive sagging and
vibration. Supports shall be arranged such that valves and other pieces
of equipment or instruments can be easily dismantled for inspection,
maintenance and servicing without the use of temporary supports.

4.5.3

Supports shall be provided very close to equipment/machinery in order

to avoid excessive loads on the equipment nozzles and to ensure that
equipment and associated piping are free of stresses for the ease of
machinery/train alignment.

4.5.4

Piping shall not be supported from the equipment to the extent possible,
except in the case of piping from tall columns or top of storage tanks, in
which case, suitable support brackets have to be provided on the

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equipment. As far as possible, supports shall not be provided under
elbows and tees or from the valve flanges.
4.5.5

Where pipes are supported on concrete sleepers on-plot or off-plot, the

sleeper height shall be 300mm above grade level.

4.5.6

Direct contact between dissimilar materials like stainless steel pipe on

G.I. support or G.I. pipe on steel support shall be avoided in order to
prevent galvanic corrosion. Suitable isolating material shall be provided.

4.5.7

In the case of skid piping, pipe supports shall be welded to the skid
structural members and should be vibration free.

4.5.8

Tubing, where applicable, shall be neatly installed and rigidly

supported without any vibration on the supports.

4.5.9

Piping system shall be adequately designed to allow for dead loads

(empty and full conditions), thermal movements, wind loads, vibration,
hydrostatic loads produced during testing, and loads arising on account
of pipeline surges, if any, relief valve blowing during normal operation,
vortex shedding, water hammer, etc. Piping Stress (Flexibility) Analysis
shall be undertaken in order to verify that stresses in piping, as
designed, do not exceed code-defined allowable limits, and forces and
moments on the various nozzles are within acceptable limits.

4.5.10

Pipe flexibility analysis shall include relevant existing pipe sections up to

existing fixed anchor supports in order to complete the stress model, so
as to incorporate the effect of displacements and stresses of the
existing system on the new system.

4.5.11

Pipe stress analysis shall be performed using the latest version of the
software CAESAR II or AUTOPIPE, or any other equivalent or superior
software. A soft copy of the model, with input and output files along with
the required number of hard copies shall be forwarded for QP review.

4.5.12

Use of expansion bellows to accommodate pipe expansion shall be

avoided and be limited to cases where severe space constraints are
encountered, or for hot process service. QP approval is required for
using the same.

4.5.12

Where required, installation stress calculations shall be furnished.

4.5.13

Stress analysis and pipe supports for GRE piping shall be engineered
by GRE pipe manufacturer.

4.6
4.6.1

DELIVERABLES
A comprehensive list of deliverables is included in another Attachment.

4.6.2

CONTRACTOR shall provide tie-in drawings and details associated

with the new installation, based on a tie-in philosophy ensuring
minimum plant shut down requirements. A Method Statement covering
change-over procedure from the existing installation to the modified
facilities with minimum shut down requirements shall be produced and
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APPENDIX A
included along with the constructability analysis in the Design Basis
Memorandum.
4.6.3

CONTRACTOR shall review the FEED / Conceptual drawings provided

in Appendix F and prepare new drawings based on the list of
deliverables, as appropriate, and submit the same in packages as per
the approved Technical Document Register (TDR).

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PART 2

Fabrication and Testing

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General
The pipework and fittings to be fabricated and installed under this
CONTRACT shall be in accordance with the requirements of the relevant
standards listed in the specification.

Fabrication and Inspection

The pipe work shall be fabricated, inspected and tested in accordance with
following:

2.1 Engineering Standard QP-STD-R-002 (Formerly ES.5.14.0010)

Specification For Fabrication, Inspection And Installation Of Carbon,
Carbon-Manganese And Low Alloy Ferritic Process Pipe work
(addendum to ASME B 31.3).
2.2 Engineering Standard QP-STD-R-003 (Formerly ES.5.14.0020)
Specification For Fabrication, Inspection And Installation Process Pipe
work in Austenitic Stainless Steel, Copper Base and Nickel Base Alloy
(addendum to ASME B 31.3).
2.3 ASME B 31.3: ASME Code for process piping. Where there is a conflict
between various QP guides and ASME B 31.3, the most stringent
requirement, as decided by QP, shall apply.

Welding Procedure Qualification Tests

3.1 Prior to commencement of WORK, CONTRACTOR shall submit to QP

his proposed welding specifications in accordance with the listed
standards.
3.2 On receipt of approval of the specifications, CONTRACTOR shall carry
out the appropriate welding procedure qualification tests and welds in
accordance with the Standards.
3.3 QP REPRESENTATIVE shall witness all welding procedure qualification
test welds. CONTRACTOR shall give notification in writing to QP, one
(1) week in advance of the proposed test.
3.4 The results of all tests shall be submitted to QP for approval.

Qualification of Welders

4.1 All welders shall be qualified using the approved welding procedures.
4.2 CONTRACTOR shall maintain adequate records of each welders work,
as required by the relevant codes.

Repair of Welds

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5.1 Prior to commencement of WORK, CONTRACTOR shall submit to QP
proposed weld repair procedure specifications, for approval, in
accordance with the listed Standards.
The repair procedure
specification shall be qualified by the repair of test coupons.
CONTRACTOR shall give one (1) week notification in writing to QP so
that all weld repair procedure qualification tests may be witnessed by QP
REPRESENTATIVE.
5.2 Weld repairs must be agreed by QP prior to commencement of the
WORK.
5.3 Following the repairs, the welds shall be inspected and tested in
accordance with the Listed Standard. Weld repairs and subsequent
N.D.T. costs shall be borne by CONTRACTOR.

6 Joint Alignment/Weld Preparation

6.1 Joint alignment and end preparation shall be in accordance with the
Listed Standards. Any deviation from the tolerances specified shall result
in the weld being cut out and the joint remade.
6.2 The use of backing rings is not permitted.
6.3 There shall be no measurable angle formed at butt welds either before or
after welding. Where such an angle is observed, after completion of
welding the weld will be cut out and the joint remade, in accordance with
Listed Standards. The cost to all repairs of welds and N.D.T. shall be
borne by CONTRACTOR.

7 NON-DESTRUCTIVE TESTING
7.1 All non-destructive testing shall be carried out in accordance with the
listed Standards.
7.2 For radiographic and magnetic particle examination level of welds, the
following shall apply:
7.2.1 Tie-ins to existing pipework and fittings: 100% RT and 100 % MPI.
7.2.2 Other NDT requirements shall be as per QP-STD-R-002 and QP-STDR-003.
7.3 Where 10% Radiography is specified, failure of one of the joints shall
result in a further 10 50 % of the remaining welds of the same welder
being randomly selected by QP REPRESENTATIVE for radiographic
examination, at CONTRACTORS expense. In case of a further failure,
100% radiography shall be undertaken at CONTRACTORS cost.
Offending welders shall be retested and/or put off Site, at QPs discretion.
7.4 Where less than 100% Radiography has been specified, all welds to be
examined shall be identified by QP REPRESENTATIVE.
7.5 The Welding Inspector shall prepare a written interpretation of
radiographs for submission, within 48 hours of completion of the weld(s).
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7.6 Ultrasonic inspection of welds shall be carried out where circumstances
demand, and/or where deemed necessary by QP, and in accordance with
the listed Standards.
7.7 CONTRACTOR shall provide N.D.T. services to meet the requirements of
the listed Standards.
7.8 CONTRACTOR shall be responsible for all costs associated with the
provision of approved NDT services. This shall include, but not be limited
to, the provision of all materials, equipment, facilities, qualified operators,
inspectors and consumables.

5
5.1

TESTING
GENERAL

5.1.1 CONTRACTOR shall inspect and test by appropriate methods all items
of equipment prior to and after installation. Such testing shall include
but not be limited to the procedures and tests set out in this
Specification.
5.1.2 CONTRACTOR shall provide all test rigs, gauges, pressure raising
equipment, pressure recording instruments welding caps, pigs spades
and blinds, temporary pig traps, and all other equipment necessary to
satisfactorily carry out the testing as specified.
5.1.3 All gauges are to be calibrated by CONTRACTOR within one (1) week
prior to the date of testing, and a valid test certificate authorised by an
approved testing body shall be available.
5.2

HYDROSTATIC TESTING (PIPING SPOOLS)

5.2.1 CONTRACTOR shall define and detail the piping spools on piping
drawings, all pipework shall be subject to a pressure testing, and shall
be carried out in accordance with listed standards.
5.2.2 The hydrostatic tests shall be witnessed by QP REPRESENTATIVE
and tested in accordance with the listed standards. Test pressure shall
be maintained for a sufficient period of time to enable QP
REPRESENTATIVE to satisfy himself that the test is acceptable. A
section of piping shall be deemed to have failed the test due to
leakage, if any loss of water is recorded when the piping is held at full
test pressure.
5.3

HYDROSTATIC TESTING (INSTALLED SYSTEM)

5.3.1 CONTRACTOR shall carry out the hydrostatic testing in accordance

with the minimum requirements of ASME B31.3.
5.3.2 The minimum hydrostatic test duration shall be as follows:
a) Above ground piping

1 hour.

5.3.3 If the system is likely to be subjected to thermal expansion during the

hydrostatic test, precautions must be taken to avoid overpressure.
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Short term tests of maximum duration 1 hour should be undertaken
early morning or late afternoon if possible.
5.3.4 The supply of sweet potable water to be used for hydrostatic testing
shall be provided and disposed of by CONTRACTOR, and QP
REPRESENTATIVE shall approve the quality of the water prior to use.
5.3.5 CONTRACTOR shall supply a time/pressure chart recorder indicating
test pressure, and temperature where specified, and shall complete a
QP Standard Hydro-test Certificate for each spool piece tested. The
hydrostatic tests shall be witnessed and approved by QP
REPRESENTATIVE.
5.3.6 CONTRACTOR shall display warning notices, in positions designated
by QP REPRESENTATIVE, during hydrostatic testing.
5.3.7 Additional piping welds shall not be permitted after completion of the
final hydrostatic test.
5.3.8 CONTRACTOR shall be responsible for the removal of hydrostatic test
equipment, after hydrostatic testing, and remaking joints, to the
satisfaction of QP REPRESENTATIVE.
5.3.9 QP REPRESENTATIVE reserves the right to reject any part of the
piping system which in his opinion, does not conform with project
specifications, or fails to meet with testing and inspection
requirements.
Any equipment which is rejected by QP
REPRESENTATIVE shall either be replaced, or rectified as directed by
him, and cost shall be borne by CONTRACTOR.
5.3.10 All hydrostatic test equipment, including facilities for collecting,
transporting and removing water and electrical power, shall be
provided by CONTRACTOR, and shall be approved by QP.
5.3.11 CONTRACTOR shall dispose of the hydrostatic testing water safely
and without risk to the environment.
5.3.12 In addition to foundation level survey prior to erection, level surveys
shall be performed of the tank periphery for settlement at regular
intervals before hydro testing, during hydro-testing (at full, full,
full and full), and after emptying, the reading shall be recorded. All
level and settlements shall be measured with optical survey apparatus.
The reading record shall be submitted for QP review/approval.
5.3.13 Any additional materials required for testing and commissioning shall
be provided by CONTRACTOR at his expense.

INTERNAL CLEANING OF PIPEWORK

6.1

CONTRACTOR shall be responsible for ensuring that the internal

surfaces of all pipe-work are thoroughly cleaned before
commissioning.

6.2

The procedure adopted is to include the following as a minimum:

6.2.1 Compliance with the clauses of this Specification, relating to packing

and marking, galvanising and painting.
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6.2.2 Thorough cleaning of all internal surfaces prior to erection to remove
accumulations of dirt, rust, scale, and welding slag.
6.2.3 Prior to, and during erection, all parts shall be inspected to make sure
that they are clean, and adequate steps shall be taken to prevent entry
of foreign matter both during and after erection. Each section erected
shall be cleaned out before the next section is connected to it. All
headers shall be cleaned before closing up.
6.2.4 Thorough cleaning of all pipe-work after erection by blowing through to
atmosphere with steam or flushing with water.

7
7.1

MARKING
Stencil marking of line designation and direction of flow shall be made
at all locations of entry, change in direction, branch and exit. Colour
coding/banding shall be done in accordance with the requirements of
QP Technical Specification for Painting and Wrapping of Metal
Surfaces QP-SPC-L-002.

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