Вы находитесь на странице: 1из 34

CARIGALI – PTTEPI OPERATING COMPANY

SDN BHD

CPOC

CPOC GENERAL SPECIFICATION


(CGS)

PIPING DESIGN, FABRICATION AND


INSTALLATION
CPOC-GS-PI-0001

0 16/02/11 APPROVED FOR DESIGN Devdatt Pongpun

REV DATE DESCRIPTION BY CHKD FINALIZE APPD APPD


Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 1 of 31

TABLE OF CONTENTS
1.0 SCOPE 2
2.0 REFERENCES 2
2.1 Industry Codes and Standards 3
2.2 CPOC General Specifications 6
3.0 GENERAL 6
3.1 Definitions 6
3.2 Abbreviations 8
3.3 Piping Design 9
3.4 Piping Layout 12
3.5 Piping Connections 21
3.6 Pipe Supports and Piping Flexibility 23
4.0 FABRICATION REQUIREMENTS 24
4.1 General 24
4.2 Welding 25
4.3 Heat Treatment 27
4.4 Non Destructive Testing (NDT) Requirements 27
4.5 Particular Case of Welds of Piping Supports 28
5.0 INSTALLATION REQUIREMENTS 29
5.1 General 29
5.2 Installation of Valves 29
5.3 Installation of Threaded Assemblies 29
5.4 Installation of Flanged Assemblies 30
5.5 Installation of Line Blinds, Spectacle Blinds and Blind Flanges 30
6.0 PROTECTIVE COATING 30
7.0 INSPECTION AND TESTING REQUIREMENTS 30
7.1 Pressure Tests 30
7.2 Final Inspections 31
8.0 ATTACHMENTS 31
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 2 of 31

1.0 SCOPE
This Specification describes the minimum requirements for the design, fabrication and
installation of piping. It applies to piping for all types of process fluid services and all utility fluid
services in offshore oil and gas production and process facilities. Sanitary sewers, pipelines
and pipeline facilities are excluded from the scope of this specification.

2.0 REFERENCES
The reference documents listed below, including Industry Codes and Standards and
COMPANY specifications, form an integral part of this General Specification. Unless
otherwise stipulated, the applicable version of these documents, including relevant
appendices and supplements, is the latest revision published on the effective date of the
contract.
The overall order of precedence of the applicable documents shall be:
1) Government Laws, Rules and Regulations
2) Purchase Order/ Service Order/ Contract Documents
3) Project Particular Specification (PPS)
4) Company General Specification (CGS)
5) Codes and Standards in reference
Any conflict between any of the Contract Documents, or between this specification and any
other Contract Document, shall be reported to the COMPANY for decision. In such a case,
and unless otherwise agreed or decided by the COMPANY, it is understood that the more
stringent requirement shall apply.
Exceptions to, or deviations from this specification are not permitted unless previously
accepted in writing by the COMPANY. For this purpose, requests for substitutions or changes
of any kind shall be complete with all pertinent information required for COMPANY
assessment. COMPANY’s approval, nevertheless, will not, in any way, relieve the
responsibility of the Supplier to meet the requirements of the industry Codes and Standards
referred to and amended herein, in the event of conflict.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 3 of 31

2.1 Industry Codes and Standards

Reference Title

ASME Standards

ASME Section I Power Boilers

ASME Section VIII,


Rules for Construction of Pressure Vessels
Div.1

ASME Section V Non Destructive Examination

ASME Section IX Welding and Brazing Qualifications

ASME B1.1 Unified Inch Screw Threads (UN & UNR Thread Form)

ASME B1.20.1 Pipe Threads General Purpose (Inch)

ASME B16.5 Steel Pipe Flanges and Flanged Fittings

ASME B16.9 Factory-made Wrought Steel Butt welding Fittings

ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves

ASME B16.11 Forged Steel Fittings, Socket Welded and Threaded

Metallic Gaskets for Pipe Flanges- Ring Joint, Spiral Wound,


ASME B16.20
and Jacketed

ASME B16.21 Non-metallic Flat gaskets for Pipe Flanges

ASME B16.34 Valves- Flanged, Thread and Welded End

ASME B16.36 Orifice Flanges

ASME B16.47 Large Diameter Steel Flanges

ASME B16.48 Steel Line Blanks

ASME B18.2.1 Square and Hex Bolts and Screws (inch)

ASME B18.2.2 Square and Hex nuts (inch)

ASME B31.3 Process Piping

ASME B36.10 Welded and Seamless Wrought Steel Pipe

ASME B36.19 Stainless Steel Pipe

ASME B46.1 Surface Texture Surface Roughness, Waviness and Lay


Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 4 of 31

API Standards

API RP 2A Planning, Designing and Constructing Fixed Offshore Platforms

Recommended Practice for Analysis, Design, Installation and


API 14C
Testing of Basic Surface Safety Systems for Offshore Platforms

Recommended Practice for Design and Installation of Offshore


API RP 14E
Production Platform Piping Systems

Recommended Practice for Design and Hazard Analysis for


API RP 14J
Offshore Production Facilities

Sizing, Selection and Installation of Pressure - Relieving


Devices in Refineries
API RP 520
Part I “Sizing and Selection”
Part II “Installation”

Recommended Practice for Installation of Pressure Relief


API RP 521
Valves

Recommended Practice for Design, Construction, Operation,


API RP 1111
and Maintenance of Offshore Hydrocarbon Pipelines

Inspection, Repair, Alteration and Re-rating Of In-Service


API 570
Piping Systems

API 5L Line Pipe

API 6A Wellhead and Christmas Tree Equipment

API 6D Pipeline Valves (Gate, Plug, Ball, Check Valve)

API 6FA Specification for Fire Test for Valves

API 590 Steel Line Blanks

API 594 Check Valves - Wafer, Wafer-Lug and Double Flanged Type

API 598 Valve Inspection and Testing

API 599 Metal Plug Valves- Flanged, Threaded and Welding Ends

API 600 Steel Gate Valves, Flanged or Butt welded Ends

API 602 Compact Carbon Steel Gate Valves

API 607 Fire Test for Soft Seated Quarter-Turn Valves

API 608 Metal Ball Valves - Flanged, Threaded and Welding Ends

API 609 Butterfly Valves - Double Flanged, Lug, and Wafer- Type
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 5 of 31

MSS Standards

Standard Finished on Contact Faces of Pipe Flanges and


MSS SP 6
Connecting Ends Flanges of Valves and Fittings.

Standard Marking System for Valves, Fittings, Flanges and


MSS SP 25
Unions.

Quality Standard for Steel Castings for Valves, Flanges and


MSS SP 55 Fittings and Other Piping Components Visual Inspection
Method.

Pipe Hangers and Supports – materials, design and


MSS SP 58
manufacture

MSS SP 69 Pipe Hangers and Supports – selection and application

MSS SP 75 Specification for High Test Wrought Butt Weld Fittings

Integrally Reinforced forged Branch outlet fitting socket


MSS SP 97
welding, Threaded and Butt welding ends

AWS Standards

AWS D1. 1 Structural Welding Code, Part III of Section 6

NFPA Standards

NFPA 13 Fire Water System for Offshore Installations

European Standard

BS EN 10204 Inspection Documents for the Delivery of Metallic products

Pipe Fabricators Institute Standards

ES-11 Permanent Identification of Piping Material

EEMUA 90:10 Copper Nickel Piping

EEMUA No 144 Section 1 Seamless Piping

EEMUA No 144 Section 2 Seamless Weld Pipe

EEMUA No 146 Pipe Fitting

EEMUA Publication ‘O’ Annealed Properties

NACE

National Association of Corrosion Engineers: Standard


NACE MR 0175 / ISO Material Requirements; Sulfide Stress Cracking Resistant
15156 Metallic Materials for Oilfield Equipment/Materials for Use in
H2S Containing Environments in Oil and Gas Production
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 6 of 31

In addition to the requirements of this Specification, all requirements of the governing


authority, i.e., the country and/or its subdivisions where the piping is to be installed
shall be met.

Non metallic piping materials shall be as per ASME B31.3. Fabrication and Installation
of non metallic material piping shall be as per manufacturer / supplier proven / certified
methods.

2.2 Company General Specifications


The following General Specification (CGS) shall be applied to the subject work. In
cases of conflict between the General Specification and any of the applicable codes,
shall immediately submit the matter in writing to COMPANY who will prepare a written
clarification.

Reference Title

CPOC-GS-ST-0009 Painting of Offshore and Coastal Structures and Facilities

CPOC-GEN-0002 Site Conditions and Climate

Instrumentation Engineering, Supply and Construction


CPOC-GS-IN-0001
General Requirement

CPOC-GS-ME-0001 Unfired Pressure Vessels

CPOC-GS-PI-0003 Piping and Valve Materials

CPOC-GS-PI-0004 Pressure Testing of Platform Piping Systems

CPOC-GS-PI-0005 Insulation

CPOC-GS-PR-0001 Process Sizing Criteria

3.0 GENERAL
3.1 Definitions
As used in this Specification, the following definitions shall apply:

Reference Description

The authorization in writing given by the COMPANY to the


Contractor on a procedure or to proceed with the
performance of a specific part of the work without releasing
Approval in any way the Contractor from any of his obligations to
conform with the technical specifications, requisitions, etc.
The words “Approve”, “Approved” and “Approval” shall be
construed accordingly
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 7 of 31

Reference Description

COMPANY Carigali – PTTEPI Operating Company Sdn. Bhd. (CPOC)

The material requisitions, material specifications, etc. issued


Contract Documents by the COMPANY and attached to the Contract or the
Purchase Order

Any company that CPOC has signed a contract with for the
Contractor Engineering, Procurement, Construction and Installation of
a part of a project

The company or its sub-contractors selected by the


Manufacturer
Purchaser as the Manufacturer of the said materials

Designates Project Particular Specification detailing the


additional tests and requirements or the possible
PPS modifications to the present specification, based on the
particular design conditions or the local legislation of the
project

The order issued by Purchaser consisting Terms and


Conditions and attachments thereto including but not
Purchase Order limited to Data Sheets and Drawings, Specifications
including referenced documentation therein, and all other
documents and attachments

The COMPANY or the Contractor (as applicable) which


Purchaser
have placed the Purchase Order to the Manufacturer

The company designated on the Purchase Order form or


Supplier Contract as being the selected supplier of the said
materials.

The company designated on the Purchase Order form or


Supplier / Vendor Contract as being the selected supplier of the said
materials.

Shall Used to indicate that a provision is mandatory

Used to indicate that a provision is not mandatory but is


Should
recommended as good practice

May Used to indicate that a provision is optional


Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 8 of 31

3.2 Abbreviations

Reference Description

BDV Blow Down Valve

DPI Dye Penetrant Inspection

GMAW Gas Metal Arc Welding

GTAW Gas Tungsten Arc Welding

LC Locked Close

LO Locked Open

MAWP Maximum Allowable Working Pressure

MPI Magnetic Particle Inspection

NB Nominal Bore

NC Normal Close

NDT Non Destructive Testing

NPS Nominal Pipe Size

NPSH Net Positive Suction Head

NPT National Pipe Thread

OD Outside Diameter

P&ID Process and Instrument Diagram

PCV Pressure Control Valve

PO Purchase Order

PQR Procedure Qualification Records

RT Radiographic Test

SP Set Pressure

WPS Welding Procedure Specification


Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 9 of 31

3.3 Piping Design


3.3.1 General
1) All piping shall be designed in conformance with ASME B31.3 unless modified by
this Specification and or the Equipment Specifications. API RP 14E
recommendations shall be followed. Design calculations, which show compliance
with ASME B31.3, API RP 14E and this Specification shall be made available to
COMPANY upon request.
2) COMPANY’s written approval shall be obtained prior to substitution or change
from the piping specification. Sufficient information about proposed substitution
or change must be submitted to COMPANY to facilitate proper evaluation.
3) Interface with other piping design codes shall be as indicated in the Equipment
Specification and shall be in accordance with API RP 1111. All the jurisdictional
limits shall be clearly indicated in Piping and Instrumentation Diagrams. Piping
isometrics shall indicate the same.
4) In addition, piping design shall take into consideration and address safety and
environmental issues including risk of any failure and subsequent spills, hazards,
etc.
3.3.2 Line Sizing and Pressure Drop

1) Line sizing shall be preferably as per API RP 14E Section 2 guidelines. After the
pipe lengths, the number of valves, control valves, fittings, elevations, etc. have
been determined, the allowable pressure drop for the tentative line sizes shall be
checked. Pressure drop in control valves shall be taken as at least 30 % of the
total pressure drop in the system, but should be determined in consultation with
parties responsible for instrumentation. For equipment, the pressure drop shall
be taken from the data obtained from the equipment manufacturer.
2) A calculation sheet for pumping data shall be prepared for each pump, showing
calculations for suction and discharge conditions, static head, static pressure,
vapour pressure at pumping temperature and minimum available net positive
suction head (NPSH), including the calculated pressure drop in equipment,
piping, valves, fittings and control valves.
3.3.3 Design Temperature and Pressure

3.3.3.1 Design Temperature

1) The design metal temperature shall be not less than the maximum operating
temperature under continuous operation. For piping systems where materials for
pressure parts are selected for notch toughness, the minimum expected
operating temperature shall be the design minimum temperature.
2) Unless specified otherwise by the Equipment Specification the normal ambient
temperature shall be as specified in CPOC-GS-GEN-0002 “Site Conditions and
Climate”.
3) When selecting the design metal temperature for piping flexibility analysis, the
effects of solar radiation shall be accounted for, especially if the lines are over 30
meters long.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 10 of 31

3.3.3.2 Design Pressure

1) Ambient pressure shall be considered to be 1.01 bar (14.7) psig unless modified
by the Equipment Specification.
2) The maximum allowable working pressure are as indicated in Process Line List
and CPOC-GS-PI-0003.
3) In the absence of this information the following guidelines are offered:

a) When practical, the maximum allowable working pressure shall be limited


only by the flange rating indicated in ASME B16.5.
b) Discharge piping attached to centrifugal pumps and compressors shall be
designed for the maximum shut-in pressure for the equipment selected.
c) Allowance for pressure drop through pipe or equipment such as heat
exchangers shall not be used when establishing the design pressure.
d) If an external pressure can occur only due to structural failure of equipment,
failure of safety devices, or due to other unpredictable events, it shall not
be taken into consideration when establishing design pressure of the
piping.
e) Piping subject to sub atmospheric pressure shall be designed for full
vacuum.
f) The following components shall be designed in accordance with the
following criteria:

Design Criteria: Miscellaneous Piping Components

Item Component Size Operating Pressure, Applicable


in Gauge, bar (psi) Design Code

Pulsation all sizes 0 to 1.03 (15) ASME B31.3


Dampeners
over 1.03 (15 )or ASME Section VIII
below 0 Div 1 or Div 2

Surge Bottles, 24 and under All ASME B31.3


Knock-Out Pots,
and Like Items over 24 0 to 1.03 (15 ) ASME B31.3

over 1.03 (15) or ASME Section VIII


below 0 Div 1 or Div 2
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 11 of 31

3.3.4 Piping Components


1) Materials of pipe and piping components shall be determined by the applicable
piping classes of CPOC-GS-PI-0003. Piping systems connected to other
systems or equipment with a higher design rating shall have the higher rating for
all components up to and including the first block valve in system of lower rating.
2) Pipe sizes 1-1/4”, 2-1/2”, 3-1/2”, 5”, 7”, 9” and 22” are prohibited except as
necessary to connect to equipment. Any prohibited size necessary shall be
changed to conventional size immediately adjacent to equipment.
3) Pipe sizes below 2” and pipe sizes 14”, 18”, 22” and 26” shall not be used to
satisfy upstream and downstream run length requirements for orifice meter
installations.
4) The minimum pipe run size shall be 3/4”, except for air, water and instrument
piping. Minimum pipe run size on pipe racks shall be 2”.
5) The corrosion allowance as indicated in CPOC-GS-PI-0003 shall be applied.
6) Except for removable piping sections arising from pipe-erection requirements,
and piping requiring dismantling for cleaning, the use of flanges in piping shall be
limited to connections to flanged components or equipment.
7) Flanged connections shall be used for all piping 2” and larger, unless modified by
the Equipment Specification.
8) Slip-on and lap joint flanges are not allowed.
9) Specialized piping items shall be marked “SP” on the piping isometrics.
10) All piping 1 1/2” or smaller, except instruments piping, shall be socket welded.
11) Threaded connections shall not be used for “critical services” or “hydrocarbon
service” where service promotes corrosion, stress corrosion cracking and
concentration cell corrosion or for high pressure service.
12) Instrument piping shall be per CPOC-GS-IN-0001. Minimum rating of threaded
and socket weld fittings used shall be as per CPOC-GS-PI-0003.
13) Unions, when not prohibited by the CPOC-GS-PI-0003 shall be installed to
provide removal of components for repair, cleaning or replacement, whether they
are shown on piping drawings or not. All unions shall be “ground joint” type
unions. Unions shall be used for utility service application only.
14) Threaded and socket weld crosses are not acceptable.
15) Bushings, close nipples, or street elbows in threaded piping may be used only
with the approval of COMPANY. Threaded half - couplings are prohibited.
16) Wheel and Gear Operators; Impact-type hand wheels shall be provided as
required in the Project Specification. Impact hand wheels shall not be used on
cast-iron valves or on valves with cast-iron wheels. Chain operated hand wheels
shall not be used.
17) Raised face detail shall be designed with Spiral Finish with 45 to 55 grooves per
inch and the resultant surface finish shall have a 125 – 250 micro inch roughness
in accordance with ASME B16.5.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 12 of 31

18) Flat face detail shall be designed with Spiral Finish with 45 to 55 grooves per
inch and the resultant surface finish shall have a 250 – 500 micro inch roughness
in accordance with ASME B16.5.
3.4 Piping Layout
3.4.1 General
1) All piping drawings shall be submitted to COMPANY for approval prior to
fabrication.
2) Piping shall be routed to ensure that the shortest practical length and a minimum
number of flanges, fittings and valves are used.
3) Sufficient distance shall be allocated between flanges, branches and supports of
insulated lines to allow the application of the insulation, including expansion /
contraction joints of the insulation system.
4) If the equipment flanges deviate from the selected standard sizes the matching
flanges shall be ordered with the equipment.
5) In addition to piping design requirements, all installation, operability and
maintainability issues related to the piping system and associated equipment
shall be considered in the final piping layout.
6) Where field welds are indicated, an over length allowance of 150 mm (6”) shall
be provided in the lay-out to facilitate field adjustment of pipe lengths. Contractor
shall be responsible for determining the location of field welds and assigning
spool numbers.
7) Piping, pipe supports, valves, valve handles, and valve operators shall be
located safely to prevent stumbling or striking hazards to operating personnel.
8) All piping shall be arranged in as neat and simple a manner as possible. In
general, process piping should be arranged on overhead support beams. Piping
headers should terminate with flanges. Space for future expansion should be
considered for all piping systems.
9) Pipe-ways shall be designed with a minimum of 20 percent (20 %) more pipe
space than is required for the initial installation, unless otherwise specified in the
Project Specification.
10) Piping passing through blast / firewalls shall be sealed with a fire retarding seal.
11) For isolation of equipment, PSV’s, bypass lines and instrument connection lines
shall be provided with double isolation block valves, with bleed valve in between.
Double block and bleed valves shall be provided for lines which are in the
following cases;
a) Operating pressure greater than 70 barg or 1015 psi.
b) H2S partial pressure greater than 1 bar.
c) Line content is corrosive or abrasive fluid.
d) High temperature fluid (more than 200 oC)
12) Hot and cold piping shall be grouped together. Hot piping shall be located to the
outside of the pipe-way and away from any personnel access routes. Heavier
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 13 of 31

lines shall be located as close to support columns as practical.


13) Where layouts require main pipe-rack intersections, elevations shall be
established for lines running north-south, and other elevations for lines running
east-west.
14) To minimize exposure in the event of a fire from hydrocarbon services piping,
flanges in such piping located overhead shall be avoided whenever practical.
15) For piping service with hot fluid operating temperature exceeding 70 °C, refer to
CPOC-GS-PI-0005 “Insulation”.
16) Valves shall be manufacturer’s standard pattern, selected to meet the necessary
service requirements.
17) Flanged valves shall be used in line with CPOC-GS-PI-0003 requirements.
18) Lubricated plug valves shall be used only when required for special operating
conditions and are subject to COMPANY approval for the service.
19) Valves which will be operated frequently to meet operating requirements shall be
easily accessible from floor, platform or a fixed ladder.
20) Valves which will be operated only for shutdown and of which the centerline of
the hand wheel is at height not exceeding 3.5 m above the operating level shall
be accessible by means of a mobile ladder. For valves above 3.5 m, permanent
access (platforms, ladders, etc.) shall be provided.
21) Small bore valve (1 1/2” and smaller) shall be socket weld and 2” and above
diameter shall be flange type except for galvanize line, GRE, GRP line and steel
pipe with 10000 API rating classes.
22) The equipment layout drawings shall reflect the overall design philosophy and
geometry and show the outline and location of all major equipment as specified
by all disciplines. The drawings shall also show main access and maintenance
ways, dropout and loading areas and fire/blast walls if applicable. Perimeter
dimensions and dimensions between main grid lines shall be shown. It is
intended that these layouts shall provide the basis for other disciplines layout
drawing requirements.
a) The layouts shall be updated to reflect any approved changes as
necessary.
b) Platform North / True North shall be shown.
c) Layouts shall also include a list of all equipment shown.
d) Drilling rig approach direction.
e) Chart Datum (EL 0.0) for all elevations on drawings is Lowest Astronomical
Tide Level (LAT).
3.4.2 Operability and Maintainability
Equipment layout shall take into account operation and maintenance requirements,
drilling and well services activities and ensure sufficient access around equipment
along with dedicated laydown areas for cranage operations. Break-out flanges shall be
provided to facilitate the removal of equipment where necessary. Particular emphasis
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 14 of 31

shall be placed on items of wellhead platform and other platforms that require regular
maintenance or which is critical to production.
3.4.3 Access Requirements
Detailed below are the operational and maintenance access requirements for various
situations:

Item Description Min Clearance (mm)

Main Access Ways - Headroom for primary access 2100


(including ways (under pipe racks),
Equipment Removal equipment inside modules
Access) 750
- Width
- Mobile lifting equipment in
2400
operating area
Access for - Headroom for maintenance access 2100
Maintenance of ways
Equipment
- Width required for maintenance 750
access ways (not necessarily in a
straight line) and unless otherwise
dictated by equipment
requirement.
Maintenance - Headroom 2100
Passageways and
- Width required (not necessarily in
Walkways
a straight line) 750
Escape Routes - Headroom 2200
- Primary Escape Route Horizontal
clearance ( suitable for stretcher ) 1200
- Secondary Escape Route 1000
Horizontal clearance
Equipment - Maintenance space required 450
between extremities of equipment
arranged in pairs
- Access space around vertical or
750
horizontal drums
- Space for Vessel internals removal
Internals + 1500

Pipe - Clearance between pipe OD,


insulation OD, wire mesh
Calculated thermal
personnel protection, flange OD
Movement + 25
and other equipment (i.e. structural
members, adjacent piping, etc)
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 15 of 31

Item Description Min Clearance (mm)

- Clearance between bottom of pipe 350 ( Normal )


to Top of finished floor/deck level
200 (Extreme case)
For corrosion monitoring, chemical injection or sampling equipment requiring access
under pressure, retrieving tools retrieval space shall be provided.
The layout shall attempt to locate common and associated equipment together. This
shall assist onshore testing and shall minimize interconnecting pipework, power
cables, control wiring and instrument connections.
Access hatches shall be provided where required for removal of equipment or its
component such as Wellhead and Block Valve Assembly, etc. using the deck crane.
Access hatch for the removal of future compressor components shall be provided
taking into consideration the largest module or part that needs to be installed and
taken out.
3.4.4 Overhead Piping
1) Equipment that is a potential source of fire should not be located under pipe
racks. Piping with instrument connections shall be routed to ensure accessibility
of these connections and if necessary, platforms or walkways shall be provided.
2) To protect austenitic stainless steel piping from liquid embitterment failure that
may be caused due to zinc dripping (from galvanized pipe or structural surface)
during fire, the following precautions shall be taken. Galvanized steel piping shall
not be run above austenitic stainless steel piping. Any close proximity by
overhead structural galvanized surface near austenitic stainless steel piping shall
be avoided.
3.4.5 Equipment Piping
3.4.5.1 General
1) Piping shall be routed to allow access for maintenance. Removal or replacement
of equipment shall be possible with a minimum dismantling of piping.
2) Piping at equipment e.g. manual valves, control valves, meters, strainers,
pumps, compressors, turbines, etc., shall be arranged so that such equipment
may be removed without dismantling adjacent equipment or piping except for
connecting flanges at equipment nozzles.
3) Equipment drain, vent, and pressure relief shall be connected to piping system
as appropriate. For equipment handling sand or slurries, the minimum size of
drain shall be 1”.
4) Inlet and outlet isolation valves, discharge check valves and inlet strainers shall
be provided for each item of equipment as appropriate. Inlet and outlet isolation
valves shall be through bore type to ensure minimal obstruction of flow.
5) Operational drains for equipment and piping containing hydrocarbon shall be
provided with proper isolation and regulating valve.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 16 of 31

6) Piping shall be designed so that process equipment connections can be isolated


for safe maintenance. This may be accomplished by providing for the insertion of
line blinds or spectacle blinds at strategic points. The blinds shall be installed so
that insertion or operation can be made from permanent platforms, walkways, or
grade.
Where positive isolation blinds are not provided for safe maintenance of in-line
equipment or tanks, option for isolation by valve removal or removable spool
shall be provided. In event of the de-pressurizing, drainage or sample manual
globe valves which may induced freezing during operation shall be located at
least 600 mm downstream of block valve. The permanent spectacle blind and
spacer and rings will be installed depending on diameter and rating as follows;

No positive Permanent spectacle Spacer or ring


isolation device blinds blinds
Rating

150 RF φ < 8” 8” < φ <14” φ >14”

300 RF φ < 6” 6” < φ <10” φ >10”

600 RF and RJ φ < 4” 4” < φ <8” φ >8”

900 RJ and φ < 2” 2” < φ <6” φ >6”


above

7) Where pump vents are connected to vapor space of vessel to facilitate priming or
for operation under vacuum, such vents shall be provided with one isolation
valve at the pump end and the other isolation valve at the vessel end.
8) Positive displacement equipment shall be provided with pressure relief device to
safe guard against over pressurization due to blocked discharge valve. This shall
not be an integral part of the pump or compressor.
9) Where vent line for equipment connected to closed drain piping system or flare
system, an isolation valve shall be provided to facilitate positive isolation.
10) Drip pans or coamings shall be provided where hydrocarbon liquids are to be
contained; the hydrocarbon liquids then shall be removed manually or by drain
box.
11) Suction line between suction scrubber and compressor shall be as short as
practicable, without pockets, and slope towards the suction scrubber.
12) Piping at equipment shall be sufficiently flexible and adequately supported to
prevent excessive loading at equipment nozzle. Allowable equipment nozzle
loads shall be specified to the equipment vendor and Contractor shall limit the
nozzle load due to piping within that allowable. In case piping design cannot limit
nozzle loads within the specified allowable loads, the actual loads will be sent to
the equipment vendors for confirmation.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 17 of 31

13) Equipment Specification shall specify whether flanged vent and drain nozzles are
required.
14) Auxiliary piping shall be neatly routed along the base plate and shall not extend
across the operating floor. This piping shall not obstruct inspection covers,
bearing caps, upper halves of casing or any other item which requires access for
operation or maintenance.
15) Lubricating oil, control oil and seal oil lines shall not be routed in the vicinity of
hot process and hot utility lines, as a fire hazard prevention consideration.
16) Cooling water lines shall not be less than 3/4” in size. Lines size 1” or less shall
have take off connection from the top of the water main line to prevent plugging
during operation.
3.4.5.2 Integral Valve Bypasses
1) Bypasses shall be installed where slow warm-up of a system would require the
main block valve to be cracked open for a period of time during which seating
surfaces would be damaged.
2) Bypasses shall be installed as indicated in P&IDs (as pressure equalizers) to
facilitate smooth operation of valves of large diameter and or valves that need to
operate at high differential pressures.
3) Bypass valves and the fabrication of the bypass shall conform to the same piping
classification as the principal valve. The bypass valve shall be ball or globe or
choke type. The manufacturer of the principal valve shall furnish the bypass
valve. Nominal minimum size of the bypass shall be as follows:

Size of Principal Valve Size of Bypass

4” 1/2”

6”- 8” 3/4”

10”- 20” 1”

24” and larger (per Equipment Specification)

3.4.5.3 Rotating Equipment


1) Piping at pumps, compressors, turbines, etc., shall be designed with sufficient
flexibility to ensure that under no circumstances will the nozzles of the equipment
be subjected to stresses that could disturb the proper alignment, internal
clearance, or otherwise affect the trouble-free operation of the equipment.
2) In the absence of manufacturer’s allowable loading criteria or API specifications
other industry standards shall be used to specify the allowable nozzle loads.
3) Pump suction lines shall be sloped not less than 20 mm per m (1/4” per ft)
downward from a vessel toward the pump if vapours may be present. Where
reduction is required at horizontal pump suction, use eccentric reducers piped to
eliminate vapour pockets (flat part of reducer on top).The preferred straight
length for horizontal end suction centrifugal pumps, is 5D but in no case shall it
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 18 of 31

be less than 3D.


4) If the discharge line size differs from the pump discharge nozzle, a concentric
reducer shall be installed.
5) Where a bypass line with isolation valve is provided for equipment, the pressure
rating of bypass piping, bypass valve and suction valve shall be of the same
pressure rating as the discharge piping and valves.
6) Where the suction or discharge of pump or compressor is connected to common
header, a spectacle blind shall be provided at the downstream side of the suction
valve and upstream side of the discharge valve to facilitate positive isolation.
7) Compressors in hydrocarbon or toxic service shall have purge facilities.
8) Heavy internal scale shall be removed by abrasive blasting/water jetting for large
diameter carbon steel spools in compressor suction network. Internally blasted
pipe spools, if required, shall subsequently be subjected to chemical cleaning
operation.
3.4.5.4 Reciprocating Equipment
The acceleration effects exhibited by reciprocating pumps and compressors shall be
accounted for in the design of associated piping systems. The use of pulsation
dampeners or volume bottles shall be utilized to assure compliance with the
limitations of maximum piping vibration levels as stipulated in paragraph 3.6.1.
Design of pulsation dampeners shall be in accordance with paragraph 3.3.3.2.
3.4.5.5 Heat Exchangers
1) Process and water piping to shell and tube exchangers shall be arranged to
permit easy removal of shell covers, channel covers, channels and bundles.
Piping shall be arranged to permit removal of the exchanger as a unit.
2) Cooling water to shell-and-tube equipment shall be so arranged that water will
not drain from outlet of equipment in case of supply failure.
3) Collecting and disposal facilities shall be provided for product spillage during
maintenance.
4) Pressure relief valve shall be provided to protect the equipment and piping from
over pressurization due to thermal expansion of the contained fluid under
isolation condition.
5) Check valves shall be provided, at the inlet of shell and tube type heat
exchangers with hydrocarbons, to avoid possible back flow or mixing of fluid
streams.
3.4.5.6 Pressure Vessel Piping
1) A number of pipe runs to and from top of pressure vessel should be routed
together, parallel in one plane for ease of support.
2) Pressure vessels which are grouped together should have their level gauges at a
common level.
3) Flanged or threaded connections shall not be located inside vessel skirt.
4) Pressure vessel shall have drains located outside the skirt. The minimum size of
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 19 of 31

the drain shall be 2” in accordance with CPOC-GS-PR-0001 Table 7. Drain lines


shall be sized to empty the vessel volume or the volume below a column bottom
tray within two hours.
3.4.5.7 Utility Piping
1) Contamination of potable water from a connected piping system shall be
prevented by provision of isolation valves, check valves, break tank with siphon
breaker or other back flow prevention device.
2) Instrument air piping between after coolers and air dryers shall be provided with
self draining system with auto operated drain valve.
3) Utility air system shall be provided with facilities for temporary connection to the
serviced equipment through a check valve and an isolation valve. Utility air hoses
shall be of minimum size 1” with quick coupling end.
4) All utility system hook-ups to pressurized process equipment or piping shall be
equipped with check valve to prevent process fluids from entering the utility
system. The piping class “break” between utility and process shall be so located
that at least two valves (including check valve) satisfy the process piping class.
3.4.5.8 Strainers
1) Temporary strainers shall be provided in pump suction lines. The open area shall
be between 150 percent to 200 percent (150% to 200%) of the cross-sectional
area of the pipe. Piping shall be arranged so that the strainer can be removed
without altering the piping, supports, or pump alignments.
2) Temporary strainers shall be provided in compressor suction lines for start-up
and initial operation unless the lines are accessible for internal visual inspection,
and are clean and free of foreign objects. Strainer opening shall be as specified
by the compressor manufacturer.
3) Permanent Strainers shall be Y, T or basket type. Y type strainers shall be
limited to 6” NB size and 300 # class and T type for all sizes and classes for
process systems. Y or T type strainers shall be equipped with ball valves as
drain valves
4) Permanent strainers or screens shall be installed in:
a) Inlet hood of centrifugal air compressors.
b) Auxiliary systems. External seal oil systems for mechanical seals, wearing
rings, or throat bushings shall be equipped with self-cleaning type or twin
0.4 mm (0.014”) perforation strainers in the main distribution header.
c) Turbine meters – Y-type or Basket type, approximately 1.6 mm (1/16”)
perforations.
3.4.5.9 Pressure Relief Valves
1) Relief valve configurations shall be as shown in Attachment 1. Critical Service is
defined as piece of equipment, which if shutdown for relief valve maintenance or
recertification would result in an unacceptable loss of production. Non-critical
Service means all other cases i.e. equipment items that can be taken offline for
relief valve maintenance or re-certification.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 20 of 31

2) Sizing; the preferred sizing for each relief valve is for 100 % relieving capacity.
COMPANY does not, as general practice, use multiple relief valves for delivering
the required relieving capacity. Exceptions should be approved on a case by
case basis and meet the requirements of API 520/521 for both capacity and set
points.
3) Set Points; set points on all 100 % capacity relief valves will be 100 % MAWP of
the system to be protected.
4) Full bore isolating ball valves will be provided on the inlet and outlet of the relief
valve as per the Attachment 1. A bleed ring/valve will be provided on the inlet
flange of the relief valve. Where suitable, an aligning tool or other means will be
provided to the field maintenance personnel for reinstallation of the bleed ring
after removal/replacement of a relief valve. A vent is to be provided on the outlet
line between the relief valve discharge flange and the outlet isolation valve
unless the outlet isolation valve is bolted directly onto the relief valve discharge
flange. Inlet and outlet valves are designated as ‘safety critical’ and shall be
shown as “locked open” (LO) on the P&ID’s. Where a manual vent is required
on the equipment being protected and other means of venting are not available
(such as PCV or blowdown BDV) it may be preferable, where access and piping
capacity allows, to have this valve discharge into the relief valve discharge line
(shown as a dotted line in Attachment 1).
5) Relief valve chattering is a potential concern on critical service installations, if
both 100 % relief valves are on-line. To prevent relief valve chattering, one of the
inlet isolation valves shall be in the closed position and shown as “Closed” (C) on
the P&ID.
6) The locking mechanism should preferably be supplied by the block valve
manufacturer and be an integral part of the valve rather than a separate
restraining collar. For both critical and non-critical relief valves, the locking
mechanisms on inlet and outlet isolation valves should be in the open position
and one of the following means of securing the device applied:
a) By a positive means (such as padlock)
b) Car sealing the valves
c) Tagging
7) Discharge piping; the pressure rating specification for the relief valve discharge
piping will nominally be ANSI 150# unless:
a) The outlet flange of selected relief valve has a higher rating (i.e., ANSI
300#)
b) It has been demonstrated, by calculation, that the superimposed or built-up
backpressure on the relief valve requires a higher specification.
8) Where a pressure rating specification break is required in the discharge piping it
should be downstream of the outlet isolation valve unless it has been
demonstrated, by calculation, that superimposed or built-up backpressure would
be low enough to permit a lower pressure rating specification on the next flange
downstream of the relief valve discharge.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 21 of 31

9) For individual cases of ANSI 150# or ANSI 300# discharge piping where the
maximum superimposed or built-up back pressure exceeds the MAWP of the
piping components the provisions of ASME B31.3 section 302.2.4 (f) may be
used (i.e., short period excursions up 20 % over the MAWP).
10) High built-up back pressures (>MAWP of discharge piping) may not be
consistent with a good overall flare system design and give rise to other
concerns (high velocities and noise). Other options should be investigated.
3.4.5.10 Fire Water System Piping
1) Fire water system piping shall be located so that there is limited exposure to
impinged fire. Wherever possible, design shall use structural beams, to shadow
or protect piping.
2) Piping and fittings shall be supported and braced to accept water hammer from
fire pump.
3) Fire water deluge system piping and distribution mains shall be sloped to drain.
Low point drains shall be provided to drain system. Drains shall be piped to open
drain system.

3.5 Piping Connections


3.5.1 Primary Take off Connections
1) Primary connections on process piping shall be 1” minimum through the first
block valve.
2) Primary connections on utility piping (air and water) shall be 3/4” minimum
through the first block valve.
3) Instrument piping beyond the first block valve shall be as per CPOC-GS-IN-0001.
4) Thermowell connections shall be 1-1/2” Nipoflange for 2” pipe and larger. Top of
pipe to top of flange shall be 6”.
3.5.2 Branch Connections
1) Welded-on integrally reinforced fittings (weldolets, sockolet and brancholets)
which are attached to the outside header are required when the d/D ratio (d
branch nominal diameter, D header nominal diameter) is 0.5 or less. Sockolet is
allowed to use if the small bore branch pipe diameter is smaller than 1 1/2” and
d/D ratio is 0.5 and less. In case of piping classes 10000 API ratings, sockolet,
theadolet and weldolet branch connection types are not allowed. Only sweepolet
for branch diameter less than 2” is acceptable and reduced tees, equal tees or
equal tee plus reducer for larger diameters are acceptable.
2) All branch connections shall be joined to the header with full penetration welds.
3) Inserted piping branches with reinforcing pads may be used only when the d/D
ratio is 0.5 or less. For ratios above 0.5, a reducing tee or a full size tee with a
reducer shall be used.
4) The angle between any branch and header shall not be less than 45°.
5) Reinforcing pads are to be designed and fabricated in accordance with ASME
B31.3. Reinforcing pads shall be added only after external and internal visual
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 22 of 31

inspection of the attachment welds has been accomplished.


6) Reinforcing pads shall be provided with 1/8” NPT drilled and tapped hole. The
telltale hole is to be used to pneumatically test attachment welds on reinforcing
pads.
7) All instrument air and fuel gas connections shall take off from the top of the
header.
3.5.3 Vent, Drain, Bleed and Test Connections
1) High points of all lines shall be provided with a 3/4” (minimum) pipe nipple with
thread cap vent connection to facilitate hydrostatic testing and shall be seal
welded after hydrostatic test.
2) The location of the drain shall permit the complete removal of the test medium
after the test. Any low point (trap) in a line shall be drained and provided with a
3/4” (minimum) size pipe nipple with thread cap. Seal weld shall be done after
hydrostatic testing.
3) Certain drains and vents shall be equipped with permanent valves as determined
by COMPANY as per operation or maintenance requirement. The minimum size
connection shall be 3/4”. Such drains and vents with isolation valves shall be
indicated in the P&IDs.
4) Vents and drains shall be as short as possible. If long connections are required
(e.g., due to thick insulation on main line) supports / bracings shall be provided.
5) The supply connection for the pressure tests shall ensure filling of the system
within reasonable time, and it shall have a temporary flanged globe valve which
shall also be used for de-pressurizing.
3.5.4 Sample Connections
1) Dedicated connections are required for sample collection.
2) Sample taps on horizontal piping shall be on side of pipes. A sample points shall
not be located in dead ends of piping. They shall be easily accessible. Sample
lines shall be as short as possible. In case of sampling on the discharge of
pumps, in particular, it shall be installed on the length common to the pump in
service and the standby pump.
3) Sample points shall have two valves, one valve at the take off point of the
process line and another one at the sampling point. The block valve at the take
off point shall have the same size as standard drain valve. The sampling valve
size shall be maximum 1/2”. This valve shall have good throttling properties. If a
sample take off line cannot be built short a closed loop shall be provided. The
closed loop shall be a connection to the same process stream at different
pressures. The loop shall be provided with block valves at the connection with
the process lines. The take off valve shall be double block and bleed and the
sampling valve shall be threaded at both ends to allow plugging or replacing.
4) Gas sample points shall tie-in on top of a horizontal pipe. Sample outlets for self-
igniting or toxic products shall have a self-closing downstream valve.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 23 of 31

3.5.5 Thermowell Connections


Thermowells shall be generally flange-mounted type and the run pipe diameter shall
not be less than 2”. Welding thermowells shall only be installed when due to high
velocity and density of the fluid the bending forces are too high for flanged
thermowells. For thermowells required to be installed in lines smaller than 4” NB, the
line size shall be increased locally to 4” NB.
3.6 Pipe Supports and Piping Flexibility
3.6.1 General
1) Piping shall be adequately supported for the dead weight of the pipe, filled with
water, including attached unsupported components, insulation, and other
external sustained loadings. Analysis of supports for periodic loadings shall be in
accordance with ASME B31.3.
2) Piping shall be installed with supports, pulsation dampeners, and other
necessary devices as required to prevent excessive equipment and piping
vibration. Excessive vibrations are those which would cause damage to the
equipment. The Equipment Specification will indicate the allowable vibration
levels based on the associated equipment. In general, the allowable vibration
peak velocity will be twice that allowed for the indicated equipment. In lieu of any
other information, the maximum allowable peak velocity in any part of the piping
system shall be 0.6”/sec.
3) Piping design shall provide adequate space to allow line-up clamps to be used
on field welds.
4) The minimum spacing for pipe supports shall be such that the stress developed
by the piping shall be less than the allowable stress for sustained loads per
ASME B31.3 and in no case shall the deflection exceed 13/16”.
5) The design methods, analysis procedures, fabrication techniques, and
acceptance criteria for achieving adequate flexibility in piping systems shall be in
accordance with ASME B31.3.
6) Non-insulated pipe shall sit on a thermoplastic half-round spacer to prevent
crevice corrosion. U-bolts shall be plastic coated over the shank. Deck
penetrations shall have sleeves to prevent spills flowing to a lower deck or
overboard, pipes shall be located in the geometric center of the sleeves.
7) Piping entering vessel will preferably be supported from brackets attached to the
vessel which shall be designed accordingly if the pipe support on deck is not
practical design. Piping load shall be provided for structural design or vessel
shell local stress review.
8) Pipe support for Cryogenic Service shall be designed to minimize thermal
conduction which could adversely affect the fluid in the pipe and/or the
surrounding structure. Cryogenic supports shall be designed taking into account
warm-up and cool-down conditions. Adequate systems shall be used in order not
to induce additional stresses on insulation material. Clamps will be installed
around insulation.
9) For piping containing gas and not subjected to an hydrostatic testing, weight of
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 24 of 31

liquid shall not be considered that precautions against liquid entrance into the
piping have been taken.
10) Non-insulated lines will rest directly on a thermoplastic half-round spacer which
installed on the support member except as otherwise stated below.
a) Hanger rods for lines subject to thermal displacement should be set out of
plumb to an amount equal to one-half of the anticipated displacement of the
pipe at the point of support.
b) On galvanized carbon steel pipes, a rubber sheet shall be placed between
the clamp and the pipe.
3.6.2 Means of Increasing Flexibility
1) The use of offsets and changes in direction should be utilized as the preferred
method to improve flexibility.
2) The use of commercially available expansion joints must be approved by
COMPANY prior to purchase. Expansion joints shall preferably be selected as
offset type in lieu of axial type.
3) All bellows units shall include tie-rods. Thrust calculations as well as computer-
analyzed flexibility calculations shall be submitted to COMPANY for approval.
Slip- joints can be used if service condition is in scope of 3.3.4 and COMPANY
approved.
4) The application of cold spring is not allowed.

4.0 FABRICATION REQUIREMENTS


4.1 General
1) All pipework, valves (check, globe, ball, gate, needle, butterfly) and fittings shall
be supplied by Contractor in accordance with the requirements of CPOC-GS-PI-
0003, “Piping and Valve Materials”. All valves shall be painted per CPOC-GS-
ST-0009, “Painting of Offshore and Coastal Structures and Facilities”.
2) Piping shall be fabricated in accordance with the Contract Specifications and
Drawings. Fabrication shall not proceed until the fabrication drawings have been
approved by COMPANY.
3) Fabrication, welding procedures, and welder qualifications shall be in accordance
with ASME B31.3 except as modified by this Specification.
4) Hot tapping shall be carried out in compliance with COMPANY approved
procedure.
5) Minimum spacing of circumferential welds between centre lines shall be
minimum one (1) pipe diameters or two (2”) inch whichever is greater unless
otherwise indicated on the drawings or approved by the Inspection Agency. In
restriction zone, the minimum spacing shall not be less than four (4) times of the
wall thickness or one (1”) inch whichever is greater.
6) With exception of galvanized system which shall be joined together only by
threaded connections, small bore pipe (1 1/2” and smaller) shall be joined
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 25 of 31

together by socket welding. This requirement is not applicable to 10000 API


rating classes where “Butt welding” type shall apply. The thread carbon-steel
piping used for process services shall be at least schedule 80 and 1-1/2”
maximum diameter. Other than flanged connections, only approved mechanical
joints shall be used.
7) Threaded connections shall be gauge/checked, or chased after welding or heat
treatment.
8) Socket weld fittings and valves shall be used in accordance with CPOC-GS-PI-
0003. In case of threaded connection is required, seal welding of threaded
connections is permitted after testing. The seal welding shall be accomplished in
accordance with ASME B31.3.
9) Thermowells, caps and plugs on vents and drains, shall not be seal welded in
case of normal use purpose unless in case of vent and drain for hydrostatic tests,
sealing weld after testing is required.
10) All small bore fitting branch welding shall be performed by Gas Tungsten Arc
Welding (GTAW).
13) Only 1.5D radius bends (elbows) shall be used.
14) Centre line radius of shop pipe bends shall be at least equal to three (3) times
the nominal pipe diameter. All pipe bends shall be accomplished in accordance
with ASME B31.3.
15) Piping designed for pigging operations shall have 3D radius bends, unless
otherwise specified.
16) Cold-formed pipe bends are not permitted.
17) The pipe wall thickness at the thinnest point after bending, less corrosion
allowance, shall not be less than the calculated thickness required for pressure
and temperature. Pipe bends shall be free from cracks, wrinkles, and bulges
after bending and heat treatment. Weld repair of cracks in pipe bends is not
acceptable.
18) Galvanized pipe shall not be bent, or welded. Piping requiring bending or welding
shall be galvanized after fabrication.
19) Material Certificate BS EN 10204 Type 3.1 shall be cited before use of any pipe
or fittings or flanges for fabrication.
20) All free issue materials shall be identified and stored separately in the
Fabricator’s yard.
21) All pipe spools shall be tagged as indicated in the piping isometrics.

4.2 Welding
4.2.1 Welding Procedure Qualifications and Welder Qualifications
1) All welding procedures and repair procedures shall be as per ASME Section IX
and shall be submitted to COMPANY for approval. Procedure qualifications
including all destructive and non-destructive testing shall be completed and
submitted to COMPANY for approval prior to starting fabrication.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 26 of 31

2) All welding procedures and repair procedures shall be identified by number and
shall be referenced on all fabrication drawings.
3) Details of welding procedures qualification tests, including test results, shall be
submitted to COMPANY for review and approval prior to starting fabrication.
COMPANY may choose to witness such qualification tests.
4) Welders and welding operators shall be qualified per ASME Section IX prior to
fabrication and records shall be made available to COMPANY upon request.
5) Particular attention shall be made to ensure Weld Procedure Specifications
(WPS) and Procedure Qualification Records (PQR) meet the requirement of
NACE MR-0175/ISO 15156, where specified.
6) Longitudinal seam welded pipe shall have the seam welds staggered at least one
quarter of the diameter between abutting joints of pipe.
4.2.2 Filler Metal
1) The deposited filler metal shall match the nominal analyses and physical
properties of the base material when similar metals are welded. Alloyed welding
material (manganese and silicon) shall not be used.
2) When metals of different nominal analyses or physical properties are to be joined
by welding, Fabricator is to supply to COMPANY the welding procedure for
approval prior to fabrication.
3) Where impact testing is required, the filler metal for welds shall meet the same
impact test requirements as the base metal.
4.2.3 Other Requirements
1) Permanent backing rings and consumable inserts shall not be used. Temporary
backing rings may be used after approval by Engineering COMPANY and only if
they are made of the same material that has to be welded; in such a case, at
least the two first layers of passes shall be gouged out after completion of the
weld, and rewelded. Other technique shall require the specific COMPANY prior
approval.
2) Peening is not permitted.
3) Semi-automatic or full-automatic welds shall be made with a multi-pass
technique.
4) GMAW welding process for other than root pass must be reviewed and approved
by COMPANY.
5) Arc burns shall be removed by grinding or by cutting out a cylindrical section of
pipe and replacing with an undamaged spool. Grinding is permitted only if
sufficient wall thickness remains after grinding to sustain the pressure in the
corroded condition.
6) The gap between the socket weld component and pipe end shall be
approximately 1/16” to avoid “bottoming” which could result in excessive weld
stress.
7) Minimum of 2 passes is required for all types of fillet welds on pressure
containment components, e.g. socket weld fittings.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 27 of 31

8) All flange bolt holes shall straddle normal horizontal and vertical centre lines of
the pipe, except where connecting to equipment dictates otherwise.
9) Should laminations, split ends, longitudinal seam defects, ovality or other
injurious defects be discovered during the non-destructive weld testing, the full
pipe joint containing the defect shall be removed from the line.
10) All leaks or other defects discovered by testing and resulting from faulty
workmanship or faulty materials furnished by Contractor shall be repaired to
COMPANY satisfaction or replaced by Contractor at no cost to COMPANY.
4.3 Heat Treatment
1) Exposed machined and threaded surfaces shall be protected from oxidation
during heat treatment.
2) No welding shall be performed after heat treatment is completed.
3) Heat treatment requirements and hardness specifications for attachment welds
of non- pressure parts, such as gussets and trunnion attachments, shall match
those requirements specified for the nominal analyses of the attached pressure
part.
4) Minimum pre-heat temperatures for thermal cutting, welding, and tack welding
shall be as specified in ASME B31.3.
5) Post-weld heat treatment shall be as per ASME B31.3 or as required by
COMPANY.
4.4 Non Destructive Testing (NDT) Requirements
4.4.1 General Requirements
1) All examinations inclusive of in-process examinations shall be carried out in full
compliance with requirements specified in ASME B31.3 and this specification
and any other requirements covered by COMPANY General Specifications
referenced herein.
2) Castings shall be inspected as per ASME B31.3 and the listed standards therein.
3) Weld examinations shall be performed in accordance with the following
standards:
a) Visual ASME Section V, Article 9
b) Radiographic ASME Section V, Article 2
c) Magnetic Particle ASME Section V, Article 7
d) Liquid Penetrant ASME Section V, Article 6
e) Ultrasonic ASME 16.34 Mandatory Appendix IV.
4) Welds that are to be examined by non-destructive methods shall be finished as
required in ASME B31.3 and the standards listed above.
4.4.2 Radiographic Tests
1) First 2 welds by each welder shall be fully radiographed. Spot radiography shall
then be performed on a minimum of one shot on weld in each 20 welds for each
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 28 of 31

welder on the following piping:


a. Water
b. Air
c. Atmospheric drain lines
2) The length of film for each weld shall be 250 mm (10”) or half the pipe
circumference whichever is less
3) 100% radiography shall be performed on the following piping:
a. Hydrocarbon services
b. Water (ASME B16.5 – Class 600 and above)
c. Glycol
d. Heat-transfer fluids
e. Hot oil service
f. Cu-Ni piping – firewater service
g. Other piping as specified by the Equipment Specification
h. 10% radiography with 10% random liquid penetrant test or Magnetic
particle inspection is recommended for Open drains, utilities-vent, non-
hazardous and non-critical services
4) Ultrasonic Test / Magnetic particle inspection may be substituted with COMPANY
approval when radiography is difficult to interpret.
4.4.3 Acceptance Criteria
1) Acceptance criteria based on visual inspection, radiography, and other types of
examination shall be per ASME B31.3, with the following modifications:
a) The internal weld protrusion on lines subject to pigging operations shall not
exceed 1/16”.
b) Orifice-flange butt welds shall be internally ground smooth and flush
c) Any other COMPANY specified criteria e.g.- severe cyclic service criteria
for specific fluid service piping
2) Acceptance criteria for castings and welds shall be as stated in the engineering
design and ASME B31.3 as applicable for cyclic, severe cyclic or high pressure
service.
4.5 Particular Case of Welds of Piping Supports
All welds should be 100 % visual inspection.
1) Fillet welds between supports and main or secondary steel structure to which
they are attached shall be subjected to 100 % Magnetic Particle Inspection (MPI)
or Dye Penetrant Inspection (DPI) if they are supporting at least one line of NPS
10 inches or larger. In case of supported pipe which is smaller than NPS. 10
inches, welds shall be subjected to 10 % Magnetic Particle Inspection (MPI) and
Dye Penetrant Inspection (DPI). Other welds shall be subjected to MPI or DPI of
one weld every 20 welds made by each welder or welder operator.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 29 of 31

2) Butt welds shall be examined by Radiographic Examination every 10 welds


made by welder or welder operator.

5.0 INSTALLATION REQUIREMENTS


5.1 General
1) The following documents and any other relevant documents related to piping
material and equipment shall be reviewed before starting of the installation at
site:
a) Material certificates for pressure containing parts
b) NDT certificates
c) Shop fabrication inspection reports
d) Installation, operating and maintenance instructions
e) Safety data on equipment and contained materials
2) As a minimum requirement, all valves shall be inspected for :
a) Number, type, size, bore, body material, pressure and temperature ratings
b) Face to face dimensions
c) Flange face finish
d) Weld end preparation (if field weld mounted)
e) Nameplate details inclusive of PO No. etc
f) Trim materials inclusive of seat material, stem packing material, bonnet
gasket material etc
g) Arrow for flow direction (if relevant)
h) Orientation of valve hand wheel / operating mechanism
i) General condition
j) Protective coating

5.2 Installation of Valves


1) Spring loaded type check valves must be installed with the pin in vertical position
when flow is horizontal.
2) Ball valves with socket weld type, the need for disassembly or other
requirements to prevent seat damage shall be investigated.
5.3 Installation of Threaded Assemblies
Threads shall be clean cut with no burrs or stripping and thread shall be per ASME B
1.20.1 tapered. Ends shall be reamed to remove burrs. Immediately before erecting
piping, pipe and fitting threads shall be thoroughly cleaned of cuttings, dirt, oil, or other
foreign matter. The male threads shall be coated with thread sealant and the piping
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 30 of 31

made up sufficiently for the threads to seize. Thread sealant such as three bond
sealant and thread locker shall be used.
5.4 Installation of Flanged Assemblies
1) Flange bolts shall be tightened uniformly and in the proper diametric sequence to
impose equal pressure on the gasket and to avoid distortion or overstressing of
equipment.
2) Bolt tensioning equipment shall be used for bolts of diameter greater than 1-1/2”.
Bolt tensioning shall be used for hot oil service for all sizes of bolts irrespective of
rating. Hydratight bolt tensioning equipment shall be used, or COMPANY
approved equivalent.
3) Gaskets once taken out from a made-up assembly shall not be reused.
4) Before installation of new gasket, the old gasket shall be completely removed
and the flange facings shall be thoroughly cleaned.
5) Colloidal molybdenum disulfide or other approved lubricant shall be applied to all
flange bolts before the joints are assembled.
5.5 Installation of Line Blinds, Spectacle Blinds and Blind Flanges
1) Line Blinds, spectacle blinds or blind flanges shall be installed :
a) To positively isolate equipment for inspection / testing / maintenance /
vessel entry.
b) To isolate systems that are not used during normal operation or are only
used during emergency operation.
3) The number of line blinds required for pressure testing of piping system shall be
determined by the Contractor. These line blinds shall not be shown on the
P&IDs.

6.0 PROTECTIVE COATING


Surface treatment and protective coating of all the piping shall be in accordance with CPOC-
GS-ST-0009.
Supports in marine atmosphere shall be designed to avoid potential corrosion built-up. To this
end metal to metal sliding contact which may damage the pipe coating shall be avoided as
well as potentiality of water accumulation between pipe and support.

7.0 INSPECTION AND TESTING REQUIREMENTS


7.1 Pressure Tests
1) Pressure tests and system service tests of fabricated piping and installed piping
shall be carried out as per ASME B31.3 and CPOC-GS-PI-0004.
2) Pneumatic test of reinforcement plates with tell tale holes shall be carried out as
specified in CPOC-GS-ME-0001. All outside welds and inside welds where
possible shall be inspected during the test. Test holes shall be plugged with a
non-hardening sealant or heavy grease after the test.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page 31 of 31

7.2 Final Inspections


1) Where required, insulation shall be installed in compliance with CPOC-GS-PI-
0005.
2) A final visual inspection shall be carried out of all the piping and pipe supports for
integrity of installation. A check on protective coating shall be carried out. A
punch list shall be prepared of any repair or rework that will need to be carried
out before final acceptance of piping.

8.0 ATTACHMENTS
ATTACHMENT 1 Relief Valve Configurations
ATTACHMENT 2 Piping Fabrication Tolerances
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page ATTACHMENT 1

ATTACHMENT 1
RELIEF VALVE CONFIGURATIONS

Note: Vent valve upstream of the outlet isolation valve is not required where the outlet
isolation valve bolts directly onto the relief valve discharge flange.
Doc. No. CPOC-GS-PI-0001

PIPING DESIGN, FABRICATION AND Rev. 0


CPOC INSTALLATION Date 16/02/11
Page ATTACHMENT 2

ATTACHMENT 2
PIPING FABRICATION TOLERANCES

Оценить