WELDING SPECIFICATION FOR AUSTENITIC,

DUPLEX, AND SUPERDUPLEX PIPEWORK

 CONTENT

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1. No table of contents entries found.

1. SCOPE

This technical specification is applicable to stainless steel piping that forms part of the “RO Plant”.
Stainless steel piping includes austenitic, duplex and super duplex grades of material as shown in the
following table:

Type Grade UNS

Austenitic SS 316L S31603

Duplex SAF 2205 S31803 or S32205

Super Duplex SAF 2507 S32750 or S 32760

This specification covers the basis of fabrication, non-destructive examination, installation, flushing, pressure
testing, chemical cleaning and coding of stainless steel piping for the “RO Plant”.
This Specification does not cover:
∙ Building services piping
∙ Thermoplastic or GRP piping
∙ Carbon steel or ductile iron piping
∙ Instrument piping or tubing downstream of the first piping block (root) valve

The philosophy is such that specialist organisations will provide Quality Plan, ITP (Inspection Test Plan) and
work method statements based upon the requirements of the EPC contract, this technical specification and the
referenced documents.

2. DEFINITIONS

CF: Crevice Factor

FL: Fusion line
GTAW: Gas Tungsten Arc Welding
GMAW: Gas Metal Arc Welding
SMAW: Shielded Metal Arc Welding
STT: Surface Tension Transfer
MDR: Manufacturer’s Data Record
NATA: National Association of Testing Authorities
NDE: Non destructive Examination
 PAW: Pulse Arc Weld
PRE or PREN: Pitting Resistance Equivalent or
Pitting Resistance Equivalent Number
SAW: Submerged Arc Weld
WMS: Work Method Statement
WPQR: Welding Procedure Qualification Record
WPS: Welding Procedure Specification
OEM: Original Equipment Manufacturer
ITP: Inspection Test Plan

3. STANDARD & NORMS

3.1. Statutory Compliance

The requirement of all relevant international and national standards and in addition the regulations,
recommendations and directives listed in the EPC contract apply to work under this specification.
All piping shall conform to requirements of ASME B31.3 for Process piping.

3.2. Currency of Standards

The last edition and version of standards shall be applied.

3.3. Normative References

The fabrication, non destructive testing, installation, flushing, pressure testing, chemical cleaning and coding of
stainless steel piping for the ”RO Plant” shall be in accordance, but not limited to, with all applicable sections of
the following standards and codes:

● ASME B31.3 Process Piping ASME Code for Pressure Piping

● ASME Section IX Welding and Brazing Qualifications
● NORSOK M 601 for Superduplex welding requirement
● NORSOK M 630 for Superduplex welding requirement
● ASME B1.20.1 Pipe Threads, General Purpose
● ASTM G48-03 Standard Test Methods for Pitting and Crevice Corrosion Resistance of Stainless Steels
and Related Alloys by Use of Ferric Chloride Solution
● ASTM A370-06 Standard Test Methods and Definitions for Mechanical Testing of Steel Products
● ASTM E92-82(2003)e2 Standard Test Method for Vickers Hardness of Metallic Materials
● ASTM E562-02 Standard Test Method for Determining Volume Fraction by Systematic Manual Point
Count
● ASTM A923 Standard Test Method for Detecting Detrimental Intermetallic Phase in Wrought Duplex
Austenitic/Ferritic Stainless Steels
 ● ASTM A380 Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts,
Equipment and Systems

4. DESIGN

4.1. Shop / Spool drawings

The subcontractor shall be responsible to execute the shop and spool drawings, based on the isometric provided
by OTV and the site investigations done by the Subcontractor.
Any modification on OTV isometrics shall be submitted to OTV for approval.

5. WELDING LIFE AND PROBLEMATIC FOR DUPLEX AND

SUPERDUPLEX WELDING

5.1. Welding life and Durability

The Subcontractor shall ensure that the welding of stainless steel, and particularly the welding on super
duplex and duplex shall withstand for a minimum life of 30 (250,000 hours) years, taking account of industry
standards for operation and maintenance.

The purpose of this specification is also to set the minimum requirement for welding in order to ensure “the
welding durability”.

5.2. Problematic for duplex and superduplex welding

During operation, the main problematic on welding of superduplex and duplex are:
Pitting corrosion
Crevice corrosion

Pictures showing corrosion welding’s problem for superduplex welding during plant operation:
The area most susceptible to corrosion pitting is the welded joints. The welded joints are susceptible to pitting
attacks. However if these welds are subject to pickling and passivation the resistance to pitting increases All
piping and welds will be subject to internal acid pickling and passivation which is carried out to clean and remove
any chromium depleted surfaces (due to welding) allowing a strong chromium rich oxide bond to be formed
which is highly resistance to corrosion attack providing oxygen is maintained to the surfaces. External protection
of the welds will be done by applying a pickling and passivation paste or similar.
Provided the welds are pickled and passivated they will have a pitting resistance for a continuous exposure of
seawater. As mentioned all shop and field welds will be subject to an acid pickling and passivation procedure on
site. Once this procedure is complete examination of typical (accessible) welds will be done to ensure protection
of the welds has been achieved. It is essential the system is properly protected before going into the
commissioning and operation phases.

It is in the area of pipe and connection welds, including the heat affected zones, that is considered the most
susceptible to crevice corrosion (due to undercutting of the weld, inclusions, etc.) during the welding process
which is the starting point for corrosion. Small crevices present a bigger risk to corrosion than large crevices due
to the lack of movement of seawater in the small crevice. It is essential that correct welding and qualification
procedures are adopted and strict quality control of welders and welds are in place for both shop and site welds.
Site welds are more difficult to control due to welding in situ and these are being kept to a minimum. Provided
proper precautions are in place “in situ” site welding will achieve good results to the same standard as shop
welds. The Subcontractor has to produce a tight stainless steel fabrication, installation and welding specification
which will provide a solid base for producing quality work which is one of the keys in minimizing corrosion risk.
The welding procedures are applied to both in situ and off site welding.

It is clear that without due diligence in the welding process corrosion will occur irrespective of the selection of
material. This is amply demonstrated in a major desalination plant overseas where super duplex piping material
has been attacked by crevice corrosion of the welds and is a major ongoing problem. Whilst no definitive reason
has been provided for this corrosion it does appear that quality control of the welds may have been a major
issue. Welding defects appear to have been the most significant issue in the poor performance of the HP super
duplex system. Pitting of the pipe barrels is also a problem in this overseas plant which would tend to indicate
problematic quality control during fabrication and/or erection. Whether acid pickling and passivation has been
done (or to the correct standard) is unknown as this question remains unanswered.
The risk of systemic corrosion pitting of the welds resulting in systemic failures requiring repair or replacement of
piping is considered a low risk subject to the precautions being undertaken as outlined above.
6. ENVIRONMENTAL, HEALTH AND SAFETY PLAN (EHS)

All Subcontractors shall comply with the EHS plan. The Subcontractors shall comply with all statutory and
legislative requirements for off site work. A specific plan EHS shall be submitted for approval to OTV prior start of
work (including work on site and work out of site).
The Envrironmental, Health and Safety Plan shall also include the requirements related to:
Electrical Equipment, Pressurised Gases, Personnel Protection, Fire, Fume, Arc Radiation,…

7. QUALITY PLAN & ITP

Prior to commence the work, the quality plan with the Inspection and Test Plan shall be submitted to OTV for
approval.
For all the differents type of work and at the different stage, a detailed procedure, method statement and process
verbal shall be issued, submitted to OTV’s representative for approval.

8. THIRD PARTY CERTIFICATION

8.1. Certification of ITP, WPS and WPQR. Qualification of welders.

The Subcontractor shall arrange for an independent third party to certify:

- Inspection Test Plan,
- Welding Procedure Specifications and Procedure Qualification Record,

The third party certified ITP, WPS and WPQ shall be submitted by the Subcontractor to OTV for approval.

After approval of the documents by OTV, the Subcontractor shall arrange the independent third party to certify:

- The Qualification of welders

OTV’s representative or the third party has the right to disqualify any welder whose performance is not meeting
the required standard, codes and approved procedure.
The Subcontractor shall not start work before having fulfilled these conditions.

8.2. Certification during production.

As an option, the Subcontractor shall arrange the independent third party to certify:
- Each stage during production (on site and in subcontractor workshop),
- The certified documents shall be submitted for approval to OTV.
 8.3. Pressure test Certification.
As an option, the Subcontractor shall arrange the independent third party to certify:
- Test pressure at Subcontractor’s workshop and final test pressure on site.
The certified documents shall be submitted for approval to OTV.

9. MATERIALS
9.1. Marking of Materials
Materials shall be, colour coded, stencilled or bar coded to differentiate between austenitic, duplex and super
duplex grades of stainless steel. All coding shall be maintained until a spool is complete and tagged.
Colours shall be painted on in one continual stripe approx 20 mm thick:
Green 316L (Non magnetic)
Blue Duplex (Magnetic)
Yellow Super Duplex (Magnetic)
If such coding is missing or unclear the materials shall be quarantined until identified (via testing) and marked
prior to being used for the permanent works.
Paint coatings or labels shall not be applied to the internal surfaces of pipes or to the external surfaces where
they would subsequently be exposed to permanent immersion in drinking, sea
or brine waters.
In the event that the material cannot be identified it shall not be used for stainless piping service. All short lengths
shall be segregated and coded to ensure that materials are not mixed.

9.2. Material Storage, Handling, Receipt and Identification Control

Piping will be delivered directly to the Subcontractor facilities or on Fujairah site. Off-loading of the piping shall be
done by the Subcontractor. On-loading, transport and off-loading of all the material shall be done by the Sub-
contractor.
Procedures for transport, on-loading, off-loading, storage, receipt, control, traceability and inspection of piping
material supplied for fabrication and installation shall be provided for OTV’s representative approval.
All stainless materials should be handled and stored under conditions which prevent contamination from other
ferrous and non ferrous alloys. Please refer to “MATERIAL HANDLING OF SUPER DUPLEX STAINLESS
STEELS” attached in appendix 1.
Stainless steel, wood, plastic or other non-metallic materials shall be used as protective covers with storage
racking, fork lift truck arms, overhead crane slings etc.

9.3. Consumables
Consumables shall be compatible with the pipe. All consumables shall be preserved in accordance with the
manufacturer’s requirements prior to their use. Opened packs of electrodes and flux should be preserved
according to the manufacturer’s requirements.
 9.4. Shield Gases
Only Gas mixtures specified in this specification and that have been approved satisfactory as a result of Welding
procedure Qualifications shall be used.
All shielding gases shall be applied with certification stating purity limits and compliance with permitted
tolerances on composition limits.
Shielding gases shall be kept vertically in containers properly marked and colour coded.

9.5. Weld Preparation Fittings

All fittings shall have weld preparations to suit pipe specifications except where otherwise noted.
All weld preparations shall enable full penetration, crevice free welds to be produced.
Some fittings may be of heavier wall than shown in pipe material specifications however these shall be further
machined by subcontractor to enable weld preparations in accordance with ASME B31.3 Fig 328.4.3.
In case of use of weldolets on headers, it may have a weld preparation to suit a thinner wall pipe than the pipe
specified. All pipe ends shall be prepared to suit the weldolet weld preparation. This shall be in accordance with
ASME B31.3 Fig 328.4.3. Such instances are shown on isometric drawings.
Weld thickness for weldolets shall be ≤ to 1.5 times the thickness of the parent material and be of a concave appearance in
accordance with the manufacturer’s requirements.

9.6. Efficient Use of Materials

The use of straight run pipe shall be planned to maximise the use of off-cuts effectively. A straight run of pipe
shall contain a minimum number of butt welds.

9.7. Tools for examination and inspection

Prior to commence the work, the Subcontractor shall submit a list of the tools which will serve during the
qualifications, production, installation, flushing, pickling, testing for the control, inspection and examination. All
the cost related to these tools shall be born by the Subcontractor.
The tools shall be first quality, calibrated and with certification.

10.FABRICATION
10.1. Iron Contamination
Stainless steel and carbon steel materials shall be stored separately and fabricated separately in such a way that
the stainless steel cannot be contaminated by carbon steel dust or airborne particles.
Cutting shall be performed with mechanical shop tools, plasma arc, laser, or water jet. Carbon arc or iron powder
cutting shall not be used on stainless steel. Edges shall be ground to a smooth, uniform surface by removing
approx 0.5 mm of metal.
Hand wire brushes made of stainless steel could be used. Rotary wire brushing wheels are not permitted.
Grinding and cutting wheels shall be iron free. Hand tools, such as grinders, wire brushes, files used for
fabrication on stainless steel shall be marked for easy identification to avoid contamination.
Carbon steel materials shall not come into contact with stainless steel materials i.e. fabrication aids such as pipe
clamps, stands, benches etc shall be covered to avoid contamination from carbon steel surfaces.
Procedures shall be in place to ensure that stainless steel fabrications cannot be contaminated by windblown or
airborne iron particles from adjacent areas where fabrication, cleaning or blasting of carbon steel is taking place.

10.2. Site investigation and survey

Prior start of work, survey shall be done on site by the Subcontractor in order to check and verify if any
discrepancies between the drawing and the site conditions. In case of discrepancies, the Subcontractor shall
submit it to OTV, advise the different adaptation to be done on the isometric drawing.

10.3. Dimensional Tolerances for Pre-fabricated Piping Assemblies

Only drawings endorsed ‘Valid for Construction’ (VFC) shall be used. Preliminary drawings are to be used for
tender purposes only, and could be used for preparation works.
The tolerances on linear dimensions (intermediate or overall) are illustrated on figures 1 and 2. These tolerances
are not accumulative. Angularity tolerances across the face of flanges, weld end preparation and rotation of
flanges shall be as stated in figures 1 and 2.
Closer tolerances on weld end preparations than stated in figures 1 and 2, may be specified and shown on the
fabrication isometric(s). When closer tolerances other than those given above are required, these shall be as
specified on the isometric drawing.
Isometric drawings generally show cut lengths with no root gap. The Subcontractor shall apply the appropriate
trim to suit the required root gaps for the weld procedure, to ensure that overall pipe lengths and tolerances are
achieved.
 Tolerances (mm)
Nominal Dia (DN) L (m)
∆L T

DN50 ≤ d ≤ DN250 All ±3 ±1

DN300 ≤ d ≤ DN500 All ±5 ±1

d>DN500 All ±5 ±1

d = nominal diameter

Figure 1 - Tolerances for Prefabricated Piping

 Tolerances (mm)
Nominal Dia
L L1 L2 H T A K
 DN50≤d≤DN250 ±3 ±3 ±3 ±3 ±1 ± 1.5 ±2

DN300≤d≤DN500 ±5 ±5 ±5 ±3 ±1 ± 1.5 ±3

d>DN500 ±5 ±5 ±5 ±3 ±1 ± 1.5 ±3

d = nominal diameter

Figure 2 - Tolerances for Prefabricated Piping Assemblies

For spools with field welds, if no trim allowance is stated on the isometric drawings, the overall length shall be
approximately 100 mm over length. Bolt holes on flanges shall straddle the horizontal or vertical lines or plant
north/south centre lines when orientation is not given on drawings.

In case of more restrictive tolerance, because specified on the isometric drawing or specified by equipment
supplier, the most restrictive tolerance shall be applied.

10.4. Branch Connections and Outlets

All welded branch connections shall be jointed to the header with full penetration welds.
Branch connections shall be set-on type. Set-in type may be used provided that a weld procedure is provided to
OTV for approval inclusive of a distortion control proposal.
Reinforcement pads or saddles required by specifications and drawings shall be of the same material as the
main pipe (unless specified otherwise) and shall be formed and contoured to provide a good fit to both main and
branch pipe.
Branch reinforcing pads shall be detailed by OTV. Branch reinforcement pads or each segment thereof shall be
provided with a minimum 6 mm drilled and tapped hole prior to fitting to the pipe, so ensuring leak detection,
venting and testing facilities. Whenever possible, pad should be made in one piece before fitting onto pipe.

10.5. Welded Pipe

Adjacent sections of longitudinally welded pipe that are joined by butt welding shall have the longitudinal weld
seams positioned so that they are at least 30º apart.
The Subcontractor shall position the longitudinal weld seam off the pipe top or bottom so that branch connections
such as couplings, stab-ins, etc., do not fall within the weld HAZ area.

10.6. Pipe Joints

Seal faces of mechanical couplings/hubs and flanges shall be protected during fabrication, transport and storage.
Welding earth clamps shall be attached in such a manner as to prevent stray arcing and contamination.
 10.7. Location of Field Joints
OTV will specify for information the location of field fit and welds on isometric or general arrangement drawings.
The Subcontractor shall after review of the isometric drawing specify the final location of filed joints and weld,
and submit for approval. Materials for cutting allowances will be dimensioned & included in the bill of materials.
All off-cuts shall be segregated positively identified as per relevant section of this data sheet and coded for
potential re use.
After finalizing the works, remaining stainless steel part not used shall remain OTV’s properties.

10.8. Venting & Draining

Venting and draining of all lines will be provided at locations indicated on isometric and general arrangement
drawings. Additional vents and drains required to meet the commissioning requirements can only be fitted in
exceptional circumstances because of the difficulty of pickling and passivation of the internal weld. Any proposed
vent or drain must be close to a flange or coupling such that the local pickling paste process can be used and
shall be approved by OTV.
Vents and drains shall be in accordance with the piping material specifications and drawings and applicable
standards.

10.9. Cleaning
All stainless steel accessible welds shall be cleaned both internally or externally of scale, grease and oil, dirt,
flux, weld spatter, and other contaminates before undertaking the welding process.
Solvent cleaning shall be used to remove grease, oil and foreign matter. Chlorinated solvents shall not be used.
All cleaning solvents shall be approved by OTV. For example the use of “avesta cleaning paste 401” or
equivalent and “avesta pickling & passivating paste 601” or equivalent can be accepted.

11.WELDING
All welding shall be carried out in accordance with the applicable standard ASME IX, ASME B31.3.

11.1. Welding Management Quality System

In addition to the requirements of ISO 9001 a welding management system incorporating the elements of ISO
3834.2 – Comprehensive Quality Requirements shall be prepared and managed. Compliance with this
requirement shall be demonstrated in full in the manufactures project specific quality plan to the OTV before work
is commenced.
Work Method Statements (WMS) shall be prepared and submitted fully outlining the steps to be taken and
implemented to control fabrication, welding, tolerance and distortion, and inspection.
The welding procedures shall be submitted for the OTV approval provided that they demonstrate that the weld
can meet the requirements of OTV’s specification and the applicable Code and Standard.
All WPQR and WPS and Welder Qualifications shall be witnessed, reviewed and approved by the Subcontractor
by an approved third party company. After approval by the third party, all the WPQR, WPS and Welder
Qualification, ITP Plan shall be submitted to OTV for approval.
 11.2. Welding Condition

All welding shall be done in a protected area, or protected by shelter upon approval of OTV.

11.3. Welding of Duplex and Super Duplex Stainless Steel

11.3.1. General
This clause refers to materials defined in OTV piping materials.
These requirements apply to the welding of duplex and super duplex stainless steel.
The principles given in The Avesta Welding Manual Practice and Products for Stainless Steel Welding and
document “HOW TO WELD duplex stainless steel, or approved equivalent could be used in developing specific
processes in the welding of these materials.
Furthermore the requirements of the standard NORSOK M 601 for welding and inspection of piping superduplex
shall also be applied.

11.3.2. Required Welding Processes

Only GTAW (TIG) is permitted for duplex and superduplex welding processes for the root and cold pass (1rst
and 2nd pass) but also for all filling passes

11.3.3. Essential Variables

For all welding applications:

∙ ASME 6G position shall be used in the PQR

● A consistent joint fit up as detailed in the qualified WPS shall be used by the Subcontractor, All welded joints
shall be mechanically cleaned for a minimum 2” (50mm) each side of the weld area and degreased using an
approved cleaning fluid.

∙ For duplex Stainless Steel base material, mixture of UNS specifications is not permitted without approval

∙ All welding wire shall be cleaned using an approved cleaning fluid before commencing any welding
operation.
∙ The shielding and backing gas shall be composed of 2% Nitrogen 98% ARGON, and certificate shall be
submitted for approval prior start of the works. The backing flow rate shall be between 12 and 15 ltr/mn.,

∙ The backing gas composition shall be monitored at the joint line using a calibrated portable oxygen monitor
immediately prior to starting or re-starting welding. The purge must be checked before each pass and must be
within the range of maximum 0.5% oxygen. A method statement and daily log shall be done for this purpose by
the Subcontractor and submit for approval to OTV prior start of work.

∙ For all welds purge gas of the root shall be applied for the duration of the complete weld (all passes).

∙ A purge dam shall be inserted within pipe to minimise oxygen content within enclosure. For difficult
accessible areas, plastic flexible soluble disc shall be used or equivalent approved system.

∙ Interpass temperature shall be limited to maximum 100ºC unless a lower temperature is specified by the OEM
for their equipment (e.g. butt weld plug valve). The interpass temperatures shall be monitored using
appropriate tools and controlled by the Subcontractor, and the Subcontractor shall ensure that the maximum
temperature quoted qualified WPS is not exceeded.

∙ To maintain the required interpass temperature forced draught cooling could be employed.

∙ Acceptable Energy Input, travel speed are detailed in the following table for the use in welding procedure
specification:

This table is for information only and parameters should be adapted to welders ability to weld (Travel speed).
 Wall Amps Volts Travel speed Min – Max Heat
Thickness p/mn Input KJ/mm

< 3mm 90-120 10-12 100 mm 0.5 - 0.6

3 - 6mm 90-140 12-14 100 mm 0.6 -0.8

6 - 10mm 90-140 12-14 100 mm 0.8 - 1.2

10 - 14 mm 90-150 12-16 100 mm 1.2 - 1.5

> 14 mm 90-150 12-16 100 mm 1.5 max

In order to control these value during production, a method statement and daily log shall be done for this
purpose by the Subcontractor and submit for approval to OTV prior start of work

∙ 2nd pass (cold pass) after the root must be of 80% lower heat input than the root pass.

∙ 2nd pass must be done in a single run

∙ No root tacking is permitted (bridge and bullet)

∙ Τacking shall be gased

∙ Sequence welding in opposite side to balance the forces applied to the parent metal. Length of run should not
exceed 150 mm.

∙ Post weld pickling & passivation should be performed in all accessible areas.

∙ A separate WPS is required for each different material combination

∙ Welding process or any change in welding process or the combination of welding process

∙ Change in wall thickness ½T to 2T of that qualified as per ASME IX

∙ Change in nominal piping diameter (DN) from the following qualified grouping

∙ Repair Welds shall be qualified and tested as per normal butt Welds
 ∙ In addition to the above a multiple weld repair procedure (i.e. a repair on a repair) shall be qualified. The
repair procedures shall ensure that the heat affected zone from the original weld remains in place and is not
affected by the subsequent thermal cycles of the repair welds.

11.3.4. Filler Metal Pitting Resistance Equivalent Number (PREN)

Filler metal Pitting Resistance Equivalent Number is defined as PREN= Cr(%) + 3,3 x Mo(%) +16 x N(%)
The filler metal PREN in contact with seawater and concentrate (brine) in minimum shall have a Pitting
Resistance Equivalent Number (PREN) shall be as follows:

PREN = Cr(%) + 3.3 x Mo (%) + 16 x N (%) for austenitic material or

PREN = Cr(%) + 3.3 x Mo (%) + 30 x N (%) for Duplex and Superduplex material of not less than 38 and,

A Crevice Factor of:

CF = Cr(%) + 3 x Mo(%) + 15 x N (%) of not less than 35.

11.3.5. Impact Testing

Impact testing shall be in accordance with NORSOK M 630.

Charpy V notch testing shall be performed for each welding procedure qualification in accordance with the
following:
∙ Charpy V Notch per ASTM A 370 (3 test specimens per set)
∙ Not applicable where the maximum permissible obtainable Charpy specimen has a width along the notch of
less than 2.5 mm
∙ Charpy samples shall be taken across the weld
∙ Notch placement shall be in the weld centre, FL, FL + 2 mm and FL + 5 mm (total 4 sets per qualification) and
normal to the pipe surface
∙ Absorbed energy shall be 48 J average and 36 J single value minimum per full size specimen
∙ Test temperature shall be -46ºC or MDMT (if lower)

A detailed procedure shall be submitted prior the testing to OTV for approval.

11.3.6. Hardness (ASTM E92)

Hardness testing shall be in accordance with NORSOK M 630.

Each welding procedure qualification test shall be hardness tested. Vickers hardness shall be measured on a
prepared weld cross section. Hardness shall be measured in the base metal, HAZ and weld metal. Hardness
results shall be submitted to OTV.
The hardness shall be maximum 290HV10 for base material, 350HV10 for HAZ and weld metal.

11.3.7. Corrosion Testing

Corrosion testing shall be in accordance with NORSOK M 630.

.
Corrosion testing shall be performed for each welding procedure qualification in accordance with the following:
∙ ASTM G48 method A
∙ Exposure time shall be 24 hours
∙ Specimens shall be full thickness
∙ Sample shall include the weld orientated in the transverse direction in the centre of the sample and the
sample shall include both heat affected zones and associated unaffected base metal
∙ All surfaces shall be exposed
∙ The weld cross section shall be prepared to a finish of 400 grit or finer. The edges may be rounded. All other
surfaces shall only be cleaned of dirt, oil and grease. No other alteration of the surfaces may be performed.
∙ Samples shall be pickled and passivated prior to the test.
∙ Test temperature for UNS S31803 & UNS S32205 weld samples (22% chromium duplex) shall be 40ºC.
∙ Test temperature for UNS S32750, UNS S32760 weld samples (25% chromium super duplex) shall be 40ºC.
∙ Test temperatures for welds of dissimilar materials, with combinations of UNS S31803 or UNS S32205 with
UNS S32750 (22% & 25% chromium duplex respectively) shall be 40ºC.
∙ Acceptance criteria shall be no pitting when inspected at a magnification of 20 X and maximum weight loss
shall be 4.0 g/m².

11.3.8. Ferrite Measurement

Ferrite measurement shall be performed in accordance with ASTM E562 on each welding procedure qualification
with following:
∙ Measurement shall be made at four evenly spaced locations (3, 6, 9 &12 o’clock positions) around the
circumference of the qualification test pipe.
∙ Measurements shall be made in accordance with the approved ferrite scope procedures.
∙ For previously qualified welders the first production run may be used for ferrite content qualification.
∙ ASTM E562 (Point Counting) Ferrite content shall be determined on a prepared cross section and shall
include measurements near the OD and ID surfaces and at mid wall for each location: base metal, heat
affected zone and weld metal.
∙ Samples shall be electrolytically etched in either NaOH or KOH in such a manner as to provide optimum
contrast for austenite and ferrite phase discrimination.
 ∙ The ferrite content shall be determined according to ASTM E 562 or equivalent and shall be within
- 35-55% for the base material
- 35-65% for the material welds
- 30-70% after welding during. fabrication
The microstructure, as examined at 400 X magnification on a suitably etched specimen, shall be free from
inter-metallic phases and precipitates.
∙ A minimum of 15 fields and 36 points per field shall be used.
∙ Average ferrite content shall be between 25% and 60%.

11.3.9. Metallographic Examination

Each welding procedure qualification shall have a metallographic examination in accordance with the following:
∙ Samples shall be prepared to a suitable metallographic finish for examination at 400 to 500 x magnification.
∙ Samples shall be etched using ASTM E407 etchant number 98 (K 3Fe(CN)4 with KOH or NaOH).
∙ Weld sample cross section shall be examined at OD, ID and mid-wall for each location; base metal, heat
affected zone and weld metal.
∙ Examination shall be conducted by a suitably qualified person at a minimum 400 x magnification.
∙ The microstructure shall be free from third phases other then austenite and ferrite for example carbides,
nitrides and inter-metallic phases.

11.3.10. Radiographic examination

Each welding procedure qualification shall have radiographically test. At least 3 full circumferential welding for
each one of the individual welders will be 100% radiographically tested.

11.3.11. Gas Purging or Shielding

Purge gas shall be as specified in the essential variable section and in the qualified in the WPQR.
Purge gas shall be started prior to arc being struck and continued throughout the entire weld, including capping
runs. Welding shall not commence until the oxygen content in the purge gas has fallen below the level qualified
by the welding procedure qualification test. The purge gas composition should be monitored at the joint line using
a calibrated portable oxygen monitor immediately prior to starting or re-starting welding in order that consistency
can be maintained. A method statement and daily log shall be done for this purpose by the Subcontractor and
submit for approval to OTV prior start of work, including documentation of the oxygen monitor and calibration
certificate.

Root runs and the internal surfaces shall be purged to reduce oxygen to < 0.5% by volume before welding.
Grinding of the weld root at start/stop locations introduces air into the purge gas, welding shall only be continued
when the oxygen levels are <0.5% by volume As already mentioned, a purge dam could be used and inserted
within pipe to minimise oxygen content within enclosure, and to limit the purged volume and gas used. For
difficult accessible areas, plastic flexible soluble disc shall be used or equivalent approved system.
Fig 1- Heat tints (weld discolouration) on pickled duplex stainless steel tube butt welds
made with Formier purging gas (NH10) containing known oxygen levels.

11.3.12. Grinding and polishing

Where grinding is used the final surface finish shall be no coarser than the original surface finish of the stainless
material. Progressive grinding shall be adopted to achieve the final ground surface. The low thermal conductivity
of stainless steels requires care in grinding operations to avoid colouration due to overheating with a consequent
reduction in corrosion resistance.
Following the final grinding application the surfaces shall be treated in accordance with OTV’s specification.

11.4. Welding of Austenitic Stainless Steel

11.4.1. General
This refers to materials defined in OTV piping Materials Specifications.
The principles given in The Avesta Welding Manual Practice and Products for Stainless Steel Welding, or
approved equivalent shall be used in developing specific processes in the welding of these materials.

11.4.2. Required Welding Processes

Only GTAW (TIG) is permitted for austenitic stainless steel welding processes for the root and hot pass (1rst and
2nd pass)
For the Fill and capping passes, GTAW can be used, or SMAW.

11.4.3. Essential Variables

For all welding applications:

∙ A separate WPS is required for each different material combination.

∙ Any decrease in the heat input per pass greater than 50% of that used in the WPQR.
∙ Any increase in heat input per pass of that used in the WPQR.
∙ Heat input for manual GTAW 1.5 kJ/mm maximum.
∙ Interpass temperature to be limited to 100 ºC maximum.
∙ Welding process or any change in welding process or the combination of welding Process.
∙ Change in wall thickness ½T to 2T of that qualified.
∙ Repair Welds shall be qualified and tested as per normal butt Welds
∙ In addition to the above a multiple weld repair procedure (i.e. a repair on a repair) shall be qualified. The
repair procedures shall ensure that the heat affected zone from the original weld remains in place and is not
affected by the subsequent thermal cycles of the repair welds.

11.4.4. Impact Testing

Charpy V notch testing shall be performed for each welding procedure qualification in accordance with the
following:
∙ Charpy V Notch per ASTM A 370 (3 test specimens per set) or ASTM A923
∙ Not applicable where the maximum permissible obtainable Charpy specimen has a width along the notch of
less than 2.5 mm
∙ Charpy samples shall be taken across the weld
∙ Notch placement shall be in the weld centre, FL, FL + 2 mm and FL + 5 mm (total 4 sets per qualification) and
normal to the pipe surface
∙ Absorbed energy shall be 48 J average and 36 J single value minimum per full size specimen
∙ Test temperature shall be -46ºC or MDMT (if lower)

11.4.5. Hardness (ASTM E92)

Each welding procedure qualification test shall be hardness tested. Vickers hardness shall be measured on a
prepared weld cross section. Hardness shall be measured in the base metal, HAZ and weld metal. Hardness
results shall be submitted to OTV’s Representative.
The hardness shall be maximum 290HV10 for base material, HAZ and weld metal.
 11.4.6. Radiographic examination
Each welding procedure qualification shall have radiographically test. At least 3 full circumferential welding for
each one of the individual welders will be 100% radiographically tested.

11.4.7. Material Specifications

Stainless steel pipe materials shall comply with the OTV Piping Material Specifications.

11.5. Welding Supervision for Stainless Steel pipework

Full supervision of welding operations shall be done by a welding supervisor holding certification or OTV
approved alternative.

11.6. Welder Qualification for Stainless Steel pipework

Welder qualification and certification shall be in accordance with the current revision of ASME IX & ASME B31.3.
All WPS and WPQR shall be submitted to OTV, and approved by OTV, prior to commencement of fabrication.
Welders carrying out welds for pressure pipe shall be qualified as per ASME 6G position, for all variables in
production prior to commencing welding operations and records shall be submitted for review and approval to
OTV and included in the MDR.

● For duplex and superduplex, each welder shall be qualified for each essential variable and for the
following destructive (DT) and non destructive testing (NDT):
1) Visual examination
2) Corrosion testing,
3)Impact testing
4)Hardness testing
5) Ferrite level measurement
6) Metallographic examination
7) Dye penetrant tests
8) Radiographic tested (R.T)

● For austenitic stainless steel, each welder shall be qualified for each essential variable and for the
following destructive (DT) and non destructive testing (NDT):
1) Visual examination
2) Dye penetrant tests
3) Radiographic tested (R.T)

Each welder shall be requalified for this project. Copies of welder qualification certificates of the personnel
employed on the welding operations shall be approved first by a third party. And then the certificates shall be
submitted to the OTV’s Representative for approval.
OTV’s Representative will witness Welding Procedure Qualifications, Welder qualifications and be notified 1
week (or at least 72 hrs) prior to commencement of these qualifications.
All weld preparations, welding heat treatments, weld examination, welding equipment, filler wire, electrodes,
welding symbols, terms and definitions shall conform to the Standards.

11.7. Weld Inspection and Testing

11.7.1. Inspection
All NDE of welds shall be carried out by a certified authority in accordance with applicable standard ASME B31.3
Normal and Category M Fluid service and as a minimum the following non destructive examination shall be
undertaken:

● For duplex and superduplex:

1) All welds 100% visual and dimensional examination,
2) All butt welds and socket welds shall be 100% dye penetrant tested
3) All welds, 10% of fillet welds shall be dye penetrant tested
4) For Butt Welds, 10% of the total weld of each piping line shall be random radiographically
examined over the full circumference
5) For Socket Welds, 10% of the total weld of each piping line shall be random radiographically
examined over the full circumference
6) For piping with schedule 20 thickness, all socket and butt weld shall be 100% radiographically
examined over the full circumference
7) 100% of the weld shall be ferrite content tested with a calibrated portable ferrite. Measurement
technique shall be in accordance with an approved procedure using a Fischer type Ferrite Scope
or equivalent. Ferrite content shall be between 20-60 % with no negative tolerance on minimum
value.

● For Austenitic stainless steel:

1) All welds 100% visual and dimensional examination,
2) All butt welds and socket welds shall be 100% dye penetrant tested
3) All welds, 10% of fillet welds shall be dye penetrant tested
4) For Butt Welds, 10% of the total weld of each piping line shall be random radiographically
examined over the full circumference
5) For Socket Welds, 10% of the total weld of each piping line shall be random radiographically
examined over the full circumference
6) For piping with schedule 20, all socket and butt weld shall be 100% radiographically examined
over the full circumference

11.7.2. Rejection
Any rejected welds shall be reported to the OTV’s Representative immediately, an authorised approved weld
repair procedure shall be used. The OTV’s Representative will nominate alternate welds to be examined. Each
weld shall be identified by welder’s name and number. Records of each welder shall be kept including but not
limited to the number of rejected welds, repairs and re examinations.
The severe cyclic service conditions shall be applied to the acceptance criteria of external undercut per ASME
B31.3 Table 341.3.2, for all butt welds.
 11.7.3. Manufacturing Data Records
Full manufacturing data records (MDR) shall be provided including the following, but not limited to:
● Initial survey
● Pipework Material certification:
o Material supplied by subcontractor certifications (such as bolting, gasket,…)
o Welding Consumable Certifications,
o Others material certifications,
● Approved Inspection and Test Plans (ITPs)
● Approved Quality Plan
● Approved WPS / WPQR
● Approved Welder Qualifications
● List of tools for examination, inspection,…and technical documentation with certificate
● As Built Drawings (red line mark-ups and in autocad format) including survey dimensional control, spool
register
● Works method statement
● 100% Weld data records including (Weld n°/ position/ Pass n°/ Volts/Amps/Travel Speed/Energy Input)
● Traceability Records / Visual Inspection Reports
● Pressure Test Records
● Pressure test procedure including risk assessment
● NDT, NDE and Mechanical test Reports / Certification
● Passivation / Cleaning Reports
● Flushing record,
● Repair Reports,
● Delivery Dockets
● Miscellaneous Records & Reports

11.8. Cleaning
Surfaces shall be cleaned as required with the appropriate cleaning to ensure all contaminants are removed in
accordance with OTV’s specification.

11.9. Pickling & Passivating

Surfaces shall be pickled and passivated as required with the appropriate paste to ensure all contaminants are
removed in accordance with OTV’s specification.

Cleaner agreed with NORSOK 20%HNO3 + 5%HF @ 60oC for 5 mins and passivated over 24 hours in
atmosphere.

11.10. Welding Procedures

As already stipulated, a critical aspect of the welding of stainless steels is ensuring welding procedures do not
compromise the metallurgical structure and corrosion resistance. It is essential that the welding and other
fabrication processes do not compromise the performance of the stainless steels.
Welding procedures for all grades of stainless steel can be developed by the subcontractor and submitted to the
OTV for approval. OTV has qualified numerous GTAW 316L, duplex and super duplex welding procedures which
can be made available as a guideline to the Subcontractor for use.
All welds shall be marked to enable the identification of the welder who produced the weld.
Weld maps with full traceability are required to be submitted to OTV as part of the contract documentation MDR.
Traceability per weld shall include welder ID, date welded, WPS No, material heat number, location in drawing
per item, consumable batch number per weld, NDE/NDT type, percentage and results. A permanent record shall
be submitted verifying visual weld inspection is completed per weld.

11.11. Socket welding

Socket welding on superduplex pipework is not permitted as water is trapped in the interstice area creating a
dead zone with severe corrosion.

For the socket welding on Stainless steel, in order to get proper socket weld fit-up (minimum of 1/16" before
welding as per ASME code), a “gap-a-let” shall be used and grade of material shall be same than the support.
The Subcontractor shall submit for approval one sample, technical documentation and certificate of the gap-a-let
prior to commencement work.

11.12. Backing Rings

Permanent backing rings shall not be used.

11.13. Welding Wires

All consumables shall be submitted to the OTV Representative for approval.

11.14. Butt welds for Orifice & Meter Runs

When the design of an orifice run necessitates welds, these shall be ground smooth and flush with the inside of
the pipe. Pipe-tap connections where required, shall be drilled through the pipe wall and be smooth inside.

12.PROTECTION, PACKING & MARKING

12.1. Protection
Prior to transport, all piping shall have the ends, pipe openings and branch connections adequately sealed and
protected against the ingress of contaminants and moisture. All threaded connections shall be adequately
protected against thread damage and corrosion.
Flanged openings shall be protected with suitable flange protectors. The protectors shall be sealed with
waterproof tape.
12.2. Packing
Carbon steel shall not come into contact with stainless steel.
All pipes and components shall be adequately protected from damage during handling and shipment. Handling
equipment, blocking, strapping, or hold-down devices shall be applied so as not to mar the components in any
way. During shipment components shall be further separated by dunnage as may be necessary to prevent
damage.
Piping shall not be exposed to salt or salt spray. Pipework is to be ‘shrink wrapped’ in plastic wrap for transport to
ensure contamination does not occur.

12.3. Marking
Each welder will stamp all his welds with his personal I.D. stamp and the batch number of the welding wires and
electrodes for the purpose of identification and tracing.
The isometric pipe drawing number shall mark on each completed pipe section.
The marking on the pipe section shall be done with an “electric – pencil” or any other marking system approved
by the OTV Quality Control Manager or a third party approved by OTV.
In all the case the pens or paint markers, these must be free of chlorides, sulphides, halides and Zinc.
Certificates of the pens or paint markers shall be submitted and approved by the OTV Quality Control Manager
or a third party approved by OTV.
The location of the marking and stamping will be in a distinct place on the item.
Material supplied by the OTV will be bar coded or similarly identified.

13.STORAGE & HANDLING PROCEDURES

Pipework shall be handled, transported and stored strictly in accordance with the piping manufacturer’s
recommendations and in a manner that will not cause permanent deformation nor result in contamination or
damage. Pipework damaged during handling, transportation or storage may be liable for rejection.
Stainless steel piping shall not be handled with bare steel hooks, chains or lifting slings without the use of
protective insulating material.
Stainless steel piping shall be segregated to prevent any contact with carbon steel.
Spools shall be stored off ground on clean wooden dunnage.
Suspected free iron contamination, such as evidenced by stains or discolouration, shall be verified by ferroxyl
testing in accordance with the procedures outlined in ASTM A380 Standard Practice for Cleaning, Descaling,
and Passivation of Stainless Steel Parts, Equipment and Systems. Free iron contaminated areas shall be
cleaned and passivated, at the Subcontractor expense, using the procedure outlined in ASTM A380 prior to
delivery to the site.

14.INSTALLATION OF PIPING
14.1. Iron Contamination
Refer to the requirements already specified.
14.2. Pipework Erection
All pipes shall be inspected before erection to ensure that they are free from loose scale and contamination. Pipe
spools shall be inspected for damage, contamination or other non-conformance to specification. Pipework shall
be erected on permanent supports designated for the line.
Temporary supports shall be kept to an absolute minimum, but to an extent sufficient to protect nozzles and
adjacent piping from excessive loads during the erection.
Pipework shall be fitted in place without springing or forcing to avoid undue stressing of the line or strain being
placed on a vessel or item of equipment, etc.
Where possible, shop fabricated spools shall be erected before field fabricated spools.
Prefabricated sections shall be fitted into position without damage or distortion.

14.3. Temporary Pipe Supports

Temporary supports shall be designed to carry the loads during the erection phase.
Temporary supports shall be spaced at intervals not exceeding that required to prevent excessive bending
stresses or deflections. For pipelines which are liquid filled in normal service all temporary supports shall be
removed prior to hydro testing except with the approval of the OTV’s Representative.
Welding of temporary pipe supports to pipelines shall be avoided. Any pipe support welding required to meet the
construction requirements can only be fitted in exceptional circumstances because of the difficulty of pickling and
passivation of the internal weld. Any proposed welding must be close to a flange or coupling such that the local
pickling paste process can be used and shall be approved by the OTV’s Representative. Alternatively internal
gas purging of the pipe may be used and shall be approved by the OTV’s Representative.
All temporary pipe spools and supports that are an aid to erection, testing/flushing, etc. are to be specially
marked for removal identification. A schedule of temporary supports shall be maintained to document the
installation and removal. The removal of such supports shall be verified by OTV’s Representative.

14.4. Flanged Joints

Before assembly, flanges shall be clean and free from any detritus matter (e.g. rust, dirt, welding metal or other
contamination). The joints shall be brought up flush and square without forcing so that the entire mating surfaces
bear uniformly on the gasket and then mated-up with uniform bolt tension.
Flanged connections shall be made up using a construction gasket before butt welding the sections of piping to
ensure that no misalignment occurs.
Flange gaskets shall not protrude into the bore of the pipe.

14.5. Threaded Pipework

Threaded pipe and fittings connections shall be avoided for seawater applications.

If used on other application the following should be followed:

Unless otherwise stated on approved drawing or specifications, pipe threads shall be American National
Standard Pipe Threads to ASME B1.20.1. All threading shall be carried out after bending, forging or heat
treatment but where this is not possible, suitable thread protection must be provided.
All threads shall be covered with a Teflon tape or paste such that the stainless material does not gall.
Threaded fittings shall not be seal welded unless approved by the OTV’s representative.

14.6. Butt Welded Valves

Particular care shall be taken during the welding of butt welded valves to piping to ensure that the valve internals
are not damaged. All welding shall be carried out in accordance with the valve OEM’s recommendations.

14.7. Valve and Equipment Flange Connections

Flange covers shall be retained on all flange connections to valves or equipment, until ready to connect the
mating piping. All equipment shall be blanked, either by pressure test blanks, spades or blinds, to stop the
ingress of internal pipe debris.
In general, flange connections to equipment shall be the last connection made on completion of a line or
interconnecting system of lines. With the piping flange fitted and prior to bolting up the joint, the following
tolerances shall be maintained:
∙ Bolting shall move freely through accompanying bolt-holes at right angle to the flange faces.
∙ There shall be a clear gap between two flange faces before gasket installation. There shall be sufficient
flexibility to install and replace gaskets.
All flange bolts to equipment and tanks shall be slipped to demonstrate to the OTV’s Representative that no load
is imposed on the equipment or tank flange connection.

14.8. Piping associated with instrumentation

The instrumentation in line with the piping shall be installed by the Subcontractor according to manufacturer’s
OEM documentation, relevant standard and OTV’s specification.

For the instrumentation like the vortex and magnetic type flowmeter, the earthing shall be done by the
Subcontractor. A work method statement shall be submitted prior start of work.
For DN ≤ 300: The ground cable is in direct connection with the conductive flange coating and is secured by the flange
screws.
For DN ≥350: The ground cable connects directly to the metal transport bracket.

For instrumentation which have direct connection to the piping, the principle shall be as following (see figure): the
Subcontractor shall manufacture, install and test until the isolation valve. Connection of the instrumentation with
block valve shall be done by others.
14.9. Piping for air process

For piping for air process purpose, the earthing shall be done by the Subcontractor. A work method statement
shall be submitted prior start of work.

14.10. Piping Associated with Rotating Equipment

During construction, piping shall not be connected to the equipment, unless pipe supports are installed.
Piping work shall not start from the equipment nozzles. Piping, upstream and downstream of the machinery shall
be erected progressively away from the nearest anchor support. The piping shall be erected so that no residual
strain is imposed on the nozzles (i.e. the pipe is free of “cold pull” or “cold spring”.
All work on piping systems (except final bolt tightening of piping flanges adjacent to equipment nozzles) shall be
completed before the equipment can be offered for final alignment inspection. This includes pressure tests,
cleaning or air blowing, insulation, and installation of permanent supports (fixed, sliding and spring supports).
The lock pins of any spring supports immediately adjacent to rotating equipment shall be kept in place until
systems are filled with product and pressurised.
All equipment nozzles and mating flanges shall be erected such that the vertical, horizontal and rotational bolt
hole offset is less than 0.5 mm. In order to limit the load on equipment, flanges with a pressure rating of Class
300 and higher shall be parallel to within 0.15 mm over the flange diameter. Flanges with lower pressure ratings
shall be parallel to within 0.2 mm over the flange diameter.
Unless final flange joint make-up is witnessed by a OTV’s representative, all bolt-hole offsets and face parallel
readings shall be recorded and submitted to the OTV’s for approval.
14.11. Gaskets
Gaskets shall be stored handled and installed in accordance with manufacturers’ instructions. Gaskets shall be
replaced after opening or dismantling of flange connections.
Gasket shall be supplied by the Subcontractor. The Subcontractor shall submit to OTV’s representative for
approval prior start of work sample of gasket, certificate and technical documentation.
Gaskets shall be in accordance with OTV’s technical specification.

14.12. Bolting
Fasteners shall be in accordance with the requirements in the piping and valve material Specifications and Data
Sheets.
All stainless steel fasteners shall be coated with an anti seize compound such as Loctite Nickel 771 or approved
equivalent.
Fasteners that are cadmium plated and coated with Xylan shall not be coated with lubricant.
Where the coating is damaged during installation they shall be replaced.
Manually pulled flange bolts and stud bolts shall extend fully through their nuts by at least one thread, but not by
more than 15 mm.
All flanged stud bolts shall be progressively tightened to equalise bolt pressure on the gasket. A detailed
procedure shall be developed prior to flange assembly, which will follow the different step:
a) The required torque value shall be calculated by the subcontractor and submitted to OTV for approval
b) Always use a torque wrench or other controlled-tensioning device (recently calibrated)
c) Tighten nuts loosely by hand in the first instance, according to the cross bolt tightening pattern, then
hand-tighten evenly
d) Using a torque wrench, torque to a maximum of 30% of the full torque first time around, according to
the cross bolt tightening pattern. Check that the flange is bearing uniformly on the gasket
e) Torque to a maximum of 60% of the full torque, according to the cross bolt tightening pattern
f) Torque to the full torque, according to the cross bolt tightening pattern
e) Final pass at full torque, in a clockwise direction on adjacent fasteners.
The tightening operation shall be always done according to the cross bolt tightening pattern.
After the five basic torquing passes are completed, it may be beneficial to repeat pass e) until no further rotation
of the nut is observed. The final tightening must be uniform, with each bolt pulling the same load
The torque necessary shall be confirmed for each bolt size and each pipe specification with threads coated as
specified using a load cell for test work. All torque wrenches shall be calibrated.
Nuts and bolts shall have their grade marks visible after installation. Stud bolts cut from long lengths of studding
shall have material grade stamped on end of each cut.
Coated fasteners shall not be cut but replaced with a fastener of the correct length.

14.13. Pipe Supports

Pipe supports shall be in accordance with the OTV’s specifications for pipe support and typical guide drawings.
The Subcontractor shall do the shop drawing for each support based on the typical guide drawing supplied by
OTV.
Piping shall not be forced to fit with support locations in such a manner that additional stress is introduced.
Where spring supports are installed the spring shall be locked/gagged until commissioning/start up.
Where non stainless steel components are used to support stainless steel pipe isolation materials shall be used
to prevent dissimilar metal corrosion.
Pipe supports secured to concrete shall be packed with packers of similar material (stainless steel supports shall
have stainless steel packers). The gap beneath the support base and the concrete shall be filled with a non
shrink epoxy based grout installed in accordance with the manufacturer’s instructions. The grout shall be a
minimum of 20 mm and a maximum of 50 mm thickness.
Generally it should not be necessary to weld wear plates, reinforcing pads or trunnions during site erection
although there may be instances where it is required. Vent holes in wear plates and trunnions are generally not
required. However, when the wear plate or a trunnion covers a circumferential weld that has not been pressure
tested, a vent hole is required for leak detection.
Prior start of work, at least the following documentation concerning the support shall be submitted to OTV for
approval: documentation, certification, detailed drawing, coating documentation….

14.14. Cold Springing & Alignment

Unless otherwise indicated on drawings cold springing and manipulative heating shall not be employed to make
up dimensions. Inaccuracies in the positioning or alignment of equipment, or errors in shop fabricated piping,
shall be accommodated by allowing closing spool pieces and site welds.
Pipe line-up clamps shall be used. Tack welding of steel shapes to the pipe for line-up purposes shall not be
used unless incorporated into an approved procedure for the use of bridging pieces. Such procedures shall
include the removal and surface repair after removal of the bridges.

15.PIPING AND INSTRUMENTATION DIAGRAM & ISOMETRIC CHECK

15.1. General
Before undertaking a pressure test of a completed system a check against the piping and instrumentation
diagram (P&ID) and Isometric shall be undertaken to ensure conformity of the system. Any variance to the Piping
& Instrumentation Diagram shall be advised to the OTV’s Representative.

16.PRESSURE TESTS
16.1. General
The design and test pressure and design standard is defined in OTV’s piping material specifications.
Piping shall be subject to a hydrostatic test.

The Subcontractor will perform two pressure tests on each piping section:
▪ First Pressure Test: Will be performed at the end of the prefabrication stage, and after successful all
N.D.T. tests of the welded pipe section.
 ▪ Second Pressure Test & Leak Test: Will be performed on site after completion of assembly of the
complete piping system, and after successful N.D.T tests for field welds.
The Subcontractor shall do a risk assessment and specific procedure for the pressure test.
Prior to the pressure test on site, a pneumatic test with Azote shall be done at maximum 0,1 bar in order to
detect major leak.
Subcontractor shall develop specific procedures for welded pipes pressure test. The test pressure shall be done
a different step of pressure (20%, 50%, 100% of test pressure and decrease of the pressure at 20% for
example).

Piping designed to ASME B31.3 shall be subject to a hydrostatic leak test in accordance with Clause 345.4,
except as modified in the following sections.
The test pressure shall, unless otherwise specified, be in accordance with the piping specification.
Testing shall not take place with system temperatures of 4°C or less or where the ambient temperature during
test falls by 5°C or more, nor during rain or fog unless under suitable cover.
The following are excluded from pressure tests:
∙ All small bore instrument control piping downstream of the first piping block valve.
∙ Open drains and vents to atmosphere (leak test only)
∙ Closure welds as defined in ASME B31.3 Clause 345.2

16.2. Test Equipment

Certified and calibrated pressure, temperature and time recorders shall be used for all pressure tests. The
pressure shall be shown in bar. Pressure gauges and recorders used to indicate and record test pressure shall
be dead weight tested for accuracy according to a procedure, dependent on the type of equipment.
A minimum of one gauge shall be positioned at the highest point and one recorder is to be positioned at the
lowest point. Accuracy of pressure gauge shall be at least 0.5% at full scale and 0.5% for the recorder. The test
pressure shall be within 60% of the gauge range (20% from top and 20% from bottom). If there is a deviation of
more than 2% between gauge and recorder during test, the test shall be stopped and the equipment recalibrated.
Test pumps shall be used rather than manual bucket methods. Test pumps shall be rated for the pressure of the
system to be tested.

16.3. Test Preparation

Amongst other things, the requirements of ASME B31.3 Clause 345.3 shall be met.
All piping shall be adequately supported before the pressure test is performed. Spring or other variable type
supports shall be blocked to prevent movement. Unless otherwise noted, all valves are to be through body
tested. First block valve for pressure instruments shall be included in the test.
Piping containing check valves shall have the source of test pressure on the upstream side.
If this is not possible, the check valve disc shall be removed or jacked open.
Where the test pressure to be applied to the piping is greater than the maximum allowable test pressure for
valves, the valves shall be blinded off on the side to be tested, or removed and replaced by dummy spools. The
valve OEM data shall be referred to in respect of allowable test pressure.
Pumps, compressors, filters, tanks and vessels shall be blinded off prior to pressure testing.
All test sections shall be provided with over pressure protection set at 10% above the test pressure.
A schedule shall be prepared for sensitive equipment that shall be removed, blocked off or isolated during
testing, such as relief valves, inline instruments, pumps, compressors and vessels. This schedule shall be a part
of the test procedure.

16.4. Test Media

For hydrostatic testing the test medium shall be fresh treated, oxygenated potable water.
Bore water, seawater or other untreated water shall not be used.
The chloride ion content of the water used for pressure testing Stainless Steel lines shall be less than 200 mg/l
(200 ppm). The Subcontractor shall supply the test media in order to perform the test, including certificate and
laboratory analysis.

The pH value of the water shall be between 6.5 and 8.5.

Preservation fluids shall not be added to the test media.

16.5. Hydrostatic Leak Test

The test pressure shall be maintained for a sufficient length of time to permit visual examination to be made of all
surfaces, welds and connections, but not less than thirty minutes. One hour test duration shall apply for piping
systems at the test pressure value. Care shall be taken to ensure that over pressuring due to static head does
not take place.
Piping sections shall be filled to expel all air prior to the test being undertaken. The vent valves shall be closed
and the pressure increased to the leak test pressure. Pressures shall be recorded.
The piping systems shall not show any sign of plastic deformation or leakage.

16.6. Pneumatic Testing

Where a pneumatic leak test is specified in lieu of a hydrostatic leak test, the test shall be in accordance with
ASME B31.3 Clause 345.5 except as modified below. The sequence of test pressuring installed systems shall be
as follows:
∙ A pressure of 0.5 barg shall be introduced in the system and a leak test performed. The pressure shall gradually
be increased to 50% of the specified test pressure and kept for minimum 10 minutes to equalise strain.
∙ The pressure shall then be increased in steps of 10% of the specified test pressure, until the specified test
pressure is reached. At each step, the pressure shall be kept for a minimum of 10 minutes to equalise strain.
∙ The specified test pressure shall be kept for one hour. The pressure shall than be reduced to the design
pressure before examining for leakage.
Pneumatic testing shall not be carried out without the approval of the OTV’s Representative.
For pneumatic testing, the test media shall be oil free, dry air or any inert gas. The use of air for testing shall be
limited to a maximum pressure of 7.0 barg. Above this pressure nitrogen shall be used. Pneumatic testing
introduces risks and hazards to the work environment.
Procedures shall include necessary measures to meets the OH&S requirements.
The piping systems shall not show any sign of plastic deformation or leakage.

16.7. After Completion of Test

The tested systems shall be depressurised by opening the depressurising valve in the test.
After depressurisation, all vents and low point drain valves shall be opened and the system shall be thoroughly
drained where the test medium is water.
The pipework shall be drained within 4 hours of completion of the pressure test.
Reinstallation of the system shall be performed in accordance with the test procedure.
Where permanent or temporary strainers have remained in place for the hydrostatic pressure test, they shall be
removed following the test and thoroughly cleaned before reinstalling.
Ends of pipes and nozzles shall be fully protected against the ingress of foreign material by the use of caps,
plugs or plate blinds sealed with gaskets. These shall not be removed until just prior to final assembly.
Parallel orientation of flange faces and alignment to equipment shall be checked prior to reinstatement.
Where vent holes are required in reinforcing pads they shall be sealed upon completion of pressure test.

16.8. Rectification of Leaks

Leaks shall be rectified in accordance with a OTV’s approved method. Care shall be taken that any rectification
work does not in anyway compromise the durability requirements of the fabrication of stainless steel piping.

16.9. Retest
Should a piping section fail a pressure test, the section shall be retested after rectification of the defect. Details of
failure and rectification method shall be recorded

17.PAINTING OF PIPING

The Subcontractor shall refer to the painting specification. Austenitic stainless steel pipework shall be outside
painted as per the specification.

18.FINAL PIPE MARKING

The piping shall be marked by the Subcontractor according to OTV’s specification. A work method statement
shall be submitted to OTV’s for approval. As already specified, attention shall be paid in order to use compatible
material that will not corrode the support material.
19.FINAL INSPECTION

During start-up of the plant and commissioning, the Subcontractor shall make available on site skilled personal to
assist and correct immediately any failure and leakage which will occur on the system supplied and installed by
the Subcontractor.

20.SPARE-PARTS

The Subcontractor shall supply the list of the quantity, type and diameter of gasket / bolts used for the installation
of piping. The Subcontractor shall supply as a spare parts:
- 5% of gaskets (minimum 4 gaskets/ diameter and Class),
- 1 set of bolts for each diameter,
APPENDIX 1 – MATERIAL HANDLING AND STORAGE

MATERIAL HANDLING OF SUPER DUPLEX STAINLESS STEELS

1. All SDSS materials will be stored in clean dry areas apart from other materials and covered to keep
from contamination from other ferrous and non-ferrous alloys.

2. Storage will be carried out within racking either unpainted or protected carbon steel. Painted racking
will cause welding problems however small the contact is and carbon steel unprotected racking will
cause contamination problems.

3. Fittings and Flanges supplied on pallets or in boxes will be stored within the racking system and
remain covered until called for usage.

4. Forklift trucks if used must have the Forks suitably protected to prevent Carbon Steel contact with
the SDSS materials.

5. Pipe Clamps ( Camlocks ) must not be used as the teeth are intended to bite into the surface for grip
but with the hard surface of SDSS this will not be possible and could result in an accident.

6. Cutting of pipes and fittings will be carried out cold using only new and clean good quality tooling
specifically and solely for SDSS use. Machine Cutting with use of lubricant is acceptable but the
pipes and fittings require to be solvent cleaned inside and outside afterwards to remove any traces
of lubricant.

7. Cutting by Plasma is acceptable providing the local HAZ area is removed by grinding. ( 0.5mm )

8. Grinding will be carried out by new discs solely for SDSS use avoiding scorch and burn marks. All
Grinding shall only be carried out in areas isolated from the SDSS material.

9. Flapper Wheels, Files and Wire Brushes must only be for SDSS use only.

10. Power Wire tooling shall be avoided in particular at inner bores as smear contamination of the
surfaces can occur.

11. Material Transfer shall be carried out pre cut and use shall be made of vibro etch engravers.

12. Temporary attachments of any kind will not be allowed on the material.
13. TIG wires shall be wiped clean with acetone or similar prior to use.

14. Work Benches, Vices, Positioner Chuck Jaws etc must all be protected. These areas shall be vacuum
cleaned at regular intervals to remove grinding dust / particles.

15. Tooling suspected of contamination shall be disposed of.

16. Markings of material shall be by use of paint markers or pens free of Chloride and Sulphides and
suitable for S.S. use.

17. Consumables shall be handled and stored as recommended by the manufacturer.

18. Work Areas shall be specific for SDSS usage free from potential contamination from other materials
and must be covered and wind free. Continual Good House Keeping Operations shall be carried out
to maintain this Quarantine Area.