PDO SPECIFICATIONS

Contractor : Special Technical Services Tebodin

Contract Number : C31-1162

Contract Type : Engineering Maintenance Contract

Quality Control Procedure

Scope

Guidelines for the fabrication, assembly, erection, welding, painting & testing of carbon steel,
stainless steel, duplex stainless steel piping spools for the construction/Installation of
maintenance & overhaul
Reference Codes

SP-1208 : Pipeline Construction Specification

Sp-1190 : Design for sour service specification

SP-1177 : Specification for Welding of Class 1 Pipeline

SP-1173 : Specification for Welding of On-Plot Pipe work

SP-1174 : Specification for Welding of Class 2 Pipelines

SP-1176 : Non-Destructive Examination

SP-1212 : Hydrotest Requirements for Pipeline Systems

SP-1246 : Specification for Painting and Coating of Oil & Gas

SP-2051 : Specification for Flushing, Pressure Testing, Pickling and Sensitive

Leak Testing of Mechanical Equipment and Piping

SP-1097 : Specification for Welding of Duplex Stainless Steel Pipelines

SP-1189 : Specification for Duplex Stainless Steel Line Pipe

SP-2020 : Flange Connections Bolt Torquing and Tensioning

SP-2163 : Spec of PDO Standard Piping Class

DEP 31.38.01.11 : Piping - general requirements

DEP 31.38.01.31- Gen. : Shop and field fabrication of piping

DEP 30.10.60.18- Gen. : Welding of metals

DEP 31.38.01.29 : Pipe supports

DEP 30.10.60.31- Gen. : Oxidation of stainless steel Weldment

 PDO SPECIFICATIONS

DEP 31.10.00.10- Gen. : Material traceability and PMI

DEP 61.40.20.30 : Welding of pipelines and related facilities (amen

DEP 30.48.00.31- Gen. : Protective Coatings for Onshore Facilities

DEP 61.10.08.11- Gen. : Field inspection prior to commissioning of mechanical

equipment
PDO MESC Specifications
1. MESC Group 74 - line pipe
2. MESC Group 76 - fittings and flanges
3. MESC Group 77 - valves
4. MESC Group 81 - bolting
5. MESC Group 85 - gaskets and packing

Material
1. Bolt and Nut
a) ASME SA 193 / SA 193M is – Specification for alloy-steel and stainless steel
bolting material for high-temperature service.
b) ASME SA 194 / SA 194M is – Specification for carbon and alloy steel nuts for
bolts for high-pressure or high-temperature service, or both
c) SA 320 / SA 320M is – Specification for alloy steel bolting material for low-
temperature service
d) SA 354 is – Specification for quenched and tempered alloy steel bolts, studs, and
other externally threaded fasteners
2. Pipes
a) SA-106/SA-106M - Specification for seamless carbon steel pipe for high-
temperature service
b) SA-312/SA-312M - Specification for seamless and welded austenitic stainless
steel pipes
c) SA-333/SA-333M -Specification for seamless and welded steel pipe for low-
temperature service
d) SA-335/SA-335M - specification for seamless ferritic alloy steel pipe for high-
temperature service
e) API 5L - Seamless and welded steel pipes for use in pipeline transportation
systems

3. Fittings
a) SA-105/SA-105M - Specification for carbon steel forgings for piping applications
b) SA-182/SA-182M - Specification for forged or rolled alloy and stainless steel pipe
flanges, forged fittings, and valves and parts for high temperature service
c) SA-234/SA-234M - Specification for piping fittings of wrought carbon steel and
alloy steel for moderate and high-temperature service
 PDO SPECIFICATIONS

Certification type as per BS EN ISO 10204

Type 2.1 - Declaration of compliance with the order by the company

Type 2.2 - Test report by the company
Type 3.1 - Inspection certificate 3.1, the manufacturer’s authorized inspection
representative independent of the manufacturing department
Type 3.2 - Inspection certificate 3.2, the manufacturer’s authorized inspection
representative independent of the manufacturing department and
either the purchaser’s authorized inspection representative or the
inspector designated by the official regulations

SP-1173
DEP- 31.38.01.31
Incoming material inspection report, not accepted without proper identification or to carry out
PMI. CS, SS, and DSS shall be separated to avoid cross contaminations. Color coding for
identifications

Joint Preparation
a) All surfaces to be welded and the surrounding areas for a distance of at least 50 mm
from fusion faces shall be cleaned by wire brush / pencil grinder. The fusion and
surrounding surfaces shall be clean and free from oil, paint, dirt, rust, oxides or any
other foreign matters which could interfere with/spoil the welding.
b) Heat/cast numbers shall be transferred during mark out and prior to any cutting
operation.
c) The markers used on SS, DSS and SDSS materials shall be free from sulphur, chloride and
other halogens
d) Cutting and bevelling of stainless steel and duplex stainless steel shall be done using
plasma cutting or grinding.
e) Thermally- cut surface edges of low alloy and high alloy steels and cold sheared plates
shall be dressed to 2mm (approx.) by machining or girding to remove notches and scale.
End Preparation
a) End bevels and holes for branches shall be prepared by machining or machine flame
cutting or by using bevelling machine and or grinding machine. Holes for branches less
than 25 mm (1 inch) nominal bore shall be drilled or machined.
b) For stainless steel applications grinding wheels and wire brushes of stainless steel grade
shall be used and shall be dedicated to this work
Alignment & Fit-Up
a) Bridge tacks/pieces shall be made from parent metal. Alignment and joint fit up
dimensional tolerances shall be maintained as per the applicable WPS.
b) Internal misalignment in circumferential butt joints shall be limited to a maximum of
1.5 mm and shall be equally distributed around the circumference in order to
facilitate welding of the root pass.

Size DN
 PDO SPECIFICATIONS

Weld Separation
a) The minimum distance between the edges of two pressure containing parts shall be
twice the wall thickness of the thicker pressure part. The same requirement applies to
the distance between non-pressure attachment welds and a pressure-containing weld in
order to allow non-destructive inspection of the pressure-containing weld. Longitudinal
welds in two adjacent pipes should be 180° apart.
b) If the pipe contains a longitudinal weld, this weld shall not be located at the bottom of
the pipe after installation and it shall be located at least 45° from the bottom of the
pipe.
c) The toes of adjacent circumferential weld shall be separated as shown below

Welding Process
a) Butt welds and pressure containment fillet welds of all piping shall use GTAW process
with addition of filler metal.
b) For piping’s GTAW and SMAW process shall be used as per the following table

c) A minimum of three weld passes, where practical, should be deposited for all pressure
containment fillet welds. A minimum of two passes should be visible for visual
inspection.
d) Downhill welding shall not be employed for welding of pipes.
Welding Consumables
a) Electrodes and filler wires shall conform to the requirements of ASME Boiler and
Pressure Vessel Code, Section IX and Section II C. All consumables shall be
clearly identified with the AWS or other approved classification mark.
b) All consumables shall conform to EN 10204 Type 3.1certification. Lot
classification of the consumables shall be in accordance with ASME SFA
5.01/AWS A5.01 Schedule J
c) For GTAW process, tungsten electrode shall conform to AWS class EW Th -2.
Shielding and Purging Gases
a) Argon shall be of welding grade and shall meet the following requirements
b) Argon- 99.997% (Minimum)
c) When mixed gases are used, the volumetric percentage of minor components
shall be within +/- 10% relative to the nominal percentage of the minor
component of the classification.
d) Moisture SG-A-11.1 ppm (Maximum) @ -60°C Dew point
e) The shielding/purging gases shall conform to the requirements of AWS A5.32
Welder Performance Qualification
Welders shall be qualified in accordance with relevant code of practice, eg
ASME IX and the applicable fabrication specification where applicable.
Tack Welding
a) All tack welds shall be made by qualified welders using approved electrodes
 PDO SPECIFICATIONS

b) Tack welds to assist alignment shall have a minimum length of 25 mm

c) All tack welds that are to become an integral part of the root weld shall be
ground to feather edge at both ends
d) Tack welding in the root shall not permitted
e) Temporary tack welds shall be removed by grinding or chipping and the area
ground smooth without reduction of wall thickness, followed by MT or PT
inspection to confirm the absence of linear indications.
Back Purging
a) For Austenitic Stainless Steel welding back purging shall be maintained, unless
otherwise stated in the WPS, for a minimum of 6 mm of weld metal deposition
or a minimum of 3 passes whichever is higher for single side welding
b) For Duplex stainless steel welding back purging shall be maintained during
welding of first three passes or as stated in the WPS
c) The oxygen content in the escaping purging gas shall not be more than 0.02 max

Arc Strikes
Arc strikes on parent material shall be avoided. Any stray arcing shall be ground out to a
smooth profile. The ground area shall be examined by liquid penetrant examination and
shall be ensured free from cracks
Preheat Temperature Control
a) The minimum preheat temperature shall be established on both sides of the
joint preparation for a minimum distance of 75 mm or a distance equal to 4
times the material thickness, whichever is greater
b) Preheating should be applied by either electrical resistance method or heating
with oxy-propane torch with rosebud nozzles
c) Oxy-Acetylene welding or cutting torches shall not be used for preheating
purpose.
Inter Pass Cleaning
a) After welding each pass weld metal shall be thoroughly cleaned using a wire
brush or power wire brush or grinding or hand chipping tools before a further
run is deposited. Remove visible defects such as clusters of surface porosity,
stops and starts, high points, cavities, and other deposition faults by light
grinding prior to deposition of further weld metal.
b) For Stainless Steel and duplex stainless steel works, hand and power tools shall
be dedicated to SS materials and shall not have been used on carbon steels or
other materials.
c) All equipment and tools, which come into direct contact with SS material shall
be color coded YELLOW
Interruption of Welding
a) Interruption of welding should be avoided. Where interruption is unavoidable, a
minimum of three passes or one third of the joint thickness, whichever is
greater, shall be deposited. In such cases the weldment shall be wrapped using
a dry thermal insulating blanket for slow cooling to room temperature.
b) Before welding is resumed the weld shall be preheated to the specified
temperature mentioned in the WPS
Inter-Pass Temperature Control
 PDO SPECIFICATIONS

a) The maximum inter-pass temperature shall not exceed 250°C for carbon steel,
150°C for stainless steel and duplex stainless steel unless otherwise stated in the
WPS.
b) Digital thermometers, Thermocouples or temperature indicating crayons shall
be used to measure preheat and inter-pass temperature of carbon steel
c) Digital thermometers shall be used for stainless steel and duplex stainless steel
only
Weld Identification
a) The weld identification shall include Joint number, Welder ID, applicable WPS,
Fit-up inspection date & Visual inspection date
b) The chlorine and sulphur free marker pens should be employed for marking on
the stainless steel and duplex stainless steel material to support corrosion.
c) Temporary markings shall be removed by cleaning with a suitable degreaser
such as acetone. Light dressing with emery cloth or flapper wheel abrasives may
be used to remove stubborn markings

Post Weld Heat Treatment (PWHT)

a) PWHT shall be applied for all carbon steel materials of thickness >20.0 mm
b) The minimum no. of the thermocouple shall be:
i. For pipe diameter< DN 50, one thermocouple at a location of 6 O`clock
position
ii. For pipe diameter between DN 50 to DN 250, two thermocouple at a
location of 12 and 6 O`clock.
iii. For pipe diameter> DN 250, three thermocouple at a location of 12, 3
and 6 O`clock.
Extent of Examination
a) Para 341.4 of ASME B31.3 and
b) DEP 31.38.01.31-Gen. Appendix-4
NDT Examination

S.No NDT Procedure Acceptance

1 RT ASME V, Article 2 ASME B31.3 Table 341.3.2.
2 LPE ASME V, Article 6 ASME B31.3 Table 341.3.2.
3 UT ASME V, Article 4 ASME B31.3 Table 344.6.2.
4 MPE ASME V, Article 7 ASME B31.3 Table 341.3.2.
 PDO SPECIFICATIONS

The amount of ferrite present in austenitic or duplex stainless steels is called "FN" or Ferrite
Number
Ferrite Examination
Applicable Code : ISO 8249/ Feritscope user manual/ SP-1173
Acceptance STD : DEP 31380131
Personnel Qualification : Familiar with Feritscope instrument
Equipment : Feritscope (Magnetic induction test method)
Calibration : Manufacturer recommendation
Acceptance Criteria : For DSS – 35FN to 70FN/ For SS – 3FN to 8FN
Liquid Penetrant Examination
Principle : Capillary Action
Applicable Code : ASME Sec V Article 6/SP-1176
Acceptance STD : ASME B 31.3/SP-1173
Personnel Qualification : SNT-TC-1A
Materials : All Materials from one manufacturer
Control of contaminants : Sulphur & total Halogen shall be < 1%
Surface preparation : Adjacent sides 25mm free from dirt, grease etc.
Technique : Visual penetrant using solvent removal shall be used
 PDO SPECIFICATIONS

Surface Temperature : Shall not be below 50C and above 520C

Light Intensity : 1060Lux
Calibration : Light meter shall be calibrated once a year
Penetrant Application : By Spraying
Penetration Dwell Time : 5 min
Excess Penetrant removal : By clean lint free cloth
Developer Application : shall not exceed 10min after penetrant removal
Interpretation Time : 10 Minimum & 30 Maximum

General Requirements
Specification : SP-1173

Radiography
Applicable Code : ASME Sec V Article 2 & 22/SP-1176
Acceptance STD : ASME B 31.3
Personnel Qualification : SNT-TC-1A
Radiation Source : Iridium 192
Film : Agfa D4/Kodak MX 125
Intensifying lead Screen : 0.125mm (Front & Back)
Location Markers : Adjacent to the weld
Scattered Radiation : ‘B’ Letter (13mm ht & 1.6mm thk)
Sensitivity : 2% or Better
Penetrameter (IQI) : EN 462-1 Type
No of IQI : DWSI/SWSI-1No IQI in 130mm or Less & 2No IQI if Length
>130mm
SWSI Panoramic- Min 4Nos IQI @900
DWDI Elliptical Exposure-1No IQI/each exposure
Density : 2 to 3.5 for Gamma Ray & area of interest range -15% to +30%
: 1.8 to 3.5 for X-Ray
Density of film before process : Shall not exceed 0.3
Densitometer : Range shall be 0 to 4
Calibration : Step Wedge Calibration Film – 2 yrs from the date of opening
Densitometer Calibr : Beginning of each shift/8 hrs of continuous use
 PDO SPECIFICATIONS

Geo. Unsharpness (Ug) : Under 50mm Thk-0.5mm

Exposure Technique : Dia 89mm and below - Double Wall Elliptical with 2 exposure
Dia 89mm and over - DWSI with 3 exposures 1200 apart
Acceptance Criteria : As per table 341.3.2 of ASME B31.3

Hardness Testing - Hardness is defined as the ability of a material to resist any deformation
Principle : Rebound Technique
Applicable Code : ASTM E110-82
Acceptance STD : ASME B 31.3/DEP 31380131/SP-1173
Equipment : Shall work on rebounce velocity principle
Surface preparation : Metallic Smooth
Operating Temperature : 00C to 500C
Equipment Range : Min 90 to 500
No of Indentation : Dia Less than 100 – 1 reading/weld
Dia 150 to 300 – 2 readings/weld
Dia over 300 – 1 reading every 400mm/weld length
Acceptance for sour : Shall not exceed 248HV10
Acceptance for non sour : Max for CS/Alloy – 325 HV10
Max for DSS (22 Cr) – 310 HV10
Max for SDSS (25 Cr) - 330 HV10
Magnetic Particle Examination
Principle : Magnetic flux leakage
Applicable Code : ASME Sec V Article 7/SP-1176/ASTM E709
Acceptance STD : ASME B 31.3/SP-1173
Personnel Qualification : SNT-TC-1A
Equipment : Permanent Magnet shall be used
Magnetic Particle Size : Less than 45 Micron (Black ink & white contrast)
Surface Temperature : Shall between 150C to 480C
 PDO SPECIFICATIONS

Surface preparation : Adjacent sides 25mm free from dirt, grease etc.
Technique : Permanent Magnetic Yoke
Application : By Aerosol spray can
Light Intensity : 1000Lux Minimum
Calibration : Light meter shall be calibrated once a year
Calibration of Yokes : Daily prior to use/shall lift 18 kg/ Pie gauge (Field Indicator)
Demagnetization : Shall be demagnetize
 PDO SPECIFICATIONS

Welding Consumables
 PDO SPECIFICATIONS

Applicable Code : SP-1173/SP-1174/SP-1177/DEP 30.10.60.18/ASME Sec II Part C

Certifications : As per EN 10204/ISO 10474 Type 3.1/3.1B
Storage conditions : Store-room relative humidity should be maintained at 50%
Max and the temperature shall be above 20° C
a) General Guidelines
b) Re-Baking shall be allowed only once for low hydrogen electrodes
c) Electrodes exposed to the atmosphere (outside oven or quiver) for more than 4
hours shall be scrapped.
d) Basic low hydrogen electrodes and fluxes should be ensured that they are
capable of giving weld metal deposit with a diffusible hydrogen content not
exceeding 10 ml/100gm of weld metal.
e) Extra moisture resistant (EMR) consumables with a diffusible hydrogen content
of less than 5ml/ 100gm may be used without pre heating for a period of max 8
hrs.
f) Immediately after opening the hermetically sealed containers the low hydrogen
type electrodes shall be transferred to the holding oven which is maintained at
150C.
g) The electrodes shall be held in the holding oven at a temperature for a period
prescribed by the manufacturer
h) Electrodes taken from the Vacuum packages can be directly used without baking
and shall be consumed within 12 hours or as specified by the manufacturer
i) In order to tolerate the severe site conditions the cellulose coated electrodes
require some moisture in the coating to aid the running characteristics
j) The cellulose coated electrodes must never be baked
k) All Low hydrogen Electrodes that have been exposed to the atmosphere in
opened containers and the electrodes taken from the non-hermetically sealed
containers shall be baked at a temperature 260-430°C for at least 2 hours or at
the temperature and time prescribed by the respective manufacturers
l) After baking is over the electrodes shall be transferred to the holding oven
which is maintained at 150C
m) Immediately after receipt the electrodes shall be placed inside the quivers that
are maintained at 70C
n) Filler wires and new electrodes that are un packed and before subjecting to
baking shall be color coded by applying a paint spot near the gripping ends of
the electrodes and near the embossing mark for the filler wires
The color coding shall be
a) DSS Electrodes and Filler wires : Pink
b) SDSS Electrodes and filler wires : Grey
c) SS type 304/304L : Red
d) SS type 316/316L : Blue
e) Nickel Electrodes/Fillers : Light Blue
f) Returned DSS & SDSS Electrodes/Fillers : Black color shall be applied near to the
previous color code
g) Carbon steel electrodes which are to be re-baked shall be color coded as White

Painting Scheme PCS-1/3 Coat PCS-1/2 Coat PCS-2A PCS-2A PCS-2C

 PDO SPECIFICATIONS

System Upto System Upto

100 0c 100 0c Upto 70 0c Upto 70 0c STOPAQ
Blasting
Pressure(Bar) 6.5 to 6.9 6.5 to 6.9 6.5 to 6.9 6.5 to 6.9

Garnet Size(mm) 0.20 to 1.4 0.20 to 1.4 0.20 to 1.4 0.20 to 1.4

Surface Temp 0c >5 >5 >5 >5 >5 - 70

RH (%) <85 <85 <85 <85 <85

Steel temp shall Steel temp shall Steel temp shall Steel temp shall
be 3 0c above be 3 0c above be 3 0c above be 3 0c above
Dew Point 0c dew point temp dew point temp dew point temp dew point temp
Air Temperature
0
c >5 h>5 >5 >5

Bressle sampler Bressle sampler Bressle sampler Bressle sampler

test(20 - 40 test(20 - 40 test(20 - 40 test(20 - 40
Blasted surface mg/m2) Elcometer mg/m2) Elcometer mg/m2) Elcometer mg/m2) Elcometer
cleanness satl test ( 2-4ppm) satl test ( 2-4ppm) satl test ( 2-4ppm) satl test ( 2-4ppm)
Wire Brushing St
Blasting Profile 2/St 3 or Abrasive
(µ) 30-75, Testex 30-75, Testex 75 Min, Testex 75 Min, Testex SA 1

WFT(µ) 100-115 100-115 715-735 555-575

1.8 to 2.2mm thk
DFT 1st Coat(µ) 50-60 170-180 600 Min 500 Min Green

Over Coat Time 6 Hrs Min 6 Hrs Min 6 Hrs Min 6 Hrs Min
0.63mm thk
DFT 2nd Coat(µ) 150-180 230-240 NA NA Black

Over Coat Time 6 Hrs Min 6 Hrs Min NA NA

DFT 3rd Coat(µ) 200 Min 200 Min NA NA

Inspection- 9V wet sponge 9V wet sponge 3KV High voltage 90V wet sponge 15 KV Holiday
Pinhole method method spark test method testing
Inspection- cross cut & peet cross cut & peet cross cut & peet cross cut & peet
Adhesion test ASTM D 3359 test ASTM D 3359 test ASTM D 3359 test ASTM D 3359
Hempadur Primer- Hempadur Primer Hempadur 85531 Hempadur XSP
1st Coat Paint Red 45881 -Grey Primer-Red 87550 Primer-Red
Hempathane
Hempadur HB 55210 RAL
2nd Coat Paint 45201- L. Grey 9010 White NA NA
Hempathane
55210 RAL
3rd Coat Paint 9010 White NA NA NA
 PDO SPECIFICATIONS

Welding
Base Metal Filler Metal Preheat Interpass
Scheme
Root Hot fill Cap Min 0c Max 0c PWHT 0C
API 5L X60 ER
ER 70S-2 E7018 E7018 100 250
A 105 70S-2

API 5L X42
CARBON
STEEL A 106
ER NIL IF
A 105 ER 70S-2 ER 70S-2 ER 70S-2 250
70S-2 > 10
API 5L Gr.B
A 234 WPB
A 333 Gr.6 ER 620-640
ALLOY STEEL ER 70S-6 E7018-1 E7018-1 F6P6 250
A 350 LF2 CL1 70S-6 550C/Hr
A 790
DUPLEX
A 928 ER 500C IF
STAINLESS ER 2509 ER 2209 ER 2209 150
API 5LC 2509 < 100C
STEEL
A 182 F51
A 312 TP 316
AUSTENITIC A 182 F 316
ER 500C IF
STAINLESS A 213 TP 316 ER 316L ER 316L ER 316L 150
316L < 100C
STEEL
A 403 WP 316
A 240 TP 316
API 5L X52 & 1000C
ALLOY STEEL BELOW E6010 E7010 P1 E7010 P1 E7010 P1 IF < 250
200C
 PDO SPECIFICATIONS

Hydrotest of piping system

Procedures: As per SP-2051
1. Shall provide a pressure relief valve
2. Shall provide 2 pressure gauges
3. Pressure gauge readings shall be 2 to 3 times of test pressure
4. Test Pressure readings shall be 50%-75% of gauge full scale reading.
5. Gauge diameter shall be at least 125mm in diameter
6. Shall have pressure-temperature recorder
7. Water shall not contain a concentration of chlorides
8. Austenitic stainless steel may be tested with potable water with a verified chloride
content not exceeding 200 mg/kg (200 ppm) provided that it is drained and
mechanically dried immediately but no longer than 24 hours.
9. High point vents and other connections which serve as vents shall be open during filling
of the equipment / system and that all air is vented prior to applying test pressure to the
system.
10. Filling hose from the pump shall be connected to the lowest point of the system to be
tested
11. Gaskets required for service SHALL [PS] be used during hydrostatic pressure test
12. A pressure relief valve shall be installed on the discharge of the test pump. This pressure
relief valve (PRV) shall be set at 110 % of test pressure
13. All pressure gauges to be used for the test shall have a unique number and shall be
calibrated prior to each test using a standard Dead Weight Gauge Tester
14. The perimeter of the hydrostatic testing should be barricaded and signs set up
15. During the test, the pressure shall be increased in stages 25%, 50%, 75% and 100% of
test pressure and shall be held for 2 minutes in each intermediate stage for equalizing of
strain during the test.
16. The actual pressure applied shall not exceed the test pressure by more than 1%.
17. Tightening of bolts on flanges or joints shall not be undertaken with pressure on the
equipment / system.
18. Piping system may be blown dry with air to a dew point of -1°C
19. If piping system is drained, dried and to be left idle longer than one month, it shall be
preserved in accordance with DEP 70.10.70.11-Gen in order to prevent egress of air and
water
 PDO SPECIFICATIONS

Hydrotest of pipelines/flow lines

Procedures: As per SP-1212
1. Hydrotest pressure : 1.25 x Test pressure
2. The rate of pressurization should be constant and should not exceed 1 bar/minute until
a pressure of 35 bar or 50 % of the test pressure, whichever is lower, has been attained.
3. When the pressure of 35 bar or 50 % of the test pressure, whichever is lower, has been
reached, the air content shall be determined
4. Percentage air content = (Volume of air / Volume of line) x 100
5. If the air content exceeds 0.2 % of the line volume, testing SHALL be terminated and
the cause investigated
6. For all buried pipelines and flow lines the minimum duration for the hydrostatic
pressure test shall be a 4 hr strength test followed by a 24 hr leak tightness test
7. Assembly testing, above ground pipelines & flow lines shall comprise a 4 hour strength
test followed by visual examination (no leak tightness test)
8. After stabilization, the pressure should be raised to 95 % of the test pressure and held
for 30 min, then the pressurization should be continued to the specified test pressure at
a rate not exceeding 0.5 bar/min
9. During this period, the pressures and added volumes should be continuously plotted
until the specified test pressure has been achieved. The plot should be constantly
checked and, in the event of any deviation of 10 % or more from the theoretical line
corresponding to 100 % water content, the test should be terminated.
10. The water should be filtered through 50 micron filters immediately prior to entering the
pipeline for oil lines. For use in Water Injection lines the filter size shall be 10 microns.

SP-1174

1. WPS/PQR
The WPS and PQR SHALL be approved by the welding TA-3 for each project
Test Weld Outside Diameter Qualified Diameter Range

< 323.9 mm 0.5 OD to 2 OD

323.9 mm > 0.5 OD

The wall thickness range shall be 0.5t to 1.5t of the test weld.
2. Joint design
Permanent backing bars shall not be used. Joints shall be completed with a minimum of three
passes
 PDO SPECIFICATIONS

3. Alignment
 The offset(misalignment) shall not exceeds 2.0 mm
 When pipes with longitudinal seam are used, the seams shall be within the top 1200 of the
circumference.
 The longitudinal seams of consecutive pipes shall be offset by at least 450


Direction of welding

1. For the following, the root bead shall be deposited with a vertical-up progression:
 Tie-in welds
 Welds where an external line-up clamp is used
 Welds to fittings
 Full penetration repairs
 Welds where temporary tack welds have been employed for alignment.

2. For the following, the complete weld shall be made with a flat position or vertical-up progression
 Welds to valves
 Fillet welds.

Time between passes

When cellulosic electrodes are used, the hot (second) pass shall be deposited immediately after
completion of the root run and the time lapse shall not be greater than that used in procedure
qualification. For other passes shall not be greater than that used in procedure qualification

Type and removal of line-up clamp

 An internal or external line-up clamp shall be used for all girth welds
 An internal line-up clamp shall not be removed until deposition is completed of the first two
passes.
 An external line-up clamp shall not be removed until the root bead is at least 50% complete,
equally distributed around the joint.
Number of welders
 For pipe of greater than NPS 12, a minimum of two welders shall be employed for all passes
 The minimum number of passes before the joint is allowed to cool to ambient temperature
shall be three passes.
Qualification of Welders
Qualification shall be valid for a period of six months. This period may be extended every six
months when it can be shown by NDT from production welding and demonstrated statistical repair rate of
less than 3 %.

Retesting
If the test weld does not meet the specified acceptance criteria, the welder may carry out two
repeat tests provided that the failure can be attributed to unavoidable conditions. Both of the repeat
welds shall meet the specified acceptance criteria. Failure of one or both repeat welds shall result in
disqualification of the welder until such time as the Contractor can demonstrate to the Company by
records that satisfactory training has been received. The welder may then be presented for further
qualification testing.