TECHNICAL SERVICES GROUP

SPECIFICATION FOR PIPING FABRICATION AND INSTALLATION FOR

OFFSHORE APPLICATION

CAIRN-TSG-L-SP-0015

CAIRN ENGINEERING STANDARD

A1 27.09.2013 Issued for Review AK VB AA

Revision Date Description Originator Checker Approver
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SPECFICATION FOR PIPING FABRICATION AND INSTALLATION FOR OFFSHORE APPLICATION
CAIRN-TSG-L-SP-0015 A1
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REVISION RECORD

Revision Philosophy
All revisions for review will be issued at A1, with subsequent A2, A3, etc as required.
All revisions approved for issue or implementation will be issued at B1, with subsequent B2, B3, etc as required.
All revisions approved for issue or design and construction will be issued at C1, with subsequent C2, C3, etc as
required.
Narrative sections revised from previous pprove issues are to be noted in the table below and/or highlighted using
the appropriate revision status thus: | A2
Previous revision highlighting to be removed at subsequent issues.
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas and by
the use of a triangle containing the revision status.

Revision History

Revision No. Date of issue Reason for change

A1 09.09.2013 Issued for review

B1 26.09.2013 Issued for Implementation

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SPECFICATION FOR PIPING FABRICATION AND INSTALLATION FOR OFFSHORE APPLICATION
CAIRN-TSG-L-SP-0015 A1
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TABLE OF CONTENTS

1.0 SCOPE 4

2.0 CODES AND STANDARDS 4

3.0 FABRICATION 4

4.0 WELDING 5

5.0 EXAMINATION, INSPECTION & TESTING 5

6.0 INSTALLATION 8

7.0 REQUIREMENT OF BOLT TORQUING 9

8.0 PROTECTIVE COATING 9

9.0 INSULATION 9

10.0 SHIPPING AND HANDLING 9

11.0 FIG-1 DIMENSIONAL TOLERANCES 11

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SPECFICATION FOR PIPING FABRICATION AND INSTALLATION FOR OFFSHORE APPLICATION
CAIRN-TSG-L-SP-0015 A1
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1.0 SCOPE
This specification covers the requirements governing the fabrication, installation, inspection & testing of
piping assemblies in shop or field. This specification is to be used with the individual specification and/or
drawings, if furnished. In case of conflict, the individual specification and /or drawings shall govern.

2.0 CODES AND STANDARDS

All piping shall be designed, fabricated and installed as per codes & standards except as modified by this
specification.

3.0 FABRICATION
3.1 Carbon steel pipes shall be cut by mechanical or thermal cutting depending upon thickness and size however
thermal cutting shall not be employed for galvanized and stainless steel materials.
3.2 Bevel end preparation shall be done by bevel cutting machines and suitably grinded.
3.3 For pipes up to 2 Inch NB, the internal burrs shall be removed by suitable grinding.
3.4 Dimensional tolerances: In addition to the tolerances contained within specified codes and standards,
dimensional tolerances for finished fabricated piping shall conform to those shown in Figure-1 attached
herewith.
3.5 Care shall be taken during cutting & welding such that the final dimensions of spools are within the applicable
tolerances.
3.6 Threaded, Socket Weld & Brazed Piping
3.6.1 Threads shall be clean cut with no burrs or stripping and shall be according to ASME B1.20.1,
tapered. Dies shall be new, sharp and properly designed for the piping material. Ends shall be
reamed to remove burrs.
3.6.2 Immediately before erecting the piping all threads of pipe and fittings shall be thoroughly cleaned of
cuttings, dirt, oil or other foreign matter. The male threads shall be coated with thread sealant
and the piping made up sufficiently for the threads to seize. Sealant shall be Teflon tape.
3.6.3 Threaded connections shall be gauge checked or chased after welding or heat treatment.
3.6.4 When socket weld/brazed fittings or valves are used, pipe shall be spaced approximately 1/16-inch
to avoid “bottoming” which could result in excessive weld stresses.
3.6.5 The inside of the brazed fitting and outside of the tube shall be cleaned with sand paper. Flux paste
to be evenly applied to the joint.
3.6.6 Brazing temperature shall be achieved as quickly as possible using a suitably sized torch.
3.6.7 Seal welding of threaded connections when specified shall include the first block valve, cover all
threads and be done with electrodes not to exceed 1/8 inch in diameter. The joint shall be cleaned
of all cutting oil & other foreign material and made up of dry to full thread engagement. Thermo wells
shall not be seal welded.
3.7 Branch connections
3.7.1 All branch connections shall be joined to the header with full penetration welds.
3.7.2 Reinforcing pads shall be added only after external and internal visual inspection of the attachment.
Reinforcing pads shall be provided with ¼” tapped weep hole. Weep holes shall be plugged after
completion of welding.
3.8 Exposed machined and threaded surfaces shall be protected from oxidation during heat treatment.

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SPECFICATION FOR PIPING FABRICATION AND INSTALLATION FOR OFFSHORE APPLICATION
CAIRN-TSG-L-SP-0015 A1
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3.9 Flange bolt holes shall straddle the established horizontal and vertical centerlines of the pipe except where
connection to equipment dictates otherwise.
3.10 Cleaning of the piping after fabrication and heat treatment shall be performed externally and internally to
remove all loose scale, weld spatter, sand and other foreign materials.
3.11 All piping supports shall be fabricated and installed as per approved drawings/standards.

4.0 WELDING
4.1 Welders and welding procedure shall be qualified per ASME B 31.3, latest edition.
4.2 For 90-10 Cu-Ni piping, welders and welding procedures shall be qualified as per ASME Code Section IX.
4.3 Welding shall be performed as per approved WPS and PQR.
4.4 No chill rings or backup rings are to be used.
4.5 The joints to be field welded shall be beveled as per ASME B 16.25
4.6 The deposited filler metal shall match the chemistry and minimum physical properties when similar metals
are welded.
4.7 Stress relieving shall be as per ASME B 31.3.

5.0 EXAMINATION, INSPECTION & TESTING

5.1 Random radiography shall be performed on one weld in each 10 welds for each welder on the following:
a) Water (in case of Carbon steel)
b) Air
c) Chemicals
d) Diesel
e) Closed drain
f) Relief
g) Hydraulic oil
h) Oily water
i) Slops
5.2 25% Radiography shall be performed on the following:
a) Glycol & Therminol
b) Vent gas
c) Lube oil & seal oil
5.3 100% Radiography shall be performed on size 2” and above and 25% on sizes below 2” for the following:
a) Crude oil
b) Jet fuel
c) Fuel gas / Instrument gas
d) Process gas
e) Production flow lines (Well fluid)
f) Injection water
g) Hydrocarbons (process)
h) HP & LP flare lines
5.4 For fillet welds and brazed joints where carrying out radiography is not possible, magnetic particle or dye
penetrant test shall be carried out. The extent of inspection shall remain same as for radiography.
5.5 All the lines, which are stress relieved or have design pressure more than 50 kg/cm2 shall be fully radio
graphed (100%) even if not required as per clause 5.1 to 5.3.
5.6 Radiographic procedure shall be as per ASME B 31.3.

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SPECFICATION FOR PIPING FABRICATION AND INSTALLATION FOR OFFSHORE APPLICATION
CAIRN-TSG-L-SP-0015 A1
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5.7 Acceptance criteria based on visual, radiography and other types of examination shall be as per ASME
B 31.3 with the following modifications.
5.7.1 The internal weld protrusion on ‘pigged lines’ shall not exceed 1.6 mm (1/16 inch).
5.7.2 Orifice flange butt welds shall be internally ground smooth and flush.
5.7.3 For 90-10 Cu-Ni piping, radiographic examination of welds shall be as per ASME Section VIII, UW
51.
5.8 Hydrostatic testing is not required for shop-fabricated piping where the pipe is to be field-tested.
Hydrostatic testing is required on skid-mounted assemblies. Pressure test shall be performed as per
ASME B 31.3 and the appropriate specification class chart.
5.9 All instruments shall be excluded during hydro test.
5.10 All piping shall be flushed prior to hydro testing.
5.11 Those field weld joints, which cannot be leak tested due to unavoidable reasons, shall always be 100%
radiographed.
Requirements as given above in clause 5.1 to 5.11 are general however in case of any conflict with welding
and weld inspection specification, the welding specification shall govern.
5.12 TESTING
Pressure test shall be performed as per ASME B31.3, latest edition.
5.12.1 The following items coming in line with piping shall not be subjected to field pressure testing:
a) Strainers and Filter elements.
b) Pressure relieving devices such as rupture discs and pressure relief valves.
c) Locally mounted pressure gauges.
d) Control valves, shutdown valves etc.
e) Vessel and equipment like pumps, compressors etc. vessel may be tested along with a
piping system, provided the vessel test pressure is not less than the piping system test
pressure.
f) Any other equipment designated by the Company.
5.12.1.1 All the elements which are not to be tested along with the piping shall either be
blanked off during testing or spool pieces inserted during testing.
5.12.1.2 Any temporary corrosion protection coating given on piping at manufacture’s shop /
fabrication yard is to be removed at all inspection points, before final testing.
5.12.1.3 Prior to hydrotesting, vessels & piping are to be flushed by high pressure, high
Volume fresh water or inhibited sea water. However for using Inhibited sea
water company approval shall be required.
5.12.1.4 All piping shall be supported as per approved drawing before pressure testing, spring
and other variable type supports shall be locked to prevent movement.

5.12.2 Following are the general requirements for testing of piping.

5.12.2.1 Test pressure shall be maintained for a sufficient length of time to permit thorough
inspection of all the joints for leakage or sign of failure. The duration shall in no case

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SPECFICATION FOR PIPING FABRICATION AND INSTALLATION FOR OFFSHORE APPLICATION
CAIRN-TSG-L-SP-0015 A1
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be less than four (4) hours.

5.12.2.2 Instrument take-off piping up to the first block valve shall be tested with the
connected piping.
5.12.2.3 Lines open directly to atmosphere such as vents, drains, safety valve discharge etc.
shall be leak tested and all the joints shall be visually inspected.
5.12.2.4 Maximum allowable valve test pressure:
Seats of all valves shall not be subjected to a pressure in excess of maximum cold working pressure
of the valve. Test pressure applied to valves shall not be greater than the manufacturer’s
recommendation nor less than required by applicable code. Where the test pressure is greater than
the allowable seat pressure, test shall be made through the open valve.
5.12.3 Hydrostatic test fluid
5.12.3.1 Fresh potable water shall be used as the testing medium for hydrostatic testing of
piping in fabrication yard and at offshore, if available.
5.12.3.2 For Austenitic Stainless Steel piping, water with pH- valve not over 7 and
chlorides less than 350 ppm shall only be used for hydrostatic testing. The lines shall
be completely drained and dried by air immediately after the successful completion
of testing.
5.12.3.3 Salt water may be permitted for testing non austenitic piping, provided the
Contractor’s test procedures are approved by the Company and that they include the
following:
5.12.3.4 Chemical treatment (inhibition, oxygen scavenger) to mitigate corrosion if salt water
is used.
5.12.3.5 Method of isolating austenitic piping and connected equipment from contact with salt
water.
5.12.3.6 Adequate steps are taken to ensure complete removal of salt water from the system
after testing.
5.12.3.7 A strainer shall be installed in the line to minimize the possibility of foreign matter
being introduced into the system during the pressure test and flushing operations.
5.12.3.8 Test medium shall be hydraulic oil for hydraulic service.
5.12.4 Pneumatic Testing
5.12.4.1 Pneumatic testing of instrument air, utility air, starting air and instrument gas piping
shall be performed with compressed air. The test pressure shall be 110 percent of
design pressure. Test duration shall be as given in 5.12.2.1.
5.12.4.2 Pneumatic testing of other piping is acceptable if the test procedure and test
pressures have been approved by the Company.
5.12.4.3 When pneumatic testing at over 25 psi, a preliminary test at 25 psi shall be made to
locate major leaks. Then the pressure shall be increased gradually to test pressure.
5.12.5 Test Procedure
5.12.5.1 All vents and other connections, which serve as vents, shall be open during filling so
that all air is vented prior to applying test pressure to the system.
5.12.5.2 At least two nos. gauges will be installed for testing as close as possible to the

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SPECFICATION FOR PIPING FABRICATION AND INSTALLATION FOR OFFSHORE APPLICATION
CAIRN-TSG-L-SP-0015 A1
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highest point of the piping system & will be caliberated and checked for accuracy.
5.12.5.3 Care shall be exercised to avoid increase in pressure due to temperature variation
during the test.
5.12.5.4 After completion of hydrostatic test, the pressure shall be released gradually in
steps. All the vents and drains shall be kept open till the lines are fully drained.
The contractor shall then dry the system by blowing compressed dry air and reinstall
items removed during hydrotesting.
5.12.5.5 All testing and calibration of gauges, instrument etc. will be carried out in presence of
company or its authorised representative. Record shall be made of each piping
system during the testing. These records shall be prepared in tabulated
forms and shall include
a) Date of Test
b) Identification of piping and equipment tested with medium.
c) Test medium.
d) Test Pressure.
e) Test Duration.
f) Acceptance of Test result by Company.
5.12.5.6 Testing shall be deemed as complete only after defects noticed during testing have
been rectified and retesting of the system/line has been done to the satisfaction of
the company’s representative.
5.12.5.7 Temporary supports shall be provided wherever required during testing.
6.0 INSTALLATION
6.1 Piping shall be installed in accordance with the approved piping drawings.
6.2 Piping installation shall include the supply and installation of supports shown in the drawing.
6.3 All lines shall be installed true and plumb except where specifically noted on the drawing.
6.4 Installation of piping shall be scheduled so that no undue strain shall be inflicted on equipment due to lack of
support, dead weight or misalignment.
6.5 Piping shall be removed after installation at all rotating equipment connecting points to check the alignment
with and without piping to ensure that the piping does not affect the alignment of the equipment. After
checking the alignment, piping shall be re-installed.
6.6 Flange bolts shall be tightened evenly and sequentially to avoid distortion or overstressing of
equipments.
6.7 During installation/fabrication, care shall be taken at all times to protect the entry of foreign materials by
providing protector caps and covers or other suitable means.
6.8 Before installing prefabricated piping, the inside of the pipe shall be inspected by the contractor to ensure that
all foreign mater is removed.
6.9 Stainless steel materials shall be lifted with nylon or other approved slings, which are free from dirt or ferritic
particles. Under no circumstances, chain or wire ropes shall be used.
6.10 To prevent damage to valve seal and seat surfaces, valves when installed shall be left in following open/close
positions:

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SPECFICATION FOR PIPING FABRICATION AND INSTALLATION FOR OFFSHORE APPLICATION
CAIRN-TSG-L-SP-0015 A1
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Ball and plug valves - Fully open

Globe and gate valves - Fully closed.
7.0 REQUIREMENT OF BOLT TORQUING
7.1 Bolt torquing shall be applied to all the flange joints.
7.2 Torque wrenches shall be used with specific value, reviewed/approved by the company.
7.3 Mechanical integrity of all flange joints has to be ensured. A standard checklist for the activity along with post
box-up checkup should be developed & practiced. The checklist shall include the following:
a) (i) Alignment of flanges
(ii) Inspection of gasket surface for possible defects such as bends or greases.
(iii) Inspection of mating flanges for dirt, mechanical damage and corrosion. Use suitable
solvent to clean the surface. The contact area of flanges shall be free from excess
pitting and radial scratches.
(iv) Ensuring the gasket is properly seated
(v) Ensuring that fasteners are tightened as per tightening procedures and using specific
values with well maintained tools and torque wrenches.
b) Each joint shall be boxed up and tightened by only skilled technician.
c) Ensuring right type of gaskets & fasteners etc confirming to the specifications.
d) Ensuring that the stud & nuts are free of dirt and corrosion. The studs should be straight and
threads free from nicks, burr and chips etc.
e) Checking of individual joint for any leak during commissioning/pressure testing by
special tapes, soap solution or as per relevant code.
QUALITY ASSURANCE:
Tool Calibration: 1. The calibration of the torque wrench and tensioner shall be checked against
manufacturer’s specifications upon receipt. Any tool that is out of calibration shall
be rejected.
2) A recheck of calibration shall be made on regular basis. Any tool found to be
out of calibration shall be immediately be taken out of service for repair.
3) All flange joints secured with tool found to be defective shall be rechecked
with a properly functioning and calibrated tool.

8.0 PROTECTIVE COATING

Protective coating shall be applied as stated in the Specification for Protective coating.
9.0 INSULATION
Insulation shall be provided as per Specification for Insulation.

10.0 SHIPPING AND HANDLING

10.1 All openings shall be protected after inspection as follows:
10.1.1 Mechanical integrity of all flange joints has to be ensured. A standard checklist for coating with a
removable rust preventive and attaching a bolted or steel strapped 20 mm thick wood/plastic or
metal blank. Unpainted steel blanks shall not be used where rust would discolor the coated surface
of skid- assembled components. Gasket contact surfaces shall not be painted. If the surface is

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SPECFICATION FOR PIPING FABRICATION AND INSTALLATION FOR OFFSHORE APPLICATION
CAIRN-TSG-L-SP-0015 A1
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painted, it shall be restored to original specification condition before installation.

10.1.2 Threaded connections shall be closed with a steel/plastic pipe plug.
10.1.3 Plain or bevelled ends shall be closed with metal or a plastic cover to protect the inside of the pipe.
10.2 Each spool piece shall be clearly marked on both ends with the line number. Marking shall not be done by
stenciling the pipe. Marking shall be done by a method which will ensure that it will withstand exposure to the
hazards during shipping to the job site.
10.3 Small diameter branches shall have ¼”x 1” steel plate tack welded to branch and header to prevent bending
of branch pipe during transportation.
10.4 Extra caution shall be exercised when handling Cu-Ni pipe to prevent damage.
10.5 Piping materials to be shipped shall be made dry, clean and free from moisture, dirt and loose foreign
material of any kind.
10.6 Piping materials shall be protected from rust, corrosion and mechanical damage during transportation,
shipment and storage.
10.7 Rust preventive used on machined surfaces shall be easily removable with a petroleum solvent and
the same shall not be harmful to welding.
10.8 Both ends of pipes, valves & flanges shall be protected securely with the following material
Plain end : Plastic cap
Bevel end : Wood, metal or plastic cover
Threaded end : Metal or plastic threaded cap
Flange face : Wood or Plastic cover

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SPECFICATION FOR PIPING FABRICATION AND INSTALLATION FOR OFFSHORE APPLICATION
CAIRN-TSG-L-SP-0015 A1
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11.0 FIG-1 DIMENSIONAL TOLERANCES

FIG-1 DIMENSIONAL TOLERANCES

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