HEN-0000-PI-SP-0001_B3

Hengam Offshore Development Project EPCI For Topsides and Infield Pipelines and Subsea Cables

Contract No. 4405-90-2FG SPECIFICATION SPECIFICATION FOR PIPING MATERIAL S

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SPECIFICATION SPECIFICATION FOR PIPING PIPING MATERIAL MA TERIALS S

Re-Issue as H.R. Jang Ranga AFD Approved For B2 04.Mar.2013 Suganthi Ranga Design Issued for B1 24.Jan.2013 Suganthi Ranga Approval Issued for B0 29.Sep.2012 W.C.KWON Balvinder Comment Prep. Prep. Checked Checked Purpose of Rev. Date Issue ISI / Ocean Ocean Developm ent B3

4.Mar.2014

S.Behniafar

H. Karimi

ARUN C.I.PARK C.I.PARK Approv ed IOOC

Appro ved


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Document Number HEN-0000-PI-DB-0001

HEN-0000-MW-BD0001 HEN-0000-MW-SP0001

Rev. B3

INPUTS Title Piping Design Criteria

Status B1

Material Selection Diagram

B2

Material Selection and Corrosion Management Specification and Report

B3

REVISONS & HOLDS Revisio Revisio n

B3

Descri Descri ption of Changes Changes & Holds

Per latest Material Selection report, PMS is revised accordingly. (Sec. 9,10 and Annexure –I)



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Document Number HEN-0000-PI-DB-0001

HEN-0000-MW-BD0001 HEN-0000-MW-SP0001

Rev. B3

INPUTS Title Piping Design Criteria

Status B1

Material Selection Diagram

B2

Material Selection and Corrosion Management Specification and Report

B3

REVISONS & HOLDS Revisio Revisio n

B3

Descri Descri ption of Changes Changes & Holds

Per latest Material Selection report, PMS is revised accordingly. (Sec. 9,10 and Annexure –I)



Sheet Sheet B0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

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TABULATION OF REVISED PAGES Revis Revis ion s Sheet Sheet Revis Revis ion s B2 B3 B0 B1 B2 B3 X X 36 X X X 37 X X X 38 X X X 39 X X X 40 X X X 41 X X X 42 X X X 43 X X X 44 X X X 45 X X X 46 X X X 47 X X X 48 X X X 49 X X X 50 X X X 51 X X X 52 X X X 53 X X 54 X X 55 X X 56 X X X 57 X X X 58 X X X 59 X X X 60 X X X 61 X X X 62 X X X 63 X X X 64 X X X 65 X X X 66 X X X 67 X X X 68 X X X 69 X X X 70



Sheet Sheet 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

B0

B1

X X X X X X X X

X X X X X X X X X X X X

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Revisi Revisi ons B2 B3

Sheet Sheet B0

B1

Revisio Revisio ns B2 B3



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Table of Contents

1.

2.

3.

4.

Rev. B3

GENERAL 1.1

Introduction

1.2

Definition

1.3

Scope Item Included

1.4

Appl Ap pl ic abl e Codes, Cod es, St andard and ard s an d Sp eci fi cat ions io ns

1.5

Order of Precedence

1.6

Abbr Ab br evi ati on s

DESIGN MANUFACTURE 2.1

General

2.2

Design

2.3

Material

2.4

Piping Component Manufacture

2.5

Fabrication

INSPECTION AND TESTING 3.1

Pressure Pressure Testin Testin g

3.2

Examination

3.3

Testing

IDENTIFICATION AND TAGGING 4.1

Marking

4.2

Color Coding

4.3

Color Marking Schedule


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5.

PREPARATION FOR SHIPMENT

6.

PROTECTION AGAINST CORROSION AND MECHANICAL DAMAGE

7.

DOCUMENTS SUBMITTALS

8.

Rev. B3

7.1

Certif icate of Compliance

7.2

Material Test Report s

7.3

Welding and NDE Proc edures

7.4

Supply of Calculation and Drawings

QUALITY ASSURANCE 8.1

Inspection Authorization

8.2

Refurbishment

8.3

Auth or izat io n

9.

PIPING CLASS DESIGNATION

10.

PIPING CLASS SERVICE INDEX –

1. GENERAL

The Hengam Field is located in the Persian Gulf at approximately 45 km south of Qeshm Island. Iranian Offshore Oil Company (IOOC) has awarded HENGAM offshore development EPCI project to Intelligent Solutions Inc. and Ocean development LLC. Joint Venture to perform Basic & Detailed Engineering, as well as procurement, fabrication, installation, precommissioning & commissioning for: •

Topside facilities of three offshore wellhead platforms

•

Infield pipe lines


Contract No. 4405-90-2FG SPECIFICATION FOR PIPING MATERIAL S

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Submarine composite Cable (Power, Control, Fiber optic) from offshore to onshore facilities.

1.1

Introduction

Refer to scope of work. 1.2

Definition

For the purpose of this specification, the following definitions shall hold: COMPANY

IOOC (also referred to as the PRINCIPAL) or any duty appointed party

authorized to act for, and on its behalf. CONTRACTOR

A party to a contract with IOOC (PRINCIPAL) that is responsible for the supply of all or part of any facilities, product or service to perform the duties specified by IOOC (PRINCIPAL). IOOC (PRINCIPAL) may undertake all or part of the duties of the CONTRACTOR

SELLER

A party to purchase order with IOOC that is responsible for the supply of all or part of any facilities, product or service to perform the duties specified by IOOC. IOOC may under take all or part of the duties of the SELLER.

SHALL

Indicates a requirement.

SHOULD

Indicates a recommendation.

1.3

Scope Item Inclu ded

This specification covers minimum technical requirements for pipe and piping components to be used for the Hengam Field to be installed on Hengam Offshore Development Project – Phases WHP1, WHP2 and WHP3 Offshore Platforms.

This specification in conjunction with relevant International codes and standards, other referenced General Specification and related documents determine the overall technical requirement for design, materials, manufacture, marking, inspection & testing, packing & shipment of piping materials.



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Where no exceptions are not indicated, the Supplier's quotation for the supply will be interpreted as being in full compliance.

Item Excluded

- All heating, ventilation, domestic water and sewage services - Subsea pipework, pipelines, risers, etc. - Special Piping Items (SPs) (Unless referring to this specification) - Instrument tubing and fittings - Installation of pipe, fittings, or flanges is not included in Supplier's scope under this specification.

1.4

Applic able Codes, Standards and Specific ations

All piping components, systems and design shall, as a minimum, meet the requirements of the latest edition of the National and International codes and standards listed below. Should any requirements be in conflict, the more stringent requirements shall apply. ASME B31.3

Process Piping

ASME B31.4

Pipe-Line Transportation System for Hydro Carbon and Other Liquids

ASME B31.8

Gas Transmission & Distribution Piping Systems

ASME B1.1

Unified Inch Screw Threads

ASME B1.20.1

Pipe Threads, General Purpose (Inch)

ASME B16.1

Cast Iron Pipe Flanges and Flanged Fittings Classes 25, 125 and 250

ASME B16.11

Forged Fittings, Socket-Welding and Threaded

ASME B16.5

Pipe Flanges and Flanged Fittings

ASME B16.20

Metallic Gaskets for Pipe Flanges

ASME B16.21

Non Metallic Flat Gaskets for Pipe Flanges

ASME B16.25

Butt-Welding Ends

ASME B16.36

Orifice Flanges

ASME B16.47

Large Diameter Steel Flanges (NPS 26 through NPS 60)

ASME B16.48

Steel Line Blanks

ASME B46.1

Surface Texture

ASME B16.9

Factory-made Wrought Steel Butt welding Fittings



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ASME B36.10

Welded and Seamless Wrought Steel Pipe

ASME B36.19

Stainless Steel Pipe

ASME B46.1

Surface Texture

ASME Section II

Boiler and Pressure Vessel Code – Ferrous Material Specifications

ASME Section V

Boiler and Pressure Vessel Code - Non Destructive Examination

ASME Section VIII

Boiler and Pressure Vessel Code

- Pressure Vessel

Division I ASME IX

Welding and Brazing Qualifications

ASME Section X

Boiler and Pressure Vessel Code - Welding and Brazing Qualification

API 590

Line Steel Blanks - Dimensional Standard (Withdrawn and replaced by ASME B16.48)

API 5L

Specification for Line Pipe

ASTM Standard-

Volume 01.02 Ferrous Castings; Ferroalloys

Section 1 ASTM 105/A105M

Standard Specification for Carbon Steel Forgings for Piping Applications

ASTM A106

Standard Specification for Seamless Carbon Steel Pipe for HighTemperature Service

ASTM A153/A153M

Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A182/A182M

Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High- Temperature Service

ASTM A193/A193M

Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service

ASTM 194/A194M

Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or both

ASTM A216/A216M

Standard Specification for Steel Casting, Carbon, Suitable for Fusion Welding, for High Temperature Service

ASTM A234/A234M

Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM A240/A240M

Standard Specification for Chromium and Chromium-Nickel Stainless



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Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications. ASTM A312/A312M

Standard Specification for Seamless and Welded Austenitic Stainless Steel Pipes

ASTM A333/A333M

Standard Specification for Seamless and Welded Steel Pipe for LowTemperature Service

ASTM A350/A350M

Standard Specification for Carbon and Low-Alloy Steel Forgings, Requiring Notch Toughness Testing for Piping Components

ASTM A351/A351M

Standard Specification for Casting, Austenitic, Austenitic-Ferritic (Duplex) for Pressure-Containing Parts.

ASTM A352/A352M

Standard Specification for Casting, Ferritic and Martensitic, for Pressure-Containing Parts, Suitable for Low- Temperature Service.

ASTM A358/A358M

Standard

Specification

for

Electric-Fusion-Welded

Austenitic

Chromium-Nickel Alloy Steel Pipe for High- Temperature Service ASTM A403/A403M

Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings

ASTM A420/A420M

Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Low-Temperature Service

ASTM A488/A488M

Standard Practice for Steel Castings, Qualifications of Procedures and Personnel

ASTM A516/A516M

Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate and Lower Temperature Service.

ASTM A530

Standard Specification for General Requirements for Specialized Carbon and Alloy Steel Pipe

ASTM A671/A671M

Standard Specification for Electric-Fusion-Welded Steel Pipe for Atmospheric and Lower Temperatures

ASTM A694/A694M

Standard Specification for Carbon and Alloy Steel Forgings for Pipe Flanges, Fittings, Valves, and Parts for High- Pressure Transmission Service

ASTM A790/A790M

Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless Steel Pipe



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ASTM A860/A860M

Standard Specification for Wrought High-Strength Low Alloy Steel Butt-welding Fittings

ASTM A123/A123M

Standard Specification for zinc (Hot-dip Galvanized) on Iron and Steel Products

ASTM A153/A153M

Standard Specification for zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM B366

Standard Specification for Factory-Made Wrought Nickel and Nickel Alloy Fittings

ASTM B444

Standard Columbium

Specification Alloys

(UNS

for

Nickel-Chromium-Molybdenum-

N06625)

and

Nickel-Chromium-

Molybdenum-Silicon Alloy (UNS N06219) Pipe and Tube ASTM B564

Standard Specification for Nickel Alloy Forgings

ASTM D2310

Standard Classification for Machine-made Reinforced Thermosetting Resin Pipe

ASTM D2992

Method for Obtaining Hydrostatic Design Basis for Reinforced Thermosetting Resin Pipe and Fittings

ASTM E94

Recommended Practice for Radiographic Testing.

ASTM E165

Recommended Practice for Liquid Penetrate inspection.

BS 3799

Steel Pipe Fittings Screwed and Socket weld for the Petroleum Industry

ASNT-SNT-TC-1A

Recommended

Practice for Nondestructive Testing Personnel

Qualification and Certification ISO 4427

Polyethylene (PE) Pipes for Water Supply Specification

ISO 14692

Glass Reinforced Plastic (GRP) Piping

NACE MR0175/

Petroleum and Natural Gas Industries-Materials for use in H2S

ISO 15156

containing Environments in Oil and Gas Production

MSS SP-6

Standard Finishes for Contact Faces of Pipe Flanges and Connecting - End Flanges of Valves and Fittings

MSS SP-9

Spot Facing for Bronze, Iron and Steel Flanges

MSS SP-25

Standard Marking System for Valves, Fittings, Flanges and Unions

MSS SP-43

Wrought Stainless Steel Butt Welding Fittings

MSS SP-44

Steel Pipe Line Flanges



MSS SP-53

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Quality Standard for Steel Castings and Forging for Valves, Flanges, Fittings,

and

Other

Piping

Components

-

Magnetic

Particle

Examination Method MSS SP-54

Quality Standard for Steel Castings for Valves, Flanges, Fittings, and Other Piping Components - Radiographic Examination Method

MSS SP-55

Quality Standard for Steel Castings for Valves, Flanges, Fittings, and Other Piping Components -Visual Method

MSS SP-75

High Test Wrought Butt Welding Fittings

MSS SP-79

Socket Welding Reducer Inserts

MSS SP-83

Steel Pipe Unions, Socket Welding and Threaded

MSS SP-93

Quality Standard for Steel Castings for Valves, Flanges, Fittings, and Other Piping Components - Liquid Penetrant Examination Method

MSS SP-94

Quality Standard for Steel Castings for Valves, Flanges, Fittings, and Other Piping Components - Ultrasonic Examination Method

MSS SP-95

Swage(d) Nipples and Bull Plugs

MSS SP-97

Forged

Carbon

Steel

Branch

Outlet

Fittings-Socket

Welding,

Threaded and Butt welding ends BS EN 10204

Metallic Products- Type of Inspection Documents

EEMUA 144

90/10 Copper Nickel Alloy Piping for Offshore Applications - Tubes Seamless and Welded

EEMUA 145

90/10 Copper Nickel Alloy Piping for Offshore Applications - Flanges Composite and Solid

EEMUA 146 1.5

90/10 Copper Nickel Alloy Piping for Offshore Applications - Fittings

Order of Precedence

In case of conflict between this specification, other referenced specifications and the above Codes and Standards; the conflict shall be brought to the Purchaser I Company's attention for resolution and approval in writing. In all cases, the most stringent requirements shall apply.

Should any conflict occur as a result of complying with the data sheets and specifications, the order of precedence shall be as follows:



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- Design Basis - Piping & Instrumentation Diagrams - Data Sheet - General Layouts - Project Specifications - General Specifications - Applicable Codes & Standards - Dedicated Software's - Specific Studies and schematic Diagrams

All deviations from the requirements of this Specification, its Attachments and the referenced Codes and Standards shall be advised to the Purchaser I Company. In the absence of such a statement full compliance will be assumed. 1.6

Abbreviations

AISI

American Iron and Steel Institute

API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

ASTM

American Society for Testing and Materials

BS

British Standard

BSI

British Standards Institute

℃

Degrees Celsius

℉

Degrees Fahrenheit

C

Carbon

CE

Carbon Equivalent

Cr

Chromium

CRA

Corrosion Resistant Alloy

CS

Carbon Steel

Cu

Copper/Cupro

D

Diameter

DPI

Dye Penetrant Inspection

EN

Euro Norm



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ERW

Electro Resistance Weld

Fe

Iron

HIB

Hardness Brinell

HIC

Hydrogen Induced Cracking

HYCS

High Yield Carbon Steel

INS

Inches

LTCS

Low Temperature Carbon Steel

MAX

Maximum

MIN

Minimum

m

Meter

mm

Millimeter

Mn

Manganese

Mo

Molybdenum

MPI

Magnetic Particle Inspection

MR

Material Requirement

MSS

Manufacturers Standardization Society

N

Newton’s

NB

Nominal Bore

NDE

Non-Destructive Examination

Ni

Nickel

NPS

Nominal Pipe Size

NPT

American National Standard Taper Pipe Thread

Nm

Newton Meters

PMI

Positive Material Identification

PPM

Parts Per Million

PREN

Pitting Resistance Equivalent Number

Ra

Surface Roughness

RP

Recommended Practice

SAW

Submerged Arc Weld

V

Vanadium



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2. DESIGN MANUFACTURE 2.1

General

The Supplier shall advise the Purchaser at the bid stage of all intended sources of material supply and proposed sub-contractors. All items shall be supplied in accordance with the specifications stated in this document and the appropriate National Standards.

Materials for pipes, fittings and flanges shall be as stated in the relevant material requisition. Materials shall meet the requirements detailed in this specification and in the product specification as stated in the material requisition. All materials shall be new, clean and free from rust, mill scale, pits and defects.

Weld repair of seam welded pipe and fittings is only permitted on the seam welds.

Weld repair of wrought or forged material will not be permitted. Cast materials shall only be repaired subject to prior written approval by the Purchaser I Company.

Where a Supplier wishes to supply a suitable alternative to that specified, he shall submit the relevant specification of the alternative to the Purchaser I Company for approval at the bid stage.

Threads shall conform to ASME B1.20.1 taper.

Material manufactured from bar-stock is not acceptable. 2.2

Design

End Preparation

End of pipe, fittings, and flanges shall be in accordance with the following: - Pipe 1-1/2" and smaller may be furnished with plain ends, and cut square. - Pipe 2" and larger and butt weld end fittings and flanges shall be furnished with beveled end in accordance with ASME B16.25, Figures 2a or 3a. Flame cut weld bevels Socket weld ends of fittings and flanges shall be in accordance with ASME B16.11.



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- Threaded ends of pipe, fittings, and flanges shall be taper pipe threads (NPT) in accordance with ASME B1.20.1.

Hardness of Pipe

Except for wrought pipe fitting in accordance with ASTM A234 Gr. WPB and WPC and forgings in accordance with ASTM A105, all Carbon Steel and High Yield Carbon Steel internally clad with corrosion resistant alloy (CRA) material, i.e. Alloy 625 UNS N06625, piping shall be supplied with a maximum hardness of 248 HV 10 (22 HRC) in compliance with ISO 15156-2 wherever Sour Service or ISO 15156 is specified.

The maximum hardness for Pipeline High Yield Carbon Steel (HYCS) piping components, i.e. API 5L Gr X60, ASTM A860, ASTM A694, etc. shall be in accordance with Piping Design Criteria, Doc No. HEN-0000-PI-DB-0001.

The maximum hardness of the base metal, weld seam, and heat affected zone, after required heat treatment, shall not exceed the requirement of the material supply specification referenced for manufacture.

Galvanizing

Pipe, fittings, and flanges specified in the Item Code Purchased Description as galvanized, shall be hot-dip galvanized in accordance with ASTM A53 or ASTM A153, as applicable.

Galvanized pipe up to 1” shall be supplied in double random lengths, threaded both end and with a hand tightened pipe coupling fitted to one end.

Galvanized pipe and coupling shall be supplied with threads free of galvanizing. ISO

Wherever Sour Service or ISO 15156 is specified, all piping materials shall comply with ISO 15156 In addition the maximum sulfur content on Carbon, Low Alloy and High Yield Carbon Steel material shall be as follows: - Flat rolled: 0.003%



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- Seamless: 0.01% - Forging: 0.025% 2.3

Material

2.3.1 Carbo n Low All oy Steels and High Yield Carbon Steel (H.Y.C.S.)

- The steel used for the manufacture of carbon steel pipe, fitting, flanges and bolting shall be produced by either an electric furnace or by the basic oxygen process. - API 5L Grade X60 Seamless pipe shall not be cold expanded, and shall be supplied to API-5L Product Specification Level 2 (PSL2) - API 5L Grade X60 SAW pipe shall be 100% radiography and supplied to API-5L Product Specification Level 2 (PSL2). - Low temperature carbon steel materials to ASTM A350 LF2 CL.1 shall be supplied as Class 1 (Impact Tested at -46 deg C). The acceptance criteria energy values for ASTM A350 LF6 CL.3 and ASTM A420 WPL6 shall be accordance with Section 3.3.2.2 - Impact Testing. - All Carbon and Carbon-Manganese steel (except High Yield Strength Carbon steels) shall meet the Following weight percent limits by ladle analysis: Carbon Content for Carbon Steel: Pipe & fittings

0.23% (Max)

Casting & forging

0.23% (Max)

Carbon Equivalent(CE)

Shall be less than 0.42 (ladle analysis)

Where CE = C + Mn/6 + (Cr + Mo + V)/5 + (Cu + Ni)/15 If the content of alloying elements other than C or Mn is unknown, the formula to be used shall be CE = C + Mn/6 and, in this case, the carbon equivalent shall be less than 0.40 (ladle analysis). 2.3.2

Substitu tion of Equivalent Materials

In general, carbon steel pipes for which grade B is specified shall in no case be replaced by grade A pipes. Substitution with ERW pipe, where SAW pipe is specified, is prohibited. However, some other substitutions of materials may be accepted:



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- Substitutions acceptable without prior approval by the Purchaser. Carbon steel pipes to API 5L Grade B may be replaced with carbon steel pipes to ASTM A106 Grade B. - Possible substitutions requiring prior approval by the Purchaser I Company. Stainless steel pipes to ASTM A312, welded by electric fusion (SAW) may be replaced with welded stainless steel pipes to ASTM A358 CL.3 and vice-versa, subject to prior approval by the Purchaser I Company. 2.3.3 Hydrog en Induc ed Crackin g (HIC) Test Requir ement

The material shall be tested at a frequency of one set of tests per heat of material in accordance with the NACE Standard TM0284 using the sulfide stress corrosion cracking test solution defined in NACE Standard TM0177. The test coupons shall be sectioned in accordance with NACE TM0284. The acceptance criteria shall be:

Crack Length Ratio (CLR)

≤

15%

Crack Thickness Ratio (CTR)

≤

5%

Crack Surface Ratio (CSR)

≤

1.5%

No Individual Crack Length

>

5mm

Pipe and plate which is internally clad with corrosion resistant alloy (CRA) shall be guaranteed by vendor, otherwise HIC test of base metal is required as per ISO 15156

2.3.4 Heat Treatment

All carbon steel (impact tested and non-impact tested) shall be supplied in the normalized or normalized and tempered heat-treated condition where the minimum tempering temperature shall be 1184°F (640°C) with the following exceptions: - Hot finished pipe to ASTM A106 - Where it becomes necessary to quench and temper material to achieve the specified mechanical properties. In such instances the preferred minimum tempering temperature shall be 650°C



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- High yield carbon steel grades X60 and above shall be manufactured with thermo mechanical controlled process (TMCP). In this case no additional tempering shall be utilized, else mechanical properties will decline. The Supplier shall provide full details of all heat treatments proposed at the bid stage

2.3.5 Impact Test ing

Where Charpy impact tests are required by the product specification or specified in the material requisition and ASME B31.3, the test temperature shall be at the product specification test temperature or the minimum design temperature, whichever is the more stringent, or as specified in the material requisition. Longitudinal samples shall only be used by prior agreement with the Purchaser. Charpy acceptance values for longitudinal samples shall be agreed with the Purchaser. Specific Charpy Impact Energy Values shall be as follows for full size material specimens:

ASTM A333 Grade 6, ASTM A671 Gr. CC65 CL32, ASTM A420 WPL6, ASTM A350 LF6 CL.3 27 joules min. average 20 joules min. Individual Test Temperature -50℉(-46℃) ASTM A860 WPHY 65, MSS SP-75, ASTM A694-F65 42 joules min. average 35 joules min. Individual Test Temperature -20℉(-29℃)

For HYCS to API 5L X60, the average impact energy of 3 samples in the transverse direction and the minimum design temperature, Tmin. Shall be as follows:

API 5L X60 73 joules min. average 55 joules min. Individual Test Temperature -20℉(-29℃)



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Sub-size specimens are only acceptable where full size specimens (10mm x 10 mm) cannot be extracted. The largest possible sub-size specimen shall be taken. Adjusted acceptance criteria for sub-size transverse specimens shall be not less than the following: 10mm x 7.5mm

80% of the full size value

10mm x 5mm


10mm x 2.5mm


2.3.6 Impact Testing on Welded Items

Where welding is involved in manufacture, welding procedure qualification impact tests shall be performed where impact testing of the parent material is required or where high strength materials are used.

The test method shall be as per ASTM E23 or BS EN 10045-1.

The acceptance criteria and test temperature shall be as for transverse samples of parent material. On welded pipe, additional impact tests shall be performed on coupons from welding procedure qualification tests. The number of specimens shall be as below in Table 1. Where the thickness at the weld exceeds 25mm a further set of 3 specimens shall be taken with the notch at the root of the weld. Specimens shall be etched in order to accurately locate the Charpy V-notch. Table 1 - Impact Testing for Welded Pipe TEST REQUIREMENT

NUMBER

Charpy Testing of Weld Metal

3 off

Fusion Line Fusion Line + 2mm

3 off

3 off



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Fusion Line + 5mm

3 off

Where the carbon content is limited the actual tensile strength of the steel should not exceed the minimum required by the relevant specification by more than 130 MPa (18,850 psi). 2.3.7 Aust eniti c Stainless Steels

Manufacturing of the 300 series austenitic stainless steel shall be to ASTM A312, A351 and A403. Grade 316/316L stainless steel shall be dual certified, i.e. chemical composition to Grade 316L SS and mechanical strength to Grade 316 SS.

All material shall be supplied in the fully solution annealed heat-treated condition and free of subsequent cold work. Welded items shall be solution annealed after welding. If welding repairs are required to the bodies of cast (A351) items in 316 stainless steel, the procedure shall be subject to approval. Welded pipe shall be made by a continuous automatic electric fusion welding process to the requirements of ASTM A358 CL.3. The composition of all filler metals shall be chosen such that the resistance to corrosion and other properties of the weld deposited weld metal shall have a ferrite content of between 3% and 10%. No weld repairs shall be permitted without prior COMPANY's approval.

Welded 316/316L SS pipe shall be ASTM A358 CL.3 Grade 316/316L.

Longitudinally seam welded (with the mandatory use of weld filler metal) shall be supplied in the fully solution annealed condition.

Welding shall be by use of qualified welders and approved welding procedures and welding procedure qualification records, in accordance with ASME IX. PQRs of welded fittings. The deposited filler metal should provide a minimum ferrite content of 3%.



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Welded 316/316L SS fittings shall be 100% radiographed to ASME V Art. 2 and acceptance criteria to ASME VIII Div. 1 UW51.

Welded 316/316LSS fittings shall be ASTM A403 Grade WP316/316L Class WX.

100% DPI shall be performed on all 316/316LSS materials.

100% Positive Material Identification (PMI) shall be performed on austenitic stainless steel material.

AII 316SS grade material certified to IS015156 shall have a maximum hardness of248 HV10.

In order to use austenitic stainless steel at low temperature, weld metal deposits and heat affected zone

Shall be impact tested as required by ASME B31.3 par. 323.2.2 and 323.3

All SS grade material shall be annealed, quenched & normalized.

All items/parts shall be supplied in solution annealed condition. For all Austenitic Stainless steels, Inter granular Corrosion (IGC) Test shall be conducted as per following:

ASTM A262 Practice 'B' with acceptance criteria of 60 mils/year (max.) for casting. ASTM A262 Practice 'E' with acceptance criteria of 'No cracks as observed from 20X magnification' & microscopic structure to be observed from 250 X magnification for other than casting.

For IGC test, two sets shall be drawn from each solution annealing lot; one set corresponding to highest carbon content and other set corresponding to the highest rating/thickness.



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For all items of stabilized SS grades, stabilizing heat treatment shall also be done. It shall be carried out subsequent to normal solution annealing. Soaking temperature and holding time shall be 4hrs and 900 deg C respectively. 2.3.8 Duplex Stainless Steel

This section defines the minimum requirements for Duplex stainless steel materials. Material shall conform to the mechanical properties and the chemical composition of the relevant ASTM standard as defined in ASME B31.3.

UNS S31803 shall be used as the basis of this material.

The chemical composition shall meet the requirements of the relevant ASTM standard for the relevant grade of material. A product analysis shall be conducted in accordance with the relevant ASTM standard (e.g. ASTM A182). The maximum carbon content shall be 0.03% maximum by ladle and product check analysis. Minimum nitrogen content shall be 0.15%.

Duplex stainless steel fittings shall be seamless up to 8" NB and longitudinally seam welded at 10" NB and larger (with the mandatory use of weld filler metal) and shall be supplied in the fully solution annealed and water quenched condition. Welding shall be by use of qualified welders, approved

welding procedures and welding procedure qualification records in

accordance with ASME IX. PQR’s of welded fittings.

Welded Duplex stainless steel fittings shall be 100% radiographed to ASME V Art 2 and acceptance criteria to ASME VIII Div.1 UW51.

Welded Duplex stainless steel fittings shall have a ferrite content of 40-60% for the base material and 25-60% for welds, determined by a metallographic method in accordance with ASTM E562.

Charpy impact energy values shall be as follows for full size specimens:



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UNX S31803 45 joules min. average 32 joules min. Individual Test Temperature -60℉(-51℃)

The steel shall be made by electric arc and/or electric induction furnace process. Refining by the Argon Oxygen Decarburization (AOD) or the Vacuum Oxygen Decarburization (VOD) or similar is required.

The minimum PREN based on product analysis shall be 33 for 22% Cr duplex stainless steel. PREN is defined as: PREN = %wt Cr = (3.3 x %wt Mo) = (16 x %wt N)

100% PMI shall be performed on all Duplex Stainless Steel material. Duplex stainless steel pipe and fittings shall be supplied in the fully solution annealed and quenched condition. 2.3.9 High Nickel Allo y

Solid Nickel Alloy 625 UNS N06625 All Solid Nickel Alloy 625 UNS N06625 shall be supplied in accordance with:

Pipe

ASTM B444

Plate

ASTM B443

Fitting

ASTM B366

Flanges & forging

ASTM B564

All deposited weld metal shall be Alloy 625 UNS N06625 only.

Welded pipe shall be supplied in the solution annealed and descaled condition and free of subsequent cold work. All Alloy 625 UNS N06625 shall be supplied with the following minimum mechanical properties:



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Tensile Strength

827 MPa (120,000 psi)

Yield Strength

414 MPa (60,000 psi)

Elongation in 50mm 30%

Low Temp High Yield Carbon Steel with Alloy 625 UNS N06625 Weld Overlay

Fabrication by welding of Alloy 625 UNS N06625 overlaid on Low Temp HYCS piping component shall comply with clause 323.4.3 (d) of ASME B31.3 Code and supplementary requirement below

Additional Requirements for Alloy 625 UNS N06625 Clad Pipe and Fittings

a. All cladding material shall conform to Alloy 625 UNS N06625. The minimum cladding thickness for all pipes and fitting shall be 3mm b. All substrate materials for clad pipe, fittings and flanges shall be High Yield Strength Carbon Steel (HYCS) to minimum yield strength of 65ksi. Seamless carbon steel pipe shall meet the requirements of API 5L X60. Fittings shall meet the requirements of MSS SP75 WPHY 60. Flanges shall meet the requirements of ASTM A694 GR F60. c. All dimensions for clad pipe shall be to API 5L. All dimensions for clad fittings shall be to ASME B16.9. All dimensions for clad flanges shall be to ASME B16.5. d. Clad pipe shall meet the requirements of API 5LD metallurgical bonded seamless pipe unless otherwise specified. 20"NB API 5L X60 pipe for cladding is acceptable as SAW with 100% radiographic examination. e. HYCS Clad Alloy 625 UNS N06625 pipe & fittings shall conform to ASME B31.3 para.323.4.3 (b) integrally clad, and ASTM A265/B444 bond strength tested, or equivalent. f. Supplier shall provide full details of the pipe, fitting and flange manufacturing process, including details of all welding, heat treatment, testing and inspection at the bid stage. g. Clad fittings shall be seamless and may be made by one of the following processes depending on the type, size and geometry of the fitting:

- From clad pipe by the hot or cold forming process. - By weld overlaying.



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- Where fittings cannot be manufactured from these two processes, other processes may be proposed by the Vendor for consideration by the Purchaser. Otherwise the fittings shall be solid Alloy 625 UNS N06625

h.

Where CRA-clad pipe, fittings and flanges are fabricated by weld overlaying; the Welding Procedure Specification (WPS) shall be approved by Company before welding is started. Welding procedure for each welding process shall be qualified in accordance with ASME IX or EN 15607. Design of clad fittings shall be in accordance with accepted standards and manufacture shall generally be in accordance with the provisions of the high yield carbon steel fitting standards.

i. Where weld overlaying with Alloy 625 UNS N06625 is used, preference shall be given to the use of two layers of welding deposit to the minimum thickness of 3mm, in order to minimize dilution of the 625 with iron at the surfaces in contact with the process fluids. A single layer deposit may be used providing that the iron level in the Alloy 625 UNS N06625 surface in contact with the process is less than 7% after dilution has occurred. If this iron level is exceeded, the minimum chromium content shall be 20% and the minimum molybdenum level shall be 8%, otherwise 2 layers of welding shall be used.

j. Where necessary, a post weld heat treatment shall be employed after weld overlaying if the hardness of the backing steel exceeds the limits specified on section 2.2.2

k. Welding specifications, welder qualifications and welder experience must be suitable for Alloy 625 UNS N06625 clad materials.

I. All seams shall be 100% radiographed in accordance with ASME VIII Division I. All weld overlaid surfaces shall be 100% dye Penetrant tested in accordance with ASME V, with no indications acceptable.

m. All Alloy 625 UNS N06625 clad pipe, fitting and flange are to be used in low temperature service, the mechanical properties of the backing steel must meet the low temperature limit for the intended service application and complied with impact testing. For Alloy 625 UNS



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N06625 clad HYCS X65 steel, the clad material shall be tested in accordance with the requirements for the backing steel. The as-deposited weld yield strength of the Alloy 625 UNS N06625 filler material shall meet the requirements of the HYCS X65 backing steel.

n. The cladding material must be resistant to corrosion and cracking in the service environment and any heat treatment required for manufacturing or code compliance purposes must not cause sensitization, segregation or third-phase formation in the CRA that could reduce its corrosion resistance. 2.3.10 Copp er-Nick el Material (Cu-Ni)

Seamless and welded pipe shall comply with the requirements of EEMUA 144 for 90/10 copper nickel alloy piping. Pipe shall include supplementary requirements of 1.7.2(a)(b)(c) and 1.9.1. Pipe shall be seamless up to and including 6.” NB. Copper Nickel pipe shall be cut by mechanical means. Minimum random lengths for all Copper Nickel pipe shall be to EEMUA 144 90/10 Copper Nickel Alloy pipe fittings shall comply with EEMUA 146. BW Tees shall be in accordance with ASME B31.3 App 'D' for welding tees to ASME B16.9 where rx ≥ 1/8 Db & Tc ≥ 1.5T "Olets" shall as per MSS-SP-97. The internal bore of "Olets" shall be tapered with a slope of 1 in 3 minimum Proof test reports of all fittings shall be submitted at the bid stage. 90/10 Copper Nickel Alloy pipe flanges (composite and solid) shall comply with EEMUA 145. Weld neck flanges shall be bored to match pipe wall thickness. Lap joint flanges (Weld Neck Stub Ends) shall be bored to match pipe wall thickness and shall be "LONG" type. All stub ends shall be seamless.

Gasket contact surface finish for flanges and stub ends shall be Ra 3.2 to 12.5 µm. Copper Nickel facing discs on blind flanges and spades shall be 1.5mm thick and with a diameter equal to or greater than diameter d4 in Table 1.3 of EEMUA 145.



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Pipin g Compon ent Manufactu re

2.4.1 Pipe

Dimensions of pipe, except for copper-nickel material, shall be in accordance with ASME B36.10, ASME B36.19, and API 5L as defined in the Purchase Order.

API 5L Gr. B pipes are specified in the Purchase Order, alternative offer of ASTM A106 Gr. B pipes is acceptable.

Nominal Standard pipe lengths for carbon steel, galvanized carbon steel and austenitic stainless steels shall be supplied in double random length as defined in the applicable standard. If the applicable standard does not state the limits of a double random length the following shall be adopted: - double random lengths with a minimum average length of 35 ft. (10.7m) and a minimum length of 22ft (6.7 m).

Beveling the ends of the pipes shall be performed by machine cutting. This process shall assure the production of clean, burr-free bevel cuts.

Unless indicated otherwise in the Purchase Order, steel pipes of 1-1/2" NB and smaller shall be supplied with plain ends, square cut. Steel pipes 2" NB and larger shall be supplied with butt weld ends, beveled in accordance with ASME B16.25 figures 2a or 3a, as applicable, to match nominal pipe sizes and wall thicknesses of ASME B36.10, ASME B36.19, API 5L and/or as specified on the Purchase Order Galvanized carbon steel pipe 4" NB and smaller shall be supplied with ends threaded Couplings shall be attached at one end, Threads shall conform to ASME B1.20.1 taper. Couplings shall be to ASME B16.11 and ASTM A105N (Galvanized).

Dimensions of Copper-Nickel tube shall be in accordance with EEMUA 144. Copper-nickel pipe shall be plain ended for 6" NB and smaller. The mill tolerance applicable to all pipes shall be that required by the relevant product specification unless stated otherwise in the Purchase Order.



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The inside bead of welded pipe shall be removed at each end of the pipe for a distance of 100mm with a gradual transition. Finished pipe shall not include circumferential butt welds. Spiral wound seam pipe shall not be used. Jointers shall not be used. Hydrostatic tests shall be carried out on all pipes in accordance with the referenced codes, standards, and product specifications, using water containing 1% by volume of BP NID 260S liquid or other equivalent biodegradable wetting agent. Pipes shall be flushed out with clean potable water and drained and thoroughly dried after hydro test.

Maximum chloride content of water for hydro testing and flushing of austenitic stainless steel and high alloy steel shall be 50ppm.

The chloride content shall not exceed 30 ppm for

stainless steel valves, but shall not exceed 5 ppm when component to be tested is stainless steel valve for which drying operation cannot be properly secured. 2.4.2

Fittings

Butt weld fittings shall conform to ASME B16.9 and ASME B16.28 (for short radius elbows) or MSS SP-75 as applicable.

Socket weld fittings shall conform to ASME B16.11.

Threaded fittings shall conform to ASME B16.11 and ASME B1.20.1 (NPT).

Branch reinforcement fittings (sockolets, thredolets, weldolets, nipoflanges, etc.), shall comply with MSS SP-97, and the relevant Vendor's standards. The Supplier shall confirm with certification at the bid stage that the fittings comply with the requirements of ASME B31.3 Para 304.3.2 "Strength of Branch Connections" (i.e. verified burst test certificates or mathematical calculations) Prototypes of all butt-weld fittings supplied to this specification shall have been subjected to burst tests by the Vendor to prove that they comply with the bursting strength requirements of the Standards to which they relate (i.e. ASME B16.9 para.9 or MSS SP75 Para.4 as



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appropriate). Alternatively, subject to agreement with the Purchaser, the design of fittings may be established by mathematical analysis to demonstrate compliance with the design.

Where seamless butt-weld fittings are specified, fittings of welded construction shall not be substituted without the Purchaser's prior approval in writing. Butt-weld forged tees shall have crotch radius and crotch wall thickness in accordance with ASME B31.3 Appendix D for welding tee to ASME B16.9. Manufacture of fittings shall be as follows: - Fittings up to 1-1/2" NB All fittings up to 1-1/2" NB shall be forged - Fittings 2" NB or more i. Seamless Fittings Seamless fittings shall be forged or extruded. Fittings machined from bars are not acceptable. ii. Welded Fittings Following the welding operation, which may be carried out on welded tubular elements, the thickness of the fittings must be within the tolerances required by the reference standards. If the welded fittings are manufactured from plate, the minimum wall thickness at any point of fitting above 24" NB shall not be less than 0.3mm under the specified wall thickness.

The welds shall be made by an approved process. The seams shall be back-welded if the welding process does not assure full penetration with, on the back, a weld reinforcement of uniform thickness, free of appreciable distortion. "Fabricated" fittings shall consist of a single rolled and welded plate. However, fabricated fittings may, if necessary, be made with two longitudinal welds. For all "Fabricated" fittings, the vendor shall submit, with his quotation, drawings showing all dimension and tolerances of the fittings offered, giving details of method of manufacture, heat treatment (including PWHT), showing location of all welds, with joint details, for review by the Purchaser All welds shall undergo radiographic examination in accordance with the reference codes and standards. Hardness testing is also required for service specified as "Sour Service" or ISO 15156.



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Beveling the ends of the pipes shall be performed by machine cutting. This process shall assure the production of clean, burr-free bevel cuts. Fabricated fittings shall comply design requirements as per ASME B16.9 & ASME B31.3. 2.4.3 Flanges

Dimensions of pipe flanges shall be in accordance with ASME B16.5 (or ASME B16.47 Series A, above 24") as applicable; except for cupro-nickel flanges which shall be to EEMUA 145.

All carbon steel forgings shall be supplied in the normalized and tempered, or quenched conditions.

The dimensions of orifice flanges shall be in accordance with ASME B16.36 or as specified on datasheets.

The weld bevel of weld neck steel flanges shall be in accordance with ASME B16.25 Figures 2a or 3a as applicable, to match nominal pipe sizes and wall thickness to ASME B36.10, ASME B36.19 or API 5L. Cupro-nickel weld neck and composite flanges shall be beveled in accordance with EEMUA 145.

Spades, spacers and spectacle blinds shall be in accordance with ASME B16.48.

Facings on all ring type joint spades, spacers and spectacle blinds shall be female only. All ring type joint contact faces, including side walls, shall have a surface roughness between 0.4 and 1.6 micrometers Ra, in accordance with ASME B46.1.

The gasket contact surface roughness for raised face flanges, spades, etc., shall be between 3.2 and 6.3 micrometers Ra (smooth finish) in accordance with ASME B46.1.

Flange facing for ring type joint (RTJ) flange shall have the following minimum hardness values as follows:

Carbon Steel

:

120 HB



Austenitic

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Stainless

Steel

Gr.

:

150 HB

Steel

:

120 HB

:

230 HB

316/316L Low

Temperature

Carbon

(LTCS) Nickel Alloy 2.4.4

Bolting

Threading of all bolting shall be in accordance with ASME B 1.1, UNC series for diameters up to and including 1" and 8" UN series for diameters 1 1/8" and larger.

All stud bolts shall be threaded full length and supplied with two heavy series hexagon nuts. The length of stud bolt 2" diameter and larger has been calculated to allow for the use of hydraulic bolt tensioning equipment, the extra length is included in the length stated on the material requisition. 3 nuts shall be provided for all 2" diameter and larger bolts.

All bolting including NACE compliant bolting shall comply with the Piping Specification.

Bolts/nuts of material of construction B7M/2HM shall be 100% Hardness tested as per supplementary requirement S3 of ASTM A 193. All bolts and nuts shall be zinc coated (Hot-Dip) to ASTM A153.

All jack screws and hexagon headed bolts shall have threads extended to the underside of the head.

All bolting shall be Hot Dip Galvanized in accordance with ASTM A153 and fully passivity. Nut shall be re-tapped after galvanizing and be fully assembled with stud bolts prior to dispatch.

All bolting material shall comply with the manufacturing and testing requirement of the applicable ASTM specifications.



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All NACE and non NACE compliant ASTM A320 L7M and 7M bolting shall be supplied impact testing at minus 101°C. All nuts to ASTM A194 Grade 4 and 7 shall be impact tested in accordance with the 'Supplementary Requirements' S3 of ASTM A194 at minus 101 °C.

The stud bolts shall be threaded along their entire length. The machining and surface condition tolerances applicable to various threading shall be in conformity with the following classes: - Class 2A of ASME B1.1 Standard for Stud Bolts and Screws - Class 2B of ASME B18.2.2 Standard for Nuts 2.4.5 Gasket

Flat ring gaskets shall be compressed non-asbestos fiber in accordance with ASME B16.21.

- Gasket thickness shall be 2 mm unless specified otherwise. - Asbestos in any form shall not be used in the manufacture and construction of gasket. - Gasket shall be suitable for Hydrocarbon gas, oil, amine, potable water and wet sour service as defined in ISO15156.

Spiral wound gaskets shall be in accordance with ASME B16.20. Unless stated otherwise gasket shall be 4.5 mm thick graphite filled with 3 mm thick inner and outer centring ring to ASME B16.20. - Material inner ring and center ring shall be per requisition. - Material of winding shall be per requisition. - All spiral wound gasket shall comply with ISO15156.

ASME RTJ metal seal rings shall comply with the applicable dimensional standard ASME B16.20 The RTJ gasket material shall be as follows:

- For Alloy 625 Flange: Alloy 625 (UNS N06625) Oval ring gasket, 220HB Max. - For SS Flange: SS316L Oval ring gasket, 135HB Max. - For CS & LTCS Flange: Soft Iron Oval ring gasket, 90HB Max.



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2.4.6 Other Fitti ngs 2.4.6.1

Dimensi on and Weights.

Forged fittings of class 3000, 6000 or 9000 rating shall be in accordance with ASME B16.11. Wrought butt welding fittings shall be in accordance with ASME B16.9. Integrally reinforced branch connection fittings shall be in accordance with MSS SP-97.

Low temperature carbon steel forgings ASTM A350 LF2 shall be supplied to class 1 for minus 46°C design temperature

2.4.6.2

Materials of Manufactur e

Unless otherwise specified, thread or socket welding forged carbon steel fittings shall be supplied with material according to ASME B16.11, and wrought butt welding fittings shall be supplied with material according to ASME B16.9. Fitting machined from rolled bar or bar stock are not permitted.

2.4.6.3

But t weldi ng Tees Crotc h Thick ness and Radius

Tees shall be furnished with radii and thickness limits as specified in Table D300 in Appendix D of ASME B31.3.

2.4.6.4

Fabricat ed Fitti ngs (Tees and Reducers)

Mitered type fittings and fabricated tees, made by joining sections of pipe, are not permitted. Tapered conical reducers (reducers without knuckle radius on both ends as illustrated in ASME B 16.9) are not permitted. 2.4.6.5

Overs ize Ends

Beveled and plain ends of 2" NB and smaller pipe and swage nipples shall be capable of fitting into ASME B16.11 socket welding connections, to the full depth of the fitting socket. Oversize ends are not permitted



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2.4.6.6

Integrally Reinfor ced Branch Fittings ("Olet" )

Integrally reinforced branch connection fittings shall reinforce the header pipe wall thickness with equivalent material, and provide 100 percent header pipe strength in accordance with the requirements of MSS SP-97 and the applicable Piping Code. Branch reinforcing fittings shall be designed in accordance with the requirement of ASME B31.3. Supplier shall submit sample calculations for approval with his bid. 2.4.6.7

Substitutions

It is permissible to substitute seamless fittings in place of welded fittings of the same grade and wall thickness. Other substitutions are not permitted without Buyer approval. 2.5

Fabrication

- Fabrication and Manufacturing by Welding Fabrication of pipe or fitting by welding shall be in accordance with the requirements of the specification referenced for manufacture. In addition, welding preheat temperatures shall be in accordance with applicable Piping Code, i.e. ASME B31.3, ASME B31.8, etc. - Repairs Casting repairs are not permitted for cast iron, malleable iron, ductile iron, brass, or bronze materials. Major repairs of castings, as defined by ASTM A217, are not permitted. Limitations on imperfections, and method and extent of required examination for repairs, shall be the same as required for the original castings. Repair of castings by peening or impregnation with metallic on nonmetallic materials is not permitted. - Modification Modification or repair, including the re-facing of flange gasket seating surfaces, shall be in accordance with referenced specifications. - Post Weld Heat Treatment Where welding is performed as part of the manufacturing process, pre and post weld heat treatment shall be carried out in accordance with a qualified heat treatment procedure specification as part of the Contractor's Company-approved welding procedure specification and in conformance with the requirements of ASME B31.3/ ASME IX.



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The necessity for preheating and the required temperature shall be specified in the welding procedure and demonstrated by procedure qualification. The pre-heat temperature shall take into account the type of joint, the metal thickness, the composition of the material and the heat input to each run of welding 3. INSPECTION AND TESTING 3.1

Pressur e Testing

Each length of pipe shall be subjected to a hydrostatic test in accordance with ASTM, ASME, or API specification referenced for manufacture. Where there is a choice in the specification of hydrostatic test or other NDE (Non-destructive Examination), the hydrostatic test shall be performed. If no hydrostatic test is required in the Vendor's specification, then the ASTM A530 hydrostatic test shall be performed.

For Austenitic stainless pipes, only water containing less than 50 ppm (0.050 mg/litre) chloride ion shall be used for pressure testing 3.2

Examination

Examination is required only where specified by the specification and grade of manufacture, or where specified in the Item Description or in the PO.

Surfaces to be examined shall be clean and free from surface conditions that may mask unacceptable conditions.

All items shall be free from crack, scores, laps and other defects.

Personnel performing and evaluating examinations other than visual examination and hardness testing shall be qualified in accordance with the ASNT SNT-TC-1A. Only Level II and Ill personnel shall be authorized to interpret results for radiographic and ultrasonic examinations.



3.3

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Testing

3.3.1 Mechanical Testing

Testing shall meet the minimum requirements of the referenced product specification as stated on the Purchase Order or as otherwise stated in the project specifications. Test pieces may originate from prolongations of the forgings or material which has undergone the same deformation and heat treatment as the component or individual components which are designated to be sectioned for testing purposes.

One set of mechanical tests shall be conducted per heat and/or per heat treatment batch. For pipe, where heat treatment is carried out in a continuous furnace, one set of tests shall be conducted every 60m for the same heat and size (wall thickness and diameter).

Tests shall be conducted after final heat treatment in accordance with the appropriate manufacturing standards, plus any supplementary requirements identified in this Specification 3.3.2 Charpy V-Notc h Impact Test ing

Charpy impact tests shall be carried out on material when stipulated in the referenced codes or specifications or on the material requisition or relevant sections of this specification. Tests shall be carried out in accordance with the requirements of the referenced product specification and as required by EEMUA 153, supplement to ASME B31.3 (to the method of ASTM A370).

For Pipe, test samples shall be cut out from the finished end.

Charpy tests shall be conducted in accordance with ASTM E23 or BS EN 10045-1. Test temperature and acceptance criteria shall be defined by the Purchaser.

If the specified average impact value is not attained or if one specimen only shows a value less than the specified minimum individual value, then three additional specimens shall be selected from a position similar to that from which the set of specimens under consideration were taken. The average impact value of the six specimens shall be not less than the specified minimum average value and not more than two specimens shall show values below



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the specified minimum average value, only one of which may be below the specified individual value. 3.3.3 Non Dest ruc tiv e Examinati on (NDE)

All Pipe, Flanges, and Fittings shall be tested and inspected in accordance with their referenced product specification and shall be subject to the following additional Nondestructive examination, which shall be performed after any heat treatment. NDE shall also apply to any repair welds. MPI or DPI shall be performed after any machining operations. MPI shall be used for ferrous materials and DPI for stainless steel materials.

No cracks, linear

defects or dye Penetrant indications shall be permitted.

For pipe, fittings and flanges with a wall thickness greater than 20mm, 100% MPIIDPI shall be performed over the entire machined surface including 100mm from the bevel.

The external surfaces of all flanges and fittings, and welds of lateral tees shall also be inspected by 100% MPIIDPI.

Surface defects such as slivers, sharp notches and scores may be machined or ground out provided that the wall thickness is not reduced locally by more than the minimum required section thickness. No cracks or linear defects shall be permitted. The remaining wall thickness shall be verified by ultrasonic or other calibrated instruments. If the section thickness is reduced below the minimum required section thickness, the flange shall be rejected. Material shall be rejected where imperfections are not scattered but appear over a large area in excess of what is considered a workmanlike finish by the Purchaser's Inspector

100% Ultrasonic examination of all applicable Pipe, Flanges and Fittings shall be carried out in accordance with ASME V Article 5, using both compression and shear wave probes over the entire surface. Ultrasonic testing shall meet the requirements of ASTM A388. When using compression waves, any area giving an indication equal to or greater than a signal received from a 3mm flat-bottom

hole shall be rejected. Multiple indications with an amplitude

exceeding 50% of the indication from the calibration hole, accompanied by a loss of back reflection exceeding 50% shall be rejected. Any indication that results in a complete loss of



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back wall echo shall be rejected. For shear beam examination indications which are equal to or greater than those obtained from a rectangular notch 25mm long and having a depth not greater than 5% of the nominal wall thickness are to be rejected.

NDE shall be performed after final heat treatment and machining. MPI examination shall be completed in accordance with ASME Section V, Article 7.and ASTM E709. Ultrasonic examination shall be completed in accordance with ASME Section V, Article 5, and ASTM A388 as applicable.

DPI examination shall be completed in accordance with ASME Section V, Article 6.

Suppliers shall use only qualified NDE Operators and, as a minimum, the operators shall have the following qualifications or equivalent:

Ultrasonic

PCN-WSB-UT-001-87 Level 2

Dye Penetrant

PCN-WSB-PT-001-87 Level 2

Magnetic Particle

PCN-WSB-MT-001-87 Level 2

Radiography

PCN-WSB-RT-001-88 Level 1 with Level 2 interpreter

PCN-Personnel Certification in Non Destructive Examination Note: Equivalent qualifications are subject to approval by the Purchaser / Company. 4. IDENTIFICATION AND TAGGING 4.1

Marking

Each fitting or flange shall be marked in strict accordance with the specification referenced for manufacture, or MSS SP-25 as a minimum. Pipe shall be marked in strict accordance with the ASTM, ASME, or API specification of manufacture.

In addition to the marking required by the relevant specification, each item 2" NB and larger shall have its stock code number, Purchase Order number and Purchase Order item number



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painted on. For pipe this shall be near each end. For items 11/2" NB and smaller, these marking shall be marked on metal tag (for pipe), or on the packing carton (for flanges, and fittings).

If blasting and priming of pipe are required by the Item description or the PO, then the original marking such as material grade designation, schedule, and heat number shall be re-stenciled on the exterior of the pipe at 2 meters intervals with paint compatible with primer.

Pipe, fittings, and flanges shall be color coded when specified in the Item Description or PO. Color coding is intended to supplement, not replace, normal identification marking required by ASTM, ASME, API, MSS, or other standards.

Marking paint or ink shall be resistant to salt water atmosphere, tropical or freezing climates, or similar attack; it shall not, in itself, cause corrosion of the piping components to which it is applied. For austenitic stainless steel or nickel alloy piping component, it shall not contain chlorides, nor shall it contain metals, such as zinc or lead, that may cause corrosive attack at high temperatures.

Paint shall not be applied to the inside of pipe, threads, weld bevels, gasket surfaces, symbols, or markings, if doing so would obliterate identification.

In addition to the above markings required by the relevant product specifications and the colour code marking, the following markings shall appear on each item as appropriate where space permits: - Material Specification and Grade - Cast or Heat Number (Shall be permanent marking) - Batch Number (as applicable) - Flange Rating - Nominal Diameter - Wall Thickness - Ring Joint Number - Purchase Order Number and Purchase Order Item Number



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- Stock Code Number (as applicable) Where space is not available (with the exception of Cast/Heat Number) it shall be stamped on a stainless steel tag wired to the item.

Marking materials used on austenitic stainless steel material shall not contain any harmful metals such as zinc, aluminum, lead, copper or chloride containing compounds that will cause corrosive attack when heated.

Pipe with wall thickness less than 5mm and items manufactured from high yield carbon steel, type 316 stainless steel and cupro-nickel materials shall be marked by vibro-etching. All other materials, including impact tested carbon steel, shall be marked by cold stamping using round nosed low stress stamps, vibro-etching, dot stamps, or Supplier's rolling stamp method. Punching or stamping shall only be used on unstressed areas and the punching depth shall not exceed 1mm.

Marking shall appear on each individual length of pipe and shall be highlighted with a circle of paint. This paint shall be the same as that used for color coding.

Galvanized pipe shall be marked by stenciling in letters not less than 20mm high with a waterproof material that is not injurious to the coating. 4.2

Color Coding

A system of color marking shall be used to identify pipe, fittings and flanges for procurement identification purposes. Suppliers are required to brush paint or otherwise apply the color markings. The color-marking schedule is detailed in Section 4.3 below.

The paint to be used shall be Drynamel's Steel Identification Paint, Grade B98 or equivalent and shall conform to the colors shown below to BS 4800.

Marking materials shall not contain any harmful metals or metallic salts such as zinc, aluminum, tin, lead, copper or chloride containing compounds which would adversely affect the material on heating or welding



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Pipe shall be marked as follows: - 1 ½" NB and smaller- broad rings painted 1.5m apart. - 2" NB and larger- broad line(s) painted along the entire length of pipe.

Galvanized steel and Cupro-Nickel pipe do not require identification by color marking. 4.3

Color Marking Schedule

Marking shall not encroach upon butt weld ends prepared for welding. All CS, LTCS, 3168S, Duplex 8S, high strength carbon steels and Alloy 625 UN8 N06625 materials shall be color coded as follows: MATERIAL

COLOR

BS 4800 REF

ASTM A106 Gr.B

Light Green

14E51

ASTM A234 WPB

Light Green

14E51

ASTM A105N

Light Green

14E51

ASTM A333 Gr.6

Light Brown

08C37

ASTM A420 WPL6

Light Brown

08C37

ASTM A350 LF2

Light Brown

08C37

ASTM A312 TP316L

Light Blue

18E49

ASTM A403 TP316L

Light Blue

18E49

ASTM A182 F316L

Light Blue

18E49

ASTM A790 UNS S31803

Red

04E53

ASTM A815 UNS S31803

Red

04E53

ASTM A182 F51 (UNS S31803)

Red

04E53

API 5L X65

White/Green

00E55/12D45

MSS SP 75 WPHY 65

White/Green

00E55/12D45

ASTM A694 F65

White/Green

00E55/12D45

ASTM B444 (UNS N06625)

Yellow

10E53

ASTM B564 (Alloy 625 UNS N06625 Forgings)

Yellow

10E53

ASTM B705 (Alloy 625 UNS N06625 Welded

Yellow

10E53

Yellow/White

10E53/00E55

Pipe) HYCS + Alloy 625 UNS N06625 internal cladding



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Note: For materials shown with 2 colors above, one stripe of each shall be applied for identification purposes. 5. PREPARATION FOR SHIPMENT

Carbon steel and chrome steel pipe, fittings, and flanges, when not galvanized or prime coated, shall be furnished with the 's standard protective mill coating on external surface only. Austenitic stainless steel pipe, fittings, and flanges shall not be coated.

Austenitic stainless steel or nickel alloy pipe, fittings, and flanges shall be protected from ferritic contamination and chloride attack such as might occur from exposure to salt water spray or atmosphere during shipment, cleaning, fabrication, testing, or storage. Consideration shall also be given to enclosing or wrapping in a vapor proof barrier material.

Piping components with beveled ends shall be palletized and shrink wrapped or banded with steel or plastic strapping. Supplier shall submit their standard packing procedure for approval.

Threaded ends of pipe shall be fitted with plastic thread protectors. Threaded or socket weld openings in fittings and flanges shall be fitted with plastic plugs. Pipe ends shall be supplied with protective plugs or caps, to protect weld bevels.

Flanges shall be suitably shipped on pallets or in wooden crates and shrink-wrapped or tied down and shall have cardboard, pressboard, rubber, or plastic face protectors between layers of flanges in order to avoid any contact. Single loose flanges shall have high-impact plastic protectors secured with lock plugs (integral or separate). Wood, cardboard or pressboard protectors (that can absorb water) are not acceptable as flange face protectors.

Supplier shall be responsible for suitably shielding the open ends of pipes, and flanges to protect weld I threaded ends from damage during handling and shipment.

Each length of pipe shall be clear of debris, thoroughly clean inside and out, and free of any dirt and foreign matter before shielding the ends.



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Machined surfaces other than weld bevels (e.g. threads, flange faces, gasket seating surfaces) shall be coated with a corrosion inhibitor.

Pipe and fittings shall not be transported as open above deck cargo without prior written approval of the Purchaser. 6. PROTECTION AGAINST CORROSION AND MECHANICAL DAMAGE

The Supplier shall ensure that all items are protected against corrosion, contamination and mechanical damage in accordance with the Supplier's standard procedures that shall be submitted to the Purchaser for approval.

A copy of the instructions for the renewal and/or removal of any rust preventatives shall be supplied with the goods by the Supplier.

Threaded ends shall be greased and fitted with a plastic cap or plastic thread protector to ensure adequate thread protection.

Pipe beveled ends shall be coated with a Purchaser approved corrosion preventative and fitted with a plastic cap.

All carbon steel pipes shall have a Purchaser approved desiccant stapled inside the plastic end cap at each end of the pipe. Any strapping shall be stainless steel or plastic coated steel with a minimum thickness of 0.27mm.



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7. DOCUMENTS SUBMITTALS 7.1

Cert ifi cate of Compli ance

Supplier shall furnish certification of material composition I chemistry, radiographic and hydrostatic testing in compliance with ASTM, API, or ASME specification. Certification shall be as follows. The certification levels shown shall also apply to all NDE. Basic Material

Certification Level BS EN 10204-2004

C.S (Galv)

2.2

C.S & LTCS.

3.1

S.S.

3.1

Duplex S.S

3.1

Alloy 625 UNS N06625

3.2

C.S High Yield 65 ksi Cladded with

3.2

3mm Thk.(min.) Alloy 625 UNS N06625 C.S High Yield 65 ksi

3.1

Copper / Nickel Alloy

3.1

Fiberglass Reinforced Plastic

3.1

Bolting materials

3.1

And contain following information as a minimum: - Chemical Analysis by Product - Mechanical Properties - Heat Treatment Statement - Heat Number - Hardness Report (Compliance with 18015156)

The certification shall state the Purchaser's PO Number, Item Code Numbers, name and address of Supplier or Vendor, and shall be certified by Supplier's authorized agent. 7.2

Material Test Reports

For impact tested steel, low alloy steel, chrome steel, stainless steel, or nickel alloy pipe, fittings and flanges, Supplier shall furnish the Manufacturer MDRs (Manufacturers Data



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Reports) showing actual results of chemical analysis and mechanical test in compliance with the

referenced ASTM

specification. The test reports shall be originated by the primary

material and shall be traceable to each item or length of pipe through legible paint stenciled heat numbers or equivalent. The documents shall be identified with Buyer's PO number and Item Code number and shall be signed by the Vendor's authorized agent.

All chemical analysis shall be certified by product check analysis with the exception of galvanized carbon steel for which ladle analysis will be acceptable.

Vendor's reports, etc., shall be kept available by the Supplier for examination by the Company or his representative, for a minimum period of 5 years.

The actual temperature of all heat treatment shall be recorded on the material certificates.

The supplier shall ensure that appropriate certificates showing mill heat or batch markings, are received I delivered for all furnished materials. Materials furnished without documentation are unacceptable.

The Supplier shall be responsible for maintaining an effective Quality system and maintaining records in accordance with the requirements of the relevant procedures I specifications contained in Purchase Order 7.3

Welding and NDE Procedur es

The welding procedures and qualifications shall be in accordance with ASME Section IX. The qualifications shall include hardness testing in accordance with ASTM A370. The hardness testing shall be performed on the weld and the heat affected zone and after required heat treatment.

The NDE procedures shall be in accordance with ASME Code Section V.

For all fabricated piping items, the welding procedures, procedure qualifications, and NDE procedures for the following materials shall be submitted for authorization.



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- Stainless Steels, greater than 12.5mm (112 inch) wall only. - Nickel alloy steels. 7.4

Supply of Calculation and Drawings

Dimensional drawing and calculations shall be furnished as follows:

- Fittings and flanges not covered by a recognized national dimensional standard. - Flanges not made to an ASME standard. - All Olets whether they are butt welding, socket welding or threaded,

Any waiver to this requirement will require Buyer approval and will depend on the integrity, accreditation and reputation of the vendor.

All drawings and calculations shall be checked and certified by the Vendor. 8. QUALITY ASSURANCE 8.1

Inspection Authori zation

Examinations and tests may be reviewed and witnessed by Purchaser I Company or its authorized agent at Supplier's or Vendor's facility.

Seamless pipe, fittings, and flanges shall have inspection in accordance with the ASTM, ASME, API, or MSS specification to which they are manufactured, witnessed as selected by the Purchaser. A general inspection of the facility for QA procedures may be made as selected by the Purchaser.

Welded Pipe shall meet the requirements of the material specification per above and shall have 100 percent radiography examination for welded joint efficiency Ej=1 as required per the item description or as offered as an alternative material by the Supplier. Where welded pipe is specified without a nominated joint efficiency, a joint efficiency of Ej=1 shall be assumed.



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Laminations having a transverse dimension exceeding 6mm will be considered injurious defects. Pipe containing such defects shall be cut back until such defects are removed.

Seam welded pipe shall have no evidence of cracks, craters, slag, undercut, or overlap, and shall have good workmanlike characteristics and appearance. Evidence of weld flash on ID shall be removed.

Pipe that arrives at Purchaser store displaying questionable areas of workmanship shall be rejected by Purchaser and replaced by Supplier and all incurred costs shall be to Supplier's account. 8.2

Refurbishment

Refurbishment of previously used material is not permitted. 8.3

Authorization

Repairs, over and above those allowed by the material specification, applicable Codes and Standards, and are not permitted without the written permission of the Purchaser.



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9. PIPING CLASS DESIGNATION

Class Rating (X)

Basic Material (Y)

Corrosion Allowance (Z)

(1st digit)

(2nd Digit)

(3rd digit)

Legend

Definition

Legend

Definition

Legend

Definition

B

150#

0

CS

0

0 mm

C

300#

1

CS Galvanized

1

1.5 mm

D

600#

2

SS 304

3

3 mm

E

900#

3

SS 316L

4

4.5 mm

F

1500#

4

GRE

6

6 mm

G

2500#

6

Copper Nickel 90/10

H

10000#

7

--

8

Alloy 625


Contract No. 4405-90-2FG SPECIFICATION FOR PIPING MATERIALS

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10. PIPING CLASS SERVICE INDEX Pipe class

Design Conditions

Service Code

Service

OD

DIESEL OIL

V

COLD VENT

DO

OPEN DRAIN

CD

CLOSED DRAIN

CD

CLOSED DRAIN

V

COLD VENT

DO

OPEN DRAIN

P

PROCESS HYDROCARBON FLUID

V

COLD VENT

AU

UTILITY AIR

AI

INSTRUMENT AIR

DO

OPEN DRAIN

WP

POTABLE WATER

DO

OPEN DRAIN

CI

CORROSION INHIBITOR

XD

DEMULSIFIER

V

COLD VENT

WF

FIRE WATER

WS

SEA WATER

WG

GRAY WATER

B60

WF

E03

E06

B03

B04

B11

B30

B40

Size range

Piping Material

Trim

Corrosion Allowance (mm)

NACE required

Rating and Facing

Pressure (barg)

Temp. (Deg C)

DN 15 - DN 400

3.5

225

Carbon Steel

Trim 5

3.0

N

ASME B 16.5 CL 150 RF

DN 15 - DN 350

3.5

225

Carbon Steel

Trim 5

4.5

N


DN 15 - DN 200

13

85

Carbon Steel Galvanized

Trim 12

1.5

N


DN 15 - DN 200

3.5

85

SS316L

SS316 + Stellited

0.0

N


DN 15 - DN 200

15

85

GRE

AluminumBronze

0.0

N

ASME B 16.5 CL 150 FF

FIRE WATER

DN 15 - DN 200

15

85

Cu-Ni

AluminumBronze

0.0

N

ASME B 16.5 CL 150 FF

MEG

MONO ETHYLENE GLYCOL

DN 15 - DN 200

121

85

Carbon Steel

Trim 5

3.0

N

ASME B16.5 CL 900 RTJ

P


DN 15 - DN 200

121

137

Carbon Steel (NACE)

Trim 5

6.0

N



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Design Conditions

Service Code

Service

CI

CORROSION INHIBITOR

E30

XD

DEMULSIFIER

P

AQUEOUS PHASE

DC

CLOSED DRAIN

V

COLD VENT

P

GAS PHASE

P

OIL PHASE

E80 P P

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Piping Material

Trim

Corrosion Allowance (mm)

NACE required

Rating and Facing

Pressure (barg)

Temp. (Deg C)

DN 15- DN 80

121

85

Stainless Steel 316L

SS316L + Stellited

0.0

N


DN 15 - DN 400

121

137

Alloy 625

INCONEL 625 + Stellite

0.0

Y


Carbon Steel

Trim 5

3.0

N


TRIM 12

0.0

Y


SS316L + Stellited

0.0

N


PROCESS HYDROCARBON FLUID OIL+AQUEOUS PHASE

CI

CORROSION INHIBITOR

XD

DEMULSIFIER

MEG


F03

MEG


DN 15- DN 200

121

85

G80

P

PROCESS HYDROCARBON FLUID

DN 40-DN 300

413

137

G30

ME

METHANOL

DN 15-DN 50

413

85

Alloy 625

Stainless Steel 316L

HEN-0000-PI-SP-0001_B3

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