Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 1 of 26

SPECIFICATION FOR PIPING FABRICATION

ERECTION AND INSTALLATION

CONTRACT TITLE: HYDRA – PK & SWP PROJECT EPC CONTRACT NO: 2007/B/PM/PRJ/1027 OWNER: BG EXPLORATION AND PRODUCTION INDIA LIMITED EPIC CONTRACTOR: SWIBER OFFSHORE CONSTRUCTION Pte., Ltd.. EPC SUB-CONTRACTOR: CUEL LTD. DETAILED DESIGN: TECHNIP ENGINEERING THAILAND LTD.

Reviewed & Approved Date Name Signature Company Originator Melvyn See TET 2-Jul-08 Manager David Upson TET 2-Jul-08 Other1 (As Required)

Other2 (As Required) Revision Record

Revision Description Date By Checked Approved A Engineer review check 4-Jun-08 KTR SKC DU

B Check Print 5-Jun-08 KTR SKC DU

C Issued for Review 11-Jun-08 KTR SKC DU

0 Approved for Construction 2-Jul-08 KTR SKC DU

FORM BGG0801V_PRJ_Q_FRM_0002 Rev 0

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 2 of 26

CONTENTS

1. INTRODUCTION ............................................................................................................. 4

1.1 Project Description ............................................................................................... 4

1.2 General ................................................................................................................. 4

1.3 Application of this document ................................................................................ 4

1.4 Supplier’s Responsibilities ................................................................................... 5

1.5 Sub-suppliers ....................................................................................................... 5

1.6 Definition of Terms ............................................................................................... 5

2. CODES AND STANDARDS ........................................................................................... 6

2.1 Codes, Standards and Regulations ..................................................................... 6

2.2 Order of Precedence ............................................................................................ 7

3. SCOPE OF WORK ......................................................................................................... 8

3.1 General ................................................................................................................. 8

3.2 Scope of Supply ................................................................................................... 8

4. GENERAL REQUIREMENTS ........................................................................................ 9

4.1 General Requirement ........................................................................................... 9

4.2 Dimensions ........................................................................................................... 9

4.3 Documentation ..................................................................................................... 9

5. MATERIALS ................................................................................................................. 10

5.1 General Specification ......................................................................................... 10

5.2 Support and Miscellaneous ................................................................................ 10

5.3 Bolting ................................................................................................................. 10

5.4 Gaskets .............................................................................................................. 10

5.5 Storage and Handling of Materials ..................................................................... 10

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 3 of 26

6. FABRICATION.............................................................................................................. 11

6.1 General ............................................................................................................... 11

6.2 Flanging and Bolting .......................................................................................... 11

6.3 Threaded and Socket Weld Piping .................................................................... 11

6.4 Brazed Piping ..................................................................................................... 12

6.5 Pipe Support ....................................................................................................... 12

6.6 Penetrations ....................................................................................................... 12

6.7 Piping at Equipment ........................................................................................... 12

7. FABRICATION TOLERANCES ................................................................................... 14

8. IDENTIFICATION AND RELEASE FOR DELIVERY ................................................... 15

9. INSTALLATION ............................................................................................................ 16

10. CLEANING .................................................................................................................... 18

11. FUNCTIONAL SPECIFICATION FOR WELDING AND NDT ...................................... 19

11.1 Scope ............................................................................................................... 19

11.2 Codes and Standards ...................................................................................... 19

11.3 General Technical Notes ................................................................................. 19

11.4 Extent of NDT Coverage ................................................................................. 20

11.5 Technical Notes for Pipe Welding ................................................................... 21

12. PRESSURE TESTING .................................................................................................. 25

13. PROTECTIVE COATING .............................................................................................. 26

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 4 of 26

1. INTRODUCTION

1.1 Project Description

Oil & Natural Gas Corporation ( ONGC), Reliance Industries Ltd ( RIL) and BG Exploration and Production India Limited (BGEPIL) are joint operators of the Panna-Mukta offshore oil & gas production field situated in the Arabian Sea, off the west coast of India near Mumbai. The Panna Field is located 95 kilometres offshore northwest of Mumbai, India. The average water depth in the field is 47 Metres. Panna & Mukta fields have eight well head platforms and a Processing Platform (PPA). PPA is bridge connected to PA wellhead platform, PQ living quarter platform and PFP flare platform.

In the Panna-Mukta PSC, the development plans approved and executed so far has resulted in drilling of more than 25 infill wells in last two years and installation of two wellhead platforms (PH and PJ). Over next couple of years, it is planned to drill a number of development wells from EPOD platforms and further infill wells in the field. However, there will still be regions in the contract area which will not be drained by the existing platforms. Project Hydra aims to exploit the reserves from previously undrained areas of Panna field as well as to develop the newly discovered accumulations in South West Panna.

In the current scope of work, project Hydra will include development of PK area (area in the main Panna field, currently inaccessible from any of the well head platforms) and South West Panna (a small separate culmination, SW of main Panna field)

The new wellhead platforms will be:

• PK, a new 6 slot wellhead platform having water depth of 40 m approximately 8 km north-west of the Panna Processing Platform (PPA)

• SWP, a new 6 slot wellhead platform having water depth of 58 m approximately 12 km south-west of PPA.

1.2 General

This specification identifies the general requirements for the fabrication, installation, inspection and testing of piping materials, fittings and valves for this project. This specification covers all topside pipe work pertaining to this project except the following:

• Piping in piping classes EP3N and EP6N, comprising topside piggable lines and pig launchers and receivers which are covered by pipeline specifications BGEP-WPML-B104-GENX-PL-10-003-0012-F and BGEP-WPML-B104-GENX-PL-10-003-0013-F.

• Instrument tubing downstream of the last piping block valve, as normally defined on the approved P&ID’s.

1.3 Application of this document The scope of this document is limited to piping fabrication, testing, inspection, coating, erection and installation for this project. This document shall not be used for any other purpose.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 5 of 26

1.4 Supplier’s Responsibilities The SUPPLIER shall be responsible for the complete fabrication, installation, inspection and testing, including full compliance with all applicable drawings, design codes and standards.

1.5 Sub-suppliers Approval shall be obtained from the PURCHASER before any work is subcontracted.

1.6 Definition of Terms

PURCHASER BG Exploration and Production India Limited (BGEPIL)

SUPPLIER Party who carries out scope of work of this specification

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 6 of 26

2. CODES AND STANDARDS

2.1 Codes, Standards and Regulations The piping shall be designed, manufactured and tested in accordance with the requirements of this specification and the latest edition of the following Codes, Standards and Statutory Regulations (where applicable):

1 API RP 14E Recommended Practice for Design & Installation of Offshore Production Platform Piping

2 ASME II Materials

3 ASME V Non-Destructive Examination

4 ASME IX Welding and Brazing Qualifications

5 AMSE B1.20.1 Pipe Threads, General Purpose (Inch)

6 ASME B16.20 Metallic Gaskets for Pipe Flanges

7 ASME B31.3 Process Piping

8 ASME B16.25 Butt Weld Ends for Pipes, Valves, Flanges & Fittings

9 ASTM A283 Carbon Steel Plates

10 ASTM A370 Standard Test Methods & Definitions for Mechanical Testing

11 ASTM A435 Ultrasonic Examination of Steel Plates

12 AWS Welding Handbook

13 ISO 15156 Petroleum and Natural Gas Industries – Materials for Use in the H2S Containing Environments in Oil and Gas Production

14 BGA-ENG-MATL-TS-0001 Material Selection and Corrosion Control

15 BGA-ENG-MATL-TS-0003 Piping in Sour Service

16 BGA-ENG-MATL-TS-007 Fabrication of Equipment and Piping

17 BGA-ENG-MECH-TS-0012 Flange Joint Management, Cleaning and Pressure Testing

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 7 of 26

2.2 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’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:

• Purchase Order • Data Sheets • This Specification • Other referenced Project Specifications • Codes and Standards referred to within this Specification and its Attachments.

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

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 8 of 26

3. SCOPE OF WORK

3.1 General The SUPPLIER shall be responsible for fabrication, installation, inspection and testing of the pipe work, all PURCHASER coordination and guarantees as required and provision of certificates, quality control records and as-built drawings, not withstanding any omissions from this specification.

This specification covers all topside pipe work on this project except that in piping classes EP3N and EP6N and the Instrument tubing downstream of the last piping block valve, as defined in the approved P&ID’s.

3.2 Scope of Supply The SUPPLIER shall furnish all labour, materials and equipment necessary to perform the fabrication and installation.

The SUPPLIER shall also supply the documentation required by this specification.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 9 of 26

4. GENERAL REQUIREMENTS

4.1 General Requirement Fabrication, installation and testing of pipe work shall conform to this Specification and ASME B31.3 and API RP 14E.

All equipment used, and materials used, are subject to inspection by the PURCHASER. The PURCHASER reserves the right to approve all material, tools and fabrication procedures, prior to the SUPPLIER proceeding with the work.

4.2 Dimensions Dimensions shall be in mm and be related to the Platform datum or reference lines.

SI units shall be used, with the sole exception of design pressure and design temperature, for which Psi and Fahrenheit shall be used.

4.3 Documentation The SUPPLIER shall comply with all the specifications. The SUPPLIER shall provide the PURCHASER with all weld qualifications and procedures and fabrication procedures for approval. Shop work shall not start until the relevant drawings and weld qualifications and procedures are received and approved by the PURCHASER. Weld procedures shall be accompanied by a weld procedure index and weld map for each line.

After construction, the SUPPLIER shall supply project isometric drawings and P&ID’s annotated to show as-built information ie any change made to the pipe work design during fabrication and installation.

The SUPPLIER shall be responsible for compiling and handing over all material certificates, welder qualification certificates, weld records, signed inspection and test plans, mechanical clearance report, installation check lists, charts of weld heat treatments, test and inspection records applicable to the completed work. The SUPPLIER shall furnish these certificates/reports and relevant documents for the PURCHASER’s review and approval.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 10 of 26

5. MATERIALS

5.1 General Specification Materials shall comply with the Piping Material Specification BGEP-TETL-B104-GENX-PI-10-012-0010-D, Valve Datasheets BGEP-TETL-B104-GENX-PI-07-012-0055-D, Specification for the Procurement of Valves BGEP-TETL-B104-GENX-PI-10-012-0026-D and Specification for the Procurement of Pipe Fittings and Flanges BGEP-TETL-B104-GENX-PI-10-012-0027-D.

5.2 Support and Miscellaneous Material shall not be welded directly to process piping unless shown by PURCHASER’s drawings. If the situation arises then prior approval of the PURCHASER shall be sought and shall note that the material welded directly to pressure retaining pipe work shall be of similar quality as the pipe work.

5.3 Bolting Bolting shall be as per Piping Material Specification BGEP-TETL-B104-GENX-PI-10-012-0010-D.

5.4 Gaskets Gaskets shall be as per Piping Material Specification BGEP-TETL-B104-GENX-PI-10-012-0010-D.

5.5 Storage and Handling of Materials Carbon steel, stainless steel and duplex stainless steel shall be stored and handled separately.

The fabrication shop for stainless steel and duplex stainless steel shall be used exclusively for stainless and duplex stainless steel with no fabrication of any carbon steel being undertaken. No carbon steel shall come in contact with stainless steel or duplex stainless steel including lifting devices, tools, crating, straps and such like.

Carbon steel piping shall be fabricated in a separate fabrication shop to that used for stainless steel and duplex stainless steel.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 11 of 26

6. FABRICATION

6.1 General Piping shall be fabricated in accordance with the requirements of this Specification, with the piping codes and standards specified herein and under the individual material specification classes.

Piping design drawings and isometrics shall govern dimensions and materials. However, site verification shall be done by the SUPPLIER and the anomalies if any shall be brought to the notice of the PURCHASER’S representative.

The requirements of this specification shall apply to shop and field fabrication and to piping within packaged units.

Piping shall be prefabricated to the most practical extent onshore to minimise offshore fabrication or installation.

6.2 Flanging and Bolting Flange boltholes shall straddle the established horizontal and vertical centrelines of the pipe except where connecting to equipment dictates otherwise and any deviation shall be shown on the piping design drawings and/or isometrics.

PURCHASER-approved lubricants such as colloidal molybdenum disulphide shall be applied to all flange bolts before the joints are assembled.

Flange bolts shall be tightened evenly and sequentially to impose equal pressure on the gasket and to avoid distortion or overstressing of equipment.

All studs 1 inch diameter and larger shall be hydraulically tensioned.

Flange make up shall be made with clean new gaskets. The use of gasket sealing compounds or sealing agents is prohibited except for anti-stick release agent.

Prior to installation, stud bolts shall be smeared with API thread compound containing molybdenum disulphide, on that portion of the stud bolt, which will be in the holes of the flanges and under the nut. Bolts shall be progressively tightened to full bolt torque using sequence tightening as per the gasket manufacturer’s recommendation.

Flanges used in conjunction with spectacle blinds, spacers, blinds and orifice flanges shall be purchased as “standard” and drilled and tapped at fabrication site during construction to accept jack screws.

6.3 Threaded and Socket Weld Piping Threaded or socket welded piping shall not be used in sour service including piping classes A1N, A3N, A4N, A8N, E1N, E2N, and E4N.

Threads shall be concentric with outside of pipe, as per ASME B 31.3, tapped and cleaned out.

The inside of each pipe spool shall be de-burred by Reaming.

When socket weld fittings are used, pipe shall be spaced approximately 1.55 mm away from the “bottom” of the socket.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 12 of 26

Seal welding is required as follows:

a) All services which are subject to vibrations (such as lines to/from reciprocating pumps etc);

b) Seal welding of threaded connections, when specified, shall include the first block valve, cover all threads and be done with electrodes not to exceed 3 mm in diameter;

c) Thermo wells shall not be seal welded;

d) Immediately before erection of piping, all threads of the pipe and fitting shall be thoroughly cleaned of cuttings, dirt, oil and any other foreign matter. The male threads shall be coated with thread sealant and the piping made up sufficiently for the threads to full thread engagement; and

e) Threaded connections shall be protected from oxidation during heat treatment and be gauge checked after welding or heat treatment.

6.4 Brazed Piping Brazing temperatures shall be achieved as quickly as possible using a suitably sized torch.

The inside of brazed fittings and the outside of the associated tube shall be cleaned with sand paper. Flux paste is to be evenly spread over the joint.

6.5 Pipe Support Piping shall be suitably supported to prevent sagging, mechanical stresses and vibrations, while allowing for thermal and structural movement. Piping shall generally be supported as shown by the piping isometric drawings and pipe support drawings.

All pipes in hazardous service shall have shoes or alternatively wear pads with thickness same as pipe (minimum) between the pipe and support when the pipe would otherwise be resting directly on the support steel.

In locations where potentially severe vibration can occur, such as near control valves, pressure relief valves, pumps, and in high velocity streams, all small branch connections shall be braced by means of welded gussets or brackets in two (2) planes.

Piping shall not sit directly on pipe supports without use of neoprene pads.

6.6 Penetrations Final location and dimensional checks of the pipe penetrations are the responsibility of the SUPPLIER.

Deck or skid penetrations shall provide a minimum of 25 mm radial clearances around the piping.

All open deck drain cups shall be properly covered with suitable hinged caps in order to restrict the blockage due to debris and unwanted mud/dirt.

6.7 Piping at Equipment Equipment shall not be used to anchor piping. Forces transmitted to equipment at tie-in points shall be within the recommended limits.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 13 of 26

Piping connected to rotating equipment shall be supported to minimise the transmission of vibrations from the machines.

Piping connections to exchangers shall be properly aligned to allow for hot and cold service and to limit the stress on exchanger nozzles to be within allowable levels.

Piping at pumps shall be supported so that equipment can be dismantled or removed with a minimum number of temporary supports and without dismantling valves and piping other than the spool that connects to the pump. Clearances shall permit installation of blind flanges against block valves when the service is hazardous and permit the removal of the pump wet end without removing the remainder of the pump. Where reducers are required on suction lines, they shall be eccentric and installed flat side down, unless otherwise shown by the relevant piping isometric drawing.

Pump suction lines in which vapours may be present shall be inclined with sufficient slopes so that the vapour may flow to the vessel or tank attached to the suction line.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 14 of 26

7. FABRICATION TOLERANCES Dimensional tolerances shown below shall apply to in-line items and connections or branches for other lines.

Flange alignment for piping connected to rotating machinery must not cause machine-to-driver misalignment to exceed the equipment manufacturer’s tolerances.

Material which has been locally stress-relieved shall be rechecked for tolerances in accordance with the drawings. Small residual deviations remaining after heat treatment may only be corrected by cold straightening. Cold straightening or cold bending of piping in sour service including piping in classes A1N, A3N, A4N, A8N, E1N, E2N, and E4N will not be approved. Also hot straightening after heat treatment, except for non-pressure attachments, will not be approved.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 15 of 26

8. IDENTIFICATION AND RELEASE FOR DELIVERY Piece marking of prefabricated piping for identification during installation shall be the responsibility of the SUPPLIER.

Piece marks shall bear the line number with a suffix painted or tagged on each piece.

After inspection, testing of piping and application of protective coating, identification numbers shall be stencilled in several places along the length of each spool.

Marking paint or ink containing harmful metal salts such as zinc, lead or copper shall NOT be used to mark piping.

Stamping of identification on pipe or flanges is not permitted.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 16 of 26

9. INSTALLATION

Piping shall be installed in accordance with the piping drawings and P&ID’s.

Piping installation includes the supply and installation of supports shown in the drawings and piping schedules together with any additional supports necessary to adequately and properly secure the piping.

All lines shall be installed true and plumb except where specifically noted on the drawings.

Installation of piping shall be scheduled so that no undue strain will be inflicted on equipment due to lack of support, dead weight or misalignment.

Piping shall be made, broken, and re-made at all rotating equipment connecting points, with alignment checks made with and without pipe in order to prove piping does not effect alignment.

Flange bolts shall be tightened evenly and sequentially to avoid distortion or overstressing of equipment.

If any piping does not meet alignment checks, the SUPPLIER shall cut and refit that pipe.

No heating or bending may be done except by using the PURCHASER’s approved procedures.

Pipe shall be installed beginning at the equipment connection then moving away as the piping is assembled.

Where required, field welds shall be used when installing pipe to equipment.

Field modification of prefabricated piping shall be performed in strict accordance with this specification and the applicable codes, standard or recommended practice.

All weld burrs and all foreign matter shall be removed from the piping prior to closure.

Construction supports required during installation shall be provided by the SUPPLIER and shall be clearly marked by the SUPPLIER for removal before commissioning.

At all times when piping fabrication or installation is not in progress and at other times when openings in pipe work are not required to be left exposed, they shall be protected against entry of foreign matter by reinstalling shipping protector caps and covers or other suitable means.

Tack welded fit-ups lacking a completed root pass at the cessation of a work period shall be covered at the seam with polyethylene tape.

Before installing pre-fabricated piping, the inside of the pipe shall be inspected by the SUPPLIER to ensure that all foreign matter has been removed.

Austenitic stainless steel pipe and fittings and all valves and special items shall be stored out of contact with the ground. Valves and special items shall also be covered to prevent entry of moisture or foreign matter.

The SUPPLIER shall take all possible care to avoid contamination of stainless steel materials. Stainless steel materials shall be lifted with nylon or other approved slings, which are free from dirt or ferritic particles. Under no circumstances shall chains or wire ropes be used.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 17 of 26

Shoes and cradles shall preferably be located and attached to the pipe work after the line has been installed. They may be attached to pipes prior to installation provided that when the pipe is installed the shoes and cradles are central over the pipe supports.

To prevent damage to valve seal and seat surfaces, valves, when installed, shall be left in the following positions:

Ball and plug valves Fully open

Globe and gate valves Fully closed

Valves shall be installed with spindle/actuator orientation/position shown in the layout drawings. Mono directional valves such as non-return valves and globe valves, special piping items, orifice plates and other instrument items shall be installed in the correct flow direction.

Piping shall not be connected to a valve of any description unless the joints can be made without inducing stress in either the valve or the pipe work.

Temporary strainers, slip-plates, blind flanges and the like shall be properly installed in the location and orientation shown in the drawings.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 18 of 26

10. CLEANING After installation, each line shall be thoroughly cleaned to remove all moisture and loose scale, sand, paint and any other foreign matter.

Special cleaning procedures may be required for specific services.

After fabrication and cleaning, assembly ends shall be protected for handling and shipment.

If the pipe is not immediately installed and is to be stored or barged to the platforms, all ends and openings shall be sealed in a suitable and approved method so as to prevent the entrance of moisture, dirt or other foreign matter.

The SUPPLIER shall furnish all materials for field flushing, cleaning and protection during shipment and handling.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 19 of 26

11. FUNCTIONAL SPECIFICATION FOR WELDING AND NDT

11.1 Scope This specification supplements the referenced codes which apply to all piping welding. These requirements cover welding done at SUPPLIER’s fabrication plant, SUPPLIER’s Yard, or field installation, either onshore or offshore.

11.2 Codes and Standards

The following Codes and BG Standards shall be the minimum acceptable codes and standards for welding and inspection. The latest edition, addenda, and supplement available at the time of bidding will be used. Any part of any other non-listed code referred to in these listed codes as augmentation is to be considered applicable.

ASME Sec. IX

ASME B 31.3

ASME Sec. V

ASME Sec. II Part C

ISO 15156

BGA-ENG-MATL-TS-0001

BGA-ENG-MATL-TS-0003

BGA-ENG-MATL-TS-007

BGA-ENG-MECH-TS-0012

11.3 General Technical Notes

Low hydrogen electrodes shall be used for welding and shall be capable of achieving a maximum hydrogen level of less than 5ml/100gm weld metal.

Consumables for material conforming to NACE requirements shall have physical, chemical, fatigue and corrosion resistance properties comparable to base metal. For carbon steel, the maximum level of nickel in deposit weld metal shall be 1%.

Manufacturer’s batch test certificate shall be submitted for each batch of consumables used. Test results shall include chemical, physical (including impact) and corrosion resistance (if welding material with NACE Requirement).

The PURCHASER shall approve all consumables including brands.

Internal line up clamping shall be used for welding piping 6” nominal diameter and above.

Welded joints, including longitudinal and circumferential joints shall not be placed within the greater of 50mm or three (3) times pressure component wall thickness, from openings, branch welds, reinforcements, supports and any other attachment. PURCHASER reserves the right to specify additional requirements such as radiography, ultrasonic inspection or PWHT in case of deviation.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 20 of 26

11.4 Extent of NDT Coverage

Extent of NDT coverage shall be as follows:

All welds shall be subject to 100% visual inspection.

For fillet welds and brazed joints where carrying out radiography is not possible, magnetic particle test or dye penetrant test shall be carried out. The extent of inspection shall remain same as for radiography.

Welds selected for radiography shall be fully examined by MPI/DPI.

Random radiography shall be performed on one weld in each 10 welds on the following:

a) Potable water (fluid code WP)

b) Diesel (fluid code DF)

25% RADIOGRAPHY shall be performed on the following:

a) Vent gas (fluid code VL)

b) Closed Drain (fluid code CD)

c) Open Drain (fluid code OD)

d) Chemicals (fluid code CI)

100% RADIOGRAPHY shall be performed for the following:

a) Crude oil

b) Fuel gas

c) Process gas

d) Production flow lines (well fluid)

e) Piping which is ASME class 900#

f) All hydrocarbon lines (fluid codes PF, PG, PL)

All the lines which are stress relieved or are ASME class 900# or are in sour service shall be fully radiographed (100%).

5 % of welds for sour service lines shall be hardness tested. Acceptance criteria shall be as per ISO 15156. Joints shall be stress relieved if measured hardness is not as per ISO 15156.

Hardness testing method, equipment and personnel shall be subject to PURCHASER approval.

Magnetic Particle Test shall be carried out on all socket welds. (Socket welds are not permissible for piping in sour service).

Radiographic Procedure shall be as per ANSI B 31.3 / ASME Sec. V

Acceptance criteria based on visual, radiography and other types of examination shall be as per ANSI B 31.3 with the following modifications:

Orifice flange butt-welds shall be internally ground smooth and flush.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 21 of 26

Those field welded joints which cannot be hydro tested due to unavoidable reason shall always be 100% radiographed.

Welding shall not be performed when surfaces are wet or exposed to rain, snow or high wind velocities, when welders are exposed to inclement conditions, or when conditions prevent required inspections.

Only welding equipment that is in good working condition and that is properly grounded shall be used. All welding machines shall be calibrated prior to commencement of fabrication and calibration certificates shall be available for audit by the PURCHASER. Certification shall be valid for 6 (six) month periods, or as per manufacturer’s recommendation.

Grounding of Equipment

• Each welding machine shall be individually grounded to the platform or portion of the platform being welded

• No machine shall be grounded to floating equipment during welding on the platform.

Arc strikes should be made in the weld groove. Arc strikes on the surface of the base metal shall be removed by grinding, including any hardened zone beneath the strike. Any such repair shall be visually and magnetic particle or dye penetrant inspected.

11.5 Technical Notes for Pipe Welding

Circumferential welds on pipes shall be staggered at least four times the pipe wall thickness or 25 mm apart, whichever is greater.

Branch connections shall be joined to their headers with full penetration welds.

Backing rings, back-ups rings or chill rings shall not be used.

Oxy-acetylene cutting torches shall not be used for pre-heating.

Piping requiring special cleaning as shown in the drawings shall have the root pass deposited by the gas tungsten arc process. The backside of the root pass shall be purged with inert gas.

If the bore of the pipe is different from the bore of fittings or flanges, to which it is welded, by more than 3 mm (total bore diameter), the thicker member shall be bored, taper bored or ground smooth to match the specified bore. Figure 328.4.3 of ASME B 31.3 shall govern the geometry of all taper boring and bevelling.

Coupling or other weld-on type branch connection shall be located as least 80 mm away from the nearest adjacent weld joint.

When socket weld fittings or valves are used, pipe shall be space approximately 1.6 mm to avoid “bottoming” which could result in excessive welds stress.

Reinforcing pads shall be added only after external and internal visual inspection of the attachment. Reinforcing pads shall be provided with 6 mm tapped weep hole. Weep holes shall be plugged after welds of pads and testing is complete.

All welders working on the project shall wear identification cards made at SUPPLIER’s cost which shall contain photograph, welder’s name, welder number, process, position and diameters qualified and the PURCHASER’s representative’s signature.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 22 of 26

Welder shall be supplied with tempil stick – thermal crayons, by the SUPPLIER, so that welders and inspector can check and control the temperature of weldment.

No weld shall be coated or hydro tested before it has been inspected and accepted.

No weld is to be cooled by quenching or by any means other than air.

Field Welding

Where field welds are designated, the prefabricated pipe shall be cut off 150 mm longer than the dimensions shown on the pipe fabrication drawings to allow for modification then precise fit-up in place.

Additional field fit welds may be included in a spool by the SUPPLIER for those locations which may have restricted site access or for those spools which may otherwise be cumbersome for transportation.

Marking of the location of field welds on the drawings will be the responsibility of the SUPPLIER.

Weld Procedures and Documentation

Weld procedures shall be qualified as per ASME B 31.3 and ASME Code Section IX. NDT procedures shall be performed as per ASME Section V. Acceptance criteria shall be as per ASME B 31.3 and ASME Section IX.

Mechanical testing of Test coupons for piping shall conform to the requirements of ASME Sec. IX / ANSI B 31.3. In addition to the above requirement, hardness testing shall be performed on each test coupon. Charpy Impact Testing of Carbon Steel Pipe work shall be performed in accordance with ASME B 31.3 Table 323.2.2.

The SUPPLIER shall not commence welding until appropriately qualified welding procedures have been accepted by the PURCHASER’s representative.

For each welding process, the welding procedures shall specify all equipment settings. The SUPPLIER’s Welding Supervisor shall check daily and record machine settings for each weld procedure used during welding activities. This record shall be available for audit by the PURCHASER’s representative.

A welding procedures record shall be prepared by the SUPPLIER prior to the start of welding and shall be available or review by the PURCHASER. A welding summary recording progress of all welding shall be prepared by the SUPPLIER daily.

Welder Qualification

Welders and welding procedures shall be qualified as ASME Boiler and Pressure Vessel Code Section IX. Qualification of production welds is not permitted. A welder shall not be permitted to weld on pipe work or attachments to pipe work unless qualified to the procedure in use and the documentary evidence has been sighted by the PURCHASER’s representative.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 23 of 26

Tack welds shall be made by a qualified welder using the same type of electrode as is used for the root pass.

The PURCHASER’s representative shall be advised in advance that the SUPPLIER’s conducting welder qualification to enable auditing by PURCHASER’s representitive of test facilities. Qualification test welds shall be made on test coupons prepared in accordance with the relevant standard. A test certified amp/volt tong tester shall be available at the SUPPLIER’s establishment at all times.

The SUPPLIER shall be responsible for all costs, including labour and laboratory testing associated with welder qualification tests and retests.

The PURCHASER may request a retest of any welder at any time and from time to time during the work. If a welder fails to qualify, then at the discretion of the PURCHASER’s representative, all non-installed welds completed by that welder shall be examined by additional radiographic tests, over and above that which would normally be required or specified in the drawings for that pipe work and the same shall be charged to the SUPPLIER’s account.

Welds not identified and recorded, or welded by unqualified welders, shall automatically be rejected. It will be the SUPPLIER’s responsibility to prove that the welds conform to the applicable Specification.

Repairs

If the PURCHASER’s representative considers a weld to be grossly defective, it shall be cut out and the joint re-welded and all costs associated therewith shall be the SUPPLIER’s responsibility.

Repair of weld defects shall be made using the approved welding procedure.

Mechanical defects such as scratches and gouges may be ground smooth provided the depth of the defect does not exceed 10% of the nominal wall thickness of the pipe.

Dents or grooves whose depth is greater than 10% of the nominal pipe wall thickness shall be removed by cutting out and replacing that length of pipe in which the defect occurs. The minimum length of a cut-out shall be four times the nominal diameter or 150 mm, whichever is lesser.

Internal weld metal projecting into the pipe on weld neck orifice flanges shall be removed and ground smooth with the pipe.

Heat Treatment

Preheat and post-weld heat treatment (PWHT) shall be in accordance with ASME B 31.3.

The method and equipment used in heat treatment shall be subject to approval by the PURCHASER and its Inspector.

Exposed machined and threaded surfaces shall be protected from oxidation during heat treatment.

Cleaning of pipe work after fabrication and heat treatment shall be performed externally and internally to remove all loose scale, weld spatter, sand and other foreign materials.

All welds requiring PWHT shall have the required NDT carried out after the PWHT. NDT prior to PWHT performed in addition to mandatory NDT following PWHT shall be at the discretion of the SUPPLIER. However, where defects requiring repair are located by this inspection, it shall be brought to the notice of the PURCHASER.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 24 of 26

After final heat treatment, the SUPPLIER shall identify the piping as having received PWHT. The method of identification shall be recorded on the as-built isometric and P&ID together with the other recorded information.

A legible heat treatment chart shall be provided to the PURCHASER. This chart must show the rate of increase of temperature, the holding temperature and time and rate of decrease of temperature.

Inspection, Examination and Testing Destructive tests required by this Specification shall be performed by an accepted third-party laboratory.

Radiographic Examination At least one of each type and position of weld made by each welder will be examined. A record shall be kept by the SUPPLIER of the quality and extent of each welder’s work.

Because of the limited sensitivity of gamma radiography when used with heavy wall pipe, all welds in material over 19 mm thick shall, in addition to radiographic requirements, be 100% ultrasonically tested.

Welds that cannot be radiographed because of their location will be examined by ultrasonic, liquid penetrant or magnetic particle method as applicable. The extent of inspection shall be the same as for radiography.

Radiography is not required for the welds on slip-on flanges or socket welds or seal welds.

For each weld found to be defective, two additional welds made by the same welder who produced the defective weld will be subjected to radiographic examination. These additional examinations will be made immediately after the defective weld is found and are in addition to the minimum examination requirements for the line class as specified in the drawings or specifications.

Weld repairs shall be re-examined by the same method used to detect the original defect.

Ultrasonic Examination Ultrasonic examination may be employed where the material thickness and degree of defect are such that determination is not possible by any other method. The procedure used and criteria of acceptance shall be based on the recommendations of ASME Boiler and Pressure Vessel Code Section V.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 25 of 26

12. PRESSURE TESTING

Hydrostatic testing shall be performed in accordance with ASME B 31.3 and the appropriate piping specification class chart or piping isometric drawing. Shop hydrotesting is not required for shop fabricated pipe where the pipe is to be field hydrotested.

Piping shall be flushed prior to hydrotesting. SUPPLIER’s flushing procedure may be used, subject to review and approval by the PURCHASER.

Following hydrotest, all lines shall be drained, blown and dried.

The fluid used for pressure testing shall be fresh water, treated with biodegradable, environmentally safe corrosion inhibiting solution.

Stainless steel piping and equipment must be tested with demineralised water containing less than 50 ppm chlorides.

Rotating machinery shall be hydrotested by the machinery vendor and need not be retested.

The following shall be removed or isolated from the piping system prior to hydrotest (and reinstated after hydrotest is complete):

• Relief valves and bursting disks

• Self contained regulators and control valves

• Expansion joints

• Instruments

All items shall be included for leak testing.

Document Number: BGEP-TETL-B104-GENX-PI-10-012-0023-D

Rev: 0 Date: 2-Jul-08

Page: 26 of 26

13. PROTECTIVE COATING Protective coating shall be applied in accordance with the project coating specification BGEP-TETL-B104-GENX-MT-10-0012-001-D and the piping isometric drawings.