1

13/08/
2001

ISSUED FOR CONSTRUCTION

CHULKOV

RUDENKO

REV

DATE

SHEET

DESCRIPTION

DESIGNED

APPROVED

REVISIONS

REV SHEET

DOCUM No.

SIGN.

DATE

DESIGNED

CHULKOV

13.08.

2000

INSPECTOR

LEBEDEV

13.08.
2000

APPROVED

13.08.

RUDENKO

2000
File: BKP3325000101e

doc

BK-9.360250.001
GENERAL TECHNICAL
REQUIREMENTS FOR
FABRICATION, INSTALLATION
AND TESTING OF PIPELINE
SYSTEMS

LIT

SHEET

SHEETS

16

OJSC CDB CORALL

OPEN JOINT STOCK COMPANY CDB CORALL

CONTENTS
1

GENERAL...................................................................................................................... 3

INSTALLATION OF MACHINERY AND UNITS......................................................3

PREPARATION OF PIPES FOR ASSEMBLING.......................................................4

INSTALLATION OF PIPELINES..............................................................................13

BK-9.360250.001

OPEN JOINT STOCK COMPANY CDB CORALL

GENERAL
The present technical requirements are applied to installation of equipment and
fabrication and installation of pipelines.
Pipes are to be fabricated, pipelines are to be installed and tested in accordance with
the present requirements and requirements given in installation drawings.
Pipelines have not detachable connections because of requirements on providing the
safety of operation for the process complex systems. Pipe connections should be
welded ones, with use of standard bends, reducers and tees. At discretion of the
manufacturer, it is permitted to install flange connections.
Flange connections are used in places where pipes are connected to fittings.
The fittings and equipment shall be supplied with the counter flanges.

INSTALLATION OF MACHINERY AND UNITS

2.1

The following basic operations shall be performed when installing the machinery:
-

machining of foundation supporting surfaces,

machining of holes for fasteners,

loading of machinery,

fabrication and installation of gaskets,

fastening of machinery with welding or bolt connections.

Warning! It is forbidden to cut holes for bolts and studs using gas burner or
plasma cutting!
2.2

The following is to be checked before loading the equipment on the wellhead satellite
platform:
-

readiness of supporting surfaces of foundations, welded fittings and other places

for installation of the equipment,

BK-9.360250.001

OPEN JOINT STOCK COMPANY CDB CORALL

hull structures field joints, located directly under the equipment and inaccessible
for inspection after completion of the installation works. These field joints are
finally welded and accepted by quality control department.

2.3

When installing the equipment having unmachined supporting surfaces, installation

procedure with using levelling spacers is applied. Thickness of these spacers is to be
specified more exactly in situ when providing simultaneous close-fitting of the
equipment frames to all levelling spacers and to supporting surfaces of hull structures.
It is permitted to use the spacers with unmachined surfaces. Clearance gauge of
1.0 mm thickness should not pass between the mated surfaces.
Maximum clearance between the mated surfaces may be equal to the value of
tolerance for the dimension between prepared edges of mated details.

2.4

After completing the installation of the equipment, welding places of earthing details
should be primed with the coating adopted by the construction company.

2.5

After completing the installation of the equipment on the wellhead satellite platform, it
is necessary to check this equipment for correspondence to the requirements of
process and design documentation.

PREPARATION OF PIPES FOR ASSEMBLING

3.1

Technical requirements for the quality of pipes in condition of supply

3.1.1 The pipes to be supplied to the subcontractor for fabrication of shipboard pipelines
shall comply with the requirements of DNV Regulations or other recognized
Classification Society.
3.1.2 Each batch of pipes supplied to the subcontractor shall have a certificate. When the
certificate is not available, the pipes may be used exclusively after approval of the
quality control representative, customer and DNV representative if the laboratory test
results of chemical composition, mechanical properties and functioning tests meet the
requirements of DNV Regulations.
BK-9.360250.001

OPEN JOINT STOCK COMPANY CDB CORALL

3.1.3 The representative of the quality control department shall accept the pipes delivered to
the warehouse provided that the certification data comply with the requirements of
regulations and standards for supply including the following:
-

compliance with the pipe packing quality, marking and stamps of Vendors quality

control,
-

compliance of pipe quality and sizes with the data specified in the certificate when

random control is carried out, as well as compliance with the actual deviations in outer
diameter and wall thickness, which are within the limits ofparameters specified by the
regulations and standards,
-

availability of data on pipe test results and chemical composition in the certificates.

3.1.4 For corrosion-resistant steel pipes the following shall be controlled:

-

wall thickness on both ends of pipe at four generating lines in mutually

perpendicular direction,
-

outer diameter at two/three points along the length of pipe in mutually

perpendicular direction,
-

quality of outside and inner surface of pipes.

3.1.5 The pipes which quality does not comply with the requirements of regulations and
standards for supply are forbidden for production.
3.1.6 The pipes accepted by the income control shall have marking on the surface with paint
depending on the grade of material, identification tags or labels.
3.1.7 Ends of pipes, made of corrosion resistant steel and received by the receipt control,
should be closed with polyethylene plugs or film material to prevent damage and
soiling of their inner surface when storing and transporting.
3.2

Requirements for storage and transportation of pipes

Methods of storage and transportation of pipes shall prevent their deformation,
damage of outside surface and change of material physical and chemical properties.

3.3

Construction of pipelines
BK-9.360250.001

OPEN JOINT STOCK COMPANY CDB CORALL

3.3.1 The preparatory operations for fabrication of pipelines (determination of pipe

geometrical sizes, information acquisition for fabrication of semifinished pipes in the
shop, fabrication of pipe gages and models) shall comply with the procedure for
fabrication of pipelines used by Manufacturer.
3.3.2 Before putting into production, the pipes shall be cleaned from rust, dust, protective
grease and heat treated if necessary.
3.3.3 The semifinished pipes shall be marked out taking into account the lay-out of
pipelines shown in the erection drawings and machining allowances used by
Manufacturer.
3.3.4 When cutting the semifinished pipes with nonstandard length, the longest pipes shall
be marked out first of all, the remainder of pipes being used for marking out the short
pipes. After cutting the semifinished straight pipes shall be delivered to the assembly
stands and the pipes to be bend shall be delivered to the pipe-bending machines.
3.3.5 The quantity and arrangement of connecting details for pipes may be changed
depending on assembling conditions.
3.3.6 The standard ANSI elbows shall be used for making pipeline bends. It is permitted to
bend the pipes of low pressure systems on pipe-bending equipment. The pipe bending
radii shall be unified and correspond to the requirements of the DNV regulations.
3.3.7 The equal tees shall be used for branches of pipeline with the same diameter.
The branches of pipeline with the diameter different from the main pipe shall be made
by using welding branch pieces and welding bosses.
The holes for welding branch pieces shall be cut and bored in pipes when assembling
them with the connecting details in accordance with the procedure used by
Manufacturer.
Instead of standard tees supplied the welding branch pieces may be used which angle
and length are specified in 3.3.8.

BK-9.360250.001

OPEN JOINT STOCK COMPANY CDB CORALL

3.3.8 The welding branch pieces shall be installed and welded perpendicular or at an angle
of less than 90 relative to the pipe axis in direction of medium flow depending on
assembling conditions. The angle of welding branch piece installation shall be not less
than 45, but 90 and 60 is applied as a rule.
Depending on the diameter and angle of inclination to the pipe, the length of welding
branch pieces shall be unified and correspond to the values given in Table 3.3.8-1.
Table 3.3.8-1
Length of welding branch pipe at
an angle of inclination, m

Nominal diameter

Under 20 incl.

60
120

90
80

21 50

150

100

51 100

200

120

101 150

250

120

151 250

350

150

The length of welding branch pieces may be changed depending on assembling

conditions.
3.3.9 The standard reducers shall be used to connect pipes with different diameters.
Instead of standard reducers reduction or expansion of pipe may be used to connect
the pipes with different diameters in accordance with the procedure used by
Subcontractor.
3.3.10 Deviations of the pipes construction sizes, given in a drawing, should not exceed the
following values:
-

for straight pipes

for bent pipes:

3 mm;

of ID up to 100 mm

10 mm;

of ID more than 100 mm

15 mm;

deviations of bend angles

1;

BK-9.360250.001

OPEN JOINT STOCK COMPANY CDB CORALL

for bends and bends fittings:

deviation of coordinates

10 mm;

deviation of branch height

3 mm;

deviation of the inclination angle relative

to the pipe and bending plane:
of ID up to 100 mm

1;

of ID more than 100 mm

5;

3.3.11 To improve the installation inaccuracy, the pipes shall be fitted in accordance with the
procedure used by Subcontractor.
3.3.12 The tailor-made shall be fitted after the pipes finished in the shop have been
temporarily installed at the platform.
When fabricating the units, the pipes shall be fitted either in situ with further delivery
to the shop for assembling and welding with connecting details or by models
fabricated in situ.
3.3.13 The thread-cutting machines shall be used to produce a thread on the pipes. The length
of the thread depends on the construction of connecting details and it is determined in
each specific case in accordance with the regulations and standards.
3.4

Welding of pipes

3.4.1 Types of welded connections, structural components, preparation of edges for

welding, welding procedures, methods of welding quality control shall correspond to
the Table of Welding BK-9.360069.002.
3.4.2 The butt welded joints and welded end fitting shall be arranged only on the straight
portions of pipelines. The minimum distance between the welds shall be equal to half
pipe size but not less than 20 mm.
3.4.3 The ends of pipes to be butt welded with the connecting details or each other shall be
calibrated. The centralizing appliances machined as per inner diameter of pipe shall
provide the alignment of edges to be jointed when assembling.
3.4.4 After fabrication the heat treatment shall be applied to the following pipes:
BK-9.360250.001

OPEN JOINT STOCK COMPANY CDB CORALL

corrosion-resistant steel pipes after hot bending,

corrosion-resistant steel pipes after reduction or expansion of ends,

heat treated corrosion-resistant steel pipes after cold bending at an angle more
than 4.

After bending the Manufacturers methods of pipe heat treatment shall be applied.
3.5

Testing of pipes

3.5.1 After fabrication and acceptance by the representative of quality control department,
the pipes shall be hydraulically tested in a shop under pressure given in the isometric
drawings or Table 3.5.2-1.
The corrosion-resistant steel pipes shall be hydraulically tested before cutting the
allowances after the blank flanges have been welded. The construction of the blank
flange shall make possible an air extraction from the pipe to be tested.
The hydraulic test of pipes for strength shall be carried out in the shop in accordance
with the procedures of construction company.
Fresh water shall be used for hydraulic test of pipes in the shop.
While testing the pipes for strength they shall be kept under pressure for the time
enough to inspect all the connections but this period shall not be less than 15 minutes.
The hydraulic test of pipes shall be considered successful when no leakage or visible
drops observed. Before inspecting the outside surface of pipes shall be wiped dry from
occasional moisture. When leakage is detected, the defective portions shall be cleaned
and welded. After elimination of defects the duplicate hydraulic test of pipes shall be
carried out.
3.5.2 Hydraulic test of pipelines for leakage shall be carried out at the platform in
accordance with the procedure used by construction company
Depending on the system to be tested, an appropriate medium shall be used for
hydraulic test of pipes (Refer to Table 3.5.2-1).
The purity of a testing medium shall be not worse than the purity of working medium
for the system to be tested.
BK-9.360250.001

OPEN JOINT STOCK COMPANY CDB CORALL

As for the pressure for testing the pipelines for leakage, refer to Table 3.5.2-1.
While testing the pipelines for leakage they shall be kept under pressure for the time
enough to inspect all connection but this period shall be not less an 15 minutes.
If the high quality of welding is provided, the combined hydraulic test for strength and
leakage is permissible at the platform instead of separate hydraulic test for strength in
the shop and hydraulic pressure test for leakage at the facility by using the medium
given in Table 3.5.2-1.

Nos.

Table 3.5.2-1
Testing
medium

Design
pressure,
MPa

Testing
pressure in
the shop,
MPa

Testing pressure at
the platform, MPa

Fire main system

Foam extinguishing
system
Sprinkler system
FM 200 system
Foam extinguishing
system
Fresh
Intake
washing
pipelines
water
Other
system
pipelines

Fresh water

0.9

1.35

1.13

Fresh water

0.9

1.35

1.13

7.

Sewage system

Fresh water

8.

Compressed air system

9.
10.

1
2
3
4.
5.
6.

System to be tested

Fresh water
0.9
1.35
1.13
It is specified as per Vendors documentation
Fresh water

0.9

1.35

1.13

0.4

0.6

0.5

0.2

0.3

0.2

1.0

1.5

Fresh water

To be tested in
operation
To be tested in
operation

Fuel system
Lube oil system

Compressed
air
Air
Air

1.02
0.4

1.53
0.6

11.

Drainage system

Fresh water

0.4

12.

Gas exhaust system

Fresh water

0.1

13.

Measuring piping
Pipeline of well
products
Oil pipeline
Gas pipeline
Discharge pipeline
Industrial waste
pipeline
Draining liquid pipeline
Pipeline of low pressure
air

Water

5.0

7.5

1.28
0.5
To be tested in
operation
To be tested in
operation
6.25

Water

5.0

7.5

6.25

Water
Gas
Water

5.0
5.0
4.7

7.5
7.5
7.05

6.25
6.25
5.88

Water

0.2

0.3

0.25

Water
Compressed
air

4.7

7.05

5.88

14.
15.
16.
17.
18.
19.
20.

BK-9.360250.001

1.0

1.5

1.25

1.25
10

21.
22.

Injection water pipeline

Well killing pipeline

Water
Water

OPEN JOINT STOCK COMPANY CDB CORALL

23.24
25.0

34.86
37.5

29.05
31.25

The portions of the compressed air pipeline system which are continuously under
pressure shall be tested within 24 hours. During this period of time the pressure drop
shall not exceed 10 %.
The hydraulic test of the pipeline shall be considered successful if no raptures,
sweating, nontightness of joints and visible residual deformations are detected when
controlling the welded and detachable connections.
3.6

Cleaning of pipes

3.6.1 Operations for cleaning, preservation, protective coating and insulation applications of
the pipes prepared in the shop shall be carried out after completing their tests for
strength.
3.6.2 All the pipes shall be cleaned from scale, rust, moisture, dust, lub-oil and other
impurities irrespective of material grade.
3.6.3 The chemical cleaning of pipes, gaskets and hoses shall be carried out in accordance
with the procedure used by Manufacturer. The corrosion-resistant steel pipes shall be
cleaned by using both chemicals and wads.
3.6.4 After cleaning the inner and outside surface of pipes shall be not have scale, rust, dust,
dirt, grease (oil) and remaining process solutions (acid, alkaline and salt) and also the
defects which are not stipulated in the Regulations and Standards for supply.
3.6.5 The surfaces of pipes shall be of colour as follows:
-

gray for steel pipes,

pink for copper pipes,

light grey for corrosion-resistant pipes,

light grey for galvanized pipes,

light grey with tints of bluish for pipes with chromium plating.

3.6.6 The cleaning process and cleaned surfaces of pipes shall be controlled in accordance
with the procedures used by Manufacturer.
3.7

Coating and insulation of pipes

BK-9.360250.001

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OPEN JOINT STOCK COMPANY CDB CORALL

3.7.1 The protection of the carbon steel pipes shown in the erection drawings shall be
provided by hot zink coating.
3.7.2 Thickness of protective coating shall be as follows:
-

for the pipelines of well products

for sea water pipelines

(water injection system)

- 50 m,
- 200 m,

for the pipelines of drainage

and industrial wastes

- 150 m,

for the pipelines of sewage system

- 200 m,

for the pipelines of water fire

extinguishing system, foam and
foam-water fire extinguishing
systems

- 200 m,

for the pipelines of sprinkler system

- 150 m,

for the pipelines of fresh washing water

- 150 m.

3.7.3 Before hot zink coating, the pipes shall be completely fabricated , tested for strength
and accepted by the quality control service.
3.7.4 The pipes shall undergo the process of cleaning before being zink coated.
3.7.5 The surfaces of pipes to be plated after cleaning shall be grey. Availability of scale,
rust, oil and other substances is forbidden.
3.7.6 The pipes shall be zink coated in accordance with the procedure used by
Manufacturer.
3.7.7 All the surface to be protected shall be coated except the thread and places for welding
shown in the drawings.
3.7.8 The surface of coating shall be homogeneous without foreign inclusions and
blistering, smooth and light grey.

BK-9.360250.001

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OPEN JOINT STOCK COMPANY CDB CORALL

3.7.9 The portions, where the zink layers are thicker than required and prevent assembling,
shall be machined to the desired thickness and the threads shall be calibrated at the
places of zink deposition.
3.7.10 The coating shall be tightly bonded with the base material without any scouring,
spelling, cracking and withstand the bonding strength testing.
3.7.11 The coating integrity damage of pipe inner surface is forbidden.
3.7.12 The steel non-galvanized pipes and pipes made of other materials shall be primed and
painted in accordance with the painting schedule.
3.7.13 Bending and welding of the zink-coated pipes shall be not permissible.
3.7.14 Gas exhaust pipelines of diesel-generators and hot water pipelines should be insulated.
The pipes to be insulated shall be shown in the erection drawings. The insulation shall
be made at the platform after painting the pipelines.
The type of isolation and isolating materials shall be selected by the Vendor of
isolation.
4

INSTALLATION OF PIPELINES
The pipeline installation procedure shall include the following:

4.1

preparation of pipes and fitting for assembling,

assembling of pipes and fitting,

hydraulic tests of pipelines for leakage,

insulation of pipelines,

pipeline flushing with working medium.

Preparation of pipes and fittings for assembling

4.1.1 The pipes, connecting details (tees, angles, etc.) and fittings for assembling shall be
cleaned. The ends of pipes are to be capped.

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OPEN JOINT STOCK COMPANY CDB CORALL

4.1.2 Before pipe assembling, the condition of outside surface, availability of marking and
stamps certifying the pipe acceptance shall be inspected.
4.1.3 Before mounting at the platform, such items as fittings, filters, manometers, etc shall
be depreserved in accordance with the technical description and maintenance manuals
and inspected for cleanliness by the representative of the quality control department
and if necessary, they shall be additionally cleaned and capped.
4.1.4 The threads of pipes and connecting details, which have been subjected to hot zink
coating, shall be cleaned from zink deposits.
4.1.5 The male thread of pipe connecting details shall be protected from mechanical damage
by arranging the plastic, rubber caps or wrapping with flexible PVC.
4.1.6 After assembling and reduction of joints, the projection of bolts and studs above the
nuts shall correspond to the values given in Table 4.1.6-1.
Table 4.1.6-1

4 - 10

Length of bolt projection above the nuts taking

into account the chamfer is not more than, mm
10

11-22

14

23 - 48

20

Thread diameter, mm

The minimum length of bolt projection shall be not less than the chamfer dimensions.
4.2

Installation of pipelines and fittings

4.2.1 Before installation of pipelines and fitting the following operations shall be finished at
the platform:
-

assembling, welding and testing of hull structures,

installation of machinery, apparatus and other equipment or their models fabricated

in accordance with the drawings developed by construction company,

-

delivery of fittings to the installation site.

When the fittings are not available, their models may be used. Construction sizes of
these models shall be within limits for these devices.
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OPEN JOINT STOCK COMPANY CDB CORALL

4.2.2 The temporary installation of pipelines may be performed if necessary. Two/three

bolts (studs) and temporary gaskets in the form of strips or wire equal in thickness to
the standard gaskets shall be used for assembling the flange connections. The nipple
connections shall be assembled by screwing the nipple on the thread manually against
the stop or by the spanner of standard length without a special effort.
4.2.3 The final installation of pipelines shall be performed after examination whether the
temporary installation is performed properly. The temporary bolts and gaskets shall be
changed for standard ones and the pipelines shall be secured on the fixed hangers.
4.2.4 The uniform reduction of gaskets and proper tightening of bolts and units shall be
provided when the flange connection are finally mounted.
4.2.5 The pipelines shall be laid taking into account an arrangement of equipment,
machinery and other pipelines.
The arrangement of pipelines shall provide easy maintenance of fittings and repair of
pipeline with a minimum quantity of pipes and details to be removed.
4.2.6 The air pipes of tanks, drainage and discharge pipelines shall be designed and installed
with the permanent inclination to the side of tanks without pockets.
4.2.7 The bolts of the flange connection for vertical portions of pipes and bolts for securing
the machinery to foundation shall be inserted from the bottom.
4.2.8 The fittings and pipeline connections shall not be arranged above electrical equipment
and cable routes.
The electrical equipment edges and cable routes shall be located apart from the fitting
and pipeline connections at a horizontal distance which is to be not less than:
-

200 mm for cold pipelines except for the fittings servicing the electrical

equipment,
- 500 mm for hot non-insulated pipelines.
The electrical equipment edges and cable routes shall be located apart from the
insulation of hot pipelines at a distance which is to be not less than:
BK-9.360250.001

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100 mm for water supply pipelines,

130 mm for DG exhaust gas system.

OPEN JOINT STOCK COMPANY CDB CORALL

4.2.9 Pipes are to be secured on supports and suspensions in accordance with the hull
steelworks location. The pipes supports shall be installed in places of the greatest
concentration of loads applied to pipelines (nearby of fittings, pipe connections etc.).
Fittings of more than 20 kg weight shall be provided with individual fastenings.
4.2.10 Distances between supports and suspensions are given in detail drawings.
When specifying more exactly the layout of supports and suspensions, the distance
between supports and suspensions shall be defined in accordance with the
Table 4.2.10-1.
Table 4.2.10-1
Nos

1.

Pipeline diameter, mm

6 to

Distance between supports, m

0 included

0.8 to 1.2 included

2.

Over 20 to 45 included

Over 1.2 to 1.5 included

3.

Over 45 to 100 included

Over 1.5 to 2.0 included

4.

Over 100 to 530 included

Over 2.0 to 3.0 included

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