CAIRN TSG Q GUI 0005 B1 Guideline For Material Inspection Requirements

TECHNICAL SERVICES GROUP
GUIDELINE FOR MATERIAL Rev B1

DOCUMENT TITLE:
INSPECTION REQUIREMENTS
DOCUMENT NO: CAIRN-TSG-Q-GUI-0005 Page 2 of 47
REVISION RECORD
Revision Philosophy
All revisions for review will be issued at A1, with subsequent A2, A3, etc as required.
All revisions approved for issue or implementation will be issued at B1, with subsequent B2, B3, etc as
required.
All revisions approved for issue or design and construction will be issued at C1, with subsequent C2, C3,
etc as required.
Narrative sections revised from previous approve issues are to be noted in the table below and/or
highlighted using the appropriate revision status thus: | A2
Previous revision highlighting to be removed at subsequent issues.
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas
and by the use of a triangle containing the revision status.
Revision History
Revision Date of issue Reason for change

No.
A1 27.10.2015 Issued for Review
A2 19.11.2015 Issued for Review
B1 16.02.2016 Issued for Implementation
This document is controlled electronically and is uncontrolled when printed

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CONTENTS
1.0 SCOPE 4
2.0 PURPOSE 5
3.0 DEFINITIONS & ABBREVIATIONS 5

4.0 REFERENCES 6
5.0 ROLES AND RESPONSIBILITIES 11
6.0 GENERAL REQUIREMENT 11
7.0 METALLIC MATERIALS 17
8.0 NON METALLIC MATERIALS 39

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1.0 SCOPE
The scope of this guideline covers the primary manufacture, inspection and testing of base
material components for use in CIL facilities and applies to the following materials of construction:
• Ferritic steels
• Corrosion resistant alloys (CRAs)
• Fibre reinforced plastic composite (FRP) materials
• Thermoplastic materials (including seals)
• Elastomeric seal materials;
• Metallic and non-metallic gaskets
The scope shall not be construed as covering all materials of construction that may be necessary
as a mitigation measure resulting from the corrosion risk assessment required by material
selection & corrosion control. Where the corrosion risk assessment identifies that alternative
materials of construction are necessary, the requirements for these shall be identified in
accordance with the principles in this guideline and submitted for CIL Engineering review and
agreement prior to their use.
This guideline is applicable to both new construction activities and to in-service

modifications/refurbishment at CIL operated facilities as follows:
a) For new ‘green field’ or ‘brown field incremental’ construction, the requirements shall be met in
full.
b) For in-service modifications to, or refurbishment/replacement of, existing components

at CIL operated facilities, the requirements shall be met in full unless the following can be
demonstrated to the satisfaction of the CIL Engineering:
• That implementing the requirements is incompatible with the existing facility’s materials of
construction and would negatively impact the mechanical integrity as a result
• That the intended replacement materials have properties no worse than those already
installed
• That the existing materials show no sign of degradation as a result of non- compliance
with this guideline as demonstrated from appropriate in-service inspection.
The guideline embeds feedback and lessons learned from CIL facilities and external industry
experience and international standard development works.
The guideline supplements the requirements in the relevant and appropriate industry codes and
component material specifications pertaining to the scope of supply and shall be read in
conjunction with these. Where reference is made in the guideline to specific industry codes and
component material specifications, this shall be taken as meaning the latest published version,
including any amendments etc. current at the time of purchase order placement. Alternatives to

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these referenced documents may be acceptable providing the alternative can be shown to
provide an equivalent or better level of quality, safety and design integrity.
2.0 PURPOSE
The purpose of this guideline is to define the minimum requirements for the manufacture,
inspection and testing of the most common metallic and non-metallic materials of construction
used in CIL facilities and to develop a consistent CIL approach to the specification of ‘base
material’ components to facilitate - wide procurement policies for the materials and components
referenced herein.
3.0 DEFINITIONS & ABBREVIATIONS
Vendor : Primary manufacturer of base material components. The definition shall also apply to
any third party contracted to provide manufacturing, inspection or testing services to the Vendor
Intermediary : An organisation which is supplied with components by the Vendor and which then
in turn supplies them without further processing or after processing without changing the
properties specified in the purchase order and referenced product specification e.g. machining
only
Base material component : Components such as plates, forgings, castings, seamless and
longitudinally welded pipes (including induction bends), tubes and fittings (including instrument
tubing and compression fittings), fibre reinforced composite tubular products and structural
components, thermoplastic tubular components, elastomeric and thermoplastic seals, metallic
and non-metallic gaskets.
Ferritic steel : Steels with a nominal alloy content of less than 11% (refer to ASTM A941 for
specific definitions):
• Carbon steels with carbon content of 0.12-0.25%
• Weldable HSLA or microalloyed steels with carbon content ≤0.12%
• Alloy steels with maximum nominal nickel content of 9%
• Alloy steels (AISI 4xxx & AISI 8xxx series, 1¼Cr-½Mo & 2¼Cr-1Mo)
Corrosion resistant alloy : Alloys with a nominal alloy content of 11% and above e.g.
• Martensitic stainless steels
• Weldable low carbon martensitic stainless steels
• Austenitic 300-series stainless steels
• High alloyed stainless steels (PREN ≥ 40 or (%Ni + (2x%Mo)), ≥ 30 with %Ni ≥ 2)
• Duplex & Super Duplex stainless steels
• Nickel-based alloys

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Pitting Resistance Equivalent Number : PREN = (%Cr + 3.3(%Mo + 0.5%W) + 16%N)
Fibre reinforced plastic composite component : Composite component manufactured from a

polymer matrix reinforced with fibres (e.g. glass, carbon or aramid)
Thermoplastic component : Refer to ISO 23936-1
Elastomeric seal component : Refer to ISO 23936-2
Critical Exposure Temperature :
Sour environments : Sour Environments are defined as fluids containing water as a liquid and
hydrogen sulfide exceeding the limits defined. These environments may cause sulfide stress
cracking (SSC) of susceptible materials.
Non-sour environments : All other process and utility environments e.g. elevated temperature,
high pressure & cyclic fatigue environments or hazardous, extreme hazardous & cryogenic
environments. For the purposes of this guideline, the definition also applies to structural steel
components for fixed jacket structures, jetties, trestles, pipe racks, equipment and pipe support
etc.
Special forging or casting : Forging or casting manufactured for a specific application (i.e. not
standard’ piping or pressure vessel components). This will include:
• All components manufactured by the HIP process;
• Forged pressure vessel heads or shell strakes (all materials);
• Forged or cast valve or rotating machinery casings for service in high pressure
environments (all materials);
• Forgings meeting the requirements of FSL-4 in API 20C;
• Castings meeting the requirements of CSL-4 in API 20A;
• Forged flanges for service in high pressure environments (all materials);
• Forged or cast HSLA or microalloyed nodes for fixed jacket structures.
Rolled products : Pipe or fitting manufactured from plate or strip
Lot : Components from the same heat and subject to the same heat treatment (metallic
materials) or components from the same manufacturing batch (non-metallic materials).
Alternative sampling in accordance with ISO 2859-1 may be considered if referenced in a specific
design code or as agreed with CIL.
Non-conductive fluid : Fluid with a conductivity less than or equal to 10000pS/m
4.0 REFERENCES
International Standards Organisation (ISO)
ISO 10684 Fasteners – Hot Dip Galvanised Coatings

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ISO 10893 series Non-destructive testing of steel tubes

ISO 13477 Thermoplastics pipes for the conveyance of fluids —
Determination of resistance to rapid crack propagation (RCP)
— Small-scale steady-state test (S4 test)
ISO 13478 Thermoplastics pipes for the conveyance of fluids —
Determination of resistance to rapid crack propagation (RCP)—
Full-scale test (FST)
ISO 13479 Polyolefin pipes for the conveyance of fluids — Determination of
resistance to crack propagation — Test method for slow crack
growth on notched pipes
ISO 14692 Petroleum and natural gas industries — Glass-reinforced
plastics (GRP) piping
ISO 15590-1 Petroleum and natural gas industries — Induction bends, fittings
and flanges for pipeline transportation systems — Part 1:
Induction bends
ISO 15653 Metallic materials — Method of test for the determination of
quasistatic fracture toughness of welds
ISO 23936-1 Petroleum, petrochemical and natural gas industries — Non-
metallic materials in contact with media related to oil and gas
production — Part 1: Thermoplastics
ISO 23936-2 Petroleum, petrochemical and natural gas industries — Non-
metallic materials in contact with media related to oil and gas
production — Part 2: Elastomers
ISO 2859-1 Sampling procedures for inspection by attributes - Sampling
schemes indexed by acceptance quality limit (AQL) for lot-by- lot
inspection
ISO 6507-1 Metallic Materials – Vickers Hardness testing
ISO 9001 Quality Management Systems - Requirements
ISO 9712 Non-destructive testing - Qualification and certification of NDT
personnel
ISO/TS 29001 Petroleum, petrochemical and natural gas industries — Sector-
specific quality management systems — Requirements for
product and service
American Society of Mechanical Engineers (ASME)
Section V Non Destructive Examination
B16.5 Pipe Flanges and Flanged Fittings
B16.9 Factory-Made, Wrought Butt Welding Fittings
B16.11 Forged Fittings Socket Welding and Threaded
B16.20 Metallic Gaskets for Pipe Flanges
B16.21 Non-metallic Flat Gaskets for Pipe Flanges

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B16.49 Factory-Made, Wrought Steel, Butt Welding Induction Bends for

Transportation and Distribution Systems
B18.18 Quality Assurance for fasteners
American Petroleum Institute (API)
API 20A Carbon Steel, Alloy Steel, Stainless Steel, and Nickel Base Alloy
Castings for Use in the Petroleum and Natural Gas Industry
API 20C Closed Die Forgings for Use in the Petroleum and Natural Gas
Industry
API 5L/ISO 3183 Specification for Line Pipe
API 5L3 Recommended Practice for Conducting Drop-Weight Tear
Tests on Line Pipe
API 5LC Specification for CRA Line Pipe
API 5LD Specification for CRA Clad or Lined Steel Pipe
API 6A718 Specification of Nickel Base Alloy 718 (UNS N07718) for Oil and
Gas Drilling and Production Equipment
American Society for Testing and Materials (ASTM)
A53 Pipe, Steel, Black and Hot-Dipped, Zinc Coated, Welded and
Seamless
A105 Forgings, Carbon Steel, for Piping Components
A106 Seamless Carbon Steel Pipe for High Temperature Service
A182 Standard Specification for Forged or Rolled Alloy-Steel Pipe
Flanges, Forged Fittings, and Valves and Parts for High-
Temperature Service
A193 Standard Specification for Alloy-Steel and Stainless Steel
Bolting for High Temperature or High Pressure Service and
Other Special Purpose Applications
A194 Standard Specification for Carbon and Alloy Steel Nuts for Bolts
for High Pressure or High Temperature Service, or Both
A216 Steel Casting, Carbon, Suitable for Fusion Welding for High
Temperature Service
A234 Pipe Fittings of Wrought Carbon Steel and Alloy Steel for
Moderate and Elevated Temperatures
A264 Standard Specification for Stainless Chromium-Nickel Steel-
Clad Plate
A265 Standard Specification for Nickel and Nickel-Base Alloy-Clad
Steel Plate
A312 Standard Specification for Seamless and Welded Austenitic
Stainless Steel Pipes
A320 Alloy-Steel and Stainless Steel Bolting for Low-Temperature
Service

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A333 Standard Specification for Seamless and Welded Steel Pipes for
Low Temperature Service
A370 Standard Test Methods and Definitions for Mechanical Testing
of Steel Products
A388 Standard Practice for Ultrasonic Examination of Steel Forgings
A403 Standard Specification for Wrought Austenitic Stainless Steel
Piping Fittings
A420 Standard Specification for Pipe Fittings of Wrought Carbon Steel
and Alloy Steel for Low Temperature Service
A435 Standard Specification for Straight-Beam Ultrasonic
Examination of Steel Plates
A578 Standard Specification for Straight-Beam Ultrasonic Examination
of Plain and Clad Steel Plates for Special Applications
A745 Standard Practice for Ultrasonic Examination of Austenitic
Steel Forgings
A770 Standard Specification for Through-Thickness Tension Testing
of Steel Plates for Special Applications
A961 Common Requirements for Steel Flanges, Forged Fittings,
Valves, and Parts for Piping Applications
A962 Common Requirements for Bolting Intended for Use at Any
Temperature from Cryogenic to the Creep Range
A991 Standard Test Method for Conducting Temperature Uniformity
Surveys of Furnaces Used to Heat Treat Steel Products
E112 Standard Test Method for Determining Average Grain Size
E1268 Standard Practice for Assessing the Degree of Banding or
Orientation of Microstructures
E280 Standard Test Method for Conducting Drop-weight Tests to
Determine Nil-Ductility Transition Temperature of Ferritic Steels
E407 Micro-etching Metals and Alloys
E562 Determining Volume Fraction by Systematic Manual Point
Count
F788 Surface Discontinuities of Bolts, Screws and Studs
F812 Surface Discontinuities of Nuts
G48 Standard Test Methods for Pitting and Crevice Corrosion
Resistance of Stainless Steels and Related Alloys by Use of
Ferric Chloride Solution
NACE International Standards
NACE MR0175/ISO 15156 Petroleum and Natural Gas Industries - Materials for use in

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H2S-containing Environments in Oil and Gas Production

NACE MR0103 Materials Resistant to Sulfide Stress Cracking in Corrosive
Petroleum Refining Environments
TM0177 Laboratory Testing of Metals for Resistance to Sulfide Stress
Cracking in Hydrogen Sulfide (H2S) Environments
TM0284 Evaluation of Pipeline and Pressure Vessel Steels for
Resistance to Hydrogen-Induced Cracking
British Standards (BS)
BS 7448-1 Fracture Mechanics Toughness Tests - Part 1: Method for
Determination of KIC, Critical CTOD and Critical J Values of
Metallic Materials
BS 7448-4 Fracture Mechanics Toughness Tests - Part 4: Method for
Determination of Fracture Resistance Curves and Initiation
Values for Stable Crack Extension in Metallic Materials
BS 7910 Guide to methods for assessing the acceptability of flaws in
metallic structures
European Norms (EN)
EN 10204 Steel and Steel Components – Inspection Documents
EN 10168 Steel products - Inspection documents - List of information and
description
EM 10160 Ultrasonic Testing of Steel Flat Product of Thickness Equal or
Greater than 6mm (Reflection Method)
EN 10306 Iron and Steel - Ultrasonic Testing of H Beams with Parallel
Flanges and IPE Beams
EN 10225 Weldable structural steels for fixed offshore structures -
Technical delivery conditions
Det Norske Veritas (DNV)
RP-F-112 Design of Duplex Stainless Steel Sub-sea Equipment Exposed
to Cathodic Protection
Norsok
M-122 Cast Structural Steel
M-123 Forged Structural Steel
M-650 Qualification of Manufacturers of Special Materials
American Welding Society (AWS)
A4.2 Standard Procedures for Calibrating Magnetic Instruments to
Measure the Delta Ferrite Content of Austenitic and Duplex
Ferritic-Austenitic Stainless Steel Weld Metal
American Society of Non-destructive Testing (ASNT)
SNT-TC-1A Personnel Qualification and Certification in Non-destructive

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Testing
ACCP ASNT Central Certification Program
5.0 ROLES AND RESPONSIBILITIES

PROJECT MANAGER. (PM)
The Project Manager is responsible for the overall management of the contract to achieve the
stated requirements. The Project Manager shall ensure that the relevant inspection requirements
of this procedure are included in any future contracts.
QUALITY MANAGER. (QM)
The Quality Manager (QM) is responsible for the implementation and maintenance of the
Company’s Quality Management System throughout the project and irrespective of other
responsibilities and authorities; he has responsibilities and authorities that include:
• Reporting to the Head of Project or Corporate Management on the performance of the
Project QMS and any need for improvement;
• Ensuring the promotion and awareness of stakeholders requirements throughout the
project organization;
• Assisting Head of Project in conducting Management Reviews at periodical intervals
based on project schedule.
• Management of Internal audits and corrective action follow up.
He shall ensure that the requirements of this Inspection requirement are properly implemented
through the project. He also provides professional advice on all Company QA arrangements, Co-
ordinates with the contractors in the resolution of quality issues.
QUALITY CONTROL TEAM
Quality Control team shall ensure that the requirements of this Inspection requirement are
properly implemented through the project.
The Team has responsibilities and authorities that include:
• Review and approve Suppliers and EPC contractors’ Quality Plans, Procedures as per
this inspection requirements.
• Ensure relevant QA and QC training for all site personnel and ensure all personnel
understand and effectively deliver their QA and QC responsibilities as per Quality Plan
and this Procedures.
6.0 GENERAL REQUIREMENT
6.1 General Manufacturing and HSSEQ Requirements
6.1.1 All components manufactured in accordance with this guideline shall meet the requirements of:
• Any applicable statutory regulations, including referenced codes or standards, of the
country where the components will be installed;
• The applicable design code and component material specifications;
• Other CIL Standards as applicable to the scope of supply.

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6.1.2 All components for new construction shall be unused and less than 24 months old for metallic
components and 6 months old for non-metallic components (defined as the period from the date
of manufacture to the date of purchase on behalf of CIL).
6.1.3 In specific circumstances for in-service modifications to,or refurbishment/replacement of,
existing components, the re-use of existing components may be considered but shall be
subject to a continued fitness-for- service evaluation and detailed inspection regimes, using
methodologies and techniques approved by the CIL Engineering & Quality Authorities.
6.1.4 CRA components (with the exception of martensitic and 300-series stainless steels) shall
be procured from Vendors holding a current CIL qualification criteria relevant to their
scope of their supply, or CIL approved equivalent qualification programme . If these CRA
components are supplied from an intermediary, the intermediary shall demonstrate to the
satisfaction of CIL that the components have been procured from a Vendor holding an
appropriate qualification certificate current at the time of their manufacture, or CIL approved
equivalent qualification programme (as demonstrated above).
6.1.5 Fasteners shall be procured from Vendors operating a Quality Management System (QMS)
in accordance with the requirements of ASME B18.18 and this CIL Guideline. If the components
are supplied from an intermediary, the intermediary shall demonstrate to the satisfaction of CIL
that the fasteners have been procured from a source that operates in accordance with the above
requirements. Unless otherwise agreed with CIL, fasteners shall be assigned the following
categories for inspection:
Environment/Application Category
Non-sour process and utility environments 3
Structural steel application (including fixed jacket
structures) On-land buried applications
Sour process environments 2

Submerged applications
6.1.6 Where components are offered from an intermediary and do not comply with the requirements of
this guidline, acceptance of the components shall be subject to the approval of CIL Engineering
and Quality Authorities, based on the following principles:
a) All non-compliances shall be detailed for review by CIL Engineering and Quality
Authorities.
b) Where the data required by this guideline is missing or is not provided by the
intermediary, the components shall be rejected in the first instance.
c) Further to b) above, and subject to the approval of CIL Quality Authority, one component
in 25 from each lot shall be randomly selected by CIL for testing in accordance with this
guideline – if the tests meet the requirements of this guideline, the remaining
components of that lot may be accepted; if the tests fail to meet the requirements, the
components shall be rejected in accordance with Section 6.2.11.
d) Where the data required by this guideline is provided but the results do not meet the
requirements of this guideline, acceptance shall be based on either:

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• Additional testing in accordance with c) above; or

• A fitness-for-service evaluation shall be undertaken to evaluate the risk associated
with the non-compliance on a case-by-case basis and if the risk is ‘low’ then the
components may be accepted; or
• If the non-compliance is only associated with inspection requirements, one component in
25 from each lot shall be randomly selected by CIL for further inspection in accordance
with this guideline – if the inspection results meet the requirements of this guideline, the
remaining components of that lot may be accepted; if the tests fail to meet the
requirements, the components shall be rejected in accordance with Section 6.2.11.
6.1.7 All work associated with the manufacture, inspection and testing of base material components
shall comply with all relevant statutory health, safety and environmental legislation including:
a) Provision of adequate ventilation, detection and extraction facilities in enclosed or
confined spaces to prevent the build-up of inert, toxic or flammable atmospheres, fumes,
dust etc.
b) Provision of appropriate personal protective equipment including eye, breathing and
hearing protection.
c) Provision of adequate safety systems to prevent electric shock and build-up of static
electricity.
d) Provision of appropriate safety systems for use of pressurised air, oxy-fuel or plasma
cutting equipment, welding equipment etc.
e) Provision of appropriate disposal facilities for waste or consumables.
6.1.8 Manufacturing, inspection and testing activities, and any consumables used during these
activities, shall comply with the following:
a) All relevant statutory health, safety and environmental legislation both in the country
where any manufacturing activity takes place and in the country where the facilities will
be operated.
b) Shall not use, or contain, constituents that are known to be harmful to the health of
individuals or to the environment nor have radioactive contamination levels out with the
statutory legislative limits.
6.2 Quality Assurance & Quality Control Requirements
6.2.1 All Vendors and intermediaries shall have in place an accredited QMS (ISO 9001, ISO/TS 29001
or equivalent) and appropriate working practices and quality control procedures to ensure that
the requirements of this guideline are met.
6.2.2 CIL reserves the right to undertake its own surveillance of Vendor or intermediary QMS
activities to ensure that the requirements of this guideline are being met. The level of surveillance
shall be based on the criticality of the components and shall be assessed in accordance with the
recommendations in Materials & Equipment Criticality Ratings Procedure: CAIRN-TSG-Q-PRO-
0006 Rev.B1.
6.2.3 Specifications, data sheets etc. shall be developed to ensure that the relevant requirements of
this guideline are included in the appropriate purchase order, contract and sub-contract
documentation.
6.2.4 The Vendor shall develop an inspection and test plan that is appropriate to its scope of supply
and shall identify all critical stages required for the manufacture of the specific component and
that are subject to inspection and testing, and shall identify the controlling documents and parties

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responsible for each stage - in all cases a column shall be included for the involvement of CIL or
its nominated representative.
6.2.5 For components supplied by an intermediary, an inspection and test plan is not required unless
the scope of supply includes further manufacturing, processing or inspection activities.
6.2.6 Components shall be supplied with the following Material test Report (MTR) type in accordance
with EN 10204:
Component MTR Type

Metallic materials
• Structural steel components for offshore jacket structures (including caissons, Type 3.1
conductor casings, support piles, mud mats), jetty or trestle structures (including
support piles), and any components connected directly to these items with the
exception of components noted below:
• Plate for Pipeline & Piping Type 3.2

• Structural steel components for submerged applications (e.g. pipeline manifold and Type 3.1
end termination structures)
• Structural steel components for equipment and piping supports, pipe racks, flare
structures, etc.
• Pressure retaining components and any components connected directly to these Type 3.1
items with the exception of components noted below for submerged applications:
• Special forgings or castings Type 3.2
• CRA line pipe
• Metallurgically bonded (clad), weld overlaid or mechanically-lined line pipe
• Shell and base plates for above or below ground atmospheric or low pressure Type 3.1
storage tanks
• Fasteners (excluding washers, circlips, holding-down bolting for gratings and
handrails
• Metallic gaskets & seals,
• Grating & handrails, cable trays, spiral wound gaskets Type 2.2
Non-metallic materials
• Pressure retaining components Type 3.1
• Thermoplastic seals, elastomeric seals
• Grating & handrails, cable trays spiral, sheet gaskets Type 2.2
Note: The material certification type shall be in line with what is described in this table irrespective of the
quality and sources. In case of any deviation; approval is to be obtained from CIL
6.2.7 In addition, each Type 3.1 or 3.2 MTR shall include any additional testing required by this
guideline.

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6.2.8 For components referenced in Section 7.1.3, the original MTR from the raw material source
(e.g. cast billet) shall be supplied with the finished component in addition to the MTR for the
finished component.
6.2.9 For components supplied by an intermediary, the MTR shall comply with the following:
a) The intermediary shall submit either:
• An original MTR in accordance with Section 6.2.6;
• A copy of the original MTR certified by the intermediary as a ‘true copy of the original’;
• An intermediary-generated MTR complying with the requirements of Section 6.2.6 and
certified by the intermediary as a ‘true copy of the original’.
b) For components covered by Section 6.2.8, the original MTR or a copy of the original
MTR certified by the intermediary as a ‘true copy of the original’ shall be submitted.
C) For any component supplied with either a ‘true copy’ MTR or an intermediary- generated
MTR that is dated more than 18 months from the original test date, the original MTR for
the component shall be made available for CIL review. CIL reserves the right to require
additional testing of a representative component per lot to verify the stated properties.
6.2.10 Where an electronic certification scheme for the issue and control of MTRs is utilised, the
Vendor’s or intermediary’s QMS shall ensure that the scheme complies with the requirements
of EN 10204 and that full traceability is maintained between the electronic version of the MTR
and the component.
6.2.11 Any component identified as not complying with the requirements of this guideline shall be
quarantined and subject to an appropriate disposition as agreed with CIL, or removed and
replaced by a component complying fully with this guideline.
6.3 Marking and Identification
6.3.1 All acceptable components shall be clearly identified, and traceable back to the appropriate
MTR.The identification shall be retained until all inspection is complete and documentation
accepted by CIL
6.3.2 Identification of metallic components shall be by hard stamping using low stress, dot or U-type
stamps, engraving or non-deleterious indelible ink or paint. Hard stamping is not permitted for
thin-wall components (T<6.4mm).
6.3.3 Identification of non-metallic components shall be by non-deleterious indelible ink or paint.
6.3.4 Marking and identification for specific components shall comply with the following:
Component Marking & identification requirements

Metallic components (plates, forgings, Each component shall be clearly and indelibly
castings, pipes, fittings, section) identified in accordance with the relevant
component material specification
Fasteners (bolts, studs and nuts) Each component shall be clearly and indelibly
identified in accordance with ASTM A962, with
the additional requirement that for submerged
applications all sizes shall be so identified
Fasteners specified to be hot dipped and spun Identification shall comply with the requirements
galvanized of ISO10684

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Other fastener components (washers, circlips Traceability shall be maintained with

etc.) the MTR in accordance with the
Vendor’s standard Quality
Assurance/Quality Control (QA/QC)
procedures
Ring-joint gaskets and clamp type connector seal Each component shall be clearly and indelibly
rings identified on the edge with the Vendor’s
identification, material grade, heat number and
size by engraving
Color coding alone is not permitted nor is hard
stamping on the sealing surface
Spiral wound and jacketed metal gasket Each component shall be clearly and durably
identified and color coded in accordance with
ASME B16.20
Non-metallic gaskets Each component shall be clearly and durably
identified with the Vendor’s identification and
material type/grade in accordance with ASME
B16.21
FRP components Each component shall be clearly and durably
identified in accordance with the Vendor’s
identification and material type/grade
Thermoplastic pipe and fittings for use in gas Each component shall be clearly and durably
service identified and color coded
Thermoplastic pipe and fittings for use in utility Each component shall be clearly and durably
service marked in accordance with the Vendor’s
identification and material type/grade
Elastomeric and thermoplastic seals Traceability shall be maintained with the MTR in
accordance with the Vendor’s standard QA/QC
procedures
The shelf life of each type of component
shall be clearly identified on the packaging
and this shall be maintained during
subsequent storage
6.4 Transport, Handling, Storage and Protection

6.4.1 Components shall be transported, handled and stored in a manner to prevent physical damage
or degradation, including but not limited to:
a) Prohibition on the use of steel ropes, slings, bands etc. in direct contact with the
component.
b) Stacking/storage of bulk pipe to prevent flattening. Individual pipes shall be separated by
wooden straps or battens or, for coated pipe, 25mm diameter rope.
c) Small components (e.g. nuts and bolts, small bore piping components) shall be packed
in waterproof crates or containers.
d) For shipping over water, components shall be transported below deck unless fully
enclosed in a waterproof container. Where the size of the component precludes this, the
components shall be coated externally (and internally if necessary) with a temporary or

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permanent coating system that is suitable for direct exposure to a marine environment,
and all openings shall be protected with end caps or other appropriate closure.
e) Components shall not be stored or stacked in direct contact with the ground. Where such
storage is necessary, a barrier layer shall be installed between the component and the
ground.
f) In addition to e) above, CRA components shall be protected from exposure to marine
atmospheres and shall have all open ends protected with end caps or other appropriate
closure.
g) Material shall be protected, stored and preserved in accordance with procedure “New
Material and Equipment Preservation-(CAIRN-TSG-J-PRO-0011)” in ordered to assertain
fit for purpose condition of material.
h) Fibre reinforced composite and thermoplastic components shall be stored under
cover unless they are manufactured to withstand ultra violet (UV) exposure in
accordance with Section 8.2 or Section 8.3 under cover to prevent unnecessary
exposure to UV light.
i) Elastomeric and thermoplastic seals and non-metallic gaskets shall be transported
and stored in waterproof crates or containers to prevent exposure to UV light and
humidity and shall be packed to ensure that no force likely to induce permanent
deformation (‘set’), is placed on the components.
6.4.2 Where components are supplied in containers, crates or bags, these shall be inspected prior to
shipment and further on receipt to confirm that these are unopened and that no damage has
occurred that would affect the integrity of the contents. In the case where any damage has
occurred, the components shall be rejected in accordance with Section 6.2.11.
6.4.3 Where components are supplied with temporary protective coatings, these shall be selected to
ensure that they can be removed easily prior to further processing. Where permanent protective
coatings are specified as part of the component supply, these protective coatings shall meet the
requirements of CAIRN-TSG-L-SP-0005.
7.0 METALLIC MATERIALS
7.1 General Manufacturing Requirements
7.1.1 Where Unified Numbering System (UNS) wrought designations, the requirements shall apply to
the appropriate UNS cast designations unless otherwise specified.
7.1.2 The following specific manufacturing requirements are applicable for all ferritic steel and CRA
materials:
Component Manufacturing requirements
Pipe 1. Seamless and welded line pipe shall meet the requirements of API 5L/ISO
3183 (carbon steel, high strength low alloy (HSLA) & micro alloyed steels) or API
5LC (CRA materials) or Piping Material Specification or CIL Specification
whichever is stringent.
2. Electric welded (EW) pipe/tube shall only be supplied from mills that utilise the
following manufacturing controls:
● high frequency (greater than 100kHz) welding processes
● on-line feedback systems for controlling heat input and roll pressure
● in-line capability for automatic weld seam tracking control, full weld volume
ultrasonic inspection and induction heat treatment capability
3. Skelp end welds shall be cut out of the finished pipe

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4. Weld jointers are not permitted

5. Cold expansion (where permitted) shall be limited to ≤1.5% of the unexpanded
pipe diameter
Induction bends Induction bends shall meet the requirements of ISO 15590-1 or ASME B16.49 or
Piping Material Specification or CIL Specification whichever is stringent and the
(1)
following:
● Seam welds shall be orientated along the neutral axis
● A minimum tangent (un-bent) length of 500mm shall be maintained at each end
Forgings 1. Special forgings for pressure retaining components shall meet the
requirements of API 20CD or Piping/Valve Material Specification or CIL
Specification whichever is stringent and the following:
a) be forged as closely as possible to the finished shape with a minimum forging
reduction of 4:1 and 20% reduction in size from the ingot, billet or continuous-
cast bloom
b) The component shall be subject to a final ‘quality heat treatment’ after all
forging operations are completed
2. Flanges and valve stems shall achieve at least ⅔ of the change in diameter by
forging, thereby limiting machining to ⅓ of the diameter change
3. All forgings shall:
a) Be free from flakes, cracks, seams, laps, and any open discontinuities
(porosity, shrinkage, piping, cracks, etc.) when macro-etched or viewed under a
light microscope at x25 magnification and
b) Have a homogenous microstructure in any given area with no evidence of
macro segregation. Some banding in heavy sections is permitted providing this is
documented and included in the forging qualification record
4. Components manufactured from bar stock shall be limited to systems with a
maximum 300# pressure rating and a starting diameter of 350mm. Forged
flanges and fittings machined from bar stock shall comply with the restrictions in
ASTM A961
Castings 1. Special castings for pressure retaining components shall meet the
requirements of API 20A or Piping/Valve Material Specification or CIL
Specification whichever is stringent.
Metallurgically bonded
(clad) components 1. Metallurgically bonded (clad) components shall comply with the following
requirements:
2. Clad plate shall be manufactured in accordance with ASTM A264 or ASTM

A265 (roll bonded or explosion bonded with or without conversion rolling)
3. Clad forgings shall be manufactured by explosion bonding with or without
conversion rolling
4. Cladding thickness shall be 3mm minimum after finishing. Joining of CRA
sheets by welding prior to cladding or the use of inter-layers/multiple layers to
achieve the specified cladding thickness is not permitted
5. Where subsequent heat treatment is required, the heat treatment shall be

performed after any repair welding but prior to any subsequent straightening or
(2)
forming

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6. Metallurgically bonded (clad) line pipe shall meet the requirements of API 5LD
Weld overlaid Weld overlaid components shall meet the requirements of CIL Fabrication
components Specification
CRA-lined pipe 1. Mechanically-lined line pipe shall meet the requirements of API 5LD or
Pipeline Specification or CIL Specification whichever is stringent.
2. The liner shall have a minimum thickness of 2.5mm, consistent with obtaining
an acceptable interference fit and weld end preparation
3. The pipe ends shall be weld overlaid for a minimum distance of 50mm from the
(3)
edge
Notes:
1. The principles within ISO 15590-1 or ASME B16.49 shall be followed in developing appropriate
manufacturing procedure specifications for CRA induction bends
2. Minor cosmetic weld repairs are permitted after heat treatment provided the repair depth does not
encroach on the base material and the relevant welding procedure is qualified to demonstrate that the
hardness level below the repair area does not exceed the values stated in relevant standard
3. A greater length may be required subject to the final selection of the automated ultrasonic testing
methodology for the girth welds and results of any fatigue analysis
7.1.3 A procedure qualification test programme shall be undertaken for the following components to
demonstrate that the proposed manufacturing route and production parameters results in
components meeting the requirements of this guideline and further, that the proposed production
test sampling will give results which are representative of the actual component properties:
• HSLA or microalloyed line pipe with specified minimum yield strength (SMYS) ≥320MPa
(with reference to API 5L/ISO 3183);
• All special castings and standard castings for high pressure service (with reference to the
requirements of API 20A) or fixed jacket structures (with reference to Norsok M122);
• All special forgings and standard forgings for high pressure service (with reference
to the requirements of API 20C) or fixed jacket structures (with reference to Norsok
M123);
• HSLA or microalloyed steel plate, rolled product or hollow section from a new Vendor,
location or process route that does not possess relevant manufacturing and qualification
data to demonstrate compliance with the requirements of this guideline;
• Newly developed ferritic steels or ones that have not previously been supplied and for
which manufacturing and qualification data, or extensive fabrication experience, is not
available to demonstrate compliance with the requirements of this guideline;
• Integrally clad, mechanically lined pipe (with reference to API 5LD) or weld overlaid CRA
pipe and fittings.
7.1.4 For components referenced in Section 7.1.3:
a) A manufacturing procedure specification shall be developed to define all
necessarymanufacturing steps and essential variables for component
qualification. Re-qualification is required when the essential variables defined during the
qualification stage change.
b) A qualification test coupon shall be taken subject to the relevant requirements of the
component material specification.
7.1.5 Unacceptable surface or embedded flaws/imperfections shall be rectified or repaired as
follows:

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Component Rectification or repair options

All (with exception of metal gaskets and Where permitted by the component material
seal rings) specification, design code or this Standard, grinding of
surface flaws/imperfections shall ensure that the
dressed area blends in smoothly with the surrounding
surface and does not encroach on the minimum
permissible thickness
Plate, seamless or EW pipe or tube,
forging, bar stock, seamless or EW fittings Weld repairs are not permitted
Castings 1. Weld repairs are not permitted for castings that leak
through the body of the casting during pressure testing
2. CSL-4 and duplex stainless steel castings in
accordance with API 20C may be weld repaired
subject to CIL approval
3. Where weld repairs are permitted:
a) The maximum individual weld repair area shall not
exceed 65cm2 and the total area of all weld repairs
shall not exceed 10% of the total surface area
b) Maximum weld repair depth shall not exceed
0.25T
Fusion welded pipe & fittings 1. Weld repairs are not permitted to the pipe/fitting
body
2. Weld repairs to the manufacturing weld are
permitted subject to a maximum repair length
equivalent to 5% of the weld length
Metallurgically bonded (clad) & weld 1. Grinding of surface flaws/imperfections on the clad
overlaid components surface and weld overlay is permitted but shall ensure
that the dressed area blends in smoothly with the
surrounding surface and does not encroach on the
minimum permissible cladding or weld overlay
thickness
2. The maximum individual weld repair area shall not
exceed 58cm2 and the total area of all weld repairs
shall not exceed 5% of the total surface area
3. Repair to the backing component is permitted
subject to the restrictions noted against the specific
component above
CRA-lined pipe 1. Weld repairs are not permitted to the CRA liner but
may be undertaken on the pipe end weld overlay
2. Grinding of surface flaws/imperfections in the CRA
liner is permitted but shall ensure that the dressed
area blends in smoothly with the surrounding surface
and does not encroach on the minimum permissible
liner thickness
3. Repair of the carrier pipe is permitted subject to the
restrictions for the specific component form above

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7.2 Welding Requirements

7.2.1 Where fusion welding is necessary during manufacture, including any repair welds, the welding
shall be performed in accordance with a qualified welding procedure to produce welds that meet
the requirements CIL material specifications.
7.2.2 CIL material specifications specifies properties for weld metal, these requirements apply to the
deposited weld metal as determined from production welds or welding procedure qualification
testing, not from welding consumable MTRs.
7.2.3 For components exposed to sour environments, welding consumables shall be selected to
deposit weld metal meeting the hardness requirements of NACE MR0175/ISO 15156 and this
guideline. The use of consumables that deposit a nickel (Ni) level greater than 1% shall only be
permitted subject to successful sulphide stress corrosion (SSC) test results.
7.2.4 Where permitted by Section 7.1.5, a weld repair (whether considered minor or major per the
relevant component material specification) shall meet the following requirements:
a) Each repair area shall be recorded and suitably prepared for welding followed by visual
inspection and surface non-destructive examination (NDE) over the full area of the repair
to demonstrate the absence of surface breaking flaws.
b) Qualified welding procedures, including any additional testing specified in CIL
Fabrication and Material Specifications and appropriately qualified welders, shall be used
the repair weld.
c) Only low hydrogen consumables or welding processes are permitted (non-low hydrogen
shielded metal arc welding (SMAW) consumables may be used for repairs to austenitic
300-series stainless steels).
d) Where applicable, the repair weld shall be heat treated in accordance with the original
component material specification and CIL Fabrication Specifications
e) Each completed weld repair shall meet the requirements of CIL Material and Fabrcation
specifications, code or standard and shall be subject to the inspection requirements in
with this guideline.
f) The location of each repair weld shall be recorded on the component MTR, or an
additional test report, which shall accompany the component MTR, and shall include a
drawing/sketch of the repair area plus the applicable welding procedures and
supporting welding procedure qualification records, NDE reports and any specified
additional test and inspection reports.
7.3 Heat Treatment
7.3.1 The following requirements shall be met where heat treatment is required:
a) Furnaces shall be sized to ensure that the heat treated items fit completely within the
calibrated working zone and shall have full automatic control of heating and cooling rates
with automatic temperature recording. Controlling, measuring and recording instruments
shall possess an accuracy of ±1°C of their full scale range and shall be calibrated at least
once every three months.
b) The furnace shall be calibrated to ASTM A991 or equivalent recognised standard
at least once a year using the maximum specified load for the furnace and shall be
capable of maintaining a uniform temperature within the calibrated working zone of
±14°C of the set point during austenitizing heat treatments and ±8°C of the set point
during tempering heat treatments.

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c) Items shall be loaded in the furnace in a manner that allows free movement of air or
water and ensures all surfaces are heated or cooled evenly.
d) For bulk piping components, temperature monitoring by the furnace thermocouples
is acceptable providing the thermocouple measures temperatures within the
calibrated working zone. For special forgings or castings, a thermocouple shall be
attached to the surface of the heaviest cross section of the largest item in the heat
treatment load.
e) The hold time at temperature shall not commence until all the thermocouples reach the
specified hold temperature.
f) The rise, hold and fall times and temperatures shall be recorded on a hard copy chart in
addition to any computer readout and a certified copy of this chart shall accompany the
MTR.
g) The test coupon shall be included in the furnace load based on a minimum of one test
coupon per heat and heat treatment load.
h) When a furnace is repaired or rebuilt, a new temperature survey shall be carried out
before the furnace is used for heat treatment, unless it can be demonstrated that the
repairs do not affect the temperature tolerance of the furnace.
7.3.2 Where subsequent liquid quenching is required, the following requirements shall be met:
a) Quenching facilities shall be located in the immediate vicinity of the heat treatment
furnace to ensure that the time between removing the component(s) from the furnace
and quenching is less than 60 seconds from the time the furnace door is fully open or the
roof removed. An elapsed time greater than 60 seconds shall be subject to specific
qualification and shall be limited to components within the qualified range.
b) The quench tank shall be designed to completely immerse the components and the
medium agitated to ensure that all surfaces of the items are in contact with the circulating
medium.
c) The temperature of the medium during quenching shall be continuously monitored to
ensure the temperature does not exceed approximately 50°C at the end of quenching.
Measuring and recording instruments shall possess an accuracy of ±5°C of their full
scale range and shall be calibrated at least once every three months.
d) The quench medium shall be selected to ensure that the final specified properties
are met whilst minimising the likelihood of distortion or quench cracking. Any change in
the selected medium from that used during qualification will require re-qualification.
7.3.3 The tempering heat treatment temperature shall be at least 20°C higher than the upper limit of
the temperature range specified for any specified or anticipated heat treatment required during
subsequent fabrication e.g. hot forming, post weld heat treatment (PWHT).
7.3.4 A detailed procedure shall be developed to control the heat treatment and subsequent
cooling operations. All critical steps shall be included in the inspection and test plan in
accordance with Section 6.2.4.
7.4 Fasteners
7.4.1 Unless otherwise specified in the design code, fasteners shall be manufactured in accordance
with ASTM A962 and the follow

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Non-sour
environments &
below ground Submerged applications
Requirements Sour environments
applications (including water-air interface)
(including soil-air
interface)
Steelmaking process:
Deoxidation Steel shall be fully killed & fine grained
Manufacturing process:
1. Rolling or machining of threads shall be performed after any specified heat

treatment (unless specifically prohibited by the component material specification)
Thread forming
2. Thread tolerances for fasteners that are specified to be hot dipped and
spun galvanised in accordance with CIL Material specification shall meet the
requirements of ISO 10684
Mechanical properties:
All grades
(with
exceptions ≤35HRC
as noted
below):
In accordance with In accordance with

the design the requirements of Duplex
Hardness
code/component CIL Material
material specification Specification
stainless ≤28HRC
steels:
ASTM
A194Gr.2HM
≥200HB
(2)
& Gr.7M
nuts:
Maximum actual yield

In accordance with the design ≤950MPa
stress (AYS)
code/component material specification
SMYS-to-tensile ratio ≤0.9
Notes:
1. A limit on the maximum hardness for submerged applications is specified to minimise the likelihood of
hydrogen embrittlement under cathodic protection
2. Only required when these nuts are used in conjunction with high strength bolts/studs (e.g. ASTM A193
Gr.B7 or ASTM A320 Gr.L7 or L43)
7.5 Metallic Gaskets and Seal Rings

7.5.1 All gaskets shall be compatible with the process fluid and flange material.

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7.5.2 Ring-joint gaskets shall meet the surface finish and maximum hardness limits specified in ASME
B16.20 and shall be at least 30HRB points lower than the flange seating surface.
7.5.3 The strength and hardness of seal rings shall be selected to ensure that the completed joint
meets the integrity requirements of Flange Joint Management, Cleaning & Pressure Testing
according to CIL Specification.
7.5.4 In addition to the requirements of ASME B16.20 spiral wound gaskets shall meet the following
requirements:
a) The filler shall not contain asbestos.
b) Each gasket shall be supplied with a centring ring irrespective of the service
environment.
c) Each gasket shall be supplied with a solid metal inner ring when installed in the following:
• High pressure environments;
• Hazardous & extreme hazardous environments;
• Elevated & cryogenic temperature environments;
• Vacuum service;
• Cyclic fatigue service;
• Erosive service;
• Suction side of rotating machinery.
7.5.5 Gaskets and seal rings shall be identified in accordance with the requirements of Section 6.3
7.6 Mechanical and Corrosion Testing Requirements

7.6.1 Components shall be tested during procedure qualification testing and manufacturing
production to demonstrate that they meet the requirements of the design code, component
material specification and CIL material specifications.
7.6.2 In addition to the requirements of the design code and component material specification,
mechanical and corrosion tests shall meet the following requirements:
Test type Test requirements

1. Testing shall be performed in accordance with the requirements in ASTM A370
2. A minimum number of three test specimens shall be taken from each location (base
metal, weld metal and heat affected zone (HAZ) as applicable)
3. Where a repair weld is permitted, the following areas shall be tested unless otherwise
agreed with CIL
● The repair weld metal
Impact test ● The HAZ of the base material component and repair weld metal
● The HAZ of the original weld metal and repair weld metal
4. The test temperature shall be the lowest of:
● The specified CET for the component
● The component specification test temperature

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5. Where possible, full size specimens (10mmx10mm) shall be removed for testing.
Where full size specimens cannot be taken due to component thickness, size or
orientation constraints, sub-size specimens shall be removed. Unless otherwise
specified in the relevant design code, the impact energy shall be adjusted as follows:
Width of subsize specimen
Energy value for full size specimen × ------------------------------------------------------------
Width of full size specimen
6. The minimum impact energy values specified within this Standard are applicable
irrespective of sample orientation. Some design codes may require higher values for
specimens orientated in the longitudinal (axial) direction
7. The impact energy values as specified in CIL material specifications
8. Lateral expansion values shall be reported where required by the component material
specification, design code, or CIL Material Specifications
Fracture toughness 1. Testing shall be performed in accordance with the requirements of BS 7448-1, ISO
test 15653 or BS 7448-4 as appropriate
2. The number of test specimens will depend on the design basis and assessment level
used during the fitness-for-service evaluation and shall be agreed with the CIL
Engineering prior to Commencing testing. As a minimum, the following requirements
shall be met:
a) For a Level 1 and Level 2 deterministic assessment in accordance with BS 7910, or
as specified in the basis of design, a minimum of three valid test results are required to
represent each location (base metal, weld metal and HAZ as applicable)
b) The values obtained from these three specimens shall meet the requirements of
BS7910 with respect to scatter. Where the results do not meet these requirements an
additional number of test specimens shall be taken and the values from all the
specimens shall be included (not just the re-test values) in determining the acceptable
degree of scatter and where the results still do not comply with BS 7910 requirements
the test shall be considered invalid and the component rejected in accordance with
Section 6.2.11
c) For a Level 3 tearing instability assessment, a valid resistance curve representative
of each location (base metal, weld metal and HAZ as applicable) shall be determined.
The validity limits of these curves shall be determined in accordance with the
requirements of BS 7448-4
d) For wrought base components, specimens shall be through-thickness notched, taken
transverse to the direction of principal deformation (major rolling/forging direction)
e) For cast or hot isotactic pressed (HIP) base components, specimens shall be taken
transverse to the direction of maximum stress
f) For weld metals and HAZ, specimens shall be through-thickness notched, “NP” type
in accordance with ISO 15653
g) Test results in which ‘pop-in’ behavior is observed shall be subject to post-test
metallography to determine its significance
3. Where a repair weld is permitted, the following areas shall be tested as noted above:
● The repair weld metal
● The HAZ of the base material component and repair weld metal
● The HAZ of the original weld metal and repair weld metal
4. The test temperature shall be the lower of:

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● -10°C
● As specified in CIL Material Specifications
5. The following shall be subject to CIL Quality Authority approval:
a) The selection of non-standard fracture test specimens (such as shallow notch or
tension loaded)
b) The use of a probabilistic assessment in accordance with BS 7910
c) Fracture toughness testing of CRA components
6. A detailed procedure/methodology statement shall be supplied for CIL review
DWTT test (line pipe) 1. Testing shall be performed in accordance with the requirements of API 5L3
2. Two test specimens shall be taken from the body of the pipe (90° from the weld line in
welded pipe) and transverse to the direction of rolling
3. The test temperature shall be the lower of:
● 0°C
● As specified in CIL Material Specifications
4. Where the fracture face exhibits abnormal fracture, the analysis of the shear fracture
area shall be subject to agreement with the CIL Engineering
DWTT test (plates) 1. Testing shall be performed in accordance with the requirements of ASTM E208
2. Where the Vendor has previous qualification DWTT data demonstrating the nil ductility
transition temperature (NDTT) of material of equivalent thickness, two test specimens
shall be taken from a test coupon from each end of the thickest plate (four in total)
proposed for use, and each test specimen shall exhibit “no break” at the specified test
temperature
3. Where the Vendor has no previous qualification DWTT data demonstrating the NDTT
of material of equivalent thickness, sufficient test specimens shall be prepared and
tested to reliably determine the NDTT on the thickest plate proposed for use. Thereafter
the Vendor shall undertake the testing noted in 2. above to demonstrate that the NDTT is
at least 5°C lower than the specified test temperature
4. The test specimens shall comply with the following:

Hardness test 1. Testing shall be performed in accordance with the requirements in ASTM A370
(Rockwell C (HRC) or Brinell (HB)) or ISO 6057-1 (Vickers (HV))
2. The location for hardness indentations shall comply with the design code, component
material specification & the following:
a) For line pipe, the requirements in API 5L/ISO 3183, API 5LC or API 5LD as
applicable

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b) For components exposed to sour environments, the requirements in NACE

MR0175/ISO15156-2
(1)
Strain ageing 1. The strain applied to the test samples shall not be less than specified/predicted during
fabrication, installation or operation
2. For line pipe subject to reeling, the strain applied shall represent two full reeling cycles
(loading, unloading, straightening) in addition to any strain imposed during laying or
(2)
operation
3. Samples shall be aged at 250°C for one hour after straining
4. For line pipe only, a stress-strain curve shall be generated from the first three lots of
pipe for information only
Through-thickness
1. Testing shall be performed in accordance with the requirements in ASTM A770
SRTA tensile test
2. The longitudinal axis of the test specimens shall be orientated perpendicular to the
surface as follows:
a) For ingot cast plate, the test coupon shall be located on the ingot axis at the end of
the plate
b) For continuously cast plate, the test coupon shall be located either on the
longitudinal axis of the product or from approximately midway between the edge and the
c) For flanged sections, the test coupon shall be located at one end on the flange
unless the design imposes through-thickness strain on the web
3. The full plate thickness shall be contained within the uniform section of the specimen
with no taper permitted
HIC test 1. Testing shall be performed in accordance with Table B.3 of NACE
MR0175/ISO15156-2 and the following:
a) For component qualification purposes, the test environments shall be NACE TM0177
Environment A
b) For specific field application, the test environment shall be no less severe than the
predicted environment or the environment as measured during operations or from well
testing
c) The test solution shall be de-aerated to a maximum of 50ppb oxygen prior to starting
the test and maintained throughout
d) The pH shall be checked before and after testing to ensure that initial and final pH
values have been met within ±0.2 pH units
2. The test coupon shall be taken from the thinnest plate or finished component per each
lot
3. A specimen (or specimens) representing the full section thickness shall be polished
and etched to confirm the grain size specified in Section 7.4.1
4. Ultrasonic examination of test specimens to evaluate areas of cracking prior to
sectioning shall be undertaken during procedure qualification testing in accordance with
Section 7.1.3
5. The report shall meet the requirements of NACE TM0824 and shall include un-etched
photomicrographs of the samples before and after testing along with the polished and
etched photomicrographs
SSC test - ferritic 1. Testing shall be performed in accordance with Table B1 of NACE MR0175/ISO15156-
steels 2 and the following:
a) Four point bend specimens shall be used

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b) The test environment shall be selected to ensure that it is no less severe than the
testing
d) The pH shall be checked before and after testing to ensure that initial and final pH
2. Specimens from welded components shall be taken transverse to the weld centerline
and tested in the as-welded condition with the weld root face in tension
3. Each specimen shall be strain gauged using a bi-axial strain gauge centered on the
loading surface for base material samples or on either side of the weld for welded
samples
4. For components subject to straining, the test coupon shall be subject to the same
requirements noted above for strain ageing
5. On completion of testing, the samples shall be cleaned and subject to surface NDE
and visually examined at x10 and x40 magnification to evaluate for any surface cracking
or localised corrosion
6. In certain applications, a full pipe ring test may be specified by CIL. When applicable,
the details shall be agreed with the CIL Quality Authority prior to commencing testing
SCC/SSC test – CRAs 1. Testing shall be performed in accordance with Annex B of NACE MR0175/ISO15156-
3 and the following:
a) Four point bend specimens under constant displacement loading shall be used
b) The test environment shall be selected to ensure that it is no less severe than the
testing
d) The test shall be undertaken at 23°C±3°C and at the maximum design temperature.
For duplex shall be
e) The pH shall be checked before and after testing to ensure that initial and final pH
2. Specimens from welded components shall be taken transverse to the weld centerline
and tested in the as-welded condition with the weld root face in tension. For materials
that exhibit ‘cold creep’ (e.g. duplex stainless steel), the specimen may be machined if
this can be demonstrated to avoid strain relaxation
3. Each specimen shall be strain gauged using a bi-axial strain gauge centered on the
loading surface for base material samples or on either side of the weld for welded
samples
4. For components subject to straining, the test coupon shall be subject to the same
requirements noted above for strain ageing
5. On completion of testing, the samples shall be cleaned and subject to surface NDE
and visually examined at x10 and x40 magnification to evaluate for any surface cracking
or localised corrosion
6. In certain applications alternative test samples and loads may be specified by CIL
When applicable, the details shall be agreed with the CIL Quality Authority prior to
commencing testing

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Micrographic 1. Two specimens shall be selected from the same location as that selected for removal
examination- of mechanical and corrosion testing specimens
intermetallic precipitate 2. The sample area shall be a minimum of 10mm x 10mm and include the mid-thickness
determination in duplex area of the specimen
stainless steels
3. The specimens shall be mechanically or electro polished and etched using potassium
hydroxide, sodium hydroxide or oxalic acid solutions in accordance with ASTM E407.
Alternative etchants may be proposed that have been demonstrated to reveal the
relevant microstructural constituents and intermetallic precipitates of interest
4. The area shall be examined at a minimum x400 magnification
Ferrite determination – 1. Micrographic ferrite limits shall be determined in accordance with ASTM E562 on the
duplex & super duplex same prepared specimens used for the micrographic examination noted above
stainless steels 2. For welded specimens, the examination shall include the root, cap and mid-thickness
regions of the weld metal and HAZ
3. The specimens shall be examined at a magnification between x500-x1000 consistent
with resolving the microstructure without interference between adjacent grid lines and
constituent feature. A minimum of 30 random fields with 16 points per field is
recommended
Ferrite determination -
Ferrite Number (FN) limits shall be determined in accordance with the WRC-1992
300-series stainless
diagram or suitably calibrated magnetic instrument in accordance with AWS A4.2
steels
Pitting corrosion 1. Specimen preparation and test solution shall comply with the requirements of ASTM
Note E G48
Method A. A tolerance of ±10% for each dimension is acceptable; tolerances above this
limit are not permitted – in this case new samples shall be prepared
2. A minimum of two specimens from each test coupon shall be prepared for testing. For
pipe, tube and fittings, a full wall thickness specimen shall be used; for forgings and
castings, the specimens shall be taken from the same location on the test coupon as
other mechanical test samples
3. Specimens shall be prepared as follows:
a) Non-test surfaces shall be prepared to 1200 grit finish
b) Welded samples shall have the test face intact i.e. no grinding or polishing is
permitted
c) Specimens may be chemically cleaned using a 20% HNO3 + 5%HF solution
providing the specimens are left to stabilize for at least 24 hours prior to testing
d) Weighing of the specimens shall be to an accuracy of ±1mg or better
4. Each specimen shall be orientated in the test solution with its test face uppermost and
at an angle of approximately 45° to the vertical.
5. The temperature of the test solution shall be maintained to within ±0.5°C of the
specified value throughout the exposure period and shall be constant monitored by a
calibrated thermometer or thermocouple throughout the test
6. The duration shall be no less than 24 hours once the test solution reaches the
specified temperature value, allowing for the water bath, test solution and samples to
reach equilibrium
7. Examination and reporting shall meet the requirements of ASTM G48

DOCUMENT TITLE:
8. Any evidence of pitting above the specified limit on the non-test surfaces shall
invalidate that test specimen and an additional specimen shall be prepared and tested
Weldability testing 1. The test coupon shall be selected from the same grade and heat treatment condition
as the as-delivered component and shall be of sufficient length to provide all required
test specimens
2. The thickness of the test piece shall be the maximum thickness supplied (but need not
exceed 75mm) to provide similar heat conductive paths as will be experienced in
fabrication
3. The weld preparation shall be similar to that proposed during fabrication (unless a
square- edged test piece is required for fracture toughness testing of the HAZ)
4. The same welding process and consumables shall be used as proposed during
fabrication with the exception that SMAW and gas shielded flux cored arc welding
(FCAW-GS) may be interchanged providing the same heat input is used and the
essential and supplementary essential variables of the design code for each process are
met
5. The same preheat and PWHT (if applicable) conditions shall be used as proposed
during fabrication
6. The Crack Tip Opening Displacement (CTOD) method uses fatigue pre- cracked
specimens. The tests are carried out in displacement control with monotonic loading and
at a constant rate of increase in stress intensity factor within the range 0.5 – 3 MPa Ѵm
s-1 during the initial elastic deformation. The specimens are loaded to the maximum
force associated with plastic collapse. The method is especially appropriate to materials
that exhibit a change from ductile to brittle behavior with decreasing temperature. No
other influences of environment are covered. This test shall be conducted in line with
British Standard, BS 7448. Part 1-1991: Amendment 1: August 1999.Standards.
Notes:
1. HSLA line pipe steels may suffer strain ageing during coating with FBE – to demonstrate that there is no
deterioration in properties the test coupon shall be subject to the same heating cycle as proposed during coating
but without any imposed strain
2. Specific requirements will need to be developed on a case-by-case basis depending on the actual reeling cycle
and whether the load case is stress or strain based as this will affect the upper or lower bound tensile properties
and hence the result of a fracture assessment. These requirements shall be subject to agreement with CIL.
E. The requirements for the pitting corrosion test are based on the results of a sponsored project in which CIL took
part in and these have been summarised in a recommended practice document that is available from CIL
7.6.3 Components shall be tested during the manufacturing production in accordance with the design
code, component material specification and the following:
Component Number and location of test coupons Extent of testing

Plate and strip 1. One test coupon shall be prepared from each One set of tests for each plate
plate or coil or coil
2. The test coupon shall be subject to the specified
heat treatment for the plate

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Forging & HIP products 1. One test coupon shall be prepared from either: One set of tests for each lot to
a) a representative sacrificial forging represent a maximum lot of
b) a prolongation 2000kg for components with
c) a separately forged test blank from the same an as-forged weight ≤50kg or
heat, and of the same nominal thickness reduced 5000kg for components with
by forging in the same manner and by the same an as-forged weight >50kg
amount of working and number of reductions, as
the production forging (not permitted for special
forgings or where the finished section thickness
T>100mm)
d) an integrated test block (HIP products)
2. A sacrificial forging or integral prolongation shall
be used for die forged or ring rolled components
and for tees
3. The test coupon shall not be removed until after
the final heat treatment.
4. Unless otherwise specified in the design code,
test specimens shall be taken from the T/2xT
location for forgings with a maximum section
thickness T≤50mm and T/4xT for forgings with
section thickness T>50mm. Additional test
specimens in accordance with the above shall be
taken from the crotch region of special forged tees
for a second full set of tests
5. For special forgings, sketches shall be
established showing type, size and location of test
specimens
Casting 1. One test coupon shall be prepared from either: One set of tests for each lot to
a) a representative sacrificial casting represent a maximum lot of
b) a test block integrally cast or gated onto the 2000kg
casting
2. The test coupon shall not be removed from the
casting until after the final heat treatment
3. Unless otherwise specified test specimens shall
be taken from the T/4 x T/2 location
4. For special castings sketches shall be
established showing type, size and location of test
specimens
Fittings, pipe, tube One test coupon shall be prepared from a One set of tests for each lot
representative sacrificial component
(1)
Induction bends One test coupon shall be prepared from a test One set of tests per bend
bend manufactured to the smallest radius for each
NPS
Metallurgically bonded One test coupon shall be prepared from each plate One set of tests as for
(clad) components or forging as specified above plates/forgings as above
CRA-lined pipe One test coupon shall be prepared from a One set of tests for each lot
representative sacrificial pipe
Weld overlaid component One test coupon shall be prepared from a One set of tests for each lot
representative sacrificial component

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Notes: 1. If the results of mechanical testing from the test bend are considered acceptable then no further
destructive testing of the production bends will be required providing all the essential variables have been met
during production
7.6.4 Test coupons shall be sized to represent the thermal response of the component and large
enough to enable all required test samples to be obtained from a single coupon.
7.6.5 The method of removing a test coupon shall not influence the material properties i.e. if the test
coupon is removed by flame cutting, sufficient material shall be discarded to remove any heat
affected zone that would influence the final properties (such as strain ageing).
7.6.6 All test coupons shall be clearly identified and traceable back to the test lot/component.
7.6.7 Where further heat treatment is required or anticipated during subsequent fabrication, the
test coupon shall be subjected to a simulated heat treatment cycle (or cycles as appropriate) to
represent the maximum anticipated heat treatment applied during the fabrication to the following
materials:
• Conventional carbon steels with T>50mm;
• HSLA steels – all thickness’;
• Low alloy & nickel alloy steels with T>13mm.
7.6.8 Where tests from a sample fail to meet the acceptance criteria specified in the design code,
component material specification or, an additional two sets of test specimens shall be tested
unless otherwise noted in this guideline. If these additional specimens meet the acceptance
criteria, the representative lot shall be accepted; where they fail to meet the acceptance criteria
the representative lot shall be considered unacceptable and rejected in accordance with
Section 6.2.11.
7.7 Inspection Requirements
7.7.1 Components shall be inspected during manufacturing production in accordance with the design
code, component material specification and the following:
Test method (refer to Acceptance

Component Extent
‘Legend’ below) criteria
All (excluding Visual 100% coverage of surface of No cracks or planar
fasteners & each component imperfections (such as cold
gaskets/seals) laps/seams/shuts, slivers,
folds etc.)
No indentation, roll marks,
pitting, scratches/grooves
having a depth of 0.8mm or
10% of the minimum
permissible thickness
(whichever is less) extending
over no more than 10% of the
surface area of the
component.
CRA components shall be
free of scale and subject to
chemical treatment to remove
(1)
any weld or HAZ oxidation

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Seamless & EW 100% coverage of surface of Per code or product

tube 1 or 2 or 3
each tube specification
Per code or product
9 Each tube
specification
1% sample per lot (CRA tubes ±12.5% of specified limit for
10
only) major alloying elements
Seamless pipe 100% coverage of surface of
1 or 2 or 3 Per code or purchase order
each pipe
100% coverage of 150mm API 5L/ISO 3183 PSL-2
4 or 6 distance from each end on (carbon, HSLA & microalloyed
each pipe (line pipe only) steels) or API 5LC (CRA
materials)
100% coverage of 50mm
5 distance from each end on
each pipe (line pipe only)
7 or 8 distance from each end on
Per code or product
9 Each pipe
specification
1% sample per lot (CRA pipes ±12.5% of specified limit for
10
EW pipe 100% coverage of each weld Per code or product
1 or 2 or 3
on each pipe specification
materials)
7 or 8 distance from each end on
Per code or product
9 Each pipe length
specification
±12.5% of specified limit for
1% sample per lot (CRA pipes major
10
only)
alloying elements
Fusion welded pipe 100% coverage of weld length Per code or product
3
on each pipe specification
materials)
7 or 8 distance from each end - each
pipe (line pipe only)

DOCUMENT TITLE:
100% coverage of each repair

4 or 6 & 7 or 8 weld (where permitted by Per code or product
Section7.1.5) specification
9 Each pipe
1% sample per lot (CRA pipes ±12.5% of specified limit for
10
Metallurgically Inspection of pipe prior to cladding in accordance with requirements for specific pipe form
bonded (clad) pipe above
100% coverage of area within No unbounded area greater
50mm of pipe ends than 6.4mm in the
5
circumferential direction or
greater than 1% of the area
Following indications shall be
rejected: Round indications
with diameter above 2mm or
elongated indications
(indications separated by a
distance less than the
8 diameter or length of the
smallest indication, shall be
considered as one indication)
Accumulated diameters of
round indications in any
100mm length of weld greater
than 6mm
5&8 weld (where permitted by As noted above
Section 7.1.5)
Per code or product
9 Each pipe
specification
CRA-lined pipe
Inspection of pipe & liner prior to lining in accordance with requirements for specific pipe
form above
100% of weld overlay at pipe No unbounded area greater
ends than 6.4mm in the
5 circumferential direction or
greater than 1% of the weld
overlaid area
rejected: Round indications
with diameter above 2 mm or
elongated indications
(indications separated by a
distance less than the
8 diameter or length of the
smallest indication, shall be
considered as one indication)
Accumulated diameters of
round indications in any
100mm length of weld greater
than 6mm

DOCUMENT TITLE:

5&8 weld (where permitted by As above
Section7.1.5)
Per code or product
9 Each pipe
specification
Seamless pipe 100% coverage of accessible
fittings/flanges Per code or product
7or 8 surface of 10% of each
specification
heat/heat treatment lot
1% sample per lot (CRA ±12.5% of specified limit for

10
components only) major alloying elements
Welded pipe fittings 100% coverage of each weld

4 or 6
on each fitting
100% coverage of 10% of each
7 or 8 Per code or product
heat/heat treatment lot
specification
4 or 6 & 7 or 8 weld (where permitted by
Section7.1.5)
1% sample per lot (CRA ±12.5% of specified limit for

10
components only) major alloying elements
Pressure vessel Scanning on perpendicular grid ASTM A578, Level B or EN

plate (T≥6mm) - lines on 100 mm or closer 10160 S 2 E 1
non-sour centers or parallel paths on
5
environments 75mm centers transverse to
the major rolling axis on each
plate
Pressure vessel ASTM A578, Level C or EN
Scanning on perpendicular grid
plate (T≥6mm) - 10160 S 2 E 3
lines on 100 mm or closer
sour environments
centers or parallel paths on
5
75mm centers transverse to
plate
Metallurgically Scanning on perpendicular grid ASTM A578, Level B or EN
bonded (clad) lines on 100 mm or closer 10160 S 2 E 1
pressure vessel centers or parallel paths on
plate (T≥13mm) 75mm centers transverse to
plate prior to cladding
1. Scanning on perpendicular ASTM A264, Class 3 or ASTM
5 grid lines on 100 mm or closer 265 Class 3
centers or parallel paths on
the major rolling axis
2. Scanning of 100% of area
within 25mm distance from
each edge on each plate after
cladding

DOCUMENT TITLE:
Metallurgically Scanning on perpendicular grid

bonded (clad) lines on 100 mm or closer
pressure vessel centers or parallel paths on ASTM A578, Level C or EN
plate for heat 75mm centers transverse to 10160 S2E3
exchanger tube the major rolling axis on each
sheets (T≥13mm) plate prior to cladding
1. Scanning on perpendicular ASTM A264, Class 1 or ASTM
5 grid lines on 100 mm or closer 265 Class 1 with no loss of
centers or parallel paths on bond in the tube area
the major rolling axis
2. Scanning of 100% of area
within 25mm distance from
each edge on each plate after
cladding
Weld overlaid
forging or pipe Inspection of forging or pipe prior to weld overlay in accordance with requirements for the
specific component from
Equivalent acceptance criteria

to ASTM A264, Class 1 or
5 ASTM 265, Class 1 with no
100% coverage of weld overlay loss of bond in tube area for
heat exchanger tube sheets
8
100% coverage of each repair Per code or purchase order
8 weld (where permitted by
Section7.1.5)
Fixed jacket Scanning on perpendicular grid
structures plate lines on 200mm or closer
(T≥6mm) centers or parallel paths on ASTM A578, Level A or EN
5
100mm centers transverse to 10225
plate prior to cladding
Fixed jacket
structures rolled 100% coverage of each EN 10225 (ISO 10306 Class
5
sections (T≥12mm) section 2.1)
structures seamless lines on 200mm or closer
hollow sections centers or parallel paths on EN 10225 (ISO 10893-9 Level
5
100mm centers transverse to U3)
strip/plate
EN 10225 (ISO 10893-10
100% coverage of surface of
3 Level U4 or Level U2/C if
each section
used as primary member)

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structures welded lines on 200mm or closer
hollow sections centers or parallel paths on EN 10225 (ISO 10893-9 Level
5
100mm centers transverse to U3)
strip/plate
● EN 10225 (ISO 10893-2
Level E4 or;
100% coverage of weld length ● ISO 10893-3 Level F4 or;
1 or 2 or 3
on each section ● ISO 10893-11 Level U4 or
ISO 10893-11 Level U2/C if
used as primary members
Special forgings - 100% coverage of accessible Per code or product
feritic steels 7 or 8 surface of each forging specification
rejected:
● Any indications having
amplitudes above the
reference level
● Any indications having
amplitudes greater than 50%
(2) (2)(3) of the reference level and
5 or 6
which are clustered or that
travel in accordance with
ASTM A388
● Planar indications if they are
continuous over an area of
which the major dimension
exceeds 38mm, regardless of
amplitude
Each special low alloy or nickel ±12.5% of specified limit for
10
alloy forging major alloying elements
Special forgings – 100% coverage of accessible
CRA materials 8 surface of each forging Per code or purchase order
(2) (2)(3)
5 or 6 ASTM A745 Quality Level 2
±12.5% of specified limit for
10 Each special forging
major alloying elements
Special casting - all 100% coverage of accessible Per code or product
materials 7 or 8 surface of each casting specification
4
(for T≥80mm)
(2) (2)(3)
5 or 6
7 or 8 weld (where permitted by
Section7.1.5)
Each special CRA casting and ±12.5% of specified limit for
10 any repair weld (where major alloying elements
permitted Section 7.1.5)

DOCUMENT TITLE:
Fasteners Visual Per ASTM A962 Bolts & studs – all

environments/applications
excluding submerged
applications as per ASTM
A962
Bolts & studs - submerged
applications as per ASTM
A962
S54/ASTM F788
Nuts – all
environments/applications as
per ASTM A962
& ASTM F812
Dimensional 1. All dimensions shall meet
the requirements of the
component material
specification. No under-sizing
of bolt/stud threads or over-
sizing of nut threads is
ASME B18.18
permitted to accommodate
corrosion protection coating.
2. Nuts may be re-tapped
after application of corrosion
protection to ensure the
correct thread clearance
5% sample per lot for CRA ±12.5% of specified limit for
10 major alloying elements
fasteners
Gaskets/seals 100% coverage of surface of Per ASME B16.20
Visual
each component
5% sample per lot for CRA ±12.5% of specified limit for
10 major alloying elements
gaskets/seals fasteners
Legend:
1 In-line eddy current
2 In-line magnetic flux leakage
3 In-line ultrasonic testing
4 Radiography
5 Ultrasonic testing – straight beam
6 Ultrasonic testing - angle beam probe
(4)
7 Magnetic particle testing (for use on non-magnetic ferritic steels)
8 Liquid penetrant testing (for use on non-magnetic materials or where materials are
(5)
susceptible to magnetization e.g.9%Ni-alloy steels)
9 Hydrostatic testing
(6)
10 Positive material identification (PMI)
Notes:
1. Where the weld or HAZ oxidation is darker than light straw, chemical treatment is not permitted and in such
cases the weld shall be removed and the component re-welded
2. The thickness of the calibration block shall be within ±10% of the forging or casting reference thickness and
shall be made of the same material as the component or with similar acoustic attenuation properties

DOCUMENT TITLE:
3. An angle beam probe shall be used where the forging or casting configuration makes interpretation of
ultrasound signals from a straight beam probe difficult, or where specified by the code
4. Where magnetic particle testing is specified, the wet contrast method shall be used with electromagnetic yolk or
permanent magnet
5. Where liquid penetrant testing (PT) is specified, penetrant materials shall meet the requirements of
Paragraph T-625 of ASME V for sulphur and halogen content regardless of the type of material to be examined
6. All CRA components shall be subject to selective PMI programme at the source of supply or on component
receipt, unless a criticality risk assessment in accordance with CIL Guideline to demonstrates that the risk of
incorrect components supply is low
7.7.2 For components subject to procedure qualification testing in accordance with Section 7.1.2, all
NDE operators shall be certified in accordance with a scheme meeting the requirements of ISO
9712. For Vendors with NDE operators certified in accordance with ASNT SNT-TC-1A, only
schemes under the supervision of an ASNT Certified NDE Level III or ASNT ACCP Professional
Level III operator are acceptable in meeting the intent of ISO 9712.F
7.7.3 For components other than those in Section 7.1.2, NDE operators shall be certified in
accordance with SNT TC 1 A or alternatively with an ASNT SNT-ST-1A scheme under the
supervision of a Vendor certified Level III operator.
8.0 NON METALLIC MATERIALS
8.1 General Manufacturing Requirements
8.1.1 All components shall be new (less than one year from the date of manufacture).
The re-use of existing components for modifications or refurbishment of existing facilities is not
permitted.
8.1.2 Components shall be supplied from a single Vendor to ensure the design basis is consistent and
there is compatibility of components during subsequent fabrication. The selection of components
from different Vendors will require CIL Quality Authority approval.
8.2 Fibre Reinforced Composite Materials
8.2.1 For tubular components, fittings and flanges, a procedure qualification test programme in
accordance with ISO 14692 shall be undertaken as follows to demonstrate that the proposed raw
materials, manufacturing method and production parameters results in components meeting the
requirements of this guideline:
a) The manufacturer’s pressure rating (MPR) and threshold envelope for alternative sizes
and pressure ratings shall be determined;
b) All tests involving the use of internal pressure shall be conducted on components with
unrestrained ends (i.e. no axial load shall be applied to the ends).
c) The fluid used for the qualification programme shall be potable water. Previous Vendor
data using other water environments may be accepted providing the chloride content
does not exceed 35g/L;
d) Unless otherwise agreed with CIL, the qualification programme shall be based on a
design life of 20 years.
8.2.2 For load-bearing structural members, decks, gratings and stairs, a procedure qualification test
programme shall be undertaken to demonstrate that the load carrying capacity meets the

DOCUMENT TITLE:
minimum design requirements and that the proposed raw materials, manufacturing method and
production parameters results in components meeting the requirements of this guideline.
8.2.3 Components that are to be used in fire hazardous areas shall be qualified to demonstrate
acceptable performance as specified in the basis of design under the following service and
operating conditions:
a) Fire type (e.g. jet fire, hydrocarbon pool or impinging fire);
b) Process fluid (e.g. water, hydrocarbon gas or liquid);
c) Service flow condition (e.g. flowing, stagnant, dry or empty, dry or empty followed by
flowing conditions);
d) Integrity and endurance limits;
e) Surface spread of flame and heat release;
f) Smoke obscuration and toxicity;
8.2.4 Re-qualification is required when the essential variables noted below change:
a) Manufacturing method, winding angle greater than ±5°;
b) Generic resin/adhesive system or respective manufacturers;
c) Curing system chemistry, catalyst or respective manufacturers;
d) Curing time and/or temperature by more than ±20%;
e) Structural reinforcement material type or composition, finish or manufacturer;
f) Addition or deletion of additives, fillers or coatings specifically intended to enhance the
performance (e.g. conductivity, fire performance);
g) Geometry and dimensions outside of qualified threshold envelope.
8.2.5 The following specific manufacturing requirements are applicable for tubular components:
8.2.6 The following specific manufacturing requirements are applicable for all load- bearing
structural components, including gratings, stairs, handrails and cable trays:
8.2.7 Components shall be tested during manufacturing in accordance with the design code,
component material specification and the following:

DOCUMENT TITLE:
Component Test method Extent Acceptance criteria

Tubular Visual:
components
CRL 100% coverage of Blisters, chips, cracks, Not permitted
accessible surfaces crazing, dry spots, exposed
of 10% of each lot glass, exposed cut edges,
or once every four foreign matter, surface
hours (whichever is porosity, air bubbles
greater)
Pit/pinhole ≤3.0mm dia. x
0.5mm deep &
less than 1 pit per
100cm²
Mechanical damage, ≤0.20mm deep &
scratch or scores area less than
25mm²
Structural Cut or broken roving, dry Not permitted
layer & outer spot, fracture or rupture of
surface layer laminate, foreign matter,
incorrect lamination lay-up
and/or missing plies, impact
damage
Blisters ● Not permitted in
structural layer
● ≤6.0mm dia. in
surface layer
Burn/Discoloration No distortion
and/or burn
deeper than
surface resin
layer
Chip No exposed or
damaged fibres &
area less than
25mm²
Crack ● Not permitted in
structural layer
● ≤6.0mm length
in surface layer
Crazing at or under surface ≤25mm length in

layer surface layer
≤3.0mm dia. x
0.5mm deep &
Pinholes less than 1 pit per
100cm²

DOCUMENT TITLE:
(1)
Degree of 1% of each Measured Tg ±5% of Vendor’s baseline data
cure production lot or
once every 24 hours Barcol hardness greater than or equal to
(whichever is Vendor’s baseline data with no single reading
(2)
greatest) less than 90% of this baseline data
Glass ±6% of Vendor’s baseline data (filament wound)

content ±7.5% of Vendor’s baseline data (other
manufacturing methods)
Surface or ● ≤109 ohm (surface)
volume ● ≤105 ohm-m (volume)
resistivity
tests
Pressure test
For pipes Each pipe 1.5 x MPR for 2 hours minimum with no sign of
with leakage or weeping
prescribed
threaded
joints in
accordance
with
API15HR
For pipes 100% of the first
with other day’s production per
joints production lot or first
10 pipes (whichever
is less) and
thereafter 5% of
each production lot
Load-bearing Visual 100% coverage of Cut or broken roving, dry Not permitted
structural accessible surfaces spot, fracture or rupture of
components, of 10% of each lot laminate, incorrect
deck, gratings, or once every four lamination lay-up and/or
stairs, hours (whichever is missing plies, impact
handrails, greater) damage
cable trays
Blisters ≤6.0mm dia. x
1.5mm high
Chip No exposed or
damaged fibres &
area less than
50mm²
Crack, crazing at or under ≤25mm length in
surface layer surface layer
Pinholes ≤3.0mm dia. x
0.5mm
deep & less than
1 pit per 100cm²

DOCUMENT TITLE:
Notes:
1. Degree of cure shall be determined using either differential scanning calorimetry (DSC), modulated
differential scanning calorimetry (MDSC) or dynamic mechanical thermal analysis (DTMA) with the same
method as used during qualification used during production
2. For polyester and vinyl ester resin systems, Barcol hardness testing may be substituted for DSC,
MDSC or DTMA providing a minimum of ten readings are taken with the two highest and two lowest
reading discarded and the remaining six readings used to calculate an average reading. If Vendor
proposes this method, the hardness testing methodology shall be undertaken as part of the qualification
programme
8.2.8 Repairs are limited as follows and shall be subject to CIL. approval:
a) Not permitted to the CRL of tubular products nor structural layer of all components;
b) Grinding or cleaning and application of resin/hardener or CSM, is permitted for repair of
the surface layer;
c) Where permitted, an approved repair procedure, as recommended by the Vendor, shall
be used;
d) All repaired areas shall be recorded and re-inspected for compliance, and the inspection
reports included on the MTR or in final hand-over documentation.
8.2.9 The use of FRP components with inner/outer thermoplastic liners or steel strip laminate
components shall be subject to review and agreement by CIL Advance.
8.3 Thermoplastic Materials
8.3.1 A procedure qualification test programme shall be undertaken as follows to demonstrate
that the proposed raw materials, manufacturing method and production parameters results in
components meeting the requirements of this guideline:
Tubular components (pipes, fittings and

Requirements Seals
flanges)
Chemical resistance (ageing) tests in accordance

Required Required
w ith ISO 23936-1(1)
Slow crack propagation in accordance w ith ISO

Required Not required
13479
Rapid crack propagation in accordance w ith ISO

Required(2) Not required
13477 and ISO 13478
Notes:
1. Where the component w ill be exposed to production chemicals (such as corrosion or w ax inhibitors, glycols etc.) or w ell stimulation fluids, these shall be
included in the test environment
2. Only required for pipe w ith T≥15m. Where the Vendor has previous data from full scale testing in accordance w ith ISO 13478, small scale testing is acceptable in
accordance w ith ISO 13477
8.3.2 Re-qualification is required when any of the following essential variables change or once every
five years (whichever occurs first):

DOCUMENT TITLE:
a) A change of polymer manufacturer, polymerization process or chemical nature of co-

monomer;
b) Any change in the melt flow rate of greater than 20% or a change in the density of the
base polymer;
c) Any change in the manufacturing site for the base polymer;
d) Any change in the chemical nature or colour of pigment or increase of greater than 30%
in the pigment level;
e) Any change in the chemical nature, addition or deletion, or change in the level of greater
than 30% of additives other than pigments;
f) Any decrease greater than 30% or increase greater than 50% in the level of UV
stabilisers.
8.3.3 The following specific manufacturing requirements are applicable for tubular components
and seals:
Above ground applications Below ground

Requirements Seals
(including soil-air interface) applications
1. Components shall be manufactured by extrusion, injection moulding or transfer moulding

2. Components shall be manufactured from virgin compound or the Vendor’s own clean
rework (re- processable) compound, or a blend of both, and shall be from the identical
Manufacturing
thermoplastic base polymer
methods
3. The maximum amount of rework compound used during production shall not exceed the
level used during the procedure qualification test
4. Use of rework compound from other sources is not permitted
1. Only pre-compounded materials shall be used to ensure Only pre-compounded
complete and even dispersion throughout the component materials shall be used to
Additives ensure complete and even
2. Addition of additives at the pipe extruder is not permitted dispersion throughout the
component
UV stabilisation 1. For black coloured Not required(2) Not required
components, a minimum of 2%
carbon black shall be
incorporated into the pre-
compounded materials

DOCUMENT TITLE:
Above ground applications Below ground

Requirements Seals
(including soil-air interface) applications
2. For other coloured

components, or for marking
compounds, a minimum of
0.2% UV stabiliser shall be
added to the material or the
component shall be qualified to
demonstrate adequate
weathering characteristics
(≥350% elongation at break
after UV exposure)
Notes: 1. UV stabilisation is not required for below ground applications providing the storage requirements of Section
6.4.1 are met. If this cannot be confirmed at time of order, UV stabilisation shall be specified as for above ground
applications
8.3.4 Components shall be inspected in accordance with the Vendor’s internal QA/QC requirements
and the following:

Freedom from blisters, voids, cracking,
100% coverage of accessible dissolution, manufacturing debris or swarf
Visual
surfaces of 10% of each lot or Each component end shall be free from
once every four hours chips, burrs or rough edges
Dimensional (whichever is greater)
Per code and purchase order
measurement
Tubular components Additive dispersion Once per lot of compound
Colour
Tensile strength (at Per qualification data
1% of each production lot or
break, Elongation, E- once every 24 hours
Modulus (whichever is greatest)
Resistance to internal
No leaks, weeps or rupture
pressure
100% coverage of all surfaces
of 10% of each lot or once Freedom from blisters, voids, cracking,
Visual
every four hours (whichever is dissolution, manufacturing debris or swarf
greater)
Seals Dimensional
Per code and purchase order
measurement 1% of each production lot or
Volume change, Tensile once every 24 hours
strength (at break), (whichever is greatest) Per qualification data
Elongation, E- modulus
8.3.5 Repairs to component are not permitted.
8.4 Elastomeric Seals
8.4.1 A procedure qualification test programme shall be undertaken in accordance with ISO 23936-2 to
demonstrate that the proposed raw materials, manufacturing method and production
parameters results in components meeting the requirements of this guideline.

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8.4.2 In addition to the requirements of ISO 23936-2, the qualification programme shall also meet the
following requirements:
a) Where the component will be exposed to production chemicals (such as corrosion, scale
or wax inhibitors, glycols etc.) or drilling or well stimulation fluids, these shall also be
included in the test environment.
b) For flexible joints, where the component will potentially be exposed simultaneously to
production fluids/chemicals and seawater/air, and to cyclic fatigue, the qualification
programme shall be agreed with CIL
8.4.3 For RGD testing, the following additional requirements to those in ISO 23936-2 shall apply:
a) Where the standard test environment in ISO 23936-2 is less severe than the actual
service environment, the test environment shall be set at the maximum temperature,
pressure and rate of depressurisation expected in service;
b) A chemically aged specimen shall be included in the rapid gas decompression (RGD)
testing programme to demonstrate that the latter is not adversely affected by service
(unless the vendor has previous documented test data at the service conditions);
c) Where no previous documented data exists, samples shall be removed after the first and
third or fifth cycle of RGD testing to establish whether any damage is occurring;
d) Acceptance criteria for O-ring elastomers shall be as follows:
Environment Rating per Table B.4 of ISO 23936-2

Hazardous, extreme hazardous and high
1
pressure environments
All other environments 3
8.4.4 Re-qualification is required when any of the following essential variables change or once every
five years (whichever occurs first):
a) A change of base polymer manufacturer, curing system or post cure processing;
b) Any change in the manufacturing site for the base polymer;
c) Any change in the chemical nature of fillers, anti-degradents or plasticisers.
8.4.5 Components shall be inspected in accordance with the Vendor’s internal QA/QC requirements
and the following:

100% coverage of all surfaces
Freedom from blisters, voids, cracking,
Visual of 10% of each lot or once every
dissolution, manufacturing debris or swarf
four hours (whichever is greater)
All components Per code and component material
Dimensional measurement
1% of each production lot or specification
Hardness, Volume change, once every 24 hours (whichever
Tensile strength, Elongation is greatest) Per qualification data
(at break)

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8.4.6 Repairs are not permitted.
8.5 Non-metallic Gaskets
8.5.1 All gaskets and seals shall be compatible with the process fluid and flange material.
8.5.2 In addition to the requirements of ASME B16.21 reinforcement or filler material for gaskets shall
not contain asbestos.

CAIRN TSG Q GUI 0005 B1 Guideline For Material Inspection Requirements

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CAIRN TSG Q GUI 0005 B1 Guideline For Material Inspection Requirements

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TECHNICAL SERVICES GROUP

GUIDELINE FOR MATERIAL Rev B1

DOCUMENT NO: CAIRN-TSG-Q-GUI-0005 Page 2 of 47

Revision Date of issue Reason for change

A1 27.10.2015 Issued for Review

A2 19.11.2015 Issued for Review

B1 16.02.2016 Issued for Implementation

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3.0 DEFINITIONS & ABBREVIATIONS 5

5.0 ROLES AND RESPONSIBILITIES 11

6.0 GENERAL REQUIREMENT 11

7.0 METALLIC MATERIALS 17

8.0 NON METALLIC MATERIALS 39

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• Corrosion resistant alloys (CRAs)

• Fibre reinforced plastic composite (FRP) materials

• Thermoplastic materials (including seals)

• Elastomeric seal materials;

• Metallic and non-metallic gaskets

This guideline is applicable to both new construction activities and to in-service

b) For in-service modifications to, or refurbishment/replacement of, existing components

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3.0 DEFINITIONS & ABBREVIATIONS

• Carbon steels with carbon content of 0.12-0.25%

• Weldable HSLA or microalloyed steels with carbon content ≤0.12%

• Alloy steels with maximum nominal nickel content of 9%

• Martensitic stainless steels

• Weldable low carbon martensitic stainless steels

• Austenitic 300-series stainless steels

• High alloyed stainless steels (PREN ≥ 40 or (%Ni + (2x%Mo)), ≥ 30 with %Ni ≥ 2)

• Duplex & Super Duplex stainless steels

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Pitting Resistance Equivalent Number : PREN = (%Cr + 3.3(%Mo + 0.5%W) + 16%N)

Fibre reinforced plastic composite component : Composite component manufactured from a

Thermoplastic component : Refer to ISO 23936-1

Elastomeric seal component : Refer to ISO 23936-2

Critical Exposure Temperature :

• All components manufactured by the HIP process;

• Forged pressure vessel heads or shell strakes (all materials);

• Forgings meeting the requirements of FSL-4 in API 20C;

• Castings meeting the requirements of CSL-4 in API 20A;

• Forged flanges for service in high pressure environments (all materials);

• Forged or cast HSLA or microalloyed nodes for fixed jacket structures.

Rolled products : Pipe or fitting manufactured from plate or strip

Non-conductive fluid : Fluid with a conductivity less than or equal to 10000pS/m

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ISO 10893 series Non-destructive testing of steel tubes

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B16.49 Factory-Made, Wrought Steel, Butt Welding Induction Bends for

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H2S-containing Environments in Oil and Gas Production

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