FACILITIES ENGINEERING

FE TA - WORK PACK
ALP TURNAROUND

WORK PACK NUMBER: TAK-ALP-CNS-WKP-620439-308

WORK ORDER NUMBER: 620439

FACILITY: TAKULA - ALP

WORK DESCRIPTION:

WLI# 3.08 - Replace corroded section of line.

ASSIGNED TO: Piping

COMMENTS (Including VWR/IT#):

VWR-52338 - Remove clamp and replace section of line from GSM to ALP.

WP Rev. 0 Review / Approval

DRAFTED REVIEWED REVIEWED
FE WP ENG./ WRITER QA/QC. FE Construction
NAME BYVZ Shared: AFEQAC01
AFEQAC05 Shared: AFETKS
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DATE evron.com Date: 2015.01.01
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Work Pack No: TAK-ALP-CNS-WKP-620439-308
Field: Takula
Platform/Jacket: ALP FE TA - WORK PACK
Work order No: 620439
Visions WR/IT No: VWR-52338
MOC No: N/A
Work Description: WLI# 3.08 - Replace corroded section of line.

System: Equipment #: Area / Deck:

Drain 6"DH-A6-2125 Cellar Deck(ALP Bridge)

Index

1 Front Page X

2 Index X

3 Pre-Task & Resource Requirements X

4 Installation Process/ Job Steps by Phase X

5 Material List Estimation X

6 Equipment Requirements X

7 Drawings & Document Register X

a. Applicable Piping Classification / Line Class MR8 / A6 X

b. Fixed Equipment Arrangement Drawings N/A

c. Demolition Plan / Drawings N/A

d. P&ID (Marked as related item) X

e. Isometric X

f. Pipe Support Details X

g. Plot Plan (Marked as related item) X

h. E&I Drawings N/A

i. Standard Drawings N/A

8 Photographs Marked-up X

9 Inspection Task (IT) # N/A

10 Visions Work Request (VWR) # VWR- 52338 X

11 Quality Control Plan (QCP) # X

12 Management Of Change (MOC) # N/A

13 Datasheets / Procedure / Others # DBB Hydro. Procedure X

14 RFI Report Blank Form and Any Completed Reports N/A

15 Isolation Plan / Flushing Plan & LOTO to be provided by Operations X Refer to WP-3.05

16 Joint Integrity Record (JIR) X

Work Pack No: TAK-ALP-CNS-WKP-620439-308
Field: Takula
Platform/Jacket: ALP FE TA - WORK PACK
Work order No: 620439
Visions WR/IT No: VWR-52338
MOC No: N/A
Work Description: WLI# 3.08 - Replace corroded section of line.

System: Equipment #: Area / Deck:

Drain 6"DH-A6-2125 Cellar Deck(ALP Bridge)

Pre-Task Requirements
Work Permits
General Work: Hot Work: Open Hole: Confined Space: Lockout/Tag out: Others:
Yes X Yes X Yes Yes Yes X
No No No X No X No
Installation Operations Phase
X Scaffolding X Blow down X Pre-Shutdown
X Demolition X Hydrocarbon Removal X Shut Down
X Wind Protection X Gas/Vapor Release X Post-Shutdown
N/A Boat X Purge/Flush N/A Others
X Spreader Bar/Slings X Process Isolation
N/A Tuggers X LOTO Marked up P&ID
X Fire Protection N/A Others
N/A Crane

Contractor
X JSA X Welders Qualification N/A Others
X WPS N/A Rigging Plan N/A Others
X PQR N/A Lifting Plan N/A Others

Resource Requirements
Total hrs.
Contractor Discipline Man-power Man-hrs. Comments
(Estimation)
Scaffolder Required
Scaffold Foreman Required
Scaffold Inspector Required
Mech Inspector Required
Mech Foreman Required
Pipe Fitter Required
Instrument Technician
Rigger Required
Fire Watch Required
Welder Required
Vessel Cleaning F/man
Vessel Cleaner
Painter Required
Paint Foreman Required
Helper Required
Specialist
House Keeping
Draftsman
Insulator

Total: 0
Work Pack No: TAK-ALP-CNS-WKP-620439-308
Field: Takula
Platform/Jacket: ALP FE TA - WORK PACK
Work order No: 620439
Visions WR/IT No: VWR-52338
MOC No: N/A
Work Description: WLI# 3.08 - Replace corroded section of line.

System: Equipment #: Area / Deck:

Drain 6"DH-A6-2125 Cellar Deck(ALP Bridge)

Installation Process / Job Steps by Phase

Pre-Shutdown (Fabrication / Shop Timeline)
Steps Description of Activity
Fabricate/assemble pipe spools per Isometric Drawing. Line 6"-DH-A6-2125 (cutting, fit-up, welding, painting, etc.) as per
1
CABGOC Piping Fabrication Specification Rev. 8 (Painting to be performed according GS 2.02 general Specification).

Pre-Shutdown (Installation / Field Timeline)

Steps Description of Activity
1 Mobilize equipment and tools to designated location (tools, rigging equipment, safety equipment, etc.).
2 Prepare / Review JSA & work pack during pre-job safety meeting and secure required permits.
3 Erection of scaffolding.
Shutdown (Turnaround)
Steps Description of Activity
1 Review JSA and obtain Work Permits.
2 Isolate / LOTO per SCS Plan.
3 Temporary support 6" line .
4 Unbolt, cut, rig and remove pipe line highlighted in P&ID and photos.
5 Cold cut 6" line on T-011-07 & T-011-08. Note: Refer to Isometric, marked up P&ID and photo before cutting.
6 Perform beveling on T-011-07 & T-011-08 for welding. Ensure that a mechanical plug is inserted before beveling.
7 Weld 6" 150# flanges on T-011-07 & T-011-08 (refer to Isometric). Perform NDT as required.
Perform Hydrotest on T-011-07 & T-011-08 6" 150# flange using 6" Sch. 80 DBB Plug. Refer to DBB hydrotest Procedure. Note:
8 Hydrotest pressure for ANSI 150# = 450 psig. Hydrotest pressure shall be maintained for a minimum of 2 hours after stabilization
test period. Refer to CABGOC Piping Fabrication Specification, Rev. 8 (Section 8).
9 Clean and paint all pipe supports.
10 Install prefabricated piping spools in position.
11 Adjust spools as required and perform field welds on joints as per Isometric. Perform NDT as required.

Perform Spool hydrotest on site. NOTE: Hydrotest pressure for ANSI 150# = 450 psig. Hydrotest pressure shall be maintained for a
12
minimum of 2 hours after stabilization test period. Refer to CABGOC Piping Fabrication Specification, Rev 8 (Section 8).

13 Install required U-bolts.

14 Remove temporary supports.
15 Perform final bolting on T-011-07 & T-011-08.
16 De-isolate the line.
17 Final inspection with Ops & AIR Inspector.
18 QA/ QC & PSSR.
Post-Shutdown
Steps Description of Activity
1 Perform touch up painting as required per GS-2.02.
2 Removal of scaffolding.
3 Perform area clean-up and equipment de-mobilization.
Work Pack No: TAK-ALP-CNS-WKP-620439-308
Field: Takula
Platform/Jacket: ALP FE TA - WORK PACK
Work order No: 620439
Visions WR/IT No: VWR-52338
MOC No: N/A
Work Description: WLI# 3.08 - Replace corroded section of line.

System: Equipment #: Area / Deck:

Drain 6"DH-A6-2125 Cellar Deck(ALP Bridge)

Material List Estimation

Fabrication Materials
Item QTY Unit Description Stock No. PO Required
1 104' ea 6" PIPE, ASTM A106 Gr. B, SMLS, SCH 80

2 4 ea 6" ELL, 90 LR BW, ASTM A234 WPB, SCH 80

3 4 ea 6" FLG, RFWN 150LB, ASTM A-105, SCH 80

Installation Materials
Item QTY Unit Description Stock No. PO Required

1 2 ea 6" GASKET, 150LB RF, 304SS SPWND, FLEX GRAPH, FLEX. STYLE "CG" OR EQUAL

2 16 ea ¾" x 4 STUD BOLTS (6"-150LB RF) ASTM A193-B7M W/A194-2M NUTS, TEF. CTD

3 6 ea 6"NU BOLT w/ I-ROD ASSEMBLY

Isolation Materials
Item QTY Unit Description Stock No. PO Required

1 2 ea 6"x150# Slip Blind

2 6 ea 6" GASKET, 150LB RF, 304SS SPWND, FLEX GRAPH, FLEX. STYLE "CG" OR EQUAL

3 16 ea ¾" x 4 STUD BOLTS (6"-150LB RF) ASTM A193-B7M W/A194-2M NUTS, TEF. CTD

4 1 ea 3" Slip Blind

5 3 ea 3" GASKET, 150LB RF, 304SS SPWND, FLEX GRAPH, FLEX. STYLE "CG" OR EQUAL

6 4 ea ¾" x 4 STUD BOLTS (6"-150LB RF) ASTM A193-B7M W/A194-2M NUTS, TEF. CTD

6" GASKET, 150LB RF, 304SS SPWND, FLEX GRAPH, FLEX. STYLE "CG" OR EQUAL
7 4 ea
(for spectacle blind)

8 8 ea ¾" x 5 STUD BOLTS (6"-150LB RF) ASTM A193-B7M W/A194-2M NUTS, TEF. CTD
Work Pack No: TAK-ALP-CNS-WKP-620439-308
Field: Takula
Platform/Jacket: ALP FE TA - WORK PACK
Work order No: 620439
Visions WR/IT No: VWR-52338
MOC No: N/A
Work Description: WLI# 3.08 - Replace corroded section of line.

System: Equipment #: Area / Deck:

Drain 6"DH-A6-2125 Cellar Deck(ALP Bridge)
Equipment Requirements
Description QTY Description QTY
General Equipment Hydro-test Equipment
MMA Welding Machine 1 Hydro test Pump 1
Tig Welding Machine N/A Chart Recorder 1
Air Compressor CFM 150 1 Pressure Gauges 1
Air Compressor CFM 300 N/A Pressure relief valve for Hydro Test 1
Air Compressor CFM 400 N/A 2" Sch.80 DBB Plug 1
Set of Oxy & Acet Cutting Equipment 2
Cold Cut Saw 2 Lifting Equipment
Pipe Beveling Machine 1 2 Ton Chain Falls 2
Angle Grinders 4" 1 5 Ton Chain Falls N/A
Angle Grinders 7" N/A 10 Ton Chain Falls N/A
Torque Wrench 2 2 Ton Turfor N/A
Hydro torque Machine N/A 5 Ton Webbing Slings N/A
Flogging Spanners 2 3 Ton Webbing Slings 2
Fitters Tool Boxes 1 5 Ton Wire Slings N/A
Tool Container 1 3 Ton Wire Slings N/A
Tarpaulins N/A 10 Ton Wire Slings N/A
5 Ton Beam Clamps 1
10 Ton Beam N/A
Painting Equipment
Mini Blast Pot & Hoses 1
Paint Gun and Hoses 1 Scaffold Materials
Paint brush 1 TBA
Special Equipment / Others
PWHT Equipment N/A
Hot Tap Machine N/A

Drawings / Document Register

Drawing / Document No.
D-CAB-TAK-ALP--10-011
D-CAB-TAK-ALP-35-10-011
D-CAB-TAK-ALP-30-003
6"DH-A6-2125
VWR-52338
Pipe Class A6
DC2685 08/05
CAB-PIP-PLN-FE-00001-00
CAB-PIP-REC-FE-00001-00
Revision Drawings / Document Description
25 P&ID ALP-GSM Bridge
4 Demo P&ID ALP / GSM Bridge
7 Equipment Layout Cellar Deck
0 Isometric drawing
Replace corroded section of line
8 Piping Material Specification
5 Operating Procedures for Double Block and Bleed Plugs Hydrotesting
B02 QCP - Piping Quality Control Plan
B02 Joint Integrity Record
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vron.com Date: 2014.09.11 13:15:15
+01'00'
Note: This section of line replacement were
removed from Turnaround 2015 SOW. 11-Sep-14
 Digitally signed by
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removed from Turnaround 2015 SOW. 11-Sep-14 vron.com Date: 2014.09.11 13:15:07
+01'00'
 SUPERSEDED

ALP-Turnaround
3.08
 Digitally signed by cfrp, cfrp
cfrp, cfrp (SmartBadge)
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e) Date: 2015.02.18 07:36:00

+01'00'
 T
01 T
08 01
07
ALP-Turnaround
3.08
 Visions 4
Work Request
BLOCK0-TAK

Plant ID: TAK-ALP Equipment Type: Pipe

Equipment Number: 6"-DH-A6-2125 Equipment Name: Closed Drain Header to V-8050 & GS-Mike
ERP Number:
Equipment Classification: Equipment In Service: Yes
52338 Work Request
Memo No.: 52338 Replace section of line
Work Order Number: 492849 Memo Type: WR
Priority Code: P2 Job File No.:
Activity Code: REP Date Created: 6/20/2012
Component Code: Extent Partial
Inspector Name: Bert van der Heyden (bvbo) Department: Maint/Ops/Const.
ERP Notification Required:  Equipment or Component: Equipment
Notification Type: Repair Type: Replacement
Prob/Failure Code: ECORR Surface Prep.:
Cleaning Code: Access Required: Scaffold
Paint Code: Permit: Hot Work
Estimated Hours: Insulation Removal: 
Est. Labour Cost: Auditable: 
Est. Material Cost: Lighting Required: 
Actual Labour Cost: Sentry: 
Actual Hours: Stream: External (Off)
Actual Material Cost: Major Work: 
Management of Change:  Reason For Work: Failure or Damage
Degradation Method: Cause: External Corrosion
Completed By:
Scheduling Details
Status: Open Reason Closed:
Due Date: 8/22/2011 Date Completed/Closed: Calc Due Date:

Problem Description

Proposed Disposition

Work Description
Action To Date

Print Date: 6/20/2012

05/20/2009 Page 1 of 2
Report Criteria: Unit Id = 'BLOCK0-TAK', Plant = 'TAK-ALP', Equipment Type = 'Pipe', Equipment Number between '6"-DH-A6-2125 AND
6"-DH-A6-2125', Status = 'In Service', Memo No = '52338', Activity Code = 'REP', Priority Code = 'P2', Date Created between
'6/20/2012 AND 6/20/2012', Due Date between '8/22/2011 AND 8/22/2011', Status = 'Open', Stream = 'External (Off)', Type =
ALP-Turnaround
3.08
 Visions 4
Work Request
BLOCK0-TAK

Plant ID: TAK-ALP Equipment Type: Pipe

Equipment Number: 6"-DH-A6-2125 Equipment Name: Closed Drain Header to V-8050 & GS-Mike
ERP Number:
Equipment Classification: Equipment In Service: Yes
52338 Work Request
Memo No.: 52338 Replace section of line

Pre-Approvals
Auth. Inspector:  Pre AI Sign Off:
Engineering:  Pre Eng Sign Off:
Maintenance:  Pre Maint Sign Off:
Post Approvals
Auth. Inspector:  Post AI Sign Off:
Inspector:  Post Insp Sign Off:
Maintenance:  Post Maint Sign Off:

Print Date: 6/20/2012

05/20/2009 Page 2 of 2
Report Criteria: Unit Id = 'BLOCK0-TAK', Plant = 'TAK-ALP', Equipment Type = 'Pipe', Equipment Number between '6"-DH-A6-2125 AND
6"-DH-A6-2125', Status = 'In Service', Memo No = '52338', Activity Code = 'REP', Priority Code = 'P2', Date Created between
ALP-Turnaround '6/20/2012 AND 6/20/2012', Due Date between '8/22/2011 AND 8/22/2011', Status = 'Open', Stream = 'External (Off)', Type =

3.08
 Visions 4
Work Request
BLOCK0-TAK

Plant ID: TAK-ALP Equipment Type: Pipe

Equipment Number: 6"-DH-A6-2125 Equipment Name: Closed Drain Header to V-8050 & GS-Mike
ERP Number:
Equipment Classification: Equipment In Service: Yes
20478 Work Request
Memo No.: 20478 Permanent Repair to clamped section
Work Order Number: Memo Type: WR
Priority Code: P1 Job File No.:
Activity Code: RA Date Created: 7/26/2011
Component Code: Extent Partial
Inspector Name: Bert van der Heyden (bvbo) Department: Maint/Ops/Const.
ERP Notification Required: … Equipment or Component: Equipment
Notification Type: Repair Type: N/A
Prob/Failure Code: ECORR Surface Prep.:
Cleaning Code: Access Required: Scaffold
Paint Code: Permit: Hot Work
Estimated Hours: Insulation Removal: …
Est. Labour Cost: Auditable: ;
Est. Material Cost: Lighting Required: …
Actual Labour Cost: Sentry: …
Actual Hours: Stream: External (Off)
Actual Material Cost: Major Work: …
Management of Change: … Reason For Work: Failure or Damage
age
ge
Degradation Method: Cause: External Corrosion
ros
osion
Completed By:
Scheduling
Sch gDDetails
Status: Open Reason Closed:
Due Date: 8/5/2011 Date Completed/Closed: Calc Due Date
Cal Date:
te:

Work Event
Integrity Issue Log (IIL)
Problem Description
Line was VT/UT inspected in June 2010, with recommendation
ndation
nda to replace
replac fully
ll based
sed on external
corrosion. Line has subsequently been blasted & painted,
inte
nted, howe
however ha been observed on
everr one cclamp has
the bridge section between GSM & ALP. (bvbo)
Proposed Disposition
Remove clamp and execute sectional repairr to previous
vious leak
leak-location,
k-locat as per CABGOC piping
specification A6.
NB: Material must comply with NACE Standard MR-0
MR
MR-01-75
-75 (bvbo)
Work Description
Action To Date

Pre-Approvals
Auth. Inspector: ; Bert van
an der Heyden
eyden (bvbo)
bvbo)
b Pre AI Sign Off:
P 7/26/2011
Engineering: … Petra
ra
a Gordo
G Pre Eng Sign Off:
Maintenance: … Pre Maint Sign Off:
Post Approvals
Auth. Inspector: … Post AI Sign Off:
Inspector: … Post Insp Sign Off:
Maintenance: … Post Maint Sign Off:

Print Date: 7/26/2011

05/20/2009 Page 1 of 1
Report Criteria: Unit Id = 'BLOCK0-TAK', Plant = 'TAK-ALP', Equipment Type = 'Pipe', Equipment Number between '6"-DH-A6-2125 AND
6"-DH-A6-2125', Status = 'In Service', Memo No = '20478', Activity Code = 'RA', Priority Code = 'P1', Status = 'Open', Stream
ALP-Turnaround = 'External (Off)', Type = 'WR', Extent = 'Partial'

3.08
 6-DH-A1-2125
ALP-CC-008-010

Temporary clamp
fitted

ALP-Turnaround
3.08
 6-DH-A1-2125
ALP-CC-008-010

Active corrosion scaling

noted @ U-bolt and @
contact point between
pipe and pipe support.

PHOTO #3
ALP-Turnaround
3.08
 6-DH-A1-2125
ALP-CC-008-010
Active pitting noted.
Depth = 0.157"
Adj WT = 0.290"
Remaining WT = 0.133"

PHOTO #5
ALP-Turnaround
3.08
 6-DH-A1-2125
ALP-CC-008-010

Active pitting noted.

Depth = 0.157"
Adj WT = 0.285"
Remaining WT = 0.128"

PHOTO #6
 6-DH-A1-2125
ALP-CC-008-010

Active corrosion scaling noted

@ contact point between pipe
and pipe support.

PHOTO #7
ALP-Turnaround
3.08
 6-DH-A1-2125
ALP-CC-008-010

Active pitting noted.

Depth = 0.157"
Adj WT = 0.290"
Remaining WT = 0.133"

PHOTO #8
ALP-Turnaround
3.08
 6-DH-A1-2125
ALP-CC-008-010

Active pitting noted.

Depth = 0.157"
Adj WT = 0.260"
Remaining WT = 0.103"

PHOTO #9
ALP-Turnaround
3.08
 TAK-ALP-6"-DH-A6-2125
D-CAB-TAK-ALP-10-011, Circuit #: ALP-CC-008-010

General View 2 of 7

ALP-Turnaround
3.08
 TAK-ALP-6"-DH-A6-2125
D-CAB-TAK-ALP-10-011, Circuit #: ALP-CC-008-010

3 of 7

ALP-Turnaround
3.08
 TAK-ALP-6"-DH-A6-2125
D-CAB-TAK-ALP-10-011, Circuit #: ALP-CC-008-010

4 of 7

ALP-Turnaround
3.08
 TAK-ALP-6"-DH-A6-2125
D-CAB-TAK-ALP-10-011, Circuit #: ALP-CC-008-010

5 of 7

ALP-Turnaround
3.08
 TAK-ALP-6"-DH-A6-2125
D-CAB-TAK-ALP-10-011, Circuit #: ALP-CC-008-010

6 of 7

ALP-Turnaround
3.08
 Piping Material Specification
July, 2003 Rev 8
Cabinda Gulf Oil Company Limited

PIPING CLASSIFICATION: A6 - HYDROCARBON SERVICE (SOUR)

ANSI RATING: Class 150 RF All Material must comply with
CORROSION ALLOWANCE: 0.125 Inches NACE Standard MR-01-75
SERVICE: BD, BG, DH, FG, FL, GL, GU, P, SV, VG, W

½" to 42” ½", ¾" Sch 160

PIPE ASTM A106 Gr. B or API 5L Gr. B 1" to 8" Sch 80
Seamless 10" to 24" Std
Over 24" (Calculate wall thickness)
BRANCH CONNECTIONS- Refer to TABLE I.a

ELBOWS ½”, ¾", 1" 6000# Scr’d ASTM A105 (Instruments only- see note 2)
AND 1"-1½" 6000# SW, ASTM A105 (Process Piping- see note 1)
TEES 2" & Larger Buttweld, ASTM A234 WPB, Wall to match pipe
FITTINGS UNIONS ½", ¾", 1" 6000# SW, ASTM A105
THREDOLETS ½", ¾", 1"; 6000# ASTM A105 (Instruments only- see note 2)
SOCKOLETS 1"-1½"; 6000# ASTM A105 (Process Piping- see note 1)
WELDOLETS 2" & Larger; ASTM A105, Bore to match piping
PLUGS 1" & Smaller; Solid 316SS Hex Head NPT Plugs ASTM A182-F316

ANSI B16.5 1"-1½"; ANSI 150# RF SW (Process Piping- see note 1)

FLANGES
ASTM A105 2" & Larger; ANSI 150# RF WN, Bore to match piping
BOLTING- STUDS ASTM A193-B7M Stud Bolts w/A194-2M Nuts, Cadmium Bichromated
BOLTING-
ASTM A320-B8M 316 SS Cap Screws
CAPSCREWS
PROCESS TUBING 3 8 / " x 0.035 WT & ½" x 0.049 WT; 316 SS Seamless Tubing
TUBING FITTINGS Parker or Swagelok, 316 SS
GASKETS ANSI B16.20, 304SS Spiral Wound, Flexible graphite; Flexitallic style "CG" or equal

VB-30N (½"-1") MxF Preferred; VB-31N (½"-1") FxF Alternate

BALL VALVES
VB-50N (1"-1½"), VB-60N (2"-4"), VB-62N (6"-24")
GATE VALVES VG-42N (1"-1½"), VG-60N (2"-42"),
VG-90N (Thru Conduit 6"-42")
VALVES GLOBE VALVES VGL-42N (1"-1½"), VGL-60N (2"-8")
BUTTERFLY VALVES VBT-27N (8"-24")
CHECK VALVES VC-42N (1"-1½"), VC-60N (2"-4"), VC-61N (6"-24")
NEEDLE VALVES VN-45N (½"-¾") or VN-50N (½"-¾") Preferred - see note 3
VN-60N (½"-¾"), VN-30N (½"-¾")
Maximum Design Conditions: Notes:
Temperature: 200 °F 1) Use 1" and larger for Process and Utility Piping, Vent and Flare System
Pressure: -20 °F to 100 °F 285 psig Piping, Atmospheric and Pressurized Drain Lines.
150 °F 272 psig 2) Use ½", ¾", and 1" screwed piping for instrument connections only.
200 °F 260 psig 3) Use VN-45N in crude oil service, VN-50N in clean service.

ALP-Turnaround
3.08 Page 7 of 22
EST GROUP DC2685 08/05
REV 5 11/10
PAGE 1 OF 6
OPERATING PROCEDURES FOR DOUBLE BLOCK AND BLEED PLUGS - USA
WARNING!
PRESSURE TESTING IS INHERENTLY DANGEROUS. STRICT ADHERENCE TO THESE OPERATING INSTRUCTIONS
AND INDUSTRY SAFETY PRACTICES COULD PREVENT INJURY TO PERSONNEL.
ALL PERSONNEL MUST BE CLEAR OF TEST PLUG WHEN PRESSURE TESTING.
FOR SAFETY, AN INCOMPRESSIBLE LIQUID SUCH AS WATER SHOULD BE USED AS THE TEST MEDIUM.
RESIDUAL AIR OR GAS IS TO BE EVACUATED FROM THE PIPE PRIOR TO TESTING.

PRIOR TO INSTALLATION

1. Visually inspect the plug for worn or damaged components. Replace worn or damaged components as needed.

2. To insure that all installation torque is transmitted to the seal, liberally spread antiseize over both sides of the hardened
washer(s) and onto the threads of the shaft(s). Use caution when applying the lubricant and handling the test plug after
lubrication. The lubricant must not come in contact with the seals or tube ID.

WARNING! FAILURE TO USE ANTISEIZE MAY CAUSE AN INCOMPLETE TORQUE TRANSMITTAL, WHICH WILL
RESULT IN A DECREASE IN THE PRESSURE RATING.

3. Verify that stamping on the plug is equivalent to the pipe size being tested. The plug should be stamped with the pipe size
and pipe schedule. Example: The stamp “15P80” should be interpreted as 1-1/2” Sch 80 pipe sizes. The seal OD should
agree with the Plug OD listed in Tables 1 & 2 for the corresponding pipe size.

4. Complete Site safety standard checklist.

5. Prior to installing the plug, clean and dry the pipe ID. Remove all moisture, debris and excessive scale from the pipe ID.

6. Make Pressure and Upstream Monitor connections to plug.

6.1 Monitor connection: Connect pressure gauge leak tight to this connection to monitor upstream pressure (See Figure
1). Alternatively, upstream vapors may be vented by attaching approximately 50 ft. of hose to the port and locating
the end of the hose well downwind from the weld area. If upstream vapors are to be vented a tee fitting should be
used such that the hose and the pressure gauge are both connected to the monitor connection (See Figures 2 & 3).
6.2 Pressure connection: Connect pressure source to pressurize between seals for isolation and/or test purposes.

7. Install the plug so both seals are inside the pipe. When using the plug as an isolation and/or welding plug position the plug
so that the seals are at least 12” from the weld location. When testing the weld position the plug so that the seals straddle
the weld or area to be tested.

8. If the residual air between the seals must be removed the following technique may be implemented.

8.1. Ensure the port between the seals is at the six o’clock position.

8.2. Tighten the hex nut(s) on the plug until the plug is just snug in the pipe. At this point, the plug should barely be able to
slide within the pipe. Then apply slight pressure of the test medium until a small amount of medium escapes past the
seals. This technique will push the majority of the residual air out from between the seals.

TIGHTENING AND EXPANSION OF SEAL ELEMENT

9. Correctly tightening the hex nut(s) to the prescribed torque is critical to the operation of the Double Block & Bleed Plug. A
leak of the seal is usually an indication that the hex nut(s) was not adequately tightened. The normal torque values listed in
Tables 1 & 2 should be adequate for most installations, however due to variations within the pipe ID finishes the torque may
need to be increased up to the maximum torque values listed in Tables 1 & 2. If at the maximum torque the plug still leaks,
verify the correct seal and washers are being used, correct if necessary, reinstall and torque the plug in increasing
increments starting at the normal installation torque.

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For Sizes 3/4" to 3” (See Figures 1 & 2)
10. Tighten hex nut to normal installation torque listed in Table 1 using a calibrated torque wrench. If shaft spins while hex nut is
being tightened, a crowsfoot and a pipe wrench/opened end wrench must be used. After initial tightening it may be possible
to use a deep socket as the friction created when the seals contact the pipe ID will prevent the shaft from spinning during
further tightening of the hex nut. (See Table 1 for crowsfoot sizes.)

For Sizes 4” to 24” (See Figure 3)

11. Tighten the hex nuts by hand to remove any slack from the parts. Then use a socket wrench capable of producing the
torque value listed in Table 2. A socket is required (See Table 2 for socket sizes). Tightening the bottom hex nuts first will
aid in centering the plug. If the plug spins during tightening, remove the plug from the pipe. Then tighten the hex nuts to
expand the seal slightly and place the plug back into the pipe. This will create a larger contact/friction surface between the
plug and the pipe, which should stop the plug from rotating. Once the seals have fully contacted the pipe ID then the hex
nuts must be tightened in a star pattern. Complete installation by using a calibrated torque wrench to ensure that the hex
nuts have been tightened to the proper torque.

WARNING! FAILURE TO APPLY THE INSTALLATION TORQUE SPECIFIED IN TABLES 1 & 2 COULD RESULT IN
UNSAFE OPERATION OR LEAKAGE. INSTALLATION EQUIPMENT AND TOOL MUST BE ADEQUATELY SIZED TO
HANDLE INSTALLATION TORQUE.

NOTICE: IF THE PLUG IS INSTALLED FOR MORE THAN A FEW HOURS AT A TIME, THE SEALS MAY EXPERIENCE
PERMANENT SEAL DEFORMATION, WHICH WILL RESULT IN AN INCREASED SEAL OD. THE PLUG WILL STILL
FUNCTION AS DESIGNED AS LONG AS THE PLUG FITS INTO THE PIPE, HOWEVER EXTRA CARE SHOULD BE
TAKEN TO LIMIT INTERNAL WELD REINFORCEMENT TO PREVENT THE PLUG FROM BECOMING LODGED IN THE
PIPE.

PRESSURIZATION

12. Prior to pressurizing the system the operator should be aware of the following.

12.1 During pressurization there may be some settling of the plug. If at any time during pressurization or testing the test
plug moves more than a total of .125” (3mm) the test must be halted and the pressure released immediately. The
test plug and pipe ID should be inspected for damage, and the installation procedure should be reviewed prior to
reinstalling the plug and retesting. If the situation continues please contact EST Customer Service for technical
assistance.

12.2 During pressurization and testing all personnel should remain clear of the test plug and immediate test area.

WARNING! CONSTANTLY MONITOR UPSTREAM PRESSURE. IMMEDIATELY DISCONTINUE WORK IF AN

INCREASE IN UPSTREAM PRESSURE OCCURS.

13. Slowly introduce the test pressure. If a pressure decay test will be conducted, it may be necessary to hold at desired
pressure with pump for a minimum of 5 minutes prior to closing isolation valve. This will allow parts to settle. Do not exceed
the maximum test pressure listed in Tables 1 & 2.

PLUG REMOVAL

14. After isolation or testing application is complete, insure all back pressure is released from pipe.

15. Relax the seal by loosening the hex nut(s). Ensure to loosen hex nut(s) until the top of the nut is at the top of the threads.
This will prevent permanent seal deformation. When removing plugs with multiple shafts loosen the hex nuts incrementally,
using the standard bolting pattern so that the load continues to be distributed over all of the shafts.

16. Withdraw the plug from the tube end.

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Figure 1. Double Block & Bleed, ¾” to 1 ¼” Plug Sizes

Figure 2. Double Block & Bleed, 1 ½” to 3” Plug Sizes

Figure 3. Double Block & Bleed 4” to 24” Plug Sizes

(If this multi-shaft configuration does not meet the design configuration of your plug, please contact the factory)

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INSPECT PLUG AFTER EACH USE

17. Inspect the plug for wear and replace any worn components. Any component, which is worn or damaged, must be replaced
before attempting any further testing. Contact the factory for additional information on the replacement of worn or damaged
parts.

WARNING! FAILURE TO REPLACE WORN OR DAMAGED COMPONENTS MAY AFFECT THE ABILITY OF THE PLUG
TO HOLD PRESSURE AND MAY CAUSE INJURY OR DAMAGE TO PERSONS OR PROPERTY IN THE TEST AREA.

18. Prior to storing, clean and dry the plug. Re-lubricate the shaft threads and between the hex nut and mating surface as
previously described.

19. Store plug in an area out of contact with sun or UV light. UV light will damage and prematurely age the seal elements.

Table 1. Double Block & Bleed Installation Torque Specifications, Sizes 3/4" to 3”

Clearance Normal Maximum Maximum

Distance Crow- Maximum
Nominal Between Install. Install. Pressure
Sales Part Plug OD Length Between foot Upstream
Plug SCH Plug & Torque Torque Between
Number [in (mm)] [in (mm)] Seals Size Pressure
Size Pipe [ft-lbs [ft-lbs Seals
[in (mm)] (in) [psi (Bar)]
[in (mm)] (N-m)] (N-m)] [psi (Bar)]
DBB-75P80 3/4" 80 0.65 (16.5) 0.09 (2.3) 23-1/2 (597) 1.50 (38) 2.5 (3.4) 5.0 (6.8) 7/16 2250 (155) 10 (0.7)
DBB-75P10 3/4" 10 0.78 (19.8) 0.10 (2.5) 23-1/2 (597) 1.50 (38) 4.0 (5.4) 7.0 (9.5) 7/16 2250 (155) 10 (0.7)
DBB-1PXXS / 1” XXS 0.06 (1.5)
0.54 (13.7) 21-1/2 (546) 1.25 (32) 1.5 (2.0) 3.0 (4.1) 7/16 2250 (155) 10 (0.7)
75P160 3/4" 160 0.07 (1.8)
DBB-1P160 / 1” 160
0.72 (18.3) 0.10 (2.5) 23-1/2 (597) 1.50 (38) 3.5 (4.7) 6.5 (8.8) 7/16 2250 (155) 10 (0.7)
75P40 3/4" 40
DBB-1P80 1” 80 0.84 (21.3) 0.12 (3.0) 23-1/2 (597) 1.50 (38) 4.0 (5.4) 7.0 (9.5) 7/16 2250 (155) 10 (0.7)
DBB-1P40 1” 40 0.93 (23.6) 0.12 (3.0) 23-1/2 (597) 1.50 (38) 5.0 (6.8) 7.0 (9.5) 7/16 2250 (155) 10 (0.7)
DBB-1P10 1” 10 0.98 (24.9) 0.12 (3.0) 23-1/2 (597) 1.50 (38) 5.0 (6.8) 7.5 (10.2) 7/16 2250 (155) 10 (0.7)
DBB-125P160 1-1/4" 160 1.01 (25.7) 0.15 (3.8) 24-3/4 (629) 1.50 (38) 8.0 (10.8) 12 (16.3) 1/2 2250 (155) 10 (0.7)
DBB-125P80 1-1/4" 80 1.13 (28.7) 0.15 (3.8) 24-3/4 (629) 1.50 (38) 10 (13.6) 13 (17.6) 1/2 2250 (155) 10 (0.7)
DBB-125P40 1-1/4" 40 1.23 (31.2) 0.15 (3.8) 24-3/4 (629) 1.50 (38) 11 (14.9) 14 (19.0) 1/2 2250 (155) 10 (0.7)
DBB-125P10 1-1/4" 10 1.29 (32.8) 0.15 (3.8) 24-3/4 (629) 1.50 (38) 12 (16.3) 14 (19.0) 1/2 2250 (155) 10 (0.7)
DBB-15P160 1-1/2” 160 1.19 (30.2) 0.15 (3.8) 27 (686) 2.50 (64) 15 (20) 20 (27) 3/4 2250 (155) 10 (0.7)
DBB-15P40 1-1/2” 40 1.46 (37.1) 0.15 (3.8) 27 (686) 2.50 (64) 15 (20) 20 (27) 3/4 2250 (155) 10 (0.7)
DBB-2PXXS / 2” XXS
1.35 (34.3) 0.15 (3.8) 27 (686) 2.50 (64) 15 (20) 20 (27) 3/4 2250 (155) 10 (0.7)
15P80 1-1/2” 80
DBB-2P160 / 2” 160 0.16 (4.1)
1.53 (38.9) 27 (686) 2.50 (64) 20 (27) 30 (41) 3/4 2250 (155) 10 (0.7)
15P10 1-1/2” 10 0.15 (3.8)
DBB-2P80 2” 80 1.76 (44.7) 0.18 (4.6) 28-1/2 (724) 2.50 (64) 30 (41) 50 (68) 7/8 2250 (155) 10 (0.7)
DBB-2P40 2” 40 1.89 (48.0) 0.18 (4.6) 28-1/2 (724) 2.50 (64) 30 (41) 50 (68) 7/8 2250 (155) 10 (0.7)
DBB-2P10 2” 10 1.98 (50.3) 0.18 (4.6) 28-1/2 (724) 2.50 (64) 35 (47) 60 (81) 7/8 2250 (155) 10 (0.7)
DBB-25P160 2-1/2" 160 1.95 (49.5) 0.18 (4.6) 28-1/2 (724) 2.50 (64) 35 (47) 60 (81) 7/8 2250 (155) 10 (0.7)
DBB-25P40 2-1/2" 40 2.29 (58.2) 0.18 (4.6) 29 (737) 2.50 (64) 60 (81) 90 (122) 1-1/4 2250 (155) 10 (0.7)
DBB-3PXXS / 3” XXS 0.17 (4.3)
2.13 (54.1) 29 (737) 2.50 (64) 60 (81) 90 (122) 1-1/4 2250 (155) 10 (0.7)
25P80 2-1/2” 80 0.19 (4.8)
DBB-3P160 3” 160 0.17 (4.3)
2.46 (62.5) 33-5/8 (854) 2.50 (64) 100 (136) 150 (203) 1-13/16 2250 (155) 10 (0.7)
25P10 2-1/2” 10 0.18 (4.6)
DBB-3P80 3” 80 2.69 (68.3) 0.21 (5.3) 33-5/8 (854) 2.50 (64) 150 (203) 200 (271) 1-13/16 2250 (155) 10 (0.7)
DBB-3P40 3” 40 2.86 (72.6) 0.21 (5.3) 33-5/8 (854) 2.50 (64) 150 (203) 200 (271) 1-13/16 2250 (155) 10 (0.7)
DBB-3P10 3” 10 3.04 (77.2) 0.22 (5.6) 33-5/8 (854) 2.50 (64) 175 (237) 250 (339) 1-13/16 2250 (155) 10 (0.7)

Note: For plugs that require torques greater than 91 ft-lbs a high strength crowfoot may be required. EST Group does offer
high strength crowfoot wrenches. Please contact the factory with any inquires.

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Table 2. Double Block & Bleed Installation Torque Specifications, Sizes 4” to 24”

Clearance Normal Maximum Maximum

Distance Deep Maximum
Nominal Between Install. Install. Pressure
Sales Part Plug OD Length Between Socket Upstream
Plug SCH Plug & Torque Torque Between
Number [in (mm)] [in (mm)] Seals Size Pressure
Size Pipe [ft-lbs [ft-lbs Seals
[in (mm)] [in] [psi (Bar)]
[in (mm)] (N-m)] (N-m)] [psi (Bar)]
DBB-4PXXS 4” XXS 3.00 (76.2) 0.15 (3.8) 6-1/2 (165) 3-1/2 (89) 10 (14) 15 (20) 9/16 2250 (155) 10 (0.7)
DBB-4P160 4” 160 3.29 (83.6) 0.15 (3.8) 6-1/2 (165) 3-1/2 (89) 15 (20) 25 (34) 9/16 2250 (155) 10 (0.7)
DBB-4P120 4” 120 3.48 (88.4) 0.15 (3.8) 6-1/2 (165) 3-1/2 (89) 20 (27) 30 (41) 9/16 2250 (155) 10 (0.7)
DBB-4P80 4” 80 3.63 (92.2) 0.20 (5.1) 6-1/2 (165) 3-1/2 (89) 20 (27) 30 (41) 11/16 2250 (155) 10 (0.7)
DBB-4P40 4” 40 3.83 (97.3) 0.20 (5.1) 6-1/2 (165) 3-1/2 (89) 20 (27) 30 (41) 11/16 2250 (155) 10 (0.7)
DBB-4P10 4” 10 4.06 (103.1) 0.20 (5.1) 6-1/2 (165) 3-1/2 (89) 20 (27) 30 (41) 11/16 2250 (155) 10 (0.7)
DBB-6P160 6” 160 4.99 (126.7) 0.20 (5.1) 9 (229) 4 (102) 70 (95) 110 (149) 1-1/16 2250 (155) 10 (0.7)
DBB-6P120 6” 120 5.30 (134.6) 0.20 (5.1) 9 (229) 4 (102) 80 (109) 120 (163) 1-1/16 2250 (155) 10 (0.7)
DBB-6P80 6” 80 5.56 (141.2) 0.20 (5.1) 9 (229) 4 (102) 80 (109) 130 (176) 1-1/16 2250 (155) 10 (0.7)
DBB-6P40 6” 40 5.87 (149.1) 0.20 (5.1) 9 (229) 4 (102) 90 (122) 140 (190) 1-1/16 2250 (155) 10 (0.7)
DBB-6P10 6” 10 6.16 (156.5) 0.20 (5.1) 9 (229) 4 (102) 90 (122) 140 (190) 1-1/16 2250 (155) 10 (0.7)
DBB-8P160 8” 160 6.56 (167) 0.25 (6.4) 9-3/4 (248) 4 (102) 125 (169) 200 (271) 1-7/16 2250 (155) 10 (0.7)
DBB-8PXXS 8” XXS 6.63 (168) 0.25 (6.4) 9-3/4 (248) 4 (102) 125 (169) 200 (271) 1-7/16 2250 (155) 10 (0.7)
DBB-8P140 8” 140 6.75 (171) 0.25 (6.4) 9-3/4 (248) 4 (102) 125 (169) 200 (271) 1-7/16 2250 (155) 10 (0.7)
DBB-8P120 8” 120 6.94 (176) 0.25 (6.4) 9-3/4 (248) 4 (102) 125 (169) 200 (271) 1-7/16 2250 (155) 10 (0.7)
DBB-8P100 8” 100 7.19 (183) 0.25 (6.4) 9-3/4 (248) 4 (102) 125 (169) 200 (271) 1-7/16 2250 (155) 10 (0.7)
DBB-8P80 8” 80 7.38 (187) 0.25 (6.4) 9-3/4 (248) 4 (102) 150 (203) 225 (305) 1-5/8 2250 (155) 10 (0.7)
DBB-8P60 8” 60 7.56 (192) 0.25 (6.4) 9-3/4 (248) 4 (102) 175 (237) 250 (339) 1-5/8 2250 (155) 10 (0.7)
DBB-8P40 8” 40/STD 7.73 (196) 0.25 (6.4) 9-3/4 (248) 4 (102) 175 (237) 250 (339) 1-5/8 2250 (155) 10 (0.7)
DBB-8P20 8” 20 7.88 (200) 0.25 (6.4) 9-3/4 (248) 4 (102) 175 (237) 250 (339) 1-5/8 2250 (155) 10 (0.7)
DBB-8P10 8” 10 8.08 (205) 0.25 (6.4) 9-3/4 (248) 4 (102) 175 (237) 250 (339) 1-5/8 2250 (155) 10 (0.7)
DBB-10P100 10” 100 9.06 (230) 0.25 (6.4) 9-3/4 (248) 4 (102) 200 (271) 275 (373) 1-5/8 2250 (155) 10 (0.7)
DBB-10P80 10” 80 9.31 (236) 0.25 (6.4) 9-3/4 (248) 4 (102) 200 (271) 275 (373) 1-5/8 2250 (155) 10 (0.7)
DBB-10PXS 10” 60/XS 9.50 (241) 0.25 (6.4) 9-3/4 (248) 4 (102) 200 (271) 275 (373) 1-5/8 2250 (155) 10 (0.7)
DBB-10P40 10” 40/STD 9.77 (248) 0.25 (6.4) 9-3/4 (248) 4 (102) 225 (305) 300 (407) 1-5/8 2250 (155) 10 (0.7)
DBB-10P10 10” 10 10.17 (258) 0.25 (6.4) 9-3/4 (248) 4 (102) 225 (305) 300 (407) 1-5/8 2250 (155) 10 (0.7)
DBB-12P80 12” 80 11.00 (279) 0.38 (9.7) 9-3/4 (248) 4 (102) 200 (271) 250 (339) 1-5/8 2250 (155) 10 (0.7)
DBB-12P40 / 40 0.32 (8.1)
12” 11.62 (295) 9-3/4 (248) 4 (102) 225 (305) 275 (373) 1-5/8 2250 (155) 10 (0.7)
12PSTD STD 0.38 (9.7)
DBB-14P80 14” 80 12.12 (308) 0.38 (9.7) 10-1/4(260) 4-1/2 (114) 225 (305) 275 (373) 1-5/8 2250 (155) 10 (0.7)
DBB-14P40 14” 40 12.74 (324) 0.38 (9.7) 10-1/4(260) 4-1/2 (114) 225 (305) 275 (373) 1-5/8 2250 (155) 10 (0.7)
DBB-14PSTD 14” 30/STD 12.87 (327) 0.38 (9.7) 10-1/4(260) 4-1/2 (114) 225 (305) 275 (373) 1-5/8 2250 (155) 10 (0.7)
DBB-16P80 16” 80 13.93 (354) 0.38 (9.7) 10-1/4(260) 4-1/2 (114) 200 (271) 250 (339) 1-5/8 2250 (155) 10 (0.7)
DBB-16P40 16” 40/XS 14.62 (371) 0.38 (9.7) 10-1/4(260) 4-1/2 (114) 225 (305) 275 (373) 1-5/8 2250 (155) 10 (0.7)
DBB-16PSTD 16” 30/STD 14.87 (378) 0.38 (9.7) 10-1/4(260) 4-1/2 (114) 250 (339) 300 (407) 1-5/8 2250 (155) 10 (0.7)
DBB-18P80 18” 80 15.74 (400) 0.38 (9.7) 10-1/4(260) 4-1/2 (114) 250 (339) 300 (407) 1-5/8 2250 (155) 10 (0.7)
DBB-18P40 18” 40 16.50 (419) 0.38 (9.7) 10-1/4(260) 4-1/2 (114) 250 (339) 300 (407) 1-5/8 2250 (155) 10 (0.7)
DBB-18PSTD 18” STD 16.87 (428) 0.38 (9.7) 10-1/4(260) 4-1/2 (114) 275 (373) 325 (441) 1-5/8 2250 (155) 10 (0.7)
DBB-20P80 20” 80 17.56 (446) 0.38 (9.7) 10-3/4(273) 4-1/2 (114) 225 (305) 275 (373) 1-5/8 2250 (155) 10 (0.7)
DBB-20P40 20” 40 18.43 (468) 0.38 (9.7) 10-3/4(273) 4-1/2 (114) 175 (237) 225 (305) 1-5/8 2250 (155) 10 (0.7)
DBB-20PSTD 20” 20/STD 18.87 (479) 0.38 (9.7) 10-3/4(273) 4-1/2 (114) 225 (305) 275 (373) 1-5/8 2250 (155) 10 (0.7)
DBB-24P80 24” 80 21.18 (538) 0.38 (9.7) 10-3/4(273) 4-1/2 (114) 275 (373) 325 (441) 1-5/8 2250 (155) 10 (0.7)
DBB-24P40 24” 40 22.24 (565) 0.38 (9.7) 10-3/4(273) 4-1/2 (114) 300 (407) 350 (475) 1-5/8 2250 (155) 10 (0.7)
DBB-24PSTD 24” 20/STD 22.87 (581) 0.38 (9.7) 10-3/4(273) 4-1/2 (114) 275 (373) 325 (441) 1-5/8 2250 (155) 10 (0.7)

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SEAL AND O-RING INSPECTION AND REPLACEMENT INSTRUCTIONS

INSPECTION

1. Seals should be inspected prior to testing and upon completion of testing.

2. Visually inspect seals for damage. Including cuts, scores, and deformations. Any seal damage that has the potential to
cause the plug to fail or leak should be addressed.

3. O-rings do not need to be inspected before and after each use, but if leakage or a pressure drop is noticed o-rings should be
inspected at that time and replaced as necessary.

4. O-rings are shown in Figures 1, 2, & 3 for reference. O-rings are designated by „ in the figures.

SEAL / O-RING REPLACEMENT - DISASSEMBLY

5. When disassembling plugs, be sure to keep track of assembly order. For all plugs start by removing the top hex nut(s) then
continue disassembly piece by piece, inspecting each piece as it is removed.

6. Occasionally a flathead screwdriver is required to remove seals. If this is the case be sure not to damage any components
while using the flathead screwdriver.

QUESTIONS? Contact EST Group Customer Service at any of the following locations with questions.
In USA and Canada: tel: 800-355-7044, fax: 215-721-1101, e-mail: est-info@curtisswright.com
In Europe: tel: +31-172-418841, fax: +31-172-418849; e-mail: est-emea@curtisswright.com
In Asia: tel: +65-6745-8560, fax: +65-6742-8700, e-mail: est-asia@curtisswright.com
On the Internet: http://estgroup.cwfc.com

EST Group is a business unit of Curtiss-Wright Flow Control Company. EST Group provides a complete range of repair products, services
and replacement parts covering the life cycle of tubular heat exchangers and condensers; additionally EST Group provides products and
services to facilitate pressure testing pipe, piping systems, pressure vessels and their components. Visit EST Group on the Internet at
http://estgroup.cwfc.com.

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 PIPING QUALITY CONTROL PLAN
CAB-PIP-PLN-FE-00001-00 Rev B02
FE CONSTRUCTION

Facility: Takula-ALP Work Order N°: 620439 Work Pack N°: TAK-ALP-CNS-WKP-620439-308
1
2 6"-DH-A6-2125 Rev 0 6"-DH-A6-2125 TAK-ALP-10-011 (Rev.25)
Isometric/
P&ID N° &
Drawing N° 3 Line N°:
Rev:
& Rev.
4
5
ISSUED BY (ASSET ENGINEER/AIR GROUP LEAD/OTHER)
Name: Shared E-mail: Dept/Position

H=HOLD / W=WITNESS / M=MONITOR / R=REVIEW / C/R=CERTIFICATE/REPORT REQUIRED

FE CONST. AIR
APPLICABLE CONTRACTOR
ITEM# TASK DESCRIPTION COMPLIANCE INSPECTOR INSPECTOR
YES/NO SIGN/DATE
SIGN/DATE SIGN/DATE

SECTION A: PRE-APPROVALS

Review Engineering requirements as per CABGOC Gen. Piping Spec H652-PCD-SPC-

1 YES H-R H-R
applicable Scope of Work / Work Order. 0001 Rev8/ASME B31.3/NACE MR0175

CABGOC Gen. Piping Spec H652-PCD-SPC-

2 Review QC requirements, YES H-R H-R
0001 Rev8/ASME B31.3/NACE MR0176

Review Approved WPS,PQR & Consumable

3 ASME IX YES H-C/R H-C/R
Test Certificates.

CABGOC Gen. Piping Spec H652-PCD-SPC-

4 Review Materials & Test Certifcates. YES H-R H-R
0001 Rev8/ASME B31.3/NACE MR0176

5 Review Calibration Certifcates. YES H-R H-R

Page 1 of 5
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3.08
 FE CONST. AIR
APPLICABLE CONTRACTOR
ITEM# TASK DESCRIPTION COMPLIANCE INSPECTOR INSPECTOR
YES/NO SIGN/DATE
SIGN/DATE SIGN/DATE

SECTION B: SHOP FABRICATION

Confirm all materials issued are in

CABGOC Gen. Piping Spec H652-PCD-SPC-
6 accordance with Specification. Perform PMI YES H-R H-R
0001 Rev8/ASME B31.3/NACE MR0176
on materials as specified, review report.

CABGOC Gen. Piping Spec H652-PCD-SPC-

7 Fabrication YES H-R H-R
0001 Rev8/ASME B31.3/NACE MR0176

Perform Visual & Dimensional Inspection on CABGOC Gen. Piping Spec H652-PCD-SPC-
8 YES H-R H-R
completion of fabrication, review report. 0001 Rev8/ASME B31.3/NACE MR0176

Perform PWHT (when applicable) & NDT as CABGOC Gen. Piping Spec H652-PCD-SPC-
9 YES H-R H-R
specified, review chart & reports. 0001 Rev8/ASME B31.3/NACE MR0176

Perform Baseline UT thickness surveys on

10 ASME V/Contractors NDE Technique sheets YES H-R H-R
spools & fittings.

Perform Pressure Testing and associated CABGOC Gen. Piping Spec H652-PCD-SPC-
11 YES H-R H-R
activities, review chart & reports. 0001 Rev8/ASME B31.3/NACE MR0176

12 Perform Coating, review report. GS 2.02 Rev 2 YES H-R H-R

SECTION C: INSTALLATION

Confirm installation as per specifications, CABGOC Gen. Piping Spec H652-PCD-SPC-

13 YES H-C/R H-C/R
review Joint Integrity Records. 0001 Rev8/ASME B31.3/NACE MR0176

Record Valve Serial ζ & Manufacturer on

14 YES H-C/R H-C/R
applicable isometric/drawing.

Perform PWHT (when applicable) & NDT on CABGOC Gen. Piping Spec H652-PCD-SPC-
15 YES H-C/R H-C/R
Tie-In Welds. 0001 Rev8/ASME B31.3/NACE MR0176

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 FE CONST. AIR
APPLICABLE CONTRACTOR
ITEM# TASK DESCRIPTION COMPLIANCE INSPECTOR INSPECTOR
YES/NO SIGN/DATE
SIGN/DATE SIGN/DATE

Perform Pressure Testing, review chart & CABGOC Gen. Piping Spec H652-PCD-SPC-
16 YES H-C/R H-C/R
reports. 0001 Rev8/ASME B31.3/NACE MR0176

Perform Coating to Tie-in Welds and/or any

17 mechanical damage to coating, review GS 2.02 Supp Rev 2 YES H-C/R H-C/R
report.

SECTION D: DOCUMENTATION

QCP CLOSE-OUT
AND ACCEPTANCE Forward complete copy of QC Close
QC Close Out/Work Pack Contents YES H-C/R H-C/R
(SHOP Out/Work Pack to assigned FE Foreman.
FABRICATION)

QCP CLOSE-OUT Forward complete copy of QC Close

AND ACCEPTANCE Out/Work Pack to the assigned Engineer (FE QC Close Out/Work Pack Contents YES H-C/R H-C/R
(INSTALLATION) Const. and/or AIR Group).

H = HOLD: This refers to a job step hold point for the assigned accountable person. The job cannot proceed past this point until the Job Step has been signed off by the assigned
accountable person.
W = WITNESS: This refers to a Job Step where the assigned accountable person must witness this Job Step and sign off.

M = MONITOR: This refers to the assigned accountable person who is responsible for monitoring the activity of job steps on a continuing basis. Where a QC/Nonconformance is
observed, the assigned accountable person has the authority to stop work. The assigned accountable person shall monitor this Job Step and sign off.

R = REVIEW: This refers to the review of completed documentation or job steps by the assigned accountable person. The assigned accountable person shall ensure that all required
sign off steps and documentation are in place and within the acceptance criteria. The assigned accountable person shall review the documentation and sign off.

C/R = CERTIFICATION/REPORT REQUIRED: This refers to the documentation required at the job step. Including, but not limited to the following: - NDT, PWHT, Pressure Test
and Painting reports.
Note: Where two requirements are indicated in a Job Step, both requirements shall be complied with. When referencing a specification, code or other, the reference should be
specific with the applicable revision. For example, the term ‘CABGOC Piping Spec.’ is not acceptable.

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3.08
SECTION A: PRE-APPROVALS
1) Review Engineering requirements as per applicable Scope of Work.
a. Copy of Work Pack/Work Order.
b. Copy of Visions Work Request/Inspection Report.
c. Outline of scope of work.
d. Copy of AFC Isometric & P&ID.
e. Copy of Line Class.
f. QCP
2) Review QC Requirements (applicable codes & specifications shall be referenced on the QCP).
a. Chevron Engineering Standard (CES) 3.03.
b. CABGOC General Piping Specification Rev 8.
c. ASME B31.3
d. ASME IX
e. NACE 0175
3) Review WPS, PQR, WQR & Consumable Test Certificates.
a. Copy of approved WPS.
b. Approved PQR shall be retained and filed by Contractor.
c. Approved WQR shall be retained and filed by Contractor.
d. Consumable Test Certificates shall be retained and filed by Contractor.
4) Review Materials & Test Certificates.
a. Material Test Certificates shall be retained and filed by Contractor.
5) Review Calibration Certificates.
a. Calibration Certificates shall be retained and filed by Contractor.
SECTION B: EXECUTION (SHOP FABRICATION)
6) Confirm all materials issued are in accordance with Specifications. Perform PMI on material as specified, review report.
a. Copy of Line Class
b. Copy of PMI Report (if applicable).
7) Fabrication.
a. Monitor Fabrication.
b. Verify Fabrication as per Line Class and Approved Isometric.
8) Perform Visual & Dimensional Inspection on completion of Fabrication, review report.
a. Verify dimensional tolerances & orientation.
b. Verify Visual Acceptance.
c. Copy of Visual Acceptance Report.
d. Copy of As-built (Red Lined) Isometric.

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9) Perform PWHT (as required) & NDT as specified, review chart & reports.
a. Copy of Pre-PWHT RT Report.
b. Copy of PWHT chart.
c. Copy of Post-PWHT RT Report.
d. Copy of DPI / MPI Report.
e. Copy of Hardness Testing Report.
f. Copy of Weld Map.
g. Copy of Weld History Record (WPS & Material Heat Numbers to be recorded).
10) Perform Baseline UT Thickness Surveys on spools & fittings, review report.
a. Copy of UT Report (one reading to be taken at a centralized location for all fabricated sections of spools, plus each elbow, reducer & T-piece).
b. Copy of Survey Map.
11) Perform Pressure Testing & Associated activities, review chart & reports.
a. Copy of Pressure Testing Report & Chart.
b. Copy of marked up As-built Isometric/P&ID showing Test Limits.
c. Copy of Flushing Report.
12) Perform Coating, review reports.
a. Copy of Coating Reports.
SECTION C: EXECUTION (INSTALLATION)
13) Confirm Installation as per specifications, review Joint Integrity Record.
a. Verify Installation as per Isometric, Piping Specification & Line Class.
b. Copy of Joint Integrity Record.
5HFRUG9DOYH6HULDOʋ 0DQXIDFWXUHURQDSSOLFDEOHLVRPHWULFGUDZLQJ
D9HULI\9DOYH6HULDOʋ 0DQXIDFWXUHUDUHUHFRUGHGRQWKHDSSOLFDEOHLVRPHWULFGUDZLQJ
15) Conduct PWHT & NDT on Tie-In Welds.
a. Copy of Pre-PWHT RT Report.
b. Copy of PWHT Chart.
c. Copy of Post PWHT RT Report.
d. Copy of DPI/MPI Report.
e. Copy of Hardness Testing Report.
f. For Golden Welds, requirements of WEM-SU-5246 shall be adhered to.
16) Perform Pressure Testing, review chart & reports.
a. Copy of Pressure Testing Report & Chart.
b. Copy of marked up P&ID showing Test Limits.
17) Perform Coating to Tie-In Welds and/or mechanical damage to coating, review reports.
a. Copy of Coating Reports.

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 JOINT INTEGRITY RECORD
CAB-PIP-REC-FE-00001-00 Rev B02
FE CONSTRUCTION
Facility Work Order N° Work Pack N° Isometric/Drawing N° Line N° P&ID N° & Rev. Sheet N°
TAK-ALP 620439 TAK-ALP-CNS-WKP-620439-308 6"-DH-A6-2125 Rev 0 6"-DH-A6-2125 TAK-ALP-10-011 (Rev.25)
Flange Bolt Torque Tension Operator
Gasket Lubricant
Joint ID Size Tool Serial N° Tool Serial N° Name Date
Qty Dia. Length Type/ Material Type/ Material Used
Rating Pass/% Value Pass/% Value Signature

CONTRACTOR CLIENT OTHER COMMENTS:

For flanges that have been tightened by slug wrench or other,
COMPANY the torque and tension sections shall be recorded as N/A.

POSITION

NAME

SIGNATURE

DATE
Page 1 of 2
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 JOINT INTEGRITY RECORD
CAB-PIP-REC-FE-00001-00 Rev B02
FE CONSTRUCTION
Note: Flanges that are torqued, tensioned or tightened by slug wrench or other, shall be recorded on the Joint Integrity Record, this also applies to Hot Bolting.

TIGHTENING SEQUENCE
Note: The exception to the following Tightening Sequence is for Hot Bolting, which shall be in accordance with the approved FE Hot Bolting Procedure.
To achieve an even bolt load around the flange and compress the gasket or seal in a uniform manner, therefore it is important to follow the correct tightening sequence for the flange
bolts that are being worked on. Tightening sequences shall be applied for each pass as follows:

1 1 1
8 9 16 9
8 5 8 5
12 5
12 13
4 3 4 3 4 3

6 11 14 11
6 7 6 7
10 7 10 15
2 2 2

For other flange sizes, the principle is the same. It is important to consider the tightening sequence prior to commencement of activities and the following steps help ensure that the
pattern is applied:
1) Using a paint ball marker or similar, number the bolts as shown above.
2) Follow the numbered sequence.
FLANGE, BOLTS & GASKETS (SPIRAL WOUND & RING TYPE)
Note: The exception to the following is for Hot Bolting, where the joint will not be dissembled for inspection or gasket replacement.
1) Sealing surfaces shall be free from deep pits, gouge marks, corrosion damage or excessive coinage.
2) Gaskets & Stud Bolts shall not be reused once a joint is broken. (Stud Bolts shall only be reused if recently replaced during Hot Bolting for Maintenance work)
3) Gasket & Stud Bolt material shall be verified to be in compliance with specified requirements prior to installation.

4) Flanges shall be evenly spaced and aligned correctly on completion of joint.

5) Bolts shall be long enough to ensure that all threads in the nut are engaged on completion of joint.
APPLICATION OF TORQUE
Note: The exception to the following is for Hot Bolting, where the torque shall be applied 100% at Stage 1 with a circular check pass.
The torque should be applied in the following sequence:
1) Stage 1 - 33% of final torque figure applied.
2) Stage 2 - 66% of final torque figure applied.
3) Stage 3 - 100%, final torque figure applied.
4) Stage 4 - A circular check pass.
For torque values and additional detailed requirements refer to Chevron Engineering Standard (CES) GEN-SU-5209.

Page 2 of 2
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Prepared By: Approved By: List Rev Date: Blind LIST
BU: BLOCK 0 Area: TAK-Takula Asset: ALP SYS #: Maintenance Supervisor:
WORK LIST No: WLI 3.08 EQUIPMENT: WLI 3.08 Replace corroded section line Impact Supervisor:
WORK ORDER No: SHUTDOWN: ALP 1Q 2015 TA Operations Coordinator:
TAG TRACKING VERIFICATION SECTION
Date Date Date Date Date

FRESH AIR
DESCRIPTION / LOCATION FLANGE

STAGING
Init Init Init Init Init
Purpose Type Product

REQ’D

REQ’D
TAG Hung BLIND IN BLIND OUT SIZE of of
NUMBER (in.) Rating Type Isolation Isolation System
Ops Ops FE Insp Ops FE Insp

WLI 3.08-01 Install 3" slip blind from Test & Prod. Sep. 3" Hot Work Blind Slip No No

This SD 3"-W-A1-1148 PID No: GSM-10-023

WLI 3.08-02 Swing closed 6" spectacle blind from flotation unit 6" Hot Work Blind No No
Spectacle
This SD 6"-VG-A6-2801 PID No: GSM-10-024A

Malongo DB Rev. 1.0 July 7, 2012 Print Date: Saturday, November 29, 2014 5:00:55 PM Pints to Tag MFG-4506-L Page 1 of 1
WP 3.08
WLI 3.08-02 Swing closed 6"
spectacle blind from flotation
unit
WLI 3.08-01 Install 3" slip
blind from Test & Prod. Sep.