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SBT EI Guidance - DRAFT 14-02-2022

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Guidelines for the design, installation and management of

small bore tubing assemblies

2nd 3rd edition- DRAFT 14-02-2022

2nd 3rd

edition

May

2013Feb

2022

As a Royal Charter organisation, the EI offers professional recognition and sustains personal career development through the
accreditation and delivery of training courses, conferences and publications and networking opportunities. It also runs a highly valued
technical work programme, comprising original independent research and investigations, and the provision of EI technical
publications to provide the international industry with information and guidance on key current and future issues.

The EI promotes the safe, environmentally responsible and efficient supply and use of energy in all its forms and applications. In fulfilling
this purpose the EI addresses the depth and breadth of energy and the energy system, from upstream and downstream
hydrocarbons and other primary fuels and renewables, to power generation, transmission and distribution to sustainable
development, demand side management and energy efficiency. Offering learning and networking opportunities to support career
development, the EI provides a home to all those working in energy, and a scientific and technical reservoir of knowledge for
industry.

This publication has been produced as a result of work carried out within the Technical Team of the EI, funded by the EI’s Technical
Partners. The EI’s Technical Work Programme provides industry with cost-effective, value-adding knowledge on key current and
future issues affecting those operating in the energy sector, both in the UK and internationally.

For further information, please visit http://www.energyinst.org

The EI gratefully acknowledges the ﬁnancial contributions towards the scientiﬁc and technical programme
from the following companies

BG Group Phillips 66
BP Exploration Operating Co Ltd Premier Oil
BP Oil UK Ltd RWE npower
Centrica Saudi Aramco
Chevron Scottish Power
ConocoPhillips Ltd Shell UK Oil Products Limited
Dong Energy Shell U.K. Exploration and Production Ltd
EDF Energy SSE
ENI Statkraft
E. ON UK Statoil
ExxonMobil International Ltd Talisman Energy (UK) Ltd
International Power Total E&P UK Limited
Kuwait Petroleum International Ltd Total UK Limited
Maersk Oil North Sea UK Limited Valero
Murco Petroleum Ltd World Fuel Services
Nexen Vattenfall

However, it should be noted that the above organisations have not all been directly involved in the development of this publication,
nor do they necessarily endorse its content.

Copyright © 2013 by the Energy Institute, London.

The Energy Institute is a professional membership body incorporated by Royal Charter 2003.
Registered charity number 1097899, England
All rights reserved

No part of this book may be reproduced by any means, or transmitted or translated into
a machine language without the written permission of the publisher.

ISBN 978 085293 651 1

Issued by the Energy Institute

The information contained in this publication is provided for general information purposes only. Whilst the Energy Institute and the
contributors have applied reasonable care in developing this publication, no representations or warranties, express or implied, are made
by the Energy Institute or any of the contributors concerning the applicability, suitability, accuracy or completeness of the
information contained herein and the Energy Institute and the contributors accept no responsibility whatsoever for the use of this
information. Neither the Energy Institute nor any of the contributors shall be liable in any way for any liability, loss, cost or damage
incurred as a result of the receipt or use of the information contained herein.

CONTENTS
Page
Foreword..................................................................................................... 3

Acknowledgements........................................................................................4

1 Introduction.........................................................................................5
1.1 Vulnerability and consequences of releases............................................................5
1.2 Scope....................................................................................................................... 6
1.3 Application................................................................................................................ 7
1.4 Overview of principal changes.................................................................................7

2 Management systems..........................................................................8
2.1 Introduction.............................................................................................................. 8
2.2 Management policy.................................................................................................. 8
2.3 Management process............................................................................................. 10

3 Performance standards..........................................................................11

4 Design...........................................................................................12
4.1 Introduction............................................................................................................ 12
4.2 Policy, philosophy, engineering standards and specifications................................12
4.3 Design activities..................................................................................................... 13
4.3.1 Initial assessment...................................................................................13
4.3.2 Material selection....................................................................................14
4.3.3 Tubing specification................................................................................14
4.3.4 Fittings specification................................................................................14
4.3.5 Valve selection........................................................................................16
4.3.6 Identification of static loads.....................................................................16
4.3.7 Identification of dynamic loads and vibration..........................................17
4.3.8 Supporting SBT assemblies....................................................................17
4.3.9 Selection of clamps/supports for SBT assemblies..................................19
4.3.10 Trace heating and/or insulation...............................................................20
4.3.11 Tools....................................................................................................... 20
4.4 Design deliverables................................................................................................ 21
4.5 Checking the design............................................................................................... 21
4.6 Close-out and as-building......................................................................................22

5 Installation.........................................................................................23
5.1 Introduction............................................................................................................ 23
5.2 Materials handling and stock control......................................................................23
5.3 Installing SBT components.....................................................................................24
5.3.1 Initial review............................................................................................24
5.3.2 Weld ﬁttings............................................................................................ 24
5.3.3 Threaded connectors..............................................................................25
5.4 Tubing.................................................................................................................... 25
5.4.1 Installation practice.................................................................................26
5.5 Support.................................................................................................................. 26
5.6 Thermal expansion and anti-vibration arrangements.............................................27
5.7 Selection and use of thread sealant.......................................................................27
5.7.1 PTFE tape............................................................................................... 27
5.7.2 Anaerobic sealants.................................................................................27

5.8 Installation checklist......................................................................................................28

5.9 Conﬁrmation and close-out....................................................................................28
6 Inspection and repair.............................................................................29
6.1 Introduction............................................................................................................ 29
6.2 Inspection............................................................................................................... 29
6.2.1 Overview................................................................................................. 29
6.2.2 Inspection strategy........................................................................................30
6.2.3 Inspection planning.......................................................................................33
6.2.4 Inspection procedures...................................................................................33
6.2.5 Hidden faults........................................................................................... 34
6.2.6 Execution of inspection work........................................................................34
6.3 Intervention management.............................................................................................34
6.3.1 Containment failures and/or severe mechanical damage.............................35
6.3.2 Remedial/corrective operations following inspection....................................35
6.3.3 Isolation of associated plant and equipment where SBT assemblies need to be
disturbed.................................................................................................. 37
6.3.4 Pressure testing after SBT assembly intervention........................................38

Annexes
Annex A Terms and abbreviations.....................................................................................................39
Annex B References and bibliography..............................................................................................41
Annex C Competency requirements..................................................................................................43
Annex D Policies relating to design of SBT assemblies................................................................52
Annex E Materials selection for SBT assemblies...............................................................................56
Annex F Component selection................................................................................................... 61
Annex G Identiﬁcation and mitigation of static loads.............................................................68
Annex H Identiﬁcation and mitigation of dynamic loads and vibration...................................95
Annex I Tubing support........................................................................................................... 110
Annex J Close-coupled instrument arrangements.........................................................................114
Annex K Design deliverables...........................................................................................................117
Annex L Designer self-checks.........................................................................................................121
Annex M Pressure testing (following SBT assembly intervention)..............................................122
Annex N Assembly practice.............................................................................................................124

FOREWORD

This publication provides good practice for the management of integrity of Small Bore Tubing
(SBT) assemblies throughout their entire life cycle with the aim of maintaining their
safety and integrity as well as the systems in which they are deployed. It aims to assist all
personnel involved with the design, installation, inspection and maintenance of SBT
assemblies, including those involved in operations, site management, and those having
speciﬁc safety and integrity roles with their organisation.
This document is a substantially revised version of the 1st 2nd edition (June,
2000May 2013). The revision was under the technical direction of a Steering Group (SG)
convened from a cross section of UK offshore operators, consultants and specialist
companies who play a key role in the design, inspection, installation and repair maintenance
of SBT assemblies for the offshore oil and gasEnergy industry.
Adoption of these guidelines should assist in managing the operator’s
responsibilities, instilled by the UK Health and Safety at Work etc. Act and its supporting
statutory instruments, or by equivalent legislative requirements elsewhere in the world.
Although prepared primarily for use by the petroleum, process and petrochemical
industries in the United Kingdom, the principles and practices are likely to be applicable
to similar industries, including the renewables sector, worldwide.

Note:
In several places throughout this document, examples provided by members of the SG have
been utilised. Where these have been cited, it is implicit that there are alternative ways and
methods that other users may use to meet the same objectives. Therefore, these examples
are provided for guidance only and should not be regarded as a recommendation or an
industry standard.

The Energy Institute and those involved with compiling this document cannot accept any
responsibility of whatsoever kind for loss or damage or alleged loss or damage arising
or otherwise occurring in or about premises, areas or facilities to which these guidelines
have been applied.
It is intended that these guidelines will be reviewed and revised when there are
changes in related standards, industry practices or in the light of practical experience.
Comments on the document are welcome with a view to incorporating improvement at
the next issue. Comments should be addressed to:

The Technical
Department The Institute
of Petroleum 61 New
Cavendish Street London
W1M 8AR United
Kingdom

ACKNOWLEDGEMENTS

This publication has been developed under the direction of a steering group (SG) which
incorporated representatives of UK offshore ﬁeld operators and companies engaged in
specialist activities relating to the design, installation, inspection and repair maintenance of
SBT assemblies. The Energy Institute wishes to record its appreciation of the
commitment to the project and the work carried out by the following personnel who
provided valuable expertise through attendance at SG meetings and submissions essential
to the development of this publication:

Edward Barr Instrument Engineering Consultants (Aberdeen)

Ben Coutts Hydrasun
Rick Kirk Quick Hydraulics Limited
Alasdair MacNeil AFS Technologies
Jim McGhee Xodus Group
Steve Warr Nexen
David Scott Taqa
Stephen Cook Harbour Energy
Kaustuv Ghosh Worley
Colin Bruce 360 Energy

The Energy Institute also wishes to record its appreciation of the support afforded by the
following members of the group who additionally, provided input and guidance on the
various draft documents, advice at SG meetings and who submitted support material
over the development period:

Blair BarclayAaron Kinney ECITB

Ian Cockburn DNV
Alan Haining BP
Sandy Leitch Conoco Phillips
Peter Rutherford BP
Wyn Davies HSE
Fraser Balsillie Plant Integrity Management
Roland Martland ENI
Colin McIlwrath Wood
Rob Swindell Wood

The work was managed by Keith HartAlasdair MacNeil (consultant to the Energy Institute)
who was also the principal editor and SG chairman.

1 INTRODUCTION

Small bore tubing (SBT) assemblies are used extensively in industry including onshore and
offshore oil and gas processing plants, petroleum refineries, power generation stations, and
petrochemical plants, as well as, hydrogen generation, storage and transmission. As well
asIn addition to hydrocarbon and other process liquids and gases crude oil, gas and natural
gas liquids (NGL) systems, SBT also features in utility plant such as air, high pressure
water, chemical injection, sampling and hydraulic fluid. One of their principal uses is for
the connection of instruments to the process plant for monitoring, control and safeguarding
purposes.
An SBT assembly comprises tubing and all associated fittings and can range in size
from 1/8" to 2" outside diameter or 2mm to 50mm metric equivalents; 90 % of assemblies
usually being ½” (12mm) and below. The routing geometry of a given tubing ‘run’ is often
complex; involving the use of many in-line tube connectors, tees, bends, valves and
supporting arrangements.
The mechanical features of SBT assemblies make them economically attractive
because of their ease of installation and by design, they should provide the required integrity
over the entire installation life cycle. Consequently, they are widely deployed particularly
as modern processing plants feature large numbers of control and monitoring
instruments which require a considerable inventory of SBT assemblies that involve a
large number of fittings and joints.
This presents a challenge for managing associated integrity assurance programmes
as these need to take into account, the large number of assemblies usually present. Most will
be integral parts of main systems, standalone plant or other items, any of which could
be classed as safety critical. (See EI Guidelines for the management of safety critical
elements).

1.1 VULNERABILITY AND CONSEQUENCES OF RELEASES

Due to their complexity and extensive use, SBT assemblies are vulnerable to failure due to
poor installation practice, vibration fatigue or the lack of effective inspection and maintenance
programmes. This means that if good practice is not being applied throughout the whole
SBT assembly life-cycle, there is a relatively high probability that an integrity failure event will
occur at some time during service.
The need to recognise SBT assemblies as potentially being high risk is also evident
from incident statistics for the offshore UKCS collated by the Health and Safety
Executive (HSE) in 1997. These indicated that SBT assemblies were one of the largest
single contributors to the incidence of loss of process containment in potentially hazardous
plants and that there was considerable room for improvement in terms of installation,
inspection and maintenance practices.

Separate HSE statistics collated for the period 2009 to 2010 2016 to 2020 indicate that:
−20,410 % of all reported hydrocarbon leaks recorded on the Hydrocarbon Release
(HCR) database were related to ‘instruments’, i.e. they are regarded as SBT
related.
−Of these events, just over half were classified as major or significant HCRs, i.e. 11 %
of all reported HCRs were classed as major or significant severity HCR events linked to SBT assemblies.23%
of major releases were SBT related and;
−68 % of all ‘instrument’ leaks were gas releases, for which the 'significant'
severity threshold was breached13% of significant releases were SBT
related (notionally an amount greater than 1 kg).

It should be noted that complete fracture of a section of SBT, or parting of an SBT coupling,
can potentially rapidly escalate to a major release, particularly if operating in gas service

and not quickly isolated. For example, release from a 6 mm diameter hole in a gas
system operating at around 150 bar can result in a major severity release (i.e. > 300 kg)
in around eight minutes.
Whilst all HCRs are of concern, gas or liquid gas releases are considered especially
hazardous as the gas cloud produced has the ability to rapidly migrate across the
installation. Failed components may also become projectiles which have the potential to
cause injury to personnel and damage to plant.
The environmental impact of any fluid leakage should also be considered throughout
the lifecycle of the SBT assembly, as many fluids can affect our land, water and upper
atmosphere.

Figure 1 Example arrays of typical SBT assemblies

1.2 SCOPE

This guidance document aims to assist the operator by identifying the major elements
required to build an effective strategy for management of SBT assemblies on an installation,
process plant or construction site, to ensure continued integrity during their entire service life.
It refers essentially to three principal areas of activity for new or replacement SBT
assemblies:
−Design
−Installation
−Inspection and maintenance of assemblies in service

An important aspect for ensuring lifecycle integrity is the training and competency of all
personnel involved in the above activities and in the operation of plant. Annex C
provides guidance on how operators should address this important aspect of integrity
management.
It should be noted that all on-site work associated with SBT assemblies involves
compliance with permit-to-work systemssafe systems of work and process isolation
procedures relevant to each respective work site but which are outside the scope of this
publication.

Exclusions from the scope of this publication include:

−Full details of performance limits for the various materials of manufacture.
−Welding of SBT components.

−The ﬁner details of component assembly and installation practice.

−Hydraulically swaged ﬁttings.
−Vibration tolerant design for tubing diameters and wall thickness other than
those listed in Table H.2.

1.3 APPLICATION

These guidelines are intended to assist with the management of SBT assemblies deployed
within onshore and offshore oil and gas processing plants, petroleum reﬁneries, power
generation stations, renewable energy and petrochemical plants. The guidance is
applicable for new, and existing installations, and where SBT assemblies are replaced, or
added to, existing plant.
Adoption of these guidelines should assist in managing the responsibilities which
operators have placed upon them by the UK Health and Safety at Work etc. Act and its
supporting statutory instruments, or by equivalent legislative requirements elsewhere in the
world. Although prepared primarily for use by the petroleum, process and petrochemical
industries in the United Kingdom, the principles and practices are likely to be applicable
to similar industries worldwide.

1.4 OVERVIEW OF PRINCIPAL CHANGES

This publication incorporates signiﬁcant changes to the 1st 2nd edition throughout; the
principal changes including the:
−Design section aligned to current practice.
−Inclusion Expansion of guidance on the design for the prevention of fatigue
failure which has been underpinned by research and development work.
−Simpliﬁcation of the installation section.
−Updating inspection and repair sections.
−Alignment Updating theof training and competency section.with current industry practice.

2 MANAGEMENT SYSTEMS

2.1 INTRODUCTION

Operating companies should have policies and strategies in place that ensure the integrity of
SBT assemblies on installations is retained over their entire life cycle. This should be
achieved through its management systems where policies and strategies for management of
integrity of SBT assemblies have been specifically identified and engineering specifications
and/or philosophies for design, installation, inspection, maintenance and operations
have been developed. Special emphasis should be placed on risk management, control of
component types and personnel competency.
Responsibility for carrying out the management policy activities should be allocated
to specific technical authorities (TAs) within the management system. Monitoring of the
policy implementation should be specifically included within technical audit programmes.

2.2 MANAGEMENT POLICY

The operator’s management policy should reﬂect the vision of the organisation and a
genuine commitment to action by ensuring that the risk to personnel and plant resulting from
the loss of integrity of SBT assemblies is identiﬁed. This is especially important where SBT
assemblies are deployed as part of a safety critical system or element where loss of integrity
could lead to a major incident. The policy should also ensure that the necessary mitigating
management activities are cascaded to individual discipline management processes
including design philosophies, standards and procedures.
The management policy should therefore require that a strategy for implementation
of the policy is developed that governs the design, installation, operation, inspection,
and repair of all SBT assemblies in service. The strategy should address as a minimum,
management of the following principal activities:

a) Training and competency – Training standards and competency assessment

schemes should be in place for personnel involved with design, installation,
intervention, inspection and maintenance to ensure continued integrity of all
SBT assemblies throughout their entire service life.
b) Risk Assessment – The operator should ensure that risk assessment and minimisation
of risk to ALARP is embedded with its engineering design and construction
management processes and that it can be demonstrated on an on-going basis.
c) Standardisation of fitting types – There should be standardisation and control of
the various brands and sizes (metric/imperial) of fitting and tubing on individual
installations in order to reduce the scope for construction and maintenance
errors caused by inadvertent mixing of components from differing suppliers.
Control of the materials used for each component item is also essential.
d) Design – The relevant design philosophy, engineering specifications and procedures
should be applied to the design, modification and installation of SBT assemblies;
these should be based on current good practice and be consistent with current
national and international standards.

e) Installation (construction or hook-up) – The operator should ensure that good

practice is identiﬁed and followed during the construction activities associated
with the installation of SBT assemblies. This links closely with design activities and
competency programmes for personnel involved with the on-site activities.
f) Inspection and Repair – The assurance of both the initial (post installation) and
the continuing integrity of SBT assemblies should be embedded within the
operator’s maintenance management system. These should include
development and deployment of inspection, reporting, review and correction,
and repair procedures which should be implemented according to a schedule that
is continually reviewed.

For new projects, the operator should develop and have in place, the relevant
strategies, and project teams should develop appropriate philosophies, engineering
speciﬁcations and procedures for the design and installation of SBT assemblies.
Inspection and repair strategies speciﬁcally for the management of integrity should also be
developed prior to the commissioning and operational stage.
For existing installations, managers should review their policies and strategies regularly
and ensure that they are consistent with this guidance. On installations where several brands
and types of equipment and/or inappropriate metallurgies are already present, a
management strategy should be implemented which may they should also consider
incorporating a migration strategy to reduce the number of brands and types in use and,
if needed, to correct component metallurgy.
Continuing integrity of SBT assemblies should also be embedded within the
management systems for day-to-day operations by ensuring that:

−First line operations personnel are aware of the risks associated with failure of SBT
assemblies (e.g. through training and site brieﬁngs).
−Procedures involving all activities relating to SBT assemblies do not compromise the
integrity of the systems.

Front-line operations personnel should also be aware of the importance of regular inspection
and promptly making the required corrective action or repairs.
Further guidance on developing policy, design philosophy and engineering
speciﬁcations for SBT assemblies can be found in Annex D.

2.3 MANAGEMENT PROCESS:

Figure 2 is an example of the main features of a management process that can be set up for
the management of the integrity of SBT assemblies. It is based on processes set out in
the HSE document HS(G) 65.

Safety;
equipment
Getting it right
integrity

Policies on risk and reliability

Clear policies &
Targets for hydrocarbon leak reduction
objectives
Targets for reliability and cost
Standards for measuring performance
Reports used
to achieve
Training and competence improvements
Deﬁne roles and Personnel &
responsibilities competency
Ensure co-operation & communication

Application of current speciﬁcations Reviews used

Identify hazards and assess risks Design & risk to provide
Avoidance of fatigue failure assessment correction
Produce design dossier and work packs

Application of good practice

Installing to requirements of work Installation &
pack As-building commissioning
Feedback to designers

Risk assessment and prioritisation

Inspection programmes Inspection -
Procedures for correction and repair integrity status
Reporting YES NO

Monitor inspection reports

Repair defective SBT assemblies Corrective actions Meeting
Targets for number of anomalies & review objectives?
Targets for reliability and cost
Independent
audit

Figure 2 Example integrity management process

3 PERFORMANCE STANDARDS

In the UK offshore industry, items that are deemed safety critical elements (SCE’s) should be
identified and performance standards or their ‘duty requirement’ equivalent, should be
created for each. An SCE can be part of or whole systems, structures or process and
emergency control facilities.
Regulations require that an Independent Competent Person (ICP) should provide
comment on equipment specification as to its suitability and the performance standard
provides criteria for this. For similar operations in other parts of the world, there may be
equivalent local provisions and/or regulations.
However, performance standards for SBT assemblies are not normally required, but
may be necessary where a hazardous situation could arise or be intensified, in the event of
rupture or failure.
When designing new, or modifying existing, process plant, the performance standard
of the system in question should be taken into account and designers should ensure that the
required integrity level is not degraded by the installation of the given SBT assembly.
The requirement for a performance standard would normally be identified as a result
of a Quantified Risk Assessment (QRA) applied to the overall system and not solely to the
SBT assemblies. In these cases, consideration should first be given to 'designing out' the
hazard presented by containment failure of the SBT installation.

A typical performance standard for SBT assemblies may be required to specify:

a. The role of the installation: described by a role statement which should be a high
level brief statement of what the system is intended to achieve and in what
circumstances.
b. What the installation is required to do under stated circumstances: described within
a functional specification which should include definitions of the system
boundary, interfaces and interactions with other systems, process and
environmental conditions, operational and maintenance requirements and any other
relevant parameters.
c. What integrity level is required in these circumstances: described within an integrity
specification which should be a qualitative response to the requirements of the QRA
including personnel competence requirements.
d. Any requirements for survivability after a major incident: described within a
survivability specification which should identify any requirement for the system or
part of the system to remain functional during or after a major incident as
identified by the risk assessment.

4 DESIGN

4.1 INTRODUCTION

Detailed design of SBT assemblies should comply with, and be referenced to, relevant
company policies, design philosophies, and be in accordance with the appropriate
engineering specifications and standards (see Annex D).
The design should be practical and capable of being installed safely by construction
personnel without the introduction of faults leading to integrity loss of the system to which it
is being applied. The continuing integrity of SBT assemblies is reliant upon good initial
design, and therefore designers should be aware of those factors that degrade integrity
to ensure that these are addressed.
Designing an SBT assembly is a complex process which requires that, as a
minimum, the following criteria are taken into account:
−Safety – risk assessment and risk mitigation.
−Process service conditions, i.e. pressure, temperature, flow, dynamics (fluid phase
changes, pressure and temperature extremes).
−Static and dynamic loading.
−Maintenance of system safety and integrity.
−Environmental conditions.
−Metallurgy – selection of materials for construction.
−Requirements for control, isolation, free draining and venting.
−Standardisation and control of component types.
−Installation practicalities and access during service.

In addition, information from experience gained from sources such as lessons learned from
incident reports, as-building, safety or technical bulletins and improved technology
should feed into the activity.
The deliverables of the design process should comprise a package of
information that defines the engineering requirements of the project and most importantly,
provides the installer with sufficient narrative and graphic information, instruction, guidance
and materials to safely and efficiently install the respective assembly.
Failure to provide the installer with these basic elements raises the probability that a
latent failure will occur at some time in the future.

4.2 POLICY, PHILOSOPHY, ENGINEERING STANDARDS AND SPECIFICATIONS

An important aspect of design is the use of company policy or philosophy documents and
any appropriate engineering standards and specifications that are applicable for the
respective installation or process plant throughout the design stage.
However, changes in philosophy or policy may require these to be modified from
time to time and the designer should maintain awareness of any revisions to company
engineering specifications. Such changes may be required due to:
−The current specification may not include, or be aligned with, the latest international
standards, codes of practice and knowledge.
−There may be changes in material selection due to recent industry experience.
−The designer should be alert to any unique application conditions which are not
adequately covered within the available specifications, e.g. guidance to avoid
excessive static and dynamic loading.

Where deviations from the current speciﬁcations are deemed necessary, guidance should be
sought from the relevant TA.
For further guidance on the requirements for policy and philosophy for SBT
assemblies see Annex D.

4.3 DESIGN ACTIVITIES

This section provides guidance on all the recognised stages of design including special
treatment for the avoidance of fatigue failure.

Note: Generic or ‘off-the-shelf’ designs should not be utilised without performing due
diligence in respect of the suitability for the intended application.

4.3.1 Initial assessment

When designing new, or modifying existing, process plant, the performance standard of
the system in question should be taken into account, and designers should ensure that
the required integrity is not degraded by the installation of the given SBT assembly. This
is especially the case for safety critical equipment and where necessary, appropriate
measures to mitigate the threat should be applied.

Examples of how certain threats could be mitigated include:

−Alternatively, selecting an appropriate piping specification where the failure of
a SBT assembly could result in a hazardous situation, e.g. failure of large bore tubing
or systems with large inventories of hydrocarbon and/or hazardous fluids, then
consideration should be given to the application of an appropriate piping specification.
−Taking into account any vulnerability to blockage which may impair functionality
or safety where SBT assemblies for hazardous process fluid duty are installed in
vulnerable locations, consideration should be given to limiting the loss of process
fluids in the event of tube rupture by the installation of velocity check valves.

Welded assemblies should be considered:

−where the tubing geometry is complex;
−for critical applications involving corrosive ﬂuids, and
−where shock from pressure surges and temperature cycling can occur.

Installation of new or modiﬁcations to, SBT assemblies on existing plant should be controlled
under the operator’s management of change process. This may require the risks to be
assessed which in turn may require a more formal assessment such as HAZOP to provide
an opportunity to design out potential hazards presented by risk of containment failure.
Where a service requires fluid flow through the tubing the effects of flow must be considered,
examples of this could be where larger bore tubing is used in placeof small-bore pipe work
such as in seal oil systems or utility system headers. Inthese services’ erosion checks,
pressure drop calculations, effects of flowinduced vibration as well as venting and draining
requirements should be considered by the designer. Where the tubing is in effect an
extension of thepiping system due consideration of the piping system design pressures and
temperatures must be taken. The designer should also review any requirements
for physical protection measures for the tubing

For locally installed instruments, deployment of direct-mounted or close-coupled

arrangements may provide an overall advantage and therefore should be considered (see
Annexes H and K).

4.3.2 Material selection

Material selection for all components is a very important aspect of the design process.
Therefore the latest specifications developed for SBT assembly metallurgy for the installation
or plant in question should be adhered to by the designer when specifying all associated
tubing, and fittings and valves.
The component parts of an SBT assembly, i.e. tubing, fittings and valves, should be
materially compatible, be suited to the range of design applications, and should be specified
in accordance with the operator’s material selection requirements for use in the project and
operational phases of the systems.
Components such as valves should be tagged (or clearly marked) for identification
purposes.
Further information on material selection for SBT assemblies can be found in Annex
E.
Where the SBT assembly directly interfaces with the piping system the possibility for galvanic
corrosion internally and/or externally due to dissimilar materials must be considered in the
overall design.

4.3.3 Tubing speciﬁcation

Tubing is a component having precise dimensions and composition which means that correct
specification is important. As there are many options available, guidance provided in Annex
F.2 should be taken into account when specifying tubes for a particular application.
For a given installation, designers should consider specifying only one wall thickness
for each OD size in order to prevent the accidental use of thin wall tubing on high
pressure applications. However, whilst this principle has obvious merit, specifying the
heaviest wall thickness can lead to other undesirable problems (such as failure of
compression fitting ferrule to achieve the correct ‘bite’, restricted flow, etc). This concept
therefore should be considered thoroughly and in consultation with the relevant
technical authority.
Where larger bore tubing is being used in place of small bore pipework then
consideration should be given to the existing piping specification with guidance taken for
valve specification, corrosion, solid content etc.
Applicable process temperature shall be considered for all SBT designs.
Guidance provided in Annex F2.1

4.3.4 Fittings speciﬁcation

The term ‘ﬁttings’ is used as a collective term for those items used to facilitate the connection
of the tubing to various components, to tee joints, angled bends and to simply join
lengths of tubing. Here, the term ‘types’ of ﬁtting refers to the method used for jointing
onto the tubing.

4.3.4.1 Fitting types

There are many types of ﬁttings available for use within SBT assemblies as described further
in Annex F. The scope of this document includes the following:
−single or twin ferrule – used for low-to-high pressure applications;
−coned and threaded – used for medium-to-very-high pressures;
−hydraulic swage – used for medium-to-very-high pressure applications, and
−ﬂared – used for low-to-high pressure applications

Note that welded ﬁttings used for special SBT applications including subsea, difﬁcult
geometries, etc. are not within the scope of this document.

In addition to process and ambient conditions, the mechanical speciﬁcation of tube

ﬁttings, particularly those incorporating ferrules, should meet the necessary requirements for
resistance to vibration, repeatable make/break ability, and resistance to impulse and shock.

4.3.4.2 Specifying ﬁttings

When specifying tube fittings, the designer should refer to the operator’s design policy and
also consider the following:
a) There to be no intermixing of component parts from different manufacturers and the
requirements of the operator’s policy on standardisation should be applied.
b) Uniform sizes and common fittings types (e.g. connectors, screwed couplings) to
reduce inventory.
c) Where tubing OD sizes on a project range up to 50mm OD the use of twin
ferrule fittings should be considered across the whole project
d)[c)] Where possible, complex fittings should be avoided. In addition to over-complicating
the design, complex fittings often have longer delivery times which could be an
issue.
e)[d)] The types and sizes of tapered and parallel pipe threads which may be utilised should
be identified from the design philosophy or engineering specification and the limiting
factors regarding the MAWP should be clearly understood, particularly in the case of
female screwed fittings which can result in a de-rating factor.
f)[e)] Screwed pipe fittings such as nipples, bends, tees, etc., as an alternative to tube and
ferrule type fittings when added strength and support requirements are needed.
Pipe fittings can be especially useful for close-coupled instrument applications.
g)[f)] Geometry and dimensions of the fittings should be considered; this can assist with
avoiding the designing in of potential weak points. See Box 4.1.

Box 4.1 Appreciation of geometry

The designer should have an appreciation of the size, geometry and dimensions of
the
ﬁttings as this can help to avoid the introduction of weak points into the design.
The following illustrates how the graphic representation for a reducing connector
can be depicted in a catalogue and how it could vary from the actual:

Standard fitting as
Standard ﬁtting as Scale
Scale version of
of aa
depicted
depicted reducing connector
connector
This is not an integrity issue per se; however, a problem could arise if inappropriate
support facilities were to coincide with the application of excessive weight on the
selected ﬁtting.

4.3.4.3 Future designs

As new ﬁtting designs and technologies emerge and become common in use, then their
deployment should be reviewed by the designer and approved by the relevant TA on a case-
by-case basis.

4.3.4.4 Thread sealants

The type of thread sealant for tapered threads on ﬁttings should also be speciﬁed by
the designer (e.g. PTFE tape, liquid, or paste) in accordance with the operator’s policy
and stated on the design drawing/specification. Consideration should be given to the
suitability of the selected method relative to the process medium, temperature, pressure
and to the required cleanliness of the components and/or system to which they are to be

connected.
For example, PTFE tape must not be used in the Nuclear industry (due to degradation
by radiation), liquid sealants can perform poorly in high pressure applications and low
temperature applications, etc. It is the role of the designer to highlight the correct thread
sealant to be used for the assembly.

Installers should be made fully aware of the potential problems associated with each
of these methods and be competent in the application of each type (see also section 5.7).

4.3.5 Valve selection

SBT assemblies can incorporate a variety of valve types in order to provide isolation or
control. The requirements of the European Pressure Equipment Directive (PED) should be
taken into account when specifying valves, and all hydrocarbon and valves identified as
safety critical may need to be certified as fire-safe.
General guidance on these valve types is provided here, with further details of
instrument valves and their general application is included in Annex F.10:

4.3.5.1 Primary isolation

Primary isolation valves for SBT assemblies should be provided by the ‘piping’ discipline and
comply with the relevant specifications. These invariably comprise a double block and bleed
(DBB) configuration and can be conventional (e.g. a ball valve configuration), compact
or mono-flange type valves.
The interface point between the piping valve and the SBT assembly is usually a
flange or a screwed connection; the size and configuration of this interface should be agreed
at the earliest opportunity.
Where tubing is being used in place of small bore pipework, such as larger bore
tube on utility systems, the primary isolation valves may be on sections of tubing. In
these circumstances, the primary valve specification should be comply with the piping
specification.

4.3.5.2 Instrument
Many versions of instrument valves are available for isolation, regulation, directing flow and
for protection purposes. They are produced in a wide range of materials, size, operating
temperatures and pressure ratings, and with varying integral connections for connection
to tubing and other fittings. These connections can include tube, taper pipe thread, weld,
flange and face seal type connections, and all have limitations in their operating
maximum pressure and maximum/minimum temperature range.

4.3.6 Identiﬁcation of static loads

Static loads are defined as loads which do not vary continually with time, and those
which will affect the SBT assembly should be quantified by the designer and mitigated
for where too high. Static loads may be present at all times due to component weight, or
they may alter depending on operating conditions especially where there are changes to
pressure and temperature between operating and non-operating states. These can be
considered as being the equivalents to the operating and sustained loads defined in process
piping design codes such as ASME B31.3.
Most operating companies will have clear design criteria relating to system
pressures and temperatures and most static load considerations will be accounted for by the
selection of the appropriate material, tubing diameter, valves and fittings (see 4.3.2 to
4.3.5). The effects of large point masses such as heavy, high pressure valves, high
intermittent levels of applied torque, as a result of, for example, valve static friction (stiction)
and thermal expansion of pipework systems to which SBT assemblies are connected, should
be carefully reviewed as these aspects are understood less.
Where SBT assemblies are being used in services where the fluid is flowing
through the tubing, eg utility header systems, the use of pipe stress analysis techniques
should be considered to analyse the proposed support arrangements and confirm the
position and duty for each support on the system. The pipe stress analysis techniques
will consider static loadings.

Further guidance on the identiﬁcation of static loads and design criteria for
avoidance of static load failure can be found in Annex G.

4.3.7 Identiﬁcation of dynamic loads & vibration

One of the most common causes of SBT assembly failure is excessive dynamic loading. This
can take the form of:
−Low cycle/high amplitude motion (such as that induced by wave motion on offshore
well conductors).
−High cycle/low amplitude vibration.
−Combinations of these.
−The dynamic loading should be correctly speciﬁed during design so as to ensure that
assemblies are not vulnerable to excessive movements and vibration. The dynamic
loads which should be identiﬁed by the designer include:
−High amplitude cyclic motion; as found in offshore well bay applications.
−Machinery induced vibration; as found in the vicinity of reciprocating and rotating
machinery.
−Flow induced vibration; as found in many other areas of typical process piping
systems.
−Where tubing crosses boundaries between modules on floating structures (eg
ships or Floating Production Storage and Offloading (FPSO) assets) there
can be relative motion between the modules due to flexing of the
infrastructure. This may also be a consideration where onshore facilities
have been built as a number of modules and land settlement can cause
relative motion between modules.

Where a potential vibration threat is identiﬁed, dynamic design criteria should be followed so
as to avoid vibration induced fatigue failure. See Annex H for further guidance on
dynamic loading and dynamic design criteria.
Alternative anti-vibration techniques should be considered on their own merits; in
particular, new designs should be reviewed in detail and their use should be discussed and
agreed with the relevant TA.
Where SBT assemblies are being used in services where the fluid is flowing
through the tubing, eg utility header systems, the use of pipe stress analysis techniques
should be considered to analyse the proposed support arrangements and confirm the
position and duty for each support on the system. The pipe stress analysis techniques
will consider dynamic loadings as well as consider potential vibration issues.

4.3.8 Supporting SBT assemblies

The primary function of the SBT supporting arrangement is to prevent failure of the
tubing through excessive stress and fatigue. To achieve this, careful consideration should
be given to design methodology as well as the components used, as a poorly designed
support system could increase risk of failure. 4.3.9 discusses the selection of the
components used for support, whereas this section provides information on the design of
the support arrangements themselves.
SBT assemblies are commonly used for connection of measuring or monitoring
instruments (e.g. gauges and transducers) to piping systems. For this duty, two basic
conﬁgurations apply: ‘pipework mounted’ and ‘steelwork mounted’.

a) Pipework-mounted:
Very similar to close-coupled or direct mounted arrangements where the entire
assembly is connected to, and only supported from, the host pipework. No part
of the assembly is connected to any other unconnected section of pipework or
part of the structure. It is self-contained. Figure 3 provides an example.

SBT assembly not

connected at other
end

Connection to
process pipework
fitting

Secondary isolation Primary isolation

valve valve

Figure 3 Example of pipework-mounted SBT assembly

b) Steelwork-mounted:
The assembly is connected at one end to the process pipework ﬁtting, and at the
other, to structural steelwork (or some other unconnected piping system or part
of the structure which is distinct from the host pipework). Figure 4 provides an
example.

Connection to
structure
Connection to
process pipework
fitting

Primary isolation
valve

Figure 4 Example of steelwork-mounted SBT assembly

These deﬁnitions should be taken into account when considering lifecycle

performance. The demands placed on the assembly for steelwork-mounted systems
are much greater than those for pipework-mounted systems. This is due to the
relative movement which occurs between pipework systems and structural
steelwork and this must be accounted for in the design process. If not connected
to the structure, there will be no need to account for this additional load.

Where SBT assemblies are being used to in services where the fluid is flowing
through the tubing, eg utility header systems, the use of pipe stress analysis
techniques should be considered to analyse the proposed support arrangements
and confirm the position and duty for each support on the system. The pipe
stress analysis techniques will consider static and dynamic loadings as well as
consider potential vibration issues.

4.3.8.1 Pipework-mounted SBT assemblies

The most vulnerable part of a pipework-mounted assembly is its connection to the
piping system; normally made at the primary isolation valve (DBB, mono-flange, etc). An
unsupported assembly can vibrate in a cantilever mode inducing high dynamic loads at
the connection point. Large heavy components can exacerbate the situation by inducing
high static loads on the connection as well as on other fittings in the assembly.
The general principle should be to protect the connection to the piping system.
This is achieved by designing the support arrangement so that relative motion between the
primary isolation valve or host pipework and the end of the SBT assembly is prevented.
When designing complex assemblies it should be ensured that adequate support can be
effectively implemented.
Further discussion on support systems for pipework-mounted SBT assemblies can
be found in Annex I and that for optimising the configuration of close-coupled assemblies is
provided in Annexes H and K.

4.3.8.2 Steelwork-mounted SBT assemblies

The most vulnerable parts of steelwork-mounted SBT assemblies are their extremities which
are:
−The connection to the piping system (normally made at the primary isolation valve).
−The ﬁrst connection to the structural steelwork.

Due to the dynamic nature of process systems, there is usually some level of vibration
present in the host piping system, and since the structural steelwork is nominally free from
vibration, relative motion will exist between the two ends of the assembly. The design of the
tubing must accommodate this relative motion without overloading any components in the
assembly.
Thermal expansion of the process pipework is also very important and requires
careful consideration. On offshore installations up to 200 mm pipework growth/expansion
relative to the structure is possible; meaning that the two ends of the assembly and the
tubing support arrangement must be able to accommodate this movement without
incurring failure.
For further guidance on support systems for steelwork-mounted SBT assemblies,
see Annex I.

4.3.9 Selection of clamps/supports for SBT assemblies

Manufacturers of tube clamps offer a number of designs intended for quick installation of
single or multiple tubes. Most feature a tube clamp arrangement which can be ﬁxed to tray,
plate or channel. Designers should consider the following when selecting tube clamp types:

a. Prevention of corrosion - Corrosion of tubing under clamps especially in marine

environments due to the creation of pitting or crevice corrosion cells when salt
water becomes trapped within the clamp mechanism. Tubing material selection and
improved clamp design can prevent this form of corrosion.
b. Static loading - Static loads should be identiﬁed as discussed in 4.3.6 and the
supports selected to provide appropriate performance, thereby ensuring that no
excessive static loads are imparted onto the tubing or the structure.
c. Dynamic loading - Dynamic loads should be identiﬁed as discussed in 4.3.7 and
the supports selected to provide appropriate performance, thereby ensuring that no
excessive dynamic loads are imparted onto the tubing or the structure.
d. Physical damage - To prevent physical damage to the tubing, clamps should be
manufactured from a softer material than that of the tubing.

e. Metal-to-metal contact - Tube clamps that employ metal-to-metal contact should be

avoided, especially where vibration is likely.
f. Ease and speed of tube clamp assembly - This is an important consideration, especially
if the environment is hostile and there are signiﬁcant installation hours involved.
However, choice of tube clamp should be consistent with good engineering practice.
g. Multiple tube runs - Tray or channel systems are preferred for multiple tube runs to
ensure the tubing is adequately supported and protected throughout its length.
h. Protection - Where tubing is vulnerable or susceptible to potential damage due to its
exposed location, then additional mechanical protection should be incorporated.
i. Earthing requirements - Earthing should be speciﬁed for tube support systems to
eliminate static electricity.
j. Spacing - Clamp spacing should be determined with due consideration given to
manufacturer’s recommendations, tube size, vibration/stress and potential for
damage.

Special bracketing or mounting facilities should be considered and speciﬁed for heavy
components such as valves, instruments, etc. For some assemblies (e.g. those impulse lines
liable to accumulate liquid condensate) the designer may need to ensure that the tubing
is free-draining.
Further guidance on support for SBT assemblies is provided in Annex I.

4.3.10 Trace heating and/or insulation

It is sometimes necessary to trace heat and/or insulate certain SBT sections for
environmental protection and to prevent blockage, e.g. due to wax or hydrate deposition.
The designer should therefore consider any detrimental corrosion effects and provide
mitigating measures where necessary.
For ﬂow measurement instruments using differential pressure, both impulse lines
should be run as close as possible together so that application of trace heating and/or
insulation can be common to both lines, thus avoiding any errors due to differential
temperature.
Assessment should be made of the possibility of inducing chloride pitting or
stress corrosion cracking. There should be measures in place to avoid these threats; these are
usually provided within the operator’s standards for insulation and trace heating of SBT
assemblies.

4.3.11 Tools

Integrity of the installed SBT assembly is dependent on the on-site availability of the correct
range of tools, and therefore the designer should include these when specifying all
necessary component parts. These should include tools that are not routinely issued to the
installer such as hydraulic make up and/or forming tools, ﬁtting gauges as needed.
Reference should be made to the vendor’s recommended tool kit provisions
when deciding on the range of tools needed.

4.4 DESIGN DELIVERABLES

The designer should impart sufficient narrative and graphic information within the design
deliverables to ensure the installation of the SBT assembly in a safe and efficient
manner. Therefore the designer should develop a coherent set of deliverables that fulfils this
basic aim; ensuring that the fundamental aspects of design are addressed.
Where tubing is being used for a flowing fluid the bore size and material should
be confirmed using techniques similar to those used for piping system design, ie
pipework nominal bore and material selection. This should involve pressure drop
calculations and fluid velocity calculations to determine the erosional effects and
therefore confirm material choice. In addition, momentum and vibration checks should
be carried out using the “ρv2” process (density times velocity squared). This can be an
iterative process where tubing bore to suit the correct pressure drop may cause erosion
or vibration issues therefore the process is repeated until a suitable OD, wall thickness
and material are selected.
The deliverables should typically comprise the following (dependent on how the
project is managed and the relationship between the design and construction entities and to
a certain extent, in which industry sector it applies to):

a. Design books: produced by the design team and containing the relevant design
drawings, procedures and narratives. They are effectively precursors to the
construction work pack and should contain sufﬁcient information to allow a third
party construction team to develop the necessary job instructions or construction
work packs.
b. Installation or job instructions: used to convey methodology and sequence of
installation in narrative terms, usually referencing schematics, arrangement
drawings, hook-ups, isometrics and material schedules.
c. Work packs: often produced by the construction team with input from the
relevant design disciplines. They can take the form of single or multi-discipline
documents and usually break the scope of work down into discrete and manageable
segments. The design narrative and graphic details for the work elements are
usually supplemented by safety considerations/guidelines, job cards, testing and
commissioning procedures or guidelines, close-out procedures and more general
project management sections.

For further guidance and details of the design deliverables, see Annex K.

4.5 CHECKING THE DESIGN

Commitment to checking and approval of the design should be prioritised by project

managers. Consideration should therefore be given to incorporating up to four levels of
checking by various disciplines as outlined:
a. Designer self-check: carried out by the designer utilising a pre-formatted prompt
sheet which challenges the designer to assess their own work in terms of
speciﬁc requirements, so as to avoid generic or familiar mistakes. An example of
how a designer self-checklist could be developed for use at the end of the design
process is provided in Annex L.
b. Design check: carried out by an independent competent designer (possibly utilising
a pre-formatted check sheet) which tests the intent, quality and accuracy of the
drawings and materials listing against the operator’s design philosophy and relevant
standards as well as a review of the designer’s own self-check sheet.
[c.] Engineering check: carried out by a senior engineer, counter-checking and endorsing the

same checking process adopted by the senior designer.checking all engineering

aspects of the design. The objective should be to test the engineering intent as
well as the quality and accuracy of the drawings, materials listing as well as a
review of the designer self-check sheet(s).and compliance with engineering
standards.
[d.] Engineering approvalApproval: carried out by a competent senior engineer (TA),
approving the quality, accuracy and overall design and engineering intent of the
drawings, material lists as well as the designer self-check sheet(s).ensuring the
previous checks were compliant with the intent.

4.6 CLOSE-OUT AND AS-BUILDING

Close-out and as-building is the final, but no less important, phase of the construction
scope involving formal verification and handover of documentation, typically comprising the
following:
−construction check sheets;
−commissioning check sheets;
−certification, and
−as-built (as installed) drawings

Part of this process involves the close-out and as-building of the installation whereby all
relevant drawings and documents are checked for completeness; controlled documents
should be updated. This process should be considered at the beginning of a project and
not disregarded as an afterthought. Close-out and as-building procedures should therefore
be developed and featured as part of the overall management of the project and/or the
governing management of change (MoC) procedure.
As-building can also be a valuable process as it provides:
−The installer with an opportunity to review their own work in relation to the
intended design. This could also reveal installation errors that have occurred due
to misconceptions or misunderstandings which might constitute latent failures
and enabling such errors to be rectiﬁed.
−The installer with the opportunity to feedback useful and important learning
points to the designer.
−The designer with the opportunity to re-review the attributes of their design against
the as-built situation and provide valuable feed-back. This also provides the designer
with a ﬁnal check to ensure that the intent of the design has been followed in full
and the opportunity to learn from any errors due to misinterpretation.

The designer should deﬁne the extent of as-building within the job instruction,
construction work pack or design book, taking account of the following principles:
−Installation of new or, alteration to existing, SBT assemblies that would require
changes to any controlled documents or drawings should be as-built and sent for
formal close-out (typically, updating the relevant P&ID(s)).
−Commonplace or duplicated designs, e.g. pressure transmitter hook-ups, should be
as-built for the ﬁrst occurrence at least and thereafter, a random sample should be
considered. It may be considered worthwhile as-building such designs each time the
project enters a new phase.

‘Lessons learned’ exercises or sessions involving the installers, management and the designers
carried out post-installation should be considered, as these usually prove to be valuable
learning opportunities.

5 INSTALLATION

5.1 INTRODUCTION

This section deals with the installation aspects of SBT assemblies which should be
undertaken by personnel who have been properly trained and assessed as competent for the
relevant task(s) (see Annex C). All relevant information for the installer should be contained
within the work pack (see section 4.4).

It is important that the work pack should also include:

a. Relevant manufacturers’ technical literature for speciﬁc product installation
instructions.
b. Installation requirements for the avoidance of fatigue failure due to static and
dynamic loading (see Annexes G and H respectively).

Note that this section only provides generic guidance regarding equipment installation;
readers should also consider additional information necessary for installation of a speciﬁc
item of equipment.

5.2 MATERIALS HANDLING AND STOCK CONTROL

Where an installation’s scope of work speciﬁes the requirement to utilise various

material types, consideration should be given to material handling, warehousing and site
storage facilities. A strict segregation policy for items differing in their material properties
should be in operation, especially as it is often difficult to visually discriminate between the
varying types of stainless steels and alloys deployed. It is implicit therefore that those
responsible for controlling storage and distribution should be properly trained in awareness
and identification of the range of materials that could be encountered.
SBT components should be clearly marked with the material identification; each
component part should be marked with a material code or designator (such markings
may be applied during manufacture). Risks should be minimised by adhering to the
following procedures and controls:
−On installations and plants where several fittings and tubing types/materials exist,
there should be procedures in place to ensure that the risks for intermixing of
component parts and of mixing tubing of different material and size (including
mixing of metric and imperial sizes) are eliminated.
−Stock control procedures for tube fittings should ensure adequate segregation and
identification of type by specification, manufacturer, dimension and material.
−Components held in stock should be complete and retained in sealed vendor
packaging when possible.
−Stocking of loose ferrules should be avoided to prevent interchange.
−Only approved tubing should be stocked and clearly identified by specification,
material, size and wall thickness.
−When transporting tubing, it should be packaged in such a way as to prevent damage
and corrosion.
−Stock return procedures should ensure that only complete fittings are returned to
stock ensuring that they are correctly identified and located. Loose ferrules and used
components should not be returned to stock.

−Component stock should be held in a central secure and environmentally acceptable

area and only be available to competent personnel. There should be no
unauthorised ‘satellite’ or ‘squirrel’ stores.
−Routine audits of stock holding control mechanisms and security should be conducted.

Tube storage facilities located on site should incorporate adequate protection from the
environment and from physical damage.

5.3 INSTALLING SBT COMPONENTS

Personnel involved in the installation of SBT assemblies should adhere to the following
general requirements:
−Work performed on site should be in accordance with the local safety requirements
and work control permit system.
−New SBT assemblies should be installed by competent personnel (see Annex C) in
accordance with the guidance provided with the design work pack (see Annex K for
details of the design deliverables).
−Assembly, including the use of special equipment such as cutters, bend formers and
swaging tools, should be in accordance with the speciﬁc manufacturer’s instructions.

5.3.1 Initial review

The installer should first review the work pack contents to gain a thorough understanding of
the design intent. This should include a detailed review of the design drawings and materials
specifications and a survey of the site location prior to installation. In the event that the work
pack is not complete or well enough defined, a formal site query should be submitted to the
relevant engineering department.
Material specifications for assembly components should also be checked for
consistency with the design intent as specified within the work pack.
Any anomalies, deficiencies or errors discovered that contradict the design intent
should be catalogued and communicated to the designer using the appropriate ‘site
query’ (or equivalent) reporting system.

5.3.2 Weld ﬁttings

Welding of components in tubing systems is a specialist activity and is outside the scope of
these guidelines. However, general guidance is provided here which should be incorporated
in the management controls and procedures:
−Welding should only be undertaken by authorised (qualified 'coded') personnel
who have been formally assessed as competent to carry out the necessary welding
procedures.
−Competent supervision of the preparation, welding and inspection activities should
be provided and pertinent safety precautions should be identified and implemented.
−Welding should be carried out in accordance with the design specification.
−Welding procedures (including the welding equipment, etc. to be used) and inspection
procedures should be fully documented.

5.3.3 Threaded connectors

Installation personnel should be able to correctly identify thread types; management controls
and procedures should ensure that these are identiﬁed, and that the necessary level of
competence in identifying and installing threaded connections is assured.
Incidents have occurred following installation errors as a result of combining different
thread types and from insufﬁcient depth of thread engagement. Therefore, installation
personnel should have knowledge and understanding of the range of threaded connections
likely to be encountered, as set out in 5.3.3.1- 5.3.3.2.

5.3.3.1 Tapered pipe threads (NPT and BSPT)

These are commonly used in process and instrument connections. Being tapered, they
operate on an 'interference fit' principle effected by wrenching together the male and female
threaded components.
If NPT and BSPT components are intermixed, it is likely that the materials will
gall and the connection will leak. However, it is difficult to visually check fittings for
thread type especially as some manufacturers do not use markings. Therefore, prior to
installation, the respective male and female sections should be screwed together ‘hand-
tight’ to check that approximately four threads become engaged, which would indicate that
the thread types are the same.

5.3.3.2 Parallel pipe threads (ISO 228/1, unified and metric screw threads)
Fittings using parallel threads rely on a gasket, an O-ring or a sealing face to obtain a seal.
The integrity of parallel pipe thread joints is dependent on the correct selection of
components and installation practices.
To ensure that an effective joint is made, the mating threads must be compatible by
specification and the correct seal type should be deployed. Therefore the design should be
consistent with the compatibility of the thread used on the fitting. Threads should be
clean and where applicable, the correct gasket or O-ring should be installed.
Installers should be able to identify sealing methods and parallel threads likely to be
encountered in order to avoid the inappropriate mixing of thread types.

5.4 TUBING

Tubing should be carefully selected, examined for damage, properly prepared and
assembled with the intended components and installed correctly.
Tubing runs and conﬁgurations should be installed in accordance with the
relevant generic design or speciﬁc requirements such as routing, gradient for drainage
purposes, etc. and with regard to allowable static and dynamic loads (see section 4.3).
Tubing should be checked for material type and wall thickness prior to
installation and should be free from scratches, deformity and corrosion. Damaged tubing
should be discarded.

1/2" OD x .049
AVESTA HEAT CODE IDENT. 316 ASTM A269
(Imperial) 12mm x

MANUFACTURER BATCH MATERIAL SIZE & WALL

THICKNESS

TUNGUM BATCH No. BS2871CZi27 TLC 100 1/2" OD x .044

(Imperial) 12mm x

Figure 5 Examples of tubing identiﬁcation

5.4.1 Installation practice

The installer should give due consideration to the following points during the execution
of the work and refer where appropriate to Annexes G, H and J:
−Tubing bends and offsets should be formed using bending machines to avoid
distortion.
−To prevent unacceptable static and dynamic stresses on all sections of the SBT
assembly, tube routing and support provision should be as set out within the
work pack.
−Special care should be taken to avoid the inadvertent introduction of unsupported
weak points; especially where the possibility of heavy loads could be applied during
service.
−Equipment such as valves, gauges, etc. should be independently mounted where
necessary and the tubing run should remain fully supported when equipment is
removed.
−Due consideration should be given to the operability and maintainability of
components such as valves, manifolds and instruments, as well as to the orientation
of indicating instrumentation to ensure ease of reading.
−Potential leak paths should be minimised by utilising the maximum length tube
sections, minimum connections and by utilising formed bends rather than elbow
ﬁttings.
−Tube sections vulnerable to mechanical damage should be mechanically protected.
−Tube routing should ensure:
- Good alignment with associated ﬁttings.
- Adequate drainage slope incorporated (refer to the work pack).
- That no dead legs or air locks are incorporated.
- That access to adjacent equipment is not hindered.
−Anti-static provisions should be provided.

5.5 SUPPORT

Details of the supporting requirement should be provided in the work pack dealing with
the installation of the respective SBT assembly. Of particular importance is the avoidance
of excessive static loading and vibration induced fatigue failure. Therefore the design
requirements for supporting assemblies should be adhered to (see also Annex I).

5.6 THERMAL EXPANSION AND ANTI-VIBRATION ARRANGEMENTS

For certain SBT assemblies, measures should be provided to prevent damage due to high
levels of thermal expansion and/or vibration induced fatigue failure. These systems should
be identiﬁed during the design process and appropriate design and support measures should
be speciﬁed within the work pack.

5.7 SELECTION AND USE OF THREAD SEALANT

There are basically two sealing methods commonly used: PTFE tape and anaerobic liquid.
Most operators specify a particular sealing method and the installer should comply with such
speciﬁcations where these exist and the designer should state which thread sealant is to be
used. The various attributes of each method are discussed in 5.7.1 and 5.7.2 (with further
advice in section 4.3.4.4) and these should be considered by the installer as there are certain
performance and safety aspects which should be taken into account:

5.7.1 PTFE tape

−PTFE tape is available in a range of different thicknesses/densities which affect the

performance and installation, e.g. thicker/denser tape requires fewer layers and
provides better sealing performance on gas systems than those that are less thick/
dense.
−Care should be taken to ensure that neither excessive nor insufficient tape is applied.
Excessive layers of tape may prevent interaction of the threads, with the possibility
that the connection may part under pressure and insufficient tape may lead to galling
and leakage.
−PTFE tape should not be applied ahead of the first thread to prevent ‘shreds’ of tape
accumulating inside the pressurised systems and blocking lines, such as pilot valves
on air or hydraulic supplies to process valves.

5.7.2 Anaerobic sealants

−These are liquid sealants requiring a curing period (varying from three to 72
hours) which is not always clearly stated on the instructions or datasheets.
−If pressure is applied before curing, the sealant may initially appear to hold pressure,
but may leak later during service.
−Compatibility with the process ﬂuid requires checking as the compound may dissolve
if used for certain applications containing solvents such as methanol dosing systems.

5.8 INSTALLATION CHECKLIST

All SBT assemblies should be thoroughly checked on completion of the installation (hook-up)
process. Figure 6 is an example of how an installation checklist could be compiled for
this purpose:

INSTALLATION CHECKLIST
Hook up ID: Installer: Date:

Item Check Y/N

1 Are all materials as per the design speciﬁcation?
2 Is the tubing adequately supported?
3 Have all tube bends been formed correctly?
4 Were all tube ﬁttings gauged?
5 Is appropriate sealant used on tapered thread connections?
6 Can the assembly be safely drained or depressurised?
7 Have 10 % of assemblies been disconnected and internally checked?
8 Have any as-built deviations been recorded and communicated (if
applicable)?
9 Has the assembly been leak/pressure tested, and to the
correct procedure?
10 Has the area been left in a clean and tidy state with excess materials
placed in the correct waste location?
Comments:

Signature:

Figure 6 Example installation checklist

5.9 CONFIRMATION AND CLOSE-OUT

The requirements for close-out and as-building the installed assembly should be provided
within the work pack. This ﬁnal part of the project should not be overlooked as it is an
important step in assuring that the assembly has been undertaken correctly. It also provides
valuable feedback to both the installer and the designer and is critical for maintaining
controlled documents (see section 4.6)

[6] INSPECTION, AND REPAIR AND MAINTENANCE

5.10[6.1] INTRODUCTION

SBT assemblies require regular inspection and maintenance to ensure ongoing integrity
throughout their entire service life, thus avoiding situations developing that are hazardous to
personnel and to the plant operations.
To assist the inspection and repair activities, SBT assemblies are best treated as
discrete components subject to the controls and procedures of the maintenance system.
However, the number of assemblies on a given installation is usually very high and will
not normally be identiﬁed by, for instance, a line number, as is the case for piping
(although unique instrument and valve tag numbers should be used if available).
Therefore, the development of a suitable electronic database should be considered
where the complete range of SBT components is identiﬁed and registered on the plant,
to ensure the effective management of spares and maintenance/intervention activities,
particularly with respect to the prevention of interchange or intermix of SBT components
of different sizes, shapes, materials and from different suppliers.

5.11[6.2] INSPECTION

6.2.1 Overview

Inspections of over 200 000several million SBT assembly components made by AFS
Technologies Limited during 2006 to 2012 2021 on offshore process plant installations
revealed that more thanas many as 25 % failed the integrity criteria required on the first
inspection. This indicates that it is important to have a system in place to ensure that
SBT assemblies, especially those on critical systems, are inspected on a regular basis and
appropriate remedial actions taken to correct any faults found. Faults relating to
assembly components most commonly found are:
−under-tightening of connections (see Box 2);
−interchange of materials or components;
−ﬂuid leakage;
−unsupported tubing and associated equipment;
−vibration fatigue failure;
−damaged and/or obstructed tubing, and
−material degradation.

Management system faults most commonly found are:

−Inventory issue and inventory storage control.
−Lack of management processes and procedures.
−Lack of installer competence during initial installation and reinstatement
following operations and maintenance interventions.

Box 2
The practice of ‘nipping up’ under-tightened or weeping connections still
prevails. From statistics, 25 % of all under-tightened or weeping connections,
when disassembled, have been found to have further internal faults that are not
apparent during a visual inspection. Typically these secondary faults are:
−missing ferrules (these are required to ensure a leak-free seal);
−ferrules in the wrong orientation;
−tubing not fully bottomed;
−tubing internals not de-burred;
−tubing not cut square;
−intermix of ferrule manufacturer and/or material;
−cracked tubing not visible, and
−seal area damaged/corroded.
(See also Annex N)

6.2.2 Inspection strategy

Speciﬁc inspection programmes should be planned and implemented on a regular basis to

establish the current condition of SBT assemblies and identify any remedial work required.
New and existing assemblies should be included in a routine inspection process which
typically forms an integral part of the maintenance of the corporate safety performance
standards (or their equivalent) for the installation. Integration of SBT assemblies into these
maintenance systems should assist in driving improvements in maintaining their integrity.
An example of a scheme linked to a maintenance management system is depicted in Figure 7.

All SBT assemblies to be correctly

Corporate Hydrocarbon designed and installed:
safety containment: - Correct materials
performance Separation & gas - No inter-mixing of ﬁttings
standards systems & non-HC - Adequate support
hazardous systems - Vibration control

Inspections of SCE equipment to

Assurance scheme
be scheduled within the MMS

SBT assemblies Risk assessments for systems in

inspection which SBT assemblies are used,
programme prioritising and planning

Criteria:
R1 - Leak(s)
Record results in YES Do SBT R2 - Distress: excessive vibration
MMS & close job assemblies R3 - Correctly matched ﬁttings
card meet PS? R4 - Correctly matched materials
R5 - Gauge tests
R6 - No remedial action taken

Record results in Determine Determine overall

Risk assess failures MMS & prioritise mitigating control SCE failure
remedial tasks measures criticality

Figure 7 Example of integration of inspections into corporate safety performance

standards

The inspection strategy should be developed using risk assessment. Risk assessment
should enable the planning and implementation of inspection programmes by:
−setting priorities, and
−identifying inspection frequency

However, due to the high numbers present, to risk assess every SBT assembly and subsequently
prioritise is not always practical to undertake and then to implement. Therefore, it may
be more pragmatic to take a system, part system or process package approach as deﬁned
by a boundary drawn onto the relevant P&ID.

The scheduling of inspection routines resulting from the inspection strategy

review should be integrated into the safety performance standards for each installation,
which will drive the scheduling and frequency of inspections.

6.2.2.1 Determine risk

Risk assessments should take into account threats to system operability, consequences of containment
failure, projectile release and any appropriate safety case requirements such as reliability of emergency
shutdown systems.
SBT assemblies with potentially high risk include but are not limited to, all those on hydrocarbon service,
water service greater than 20 Bar(g), toxic or corrosive chemical service, high pressure fluid power service,
assemblies required to ensure emergency action, any other system where loss of containment would
present a significant hazard.
Where no historical data exists, the inspection period of known similar systems or processes with similar
materials of construction should be considered.
Risk is a measure of potential failure leading to loss or injury, and is expressed as the
combination of the probability that an incident will occur and its consequences. Risk
assessments should take into account threats to system operability, consequences of
containment failure, projectile release and any appropriate safety case requirements such as
reliability of emergency shutdown systems.
SBT assemblies with potentially high risk include, but are not limited to, those used
for:
−Hydrocarbon service.
−Water service where operating pressures are greater than 20 bar(g).
−Toxic or corrosive chemical service.
−High pressure ﬂuid power service.
−Emergency systems.
−Other systems where loss of containment would present a signiﬁcant hazard.

Other risk impacts such as environmental damage and corporate reputation should also be
assessed using the appropriate operator’s procedures.

6.2.2.2 Determine the inspection frequency

The inspection period to be applied should be commensurate with the perceived risks. This implies
a local judgement and account should also be taken of the associated scale of activities and costs.
Information and data from the assessment of the criticality and inspection of the associated piping
systems should be considered.
Where sufficient information on the status of a potentially high risk system is not available, (or one
which has a history of successive failures) then a specific inspection (invasive or non-invasive) and
rectification activity should be considered.
Inspection frequencies should be consistent with the assessed risks. This requires a local
judgement taking into account the associated scale of activities and costs. Information
and data from the assessment of the criticality and inspection of the associated piping
systems should also be taken into account.
In the absence of relevant data, inspection periods of known similar systems or
processes with similar materials of construction can also be considered. Where sufﬁcient
information on the status of a potentially high risk SBT assembly is not available, (or one
which has a history of successive failures) then a speciﬁc inspection regime (invasive or non-
invasive) should be considered.

6.2.2.3 Prioritise inspections

As there will be numerous SBT assemblies to be included in the inspection programme,

inspection campaigns should be planned based on a priority system appropriate to the

installation, its management system, availability of resources and site access. An example of
a systems based prioritisation scheme is shown in Figure 8.

L1 L2 L3 L4 L5

Figure 8 Example of system prioritisation for inspection of SBT assemblies

Note 1: L1 being the highest priority and L5 the lowest

Figure 8 Example of system prioritisation for inspection of SBT assemblies

Note 1: P1 being the highest priority and P3 the lowest

6.2.3 Inspection planning

Planning inspection programmes and their implementation should be from within the
respective installation maintenance management system (MMS). It is normally convenient
to determine and then plan scopes of work on a ‘per inspection visit’ basis which could
be system or equipment package-based with boundaries as shown on, or marked up
on, the respective P&IDs.

6.2.4 Inspection procedures

Inspection procedures will differ for component types, should be produced as a result of a
maintenance strategy review and should include the following elements:

6.2.4.1 Visual inspection

a) Assembly:
— Under-tight connections (using manufacturer’s gauges where applicable).
— Over-tight connections (assessed by experience).
— Tubing bends too close to ﬁttings.
b) Fluid leakage
c) Adequate support for tubing and other components, such as valves, manifolds and
instruments:
[d)] Mechanical damage to tubingcomponents.

d)[e)] Vibration likely to lead to fatigue failure.

e)[f)] Tubing obstructed or in contact with structures or components
f)[g)] Poor quality bends or helixes
g)[h)] Corrosion under support clamps*
h)[i)] Pitting corrosion*
i)[j)] Combinations of different manufacturer’s components
j)[k)] Combination of non-compatible materials with or without galvanic corrosion
k)[l)] Appropriate valve handles ﬁtted
l)[m)] Proper system tagging, if applicable, as per the relevant P&ID.

For guidance on identiﬁcation and management of corrosion of stainless steels see EI

Guidance for corrosion management in oil and gas production and processing, Annex
B.11 Stress corrosion cracking and localised corrosion of stainless steels in chloride
environments.

6.2.5 Hidden faults

Annex N shows examples of ‘invisible’ faults that can arise from faulty assembly.

6.2.6 Execution of inspection work

The execution of inspection campaigns on SBT assemblies should be monitored and

controlled in accordance with good management practices and complying with relevant
procedures provided within the site safety management system.
The condition of each SBT assembly should be reported as required in the relevant
inspection procedure or by the work order system as appropriate. The information
should include detailed records of each component comprising the assembly, such as
material, tube OD, ﬁtting type, thread type, size, ﬂuid, pressure access, isolation and
manufacturer.
Inspection results should be recorded electronically by system, sub-system and/or
tag number to allow traceability of component parts inspected. This electronic record
may can be used to form a register of SBT components. Some operators may make use
of their MMS to record the inspection data.
All anomalies should be labelled with a unique reference to track remedial action
progress (see Figure 12) and if practicable, each anomaly should be photographed to assist
with remedial risk assessment.
Where an SBT assembly is found not to meet the required performance standard (PS),
an electronic copy of the relevant entry in an SBT anomalies register should be created and
from this register, maintenance work orders should may be generated.

5.12[6.3] INTERVENTION MANAGEMENT

Correctly designed, speciﬁed and installed SBT assemblies should require minimum levels of
maintenance and therefore, should require the minimum levels of intervention.

However, where intervention is required, it is mainly due to:

−Containment failures and/or severe mechanical damage.
−Remedial/corrective operations following inspection.
−Maintenance or isolation of associated plant and equipment where SBT assemblies
need to be disturbed.

6.3.1 Containment failures and/or severe mechanical damage

In the event of a containment failure and/or major mechanical damage, an investigation

of the root cause should be carried out by competent personnel, commensurate with the
level of risk assessed for the SBT assembly. Where appropriate, this information should be
fed back to the designers to assist with improving robustness of future designs.
Designing out potential failures and/or damage should be considered on all such
occasions (see section 4).

6.3.2 Remedial/corrective operations following inspection

6.3.2.1 Anomaly criticality assessment

Risk assessment should be carried out for each defect identiﬁed during routine inspections.
The consequence of failure of each defect identiﬁed should be assessed against criteria
such as personnel safety, production loss and environmental damage.
The Prioritisation tool in Figure 2 can be used as a part of the risk assessment to categorise the
risk, thereafter, the type and severity of the anomaly should be considered when building a risk
assessment. See Figure 9 for an example of the process, which may be employed with P1 as
high risk and P3 as low risk.
Operators should have a scheme in place to cover criticality assessment of anomalies.
Figures 9, 10 and 11 are examples of schemes which show how prioritisation for
interpretation of personnel safety, production and environmental consequences of failure
may be achieved:

Impact on Impact on the

Impact on production
personnel environment
safety
Slight injury or no Minor operational upset, Negligible release or
Low injury, non-permanent minor damage to no damage to the
(lost time) incident. equipment, no production environment
loss.
Moderate operational upset, Moderate release
Severe injury, (Lost moderate damage to or/and minor
Medium
Time Incident) equipment, unit shutdown damage to the
or production loss environment

Significant operational upset,

Significant release,
significant damage to
High Fatality significant damage
equipment, plant shutdown
to the
or significant production loss
environment

Figure 9 Examples of risk level deﬁnitions

Impact on production, personnel &

High Medium Low
environment
► Hydrocarbons - gas & liquid P1 P1 P2

► High pressure fluid power service

► Toxic & corrosive chemical systems
P1 P2 P3
► Produced water
► Other hazardous substances

► Water service >20 bar (g)

► Utilities P2 P3 P3
► Low pressure water service

Figure 10 Example of risk-based remedial prioritisation matrix

It may be useful to provide a decision-making process to re-assess priorities for

remedial action if the anomaly is seen to be subject to vibration. Figure 11 is an
example of how this may be achieved.

SBT Priority Level Leak, Major Moderate Interchange,

mechanical mechanical handle missing
damage or damage, poor and minor
severe support and damage
corrosion other faults
L1 P1 P1 P1
L2 P1 P1 P2
L3 P1 P2 P3
L4 P1 P2 P3
L5 P2 P3 P3

Figure 9 Example of a risk-based anomaly prioritisation matrix

Note: P1 being the highest priority and P3 the lowest

Defect under
excessive P1 P2 P3
vibration?

Perform risk Perform risk Repair within 12

No
assessment assessment months

Repair / reconfigure Repair / reconfigure Repair / reconfigure

Perform immediately. Repair period to be Repair period to be

Yes
i.e. as soon as determined by risk determined by risk
anomaly assessment. assessment.
identified

Figure 11 Example of a remedial work scheduling matrix

Note: P1 being the highest priority and P3 the lowest

6.3.2.2 Execution of remedial work

Prior to commencement of any remedial work, the system concerned should be
depressurised and the faulty connection taken apart and checked for further anomalies.
During such remedial works, components will need to be identiﬁed, corrected
and returned to service. As this may take a series of small but separate tasks, the operator
should have a system in place to manage and track the status of the ﬁtting as it undergoes
repair. Good management practice involves the use of a labelling/tear-off tag system to
indicate the status during the repair time. Examples of these are provided in Figures 12
and 13.

Refer to the example tag shown in Figure 12:

−On completion of the remedial campaign activity, remove the ORANGE tear-off
bearing the unique number.
−After removal of the ORANGE tear-off, arrange an appropriate SBT assembly pressure/
service test (See 6.3.4).
−On completion of the pressure/service test, remove the green tag and return to
coordinator.

Figure 12 Example inspection and remedial tracking tag

When the remedial tasks have been completed, the anomalies register should be updated to
record all actions taken and any further anomalies discovered.

6.3.3 Isolation of associated plant and equipment where SBT assemblies need to be
disturbed

An example of a simple tracking system using tear-off tags to track SBT assemblies which
may be disturbed during maintenance of associated plant and equipment is provided
here (refer to example tag in Figure 13). Such a procedure should involve a central co-
ordinator person responsible for managing the assurance process.

The procedure using this method should be as follows:

a) Identify the SBT fittings to be broken, tag and isolate as appropriate.
b) Loosen or remove SBT assembly components as required and tear off the RED section.
c) On completion of isolation or maintenance intervention work, check condition of all
fittings and replace if necessary.
d) Reinstate the assembly fittings.
e) Remove the ORANGE tear-off section (leaving the GREEN one in place).
f) Undertake an appropriate pressure/service test (see 6.3.4).
g) On completion of the pressure/service test, remove the green tag and return to
the coordinator.

h) Carry out line-walk and checks of disturbed assembly to ensure all tags have been
removed.

All activities should be undertaken by the appropriate competent personnel.

PART 3 - ON COMPLETION PART 2 - ON RE-MAKE PART 3 - ONCE JOINT

OF PRESSURE/SERVICE OF FITTING, RETURN BROKEN, RETURN
TEST, RETURN THIS TAG THIS TAG SECTION TO THIS TAG SECTION TO
SECTION TO SSoW CO- SSoW CO-ORDINATOR SSoW CO-ORDINATOR
ORDINATOR

Figure 13 Example intervention tracking tag

6.3.4 Pressure testing after SBT assembly intervention

Test procedures should be generated and made available to all personnel involved in
installation and intervention of SBT assemblies. An example of a pressure testing regime
following intervention and re-instatement of a given assembly or installation of new
components is shown in Annex M.
Any pressure testing procedure should comply with HSE Guidance note GS4: Safety
in pressure testing.

ANNEX A
TERMS AND ABBREVIATIONS
This annex contains brief descriptions of terms and abbreviations used herein that may
be encountered when working with SBT assemblies and components. For the purpose
of this publication, the interpretations of terms in A.1 and abbreviations in A.2 apply,
irrespective of the meaning they may have in other connections.

A.1 TERMS

close-coupled An attachment arrangement where the process instrument is

mounted directly onto the process isolation
hook-up Sometimes referred to as a construction function
hook-up drawing A schematic used on site for installation of the SBT assembly
operator A company appointed by the licensee for the development of
the
asset or field and operation of the associated process facilities.
Also refers to the duty holder company to which the operator
has delegated this legal responsibility.
Small bore tubing (SBT) Tubing having an outside diameter in the range 1/8" to 2" (or metric
equivalent) and associated fittings and supporting arrangements.
SBT Assembly An assembly comprising SBT and its associated fittings (valves,
non-return (check) valves, elbows and reducers) complete with
all installation and support fittings and those deployed to reduce
damage by stress and vibration.
Safety critical element
(SCE) SCEs are any part of the installation, plant or computer
programmes whose failure will either cause or contribute to a
major accident, or the purpose of which is to prevent or limit the
effect of a major accident.
SCQF Scottish credit and qualifications framework
Step Change in Safety A UK partnership between Oil and Gas UK, trade unions and the
HSE which through collaborative efforts, aims to improve safety
throughout the UK upstream petroleum industry
Technical Authority (TA) Discipline personnel appointed by management to be responsible
for the functional integrity of management systems and
procedures.
work pack A dossier of information for a project containing relevant
information for procurement, installation drawings and
sketches, commissioning and job close-out requirements.

A.2 ABBREVIATIONS

ALARP As Low As Reasonably Practicable

BSPT British standard pipe thread
COSHH Control of Substances Hazardous to Health
CSCC Chloride stress corrosion cracking
DBB Double block and bleed
ECITB Engineering and construction industry training board (a UK body)
HAZOP Hazard and operability study
HCR Hydrocarbon release
H2S Hydrogen sulphide
ICP Independent Competent Person
JIC Joint Industry Council.
LSD large scale deformation
MAWP Maximum allowable working pressure
MJI mechanical joint integrity
MMS maintenance management system
NOS national occupational standards
NPT national pipe thread
NPTF national pipe tapered thread
OD outside diameter
OEM original equipment manufacturer
P&ID process and instrument diagram.
PED (European) Pressure equipment directive
pH A numerical value expressing the hydrogen ion concentration indicating
the acidity or alkalinity of a solution.
PS Performance standard
PTFE Polytetrafluoroethylene (a synthetic polymer)
QCF quality credit framework
QRA quantitative risk assessment
SBT Small bore tubing: tubing having an outside diameter in the range
1/8" to 2" (or metric equivalent) and associated fittings and
supporting arrangements.
SSOW Safe System of Work
SCQF Scottish credit and qualifications framework
UKCS United Kingdom Continental Shelf
WBTA Work based task assignment
WT Wall thickness

the term ‘types’ of ﬁtting refers to the method used for jointing onto the tubing.

ANNEX B
REFERENCES AND BIBLIOGRAPHY

B.1 REFERENCES

American Petroleum Institute (API) (http://new.api.org)

API 607: Fire Test for Quarter-turn Valves and Valves Equipped with Non-metallic
Seats

American Society of Mechanical Engineers (ASME) (http://www.asme.org/kb/

standards)
B31.3: Chemical Plant and Petroleum Reﬁnery Piping Code

British Standards Institute (BSI) (http://shop.bsigroup.com)

BS 6755-2: Testing of valves. Speciﬁcation for ﬁre type-testing requirements

Energy Institute (EI) (http://www.energypublishing.org)

Guidance for corrosion management in oil and gas production and
processing Guidelines for the management of ﬂexible hose assemblies
Guidelines for the avoidance of vibration induced fatigue failure in process
piping Guidelines for the management of safety critical elements
High level framework for process safety management

European Parliament (http://ec.europa.eu)

Enterprise and Industry: Directive 97/23/EC of the European parliament and of
the council of 29 may 1997

Health and Safety Executive (HSE) (http://www.hse.gov.uk)

HSG65: Successful health and safety management
HSGS4: Health and Safety Executive, Safety in pressure testing
Research Report 168/1998:HSE Pressure Test Safety
Research Report 509: Plant ageing, Management of equipment containing
hazardous ﬂuids or pressure
CRR363/2001: Best practice for risk based inspection as a part of plant
integrity management
PUWER: Provision and Use of Work Equipment
Regulations OSCR: Offshore Installations (Safety Case)
Regulations KP3: Asset Integrity Programme Report, 2007
KP4: Ageing & Life Extension Inspection Programme Report, 2010
COSHH: Control of Substances Hazardous to Health Regulations

International Standards Organisation (ISO) (http://www.iso.org)

ISO 15156-3: Petroleum and Natural Gas Industries - Materials for Use in H
2S Containing Environments in Oil and Gas Production. Part 3 – Cracking
Resistant CRAs and Other Alloys

ISO 228-1: Pipe Threads Where Pressure-Tight Joints Are Not Made on the Threads
- Part 1: Dimensions, Tolerances and Designation
ISO 7/1: Pipe threads where pressure-tight joints are made on the threads

National Occupational Standards (http://nos.ukces.org.uk)

ECI SBT 01 Plan and conﬁgure small bore tubing systems
ECI SBT 02 Shape small bore tubing components
ECI SBT 03 Assemble small bore tubing components to meet speciﬁcation
ECI SBT 04 Install small bore tubing components
ECI SBT 05 Inspect and test small bore tubing assemblies
ECI SBT 06 Dismantle and remove components from small bore tubing assemblies
ECI SBT 07 Replace components in small bore tubing assemblies
ECI SBT 08 Prepare work areas, equipment and materials
ECI SBT 09 Reinstate the work area and store resources

Step Change in Safety (www.stepchangeinsafety.net)

Mechanical joint integrity: route to competence guidance.

B.2 INTERNAL REPORTS

Xodus Group (xodusgroup.com)

L-10036-S00-REPT-001-R01 FE Analysis of Mungo tubing geometries - Tubing
design guidelines, D. Stewart/J. Hill, March 2012
A-10323-S00-REPT-001-A02, EI SBT systems guidelines update - Definition of
support requirements for high mass tubing elements, B. Egun/J. McGhee, March
2013,
A-300132-S00-REPT-001-A01, BP Mungo: FEA of 1/2" NPT pressure gauge
assemblies, C. McIlwraith, August 2012,
A-10323-S00-REPT-002-A02, EI SBT systems guidelines update - Definition of
support requirements for tubing elements subject to stiction effects, B.
Egun/J. McGhee, March 2013,
A-10323-S00-REPT-003-A01, EI SBT systems guidelines update - Effect of
tubing diameter on large scale deformation stresses in tubing systems, D.
Stewart, October 2012,
A-10323-S00-REPT-004-A01, EI SBT systems guidelines update - SBT system
vibration response - critical tubing length investigation, C. McIlwraith, December
2012,
A-300295-S00-REPT-001-A01, ConocoPhillips SBT analysis – Vibration response,
C. Smith/J. McGhee March 2013,
A-300295-S00-REPT-002-A01, ConocoPhillips SBT analysis - Large scale deflections,
D. Stewart, February 2013,

ANNEX C
COMPETENCY REQUIREMENTS

C.1 INTRODUCTION

The continued integrity of SBT assemblies deployed on process plant and machinery relies
heavily on the competence of relevant personnel throughout the lifecycle from design
through to inspection. As described in section 1.2, the operator should ensure that its
management policy addresses this aspect effectively.
Figure C.1 is an example of how an operator’s strategy for reduction of loss of
hydrocarbon containment can be enhanced by maintaining the integrity of SBT assemblies
through ensuring competency of relevant personnel.

Integrity of
SBT assemblies
Getting it right
through
competency

No loss of containment Clear policies &

Annual anomaly reductions objectives
Reduce/eliminate emissions
Reports used
to achieve
Design, install, inspect and maintain improvements
Identify key roles
Assess skills & competency requirements
Ensure co-operation & communication

Adopt competency models Reviews used

Competency
Adopt training programmes to provide
(training &
Approve registered training centres correction
experience)

Adopt assessment criteria Assessments

Implement assessment programmes to adopted
Implement a competency register standards

Proactive measurements using regular Measure system

checks to show controls are working performance
Reactive measurement identiﬁes why YES NO
performance was substandard

Review incidents & inspection Review system Meeting

results Analyse causes of failure performance objectives?
Check competency compliance

Independent
audit

Figure C.1 Process for management of integrity of SBT assemblies through competency

This annex sets out those competencies that apply to a range of disciplines relevant to
the design, installation, operation, inspection and maintenance of SBT assemblies. It
outlines the differing levels associated with the various activities involved. It also lists speciﬁc
tasks where knowledge, skill and understanding should be demonstrated within a given
competency scheme.
C.3 5 provides an example of a competency scheme pathway which has been
devised for the UK offshore oil and gas industryEngineering Construction Industry and
which could be adopted by other similar industries.
It should be noted that all on-site work associated with SBT assemblies involves
compliance with permit-to-work systemssafe systems of work and process isolation
procedures relevant to each respective work site but which are outside the scope of this
publication.

C.2 COMPETENCE ASSURANCE AND REGISTRATION

Only personnel who have satisfactorily achieved the required level of competency for
their role, against a formal training programme (see example provided in C.3) should be
authorised to work on SBT assemblies. A register of authorised personnel should be
maintained and refresher training and competency assessment carried out as per the
requirements of the company’s policies and procedures.
Personnel working in the following disciplines should receive training and
assessment appropriate to their role:
−management;
−supervision;
−design;
−speciﬁcation and selection of materials;
−installation/assembly;
−maintenance, and
−inspection.

Competency schemes pathways should apply to all personnel working on SBT assemblies,
i.e. staff, short and long term contractors, etc. When working on site, such personnel
should also receive training on local policies and procedures such as those for
standardisation, storage and materials etc.

[C.2.1] Competency matrix

A typical competency model has been developed as part of a National Occupational

Standard (NOS) and Table C.1 is an example matrix showing how these requirements can
be reﬂected for the range of disciplines involved. This should be considered in
conjunction with the training and competency ﬂow chart shown in Figure C.1.

Table C.1 Example of key role competence criteria

Technician/Installer
Activity

Material Speciﬁer
(Reference: NOS ECI SBT series)
Key:

Maintenance
EK - Expert knowledge

Supervisor

Inspector
Manager

Designer
DK - Detailed knowledge
WK - Working
knowledge AP -
Appreciation
Plan and configure SBT systems
Mark out SBT systems to AP AP AP AP EK WK DK
required specification
Shape SBT components (tubing) AP AP AP AP EK WK DK
Assemble SBT components to
AP AP AP AP EK WK DK
meet specification
Install SBT components AP AP AP AP EK WK EK
Inspect SBT installations
Test the performance and condition of SBT AP AP AP AP DK WK EK
systems
Dismantle and remove components from
AP AP AP AP EK DK DK
SBT systems
Replace components in SBT systems AP AP AP AP EK DK DK
Prepare work areas equipment and materials WK WK AP AP EK DK DK
Reinstate work areas and store resources WK WK AP AP EK DK DK
Review technical information to produce
WK WK EK DK WK WK DK
detailed engineering drawings
Produce detailed drawings to support
AP AP EK AP AP AP AP
engineering activities
Minimise risk to life, property and the
environment within a design and AP AP EK EK AP AP AP
draughting context
Generate and evaluate engineering design
AP AP EK EK AP AP AP
options

[C.2.2] Typical content of learning and competency programmespathways

For the key roles stated in Table C.1, the following knowledge base and skill base elements
are typical (although not exhaustive) of the content of a SBT learning and competency
programmepathway.

C 2.2.1 Knowledge base

a) Understand the:
−principles of tube fitting sealing action.
−principles and requirements of tube gripping, holding and sealing action.
−importance of tubing surface hardness and being free from external flaws for
achieving a proper seal.
−main causes of tube and fitting system failure and loss of integrity.
−importance of tube selection, purchase, handling, and proper preparation, including
cutting, de-burring, and bending to proper system performance.
−make-up procedure for approved and installation-specific fittings.
−difference between initial make-up and re-make instructions for approved fittings.
−different assembly instructions involved when setting ferrules vs. installation of
fittings without ferrules.
−criteria for the permitted re-use of fittings and sub-components.
−prohibition on mixing components of different types and brands of fittings.
−recognition and rectification of potential problems.
- the application of tubing in high frequency applications
- the application of tubing in large scale deflection applications
- difference in tooling requirements for larger diameter and heavy wall tubing

and:
−why over-tightening is undesirable and how different manufacturers’ ﬁttings are
more susceptible to this problem.
−good installation practice; including correct and incorrect use of tools, including pre-
setting tools, if applicable.
−inspection criteria.

b) Able to identify:
−approved and other major manufacturer trade marks.
−criteria for selection of tube fittings and other components.
−approved imperial and metric tubing by dimension and material.
−approved imperial and metric tube fittings and component parts by
manufacturer identification, dimension and material.
−thread types.

c) Have awareness of:

−fitting/tube material compatibility limitations.
−pressure and temperature de-rating factors.
−hostile environmental factors (corrosion, vibration etc.).
−safety precautions.
−pressure testing requirements on completion of new or re-instatement work.
−installation/plant-specific policy on tube fittings and tubing system management
including the control and standardisation policy.
−installation practice for all applicable thread connections in use on the installation or
site.
−the design and technical information relating to the plant and equipment.

C.2.2.2 Task skill base

Demonstrate ability to competently execute:
−tube preparation.
−fitting make-up (approved and installation-specific types).
−re-make of fittings.
−tube bending practice.
−good installation practice.

−selection and use of approved tools.

−inspection and testing of SBT installations.

−safe isolation and dismantling.
−diagnosis and rectiﬁcation of installation problems.
−pressure testing of new and reinstated work.

C.3 COMPETENCIES FOR DIFFERING DISCIPLINES

[C.3.1] Managers

Managers should have the required training, experience and skills to effectively manage their
activities, which should include SBT assembly design through to installation and inspection,
in accordance with appropriate standards, policies and these guidelines to ensure safe,
reliable and cost-effective operations.

[C.3.2] Supervisors

Supervisors should have the required training and experience to ensure activities associated
with SBT assemblies are carried out in accordance with company processes and procedures
to ensure safe, reliable and efﬁcient operations.

C.3.1[C.3.3] Designers

Designers should be competent in the design of SBT assemblies and should have had
experience of the practical aspects of SBT assemblies through survey, installation,
inspection, testing, and commissioning. In addition, they should have attended speciﬁc
training courses. They should be aware of the principles of operation, limitations and
intricacies of the equipment and of their performance over their life-cycle.
Designers should have a thorough understanding of the failure mechanisms
encountered in SBT assemblies, e.g. faulty workmanship, corrosion mechanisms, static
loading, vibration induced fatigue and loss of support. They should consult with vendors’
representatives, operations personnel and engineering disciplines in the event that
uncertainties arise during the design process.
Designers should also be aware of the need to comply with the operator’s control
and standardisation of ﬁtting types policy (see Annex D.3), the management of change
(MoC) procedure and the requirement to invoke the design deviation approval procedure
where deviation is unavoidable due to, for instance, equipment packages utilising SBT
components from different original equipment manufacturers (OEMs).
Designers, in addition to knowledge-based training be assessed and deemed
competent in their knowledge of SBT assemblies.

[C.3.4] Material speciﬁer, procurement and stores

Buyers and stores personnel should be aware of the engineering speciﬁcations (see Annex
D.4) detailed by designers for any SBT projects/maintenance work, to ensure the correct
materials are procured, managed and issued in accordance with the job requirements.

C.3.2[C.3.5] Installation and construction personnel (SBT technician/installer)

Personnel carrying out the installation of new SBT assemblies should be trained, assessed and
deemed competent.

Installers should have experience in the general and speciﬁc details of installation or
‘hook-up’ phase and should be competent in the practical aspects of SBT assemblies from
selection of components, preparation and make-up of connections through to
installation, inspection, testing and commissioning.

C.3.3[C.3.6] Maintenance/operators

Maintenance and operator personnel who are required to work on SBT assemblies should
be trained, assessed and deemed competent. They should be aware of, and adhere to, their
company’s policies, standards and procedures applicable to SBT assemblies.

C.3.4[C.3.7] Inspector

Personnel carrying out inspections should be trained, assessed and deemed competent.

C.4 TRAINING

A comprehensive, structured training and development programme pathway should be

in place to provide both initial and refresher training and to assess learning and skills.
The extent of training and assessment should align with the person’s role in SBT activities
as described in
C.2.1. Approved courses covering the typical competency proﬁle shown in Figure Table C.2
should be used as a basis to acquiring a competency standard. Training and assessment
should also include the following essential elements (or ‘prior learning’):
−Knowledge of, or ability to do, risk assessment
−Familiarity with relevant company controls (such as permit-to-work and
isolation procedures), industry guidance and regulatory requirements, and
−Awareness of legal requirements.

Training should include site familiarisation and a period of on-the-job experience

involving developing and putting into practice, new skills and attained knowledge. Site-
speciﬁc training ensures that knowledge can be successfully applied. The operator should
consider whether safe working also requires further speciﬁc training and assessment (e.g.
manual handling, COSHH regulations).
Training should also include assessment of performance against a standard such as
the UK National Occupational Standards (NOS). Demonstration of competence may involve
direct and indirect observation, written records, logbooks and practical and written tests.
Wherever possible, the emphasis should be on workplace assessment.

C.5 EXAMPLE COMPETENCY SCHEMES

C.5.1 The ECITB/Step Change in Safety competency scheme

In the UK, the Engineering Construction Industry Training Board (ECITB) in collaboration
with Step Change in Safety have developed a method of training and validating skills for a
range of personnel involved with SBT assemblies that is aligned to the offshore oil and
gasEngineering Construction industry. The scheme is a code of practice outlining a 4-stage
model to follow as a route to achieving and maintaining competency and is an integral
part of the Mechanical joint integrity route

to competence guidance. This guidance was developed in association with the ECITB making
reference to the UK NOS for SBT.
The section relating to developing competence for those involved in SBT assemblies
has been reproduced in Figure C.2 but amended so that it aligns more closely with
current practice.

Stage 4
Reassessment Reassessment Reassessment
every 3 years every 3 years every 3 years
(Assessment centre)

Stage 3 TSBT01 TSBT02 TSBT03

Technical competence Install and assemble Disassemble Install and assemble
(Assessment centre) SBT assemblies and reinstall SBT coned and threaded
assemblies assemblies

Stage 2 Assemble and

Assemble and Disassemble and
install coned and
Workplace practice install install
threaded

SBT01 SBT01 SBT02

Stage 1 Assemble and Assemble and Assemble and instal
instal SBT with twin instal SBT with twin SBT with coned &
(Onshore training ferrule mechanical ferrule mechanical threaded; medium
centre) grip ﬁttings grip ﬁttings and high pressure

SBT competence route

Personnel undertaking operations on non-ferrous SBT assemblies.
Based on ECITB technical training standards and technical competence validation tests for
SBT assemblies.

Figure C.2 SBT competence route (based on Step Change in Safety/ECITB scheme)

C.5.1.1 Experienced personnel

It is recognised that this 4-stage scheme should incorporate those who are already have
experience in the tasks being assessed and therefore, the scheme provides for such personnel
to enter at Stage 3 and move on to Stage 4. Here, experienced workers may enter at Stage
3 where their company can conﬁrm that the existing worker has previously attended a
training course in SBT and has recent experience in that subject area.
However, some existing workers may require refresher training on the
knowledge aspects, and computer-based training modules that are aligned with the
technical training standards can behas been deployed for this purpose.

C.5.1.2 Roles and responsibilities

The matrix in Table C.2 provides guidance on the roles and responsibilities in SBT
operations which should be applied in conjunction with Figure C.2. The numbers refer to
the 4-stage model example.

Table C.2 Example discipline roles vs. responsibilities in MJI operations matrix

Key role – stages required

Decommissioning

Construction

SBT tech/Inst.
Maintenance
technician
Supervisor

operative

Inspector
Designer

Operator
Productio
Activity

Pipefitter
n
Work safely and minimise risk
in mechanical joint integrity 1 1 1,2,3 All 1,2,3 All All All
operations
Identify and deal with hazards
and emergencies in SBT 1 1 1,2,3 All 1,2,3 All All All
operations
Plan and conﬁgure SBT
assemblies in the engineering 1 1 1,2,3 All 1,2,3 All All All
construction industry
Dismantle and remove
components from SBT assemblies 1 1 1,2,3 All 1,2,3 All All All
in engineering construction
Shape SBT components in the
1 1 All 1,2,3 All All All
engineering construction industry
Replace components in SBT
assemblies in engineering 1 1 All 1,2,3 All All All
construction
Assemble SBT components
to meet speciﬁcation in 1 1 All 1,2,3 All All All
the
engineering construction industry
Install SBT in the
1 1 All 1,2,3 All All All
engineering construction
industry
Test SBT assemblies in the
1 1 1 1,2,3 1 All All
engineering construction industry
Inspect SBT in the 1 1 1 1,2,3 1 All All
engineering construction
industry

[C.5.2] In-house competence

In-house competency schemes should include assessment of performance against a

standard such as the UK National Occupational Standards (NOS). Demonstration of
competence may involve direct and indirect observation, written records, log books and
practical and written tests. Whenever possible, the emphasis should be on workplace
assessment (for example, competency assessment should involve completion of assigned
ﬁeld assessments in SBT component assembly, repair practices and completion of
relevant documentation).

[C.5.3] Example vocational qualiﬁcations

In the UK, the ECITB has developed a vocational qualification, which has been
approved for England and Wales as a Qualification Credit Framework (QCF) Diploma in
Installing Engineering Construction Plant and Systems – Small Bore Tubing Assemblies
Level 3, and in Scotland, as a Scottish Credit and Qualifications Framework (SCQF)
Diploma in Installing Engineering Construction Plant and Systems – Small Bore Tubing
Assemblies Level 6. Both have been derived from the UK NOS for SBT assemblies

C.5.1.3 Design Competencies

Due to the knowledge and skills required to competently perform the role of an SBT
designer, technical hands-on skills should not be compulsory to be deemed competent.
A similar pathway to competence should be developed with ECITB to provide stage 1
classroom training with a stage 3 online technical knowledge testing in a 3 year cycle.
The areas of competency required are listed in Table C.3

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Table C.3 Design Competence Requirements
Item Area EI Guideline Required Level
No Ref
1 Implication of releases 1.1 Awareness
2 Management Systems, Policies, 2 Awareness
Philosophies
GUIDELINES and Standards
FOR THE DESIGN, INSTALLATION AND MANAGEMENT OF SMALL BORE TUBING ASSEMBLIES
3 Safety Case and Performance 3 Awareness
Standards
4 Initial Assessment 4.3.1 Working
Knowledge
5 Material Selection 4.3.2, Annex E Working
Knowledge
6 Tubing Specification 4.3.3, Annex F Working
Knowledge
7 Fittings Specification 4.3.4, Annex F Working
Knowledge
8 Valve Selection 4.3.5, Annex F Working
Knowledge
9 Identification and mitigation of static 4.3.6, Annex G Working
Loads Knowledge
10 Identification and mitigation of 4.3.7, Annex H Working
dynamic Loads and vibration Knowledge
11 Supporting SBT Assemblies and 4.3.8, 4.3.9, Working
suitable clamps Annex I Knowledge
12 Close-coupled instrument Annex J Working
arrangements Knowledge
13 Traceheating and/or insulation 4.3.10 Good
appreciation
14 Design Deliverables 4.4, 4.5, Working
Annex K Knowledge
15 Close-out and asbuilding 4.6 Working
Knowledge
16 Pressure Testing Annex M Working
Knowledge
17 Installation 5, Annex N Good
appreciation
18 Inspection and repair 6, Annex M Awareness
‍

C.5.1.4[C.5.1.3] Inspector Competencies

In order to maintain the integrity of SBT inspections, Inspectors should complete a

technical competence validation test, which will specifically test the individual’s
knowledge and practical performance.

ANNEX D
POLICIES RELATING TO DESIGN OF SBT ASSEMBLIES

D.1 GENERAL

In general, corporate safety-related policies should set a clear direction for the organisation
to follow for elimination of risk and improvement in operational reliability. Such policies
should make specific reference to the management of SBT assemblies and should set the
direction for development of strategies, design philosophies and engineering specifications
derived from this. These documents are usually prepared for the initial engineering
design of a project during its development and will often remain applicable during the life
of the installation under a controlled document regime.
As a minimum, operators should develop and implement the principal policies
and documents specific to SBT assemblies (or their equivalents) set out in D.2-D.4:

D.2 DESIGN PHILOSOPHY

A design philosophy (or an equivalent) for the selection of equipment and installation of SBT
assemblies should be prepared by project teams that is consistent with relevant corporate
policy. The philosophy should also be consistent with project and piping system philosophy
and, together with current national and international standards, should be used to generate
engineering speciﬁcations (see D.4).

The following requirements should be incorporated within the design philosophy:

−Using SBT assemblies for connecting instrumentation to the process for monitoring
and control (i.e. impulse lines), chemical injection, hydraulic power, sample lines
for chemical analysis purposes, etc. Not using SBT assemblies for general process
purposes.
−Identifying and mitigating static and dynamic loads and providing appropriate
information on support requirements to the installer.
−Updating controlled P&IDs so that SBT assemblies used for process operations (e.g.
chemical injection) are depicted ‘as-built’.
−Specifying tubing, fittings and valves in accordance with a control and standardisation
of fittings type policy (see D.3) and procuring using the coded materials management
system for use in the project and operational phases of the installation. Tagging (or
clearly marking) components such as valves should be for identification purposes.
−Not have more than one type of tube fitting on sub-systems unless specifically
approved.
−Specifying components and the design of the assembly to meet the requirements
for resistance to vibration, repeatable make/break ability, resistance to impulse and
shock, temperature and pressure. Considering using an independent laboratory
when determining the suitability of previously un-assessed components such as a
new source of tube fittings.
−Specifying means of connection between instrument valves and the tubing assembly.
−Specifying twin ferrule fittings for safety, high pressure, corrosive and hydrocarbon
service because of their performance in high vibration situations.

−Specifying special fittings for high vacuum, high pressures applications etc.
appropriate to the range of application should be considered where
appropriate.
−Categorising fluid service in accordance with ANSI/ASME B.31.3 Section 300
Appendix M - Requirements for fluid service categorisation.
−Considering process conditions (e.g. pressure, temperature, process fluids and
properties, etc.), together with the process piping specification to allocate appropriate
corrosion allowances and to specify the range of fittings and tubing materials
and dimensions (see Annex E).
−Determining the environment in which the assembly will operate and its potential
effect on the assembly. Identifying the threats imposed by corrosion caused by
the external environment and the damage which excessive vibration could impose
(see Annex E).
−Consulting vendors where severe service is foreseen.
−Using flexible hose assemblies (FHAs) to accommodate extremes of movement but
not using them for convenience. Selecting, installing and using them in accordance
with EI Guidelines for the management of flexible hose assemblies.
−Providing primary isolation in accordance with the relevant piping specification.
Selecting flanged mono-block primary isolation valves with an integral DBB facility
designed to piping standards, or selecting a single piping isolation valve with
additional instrument valves for secondary block and bleed purposes. Where necessary,
facilities should be specified to allow valves to be locked in position. Taking particular
care in designing end fittings on valves with ratings in excess of 690 bar (10 000
psi).
−Providing individual instruments with isolation and bleed valves to allow their removal
for maintenance. This may be partly provided by the process isolation provisions and
supplemented with individual instrument valves or valve manifold arrangements.
−Specifying earthing requirements for tube supports to eliminate static electricity.
−Specifying the type of thread sealant for tapered threads e.g. tape, liquid, or
paste with consideration given to the suitability of the selected method relative
to the process medium, temperature, pressure and to the required cleanliness of
the components and/or system to which they are to be connected. For example,
specifically considering the consequences of contamination by thread sealant on
hydraulic control systems (e.g. subsea control systems).
−Specifying spares provision for the installation and start-up project phases during
detailed design.
−Identifying the types and sizes of tapered and parallel pipe threads.

D.3 POLICY ON CONTROL AND STANDARDISATION OF FITTING TYPES

Operators should aim to have no more than one type of tube fitting on a given
installation and the respective policy or design philosophy should state the preferred brand
and types of fittings and tubing, their metallurgy and the allowable combinations of these.
This can be manifested as appropriate within a specific policy document or embedded within
the design philosophy (see D.2) or within engineering specifications (D.4) and relevant
procedures for maintenance and repair; all of which should be controlled documents.
The strategy for implementing the policy should feature the technical management
and minimisation of the tubing, fitting and valve types. It should:
−Be communicated to, and understood by, all personnel involved in the design,
installation, commissioning, maintenance, operation and procurement of components
and plant and equipment containing SBT assemblies.

−Feature auditing programmes for selected vendors of SBT assembly components

and tubing to ensure their compliance with the policy.

The policy or design philosophy (and/or engineering standards) should include the following
minimum requirements:
−Preferred brand and types of fittings and tubes, their metallurgy and the
allowable combinations of tubes and fittings per assembly.
−Compliance of new and replacement assemblies with the defined requirements.
−Vendor compliance.

Such policies should be implemented for each new or existing installation or plant and where
such policy is not in place for existing plant and equipment, one should be developed by the
relevant TA.
On installations or plants where several brands and types of equipment and/or
inappropriate metallurgies are already present, a migration strategy to reduce the
number of brands and types in use and if needed, to correct component metallurgy,
should be considered.

Therefore, if applicable, the policy should also provide:

−A planned tubing, ﬁtting and valve type migration strategy per process system
or sub-system.
−A strategy to minimise the inventory by ‘design-out’, refurbishment and ad hoc
maintenance.

However, it may not be economically justiﬁable or technically desirable to convert all systems
to the preferred equipment type. In this event, it should be demonstrated that the range
of tubing, ﬁttings and valves has been minimised to that which is reasonably practical and
manageable and that management controls and personnel competencies are consistent with
the variable inventory.

D.4 ENGINEERING SPECIFICATIONS

Engineering specifications are generated from the design philosophy and provide detailed
information on the mechanical requirements for an SBT assembly for a given
installation. These are generated for each individual project and should be based on the
equipment range approved in the control and standardisation of fitting types policy (see
D.3).
The following should be taken into account when developing engineering
specifications:
−Specifications for tubing cover the range of applications in terms of material,
diameter, wall thickness, hardness, surface finish, ovality, etc. for the conditions to
be encountered.
−In specifying wall thicknesses and hardness, ascertaining compatibility with the
intended range of tube fittings. Over-thin or over-thick walls or improper
hardness will result in imperfect connections.
−Usually specifying seamless tubing for instrumentation applications.
−Ensuring the specifications are consistent with the associated process piping design
standards requirements.

−Including generic construction (hook-up) and routing drawings with associated

components lists. Annotating the drawings to provide guidance where necessary to
identify speciﬁc integrity requirements such as tubing expansion provisions.

D.5 MANAGEMENT OF CHANGE PROCEDURE

The operator should have in place a management of change (MoC) procedure for the
management of change to facilities, process plant and organisational arrangements in order
that no modiﬁcation takes place without risk assessment and approval by the relevant TAs.
EI High level framework for process safety management sets out guidance on the
general scope of an MoC procedure. This procedure is normally put in place to cover all
engineering changes for a speciﬁc installation including those made involving SBT
assemblies.
Therefore, physical changes to, or addition of, SBT assemblies to existing plant,
should be executed in compliance with the operator’s MoC procedure, which should include
gaining approval from the relevant TAs.

ANNEX E
MATERIALS SELECTION FOR SBT ASSEMBLIES

E.1 INTRODUCTION

SBT and associated fittings are produced from a wide range of materials and part of the
design process is to select the optimum materials for the intended service. This not only
includes compatibility with the internal fluids, but also the severity of the external
environment which can often in itself, dictate the materials selection process.
The component parts of an SBT assembly should be suitable for the range of design
applications and the metallurgy should be clearly shown in the company’s relevant
design philosophy or engineering specifications developed from that philosophy.
The potential for external corrosion damage from the installation arrangement
should also be considered especially where contact with clamps, fittings, adjacent tubing
and systems are of differing metallurgy. Chloride stress corrosion cracking (CSCC) caused
by exposure to saline water is of particular concern even at relatively low operating
temperatures.
The materials selection process should be undertaken by a qualified metallurgist
who has knowledge of current international standards and experience in the use of stainless
steels for SBT assemblies. Material selection should also be an element considered when
performing risk assessments associated with SBT design and installation.
Any engineering specification developed should be consistent with the associated
process piping design standards requirements. On projects, particularly large ones,
consideration should be given to standardising the material choice for all of the SBT
assemblies to avoid potential cross-contamination of tubes, fittings and valves.

E.2 INTERNAL COMPATIBILITY

Material compatibility with the internal fluid for all components should be ensured over
the temperature range, including any increases due to solar or other radiation sources. For
chemical injection points, this should include the possibility of backflow of other
chemicals or hydrocarbon fluids in and around the point of discharge.
As the SBT assembly service often involves transferring fluids that are proprietary
material (production chemicals hydraulic fluids) the supplier should be asked for guidance as
to the suitability and compatibility of the tubing materials during the design stage.
With oil and gas production fluids, especially if there is water present, material
suitability will depend on the temperature, in situ pH (being the pH value of the water
phase at the appropriate pressure and temperature), chloride content of the water phase
and the presence of hydrogen sulphide (H2S) and other contaminants, especially mercury.
A combination of H2S and chlorides can result in failures by sulphide stress cracking
or stress corrosion cracking, whilst elemental mercury can cause mercury embrittlement in
susceptible alloys.
Increased levels of CO2 in the fluids will result in a corresponding decrease in the in
situ pH (i.e. increase in acidity), and with increasing quantities of chloride salts and H 2S there
is an increasing risk of failure by sulphide stress cracking or stress corrosion cracking.
The materials selection process for each SBT assembly will therefore be on a case-by-
case basis in accordance with the composition of the fluid. For service with fluids containing
H2S, further guidance can be found in ISO 15156-3 [2].

Metallurgists should carefully assess the risk of mercury embrittlement when using
copper-based alloys such as Tungum ® (UNS C69100) for instrument tubing where
elemental mercury is present in the ﬂuid being carried. Such alloys may also be susceptible
to stress corrosion cracking from ammonia compounds.

E.3 EXTERNAL CORROSION CONSIDERATIONS

SBT assemblies often suffer and sometimes fail from external corrosion induced from
galvanic effects due to contact with other materials or the external environment.
Therefore, an environment severity assessment should be included in combination with
any design life and life-cycle analysis. The severity of the environment increases with
increasing temperature and the presence of chloride contamination of the external
surfaces, whether this is from seawater spray, ﬁrewater deluge systems or a coastal
location.

To assess material suitability, the following factors should be considered:

−The external environment, i.e. potential for CSSC.
−Potential effects of insulation.
−The design and positioning of the clamps to minimise the risk of crevice
corrosion and to prevent water collecting at the clamp location; and
−Galvanic corrosion between tubing and fittings; ideally the fitting should be the same
material as the tubing (for example, problems have been encountered with the
use of Monel™ fittings on Tungum® tubing);

316L stainless steel is a commonly used material for SBT assemblies; however, some external
environments have given rise to expensive failures due to:
−galvanic corrosion;
−CSSC, and
−pitting and crevice corrosion (particularly at supports and clamp locations).

CSSC is a particular risk, especially to alloy 316L, when at elevated temperatures and in a
salt-laden environment, which can occur in exposed regions of process plant such as turbine
halls or from solar radiation in tropical climates. At lower temperatures, pitting and
crevice corrosion are the greatest concern; for example, in severe environments 316L
tubing can become perforated within a relatively short period (months).

E.4 ALTERNATIVE ALLOYS

Several different stainless steels have been used to try and avoid the problems of CSCC and
crevice corrosion with various degrees of success. Table E.1 illustrates the range of alloys
currently deployed.

E.5 JACKETED/COATED TUBING

Jacketed or coated tubing offers the potential to minimise the risk of external corrosion.
It can be especially useful in extreme environments and where additional insulation/heat
tracing is required, e.g. for analyser instrument sampling lines.
The main advantage is its use where there are long multiple tube runs with no
vibration present, no future intervention activities planned and where the terminations do
not require protection from the environment. The main disadvantage being that the
fittings have to be installed at a cutback in the sleeving, leaving an area of metal exposed
creating a potential crevice corrosion site.
However, sealing methods for joints are available using heat shrink boots or sleeves
or silicon bonding tape to isolate the external surfaces of the entire fitting and adjacent bared
tubing following assembly.
Use of this approach depends on whether a life-cycle analysis shows sufficient benefits
,although the long term performance of certain coatings under ultraviolet degradation
requires confirmation. Competent installers should be deployed to ensure success.
Experience has indicated the following should be considered:
−As the ends of the tube and fitting require sealing using a heat-shrinkable boot, any
imperfections may cause ‘invisible’ accelerated crevice corrosion.
−The boot must be removed each time a connection is assembled/dismantled which
may give rise to faults in the reinstated seals.
−If the outer skin is damaged, there is the potential for crevice corrosion to occur.
−Where subject to high vibration the flat plate type clamps specific to multiple
assemblies can loosen and damage the outer cover.

Jacketed or coated tubing should not be used as a replacement for special alloys, except
where the only criterion for the material selection is for external corrosion protection, and
even in these applications crevice corrosion can become a concern as it is generally not visible.
Conventional paint coating of 316L is also an option, but is often seen as an impractical
solution as it needs to be kept in good condition at all times (free of chips or scratches)
otherwise crevice corrosion will set in. The paint thickness will also make dismantling joints
more difﬁcult.

E.6 MATERIALS SELECTION OVERVIEW

Although a wide range of materials could be used, determined by a range of corporate,

engineering and system variables, it is not appropriate to fully detail all their performance
limits as this is beyond the scope of this publication. However, in order to assist with the
materials selection process, some generic guidance can be provided as shown in Table
E.1.
Where materials for a service deviate from the generic guidance in Table E.1, a further risk
assessment should be carried out to determine the suitability of the material selected.

Table E.1 Materials for SBT assemblies

Fitting Ext.
Fitting Max
Tubing UNS material Temp Application
material PREN tubing Comments
material No (alterna- Limit recommendations

GUIDELINES FOR THE DESIGN, INSTALLATION AND MANAGEMENT OF SMALL BORE TUBING ASSEMBLIES
(primary) hardness
tive) (oC)
Not recommended for process or
marine environment use. Subject
to pitting and crevice corrosion
at typical ambient temperature;
AISI 20-50 Not normally for SCC
S31603 316 SS N/A 32 HRB90
316LSS (CISSC) hydrocarbon service occurs below 50 ºC if chloride levels
are very high (e.g. salt build-ups on
tubing). Might be acceptable where
the consequence of failure is low or
where design life is short or for use
in enclosed areas
Not recommended for general use.
AISI 316 SS (16 20-50 Not normally for
59

S31703 N/A 26 HRB90 Offers no signiﬁcant improvement

317LSS – 18 Cr) (CISSC) hydrocarbon service
over 316L
AISI Industry Standard. Failures occur by
316LSS 316 SS (16 20-50 General service. Review SCC and crevice corrosion at very
S31603 N/A 25 HRB75
>2,5 % – 18 Cr) (CISSC) required for well bay use high chloride levels due to salt build-
Mo up on tubing).
Good resistance to SCC, pitting or
Alloy Alloy 400 General service. crevice corrosion. Galvanic
400 - N04400 N/A HRB90 No limit
/ Cu - Ni Well bay coupling (with titanium, stainless
[Monel™]
steels, etc.) issues have to be
controlled
Good track record in hydraulic
service/ seawater service/ subsea.
Hydraulic and utilities. Not subject to SCC, pitting or
Cu – Cr HRB90 crevice corrosion. Monel ™ ﬁttings
Tungum® C69100 316SS No limit Not generally for
alloy mix should not be used with
hydrocarbon service Tungum® tubing due to the
potential for galvanic corrosion.
Do not use if liquid mercury is
present.
+44 (0)207 467 7100
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Table E.1 continued.

Fitting Ext.
Fitting Max
Tubing UNS material Temp Application
material PREN tubing Comments
material No (alterna- Limit recommendations

GUIDELINES FOR THE DESIGN, INSTALLATION AND MANAGEMENT OF SMALL BORE TUBING ASSEMBLIES
(primary) hardness
tive) (oC)
Subject to pitting (40-50 °C) and
22Cr 25Cr Super General service. crevice corrosion (15-20 °C), e.g.
S31803 N/A 31 HRB95 70-100
Duplex Duplex Well bay when salt builds up on tubing
but more resistant than 316L
Subject to pitting (60 °C) and crevice
25Cr
25Cr Super General service. corrosion (30-40 °C), e.g. when
Super S32750 N/A 40 HRC32 80-100
Duplex Well bay salt builds up on tubing but
Duplex
more resistant than 316L
Routinely used in the Middle East
Alloy 825- and North Sea on instrument tubing
Inconel: Ni General service. applications. Good resistance to
Alloy 825 N08825 316SS 28 HRB90 >120
alloy (not Well bay SCC, pitting and crevice corrosion
60

weldable) but suffers crevice corrosion in

tropical conditions.
Routinely used in the Middle East
and North Sea on instrument tubing
6 Mo SS: applications. Higher resistance to
100- Higher classification
6Mo SS S31254 (6 Mo-Cr N/A 40 HRB90 SCC, pitting and crevice corrosion
120 General service. Well bay
alloy) than other Austenitic SS but is still
subject to pitting (50-60 °C) and
crevice corrosion (30 °C)
Alloy 625 Used in process instrument tubing
Higher classification
Inconel: applications. Not subject to
Alloy 625 N06625 N/A 43 HRB90 No limit General service. Well
Ni alloy sulphides, SCC, pitting or crevice
bay. Sour gas
(weldable) corrosion.
applications
Routinely used in the Middle East
Alloy Higher classification. on process instrument tubing
Alloy C-276- General service. applications. High H2S (sour process
N10276 Hastelloy; N/A 45 HRB90 No limit
C-276 Well bay. oil/water) resistance - Not subject
Ni - Cr alloy Sour gas applications to sulphide SCC, pitting or crevice
corrosion.
GUIDELINES FOR THE DESIGN, INSTALLATION AND MANAGEMENT OF SMALL BORE TUBING ASSEMBLIES

ANNEX F
COMPONENT SELECTION

F.1 INTRODUCTION

All component parts of an SBT assembly must be constructed of materials suitable for
the range of design applications. This section aims to assist the designer with the selection
of the principal components comprising an SBT assembly.
Design should be consistent with the appropriate design philosophy and
consequently with its engineering specifications throughout the respective installation or
plant. Where applicable, all components selected must meet the requirements of the
European Pressure Equipment Directive 97/23/EC (PED) or national implementing
legislation.
The range of principal components includes: tubing, twin and single ferrule tube
fittings, primary isolation valves, Joint Industry Council (JIC) fittings, vacuum seal fittings,
butt-welded fittings, O-ring seal fittings, connectors, threaded connections and valves. A
range of SBT assembly fittings is shown in Table F.1 and descriptions of the more commonly
deployed fitting and valve types are provided in F.3-F.6.

F.2 TUBING

There are many tubing options available and it would be unrealistic to expect
engineering speciﬁcations to cover all possibilities. However, to assist with specifying tube
for a particular application, the following considerations should be taken into account in
addition to the requirements of the design philosophy:

a) Considering manufacturing quality requirements such as the need for seamless, fully
annealed tubing with acceptable hardness factors, surface finishes, and dimensional
accuracy.
- Tube hardness is critical and should be compatible with the fitting
specifications. Vendors should be consulted when specifying tubing and
tubing/fitting combinations.
b) Determining at the outset whether to select metric or imperial tubing sizes. As cost,
technical attributes and quality are the same for both versions, the decision will
be based on project or national preferences, together with material availability.
c) Whilst OD size is application-specific, taking the following into consideration:
- Process conditions such as pressure, temperature, flow regimes, fluid
properties presence of solids (suspended solids).
- Process flow requirements for metering applications and motive energy for
sampling systems.
- Capacity considerations for pneumatic and hydraulic distribution systems
- Mechanical strength, where sections are either exposed to potential damage
or they are connected to heavy components, e.g. valves, instruments.
d) Determination of wall thickness having considered the process conditions,
particularly pressure and temperature.
- MAWP from data tables should be referenced but special attention is required
when considering extremes of temperature.
- Erosional velocities should also be considered for fluid transfer duty and wall
thickness should be determined accordingly.

Notes
i. Fitting manufacturers may not recommend the use of their fittings on heavy wall
applications. In such cases, advice should be sought from the manufacturers
and where necessary, alternative fitting types should be considered.
ii. In all circumstances involving the combination of heavy wall tube and ferrule
type fittings, the use of a hydraulic swaging tool should be specified by the designer.
For consistent results, the designer may wish to extend the use of the hydraulic
swaging tool for all applications where ferrule type fittings are utilised.

Welded assemblies should be considered where the tubing geometry is complex, for
high vacuum service, for critical applications involving corrosive ﬂuids and where shock from
pressure surges, temperature cycling, high vibration, etc. can occur.

F2.1 Temperature Consideration

It is important to consider applicable process temperature for all SBT designs. Any
pressure, differential pressure gauges and transmitters are only suitable for a range of
process temperature as specified by the respective manufacturer. SBT design should
carefully consider the design temperature range of the applicable process and ensure
that the design is suitable for the instrument for which it is meant. Designers should
consider the following in SBT design:
a. Temperature derating factor, as specified by SBT manufacturer, shall be
applied in determining required wall thickness of tube for the applicable
process design pressure.
b. Instruments should be selected such that the maximum allowable
temperature is equal to or above the process design temperature. Where
this is not possible, a minimum length of SBT should be considered and
specified in the hook-up diagram for process design temperatures
exceeding that of the instrument for which the SBT design is meant.
Considering SBT as heat sink fin of finite length that loses heat by
convection at both ends, the following heat transfer equation 1 can be used
to calculate minimum tube length sufficient to dissipate heat to bring the
process fluid at an acceptable temperature for the instrument:

(T - T∞) = cosh m (L – x) + (h/mk) sinh m (L – x)

(T0 - T∞) cosh mL + (h/mk) sinh mL

Since ‘L’ is equal to ‘x’ in this application, the above equation simplifies as:

(T - T∞) = 1

(T0 - T∞) cosh mL + (h/mk) sinh mL

Value of ‘m’ can be calculated as below considering m2 = hP / kA:

m = √ ( 4 h D1 / 12 k (D12 – D22).

Where,
T = Temperature at the point of interest (i.e. at instrument end), in 0F
T0 = Temperature at the base of the fin (i.e. at process line/ vessel end) , in 0F
T∞ = Temperature of surrounding atmosphere/ air, in 0F
m = Mass, in lb
L = Length of fin (i.e. length of tube), in inches

x = Distance from process line/ vessel, in inches

k = Co-efficient of heat transfer (thermal conductivity), in BTU/ hr * ft * °F
h = Convection heat transfer co-efficient from tube to surrounding atmosphere/ air (can be
assumed as 1.44 BTU/ hr * ft2 * °F assuming surrounding air at 100 °F temperature)
D1 = Tube OD, in inches
D2 = Tube ID, in inches
A = Area (cross section area of fin) = π (D12 – D22) / 4
P = Perimeter = π D1.

Note: It is advisable to allow enough margin on calculated minimum tube length ‘L’ in SBT
design.

F.3 MECHANICAL GRIP TUBE FITTINGS

There are many manufacturers of tube fittings worldwide each with their own design,
specification and make-up action. Mechanical grip fittings are very dependent on rigid material
specification and manufacturing tolerances and the individuality of each manufacturer’s
design makes their sub-components non-interchangeable with other designs. The fittings are
proprietary items and their sub-components must not be interchanged with those of other
manufacturers unless specifically approved by policy and procedure.
There are principally two types of ferrule tube fittings; twin and single:

F.3.1 Twin ferrule ﬁttings

Twin ferrule tube fittings are generally the most commonly used components in SBT
installations. They are used primarily to connect tubing to tubing and/or to threaded
ports of other elements of the assembly such as instruments. Their simple operation
facilitates ease of installation. They are available in a wide range of configurations, sizes,
thread types, materials and pressure ratings for normal and heavier walled tubing. To date,
there are no national or international standards applicable to the design of twin ferrule
fittings for SBT.
This type of fitting is used extensively in high integrity, high performance applications
(e.g. hydrocarbon and toxic processes, high pressure, low to medium vacuum; they generally
have good resistance to vibration).
The integrity of twin ferrule tube fittings is dependent on the correct selection of
fittings and tubing for the intended application and their correct installation. The
approved combinations of fittings and tubing should be specified for the range of
applications within the operator’s engineering standards or specifications and only these
combinations should be applied. Positive identification of the fittings and tubing must be
established by installation personnel.

F.3.2 Single ferrule tube ﬁttings

Single ferrule tube fittings (like their twin ferrule counterpart) are used in some specific
SBT installations. They are available in a wide range of configurations, sizes, thread types,
materials and pressure ratings. Currently there are no national or international standards
applicable to single ferrule fittings for SBT.
The integrity of single ferrule tube fittings, like their twin ferrule counterpart, is
dependent on the correct selection of fitting and tubing for the intended application and

their correct installation. The approved combinations of fitting and tube should be specified
for the range of applications in the design manual and only these combinations should
be applied. Positive identification of the tube and fitting must be established by
installation personnel.

F.4 JIC FITTINGS

JIC fittings are commonly used in SBT assemblies installed in diving systems within hydraulics,
breathing air, and water system applications, etc. They are used to connect tubing and
pipework to equipment and are produced by several manufacturers with individual approvals
and specifications appropriate to the manufacturer’s target market application. The specific
approvals and specifications for the range of equipment to be used should be checked
against the intended use. They are available in a wide range of configurations, sizes
(imperial and metric), materials and pressure ratings.
Seamless, fully annealed, cold drawn tube is generally best for end flaring and should
be softer than the fitting material and fitting manufacturers should be consulted on the
required tubing specification.
The integrity of JIC fittings is dependent on the correct selection of fitting and tubing
for the intended application. Combinations of fitting and tube should be specified for the
range of applications in the relevant specification and approved by the relevant TA.

F.5 VACUUM SEAL FITTINGS

Fittings suitable for vacuum service in SBT assemblies are available from several manufacturers
and include twin ferrule tube fittings, weld fittings, metal gasket and O-ring face seal fittings
and specialist fittings for quick assembly. A large range of configurations is available, e.g. O-
ring seal connectors in parallel thread female port configuration. Designers should strive to
minimise the number of fittings to reduce the potential cumulative leakage path, and should
attempt to standardise on one thread form for equipment connections.
Manufacturers’ technical data should be consulted to establish the suitability of these
fittings for specific vacuum applications.

F.6 WELDED FITTINGS

Weld fittings are used in high vacuum, high toxic fluid, high purity or limited space
applications. Weld fittings are produced on a range of components (e.g. elbows, tees,
reducers and valves) by several manufacturers to full tubing and piping specifications with
butt, tube socket and proprietary weld ends.
Guidance on the practical aspects of welding of components in SBT assemblies is a
specialist activity and is outwith the scope of these guidelines.

Table F.1 Commonly deployed SBT assembly ﬁttings

Fitting Type Material Typ. Max OD size Tooling Typical Usage Comments
examples pressure range requirements application
(bar)

GUIDELINES FOR THE DESIGN, INSTALLATION AND MANAGEMENT OF SMALL BORE TUBING ASSEMBLIES
Carbon steel, The standard
Hand tools Three main
316SS method of
1/16” to for smaller manufacturers dominate
Alloy 400 6Mo connecting tubing
2” sizes. All surface the market.
Twin ferrule Alloy 825 695 in the oil and gas
3 mm to Dependent on facilities industry. There are however,
Alloy 625
50 mm material, size & over 40 manufacturers
Super duplex Used in all offshore
alloy C-276 manufacture; of twin ferrule tube
installations in UKCS.
powered tooling. fitting.
Hand tools
for smaller
Carbon steel Frequently found on There is a wide variety
sizes.
316SS vendor equipment. of manufacturers of
All surface
Single ferrule Alloy 400 695 this type of fitting, with
facilities Not specified on any
6Mo an equally wide variety
Dependent on UKCS installations
Alloy C-276 of quality standards.
material, size &
manufacture;
64

powered tooling.
Subsea control Brass versions used JIC or AN type female
Carbon steel hydraulics, mostly on diving gas swivel is a standard
Tube ﬂaring tool equipment. hose termination
316SS 1/4” to diver
Flared 350 for each size
Monel 2” breathing air Once the standard having a 37º ﬂare and
range.
Brass and water for gas turbine manufactured to SAE
systems packages. J514.

High pressure
Twin ferrule, hydraulics A relatively new Developed as an
1/4” to
medium 316SS 1 034 Hand tools technology <six alternative to coned and
1” Process
pressure years in use threaded technology
impulse lines

316SS High pressure The standard

Coned & hydraulics
Alloy 400 Tube has to method of
threaded, 1/4” to
Alloy 825 1 360 be coned and Process connecting medium
medium 1”
Alloy 625 threaded impulse lines pressure tubing in
pressure
Alloy C-276 Subsea control the offshore UKCS.
Hydraulically 316SS 1/4” to Hydraulic High pressure A relatively new For reference – outside
swaged 1” swaging tool for hydraulics technology <four the scope of this
Super duplex
1 360 6mm to all sizes. Process years in use publication.
25mm impulse lines
Subsea control
GUIDELINES FOR THE DESIGN, INSTALLATION AND MANAGEMENT OF SMALL BORE TUBING ASSEMBLIES

F.7 O-RING AND METAL GASKET FACE SEAL FITTINGS

O-ring and gasket face seal ﬁttings (or zero clearance ﬁttings) are essentially a parallel threaded
connection. They require no axial clearance and permit easier connection and disconnection
of components to and from SBT assemblies with little disturbance of the tubing.
The manufacturer’s installation instructions should be followed at all times.

F.8 ADAPTER FITTINGS AND PORT CONNECTORS

Adapter fittings and port connectors are provided by manufacturers in a range of sizes and
configurations to facilitate the close coupling of components in congested locations (e.g.
control panels), when two components have to be coupled together, or when the relative
orientation of the components is critical. The connection is made without the use of
tubing and provides a consistent connection methodology.
Adapter fittings and port connectors are manufactured to high tolerances by
individual manufacturers for operation with their proprietary range of tube fittings and
they are not suitable for use with fittings of other manufacturers. This should also apply for
SBT/ FHA tube adapter fittings.
Port connectors allow two components with integral tube fittings to be close-coupled
without the use of short lengths of tubing. Manufacturers of such fittings should provide
specific make-up procedures.

F.9 THREAD CONNECTORS

Tapered pipe threads and parallel threads are used extensively in SBT assemblies generally to
join tubing to equipment. The main types likely to be encountered are:

Table F.2 Common pipe threads used in SBT ﬁttings

Pipe threads (tapered): Parallel threads:

American standard pipe thread (NPT) British standard pipe parallel (ISO 228/1)
National pipe tapered thread (NPTF) Metric screw thread (metric ISO)
British standard pipe thread (BSPT) (ISO 7/1) Uniﬁed screw thread

The above threads and their make-up action are further described in 5.3.3.
Galling of tapered threads, particularly stainless steel, is a recognised issue with
the use of this thread form. Where applications require multiple make and break of the
connections, tapered threads should be avoided wherever practicable. In addition to
reducing the risk of galling, the use of alternative thread forms reduces the potential of
contamination from sealant material.

F.10 VALVES

There are many valve types available for use with SBT assemblies as listed in Table F.3.
They are mostly provided for isolation and for use on site-mounted instruments.

Table F.3 Valve types associated with SBT assemblies

Valve type Uses

Mono-flange −Primary isolation in the form of a flange where space for a more conventional
isolation valve might be limited.
−Available in a number of configurations but typically used in double block and
bleed applications.
Compact −Primary isolation utilising standard valves in a compact arrangement,
generally to save space.
−Available in a number of configurations but typically used in DBB applications.
−Often provide a transition from the main pipeline flange connection to
the instrument hook-up screwed connection
Needle −Secondary isolation or for precision flow control applications.
Check −To limit the flow in one direction
Velocity −To provide rapid closure in the event that an abnormal downstream
check differential pressure occurs, i.e. tube rupture or damage
−Can prevent or at least limit the extent of a leak
−Suitable only for clean fluid service
Quick −To provide rapid discharge of controlling medium on detection of an
exhaust abnormal upstream differential pressure, e.g. on a valve actuator where rapid
valve closure is desirable given a release of upstream pressure in the control
line.
Ball −For secondary isolation where full bore flow is normally required
Diverter −To control the direction of flow. These are often configured ball valves.
Flow or −To control the flow in at least one direction. These often allow free flow in
speed the return direction
control
Regulator −To regulate pressure. These do not guarantee tight shut-off
Metering −To regulate the flow, usually impervious to inlet pressure fluctuations
Relief −To relieve pressure where overpressure can create a hazardous situation
Solenoid −For control circuits to vent or divert flow depending on the status of
the control signal
Pilot −For control circuits to vent or divert flow depending on the status of
operated the signal pressure.
Fusible plug −Used in control circuits to vent or divert flow depending on the status of
the fusible plug.
−An added safety device where action is needed in the event of localised fire.
Manual −Used in control circuits to vent or divert flow depending on the position
diverting of the manual pushbutton or lever.
Cam −Used in control circuits to vent or divert flow.
operated
Manifold −Can be 2, 3 and 5 valve manifolds and are used for secondary isolation,
venting, diverting and equalising pressure at the instrument.
−Particularly useful for calibration, test and maintenance purposes.
Gauge −For direct mounting of instruments allowing flexibility in terms of orientation

The designer should also consider the following when selecting valves for a particular SBT
assembly:
−Selecting relief/safety valves and accessories classified to Pressure Equipment
Directive (PED) as category IV. Safety accessories manufactured to protect specific
pressure equipment classified to a lower category may be acceptable provided they
are classified in the same category as the specific pressure equipment they protect.
−Not selecting ball valves for use on high pressure systems for instrument isolation
purposes as damage could occur to the instrument diaphragm due to surge
when the valve is opened.
−When using a single isolation valve arrangement, considering use of additional block
and bleed valves normally provided within SBT assemblies using instrument valves.
The tubing connection to the single piping isolation valve is normally made via a
flange to tubing connection, e.g. a lap joint adapter to tube fitting or threaded flange.
−Each instrument having a single block and bleed as a minimum means of isolation.
−Specifying valves for use with instruments that are appropriate to their function (e.g.
isolation, regulation, direction, protection). It should be noted that all instrument
valves have limitations in their temperature-operating constraints and therefore their
temperature specification should be checked against the duty conditions. The valve
flow coefficient (Cv) should be specified commensurate with its duty.
−Specifying the materials for soft seals or gaskets within valve assemblies must be
selected with regard to compatibility with the process fluid (see Annex E). When
deployed for pressurised gas service, rapid (explosive) decompression of the system
can affect soft seals and careful material selection can prevent this.
−Specifying valves, manifolds and instruments for use on hydrocarbon service that are
designated fire-safe (e.g. designed to API 607 or BS 6755).

ANNEX G
IDENTIFICATION AND MITIGATION OF STATIC LOADS

G.1 INTRODUCTION

The primary static loads that affect an SBT assembly should be identiﬁed by the designer. Static
loads in this context are those which are considered to be the equivalent to the operating and
sustained loads described in piping design codes such as ASME B31.3. These are
essentially weight, pressure and temperature.
The design considerations for pressure and temperature should be accounted for by
appropriate selection of material, tubing diameter, valve and ﬁtting type and these effects
should be covered in the operator’s standards. The effects of distributed mass (the weight of
the tubing and primary components), are catered for by the appropriate selection of support
type and placement; see Annex I.
The static load considerations that are not adequately catered for in existing
standards and guidelines are the:
−Effects of high mass components (mass point loads).
−High transient torque loads which can be applied when opening and closing
high- stiction valves.
−Effects of temperature-related thermal expansion of host piping and the resultant
loads induced in the SBT assembly.

These aspects of static load are each discussed within this annex.
The concepts discussed in this annex apply to the tubing materials and dimensions
listed in Tables G.1 and G.2.

Table G.1 List of applicable tubing material properties

Description Density Modulus of 0,2 % Poisson’s

(kg/m3) elasticity proof ratio
(MPa) stress
(MPa)
SS254 SMO (6 % Molybdenum) 8 000 1,95 x 10 5
350 0,3
SS316 (316 stainless steel) 7 850 2,00 x 105 290 0,3
UNS N10276 (Alloy C-276) 8 890 2,05 x 105 358 0,3

Table G.2 List of applicable tubing dimensions

Outside diameter Wall thickness Bend radius

(OD) (WT)
0,028”
0,035”
1/4” 0,56”
0,049”
0,065”
0,035”
3/8” 0,049” 0,94”
0,065”
0,049”
1/2” 0,065” 1,5”
0,083”
1,0 mm
6 mm 15 mm
1,5 mm
1,0 mm
10 mm 24 mm
1,5 mm
1,0 mm
12 mm 1,5 mm 38 mm
2,0 mm

Design deﬁnitions for tubing systems other than those listed in Tables G.1 and G.2
require detailed analysis and are not presently covered by this publication.

G.2 HIGH MASS POINT LOADS

The existence of unsupported high mass valves and other components in SBT assemblies
(high mass point loads) represents a potential threat in terms of the permanent high
sustained loads which act on the components of the assembly, increasing the threat of
damage and failure to the more vulnerable elements. High mass components also have
the potential to signiﬁcantly reduce the stiffness of their respective SBT assemblies, in turn
increasing the threat of low frequency vibration induced failures (covered in more detail
in Annex H).
The mass required to cause damage to an SBT assembly is a function of both
the actual component weight and the stiffness of the surrounding tubing arrangement.
The designer should therefore be aware of both the individual weights of the high mass
components present in the SBT assemblies and the position of the masses in relation to
other SBT components, tubing sections and supports.
It is the responsibility of the designer to identify these vulnerable combinations of
mass/SBT assembly stiffness and determine whether additional support is required at the
location of the point mass(es).
Tables G.3.A and G.3.B are provided to assist the designer in identifying these
vulnerable arrangements (reference Xodus report A-10323-S00-REPT-001-A02). Note, the
distances shown on the stiffness axis are normalised to numbers of diameters. Deﬁnitions of

stiffness factors are provided in Table G.4 and a conversion table from length to diameter for
common tubing is provided in Table G.5.

Table G.3.A Support deﬁnition for high mass components in SBT assemblies
– 6 mm and 1/4” tubing diameters

SBT Arrangement stiffness (DM – Support distance in diameters from mass, Mc)

Component Low Low to med Medium Med. To high High

Unknown
mass, (Mc) kg DM > 40D 40D > DM > 30D > DM > 20D > DM > 10D DM < 10D
30D 20D

Support Support Support Support Support Support

5 < Mc
required required required required required required

Support Support Support Support Support

2 < Mc ≤ 5 OK
required required required required Required

Support Support Support Support

1 < Mc ≤ 2 OK OK
required required required required

Support Support
0,5 < Mc ≤ 1 OK OK OK OK
required required

Support
Mc ≤ 0,5 OK OK OK OK OK
Required

Support Support Support Support Support Support

Unknown
required required required required required required

Notes:
1 DM – Support distance in diameters from component mass, Mc
2 D – Tubing diameter

Table G.3.B Support deﬁnition for high mass components in SBT assemblies
– 10 mm, 12 mm, 3/8” and 1/2” tubing diameters

SBT Arrangement stiffness (DM – Support distance in diameters from mass, Mc)

Component Low Low to med Medium Med. To high High

Unknown
mass, (Mc) DM > 40D 40D > DM > 30D > DM > 20D > DM > DM < 10D
kg 30D 20D 10D

Support Support Support Support Support Support

10 < Mc
required required required required required required

Support Support Support Support Support

5 < Mc ≤ 10 OK
required required required required Required

Support Support Support Support

3 < Mc ≤ 5 OK OK
required required required required

Support Support Support

2 < Mc ≤ 3 OK OK OK
required required required

Support
Mc ≤ 2 OK OK OK OK OK
Required

Support Support Support Support Support Support

Unknown
required required required required required required

Table G.4 Tubing stiffness factors used in Tables G.3.A and G.3.B

Stiffness Support distance (diameters from

component mass)
Low DM > 40D
Low to medium 40D > DM > 30D
Medium 30D > DM > 20D
Medium to high 20D > DM > 10D
High DM > 10D
Notes:
1 DM – Support distance in diameters from component mass, Mc
2 D – Tubing diameter

Table G.5 Converting no. of diameters to distance for common tubing diameters

Distance (mm)
Diameters 6 mm OD 10 mm OD 12 mm OD
10 60 100 120
20 120 200 240
30 180 300 360
40 240 400 480

To use Tables G.3.A and G.3.B, the designer should ascertain the mass of each component in
the SBT assembly and should have an understanding of the actual SBT conﬁguration. If
either the component mass or the conﬁguration is unknown, the component should be
supported.

G.3 HIGH STATIC FRICTION (STICTION) VALVES

When operating valves, torque loads are developed through the handle mechanism and are
typically reacted on the external surface of the valve body, at the points which prevent the
valve body from moving. If the valve body is not supported adequately (e.g. from steelwork),
these torque loads are applied directly to the instrument tubing connections. These
connections are relatively weak and can easily be damaged by repeated valve operation.
Designers should therefore identify valves which may be subject to high levels of stiction
and which could cause damage to the SBT assembly.

G.3.1 Identifying high stiction valves

The primary factors affecting the degree of stiction in valves are.

−Pressure differential across the valve.
−Valve design.
−Mechanical friction between sliding surfaces (level of lubrication, surface deterioration,
corrosion, etc.)

Using the above factors, it may be possible to define broad criteria which would
allow valves to be ranked in order of the level of stiction generated when operated. In
general, the higher the pressure differential across the valve, the more difficult the valve
is to operate. However, valve design has an influence, e.g. regulating stem (needle) valves
typically induce less torque than rising plug needle valves due to the difference in the
exposed surface area in the valve cavity.
To define an accurate pressure differential table for each different type of valve
and to maintain the accuracy of this table through the development of new valves, etc.
is a considerable task. In addition, all valves are to a greater or lesser degree subject to
deterioration of the moving parts and surface finishes and the age and condition of the
valves would also have to be factored into such a table; consequently, it is considered to be
impractical to attempt to identify which valves in a system may be subject to
unacceptable levels of stiction.
Designers should therefore assume that some degree of stiction will be present
in all valves and the SBT assembly be designed to compensate for its presence. In principle,
this means that stiction forces should be considered to be equivalent to a mass load, i.e. it is
permanently present and is a fundamental element of the design.

G.3.2 Supporting high stiction valves

The requirement for supporting valves in relation to stiction is very similar to that for
supporting due to the high point masses discussed in G.2. That is, provided the local system
stiffness is high enough, the torque loading should not induce unacceptable levels of stress at
the tubing connections, i.e. it is not necessary to support every valve, as the combination of
tubing, valves and supports may be sufficient to prevent stiction damage to the SBT assembly.
Tables G.6 and G.7 are derived from Xodus Report: A-10323-S00-REPT-002-A02
and are provided to assist the designer in identifying whether specific valves require
dedicated support or whether the local SBT support is sufficient. These are similar to the
component mass/stiffness Tables G.3; however, the effect of a double support (one
either side of the valve) has a marked difference on the torque loading and is treated
separately. If the stiction is unknown, the last table entry (unknown) should be used to
determine the support requirement.

Table G.6.A Support deﬁnition for valve stiction in SBT assemblies – Support on one side
of valve only – 6 mm and 1/4” tubing diameters

SBT Arrangement stiffness (DV – Support distance in diameters from valve)

Valve Torque,
Low Low to Med Medium Med. To High High
Stiction T Unknown
DV > 40D 40D > DV > 30D 30D > DV > 20D 20D > DV > 10D DV < 10D
(Sv) (Nm)

Support Support Support Support Support Support

T >3
Required Required Required Required Required Required

Support Support Support Support Support

Low 2<T≤3 OK
Required Required Required Required Required

Support Support
0<T≤2 OK OK OK OK
Required Required

None 0 OK OK OK OK OK OK

Support Support Support Support Support Support

Unknown T >3
Required Required Required Required Required Required

Table G.6.B Support deﬁnition for valve stiction in SBT assemblies – Support on one side
of valve only – 10 mm, 12 mm, 3/8” and 1/2” tubing diameters

SBT Arrangement stiffness (DV – Support distance in diameters from valve)

Valve Torque,
Low Low to Med Medium Med. To High High
Stiction T Unknown
DV > 40D 40D > DV > 30D > DV > 20D > DV > DV < 10D
(Sv) (Nm)
30D 20D 10D

Support Support Support Support Support Support

Moderate T >9
Required Required Required Required Required Required

Support Support Support Support Support

4<T≤9 OK
Required Required Required Required Required
Low
Support Support Support
0<T≤4 OK OK OK
Required Required Required

None 0 OK OK OK OK OK OK

Support Support Support Support Support Support

Unknown T >9
Required Required Required Required Required Required

Table G.7.A Support deﬁnition for valve stiction in SBT assemblies – Support on both
sides of valve – 6 mm and 1/4” tubing diameters

SBT Arrangement stiffness (DV – Support distance in diameters from valve)

Valve Torque,
Low Low to Med Medium Med. To High High
Stiction T Unknown
DV > 40D 40D > DV > 30D > DV > 20D > DV > DV < 10D
(Sv) (Nm)
30D 20D 10D

Support Support Support Support Support Support

T >6
Required Required Required Required Required Required

Support Support Support Support

Low 3<T≤6 OK OK
Required Required Required Required

Support
0<T≤3 OK OK OK OK OK
Required

None 0 OK OK OK OK OK OK

Support Support Support Support Support Support

Unknown T >6
Required Required Required Required Required Required

Table G.7.B Support deﬁnition for valve stiction in SBT assemblies – Support on both sides
of valve – 10 mm, 12 mm, 3/8” and 1/2” tubing diameters

SBT Arrangement stiffness (DV – Support distance in diameters from valve)

Valve Torque,
Low Low to Med Medium Med. To High High
Stiction T Unknown
DV > 40D 40D > DV > 30D > DV > 20D > DV > DV < 10D
(Sv) (Nm)
30D 20D 10D

Support Support Support Support Support Support

High T >19
Required Required Required Required Required Required

Support Support Support Support Support

Moderate 9<T≤19 OK
Required Required Required Required Required

Support
Low 0<T≤9 OK OK OK OK OK
Required

None 0 OK OK OK OK OK OK

Support Support Support Support Support Support

Unknown T >19
Required Required Required Required Required Required

Notes:
1 DV – Support distance in diameters from valve with stiction, SV
1 D – Tubing diameter

G.4 THERMAL EXPANSION

SBT assemblies can be installed in areas of plant that are subject to high levels of
thermal and/or mechanical expansion. Such areas typically include the well bay on offshore
oil and gas production installations, expansion bellows on various process and utilities
systems and other areas where high temperature differentials are experienced between
the operating and non-operating conditions of the plant. The thermal and/or mechanical
expansion does not normally occur directly within the SBT assembly (i.e. it is not the
thermal expansion of the SBT that normally gives rise to concern) rather, it is the growth
in the host system that the assemblies are attached to, which generates the problem. The
resulting large scale deformation (LSD) of the assembly that occurs can result in direct
failure due to overload, low cycle fatigue failure (due to a small number of repeated start-up
and shut-down cycles), and continued operation in such highly deformed conditions can
signiﬁcantly reduce the fatigue endurance of the vulnerable elements of the SBT
assemblies.

G.4.1 Identiﬁcation of thermal and mechanical expansion limits

Designers should verify whether the SBT assemblies that are being designed will be subject
to potential LSD. Those which are associated with pipework in the following areas/systems
typically fall into this category:
−Well and drill string termination devices (Xmas tree valves, etc.).
−Flow lines in well bays of onshore and offshore installations.
−Pipework attached to mechanical expansion bellows.
−Pipework subject to high operating temperatures (typically in excess of 100 °C).

This list is not exhaustive and the designer should take care to ensure that the potential
differential movement between the ‘fixed end’ of the SBT assembly (part fixed to structural
steelwork) and the ‘moving end’ (the part attached to the Xmas tree, flow line, etc.) is
quantified. This potential differential movement should be expressed as a distance in mm in
both the lateral and vertical directions. If the potential differential movement in any direction
exceeds 12 mm, the system should be considered to be a large scale deformation system
and is subject to the design considerations discussed in G.4.2.
The degree of flexibility that is required in an SBT assembly subject to LSD is dependent
on the degree of expansion it will be subjected to. In the majority of instances, the LSD
will occur in one principal direction (normally vertically on petrochemical installations)
with a lower, limited level of LSD occurring in the other principal planes of motion
(normally the horizontal directions on petrochemical installations). To provide reference
values for further assessment, standard LSD level definitions have been derived; those used
in this publication are presented in Table G.8.

Table G.8 LSD level deﬁnition table

Maximum potential expansion Emax

LSD level
(mm) (inches)
1 12  Emax < 50 ½  Emax < 2
2 50  Emax < 100 2  Emax < 4
3 100  Emax < 150 4  Emax < 6
4 150  Emax < 200 6  Emax < 8
5 200  Emax < 250 8  Emax < 10
6 250  Emax 10  Emax

G.4.2 Use of expansion coils for LSD

The primary method of compensating for LSD and ensuring that the SBT assemblies have
sufficient flexibility is to increase the length of tubing between the stationary (fixed end) and
non-stationary (moving end) parts of the system. The degree of additional length
required is dependent on the level of LSD (as defined in Table G.8). Where tubing runs
become impractically long, the assembly should be configured to incorporate changes in
direction in a manner which ensures that the linear length requirements are maintained, but
also that it can be installed within a reasonable physical space.

G.4.2.1 Helical coils

Accommodation of expansion has traditionally been achieved by the inclusion of a ‘helix’
or circular coil type arrangement within the assembly, the assumption being that the coil
will perform like a bellows, providing the expansion required and incorporating additional
length in a minimal volume. A typical example of this arrangement is shown in Figure
G.1. Detailed analysis has shown, however, that the traditional helix arrangements do not
behave as predicted and in fact, the work hardening that is induced during its fabrication
renders the arrangement very stiff and unable to expand or contract as was assumed.

Figure G.1 Example helix/helical coil arrangement on an offshore ﬂow line

A comprehensive programme of load, deﬂection and strain testing and analysis of

various tube geometries incorporating fabricated coils has been undertaken and this
has shown that site-fabricated helical tube coils experience significant work hardening and
as a result, become extremely stiff and inflexible. Such coils do not provide the compliance
or flexibility required in these LSD applications and are generally ineffective. In addition,
the fabrication methods used often give rise to deformation of the tubing resulting in an
oval cross section. Site-fabricated helical coils should not be used as they provide
virtually no benefit in
LSD applications.

G.4.2.2 Rectangular coils (Rectoils)

In order to include the principle of an expansion element within a given SBT assembly while
overcoming the problems associated with the helix type coils, different tubing arrangements
have been investigated and analysed (Reference, Xodus Report: L-10036-S00-REPT-001-R01).
This has resulted in the identification of an optimum arrangement featuring a rectangular
coil (or ‘Rectoil’). The Rectoil achieves the goals of incorporating a significant linear
length of tubing in a relatively small volume and providing expansion capability. It also
achieves the significant benefit of moving the highest stress in the arrangement away from
the vulnerable connection at the moving end, to the tubing in the vicinity of the fixed end.
In addition, the Rectoil arrangement can be made using standard pipe bending
equipment, ensuring the cross section of the tubing is maintained through the
fabrication/installation process and the tubing integrity is not compromised.
An example of an arrangement incorporating a standard Rectoil which illustrates the
main features, is shown in Figure G.2.

Primary LSD Direction

Secondary Deflection Directions

Short side of Rectoil must

be contained in the first
run, R1 Two rectangular coils
R3 ‘Rectoils’ dimensions
R2 x R3

Moving
End
R1
R2
Section ‘B’ return
Fixed straight length
(R1) between ‘Moving MUST ‘enclose’
End’ connection and Rectoil
first bend
A
B C

Dimensions A, B and C
altered to suit LSD
requirements Fixed
End

Figure G.2 Example LSD tubing arrangement showing features of standard ‘Rectoil’

As can be seen, the standard features of the arrangement are:

−Fixed dimension R1 from the valve connection to the first bend.
−Two Rectoils of dimensions R2 x R3.
−Vertical separation of the coil sections is between one and two tubing diameters.
−Rectoils are oriented normal to the direction of primary LSD and the ‘hand’ of the
turns must be such that motion in the LSD direction expands the coil, i.e. does
not compress it.
−The ‘short’ side of the Rectoil (R3) must be contained in the first run (R1) from
the valve connection at the ‘moving end’, not the long side (R2).
−Lengths A, B and C are defined based on specific LSD requirements.
−The return section B must be oriented such that it encloses the Rectoil, i.e. it
must return on the same side of the configuration, not on the opposite side.
−Further qualifications apply to the lengths A, B and C as defined in G.4.4
−The lengths of the first run (R1) and the Rectoil dimensions (R2 and R3) are provided
in Table G.9.

Table G.9 Dimensions R1, R2 and R3 for different tubing diameters

Tubing diameter R1 (mm) R2 (mm) R3 (mm)

6 mm, 1/4”120 210 90
10 mm, 3/8”185 320 140
12 mm, 1/2”200 350 150

The placement of the Rectoil in the tubing arrangement is critical to the design. Most of
the fabrication and installation requirements for the Rectoil are straight-forward and do not
vary. The requirement for the ‘B’ section to be oriented correctly however is critical and
is not so readily apparent. To illustrate the correct orientation of the Rectoil and the return
section B, correct and incorrect implementations of the design are shown in Figures G.3 and
G.4.

Primary LSD Primary LSD

direction direction

Primary LSD
direction

Figure G.3 Example correct implementations of SBT design incorporating ‘Rectoils’

Primary LSD
direction

Rectoil located

‘outside’ length B
return.

Primary LSD
direction
Primary LSD

 direction


Rectoil ‘inside’ length
B return but has
wrong orientation.

Rectoil correct orientation

but is in the wrong plane
relative to primary expansion
direction.
Figure G.4 Example incorrect SBT design incorporating ‘Rectoils’

Figures G.3 and G.4 show that the tubing connection to the ‘moving end’ isolation valve
and the bend at the transition from section ‘B’ to section ‘C’ can be used to form the
diagonally opposite corners of an imaginary rectangle. The Rectoil should be located within
the boundaries of this imaginary rectangle and the short side of the Rectoil (the 150 mm
side) should be located on the ﬁrst tubing section at the moving end. Also, the Rectoil
arrangement should be orientated normal to the primary LSD direction.

G.4.3 Primary and secondary LSD directions

The principal direction that the LSD acts, i.e. expands and contracts in, is critical in
relation to the configuration of the Rectoils and the ability of the SBT arrangement to
provide the necessary expansion capability. For offshore well bay Christmas tree and flow
line related applications, SBT assemblies should be configured to provide LSD in the vertical
direction to accommodate the growth and contraction of the tree and flow line between
the operational and non-operational conditions. If the assembly is installed when the flowline
or tree is in the non-operational (cold) position, the direction that needs to be considered for
LSD is vertical up. This is termed the ‘primary LSD direction’. Examples of this in relation
to the Rectoil arrangement are shown in Figures G.2 and G.3.
It should be noted that the primary LSD direction is not always the vertical (up
direction). Considering the flow line example described here; if the SBT assembly is installed
when the flow line is in the operational (hot) position, the primary expansion capability
must be provided in the vertical down direction, Therefore, the primary LSD direction for
installation of SBT assemblies on operational Christmas trees and flow lines will be vertical
down – not vertical up. This is of critical importance as incorrectly defining the primary
LSD direction will result in failure.
In addition to accommodating the motion of the host system in the primary LSD
direction, the SBT assembly should also be able to accommodate a degree of motion in the
other principal movement directions. These directions are termed the ‘secondary deflection
directions’ and act in the two principal orthogonal planes, relative to the primary LSD
direction. Examples of the relationship between the primary LSD direction and the
associated secondary deflection directions for various primary LSD directions are presented
in Figure G.5.

Primary LSD
Secondary deflection
direction
directions

Primary LSD
direction

Secondary deflection
directions
Primary LSD
direction
Secondary deflection
directions

Figure G.5 Relationship between primary LSD direction and secondary deﬂection
directions

G.4.4 Optimum SBT conﬁgurations for LSD

Using the standard Rectoil arrangement and varying the lengths A, B and C to provide
the required flexibility for different levels of LSD, standard designs have been developed.
(Reference, Xodus Reports: A-10323-S00-REPT-003-A01 and A-300295-S00-REPT-002-A01).
Example designs for 12 mm and ½” diameter tubing are provided in Figures G.6 to
G.9. These apply to systems which may exhibit primary deflections of up to and
including LSD level 5 as given in Table G.8 (Emax = 250 mm) and secondary deflections
(deflections perpendicular to the primary LSD direction) of up to 50 mm (peak to peak).
Design definitions for tubing systems with material and dimension properties
other than those listed in Tables G.1 and G.2, require detailed analysis and are not presently
covered by this publication.
Note that in Figures G.6 to G.9, the fixed end clamp location represents the closest
position that the clamp is permitted relative to the moving end i.e. it represents the minimum
distance. It is recognised that in practice, it is unlikely that this precise location will be
achieved due to the proximity of local steelwork and other actual installation considerations.
Therefore a range of clamp locations is permitted for each arrangement which is
achieved by adding up to 200 mm in each of the A, B and C directions.

500 mm
400 mm
420 mm

(a) Minimum A dimension. A = 400 mm, B = 500 mm, C = 420 mm

500 mm
400 mm
420 mm

(b) Maximum A dimension. A = 500 mm, B = 400 mm, C = 420 mm

Figure G.6 SBT conﬁguration for level 1 and level 2 (< 100mm) LSD
(12 mm and ½” OD tubing)

650 mm 420 mm
500 mm

(a) Minimum A dimension. A = 500 mm, B = 650 mm, C = 420 mm

650 mm
500 mm
420 mm

(b) Maximum A dimension. A = 650 mm, B = 500 mm, C = 420 mm

Figure G.7 SBT conﬁguration for level 3 (100 mm Emax < 150 mm)

LSD
(12 mm and ½” OD tubing)

800 mm 390 mm
600 mm

(a) Minimum A dimension. A = 600 mm, B = 800 mm, C = 390 mm

800 mm 600 mm
390 mm

(b) Maximum A dimension. A = 800 mm, B = 600 mm, C = 390 mm

Figure G.8 SBT conﬁguration for level 4 (150 mm Emax < 200 mm) LSD
(12 mm and ½” OD tubing)

300 mm
950 mm
700 mm

(a) Minimum A dimension. A = 700 mm, B = 950 mm, C = 300 mm

950 mm 300 mm
700 mm

(b) Maximum A dimension. A = 950 mm, B = 700 mm, C = 300 mm

Figure G.9 SBT conﬁguration for level 5 (200  Emax < 250) LSD
(12 mm and ½” OD tubing)

Generic designs should not be used for assemblies where the LSD exceeds 250 mm; these
should be designed on a case-by-case basis.

G.4.5 Design criteria for SBT assemblies subject to LSD

The following design criteria should be used to allow SBT systems to be designed in
instances where the arrangements shown in Figures G.6 – G.9 cannot be implemented
or where a different tubing diameter than that shown is required:
−A ﬁxed dimension, R1, should exist between the valve connection at the moving end
and the ﬁrst Rectoil bend (dimensions provided in Table G.9).

−A double Rectoil arrangement should be used. The dimensions of each Rectoil

should be R2 x R3 (dimensions provided in Table G.9).
−The vertical separation of the coil sections should be between one and two
tubing diameters.
−The Rectoils should be oriented normal to the direction of Primary LSD.
−The ‘short’ side of the Rectoil (R3) should be contained in the ﬁrst run (R1) from the
valve connection at the ‘moving end’ (dimensions provided in Table G.9).
−The return section B should be oriented such that it encloses the Rectoil, i.e. it must
return on the same side of the conﬁguration, not on the opposite side.
−Length A should be greater than or equal to the dimension shown in Table G.10.
Length B should be greater than or equal to 0,7 x length A and less than or equal to
1,4x length A (0,7A  B  1,4A).
−Length C should be greater than or equal to 200 mm (C  200 mm), (where
required). This can be reduced to 120 mm if necessary for 6 mm & 1/4”
diameter tubing.
−Ready Reckoner tables for lengths A, B and C for the three primary tubing diameter
pairs are provided in Tables G.11, G.12 and G.13.

Table G.10 Dimension A for different tubing diameters

Tubing diameter 6 mm, 1/4” 10 mm, 3/8” 12 mm, 1/2”

Dimension A 360 mm 375 mm 400 mm

Table G.11 (A) Length A and B ready reckoner table for 6 mm and 1/4” tubing

Vertical deﬂection (mm)

100 125 150 175 200 225 250 275 300

(A+B)860 980 1 080 1 180 1 270 1 350 1 430 1 500 1 570

Table G.11 (B) Length C ready reckoner table for 6 mm and 1/4” tubing

Vertical deﬂection (mm)

C
100 125 150 175 200 225 250 275 300
250 0 0 0 0 0 0 0 0
Horizontal Deﬂection

300 0 0 0 0 0 0 0 0
(mm, Pk-Pk)

35180 120 120 0 0 0 0 0 0

40260 170 120 120 120 120 0 0 0
0
45380 250 180 120 120 120 120 120
50400 270 190 130 120 120 120 120

55 550 300 220 160 120 120 120

60 500 260 200 160 120

Table G.12 (A) Length A and B ready reckoner table for 10 mm and 3/8” tubing

Vertical deﬂection (mm)

100 125 150 175 200 225 250 275 300
(A+B)890 1 050 1 180 1 320 1 430 1 540 1 630 1 720 1 810

Table G.12 (B) Length C ready reckoner table for 10 mm and 3/8” tubing

Vertical deﬂection (mm)

C
100 125 150 175 200 225 250 275 300
250 0 0 0 0 0 0 0 0
Horizontal Deﬂection

30200 0 0 0 0 0 0 0 0
(mm, Pk-Pk)

35290 260 210 0 0 0 0 0 0

40390 360 300 240 200 0 0 0 0
45470 430 390 330 280 230 0 0 0
50530 500 460 410 360 310 260 220 0
55590 570 520 470 430 380 340 300 250
60650 620 580 530 490 450 410 370 330

Table G.13 (A) Length A and B ready reckoner table for 12 mm and 1/2” tubing

Vertical deﬂection (mm)

100 125 150 175 200 225 250 275 300
(A+B)960 1 080 1 230 1 360 1 490 1 600 1 700 1 810 1 890

Table G.13 (B) Length C ready reckoner table for 12 mm and 1/2” tubing

Vertical deﬂection (mm)

C
100 125 150 175 200 225 250 275 300
250 0 0 0 0 0 0 0 0
Horizontal Deﬂection

30270 230 0 0 0 0 0 0 0
(mm, Pk-Pk)

35320 270 200 0 0 0 0 0 0

40370 320 260 200 0 0 0 0 0
45420 380 310 250 200 0 0 0 0
50470 430 370 310 250 200 0 0 0
55520 480 430 380 320 260 200 0 0
60580 540 490 440 390 330 280 220 0

The broad design principles shown in Tables G.11, G.12 and G.13 should enable designers
to configure SBT assemblies to suit the available space requirements, while ensuring that
the flexibility demands are met for the application.
In addition, in terms of space planning and identifying the footprint of any given
tubing configuration, the plot plans provided in Figures G.13, G.14 and G.15 will allow
the designer to identify the optimum location for the ‘fixed end’ clamp, while keeping to
the design principles outlined above.
Finite element modelling can be used to estimate the stresses in the tubing
associated with any anticipated differential movement. Specialist assistance should be
sought on determining acceptance criteria for use in different environments.

1200
LSD Level Range (mm)
1100 3 100 to 149

4 150 to 199
1000
5 200 to 249

6 250 to 300
900 Level 6
Possible ‘landing’
800 regions for Level 5
different LSD
levels
700
B (mm)

Level 4

600 Point D:

Level 3 Point C:
500
Rectoil
(150x350 mm)
400 Examples of possible
route and location
of first support for 3
300 different LSD levels

200
Example 3
100 Example 2

Example 1
0
1000

1100

1200
100

200

300

400

500

600

700

800

900
0

Point A:
Moving
end connection A (mm)

Figure G.10 Plot plan layout and conﬁguration guide for 12mm, 1/2” tubing

In Figure G.10, 3 examples of potential tubing routes are shown for a 12 mm or 1/2”
SBT assembly corresponding with three different LSD requirements. For all three examples,
point

A represents the connection to the moving end (e.g. the flow line connection/isolation valve
in oil production well bay applications) and points B, C and D represent potential tubing
clamp locations at the fixed end. It should be noted that for each of the examples, the clamp
could be located anywhere in the defined region.

G.4.6 Custom tubing conﬁguration worked example

Well bay application

A pressure transmitter is required to be connected to a flow line connected to an oil
production Christmas tree using an SBT assembly. The tubing is to be connected to
instrumentation mounted on local steelwork. The design criteria for the flow line are
vertical tree growth of 150 mm and lateral displacement requirement of ± 25 mm. The SBT
assembly is to be installed in the flow line ‘cold’ position using SS254 SMO (6 %
molybdenum), 12 mm diameter tubing with wall thickness 1,5 mm.
Solution:
a. Primary LSD direction is vertical – up.
b. LSD level = 150 mm = level 4.
c. Secondary deflection magnitude = ± 25 mm = 50 mm peak to
peak. Possible lengths A and B are defined in plot plan shown in Figure
G.11.
Length C = 370 mm (from Table G.13.B, LSD = 150, secondary deflection, 50 mm).

200

100

000

900 Level 6

800 Level 5

700
Level 4

600

Level 3
500
Clamp ‘landing’ area
400 (fixed end). Clamp can
be located anywhere
300 inside this box

200 Connection to flow line

(moving end)
100

0
1000

1100

1200
100

200

300

400

500

600

700

800

900
0

A (mm)

Figure G.11 Plot plan conﬁguration guide

Two possible solutions for this scenario are presented in Figure G.12.

1200

1100
Plot plan Option 1
1000

900 Level 6

800 Level 5

700
B (mm)

Level 4

600

Level 3
500

400

300

200

100 Isometric
0 0
0

100

200

300

400

500

600

700

800

900

1000

1100

1200

A (mm)

1200

1100
Plot plan Option 2

1000

900 Level 6

800 Level 5

700
B (mm)

Level 4

600

Level 3
500 Isometric

400

300

200

100

0
1000

1100

1200
100

200

300

400

500

600

700

800

900
0

A (mm)

Figure G.12 Two possible solutions for example 1

1200

Dimension
1100 Length
(mm)
A
B
1000
C

900

800
Level 6
700
B (mm)

Level 5

600 Level 4

500
Level 3

400

300

200

100

0
1000

1100

1200
100

200

300

400

500

600

700

800

900
0

A (mm)

Figure G.13 Plot plan layout and conﬁguration guide for 6 mm and 1/4” SBT assemblies

1200

Dimension
1100 Length
(mm)
A
B
1000
C

900
Level 6

800
Level 5

700
B (mm)

Level 4
600

500 Level 3

400

300

200

100

0
0

100

200

300

400

500

600

700

800

900

1000

1100

A (mm) 1200

Figure G.14 Plot plan layout and conﬁguration guide for 10 mm and 3/8” SBT assemblies

1200

Dimension
1100 Length
(mm)
A
B
1000
C

900 Level 6

800 Level 5

700
B (mm)

Level 4

600

Level 3
500

400

300

200

100

0
0

100

200

300

400

500

600

700

800

900

1000

1100

A (mm) 1200

Figure G.15 Plot plan layout and conﬁguration guide for 12mm and 1/2” SBT assemblies

ANNEX H
IDENTIFICATION & MITIGATION OF DYNAMIC LOADS &
VIBRATION

H.1 INTRODUCTION

In virtually all process piping applications, SBT assemblies will be subjected to some level of
vibration and dynamic loading and in the vast majority of cases, these levels of dynamic load
will be insufﬁcient to result in a vibration induced fatigue failure. In cases where high levels
of vibration do exist, however, vibration induced failure is not only possible but in many cases
likely, if appropriate steps are not taken at the design stage to mitigate the effects of the
vibration.
The designer should identify whether the SBT systems will be located in an area
where high levels of vibration exist and if so, to take steps to ensure that the design is
appropriate.

High levels of vibration are typically associated with the following areas:
−offshore well bays, Christmas tree valves and all associated pipework e.g. flow lines,
gas lift and chemical injection piping.
−reciprocating, positive displacement and rotating machinery (pumps and compressors).
−high velocity/high momentum process flow pipework.
−severe duty control valves (e.g. anti-surge/recycle control, high differential pressure
vent valves, etc.).
−sections of piping which are not effectively supported, are poorly configured, witness
significant variation in flow rates, etc.
−high energy transient valves such as PSVs and ESDs.

Due to the wide ranging nature of the potential vibration threat, determining the potential
for vibration induced failure is a non-trivial task. It is therefore considered more
appropriate to define a range of generic vibration tolerant designs that can be applied in
all situations. These designs were introduced in section 4.3.8 and are further discussed in
this annex.
The information presented here is not intended to be exhaustive and alternative anti-
vibration techniques can be considered on their own merits. Where new designs
become available, these should be reviewed in detail and their use should be discussed and
agreed with the relevant technical authority.
The most common use of SBT assemblies is for connection of measuring or
monitoring instruments (e.g. gauges and transducers) to piping systems and for this
duty, there are two basic configurations which can be adopted: ‘pipework mounted’
(close coupled) and ‘steelwork mounted’. Generic vibration tolerant configurations for
pipework mounted SBT configurations are presented in H.2 and those for steelwork
mounted configurations are provided in H.3

H.2 PIPEWORK MOUNTED (CLOSE COUPLED) CONFIGURATIONS FOR VIBRATION

SERVICE

H.2.1 General design principles for pipework mounted conﬁgurations

In order to minimise the potential for vibration induced fatigue failure of pipework
mounted (close-coupled) SBT assemblies, the following design and configuration principles
should be adhered to:
−Minimise the overall length of the assembly.
−Where configurations utilise T sections, minimise the overall length of each section.
−Minimise the overall mass of the assembly.
−Arrange components such that the highest mass elements are located nearest to the
host (parent) system, and the lightest elements furthest away from the host (parent)
system.
−Configure SBT assemblies using only manufactured fittings.
−Do not incorporate ‘bridging’ sections of instrument tubing into the assembly.

H.2.2 Examples of vibration tolerant pipework mounted conﬁgurations

The general design principles outlined in H.2.1 are illustrated in the examples presented in
Figures H.1 to H.3. In order to verify the acceptability of these conﬁgurations, their static
and dynamic loading characteristics and performance have been assessed using advanced
analytical techniques (see Xodus Report: A-300132-S00-REPT-001

Arrangement uses only

manufactured fittings with no
bridging sections of tubing
used

Overall length
minimised

Low mass
components
used

Figure H.1 Pipework mounted vibration tolerant conﬁguration - Example 1

Overall length of both

parts of T section
minimised

Arrangement uses only

manufactured fittings with no
bridging sections of tubing
used
Higher mass components connected
directly to host system

Figure H.2 Pipework mounted vibration tolerant conﬁguration - Example 2

Arrangement uses only

manufactured fittings with
no bridging sections of
tubing used

Highest mass components connected

directly to host system. Smallest mass
components arranged at free end of
configuration

Figure H.3 Pipework mounted vibration tolerant conﬁguration - Example 3

H.2.3 Examples of vibration intolerant pipework mounted SBT conﬁgurations

Examples of non-vibration tolerant pipework mounted (close-coupled) SBT conﬁgurations

are provided in Figures H.4-H.6.

High vibration here

Bridging section of tubing used

between DBB valve and gauge. This
introduces a high level of flexibility
Overall length resulting in vibration and potential
not minimised failure of the gauge and the tubing at
the lower insertion point

 Potential failure at gauge and at

tubing insertion point

Figure H.4 Pipework mounted vibration intolerant conﬁguration – Example 1

Overall length not minimised

High mass components located at free

end of assembly

High vibration
here

Bridging section of tubing

used. Potential failure

locations

Figure H.5 Pipework mounted vibration intolerant SBT conﬁguration – Example 2


High mass components
located at free end of
assembly

Overall length of both T sections minimised


Only manufactured fittings used – no bridging
sections of tubing


Figure H.6 Pipework mounted vibration intolerant conﬁguration – Example 3

H.3 STEELWORK-MOUNTED CONFIGURATIONS FOR VIBRATION SERVICE

H.3.1 General design principles

In order to minimise the potential for vibration induced fatigue failure of steelwork
mounted SBT assemblies, an optimised SBT conﬁguration has been developed (see Xodus
Reports: A-10323-S00-REPT-0042-A01 and A-300295-S00-REPT-001-A01).
The optimised conﬁguration applies to the tubing materials and dimensions listed in
Tables H.1 and H.2.

Table H.1 List of applicable tubing material properties

Description Density Modulus of 0,2 % Poisson’s

(kg/m3) elasticity Proof ratio
(MPa) stress
(MPa)
SS254 SMO (6 % molybdenum) 8 000 1,95 x 105 350 0,3
SS316 (316 stainless steel) 7 850 2,00 x 105 290 0,3
UNS N10276 (alloy C-276) 8 890 2,05 x 105 358 0,3

Table H.2 List of applicable tubing dimensions

Outside diameter Wall thickness Bend radius

(OD) (WT)
0,028”
0,035”
1/4” 0,56”
0,049”
0.065”
0,035”
3/8” 0,049” 0,94”
0,065”
0,049”
1/2” 0,065” 1,5”
0,083”
3/4” 0,083” 1,77”
1,0 mm
6 mm 15 mm
1,5 mm
1,0 mm
10 mm 24 mm
1,5 mm
1,0 mm
12 mm 1,5 mm 38 mm
2,0 mm
1,5 mm
20 mm 67 mm
2,0 mm

100

The configuration shown in Figure H.7 applies to steelwork mounted systems which may
exhibit vibration (cyclical deflections about a mean point) of 6 mm peak to peak (± 3
mm), when measured relative to a stationary (non-vibrating) steelwork mounted part of the
system. The vibration can occur in any direction.
Design definitions for tubing other than the diameters and wall thickness listed
in Table H.2 should be subject to detailed analysis and are not presently covered by this
publication.

75 mm
Bend 1
Fixed
end

Bend 3 Minimum distance as

Bend 2 A defined by
manufacturer

Moving
end
B

A total of 3 bends between the connection

to the host system and the first support

Bends should be made in a minimum of 2

planes

Figure H.7 Optimised arrangement for steelwork mounted systems

The optimised configuration in Figure H.7 has some design principles that should be applied:
−Incorporating a total of three bends into the configuration between the block
valve connection (moving end) and the first support (fixed end).
−Configuring bend 1 and bend 2 so that they act in two different principal planes
(horizontal and vertical).
−Making the distance from the block valve connection at the moving end and the first
bend to be the permitted minimum, as defined by the tubing manufacturer. See
the ready reckoner table that is provided in Table H.2.
−Making the minimum tubing length between bend 1 and bend 2 to be dimension
A as shown in Table H.4.
−Making the minimum tubing length between bend 2 and bend 3 to be dimension
B as shown in Table H.4.
−Making the distance from bend 3 to the clamp insertion point to be 75 mm.
−Having no other fittings or components (lumped masses) contained in the tubing run
between the block valve connection and the clamp insertion point (run tubing only).
−Using alternative clamp orientations providing the bend direction conditions are met
and the minimum distances are adhered to.

101

It is recognised that in practice, it may not be possible to achieve these optimum tubing
lengths. Alternative acceptable lengths for the tubing runs between bends 1 and 2 and
between bends 2 and 3 have therefore been determined (see Xodus reports Xodus Reports:
A-10323-S00-REPT-004-A01 and A-300295-S00-REPT-001-A01 A-10323-S00-REPT-
002-A01) and are presented in H.3.2.

Figure H.8 Minimum length from end of tube to ﬁrst bend

Table H.3 Minimum length from Figure H.8 from end of tube to ﬁrst bend for various
tubing OD and tube bender radii

Imperial tubing (inches) Metric tubing (mm)

Tube OD1/4” 3/8” ½” ¾” 6 10 12 20
Tube bender 5/8” 15/16” 1 1/2” 2,20” 16 24 38 67
radius
L1,45” 1,89” 2,7” 3,45” 37 49 69 101

Table H.4 Dimensions A and B for different tubing diameters

Tubing diameter A (mm) B (mm)

6 mm, 1/4” 400 350
10 mm, 3/8” 400 300
12 mm, 1/2” 400 300
20 mm, 3/4” 450 350

Sketches showing implementations of the optimum arrangement for steelwork mounted

SBT assemblies which are subject to vibration are shown in Figure H.9; whereas, Figure
H.10 shows examples of non-implementation of the optimum arrangement of tubing for
steelwork mounted SBT assemblies that are subject to vibration.

102

Figure H.9 (a) Implementation of optimum tubing arrangement for steelwork mounted
SBT assemblies subject to vibration

Figure H.9 (b) Implementation of optimum tubing arrangement for steelwork mounted
SBT assemblies subject to vibration

103

Figure H.9 (c) Implementation of optimum tubing arrangement for steelwork mounted
SBT assemblies subject to vibration

Figure H.9 (d) Implementation of optimum tubing arrangement for steelwork mounted
SBT assemblies subject to vibration

104

1st and 2nd bends in

different planes (correct)


Clamp installed between
2nd and 3rd bends
(incorrect)

Figure H.10 (a) Incorrect implementation of tubing arrangement for steelwork mounted
SBT assemblies subject to vibration

1st and 2nd bends in

the same plane
(incorrect)

Clamp installed between

2nd and 3rd bends
(correct)

Figure H.10 (b) Incorrect implementation of tubing arrangement for steelwork mounted
SBT assemblies subject to vibration

105


Arrangement does not comply
with any design criteria

Figure H.10 (c) Incorrect implementation of tubing arrangement for steelwork mounted
SBT assemblies subject to vibration

1st and 2nd bends in

the same plane
(incorrect)

Clamp installed after

3rd bend (correct)


Figure H.10 (d) Incorrect implementation of tubing arrangement for steelwork mounted
SBT assemblies subject to vibration

106

All bends in
the same plane

(incorrect)

Clamp installed after

3rd bend (correct)

Figure H.10 (e) Incorrect implementation of tubing arrangement for steelwork mounted
SBT assemblies subject to vibration

Minimum distance from

st
fitting to 1 bend not
established

rd
Minimum distance from 3
bend (75 mm) not
established


Figure H.10 (f) Incorrect implementation of tubing arrangement for steelwork mounted
SBT assemblies subject to vibration

107

H.3.2 Steelwork mounted conﬁgurations – tubing length variations

It may not always be possible to implement the optimum SBT conﬁguration for steelwork
mounted systems due to space restraints and other practical considerations. Acceptable
length variations have therefore been calculated for alternative scenarios (see Xodus Report:
A-10323-S00-REPT-002-A01). It should be stressed that where possible the optimum design
principles set out in section H.3.1 should be used in the ﬁrst instance.

75 mm

Minimum distance as defined

A by manufacturer

Figure H.11 SBT conﬁguration variable tubing lengths A and B

108

Table H.5 (a) Acceptable length variations for sections A and B in Figure H.11 - 6 mm
and 1/4” diameter tubing

Design point ref. Table H.4

Table H.5 (b) Acceptable length variations for sections A and B in Figure H.11 - 10 mm
and 3/8” diameter tubing

Design point ref. Table H.4

109

ANNEX I
TUBING SUPPORT

I.1 INTRODUCTION

The primary goal of any support system for SBT assemblies is to prevent failure of the
tubing. To achieve this goal, due consideration should be given to support system design,
as well as the components used: a poorly designed support system may increase the risk of
failure.
The most common use of SBT assemblies is for connection of measuring or
monitoring instruments (e.g. gauges and transducers) to piping systems and for this duty,
there are two basic configurations which can be adopted: pipework mounted and
steelwork mounted. These configurations were introduced in section 4.3.8 and further
described in Annex H.
In terms of the performance of the SBT assembly, these definitions are critical as the
demands placed on the assembly for those that are steelwork supported are much
greater than those that are pipework supported. This arises due to the relative
movement which occurs between pipework systems and structural steelwork which
must be accounted for in the design process. If the assembly is not connected to the
structure, there is no need to account for this additional load. The support
considerations for each type of assembly are described in I.2 - I.5.

I.2 SUPPORT CONSIDERATIONS FOR PIPEWORK MOUNTED ASSEMBLIES

I.2.1 Operational considerations

Tubing assembly, layout and supporting should comply with the need to permit effective
operations as well as avoiding excessive static and dynamic loading. The following design
principles should be observed:
−Use of offsets for multiple tubing runs to facilitate installation and maintenance of
unions.
−Minimise the risk of damage from passing traffic or other operations by
appropriate orientating and routing of equipment and tubing.
−Minimise the effect of excessive stress and vibration by using tubing support
arrangements specified by the designer, which are in accordance with the provisions
of Annexes G and H. Tubing should not support the weight of equipment,
instruments, valves or components; these should be supported independently.
−Ensure tubing remains adequately supported when detached where tubing has to be
regularly removed (e.g. changing filters). Consider the use of zero clearance fittings
to facilitate this.
−Specify adapters, connectors or welded components to reduce the possibility of
faulty installation (see Annex J) where equipment has to be close coupled and
the piping is complex.
−Specify appropriate thread sealants and cleaning requirements to prevent
contamination of SBT assemblies used for hydraulics.
−Consider the additional weight loading in the design of the support arrangement
where SBT assemblies are fitted with trace heating, fireproofing or insulation
(additional distributed mass as opposed to lumped masses as discussed in Annex
G).

110

−Clearly indicate on schematic and construction drawings, drain and vent gradients.
A typical gradient is 1:12.
−Consider free draining for SBT assemblies, especially for instrument impulse lines, to
prevent the accumulation of unwanted medium and to maintain the accuracy of the
measuring element.
−For differential pressure applications, ensure the design has each leg equal in terms
of size, length, routing and temperature (ambient or traced).

I.2.2 Static and dynamic loading considerations

The most vulnerable part of a pipework mounted SBT assembly is the connection to the
piping system; normally made at the primary isolation valve (double block and bleed, ‘mono
ﬂange’, etc.). An unsupported assembly can vibrate in a cantilever mode inducing high
dynamic loads at this connection point. Heavy components can also induce high static loads
on the connection and also on the assembly ﬁttings.
With such arrangements, it is therefore necessary to protect the connection to
the piping system by designing the supporting arrangement such that relative motion
between the primary isolation valve/host pipework and the end of the assembly is not
possible. If such a design is not possible, the SBT elements at the free end of the
assembly should be adequately supported from the primary isolation valve/host
pipework.

I.3 SUPPORT CONSIDERATIONS FOR STEELWORK MOUNTED ASSEMBLIES

The most vulnerable parts of steelwork mounted SBT assemblies are the extremities. These
are the connection to the piping system, normally made at the primary isolation valve and the
first connection to the structural steelwork.
As process systems are dynamic, some level of vibration is usually present in the
host pipework. As structural steelwork is nominally free from vibration, relative motion
between the two extremities of the assembly will normally exist and therefore the design of
the tubing should accommodate this relative motion without overloading any of the SBT
assembly components. Provided the design criteria described in Annex H.3 are adhered to,
this relative motion should not result in fatigue failure at the primary isolation valve.
For steelwork mounted SBT assemblies, another issue that should be considered is
thermal expansion of the process pipework. For certain piping systems such as well stream
flow lines on offshore installations, significant growth of the pipework relative to the structure
of up to 200 mm can occur, meaning that the two ends of the assembly should be able
to accommodate up to 200 mm of growth/expansion without failing. Therefore the
support system too should be designed to accommodate such extreme motion. Provided the
design criteria described in Annex G.4 are adhered to, this thermal expansion and the
associated LSD should not result in failure at the primary isolation valve.

I.4 SUPPORT SPACING

The design criteria which should be applied to the ‘ends’ of an SBT assembly are provided in
Annexes G and H. Provided these criteria are adhered to, no failures due to static or
dynamic loading should occur at the end connections. It only remains therefore to provide
appropriate support guidance for the tubing runs that make up the remainder of the
assembly. These will typically be long runs of tubing that require support at regular
spacing intervals.

111

A generic speciﬁcation for tubing support spacing for a straight run is shown in
Figure I.1 and nominal spacings are provided in Table I.1.

Figure I.1 Tubing spacing A between supports

Table I.1 Nominal spacing for tubing supports

Tube OD Maximum dimension ‘A’ (mm)

< 1/4” or 6 mm 400
1/4”-3/8” and 6 mm-10 mm 600
1/2”-7/8” and 12 mm-22 mm 900
1”-11/4” and 25 mm-32 mm 1 400
11/2”-2” and 38 mm-50 mm 2 100

Special bracketing or mounting facilities should be considered and speciﬁed for heavy
components within the SBT assembly such as valves and instruments. Some assemblies
should be provided with sufﬁcient gradient to permit free-draining, e.g. in impulse lines
liable to accumulate condensate.
Where tubing runs are oriented vertically, the support spacing requirement is
less onerous and fewer supports are typically required. It is recommended that the support
spacing criteria shown in table I1 are still adhered to however. This will ensure that the
mass of the tubing is distributed between the supports vertically and that excessive
loads do not act on the support at the bottom of the vertical run. Adhering to the support
spacing recommended in Table I.1 will also ensure that excessive mid-span vibration of the
tubing does not develop.

I.5 SUPPORT PLACEMENT

For long SBT runs featuring several changes of direction, placing of the supports should be
considered in addition to the general spacing.
In order to ensure that long tubing sections are not under-supported and vulnerable,
the support distribution should be planned so that the supports are installed in a clearly
deﬁned way. The support placement should be implemented in the following manner:

1. Install main supports at the ends of tubing run (as defined in Annexes G and H).
2. Install supports to other critical elements in the SBT configuration: critical elements
include high mass point loads (e.g. instruments, valves, etc.), twin ferrule tube
coupling fittings, tube bends, tees ,etc.

112

3. Install supports to remainder of straight tubing runs as per the nominal spacing guide
in Table I.1.

Supports should not be installed by simply starting at one end of the SBT assembly, and
working along the tubing run to the other end following the nominal support spacing
speciﬁed in Table I.1. If this installation process is used, it is unlikely that end connections
will be supported as per Annexes G and H, and it is highly likely that other critical
elements will be left in a vulnerable condition.

113

ANNEX J
CLOSE-COUPLED INSTRUMENT ARRANGEMENTS

Although not involving SBT assemblies, it has become common practice to install process
instruments ‘directly’ onto the process isolation point thereby effecting a close-coupled
installation. Annex H.2 provides guidance on the conﬁguration of such assemblies whereas
this Annex complements that information by providing guidance for designers on the
initial assessment when considering specifying such an arrangement.

J.1 ADVANTAGES AND DISADVANTAGES

By selecting the close-coupled arrangement, certain advantages can be realised. However,

when considering the close-coupled option, sound engineering judgement should be applied
as the advantages can be overshadowed by undesirable outcomes such as those listed in
Table J.1:

Table J.1 Advantages and disadvantages of the close coupled option

Advantages Disadvantages
Fewer potential leak paths Excessive cantilever weight leading
to fatigue failure (see Annex H)
Simpliﬁed construction therefore Excessive cantilever dimensions leading
easier to install (reduced costs) to access problems and increased
vulnerability
Reduced material requirements Isolation problems where the philosophy
for primary and secondary instrument
isolation has not been fully considered.
Reduced vibration potential Excessive vibration at the instrument
leading to failure.
Reduction in gauge line error Excessive maintenance burden.
Ease of replacement during Accessibility issues
maintenance

It is also important that the designer carefully considers the attributes listed in section K.2.

J.2 DESIGN CONSIDERATIONS FOR THE CLOSE-COUPLED OPTION

a. Vertical orientation is generally preferred where the mass of the instrument or

device is bearing directly down. However, the issues described in points 3, 4,
5, 6, 7, 8, 9, 10, and 11 should be taken into account.
b. With horizontal orientation, the cantilever effect and instrument orientation
(for viewing) should be considered and the issues outlined in items 1, 2, 3. 4,
5, 6, 7, 8, 9, 10, and 11 should be taken into account.

114

1. Isolation philosophy - The designer should assess the requirement for isolating the
instrument for maintenance and testing. The philosophy should adopt either single
or double process isolation:
a. A standard 2-valve (isolation and vent) instrument manifold may need to
be utilised but this can add undesirable weight and size to the assembly.
b. As an alternative, a compact integral DBB arrangement can be installed
directly onto the process isolation valve to minimise the weight and
dimensional problems, especially when in the horizontal plane.
2. Configuration - The ideal configuration should involve the least number of
component parts. Depending on orientation of the instrument and isolation
philosophy, it is possible for the close-coupled design to become unwieldy, causing
more problems than it solves; for example:
a. Additional valves (or a manifold) for isolation add to the weight and dimension.
b. Swivel joints may be needed to adjust instrument orientation.
c. Additional pipe fittings (e.g. bends) may be required to change orientation
from horizontal to vertical. The use of SBT and SBT fittings for this purpose
should be avoided because they can inadvertently introduce weak points.
d. Additional components increase the number of leak paths which then
tends to defeat the purpose of using the close-coupled option.
3. Additional supports - It may be necessary to provide additional support features
to prevent lateral movement; especially where the installation has had to be
changed from the horizontal plane to vertical. In such cases, the support should
be fixed to the same body mass as the process connection to prevent opposing
loads.
4. Weight - The total weight of the instrument and associated components should
be taken into account, especially when in the horizontal plane as this can apply
stress at the connection point which can lead to failure.
5. Dimension - The designer should aim to achieve the absolute minimum stand-off
dimension however; the configuration requirements (see point No.2 above) can have
a significant impact on this.
6. Vibration - Whilst there is an advantage of close-coupling to a vibrating process
connection (i.e. the instrument moves with the connection whereas the SBT
option features a fixed point instrument stand which then subjects the connecting
assembly to opposing loads and vibration), the designer should understand the type
of inherent vibration and should ensure that the instrument can withstand the
induced stresses. Although most modern instruments are designed to withstand
vibration, there will be limits as, e.g. mechanical instruments such as pressure
gauges are not suited to high vibration service.
7. Location - The designer should determine the physical location of the process
connection before deciding to deploy close-coupled instruments. There may be
physical clashes with adjacent equipment or they may not be suitable if located
within a confined space; especially if the plant operator needs to view the ‘indicating’
instrument on a routine basis and/or where regular maintenance is required.
8. Accessibility - The installation should be easily accessible for maintenance and
for viewing if an indicator is involved. Where an indicator is involved, orientation
and viewing angle should be considered as it may be necessary to add
additional components to achieve the required positioning.
9. Vulnerability - Since the process connection will fix the location, the designer
should consider vulnerability issues, avoiding close-coupled installations at locations

115

subjected to trafﬁc, heavy moving objects, swinging loads or regular scaffolding

campaigns.
10. Instrument connection - As the weight of the instrument will effectively hinge on the
process connection, the designer should consider specifying a larger ﬁtting to give
added strength, especially when installed horizontally.
11. Design convention - It is very easy to depict a false impression of the physical
arrangement and consideration should be given to developing a scale drawing
rather than the traditional diagrammatic hook-up for close-couple instruments. The
need for additional components (e.g. a hexagon nipple) to address accessibility (see
point No.8) can only be evaluated if the schematic is drawn to scale together
with knowledge of the valve operating mechanism and with consideration given to
space requirements for ﬂange bolts.
Figures J.1 and J.2 show typical close-coupled arrangements used for locally mounted process
instruments

Figure J.1 Typical vertically orientated close-coupled arrangements with compact

isolation valve assemblies

Figure J.2 Typical horizontally orientated close-coupled arrangement with compact

isolation valve assembly

116

ANNEX K
DESIGN DELIVERABLES

K.1 MAIN SECTIONS

The principal design deliverables have been discussed in section 4.4: the designer should
consult the following when compiling the design book, installation or job instructions
and/ or work packs:
The contents of the various design deliverables will normally include the
following information:
−Schematics (non-dimensional): used to convey complex SBT assemblies that fall
within a fixed boundary or envelope, e.g. hydraulic control panels, chemical injection
packages.
−Arrangement Drawings (dimensional): used to depict precise installation
configurations that fall within a fixed boundary or envelope, e.g. hydraulic control
panels, chemical injection packages.
−Hook-up diagrams (non-dimensional): used to depict individual SBT assemblies that
do not necessarily fall within a fixed boundary or envelope. This is a particularly
useful tool for elements of installation that are repeated numerous times within a
project, e.g. a pressure transmitter.
−Material schedules: used in conjunction with schematics, arrangement drawings and
hook-up diagrams to define the material requirement at component level.
−Data sheets: used to define individual component parts that need a greater level
of detail description or definition.

Design deliverables should be concise yet comprehensive enough to avoid any uncertainty
or ambiguity.

K.2 INFORMATION DETAILS

The finer details that should normally be considered, compiled and included if appropriate
within the above design output documentation are:
−Purpose of the SBT - Service description, equipment tag number, etc.
−Process - Fluid description and basic pressure and temperature information.
−Location - Plant location description.
−Envelope - Size constraints, height limitations.
−Orientation or convention - Tapping location (i.e. top, bottom or side of main
pipework) and instrument location in relation to the tapping points (i.e. above or
below).
−Sequence - Installation sequence if this is an important factor.
−Tube/fitting/component size - Tube OD and wall thickness.
−Material of construction - Material specification for tube, fittings and components.
−Component type - Component manufacturer, model number, type, etc.
−Quantity - Tube, fitting and component quantity per drawing or per instance.
−Method of installation - Tools to be utilised, drain gradients, low point drains,
high point vents, above/below the line, slope for drainage.

117

−Method of support - Tube and component clamps, ﬁttings, brackets, etc.

−Testing requirements - Leak and pressure test parameters.
−Notes - Important installation instructions or guidelines.
−Interface and isolation requirements - Important instruction/restriction relating to the
tie-in to live plant.
−Reference information - Vendor and project P&IDs, instrument and tube speciﬁcations,
continuation drawings, test and pre-commissioning procedures.

K.3 COMPLEXITY OF DRAWINGS

The choice of drawing and style used to depict a particular SBT assembly should be considered
at the beginning of every project. An overly complex drawing and style can add
signiﬁcant design costs to a project without adding any real value to the process.
Conversely, an overly simplistic drawing and style can introduce potential for
misinterpretation during installation, possibly leading to serious consequences.
Where the assembly is unique and complex, a schematic drawing may be
considered together with a coded material schedule. However, for a small section of an
assembly and where the design is commonplace, a generic (hook-up) drawing may be
more appropriate.

K.3.1 Use of standard documentation and drawings

To prevent errors, engineering management should guard against choices being made
based on previous common practice or ingrained cultural reasoning. New schematics and
hook-ups should be carefully reviewed on their own merits, even though the particular SBT
assembly may appear to have been designed many times before.

K.3.2 Use of non-dimensional schematics

The format most commonly used for schematics and hook-ups is non-dimensional,
block diagrammatic with uniform line thickness and simple symbols (see Figure K.1).
Isometric versions can also be prepared (see Figure K.2); however, of late this
option is not usually considered preferable due to the following drawbacks:
−They can inadvertently corrupt the visual intent of the design (e.g. they tend make
items appear below a set level when in reality, they should be mounted above) and
the depiction of adopted symbols.
−They generally require more time to produce (potential cost and schedule
impact; especially on projects involving numerous SBT assembly installations).

K.4 STANDARD DESIGN SCHEMATICS (HOOK-UPS)

Certain design schematics have become almost standard in terms of layout, style and
content and it has become common practice to draw from previous project designs. This
practice is intended to reduce costs; however, care should be exercised as generic errors
may result. When utilising such designs and formats, the designer should ensure that the
following criteria are met for the current project:
−Tube size (particularly wall thickness), manufacturer and material choice.
−Process and environmental requirements in terms of pressure, temperature,
corrosion/ erosion, wax/silt accumulation, vibration.

118

−Required convention for tappings and instrument location.

−Provide sufﬁcient, non-ambiguous information to allow the tube installer to install
the assembly in a safe and consistent manner.
−Are suitable for the new or unique requirements of the current design.

Figure K.1 Extract from a typical hook-up schematic

Figure K.2 Extract from a typical isometric hook up schematic

119

Notes on the design schematics can be important aids for the installer by providing guidance
and imposing limiting factors. Superﬁcial, generalised or obvious notes having no
speciﬁc purpose should be avoided.

K.4.1 Multiple generic installations

On larger projects where numerous schematics or hook-up drawings need to be generated,

consideration should be given to the development of a single materials database with each
item individually coded which could provide the project with the following advantages:
−One list of material maintained as an entity in itself.
−One list of material with intelligence to populate drawings, material take-off
documents and purchase systems with consistent, error free material descriptions.
−Signiﬁcant savings in design and procurement time.

The material lists or databases should include the following information:

−Component code - can be coded per drawing or can be drawn from a standard
project coding schedule.
−Quantity - can be per instance or composite for all instances.
−Description - of the items including any equipment or tag numbers.
−Material - refers to the materials of construction, e.g. 316 stainless steel , Monel™,
etc. should include either a simplified coded material listing or be referenced to a
master listing or database.
−Manufacturer - optional; but can be important to avoid accidental use of the wrong
type of fitting, appreciating that some warehouse and storage facilities serve more
than one asset and therefore carry stocks of other types of fitting.
−Manufacturer’s part number - optional; depending on the availability of a composite
material schedule.
−Schematic or hook-up drawing reference - optional; but this can be advantageous in
terms of the allocation of specific materials for specific installation phases.
−Work pack or design book reference - optional; but this can also be advantageous
in terms of allocation of specific materials for specific installation phases and
cost centres.

K.4.2 Use of symbols

Symbols used on schematics or hook-ups should be consistent across the project design in
accordance with relevant standards. On larger projects, consideration should be given to the
production and maintenance of a separate symbol legend drawing. Ideally, symbols should
be industry standard or common use, conveying the features of each component in sufﬁcient
detail without being overly complex. Where there are no standard symbols existing, then
these should be compiled and agreed with the relevant TA.

120

ANNEX L
DESIGNER SELF-CHECKS

To ensure that all relevant aspects have been attended to, designers should undertake
a check of the completed design prior to issue for approval (see section 4.5). Figure L.1 is an
example of how a designer self-checklist could be developed for each design.

DESIGNER SELF CHECKLIST

Project number: Designer: Designer grade: Date:
Item Design check Y/N Sign
1 Are the specifications for tubing, fittings, valves and components
suitable for the service and process conditions in terms of material
choice, wall thickness and pressure rating?
2 Have the static load requirements been identified including thermal
expansion requirements and identification of heavy components?
Has the SBT assembly configuration and support system
been optimised to accommodate thermal expansion and
heavy components?
3 Have the dynamic load requirements and potential vibration threats
been identified?
Has the SBT assembly configuration and support system
been optimised to accommodate dynamic loads and
vibration?
4 Are there any dissimilar material interfaces and if so, have the
chemical or capillary reactions been considered?
5 Are all of the tubing and hook-up components adequately
supported and are the support requirements adequately defined?
6 Are there any unnecessary components that over complicate the
hook-up and add to the number of potential leak paths?
7 Are all drains and vents adequately defined and has enough care
been taken to prevent personal injury when opening vent or drain
lines?
8 Have all necessary drain slopes been applied to the assemblies?
9 Have the constraints of the physical envelope been taken into
account?
10 Has due consideration been given to potential weak points in the
hook-up?
11 Does the material listing adequately cover and define all
component parts of the hook-up?
12 Are the notes comprehensive enough and do they adequately
cover the scope?

Figure L.1 Example designer self-checking sheet

121

ANNEX M
PRESSURE TESTING (FOLLOWING SBT ASSEMBLY INTERVENTION)

An example of a pressure testing regime following intervention and re-instatement of an SBT

assembly or installation of new components is shown in Figure M.1 together with notes
on selection of the applicable test pressure to be used.

Fluid
Have any Do they have
Hydrocarbon gas Yes new pressure Yes a pressure test Yes
or hydrocarbon containing certiﬁcate for
liquid components been ≥1,5 x design
installed? pressure?

Hydraulic or Yes
lubricating ﬂuid No No

Test to T1
Yes Is design Yes speciﬁcation
Chemicals pressure
>55 bar?

Yes Test to T2
All other liquids speciﬁcation

All other gases Yes Is design Yes

(including air pressure
systems) >20 bar?

Figure M.1 Example of a pressure testing regime

For this example:

T1: Sometimes termed ‘proof or strength test’, T1 applies for the testing of new
components at 1,5 x system design pressure with potable water or system fluid for 10
minutes’ duration; observing for leaks and/or pressure drop.
After final installation or re-instatement of the assembly, a T2 pressure test should
be carried out.
T2: Sometimes termed a ‘leak or service test’, T2 applies for the testing of the complete
assembly at normal operating pressure with system fluid for 10 minutes’ duration; observing
for leakage and/or pressure drop.

122

Notes:
−T1 is a test of the structural integrity of the components.
−A suitable recording device should be used to verify each test.
−Repeated testing of components above their design pressure could result in a
reduction in the lifespan of the tested components.
−Where possible, components should be bench-tested in a controlled environment.
−Instruments should be isolated from the test to prevent damage from over-
pressurisation.
−Where there is no DBB isolation, the instrument should be removed from the assembly.
−Where there is no DBB isolation at the process interface, the tubing should be
disconnected and capped prior to testing.

If the SBT assembly fails the pressure test, then it should be subjected to the same test
following repair of the faulty component(s). Where the repair involves replacement of
components with new items that do not have a pressure certiﬁcate, then test type T1 should
be performed.
Repair or remedial action should take place under the applicable site control
procedures and should include proper isolation and de-pressurisation prior to
intervention work taking place (see section 6.3).

123

ANNEX N
ASSEMBLY PRACTICE

This Annex provides pictorial examples of faults that have resulted from bad installation
practice, corrosion and layout namely:
−Ferrule-related faults.
−Corrosion, erosion and chaﬁng of installed components.
−Faults generated during assembly of components.
−Good and bad layout examples of SBT installations.

Tube not ‘bottomed’ Tube cracked behind ferrules

Extra rear ferrule

Over-tight fitting

Rear ferrule reversed Both ferrules wrongly orientated

Figure N.1 Ferrule related faults

124

Crevice corrosion pitting

under tubing clamps Galvanic corrosion

Erosion from sand & pitting corrosion Corrosion under tubing clamps

Chloride pitting
Tubing failure due to chafing (under PVC tape used for line
(lack of separation or support) marking)

Figure N.2 Corrosion, erosion and chaﬁng related faults

125

Intermixing of three differing

Bend radius too ‘tight’ manufacturer’s components

Seal wrongly ‘enhanced’ Tubing not ‘bottomed out’

using PTFE tape (Front ferrule not seated)

Tube not bottomed & Rear ferrule reversed

end not de-burred

Metric/imperial mixed components

(3/8” OD tubing with 10 mm OD male
connector) Poor tube end preparation

Figure N.3 General assembly faults

126

Unprotected runs Protected runs

Poor instrument access Good instrument access

Figure N.4 SBT installation examples

127

Street London W1G work carried out within the Technical Team of the

7AR, UK Energy Institute (EI), funded by the EI’s Technical

Partners. The EI’s Technical Work Programme

t: +44 (0) 20 7467 7100 provides industry with cost effective, value adding

f: +44 (0) 20 7255 1472 knowledge on key current and future issues

e: pubs@energyinst.org affecting those operating in the energy sector,

www.energyinst.org both in the UK and beyond.

ISBN 978 0 85293 651 1

Registered Charity Number

1097899

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