10. PLNB-UBE-OrF-KPM-40.5.005 Pig Trap Specification Rev 0-1

SISTEM PIPA GAS GAS BAWAH BAWAH LAUT DIAMETER DIAMETER 16” SEPANJAN SEPANJANG G + 13.5 KM DARI ORF ORF DI PULAU PEMPING KE PLANT GATE PEMBANGKIT LISTRIK TANJ TANJUN UNG G UNCANG UNCANG - BATA BATAM M

PIG TRAP SPECIFICATION

0

5-Sept-13

Issued Issued for Review

HD

SD SDC

NSR

PREPARED

CHECKED

APPROVED

OWNER

REV

DATE

PMT

DESCRIPTION

KOMITE MANAGEMENT

BOT

CONTRACTORS

COMPANY

STATUS STATUS CODE A = Issued for Review, B = Issued for Approval, Approval, C = Approved For Construction, onstruction, D = As Built Built,, CLD = Cance Canceled led and INFO= For Information Information Only Only

SISTIM PIPA BAWAH LAUT DIAMETER 16” SEPANJANG SEPANJANG+ + 13.5 KM DARI ORF DI PULAU PEMPING KE PLANT GATE PEMBAK PEMBAKIT LISTRIK LISTRIK TANJUNG UNCAN UNCANG – BATAM BATAM Contract No. : 05.001.PJ/611/KONSORSIUMPLNB – UBE/2013

PLNB–UBE/ORF-KPM-40.5.005

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KONSORSIUM PLNB - UBE Document Title :

PIG TRAP SPECIFICATION Document No. :

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Contents 1 INTRODUCTION............................................................................................................4 1.1 GENERAL ....................................................................................................................... .3 1.2 SCOPE............................................................................................................................. 4 1.3 M ANUFACTURER RESPONBILITY ...................................................................................... 4 1.4 Definitions...................................................................................................................................5 1.5 Abbreviations..............................................................................................................................5 2 REFERENCE DOCUMENTS.. .............................................................................................. 6 2.1 National / International Codes and Standards.............................................................................6 2.2 Applicable Project Documents....................................................................................................7 2.3 Conflicing Requirement...............................................................................................................7 3. DESIGN & MANUFACTURE REQUIREMENT ................................................................8 3.1 General.........................................................................................................................................8 3.2 Materials.......................................................................................................................................8 3.3 Barrel............................................................................................................................................9 3.4 End Cloure................................................................................................................................. ..9 3.5 Branch, Fitting and Flange..........................................................................................................10 3.6 Supports.................................................................................................................................... 10 3.7 Fabrication..................................................................................................................................11 3.8 Surface Preparation and Coating................................................................................................12 3.9 Equipment Tagging....................................................................................................................12 4. INSPECTION AND TESTING REQUIREMENT.. ...........................................................13 4.1 General.......................................................................................................................................13 4.2 Hydrostatic Pressure Test...........................................................................................................14 4.3 Surface Preparation....................................................................................................................14 4.4 Weight and Dimensional Control...............................................................................................14 5. PACKING AND PREPARATION FOR SHIPMENT .........................................................14 5.1 General........................................................................................................................................15 5.2 Packing........................................................................................................................................15 6. MANUFACTURER'S DOCUMENTATION .......................................................................15 6.1 Language and Format of Documents.........................................................................................15 6.2 Vendor Data Requirement List (VDRL)...................................................................................15 6.3 Document Review......................................................................................................................15 7. QUALITY ASSURANCE AND QUALITY CONTROL .................................................... ...16 Appendix A - Typical Main Dimension of Pig Trap........................................................................17



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1. INTRODUCTION 1.1 General Consortium PT Pelayanan Listrik Nasional Batam (PLNB) - PT. Universal Batam Energy (UBE) will perform the development of new 16” Subsea Gas Pipelines system along the + 13.5 km from ORF Pemping Island to Plant Gate of Gas Power Plant in Tanjung Uncang – Batam. Which is refered to as Pipeline Section #2. For a long offshore pipeline approximately 12, 5 km and 1 km for the onshore. As for the pipeline section # 1 will be constructed by PT Premier Indonesia as Gas Seller which this pipe will be built with Hot Tapping sistem of WNTS existing line heading to ORF facilities on the Pemping Island.

The first time this pipeline will transport the gas 40 MMSCFD respectively owned by PT PLNB and PT UBE and will increased to 55 MMSCFD within 6 years after the first commercial date accordance with Gas Sales Aggrement (GSA GSA # 3 and # 4). The Gas pipeline system is designed with pressure 550-710 Psig at a received point with a gas maximum flow capacity 125 MMSCFD to meet transportation needs in the future. The both parties will use any volume of this gas for its own interest to drive the new gas turbine power plant, to be built in Tanjung Uncang Batam with an installed capacity approximately 210 MW. Location of the pipeline and associated facilities are illustrated in Figure 1-1 below: Figure 1-1 Pipeline Route Layout



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1.2 Scope This Specification def ines the minimum requir ements f or the design, materials, manufacture, inspection, testing, surface pr eparation, coating, and delivery of Pig Tr aps (Launcher and Receiver) f or 16” Subsea Gas Pipelines System along ± 13.5 km from ORF Pemping Island to Plant Gate of Power Plant in Tanjung Uncang - Batam. Any deviation f r om this Specification shall be approved, in wr iting, by COMP ANY

1.3 Manufacturer Responbility The Vendor /Manufactur er shall be r esponsible for design, supply, manufactur e, inspection, testing, painting, export protection and deliver y of pig trap (launchers/receiver s) in accordance with this specif ication, refer enced codes, standards and pr oject Datasheets, specif ications and drawings.

1.4 Definitions The definitions below shall apply: COMP ANY

Consortium PT PLNB – PT UBE

Vendor /Manuf acturer

The par ty which provides/manuf actures equipment / material specified and or der ed by Contractor

Project

16” Subsea Gas Pipelines System along the + 13.5 km from ORF Pemping Island to Plant Gate of Power Plant in Tanjung Uncang – Batam

1.5 API ASME

Abbreviations

American Petroleum Institute

Amer ican Society of Mechanical Enginee

ASTM

American Society f or Testing and Materials

AWS

American Welding Society

BPV

Boiler and Pressure Vessel

BS

British Standar d

COG

Centr e of Gr avity

Div.

Division

MT

Magnetic Test



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NACE

National Association of Corrosion Engineer s

ISO

International Standar ds Or ganization

ppm

Part Per Million

PSL

Pr oduct Specif ication Level

PWHT

Post Weld Heat Treated

RT

Radiographic Test

Sec.

Section

SMYS

Specified Minimum Yield Str ess

Std.

Standards

Spec.

Specification

UBE

Universal Batam Ener gy

UT

Ultr asonic Test

VDRL

Vendor Data Requir ement List

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REFERENCE DOCUMENT

2.

The latest editions and addenda of the following Codes and Standards shall be the Ref erence Documents f or this Specif ication.

2.1

National/International Codes and Standard s

Standar Nasionallndonesia SNI 3474 : 2009

(SNI): Standar Nasional Indonesia: Sistim Penyalur an Dan Distribusi Pipa Gas.

American Society of Mechanical Engineers (ASME): ASME B31.8 ASME B16.5 ASME BPV Sec. V ASME BPV Sec. VIII Div.1 ASME BPV Sec IX

Gas Tr ansmission and Distribution Piping Systems Pipe Flanges and Flanged Fittings Non-Destr uctive Examination ASME Boiler and Pr essure Vessel Code Qualification Standard for Welding and Brazing Procedures, Welder s, Br azer s, Welding and Br azing Pr ocedure.

American Petroleum Institute (API) API Spec. 5L API 1104

Specification for Line Pipe Welding of Pipe Lines and Related Facilities



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American Society for Testing Materials (ASTM) ASTM A36

Specification for Str uctur al Steel

British Standar d (BS) BS EN 10204:2004

Metallic Products - Types of Inspection Documents

National Association of Corrosion Engineers (NACE) NACE MR0175

Sulphide Stress Cracking Resistance Metallic Materials for Oilfield Equipment

International Standard Organization (ISO) ISO 8501 ISO 9001:2000

Pr eparation of steel substr ates bef or e application of paints and related pr oducts Quality Management Systems – Requirements

Society of Nondestructive Testing (SNT) ASNT-TC-1A

2.2

Per sonnel Qualif ication and Certif ication in Non-destructive Testing

Applicable Project Documents

Datasheet and Drawings : PLNB-UBE/ORF-KPM-40.8.005 PLNB-UBE/PLO-KPM-10-9-001 PLNB-UBE/ORF-KPM-10-9-004

2.3

Pig Launcher and Pig Receiver Data Sheet Pig Launcher Pemping Island Pig Receiver Tanjung Ucang

Conflicting Requirements

In the event of conflicting technical requirements, the or der of precedence shall be as follows: 1) 2) 3) 4) 5) 6)

Local Authority or Statutory Regulations Requisition / Purchase Order Datasheets This Specif ication Referenced Project Specifications Ref er enced National/International Standar ds



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DESIGN & MANUFACTURER REQUIREMENT General

3.1.1

Pig tr aps are r equired f or use in steel pipelines and consider ed within the scope of the tr anspor tation pipeline code, SNI 3474:2009/ ASME B31.8.

3.1.2

The Vendor /Manufactur er is r esponsible for design calculations f or all pr essure and structur al parts of the equipment, for ensur ing that the equipment design is adequate to withstand all internal and external loads, and for meeting the relevant code r equir ements f or design, f abrication, examination, testing and cer tification.

3.1.3

Cor r osion allowance shall be as specif ied in the Pur chase Order or in datasheet and drawing attached to the Pur chase Or der.

3.1.4

Additional thickness shall be provided for the corrosion allowance specified in the Pig Launcher and Pig Receiver Datasheet. The overall dimensions for pig traps shall be in accor dance with the drawing specif ied in the Pur chase Or der, or the design drawing attached to the Pur chase Or der . Pig signaler s, installation, star t-up and commissioning, and bolting and gasket f or nozzle do not f or m part of this specification, and will be supplied by other s.

3.1.5 3.1.6

3.1 3.2.1 3.2.2 3.2.3

3.2.4 3.2.5

Mater ials Material of construction shall be in accordance with materials as specif ied on the Equipment Data sheets. Materials of construction of the shells shall be identified with the applicable API Spec 5L PSL2, including material grade. All mater ials for pr essur e par ts and welded attachments to pr essur e parts shall have f ull chemical analysis and mechanical test certif ication to BS EN 10204:2004 type 3.1 or ISO 10474 type 3.1B. All car bon steels shall be normalised and fully killed and, unless other wise agr eed, be made to fine grain pr actice. The maximum carbon equivalent (CEQ) r ef er s to API Spec 5L-PSL2 shall be 0.43% based on the f ormula:

The carbon content shall not exceed 0.23% f or f or ging. The base mater ial and welds shall have a maximal har dness of 325 HV 10. Base metal hardness r eading shall be made in accor dance with ASTM E920n each heat at 5 tostr ength ratio shall not exceed 0.9.

r andom

locations. The actual yield



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Materials supplied by Vendor /Manufacturer for piping elements or str uctural attachments shall confor m to the r equirements of the applicable code and shall be tr aceable to mill certif icates. Mater ial selection may be further limited in this specif ication or in the Pur chase Order . Should any mater ials pr ove unsatisfactory during fabrication they shall be r e jected not with standing any previous certification of satisfactory examination or tests.

3.3

Barrel

3.3.1

The internal diameter of the minor bar re l should be the same as that of the main line.

3.3.2

However , transitions in the internal diameter due to wall thickness var iations greater than 0.095-inch (2.4mm) shall be taper ed to a maximum angle of 14° to the pipe allow the smooth passage of a pig. Pig tr ap should be designed f or the longest pig that will be used (usually an intelligent pig) plus a margin of 10%. Dimensions f or pig tr aps designed for intelligent pigs ar e shown in Appendix A. The r educer between the ma jor and minor barr el shall be eccentric with the bottom of the

3.3.3

entire bar r el at the same level. For horizontal pig tr aps the barr el may be sloped (typicall1:100) down towar ds the end closur e to impr ove draining of liquids f ro m the barr el. 3.3.4

Blind flanges ar e to be pr ovided f or each nozzle (except the end closur e). Blind f langes should be of the same r ating as the flanges.

3.4

End Closure

3.4.1

The pig tr ap shall be equipped with a quick opening closur e, designed to allow one man oper ation f or both opening and closing, with a pressur e interlock to pr event opening of the door while the barr el is pr essurized.

3.4.2

The end closur e shall consist of the following components: 









3.4.3

A r emovable door , which pr ovides f ull-bor e access when open, and ter minates and seals the bor e when closed. A welding end hub, f or joining to the ma jor barr el of a pig tr ap. The mater ial used f or the welding end hub shall be compatible with the major barr el mater ial, as pr ovided in the data sheet. A closur e handling device, suitable to lift, hinge or swing the door. When the handling device is attached to the closur e, it shall be attached to the welding hub, not to the ma jor barr el of the pig tr ap Ring seals for pr essure containment (see 3.4.9). Two saf ety devices to prevent inadver tent opening of the closur e bef ore the pig tr ap is depressurized (see 3.4.7 & 3.4.8).

Quick opening closur es shall conf or m to the gener al r equir ements of ASME VIII Div.1, Sec. UG-35. Attention shall be dr awn to the r equirement f or a f ail-safe design of the opening



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mechanism; specifically, the f ailur e of any part of the opening mechanism shall leave the closure closed r ather than open. 3.4.5 3.4.6

3.4.6

3.4.5 3.4.6

3.4.8

3.4.9

3.5

The design of quick opening closur es shall be suitable f or permanent location in an open environment. Quick opening closur e with exposed scr ew expander s or captive r atchet br aces shall not be used. Screw type quick opening closur es that have no visible means of identifying if the closure is positively closed prior to pr essurization shall not be used. Quick opening closur e with exposed scr ew expander s or captive r atchet br aces shall not be used. Screw type quick opening closur es that have no visible means of identifying if the closure is positively closed prior to pr essurization shall not be used. The design of quick opening closur es shall be suitable f or permanent location in an open environment. Quick opening closur e with exposed scr ew expander s or captive r atchet br aces shall not be used. Screw type quick opening closur es that have no visible means of identifying if the closure is positively closed prior to pr essurization shall not be used. An inter locking system between various valves and the end closur e door oper ating mechanism may be considered to pr otect personnel and equipment depending on the ser vice, tr ap location and the planned pigging frequency. The necessity f or interlocking shall be decided by the Principal. Interlock system f eatur es may be micro-pr ocessor solid-state type logic, mechanical key systems or relay-based. The activation of the seals shall be such that the f luid within the trap is contained at any pressur e between 1 bar (abs) and the pig trap design pr essur e. Elastomeric mater ials f or r ing seals shall resist explosive decompr ession and shall be suitable f or long-ter m exposur e to the transported f luid at the design pressure and temper atur e conditions. The cross section of the seals shall not exceed 7-mm in diameter for design pr essur e of 150 bar and above.

Branch,Fitting and Flange

3.5.1 Full r einf or cements shall be pr ovided on all br anch connections. 3.5.2 Branch connections shall either be welded, for ged or extr uded. Reinfor cing pads requir ed by the specif ied code shall be fully welded and shall be provided with a vent hole. The vent hole shall be tapped with a 3 mm to 6 mm pipe thread. The tapped hole shall be filled with heavy gr ease. 3.5.3 All flanges shall be as per ASME B16.5. 3.5.4 All flanges shall have the same bor e as the pipe. 3.5.5 All flanges and br anch f ittings shall be for ged carbon steel fittings with the same specified yield strength as the pipe.

3.6 3.6.1

3.6.2

Supports The pig tr aps shall be provided with saddle supports. Per manent saddles shall be used to support and restrain pig tr a ps and these shall be designed to car r y the weight of the pig tr aps system f illed with water together with the weight of the pigs. Structur al steel used f or non-pr essure containing par ts shall be equivalent to ASTM A285 or better .



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3.6.3

3.6.5 3.6.6

3.7.1 3.7.2

3.7.3

3.7.4 3.7.5

3.7.6 3.7.7 3.7.8

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The suppor ts under the barr el shall be of the sliding type to compensate f or expansion of the unr estr ained part of the pipeline. Other supports may be f ixed if design calculations indicate that sufficient flexibility is incorpor ated in the pipewor k to compensate for any possible axial and transver se movements. Suppor ts may need to be electr ically isolated wher e isolating joints ar e not used. Suppor ts should be positioned such that the pig tr a p valves can be removed for maintenance or r eplacement without removal of the barr el.

3.6.4

3.7

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Fabrication Fabr ication of pig trap shall be in accor dance with the applicable design code (SNI 3474:2009/B31.8) and stated in this specification. All welding pr ocedur es, qualification of welder s and welding pr ocedur e qualifications, design and pr epar ation of joints, inspection and testing, standards of acceptability of welding, r epair s and r adiogr aphy shall be f ully in accor dance with API Std. 1104 or ASME BPV Sec. V and ASME BPV Sec. IX, and shall be documented befor e fabrication commences. Single-welded butt joints ar e per mitted for cir cumf er ential joints and shall be 100% r adiogr aphically tested. Vendor /Manufactur er shall provide ultrasonic tests where radiography pr oduces questionable r esults. In the event that welds perfor m ed on any for ging cannot be 100% radiographed, 100% UT or wet MT shall be utilised. UT is requir ed on the shell mater ial where locally reinf orced f ittings are to be welded. Pr ior to welding all weld ends are also to be checked using ultr asonic inspection. The Welding Pr ocedur e Specif ication (WPS) shall be submitted to COMP ANY f or appr oval and welding shall not proceed until wr itten appr oval of the welding pr ocedur e specif ication has been r eceived. Tempor ar y, per manent or consumable backing strips shall not be used for any weld whether longitudinal or cir cumf er ential. Peening of welds shall not be permitted. Welds attaching non-pressur e par ts such as pipe support clips and lugs to the surf ace of pig tr ap barrel shall be examined on all exposed surfaces by Magnetic Par ticle (MPI) or Dye Penetr ant (DP) method in accordance with the r equir ements of codes and standar ds.

3.7.9

All butt welded joints shall be f ully r adiogr aphed (100% radiogr aphy) after post weld heat tr eated (PWHT). Completed weld shall also undergo 100% Magnetic Particle Inspection or Dye Penetr ant check in all cases pr ior to r adiography.

3.7.10

The wrapper plate to which saddle suppor ts ar e attached shall be examined by both

3.7.11

3.7.12

Ultr asonic and Dye Penetrant testing after PWHT. The pig tr a ps shall be post weld heat tr e ated (PWHT) when specif ied on the design Datasheet or as r equired by codes and standard. The PWHT shall be perfor med in accor dance with the codes and standards. The detailed heat-tr eatment procedur e shall be submitted for COMP ANY approval. Heat tr eatment must be carried out after completing all forming and welding and befor e final NOT. Welding may be car ried out after PWHT only when components will be damaged by heat such as valves and closur e seals. In this case, localised PWHT may be car r ied out on the f inal welds, giving due attention to the protection of the components at r isk.



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3.8

Surf ace PreparationandCoating

3.8.1

After completion of fabr ication and testing, the vessels shall be thor oughly dr ained of water and dr ied. All sharp surface pr otr usions and all weld splatter shall be removed (f lush) prior to blast cleaning, to ISO 8501-1 Gr ade 2 Y2. Weld spatter and remains of temporar y welds, deposits or surf ace defects shall be eliminated by appropriate means; r emoval by deep grinding is sub ject to the appr oval of the COMP ANY. The pig tr aps shall be painted with pr imer only. All bare surf aces shall be coated with two coats of alkyd primer. Either the f ir st or second coat shall be tinted with 1 or 2% of black alkyd enamel to ensur e that the two f ull coats ar e applied. Both pr imer coats must be applied by br ushing and must be well wor ked into the surf ace. The minimum dr y film thickness of each prime coat shall be 40 microns. Final coats shall be applied by Vendor /Manufactur er . Primer shall be applied f ollowing satisf actor y completion of shop testing and all functional tests.

3.8.2 3.8.3

3.8.4

3.8.5

3.9 3.9.1

3.9.2 3.9.3 3.9.4 3.9.5

EquipmentTagging All equipment, sub-assemblies and select components must be tagged. Gener ally the COMP ANY will allocate equipment and component tags dur ing detailed design. In the event that the Vendor /Manufactur er has the detailed design of a package within his scope, tagging in accor dance with the pr ocedur e shall be pr oposed by the Vendor /Manuf actur er and appr oved by the COMP ANY to ensur e pr oject consistency to avoid duplications. All documents and dr awings pr oduced by the Vendor /Manuf actur er applicable to the equipment being supplied shall include pro ject-specific equipment tags. All items supplied must be identif ied by means of a nameplate, tag engraving, hard stamping or any other indelible method. Painting is not consider ed suff iciently lasting. All nameplates shall be of a non-corr oding material (such as SS 316L) and shall be f ixed to the item by a method that precludes unauthor ised casual r emoval. Each piece of equipment having a nameplate as specified by the purchase or der and/or Equipment Datasheet shall have the nameplate per manently pr otected dur ing welding, painting and shipping. The following infor mation shall be stamped on the nameplate. (a) (b) (c) (d) (e) (f) (g) (h) (i) ( j) (k) (l)

Pur chase Or der Number Item Name and Equipment Number Manufactur er Serial Number Hydro Test Pr essur e Year Built Maximum Working Pressur e Maximum Temper atur e Maximum Test Pressur e Design Code Material Grades Nominal Sizes



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Connections furnished on the equipment shall be identif ied and shall be tagged to with Vendor ’s/Manufacturer’s connection table or gener al arr angement drawing.

comply

INSPECTION AND TESTING REQUIREMENT

General 4.1.1

Inspection shall be performed before coating or paint is applied

4.1.2

All components shall be visualy examined in accordance with ASME div.1, part UG 93.

4.1.3

For the end closure, all mating elements and f langes machined surface, door hinge, hinge attachments and locking mechanisms shall be subject to magnetic particle inspections. Any def ect shall constitute a basis f or r e jection. Third Party Inspection is required for witnessing and cer tification for non-destr uctive and

4.1.4

Other testing and examination. 4.1.5

The COMP ANY r eserves the right to inspect mater ial, manufacturing pr ocess, testing etc.

4.1.6

Such inspection does not relieve the Vendor /Manufacturer of the responsibility of suitable design and workmanship. Vendor/Manuf actur er shall submit to COMP ANY a detailed Inspection and Test Plan (ITP) for appr oval with scheduled activities and acceptance cr iter ia, bef ore start of manuf actur ing.

4.1.7

4.1.8 4.1.9

Access shall be made available to the COMP ANY’s r epresentative at any time during the manuf actur e of the equipment and packages. For all witnessed tests the Vendor /Manuf acturer shall give the COMPANY the agreed notice period. All NDT including r adiographic, ultrasonic, magnetic par ticle or liquid penetrant examinations shall be perf or med bef or e and after Post Weld Heat Treatment (PWHT). NDT shall be conducted as f ollows: UT shall be in accordance with ASME BPV Sec. V, Ar ticles 5 & 23; X - Ray shall be in accordance with ASME BPV Sec. V, Ar ticles 2 & 22; and MT shall be the wet method and in accor dance with ASME BPV Sec. V, Article 7 & 25. Results shall be reviewed, interpreted, and evaluated in accordance with the following criteria : X-ray : ASME BPV Sec VII Div. 1, Section UW51; MT : ASME BPV Sec. VIII. 1, Appendix 6; UT : Forwelds, ASME BPV Sec. VIII Div. 1, Appendix 12 ;and UT : For Forging, ASME Sec. VIII Div. 2, Section. AM203.2 (c) •

•

•

4.1.10

•

•

•

•

4.1.11 4.1.12

4.1.13

All oper ator s, including for Dye Penetr ant or Magnetic Particle Inspection, must be qualified to SNT-TC-1 A level, as a minimum. Any manuf actur ed part, which does not comply with the requir ements, or any material which shows def ect dur ing inspection, will be r e jected. In such event, Vendor /Manuf acturer will be notified in wr iting. No goods shall be packed, sealed or dispatched prior to receipt of a written release note by the COMP ANY or his appointed agent.



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Hydrostatic Pr essur e Test

4.2.1

All equipment shall be shop hydrostatically tested in accor dance to code r equirements (Ref . ASME BPV Sec. VIII Div. 1) based on the maximum allowable working pr ess ure.

4.2.2

Hydrostatic pressur e tests shall be car r ied out by Vendor/Manuf actur er at a test pressure based on a fiber str ess of 90% of the specified minimum yield str ength (SMYS) in the shell or at the applicable test pr essure listed in ASME B16.5, whichever is the lower.

4.2.3

The temperature of the pig traps material and test liquid shall not be less than 50°F dur ing the hydrostatic test. Fr esh water shall be used f or all testing. For equipment of stainless steel constr uction, or of partly stainless steel construction, the test fluid shall not contain mor e than 30 ppm chlorides. Pr essure testing is to be conducted using calibr ated test gauges. Test pressur es shall be held a minimum of 4 hours. As soon as possible after completion of the hydr otest, all equipment shall be dr ained, and dried throughout. Stainless steel equipment pr ior to drying shall be r insed out with water containing less than 5ppm chlor ides. All reinfor cing pads, doubler plates and wrapper plates shall be pneumatically tested at a minimum pressur e of 1 bar, using soap solution, befor e str ess r elief and/or hydr otest. All tests ar e to be car ri ed out in the presence of the COMP ANY’s inspector and/or r epr esentative.

4.2.4

4.2.5 4.2.6

4.2.7 4.2.8

4.3

Surface Preparation

4.3.1 After acceptance of hydrostatic test, all external surf a ce shall be pr epared and prime coated. The vendor proposed method of surface prepar ation shall be approved by the COMP ANY.

4.4

Weight and Dimensional Control

4.4.1

A Weight / Centre of Gr avity (COG) Datasheet shall be submitted with the quotation for each package, detailing the package weight, dimensional envelope and coordinates of the COG in r elation to the package envelope. At the quotation stage, the requir ed accur acy for the weight shall be +/- 10%, and +/-5% f or the length par ameter s. The Datasheet shall be periodically re-issued during the cour se of design and f abr ication to assist ongoing platfor m design ver ification with closer toler ances. A final "as-built" issue shall be based on actual measurements carr ied out in the shop of the completed equipment.

4.4.2

5. 5.1 5.1.1 5.1.2

PACKING AND PREPARATION FOR SHIPMENT

Genera l Cleaning, packing, shipping and stor age requir ements shall be subject to the COMP ANY appr oval. No pig tr aps section shall be r eleased for shipment without the COMPANY prior written authorisation.



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5.2

Packing

5.2.1

The package and protection of equipment shall be suitable for inland and/or sea tr anspor tation and f or a stor a ge period as defined in the pr oject. Supply shall include complete expor t boxing packing in compliance with this requirement. All equipment and piping likely to vibr ate during tr ansportation shall be pr oper ly br aced to prevent damage. Desiccant bags shall be located in all capacities to pr event built-up of condensation and warning notices shall be attached.

5.2.2 5.2.3

6.

MANUFACTURER’S DOCUMENTATION

6.1

Language and Format of Document

6.1.1

The Manuf acturer ’s documentation shall be: •

• •

Identified as r equir ed in the contr act; In English language; and In S.1.units (except diameter of nozzles and f langes which shall be in nominal inch size

6.2 Vendor Data Requirement List (VDLR) 6.2.1

Following documents shall be f urnished as a minimum r equirement: (a) Thr ee copies of the cer tified mill test repor t showing the chemical and physical pr operties f or each item of material furnished by the Vendor /Manuf actur er shall be provided f or COMP ANY’s appr oval. (b)

A r eport of results obtained from MT and X-r ay of welds indicating all def ects wer e identified and the disposition of all r epairs shall be provided. All original r adiogr aphs shall be available to the COMP ANY for review upon request. (c) Weld identification dr awings of the f abrication and the weld number f or each weld. (d) A certif ied copy of all hydrostatic test charts shall be pr ovided.

6.3

(e) (f )

Two years r ecommended spar e par ts list. Installation, Oper ation, and Maintenance instr uctions/manuals cover ing end closur e, and other equipment supplied in the pig tr aps packages.

(g)

Assembly dr awings with corresponding keyed par ts lists of all equipment supplied in the pig tr aps packages.

Document Review

6.3.1

Consistent with the initiative to minimize documentation, only documents listed in the VORL will be r equired f or r eview and appr oval by COMP ANY.

6.3.2

The Vendor /Manuf actur er shall check and verif y the completeness of the Vendor Data Requir ement List (SDRL) pr oposed and highlight any discrepancy or missing required documents. In addition, the Vendor /Manufactur er shall complete and conf ir m



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the accuracy of the Vendor /Manufactur er Document Master List to ensure the expedient transmittal of documentation.

7.

QUALITY ASSURANCE AND QUALIT Y CONTROL

7.1.1

Vendor /Manufacturer shall establish and maintain a quality assurance system in accordance with ISO 9001:2000 or an appr oved equivalent. The COMP ANY shall have the r ight to under t ake such audits as he deems necessary to assess the effectiveness of the Vendor ’s/Manufactur er ’s quality system.

7.1.2

A pro ject-specif ic, dr af t Quality Plan shall be submitted by the Vendor /Manufacturer with the bid. The contents and f ormat must be agreed with the COMP ANY, pr ior to or der placement. A detailed, f ir m Inspection and Testing Plan (ITP) must be submitted with the Quality Plan.



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Appendix A – Typical Main Dimension of Pig Trap

MARK

DESCRIPTION

MARK

DESCRIPTION

N1

Inlet/Outlet

N7

Pressure gauge

N2L

Kicker/BypassConnection

N8

Balancing Line

N9

Purge Connection

for Launcher N2R

Kicker/Bypass Connection for Receiver (not use for Pig Receiver)

N3

Vent Connection

N10

Drain

N4

Pressure

N11

Drain

N5

Pressure Safety Valve

N12

End Closure

N6

Pig Signaler



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Pipeline Diameter (inch)

Page

Revision :

Dimension

(1)

(m) (2)&(3)

D1

D2

N2L/N2R

AL

BL

AR

BR

6

8

2

2.8

1.5

2.8

2.8

8

10

3

4.1

1.5

3.9

3.9

10

12

4

4.3

1.5

4.3

4.3

12

16

4

4.3

1.5

4.3

4.3

14

18

6

4.8

1.5

4.8

4.8

16

20

6

5.1

1.5

5.1

5.1

18

22

6

5.1

1.5

5.1

5.1

20

26

8

5.1

1.5

5.1

51

24

30

8

5.7

1.5

5.7

5.7

Notes : 1.

Diameter of pipework (drain, vent, balance, line, etc) shall refer to project P&ID

2.

L = related to Pig Launcher, R = related to Pig Receiver

3.

These lengths are extreme figures, based on data for presently available magnetic flux and ultrasonic tools. The extreme dimension will be useful for conceptual design but the user should check the lengths of the latest available tools from various relevant manufactures when performing detailed design since there are significant variations between tools (particularly between magnetic flux and ultrasonic tools). Thus it may be decided to design for only one type of tool or the use of temporary extension pieces for the major barrel could be considered.

10. PLNB-UBE-OrF-KPM-40.5.005 Pig Trap Specification Rev 0-1

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