257002289 SP 2069 Specification for Pressure Vessels 1 Doc PDF

Petroleum Development Oman LLC

Revision: 1 Effective: Dec-12

Petroleum Development Oman L.L.C. Specification for Pressure Vessels

Document ID

SP-2069

Document Type

Specification

Security

Unrestricted

Discipline

Owner

Issue Date

Version

Mechanical_Static

Abdulnabi Al-Balushi, UEP/1S

31-Dec 2012

1.0

Development Oman, LLC. Neither the whole Keywords: This document is the property of Petroleum Development nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.

Page 1

Specification for Pressure Vessels SP-2069

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The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED. UNCONTROLLED.



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i


Document Authorisation Authorisation

Authorised For Issue

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ii


Revision History

The following is a brief summary of the 4 most recent revisions to this document. Details of all revisions prior to these are held on file by the issuing department.

Version No.

Date

Author

Scope / Remarks

Verison 0

Sep 08

E.S. Mahadevan, UEP/12M

Version 1

Dec 12

Basanagoud UEP121S

Specification for Pressure Vessels Initial issue. Second issue – Some requirements modified/added (See Appendix-9).

iii

M

Biradar,

Related Business Processes

Code

Business Process (EPBM 4.0)

EP.64

Design, Construct, Modify and De-Commission Facilities

iv Related Corporate Management Frame Work (CMF) Documents The related CMF Documents can be retrieved from the Corporate Business Control Documentation Register TAXI. Refer to Section 2 – Applicable Standards, Specifications and Codes of this Specification for Related Corporate Frame Work (CMF) Documents

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The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.



TABLE OF CONTENTS 1

2

3

4

5

6

7

INTRODUCTION .............................................................................................................. 7 1.1

PURPOSE AND OBJECTIVES ................................................................................... 7

1.2

CHANGES TO THE SPECIFICATION ........................................................................ 7

1.3

DEFINITIONS AND ABBREVIATIONS ....................................................................... 8

1.4

USAGE ........................................................................................................................ 9

1.5

ADHERENCE TO SPECIFICATIONS ......................................................................... 9

1.6

HEALTH, SAFEY AND ENVIRONMENT .................................................................... 9

1.7

SUMMARY OF MAIN CHANGES ............................................................................. 10

APPLICABLE STANDARDS, SPECIFICATIONS AND CODES..................................... 11 2.1

COMPANY STANDARDS ......................................................................................... 11

2.2

SHELL GROUP STANDARDS .................................................................................. 11

2.3

SHELL STANDARD DRAWINGS ............................................................................. 12

2.4

INTERNATIONAL STANDARDS .............................................................................. 14

2.5

COMPANY AND SHELL GROUP STANDARD DATA / REQUISITION SHEETS .... 14

2.6

LIST OF COMPANY APPROVED SUB-VENDORS ................................................. 14

2.7

COMPLIANCE W ITH STANDARDS ......................................................................... 15

2.8

LANGUAGE AND UNITS OF MEASUREMENT ....................................................... 15

2.9

CONFLICTING REQUIREMENTS ............................................................................ 15

SCOPE OF SUPPLY....................................................................................................... 16 3.1

MECHANICAL EQUIPMENT .................................................................................... 16

3.2

SERVICES ................................................................................................................ 16

3.3

SPARE PARTS ......................................................................................................... 16

3.4

ENGINEERING SERVICES ...................................................................................... 17

3.5

GUARANTEE / WARRANTY .................................................................................... 17

3.6

EXCLUSIONS ........................................................................................................... 18

DESIGN .......................................................................................................................... 19 4.1

MECHANICAL REQUIREMENTS ............................................................................. 19

4.2

MATERIALS OF CONSTRUCTION .......................................................................... 22

4.3

SURFACE PREPARATION AND PAINTING ............................................................ 22

QUALITY ASSURANCE ................................................................................................. 23 5.1

GENERAL ................................................................................................................. 23

5.2

QUALITY SYSTEM ................................................................................................... 23

INSPECTION & TESTING REQUIREMENTS ................................................................ 24 6.1

INSPECTION REQUIREMENTS .............................................................................. 24

6.2

TESTING REQUIREMENTS ..................................................................................... 26

6.2.1

Hydrostatic Test ....................................................................................... 26

6.2.2

Site Supervision for Testing & Commissioning ....................................... 26

DOCUMENTATION REQUIREMENTS .......................................................................... 27 7.1

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INFORMATION TO BE SUBMITTED ALONGW ITH THE BID ................................. 27


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Petroleum Development Oman LLC 7.2

8

9


INFORMATION TO BE SUBMITTED AFTER ORDER............................................. 27

7.2.1

Drawings and Documents to be submitted after Order ........................... 27

7.2.2

Material Certificates ................................................................................. 27

7.2.3

Test Certificates ....................................................................................... 28

7.3

METHOD OF DOCUMENTATION TRANSMISSION ............................................... 28

7.4

IDENTIFICATION ...................................................................................................... 28

7.5

DATA ......................................................................................................................... 28

7.6

TRANSMITTAL ......................................................................................................... 28

7.7

MANUALS ................................................................................................................. 29

7.8

RECORD CARDS ..................................................................................................... 29

PACKAGING & PRESERVATION FOR SHIPMENT ...................................................... 30 8.1

PACKING REQUIREMENTS .................................................................................... 30

8.2

CRATING IDENTIFICATION ..................................................................................... 30

PLANNING & SCHEDULING .......................................................................................... 32 9.1

GENERAL ................................................................................................................. 32

9.2

MEETINGS ................................................................................................................ 32

9.2.1

Kick-off Meeting ....................................................................................... 32

9.2.2

Vendor pre-manufacturing Meeting ......................................................... 32

9.2.3

Review Meetings...................................................................................... 33

9.3

REPORTING ............................................................................................................. 33

9.4

PURCHASE ORDERS .............................................................................................. 33

APPENDICES :....................................................................................................................... 34 APPENDIX-1

ENVIRONMENTAL & SITE CONDITIONS.............................................. 35

APPENDIX-2

EQUIPMENT DATASHEETS & DRAW INGS .......................................... 36

APPENDIX-3

REQUISITION FOR ENGINEERING DOCUMENTS (RED FORMS) ..... 45

APPENDIX-4

TABLE OF COMPLIANCE....................................................................... 55

APPENDIX-5

ALLOWABLE NOZZLE LOADS .............................................................. 58

APPENDIX-6

SPIR FORMAT ........................................................................................ 59

APPENDIX-7

USER FEEDBACK PAGE ....................................................................... 63

APPENDIX-8

INSPECTION AND TEST PLAN (ITP) FORMAT .................................... 64

APPENDIX-9

DOCUMENT CHANGE IDENTIFICATION TABLE ................................. 70

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1 INTRODUCTION 1.1

PURPOSE AND OBJECTIVES

Specifications (SP) contain information/requirements on PDO facilities that are either used repeatedly, or that are retained for future reference. These documents are intended for use by the Company and its nominated Consultants and Contractors. It is the responsibility of the User to ensure that he is using latest revision of this specification The SP system is intended to: Publish guidelines or codes of practice. Set the Company standards. Form a basis of technical specifications for the procurement of equipment or technical services. Disseminate and record engineering information, experience and procedures. This Document is fully restricted for PDO. The accessibility for this document shall be maintained by PDO Mechanical Corporate Functional Discipline Head (CFDH) and his technical focal point. This specification together with standard drawings, SPs, DEPs as mentioned in section 2 sets out the minimum requirements for the design, engineering, supply of materials, fabrication, assembly, inspection, testing, transportation, installation, commissioning supervision, functionality and supply of Pressure Vessel package. It has been written in a format that enables the Project engineer and the Consultant to easily and uniformly prepare a requisition and purchase Pressure Vessels, storage (atmospheric) vessels, pressure parts of filters, shell & tube heat exchangers etc. for a variety of applications in PDO. For a specific purchase the Project Engineer / Consultant shall: Follow this specification in general and do not require to produce additional specification. But in case of any project or equipment specific requirements, which are different from the ones specified in this specification, shall be prepared and attached as an amendment/addition to the particular sections of this specification. Ensure that the Vendor receives the applicable documentation listed in subsections 2.1, 2.2, 2.3 & 2.5. Ensure that procedures for Vendor Drawings/Documentation are in accordance with SP-2047 'Preparation and Content of Engineering Drawings' and Section 7 of this specification. This specification shall be used in conjunction with relevant equipment data sheets in the DEP format attached in Appendix-2 and Environmental & Site Conditions attached in Appendix-1. The User shall complete/follow these data sheets as applicable.

1.2

CHANGES TO THE SPECIFICATION

Custodian of this document is specified in Document Authorisation section of this document in page 3. Any user of this document, who encounters an inaccuracy or an ambiguity, is requested to notify the Custodian, using the SP User Feedback Page included in Appendix-7. Reviews, modifications and adjustments to the document will normally be made by the Corporate Functional Discipline Head (CFDH) for Mechanical Engineering every four years or earlier when justified.

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DEFINITIONS AND ABBREVIATIONS

The following Definitions, terms and abbreviations used in this document, are defined below: GENERAL DEFINITIONS Shall Should May Include, Including

Includes, -

Company /Principal Consultant -

EPC Contractor Contractor

/ -

Purchaser

-

Scope

-

User

-

Vendor/Supplier

-

Sub-Vendor

-

Inspector

-

Others

-

The word 'shall' is to be understood as mandatory. The word 'should' is to be understood as strongly recommended. The word 'may' is to be understood as indicating a possible course of action. If the word “include” or “includes” or “including” is used in any document and this specification, it shall be taken as having the meaning “including but not limited to” and shall not be considered as creating or inferring any limitation on the description that follows if other components/equipments required Petroleum Development Oman L.L.C. Muscat, Sultanate of Oman. A contracted party by the Company who is responsible for providing design engineering and other related consultancy service under a contract. A contracted party by the Company who is responsible for providing design engineering, procurement and construction service under a contract. A party, who places the order on, or requests tender from, the Vendor/ Supplier. This can be the Company/ Contractor. All works executed and all services carried out by the Vendor/Supplier in accordance with this Specification and its referenced standards and data sheets. A responsible party who applies this Specification in the procurement of specified equipment. A party responsible for the supply of equipment, materials or productrelated services in accordance with this Specification and its referenced standards and data sheets. All Sub-Vendors shall be subject to written approval by the Company. All terms and conditions applicable to the Vendor shall be applicable to the Sub-Vendor as well. A party appointed by the Vendor for supply of equipment, materials or product-related services in accordance with this Specification and its referenced standards and data sheets. Any person/party whom the Purchaser certifies as acting for and on behalf of the Company to inspect items to be purchased and/or the work done by the Vendor/Sub-Vendor. Any party contracted by the Purchaser to supply equipment, services, material which are not part of the scope mentioned in this specification.

GENERAL ABBREVIATIONS API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

CSR

Construction Site Representative

DEP

Design and Engineering Practice (Shell Group standard)

E-SPIR

Electronic Spare Parts Interchangeability Record (Company standard)

HAZOP

Hazard and Operability Analysis

ISO

International Organisation for Standardisation

ITP

Inspection and Test Plan

PT

Liquid Penetrant Testing

PMI

Positive Material Identification

MESC

Materials and Equipment Standards and Code

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MT

Magnetic Particle Testing

NDT / NDE

Non-Destructive Testing / Non-Destructive Examination

PDO


PEFS

Process Engineering Flow Scheme

PR

Procedure

PWHT

Post Weld Heat Treatment

RED

Requisition for Engineering Documentation

RT

Radiographic Testing

SP

Specification (New Company standard)

TPI / TPIA

Third Party Inspector / Third Party Inspection Agency or Authority

UT

Ultrasonic Testing

NOTE: Contractors, Consultants, Suppliers, Vendors and users SHALL ensure the Company is consulted for any deviations on "SHALL" and "SHOULD" requirements through company variance tracking tool.

1.4

USAGE

This Specification together with the referenced standards and data sheets shall form the purchase requisition package for Pressure Vessels, storage vessels, filters, etc. as required by the Company. The Consultant / EPC Contractor may consider augmenting this SP under exceptional circumstances where it may not precisely meet either enquiry or purchase requirements (eg. In case of special equipment). Nominally it is anticipated that this SP and data requisition sheets should finalise fully meaningful enquiry and purchase without generating additional documentation. Under certain exceptional cases the additional requirements, project or equipment specific special requirements/changes shall be specified as a separate amendment to this SP subjected to approval by the Company.

1.5

ADHERENCE TO SPECIFICATIONS

The Vendor shall provide an itemized list of any additional projects specific comments or exceptions to this specification and its appendices. These shall be listed on the Table of Compliance provided in Appendix-4 for review & approval by Purchaser. Unless referred to in these listings, it will be assumed that all specifications are adhered to and that they do not have implications with respect to cost, delivery and integrity of the plant. Only those comments/exceptions that are accepted by the Company, in writing, shall be incorporated into the Purchase Specification at time of order. Note that “lead times” will not be considered by the Company as a justifiable reason for using alternate Vendors/deviations.

1.6

HEALTH, SAFEY AND ENVIRONMENT

The Vendor shall throughout the progress of the work have the strongest regard for the Health Safety and Environment (HSE) of all persons and/or places upon and around the worksite and shall keep the worksite and the work in an orderly state appropriate to the avoidance of danger to all persons and properties and shall provide its personnel, at the Vendor’s cost, with protective clothing and equipment as may be required for the work under the PDO HSE regulations.

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SUMMARY OF MAIN CHANGES

This SP is a revision of the SP-2069 dated September 2008. Major Technical Changes are listed in Appendix 9.

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2

APPLICABLE CODES

STANDARDS,


SPECIFICATIONS

AND

This SP shall be read in conjunction with the latest revision of the following Standards, Specifications and Codes. The Vendor shall also consider all other relevant SPs, DEPs, Shell Standard Drawings and International Standards, which may not be mentioned here but are listed within these major specifications, standards and codes. The applicable editions shall be the editions in force at the date of the enquiry requisition / order or as mutually agreed during purchase order. The international standards shall be read in conjuction with the corresponding DEP amendment. It should be noted that references to DEP's and International standards within this SP are based on the current revision of those standards at the time of publication of this SP. The Vendor is deemed to be in possession and familiar with specifications, standards listed being a regular supplier to Company. If any of the documents listed are not in the V endor’s possession, same shall be obtained from the Consultant / Purchaser. Not possessing the referred standards / specifications shall not be a cause for deviation or non-compliance. Including this SP the following engineering specifications shall be f ollowed:

2.1

COMPANY STANDARDS

SP-1171

Specification for Quality Management System Requirements for Product and Service

SP-1173

Welding of Metals

SP-1246 (Part 1 to 5)

Specification for Painting and Coating of Oil and Gas Production Facilities

SP-1275

Specification for Civil and Works - Design Criteria Manual

SP-2020

Flange connections Bolts Torquing & Tensioning

SP-2041

Specification for Selection of Cracking-Resistant Materials for H 2S Containing Environments

SP-2047

Preparation and Contents of Engineering drawings

STD-2-3950-001

Foundation bolts (J type to be used for horizontal/vertical Vessels)

STD-4-0304-001

Earthing Boss of Steel Structures, Tanks, Vessels, etc.

2.2

SHELL GROUP STANDARDS

DEP 30.10.02.11-Gen

Metallic Materials-Selected Standards

DEP 30.10.02.15-Gen

Materials for use in H2S-containing environments in oil and gas production (amendments and supplements to ISO 15156:2009)

DEP 30.10.02.16-Gen

Hydrogen induced cracking sensitivity test (amendments/supplements to NACE TM0284)

DEP 30.10.02.17-Gen

Wet H2S requirements for Downstream pressure vessels and piping

DEP 30.10.02.31-Gen

Metallic Materials-Prevention of Brittle Fracture in new assets

DEP 30.46.00.31-Gen

Thermal Insulation

DEP 30.48.40.31-Gen

Thermal Spray Coatings of Aluminium

DEP 31.10.00.10-Gen

Material Traceability and Positive Material Identification (PMI)

DEP 31.10.03.10-Gen

Symbols & Identification System – Mechanical

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DEP 31.20.20.31-Gen

Internals for Columns

DEP 31.22.05.11-Gen

Gas/Liquid Separators – Type selection and design rules

DEP 31.22.05.12-Gen

Liquid/Liquid and Gas/Liquid/Liquid (three-phase) Separators – The selection and design rules

DEP 31.22.10.35-Gen.

Manufacturing Reports for Pressure Vessels

DEP 31.22.20.31-Gen

Pressure Vessels(based on ASME Section VIII)

DEP 34.00.01.30-Gen

Structural design and engineering

DEP 34.19.20.11-Gen

Fire Proofing of Steel Structures

DEP 39.01.10.11-Gen

Selection of materials for life cycle performance (Upstream facilities) - Materials selection process

DEP 39.01.10.12-Gen

Selection of materials for life cycle performance (Upstream facilities) - Equipment

DEP 74.00.10.10

Shop and field pressure testing of piping systems

DEP 70.10.90.11-Gen.

Spare Parts.

2.3

SHELL STANDARD DRAWINGS

S 10.010

Vortex breakers for nozzles

S 10.016

Flanges for Non-Pressure Piping Connections Inside Vessels

S 10.030

Lifting lug for Top covers (material: carbon steel, low alloy steel or stainless steel

S10.045

Anchor Bolt with sleeve for concrete foundations and structures

S10.056

Typical details for insulation collar for carbon, low-alloy steel and stainless steel apparatus

S 10.070

Davit for ANSI or BS flanges, DN 300-600mm (12” – 24”), classes 150-600 incl.

S 10.101

Equipment Nozzles

S 10.103

Typical details of bush-lined, overlay welded and clad steel nozzles

S 10.114

Name plate with bracket for vessels and heat exchange equipment

S 10.115

Typical details of lifting trunnion for vertical vessels

S 10.116

Bolting of Non-standard Flanges with Metric Screw Threads

S 10.119

Grab rungs and steps for Manways

S 20.001

Skirts, cylindrical and conical

S 20.002

Fireproof protection of Skirts

S 20.003

Support ring for insulation

S 20.004

Anchor bolt rings for lugs and base plate for columns

S 20.015

Typical details of Schoepentoeter (vane feed inlet) (type II)

S 20.016

Typical details of Schoepentoeter (vane feed inlet) (type III)

S 20.017

Typical details of Schoepentoeter (vane feed inlet) (type IV)

S 20.019

Typical details of Schoepentoeter (vane feed inlet) Vane ladder-

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supports and general notes S 20.020

Typical details of schoepentoeter (vane feed inlet) with single section vane ladder, max. height 800 mm (type 1A)

S 20.021

Typical details of schoepentoeter (vane feed inlet) with catcher cap (type 1B)

S 20.022

Typical details of schoepentoeter (vane feed inlet) with multiple section vane ladder (type 1C)

S 20.025

Typical details of schoepentoeter (vane feed inlet) (type Hi Fi)

S 20.026

Typical details of schoepentoeter (vane feed inlet) (type Hi Fi) vane distribution and general notes

S 20.028

Typical details of Demisters

S 20.029

Typical details of Demister attachments

S 20.030

Typical details of Demister supports

S 22.001

Saddles for Horizontal vessels- Shell dia. Nom 150mm OD upto and Including 1000mm OD.

S 22.002

Saddles for Horizontal vessels- Shell dia. 1050mm OD upto and Including 3600mm OD.

S 22.003

Sliding plates for saddles of horizontal vessels.

S 22.005

Supports for Vertical vessels shell dia. 350mm OD upto and Including 1500mm OD (half skirts).

S28.001

Stairways, general arrangement

S28.002

Stairways, stair details

S28.003

Stairways, hand railing connections

S28.004

Stairways, intermediate platform

S28.005

Stairways, top connections of stringers

S28.006

Hand railing, type A

S28.007

Hand railing, type B

S28.008

Hand railing, type C

S28.009

Hand railing, connection of railing to concrete type A

S28.010

Hand railing, connection of railing to concrete types B & C

S 28.011

Ladder General arrangement to columns, stacks and structures

S28.012

Ladder - typical details of sliding/fixed connections

S28.013

Platforms - cleats and brackets to columns (design load max 300 kg)

S28.014

Platforms - cleats and brackets to columns (design load over 300 kg)

S28.015

Davit general arrangement and typical details

S28.016

Grating typical of steel curb angles and cheqered plate

S28.020

Anchor bolts

S28.022-001

Grating, type I (sheet 1 of 3)

S28.022-002

Grating, type II (sheet 2 of 3)

S28.022-003

Grating, type III (sheet 3 of 3)

S28.022-004

Grating, type IV

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S28.022-005

Grating, type V

S28.023

Fastening of apparatus to fireproofed beams

2.4


INTERNATIONAL STANDARDS

ASME Section VIII Div.1

ASME Boiler and Pressure Vessel Code – Rules for Construction of Pressure Vessels

ASME Section VIII Div.2

ASME Boiler and Pressure Vessel Code – Alternative Rules for Construction of Pressure Vessels

ASME Section V

Non-Destructive Examination

ASME Section IX

Welding and Brazing Qualification

ASME B 16.5

Pipe Flanges and Flanged Fittings

ASME B 16.47

Large diameter steel flanges NPS 26 thro’ NPS 60

NACE 15156

MR0175

/

ISO Petroleum and natural gas industries - Materials for use in H2S containing environments in oil and gas production, Part1, 2 & 3.

ISO 10474

Steel and Steel Products – inspection Documents.

BS/DS/DIN-EN 10204

Metallic products - Types of inspection documents

ISO 9001: 2008

ISO Quality Management System – Requirements.

2.5

COMPANY AND SHELL GROUP STANDARD DATA / REQUISITION SHEETS

DEP 30.10.01.92-Gen. -

Mass/Centre of Mass of Equipment

DEP 31.22.00.94-Gen. -

Pressure Vessels (columns, reactors, accumulators etc.)

DEP 31.22.00.98

Pressure vessels - ASME - User's design specification for general service pressure vessel and engineered pressure vessel

-

DEP 31.22.05.93-Gen. -

Demister Mat

DEP 31.20.41.93-Gen

Schoepentoeter

-

DEP 31.27.20.93-Gen. Strainers/Filters (use this datasheet instead of Pressure Vessels datsheet only in case of Filters)

2.6

LIST OF COMPANY APPROVED SUB-VENDORS

The Vendor shall select sub-vendors from the list of relevant Company approved Vendor ’s list. The Vendor shall in respect of this order, procure third party material from sub-vendors listed in the Company’s approved list, unless the particular type of material is not covered by the list, or a special dispensation to deviate from the list has been granted in writing by the Company during the technical evaluation and award stages. Any item not covered in the sub-vendor’s list shall be brought to the attention of the Company for agreement before any sub-order is placed. The Vendor shall ensure that the equipment proposed to meet this specification is designed and manufactured for the intended performance/service requirements, for safe operation and to achieve the highest possible level of reliability and availability of the package.

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COMPLIANCE WITH STANDARDS

The Vendor/ Supplier shall complete the Table of Compliance (Appendix-4) and highlight deviations if any from standards and specifications. The Purchaser shall obtain the written approval from the technical authority within the Company for any deviations from this Specification. Only those deviations that are approved by the Company shall be deemed to be part of the scope. In all cases the Company shall determine the compliance of the design carried out and works executed by the Vendor/Supplier in accordance with this Specification.

2.8

LANGUAGE AND UNITS OF MEASUREMENT

The English language and the SI system in accordance with DEP.00.00.20.10-Gen of units shall be used throughout for all documentation and drawings. Where necessary for a specific application, alternative units may be indicated in brackets together with the SI units.

2.9

CONFLICTING REQUIREMENTS

All conflicts between the requirements of this specification, related specifications, standards, codes, requisition data sheets and data sheets shall be referred to the Company for clarification before proceeding with the manufacture of the affected parts. Vendor shall make a formal request with full supporting information when a deviation from standard is required. Vendor is requested to notify any inaccuracy or am biguity encountered in this document. Nothing contained in this specification and related documents shall be construed as relieving the Vendor of the responsibility for designing and manufacturing the equipment to meet the specified operating conditions. The general hierarchy of documents shall be followed as below: First priority

:

The Contract / Purchase order

Second priority

:

This specification with attached datasheets

Third priority

:

Company SPs

Fourth priority drawings .

:

Company ERDs.Shell Group DEPs & Shell standard

Fifth priority

:

International standards & codes

In case of conflict among documents or sections relating to this specification, the more stringent requirements shall apply, unless otherwise agreed in writing. Where the Company technical specifications refer to or amend international codes and standards, these international codes and standards shall be deemed to be part of the specifications. Where the technical specifications refer to other specifications, standards and codes, these shall be deemed part of the specifications.

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3


SCOPE OF SUPPLY

The scope of supply shall include but not limited to the equipment and services defined below, detailed in this specification, on the attached data or data/requisition sheets, standard drawings and in accordance with the applicable standards, specifications and codes. The Vendor shall supply complete, assembled and tested equipment including, but not limited to, the scope of supply detailed below unless otherwise specified. Items which are optional and required only if specified are marked with an asterisk (*) below. The Supplier’s scope of supply shall include, but not be limited to:-

3.1

MECHANICAL EQUIPMENT

a)

The equipment complete with all parts including supports, spares etc..

b)

All Internals viz. schoepentoeter, demister mat, internal dip/header pipe, vortex breaker, baffles, column trays, plate packs etc. as applicable and specified in the specification/datasheets including supports for internals.

c)

Manhole with davit arrangement.

d)

Lifting lugs / trunnions, cleats/clips for pipe support, ladder, platform, insulation, & fireproofing (if required) etc.

e)

The vessels shall be provided with ASME code stamp.

f)

Fabrication, supply, certification & guarantee of the equipment and internals.

g)

Surface preparation and painting as per SP-1246 Part 1 to 5.

h)

Minimum 2 Nos. of Earthing bosses for each equipment.

i)

Nozzles with blind flanges and wherever counter flanges are in Vendor’s scope shall be provided with gaskets and fasteners alongwith spares (10% bolts (min. 2nos.) and 200% gaskets).

j)

Nameplate & bracket for each Vessel.

k)

Foundation template for vertical skirt supported vessel.

l)

Special tools, if any, for installation, commissioning, maintenance and start-up.

m)

All buried vessel shall be supplied with external impressed current cathodic protection (by others – not by vessel vendor).

3.2

SERVICES

a)

Transportation & Delivery to Project Site or as agreed in Purchase Order specified Location.

b)

Assistance/Supervision during installation & commissioning (*).

3.3

SPARE PARTS

a)

Installation & Commissioning spares – 10% bolting (min. 2nos.) for each size and 200% gaskets for each blinded flange joints including internal joints. These spares shall be part of vessel supply and to be included in vessel offer.

b)

Two years Trouble free operation spares – 10% bolting (min. 2nos.) for each size and 300% gaskets for each blinded flange joints including internal joints.

The Vendor shall advise on the requirement of any additional spare parts & special tools and shall state the lead times and costs in the offer. Vendor shall subm it the same by filling in the SPIR format, attached in Appendix-6.

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The Vendor shall provide a separate itemized price list of spare parts for two years Trouble free operation along with the bid. The Vendor shall also complete the E-SPIR (Electronic Spare Parts and Interchangeability Record, DEP 70.10.90.11) data for 2 years of operation in accordance with the instructions for use of E-SPIR information. The E-SPIR information shall be submitted within the period indicated in the RED form to enable processing and ordering spare parts such that these can be delivered within the period of the purchase order.

3.4

ENGINEERING SERVICES

This specification shall in no way relieve the Vendor from final guarantee as to material, equipment, workmanship and performance of the vessel. The Vendor shall assume overall responsibility for the design and engineering of all equipment supplied, as indicated in this specification. This shall include, but not necessarily be limited to: a)

Resolving engineering questions relating to equipment within the scope of supply.

b)

Providing / coordinating the complete detailed mechanical design as specified in this specification and the referenced specification, standards and / or the datasheets for all equipment & components within the scope of supply (including foundation loads, design (size and number) of foundation bolts and design of internals like Schoepentoeter, demister etc. as per DEP/other standards).

c)

Inspection and Testing along with material certification.

d)

Company approved 3 party inspection agency to be appointed by the Purchaser for inspection / testing & certification of all equipment and lifting appliances, in addition to the authorized inspectors for design approval and code (ASME) stamping of vessels.

e)

Installation of internals at Vendor’s shop and then if feels necessary (due to criticality and to avoid damage during transportation and installation) remove the internals and deliver as loose supply in separate cratings, alongwith site installation procedure.

f)

Ensuring that all equipment supplied meet the requirements of the specifications and standards referenced herein.

g)

Providing design parameters for foundations and overhead lifting facilities.

h)

Providing all documentation as per RED form attached in Appendix-3.

i)

Furnishing progress reports, third party inspection reports etc.

j)

Providing expediting services for all sub-Vendors and ensuring timely and proper execution of the job.

k)

Attending Vendor coordination meeting / kick-off meeting / pre-inspection meeting at Company / Purchaser / Consultant / Contractor’s office.

l)

Coordinating with the Purchaser’s design Consultant for all design / technical matters.

m)

Providing quality assurance for all sub-Vendors with respect to ISO 9001:2008.

n)

When ever sizing of vessel is not specified in data sheet OR specified as preliminary/check, contractor/vendor shall perform sizing calculation as per relevant DEP’s.

rd

3.5

GUARANTEE / WARRANTY

The equipment shall perform satisfactorily under the operating conditions specified in this Specification and datasheets and shall be fit for the purpose intended. The guarantee / warranty requirements are as per the General Terms and Conditions. The Vendor shall guarantee the equipment minimum as follows:

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i)

Process design (eg. Internals design) / performance as specified in data/requisition sheet included in Appendix-2 of this specification.

ii)

Mechanical design, structural integrity, material and workmanship.

iii)

If any defect or mal-performance is observed during the guarantee period, the Vendor shall make all necessary alteration, repair or replacement free of charge.

Unless a specific exception is given in the Vendor ’s tender, it shall be understood that he guarantees and agrees to the above.

3.6

EXCLUSIONS

The following are excluded from the Vendor’s scope of supply, however, shall be part of Purchaser’s scope: Concrete foundation design based on Vendor supplied technical data.



External access ladder / operation platform / grating / handrailing / pipe supports (but Vendor shall provide suitable support clip/cleats for these parts. Vendor shall quote unit price on per kg. basis for ladder, cleats, supports and per sq. metre basis for platform).



Supply of Anchor bolts.(sizing is in Vendor scope)



Lifting & hoisting (but Vendor shall provide weight of all equipment parts which are to be removed / installed during installation & maintenance).





Site installation and commissioning (optional).



Any instrumentation.



Any electrical connection.



Insulation (but cleats / supports for insulation attached to vessel shall be provided).



Fire proofing (but fire proofing supports attached to skirts/legs shall be provided).



Process piping from vessel nozzle flanges, unless otherwise specified.

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4


DESIGN

4.1

MECHANICAL REQUIREMENTS

4.1.1

The equipment shall be designed, fabricated and tested in-accordance with DEP 31.22.20.31-Gen., ASME VIII Div 1 / Div.2, as indicated on the datasheets attached in Appendix-2. In addition to the design approval and code stamping by the rd authorized inspection agency, the Purchaser shall appoint a Company approved 3 party inspection agency, who are different from the authorized inspection agency for certification of design and inspection.

4.1.2

Process design (calculation) for internals, mechanical design of all parts of the vessel are responsibility of the Vendor.

4.1.3

All equipment shall be designed for a service life of 30 years OR as specified in project design basis which ever is lower.

4.1.4

All the internals shall be assembled at the Vendor’s works to check f or proper fit and alignment. To avoid damage during transportation/installation, the internals shall be removed prior to transportation and delivered loose in separate cratings alongwith site installation procedure. Generally, internals shall be of removable type and should be bolted to the internal supports and direct welding to equipment wall should be avoided, but whenever internals are required to be welded to equipment wall, Vendor to obtain necessary approval from the Company.

4.1.5

All of the equipment internals shall be designed and constructed so that it is possible to remove them through the manhole.

4.1.6

All nozzle flanges and body flanges shall be welding neck raised face (WNRF) or long weld neck raised face (LWNRF) type, 3.2-6.3 microns face finish as per ASME B 16.5, unless otherwise specified on the datasheets.

4.1.7

Bolting and threads shall comply with ISO metric standards, except for ASME flange connections, which shall be in-accordance ASME B16.5.

4.1.8

Bolt holes on all nozzle flanges shall straddle to natural centre line.

4.1.9

Lifting lugs shall be provided and attached to pressure containing parts via doubler plates. The doubler/reinforcement plates shall be provided with ¼” NPT tapped tell tale holes and these holes shall be closed by filling with non-corrosive compound after testing and final painting. Lifting lugs and associated supports and bracing shall be designed for transportation and installation of the equipment considering a minimum impact factor of 2. Plates to which lifting lugs are attached shall be ultrasonically examined over an area extending 100mm beyond the edges of the attachment welds to ensure that it is free from laminations/defects. All lifting lugs and the lifting lug welds (where possible) shall be ultrasonically tested, 100% MT/PT and visual testing.

4.1.10 All nozzle openings shall be flush with the inside of the vessel and sharp edges shall be rounded off to a radius of 3mm unless otherwise specified. Nozzles shall be provided with reinforcing pads required as per design code and for the preliminary allowable nozzle loads specified in Appendix-5. T he Purchaser will advise the Vendor on the actual nozzle loads during detailed design (after award of Purchase Order). Vendor to design the nozzles/vessel for these loads. 4.1.11 Body flanges shall be provided for Compressor Scrubbers and vessels with removable type internals, viz.Shoepentoeter, Mistmat, Swirldeck, trays, etc., which are less than or equal to 1200mm vessel inside diameter and as specified in the datasheet. Location of the body flange shall be agreed with the Company. 4.1.12 Horizontal vessels shall be saddle supported with one saddle fixed and the other sliding alongwith sliding plate as per Shell standard drawing S.22.003. Vendor shall consider saddle friction factor 0.3 for Steel plate to concrete/steel and 0.1 for Steel plate to PTFE/NYLON plates in ZICK analysyis.

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4.1.13 Vertical vessels shall be either full skirt supported with inspection / access openings and skirt vents or leg supported or lug/bracket supported as specified in the datasheets. 4.1.14 All bottom head piping which penetrate vertical pressure vessels inside the skirt shall be extended outside the skirt with pipe flanged in the horizontal run. Welding of nozzles or piping to vessel skirts shall not be permitted. Skirt penetration point shall be reinforced with a sleeve three (3) sizes larger than the bottom head piping. Gusset plates shall be provided to the bottom head piping at the skirt penetration point, and in no case shall the gusset plates be welded to the sleeve. Adequate openings shall be provided for maintenance access to the Skirt 4.1.15 Flange inside diameter shall be same as that of mating nozzle neck/shell inside diameter. 4.1.16 Nozzles shall not be located on longitudinal weld seams and shall avoid girth seams. 4.1.17 Nuts for all external flange joints shall be of heavy hexagonal type. Any external coating requirements on fasteners shall be as per the applicable piping class. 4.1.18 The equipment supports shall be designed to withstand all induced stresses by transportation & installation, wind load, operating conditions and pressure testing. 4.1.19 The material and inspection test certification shall be minimum according to ISO 10474 - 3.1B / EN 10204 – 3.1. All pressure retaining materials shall be certified to ISO 10474, 3.1C/EN 10204, 3.2 for supplementaory tests viz. Impact, HIC, corrosion, etc. 4.1.20 Vendor shall provide complete calculation to demonstrate the integrity of all components including but not limited to Code calculations, nozzle local loading, lifting lugs, hold down bolting, transportation and wind loading. 4.1.21 Asbestos in any form shall not be used as material for any item, including the packaging. Molybdenum disulphide compounds shall not be used for any screwed item. 4.1.22 Minimum nozzle size on all equipment shall be DN50. Smaller size requirement shall be reduced in piping. 4.1.23 All equipment shall be fitted with two nos. of earthing boss each in accordance with the drawing STD-4-0304-001. 4.1.24 Nameplate and nameplate bracket as per Shell standard drawing S.10.114. The nameplate shall be clearly die-stamped with the tag number and other data as per the standard drawing. 4.1.25 Manway/Access openings shall be provided with blind flange and davit arrangement as per drawing S.10.070, unless the equipment is provided with cold insulation, in which case hinge with handle shall be provided to facilitate blind flange/cover opening. Internal ladder rungs and hand grip shall be provided for easy internal access to the vessel through manholes. 4.1.26 Proper electrical isolation shall be provided between dissimilar metals (stainless steel internals, if any, and mating carbon steel parts / supports) to prevent formation of galvanic corrosion. 4.1.27 Vendor shall indicate the requirements of Impact testing, PWHT, and heat treatment requirements for the entire equipment / dished ends, if any, in the quotation & fabrication drawings. 4.1.28 Vendor shall follow the exact location & orientation of nozzles and requirement/dimensions of cleats/clips for pipe supports, platform, ladder, if any, provided by Purchaser later during detail engineering. 4.1.29 If a vessel is subject to PWHT then on completion of all painting activities the following statement shall be stencilled onto the vessel adjacent to the manway(s) in letters of 50mm high minimum. "Stress Relieved Vessel - No Welding Permitted".

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4.1.30 All gaskets fitted to the equipment shall be new and service gaskets shall be used for hydrotesting. On no account gaskets shall be reused after hydro-testing. 4.1.31 For vessels with internal weld overlay, the undiluted chemical composition requirement of the overlay shall be ensured by using a two-layer technique in which the first layer is applied with a low heat input. 4.1.32 The equipment data sheets are included in Appendix-2. Vendor shall submit updated completed data sheet along with the offer. 4.1.33 Vendor shall consider Project environmental wind data OR wind speed defined in the environmental and site condition in Appendix-1 which ever is stringent. Wind pressure shall be designed according to SP-1275 and DEP 34.00.01.30-Gen, considering 3-second gust wind speed in the design. 4.1.34 Vendor shall consider sizing of anchor bolts with maximum allowable tensile stress 2 of bolt material as 100 N/mm only. 4.1.35 The Vendor shall provide all details required for the foundation design such as foundation loads, lay-out and positioning of foundation bolts alongwith template, requirement of leveling plates, etc. the Vendor shall provide clear drawings and instructions well in advance. 4.1.36 The Vendor shall indicate the location, weight, and space requirements for equipment parts, to be removed for normal maintenance. This will enable the design of hoisting facilities above the equipment ( by others). 4.1.37 Wherever corrosion allowance is specified in the datasheet for vessel, one corrosion allowance thickness shall be added to vortex breaker specified in shell standard drawing S.10.010. 4.1.38 The weld clearance between two adjacent pressure part welding shall be 2 times the thickness of thinner part or 50mm, which ever is higher. For non pressure parts, the weld clearance shall be 5 times thickness of thinner part or 50mm (max). The distances are measured from the toe of the weld. 4.1.39 All vessels opearating at atmospheric pressure and designed for less than or equal to 3.5 bar shall be designed as per the requirement of “Minimum Service Pressure Vessels” as mentioned in DEP 31.22.20.31. 4.1.40 All other ASME section VIII div 1 pressure vessels shall be designed as per the requirement of “General Service Pressure Vessels” as mentioned in DEP 31.22.20.31. 4.1.41 All ASME section VIII div 2 pressure vessels shall be designed as per the requirement of “Engineered Pressure Vessels” as mentioned in DEP 31.22.20.31. 4.1.42 No backing strip welding is allowed in pressure parts. 4.1.43 Plates above 16mm and forgings above 50mm thick shall be subjected to UT to check for any lamination defects. 4.1.44 Minimum of 1.5 mm (1/16 in) corrosion allowance shall be applied for skirt/leg supports. 4.1.45 All pressure vessels shall be designed with 100% radiography. 4.1.46 All presure vessels designed according to ASME section VIII div 2 shall have integral reinforced nozzles with extended lips to have butt weld joints to facilitate proper NDT. 4.1.47 Contractor/Consultant/Vendor shall Prepare User Defined Specification (UDS) for all ASME Section VIII Div.2 designed pressure vessels/equipment. Required Input data for UDS shall be provided by Purchaser/Company. Approval of UDS from Registered Professional Engineer (RPE) is in contractors/Consultants/Vendor scope, however Purchaser/Company shall endorse all input data before RPE approval. 4.1.48 All cold formed statinless steel dished heads shall be subjected to solution annealing.

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MATERIALS OF CONSTRUCTION

All materials shall be as specified in the datasheets with any additional Requirements specified in material selection Report. Format of data sheet is attached in Appendix-2. However, Consultant/ Contractor to confirm the suitability of the specified materials for the process conditions. All pressure retaining carbon steel materials shall be supplied in normalized condition. All materials for sour service and HIC requirements shall be in accordance with requirements of latest editions of NACE-MR-01-75/ISO 15156, DEP 30.10.02.15 and SP 2041. All stainless steel and nickel based alloy materials shall be pickled and passivated as per DEP 30.10.60.31 and SP-1173. Galvanized steel components shall not be used in the proximity of stainless steel materials. The material for the vessel and internals shall be fully in accordance with the materials specified in the datasheet. Vendor shall take all necessary steps to avoid change of materials during manufacturing and shall do so only with Company / Purchaser ’s approval.

4.3

SURFACE PREPARATION AND PAINTING

All equipment surfaces shall be prepared an d painted in accordance with the requirements of SP-1246 (Part 1 to 5) ‘Specification for Painting and Coating of Oil and Gas Production Facilities’. For proprietary equipment, the Vendor may offer their standard painting system for approval by the Company / Purchaser, but this shall be at least equal to the paint system detailed in SP-1246 (Part 1 to 5) ‘Specification for Painting and Coating of Oil and Gas Production Facilities’ . o

o

All exposed stainless steel/DSS parts subjected to temperatures above 60 C upto 100 C shall be painted as per PCS-6 of SP-1246. For temperature more than 100°C, SS/DSS parts shall be protected against external pitting and crevice corrosion by means of coating with Thermally Sprayed Aluminium (TSA) according to DEP 30.48.40.31. The Equipment Tag numbers shall be clearly stenciled on all equipment, in a prominent location.

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5


QUALITY ASSURANCE

5.1

GENERAL

The Vendor shall comply with the requirements of Company’s Specification for Quality Management System Requirements for Product and Service SP-1171. The Vendor shall appoint an Authorized Inspection Agency. The Vendor shall submit with the bid, the name of the Authorized Inspection (AI) agency that will be contracted to provide inspection services, in accordance with the requirements of the specifications, codes and SP1171. The Purchaser shall nominate a Third Party Inspection Authority (TPIA) to carry out the Quality Assurance function on the Purchaser’s behalf. The Purchaser’s TP IA shall have the same access as the Purchaser to the Vendor’s Quality System and the manufacturer’s premises to carryout inspection activities.

5.2

QUALITY SYSTEM

The Vendor shall maintain and use a Quality System, which is based on ISO 9001:2008, to control the work and assure the quality. The Vendor selected sub-contractors, or suppliers-shall demonstrate that they operate Quality Systems based on ISO 9001:2008. The Vendor shall give his sub-contractors or suppliers assistance in attaining the required standard if necessary. This shall not relieve the Vendor of his responsibility for the quality of the finished work. The Purchaser reserves the right to audit the Vendor’s Quality System and this can be carried out by the Purchaser or its nominee. The Vendor shall assign sufficient full time personnel to the project to ensure the Quality Assurance / Quality Control System, documented in a Quality Assurance / Control manual, is maintained and kept up-to-date throughout the duration of any purchase order. A kick-off / co-ordination meeting shall be held between the Vendor and Purchaser, after the purchaser order placement at design Consultants/Purchasers office in Om an. At the discretion of the Purchaser the kick-off meeting may be waived. At the kick-off meeting the Vendor and Purchaser shall review the Inspection and Test Plan (ITP) submitted with the Tender and shall agree a date f or issuing final ITP with Vendor. The Vendor shall organize a prefabrication meeting to be attended by the Vendor, the Vendor’s TPI, the Purchaser and the Purchaser’s TP IA. A provisional notice of 10 working days is the m inimum required by the Purchaser to attend the inspection meetings. Vendor shall keep a material control book, to which the Purchaser shall have access to any time they wish. The book shall contain Sub-Vendor’s contact details, purchase orders, equipment tag no., make/model nos., date of order, delivery and documentation required.

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6


INSPECTION & TESTING REQUIREMENTS

6.1

INSPECTION REQUIREMENTS

Inspection and testing requirements shall be in accordance with the applicable Company, Shell Group and International standards, with the relevant sections of this specification and the data sheets. The Vendor shall specify all of the inspection and testing requirements in the ITP which shall identify the activities requiring the Purchaser's approval, review, witnessing etc. Vendor shall submit Separate ITP for sub-vendor activities for Purchaser's approval, review, witnessing etc. For sour service company shall identify additional Witness/hold points in ITP without any impact on delivery and purchase Terms and conditions. A typical general ITP is attached in Appendix-8. Purchaser reserves the right to inspect every component or item, which will form part of the pressure vessel. The responsibility for the inspection, certification, etc. of all materials, parts, etc. lies with the Vendor. Not withstanding the above, the Purchaser or his authorized representative shall have free access to all parts of the Vendor's and his Sub-V endor’s works at all times during the manufacturing period. The Vendor shall be responsible for coordinating the inspection and testing of Sub-Vendor supplied equipment, and for ensuring that the Purchaser's representatives are given the necessary access for inspection, and adequate warning of inspection and witness tests. The Vendor (and all Sub-Vendors) shall give the Company, as required, without charge, all reasonable facilities for the purpose of inspecting the equipment to ensure that it is manufactured in accordance with the requisition, drawings and technical specification and QA/QC procedures and practices. The Purchaser shall be given a minimum of 21 days notice prior to carrying out any tests on the equipment covered by this specification. All equipment shall be inspected for compliance with : a. b. c. d. e. f.

Approved for Construction drawings, latest revision. Requirements of the Purchaser's requisition and correspondence thereafter. Applicable standards, which shall also include the sub-referenced standards therein. Inspection and Test plans (ITP) produced by the Vendor. Approved process control procedures. Welding of Metals as per SP-1173

Except as approved by the Purchaser, all equipment shall be presented for inspection in an unpainted condition. All measuring instruments required for shop testing shall be furnished by the Vendor, and be supported by valid calibration certification. All spare parts shall be subject to the same inspection standards and full material certification as the purchase order. Inspectors have the right to request additional inspections or tests to ensure that the equipment complies with this specification and all relevant codes and standards.

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All welds shall be continuous and wherever sound back welding is not feasible due to inaccessibility, single side welded joints with GTAW root pass shall be used. All welding and welding consumables shall be in accordance with SP-1173, unless indicated otherwise in this specification. Only Low Hydrogen welding consumables shall be used. Diffusible Hydrogen level shall be less that 10ml/100g weld metal, unless agreed and approved by the Purchaser. All welding consumables shall have specified mechanical properties equal to or greater than the m aterial being welded, unless agreed and approved by the Purchaser. The Vendor shall supply all necessary equipment and record welding variables during the Procedure Qualification Record (PQR) Test, production welding and weld qualification tests. Prior to the start of production welding all WPS with supporting PQR shall be submitted for approval to the Purchaser. Wherever PWHT is specified, PQR shall be established with 3 cycle PWHT and results shall meet deisgn code requirements. All pressure retaining butt welds shall be 100% radiographed/UT. All components including plates, forgings, fittings, welding consumables etc. shall be checked for impact test requirements to the specified lower design temperature (LDT) as the minimum design metal temperature (MDMT) to meet the applicable codes and standards. Vendor shall confirm with the material supplier the required impact test value at specified LDT conform to the specified impact value as per DEP 30.10.02.31-Gen and applicable codes and standards. Certified Material T est Report shall clearly specify the test results. PWHT shall be performed as per the code requirements and as specified in the equipment datasheet. Positive Material Identification (PMI) shall be carried out on all wetted parts made of low alloy and high alloy steels. Extent of PMI shall be carried out as per DEP 31.10.00.10-Gen. Vendor shall submit PMI procedure with the bid for Company/Purchaser review. . Vendor shall furnish Inspection Test Plan (ITP) specifying the responsibility, scope of Authorized Inspection Agency in accordance with SP-1171. The minimum requirements of inspections for Purchaser are: a)

The verification of materials and certification of the equipment for conformity with the specification requirements.

b)

The Hydrostatic test.

c)

The verification of welding procedures, welder’s qualifications, NDT personnel qualification, NDT results, heat treatment charts.

d)

Visual examination.

e)

NDT witness / review.

f)

Witness / review of PWHT.

g)

The dimensional check of the equipment as per approved drawing.

h)

The surface preparation and painting application.

i)

The testing of the lifting frame for the transportation of the equipment. The lifting frame shall be certified by TPIA.

j)

The completeness of shipment including checking of supply of spares and accessories, Manufacturer’s Data Book, name plate details .

k)

Material test certification in accordance with ISO 10474/EN 10204 and any additional requirements of the requisition.

Mill and shop inspection shall not relieve the Vendor from his contractual responsibility for replacing any defective material and for repairing any defective workmanship that may be discovered in the field.

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Any defects found by the TPIA shall be rectified in his presence. Where this is not possible or practical, checklists shall be prepared and signed by the TPIA stating all 'pending items'. Copies of these lists shall be sent to the Purchaser to enable their subsequent checking. The equipment shall not be tested or leave the factory before all discovered defects have been rectified.

6.2

TESTING REQUIREMENTS

This section describes the minimum requirements for the testing of the equipment. This testing shall be performed in the Vendor ’s works. The Purchaser reserves the right to observe any of the testing, dismantling, inspection and reassembly of equipment as specified. Unless otherwise specified, all testing equipment required shall be provided by the Vendor. Purchaser’s witnessing of shop test results shall not constitute a waiver of the Vendor ’s obligation to provide equipment which meets all specified operating conditions. 6.2.1

Hydrostatic Test

Hydro testing shall be as per the code, this specification, applicable DEPs, data sheets and Inspection & Testing Plan. Inspector shall witness all hydrostatic tests. Drainage / flushing / drying of the equipment shall strictly follow immediately after the hydrostatic testing as specified in DEP 74.00.10.10. The water to be used for the hydrostatic test apart from the requirements as to chloride content shall be free from sediment, i.e. un-dissolved solids of any description and as specified in DEP 74.00.10.10. The equipment shall be cleaned prior to final assembly and hydrostatic testing. After the hydrostatic test, the equipment shall be drained, dried and cleaned thoroughly of all grease, loose scale, rust, flux, etc. 6.2.2

Site Supervision for Testing & Commissioning

Purchaser will install and commission the equipment at site. The Vendor shall detail in the bid the extent of specialist supervision and commissioning, if any, deemed necessary to satisfy Vendor that installation and operation of the equipment meets the specification and warranty requirements, the Vendor representative shall satisfy himself that the installation is acceptable for commissioning of the equipment. For field tesing / commissioning, if any, the Vendor shall provide the results of any shop tests executed prior to shipment. The Vendor as an option shall include for supervision during pre-installation of the equipment to ensure all quality requirements for the installation is within acceptable limits. These may include but not be limited to i)

Checking of foundations,

ii)

Anchor bolt type, installation & positioning in foundations.

The above measures should be reflected in the installation section of the manuals. The Purchaser will commission the system under the direct supervision of the Vendor’s specialists, if required. Provision of specialist services at site for installation checks and commissioning for an estimated period if required, which will be subject to service contract agreement with the Vendor. The Purchaser will give a minimum of 2 weeks advance notice for the mobilization of the Vendor’s specialists in such cases.

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7

DOCUMENTATION REQUIREMENTS

Requirements for Vendor documentation are listed in the Requisition for Engineering Documents (RED) form included in Appendix-3 and sections below. The Vendor shall prepare a Vendor Document Register (VDR) or Suppliers Document Schedule (SDS) in the Company standard format using the above information as a guide. The Vendor shall submit the Document Register to Purchaser for review and approval together with document delivery schedule after award and prior to submission of any other documentation. The Document Register will thereafter form the basis of submission and control of all documents. The Company title block/drawing number can be included on the front sheet. All documentation shall be submitted for review/approval to the Purchaser within the committed schedule. It shall be the responsibility of the Vendor to ensure that the production schedule takes into account documentation submission, including a two weeks review period by the Purchaser, which includes document delivery time.

7.1

INFORMATION TO BE SUBMITTED ALONGWITH THE BID

Vendor shall submit all the required documents as specified/identified in the RED form attached in Appendix-3. In addition to this Vendor shall submit the following: 1.

Table of Compliance, Appendix-4 duly completed, signed and stamped.

2.

Unit rates for nozzles with flange rating as mentioned in datasheets for sizes NPS2 to NPS 24 and any higher sizes if specified in the datasheets.

3.

Unit rate for cleats & ladders on per kg basis and platform on per m basis.

4.

Commissioning assistance rate per day per person including mobilization and demobilisation charges.

2

7.2

INFORMATION TO BE SUBMITTED AFTER ORDER

7.2.1

Drawings and Documents to be submitted after Order

The documents/drawings shall be provided as outlined on the RED form , Appendix-3. It is the Vendor's responsibility to ensure drawings are brought up to 'as built' level. Additional drawings not specifically listed but of value, shall also be provided in the final package. All drawings and documents shall be prepared in accordance with DEP 02.00.00.10.The drawing shall be prepared in AutoCAD latest version and final drawings shall be submitted in electronic form in addition to the hard copies as part of final document submission. The text on all drawings and data shall be in English language. Text in the language of the Vendor may also be shown, provided the English translation is shown in prominent location. All data, calculations and drawings shall utilize SI metric units. The design verification by TPIA is required and shall be the Vendor ’s responsibility. The verification agency shall be subject to Purchaser approval. The documents required by TPIA are not covered under this specification. The Vendor shall provide all the drawings and documents required by the TPIA for the approval of design and manufacturing in compliance with the code. 7.2.2

Material Certificates

Material certificates shall be furnished in accordance with the relevant DEP, ASME, ASTM, EN 10204 and ISO 10474 standards as amended by this specification and as identified in RED form, Appendix-3. All pressure retaining materials shall be certified to ISO 10474,

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3.1C/EN 10204, 3.2 for vessels operating in high sour service with HIC testing and for high alloy materials.

7.2.3

Test Certificates

Certificates for each mechanical, performance or calibration test, as applicable shall be furnished, including hydrostatic test certificates and as identified in RED form, Appendix-3.

7.3

METHOD OF DOCUMENTATION TRANSMISSION

All documentation for review/approval shall be transmitted via internet (soft copy) or hard copy by use of courier services and shall be sent to the Purchaser, the details of which shall be discussed during the bid clarification meeting. Final documentation shall be in the form of hard copy as well as electronic form as specified in RED form, Appendix-3.

7.4

IDENTIFICATION

Each drawing and document shall be identified with the following information (for drawings a title block shall be used): a) Identity and signature of originator, checker and approver. b) Title c) Purchase order number d) The item/tag number or equipment number e) Official name of Vendor ’s company f) Vendor ’s drawing number. g) Latest revision by means of a number or letter in triangle with that number or letter adjacent to the alterations. h) Company drawing number.

7.5

DATA

Vendor shall provide full information to enable completion of the data sheets, first for “as purchased”, and then “as built”, within the confines of the supply. Preferably this should be done by correcting and filling out the data sheet and submitting copies, both hard copy as well as electronic copy (in CDs). Additional data as required by this specification shall also be provided. The Vendor shall maintain a record of shop test data for at least 36 months from date of shipment. All revised data must be resubmitted in its entirety. Revised data should state control numbers and indicate, where appropriate, which drawings/data the revised document supersedes. Revised data / changes shall be clearly highlighted by clouding and proper revision mark for easy identification. The drawings / documents submitted without highlighting the changes with clouding or identification revision mark, the documents shall be rejected and returned to Vendor without checking / review.

7.6

TRANSMITTAL

All documentation for review/approval shall be transmitted via internet (soft copy) or hard copy by use of courier services and shall be sent to the Purchaser.

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The Vendor shall submit the required documents and CDs for comment and approval by the Purchaser under the cover of a transmittal form, Review Document Transmittal (RDT). The Purchaser will review and may comment on all drawings, calculations and documents submitted. Corrections will be marked on the drawings. Marked-up copies of the drawings will be returned to the Vendor under cover of the appropriate transm ittal form. The Vendor shall at all times be responsible for review and correction of Sub-Vendor ’s drawings and documents prior to submittal to Purchaser for approval. The Purchaser will clearly indicate on the documents which parts, i f any, are ‘hold’. The Purchaser will inform the parties concerned, of the reasons for placing “hold”, and the date(s) on which release of these “holds” can be expected. The V endor shall not delay manufacturing of released parts because of “hold” placed on other parts. Upon approval of the Vendor ’s drawings by the Purchaser, the Vendor shall forward to the Purchaser the required number of approved documents, prints and diskettes as stated on the RED form under cover of a transmittal form, Final Document Transmittal (FDT). Manuals shall also be submitted to Purchaser under cover of a FDT.

7.7

MANUALS

The manual with all the relevant details to install, commission and operate/maintain the equipment shall be provided, with all the applicable drawings and details. The manual shall include all instructions on specific safety procedures for the installation and start-up of the equipment.   

Installation, operation and maintenance instructions including Sub-Vendor manuals. Technical design data and test results (Manufacturer databook). Certification data.

The information presented in the manual shall be specific to the equipment being supplied. All manuals shall be A4 size. Drawings shall be reduced to A3 and folded to A4 size so that the title block is visible. All manuals shall also be provided in software form on CD ROM compatible with Microsoft Word for Windows application and all drawings on Auto CAD latest version (version 2012 or higher).

7.8

RECORD CARDS

The Vendor shall submit duly completed SAP PM Master Data forms as per the Requisition for Engineering Documents (RED form, Appendix-3). An electronic copy of these forms shall be provided to the Vendor for completion and return to the Purchaser, during engineering stage after order, as indicated in the RED forms.

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8


PACKAGING & PRESERVATION FOR SHIPMENT

The preparation for shipment of equipment and materials shall be in accordance with project specific requirement, DEP 70.10.70.11-Gen and additional requirements as defined in this section. Special care should be taken for the packaging of delicate equipments / parts.

8.1

PACKING REQUIREMENTS

All nozzles and open ends of the equipment shall be treated with Shell Ensis Fluid SDC and closed off by wooden or plastic blanks and taped. Small bore connections shall be taped over. Preservation of the packages shall be suitable for a storage period of at least 6 months. All equipment under sea shipment and those with Cr-Mo or higher alloy steel material shall be cleaned, dried and then purged with nitrogen and sealed with nitrogen with a small positive pressure not less than 0.7 bar(g). Nitrogen bottles shall be provided and secured to the shipping saddles for refilling. All associated valves and gauges shall be provided to monitor the nitrogen pressure inside the vessel. The equipment shall be packed in a seaworthy close boarded case with a waterproof lining. The case shall be sufficiently strong to withstand handling and storage. For transportation of any equipment in Sultanate of Oman, the maximum height including the trailer (standard height of low bed trailer 1.3 metres, special low bed trailer height 1 metre) shall be 5.5 metres. The Vendor shall critically review this requirement and obtain necessary approvals from local authorities / Purchaser prior to transportation. The equipment shall be completely shop fabricated and transported in a single piece to site as far as possible. All lifts should be single point unless adequately demonstrated by the Vendor that single point lifts are not possible. Adequate lifting accessories such as lifting beam/frame, slings, shackles etc. (as part of the shipment) shall be included, if required and agreed during order. rd

Completeness of shipment shall be witnessed by the 3 party inspection agency and a certificate of complete shipment issued by the Vendor will be verified against the packing lists. A detailed, itemized packing list shall be sent to the Purchaser prior to dispatch. A copy of the same signed packing list shall be included with the freight. Any shortages at site shall be air freighted by Vendor at his expense within the scheduled delivery time. Spares shall be packaged in a separate rigid box placed in the case containing the main equipment. All special tools are to be supplied in sectionalized purpose built cases with hinged lids. In general, within Oman, all items shall be transported to site by truck. The majority of roads are rough, corrugated, dusty desert graded roads. The equipment and packing must be able to withstand rougher than normal treatment, with greater use made of shock absorbent materials.

8.2

CRATING IDENTIFICATION

The exterior of all crated equipment shall be identified in accordance with the purchase order and, as a minimum, shall include the following: 

Crate dimensions and gross weight

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

Specific lifting and/or storage instructions



Crate identification



Supplier and Purchaser details



Brief material specification



Purchase order number



Final destination


A complete packing list in a waterproof sleeve shall be firmly attached to the outside of each crate. An identical list shall be attached to the inside of the crate.

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9


PLANNING & SCHEDULING

9.1

GENERAL

This section covers the minimum requirements of planning, scheduling, control and reporting for the equipment. The Vendor shall submit a project schedule indicating clearly the plan to meet the delivery schedule required, including the required transportation time to installation site. A network type project schedule representing all relevant activities and milestones, including all Sub-Vendor ’s equipment etc. shall be submitted by the Vendor within two (2) weeks after receipt of the order.

9.2

MEETINGS

The following meetings shall be held between the Vendor and Purchaser:   

Kick-off meeting. Vendor pre-manufacturing meeting. Any review meetings deemed necessary.

Certified minutes of meeting for all the meetings, recording all action items/parties shall be prepared by the Vendor and faxed to the Purchaser for his approval/signature within two (2) working days from the date of the meeting. 9.2.1

Kick-off Meeting

Kick-off meeting shall be held at Purchaser’s office. An agenda shall be prepared by the Purchaser and distributed prior to this meeting and, as a minimum, shall include the following items: 

Schedules for transmittal of drawings, production and testing.



Inspection, expediting and testing, QA/QC.



Commercial aspects.



Schedule for future meetings.



Any other clarifications.

Certified minutes of meeting shall be prepared by the Vendor and faxed to the Purchaser for his approval/signature within two (2) working days from the date of the meeting. 9.2.2

Vendor pre-manufacturing Meeting

The Vendor shall organize a pre-fabrication/inspection meeting with the Purchaser and the Purchaser ’s nominated inspection agency at Vendor facility. The following points represent the minimum that will be discussed and on which total agreement of all parties will be minuted: 

Status and review of schedule for design deliverables.



Review of design engineering procedures and system.



Status and review welding procedures, NDT personnel qualification, NDT schedule.

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Ensure Purchaser/Company Representatives (engineers/INSPECTORS) have free access to all fabrication areas at any reasonable time, including all times that fabrication work is being performed.





Review the production program, including input from sub-contractors.



Review material substitution(s), if any.





Review scope of the overall inspection plan and define responsible parties regarding interpretation, witnessing and reviewing. Review any conflicts in codes/specifications and record which prevails.

Review any requirements to witness any particular inspection by Purchaser ’s Representative.









Review test program and procedures. Review purchase order variation procedures and agree that any variation in design or fabrication not approved by the Purchaser in writing shall be considered by the INSPECTOR as non-acceptable. Certified minutes of meeting shall be prepared by the Vendor and issued to the Purchaser for his approval/signature within two (2) working days from the date of the meeting.

9.2.3

Review Meetings

Meeting agenda will be agreed upon and communicated no less than 10 working days before the scheduled meeting date. Other meetings shall be held, as required, to perform the work and complete all interface details.

9.3

REPORTING

Vendor shall report the progress of the job to the Purchaser during the entire period of the contract. This shall be done as specified in the RED form, Appedix-3.

9.4

PURCHASE ORDERS

The Vendor shall supply to the Purchaser the un-priced copies of each purchase order for major equipment / items ordered by the Vendor. Refer to RED forms (see Appendix-3) for details. The Vendor shall maintain and issue to the Purchaser as part of his Monthly Progress Report an updated register of all purchase orders issued by the Vendor.

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APPENDICES :

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Specification for Pressure Vessels

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Revision: 1 Effective: Jun-12


APPENDIX-1

ENVIRONMENTAL & SITE CONDITIONS

The project specific environmental and site conditions shall be confirmed/provided by the Purchaser based on the site location. The facilities shall be suitable for operation in the specified environmental conditions in addition to the operating conditions. The local environmental conditions are severe. There are frequent sandstorms, and the atmosphere is heavily laden with airborne dust particles, some as small as 2 microns. It rains rarely. The rain is often combined with hail and sandstorms. Average Environmental conditions for the production stations are: Relevant Ambient Data: Barometric pressure

Ambient temperature

Summer

Maximum

98.9

kPa

Average

97.5

kPa

Minimum

95.7

kPa

Maximum

60

Minimum

5

°C

Black bulb temperature

Maximum

82

°C

Relative humidity

Maximum

98

%

Minimum

30

%

Max. hourly avg.

26

meters/s

3 sec. Gust

35

meters/s

Wind speed

Prevailing wind direction

Rainfall

March - April

NW

May - June

SW

Remainder

SE

Design

25

Average annual Site elevation, above mean sea level





°C **

mm/ hour

Negligible 185.5

meters

The above maximum shade temperature (60 deg C) occurs for short intervals only. Equipment shall be designed to achieve its rated capacity with a shade temperature of 50 deg C. It shall also be designed to function safely with a shade temperature of 60 deg C, but not necessarily at its rated capacity. In addition, all instrumentation shall be designed to function correctly at maximum temp. of 60°C if shaded and 82°C if unshaded. Instrument supplied shall be suitable for the environmental conditions as per location class Dx (4K6/4Z2/4Z4/4Z6/4C2/4S4/4M1) of IEC654-1 (IEC721-3-4 incl. Amendment 1) 4K6:

Tropical dry climate max. Ambient up to 60 degC

4Z2:

Negligible heat radiation from process sources

4Z4:

Air speed up to 30m/s

4Z6:

Negligible effects of water sources other than rain

4C2:

Effects of salts & other chemicals, including H2S also for coastal areas

4S4:

Effects of sand and dust

4M1:

Mechanical conditions (Vibration and shock)

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APPENDIX-2


EQUIPMENT DATASHEETS & DRAWINGS

1. Pressure Vessel Datasheet (for ASME SEC VIII Div2 Vessels, refer DEP 31.22.00.98 also for User Design Specification (UDS)) 2.

Demister Datasheet

3.

Schoepentoeter Datasheet

4.

Mass/Centre of Mass of Equipment Datasheet

Page 36

Specification for Pressure Vessels

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SP-2069, Page : 37

SP-2069, Page 38

SP-2069, Page 39

SP-2069, Page 40

SP-2069, Page 41

SP-2069, Page 42

Data/requisition sheet f or

Design book

SCHOEPENTOETER

Contr. Job MESC

Top view of schoepentoeter

Inner diameter of column Feed nozzle num ber Nozzle inside diameter Nozzle nominal diameter Type Applica ble Standa rd Drawing Catcher cap allowed Split vane ladder allowed Length of straight part of vanes Vane radius Number of vanes per side Vane angle Actual vane openin g Vane thickness Schoepentoeter to pass through own nozzle Schoepentoeter to pass through manhole ID MATERIALS Schoepentoeter material Corrosion allowance

Made by:

Notes: 1) Design and construction shall be in accordance

mm inch/DN

w ith DEP 31.22.05.11-Gen. 2) The manufacturer shall check the information on equipment requisition/draw ing and on the standar d draw ing for compatibility. He shall

YES/NO YES/NO

indicate in the tender all missing information.

mm mm deg mm mm YES/NO mm

mm

Date

Checked by:

Date

Approved by:

Date

Rev.

EQUIPMENT:

Date

PLANT:

Sign.

CONSIGNEE:

DEP 31.20.41.93-Gen., Januar y 2002

P.D.O.

Eng. By : Principal :

SP-2069, Page 43

mm

Equipment No. Petroleum Development Oman LLC.

Datasheet No.

page:

SP-2069, Page 44



APPENDIX-3 (RED FORMS)

REQUISITION FOR ENGINEERING DOCUMENTS

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SP-2069, Page 46

SP-2069, Page 47

SP-2069, Page 48

SP-2069, Page 49

SP-2069, Page 50

SP-2069, Page 51

SP-2069, Page 52

SP-2069, Page 53

SP-2069, Page 54



APPENDIX-4

TABLE OF COMPLIANCE

The Vendor shall confirm below that the offer complies with all the clauses contained in this specification or otherwise highlight deviation / exceptions under the clarification column. Vendor can use separate sheets if space provided in the clarification column is insufficient. Words such as “Noted” shall not be used. Client : Petroleum Development Oman (PDO)

Vendor :

Client Ref. No. : PR No.

Vendor Ref. No :

Specification Reference

Conforms

Alternative

Section

Yes / No

Yes / No

Clarification

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 3.1 3.2 3.3 3.4 3.5 3.6 Page 55


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Petroleum Development Oman LLC Client : Petroleum Development Oman (PDO)

Vendor :


Vendor Ref. No :


Conforms

Alternative

Section

Yes / No

Yes / No

Clarification

4 4.1 4.2 4.3 5 5.1 5.2 6 6.1 6.2 6.2.1 6.2.2 7 7.1 7.2 7.2.1 7.2.2 7.2.3 7.3 7.4 7.5 7.6 7.7 7.8 8 8.1 8.2 9 9.1 Page 56


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Petroleum Development Oman LLC Client : Petroleum Development Oman (PDO)

Vendor :


Vendor Ref. No :


Conforms

Alternative

Section

Yes / No

Yes / No

Clarification

9.2 9.2.1 9.2.2 9.2.3 9.3 9.4 Appendix-1 Appendix-2 Appendix-3 Appendix-5 Appendix-6 Appendix-7 Appendix-8

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APPENDIX-5


ALLOWABLE NOZZLE LOADS

Refer DEP SPECIFICATION FOR PRESSURE VESSELS (BASED ON ASME SECTION VIII) DEP 31.22.20.31-Gen. February 2012,ECCN EAR99 - ANNEX VIII MINIMUM DESIGN VALUES FOR NOZZLE FORCES AND MOMENTS.

1.

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APPENDIX-6

SPIR FORMAT

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SP-2069, Page 60

SP-2069, Page 61

SP-2069, Page 61

SP-2069, Page 62

SP-2069, Page 62


APPENDIX-7


USER FEEDBACK PAGE

SP- 2069 – SPECIFICATION FOR PRESSURE VESSELS USER FEEDBACK FORM Any user who identifies an inaccuracy, error or ambiguity is requested to notify the custodian so that appropriate action can be taken. The user is requested to return this page fully completed, indicating precisely the amendment(s) recommended. Name: Ref ID

Page Ref:

Date:

Brief Description of Change Required and Reasons



APPENDIX-7

USER FEEDBACK PAGE

SP- 2069 – SPECIFICATION FOR PRESSURE VESSELS USER FEEDBACK FORM Any user who identifies an inaccuracy, error or ambiguity is requested to notify the custodian so that appropriate action can be taken. The user is requested to return this page fully completed, indicating precisely the amendment(s) recommended. Name: Ref ID

Page Ref:

Date:

Brief Description of Change Required and Reasons

UEP/12M Custodian of Document

Page 63

Date:


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APPENDIX-8

INSPECTION AND TEST PLAN (ITP) FORMAT

Page 64


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Contractor’s Name Quality Control Plan Ref.:

Discipline Sl. No

Project: Element: Pressure Manufacture Controlling Document

Activity

1.

Design Calculations and Drawings

Contract Specifications

2.

Welding Procedures

Applicable Code & relevant Shell DEP

3.

Approval of Procedures

NDT Applicable Code & SP 1176

4.

Review of operators’ qualification validity

NDT

5.

Review of welder Applicable Code qualification records

6.

Approval of PWHT Applicable Code Procedure (if & relevant Shell applicable) DEP Material Inspection – Applicable Chemical, Physical, material Heat treatment specification, condition (including relevant DEP simulation heat additional treatment if any), UT requirements,

7.

ISO 9712 / ASNT SNT TC and 1A / CSWIP / PCN

TYPICAL INSPECTIN TEST PLAN Revision No 0 Contract / P.O No.: Vessel Vessel Tag # :

Acceptance Criteria. Frequency of Test.

Conformance to manuf. code and contract specification requirements – Approval - All Approval – All WPS related to pressure retaining parts Conformance to relevant code & spec Minimum level II valid qualifications (Level I could be used as only assistant) All welders shall have valid qualifications Conformance to relevant code & spec Conformance to the controlling documents & delivery conditions

Supplier’s Verification Personnel

Design Manager

Page 65

Verification Document

EPC Manufacturer Contractor / TPI

Authorised Inspector

PDO

Approved calculations and Drawings

H

H

H or Review as per contract

Welding / QA Approved for Engineer construction procedure

H

H

H

Welding / QA Approved NDT Engineer procedures

H

H

R

QC Inspector

H

S

H

R

H

H

W

R

NDT qualification record

Welding / QA Engineer

Valid Qualification records Welding / QA Approved Engineer PWHT procedures QC Inspector Material inspection report & material heat certificate

R

LEGEND : H – Hold Point


Discipline Sl. No

W – Witness


Activity

of plates, etc

8.

Verification of transfer of material marking on cut segments

9.

Cutting, preparation Forming

edge &

10. Fit-up Inspection

11. Welding

12. Inspection of Back gouging and NDT as required 13. Visual Inspection of welds 14. Positive Material Identification (PMI)

R – Review

S – Surveillance



Approved drawings, Data Sheets, etc Manufacturer’s All cut material procedures shall bear the material details including heat numbers Manufacturer’s Dimension as per procedures, approved Applicable Code drawings and & relevant Shell tolerance limits of DEP codes & DEP Approved WPS, As per approved code and WPS, code and relevant Shell relevant Shell DEP DEP Approved WPS Weld parameters in accordance with approved WPS Approved WPS Conformance to and relevant relevant spec spec Applicable Code Conformance to & relevant Shell relevant code & DEP spec Approved Material Drawing and composition in DEP accordance with 31.10.00.10 MTO spec. Frequency in accordance with


W – Witness

R – Review



QC Inspector

Traceability record

H

R

QC Inspector

Dimension Inspection report

H

S

QC Inspector

Fit-up Inspection Report

W

S

Welding Supervisor & Inspector Welding Supervisor & Inspector QC Inspector

Parameter log

W

S

Visual / Reports

NDT

W

S/R

visual

W

S

QC Inspector

PMI Report

H

W


Page 66

S – Surveillance

Weld Report


PDO


Discipline Sl. No


Activity

of plates, etc

8.

Verification of transfer of material marking on cut segments

9.

Cutting, preparation Forming

edge &

10. Fit-up Inspection

11. Welding

12. Inspection of Back gouging and NDT as required 13. Visual Inspection of welds 14. Positive Material Identification (PMI)



Approved drawings, Data Sheets, etc Manufacturer’s All cut material procedures shall bear the material details including heat numbers Manufacturer’s Dimension as per procedures, approved Applicable Code drawings and & relevant Shell tolerance limits of DEP codes & DEP Approved WPS, As per approved code and WPS, code and relevant Shell relevant Shell DEP DEP Approved WPS Weld parameters in accordance with approved WPS Approved WPS Conformance to and relevant relevant spec spec Applicable Code Conformance to & relevant Shell relevant code & DEP spec Approved Material Drawing and composition in DEP accordance with 31.10.00.10 MTO spec. Frequency in accordance with


Page 66



QC Inspector

Traceability record

H

R

QC Inspector

Dimension Inspection report

H

S

QC Inspector

Fit-up Inspection Report

W

S

Welding Supervisor & Inspector Welding Supervisor & Inspector QC Inspector

Parameter log

W

S

Visual / Reports

NDT

W

S/R

visual

W

S

QC Inspector

PMI Report

H

W

Weld Report


PDO



Discipline Sl. No

15.

Activity

W – Witness

R – Review




DEP (as API RP 582 & API RP 582 AWS A4.2 Approved Conformance drawings, code within the and relevant tolerance limits DEP specified in the controlling docs Clearance for Approved All Welding (Hot PWHT of the vessel Drawings & work) works Data sheets completed and visually accepted PWHT Approved Conformance to PWHT code & spec procedure requirements Hardness Relevant DEP Shall not exceed measurement 248 HV10 Production control Relevant Code Conformance to Test plates (as and DEP Code and Spec applicable) testing requirements NDT (Shall include Applicable Conformance to requirements for Code, relevant relevant code & butt welds, nozzle Shell DEP & DEP welds, attachment Approved NDT welds, etc) Procedures NDT and Chemical Code and Conformance to analysis of weld relevant DEP relevant code & overlay for cladded DEP vessels (if applicable) Repairs Code and Conformance to

Ferrite check required) 16. Dimensional Inspection

17.

18.

19. 20.

21.

22.

23.

S – Surveillance


QC Inspector

W – Witness

R – Review


Ferrite Check Report Dimensional inspection report

W

W

W

W

QC Inspector

Clearance Report

H

H

QC Inspector

PWHT chart

R

R

QC Inspector

W

W

QC Inspector

Hardness test report Test reports

H

W

QC Inspector

NDT Reports

W

R

QC Inspector

NDT and Chemical analysis report

QC Inspector

NDT report

H

H

QC Inspector



Page 67

S – Surveillance


PDO

Approval


Discipline Sl. No

15.

Activity




DEP (as API RP 582 & API RP 582 AWS A4.2 Approved Conformance drawings, code within the and relevant tolerance limits DEP specified in the controlling docs Clearance for Approved All Welding (Hot PWHT of the vessel Drawings & work) works Data sheets completed and visually accepted PWHT Approved Conformance to PWHT code & spec procedure requirements Hardness Relevant DEP Shall not exceed measurement 248 HV10 Production control Relevant Code Conformance to Test plates (as and DEP Code and Spec applicable) testing requirements NDT (Shall include Applicable Conformance to requirements for Code, relevant relevant code & butt welds, nozzle Shell DEP & DEP welds, attachment Approved NDT welds, etc) Procedures NDT and Chemical Code and Conformance to analysis of weld relevant DEP relevant code & overlay for cladded DEP vessels (if applicable) Repairs Code and Conformance to

Ferrite check required) 16. Dimensional Inspection

17.

18.

19. 20.

21.

22.

23.


QC Inspector

Page 67



Ferrite Check Report Dimensional inspection report

W

W

W

W

QC Inspector

Clearance Report

H

H

QC Inspector

PWHT chart

R

R

QC Inspector

W

W

QC Inspector

Hardness test report Test reports

H

W

QC Inspector

NDT Reports

W

R

QC Inspector

NDT and Chemical analysis report

QC Inspector

NDT report

H

H

QC Inspector


PDO

Approval



Discipline Sl. No

Activity

W – Witness

R – Review


S – Surveillance





relevant DEP

24. Clearance for Flushing / cleaning & Pressure Test 25. Flushing / Cleaning

26. Pressure Testing

27. Inspection of internals Installation

28. Painting system

29. Surface preparation (for painting) inspection All inspections listed in Table 1 of SP-1246 Part 4 shall be carried out

relevant code & DEP Approved All fabrication & drawings (GA & NDT in the vessel PEFS) & Data completed and sheets accepted Manufacturer’s All internal surface Procedure & shall be dirt free contract Spec Manufacturer’s Test pressure Procedure, maintained as per Code, approved controlling docs drawings & data and no leakages sheets Manufacturer’s All internal Procedure, installation in Code, approved accordance with drawings & data approved sheets and drawings internals manufacturer’s instructions PDO Spec SP Conformance to 1246 Part 1, 2 & SP 1246 Part 2 & 5 5 PDO Spec SP All test results in 1246 Part 4 accordance with the respective painting system requirements & Table 1 of SP 1246 Part-4


Page 68

W – Witness

R – Review

PDO

of major repairs QC Inspector

Clearance Report

Fabrication Supervisor & QC inspector QC Inspector

Flushing Cleaning Report Pressure Report

Fabrication Supervisor & QC inspector

Painting Supervisor & QC inspector Painting Supervisor & QC inspector



S – Surveillance

H

H

/

H

W

Test

H

H

Installation Inspection Report

H

W

PDO Approved painting system

H

W

Painting Inspection Report, Holiday Test Report & Adhesion Test Report

W

W


Discipline Sl. No

Activity







relevant DEP

24. Clearance for Flushing / cleaning & Pressure Test 25. Flushing / Cleaning

26. Pressure Testing

27. Inspection of internals Installation

28. Painting system

29. Surface preparation (for painting) inspection All inspections listed in Table 1 of SP-1246 Part 4 shall be carried out

relevant code & DEP Approved All fabrication & drawings (GA & NDT in the vessel PEFS) & Data completed and sheets accepted Manufacturer’s All internal surface Procedure & shall be dirt free contract Spec Manufacturer’s Test pressure Procedure, maintained as per Code, approved controlling docs drawings & data and no leakages sheets Manufacturer’s All internal Procedure, installation in Code, approved accordance with drawings & data approved sheets and drawings internals manufacturer’s instructions PDO Spec SP Conformance to 1246 Part 1, 2 & SP 1246 Part 2 & 5 5 PDO Spec SP All test results in 1246 Part 4 accordance with the respective painting system requirements & Table 1 of SP 1246 Part-4


Page 68

PDO

of major repairs QC Inspector

Clearance Report

H

H

Fabrication Supervisor & QC inspector QC Inspector

Flushing Cleaning Report Pressure Report

/

H

W

Test

H

H

Fabrication Supervisor & QC inspector

Installation Inspection Report

H

W

Painting Supervisor & QC inspector Painting Supervisor & QC inspector

PDO Approved painting system

H

W

Painting Inspection Report, Holiday Test Report & Adhesion Test Report

W

W



Discipline Sl. No

Activity

30. Painting inspection All inspections listed in Table 1 of SP1246 Part 4 shall be carried out

31.

Code Stamping / Name Plate details

32. Review of MDB & final Release

W – Witness

R – Review


S – Surveillance



PDO Spec SP All test results in 1246 Part 4 accordance with the respective painting system requirements & Table 1 of SP 1246 Part-4 Manufacturing In accordance Code with manufacturing code requirements Contract & Complete in Code accordance with requirements contract and code requirements


Painting Supervisor & QC inspector

W – Witness

R – Review


Painting Inspection Report, Holiday Test Report & Adhesion Test Report QC Inspector Code stamp / Name plate

W

W

H

W

QAQC Manager

H

H



Page 69

S – Surveillance

MDB


PDO


Discipline Sl. No

Activity

30. Painting inspection All inspections listed in Table 1 of SP1246 Part 4 shall be carried out

31.

Code Stamping / Name Plate details

32. Review of MDB & final Release




PDO Spec SP All test results in 1246 Part 4 accordance with the respective painting system requirements & Table 1 of SP 1246 Part-4 Manufacturing In accordance Code with manufacturing code requirements Contract & Complete in Code accordance with requirements contract and code requirements



Page 69


Painting Supervisor & QC inspector

Painting Inspection Report, Holiday Test Report & Adhesion Test Report QC Inspector Code stamp / Name plate

W

W

H

W

QAQC Manager

H

H

MDB


PDO


W – Witness

R – Review

S – Surveillance


APPENDIX-9 Section


DOCUMENT CHANGE IDENTIFICATION TABLE Major Changes List

1.1

All ERD’s are obselete, r eference to ERD is Removed.

1.3

Replaced Terminalogy with Definitions, Reference to ERD is Removed, LT replaced with PT for Liquid Penentrant Testing.

1.6

New section Health, Safety and Environment added.

1.7

New section Summary of main changes added.

2

Reference to ERD is Removed.

2.1

Obselete standards are removed. Added SP-1173 and SP-2020 standard, SP2051 is replaced with DEP 74.00.10.10.

2.2

Some DEP standards are removed. DEP 30.10.60.18 is replaced by SP-1173. NEW DEP’s are added.

2.4

New International Standards are added.

2.3

Manway Rungs, Spere leg fire proofing, grating type IV and V Drawings added

2.5

DEP 31.22.00.98 and DEP 31.20.41.93 are added.


APPENDIX-9 Section


DOCUMENT CHANGE IDENTIFICATION TABLE Major Changes List

1.1

All ERD’s are obselete, r eference to ERD is Removed.

1.3

Replaced Terminalogy with Definitions, Reference to ERD is Removed, LT replaced with PT for Liquid Penentrant Testing.

1.6

New section Health, Safety and Environment added.

1.7

New section Summary of main changes added.

2


2.1

Obselete standards are removed. Added SP-1173 and SP-2020 standard, SP2051 is replaced with DEP 74.00.10.10.

2.2

Some DEP standards are removed. DEP 30.10.60.18 is replaced by SP-1173. NEW DEP’s are added.

2.4

New International Standards are added.

2.3

Manway Rungs, Spere leg fire proofing, grating type IV and V Drawings added

2.5

DEP 31.22.00.98 and DEP 31.20.41.93 are added.

2.9


3.1

Minimum 2 nos of earthing bosses specified, Foundation template for vertical vessel and cathodic protection for buried vessel added.

3.2

Transportation location revised to project site OR as per Purchase Order specified location.

3.3

Spares requirement elaborated.

3.4

Sub clause b) revised and sub clause n) added.

4.1

Sub clauses 4.1.3, 4.1.6, 4.1.11, 4.1.12, 4.1.14, 4.1.17, 4.1.19, 4.1.27, 4.1.33, 4.1.34 are revised. New sub clauses 4.1.37 to 4.1.48 are added.

4.2

Material of Construction requirements are revised.

4.3

External Painting for Stainless steel vessel parts is added.

5.2

ISO 9001: 2008 version added instead of 2000.

6.1

ITP requirements are elaborated. Subclause e) and f) added. 3 cycle PWHT for PQR is added. 100% radiography for butt welds added. DEP 31.10.00.10 for PMI

Page 70


Printed 01/01/13


257002289 SP 2069 Specification for Pressure Vessels 1 Doc PDF

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