DGS-PU-304-Rev-0

Ab u Dh abi Oil Refi ning ni ng Com pany

DGS-PU-304 Rev-0 March 2006 2006

PIPELINE PIGGING TEES

DGS-PU-304 Rev Rev-0 -0


Am end men t Hi st or y

No

Date

Amendment

Description

Proposed

Approved

Incorporated

DGS History

0

No

March 2006

Date

DGS-PU-304-Rev-0

Description

Previous Project / Lessons Learnt Incorporated Source

Takreer DGS-PU-304-Rev-0 March-2006 Printed 20-Apr-09 08:45:18

AH/DDC

Reviewed

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ETSDM / EPDM

Approved

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Ab u Dhabi Oil Refi ning Com pany

DGS-PU-304 Rev-0 March 2006


TABLE OF CONTENTS 1.0

GENERAL ...................... ........................... ......................... ........................... ........................... 3 1.1 INTRODUCTION.............................................................................................................3 1.2 PURPOSE.......................................................................................................................3 1.3 DEFINITIONS .......................... ......................... ......................... ........................... ..........3 2.0 CODES AND STANDARDS .......................... ........................ ........................... ........................ 3 3.0 REFERENCE DOCUMENTS ....................... ........................ .......................... ......................... .4 4.0 DOCUMENT PRECEDENCE...................................................................................................5 5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL ........................... ......................... ..5 6.0 QUALITY ASSURANCE/QUALITY CONTROL ........................ ............................. ................... 5 7.0 SITE CONDITIONS ........................ ......................... ......................... ........................... .............5 8.0 DESIGN AND FABRICATION...................................................................................................6 9.0 MATERIAL REQUIREMENTS ............................ .......................... ............................ ................ 6 10.0 MANUFACTURE QUALIFICATION AND PRODUCTION TESTING........................................7 10.1 MANUFACTURE.............................................................................................................7 10.2 MANUFACTURING PROCEDURE QUALIFICATION ......................... .......................... .7 10.3 PRODUCTION TESTING ............................ ........................... ............................ ............ 8 11.0 HYDROSTATIC TESTING........................................................................................................8 12.0 NON DESTRUCTIVE TESTING AND VISUAL ....................... ............................ ..................... 8 12.1 GENERAL ....................... ........................... ......................... ........................... ................. 8 12.2 VISUAL INSPECTION ........................... ......................... ........................... ..................... 9 12.3 NON-DESTRUCTIVE TESTING OF FITTINGS..............................................................9 12.4 REMOVAL OF DEFECTS .......................... ......................... ........................... ............... 10 12.5 WELDING PROCEDURES...........................................................................................10 13.0 DIMENSIONAL INSPECTION................................................................................................10 14.0 COATINGS ...................... ........................... ......................... ........................... ........................ 11 15.0 MARKING............................ ........................... ......................... ........................... .................... 11 16.0 PREPARATION FOR SHIPMENT .......................... ........................... ............................ ......... 11 17.0 MATERIAL CERTIFICATION AND TRACEABILITY........................ ............................. .......... 11 18.0 VENDOR DATA REQUIREMENTS (VDRL) ......................... ............................ ...................... 12 EXHIBIT – A.....................................................................................................................................14 ADDENDUM SHEET ........................ ............................ ......................... ............................ .............. 15

List of Authorized Signatures/ Initials

DGS Discipline Committee Member, ADRD

------------------------------

DGS Discipline Committee Member, RRD

------------------------------

DGS Discipline Committee Member Leader, E&PD

Abdul Hakim (AH)

Engineering & Technical Services Manager, E&PD

Quazi Abdul Matin (QAM)

Engineering & Projects Division Manager, E&PD

Mohamed Al Yabhouni (MAY)


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1.0

GENERAL

1.1

INTRODUCTION The specification gives the minimum technical requirements for the design, manufacture, testing, inspection, coating/painting and supply of Pipeline Pigging Tees to be used for non sour, liquid service on onshore pipelines.

1.2

PURPOSE This specification supplements the codes listed in Section 2.0 of this specification.

1.3

DEFINITIONS For the purpose of this specification, the following definitions shall apply:

1.3.1

CONCESSION REQUEST - A deviation requested by the CONTRACTOR / SUBCONTRACTOR or VENDOR / SUBVENDOR, usually after receiving the contract package or purchase order. Often, it refers to an authorisation to use, repair, recondition, reclaim, or release materials, components, or equipment already in progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.

1.3.2

SHALL - The use of the word “shall” indicates a mandatory requirement.

1.3.3

SHOULD - The use of the word “should” indicates a strong recommendation to comply with the requirements of this document.

2.0

CODES AND STANDARDS It shall be the CONTRACTOR’s, VENDOR’s, SUBCONTRACTOR’s and or SUBVENDOR’s responsibility to be, or to become knowledgeable of the requirements of the referenced codes and standards. The following codes and standards, to the extent specified herein, form a part of this specification. When an edition date is not indicated for a code or standard, the latest edition in force at the time of contract award shall apply. American Society of Mechanical Engineers (ASME) ASME B16.9

Factory-Made Wrought Steel Butt Welding Fittings

ASME B16.25

Butt Welding Ends

ASME B31.4

Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids.

American Society for Testing Materials (ASTM) Takreer DGS-PU-304-Rev-0 March-2006 Printed 20-Apr-09 08:45:18

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ASTM A370

Standard Test Methods and Definitions for Mechanical Testing of Steel Products.

ASTM E92

Standard Test Method for Vickers Hardness of Metallic Mater ials.

ASTM E709

Standard Guide for Magnetic Particle Examination

American Petroleum Institute (API) API 5 L

Line Pipe

American Society for Non-Destructive Testing, Inc. (ASNT) ASNT 2510A

Guide to Personnel Qualification and Certificat ion

International Organization for Standards (ISO) ISO 9001-2000

Quality Management System Requirements

ISO 9004-2000

Quality Management Guidelines for Performance Improvement System

ISO 9011

Guidelines for Quality and/or Environmental System Auditing

ISO 9712

Non-Destructive Personnel.

ISO 10474

Steel and steel products; Inspection documents.

ISO 12094

Welded steel tubes for pressure purposes - ultrasonic testing for the detection of laminar imperfections in strips/plates used in the manufacture of tubes.

Testing

-

Qualification

and

Certification

of

Manufacturers Standardization Society (MSS) MSS SP- 75 3.0

Specification for High Test Wrought Butt Welding Fittings

REFERENCE DOCUMENTS The following reference documents, to the extent specified herein, form part of this specification. When an edition date is not indicated for a document, the latest edition in force at the time of contract award shall apply. Design General Specifications DB-PU-401

Pipeline Engineering Design Basis

DB-PU-001

Process Design Basis

DGS-PU-307

HFW Line pipe


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DGS-PU-319

Pipeline Welding

DGS-PU-320

Seamless Line Pipe

DGS-MX-001

Design General Specification/Procedures (Painting)

DGS-MY-001

Coatings for Underground Steel Pipe

Applicable project line pipe specification shall be referred. Specification Exhibits Exhibit A 4.0

Design of Barred Tees

DOCUMENT PRECEDENCE The CONTRACTOR and or VENDOR shall notify the COMPANY of any conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design or manufacture. In case of conflict, the order of precedence shall be stated in the AGREEMENT or other PROJECT documents as applicable.

5.0

SPECIFICATION DEVIATION/CONCESSION CONTROL Any technical deviations to the Specifications and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be sought by the CONTRACTOR / VENDOR / SUBVENDOR only through CONCESSION REQUEST format. CONCESSION REQUESTS require COMPANY’S review/approval prior to the proposed changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

6.0

QUALITY ASSURANCE/QUALITY CONTROL VENDOR’S proposed quality system shall fully satisfy all the elements of ISO 9001 2000 and ISO 9004 - 2000. The quality system shall provide for the planned and systematic control of all quality-related activities performed during design, development, production, installation or servicing (as appropriate to the given system). Implementation of the system shall be in accordance with the CONTRACTOR’S Quality Manual and Project Specific Quality Plan, which shall both together with all related/referenced procedures, be submitted to COMPANY for review, comment and approval as required by purchase/contract documents. Material certification and traceability shall be in accordance with para. 17.0 and 18.0

7.0

SITE CONDITIONS


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Site conditions shall be in accordance with Process Design Basis, document number DB-PU-001. 8.0

DESIGN AND FABRICATION The Design Code, design factor, rating, corrosion allowance, grade of material, nominal diameter and wall thickness for the mating main pipe and branch pipe and any other requirement for sour service will be as stated in material requisition. Design factor and corrosion allowance, as indicated in material requisition shall be taken into account for design of tees. Tees with branches larger than 25 percent of pipeline diameter shall have a configuration of bars as indicated in Exhibit A. The bars shall be made of mild steel and shall be welded with full penetration welds to a qualified procedure. Full encirclement tees shall not be allowed. Weld preparation for the tees shall be in accordance with MSS SP-75. All Pipeline Pigging Tees shall be suitable for the passage in either direction of instrumented inspection tools. The tees shall be designed to the design code as stated in material requisition and manufactured to MSS SP-75 or ASME B 16.9 as appropriate and requirement of this specification. The tees shall meet or exceed the strength requirements of the matching pipe as calculated by the appropriate ASME Code. Data supporting the design in the form of calculations and drawings shall be submitted for approval prior to commencement of manufacture. Design shall be in strict accordance with the appropriate Design Code. Documented data of successful proof tests according to the relevant standard shall be submitted in support of the design. The wall thickness of weld ends at the bevel of main run and branches of tees shall have a bevel thickness no greater than 1.5 times the nominal wall thickness of the mating pipe. Taper on the outside diameter at the ends meeting the requirement of design code will be acceptable for welding to take care of miss-match in wall thickness.

9.0

MATERIA L REQUIREMENTS

9.1

All materials shall be suitable for the product and environmental conditions in desert areas above ground and buried service.

9.2

Grade of material for tees shall be in line with the connected line pipe. Carbon steel used in the manufacture of tees shall be fully killed. All bars material shall be pressure vessel quality and shall be specified in the material requisition. Carbon equivalent shall be maximum 0.42.


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9.3

Chemical analysis shall include all elements required by applicable ASTM standards as well as the elements used for the determination of Carbon Equivalent (CE) using formula CE

=

C + Mn + (Cr + Mo + V) + (Cu + Ni) 6

5

15

9.4

Physical tests requirements shall be in line with Connected Line Pipe specifications.

9.5

Tees shall be manufactured from material, which meets the specified minimum yield strength of the mating pipe. Actual yield shall not exceed the SMYS by more than 20000 psi.

9.6

A ring of material may be required from main run of pipe (or forging), used for tee fabrication, for weld procedure qualification for the main pipeline. This shall be indicated on the purchase order by CONTRACTOR. Ring shall be minimum 500mm in length and subject to same forging and heat treatment as supplied tees.

9.7

Tees shall be furnished in the normalised condition unless otherwise agreed. Full details of the intended heat treatment and procedure are to be submitted for Company approval.

10.0

MANUFACTURE QUALIFICATION AND PRODUCTION TESTING

10.1

MANUFACTURE Tees shall be made by forging the branch from line pipe and/or a pre-bent fabrication and shall have a maximum of one seam weld only. Circumferential welds are not permitted. Seamless fittings are preferred. The manufacturer shall produce a manufacturing procedure for approval by the COMPANY prior to manufacture of the tees.

10.2

MANUFACTURING PROCEDURE QUALIFICATION A tee shall be qualified when it passes all production testing as required by clause 10.3 and this section. The qualification is valid for the main and branch nominal pipe size combination, per grade, heat treatment and manufacturing route only. A tee with an equal branch, however will qualify for tees with the same main OD with smaller branch OD’s of the same grade or lower grades. A test ring from the main run and prolongations of the forged branch of the tee shall be tested to qualify the manufacturing route per size, grade, heat treatment and material source. Welds and body shall be tested in accordance with clause 10.3 of this Specification. Testing shall be carried out per steel source per heat.


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The full penetration welds for the bars shall be qualified to ASME IX or other welding code approved by the COMPANY. The maximum hardness for sweet service shall not exceed 325 HV10. 10.3

PRODUCTION TESTING Destructive testing of fittings shall include the tests as given below. Specimens and testing shall be carried out in accordance with clause 6.2 of API 5L and shall meet the acceptance criteria of the relevant line pipe specification. Test frequency shall be once per heat, per heat treatment batch, per grade of material for each size of tee. •

•

•

11.0

One tensile test to include the weld and one tensile test to include the body of the main run. One tensile test to include the extruded branch. Specimens shall be transverse. Proof tests (bursting tests) as per MSS SP-75 are required. However, this requirement may be waived by COMPANY where documentary evidence is provided for the design of tee proven by previous proof testing, in support of the design by the Vendor. A Vickers hardness test, if required in accordance with ASTM E92 shall be carried out on a macro, which includes the weld. Hardness indents shall be in accordance with the relevant line pipe specification.

HYDROSTATIC TESTING A Shop Hydrostatic Test shall be carried out on each completed tee, using potable water to a procedure previously approved by COMPANY. The COMPANY has the right to witness any and all hydrostatic test(s) carried out on tees. The hydrostatic test shall be carried out to a test pressure equivalent to give a hoop stress of 95 percent SMYS based on minimum wall thickness of the mating pipe. Test pressure shall be maintained for four (4) hours. The test pressure shall be stated on the drawing submitted for approval. No leaks or weeps are permitted and no drop in pressure is allowed. Tees shall be thoroughly dried out before storing and/or transportation.

12.0

NON DESTRUCTIVE TESTING AND VISUAL

12.1

GENERAL All personnel performing Non-destructive Tests (NDT) shall be qualified in the technique applied, in accordance with ASNT-TC-1A Level II by a third party, or equivalent approved by the COMPANY. Original certificates shall be made available for inspection by COMPANY’s REPRESENTATIVE at the CONTRACTOR’s/VENDOR’s premises, if required. Personnel interpreting results of any non-destructive testing shall be qualified by a third party to ASNT-TC-1A, levels II or III.


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All Non-destructive testing (NDT) shall be performed in accordance with written procedures. These procedures shall have the prior approval of the COMPANY. NDT shall be carried out on tees after all mechanical testing and manufacturing stages including hydrostatic testing and any heat treatment have been completed. 12.2

VISUAL INSPECTION •

12.3

100% Visual Inspection. The body of every fitting shall be examined internally and externally for surface defects. The surfaces of the fittings shall be free from all dents, gouges, laps, score marks, arc strikes, laps, undercuts or other detrimental defects. Welds shall be inspected for 100% of the length, both outside and inside. The requirements of Workmanship and defects shall be as per the connected line pipe specification. Defects shall be removed by grinding or by weld repair, except that weld repair is not allowed on the body of the tee. Weld repairs shall be qualified and carried out in accordance with the applicable line pipe specification.

NON-DESTRUCTIVE TESTING OF FITTINGS Non Destructive Testing of fittings shall include: •

100 percent radiographic testing of all seam welds. Radiography of seam welds shall be in accordance with ASME VIII Div 1, Clause UW - 51. For butt welds in tees, with a thickness greater than 20 mm (0.8 inches), radiographic inspection may be replaced by ultrasonic inspection, at the discretion of VENDOR. For the acceptance of radiographic films, the technique used shall result in sensitivity better than 2% of the thickness of the weld metal and a relative film density of 2.0 to 3.5 in the weld metal. The manufacturer shall record on a review form accompanying the radiograph, the interpretations of each radiograph and disposition of the fitting inspected. The penatrameter used shall be of the wire type in accordance with ISO 1027. The selection of penatrameter wire diameters shall be based on a sensitivity of 2% of weld metal thickness.

•

•

Magnetic Particle inspection (MPI) of all bevel ends, all welds and 100% of extruded branch crotch area shall be in accordance with the requirements of ASTM E709. The wet method shall be used, the use of prods is unacceptable. Relevant linear indications greater than 3mm in bevel ends shall require rebevelling. Any ground surface shall be re-inspected by MPI to verify that the indication has been removed. The bevelled surface shall be free from defects such as cracks, laps or laminations visible to the naked eye as revealed by magnetic particle inspection. All forging shall be 100% surface MPI examined. Ultrasonic tests (UT) shall be carried out on all bevel ends of all fittings plus compressive wave check of extruded branch crotch area, in accordance with ASTM E709. No relevant linear defects are allowed greater than 3mm.


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Longitudinal edges and body of plate for seam-welded fittings shall be tested in accordance with applicable specification of Line pipe. UT shall be as per the applicable line pipe specifications. 12.4

REMOVAL OF DEFECTS •

•

12.5

Repair welding of parent metal is not acceptable.

WELDING PROCEDURES •

•

13.0

Defects may be removed by grinding, provided the remaining wall thickness is not below the nominal wall thickness less the minus tolerance and provided that the edges of the above defects have been ground out. In all cases where grinding repairs are made as a result of imperfections disclosed by NDE, the component containing such repairs shall be given an additional MPI test after grinding operation.

All proposed welding manufacturing and repair welding procedures shall be submitted for approval to Company. Qualification testing shall generally be carried out in accordance with the requirements of ASME IX except for the puppiece to tee welds, which, if applicable, shall be to the requirements of the Pipeline welding specification. The Manufacturer shall supply data to demonstrate the field weldability of the tees.

DIMENSIONAL INSPECTION Each tee shall conform to the dimensional requirements of ASME B 16.9 or MSS-SP 75 as appropriate and the additional requirements of this section. The ends of each fitting shall be tested for out-of-roundness using an internal ring gauge with a diameter of 5 mm (0.2 inch) less than the nominal internal diameter. The gauge shall pass freely into each end of the fitting for a distance of 100mm when held perpendicular to the fitting axis. The tolerance for the internal diameter of the run pipe part of the tee shall be within -0mm +1.5mm (-0 +0.059 inches) of the nominal dimension of the connecting pipe at the ends. End bevel preparation for the tees shall be in accordance with API 5L. If necessary, the ends shall be machined such that the maximum wall thickness at the ends of the tee is no greater than 1.5 times the nominal wall thickness of the mating pipe. A taper of 1:4 is permitted on the outside only to reduce the thickness of the tee body to meet the thickness of the weld bevel. A gauging pig shall be passed through the main run of each tee. The pig shall consist of two aluminium plates of at least 3mm thick, joined by a rigid rod through their


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centres. The diameter of the plates shall be 95% (-0mm +1mm) of the nominal inside diameter of the main pipe. The pig shall pass without sticking or damage to the tee. 14.0

COATINGS Painting or coating, if required, shall be specified in the Purchase Order and shall be in accordance with the applicable project specifications.

15.0

MARKING The CONTRACTOR shall mark each fitting with the information specified below as a minimum. The markings shall be carried out with white paint with letter height as minimum 20 mm.

16.0

•

Project Name

•

Manufacturer’s name and unique identification number of fitting

•

Nominal header pipe diameter (inches) and wall thickness (mm)

•

Nominal branch pipe diameter (inches) and wall thickness (mm)

•

Material grade.

•

Design pressure and Test pressure (when applicable)

•

Purchase order and Item number

•

Grade of steel and heat/Cast Number

PREPARA TION FOR SHIPMENT The CONTRACTOR/VENDOR shall submit shipping and handling procedures to the COMPANY for approval. The procedures should adequately address storage, shipping and handling in view of the long voyage from manufacturing locations and climatic extremes at the job site. An appropriate design of end cap shall be fitted to each opening to protect the butt weld ends and prevent ingress of foreign material.

17.0

MATERIAL CERTIFICATION AND TRACEABIL ITY Material Test Certificates and Manufacturer Test Reports shall be traceable to each tee within the CONTRACTOR Fabrication Book, which shall be part of the QC Data Book. The pressure containing and load bearing/stressed materials shall be fully covered by the Material Test Certificates which shall bear Equipment Tag Numbers, Purchase Order Numbers and any other Purchase Order requirements.


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For quality assurance requirements and inspection requirements, refer to the Purchase Order and its referenced documents. 18.0

VENDOR DATA REQUIREMENTS (VDRL) The CONTRACTOR/VENDOR shall submit certification and inspection documents to the COMPANY’s representative as specified in the purchase order. Mutual agreement on scheduled submittal of drawings and engineering data shall be an integral part of any formal Purchase Order. All documents, drawing text and dimensions shall be expressed in English language and shall be in the metric system. Comments made by CONTRACTOR on drawing submittal shall not relieve VENDOR or SUBVENDORS of any responsibility in meeting the requirements of the specifications. Such comments shall not be construed as permission to deviate from requirements of the Purchase Order unless specific and mutual agreement is reached and confirmed in writing. Each drawing shall be provided with a title block in the bottom right-hand corner incorporating the following information: •

Official trade name of the VENDOR.

•

VENDOR’S drawing number.

•

Drawing title giving the description of contents whereby the drawing can be identified.

•

A symbol or letter indicating the latest issue or revision.

•

PO number and item tag numbers.

Revisions to drawing shall be identified with symbols adjacent to the alterations, a brief description in tabular form of each revision shall be given, and if applicable, the authority and date of the revision shall be listed. The term "Latest Revision" shall not be used. The CONTRACTOR/VENDOR shall submit certification and inspection documents to the COMPANY’s representative as specified in the purchase order. Documents shall include the following as a minimum: •

Quality plan

•

Design Calculations

•

Manufacturing procedure covering steel making, chemical composition, welding and forming procedure.


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•

Marking Procedure

•

Production Schedule

•

Approved Welding Procedures

•

Weld Procedure Qualification and Welder Qualification Certificates

•

Inspection and Testing Plan

•

Certified material test reports, to ISO 10474 : 3.IC Type

•

Certified Chemical Analysis

•

Non-destructive test records and operator qualifications

•

Hydrostatic test procedure and records

•

All mechanical test reports

•

All corrosion test results

•

Dimensional Drawings

•

General Arrangement Drawings

•

Parts List with corresponding Assembly Drawing

•

Certificate of conformance and dimensional check reports

•

Verification Certificates for Standard Compliance

•

Heat treatment procedure reports

•

Final Inspection Report

•

All concession requests


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EXHIBIT – A


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ADDENDUM SHEET All revisions to this DGS subse quent to the issue of Rev Zero shall be recorded in this addendum sheet and shall be incorporated into the DGS in the next revision. Date

Proposed Revision


Remarks

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DGS-PU-304-Rev-0

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