Table of Contents
PART I .................................................................................................................................................................... 3 1
INTRODUCTION .......................................................................................................................................... 3 1.1 1.2 1.3 1.4
SCOPE ...................................................................................................... .................................................... 3 DEFINITIONS ......................................................... .............................................................. ...................... 3 ABBREVIATIONS ..................................................................................................... ................................. 4 GUARANTEE ......................................................................................... .................................................... 5
2
CODE AND STANDARDS .......................................................................................................................... 5
3
DOCUMENT PRECEDENCE ...................................................................................................................... 7
4
SPECIFICATION DEVIATION/CONCESSION CONTROLS .................................................................... 7
5
QUALITY ASSURANCE/QUALITY CONTROL ........................................................................................ 8
PART II
ADCO’S ADDITIONAL RE QUIREMENTS ...................................................................................... 9
1.
DESIGNATION ............................................................................................................................................. 9
2.
PRESSURE RATING AND DESIGN .......................................................................................................... 9
3.
MANUFACTURING ..................................................................................................................................... 9 3.1 3.2 3.3 3.4
4.
MANUFACTURING PROCEDURE SPECIFICATION ............... ............................................................... ........... 9 STARTING MATERIAL ............................................... .............................................................. .................... 10 FITTING MANUFACTURE ................................................................................................ ............................. 10 END PREPARATION ............................................................. .............................................................. ......... 11
TESTING AND INSPECTION ................................................................................................................... 11 4.1 4.2 4.3
5.
CHEMICAL COMPOSITION ............................................................. ............................................................. 11 MECHANICAL TESTING ....................................................... ............................................................... ......... 11 HIC TESTING ............................................................ .............................................................. .................... 12
NON-DESTRUCTIVE TESTING ............................................................................................................... 12 5.1 5.2 5.3 5.4
ULTRASONIC INSPECTION (UT)................................................................ .................................................. 12 MAGNETIC PARTICLE INSPECTION (MPI) ......................................................................................... ......... 13 GAUGING ....................................................................................... ............................................................. 13 H YDROSTATIC TESTING .......................................................................................................... .................... 13
6.
INSPECTION .............................................................................................................................................. 13
7.
PROTECTIVE COATINGS ........................................................................................................................ 14
8.
CERTIFICATION ........................................................................................................................................ 14
9.
MARKING ................................................................................................................................................... 14
10.
PREPARATION FOR SHIPMENT ....................................................................................................... 14
11.
DOCUMENTATION ............................................................................................................................... 15
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PART I 1
INTRODUCTION
1.1
Scope
This specification defines ADCO’s additional requirements on the design, materials, manufacture, testing, inspection etc. for supply of pipeline barred tees, for use in onshore pipelines in sour service. This document as an amendment to DEP 31.40.21.30 covers pipeline barred tees only, other fittings as included in DEP 31.40.21.30 is outside the scope of this document. This specification shall be read in conjunction with the latest edition of following documents:
DEP 31.40.21.30- (Feb 2013) Pipeline Fittings (Amendments / Supplements to ISO 15590-2). ISO 15590-2: Petroleum & Natural Gas Industries – Induction Bends, Fittings and Flanges for Pipelines transportation systems – Part 2 : Fittings
Part II of this contains ADCO’s additional requirements to above referred SHELL DEP. All clauses of SHELL DEP and ISO shall be applicable, unless specifically supplemented by this Specification. Additional requirements as indicated in this specification shall take precedence over relevant sections of DEP and ISO.
1.2
DEFINITIONS
COMPANY
ADCO (Abu Dhabi Company for Onshore Petroleum Operations Ltd.) Wherever the word “Principal” is used in SHELL DEP, the same shall be replaced by the word “COMPANY”, with the same authorities / responsibilities as defined in SHELL DEP
CONTRACTOR
The party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of the project. Contractor includes its approved manufacturers, vendors, suppliers and subcontractors. Requirements of this specification shall be enforced at all levels of the contractor's procurement and construction process. The company shall have access to Project No.: MASTER
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all contractor suppliers to the same extent as required of contractor VENDOR/ MANUFACTURER/ SUPPLIER
The Party (Parties) which manufactures and/or supplies materials, equipment, technical documents or drawings and/or services to perform the duties specified by the COMPANY.
SUBCONTRACTOR
Any person or persons, firm, partnership, corporation or combination thereof (not being an employee of CONTRACTOR), including vendors to whom any part of the works has been subcontracted by CONTRACTOR
SHALL
Indicates a mandatory requirement
SHOULD
Indicates a strong recommendation to comply with the requirements of this document
MAY/CAN
Indicates an acceptable course of action
1.3
ABBREVIATIONS ADCO
Abu Dhabi Company for Onshore Oil Operations
DEP
Design & Engineering Practice
EPC
Engineering Procurement and Construction
FEED
Front End Engineering Design
FFD
Full Field Development
HIC
Hydrogen Induced Cracking
ITP
Inspection & Test Plan
ID
Internal Diameter
MR
Material Requisition
MPS
Manufacturing Procedure Specification
MPQ
Manufacturing Procedure Qualification
OD
Outside Dimater
PQR
Procedure Qualification Report
RDS
Remote Degassing Station Project No.: MASTER
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1.4
SSC
Sulphide Stress Cracking
SMYS
Specified Minimum Yield Strength
TPI
Third Party Inspector Agency
VDRL
Vendor Document Requirement List
VQRF
Vendor Quality Requirement Form
UT
Ultrasonic Inspection
UAE
United Arab Emirates
GUARANTEE
VENDOR shall bear all costs to seek, find, and repair all leaks and/or ruptures which may occur during field hydrostatic testing, and which result from defects traceable to the material / manufacture of tees. The field test will not exceed a pressure that will cause a circumferential fibre stress greater than 95 percent of the specified minimum yield strength of the pipe. The hydrostatic test pressure may be applied in several cycles (cyclic test).
2
CODE AND STANDARDS The latest edition of following codes shall be applicable. SHELL DEP 31.40.21.30
Pipeline Fittings ( Amendments/Supplements to ISO 15590-2)
ADCO Amendments to shell DEPs
31.40.40.38A (2001)
Amendments/Supplements to DEP No. 31.40.40.38-Gen.-1993, Hydrostatic Pressure Testing of New Pipelines
30.99.00.0041-1 (2006)
Amendments/Supplements to DEP No. 61.40.20.30.-Gen.-1993, Welding of Pipelines and Related Facilities (Amendments/Supplements to ISO 13847:2000)
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International Standards Organization (ISO) ISO 15590-2
Petroleum and natural gas industries - Induction bends, fittings and flanges for pipeline transportation systems Part 2: Fittings
ISO 13847
Pipeline transportation systems - Welding of pipelines
ISO 10474
Steel and Steel products - Inspection documents
ISO (2008)
Quality Management Systems Requirements
9001
ISO 9000
Quality Management (12th Edition Compendium)
American Society for Testing and Materials (ASTM) ASTM E709
Standard Guide for Magnetic Particle Testing
American Petroleum Institute (API)
API 5L
Specification for Line Pipe
API 1104
Welding of Pipelines & Related Facilities
European Committee for Standardization (CEN) EN 10204
Metallic Materials – Types of Inspection
National Association of Corrosion Engineers (NACE) NACE MR0175/ ISO15156-1
Petroleum and natural gas industries - Materials for use in H2S-containing environments in oil and gas production Part1: General Principles for Selection of Cracking Resistant Materials
NACE MR0175/
Petroleum and natural gas industries - Materials for use in H2S-containing environments in oil and gas Project No.: MASTER
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3
ISO15156-2
production Part2: Cracking Resistant Carbon and Low Alloy Steels and the Use of Cast Irons
NACE TM0284 (2003)
Standard Test Method, Evaluation of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen Induced Cracking.
DOCUMENT PRECEDENCE The order of precedence of requirements shall be as follows, unless otherwise directed in writing by COMPANY: 1.
The laws, standards and Regulations of United Arab Emirates
2.
ADNOC Code of Practice
3.
Data sheets (Project specific)
4.
Design Basis & Project specifications (Project specific)
5.
Amendments to Shell DEP ( this document)
6.
Shell DEP/ ADCO standards
7.
Applicable International codes and standards
In case of conflict between any of the Project documents (Specification, Data Sheets, Drawings, DEP, International Standards, etc.). VENDOR shall notify CONTRACTOR in writing of the conflict and recommend a suitable solution for CONTRACTOR/COMPANY’s approval. COMPANY maintains the right to choose the most optimum solution.
4
SPECIFICATION DEVIATION/CONCESSION CONTROLS Any technical deviations to this specification and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be obtained by the Contractor only through Deviation Request format. Deviation Request requires Company’s review/approval prior to implementation of the proposed changes. Technical changes implemented prior to Company approval are subject to rejection.
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5
QUALITY ASSURANCE/QUALITY CONTROL The Vendor shall operate a quality system to ensure that requirements of the standard ISO 9000 are achieved. The Vendor shall submit a copy of the certification ISO 9000 or, alternatively, a Corporate Quality Manual. The Vendor shall identify in documents to its supplier and subcontractors all applicable QA/QC requirements imposed by the Contractor/Company, and shall ensure compliance. On request, Vendor shall provide objective evidence of its QA/QC surveillance for all levels of its activity.
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PART II
1.
ADDITIONAL REQUIREMENTS (PART III of SHELL DEP) ADCO’S
Designation
Fitting Class shall be “CS”. Sour service requirements apply accordingly.
2.
Pressure Rating and Design
The design code, design parameters (pressure and temperature) and the design Factor to be used for design of Barred Tees shall be as indicated in the data sheets. Design factor shall not be more than 0.6. A corrosion allowance as shown in the data sheets shall be included in the design of barred tees. Proof tests are required as per ISO 15590-2. The design calculations and results of proof testing shall be submitted to COMPANY for review. However, test 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. Tees with branches larger than 40 percent of main pipeline diameter shall have the configuration of bars as shown in Figure G of DEP 31.40.21.30.
3.
Manufacturing
3.1
Manufacturing Procedure Specification
Vendor shall submit a MPS to COMPANY before commencement of manufacture. Manufacturing shall not proceed until the VENDOR has an approved MPS. An approval of MPS shall include either review of the VENDOR’s previous production data or by performance of the mandatory tests listed in table 2 (ISO-15590-2), at the beginning of the production. COMPANY reserve the right to reject previous production test data if that data is not representative of the fitting to be manufactured or test data is not in compliance with specification requirements. The MPS shall also include the following:
Inspection procedure for all destructive and non-destructive testing during qualification and production Inspection and Test Plan (ITP) covering all destructive and non-destructive testing, both during qualification and production Detailed production schedule. Project No.: MASTER SPECIFICATION FOR PIPELINE
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3.2
Starting Material
The steel to be used in the manufacture of barred tee shall be made in a basic oxygen or electric arc furnace. It shall be fully killed with a grain size of ASTM 7 or finer, as defined in ASTM E112. For quenched and tempered fittings, this grain size requirement shall not apply. Fittings shall not be made using isostatic pressing or powder metallurgy, unless approved by the COMPANY.
3.3
Fitting Manufacture
Carbon steel barred tees shall be forged construction with extruded branch, and shall be either seamless or welded. Welded only in case connecting linepipe is of welded type. Barred tee welded type shall have a maximum of one longitudinal seam weld only (location of seam shall be opposite to branch). Circumferential welds are not permitted. Stub-in or pipe to pipe connection shall not be used in the manufacture of tee. The material of the barred tees shall be weldable carbon steel with carbon Equivalent, Pcm and chemical composition shall be in line with the referenced ADCO specification of the line pipe (Seamless/SAW/HFI as applicable per project). The chemical composition of barred tee shall be determined for every heat by product analysis. Barred tees shall be piggable and designed as per ASME B31.8 for branch compensation. Guide bars shall prevent pig entry into the branch. Guide bars shall be made of steel having same chemical composition as the line pipe and shall be welded with full penetration welds. . Bars are to be flush with the inside bore of the tee Welds shall be made by welding procedure specifications (WPS) qualified as per ASME Sec. IX or API 1104 using welders/welding operators qualified by above codes. Weld procedure qualification record (PQR) on similar material of past supplies is acceptable subject to COMPANY approval. The welding consumables and deposited weld metal shall comply with NACE MR 0175. Where stress relieving (PWHT) of fittings will be performed, e.g. for field welding, additional tensile testing of the fitt ing shall be performed on stress relieved specimens.
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3.4
Pup pieces (if specified in data sheet) shall be factory welded to the formed tee by the VENDOR. Pup pieces shall not be less than 300m or one pipe diameter in length whichever is greater. Pup pieces shall be in accordance with the Specification for connecting line pipe. All materials shall be suitable for sour service as per NACE MR0175 / ISO 15156 Part 1-3. Materials for tees shall be suitable for installation above ground / underground in prevailing environmental conditions in desert areas.
End Preparation
End bevel preparation for the tees shall be in accordance with MSS-SP-75. 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.
4.
Testing And Inspection
4.1
Chemical Composition
Chemical composition of steel shall be identical to the connecting pipeline material as specified in applicable ADCO standard for line pipe (ES-30-99-00-0104/ ES-30-99-000105/ES-30-99-00-0106).
4.2 4.2.1
Mechanical Testing Charpy V Notch Impact Testing
Test Pieces In addition to the specimens specified in SHELL DEP 31.40.21.30-Gen., Charpy Vnotch testing shall also be done on one set of three specimens taken from the extruded branch of both welded/forged tee. Specimens shall be transverse and taken from midthickness location. Charpy V-notch testing is not required in the simulated stress-relieved condition. Minimum design temperature shall be as per the data sheet. Project No.: MASTER SPECIFICATION FOR PIPELINE
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4.2.2
Acceptance Criteria (Hardness Testing) Hardness for base metal, weld metal and heat affected zone shall not exceed or equal to 248HV10.
4.3
HIC Testing
HIC sensitivity testing to be performed for components fabricated from plate or pipe. Test solution “A” as per NACE Standard TM0284-96 shall be used. Method of testing, pH values, test duration and test temperature shall be as per NACE Standard TM02842011 and SHELL DEP 30.10.02.16 (v36) amendment/supplement to NACE TM0284.
Frequency shall be one fitting per inspection lot (common diameter, grade, wall thickness, heat number, steel mill combination). If any specimen fails to meet acceptance criteria, heat of steel represented by the test shall be rejected. HIC testing is not required for forged fittings, when compliance to NACE MR -0175/ISO 15156 and hardness as per this specification is met.
5.
Non-Destructive Testing
VENDOR shall submit NDT procedures to COMPANY for approval before commencement of fitting manufacture. Manufacturing shall not proceed until COMPANY has approved NDT procedures.
5.1
5.1.1
Ultrasonic Inspection (Ut)
Fitting Ends Ultrasonic tests shall be carried out on all bevel ends (50 mm wide band at each end) of all tees plus compressive wave check of extruded branch crotch area shall be inspected in accordance with ISO 11496. There shall be no laminations within 25mm of the bevels. No relevant linear defects longer than 3 mm are allowed.
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5.1.2
Fitting Body UT shall be carried out on all fittings with minimum 25% area (fitting body) coverage in accordance with ISO 10893-8.
5.2
Magnetic Particle Inspection (MPI)
Magnetic Particle Inspection of all bevel ends, all welds and 100% of extruded branch crotch area shall be done in accordance with the requirements of ASTM E709. The wet method shall be used. Relevant linear indications greater than 3 mm in bevel ends shall require re-bevelling. 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 forgings shall be 100% surface MPI examined.
5.3
Gauging
A gauging pig shall be passed freely through run of each tee. The gauging pig shall have two parallel 6 mm thick circular aluminium plates, each a minimum of 97% of the nominal main run pipe ID, separated rigidly by a bar of length twice the nominal run pipe ID. The pig shall pass without sticking or damage to the tee.
5.4
Hydrostatic testing
Hydrostatic testing is not required. However, MANUFACTURER shall submit certificate confirming that the barred tees supplied shall be capable of withstanding a field hydrostatic test pressure of 95% SMYS of connecting main linepipe material grade based on minimum wall thickness. The hydrostatic test pressure may be applied in several cycles (cyclic test).
6.
Inspection
All material certification shall be in accordance with EN 10204, Type 3.2. Material certificates shall contain as minimum, the f ollowing information as per specification:
Chemical analysis report
Heat treatment report
Mechanical tests results
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Non-destructive tests results
Heat number
Material Test Certificates and Reports shall be traceable to each t ee.
7.
Protective Coatings
Tees shall be supplied with a coat of suitable corrosion resistant paint, for protection against corrosion during transit. Details of paint shall be proposed by VENDOR and shall be approved by COMPANY.
8.
Certification
Material certification shall be in accordance with ISO 10474 /EN 10204 Type 3.2.
9.
Marking
Marking on the flanges shall be as specified in SHELL DEP 31.40.21.30.
10.
Preparation For Shipment
Handling procedures should adequately address storage, shipping and handling during transit. An appropriate design of end cap shall be fitted to each opening to protect the butt weld ends and prevent ingress of foreign material. All handling, loading and unloading shall be done in such a manner as to minimise mechanical damage and corrosion. Export packages shall be designed and constructed to withstand the hazards of inland and ocean transportation, below and on deck stowage, Multiple handlings and 18 month storage at the destination in open yards with all possible adverse climatic conditions and exposure. Special considerations shall be given to the packing to insure that:
Breakage, damage and theft are prevented. Rust and corrosion are inhibited. Water intrusion is prevented. Handling is facilitated. Economical costs.
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Open ends of all below 16-inch fittings shall be protected with plastic end caps, whereas for 16-inch & above, same shall be protected with heavy duty plastic protective plugs or bevel end protectors. The bevel end protectors and caps shall protect the full area of the bevel.
11.
Documentation
Documents and drawings shall be supplied in accordance with requirements specified in material requisitions (VDRL). However, following documents shall be submitted as minimum. Bid stage:
Name of MANUFACTURER, location of Works References of previous supply Record of successful proof test for fittings as per ISO 15590-2 Categorical confirmation for compliance to COMPANY specifications / list of deviations, as appropriate MANUFACTURER’s technical catalogue Typical Quality Plan
Before Commencing Fabrication MANUFACTURER shall furnish following documents at least 2 weeks prior to start of fabrication: • Manufacturing Procedure and Welding Procedures • Drawings for the barred tees for all sizes showing overall dimensions and crosssection details • Details of all materials • Inspection and Testing Plan • Proposed coating / painting • Shipping and handling procedures Production shall commence only after obtaining COMPANY’s approval on all procedures in writing. Upon Completion of Fabrication The following documents shall be furnished by MANUFACTURER within 15 days of shipment of the Tees:
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• • • • • • •
• • •
Quality Plan All approved Manufacturing, welding and testing procedures and approved drawings Certified material test reports Non-destructive test records and operator qualifications All mechanical test reports Certificate of conformance and dimensional check reports Certificate confirming that the Tees supplied shall be capable of withstanding a field hydrostatic test pressure of 95% SMYS of connecting main line pipe. The hydrostatic test pressure may be applied in several cycles (cyclic test) Dimensional check Reports Details of Heat treatment carried out All approved concession requests
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