P14395-MR-ME-012-PIG TRAP

EPC FOR QUSAHWIRA PHASE-II DEVELOPMENT PROJECT Contract No. XXXXX Project No. P14395 Document No. P14395-MR-ME-016 MATERIAL REQUISITION FOR PIG TRAPS

This Document is intended for CPECC tendering purpose only Internal Ctrl. Doc. No.: P14395-MR-ME-016

0

15.03.2015

Zhao YiHao

Zhou Gang

Derek Meyn

Issued for Bid

REV

DATE

ORIGINATOR

REVIEWED

APPROVED

DESCRIPTION

DOCUMENT TITLE : Material Requisition for Pig Traps ADCO PROJECT No. P14395

ADCO DOCUMENT No. xx-xx-xx-xxxx Page 1 of 25 Rev. 0

Date : 15.03.2015

Table of Content 1.0 PROJECT INTRODUCTION................................................................................................................... 3 1.1 Overall Facility....................................................................................................................................... 3 1.2 Project Scope........................................................................................................................................ 4 2.0 DEFINITIONS AND ABBREVIATIONS...................................................................................................5 2.1 Definitions:............................................................................................................................................ 5 2.2 Abbreviations........................................................................................................................................ 6 3.0

SCOPE OF SUPPLY........................................................................................................................ 8

4.0 INFORMATION REQUIRED WITH THE BID........................................................................................11 5.0

APPLICABLE DOCUMENTS AND DRAWINGS............................................................................11

6.0

VENDOR DOCUMENT INSTRUCTIONS.......................................................................................14

6.1

VDRL-General Instructions..........................................................................................................14

7.0

DEVIATION LIST........................................................................................................................... 19

8.0

INSPECTION REQUIREMENTS....................................................................................................19

8.1 Definitions............................................................................................................................................ 19 8.2 Criticality Rating & Inspection Class.................................................................................................19 8.3 Principal Stages of Inspection and Testing.......................................................................................20 8.4 Inspection / Release Requirements...................................................................................................21 9.0

QA REQUIREMENTS.................................................................................................................... 23

9.1 Quality System.................................................................................................................................... 23 9.2 Release for Manufacture..................................................................................................................... 23 9.3 Non Conformities and Concessions..................................................................................................23 9.4 Codes and Regulations...................................................................................................................... 23 9.5 Material Identification......................................................................................................................... 23 ANNEXURE-1: TYPICAL VENDOR DOCUMENT REQUIREMENT LIST (VDRL).....................................24 ANNEXURE-2: TYPICAL VENDOR QUALITY REQUIREMENT FORM (VQRF).......................................24 ANNEXURE-3: APPROVED SUB VENDOR LIST.....................................................................................24



Date : 15.03.2015

1.0 PROJECT INTRODUCTION 1.1 Overall Facility ADCO has been chartered by their shareholders to expand sustainable crude oil production from its current level of 1.4 MMBOPD to 1.8 MMBOPD. Accordingly, ADCO has undertaken projects for development of its marginal fields to help achieve this target, which involves increasing production at existing Bab & North-East Bab oil fields and beginning productions from two new oil fields, namely, Bida Al Qemzan & Qusahwira. Qusahwira is a new field located about 80 Km Southeast of existing ASAB oil field and approximately 200 km south-southeast of Abu Dhabi city. The location of the Qusahwira field is depicted in Figure 1-1 below: Figure 1-1

Full development drilling of the Qusahwira field will be executed in two phases. The development under Phase- I is limited to the southern block of the field, involving Thamama Zones A/B and F. The Phase-I of Qusahwira project will contribute 30,000 BOPD (sustainable) to 1.8 MMBPOD scheme from year 2013 for a period of about five years (currently under operation). After completion of Phase-II (under this scope), its total production shall increase to 55,000 BOPD (sustainable). Additionally, 20,000 BOPD from Mender shall flow up by 2017



Date : 15.03.2015

1.2 Project Scope Phase-II facilities will be distributed between the wellpads, gathering stations, and existing facilities at CDS and RDS-1 as follows: 

Wellpads (24)



Gathering Stations (3)



Water Injection Clusters (3)

The EPC Contractor shall do the complete design for the wellpads (as per scope of work). Each drilling pad will have a combination of oil producers and injectors. Chemical injection and OHL power shall be provided on each wellpads. Following are the associated facilities involved in each wellpad: 

Oil and WAG injectors well heads & associated piping



Manifolds (For Gas Lift, WI, GI and Oil Production)



Chemical Injection Skid



OHL



WHCPs

Each gathering station shall be equipped with a production header to gather the gross production from a set of wellpads through non-piggable flowlines from the pads. Testing of all the wells shall be carried out at the gathering stations for which individual test lines from each pad run parallel to the production flow line towards the GS. The test line from each pad will serve for both testing as well for draining/venting the flow line to the GS during depressurisation. Following are the associated facilities involved in each of the gathering stations. 

Production Headers (OIL, GL, GI & WI)



Multiphase Flow Meters (MPFM)



Instrument Air System



N2 Supply System



Chemical Injection skids



Flare and Closed Drain System



Potable Water System

Two (2) transfer lines are provided from gathering stations GS-2 and GS-3 in the northern sides of the field, whereas the transfer lines from gathering station GS-4 in the southern side of the fields are connected to existing RDS-1 then exported to CDS through the existing 20” TL. The total oil production from CDS is exported to Asab through the existing 14” MOL. All these transfer lines shall be buried, coated and CP protected.



Date : 15.03.2015

Three (3) new WICs will be provided (i.e. one (1) at GS-2 location, one (1) at GS-3 and one (1) at GS-4). Each new WIC shall have a design capacity of 30,000 BWPD. Injection flow shall be delivered from the surface pumps via surface laid injection headers to distribution manifolds at the well pads where shorter surface laid injection lines will be branched off and routed to individual WI/WAG wells. The WICs located at GS-2 & GS-3 shall be connected. The WIC at GS-4 shall be connected to existing WIC located near existing RDS-1. The existing facilities at CDS are not adequate to cater for the Phase-II production and additional equipment is required for Phase-II as follows:          

Three (3) Slug catchers; One (1) Production separator; Two (2) Oil booster pumps; Three (3) MOL export pumps; One (1) Gas injection compressor train; One (1) Gas lift compressor train; One (1) Gas dehydration and glycol regeneration system; One (1) Water separation tank; One (1) Water disposal tank; and Two (2) Water disposal pumps.

2.0 DEFINITIONS AND ABBREVIATIONS 2.1 Definitions: COMPANY:

Abu Dhabi Company for Onshore Oil Operations (ADCO) including its Successors and assignees.

PROJECT:

QUSAHWIRA PHASE II DEVELOPMENT PROJECT

FEED CONSULTANT:

SNC Lavalin International

EPC CONTRACTOR:

The party which carries out all or part of the engineering, procurement, Construction, pre-commissioning and commissioning of the project.

VENDOR / MANUFACTURER / SUB VENDOR:

The person, firm, Company or Corporation including their assignees to which the purchase works are awarded.

WORKS:

All the temporary and permanent work described in this specification and in the Contract

SHALL:

Indicates a mandatory requirement

SHOULD:

Indicates a strong recommendations to comply with the requirement of this document



Date : 15.03.2015

2.2 Abbreviations ADCO

: Abu Dhabi Company for Onshore Oil Operations

ADNOC

: Abu Dhabi National Oil Company

AG

: Above Ground

API

: American Petroleum Institute

CDS

: Central Degassing Station

DEP

: Design Engineering Practice – Shell Standards

EPC

: Engineering Procurement Design

FEED

: Front End Engineering Design

FFD

: Full Field Development

GI

: Gas Injection

GL

: Gas Lift

GS

: Gathering Station

HIC

: Hydrogen Induced Cracking

IRC

: Inspection Release Certificate

ISO

: International Standards Organization

ITP

: Inspection & Test Plan

MPS

: Manufacturing Procedure Specification

MR

: Material Requisition

MRB

: manufacturing Record Book

NACE

: National Association of Corrosion Engineers

NDT

: Non Destructive Testing

OD

: Outside Diameter

P&ID

: Piping and Instrumentation Diagram

PFD

: Process Flow Diagram

PMS

: Pipeline Material Specification

PO

: Purchase Order

QA

: Quality Assurance

QC

: Quality Control

RDS

: Remote Degassing Station

SAW

: Submerged Arc Welding

SDI

: Supplier Document Index

SMYS

: Specified Minimum Yield Strength DOCUMENT TITLE : Material Requisition for Pig Traps ADCO PROJECT No. P14395


Date : 15.03.2015

SSC

: Sulfide Stress Cracking

Th-A/B

: Thamama-A/B

Th-F

: Thamama-F

TPI

: Third party Inspection

UAE

: United Arab Emirates

UG

: Under Ground / Buried

VDRL

: Vendor Data Requirement List

VQRF

: Vendor Quality Requirement Form

WI

: Water Injection

WIC

: Water Injection Cluster

WSW

: Water Supply Well

WT

: Wall Thickness



Date : 15.03.2015

3.0

SCOPE OF SUPPLY Vendor’s scope shall include but not limited to design, procurement of all materials, fabrication, inspection and testing, surface preparation and painting, preparation for shipment and guarantee for the equipments mentioned in the table below, in accordance with this requisition, attached datasheets, PID`s, PFD`s, specifications, Shell DEPs, Shell Standard Drawings and all applicable Codes & Standards. Detailed scope of supply & work shall be as defined in Project Specification for Scrapper Traps, Doc# 58.78.12.0601.

Ite m No

Item / Tag No

Qty

69015Refer 1 Table-1 1 set per tag furnished below (Total 12 Sets ) for the Tag Nos / item description

Description

Pig Trap Design, Material Supply, Complete Shop Fabrication as per specification number 58.78.12.0601 and other applicable specifications, data sheets, PID`s etc including but not limited to: 

Pig traps with supports, nozzle connections



etc. Quick

closure

door

with

provision

for

Mechanical key interlocking system.( For detail interlock arrangement refer ADCO ES No.30-99-00-0103

&

data

sheet

no

58.78.18.0608) 

Pig handling facility along with each



launcher, receiver, pig handling tray etc. Jib crane for each Pig Trap (refer spec no 58.78.12.0601 and 58.99.24.0615)

 

   DOCUMENT TITLE : Material Requisition for Pig Traps ADCO PROJECT No. P14395

Pig Signallers (ref doc no 58.78.12.0607 & 58.78.18.0603) External Attachments such as lifting lugs / trunnions, platform clips, ladder clips, pipe supports, pipe guides, foundation bolts (min 2 supports per set) etc complete . Earthing bosses Material Certification as per BS EN 10204 Type 3.2 Name plate with bracket ADCO DOCUMENT No. xx-xx-xx-xxxx Page 8 of 25 Rev. 0

Date : 15.03.2015



2

1Lot

3

1Lot

4

1Lot 1Lot

5 6

1Lot

7

1Lot

8

1Lot

9

1Lot

10

1Lot

12

1Lot

13

Lot


Blanks, bolting, gaskets etc required for testing purpose  Temporary covers and bolting to protect nozzle flange faces during shipment. Testing and inspection in accordance with Code requirements, this Material Requisition (Section 8) and all referenced specifications, standards, data sheets etc (including pressure testing, weld hardness testing, impact testing etc) complete. This requirement includes ASME Code stamping as specified on equipment data sheets & registration of Code stamped vessel with the National Board PMI, if applicable as per DEP and other applicable documents, specifications, data sheets etc Special equipments, if required during transport to site or during installation (vendor to specify) Special tools required for installation, field testing, operation or maintenance of the system (vendor to specify) Special lifting beams or lifting equipment, if required to lift the equipment during transport to site or during installation(vendor to specify) Provision of all documents / drawings as specified in this Material Requisition (Section 6), VDRL form (Annexure 2) and all referenced Specifications, Standards and Equipment Data Sheets. This shall include all the required data for CONTRACTOR design of equipment foundations. Construction, pre-commissioning and startup spare parts; required to install and test the equipment and spare parts required during commissioning and in accordance with project specification 58.78.12.0601. Spare parts list recommended for one Year of normal operation within Company’s SPIR form to be included with Supplier’s quotation. Operational spare parts list recommended to cater for the maintenance requirements for Two Years of operation, after one year of operation, within Company’s SPIR form to be included with Supplier’s quotation. Corrosion protection, surface preparation and painting, internal lining/ coating etc all in accordance with documents referenced within the project specification # 58.78.12.0601and this MR Export Packing, Preservation and Preparation for shipment suitable for seaworthy transport and suitable for outdoor storage for more than 6 months ADCO DOCUMENT No. xx-xx-xx-xxxx Page 9 of 25 Rev. 0

Date : 15.03.2015

for the complete scope of supply, as per specifications. Site Supervision Suitably qualified and experienced personnel for the supervision of field services shall be deputed on per diem rate basis for the provision of the following field services. • Commissioning • Performance Testing Delivery charges for below 3 options (Note 2) a) Vendor Ex-Works b) C.I.F. Abu Dhabi Port c) ADCO ASAB Site and Unloading charges

14

15

Lot

Notes: 1. Please note that COMPANY will nominate the Third Party Inspection Agency at its own cost. VENDOR shall be responsible to provide free and fair access to the manufacturing premises including those of Sub- VENDORs, to COMPANY and its nominated representatives including the inspection agency for the purpose of Inspection or Expediting. 2. Delivery price shall be quoted separately for mentioned three (3) options TABLE-1 DETAILS OF PIG TRAPS Sr N o 1

2

3

4

5

6

7

Pig Trap

Pig Launcher

Tag No / Description

P&ID

Data Sheet

58.12.LP.1301 (28” x 24”) For 24” oil transfer line at GS-2 (to CDS) 58.13.LP.1301(12”x10”) For 10” oil transfer line at GS-3 (to CDS) 58.14.LP.1301(12”x10”) For 10” oil transfer line at GS-4 (to GS1) 58.01.LP.3903 (8”x6”) For 6” Gas Injection Transfer line at CDS (to GS-2) 58.01.LP.3905 (10”x8”) For 8” Gas Lift Transfer line at CDS (to GS-2) 58.01.LP.3904 (8”x6”) For 6” Gas Lift Transfer line at CDS (to GS-1 or RDS1) 58.01.RP.1308 (28” x 24”) DOCUMENT TITLE :

58.12.08.061 9

58.12.27.064 8

58.12.08.061 9

58.13.27.064 6

58.12.08.061 9

58.14.27.064 6

58.01.08.065 2

58.01.27.062 3

58.01.08.065 4

58.01.27.062 2

58.01.08.065 3

58.01.27.062 1

Material Requisition for Pig Traps ADCO PROJECT No. P14395

58.01.08.062 58.01.27.062 ADCO DOCUMENT No. xx-xx-xx-xxxx Page 10 of 25 Rev. 0

Date : 15.03.2015

Remark s

For 24” oil transfer line at CDS 8 4 Pig (from GS-2) 8 58.01.RP.1309(12”x10”) 58.01.08.062 58.01.27.062 Receiver For 10” oil transfer line at CDS 9 5 (from GS-3 ) 9 58.11.RP.1303(12”x10”) 58.11.08.0612 58.11.27.0612 For 10” oil transfer line at GS-1 (from GS4 ) 10 58.12.RP.3902 (8”x6”) 58.12.08.061 58.12.27.064 For 6” Gas Injection Transfer line 8 7 at GS2 (from CDS ) 11 58.12.RP.3901 (10”x8”) 58.12.08.062 58.12.27.064 For 8” Gas Lift Transfer line at 3 6 GS2 (from CDS ) 12 58.11.RP.3907 (8”x6”) 58.11.08.0607 58.11.27.0611 For 6” Gas Lift Transfer line at GS1 (from CDS ) Note: In case of conflicting requirements among MDS, PDS and PID, the order of precedence shall be as follows 1. Mechanical Data Sheet 2. Process Data Sheet 3. Piping and Instrument Diagram

4.0 INFORMATION REQUIRED WITH THE BID Minimum bid offer documentation to be submitted is as follows:                   

Copy of Vendor’s Quality Assurance System certificate of ISO 9001 Series of Quality Standards registration or recognised equivalent National or International Standard. Proposed list of sub-vendors for Components, if any. Quality Manual (Uncontrolled copy). Vendor catalogues covering full details of the offer, etc. GA drawing detailing relevant dimensions, equipment envelope, weight estimate, materials of construction and other interface data. Completed data sheets. P&IDs Details of the first fill of all lubricants, chemicals, etc. required to put the equipment into operation. Performance guarantee, Utilities consumption list including lube oil type and quantity, Typical Quality Plan / Inspection and Test Plan. Manufacturing and Delivery Schedule. Documentation / Deliverable Schedule. List of Deviations and Exceptions (if any) Construction / commissioning spare part list. Priced Recommended Spares List (SPIR form). Comments / Deviations / Exceptions. Special Tools List (as applicable). Packaging details. DOCUMENT TITLE : Material Requisition for Pig Traps ADCO PROJECT No. P14395


Date : 15.03.2015

 

Site Service Rates, Training Rates. Any other document that have been specified in the Vendor Document Requirement List (Annexure-2) as “With bid”. Any other document that have been specified in the attached Specifications as “Documents required with the Proposal/Bid”.

5.0

APPLICABLE DOCUMENTS AND DRAWINGS

The documents listed below are applicable in their entirety Sr No Document No Revisio n Data Sheets & PI&D 58.01.27.0621 1

3

2

58.01.27.0622

3

3

58.01.27.0623

3

4

58.01.27.0624

2

5

58.01.27.0625

2

6

58.11.27.0611

2

7

58.11.27.0612

2

8

58.12.27.0646

1

9

58.12.27.0647

1

10

58.12.27.0648

1

11

58.13.27.0646

1

12

58.14.27.0646

1

13

58.01.08.0628

1

14

58.01.08.0629

1

15

58.01.08.0652

2

16

58.01.08.0653

2

17

58.01.08.0654

3

Title

Attached (Yes/No)

Data sheet for Pig Launcher for Gas Lift transfer line from CDS to GS1 Data sheet for Pig Launcher for Gas Lift transfer line from CDS to GS2 Data sheet for Pig Launcher for Gas Injection transfer line from CDS to GS2 Data sheet for Pig Receiver for Oil transfer line from GS2 to CDS Data sheet for Pig Receiver for Oil transfer line from GS3 to CDS Data sheet for Pig Receiver for Gas Lift Transfer line from CDS to GS1 Data sheet for Pig Receiver for Oil transfer line from GS4 to GS1 Data sheet for Pig Receiver for Oil transfer line from CDS to GS2 Data sheet for Pig Receiver for Gas Injection transfer line from CDS to GS2 Data sheet for Pig Launcher for Oil transfer line from GS2 to CDS Data sheet for Pig Launcher for Oil transfer line from GS3 to CDS Data sheet for Pig Launcher for Oil transfer line from GS4 to GS1 PID GS2 Pig Receiver RP 1308-QusahwiraCDS PID GS3 Product Oil Pig Receiver RP 1309Qusahwira- CDS PID Injection Gas Launcher LP 3903 to GS2Qusahwira- CDS PID Lift Gas Launcher LP 3904 to GS1Qusahwira- CDS PID Lift Gas Launcher LP 3905 to GS2-

Yes



Date : 15.03.2015

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

18

58.11.08.0607

1

19

58.11.08.0612

1

20

58.12.08.0618

1

21

58.12.08.0619

1

22

58.12.08.0623

1

23 24 25

58.78.18.0603 58.78.18.0606 58.78.18.0608

2 2 1

Project Specifications and Procedures 1 58.78.12.0601 1 2 58.78.12.0602 2 3 58.78.12.0604 1 4

58.78.12.0607

1

5 6 7 8 9 10

58.78.12.0608 58.78.12.0609 58.78.12.0611 58.78.12.0615 58.78.24.0615 58.99.00.0601

1 1 2 1 1 1

11 12 13 14 15

58.99.32.0601 58.99.32.0602 58.99.75.0601 58.99.75.0604 58.99.76.0612

1 1 1 1 1

16 17 18 19 20

58.99.76.0613 58.99.76.0614 58.99.76.0615 58.99.76.0617 58.99.90.0673

1 1 1 1 1

21 22 23 24 25 26 27

58.99.91.0601 58.99.91.0602 58.99.91.0603 58.99.91.0604 58.99.91.0605 58.99.91.0608 58.99.91.0609

1 1 1 1 1 1 1

Qusahwira- CDS PID Gas Lift Pig Receiver RP 3907Qusahwira- GS1 PID GS1-Product Oil Receiver RP 1303Qusahwira- GS1 PID Gas Injection Pig Receiver RP 3902Qusahwira- GS2 PID Product Oil Pig Launcher LP 1301 (Typical)-Qusahwira- GS2/GS3/GS4 PID Gas Lift Pig Receiver RP 3901Qusahwira- GS2 Data Sheet for Pig Signallers- Intrusive Type Data Sheet for Barred Tees Data Sheet for Mechanical Key Interlocking System for Pipeline Pig Traps Specifications for Scraper Traps Specifications for External Pipeline Coating Specifications for Pipeline Fittings and Barred Tees Specifications for Pig Signallers: Intrusive Type Specifications for Pipeline Flanges Specifications for Pipeline Valves Pipeline Material Specification Specifications for Pipeline Welding Specifications for Jib Crane Environmental Site Conditions and Units of Measures Specifications for pressure vessels Specifications for pressure vessels Details Structural Design Criteria. Specification for Structural steel Structural steel general notes and Abbreviations Anchor bolts Typical details Ladder standard drawing Grating standard drawings Standard drawing for Hand railing Transportation, Logistic And Handling Requirements For Project Equipment/ Material And Line Pipe Process and Utilities Design Basis Design temperature and pressure philosophy Equipment sizing philosophy Line Sizing Philosophy Sparing philosophy Isolation and Maintenance philosophy Drain system philosophy



Date : 15.03.2015

Yes Yes Yes Yes Yes Yes Yes Yes

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

Yes Yes Yes Yes Yes Yes Yes

28 29

58.99.91.0610 58.99.91.0611

1 1

Operation and control philosophy Emergency shutdown and depressursing philosophy 30 58.99.91.0621 1 Mechanical Design Basis 31 58.99.91.0623 1 Material selection and corrosion control Philosophy 32 58.99.91.0641 1 Pipeline Pigging Philosophy 33 58.99.91.0642 1 Engineering Design Basis-Pipeline 34 58.99.93.0601 1 Equipment Criticality rating ADCO Engineering Specifications and Procedures 1 30.99.37.0002 X Painting and Coating of Production Equipment 2 30.99.37.0013 1 Specification for painting & coating of new equipment 3 30.99.53.0614 X Specification for equipment Earthing 4 30.99.90.0024 3 Engineering Procedure for Preparation of Supplier’s/ Vendor Engineering Drawings and Documents 5 30.99.90.0002 X Project Drawings, as Built Drawings and Documents 6 30.99.90.0028 5 ADCO Approved Vendors List 7 30.99.90.1702 X Equip, Material, Document numbering procedure 8 30.99.91.0003 X HSE Philosophy / Design HSE Plan 9 EM30.99.95.0006 1 ADCO Guidelines for Submission of Electronic Documentation. 10 EP30.99.90.0001 8 Drawing Design and Numbering Systems. 11 ES30.99.00.0001 2 Engineering Specification for Tag Plates for Field & Indoor Equipment 12 30.99.90.0043 3 Project Health, Safety And Environmental Review (PHSER) Procedures

Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes

No Yes No No Yes Yes Yes Yes

Shell DEP Standards (v37) All listed in the specifications and other related documents

No

Shell DEP Standard drawings (v37) All listed in the specifications, Shell DEP Standards and other related documents

No

Other International Codes and Standards All listed in the specifications and other related documents

No

Notes 1) Vendor shall be familiar with and in possession of Shell DEPs & Shell Standard Drawings listed in this requisition, project specifications and / or cross referenced in the data sheets, specifications or any other documents. These are not attached with this MR. However, if any of these documents is not in Vendor’s possession then it is the responsibility of Vendor to highlight the same and obtain from Contractor for compliance. It is Vendor’s responsibility to provide the equipment in full compliance with the requirements of applicable Shell DEPs and Shell Standard Drawings. 2) Vendor shall be familiar with and in possession of other International Codes and Standards listed in this requisition, project specifications and / or cross referenced in the data sheets, specifications or DOCUMENT TITLE : Material Requisition for Pig Traps ADCO PROJECT No. P14395


Date : 15.03.2015

any other documents. These are not attached with this MR. It is Vendor’s responsibility to provide the equipment in full compliance with the requirements of these Codes and Standards. 3) Latest codes with applicable addenda, as of this document date, shall be followed unless otherwise specifically stated. 4) Vendor to note that ADCO is currently in the transitional period to change the review, approval of operating SPIR forms and subsequent ordering of operating spares to an electronic process to reduce review and ordering period and ensure timely availability of spares. The current attached SPIR procedure will be replaced in due course by the new ASPIR procedure. The process and purchase of initial and insurance spares remain unchanged. 5) For all applicable ADCO Amendments to Shell DEP’s, refer to attached specifications.

6.0

VENDOR DOCUMENT INSTRUCTIONS The VENDOR shall include the supply of all Documentation to define the Equipment supplied for the purposes of: • Integration into the Plant Design • Design Standard Compliance • Operation and Maintenance Detailed requirement of Vendor documents are specified in Vendor Document Requirements List (VDRL) attached with this specification. Vendor shall prepare Vendor Document Register in accordance with VDRL and submit for Contractor’s approval.

6.1

VDRL-General Instructions 6.1.1 General It is a condition of any Purchase Order that all data and drawings (hereinafter called documents) shall be submitted to the CONTRACTOR in the manner and time period stated. The Purchase Order will not be considered complete until all documentation has been submitted and accepted. 6.1.2 Presentation All documents shall be full size based on ‘A’ series sizes, i.e. A1, A2, A3 or A4. A0 is not acceptable. All documents shall be checked before submission, unchecked documents may be returned, unreviewed. All documents submitted shall be clearly marked with the Purchase Order No., Item No, VENDOR’s Job No., Equipment / Tag No. (if applicable), VENDOR’s Document No. and CONTRACTORs Document No. In addition the Project Title Block shall be added by VENDOR in accordance with Engineering Procedure 30.99.90.0024. All documents and technical data shall be provided in the English Language. Dimensions and other units of measurement are defined within document No. 58.99.00.0601, Environmental Site Conditions and Units of Measure, and shall be SI and other units recognized by SI, preferably: mm, °C, bar. Except that pipe and bolt diameters may be in inches, pipe wall thicknesses may be in inches and/or pipe schedules, and tube wall thickness in BWG. A free space 80 mm x 50 mm shall be provided adjacent to the document’s title block for the CONTRACTOR to add his own status review stamp. DOCUMENT TITLE : Material Requisition for Pig Traps ADCO PROJECT No. P14395


Date : 15.03.2015

All document preparation, photocopying and printing shall be of sufficient clarity and legibility to ensure satisfactory quality for electronic documentation. All document prints larger than A4 shall be folded to A4 size with identification data visible at the bottom right 6.1.3 Submission Documents required for submission are indicated in the attached VDRL. Documents required to form part of the final documentation which will not be submitted for individual review are indicated in the data book column only. Any revision to a document after its first submission shall be clearly identified on the document in the revision box. Once issued, a document number shall not be changed or re-used. All documents shall be sent under cover of a transmittal using the standard project format (to follow after P.O. assignment). The number of copies of each document to be submitted shall be as indicated. Certified Final submissions shall be made within 14 calendar days of receipt of document with CONTRACTOR review status of “No Comments”. 6.1.4 Review Cycle The CONTRACTOR will complete his review within 14 calendar days. The VENDOR shall update and return the documents inclusive of the comments within 7 calendar days. These periods shall be taken into account with planning submissions and manufacturing activities. Drawings showing overall dimensions of equipment “footprints” and termination points will be considered fixed and final with regard to these details, once they have been acceptably reviewed and returned. No alteration to these documents will be accepted when they have achieved this status. 6.1.5 Vendor Design Documentation The content of Manufacturing Procedures, Quality Control Procedures, Calculations, Reports, Data and Drawings will be stated in this requisition and referenced specifications, standards and data sheets. Prior to issue to CONTRACTOR, all required VENDOR and sub-VENDOR documentation shall be signed, dated and approved by the VENDOR. VENDOR shall ensure that all sub- VENDOR's documentation conforms to CONTRACTOR purchase order. VENDOR shall ensure that all applicable Design Code, Standards and Data sheets requirements for the design review of subVENDOR's documentation are performed at VENDOR's cost. When the equipment is to be supported on foundations or structures whose design is based upon the information provided by VENDOR, these drawings shall show all dimensions and data required to design foundations and connect equipment, including required data for installation services and DOCUMENT TITLE : Material Requisition for Pig Traps ADCO PROJECT No. P14395


Date : 15.03.2015

for installed clearances. The Drawings shall show weights, forces, moments and the centers through which these forces act for foundation design. 6.2 Technical Documentation Descriptions This Section describes the content of specific documents. 6.2.1 Vendor Document Index Documents which satisfy the VDRL Document Titles shall be listed on the VENDOR (Supplier) Document Index (SDI), indicating their earliest submittal dates. This will then be used by the VENDOR and the CONTRACTOR and shall be updated on a continuous basis. The VENDOR shall list all documents and their document number on the SDI. The CONTRACTOR’s documents numbers will be added at the first review of the SDI. All documents subsequently submitted shall be identified with their relevant CONTRACTOR document number. Any urgent documents submitted with, or prior to, the SDI will be marked with a CONTRACTOR document number as part of the review comments. These numbers shall be identified on the originals by the VENDOR for their next submission. All Vendor documents shall be numbered in accordance with EP 30.99.90.0024 and EP 30-99-900001. 6.2.2 Vendor Quality Plan The VENDOR Quality Plan shall show the planned activities, resources and events serving to implement and record the implementation of the VENDOR Quality system relevant to the goods in accordance with ISO 9001: 2008. The Quality Plan shall list documentation / design reviews and for each item of equipment, major assembly or sub-VENDOR item, the principal manufacturing steps, type of inspection / test, the Controlling Procedure, the acceptance standard and the appropriate certification issued at successful completion. The Quality Plan shall include space for CONTRACTOR and / or COMPANY to advise inspection Hold / Witness points and whether the inspection will be by CONTRACTOR, Third Party, or Company. VENDOR shall indicate on the Quality Plan all surveillance that VENDOR will carry out of sub-VENDOR's goods. As a minimum, the Quality Plan shall cover all stages indicated under clause 8.3. VENDOR may use his standard format of quality plan provided the content includes the minimum information shown in VQRF. The Quality Plan will be discussed with the VENDOR during any pre-production meeting at the VENDOR's works. The agreed Quality Plan will be held by the VENDOR and initialed progressively by the VENDOR's inspector, CONTRACTOR’s/ COMPANY’s inspector, and any other authorized inspectors to demonstrate successful completion of each inspection activity. 6.2.3 Production Program A network or bar chart showing all activities from award through to shipment of equipment / material, containing complete details of VENDOR’s and sub-VENDOR’s activities. It shall be suitable for VENDOR to report progress and CONTRACTOR to assess and monitor performance.



Date : 15.03.2015

6.2.4 List of Terminations The list shall summarize details of terminations, for example: service, size, rating, allowable loads, pipe schedule, material, operating / design conditions and insulation requirements as applicable. 6.2.5 Parts List The Parts List shall contain enough information to identify fully the components, such as; item and part number, description, make, size and type, quantity, design / operating / test conditions. 6.2.6 Test and Material Certificates The requirements for material and test certificates are defined within this document and referenced specifications and data sheets. CONTRACTOR reserves the right to request. Certificates for any inspections listed on the VENDOR Quality Plan. Test certificates are required for all shop tests for both VENDOR's and sub-VENDOR's goods. All certificates shall be fully identified with the equipment Item Number and CONTRACTOR Purchase. Order Number and shall include a description of the test method and the full results. VENDOR shall maintain suitable control of all materials used and shall keep a record of their certified chemical and mechanical properties. 6.2.7 Manufacturing Record Book The Manufacturing Record Book is a compilation of Production record documents, as defined in the Vendor Document Requirements List (VDRL). All MRBs must have a Table of Contents detailing all sections and total number of pages. The Manufacturing Record Book shall include all documentation relating to the manufacturing / production process involved in the supply of the equipment or the material, such as, analysis of raw materials, production inspection and testing reports, expediting and shipping, and correspondence related to the above. One Manufacturing Record Book containing original or certified as original documents is required. A separate Manufacturing Record Book shall be supplied for each tagged item. All pages within the Manufacturing Record Books must be clearly marked on both front and spine with: i) Project Title & Purchase Order Number ii) Equipment / Material Description iii) Item or Tag Number iv) Page Number (where practicable) v) Volume Number (if applicable) Manufacturing Record Book shall be prepared in accordance with project procedure / specification & VDRL. All prior approved documents must show the signed acceptance stamp of the CONTRACTOR. The Manufacturing Record Book shall be complete for final inspection and submitted to the Inspector prior to material dispatch. Following Inspectors acceptance, the VENDOR shall dispatch one complete hard copy set of the Manufacturing Record Book with the goods, and the remaining copies shall be dispatched to the CONTRACTOR.



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Note: Technical / Engineering data, such as drawings, data sheets, etc. which may be used post project by ADCO’s operations and technical staff, shall be included in the vendor Data Book, described in 6.2.8 below.

6.2.8 Vendor Data Books Vendor shall compile Vendor Data Books, complete with vendor’s instructions for installations, operation and maintenance, cross sectional drawings, part-numbered drawings, part lists, SPIR’s, etc. Six copies of the Vendor Data Book are required. Electronic copy of all documents in the Vendor Data Book shall be provided on a CD. 6.2.9 Certificates of Conformity The VENDOR shall certify that the goods are manufactured in accordance with the Purchase Order. The Certificates of Conformity shall be available to the CONTRACTOR’s inspector during final inspection. 6.2.10 Spare Parts Lists Vendor shall furnish list of spares as per MR on the ADCO SPIR form. Spare parts shall comply with all the requirements for the main equipment requisitioned. VENDOR shall include recommended spare parts for all auxiliary equipment and accessories. VENDOR shall include the equipment identification for which the part is intended, reference number and the relevant drawing. 6.2.11 Certified Final Documents and As Built VENDOR shall provide Certified Final documents as specified herein. VENDOR's authorized Engineer shall mark the documents "CERTIFIED FINAL" and sign and date the documents to confirm that these are final VENDOR documents or final sub-VENDOR documents, incorporating all CONTRACTOR’s / COMPANY’s comments, and that the documents accurately describe the design. VENDOR shall revise and reissue immediately the Certified Final documents to show any agreed concessions or corrective actions.

7.0

DEVIATION LIST Deviations, exceptions or additions to the Material Requisition, Attachments, Equipment Data Sheets, and Applicable Standards, Codes and Specifications, if any shall be clearly listed in the Deviation List Form included in the Annexure 1 of this MR.

8.0

INSPECTION REQUIREMENTS 8.1 Definitions 8.1.1 Surveillance Surveillance comprises all CONTRACTOR and / or COMPANY activities performed to verify that goods meet the specified requirements, including audit, design review, and inspection. DOCUMENT TITLE : Material Requisition for Pig Traps ADCO PROJECT No. P14395


Date : 15.03.2015

8.1.2 Inspection The process of measuring, examining, testing, gauging or otherwise comparing the items with the applicable requirements. 8.1.3 Hold (H) Inspection A Mandatory Hold shall be applied to the production schedule and the test shall be performed with the CONTRACTOR and / or COMPANY in attendance. 8.1.4 Witness (W) Inspection The CONTRACTOR and / or COMPANY requires notification of the inspection timing. However, the inspection is performed as scheduled and if the CONTRACTOR and / or COMPANY is not present, the VENDOR can proceed to the next step. 8.1.5 Review (R) Inspection The CONTRACTOR and / or COMPANY shall review the appropriate inspection documentation / certification but does not require a formal notification of the inspection timing. This inspection is normally performed as part of a scheduled inspection visit by the CONTRACTOR and / or COMPANY. If the CONTRACTOR and / or COMPANY is not present, the VENDOR can proceed to the next step, with formal notification to the CONTRACTOR and COMPANY. 8.1.6 Source This normally means the VENDOR's works where the goods are manufactured and where surveillance is carried out.

8.2 Criticality Rating & Inspection Class CONTRACTOR and / or COMPANY shall control the level of surveillance of VENDOR's work by assigning a Criticality Rating to the goods. The Criticality Rating and corresponding Inspection Class for the equipment contained within this Material Requisition are as given below. Equipment

Criticality Rating

Pig Launcher Package Pig Receiver Package

2 2

Inspection Class II II

Material Certification (as per EN10204) 3.2 3.2

Material certification requirements stated above shall be provided by the VENDOR for all pressure parts and welded attachments. For Structural parts and equipment supports, material certification shall be as per EN10204 Type3.1. 8.3 Principal Stages of Inspection and Testing The following table gives the minimum level of source inspection which will be carried out by the CONTRACTOR and / or COMPANY or his nominated representative: STAGES OF INSPECTION


Extent of


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CONTRACTOR COMPANY Involvement H

Pre-Production Meeting Materials

Cutting

Forming

Documentation

Non DestructiveExamination

Destructive Testing

Fabrication

Verify Major Materials (Visual, dimensional, markings, analysis, properties, condition). Supplementary testing Supplementary NDE Verify other materials Material Test Certificates Transfer of markings Cutting, dress / prepare cut edges, visually inspect edges, NDE edges. NDE existing welds Check thickness Forming Heat treatment and descaling Visual/dimensional Verify/reinstate material marks Welders/operators qualifications WPS and PQR Repair procedures NDE procedures and operators qualifications Fabrication procedures Heat Treatment Procedure Hydrotest Procedure Performance test procedure Painting Specification & Procedure Progress report NDE during Welding NDE Weld repairs Select X-ray spots Review Radiographs NDE completed welds PMI checks (as applicable) NDE after PWHT Production Test Plates Production Chemistry/Ferrite Check Base ring template marking out Base ring Final dimensional Weld preparations/ fitup/ alignment/ tack welds


W/R

W/R R W/R R W/R W/R

R W W/R R W W H/R H/R H/R H/R H/R H/R H/R H/R R R W/R W/R H W/R W/R H R W/R W/R H H H/W


Date : 15.03.2015

/

Inspection and Tests

Final Inspection

Preparation for shipment

Final Documentation

Weld long and circ seams: inspect root, reverse side inspection. Welding parameters Visual inspection of welding Internal Attachments External Attachments Post Weld Heat Treatment (review of support methods, location of thermocouples etc). Dimensional check and visual Inspection for connection welds (radiography, as applicable) Additional subsurface examination Hydrostatic test Water chloride, temp, calibration test equip, supports, drying afterwards etc. Cleanliness prior to final assembly Performance Test Shop inspection Visual/dimensional inspection Completeness check Nameplate rubbing Warning plates/markings

Blasting and Painting Drying and Preservation Marking and packing Quality Plan complete Manufacturing report

W

W/R R H/W H/W W/R

R R

R W/R

R R H H H H H/R

R R R H/R H/R

8.4 Inspection / Release Requirements 8.4.1 Reports of VENDOR Surveillance VENDOR shall make available to the CONTRACTOR, on request; - Inspection Reports covering: receipt inspection, in-process inspection, sub-VENDOR inspection, and final inspection. - QA Audit Reports covering internal VENDOR audits and VENDOR audits of sub- VENDOR's. - Design Review Reports (or other evidence) covering the VENDOR review of VENDOR and subVENDOR design. 8.4.2 Certifying Authority / Independent Third Party / Authorized Inspector DOCUMENT TITLE : ADCO DOCUMENT No. xx-xx-xx-xxxx Material Requisition for Pig Traps Page 22 of 25 ADCO PROJECT No. P14395

Rev. 0

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Where required, written design approval for the material / equipment will be obtained by the VENDOR from the Certifying Authority / Independent Third Party / Authorized Inspector before manufacture commences. The VENDOR shall submit under cover of a transmittal to the Certifying Authority / Independent Third Party / Authorized Inspector, two copies of all main design drawings, calculations, weld procedures and any other requested information. Where required, the VENDOR shall arrange for ADCO approved Certifying Authority / Independent Third Party / Authorized Inspector’s survey of the material / equipment, giving due notice of all inspection points and allowing full access to his works. The VENDOR shall submit to them a manufacturing schedule together with a list of sub-VENDOR’s / locations / works / sites at which material / equipment is to be manufactured, one month before manufacture commences. The VENDOR shall issue to the CONTRACTOR a copy of all transmittals and correspondence sent to the Certifying Authority / Independent Third Party / Authorized Inspector. Upon satisfactory completion of manufacture, the Certifying Authority / Independent Third Party / Authorized Inspector will issue a release note which the VENDOR shall include in the Manufacturing Record Book. 8.4.3 Traceability Material traceability is required to ensure that the principal components of equipment and all significant bulk material can be identified against material certificates issued by the original VENDORs. It shall be the responsibility of the VENDOR to obtain the above certificates, suitably verified if appropriate as required by the VDRL. All co-ordination and expediting of the sub- VENDORs to comply with these requirements shall be the responsibility of the VENDOR. The VENDOR shall be responsible for ensuring his material control system is operating in such a manner that all principal component materials are traceable to their relevant original material certificates. 8.4.4 Inspection Release Certificates (IRC) Upon release of the material, or any part of the order, the CONTRACTOR’s inspector shall issue an IRC defining the release and recording any conditions relating to it. Where the CONTRACTOR’s inspector inspects major sub-components at the sub- VENDORs’ works, he may issue an interim IRC covering their release. These interim IRC’s shall have all the validity and the requirements of final release certificates. The IRC shall be marked with or have attached a list of references of its supporting material certificates (bulk items only). Where the list is separate, it shall also be wet stamped by the CONTRACTOR’s inspector. 8.4.5 Certification to Accompany Goods • VENDOR’s certificate of compliance / final inspection clearance • Certifying authority inspection release notes (where applicable) • CONTRACTOR’s inspection release certificate (IRC) or waiver • Test results (as applicable) • QC punch list detailing any uncompleted work (approved by the CONTRACTOR) DOCUMENT TITLE : Material Requisition for Pig Traps ADCO PROJECT No. P14395


Date : 15.03.2015

The VENDOR shall ensure that unless identified otherwise in the purchase order, as a minimum, one authenticated copy (i.e. stamped by the VENDOR as a true copy) of the above documentation accompanies goods shipped to the CONTRACTOR’s sites.

9.0

QA REQUIREMENTS 9.1 Quality System VENDOR shall operate a Quality System to the appropriate part of ISO 9001:2008 or an equally recognized national QA Standard, commensurate with the type of goods and scope of services provided. Quality system shall also comply with Shell DEP 82.00.10.10_GEN and ADCO Quality System Requirements 30.99.97.0006-1. CONTRACTOR, or appointed representative, reserves the right to carry out Quality Audits at the VENDOR's / sub-VENDOR's office and works, to verify that the Quality System requirements are being met. 9.2 Release for Manufacture Following acceptance of a Purchase Order, VENDOR shall proceed to submit documentation, order materials and place all sub-orders sufficiently early to meet the requirements of the production program. Where the requisition specifies that certain documents shall be received and cleared by CONTRACTOR before manufacture may proceed, manufacture shall be considered held until the CONTRACTORs comment status code indicates otherwise. 9.3 Non Conformities and Concessions VENDOR shall at his own expense correct any non-conformities to the Purchase Order or any feature which may affect operation, integrity or interchangeability. However, if correction of a nonconformity would prevent VENDOR meeting his schedule obligations, VENDOR shall propose appropriate action to the CONTRACTOR via a Concession Request form. CONTRACTOR’s formal written agreement on a Concession Request is required before proceeding with corrective action. Unless otherwise instructed in writing by CONTRACTOR, Purchase Order requirements shall be adhered to. 9.4 Codes and Regulations VENDOR shall ensure that all equipment and materials conform to all applicable codes and regulations, and shall obtain approval of local or national authorities or any specific approvals required by the Purchase Order. 9.5 Material Identification All material shall be identified, tagged, marked, or colour coded as stated within this document and it’s referenced specifications, standards and data sheets. If the method of material identification is not stated, a weather resistant metal tag shall be permanently affixed (not wired to a bolt hole) indicating the CONTRACTOR Requisition number and the item number.



Date : 15.03.2015

ANNEXURE-1: TYPICAL VENDOR DOCUMENT REQUIREMENT LIST (VDRL) ANNEXURE-2: TYPICAL VENDOR QUALITY REQUIREMENT FORM (VQRF) ANNEXURE-3: APPROVED SUB VENDOR LIST



Date : 15.03.2015

P14395-MR-ME-012-PIG TRAP

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