Piping Tie in Procedure Rev A

PREMIER OIL VIETNAM OFFSHORE B.V BLOCK 12W DEVELOPMENT- CHIMSAO FIELDS – HOOK-UP AND COMMISSIONING CHIM SAO PROJECT CONTRACTOR: PETROVIETNAM TECHNICAL SERVICES CORPORATION SUB CONTRACTOR: PTSC OFFSHORE SERVICES

PIPING TIE-IN / INSTALLATION PROCEDURE Document No.: VN01-205-50-91-AA-14001

PTSC/POS RE V. NO .

DAT E

A

27/1/10

PREPARED BY SUB NAME NN T

SIGN

DATE

POVO

APPROVED BY SUB NAME

SIGN

DATE

APPROVED BY PTSC NAME

SIGN

DATE

REVIEWED BY NAME

SIGN

DATE

APPROVED BY NAM E

SIGN

DATE

POVO /PTSC

POS

BLOCK 12W DEVELOPMENT- CHIMSAO FIELDS HOOK-UP AND COMMISSIONING CHIM SAO PROJECT Document No.: VN01-205-50-91-AA-14001 Revision No.: A

PIPING TIE-IN / INSTALLATION PROCEDURE

Page 1 of 16 Date: January 27, 2010

REVISION RECORD SHEET NO.

REV. NO.

CONTENT OF REVISION

DATE OF REVISION

1

A

Issued for review by Company

January 27, 2010

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TABLE OF CONTENTS SECTION

DESCRIPTION

PAGE

1.0

PURPOSE......................................................................................................... 3

2.0

SCOPE .............................................................................................................. 3

3.0

REFERENCES ................................................................................................ 3

4.0

DEFINITIONS................................................................................................. 3

5.0

PROCEDURE .................................................................................................. 4

6.0

RECORDS...................................................................................................... 13

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1.0

PURPOSE This procedure details sequence instruction for the installation of piping spools and equipment that is used by POS’s engineers and workers.

2.0

SCOPE This procedure describes the general requirements for field fabrication, offshore installation and inspection of all piping materials (except for hydraulic system, PVC) for the CHIMSAO platform. In addition to the information contained in this procedure, POS will carry out field fabrication and offshore installation work to meet the requirements of drawings, technical specification, standards and codes, as set out in the contract, should there be any conflict between this procedure and contract document, the contract shall govern.

3.0

REFERENCES VN01-205VN01-205VN01-205VN01-205VN01-205VN01-205- 30-59-SP-10004 VN01-205VN01-205VN01-205VN01-205-50-41-SY-14001 VN01-205ASME 31.3

4.0

Piping Fabrication Specification Piping Specification. Piping Standard Detail. Piping Welding Procedure Specification. Post Weld Heat Treatment procedure. Spec. for protective coating Hydro testing and Flushing Procedure. Material Control Procedure. Weld Repair and Buttering Procedure. Project HUC Execution Plan. Inspection and Test Plan Process Piping.

DEFINITIONS ANSI ASME AWS DE DSS DPT GRP GTAW MPI MT NDE NDT OD POVO POS

The American National Standard Institute. The American Society of Mechanical Engineer. American Welding Society. Destructive Examination. Duplex Stainless Steel. Dye Penetration Test. Glass Reinforced Plastic. Gas Tungsten Arc Welding. Magnetic Particle Inspection. Magnetic Testing. Non Destructive Examination. Non Destructive Testing. Outside Diameter. Premier Oil Vietnam Offshore B.V PTSC Offshore Services. Page 3 of 14

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PPM PQR PT PTW PTSC PVC QA QC RT RTJ SS SSV WPS WV ITP

5.0


Parts Per Million. Procedure Qualification Record. Penetration Testing. Permit To Work. PetroVietNam Technical Services Corporation. Polyvinyl Chloride. Quality Assurance. Quality Control. Radiographic Testing. Ring Type Joint. Stainless Steel. Safety Shutdown Valve. Welding Procedure Specification. Wellhead Valve. Inspection and Test Plan

PROCEDURE 5.1 Quality Control 5.1.1

Work Monitoring POS will provide all supervision and inspection of fabrication necessary to ensure compliance with specification requirements and the relevant codes and standards. Supervision and inspection will meet in accordance with the approved inspection procedure. (Refer above procedure as ASME B31.1, welding procedure specification, hydro test procedure, Surface Preparation and Painting Procedure… ) and Inspection and Test Plan. (VN01)

5.1.2

Fabrication Area: In generally, spools will be fabricated on deck, where they are going to be installed. Small and short spools may be fabricated at designated area and moved to their deck for installation. All possibilities for contamination of SS and high alloy materials with ferrous materials, carbon steel grinding particles shall be eliminated. SS and high alloy materials will be stored in separate areas on the timber lined floor of the stock area and will be moved by the use of web slings or by hand into clean timber / rubber lined trestles / work benches. There shall be no direct contact between carbon steel and SS nonferrous material under any circumstances. Carbon steel and SS shall be stored separately. Tools for use on stainless steel and high alloy materials will be kept in separate tool boxes under the control of the Material Controller and Foreman. Page 4 of 14

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5.1.3



Material Control Material controller will be received material and material report from vendor, They have to check dimension, condition, Quantity ,type material …Material found to be defective or incorrectly marked shall be immediately placed in a quarantine area separate from accepted material with sufficient safeguards to preclude it from being used and should be marked with QA “HOLD” label. Carbon steel and stainless steel materials will not be transported or stored in such a way as to cause cross contamination of the materials as per the Material Control Procedure. All flange faces including gasket grooves in ring joint flanges shall be protected by plastic cap, plywood or equivalent method. All materials, whether loose or prefabricated will be stored as per the Material Control Procedure. Materials/Spools which have been damaged or found to have defects will not be used except where there are only minor surface marks, in which case POS will obtain approval from POVO. The materials shall be dressed provided the minimum wall thickness is not reduced and the manufacturing tolerances defined in the appropriate material or purchasing specification are complied with. Radial grooves or scratches on gasket faces are not allowed. Refacing/machining will require POVO’s approval. Any re-facing that reduces the flange thickness to less than the minimum thickness allowed by the relevant code or standard is rejected. Edge thickness of flange will be checked after re-facing.

5.2 Fabrication & Installation Sequence 5.2.1

Spool Fabrication & Installation Flow The spool fabrication & installation will be implemented with the sequence of fitting in location and marking; cutting; fit-up; Welding; NDT; PWHT (if any) hydro-test; installation and bolt up; bolt torque applying; support installation; leak test( if required) and touching up painting. The above activities shall be in accordance with the approved ITP.

5.2.2

Fitting in & Marking Spools identification and inspection: Check the tags of spools and double check based on isometric shop drawings. Inspect for any damage on spool especially on flange faces. POS Offshore PTW ( Hook-Up activities.

) shall apply for all piping and equipment

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Arrange lifting gear: All lifting gear and lifting arrangement must be checked by authorized riggers. Lifting gear shall current certification and colour coded accordingly. Lift and move spools to their location, temporary support, alignment, fit in and mark. 5.2.3

Cutting and Edge preparation Carbon steel shall be cut by methodology of flame cutters, high speed cutters, grinders or band saw machines. SS shall be cut by a high speed cutters, grinders, plasma cutting or band saw machine. All cutting tools shall be compatible materials for SS to avoid any contamination. All materials cut by a flame or arc shall have the cut edge ground back to clear the heat affected zone. The grinding wheel is marked by an impregnated red dye in the make-up of the disc which denotes chloride and sulfur free material when used for SS and high alloys. Wire brushes with stainless steel bristles will be used, dedicated to SS and high alloy materials. Files for use on stainless steels and non ferrous alloys shall be new and dedicated to a particular alloy only. All edges shall be accurately maintained as per design requirement with a smooth even surface with all slag removed. Beveling will be performed with a beveling machine or grinder. Separate machine will be used for carbon steel and SS. Preparation will be in accordance with the approved WPS.

5.2.4

Edge Preparation for Welds The preparation of edge for welding shall be done by machining or grinding. Edge preparation shall be performed in accordance with the approved WPS & ANSI /ASME B31.1. The surfaces of the edge preparation shall be free from tears, grease, oil slag, scale or internal burrs. Stainless steel and high alloy pipe shall be beveled by a grinding or beveling machine only. Separate machines will be used for carbon steel and stainless steel.

5.2.5

Fit –up Alignment for the fit-up of the piping components shall be executed at it’s final location on the temporary supports. For SS and high alloy spool fabrication the supports will be covered with wooden planks or rubber for insulation so that can prevent contamination of the spools. Under no circumstances shall stainless steel, high alloy & non ferrous materials be allowed to come into contact with carbon steel. Page 6 of 14

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Pipe shall be properly supported and aligned by jigs or clamps in order to eliminate strains prior to tack welding in accordance with the approved WPS. Where jigs or clamps are used for stainless steel and high alloy fabrication, these items will be lined with clean rubber or stainless steel material to eliminate the possibility of contamination with other project material. The internal radial misalignment for bore up to 100 mm should not exceed 1.0 mm. If exceed, it shall be taper-trimmed, machining may be conducted to improve root alignment providing the taper is not steeper than 1 in 4. Misalignment may be alleviated by the use of hydraulic or screw type clamps. Hammering, jacking or heating the pipe is not permitted. Tack welding shall be performed by qualified welders using the same qualified welding procedures and electrodes as will be used for the main weld. All tack weld which will form a part of the main weld shall be cleaned ground down to a feather eage at both ends and visually inspected prior to welding the root pass Cracked tack welds and temporary tack welds shall be removed by grinding to a smooth finish, followed by MT/PT of the affected areas. The length and number of tack welds for the diameter of pipe being welded shall be specified as follows (see table): Nominal OD (mm)

Length of Tack (mm)

Number of Tack

Up to 50

Min 10

Min 3

50 to 150

10 -15

3 -4

Over 150

20 -25

3 -6

The bolt holes of flanges shall straddle the normal horizontal and vertical centerline of pipe. 5.2.6

Welding Minimum spacing of circumferential welds between center lines shall be minimum two (2) pipe diameters or six inches (6”) whichever is less. In restricted circumstances minimum spacing shall not be less than four (4) times the wall thickness or one inch (1”) whichever is the greater. Long seam of pipe (if any) shall not be located below of pipe. It should be located at less 45 degrees from bottom of pipe. All welds shall be performed in accordance with the approved WPS which shall be displayed on a notice board close to the work. The welding grooves and root gap shall conform to the approved WPS All edges of surfaces to be welded shall be cleaned to a bright metal finish, in a Page 7 of 14

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manner suitable to remove any oxides, scale, grease, oil, or contamination due to flame cutting or machining. Oil paint and dirt shall be removed from the pipe surface, for at least one (1) inch from the bevel before welding is started. Cleaning must be carried out just prior to tacking and repeated just prior to welding. Stainless steel wire brushes shall be used for all other materials except carbon steel and low alloy steel. No sealing or back-up rings shall be used. Any cracks, blowholes, cold laps, unusual irregularities, slag, flux, or other impurities that appear on the surface of any welding bead shall be removed by grinding or chipping before depositing the next successive bead. The requirement of the finished weld reinforcement for all materials shall comply to ASME B 31.3 specification for piping. If arc strike occurs, this shall be removed by grinding followed by MT or DPT. For new piping, the acceptable wall thickness is the thickness as calculated inclusive manufacturing tolerances, corrosion and erosion allowances. If pipe is ground severely to repair, the damaged part of the pipe shall be removed. Internal purge of argon shall be used for the GTAW process root pass on stainless steels as specified by WPS 1. Purging will be carried out by using the best method for the particular application during welding. 2. Each end of the pipe adjacent to the weld of tie in spools shall be dammed by using water soluble paper or sponges at a distance of 150mm from the weld edge preparation. Prior to the commencement of welding of SS, the weld preparation area and filler metals shall be cleaned with acetone and clean rags without excessive rubbing of the surface. Physical touching of the weld preparation area without clean gloves is prohibited. 3. For all materials, pipe butt joint of 2 inches and below shall be made entirely with GTAW process. 4. The GTAW process shall be used for root pass of all diameters. 5. A dedicated experienced SS welding Inspector shall be assigned during fabrication and welding of all SS material. 6. All Shielding gas to be used during SS welding shall be 99.9% argon. Gas shielding shall extend for at least 30 seconds after completion of weld to prevent gas pore entrapment while element is solidifying and still hot. The sketches demonstrate: Page 8 of 14

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Weld

7. All markers to be used for SS for identifying the weld joins and line number etc. shall be free of sulfur content. 8. During the welding process of SS, an oxygen analyzer must be in place to monitor the oxygen content on all weld joints. The allowable oxygen content during welding shall not exceed 500 ppm as per approved WPS. 9. The use of a mechanical brush for cleaning weldments of SS is not permitted. The use of pickling paste is preferred. No undercut or overlapping (cold lap) is permitted. Weld projection and depression. The specification for weld projection and depression shall be in accordance to ANSI B 31.3, Table 341.3.2, as applicable. Preheating and inter pass shall be maintained as per approved WPS Peening and hammering of weld runs are prohibited. Storage and issue of consumables shall be controlled by Electrode Manufacturer Instructions and approved procedure. Qualification of welders and welding operators shall be as below: 1. Performance qualifications will be carried out for all welders and welding Page 9 of 14

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BLOCK 12W DEVELOPMENT- CHIMSAO FIELDS HOOK-UP AND COMMISSIONING CHIM SAO PROJECT Document No.: VN01-205-50-91-AA-14001


Revision No.: A


operators in accordance to WPS. 2. All welders should always keep their identification cards at all times with their name and number plus a photograph, signed by POS and POVO 3. The qualification limits and ranges for welders will be based on ASME IX. 4. The acceptability of the test weld shall be judged as follows.

5.2.7

5.2.8

•

Visual inspection by inspector: Root bead and surface of weld.

•

Burn thru during application of hot pass and subsequent passes, after visual acceptance, is cause for immediate disqualification.

•

Radiographic examination in accordance with ASME B 31.3.

Temporary Attachments •

Piping fabrication and installation shall be achieved by use of clamps, jigs, fixtures, etc.

•

The use of cleats, bridge pieces, tacking strip or other attachments welded temporarily to pipe work to facilitate fabrication shall be of the same or equivalent material as the pipe work to which they are supposed to be attached.

•

Initial fitting up can be achieved using temporary bridge tacks across the groove.

•

All area to be attached by welding shall be inspected by MT or PT.

Material Segregation Direct contact between carbon steel and stainless steels or non-ferrous alloys is not permitted unless authorized and approved by POVO. Tools and wire ropes containing carbon steel, grinding wheels and discs contaminated with carbon steel shall not be used on stainless steel and nonferrous alloys.

5.2.9

Tolerance The dimensional tolerance should be in accordance with figure 2 below.

Figure 2 Pipe Fabrication Tolerances

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5.

5.2.10 5.2.10

5.2.10 Inspection, NDT , PWHT (if any) and Repair of Defects Visual inspection and NDT to ASME V and ASME VIII shall be carried out per approval welding inspection procedure and performed in accordance with ANSI Page 11 of 14

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Revision No.: A


B 31.3 for piping. All welding shall be 100% visually examined. Extent of NDE shall be in accordance with the line class as noted on the AFC isometric drawing. All final examinations shall be performed after carry out post weld heat treatment Root concavity is not permitted. (Refer to: ANSI B 31.3 table 341.3.2, as applicable) Undercut shall be limited to 0.5mm occasional, intermittent. No internal undercut is allowed. The surface of repair welding will be cleaned thoroughly before welding in accordance with applicable WPS. All repairs shall meet the inspection requirements and acceptance standards for the original material. Repair welding shall be performed in accordance with repair procedure. 5.2.11 Hydro-testing, Flushing Drying: This work shall be performed in accordance with hydro-test procedure 5.2.13 Installation and Bolt up Gasket •

Gaskets shall be treated in accordance with manufacturers' instructions. Gaskets shall be replaced after opening or dismantling of flange connections

•

After cleaning the flanges for make-up, dry gaskets shall be inserted. Flat gaskets shall be centered by the flange bolts. Centering rings of spiral wound type or RTJ type gaskets shall be properly centered.

Flange joint: •

Before assembly, flanges shall be clean and free from any deleterious matter (e.g rust, dirt or other contamination) and totally free of damage on the gasket or sealing face / groove.

•

Flange alignment shall be checked for both lateral alignment and parallelism alignment.

•

The measured lateral misalignment shall not exceed 2mm for pipe size ≤ 100 mm, and shall not exceed 3mm for pipe size >100 mm .

•

The measured parallelism misalignment for all size, rating of ASME B 16.5 flange is 2.5 mm/m.

•

Flange face misalignment shall be checked and the acceptable tolerances Page 12 of 14

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Revision No.: A


shall not exceed the tolerance specified. •

Flange bolts shall be tightened by torque or tensioning evenly and sequentially to impose equal pressure on the gasket and to avoid distortion or overstressing of equipment.

5.2.14 Pipe supports Installation: Pipe supports shall be installed after pipe spool installation completed. Pipe supports shall be in accordance with the relevant pipe support detail drawings. Piping shall not be forced to fit with support locations in such a manner that additional stress is introduced. Visual Inspection and NDE shall be conducted by approved Welding Inspector and Technicians. 5.2.15 Painting Final painting of all field butt welded joints shall be applied only after successful completion of hydrostatic test. A protective coating will be applied in accordance with the Client specification and approved painting procedure. 5.2.16 Insulation: This work shall be performed in accordance with insulation procedure (Procedure No: ) 5.2.17 Mark and Tag: All spool after finish will be marked and hung tag name. Tag name have been written with name of that spool. Describe the type of tags and how they are fastened. Ie Stainless Steel, Traffolite etc. 6.0

RECORDS POS shall generate quality records from the inspection test activities in accordance with this procedure and the approved Inspection and Test Plan. The records shall be compiled and reviewed by POS and approved by the Client Representative following the completion of each inspection and test. Records, Certification etc. shall be compiled progressively as inspection and testing proceeds and available for Client Representative review throughout the contract period and thereafter retained in accordance with the contract requirement. POS shall ensure that all changes made to pipework and piping fabrication drawings, are properly recorded as “Red line mark up” drawings and that they accurately match the installed condition of the pipework. These drawings shall be subject to review and audit by the Client Representative. POS shall compile the following quality records as a minimum and clarify by POVO: Page 13 of 14

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•

Weld procedure qualification records

•

Welders qualification tests and welder register

•

Fit-up Inspection Reports

•

Weld Visual Report

•

NDT Reports

•

Weld Maps / Weld Completion Summary

•

Coating / Insulation Records

•

Post Weld Heat Treatment Records

•

Hydrostatic Packages

•

Leak Test Packages

•

Red line mark up / As Built drawings

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Piping Tie in Procedure Rev A

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