Petroleum Development Oman LLC
Revision: 0 Effective: Sep-08
Petroleum Development Oman L.L.C. RESTRIC TED Feb-13
Document ID: SP-2069 Filing Key: Business Control
[MECHANICAL ENGINEERING] Specification for Pressure Vessels
User Note: The re The requ quire iremen ments ts of thi this s doc docume ument nt ar are e man mandat datory ory.. No Non-c n-comp omplia liance nce sh shall all onl only y be authorised by the Document Owner or his Delegate through STEP-OUT STEP-OUT approval. approval.
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Petroleum Development Oman LLC
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Document Authorisation
Authorised For Issue
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Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all revisions prior to these are held on file by the issuing department. department.
Version No.
Date
Author
Verison 0
Sep 08
E.S. UEP/12M
iii
Scope / Remarks
Mahadevan,
Specification for Pressure Vessels Initial issue.
Related Business Processes
Code
Business Process (EPBM 4.0)
EP.6 EP.64 4
Desi Desig gn, Con Constr struct, ct, Mod Modify ify and and DeDe-C Commi ommis ssion sion Facili ciliti tie es
iv Related Corporate Management Frame Work (CMF) Documents The relate related d CMF Docume Documents nts can be retri retrieved eved from the Corp Corpora orate te Busine Business ss Contr Control ol Documentation Register TAXI Register TAXI
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TABLE OF CONTENTS 1 INTRODUCTION........................ ........................... ........................... ................................6 1.1 PURPOSE AND OBJECTIVES........................... ........................... ..............................6 1.2 CHANGES TO THE SPECIFICATION........................ ........................... ......................7 1.3 DEFINITIONS......................... .......................... ........................... ......................... ........7 1.4 USAGE......................... .......................... ........................... ........................... ................9 2. APPLICABLE STANDARDS, SPECIFICATIONS AND CODES....................... .............10 2.1 COMPANY STANDARDS........................... ........................... ....................................10 2.2 SHELL GROUP STANDARDS....................... ........................... .......................... .......10 2.3 SHELL STANDARD DRAWINGS........................... ........................... .........................11 2.4 INTERNATIONAL STANDARDS........................... ........................... ....................... ...13 2.5 COMPANY AND SHELL GROUP STANDARD DATA / REQUISITION SHEETS... ..13 2.6 LIST OF COMPANY APPROVED SUB-VENDORS..................................................13 2.7 COMPLIANCE WITH STANDARDS......................... ....................... ..........................14 2.8 LANGUAGE AND UNITS OF MEASUREMENT.......................... ..............................14 2.9 CONFLICTING REQUIREMENTS....................... ........................... ...........................14 3 SCOPE OF SUPPLY........................... ........................... ........................... .....................15 3.1 MECHANICAL EQUIPMENT........................ ........................... ........................... ........15 3.2 SERVICES
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7.2.3 Test Certificates ..................................................................................................26 7.3 METHOD OF DOCUMENTATION TRANSMISSION........................ .........................26 7.4 IDENTIFICATION........................... ........................... ........................... ......................26 7.5 DATA.......................... ........................... ........................... ........................... ...............26 7.6 TRANSMITTAL.......................... ........................... ......................... ............................26 7.7 MANUALS........................... ........................... ........................... .................................27 7.8 RECORD CARDS.......................... .......................... .......................... ........................27 8. PACKAGING & PRESERVATION FOR SHIPMENT ....................................................28 8.1 PACKING REQUIREMENTS......................... ........................... .................................28 8.2 CRATING IDENTIFICATION........................ .......................... ........................ ............28 9. PLANNING & SCHEDULING......................... ........................... ........................... ..........30 9.1 GENERAL....................... ........................... ........................... .....................................30 9.2 MEETINGS........................... ........................... ........................... .......................... ......30 9.2.1 Kick-off Meeting.......................... .......................... ........................... ....................30 9.2.2 Vendor pre-manufacturing Meeting........................ ........................... ...................30 9.2.3 Review Meetings....................... ........................... ........................... .....................31 9.3 REPORTING........................ ........................... ........................... ................................31 9.4 PURCHASE ORDERS......................... ........................... ........................ ...................31 APPENDICES :
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This Document is fully restricted for PDO. The accessibility for this document shall be maintained by PDO Mechanical Corporate Functional Discipline Head (CFDH) and his technical focal point. SP's shall be prepared and revised in accordance with ERD-00-10 'Proposal, Production, Issue and Maintenance of Engineering Reference Documents'. This specification together with standard drawings, SPs, ERDs, DEPs as mentioned in section 2 sets out the minimum requirements for the design, engineering, supply of materials, fabrication, assembly, inspection, testing, transportation, installation, commissioning supervision, functionality and supply of Pressure Vessel package. It has been written in a format that enables the Project engineer and the Consultant to easily and uniformly prepare a requisition and purchase Pressure Vessels, storage (atmospheric) vessels, pressure parts of filters, shell & tube heat exchangers etc. for a variety of applications in PDO. Users shall consult the current list of PDO approved manufacturers/suppliers. For a specific purchase the Consultant shall: Follow this specification in general and do not require to produce additional specification. But in case of any project or equipment specific requirements, which are different from the ones specified in this specification, shall be prepared and attached as an amendment/addition to the particular sections of this specification. Ensure that the Vendor receives the applicable documentation listed in subsections 2.1, 2.2, 2.3 & 2.5. Ensure that procedures for Vendor Drawings/Documentation are in accordance with SP-2047 'Preparation and Content of Engineering Drawings' and Section 7 of this specification.
Petroleum Development Oman LLC
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on the description that f ollows if other components/equipments required
Company /Principal Consultant -
EPC Contractor
Purchaser Scope
User Vendor/Supplier
Sub-Vendor
Inspector
Others
Petroleum Development Oman L.L.C. Muscat, Sultanate of Oman. A contracted party by the Company who is responsible for providing design engineering and other related consultancy service under a contract. - A contracted party by the Company who is responsible for providing design engineering, procurement and construction service under a contract. - A party, who places the order on, or requests tender from, the Vendor/ Supplier. This can be the Company/ EPC contractor. - All works executed and all services carried out by the Vendor/Supplier in accordance with this Specification and its referenced standards and data sheets. - A responsible party who applies this Specification in the procurement of specified equipment. - A party responsible for the supply of equipment, materials or productrelated services in accordance with this Specification and its referenced standards and data sheets. All Sub-Vendors shall be subject to written approval by the Company. All terms and conditions applicable to the Vendor shall be applicable to the Sub-Vendor as well. - A party appointed by the Vendor for supply of equipment, materials or product-related services in accordance with this Specification and its referenced standards and data sheets. - Any person/party whom the Purchaser certifies as acting for and on behalf of the Company to inspect items to be purchased and/or the work done by the Vendor/Sub-Vendor. - Any party contracted by the Purchaser to supply equipment, services, material which are not part of the scope mentioned in this specification.
Petroleum Development Oman LLC
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TPI / TPIA
Third Party Inspector / Third Party Inspection Agency or Authority
UT
Ultrasonic Testing
NOTE: Contractors, Consultants, Suppliers, Vendors and users SHALL ensure the Company is consulted for any deviations from "SHALL" and "SHOULD" requirements.
1.4
USAGE
This Specification together with the referenced standards and data sheets shall form the purchase requisition package for Pressure Vessels, storage vessels, filters, etc. as required by the Company. The Consultant / EPC Contractor may consider augmenting this SP under exceptional circumstances where it may not precisely meet either enquiry or purchase requirements (eg. In case of special equipment). Nominally it is anticipated that this SP and data requisition sheets should finalise fully meaningful enquiry and purchase without generating additional documentation. Under certain exceptional cases the additional requirements, project or equipment specific special requirements/changes shall be specified as a separate amendment to this SP subjected to approval by the Company. ADHERENCE TO SPECIFICATIONS The Vendor shall provide an itemized list of any additional projects specific comments or exceptions to this specification and its appendices. These shall be listed on the Table of
Petroleum Development Oman LLC
2. APPLICABLE CODES
STANDARDS,
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SPECIFICATIONS
AND
This SP shall be read in conjunction with the latest revision of the following Standards, Specifications and Codes. All listed documents, ERD, SP, DEPs shall be the latest issue at the time or Purchase order. The international standards shall be read in conjuction with the corresponding DEP amendment. It should be noted that references to DEP's and International standards within this SP are based on the current revision of those standards at the time of publication of this SP. The Vendor is deemed to be in possession and familiar with specifications, standards listed being a regular supplier to Company. If any of the documents listed are not in the Vendor’s possession, same shall be obtained from the Consultant / Purchaser. Not possessing the referred standards / specifications shall not be a cause for deviation or non-compliance. Including this SP the following engineering specifications shall be followed:
2.1
COMPANY STANDARDS
GU-256
Static Equipment Inspection Guideline
GU-556
Guideline for Vendor Project Document Deliverables
ERD-06-01
Instructions for Packing and Corrosion Prevention of Plant Equipment & machinery.
PR-1013
Static Equipment Inpsection and Maintenance Procedure
PR-1708
Lifting and Hoisting – Inspection, Testing and Certification
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DEP 02.00.00.10-Gen
Preparation and microfilming of technical drawings
DEP 30.10.02.11-Gen
Metallic Materials-Selected Standards
DEP 30.10.02.31-Gen
Metallic Materials-Prevention of Brittle Fracture
DEP 30.10.60.18-Gen
Welding of Metals
DEP 30.46.00.31-Gen
Thermal Insulation
DEP 31.10.00.10-Gen
Material Traceability and Positive Material Identification (PMI)
DEP 31.10.03.10-Gen
Symbols & Identification System – Mechanical
DEP 31.20.20.31-Gen
Internals for Columns
DEP 31.22.05.11-Gen
Gas/Liquid Separators – Type selection and design rules
DEP 31.22.05.12-Gen
Liquid/Liquid and Gas/Liquid/Liquid (three-phase) Separators – The selection and design rules
DEP 31.22.10.35-Gen.
Manufacturing Reports for Pressure Vessels
DEP 31.22.20.31-Gen
Pressure Vessels (Amendments/Supplements to ASME Section VIII, Div 1 and Div 2)
DEP 34.00.01.30-Gen
Structural design and engineering
DEP 34.19.20.11-Gen
Fire Proofing of Steel Structures
DEP 39.01.10.11-Gen
Selection of Materials for Life Cycle Performance
DEP 70.10.90.11-Gen.
Spare Parts.
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S 20.016
Typical details of Schoepentoeter (vane feed inlet) (type III)
S 20.017
Typical details of Schoepentoeter (vane feed inlet) (type IV)
S 20.019
Typical details of Schoepentoeter (vane feed inlet) Vane laddersupports and general notes
S 20.020
Typical details of schoepentoeter (vane feed inlet) with single section vane ladder, max. height 800 mm (type 1A)
S 20.021
Typical details of schoepentoeter (vane feed inlet) with catcher cap (type 1B)
S 20.022
Typical details of schoepentoeter (vane feed inlet) with multiple section vane ladder (type 1C)
S 20.025
Typical details of schoepentoeter (vane feed inlet) (type Hi Fi)
S 20.026
Typical details of schoepentoeter (vane feed inlet) (type Hi Fi) vane distribution and general notes
S 20.028
Typical details of Demisters
S 20.029
Typical details of Demister attachments
S 20.030
Typical details of Demister supports
S 22.001
Saddles for Horizontal vessels- Shell dia. Nom 150mm OD upto and Including 1000mm OD.
S 22.002
Saddles for Horizontal vessels- Shell dia. 1050mm OD upto and Including 3600mm OD.
S 22.003
Sliding plates for saddles of horizontal vessels.
Petroleum Development Oman LLC S28.022-002
Grating, type II (sheet 2 of 3)
S28.022-003
Grating, type III (sheet 3 of 3)
S28.023
Fastening of apparatus to fireproofed beams
2.4
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INTERNATIONAL STANDARDS
ASME Section VIII Div.1
ASME Boiler and Pressure Vessel Code – Rules for Construction of Pressure Vessels
ASME Section VIII Div.2
ASME Boiler and Pressure Vessel Code – Alternative Rules for Construction of Pressure Vessels
ASME Section V
Non-Destructive Examination
ASME Section IX
Welding and Brazing Qualification
ASME B 16.5
Pipe Flanges and Flanged Fittings
ASME B 16.47
Large diameter steel flanges NPS 26 thro’ NPS 60
NACE MR0175 / ISO Sulfide Stress Cracking Resistant Metallic Materials for Oil-field 15156 Equipment ISO 10474
Material Testing Certificates
ISO 9001: 2000
ISO Quality System
Petroleum Development Oman LLC 2.7
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COMPLIANCE WITH STANDARDS
The Vendor/ Supplier shall complete the Table of Compliance (Appendix-4) and highlight deviations if any from standards and specifications. The Purchaser shall obtain the written approval from the technical authority within the Company for any deviations from this Specification. Only those deviations that are approved by the Company shall be deemed to be part of the scope. In all cases the Company shall determine the compliance of the design carried out and works executed by the Vendor/Supplier in accordance with this Specification.
2.8
LANGUAGE AND UNITS OF MEASUREMENT
The English language and the SI system in accordance with DEP.00.00.20.10-Gen of units shall be used throughout for all documentation and drawings. Where necessary for a specific application, alternative units may be indicated in brackets together with the SI units.
2.9
CONFLICTING REQUIREMENTS
All conflicts between the requirements of this specification, related specifications, standards, codes, requisition data sheets and data sheets shall be referred to the Company for clarification before proceeding with the manufacture of the affect ed parts. Vendor shall make a formal request with full supporting information when a deviation from standard is required. Vendor is requested to notify any inaccuracy or ambiguity encountered in this document. Nothing contained in this specification and related documents shall be construed as relieving
Petroleum Development Oman LLC
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3 SCOPE OF SUPPLY The scope of supply shall include but not limited to the equipment and services defined below, detailed in this specification, on the attached data or data/requisition sheets, standard drawings and in accordance with the applicable standards, specifications and codes. The Vendor shall supply complete, assembled and tested equipment including, but not limited to, the scope of supply detailed below unless otherwise specified. Items which are optional and required only if specified are marked with an asterisk ( *) below. The Supplier’s scope of supply shall include, but not be limited to:-
3.1
MECHANICAL EQUIPMENT
a)
The equipment complete with all parts including supports, spares etc..
b)
All Internals viz. schoepentoeter, demister mat, internal dip/header pipe, vortex breaker, baffles, column trays, plate packs etc. as applicable and specified in the specification/datasheets including supports for internals.
c)
Manhole with davit arrangement.
d)
Lifting lugs / trunnions, cleats/clips for pipe support, ladder, platform, insulation, & fireproofing (if required) etc.
e)
The vessels shall be provided with ASME code stamp.
f)
Fabrication, supply, certification & guarantee of the equipment and internals.
g)
Surface preparation and painting as per SP-1246 Part 1 to 5.
h)
Earthing bosses for each equipment.
Petroleum Development Oman LLC
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indicated in the RED form to enable processing and ordering spare parts such that these can be delivered within the period of the purchase order. Spare parts shall be individually priced per article to facilitate ease of comparison between Vendors, & also to allow meaningful decision making when compiling the final selection to be reflected in the purchase requisition Vendor’s recommendations should then be reconciled with Company’s experience / suggestions in order to formulate an essentially common list spares for all Vendors to quote against including any special tools required.
3.4
ENGINEERING SERVICES
This specification shall in no way relieve the Vendor from final guarantee as to material, equipment, workmanship and performance of the vessel. The Vendor shall assume overall responsibility for the design and engineering of all equipment supplied, as indicated in this specification. This shall include, but not necessarily be limited to: a)
Resolving engineering questions relating to equipment within the scope of supply.
b)
Providing / coordinating the complete detailed mechanical design as specified in this specification and the referenced specification, standards and / or the datasheets for all equipment & components within the scope of supply (including foundation loads & calculation and design of internals like Schoepentoeter, demister etc. as per DEP/other standards).
c)
Inspection and Testing along with material certification.
d)
Company approved 3 rd party inspection agency to be appointed by the Purchaser for
Petroleum Development Oman LLC
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i)
Process design (eg. Internals design) / performance as specified in data/requisition sheet included in Appendix-2 of this specification.
ii)
Mechanical design, structural integrity, material and workmanship.
iii)
If any defect or mal-performance is observed during the guarantee period, the Vendor shall make all necessary alteration, repair or replacement free of charge.
Unless a specific exception is given in the Vendor’s tender, it shall be understood that he guarantees and agrees to the above.
3.6
EXCLUSIONS
The following are excluded from the Vendor’s scope of supply, however, shall be part of Purchaser’s scope: •
•
•
•
Concrete foundation design based on Vendor supplied technical data. External access ladder / operation platform / grating / handrailing / pipe supports (but Vendor shall provide suitable support clip/cleats for these parts. Vendor shall quote unit price on per kg. basis for ladder, cleats, supports and per sq. metre basis for platform). Anchor bolts. Lifting & hoisting (but Vendor shall provide weight of all equipment parts which are to be removed / installed during installation & maintenance). Site installation and commissioning (optional).
•
•
Any instrumentation.
Petroleum Development Oman LLC
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4. DESIGN 4.1
MECHANICAL REQUIREMENTS
4.1.1
The equipment shall be designed, fabricated and tested in-accordance with DEP 31.22.20.31-Gen., ASME VIII Div 1 / Div.2, as indicated on the datasheets attached in Appendix-2. In addition to the design approval and code stamping by the authorized inspection agency, the Purchaser shall appoint a Company approved 3 rd party inspection agency, who are different from the authorized inspection agency for certification of design and inspection.
4.1.2
Process design (calculation) for internals, mechanical design of all parts of the vessel are responsibility of the Vendor.
4.1.3
All equipment shall be designed for a service life of 30 years.
4.1.4
All the internals shall be assembled at the Vendor’s works to check for proper fit and alignment. To avoid damage during transportation/installation, the internals shall be removed prior to transportation and delivered loose in separate cratings alongwith site installation procedure. Generally, internals shall be of removable type and should be bolted to the internal supports and direct welding to equipment wall should be avoided, but whenever internals are required to be welded to equipment wall, Vendor to obtain necessary approval from the Company.
4.1.5
All of the equipment internals shall be designed and constructed so that it is possible to remove them through the manhole.
4.1.6
All flanges shall be generally of the welding neck raised face (WNRF) or long weld neck raised face (LWNRF) type, 3.2-6.3 microns face finish as per ASME B 16.5,
Petroleum Development Oman LLC
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4.1.14 All bottom head piping which penetrate vertical pressure vessels inside the skirt shall be extended outside the skirt with pipe flanged in the horizontal run. Welding of nozzles or piping to vessel skirts shall not be permitted. Skirt penetration point shall be reinforced with a sleeve three (3) sizes larger than the bottom head piping. Gusset plates shall be provided to the bottom head piping at the skirt penetration point, and in no case shall the gusset plates be welded to the sleeve. Adequate openings shall be provided f or maintenance access to the flange. 4.1.15 Flange inside diameter shall be same as that of mating nozzle neck/shell inside diameter. 4.1.16 Nozzles shall not be located on longitudinal weld seams and shall avoid girth seams. 4.1.17 All external bolting of external flange joints shall be A193Gr.B7/A194Gr.2H with nonmetallic coating (eg. fluorocarbon top coating). The nut shall be of heavy hexagonal type. 4.1.18 The equipment supports shall be designed to withstand all induced stresses by transportation & installation, wind load, operating conditions and pressure testing. 4.1.19 The material and inspection test certification shall be according to ISO 10474 - 3.1B / EN 10204 – 3.1. 4.1.20 Vendor shall provide complete calculation to demonstrate the integrity of all components including but not limited to Code calculations, nozzle local loading, lifting lugs, hold down bolting, transportation and wind loading. 4.1.21 Asbestos in any form shall not be used as material for any item, including the packaging. Molybdenum disulphide compounds shall not be used for any screwed item.
Petroleum Development Oman LLC
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4.1.33 For vessels with internal weld overlay, the undiluted chemical composition requirement of the overlay shall be ensured by using a two-layer technique in which the first layer is applied with a low heat input. 4.1.34 The equipment data sheets are included in Appendix-2. Vendor shall submit updated completed data sheet along with the offer. 4.1.35 According to the wind speed defined in the environmental and site condition in Appendix-1, wind pressure shall be defined according to SP-1275 and DEP 34.00.01.30-Gen, considering 3-second gust as the wind speed to be used in the design. 4.1.36 For sizing of anchor bolts, Vendor shall consider the maximum allowable tensile stress of bolt material as 100 N/mm 2 only. 4.1.37 The Vendor shall provide all details required for the foundation design such as foundation loads, lay-out and positioning of foundation bolts alongwith template, requirement of leveling plates, etc. the Vendor shall provide clear drawings and instructions well in advance. The Vendor shall indicate the location, weight, and space requirements for equipment parts, to be removed for normal maintenance. This will enable the design of hoisting facilities above the equipment (by others).
4.2
MATERIALS OF CONSTRUCTION
All materials shall be as specified in the datasheets attached in Appendix-2. However, Consultant/EPC Contractor to confirm the suitability of the specified materials for the process conditions. All materials for sour service environment shall be in accordance with
Petroleum Development Oman LLC
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5. QUALITY ASSURANCE 5.1
GENERAL
The Vendor shall comply with the requirements of Company’s Specification for Quality Assurance of Design, Construction and Engineering Works SP-1171. The Vendor shall appoint an Authorized Inspection Agency from one of the Company approved agencies. The Vendor shall submit with the bid, the name of the Authorized Inspection (AI) agency that will be contracted to provide inspection services, in accordance with the requirements of the specifications, codes and SP-1171. The Purchaser shall nominate a Third Party Inspection Authority (TPIA) to carry out the Quality Assurance function on the Purchaser’s behalf. The Purchaser’s TPIA shall have the same access as the Purchaser to the Vendor’s Quality System and the manufacturer’s premises to carryout inspection activities. The requirements as per SP-1171 are listed below in brief. The full requirements are as stated in SP-1171.
5.2
QUALITY SYSTEM
The Vendor shall maintain and use a Quality System, which is based on ISO 9001:2000, to control the work and assure the quality. The Vendor selected sub-contractors, or suppliers-shall demonstrate that they operate Quality Systems based on ISO 9001:2000.
Petroleum Development Oman LLC
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6. INSPECTION & TESTING REQUIREMENTS 6.1
INSPECTION REQUIREMENTS
Inspection and testing requirements shall be in accordance with the applicable Company, Shell Group and International standards, with the relevant sections of this specification and the data sheets. The Vendor shall specify all of the inspection and testing requirements in the ITP which shall identify the activities requiring the Purchaser's approval, review, witnessing etc. A typical ITP is attached in Appendix-8. Purchaser reserves the right to inspect every component or item, which will form part of the pressure vessel. The responsibility for the inspection, certification, etc. of all materials, parts, etc. lies with the Vendor. Not withstanding the above, the Purchaser or his authorized representative shall have free access to all parts of the Vendor's and his Sub-Vendor’s works at all times during the manufacturing period. The Vendor shall be responsible for coordinating the inspection and testing of Sub-Vendor supplied equipment, and for ensuring that the Purchaser's representatives are given the necessary access for inspection, and adequate warning of inspection and witness tests. The Vendor (and all Sub-Vendors) shall give the Company, as required, without charge, all
Petroleum Development Oman LLC
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All welding and welding consumables shall be in accordance with DEP 30.10.60.18-Gen, unless indicated otherwise in this specification. Only Low Hydrogen welding consumables shall be used. Diffusible Hydrogen level shall be less that 10ml/100g weld metal, unless agreed and approved by the Purchaser. All welding consumables shall have specified mechanical properties equal to or greater than the material being welded, unless agreed and approved by the Purchaser. The Vendor shall supply all necessary equipment and record welding variables during the Procedure Qualification Record (PQR) Test, production welding and weld qualif ication tests. Prior to the start of production welding all WPS with supporting PQR shall be submitted for approval to the Purchaser. Where it is demonstrated that on nozzle / branch weld neither radiography nor ultrasonic examination can be performed, the root pass after deposition and the weld shall be examined visually and subject to MT / LT. All components including plates, forgings, fittings, welding consumables etc. shall be checked for impact test requirements to the specified lower design temperature (LDT) as the minimum design metal temperature (MDMT) to meet the applicable codes and standards. Vendor shall confirm with the material supplier the required impact test value at specified LDT conform to the specified impact value as per DEP 30.10.02.31-Gen and applicable codes and standards. Certified Material Test Report shall clearly specify the test results. PWHT shall be performed as per the code requirements and as specified in the equipment datasheet. Positive Material Identification (PMI) shall be carried out on all wetted parts material.Vendor
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Any defects found by the TPIA shall be rectif ied in his presence. Where this is not possible or practical, checklists shall be prepared and signed by the TPIA stating all 'pending items'. Copies of these lists shall be sent to the Purchaser to enable their subsequent checking. The equipment shall not be tested or leave the factory before all discovered defects have been rectified.
6.2
TESTING REQUIREMENTS
This section describes the minimum requirements for the testing of the equipment. This testing shall be performed in the Vendor’s works. The Purchaser reserves the right to observe any of the testing, dismantling, inspection and reassembly of equipment as specified. Unless otherwise specified, all testing equipment required shall be provided by the Vendor. Purchaser’s witnessing of shop test results shall not constitute a waiver of the Vendor’s obligation to provide equipment which meets all specified operating conditions. 6.2.1
Hydrostatic Test
Hydro testing shall be as per the code, specification, data sheets and Inspection & Testing Plan. Inspector shall witness all hydrostatic tests. Drainage / flushing / drying of the equipment shall strictly follow immediately after the hydrostatic testing as specified in SP-
Petroleum Development Oman LLC
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7. DOCUMENTATION REQUIREMENTS Requirements for Vendor documentation are listed in the Requisition for Engineering Documents (RED) form included in Appendix-3 and sections below. The Vendor shall prepare a Vendor Document Register (VDR) or Suppliers Document Schedule (SDS) in the Company standard format using the above information as a guide. The Vendor shall submit the Document Register to Purchaser for review and approval together with document delivery schedule after award and prior to submission of any other documentation. The Document Register will thereafter form the basis of submission and control of all documents. The Company title block/drawing number can be included on the front sheet. All documentation shall be submitted for review/approval to the Purchaser within the committed schedule. It shall be the responsibility of the Vendor to ensure that the production schedule takes into account documentation submission, including a two weeks review period by the Purchaser, which includes document delivery time.
6.1
INFORMATION TO BE SUBMITTED ALONGWITH THE BID
Vendor shall submit all the required documents as specified/identified in the RED form attached in Appendix-3. In addition to this Vendor shall submit the f ollowing: 1.
Table of Compliance, Appendix-4 duly completed, signed and stamped.
2.
Unit rates for nozzles with flange rating as mentioned in datasheets for sizes NPS2 to NPS 24 and any higher sizes if specified in the datasheets.
3.
Unit rate for cleats & ladders on per kg basis and platform on per m 2 basis.
Petroleum Development Oman LLC 7.2.3
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Test Certificates
Certificates for each mechanical, performance or calibration test, as applicable shall be furnished, including hydrostatic test certificates and as identified in RED form, Appendix-3.
7.3
METHOD OF DOCUMENTATION TRANSMISSION
All documentation for review/approval shall be transmitted via internet (soft copy) or hard copy by use of courier services and shall be sent to the Purchaser, the details of which shall be discussed during the bid clarification meeting. Final documentation shall be in the form of hard copy as well as electronic form as specified in RED form, Appendix-3.
7.4
IDENTIFICATION
Each drawing and document shall be identified with the following information (f or drawings a title block shall be used): a) Identify and signature of originator, checker and approver. b) Title c) Purchase order number d) The item/tag number or equipment number Official name of Vendor’s company e) f) Vendor’s drawing number. g) Latest revision by means of a number or letter in triangle with that number or letter adjacent to the alterations. h) Company drawing number.
Petroleum Development Oman LLC
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Corrections will be marked on the drawings. Marked-up copies of the drawings will be returned to the Vendor under cover of the appropriate transmittal form. The Vendor shall at all times be responsible for review and correction of Sub-Vendor’s drawings and documents prior to submittal to Purchaser for approval. The Purchaser will clearly indicate on the documents which parts, if any, are ‘hold’. The Purchaser will inform the parties concerned, of the reasons for placing “hold”, and the date(s) on which release of these “holds” can be expected. The Vendor shall not delay manufacturing of released parts because of “hold” placed on other parts. Upon approval of the Vendor’s drawings by the Purchaser, the Vendor shall forward to the Purchaser the required number of approved documents, prints and diskettes as stated on the RED form under cover of a transmittal form, Final Document Transmittal (FDT). Manuals shall also be submitted to Purchaser under cover of a FDT.
7.7
MANUALS
The manual with all the relevant details to install, commission and operate/maintain the equipment shall be provided, with all the applicable drawings and details. The manual shall include all instructions on specific safety procedures for the installation and start-up of the equipment. • •
Installation, operation and maintenance instructions including Sub-Vendor manuals. Technical design data and test results (Manufacturer databook).
Petroleum Development Oman LLC
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8. PACKAGING & PRESERVATION FOR SHIPMENT The preparation for shipment of equipment and materials shall be in accordance with ERD06-01, DEP 70.10.70.11-Gen and additional requirements as defined in this section. Special care should be taken for the packaging of delicate equipments / parts.
8.1
PACKING REQUIREMENTS
All nozzles and open ends of the equipment shall be treated with Shell Ensis Fluid SDC and closed off by wooden or plastic blanks and taped. Small bore connections shall be taped over. Preservation of the packages shall be suitable for a storage period of at least 6 months. All equipment under sea shipment and those with Cr-Mo or higher alloy steel material shall be cleaned, dried and then purged with nitrogen and sealed with nitrogen with a small positive pressure not less than 0.7 bar(g). Nitrogen bottles shall be provided and secured to the shipping saddles for refilling. All associated valves and gauges shall be provided to monitor the nitrogen pressure inside the vessel. The equipment shall be packed in a seaworthy close boarded case with a waterproof lining. The case shall be sufficiently strong to withstand handling and storage. For transportation of any equipment in Sultanate of Oman, the maximum height including the trailer (standard height of low bed trailer 1.3 metres, special low bed trailer height 1 metre) shall be 5.5 metres. The Vendor shall critically review this requirement and obtain
Petroleum Development Oman LLC •
Crate dimensions and gross weight
•
Specific lifting and/or storage instructions
•
Crate identification
•
Supplier and Purchaser details
•
Brief material specification
•
Purchase order number
•
Final destination
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A complete packing list in a waterproof sleeve shall be firmly attached to the outside of each crate. An identical list shall be attached to the inside of the crate.
Petroleum Development Oman LLC
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9. PLANNING & SCHEDULING 9.1
GENERAL
This section covers the minimum requirements of planning, scheduling, control and reporting for the equipment. The Vendor shall submit a project schedule indicating clearly the plan to meet the delivery schedule required, including the required transportation time to installation site. A network type project schedule representing all relevant activities and milestones, including all Sub-Vendor’s equipment etc. shall be submitted by the Vendor within two (2) weeks after receipt of the order.
9.2
MEETINGS
The following meetings shall be held between the Vendor and Purchaser: • • •
Kick-off meeting. Vendor pre-manufacturing meeting. Any review meetings deemed necessary.
Certified minutes of meeting for all the meetings, recording all action items/parties shall be prepared by the Vendor and faxed to the Purchaser for his approval/signature within two (2)
Petroleum Development Oman LLC •
Ensure Vendor’s Representatives (engineers/INSPECTORS) have free access to all fabrication areas at any reasonable time, including all times that fabrication work is being performed.
•
Review the production program, including input from sub-contractors.
•
Review material substitution(s), if any.
•
•
•
•
•
•
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Review scope of the overall inspection plan and define responsible parties regarding interpretation, witnessing and reviewing. Review any conflicts in codes/specifications and record which prevails. Review any requirements to witness any particular inspection by Purchaser’s Representative. Review test program and procedures. Review purchase order variation procedures and agree that any variation in design or fabrication not approved by the Purchaser in writing shall be considered by the INSPECTOR as non-acceptable. Certified minutes of meeting shall be prepared by the Vendor and issued to the Purchaser for his approval/signature within two (2) working days from the date of the meeting. 9.2.3
Review Meetings
Meeting agenda will be agreed upon and communicated no less than 10 working days before the scheduled meeting date. Other meetings shall be held, as required, to perform the work and complete all interface details.
Petroleum Development Oman LLC
APPENDICES :
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Petroleum Development Oman LLC
APPENDIX-1 ENVIRONMENTAL & SITE CONDITIONS The project specific environmental and site conditions shall be confirmed/provided by the Purchaser based on the site location. The facilities shall be suitable for operation in the specified environmental conditions in addition t o the operating conditions. The local environmental conditions are severe. There are frequent sandstorms, and the atmosphere is heavily laden with airborne dust particles, some as small as 2 microns. It rains rarely. The rain is often combined with hail and sandstorms. Average Environmental conditions for the production stations are: Relevant Ambient Data: Barometric pressure
Maximum
98.9
kPa
Average
97.5
kPa
Minimum
95.7
kPa
Maximum
60
Minimum
5
°C
Black bulb temperature
Maximum
82
°C
Relative humidity
Maximum
98 %
Minimum
30
%
Max. hourly avg.
26
meters/s
3 sec. Gust
35
meters/s
Ambient temperature
Summer
Wind speed
P
ili
i d di
i
M
h A il
NW
°C **
Petroleum Development Oman LLC
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APPENDIX-2 EQUIPMENT DATASHEETS & DRAWINGS
1. Pressure Vessel Datasheet 2. Demister Datasheet 3. Mass/Centre of Mass of Equipment Datasheet
Petroleum Development Oman LLC
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Petroleum Development Oman LLC
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Petroleum Development Oman LLC
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Petroleum Development Oman LLC
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Petroleum Development Oman LLC
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APPENDIX-3 REQUISITION FOR ENGINEERING DOCUMENTS (RED FORMS)
Petroleum Development Oman LLC
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Petroleum Development Oman LLC
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Petroleum Development Oman LLC
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Petroleum Development Oman LLC
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Petroleum Development Oman LLC
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Petroleum Development Oman LLC
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Petroleum Development Oman LLC
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Petroleum Development Oman LLC
APPENDIX-4 TABLE OF COMPLIANCE The Vendor shall confirm below that the offer complies with all the clauses contained in this specification or otherwise highlight deviation / exceptions under the clarification column. Vendor can use separate sheets if space provided in the clarification column is insufficient. Words such as “Noted” shall not be used. Client : Petroleum Development Oman (PDO)
Vendor :
Client Ref. No. : PR No.
Vendor Ref. No :
Specification Reference
Conforms
Alternative
Section
Yes / No
Yes / No
1 1.1 1.2 1.3 1.4 2 2.1
Clarification
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Petroleum Development Oman LLC Client : Petroleum Development Oman (PDO)
Vendor :
Client Ref. No. : PR No.
Vendor Ref. No :
Specification Reference
Conforms
Alternative
Section
Yes / No
Yes / No
5 5.1 5.2 6 6.1 6.2 6.2.1 6.2.2 7 7.1 7.2
Clarification
Revision: 0 Effective: Sep-08
Petroleum Development Oman LLC Client : Petroleum Development Oman (PDO)
Vendor :
Client Ref. No. : PR No.
Vendor Ref. No :
Specification Reference
Conforms
Alternative
Section
Yes / No
Yes / No
9.4 Appendix-1 Appendix-2 Appendix-3 Appendix-4 Appendix-5 Appendix-6 Appendix-7 Appendix-8
Clarification
Revision: 0 Effective: Sep-08
Petroleum Development Oman LLC
APPENDIX-5 ALLOWABLE NOZZLE LOADS This appendix defines the allowable piping loads acting on nozzles of process vessels such as columns, drums and shell and tube heat exchangers interconnected with piping designed by the Purchaser. N ozzleR ating(per A SM EB16.5) N ozzle S ize (D N )
1 5 0 lb
3 0 0 lb
6 0 0 lb
Force kN
M o m e n t kNm
Force kN
M o m e n t kNm
5 0
1 .5
0 .5
1 .5
8 0
3
1
3
1 0 0
3 .5
2
3 .5
1 5 0
6
6
6
6
2 0 0
7
9
7
9
2 5 0
9
1 3
9
1 3
3 0 0
1 2
1 9
1 2
3 5 0
1 3
2 1
4 0 0
1 6
4 5 0
90 0b l
150 0lb
Force kN
M o m e n t kNm
Fo rce kN
M o m e n t kNm
Fo rce kN
M o m e n t kNm
0 .5
2
0 .5
2
0 .5
2
0 .5
1
3 .5
1 .5
4
1 .5
5
2
2
4
2 .5
5
3
6
3 .5
8
7
1 0
9
1 2
1 0
1 2
1 4
1 4
1 6
2 0
2 1
1 5
2 2
1 8
2 5
2 7
3 4
1 9
2 1
3 2
2 5
3 9
3 3
5 3
1 3
2 1
2 2
3 6
2 8
4 3
4 0
6 0
2 6
1 6
2 9
2 9
5 0
3 5
5 8
5 2
8 1
1 7
3 1
2 0
3 8
3 6
6 5
4 4
7 7
R efertoPrincipa l
5 0 0
1 7
3 2
2 1
4 0
3 9
7 0
4 8
8 4
R efertoPrincipa l
6 0 0
2 2
4 1
2 9
5 4
5 5
9 8
6 8
1 1 8
R efertoPrincipa l
> 6 0 0
R efertoP rincipa l
N o te s : 1 Fo r al nozzlesan dcon ne ction s, excep tm an w aysan dother o pe nn i gsintend edsoley l for acce ssor n i spe ction , theS up pliersha ll de term inethestresse sintheve sselorexch an ge rresultingfromthew orstcom bina tionof an yin te rna l pre ssu reuptoth ede sig
2
T heS up pliersh al assu m etheforcesan dm om en tsinthetab leabo veactsim ultan eo uslyinall3plan esinthe w orstcom bina tionan ddire ctio ni.e. ±at theno zzletoshe ll ju nc tion .
3
T heloa dsinthetab leabo veareno t inten de dforuseonpu m ps,com pre ssors,firedhe atersorothersuch eq uipm en t tha t alread yha veno zzleloa dsde fine dw ithinthe irba sedesigncod ei.e.A P I stand ard s.
4
T heloa dsinthetab leabo veareno t inten de dforuseonlowp ressu reoratm osp he rictan ks.
5
Fo rnozze l sw ithaflan geratingexcee dn i gA SM EB16 .5class15 00orforno m ina l da im eterexcee dn i gD N 60 0 i.e. A S M EB1 6.47 , refe rtothePrincipa l forlo ad stobeutilise d .
Petroleum Development Oman LLC
APPENDIX-6 SPIR FORMAT
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Petroleum Development Oman LLC
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Specification for Pressure Vessels
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Printed 23/09/08
Petroleum Development Oman LLC
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Specification for Pressure Vessels
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Printed 23/09/08
Page 73
Specification for Pressure Vessels
Printed 23/09/08
Petroleum Development Oman LLC
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APPENDIX-7 USER FEEDBACK PAGE
SP- 2069 – SPECIFICATION FOR PRESSURE VESSELS USER FEEDBACK FORM Any user who identifies an inaccuracy, error or ambiguity is requested to notify the custodian so that appropriate action can be taken. The user is requested to return this page fully completed, indicating precisely the amendment(s) recommended. Name: Ref ID
Page Ref:
Date:
Brief Description of Change Required and Reasons
Petroleum Development Oman LLC
Revision: 0 Effective: Sep-08
APPENDIX-8 INSPECTION AND TEST PLAN (ITP) FORMAT
Contractor’s Name Quality Control Ref.:
TYPICAL INSPECTIN TEST PLAN Revision No 0 Plan
Contract / P.O No.:
Element: Pressure Manufacture
Discipline Sl. No
Project:
Controlling Document
Activity
1 Design Calculations . and Drawings
Contract Specifications
2 Welding Procedures .
Applicable Code & relevant Shell DEP
3 Approval of . Procedures
NDT Applicable Code & SP 1176
4 Review of . operators’ qualification validity
NDT
ISO 9712 / ASNT SNT TC and 1A / CSWIP / PCN
5 Review of welder Applicable Code . qualification records 6 Approval of PWHT . Procedure (if applicable) 7 Material Inspection . – Chemical, Physical , Heat treatment condition (including simulation heat treatment if any), UT of plates,
LEGEND :
Applicable Code & relevant Shell DEP Applicable material specification, relevant DEP additional requirements, Approved
Page 1
Vessel
Acceptance Criteria. Frequency of Test.
Conformance to manuf. code and contract specification requirements – Approval - All Approval – All WPS related to pressure retaining parts Conformance to relevant code & spec Minimum level II valid qualifications (Level I could be used as only assistant) All welders shall have valid qualifications Conformance to relevant code & spec Conformance to the controlling documents & delivery conditions
Vessel Tag # : Supplier’s Verification Personnel
Design Manager
Verification Document
Authorised Inspector
PDO
H
H
H or Review as per contract
W elding / Approved for QA Engineer construction procedure
H
H
H
W elding / Approved NDT QA Engineer procedures
H
H
R
QC Inspector
H
S
H
R
H
H
W
R
W elding / QA Engineer
Approved calculations and Drawings
EPC Manufacturer Contractor / TPI
NDT qualification record
Valid Qualification records W elding / Approved QA Engineer PWHT procedures QC Inspector Material inspection report & material heat certificate
R
Contractor’s Name Quality Control Ref.:
Plan
Project:
Activity
Controlling Document
Page 2
Contract / P.O No.:
Element: Pressure Manufacture
Discipline Sl. No
TYPICAL INSPECTIN TEST PLAN Revision No 0
Vessel
Acceptance Criteria. Frequency of Test.
Supplier’s Verification Personnel
Verification Document
EPC Manufacturer Contractor / TPI
etc 8 .
9 .
1 0 . 1 1 . 1 2 .
drawings, Data Sheets, etc Veri ficat ion of Manufacturer’s All cut material transfer of material procedures shall bear the markin g on cut material details segments including heat numbers Cutting, edge Manufacturer’s Dimension as per preparation & procedures, approved Forming Applicable Code drawings and & relevant Shell tolerance limits of DEP codes & DEP Fit- up Inspection Appro ved W PS, As per approved code and WPS, code and relevant Shell relevant Shell DEP DEP Welding Approved WPS Weld parameters in accordance with approved WPS Inspection of Back Approved WPS Conformance to gouging and NDT as and relevant relevant spec required spec
Vessel Tag # :
QC Inspector
Traceability record
H
R
QC Inspector
Dimension Inspection report
H
S
QC Inspector
Fit-up Inspection Report
W
S
Welding Supervisor & Inspector
Parameter log
W
S
Welding Supervisor & Inspector
Visual / Reports
NDT
W
S/R
v isual
W
S
H
W
1 Visual Inspection of Applicable Code 3 welds & relevant Shell . DEP
Conformance to relevant code & spec
QC Inspector
W eld Report
1 Positive Material Approved 4 Identification (PMI) Drawing and . DEP 31.10.00.10
Material composition in accordance with MTO spec.
QC Inspector
PMI Report
LEGEND :
Authorised Inspector
PDO
Contractor’s Name Quality Control Ref.:
TYPICAL INSPECTIN TEST PLAN Revision No 0 Plan
Contract / P.O No.:
Element: Pressure Manufacture
Discipline Sl. No
Project:
Controlling Document
Activity
1 Ferrite check 5 required) .
Vessel
Acceptance Criteria. Frequency of Test.
Frequency accordance DEP (as API RP 582 & API RP 582 AWS A4.2
1 Dimensional 6 Inspection .
Page 3
Supplier’s Verification Personnel
Verification Document
EPC Manufacturer Contractor / TPI
in with QC Inspector
Ferrite Report
Conformance within the tolerance limits specified in the controlling docs All Welding (Hot & work) works completed and visually accepted Conformance to code & spec requirements
QC Inspector
Approved drawings, code and relevant DEP
1 Clearance for Approved 7 PWHT of the vessel Drawings . Data sheets
Vessel Tag # :
Check
W
W
Dimensional inspection report
W
W
QC Inspector
Clearance Report
H
H
QC Inspector
PWHT chart
R
R
W
W
1 PWHT 8 .
Approved PWHT procedure
1 Hardness 9 measurement .
Rele vant DEP
Shall not exceed 248 HV10
QC Inspector
Hardness report
2 Production control 0 Test plates (as . applicable) testing
Relevant and DEP
Code
Conformance to Code and Spec requirements
QC Inspector
Test reports
H
W
2 NDT (Shall include 1 requirements for . butt welds, nozzle welds, attachment
Applicable Code, relevant Shell DEP & Approved NDT
Conformance to relevant code & DEP
QC Inspector
NDT Reports
W
R
LEGEND :
test
Authorised Inspector
PDO
Contractor’s Name Quality Control Ref.:
TYPICAL INSPECTIN TEST PLAN Revision No 0 Plan
Contract / P.O No.:
Element: Pressure Manufacture
Discipline Sl. No
Project:
Activity
welds, etc) 2 NDT and Chemical 2 analysis of weld . overlay for cladded vessels (if applicable) 2 Repairs 3 .
Controlling Document
Procedures Code and relevant DEP
Page 4
Vessel
Acceptance Criteria. Frequency of Test.
Vessel Tag # : Supplier’s Verification Personnel
EPC Manufacturer Contractor / TPI
Verification Document
Conformance to relevant code & DEP
QC Inspector
NDT and Chemical analysis report
Conformance to relevant code & DEP
QC Inspector
NDT report
H
H
2 Clearance for Approved All fabrication & 4 Flushing / cleaning drawings (GA & NDT in the vessel . & Pressure Test PEFS) & Data completed and sheets accepted 2 Flushing / Cleaning Manufacturer’s All internal 5 Procedure & surface shall be . contract Spec dirt free
QC Inspector
Clearance Report
H
H
/
H
W
2 Pressure Testing 6 .
QC Inspector
Test
H
H
2 7 .
Fabrication Installation Supervisor & Inspection QC inspector Report
H
W
Paintin g
H
W
2
Code and relevant DEP
Manufacturer’s Test pressure Procedure, maintained as per Code, approved controlling docs drawings & data and no leakages sheets Inspection of Manufacturer’s All internal internals Installation Procedure, installation in Code, approved accordance with drawings & data approved sheets and drawings internals manufacturer’s instructions Paint ing system PDO Spec SP Conf orm ance to
LEGEND :
Fabrication Flushing Supervisor & Cleaning QC inspector Report Pressure Report
PDO Approve d
Authorised Inspector
PDO
Approval of major repairs