Supplement to Specification for Linepipe Induction Bends

Table of Contents 1

INTRODUCTION ................................................................................................................. 3 1.1 1.2 1.3 1.4 1.5 1.6

2

MANUFACTURING ............................................................................................................ 5 2.1 2.2 2.3 2.4 2.5 2.6

3

CHEMICAL COMPOSITION ............................................................................................... 7 HIC/SWC TEST ............................................................................................................ 7 DIMENSIONS ................................................................................................................. 8 H YDROSTATIC TESTING ................................................................................................. 8

INSPECTION DOCUMENT ................................................................................................ 8 4.1 4.2 4.3

5

MOTHER PIPE ............................................................................................................... 5 MANUFACTURING PROCEDURE SPECIFICATION (MPS).................................................... 6 QUALIFICATION TEST BEND........................................................................................... 6 PRODUCTION BENDING ................................................................................................. 7 POST-BENDING HEAT TREATMENT .................................................................................. 7 FORMING AND SIZING AFTER BENDING ............................................................................ 7

TESTING AND INSPECTION.............................................................................................. 7 3.1 3.2 3.3 3.4

4

SCOPE ........................................................................................................................ 3 DEFINITIONS ................................................................................................................ 3 ABBREVIATIONS ........................................................................................................... 4 GUARANTEE ................................................................................................................ 4 NORMATIVE REFERENCES ............................................................................................ 5 PARTICULAR REQUIREMENTS ........................................................................................ 5

MILL CERTIFICATES ...................................................................................................... 8 PRODUCTION REPORT ................................................................................................... 9 PROTECTIVE COATING ............................................................................................ 9

MARKING .........................................................................................................................10

SUPPLEMENT TO SPECIFICATION FOR LINEPIPE INDUCTION BENDS

Project No.: MASTER ADCO DOC. NO.: 30-99-23-0116 REV. 1 PAGE

DATE: Sept 2014 2 OF 2

1 INTRODUCTION 1.1

Scope This specification defines ADCO’s additional requirements that apply for materials, design, manufacture, testing and supply of factory made hot induction bends for use in onshore pipelines in Sour service. This specification shall be read in conjunction with the latest edition of the following documents: 



DEP 31.40.20.33- Linepipe Induction Bends (Amendments / Supplements to ISO 15590-1) ISO 15590-1: Petroleum & Natural Gas Industries – Induction Bends, Fttings and Flanges for Pipelines transportation systems – Part 1 : Induction Bends

All clauses of above referred SHELL DEP and ISO shall be applicable, unless specifically modified / supplemented by this Specification. Additional requirements as indicated in this specification shall take precedence over relevant sections of DEP and ISO. 1.2

Definitions COMPANY

: ADCO (Abu Dhabi Company for Onshore Oil Operations) Wherever the word “Principal” is used in SHELL DEP, the same shall be replaced by the word “COMPANY”, with the same authorities / responsibilities as defined in SHELL DEP

CONTRACTOR

: The party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of the project. Contractor includes its approved manufacturers, vendors, suppliers and subcontractors. Requirements of this specification shall be enforced at all levels of the contractor's procurement and construction process. The company shall have access to all contractor suppliers to the same extent as required of contractor




1.3

1.4

VENDOR/ MANUFACTURER /SUPPLIER

: The Party (Parties) which manufactures and/or supplies materials, equipment, technical documents or drawings and/or services to perform the duties specified by the COMPANY.

SUBCONTRACTOR

: Any person or persons, firm, partnership, corporation or combination thereof (not being an employee of CONTRACTOR), including vendors to whom any part of the works has been subcontracted by CONTRACTOR

Abbreviations ADCO

Abu Dhabi Company for Onshore Oil Operations

ADNOC

Abu Dhabi National Oil Company

BEDD

Basic Engineering Design Data

CDS

Central Degassing Station

DEP

Design & Engineering Practice

EPC

Engineering, Procurement and Construction

FEED

Front End Engineering Design

FFD

Full Field Development

ITP

Inspection & Test Plan

MR

Material Requisition

PQR

Procedure Qualification Report

RDS

Remote Degassing Station

SAS

Sahil, Asab and Shah

TPI

Third Party Inspector Agency

VDRL

Vendor Document Requirement List

VQRF

Vendor Quality Requirement Form

UAE

United Arab Emirates

Guarantee VENDOR shall bear all costs to seek, find, and repair all leaks and/or ruptures which may occur during field hydrostatic testing, and which result from defects traceable to the material / manufacture of Induction bend. The field test will not exceed a pressure that will cause a circumferential fibre stress greater than 95 percent of the specified minimum yield strength of the connecting pipe.




1.5

Normative References Manufacturer shall also comply with the requirements of the following documents. ADCO standard ES-30-99-00-0105: Seamless line pipe for sour service ADCO standard ES-30-99-00-0106: Submerged Arc Welded (SAW) line pipe for sour service ISO 15156: Petroleum and Natural Gas Industries – materials for use in H 2S containing environments in oil and gas production.

1.6

Particular Requirements

a)

Steel grade and nominal wall thickness of bends (after forming) shall be as specified in the Purchase Requisition. The hot bend wall thickness after bending process shall not be less than the mother pipe wall thickness. Bend manufacturer shall submit the bending procedure to the COMPANY for approval prior commencing bending process.

b)

Steel grade shall be similar to that of the connecting pipe.

c)

Radius of curvature of bends shall be 5D unless otherwise specified in the data sheet; D is the pipe outside diameter. Angles of bend shall be as per data sheet.

d)

Bend shall be fabricated in one piece including tangent length (no circular welds or stop/ starts within the bend zone). Minimum length of tangential ends shall be 1 meter. Bends shall be supplied with beveled ends.

2

MANUFACTURING

2.1

Mother pipe 

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

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Mother pipe to be used for bending shall conform the ADCO Engineering Specification for line pipe (ES 30-99-00-0105 & ES 30-9900-0106 as applicable) to which bend shall eventually be welded. Increased line pipe thickness may be considered by MANUFACTURER for compensating any reduction in mechanical properties due to bending process. Use of different steel grade higher or lower than connecting line pipe grade shall require COMPANY approval. The material shall be suitable for sour service and shall comply with the requirements of ISO 15156/ NACE MR 01-75 and this specification. A coupon (minimum 500mm) shall also be removed from one pipe from




each lot (same grade, diameter, wall thickness, heat number) of mother pipes before bending to ensure suitably identified and kept for any future testing of the initial properties of the line pipe.

2.2

Manufacturing Procedure Specification (MPS) The Manufacturer, prior to production shall submit a Manufacturing Procedure Specification (MPS) to the Company for approval. The pipe bends shall be made using the continuous induction-bending process. The process shall include an induction heating system to heat a circumferential band around the pipe to the appropriate bending temperature. When the bending temperature is reached, the bending moment shall be applied. The bend area shall be immediately cooled after bending. Cold or hot working of the bends to meet the dimensional tolerances after bending or final heat treatment shall not be permitted. The metal temperature prior to and during bending shall be accurately determined using an optical pyrometer. The temperature data shall be recorded for each bend and shall be provided to COMPANY’s Representative at his request. The MPS shall be qualified by a Manufacturing Procedure Qualification (MPQ), as specified in Shell DEP. In case of SAW mother pipe, prior to manufacture of a test bend, the seam welded pipe which is to be subjected to a post bending heat treatment, a section of pipe including the weld shall be heat treated and the tensile and impact properties of the weld metal checked. The qualification test bend shall only be made once satisfactory results from this test are obtained and approved. In addition to the requirements of Shell DEP and ISO, the manufacturer shall include the following as part of the MPS. -Inspection procedure for all destructive and non-destructive testing both during qualification and production -Inspection and Test Plan (ITP) covering all destructive and nondestructive testing, both during qualification and production -Detailed production schedule

2.3

Qualification Test Bend For each bend size, grade and steel source, a trial bend of the tightest radius / maximum wall thickness combination with sufficient arc length to allow extraction of the necessary test specimens shall be manufactured in accordance with each preliminary MPS. The inspection and testing of the test bend shall include tangents and transition zones if included in the produced bends.




Procedures established on trial bends shall be fixed for the successive production bends. The bend shall be subject to the same thermal treatment during qualification as a pipe would receive in production. All mechanical testing shall be conducted after final heat treatment. If post bend heat treatment is required, then both the test bend and the tangent ends shall be heat treated.

2.4

Production Bending The pipe bends shall be made using the continuous induction-bending process. The process shall include an induction heating system to heat a circumferential band around the pipe to the appropriate bending temperature. When the bending temperature is reached, the bending moment shall be applied. The bend area shall be immediately cooled after bending. The bend radius shall be as specified in data sheet. The metal temperature prior to and during bending shall be accurately determined using an optical pyrometer. The temperature data shall be recorded for each bend and shall be provided to COMPANY’s Representative at his request.

2.5

Post-bending heat treatment If post bend heat treatment is required, then both the test bend and tangent ends shall be heat treated.

2.6

Forming and sizing after bending Cold or hot working of the bends to meet the dimensional tolerances after bending or final heat treatment shall not be permitted.

3

TESTING AND INSPECTION

3.1

Chemical composition The Chemical composition of each bend shall comply with the requirements for pipe of the same grade and type as specified in ADCO standard ES-30-99-000105/ ES-30-99-00-0106 as applicable.

3.2

HIC/SWC Test HIC/SSC test for Induction bend shall be carried out in case the test certificates for mother pipe are not available.




HIC / SSC tests shall be performed in accordance with NACE TM0284 & NACE TM 0177 respectively.

3.3

Dimensions All bends shall have the wall thickness checked by ultrasonic thickness measurement in accordance with ASTM E 797 for a minimum of ten measurements each, on the outer, inner and neutral axes of the bend. The thickness after bending shall not be less than the minimum thickness specified for the connecting line pipe. Wall thickness measurements shall be taken at spacing of a minimum 75 mm along the entire length of the bend. At each of the above locations, thickness measurements shall be taken at four locations around the circumference as follows:

3.4

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At the inside radius of the bend

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At the outside radius of the bend

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At 90 degrees from the inside radius (neutral axis)

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At 180 degrees from the outside radius (neutral axis)

Hydrostatic Testing Hydrostatic testing shall be carried out for the 20% of production bends (minimum 1, whichever is higher).Hydrostatic test pressure shall be such that the resultant hoop stress corresponds to 95% of SMYS of pipe material. Test pressure shall be held for a minimum period of 10 minutes.

4

INSPECTION DOCUMENT

4.1

Mill Certificates The required inspection test certificate to support the delivered bends shall be according to BS EN 10204 type 3.2. Mill Certificates shall show the following: 

Type and origin of base material

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Ladle analysis including Carbon Equivalent and Pcm for base material

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Bend No. with reference to heat No.

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Mechanical test results with reference to bend No.




4.2

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Dimensional inspections with results

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Non-destructive tests performed with results

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Any supplementary tests and inspections carried out

Production Report Vendor shall ensure that material is fully traceable throughout the production process. A unique identification number shall be assigned to each bend. This shall be traceable to the original material certificate for Vendor supplied material or the original pipe identification number for free issue material. Upon completion of bend manufacture, the MANUFACTURER shall produce a production report which shall include the following minimum information and documents: 

Mill test certificates of mother pipes



Manufacturing Procedure Specification of bends



MPS qualification test results



Production test reports



Mill Certificates of bends (as per 6.1 above)



Mill hydrostatic test certificate of compliance



Quality Control Plan



Compilation of concessions / deviations, if any, granted by the COMPANY during bend production.

Number of originals and copies of the production report shall be as indicated in the Requisition. All documents listed at 4.1 and 4.2 above, shall be submitted in electronic format in CD-ROM in addition to hard copies.

4.3

PROTECTIVE COATING The Induction Bends shall be provided with a protective coating for storage and transportation. The applied coating shall be in accordance with manufacturers standard, however shall be easy removable by light shot blasting, solvent cleaning or steam out of lines after fabrication.




Excessive (local) layers of paint, oil, shot blasting resistant coatings or “Japanese Black” is not permitted.

5

MARKING VENDOR shall apply a 200 mm band of indelible paint of different colours on the inside surface of bends to distinguish between bends of same diameter, but with different wall thickness. The colour code corresponding to the various wall thicknesses shall be as specified in the Purchase Order. For bend size 10 inch and above the marking shall be provided internally. For smaller sizes the paint marking shall be on the outside surface.




Supplement to Specification for Linepipe Induction Bends

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