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BLOCK 12W DEVELOPMENT- CHIMSAO FIELDS
HOOK-UP AND COMMISSIONING CHIM SAO PROJECT
CONTRACTOR: PETROVIETNAM TECHNICAL SERVICES CORPORATION
SUB CONTRACTOR: PTSC OFFSHORE SERVICES
PTSC/POS
RE
V.
NO
.
DAT
E
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
Page 1 of 16
Date:
January 27, 2010
REV. NO.
CONTENT OF REVISION
DATE OF REVISION
Page 1 of 14
POVO /PTSC
POS
Page 2 of 16
Date:
January 27, 2010
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
Page 2 of 14
POVO /PTSC
POS
Page 3 of 16
Date:
January 27, 2010
1.0
PURPOSE
This procedure details sequence instruction for the installation of piping spools and
equipment that is used by POSs 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
DEFINITIONS
ANSI
ASME
AWS
DE
DSS
DPT
GRP
GTAW
MPI
MT
NDE
NDT
OD
POVO
POS
POVO /PTSC
POS
PPM
PQR
PT
PTW
PTSC
PVC
QA
QC
RT
RTJ
SS
SSV
WPS
WV
ITP
5.0
Page 4 of 16
Date:
January 27, 2010
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
POVO /PTSC
POS
5.1.3
Page 5 of 16
Date:
January 27, 2010
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 POVOs 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.
5.2.2
Page 5 of 14
POVO /PTSC
POS
Page 6 of 16
Date:
January 27, 2010
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
5.2.4
5.2.5
Fit up
Alignment for the fit-up of the piping components shall be executed at its 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
POVO /PTSC
POS
Page 7 of 16
Date:
January 27, 2010
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
POVO /PTSC
POS
Page 8 of 16
Date:
January 27, 2010
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
POVO /PTSC
POS
Page 9 of 16
Date:
January 27, 2010
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
POVO /PTSC
POS
Revision No.: A
Page 10 of 16
Date:
January 27, 2010
5.2.7
5.2.8
Burn thru during application of hot pass and subsequent passes, after
visual acceptance, is cause for immediate disqualification.
Temporary Attachments
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.
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
Page 10 of 14
POVO /PTSC
POS
Page 11 of 16
Date:
January 27, 2010
5.
5.2.10
5.2.10
POVO /PTSC
POS
Revision No.: A
Page 12 of 16
Date:
January 27, 2010
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.
POVO /PTSC
POS
Revision No.: A
Page 13 of 16
Date:
January 27, 2010
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
POVO /PTSC
POS
NDT Reports
Hydrostatic Packages
Page 14 of 14
Page 14 of 16
Date:
January 27, 2010