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DEFINE PHASE
A1
JAN 02
AM
IR
REV
DATE
DESCRIPTION
PREPARED
CHECKED
APPROVED
Document Number
REV
KPD20-01-W-SPE-0018
A1
CONTENTS
Section
Page
ABBREVIATIONS
KPD20-01-W-SPE-0018
Jan 03
INTRODUCTION
1.1
1.2
1.3
1.4
1.5
1.6
Project Description
Scope
Intent
S.I. Units
English Language
Definitions
2.1
2.2
2.3
2.4
Acts
Codes and Standards
Project Specifications
Conflict
GENERAL REQUIREMENTS
3.1
3.2
3.3
3.4
3.5
WELDING ACTIVITIES
4.1
4.2
4.3
4.4
4.5
General
Processes
Consumables
Weld Procedure Qualifications
Production Welding
INSPECTION ACTIVITIES
5.1
5.2
5.3
5.4
Receipt Inspection
Visual Inspection of Welds
Non-Destructive Testing Requirements
Production/Inspection Traceability
DOCUMENTATION
ii
4
4
4
5
5
5
5
6
6
6
7
7
7
8
8
8
9
9
9
11
12
12
13
13
Abbreviations
API
CPP
DNV
GMAW
GTAW
HAZ
HSE
ITP
MDR
NDT
ORF
PQR
RPSE
SDRL
WHT
Wellhead Tower
WPS
WMSS
KPD20-01-W-SPE-0018
Jan 03
iii
INTRODUCTION
1.1
PROJECT DESCRIPTION
The Kepodang field is a gas discovery, part of the Muriah PSC, operated by BP Muriah
Ltd, covering an area of approximately 2788 square kilometres. It is located in the East
Java Sea approximately 180km North-East of Semarang, the largest city in Central Java.
The market for the Kepodang gas reserves is the existing Tambak Lorok power station
operated by PLN and located in Semarang. The Tambak Lorok power station currently
generates electrical power by six diesel fuelled gas turbines (110 MW each) with cogeneration from two steam turbines (175 MW each).
The development plan for the Kepodang field comprises two Phases. Phase 1 will consist
of 8 wells drilled from two areas of the reservoir. A further 3 wells will be drilled during
Phase 2 from two additional areas to maintain security of supply over the contract life.
Phase 1 development will include installation of:
A DN350 diameter 200km export pipeline to transfer the dry gas to the ORF at
Tambak Lorok power station.
SCOPE
This Specification outlines the minimum technical requirements for the welding of
Weldable Martensitic Stainless Steel (WMSS) linepipe for the Kepodang Gas
Development Project.
1.3
INTENT
The intent of this Specification is to provide a minimum standard for welding of WMSS
linepipe based on industry practice and BP (RPSE) requirements, it also covers standard
requirements for welding WMSS linepipe for the Kepodang Development Project.
KPD20-01-W-SPE-0018
Jan 03
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1.4
S.I. UNITS
The International System of units (SI) shall be used in all documentation. Equivalent
imperial dimensions may be shown on manufacturing drawings in parenthesis following
the SI units.
1.5
ENGLISH LANGUAGE
All documentation and correspondence shall be in the English Language.
1.6
DEFINITIONS
The following definitions shall apply within this specification:
BP
BP Muriah Ltd, or
Persons or Company nominated by BP to act on their behalf
Contractor
EPC Contractor
Third Party
2.1
ACTS
The following Indonesian Regulations and Decrees are those identified as applicable to
the scope of work contained within this document.
Decree
84.k/38/DJM/1988
Regulation
06P/0746/M.PE/1991
Regulation
05/P/II/PERTAMB/1977
Regulation Number 11
Year 1979
KPD20-01-W-SPE-0018
Jan 03
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The above are listed only as a guide to the applicable Indonesian Acts. Contractor shall
be responsible for determining all statutory requirements applicable to the scope of work
included in this Specification.
2.2
2.3
PROJECT SPECIFICATIONS
This Specification shall be read in conjunction with the following Project Specifications:
KPD99-01-G-SPE-0002
KPD99-01-G-SPE-0005
KPD20-01-W-SPE-0013
Quality Requirements
Pipeline and Flowline Installation Specification
KPD20-01-W-SPE-0001
The latest revision of the above Project Specifications shall apply at time of placement of
Contract.
2.4
CONFLICT
In case of conflict between this specification, its associated specifications, data sheets and
the codes and standards, the Contractor shall bring the matter to BP's attention for
resolution and approval in writing.
Should any conflict occur as a result of the application of these regulations, data sheets
and specifications, the order of precedence shall be as follows:
This Specification
Project Specifications
All deviations from the requirements of this specification, its attachments and the
referenced codes and standards shall be stated in the quotation. In the absence of such a
statement, full compliance shall be assumed.
Compliance by the Contractor with the provisions of this specification does not relieve
him of his responsibility to furnish equipment and accessories of a proper mechanical
design suited to meet the specified service conditions and/or local codes governing health
and safety.
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Jan 03
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GENERAL REQUIREMENTS
3.1
3.2
3.2.1
all work shall be completed in a safe manner such that no harm can be caused to
personnel in the Contractor's facilities.
3.2.2
3.2.3
3.3
QUALITY RECORDS
The Contractor shall generate quality records from the inspection and test activities listed
in this specification and in accordance with the approved inspection and test plan(s).
Documents and drawings shall be submitted as agreed in the Contractor's Supplier Data
Requirements List (SDRL).
The records shall be compiled and reviewed by the Contractor following the completion
of each inspection and test.
Quality Records to be included in the MDR are nominated in Table 6.1. Those records
not nominated for inclusion in the MDR shall be available for BP review throughout the
contract period and thereafter retained in accordance with industry standards. Quality
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Jan 03
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3.5
TRACEABILITY
Contractor shall mark items and establish documented means of:
1. Locating the item (traceability record);
2. Locating the quality records generated from inspection and testing of the item.
Traceability requirements are summarised below in Table 3.1.
Production Welds
Traceability Levels
Each Weld
Quality Records
WELDING ACTIVITIES
4.1
GENERAL
Welding of Weldable Martensitic Stainless Steels (WMSS) shall follow specified
requirements in DNV OS-F101 Submarine Pipeline Systems Appendix C, with additional
requirements given in this specification.
When deviation exists between this
Specification and the below mentioned Standards, this Specification shall apply.
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Jan 03
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4.2
PROCESSES
The following welding processes are approved for use on this project. Formal approval
from BP for any other process is required prior to submission of preliminary WPSs for
approval for qualification:
GTAW
GMAW
Root runs shall be back-purged with welding grade argon backing purge.
4.3
CONSUMABLES
The root run shall be performed with ER 2209 consumables (22Cr duplex stainless steel),
with all passes after the root pass to be installed with ER 2509 (25Cr duplex stainless
steel). In all cases the weld strength shall be greater than or equal to the parent material.
4.3.2 Hydrogen Certification
All consumable batches to be used in production welding shall be tested for hydrogen
content in accordance with an internationally recognised standard for this test, to be
approved by BP. The maximum allowable hydrogen content shall be that determined for
the consumables used in the weld procedure qualification, but in all cases shall be less
than 3.0 mls/100 grams of weld metal. Testing of batches shall be performed with BP
representatives in attendance.
4.3.3 Gas Quality
All gases used shall be welding quality. Where mixed gases are utilised the variation in
composition shall be clearly identified. Purging shall be applied to the root run with less
than 0.50% oxygen as measured by an oxygen analyser of appropriate accuracy. Purging
shall be maintained for sufficient passes to ensure freedom from oxidisation on the root
bead and associated HAZ.
4.4
4.4.1 General
Page 9 of 15
extra coupon passes, the coupon shall be indelibly marked with the PQR identification
and supplied to BP for later testing if so desired by BP.
PQR testing shall measure the oxygen levels present in the purge during the installation
of the root run. The maintenance of the purge shall be specified on the WPS and the
adequacy of such determined by sectioning of the coupon and visual inspection of the
internal bore. The degree of oxidisation shall be clearly recorded by colour photography.
If BP determines that the degree of oxidisation is excessive, BP shall require further
passes to be installed prior to the removal of the purge. The Contractor may offer
alternative solutions such as corrosion testing to prove the corrosion resistance of the
oxidised WMSS in the service environment. The corrosion test proposals shall be
accepted at the sole discretion of BP.
4.4.2 Consumables
Consumable batches used for weld procedure qualification shall be tested for hydrogen
content immediately after the PQR coupon(s) have been welded. The testing shall be in
accordance with an internationally recognised standard for this test, to be approved by
BP. Consumables packaging used for qualification testing shall be opened in the
presence of BP representative(s).
4.4.3 Essential Variables
The essential variables as identified in DNV OS-F101 Appendix C shall apply with the
following additional requirements:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
All weld coupons shall be tested in accordance with DNV OS-F101, as modified by the
following:
(i)
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Jan 03
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(ii)
(iii)
The mechanical testing requirements of DNV OS-F101 Table C-4, and C-5 as appropriate
for PQRs shall be modified as detailed below.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
4.5
PRODUCTION WELDING
The following control procedures shall be submitted for BP review and approval prior to
mobilisation offshore:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Maximum interpass temperature shall be 150C for all passes. The maximum heat input
shall be 2.0 kj/mm for all passes using ER 2209 consumables and 1.5 kj/mm for all
passes using ER 2509 consumables.
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Jan 03
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4.5.2 Contamination
The weld bevels and consumables used to produce the welds shall be free from any form
of contamination that may adversely affect the serviceability of the weld. If filler wire
consumables are contaminated with grease or oil they shall be discarded and not used on
the project. Each joint shall be monitored for oxygen contamination of the purge, with no
welding performed until the oxygen content of the purge is below 0.50%. All grinding
and buffing tools shall be uncontaminated with carbon steel. At no stage of handling and
welding shall any carbon steel materials contact the weld bevels or internal surface of the
pipe. If internal contamination is suspected the offending joint of pipe shall be removed
from the production deck and quarantined to ensure that the joint is not incorporated into
the pipe line. If the bevel has been contaminated the bevel shall be removed by an
appropriate machining procedure. Grounding clamps shall be stainless steel materials.
Contact between the pipe and copper based materials other than approved backing
mechanisms shall not be permitted.
4.5.3 Qualification of Welders
Welders shall be qualified in accordance with API 1104 and this specification. All
welders operating orbital automatic equipment shall demonstrate their ability to operate
the equipment without interruption and supervision. During the test welders shall
demonstrate their ability to follow written instructions on consumable control, interpass
temperature control, and purging practices as appropriate.
All welders shall either have been qualified in the presence of BP representative(s) using
equivalent equipment to be used in production welding. The procedures used for
qualification shall be approved by BP. Each welder shall perform the qualification test,
whether part or full, without prompting from supervision. Any such prompting shall
disqualify the test and the welder shall be retrained for at least 1 week prior to retesting.
INSPECTION ACTIVITIES
5.1
RECEIPT INSPECTION
All materials received by the Contractor that will be used to construct the pipeline and the
condition of such materials that could affect the fitness for purpose of the pipeline shall
be received, inspected and stored under controlled conditions. Procedures shall be
developed to ensure that all such items are verified as fit for purpose on receipt and that
they are handled and stored in a manner that will ensure continued fitness for service
throughout the construction program. Receipt inspection reports shall be generated for all
such BP or Contractor supplied items.
5.2
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Jan 03
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(i)
(ii)
(iii)
(iv)
The edge preparation and fit-up shall be in accordance with approved weld procedure
specifications. Visual acceptance criteria shall be in accordance with DNV OS-F101
Appendix D.
5.3
5.3.1 General
PRODUCTION/INSPECTION TRACEABILITY
A production welding inspection plan shall be produced as part of the project Inspection
Test Plan (ITP) that addresses in-process inspection of welding variables and equipment
to ensure that welds are being produced in accordance with the approved WPS(s). As a
minimum the essential variables and equipment controls that regulate the essential
variables shall be checked for compliance and accuracy at least four times per shift.
These inspections shall be documented with actual parameters recorded.
The following items as a minimum shall be traced in terms of an as built drawing,
detailing positions within the pipe line where the items have been used/applied and
incorporated into the pipeline:
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Jan 03
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All materials
All consumables
Procedures applied
Personnel applying procedures
Inspections applied
Personnel applying inspections
Material traceability shall be maintained to the most detailed possible level for any
particular item, (e.g. pipe number shall be recorded not just heat number).
DOCUMENTATION
Engineering documents to be submitted for BP review and/or approval are summarised in
Table 6.1. Timing for submission of these documents as well as documents to be
included in the MDR are also nominated in Table 6.1
Table 6.1
Documentation
Company
Review
Timing
Included in
MDR
YES
3A
NO
YES
4A
NO
Traceability System
YES
4A
YES
YES
4A
NO
YES
4A
YES
YES
4A
NO
YES
4A
NO
NDT Procedures
YES
4A
YES
YES
4A
NO
YES
WPQ
YES
YES
Performance Records
YES
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Jan 03
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Progressively during
Contract and 2 weeks
after completion
Documentation
YES
YES
YES
NO
NO
Documentation
Company
Review
Timing
Included in
MDR
YES
YES
YES
YES
NDT Reports
YES
YES
YES
NO
YES
NO
As Built Drawings
YES
YES
YES
YES
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Jan 03
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