Basis of Design - Pig Launcher & Receiver [PDF]

Zitiervorschau

PIPELINE PROJECT JOB No: 001

PT. PERTAMINA EP – FIELD LIMAU

PROJECT SPECIFICATION PIG LAUNCHER AND RECEIVER

DOCUMENT NUMBER: 007/2014-LMU-001

DESCRIPTION

PREP’D

REV

REV

A

00

ISSUED FOR INTERNAL REVIEW

AS

B

00

ISSUED FOR CONSTRUCTION

AS

CHK’D

APP’D

NOTE

PIPELINE PROJECT PT. PERTAMINA EP – FIELD LIMAU

PROJECT SPECIFICATION PIG LAUNCHER AND RECEIVER TABLE OF CONTENTS Page 1.0

SCOPE …………………………………………………………………………………………….. 3

2.0

CODES AND COMPANY SPECIFICATIONS………………………………………………….. 3

3.0

GENERAL REQUIREMENTS ……………………………………………………………………. 3

4.0

SCOPE OF SUPPLY …………………………………………………………………….………… 4

5.0

DESIGN REQUIREMENTS ………………………………………………………………………. 4

6.0

MATERIALS………………………………………………………………………………………. 5

7.0

SPARE PARTS AND TOOLS ……………………………………………………………………. 6

8.0

INSPECTION AND TESTING……………………………………………………………………. 6

9.0

EQUIPMENT/MATERIAL IDENTIFICATION ………………………………………………… 7

10.0

PREPARATION FOR SHIPMENT ……………………………………………………………….. 7

11.0

GUARANTEE…………………………………………………………………………………….. 7

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PIPELINE PROJECT PT. PERTAMINA EP – FIELD LIMAU

1.0

SCOPE This specification covers minimum requirements governing for design, material, fabrication, inspection and testing of pig launcher and receiver barrels, complete with spare parts and Vendor data.

2.0

CODE AND COMPANY SPECIFICATIONS The requirements and recommendations of the latest revision of the following listed codes, standards, COMPANY's general specifications and project documents shall apply. 2.1

3.0

Codes 2.1.1

ASME B1.5

-

Acme Screw Threads

2.1.2

ASME B16.5

-

Steel Pipe Flanges and Flanged Fittings

2.1.3

ASME B31.3

-

Chemical Plant and Petroleum Refinery Piping

2.1.4

ASME B31.4

-

Liquid Transportation for Hydrocarbons

2.1.5

ASME B31.8

-

Gas Transmission & Distribution Piping system

2.1.6

API 5L

-

Specification for Line Pipe

2.1.7

ASTM A370

-

Standard Test Methods for Mechanical Testing of Steel Products

GENERAL REQUIREMENTS 3.1

The purpose of this specification and referenced codes, standards, general specifications and project documents is to establish a minimum level of acceptable quality. Alternate standard designs of equal or superior quality may be proposed, provided all exceptions are listed and written approval for all exceptions is obtained from COMPANY.

3.2

In the case of any conflict in the requirements specified in the documents attached to the enquiry/order, the most stringent of the specified requirement shall govern. Purchasers interpretation in this regard shall be final and binding on the Vendor. The following is the order of precedence of the documents accompanying the enquiry/order: 1. Data Sheet. 2. Job Specification (if any). 3. P&ID’s and Drawings (if any). 4. This Specification. 5. Other Specifications (if any). 6. Referenced Codes & Standards.

3.3

Equipment specified by this specification shall be complete in all detail and ready for installation.

3.4

Equipment shall be designed for continuous use in an exposed, tropical, onshore, corrosive atmosphere with 95°F ambient temperature and 100% relative humidity.

3.5

Launchers and receivers shall be certified by a third party inspection agency approved by applicable Indonesian authorities. Page 3 of 8

PIPELINE PROJECT PT. PERTAMINA EP – FIELD LIMAU

3.6

4.0

Unless otherwise specified in the individual data sheets, launchers and receivers will be installed in the horizontal position.

SCOPE OF SUPPLY 4.1

Launchers/Receivers shall include the following major components which shall be assembled and shop tested in accordance with the Data Sheets prior to shipment from the Vendor/Manufacturer's facilities: Each Launcher / Receiver consisting of the following:

5.0



One (1) Barrel, Reducer & Flange



Saddle



One (1) Closure c/w safety device



Flanges for Nozzles



Lifting Lugs & Grounding Lugs



Vendor Data (Mill Certificate, Inspection & Test Report, etc.)

DESIGN REQUIREMENTS 5.1

Design Parameters Design pressure and temperature shall be as specified on COMPANY supplied data sheets and equipment outline drawings. Pressure design of the wall thickness of the barrel and nozzle pipe, excluding corrosion allowance, shall be determined in accordance with ASME B31.8 or ASME B31.4, as applicable. Corrosion allowance shall be 0.125 inches unless specified otherwise on COMPANY supplied data sheets. Minimum barrel and nozzle pipe wall thickness shall be equal to or greater than nominal wall thickness calculated for mechanical requirements, plus corrosion allowance plus an additional 12.5 % of nominal wall thickness calculated for mechanical requirements to compensate for minus 12.5 % for mill tolerance for nominal pipe wall thickness.

5.2

Barrel & Reducer The barrel shall be at least two nominal pipe diameters larger than the pipeline. Barrels shall be seamless pipe for 14" and smaller. Double submerged arc welded pipe may be used for 16" and larger barrels. The seam shall be 100% radiographed. Reducer shall have a nominal wall thickness is at least equal to the specified nominal wall thickness of the matching pipe at the large end.

5.3

Closure 5.3.1 Closure welding hub bevel end shall be in accordance with ASME IX. 5.3.2 Closure cap to closure welding hub shall be screwed type with Acme wide-pitch standard thread in accordance with ANSI B1.5. 5.3.3 Closure cap shall be suspended by davit to the closure welding hub and shall be a hinged, quick opening design with a pressure Lock Safety Device to prevent opening under pressure. Page 4 of 8

PIPELINE PROJECT PT. PERTAMINA EP – FIELD LIMAU

5.3.4

A lever, screw or other similar device to facilitate easy closing and opening of the closure cap shall be provided by the closure manufacturer.

5.3.5 A safety device, as part of the closure component, shall be provided by the closure manufacturer to warn the operator of any residual pressure in the launcher or receiver before the operator starts to loosen the closure cap. 5.4

Flanges All flanges shall be in accordance with Specification in ASME B16.5.

5.5

Nozzles 5.5.1

Nozzles shall be designed to include the applied load forces and bending moments of attached piping. Nozzle pipe shall be seamless.

5.5.2 Nozzles larger than 1.5" NPS shall be flanged. 5.5.3 Threaded connections shall not be allowed. 5.5.4 Reinforcing pads shall be designed in accordance with ANSI B 31.3. Reinforcing pads shall be 2" minimum width and 1/4" minimum thickness. Pads shall be one (1) piece. Reinforcing pads shall be provided with 1/8" telltale hole. Telltale holes shall be filled with a non-hardening sealant or heavy duty grease after completion of hydrotest. 5.6

6.0

Fabrication 5.6.1

The Vendor shall submit to the COMPANY for approval, all detailed shop drawings, design calculations and all welding procedures and qualification records prior to commencement of fabrication.

5.6.2

Minimum spacing of circumferential welds between centerlines shall not be less than four times the pipe wall thickness or 4", whichever is greater.

5.6.3

Flange bolt holes shall straddle the horizontal and vertical centerlines.

5.6.4

Nozzles shall be installed flush with the barrel interior.

5.6.5

Welding procedure and qualification records shall be in accordance with ASME IX.

5.6.6

All branch connections shall be joined to the barrel with full penetration welds.

5.6.7

Internal weld protrusion in the barrel shall not exceed 1/16".

5.6.8

Preheat and post-weld heat-treatment shall be in accordance with ASME B31.3.

5.6.9

Face to face, center to face, location of nozzle +1/8" tolerance.

5.6.10

Nozzle tolerance: Lateral

+ 1/4"

Level

+ 1/2 degree

Deviation of bolt holes

+ 1/8"

MATERIAL Pipe and flange materials fabricated in accordance with ASME B 31.4 or ASME B 31.8, as applicable and referenced specifications, codes & standards.

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PIPELINE PROJECT PT. PERTAMINA EP – FIELD LIMAU

7.0

SPARE PARTS AND TOOLS 7.1

Installation Spares The Vendor shall include, as part of his bid, a detailed price list of installation spares which shall be supplied as part of the original purchase package.

7.2

Commissioning Spares The Vendor shall include, as part of his bid, a detailed price list of commissioning spares. These spares shall be supplied as part of the original purchase package.

7.3

One Year Spares The Vendor shall include, as part of his bid, a detailed list of recommended spare parts for one year continuous operation. These spares shall be costed for separate purchase by COMPANY.

7.4

Tools The Vendor shall supply one full set of special tools required for the complete disassembly and reassembly of all items of equipment supplied as part of the unit. Each tool shall be clearly labeled and identified in the Special Tools List specified in the Data Requirement Sheets.

8.0

INSPECTION AND TESTING 8.1

The Vendor shall be responsible for inspection and testing of the unit. Vendor shall furnish Third Party Certification agent as part of his scope of work. A copy of typical ITP (Inspection and Test Plan) shall be furnished with the tender.

8.2

Following assembly, the unit shall be inspected for completeness, quality of construction and appearance.

8.3

Welding Inspection

8.4

8.3.1

Weld examination shall be in accordance with ASME B31.4 or ASME B31.8, as applicable

8.3.2

All welds shall be 100% radiographed. Magnetic particle inspection may be substituted on a case by case basis with COMPANY approval when radiography is difficult to interpret. The Radiograph shall be interpreted in accordance with paragraph UW-51 of the ASME Boiler & Pressure Vessel Code, section VIII.

8.3.3

When heat treatment is required, radiography shall be performed after completion of heat treatment.

Hydrostatic Testing 8.4.1

Vendor shall submit hydrotest procedure to COMPANY for approval prior to commencement of testing.

8.4.2

Hydrostatic testing shall be performed in accordance with ASME B31.8 or ASME B31.4. Test pressure is to be held for at least 4 (four) hours. Pressure testing shall be completed prior to painting.

8.4.3

Any repairs necessary as a result of defects discovered during the course of inspection and hydrostatic testing shall be at Vendor's expense.

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PIPELINE PROJECT PT. PERTAMINA EP – FIELD LIMAU

9.0

8.5

Hydrostatic testing will be witnessed by COMPANY and Third Party Certification agency representatives.

8.6

The Vendor shall notify COMPANY of all inspections and test at least fourteen (14) days prior to scheduled factory inspection/test dates such that COMPANY and Third Party Representative may be mobilized to witness the tests.

8.7

The Vendor shall submit to COMPANY reports of all inspections and tests within fourteen (14) days following test completion.

8.8

COMPANY shall have free and immediate access to Vendor's facilities to inspect all work pertaining to COMPANY equipment at all stages of manufacture.

EQUIPMENT/MATERIAL IDENTIFICATION Each launcher/receiver shall have a permanently attached by rivets, impression stamped, 316 stainless steel or Monel name plate. The nameplate shall include the following information: 

Description



Tag No.



Size



Purchase Order No.



Design pressure and temperature



Date of fabrication



Service



Corrosion allowance



Fabrication and Testing Codes



Third Party Inspection Company's Name



Hydrostatic Test Pressure

10.0 PREPARATION FOR SHIPMENT 10.1 Equipment shall be prepared for shipment and shall be crated to provide maximum protection during shipment and extended outdoor storage. Following shop testing, barrels shall be drained, evacuated, dehumidified and sealed. Any items which are liable to be damaged during shipment shall be removed, packed separately and shipped with the unit. 10.2 All openings shall be provided with Plugs, Caps or Closures to prevent the entrance of moisture or foreign materials. 10.3 Tools and spare parts shall be packed in metal boxes suitable for long term storage. The boxes shall be galvanized or coated. 11.0 GUARANTEE Material and/or equipment shall be guaranteed by Vendor to perform in accordance with specification requirements and to be free of defects and poor workmanship including, but not limited to, those caused by inadequate preparation for shipment, as per Section 10.0 of this document, for a period of one (1) year after material/equipment is placed in service, but not exceeding eighteen (18) months following delivery to the contracted destination. Page 7 of 8

PIPELINE PROJECT PT. PERTAMINA EP – FIELD LIMAU

Vendor shall repair or replace all defective items during the guarantee period at no cost to COMPANY.

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