ITP For Pipeline Welding Procedure [PDF]

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EPC for Flowlines, Gathering lines and Export Pipelines (BOC-1703)

ITP for Pipeline Welding Procedure

002

issued for Approval

13/05/2021

Huang Xianke

Zhang Shuli

Tao Ji

001

Issued for Review

03/05/2021

Huang Xianke

Zhang Shuli

Tao Ji

Rev.

Reason for Issue

Date

Author

Checker

Approver

Rev.

MGP1-PL1-CPP-QA-5733-0002

002

Project:

EPC for Flowlines, Gathering lines and Export Pipelines (BOC-1703)

Document Title

ITP for Pipeline Welding Procedure

Document No.:

MGP1-PL1-CPP-QA-5733-0002

Revision No.:

002

Revision History

Revision Date

Revision Number

Approver

Summary of Changes

03/05/2021

001

Taoji

Issued for Review

13/05/2021

002

Taoji

Edit according to comments

Holds Hold Ref.

Description / Reason for Hold

Ref. Section

Reference Documents Ref.

Document Number

Rev.

Page 2 of 15

Document Title

Rev002

CHINA PETROLEUM PIPELINE ENGINEERING COMPANY BASRA OIL COMPANY LIMITED Project: Contract №: EPC for Flowlines, Gathering lines and Export BOC-1703 Pipelines (BOC-1703) Security Classification:

Revision:

Restricted

002

Rev. Date:

13/05/2021

Sheet №:

15

Document Number: Project ID

Plant Code

Originator Code

Discipline

Doc Type

Sequential №

MGP1

PL1

CPP

QA

5733

0002

Document Title: ITP for Pipeline Welding Procedure

Abstract:

This ITP procedure is complied in accordance with the project requirement of BOC-1703 and is applied for the pipeline welding activities in EPC for Flowlines, Gathering lines and Export Pipelines construction activities.

Page 3 of 15

Rev002

4

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002

Content 1. INSPECTION AND TEST PLAN..............................................................................................................................5 2. CONSTRUCTION REPORT.................................................................................................................................. 11

Page 4 of 15

Rev002

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002 1. INSPECTION AND TEST PLAN

MAJNOON EPC FOR FLOWLINES, GATHERLINES AND EXPORT PIPELINES ITP FOR PIPELINE WELDING PROCEDURE

DEFINITION OF INSPECTION AND TEST PLAN SYMBOLS “H” - HOLD: A point beyond which work shall not proceed without formal approval by appropriate inspectorate. Achievement of “H” points shall be notified to COMPANY. “W” - WITNESS: A point beyond which work may proceed without formal documented approval by any of the inspectorate. Achievement of “W” points shall be notified to COMPANY. “S” - SURVEILLANCE: A point where CONSORTIUM and others may carry out surveillance of work in progress and documentation associated on an unscheduled basis, with no notification required by any party and without amendment to the scheduled production programme. “R” - REVIEW: The documents are to be submitted to the appropriate inspectorate for review by COMPANY. Note that where a document is subject to COMPANY approval, work shall not proceed until the COMPANY’s approval is given. “C” - CERTIFICATION: Specific and appropriate certification documentation is to be included in the document package.

REMARKS

Page ５ of 15

Rev002

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002

MAJNOON EPC FOR FLOWLINES, GATHERLINES AND EXPORT PIPELINES ITP FOR PIPELINE WELDING PROCEDURE Item No. 1.0

Inspection Activity & Specific Check Point Area

Reference Document

Acceptance Criteria, Code & Standard

FORM-QA-5733-0002API 1104 0001 Welding of pipelines Daily Welding Report and Related Facilities

Welding procedure review for final approval.

1.2

HSE Requirements for PPE and certified lifting API 1104 Welding of pipelines equipment. and Related Facilities Pipe inspection for pipe identification, physical and physical damage, manufacturing stamp. MGP1-PL1-CPP-BAASME B31.4-2019 Electrode Control for class batch No. 6070-0009 Pipeline Welding Procedure Chapter V Electrode Tracing by marking batch No. against Construction,Weldin welding g and Assembly

1.4 1.5 1.6

CPP

COMPANY

H

H

W/C

R

W/C

C/S

W/C

S

W

C/S

W/H

C/S

General

1.1

1.3

Verifying Record

Pipe tracing by pipe No, heat No, and length.Check material spec,diameter,schedule,colour coding and preservation the ID prior to cutting.

FORM-QA-5733-00020002 Pipe Log Book

FORM-QA-5733-00020003 Weld Box

Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C – Certification

Page ６ of 15

Rev002

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002

MAJNOON EPC FOR FLOWLINES,GATHERLINES AND EXPORT PIPELINES ITP FOR PIPELINE WELDING PROCEDURE

Item No. 2.0 2.1 2.2 2.3

2.4

2.5 2.6

Inspection Activity & Specific Check Point Area

Reference Document

Acceptance Criteria, Code & Standard

Verifying Record

CPP

COMPANY

H/W

H

H/W

H

H/W

H

H/W

H

H/W W/C

S/C S/C

Welder Qualification

FORM-QA-6066-00010001 Welder API 1104 Weld qualification test procedure Status for final Qualification Test Welding of pipelines Record approval. and Related Facilities Pre-weld preparations by bevel dimensions, clamp API 1104 Welding of pipelines FORM-QA-6066-0001type, root gap, alignment. and Related Facilities 0002 WQT Visual Welding Control by weather protection like wind Inspection Report shield, welding parameters as per WPS, ensure ASME B31.4-2019 FORM-QA-6066-0001finishing by removal of slag grind high points and file MGP1-PL1-CPP-BA6070-0009 Pipeline 0001 Welder out under cuts. Chapter V Welding Procedure Qualification Test Visual Inspection for marking and good workmanship Construction, Certificate of fit up inspection, root, cap, profile, surface Approved WPS & PQR Welding and discontinuities. FORM-QA-5733-0002Assembly NDT 100% for RT for butt welds. 0004 NDT Request Welder approval in WQT records with qualification, status, welder certificates, and cards

Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C – Certification

Page ７ of 15

Rev002

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002

MAJNOON EPC FOR FLOWLINES,GATHERLINES AND EXPORT PIPELINES ITP FOR PIPELINE WELDING PROCEDURE Item No.

Inspection Activity & Specific Check Point Area

3.0 3.1

Pipeline Welding Pipe size, type and quality. Check quality of welding product and handle, storage, oven and issue Verifying welding procedure Verifying welder qualification Line up joint clean Check line up clearance, high-low of spiral seam or/and long seam Check preheat temperature as per WPS Check welding environment in accordance with requirement Check length of Fixed welding, weld identification 100% visual examination for all joints, slag& spatter removed. Cap height, under cut, porosity, arc strikes, welder ID number(s), joint number. Ensure avoiding foreign matter into pipeline (add flange) Job site inspection （ensure ROW without any electrode heads, etc.） Transfer of heat NO. & color coding where applicable on piping to be cut.

3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9

3.10

3.11

Reference Document

API 1104 Welding of pipelines and Related Facilities

Acceptance Criteria, Code & Standard

Verifying Record

API 1104 Welding of pipelines FORM-QA-5733-0002-0001 and Related Facilities Daily Welding Report

ASME B31.4-2019 MGP1-PL1-CPP-BA- Chapter V 6070-0009 Pipeline Construction, Welding Procedure Welding Assembly Approved WPS & PQR

and

FORM-QA-5733-0002-0002 Pipe Log Book FORM-QA-5733-0002-0003 Weld Box

Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C – Certification Page ８ of 15

Rev002

CPP

COMP ANY

W/S

S

S/R S/C W W

S S S S

W W

S S

W H

S S/R

W

S

W

S

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002

MAJNOON EPC FOR FLOWLINES,GATHERLINES AND EXPORT PIPELINES ITP FOR PIPELINE WELDING PROCEDURE Item No.

Inspection Activity & Specific Check Point Area

4.0 4.1

Tie-in Trench is clear of debris and water. The inside of adjoining pipes is clear from foreign material. Both ends of adjoining pipes are beveled as per WPS joint design, and the surface are clean within 100mm distance from the ends Bell hole for Tie-in is adequate for Tie-in welding operation, and as per specifications. Ensure that adjoining pipes are stress free before welding. Offset of adjoining pipes is divided equally around the pipes, and within specified tolerance. Tie-in welding is performed by qualified welders with approved WPS. Visual inspection to the final weld is acceptable. Tie-in weld is passed by RT/UT/PT testing.

4.2

4.3 4.4 4.5 4.6 4.7 4.8

Reference Document

Acceptance Criteria, Code & Standard

Verifying Record

FORM-QA-57330002-0001 Daily Welding Report

API 1104 Welding of pipelines API 1104 FORM-QA-5733Welding of pipelines and Related Facilities 0002-0002 Pipe Log and Related Facilities Book MGP1-PL1-CPP-BA6070-0009 Pipeline ASME B31.4-2019 Welding Procedure Chapter V Construction,Welding Approved WPS & PQR and Assembly

FORM-QA-57330002-0003 Weld Box FORM-QA-57330002-0004 NDT Request

Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C – Certification

Page ９ of 15

Rev002

CPP

COMPA NY

W

S

W

S

W/S

S/R

W

S

W

S

W/R

S

W R/C

S/R R

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002 2. CONSTRUCTION REPORT MAJNOON EPC FOR FLOWLINES,GATHERLINES AND EXPORT PIPELINES ITP FOR PIPELINE WELDING PROCEDURE Item No. 5.0 5.1

5.2 5.3

5.4 5.5

5.6

Inspection Activity & Specific Check Point Area

Reference Document

Acceptance Criteria, Code & Standard

Pipeline welding NDT Non-destructive test inspecting technician shall be experienced and competent with qualification certificate. NDT operator API 1104 qualification requirement e.g. BINDT Level II, Welding of pipelines API 1104 ASNT-TC-1A Level II or equivalent etc. and Related Facilities Welding of pipelines and Related Facilities Inspect RT films and inspection reports Inspect MT reports

equipment

and inspection MGP1-PL1-CPP-BA6070-0009 Pipeline Welding Procedure ASME B31.4-2019 Chapter V Inspect PT liquid and inspection reports. Construction,Welding and Assembly Inspect UT equipment and inspection reports.

Verifying Record

FORM-QA-5733-0002-0004 NDT Request

Record welding history and NDT reports on a daily basis.

Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C – Certification Page １０ of 15

Rev002

CPP

COMPANY

H

R

W

S/R

W

S/R

W

S/R

W

S/R

R

R

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002 NO. FORM-QA-5733-0002-0001 Daily Welding Report Report No. Pipe NO.

Heat No.

Line No. Pipe Material

Diamete r (Inch)

W.T. (mm )

Joint No.

Date: WPS NO.

Fitup

Preheat (℃)

CPP

Sheet Welders

Root

Hot

Fill1

Fill2

Fill3

COMPANY

Name Signature Date

Page １１ of 15

of

Rev002

Cap

Visual Inspection

Remarks

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002 NO. FORM-QA-5733-0002-0002 Pipe Log Book Pipe NO.

Heat No.

Length Dia. (m) (Inch)

W.T. (mm)

Joint Welding WPS No. Date NO.

Welders Root

Hot

Fill1

Fill2

Page １２ of 15

Fill3

Cap

Welding Report No

RT/UT/MT/PT Reports Date

Resul ts

Rev002

Report No.

Coating Date

Resu lts

Repor t No.

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002 NO. FORM-QA-5733-0002-0003 WELD BOX

WELD NO.

WPS NO.

L

R

PIPE NO.

HEAT NO.

R

H

F

C

VT

DATE

Page 13 of 15

Rev002

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002

NO. FORM-QA-5733-0002-0004 Report NO.: Drawing No.: S.N.

Weld NO.

NDT REQUEST Line No.: Date: DIA X THICK

WPS NO.

CPP

Sheet: REQUEST FOR RT

UT

PT

MT

of

Welders

NDT COMPANY

Name Signature Date Page 14 of 15

Rev002

REMARKS

ITP for Pipeline Welding Procedure MGP1-PL1-CPP-QA-5733-0002

NO. FORM-QA-5733-0002-0005

TIE-IN CHECK LIST

Report No.:

Line No.: Date:

QC CHECK POINTS

YES/NO

1.

Trench is clear of debris and water.

2.

The inside of adjoining pipes is clear from foreign material.

3.

Both ends of adjoining pipes are bevelled as per WPS joint design, and the surface are clean within 100mm distance from the ends

4.

Bell hole for Tie-in is adequate for Tie-in welding operation, and as per specifications.

5.

Pipes to be joined are free from any mechanical damages; pup piece length is more than 2.0 meter if used.

6.

The weld seams of the adjoining pipes are offset as per specification.

7.

Ensure that adjoining pipes are stress free before welding.

8.

Offset of adjoining pipes is divided equally around the pipes, and within specified tolerance.

9.

Tie-in welding is performed by qualified welders with approved WPS.

10.

Visual inspection to the final weldment is acceptable.

11.

Tie-in weldment is passed by radiographic, ultrasonic and penetrating testing.

REMARKS

APPROVALS

CPP

COMPANY

Name Signature Date

Page 15 of 15

Rev002