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BP MURIAH LTD

KEPODANG GAS DEVELOPMENT PROJECT

DEFINE PHASE

WMSS Linepipe Welding Specification

A1

JAN 02

ISSUED FOR REVIEW

AM

IR

REV

DATE

DESCRIPTION

PREPARED

CHECKED

Kellogg Brown & Root Pty Ltd


Level 2, Capital Centre

APPROVED

Document Number

REV

KPD20-01-W-SPE-0018

A1

256 St Georges Terrace


Perth Western Australia 6000
Telephone No: (08) 9278 4100
Facsimile No: (08) 9278 4200

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

ACTS, CODES, STANDARDS, PROJECT


SPECIFICATIONS AND REFERENCES

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

Health, Safety and Environment


Inspection And Testing
Quality Records
Marking and Identification
Traceability

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

American Petroleum Institute

CPP

Central Production Platform

DNV

Det Norske Veritas

GMAW

Gas Metal Arc Welding

GTAW

Gas Tungsten Arc Welding

HAZ

Heat Affected Zone

HSE

Health, Safety & Environment

ITP

Inspection and Test Plan

MDR

Manufacturers Data Report

NDT

Non Destructive Testing

ORF

Offshore Receiving Facility

PQR

Procedure Qualification Report

RPSE

Recommended Practices and Specifications for Engineering

SDRL

Supplier Data Requirements List

WHT

Wellhead Tower

WPS

Weld Procedure Specification

WMSS

Weldable Martensitic Stainless Steel

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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:

Central Production Platform (CPP) consisting of a Process Deck with separation,


dehydration, compression, chemical injection and utilities, and a Wellhead
Module with 8 slots/5 wells. The CPP will be normally unattended and will be
controlled and monitored from the Onshore Receiving Facility (ORF). A satellite
Wellhead Tower (WHT) with 5 slots/3 wells tied back to the CPP via an infield
flowline.

A DN350 diameter 200km export pipeline to transfer the dry gas to the ORF at
Tambak Lorok power station.

ORF comprising a pig receiver, gas filter/separator, superheater, fiscal metering,


and a main control and communications room, manned 24 hours.

Phase 2 development will include the installation of 2 additional satellite WHTs (3


wells) tied back to the CPP. Flexibility in the Phase 1 facility will allow for the Phase 2
wells to be a subsea development if appropriate.
1.2

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.

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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

Independent Verification Body and/or Certifying Authority


acting on behalf of MIGAS

ACTS, CODES, STANDARDS, PROJECT SPECIFICATIONS


AND REFERENCES
The WMSS welding shall be performed in accordance with the requirements of this
specification, the following project specifications, other project specifications where
referenced in the Contract, and the latest editions of the following codes, standards and
regulations and other documents referenced therein.
When Indonesian national regulations exist, the recommendations of the latter shall
always apply together with the standards and codes to which they refer. These
regulations may thus complement or amend the provisions of the present document.

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

Guidelines and Procedures of Working Safety Inspection


on Installation, Equipment and Engineering used in
Natural Gas Mining and Geothermal Source Exploitation

Regulation
06P/0746/M.PE/1991

Safety Audit to Installation, Equipment and Technique


used in Oil and Gas Mining and Geothermal Activities

Regulation
05/P/II/PERTAMB/1977

Obligation to Own Certificate of Construction Worthiness


for Oil and Gas Platform in the Off-shore area

Regulation Number 11
Year 1979

Working Safety on Refinery and Processing Oil and Gas

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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

CODES AND STANDARDS


The requirements of the latest editions of the following Codes and Standards shall be
complied with.
DNV OS-F101
Det Norske Veritas, Submarine Pipeline Systems, 2000.
API 1104

2.3

Welding of Pipelines and Related Facilities

PROJECT SPECIFICATIONS
This Specification shall be read in conjunction with the following Project Specifications:
KPD99-01-G-SPE-0002

Supplier Documentation Requirements Specification

KPD99-01-G-SPE-0005
KPD20-01-W-SPE-0013

Quality Requirements
Pipeline and Flowline Installation Specification

KPD20-01-W-SPE-0001

WMSS Linepipe Specification

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:

Government Legislation, Statutory Codes and Regulations

Data Sheets and Drawings

This Specification

Project Specifications

Industry Standards and Codes

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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GENERAL REQUIREMENTS

3.1

HEALTH, SAFETY AND ENVIRONMENT


BP has set targets for HSE of no accidents or harm to people or environment. To achieve
this goal, the following shall be applied:

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.

equipment shall be designed to eliminate or reduce emissions to as low as


reasonably practical.

INSPECTION AND TESTING


General
Inspection and tests shall be as defined on the data sheets, Indonesian Regulations, this
specification, other specifications where referenced in the Contract and codes and
standards listed. The requirements of Indonesian Regulations shall take precedence.
Inspection and tests shall also comply with the requirements of Decree
84K/38/DJM/1998 where applicable. This shall include, but not be limited to physical
inspection, testing, repairing and reporting.

3.2.2

Inspection and Test Plan (ITP)


The Contractor shall develop an Inspection and Test Plan (ITP) during detailed design
engineering for submission to BP for approval prior to the commencement of
manufacture. The Contractor shall perform inspection and testing activities in accordance
with the requirements of this specification and the approved inspection and test plan(s).

3.2.3

Inspection and Test Procedures


The Contractor shall prepare all necessary inspection and test procedures required for the
works and submit to BP for review and approval.

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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records requiring BP review and or endorsement shall be forwarded to BP progressively


throughout the Contract period.
3.4

MARKING AND IDENTIFICATION


Contractor shall mark items for identification and traceability in accordance with this
Specification and the requirements of Project Specification KPD99-01-G-SPE-0007.
Items marked to facilitate traceability shall maintain the marking throughout manufacture
and fabrication stages. The transfer of markings to traceability quality records may be
subject to BP verification.
Items marked to permit identification only shall maintain the marking throughout
manufacture stages until included in the final assembly.

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.

Table 3.1 Traceability Requirements


Item Description

Production Welds

Traceability Levels

Each Weld

Quality Records

Linepipe unique pipe number.


Consumable batch number.
Welder/welding operators ID.
Weld procedure Specification No.
Heat treatment records, if
applicable
NDT 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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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

4.3.1 Consumable Types

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

WELD PROCEDURE QUALIFICATIONS

4.4.1 General

Weld procedure qualification shall be performed in accordance with DNV OS-F101 as


amended by this specification. After approval of the preliminary weld procedure
specifications by BP, the Contractor shall perform qualification activities in the presence
of the BP representative(s).
An extra weld procedure qualification coupon welded to the same parameters as the weld
procedure qualification coupon to be destructively tested shall be produced and nondestructively tested in accordance with 4.4.4 below. The non-destructive test acceptance
criteria detailed below shall also apply to the extra coupon. If the extra coupons fail due
to cracking, or lack of fusion, or root defects in excess of the allowable, which are
attributable to the weld procedure, the weld procedure shall be deemed to fail. If the
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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)

Any reduction in the number of runs installed prior to removal of the


line-up clamp
Any reduction in the number of runs installed prior to removal of gas
backing purge
Any change to the contour of a backing shoe if used
Any change in the number of runs of any filler wire consumable type
Any increase in the oxygen content of the purge gas from that
measured in the PQR
The method of bevel preparation as applied to cut-outs unless it is
intended to prepare each joint in the same fashion.

4.4.4 Non-Destructive Testing

All weld coupons shall be tested in accordance with DNV OS-F101, as modified by the
following:

(i)

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The coupons shall be 100% radiographic, ultrasonic and surface crack


detection tested. Any defects identified as cracks, or lack of sidewall
or inter-run fusion in excess of the acceptance criteria specified in
DNV OS-F101 Appendix D Table D-5 shall be cause for rejection of
the weld procedure.

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(ii)

(iii)

No defects attributable to the weld procedure shall be present in the


root. Welder installed defects are exempt from this requirement,
however the Contractor shall present a report to BP for approval
justifying the exemption of root run defects. BP reserves the right to
sentence the defects as a final decision as to whether the defects were
attributable to the weld procedure or to the welder. If a root defect is
attributable to the weld procedure, the procedure shall require
requalification.
All testing shall be performed no sooner than 48 hours after welding.

4.4.5 Mechanical Testing

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

Fracture toughness shall not be required.


Four additional side bends shall be removed and tested in accordance
with DNV OS-F101 if GMAW process is used for root and/or fill
passes. These shall be removed at the 2, 5, 8 and 10 oclock positions.
Any cracking noted in the macro-section specimens shall be cause for
rejection of the procedure.
All test specimens shall be removed from the coupon no sooner than
48 hours after welding.
Impact testing shall be performed at -20C, with 100 joules minimum
single and average value.
Hardness test acceptance criterion shall be 350 Hv10 maximum.
All weld metal tensile testing shall prove the weld metal yield and
tensile strength at least equal to the minimum specified for the parent
material.

PRODUCTION WELDING

4.5.1 Welding Control Procedures

The following control procedures shall be submitted for BP review and approval prior to
mobilisation offshore:

(i)
(ii)
(iii)
(iv)
(v)
(vi)

Consumable control procedure


Purging procedure
Bevelling procedure (if applicable)
Interpass temperature control procedure
Welding activities control procedure
Materials handling/preservation procedure

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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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

VISUAL INSPECTION OF WELDS


All of the following items shall be 100% visually inspected:

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(i)
(ii)
(iii)
(iv)

Edge preparation prior to welding


Fit up prior to welding
Root run external surface
Completed weld external surface

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

NON-DESTRUCTIVE TESTING REQUIREMENTS

5.3.1 General

Non-destructive testing (NDT) shall be performed in accordance with the requirements of


DNV OS-F101 and this specification. All NDT procedures shall be submitted for review
and approval to BP. All NDT procedures shall be qualified in accordance with DNV OSF101 and this specification.
5.3.2 NDT Procedures

All NDT procedures qualification shall be performed in the presence of the BP


representatives.
The qualification documents shall be authorised by the BP
representative(s) and these documents shall be submitted for review and approval.
Ultrasonic Inspection shall be applied. Methods of test shall comply with DNV OS-F101.
All acceptance criteria shall be in accordance with DNV OS-F101 Appendix D section H,
as appropriate, with the exception that clause H 305 of Appendix D shall not apply.
5.3.3 Production NDT

All girth welds shall be 100% ultrasonically or automatic ultrasonically tested in


accordance with qualified, reviewed and approved procedures.
If welding activities are performed on-shore, the NDT shall be performed with as long a
delay as possible after welding. This delay need not interfere with production activities,
however the Contractor shall propose an NDT plan for BP approval that manages this
requirement to maintain the longest practical delay between welding and NDT activities.
If possible the NDT shall be applied no sooner than 48 hours after welding.
5.4

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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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

Inspection and Test Plan

YES

3A

NO

Inspection and Test Procedures

YES

4A

NO

Traceability System

YES

4A

YES

Welding System Specification

YES

4A

NO

Welding Procedure Specification and Register

YES

4A

YES

Consumable Handling Procedure

YES

4A

NO

Welder Training Procedure

YES

4A

NO

NDT Procedures

YES

4A

YES

Mechanical Testing Procedures and Testing


Laboratory Details

YES

4A

NO

Consumable Batch Testing Records


WPS

YES

WPQ

YES

Qualification Test Record

YES

Performance Records

YES

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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

Heat Treatment Time Temperature Report

YES

YES

NDT Procedure Qualification

YES

YES

NDT Reports

YES

YES

NDT Operators Qualification

YES

NO

Equipment Calibration Records

YES

NO

As Built Drawings

YES

YES

Document Control Records

YES

YES

3A = 3 Weeks after contract award


4A = 4 Weeks after contract award

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