Marjan Increment Program - Package 1 - GOSP 4

Methodology of FBE Piping Spools

March 2021 By Bharath, Indra & Thirunavukkarasu

Piping & Layout, APAC
 FBE Piping spool with break-up Flanges
(methodology used in previous projects)
Spool size limited by FBE coating

Spool size limited by FBE coating

Legends

Flange connection with Valve or Equipment

Additional break-up flange added due to

limitation of FBE coating

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 FBE Piping spool with Pup Pieces
For Hydrocarbon excluding OW service

Spool size limited by FBE coating

Field Weld

Spool size limited by

Assembly Sequence
FBE coating
1. Cladding of pup pieces
2. Spool fabrication of CS
pipes, fittings, flanges
and CS clad pup pieces
3. FBE coating
4. Assembly of FBE coated
spools by field Inconel
welds
INC 625 Weld
CS Weld (post FBE coating)
(prior to FBE coating)

Legends
CS Pipe CS Pup Piece CS Pup Pipe CS Pup Piece
CS FBE coated Pipes, Fittings and Flanges

25mm 25mm
overlap
CS + Inconel 625 clad pup piece FBE coating
1200 mm of PWHT pipes 6-7°Angle Inconel 625 clad 3mm Inconel 625 clad 3mm
600 mm for pipe sizes 24” & above
300 mm for others
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 Buttering on Girth weld Bevel

INC 625 Weld INC 625 Weld

(post FBE coating) (post FBE coating)

CS Pup Pipe CS Pup Piece CS Pup Pipe CS Pup Piece

Additional work
1. Buttering
2. RT

Inconel 625 Benefits

buttering 6 mm 3. Reduction of cladding on pup piece

CS Pup Pipe 4. No PWHT

CS Pup Pipe
5. Reduction of field joint touchup
coating
400 mm
1200 mm

Inconel 625 clad 3mm

Case 1 – Girth weld with PWHT Case 2 – Girth weld without PWHT

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 FBE Piping spool with Pup Pieces & Cladded fittings
For Hydrocarbon excluding OW service

Spool size limited by FBE coating

Field Weld

Assembly Sequence Spool size limited by FBE coating

1. Cladding of Fittings
2. Cladding of pup pieces
3. Spool fabrication of CS
pipes, fittings, flanges Field Weld
and CS clad pup pieces/
clad fittings
Field Weld
4. FBE coating
5. Assembly of FBE coated INC 625 Weld
spools by field Inconel CS Weld (post FBE coating)
welds (prior to FBE coating)

Legends

CS Pipe CS Pup Piece CS Pup Pipe CS Pup Piece

CS FBE coated Pipes, Fittings and Flanges

25mm 25mm
overlap
CS + Inconel 625 clad pup piece
1200 mm of PWHT pipes FBE coating
6-7°Angle Inconel 625 clad 3mm Inconel 625 clad 3mm
600 mm for pipe sizes 24” & above
300 mm for others
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 FBE Piping spool with Flange joints
For Utilities and OW services

Spool size limited by FBE coating

Assembly Sequence
Spool size limited by FBE coating
1. Spool fabrication of CS
pipes, fittings and
flanges
2. FBE coating
3. Assembly of FBE coated
spools by flange joints.

Legends

Flange, where connect with Valve or Equipment

Additional break-up flange added due

limitation of FBE coating

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 FBE Piping spool – Robotic FBE Coating
(Bridge straight pipes)

Spool size limited by FBE coating

CS Weld

CS Pipe CS Pipe

Legends

CS FBE coated Pipes

FBE coating – prior
to girth weld
FBE Robotic coating –
post girth weld
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 FBE Piping spool – Robotic FBE Coating
(Typical Bridge Piping)
Bridge-8 (ref) Bridge-7 (ref)
TIE-IN

Hook-up
Hook-up

17m

EDP
Hook-up Spool is CS+ Inconel 625 Clad, hence only one(1)
pup piece considered.
7m

53.5m 3.5m 70m

20m

13m
Pup Piece required due to following limitations. Joint required due to limitation on Max length & spool configuration
1. Lifting limitation of straight pipes being coated imposed by FBE vendor. Hence Pair of Pup Piece considered.
2. Hot work on FBE coated spool to join damages FBE coating
3. Max travel length of Robotic Crawler
5.2m

LEGENDS
FBE coating Vendor limitations Indicates Joint, 2nos of PUP pieces

Indicates Joint, 1no of PUP piece for Connection with Hookups

Indicates Girth weld every 11 to 12m

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 FBE Piping spool joint methodology
(By location by service and size range)

  Process Piping OW & Utility Piping

Location of Piping 4" and Below 6" 8" and above 1-1/2 and below 2" and above
Platform Piping CS + Inconel 625 Clad pup piece* Flange joint
Bridge Piping - Expansion Solid Inconel 625 CS + Inconel 625 Clad pup piece Solid Inconel 625 Flange joint
loops Piping Piping
Bridge Piping - Stright lines CS + Inconel 625 Clad pup Robotic Flange joint
piece coating

* Where CS + Inconel 625 clad pup piece can't be accommodated in process piping, fitting shall be Inconel 625 Clad

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Details of Pup Piece

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MIP Package 01 – Quantum of FBE Piping

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MIP Package 01 – Quantum of FBE Pipes
All units are in Meters

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MIP Package 01 – Quantum of FBE Fittings
All units are in pcs

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MIP Package 01 – Quantum of FBE Flanges
All units are in pcs

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Optimized Pup Piece Cladding sequence

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 Proposed Pup Piece cladding sequence

Length of 2 pup pieces 50 mm gap

1st cut

CS + Clad Pup Piece

2 cutnd

40mm 25mm
overlap
Inconel 625 clad 3mm
FBE coating
CS Pipes

6-7° slope Details of Pup Piece

Inconel 625 clad 1200 mm of PWHT pipes
600 mm for pipe sizes 24” & above
300 mm for others
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Logistics of FBE Spool

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 SMLS Pipes Logistics of FBE Piping Spool

Fittings

SAW Pipes

Flanges
Spool fab

FBE Coating

Tyhoo

Spool fab

Spool fab

FBE Coating Cladding

Bare  Clad  Spool  FBE  Install

 SMLS Pipes Logistics of clad items in FBE Piping

Fittings

SAW Pipes
TBA?
Flanges

COOEC &
QMW

Aasia Steel
TYHOO
JAY

Batam

Al Qatani Cladtek

Bare  Clad  Spool  FBE  Install

 SPMat PR for Clad items
Engineering PR for CS SMLS Pipes (similarly for Fittings and Flanges PR’s)
Delivery location
SPMat BOM for CS SMLS pipes, PVK01-0001-1
Ident Tag No Item Description Qty Unit
PPPXXPPX0057183 6 IN x S-120, Pipe , ASME B36.10M , BE , API 5L Grade X60, PSL 2, SMLS, Impact 60 M Fab Yard
Tested, NACE MR0175/ISO 1515

Dummy
ident SPMat BOM for CS SMLS pipes, PVK01-0002-1
Ident Tag No Item Description Qty Unit
PPTPXTPX0003597 PPPXXPPX0046075 6 IN x S-120, Pipe , ASME B36.10M , PE , API 5L Grade X60, PSL 2, SMLS, Impact 90 M Clad Vendor
Tested, NACEMR0175/ISO 15156, Bare pipe for INC 625 Clad

Engineering PR for Cladding

SPMat BOM for Cladding, PVK04-0001-1
Ident Tag No Item Description Qty Unit
PPPXXPPX0046075 6 IN x S-120, Pipe , ASME B36.10M , BE , API 5L Grade X60, PSL 2, SMLS, Impact 90 M
Tested, Inconel 625 cladded, NACEMR0175/ISO 15156
Fab Yard

PPPXX………. – Ident appears in SPRD Spec, SPMat MTO, Isometrics, Spool Iso and AFC MTO 20
 FBE spool field joint strategies
Service Field joint Size Range PWHT Field Joint options Pup piece Proc.. Remarks
type Strategy
6” to 28” No 1. 300 to 400mm Pup Piece w/o PWHT Proceed with Pup Manual LE coating may
Piece 100% not possible

30” to 60” No 1. 300 to 400mm Pup Piece w/o PWHT HOLD 100% due to
point no 2
2. Perform partial cladding on pipe to avoid 2 CS shop weld on every spool.
3. On Elbow spools – 300-400 mm Pup Pieces (60%) & on straight spools
Field Liquid Epoxy coating (40%)

10” to 28” Yes 1. 1200 mm Pup Piece + PWHT HOLD 100% due to
points 4
2. 300 to 400mm Pup Piece w/o PWHT (waiting for Aramco approval TQ-L-
Process Pup Pieces 1127)
3. 300 to 400mm Pup Piece + bevel buttering w/o PWHT (TQ yet to be
issued)
4. Perform partial cladding of above 3 options on pipe to avoid 2 CS shop
weld on every spool.

30” to 42” Yes 1. Above 4 option HOLD 100% due to

points 4
5. On Elbow spools – 1200 mm Pup Pieces (60%) & on straight spools Field
Liquid Epoxy coating (40%)

2” to 28” No 1. Flange Proceed with Flange Robotic coating may

100% costlier than flange

Utility Flange 30” to 42” No 1. Flange Proceed with Flange

100%
2. On Elbow spools – 1200 mm Pup Pieces & on straight spools Field Liquid
Epoxy coating

1 2 3 4 5 21
 FBE spool field joint strategies

1200 mm Pup Piece + PWHT 300 mm Pup Piece w/o PWHT 300 mm Pup Piece + butting
w/o PWHT

Field LE coating on straight sections Utility

Local partial cladding
w/o pup pieces

1 2 3 4 5 22
 Proposed Manual/Robotic Field weld coating on
Straight spools

Pup piece field weld on horizontal-straight lines

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Proposed Top up – Sample for 42” Pipe

PO issued Qty Split in Top-up

Ident 1 Ident 1
Pipe 42” x 2.591” Pipe 42” x 2.591” for FBE
PO Qty - 2, 550 M PO Qty – 1, 800 M

Ident 2
Pipe 42” x 2.591” for Clad 30% of Pup Piece Qty
PO Qty – 200 M

Ident ? 70% of Pup Piece qty

Pipe 42” x 2.591” for Clad Ident number, beveling
or FBE scope and delivery
PO Qty – 550 M location are HOLD

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 SPMat PR - ident transfer for pup pieces

Colour
Codes

1,000 IFH or PO qty 789HOLD Qty

1,050IFD Qty 150Pup Piece Delta

50Delta of IFD - IFH IFD & IFH Total MTO Qty -> 2,411 2,435 (24)

IFD PR & IFH PO Qty -> 2,544 2,550 (6)

Procurem Last
ent Procurement Size 1 Release Increase
Package Package Name Ident codes Ident description HOLD (IN) Engg Remarks Qty Release Quantity
No Quantity

42 IN x 2.591", Pipe , BE , ASME B36.10M  , API 5LGrade X60, PSL 2 No Deletion. 726 M may

PVK01- Pipe - CS/LTCS SAW PPPXXPPX038 , SAW,100% Radiography, With Internal FBE Lined, Impact Tested  No 42 change to Pup Piece in 1,638 2,550 -912
0002 5105 @ 0°C, NACE MR0175/ISO 15156 + HIC Hold Future
42 IN x 2.591", Pipe , BE , ASME B36.10M  , API 5LGrade X60, PSL 2
PVK01- PPPXXPPX038
0002 Pipe - CS/LTCS SAW 5105 , SAW,100% Radiography, With Internal FBE Lined, Impact Tested  Hold 42No HOLD in EDP Platform 180  180
@ 0°C, NACE MR0175/ISO 15156 + HIC

PVK04- Pup pieces - PPPXXPPX051 42 IN x 2.591", Pipe , BE , ASME B36.10M  , API 5LGrade X60, PSL 2 No PMT to confirm Pup piece

SMLS/SAW - Clad , SAW, 100% RT, With 3mm Inconel 625 Weld Overlay, Impact Teste 42 636 0 636
0003 scope 7231 d at (0)°C, NACE MR0175/ISO 15156 + HIC Hold procedure

Pup pieces - 42 IN x 2.591", Pipe , BE , ASME B36.10M  , API 5LGrade X60, PSL 2

PVK04- SMLS/SAW - Clad PPPXXPPX051 , SAW, 100% RT, With 3mm Inconel 625 Weld Overlay, Impact Teste Hold 42 PMT to confirm Pup piece 90  90
0003 7231 procedure
scope d at (0)°C, NACE MR0175/ISO 15156 + HIC

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 FBE spool field weld w/ PWHT
Sum of Joints (EA) PWHT Total No. of No of Elbows Joints in Straight Joints in % of Joints in
Facility Size THK-1 (mm) NO YES Joints Spool (Hor + Ver) Horizontal Horizontal
Straight Spool Straight Spool

Bridge 14 27.79 0 45 45 34 11 11 24%

Bridge 36 38.45 0 20 20 16 4 4 20%
Bridge 42 65.80 0 91 91 61 30 30 33%
EDP 14 27.79 0 26 26 14 12 8 32%
EDP 36 38.45 0 11 11 8 3 2 17%
EDP 42 65.80 0 42 42 32 10 7 16%
PF 12 25.40 0 6 6 27 0 0 0%
PF 14 27.79 0 23 23 34 0 0 0%
PF 16 21.44 0 4 4 10 0 0 0%
PF 20 26.19 0 38 38 29 9 6 17%
PF 20 38.10 0 13 13 4 9 7 49%
PF 28 30.95 0 10 10 10 0 0 2%
PF 36 38.45 0 16 16 11 5 4 23%
PF 42 65.80 0 103 103 45 58 40 39%
TP 10 25.40 0 87 87 144 0 0 0%
TP 12 25.40 0 2 2 8 0 0 0%
TP 14 27.79 0 39 39 26 13 9 24%
TP 24 38.89 0 20 20 6 14 10 49%
TP 24 46.02 0 7 7 9 0 0 0%
TP 30 41.30 0 35 35 12 23 16 46%
TP 30 48.35 0 19 19 17 2 1 6%
TP 36 38.45 0 12 12 10 2 1 12%
TP 36 48.92 0 7 7 2 5 3 49%
TP 36 57.08 0 9 9 10 0 0 0%
TP 42 65.80 0 49 49 23 26 18 37%
Grand Total 0 732 732 602 235 178 24%
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 FBE spool field weld w/o PWHT
Sum of Joints (EA) PWHT Total No. of No of Elbows Joints in Straight Joints in % of Joints in
Facility Size THK-1 (mm) NO YES Joints Spool (Hor + Ver) Horizontal Horizontal
Straight Spool Straight Spool

Bridge 42 12.70 41 0 41 33 8 8 19%

CP 28 9.53 19 0 19 15 4 3 15%
CP 42 12.70 17 0 17 2 15 11 62%
CP 48 12.70 5 0 5 0 5 3 70%
EDP 42 12.70 103 0 103 14 89 62 60%
PF 6 7.11 75 0 75 207 0 0 0%
PF 6 14.27 62 0 62 49 13 9 15%
PF 8 8.18 7 0 7 38 0 0 0%
PF 8 12.70 23 0 23 27 0 0 0%
PF 10 9.27 50 0 50 56 0 0 0%
PF 10 15.09 22 0 22 38 0 0 0%
PF 16 7.92 13 0 13 10 3 2 17%
PF 18 7.92 13 0 13 9 4 3 22%
PF 24 9.53 2 0 2 3 0 0 0%
PF 28 9.53 11 0 11 12 0 0 0%
PF 30 9.53 110 0 110 49 61 42 39%
PF 32 9.53 93 0 93 35 58 41 44%
PF 36 12.70 23 0 23 7 16 11 49%
PF 42 12.70 79 0 79 22 57 40 50%
PF 44 12.70 19 0 19 8 11 8 40%
PF 60 15.88 22 0 22 0 22 15 70%
TP 6 7.11 75 0 75 12 63 44 59%
TP 8 8.18 47 0 47 15 32 22 48%
TP 8 18.26 23 0 23 10 13 9 39%
TP 10 18.26 335 0 335 9 326 228 68%
TP 12 17.48 9 0 9 5 4 3 30%
TP 36 31.75 14 0 14 3 11 8 55%
Grand Total 1311 0 1311 688 814 572 44%

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