ABU DHABI NATIONAL OIL COMPANY (ADNOC)
EPC FOR DALMA GAS DEVELOPMENT PROJECT
CONTRACT AGREEMENT NO: 6000001102 (A)
PROJECT NO: P4331432
DOCUMENT TITLE: METHOD STATEMENT FOR INCONEL
BUTTERING ON CLADDED PIPING FOR WELDOLET FITTING
Rev
Page
DOCUMENT NO:- VF0133-CF0001-28-MES-0001
B01
1 of 16
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
EPC FOR DALMA GAS DEVELOPMENT PROJECT
CONTRACT AGREEMENT NO: 6000001102 (A)
PROJECT NO: - P4331432
MES
METHOD STATEMENT FOR INCONEL BUTTERING ON CLADDED
PIPING FOR WELDOLET FITTING
PACKAGE-A (OFFSHORE FACILITIES)
This document is developed from FEED document number: NA
CONTRACTOR DOC NO:- 8405-112A-X007-005
B01
19-Sept-23
IFA
ISSUED FOR APPROVAL
ST
KB
RM
A01
24-May-23
ICR
ISSUED FOR COMPANY REVIEW
ST
KB
RM
Rev
Date
(DD/MM/YY
YY)
Status
Status Description
Prepared
Reviewed
Approved
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers
and Suppliers.
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ABU DHABI NATIONAL OIL COMPANY (ADNOC)
EPC FOR DALMA GAS DEVELOPMENT PROJECT
CONTRACT AGREEMENT NO: 6000001102 (A)
PROJECT NO: P4331432
DOCUMENT TITLE: METHOD STATEMENT FOR INCONEL
BUTTERING ON CLADDED PIPING FOR WELDOLET FITTING
Rev
Page
DOCUMENT NO:- VF0133-CF0001-28-MES-0001
B01
2 of 16
SUMMARY OF DOCUMENT REVISIONS
Rev.
Date
No.
Revised
Section
Revised
A01
24/05/2023
N/A
B01
19/09/2023
*
Revision Description
Issued For Company Review
Issued for Approval
*. Revision changes are Highlighted in Blue Italic
SUMMARY OF HOLDS
Hold No.
Section / Page
Hold Description
This document is produced in compliance to FEED Documents and further amendment made as per RFT,
Tender clarification and Tender Bulletins.
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PROJECT NO: P4331432
EPC FOR DALMA GAS DEVELOPMENT PROJECT
Rev
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METHOD STATEMENT FOR INCONEL BUTTERING ON
CLADDED PIPING FOR WELDOLET FITTING
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Contents
1.
INTRODUCTION................................................................................................................ 4
1.1
PROJECT BACKGROUND .................................................................................... 4
1.2
PROJECT OVERVIEW........................................................................................... 4
1.3
BRIEF PROJECT FACILITIES ............................................................................... 4
2.
PURPOSE ......................................................................................................................... 6
3.
ABBREVIATIONS .............................................................................................................. 6
4.
DEFINITIONS .................................................................................................................... 7
5.
PROJECTS CODES AND STANDARDS ........................................................................... 8
6.
REFERENCE DOCUMENTS ............................................................................................. 8
6.1
INTERNATIONAL CODES AND STANDARDS ................................................................. 8
6.2
ADNOC-COMPANY CODES AND STANDARDS .............................................................. 9
6.3
PROJECT DOCUMENTATION ........................................................................................ 10
7.
ORDER OF PRECEDENCE............................................................................................. 12
8.
RESPONCIBILITIES ........................................................................................................ 12
9.
PROCEDURE .................................................................................................................. 12
10
ATTACHMENT................................................................................................................. 16
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1. INTRODUCTION
1.1 PROJECT BACKGROUND
ADNOC has initiated development of new gas reserves, namely Dalma Gas Development
(DGD) project in Northwest offshore region of Abu Dhabi. DGD Project is an integral part of the
overall efforts to develop these untapped hydrocarbon reserves, with priority given to produce
340 MMscfd of raw gas from Satah, Hair Dalma and Bu Haseer fields by 2024.
The overall DGD project development shall comprise of offshore facilities (PKG-A) and onshore
facilities on Arzanah Island (PKG-B) to export gas to Habshan and export condensate to Zirku
Island. The DGD project has now moved into EPC stage
1.2
PROJECT OVERVIEW
The overall DGD Project development shall comprise of the following works:
• Installation of Unmanned Wellhead Platform topsides in Satah, Bu Hasser and
Hair Dalma fields.
• Full Well Stream transfer to Arzanah Island
• Processing facilities and power generation at Arzanah island.
• Gas Export via tie-in to the 42” gas export pipeline to Habshan.
• Condensate Export to Zirku Island.
• Subsea pipelines, umbilical, composite cable and FO cables.
• Infrastructure and Enabling facilities at Arzanah Island.
1.3 BRIEF PROJECT FACILITIES
1.3.1
Offshore Facilities – Package A
The scope of work under offshore facilities (PKG-A) comprises of:
•
Three new unmanned Wellhead Platforms in Satah (ST WHP-10), Bu Haseer
(BH-03) and Hair Dalma (HD T-4) fields along with necessary modifications on
Jackets. Jacket design and installation for these three WHPs are by OTHERS.
•
Removal of existing topside and replacing it with new topsides for Hair Dalma
HD-03 Wellhead.
•
New gas producer subsea pipelines including associated risers and other
appurtenances.
o
o
o
o
•
Hair Dalma (HD T-4) Platforms to Arzanah Island.
Satah (ST WHP-10) Platform to Arzanah Island.
Bu Haseer (BH-03) Platform to Arzanah Island.
New subsea umbilical including associated J-tubes and shore approach:
o
o
o
o
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Hair Dalma HD-03 platform to Hair Dalma (HD T-4) platform.
Arzanah Island to Satah (WHP-10) Platform.
Arzanah Island to Bu haseer (BH-03) Platform.
Arzanah Island to Hair Dalma (HD T-4) Platform.
Hair Dalma (HD T-4) platform to Hair Dalma HD-03 platform.
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•
New gas export subsea pipeline from Arzanah Island to existing IGD-E tower (KP38) including associated riser, pig receiver, and tie-in to existing 42” IGD-E
pipeline along with modifications to existing topsides on the IGD-E tower (KP-38).
•
New subsea composite cable from Arzanah Island to IGD-E tower (KP-38)
including associated J-tube and shore approach.
•
New condensate export subsea pipeline from Arzanah Island to Zirku Island, Tiein to Zirku Island Facilities, shore approaches, shore pull-in and piggybacked
Fibre Optic Cables.
•
Interface with COMPANY novate LLI i.e.Umbilicals and associated TUTU Panels.
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2. PURPOSE
NPCC (Here after CONTRACTOR) has awarded the scope of Piping Pre-fabrication of EPC
for DALMA GAS DEVELOPMENT PROJECT to Emarat Aloula Industies (Here after EAI).
This Method statement provides guidelines for Inconel 625 Buttering on Inconel 625-Cladded
CS/LTCS Pipes during piping fabrication works carried out by Emarat Aloula Industries (EAI)
in accordance with the quality and contractual requirements of the project. It set out minimum
quality control activities to be executed during execution of the activities at EAI Mussafah
yard. This procedure describes the step by step activities performed during the execution of
Weldolet fitting on cladded pipes during piping prefabrication.
.
3. ABBREVIATIONS
ADMA-OPCO
Abu Dhabi Marine Operating Comapany
ADNOC
Abudhabi National Oil Company
AFC
Approved for Construction
BP
British Petroleum
DGD
Dalma Gas Development
CA
Corrective Action
CAR
Corrective Action Request
CONT
Contractor
CPY
Company
DC
Document Controller
EDMS
Electronic Data Management System
EPC
Engineering, Procurement and Construction
EAI
Emarat Aloula Industries (Sub-Contrcator)
FEED
Front End Engineering Design
IRN
Inspection Release Note
ITP
Inspection and Test Plan
KPI
Key Performance Indicator
KOM
Kick Off Meeting
MRV
Material Receive Voucher
MOM
Minutes of Meeting
MTC
Material Test Certifcate
MTR
Material Treaceabilty Report
MTO
Material Take Off
PO
Purchase Order
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PQR
Procedure Qualification Recore
QA/QC
Quality Assurance/Quality Control
QCI
Quality Control Inspector
QHSE
Quality, Health, Safety & Environment
QI
Quality Incharge
PO
Purchase Order
PQP
Project Quality Plan
RFI
Request for Inspection
SOW
Scope Of Work
TQ
Technical Query
TPI
Third Party Inspector
WPS
Welding Procedure Specification
4. DEFINITIONS
The following definitions apply to terms used within this document:
Project Number
P4331432
Project
EPC FOR DALMA GAS DEVELOPMENT
ADNOC
Abudhabi National Oil Company
PMT
Project Management Team
PMC
Project Management Consultant appointed by the COMPANY to
Provide Management Consultancy services for the Project.
Works
Any Works and services performed under the AGREEMENT, as
further described in the scope of work , including the works
Documentation and any other deliveriables specified in the
AGREEMENT.
Contractor
National Pertroleum Construction Company (NPCC), appointed EPC
contractor by COMPANY to perform the EPC SCOPE OF WORK for
the project.
Subcontractor
Emarat Aloula Industires, appointed as SUBCONTRACTOR BY
NPCC to perform Piping Pre-Fabrication.SUBCONTRACTOR means
any person or COMPANY to whom execution of any part of the
SERVICES is subcontracted by the CONTRACTOR or to whom the
CONTRACTOR proposes to subcontract any part of the EPC works
if awarded the EPC CONTRACT and includes the legal successors
or permitted assigns os such person.
Vendor
Person, fims, partnerships, companies, bodies, entities or a
combination thereof who are providing GOODS.
SHALL
The word Shall is understood to be Mandatory to comply with the
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requirements
SHOULD
The word Should is understood to be strongly recommended to
comply with the requirement.
MAY
Indicates a possible course of an action
5. PROJECTS CODES AND STANDARDS
The CONTRACTOR Shall comply and ensure compliance from its SUBCONTRACTORS with
UAE Legislation and Environmental Regulations, applicable International Laws &
Regulations,ADNOC Guidelines/, ADNOC/ COMPANY-Specifications and Standards,
ADNOC HSE Regulations, Standards, Code of Practice and relevant International code and
Standards.
Only latest version of all applicable codes, Specifications and standards shall be used by the
CONTRACTOR and SUBCONTRACTORS.
Where equal but conflicting requirements are identified between regulations, codes,
standards, the order of precedence shall be;
1) UAE Statutory Legisalation and Regulations
2) ADNOC HSE Regulations and standards
3) Project Data Sheet
4) Project Specifications and Standards
5) Approved Amendments of ADNOC Offshore Engineering specifications, Standards,
Procedures
6) ADNOC Engineering specification, Standards and Procedures
7) ADNOC Guidelines, Procedures
8) International Codes and Standards
6. REFERENCE DOCUMENTS
Reference shall be made to the following documents:
6.1 INTERNATIONAL CODES AND STANDARDS
S.No
Document Number
Document Description
1
ISO 9001: 2015
Quality Management Systems Requirements
2
ASME B31.3 :.2020
3
ASME B16.5 :2020
4
ASME B16.20 :2017
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Process Piping
Pipe Flanges and Flanged Fittings NPS
1/2” through NPS 24”
Metallic Gaskets for Pipe Flanges: RingJoint, Spiral Wound, and Jacketed
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S.No
Document Number
Document Description
5
ASME B36.19 :2018
Stainless Steel Pipe
6
ASME SEC II (Ed.2021 DT01.07.2021)
Materials
7
ASME SEC V (Ed.2021 DT01.07.2021)
Non-Destructive Examination
6.2 ADNOC-COMPANY CODES AND STANDARDS
S.No
Document Number
Document Description
1
SP-1007 Rev.0
Quality Assurance and Quality Control
Requirements for Construction Works
2
SP-1009 Rev.2
Specification for Requirements for Projects
contractor Quality system
3
SP-1035 rev 1
Pre and Post Weld Heat Treatment of Ferrous
Materials
4
SP-1064 rev 1
Integrity Requirement for Baseline Survey of New
Equip. in projects
5
SP-1108 Rev.1
Specification for fabrication of Fixed Offshore
Steel Structures
6
SP-1107 Rev.
Specification for Strucutal steel Material Offshore
Structures
7
SP 1131 Rev 1
Specification for Piping Classification
8
A0-ENG-S-SP-oo1 Rev.1
Specification for steel material for Offshore
Structures
9
Annexure- 9E
Quality Management Requirements
10
CP 108 Rev.1
SEP 2016
Minimum Recommended Spacing for Welded
Connections
11
SP-1031 Rev.0 DEC 1992
Quality Control Personnel for Fabrication and
Construction
12
SP-1035-Rev.1- May,2006 Pre & Post weld Heat Treatments of Ferrous
Materials
13
EP-GIS 18-011
24 MAY 2016
14
EP-GIS 18-012
24 May 2016
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Specification for Welded Fabrication and
Construction
Specification for Procurement, Storage, and
Control of Welding Consumables
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S.No
Document Number
Document Description
15
EP-GIS 36-103
30 Jun 2015
Specification for Positive Materials Identification
(PMI)
16
EP-GIS 42-103
31 MAR 2016
Specification for Fabrication, Assembly, Erection,
and Inspection of Pipework (ASME B31.3)
17
GP 18-01
27 AUG 20212
Welded Fabrication and Construction
18
GP 42-10
15 DEC 2014
Group Practice GP 42-10 Piping Systems (ASME
B31.3)
6.3 PROJECT DOCUMENTATION
A. Contractor Documents:
S.No Document Number
Document Description
1
CA0000-63-PLN-0001
Project Quality Plan
2
CA0000-63-PRO-0001
NCR Procedure
3
CA0000-63-PRO-0024
Corrective and Preventive Action Procedure
4
CA0000-63-PRO-0020
Project Quality Audit Procedure
5
CF0000-28-BOD-0001
Piping Design Basis
CF0000-28-SPE-0017
Piping Specification for Fabrication, Erection
and Testing
7
CF0000-28-STD-0002
Piping Construction Standards
8
CF0000-28-SPE-0020
6
9
Specification for Pressure Testing of Piping
Project Welding Specification (Pressure
Vessels & Piping).
CA0000-63-SPE-0002
B. Sub-Contractor Documents:
S.No Document Number
Document Description
1
VF0133-CF0001-28-REG-0001
Supplier Data Register
2
VF0133-CF0001-28-PRO-0001
WPS Register along with WPS & PQR 1,2,3
etc
3
VF0133-CF0001-28-PRO-0002
Welder Performance Qualification (WPQ)
Register as per ASME Sec IX
4
VF0133-CF0001-28-ITP-0001
ITP for Piping Fabrication,Welding & NDE
5
VF0133-CF0001-28-PRO-0003
Piping Fabrication Procedure
6
VF0133-CF0001-28-PRO-0004
Painting Procedure
7
VF0133-CF0001-28-PRO-0005
Visual Examination Procedure
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S.No Document Number
Document Description
8
VF0133-CF0001-28-PRO-0006
Radiographic Examination Procedure
9
VF0133-CF0001-28-PRO-0007
Magnetic Particle Examination Procedure
10
VF0133-CF0001-28-PRO-0008
Liquid Penetrant Examination Procedure
11
VF0133-CF0001-28-PRO-0009
Hardness Test Procedure
12
VF0133-CF0001-28-PRO-0010
Ferrite Testing Procedure
13
VF0133-CF0001-28-PRO-0011
Positive Material Identification Procedure
14
VF0133-CF0001-28-PRO-0012
Post Weld Heat Treatment Procedure Local
15
VF0133-CF0001-28-PRO-0013
Post Weld Heat Treatment Procedure Furnace
16
VF0133-CF0001-28-PRO-0014
Ultrasonic Testing Procededure
17
VF0133-CF0001-28-WIN-0001
NDE Personnel List with Certification
18
VF0133-CF0001-28-PRO-0015
Galvanization Procedure
19
VF0133-CF0001-28-PRO-0016
Material Control Procedure
20
VF0133-CF0001-28-PRO-0017
Welding Consumable Control Procedure
21
VF0133-CF0001-28-PRO-0018
Weld Repair Procedure
22
VF0133-CF0001-28-PVD-0001
MRB Index for Piping
23
VF0133-CF0001-28-PLN-0001
Project Quality Plan
24
VF0133-CF0001-28-PRO-0019
Baseline Survey Procedure
25
VF0133-CF0001-28-MES-0001
Method Statement for Inconel Buttering on
Cladded Piping for Weldolet Fitting
26
VF0133-CF0001-28-ITP-0002
ITP for Surface Preparation & Painting Piping
27
VF0133-CF0001-28-PRO-0020
Pickling & Passivation Procedure
28
VF0133-CF0001-28-PRO-0021
RT Digitalization Procedure
29
VF0133-CF0001-28-PRO-0041
30
VF0133-CF0001-28-PRO-0042
31
VF0133-CF0001-28-PRO-0043
32
VF0133-CF0001-28-PRO-0044
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Welding Procedure Specification For
Piping: 3100-WPS-020
Welding Procedure Specification For
Piping: 3100-WPS-021
Welding Procedure Specification For
Piping: 3100-WPS-022
Welding Procedure Specification For
Piping: 3100-WPS-023
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Welding Procedure Specification for
Piping - 3100-WPS-028
VF0133-CF0001-28-PRO-0049
7. ORDER OF PRECEDENCE
CONTRACTOR shall comply (and ensure compliance by all its SUBCONTRACTORs) with UAE
Legislation and Environmental Regulations, ADNOC Guidelines / Codes of Practice, COMPANY
Engineering Specifications, Standards and Procedures and HSE Regulations, BP Standards,
Guidance and Practice Documents and all relevant International Codes and Standards.
In case of conflict, among any referenced regulations, codes and standards and technical
specifications, CONTRACTOR shall notify COMPANY of any conflict and confirm resolution of
the same in accordance with the order of precedence specified below.
•
UAE Statutory Legislation and Regulations
•
ADNOC Code of Practices and new HSE Standards
•
Project Data Sheets
•
Project Specifications
•
ADNOC Offshore (ADMA-OPCO) Engineering Specifications, Standards, Procedures
and HSE Documents
•
BP Engineering Technical Practices
•
International Codes & Standards
8. RESPONCIBILITIES
Welding Supervisor
Welding Supervisor is responsible with regards to above scope, to ensure proper implementation
of Ovelay Buttering Procedure as prescribed in section 9.
QC Inspector
QC inspectors are responsible to monitor the Buttering activities and coordinate with COMPANY
or CONTRACTOR for when required.
9. PROCEDURE
Method statement covers fabrication and welding by buttering for the branch of set-on type
weldolet on Inconel 625 Cladded Carbon steel/Low Temperature Carbonsteel Pipe, and to be
strictly adhered during the whole operation.
9.1 Measuring the Weldolet Inside diameter “X”and the Maximum outside diameter “Y”from
the end where to be welded to the main pipe.
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9.2 Mark the center point of the Weldolet “O” and 8 No. Peripheral equidistant points “P” on
the header pipe having “O” as center at a radius “OP”,
OP = (Y+20)/2
9.3 Using Conical Drilling Bit of diameter (IDL + “X”-4mm), drill a hold on header pipe with
“O” as center to form inside diameter of Inconel lip.
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9.4 Using flat drill bit, on the main pipe drilla hole at the center point “O” with diameter “ODL”
= X+14mm to form Outside Diameter of the Inconel lip.
Drill bit should touch the upper part from the Inconel of the main pipe internal
diameter
9.5 Using Tungsten Carbide grinding tools, grind the remaining carbonsteel from the curved
top part of the inconel lip area.
Note : Tools and equipment shall be dedicated to Exotic material work.
9.6 Wipe the top surface of the Inconel lip using Copper Sulphate (CuSO4) Soultion with
tissue Paper. The area shall be free CS/LTCS free. If any discoloration is detected steps
mentioned in 9.5 and 9.6 shall be repeated untill no discoloration is visible.
9.7 Carry out domension measurement at 8 locations of the hole eccentricity using point “P”
as referance. Record the values in attachment 1.
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9.8 Deposite Stinger weld passes (minimum 3Layers) on the pheriperal Carbon steel area
using SMAW Process in accordance to the approved applicable WPS, the deposite weld
thickness shall be such that the diameter of the weld overlay “DWOL”=IDL or X-4mm.
9.9 Carryout Centric Drilling using the Previously marked Points “P” as referance, the
diameter shall be equal to “X”.
Grind flush the excess deposited weld metal to make it flush with base material of the
header pipe outside diameter.
9.10
Carry out final dimension measurement for the weldoverlay thickness at 8
Locations using marked point “O” as reference. Record the values in attachment 1. The
minimumacceptable thickness shall be 6 mm.
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9.11
Carry Out PT on the Welded Surface to confirm non existence of surface defects
prior to fitup of the Weldolet.
10 ATTACHMENT
Attachment 1 : Report for verification of Inconel Buttering On Cladded Piping For Weldolet
Fitting
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Attachment 1
Report for verification of Inconel Buttering On Cladded Piping For Weldolet Fitting
EAI Job No.
Date
ISO No.
Rev. No
Spool No.
Joint No
Weldolet Size
Header Pipe Size
(Inconel 625)
(CS/LTCS+ Inconel
625)
0◦
45◦
90◦
135◦
180◦
225◦
270◦
315◦
TC(mm)
TCI(mm)
TI (mm)
(TCI-TC)
X=
RP=
IDL=
ODL=
Verified By:
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