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PTM YARD - WELDING BOOK FOR PLETS PIPING
FABRICATION DESIGNED ASME B31.8 - INCONEL
Kilusi Emmauel Kiala
cn=Kilusi Emmauel Kiala,
o=Saipem, ou=Yard
Welding Engineer,
email=KilusiEmanuel.Kial
a@saipem.com, c=AO
2023.11.21 08:07:34
+01'00'
P.P
Angelo
Carlota
Digitally signed by
Angelo Carlota
DN: cn=Angelo Carlota,
o=Petromar, ou=PTM,
email=angelo.carlo@pe
tromar.co.ao, c=US
Date: 2023.11.21
15:42:37 +01'00'
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TABLE OF CONTENTS
1.0
1.1
1.2
1.3
2.0
2.1
2.2
3.0
3.1
3.2
3.3
INTRODUCTION ................................................................................................................................................ 4
DISCOVERY ........................................................................................................................................................ 4
INTEGRATED DEVELOPMENT CONCEPT ............................................................................................................... 4
SCOPE OF THE DOCUMENT .................................................................................................................................. 6
ABBREVIATIONS & DEFINITIONS ............................................................................................................... 7
ABBREVIATIONS ................................................................................................................................................ 7
DEFINITIONS ...................................................................................................................................................... 8
LIST OF REFERENCED DOCUMENTS ......................................................................................................... 9
COMPANY DOCUMENTS.................................................................................................................................. 9
CONTRACTOR DOCUMENTS........................................................................................................................... 9
INDUSTRY CODES & STANDARDS ...................................................................................................................... 9
4.0
PROJECT BASE MATERIALS ....................................................................................................................... 10
5.0
WELD IDENTIFICATION ............................................................................................................................... 10
6.0
BEVELING ......................................................................................................................................................... 11
7.0
FIT-UP ................................................................................................................................................................. 11
8.0
HI-LO MEASUREMENT .................................................................................................................................. 11
9.0
EQUIPMENT ...................................................................................................................................................... 12
10.0
REPAIR METHODOLOGY ............................................................................................................................. 12
11.0
REPAIR SEQUENCE ........................................................................................................................................ 12
12.0
WELDING MONITORING .............................................................................................................................. 12
13.0
WELDING QUALIFICTAION ......................................................................................................................... 12
14.0
NDT ...................................................................................................................................................................... 12
15.0
APPENDIX A – WPS ......................................................................................................................................... 13
16.0
APPENDIX B – WPQR ...................................................................................................................................... 13
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1.0
INTRODUCTION
1.1
Discovery
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Agogo discovery is located into the West Hub part of the block 15-06, approximately 180 kilometres off the
coast and about 20 kilometres west from the Ngoma FPSO (West Hub), which is in operation since November
2014. Water depth of the field is ranging from about 1650 to 1750 m.
Ndungu field is located in the same block and approximately 10 km from Ngoma FPSO (West Hub) and close
to the subsea systems of Mpungi Field, in a water depth of approximately 1100 m.
Figure 1 - Agogo field location in Block 15/06
1.2
Integrated development concept
Agogo Integrated West Hub development concept has been defined in order to maximize the exploitation of
the reserves associated to the following fields:
• Agogo Field;
• Ndungu Fields;
• All other WH area Fields.
Agogo Field started its development and production with the Agogo Early Production Project (produced
through Ngoma FPSO) subdivided into two phases:
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•
Phase 1 (i.e. Agogo EP Ph 1): Conversion of exploration well, Agogo-1, controlled from a semi-sub
control vessel and connected to the existing West Hub network;
• Phase 2 (i.e. Agogo EP Ph 2): Development of 3 wells (1OP + 1WI + 1GI) tied-back to the existing
West Hub network.
Ndungu Field started its development and production with the Ndungu Early Production Project (produced
through Ngoma FPSO) subdivided into two phases:
•
•
Phase 1 (i.e. Ndungu EP): Development of 2 wells (1OP + 1WI) tied-back to the existing West Hub
network;
Phase 2 (i.e. Ndungu Phase 2): Development of 2 wells (1OP + 1WI) tied-back to the existing West
Hub network.
The Agogo Integrated West Hub project will be instead developed through the following 3 main phases:
Figure 2 - Agogo Integrated West Hub Phase 1
Figure 3 - Agogo Integrated West Hub Phase 2
Figure 4 - Agogo Integrated West Hub Phase 3
Each project phase will have different main steps and events that will mark the overall project targets:
Phase 1 (production gathered by Ngoma FPSO)
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Ndungu Field development phase: the new Ndungu Field consist of the development of 9
production wells and 5 injection wells tied-back to Ngoma FPSO.
Phase 2 (production gathered by Ngoma FPSO and Agogo FPSO)
• Agogo Field development phase: the new Agogo Field development will be based on a long-term
solution with a new FPSO and consists in the development of 12 production wells and 9 injection
wells;
• Agogo EP production will be diverted to Agogo FPSO as soon as possible, releasing Ngoma
topside load, with the aim to accommodate Ndungu Field production;
• Ndungu Field wells will continue production through Ngoma FPSO, along with the other West Hub
fields wells, till the end of Ngoma FPSO life.
Phase 3 (production gathered by Agogo FPSO)
• West Hub tails phase: after the Ngoma FPSO disconnection, all production tails of West Hub area
(Ndungu, Mpungi and Vandumbu) will be tied-in to Agogo FPSO in order to maximize the related
production.
1.3
Scope of the document
The purpose of this document is to identify the Welding Procedure Specifications to be applied at Petromar
Ambriz Yard for the fabrication of:
•
Production PLET
This welding book covers only ASME B31.8 welds qualified as per ASME IX.
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2.0
ABBREVIATIONS & DEFINITIONS
2.1
Abbreviations
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ASME
American Society of Mechanical Engineers
BM
Base Metal (or Base Material)
CRI
Company Representative Inspector
GTAW
Gas Tungten Arc Welding
MC
Material controller
NDT
Non-Destructive Testing
PLET
Pipe-Line End Termination
QC
Quality Control Department
RT
Radiographic Testing
RTP
Recognize Third Party
SMAW
Shielded Metal Arc Welding
SOW
Scope Of Work
VT
Visual Testing
WE
Welding Engineer
WOP
Welding operative personnel (welders, tack welders and welding operators)
WI
Welding Inspector
WPQR or PQR
Welding Procedure Qualification Record
WPS
Welding Procedure Specification
WQT
Welder qualification tests
WS
Welding Supervisor
WT
Wall Thickness
CJ
Complete Joint Penetration
BW
Butt Weld
ASME
American Society of Mechanical Engineers
BM
Base Metal (or Base Material)
HAZ
Heat Affected Zone
NDT
Non-Destructive Testing
PLET
Pipeline End Termination
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WPQ (WPQT/WPQR)
Welding Procedure Qualification (Test/Report)
PT
Penetrant Testing
RT
Radiographic Testing
SMAW
Shielded Metal Arc Welding
SOW
Scope Of Work
VT
Visual Testing
WI
Welding Inspector
WPS
Welding Procedure Specification
WT
Wall Thickness
2.2
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Definitions
COMPANY
CONTRACTOR
PROJECT
SUPPLIER
SUPPLY
SUBCONTRACTOR
VENDOR
WORK
Azule Energy Angola S.p.A
Consortium between Saipem SA, Saipem Luxembourg branch and Petromar
Lda led by Saipem SA.
means Angola Block 15/06 – Agogo Integrated West Hub Development
Project.
means SUBCONTRACTOR.
means the GOODS and relevant SUPPLIER DOCUMENTS, together with the
delivery thereof, the performance of the SERVICE and any tangible or
intangible thing which arises out of or in connection with the performance of
the SERVICES by SUPPLIER GROUP, to be provided by
SUPPLIER/VENDOR in accordance with the provision of the corresponding
PRUCHASE ORDER DOCUMENTS (which correspond to a part of the
WORK subcontracted by CONTRACTOR to VENDOR).
means any person, including any vendor or supplier, with whom
CONTRACTOR has entered into any contract to provide any part of the scope
of work, including any person at any tier with whom any SUBCONTRACTOR
has further contracted any part of the scope of work, and their legal successor
and assigns.
means SUBCONTRACTOR.
means all of the works and services to be performed by CONTRACTOR under
the PROJECT as are more fully described in the CONTRACT including but
not limited to the provision of all labour, facilities, equipment, services and
works as may be reasonably inferred therefrom, as necessary for the stability,
completion and safe, reliable and efficient operation of the FACILITY.
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3.0
LIST OF REFERENCED DOCUMENTS
3.1
COMPANY Documents
Ref
CPY Document No.
[1]
18046.ENG.SSE.STD
[2]
363010BXSH01264
3.2
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Document Title
API RP 17P RECOMMENDED PRACTICE FOR SUBSEA
STRUCTURES AND MANIFOLDS
SPECIFICATION FOR WELDING OF CARBON STEEL
PIPE AND CRA CLAD OR LINED PIPE FOR PIPE-INPIPE SUBSEA FLOWLINE
Revision
01
01
CONTRACTOR Documents
Ref
CTR Document No.
CPY Document No.
Document Title
[3]
363009DXPTS3113
F10395-SAI-WEL-PROS3113
[4]
363009CXSTS3220
F10395-SAI-WEL-PROS3220
[5]
363009DXPTS3089
[6]
363009DXPTS3094
[7]
363009DXPTS3095
[8]
363009CBQBS3214
[9]
363009CBQBS3206
[10]
363009CXMRS3221
[11]
363009CXSTS3222
WELDING CONSUMABLE CONTROL
PROCEDURE ALL SCOPE
PTM YARD - WELDER QUALIFICATION
PROCEDURE FOR PLET PIPING UNDER
ASME IX
VT (VISUAL TESTING) PROCEDURE - CRA
SOW
PT (PENETRANT TESTING) PROCEDURE
– CRA SOW
PTM YARD – RT (RADIOGRAPHIC
TESTING) -CRA/CS SOW
PTM YARD - QUALITY CONTROL PLAN WELDING OF PIPING CRA & CS
PTM YARD - QUALITY CONTROL PLANPIPING (PLETS)
PTM YARD - LIST OF WELDING
OPERATORS
PTM YARD -MANAGEMENT OF WELDING
REGISTER (FMS)
3.3
F10395-SAI-NDT-PROS3089
F10395-SAI-NDT-PROS3094
F10395-SAI-NDT-PROS3095
F10395-SAI-WEL-ITPS3214
F10395-SAI-QUA-ITPS3206
F10395-SAI-WEL-LSTS3221
F10395-SAI-WEL-PROS3222
Revision
04
00
02
02
00
00
00
00
00
Industry Codes & Standards
Ref
CPY Document No.
[12]
ASME IV
[13]
ASME B31.8
[14]
DNV RP B204
Document Title
BOILER AND PRESSURE VESSEL CODE SECTION IX –
WELDING, BRAZING AND FUSING QUALIFICATIONS
GAS TRANSMISSION AND DISTRIBUTION PIPING
SYSTEMS – ASME CODE FOR PRESSURE PIPING
WELDING OF SUBSEA PRODUCTION SYSTEM
EQUIPMENT
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Revision
2019
2019
2019
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PROJECT BASE MATERIALS
Tables 4.1 describes the material grades that have been selected for the fabrication of Inconel piping scope.
Table 4.1: PLET Piping
Location
Material
OD (mm)
WT (mm)
2”
(73.03)
6.35
Production (Inconel):
PLET
5.0
•
•
•
•
•
Pipe (N06625)
Bend (N06625)
Hot Stab (ASTM N06625)
Gate Valve (ASTM N06625)
Reducing Tee (ASTM N06625)
WELD IDENTIFICATION
Table 5.1: Production Plet
Welds to be
performed
OD x WT (mm)
Position
Reducing Tee to Pipe
73.03 x 6.35 mm
All
Pipe to Bend
73.03 x 6.35 mm
All
Pipe to Pipe
73.03 x 6.35 mm
All
Pipe to Gate Valve
73.03 x 6.35 mm
All
Pipe to Hot Stab
73.03 x 6.35 mm
All
Supporting PQR
ERSAI-P-095
Figure 5.1: Production
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BEVELING
Beveling shall be done by machining or grinding.
7.0
FIT-UP
Fit-up shall be done by tack welding as follows:
Figure 7.1: Fit-Up
Tack weld shall be removed progressively during root pass.
The material of the tack bullets must be similar to the base metal.
8.0
HI-LO MEASUREMENT
Open Gap Tool shall be used for the Internal Hi-Lo measurement.
The instrumentation's accuracy shall be of +/- 0.1 mm.
Each instrument shall be provided with its calibration certificate.
Hi-Lo measurement shall be done after pipe fit-up but prior welding at 4 equidistant locations as
indicated in Figure below:
Figure 8.1: Measurement Location along the circumference
Frequency :
•
•
100% for first 3 welds. Internal Hi-Lo measurements at the 4 locations indicated in Figure above, shall
be recorded on the Internal Hi-Lo Records Report for each pipe joint (see template in Appendix).
Then, based on the above measurements (i.e., if no measurements fall outside the acceptable
tolerance), recording will be done on a random basis only (Hi-Lo measurements at the 4 locations
indicated in Figure 10 on 10% of the joints). However, hi lo verification will be performed for all welds
as part of the fit-up step of the ITP (without recording).
Maximum internal Hi-Lo shall be as per WPS.
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EQUIPMENT
All tools and equipment used (discs, wire brush, hand tools) shall be free from iron and specific to the material:
- Inconel (UNS N06625)
10.0 REPAIR METHODOLOGY
Due to the thicknesses on the Inconel 625 pipes, repairs are not allowed. If repairs are required, the weld will
be cut and re-bevelled.
11.0 REPAIR SEQUENCE
•
Localization of the defect area.
•
Carry out cut-out of weld with removal of HAZ. To ensure the HAZ removal, the weld shall be cut
back at least 6 mm into the base material measured from the OD cap weld toe.
•
VT to be performed after removal of HAZ, VT and PT to be performed after welding.
12.0 WELDING MONITORING
Welding parameters will be monitored by means of Ammeter and Voltmeter by the QC Welding Inspectors
or the project welding engineer(s).
The following welding parameters will be provided in a report:
•
•
Iave, Vave, TS based on actual ROL measured with a tape and recorded welding time.
HI based on the above values and k factor based on according to EN1011-1.
Volts, amps and travel speed ranges are given for guidance only. Heat-input range shall be fulfilled.
13.0 WELDING QUALIFICTAION
Welders shall hold a valid certificate to perform the scope of work.
All new welder qualifications will be done in accordance with project welder qualification procedure Ref. [3].
14.0 NDT
All NDT to be done in accordance with NDT Project procedure Ref. [4], [5] and [6].
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15.0 APPENDIX A – WPS
-
AFF-PIP-AMSE-INCO
16.0 APPENDIX B – WPQR
-
84-2021
BAR-PIP-12
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