FCPG 00000 CPP143 00 QA 5733 00010 006 ITP for Method Statement for Pipeline Welding

COMPANY CONTRACTOR

Shell Iraq Petroleum Development B.V. CPP Petroleum Pipeline Bureau

INFIELD PIPELINE WORKS FOR FCP, MAJNOON OIL FIELD PROJECT (SIPD-143)

ITP For Method Statement For Pipeline Welding

Project Infield Pipeline Works for FCP, Majnoon Oil Field Project

Originating Company China Petroleum Pipeline Bureau (Iraq)

Document Title ITP For Method Statement for Pipeline Welding

Document Number FCPG-00000-CPP143-00-QA-5733-00010

Document Revision 006

Document Status IFA-Issued for Approval

Document Type QA5733-Inspection Plan

Originator/Author CPP

Security Classification Restricted

Authorizer Zhou Xiaoqiu

Issue Date 24-June-12

INFIELD PIPELINE WORKS FOR FCP MAJNOON OIL FIELD PROJECT

(SIPD-143)

Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 3 of 16

Revision History

Rev# Date of Issue

Transmittal No. Status Description Author Authoriser

000 21-Feb-12 CPP143-PIUL-2002C-0051-TX IFA-Issued for Approval CPP Zhou Xiaoqiu

001 28-Feb-12 CPP143-PIUL-2002C-0068-TX IFA-Issued for Approval CPP Zhou Xiaoqiu

002 06-Mar-12 CPP143-PIUL-2002C-0073-TX IFA-Issued for Approval CPP Zhou Xiaoqiu

003 15-Apr-12 CPP143-PIUL-2002C-0153-TX IFA-Issued for Approval CPP Zhou Xiaoqiu

004 20-Apr-12 CPP143-PIUL-2002C-0159-TX IFA-Issued for Approval CPP Zhou Xiaoqiu

005 13-May-12 CPP143-PIUL-2002C-0177-TX IFA-Issued for Approval CPP Zhou Xiaoqiu

006 24-June-12 CPP143-PIUL-2002C-0220-TX IFA-Issued for Approval CPP Zhou Xiaoqiu

Rev # Reason for Issue/Change

000 First draft issued for Approval

001 Issued for Approval(COMPANY comments incorporated)





006 Issued for Approval(Check point and WELD BOX have been revised)

INFIELD PIPELINE WORKS FOR FCP

MAJNOON OIL FIELD PROJECT (SIPD-143)


Content

1. INSPECTION AND TEST PLAN..................................................................................................................... 5

2. CONSTRUCTION REPORT ......................................................................................................................... 12


(SIPD-143)


1. INSPECTION AND TEST PLAN

INFIELD PIPELINE WORS FOR FCP, MAJNOON OIL

ITP FOR METHOD STATEMENT FOR PIPELINE WELDING

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

COMPANYs approval is given.

C - CERTIFICATION: Specific and appropriate certification documentation is to be included in the document package.

REMARKS






Item No.

Inspection Activity & Specific Check Point Area

Reference Document Acceptance Criteria,

Code & Standard Verifying Record

Contractor ICMT

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

General

Method statement review for final approval.

HSE Requirements for PPE and certified lifting

equipments.

Equipment Status for type range calibration earth

clamp contact point in pipe line.

Pipe inspection for pipe identification, physical and

physical damage, manufacturing stamp.

Electrode Control for class batch No.

Electrode Tracing by marking batch No against

welding

Pipe tracing by pipe no heat no and length. Transfer

the ID prior to cutting.

FCPG-00000-CPP143-00-BA-5537-00001 Method statement for pipeline welding

ISO 13847:2000 Petroleum and natural gas industries-Pipeline transportation systems-Welding of pipelines DEP 61.40.20.30-GEN Welding of pipelines and related facilities

FORM-QA-5733-00010-01

Daily Welding Report

FORM-QA-5733-00010-02

Pipe Log Book

FORM-QA-5733-00010-03

Weld Box

H

W/C

W

W/C

W/C

W

W/H

H

R

S

C/S

S

C/S

C/S

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






Item No.


Reference Document Acceptance

Criteria, Code & Standard

Verifying Record

Contractor/TPI ICMT

2.0

2.1

2.2

2.3

2.4

2.5

2.6

2.7

Welder Qualification

Welding Procedure Status for final approval

Pre-weld preparations by bevel dimensions ,clamp

type, root gap , alignment, mismatch with in 3mm

Welding Control by weather protection like wind

shield, welding parameters as per WPS, ensure

finishing by removal of slag grind high points and file

out under cuts.

Visual Inspection for marking and good workmanship

of root, cap, profile, surface discontinuities.

Mechanical Test

NDT 100% for RT for butt welds.

Welder approval in WQT records with qualification,

status, welder certificates, and cards

FCPG-00000-CPP143-00-BA-5537-00001 Method statement for pipeline welding WPS


FORM-QA-6050-0001-01 Welder Qualification Test Record

FORM-QA-6050-0001-02 WQT Visual Inspection Report FORM-QA-6050-0001-03 Welder Qualification Test Certificate

FORM-QA-5733-00010-04

NDT REQUEST FORM-BA-6070-0003-01 RT Report

H/W

H/W

H/W

H/W

H/W

H/W

C/R

H

S

S

S

S/C

S/C

S/C







Item No.


Reference Document

Acceptance Criteria, Code & Standard

Verifying Record

Contractor ICMT

3.0

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

3.11

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

Check welding environment in accordance with

requirement

Check length of Fixed welding, weld identification

Visual inspection for each pass

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.


WPS & PQR

WQR


FORM-QA-5733-00010-01


FORM-QA-5733-00010-02

Pipe Log Book

FORM-QA-5733-00010-03

Weld Box

W/S

S/R

S/C

W

W

W

W

W

W

W

W

S

S

S

S

S

S

S

S

S

S

S







Item No.




Contractor ICMT

4.0

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

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 radiographic testing.

Tie-in weld is passed by ultrasonic testing.


FCPG-00000-CPP143-

00-BA-6070-00013

Tie-In Procedure

WPS & PQR

ISO 13847:2000 Petroleum and natural gas industries-Pipeline transportation systems -Welding of pipelines DEP 61.40.20.30-GEN Welding of pipelines and related facilities FCPG-00000-CPP143-00-QA-6050-00011 RT Procedure FCPG-00000-CPP143-00-QA-6050-00012 UT Procedure

FORM-QA-5733-00010-01


FORM-QA-5733-00010-02

Pipe Log Book

FORM-QA-5733-00010-03

Weld Box

FORM-QA-5733-00010-04

NDT REQUEST

FORM-QA-5733-00010-05

TIE-IN CHECK LIST

W

W

W/S

W

W

W/R

W

R/C

R/C

S

S

S/R

S

S

S

S/R

R

R







Item No.




Contractor ICMT

5.0

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

Pipe weld repair and cut out

Pipe size, type and defects at Field Visual

inspection for each pass

Defect inspection; check the thickness after the

removal arc strikes, surface imperfections, damages

to pipe materials or fittings.

Check for the weld repair by liquid penetrate

technique

Check the cut out for min 500 mm lengths.

Dress the ground area to ensure smooth transition

with surrounding surface.

Welding as per approved WPS

Verifying welder qualification

Line up joint clean

Check preheat temperature


FCPG-00000-CPP143-00-BA-6064-00001

Pipe Weld Repair and

Cut Out Procedure

FCPG-00000-

CPP143-00-QA-6050-

00009 PT Procedure

WPS &PQR


FORM-QA-5733-00010-01


FORM-QA-5733-00006-02

Weld Repair Log

W

W

R

W

W

W/S

S/R

W

W

S/R

S/R

R

S

S

S

S

S

S







Item No.




Contractor ICMT

6.0

6.1

6.2

6.3

6.4

6.5

Pipeline welding NDT

Non-destructive test inspecting technician

shall be experienced and competent with

qualification certificate.

Inspect RT films and inspection reports

Inspect MT equipment and inspection reports

Inspect PT liquid and inspection reports.

Inspect UT equipment and inspection reports.

FCPG-00000-CPP143-00-BA-5537-00001 Method statement for pipeline welding FCPG-00000-CPP143-00-QA-6050-00011 RT Procedure FCPG-00000-CPP143-00-QA-6050-00010 MT Procedure FCPG-00000-CPP143-00-QA-6050-00009 PT Procedure FCPG-00000-CPP143-00-QA-6050-00012

UT Procedure


FORM-QA-6050-00011-01

RT Report

FORM-QA-6050-00010-01

MT Report

FORM-QA-6050-00009-01

PT Report

FORM-QA-6050-00012-01

UT Report

S/R

W

S/R

S/R

S/R

R

S/R

S/R

S/R

S/R





2. CONSTRUCTION REPORT NO. FORM-QA-5733-00010-01

Daily Welding Report Report No. Line No. Date: Sheet of

Pipe NO.

Heat No.

Pipe Material

Diameter (Inch)

W.T. (mm)

Joint No. WPS NO.

Fit-up

Pre-heat

()

Welders Visual Inspection

Remarks Root Hot Fill1 Fill2 Fill3 Cap

Contractor ICMT

Name

Signature

Date




NO. FORM-QA-5733-00010-02

Pipe Log Book

Pipe NO.

Heat No.

Length(m)

Diameter W.T. (mm)

Joint No.

Welding Date

WPS NO.

Welders Welding Report

No

RT Reports

Root Hot Fill1 Fill2 Fill3 Cap Date Results Report 1

No. Report 2

No.


(SIPD-143)


NO. FORM-QA-5733-00010-03

WELD BOX

WELD NO.

WPS NO.

L R

PIPE NO.

HEAT NO.

R

H

F

C

VT

DATE




NO. FORM-QA-5733-00010-04

NDT REQUEST Report NO.: Line No.: Drawing No.: Date: Sheet: of

S.N. Weld NO. DIA X THICK WPS

NO.

REQUEST FOR Welders REMARKS

RT UT PT MT

Contractor ICMT

Name

Signature

Date




NO. FORM-QA-5733-00010-05

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 beveled 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. Weather conditions are suitable for tie-in welding, ambient temperature shall not be less than 10C .

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

8. Ensure that adjoining pipes are stress free before welding.

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

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

11. Visual inspection to the final weldment is acceptable.

12. Tie-in weldment is passed by radiographic testing.

REMARKS

APPROVALS CONTRACTOR ICMT

Name

Signature

Date

Documents

FCPG 00000 CPP143 00 QA 5733 00010 006 ITP for Method Statement for Pipeline Welding