Specification for Pipe Fittings

Transcription

1 Specification for Pipe Fittings Specification for Pipe Fittings Page 1 of 11

2 Table of Contents 1.0 SCOPE DEFINITIONS REFERENCES, CODES AND STANDARDS CONTRACTOR'S RESPONSIBILITIES MANUFACTURING REQUIREMENTS INSPECTION AND TESTING REPAIRS OF INJURIOUS DEFECTS MARKING STORAGE, HANDLING AND SHIPPING PERFORMANCE OF WORK...9 Specification for Pipe Fittings Page 2 of 11

3 1.0 SCOPE This specification shall govern the minimum requirements for the manufacturing, inspection, testing, marking and shipping of the subsea pipe fittings. The work includes providing all labor, materials, tools and equipment and the performance of all operations and incidentals necessary for the handling, fabrication, storing and shipping of the fittings and accessories. In addition, the work shall meet any other requirements stated elsewhere in the CONTRACT. 2.0 DEFINITIONS For the purposes of this specification, the following definitions apply: COMPANY: Williams Energy Services and/or Coflexip Stena Offshore, Inc. CONTRACTOR: The firm responsible by CONTRACT for the supply/manufacture of the fittings and accessories. CONTRACT: The entire signed written agreement between COMPANY and CONTRACTOR STANDARDS: Industry codes, standards, and recommended practices referenced herein. WORKS: The location(s) at which manufacturing, inspection and testing are performed. 2.1 Contractor Representative Vendor shall designate in writing to Company an authorized representative to serve as liaison with COMPANY on matters associated with this Specification and on the Purchase Order or Contract referencing this Specification. This representative shall be designated prior to the performance of services associated with this Specification and the Purchase Order or Contract referencing this Specification. 2.2 Document Precedence In the event of conflict between documents, the priority shall be as follows: a) Purchase Order or Contract b) This Specification c) Referenced Standards However, conflicts shall be reviewed and resolved with COMPANY's Representative prior to initiation or continuation of the services to be performed in association with the Purchase Order or Contract. 3.0 REFERENCES, CODES AND STANDARDS This specification incorporates all or parts of the latest versions of the following codes, standards and specifications. American National Standards Institute ASME/ANSI B16.9 Factory Made Wrought Steel Buttwelding Fittings ANSI/ASME B31.8 Gas Transmission and Distribution Piping Systems ANSI/ASME B31.4 Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols American Petroleum Institute API SPEC 5L Specification for Line Pipe American Society of Mechanical Engineers ASME BPV Code Sec VIII Rules for Construction of Pressure Vessels Div 1 Specification for Pipe Fittings Page 3 of 11

4 American Society for Testing and Materials ASTM A 370 Standard Testing Methods and Definitions for Mechanical Testing of Steel Products ASTM E 92 Standard Test Method for Vickers Hardness of Metallic Materials ASTM A694 Forgings, Carbon and Alloy Steel for Pipe Flanges, Fittings, Valves and Parts for High Pressure Transmission Service ASTM A388 Practice for Ultrasonic Examination of Heavy Steel Forgings Manufacturers Standardization Society MSS SP 75 Specification of High Test Wrought Butt Welding Fittings MSS SP 44 Steel Pipe Line Flanges 4.0 CONTRACTOR'S RESPONSIBILITIES 4.1 General CONTRACTOR shall provide all labor, materials, tools and equipment and shall undertake all engineering, manufacturing, inspection, reporting, storage, field services and shipping necessary to do the work required in this specification and whatever else is necessary to furnish products and services that are suitable to the application. If CONTRACTOR believes that this specification is inconsistent with the intended use or other terms of the CONTRACT, CONTRACTOR shall inform COMPANY and resolve the conflict by the terms of the CONTRACT. 4.2 Subcontractors CONTRACTOR shall be responsible for the actions and performance of subcontractors. 4.3 Reporting and Approvals Deviations and Disclaimers Work done under this specification shall be according to all requirements herein, without deviations or disclaimers. If COMPANY approves changes, they will be incorporated into a revised specification, and this specification will be void CONTRACTOR's Work Plan Within two weeks of the time the CONTRACT is issued, CONTRACTOR shall submit a work plan for carrying out the work required by this specification and the CONTRACT. CONTRACTOR shall obtain COMPANY's written approval for the work plan before other work begins. The work plan shall include: a) Schedules that show the sequence and duration of each step in the engineering and production processes; b) Quality control procedures and a list of production and qualification tests and inspections, test procedures and the projected dates; c) Procedures for identifying, documenting, and segregating or disposing of nonconforming materials; d) A complete list of deliverable items, including plans, specifications, drawings, hardware components and their expected delivery date; e) Manufacturing methods and procedures including a list of facilities and equipment to be used and a description of each step in the manufacturing process. Specification for Pipe Fittings Page 4 of 11

5 4.3.3 Design Report and Specifications At a time specified in the approved work plan of the preceding paragraph, CONTRACTOR shall submit a report for COMPANY's approval that includes a complete set of designs, specifications and supporting information. The CONTRACTOR shall provide seven (7) copies of the approved report and appendices. As a minimum, the report shall include: a) Summary; b) Reference documents, codes and standards; c) Design criteria; d) Design considerations; e) Methods of analysis; f) Design limits, including operating pressures, pressure limits and temperature limits; g) List of component parts; h) Specifications for all component materials, including: Physical characteristics, Chemical composition, i) Appendices Design calculations, Computer output, and Results of tests done in the design process As Built Report Before delivery of the fittings, CONTRACTOR shall furnish COMPANY an as built report with detailed instructions for installation and use that includes: a) As built drawings and specifications; b) Evidence of satisfactory performance of all required tests and examinations; c) A complete description of, and evidence of approval for variations in the delivered product and the design specifications described in Section ; d) Material certificates; and e) A certificate signed by CONTRACTOR's authorized representative certifying that the delivered fittings comply with the requirements of this specification and CONTRACTOR's COMPANY approved design Certification Where this specification or CONTRACTOR's work plan requires material certificates, CONTRACTOR shall furnish COMPANY with eight copies of each. Such certificates shall include the following: a) Material vendor and producer; b) All elements of the chemical composition; c) Material specification and physical properties; and d) Evidence of satisfactory performance test results, as specifically required in this specification Disposition of Nonconforming Materials When the work is complete, CONTRACTOR shall submit a summary report of all nonconforming materials and their disposition. For the purpose of this report, dispositions of nonconforming materials should be classified as "scrap", "use elsewhere", "rework" or "use as is". CONTRACTOR shall also include a detailed description where necessary to describe the disposition fully. If CONTRACTOR cannot eliminate a nonconformity by replacement or by a procedure set out herein, then immediately upon its occurrence or discovery, CONTRACTOR shall present a proposed disposition to the authorized COMPANY Representative. COMPANY's representative must approve all such dispositions and may reject nonconforming materials. 4.4 Records CONTRACTOR shall keep up to date records adequate to confirm that the work, including all required tests, inspections and reviews, has been Specification for Pipe Fittings Page 5 of 11

6 carried out to this specification. These records shall be indexed and legibly recorded in enough detail that they can be accessed and understood by a qualified, independent third party. In absence of other instructions, CONTRACTOR shall keep these records available to COMPANY for inspection or photocopying for five years. The records should include: a) A description of each test or inspection and its results, with a reference to the paragraph number of the test requirement in this specification or CONTRACTOR's work plan; b) The date of the test or inspection; c) The name and qualifications or authority of the inspector or reviewer and his employer; d) Evidence of calibrations; e) Pertinent information about nonconformities or test failures, including: Material or condition that caused rejection, Method of detection, Number of items involved, if more than one, Proposed and actual disposition, and Preventive action taken. 4.5 Interactions between Contractor and Company CONTRACTOR shall allow COMPANY free access to his facilities and processes where work is being done under this specification for monitoring, surveillance and inspection, including but not limited to: a) Review of adequacy of facilities and equipment; b) Review of personnel qualifications; and c) Performing or witnessing inspections test and analyses COMPANY deems necessary to confirm compliance with requirements. CONTRACTOR shall give COMPANY notice of the production start up and all tests and inspections required herein. The number of days notice shall be according to the requirements of the CONTRACT. CONTRACTOR shall provide all reasonable facilities to COMPANY for the above purposes. Such facilities shall include office equipment, telecommunications equipment and a temporary office work space. The CONTRACTOR shall submit to the COMPANY full certified documents on the fittings in a "Production Report". The report shall include, but not be limited to, the following information and documents: Fabrication, heat treatment and inspection procedure specifications Fabrication procedure qualification test records Non destructive inspection and test results Mill certificates for heat and product analysis Mill certificates for all mechanical tests Dimensional inspection reports List of fittings with reference numbers, heat numbers, fitting dimensions, grade of materials and weights of fittings The CONTRACTOR shall submit to the COMPANY full certified documents on the fittings in a "Production Report". The report shall include, but not be limited to, the following information and documents: Fabrication, heat treatment and inspection procedure specifications Fabrication procedure qualification test records Non destructive inspection and test results Maximum hardness values Fitting Welds Fitting Heat affected zones Mill certificates for heat and product analysis Mill certificates for all mechanical tests Dimensional inspection reports Specification for Pipe Fittings Page 6 of 11

7 List of fittings with reference numbers, heat numbers, fitting dimensions, grade of materials and weights of fittings. All fittings shall be certified that they are in compliance with MSS SP 75 or COMPANY approved equal. The CONTRACTOR shall submit to the COMPANY all documents required by this specification or applicable parts of the referenced codes. All records and documents shall be combined and submitted in a report at the end of the work. 5.0 MANUFACTURING REQUIREMENTS 5.1 General The fittings shall be designed, manufactured and supplied according to ASME/ANSI B16.9, MSS SP 75, ANSI/ASME B31.4 and ANSI/ASME B31.8 except when modified by this specification. Fittings shall be of a size, wall thickness and type as specified in the CONTRACT. The pipe fittings shall have a standard 30 degree weld bevel and be suitable for welding to pipe grade specified line pipe of the size as specified in the CONTRACT and shown in COMPANY Drawings. The transition pieces shall have also have standard 30 degree bevel on each end and shall be tapered to match the thickness of the pipe at each end. Before manufacture, CONTRACTOR shall submit for acceptance by COMPANY, detailed drawings, design calculations and detailed manufacturing procedures. 5.2 Materials The material specification shall be according to MSS SP 75. The steel grade shall be WPHY 70 or COMPANY approved equal as specified in COMPANY drawings. Pipe material for the pipe nipples shall be seamless API 5L X 70 or other specified steel grade as COMPANY approved equal. 5.3 Heat Treatment Heat treatment of fittings shall be according to Section 9 of MSS SP Chemistry For each heat of steel used, the CONTRACTOR shall carry out chemical analysis to determine all the alloy elements which constitute the steel. The chemical composition as determined by product analysis shall conform to the requirements of Section 7 of MSS SP 75. On check analysis, the carbon equivalent (C.E.), derived from the following formula shall not exceed 0.42%: C.E. = C + Mn/6 + (Cr + Mo + V)/5 + (Cu + Ni)/ Mechanical Characteristics The minimum rated value of the mechanical characteristics shall be according to Section 8 of MSS SP 75. The minimum rated value of the mechanical characteristics for the transition pieces and pipe nipples shall be according to Table 4.1 of API Spec 5L X 70 material or other specified steel made. 6.0 INSPECTION AND TESTING 6.1 General Inspection and testing shall be carried out according to MSS SP 75 except where modified by this specification. 6.2 Inspection by Company When fittings are being tested specially for the COMPANY, the CONTRACTOR shall give COMPANY Specification for Pipe Fittings Page 7 of 11

8 at least 48 hours advance notice of scheduled inspection or test so that COMPANY may witness same. CONTRACTOR shall give the COMPANY Representative access to any and all parts of CONTRACTORs facilities where tests and inspections take place. When fittings have already been tested, CONTRACTOR shall supply the necessary certified documents to ensure that all the tests have been performed successfully. COMPANY will have the right to conduct NDE by ultrasonic inspection, magnetic particle inspection, radiography, visual inspection and other means. Also COMPANY will have the option to require the following: Pressure test at two times the maximum design pressure per API 6A, Clause 1.7 Liquid Penetrant per ASTM E165 Ultrasonic per ASTM A Fracture Toughness Test Charpy V notch impact test specimens shall be full size according to the requirements of ASTM A 370. Test specimens shall be taken from a suitable extension of the parent material, the extension having had the same treatment and conditioning as the finished product. Three transverse specimens representing one test shall be taken from each heat. For small diameter (less than 8 inch) fitting, three longitunal specimens shall be taken instead of transverse ones. Charpy testing temperature shall be 0 degrees C (+32 degrees F). Charpy energy requirements shall be 30 ft lbs individual minimum and 35 ft lbs minimum average. If the fittings fail to meet the requirements, the CONTRACTOR shall take remedial action acceptable to the COMPANY. Further test failures shall be basis for rejection. 6.4 Magnetic Particle Examination All available surfaces of each forging shall be examined by magnetic particle technique according to the requirements in Paragraphs 6 1 through 6 3 of Appendix 6, ASME Section VIII, Division 1. Acceptance shall be to the requirements according to Paragraph 6 4 of Appendix Hardness Testing Macro sections for hardness testing shall be taken from the fitting body. The hardness tests shall be performed for each wall thickness from each heat. Hardness requirements shall meet the criteria of SR 5 of MSS SP 75. Hardness testing criteria shall be according to ASTM E REPAIRS OF INJURIOUS DEFECTS Repair to defective parts shall be made strictly according to a repair procedure submitted by CONTRACTOR and approved by the COMPANY before starting work. 8.0 MARKING Each fitting shall be permanently stamped on the outside surface with the manufacturer's name or trademark and the fitting identity number. In addition, the fitting shall have the following items paint stencilled on the outside surface. Nominal O.D. x W.T. or welding ends Steel grade Heat number CONTRACT number Weight ASTM material specification number Specification for Pipe Fittings Page 8 of 11

9 All marks which are painted on fitting before applying the final coating shall be retained and reapplied to the fitting after the coating is applied. 9.0 STORAGE, HANDLING AND SHIPPING CONTRACTOR shall pack and ship the fittings to the COMPANY's designated delivery point according to the instructions in the CONTRACT. Shipping and handling shall be according to acceptable industrial practice. Before shipment, the ends of the fittings shall be adequately protected against deterioration during transport. Bevel protection end caps shall be provided to protect ends prepared for butt welding. Other surfaces should be protected with timber. All fittings damaged during shipment or handling shall be replaced by CONTRACTOR at no cost to COMPANY PERFORMANCE OF WORK CONTRACTOR shall guarantee that work performed when fabricating the fittings shall be according to this specification. The COMPANY Representative shall have full access to the CONTRACTOR's facilities and property to assure the COMPANY that these specifications are being followed. Specification for Pipe Fittings Page 9 of 11

10 Appendix A SUMMARY OF TEST REQUIREMENTS Specification for Pipe Fittings Page 10 of 11

11 TEST CERTIFICATES CHEMICAL COMPOSITION/CE CHARPY IMPACTS/TOUGHNESS ASTM (Verify) ASTM (Sec. 5.4) ASTM (Sec. 6.3) Table 1 MATERIAL QUALIFICATION TESTS VISUAL & DIMENSIONAL FRACTURE TOUGHNESS HARDNESS TRAVERSE LIQUID PENETRANT EXAM ULTRASONIC EXAM MAG. PARTICLE EXAM ANSI B16.9 (Sec. 6.3) (Sec. 6.5) (Sec. 6.2) ASTM A388 (Sec. 6.4) Table 2 TESTS ON COMPLETED FITTINGS Specification for Pipe Fittings Page 11 of 11