9706-120-pro-1004 Rev 0 Construction Engineering Procedure

MELIWIS DEVELOPMENT PROJECT – CONSTRUCTION AND ENGINEERING BLANKET STRUCTURE – PIPING PROCEDURE SUPPLY AND FABRICATION SERVICES Consortium BOS - BMDA

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CONSTRUCTION AND ENGINEERING PROCEDURE Contract No. 904094

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Date

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Checker

Project Engr

Contractor

0

09 Apr 19

Issued For Review

WHY

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Company

Date

CONSTRUCTION AND ENGINEERING PROCEDURE Consortium BOS - BMDA

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RECORD OF REVISIONS THE REVISIONS LISTED BELOW HAVE BEEN INCORPORATED IN THIS COPY OF THE DOCUMENT Rev No.

E1

Section

General

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Company Comment

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its totally confuse between title and content? the content is most like engineering scope

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Material

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Fabrication

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Fabrication

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Welding

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Welding

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Need to consider to added: For any utilization of repaired/used/recondition material, it shall be approved first by QA/QC material inspector, Discipline Engineering. Need to consider to added: For Any modification, substitution and alteration from approval construction, it shall be approved by Discipline engineering, filed engineering or other authorized parties . Need to consider added new paragraph regarding: Fit-up and Alignment & please specify Please added: All welding shall conform to requirement of ANSI/ASME B31.3 and this specification All welding fabrication activities shall be carried out base on approved construction drawing, strictly follow the used qualified WPS PQR and

Implemented (Y/N)

Explanation

Y

added section for explain in more detail about construction and put in (and) word in the title

Y

added those statement

Y

added those statement

Y

We are added new section based on request

Y

added those statement

Y

added those statement

CONSTRUCTION AND ENGINEERING PROCEDURE Consortium BOS - BMDA

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Welding

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Please added: Weld Map & NDT plan shall be prepared for each of fabrication activity.

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added those statement

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Table of Contents 1.0

INTRODUCTION ......................................................................................................................................... 5 1.1

PROJECT OVERVIEW ..................................................................................................................... ....5

1.2

PROCEDURES OVERVIEW ................................................................................................................. 6

2.0

SCOPE ........................................................................................................................................................ 6

3.0

DEFINITION ................................................................................................................................................ 6

4.0

CODES, STANDARDS AND REFERENCES ...................................................................................................... 7 4.1

International Codes and Standards ................................................................................................... 7

5.0

UNITS......................................................................................................................................................... 7

6.0

LANGUAGE ................................................................................................................................................ 8

7.0

SPECIFICATION ........................................................................................................................................... 8 7.1

Quality Control................................................................................................................................. 8

7.2

Engineering Shop and As-Build Drawing ........................................................................................... 9

7.3

Engineering Calculation .................................................................................................................... 9

7.4

Materials........................................................................................................................................ 10

7.5

Fabrication ..................................................................................................................................... 11

7.6

Fit-up and Alignment...................................................................................................................... 12

7.7

Welding ......................................................................................................................................... 13

7.8

Erection/Handling .......................................................................................................................... 14

7.9

Flanging and Bolting ....................................................................................................................... 14

7.10

Coating .......................................................................................................................................... 15

7.11

System Completion ........................................................................................................................ 15

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1.0

INTRODUCTION

1.1

PROJECT OVERVIEW The Meliwis field is located in the Madura Offshore PSC in the Madura Straits approximately 46 km south of Madura Island and 142 km east of Surabaya. The field is 11 km south of the Maleo gas field, which is commenced gas production in September 2006.

Figure 1.1 – Meliwis Field Location (Maleo PSC) The Madura Offshore Production Sharing Contract (PSC) is operated by Santos (Madura Offshore) Pty Ltd on behalf of the Madura Offshore PSC Joint Venture with participant equity interests as follows: Santos (Madura Offshore) Pty Ltd 77.5% PC Madura Ltd 22.5% The Meliwis field was discovered by the Meliwis-1 well in April 2016, which encountered a 53 m gross column in the Upper Mundu, GlobigerinidLimestones. Two drill stem tests (DST’s) were carried out, with a maximum test rate of 13.07 MMSCFD. A conceptual study was performed in 2017 by Santos which concluded that the optimum development option is a minimum facility wellhead platform option tied

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PROCEDURES OVERVIEW This Standard Specification is applicable to all new project within OPHIR-Energy Assets under Construction of The consortium of BOS-BMDA and. Projects designed to upgrade or expand an existing facility may choose to remain consistent with the design philosophies or Specification already in place at that facility or use this Specification only in areas that do not conflict with the facility’s existing Specification. The document shall not be altered or revised without review and approval by the Technical Authority assigned to this standard specification. Revisions and addendums to this standard specification shall be approved by the OPHIR-Energy. Each deficiency of this standard specification must follow other specifications in the related subject/section.

2.0

SCOPE This specification defines the minimum technical requirement for fabrication and erection both for shop and field fabricated and erection. This document and the codes, specifications and referenced documents listed below are not intended to be all-inclusive. The requirements set forth do not relieve Contractor of his responsibility to perform all services in a safe manner, to meet applicable codes and standards, to comply with government regulations or to supply a product capable of performing its intended service. This standard specification shall be used by Contractor to ensure uniformity of approach in design within the engineering team.

3.0

DEFINITION Term Company Consortium Purchaser Shall Should Standard Specification

Definition OPHIR-Energy BOS-BMDA Persons responsible for procurement of equipment, material and or services Shall is an absolute requirement which shall be followed strictly when referenced Strongly recommended suggestion Business unit standard technical specification

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4.0

CODES, STANDARDS AND REFERENCES The following section of this specification may define specific codes and standards which must be followed. However, when there are conflics or when no design codes or standards are specified, Contractor shall perform the design on the basis, standards and practice.

4.1

International Codes and Standards International codes and standards to be referred to :

5.0



American Society of Mechanical Engineers (ASME) No. Standard Description 1 ASME B31.8 Gas transmission and Distribution Piping System 2 ASME Section II Part Material Specification A-C 3 ASME Sect IX Welding and Brazing, Qualification



American Petroleum Institute (API) No. Standard Description 1 API RP 14E Welding Guidelines for the Chemical, Oil and Gas Industries 2 API Specification 5L Specification for Line Pipe

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American Welding Society (AWS) No. Standard Description 1 B1.10 Guide for the Non-Destructive Inspection of Welds 2 D1.1 Structural Welding Code-Steel



International Standard of Organization (ISO) No. Standard Description 1 ISO. 10721-2 Steel Structures 2 D1.1 Structural Welding Code-Steel

UNITS There is a mix of imperial units, metric units, and various other systems of units on existing OPHIR drawings and documents. As general rule, The consortium of BOS-BMDA shall use consistent units to those on the original drawing or document, whenever revisions to these existing documents are required.

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6.0

LANGUAGE All documents, drawings, specifications, vendor data, reports and all other written information prepared by Contractor or by Suppliers to Contractor for the work shall be in the English Language. Any document submitted to Company by Contractor which does not comply with this requirement will be rejected until such time that Contractor resubmits the document in English Language. The only exception to this requirements is that all maintenance and operating manuals shall be furnished separately in English editions and in Indonesian language editions.

7.0

SPECIFICATION

7.1

Quality Control 

The consortium of BOS-BMDA shall have a quality control system and quality control covering all fabrication activities. Controlled copies of the quality control manual shall be available for OPHIR approval and for monitoring of all construction activities.



The consortium of BOS-BMDA shall establish detailed procedures for control of welding quality. The following procedures shall be submitted for review and approved by OPHIREnergy prior to starting fabrication :



a.

Welding and weld repair

b.

Storage, control, and identification of welding consumable

c.

Welder qualification records

d.

Inspection/NDT

e.

Post-weld heat treatment, if required

f.

Monitoring the progress and quality of welding

The consortium of BOS-BMDA/Supplier shall ensure the “in progress” material documentation is maintained on a daily basis. All materials, which require documentation in use during fabrication or installation that cannot be identified with documentation shall be immediately removed from area and replaced at the consortium of BOSBMDA/Supplier expense.

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All Structure and piping materials shall be provide with Mill Test Report or Certified Test Report. The reports shall be identify the type of steel, composition, heat number and any special test that has been performed

7.2

Engineering Shop and As-Build Drawing 

The consortium of BOS-BMDA shall prepare piping isometric and spool drawing for all piping. The isometric drawings should show spool numbers, welded attachments, location and type of welds (shop or field).



The consortium of BOS-BMDA shall prepare shop drawing for Topside and other detailed drawing based on contract project with OPHIR-Energy.



The consortium of BOS-BMDA shall prepare all shop drawing and spool drawing refer to Plan drawing and detailed drawing for determine all elevations, sections, and dimension of object related.



The consortium of BOS-BMDA shall maintain an up to date, complete and accurate record of all changes made to design drawing during the fabrication and erection of the structure and piping.

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Each piece of major equipment shall be identified on the drawings. The identity shall correspond to the title and tag number indicated.



Each shop drawing that produced shall be identified with the drawing number in accordance with the OPHIR-Energy details drawing related.

7.3

Engineering Calculation All calculations prepared by consortium of BOS-BMDA shall comply with the minimum requirements defined in the following : a)

Each calculation shall be identified by a subject description consisting of Company number, discipline, and descriptive tittle.

b)

Names of the persons preparing and checking the calculation shall be entered with the first initial followed by the full last name. Names shall be printed rather than written. Dates shall refer to the day each person started working on the calculation.

c)

All assumptions shall be clearly stated after defining the problem, including references, if any.

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Sources of formula, equations, data and other references used in the calculations shall be clearly stated.

e)

Numerical approximations and other "judgement" type assumptions made by the preparer shall be identified with phrases similar.

f)

All logical steps shall be numbered and identified with a brief phrase.

g)

A summary of all significant results and/or conclusions shall be made at the end of the calculation.

h)

Calculations shall be made using the units defined in this Scope of Work.

i)

Calculations shall not be considered valid until they have been checked by a second qualified person. The checker will mark through incorrect item sand write the correct item adjacent to them. Checkers shall not erase data from the computation. The checker will return the calculation to the prepared when checking is complete

j)

Calculations shall be prepared to support all significant design engineering decisions, and, where applicable, shall be referenced to the appropriate drawings.

k)

Copies of significant drawings, sketches, graphs, and other original work shall be included as part of the calculation.

l)

Computer calculations shall be supported by print outs which clearly defined all input data, results and the method consortium of BOS-BMDA.

7.4

Materials 

Material used for structure and piping shall meet the requirement of OPHIR material specifications or request by OPHIR.



Special attention shall be paid to segregation of carbon steel and corrosion resistant alloy materials during storage, fabrication, transport and handling. All necessary measures shall be taken to prevent contamination of stainless steel, duplex or superduplex materials. The area used for storage of fabrication of stainless steel material shall be segregated from areas where carbon steel is stored or fabricated. Tools for cutting, grinding and similar operations on carbon steel shall not be used for stainless steel.



If any utilization of repaired/reused/recondition material, the consortium of BOS-BMDA shall be needed approved by QA/QC material inspection or discipline engineer from OPHIR-Energy

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The consortium of BOS-BMDA shall submit to Company for approval a written procedure covering material receipt, inspection and storage. The procedure should cover but not limited to:

7.5

a.

Defective materials,

b.

Storage and Segregation,

c.

Materials allocation,

d.

Transfer of Markings for trace ability

Fabrication 

Piping shall be fabricated in accordance with the requirements of this specification and the latest edition of the piping codes and regulations specified under the individual material specification classes



Steel Structure shall be fabricated with the requirement of this specification and refer to shop drawing that has been approved by OPHIR or based on request by OPHIR.



Piping design drawings and piping line isometrics shall govern dimensions and materials.



Steel Structure design drawings and Shop drawing shall govern dimensions and materials.



Where field welds are designated, the prefabricated pipe and steel structure should be cut off to suitable over lengths longer than the dimensions shown on the fabrication drawings to allow for precise fit-up in place. The location of field welds where not indicated on the drawings will be the responsibility of the general Contractor.



The consortium of BOS-BMDA shall maintain "clean" fabrication areas for the fabrication of stainless steel and nickel alloy piping to minimize the possibility of contamination.



The consortium of BOS-BMDA shall utilize shop tools and equipment compatible with materials in fabrication, including but not limited to grinding discs, cutting tools, and wire brushes designed for use with stainless steel and/or other high alloy materials.



Where reinforcement pads (doublers) or saddles are required they shall be of the same material as the run pipe or steel structure (unless specified otherwise) and shall be formed and contoured to provide a good fit.

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For any modification, substitution and alteration from approval construction drawing, it shall be approved by discipline engineering, field engineering or other authorized parties.

7.6

Fit-up and Alignment 

For fit-up activities shall be conform to requirement of this specification



Before fit-up activities, fitter must obtain approval from QC and Engineer of the consortium of BOS-BMDA to ensure the material cutting profile matches the approval construction drawings.



After fit-up material, from QC and Engineer of the consortium of BOS-BMDA need to check the orientation, shape and dimension to ensure compatibility with approval construction drawings.



Gap maximum and minimum fit-up of steel structure must be following figure 7.1 Shape connection of profile must be following figure 7.2.

Figure 7.1. Butt weld connection and fillet connection

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Figure 7.2. Shape of connection main beam to branch



Cleaning and internal surface shall be free of rust, grease and paint for at least 13mm from the root face

Figure 7.3. Shape of connection main beam to branch

7.7

Welding 

Welding process, welding procedure and welder performance qualification shall comply with requirement of code and standard ANSI/ASME B31.3, AWS D1.1 and this specification.



All welding fabrication activities shall be carried out base on approved construction drawing, strictly follow the used qualified WPS PQR and comply with codes, standard and specification



Welding Spacing a. Circumferential butt welds shall be separated by the maximum possible distance and not less than 1 x D without written approval from OPHIR. However, between piping fittings, etc., short pipe lengths may be required. In this situation, butt welds shall not be within 3 inches (75 mm) of adjacent butt welds. For pipe sizes less than

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14 of 15 3 inches nominal bore, butt welds may be within the greater of 4 times the wall thickness or one pipe diameter of adjacent butt welds, whichever is greater. Circumferential butt-welds closer than the above limits shall be brought to the attention of the OPHIR representative for approval b. Longitudinal but weld shall be separated by maximum possible distance and not less than 2in without written approval from OPHIR. c. Welding gap for piping and steel structure is ± 3mm or based on request by OPHIREnergy. 

Welder and Welding Operator shall be qualified in accordance with essential variable of ASME section IX.



7.8

Welding Map & NDT plan shall be prepared for each fabrication activity.

Erection/Handling 

Piping and Steel Structure shall be erected in accordance with detailed drawing



All component shall be installed true based on related drawing



Erection of piping and steel structure shall be scheduled so that no undue strain will be inflicted on equipment due to lack of support, dead weight or misalignment. It shall be design, fitted and assembled / erected strain free without any misalignment.



Piping which has been painted prior to erection shall be handled with care to avoid damage to coatings.



The consortium of BOS-BMDA shall provide padded slings or straps for handling coated pipe or steel structure and nonferrous padded slings for stainless steel and alloy steel. The consortium of BOS-BMDA shall exercise care in lowering, assembling and installing all coated piping.



Internal grinding or machining may be conducted to improve root alignment of misalignment equal to or less than 1/16” (1.6 mm). However, the taper shall not exceed 1 in 4 and the minimum wall thickness shall be maintained.

7.9

Flanging and Bolting 

Flange bolt holes shall straddle horizontal and vertical centre lines unless noted otherwise on the construction drawings.

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Coating 

All process piping and component shall be coated in accordance with applicable consortium of BOS-BMDA Coating Standard Specification.



In general, piping shall be blasted and painted up to the final coat of paint prior to installation on skid packages or platform interconnections.

7.11

System Completion 

Piping In order to demonstrate system completion ready for pre-commissioning consortium of BOS-BMDA shall carry out a ‘line by line’ walk to check the system and its components have been installed in accordance with the latest revision of the P&ID’s. The installed system shall also be checked against the isometric and pipe support design for compliance and a punch list produced of outstanding items for rectification



Steel Structure In order to demonstrate system completion ready for pre-commissioning consortium of BOS-BMDA shall carry out a ‘Structure by structure’ walk to check the system and its components have been installed in accordance with the latest revision of the Detail Drawing. The installed structure shall also be checked against the shop drawing design for compliance and a punch list produced of outstanding items for rectification