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NONG YAO PROJECT - Subsea Valve Vendor visit: BÖHMER GmbH Country of Origin: Germany Visitation Date: 6 th Oct- 8 th Oct Generated on 10 th Oct Year: 2014 By Gowri Sankar Doc No. Info-PPT-001 Rev.0 Total Pages include this page : 27 pages

NONG YAO PROJECT SUBSEA VALVE Rev 0

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Page 1: NONG YAO PROJECT SUBSEA VALVE Rev 0

NONG YAO PROJECT- Subsea Valve

Vendor visit: BÖHMER GmbH Country of Origin: Germany

Visitation Date: 6th Oct- 8th Oct

Generated on 10th Oct Year: 2014

By Gowri Sankar

Doc No. Info-PPT-001 Rev.0Total Pages include this page : 27 pages

Page 2: NONG YAO PROJECT SUBSEA VALVE Rev 0

1. General Information2. Scope Of Work3. Applicable Codes & Standards4. Documents Review5. Test Criteria6. Product Testing

A. Hydrostatic TestB. Function TestC. Pneumatic TestD. Drift Test

7. Test Pictures & Descriptions8. API 6DSS Checklist - Information9. Corrosion Prevention - External10. Packing & Shipping11. Any Questions?

Title

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To follow (indefinitely) contractual agreement to derive (use) product (i.e. valve) for G11/48 Nong Yao Development Project as per the following specification.

As per the guidelines/requirements defined in the specification Subsea Valve & Doc No. NY-PPL-X-WPTL-PL-SP-0017 Rev. B.

Specification has defined that the product (valve) is to be Designed, Manufactured, Tested to ISO 14723/API 6DSS.

Contractor responsibility (NSENGI) to ensure & select the product (valve) is capable of performing its intended service by ensuring Only Quality Product is being considered & selected.

Witnessing & contractor (NSENGI) presence during product test prior to delivery is Important & Compulsory.

1. General Information

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API 6DSS (ISO 14723) API (American Petroleum Institute) 6DSS was first developed in

June 2007 (which nationally adopted ISO 14723) & primarily based on ISO 14313 – Petroleum & Natural Gas Industries – Pipeline Transportation.

API 6DSS is specifically developed to address special requirements for subsea pipelines valves.

International standard prepared by Technical Committee ISO/TC 67: Materials, Equipments & Offshore Structures for petroleum & natural gas industries. Sub-committee SC 2, Pipeline Transportation System

Specify requirements & provide recommendations for the design, manufacturing, testing and documentation of Ball Valve, Check Valve, Plug & Gate Valve relating to subsea pipelines.

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Subsea Ball Valve

6” DN150 Class 300 – Subsea Valve

6” DN150 Class 300 – Subsea Valve

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2. Scope Of Work To understand on Types of Valves & valve function 6” DN150 Pressure: Class 300 – Ball Valve Type 2” DN150 Pressure: Class 300 – Ball Valve Type

To understand Industrial Standards & Guidelines API 6DSS (ISO 14723) Requirements

To understand Client Specification & Requirements (Nong Yao Project) NY-PPL-X-WPTL-PL-SP-0017 Rev.B – Subsea Valve specification.

To Review of Vendor Supplied Documents & Acceptance – Prior to visit Documents i.e. Material Specification, Qualification of Inspection & Test Personnel etc.

(Further Info. in Section 4; Document Review)

To Witness Product Test – At vendor site (if avail. or 3rd Party Test Lab) Hydrostatic Test Function Test Pneumatic Test Drift Test

(Further info in Section 6; Product Test)

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3. Applicable Code & StandardsSpecifications TitlesAPI 6D Specification for Pipelines ValvesAPI 6A Specification for Wellhead & Christmas Tree

EquipmentAPI 17D Specification for Subsea Wellhead & Christmas

Tree EquipmentAPI 598D Valve Inspection & TestingANST – TC- 1A Personnel Qualification & Certification in Non

Destructive TestingASTM A370 Standard Test Methods & Definitions for

Mechanical Testing of Steel ProductsAPI 6DSS (ISO 14723)

Petroleum & natural gas industries – Pipeline Transportation systems – Pipeline Valves

BS EN 10204: 2004

Metallic Products – Type of inspection documents

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4. Documents Review

• Pressure Gauge or Pressure Transducers

• Calibrated Periodically

• Qualified to ISO 15607, ISO 15609 etc.

• Welding Operators to ISO 9606 etc.

• Qualified as per ISO 9712 requirements

• Qualified Welders & Operators to AWS QC1

• Mill Certificates• Pressure Control Parts

Specifications i.e. Manufacturer Specifications

A) Material Specification

(ISO 10474.3.1B & ISO 14723

Req.)

B) Qualification Of Inspection

& Test Personnel

(ISO 14723 Req.)

C) Pressure Monitoring Device (ISO 14723 Req.)

D) Welding (ISO 14723

Req.) E) NDE

(ISO 14723 Req.)

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A. Material Specifications• To comply with ISO 10474-3.1B• Require review by Client Inspector

Mill Certificates

• Chemical Analysis• Carbon Equiv.• Heat Treatment• Mechanical Properties

Manufacturer Specifications Requirements

• C = 1.21%• S = 0.020% - max• P = 10120% max• CE = 0.41%

Chemical Composition API 6DSS (ISO 14723)

• Specified Min. Yield Strength<277 277 to 299 300 to 321 >321

• Avg. of 3 Specimens 28 30 32 37

• Min. Of single Specimens 21 23 25 28

Charpy V – Notch (ASTM A370 or ISO 148-1)

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B. Qualification of Inspection & Test Personnel

• Ref. to API 6DSS (ISO 14723) procedures.• NDE Personnel require to be qualified to ISO 9712 or

ASNT-TC-1A.• Welding Inspectors qualified to AWS QC1 or equivalent.

Personnel Qualifications

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C. Pressure Monitoring Device

• Ref. to API 6DSS (ISO 14723) procedures.

• Pressure Gauges or pressure transducers. Accuracy ±2.0%

• Periodically recalibrate with master pressure measuring device or Dead Weight Tester at 25%, 50% & 75% of Full pressure scale

Test Pressure Measuring Device

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D) Welding

• Applicable to welding, weld overlays & repairs on pressure-containing and pressure controlling parts of the valve

• Procedures Qualified to ISO 15607, ISO 15609, ISO 15614-1 or ASME SEC IX 9.2 & 9.3

Procedure Qualifications

• Personnel Qualified to ISO 9606. ASME SEC IX or EN 287

Welders & Welding Operators

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E) NDE

• Non Destructive Examination requirement & acceptance criteria shall be selected from the list in accordance with ISO 14723 Annex A.

• Purchaser shall specify the type of NDE requirement based on service fluid, size, pressure and temperature

• If there is any defect during welding , after defect removal the excavated area shall be examined by Magnetic particle testing or penetrant testing .

Requirements & Acceptance criteria

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5. Test Criteria• Guidelines & Acceptance criteria to

conform during Product Testing as required in F.A.T included in Client specification (NY-PPL-X-WPTL-PL-SP-0017 Rev.B Attach. 2)

Factory Acceptance Testing (FAT)

• Further test guidelines & requirements to conform on i.e. API 6DSS (ISO 14723, i.e. Pg 50)

• Pressure Class to be defined by purchaser either using PN Class or ANSI Class

API 6DSS (ISO 14723)

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6. Product Testing

• Low Pressure Seat Test (ITP Req. 6 Bar)

• Pressurized medium used is air

• Various Op. Position

• To test & demonstrate on the valve capability to proof 98% of nominal matching pipe

• To test function of the valve at max. operating pressure.

• Pressurized Test fluids i.e. water.

• Various Op. Pos.

• To test leakage on shell by pressurized medium (test fluid) i.e. water.

• Duration & Hydro. Pressure applied

• Various Op. Position.

A) Hydrostat

ic Shell Testing

B) Operation

al Function

Test

C)

Pneumatic Seat Test

D) Drift Test

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Valve end operating position during testing will be according to the test plan approved by COMPANY

Test pressure should be more than 1.5 times in stage 1 and from stage 2 to 4 will be more than 1.1 times.

Time of test duration and acceptance criteria will be based on ISO 14723

A) Hydrostatic Test

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A) Hydrostatic Test N-Left Side (bar)

Cavity

(bar)

P-Right Side(bar)

Medium

Time

(min)Operating Positions

Acceptance Criteria/

Requirements

**NOTE A

1.5 X MPD 77.0 77.0 Water 30F.A.T &

API 6DSS (ISO 14723)

**NOTE B

1.1 X MPD 0.0 0.0 Water 5F.A.T &

API 6DSS (ISO 14723)

0.0 0.0 **NOTE B

1.1 X MPD

Water 5F.A.T &

API 6DSS (ISO 14723)

**NOTE B

1.1 X MPD 0.0**NOTE B

1.1 X MPD

Water 5F.A.T &

API 6DSS (ISO 14723)

Note: Applicable to both 6” & 2” Valve

P: Right Side N: Left Side (As per pressure requirements)C: Cavity (Fluid Trapped in Valve Body Released Pressure)

**NOTE B: Above1.1 X MPD (MOP)**NOTE A: Above 1.5 X MPD (MOP) MPD:46bar

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An operational torque test shall be carried on the valve

Torque test shall be done with maximum operating pressure on one side and zero in the bore and cavity to be held for 1 minute

The valve shall then be opened during operation the maximum torque required to initiate and sustain movement should be recorded

B)Function test

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Torque test shall be performed 3 times each side

Valves requiring input forces that specified in ISO 14723 Sec 7.20.1 or that fail to seal after operation shall be rejected

B) Function test

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B) Function TestN-Left Side (bar)

Cavity(bar)

P-Right Side(bar)

Medium Test Set-up

Acceptance Criteria/

Requirements

*MPD 0.0 0.0 Water Valve operating at max.

Operating pressure as per

specified

F.A.T & API 6DSS (ISO 14723)

0.0 0.0 *MPD Water F.A.T & API 6DSS (ISO 14723)

Note: Applicable to both 6” & 2” Valve

*MPD (Maximum Pressure Differential) or MOP (Maximum Operating Pressure) is maximum pressure required to allow valve opening using lever, gearbox or actuator = 46.0bar

P: Right Side N: Left Side (As per Pressure Requirements)C: Cavity (Fluid Trapped in Valve Released Pressure)

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Valve subjected to low pressure seat test as per test plan

Valve shall be operated to the open position and then closed

Gas pressure shall be applied to one side of valve (6 bar),measuring the leakage at the center section after 5 minutes

Acceptance criteria will be based on API 6D

C)Low pressure seat test

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Valve subjected to high pressure seat test as per test plan

Valve should be cycled open to close Pressure should be increased to 1.1 times

maximum operating pressure and maintained for 5 minutes to measure the leakage

Acceptance criteria will be based on API 6D

High pressure seat test

Page 23: NONG YAO PROJECT SUBSEA VALVE Rev 0

C) Pneumatic TestN-Left Side (bar)

Cavity(bar)

P-Right Side(bar)

Medium

Time

(min)Operating Positions

Acceptance Criteria/

Requirements

6.0 0.0 0.0 Air 5F.A.T &

API 6DSS (ISO 14723)

0.0 0.0 6.0 Air 5F.A.T &

API 6DSS (ISO 14723)

**NOTE B

1.1 X MPD

0.0 0.0 Air 5F.A.T &

API 6DSS (ISO 14723)

0.0 0.0**NOTE B

1.1 X MPD

Air 5F.A.T &

API 6DSS (ISO 14723)

Note: Applicable to both 6” & 2” Valve

P: Right Side N: Left Side (As per Pressure Test Requirements)C: Cavity (Fluid Trapped in Valve Body Released Pressure)

MPD:46bar**NOTE B: Above1.1 X MPD (MOP)

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After completion of pressure test, Valve will be subjected to drift test by drift tool when pulled through each end of valve

D) Drift test

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D) Drift TestN-Left Side (bar)

P-Right Side (bar)

Operating Position Notes

Acceptance Criteria/

Requirements

130.2m Measured Bore Diameter

•98% of Nominal matching Pipe.•As per ITP 6” Valve is the only valve size required for test.

F.A.T & API 6DSS (ISO

14723)

P: Right Side N: Left Side (As per Pressure Test Requirements)

Page 26: NONG YAO PROJECT SUBSEA VALVE Rev 0

7. Test Pictures & Descriptions

N-Left Side

P-Right Side

Test Bench

Pressure Gauges

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Test Pictures & Descriptions

Torque Wrench

Torque Wrench – MPD/MOP = 46bar(For Function Test)

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Test Pictures & Descriptions

Pressure Manometer Test Bench Data Monitor

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Useful Information Checklist Guide from API 6DSS prior to Product Testing at Site.

8. API 6DSS Checklist - Info

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API 6DSS Checklist – Info (Contn’)

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9. Corrosion Prevention - External

Surface Preparation

Paint System

Requirement

No. Of Coats

Dry Film Thickness

Other Requiremen

t Abrasive Blast Min. SA 2 As Required in

Product Data Requirements

Immersion/ Underwater Paint

Barrier Coating Type

1st Coat -Primer Coat

2nd Coat-Finishing Coat (Color)

Min. Total DFT 350µm

As Required in Product Data.

Cathodic Disbondment Resistant

Anti-Corrosive

Subsea Valve – External Protective Coating Recommendation

Subsea Valve – External Protective Coating System Selection

Surface Preparation Paint System No. Of

CoatsDry Film

ThicknessOther

Requirement

Abrasive Blast to SA 3

Interzone 954 X 2 Coats

Modified Epoxy 2-Pax Immersion Paint & Barrier Coat

1st Coat -Primer Coat

2nd Coat-Finishing Coat (Golden Yellow)

Total: >450µm

Cathodic Disbondment Resistant

Anti-Corrosive A

s pe

r Doc

. No.

(PC

-200

-91

2-80

19-5

1)

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10. Packing & Shipping To Protect: The product (valve) from damage or loss during handling.

To Protect: The product (valve) from atmospheric corrosion.

Open Position: Product (valve) to be dispatched in this Open Position.

Required Markings – Project valve no. Tender/Purchase Order. Requisition no & Project No. On Packaging.

Even Weight Distribution - Packed appropriately with even weight distribution with lifting lugs or designated lifting points.

Page 33: NONG YAO PROJECT SUBSEA VALVE Rev 0

11. QuestionsFor Any Questions

please direct email to QA/QC Singapore Site;

[email protected]