Specification for Fabrication of Pipeline End...

Specification for Fabrication of Pipeline End Manifold 1 of 23

Specification for Fabrication of Pipeline End Manifold

Table of Contents

1.0 SCOPE ..................................................................................................................................... 3 2.0 DEFINITIONS ........................................................................................................................... 3 3.0 REFERENCE DOCUMENTS........................................................................................................ 3 4.0 CONTRACTOR RESPONSIBILITIES............................................................................................. 5 5.0 GENERAL SPECIFICATIONS ...................................................................................................... 7 6.0 PRESSURE TESTING ............................................................................................................... 17 7.0 PLEM ACCEPTANCE TESTING................................................................................................. 17 8.0 TRANSPORTATION................................................................................................................ 18 9.0 DOCUMENTS ON COMPLETION OF FABRICATION ................................................................. 18


1.0 SCOPE

This specification describes the minimum requirements for the fabrication of the pipeline end manifold (PLEM) other structural steel assemblies required for Boomvang Nansen Project located in the Gulf of Mexico in water depths of 3500 ft. This specification describes the materials, fabrication, testing and inspection for the pipeline end manifold (PLEM). The work includes the furnishing of all labor, materials, tools and equipment and the performance of all operations and incidentals necessary for the fabrication, assembly, testing, inspection and repair of these items. Further, the work shall meet any additional requirements stated in the CONTRACT.

2.0 DEFINITIONS

For the purpose of this specification, the following definitions shall apply: COMPANY: CONTRACTOR: The company with whom the COMPANY enters into a CONTRACT to which this specification applies. CONTRACT: The entire written agreement

between COMPANY and CONTRACTOR for the work of this specification.

STANDARDS: Industry codes, standards, and recommended practices referenced herein.

WORKS: The location(s) at which manufacturing, inspection and testing are performed.

Manufacturer: The person, firm or company who supplies the CONTRACTOR with materials for the work.

2.1 Contractor Representative CONTRACTOR 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 REFERENCE DOCUMENTS

3.1 General This specification is based on the latest version of the appropriate sections of the following codes, regulations, specifications, standards and guidelines. This specification shall prevail where there are differences between this specification and references. CONTRACTOR may use other


standards that are suitable for the work with prior approval by COMPANY. 3.2 Codes and Standards The PLEM shall be fabricated, assembled, tested and transported according to the latest editions and addenda of the following codes and standards. ANSI B16.5 Pipe Flanges and Flanged Fittings

ANSI B16.9 Factory ‐ Made Wrought Steel

Buttwelding Fittings

ANSI B16.11 Forged Steel Fittings, Socket ‐ Welding and Threaded

API API 1104 Standard for Welding

Pipelines and Related Facilities API API RP2X Ultrasonic Examination of

Offshore Structures and Qualification of Ultrasonic Technicians.

ASTM A20 Standard Specification for

General Requirements for Steel Plates for Pressure Vessels

ASTM A36 Specifications for Structural Steel ASTM A106 Specification for Seamless

Carbon Steel Pipe for High‐Temperature Service

ASTM A307 Specification for Carbon Steel

Externally Threaded Standard Fasteners

ASTM A435 Method and Specification for

Straight‐Beam Ultrasonic Examination of Steel Plate for Pressure Vessels

ASTM D2240 Test Method for Rubber

Property‐Durometer Hardness ASTM E 23 Notched Bar Impact Testing of

Metallic Materials ASME SEC 9 Welding ASTM E 140 Hardness Conversion Tables

Vickers vs. Brinell vs. Rockwell ASTM E 165 Recommended Practice for

Liquid Penetrant Inspection ASTM E 709 Magnetic Particle Examination AWS AWS D1.1 Structural Welding Code ASNT SNT‐TC‐1A Recommended Practice

for Nondestructive Testing NAS 1638 Standard for Cleanliness of

Hydraulic Systems SSPC SSPC‐SP‐5 White Metal Blast

Cleaning 3.3 Company Specifications Seamless Line Pipe Ball Valves Subsea Check Valves Standoff Anodes


Pipe Fittings Pipe Flanges DSAW Pipe Welding and NDE Inspection Diverless Connection System Pipe Bends Pipe Handling and Storage

4.0 CONTRACTOR RESPONSIBILITIES

Forty‐five (45) days before the scheduled start of fabrication, the CONTRACTOR shall submit a work plan, including as a minimum the documentation listed below, to the COMPANY for approval: • Fabrication drawings; • Work schedule; • Welding Procedure Specifications (WPS) and

Supporting Procedure Qualification Records (WPQ);

• Weld repair procedures. Fabrication procedures including procedures for pipe cleaning, alignment of pipe joints and elbows, cutting and preparation of saddle cuts on tubular members, fit‐up, details of temporary supports, etc. • Cleaning, surface preparation and coating

procedures; • Pressure test procedures; • Acceptance testing procedures; • Handling, transport and storage procedures. The CONTRACTOR shall provide all labor, materials and equipment and shall undertake all fabrication, testing, inspection, NDE, handling, reporting, documenting required to perform the work according to this specification, references and drawings. Conflicts in these documents

shall be brought to the attention of the COMPANY for resolution prior to starting work. CONTRACTOR may select alternative fabrication methods or use non‐specified materials, only with advance COMPANY review and approval. CONTRACTOR shall be responsible for the actions and performance of subcontractors, including those hired for handling and transportation. The COMPANY shall provide materials and services listed in the Appendices of this specification. All other material shall be provided by the CONTRACTOR. The CONTRACTOR shall check the drawings for accuracy, completeness and for fabrication suitability. Any additional drawings required shall be produced by the CONTRACTOR as part of this contract. CONTRACTOR shall provide reasonable facilities which includes sufficient office space, files, furniture, office supplies, telephones, fax machine, secretarial services, janitorial services and vehicle parking for inspection staff use during the assembly of material, fabrication, inspection and testing of the units of this specification. 4.1 Quality Assurance All of the work of fabrication and services according to this specification shall be performed under the control of a quality assurance control program. Forty‐five (45) days before starting fabrication, CONTRACTOR shall provide COMPANY with a quality assurance program for review and approval. COMPANY and CONTRACTOR are to


reach agreement on amendments and adjustments before starting the fabrication work. The quality and integrity of the Work shall be related to the best offshore oil industry and marine practices for gas transmission pipeline systems, the inaccessible location in deep water, the permanent nature of the facilities and the risks to the marine environment. This specification and the referenced standards are intended to achieve a high fabrication quality without imposing unnecessary difficulties on the CONTRACTOR. The CONTRACTOR shall have an effective quality control system acceptable to the COMPANY. CONTRACTOR shall provide the specified quality without regard to COMPANY presence or absence. The COMPANY shall have access to the CONTRACTOR's facilities, plant, factory or fabrication site, and similarly, the Subcontractor's facilities at any time during the work period of this Contract, for inspection purposes of work in progress or finished work. COMPANY has the right to accept or reject work that does not satisfy the requirements of this specification and its referenced documents. Rejected work shall be repaired or replaced to COMPANY's satisfaction without extension of delivery date or additional cost. Such rejected work that is repaired or replaced shall be at CONTRACTOR's expense. COMPANY shall advise CONTRACTOR of the Project Chief Inspector. CONTRACTOR shall designate their supervisor for liaison and coordination with the Chief Inspector.

COMPANY Inspection Staff may use any of the visual, mechanical, destructive and non‐destructive tests available for quality control purposes. 4.2 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. 4.3 Records CONTRACTOR shall keep up to date records adequate to confirm that the work, including all required tests, inspections and reviews, has been 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 shall include: • A description of each test or inspection and

its results, with a reference to the paragraph number of this specification or the manufacturer's work plan that required the test;

• The date of the test or inspection; • The name and qualifications or authority of

the inspector or reviewer and his employer; • Evidence of calibrations. CONTRACTOR shall record pertinent information about non‐conformities 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; Preventive action taken.

4.4 Conflicts with Contract If CONTRACTOR believes this specification conflicts with other terms of the CONTRACT, CONTRACTOR shall inform COMPANY. Such conflicts shall be resolved by the terms and specific requirements of the CONTRACT. 4.5 Deviations to Specification CONTRACTOR shall obtain COMPANY's written approval for any deviations from the requirements of this specification or specifications, standards and drawings referenced herein or elsewhere in the CONTRACT. 4.6 Performance of Work This document is not intended to be all inclusive, and the use of the requirements set forth does not relieve the CONTRACTOR of his responsibility to perform all services in a safe manner, to meet applicable codes and standards specified by the COMPANY, to comply with government regulations or to supply a product capable of performing its intended service.

5.0 GENERAL SPECIFICATIONS

5.1 Materials 5.1.1 General All materials used in the fabrication of the PLEMs shall be new and conform to this

specification. Before starting fabrication, the CONTRACTOR shall provide selected material lists with material information for COMPANY review and approval. Material substitutions require prior COMPANY approval. All structural and flowline materials used in the PLEMs shall satisfy the requirements of the applicable referenced codes and standards in Section 3.2. All structural materials shall demonstrate Charpy V‐Notch impact energy at 32º F = 35 ft/lb. average with 50% minimum shear. The quality assurance control system shall be followed. Mill Test Reports shall accompany all material deliveries for review according to this specification. CONTRACTOR furnished steel materials shall have complete mill test reports for COMPANY review and approval prior to using any such material in the Work. Such reports shall include the following: • Material vendor and producer; • All elements of alloy's chemical composition; • The method of analysis; • Material specification; • Evidence of satisfactory performance test

results, as specifically required elsewhere in this specification.

5.1.2 Pipe Export Oil and Gas Pipelines COMPANY furnished line pipe for the pipelines and pipe bends shall be according to API Standard 5L X‐60 and COMPANY Specifications. Structural Tubulars


Tubular material for the fabrication of the PLEMs shall be ASTM A106 Grade B or API Standard 5L Grade B. 5.1.3 Valves All valves used permanently on the PLEM shall be suitable for subsea service to a maximum external pressure of 3500 feet of sea water. Sealant ports to be plugged with pipe plugs. The following valves shall be required for the PLEMs. For sea flooding of tubulars: • Ball Valve 2" dia. Regular Port, ANSI 600

Class with removable handle and extra long shaft for ROV;

• Cameron C2W 80 06 0 2‐1‐212 ‐ 4 required per sled.

All valves shall have the surface preparation and coating according to the epoxy coating system in Section 5.10.2 of this specification. 5.1.4 Structural Steel Plates The plate for fabrication of sleeves, padeyes, stiffeners, saddles, brackets and other items shall be mild steel to SA‐516‐70. The steel plates shall be tested according to Pressure Vessel Standard ASTM A20, for the mechanical properties of this grade of steel. All steel plates shall be ultrasonically tested according to Pressure Vessel Standard ASTM A435. Standard rolled structural steel shapes shall be to ASTM A36.

5.1.5 Fittings The fittings shall be according to ANSI B16.5, B16.9 and B16.11 as appropriate. All forged fittings shall meet requirements of MSS SP‐75. 5.1.6 Control Tubing and Fittings The COMPANY supplied control line tubing shall be super duplex (Sandvik 2507 or equivalent) stainless steel. Tubing shall meet the "Class 6" standard of NAS 1638 Standard for Cleanliness in Hydraulic Systems. Plastic end caps shall be installed in tube ends at the mill or immediately after cleaning if the tube is cleaned after it leaves the mill. These caps shall remain in place until the tubing is delivered. 5.1.7 Steel Wire Rope Steel wire rope shall be of improved plow steel, 6 x 36 IWRC construction according to the applicable military specifications. The wire rope and end fittings shall be galvanized. 5.1.8 Shackles and Wire Rope Fittings The shackles and wire rope fittings shall be as manufactured by Crosby‐Laughlin or COMPANY approved equal and shall be galvanized. 5.1.9 Pipe Bends COMPANY will furnish line pipe bends. 5.1.10 Pins


Pins shall be of high carbon steel, heat treated to produce a minimum yield strength (defined as 0.2 percent proof stress) of 87 ksi and surface hardness of HB 230 minimum.

5.1.11 Screws, Bolts and Nuts Hexagon headcounter sunk screws, and hexagonal head screws and bolts shall be made from teflon coated, high carbon steel with a minimum yield strength 72 ksi or equal. When assembled, contact surfaces shall be free of paint, dirt, sand, metal particles or other foreign materials that would prevent full and complete seating contact of the components. Bolt holes shall be drilled and the burrs shall be removed. No flame cutting of bolt holes. No bolt holes shall be enlarged by flame cutting. 5.2 Anodes All anodes shall be according to COMPANY Specification SP‐007. 5.3 Fabrication 5.3.1 General All provisions in ANSI/AWS D 1.1, Structural Welding Code, shall apply, unless otherwise stated in this specification. 5.3.2 Vent Holes All of the vent holes in the sled units shall be at locations shown on drawings. CONTRACTOR shall maintain a record of inspecting vent holes prior to making welds that could render vent holes inaccessible.

5.3.3 Fabrication Tolerances The dimensions of the fabricated units shall not have a variation more than 1/16‐inch from the lengths shown on the drawings. The dimension variation of welded structural members shall be according to AWS D 1.1. Tolerances shall not be accumulative. 5.4 Welding Requirements All welding performed shall meet the general requirements of this section and the applicable sections for flowlines, stainless tubing and structural welding. CONTRACTOR shall qualify the Welding Procedure Specifications (WPS) required for the fabrication and testing of the bundle sleds. The welding procedures shall be according to Section 3.0 entitled "Reference Documents" and this specification. Pipe Welding: According to COMPANY

Specification 2136600‐SP‐012 and API‐1104

Structural Welding: According to Section 5.7 of this specification and AWS D1.1

The material required for the welding procedure tests shall be furnished by the CONTRACTOR except for the flowline pipe and stainless steel tubing that is listed to be provided by COMPANY. The welding procedure tests shall be performed on material of the same size and grade as will be used in unit fabrication. 5.4.1 Material


Line Pipe and Pipe Bends All flowline line pipe and pipe bends shall meet the requirements of: • COMPANY Specification 2136600‐SP‐002; • COMPANY Specification 2136600‐SP‐011; • COMPANY Specification 2136600‐SP‐015 Stainless Steel Tubing Stainless steel tubing shall be super duplex (Sandvik 2507). The sizes are 1‐inch, 0.75‐inch and 0.5‐inch. Tubing shall be flushed and cleaned to NASG. Material Verification On receipt of the COMPANY provided materials, the CONTRACTOR shall inspect the materials to determine that the quantities are correct and the material is free from damage. Any damage or shortages shall be reported to the COMPANY in writing. Material Substitutions CONTRACTOR furnished material shall be of the type, quantity and quality required in the Contract. No substitutions shall be made without the COMPANY's written approval. Where applicable, material certification shall be obtained and presented to the COMPANY for approval prior to use. 5.4.2 Weldability CONTRACTOR is advised to select compatible materials to be joined by welding for achieving full strength welds.

Materials with a carbon equivalent more than 0.42 percent shall not be used in the Work. Carbon equivalent of 0.42 percent or less with a single qualification is satisfactory without requalifying. Greater carbon equivalent materials shall be evaluated on a case by case basis. The carbon equivalent shall be determined as follows: Carbon Equivalent equals the Carbon percent plus 1/6 Manganese percent + 0.05. 5.4.3 Cleaning and Beveling Construction materials and the inside of each joint of pipe shall be adequately swabbed and cleaned by a method approved by COMPANY to remove dirt, debris and other visible foreign matter before welding. CONTRACTOR shall provide a cleaning procedure for COMPANY approval. The beveled ends and adjacent 2‐inches of each joint of pipe shall be thoroughly cleaned of paint, rust, mill scale, dirt or other foreign matter. CONTRACTOR shall re‐cut and bevel pipe ends according to the approved Welding Procedure Specification to ensure proper fit‐up. All bevel cuts shall be done with mechanized equipment. Where the methods of preparation are other than machining, the cut surface shall be prepared by grinding or machining to bright metal.


All surfaces and edges to be welded shall be smooth, uniform and free from tears, cracks, gouges and other discontinuities which might otherwise affect the quality or integrity of the weld. The joint, or preparation, and the surrounding areas shall be clean and free of moisture, oil, grease, scale, protective coatings, oxides or any other foreign matter before the application of pre‐heat or the beginning of welding. 5.4.4 Alignment and Fit‐Up The CONTRACTOR shall take all necessary steps to ensure that joints are adequately supported and prevented from moving during welding. The alignment and fit‐up of joints shall be subject to inspection by the COMPANY before welding commences. All saddle cuts on structural pipe members shall be done with a mechanized contour cutting machine. CONTRACTOR shall submit alignment and fit‐up procedures prior to production start. 5.4.5 Welding Process GMAW (MIG) welding, regardless of transfer mode, shall not be allowed for PLEM fabrication. 5.4.6 Welding Procedure Specification CONTRACTOR shall submit complete Welding Procedure Specifications (WPS) and weld repair procedures for COMPANY approval. Welding Procedure Specifications shall include full details of welding processes, consumables, preheat and weld parameters, essential and

non‐essential variables as specified by the applicable code. Welding Procedure Specifications shall be submitted to the COMPANY a minimum of forty five (45) days prior to the scheduled start of production welding. 5.4.7 Procedure Qualification Records The CONTRACTOR shall submit all Procedure Qualification Records (PQR) to the COMPANY for approval before starting any production welding. The approval of welding procedure qualifications will be based on satisfactory non‐destructive examination and mechanical testing of the test welds according to this specification. CONTRACTOR shall qualify proposed Welding Procedures in accordance with the applicable construction code as defined in Section 5.4 and with the same equipment to be used in fabrication. All necessary welding equipment and welding materials shall be provided by the CONTRACTOR. 5.4.8 Procedure Qualification Tests The test welds shall be 100% radiographed by a COMPANY approved third party NDE contractor. The welded joints shall be destructively tested and interpreted by a COMPANY approved third party mechanical testing laboratory, according to the applicable code and this specification. 5.4.9 Procedure Approval COMPANY approval of welding procedure qualifications will be based on non‐destructive examination and mechanical testing of the test welds according to this specification. COMPANY approval of welding procedure qualifications is


required before the start of any production welding. COMPANY shall witness and approve the qualification of the welding specification and mechanical tests. 5.4.10 Welders Qualification COMPANY shall witness and approve the Welder Performance Qualification Tests. Each welder shall pass a Welder Qualification Test using the qualified Procedure for the weld that the welder will perform. Test welds shall meet the required minimum standards of acceptability for visual examination, 100% radiographic examination and mechanical testing by the applicable code. No welder shall perform any phase of welding which that welder has not been tested, qualified and approved by the COMPANY. Welder qualification shall lapse after three months without production welding experience. All welders will be assigned unique identification numbers when qualified. If qualified welders leave the Project, their numbers shall not be reassigned. 5.4.11 CONTRACTOR Equipment and Supplies CONTRACTOR shall provide all required welding machines, line‐up clamps, beveling machines, contour cutting machines, welding electrodes and all other equipment, supplies and consumables used in connection with the welding activities. 5.4.12 Equipment

All welding equipment shall be in good working order and capable of producing welds of the required quality. Any equipment which does not meet these requirements shall be replaced. Prior to the start of production welding CONTRACTOR shall check and calibrate all welding machine volt and amp meters to within 1% of the reference standard. During production welding, the CONTRACTOR shall check voltage amperage readings by independent instrumentation at least once per shift and when any inaccuracy is suspected. 5.4.13 Consumables All welding consumables used in production welding shall be qualified to AWS D 1.1. Test results shall be presented to the COMPANY for evaluation and approval. All welding consumables shall be supplied in hermetically sealed containers and stored according to Section 5.4.14 on Electrode Storage in this specification. The CONTRACTOR shall be responsible for maintaining control and identification of welding consumables and shall ensure that they are kept clean and free from grease, oil, dirt, rust and other contaminates. All unidentified damaged or rusty filler materials shall be discarded. Welding consumables which are wet or moist shall also be discarded. 5.4.14 Electrode Storage The following are electrode storage requirements for different conditions: • Hermetically sealed containers indoors, out

of weather and off ground;


• Opened Containers ‐ 200 degrees F minimum/300 degrees F maximum or as recommended by Manufacturer;

• Electrodes withdrawn from use ‐ after two hours must be discarded to prevent the problem of mixing good and bad electrodes;

• SMAW electrodes shall be properly stored according to manufacturers instructions after opening. Heaters used for storage shall have a thermometer;

• General storage of consumables shall be maintained to prevent damage to the consumable and shall be maintained clean and dry.

5.4.15 Equipment Settings Procedures and welders shall be approved by COMPANY before starting any welding. During welding, welding speeds shall not vary by more than plus or minus twenty (± 20%) percent in the Procedure Qualification Tests, and the voltage and amperage shall not vary from the settings approved for the Procedure qualification by more than plus or minus twenty (± 20%) percent. 5.4.16 Grounding Clamps Grounding clamps shall be made of steel and shall have solid contact with the pipe to prevent the possibility of arc burns. Copper or copper alloys are prohibited. Grounding clamps shall not be welded to structure. 5.4.17 Retest of Welds At COMPANY discretion, additional welds for test purposes shall be cut out for further examination. For welds proven to be satisfactory, CONTRACTOR shall be reimbursed

by COMPANY according to the Price Schedule of the CONTRACT. 5.4.18 Frequency of Weld Defects Frequent weld defects of a similar nature, which occur in spite of good welder technique, shall be sufficient cause for CONTRACTOR and COMPANY to review the welding equipment and electrodes to determine the corrective steps to be taken. 5.4.19 Weather All welding shall be done in‐doors in a covered fabrication shop. 5.4.20 Clean Sled Components CONTRACTOR shall clean out the sled components before closing the ends. 5.4.21 Weld Repairs Weld repairs shall be performed using procedures and welders qualified according to this specification. Repairs of weld defects shall not be made without the knowledge and concurrence of the COMPANY. The repair weld preparation shall be smooth, with a regular contour, and shall be free from rust, grease, oil, or other extraneous material. The applied pre‐heat shall be 150 degrees F minimum. Repair welds to circumferential weld seams, when approved, shall be separated by at least 6‐inches.


Arc air gouging shall be allowed on structural components only. The COMPANY shall witness the inspection and NDE of all repair welds. 5.4.22 Arc Burns All arc burns shall be removed by grinding and suitably etched to ensure that all evidence of arc strikes are removed. 5.4.23 Daily Weld Log The NDE contractor shall submit a weld identification procedure, a radiographic record log and film for approval by the COMPANY prior to use. Each weld shall be numbered consecutively in accordance with the procedure. The CONTRACTOR shall record the identification of each pipe joint and weld number in a daily log. This daily log shall have the daily welds inspected, the name of the inspector, the identification of the welders and the portion of the weld performed. Steel die stamps shall not be used for marking production welds. The radiographic record log and film shall be traceable to a specific weld, location, welder or welders and shall include the results of all of the radiographic, ultrasonic or other inspections performed. Daily Weld Log shall be kept during the work and becomes part of COMPANY project records. This log shall include but is not limited to the following: • Drawings showing location of each weld;

• Identification of each element welded, grade, thickness and width;

• Identification number of each weld; • Welding procedure used for each weld; • Welder(s) identification and the portion

welded; • Date of each weld completion; • Inspector, date of weld inspection and

results; • Defects found, weld repair and date

repaired. 5.4.24 Documentation Thirty (30) days prior to start of production welding, the CONTRACTOR shall provide the COMPANY with welding document record. This record shall contain as a minimum the following information: • Procedure Qualifications Records (PQR); • Welder Performance Qualifications (WPQ); • Quality Control Records. 5.5 Welding Flowlines All flowline welding and NDE shall be according to COMPANY Specifications 2136600‐SP‐012. 5.6 Welding of Stainless Steel 5.6.1 General Welding of stainless steel tubing shall meet the requirements in this specification. CONTRACTOR shall submit to COMPANY for approval written procedures as required by the relevant clauses in this specification to the COMPANY for approval a minimum of forty‐five (45) days prior to flowline bundle fabrication.


5.6.2 Qualification Tests The qualification tests shall be according to ASME IX for welder performance. In addition, one microscopic section for each position welded shall be done. CONTRACTOR shall carry out welding procedure qualification test utilizing a COMPANY approved testing laboratory. CONTRACTOR shall furnish X‐ray, mechanical test results and micro sections. The welding procedure qualification shall be carried out before the beginning of the field work. Duplex stainless steel shall require additional tests including ferrite count in the HAZ of tube, fitting and weld areas (allowable is 35% to 65%) and three (3) burst test to failure. 5.6.3 Radiography CONTRACTOR shall submit to COMPANY, for approval, written inspection and non‐destructive examination procedures thirty (30) days prior to start‐up of production welding. All NDE field inspection shall be in accordance with the approved procedures. The radiography shall meet the requirements of ASME B31.3 and include 100% of the weld. 5.6.4 Repairs Weld repairs shall not be allowed. Welds which fail radiographic requirements shall be removed entirely. 5.6.5 Duplex Tubing Duplex stainless steel tubing shall be controlled to a ferrite count of 35% to 60%.

5.7 Structural Welding Structural Welding shall meet the requirements as specified in the latest edition of AWS D1.1 Code. NDE is according to NDE of sled structures, SP‐065. 5.7.1 Preheat Preheating for welding shall be applied according to the requirements of AWS D 1.1 Code. Whenever necessary, preheating shall be performed by electric resistance or induction equipment or with special shaped gas burners. Hand‐cutting torches shall not be used for preheating. Preheating is also required when the ambient temperature falls to 41° F or lower. When preheating is required, the heated material shall be kept at the required temperature until the weld is completed. The temperature shall be measured by means of thermo‐crayons or equal. 5.7.2 Seal Welding All structural welding shall be seal welded. All sharp corners shall be suitable removed to ensure proper coating application. 5.8 Welders Qualification Welders qualified position is 6G or 6GR for structural as applicable. 5.9 Non‐Destructive Examination All Non‐Destructive Examination shall be according to COMPANY Specifications SP‐018.


5.10 Protective Coatings CONTRACTOR shall submit to COMPANY, for approval, cleaning, surface preparation and coating procedures prior to start of work. All of the external structural surfaces of the PLEMs and porches shall be cleaned and coated with a three coat epoxy coating system except for the neoprene coated flowlines and the abrasion coated bottom half of the sleds. The finished coating shall be a non‐glossy yellow color. 5.10.1 Surface Preparation Surfaces shall be free from oil, grease, dirt and other foreign matter before blasting. Once clean, the surface shall be blasted to near white metal (SA 3.0) according to SSPC‐SP‐5 with a 1.5 to 2.5 mil anchor profile, and shall be verified by COMPANY. Any portion of the fabrication to be blast cleaned, including the drilling of bolt holes, shall be complete and in final condition before blasting is started. Blasting procedure, schedule and equipment shall be approved by COMPANY. Blast cleaned surfaces shall be coated with primer immediately after blast cleaning. No blasting shall be done between sunset and sunrise. No acid washes, cleaning solutions or rust inhibitors shall be used on metal surfaces after blast cleaning. Blast cleaning shall not be done on moist surfaces or those that may become moist before the application of primer. The maximum relative humidity shall be

less than eight five (85) percent, and the metal surface temperature must be at least +10 degrees F above dew point.

No blast cleaning shall be done near surface coating activities or near other surfaces sensitive to dust and particle contamination.

5.10.2 Epoxy Coating Systems External protective coatings shall be manufactured by International Paint, and are as follows: DRY FILM THICKNESS Prime Coat International Intergard FP 5.0 ‐ 7.0 mils prime coat Second Coat International Intergard FP 5.0 ‐ 7.0 mils second coat

TOTAL: 10.0 ‐14.0 mils See Appendix D for Coating Data Sheet 5.10.3 Paint Coating Application CONTRACTOR's equipment for spray application shall be inspected and approved by COMPANY before application. The paint manufacturers recommendations for the selection and use of paint spray equipment shall be followed. CONTRACTOR shall apply each of the epoxy coats following the manufacturers specifications for application and repair. The pressure gauges shall be in working order. All surface defects including cracks, laminations, deep pitting, and weld splatter that would interfere with the coating application shall be removed. All fins, saw cuts, barbs and sharp edges shall be removed. Where extensive


grinding is required, the dressed area shall be reblasted to remove all rust. Coating application shall be in accordance with manufacturer’s recommended practices. Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drops shall be avoided. On beams and irregular surfaces and shapes, edges shall be coated first with an additional pass made later. Each coat shall be allowed to dry for the time specified by the manufacturer. Specified film thickness for coating materials shall be achieved. Film thickness shall be checked with calibrated gauges. All installed equipment and facilities shall be protected from overspray from the coating operations. Threaded surfaces shall be sealed with grease before the application of epoxy coatings. Coatings shall be free of pin holes, voids, bubbles and other holidays. The defects shall be repaired per coating manufacturer recommended practices.. Precautions shall be taken to prevent the deposit of dust, moisture and other foreign matters on the surface of the coating. If such contaminants occur, the surface area shall be reblasted and coated again. When coatings are applied by brushing, brushes shall be of style and quality for application of the material.

6.0 PRESSURE TESTING

The pressure testing procedures shall be prepared by the CONTRACTOR for COMPANY approval. The flowlines on the PLEM shall be

hydrostatically pressure tested for a minimum of two (2) continuous hours. The hydrostatic test shall be witnessed by the COMPANY. All the flowlines and control lines shall be cleaned, dried and capped. (The control lines shall be cleaned to Class "6" of NAS 1638). Some of the structural members of the sleds shall be tested with compressed air to 150 psi pressure for a minimum period of 2 hours. All welds shall be soaped to check for leaks in the presence of COMPANY.

7.0 PLEM ACCEPTANCE TESTING

7.1 General CONTRACTOR shall check and test the fabricated units including the mechanical components. CONTRACTOR shall prepare test procedures to achieve the test requirements of this specification, for COMPANY approval. The results of the tests and pre‐commissioning report shall be documented and copies given to the COMPANY within two weeks after the final pre‐commissioning test. 7.2 Sled Testing The minimum requirements for checking and testing of the PLEM are as follows: 7.2.1 Detailed Dimensional Survey CONTRACTOR shall prepare a report of the as built dimensions of the PLEM. Special attention shall be given to the position of the flowline connector hubs. Measurement accuracy required is 1/8‐inch for piping and 1/4‐inch for the structural members.


7.2.2 Sled Dry Weight and Center of Gravity CONTRACTOR shall determine the dry weight and the center of gravity of the PLEM. Measurement accuracy required is the weight within 200 lbs. and the Center of Gravity to within 1/2‐inch. 7.3 Submerged Weight Determination The PLEM shall be completely submerged in water to determine the submerged weight to an accuracy of 200 lbs. All of the water shall be drained from the units after the submerged test. CONTRACTOR shall record temperature, air and coater, at the start and end of weighing and shall provide water sample(s) to determine water density.

8.0 TRANSPORTATION

The PLEM shall be sent to the COMPANY’s fabrication facility for assembly and launch purposes. There may be road and marine access to the site. CONTRACTOR, as part of the fabrication contract, shall provide load out crane support, for lifting, tie‐down materials and labor for the PLEMs on COMPANY provided transportation.

9.0 DOCUMENTS ON COMPLETION OF FABRICATION

The Work is not considered to be complete until all of the required documents in this section are furnished to the satisfaction of the COMPANY. Within thirty (30) days following completion of the fabrication, the CONTRACTOR shall submit the following documentation to the COMPANY.

• Complete "As Built Drawings" of the sleds; • Dimensional control and survey reports; • Results of the day weight and center of

gravity measurement; • Records of the hydrostatic tests; • Results of the submerged weight

measurements; • Ultrasonic testing reports of plate material; • Post weld heat treatment reports; • Structural Steel Plate mill certificates; • Other Components mill certificates; • Change order requests and acceptance; • Non‐conformance reports; • Information on tie‐down, transport and

storage of fabricated units; • Part lists with certificate numbers; • Information on the lubricants used; • Operating and maintenance manual with

technical specifications and other information.

9.1 As‐Built Drawings CONTRACTOR shall prepare "As‐Built Drawings" showing all of the deviations, changes and revisions from the "Approved for Construction Drawings". CONTRACTOR shall provide one complete set of reproducible drawings to COMPANY. 9.2 Materials COMPANY shall provide certain materials to the CONTRACTOR for the Work. CONTRACTOR shall furnish a complete accounting of the material used, unused and waste. The documents shall include the variations and revisions in material lists.



COMPANY shall arrange for the surplus unused material to be transported to COMPANY warehouse facilities. 9.3 Weekly Progress Reports The Weekly Progress Report will be in a form and level of detail as agreed between CONTRACTOR and COMPANY, including manpower and equipment as well as weather and downtime. The Weekly Progress Report prepared by the CONTRACTOR shall be forwarded to COMPANY on the first day of the following week. 9.4 Minutes of Meetings The CONTRACTOR shall prepare and distribute minutes of project meetings as well as of meetings with vendors and subcontractors on the day after the meeting. CONTRACTOR shall

prepare and distribute letters confirming verbal instruction from the COMPANY. 9.5 Accident Reports The CONTRACTOR shall prepare and provide to the COMPANY detailed reports of all accidents with extent of damage, cause, results and disposition in an acceptable form to insurers and law enforcement agencies. 9.6 Notice of Work Completion The CONTRACTOR shall provide verification documents that all material, subcontractors and services with any liens and claims have been satisfied by all parties that were connected with the Work. These records must be provided to the COMPANY and reviewed before a Notice of Work Completion may be issued to the CONTRACTOR.

Appendix A

SUMMARY OF CONTRACTOR DELIVERABLE DOCUMENTS


ITEM SECTION DESCRIPTION REQUIRED BY 1. 4 Work Plan 45 days prior to start 2. 4.1 Quality Assurance Program 45 days prior to start 3. 5.1.1 Material Lists and Mill Test Before start of fabrication 4. 5.4.6 Welding Procedure Specifications 45 days prior to start 5. 5.4.25 Procedure Qualif. Records 30 days prior to start of

Welder Performance Qualif. production welding 6. 5.6.1 Welding Procedure Specifications 7. 5.6.3 Inspection and NDE Procedures 8. 5.10 Coating Procedures 9. 7.1 Test and Precommissioning Reports 10. 9 Document on Completion of 30 days after completion

Fabrication 11. 9.1 As Built Drawings 30 days after work completion 12. 9.3 Weekly Progress Reports Day after 13. 9.4 Minutes of Meetings Day after 14. 9.5 Accident Reports 15. 9.6 Verification Documents


Appendix B

LIST OF COMPANY PROVIDED MATERIALS AND SERVICES (Check complete list in CONTRACT)


LIST OF COMPANY PROVIDED MATERIALS AND SERVICES

1. Buoyancy Modules for Sleds 2. Line Pipe 18 “OD x 1.0” WT X‐60, 16 “OD x 0.812” WT X‐60, 14 “OD x 0.688” WT X‐60 and 12.75

“OD x 0.562” WT X‐60. 3. Bends 4. Valves 5. Piggable Wyes 6. Swivels


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