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NONG YAO PROJECT SUBSEA VALVE Rev 0

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NONG YAO PROJECT SUBSEA VALVE Rev 0

  1. 1. 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.0 Total Pages include this page : 27 pages
  2. 2. 1. General Information 2. Scope Of Work 3. Applicable Codes & Standards 4. Documents Review 5. Test Criteria 6. Product Testing A. Hydrostatic Test B. Function Test C. Pneumatic Test D. Drift Test 7. Test Pictures & Descriptions 8. API 6DSS Checklist - Information 9. Corrosion Prevention - External 10. Packing & Shipping 11. Any Questions?
  3. 3.  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.
  4. 4.  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.
  5. 5. 6” DN150 Class 300 – Subsea Valve 6” DN150 Class 300 – Subsea Valve
  6. 6.  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)
  7. 7. Specifications Titles API 6D Specification for Pipelines Valves API 6A Specification for Wellhead & Christmas Tree Equipment API 17D Specification for Subsea Wellhead & Christmas Tree Equipment API 598D Valve Inspection & Testing ANST – TC- 1A Personnel Qualification & Certification in Non Destructive Testing ASTM A370 Standard Test Methods & Definitions for Mechanical Testing of Steel Products API 6DSS (ISO 14723) Petroleum & natural gas industries – Pipeline Transportation systems – Pipeline Valves BS EN 10204: 2004 Metallic Products – Type of inspection documents
  8. 8. •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.)
  9. 9. •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)
  10. 10. •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
  11. 11. • 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
  12. 12. • 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
  13. 13. • 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
  14. 14. •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)
  15. 15. •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) Hydrostatic Shell Testing B) Operational Function Test C) Pneumatic Seat Test D) Drift Test
  16. 16.  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
  17. 17. 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 30 F.A.T & API 6DSS (ISO 14723) **NOTE B 1.1 X MPD 0.0 0.0 Water 5 F.A.T & API 6DSS (ISO 14723) 0.0 0.0 **NOTE B 1.1 X MPD Water 5 F.A.T & API 6DSS (ISO 14723) **NOTE B 1.1 X MPD 0.0 **NOTE B 1.1 X MPD Water 5 F.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
  18. 18.  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
  19. 19.  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
  20. 20. N-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)
  21. 21.  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
  22. 22.  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
  23. 23. N-Left Side (bar) Cavity (bar) P-Right Side (bar) Medium Time (min) Operating Positions Acceptance Criteria/ Requirements 6.0 0.0 0.0 Air 5 F.A.T & API 6DSS (ISO 14723) 0.0 0.0 6.0 Air 5 F.A.T & API 6DSS (ISO 14723) **NOTE B 1.1 X MPD 0.0 0.0 Air 5 F.A.T & API 6DSS (ISO 14723) 0.0 0.0 **NOTE B 1.1 X MPD Air 5 F.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)
  24. 24.  After completion of pressure test, Valve will be subjected to drift test by drift tool when pulled through each end of valve
  25. 25. N-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)
  26. 26. N-Left Side P-Right Side Test Bench Pressure Gauges
  27. 27. Torque Wrench Torque Wrench – MPD/MOP = 46bar (For Function Test)
  28. 28. Pressure Manometer Test Bench Data Monitor
  29. 29.  Useful Information Checklist Guide from API 6DSS prior to Product Testing at Site.
  30. 30. Surface Preparation Paint System Requirement No. Of Coats Dry Film Thickness Other Requirement  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 Coats Dry Film Thickness Other 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 AsperDoc.No.(PC-200- 912-8019-51)
  31. 31.  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.
  32. 32. For Any Questions please direct email to QA/QC Singapore Site; gowri.sankar@nsc-eng.com

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