Awareness of RIG high pressure piping activities

DNV GL © 25 April 2015 SAFER, SMARTER, GREENERDNV GL © 25 April 2015
OIL & GAS
AWARENESS OF HIGH PRESSURE RIG
PIPING INSPECTION ACTIVITIES
1
Project : Land Rig Acquisition Project-2
Prepared by Abdul Sayeed Mohammed

DNV GL © 25 April 2015
Scope of LRAP-2 Project
List of RIG Piping System and Rating operated in LRAP
List of Materials used in LRAP
Reference Standards
Applications
Supplementary Requirements
Chemical Analysis & Mechanical Testing
Forging & Heat Treatment Process
Major Fabrication & Welding Issues
Functional Testing
Lessons Learned
2

List of Piping System
Operated Rating : 1500Hp & 2000Hp
Discipline Piping System:
 Drilling Fluid Manifold and Piping System
 Cementing Piping and Manifold System
 Jet Piping System
 Relief Piping System
 Choke & Kill Line Piping System
 Injection Piping System
3

List of Materials
Plates/Shapes/Pipes/Rods/Round bars
Q345 Grade - B
Q235 Grade - B
Grade 20
35CrMoA
35CrMo
30CrMo
410
4

Reference Standards
 API 6A/API 7K/B31.3/B16.5 /GB Stds (Hp Piping)
 ASTM-370 (Mechanical Testing)
 ASME-SEC-V & ASTM (NDT)
 NACE-MR-0175 (Hardness)
 ASME Sec-IX (Welding Qualifications)
 ASME Sec-II (Part C) (Filler Metal Requirements)
5

Applications
Swivel Joint Elbows for Cementing System
35CrMo
Cross Section of Swivel Elbow
6

Applications
Union Components for Jet Piping System
35CrMo
7

Applications
Female Head Components for Cementing System
Wing Nuts for Jet piping System
35CrMoA
8

Applications
Hammering Nuts for Drilling Fluid System
35CrMoA
9

Applications
Cross TEEs for Piping Manifold System
35CrMoA
10

Applications
TEE Components for HP Piping System
30CrMo
11

Applications
Weld Neck Flanges for Drilling Fluid System
30CrMo
12

Applications
Relief Valves for Drilling Fluid System
30CrMo
13

Applications
Locking Devices for Drilling Fluid System
30CrMo
14

Applications
Valve Components for HP Piping System
30CrMo
15

Applications
Valve Components (Stem & Gate)
410
16

Applications
Stabilizer Spools for Injection System
Grade-20
17

Applications
Skid Frame for High Pressure Manifold
Q345B
18

Applications
Skid Frame for Cementing Manifold
Q345B
19

Applications
Supports and Staircase for Piping System
Q235B
20

Applications
Supports for Skid & Piping System
Q235B
21

Supplementary Requirements
HP Piping / Choke and Kill
ASTM A 519 4130/ 30CrMo – Hardness Requirement
as per NACE MR 0175
Samples to be tested for SSCC
 (Above requirements are mandatory when pressure
and sour service are combined)
Forging
Heat treatment based on code and /or designer
requirement
22

Chemical Analysis
• Chemical composition testing to be done
according to the MTC and Reference
standards
23

Mechanical Testing
Tensile
Reference Standards
o ASTM-370
o NACE-MR-0175
o API-6A
24

Mechanical Testing
Impact
Reference Standards
o ASTM-370
o NACE-MR-0175
o API-6A
25

Mechanical Testing
Hardness
Reference Standards
o ASTM-370
o NACE-MR-0175
o API-6A
26

Forging Process
Flanges
Cross Tees
Valve Body
Valve Components
Wing Nuts
27

Heat Treatment Process
Flanges
Elbows
Tees
Union Components
Wing Nuts
Elbows
End Caps
Valve Body & Components
28

Holding Temperature Prior to Quenching
860˚C/3hrs
29

Quenching Process prior to Tempering
30

Major Fabrication & Welding Issues
31
S.l
No
Description of Non Conformance
Recommendation &
Resolution
1.
During fit up inspection noticed socket
flanges were fabricated instead of slip on
flanges for Hp piping 6’’Ø (Jet piping) as
per ASME-B16.5 socket flanges shall be
used below 3” Ø
Insisted to engineering to revise
the weld geometric design based
on ASME-B16.5.
2.
Observed hardness values for piping
components were not meeting the
requirement as per NACE-MR-0175
standard required is less than 22HRC.
Recommended to repeat re
tempering process as per ASTM-
A29 to achieve lower hardness
values.
3.
Heat treatment was carried out for
7hours on welded joints for cementing
system. As per approved WPS 2hours
required.
Conducted tool box talk for
technicians to follow the essential
requirements. Affected joints
were cut and re welded prior to
Re PWHT.
4.
ER70S-G filler wire was used in WPS
which is lower strength than base
material.
Qualified new PQR with higher
strength filler wire .
Affected joints were cut and re
welded.

32
S.l
No
Recommendation &
Resolution
5.
Non heat treated pipes (Lower hardness
values) are used in Jet piping system.
Re fabricated all affected pipes
after replacement of heat
treated pipes .
6.
Pipe materials (35CrMo) tensile and yield
strength is not meeting the requirement as
per GB/T8162-2008.
According to client and
contractor recommendation
agreed to follow API-6A &
NACE-MR-0175 requirements to
achieved hardness values after
heat treatment process.
7.
Noticed conflicting in fabrication drawing,
hardness ranges was specified more than
NACE-MR-0175 requirement.
Engineering drawings has been
revised.
8.
During surveillance noticed welder was
deposited the weld metal as segment wise
instead of continuation passes as per WPS.
Conducted tool box talk and
explained importance of
essential variables.
Affected joints are cut and re
welded as per WPS.

33
S.l
No
Recommendation &
Resolution
9.
Observed during PWHT. Thermocouples
are not maintained both sides of slip on
flange joints.
Implemented to maintain
additional thermocouples which
is not affected to that particular
areas.
10.
Noticed improper protection of mud gate
valves during welding and NDT
Implemented to protect against
ingress of sand. The adequacy
of protection was maintained till
the completion of installation
activities.
11.
Repair percentage of Individual welders
was increased more than the requirement.
Conducted tool box meeting and
explained about each
defects/discontinuities which is
beyond the acceptance criteria .

Root Causes for Major Issues
Improper Process Control
Used of cheap Materials
Improper Heat Treatment process.
Improper Quality control measures
Poor Technical Engineering measures
Incompetent of welders & technicians
34

Contributing factors for Major Issues
Heat treatment temperature was not maintained
Poor QC System & Technical Engineering
Lack of awareness
Code compliance
35

Functional Testing
Non Destructive Testing
Reference Standards:
ASME SEC-V,ASTM,API6A
RT (Radiography Testing)
UT (Ultrasonic Testing)
MT (Magnetic Particle Testing)
WFMT (Wet Fluorescent Magnetic Particle Testing)
DPT (Dye Penetrant Testing)
36

Functional Testing
Hydrostatic Testing
Reference Standard – B31.3/API 6A/API 7K
37

Functional Testing
Bubble Leak Testing
Reference Standard – B31.3/API 6A/API 7K
38

Lessons Learned
Document Distribution
 Document distribution required significant clarification
and development.
Reporting Requirements
 Contractor shall be ensure that reports are actually
required.
Procedures
 Ensure client procedures shall be provide to contractor.
Safety
 Contractor should maintain minimum safety practices
during fabrication and welding activities.
39

Lessons Learned
ITP
 Prior to submission of ITP contractor shall be add
applicable reference standards and stage wise inspection.
Selection of Electrodes
 Prior to procedure qualification welding engineer shall be
confirm proper selection of higher strength electrode for
Hp piping.
Furnace Heat Treatment
 Prior to loading of components minimum distance shall
be maintain as per NACE requirement.
40

Lessons Learned
PWHT
 Heating band and insulation band widths for Post Weld
Heat Treatment (PWHT) shall always be calculated,
recorded, verified and implemented in accordance with
Project specification requirements.
Storage of valves
 All valves stored on the construction site shall be
adequately protected against ingress of sand. The
adequacy of protection shall be regularly reviewed in
order to ensure that an acceptable standard is
maintained.
41

Lessons Learned
42
As Built Drawings
 All site design modifications that related to primary
documents and drawings shall be submitted for NDC
approval in accordance with Contract requirements.
Audits
 Contractor internal and external Quality Assurance (QA)
audit schedules shall be continually updated during
Project execution in order to ensure that QA audits of
construction activities are planned and conducted over
the complete Project duration including any extension to
the original Project schedule.
Storage of Materials
Corroded materials shall be quarantine. should be
separate with new materials.

SAFER, SMARTER, GREENER
www.dnvgl.com
Thanking You
Any Question???
43

Awareness of RIG high pressure piping activities

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