structural fabrication specification

NO. OF DOC. SHEETS

18

CONTRACT NO:

NSBU-064101

DOCUMENT NO:

JA00-03-AJ-00006

REV:

O1

CONOCOPHILLIPS PETROLEUM COMPANY U.K. LIMITED

J-BLOCK OU

DOCUMENT TITLE:

JASMINE DEVELOPMENT PROJECT

Structural Fabrication Specification

Facility Code System Code Area Code Discipline Code SDRL Code Document Type

JA00 99 N/A AJ N/A 37

O1 Approved for Construction

RD 15/01/10 KM 15/01/10 NT 15/01/10 RSC 23/01/10

A2 Issued for ICR RD 11/12/09 KM 11/12/09 TW 11/12/09

C1 Issued for AFD KM 27/08/09 DNRG 27/08/09 TW 27/08/09 KK 27/08/09

A1 Issued for IDC/ICR RD 27/07/09 DNRG 27/07/09 TW 27/07/09

REV ISSUE OR REVISION DESCRIPTION

ORIG BY

DATE CHKD BY

DATE APPD BY

DATE CLIENT ACCEPT

DATE


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JA00-03-AJ-00006 Rev O1 3 NSBU-064101

REVISION CHANGE NOTICES

Rev Location of Change Brief Description of Change

C1 Section 4.2 Forming Restrictions Hot forming prohibited.

A2 Section 3 -4.4.1 NDE qualification clarified

A2 Section 3 -4.4.4(f) CTOD of HAZ clarified

A2 Section 3- 5.2.4 Extent of point to point welding clarified

A2 Section 3- 7.3.1 NDE qualification clarified

A2 Section 3- 7.4.2 Use of API RP2X clarified

A2 Section 3- 7.5.3 Additional Clause added as a advisory

A2 Section 3 –Table 3 General Note Use of API RP2X clarified

O1 Section 1.1 General information amended

O1 Section 1.4 Reference to JA00-03-AJ-00010 deleted


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JA00-03-AJ-00006 Rev O1 5 NSBU-064101

CONTENTS

1.0 INTRODUCTION 7 1.1 GENERAL 7 1.2 DEFINITIONS 7 1.3 ABBREVIATIONS 7 1.4 REFERENCED DOCUMENTS 8 1.5 UNITS OF MEASUREMENT 9

2.0 PURPOSE 9

3.0 PROJECT SPECIFIC AMENDMENTS TO EEMUA158 10

4.0 FABRICATION OF ROLLED AND WELDED TUBULARS 17 4.1 MANUFACTURING PROCESS 17 4.2 FORMING RESTRICTIONS 17


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JA00-03-AJ-00006 Rev O1 7 NSBU-064101

1.0 INTRODUCTION

1.1 GENERAL

The Jasmine field is located in blocks 30/6 and 30/7a in the UK sector of the Central North Sea, about 240 km south-east of Aberdeen, in the ConocoPhillips operated J-Block Area. The Jasmine development will utilise the existing processing capacity on the Judy Platform.

The J-Block Area currently comprises three fields: Judy, Joanne and Jade. The Judy Platform currently serves as a hub for petroleum operations from production wells situated on the Judy Platform, fluids from the Joanne subsea manifold and fluids from the Jade normally-unmanned Wellhead Platform.

The combined gases leaving Judy are exported to the Central Area Transportation System (CATS) to Teesside, UK. Oil is exported to the NORPIPE system to Teesside, UK.

The Jasmine Development comprises the following:

Jasmine Wellhead Platform (JWHP)

Jasmine Accommodation and Utility Platform (JLQ), bridge linked to the Jasmine Wellhead Platform (JWHP)

Judy Riser and Separation Platform with additional Judy well slots (JRP), bridge linked to the existing Judy Platform

Multi-phase pipeline from Jasmine Wellhead Platform to the Judy Riser Platform

1.2 DEFINITIONS

COMPANY ConocoPhillips Petroleum Company UK Limited

CONTRACTOR WorleyParsons Europe Limited

PURCHASER WorleyParsons Europe Ltd. On behalf of ConocoPhillips Petroleum Company UK Limited

INSPECTION AGENCY Inspection Body employed by Company to provide inspection services.

NOTIFIED BODY (NoBo) Notified Body (NoBo) engaged to inspect and certify that equipment is designed and manufactured to European regulations

INDEPENDENT COMPETENT PERSON (ICP)

Independent Body employed by Company to verify that equipment and systems are designed and manufactures to conform to performance standards

SUPPLIER A company identified in a Purchase Order to supply equipment and/or materials and technical data pertaining thereto.

MANUFACTURER COMPANY engaged in the manufacture of equipment

SHALL Indicates a mandatory action

SHOULD Indicates a preferred course of action

MAY Indicates one acceptable course of action

1.3 ABBREVIATIONS

CTOD- Crack Tip Opening Displacement

SSFCAW - Self-shielded flux cored arc welding

TMCP- Thermo-mechanical controlled process


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1.4 REFERENCED DOCUMENTS

JA00-03-AJ-00007 Specification for Painting and Application of Passive Fire Protection JA00-03-AJ-00008 Specification for Structural Steel JA00-03-AJ-00009 Specification for Structural Castings

EEMUA Publication No.158 Engineering Equipment and Materials Users Association (EEMUA) Publication No.158 (1994 Edition), Construction Specification for Fixed Offshore Structures in the North Sea with all amendments up to and including Amendment No.4 March 2005.

EEMUA Publication 197:1999 Specification for the Fabrication of Non-Primary Structural Steelwork for Offshore Installations

BS EN 875 Destructive Tests on Welds in Metallic Materials - Impact Tests - Test Specimen Location, Notch Orientation and Examination BS EN 10045- 1 Charpy Impact Test on Metallic Materials - Part 1: Test Method (V- and U-Notches) BS EN 910 Destructive Tests on Welds in Metallic Materials - Bend Tests (F) BS EN 1043-1 Destructive Tests on Welds in Metallic Materials Hardness Testing Part 1: Hardness Test on Arc Welded Joints BS EN 1043-2 Destructive Tests on Welds in Metallic Materials - Hardness Test Part 2: Micro Hardness Testing on Welded Joints BS EN 895 Destructive Tests on Welds in Metallic Materials - Transverse Tensile Test BS EN 876 Destructive Tests on Welds in Metallic Materials - Longitudinal Tensile Test on Weld Metal in Fusion Welded Joints BS EN 10002-1 Metallic Materials - Tensile Testing - Part 1: Method of Test at Ambient Temperature BS EN 1321 Destructive Tests on Welds in Metallic Materials - Macroscopic and Microscopic Examination of Welds EN1461 Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and test methods BS EN 10160 Ultrasonic Testing of Steel Flat Product of Thickness Equal or Greater Than 6 mm (Reflection Method) ASTM A578 Standard Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications BS EN 1435 Non-destructive testing of welds Radiographic testing of welded joints BS EN 1714 Non-destructive testing of welds Ultrasonic testing of welded joints ASME BPVC- V NONDESTRUCTIVE EXAMINATION API RP 2X Recommended Practice for Ultrasonic and Magnetic Examination of Offshore Structural Fabrication and Guidelines for Qualification of Technicians


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1.5 UNITS OF MEASUREMENT

The SI system of units shall be used on all nameplates, project documents, drawings and calculations with the exception of pipe nominal diameters, associated flange sizes, and flange bolting, which shall be in inches and pressures in bars. Any other units required for specific process measurements will be defined in the equipment specifications or data sheets.

PARAMETER UNIT ACCEPTABLE ALTERNATIVES

Length m mm

Weight kg tonne

Time second minute; hour; day

Area m2 cm2

Volume m3 litre

Gas Volumetric Flow Nm3/h MMscfd

Liquid Volumetric Flow m3/h litre/h; barrels/day

Mass Flow kg/h tonnes/day

Molar Flow kg mole/h

Temperature OC K

Pressure bar mbar; kPa

Energy, Work, Heat kJ kcal

Power kW W; MW

Heating Value kJ/m3; kJ/kg kcal/m3; kcal/kg

Viscosity cP

Electrical Potential V mV; kV; MV

Electrical Current A mA

2.0 PURPOSE

This specification defines the supplementary requirements to Engineering Equipment and Materials Users Association (EEMUA) Publication No.158 (1994 Edition), Construction Specification for Fixed Offshore Structures in the North Sea with all amendments up to and including Amendment No.4 March 2005. This specification shall be used for the construction for all primary structural steel work for, topsides and substructures (including piles) for the Jasmine Development.

Non-primary steel work may be fabricated in accordance with this specification or the requirements or EEMUA Publication 197:1999 Specification for the Fabrication of Non-Primary Structural Steelwork for Offshore Installations.


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3.0 PROJECT SPECIFIC AMENDMENTS TO EEMUA158

General

Wherever Grade 450 is referenced in EEMUA 158 the requirements will be applicable to the project Grade 460.

EEMUA 158 Clause Addition / Amendment (2) This section may be superseded in part by the requirements of the

Contract. (3.1) Amend to read: -

The structural steel plate, tubulars and sections shall be supplied in accordance with Jasmine Project Specification for Structural Steel JA00-03-AJ-00008.

(3.2) The following paragraphs is in addition to 3.2: -

“All welding consumables shall be of the low hydrogen type. The Contractor shall advise the deposited weld metal hydrogen content for each type of consumable proposed and this shall be subject to approval by the Purchaser.” “The manufacturers of welding consumables shall be subject to approval by the Purchaser”

(3.3.1) The following is a modification to the sections of 3.3.1 referencing

corrosion protection of bolts: - “Corrosion protection for bolts, nuts and washers shall be hot spun galvanised in accordance with EN1461 to achieve a zinc thickness in accordance with Table 3 of EN1461”

(3.3.2) Amend to read: -

Steel castings shall be supplied in accordance with Jasmine Project Specification for Structural Castings JA00-03-AJ-00009.

(4.2.2) Previous qualification testing is not acceptable for Grade S460 steel.

New qualifications using contract materials is required

4.3(h) The use of SSFCAW for root passes in single sided welds are not

permitted unless removed by back gouging or grinding. 4.3 (x) Additional Clause

“Heat inputs exceeding 3.0kJ/mm for Structural Steel castings”

4.3(w) For Grade 450 read Grade 460. This requirement applies throughout

the document.


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EEMUA 158 Clause Addition / Amendment 4.4 (y) Additional Clause

“Use of single bevel of K weld preparations for butt welds”

(4.4.1) The following is an addition to Section 4.4.1, sixth paragraph, “On

node joints... NDT procedure qualification.”- “In addition to all other inspection required by this specification, the attachment weld on the mock-up shall be subjected to ultrasonic inspection using a 0° compression probe under the full area of the attachment weld. The joint mock up to be used for NDT procedure qualification shall include simulated lack of fusion defects on both weld faces, root and cap, at 12 o’clock and 3 o’clock. These defects shall be a maximum of 20mm in length and 4mm in height and shall be located not more than 4mm from the surface. Additionally, a minimum of two surface breaking root defects, of same dimensions as mentioned above, shall be simulated. NDE qualification shall be undertaken by inspection from the external surfaces only” Section 4.4.1 Paragraph 8: “Where fillet welds................AWS D1.1,” is deleted and replaced with: - “Only consumables which have been qualified on butt welds may be used on fillet welds”

(4.4.4) BS 709 has been withdrawn and replaced by the following standards: -

BS EN 875 & 10 045 Charpy Impact tests BS EN 910 Bend tests BS EN 1043 Hardness tests BS EN 895 Transverse tensile tests BS EN 876 Longitudinal tensile tests BS EN 10002-1 Tensile testing BS EN 1321 Macro & Micro testing of welds Any reference to BS 709 in this section, the meaning shall be the appropriate British Standard above.

(4.4.4(b)) The yield strength of the all weld metal tensile test pieces taken from

the grade S460 steel shall exceed the minimum strength of the base metal by at least 10%.


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EEMUA 158 Clause Addition / Amendment (4.4.4(f)) The following is an addition to paragraph 7: -

“CTOD acceptance criteria shall be a value greater than 0.25mm at -10°C for both as welded nodal sections >40mm and non nodal sections >50mm. Retests are permitted on the basis of invalid crack fronts or equipment malfunction.” Delete paragraph 9 and replace by “If steel manufactures HAZ CTOD weldability data (see JA0303-AJ-00008) is supplied and providing welding from the weldability data was carried out within the heat input limits of section 4.3(l), HAZ CTOD testing in accordance with Appendix A will not be required. In the absence of suitable weldability data, HAZ testing in accordance with Appendix A is required on all steel sources, grades, supply conditions and manufacturing routes The welding heat input in fabrication shall not exceed the maximum heat input qualified by the steel Manufacturer’s weldability data”

4.5.3(f) In addition to classification and nominal composition add

manufacture’s trade name. (5.2.1) The following is an addition to Section 5.2.1: -

“Coating of Structural Steel members shall be in accordance with the Jasmine Project Specification for Painting and Application of Passive Fire Protection JA00-03-AJ-00007. Coated components shall be handled using approved procedures that minimise damage to the coatings. The coating procedures shall include repair to damaged coatings which shall be subject to approval by the Purchaser.”

(5.2.3(h)) Amend to read: -

“The locations of all splices shall be shown on the as-built drawings.”

(5.2.3(l)) The following is an addition to Section 5.2.3(l): -

“Wherever possible the minimum angular spacing between the weld toe of attachment welds for incoming braces and the weld toe of node can longitudinal weld seams shall not be less than 30°.”


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EEMUA 158 Clause Addition / Amendment (5.2.4) Delete the first and second sentences and replace with –

“All welds shall be continuous full penetration and welded from both sides. Point to point construction shall not be permitted for any primary nodes, leg nodes and face bracing nodes. However, if for any other brace less than 600mm in diameter, the Contractor wishes to employ point-to-point construction, a proposal shall be submitted to the Company for approval. Approval shall be given on a case by case basis. This proposal shall include details of how joint fit-up will be achieved, welding methods, NDT procedures, dimensional controls and previous experience.” Delete second and third paragraphs and replace by - “On point to point constructions with single sided welds the rules of AWS D1.1 and API RP 2X shall apply with respect to root defect

(5.2.6) In section 5.2.6 delete the second sentence of the second paragraph,

“If the Contractor...welded.” (5.2.7) The following paragraph is an addition to Section 5.2.7, first

Paragraph, “For any.............the Purchaser and Contractor.”- “In addition to the ultrasonic testing in Section 7.0, a 0º compression wave scan in accordance with BS 10160 S3E4 or ASTM A578 level C shall be conducted. No attempt shall be made to weld a member onto any item rejected by this examination.”

(5.2.8) The following is in addition to Section 5.2.8: -

“Location details of all manholes and inspection access points to be approved by the Purchaser. All cut outs to be shown on the as built drawings.” Add 5.2.8(d): - “All permanent rat holes and cut outs on the substructure, except where marked on the design drawings, shall be subjected to 100% MPI.”

(5.3.3) Delete the first two paragraphs and substitute the following: -

“The minimum preheat and interpass requirements are given in the following paragraphs”

(5.3.4) Any damage to primary steelwork shall be reported to the Company,

approval for repairs shall be given on a case by case basis.


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EEMUA 158 Clause Addition / Amendment (5.3.5) The following is in addition to Section 5.3.5 fourth paragraph, “The

Contractor shall make………continue to completion.” “The locations of single sided plate and single sided tubular butt closure welds shall be subject to approval by the Company. For single-sided closure welds, the ultrasonic inspector shall perform a pre-weld survey of the joint fit-up. Scribed lines shall be drawn 100 mm away from the root face on either side of the weld to assist ultrasonic examination of the completed weld.”

(5.3.7) The following is an addition to section 5.3.7: -

“No more than two attempts at repairing any defect shall be permitted.

(5.3.10) The following is an addition to the sixth paragraph of section 5.3.10: -

“If a satisfactory monitoring system is not available the Contractor shall prepare a production test plan for approval which shall state which welds are covered by the tests. These plans shall be progressively produced as fabrication proceeds. If a production test fails, all the associated welds shall be quarantined until the reason for failure is established.”

(5.4.2) Add: -

“For TMCP steel the soaking temperature shall not exceed the temperature advised by the steel manufacturer.”

(5.7) Additional Clause:

“Members may be straightened if cold deformation does not exceed 5% strain. Hot straightening shall not be carried out.”

(7.3.1) Delete the last sentence and replace with:

“The Contractor shall demonstrate to the Purchaser that the proposed ultrasonic procedures are capable of detecting known defects in nodal joints, irrespective whether the node is welded from one side(point to point) or both sides, as described in Clause 4.4.1 6th paragraph as amended by this specification ”

(7.4) The referenced NDT standards have been withdrawn and replaced as

follows:

Old Standard New Standard BS 3923 Ultrasonic Examination BS EN 1714 BS 2910 Radiographic Examination BS 2600

BS EN 1435

BS 6072 Magnetic Particle Examination -


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EEMUA 158 Clause Addition / Amendment (7.4.2) Add new first paragraph as clarification:

“Although BS 3923 has been replaced it is still available for and shall be used to develop a project specific procedure. For point to point nodal welds where permitted, API RP2X may be applied using Level C.”

(7.4.3) Add new second paragraph as clarification:

“BS 2910 and BS 2600 have been replaced but are still available for reference. The requirements of these specifications shall be used to develop an equivalent procedure based on BS 1435 or ASME V or alternatively AWS D1.1. may be applied.

(7.4.4) Add new first paragraph as clarification:

“BS 6072 and BS 6513 have been replaced but are still available for reference. The requirements shall be used to develop an equivalent procedure based on ASME V or alternatively API RP 2X may be applied.

(7.5.3) Additional sentence:

“It may be necessary to specify more stringent acceptance levels for critical welds which fail the initial fracture mechanics assessment and for the Contractor to demonstrate that the ultrasonic procedures can detect the more stringent acceptance levels”

(Table 3) Amend note (c) to read: -

“10% examination is defined as examination of 10% of the length of each weld. Where the weld is less than one metre in length then 10% inspection shall be taken to mean 100% inspection of 10% of all such welds, subject to the qualifications outlined in Section 7.2.1.5; the welds selected for inspection shall be approved by the Purchaser.” Add these additional notes: - “For joints on the substructures where scanning from internal surfaces is not possible, examination shall be carried out from all accessible surfaces using at least 3 different angle probes from each surface. Wherever the Point-to-Point fabrication technique has been used, ultrasonic inspection in accordance with clause 5.2.4 of this specification shall be carried out. Note (a) applies to inspection categories I to IV only.” Add as a general note: “BS 3923 has been withdrawn but is still available for reference and shall be used as a guide to the interpretation of the intent of Table 3 and the preparation of an equivalent inspection stand. For point to point nodal welds where permitted, the examination level shall be API RP2X Level C.”


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EEMUA 158 Clause Addition / Amendment (Table 6) 3D defects (a) amend to: -

“For welds in inspection category I, indications greater than 100% of the reference curve, irrespective of length, shall be acceptable only following Company review and approval.”


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4.0 FABRICATION OF ROLLED AND WELDED TUBULARS

4.1 MANUFACTURING PROCESS

The manufacturing process shall be specified by the Contractor (or his sub-contractor) and agreed by the Purchaser prior to commencement of production. Rolled and welded tubulars shall be fabricated in accordance with EEMUA 158 and this specification.

4.2 FORMING RESTRICTIONS

Cold forming of tubulars with D/t ratios in the range 16 to 20 (where D is the outside diameter of the can and t is the wall thickness of the can) is acceptable provided the fabricator demonstrates that the steel is not subjected to strain greater than the strain aging requirements of the structural steel specification JA00-03-AJ-00008.

Hot forming of tubulars is not permitted.


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structural fabrication specification

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