dgs-pu-303-rev-0

Abu Dhabi Oil Refining Company

SCRAPER SIGNALLER DGS-PU-303 Rev-0 March 2006

Takreer DGS-PU-303-Rev-0 March-2006 Printed 20-Apr-09 08:45:06 Initials of 12

SCRAPER SIGNALLER

Amendment History

No Date Amendment Description Proposed Approved Incorporated

DGS History

0 March 2006 DGS-PU-303-Rev-0 Previous Project / Lessons Learnt Incorporated

AH/DDC ETSDM / EPDM

No Date Description Source Reviewed Approved

DGS-PU-303 Rev-0




TABLE OF CONTENTS

1.0 GENERAL ................................................................................................................................3 1.1 INTRODUCTION.............................................................................................................3 1.2 PURPOSE.......................................................................................................................3 1.3 DEFINITIONS .................................................................................................................3

2.0 CODES AND STANDARDS .....................................................................................................3 3.0 REFERENCE DOCUMENTS ...................................................................................................4 4.0 DOCUMENT PRECEDENCE...................................................................................................5 5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL ......................................................5 6.0 QUALITY ASSURANCE/QUALITY CONTROL ........................................................................5 7.0 SITE CONDITIONS..................................................................................................................5 8.0 DESIGN AND FABRICATION...................................................................................................5 9.0 MATERIAL REQUIREMENTS ..................................................................................................7 10.0 INSPECTION AND TESTING...................................................................................................7

10.1 EXAMINATION OF WELDS............................................................................................8 11.0 COATINGS ...............................................................................................................................8 12.0 MARKING.................................................................................................................................8 13.0 PREPARATION FOR SHIPMENT ............................................................................................9 14.0 MATERIAL CERTIFICATION AND TRACEABILITY.................................................................9 15.0 VENDOR DATA REQUIREMENTS LIST (VDRL).....................................................................9 16.0 SPECIAL TOOLS ................................................................................................................... 11 ADDENDUM SHEET .......................................................................................................................12

List of Authorized Signatures/ Initials

DGS Discipline Committee Member, ADRD ------------------------------

DGS Discipline Committee Member, RRD ------------------------------

DGS Discipline Committee Member Leader, E&PD Abdul Hakim (AH)

Engineering & Technical Services Manager, E&PD Quazi Abdul Matin (QAM)

Engineering & Projects Division Manager, E&PD Mohamed Al Yabhouni (MAY)




1.0 GENERAL

1.1 INTRODUCTION

The specification gives the minimum technical requirements for the design, manufacture, testing, inspection, coating/painting and supply of scraper signallers (pig signallers) to be used for non sour, liquid service on onshore pipelines.

1.2 PURPOSE

This specification supplements the codes listed in Section 2.0 of this specification.

1.3 DEFINITIONS

For the purpose of this specification, the following definitions shall apply:

1.3. 1 CONCESSION REQUEST - A deviation requested by the CONTRACTOR / SUBCONTRACTOR or VENDOR / SUBVENDOR, usually after receiving the contract package or purchase order. Often, it refers to an authorisation to use, repair, recondition, reclaim, or release materials, components, or equipment already in progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.

1.3.2 SHALL - The use of the word “shall” indicates a mandatory requirement.

1.3.3 SHOULD - The use of the word “should” indicates a strong recommendation to comply with the requirements of this document.

2.0 CODES AND STANDARDS

It shall be the CONTRACTOR’s, VENDOR’s, SUBCONTRACTOR’s and or SUBVENDOR’s responsibility to be or to become knowledgeable of the requirements of the referenced codes and standards.

The following codes and standards, to the extent specified herein, form a part of this specification. When an edition date is not indicated for a code or standard, the latest edition in force at the time of contract award shall apply.

American Society of Mechanical Engineers (ASME)

ASME BPV Section V Boiler and Pressure Vessel Code: Non-destructive Examination

ASME BPV Section VIII Boiler and Pressure Vessel Code: Division I - Pressure Vessels

ASME B31.4 Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids.




ASME B16.5 Pipe Flanges and Flanged Fittings

American Petroleum Institute (API)

API 1104 Welding of Pipelines and Related Facilities

American Society for Testing Material (ASTM)

ASTM E92 Standard Test Methods for Vickers Hardness of Metallic Materials

ASTM A694 Standard Specification for Forgings, Carbon and Alloy Steel for Pipe Flanges, Fittings, Valves and Parts for High Pressure Transmission Service

Manufacturers Standardisation Society of Valve Fitting Industry, Inc. (MSS)

MSS SP-75 High -Test Wrought, Butt-Welded Fittings.

International Organisation for Standards (ISO)

ISO 9001-2000 Quality Management System Requirements

ISO 9004-2000 Quality Management Guidelines for Performance Improvement System

ISO 9011 Guidelines for Quality and/or Environmental System Auditing

ISO 10474 Steel and steel products - Inspection documents.

3.0 REFERENCE DOCUMENTS

The following reference documents, to the extent specified herein, form part of this specification. When an edition date is not indicated for a document, the latest edition in force at the time of contract award shall apply.

Design General Specifications:

DB-PU-401 Pipeline Engineering Design Basis

DB-PU-001 Process Design Basis

DGS-PU-319 Pipeline Welding

DGS-MX-001 Design General Specification/Procedures (Painting)

DGS-PU-307 HFW Line Pipes

DGS-PU-320 Seamless Line Pipe




4.0 DOCUMENT PRECEDENCE

The CONTRACTOR and or VENDOR shall notify the COMPANY of any conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design or manufacture.

In case of conflict, the order of precedence shall be stated in the AGREEMENT or other PROJECT documents as applicable.

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to the Specifications and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be sought by the CONTRACTOR / VENDOR / SUBVENDOR only through CONCESSION REQUEST format. CONCESSION REQUESTS require COMPANY’S review/approval prior to the proposed changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

6.0 QUALITY ASSURANCE/QUALITY CONTROL

VENDOR’S proposed quality system shall fully satisfy all the elements of ISO 9001 - 2000 and ISO 9004 - 2000. The quality system shall provide for the planned and systematic control of all quality-related activities performed during design, development, production, installation or servicing (as appropriate to the given system).

Implementation of the system shall be in accordance with the CONTRACTOR’S Quality Manual and Project Specific Quality Plan, which shall both together with all related/referenced procedures, be submitted to COMPANY for review, comment and approval as required by purchase/contract documents.

Material certification and traceability shall be in accordance with para 14.0 and 15.0.

7.0 SITE CONDITIONS

Site conditions shall be in accordance with Process Design Basis, document number DB-PU-001.

8.0 DESIGN AND FABRICATION

Signallers shall be capable of indicating the passage of all types of pigging devices, including intelligent pigs and spheres. Signallers shall be bi-directional.

The pressure housing for pig signallers shall be designed in accordance with ASME Section VIII Div. I.




Scraper Launcher and Receiver signallers will be connected to the top of the scraper trap nozzle by way of a 2 inch butt weld boss (Weldolet).

Pipeline mounted signallers, the connection to the top of the Pipeline branch shall be an appropriate 2 inch butt weld boss (weldolet) connection, isolation will be achieved via butt weld/flanged 2” full bore ball valve through which the signalling probe shall pass.

The indicating device, “Flag” shall be set in the horizontal position for “pig not passed” and vertical for “pig passed” condition with a manual latch reset to the horizontal position.

In addition to the local indicating device, the signaller shall activate a snap acting micro switch (DPDT) contacts, gold plated with 24V DC 2amps rating to provide a remote indication in control systems/SCADA systems when specified in P&IDs. The design of this switch for remote indication shall be suitable for the hazardous area.

Pipeline mounted pig signallers shall be designed to allow maintenance and/or replacement with the main pipeline under pressure (retrievable type).

Pig signaller shall have sliding internal mechanism to allow the closure of the isolation valve and safe release of the pressure contained in the isolated section when the valve is closed.

Pig signaller shall be designed to remain in position during pipeline pressurisation. Marking shall be provided to clearly indicate that probe has cleared the ball valve and depressurisation equipments. The signaller shall have an adjustable trigger to reset in the field.

The signaller and trigger shall be capable of manual testing in the installed position while the pipeline is pressurised and operational.

The pig signallers on the buried pipeline sections, for example at sectionalising valve station, shall be provided with extended spindle and supports etc to position the indicating devices, flag, above grade. VENDOR shall provide suitable arrangement for accessing buried portion of pig signaller for maintenance purposes.

Welding shall be in accordance with DGS-PU-319.

Butt-welded joints for circumferential joints shall be 100 percent radiographically inspected. The COMPANY reserves the right to require ultrasonic testing where radiography may produce questionable results.

In the event that welds performed on any forging cannot be 100 percent radiographed by gamma and x-ray, then ultrasonic and wet florescent magnetic particle testing may be used with the approval of the COMPANY.

Welding procedure specifications and procedure qualification records shall be furnished to the COMPANY for approval prior to fabrication.




All welding procedure specifications, procedure qualification records, welder qualification tests, design and preparation of joints, inspection and testing, standards of acceptability, repairs, and radiography shall be in accordance with DGS-PU-319.

9.0 MATERIAL REQUIREMENTS

All components in contact with the pipeline fluids whose operational efficiency will be affected by corrosion shall be constructed from AISI 316L Stainless Steel.

Material test reports, chemical analysis, mechanical properties shall be available for review by the COMPANY’S representative at the time of inspection.

The material of body, bonnet, and flange shall be in accordance with the requirements of ASTM A 105(N), Scarfed welding base shall be in accordance with ASTM A694 and grade to match the pipeline grade. The carbon equivalent (CE) shall not be greater than 0.42 on check analysis, calculated as per the following formula:

CE = C + Mn + (Cr + Mo + V) + (Cu + Ni)

6 5 15

Elastomeric materials for ring seals shall resist explosive decompression and shall be suitable for the long-term exposure to the transported fluid at the design pressure and temperature conditions. The cross-section of the seals shall not exceed 7 mm diameter for design pressures of 150 bar and above.

10.0 INSPECTION AND TESTING

Testing and assembly procedures shall be detailed by VENDOR, approved by the COMPANY and implemented during the work.

Inspection and Testing shall be performed before any Coating or Painting is applied.

The equipment shall be hydrostatically tested for duration of four (4) hours. Test pressure shall be equal to the test pressure for pig scraper launcher/receiver and end closure door i.e. 1.5 times the design pressure. The signaller shall be manually operated 10 times at the start of the test and 10 times at the end of the test.

A continuous recording shall be made of the pressure test at ambient temperature throughout the duration of the test including a calibration (witness and certification) and shall be included in the documentation the VENDOR provides to the COMPANY.

The VENDOR shall adequately demonstrate that all aspects of the insertion tool operate in a simple foolproof manner. The removal and reinsertion shall be demonstrated at test pressure using a dead-weight tester or some other device to ensure the release of fluid at high pressure is minimised while maintaining test pressure +/-5 percent.




Visual examination methods shall be in accordance with ASME BPV Code Section V, Article 9.

All components shall be visually examined in accordance with ASME Code Section VIII, Division 1, Part UG-93.

A functional test shall be performed to demonstrate that the trigger mechanism trips the mechanical indicator.

10.1 EXAMINATION OF WELDS

Each weld shall be examined by 100 percent radiography (RT). In addition, carbon steel welds shall receive 100 percent magnetic particle examination (MT) and stainless steel welds shall receive 100 percent liquid penetrant examination (PT).

RT shall be in accordance with ASME BPV Code Section V, Articles 2 and 22, with acceptance criteria in accordance with ASME BPV Code Section VIII, Division 1, Part UW-51.

MT shall be in accordance with ASME BPV Code section V, Articles 7 and 25, with acceptance criteria in accordance with ASME BPV Code Section VIII, Appendix 6.

PT shall be in accordance with ASME BPV Code Section V, Articles 6 and 24, with acceptance criteria in accordance with ASME BPV Code Section VIII, Appendix 8.

U.T : For Welds, ASME BPV Code Section VIII, Division 1, Appendix 12.

U.T : For forging, ASME BPV Code Section VIII, Division 2, Section AM 203.2 (c).

11.0 COATINGS

Painting and coating are to be in accordance with the Design General Specification DGS-MX-001.

12.0 MARKING

A corrosion resistant metal tag shall be permanently attached with each unit with the following marking:

• Project Name

• Manufacturer’s Name

• Suitable for installation in ____ mm diameter pipeline

• Material Grade




• ANSI Rating

• Design Pressure and Hydrostatic Test Pressure

• Purchase Order and Item Number

• Year of Manufacture

• Tag Number

13.0 PREPARATION FOR SHIPMENT

The VENDOR shall submit shipping and handling procedures to the COMPANY for approval. The procedures should adequately address storage, shipping and handling in view of the long voyage from manufacturing locations and climatic extremes at the job site.

14.0 MATERIAL CERTIFICATION AND TRACEABILITY

Material Test Certificates and Manufacturer Test Reports shall be traceable within the VENDOR Fabrication Book, which shall be part of the QC Data Book.

The pressure containing and load bearing/stressed materials shall be fully covered by the Material Test Certificates, which shall bear Equipment Tag Numbers, Purchase Order Numbers and any other Purchase Order requirements.

After all testing is complete, one scraper-signaller device per lot shall be dismantled. A complete visual inspection of all parts including withdrawal tools shall be carried out for distortion or defects, and the units reassembled.

For quality assurance requirements and inspection requirements, refer to the Purchase Order and its referenced documents.

15.0 VENDOR DATA REQUIREMENTS LIST (VDRL)

The CONTRACTOR/VENDOR shall submit certification and inspection documents to the COMPANY’s representative as specified in the purchase order. Mutual agreement on scheduled submittal of drawings and engineering data shall be an integral part of any formal Purchase Order.

All documents, drawing text and dimensions shall be expressed in English language and shall be in the metric system.

Comments made by CONTRACTOR on drawing submittal shall not relieve VENDOR or SUBVENDORS of any responsibility in meeting the requirements of the specifications. Such comments shall not be construed as permission to deviate from requirements of the Purchase Order unless specific and mutual agreement is reached and confirmed in writing.




Each drawing shall be provided with a title block in the bottom right-hand corner incorporating the following information:

• Official trade name of the VENDOR.

• VENDOR’S drawing number.

• Drawing title giving the description of contents whereby the drawing can be identified.

• A symbol or letter indicating the latest issue or revision.

• PO number and item tag numbers.

Revisions to drawing shall be identified with symbols adjacent to the alterations, a brief description in tabular form of each revision shall be given, and if applicable, the authority and date of the revision shall be listed. The term "Latest Revision" shall not be used.

VENDOR shall submit certification and inspection documents to the COMPANY’s representative as specified in the purchase order. Documents shall include the following as a minimum:

• Installation, Operation and Maintenance Manual

• Quality Plan

• Inspection and Testing Plan

• Production Schedule

• Parts List with corresponding assembly drawings

• Schematic drawings

• Dimensional Drawings

• General Arrangement Drawings

• Certificate of Conformance and Dimensional Check Reports

• Certified Material Test Reports and Manufacturing Certifications

• Forging Certificate shall be ISO 10474 type 3.1.B

• Verification Certificates for Standard Compliance

• Heat Treatment Procedure and Records




• Marking Procedure

• Mechanical Test Report

• Hydrotest and NDE Test Reports

• Spare Parts List

• Special Tools

• Recommended two years spare parts list

• Design Calculations

• All Concession Requests

• Final Inspection Report

16.0 SPECIAL TOOLS

VENDOR shall supply two (2) sets of retrieval tool along with any other special tool required for maintenance/operation of Pig Signaller. The training to maintenance and the Operation staff shall be provided as part of the package supply.




ADDENDUM SHEET

All revisions to this DGS subsequent to the issue of Rev Zero shall be recorded in this addendum sheet and shall be incorporated into the DGS in the next revision.

Date Proposed Revision Remarks