(~. ,.. ~) ~.tSJ' bi, U~ KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specification Number o 15-IH-1 006

Pig Launchers/Receivers

1 23 MAY 94 ISSUED AS KOC ENG. GROUP SPEC.

o 26 FEB 94 ISSUED FOR INVITATION TO BID

Rev Date Revision By Chkd Section PE Client

Specification Number

015-IH-1006

CONTEN,.S

Rev

1

Data

23-5-94

1.0 SCOPE ............................................ 3

2.0 STANDARD SPECIFICATIONS . 3

3.0 SERVICE CONDITIONS ... 5

4.0 TECHNICAL REQUIREMEN1"S . 5 4.1 General...................................... 5 4.2 Design .............................. 5 4.3 Materials................... ~ . . . . . . . . . . . . . . . . . 6 4.4 Charpy V-Notch Impact Tests ................. 7 4.5 Non-Destructive Examination(NDE) ......... 7 4.6 Welding ................. 7 4.7 Hydrostatic Test ........................... 8 4.8 Pig Signallers . . . . . . . . . . . . . . . . . . 8 4.9 Sacrificial Pig Stop ........... 9 4.10 Nameplate . . . . . . . . . . 9

5.0 PAINTING....................................... .. 9

6.0 INSPECTION AND QUALITY ASSURANCE .. 9

7.0 DRAYt(INGS ....... 9

8.0 PREPARATION FOR SHIPMENT . 9

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Shalt

2 of 9

( ,

Spaclflcatlon Numb ..

015-IH-100e

Rav

1

Data

23-5-94

Sheet

3 of 9

1.0 SCOPE

1.1 This specification covers the design, manufacture and supply of pig launchers/receivers for installation at the Facility in Kuwait.

1.2 The pig launchers and receivers shall fully comply with all relevant contractual requirements specified in the Scope of Work and Technical Specification of the Contract.

2.0 STANDARD SPECIFICATIONS

2.1 The pig launchers/receivers shall conform in design, materials and performance, except where otherwise specified, with the current issue any amendments of the following prevailing on the effective date of the Contract:

2 .. 1.1 International Standards

ASME Sec. VIII, Div. 1

ASME 831.8

ASMEV

ASME 816.5

ASME 816.9

ASME 831.3

ASME 846.1

ASME A370

API 605

NACE MR0175

Pressure Vessels

Gas Transmission and Distribution Piping Systems

Non-Destructive Examination

Steel Pipe Flanges and Flanged Fittings

Factory-Made Wrought Steel 8uttwelding Fittings

Chemical Plant and Petroleum Refinery Piping

Surface Texture

Charpy V-Notch

Large-Diameter Carbon Steel Flanges (Nominal Pipe Sizes 26-60; Classes 75, 150, 300, 400, 600 and 900) Standard Material Requirements for Sulphide Stress Cracking Resistant-Metallic Materials for Oilfield Equipment

Institute of Petroleum Model Code of Safe Practice Part 6 Pipeline Safety Code

N43-0285

N43-o285

Specification Number

016-IH-1006

Rev

1

Date

23-6-94

Sheet

4 of 9

API6D

2.1.2 British Standard

BS 5750

Specification for Pipeline Valves (Gate, Plug, Ball, and Check Valves)

Quality Systems

2.1.3 Engineering Group Specifications

o 15-AH-1 001

015-AH-1002

015-CH-1001

015-IH-1001

015-IH-1002

015-IH-1004

015-IH-1005

015-IH-1008

015-IH-1 01 0

015-IH-1011

015-IH-1014

Basic Design Criteria

International 'Codes and Standards

Pressure Vessels

Pipeline Construction

Pipeline Design

Pipeline Pigging and Hydrostatic Test

Pipeline Dewatering and Drying

Pipeline Field Welding Non-sour Service

External Coating of Line Pipe with Coal Tar Enamel

Induction Bends

Line Pipe Materials (Spiral Pipe) Submerged-Arc Welding (SAW)

015-KH-1902 Spare Parts and Maintenance Requirements

015-XH-1005 Shop and Field Painting

015-WH-1006 Cathodic Protection Design Requirements

2.2 Compliance with this specification shall not relieve the Contractor of its responsibility to supply equipment suited to meet the specified service conditions and applicable requirements.

2.3 Where conflicts exists between this specification and other Drawings, standards, codes and specification, the most stringent shall be applied.

f '-

Specification Number

o 15-IH-l 006

Rev

1

Date

23-5-94

Sheet

5 of 9

3.0 SERVICE CONDITIONS

3.1 The equipment shall be suitable for continuous operation at a desert location under high ambient temperature and humidity. The atmosphere at the Facility is generally dusty and corrosive and may contain traces of hydrogen sulphide.

3.2 The pig launchers/receivers shall in all respects be suitable for continuous operation in the service conditions stated in the Engineering Group Speci-fication entitled "Basic Design Criteria" (Number 015-AH-1001).

4.0 TECHNICAL REQUIREMENTS

N43-o285

4.1 General

Launchers/receivertraps shall be used to launch and receive scraper pigs and inspection vehicles.

4.2 Design

4.2.1 The pig launcher(s) and receiver(s) shall be sized and designed by the Approved Manufacturer and submitted to the Company for approval, and fabricated, welded and inspected in accordance with the latest edition and amendments of ASME VIII Div. 1.

4.2.2 The pig trap should be tested at the pipeline test pressure as calculated in accordance with Institute of Petroleum, Part 6.

a.

b.

c.

d.

e.

The barrel and neck section shall be from seamless pipe, rolled plate. The connecting eccentric reducer shall be from rolled plate, designed, constructed and tested in accordance with ASME Sec. VIII Div. 1.

The internal surface of the units shall be smooth throughout their entire length and free from any deposits or features likely to restrict pig passage or cause hang-up. The maximum permissible protrusion into the bore of the neck shall be 0.3 mm.

The throat of the neck shall match the relevant pipeline bores.

All nozzles except drain shall be located on the top or the side of the horizontal units. All nozzles shall be of the integral self-reinforcing type.

The closure shall be provided with a pressure interlocj~Jo prevent openings while the trap is under pressurKv. fl ..

N43-0285

Specification Number

o 16-IH-1 006

Rev 1

Date

23-6-94

Sheet

6 of 9

f. The barrel closure shall be flanged and blinded. End closures shall be rated per ASME 816.5 pressure and temperature rating. For sizes up to 24 in. and thereafter, API 605 shall apply.

g. The pipeline nozzle shall be flanged and rated per ASME 8 16.5 pressure and temperature rating. For sizes up to 24 in. and thereafter, API 605 shall apply.

h. The Approved Manufacturer shall provide maximum reaction loads for design of support steel/foundations.

i. Lubrication nipples shall be provided on the davit swivel. Davits shall be provided for sizes 19 in. and larg~r. The number and size of the nozzles/connections shall be as per Project Drawings for the respective service pig

.--------- - launcher/receiver.---------- --_ .. ----.-.----

J. The minimum number and size of nozzles/connections shall be as per Project Drawings for the respective service pig launcher/receiver.

4.3 Materials

The materials of construction shall be as specified on the Approved launcher /receiverManufacturer' s design data approved by the Company.

4.3.1 Corrosion allowance shall not be less than that for the respective pipeline.

4.3.2 The design of the supports shall be based upon the combined loading of the trap assumed full of water together with the maximum weight of any operational pig and piping loads.

4.3.3 End closures of the threaded type shall not be utilised. Quick-release type closure only to be provided. End closures shall be designed to ASME VIII Div. 1. Design shall ensure that the hinges and locking mechanism are efficiently robust to withstand repeated usage. End closure and associated safety and operating gear shall be designed to ensure safety and operating and ease of utilisation by one person with only hand tools to open and close the door.

4.3.4 The barrel size shall be two pipe sizes larger than the size of the pipeline and shall be suitable for both launching and receiving.

(

N43-0285

SpecIfication Numb.

016-IH-1006

4.4 Charpy V-Notch Impact Tests

Rev

1

Date

23-6-94

Sheet

7 of 9

4.4.1 All the materials used for the pig trap assemblies shall be subject to impact test. For weld procedures, the notch shall be in the weld metal, fusion line and fusion line zone plus 2 mm.

4.4.2 These tests shall be in accordance with ASTM A370.

4.4.3 The impact tests shall be carried out at -2C and shall meet the following minimum impact energy requirements at this temperature:

Specimen Minimum Average Minimum Oimenslon(mm) (of 3 Tests) Allowable

Value Impact Value Single (Joules) (Joules) -~ - ~

10 x 10 27 20 10 x 7.5 23 17 10 x 5 18 14

4.4.4 The Company reserves the right to witness all tests.

4.5 Non-Destructive Examination (NOE) 4.5.1 Non-destructive tests shall include visual, magnetic particle

examination and radiography.

4.5.2 NOEs shall be carried out using methods as described in ASME Sec. V. Acceptance levels shall be as specified in ASME VIII Div.1. All butts welds shall be 100% radiographed. Other welds which cannot be radiographed shall be subjected to magnetic particle examination.

4.5.3 All acceptance non-destructive examinations shall be carried out after any post weld heat treatment (PWHT).

4.6 Welding

4.6.1 WeJding and welding qualification shall be in accordance with the Engineering Group Specification entitled "Pipeline Field Welding Non-Sour Service" (Number 015-IH-1008). The weld procedure and welder qualification shall include low temperature toughness testing in accordance with section 4.4.

4.6.2 Maximum hardness values for base metal, weld metal and heat affected zone (HAZ) shall not exceed 248-HV 10.

Wi ~

N43-o285

Specification Number

015-IH1006

Rav Data

23-5-94

Sheet

8 of 9

4.6.3 The Company reserves the right to be present during the welder qualification test and/or request requalification if deemed necessary.

4.6.4 Weld Repairs

a. All proposed repairs and repair procedures shall be approved by the Company.

b. All repairs shall be completed prior to final PWHT.

4.7 Hydrostatic Test

The trap assemblies shall be tested in accordance with the design code and the requirements of the Engineering Group Specification entitled "Pressure Vessels" (Number 015CH-1oo1) and "Pipeline

-P-igginU-Hydrostatic.Test" (Number 015-IH-1 004).. .. 4.8 Pig Signallers

4.8.1 Two pig signallers shall be supplied with each launcher/receiver, one of which shall be supplied loose for installation on the pipeline.

4.8.2 All pig signallers shall be equipped with mechanical flags. The signallers supplied loose shall also be provided with electrical switches to provide remote indication.

4.8.3 The Approved Manufacturer shall confirm that these switches can be classified as a "simple devicell under BASEEFA standards. Barriers for the safe system are by Pepperl & Fuchs, and switches shall be compatible with these barriers.

4.8.4 All switches shall be fully weatherproof to IP56 (BS 5490) and supplied with a cable entry of M20 x 1.5.

4.8.5 Switch contacts are to be SPCO rated at 0.5 A, 24 VDC.

4.8.6 Supplied documentation shall include the relevant electrical classification certification (BASEEFA).

4.8.7 The signallers supplied loose shall be designed to permit removal of mechanism, under full line pressure, for service and replacement and shall have double isolation valves.

4.8.8 The Approved Manufacturer shall supply full details and type of pig Signaller for approval by the Company.

4.9 SaCrificial Pig Stop

Specification Number

015-IH-1006

Rev Date

23594

A sacrificial pig stop is required for each launcher and receiver.

4.10 Nameplate

Sheet

9 of 9

A corrosion-resistant nameplate shall be permanently affixed to each item of equipment in a visible and accessible place and shall bear the following data: "As set out on Project standard Drawing 015-CB-1012."

5.0 PAIN1"ING

After final assembly and hydrotesting, the external surfaces of the equipment, except machined surfaces, shall be blast cleaned and painted in accordance with the Engineering Group Specification entitled "Shop and

F-ield-Palnting~.(Number 015,..XH-l005).- 6.0 INSPECTION AND QUALITY ASSURANCE

6.1 All data obtained in tests shall be properly logged, together with any material test certificates, etc. and shall be bound together and sent to the Company for approval, to form part of a manufacturing record book.

6.2 Inspection shall be in accordance with the requirements of the construction code and the Engineering Group Specification entitled "Pressure Vessels" (Number 015-CH-1 001).

( . 7.0 For packing, marking and documentation for all relevant requirements, refer to the Engineering Group Specification entitled "Packing, Marking and Documentation" (Number 015-UH-1001).

8.0 For spare parts and maintenance requirements, refer to the Engineering Group Specification entitled Spare Parts and Maintenance Requirements" (Number 015-KH-1902).

N43-0286