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REVISION RECORD SHEET
D 15-Sept-99 Issued for Bid RJ H SM BJ B
C 10-Sept-99 Revised per Cost Challenge RJ H SM BJ B
B 4-Dec-98 Issued for use on the Bonga Project SM SM BJ B
A 21-Oct-98 Initial Issue For Client Review and Approval SM SM BJ B
Rev. Issue Date Description of Revision ENGR
APPR.
PROJ.
APPR.
SDDSI
Approval
Shell Deepwater Development Systems, Inc.
Bonga Project
Document Title:
Fabrication of Topsides Structural
Document
Number
Bonga - SPEC - ST - 006
Rev. No.
D
Page Total (Including this Cover)
18
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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Table of Contents
Section Description Page
- Revision Record and Cover Sheet 1
- Table of Contents 2
1.0 General 4
1.1. Scope 4
1.2. Definitions 4
1.3. Applicable Documents 5
1.4 Documents Requiring Submittal 5
2.0 Materials 6
2.1 Specification 6
2.2 Material Control Procedure 6
2.3 Material Handling 6
2.4 Mill Certificates 7
2.5 Dimensional Tolerances 7
3.0 Fabrication 8
3.1 General 8
3.2 Identification of Welding 8
3.3 Fabrication Engineering 8
3.4 Forming 11
3.5 Post Weld Heat Treatment (PWHT) 11
3.6 Straightening 11
3.7 Test Fitting Field Installed Components 12
3.8 Hold Points 12
4.0 Tolerances/Dimension Control 12
4.1 Dimensional Control Procedure 12
4.2 Survey Transmittal Requirements 13
4.3 Miscellaneous 13
4.4 Drifting Requirements 13
5.0 Tank Testing 13
6.0 Weight Control 13
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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Table of Contents (Cont)
Section Description Page
6.1 General 13
6.2 Procedure 14
6.3 Subassemblies to be Weighed 14
6.4 Weight Measurement Report 14
- Table 1.4 15
- Appendix A3.5 16
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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1.0 General
1.1 Scope
This SPECIFICATION defines SNEPCO's minimum requirements for structural materials, fabrication,
tolerances, testing, and weighing of the BONGA FPSO Topsides.
The requirements in this SPECIFICATION are applicable to CONTRACTORs and subcontractors
performing any portion of the WORK.
SNEPCO shall have the right to apply professional judgment to revise the requirements set forth in this
SPECIFICATION on a case-by-case basis.
Throughout this SPECIFICATION reference is made to "zone(s)", these zones are identified on AFC
DRAWINGS.
1.2 Definitions
The following words used in this SPECIFICATION have specific definitions as follows:
a. "CRITICAL STEEL" shall mean steel designated as Critical on AFC DRAWINGS.
b. "DRAWINGS" shall mean the APPROVED Drawings and revisions thereof which define the system
configuration in enough detail to allow material order and construction. Depending on the
specification documents invoked by the CONTRACT, these may alternatively be referred to as
Approved for Construction Drawings (AFC DRAWINGS) .
c. "PRIMARY STEEL" shall mean steel designated as Primary or Grade 50B or 60B on AFC
DRAWINGS.
d. "SECONDARY STEEL" shall mean steel designated as Secondary or Grade 50C on AFC
DRAWINGS.
e. "SPECIAL STEEL" shall mean steel designated as Special on AFC DRAWINGS.
f. "STEEL REQUIREMENTS" refers to Table A-1, Steel Requirements on Drawing 566M-98-780AA,
Typical Welding Details.
g. "TEAM QC" refers to the joint team of SNEPCO and Contractor personnel responsible for Quality
Control and Quality Assurance.
h. "TERTIARY STEEL" shall mean steel designated as Tertiary or Grade 36C on AFC DRAWINGS.
i. Zone 1 shall be defined as any weld or section of steel designated as Zone 1 or Z1 on the AFC
DRAWINGS. In the absence of a specific designation, all PRIMARY, CRITICAL, AND SPECIAL
STEEL within 3 of a weld shall be considered Zone 1.
j. Zone 2 shall be defined as any weld or section of steel designated as Zone 2 or Z2 on the AFC
DRAWINGS.
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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k. Zone 3 shall be defined as any weld or section of steel designated as Zone 3 or Z3 on the AFC
DRAWINGS. In the absence of a specific designation, all SECONDARY AND TERTIARY
STEEL shall be considered Zone 3.
1.3 Applicable Documents
In addition to conformance with this SPECIFICATION, WORK shall be in accordance with referenced
sections or paragraphs of the following codes, specifications, publications and standards which shall be a
part of this SPECIFICATION. Where reference in this SPECIFICATION is not limited to a specific
section, paragraph, or topic, the entire Applicable Document shall be considered referenced.
a. American Institute of Steel Construction, Inc. (AISC), "Manual of Steel Construction, Allowable
Stress Design, Ninth Edition, 1989.
b. American Petroleum Institute, "Recommended Practice for Planning, Designing and Constructing
Fixed offshore Platforms - Working Stress Design". API RP2A-WSD, Twentieth Edition, 1993.
c. American Petroleum Institute, "API Specification for Fabricated Structural Steel Pipe", API Spec
2B, Fourth Edition, 1990.
d. American Petroleum Institute, "Specification for Carbon Manganese Steel Plate for Offshore
Platform Tubular J oints", API Specification 2H, Seventh Edition, 1993.
e. American Petroleum Institute, Recommended Practice for Planning, Designing and Constructing
Fixed Offshore Platforms - Working Stress Design API Recommended Practice 2A - WSD,
Twentieth Edition, J uly 1, 1993.
f. American Petroleum Institute, "Specification for Steel Plates for Offshore Structures, Produced by
Thermo-Mechanical Control Processing (TMCP)", API Specification 2W, Third Edition, 1993.
g. American Petroleum Institute, "Specification for Steel Plates, Quenched-and-Tempered, for
Offshore Structures," API Specification 2Y, Third Edition, 1993.
h. American Petroleum Institute, "Recommended Practice for Preproduction Qualification for Steel
Plates for Offshore Structures," API Recommended Practice 2Z, Second Edition, 1992.
i. American Petroleum Institute, "Specification for Line Pipe", API Specification 5L (SPEC SL)
Thirty-eight Edition, 1990.
j. American Welding Society, "AWS Structural Welding Code - Steel" AWS D1.1-92, Thirteenth
Edition.
CONTRACTOR shall maintain copies of the referenced or applicable portions of Applicable Documents
at locations readily accessible to work sites.
1.4 Documents Requiring Submittal
CONTRACTOR shall submit the documentation as indicated in Table 1.4.
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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2.0 Materials
2.1 Specification
Steel shall conform to the grade designation and base metal testing requirements shown on AFC
DRAWINGS.
2.2 Material Control Procedure
CONTRACTOR shall establish, submit and implement a material control procedure. Low stress die-
stamps shall be used on steels in zone 1.
2.2.1 Steel Manufacturer's Markings
a. CONTRACTOR shall transfer the manufacturer's material identification markings or,
alternatively, a unique reference number, onto cut pieces and remnants.
b. Material which does not have original or verifiable markings as allowed in this section shall
be physically segregated and clearly marked as nonconforming. For use of such materials, a
sample from each piece shall be removed and the chemical composition and mechanical
properties required by the material specification shall be obtained.
2.2.2 Steel Grade and Zone Markings
A unique color code or die-stamp marking system for the different steel grades, heat treatment
conditions, and zone shall be applied to each piece of steel. The marking system shall also
uniquely identify steel with through-thickness (z) properties.
2.2.3 Traceability
Computerized traceability of the mill certificate to its final location in the structure and from the
location in the structure to the mill certificate shall be required for CRITICAL STEEL, SPECIAL
STEEL and PRIMARY STEEL. For the purpose of material traceability, steel elements identified
as brackets and doublers in AFC DRAWINGS may be considered SECONDARY STEEL no
matter what material designation is specified. SECONDARY STEEL and TERTIARY STEEL
require mill certificates in accordance with Paragraph 2.4 and steel manufacturers markings in
accordance with Paragraph 2.2.1 but not traceability into WORK.
Traceability designations shall be transferred using die stamps. Documentation shall show the
final location of each piece in the structure.
The material control procedure shall describe the method by which the mill certificate is correlated
with the locations) of the final position of the steel in the structure.
2.3 Material Handling
Chains shall not be used in direct contact with materials.
Care shall be taken to avoid damage to coatings.
Material and equipment, including SNEPCO furnished items, shall be stored on suitable supports above
the ground and any water. Materials and equipment shall be kept free from dirt, grease, over-spray, or
other foreign matter and shall be protected from corrosion.
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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2.3.1 Damaged Materials
Damaged materials shall be segregated and shall not be used. Procedures for repair of damaged
materials shall be submitted; however, the repair of damaged materials shall be APPROVED on a
case-by-case basis.
2.3.2 Anodes
Anodes (with their shipping pallets) shall be stacked on wooden timbers, minimum 6 (150mm)
high, so that anodes are free of any contact with each other, the ground or any standing water.
Any accumulation of aluminum oxide (white powder) on the anode surface or between anodes
shall be removed by rinsing with fresh water.
2.4 Mill Certificates
Mill certificates signed by the mill testing lab shall be maintained for steel. Certified copies (Lloyd's,
DNV, ABS, or APPROVED other) of original certificates will be ACCEPTABLE. Third party or
reformatted substitutes for original certificates will not be accepted.
The mill certificate shall show the results of testing required by the material specification and by this
section. Materials received with less than a complete reporting of elements, as required by this section,
may be APPROVED on a case-by-case basis and shall be REVIEWED for compliance with reduced
preheat provisions.
In addition to the requirements of the material specification, mill certificates shall include the following:
a. Complete composition, showing elements restricted by the material specification, elements in the
Pcm and CE formulae and other residual elements identified but not normally required to be
reported. In addition, the following elements shall be reported:
Nitrogen (N) , Aluminum (Al), Titanium (Ti) .
b. Pcm shall be calculated using the formula given below and reported for steels.
Pcm =C +Si/30 +(Mn +Cu +Cr) /20 +Ni/60 +Mo/15 +5*B
c. Carbon equivalent (CE) shall be calculated by the International Institute of Welding (IIW) formula
given below and reported for steels.
CE =C +Mn/6 +(Cr +Mo +V) /5 + (Ni +Cu) /15
2.5 Dimensional Tolerances
2.5.1 Plates and Shapes
Plates shall be ordered to thickness and shall be within the permissible variations in thickness as
specified in ASTM A6 or ASTM A20. Structural shapes shall conform to the dimensional
tolerances given in AISC and as modified in AFC DRAWINGS.
2.5.2 Tubulars
Tubulars other than API 2B and API 5L used as structural members shall meet the dimensional
tolerances specified in the applicable specification and the following:
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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a. Straightness - The maximum deviation from straightness from a 10-foot straightedge shall not
exceed 1/8" (3mm) at any point. The maximum deviation for the entire length of pipe shall
not exceed 1/8" (3mm) per each 10 (3.1m) of length, with a maximum of 3/8" (10mm) in any
40 (12.3m) of length.
b. Thickness - The minimum wall thickness shall not be more than 0.01" (.25m) under the
nominal wall thickness. Surface conditioning for the removal of imperfections or depressions
on the outside or inside surface of the pipe may be done by grinding, provided the area ground
is well-faired without abrupt changes in contour and the grinding does not reduce the
thickness below the stated minimum. Imperfections exceeding this depth may be gouged or
ground to sound metal and repaired by welding if the total repaired surface area is 2% or less
of the surface area of the piece.
Pipe that meets the thickness tolerances of the standard under which it was manufactured but
not the foregoing, may be downgraded for use in other members or appurtenances at the
discretion of SNEPCO.
3.0 Fabrication
3.1 General
The sequence of fabrication and welding shall minimize the effect of built-in stresses.
Longitudinal butt weld offset requirements listed in API RP2T, Paragraph 10.2.2b, Subparagraph 1, are
not required.
Plate orientation requirements listed in API RP2T, Paragraph 10.2.2c, Subparagraph 3, are not required.
3.2 Identification of Welding
Each weld shall be identified with the weld identification number on the adjacent steel surface using an
indelible paint marking system. This number shall be as specified in the APPROVED identification
system.
The work of each welder and welding operator shall be identified at each weld or portion of weld with his
unique identifying symbol using an indelible marking system. Other welder/weld identification systems
may be APPROVED.
3.3 Fabrication Engineering
3.3.1 Fabrication Procedures
A fabrication procedure shall be submitted. This procedure shall show the method and location of
assembly of major blocks and equipment, and shall detail the erection sequence.
Typical sequences of welding of plate seams, tubular or shapes intersection welds and stiffened
panel construction that control distortion and shrinkage shall be included in a procedure.
3.3.2 Fabrication Loads and Stability
CONTRACTOR shall account for temporary erection loads imposed on the structure from
supports, jacks and slings at each stage of fabrication and assembly.
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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CONTRACTOR shall account for local and overall stability, and deflections due to self weight
and environmental loads. Temporary stresses in the structure during fabrication shall be
minimized and shown to be less than those allowed by API RP2A-WSD or API RP2T with no
increase in basic allowable stresses.
Loads due to extreme environmental events (eg. hurricanes) shall be considered for any condition
or procedure in effect during the corresponding season of exposure. Stresses in the structure
during these events shall he shown to be less than those allowed by API RP2A with the 1/3
increase in basic allowable stresses. Contingency plans to be executed prior to the arrival of such
a storm shall be included in the submitted fabrication procedures.
Any effect of wind-induced vibration shall be minimized.
3.3.3 Fabrication Support System
CONTRACTOR shall provide a fabrication support system sufficient to maintain adequate
support and ensure dimensional tolerances. Support points shall be maintained 1/4" (6mm) of a
horizontal datum during weighing, fit up of members and component tie-ins. Support points shall
be maintained 3/4" (19mm) of a horizontal datum at any other time throughout the fabrication
and assembly.
As part of the fabrication procedure, CONTRACTOR shall submit upon request by SNEPCO the
following:
a. Location of support points.
b. Fabrication support point details, including foundations.
c. Soil capacity reports, including soil boring, geotechnical analysis performed by a qualified
geotechnical engineer and any foundation (i.e., pile or mat) load test.
d. Engineering design calculations showing adequacy of supports and foundation.
e. Anticipated vertical deflections under support points during the course of the fabrication.
f. System for ensuring and maintaining levelness of support system.
g. Preliminary sequence of support removal prior to loadout.
3.3.4 Fabrication Aids
a. Fabrication aids are any members used to aid fabrication that are not detailed on AFC
DRAWINGS. Such members include temporary erection braces, sling stops, scaffolding
supports, padeyes, dogs, walkways, etc.
b. The location of fabrication aids in zone I shall be APPROVED.
c. Fabrication aids required for lifts shall be shown on the shop drawings or detailed in the
fabrication procedure.
d. Zone 1 temporary welds shall not be closer to a structural weld than 2" (50mm).
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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e. Fabrication aids shall be welded using welding procedures APPROVED for the base metals
being welded. Fabrication aids shall be of material shown on AFC DRAWINGS or selected
from AWS Group I and Group II materials.
f. Fabrication aids shall be removed unless approved by SNEPCO. Fabrication aids shall be
mapped if not removed.
g. Removal of fabrication aids in zone 1 shall be performed by cutting no closer than 1/8"
(3mm) to the structure and grinding flush and smooth with the base metal. Removal of
fabrication aids in zones 2 and 3 shall be performed by cutting " (6mm) from the structure
and grinding the cut end of the fabrication aid smooth enough for coating. "Washing off" of
temporary aids with an oxyfuel torch shall not be permitted. Areas where the removal of
aids occurred shall be accepted by visual examination. Zone 1 areas shall also be examined
by magnetic particle examination.
3.3.5 Temporary Access Openings
a. The location of temporary access openings not shown on AFC DRAWINGS shall be
submitted.
b. Access openings shall have a minimum 6" (150mm) radius at the corners and shall be welded
from two sides wherever practicable. Where a single sided weld is required to close the
access hole, backing bars shall be tack welded to the weld bevel face, not the inside surface
of the member. Access openings shall be examined 100% with UT or RT.
3.3.6 Lifts, Roll-ups or Movement of Major Subassemblies
A movement procedure, for lifting, rolling up or other movement of major subassemblies
(elements with calculated weights of 250 short tons (225 metric tons) or more) shall be submitted
to SNEPCO. The procedure shall include:
a. Calculated weight and center of gravity (C.O.G.) of subassembly (including basis, i.e.,
computer model, hand take off, etc.).
b. Details of any temporary members or supports required (fabrication aids).
c. Location of lifting and/or movement attachments, sling arrangements and calculated loads.
d. Lifting/movement equipment capacities.
e. Support reactions, if applicable.
f. Summary of subassembly and fabrication aid stresses at representative sequence points
throughout the lift/movement.
g. Maximum deformations at sequence points.
h. Calculations verifying that the lift points, support points and/or movement points are locally
adequate for the loads.
i. Sensitivity of results to weight, C.O.G. and other assumptions used.
j. Step-by-step description of planned action.
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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If requested, CONTRACTOR shall provide SNEPCO with detailed computer output,
supporting hand calculations and load certificates of lifting/movement equipment .
A movement summary report shall be submitted containing:
a. Recorded weight.
b. Summary of actual events.
c. Other items of significance.
d. Load certificates of lifting/movement equipment.
3.4 Forming
3.4.1 Cold Forming of Plates
Steel plates listed in AFC DRAWINGS may be cold formed. Forming strains shall be less than or
equal to the maximum forming strain qualified during welding procedure qualification testing.
Determination of percent strain for rolled tubulars shall be taken as 100*t/(D-t), where t is the
thickness and D is the outside diameter.
3.4.2 Warm Forming of Plates
A warm forming procedure shall be submitted for Approval for all forming procedures where
plastic deformation occurs below 400F.
Forming steel in the range between 400F (204C) and 800F (427C) shall be prohibited.
Warm forming of normalized and hot-rolled steels shall be performed between 800F (427C) and
1200F (649C). Warm forming of quenched and tempered steels shall be performed between
800F (427C) and 50F (28C) below the final tempering temperature. TMCP steel shall not be
warm formed. Testing for conformance to the material specification shall be required for each
warm-formed plate after forming. Where welds are included in the formed material, all tests
required for the PQT shall also be performed on warm formed material and meet the required
properties.
3.4.3 Heat Shrink Forming
Heat shrink forming shall be performed to the requirements of paragraph 3.6.
3.5 Post Weld Heat Treatment (PWHT)
When specified, the requirements for PWHT can be found in Appendix A3.5.
3.6 Straightening
3.6.1 Approval
Members distorted by welding may be straightened by mechanical means or by using a heat
straightening procedure providing APPROVAL is obtained for each type of welding distortion to
be corrected.
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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3.6.2 Heat Straightening Procedure
CONTRACTOR shall submit a heat straightening procedure.
a. Monitoring
For CRITICAL STEEL and SPECIAL STEEL, heat straightening should be monitored full
time and the temperature and duration of heating recorded.
b. Temperature
The temperature of heated areas shall not exceed the temperature recommended by the
material manufacturer, but in no case shall it exceed 1100F (593C) for Q&T or TMCP
steels, nor 1200F (649C) for other steels.
3.7 Test Fitting Field Installed Components
CONTRACTOR shall test-fit after fabrication is complete, all field installed components (removable
handrails, deck panels, etc.) to ensure that they will fit and serve the intended purpose.
CONTRACTOR shall prepare a tagging system that uniquely identifies each test-fit component.
Components shall be identified with APPROVED durable tags securely attached to the component.
CONTRACTOR shall submit a drawing showing the identification and location of each test-fit
component.
CONTRACTOR shall give SNEPCO at least 24 hours notice of any tests. Test fits shall be witnessed by
SNEPCO.
3.8 Hold Points
Backgouging of CRITICAL STEELS in Zone 1 shall be a hold point. Other locations of hold points are
indicated on AFC DRAWINGS. No work may proceed past a designated hold point without
ACCEPTANCE.
4.0 Tolerances/Dimension Control
4.1 Dimensional Control Procedure
a. CONTRACTOR shall submit a dimensional control procedure. The procedure shall include the
method(s) for obtaining field measurements and their conversion into specified tolerances and
controlled dimensions.
b. Tolerances for the welding, fabrication, and assembly are specified on AFC DRAWINGS and in this
section.
c. Dimensions and tolerances of major components and structures shall be corrected to a standard
temperature of 68F (20C) .
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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4.2 Survey Transmittal Requirements
4.2.1 Dimensions During Fabrication
CONTRACTOR shall submit a dimensional inspection report which includes dimensions of the
major structural components, levelness and support locations.
4.2.2 Final Surveys
CONTRACTOR shall submit a final survey report. The surveys shall be performed after all major
structural welding is complete and after levelling. Surveys shall be witnessed by SNEPCO. The
following shall be included:
a. Three dimensional coordinates of hull/topsides interface points.
b. Support points for modules and equipment not installed by CONTRACTOR.
c. Other dimensions controlled by AFC DRAWINGS and these SPECIFICATIONS.
4.3 Miscellaneous
a. Where no installation tolerances are given for SNEPCO furnished items, CONTRACTOR shall
request tolerances from SNEPCO prior to the installation of the item.
b. Other overall structural tolerances not otherwise specified shall be within " (13mm) of the
dimensions shown on AFC DRAWINGS.
4.4 Drifting Requirements
After welding is complete, CONTRACTOR shall drift all members designated on AFC DRAWINGS to
verify the specified fabrication tolerances. The drift constructed by the CONTRACTOR shall be a
minimum of 1 (300mm) in length. Drift sizes shall be submitted and final tests shall be witnessed by
SNEPCO.
5.0 Tank Testing
NOT REQUIRED.
6.0 Weight Control
6.1 General
The weighing operation shall be performed with strain gauge load cells and an electronic digital indicator
with an accuracy of 1% it. The load cells shall be provided with a rotating cap having spherical seating
to allow alignment with bearing points on the component being weighed. Strain gauge load cells shall be
loaded no more than 90% of their capacity.
Level readings shall be taken to confirm that the levelness is within the tolerances specified in Paragraph
3.3.3. The jacking system shall be designed for 1.5 times the expected load.
Zero readings for the load cells shall be established just prior to load application and checked again when
the load is removed. If load cells cannot be read simultaneously, a minimum of three independent sets of
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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readings are to be obtained with total weights that agree within 1%. The load cells shall be moved 90
between readings.
The load cells shall be calibrated with any equipment used during the weighing operation prior to their
first use. CONTRACTOR shall notify SNEPCO seven days prior to calibration, in order that SNEPCO
may witness the calibration. The load cells and equipment shall be calibrated using equipment with
traceability to a national standard. Calibration documents shall be submitted.
6.2 Procedure
CONTRACTOR shall submit a weighing procedure. The procedure shall include:
a. Method of lifting and weighing subassemblies.
c. Description of measuring, recording and lifting equipment with calibration documentation.
d. Sketches of weighing platforms used to lift the subassembly and apply the load to the load cells.
The design of the foundation and supports should incorporate the need to weigh the
subassemblies.
e. Arrangements of load cells and jacks.
f. Load application sequence.
6.3 Subassemblies to be Weighed
a. CONTRACTOR shall weigh each topsides module prior to loadout.
b. CONTRACTOR shall weigh each skid estimated to weigh over 100 tons.
c. CONTRACTOR shall weigh modules that approach project lift capacities at intervals to be
determined by SNEPCO.
6.4 Weight Measurement Report
A weight measurement report shall be submitted following the weighing operations. The report shall
include; measured weight based on the average of the readings, tabulations of load cell readings, location
and arrangement of load cells and jacks, calculation of center of gravity, and marked up drawings
showing what material and equipment we're included in the subassembly.
The weight measurement report shall also include a listing of equipment (permanent or temporary) and
any construction items (eg. scaffolding, padeyes) included in the weight measurement.
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
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TABLE 1.4
DOCUMENTS REQUIRING SUBMITTAL
DOCUMENT SNEPCO ACTION REFERENCE
Material Control Proc. APPROVE 2.2
Material Repair Proc. APPROVE 2.3.1
Fabrication Procedures APPROVE 3.3.1
Fabrication Aid Location APPROVE 3.3.4
Temporary Access Opening APPROVE 3.3.5a
Movement Procedure REVIEW 3.3.6
Movement Report REVIEW 3.3.6
Warm Forming Procedure APPROVE 3.4.2
Straightening Procedure APPROVE 3.6.1
Identification and Location of
Test-Fit Items
APPROVE 3.7
Dim. Control Procedure APPROVE 4.1a
Dim. Inspection Reports ACCEPT 4.2.1
Final Dimensional Survey APPROVE 4.2.2
Drift Sizes APPROVE 4.4
Weighing Procedure APPROVE 6.2
Weight Report ACCEPT 6.4
PWHT Procedure APPROVE A3.5.2
A3.5.11
PWHT Charts and Record
Expansion Analysis
REVIEW
APPROVE
A3.5.4
A3.5.11d
Localized Heat Treatment APPROVE A3.5.11
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
R:\Bonga\Clerical\Specs\Structural\BongaST006d(Fab Topsides).doc Page 16 of 18
APPENDIX A3.5
POST WELD HEAT TREATMENT
A3.5.1 Method
PWHT shall be performed in a furnace wherever practicable. The use of local heating shall require
APPROVAL on a case-by-case basis.
Heat treatment of an assembly shall be in one operation. Each assembly shall be independently supported
to minimize distortion. Supports should permit free access to the heating media.
A3.5.2 PWHT Procedure
CONTRACTOR shall submit a PWHT procedure. The procedure shall describe the heating arrangement,
temperature measurement details, thermocouple attachment and locations, heating and cooling rates,
holding time and temperatures and other relevant details.
A3.5.3 Temperature Measurement
Sufficient thermocouples shall be attached to each component to record the temperatures of the thickest and
thinnest cross sections and the anticipated maximum and minimum steel temperature locations based on
furnace surveys.
A3.5.4 Temperature Recording Charts
The furnace temperature and thermocouple readings shall be recorded on an automatic recording
instrument.
Following heat treatment, the time/temperature charts shall be marked with a clear identification of traces,
components being heated, the furnace, procedure, operator and date, and shall be submitted.
A3.5.5 Heating and Cooling
Components shall not be loaded into a furnace when the furnace temperature is greater than 550F (288C).
Above 550F (288C), the rate of heating (in F (C) per hour) shall not exceed a figure equal to 330F
(183C) divided by the maximum steel thickness in the component measured in inches, but in no case at a
rate greater than 400F (222C) per hour. Controlled heating at a rate less than 200F (111C) per hour is
not required.
Above 550F (288C) , cooling shall be conducted in the furnace or a cooling chamber at a rate not greater
than 330F (183C) per hour divided by the maximum steel thickness of the component in inches (25mm),
but in no case at a rate greater than 400F (222C) per hour. Below 550F (288C) , the component may be
cooled in still air at an uncontrolled rate.
A3.5.6 Holding
Components fabricated from normalized steels requiring PWHT shall be held at 1150F 30F (620C
17C) for one hour per inch (25mm) of thickness.
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
R:\Bonga\Clerical\Specs\Structural\BongaST006d(Fab Topsides).doc Page 17 of 18
Components fabricated from TMCP steels, or a combination of TMCP and other steels, requiring PWRT
shall be held at a temperature recommended by the steel manufacturer, but in no case higher than 1100F
(593C), for one hour per inch (25mm) of thickness.
A3.5.7 Temperature Distribution
During the heating period there shall not be a greater variation in temperature throughout the portion of the
component being heat treated than 300F (1661C) within any is foot (4.6m) interval of length, or 100F
(56C) between inside and outside surfaces. At the holding temperature, the temperature throughout the
portion of the component being heat treated shall be within the range specified.
A3.5.8 Preparation
Grease, oil and other contaminants that may alter the surface chemistry of the steel when exposed to
elevated temperatures shall be removed from the surface prior to placement in the furnace.
A3.5.9 Furnace Design
Furnaces of the recirculating, indirect fired, direct fired or muffle design are acceptable provided
compliance with all provisions of this section can be demonstrated.
Air, combusted liquids and gases or protective atmospheres are acceptable for heating provided the medium
does not result in carburization or excessive scaling of the metal surfaces.
Furnace shall be designed to prevent direct contact of flame with the surface of the component. Flame
deflectors shall be employed when exposure of the component or any load support is in question.
A sufficient number of temperature indicating devices shall be employed to assure control of temperature in
all working zones of the furnace.
A3.5.10 Furnace Surveys and Calibrations
a. Initial Survey
An initial temperature survey shall be conducted at the temperatures proposed for thermal treatments
before use of a furnace. At least nine test points shall be monitored, one in each corner and one at the
center of the working chamber with at least one test location for each 700 ft
3
(20m
3
) of furnace
volume. The furnace shall be stabilized before commencement of the survey and temperatures for
each point shall be recorded thereafter at 10 minute intervals for a period not less than thirty minutes to
ensure stability of operation. At equilibrium conditions, the maximum temperature variation between
any test points shall not exceed 75F (42C) and no recorded temperature shall be outside the specified
range.
b. Subsequent Surveys
A survey shall be conducted every 6 months or after any alteration of furnace design, position,
placement, heat source configuration or instrumentation which could affect temperature uniformity.
c. Instrumentation
The furnace temperature control instrumentation shall not be employed to determine the temperature of
the survey test points. Independent potentiometer equipment or multiple channel recording equipment
Shell Deepwater Development Systems, Inc.
Doc. No. Bonga-SPEC-ST-006
Bonga Project Revision D
Fabrication of Topsides Structural Date 15-Sept-99
R:\Bonga\Clerical\Specs\Structural\BongaST006d(Fab Topsides).doc Page 18 of 18
shall have been calibrated to be within 2F (lC) of a standard which is certified or traceable to a
nationally recognized source.
A3.5.11 Localized Heat Treatment
When PWHT is not possible for an entire component in a furnace, a detailed procedure shall be submitted.
Localized PWHT shall require APPROVAL on a case-by-case basis. The following requirements shall be
met:
a. Heating and Temperature Control
Sufficient thermocouples shall be placed to record temperature gradients through thickness on the weld
faces, between section thickness changes and at the half peak temperature zone. Thermocouples
attached below heating bands shall be checked to ensure that the metal temperature is accurately
represented.
The component may be heated internally if fully encased with thermal insulating material.
b. Partial Furnace Heat Treatments
The component may be heat treated in sections in an enclosed furnace, providing theoverlap is at
least:
(1) For round tubulars, 60" (1.5m) or 5* (Rt)
1/2
, whichever is the greater, where R is the internal
radius and t is the steel thickness.
(2) For all other components, 60" (1.5m).
The portion outside the furnace shall be insulated so that the distance between the peak and half peak
temperature of the longitudinal temperature gradient is not less than half of the overlap.
c. Circumferential Seams
Circumferential Seams in tubular components may be PWHT locally by a heated band around the
entire circumference. The width of the heated band shall not be less than 5*(Rt)
1/2
, the weld being in
the center. The heated band shall be insulated to ensure that the temperature at the edge of the band is
not less than half the peak temperature.
d. In Situ, Highly Restrained and Closing Welds
Prior to PWHT of components already assembled or otherwise highly restrained, a detailed analysis
evaluating thermal expansion strains and member stresses shall be submitted.