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WELCOME TO QA/QC PRESENTATION

ON NORSOK STANDARD

10/10/2014

1
DICIPLINES

• STRUCTURAL
• PIPING
• COATING
• EICT
• CDB

2
NORSOK STANDARDS

 Developed by Norwegian Petroleum Industry

 To ensure adequate safety, value adding & cost effectiveness for petroleum industry
development & operations.

 To provide the Norwegian industry input to the international standard process

3
NORSOK standards

Applicable NORSOK standards for structural fabrication


 M-001, “Materials selection”.
 M-101, “Structural Steel Fabrication”
 M-102, “Structural Aluminum Fabrication”
 M-120, “Material data sheets for structural steel”
 M-121, “Aluminum Structural material”
 M-122, “Cast structural steel”
 M-123, “Forged structural steel”
 M-501, “Surface Preparation and Protective Coating”

4
M-101 “Structural Steel Fabrication”
 Scope:

 “This standard covers the requirements for fabrication and inspection


of offshore steel structures with SMYS≤ 500MPa and with a minimum
design temperature down to -14°C. For special application steels with
SMYS up to 690 MPa may be used”.

 (Note: SMYS = Specified Minimum Yield Strength)


MPa = megapascals

5
Correlation between steel quality level, MDS number &
steel grade/designations

6
Correlation between steel quality level, MDS number &
steel grade/designations

7
NORSOK Standard M120
Material data sheets for structural steel

8
WPQR – Range of approval
( Welding Procedure Qualification Record )
For welding of steels in all strength classes

1. 0.02Pcm and 0.03 CEV are allowed more than the qualified
procedure.

2. A change in groove angle more than +20deg./-10deg. From the


qualified PQRs

3. CTOD testing shall be included in plate thickness more than


50mm

9
Welder & Welding Operators Qualifications

1. For Tack welders an internal test may be used – EN 287-1

2. Welders to be qualified on the lowest groove angle of production


weld.

(Welders shall be qualified as per EN287-1 spec.)

10
Welding /Visual Inspector & NDE Operators Qualifications

1. Welding Inspectors Shall be qualified to IWI

2. Welding Coordinators shall be qualified to IWE

3. VT/PT/MT/UT/RT operators /Interpreters shall be qualified to


ISO9712

11
FABRICATION AND WELDING REQUIREMENTS

All welding work shall be according to recommendations given in relevant


part of EN 1011.
The manufacturer shall have an implemented & documented quality
system according with ISO 3834-2.
The fabricator shall apply a weld numbering system for
identification on all shop drawings & as reference in all
documentation.

12
Forming
 Cold forming (i.e. below 250°C)
 For steel quality level I and II, the deformation limit without
documentation of mechanical properties is 5%.

If percentage of strain is more than 5%, then either heat treatment shall be performed, or strain ageing tests
shall be carried out according to the procedure in the next slide.

13
Assembly
In tubular joints, unless otherwise shown on design drawings, longitudinal weld
joints should be placed with minimum distance of 75mm (or) minimum 2 times
chord thickness, as shown in the figure below.

14
Assembly

In tubular joints, unless otherwise shown on design drawings, circumferential weld joints,
minimum distance between the welds should be as shown in the figure below.

15
Tapering

Tapering - shall be done as per engineering Drawing.


If not specified – tapering 1:4

16
Seal / Blind

o Crevices and areas which become inaccessible after fabrication or


assembly - shall be sealed off from the outside atmosphere. Seal weld
throat - min 3mm thick. The above condition is not applicable for hot
dip galvanized hollow sections

Temporary cut-outs

o As per Drawing, Corner radius min 100mm.


It shall be closed by refitting the same or an equivalent plate & welding,
inspection, documentation respectively.

17
Fabrication Control

Straightening - Steel manufacturer recommendation, but shall not exceed 600° C

Doubler plates - All attachments in the splash zone shall be attached to the structure
by using doubler plate.

Preparation for coating - All edges shall be rounded to 2mm radius

Fit-ups - Permanent backing strips - Not accepted

Buttering in excess of 20mm (Maximum per joint) - Not accepted

Tack weld shall normally have a length of Min.100MM For thickness less

equal to 25mm, tack length may be min. 4Xplate thickness

18
Preheating & PWHT Control

 Preheating- Preheating for more than 50Deg⁰C should be achieved by electric heating
elements.
 Attachments
• Temporary attachments shall be cut minimum 3 mm from the base metal and ground.
• The ground area shall be visually examined and magnetic particle/ penetrant tested.
 Post weld heat treatment (PWHT)
• Required for structural welds
a) Steel quality level I or II,
b) Quality level III with Re >400 MPa, for nominal thickness > 50 mm.
Unless welding procedure qualified with (CTOD) fracture toughness.
• PWHT shall be carried out in accordance with a procedure.
• The temperature difference between different parts of the structure during soaking time shall not
exceed 30⁰C within the heated area.
• Double sided heating shall be used as far as possible.

19
PRODUCTION TESTS
• Production tests shall be selected on weldments in critical
regions to verify that the specified requirements have been
meet. Minimum one test coupon is required from each
applied welding process.
• Test coupons shall be welded in a manner which realistically
simulates the actual production welding, normally as
extension of the production weld, and meet the requirements
for welding procedure approval tests.
• CTOD testing is not required for production testing.
• If a production test fails, the reason for the failure shall be
determined and remedial action implemented.

20
NON-DESTRUCTIVE TESTING (NDT)
Final Inspection and NDT
• Final inspection and NDT of structural steel welds
- Only after 48 hours after completion except where
PWHT is required.
• The time delay may be reduced to 24 hours
- for steel grades with SMYS <=355MPa,
- for steel grades with SMYS <= 420MPa for plate
thicknesses < 40 mm.

• For PWHT: The final NDT shall be carried out when all heat
treatment have been completed.

21
Monitoring & Control of Defect Rate

Weekly defect rate OR repeated occurrence of planar defects in inspection category B, C & D need to be
monitored & triggered in two levels.
• Trigger level 1
If a defect rate for any method exceeds 10 % per Week
- Then 100% inspection should be carried out for all welds in question, irrelevant of the required
inspection category for the welds.
• Trigger level 2
If a defect rate for any method of inspection is between 5 - 10 % per Week,
- Then NDT should be extended in two steps.
• Step 1.
• A defect rate for any NDT method exceeding 5 % (1% for MT) for a single week
- Doubling of the extent of NDT according to the inspection category.
- Spot extent shall be increased to 20%.
Step 2.
• If the defect rate for the extended testing under Step 1 > 5 %
- Increased to 100 % for all welds in question.
• The increased NDT extent
- shall cover welds of the same inspection categories,
- welded in the same period of time when the high defect rate was produced

22
Control of Defect Rate

• Unless the causes for defects found leads to immediate and


documented preventive actions, the higher level of extent of NDT
shall be maintained until the weekly defect rate is well below 5 %.

• If the defect rate approaches 10 % during any stage in production


welding, further welding should be held until investigations are
completed and corrective actions implemented.
• The defect rate is defined as :
(Defect length x 100%) / Length of tested parts of welds
• Note :
1) “Tested part of welds” means the part that is tested with the
same NDT method.
2) NDT after repair shall not be included when calculating the
defect rate.

23
Table shown Extent of NDT for Structural

24
Extent of visual examination and NDT
• Ultrasonic testing to reveal the presence of possible weld metal transverse cracking shall be included for
butt welds with thickness > 25 mm.
• The testing shall be performed on minimum 5% of welds in inspection category A and B for SAW (12) and
FCAW (131 and 136)
• Determination of inspection categories for joints subjected to static & fatigue loads, As per N001, Table 4.

25
Extent of visual examination and NDT requirement

• During the initial fabrication the extent of UT and MT of inspection category B and C welds shall be
intensified, normally to twice the level given in table 9.1.

• In addition table 9.1, the following shall apply for inspection category A & B:

a) One film at each end for longitudinal welds of tubular (including tubular for nodes and stubs).

b) Where radiographic testing is required, intersection welds, and those locations where presence of
defects is deemed to be most harmful, shall be tested.

c) Ultrasonic and radiographic testing shall not overlap, except when 100% UT is specified.

However, ambiguous imperfections revealed by UT shall in addition be tested by RT.

d) Ultrasonic testing is normally not applicable for thicknesses less than 10 mm. For such
thicknesses, UT may be replaced with RT. In general, RT should be considered if UT is not
possible. Radiographic testing is normally not applicable for thicknesses above 40 mm.

e) MT shall be performed on both external and internal surface as accessible or as required by the
designer.

26
Structural steel welds.
Visual & MT-acceptance criteria for structural steel welds

• Structural steel welds. Visual and MT-acceptance criteria for structural steel weld

27
Repair and re-repair welding

 Before repair welding, the defect shall be completely removed.

 The excavated area shall have smooth transitions to the metal surface and allow good access for
both NDT after excavation & subsequent repair welding.
After excavation, complete removal of the defect shall be confirmed by MT or PT. PWHT shall be
performed after repair if specified for the original weld.

 The excavated groove shall be minimum 50 mm long, measured at defect depth even if the defect
itself is smaller.

 Defects spaced less than 100 mm shall be repaired as one continuous defect.

 After repair welding the complete weld (i.e. the repaired area plus at least 100 mm on each side)
shall be subjected at least to the same NDT as specified for the original weld.

 Repair welding may only be carried out twice in the same area.

 After Repair, Inspection & NDT of structural steel welds shall not be carried out before 48 hours
after completion except where PWHT is required. The time delay may be reduced to 24 hours for
steel grades with SMYS of 355MPa or lower, and for steel grades with SMYS of 420MPa or lower for
plate thicknesses below 40 mm.

28
Correction of welds containing defects.
• All repairs shall be carried out in accordance with established procedures.

• Welds containing cracks shall not be repaired, until the reason for the cracking
has been determined. If necessary, the defective part of the weld shall be cut
out for further examination. Crater cracks may be repaired by grinding followed
by NDT & subsequent repair welding according to an accepted repair welding
procedure.

• Other defects shall be corrected by grinding, repair welding or re-welding.

• When weld defects are removed by grinding only, the final weld surface & the
transition to the base material shall be smooth. Removal of defects shall be
verified by local visual inspection, aided by applicable NDT methods. If
applicable, the remaining thickness in the ground area shall be measured.
Repair welding is required if the remaining thickness is less than that specified.

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ANY QUESTION ?
THANK YOU

31
Applicable NORSOK Piping Standards

 M-601, Edition 5, Welding & inspection of piping.

 M630 Rev 4, Material data sheets

 M650 Qualification of manufacturer of special materials.

 NORSOK L-001 Piping fabrication installation, flushing & testing

The intention of this standard is to provide additional requirement regarding welding & Inspection of piping systems
designed to ASME B31.3 for hydrocarbon production & process systems & supporting utility systems

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Welding Requirements M-601

General

 All welding & related activities shall comply with the requirements of ISO 3834-2 & additional
requirements of this NORSOK standard.

 The root pass of welds in stainless steels Type 6Mo, Type 25Cr duplex & Ni-alloys for
seawater service shall be made with filler metal.

 A non-slag producing welding process shall be used for the root pass on all single sided
welds in all stainless steels, nickel based & titanium based alloys carbon steel

 For welding of high-alloyed austenitic stainless steels with PREN ≥ 40 (e.g. UNS S32654
& UNS S34565) the requirements given to stainless steel Type 6Mo herein shall apply.

Drawings for fabrication


 The shop drawings shall contain:

 Material type/grade and grouping number (ISO/TR 15608),


 Dimension (outside diameter and wall thickness),
 PWHT requirement.
33
Control of Welding Process

Inter pass temperature


o The inter pass temperature shall be measured on the band 75mm/3T for pre heat on
both sides of the joint. The minimum inter pass temperature shall not be less than
the specified preheat temperature as per approved WPS & max’ inter pass
temperature shall not be more than below.
 250°C for carbon steels
 150°C for stainless steels & nickel base alloys

Backing and shielding gas


o Back Purging gas shall be used for welding of all stainless steel & non-ferrous
materials ( SDSS,DSS,6Mo), & shall be maintained during welding of minimum the
o first three passes
o The same requirement applies for tack welding.
o Purging & trailing gas for welding of titanium & its alloys shall be argon, helium or a
mixture of the two, & shall be maintained through out duration until the joint is fully
welded. The trailing gas shields shall make the weld & adjacent base material cooled
down to 400°C before the are leaving the weld.
o Any supports or pads etc attachments shall be welded with purging for
SDSS,DSS,6Mo & also with trailing gas for titanium.
o Discolorisation shall be continuously checked /monitored.
34
Welding Profile & Production Test

Welding of O-lets
 The weld bevel of O-lets shall be completely filled up to weld line on the O-lets.

 Smooth transition between the pipe & the O-lets is required.

 Notches on the weld joint & toes shall be avoided.

 Prior to welding, sufficient root gap & miss match shall be ensured as per WPS.

Production test
 Production tests shall be taken when specified. ( per each weld process )

 Each production test shall be tested and documented as for the relevant welding
procedure qualification test unless otherwise agreed. 35
Inspection & Non Destructive Testing (NDT)

General

 Implementation a system for recording of weld defect rates. The


defect rates shall be recorded on a weekly basis for VT, MT, PT, UT,
RT & PMI for each production area (geographically split in production
areas at the same yard) & shall be reported together with the
accumulated defect rate.

 Cracks & defects in any NDT method require documented


investigation/ action by the responsible welding engineer.

36
PED & NDT Groups

37
Extent of Non-Destructive Testing

38
Acceptance Criteria

Acceptance Criteria for NDTs Group

 The defect acceptance level shall be in accordance


with ASME B31.3, Chapter VI, Normal Fluid Service,
& Chapter IX, High Pressure Service, for pipe
classes with rating above class 2500 psi, unless
more severe requirements are specified on the
piping class sheet.

39
Acceptance Criteria For Others NDT Group

 For surface testing (MT/PT) the acceptance criteria shall be in accordance


with ASME Section VIII, Appendix 6 and Appendix 8, respectively.

 Weld zones in stainless steels, nickel & titanium alloys shall be visually
examined on the inside & outside & fulfill the following criteria or alternatively
evaluated as acceptable in accordance with pictures included in Annex B:

 The oxidation levels showing light brown to brown color are acceptable;

 Oxidation levels showing a narrow band of dark brown color & intermittent
spots of blue color are acceptable;

 Darker or more extensive oxidation colors are not acceptable, & shall be
chemically or mechanically removed. For titanium the weld shall be cut out &
re-welded.

40
Positive Material Identification (PMI)

 PMI shall be performed on ready installed piping systems in stainless steel materials
& Ni-alloy based materials prior to any pressure testing or coating operation.

 SS Type 6Mo,22/25Cr duplex & 3.5%Ni base metal & welds – 100%

 316 SS Base material & welds - 10%

 The testing shall be uniformly distributed to cover the different type of components,
manufacturer, pre-fabrication sites & installation sites.

 For piping systems in stainless steel & Ni-base alloys carrying seawater & systems
with MDT below minus 50 °C, the extent of PMI shall be increased to 100 %.

 Any non-conformance in material type is reported, the extent shall be increased to


ensure that all mix of material is discovered.

41
Acceptance Criteria-Visual Inspection, Magnetic Particle
& Penetrant Testing

42
Extent of Acceptance Criteria-Visual Inspection, Magnetic Particle
& Penetrant Testing

43
Figure shows Acceptance Criteria-Visual Inspection,

Magnetic Particle & Penetrant Testing

44
Acceptable Oxidations Of Welds In Stainless Steels

45
Acceptable Oxidations Of Welds In Stainless Steels

46
Weld Inspection Control

General

 Storage & handling of material & welding consumables

 Equipment: use, registration, maintenance, calibration & documentation

 Routines for certification, registration, confirmation of validity & prolongation of


welders qualifications, approval by a third party organization recognized by an EC
member (as relevant)

 Registration, confirmation of validity & prolongation of NDT personnel certificates &


approved by a third party organization recognized by an EC member (as relevant)

 Job-package: Only approved drawings, latest revision & specifications are used.
Welding numbering system & identification/traceability.

47
Checkpoints Before Welding

 Drawing
 • Material, marking/coding/traceability & handling
 • Beveling/cutting, groove preparation, fit up and staggering of adjacent longitudinal welds (
by greater of the 2t or 50mm )
 • Welding equipment & use: tools, welding machine etc. (check of calibration/maintenance
to be confirmed by stickers)
 • Preheating & protection against wind, rain etc., if necessary
 • Purging gas, if necessary (type & flow-rate is set/applied as per WPS)
 • Procedure for tack-welding. Tack-welding (parameter control)
 • Correct welding consumables are drawn from the stores through indent slips.
 • Equipment/tools accommodated as required by the type of material
 • Renovation/cleaning, ready for welding

48
Checkpoints During Welding

 Treatment of material & welding consumables


 Welding equipment & use: tools, welding machine etc. (check of
calibration/maintenance)
 Preheating, method & temperature
 Inter pass temperature & protection against wind, rain etc., if necessary
 Purging gas, trailing-gas if necessary (& having independent connection for each welder from the
source to job)
 Welders approval for the welding work/ joint.
 Welding performance (placing of run layer, welding direction & sequence, staggering
of stop/start, cleaning between layers)
 WPS on work place available for the welder & check of various parameter listed in
WPS & measuring/calculating heat input (arc energy)
 Visual inspection during welding & before leaving the place after the joint is
completed (self control / checks) done by the welder

49
Checkpoints After Welding

 Weld joints Marking/traceability


 Are welder identification & WPS number marked closed to weld (matrix box)
 Is the used WPS & welder qualification (welding certificate) relevant for the welded
joint?
 Check of “self inspection” done by the welder
 Check of weld geometry/size welding symbol on drawing/ & applicable WPS
 Check of weld surface, transition area & area close to the weld
 Oxidation levels (discolorisation of the weld joint)
 Performing & documentation of PWHT, if necessary
 Extent of NDT, NDT operator qualifications, reporting & documentation
 Marking, cleaning, flushing, preservation, protection of flange/fittings etc.
 Documentation review (weld summary list)

50
Fabrication Of Pipework NORSOK L004

General requirements
Prefabricated pipe spools shall be cleaned, painted.
 All tools shall be restricted to the relevant material group to avoid rust contamination and
shall be marked to avoid mixing of tools for different materials. Different grades of stainless
steel materials can be handled with the same tools.
 Separate tools shall be used for titanium materials.

Butt welds for orifice runs


When the design of an orifice run necessitates welds, these shall be ground smooth and
flush with the inside surface of the pipe & documented . Pipe-tap connections where
required, shall be drilled through the pipe wall & be smooth inside.

Screwed pipe work


All threading shall be carried-out after bending, forging or heat treatment but where this
is not possible, suitable thread protection must be provided.

51
Colour code on
Weld finish colour
Clamps

Colour code on Colour code on


52
Consumable Tools
Dimensional Tolerances For
Prefabricated Piping Assemblies NORSOK L-004

53
54
Dimensional Tolerances For Flanges

55
Other Fabrication Requirement

Branch connections and outlets

 All welded branch connections shall be jointed to the header with full penetration welds.
 Stub-in connections shall be set-on type. Set-in type is not acceptable.
 Reinforcement pads or saddles required by specifications & drawings shall be of the same material as the
main pipe
 Branch reinforcement pads or each segment thereof shall be provided with a minimum 3.0mm drilled &
tapped hole prior to fitting to the pipe, pad should be made in one piece before fitting onto pipe.

Pipe coupling

 Seal faces of mechanical couplings/hubs & flanges shall be protected during fabrication & storage.
 Where possible couplings/hubs shall be protected by fitting & hand tightening the complete coupling
assembly.

56
Equipment/ Flange Connections Alignment

Strain sensitive equipment with flange connections :

 All equipment shall be blanked, either by pressure test blanks, spades or blinds, to stop the ingress of internal pipe
debris.
 Flanges connecting to strain sensitive mechanical equipment (e.g. pumps, compressors, turbines, etc.) shall be fitted-
up in close parallel & lateral alignment prior to tightening the bolting. Unacceptable forces transferred on to the
nozzles shall be prevented.

57
Gaskets & Bolting Requirement During/After Erection

Gaskets

 Gaskets shall be replaced after opening or dismantling of flange connections


 RTJ gaskets are to be lightly smeared on the mating surface with a propriety anti-friction lubricant prior to
fitting between the flange grooves. Anti-friction lubricant, compatible with the flange material & process fluid
shall be used.

Bolting

 Manually pulled flange bolts & stud bolts shall extend fully through their nuts with minimum one, maximum
five threads.
 Hydraulic bolt tightening shall be used on all bolts greater than 1" diameter.
 Nuts & bolts shall have their grade marks visible after installation. Stud bolts cut from long lengths of studding
shall have material grade stamped on end of each cut.
 To archive the required bolt tension lubrication is important, all flange bolts, stud bolts threads as well as nut
spot faces shall be thoroughly lubricated prior to fitting.

58
Support & Global Tolerance During Installation Piping Spool

Pipe support

 Where spring support are installed the spring shall locked gagged until commissioning/start up.
 Pipes shall not normally be supported by other pipes, i.e. individual supporting is required.
 Vent holes in wear plates & trunnion are generally not required. However, when the wear plate or trunnion
covers a circumferential weld that has not been pressure tested, a vent hole is required for leak detection.

Global tolerances, installation

Hook-up termination points shall be within ±25 mm in all directions. Over length may be provided where required.
 Installation tolerances of piping components shall be as required by the individual service of the piping component
including requirements for
 Maintenance access,
 Position relative to surrounding steelwork, equipment, cable tray & heating, ventilation & air conditioning (HVAC) duct
routings,
 Positioning of pipe supports relative to the structural steel,
 Pipe stress

59
Pipework Flushing & Hydro Test

Hydro flushing

 Minimum pressure shall be 600 bar.


 Below 4”, High Velocity Water Flushing (HVWF) may be used. Water velocity shall be a minimum of 100
Lit/min to 150 Lit/min.
 The flushing medium shall in general be fresh water. When flushing stainless steel lines, the chloride ion
content shall be less than 50 ppm.
 Ball valves shall be flushed fully open.

Pneumatic flushing

 Where water is not desirable in the piping system (e.g. instrument/utility air), flushing by pressurized air or
PAS shall be carried out. When pressurized air is used, the minimum velocity shall be 35m/s.

Pressure Test

 The test pressure shall, unless otherwise specified, be in accordance with ASME B31.3. The test pressure
shall be calculated based on the maximum design pressure of the piping class (not the design pressure of the
individual line) at 20 ºC.

 The following are excluded from pressure tests:


o All small bore instrument control piping downstream of the first piping block valve.
o Open drains and vents to atmosphere (leak test only). 60
Hydro Test Preparation

Test preparation

 Pressure, temperature & time recorders shall be used for all hydrostatic tests. The pressure shall be shown in
barg.
 Minimum of one gauge shall be positioned at the highest point & one recorder to be positioned at the lowest
point.
 Accuracy of pressure gauge shall be at least 1-2% at full scale & 1-2% for the recorder.
 The test pressure shall be within 60% of the gauge range (20% from top & 20% from bottom).
 If there is a deviation of more than 2% between gauge & recorder during test, the test shall be stopped & the
equipment recalibrated.
 Piping joints & welds shall not be insulated or physically covered until satisfactory completion of testing in
accordance with this specification, All joints may be primed & painted prior to pressure testing.
 Ball, plug, slab gate valves & other valves where the cavity pressure may differ from the bore pressure, shall
be pressure tested in the half open position. All other valves shall be tested in the fully open position. When
check valves are included in pressure test they shall be jacked open or have their internals removed
 Where the test pressure to be applied to the piping is greater than the maximum allowable test pressure for
valves, the valves shall be blinded off on the side to be tested, or removed & replaced by dummy spools.

61
Pneumatic Testing

Pneumatic testing requirement

The sequence of test pressuring installed systems shall be as follows:

 A pressure of 0.5 barg shall be introduced in the system & a leak test to performed.

 The pressure shall gradually be increased to 50% of the specified test pressure & kept for minimum 10
minutes to equalize strain.

 The pressure shall then be increased in steps of 10% of the specified test pressure, until the specified test
pressure is reached.

 At each step, the pressure shall be kept for 10 minutes minimum to equalize strain.

 The specified test pressure shall be kept for 1 hour. The pressure shall than be reduced to the design
pressure before examining for leakage.

62
Drying & Cleanliness after test

After completion of test

 Blowing by dry air or Pressurized Air Shock Blowing to remove any trapped water to be performed.

 If more than 3 months to commissioning, drying shall be followed by preservation with nitrogen to keep the
pipe system completely dry & to avoid condense.

Verification of cleanliness

 All systems shall be internal visual inspected for acceptable cleanliness by spot check.

 Internal visual inspection includes the use of Boroscopic, video etc.

 If pipe configuration in critical parts of systems as defined in table 1, annex B is too complicated for visual
inspection, the PAS (Periodic acid-Schiff) method or other suitable methods shall be used for verification of
cleanliness.

63
CHEMICAL CLEANING

 A procedure shall describe in detail the steps for chemical cleaning.


 Chemical cleaning shall include:
 Degassing.
 Chemical cleaning/descaling.
 Neutralization.
 Passivation.
 Water flushing.
 Drying.
 Maximum temperatures used during these operations shall not exceed maximum design temperature for the
systems as listed in the Line Index.
 The following items shall not be chemically cleaned (items shall be identified on chemical cleaning ISO):
 All instrument tubing downstream the first piping block valve.
 Piping systems with copper alloy materials.
 Flexible hoses.
 Vessels.
 Exchangers.
 Pumps.
 All bolted/screwed valves and instruments.
 If more than 3 months to start up of commissioning activities, system shall be preserved with nitrogen.
Overpressure shall be 0.5 bar.

64
HOT OIL FLUSHING

General

 A detailed procedure for hot oil flushing shall be developed out prior to start.
 Filters used for hot oil flushing shall be:
 3μm ABS for hydraulic systems.
 <= 10μm ABS for lube and seal oil.

 Filling of lubricant oil shall take place through filters with 10μm ABS.
 Flushing & sampling to verify cleanness shall take place at turbulent flow, upstream any filters. The Reynolds
number shall be min. 4000.
 The level of cleanness shall be documented from an automatic particle counter or a membrane checked in a
microscope before a flushing operation is considered finalized.
 A flow meter shall be installed to verify flow used during flushing operation.
 Maximum water content in oil used for flushing shall be less than 500ppm.

Marking

 Piping spools or systems that have been chemical cleaned or hot oil flushed shall be marked in a unique
manner.

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Tightness Testing

 A tightness test (sensitive leak test) can be performed to check that all external (e.g. mechanical joints, stuffing box)
and internal (closed valves) potential leakage points meet the maximum leakage requirements. The tightness test is
performed during commissioning phase, after all construction work is finished & mechanical completion is achieved.
 The leak test shall be performed with a suitable test medium. The test medium can be divided into the following four
types:
 • Type 1 medium: N2He (1 % He)
 • Type 2 medium: N2
 • Type 3 medium: Air
 • Type 4 medium: Medium with equal or lower viscosity than actual service medium
 The different test medium shall be used in connection with the following services:
 Type 1 medium: All services containing toxic or flammable gases or volatile liquids, including first valve connecting
utility systems. Both external & internal leakage points to be checked.
 Type 2 medium: Utility systems containing gas where O2 present in the system is not acceptable. Only external leakage
points to be checked.
 Type 3 medium: Utility systems containing gas where O2 present in the system is acceptable. Only external leakage
points to be checked.
 Type 4 medium: All other services not falling into category type 1, 2 or 3 medium. Only external leakage points to be
checked.

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System Colour Coding Of Piping
Purpose
The purpose of having a system for colour coding of piping is to ensure quick recognition of medium & flow direction for any
system.
Types of markers
Adhesive band/plastic tape glued to the pipe surface
Shall be used inside living quarters/ administration/ service buildings (HVAC-controlled areas).
Laminated plastic signs
Shall be used on all painted carbon steel piping & on insulated piping
Laminated plastic signs, mounted in aluminum or stainless steel frame brackets
 Shall be used on all pipes of stainless & hiqh-alloyed materials,
 On all pipes with a surface operating temperature of more than 60 °C,
 On all pipes of OD 76,2 mm (3 in) and below & all tubing of OD 25 mm & below.

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Positioning Of Markers

 Markers shall be installed with the arrow pointing in the direction of flow. The following special application rules shall
be followed:

 Markers shall be positioned specially considering operational aspects of the plant& shall be easily readable from deck,
platform or ordinary access way. Ladders, scaffolding or other temporary equipment shall not be needed for
identification of markers;

 Markers shall be placed at each branching point;

 Markers shall be placed on each side of bulkheads, decks & other penetration points;

 Markers shall be positioned on the pipe close to major components of the actual system (vessel, pumps etc.);

 Maximum spacing between markers shall not exceed 10 m;

 Marker shall be positioned by inlet & outlet of process train;

 On elevated pipes, markers shall be positioned adjacent to stairways & platforms;

 Markers shall be positioned at start & end of pipe racks.


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Valve Marking

 Each valve (spade, spacer, spectacle blind, inline item and removable special items) shall carry a minimum of one
identification tag plate (number plate) in addition to makers tag.

 The number plate shall be of stainless steel on which the tag number shall be permanently printed.

 Minimum plate size shall be 20 mm x 50 mm with capital letters of height minimum 5 mm. The tags shall be fastened
close to the valve, not onto the valve. This to ensure the tag in position even if the valve is removed or dismantled

69
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71
NORSOK STANDARD M-501
Surface Preparation & Protective Coating

The NORSOK standards cover both paints, metallic coatings & application of spray-on passive fire
protective coatings.

The aim of the NORSOK standards is to obtain a coating system, which ensures

 optimal protection of the installation with a minimum need for maintenance

 that the coating system is maintenance friendly

 that the coating system is application friendly

 that health, safety and environmental impacts are evaluated and documented

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Health, Safety & Environment

 The following documentation shall be provided & used when evaluating coating systems

 Chemical name of organic solvent, OAR number according to Norwegian regulations, & VOC content in
g/l.

 % of low molecular epoxy (molecular weight < 700).

 Content of hazardous substances, see NORSOK S-002.

 Specification of hazardous thermal degradation components.

 Combustibility.

 Special handling precaution & personal protection.

 Content of quartz & heavy metals in blast cleaning media shall be given.
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Thermally Spray Metallic Coatings

Coating materials:

- Aluminium: Type AL 99.5 of DIN 8566-2 or equivalent.


- Aluminium alloy: Aluminium alloy with 5% Mg, DIN 8566-2 AlMg 5 or equivalent
- Zinc or alloys of zinc.

• The coating shall be firmly adherent and the surface shall be uniform, free of lumps, loosely adherent
spattered metal, bubbles, ash formation, defects and uncoated spots.

74
Thermally Spray Metallic Coatings

Thermal Spray Equipment & Application

75
Thermally Spray Metallic Coatings

Thermal Spray Aluminum Application and Finish

76
Sprayed on Passive Fire Protection

Application of passive fire protective coating shall be in accordance with the recommendations given by the
manufacturer of the material.

Thickness of coating to checked after curing & before topcoat by drilling holes or ultrasonic techniques.

The surface finish shall conform to the reference sample prepared during CPT & manufacturer application
guide.

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Sprayed on Passive Fire Protection

Equipment, Application and DFTs

78
NORSOK requirement for Surface Preparation
& Protective Coating Personnel

Qualification of supervisors, foremen & QC personnel

Personnel carrying out inspection or verification shall be qualified in accordance with NS 476 Inspector level
III, or certified as NACE coating inspector level III.

Inspectors according to NS 476 Inspector level II, may carry out the inspection work under the supervision of
an inspector level III.

Supervisors and foremen shall be qualified to tradesman level and should be qualified in accordance with NS
476 Inspector level II, or NACE level II.

Supervisors, foremen or QC personnel involved in application of passive fire protection shall in addition, be
trained & certified according to the procedures of the manufacturer of the passive fire protective material.

79
Inspection & Testing Standard requirement for
Surface Preparation & Protective Coating page 1

80
Inspection & Testing Standard requirement for
Surface Preparation & Protective Coating page 2

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ANY QUESTION ?
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83
NORSOK STANDARD
ELECTRICAL SYSTEMS

EICT
NORSOK
84
NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

The Norsok standards are developed by Norwegian


petroleum industry to ensure adequate safety, value adding
and cost effectiveness for petroleum industry development
and operations. Furthermore Norsok are as far as possible,
intended to replace oil company specifications serve as
reference in the authorities regulations.
The Norsok standards are normally based on recognized
international standards (IEC), adding the deemed necessary
to fill the broad needs of Norwegian petroleum industry.

85
NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

Each clause in Norsok standard refers the equivalent


clause in IEC 61892, edition 1, series of standards.
The Norsok standard contains provisions for electrical
installations at all voltage to provide safety in the design
of electrical systems, selections and use of equipment for
generation, storage, distribution and utilization of
electrical energy for all purposes in offshore units which
are being used for the purpose of exploration or
exploration of petroleum resources.
86
NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

ACT, LAWS AND


REGULATIONS

GUIDE LINE

STANDARDS & CODES

87
NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

AIM - To achieve:

 Safe environment for personnel and equipment

 Reliability of service

 Convenience of operation

 Ease of maintenance

 Maximum efficiency

 Easy addition of system components 88


NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

NORSOK E-001, Clause 4.4


MATERIALS
All equipment and should have low halogen content.
NORSOK E-001, Clause 4.12
Spare requirement for future modification
The installation should be prepared for
-main ladders, transits, interface cabinets, junction boxes
and cabling etc to meet a 10% increase.

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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

NORSOK E-001, Clause 6.6.4


Equipment requirements.
 After the commissioning period the drive should have
the capacity to run continuously for a period of at least
24 months under the specified condition without any
scheduled shutdown.
 No component of the drive system should require any
routine or preventive maintenance that needs a
shutdown of the system over any consecutive 24 months
period following initial operation.
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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

NORSOK E-001, Clause 9.1.1


Only one earth core is allowed to be connected
on each Earth Boss.
Distance between PE and IE reference points
( Earth Boss) shall be minimum 1m.

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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

NORSOK E-001, Clause 9.1.1


Earth bars shall be located in front of the
equipment and JBs to allow easy access for
usage, inspection and maintenance. All earth
bars and terminals shall be visible and possible to
be checked after termination of cables

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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

NORSOK E-001, Clause 9.2.2


Non-IS and IS instrument cables can be routed and
dressed / bundled together in the same tray / ladder
NORSOK E-001, Clause 9.2.3
 All the cables should be routed on cable tray and ladders.
 The cable ladder / tray should not be filled so the height
of the cable ladder side rail is exceeded

93
NORSOK STANDARD I-001
FIELD INSTRUMENTATION

94
NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

NORSOK E-001, Clause 9.2.4


 Once cable has been cut, a protective cap to be installed
on the cut end when being exposed to environment.
Sufficient cable length shall be provided for equipment
that needs future adjustments or where equipment has
to be dismounted for maintenance and calibration
without disconnecting the cables.

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NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

NORSOK E-001, Clause 9.2.6


 Temporary cables should not be pulled through multi
cable transits intended for permanent cables.

NORSOK E-001, Clause 9.7.2


 All emergency and safety system (such as emergency
lighting, smoke detector, MAC etc.) labels shall be RED
background with WHITE lettering.

96
NORSOK STANDARD I-001
FIELD INSTUMENTATION

NORSOK I-001, Clause 4.5


 All equipment which require maintenance or calibration
etc shall have easy access. Eg. Permanent platform or fixed
ladders.
NORSOK I-001, Clause 5.2.4
 Screen to be left floating in the field end and insulated in
shrink lug for access.

97
NORSOK STANDARD I-001
FIELD INSTRUMENTATION

NORSOK I-001, Clause 5.3.4


Due to possible problems of electromagnetic and interference
And electromagnetic compatibility, necessary precaution shall
be taken to avoid mixing low voltage signals with level 2 and
level 3 signals.

98
NORSOK STANDARD I-001
FIELD INSTRUMENTATION

NORSOK I-001, Clause 5.7.4


Qualification:
Tubing installation shall be carried out by skilled
personnel certified according to Norwegian oil & gas
association (OLF)requirement.

99
NORSOK STANDARD I-001
FIELD INSTRUMENTATION

100
NORSOK STANDARD T-001
TELECOM SYSTEMS

NORSOK T-001 Clause 5.2.2


 A separate room should be used for PAGA B-system

NORSOK T-001 Clause 5.4.6


 The telecommunication equipment room including
transmitter room, battery room etc. shall have 25% spare
floor capacity for installation of future new cabinets

101
NORSOK STANDARD T-001
TELECOM SYSTEMS

NORSOK T-001 Clause 5.4.6


 Cabinets, distribution frames, junction boxes, cable
trays, cables, antenna tower etc. shall have 25% spare
capacity for installation of additional equipment in the
future.

102
NORSOK STANDARD S-002
WORKING ENVIRONMENT REQUIREMENTS

NORSOK S-002 Clause 5.1.2


MEANS OF ACCESS

 All work areas shall have a layout that provides for easy and
access for operation, inspection , reading and maintenance.
 Permanent means of access shall be provided for all
equipment (JB, Motor, Valve, light, Instruments) that needs
to be accessible for operation attention during start up,
normal operation, shut down or in an emergency.

103
NORSOK STANDARD S-002
WORKING ENVIRONMENT REQUIREMENTS

NORSOK S-002 Clause 5.2.1. (prevention of musculoskeletal injuries)


Work place shall be designed such that the personnel are not exposed
to excessive work loads with risk of musculoskeletal injury.
The requirement above entail that efforts should be made to avoid.
 Excessive muscular load.
 Work with joints in extreme position.
 Work in kneeling, squatting and lying position.
 Worked in fixed or static position.
 Continuous asymmetric load on the body.
 Work long duration and of repetitive nature with hand and shoulders
or below knees.
104
NORSOK STANDARD E-001
ELECTRICAL SYSTEMS

first
Do it RIGHT at time is the most

PRODUCTIVE
approach
105
ANY QUESTION ?
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107
108
Implementation
Of Colored zones
Three Different Zones should be set up , based
on the degree of completion of the building.
GREEN ZONE: Green Zone in areas where only
the basic (Cold work) construction exists in
defined area. (After blasting & painting)
YELLOW ZONE: Yellow Zone in areas where the
building is undergoing the installation of
services within a relatively clean environment.
RED ZONE: Red Zone in areas with final
architectural finishing is taking place under
controlled environment.
109
CLEAN AND DRY BUILDING

What is Green?
1. Water Tight 2.Clean and
& Ventilation Dry
Environment

3.Commence 4.Access
out fitting control &
Defined
(Cold work)
walking path
110
CLEAN AND DRY BUILDING

What is Yellow zone?


1.Dust 2.Positive air
Control with pressure
HEPA filter

3. Air
conditioned

111
CLEAN AND DRY BUILDING

 Temporary air use to DH unit with required temperature and Relative Humidity
value in green zone

 Provide temporary air use AHU ( Air Handle unit ) with required temperature
and Relative Humidity value in yellow zone

 Maintain dust particle count in Green and Yellow zone ( particle count Min
0.3µm based on 1 CF)

 Maintain temperature and relative humidity based on contract scope.


temp- Below 30’c , RH=60% to 65 %

112
CLEAN AND DRY BUILDING

What is RED zone?

To meet INSTA
800N standard

Ceiling Wall

Furniture &
113
Fixtures Floor
Implementation
Of C&DB

114
Implementation
Of C&DB

115
ANY QUESTION ?
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117