COMPANY CONTRACTOR
Shell Iraq Petroleum Development B.V. CPP Petroleum Pipeline Bureau
INFIELD PIPELINE WORKS FOR FCP, MAJNOON OIL FIELD PROJECT (SIPD-143)
ITP For Method Statement For Pipeline Welding
Project Infield Pipeline Works for FCP, Majnoon Oil Field Project
Originating Company China Petroleum Pipeline Bureau (Iraq)
Document Title ITP For Method Statement for Pipeline Welding
Document Number FCPG-00000-CPP143-00-QA-5733-00010
Document Revision 006
Document Status IFA-Issued for Approval
Document Type QA5733-Inspection Plan
Originator/Author CPP
Security Classification Restricted
Authorizer Zhou Xiaoqiu
Issue Date 24-June-12
INFIELD PIPELINE WORKS FOR FCP MAJNOON OIL FIELD PROJECT
(SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 3 of 16
Revision History
Rev# Date of Issue
Transmittal No. Status Description Author Authoriser
000 21-Feb-12 CPP143-PIUL-2002C-0051-TX IFA-Issued for Approval CPP Zhou Xiaoqiu
001 28-Feb-12 CPP143-PIUL-2002C-0068-TX IFA-Issued for Approval CPP Zhou Xiaoqiu
002 06-Mar-12 CPP143-PIUL-2002C-0073-TX IFA-Issued for Approval CPP Zhou Xiaoqiu
003 15-Apr-12 CPP143-PIUL-2002C-0153-TX IFA-Issued for Approval CPP Zhou Xiaoqiu
004 20-Apr-12 CPP143-PIUL-2002C-0159-TX IFA-Issued for Approval CPP Zhou Xiaoqiu
005 13-May-12 CPP143-PIUL-2002C-0177-TX IFA-Issued for Approval CPP Zhou Xiaoqiu
006 24-June-12 CPP143-PIUL-2002C-0220-TX IFA-Issued for Approval CPP Zhou Xiaoqiu
Rev # Reason for Issue/Change
000 First draft issued for Approval
001 Issued for Approval(COMPANY comments incorporated)
002 Issued for Approval(COMPANY comments incorporated)
003 Issued for Approval(COMPANY comments incorporated)
004 Issued for Approval(COMPANY comments incorporated)
005 Issued for Approval(COMPANY comments incorporated)
006 Issued for Approval(Check point and WELD BOX have been revised)
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 4 of 16
Content
1. INSPECTION AND TEST PLAN..................................................................................................................... 5
2. CONSTRUCTION REPORT ......................................................................................................................... 12
INFIELD PIPELINE WORKS FOR FCP MAJNOON OIL FIELD PROJECT
(SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 5 of 16
1. INSPECTION AND TEST PLAN
INFIELD PIPELINE WORS FOR FCP, MAJNOON OIL
ITP FOR METHOD STATEMENT FOR PIPELINE WELDING
DEFINITION OF INSPECTION AND TEST PLAN SYMBOLS
H - HOLD: A point beyond which work shall not proceed without formal approval by appropriate inspectorate. Achievement of H points shall be notified to COMPANY.
W - WITNESS: A point beyond which work may proceed without formal documented approval by any of the inspectorate. Achievement of W points shall be notified to COMPANY.
S - SURVEILLANCE: A point where CONSORTIUM and others may carry out surveillance of work in progress and documentation associated on an unscheduled basis, with no notification required by any
party and without amendment to the scheduled production programme.
R - REVIEW: The documents are to be submitted to the appropriate inspectorate for review by COMPANY. Note that where a document is subject to COMPANY approval, work shall not proceed until the
COMPANYs approval is given.
C - CERTIFICATION: Specific and appropriate certification documentation is to be included in the document package.
REMARKS
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 6 of 16
INFIELD PIPELINE WORS FOR FCP, MAJNOON OIL
ITP FOR METHOD STATEMENT FOR PIPELINE WELDING
Item No.
Inspection Activity & Specific Check Point Area
Reference Document Acceptance Criteria,
Code & Standard Verifying Record
Contractor ICMT
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
General
Method statement review for final approval.
HSE Requirements for PPE and certified lifting
equipments.
Equipment Status for type range calibration earth
clamp contact point in pipe line.
Pipe inspection for pipe identification, physical and
physical damage, manufacturing stamp.
Electrode Control for class batch No.
Electrode Tracing by marking batch No against
welding
Pipe tracing by pipe no heat no and length. Transfer
the ID prior to cutting.
FCPG-00000-CPP143-00-BA-5537-00001 Method statement for pipeline welding
ISO 13847:2000 Petroleum and natural gas industries-Pipeline transportation systems-Welding of pipelines DEP 61.40.20.30-GEN Welding of pipelines and related facilities
FORM-QA-5733-00010-01
Daily Welding Report
FORM-QA-5733-00010-02
Pipe Log Book
FORM-QA-5733-00010-03
Weld Box
H
W/C
W
W/C
W/C
W
W/H
H
R
S
C/S
S
C/S
C/S
Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C Certification
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 7 of 16
INFIELD PIPELINE WORS FOR FCP, MAJNOON OIL
ITP FOR METHOD STATEMENT FOR PIPELINE WELDING
Item No.
Inspection Activity & Specific Check Point Area
Reference Document Acceptance
Criteria, Code & Standard
Verifying Record
Contractor/TPI ICMT
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Welder Qualification
Welding Procedure Status for final approval
Pre-weld preparations by bevel dimensions ,clamp
type, root gap , alignment, mismatch with in 3mm
Welding Control by weather protection like wind
shield, welding parameters as per WPS, ensure
finishing by removal of slag grind high points and file
out under cuts.
Visual Inspection for marking and good workmanship
of root, cap, profile, surface discontinuities.
Mechanical Test
NDT 100% for RT for butt welds.
Welder approval in WQT records with qualification,
status, welder certificates, and cards
FCPG-00000-CPP143-00-BA-5537-00001 Method statement for pipeline welding WPS
ISO 13847:2000 Petroleum and natural gas industries-Pipeline transportation systems-Welding of pipelines DEP 61.40.20.30-GEN Welding of pipelines and related facilities
FORM-QA-6050-0001-01 Welder Qualification Test Record
FORM-QA-6050-0001-02 WQT Visual Inspection Report FORM-QA-6050-0001-03 Welder Qualification Test Certificate
FORM-QA-5733-00010-04
NDT REQUEST FORM-BA-6070-0003-01 RT Report
H/W
H/W
H/W
H/W
H/W
H/W
C/R
H
S
S
S
S/C
S/C
S/C
Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C Certification
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 8 of 16
INFIELD PIPELINE WORS FOR FCP, MAJNOON OIL
ITP FOR METHOD STATEMENT FOR PIPELINE WELDING
Item No.
Inspection Activity & Specific Check Point Area
Reference Document
Acceptance Criteria, Code & Standard
Verifying Record
Contractor ICMT
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
Pipeline Welding
Pipe size, type and quality. Check quality of welding
product and handle, storage, oven and issue
Verifying welding procedure
Verifying welder qualification
Line up joint clean
Check line up clearance, high-low of spiral seam or/and long
seam
Check preheat temperature
Check welding environment in accordance with
requirement
Check length of Fixed welding, weld identification
Visual inspection for each pass
Ensure avoiding foreign matter into pipeline (add flange)
Job site inspection ensure ROW without any electrode
heads, etc
Transfer of heat NO. & color coding where applicable on
piping to be cut.
FCPG-00000-CPP143-00-BA-5537-00001 Method statement for pipeline welding
WPS & PQR
WQR
ISO 13847:2000 Petroleum and natural gas industries-Pipeline transportation systems-Welding of pipelines DEP 61.40.20.30-GEN Welding of pipelines and related facilities
FORM-QA-5733-00010-01
Daily Welding Report
FORM-QA-5733-00010-02
Pipe Log Book
FORM-QA-5733-00010-03
Weld Box
W/S
S/R
S/C
W
W
W
W
W
W
W
W
S
S
S
S
S
S
S
S
S
S
S
Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C Certification
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 9 of 16
INFIELD PIPELINE WORS FOR FCP, MAJNOON OIL
ITP FOR METHOD STATEMENT FOR PIPELINE WELDING
Item No.
Inspection Activity & Specific Check Point Area
Reference Document Acceptance Criteria,
Code & Standard Verifying Record
Contractor ICMT
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
Tie-in
Trench is clear of debris and water. The inside of
adjoining pipes is clear from foreign material.
Both ends of adjoining pipes are beveled as per WPS
joint design, and the surface are clean within 100mm
distance from the ends
Bell hole for Tie-in is adequate for Tie-in welding
operation, and as per specifications.
Ensure that adjoining pipes are stress free before
welding.
Offset of adjoining pipes is divided equally around the
pipes, and within specified tolerance.
Tie-in welding is performed by qualified welders with
approved WPS.
Visual inspection to the final weld is acceptable.
Tie-in weld is passed by radiographic testing.
Tie-in weld is passed by ultrasonic testing.
FCPG-00000-CPP143-00-BA-5537-00001 Method statement for pipeline welding
FCPG-00000-CPP143-
00-BA-6070-00013
Tie-In Procedure
WPS & PQR
ISO 13847:2000 Petroleum and natural gas industries-Pipeline transportation systems -Welding of pipelines DEP 61.40.20.30-GEN Welding of pipelines and related facilities FCPG-00000-CPP143-00-QA-6050-00011 RT Procedure FCPG-00000-CPP143-00-QA-6050-00012 UT Procedure
FORM-QA-5733-00010-01
Daily Welding Report
FORM-QA-5733-00010-02
Pipe Log Book
FORM-QA-5733-00010-03
Weld Box
FORM-QA-5733-00010-04
NDT REQUEST
FORM-QA-5733-00010-05
TIE-IN CHECK LIST
W
W
W/S
W
W
W/R
W
R/C
R/C
S
S
S/R
S
S
S
S/R
R
R
Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C Certification
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 10 of 16
INFIELD PIPELINE WORS FOR FCP, MAJNOON OIL
ITP FOR METHOD STATEMENT FOR PIPELINE WELDING
Item No.
Inspection Activity & Specific Check Point Area
Reference Document Acceptance Criteria,
Code & Standard Verifying Record
Contractor ICMT
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
Pipe weld repair and cut out
Pipe size, type and defects at Field Visual
inspection for each pass
Defect inspection; check the thickness after the
removal arc strikes, surface imperfections, damages
to pipe materials or fittings.
Check for the weld repair by liquid penetrate
technique
Check the cut out for min 500 mm lengths.
Dress the ground area to ensure smooth transition
with surrounding surface.
Welding as per approved WPS
Verifying welder qualification
Line up joint clean
Check preheat temperature
FCPG-00000-CPP143-00-BA-5537-00001 Method statement for pipeline welding
FCPG-00000-CPP143-00-BA-6064-00001
Pipe Weld Repair and
Cut Out Procedure
FCPG-00000-
CPP143-00-QA-6050-
00009 PT Procedure
WPS &PQR
ISO 13847:2000 Petroleum and natural gas industries-Pipeline transportation systems-Welding of pipelines DEP 61.40.20.30-GEN Welding of pipelines and related facilities
FORM-QA-5733-00010-01
Daily Welding Report
FORM-QA-5733-00006-02
Weld Repair Log
W
W
R
W
W
W/S
S/R
W
W
S/R
S/R
R
S
S
S
S
S
S
Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C Certification
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 11 of 16
INFIELD PIPELINE WORS FOR FCP, MAJNOON OIL
ITP FOR METHOD STATEMENT FOR PIPELINE WELDING
Item No.
Inspection Activity & Specific Check Point Area
Reference Document Acceptance Criteria,
Code & Standard Verifying Record
Contractor ICMT
6.0
6.1
6.2
6.3
6.4
6.5
Pipeline welding NDT
Non-destructive test inspecting technician
shall be experienced and competent with
qualification certificate.
Inspect RT films and inspection reports
Inspect MT equipment and inspection reports
Inspect PT liquid and inspection reports.
Inspect UT equipment and inspection reports.
FCPG-00000-CPP143-00-BA-5537-00001 Method statement for pipeline welding FCPG-00000-CPP143-00-QA-6050-00011 RT Procedure FCPG-00000-CPP143-00-QA-6050-00010 MT Procedure FCPG-00000-CPP143-00-QA-6050-00009 PT Procedure FCPG-00000-CPP143-00-QA-6050-00012
UT Procedure
ISO 13847:2000 Petroleum and natural gas industries-Pipeline transportation systems-Welding of pipelines DEP 61.40.20.30-GEN Welding of pipelines and related facilities
FORM-QA-6050-00011-01
RT Report
FORM-QA-6050-00010-01
MT Report
FORM-QA-6050-00009-01
PT Report
FORM-QA-6050-00012-01
UT Report
S/R
W
S/R
S/R
S/R
R
S/R
S/R
S/R
S/R
Definitions of Symbols: H - Hold Point W - Witness Point S - Surveillance R - Review C Certification
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 12 of 16
2. CONSTRUCTION REPORT NO. FORM-QA-5733-00010-01
Daily Welding Report Report No. Line No. Date: Sheet of
Pipe NO.
Heat No.
Pipe Material
Diameter (Inch)
W.T. (mm)
Joint No. WPS NO.
Fit-up
Pre-heat
()
Welders Visual Inspection
Remarks Root Hot Fill1 Fill2 Fill3 Cap
Contractor ICMT
Name
Signature
Date
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 13 of 16
NO. FORM-QA-5733-00010-02
Pipe Log Book
Pipe NO.
Heat No.
Length(m)
Diameter W.T. (mm)
Joint No.
Welding Date
WPS NO.
Welders Welding Report
No
RT Reports
Root Hot Fill1 Fill2 Fill3 Cap Date Results Report 1
No. Report 2
No.
INFIELD PIPELINE WORKS FOR FCP MAJNOON OIL FIELD PROJECT
(SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 14 of 16
NO. FORM-QA-5733-00010-03
WELD BOX
WELD NO.
WPS NO.
L R
PIPE NO.
HEAT NO.
R
H
F
C
VT
DATE
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 15 of 16
NO. FORM-QA-5733-00010-04
NDT REQUEST Report NO.: Line No.: Drawing No.: Date: Sheet: of
S.N. Weld NO. DIA X THICK WPS
NO.
REQUEST FOR Welders REMARKS
RT UT PT MT
Contractor ICMT
Name
Signature
Date
INFIELD PIPELINE WORKS FOR FCP
MAJNOON OIL FIELD PROJECT (SIPD-143)
Document No.: FCPG-00000-CPP143-00-QA-5733-00010 Page 16 of 16
NO. FORM-QA-5733-00010-05
TIE-IN CHECK LIST Report No.:
Line No.:
Date:
QC CHECK POINTS YES/NO
1. Trench is clear of debris and water.
2. The inside of adjoining pipes is clear from foreign material.
3. Both ends of adjoining pipes are beveled as per WPS joint design, and the surface are clean within 100mm distance from the ends
4. Bell hole for Tie-in is adequate for Tie-in welding operation, and as per specifications.
5. Pipes to be joined are free from any mechanical damages; pup piece length is more than 2.0 meter if used.
6. Weather conditions are suitable for tie-in welding, ambient temperature shall not be less than 10C .
7. The weld seams of the adjoining pipes are offset as per specification.
8. Ensure that adjoining pipes are stress free before welding.
9. Offset of adjoining pipes is divided equally around the pipes, and within specified tolerance.
10. Tie-in welding is performed by qualified welders with approved WPS.
11. Visual inspection to the final weldment is acceptable.
12. Tie-in weldment is passed by radiographic testing.
REMARKS
APPROVALS CONTRACTOR ICMT
Name
Signature
Date
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