eh HALFAYA PROJECT SURFACE FACILITY PHASE THREE Petrochina (Haifaya) BASIC DESIGN DOC. NO.: HFY3-GEN-CP-SP-00010 PAGE 1 OF 13 SPECIFICATION FOR INSULATING JOINT ‘A | ISSUED FOR APPROVAL | 20.06.2014 REV, DESCRIPTION DATE PREP'D cHK’D: REVD APP'DHALFAYA PROJECT SURFACE FACILITY PHASE THREE Petrochina (Halfaya) BASIC DESIGN DOC. NO.: HFY3-GEN-CP-SP-00010 PAGE 2 OF 13 CONTENT 1.0 SCOPE... 2.0 CODES, REGULATIONS AND STANDARDS. 24 General... e & & & 2.2 Codes and Standards... 2.3 Specification Annexure ... 2.4 Document Precedence. 2.8 — Specification Deviation/ Concession Control Doh RB 2.6 Quality Assurance/Qualit 3.0 MATERIALS. 4.0 DESIGN AND FABRICATION. 4.1 Mechanical 4.2 Electrical. 5.0 INSPECTION AND TEST .. 6.0 TEST CERTIFICATES... 7.0 PAINTING, MARKING AND SHIPMENT. 8.0 DOCUMENTATION 9.0 QUALITY ASSURANCe. ANNEXURE 1 OIL AND GAS COMPOSITION ANNEXURE 2. LIST OF ABBREVIATIONS...Petrochina (Halfaya) HALFAYA PROJECT SURFACE FACILITY PHASE THREE BASIC DESIGN 1.0 SCOPE DOC. NO.: HFY3-GEN-CP-SP-00010 PAGE 3 OF 13 This specification covers the minimum requirements for design, manufacture, testing and supply of insulating joints which to be installed in pipeline/ piping systems handling sour crude cil and gas. 2.0 CODES, REGULATIONS AND STANDARDS 24 General The requirements of the latest edition of the following codes, regulations and standards shall be met or exceeded, except as superseded herein. In the event of a conflict between this specification and other specifications or correspondence, the Owner shall 22 be consulted and a ruling, in writing, shall be obtained before any work is started. Codes and Standards ASME B 31.4 ASME B 31.3 ASME B 16.25 ASME Section IX ASTM A 105 ASTM A 350 ASTM A 694 ASTM A 370 API Spec 5L API 1104 MSS-SP-53 NACE MR 0175/1S015156 NACE SP 0286 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids Chemical and Process Plant Piping System Butt Welding Ends Boiler and Pressure Vessel Code Welding and Brazing Qualification Specification for Forgings, Carbon Steel for Piping ‘Components Carbon and Low-Alloy Steel Forgings, Requiring Notch Toughness Testing for Piping Components Carbon and Alloy Stee! Forgings for Pipe Flanges, Fittings, Valves, and Parts for High-Pressure Transmission Service Mechanical Testing of Steel Products Specification for Line Pipe Specification for Welding Pipeline and Related Facilities Quality Standard for Steel Castings and Forgings for Valves, Flanges and Fittings and Other Piping Components - Magnetic Particle Examination Method Methods for Sulfide Stress Cracking and Stress Corrosion Cracking Resistance in Sour Oilfield Environments The Electrical Isolation of Catholically Protected PipelinesPetrochina (Halfaya) BASIC DESIGN 23 24 25 26 HALFAYA PROJECT SURFACE FACILITY PHASE THREE IFY3-GEN-CP-SP-00010 EN 10204 Metallic Products - Type of Inspection Documents ISO 9000-8004 Quality Management and Quality Assurance Standards. PAGE 4 OF 13 Specification Annexure Annexure-1 Oil and Gas Composition Annexure -2 _List of Abbreviations Document Precedence The Contractor shall notify the Owner of any conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein Resolution and/ or interpretation precedence shall be obtained from the Owner in writing before proceeding with the design or manufacture. In case of conflict, the order of precedence shall be: 1) Equipment Data Sheet(s) 2) Equipment Narrative Specification 3). Design General Specifications and Standards 4) Industry Codes and Standards Specification Deviation’ Concession Control Any technical deviations to the Specifications and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be obtained by the Contractor only through CONCESSION REQUEST format. CONCESSION REQUESTS require Owner's review/ approval prior to implementation of the proposed changes. Technical changes implemented prior to Owner's approval are subject to rejection. Quality Assurance/Quality The Vendor shall have in effect at all mes a QA/ QC program which clearly establishes the authority and responsibility of those in charge of the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action. A copy of the Vendor's QA/ QC program shall be submitted to the Contractor with its quotation for Contractor’s review and concurrence prior to award. If Vendor's QA/ QC program and facility, where the work is to be performed, is ISO 9000 certified, then only a copy of the Vendor's ISO 9000 certificate is required. In addition, if Vendors facility is 1SO certified, Contractor's QA audit requirements will be waived in favor of ISO 9000 registrar audits, unless the Contractor's trend analysis program indicates areas of concem.Petrochina (Halfaya) eh? = HALFAYA PROJECT SURFACE FACILITY a PHASE THREE BASIC DESIGN DOC. NO.: HFY3-GEN-CP-SP-00010 | REV.:A PAGE 5 OF 13 3.0 The Vendor shall identify in purchase documents to its Sub-Vendors all applicable QA/ QC requirements imposed by the Contractor, and shall ensure compliance thereto. On request, Vendor shall provide objective evidence of its QA/ QC surveillance of its Sub- Vendor's activities. The Vendor shall submit certified reports of production tests as soon as the tests are completed satisfactorily. The Owner! Contractor reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests. The Vendor shall provide the Contractor with a copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory Owner/Contractor witness points 30 days after award but prior to the pre-inspection meeting. MATERIALS 3.1 Material for the pressure containing parts of the insulating joints shall be as indicated in the Insulating Joint Data Sheets. The Material Grade and Dimensions of the connecting line pipe shall be fully specified in the Data Sheet. The Material of the insulating joint end connections shall be suitable for and compatible with the line pipe into which the insulating joints are to be welded. Other parts shall be as per Manufacturer's standard, which shall be subject to approval by Purchaser. The materials of construction shall be suitable for the sour oil/ gas composition given in Annexure - 1 ‘Acceptable material for the pressure containing parts excluding nipples shall be ASTM A105, ASTM A350, ASTM A694, conforming to MSS-SP-75 or equivalent. Nipple material shall be the same as that of line pipe material indicated in the Insulating Joint Data Sheets and shall comply with the applicable Project Specification referred in Section 2.0 of this specification 3.2 Carbon steel used in the manufacture of insulating joints shalt be fully killed. 3.3 In addition to the requirements of the material specifications, chemical composition of each heat steel used in the manufacture shall be identical to the pipeline material as provided in project data sheet. 3.4 Each heat of steel used for the manufacture of Insulating Joint shall have carbon equivalent not exceeding 0.41 (SMLS) & 0.39 (SAW), based on check analysis, calculated as per the following formula cee c+ Mh, Cre Mos¥ . M+ Cu 6 5 5 3.5 Charpy V-notch test shall be conducted at 0°C for each heat of steel used in manufacture of pressure containing parts of insulating joints. Test procedure shall conform to ASTM A370. The Charpy impact test specimens shall be taken parallel to the axis of the fitting (ie. longitudinal specimen shall be taken). The average absorbed impact energy value of three full sized specimens of base metal, weld metal and HAZ shall be 52J and minimum impact energy value for any one specimen shall not be less than 39J. No specimen shall exhibit less than 80 percent shear area.Petrochina (Halfaya) HALFAYA PROJECT SURFACE FACILITY PHASE THREE BASIC DESIGN DOC. NO.: HFY3-GEN-CP-SP-00010 REV.: A PAGE 6 OF 13 40 44 3.6 All forgings shall be furnished either in normalized, normalized & tempered or quenched & tempered condition. 3.7 All forging if used shall control S = 0.025%, P < 0.020%. 3.8 The maximum hardness of base metal, weld metal and HAZ of all pressure containing parts shall be 248 HV10 if A105 is used, 187HB is required. Hardness test shall be carried out as per ASTM A370, for each heat of steel used, 3.9 Insulating material thickness shall be calculated by the manufacturer conforming to Section-5, NACE SP0286 requirement. Manufacturer shall submit the calculation for Owner! Contractor approval before the start of manufacturing. 3.10 The insulating material and the filler materials shall be suitable for long term ‘exposure to the transported fluid at the design pressure and temperature. DESIGN AND FABRICATION Mechanical 4.4.1 The Design Conditions of the pipeline into which the insulating joint is to be installed shall be fully specified in the Requisition and Data sheets for the insulating joints, This is to include pressure, temperature and data of the process fluid characteristics. Manufacturer shall furnish the detail load calculation for hydro test bending fatigue test for Purchaser's approval. Insulating joints shall be of integral type, fabricated by welding and with nipples on either side as shawn in Data Sheets. Bolted and threaded joints are not permitted. 4.1.2 Insulating joints shall be checked for the following two cases: Case |: Design pressure The allowable stress in this case shall be less than or equal to (f) x SMYS of the insulating joint material, where (f) is the design factor as specified in Data Sheet. Case Il: Hydrostatic test pressure The hoop stress in this case shall be less than or equal to 0.9 x SMYS (for design code 31.4). Test pressure shall be at least 1.5 times of design pressure (for design code ASME B31_3) of insulating joint material The joint shall be capable of withstanding, as a minimum, the sustained and displacement loads (axial, bending and tensional) that the line pipe is capable of. All design parameters shall be as per Insulating Joint Data Sheet. Detailed calculations shall be submitted for Purchaser approval. In case any computer software is used, the theory employed and the validation manual shall be submitted to Purchaser. 4.1.3 Insulating joints shall not restrict the pipeline bore and shall allow free passage of scraper and instrumented pigs. See also 4.1.10. 4.1.4 Insulating joint design and materials shall be capable of being vacuum tested to 1 milla.& Petrochina (Halfaya) 2, % » HALFAYA PROJECT SURFACE FACILITY © “td ri PHASE THREE BASIC DESIGN DOC. NO.: HFY3-GEN-CP-SP-00010 REV. A PAGE 7 OF 13 42 4.1.5 The joints between pipe nipple pieces and main forging shall be full penetration butt weld type. 4.1.6 Butt weld ends shall be prepared as per ASME B 16.25. However, end preparation for butt welding ends having unequal thickness with respect to connecting pipe, shall be as per ASME B.31.4 4.1.7 Insulating joints shall be principally for aboveground application. In the event that underground installation is specified, the Insulating Joint Data Sheet shall incorporate the necessary modifications. 44.8 All welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Section IX. The procedure qualification shall include hardness test for all sizes. 4.1.9 Repair welding on parent metal is not allowed. Repair of welds shall be carried out only after specific approval by Purchaser's Inspector for each repair. Repair welding shall be carried out by welders and welding procedures duly qualified as per ASME Section IX and records for each repair shall be maintained 4.1.10 The tolerances on intemal diameter and out of roundness at the ends shall be as per the applicable connected pipe specification. The internal diameter shall be at least the internal diameter of the matching pipeline 4.1.11 The internal of insulating joint including the nipple pieces shall be coated by 600 im solvent-free liquid epoxy suitable for application temperature up to 70° C. Electrical 4.2.1 The average dielectric strength of the insulating joint shall be a minimum of 15 kV. 4.2.2 Two cleats shall be provided on the nipples on either side of the insulating joint for connecting cables for measurement / shorting purposes. Cleats shall be attached to the nipple pieces by welding. 4.2.3 Spark gap shall be provided with insulating joint. The detail requirements for spark gap are as following: © IP Grade: IP65; © nominal discharge current: In (8/20 us) :100 KA; © lightning shock current: limp (10/350 xs) ; SOKA; © response time:26ns) INSPECTION AND TEST 5.1 The Manufacturer shall perform ali inspection and tests as per the requirements of this specification and the relevant codes, prior to shipment at his works. Such inspection and tests shall be, but not limited to, the following: 5.1.1 All insulating joints shall be visually inspected. 5.1.2 Dimensional checks shail be carried out as per the approved drawings.en % : * HALFAYA PROJECT SURFACE FACILITY PHASE THREE Petrochina (Halfaya) BASIC DESIGN DOC. NO.: HFY3-GEN-CP-SP-00010 [ Reva | PAGE 8 OF 13 §.1.3 Chemical composition and mechanical properties including hardness shall be checked as per relevant material standards and this specification, for each heat of steel used. 5.1.4 Non-destructive inspection of insulating joints shall be carried out as given below: + NDT of all welds shall be carried out as per Owner's QA/ QC Requirement. Extent of NDT and acceptance criteria shall as per the requirements of this specification. + All butt and repair welds of pressure containing parts shall be examined 100% by radiography. Acceptance limits shall be as per API 1104. * Welds, which in Owner's Inspector's opinion cannot be inspected by radiographic methods, shall be checked by ultrasonic or magnetic particle methods. Acceptance criteria shall be as per ASME Section Vill Appendix U and Appendix IV respectively. + All forgings shall be wet magnetic particle inspected on 100% of forged or extruded surfaces. Method and acceptance shall comply with MSS-SP-53. + The end section of the components to be welded shall be 100% radiographic tested for lamination type defects for a distance of 50 mm from the ends prior to being prepared. The presence of any discemible defects shall be cause for rejection. + All filet welds of thickness < 6 mm shall be examined 100% by Magnetic Particle Inspection and 2 6 mm shall be examined 100% by angle probe UT. Acceptance criteria for MPI and UT shall be as per ASME Sec. Vill Appendix Vi and Appendix U respectively. 5.1.5 Insulating joints shall be hydrostatically tested to a pressure as indicated in the Insulating Data Sheet in the following manner: + 5S minutes at the hydrotest pressure + Reduce to zero + Repeat above procedure twice 5.1.6 Manufacturer shall conduct both hydrostatic fatigue (combined bending) and torsional test. The test pressure shall be 80% of hydrostatic pressure test for 1 hour duration. This test shall be carried out for 5 cycles, holding for § minutes for each stage. 5.1.7 After hydrostatic test, insulating joints shall be tested with air at Skg/cm? for 10 minutes. The tightness shall be checked by immersion or with a frothing agent. No leakage will be accepted. 5.1.8 Dielectric Test + Insulating resistance of each insulating joint shall be at least 25 ©, when checked with 500 - 1000 V DC. + In addition, prior to and after hydrotesting, each insulating joint shall be tested for dielectric integrity at 5000 V AC, 50 Hz for one minute and the leakage current before and after the hydrostatic shall be equal. Testing time, voltage and leakage shall be recorded and certified. 5.2 No repairs shall be permitted to the insulating joints failed in the above-mentioned test.Peirochina (Halfaya) 1% -_ HALFAYA PROJECT SURFACE FACILITY PHASE THREE BASIC DESIGN DOC. NO.: HFY3-GEN-CP-SP-00010 REV.:A PAGE 9 OF 13 7.0 5.3 Purchaser's Inspector shall also perform stage wise inspection and witness tests at Manufacturer's Works prior to shipment. Manufacturer shall give reasonable notice of time and shall provide, without charge, reasonable access and facilities required for inspection by the Purchaser's Inspector. Inspection and tests performediwitnessed by the Purchaser's Inspector shall in no way relieve the Manufacturer's obligation to perform the required inspection and tests. TEST CERTIFICATES 6.1 Manufacturer shall submit the following certificates in accordance with EN10204 3.1 B (Class III) + Test certificates relevant to the chemical analysis and mechanical properties including hardness of the materials used for the manufacture as per relevant and this specification + Test reports on non-destructive testing. + Test certificates for hydrostatic and air tests. + Test reports of heat treatment carried out. + Test reports of electrical tests 6.2 The Certificates shall be valid only when signed by the Purchaser's inspector. Only those Joints which have been certified by the Purchaser's Inspector shall be dispatched from the Manufacturer's works. PAINTING, MARKING AND SHIPMENT After all inspection and test required have been carried out; insulating joint surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant painting. Painting including the surface preparation shall comply with Project Specification, for External Painting and Protective Coatings HFY-GEN-CP-SP- 002 Insulating joints shall be marked with indelible paint with the following data: + Manufacturer's name * Suitable for____mm diameter pipeline + End thickness in mm + Material + P.O, Number and Tag No’s. (Refer Data Sheet) Insulating joints shall be suitably protected to avoid any damage during transit. Metallic or high-impact plastic bevel protectors shall be provided for weld ends. Only those insulating joints which have been inspected and certified by Purchaser's Inspector shall be shipped.Petrochina (Halfaya) ®, « % HALFAYA PROJECT SURFACE FACILITY PHASE THREE 8.0 BASIC DESIGN DOC. NO.: HFY3-GEN-CP-SP-00010 PAGE 10 OF 13 DOCUMENTATION After placement of order, the Manufacturer shall submit, but not limited to, the following documents for Purchaser's approval + Fabrication drawings, material details and relevant calculations for pressure containing parts. + Welding, Heat Treatment, Inspection and Testing Procedures. * Quality Control Manual and Quality Control Plan. Manufacture of insulating joints shall commence only after approval of the above documents. Once approval has been given by Purchaser, any changes in design, material and method of manufacture shall be implemented only after subsequent and specific approval of the Purchaser in writing. On receipt of written approval, the Manufacturer shall submit to Purchaser all approved documents as listed in Clause 6.1 above. Prior to shipment, the Manufacturer shall submit test certificates as listed in Clause 6.0 of this specification. Documents shall be in the English language only. QUALITY ASSURANCE The Manufacturer shall operate a Quality System meeting the requirements of the relevant Part of ISO 9000. The Manufacturer shall ensure that his sub-suppliers operate a quality system meeting the specified conformance criteria to ISO 9000. The Manufacturer's quality system shall be subject to the Purchaser's approval prior to commitment to a Purchase Order, Major Sub-Suppliers shall be subject to identical approvals. The Purchaser reserves the right to conduct a Quality Audit at the Manufacturer's/ Sub-Supplier's facilities at any stage during manufacture.oe HALFAYA PROJECT SURFACE FACILITY Mar PHASE THREE eee Petrochina (Halfaya) BASIC DESIGN | DOC. NO.: HFY3-GEN-CP-SP-00010 REV. A | PAGE 11 OF 13 — ANNEXURE 1 OIL AND GAS COMPOSITION Table 1 Oil and Gas Composition Composition HF-8 Export Gas Nitrogen mold 0.97 4.01 CO; moles 2.25 1.79 Methane mor% 29.15 62.59 Ethane moW% 12.44 16.30 Propane mor. 82 at Butane mor% 2.35 1.58 n-Butane mol% 77 4.96 i-Pentane mor 3.36 0.0110 n-Pentane mol% 4.18 0.0144 HS mol% 034 0.0011 1.0 mom% 5.48 0.0087a= HALFAYA PROJECT SURFACE FACILITY PHASE THREE Petrochina (Halfaya) BASIC DESIGN DOC. NO.: HFY3-GEN-CP-SP-00010 PAGE 12 OF 13 ANNEXURE 2 LIST OF ABBREVIATIONS ‘AADL Average Annual Daily Load AC Alternating Current ANSI ‘American National Standards Institute ASME American Society of Mechanical Engineers ASTM ‘American Society for Testing and Materials API American Petroleum Institute APIRP American Petroleum institute Recommended Practices AWS ‘American Welding Society BOD Basis of Design BOF Basic Oxygen Fumace BS British Standard Bvs Block Valve Station c Carbon cE Carbon Equivalent CEN European Committee for Standardization cP Cathodic Protection cR Chromium cu Copper pe Direct Current DWIT Drop Weight Tear Tests EIA Environmental Impact Assessment EPC Engineering, Procurement and Construction ESD Emergency Shutdown FBE Fusion Bonded Epoxy FEED Front End Engineering Design HAZ Heat affected zone HDPE High Density Poly Ethylene HF-ERW High Frequency Electric Resistance Welding HMP- Hazard Management Process HSE Health Safety and Environment HV Hardness-Vickers Iso International Organization for Standardization J Joules KPH Kilometre Per Hour kv Kilo-volt LDS Leak Detection system LsBD Limit State Based Design MADL Maximum Annual Daily Load MAoP Maximum Allowable Operating PressureHALFAYA PROJECT SURFACE FACILITY MBE PHASE THREE nad eam Petrochina (Halfaya) BASIC DESIGN DOC. NO.: HFY3-GEN-CP-SP-00010 PAGE 13 OF 13 MN Manganese MO Molybdenum MPI Magnetic Particle Inspection MSL Mean Sea Level MSS Manufacturers Standardization Society Mw Molecular Weight NACE National Association for Corrosion Engineers NB Nominal Bore NDT Non Destructive Testing NFPA National Fire Prevention Association NI Nickel oD Outside Diameter Pcs Pipeline Construction Specification PE Polyethylene PFS Process Flow Scheme PO Purchase Order PQR Procedure Qualification Record PRT Pressure Reduction Terminal PSL Product Specification Level QA Quality Assurance ac Quality Control QRA Quantitative Risk Assessment ROW Right of Way RTU Remote Terminal Unit SCADA Supervisory Control and Data Acquisition SI International System of Units TRU Transformer Rectifier Unit UPS Uninterrupted Power Supply UT Ultrasonic Testing (inspection) v Vanadium WP. Work Practice WPS: Welding Procedure Specification wr Wall Thickness