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1、TECHNICAL SPECIFICATION PRECOMMISSIONING OF PIPELINES DEP 31.40.50.30-Gen. October 1994 DESIGN AND ENGINEERING PRACTICE USED BY COMPANIES OF THE ROYAL DUTCH/SHELL GROUP This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prio
2、r written consent of Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. The copyright of this document is vested in Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. All rights reserved. Neither the whole nor any part of this document may be rep
3、roduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owner. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of pub
4、lication, of: Shell International Oil Products B.V. (SIOP) and Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They are based on the experience acquired during their involvement with the
5、design, construction, operation and maintenance of processing units and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is t
6、o set the recommended standard for good design and engineering practice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefit from sta
7、ndardization. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficien
8、tly flexible to allow individual operating companies to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design and engin
9、eering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, witho
10、ut detracting from his own responsibility, consult the Principal or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Shell Group and other companies receiving technical advice and services
11、 from SIOP, SIEP or SIC. Consequently, three categories of users of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating companies is subject in all respects to the terms and conditions of the re
12、levant Service Agreement. 2)Other parties who are authorized to use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or -
13、generally - work performed on behalf of the said users comply with the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of whatsoever nature for any damage (including injury or death) s
14、uffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these companies
15、that may issue DEPs or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs sh
16、all be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange f
17、or DEPs to be held in safe custody and SIOP or SIEP may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in SIOP. NOTE: In addition to DEP publications there are Sta
18、ndard Specifications and Draft DEPs for Development (DDDs). DDDs generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribution and use of DEPs are also applicable to Standard Specifications a
19、nd DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DEP 31.40.50.30-Gen. October 1994 Page 2 TABLE OF CONTENTS 1.INTRODUCTION.5 1.1SCOPE 5 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS5 1.3DEFINITIONS 5 1.3.1General definitions.5 1.3.2Specific definitions.6 1.
20、4ABBREVIATIONS6 1.5ACTION ITEMS. 6 1.6CROSS-REFERENCES7 2.GENERAL REQUIREMENTS.8 2.1BASIC REQUIREMENTS8 2.2PRECOMMISSIONING PLAN.8 2.3CHECKS AND COMPLIANCE9 2.4PRECOMMISSIONING RECORDS AND REPORTS.9 3.HEALTH, SAFETY AND ENVIRONMENT .10 4.EQUIPMENT.11 4.1PRESSURE RETAINING EQUIPMENT11 4.2FILTERS, PUM
21、PS AND COMPRESSORS.11 4.3TEMPORARY PIG TRAPS11 4.4WELDING OF TEMPORARY EQUIPMENT.11 4.5FLEXIBLE HOSES11 4.6ELECTRICAL INSTALLATIONS.11 4.7DIESEL ENGINES.12 4.8TEST CABIN 12 4.9INSTRUMENTATION12 5.PIGGING REQUIREMENTS.14 5.1GENERAL 14 5.2PIG SELECTION.14 5.3PLANNING PIGGING OPERATIONS.14 5.4PIG TRAIN
22、 MONITORING15 5.5DISLODGING STUCK PIGS.15 5.6PIGGING RECORDS15 6.DEWATERING16 6.1GENERAL 16 6.2DEWATERING RUNS.16 6.2.1First dewatering run.16 6.2.2Second dewatering run17 6.3DEWATERING RECORDS.17 7.FINAL CLEANING.18 7.1INTRODUCTION.18 7.2LOW VELOCITY WATER CLEANING18 7.3HIGH VELOCITY WATER CLEANING
23、.18 7.4LOW VELOCITY AIR CLEANING.18 7.5HIGH VELOCITY AIR CLEANING19 7.6FINAL CLEANING RECORDS19 8.DRYING. 20 8.1INTRODUCTION.20 8.2DRY AIR AND NITROGEN DRYING20 8.2.1General 20 8.2.2Pigging. 20 8.2.3Purging for drying20 8.2.4Purging for acceptance testing20 8.3VACUUM DRYING21 8.3.1General 21 8.3.2Pr
24、e-drying checks21 DEP 31.40.50.30-Gen. October 1994 Page 3 8.3.3Leak test(s) 21 8.3.4Pump-down 22 8.3.5Evaporation/evacuation.22 8.3.6Soak test/acceptance test.22 8.3.7Filling phase. 23 8.4DRY AIR PIGGING IN COMBINATION WITH VACUUM DRYING23 8.5GLYCOL SWABBING23 8.5.1General 23 8.5.2Glycol swabbing w
25、ith dry nitrogen.23 8.5.3Glycol swabbing with dry air24 8.6DRYING RECORDS24 9.CONDITIONING AND PRESERVATION25 9.1CONDITIONING BY INHIBITION25 9.2PRESERVATION AFTER DRYING.25 9.3CONDITIONING AND PRESERVATION RECORDS.25 10.SCOPE OF WORK CHECKLIST26 11.SUMMARY OF REQUIRED APPROVALSBY THE PRINCIPAL29 12
26、.REFERENCES30 FIGURES 31 APPENDICES APPENDIX ASTAINLESS STEEL PIPELINES36 DEP 31.40.50.30-Gen. October 1994 Page 4 1.INTRODUCTION 1.1SCOPE This new DEP gives minimumrequirements for dewatering, cleaning, drying and preservation of pipelines. These activities are termed precommissioning and may be ne
27、cessary to prevent unacceptable internal corrosion and fluid contamination during commissioning and operation of the pipeline. The requirements for preparing the precommissioning work, the health, safety and environmental precautions, and the equipment and media are also included in this DEP. This D
28、EP should be used as a technical specification to be incorporated into a precommissioning or construction contract. The Principal shall provide in the scope of work the relevant pipeline and hydrotest water data and define the activities to be performed, media to be used and other requirements as st
29、ated in this DEP. This DEP is applicable for onshore and offshore carbon steel pipelines, flowcoated and non-flowcoated, and GRE/GRP pipelines which passed the hydrostatic pressure test and are filled with the hydrotest water. Appendix A specifies the additional requirements for stainless steel pipe
30、lines and pipelines with internal stainless steel cladding. This DEP is not applicable to commissioning activities. NOTES:1)Activities requiring the introduction of fluid to be conveyed into the pipeline become part of commissioning. Relevant requirements of this DEP may be incorporated in the commi
31、ssioning procedure. 2)Methanol swabbing shall only be performed with the final product as a driving medium. 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIPM, the distribution of this DEP is confined to companies forming part of the Royal Dutch/Shell Gro
32、up or managed by a Group company, and to Contractors nominated by them (i.e. the distribution code is “ C “, as defined in DEP 00.00.05.05-Gen.). ThisDEP isintended foruseby Functions intheGroupthat areinvolved in precommissioning of pipelines. If national and/or local regulations exist in which som
33、e of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, environmental, economic and legal aspects. In all cases the Co
34、ntractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this
35、DEP as closely as possible. 1.3DEFINITIONS 1.3.1General definitions The Contractor is the party which carries out all or part of the design, engineering, procurement, installation and commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the
36、duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the project and ultimately pays for its design and construction. The Principal will gen
37、erally specify the technical requirements. The Principal may also include an agent or consultant, authorised to act for, and on behalf of, the Principal. The word shall indicates a requirement. DEP 31.40.50.30-Gen. October 1994 Page 5 The word should indicates a recommendation. 1.3.2Specific definit
38、ions block valveValve for interrupting the flow or shutting-in a section of a pipeline. A block valve is normally either fully open or fully closed. commissioningAn activity where the fluid to be transported is initially introduced into the pipeline. equipmentAll temporary fittings, piping, pumps, c
39、ompressors, pigs, materials, equipment and consumables used for precommissioning of the pipeline. fluidThe fluid(s) to be conveyed in the pipeline during operation. “golden weld“A weld which is not subject to a hydrostatic pressure test and as such must pass additional non-destructive inspection. hy
40、drostatic pressureThat part of the testing operations where the pipeline is testpressurised. The hydrostatic pressure test includes a strength test and a leak tightness test. key personnelThe personnel appointed and specially named by the Contractor to be in full charge of all precommissioning opera
41、tions to be performed. pipelineA section of a system of pipes and other components or the entire system used for the transport of fluids, between plants. A pipeline extends from pig trap to pig trap (including the pig traps), or, if no pig trap is fitted, to the first isolation valve within the plan
42、t. precommissioningA series of activities, that can include fresh water swabbing, dewatering, final cleaning and drying to prepare the pipeline internally for commissioning. precommissioning planThe Contractors plan for the preparation and execution of precommissioning activities including the equip
43、ment to be used. scope of workThe part of the contract which states the overall scope for precommissioning operations. sleeping pigPig present in the pipeline at the commencement of precommissioning. 1.4ABBREVIATIONS GRP/GREGlass-fibre Reinforced Plastics / Glass-fibre Reinforced Epoxy IDInside Diam
44、eter MAOPMaximum Allowable Operating Pressure ODOutside Diameter 1.5ACTION ITEMS An (S) in the margin indicates that the Principal is required to select the method, specify the medium, to make a decision or to give a particular specification, value or parameter. NOTE:A summary check-list of these it
45、ems to be specified in the scope of work is given in (10). Where the Principals decision is only required under certain circumstances, this is not shown by a margin marker. An (A) in the margin indicates that the Contractor is required to obtain the Principals approval for a particular action or pro
46、cedure. NOTE:It is intended that most, if not all, of these approvals would be part of the precommissioning plan DEP 31.40.50.30-Gen. October 1994 Page 6 whichisrequiredtobeapprovedbythePrincipalpriortothecommencementofthe precommissioning operations. The subjects to be part of the precommissioning
47、plan including the requirements of supervising personnel are given in (2.2). A summary listing of the required additional approvals is given in (11). It is assumed that the Contractors quality systems and procedural details will have been screened prior to contract award and that the referenced appr
48、ovals merely need finalising and/or formalising. 1.6CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced by this DEP are listed in (12). DEP 31.40.50.30-Gen. October 1994 Page 7 2.GENERAL REQUIREME
49、NTS 2.1BASIC REQUIREMENTS (S)The Contractor shall perform the precommissioning in accordance with the requirements of the scope of work and this DEP. The requirements of the scope of work shall take precedence in case of conflict(s) between the requirements this DEP and the scope of work. Precommissioning should commence either immediately after completion of the hydrostatic pressure test or immediately prior to commissioning as specified in the scope of work. (S)Precommissioning activities shall be executed in the sequence defined in the flowchart in Figure 1 unless otherwise specified in
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