DEP 31.40.21.34-Gen.pdf

TECHNICAL SPECIFICATION CARBON AND LOW ALLOY STEEL PIPELINE FLANGES FOR USE IN OIL AND GAS OPERATIONS (AMENDMENTS/SUPPLEMENTS TO MSS SP-44) DEP 31.40.21.34-Gen. July 1998 (DEP Circular 61/99 has been incorporated) DESIGN AND ENGINEERING PRACTICE This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell International Oil Products B.V. and Shell International Exploration and Production B.V., The Hague, The Netherlands. The copyright of this document is vested in these companies. All rights reserved. Neither the whole nor any part of this document may be reproduced, 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 owners. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, 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 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 to 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 standardization. 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 sufficiently 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 engineering 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, without 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 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 relevant 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 - 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) suffered 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 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 shall 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 for 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 Standard 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 and DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DEP 31.40.21.34-Gen. July 1998 Page 2 TABLE OF CONTENTS PART IINTRODUCTION.4 1.1SCOPE 4 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS4 1.3DEFINITIONS 4 1.4ABBREVIATIONS5 1.5CROSS-REFERENCES5 1.6GUIDANCE FOR USE.5 1.7INFORMATION TO BE SUPPLIED BY THE PRINCIPAL.6 PART IIAMENDMENTS/SUPPLEMENTS TO MSS SP-44.7 SECTION 1 SCOPE 8 1.1GENERAL 8 1.3QUALITY SYSTEM8 SECTION 3 MATERIALS 9 SECTION 4 HEAT TREATMENT12 SECTION 5 FLANGE DESIGN.13 5.4WELDING END.13 5.9DESIGN CONDITIONS.13 5.10INTERNAL DIAMETER.13 5.11SWIVEL RING FLANGES.13 SECTION 6 MARKING 14 6.3TEMPORARY PRESERVATION.14 SECTION 9 FLANGE BOLTING DIMENSIONS.15 SECTION 10TOLERANCES16 SECTION 11INSPECTION.17 11.1VISUAL INSPECTION.17 11.2NON-DESTRUCTIVE TESTING.17 11.3ACCEPTANCE CRITERIA17 11.4REPAIR OF DEFECTS17 11.5DIMENSIONAL CONTROL.17 SECTION 12DOCUMENTATION TO BE PROVIDED BY THE MANUFACTURER.18 12.1LANGUAGE. 18 12.2PRE-MANUFACTURING DOCUMENTATION.18 12.3CERTIFICATION.18 12.4RETENTION OF RECORDS.18 PART IIIREFERENCES22 DEP 31.40.21.34-Gen. July 1998 Page 3 PART IINTRODUCTION 1.1SCOPE This new DEP specifies requirements and gives recommendations for the manufacture and supply of carbon steel and low alloy pipeline flanges. Part II of this DEP gives amendments and supplements to clauses of MSS SP-44 which are considered necessary to ensure pipeline integrity. This DEP is applicable to flanges for use in both sour and non-sour service. NOTE:Sour service is defined in DEP 31.22.20.31-Gen. In addition to the flange types included in MSS SP-44, swivel ring flanges and anchor flanges are also covered by this DEP. Bolting and gaskets are excluded from the scope of this DEP. 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIOP and SIEP, the distribution of this DEP is confined to companies forming part of the Royal Dutch/Shell Group or managed by a Group company, and to Contractors and Manufacturers/Suppliers nominated by them (i.e. the distribution code is “F“, as described in DEP 00.00.05.05-Gen.). This DEP specifies the minimum technical requirements for flanges to be used in the construction or maintenance of oil and/or gas pipelines and related facilities. It is intended for use in exploration and production facilities, transmission pipelines and, where applicable, oil refineries, chemical plants and supply/marketing installations If national and/or local regulations exist in which some 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 Contractor 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 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, construction, commissioning or management of a project, or operation or maintenance of a facility. The Principal may undertake all or part of the 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 generally 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. The word should indicates a recommendation. 1.3.2Specific definitions BevelReplaces the term “welding end” as used in MSS SP-44 Defect (in NDT)A discontinuity or group of discontinuities whose DEP 31.40.21.34-Gen. July 1998 Page 4 indication(s) do not meet specified acceptance criteria. Flaw/discontinuity (inAn interruption, which may be either intentional NDT)or unintentional, in the physical structure or configuration of a pipe. Indication (in NDT)Evidence of a discontinuity that requires interpretation to determine its significance. Minimum designThe minimum temperature to which the pipeline temperatureor section of pipeline may be exposed during normal operational activities, including start-up and shut-down operations and controlled blowdown, but excluding abnormal situations such as pipeline ruptures. Sample productFlange selected for inspection and/or testing Test unitThe number of flanges to be accepted or rejected together, on the basis of the tests carried out on sample products Test welding ringSample of tubular material from the forging required for use in welding procedure and welder approval testing. UserTerm used in MSS SP-44 which shall be taken to mean the Principal. 1.4ABBREVIATIONS CECarbon equivalent IDNominal internal diameter MTMagnetic particle testing NDTNon-destructive testing UTUltrasonic testing WPARWelding procedure approval record WPSWelding procedure specification 1.5CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced in this DEP are listed in (Part III). 1.6GUIDANCE FOR USE The amendments to MSS SP-44 given in Part II are directly related to equivalent sections in MSS SP-44. For clarity, the section and paragraph numbering of MSS SP-44 has been used as far as possible. Where clauses in MSS SP-44 are referenced within this DEP, it shall mean those clauses as amended by this DEP. Clauses in MSS SP-44 that are not amended by this DEP shall remain valid as written. 1.7INFORMATION TO BE SUPPLIED BY THE PRINCIPAL The following information shall be supplied by the Principal to the Manufacturer at the enquiry stage: -the type of flange; DEP 31.40.21.34-Gen. July 1998 Page 5 -the type of flange face; -ID of flange; -class (pressure and temperature rating); -the grade of flange material; -service: sour or non-sour; -minimum design temperature; -pipeline hydrotest pressure if in excess of 1.5 times the pressure rating for the class specified; -grade, ID and wall thickness of adjoining pipe; -type of ISO 10474 inspection certificate, or inspection report, required. The Principal shall also supply the following supplementary information, where applicable, to the Manufacturer at the enquiry stage of the order: -number and dimensions of test welding rings required for test welding; -grade of temporary preservation compound required; -whether flange design calculations are subject to the agreement of the Principal prior to manufacture; -whether previous test data can be considered for approving manufacture; -whether testing is required in the simulated stress-relieved condition; -the number of sample products to be tested per test unit; -whether the Manufacturer is required to submit a quality plan for agreement by the Principal prior to manufacture; -whether the Principal intends to witness any of the Manufacturer's production and quality control operations; -whether the chemical composition of the Manufacturers proposed flanges is subject to the agreement of the Principal prior to manufacture; -whether specific quality assurance/control procedures of the Manufacturer shall be agreed by the Principal prior to manufacture; -whether alternative bevel dimensions are required; -thepipelinedesign,testand/oroperatingconditions,togetherwiththeload combinations e.g. internal pressure bearing loads plus bending moments, for which the flange design shall be verified by the Manufacturer; -support details (for anchor flanges only). DEP 31.40.21.34-Gen. July 1998 Page 6 PART II AMENDMENTS/SUPPLEMENTS TO MSS SP-44 DEP 31.40.21.34-Gen. July 1998 Page 7 SECTION 1 SCOPE 1.1GENERAL Add the following: Blind flanges for sour service shall be manufactured from forged steel. Add new subsection: 1.3QUALITY SYSTEM The Manufacturer/Supplier should maintain and operate a quality system in accordance with ISO 9001, ISO 9002, or similar alternative standard agreed by the Principal. DEP 31.40.21.34-Gen. July 1998 Page 8 SECTION 3 MATERIALS 3.1.2Add the following: The steel used shall be suitable for welding to line pipe manufactured in accordance with DEP 31.40.20.30-Gen or DEP 31.40.20.31-Gen. (as applicable), and to fitting materials manufactured in accordance with DEP 31.40.21.30-Gen. 3.1.3Replace this section (including 3.1.3.1) with the following: The chemical composition of the flanges, as determined by product analysis, shall comply with the following limits: ElementMaximum permittedNotes content, wt% C0.23 Mn1.605 Si0.45 P0.0255 S0.010 V0.081 Nb0.051 Ti0.031 Cr0.202 Mo0.202 Ni0.352 Cu0.402 Al0.053 N0.0123 B0.0005 CE sour0.434 CE non-sour0.454 NOTES:1.V+Nb+Ti shall not exceed 0.15%. 2.Cr+Mo+Ni+Cu shall not exceed 0.6%. 3.The total Al: N ratio shall not be less than 2:1. 4.CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15. 5.For sour service Mn shall be 25T-20 T is the minimum design temperature, which shall be specified by the Principal. If no minimum design temperature is indicated, the test temperature shall be 0 °C. For approval testing, specimen location and orientation shall be as shown in (Figures A, B, and C). Tangential s