p84 - Distortion Control Procedure - Topside - Al
p84 - Distortion Control Procedure - Topside - Al
2S-1415-970-S2N-003
No.:
CLIENT: SHEET:
E&P 1 of
23
JOB:
ATAPU FIELD AREA DEVELOPMENT -
AREA:
PETROBRAS P84 (P-84) -
TITLE:
FLAME STRAIGHTENING PROCEDURE - (I)
TOPSIDE SCP84
SEATRIUM ENERGY (AMERICAS) CONTRACT: 5900.0125640.23.2
INDEX OF REVISIONS
The scope of the works is defined in [1] by the Employer which reads as follows:
“The Works consist inter alia of the EPIC/turnkey delivery of a fully working, system integrated
HVDC system (2GW 525kV) according to the System Breakdown Structure (SPE.00.003-2GW).
The HVDC system shall be fully autonomous and automated operated with contractually agreed
availability, reliability, and maintainability during the defined lifetime of the GCS.”
1. HVDC Offshore Substation inclusive the jacket and all automation and auxiliary systems
2. HVDC Onshore Substation inclusive of all Civil Works (Germany only) and automation and
auxiliary systems
The Contractor is responsible for the following summary of activities as part of the Employer
requirements:
Offshore accommodation and logistics for the Contractor's Personnel and Employer's
Personnel.
Fully train and familiarize the Employer's personnel with the complete scope.
Scope of exclusions:
525kV submarine and onshore cables (connection between HVDC Onshore Substation
and HVDC Onshore Substation)
380kV cable connection from the AC side of the HVDC Onshore Substation to the existing
380kV TenneT substation”.
This document has been prepared by SEATRIUM for the turnkey installation of the TenneT
IJmuiden Ver Beta project to serve as a guideline to control and minimize distortion caused by
welding operations on structural steel members, as well as define correction of distorted
structural members that may have been caused due to cutting, welding and other handling
operation during fabrication.
This distortion control procedure also shall be used to explains the requirements for distortion
control and / or for rectification of fabricated structural component by mechanical and thermal
means.
This document shall apply to any of the works associated to the distortion control activities that
GE perform in Seatrium yard.
1.3 Assumptions
Key assumptions:
The project assumes that the project team members responsible for quality assurance and
control possess the necessary expertise and qualifications to effectively execute their roles
and responsibilities.
The project assumes that the quality management system and processes implemented will
be followed consistently by all project team members and stakeholders involved.
The project assumes that any necessary training or skill development programs required
to ensure quality standards will be conducted and completed by the project team
members.
The project assumes that the project team members are responsible to adhere to all
applicable inspections according to project quality requirements.
The project assumes that the project team members/suppliers are responsible to adhere
to all applicable codes & standards requirements according to project requirements.
If any term in this document is also defined in [2], and that definition is different to the following,
the definition from [2] shall be considered authoritative.
Employer The set of requirements that are used to define the contract
ER
Requirements between Employer and Contractor
High Voltage
HVAC Alternating Abbreviation for High Voltage Alternating Current.
Current
Health, Safety
SHE Aspects Health, Safety and Environment
and Environment
Quality
QMS Management (Called BMS “Business Management System” by GE)
System
Nonconformance
NCR -
report
Master Document
MDR -
Register
Inspection and The Inspection and Test Plan (ITP) contains a list of all
ITP
Test plan inspections and tests to be carried out.
Key Performance
KPI -
Indicator
Certifying
CA A recognized body that endorses a product.
Authority
Responsible
RWC Welding -
Coordinator
1.5 References
Project Manager is responsible for implementing this procedure within the scope of work and
ensure that this procedure is effectively followed.
Project QA/QC Manager is responsible for monitoring this procedure is being followed.
The RWC or his nominee shall be responsible to assist the Project Manager in establishing and
implementing this procedure through the project team.
The supervisor is responsible to ensure that heat straightening is carried out in accordance with
this procedure.
3. DISTORTION CONTROL
To control distortion during welding, care shall be taken by using suitable strong backs / restraint,
pre-setting / pre-bending, correct preheat as per approved Welding Procedure Specification
(WPS), proper welding sequence to balance welding heat input etc. Project Engineer / Foreman
shall liaise with RWC/Welding Engineer or his nominee for necessary welding sequence for
critical weld locations.
If distortion has occurred, corrective action shall be taken by Seatrium to maintain the component
within acceptable dimensional tolerance and shall perform relevant Non-Destructive Testing
(NDT) and maintain record for the same. Seatrium shall inform EMPLOYER for any distortion
correction to be performed and shall provide relevant documents as and when requested.
3.1 Fit-up and edge preparation
The weld configuration (including root gap) and joint preparation shall comply with
approved drawings and WPS, held by tack welds.
Temporary support such as welding Jig, flexible clamps, strong back with wedges, and
fully welded strong back could be used for jig and fixture to minimize distortion during
welding.
A temporary clamp or strong back of the same material type and grade shall be used to
hold the joint together by tack welds. Tack welds shall be carried out by the qualified
welders.
The support shall be placed at suitable location as shown in Figure 2-1, to ensure that the
joint is fully supported.
• Tack welds shall be welded with the root pass parameters as stated in applicable WPS,
and length of tack welds shall be at minimum 50mm with sufficient number of tacks to
avoid cracking.
• Fit-up shall be checked for dimensional accuracy before welding, in order to ensure
compliance with the weld shapes.
• Upon completion of welding, temporary support shall be removed, and ttemporary
attachments shall be cut minimum 3 mm from the base metal and ground. The ground
area shall be visually examined and MT/PT tested (as relevant).
Short butt welds shall be welded first before welding longitudinal butt welds (Figure 2-3a).
Longitudinal welds shall be completed before welding circumferential welds (Figure 2-3b)
Figure 2-3 (a) Butt welds in plates, (b) Longitudinal and circumferential welds in a
vessel
Butt welds and applicable NDE shall be completed, before proceeding with fillet welds
(Figure 2-4)
Figure 2-4 Welding sequence for structure with butt welds and fillet welds
Usage of back step welding technique wherever possible, (i.e.) depositing short weld
length in the opposite direction to the general progression. This technique is very effective
in distortion control both for fillet weld or butt joint weld (Figure 2-5).
Figure 2-5 Welding sequence for back step welding technique
Welding sequence for tubular TKY connection shall be as per Figure 2-8
Figure 2-8 Typical Welding Sequence of TKY Connection
Welding sequence for tubular TKY connection shall be as per Figure 2-9
4. MECHANICAL STRAIGHTENING
Fabricated members distorted by welding shall be straightened by cold pressing or cold
rolling by means of mechanical / hydraulic jacks of capacity up to 32 MT or as required.
Careful examination of deformation and weld configuration is necessary before deciding
the process and its application. The concerned foreman should measure the deformation
or misalignment and its location.
Once the correction method is finalized, gradual application of force is necessary to
correct deviation. Pressing shall never be at a concentrated point or using sharp objects.
The area of load application must be spread so that no surface damage occurs to base
metal or the weld metal. Application of load level shall be carefully evaluated to avoid
straining of material and adding of residual stresses.
Intermediate dimensional checks should be made during the straightening process.
Upon rectification, final dimensional check shall be performed.
5. THERMAL STRAIGHTENING
Components out of tolerances shall be accurately identified based on post weld
dimensional survey. Also, it is necessary to measure the amount of correction obtained at
intervals, to judge the correctness of procedure. Unacceptable areas shall be marked prior
to any heating.
Thermal correction shall be achieved by flame heating and cooling in still-air or water.
Only heating torches (no cutting torches) shall be allowed for this purpose. Heat shall only
be applied using oxy/propane heating torch with a super heating nozzle. The heating torch
should be used with a longer lance, e.g., 90cm to minimize the effects of radiated heat at
work locations.
A neutral flame shall be used and the inner cone (white) of this flame torch should be
75mm (approximately) away from the material surface. The inner cone shall never touch
the parent material.
The allowable maximum temperature that the steel should be heated shall be as per
(Appendix A). The temperature shall be monitored by using valid digital thermometer or
valid contact thermometer. Heating is to be done where every hot correction is required,
temperature shall be measured on the same side on heated surface. No stabilization of
temperature is required for to start the correction. Welds shall not be directly heated.
The ‘hot shot’ (application of flame) is normally applied to the high point of the distortion
area. The size and length of the hot shot depends on the amount of specific distortion.
Sometimes wedge like heating is necessary, especially for lateral distortion. (Refer
Appendix D, E & F for method statements).
The maximum line heating temperature for water quenching and air cooling of thermally
heated areas of steel shall be as per (Appendix B)
All corrections shall be carried out under supervision of foreman following the distortion
straightening flowchart (Appendix C).
All dimensions are to be checked after the correction and recorded as required by relevant
drawings. (Refer Appendix G & H).
The heated areas affected by thermal straightening shall be hardness tested, after cooling
down to ambient temperature. Equotip hardness tester shall be used for testing. Minimum
3 hardness readings on each affected area shall be taken, the maximum hardness limit
shall comply with DNV-OS-C401. (Refer Appendix I)
MPI shall be performed on the corrected areas to ensure that the surfaces are defect free.
The details of thermal straightening, hardness survey & MPI test results shall be attached
to visual inspection reports for record retention.
NDT on girders weld joints shall be carried out only after completion of above activity..
Rectification by hot correction shall be notified and shall be carryout under monitoring.
Thermal straightening can only be applied if approved by EMPLOYER.
6. ATTACHMENT
METHOD STATEMENT
PROJECT: IJmuiden Ver Beta MS NO:
CLIENT: TenneT REV:
Recommended sequence for Structural welding at Node plates
DESCRIPTION: +Girder web to Conical or cylindrical quarter segment joints
welding.
WELD SEQUENCE:
Engage 4(four) welders diagonally opposite at any time to carry out the welding.
5. Weld Girder web plate to the conical / cylindrical segments fillet weld joints.
Engage 4(four) welders and do the welding on either side of the webs diagonally opposite simultaneously. I f
only one web-plate to tubular two welders on either side shall be engaged.
6. Continuous monitoring along the weld progress shall be followed to notify preheat and inter pass
temperatures.
To be welded
simultaneously all
the fillets’ welds.
Topside to
complete
first.
Bottom side to be
welded after top side
weld completion.
Weld bottom
1/ 3 thickness
Prepare by:
______________________
Welding Engineer
6.5 Appendix E: Method Statement
Sequence for Rectification:
Fig: 1
Fig 2: Heating on the deck plate shall be done along the girder flange.
Fig: 2
Fig 3: Heating at Deck column to node/ star plates. Suitable heating and Jacking shall be
done.
Fig: 3
Fig 4: Heating on girder flange a way of hot shot like shape V – form
Fig: 4
Fig 5: Distortion on tubular, heating like shaped like rhombus / diamond pattern and shall carry
heating from centre towards outside of diamond.
Fig: 5
Prepared by:
(Welding Engineer)
6.7 Appendix G: Notification for Distortion
TENNET2GWProject
NotificationforCorrectionof DistortionForm
ATTN/Dept Report No.
Others: Others:
DIMENSIONAL CHECK
Repair Area Distortion before Distortion after Distortion
No. ToleranceLimit Accepted/Rejected
/AreaNo. Correction Correction Type
Note:
Performedby Checkby
Sign: Sign:
Name: Name:
Date: Date:
6.8 Appendix H: Distortion Report
TENNET2GWProject
Correctionof DistortionReport
Project
Client / Employer
Date Inspection
Drawing No.
Note:
Temperature:Max. 550℃ Acc Reject
Dimensional check after fairing Acc Reject
Visual inspection after fairing Acc Reject
Hardness check after fairing Acc Reject
MT after fairing Acc Reject