150930 GF-GEN-P-PR-0512-A_MPS(DHF)

GF-GEN-P-PR-0512 Manufacturing Procedure Specification PAGE 1 OF 29

PROVISION OF SUPPLY AND DELIVERY OF LINEPIPES AND HOT INDUCTION BENDS FOR WATER INJECTION (PHASE 1) FOR PETRONAS CARIGALI IRAQ

HOLDING B.V., GARRAF OPERATIONS

CONTRACT NO.: PCIHBV/2015/P&E/963

Manufacturer Procedure Specification GF-GEN-P-PR-0512

(Bend)

PETRONAS CARIGALI IRAQ B.V

Supplier Document No. B15-033

REV DATE STATUS

PREPARED BY

CHECKED BY

REVIEWED BY

APPROVED BY

PCIHBV COMMENT

NAME & SIGN

NAME & SIGN

NAME & SIGN

NAME & SIGN □Approved / Reviewed

A 18-Sep-15 Issued for

Review/Approval

A,Muro

H.Hosoi

H.Hosoi

K.Tanahashi

□Approved with Comment

□Resubmit for Approval

□Resubmit for Review

Name Signature Title Date

The signing, countersigning or other endorsements of any drawings and documentation by PCIHBV’s Representatives, agents or employees shall neither be construed as implying the responsibility for the correctness and accuracy of such documents nor relieving the CONTRACTOR of its obligations to review all information, data, drawings, and specifications provided by PCIHBV.

Class 1

Sheet No. MPS No. Rev. No.

ContentsSheet No. (Sub total)

1. Scope ………….. 3

2. Manufacturing Process ………….. 3

3. Bend MTO ………….. 4

4. Manufacturing and Inspection Procedure of Bend 4- 1. Receiving of Mother Pipe ………….. 5 4- 2. Receiving Inspection ………….. 5 4- 3. Induction Bending ………….. 5 4- 4. Wall Thickness Inspection ………….. 6 4- 5. Dimensional Inspection before Bevelling ………….. 6 - 8 4- 6. Surface Hardness Testing ………….. 8 4- 7. Ultrasonic Testing on Bend Ends for Laminations ………….. 9 4- 8. Magnetic Particle Testing on Bend Surface ………….. 9 4- 9. Ultrasonic Testing on Longitudinal Weld Seam ………….. 9 4-10. Ultrasonic Testing on Bend Body for ………….. 9 Transverse Defects 4-11. End Preparation (End Bevelling) ………….. 9 4-12. Magnetic Particle Testing on Bevelled Face ………….. 9 4-13. Residual Magnetism Check ………….. 9 4-14. Visual Inspection ………….. 10 4-15. Dimensional Inspection after Bevelling ………….. 10 - 11 4-16. Marking ………….. 12 4-17. End Protection ………….. 12 4-18. Packing and Shipping ………….. 12

5. Mechanical Property Test on MPQT Bend 5- 1. Test Frequency ………….. 13 5- 2. Tensile Test ………….. 13 5- 3. Charpy V-Notch Impact Test ………….. 14 5- 4. Macro, Micro and Hardness Test ………….. 15 - 16

6. Documentation ………….. 17

APPENDIX-1 Measuring Method of Bend Angle ………….. 18APPENDIX-2 Measuring Method of Bend Radius ………….. 19APPENDIX-3 Ultrasonic Testing Procedure (Bend Ends) ………….. 20 - 21APPENDIX-4 Magnetic Particle Testing Procedure ………….. 22 - 24APPENDIX-5 Ultrasonic Testing Procedure ………….. 25 - 26

(Longitudinal Weld Seam)APPENDIX-6 Ultrasonic Testing Procedure ………….. 27 - 28

(Bend Body for Transverse Defects)

DAI-ICHI HIGH FREQUENCY CO., LTD. CHIBA WORKS

B15-033A

2


Para. 1 Scope This specification covers the requirements of manufacturing, inspection and testing of induction formed bends for "Garraf Water Injection" to be used by "PETRONAS Carigali Iraq Holdings BV (PCIHBV)".

Para. 2 Manufacturing Process

- MPQT Bend - - Production Bend -

Receiving of Mother Pipe Receiving of Mother Pipe

Receiving Inspection Receiving Inspection

Induction Bending Induction Bending

Wall Thickness Inspection Wall Thickness Inspection

Dimensional Inspection Dimensional Inspection before Bevelling

Surface Hardness Testing Surface Hardness Testing

Magnetic Particle Testing (Bend Surface) Ultrasonic Testing (Bend Ends)

Ultrasonic Testing (Longitudinal Weld Seam) Magnetic Particle Testing (Bend Surface)

Ultrasonic Testing (Bend Body) Ultrasonic Testing (Longitudinal Weld Seam)for Transverse defects

Ultrasonic Testing (Bend Body)Visual Inspection for Transverse defects

End Preparation (End Bevelling)

Magnetic Particle Testing (Bend Ends)

Residual Magnetism Check

Visual Inspection

Dimensional Inspection after Bevelling

Marking

End Protection

Packing and Shipping

3B15-033

A

Mechanical Property Test



Para. 3 Bend MTO

Outer Radius

Neutral axis

Inner Radius

Weld Seam

R

Figure-1

Table-1ItemNo. Q'ty

EA1 62 23 114 55 246 20

Top: 1,000mm

Bottom: 1,000mm

API 5LX65

PSL2HF-ERW

219.1


4

Wall Angle : Radius : RBend

45

B15-033A

1-1 to 1-6deg.

Grade & Unique Bend No.

(mm) (mm)(mm)

BendType Outside

Diameter

323.9

1,638.6 45273.1

17.3 1,943.4

Thickness

Nominal Nominal

219.1

15.1 1,638.6

1,314.612.8

3-1 to 3-114-1 to 4-55-1 to 5-246-1 to 6-20

12.8 1,314.62-1 to 2-2

9045

323.9 17.3 1,943.4 90

90273.1 15.1

Sheet No. MPS No.

4. Manufacturing and Inspection Procedure of Bend Rev. No.Para. Process Procedure & Tolerance4-1 Receiving of 1. Manufacturer :

Mother Pipe NIPPON STEEL & SUMITOMO METAL CORPORATION2. Material Grade, Type and Size of Mother Pipe ; 1) API 5L GR.X65 PSL2, HF-ERW, 219.1mmOD x 13.4mmWT 2) API 5L GR.X65 PSL2, HF-ERW, 273.1mmOD x 15.9mmWT 3) API 5L GR.X65 PSL2, HF-ERW, 323.9mmOD x 18.2mmWT

4-2 Receiving Inspection 1. The following items will be checked on each mother pipe. 1) Marking Items 2) Outside Diameter 3) Wall Thickness 4) Length 5) Quantity 6) Appearance

4-3 Induction Bending 1. Bending Method The pipe is clamped at the top straight tangent. The area to be bent is locally induction heated from the outside surface. The pipe is pushed forwards at a constant speed so that bending stress is concentrated at the heated zone and therefore continuously deformed to produce the desired bend.2. Heat Temperature : Maximum 1100 deg.C (± 25 deg.C)3. Heat temperature will be measured on the external surface of heating portion(i.e. outer radius, inner radius and upper neutral zone) by an optical pyrometer and/or emission type thermometer.4. Cooling Water Pressure : 0.02 - 0.25 MPa (0.2 - 2.5 kgf/cm2) ± 10%5. Bending Speed : 0.4 - 2.0 mm/sec. ± 0.04 mm/sec.6. Cooling Water Temperature : 20 ± 15 deg.C7. Induction Heating Frequency : 500 or 2000 Hz +/- 20%8. Power (Heat Input) : Aiming ± 10%9. Identification number of induction coil will be informed.

10. Any interruption to the bending process shall result in the rejection of the bend.

11. The longitudinal weld seam will be positioned on the top neutral axis (±15 deg.) of bend.

12. No girth welds shall be present in the finished bends.

A


5B15-033

Sheet No. MPS No.

4. Manufacturing and Inspection Procedure of Bend (Cont.) Rev. No.Para. Process Procedure & Tolerance4-4 Wall Thickness 1. Wall thickness will be measured by an ultrasonic thickness tester.

Inspection 2. Measuring Location A minimum of three readings (start, middle and end) shall be taken equally spaced along both the extrados and intrados.3. Minimum Wall Thickness : Refer to table-2.

Table-2

4. Frequency of Calibration : Every 4 Hours

4-5 Dimensional Inspection The following items will be inspected before bevelling.before Bevelling4-5-1. Bend Angle 1. Measuring Method : As per figure-2 and APPENDIX-1.

2. Measuring Equipment : Ruler3. Tolerance : ± 1 degree

X Y

= tan -1(Y/X) Figure-2

4-5-2. Bend Radius 1. Measuring Method : As per figure-3 and APPENDIX-22. Measuring Equipment : Square gauge and Ruler3. Tolerance : ± 1% of the specified bend radius

Actual inside bend radius

Theoretical inside bend radiusFigure-3

Nom.WT

219.1

Bend

6B15-033

mm

Nom.OD

mmWTRadius


6DR323.9 17.3 6DR 15.89

11.72273.1 15.1 13.87

6DR12.8mm

A

Minimum

Sheet No. MPS No.

4. Manufacturing and Inspection Procedure of Bend (Cont.) Rev. No.Para. Process Procedure & Tolerance4-5 4-5-3. Out-of-Plane 1. Measuring Method : As per figure-4

(Difference between centerlines of both ends.)2. Measuring Equipment : Spacer gauge, height gauge and

Caliper gauge.3. Tolerance (P) : (10 x A) / 90 mm (For bend with angle of 45 degree or smaller : Maximum 5mm)

Where ;(P) = |d1-d2|A : Bend Angle

Pd1 d2

Figure-4

4-5-4. Ovality 1. Ovality will be measured by a caliper gauge. (Bend portion) 2. Measuring Location ;

Ovality will be measured at three locations (start, middle and end of bend) in bent portion. 3. Calculation Method

Where ; ODmax : Maximum Outside Diameter (mm) ODmin : Minimum Outside Diameter (mm) ODnom : Nominal Outside Diameter (mm)4. Tolerance : Maximum 2.5%

Figure-5

B15-033A

x 100 (%)ODnom

ODmax - ODmin

7


Sheet No. MPS No.

4. Manufacturing and Inspection Procedure of Bend (Cont.) Rev. No.Para. Process Procedure & Tolerance4-5 4-5-5. Checking of 1. Inside diameter of each bend will be checked by pig gauge.

Inside Diameter 2. Size of Pig Gauge : As per figure-6 & table-3.by Gauging Pig 1) D : As per table-3.

2) Plate material : 6 mm thick minimum, Bakelite plates

Min. 6 mm

D : 95% of Nom.ID

Figure-6

Table-3Nominal Size (mm)

OD WT ID219.1 12.8 193.5 183.8

273.1 15.1 242.9 230.8

323.9 17.3 289.3 274.8

3. Acceptance Criteria : Free passage of gauge and No damage of gauge plates.

4-6 Surface Hardness 1. Equipment ; Testing Portable vickers hardness tester will be used.

2. Reading Location Three surface-hardness readings at each location shall be taken across two circumferential locations in the arc and across one circumferential location in each tangent. (As per figure-7)3. Acceptance Criteria : MPQT value +/- 30HV in the same location with maximum 300HV. (Average value of three readings on each location will be applied.)

Figure-7

A

Pig Size (mm)

8B15-033

Diameter : D


L= Nom. ID

194

Min.Length : L

95% pig gauge :

95% pig gauge : 243

95% pig gauge : 290

T

C

N N'

Sheet No. MPS No.

4. Manufacturing and Inspection Procedure of Bend (Cont.) Rev. No.Para. Process Procedure & Tolerance4-7 Ultrasonic Testing on 1. Extent of Testing ;

Bend Ends for For a distance of 50mm from ends over the full circumferenceLaminations of the bend ends except MPQT bends.

2. Method and Acceptance Criteria ; As per APPENDIX-3 of this specification.

4-8 Magnetic Particle 1. Extent of Testing ;Testing on Bend Over an arc of 90deg. both sides from the extrados on Surface external surface of bend portion and ground repaired portion


4-9 Ultrasonic Testing 1. Extent of Testing ;on Longitudinal Weld The complete weld seam in the arc and transition zonesSeam 2. Method and Acceptance Criteria ;

As per APPENDIX-5 of this specification.

4-10 Ultrasonic Testing on 1. Extent of Testing ;Bend Body for On the bend extrados from top neutral to bottom neutral Transverse Defects including weld seam to ensure the free from transverse defects.


4-11 End Preparation 1. Shape of Ends : As per figure-8.(End Bevelling)

30deg. +5/-0 deg.

Nom. WT +10% / -5%

1.6mm ± 0.8mm

Max. 9.5 deg. Nom. ID

Figure-8

4-12 Magnetic Particle 1. Extent of Testing ;Testing on Bevelled On the bevelled faces of bendFace 2. Method and Acceptance Criteria ;

As per APPENDIX-4 of this specification.

4-13 Residual Magnetism 1. Equipment : Tesla Meter or Flux Gauge (Gauss Meter)Check 2. Checking Location

Four equally spaced points on each bevelled face of bend pipe3. Acceptance Criteria : Maximum 2 mT (20 Gauss)

B15-0339


A

Sheet No. MPS No.

4. Manufacturing and Inspection Procedure of Bend (Cont.) Rev. No.Para. Process Procedure & Tolerance4-14 Visual Inspection 1. Each bend will be visually inspected on the external and internal

surface (where accessible from ends).2. Each bend will be free from nicks, dents, gouges, laminations and other detrimental surface defects.3. The wall thickness on ground area will be ultrasonic inspected and not be less than the specified minimum wall thickness.4. Ground area shall also be inspected by MT.

4-15 Dimensional Inspection The following items will be inspected after bevelling.after Bevelling4-15-1. Internal 1. The internal diameter will be measured using a caliper gauge

Diameter at at bevelled end of bend Ends 2. Tolerance : Nom. ID ± 1.6 mm

The average ID measured by a caliper gauge in 4 directions will be applied.

4-15-2. Ovality at Ends 1. Outside diameter will be measured at each bevelled ends by a caliper gauge.2. Calculation Method

Where ; ODmax : Maximum Outside Diameter (mm)ODmin : Minimum Outside Diameter (mm)ODnom : Nominal Outside Diameter (mm)

3. Tolerance : Maximum 1.5%

4-15-3. End Preparation 1. All bevel ends will be checked as per figure-8 in paragraph 4-11 of this specification.2. Measuring Equipment : Protractor and ruler.3. Acceptance Criteria : As per figure-8 in Para.4-11.

4-15-4. End 1. Measuring Method : As per figure-9. Squareness 2. Measuring Equipment : Square gauge and Taper gauge.

3. Tolerance : Maximum 3 mm

S

Figure-9

B15-03310

ODmax - ODminODnom

x 100 (%)

A


Sheet No. MPS No.

4. Manufacturing and Inspection Procedure of Bend (Cont.) Rev. No.Para. Process Procedure & Tolerance4-15 4-15-5. Center to End 1. Measuring Equipment : Measuring tape

or Tangent Center to end dimension can be replaced with tangent length Length from tangency point, marked on dimensional inspection stage

against theoretical drawing, to end of bend.2. Tolerance : ± 30 mm

Tangency point

Tangency point

Top Tangent

Bottom Tangent

Figure-10

4-15-6. Waving 1. Wave shapes blend into the pipe surface in a gradual manner with a maximum crest-to-valley depth, CVD, of 1% of the actual outside diameter, when appeared.2. The ratio of the distance between adjacent crests, L, to the CVD is a minimum of 25.

OD2 OD3 OD4

CVD

L

Figure-11

3. The waving will be blend smoothly in the pipe surface.

B15-033


Cen

ter-

to-E

nd

A

CVD =OD2+OD4

11

Center-to-End

2-OD3

Sheet No. MPS No.

4. Manufacturing and Inspection Procedure of Bend (Cont.) Rev. No.Para. Process Procedure & Tolerance4-16 Marking 1. The following items will be stencil marked on the outside surface

of both ends with white paint stencil.2. Marking Items (Top side) <Example> 1) Customer's Name PCIHBV

2) Project Name GARRAF WATER INJECTION

3) PCIHBV P.O. No. P.O.NO. XXXXXX

4) Unique Bend No. XXXXX

5) Material Grade API 5L GR.X65, PSL 2, HF-ERW

6) Size 219.1MM x 12.8MM x 6DR x 45DEG.

7) Heat No. HT *******

8) Weight (Kgs) ****** KGS

9) Manufacturer's Name DHF

10) Country of Origin MADE IN JAPAN

3. Marking Items (Bottom side) <Example> 1) Project Name GARRAF WATER INJECTION

2) Unique Bend No. XXXXX

3) Material Grade API 5L GR.X65, PSL 2, HF-ERW

4) Size 219.1MM x 12.8MM x 6DR x 45DEG.

4. Height of Letter : Minimum 15mm5. Stencil marking and daub mark area will be coated with mill varnish.6. A 50mm wide white daub will be applied on the weld center of inside surface at both ends.

4-17 End Protection 1. Steel bevel protector or end cap shall be installed on all bend ends.

4-18 Packing and Shipping 1. Bends shall be shipped in wooden skid package, unless otherwise agreed.

AB15-033


12

Sheet No. MPS No.

5. Mechanical Property Test on MPQT Bend Rev. No.Para. Process Procedure & Tolerance5-1 Test Frequency 1. Basically, minimum one procedure qualification test bend will

be produced in accordance with essential variable and maximum permissible variations required in table 1 of ISO 15590-1.2. Angle of one of these will be 90 degrees with 6DR.

5-2 Tensile Test 1. Test Method : As per API 5L2. Test Specimen : As per API 5L3. Sampling Direction and Location ; 3-1. Bent Portion

1) Outside Radius : Transverse2) Inside Radius : Transverse3) Weld metal : Transverse

3-2. Transition Zones1) Base Metal : Transverse2) Weld metal : Transverse

3-3. Tangent Portion (when heat treated) 1) Base Metal : Transverse2) Weld metal : Transverse

4. Acceptance CriteriaTable-4

5. Number of test : One specimen per sampling location.

6. Elevated-Temperature Tensile Test1) Test Method : ASTM E21 or ISO 7832) Test Specimen : Round bar specimen3) Sampling Direction: Longitudinal4) Sampling Location

1) Bend Portiona) Intrados base metal

5) Test Temperature: +83 deg.C6) YS determination : 0.2% offset7) Acceptance Criteria : Information purpose only8) Number of Test : One specimen per sampling Location


Yield Ratio Max. 0.90

B15-033

Yield Strength (MPa) 450 - 600

A

Base Metal

N/A

Tensile Strength (MPa) 535 - 760Elongation (%) As per API 5L

N/AMin. 535

N/A

Item

13

Weld Metal

Sheet No. MPS No.

5. Mechanical Property Test on MPQT Bend (Cont.) Rev. No.Para. Process Procedure & Tolerance5-3 Charpy V-Notch 1. Test Specimen : As per ASTM A370

Impact Test 2. Testing Machine : As per JIS (500 Joules: Equivalent to ISO)3. Sampling Direction : The orientation and size of the test pieces shall be transverse with the greatest possible width between 10 mm and 5 mm. If transverse test pieces with a minimum of 5 mm, are not possible, longitudinal test pieces with the greatest possible width between 10 mm and 5 mm shall be used.4. Sampling Location ; 4-1. Bend Portion

1) Outside Radius2) Inside Radius3) Weld centerline4) Weld centerline +2mm

4-2. Transition Zones1) Base Metal2) Weld centerline3) Weld centerline + 2mm

4-2. Tangent Portion (when heat treated)1) Base metal2) Weld centerline3) Weld centerline +2mm

5. Test Temperature : -10 deg.C

6. Acceptance Criteria for Transverse Test Pieces 1) For Full size specimen Table-5

NOTE) Energy reduction for sub size specimen ; As per API 5L

7. Number of test : One set (3 specimens) per sampling location.

Min.Sampling

10 x 10mm

Location Average(%)

Min.SpecimenSize

14

Absorbed Energy

B15-033

8527 20

Weld & HAZ 10 x 10mm

Average Individual


Base

(Joules) (Joules)

Shear Area

A

Min.

27 20 N/A

Sheet No. MPS No.

5. Mechanical Property Test on MPQT Bend (Cont.) Rev. No.Para. Process Procedure & Tolerance5-4 Macro, Micro & 1. Test Specimen : As per ASTM E340

Hardness Test 1) Macro Examination ; a) To be photographed with 1 time magnification. 2) Micro Examination ; a) To be photographed with 100 and 400 times magnification. (2mm from the external and internal surfaces and at a mid-wall) 3) Hardness Testing : Vickers Hardness Testing 2. Sampling Direction : Transverse3. Sampling Location for Macro & Micro Examination 3-1. Bent Portion

1) Weld metal 3-2. Transition Zones Base Metal 3-3. Tangent Portion (when heat treated)

1) Weld metal4. Sampling Location for Hardness Test 4-1. Bent Portion

1) Outside Radius in Bent Portion2) Inside Radius in Bent Portion3) Weld Metal in Bent Portion

4-2. Transition Zones Base Metal 4-3. Tangent Portion (when heat treated)

1) Base Metal in Tangent Portion2) Weld Metal in Tangent Portion

5. Reading Location : As per figure-12 & 136. Vickers Load : 10 Kg (98.07 N)7. Acceptance Criteria : 300 HV10 Maximum

5mm intervalsP : 1.5mm +0.5mm/- 0mm

OutsideP

1/2T

P

Inside: Hardness Indentations

Figure-12 Reading Location for Base metal

AB15-033

15


Sheet No. MPS No.

5. Mechanical Property Test on MPQT Bend (Cont.) Rev. No.Para. Process Procedure & Tolerance5-4 Macro, Micro &

Hardness Test Weld centerline(Cont.) 20mm

15mm10mm

b a a bP : 1.5mm +0.5mm/- 0mm

Outside

P

1/2T

P

a : 0.75mm from Fusion Line Insideb : 1.0mm intervals

: Hardness Indentations

Figure-13 Reading Location for Weld metal8. Grain-size measurement shall be performed in accordance with ASTM E 112. The minimum average grain-size number shall be 7.

9. Number of test : One specimen per sampling location.


B15-033A

16

Sheet No. MPS No.

6. Documentation Rev. No.Para. Process Procedure & Tolerance6-1 Documentation 1. The following documents will be submitted after completion of

production and testing as data book.2. Data book of MPQT and production bends will be submitted separately. 1) Data Book Contents for MPQT Bends

a) Material Mill Certificate (Bend)b) Material Mill Certificate (Mother Pipe)c) Material Traceability Recordd) Record of Receiving Inspection on Mother Pipee) Record of Bending Condition Parametersf) Record of Non-Destructive Testingg) Record of Visual and Dimensional Inspection

(Including wall thickness check)h) Record of Surface Hardness Testingi) Record of Mechanical Property Testj) Macro-graphs and Micro-graphs

2) Data Book Contents for Production Bendsa) Material Mill Certificate (Bend)b) Material Mill Certificate (Mother Pipe)c) Material Traceability Recordd) Record of Receiving Inspection on Mother Pipee) Record of Bending Condition Parametersf) Record of Non-Destructive Testingg) Record of Visual and Dimensional Inspection

(Including wall thickness check)h) Record of Surface Hardness Testing

B15-03317

A


APPENDIX-1 Sheet No. MPS No.Rev. No.

1. The following sketch shows that angle deviation (△θ1+ △θ2) is same as △θ1' & △θ2' measured on both tangent portions.

Theoretical drawingActual bend

△θ2' (= △θ2) △θ1'

(= △θ1)

90-△θ290-△θ1

△θ1△θ2

X2 X1 Y2 Y1

△θ2 △θ1

2. After bend pipe put on the inspection table, distance of X1 & Y1 (X2 & Y2) are measured with ruler on tangent portion. Angle deviation is calculated with following formula (trigonometrical function).

Δθ1 = TAN-1(Y1/X1) : Angle deviation on Top TangentΔθ2 = TAN-1(Y2/X2) : Angle deviation on Top Tangent

Δθ (Angle Deviation) = Δθ1＋Δθ2

DAI-ICHI HIGH FREQUENCY CO. LTD. CHIBA WORKS

Measuring Method of Bend Angle

18B15-033

A


Actual Inside Radius Radius Deviation : RTo be measured the differencebetween theoretical drawing andactual bend with ruler

Theoretical Inside Radius

: Theoretical Drawing of Inner radius { = Bend radius -(OD/2) }: Inner radius of actual bend

Bend

Square gauge

Support Stand

R Inspection Table Distance "R" will be measured with ruler.

Theoretical line Actual line


19B15-033

A

Measuring Method of Bend Radius


1. ScopeThis procedure describes a method of ultrasonic testing for both ends of tangent ends using compression wave.

2. Referred Documents ISO 11496

3. Personnel Qualification Ultrasonic testing personnel shall be qualified equal to or higher than the level II in

accordance with JSNDI (Japanese Society for Non-Destructive Inspection) equivalent to ISO 9712.

4. Equipment KRAUTKRAMER USK7S, USK8S, RYOSHO UI-25, UI-27 or equivalent will be used.

5. Probe1) Frequency : 4 MHz2) Type : Double Crystal3) Mode of Wave : Compression Wave4) Transducer Size : 24mm Dia./2

6. Couplant Glycerin and/or Water

7. Extent of Testing For a distance of 50mm from ends over the fullcircumference of the bend ends.

8. TechniqueStraight Beam, Contact Method Estimated

Figure-1 Bend End9. Scanning

1) Scanning Method : Manual2) Scanning Speed : less than 150mm/second

10. Reference Standard1) Basic Calibration Block Basic calibration block will made from mother pipe for each size. Typical block dimensions are shown in figure-3.2) Basic Calibration Reflector Basic calibration reflector will be made in the basic calibration block. Details of the basic calibration reflector are shown in figure-3.

50mm

B15-033A


20

Ultrasonic Testing Procedure (Bend Ends)


11. Reference SensitivityThe reference sensitivity will be adjusted the echo height from flat bottom hole on 80 - 100% of full screen height.

12. Reference LevelLine of full screen height will be specified as reference level.As per figure-2.

Reference level

80 - 100% 1/4T < h < 1/3T, h=10mm max.

Outside

Th

Inside(mm)

Figure-2 D.A.C Curve 6.0mm +10/-0% Flat bottom hole

Figure-3 Calibration Block

Frequency of Calibration : At least every 4 hours

13. Defects as the subject of evaluationAny discontinuity indication greater than reference level will be evaluated as a lamination.

14. For actual test, sensitivity is increased by 6dB above level established in para. 11. Any defect indication exceeding the DAC Curve is further investigated by reducing sensitivity by 6dB.

15. Acceptance Criteria Laminar imperfections shall not exceed 6.4 mm in the circumferential direction or have an area in excess of 100 mm 2.


21B15-033

A

Ultrasonic Testing Procedure (Bend Ends)


1. ScopeThis procedure describes a method of magnetic particle testing on the bend surfaceand bevelled face of bend.


3. Personnel Qualification Magnetic particle testing personnel shall be qualified equal to or higher than the level II in


4. Magnetizing Equipment Table-1Kind HANDY MAGNA HANDY MAGNA

A-1 A-2Type Portable Type

Magnetizing Alternating currentCurrentMagnetizing 2300 - 2700 A.T. 2100 - 2300 A.T.ForceLifting More than 4.5 Kg (10 lb)PowerPole 140mm 110mmSpacing (5.5 inch) (4.3 inch)

5. Magnetic Particle Table-2Kind SY-7500 MS-30Type Fluorescent Wet and Visible

SprayParticle 2 - 5 5 - 30Size μm μm

Color Greenish Grayyellow

Application Machined surface As bend surface(Standard) Bend Ends

6. Ultraviolet Lamp (Black light)BLACK LIGHT S-100, ULTRA LIGHT S-35, SUPER LIGHT D-10 or equivalent will be used.

Table-3Item BLACK LIGHT S-100 ULTRA LIGHT S-35 SUPER LIGHT D-10Intensity 100W, More than 1000μW/cm2 at examined area.

Wave length 800 - 2800 Angstrom 800 - 8000 Angstrom 800 - 7800 AngstromMaker Name EISHIN KAGAKU CO., LTD. MARKTEC

22B15-033

A

Magnetic Particle Testing Procedure



7. Bath StrengthTable-4

Magnetic Particle Bath strength MediumSY-7500 1.5 - 3.5 g/L Ready mixed liquidMS-30 5 - 20 g/L Water

8. TechniqueDirect contact yoke and wet - continuous method shall be used.

9. Direction of Magnetization Two separate examination shall be carried out on each area.The line of magnetic flux shall be parallel and perpendicular to the rolling direction.

10. Magnetizing TimeThe magnetizing time shall be longer than 3 seconds.

11. Testing Coverage The testing shall be conducted with 10% overlap of the effective magnetic flux to assure 100% coverage at the established test sensitivity.

12. Standard Test Piece JIS (Japanese Industrial Standard) Z 2320-1 (2007) A2 30/100 standard test piece will be used.Frequency of Calibration : At least every 4 hours

620 A2

30/100Unit : mm

JIS Z 2320-1 (2007) A2 30/100 Standard Test Piece

Figure-1

23



AB15-033


13. Surface Preparation Prior to magnetic particle testing, the surface to be tested shall be dry and free from any dirt, grease, lint, welding flux, spatter, oil or other extraneous matter that interfere withthe testing.

14. Extent of Testing1) Over an arc of 90deg. both sides from the extrados on external surface of bend portion and ground repaired portion2) On the bevelled faces of bend

15. Acceptance Criteria 1) Bend Surface : All laps, laminations, and all rounded indications

greater than 3 mm in any direction will be considered as defects. The defects will be repaired by grinding and if the measured wall thickness less than the specified wall thickness the bend shall be rejected. Presence of cracks shall be a cause of rejection.

2) Beveled Face : Laminar imperfections equal to or greater than 6 mm in the circumferential direction are not permitted. (As per ISO 13664, Para. 5) Re-beveling will be carried out to remove the un-acceptable defects.

Figure-2


B15-03324

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Extrados in bent section

90°

90°

Neutral Axis


1. ScopeThis procedure describes a method of ultrasonic testing on the longitudinal weld seam.

2. Referred Documents API 5L Annex K



4. Equipment KRAUTKRAMER USK7S, USK8S, RYOSHO UI-25, UI-27 or equivalent will be used.

5. Probe1) Frequency : 5 MHz2) Nominal Angle of Reflection : 45 degrees3) Mode of Wave : Shear Wave4) Transducer Size : 10 x 10 mm

6. Couplant Glycerin and/or water

7. Extent of Testing The complete weld seam in the arc and transition zones

8. TechniqueAngle Beam, Contact Method

9. Scanning1) Scanning Method : Manual2) Scanning Speed : less than 150mm/second

10. Reference Standard1) Basic Calibration Block Basic calibration block will be made from mother pipe for bend.2) Typical block dimensions are shown in figure-1.

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Ultrasonic Testing Procedure (Longitudinal Weld Seam)

B15-033



Max. 1.5 mm T

W

W : Approx. 4"d T : Wall Thickness

d : 5% of T +/- 15%(N5 notches)

Figure-1 Typical Block Reflector for ERW

11. Calibration 1) CalibrationThe examination sensitivity will be established the echo height on a 80 - 100% offull screen height amplitude from N5 notch at 0.5 skip.Then the peak echo height will be marked on C.R.T.Without changing the gain, it will be done the same way at 1.0 skip.The peak echo at 1.0 skip will be also marked on C.R.T.The reference level line will be draw as shown in figure-3.Frequency of Calibration : At least every 4 hours

Reference level

0.5S 1.0S

Figure-2 Calibration Method 0.5S 1.0SFigure-3 D.A.C Curve

2) Reference SensitivityThe testing sensitivity will be established on 80% - 100% of full screen height amplitudefrom N5 notch producing the largest response.The gain will be applied the reference sensitivity.

12. Acceptance CriteriaThe acceptance limit signal shall be primary reference sensitivity level.

T

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80 - 100%


Ultrasonic Testing Procedure (Longitudinal Weld Seam)

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1. ScopeThis procedure describes a method of ultrasonic testing on the bend body.




4. Equipment KRAUTKRAMER USK7S, USK8S , RYOSHO UI-25, UI-27 or equivalent will be used.

5. Probe1) Frequency : 5 MHz2) Nominal Angle of Reflection : 45 degrees3) Mode of Wave : Shear Wave4) Transducer Size : 10 x 10 mm

6. Couplant Glycerine and/or Water

7. Extent of Testing On the bend extrados from top neutral to bottom neutral including weld seam

8. TechniqueAngle Beam, Contact Method

9. Scanning1) Scanning Method : Manual2) Scanning Speed : less than 150mm/second

10. Reference Standard1) Basic Calibration Block Basic calibration block will have the same diameter, thickness, heat treatment and material. Typical block dimensions are shown in figure-1.2) Basic Calibration Reflector Basic calibration reflector will be made in the basic calibration block. Details of the basic calibration reflector are shown in figure-1.


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Ultrasonic Testing Procedure (Bend Body for Transverse Defects)


h

h

b : Maximum 1.5mm bh : 5% of specified WT (but 0.3mm - 1.5mm) h

ISO 9305, Level 2 / Arc notch Detail A

Figure-1 Typical Block Reflector11. Calibration

1) CalibrationThe examination sensitivity will be established the echo height on a 80 - 100%of full screen height amplitude from notch at 0.5 skip.Then the peak echo height will be marked on C.R.T.Without changing the gain, it will be done the same way at 1.0 skip.The peak echo at 1.0 skip will be also marked on C.R.T.The reference level line will be draw as shown in figure-3.Frequency of Calibration : At least every 4 hours

Reference level80 - 100%

0.5S 1.0S

Figure-2 Calibration Method 0.5S 1.0SFigure-3 D.A.C Curve

2) Reference SensitivityThe testing sensitivity will be established on 80% - 100% of full screen height amplitudefrom inside notch producing the largest response, then draw a line of DAC curve.

12. For actual test, sensitivity is increased by 6dB above level established in above para. 11. Any defect indication exceeding the DAC Curve is further investigated by reducing sensitivity by 6dB.

13. Acceptance CriteriaThe acceptance limit signal shall be the primary reference sensitivity level.Any reading beyond primary shall be a cause of rejection.(As per L2 of ISO 9305.)

Ultrasonic Testing Procedure (Bend Body for Transverse Defects)


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150930 GF-GEN-P-PR-0512-A_MPS(DHF)

Documents

Transcript of 150930 GF-GEN-P-PR-0512-A_MPS(DHF)