Api5l part 1 of 2b

Understanding API5L API SPEC 5L- 45th Edition Forty-fifth Edition, December 2012

The Inspector Perspective Reading 1 Part 1/2B 22nd April 2016

Charlie Chong/ Fion Zhang

10.2.3.7 Test pieces for the flattening test The test pieces shall be taken in accordance with ISO 8492 or ASTM A 370, except that the length of each test piece shall be 60 mm (2.5 in).

Minor surface imperfections may be removed by grinding.

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API5L Mechanical Lab

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DWTT

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Drop weight tear test (DWTT)

â– https://www.youtube.com/embed/n5aL6oM7ZAM

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10.2.4 Test methods 10.2.4.1 Product analysis Unless otherwise agreed upon when ordering, the choice of a suitable physical or chemical method of analysis to determine the product analysis is at the discretion of the manufacturer. In cases of dispute, the analysis shall be carried out by a laboratory approved by the two parties. In these cases, the reference method of analysis shall be agreed upon, where possible, with reference to ISO/TR 9769 or ASTM A751. NOTE ISO/TR 9769 covers a list of available International Standards for chemical analysis, with information on the application and precision of the various methods.

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10.2.4.2 Tensile test The tensile test shall be carried out in accordance with ISO 6892-1 or ASTM A370. For pipe body tests, the yield strength, the tensile strength, the yield ratio (as appropriate), and the percentage elongation after fracture shall be determined. For pipe weld tests, the tensile strength shall be determined. The percentage elongation after fracture shall be reported with reference to a gauge length of 50 mm (2 in). For test pieces having a gauge length less than 50 mm (2 in), the measured elongation after fracture shall be converted to a percentage elongation in 50 mm (2 in) in accordance with ISO 2566- 1 or ASTM A370.

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Tensile test

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Tensile test

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10.2.4.3 CVN impact test The Charpy test shall be carried out in accordance with ASTM A370 unless ISO 148-1 and the required striker radius (2 mm or 8 mm) are specified in the purchase order.

10.2.4.4 Drop-weight tear test The drop-weight tear test shall be carried out in accordance with API RP 5L3.

10.2.4.5 Full section bend test The bend test shall be carried out in accordance with ISO 8491 or ASTM A370. For each test unit, one full-section test piece of appropriate length shall be bent cold through 90째 around a mandrel having a diameter no larger than 12 D.

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CVN impact test

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10.2.4.6 Guided-bend test The guided-bend test shall be carried out in accordance with ISO 7438 or ASTM A370. The mandrel dimension, Agb, expressed in millimetres (inches), shall not be larger than that determined using Equation (5), with the result rounded to the nearest 1 mm (0.1 in):

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where D is the specified outside diameter, expressed in millimetres (inches); t is the specified wall thickness when using full thickness pieces, expressed in millimetres (inches). It is 19 mm (0.748 in.) when using reduced-thickness test pieces; Îľ is the strain, as given in Table 23; 1,15 is the peaking factor.

Both test pieces shall be bent 180° in a jig as shown in Figure 9.

One test piece shall have the root of the weld directly in contact with the mandrel; the other test piece shall have the face of the weld directly in contact with the mandrel.

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Figure 9 . Jigs for guided-bend test

a) Plunger type Fion Zhang/Charlie Chong

Dimensions in millimetres (inches)

Figure 9 . Jigs for guided-bend test Key 1 tapped mounting hole 2 shoulders, hardened and greased, or hardened rollers B Agb 천 2t 천 3,2 mm (0.125 in) ra radius of the mandrel for the guided-bend test rb radius of the die for the guided-bend test a These symbols have been retained on the basis of their long-standing use

by API in API 5L and API 5CT[21]. b As needed.

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Figure 9 . Jigs for guided-bend test

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Table 23 . Strain values for guided-bend test

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Guided-bend test

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Guided-bend test

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Guided-bend test

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10.2.4.7 Flattening test The flattening test shall be carried out in accordance with ISO 8492 or ASTM A370. As shown in Figure 6, one of the two test pieces taken from both endof-coil locations shall be tested with the weld at the 6 o.clock position or 12 o.clock position, whereas the remaining two test pieces shall be tested at the 3 o.clock position or 9 o.clock position. Test pieces taken from crop ends at weld stops shall be tested at the 3 o.clock position or 9 o.clock position only.

3 o.clock position or 9 o.clock position

6 o.clock position or 12 o.clock position

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Flattening test

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Flattening test Ring Flattening Test, ASTM A513

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Flattening test

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Flattening test

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Flattening test

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Flattening test

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10.2.4.8 Hardness test When suspected hard spots are detected by visual inspection, hardness tests shall be carried out in accordance with ISO 6506, ISO 6507, ISO 6508 or ASTM A370 using portable hardness test equipment and methods complying with ASTM A956, ASTM A1038 or ASTM E110 respectively depending on the method used.

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10.2.5 Macrographic and metallographic tests 10.2.5.1 Except as allowed by 10.2.5.2, the alignment of internal and external seams of SAW and COW pipes [see Figure 4d) and Figure 4e)] shall be verified by macrographic testing.

10.2.5.2 Alternative methods, such as ultrasonic inspection, may be used if agreed, provided that the ability of such equipment to detect misalignment is demonstrated. If such an alternative method is used, a macrographic test shall be carried out at the beginning of the production of each combination of specified outside diameter and specified wall thickness.

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Figure 4d) Misalignment of weld beads of SAW pipe

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Figure 4 e) Misalignment of weld beads of COW pipe

Key 1 misalignment

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10.2.5.3 For pipe that is required to be seam-heat-treated (see 8.8.1 or 8.8.2, whichever is applicable), it shall be verified by metallographic testing that the entire HAZ has been appropriately heat treated over the full wall thickness.

For pipe that is not required to be seam-heat-treated (see 8.8.1), it shall be verified by metallographic testing that no untempered martensite remains. In addition, a hardness test and maximum hardness may be agreed.

10.2.5.4 For SAW pipe seams made with tack welds, the melting and coalescence of the tack weld into the final weld seam shall be verified by macrographic testing [See 8.4.2 a)].

Question: As a alternative to metallographic as allowed in 10.2.5.2, how UT could assessed 10.2.5.3 , 10.2.5.3.

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10.2.6 Hydrostatic test 10.2.6.1 Test pressures for all sizes of SMLS pipe, and for welded pipe with D≤ 457 mm (18.000 in), shall be held for not less than 5 seconds. Test pressures for welded pipe with D > 457 mm (18.000 in) shall be held for not less than 10 seconds.

For threaded-and-coupled pipe, the test shall be applied with the couplings made up power-tight if agreed, except that pipe with D > 323.9 mm (12.375 in) may be tested in the plain-end condition.

For threaded pipe furnished with couplings made up handling-tight, the hydrostatic test shall be made on the pipe in the plain-end, threads-only or coupled condition unless a specific condition is specified in the purchase order.

5/10 Seconds Fion Zhang/Charlie Chong

10.2.6.2 In order to ensure that every length of pipe is tested to the required test pressure, each tester, except those on which only continuous welded pipe is tested, shall be equipped with a recording gauge that can record the test pressure and the test duration for each length of pipe, or shall be equipped with some positive and automatic or interlocking device to prevent pipe from being classified as tested until the test requirements (pressure and duration) have been met. Such records or charts shall be available for examination at the manufacturer's facility by the purchaser's inspector, if applicable.

The test- pressure measuring device shall be calibrated by means of a deadweight tester, or equivalent, no more than four months prior to each use. At the option of the manufacturer, test pressures that are higher than required may be used.

NOTE In all cases, the specified test pressure represents the gauge pressure value below which the pressure is not permitted to fall during the specified test duration.

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10.2.6.3 Test pressures for light-wall threaded pipe shall be as given in Table 24.

10.2.6.4 Test pressures for heavy-wall threaded pipe shall be as given in Table 25.

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Table 24 . Test pressures for light-wall threaded pipe

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Table 24 . Test pressures for light-wall threaded pipe

a Not applicable.

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Table 25 . Test pressures for heavy-wall threaded pipe

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Table 25 . Test pressures for heavy-wall threaded pipe

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10.2.6.5 Except as allowed by 10.2.6.6, 10.2.6.7 and the footnotes to Table 26, the hydrostatic test pressure, P, expressed in megapascals (pounds per square inch), for plain-end pipe shall be determined using Equation (6), with the results rounded to the nearest 0,1 MPa (10 psi):

(6)

where S is the hoop stress, expressed in megapascals (pounds per square inch), equal to a percentage of the specified minimum yield strength of the pipe, as given in Table 26; t is the specified wall thickness, expressed in millimetres (inches); D is the specified outside diameter, expressed in millimetres (inches).

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Table 26 . Percentage of specified minimum yield strength for determination of S

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10.2.6.6 If pressure testing involves an end-sealing ram that produces a compressive longitudinal stress, the hydrostatic test pressure, P, expressed in megapascals (pounds per square inch), may be determined using Equation (7), with the result rounded to the nearest 0,1 MPa (10 psi), provided that the required test pressure produces a hoop stress in excess of 90 % of the specified minimum yield strength:

(7)

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Where: S is the hoop stress, expressed in megapascals (pounds per square inch), equal to a percentage of the specified minimum yield strength of the pipe (see Table 26); is the internal pressure on end-sealing ram, expressed in PR megapascals (pounds per square inch); is the cross-sectional area of end-sealing ram, expressed in square AR millimetres (square inches); is the cross-sectional area of pipe wall, expressed in square Ap millimetres (square inches); is the internal cross-sectional area of pipe, expressed in square AI millimetres (square inches); D is the specified outside diameter, expressed in millimetres (inches); t is the specified wall thickness, expressed in millimetres (inches).

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10.2.6.7 If agreed, the minimum permissible wall thickness, tmin, may be used in place of the specified wall thickness, t, for the determination of the required test pressure (see 10.2.6.5 or 10.2.6.6, whichever is applicable), provided that a hoop stress of at least 95 % of the specified minimum yield trength of the pipe is used.

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Hydrotesting In order to ensure that every length of pipe is tested to the required test pressure, each tester, except those on which only continuous welded pipe is tested, shall be equipped with a recording gauge that can record the test pressure and the test duration for each length of pipe, or shall be equipped with some positive and automatic or interlocking device to prevent pipe from being classified as tested until the test requirements (pressure and duration) have been met. Such records or charts shall be available for examination at the manufacturer's facility by the purchaser's inspector, if applicable.

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Hydrotesting Test pressures for all sizes of SMLS pipe, and for welded pipe with D≤ 457 mm (18.000 in), shall be held for not less than 5 seconds. Test pressures for welded pipe with D > 457 mm (18.000 in) shall be held for not less than 10 seconds.

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Hydrotesting The test- ressure measuring device shall be calibrated by means of a dead-weight tester, or equivalent, no more than four months prior to each use. At the option of the manufacturer, test pressures that are higher than required may be used.

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10.2.7 Visual inspection 10.2.7.1 Except as allowed by 10.2.7.2, each pipe shall be visually inspected to detect surface defects, with an illuminance of at least 300 lx (28 fc).

Suchinspection shall be over the entire external surface and shall cover as much of the internal surface as is practical.

NOTE Generally, the entire inside surface of large diameter SAW and COW pipes is visually inspected from inside the pipe.

10.2.7.2 Visual inspection may be replaced by other inspection methods that have a demonstrated capability of detecting surface defects.

10.2.7.3 Visual inspection shall be conducted by personnel who a) are trained to detect and evaluate surface imperfections; b) have visual acuity that meets the applicable requirements of ISO 11484 or ASNT SNT-TC-1A or equivalent.

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Pipe End Visual Inspection

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Visual inspection may be replaced by other inspection methods that have a demonstrated capability of detecting surface defects.

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Visual inspection may be replaced by other inspection methods that have a demonstrated capability of detecting surface defects.

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Visual inspection may be replaced by other inspection methods that have a demonstrated capability of detecting surface defects.

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Visual inspection may be replaced by other inspection methods that have a demonstrated capability of detecting surface defects.

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Visual inspection may be replaced by other inspection methods that have a demonstrated capability of detecting surface defects.

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10.2.7.4 The surface of cold-formed welded pipe shall be inspected to detect geometric deviations in the contour of the pipe. If this inspection fails to disclose mechanical damage as the cause of the irregular surface, but indicates that the irregular surface can be attributed to a hard spot, the dimensions of the area, and if necessary its hardness, shall be determined.

The choice of the test method for hardness testing is at the option of the manufacturer. If the dimensions and hardness exceed the acceptance criteria given in 9.10.6, the hard spot shall be removed in accordance with procedures specified in 9.10.7 and Annex C. Comments: Visual inspection could detectďźš 1. Undercut 2. Arc burn 3. Dent 4. Geometric deviation 5. Weld reinforcement 6. Flash 7. Weld defect open to surface Fion Zhang/Charlie Chong

10.2.8 Dimensional testing 10.2.8.1 The diameter of pipes shall be measured at least once per 4 hours per operating shift to verify conformance to the diameter tolerances (see Table 10). Unless a method is specified in the purchase order, diameter measurements shall be made with a circumferential tape, or appropriate uses of micrometer, ring gauge, snap gauge, caliper, ovality gauge, coordinate measuring machine, or optical measuring device. Unless otherwise agreed, for D≼508 mm (20.000 in.), measurements made by circumferential tape shall govern in case of dispute.

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Circumferential Tape

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NOTE 1 Ring gauges used to measure pipe diameter are usually manufactured to specified dimensions for each pipe size from dimensionally stable material such as steel, aluminium or other approved material, and shallbe of rigid construction but sufficiently light to permit manipulation by one inspector. The ring gauge design usually incorporates handles to allow the inspector to position the gauge accurately and safely within or over the pipe.

The diameter of internal ring gauges is usually 3,2 mm (0.125 in) less than the nominal internal diameter of the pipe. External ring gauges usually have a bore diameter not exceeding the sum of the specified outside diameter of the pipe plus the allowable diameter tolerance. For inspection of submerged arc welded pipe, ring gauges can be slotted or notched to permit passage of the gauge over the weld reinforcement. It is necessary that the pipe permit the passage of the ring gauge within (internal) or over (external) each end of the pipe for a minimum distance of 100 mm (4.0 in).

NOTE 2 Coordinate measuring machines are mechanical systems designed to track a mobile measuring probe to determine the coordinates of points on a work surface.

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Plug Gauge

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10.2.8.2 The out-of-roundness of pipes shall be determined at least once per 4 hours per operating shift. Except as allowed by 10.2.8.3, the out-ofroundness shall be determined as the difference between the largest outside diameter and the smallest outside diameter, as measured in the same crosssectional plane.

NOTE Out-of-roundness measurements taken in stacks are invalid due to the elastic deformations caused by forces exerted by pipes adjacent to those being measured.

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10.2.8.3 If agreed, for expanded pipe with D ≼ 219,1 mm (8.625 in) and for non-expanded pipe, inside diameter measurements shall be used to determine conformance with the diameter tolerances. The out- of- roundness may be determined as the difference between the largest inside diameter and the smallest inside diameter, as measured in the same cross-sectional plane.

10.2.8.4 For SAW and COW pipe, the greatest deviation of flat spots or peaks from the normal contour of the pipe at the weld at a pipe end shall be measured with respect to a template that is oriented transverse to the pipe axis and has a length of 0,25 D (Âź D) or 200 mm (8.0 in), whichever is the lesser.

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10.2.8.5 Each length of pipe shall be measured for conformance to the specified wall thickness requirements. The wall thickness at any location shallbe within the tolerances specified in Table 11, except that the weld area shall not be limited by the plus tolerance.

Wall thickness measurements shall be made with a mechanical calliper or with a properly calibrated non- destructive inspection device of appropriate accuracy. In case of dispute, the measurement determined by use of the mechanical calliper shall govern.

The mechanical calliper shall be fitted with contact pins. The end of the pin contacting the inside surface of the pipe shall be rounded to a maximum radius of 38,1 mm (1.50 in) for pipe of size 168,3 mm (6.625 in) or larger, and up to a radius of D/4 for pipe smaller than size 168,3 mm (6.625 in) with a minimum radius of 3,2 mm (0.125 in). The end of the pin contacting the outside surface of the pipe shall be either flat or rounded to a minimum radius of 31,2 mm (1.25 in).

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10.2.8.6 For threaded-and-coupled pipe, the length shall be measured to the outer face of the coupling. The length of threaded-and-coupled pipe may be determined before the couplings are attached, provided the proper allowance is made for the length of the couplings.

10.2.8.7 For the verification of conformance with the dimensional and geometrical requirements specified in 9.11 to 9.13, suitable methods shall be used. Unless particular methods are specified in the purchase order, the methods used shall be at the discretion of the manufacturer.

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Threaded-and-coupled Pipe – API5B

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Threaded-and-coupled Pipe API5B

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Threaded-and-coupled Pipe API5B

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Threaded-and-coupled Pipe API5B

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Threaded-and-coupled Pipe API5B

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Threaded-and-coupled Pipe API5B

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Threaded-and-coupled Pipe API5B

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Threaded-and-coupled Pipe API5B

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Dimensional Checks Callipered Diameter/Ovality

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Dimensional Checks- String Straightness

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Dimensional Checks- Internal Diameter

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Dimensional Checks – Bevel Angle

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Dimensional Checks - Root face

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Dimensional Checks – End Thickness

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Dimensional Checks- End Squareness

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Dimensional Checks- Ovality

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10.2.9 Weighing For pipe with D ≼ 141,3 mm (5.563 in), the lengths of pipe shall be weighed individually, except that for welded jointers it shall be permissible to weigh the individual lengths comprising the jointer or the jointer itself.

For pipe with D < 141,3 mm (5.563 in), the lengths of pipe shall be weighed either individually or in a convenient group of pipes selected by the manufacturer. Threaded- end-coupled pipe shall be weighed either: a) with the couplings screwed on but without thread protectors, except for order items with a mass of 18 tonnes (20 tons) or more for which proper allowance shall be made for the weight of the thread protectors, or b) before the couplings are attached, provided that allowance is made for the weight of the couplings.

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10.2.10 Non-destructive inspection Non-destructive inspection shall be in accordance with Annex E.

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Manual UT Precalibration

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Online Automatic UT Checks

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Online Automatic UT Checks

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10.2.11 Reprocessing If any mechanical property test result for a test unit of pipe fails to conform to the applicable requirements, the manufacturer may elect to: 1. heat treat the test unit of pipe in accordance with the requirements of Table 3, consider it a new test unit, 2. test it in accordance with all requirements of 10.2.12 and 10.2.4 that are applicable to the order item, and proceed in accordance with the applicable requirements of this Standard.

Note: no mechanical strain strengthening  After one reprocessing heat treatment, any additional reprocessing heat treatment shall be subject to agreement with the purchaser.  For non-heat treated pipe, any reprocessing heat treatment shall be subject to agreement with the purchaser.  For heat treated pipe, any reprocessing with a different type of heat treatment (see Table 3) shall be subject to agreement with the purchaser.

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10.2.12 Retesting 10.2.12.1 Recheck analyses If the product analyses of both samples representing the heat fail to conform to the specified requirements, at the manufacturer's option either the heat shall be rejected or the remainder of the heat shall be tested individually for conformance to the specified requirements.

If the product analysis of only one of the samples representing the heat fails to conform to the specified requirements, at the manufacturer's option, either the heat shall be rejected or two recheck analyses shall be made using two additional samples from the heat. If both recheck analyses conform to the specified requirements, the heat shall be accepted, except for the pipe, plate, or coil from which the initial sample that failed was taken.

If one or both recheck analyses fail to conform to the specified requirements, at the manufacturer's option either the heat shall be rejected or the remainder of the heat shall be tested individually for conformance to the specified requirements. For such individual testing, analyses for only the rejecting element or elements need be determined. Samples for recheck analyses shall be taken in the same location as specified for product analyses samples.

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Question: What is the initial sampling size of product analysis & ladle analysis?

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10.2.12.2 Tensile retests Tensile retest provisions are as follows. a) For all PSL 1 products, PSL 2 products with R, N, and Q delivery conditions, and PSL 2 products with M delivery conditions of grades less than L450 or X65, (see Tables 2 and 3). If the tensile test specimen representing the test unit of pipe fails to conform to the specified requirements, the manufacturer may elect to retest two additional lengths from the same test unit. â&#x2013; If both retested specimens conform to the specified requirements, all the lengths in the test unit shall be accepted, except the length from which the initial specimen was taken. â&#x2013; If one or both of the retested specimens fail to conform to the specified requirements, the manufacturer may elect to individually test the remaining lengths in the test unit. Specimens for retest shall be taken in the same manner as the specimen that failed to meet the minimum requirements. If applicable, reprocessing shall be as defined in 10.2.11.

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b) For PSL 2 products with M delivery conditions of grades L450 or X65, or greater (see Table 3). If the tensile specimen representing the test unit fails to conform to the specified requirements, the manufacturer may elect to retest two additional lengths from the same test unit.

Specimens for retest shall be taken in the same manner as the original specimen that failed to meet the minimum requirements but should be from two different mother coils or plates, as applicable.

If one or both of the retested specimens fail to conform to the specified requirements, the manufacturer may elect to individually test the remaining lengths in the test unit.

If both retest specimens conform to the specified requirements, the test unit shall be accepted except the lengths from the mother coil or plate from which the initial specimen was taken. These lengths shall have one of the following dispositions:

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1) all pipes shall be rejected, or 2) each pipe in the test unit shall be tested with the pipe with satisfactory test results accepted, or 3) provided individual pipe traceability to mother coil/plate location, the manufacturer shall test additional lengths adjacent to (before, after and beside, as applicable) the initial failure within the mother coil or plate considering adjacent daughter coil(s) or plate(s) as applicable. Pipe testing shall continue until satisfactory results surround the non-conforming section of the mother coil/plate. The pipes from the non-conforming section of mother coil/plate shall be rejected and the remainder of the pipe from the test unit accepted. If applicable, reprocessing shall be defined as in 10.2.11.

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4.37 mother coil hot-rolled coil of steel processed from a single reheated slab which is used to produce one or more pieces of pipe 4.14 daughter coil portion of steel removed via slitting, cutting or shearing from the mother coil which is used to produce one or more pieces of pipe

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More Reading TMCP

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10.2.12.3 Flattening retests Flattening retest provisions are as follows: a) Non-expanded electric welded pipe in grades higher than L175 or A25 and non-expanded laser welded pipe smaller than 323,9 mm (12.750 in) produced in single lengths: The manufacturer may elect to retest any failed end until the requirements are met, providing the finished pipe is not less than 80% of its length after initial cropping.

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b) Non-expanded electric welded pipe in grades higher than L175 or A25 and non-expanded laser welded pipe smaller than 323,9 mm (12.750 in) produced in multiple lengths: Where one or more of the flattening tests fail to conform to the specified requirements, the manufacturer may retest the pipe end after cropping the defective pipe end. Alternatively the manufacturer may reject the defective pipe(s) and retest the adjacent end of the next pipe. The retest shall consist of two specimens, one tested with the seam weld at 0o and one tested with the seam weld at 90o.

If the retest fails to conform to the specified requirements, the manufacturer may either reject the pipes produced from the affected multiple length or retest each end of each remaining individual length produced from the coil with the weld alternatively at 0o and 90o. If the retest conforms to the specified requirements, the remaining portion of the multiple lengths shall be accepted.

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c) Cold-expanded electric welded pipe in grades higher than L175 or A25, all welded Grade L175 or A25 in sizes 60,3 mm (2.875 in) and larger; and coldexpanded laser welded pipe smaller than size 323,9 mm (12.750 in): The manufacturer may elect to retest one end of each of two additional lengths of the same test unit. If both retests are acceptable, all lengths in the test unit shall be accepted, except the original failed length. If one or both retests fail, the manufacturer may elect to repeat the test on specimens cut from one end of each of the remaining individual lengths in the test unit. If applicable, reprocessing shall be as defined in 10.2.11.

Comments: Only 1 retest with penalty is allowed, if fail, all to be tested or reheat.

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10.2.12.4 Bend retests If the specimen fails to conform to the specified requirements, the manufacturer may elect to make retests on specimens cut from two additional lengths from the same test unit. If all retest specimens conform to the specified requirements, all the lengths in the test unit shall be accepted, except the length from which the initial specimen was taken. If one or more of the retest specimens fail to conform to the specified requirements, the manufacturer may elect to repeat the test on specimens cut from the individual lengths remaining in the test unit. If applicable, reprocessing shall be as defined in 10.2.11.

Comments: Only 1 retest with penalty is allowed, if fail, all to be tested or reheat.

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10.2.12.5 Guided-bend retests If one or both of the guided-bend specimens fail to conform to the specified requirements, the manufacturer may elect to repeat the tests on specimens cut from two additional lengths of pipe from the same test unit. If such specimens conform to the specified requirements, all lengths in the test unit shall be accepted, except the length initially selected for test. If any of the retested specimens fail to pass the specified requirements, the manufacturer may elect to test specimens cut from individual lengths remaining in the test unit.

The manufacturer may also elect to retest any length that has failed to pass the test by cropping back and cutting two additional specimens from the same end.

If the requirements of the original test are met by both of these additional tests, that length shall be acceptable. No further cropping and retesting is permitted. Specimens for retest shall be taken in the same manner asspecified in Tables 19 and 20 and 10.2.3.6. If applicable, reprocessing shall be as defined in 10.2.11.

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10.2.12.6 Charpy retests In the event that a set of Charpy test specimens fail to meet the acceptance criteria, the manufacturer may elect to replace the test unit of material involved or alternatively to test two more lengths from that test unit. If both of the new tests meet the acceptance criteria, then all pipe in that test unit, with the exception of the original selected length, shall be considered to meet the requirement. Failure of either of the two additional tests shall require testing of each length in the test unit for acceptance. If applicable, reprocessing shall be as defined in 10.2.11.

Comments: Only 1 retest with penalty is allowed, if fail, all to be tested or reheat.

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10.2.12.7 Hardness retests If the hardness test specimen representing a test unit of pipe fails to conform to the specified requirements, the manufacturer may elect to retest two additional lengths from the same test unit. If both retested specimens conform to the specified requirements, all the lengths in a test unit shall be accepted, except the length from which the initial specimen was taken. If one or both of the retested specimens fail to conform to the specified requirements, the manufacturer may elect to individually test the remaining lengths in the test unit. Specimens for retest shall be taken in the same manner as the specimen that failed to meet the minimum requirements (see H.7 or J.8, as applicable).

If applicable, reprocessing shall be as defined in 10.2.11.

Comments: Only 1 retest with penalty is allowed, if fail, all to be tested or reheat.

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10.2.12.8 DWT retests In the event that a set of DWT test specimens fail to meet the acceptance criteria, the manufacturer may elect to replace the test unit of material involved or alternatively to test two more lengths from that test unit. If both of the new tests meet the acceptance criteria, then all pipe in that test unit, with the exception of the original selected length, shall be accepted. Failure of either of the two additional tests shall require testing of each length in the test unit for acceptance. Specimens for retest shall be taken in the same manner as the specimen that failed to meet the minimum requirements (see 10.2.3). If applicable, reprocessing shall be as defined in 10.2.11.

Comments: Only 1 retest with penalty is allowed, if fail, all to be tested or reheat.

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11. Marking

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11 Marking 11.1 General 11.1.1 Pipe and pipe couplings manufactured in accordance with this Standard shall be marked by the manufacturer in the same sequence as they appear in 11.2.1 a) to j) as applicable.

NOTE While the required markings are generally applied in a single straight line, the markings are permitted to wrap around on to multiple lines provided the sequence of information is maintained as read from left to right and from top to bottom.

1.1.2 The required markings on couplings shall be die-stamped or, if agreed, paint-stencilled.

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11.1.3 If the purchase order requires API Spec 5L pipe to be supplied, markings identifying Spec 5L pipe shall be required.

11.1.4 Additional markings, as desired by the manufacturer or as specified in the purchase order, may be applied but shall not interrupt the sequence of the required markings as they appear in 11.2.1 a) to j) as applicable. Such additional markings shall be located after the end of the required marking sequence or as a separate marking at some other location on the pipe.

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11.2 Pipe markings 11.2.1 Pipe markings shall include the following information sequentially, as applicable: a) name or mark of the manufacturer of the pipe (X); b) "API Spec 5L" shall be marked when the product is in complete compliance with this standard, appropriate annexes and this section.

Products in compliance with multiple compatible standards may be marked with the name of each standard; c) specified outside diameter; d) specified wall thickness; e) pipe steel grade (steel name) (see Table 1, Table H.1 or Table J.1, whichever is applicable) and if agreed, both corresponding SI and USC steel grades may be marked on the pipe with the corresponding steel grade marked immediately after the order item steel grade;

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f) product specification level designation followed by the letter G if Annex G is applicable (see G.5.1); g) type of pipe (see Table 2); h) mark of the customer's inspection representative (Y), if applicable; i) an identification number (Z), which permits the correlation of the product or delivery unit (e.g bundled pipe) with the related inspection document, if applicable; j) if the specified hydrostatic test pressure is higher than the test pressure specified in Tables 24 or 25 as applicable, or exceeding the pressures stated in note a, b, or c of Table 26 if applicable, the word TESTED shall be marked at the end of the marking immediately followed by the specified test pressure in psi if ordered to USC units or MPa if ordered to SI units.

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EXAMPLE 1 (For SI units) SAWL Y Z

X API Spec 5L 508 12,7 L360M PSL 2

EXAMPLE 2 (For USC units) YZ

X API Spec 5L 20 0.500 X52M PSL 2 SAWL

inspection representative (Y) identification number (Z) EXAMPLE 3 If pipe also meets the requirements of compatible standard ABC. (For SI units) X API Spec 5L/ABC 508 12,7 L360M PSL 2 SAWL Y Z EXAMPLE 4 If pipe also meets the requirements of compatible standard ABC. (For USC units) X API Spec 5L/ABC 20 0.500 X52M PSL 2 SAWL Y Z EXAMPLE 5 If hydrotest pressure differs from the standard pressure. (For SI units tested to 17,5 MPa) X API Spec 5L 508 12,7 L360M PSL 2 SAWL Y Z TESTED 17,5 EXAMPLE 6 If hydrotest pressure differs from the standard pressure. For USC units tested to 2540 psi) X API Spec 5L 20 0.500 X52M PSL 2 SAWL Y Z TESTED2540

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EXAMPLE 3 If pipe also meets the requirements of compatible standard ABC. (For SI units) X API Spec 5L/ABC 508 12,7 L360M PSL 2 SAWL Y Z ABC = ASTM A333 Gr6 (say) EXAMPLE 4 If pipe also meets the requirements of compatible standard ABC. (For USC units) X API Spec 5L/ABC 20 0.500 X52M PSL 2 SAWL Y Z ABC = ASTM A333 Gr6 (say) EXAMPLE 5 If hydrotest pressure differs from the standard pressure. (For SI units tested to 17,5 MPa) X API Spec 5L 508 12,7 L360M PSL 2 SAWL Y Z TESTED 17,5 EXAMPLE 6 If hydrotest pressure differs from the standard pressure. For USC units tested to 2540 psi) X API Spec 5L 20 0.500 X52M PSL 2 SAWL Y Z TESTED2540

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EXAMPLE 5 If hydrotest pressure differs from the standard pressure. (For SI units tested to 17,5 MPa) X API Spec 5L 508 12,7 L360M PSL 2 SAWL Y Z TESTED 17,5 EXAMPLE 6 If hydrotest pressure differs from the standard pressure. For USC units tested to 2540 psi) X API Spec 5L 20 0.500 X52M PSL 2 SAWL Y Z TESTED2540

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EXAMPLE 7 For USC units with both corresponding steel grades marked and application of Annex G indicated X API Spec 5L 20 0.500 X52M L360M PSL2G SAWL Y Z EXAMPLE 8 For SI units with both corresponding steel grades marked and application of Annex G indicated X API Spec 5L 508 12,7 L360M X52M PSL2G SAWL Y Z OTE For specified outside diameter markings in USC units, it is not necessary to include the ending zero digits to the right of the decimal sign.

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Markings

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Markings

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Markings

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Markings

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Fion Zhang/Charlie Chong

Markings

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API5L

Other standard Outside Diameter

Thickness

X API Spec 5L/ ASTM A333Gr6 508 12,7 L360M X52M PSL2G SAWL Y Z

PSL2 with AnnexG

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SAW Longitudin al welding

Inspecti on mark

Manufacturer traceability

Grade L360 TMCP

X52 TMCP

API5L

Other standard Outside Diameter

Thickness

X API Spec 5L/ ASTM A333Gr6 508 12,7 L360M X52M PSL2G SAWL Y Z

PSL2 with AnnexG

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SAW Longitudin al welding

Inspection mark

Manufacturer traceability

Grade L360 TMCP

X52 TMCP

11.2.2 Except as allowed by 11.2.3 and 11.2.4, the required markings shall be applied durably and legibly, as follows: a) For pipe with D 48,3 mm (1.900 in), the markings shall be in one or more of the following locations: 1) on a tag fixed to the bundle, 2) on the straps or banding clips used to tie the bundle, 3) on one end of each pipe, 4) continuous along the length; b) For pipe with D 창 48,3 mm (1.900 in), unless a specific surface is specified in the purchase order, the markings shall be 1) on the outside surface of the pipe, in the sequence listed in 11.2.1, starting at a point between 450 mm and 760 mm (1.5 ft and 2.5 ft) from one of the pipe ends, or 2) on the inside surface of the pipe, starting at a point at least 150 mm (6.0 in) from one of the pipe ends;

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Remember the Common Steel Grades A, B 42, 46 52, 56 60, 65 70, 80, 90, 100, 120

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Common API5L Steel Grades A, B 42, 46 52, 56 60, 65 70, 80, 90, 100, 120

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11.2.3 If agreed, low-stress die-stamping or vibro-etching on the pipe surface may be used, subject to the following limitations. a) Such marks shall be on the pipe bevel face or within 150 mm (6.0 in) of one of the pipe ends. b) Such marks shall be at least 25 mm (1.0 in) from any weld. c) Cold die-stamping [at temperatures < 100 째C (210 째F)] of plate, coil or pipe not subsequently heat treated shall be done only if rounded or blunt dies are used. d) Unless otherwise agreed and specified on the purchase order, cold die stamping shall not be used on all pipe with a specified wall thickness of 4,0 mm (0.156 in) or less and all pipe of grade higher than L175 or A25 not subsequently heat treated.

Keywords: Low-stress die-stamping or vibro-etching Cold die-stamping

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Low-stress die-stamping or vibro-etching Cold die-stamping

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Low-stress die-stamping or vibro-etching Cold die-stamping

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11.2.4 For pipe intended for subsequent coating, if agreed, marking may be done at the coater's facility rather than at the pipe mill. In such cases, traceability shall be ensured, e.g. by application of a unique number (by individual pipe or heat of steel).

11.2.5 If a temporary protective coating (see 12.1.2) is applied, the markings shall be legible after such coating.

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11.2.6 In addition to the markings specified in 11.2.1, the pipe length shall be marked as follows, in metres to two decimal places (feet to tenths of a foot) or, if greed, in a different format. a) For pipe with D â&#x2030;¤ 48,3 mm (1.900 in), the total length of pipe in the bundle shall be marked on a tag, strap or banding clip attached to the bundle. b) Unless a specific surface is specified on the purchase order for pipe with D > 48,3 mm (1.900 in), the individual pipe length (as measured on the finished pipe) shall be marked 1) at a convenient location on the outside surface of the pipe, or 2) at a convenient location on the inside surface of the pipe. c) For pipe furnished with couplings, the length as measured to the outer face of the coupling shall be marked.

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11.2.7 If agreed, the manufacturer shall apply a daub of paint, approximately 50 mm (2 in) in diameter, on the inside surface of each length of pipe. The paint colour shall be as given in Table 27 if the pipe grade is applicable; for all other grades, the paint colour shall be as specified in the purchase order.

Table 27 . Paint colour

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11.3 Coupling markings All couplings in sizes 60,3 mm (2.375 in) and larger shall be identified with the manufacturerâ&#x20AC;&#x2122;s name or mark together with API Spec 5L. 11.4 Marking of pipe to multiple grades 11.4.1 Marking of pipe to multiple grades is permitted only by agreement between the purchaser and the manufacturer within the following limits: a) Pipe may have multiple markings within the following grade ranges: 1) L290 (X42); 2) > L290 (X42) to < L415 (X60); b) for L415 (X60) & above, multiple grade markings are not allowed; c) Pipe shall be marked to only one PSL level.

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for L415 (X60) & above, multiple grade markings are not allowed;

X60

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API

11.4.2 The manufacturer is responsible for ensuring that the pipe conforms to all requirements of each of the certified grades. This allows pipe to be used as any of the grades individually.

11.4.3 If pipe is marked to multiple grades, a single inspection document shall be issued referencing the grade combination as marked on the pipe. The inspection document may contain a specific statement that pipe conforms to each grade individually.

11.4.4 After delivery of the pipe, no re-marking or re-certification of the pipe to a different grade or different PSL level (PSL 1 to PSL 2) shall be permitted.

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After delivery of the pipe, no re-marking or re-certification of the pipe to a different grade or different PSL level (PSL 1 to PSL 2) shall be permitted.

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11.5 Thread identification and certification 11.5.1 At the manufacturer’s option, threaded-end pipe may be identified by stamping or stenciling the pipe adjacent to the threaded ends, with the manufacturers name or mark, API Spec 5B (to indicate the applicable threading specification), the specified outside diameter of the pipe and the letters “LP” (to indicate the type of thread).

The thread marking may be applied to products that do or do not bear the APImonogram.

EXAMPLE Size 168,3 mm (6.625 in) threaded-end pipe is marked as follows, using the value that is appropriate for the pipe outside diameter specified on the purchase order: (for USC units) X API Spec 5B 6.625 LP or (for SI units) X API Spec 5B 168,3 LP

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11.5.2 The use of the letters “API Spec 5B” as provided by 11.5.1 shall constitute a certification by the manufacturer that the threads so marked comply with the requirements in API Spec 5B but should not be construed by the purchaser as a representation that the product so marked is, in its entirety, in accordance with any API Specification. Manufacturers who use the letters “API Spec 5B” for thread identification are required to have access to properly certified API master pipe gauges per API Spec 5B.

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11.6 Pipe processor markings Pipe heat treated by a processor other that the original pipe manufacturer shall be marked as stipulated in the applicable sub-clauses of Clause 11. The processor shall remove any marking that does not indicate the new condition of the product as a result of heat treating (such as prior grade identity and original pipe manufacturerâ&#x20AC;&#x2122;s name or logo). If a processor is subcontracted by the pipe manufacturer and performs operations that unavoidably remove or obliterate the marking, the subcontractor may reapply the marking provided the reapplication is controlled by the pipe manufacturer.

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Stenciling of pipe number at bevel face in progress.

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Stenciling of pipe number at bevel face in progress.

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Pipe End Internal Traceability

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Pipe End Internal Traceability

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Pipe End Internal Traceability

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Pipe End Internal Traceability

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Pipe End Internal Traceability

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Pipe End Internal Traceability

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Pipe End Internal Traceability

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12. Coatings and thread protectors

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12 Coatings and thread protectors 12.1 Coatings and linings 12.1.1 Except as allowed by 12.1.2 to 12.1.4, pipe shall be delivered bare (not coated).

12.1.2 If agreed, pipe shall be delivered with a temporary external coating to provide protection from rusting in storage and transit. Such coating shall be hard to the touch and smooth, without excessive sags.

12.1.3 If agreed, pipe shall be delivered with a special coating.

12.1.4 If agreed, pipe shall be delivered with a lining.

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12.2 Thread protectors 12.2.1 For threaded pipe with D < 60,3 mm (2.375 in), the thread protectors shall be suitable fabric wrappings or shall be suitable metal, fibre or plastic protectors.

12.2.2 For threaded pipe with D ≥ 60,3 mm (2.375 in), the thread protectors shall be of such design, material and mechanical strength as to protect the thread and pipe end from damage under normal handling and transportation conditions.

12.2.3 Thread protectors shall cover the full length of the thread on the pipe, and shall exclude water and dirt from the thread during transportation and the period of normal storage, which is considered to be approximately one year.

12.2.4 The thread forms in thread protectors shall be such that they do not damage the pipe threads.

12.2.5 Protector material shall contain no compounds that are capable of causing corrosion or promoting adherence of the protectors to the threads, and shall be suitable for service at temperatures of - 45 °C to + 65 °C (-50 °F to +150 °F).

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13. Retention of Records

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13 Retention of records Records of the following inspections, if applicable, shall be retained by the manufacturer and shall be made available to the purchaser, upon request, for a period of three years after the date of purchase from the manufacturer: a) heat and product analyses; b) tensile tests; c) guided-bend tests; d) CVN tests; e) DWT tests; f) hydrostatic-tester recorder charts or electronic methods of record storage; g) radiographic images for pipe inspection; h) non-destructive inspection by other methods where applicable;

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i) qualifications of non-destructive inspection personnel; j) radiographic images for jointer welds; k) repair welding procedure tests; l) records of any other test as specified in the annexes or the purchase order, including all welding procedure specifications (WPS) and welding-procedure qualification test records (WPQT/PQR) (see Annex A and Annex D).

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14. Pipe Loading

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14 Pipe loading If the manufacturer is responsible for the shipment of pipe, the manufacturer shall prepare and follow loading diagrams that detail how the pipe is to be arranged, protected and secured on trucks, railcars, barges or ocean-going vessels, whichever is applicable. The loading shall be designed to prevent end damage, abrasion, peening and fatigue cracking. The loading shall comply with any rules, codes, standards or recommended practices which are applicable.

NOTE For additional information refer to API RP 5L1 [18] and API RP 5LW [19].

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Storage for Delivery

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API5L1

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API5LW

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API5LW

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More Reading

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Fion Zhang/Charlie Chong

Ductile Fracture Propagation In Gas Pipelines Fion Zhang/Charlie Chong

Ductile Fracture Propagation In Gas Pipelines INTRODUCTION Design of gas transportation line needs an optimal compromise between the choice of the operating pressure, linepipe geometry (diameter and thickness) and the steel mechanical properties (tensile and toughness characteristics).

The wide variety of the possible solutions requires the development of specific tools, able to estimate the safety margin with respect to the events responsible of structural failure. The initiation and propagation of a ductile or brittle longitudinal crack is one of the most serious events. As a matter of fact, the crack can affect a long part of the line, thus causing a long and costly gas delivery service breakdown. The fracture propagation control is therefore an extremely important aspect of gas transmission design. The main philosophy followed by the gas companies is to avoid brittle fracture initiation, ensuring that the operating pipeline temperature is higher than the steel ductile-brittle transition temperature, and control the ductile fracture propagation, ensuring that the linepipe steel has the capacity to absorb sufficient energy to arrest a fast propagating ductile crack. This paper deals with the problem of the ductile fracture propagation control, and describes how the full scale burst test is an useful and (sometimes) essential tool to manage the matter.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

The Ductile Fracture Propagation In Gas Pipellne Starting from crack or defect long enough, the fracture can propagate along the pipeline, in a ductile way if the temperature is above the transition temperature of the linepipe steel. ln practice after the burst, decompression waves at various pressure levels propagate in the gas away from the crack tip. In steady state propagation conditions, the crack runs at constant speed corresponding to a definite pressure level and steel toughness; if the steel toughness is higher, the fracture speed will decrease to a lower pressure level, and new steady state propagation conditions will be reached. If the steel toughness is high enough, the fracture will continuously slow, turn in a spiral direction and arrest at last.

When gases with heavy components (named "rich gases") are used, the fracture control required significantly higher levels of fracture propagation resistance than for pipeline carrying pure methane. This is because the rich gas decompresses more slowly and so the driving force acting at the crack tip remains high.

Fion Zhang/Charlie Chong

To limit the line length interested by crack propagation: ď Ž the use of gas pipeline steels having appropriate toughness is recommended to increase the capability of crack arrest. ď Ž An alternative measure can be the use of external mechanical devices (i.e. "crack arrestors") that locally increase the pipe fracture resistance.

If the first solution is not practical, because of technological and/or economical limits, the use of crack stopper devices can be taken into account.

Fion Zhang/Charlie Chong

The Ductile Fracture Propagation In Gas Pipellne

Fion Zhang/Charlie Chong

http://folk.ntnu.no/zhiliang/?page_id=322

Figure 1: Inserting high toughness pipe as integral crack arrestor

Fion Zhang/Charlie Chong

http://www.scad.ugent.be/journal/2011/SCAD_2011_2_2_296.pdf

Figure 2: Heavy wall pipe inserts

Fion Zhang/Charlie Chong

http://www.scad.ugent.be/journal/2011/SCAD_2011_2_2_296.pdf

Figure 3: Composite crack arrestor used in the Demopipe project

Fion Zhang/Charlie Chong

http://www.scad.ugent.be/journal/2011/SCAD_2011_2_2_296.pdf

Figure 4: Examples of different external crack arrestors

Fion Zhang/Charlie Chong

http://www.scad.ugent.be/journal/2011/SCAD_2011_2_2_296.pdf

Figure 6: Classification of steel sleeve crack arrestors

Fion Zhang/Charlie Chong

http://www.scad.ugent.be/journal/2011/SCAD_2011_2_2_296.pdf

Figure 7: ClockSpring crack arrestor (1: composite coil, 2: adhesive and 3: filler)

Fion Zhang/Charlie Chong

http://www.scad.ugent.be/journal/2011/SCAD_2011_2_2_296.pdf

Figure 5: Cast iron clamps as crack arrestor [11]

Fion Zhang/Charlie Chong

http://www.scad.ugent.be/journal/2011/SCAD_2011_2_2_296.pdf

The Ductile Fracture Propagation In Gas Pipellne

Fion Zhang/Charlie Chong

The Ductile Fracture Propagation Only In Gas Pipellne A sudden rupture, flaw or hole in a pressurized containment or structure will lead to an outflow of the contents and a rapidly falling loading or driving force on the stress concentrators caused by the flaw or hole. If the initial pressure is high enough and the flaw is long or severe enough, a fracture will rapidly propagate in the structure; a so-called «running fracture». For steel materials operating above the ductile-to-brittle transition temperature, the velocity of this running fracture is determined by pressure at the proximity of the tip of the moving fracture. This pressure is again determined by the speed of sound in the pressurizing medium. That is, the speed of the fracture is determined by the speed of the depressurization wave moving away from the tip of the propagating fracture.

If the pressurization wave moves faster than the fracture, the pressure at the crack tips will eventually be below what is needed to drive the fracture forward, and the fracture will stop (arrest). However, if the depressurization speed of the medium at the pressure close to the crack tip is lower than the velocity of the fracture, the fracture will continue to propagate until e.g. some mechanical hindrance (crack arrestor) increases the local fracture resistance.

This race between the depressurization wave and the fracture, we call the «fracture race» and is illustrated in the figure below.

Fion Zhang/Charlie Chong

http://bigccs.no/research/sp2-co2-transport/co2-pipeline-integrity/particular-challenges-to-co2-pipeline-transport/

For liquids, the speed of sound is roughly 1000 m/s, while the speed of ductile fractures typically is on order of 100-300 m/s. Thus, long running (ductile) fractures never take place in high pressure liquid pipelines. However, when dense-phase CO2 is depressurized, a gas-liquid (two-phase) mixture will form.

The speed of sound in such a mixture can be lower than 100 m/s while the pressure is sufficiently high to drive the running fracture, so that the fracture will not arrest. This situation is illustrated in the animation below, where one can see the profile opening of the pipe in green color, and the pressure profile in the blue line during a simulation (pure CO2) using the coupled code developed in Task 2.1. One can clearly see in the animation that no crack arrest will take place.

Fion Zhang/Charlie Chong

http://bigccs.no/research/sp2-co2-transport/co2-pipeline-integrity/particular-challenges-to-co2-pipeline-transport/

For liquids, the speed of sound is roughly 1000 m/s, while the speed of ductile fractures typically is on order of 100-300 m/s. Thus, long running (ductile) fractures never take place in high pressure liquid pipelines.

However, when dense-phase CO2 ( and other gas pipeline) is depressurized, a gas-liquid (two-phase) mixture will form. The speed of sound in such a mixture can be lower than 100 m/s while the pressure is sufficiently high to drive the running fracture, so that the fracture will not arrest. (when the speed of sound of the medium is lower than the speed of ductile fracture) This situation is illustrated in the animation below, where one can see the profile opening of the pipe in green color, and the pressure profile in the blue line during a simulation (pure CO2) using the coupled code developed in Task 2.1. One can clearly see in the animation that no crack arrest will take place.

Fion Zhang/Charlie Chong

http://bigccs.no/research/sp2-co2-transport/co2-pipeline-integrity/particular-challenges-to-co2-pipeline-transport/

In a situation where the saturation pressure is slightly lower â&#x20AC;&#x201C; either due to higher pipe pressure or lower temperature, the same pipeline material is able to arrest the running fracture. This is shown in the animation below.

Opening of the pipe in green color, and Pressure profile in the blue line

Fion Zhang/Charlie Chong

http://bigccs.no/research/sp2-co2-transport/co2-pipeline-integrity/particular-challenges-to-co2-pipeline-transport/

- No Arrest http://434113txicu25pflj3lqxy8nen.wpengine.netdna-cdn.com/wp-content/uploads/2013/10/noarrest.mp4?_=1

Opening Pressure profile Fion Zhang/Charlie Chong

http://bigccs.no/research/sp2-co2-transport/co2-pipeline-integrity/particular-challenges-to-co2-pipeline-transport/

- Arrest

Opening Pressure profile Fion Zhang/Charlie Chong

http://bigccs.no/research/sp2-co2-transport/co2-pipeline-integrity/particular-challenges-to-co2-pipeline-transport/

Animation: https://www.nde-ed.org/EducationResources/HighSchool/Sound/js_apps/speedInMaterials/

Fion Zhang/Charlie Chong

http://bigccs.no/research/sp2-co2-transport/co2-pipeline-integrity/particular-challenges-to-co2-pipeline-transport/

Summarizing: (Ductile fracture propagation occurs, when the speed of sound of the medium is lower than the speed of ductile fracture)

Fion Zhang/Charlie Chong

http://bigccs.no/research/sp2-co2-transport/co2-pipeline-integrity/particular-challenges-to-co2-pipeline-transport/

Summarising, the ductile fracture propagation in gas pipeline is characterised by the following aspects: the driving force is coming from the energy release from gas expansion during escape;  generally the crack path is linear along the top pipe generatrix;  the crack velocity is usually up to 300 m/s;  there is a prominent effect of the pipeline steel and the backfill type (soil or water) on the fracture propagation process;  there is a strong effect of the gas nature and composition on the fracture propagation process;  there is high plastic deformation field associated with the near-the-crack;  the prevention is essentially made by choosing an adequate level of pipe toughness;  a possible impediment of the crack propagation is by the use of echanical crack arrestors.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

The determination of the toughness values required for arresting ductile fracture propagation, generally measured by Charpy-V impact tests, has been historically based on the use of empirical data from full scale burst tests.

Several models in form of predictive equations, which states the minimum required value of the Charpy energy as a function of both pipe geometry and applied hoop stress (Figure 1), have been set up using data from more than one hundred of full scale burst tests, and proposed to that goal (Eiber and Bubenik (1 ), Maxey (2), Demofonti et al (3)).

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

Figure 1 -Limit of reliability of existing empirical models

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

THE FULL SCALE TEST APPROACH By the 70's, when the ductile fracture propagation arose as one of the key point for gas pipeline design in terms of both safety and economic loss, the full scale burst testing has been recognised as the only reliable test of fracture behaviour for gas pipeline. In particular, the full scale burst test can be considered as an indispensable tool for: ď Ž assessing the minimum toughness level to arrest the ductile fracture propagation in a definite short length for a specific pipeline in a specific project; ď Ž providing the experimental data concerning the fracture behaviour, in relation to the design parameters (linepipe diameter and thickness, steel grade, hoop stress level, gas nature, etc.), for the predictive models development and validation.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

In fact a full scale test provides a direct indication of the level of toughness necessary for crack arrest and, when suitably instrumented, provides also a large amount of extremely useful data as crack propagation speed, pressure decay, elasto-plastic strain field associated with the crack tip, etc. These data may be compared with those predicted by the various models, providing both confirmation of reliability and the basis for further refinement (Demofonti et al (4), Pipes and Morrison (5)). A good example of the capability of the full scale test approach to be an indispensable tool for ductile fracture propagation control was the case of the of offshore-shore pipelines: the constraint effect due to the water backfill was correctly understood only when a reduced number of burst tests (Maxey (6), Demofonti et al (7)), some of which carried out by CSM at water depth down to 30 meters (7), were performed. Thanks to the instrumentation used at that time the over-pressure field due to the water compression acting at the crack tip during the fracture propagation was measured and the resulting decrease in the applied hoop stress (about 30%) was estimated.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

Despite the high cost necessary to perform a full scale burst test, the technical and economical importance of the results coming from these tests, both for pipe makers and gas companies, pushed for carrying out a large number of full scale tests in the last 25 years (Figure 2). These tests were carried out by several actors, as Battelle Memorial Institute, Centro Sviluppo Materiali and British Gas, on behalf of several pipe makers, gas companies and international organisations interested in funding the increase of knowledge in this field; see for example the activities sponsored by the European Pipeline Research Group (Demofonti et al (8)) As a consequence of these testing activities, a certain number of full scale burst test database have been developed (CSM, AGA, EPRG, etc.) where the main test parameters (pipeline geometry, test temperature and pressure, pipes toughness, etc.) and results (propagation and arrest pipes. crack speed, etc.) are reported. In particular, the CSM database comprises the results of more than 120 burst tests (as well as the full results of the 27 tests carried out by CSM in its test site in Sardinia) on pipes with diameter ranging from 406 to 1422 mm, wall thickness from 4.8 to 30.5 mm, steel grade from X52 to X 100, and carried out in both on-shore and offshore conditions using air, natural gas or rich gas. It is noteworthy, the up-to-date cost of this huge amount oftesting is more than 60 million US dollars.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

As it is evident in Figure 2, the main effort in terms of experimental activities was done in the 70's and in the first half of the 80's. At the end of the 80's, the comprehension of the phenomenon and the relevant predictive models were good enough to justify the full scale burst testing decrease. The full scale burst testing revival in the last five years is strictly related with the development of new high grade pipeline steels (â&#x2030;ĽAPI X70) for new applications (higher pressure, richer gas). Under these conditions the straight extrapolation of the existing predictive models is not allowable, and therefore it is necessary to investigate the full scale behaviour of these new pipeline steels in terms of ductile fracture propagation (Mannucci et al (9)).

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

Figure 2- Full scale burst tests performed in the last 25 years (CSM database)

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

THE FULL SCALE BURST TEST The actual capability of a pipeline to arrest a propagating ductile fracture under certain operating conditions can be determined by a full scale burst test, where a longitudinal crack is artificially initiated. Only few organisations all around the world are able to perform a full scale burst test. Since many years, the CSM is one of the world leader in conducting such full scale tests on pipes in both on-shore and off-shore conditions (see Figure 3 and 4), using air or methane as pressurising medium (pipe diameter can reach 1422 mm, thickness up to 30 mm and internal pressure as high as 20 MP A). The test duration is usually less than 500 ms, and the acquisition system should be able to handle data on the crack propagation speed and the pressure behaviour as well as data concerning the pipe deformation and the loads acting on pipes. During a conventional burst test more than I 00 sensor signals have to be gathered, managed and analysed.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

Figure 3 - Off-shore burst test performed Figure 4 - On-shore burst test performed by CSM in open sea (30m depth, (7)) by CSM using natural gas

Fion Zhang/Charlie Chong

EXPERIMENTAL SET-UP The pipeline under investigation (typically 70 m long and consisting of several pipes welded together having an increasing toughness from the centre) is located generally in the middle of existing permanent line composed by two reservoirs (Figure 5) long enough to guarantee, during the whole crack propagation on the central test pipes, the same driving pressure, which would act on a pipeline of indefinite length. If the line to be tested is an on-shore line, the whole test section is fully covered by soil (1m or more) that is lightly compacted to reproduce the actual operating conditions. In case of an offshore line, all the test section has to be immersed into several meters of water, according to the requirements. Under controlled temperature conditions (so to assure the fully ductile fracture propagation) the test pipeline fully instrumented is pressurised at the desired hoop stress, by means of air or natural gas according to the requirements.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

Figure 5 - Conventional layout of full scale burst test.

Fion Zhang/Charlie Chong

The burst is usually caused either using an explosive charge, able to create a through thickness cut long enough to guarantee the break conditions on pipe, or creating a part wall cut by machining the pipe thickness, and afterwards acts on that cut by means of mechanical devices in order to create a through thickness critical cut (the latter is used by CSM for the off-shore testing). After the crack initiation, the fracture propagates on the upper pipe generatrix at a very high speed in both test line sides, sustained by the driving force assured by the gas decompression at the crack tip. The first and most important result is available immediately by an inspection after the test: the pipe on the central test line, which eventually causes an arrest of the crack, determines the minimal toughness requirement for the examined conditions. Other results are provided by the data acquisition system, after proper manipulation, and concern the measurement of fracture kinematics, gas pressure inside pipes, etc. as better described in the following.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

TEST INSTRUMENTATION In a full-scale burst test two different types of instrumentation can be used on test pipes. These two types can be conventionally named "conventional" and "extra“ instrumentation. The conventional instrumentation is used to measure:  the crack propagation speed, by means of Timing Wires made by electrical cables, so an on-off signal indicates when the crack arrives on a definite spot on the pipe generatrix; usually the Timing Wires are spaced each 1 meter or less along the whole test line;  the gas decompression behaviour in side the test pipes, by means of pressure transducers; a number of transducers ranging from 8 up to 10 are usually used on purpose;  the test temperature, by means of thermocouples (usually in number of 3 or more).

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

The extra instrumentation (in the addition of the conventional one) is used for obtaining additional information on the pipe elastic and plastic deformation, on the gas decompression behaviour on pipe walls and on the behaviour of the backfill during the fracture process. This is especially used when data concerning the fracture process at the crack tip have to be gathered and afterwards compared with those predicted by analytical or FEM models (finite element method) . In particular this type of instrumentation can be used to obtain information on the following aspects of the fracture phenomenon:

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

 elastic deformation on pipe associated with the fracture process, by means of electrical strain gauges, fixed to the internal and external pipe walls, to measure the strain associated with the propagation of the fracture;  plastic deformation on pipe associated with the fracture process, by means of grid lines traced on pipe for plastic strain measurement after the test;  gas decompression behaviour in the flaps zone behind the crack tip during the crack propagation, by means of internal pressure transducers located on pipes and placed along the pipe circumference starting from top pipe generatrix, to measure the pressure decay at the crack tip in circumferential direction before and after the crack arrival;  behaviour of the backfill of soil during the fracture process, by means of soil pressure transducers located both on the external pipe walls and embedded in the trench soil to measure any backfill loading.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

Figure 6 shows a CSM test line fully instrumented by Timing Wires, pressure transducers, strain gauges, load cells and soil pressure transducers. It is good manners to monitor and record each sensor signal by two independent systems, in order to increase the reliability of the measurement. A typical test layout of a full scale burst test carried out by CSM is reported in Figure 8 together with the test results in terms of crack path and propagation speed compared with the actual CharpyY toughness of the test pipes. Figure 7 shows a typical view of an on-shore line after the test.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

Figure 6 - Test line fully instrumented (CSM test)

Fion Zhang/Charlie Chong

Figure 7 - View of an on-shore test line after the burst (CSM test)

Fion Zhang/Charlie Chong

Figure 8 - Typical full scale burst test layout and results (test carried out by CSM on behalf of EPRG, (8))

Fion Zhang/Charlie Chong

FUTURE TREND The steady increase in natural gas need on the European market compels to develop new technological solutions for the long distance transportation of huge amount of gas from remote areas. For making this way economically viable one of the key point is to increase the operating pressure (and consequently the applied hoop stress); in the last decade new high grade pipeline steels (API steel grade higher than X70 and up to X100 or more) are being developed on purpose (9). The ductile fracture behaviour of these new materials lies outside the field covered by the existing experimental data (Figure 1) therefore an extrapolation is possible but not reliable. To extend the application field of the empirical models a wide range full scale test campaign should be undertaken. The design and building of pipelines for carrying rich gas mixtures represents an option more and more interesting from the gas companies point of view; gas rich o f heavy components means in fact greater amount of energy conveyed under the same conditions. Nevertheless the fracture control when rich gases are involved required significantly high levels of fracture propagation resistance. Given that it is difficult to develop simple guidelines to adjust the existing predictive models, the full scale burst test remains one of the main way to face the question.

Fion Zhang/Charlie Chong

http://www.gruppofrattura.it/pdf/volumi_igf/Case%20histories%20in%20integrity%20and%20failures%20in%20industry/7%20%20Process%20engineering%20and%20petrolchemical/The%20full%20scale%20burst%20test%20approach%20to%20evaluate%20the%20resist ance%20to%20ductile%20fracture.pdf

Moreover with the aim to study the fracture behaviour of new high grade pipelines steels, in the last ten years FEM finite element models simulating the fracture phenomenon have been developed (4). In this context the fullscale burst test, equipped with "extra instrumentation" mentioned above, is a fundamental tool for obtaining primary information in terms of physical parameters of rracture phenomenon to develop and validate the models.

Finally, the reliability of any theoretical prediction will be only as good as the range of the experimental data from which it has been derived. Predictions outside that range require confirmation by additional full scale burst tests.

Therefore, while pipeline design continues to evolve towards higher strength steels, higher operating pressure and richer gases, the process of full scale burst testing and associated refinement of predictive models will be a continuing process (5)

Fion Zhang/Charlie Chong

Sample QMS-ITP01

Fion Zhang/Charlie Chong

QMS-Sample ITP1

Fion Zhang/Charlie Chong

INSPECTION Ref

1

2

3

4

PROCESS DESCRIPTION

Inspection And Test Plan

Pre-inspection / Kick Off Meeting Manufacturing Procedure Specification

Visual / Dimensional Procedure

CONTROL POINT

PROCEDURE /CRITERIA

VERIFICAT ION

M

C

3r d

H

H

H

Submit ITP for Approval

ITP k065_2016

Approved Inspection and Test Plan

Meeting

TBA

Minutes of Meeting

H

H

H

Submit Procedure For Approval

TBA

Approved MPS

H

H

R

Submit Procedure For Approval

TBA

Approved Procedure

H

R

R

H: Hold Point, W: Witness Point, R: Review, M: Monitor Fion Zhang/Charlie Chong

INSTRU CTIONS

INSPECTION

Ref

PROCESS DESCRIPT ION

CONTROL POINT

PROCEDURE /CRITERIA

5

NDT Procedures

Submit Procedure For Approval

TBA

6

Mechanical Testing Procedures

Submit Procedure For Approval

7

Field Weldability Procedure

Submit Procedure For Approval

VERIFICAT ION

M

C

3rd

Approved Procedure

H

R

R

TBA

Approved Procedure

H

R

R

TBA

Approved Procedure

H

R

R

H: Hold Point, W: Witness Point, R: Review, M: Monitor

Fion Zhang/Charlie Chong

INSTRU CTIONS

a

b

c

d

Steel Making Ladle Analysis

Chemical composition

Slab Continuous Casting

Slab condition

Slab Heating

Heating temperature

Strip Hot Rolling

Rolling temperature Rolling reduction Width & thickness

MPS Korea_201 6 Q-1

Process computer and technical standard

Ladle analysis data in L4

MPS Korea_201 6 Q-2

Process computer and technical standard

--

MPS Korea_201 6 Q-3

Process computer and technical standard

--

MPS Korea_201 6 Q-4

Process computer and technical standard

--

H: Hold Point, W: Witness Point, R: Review, M: Monitor Fion Zhang/Charlie Chong

M R

M R

M R

M

M

M

M

M

M

M

M

M

e

f

Strip Mechanical Testing

Strip Mechanical properties

MPS Korea_201 6 Q-5

Process computer and technical standard

Strip Visual and Dimension Inspection

Traceability Chemical composition Mechanical properties of hot coil Mechanical properties of hot coil

MPS Korea_201 6 M-1

Process computer and working instruction

H: Hold Point, W: Witness Point, R: Review, M: Monitor

Fion Zhang/Charlie Chong

Information sheet of coiled strip in MES and L4

M R

M R

M R

H

M R

M R

g

h

i

j

Coil Open

Shear/End Welding

Strip Edge Milling

Strip UT

Traceability Width & thickness

MPS Korea_201 6 M-2

Working instruction

MPS Korea_201 6 M-3

Process computer and working instruction

Operating sheets and logging

Width Shape of strip edge

MPS Korea_201 6 M-4

Process computer and working instruction

Operating sheets and logging

No requirement.

MPS Korea_201 6 M-5

Process computer and working instruction

--

Traceability

H: Hold Point, W: Witness Point, R: Review, M: Monitor Fion Zhang/Charlie Chong

List of coil charging M

M

M

M

M

M

M

M

M

M R

W R

W R

k

l

m

Cold Forming

HFW

Flash Trimming

Strip surface Circumferential length

MPS Korea_201 6 M-6

Process computer and working instruction

--

Heat input Velocity Squeeze

MPS Korea_201 6 M-7

Process computer and working instruction

PQR

Outer flash condition Inner flash height

MPS Korea_201 6 M-8

Process computer and working instruction

Operating sheets

H: Hold Point, W: Witness Point, R: Review, M: Monitor

Fion Zhang/Charlie Chong

M

M

M

M

M R

M R

M

M

M

n

o

p

q

Longitudinal MPS imperfections in Korea_201 weld 6 M-9 Minimum wall thickness along the weld seam

Process computer and working instruction

Inspection chart

Heat Treatment

Heat treatment type Heat treatment temperature Heating width

MPS Korea_201 6 M-10

Process computer and working instruction

Temperatur e chart

Sizing and Straightenin g

Reduction Outside diameter

MPS Korea_201 6 M-11

Process computer and working instruction

Operating sheets

Cutting to Length

Length

MPS Korea_201 6 M-12

Process computer and working instruction

Operating sheets and logging

Online Seam UT

H: Hold Point, W: Witness Point, R: Review, M: Monitor Fion Zhang/Charlie Chong

M

W

W R

M R

M R

M R

M

M

M

M

M

M

r

s

t

MPS Korea_201 6 M-13

Process computer and working instruction

Flattening test record

Chemical composition Mechanical property

MPS Korea_201 6 M-14

Process computer and working instruction

Material test data in L4

Shape of pipe end

MPS Korea_201 6 M-15

Process computer and working instruction

Operating sheets

Flattening Test

Cracks opening

Material Tests

End Beveling

H: Hold Point, W: Witness Point, R: Review, M: Monitor

Fion Zhang/Charlie Chong

H R

W R

W R

H

W

W R

M

M

M

u

v

Hydrostatic Testing

Test pressure Holding time

MPS Korea_201 6 M-16

Process computer and working instruction

Pressure chart

Pipe NDT

UT Longitudinal imperfections in weld and Lamination end check UT Imperfections in repaired area MT Lamination Check

MPS Korea_201 6 M-17

Process computer and working instruction

UST report Inspection chart Calibration record Inspection sheet

H: Hold Point, W: Witness Point, R: Review, M: Monitor

Fion Zhang/Charlie Chong

H R

H R

M R

H

W

M R

w

x

Visual and Dimension Inspection

First day production tests

Surface quality Shape Dimension

Mechanical Tests Chemical Composition

MPS Korea_201 6 M-18

MPS Korea_201 6 M-13 To MPS Korea_201 6 M-18

Process computer and working instruction

Process computer and working instruction

H: Hold Point, W: Witness Point, R: Review, M: Monitor Fion Zhang/Charlie Chong

Inspection sheet

MPS Korea_201 6 M-13 To MPS Korea_201 6 M-18

M R

MR

M R

H

H

H

y

z

a1

a2

Measureme nt of Length and weight

Length weight

Marking and Packing

Marking items and bevel protectors

Handling and shipping

Surface quality Pipe end quality

Documentat Traceability Inspection and ion examination result

MPS Korea_201 6 M-19

Process computer and working instruction

Weight and length list in MES

MPS Korea_201 6 M-20

Process computer and working instruction

--

MPS Korea_201 6 M-21

Process computer and working instruction

--

MPS Korea_201 6 M-22

Process computer and working instruction

Inspection Release Note IRN / Weight list

H: Hold Point, W: Witness Point, R: Review, M: Monitor Fion Zhang/Charlie Chong

M

M

M

M

M

M

M

M

M

H

H

H

QMS-Sample MPS

Fion Zhang/Charlie Chong

No

Process

Procedure

A1

Steel Making

1.1. Molten iron shall be manufactured from the Basic Oxygen blast furnace at Molten Iron Plant at XXXX.

Ladle

1.2. Iron shall be poured and carried by torpedo cars.

Analysis

1.3. Steel making method: Molten iron shall be manufactured from the blast furnace. Basic oxygen converter shall be applied.

Carbon and phosphorus are reduced to the specified levels.

1.4. Molten iron shall be desulphurised by the injection of CaO. Aiming sulfur level shall be equal to or under 0.005%.

Fion Zhang/Charlie Chong

No

Process

Procedure

Steel

1.6. Deoxidization practice: Al-Si killed steel. After the converter process, molten steel shall be poured into the ladle. Average weight of one heat would be approximately 450 tons. Al shall be added to reduce the oxygen content in the steel during tapping.

Making Ladle Analysis

1.7. Chemical composition range and aim composition [%]

Note: V+Nb+Tiâ&#x2030;¤0.12% ;Al/Nâ&#x2030;Ľ2/1 For each reduction of 0,01 % below the specified maximum for carbon, an increase of 0,05 % above the specified maximum for manganese is permissible, up to a maximum increase of 0,20 %.

Fion Zhang/Charlie Chong

No

Process

Procedure

Steel

1.8. Special additions: After this, alloy such as Nb, V, Ti and Mn shall be added to the steel and then calcium wire shall be fed to modify non-metallic inclusion morphology.

Making Ladle Analysis

1.9. Ladle treatments: While tapping, Al shall be added to reduce the oxygen content in the steel.

1.10. Vacuum de-gassing: To reduce the gaseous elements such as H, RH degassing process shall be applied. Sulfide shape control: controlled by injection of CaSi. 1.11. Heat analysis: Chemical composition shall be checked.

Fion Zhang/Charlie Chong

Steel Making Ladle Analysis

Fion Zhang/Charlie Chong

No

Process

A2

Slab 2.1. Continuous Casting Mill Standard: The continuous casting Continuous machine is 1900mm vertical bending type which produces slabs Casting with 200~250mm thickness, 900~1900mm width and maximum length 12000mm.

Fion Zhang/Charlie Chong

Procedure

No

Process

Procedure

Slab 2.2. Slab treatments: A series of advanced processes and Continuous technologies are adopted, such as argon blowing in ladle on the Casting turret, mould level control, secondary cooling section air and water cooling, and compressed casting. Central segregation are rare have been reduced and superficial cracks of the cast slabs are avoided. The techniques of multi-point straightening, EMB, on-line width-adjusting and high-frequency low-amplitude oscillation are adopted in the continuous casting process. In addition to those measures, a computer system is used for predicting the break-out and for dynamically controlling the secondary cooling, the optimum cutting length of slabs, he abnormal slab quality judgment, and the compression casting, etc. During this continuous casting process, the controlling parameter such as the pre-set cast velocity and the cast temperature are to be monitored through the industrial TV.

Fion Zhang/Charlie Chong

No

Process

Procedure

Slab 2.3. Frequency of centerline segregation monitoring: Macroscopic Continuous examination shall be done at the top of the first slab of per flow Casting and per heat.

2.4. Surfaces inspection: Each slab shall be visually checked after hot scarifying. If necessary, shall be re-scarified to comply with the mill standard.

2.5. Thermal cutting: Each slab shall be cut by the torch at the adequate length. Thermal cutting of cold slabs shall not be permitted.

2.6. Heat No. shall be stamped on the slabs automatically after cutting.

Fion Zhang/Charlie Chong

Continuous Casting Mill

Fion Zhang/Charlie Chong

Slab Continuous Casting

Fion Zhang/Charlie Chong

Slab Continuous Casting

Fion Zhang/Charlie Chong

Slab Continuous Casting

Fion Zhang/Charlie Chong

No

Process

Procedure

A3

Slab Heating

3.1. Furnace details: Waking beam type, 350 ton/hr/Furnace, 1 in pre-heating zone, 2 in heating zone and 1 in heat keeping zone.

3.2. Temperature: All slabs shall be re-heated to required temperature (SRT), before the rough rolling at the hot strip mill.

Controlling range of SRT shall be between 1160 and 1220â&#x201E;&#x192;.

3.3. Average heating rate shall be about 5 degree Celsius depending on the temperature of the slab before heating-up and the setting temperature of slab.

3.4. Hold time: about 240 min.

Fion Zhang/Charlie Chong

Slab Reheating

Fion Zhang/Charlie Chong

Slab Reheating

Fion Zhang/Charlie Chong

No

Process

Procedure

A4

Strip Hot Rolling

4.1. Location rolling mill: XXXX rolling plant, iron & steel Co., Ltd. 4.2. Rolling equipment used: 2050 or 1880 product line 4.3. Rolling details for all stage 4.3.1. Rolling direction: Longitudinal 4.3.2. Surface scales of the heated slabs shall be removed.

4.3.3. Temperature: 4.3.3.1. The FET shall be in non recrystalization temperature. The temperature before the finish rolling (FET) shall be between 1190±30°C 4.3.3.2. Percentage reduction below 950°C shall be controlled between 60.8%~82.4%.

4.3.3.3. The temperature after finish rolling (FT) shall be checked.

Measured temperature of FDT shall be between 820±15°C.

Fion Zhang/Charlie Chong

No

Process

Procedure

Strip Hot Rolling

4.3.4. Cooling medium, cooling rates and percentage: Automatically accelerated cooling by water shall be applied to achieve the fine grain structure. The temperature after cooling (CT) shall be checked. Measured temperature of CT shall be between 540¹15°C..

4.3.5. Geometry control: Width and thickness are roughly adjusted to finish rolling schedule. Strips shall be rolled to the final dimensions required from the order at the finish rolling stands.

Width and thickness of strips shall be dynamically [X-ray devices] monitored and controlled.

4.4. Appearance of coils shall be checked by online surface inspector.

4.5. Coil No. : Each coil shall be marked ID numbers automatically.

Each coil shall be packing by steel band and ID numbers shall be stamped.

Fion Zhang/Charlie Chong

Strip Hot Rolling

Fion Zhang/Charlie Chong

Strip Hot Rolling

Fion Zhang/Charlie Chong

Strip Hot Rolling

Fion Zhang/Charlie Chong

Strip Hot Rolling

Fion Zhang/Charlie Chong

Strip Hot Rolling

Fion Zhang/Charlie Chong

Strip Hot Rolling

Fion Zhang/Charlie Chong

Strip Hot Rolling

Fion Zhang/Charlie Chong

Strip Hot Rolling

Fion Zhang/Charlie Chong

Strip Hot Rolling

Fion Zhang/Charlie Chong

Strips (Coils)

Fion Zhang/Charlie Chong

Strips (Coils)

Fion Zhang/Charlie Chong

No

Process

A5

5.1. Test frequency: A set per heat.

Strip Mechanical 5.2. Heat No. and Sampling coil No. shall be recorded.

Testing 5.3. Tests requirements as below

Fion Zhang/Charlie Chong

Procedure

No

Process

Procedure

Strip 5.4. Requirements of mechanical properties Mechanical Testing

Fion Zhang/Charlie Chong

Strips (Coils) â&#x20AC;&#x201C; Mechanical Testing

Fion Zhang/Charlie Chong

No

Process

B1

Strip Visual 1.1. Strip Inspection and Dimension Inspection

Procedure

1.1.1. Surface visual inspection: No dents, Hard Spots, cracks, slivers, and depth of the others shall be less than 6% of the thickness.

1.1.2. Dimensions check shall be done per coil. The strip width measurements shall be made with a tape, and strip thickness measurements shall be made with a mechanical caliper.

Fion Zhang/Charlie Chong

No

Process

Procedure

Strip Visual 1.2. Information in the computer system of each Heat and Coil shall be checked. and Dimension Inspection

Fion Zhang/Charlie Chong

No

Process

Procedure

B2

Coil Open

2.1. Heat No., Coil No., dimension (width and thickness) and material code must be checked before the coil put into product line. The information shall be recorded in MES. (MES is the computer system for production controlling) 2.2. Strip Inspection 2.2.1. Surface visual inspection: No dents, Hard Spots, cracks, slivers, and depth of the others shall be less than 6% of the thickness.

2.3. Dimensions check shall be done per coil. The strip width measurements shall be made with a tape, and strip thickness measurements shall be made with a mechanical caliper. The values shall conform to the requirements in item M-1.

Fion Zhang/Charlie Chong

No

Process

Procedure

B3

Shear/End Welding

3.1. CO2 flowâ&#x2030;Ľ20 l/min 3.2. Offset of strip edgesâ&#x2030;¤1 mm

3.3. Drilled hole: To indicate change of Coil No., A hole is punched after the cross weld in the middle of strip. It will be identified in the following process.

Fion Zhang/Charlie Chong

Shear/End Welding

Fion Zhang/Charlie Chong

No

Process

Procedure

B4

Strip Edge Milling

4.1. Trimming speed: not higher than 30m per minute.

4.2. Strip width after milling shall be checked with a tape when any adjustment is made, and once every 4 hours thereafter. Strip width after milling shall conform to the requirements below.

4.3. Milled edge surface shall be visual checked when any adjustment is made and monitored frequently. The round part of strip edge shall be clearly trimmed. The milled surface shall be clean, free of burrs, fragments, scales and cracks.

Fion Zhang/Charlie Chong

No

Process

Procedure

B5

Strip UT

5.1. Detect laminar imperfections in the strip according to ISO 12094.

5.2. Qualification of Personnel: Level I / II according to ASNT SNTTC-1A. 5.3. search units 5.3.1. Arrangements 5.3.2. Test directions and tracks 5.3.2.1. Strip edge: Longitudinal 5.3.2.2. Strip body: Perpendicular 5.3.3. Longitudinal speed: 30m/min Max. 5.3.4. Amount: 10 probes for strip edge, and 27 probes for strip body

Fion Zhang/Charlie Chong

No

Process

Procedure

Strip UT

5.4. Material 5.4.1. Type of strip: Hot rolled strip 5.4.2. Size Width :610~2100mm Wall thickness : 4.0mm â&#x20AC;&#x201C; 20.0mm 5.4.3. Surface condition: As rolled 5.5. Inspection procedure 5.5.1. Calibration frequency 5.5.1.1. At the beginning of production run 5.5.1.2. At the beginning & end of each shift 5.5.1.3. Every four hours of each shift under continuous production run

Fion Zhang/Charlie Chong

No

Process

Procedure

Strip UT

5.5.2. Reference standard and coverage (TBA) 5.5.3. Acceptable criteria (TBA) 5.6. An audible device shall be used to indicate the loss of coupling effectiveness.

5.7. Marking: The parts with laminar defects and unexamined are stenciled in different color .

5.8. Drilled hole: The detector rise automatically to avoid been broken down, and the information of the coil is recorded.

Fion Zhang/Charlie Chong

No

Process

Procedure

B6

Cold Forming

6.1. The outer girth of strip shall be measured with a tape when any adjustment is made, and once every 4 hours thereafter.

Fion Zhang/Charlie Chong

Cold Forming

Fion Zhang/Charlie Chong

Cold Forming

Fion Zhang/Charlie Chong

Cold Forming

Fion Zhang/Charlie Chong

No

Process

Procedure

B7

HFW

7.1. All personnel performing HFW activities shall be qualified in the technique applied.

7.2. Parameter of HFW

Fion Zhang/Charlie Chong

No

Process

Procedure 7.3. Pilot line: Stenciled along the pipe at 9 oâ&#x20AC;&#x2122;clock.

7.4. Marking: The parts which are not welded properly (Not welded or the welding temperature out of the range) are stenciled in yellow.

7.5. Macro examination: Samples shall be taken from the first two coils and every heat thereafter in 12 hours.

7.5.1. Macro: to determine the heated bandwidth, flow line and welding quality, etched with 2 - 5% natal, the heated bandwidth and flow line shall be measured, flow line angle should be between 55 to 75 degrees at 1/4T and 3/4T, the welding line should be free of cracks, arc burns, discontinuities, slag inclusions.

Fion Zhang/Charlie Chong

HFW-ERW

â&#x2013; https://www.youtube.com/embed/FFpHWt9zj_w

Fion Zhang/Charlie Chong

http://1080.plus/EasyDrape_More_than_a_Pipe_and_Drape_System!_by_ShowTex/xEO_3QQqcr4.video

HFW-ERW

Fion Zhang/Charlie Chong

HFW-ERW

â&#x2013; https://www.youtube.com/embed/h7QROwtJt8Y

Fion Zhang/Charlie Chong

No

Process

Procedure

Flash Trimming

8.1. Internal weld bead: +0.5mm/-0.3mm

Fion Zhang/Charlie Chong

8.2. External weld bead: shall be trimmed to an essentially flush condition.

No

Process

Procedure

Online Seam UT

9.1. All personnel performing NDT activities shall be qualified in the technique applied, in accordance with ISO 9712 or equivalent.

9.2. Detect longitudinal imperfections along weld seam and minimum wall thickness along the welding line. Specification refers to table below.

Fion Zhang/Charlie Chong

No

Process

Procedure 9.3. Calibration frequency 9.3.1. At the beginning of production run 9.3.2. At the beginning & end of each shift 9.3.3. Every four hours of each shift under continuous production run 9.4. An audible device shall be used to indicate the loss of coupling effectiveness.

9.5. Marking: The parts with defects and unexamined are stenciled in different color on the outside surface.

9.6. Cross weld: The detector rise automatically to avoid been broken down, and the information of the coil is recorded.

Fion Zhang/Charlie Chong

No

Process

Fion Zhang/Charlie Chong

Procedure

HF-ERW Pipe Mill Pre-Heat Treatment AUT

Fion Zhang/Charlie Chong

HF-ERW Pipe Mill Pre-Heat Treatment AUT

Fion Zhang/Charlie Chong

HF-ERW Pipe Mill Pre-Heat Treatment AUT

Fion Zhang/Charlie Chong

https://www.youtube.com/embed/DCbsasWZkFw

No

Process

Procedure

Heat Treatment

10.1. All personnel performing Heat Treatment activities shall be qualified in the technique applied.

10.2. Weld Seam Heat Treatment online

10.3. The temperatures shall be continuously monitored and controlled by a computer system.

10.4. Marking: The parts not heat treated properly are stenciled in red on the outside surface.

Fion Zhang/Charlie Chong

No

Process

Procedure

Sizing and Straightening

11.1. The diameter measurements shall be made with a tape, and the values shall conform to the requirements as below.

Fion Zhang/Charlie Chong

Sizing & Straightening

Fion Zhang/Charlie Chong

Sizing & Straightening

Fion Zhang/Charlie Chong

Sizing & Straightening

Fion Zhang/Charlie Chong

No

Process

Procedure

Cutting to Length

12.1. Lengths will be confirmed by Company/Buyer in the Purchase order. The length of the first length shall be measured after any adjustment was made.

12.2. Pipe ends shall be cut square within 1.5 mm and shall be checked with a square when the weld line being halted over 30 minutes.

12.3. Jointers shall not be supplied.

12.4. Pipe No.: TBA 12.5. Drilled hole: for end joint cutting, flattening test sampling 12.6. One representative sample of pipe shall be tested to destruction.

Fion Zhang/Charlie Chong

Cu-Off Unit

Fion Zhang/Charlie Chong

Cu-Off Unit

Fion Zhang/Charlie Chong

Cu-Off Unit

â&#x2013; https://www.youtube.com/embed/acy5AjWjkq4

Fion Zhang/Charlie Chong

Cu-Off Unit

Fion Zhang/Charlie Chong

https://www.youtube.com/watch?v=J3poK0IDBsc

Cu-Off Unit

Fion Zhang/Charlie Chong

Cu-Off Unit

Fion Zhang/Charlie Chong

No

Process

Procedure

Flattening Test

13.1. Flattening test frequency and sample direction.

Fion Zhang/Charlie Chong

No

Process

Procedure 13.2. Flattening test acceptance criteria.

Fion Zhang/Charlie Chong

No

Process

Procedure 13.3. Each end of every length shall be retested if any test fails.

The retests for each end of each individual length shall be made with the weld at 90째 and 0째.

13.4. Coil No., Pipe No. and Sample No. will be recorded in the test data.

Fion Zhang/Charlie Chong

Cu-Off Section for Testing

Fion Zhang/Charlie Chong

Cu-Off Unit- Cone Testing

Fion Zhang/Charlie Chong

https://www.youtube.com/watch?v=J3poK0IDBsc

Flattening Testing

Fion Zhang/Charlie Chong

https://www.youtube.com/watch?v=J3poK0IDBsc

No

Process

Procedure

Material Tests

14.1. Test frequency: Tests as specified in the table below shall be made from a pipe/pipes representing each lot. The term â&#x20AC;&#x153;lotâ&#x20AC;? is defined as pipes of the same specified size, wall thickness from the same heat of steel, 100 lengths or fraction thereof.

14.2. Testing shall be performed after the final heat treatment and after sizing.

14.3. Heat No., Lot No. and Sampling Pipe No. shall be recorded.

14.4. Tests requirements

Fion Zhang/Charlie Chong

No

Process

Procedure

Material Tests

Temperature: Room temperature Sample shape: Rectangular TĂ&#x2014;38.1mm 50.8mm gage length Specimen shall be flattened.

Fion Zhang/Charlie Chong

No

Process

Procedure

Material Tests

Impact test ASTM A 370 Pipe body 1 set/lot Weld seam 1 set/lot 90째 from the weld seam Direction: Transverse Circumferential location:

Fion Zhang/Charlie Chong

Test temperature: 0째C Sample shape: 10*10*55mm.

Notch type: Charpy V

No

Process

Procedure

Material Tests

Metallographic- Micro examination Weld seam / HAZ 1 set/lot Cross Section HAZ of welding shall be covered by heat treatment. No Martensitic remained.

Fion Zhang/Charlie Chong

No

Process

Procedure

Material Tests

Hardness Weld seam HAZ and body 1 set/lot Spot distribute below: ASTM E92 â&#x2030;¤270HV10

Fion Zhang/Charlie Chong

No

Process

Procedure

Material Tests

14.5. Chemical composition[%]

Note: V+Nb+Tiâ&#x2030;¤0.12% ;Al/Nâ&#x2030;Ľ2/1 For each reduction of 0,01 % below the specified maximum for carbon, an increase of 0,05 % above the specified maximum for manganese is permissible, up to a maximum increase of 0,20 %.

Fion Zhang/Charlie Chong

No

Process

Procedure

Material Tests

14.6. Requirements of mechanical properties

Fion Zhang/Charlie Chong

No

Process

Procedure

B15

End Beveling

15.1. Bevel angle: 30(+5/-0)째 15.2. Root face: 1.60(+0.80mm/-0.80mm) 15.3. Internal taper: less than 7째 15.4. Variables above shall be checked once every 2 hours at least with gauge. The lengths beveled after previous check shall be recheck when any beveled end does not comply with the requirements above.

Fion Zhang/Charlie Chong

No

Process

Procedure

B16

Hydrostatic 16.1. Each length of pipe shall be hydrostatic tested, and the test Testing pressure and hold time as following:

16.3. When hydrostatic testing, weld seam shall be at the position from 11 o’clock to 1 o’clock.

16.4. Pipe No. The number of pipe shall be recorded if the length is rejected in the process of hydrostatic test.

16.5. The pressure gauge used for hydrostatic testing shall be calibrated with a “dead weight tester” in the presence of Purchaser’s Inspector.

Fion Zhang/Charlie Chong

Hydrostatic Testing

Fion Zhang/Charlie Chong

http://www.prdcompany.com/hydrostatic-pipe-testing-machine-hptm/

Hydrostatic Testing

Fion Zhang/Charlie Chong

Hydrostatic Testing

Fion Zhang/Charlie Chong

http://www.prdcompany.com/hydrostatic-pipe-testing-machine-hptm/

Hydrostatic Testing

Fion Zhang/Charlie Chong

http://www.prdcompany.com/hydrostatic-pipe-testing-machine-hptm/

Hydrostatic Testing

Fion Zhang/Charlie Chong

No

Process

Procedure

B17

Pipe NDT

17.1. All personnel performing NDT activities shall be qualified in the technique applied, in accordance with ISO 9712 or equivalent.

17.2. Purpose: Detect longitudinal imperfections and lamination along the weld by UT, Pipe ends are examined by UT and MPI, and acceptance criteria refers to the table below.

Fion Zhang/Charlie Chong

No

Process

Procedure 17.3. The distribution of probes are figured following:

No.1-4：probes used for detection of longitudinal defects, 14*14mm，4MHZ No.5-6：probes used for detection of transversal defects，14*14mm，4MHZ No.7-8：probes used for detection of laminations，35*6mm，10MHZ

Fion Zhang/Charlie Chong

No

Process

Procedure 17.4. The configuration of reference standards is given in the following pictures:

Fion Zhang/Charlie Chong

No

Process

Procedure

A：Inside longitudinal notch，B：Outside longitudinal notch，C： Drilled hole，D：Outside Transverse notch，E：Inside Transverse notch， F：Inside FBH，G：Outside FBH

Fion Zhang/Charlie Chong

No

Process

Procedure 17.5. Reference Standards 17.5.1. Reference standards shall have within 0.30mm tolerance of specified diameter and thickness as the product being inspected and contain machined notches.

17.5.2. Machined notches 17.5.2.1. Longitudinal imperfections of weld seam 17.5.2.1.1. Drilled hole: 3.2mm diameter, drilled through the wall and perpendicular to the surface of the reference standard.

17.5.2.1.2. Notch: 25mm length, 1.0 max. width, 10%WT(within 0.3~1.5mm) depth, tolerance: Âą15% notch depth(Âą0.05mm min.), on the inside and outside surface, parallel to the weld seam.

17.5.2.2. Lamination 17.5.2.2.1. FBH: <5mm diameter, 25~50%WT(max. 10mm) depth, perpendicular to the surface of the reference standard.

Fion Zhang/Charlie Chong

No

Process

Procedure 17.6. Ultrasonic flaw detector of weld seam 17.6.1. Testing method 17.6.1.1. Ultrasonic flaw detecting is in accordance with pulse-echo method of angle beam technique using water gap coupling.

17.6.1.2. Testing is carried out using three search units and each unit consists of 2 probes.

17.6.1.3. Flaw detecting is carried out by the angle probes. And the acoustic coupling condition between the search unit and the pipe tested is also checked by the same technique.

Fion Zhang/Charlie Chong

No

Process

Procedure 17.6.2. Characteristics of the equipment 17.6.2.1. 2 directions of detecting 17.6.2.1.1. Flaw detecting is carried out from both sides of welded seam.

17.6.2.2. Multi-probe search unit for tandem probe technique.

17.6.2.3. Device for correct positioning of the probe.

17.6.2.4. Acoustic coupling monitor.

17.6.2.5. Lamination test.

17.6.2.6. Untested length for pipe end: â&#x2030;¤100mm.

Fion Zhang/Charlie Chong

No

Process

Procedure 17.6.3. Acceptance criteria 17.6.3.1. Weld and nearby area lamination acceptance criteria 17.6.3.1.1. Lamination of 5mm or more is considered a defect.

Fion Zhang/Charlie Chong

No

Process

Procedure 17.7. Ultrasonic flaw detector for longitudinal imperfections of pipe ends 17.7.1. Testing method 17.7.1.1. Ultrasonic flaw detecting is in accordance with pulse-echo method of angle beam technique by direct contact method, and it is carried out from both sides of the welded seam.

17.7.2. Inspection procedure 17.7.2.1. Reference standards shall have the same specified diameter and wall thickness as the product to be inspected and shall contain artificial defect in accordance with the specification.

17.7.2.2. Coverage: within 150mm of both pipe ends 17.7.2.3. Any imperfection that produces a signal greater than the signal received from the reference standard shall not be accepted.

Fion Zhang/Charlie Chong

No

Process

Procedure 17.8. Ultrasonic flaw detector for laminations of pipe ends 17.8.1. Testing method 17.8.1.1. The test employs the pulse echo technique by direct contact method. A double crystal probe is arranged at the surface of each pipe end, and goes and returns by zig-zag scan with the stroke of 50mm.

17.8.2. Inspection procedure 17.8.2.1. Reference standard plate has the same specified thickness as the product to be inspected and contains specified artificial defect.

17.8.2.2. Untested length for pipe end: â&#x2030;¤10mm.

17.8.3. Acceptance criteria 17.8.3.1. Lamination of 5mm or more is considered a defect.

Fion Zhang/Charlie Chong

No

Process

Procedure 17.9. Ultrasonic flaw detector for laminations of pipe body 17.9.1. Testing method 17.9.1.1. Suspicious areas marked by strip UT is tested by manual UT. 17.9.2. Acceptance criteria 17.9.2.1. Lamination defects accumulation shall not exceed 4inches in longitudinal direction.

17.10. MPI inspection 17.10.1. Four inches of internal and outer surface at both ends shall be inspected by MPI. 17.10.2. No lamination is allowed.

Fion Zhang/Charlie Chong

No

Process

Procedure 17.11. Calibration frequency 17.11.1. At the beginning of production run 17.11.2. At the beginning & end of each shift 17.11.3. Every four hours of each shift under continuous production run

Fion Zhang/Charlie Chong

No

Process

Procedure 17.12. Re-inspection: 17.12.1. If the signal obtained from the calibration reflector used to establish the acceptance limit is more than 4dB lower than the acceptance limit, all pipe inspected after the last preceding acceptable calibration shall be re-inspected after recalibration has been accomplished.

17.12.2. If any factors other than sensitivity have changed with may have resulted in an inadequate UT, the equipment shall be recalibrated and the affected pipe re-inspected.

Fion Zhang/Charlie Chong

No

Process

Procedure 17.13. An audible device shall be used to indicate the loss of coupling effectiveness.

17.14. Marking: The parts with defects and unexamined are stenciled in different color on the outside surface.

17.15. Residual Magnetism: Residual magnetism in each pipe shall be less than 20 gauss (2.0 mT), checked every 2 hours.

17.16. Repair of defect and verify: Defects shall be removed by grinding or cut out. If grinding is applied to remove defects, the remaining wall thickness shall be determined using ultrasonic inspection techniques. At no time shall the remaining wall thickness be less than the specified minimum wall thickness.

17.17. All markings on the pipe denote locations where alarm limits were exceeded shall be removed once it is confirmed that a defect is not present

Fion Zhang/Charlie Chong

Sizing & Straightening

Fion Zhang/Charlie Chong

https://www.youtube.com/embed/iMR-O4e-Tio

HF-ERW Pipe Mill Pre-Heat Treatment AUT

â&#x2013; https://www.youtube.com/embed/HvFcM3jwCGY

Fion Zhang/Charlie Chong

Pipe Mill SAWH Automatic UT Spiral SAW Pipe Ultrasonic Inspection Systems - Including 100% Body Inspection

Fion Zhang/Charlie Chong

https://www.youtube.com/embed/oMpbokQK9Tk

Ultrasonic ERW Pipe Testing Feb 2016

â&#x2013; https://www.youtube.com/embed/GkTlRtz0XGM

Fion Zhang/Charlie Chong

Sizing & Straightening

â&#x2013; https://www.youtube.com/embed/oW-tNkhE5f8

Fion Zhang/Charlie Chong

No

Process

B18

Visual and Dimension Inspection

Fion Zhang/Charlie Chong

Procedure

No

Process Visual and Dimension Inspection

Fion Zhang/Charlie Chong

Procedure

No

Process Visual and Dimension Inspection

Fion Zhang/Charlie Chong

Procedure

No

Process

Procedure

Visual and

18.1. Surface inspection:

Dimension

18.1.1. Pipe must be free of dents, cracks and arc-burns.

Inspection

18.1.2. Dents: All cold-formed dents with a sharp bottom gouge and all sharp gouges (without dents) deeper than 1.0mm shall be considered injurious defect.

18.2. Defects removing: Defects may be removed by grinding, provided that the wall thickness remaining is not below the specified wall thickness less the minus tolerance, will be accepted provided that the edges of the defects have been ground smooth and that all such areas are spaced at a minimum of two pipe diameters. In all cases where grinding repairs are made as a result of imperfections disclosed by non-destructive testing, the part of the pipe containing such repairs shall be given an additional nondestructive test after the grinding operation.

18.3. All markings on the pipe denote locations where alarm limits were exceeded shall be removed once it is confirmed that a defect is not present.

Fion Zhang/Charlie Chong

No

Process

B19

Measurement of Length and weight

Fion Zhang/Charlie Chong

Procedure

No

Process

Procedure

B20

Marking and Packing

20.1. Paint color: White, Size of capitals: minimum height 19mm.

20.2. a 50mm wide daub of heat resistant white paint on the inside surface at each end of each pipe to mark the location of the weld line.

20.2.1. The progressive number shall be punched on one bevel end. Stamping is permitted only on the pipe bevel ends.

20.2.2. External surface marking: According to order requirements.

20.2.3. Internal surface marking: According to order requirements.

20.3. Stencil position: The stencil shall begin at a point at 457.2~758mm from one end on external surface.

20.4. Vanish coating shall be performed on stencil markings internal and external.

20.5. For pipe with O.Dâ&#x2030;Ľ406mm, the markings shall be on the inside.

20.6. The pipe number shall be punched on one bevel end.

Stamping is permitted only on the pipe bevel ends.

Fion Zhang/Charlie Chong

No

Process

Procedure

Handling and shipping

21.1. End protector: Each end of pipe shall be protected with cap and Knitted Cloth with Film to avoid possible damages and foreign materials entry during transportation.

21.1.1. Material: Carbon Steel 21.1.2. Strip thickness: 2mm 21.1.3. Connect mode: Screw 21.2. Stacking: The pipe must be stacked in a staggered pattern so that each pipe in the stack is continuously supported by two pipes in the row below. Height of stacking shall be within 3.5m.

21.3. Load & Unload: All handing shall be performed with certified soft slings, or pipe-shaped padded hooks.

21.4. Conveyances: Conveyances shall be cleaned of debris or any substance that might damage the line pipe. Suitable timber shall be used to protect the line pipe against damage in transit.

Fion Zhang/Charlie Chong

End Guards

Fion Zhang/Charlie Chong

No

Process

Procedure

Documenta 22.1. At the time of delivery, two copies of following documents tion shall be provided.

22.1.1. COMPANY’S Purchase Order & Item Number.

22.1.2. Pipe size &Specification.

22.1.3. Mill Heat Numbers& Control Numbers.

22.1.4. Chemical properties, mechanical properties and relative test report— Mill certificates 22.1.5. All inspection report 22.1.6. Hydrostatic test report 22.1.7. NDT report 22.1.8. Number of the pipe, heat number and purchase order number—Mill certificates & Packing lists 22.1.9. Length, weight, size— Packing lists 22.1.10. Mill certificates 22.1.11. Inspection Release Note Fion Zhang/Charlie Chong

Pipe Storage & Stacking

Fion Zhang/Charlie Chong

More Reading on TMCP

Fion Zhang/Charlie Chong

Fion Zhang/Charlie Chong

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Peach – 我爱桃子

Fion Zhang/Charlie Chong

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Fion Zhang/Charlie Chong

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Fion Zhang/Charlie Chong