Api5l part 2 of 2b by charlie Chong

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

The Inspector Perspective Reading 1 Part 2/2B 2nd May 2016

Charlie Chong/ Fion Zhang

Annex K

Fion Zhang/Charlie Chong

Annex K (normative) Non-destructive inspection for pipe ordered for sour service and/or offshore service K.1 Introduction This annex applies if the pipe is ordered for sour service or offshore service or both [see 7.2 c) 55) and/or 7.2 c) 59)]. For such pipe, the non-destructive inspection provisions of Annex E apply, except as specifically modified by the provisions in this annex.

Fion Zhang/Charlie Chong

K.2 General non-destructive inspection requirements and acceptance criteria K.2.1 Laminar imperfections at the pipe ends K.2.1.1 Laminar imperfections > 6,4 mm (0.25 in) in the circumferential direction and having an area > 100 mm2 (0.15 in2) shall be classified as defects. K.2.1.2 For pipe with t â&#x2030;Ľ 5,0 mm (0.197 in), ultrasonic inspection with automated/semi-automated systems in accordance with ISO 10893-8 or by manual methods, as specified in Annex A of ISO 10893-8, shall be used to verify that the 50 mm (2.0 in) wide zone at each pipe end is free of such laminar defects.

Fion Zhang/Charlie Chong

K.2.1.3 If agreed for pipe with t â&#x2030;Ľ 5,0 mm (0.197 in), ultrasonic inspection with automated/semiautomated systems in accordance with ISO 10893-8 or by manual methods, as specified in Annex A of ISO 10893-8, shall be used to verify that the 100 mm (4.0 in) wide zone at each pipe end is free of such laminar defects. K.2.1.4 If agreed, the end face/bevel at each pipe end shall be magnetic particle inspected for the detection of laminar imperfections in accordance with ISO 10893-5 or ASTM E709. Laminar imperfections â&#x2030;Ľ 6,4 mm (0.25 in) in the circumferential direction shall be classified as defects. Non-destructive testing of steel tubes Part 8: Automated ultrasonic testing of seamless and welded steel tubes for the detection of laminar imperfections (ISO 10893-8:2011)

Fion Zhang/Charlie Chong

ISO 10893-2011 - Non-destructive testing of steel tubes 1. Part 1: Automated electromagnetic testing of seamless and welded (except submerged arcwelded) steel tubes for the verification of hydraulic leaktightness 2. Part 2: Automated eddy current testing of seamless and welded (except submerged arcwelded) steel tubes for the detection of imperfections 3. Part 3: Automated full peripheral flux leakage testing of seamless and welded (except submerged arc-welded) ferromagnetic steel tubes for the detection of longitudinal and/or transverse imperfections 4. Part 4: Liquid penetrant inspection of seamless and welded steel tubes for the detection of surface imperfections 5. Part 5: Magnetic particle inspection of seamless and welded ferromagnetic steel tubes for the detection of surface imperfections 6. Part 6: Radiographic testing of the weld seam of welded steel tubes for the detection of imperfections 7. Part 7: Digital radiographic testing of the weld seam of welded steel tubes for the detection of imperfections 8. Part 8: Automated ultrasonic testing of seamless and welded steel tubes for the detection of laminar imperfections 9. Part 9: Automated ultrasonic testing for the detection of laminar imperfections in strip/plate used for the manufacture of welded steel tubes 10. Part 10: Automated full peripheral ultrasonic testing of seamless and welded (except submerged arc-welded) steel tubes for the detection of longitudinal and/or transverse imperfections 11. Part 11: Automated ultrasonic testing of the weld seam of welded steel tubes for the detection of longitudinal and/or transverse imperfections Fion Zhang/Charlie Chong

ISO 10893-2011 - Non-destructive testing of steel tubes 1. Part 1: Automated electromagnetic testing of seamless and welded (except submerged arc-welded) steel tubes for the verification of hydraulic leaktightness 2. Part 2: Automated eddy current testing of seamless and welded (except submerged arc-welded) steel tubes for the detection of imperfections 3. Part 3: Automated full peripheral flux leakage testing of seamless and welded (except submerged arc-welded) ferromagnetic steel tubes for the detection of longitudinal and/or transverse imperfections 4. Part 4: Liquid penetrant inspection of seamless and welded steel tubes for the detection of surface imperfections 5. Part 5: Magnetic particle inspection of seamless and welded ferromagnetic steel tubes for the detection of surface imperfections 6. Part 6: Radiographic testing of the weld seam of welded steel tubes for the detection of imperfections

Fion Zhang/Charlie Chong

7. Part 7: Digital radiographic testing of the weld seam of welded steel tubes for the detection of imperfections 8. Part 8: Automated ultrasonic testing of seamless and welded steel tubes for the detection of laminar imperfections 9. Part 9: Automated ultrasonic testing for the detection of laminar imperfections in strip/plate used for the manufacture of welded steel tubes 10.Part 10: Automated full peripheral ultrasonic testing of seamless and welded (except submerged arc-welded) steel tubes for the detection of longitudinal and/or transverse imperfections 11.Part 11: Automated ultrasonic testing of the weld seam of welded steel tubes for the detection of longitudinal and/or transverse imperfections

Fion Zhang/Charlie Chong

K.2.2 Suspect pipe K.2.2.1 Pipe giving rise to indications producing a trigger/alarm condition as a result of the specified non-destructive inspection operation shall be deemed suspect. K.2.2.2 Suspect pipe shall be dealt with in accordance with the applicable standard for nondestructive inspection of pipe, unless otherwise stated in this annex, Annex H or Annex J, whichever is applicable. K.2.2.3 Repair by welding shall be in accordance with Clause C.4. K.2.2.4 Where dressing is carried out, complete removal of defects shall be verified by local visual inspection, aided where necessary by suitable nondestructive inspection methods. K.2.2.5 Any manual non-destructive inspection applied to local suspect areas (dressed or not) shall use the same inspection sensitivity, parameters and acceptance level (reference notch depth) as used during the inspection that originally deemed the pipe to be suspect. For manual ultrasonic inspection, the scanning speed shall be 150 mm/s (6 in/s). Fion Zhang/Charlie Chong

K.3 Non-destructive inspection of SMLS pipe K.3.1 Ultrasonic inspection for longitudinal imperfections SMLS pipe shall be full-body ultrasonically inspected for the detection of longitudinal imperfections in accordance with ISO 10893-10 or ASTM E213. The acceptance limits for such inspection shall be in accordance with ISO 10893-10, acceptance level U2/C.

Fion Zhang/Charlie Chong

K.3.2 Laminar imperfections in the pipe body K.3.2.1 For sour service, individual laminations and/or lamination densities exceeding the acceptance limits for sour service given in Table K.1 shall be classified as defects. Compliance with such requirements shall be verified by ultrasonic inspection in accordance with ISO 10893-8 (except 4.2), ASTM A435 or ASTM A578. The coverage during automatic inspection shall be 20 % of the pipe surface. K.3.2.2 For offshore service, individual laminations and/or lamination densities exceeding the acceptance limits for offshore service given in Table K.1 shall be classified as defects. If agreed, compliance with such requirements shall be verified by ultrasonic inspection in accordance with ISO 10893-8 (except 4.2), ASTM A435 or ASTM A578. The coverage during automatic inspection shall be 20 % of the pipe surface.

Fion Zhang/Charlie Chong

K.3.3 Ultrasonic thickness measurements SMLS pipe shall be subjected to full peripheral ultrasonic inspection in accordance with ISO 10893-12 or ASTM E114 for verification of compliance with the applicable minimum permissible wall thickness requirement. The coverage for such inspection shall be 25 % of the pipe surface or, if agreed, a greater minimum coverage.

Fion Zhang/Charlie Chong

K.3.4 Supplementary non-destructive inspection K.3.4.1 If agreed, SMLS pipe shall be ultrasonically inspected for the detection of transverse imperfections in accordance with ISO 10893-10 acceptance level U2/C, or ASTM E213. K.3.4.2 If agreed, SMLS pipe shall be full-body inspected using the flux leakage method in accordance with ISO 10893-3 acceptance level F2, or ASTM E570 for the detection of longitudinal imperfections and/or ISO 108933 acceptance level F2, or ASTM E570, for the detection of transverse imperfections.

Fion Zhang/Charlie Chong

K.3.4.3 If agreed, SMLS pipe shall be full-body inspected for the detection of imperfections using the eddy current method in accordance with ISO 10893-2 acceptance level E2H/E2, or ASTM E309. K.3.4.4 If agreed, subsequent to all other non-destructive inspection operations and visual inspection, full-body magnetic particle inspection shall be carried out in accordance with ISO 10893-5 or ASTM E709 on one SMLS pipe per heat of steel or batch of 50 pipes produced, whichever is fewer, in order to verify compliance with the requirements of 9.10. Such pipes shall be selected at random and, before inspection, subjected to abrasive blasting to produce an external surface preparation of Sa 2?in accordance with ISO 8501-1:1988 when blasted.

Fion Zhang/Charlie Chong

Table K.1 . Acceptance criteria for laminar imperfections

Fion Zhang/Charlie Chong

■ ωσμ∙Ωπ∆∇ º≠δ≤>ηθφФρ|β≠Ɛ∠ ʋ λ α ρτ ×∫ √ ≠≥ѵФΣ

Fion Zhang/Charlie Chong

K.4 Non-destructive inspection of HFW pipe K.4.1 Non-destructive inspection of the weld seam The full length of the weld seam shall be ultrasonically inspected for the detection of longitudinal imperfections, with the acceptance limits being in accordance with one of the following: a) ISO 10893-11 acceptance level U2/U2H; b) ISO 10893-10 acceptance level U3, or, if agreed, acceptance level U2; c) ASTM E273. K.4.2 Laminar imperfections in the pipe body If agreed, the pipe or strip/plate body shall be ultrasonically inspected for the detection of laminar imperfections in accordance with ISO 10893-8 (except 4.2) or ISO 10893-9 respectively, to acceptance limits for the relevant application as given in Table K.1. The coverage during automatic inspection shall be â&#x2030;Ľ20 % of the pipe surface.

Fion Zhang/Charlie Chong

K.4.3 Laminar imperfections on the strip/plate edges or areas adjacent to the weld seam If agreed, the strip/plate edges or the areas adjacent to the weld seam shall be ultrasonically inspected over a width of 15 mm (0.6 in) for the detection of laminar imperfections, in accordance with ISO 10893-9 or ISO 10893-8 respectively, to the acceptance limits as given in Table K.1 for strip/plate edges or areas adjacent to the weld seam. K.4.4 Supplementary non-destructive inspection If agreed, the pipe body of HFW pipe shall be inspected for the detection of longitudinal imperfections using the ultrasonic method in accordance with ISO 10893-10 with acceptance level U3/C or, if agreed, U2/C or ASTM E213, or the flux-leakage method in accordance with ISO 10893-3 acceptance level F3; or, if agreed, acceptance level F2, or ASTM E570.

Fion Zhang/Charlie Chong

K.5.1 Ultrasonic inspection for longitudinal and transverse imperfections in seam welds K.5.1.1 The full length of the weld seams of SAW pipe shall be ultrasonically inspected for the detection of longitudinal and transverse imperfections in accordance with ISO 10893-11 acceptance level U2, with the following modifications. a) The notch depth shall be 2,0 mm (0.080 in). b) The use of internal and external longitudinal notches located on the centre of the weld seam for equipment standardization purposes is not permitted.

Fion Zhang/Charlie Chong

c) As an alternative to the use of the reference hole for equipment calibration for the detection of transverse imperfections, it is permissible to use acceptance level U2 internal and external notches, lying at right angles to, and centred over, the weld seam. In this case, both internal and external weld reinforcements shall be ground flush to match the pipe contour in the immediate area and on both sides of the reference notches. The notches shall be sufficiently separated from each other in the longitudinal direction and from any remaining reinforcement, to give clearly identifiable separate ultrasonic signal responses. The full signal amplitude from each of such notches shall be used to set the trigger/alarm level of the equipment. As an alternative to the use of acceptance Level U2 notches for equipment standardization, it ispermissible, if agreed, to use a fixed-depth internal and external notch and increase the inspection sensitivity by electronic means (i.e. increase in decibels). In this case (known as the â&#x20AC;&#x153;two-lambda method â&#x20AC;&#x153;), the depth of the notches shall be twice the wavelength at the ultrasonic frequency in use. The wavelength, , expressed in metres (feet), is given by Equation (K.1):

Fion Zhang/Charlie Chong

where Vt is transverse ultrasonic velocity, expressed in metres per second (feet per second); f is frequency, expressed in hertz (cycles per second). EXAMPLE At 4 MHz test frequency, the wavelength is 0,8 mm (0.031 in) and the notch depth is 1,6 mm (0.063 in). The required increase in inspection sensitivity shall be based upon pipe thickness and the manufacturer shall demonstrate to the satisfaction of thepurchaser that the inspection sensitivity achieved is essentially equivalent to that achieved when using acceptance level U2 notches. d) The manufacturer may apply the provisions of K.5.3 to retest the suspect areas. Fion Zhang/Charlie Chong

K.5.1.2 For SAWH pipe, the full length of the coil/plate end weld shall be ultrasonically inspected using the same inspection sensitivity and parameters as used on the helical-seam weld in accordance with K.5.1.1. n addition, the T-joints, where the extremities of the coil/plate end weld meet the helical- eam weld, shall be subjected to radiographic inspection in accordance with Clause E.4. K.5.1.3 For jointers, the full length of the girth weld shall be ultrasonically inspected using the same inspection sensitivity and parameters as used on the helical or longitudinal seam weld in accordance with K.5.1.1. In addition, the T- joints, where the girth weld intersects the longitudinal seam in SAWL pipe or the helical seam in SAWH pipe, shall be subjected to radiographic inspection in accordance with Clause E.4.

Fion Zhang/Charlie Chong

K.5.2 Laminar imperfections in the pipe body and on the strip/plate edges K.5.2.1 The pipe or strip/plate body shall be ultrasonically inspected for the detection of laminar imperfections in accordance with ISO 10893-9 to cceptance limits for the relevant service condition as given in Table K.1, with a coverage of 20 %. Such inspection may be carried out in the strip/plate mill or in the pipe mill. K.5.2.2 The strip/plate edges, including those adjacent to the coil/plate end weld of helical-seam pipe, shall be ultrasonically inspected over a width of 15 mm (0.6 in) for the detection of laminar imperfections in accordance with ISO 10893-9 to acceptance limits as given in Table K.1 for trip/plate edges or areas adjacent to the weld seam.

Fion Zhang/Charlie Chong

K.5.3 Non-destructive inspection of the weld seam at the pipe ends/repaired areas The length of weld seam at pipe ends that cannot be inspected by the automatic ultrasonic equipment and repaired areas of the weld seam (see Clause C.4), shall be subjected to the following. a) For the detection of longitudinal imperfections, manual or semi-automatic ultrasonic inspection using the same inspection sensitivity and inspection parameters as is specified in K.5.1.1 or, if agreed, radiographic inspection in accordance with Clause E.4. b) For the detection of transverse imperfections, a manual/semi-automatic ultrasonic inspection using the same inspection sensitivity and parameters as is specified in K.5.1.1 or a radiographic inspection in accordance with Clause E.4. For manual ultrasonic inspection, the scanning speed shall be 150 mm/s (6 in/s).

Fion Zhang/Charlie Chong

K.5.4 Supplementary non-destructive inspection operation If agreed, the external and internal surfaces of the ultimate 50 mm (2.0 in) length of weld seam at both ends of each pipe shall be subjected to magnetic particle inspection in accordance with ISO 10893-5 or ASTM E709. Any indications in excess of 3,0 mm (0.12 in) shall be investigated and treated in accordance with Clause C.2.

Fion Zhang/Charlie Chong

More Reading on: Understanding ISO 10893 Non-destructive testing of steel tubes â&#x20AC;&#x201C; Part 11:Automated ultrasonic testing of the weld seam of welded steel tubes for the detection of longitudinal and/or transverse imperfections

Fion Zhang/Charlie Chong

Sample NDT Test Plan

Fion Zhang/Charlie Chong

Summarizing: NOTE:

Fion Zhang/Charlie Chong

Annex L

Fion Zhang/Charlie Chong

Annex L (informative) Steel designations Table L.1 gives guidance on steel designations (steel numbers) which are used in Europe additionally to the steel name.

Fion Zhang/Charlie Chong

Table L.1 . List of corresponding additional steel designations (steel numbers) for use in Europe

Fion Zhang/Charlie Chong

Table L.1 . List of corresponding additional steel designations (steel numbers) for use in Europe

Fion Zhang/Charlie Chong

Table L.1 . List of corresponding additional steel designations (steel numbers) for use in Europe

Fion Zhang/Charlie Chong

Table L.1 . List of corresponding additional steel designations (steel numbers) for use in Europe

Fion Zhang/Charlie Chong

Table L.1 . List of corresponding additional steel designations (steel numbers) for use in Europe

Fion Zhang/Charlie Chong

Table L.1 . List of corresponding additional steel designations (steel numbers) for use in Europe

Fion Zhang/Charlie Chong

Table L.1 . List of corresponding additional steel designations (steel numbers) for use in Europe

Fion Zhang/Charlie Chong

Summarizing: NOTE:

Fion Zhang/Charlie Chong

Annex M

Fion Zhang/Charlie Chong

Annex M [Annex Removed] Page intentionally blank. This Annex has been removed. But in order to maintain Annex numbering, it is left in the document for historical purposes.

Fion Zhang/Charlie Chong

Summarizing: NOTE:

Fion Zhang/Charlie Chong

Annex N

Fion Zhang/Charlie Chong

Annex N (informative) Identification/explanation of deviations Page intentionally blank. (Maintaining Annex numbering for historical purposes).

Fion Zhang/Charlie Chong

Summarizing: NOTE:

Fion Zhang/Charlie Chong

Annex O

Fion Zhang/Charlie Chong

Annex O (informative) Use of the API Monogram by Licensees O.1 Scope The API Monogram Program allows an API Licensee to apply the API Monogram to products. The API Monogram Program delivers significant value to the oil and gas industry by linking the verification of an organization's quality management system with the demonstrated ability to meet specific product specification requirements. The use of the Monogram on products constitutes a representation and warranty by the Licensee to purchasers of the products that, on the date indicated, the products were produced in accordance with a verified quality management system and in accordance with an API product specification.

Fion Zhang/Charlie Chong

When used in conjunction with the requirements of the API License Agreement, API Spec Q1, in its ntirety, defines the requirements for those organizations who wish to voluntarily obtain an API license to provide API monogrammed products in accordance with an API product specification. API Monogram Program licenses are issued only after an on-site audit has verified that the Licensee conforms to the requirements described in API Spec Q1 in total, and the requirements of an API product specification. Customers/users are requested to report to API all problems with API monogrammed products.

Fion Zhang/Charlie Chong

The effectiveness of the API Monogram Program can be strengthened by customers/users reporting problems encountered with API monogrammed products. A nonconformance may be reported using the API Nonconformance Reporting System available at http://compositelist.api.org/ncr.asp. API solicits information on new product that is found to be nonconforming with APIspecified requirements, as well as field failures (or malfunctions), which are judged to be caused by either specification deficiencies or nonconformities with API-specified requirements. This annex sets forth the API Monogram Program requirements necessary for a supplier to consistently produce products in accordance with API-specified requirements. For information on becoming an API Monogram Licensee, please contact API, Certification Programs, 1220 L Street, N. W., Washington, D.C. 20005 or call 202-962-4791 or by email at certification@api.org.

Fion Zhang/Charlie Chong

O.2 References In addition to the referenced standards listed earlier in this document, this annex references the following standard: API Specification Q1. For Licensees under the Monogram Program, the latest version of this document shall be used. The requirements identified therein are mandatory.

Fion Zhang/Charlie Chong

O.3 API Monogram Program: Licensee Responsibilities O.3.1 Maintaining a License to Use the API Monogram For all organizations desiring to acquire and maintain a license to use the API Monogram, conformance with the following shall be required at all times: a) the quality management system requirements of API Spec Q1; b) the API Monogram Program requirements of API Spec Q1, Annex A; c) the requirements contained in the API product specification(s) for which the organization desires to be licensed; d) the requirements contained in the API Monogram Program License Agreement.

Fion Zhang/Charlie Chong

O.3.2 Monogrammed Product . Conformance with API Spec Q1 When an API-licensed organization is providing an API monogrammed product, conformance with APIspecified requirements, described in API Spec Q1, including Annex A, is required.

Fion Zhang/Charlie Chong

O.3.3 Application of the API Monogram Each Licensee shall control the application of the API Monogram in accordance with the following. a) Each Licensee shall develop and maintain an API Monogram marking procedure that documents the marking/monogramming requirements specified by the API product specification to be used for application of the API Monogram by the Licensee. The marking procedure shall define the location(s) where the Licensee shall apply the API Monogram and require that the Licensee's license number and date of manufacture be marked on monogrammed products in conjunction with the API Monogram. At a minimum, the date of manufacture shall be two digits representing the month and wo digits representing the year (e.g. 05-07 for May 2007) unless otherwise stipulated in the applicable API product specification. Where there are no API product specification marking requirements, the Licensee shall define the location(s) where this information is applied.

Fion Zhang/Charlie Chong

b) The API Monogram may be applied at any time appropriate during the production process but shall be removed in accordance with the Licensee.s API Monogram marking procedure if the product is subsequently found to be nonconforming with API-specified requirements. Products that do not conform to API-specified requirements shall not bear the API Monogram. c) Only an API Licensee may apply the API Monogram and its license number to API monogrammable products. For certain manufacturing processes or types of products, alternative API Monogram marking procedures may be acceptable. The current API requirements for Monogram marking are detailed in the API Policy Document, Monogram Marking Requirements, available on the API Monogram Program website at http://www.api.org/certifications/monogram/. d) The API Monogram shall be applied at the licensed facility. e) The authority responsible for applying and removing the API Monogram shall be defined in the Licensee.s API Monogram marking procedure.

Fion Zhang/Charlie Chong

O.3.4 Records Records required by API product specifications shall be retained for a minimum of five years or for the period of time specified within the product specification if greater than five years. Records specified to demonstrate achievement of the effective operation of the quality system shall be maintained for a minimum of five years. O.3.5 Quality Program Changes Any proposed change to the Licensee.s quality program to a degree requiring changes to the quality manual shall be submitted to API for acceptance prior to incorporation into the Licensee's quality program.

Fion Zhang/Charlie Chong

O.3.6 Use of the API Monogram in Advertising Licensee shall not use the API Monogram on letterheads or in any advertising (including company sponsored web sites) without an express statement of fact describing the scope of Licenseeâ&#x20AC;&#x2122;s authorization (license number). The Licensee should contact API for guidance on the use of the API Monogram other than on products.

Fion Zhang/Charlie Chong

O.4 Marking requirements for Products O.4.1 General These marking requirements apply only to those API Licensees wishing to mark their products with the API Monogram. O.4.2 Product specification identification The following marking requirements apply only to those API licensees wishing to mark their products with the API Monogram. The complete API Monogram marking consists of the following:

Fion Zhang/Charlie Chong

the letters "Spec 5L", the manufacturer's API license number, the API monogram, the date of manufacture (defined as the month and year when the monogram is applied by the manufacturer). NOTE As defined in Clause 4, the manufacturer may be, as applicable, a pipe mill, processor, maker of couplings or threader. The API Monogram marking shall be applied only to products complying with the requirements of the specification and only by licensed manufacturers.

Fion Zhang/Charlie Chong

O.4.3 Marking of pipe and couplings O.4.3.1 The API monogram marking, as defined in O.4.2, shall be inserted in the markings described in 11.2.1 and 11.3 as applicable, following the manufacturer's name or mark. O.4.3.2 Following are examples of the markings listed in Clause 11.2.1 with the monogram (API) inserted where: X represents the manufacturer; #### represents the license number; Y represents the customerâ&#x20AC;&#x2122;s inspection representative, if applicable; and Z represents the identification number which permits the correlation of the product or delivery unit (e.g. bundled pipe) with the related inspection document, if applicable. EXAMPLE 1 For USC units X API Spec 5L-#### (API) (MO-YR) 20 0.500 X52M PSL 2 SAWL Y Z EXAMPLE 2 For SI units X API Spec 5L-#### (API) (MO-YR) 508 12,7 L360M PSL 2 SAWL Y Z

Fion Zhang/Charlie Chong

   

X represents the manufacturer; #### represents the license number; Y represents the customer’s inspection representative, if applicable; and Z represents the identification number which permits the correlation of the product or delivery unit (e.g. bundled pipe) with the related inspection document, if applicable.

EXAMPLE 1 For USC units X API Spec 5L-#### (API) (MO-YR) 20 0.500 X52M PSL 2 SAWL Y Z EXAMPLE 2 For SI units X API Spec 5L-#### (API) (MO-YR) 508 12,7 L360M PSL 2 SAWL Y Z

Fion Zhang/Charlie Chong

O.4.3.3 For cases where the pipe also meets the requirements of a compatible standard .ABC., the following are examples of the markings listed in Clause 11.2.1 with the monogram (API) inserted where: X represents the manufacturer; #### represents the license number; Y represents the customerâ&#x20AC;&#x2122;s inspection representative, if applicable; and Z represents the identification number which permits the correlation of the product or delivery unit (e.g. bundled pipe) with the related inspection document, if applicable. EXAMPLE 3 For USC units X API Spec 5L-#### (API) (MO-YR) / ABC 20 0.500 X52M PSL 2 SAWL Y Z EXAMPLE 4 For SI units X API Spec 5L-#### (API) (MO-YR) / ABC 508 12,7 L360M PSL 2 SAWL Y Z

Fion Zhang/Charlie Chong

O.4.4 Bundle identification O.4.4.1 For pipe of size 48,3 mm (1.900 in) or smaller, the identification markings specified in 11.2.1 shall be placed on the tag, strap, or clip used to tie the bundle as described in 11.2.2. For example, size 48,3mm (1.900 in), specified wall thickness 3,7 mm (0.145 in), Grade B, high frequency welded, plain-end pipe should be marked as follows, using the values that are appropriate for the pipe dimensions specified on the purchase order: EXAMPLE 5 For USC units X API Spec 5L-#### (API) (MO-YR) 1.9 0.145 B PSL 1 HFW Y Z EXAMPLE 6 For SI units X API Spec 5L-#### (API) (MO-YR) 48,3 3,7 L235 PSL 1 HFW Y Z

Fion Zhang/Charlie Chong

O.4.4.2 For the case where the pipe also meets the requirements of a compatible standard ABC, the following are examples of the markings: EXAMPLE 7 For USC units X API Spec 5L-#### (API) (MO-YR) / ABC 1.9 0.145 B PSL 1 HFW Y Z EXAMPLE 8 For SI units X API Spec 5L-#### (API) (MO-YR) / ABC 48,3 3,7 L245 PSL 1 HFW Y Z

Fion Zhang/Charlie Chong

O.4.5 Thread identification At the manufacturer.s option, threaded-end pipe may be identified by stamping or stenciling the pipe adjacent to the threaded ends, with the threaderâ&#x20AC;&#x2122;s API license number, the API Monogram (API), immediately followed by the date of threading (defined as the month and year the Monogram is applied), the specified outside diameter of the pipe, and LP to indicate the type of thread. The thread marking may be applied to products that o or do not bear the API monogram. For example, size 168,3 mm (6.625 in) threaded-end pipe may be marked as follows, using the value that is appropriate for the pipe outside diameter specified on the purchase order: EXAMPLE 9 For USC units X API Spec 5L-#### (API) (MO-YR of threading) API Spec 5B 6.625 LP EXAMPLE 10 For SI units X API Spec 5L-#### (API) (MO-YR of threading) API Spec 5B 168,3 LP If the product is clearly marked elsewhere with the manufacturerâ&#x20AC;&#x2122;s identification, his license number, as above, may be omitted. Fion Zhang/Charlie Chong

O.4.6 Thread certification The use of the Monogram (API) as provided in O.5 shall constitute a certification by the manufacturer that the threads so marked comply with the requirements stipulated in the latest edition of 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 Monogram (API) for thread identification are required to have access to properly certified API reference master thread gages.

Fion Zhang/Charlie Chong

O.4.7 Units Product should be marked with U.S. customary (USC) or metric (SI) units. Combination of dual units [metric (SI) units and USC units] is not acceptable. O.4.8 License number The API Monogram license number shall not be used unless it is marked in conjunction with the API Monogram. O.5 API Monogram Program: API Responsibilities The API shall maintain records of reported problems encountered with API monogrammed products. ocumented cases of nonconformity with APIpecified requirements may be reason for an audit of the Licensee involved (also known as audit for .cause.). Documented cases of specification eficiencies shall be reported, without reference to Licensees, customers or users, to API Subcommittee 18 (Quality) and to the applicable API Standards Subcommittee for corrective actions.

Fion Zhang/Charlie Chong

Annex P

Fion Zhang/Charlie Chong

Annex P (informative) Equations for Threaded and Coupled Pipe and Background Equations for Guided Bend and CVN Test Specimens

Skip

Fion Zhang/Charlie Chong

■ ωσμ∙Ωπ∆∇ º≠δ≤>ηθφФρ|β≠Ɛ∠ ʋ λ α ρτ ×∫ √ ≠≥ѵФΣ

Fion Zhang/Charlie Chong

More Reading

Fion Zhang/Charlie Chong

Revision 3 Verfasser/Dokument PV Plates for sour Service

Requirements for steel plates in sour service

Sour Service

Revision 3 Verfasser/Dokument PV Plates for sour Service

an introduction in the world of hydrogen induced corrosion

Sour service damage is not a new issue ! The oldest reports about sour service steel damage more than 60 years old Many organisations (like NACE or EFC), oil- and gas companies, engineering companies are still improving regulations

The importance of hydrogen damage due to sour service is more and more recognised.

Verfasser/Dokument

The exploitation of sour gases and out of sour oil sources is rising. Often sweet sources get more and more sour.

Requirements for steel plates in sour service

3 3

Why this sensitivity to sour service damage?

Sour media are aggressive to steel structures, damages not easy to detect.

Health and safety of personnel and the public are in danger if precautions in survey of equipment and a right material selection are not adjusted.

Severe environmental pollution could be the consequence out of such damages.

Shutdowns due to material failures and the replacement of pressure vessels can cause dramatic economical loss. Accident at Chicago refinery in 1984; 17 people killed.

Verfasser/Dokument

A really bad example:

Many good reasons for our full attention

Requirements for steel plates in sour service

4 4

Verfasser/Dokument

Union Oil absorber vessel failure resulting from cracks growing in HAZ with no PWHT

Requirements for steel plates in sour service

5 5

The view of the steel plate manufacturer Steel plate requisitions reflect an increasing demand for plates with improved properties for sour service Large variety of customer requests: - many specifications based on published recommendations or test methods (e.g. NACE MR 0175, TM0284...) - in combination with the “in house”-experience and -prescriptions Aim of this paper: - general overview over the damaging mechanisms

Verfasser/Dokument

- general survey about the current specified requisitions for plate orders - Dillinger Hütte GTS possibilities to supply improved steel plates

Requirements for steel plates in sour service

6 6

Revision 3 Verfasser/Dokument PV Plates for sour Service

Damaging Mechanisms and Test Methods

What are the sour service corrosion mechanisms? Hydrogen-Induced Cracking (HIC) & Hydrogen Blistering

Sulfide Stress Cracking (SSC)

probably to be taken into consideration:

Verfasser/Dokument

Stress-Oriented Hydrogen-Induced Cracking (SOHIC)

Requirements for steel plates in sour service

8 8

Cracking mechanism in the steel during H2S corrosion process

Acidic, H2S -containing medium Sulfide Ionics Hydrogen Sulfide Proton Hydrogen Atom

Verfasser/Dokument

Electrons

Molecular Hydrogen

Steel with typical small imperfections Requirements for steel plates in sour service

9 9

Corrosion reaction

H2S → 2 H+ + S2Fe + 2 H+ → Fe2+ + 2 Had Fe2+ + S2- → FeS H2S + Fe → FeS + 2 Hab

Verfasser/Dokument

2 Hab → H2

Requirements for steel plates in sour service

10 0

Schematical appearance of damage mechanisms in sour service

SSC

Requirements for steel plates in sour service

Blistering

Verfasser/Dokument

HIC / SWC

SOHIC

11 1

Corrosion at stress free prismatic specimens

HIC Hydrogen Induced Cracking

Definition as per NACE MR0175/ISO 15156:

Requirements for steel plates in sour service

Verfasser/Dokument

Planar cracking that occurs in carbon and low alloy steels when atomic hydrogen diffuses into the steel and then combines to form molecular hydrogen at trap sites.

12 2

NACE TM 0284-2003 “Evaluation of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen-Induced Cracking”

HIC:

Stepwise internal cracking on different planes of the metal;

origin:

1984, for evaluation and comparison of test result

test solution:

pH 3 (sol. A) and pH 5 (sol. B) saturated with H2S

test specimens:

position (one end/mid width) , preparation, dimensions

duration:

96 h

evaluation:

metallographic examination of cross sections

acceptance crit.:

to be agreed between purchaser and supplier

documentation:

CLR, CTR, CSR values for each section, specimen, test

Requirements for steel plates in sour service

Verfasser/Dokument

no external stress

13 3

Verfasser/Dokument

Test specimen location acc. to NACE TM 0284

Requirements for steel plates in sour service

14 4

HIC test method acc. to NACE TM 0284 Test specimens 0 10

test solution Solution A

test duration: 96h test solution: saturated with H2S

- pH 3 - 5% NaCl, 0.5% CH3COOH - identical to Solution A of NACE TM 0177

Solution B - pH 5 - synthetic seawater acc. ASTM D1141

Requirements for steel plates in sour service

15 5

Verfasser/Dokument

H2S

Verfasser/Dokument

In Detail

Requirements for steel plates in sour service

16 6

test specimens during HIC-test

Requirements for steel plates in sour service

17 7

Verfasser/Dokument

HIC test vessel

sectioning of test

Examination of the polished sections:

specimens

b a T

faces to be examined

20 mm

25 m m

e 25 m dir m ing ll ro

on i t c

W CLR =

∑ a ⋅100%

CSR =

∑ (a ⋅ b) ⋅100%

CTR =

∑ b ⋅100 % T

W ⋅T

a = crack length

b = crack width

W = specimen length T = specimen thickness Crack distance < 0.5 mm => single crack

Requirements for steel plates in sour service

18 8

Verfasser/Dokument

25 m m m 5m

Verfasser/Dokument

HIC or SWC damage

Requirements for steel plates in sour service

19 9

A516 GR70 Amine Contactor1 Requirements for steel plates in sour service

Verfasser/Dokument

Hydrogen Blistering

1: NACE RP0296 2

20 0

Verfasser/Dokument

Hydrogen Blistering

A516 GR70 Amine Contactor1

Requirements for steel plates in sour service

1: NACE RP0296 2

21 1

Amine Contactor/Water Wash Tower1 Requirements for steel plates in sour service

Verfasser/Dokument

Blister Cracking

1: NACE RP0296 2

22 2

Corrosion at specimens under stress

SSC Sulfide Stress Cracking

Verfasser/Dokument

Definition as per NACE MR0175/ISO15156:

Cracking of metal involving corrosion and tensile stress (residual and/or applied) in the presence of water and H2S

Requirements for steel plates in sour service

23 3

NACE TM0177 â&#x20AC;&#x17E;Laboratory Testing of Metals for Resistance to Specific Forms of Environmental Cracking in H2S Environmentsâ&#x20AC;? 1977, revised 1986, 1990 and 1996 tensile test (sol.A); preferred by DH-GTS1 Bent-Beam Test (sol. B) C-Ring test (sol. A) Double-Cantilever-Beam test (DCB) (sol.A) 2 test solutions: A: pH: 2.7; B: pH: 3.5, H2S saturated test duration: 720 h or until failure, whichever occurs first results report: applied stress over log time (stress level of no fail. after 720h) remark DH-GTS: acceptable only if PWHT plus DICREST route! no microalloying elements 1: also 4 point bend test acc. ASTM G39, sol.A (typ. linepipe)

Requirements for steel plates in sour service

Verfasser/Dokument

origin: 4 test methods:

24 4

Verfasser/Dokument

Sulfide Stress Cracking

SSC in HAZ of head to shell weld of FCC absorber tower. Requirements for steel plates in sour service

25 5

Verfasser/Dokument

Sulfide Stress Cracking

Requirements for steel plates in sour service

26 6

Verfasser/Dokument

SSC four-point bend test

Requirements for steel plates in sour service

27 7

Verfasser/Dokument

SSC tensile test

Requirements for steel plates in sour service

28 8

Corrosion at notched specimens under stress

SOHIC Stress Orientated Stress Cracking

Verfasser/Dokument

Definition as per NACE MR0175/ISO15156:

Staggered small cracks formed approximately perpendicular to the principle stress (residual or applied) resulting in a â&#x20AC;&#x17E;ladder-likeâ&#x20AC;&#x153; crack array linking (sometimes small) pre-existing HIC cracks.

Requirements for steel plates in sour service

29 9

Stress-Oriented Hydrogen Induced Cracking (SOHIC) New phenomenon in the field of sour gas corrosion %

Sporadic documentation at spiral welded pipes and flaws in pressure vessels.

Combination of rectangular (SSC type) and parallel cracks (HIC type) in the area of a multi dimensional tension field. Typical SOHIC crack below a flaw. Created in a double beam bend test. Requirements for steel plates in sour service

30 0

Verfasser/Dokument

Stress-Oriented Hydrogen Induced Cracking (SOHIC)

SOHIC-Crack at a non PWHT repair weld of a primary absorber (deethanizer)1. 1: NACE RP0296

Requirements for steel plates in sour service

31 1

Stress-Oriented Hydrogen Induced Cracking (SOHIC)

•issue - still under large discussion •mechanism not fully understood •mixture of SSC and HIC type cracking

Verfasser/Dokument

•location close to the welds

Requirements for steel plates in sour service

32 2

SOHIC test as per NACE TM0103 / 2003 • SOHIC testing • 4 point bent double beam tests • test duration 168 h • metallographic examination of the cross sections • Reasonable acceptance criteria for CCL (Continuous Crack Length), DCL (Discontinuous Crack Length) and TCL (Total Crack Length)

Verfasser/Dokument

are not yet reported

Requirements for steel plates in sour service

33 3

Verfasser/Dokument

SOHIC test arrangement as per NACE TM0103 / 2003

NACE TM0103 â&#x20AC;&#x201C; Full Size Double-Beam Test Specimen Design Requirements for steel plates in sour service

34 4

SOHIC test specimens as per NACE TM0103 / 2003

Dimensions of the notch: Depth = 2mm, r = 0.13mm

cut line

notch

faces to be examined

n1 2 o i t c n Se tio c Se rop D Verfasser/Dokument

Sectioning across the notch into two cross sections.

(centred)

Requirements for steel plates in sour service

35 5

SOHIC evalutation of the cross sections from the double beam specimens

CCL - continuous cracks (perpendicular) in the most stressed area near to the bottom of the notch.

DCL - discontinuous (parallel) cracks below the continuous crack area, with lower stresses.

Verfasser/Dokument

TCL - length of the whole cracked area.

Requirements for steel plates in sour service

36 6

Results of the SOHIC tests at Dillinger H端tte GTS (1)

Although the tests were performed with HIC resistant DICREST material, at a load of less than 50% yield in pH3 solution first SOHIC type cracks appeared.

Rising the load increases the appearance of these cracks

Testing in pH5 solution no SOHIC cracks are detected.

Verfasser/Dokument

The notch of specimens generates a very (too ?) harmful stressed area.

Requirements for steel plates in sour service

37 7

Results of the SOHIC tests at Dillinger HĂźtte GTS (2) It should be taken into consideration, whether a notch like this is permitted generally at pressure vessels. This could explain why even HIC and SSC resistant steels (DICREST) show big amounts of SOHIC cracks with the proposed test method. Acc. to DHâ&#x20AC;&#x2122;s opinion this test method is not appropriate as SOHIC test. SOHIC resistant material (acc. to this test method) can not be produced with

Verfasser/Dokument

normalised steels. It seems to be that Q+T material will reach this aim.

Requirements for steel plates in sour service

38 8

Standards

Verfasser/Dokument

SSC + HIC

Requirements for steel plates in sour service

39 9

NACE MR0175/ISO 15156 - 2003 “Petroleum and natural gas industries—Materials for use in H2S- containing environments in oil and gas production” • By the end of 2003 NACE0175/ISO15156 was published giving requirements and recommendations for the selection and qualification of carbon and lowalloy steels, corrosion-resistant alloys, and other alloys for service in equipment used in oil and natural gas production and natural gas treatment plants in H2Scontaining environments • 3 parts: - Part 1: General principles for selection of cracking-resistant materials - Part 2: Cracking-resistant carbon and low alloy steels, and the Verfasser/Dokument

use of cast irons - Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other alloys

• Qualification route for steels not yet proved to be suitable for H2S service Requirements for steel plates in sour service

40 0

SSC in NACE MR0175/ISO 15156 - 2003 SSC:

Metal cracking under corrosion in presence of H2S and stress; same time hydrogen embrittlement especially in steel with high hardness or high strength

SSC and SCC susceptibility depends on e. g.: - steel: chemical composition, heat treatment, microstructure, cold deformation - hydrogen activity (pH-value) - total tensile stress (including residual stress) - temperature, duration, ... Definition of SSC severity levels from 0 to 3 with increasing severity Verfasser/Dokument

severity level 1starting from H2S partial pressure ≥ 0.0003 MPa No absolute resistance, material can fail in SSC-tests!

Requirements for steel plates in sour service

41 1

SSC in NACE MR0175/ISO 15156 – 2003 Requirements:

Carbon & low alloy steels: - heat treated (contr. Rolled, N, N+T, Q+T); - Ni < 1% wt - Hardness < 22 HRC (average) < 24 HRC (individual) fabrication conditions: * welding and PWHT have to respect 22HRC limitation also in HAZ and WM * > 5% cold deformation Ö SR to be applied Remark of the steel producer: NACE MR0175 shall prevent SSC-Cracking, but there is very few influence on steel making practice (Ö no influence on HIC-resistance!!) Requirements for steel plates in sour service

42 2

Verfasser/Dokument

Pressure vessel steels classified as P-No 1, group 1 or 2 in Section IX of the ASME Boiler and Pressure Vessel Code are acceptable without testing

Listing of Section IX of the ASME Boiler & Pressure Vessel Code

Spec

Grade

SA-283 A, B, C, D

P-No.1, Group 2

UNS

Spec

Grade

UNS

SA-299

...

K02803

SA-285

K02801

SA-455

...

K03300

SA-285

K01700

SA-515

K03101

SA-285

K02200

SA-516

K02700

SA-36

...

K02600

SA-537

Cl. 1

K12437

SA-515

K02800

SA-662

K02007

SA-515

K02401

SA-737

K12001

SA-516

K01800

SA-738

K12447

SA-516

K02100

SA-516

K02403

SA-562

...

K11224

SA-662

K01701

SA-662

K02203

Requirements for steel plates in sour service

Verfasser/Dokument

P-No.1, Group 1

43 3

HIC in NACE MR0175/ISO 15156 – 2003 - The user shall consider HIC and HIC testing even if there are only trace amounts of H2S present - HIC susceptibility is influenced by chemistry and manufacturing route Requirements - low Sulphur content ( < 0,003 %) - test acc. to NACE TM0284

Verfasser/Dokument

- acceptance criteria (solution A: CLR ≤ 15%, CTR ≤ 5%, CSR ≤ 2%) - other conditions may be defined as per table B.3 for specific or less severe duty

Requirements for steel plates in sour service

44 4

SOHIC in NACE MR0175/ISO 15156 â&#x20AC;&#x201C; 2003 User should consider SOHIC when evaluating carbon steels - Pre-qualification to SSC prior to SOHIC/SZC evaluation - Small-scale tests: unfailed uniaxial tensile (UT) & four point bend (FPB) specimen are metallographicly examined - UT-specimen : - no ladderlike HIC indications or cracks exceeding 0,5mm in through thickness direction allowed - after hydrogen effusion the tensile strength shall not be less than 80% of the tensile strength of unused specimens

- Full pipe ring tests may be used, test method and acceptance criteria described in HSE OTI-95-635

Requirements for steel plates in sour service

45 5

Verfasser/Dokument

- FPB-specimen: - no ladderlike HIC indications or cracks exceeding 0,5mm in through thickness direction allowed - blisters less than 1mm below the surface and blisters due to compression regardless of the depth shall be disregarded

EFC 16 “Guidelines on Materials Requirements for Carbon and Low alloy Steels for H2S-Containing Environments in Oil and Gas Production Combined specification for test methods of HIC and SSC” concerns: published:

C- and low alloy steels in oil and gas production (not in refinery service); conclusion of NACE-test methods in 1995, rev. 2 in 2002

1. HIC - low S, shape control, low segregation, low CEQ

Verfasser/Dokument

- test acc. to NACE TM0284, Solution A - acceptance criteria: CLR ≤ 15%, CTR ≤ 5%, CSR ≤ 1.5%

Requirements for steel plates in sour service

46 6

EFC 16 (2) 2.

SSC - f(pH-value/ H2S-p.pressure): Non sour, transition region, sour service - in case of sour service: see guidelines * limited hardness in HAZ to max. 250 HV30 except cap´s cap layer up to 275 HV30 (t < 9,5mm) or 300 HV30 (t > 9,5mm) * limited cold deformation (5% for PV) or PWHT > 620°/650°C - various test methods for the evaluation of SSC resistance (uniaxial, 4pointbend, C-ring,....); pH= 3; DH recommend the tensile test and 4 point bend test - load and duration of the test to be agreed; proposals are made recommendation of DH-GTS e.g.: load: 0.72 SMYS; duration: 720 h SOHIC/ SZC (Soft zone cracking)

Verfasser/Dokument

- PWHT recommended - testing the susceptibility by 4 point bend test as an option, however no acceptance criteria defined Requirements for steel plates in sour service

47 7

Guidelines RP + MR

Verfasser/Dokument

HIC + SSC

Requirements for steel plates in sour service

48 8

NACE RP0472 – 2000 “Guidelines for Detection, Repair and Mitigation of Cracking of Existing Petroleum Refinery Pressure Vessels in Wet H2S Environments”

Concerns HIC, SSC, SOHIC, ASCC (Alkaline Stress C.C.)

applicable for existing equipment in refineries made of carbon steel

valid if H2S concentration ≥ 50 ppm (but no threshold concentration defined)

reports about the parameters for each damage mechanism

reports about a large survey (in 1990) of 5000 (!) inspected pressure vessels

26% of all vessels showed cracking incidence (crack depth from 1.6 mm to more than 25 mm) recommendations for inspection

Requirements for steel plates in sour service

Verfasser/Dokument

49 9

NACE RP0472 – 2000 (2) “Guidelines for Detection, Repair and Mitigation of Cracking of Existing Petroleum Refinery Pressure Vessels in Wet H2S Environments” Definition of environment to be more susceptible to HIC, SOHIC or blistering - process temp.: Ambient to 150 °C - H2S: > 2000ppm + ph > 7.8 - H2S: > 50 ppm + ph < 5 - presence of HCN + others

Recommendations for repair: - Hardness of production welds < 200 HB - Welding procedure qualification hardness < 248 HV10 for HAZ and WELD - PWHT to be considered Verfasser/Dokument

Requirements for steel plates in sour service

50 0

NACE MR0103 – 2003 „Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining environments“ NACE MR0175: for oil- and gas handling systems NACE MR0103: for refinery service; it based on the experience with MR0175 and other NACE publications. Specific Process Conditions: > 50 ppm H2S dissolved in H2O or if pH < 4 + some H2S or if pH > 7.6 + 20 ppm HCN > 0.05 PSIA H2S in gas phase Also reference to NACE RP0472 requirements

Requirements for steel plates in sour service

some H2S or if Verfasser/Dokument

• • • • •

51 1

NACE MR0103 – 2003 (2) „Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining environments“ Responsibility of the user: - HAZ - hardness - Residual stresses - Rm increase Ö risk increase

Verfasser/Dokument

Hardness Base Metal < 22 HRC (or also 248 HV 10) Cold deformation < 5% otherwise stress relieved

Requirements for steel plates in sour service

52 2

Revision 3 Verfasser/Dokument PV Plates for sour Service

Production of HIC-resistant steels

How to produce HIC and SSC-resistant steel plates?

Basis: Well developed know how (Dillinger H端tte GTS has been engaged in this field for more than 20 years) Adequate production installations Permanent exchange with the endusers

Verfasser/Dokument

Follow up in international research projects

Requirements for steel plates in sour service

54 4

Requirements for homogeneous Dillinger Crack Resistant Steel plates

hot metal desulphurisation

deep vacuum degassing

special chemical composition (C, Mn, S, P)

cleanliness stirring by Argon

special casting parameter (no bulging, adapted superheating)

intensified QA-process

special care to avoid unacceptable segregations

high shape factor rolling (strong reduction in thickness per rolling pass)

Requirements for steel plates in sour service

Verfasser/Dokument

DICREST-route

55 5

Production route in the steel plant Hot metal desulphurisation

BOF converter

Argon stirring process

Heating

Degassing process

Casting

O2 CaC2 Mg

Ar O2

Ar Ar

Ar 2

objective: hot metal dephosphorisation slag desulphur- decarburisation conditioning, isation denitrogenisation steel desulphurisation

temperature adjustment

removal of: Carbon Sulphur Nitrogen Hydrogen

cleanliness avoiding: - reoxidation - resulphurisation

analysis adjustment

Requirements for steel plates in sour service

56 6

Verfasser/Dokument

Ar/N

Verfasser/Dokument

Requirements for steel plates in sour service

57 7

Inclusion distribution for different caster types Curved caster

Curved caster

Curved caster r = 5.0 m; vc = 1.0 m/min

Vertical caster vc = 0.5 m/min

Total oxygen in ppm

70 60 50 40 30 20 10 0 0

100

Distance from the fixed side in % Requirements for steel plates in sour service

58 8

Verfasser/Dokument

Vertical caster Vertcal caster Vertical caster

Aspects of quality assurance: HIC properties and cast length

HIC resistant steel

~ 75% of cast length

non sour gas

Verfasser/Dokument

Frequency for CLR (av. of 9 sections) < 15%

100 % > 96%

cast length begin

end

Results from HIC test, according to NACE TM 0284-96, for one single heat in dependence of the cast length of DICREST 15 pressure vessel steel; test solution acc. to TM 0284-96: A (pH3). Requirements for steel plates in sour service

59 9

Verfasser/Dokument

Influence of High Shape Factor Rolling

Requirements for steel plates in sour service

60 0

Verfasser/Dokument

Optimized production steps for DICREST plates in the heavy plate mill

Requirements for steel plates in sour service

61 1

Aspects of quality assurance: casting incidents

additional additional testing prohibited from release testing

acceptance criteria

Verfasser/Dokument

cracking extend in HIC test

incident risk range

cast strand length position

Example of deviation in casting parameter combination Requirements for steel plates in sour service

62 2

Test laboratory of Dillinger Hütte GTS to measure sour gas susceptibility:

8 laboratory fume hoods (7 for tests, 1 for cleaning)

overall 39 connections for tests vessels

12 connections for SSC tensile tests (CorTest rings) equipped with computer aided monitoring of specimen failure

3 independent gas supply systems for parallel use of 3 different types of test gases

temperature adjustment and control system Verfasser/Dokument

Equipment:

Additionally health and safety-installations: gas detection systems, flame guard system to maintain H2S combustion, activated carbon filters in the exhaust air conduit, collecting tanks for all waste waters from the process Requirements for steel plates in sour service

63 3

Sour service

Verfasser/Dokument

What can DH offer?

Requirements for steel plates in sour service

64 4

Actual statistics of requested standards and thicknesses Requested thicknesses

> 80mm

< 40mm

About 5% of the overall DICREST tonnage is requested in grades other than SA 516

Requirements for steel plates in sour service

65 5

Verfasser/Dokument

40 - 80mm

Dillinger Hütte´s standardised offer for HIC resistant plates: DICREST

DICREST 5 DICREST 10

DICREST 15 1)

acceptance criteria CLR

CTR

CSR

≤5

≤ 1.5

≤ 0.5

≤ 10

≤3

≤1

≤ 15

≤5

≤2

≤ 0.5

≤ 0.1

≤ 0.05

The requested test solution must be stated in the order in case of DICREST 15

CLR = Note: ETC = ELC =

∑ a ⋅100% W

CTR =

∑ b ⋅100% T

CSR =

∑ (a ⋅ b) ⋅100% W ⋅T

Acceptance criteria are defined as the average of all sections of all specimens per plate Extent of transverse cracking = bmax Extent of longitudinal cracking = a max

Requirements for steel plates in sour service

66 6

Verfasser/Dokument

grade

test solution max. acc. plate thickness TM 0284-96 A 80 mm (pH 3) A 80 mm (pH 3) A (pH 3) 150 mm B (pH 5)

No. of sections

plate thickness

CLR <

CTR <

CSR <

15%

0.5%

30mm < t ≤ 40mm

15%

0.5%

40mm < t ≤ 110mm

15%

0.1%

10%

0.5%

10%

0.1%

t ≤ 15mm

1.5%

0.5%

15mm < t ≤ 30mm

1.5%

0.5%

30mm < t ≤ 110mm

0.1%

t ≤ 30mm 1

9 resp. 15*

t ≤ 30mm 30mm < t ≤ 110mm

Verfasser/Dokument

Actual acceptance levels for DICREST 5 plates in pH3 solution HIC tested in dependence on averaging the values for a certain no. of section

* No. of Sections acc. to NACE TM0284-03 for t > 88mm = 15 Remark: All other requirements on request Requirements for steel plates in sour service

67 7

Risk assessment on real HIC and Pseudo-HIC plates 90 80

HIC-resistant Pseudo-HIC

Percentage [50%]

70 60 50 40 30 20

>2≤4

>4≤6

>6≤8

> 8 ≤ 10 > 10 ≤ 20 > 20 ≤ 40

> 40

Optimisation of CLR-values in NACE TM 0284-96, solution A through application of special DICREST-production route (steel grades: A 516 Gr. 60, 65 and 70; plate thickness 6-80 mm) compared to Pseudo HIC-plates with a package of certain Pseudo-HIC measures. Requirements for steel plates in sour service

68 8

Verfasser/Dokument

Requirements for steel plates in sour service

69 9

DICREST ex mill and ex stock

Verfasser/Dokument

www.ancoferwaldram.nl

Requirements for steel plates in sour service

70 0

Specification details of DICREST stock plates (AWS) thickness: 8 -80 mm grades SA 516 grade 60, 65 or 70 delivery condition: normalised toughness requirements acc. SA20-S5 HIC testing frequency: per heat on the thinnest and thickest plate HIC test per NACE TM0284-2003, solution A (pH3) hot tensile test at 400°C ultrasonic testing: acc. A578 (ed. 2001) S 2.2 Verfasser/Dokument

additionally: - conformity in harness and Ni-content to NACE MR0175 - banding check acc. to E 1268 once per heat for information

DiME specification is more customized especially for Middle Eastern market in thickness range from 10 to 50 mm Requirements for steel plates in sour service

71 1

Conclusion sour service becomes more and more important; research and standardising efforts further ongoing 2 (3) major failure mechanisms are important (HIC, SSC and probably SOHIC) SSC rules have low influence on steel making practice. The phenomenon is mostly seen at hard HAZ or hard base metal. DH-GTS applies DICREST route.

Verfasser/Dokument

SOHIC is not quite fully understood. Most appearances are related to failures in HAZ; no proper test method; research is going on. Q+T steels show advantages. HIC resistant steels need a special manufacturing route and require a lot of experience & know how

Requirements for steel plates in sour service

72 2

Dillinger H端tte GTS is prepared for the needs of sour service

Verfasser/Dokument

We contribute with 450.000 t of HIC resistant1 linepipe and pv-plates per year

Requirements for steel plates in sour service

with certified HIC-resistance 7

73 3

... but we can help you take it with a smile! Requirements for steel plates in sour service

74 4

Verfasser/Dokument

We can not transform sour to sweet...

Fion Zhang/Charlie Chong

Sample: Understanding ISO 10893 Non-destructive testing of steel tubes - Part 11: Automated ultrasonic testing of the weld seam of welded steel tubes for the detection of longitudinal and/or transverse imperfections

Fion Zhang/Charlie Chong

Ultrasonic Testing LSAW Pipes November 2015

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

Fion Zhang/Charlie Chong

Foreword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee. International organizations, governmental and nonovernmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the nternational Electrotechnical Commission (IEC) on all matters of electrotechnical standardization. International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.

Fion Zhang/Charlie Chong

The main task of technical committees is to prepare International Standards. Draft International Standards adopted by the technical committees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. ISO shall not be held responsible for identifying any or all such patent rights. ISO 10893-11 was prepared by Technical Committee ISO/TC 17, Steel, Subcommittee SC 19, Technical delivery conditions for steel tubes for pressure purposes. This first edition cancels and replaces ISO 9764:1989 and ISO 9765:1990, which have been technically revised.

Fion Zhang/Charlie Chong

ISO 10893 consists of the following parts, under the general title Non-destructive testing of steel tubes: 1. Part 1: Automated electromagnetic testing of seamless and welded (except submerged arc-welded) steel tubes for the verification of leaktightness 2. Part 2: Automated eddy current testing of seamless and welded (except submerged arc-welded) steel tubes for the detection of imperfections 3. Part 3: Automated full peripheral flux leakage testing of seamless and welded (except submerged arc-welded) ferromagnetic steel tubes for the detection of longitudinal and/or transverse imperfections 4. Part 4: Liquid penetrant inspection of seamless and welded steel tubes for the detection of surface imperfections 5. Part 5: Magnetic particle inspection of seamless and welded ferromagnetic steel tubes for the detection of surface imperfections

Fion Zhang/Charlie Chong

6. Part 6: Radiographic testing of the weld seam of welded steel tubes for the detection of imperfections 7. Part 7: Digital radiographic testing of the weld seam of welded steel tubes for the detection of imperfections 8. Part 8: Automated ultrasonic testing of seamless and welded steel tubes for the detection of laminar imperfections 9. Part 9: Automated ultrasonic testing for the detection of laminar imperfections in strip/plate used for the manufacture of welded steel tubes 10. Part 10: Automated full peripheral ultrasonic testing of seamless and welded (except submerged arc-welded) steel tubes for the detection of longitudinal and/or transverse imperfections 11. Part 11: Automated ultrasonic testing of the weld seam of welded steel tubes for the detection of longitudinal and/or transverse imperfections 12. Part 12: Automated full peripheral ultrasonic thickness testing of seamless and welded (except submerged arc-welded) steel tubes

Fion Zhang/Charlie Chong

1 Scope This part of ISO 10893 specifies requirements for the automated ultrasonic shear wave (generated by conventional or phased array technique) testing of the weld seam of submerged arc-welded (SAW) or electric resistance and induction-welded (EW) steel tubes. For SAW tubes, the test covers the detection of imperfections oriented predominantly parallel to (longitudinal) or, by agreement, perpendicular (transverse) to the weld seam or both. For EW tubes, the test covers the detection of imperfections oriented predominantly parallel to the weld seam. In the case of testing on longitudinal imperfections, Lamb wave testing can be applied at the discretion of the manufacturer, or the detection of imperfections at the weld seam of EW tubes, full peripheral ultrasonic testing is possible.

Fion Zhang/Charlie Chong

This part of ISO 10893 can also be applicable to the testing of circular hollow sections. NOTE For full peripheral ultrasonic testing of seamless and welded (except SAW) tubes, see ISO 10893-10.

Fion Zhang/Charlie Chong

For SAW tubes, the test covers the detection of imperfections oriented predominantly parallel to (longitudinal) or, by agreement, perpendicular (transverse) to the weld seam or both.

Fion Zhang/Charlie Chong

This For SAW part tubes, the test covers the detection of imperfections oriented predominantly parallel to (longitudinal) or, by agreement, perpendicular (transverse) to the weld seam or both.

Fion Zhang/Charlie Chong

For EW This parttubes, the test covers

the detection of imperfections oriented predominantly parallel to the weld seam. In the case of testing on longitudinal imperfections, Lamb wave testing can be applied at the discretion of the manufacturer, or the detection of imperfections at the weld seam of EW tubes, full peripheral ultrasonic testing is possible

Fion Zhang/Charlie Chong

http://www.thefabricator.com/article/shopmanagement/examining-electric-resistance-weld-nuggets-in-tube-and-pipe

For EW This parttubes, the test covers

Fion Zhang/Charlie Chong

http://www.thefabricator.com/article/shopmanagement/examining-electric-resistance-weld-nuggets-in-tube-and-pipe

For EW This parttubes, the test covers

Fion Zhang/Charlie Chong

http://www.thefabricator.com/article/shopmanagement/examining-electric-resistance-weld-nuggets-in-tube-and-pipe

For EW This parttubes, the test covers

Fion Zhang/Charlie Chong

http://www.thefabricator.com/article/shopmanagement/examining-electric-resistance-weld-nuggets-in-tube-and-pipe

Fion Zhang/Charlie Chong

For EW This parttubes, the test covers the detection of imperfections oriented predominantly

parallel to the weld seam. In the case of testing on longitudinal imperfections, Lamb wave testing can be applied at the discretion of the manufacturer, or the detection of imperfections at the weld seam of EW tubes, full peripheral ultrasonic testing is possible

Cross Sections of Some Upset Autogenous Seam Welds Removed from Service

http://www.carkw.com/wp-content/uploads/2013/10/9.20.12-Report-on-ERW-and-Flash-weld-seams.pdf

For EW This parttubes, the test

covers the detection of imperfections oriented predominantly parallel to the weld seam. In the case of testing on longitudinal imperfections, Lamb wave testing can be applied at the discretion of the manufacturer, or the detection of imperfections at the weld seam of EW tubes, full peripheral ultrasonic testing is possible

Fion Zhang/Charlie Chong

http://www.tubenet.org.uk/technical/vitrual.shtml

For EW This parttubes, the test

Fion Zhang/Charlie Chong

http://www.tubenet.org.uk/technical/vitrual.shtml

Fion Zhang/Charlie Chong

For EW This parttubes, the test covers the detection of imperfections oriented predominantly

http://www.cpw.gr/userfiles/cd482974-e8e4-44d3-a17d-a3fe00f8306d/TECHNICAL%20CHALLENGES%20OF%20HEAVY%20WALL%20HFW%20PIPE%20PRODUCTION%20FOR.pdf

Fion Zhang/Charlie Chong

This part

Figure 15: Weld, HAZ and base metal “as-welded” microstructures

http://www.cpw.gr/userfiles/cd482974-e8e4-44d3-a17d-a3fe00f8306d/TECHNICAL%20CHALLENGES%20OF%20HEAVY%20WALL%20HFW%20PIPE%20PRODUCTION%20FOR.pdf

Fion Zhang/Charlie Chong

For EW This parttubes, the test covers the detection of imperfections oriented predominantly

Figure 14: Pipe after double normalizing with intermediate cooling

http://www.cpw.gr/userfiles/cd482974-e8e4-44d3-a17d-a3fe00f8306d/TECHNICAL%20CHALLENGES%20OF%20HEAVY%20WALL%20HFW%20PIPE%20PRODUCTION%20FOR.pdf

Fion Zhang/Charlie Chong

Figure 16: Weld, HAZ and base metal PWHT microstructures http://www.cpw.gr/userfiles/cd482974-e8e4-44d3-a17d-a3fe00f8306d/TECHNICAL%20CHALLENGES%20OF%20HEAVY%20WALL%20HFW%20PIPE%20PRODUCTION%20FOR.pdf

Fion Zhang/Charlie Chong

Typical melting behavior of strip edges during HF ERW

Figure 16: Weld, HAZ and base metal PWHT microstructures https://app.aws.org/wj/supplement/01-2004-CHOI-s.pdf

For EW tubes, the test covers the detection of imperfections oriented predominantly parallel to the weld seam. In the case of testing on longitudinal imperfections, Lamb wave testing can be applied at the discretion of the manufacturer, or the detection of imperfections at the weld seam of EW tubes, full peripheral ultrasonic testing is possible

Fion Zhang/Charlie Chong

Lamb Wave- For EW, In the case of testing on longitudinal imperfections, Lamb wave testing can be applied at the discretion of the manufacturer

Fion Zhang/Charlie Chong

http://www.waterworld.com/articles/wwi/print/volume-27/issue-3/editorial-focus/flow-level-measurement/strength-in-numbers-matching-lamb-wave.html

Lamb Wave- For EW, In the case of testing on longitudinal imperfections, Lamb wave testing can be applied at the discretion of the manufacturer

Fion Zhang/Charlie Chong

http://www.masw.com/History-MASW.html

Lamb Wave- For EW, In the case of testing on longitudinal imperfections, Lamb wave testing can be applied at the discretion of the manufacturer

Fion Zhang/Charlie Chong

2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.  ISO 5577, Non-destructive testing — Ultrasonic inspection — Vocabulary  ISO 9712, Non-destructive testing — Qualification and certification of personnel  ISO 10893-6, Non-destructive testing of steel tubes — Part 6: Radiographic testing of the weld seam of welded steel tubes for the detection of imperfections  ISO 10893-7, Non-destructive testing of steel tubes — Part 7: Digital radiographic testing of the weld seam of welded steel tubes for the detection of imperfections  ISO 11484, Steel products — Employer's qualification system for nondestructive testing (NDT) personnel

Fion Zhang/Charlie Chong

3 Terms and definitions For the purposes of this document, the terms and definitions given in ISO 5577 and ISO 11484 and the following apply. 3.1 reference standard standard for the calibration of non-destructive testing equipment (e.g. drill holes, notches, recesses) 3.2 reference tube tube or length of tube containing the reference standard(s) 3.3 reference sample sample (e.g. segment of tube, plate or strip) containing the reference standard(s) NOTE Only the term “reference tube” is used in this part of ISO 10893, also covering the term “reference sample”.

Fion Zhang/Charlie Chong

3.4 tube hollow long product open at both ends, of any cross-sectional shape 3.5 welded tube ttube made by forming a hollow profile from a flat product and welding adjacent edges together. After welding the tube may be further processed, either hot or cold, into its final dimensions 3.6 electric welded tube tube made by pressure welding, in a continuous or non-continuous process, in which strip is formed cold into a hollow profile and the seam weld made by heating the adjacent edges through the resistance to the passage of high- or low-frequency current, and pressing the edges together NOTE The electric current can be applied either by direct electrode contact or by induction. 3.7 manufacturer organization that manufactures products in accordance with the relevant standard(s) and declares the compliance of the delivered products with all applicable provisions of the relevant standard(s) 3.8 agreement contractual arrangement between the manufacturer and purchaser at the time of enquiry and order Fion Zhang/Charlie Chong

4 General requirements 4.1 Unless otherwise specified by the product standards or agreed on by the purchaser and manufacturer, an ultrasonic test shall be carried out on tubes after completion of all the primary production process operations (rolling, heat treating, cold and hot working, sizing and primary straightening, etc.). For cold-expanded tubes, the ultrasonic testing of the weld shall be carried out after expansion. In case of spirally welded tubes, where the tube is not subsequently subjected to a hydrostatic test at the tube mill, the acceptance test may be carried out online. 4.2 The tubes under test shall be sufficiently straight to ensure the validity of the test. The surface shall be sufficiently free of foreign matter which can interfere with the validity of the test.

Fion Zhang/Charlie Chong

4.3 This test shall be carried out by suitably trained operators, qualified in accordance with ISO 9712, ISO 11484 or equivalent and supervised by competent personnel nominated by the manufacturer. In the case of thirdparty inspection, this shall be agreed on by the purchaser and manufacturer. The operating authorization issued by the employer shall be according to a written procedure. Non-destructive testing (NDT) operations shall be authorized by a level 3 NDT individual approved by the employer. NOTE The definition of levels 1, 2 and 3 can be found in appropriate nternational Standards, e.g. ISO 9712 and ISO 11484.

Fion Zhang/Charlie Chong

5 Test method 5.1 The weld seam of the tube shall be tested using an ultrasonic shear wave technique for the detection of longitudinal and/or transverse imperfections. Lamb wave technique may be applied for the detection of longitudinal imperfections of EW tubes. Unless otherwise agreed on by the purchaser and manufacturer, testing shall be carried out in two opposite directions of sound propagation for the requested type of inspection, clockwise and anticlockwise for the detection of longitudinal imperfections and forward and backward for the detection of transverse imperfections. 5.2 During testing, the tubes and the probe assembly shall be moved relative to each other such that the whole area under inspection is scanned with coverage calculated on the dimension of the transducer(s). The relative speed of movement during testing shall not vary by more than 10 %.

Fion Zhang/Charlie Chong

Unless otherwise agreed on by the purchaser and manufacturer, testing shall be carried out in two opposite directions of sound propagation for the requested type of inspection, clockwise and anticlockwise for the detection of longitudinal imperfections and forward and backward for the detection of transverse imperfections.

forward and backward for the detection of transverse imperfections. clockwise and anticlockwise for the detection of longitudinal imperfections Fion Zhang/Charlie Chong

5.3 There can be a short length at both tube ends which cannot be tested. Any untested ends shall be dealt with in accordance with the requirements of the appropriate product standard. In the case of SAW tubes, the untested ends may, at the manufacturer's discretion, be checked either by a manual ultrasonic test in accordance with this part of ISO 10893 or by a radiographic test in accordance with ISO 10893-6 or ISO 10893-7. In the case of EW tube, the untested ends may be tested in accordance with Annex A. 5.4 For the detection of longitudinal imperfections, the maximum width of each individual transducer, easured parallel to the major axis of the tube, shall be 25 mm. For the detection of transverse imperfections, the maximum width of each individual transducer, measured perpendicular to the major axis of the tube, shall be 25 mm. In case of the use of Lamb wave technique or phased array technique, the maximum length of transducer or active aperture shall be limited to 35 mm.

Fion Zhang/Charlie Chong

5.5 The ultrasonic test frequency of transducers shall be in the range 1 MHz to 15 MHz for shear wave technique and in the range of 0,3 MHz to 1 MHz for Lamb wave technique, depending on the product condition and properties, the thickness and surface finishing of tubes under examination. 5.6 The equipment shall be capable of classifying tubes as either acceptable or suspect, by means of an automated trigger/alarm level, combined with a marking or sorting system (or both). 5.7 Where manual ultrasonic testing of untested tube ends and/or local suspect areas is required (see 5.3), use Annex A.

Fion Zhang/Charlie Chong

6 Reference tube 6.1 General 6.1.1 The reference standards defined in this part of ISO 10893 are convenient standards for establishing the sensitivity of non-destructive testing equipment. The dimensions of these standards should not be construed as the minimum size of imperfection detectable by such equipment. 6.1.2 For SAW tubes, for the detection of longitudinal imperfections, the equipment shall be calibrated using four longitudinal reference notches, two on the outside surface and two on the inside surface, in the parent material close to the weld seam of a reference tube, and/or a reference hole located in the centre of the weld (see Figure 1).

Fion Zhang/Charlie Chong

Alternatively, by agreement between the purchaser and manufacturer, the equipment may be calibrated using internal and external notches located on the centre of the weld seam. In this case, the depth of the notches shall be agreed on by the purchaser and manufacturer, and the manufacturer shall demonstrate that the sensitivity is equivalent to that obtained from the edge notches. For the detection of transverse imperfections, if requested, the equipment shall be calibrated using two transverse notches in the weld seam, one on the external and one on the internal surface of reference tube, and/or a reference hole located in the centre of the weld. The selection of the notches or the hole is left to the discretion of the manufacturer.

Fion Zhang/Charlie Chong

Figure 1 â&#x20AC;&#x201D; Simplified representation of reference tube a) Submerged arc-welded (SAW) tube Key 1 through hole 2 submerged arc-weld seam 3 and 7 longitudinal internal notches 4 and 6 longitudinal external notches 5 reference tube 8 centreline of weld

Fion Zhang/Charlie Chong

Quoted: â&#x20AC;&#x153;For the detection of transverse imperfections, if requested, the equipment shall be calibrated using two transverse notches in the weld seam, one on the external and one on the internal surface of reference tube, and/or a reference hole located in the centre of the weld. The selection of the notches or the hole is left to the discretion of the manufacturer.â&#x20AC;? 8 1 4

Key

? 3 ?

5 Fion Zhang/Charlie Chong

1 through hole 2 submerged arc-weld seam 3 Transverse internal notches 4 Transverse external notches 5 reference tube 8 centreline of weld

6.1.3 For EW tubes, the ultrasonic equipment shall be calibrated using a longitudinal reference notch on the outside and inside surfaces of a reference tube. When the tube internal diameter is less than 15 mm, the manufacturer and purchaser may agree to waive the internal notch. Alternatively, a reference hole drilled through the wall of the reference tube may be used for equipment calibration, by agreement between the purchaser and manufacturer. In this case, the diameter of the drill required to produce the reference hole for a specific acceptance level shall also be agreed on and the manufacturer shall demonstrate to the satisfaction of the purchaser that the test sensitivity achieved using the reference hole is essentially equivalent to that obtained when using the specified reference notch(es). Such notches and drill holes shall be located in the centre of the weld line, unless otherwise agreed on by the purchaser and manufacturer.

Fion Zhang/Charlie Chong

Figure 1 â&#x20AC;&#x201D; Simplified representation of reference tube a) Submerged arc-welded (SAW) tubeb) Electric resistance and induction-welded (EW) tube Key 1 through hole 2 submerged arc-weld seam 3 and 7 longitudinal internal notches 4 and 6 longitudinal external notches 5 reference tube 8 centreline of weld Alternatively, a reference hole drilled through the wall of the reference tube may be used for equipment calibration, by agreement between the purchaser and manufacturer.

Fion Zhang/Charlie Chong

6.1.4 The reference tubes shall have the same nominal diameter and thickness, same surface finish and same heat treatment delivery condition (e.g. as-rolled, normalized, quenched and tempered) as the tubes under test, and shall have similar acoustic properties (e.g. sound velocity and attenuation coefficient). The manufacturer shall have the option of removing the weld bead of SAW tubes inside and outside such that it is in alignment with the curvature of the tube body. 6.1.5 In order to obtain clearly distinguishable signals, the external and internal notches and the hole shall be sufficiently separated from the ends of the reference tube/sample and from each other.

Fion Zhang/Charlie Chong

6.2 Reference notches 6.2.1 Types and preparation of notch 6.2.1.1 The reference notches shall be of the “N” type (N-notch) (see Figure 2);

for EW tubes the “V” type notch (V-notch) may be used at the discretion of the manufacturer, if specified notch depth is less than or equal to 0,5 mm (see Figure 2).

In the case of the “N” type notch, the sides shall be nominally parallel and the bottom shall be nominally square to the sides. Fion Zhang/Charlie Chong

Figure 2 — Types “V” and “N” reference notch a) “V” type notch

Key w width d depth

Fion Zhang/Charlie Chong

b) “N” type notch

6.2.1.2 For SAW tubes, the reference notches shall be located in the parent material close to the weld edges and shall lie parallel to the weld seam (see Figure 1). 6.2.1.3 The reference notch shall be formed by machining, spark erosion, etc. NOTE The bottom or the bottom corners of the notch can be rounded.

Fion Zhang/Charlie Chong

6.2.2 Dimension of reference notches 6.2.2.1 Width and depth 6.2.2.1.1 For width, w, see Figure 2. The width of the â&#x20AC;&#x153;Nâ&#x20AC;? type reference notch shall be not greater than 1,0 mm except for spirally welded tubes having the diameter equal to or greater than 406 mm where the width shall not exceed 1,5 mm. In any case, the width should not exceed twice the depth. 6.2.2.1.2 For depth, d, see Figure 2. The depth of the reference notch shall be as given in Table 1. The values of notch depth specified in Table 1 are the same, for the corresponding categories, in all International Standards concerning nondestructive testing of steel tubes where reference is made to different acceptance levels. Although the reference standards are identical, the various test methods involved may give different test results. Accordingly, the acceptance level designation prefix U (ultrasonic) has been adopted to avoid any inferred direct equivalence with other test methods.

Fion Zhang/Charlie Chong

The minimum notch depth shall be 0,3 mm for U2 and U3 category tubes and 0,5 mm for U4 category tubes. The maximum notch depth shall be 1,5 mm for U2 and U3 category tubes and 3 mm for U4 category tubes. Table 1 — Acceptance levels and corresponding reference notch depth

The tolerance of notch depth shall be ±15 % of requested notch depth or ±0,05 mm, whichever is the greater, with the exception that when the notch depth is less than 0,3 mm, the tolerance on the depth shall be ±0,03 mm. Fion Zhang/Charlie Chong

Table 1 â&#x20AC;&#x201D; Acceptance levels and corresponding reference notch depth Acceptance Level

Notch Depth of the specific Thickness, d, %t

Minimum Thickness, mm

Maximum Thickness, mm

0.3

1.5

0.3

1.5

12.5

0.5

Fion Zhang/Charlie Chong

6.2.2.2 Notch length Unless otherwise specified by the product standard or agreed on by the purchaser and manufacturer, the length of the reference notch(es) shall be greater than the width of the single transducer or active aperture. In any case, the length of reference notch shall not exceed 50 mm. 6.2.2.3 Verification The reference notch dimensions and shape shall be verified by a suitable technique.

Fion Zhang/Charlie Chong

Notch length Unless otherwise specified by the product standard or agreed on by the purchaser and manufacturer, the length of the reference notch(es) shall be greater than the width of the single transducer or active aperture. In any case, the length of reference notch shall not exceed 50 mm.

Fion Zhang/Charlie Chong

http://www.ndt.net/article/1198/davis/davis2.htm#top

Fion Zhang/Charlie Chong

http://www.ndt.net/article/1198/davis/davis2.htm#top

Verification The reference notch dimensions and shape shall be verified by a suitable technique.

Fion Zhang/Charlie Chong

The reference notch dimensions and shape shall be

verified by a suitable technique.

Fion Zhang/Charlie Chong

References should be verified by suitable technique, no mouth talk!

Fion Zhang/Charlie Chong

6.3 Reference hole 6.3.1 The reference hole shall be drilled through the wall at the centre of the weld, perpendicular to the surface of the reference tube (see Figure 1). 6.3.2 For SAW tubes, the diameter of the drill shall be selected to produce a hole no larger than that specified in Table 2. The diameter of the reference hole shall be verified. For EW tubes, see 6.1.3. Accordingly the acceptance level designation prefix U (ultrasonic) has been adopted to avoid any inferred direct equivalence with other test methods.

Fion Zhang/Charlie Chong

Table 2 â&#x20AC;&#x201D; Acceptance levels and corresponding reference drilled hole diameter

Fion Zhang/Charlie Chong

Question Time What is the difference between U2 & U3 and U3H

Fion Zhang/Charlie Chong

SNUP Ultrasonic Testing Machine - SAW pipe inspection

â&#x2013; https://www.youtube.com/embed/bOjdzHX78B8 Fion Zhang/Charlie Chong

7 Equipment calibration and checking 7.1 General At the start of each test cycle, the equipment, independently of the applied type of waves, shall be calibratedto produce consistently clearly identifiable signals from the used reference notches. These signals shall be used to activate the respective trigger/alarm level(s) of the equipment.

Fion Zhang/Charlie Chong

7.2 Adjustment of the trigger/alarm level 7.2.1 Where a single trigger/alarm level is used, the probe(s) shall be adjusted such that the signals from the internal and external reference notches are as equal as possible, and the full signal amplitude of the lesser of the two signals shall be used to activate the trigger/alarm level of the equipment. 7.2.2 Where separate trigger/alarm levels are used for internal and external reference notches, the full signal amplitude from each notch shall be used to set the relevant trigger/alarm level of the equipment. The positions and widths of the gates shall be adjusted in such a way that the entire wall thickness of the tube is tested. 7.2.3 When using the reference hole, the manufacturer shall demonstrate that the sensitivity achieved at the inner and outer surfaces is essentially equivalent to that achieved when using the specified reference notches.

Fion Zhang/Charlie Chong

7.3 Calibration check and recalibration 7.3.1 The calibration of the equipment shall be checked at regular intervals during the production testing of tubes of the same diameter, thickness and grade, by passing the tube through the inspection installation. The frequency of checking the calibration shall be at least every 4 h, but also whenever thereis an equipment operator changeover and at the start and end of the production run. 7.3.2 During a dynamic check of the calibration, the relative speed of movement between the reference tube and the transducer assembly shall be the same as that used during the production test. Other calibration conditions are allowed, provided the manufacturer can demonstrate that the same results as the dynamic check of the calibration are obtained. 7.3.3 The equipment shall be recalibrated if any of the parameters which were used during the initial calibration are changed. 7.3.4 If, on checking during production testing, the calibration requirements are not satisfied, all tubes tested since the previous acceptable equipment calibration shall be retested after the equipment has been recalibrated. Fion Zhang/Charlie Chong

8 Acceptance 8.1 Any tube producing signals lower than the trigger/alarm level shall be deemed to have passed this test. 8.2 Any tube producing signals equal to or greater than the trigger/alarm level shall be designated as suspect or, at the manufacturer's discretion, may be retested. If, after two consecutive retests, all signals are lower than the trigger/alarm level, the tube shall be deemed to have passed this test; otherwise, the tube shall be designated as suspect. Sequence: Lower than trigger Equal or higher than trigger Retest 2X Retest 2X

Fion Zhang/Charlie Chong

Pass Suspect Pass Fail/ Reject (suspect tubes)

8.3 For suspect tubes, one or more of the following actions shall be taken, subject to the requirements of the product standard: a) by agreement between the purchaser and manufacturer, the suspect area may be explored by a suitable method or may be retested by other nondestructive techniques and test methods, to agreed acceptance levels. Retesting shall be carried out in accordance with documented procedure; b) the suspect area shall be dressed by a suitable method (C2?) . After checking that the remaining thickness is within tolerance, the tube shall be retested as previously specified. If no signals are obtained equal to or greater than the trigger/alarm level, the tube shall be deemed to have passed this test; c) the suspect area shall be cropped off; (C3b) d) the tube shall be deemed not to have passed this test. (C3c?) Comments: API5L C1, C2, C3

Fion Zhang/Charlie Chong

9 Test report If specified, the manufacturer shall submit to the purchaser a test report that includes at least the following information: a) reference to this part of ISO 10893, i.e. ISO 10893-11; b) statement of conformity; c) any deviation, by agreement or otherwise, from the procedures specified; d) product designation by steel grade and size; e) type and details of test technique(s); f) equipment calibration method used; g) description of the reference standard acceptance level; h) date of test i) operator identification.

Fion Zhang/Charlie Chong

Annex A (normative) Manual/semi-automated testing of untested ends and suspect areas A.1 Untested tube ends If specified by the relevant product standard, the weld seam at the tube end zone which cannot be tested by the automated ultrasonic equipment shall be subjected to a manual/semi-automated test, from the ultimate tube ends and over the length of the original untested zone plus 10 %. The manual/semiutomated ultrasonic test shall be carried out such that the whole length of the untested end is scanned with a 10 % overlap, with reference to the ultrasonic transducer width used, measured in the direction parallel to the major axis of the tube. The manual/semi-automated ultrasonic test shall be carried out using the ultrasonic shear wave technique or Lamb wave technique, test sensitivity (reference notch depth) and general test parameters, as used during the original automated test on the main tube length, with the restrictions given in A.3.

Fion Zhang/Charlie Chong

A.2 Local suspect areas If appropriate, local areas on the tube deemed suspect by the automated ultrasonic equipment shall be subjected to a test by manual ultrasonic shear wave technique or Lamb wave technique, test sensitivity (reference notch depth) and general test parameters, as used during the original automated test, with the restrictions given in A.3, so that the whole of the local suspect area is scanned.

Fion Zhang/Charlie Chong

A.3 Manual/semi-automated ultrasonic test restrictions The following restrictions apply to the application of a manual/ semi-automated ultrasonic test to untested end zones and/or local suspect areas: a) the beam angle in steel used for manual ultrasonic testing with shear waves shall be nominally the same as that used during the original automated test; b) scanning shall be carried out with ultrasonic beam propagation in circumferential or longitudinal directions (or both); c) scanning speed over the tube surface shall not exceed 150 mm/s;

Fion Zhang/Charlie Chong

d) the ultrasonic probe type used during manual ultrasonic testing with shear waves shall be of the contact, gap-scan or immersion type. Means shall be provided to ensure that the probe is held at the correct distance in relation to the tube surface, e.g. for contact type probes, the â&#x20AC;&#x153;wear faceâ&#x20AC;? at the front face of the probe shall be fitted to the curvature of the tube under test; e) the width of the transducer, measured parallel to the major axis of the tube, used in the manual ultrasonic test shall not exceed that used during the original automated test; f) the nominal frequency of the transducer used in manual testing shall not vary from that used during the original automated test by more than Âą1 MHz. Where Lamb waves have been used in the original automated test, the frequency of shear wave transducers, if used for manual testing, shall be in the range of 4 MHz to 5 MHz.

Fion Zhang/Charlie Chong

Manual UT

Fion Zhang/Charlie Chong

Sample NDT Test Plan

Fion Zhang/Charlie Chong

Typical Probe Configuration for ERW-pipe inspection. a) Strip inspection with edge probes and oscillating strip middle probes, b) online weld test with 4 probes for longitudinal defect detection and an oscillating deburring check, and c) offline weld inspection with 4 probes for longitudinal defect detection, 2 probes for transverse defect detection and 2 probes for lamination testing in the heataffected zone.

Fion Zhang/Charlie Chong

http://www.karldeutsch.de/PDF/Papers/AutomatedUT%20WeldedPipes%20(WCNDT-Shanghai)%20WD%20Jan08.pdf

Full-Body testing and/or pipe end test with helical test traces. a) one or more probe carriers move along the rotating pipe, b) straight-beam incidence, and c) cross-sectional view of full-body and/or pipe end test.

Fion Zhang/Charlie Chong

http://www.karldeutsch.de/PDF/Papers/AutomatedUT%20WeldedPipes%20(WCNDT-Shanghai)%20WD%20Jan08.pdf

Typical Probe Configuration- Online Seam NDT

Fion Zhang/Charlie Chong

Automated system of ultrasonic testing of longitudinal pipe welded joints

â&#x2013; https://www.youtube.com/embed/X3ApBPymYeo Fion Zhang/Charlie Chong

Typical Probe Configuration- ERW 1st Online Seam UT 1.0 2.0

All personnel performing NDT activities shall be qualified in the technique applied, in accordance with ISO 9712 or equivalent. Detect longitudinal imperfections along weld seam and minimum wall thickness along the welding line. Specification refers to table below.

Position

Examination Type

Coverage

Reference Standards

Acceptance Criteria

Weld Seam

Longitudinal imperfection

Weld Seam +1.6mm both side

ASTM E273

N10

(Ref: K.4)

(Ref: Table E8)

Minimum wall thickness

Weld seam

+0.5mm

Wall Thickness

Fion Zhang/Charlie Chong

-0.3mm

3.0 3.1. 3.2. 3.3.

Calibration frequency At the beginning of production run At the beginning & end of each shift Every four hours of each shift under continuous production run

4.0

An audible device shall be used to indicate the loss of coupling effectiveness. Marking: The parts with defects and unexamined are stenciled in different color on the outside surface. Cross weld: The detector rise automatically to avoid been broken down, and the information of the coil is recorded.

5.0 6.0

Fion Zhang/Charlie Chong

No.1,2,4,5：probes used for detection of longitudinal defects, 14*14mm，4MHZ N0. 6,7 : probes used for detection of laminations，35*6mm，10MHZ No.8,9：probes used for detection of transversal defects，14*14mm，4MHZ No. 12：probes used for seam thickness check35*6mm，10MHZ Fion Zhang/Charlie Chong

Typical Probe Configuration- 2nd Online Seam UT

Fion Zhang/Charlie Chong

Ultrasonic Testing ERW Pipes November 2015

â&#x2013; https://www.youtube.com/embed/GkTlRtz0XGM Fion Zhang/Charlie Chong

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

Examination Type

Coverage

Weld Seam

Longitudinal

Within 1.6mm ASTM E273 from weld seam

N10

Transverse

Reference Standards

Acceptance Criteria

Weld Seam and Nearby

Lamination

Within 25.4mm ISO 13663 from weld seam

Pipe end & Bevel

Lamination

Within 100mm from pipe end

â&#x2030;Ľ2mm Reject

Fion Zhang/Charlie Chong

ISO 13665

Comments on the Table K2 & K.4 Non-destructive inspection of HFW pipe Position

Examination Type

Coverage

Weld Seam

Longitudinal

Within 1.6mm ASTM E273 from weld seam K4.1

N10

Within 25.4mm ISO 10893-8/9 from weld seam

Table K.1 . Acceptance criteria for laminar imperfections

Transverse Weld Seam and Nearby

Lamination K4.2/K4.3

Reference Standards

+ >20 % of the pipe surface Pipe end/ weld & Bevel

Lamination

Pipe Body

Lamination K4.2

Fion Zhang/Charlie Chong

K2.1.1/K2.1.4/

Within 100mm from pipe end

ISO 10893-5/9

Acceptance Criteria Table E8

K2.1

ASTM E709 ISO 10893-8/9

Table K.1

Table K.1 . Acceptance criteria for laminar imperfections

Fion Zhang/Charlie Chong

ASTM E273, Standard Practice for Ultrasonic Examination of the Weld Zone of Welded Pipe and Tubing E.2 Standard practices for inspection Except as specifically modified in this annex, the required non-destructive inspection, other than for surface inspection (see 10.2.7) and wall-thickness verification, shall be performed in accordance with one of the following standards or an equivalent: d) automated ultrasonic (weld seam): ISO 10893-11 or ASTM E273; K.4 Non-destructive inspection of HFW pipe K.4.1 Non-destructive inspection of the weld seam The full length of the weld seam shall be ultrasonically inspected for the detection of longitudinal imperfections, with the acceptance limits being in accordance with one of the following: a) ISO 10893-11 acceptance level U2/U2H; b) ISO 10893-10 acceptance level U3, or, if agreed, acceptance level U2; c) ASTM E273. Fion Zhang/Charlie Chong

Table E.7 . Reference indicators

Fion Zhang/Charlie Chong

g At the option of the manufacturer, N10 notches or 3,2 mm (0.125 in) holes may be used (see Table E.8 for applicable acceptance limits). Table E.8 . Acceptance limit

Fion Zhang/Charlie Chong

ISO 13665:1997 (Not quoted/specified in API5L) Seamless and welded steel tubes for pressure purposes -- Magnetic particle inspection of the tube body for the detection of surface imperfections

Fion Zhang/Charlie Chong

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

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

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

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

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. 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. Comments: reference to Table E8 is required? E.5 Ultrasonic and electromagnetic inspection E.5.5 Acceptance limits E.5.5.1 The acceptance limit for indications produced by reference indicators shall be as given in Table E.8.

Fion Zhang/Charlie Chong

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

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

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.

Fion Zhang/Charlie Chong

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. 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

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

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

API5L

Charlie Chong/ Fion Zhang

API5L

Charlie Chong/ Fion Zhang

API5L

Charlie Chong/ Fion Zhang

API5L

Charlie Chong/ Fion Zhang

API5L

Charlie Chong/ Fion Zhang

API5L

Charlie Chong/ Fion Zhang

API5L

Charlie Chong/ Fion Zhang

API5L

Charlie Chong/ Fion Zhang

Peach – 我爱桃子

Fion Zhang/Charlie Chong

Good Luck

Fion Zhang/Charlie Chong

Good Luck

Fion Zhang/Charlie Chong

https://www.yumpu.com/en/browse/user/charliechong

Fion Zhang/Charlie Chong