Manufacture of SAW welded spiral seam, non sour pipes of PSL1
1.0
Steel (Coils)
Client Specification clause4.1 & API 5L clause 8.3 &
Addendum3.
100% coils
As per Client Specification clause4.1
RMTDC & API 5L clause 8.3.5 & addendum3
Coil Mill TC
R
R
1.1
Coil procurement & inspection
API 5L. clause 8.3.5 & addendum 3
Each coil
As per Client Specification clausc4.1 .RMTDC & API 5L clause 8.3.5 & addendum 3 (#)
Mill report
H
M
1.2
Edgemilling
Std. Procedure / WPS
Each coil
Each longitudinal edge max 10.0 mm each side & root and bevel as per approved WPS
Insp. report
H
M
1.3
Pipe forming
As per mill procedure, forming angle shall be confirmed at the time of PQT.
Each pipe
As per API 5L clause no 8.1 & Table 2
Mill report
H
M
2.0
Welding including
skelp end joints
As per approved welding procedures
Aseparate welding procedure shall be qualified for skelp end welds.
Each coil
As per API 5L clause no 8.10.2&8.10.4
Prod. Report
H
M
3.0
WPS/PQR/WPQ
API 5L
Each Wall thickness. OD & Grade
API 5L Annex - C & D. Weld procedure for SAW & repair weld as per approved WPS.
WPS/PQR/ WPQ
H
W/R
3.1
Automatic submerged arc welding
API 5L clause 8.6 & 8.10
Each pipe
Current, voltage, speed, wire & flux. Shall be controlled & monitored as per approved PQR
Welding report
H
M
3.2
Continuous tack welding (if done)
ASME section IX &
API 5L clause 8.4
Each pipe
As per approved WPS & as per clause no 8.4 of
API 5L.
Welding report
H
M
3.3
Visual inspection (Preliminary)
As per Client Specification cl. 5.2
and API 5L Clause 10.2.7 & 9.10.7 &
Table 17
Each pipe
All pipes shall be visually examined both externally and internally and shall be free of defects. Acceptance as per Client Specification 5.3.3(Visual Inspection) and Clause 10.2.7 & Table 17 of API 5L
H
RW
4.0
Hydrostatic test
(95% OF SMYS)
As per Client Specification clause 5.3.2(A.2)
Each pipe
Pipe shall be tested at following test pressures & the holding time shall be 10 seconds
Graph chart showing pressure & holding time for each pipe and test report
H
RW
Item
No
Pipe OD
(inch)
WT (mm)
Grade
Pressure
(min)
BAR
1
56’’ (1422.4)
9.52
X42
37
Calibration of the pressure gauges shall be carried out at start of production further to a frequency of at least once per week.
5.0
NondestructiveTesting
5.1
Intermediate UT/
Fluoroscopy
(Internal)
Clause E3.2.2 & E. 4 of API 5L
100% Weld Length
Acceptance shall be as per API 5L clause E. 4 & as per approved WI of Internal UT / As per API 5L
clause. E.4.5. clause. E.4.6 & as per approved WI for Fluoroscopy.
Fluoroscopy report /RTR Report
H
R
5.2
Each pipe both ends up to 250 mm
As per Client Specification clause 5.3.2(A.4)
Each Pipe ends for a length of 250mm each
Both ends along a length of at least 250 mm shall be radiographically checked.
Acceptance shall be as per API 5L clause E. 4 & as per approved WI of Internal UT / As per API 5L clause. E.4.5. clause E.4.6 & as per approved WI for X-Ray.
X-Ray report & radiographs
H
R
5.3
RSO/RSI
WMEP Work
Instruction for X- Ray
If any
All restart spots shall be x-ray checked, acceptance as per clause no. E. 4.5 & F. 4.6 of API 5L 44* Edition.
X-Ray report & radiographs
H
R
5.4
T-joints of skelp ends
As per Client Specification clause 5.3.2(A.5)
If any
All T-Joints of skelp end welds with extent of 150 mm in each direction of "T" Joint shall be inspected by X-ray as per API 5L Clause E.3.1.1 & Table El
X-Ray report & radiographs
H
R
6.0
UT calibration standard
Clause E.5.3.2 of
API 5L
Twice per operating shift, with second calibration at interval of 4 hrs.
As perclause no. E.5.2 & E.5.3 & E.5.4of API 5L
Cal. Report/ graph
H
RW
6.1
As per client specification clause 5.3.2 point A.3
Each Pipe and Plate/strip edge over a minimum width of 25 mm
Each Coil
For Body: Acceptance Level B1 of ISO 12094
For edges: Acceptance Level E2 of ISO 12094
Body UT report (or)
Coil UT report
11
RW
6.2
Weld Seam Ultrasonic Testing
(AUTO UT)
As per Client Spec clause 5.3.2(A.3) and Clause E.3.1 & Table El of API 5L& Approved WI for Auto UT.
100% weld seam of each pipe (except untested length)
All indications producing signals higher than the acceptance limits of reference standard & API 5L shall be MUT checked. Acceptance as per API 5L.
UT report
H
RW
6.3
Manual ultrasonic testing
Clause E.3.2.1 of API 5L
Each Pipe untested length & repaired areas if any
Acceptance as per Clause E.5.5. E5.6&E5.7 & table E8 of API 5L & Approved WI for MUT.
MUT report
H
RW
6.4
MUT on Each pipe End untested weld length
API 5L clause E.3.2.I& Approved WI for MUT.
Each pipe End untested weld length
Acceptance as per Clause E.5.5.E5.6&E5.7 <& table E8 of API 5L
MUT report
H
RW
6.5
Auto UT indications
Clause E.5.I.E.5.2. E.5.3. E.5.4 & table E8 of API and approved WI for MUT.
If any
All indications producing signals higher than the acceptance limits of reference standard & API 5L shall be MUT verified.
Acceptance as per Clause E.5.5.2. E.5.6 & table E8of API 5L
MUT report
H
RW
6.6
MUT of 50 mm end circumference
As per Client Spec clause 5.3.2* A3) and Clause 9.10.4 & E3.2.3 of API 5L
Each Pipe ends
Covered in End UT
Acceptance as per clause 9.10 4.E3.2.3 of API 5L
UT report
H
RW
6.7
Skelp Joint
ClauseE3.1.1 of API 5L & Table El
Skelp weld 100%
The complete strip end weld shall be subjected to manual ultrasonic testing
Acceptance as per Clause E.5.5. E.5.6. table E8 of API 5L.
MUT report
H
RW
7.0
Indication from MUT
Clause E. 3.2.2 of
API 5L
If any
All the indications confirmed by MUT shall be re-confirmed by X-ray for the acceptance of the defect, acceptance as per clause no, E 4.5 & E 4.6 of API 5L
X-Ray report
H
R
7.1
Weld Repair areas
Clause C.4.6 of
API 5L
If any
As per Clause E.4.5, E.4.6 & E.4.7.
X-Ray report
H
R
8.0
Residual Magnetism
Clause E.7 & E.7.6 of API5L
Each end of pipe selected once per
4 hours
The average of the four reading shall not exceed 30 gauss and no one reading shall not exceed 35 gauss
Test Report
H
RW
9.0
Workmanship, Visual Inspection and Repair of Defects
9.1
Visual Inspection
As per Client Specification cl. 5.2 and Clause 10.2.7 of API 5L
Each pipe inside & outside
As per Client Specification cl. 5.3.3( Visual Inspection) & Clause 9.10of API 5L
Visual &
dimensional
Report
H
RW
9.2
Dents
As per Client Specification cl.
5.2&5.3.3 and Clause 9.10.5.2. of API 5L
If any
As per Client Specification cl. 5.3.3 (Dimensional Inspection-5) & (Visual Inspection-1)
i.e. Max.6mm.Length1/4 of Pipe Diameter in any direction
Visual &
dimensional
Report
H
RW
9.3
Radial Offset of edges
As per client specification Clause 5.3.3 Visual Inspection Point 3
Each pipe & maintain record 3 pipe /shift
As per Table 14 of API 5L
Visual &
dimensional
Report
H
RW
Item
Pipe OD
(Inch)
WT (mm)
PflitrvssOte Radial Offset
(mm)
1
3B-|I 422.4)
9.62
0.952
Note: These linuts also apply to strip/plate end welds
9.4
Misalignment of weld beads
As per client specification Clause 5.3.3 Visual Inspection Point 2
Once per shift for each Welding Machine
Distance between centre line of internal & external weld in weld macro section.
Max. Misalignment shall not exceed 3mm.
Macro Reports
H
RW
9.5
Height of weld bead (inside & outside)
As per client specification Clause 5.3.3 Visual Inspection Point 6
Each pipe & record 3pipcs/shift
As per client specification cl.5.3.3 point 6
The height of the weld reinforcement shall be as small as possible and shall not exceed 3.0 mm.
Note: At the Option of Manufacturer, weld beads higher than permitted may be ground to acceptable heights as per API 5L
Visual &
dimensional
report
H
RW
9.6
Cracks & leaks
As per client specification Clause 5.3.3 Visual Inspection Point 4 & NDT Inspection point 2 and Clause 10.2.7. of API 5L
If any
As per clause 9.10.1.2 of API 5L
All pipes shall be free from defects in the
finished condition.
All pipes shall be free from
The acceptance criteria for imperfections
found by NDI shall be in accordance with
annex E of API 5L
Visual & NDT reports
H
RW
9.7
Undercuts
As per client specification Clause 5.3.3 Visual Inspection Point 4 & NDT Inspection point 5 and Clause 10.2.7 of API 5L& addendum 3
If any
As per clause 9.10.2 of API 5L
Undercutsthat have a depth < 0.4 mm are acceptable regardless of length, and shall be treated in accordance with clause C. 1 of API 5L
Undercuts that have a depth > 0.4 mm (0.016 in) but <0.8 mm (0.031 in) are acceptable provided they are treated in accordance with Clause C.2 and provided that:
their individual lengths arc < 0,5 t,
their individual depths arc < 0.1 t. and
There are no more than two such undercuts in any 300 mm (12.0 in) length of weld.
All such undercut arc treated in accordance with clause C2.
C) The undercuts that exceed die limits specified in item b) shall be classified as defects and shall be treated in accordance with clause C.3 of API 5L.
As per client specification clause 5.3.3(Dimensional Tolerance-9)
Each pipe
Weld reinforcement shall be removed Up to 150mm externally & 150mm internally at both ends of the pipe.
Visual &
dimensional
report
H
RW
9.9
Hard spots
Clause 10.2.7. Of AP15L.
If any
As per clause 9.10.6.& 10.2.4.8 of API 5L Any hard spot having dimension greater than 50 mm m any direction & hardness greater than 345 HV10 shall be rejected. Pipes containing such defects shall be treated in accordance with Clause no. C.3b) or C.3c) of API 5L.
Visual report
H
RW
9.10
Laminations
As per client specification clause 5.3J.non destructive test clause 1.
If any
Laminations in strips or plates detected by continuous ultrasonic testing within 50 mm of the edges or at the beveled pipe ends and having an undesirable effect on the welding. Isolated laminations in the body in an area of 1 m x 1 m exceeding 4400 mm2 in area, or having any dimensions greater than 75 mm.
Visual report + UT report
H
RW
9.11
Arc burns
Clause 10.2.7. of API 5L & addendum 3
If any
As per clause 9.I0.3.& addendum 3 of API 5L Arc burns shall be treated in accordance with Clause C.2. C.3 b) or C.3 c). except that they may be removed by grinding, chipping or machining, provided that the resultant cavity is thoroughly cleaned and checked for complete removal of damaged material by etching with a I0<£ solution of ammonium persulfate or a 5% solution of nital.
Visual report
H
RW
9.12
Other defects
(Geometric Deviation* &. Scratch Mark)
Clause 10.2.7. of API 5L & addendum 3
If any
As per clause 9.10.5& 9.10.7 of API 5L Other Geometric deviations as per API 5L
Visual report
H
RW
9.13
Skelp end welds in finished pipes
As per client specification clause 4.2.2
If any
The distance of the transverse skelp end weld from the end of the pipe shall not be less than 500 mm. The inclusion of transverse skelp welds in the pipe is limited to no more than one joint in each pipe
Visual &
dimensional
report
H
RW
9.14
Peaking
As per client spec, clause 5.3.3(Visual Inspection) Clause 9.10.5. of API 5L
If any
Max 1.5 mm
Visual &
dimensional
report
H
RW
10
DIMENSIONS. WEIGHTS & LENGTHS
10.1
Wall thickness
As per client spec, clause 5.3.3 (Dimensional Inspection-6)
Each pipe
Table II of API 5L
Visual &
dimensional
Report
H
RW
Item •
WT (mm)|
Tolerance*
Minimum wall thickness
(mm)
maxim
t
9.52
+0-5/
- 1.5
9.02
11.2
10.2
Pipe length
As per client spec, clause 5.3.3 (Dimensional Inspection-7)
Each pipe
Min- 12 mtr.
Max - 18 mtr.
Minimum Average Length - 17 mtr.
Visual &
dimensional
Report
H
RW
10.3
Straightness
As per client spec, clause 5.3.3 (Dimensional Inspection-8) & Clause 9.11.3.4 of API 5L.
Each pipe
Record 3 pipes/ shift
As per clause 9.11.3.4 of API 5L. addendum 3
Total deviation from straight line for all pipes shall not exceed 0.2% of the pipe length & 4.0 mm max for a distance of 1000 mm from the extreme pipe ends.
Visual &
dimensional
Report
H
RW
10.4
Inside diameter at the pipe end over a length of 100 mm
As per client spec, clause 5.3.3 (Dimensional Inspection-2) and Clause 10.2.8 of API 5L
Each pipe & record 3 pipes/ shift
The internal diameter measured with an internal steel tape at any place within 100 mm from either end shall not vary more titan -0.79 mm and +2.38 mm from the nominal internal diameter
Visual &
dimensional
Report
H
RW
10.5
Outside diameter at pipe body (measured with pie tape & recorded)
As per client spec, clause 5.3.3 (Dimensional Inspection-3)
Each pipe &. record 3 pipes/ shift
The external diameter of the pipe body, as measured from the circumference, shall not deviate from the nominal diameter by more than ± 3.0 mm.
Visual &
dimensional
Report
H
RW
10.6
Out of roundness (*)
10.6.1
At Pipe Ends
As per client spec, clause 5.3.3 (Dimensional lnspcction-4) and Clause 10.2.8 & table 10 of API 5L.
Each pipe & record 3 pipes/ shift
As per table 10 of API 5L. For item 1.2.4& 5 Max. 13 mm for item 3: 0.015D
Visual &
dimensional
Report
H
RW
10.6.2
At other than ends (Body)
As per client spec, clause 5.3.3 (Dimensional Inspcction-4) and Clause 10.2.8 & table 10 of API 5L.
Each pipe & record 3 pipes/ shift
As per Clause table 10 of API 5L For item 1. 2.4& 5 Max. 15 mm for item 3: 0.020D
Visual &
dimensional
Report
H
RW
10.7
Weight
As per Clause 10.2.9 of API 5L.
Each pipe
As per Clause 9.14.1 of API 5L. + 10% & - 3.5 % of nominal weight
Visual &
dimensional
Report
H
M
10.8
Pipe Ends & End Protectors
10.8.1
Bevel angle & root face
As per client specification Clause 5.3.3 (Dimensional Inspection-9) and Clause 9.12.5.2 of API 5L
Each pipe
Bevel angle. 30° (+5°. -0°) Root face 1.6 mm (± 0.8 mm)
Visual &
dimensional
Report
11
RW
10.8.2
End Squareness
As per client specification Clause 5.3.3( Dimensional lnspcction-9) and Clause 9.12.1.4 of API 5L
At least 3 pipes per shift
Acceptance As per API 5L Squareness < 1.6 mm
Visual &
dimensional
Report
H
RW
11
Repair prohibition & procedure
111
Repair procedure
As per client specification Clause 5.4 and As per API 5L. Annex C
If any
As per approved WPS & PQR
Approved WPS & PQR
H
H
11.2
Repair Prohibition
As per client specification Clause 5.4 and API 5L
( Annex C)
If any
BaseBase Material Repair:
Isolated minor surface defects can be removed by grinding, provided that the remaining wall thickness is at no point less than 98 % of the minimum allowable wall thickness over a maximum length of 300mm and that there is a smooth transition between the ground area and the origincontour.
A repair of base material by welding is not permitted.
WelWelding Seam Repair:
Repairing of welding seams must be done before expanding or hydrostatic testing. If such a repair is required after hydrostatic- testing or expanding, this pipe shall be hydrostatically retested after repair.
The repaired locations shall be tested by UT and RT.
The complete length of all repair welds shall not exceed 4 % of the total welding seam length of a pipe.
Repeated repairs at the same spot are not allowed.
Rectification report / approved WPS & PQR
II
RW
12.0
Test report & certification of pipes
As per client specification Clause 5.5 and API 5L clause 10.1.2 & 13
Each pipe
Alall documents as per API 5L
Insp. & test reports
H
R
13
Marking on finished pipe
As per client specification Clause 6.2 and clause 11.2. & addendum 3- 11.1.3. 11.2. Kb. e, f. g) of API 5L.
Each pipe one End
Marking shall be on the inside surface of the pipe, starting of a point at least 150 mm from one of the pipe ends and include the following information, as applicable. ( SI units I
Name or mark of the manufacturer.
Specified outside diameter
Specified wall thickness.
Pipe steel grade.
Product specification level designation.
Pipe length in MM & Pipe No.
Type of pipes. (Table 2 of API 5L).
Mark of customer's inspection representative if applicable.
An identification number which permits the correlation of the product or delivery unit with the related inspection documents, if applicable.
For specified outside diameter marking in USG or SI unit, it is not necessary to include the ending zero digit to the right of the decimal sing.
Country of Origin
The area of the pipe to be marked shall be clean and dry The size of the lettering shall be 20 mm. Pipe number shall be stamped on bevel at one end of pipe.
--------------------
H
RW
c
FIRST DAY PRODUCTION TEST (ONE PIPE OF COMPLETELY FINISHED PIPE OF FIRST DAY'S PRODUCTION)AS PER API 5L
C.l
Hydrostatic test
As per client spec. Clause no 5.3.2 point A.2
PQT pipe
As per clause. 4 of this MITPS
MPQT report
H
H
C.2
Automatic & manual Ultrasonic testing
As per client spec. Clause no 5.3.2 point A.3
PQT pipe
Complete weld length shall be UT tested as per clause.6.0.6.1.6.2.6.3.6.4.6.5.6.6.6.7.7.0 & 7.1 of this MITPS
MPQT report
H
H
C.3
Radiographic testing of weld seam
As per client spec. Clause no 5.3.2 point A.4
PQT Pipe
Radiographic test along the entire length of the weld shall be conducted and acceptance shall be as per clause 5.0,5.1. 5.2, 5.3 & 5.4 of this MITPS
MPQT report
H
R
C.4
Visual &
dimensional
examination
As per client spec Clause no 5.3.3
PQT pipe
As per 9.10 & 9.11 of API 5L. As per clause 9. & 10. of this MITPS
MPQT report
H
H
C.5
Chemical analysis (Product-Base & Weld)
Table 17 of API 5L 9.2.1 & Table 4
PQT pipe
As per clause B 1 of this MITPS, All elements as per Annex. A of this MITPS for Base & as per WPS for Weld
MPQT report
H
R
C.6
Mechanical tests
C.6.1
Transverse tensile test -Helical Weld Scam
API 5L clause 9.3.1. 10.2.3.2. 10.2.4.2. Table 6& 17
PQT pipe
As per clause B 2.2.a of this MITPS
MPQT report
H
H
C.6.2
Transverse tensile of strip/plate end weld of welded pipe
API 5L clause 9.5. 10.2.3.2. 10.2.4.2, Table 6 & 17 and Addendum 3
PQT pipe
As per clause B 2.2.b of this MITPS
MPQT report
H
H
Sr.
No.
Work Description
Ref. Standard / Specification
Testing Frequency
Acceptance Criteria
Documents
Inspection Stage
WMEP | TPI/ALISHAR
C.6.3
Guided bend lest Helical Weld Seam
API 5L clause 9.5. 10.2.4.6. Table 17
PQT pipe
As per clause B 2.3.a of this MITPS
MPQT report
H
H
C.6.4
Guided-bend testing of the strip/plate end weld of welded pipe
API 5L clause 9.5. 10.2.4.6 & Addendum 3
PQT pipe
As per clause B 2.3 b of this MITPS
MPQT report
H
H
C.6.5
CVN Impact Pipe Body. Weld & HAZ .HA/+2mm
As per client specification Clause 5.3.1.5 and API 5L
PQT Pipe
1 CVN impact for base, weld and HAZ at Test Temperature. Zero Degree C shall be done and the acceptance for full size specimen shall be as per API 5L. 44th Edition Table X.
2. Additionally Transition curve shall be established by testing at following Test temperatures, -40°C.-20°C. 0"C. 20°C & 60° C. for Each Location. The transition curve will be plotted. This is for information only and no acceptance criterion is stated.
MPQT report
H
H
C.6.6
Macrographic testing of helical- scam weld of welded pipe
Hardness
As per client specification Clause 5.3.3 Visual Inspection Point 2 & 5.3.2 D and clause 10.2.5. fig.4d.Tablc 14 & Table 17 of API 5L including Addendum 3
PQT pipe
As per clause B 2.5 of this MITPS
As per clause B 2.6 of this MITPS
MPQT report
H
11
(B)
PRODUCTION TESTS
K.I
Chemical analysis
( Product - Base Metal )
Clause 9.2.1 of API 5L. Table 4. Table 17 & addendum 3
2 pipes / heat
All elements as per Annexure - A of this MITPS
Chemical test report
H
H
B.2
Mechanical Tests
B 2.1
Transverse tensile test (Base Metal)
As per Client spec,
clause 5.3.2B.I and API 5L. clause 9.3.1. 10.2.3.2. 10.2.4.2. Table 6 & 17
2 Specimen/ heat and 1 Specimen/ lot of 50 pipes
For PSL 1 pipe, the tensile properties shall be as given in Table 6 of API 5L. The tensile test shall be carried out in accordance with ISO 6892 or ASTM A370. For pipe body tests, the yield strength, the yield ratio and the percentage elongation after fracture shall be determined. The percentage elongation after fracture shall he reported with reference to a gauge length of 50 mm (2 in.). For test pieces having a gauge length less than 50 mm(2 in.), the measured elongation after fracture shall be converted to a elongation in 50 mm <2 in.) in accordance with ISO 2566 or ASTM A 370. Test pieces for tensile test as per clause 10.2 3 2.
Mech Test report
H
H
B.2.2 (a)
Transverse tensile test -Helical Weld Seam
As per Client spec, clause 5.3.2B.2 and API 5L. clause 9.3.1. 10.2.3.2. 10.2.4.2. Table 6 & 17
1 Specimen/ heat and 1 Specimen/ lot of 50 Pipes
(The samples shall be taken in such a way that the testing frequencies of API including weekly
weld tensile test per welding line is complied)
Mech. Test report
H
H
B.2.2
(b)
Transverse tensile of strip/plate end weld of welded pipe
API 5L clause 9.5. 10.2.3.2. 10.2.4.2. Table 6 & 17 and Addendum 3
Once/50 Skelp welded pipes
API 5L clause 9.5. 10.2.3.2. 10.2.4.2. Table 6 &I7 and Addendum 3
Mech. Test report
H
H
B.2.3
(a)
Guided bend test Helical Weld Seam
As per Client spec, clause 5J.2B.3 and API 5L clause 9.5. 10.2.4.6. Table 17
1 Specimen set / heat &Specimen/ lot of 50 Pipes
One face and one root face bend weld test shall
be made on samples cut from pipe.
The mandrel dimension 'A' in guided bend
test shall be as per API 5L
Acceptance criteria shall be as per API 5L
clauses 9.5. 10.2.4.6. Table 17
Mech. Test report
H
H
B.2J (b)
Guided-bend testing of the strip/plate end weld of welded pipe
API 5L clause 9.5. 10.2.4.6 & Addendum 3
0ncc/50 Skelp welded pipes
API 5L clause 9.5. 10.2.4.6 & Addendum 3
Mech. Test report
H
H
B.2.4
CVN Impact Helical Weld Seam, base metal, fusionline.fusionline +2mm
As per client specification clause 5.3.2 B.4 & API 5L
Once/Lot of 50 Pipes
As per API 5L table 8
Mech. Test report
H
II
B.2.5
Monographic testing of helical- seam weld of welded pipe
As per client specification Clause 5.3.3 Visual Inspection Point 2 and clause 10.2.5, fig.4d.Table 14 & Table 17 of API 5L including Addendum 3
Once /Operating shift for each welding machine
The centre lines of the inside and outside welds shall be within 3 mm of each other
Test report
H
H
B.2.6
Hardness Testing
As per client specification Clause 5.3.2 D
1 specimen / Lot of 50 Pipes
Max. hardness shall be 3(X) HB
Test report
II
H
B.3
Retesting & rejection criteria
As per client specification Clause 5.3.2 C and clause 10.2.12 of API 5L. Addendum 3
If any
Retesting shall be performed for each test in accordance with API 5L. section 9.12.2 "Retests" & Addendum 3
Sr.
No.
Work Description
Ref. Standard / Specification
Testing Frequency
Acceptance Criteria
Documents
Inspection Stage
WMKP | TPI/AI.ISHAR
(A)
Scope
Client Specification
clause 1 & API 5L
clause 1
Manufacture of SAW welded spiral seam, non sour pipes of PSL1
1.0
Steel (Coils)
Client Specification clause4.1 & API 5L clause 8.3 &
Addendum3.
100% coils
As per Client Specification clause4.1
RMTDC & API 5L clause 8.3.5 & addendum3
Coil Mill TC
R
R
1.1
Coil procurement & inspection
API 5L. clause 8.3.5 & addendum 3
Each coil
As per Client Specification clausc4.1 .RMTDC & API 5L clause 8.3.5 & addendum 3 (#)
Mill report
H
M
1.2
Edgemilling
Std. Procedure / WPS
Each coil
Each longitudinal edge max 10.0 mm each side & root and bevel as per approved WPS
Insp. report
H
M
1.3
Pipe forming
As per mill procedure, forming angle shall be confirmed at the time of PQT.
Each pipe
As per API 5L clause no 8.1 & Table 2
Mill report
H
M
2.0
Welding including
skelp end joints
As per approved welding procedures
Aseparate welding procedure shall be qualified for skelp end welds.
Each coil
As per API 5L clause no 8.10.2&8.10.4
Prod. Report
H
M
3.0
WPS/PQR/WPQ
API 5L
Each Wall thickness. OD & Grade
API 5L Annex - C & D. Weld procedure for SAW & repair weld as per approved WPS.
WPS/PQR/ WPQ
H
W/R
3.1
Automatic submerged arc welding
API 5L clause 8.6 & 8.10
Each pipe
Current, voltage, speed, wire & flux. Shall be controlled & monitored as per approved PQR
Welding report
H
M
3.2
Continuous tack welding (if done)
ASME section IX &
API 5L clause 8.4
Each pipe
As per approved WPS & as per clause no 8.4 of
API 5L.
Welding report
H
M
3.3
Visual inspection (Preliminary)
As per Client Specification cl. 5.2
and API 5L Clause 10.2.7 & 9.10.7 &
Table 17
Each pipe
All pipes shall be visually examined both externally and internally and shall be free of defects. Acceptance as per Client Specification 5.3.3(Visual Inspection) and Clause 10.2.7 & Table 17 of API 5L
H
RW
4.0
Hydrostatic test
(95% OF SMYS)
As per Client Specification clause 5.3.2(A.2)
Each pipe
Pipe shall be tested at following test pressures & the holding time shall be 10 seconds
Graph chart showing pressure & holding time for each pipe and test report
H
RW
Item
No
Pipe OD
(inch)
WT (mm)
Grade
Pressure
(min)
BAR
1
56’’ (1422.4)
9.52
X42
37
Calibration of the pressure gauges shall be carried out at start of production further to a frequency of at least once per week.
5.0
NondestructiveTesting
5.1
Intermediate UT/
Fluoroscopy
(Internal)
Clause E3.2.2 & E. 4 of API 5L
100% Weld Length
Acceptance shall be as per API 5L clause E. 4 & as per approved WI of Internal UT / As per API 5L
clause. E.4.5. clause. E.4.6 & as per approved WI for Fluoroscopy.
Fluoroscopy report /RTR Report
H
R
5.2
Each pipe both ends up to 250 mm
As per Client Specification clause 5.3.2(A.4)
Each Pipe ends for a length of 250mm each
X-Ray report & radiographs
H
R
5.3
RSO/RSI
WMEP Work
Instruction for X- Ray
If any
All restart spots shall be x-ray checked, acceptance as per clause no. E. 4.5 & F. 4.6 of API 5L 44* Edition.
X-Ray report & radiographs
H
R
5.4
T-joints of skelp ends
As per Client Specification clause 5.3.2(A.5)
If any
All T-Joints of skelp end welds with extent of 150 mm in each direction of "T" Joint shall be inspected by X-ray as per API 5L Clause E.3.1.1 & Table El
X-Ray report & radiographs
H
R
6.0
UT calibration standard
Clause E.5.3.2 of
API 5L
Twice per operating shift, with second calibration at interval of 4 hrs.
As perclause no. E.5.2 & E.5.3 & E.5.4of API 5L
Cal. Report/ graph
H
RW
6.1
As per client specification clause 5.3.2 point A.3
Each Pipe and Plate/strip edge over a minimum width of 25 mm
Each Coil
For Body: Acceptance Level B1 of ISO 12094
For edges: Acceptance Level E2 of ISO 12094
Body UT report (or)
Coil UT report
11
RW
6.2
Weld Seam Ultrasonic Testing
(AUTO UT)
As per Client Spec clause 5.3.2(A.3) and Clause E.3.1 & Table El of API 5L& Approved WI for Auto UT.
100% weld seam of each pipe (except untested length)
All indications producing signals higher than the acceptance limits of reference standard & API 5L shall be MUT checked. Acceptance as per API 5L.
UT report
H
RW
6.3
Manual ultrasonic testing
Clause E.3.2.1 of API 5L
Each Pipe untested length & repaired areas if any
Acceptance as per Clause E.5.5. E5.6&E5.7 & table E8 of API 5L & Approved WI for MUT.
MUT report
H
RW
6.4
MUT on Each pipe End untested weld length
API 5L clause E.3.2.I& Approved WI for MUT.
Each pipe End untested weld length
Acceptance as per Clause E.5.5.E5.6&E5.7 <& table E8 of API 5L
MUT report
H
RW
6.5
Auto UT indications
Clause E.5.I.E.5.2. E.5.3. E.5.4 & table E8 of API and approved WI for MUT.
If any
All indications producing signals higher than the acceptance limits of reference standard & API 5L shall be MUT verified.
Acceptance as per Clause E.5.5.2. E.5.6 & table E8of API 5L
MUT report
H
RW
6.6
MUT of 50 mm end circumference
As per Client Spec clause 5.3.2* A3) and Clause 9.10.4 & E3.2.3 of API 5L
Each Pipe ends
Covered in End UT
Acceptance as per clause 9.10 4.E3.2.3 of API 5L
UT report
H
RW
6.7
Skelp Joint
ClauseE3.1.1 of API 5L & Table El
Skelp weld 100%
The complete strip end weld shall be subjected to manual ultrasonic testing
Acceptance as per Clause E.5.5. E.5.6. table E8 of API 5L.
MUT report
H
RW
7.0
Indication from MUT
Clause E. 3.2.2 of
API 5L
If any
All the indications confirmed by MUT shall be re-confirmed by X-ray for the acceptance of the defect, acceptance as per clause no, E 4.5 & E 4.6 of API 5L
X-Ray report
H
R
7.1
Weld Repair areas
Clause C.4.6 of
API 5L
If any
As per Clause E.4.5, E.4.6 & E.4.7.
X-Ray report
H
R
8.0
Residual Magnetism
Clause E.7 & E.7.6 of API5L
Each end of pipe selected once per
4 hours
The average of the four reading shall not exceed 30 gauss and no one reading shall not exceed 35 gauss
Test Report
H
RW
9.0
Workmanship, Visual Inspection and Repair of Defects
9.1
Visual Inspection
As per Client Specification cl. 5.2 and Clause 10.2.7 of API 5L
Each pipe inside & outside
As per Client Specification cl. 5.3.3( Visual Inspection) & Clause 9.10of API 5L
Visual &
dimensional
Report
H
RW
9.2
Dents
As per Client Specification cl.
5.2&5.3.3 and Clause 9.10.5.2. of API 5L
If any
As per Client Specification cl. 5.3.3 (Dimensional Inspection-5) & (Visual Inspection-1)
i.e. Max.6mm.Length1/4 of Pipe Diameter in any direction
Visual &
dimensional
Report
H
RW
9.3
Radial Offset of edges
As per client specification Clause 5.3.3 Visual Inspection Point 3
Each pipe & maintain record 3 pipe /shift
As per Table 14 of API 5L
Visual &
dimensional
Report
H
RW
Item
Pipe OD
(Inch)
WT (mm)
PflitrvssOte Radial Offset
(mm)
1
3B-|I 422.4)
9.62
0.952
Note: These linuts also apply to strip/plate end welds
9.4
Misalignment of weld beads
As per client specification Clause 5.3.3 Visual Inspection Point 2
Once per shift for each Welding Machine
Distance between centre line of internal & external weld in weld macro section.
Max. Misalignment shall not exceed 3mm.
Macro Reports
H
RW
9.5
Height of weld bead (inside & outside)
As per client specification Clause 5.3.3 Visual Inspection Point 6
Each pipe & record 3pipcs/shift
As per client specification cl.5.3.3 point 6
The height of the weld reinforcement shall be as small as possible and shall not exceed 3.0 mm.
Note: At the Option of Manufacturer, weld beads higher than permitted may be ground to acceptable heights as per API 5L
Visual &
dimensional
report
H
RW
9.6
Cracks & leaks
As per client specification Clause 5.3.3 Visual Inspection Point 4 & NDT Inspection point 2 and Clause 10.2.7. of API 5L
If any
As per clause 9.10.1.2 of API 5L
All pipes shall be free from defects in the
finished condition.
All pipes shall be free from
The acceptance criteria for imperfections
found by NDI shall be in accordance with
annex E of API 5L
Visual & NDT reports
H
RW
9.7
Undercuts
As per client specification Clause 5.3.3 Visual Inspection Point 4 & NDT Inspection point 5 and Clause 10.2.7 of API 5L& addendum 3
If any
As per clause 9.10.2 of API 5L
C) The undercuts that exceed die limits specified in item b) shall be classified as defects and shall be treated in accordance with clause C.3 of API 5L.
Visual &
dimensional
report
H
RW
9.8
Inside & outside weld bead grinding (End flushing)
As per client specification clause 5.3.3(Dimensional Tolerance-9)
Each pipe
Weld reinforcement shall be removed Up to 150mm externally & 150mm internally at both ends of the pipe.
Visual &
dimensional
report
H
RW
9.9
Hard spots
Clause 10.2.7. Of AP15L.
If any
As per clause 9.10.6.& 10.2.4.8 of API 5L Any hard spot having dimension greater than 50 mm m any direction & hardness greater than 345 HV10 shall be rejected. Pipes containing such defects shall be treated in accordance with Clause no. C.3b) or C.3c) of API 5L.
Visual report
H
RW
9.10
Laminations
As per client specification clause 5.3J.non destructive test clause 1.
If any
Laminations in strips or plates detected by continuous ultrasonic testing within 50 mm of the edges or at the beveled pipe ends and having an undesirable effect on the welding. Isolated laminations in the body in an area of 1 m x 1 m exceeding 4400 mm2 in area, or having any dimensions greater than 75 mm.
Visual report + UT report
H
RW
9.11
Arc burns
Clause 10.2.7. of API 5L & addendum 3
If any
As per clause 9.I0.3.& addendum 3 of API 5L Arc burns shall be treated in accordance with Clause C.2. C.3 b) or C.3 c). except that they may be removed by grinding, chipping or machining, provided that the resultant cavity is thoroughly cleaned and checked for complete removal of damaged material by etching with a I0<£ solution of ammonium persulfate or a 5% solution of nital.
Visual report
H
RW
9.12
Other defects
(Geometric Deviation* &. Scratch Mark)
Clause 10.2.7. of API 5L & addendum 3
If any
As per clause 9.10.5& 9.10.7 of API 5L Other Geometric deviations as per API 5L
Visual report
H
RW
9.13
Skelp end welds in finished pipes
As per client specification clause 4.2.2
If any
The distance of the transverse skelp end weld from the end of the pipe shall not be less than 500 mm. The inclusion of transverse skelp welds in the pipe is limited to no more than one joint in each pipe
Visual &
dimensional
report
H
RW
9.14
Peaking
As per client spec, clause 5.3.3(Visual Inspection) Clause 9.10.5. of API 5L
If any
Max 1.5 mm
Visual &
dimensional
report
H
RW
10
DIMENSIONS. WEIGHTS & LENGTHS
10.1
Wall thickness
As per client spec, clause 5.3.3 (Dimensional Inspection-6)
Each pipe
Table II of API 5L
Visual &
dimensional
Report
H
RW
Item •
WT (mm)|
Tolerance*
Minimum wall thickness
(mm)
maxim
t
9.52
+0-5/
- 1.5
9.02
11.2
10.2
Pipe length
As per client spec, clause 5.3.3 (Dimensional Inspection-7)
Each pipe
Min- 12 mtr.
Max - 18 mtr.
Minimum Average Length - 17 mtr.
Visual &
dimensional
Report
H
RW
10.3
Straightness
As per client spec, clause 5.3.3 (Dimensional Inspection-8) & Clause 9.11.3.4 of API 5L.
Each pipe
Record 3 pipes/ shift
As per clause 9.11.3.4 of API 5L. addendum 3
Total deviation from straight line for all pipes shall not exceed 0.2% of the pipe length & 4.0 mm max for a distance of 1000 mm from the extreme pipe ends.
Visual &
dimensional
Report
H
RW
10.4
Inside diameter at the pipe end over a length of 100 mm
As per client spec, clause 5.3.3 (Dimensional Inspection-2) and Clause 10.2.8 of API 5L
Each pipe & record 3 pipes/ shift
The internal diameter measured with an internal steel tape at any place within 100 mm from either end shall not vary more titan -0.79 mm and +2.38 mm from the nominal internal diameter
Visual &
dimensional
Report
H
RW
10.5
Outside diameter at pipe body (measured with pie tape & recorded)
As per client spec, clause 5.3.3 (Dimensional Inspection-3)
Each pipe &. record 3 pipes/ shift
The external diameter of the pipe body, as measured from the circumference, shall not deviate from the nominal diameter by more than ± 3.0 mm.
Visual &
dimensional
Report
H
RW
10.6
Out of roundness (*)
10.6.1
At Pipe Ends
As per client spec, clause 5.3.3 (Dimensional lnspcction-4) and Clause 10.2.8 & table 10 of API 5L.
Each pipe & record 3 pipes/ shift
As per table 10 of API 5L. For item 1.2.4& 5 Max. 13 mm for item 3: 0.015D
Visual &
dimensional
Report
H
RW
10.6.2
At other than ends (Body)
As per client spec, clause 5.3.3 (Dimensional Inspcction-4) and Clause 10.2.8 & table 10 of API 5L.
Each pipe & record 3 pipes/ shift
As per Clause table 10 of API 5L For item 1. 2.4& 5 Max. 15 mm for item 3: 0.020D
Visual &
dimensional
Report
H
RW
10.7
Weight
As per Clause 10.2.9 of API 5L.
Each pipe
As per Clause 9.14.1 of API 5L. + 10% & - 3.5 % of nominal weight
Visual &
dimensional
Report
H
M
10.8
Pipe Ends & End Protectors
10.8.1
Bevel angle & root face
As per client specification Clause 5.3.3 (Dimensional Inspection-9) and Clause 9.12.5.2 of API 5L
Each pipe
Bevel angle. 30° (+5°. -0°) Root face 1.6 mm (± 0.8 mm)
Visual &
dimensional
Report
11
RW
10.8.2
End Squareness
As per client specification Clause 5.3.3( Dimensional lnspcction-9) and Clause 9.12.1.4 of API 5L
At least 3 pipes per shift
Acceptance As per API 5L Squareness < 1.6 mm
Visual &
dimensional
Report
H
RW
11
Repair prohibition & procedure
111
Repair procedure
As per client specification Clause 5.4 and As per API 5L. Annex C
If any
As per approved WPS & PQR
Approved WPS & PQR
H
H
11.2
Repair Prohibition
As per client specification Clause 5.4 and API 5L
( Annex C)
If any
BaseBase Material Repair:
WelWelding Seam Repair:
Rectification report / approved WPS & PQR
II
RW
12.0
Test report & certification of pipes
As per client specification Clause 5.5 and API 5L clause 10.1.2 & 13
Each pipe
Alall documents as per API 5L
Insp. & test reports
H
R
13
Marking on finished pipe
As per client specification Clause 6.2 and clause 11.2. & addendum 3- 11.1.3. 11.2. Kb. e, f. g) of API 5L.
Each pipe one End
Marking shall be on the inside surface of the pipe, starting of a point at least 150 mm from one of the pipe ends and include the following information, as applicable. ( SI units I
The area of the pipe to be marked shall be clean and dry The size of the lettering shall be 20 mm. Pipe number shall be stamped on bevel at one end of pipe.
--------------------
H
RW
c
FIRST DAY PRODUCTION TEST (ONE PIPE OF COMPLETELY FINISHED PIPE OF FIRST DAY'S PRODUCTION)AS PER API 5L
C.l
Hydrostatic test
As per client spec. Clause no 5.3.2 point A.2
PQT pipe
As per clause. 4 of this MITPS
MPQT report
H
H
C.2
Automatic & manual Ultrasonic testing
As per client spec. Clause no 5.3.2 point A.3
PQT pipe
Complete weld length shall be UT tested as per clause.6.0.6.1.6.2.6.3.6.4.6.5.6.6.6.7.7.0 & 7.1 of this MITPS
MPQT report
H
H
C.3
Radiographic testing of weld seam
As per client spec. Clause no 5.3.2 point A.4
PQT Pipe
Radiographic test along the entire length of the weld shall be conducted and acceptance shall be as per clause 5.0,5.1. 5.2, 5.3 & 5.4 of this MITPS
MPQT report
H
R
C.4
Visual &
dimensional
examination
As per client spec Clause no 5.3.3
PQT pipe
As per 9.10 & 9.11 of API 5L. As per clause 9. & 10. of this MITPS
MPQT report
H
H
C.5
Chemical analysis (Product-Base & Weld)
Table 17 of API 5L 9.2.1 & Table 4
PQT pipe
As per clause B 1 of this MITPS, All elements as per Annex. A of this MITPS for Base & as per WPS for Weld
MPQT report
H
R
C.6
Mechanical tests
C.6.1
Transverse tensile test -Helical Weld Scam
API 5L clause 9.3.1. 10.2.3.2. 10.2.4.2. Table 6& 17
PQT pipe
As per clause B 2.2.a of this MITPS
MPQT report
H
H
C.6.2
Transverse tensile of strip/plate end weld of welded pipe
API 5L clause 9.5. 10.2.3.2. 10.2.4.2, Table 6 & 17 and Addendum 3
PQT pipe
As per clause B 2.2.b of this MITPS
MPQT report
H
H
Sr.
No.
Work Description
Ref. Standard / Specification
Testing Frequency
Acceptance Criteria
Documents
Inspection Stage
WMEP | TPI/ALISHAR
C.6.3
Guided bend lest Helical Weld Seam
API 5L clause 9.5. 10.2.4.6. Table 17
PQT pipe
As per clause B 2.3.a of this MITPS
MPQT report
H
H
C.6.4
Guided-bend testing of the strip/plate end weld of welded pipe
API 5L clause 9.5. 10.2.4.6 & Addendum 3
PQT pipe
As per clause B 2.3 b of this MITPS
MPQT report
H
H
C.6.5
CVN Impact Pipe Body. Weld & HAZ .HA/+2mm
As per client specification Clause 5.3.1.5 and API 5L
PQT Pipe
1 CVN impact for base, weld and HAZ at Test Temperature. Zero Degree C shall be done and the acceptance for full size specimen shall be as per API 5L. 44th Edition Table X.
2. Additionally Transition curve shall be established by testing at following Test temperatures, -40°C.-20°C. 0"C. 20°C & 60° C. for Each Location. The transition curve will be plotted. This is for information only and no acceptance criterion is stated.
MPQT report
H
H
C.6.6
As per client specification Clause 5.3.3 Visual Inspection Point 2 & 5.3.2 D and clause 10.2.5. fig.4d.Tablc 14 & Table 17 of API 5L including Addendum 3
PQT pipe
MPQT report
H
11
(B)
PRODUCTION TESTS
K.I
Chemical analysis
( Product - Base Metal )
Clause 9.2.1 of API 5L. Table 4. Table 17 & addendum 3
2 pipes / heat
All elements as per Annexure - A of this MITPS
Chemical test report
H
H
B.2
Mechanical Tests
B 2.1
Transverse tensile test (Base Metal)
As per Client spec,
clause 5.3.2B.I and API 5L. clause 9.3.1. 10.2.3.2. 10.2.4.2. Table 6 & 17
2 Specimen/ heat and 1 Specimen/ lot of 50 pipes
For PSL 1 pipe, the tensile properties shall be as given in Table 6 of API 5L. The tensile test shall be carried out in accordance with ISO 6892 or ASTM A370. For pipe body tests, the yield strength, the yield ratio and the percentage elongation after fracture shall be determined. The percentage elongation after fracture shall he reported with reference to a gauge length of 50 mm (2 in.). For test pieces having a gauge length less than 50 mm(2 in.), the measured elongation after fracture shall be converted to a elongation in 50 mm <2 in.) in accordance with ISO 2566 or ASTM A 370. Test pieces for tensile test as per clause 10.2 3 2.
Mech Test report
H
H
B.2.2 (a)
Transverse tensile test -Helical Weld Seam
As per Client spec, clause 5.3.2B.2 and API 5L. clause 9.3.1. 10.2.3.2. 10.2.4.2. Table 6 & 17
1 Specimen/ heat and 1 Specimen/ lot of 50 Pipes
(The samples shall be taken in such a way that the testing frequencies of API including weekly
weld tensile test per welding line is complied)
Mech. Test report
H
H
B.2.2
(b)
Transverse tensile of strip/plate end weld of welded pipe
API 5L clause 9.5. 10.2.3.2. 10.2.4.2. Table 6 & 17 and Addendum 3
Once/50 Skelp welded pipes
API 5L clause 9.5. 10.2.3.2. 10.2.4.2. Table 6 &I7 and Addendum 3
Mech. Test report
H
H
B.2.3
(a)
Guided bend test Helical Weld Seam
As per Client spec, clause 5J.2B.3 and API 5L clause 9.5. 10.2.4.6. Table 17
1 Specimen set / heat &Specimen/ lot of 50 Pipes
One face and one root face bend weld test shall
be made on samples cut from pipe.
The mandrel dimension 'A' in guided bend
test shall be as per API 5L
Acceptance criteria shall be as per API 5L
clauses 9.5. 10.2.4.6. Table 17
Mech. Test report
H
H
B.2J (b)
Guided-bend testing of the strip/plate end weld of welded pipe
API 5L clause 9.5. 10.2.4.6 & Addendum 3
0ncc/50 Skelp welded pipes
API 5L clause 9.5. 10.2.4.6 & Addendum 3
Mech. Test report
H
H
B.2.4
CVN Impact Helical Weld Seam, base metal, fusionline.fusionline +2mm
As per client specification clause 5.3.2 B.4 & API 5L
Once/Lot of 50 Pipes
As per API 5L table 8
Mech. Test report
H
II
B.2.5
Monographic testing of helical- seam weld of welded pipe
As per client specification Clause 5.3.3 Visual Inspection Point 2 and clause 10.2.5, fig.4d.Table 14 & Table 17 of API 5L including Addendum 3
Once /Operating shift for each welding machine
The centre lines of the inside and outside welds shall be within 3 mm of each other
Test report
H
H
B.2.6
Hardness Testing
As per client specification Clause 5.3.2 D
1 specimen / Lot of 50 Pipes
Max. hardness shall be 3(X) HB
Test report
II
H
B.3
Retesting & rejection criteria
As per client specification Clause 5.3.2 C and clause 10.2.12 of API 5L. Addendum 3
If any
Retesting shall be performed for each test in accordance with API 5L. section 9.12.2 "Retests" & Addendum 3
Test report
H
RW