Procedure For Manual Body Ut [PDF]

Zitiervorschau

EPCM SERVICES FOR BINA-PANKI PIPELINE PROJECT

Document Title

Manual Body UT Procedure

Document Number

15984-01-TSBSL-PL010-00023

Client

Bharat Petroleum Corporation Limited

EPMC Consultant

WorleyParsons India Pvt Ltd (WPIL)

Vendor

Tata Steel BSL Limited, Khopoli

Vendor Scope

Supply of Coated Line Pipes

PO Number & Date

PLPROJ:BPPL:LINEPIPE dated 29/09/2019

2 1

08.11.2019

INCORPORATE COMMENTS & ISSUED FOR REVIEW

0

07.10.2019

ISSUED FOR REVIEW

REV

DATE

PURPOSE OF ISSUE

Doc No: 15984-01-TSBSL-PL010-00023 Rev : 0

Raghuveer Singh

PREPARED BY

Suresh Jadon

REVIEWED BY

Udyan Tyagi

APPROVED BY

Page 1 of 1

STEEL BSL LIMITED

PIPE DIVISION KHOPOLI- MAHARASHTRA , INDIA Document Title: Procedure For Manual Ultrasonic Testing at Body Document No

TSBSL/NDT/BPCL/P-04

Rev

01 Date: 08.11.2019 Page 1 of 7

Manufacturing Location

:

TATA STEEL BSL LTD. - KHOPOLI, INDIA

Plant

:

ERW PIPE MILL-01

Client

:

M/S BHARAT PETROLIUM CORPORATION LIMITED.

Project Name

:

BINA – PANKI (KANPUR) PIPELINE PROJECT

P.O. No.

:

LETTER OF ACCEPTANCE - PLPROJ: BPPL: LINEPIPE

Technical specification

:

Pipe Size & Grade

:

Third Party Inspection Agency Reference

DP-QC-06

API 5L (46th Edn-2018) , CLIENT SPEC.-14953-BP-10-PL-SPC-5004 Rev:1, 15984-BP-10-PL-SPC-0006 REV.00, 15984-BP-10-PL-SPC-0026 REV.00 MATERIAL REQUISITION FOR LINE PIPES - 15984-BP-10-PL-REQ-0001 Rev : 0 Sr. Outside Wall Material Quantity Remark Diameter Thickness Grade (MTR) No. 457 MM 7.14 MM X70M PSL2 281028 1 3LPE 457 MM 8.74 MM X70M PSL2 70536 2 3LPE 3

457 MM

12.70 MM

X70M PSL2

16920

3LPE

4

457 MM

12.70 MM

X70M PSL2

396

BARE

:

WORLEYPARSONS/ WORLEYPARSONS APPOINTED TPIA: M/S TUV INDIA PVT. LTD.

:

TSBSL/ERW/QAP/BPCL/01

Prepared & Reviewed by

Approved by

SURESH CHAND

JITENDRA SINGHAL

ASNT NDT LEVEL-III UT, RT, MT, PT- 245114

ASNT NDT LEVEL-III UT, RT, MT, PT, ET - 216605

UDYAN TYAGI

HOD QUALITY

TPI / CLIENT

STEEL BSL LIMITED

PIPE DIVISION KHOPOLI- MAHARASHTRA , INDIA Document Title: Procedure For Manual Ultrasonic Testing at Body Document No

TSBSL/NDT/BPCL/P-04

Rev

DP-QC-06

01 Date: 08.11.2019 Page 2 of 7

1 Purpose: The purpose of this document is to ensure that the straight beam manual ultrasonic testing is carried out as per the applicable Specification and Standards. 2 Scope: This procedure provides the requirement & acceptance criteria of manual ultrasonic testing of HFW pipes. This covers. 2.1 Inspection of each pipe end circumferentially up to 50 mm from both ends of HFW pipes. 2.2 Spray portions of automatic Body ultrasonic testing to detect lamination, inclusions & other laminar type of imperfections. 3 References: API 5L (46th Edition: 2018) CLIENT SPEC.-14953-BP-10-PL-SPC-5004 Rev:1 ISO 10893 – 8 : 2011 ASNT SNT-TC-1A : 2016 4 Responsibility:4.1 NDT Personnel performing Ultrasonic examination shall be ASNT Level –II & responsible for interpretation & evaluation of indications during the examination & preparation of examination reports. An ASNT Level-III shall be responsible for overall supervision. 5 Personnel Qualification: 5.1 ASNT NDT Level – II: For Calibration & operation of the system, interpretation & recording of test results. 5.2 ASNT NDT Level – III: 5.2.1 For establishment & demonstration of the procedure. 5.2.2 for approval of the procedure 5.2.3 Training of NDT personnel engaged in operation of the system. 5.2.4 Overall supervision of the NDT system. 6 Manual UT System: 6.1 Ultrasonic Equipment: A portable ultrasonic pulse echo type flaw detector shall be used to meet the requirement of this procedure. 6.2 Equipment Type: Ultrasonic flaw detector,

STEEL BSL LIMITED

PIPE DIVISION KHOPOLI- MAHARASHTRA , INDIA Document Title: Procedure For Manual Ultrasonic Testing at Body Document No

TSBSL/NDT/BPCL/P-04

Rev

DP-QC-06

01 Date: 08.11.2019 Page 3 of 7

Make - Modsonic, Model-Einstein-II TFT/ Make – EEC, Model-DIGISCAN DS-322 / Make GE, Model- USN 60 6.3 Sensitivity: Equipment has stepped amplification in units of 0.5 dB with a range of 0100dB. 6.4 PRF (pulse repetitive factor/ rate)-1500Hz 6.5 Transducers: 6.5.1 6.5.2 6.5.3 6.5.4

Type: The Normal T/R type of transducer shall be used. Crystal Size: Transducer used shall have crystal Ø 10 mm or Ø 24mm. Frequency: The transducers used are having frequency 4 MHz. Transducers may be equipped with the wear shoe which have appropriate radius of curvature for the material being examination. 6.6 Cable: Co-axial cable with lemo to minilemo Connector of length 1.5 to 2.5 meter shall be used. 7 Couplant: Water shall be used as couplant. 8 Scanning surface condition: 8.1 The full surface at probes contact area shall be free from dirt, loose scale, rust and other foreign matters which may interfere with testing process. 9 Instrument Calibration: 9.1 Screen height Linearity: The Ultrasonic Instruments screen height linearity shall be evaluated in accordance with Procedure for Instrument Calibration (TSBSL/ERW/QC/ P-07). 9.2 Amplitude Control Linearity: The Ultrasonic Instruments Amplitude Control linearity shall be evaluated in accordance with Procedure for Instrument Calibration (TSBSL/ERW/QC/ P-07). 9.3 Horizontal Linearity: The Ultrasonic Instruments Horizontal linearity shall be evaluated in accordance with Procedure for Instrument Calibration (TSBSL/ERW/QC/ P-07). 10 Calibration Standard Blocks: IIW V1 or V2 Block shall be used for range calibration. 11 Reference Standard: 11.1 The block is made up of same material, thickness, type, geometry & of same grade with Φ 6.00 mm diameter Flat bottom hole with depth half of the wall thickness. Diameter of FBH =6 mm (tolerance is +0.6mm, -0mm) Depth of FBH =T/4 to T/2 with a maximum of 25mm (where T is wall thickness) 12 Calibration procedure:

STEEL BSL LIMITED

PIPE DIVISION KHOPOLI- MAHARASHTRA , INDIA Document Title: Procedure For Manual Ultrasonic Testing at Body Document No

TSBSL/NDT/BPCL/P-04

Rev

DP-QC-06

01 Date: 08.11.2019 Page 4 of 7

A threshold level for acceptance shall be established in following steps. 12.1 Position the search unit for maximum response from FBH & adjust the sensitivity (dB) control to set the height of echo to a maximum of 80% of FSH. 12.2 Record dB level at this echo height which shall be considered the reference dB level for evaluation. 12.3 Scanning shall be performed at a gain setting of reference level plus 6 dB. 13 Calibration Frequency: The calibration shall be performed at following intervals, 13.1 At the beginning of each shift. 13.2 After every four hours. 13.3 When the equipment operator changeover 13.4 At the beginning of the new production. (When there is change of size, material). 13.5 At the end of the production. (When there is change of size or material) 13.6 Before shutdown of the system. 13.7 After restart of system during inspection. 13.8 When the running of the system raises doubt about its efficiency. 13.9 If any of the Parameter Changes which were used during initial calibration are changed. 14 Scanning sensitivity (dB) level shall be reference sensitivity (dB) +6dB. 15 Stage of Examination: 14.1 The Manual Ultrasonic Examination shall be carried out on pipe after completion of Hydro testing/Auto UT Testing 16 Technique: 15.1 Straight beam Contact Technique 17 Method of Examination: 16.1 Pulse Echo Method 18 Testing Procedure: 17.1 The operator shall verify the pipe No. and the sprayed location on the pipe which has been sprayed by automatic pipe ultrasonic testing for flaw and decoupling. 17.2 While scanning, 6dB shall be raised over reference sensitivity (dB) level. 17.3 The scanning shall be done in V shape (zigzag) with 10%overlaping and pipe to cover 50mm band from both pipe ends over the entire circumference. 17.4 The scanning shall also to be done from outside of the pipe surface at any sprayed portion from Auto pipe UT system. 17.5 Any indication having amplitude more than 80% of FSH shall be evaluated at reference dB level (6dB drop). Now the area having indication exceeding the 80% of FSH shall be sized, marked and evaluated.

STEEL BSL LIMITED

PIPE DIVISION KHOPOLI- MAHARASHTRA , INDIA Document Title: Procedure For Manual Ultrasonic Testing at Body Document No

TSBSL/NDT/BPCL/P-04

Rev

DP-QC-06

01 Date: 08.11.2019 Page 5 of 7

18 Scanning speed: Scanning speed shall not to exceed 6 Inch / Second. 19 Acceptance Criteria: 19.1 For Pipe ends:Any imperfection in Circumferential direction exceed 6.0 mm length is not acceptable. 19.2 For Pipe HAZ area:1. No individual imperfection of length less than 20 mm shall be considered for population density assessment. 2. Maximum length of imperfection in any direction shall not exceed 30 mm. 3. Maximum area of individual imperfection shall not exceed 500 mm2. 4. Maximum population density (number of imperfection smaller than the maximum permissible imperfection size and longer than 20 mm per 1 m length) shall not exceed 4. 19.3 Pipe Body:1. No individual imperfection that does not exceed all of the following dimensions shall be considered for population density assessment: Area: 300 mm2, length: 35 mm, width: 8 mm (The length is the dimension at right angles to the scan track & the width is the dimension parallel to the scan track) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissible imperfection size & larger than the minimum imperfection size per 1m x 1m square shall not exceed 10. 4. Any imperfection exceeding 100 mm in length shall not be acceptable and any planar imperfection not parallel to the plate surface is not acceptable. 20 Disposition of pipe containing defects:20.1 The defective part of the pipe which is not acceptable shall be cut-off within the applicable limit of pipe length or the full length of pipe shall be downgraded. 21 Examination Record: 21.1 The records of examination shall be prepared in Report No. TSBSL/ERW/QC/F-06.

STEEL BSL LIMITED

PIPE DIVISION KHOPOLI- MAHARASHTRA , INDIA Document Title: Procedure For Manual Ultrasonic Testing at Body Document No

TSBSL/NDT/BPCL/P-04

Rev

01 Date: 08.11.2019 Page 6 of 7

ANNEXURE – I SCANNING PATTERN FOR PIPE END (CIRCUMFERENTIAL) 50MM

Pipe End ________________________________________________________

ANNEXURE – II REFERENCE STANDARD BLOCK

T T/2

Where T is Pipe Wall Thickness

DP-QC-06

Ø 6.0 MM FBH

STEEL BSL LIMITED

PIPE DIVISION KHOPOLI- MAHARASHTRA , INDIA Document Title: Procedure For Manual Ultrasonic Testing at Body Document No

TSBSL/NDT/BPCL/P-04

Rev

DP-QC-06

01 Date: 08.11.2019 Page 7 of 7

FLOW CHART Manual Ultrasonic testing

Ends Examination

Relevant Indication observed

Intermittent Examination of indication from AUT

Non-Relevant Indication Observed

Relevant Indication observed

Interpretation & Evaluation

Re-Bevel / Cut Off till removal of defect

Re-Test Accepted

Within Acceptance limit

Beyond Acceptance limit Not Accepted

Next Process

Accepted

N.C.R