NDT 6946-6-44-0016 rev1

JOB SPECIFICATION FOR NON NON DESTRUCTIVE DESTRUCTIVE EXA MINATION REQUIREMENTS OF PIPING

JOB SPECIFICATION SPECIFICATION No.

6946-6-44-0016 Rev. 1 Page 1 of 20

JOB SPECIFICATION FOR NON DESTRUCTIVE EXAMINATION REQUIREMENT OF PIPING Client

:

NRL

Project

:

DQUP, NRL

Location

:

NUMALIGARH

Job No.

:

6946

1

26.11.08

NEW CLASSES ADDED & REISSUED AS JOB SPECIFICATION

LJ

VKS

VKB

0

30.06.08

ISSUED AS JOB SPECIFICATION

LJ

VKS

SC

Rev. No

Date

Purpose

Prepared by

Checked by

Approved by

Format No. 8-00-0001-F1 Rev. 0

Copyright EIL – All rights reserved

JOB SPECIFICATION FOR NON NON DESTRUCTIVE DESTRUCTIVE EXA MINATION REQUIREMENTS OF PIPING

JOB SPECIFICATION SPECIFICATION No.

6946-6-44-0016 Rev. 1 Page 2 of 20

Abbreviations: DP/LP MP CS AS SS ASTM ASME IBR PMS

: : : : : : : : :

Dye / Liquid Penetration Magnetic Particle Carbon Steel Alloy Steel Stainless Steel American Society for Testing & Materials American Society of Mechanical Engineers Indian Boiler Regulations Piping Material Specification



JOB SPECIFICATION FOR NON DESTRUCTIVE EXA MINATION REQUIREMENTS OF PIPING

JOB SPECIFICATION No.

6946-6-44-0016 Rev. 1 Page 3 of 20

CONTENTS

Sl. No.

TITLE

1.

GENERAL

4

2.

VISUAL EXAMINATION

4

3.

NON DESTRUCTIVE EXAMINATION

6

4.

TABLE-1 (with applicable notes to table-1)

7


PAGE




1.

GENERAL

1.1

SCOPE

6946-6-44-0016 Rev. 1 Page 4 of 20

This specification covers the general requirements for non destructive examination of shop & field fabricated piping. 1.2

RELATED CODES & ENGINEERING STANDARDS

Referred codes / standards are as follows. Latest editions of the Codes/Standards referred to shall be followed. a)

ASME Boiler & Pressure Vessel Codes, Section V & VIII (Div.1) including addenda.

b)

ASME B31.3

c)

ASME B16.5 & B16.34

d)

ASTM E10

e)

Piping Material Specification, 6946-6-44-0005

f)

Welding Specification Charts for Piping Classes, 6946-6-77-0005

g)

Standard Specification for Fabrication & Erection of Piping, 6-44-0012

h)

Welding Specification for Fabrication of Piping, 6-77-0001

i)

Design Guide for Radiography Requirements, 8-77-0010

j)

Indian Boiler Regulations (IBR)

2.

VISUAL EXAMINATION

2.1

Weld shall be visually inspected wherever accessible in accordance with the following requirements : a)

Internal misalignment

1.5 mm or less

b)

Cracks or lack of fusion

Not permitted

c)

Incomplete penetration (For other than 100% radiography butt-weld)

Depth shall not exceed the lesser of 0.8mm or 0.2 times thickness of thinner component joined by buttweld. The total length of such imperfections shall not exceed 38 mm in any 150 mm of weld length.

d)

Surface porosity and exposed slag inclusions (4.7 mm nom. wall thickness and less).

Not permitted.

e)

Concave root surface


For single sided welded joints, concavity of the root (Suck up) surface shall not reduce the total thickness of joint, including reinforcement, to less than the thickness of the thinner of the components being joined. Copyright EIL – All rights reserved



6946-6-44-0016 Rev. 1 Page 5 of 20

f)

Weld ripples irregularities

2.5 mm or less.

g)

Lack of uniformity in bead width

2.5 mm or less.

h)

Lack of uniformity of leg length

2.5 mm or less.

I)

Unevenness of bead

2.0 mm or less.

j)

Weld undercutting

0.8 mm or 1/4 thickness of thinner components joined by butt weld, whichever is less. (shall be smooth finished)

k)

Overlap

1.5 mm or less

l)

Bead deflection

2.5 mm or less

m)

n)

External weld reinforcement and internal weld protrusion (when backing rings are not used) shall be fused with and shall merge smoothly into the component surfaces. The height of the lesser projection of external weld reinforcement or internal weld protrusion from the adjacent base material surface shall not exceed the following limits unless specified otherwise by Licensor/Owner/EIL for some special services: Wall thickness of thinner component joined by butt weld (mm)

Weld reinforcement or internal weld protrusion (mm) max

6.4 and under Over 6.4 -12.7 Over 12.7 -25.4 Over 25.4

1.6 3.2 4.0 4.8

Throat thickness of fillet welds : Nominal thickness of the thinner component x 0.7 or more.

o)

Flattening Flattening of a bend, as measured by difference between the nominal outside diameter and minimum or maximum diameter at any cross section shall not exceed 5 % of the nominal outside diameter of pipe.

p)

Reduction of wall thickness Reduction of wall thickness of a bend, as measured by difference between the nominal thickness and minimum thickness shall not exceed 10 % of the nominal wall thickness of pipe.

2.2

Welds having any of imperfections which exceed the limitations specified in various clauses of 2.1 shall be repaired by welding, grinding or overlaying etc. Number of times of repair welding for the same weld, however shall conform to applicable notes to Table 1- Note 6(b)b.5.





6946-6-44-0016 Rev. 1 Page 6 of 20

3.

NON DESTRUCTIVE EXAMINATION

3.1

The type and extent of weld examination shall be in accordance with Table-1. All visual and supplementary methods of girth weld examination shall be in accordance with ASME B31.3 and the requirements of this specification.

3.2

Welds between dissimilar materials shall be examined by method & to the extent required for the material having the more stringent examination.

3.3

Certain categories of critical piping are classified under inspection Class IV (100% radiography) as follows: a)

High Pressure

:

Classes above 600 #.

b)

Severe Cyclic

:

As defined by ASME B31.3.

c)

Low Temperature

:

Below temperature of -45°C & all materials.

d)

Critical Service

:

Hydrogen, Oxygen, NACE, Caustic, Chlorine & such other critical services.

e)

High Alloys

:

5 Cr & above for all pressure classes.

f)

High Temperature

:

Above 500 C


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6946-6-44-0016 Rev. 1

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6946-6-44-0016 Rev. 1

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Page 16 of 20

3 1


6946-6-44-0016 Rev. 1

, E R , M E 7 T M M 5 D E E O O F S 5 N 1 N R E R E T F G , A B U S T S L I S E S , N R O L K E R A T 5 M F A % F R E T A 0 L 5 E 5 E 2 2 5 H 0 R 1 F M N C B G G S 1

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L E C E I T T I N A S E S T S E I U L A A T S T I C C L . E S J C B Y N U O I S C T I S E E R E D C V N I O V E R S C E O S T

S S X E L P U D E R U T A E R C E I P V R M E E T S W O L

S E C I V R E S L A R E N E G

. P S E M E C T I H V E G R I H S

) . . L C A T I E C E H , P S O ( & S E E C C I A V N R E S

) . . . D T N O C ( V I




6946-6-44-0016 Rev. 1 Page 17 of 20

Applicable Notes to Table-I

1.

Branch welds shall consist of the welds between the pipe & reinforcing element (if any), nozzles & reinforcing element and the pipe & nozzle under the reinforcing element. Reinforcing element to be interpreted as pads, saddles, weldolets, sockolets etc.

2.

Seal welds of threaded joints shall be given the same examination as socket welds.

3.

Unless specifically stated, all materials shall be for "Non-IBR" service.

4.

Magnetic Particle & Liquid Penetrant method of examination shall be in accordance with Section V of the ASME Boiler and Pressure Vessel Code, Article VII and VI respectively. The entire area of the accessible finished weld surface shall be examined. Selected root runs, subject to a maximum of 10%, before finished weld, may also be examined, at the discretion of the engineer-in-charge.

5.

a)

Wherever MP / LP testing is specified, either MP or LP test may be used. Wherever only MP test is specified, LP method of examination may be used only if MP examination is impracticable in the field as concurred by EIL site-in charge. For 100% radiography classes fillet welds shall be 100 % MP tested for CS/AS classes and 100% DP tested for SS classes.

b)

"Random 10%" of Liquid Penetrant / Magnetic Particle test shall mean testing, by applicable test, one weld for each ten welds or less made by the same welding procedure or operator or both. Similarly "Random 20%" shall mean testing, by applicable test, one weld for each five welds or less made by the same welding procedure or operator or both.

c)

When Liquid Penetrant examination is specified, the surface shall be free of peened discontinuities. Abrasive blast cleaning shall be followed by light surface grinding prior to Liquid Penetrant examination.

d)

Inspection shall be performed in the welds excluding those for which radiography has been done.

e)

Girth weld, branch weld, attachment weld & socket weld of 3-1/2 Ni steel shall be Liquid Penetrant tested only when welded with austenitic material where MP test has been specified.

Radiography : a)

"Random 10% or 20% radiography" shall mean examining not less than one from each 10 welds or less in case of "Random 10% radiography" or one from each five welds or less in case of "Random 20% radiography" made by the same welding procedure or welder or both. Irrespective of percentage, no. of welds to be radiographed shall be minimum 1. However first two welds made by each welder shall also be radiographed in case of "Random radiography". Welds selected for examination shall not include flange welds and shall be radiographed for their entire length. However, where it is impossible or impracticable to examine the entire weld length of field welds for either random or 100% radiography, and if the same impossibility is agreeable to EIL site-in- charge, then a single 120 deg. exposure of the weld length may be given a Magnetic Particle test or Liquid Penetrant test. However in such cases for ferro-magnetic materials, only MP test shall be acceptable for classes higher than 600#.




6.


6946-6-44-0016 Rev. 1 Page 18 of 20

b)

In-process examination shall not be substituted for any required radiographic examination.

c)

Number of radiographs per one circumferential weld shall be as per ASME Sec.V Articles 2 and 22.

When radiography or other non destructive inspection is specified, acceptance criteria for repairs or defects shall be as follows: a)

b)

In case of 100% examination, any unacceptable weld shall be repaired and reinspected. If required random examination reveals a defect requiring repair, then : b.1

Two additional examinations of same type shall be made of the same kind of item (if welded joint, then by the same welding procedure or operator or both).

b.2

If the group of items examined as required by b.1 above is acceptable, the items requiring repair shall be repaired or replaced and reexamined as required and all items represented by this additional examination shall be accepted.

b.3

If any of the items examined as required by b.1 above reveals a defect requiring repair, two further comparable items shall be examined for each defective item found by examination.

b.4

If all the items examined as required by b.3 are acceptable, the items requiring repair shall be repaired or replaced and reexamined as required, and all items represented by this further examination shall be accepted.

b.5

Number of times repair welding could be done for the same weld before acceptance shall be as follows: Material

No. of times repair welding is allowed

C.S. upto 300 #

3 or less

C.S. above 300 #

2 or less

Killed steel

2 or less

Low alloy steel

2 or less

Austenitic S.S.

2 or less

3.5 Ni steel

2 or less

Al & Al base alloy

2 or less

Cu & Cu base alloy

2 or less

Others

2 or less




7.


6946-6-44-0016 Rev. 1 Page 19 of 20

b.6

Welds not found acceptable for allowed number of times of repair as per b.5 above shall be replaced and reexamined.

b.7

If any of the items examined as required by b.4 above reveals a defect requiring repair, all items represented by these examinations shall be either : -

repaired or replaced and reexamined as required.

-

Fully examined and repaired or replaced as necessary, and reexamined as necessary.

Hardness Test : a)

Hardness test for each weld (unless mentioned otherwise in NDT Table-I ) shall be in accordance with ASTM specification E10, ASME B31.3 and as called for in NDT Table-I/PMS(Piping Material Specification), and shall be made after final heat treatment (wherever heat treatment is specified in welding specification). All welds which are given heat treatment shall be hardness tested. A minimum of 10% of welds of hot formed and hot bent materials in each heat treatment batch which are furnace heat treated and 100% of those which are locally heat treated, shall be hardness tested. The hardness limit applies to the weld and heat affected zone. Hardness tests of the heat affected zone shall be made at a point as near as practicable to the edge of the weld. One test per weld shall be performed.

b)

Hardness test where specifically called out in Table-I of this specification or in PMS, shall be carried out irrespective of thickness and to the extent (%age) as mentioned therein.

c)

For C - 0.5 Mo steels, a minimum of 10% of welds shall be hardness tested.

d)

Following hardness values shall be maintained :

e)

Base Metal Group

Maximum Hardness (BHN/RC)

CS

238BHN/RC22

CS (NACE, H2 service)

200BHN

Alloy Steel (Hydrogen)

225BHN

Cr 0.5% or less

225BHN

Cr >0.5% & upto 2%

225BHN

Cr 2.25%-3%(C ≤ 0.15%)

241BHN

Cr 2.25%-3%(C > 0.15%)

241BHN

Cr >3% & upto 10%

241BHN

DUPLEX SS (NACE)

RC28

In case hardness values are mentioned in both welding specifications (69466-77-0005) & table given in Note-7(d), the lower of the two values shall be applicable.




8.


6946-6-44-0016 Rev. 1 Page 20 of 20

For IBR service lines, following IBR requirements shall apply in addition to the notes 4, 5, 6, 7, 12 and Table I. In case of conflict between above notes and these requirements, the more stringent ones shall apply. IBR piping shall be erected of IBR inspector approved material and construction procedure. Erected piping shall be hydrotested, inspected and approved by IBR inspector. a)

Piping over 102 mm (4") bore : 10% of welds made by each welder on a pipeline with a minimum of two welds per welder, selected at random, shall be subjected to radio graphy.

b)

Piping 102 mm (4") bore and under, but not less than 38 mm (1-1/2") bore : Two percent of welds made by each welder on a pipeline with a minimum of one weld per welder, selected at random, shall be subjected to radiography or may be cut for visual examination and tests.

c)

Piping less than 38 mm (1.5") bore : Special tests are not normally required but 2% of welds by each welder on a pipe line may be cut out from the pipeli ne for the visual examination and bend tests.

d)

Retests : If any test specimen is unsatisfactory, two further weld specimens for retests shall be selected from the production welds and subjected to tests. In the event of failure of any retest specimens, the production welds carried out by this welder subsequent to the previous test shall be given special consideration.

9.

For fabricated fittings LP test shall be done on the final pass of welding only, in addition to visual examination.

10.

For mitres and fabricated reducers, LP / MP test shall be done on root pass in addition to radiography applicable to circumferential joint of respective pi ping class.

11.

For branch connections, LP/MP test shall be done on root pass and final pass.

12.

As per TAC requirements, 10% of the butt weld joints shall be radiographed, however, 50% of these butt weld joints shall be field weld joints.

13.

In lines where weld joints are subjected to Stress relieving , Radiography/any NDT for acceptance of the joint as required by the specification shall be carried out only after stress relieving.

14.

For lined specs, testing (MP/LP/Radiography etc.) shall be performed before lining.

15.

Weld deposits should be checked for ferrite content. A Ferrite Number (FN) not less than 3 % and not more than 10 % is required to avoid sigma phase embrittlement during heat treatment. FN shall be determined by Ferritescope or may be calculated using Schaffler or DeLong diagrams (the DeLong diagram should be used if FCAW welding is performed), prior to post weld heat treatment.

16.

Hardness test for welds of all classes of Hydrogen service of carbon steel (for thickness under 19 mm) is required and it is 10%.



NDT 6946-6-44-0016 rev1

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