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WELSPUN
QUALITY ASSURANCE DOCUMENT
Manufacturing Plant PROJECT PIPE GRADE OFFER REFERANCE / P.O NUMBER PROJECT SPECIFICATION PIPE MANUFACTURING SPECIFICATION DELIVERY CONDITION SERVICE CONDITION
ITEM NO. PIPE SPECIFIEDOUTSIDE DIAMETER INCH(MM)
1 OF 19
Grade
QTY. METERS
PIPE SIZE
1 Revision 0 01 Revision Record Description Issued for Approval Client Comments Date 21-01-2014 29-01-2014
0.375
9.53
X52M
As per PO Approved
D. P. Singh D. P. Singh
Client Client
2 OF 19
Documents Inspection Stage
WMEP TPI
Scope
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1.0
Steel (Coils) Coil Procurement & Inspection Edge milling Pipe forming
100% coils
Coil Mill TC
H H H
M M M
2.0
3.0
WPS/PQR/ WPQ
W/R
3.1
Welding report
3 OF 19
Documents Inspection Stage
WMEP TPI
Welding report
Each pipe
All pipes shall be visually examined both externally and internally and shall be free of defects. Acceptance as per API 5L As per API 5L. Clause. E.4.5, clause. E.4.6 & as per approved WI for X-Ray Pipe shall be tested at following test pressures & the holding time shall be 10 seconds Item no. Pipe OD (Inch) WT (mm) Pressure (min) BAR 1 56 (1422.4 ) 9.53 X52M 47
RW
4.0
Each Pipe
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5.0
Grade
Graph chart showing pressure & holding time for each pipe and test report
RW
Calibration of the pressure gauges shall be carried out at start of production further to a frequency of at least once per week. Non destructive Testing
4 OF 19
Documents Inspection Stage
WMEP TPI
6.0
X-Ray Inspection
As per API 5L clause. E.4.5, clause. E.4.6 & as per WI for XRay
6.1
Both ends of pipe up to a distance of 250 mm, acceptance as per clause no. E 4.5 & E 4.6 of API 5L. All restart spots shall be x-ray checked, acceptance as per clause no. E 4.5 & E 4.6 of API 5L
6.2
RSO / RSI
If any
6.3
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
7.0
UT calibration standard
RW
5 OF 19
Documents Inspection Stage
WMEP TPI
8.1
All indications producing signals higher than the acceptance limits of reference standard & API 5L shall be MUT checked. Lack of Penetration Not Accepted >100 mm in weld. Acceptance as per API 5L & WI for Auto UT. For Body: Acceptance Level U1 of ISO 10893-9 2011
UT report
8.2
Coil UT
Clause E.9 & E.3.2.3 of API 5L Clause E.3.2.1 of API 5L & As per client specification M01 clause 5.3.2 A.3
Each Coil
For edge: Acceptance Level U1(Table2) of ISO 10893-8 2011 over a zone of 25mm
H Coil UT report
8.3
Manual ultrasonic testing for weld & body Each pipe End untested weld length from Auto UT & Auto UT indications MUT of 25 mm from the beveled ends of pipe circumference
Each Pipe
As per client specification M01 & API 5L Acceptance as per API 5L & WI for MUT
MUT report
a)
W Each Pipe Acceptance as per API 5L & WI for MUT. MUT report H
b)
UT report
6 OF 19
Documents Inspection Stage
WMEP TPI
Skelp Joint
MUT report
9.0
If any
All indication from MUT shall be confirmed by X-ray, acceptance as per clause no. E 4.5 & E 4.6 of API 5L.
X-Ray report
9.1
If any
X-Ray report
Residual Magnetism 10.0 (if MPI is carried out) Workmanship, Visual Inspection and Repair of Defects
The average of the four reading shall not exceed 30 gauss and no one reading shall not exceed 35 gauss
Test Report
RW
11.0
11.1
Visual Inspection
Clause 10.2.7 of API 5L & As per client specification M01 Clause no.5.3.3 (Visual Inspection )
RW
7 OF 19
Documents Inspection Stage
WMEP TPI
11.2
Dents
If any
RW
11.3
Max. 1.6mm
RW
11.4
H RW
11.5
RW
11.6
If any
All pipes shall be free from defects in the finished condition. All pipes shall be free from cracks and leaks. Cracks shall not be repaired. The acceptance criteria for imperfections found by NDI shall be in accordance with annex E of API 5L
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RW
8 OF 19
Documents Inspection Stage
WMEP TPI
11.7
Undercuts
Clause 9.10.2 of API 5L & As per client specification M01 Clause 5.3.3 Visual Inspection Point 5
If any
RW
11.8
Clause 9.13.2.2 of API 5L & per client specification M01 clause 5.3.3.9
Each pipe
RW
11.9
If any
Visual report
RW
9 OF 19
Documents Inspection Stage
WMEP TPI
11.1 0
Laminations
If any
Visual report
RW
11.1 1
Arc burns
If any
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 chipping or machining, and Grinding provided that the resultant cavity is thoroughly cleaned and checked for complete removal of damage material by etching with 10% solution of ammonium per sulfate or a 5%solution of natal.
Visual report
RW
11.1 2
Other defects (Geometric Deviations & Scratch Mark) Skelp end welds in finished pipes
API 5L clause 9.10.5, 9.10.7 API 5L 8.10 or As per client specification M01 clause 4.2.3 API 5L clause 9.10.5.1 & As per client spec. M01 clause 5.3.3(Visual Inspection 6)
If any
Visual report
RW
11.1 3
If any
For finished helical seam pipes the junction of the strip end welds and helical-seam welds shall be at least 500 mm from the pipe ends.
RW
11.1 4
Peaking
If any
Max 1.5mm
RW
10 OF 19
Documents Inspection Stage
WMEP TPI
The negative tolerance shall be max. -0.5 mm. The positive tolerance shall be max. + 1.5 mm. 12.1 Wall thickness As per client spec. M01 clause 5.3.3 Dimensional Tolerances point no 6 Each pipe Visual & dimensional Report H RW
shall be supplied in following length 12.2 Pipe length As per client specification M01 Clause 5.3.3.7 Each pipe Min Length 12.00 meters Max Length 18.00 meters Min AVG Length 15.00 meters Visual & dimensional Report H RW
12.3
Straightness
Each pipe
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. OD = + 3.00 mm max.
RW
12.4 .
Outside diameter at pipe body (measured with pie tape & recorded)
Each pipe
Min 1419.4 mm
to
Max 1425.4 mm
RW
11 OF 19
Documents Inspection Stage
WMEP TPI
12.5
12.6
Out of roundness As per client specification M01 Cause 5.3.3.4 & API 5L Table 10 As per client specification M01 Cause 5.3.3.4 & API 5L Table 10 Clause 9.14.1 of API 5L Each pipe & record 3 pipes/ shift
12.6 .1
At Pipe Ends
Max 13.00 mm
RW
12.6 .2
Max 15.00 mm
RW
12.7
Weight Pipe Ends & End Protectors Bevel angle & root face
Each pipe
12.8 12.8 .1
Bevel angle. 30 (+5, -0) Each pipe Root face 1.6 mm ( 0.8 mm)
RW
12 OF 19
Documents Inspection Stage
WMEP TPI
End Squareness
H H
RW M
14.1
Repair procedure
If any
13 OF 19
Documents Inspection Stage
WMEP TPI
14.2
Repair Prohibition
If any
RW
15.0
API 5L clause 13
Each pipe
14 OF 19
Documents Inspection Stage
WMEP TPI
16.0
7. 8.
9.
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 Pipe number shall be stamped on bevel end.
15 OF 19
Documents Inspection Stage
WMEP TPI
Chemical test report 2 pipes / heat All elements as per Annexure A of this MITPS H H
B.1 B.2
B.2. 1
Tthe tensile properties shall be given in Table 7. 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 be reported with reference to a gauge length of 50 mm (2 in.). For test pieces having a gauge length less than 50 mm (2 in.), the measured elongation after fracture shall be converted to a 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. (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)
B.2. 2 (a)
API 5L Table 18
16 OF 19
Documents Inspection Stage
WMEP TPI
API 5L Table 18
CVN Impact B.2. 4 Helical Weld Seam & Pipe Body Hardness test API 5L Table 18 Helical Weld Seam Macro graphic examination of Helical Weld Seam Skelp Weld Tensile, Charpy and guided bend API 5L Table 18 Once / test unit Full size specimen as applicable shall be used Acceptance shall be As per API 5L table 8 Any Hard spots exceeding 50mm in any direction(if any) 1 pipe / shift Once per Lot of 50 skelp weld pipes Test Report H H
B.2. 5
Max.300 HB
Test report
B.2. 6 B 2.7
Clause 10.2.5 of API 5L API 5L clause 9.3.2, 10.2.3.2, 10.2.4.2, Table 7 &18
The alignment of internal and external seams shall be verified as per figure d of API 5L
Test report
Test report
H RW
B.3
API 5L
If any
Test report
17 OF 19
Documents Inspection Stage
WMEP TPI
FIRST DAY PRODUCTION TEST (ONE PIPE OF COMPLETELY FINISHED PIPE OF FIRST DAYS PRODUCTION ) As per client specification M01 4.2.4 & 4.2.5 As per client specification M01 clause 5.3.2 A(2) Clause E.3.1 & Table E1 of API 5L As per Client specification M01 Clause 5.3.2 A3 API 5L & As per client specification M01 Clause 5.3.1 API 5L
C.1
Hydrostatic test Automatic & manual Ultrasonic testing (Weld and Body) Radiographic testing of weld seam Visual & dimensional examination Chemical analysis (Product-Base & Weld) Mechanical tests Transverse Base Tensile
PQT pipe
MPQT report
C.2
PQT pipe
Complete weld length shall be UT tested as per clause. 8.1, 8.2 & 8.3 OF this MITPS
MPQT report H H
C.3
As per clause 6.0 of this MITPS Pipe shall be examined visually for dimensional tolerance and apparent surface defects As per clause 11.0 & 12.0 of this MITPS All elements as per Annex. A of this MITPS for Base and as per approved WPS for Weld
MPQT report
H H
R H
C.4
C.5
C.6 C.6. 1
API 5L
PQT pipe
MPQT report
18 OF 19
Documents Inspection Stage
WMEP TPI
MPQT report
API 5L
PQT pipe
MPQT report
C.6. 5
CVN Impact of Skelp end welds (Weld and HAZ) Guided bend test of Strip end weld (Root & face) Transverse tensile test (Strip end weld)
C.6. 6
C.6. 7
API 5L
19 OF 19
Documents Inspection Stage
WMEP TPI
API 5L
PQT pipe
The alignment of internal and external seams shall be verified as per figure d of API 5L
MPQT report
LEGENDS: H- HOLD, W- WITNESS, M- MONITER, R- REVIEW, RW = RANDOM WITNESS, TPI-THIRD PARTY INSPECTION AGENCY, FDPT FIRST DAY PRODUCTION TEST,WIWORK INSTRUCTION
ELEMENT C Mn Si P S Cr Cu Mo Ni
MAX. % ALLOWED X52M 0.20 1.40 0.45 0.025 0.010 0.30 0.50 0.15 0.30
ANNEXURE A MAX. % ALLOWED ELEMENT X52M CE(IIW) 0.43% Notes: 1) For each reduction of 0,01 % below the specified maximum for C, an increase of 0,05 % above the specified maximum for Mn is permissible, up to a maximum of 1,65 % for grades L245 or B, but L360 or X52 2) CE (Pcm)= C + Si/30 + (Mn+Cu+Cr) / 20 + Ni/60 +Mo/15+ V/10 +5B 3) CE (IIW)= C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15, d) The sum of the niobium, vanadium and titanium concentration shall be 0.15%.