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02·02·06
STANDARDS Subject Number
;-,
Subject
t!2NBRIDGE Inspection
United States
American Petroleum Institute (API):
• ANSI/API Std 1104 - Welding of Pipelines and Related
Facilities, Section 9
Qualification
1+1 CAN ...- ......................... Contractor personnel establishing inspection procedures or
techniques, scanning weldments, or interpreting results must be
qualified to Level II or Level III in accordance with CAN/CGSB
48.9712-2000.
Visual Inspection
Observe the welding process to ensure the weld is completed
according to the qualified procedure.
Fillet Welds
For all welding on in-service pipe, inspect the weld for defects
using MPI (a) immediately after completing the weld, and (b) at
least 12 hrs after completing the weld. IfMPI identifies crack
indications, complete ultrasonic inspection on all suspected areas.
~
\ J Ultrasonic Inspection
Use ultrasonic inspection to:
• evaluate pipe wall thickness
• evaluate internal corrosion
• examine fillet welds
• examine nozzle welds
• examine longitudinal welds on pipe (manufacturers' welds)
Defects
Welds that exceed the defect acceptance criteria of CSA 2662
(CAN) or ANSI!API Std 1104 (USA) must be repaired or removed
(see 02-02-04 Defect Repair).
- USA .................................. Retain all X-Ray Inspection of Girth Welds forms permanently in
the PLM Activity Reporting database.
1. Scope of Work
The scope of this section is to ensure the required Welding Procedure Qualification and Welding
Procedure Specification (WPS) are met and the necessa ry Welder Performance Qualifications are
adequate and current. All regulatory requirements are noted below in Section 2. Enbridge O&MP Book
4 - Welding is the primary standard and includes incorporation of other regulatory requirements.
The pipe replacement section will be welded into the existing pipeline using pre-approved Company
WPS. Welders currently qualified to the WPS will perform the welding required. Two WPS' s will be used
as part of the welding repair process. Enbridge procedure to be determined will be used as the WPS for
welding 2" branch connections on the existing line to allow thorough drain-up of any remaining product
in the line and venting during the welding process. Enbridge procedure UB-7S will be used as the WPS
for butt weld tie-ins of replacement pipe to the existing pipeline. Both procedures are manual, shielded
metal arc weld (SMAW) welding procedures. The SMAW process uses consumable electrodes coated in
flux to lay the weld. The WPS's are included as attachments to this section of the work plan.
At the completion of the respective replacement pipe segment installation welding processes, the
integrity of all welds will be verified by a non-destructive testing (NOT) . The 2" drain connections will be
tested by Magnetic Particle Inspection (MPI) . The requirements for the MPI process are addressed in
Enbridge O&MP Book 4, Section 02-02-06 Inspection and Section 02-03-03 Performing Magnetic Particle
Inspection of Fillet Welds. The butt welds will be inspected by radiography. The radiographic process is
addressed in Enbridge O&MP Book 4, Section 02-02-06 Inspection. All NOT will be performed by
independent, third party Contractors who have the required, qualified NOT procedures and technical
personnel to perform the respective NOT process.
2. Regulatory Requirements
th
API 1104 Welding of Pipelines and Related Facilities, 19 Edition
Each pipeline system must be constructed in accordance with comprehensive written specifications or standards that
are consistent with the requirements of this part.
(a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5
of API 1104 or Section IX of the ASME Boiler and Pressure Vessel Code (incorporated by reference , see § 195.3) .
The quality of the test welds used to qualify the welding proced ure shall be determined by destructive testing .
(b) Each welding procedure must be recorded in detail, including the results of the qualifying tests. This record must
be retained and followed whenever the procedure is used.
(a) Each welder must be qualified in accordance with section 6 of API 1104 (incorporated by reference , see §195.3)
or section IX of the ASME Boiler and Pressure Vessel Code, (incorporated by reference , see §195.3) except that a
welder qualified under an earlier edition than listed in §195.3 may weld but may not re-qualify under that earlier
edition.
(b) No welder may weld with a welding process unless, within the preceding 6 calendar months, the welder has-
(2) Had one welded tested and found acceptable under section 9 of API 1104 (incorporated by reference, see
§195.3).
Welding must be protected from weather conditions that would impair the quality of the completed weld.
(b) An arc bum may be repaired by completely removing the notCh by grinding, if the grinding does not reduce the
remaining wall thickness to less than the minimum thickness required by the tolerances in the specification to which
the pipe is manufactured . If a notch is not repairable by grinding. a cylinder of the pipe containing the entire notch
must be removed .
(c) A ground may not be welded·to the pipe or fitting that is being welded .
(a) Each weld and welding must be inspected to insure compliance with the requirements of this subpart. Visual
inspection must be supplemented by nondestructive testing .
(b) The acceptability of a weld is determined according to the standards in Section 9 of API 1104. However, if a girth
weld is unacceptable under those standards for a reason other than a crack, and if Appendix A to API 1104
(incorporated by reference, see §195.3) applies to the weld, the acceptability of the weld may be determined under
that appendix.
(b) Each weld that is repaired must have the defect r~moved down to sound metal and the segment to be repaired
must be preheated if conditions exist which would adversely affect the quality of the weld repair. After repair, the
segment of the weld that was repaired must be inspected to ensure its acceptability.
(c) Repair of a crack, or of any defect in a previously repaired area must be in accordance with written weld repair
procedures that have been qualified under §195.214. Repair procedures must provide that the minimum mechanical
properties specified for the welding procedure used to make the original weld are met upon completion of the final
weld repair.
(a) A weld may be nondestructively tested by any process that will clearly indicate any defects that may affect the
integrity of the weld.
(1) In accordance with a written set of procedures for nondestructive testing; and
(2) With personnel that have been trained in the established procedures and in the use of the equipment employed in
the testing.
(c) Procedures for the proper interpretation of each weld inspection must be established to ensure the acceptability of
the weld under §195.228.
(d) During construction, at least 10 percent of the girth welds made by each welder during each welding day must be
nondestructively tested over the entire circumference of the weld.
(e) All girth welds installed each day in the following locations must be nondestructively tested over their entire
circumference, except that when nondestructive testing is impracticable for a girth weld , it need not be tested if the
number of girth welds for which testing is impracticable does not exceed 10 percent of the girth welds installed that
day: .
(1) At any onshore location where a loss of hazardous liquid could reasonably be expected to pollute any stream,
river, lake, reservoir, or other body of water, and any offshore area;
(4) Within the limits of any incorporated subdivision of a State government; and
(5) Within populated areas, including, but not limited to, residential subdivisions, shopping centers, schools,
designated commercial areas, industrial facilities, public institutions, and places of public assembly.
(I) When installing used pipe, 100 percent of the old girth welds must be nondestructively tested.
(g) At pipeline tie-ins, including tie-ins of replacement sections, 100 percent of the girth welds must be
nondestructively tested .
',\ 3. Company Standards
~i
\. ) O&MP Book 4 - Welding
!lIS" mu
tlt6'
1116',
~
j;ENBRIDGE
\.. ) UB-75 Rev. 0
Company: Enbridge Pipelines Inc., PO Box 398, 10201 Jasper Avenue, Edmonton, AB T5J 2J9
Supporting PQR(s) : UB-70-1, UB-70-2, EPI-08-WP9-1
Intended Application: Above and below ground piping and repair welding
Base Metals: P1 Groups 1, 2 &3 to P1 Groups 1, 2 &3
Carbon Equivalent: 0.5 max.
Welding Process: SMAW Type: Manual Weld Types: Groove and Fillet
Minimum No. of Root Bead and Hot Pass Welders: Two for NPS 12 and greater
Position: All positions Diameters: All
Filler Metals: E6010 5P+, E8018-C3
Thickness Qualified: 3.2 mm to 25.4 mm (0.125 to 1.000 in.) inclusive
Notch Toughness: -46·C as-welded condition
JOINTS (QW-402)
Type: All groove and fillet weld joints Backing: with or without
Root Opening: 1.6 to 4.0 mm (1/16 to 5132 in.) Retainers: not required
REPAIR WELDING
Welding Technique: Welding shall be performed using the details listed in this speCification, in
addition to the details listed beiow.
Defect Removal: Defects shall be removed by grinding and may extend through the
complete wall thickness when approved by the Company representative.
Length of Repair: The minimum repair length shall be 50 mm.
Preheat: The area to be rewelded shall be preheated to 120·C.
Reexamination: The area shall be reexamined using the same method(s) originally used
t6 identify the defect.
WELDING PARAMETERS
ELECTRODE CURRENT
Pass Class Size Type & Amperage Voltage Arc Speed Heat Input
Polarity mm I min. (Lp.m.) kJ I mm (J I inch)
1a E6010 1/B DCRP 100 23.5 203 B.O 0.69 (17,625
1b E6010 11B DCRP 95 25.5 319 12.5 0.46 (11 62B
2a EB010-P1 5/32 DCRP 160 27.5 274 10.8 0.96 ' 24,444
"
\ )
2b
3a
3b
4a
4b
5a
EB010-P1
EB018-C3
E8018-C3
E8018-C3
E8018-C3
E8018-C3
5/32
3/32
3/32
1/B
1/8
1/8
DCRP
DCRP
DCRP
DCRP
DCRP
DCRP
160
115
95
155
125
160
29.5
25.5
24
25
25
25
290 11.4
90 3.5
66 2.6
82 3.2
39 1.5
80 3.2
0.9B 24,842 .
1.96. 50,271
2.07 52,615
2.B4 72,656
4.81 ( 125,000
3.00 75,000
5b E8018-C3 1/8 DCRP 120 24 45 1.B 3.84 96000)
'6a E8018-C3 1/8 . DCRP 155 23 89 (3.5) 2.40 61 ,114)
• Brad Completed the weld using six passes, Shannon used five.
-r15J1mm
L--~~_---.l~
II 1.8 mm
TENSILE TEST
. SAMPLE NUMBER T1 T2
WIDTH mm (in.) 25 .5 (1.00) 25.3 (0.996)
THICKNESS mm (in.) 15.8 (0.624) 15.7 (0.618)
404 (0.626) 397 . (0.616)
~
AREA sq. mm (sq . In.)
ULTIMATE LOAD N (Ibs) 249819 (56,200) 251 183 (56,500)
UTS MPa (psi) 618 (89,600) 632 (91,700)
FRACTURE TYPE Partial Cup & Cone Partial Cup & Cone
FRACTURE LOCATION Parent Metal Parent Metal
GUIDED·BEND TEST
SAMPLE WIDTH: 12.7 mm (0.500 In.) SAMPLE THICKNESS: 15.9 mm (0.626 In.)
PLUNGER SIZE: 88.9 mm (3.50 in.) YOKE SIZE: 120 mm (4.72 in.)
SAMPLE TYPE Side. Bend Side Bend Side Bend Side Bend
SAMPLE NUMB.ER(S) S1 S2 S3 54
RESULTS Pass Pass Pass 'Pass
SAMPLE NUMBER(S) N1 N2
REMARKS Pass Pass
We certify the test results in this report and that the specimen(s) were prepared and tested in accordance with the
requirements of C.sA Z662 ·07. Materie/lnformatlon has been provided by the Customer whose name appears
on this report.
Sample ....,Ocl.t.d with thl. report wi b. dlscard.d In 30 d.ys.
4027 · 14 SU" , S.E.• CALGARY, ALBERTA T2C 3K6 PHONE, (403) 262-7072 FAX, (403) 26&.3169 Page' of f
1925 Davits R~d. EDMONTON, ALBERTA T6£ 4N' PHONE: (780) .f68~JOJO FM:'(780) 468-3OJ1
~ , / ) LUDWIG ASSOCIATES LTD.
\. )
Materials and Welding Consulting
LABORATORY TEST REPORT
CUSTOMER: Enbrldge Pipelines Inc. Laboratory Test No.: E08-213.16
10201 Jasper Avenue Date: April 11, 2006
Edmonton, AB
T5J 2J9 .
NOTCH-TOUGHNESS TEST
We certify the test results in this report and that the speclmen(s) were prepared and tested In accordance with the
requirements o( ASME Section VIII, Div. I, UG-B4 - 2007 edition and latest addenda. Material Information has
been provided by the Customer whose name appears on this re art.
Sample. I ••ocl.ted with thl. report be dIscarded In 30 dlYS.
4027. 14S1t.. ~ S.E., CAlQlRY, Al8ERTA T2G 3K6 PHONE, (403) 262·7072 FAX, (403) 266-3169 Page 1 01 1
7925 D.vles Ro.d, EDMONTON, ALBERTA 16E 4NI PHONE, (780) 46(1.3030 FAX, (780) 468·3032
~)
" ).
Materials and Welding Consulting
LABORATORY TEST REPORT
CUSTOMER: Enbrldge Pipelines Inc. Laboratory Test No.: EOa·213.18
10201 Jasper Avenue Date: April 11. 2008
Edmonlon. AB
T5J 2J9
HARDr-lESS TEST
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We CfJrtify the test results in this report and that the speGlmen(s) were prepared and tested In OGGoroonoe with the
requIrements o( ASTM E92·82 (Reapproved 2003). Meterial inform. Yon h.s been provIded by the Customer whose name
app •• rn on this report.
Semples es.socleled with this repay"/! dlSCerd~d In 30 deys
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PROCEDURE QUALIFICATION RECORD (PQR)
t ~3j)
<) 0.2"" ,\2/) ! ?
! ( 1 "') 118"
118' I-! f
BASE METALS
Material Spec: _ _ _ _ _:::;SA~5::.1:::.6----- To: SA 537
Type or Grade: _ _.,-_ _..:6::.0'-/7"'0'--_-:-::-:-_ To: CL 2
P No: _--,1,--_ Group No.: _",,1:.;&:;.2,--_ To: P No: 1 Group No. : _-,3,--_
Heat Number: _ _ _ _ _ _ _ _ _ _ __ To:
ASME Carbon Equivalent: _ _ _ _ _---'0,;,..4'--_ _ _ __ To: 0.45
CSA Carbon £quivalent: _ _ _ _ _ _ _ _ _ _ __ To:
Coupon Thickness: Machined to 0.249" To Machined to 0.249"
Coupon Diameter: _ _--'PI:::.at::e'--_ _ _ _ _ _ _-'Tc:o_ _ _ _ _ _---'P.:;la:..:te:::...._ _ _ _ __
FILLER METALS
Process : SMAW SMAW
Number of Layers : 1 2
SFA Spec. No. : 5.1 5.5
AWS Class No. : E60105P+ E8018-C3
.,
F·No.: F3 F4
A·No. : A1 A10
Size of Filler Metal : 1/8" 3/32"
Manufacturer : Lincoln . Air Liquide
Trade Name : Fleetweld 5P+ LA8018-C3
Heat/Lot No.:
Weld Metal Thickness : 0.100" 0.149"
Flux Type : NA NA
Flux Trade Name : NA NA
Other : Covered Electrode Covered Electrode
POSITIONS
Process:
Position of Groove:
I SMAW
3G
SMAW
3G
1 of 3
PROCEDURE QUALIFICATION RECORD (PQR)
a NBRIDGE
PREHEAT
Preheat Temp: 50' F
--------------------~~~--------------------
Interpass Temp: __________------.::5::.50::.·. . , ; F , . - - - - - : - - - : - - - - - - - - - -
Other: _ _ _ _ _ _ _ _T_e_m--'-p_e_ra_t_u_re_m_o;..n_i.;..to;..r...;e..;.d_u'-s;..in-'g"-'.te;;..m---"p_le:..;s;..t",ic.;..k,,-s_ _ _ _ _ _ __
ELECTRICAL CHARACTERISTICS
Process : SMAW- F3 SMAW -F4
Current Type : Direct (DC) Direct (DC)
Polarity : Reverse (EP) Reverse (EP)
Amps : 82-87 72-92
Volts : 22-26 18-22
Maximum Heat rnpu t
(Joules/Inch) : 17,486 27,000
Tungsten Electrode
Size & Type : NA
Mode of Meta I
Transfer for GMAW : NA
Electrode Wire .'
Feed Speed : NA
Electrode Stick OUI : NA
2 of 3
PROCEDURE QUALIFICATION RECORD (PQRj
TENSILE TEST
Width Thickness Area Ultimate Total Ultimate Unit Type of Failure
Specimen No. (In.) Load {lb.1 Stress (psi)
(In.) (In') & location
~.
TOUGHNESS TEST
Impact literal
Specimen Notch Qu.,fflalUon
Notch location Temper.hlle
Value s % Shear Expansion
No. Type ft-Ibs (Inches)
We certify that the statements In this record are correct and that the test welds were prepared, welded, and
tested In accordance with the requirements of Section IX of the ASME Code.
Manufacturer: _ _ _ _ _ _ _E:;n.:.:b::.r::id"'
g;:.e.:.P;.tip:.:;e.:.;lin:.:;e:;s:.;l:.:.td::;._ _ _ _ _ __
Oate: _ _ _ _ _ _ _ _~5.:.-J:;u::.I-.:.O.:.9_ _ _ _ _ _ _ __
Signed: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
,
3 of 3
?) . PROCEDURE QUALIFICATION RECORD (PQR)
~NBRIDGE
Procedure Qualification No : UB-70-2
Welding Procedure Specification No: UB -70
JOINTS
'y?/
BASE METALS
Material Spec: _ _ _ _--'':-:-~:.....---_
SA 516 To: SA 537
Type or Grade: 60/70 To: CL 2
--------~~---------
Group No.:
PNo : _~--,_~~~~--,~~
1 1&2 To: P No 1 Group No.: 3
Heat Number: To:
------~~-------
ASME Carbon Equivalent: 0.42 To: 0.47
--------~~--------
CSA Carbon Equlvalent : _ _ _ _ _ _ _ _ _ _ ___ To:
===:...:::.....__==__
Coupon Thickness: _ _ Machin ed to 0.500" --=.::.:..
To: ___ Machined to ====-.:.:.....__
-,0;;;.5;.::0.:,0_"_
Coupon Diameter: _ _-'-.:...:.;'-_
Plate -'-_ _ _ _ _ _-'-'-=
__ _ _ _ _ _To Plate ______
FILLER METALS
Process : SMAW SMAW
Number of Layers : 1 2
SFA Spec. No. : 5.1 5.5
AWS Class No.: E6010 5P+ E8018-C3
F-No.: F3 F4
A-No. : A1 A10
Size of Filler Metal : 1/8" 3/32"
Manufacturer : Lincoln Air Liquide
Trade Name : Fleetweld 5P+ LA8018-C3
Heat/Lot No. :
Weld Metal Thickness : 0.125" 0.375"
Flux Type : NA NA
Flux Trade Name : NA NA
Other : Covered Electrode Covered Electrode
POSITIONS
process:1 SMAW SMAW
Position of Groove:I-_ _ _-'3:.:G:,.,.,..._ _ -+____--:--'3:.:G:,.,.,..._ _ _ _-+___________ ~
~--------~----------------~--------------~
10f3
filNBRI~GE
PREHEAT
PROCEDURE QUALIFICATION RECORD (PQR)
preheatTemp: ______________________________~5~0=·~F~-----------------------------
Interpass Temp: 550' F
Other: ----------------T=e-m--p-e-ra~t-u-re--m-o-n~i::'to.;;.r.;;.e-d~u-s""7in-g~te-m--p7Ie-s7t:-ic7k-s---------------
POST WELD HEAT TREATMENT
Temperature: ______________________________....;..N"-A'-_____________________________
Time:
-------------------------------------------------------
Heating: ________________________________________________________________
Cooling: ________________________________________________________________
GAS
SFA Composition Flow Rate (CFH)
Shlelding:1 NA
Backing: . NA
ELECTRICAL CHARACTERISTICS
Process : SMAW- F3 SMAW -F4
CurrentType : Direct (DC) Direct (DC)
Polarity : Reverse (EP) Reverse (EP)
Amps : 80-90 100-115
Volts : 23-24 21-22
Maximum Heat Inpu I
(Joules/Inch ): 28,800 36,225
Tungsten Electrod e
Size & Type : NA
Mode of Meta I
Transfer for GMAW : NA
Electrode Wir e
Feed 5peed : NA
Electrode Stick Out : NA
Process Filler Metal Diameter Amps Volts TravelllPM)
SMAW E6010 5P+ 1/8" 90 23/24 4.5
SMAW E8018-C3 3/32" 100 21 5
SMAW E8018-C3 3/32" 105 22 4
SMAW E8018-C3 3/32" 102 22 4
SMAW E8018-C3 1/8" 115 21 4
TECHNIQUE
2 of 3
/;;:;7 PROCEDURE QUALIFICATION RECORD (PQR)
t;ENBRIDGE
TENSILE TEST
Width Thickness Area Ultimate Total Ultimate Unit Type of Failure
Specimen No. Load (lb.1 Stress (psi)
(In.) (In.) (In') & location
TOUGHNESS TEST
Impact Lateral
Specimen Notch Qllitltflcilion
Notch location Trmper.turr
Values % Shear hpansion
No. Type ft·lbs (Inches)
PMI: _________________________~~~~--~----------------------
Nick Break see attached report
----------~~~~~~~------------
Manufacturer: _ _ _ _ _ _....:::En~b:.:.r:.:ld:2g.:.e.:...P",ip::;e:::lin~e:::s::;lt::d::..._ _ _ _ __
Date: _ _ _ _ _ _ _ _---'5:.-.:,:)u:..;I-..:O.:.9_ _ _ _ _ _ _ __
Signed: _____________________________________
30f3