30-99!90!1826-rev 0 hardness testing procedure mps ips and mot

EPC CONTRACTOR: PROJECT MANAGEMENT CONSULTANT:

China Petroleum Engineering & Construction (GROWp) Corporation Abu Dhabi Branch P.O. Box 127345

ILF Consulting Engineers

P.O.Box 73250

Abu Dhabi, UAE

PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT Habshan -Fujairah

EPC Contractor Doc. No.: ADCOP/C013/08 PAGE: 1 of 09

DOCUMENT No.: 30-99-90-1826 Rev. 0 Project No: E30153 DATE: 02/07/2009

CONSULTINGENGI NEERS

ADCOP-Abu Dhabi Crude Oil Pipeline Project

Habshan-Fujairah

30.99.90.1826

HARDNESS TESTING PROCEDURE

(MPS, IPS and MOT)

DOCUMENT TITLE : HARDNESS TESTING PROCEDURE Project No: E30153

PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECTHabshan - Fujairah

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DOCUMENT No.: 30-99-90-1826 Rev. 0 DATE : 02/07/2009

Content Page

1.0 INTRODUCTION ............................................................................................................................................. 4 1.1 Scope .............................................................................................................................................................. 4 2.0 DEFINITION AND ABBREVIATION ............................................................................................................... 4 2.1 Definition ......................................................................................................................................................... 4 2.2 Abbreviation .................................................................................................................................................... 4

3.0 REFERENCE DOCUMENTS .......................................................................................................................... 5 3.1 International Standards ................................................................................................................................... 5 3.2 ADCO documents ........................................................................................................................................... 5 3.3 Project documents ........................................................................................................................................... 5 4.0 GENERAL REQUIREMENTS ......................................................................................................................... 6 4.1 Personnel qualification .................................................................................................................................... 6 4.2 Procedure qualification test ............................................................................................................................. 6 4.3 Surface preparation ......................................................................................................................................... 6 5.0 EXAMINATION ............................................................................................................................................... 6 5.1 Methode .......................................................................................................................................................... 6 5.2 Number of test areas for circumferential welds .............................................................................................. 7 6.0 EQUIPMENT ................................................................................................................................................... 7 6.1 Equipment verification ..................................................................................................................................... 7 6.2 Maximum measurement & tolerances ............................................................................................................ 7 6.3 Test conditions ................................................................................................................................................. 7 7.0 RECORDS ...................................................................................................................................................... 7 8.0 NON CONFORMITY RECORD ...................................................................................................................... 8



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1.0 INTRODUCTION

The United Arab Emirates (UAE) authorities assigned International Petroleum Investment Company

(IPIC) to execute the Abu Dhabi Crude Oil Pipeline (ADCOP) project which will facilitate the

transferring of crude oil from Habshan production facilities to the Fujairah main oil terminal (MOT)

on the eastern seaboard of the UAE.

The main components of the ADCOP pipeline system are as follows:

Tie-in and manifold facility at MP-21.

48” 409km pipeline from ADCO MP-21 facilities to the Fujairah Main Oil Terminal.

Main Pump Station (MPS) in Habshan area..

Intermediate Pump Station (IPS) in Sweihan

Main oil terminal (MOT) located at Fujairah

MOT loading facilities with 3 SPM’s

1.1 SCOPE

This procedure describes the method which shall be used for the Hardness Testing examination on

carbon and low allow steel welds of the pump stations and the MOT loading facilities of the Abu

Dhabi Crude Oil Pipeline Project in compliance with:

ASME B31.3, Process Piping, Edition 2007

and

ASTM Code 110

The hardness measurements shall be carried out after PWHT (as applicable).

2.0 DEFINITION AND ABBREVIATION

2.1 Definition

Company International Petroleum Investment Company ( IPIC)

Owner Abu Dhabi Company for Onshore Oil Operations (ADCO)

Contractor China Petroleum Construction and Engineering Company (CPECC)

May One possible course of action

Shall/must/is to be Required

Should Request

2.2 Abbreviation

ADCOP Abu Dhabi Crude Oil Pipeline

HSE Health Safety and Environmental

HAZ Heat affected Zone

QA/QC Quality Assurance/Quality Control

NDT Non Destructive Test

HT Hardness test



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PMC Project Management Consultant

PQR Procedure Qualification Record

PQT Procedure Qualification Test

WPS Welding Procedure Specification

WPQ Welding Procedure Qualification

ASNT American Society of Nondestructive Testing

3.0 REFERENCE DOCUMENTS

3.1 International Standards

ASME B31.3 Process Piping

ASME Section V Non Destructive Examination

ASTM E 110 Standard test method for identification hardness of metallic material

portable hardness tester.

ASNT-TC-1A Personnel Qualification and Certification in Non-destructive Testing

DEP 30.38.01.31-Gen. Shop and field fabrication of piping, edition 2005

3.2 ADCO’s documents

30.99.12.1603 Specification for CS / SS piping Fabrication, Erection & Testing

WS – 1 Rev. 2 Specification for welding inspection of shop and field fabrication Carbon

Steel process and utility piping

31.38.01.31.A ADCO Amendments/Supplements to DEP No. 30.38.01.31-Gen

3.3 Project Documents

30-99-91-0638 Design Basis Manual

30-99-90-1672 HSE Management Plan

30-99-90-1611 Project Quality Plan



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4.0 GENERAL REQUIREMENTS

4.1 Personnel qualifications All NDT personnel shall have ASNT, PCN or equivalent Level II certificate.

ANST level II personnel shall be examined and certified by ASNT Level III examiners.

Only operators who have followed the necessary training shall perform testing.

Valid NDT certificates and CV shall be submitted to client and third party for approval, this approval shall

be submitted in writing within 3 working days to the NDT contractor.

4.2 Procedure qualification testing A procedure qualification report shall be generated and the results documented prior to use on actual

field welds.

The qualification process shall be as follows:

a. Welds (minimum of 2 per welding procedure) containing defects and acceptable imperfections shall

be prepared from actual production pipe material samples utilizing the approved welding procedure

specification.

b. Welder qualification welds may be used.

c. The procedure qualification welding and testing shall be witnessed and certified by the company and

no qualification testing shall be carried out without presence of company.

d. The HT procedure shall be applied and the results documented.

4.3 Surface preparation

The surfaces, on which the impression shall be made, shall be first flattened by grinding or filing and

hereafter smooth polished with sandpaper roughness 220µ at the examination areas.

5.0 EXAMINATION

5.1 Methods

Test method consists of measurements taken on 5 locations, parent material on both sides of the weld,

HAZ on both sides of the weld and as close as possible to the weld and in the middle of the weld.



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5.2 Number of test areas for circumferential welds

For carbon steel pipes and low alloy steel pipes with

- diameter < 4", one test area, at 12o’clock position, per circumferential weld.

- diameter 4", three test areas, 120 apart per weld.

The hardness of one test location shall be determined from the average of three (3) measurements.

6.0 EQUIPMENT

Portable hardness tester “Krautkramer MIC10R or Company approved and calibrated Equipment with

Vickers diamond indenter used.

Diamond pyramid 136° included angle.

6.1 Equipment verification

Prior to testing the equipment, read-out shall be verified using a reference standard.

Verification shall be performed at least three times a day.

For verification two impacts will be made on a standard test block.

6.2 Maximum measurement & tolerances

The hardness measurements shall not exceed 248HV10, there is a tolerance of max. 3% and a max.

deviation of 3.6% from the average value evaluation from 3 readings, unless ASME B31.3 table 331.1.1

specifies a lower hardness limit. Brinell hardness limits in ASME B31.3 may be converted to Vickers

hardness using ASTM E140.

6.3 Test conditions

Minimum weight of object : 5 kg

Minimum thickness of object : 5 mm

Test load : 49.0 N

7.0 RECORDS

The report must contain at least the following information:

Client

Project number

Pump station

Procedure & revision

Unique weld number

equipment used

name of operator & level;

date of examination

Report Format Attached.



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8.0 CONTROL OF NON CONFORMITY

Non conformity shall be solved within 2 working days and shall be immediately reported to the Site NDT

project manager.

Each non conformity shall be recorded.

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HARDNESS TEST REPORT

CLIENT : REPORT NO :

PROJECT : Abu Dhabi Crude Oil Pipeline Project DATE :

Drawing No : Location :

S.No Weld No Type of

Equipment Location

Inspection Result

Result Value Average

1 2 3

1

BM

HAZ

WM

HAZ

BM

2

BM

HAZ

WM

HAZ

BM

3

BM

HAZ

WM

HAZ

BM

4

BM

HAZ

WM

HAZ

BM

5

BM

HAZ

WM

HAZ

BM

6

BM

HAZ

WM

HAZ

BM

BM-Base Metal ; HAZ- Heat Affected Zone ; WM-Weld Metal Procedure : 30-99-90-1826 Rev

PPROVALS CONTRACTOR TPI CLIENT

Signature

Name

Date