inspection and test plan for epc gas pipeline project-x70m

ITP NO. YL-ITP-SAWH14-0508-1 Rev.2

SAWH Pipe Specification

SAWH 埋螺旋弧钢管技术文件 Inspection and test plan检验和试验计划（ ITP）

Specification 规格 : Φ1219×20.62MM

Material 材质 : X70M

Standard 标准 : API SPEC 5L PSL2 （ 44th edition ） and client technical requirements

（ NNPC-OB3-LPS-001 ）Document No 文件 :NNPC-OB3-ITP-003

Project 项目： OBIAFU/OBRIKOM-OBEN (OB3) GAS PIPELINE PROJECT

Owner 业主： The Nigerian National Petroleum Corporation

Location 位置： NIGERIA

2 2014-09-01 Ye Weigui Li Dong Yao Guangli




Rev. Date Describer Checked By Approved ByApproval by Third Party

Approval by NNPC

JIANGSU YULONG STEEL PIPE CO LTD江苏玉龙钢管股份有限公司


SAWH Inspection and Test Plan（ITP）SAWH检验和试验计划Inspection and Test（ITP）(1) 检验和试验计划

Action No.序

号Activity

质量控制活动Item

检验项目Acceptance criteria

验收标准Documentation

证明文件Inspector检验人员　

NNPC

Contractor

/3rd Party

Inspection

Mill

InspectionFrequen

cy

H W R H W R H W R

1.0Control prior to

production生产前控制

1.1Welding procedure specification (WPS)

焊接工艺评定●WPS●PQR

●Customer specification用户技术规范●API Spec 5L (44edition) and NNPC-OB3-LPS-001

●WPS　date焊接工艺评定资料

Welding engineer焊接工程师

W R W R H Once

1.2Welder qualification

焊工资质●Welders

qualification certificate焊工资质证书

See relevant appendix详见相关附件Note：Document will be supply at beginning of manufacture.

●Welder qualification certificate焊工资质证书


R R H /

1.3NDT operator qualification

NDT 人员资质●NDT test

certificateNDT 人员资质证书


●NDT test certificateNDT 人员资质证书

Quality engineer质量工程师

R R H /

NOTE： H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 1 of 12


1.4

Calibration of test and inspection equipment and

instrument试验，检验设备和测量仪器仪表的检

验

●Calibration certification检定证书


●Calibration certificate检定证书


R R H /

Inspection and test plan（ITP）(2) 检验和试验计划Action No.序

号Activity





NNPC

Contractor

/3rd Party

Inspection

Mill

InspectionFreque

ncy

H W R H W R H W R

1.5Material control

原材料控制

● Material incoming inspection原材料验收● Material chemical and mechanical properties test原材料性能检验● Material storage原材料的堆放

● Hot coil purchase spec.钢卷采购技术条件● Contract 合同●Product tracing procedure产品跟踪程序●Para 6, 8.3 & 9.2 of API 5L 44th Edition.●Centre slit coil is not permitted.不得使用窄带钢

●Material incoming inspection report原材料验收报告●Material mill certificate原材料质证书


R R H W

Once

per

heat



1.6

Welding consumable material control焊接材料控制

●Incoming inspection焊材入厂检验●Mill certificate 焊材质证书●Handling & storage焊材搬运保管●Drying & issue 焊材的烘干和发放●Electrode dryer 焊材

保温桶的使用

● Welding material spec.焊材技术标准● Relevant national standard，such asDGS K 1101.41-2004，GB/T12470焊材国家标准，如DGS K 1101.41-2004，GB/T12470● Approved WPS

● Welding flux mill certificate

焊剂质证书● Welding wire mill

certificate焊丝质证书● Welding electrode mill

certificate焊条质证书● Welding electrode, flux

drying record焊剂烘干记录

Welding engineer & Quality engineer焊接工程师和质量工程师

R R H WOnce

per lot


号Activity





NNPC

Contractor

/3rd Party

Inspection

Mill

Inspection Frequency

H W R H W R H W R

1.7

Manufacturing procedure qualification tests生产工艺评定检验

●Forming process, welding process, inspection process and pipe properties成型工艺，焊接工艺，检测工艺及钢管各项性能

●SAWH spec.SAWH 技术标准●API 5L 44th edition

●MPQT首检报告

Quality engineer & process engineer工艺工程师质量工程师

R R W once

2.0 Process control 过程控制NOTE： H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 3 of 12


2.1Material reception原材料验收

● Mill certificate 原材料质证书

● Marking 标识● Chemical & mechanical properties 理化性能● Appearance（surfac

e, chamber and so on）外观（表面，镰刀弯等）

● Dimension 尺寸

●Hot coil purchase specification钢卷采购技术条件●Contract 合同●Para 6 of API 5L 44th

edition

● Sampling and test record

取样送检记录● Property test report

原材料理化检验报告

● Quality information feedback list

质量信息反馈单


R R H WOnce per

heat


号Activity





NNPC

Contractor

/3rd Party

Inspection

Mill


H W R H W R H W R

2.2Skelp end weld对头焊接

● Welded seam surface quality

焊缝外观质量● Welding parameter焊接参数

Jointer welding process sheet对焊工艺卡

● SAWH Skelp end weld record

SAWH 对头焊接记录Welding engineer焊接工程师

R R W Each coil



2.3edge milling 铣　边 — forming 成型

● Surface quality表面质量● Bevel angle, root

face坡口角度，钝边● Pipe girth, offset of

plate edge管径周长，错边量

● Edge milling, forming process sheet铣边，成型工艺卡

● SAWH edge milling record

SAWH 铣边生产记录● SAWH pipe forming

recordSAWH 钢管成型记录● SAWH edge milling

process sheet SAWH 铣边工艺卡● SAWH forming

process sheetSAWH 成型工艺卡

Process engineer工艺工程师

R W H Each coil


号Activity





NNPC

Contractor

/3rd Party

Inspection

Mill

InspectionFrequ

ency

H W R H W R H W R



2.4Welding control 焊接控制

● Welded seam surface quality焊缝外观质量● Welding parameter焊接参数● Bevel grease removal 坡口锈油处理● Welding material detection焊接材料检查

● Welding process sheet

焊接工艺卡●Approved WPS

● Internal & External welding record

内外焊记录● Welding wire

and flux issue record

焊丝焊剂发放记录

Quality engineer& Process engineer质量工程师，工艺工程师

R H HEach

coil

2.5

Pipe cutting & pipe no.切管及钢管编号

●pipe length fixed cutting 钢管定尺切断长度●each pipe no shall be uniquely correspond with plate heat no.编号与钢卷炉批号是否一一对应

●comply with specification符合程序文件规定●pipe cutting process sheet切管工艺卡●API 5L 44th Edition.●Min length●Max length●Min Avg. length

● Pipe cutting record

切管记录● Material test

record（ i.e. Feeding

record）原料检验记录（即投料记录）


R R HEach

pipe


号Activity




证明文件Inspector检验人员　 NNPC

Contractor

/3rd Party

Inspection

Mill

InspectionFrequency



H W R H W R H W R

2.6

Industry TV inspection beforer hydro-test水压前工业电视检查

●welded seam RT real-time imaging焊缝 RT 探伤及时实成像

●spec. & contract技术标准和合同要求●X-ray detection

process sheetX 射线检测工艺卡

●X-ray detection record

射线探伤报告


R R W Each pipe

2.7

Chemical &mechanical test力学性能和化学分析试验

● Product and weld seam chemical

composition analysis

产品和焊缝化学成分分析 ● Welded seam & base metal

tensile test 母材、焊缝拉伸● Guided bend test 导向弯曲试验●Macro, Hardness 宏观、硬度●Impact test 冲击试验●DWTT 落锤试验

●SAWH spec.SAWH 技术标准●Chemical and mechanical test process sheet理化试验工艺卡●NNPC-OB3-LPS-001

● Chemical and mechanical test report理化性能试验报告


R W R H

One pipe

per

heat，one

heat

correspond

s to more

than 200

pipes，tw

o pipes

will be

selected to

test.


号Activity





NNPC Contractor

/3rd Party

Inspection

Mill

Inspection

Frequency



H W R H W R H W R

2.8Surface inspection外观检验

●pipe length and welded seam surface quality, dimension, defect detecting and repair钢管和焊缝外观质量，几何尺寸，缺陷判定与返修

●API 5L 44th edition PSL2 andNNPC-OB3-LPS-001 ●surface inspection process sheet

●surface inspection record钢管外检记录


R R W Each pipe

2.9Repair welding

补焊

● Electrode complying with requirements焊条的使用符合规定

● Electrode dryer 保温桶使用

● Repair welding quantity, length, gap, position 补焊处数，长度，间距，位置

●Repair welding process sheet补焊工艺卡●API 5L 44th Edition.

●repair welding record补焊记录


R W R HEach

repair

zone

2.10Hydrostatic test静水压试验

● Manometer calibration压力表的校验

● pressure、duration压力值，持压时间● leakage 渗漏情况

●hydro-test process sheet

水压工艺卡●spec. & contract标准及合同规定●NNPC-OB3-LPS-

001

● Hydro-test record静水压试验记录●Shift report●Soft copy of chart


R H H Each pipe

Inspection and test plan（ITP）(8) 检验和试验计划



Action No.序

号Activity

质量控制活动

Item检验项目

Acceptance criteria验收标准

Documentation证明文件

Inspector检验人员　

NNPC

Contractor

/3rd Party

Inspection

Mill


H W R H W R H W R

2.11

Automatic UT test自动超声波检验

● Body and Weld seam and HAZ inspection 母材、焊缝及热影响区检测

● defect detecting 缺陷判定

● Reference calibrate 标样的校准

● API 5L 44th edition PSL2& NNPC-OB3-LPS-001

API 5L 44th edition PSL2 和规范● Welded seam UT process sheet焊缝超声波检测工艺卡

● SAWH UT recordSAWH 超声波探伤记录


R R H Each pipe

2.12

manual UT test手工超声波检验

●The pipe end weld seam （ blind area of automatic ultrasonic examination ） and the imperfection painted during automatic ultrasonic inspection shall be subjected to manual ultrasonic inspection 管端焊缝（自动超声波检验的盲区）和喷标的区域都应进行手工超声波检验。

● Reference calibrate 标样的校准

● defect detecting

● API 5L 44th edition PSL2& NNPC-OB3-LPS-001API 5L 44th edition PSL2 和规范● Welded seam UT process sheet焊缝超声波检测工艺卡

● SAWH UT recordSAWH 超声波探伤记录


R R H Each pipe




号Activity

质量控制活动

Item检验项目




NNPC

Contractor

/3rd Party

Inspection

Mill


H W R H W R H W R

2.13

Bevel inspection

管端倒棱检验

● Bevel end 坡口● Root face 钝边● Beveling 切斜

●SAWHspec.SAWH 技术标准●chamfering test

process sheet管端倒棱工艺卡

●product appearance & dimension inspection record

产品外观和尺寸检验记录

Process engineer工艺工程师

R W H

Every

pipe end

bevel and

inspection

once per 4

hours

2.14

Industry TV inspection after hydro-test水压后工业电视检查

●pipe ends welded seam and repair zone radiographic （ static image）管端焊缝和补焊处抓图

●spec. & contract技术标准和合同要求●X-ray detection

process sheetX 射线检测工艺卡●API 5L 44th Edition.●NNPC-OB3-LPS-

001

●X-ray detection record射线探伤报告●Digital radioscopic

shift record工业电视检验班组记录●Digital record on CD /

DVD 抓图刻盘


R R H Each pipe




号Activity

质量控制活动

Item检验项目




NNPC

Contractor

/3rd Party

Inspection

Mill


H W R H W R H W R

2.15

Finished product

inspection 成品检验

● OD at pipe ends and pipe body and ellipticity管端与管体直径和椭圆度● wall thickness 壁厚● Length 长度● straightness 直度●Weight 重量● pipe ends 管端● offset of plate edges 径向错边● undercuts咬边●Hard lump 硬块● dents 摔坑●welded seam dimension焊缝尺寸● internal surface quality钢管内表面质量

●specification & contract requirements技术标准及合同要求●API 5L 44th Edition.

●finished product inspection record

成品检验Quality engineer质量工程师

W R W R H Each pipe



2.16

Pipe end ultrasonic

test管端超声检

验

● Pipe end 50mm circumference管端 50mm 周向

● SAWH specificationSAWH 技术标准

● Ultrasonic test report超声检验报告


R H H Each pipe


号Activity

质量控制活动

Item检验项目




NNPC

Contractor

/3rd Party

Inspection

Mill


H W R H W R H W R

2.17Magnetism

test磁粉检验

● Magnetism at pipe ends 50mm weld seam 管端 50mm 焊缝磁粉检验

● SAWH specificationSAWH 技术标准

● Magnetism test report磁粉检验报告


R R H Each pipe

2.18

Residual magnetism measurement管端剩磁检测

● Residual magnetism measurement at pipe ends

管端剩磁测量

●spec. & contract技术标准和合同规定●Residual magnetism measurement process sheet剩磁测量工艺卡

●Residual magnetism measurement record list剩磁测量记录表


R R H1 pipes

per 4h



2.19Final

inspection综合检查

● check marks and paiting 检查标识和涂层● check end protectors 检

查管端保护● check pipe stacking 检查

钢管堆放是否合乎要求● no damage from

handling 外观质量是否因吊装而发生钩伤、碰伤

●spec. & contract技术标准和合同规定●storage procedure储运程序●API 5L 44th Edition.●NNPC-OB3-LPS-001

●Final inspection record综合检验记录


R R H Each pipe


号Activity

质量控制活动

Item检验项目




NNPC

Contractor

/3rd Party

Inspection

Mill


H W R H W R H W R

2.20Dock shipping码头发运

●check pipe end for damage

检查管端是否有吊伤，钩伤，碰伤

●check pipe body for damage管体是否有撞伤

●spec. & contract技术标准和合同规定●shipping procedure发运程序

●Dock shipping check record

码头发运检查记录Quality engineer质量工程师

H R H R H Each pipe



2.21

Quality certificate review质保书审核

●review certificate form and content

审查质保书格式和内容

●spec. & contract技术标准和合同规定●relevant specification程序文件

●quality certificate 质量证明书


H R H R H Each pipe

Note ： In case of difference between the English and Chinese language, texts in English shall prevail.


inspection and test plan for epc gas pipeline project-x70m

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