inspection and test plan for epc gas pipeline project-x70m
DESCRIPTION
Sample ITP for Manufacturing on linepipe in line with API 5L Specification.TRANSCRIPT
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
1 2014-09-20 Ye Weigui Li Dong Yao Guangli
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
0 2014-09-18 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
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
Welding engineer焊接工程师
R R H /
1.3NDT operator qualification
NDT 人员资质●NDT test
certificateNDT 人员资质证书
See relevant appendix详见相关附件Note:Document will be supply at beginning of manufacture.
●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
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
See relevant appendix详见相关附件Note:Document will be supply at beginning of manufacture.
●Calibration certificate检定证书
Quality engineer质量工程师
R R H /
Inspection and test plan(ITP)(2) 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
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
Quality engineer质量工程师
R R H W
Once
per
heat
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 2 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
Inspection and test plan(ITP)(3) 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
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
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
Quality engineer质量工程师
R R H WOnce per
heat
Inspection and test plan(ITP)(4) 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
Inspection Frequency
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
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 4 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
Inspection and test plan(ITP)(5) 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
InspectionFrequ
ency
H W R H W R H W R
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 5 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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)
Quality engineer质量工程师
R R HEach
pipe
Inspection and test plan(ITP)(6) 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
InspectionFrequency
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 6 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
Quality engineer质量工程师
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
Quality engineer质量工程师
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.
Inspection and test plan(ITP)(7) 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
Inspection
Frequency
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 7 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
Quality engineer质量工程师
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
Welding engineer焊接工程师
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
Quality engineer质量工程师
R H H Each pipe
Inspection and test plan(ITP)(8) 检验和试验计划
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 8 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
Inspection Frequency
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
Quality engineer质量工程师
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
Quality engineer质量工程师
R R H Each pipe
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 9 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
Inspection and test plan(ITP)(9) 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
Inspection Frequency
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
Quality engineer质量工程师
R R H Each pipe
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 10 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
Inspection and test plan(ITP)(10) 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
Inspection Frequency
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
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 11 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
Quality engineer质量工程师
R H H Each pipe
Inspection and test plan(ITP)(11) 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
Inspection Frequency
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
Quality engineer质量工程师
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
Quality engineer质量工程师
R R H1 pipes
per 4h
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 12 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
Quality engineer质量工程师
R R H Each pipe
Inspection and test plan(ITP)(12) 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
Inspection Frequency
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
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 13 of 12
ITP NO. YL-ITP-SAWH14-0508-1 Rev.2
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
Quality engineer质量工程师
H R H R H Each pipe
Note : In case of difference between the English and Chinese language, texts in English shall prevail.
NOTE: H - Hold Point /控制点 W - Witness /检测和目击点 R - Review /审核点 Page 14 of 12