scope of work mt ut bhn inspection

BHN/U.T./MAGNETIC PARTICLE INSPECTION 26-JANUARY-2012

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SCOPE OF WORK

NON-DESTRUCTIVE INSPECTION

HARDNESS, U.T. and MAGNETIC PARTICLE INSPECTION OF WATER INJECTION

LINE AND COUPLING

DATE January 26, 2012

PREPARED BY:

Neil Scott …………………………………………..

Reliability Group

BHN/U.T./MAGNETIC PARTICLE INSPECTION 26-JANUARY-2012

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TABLE OF CONTENTS

SCOPE OF WORKS .................................................................................................................. 3

GENERAL REQUIREMENTS ...................................................................................................... 5

SPECIFICATIONS ..................................................................................................................... 7

MATERIALS AND EQUIPMENT ................................................................................................. 8

NOTES ................................................................................................................................... 9

BHN/U.T./MAGNETIC PARTICLE INSPECTION 3

INVITATION TO BID REGENERATION- NON-DESTRUCTIVE INSPECTION

ACTIVITIES

Petrojam Limited wishes to carry out Non-Destructive Inspection (Hardness/U.T., and

Magnetic Particle inspection) on it Process pipeline during its Emergency shutdown

January 2012 at its 96 Marcus Garvey Drive Kingston location.

1. SCOPE OF WORK

The contractor is required to supply all the materials, except as stated, quality assurance,

supervision, labour, transportation, tools, equipment, and other services, necessary to

execute the minimum requirements for magnetic particle inspection of ferromagnetic

materials and components, Hardness Testing and Ultrasonic Thickness Inspection as

follows:

Coupling and Reformer Feed Outlet Line to F-2

Magnetic Particle Inspection

1. Scaffolding will be erected around the equipment to facilitate access to the

couplings.

2. Ultrasonic Thickness inspection to be conducted as per ASME Section V on the

Reformer Feed Outlet Line to F-2.

3. Perform Ultrasonic Thickness and Wet Fluorescent Magnetic Particle

Examinations (MT) of the heat affected zones as per ASME Section V on the

connecting weld between Reformer Feed Outlet Line and both couplings.

4. Final magnetic particle inspection shall be performed after completion of all weld

repair operations that can generate surface or near surface discontinuities.

5. The stages in the repair process (i.e. root pass and at the completion of the repair)

where magnetic particle inspection is performed should be specified in the

welding specification and/or in the referencing codes.

6. The inspection contractor shall perform Brinnell Hardness Testing to ensure that

it is within the detection requirement of less than 225.

7. The tangential flux density shall be at least 1.0 T. The adequacy of the flux

density and/or field strength shall be verified on the surface under examination,

in each magnetizing direction, prior to or during the examination.

8. A flux density of 1,0 T is generally achieved with a tangential field strength from

2 kA/m to 6 kA/m, dependent upon the magnetic permeability of the material

being inspected.

9. The continuous method of application shall be used.


10. The powder shall be applied immediately prior to and during magnetization.

11. Magnetization shall be continued for at least two seconds after the application

has ceased to allow indications to build up and excess powder to be removed.

Ultrasonic Thickness Inspection

12. The thickness shall be checked or compared with the standard step block

thickness by placing the transducer/probe on standard step block after applying

couplant or thick lubricating oil/grease before taking measurement on the pipe.

13. Visual inspect and/or UT scan pipeline surface at location(s) where excessive

corrosion is/are observed at lower elevations where possibilities of collection and

stagnation of carry over water, acid condensation, SO2 or H2S flow exist.

14. Report of findings/recommendation to be submitted after inspection.

The location of work shall be in the Processing Unit on the basis of name and details of

Pipeline route as described in the Bill of Quantities below:

NDT Inspection of Process Unit Pipelines

Catalyst Regeneration 2012

Bill of Quantities

Unit Eq/Circ ID Pipeline Description

NDT

Inspection

Method

# of

TML

Points Cost

APS 05-88 REFORMER FEED

OUTLET TO F-2 UT/MT/BHN 4

¾” COUPLING UT/MT/BHN 4

½” COUPLING UT/MT/BHN 4

SUB-TOTAL

SUMMARY

Description Sub-Total

Insurance

Other Charges

Collection Summary

Provisional Sum

Grand Total Cost - Carried to Form of Tender (excl. provisional sum)


2. GENERAL REQUIREMENTS

The detailed specifications given hereinafter are for the items of works described in the

schedule of quantities attached herein, and shall be guidance for proper execution of

work to the required standards. It may also be noted that the specifications are of a

generalized nature and these shall be read in conjunction with the description of item in

the Engineers Bill of Quantities and drawings/sketches provided.

Unless specifically otherwise mentioned, all the applicable codes and standards (API,

ASME etc.), shall govern in all respects of workmanship, quality and methods of testing.

1. All materials and workmanship shall be in accordance with the requirements of

ASME Section V.

2. Examiners performing specific NDE procedures should be trained and qualified

in the applicable procedures in which the examiner is involved as follows:

a. Workers to be qualified to ASNT level 2 or equivalent.

b. Other certifications include American Society for Non-Destructive

Testing SNT-TC-1A or American Welding Society Welding Inspection

certification.

3. The magnetizing equipment shall be the alternating current electromagnetic yoke

type and should be prepared in accordance with standard operating procedures.

4. A function check shall be carried out prior to the inspection to ensure the proper

functioning of the inspection system. NOTE the temperature of the pipe and

coupling should be checked to ensure that it is within the detection media

manufacturer's specified temperature limits.

5. Surfaces to be examined shall be clean and free from scale, oil, grease, machining

marks, heavy paint and any other foreign matter that could adversely affect

inspection sensitivity or the interpretation of indications. Cleaning and

preparation of the surfaces shall not be detrimental to the material, the surface

finish or the detection media.

6. The engineering drawing or referencing document shall indicate the criteria by

which components are judged acceptable during MT. Where acceptance criteria

are not otherwise specified the following criteria shall apply:

a. Linear indications – all linear indications, regardless of length, shall be

cause for rejection of the component.

b. Single rounded indications – a single rounded indication greater than

0.030 inches in diameter shall be cause for rejection of the component.

c. Multiple rounded indications - two or more rounded indications each less

than 0.030 inches in diameter but separated by less than 0.030 inches shall

be cause for rejection of the component.

7. Inspection materials shall meet the requirements in ASTM E 1444.


8. The inspection contractor shall ensure that consistency and reproducibility of the

inspection at the required sensitivity level is maintained.

9. Components should be inspected prior to the application of any coatings.

10. Ultrasonic tests are carried out in accordance with relevant standards and OH&S

requirements.

11. The contractor shall depute a qualified and experienced ASNT level III

technician at site for the supervision of work.

12. Inspection areas as well as the general surface area shall be visually assessed for

the extent of corrosion under insulation, obvious irregularities or discontinuities.

13. In the case of any difference or discrepancy between the specifications and the

description in the schedule of quantities, the schedule of quantities shall take

precedence. In the case of any difference or discrepancy between specifications

and sketches, the specifications shall take precedence.

14. Ultrasonic equipment used for inspection of pipeline and coupling shall be

calibrated in accordance with ASME Section V latest edition. The calibration shall

be performed at following intervals:

a. At the beginning of normal inspection.

b. Every time the running of the systems creates uncertainty on its

efficiency.

15. Equipment(s) belonging to the contractor shall be used for one-off spot checks or

grid checks over areas where an indication was observed.

16. The equipment shall be fitted with a paint spray or automatic marking system

for areas giving ultrasonic or MT indications.

17. Where it is observed that the Ultrasonic data collected is considered erroneous,

the Contractor shall be required to redo same at no cost to the Owner.

18. The contractor shall submit the inspection/test reports in duplicate indicating

summary of recommendations including the condition of old/existing coating.

19. The work site MUST be maintained in a clean and orderly condition while work

is in progress.

20. The contractor shall be responsible for the removal of all materials (finished

couplant tubes, oil containers, waste cloth, tools etc.) upon completion of

Inspection.

21. Garbage must be taken to the municipal landfill.

22. It will be the responsibility of the contractor to acquaint his employees with

Petrojam’s safety instructions and ensure that they adhere to said instructions.

23. If the contractor needs to arrange over-time hours, he must take this into

consideration when preparing his quotation and schedule. Petrojam Limited

must authorize over-time prior to doing any over-time work.


24. A signed HOT WORK permit shall be issued by the Owner’s representative and

must be received by the contractor prior to the commencement of any hot

working procedure.

25. All contractors’ employees shall be issued identification badges by Petrojam

Limited. All contractors and contractors’ employees must have their

identification badges attached to their outer garment in a prominent position, so

that they can be easily identified.

26. Sanitary conveniences are available at the Owner’s premises. The contractor will

make his own arrangements on site for drinking water for his workers.

27. The contractor will make his own arrangements for meals for his workers.

Canteen facilities are available on the Owner’s premises on weekdays between

the hours 7:30 a.m. and 1:00 p.m.

28. The contractor may use the Owner’s portable drinking water and firewater, but

connections will be done by him with the Owner’s approval.

3. SPECIFICATIONS

The following Specifications, Codes and Standards form a part of this document to the

extent specified herein. All documents listed are assumed to be the current revision

unless a specific revision is listed. In the case of conflict between this specification and

the technical requirements cited in other referenced documents, the requirements of this

document take precedence.

1. ASME Section V- Non-Destructive Examination

2. ASTM E 1444 Standard Practice for Magnetic Particle Inspection.

3. SNT-TC-1A Personnel Qualification and Certification in Non-Destructive Testing

4. Pressure vessels – National Board Inspectors Code (NBIC)

5. API 510- Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair

and Alteration.

6. API- RP 572.

Surface Preparation

Pipe and Coupling Surface

1. All materials, workmanship, and surface preparation shall be in accordance with

the requirements of the SSPC and ASME Section V.

2. Pipe line surface preparation and painting shall meet the requirements of the

following standard


• SSPC – SP 2 – Surface Preparation Specification for Hand Tool Cleaning

3. Inspection areas shall be cleaned and prepared for testing using appropriate

procedures and materials.

4. Preparation processes are carried out in accordance with the relevant Petrojam’s

procedures and OH&S requirements.

5. Petrojam’s Mechanical Engineer or Refinery Inspector will inspect the cleaned

surface areas before the thickness survey commence.

4. MATERIALS AND EQUIPMENT

Owner Supplied

• Fire water

• Scaffolding

Contractor Supplied

All materials and equipment not listed as Owner Supplied to include but not limited to

the following:

• Magnetizing particles

• Alternating current electromagnetic yokes

• Ultrasonic Thickness gauge with through-paint.

• Half round File

• Wire brush

• Grinder, grinding discs and other hand tools

• Couplant

• Measuring Tape

• Pit Gauge

• Safety equipment for all his workmen

• Transportation


5. NOTES

1. The work on the pipeline will be done while the Process Unit is shut-down.

2. The work site must be maintained in a clean, tidy and orderly condition during

the Ultrasonic Inspection process.

3. After completion of the inspection, the work site must be left free from debris

and clean.

4. The contractor will be totally responsible, at all times, for the safety and

warehousing of his equipment, materials and any of the Owner’s materials

entrusted to him.

5. Petrojam Limited will not be held liable for loss or theft of any equipment and/or

materials suffered by the contractor.

6. At the end of the project, the contractor MUST clean the work site to the

satisfaction of Petrojam’s Project Engineer.

7. The workforce shall be comprised of skilled workmen, capable of conducting

work related activities under minimum supervision.

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