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KBR

INSPECTION TEST PLAN FOR LINE PIPE


NO.

INSPECTION ACTIVITY
Level 1 Level 2 Level 3
Selected Level of Inspection >

PRE-INSPECTION MEETING

DOCUMENTATION REVIEW
Vendor Quality Plan (To be submitted prior to Pre-Inspection Meeting)
Manufacturing Schedule
Manufacturing Procedure Specification
Material Substitution Requests
Chemical Composition of Steel
Chemical & Physical Properties of Welding Material
Material Test Reports
NDE Procedures
NDE Personnel Qualifications
Welding Procedures (WPS's & PQR's)
Welder Performance Qualifications
Weldability Data
Acceptance Test Procedure
Heat Treatment Procedure
Traceability Procedure
Marking / Identification Procedure
Hydrostatic Test Procedure
Packing, Shipping, Handling & Storage Procedure
Manufacturer's Data Report

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STEEL PRODUCING (MELTING & CONTINUOUS CASTING)


Verify Electric Furnace or Basic Oxygen Furnace Steel Producing Method
Verify Killed / Deoxidized Practice (Si and/or Al Content)
Verify Fine Grain Practice (ASTM No. 8 or Finer)
Verify Vacuum Degassed or Argon Stirred (Thickness Above 19mm)
Verify Calcium Treatment (Sulfide-Inclusion Shape Control)
Verify Continuous Casting Slab Production
Verify Hot Scarfing of Slabs (To Reveal Sub-Surface Defects)
Verify Chemical Analysis

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W

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PLATE PRODUCTION
Rolling of Slabs into Plate
Heat Treatment of Plate (If Applicable)
Shearing / Machining Edges of Plate
Ultrasonic Examination of Sheared Edges
Ultrasonic Examination of Entire Plate

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W

SW/R
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SW/R
SW/R

N/A
R
N/A
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R

Note:

H = Hold Point
W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable

KBR
INSPECTION TEST PLAN FOR LINE PIPE
NO.
5

INSPECTION ACTIVITY
Level 1 Level 2 Level 3
Selected Level of Inspection >
PIPE MANUFACTURE
Verify Production Specification Level as PSL-2 (API 5L)
Verify Welding Process as DSAW
Verify Fused Flux for SAW
Verify Acceptable Mositure Control of SAW Flux
Verify Correct Welding Consumables
Monitor Production Forming & Fit-Up
Monitor Production Welding
Monitor Cold Expansion
Monitor End Preparation

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SW/R
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SW/R
SW/R
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SW/R
SW

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N/A
N/A
N/A
N/A

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H

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H

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INITIAL TESTING
Chemical Analysis
Carbon Equivalent
Tensile Tests (Base Material)
Tensile Tests (Weld Deposit)
Flattening Tests
Manipulation Test For SWA Weld Deposits
Impact Tests (Base Material)
Impact Tests (weld Deposit)
Drop Weight Tear Test

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PRODUCTION TESTING
Chemical Analysis
Tensile Test (Base Material & Weld Deposit)
Flattening Test
Guided Bend Test
Hardness Test
Impact Test (Base Material)
Drop Weight Tear Test
Macro Etch to Verify Out-of-Line Weld Bead

W/R
W/R
W/R
W/R
W/R
W/R
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W/R

SW/R
SW/R
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SW/R
SW/R
SW/R

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MANUFACTURING PROCEDURE QUALIFICATION TEST


Testing as Required by API-5L (PSL-2)
Radiographic Examination of Welded Seam
Wet Magnetic Particle Examination of Welded Seam
All Weld Metal Tensile Tests
Impact Testing of Base Material (5 Sets)
Impact Testing of Weld Deposit & HAZ (5 Sets)
Impact Testing of Weld Deposit & HAZ (Tranisition Curves)
Hardness Testing of Weld Deposit & HAZ

Note:

H = Hold Point
W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable

KBR
INSPECTION TEST PLAN FOR LINE PIPE

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INSPECTION ACTIVITY
Level 1 Level 2 Level 3
Selected Level of Inspection >
INSPECTION OF PIPE ( * 5%-10% Random Inspection)
Traceability
Outside / Inside Diameter
Out-of-Roundness
Wall Thickness
Weight
Length
Straightness
Dents
Offset of Plates Edges
Out-of-Line Weld Bead (Etch & Inspect Weld Zone of 3 Pipes Per Shift)
Height of Weld Reinforcement
Hard Spots
Cracks & Leaks
Laminations
Arc Burns
Undersut
Sharp-Edged Imperfections
Magnetism
Pipe Ends / Bevel Preparation
FABRICATION OF JOINTERS
Fit-Up of Pipe Sections
Monitor Production Welding
Visual & Dimensional Inspection
Radiographic Examination (Review All Radiographs)
PRESSURE TESTING
Calibration of Test Gauge
Calibration of Pressure Chart
Hydrostatic Test

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N/A
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NONDESTRUCTIVE EXAMINATION (After Completion of Expansion & Hydro

Ultrasonic Examination of Reference Standard / Pipe


Ultrasonic Examination of Weld Seam
Ultrasonic Examination of Pipe Ends
Wet Fluorescent Magnetic Particle Examinationof Pipe Ends & Weld End Bevel
Radiographic Examination of Repair Welds & Weld Start / Stop Areas

Note:

H = Hold Point
W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable

KBR
INSPECTION TEST PLAN FOR LINE PIPE

NO.
13

INSPECTION ACTIVITY
Level 1 Level 2 Level 3
Selected Level of Inspection >
MARKING, TAGGING & SHIPPING INSPECTION ( * 5%-10% Random Sampli

Cleaning, Dry Out & Surface Preparation


Preservation, Marking, Bar Coding & Tagging
Round-Up Spiders / Bracing
End Shipping Protection
Quantitative Check
Shipping Preparation & Protection
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COMMENTS
* If discrepancies are detected during random sampling, additional inspection
shall be conducted to verify compliance.
If a discrepancy exists between this document and the applicable purchase
order, the information listed on the purchase order shall take precedent.

Note:

H = Hold Point
W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable

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SW
SW/R
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SW/R
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SW

KBR
INSPECTION TEST PLAN FOR LINE PIPE
Level 4

N/A

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N/A
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N/A
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R

Note:

H = Hold Point
W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable

KBR
INSPECTION TEST PLAN FOR LINE PIPE
Level 4

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N/A
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N/A
N/A

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Note:

H = Hold Point
W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable

KBR
INSPECTION TEST PLAN FOR LINE PIPE

Level 4

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N/A
N/A
SW/R
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R
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R
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R

Note:

H = Hold Point
W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable

KBR
INSPECTION TEST PLAN FOR LINE PIPE

Level 4

SW
SW
SW
SW
SW
SW

Note:

H = Hold Point
W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable