Showing posts with label Inspection. Show all posts

FCAW electrode desgination - ISO 17632

Source: SFI/IWE 1.08:2018 - Table 3

11 steps to prepare a hydrotest package

🧪 Hydrostatic Test Package Preparation Guide

Inspection Point in ITP – QA/QC Controlled Document

🔧 General Requirements

Hydrostatic testing is an essential inspection activity listed in the Inspection and Test Plan (ITP). Before performing a hydrotest, the following conditions must be fulfilled:

The hydrotest procedure has been approved by the client and/or consultant.
All welding activities within the test boundary must be completed and inspected by all parties.
Non-Destructive Testing (NDT) must be performed according to the project specification, with acceptable results.
All relevant documentation must be collected for inclusion in the test package.

📦 11 Steps to Prepare a Hydrotest Package

1. Cover Page

Include project name, client, contractor, system name, line class, and test type.
A sample form can be customized to suit your project format.

2. Content Sheet

Provides a summary index of documents included.
Pre-fill standard information (e.g., project name, test type) in templates to save time.
Forms may be typed or handwritten at the site, depending on project practice.

3. Pre-Test Checklist

Conduct this jointly with the client before pressurization.
Items include valve positions, flange bolt checks, blinds installed, supports in place, etc.

4. Line List

Include spool numbers, line numbers, service description, test pressure, and length.
Inspector must check and sign each spool on the drawing.
Use only approved drawings to prepare the test list.

5. Line Check

Verify all piping spools are installed per the approved drawings.
Mark or highlight test spools on isometric drawings and P&IDs.
Confirm valve direction, check valve orientation, and isolate components not to be tested.
Submit flagged drawings for client verification and signature.

6. Welding Data

Include welding summary logs (WPS/PQR/WPQ) and NDT reports (RT, MT, PT, etc.).
All visual and dimensional inspections should be satisfactory before pressure testing.

7. Material Traceability

Ensure all materials and spools are traceable.
Maintain MTCs and spool traceability records as part of the QA requirement.

8. Pressure Test Certificate

Record actual test pressure, date/time, duration, and hold period.
Use calibrated pressure gauges (within 6 months).
Install two gauges: one at the highest point and one at a visible point for monitoring.
Gauge range must be 1.5 to 4.0 times the test pressure per applicable code.

9. Pressure Chart Recorder (if required)

Attach the pressure chart to the package for test record verification.
Record should reflect start/hold/end time and pressure trend.

10. Temperature Record (Optional)

Record ambient temperature or water temperature during testing.
Useful for justifying pressure drops due to temperature changes.

11. Punch List

Include any outstanding work or comments found during pre-test or testing.
If no issues are found, create a "no comment" punch list endorsed by the client.

📤 Test Package Submission

Submit the complete hydrotest dossier to the client or third party for review and approval. The typical contents include:

✅ Cover page
✅ Hydrotest instruction or method statement
✅ Pre-test checklist / Line check record
✅ Line list
✅ Marked P&ID and Isometric drawings (highlight test area)
✅ Material traceability records
✅ Welding summary and NDT reports
✅ Pressure test certificate
✅ Calibration certificates (pressure gauge, chart recorder, thermometer, etc.)
✅ Photos of gauge reading at start/end of test (if required)
✅ Final punch list (with or without comments)

💡 All documents should be scanned and compiled into a single PDF file for submission.

Skid fabrication - inspection documents for QC

Following the topic, we would like to share you the quality document for small skid.

Inspection check list

Procedures and inspection should prepare and included in your hand, NDE procedure, NDE map, welding map and NDE plan also prepared.

You should make a content of procedures for control, type of inspection report, below is sample list of procedure.

Document control

Too many drawings/ document per each skid, so it should carefully update with latest revision,
Line list should be updated and control the piping spool number, all spools to be identified in the test package later.
Shop drawing, document submission to be documented revision number, date of submission, date of return, and approval code, etc.

Inspection report

To control and monitor all inspection reports, the assigned coding number should generate before starting issue.

Welding summary

For structural steel
For piping

Material receiving inspection

MRIR for piping, bolting, gasket, fitting
MRIR for consumable
MRIR for structural steel
MRIR for electric & instrument
Material traceability

Visual inspection

For piping
For structure

Dimensional inspection

Base frame - structure.
Piping spool, loose items.
Tie-in point report.

NDE Reports

MT/PT reports
RT/UT reports
Hardness test, ferrite test (if any)

Coating inspection report

Blasting and painting inspection report
Pickling and passivation report
Holiday test, salt test, dust test, pull of test (if any)

Testing reportHydrotest & Pneumatic test

See hydrotest & pneumatic test procedure, prepare the test package, and update the test package.

Factory acceptance test

Tie-in point report.

Bolt tightening report.

Leak test for instrument air.

Leak test for pipe system.

Function test for valve, equipment.

Packing report

Important do not miss during inspection: to check all the packing list, listed out all items installed or mounting on skids, spare part items, loose items, location of packing items, protection, preservation, etc.

Record all packing and photos evident should be kept.

To make sure all package had been checked and verified by all parties, and signed off in the packing list before moving next stage of the issue "IRN - Inspection Release Note".

Inspection release note

The IRN will be issued by Client or their representative inspector will issue it because the inspection point is Hold Point.

This is an evident document for payment and confirmation that had been inspection before shipping.

Final Manufacturer data book

Collect all procedure, instruction used for fabrication and inspection record to the final MDR.
MDR Index / content will be confirmed with Client before making.
Construction drawings will be made an as-built for reviewing and approval.
All outstanding work list should close out or update in the master list for further actions.
Guide to make a sample MDR.

Storage and submission

Retention of document shall follow your quality system, such 3 years or 5 years.
Document submit eight hard copy or soft copy or both to your client.
Do not submit via email with many files attached in the email, it should combine into a “.ZIP” folder, not compressed “.RAR” file.
Submission should use a secured platform such Google One, SharePoint, WeTransfer.

ASTM A516M Gr. 485 là gì?

--> Gr. 485 tương đương với Gr. 70.

Có hai đơn vị tính là US và SI
__Hệ US: ASTM A516 Gr. 70
__Hệ SI: ASTM A516M Gr. 485

ASTM A516 Gr. 70N and Gr. 70

Sự khác nhau gữa ASTM A516 Gr. 70N and Gr. 70 là gì?
--> khác nhau chính là vật liệu có xử lý nhiệt (Gr. 70N) và vật liệu không xử lý nhiệt (Gr. 70).

Về giá cả và mục đích sử dụng chắc chắn khác nhau, bạn xem trong thiết kế có apply "Normalizing" và đơn giá mua hàng.

Kiểm tra như thế nào?
__ASTM A516 Gr.70N là vật liệu có xử lý nhiệt "Material Treated" nên markings phải có đóng số cứng "MT". Yêu cầu tại ASTM A516/A516M-18 (ASME II 2021), SA-20/20M Section 13.
__ASTM A516 Gr. 70 không yêu cầu xử lý nhiệt nên không yêu cầu đánh dấu "MT".

ASTM A105 / A105N

Hiểu cách viết ASTM A105N hoặc ASME SA 105N.
--> Để hiểu rõ cần xem xét các chứng chỉ về dãy nhiệt độ và phương pháp xử lý nhiệt.
--> Tiêu chuẩn không quy định đánh dấu "N" trên sản phẩm, nhưng các nhà sản xuất sẽ tư đánh giá cụ thể để phân biệt.

__N - Normalized: thường hóa.

Chứng chỉ phải ghi rõ "Normalized" với nhiệt độ. Bạn có thể kiểm tra nhanh các note trong MTC (Material testing certificate". Để chắc chắn hơn, các nhà sản xuất còn dính kèm cái sơ đồ xử lý nhiệt để kiểm tra và đối chứng.

Trường hợp "hot forming" khác với "normalizing" là gì?

Đánh dấu "Normalizing" trên sản phẩm?

ASME SA516 70 MT LTV

ASME SA 70N: Normalized - thường hóa, vật liệu được xử lý nhiệt "Material Treated". Bạn tham khảo các yêu cầu tại MT = material heat treated, see Section 13 of SA-20 2021.

LTV = Supplementary S5 “Charpy V-Notch Impact Test”, see Supplementary Requirement S5 of SA-516 2021.

ASME SA 106 - NDE/ Hydrotest

ASTM A106

NDE/ HT có yêu cầu bắt buộc trên ống ASME SA 106 hay không?
--> Yêu cầu bắt buộc theo ASME SA 106 2021 - Table 4 đối với ông có đường kính NPS 2" trở lên. Các kích thước còn lại marking trên secured tag. Xem tại SA 530 Section 23 và SA 106 Section 24.

___ Hydrotest: thì phải nhận dạng áp suất thử, không đánh dấu "HT", áp suất thử phải thể hiện trên MTC (Material Testing Report), tiêu chí chấp nhận SA-106 Section 13.
___NDE: thì đánh dấu "NDE", phương pháp NDE phải ghi rõ trên MTC (Material Testing Report), tiêu chí chấp nhận SA-106 Section 14.

ASTM A106 - Weight class

ASTM A106

Orignal marking khối lượng trên ống ASTM A106 là bắt buột?
--> Đúng, yêu cầu tại SA 106 2021 Section 25 đối với ống có đường kính DN100 trở lên phải đánh dấu khối lượng. tham khảo ... "the schedule number, weight class, or nominal wall thickness; and, for sizes larger than NPS 4 [DN 100], the weight", ...

Một trong những vật liệu mua từ TQ thường không có hoặc các nhà cung cấp sửa thông tin hoặc unmarkings sẽ sót chỗ này. Tùy theo mục đích sử dụng và yêu càu để xác nhận / kiểm tra sự phù hợp.

ASTM A106 - seamless pipe or welded pipe

ASTM A106 không có ống hàn (welded) pipe. Yêu cầu kỹ thuật chỉ có ống seamless.

--> Xem title và Section 1 - Scope.

Trường hợp dual markings với API 5L?

--> Nếu đánh dấu cả hai (dual markings) thì chỉ áp dụng cho seamless pipe.

Còn ống hàn (welded) thì chỉ áp dụng theo Tiêu Chuẩn API 5L hoặc tiêu chuẩn khác như A53.

ASTM A106 Production Analysis

ASTM A106 Production Analysis tại sao phải kiêm tra MTC là 2 mẫu (test coupon).

ASME SA 106 2021 - Section 9: đối với trường hợp yêu cầu dự án thực hiện trên production, thì báo cáo MTC phải thể hiện ít nhất 2 mẫu kiểm tra và kết quả kiểm tra.

Sampling xem tại Section 20 của tiêu chuẩn này.

Rất nhiều MTC sót chỗ này, bạn xem các chứng chỉ từ Nippon Steel thì rất tuyệt vời, họ làm khá đủ để tự tin so với các MTC từ TQ.

ASTM A106 - Tolerance

Dung sai kiểm tra ống ASTM A106 ở đâu?
--> Phiên bản áp dụng và chuẩn bị áp dụng là ASME SA-106/106M 2021 hoặc ASTM A106-08.
___Dung sai đường kính: theo ASTM A106 Section 16.2 và ASTM A530.
___Dung sai khối lượng: ASTM A106 Section 16.1 là -3.5% / +10%.
___Dung sai thickness: ASTM A106 Section 16.3, -12.5% / không giới hạn max..

Lý do, tăng thickness thì tăng khối lượng nên phải xác định khối lượng tịnh trên MTC thì bạn sẽ hiểu sai sót ở đâu? Nhà sản xuất khó sai số liệu này, chỉ có nhà phân phối sai sót chủ yêu.

AWS A5.18 ER70S-6 & ER70S-G

Diễn giải

ER: indicates filler metal may be used as either an electrode or rod.
70: indicates in 1000 psi increments the minimum tensile strength of the weld metal produced by the electrode when tested according to the specification. In this case, 70 indicates 70,000 psi.
S: indicates that the filler metal wire is solid.
6: indicates the chemical composition of the solid filler metal wire. This wire has a Charpy V Notch impact property of -29 C.
G: "as agreed to by purchaser and supplier". No specific requirements for chemistry, yield strength, elongation, impact strength.

Khác nhau về chi phí

ER70S-6 giá sẽ cao hơn ER70S-G.

Quy trình hàn

Khuyến khích chạy PQR mới với que hàn chịu nhiệt độ âm (-) tốt hơn.

Phân loại

Khác nhau về nhu cầu sử dụng thì phân loại khác nhau, nếu bạn làm về tàu bè / dịch vụ offshore thì tìm kiếm các hãng được chứng nhận bới các đăng kiểm uy tín như ABS, DNV, BV, ..

ASTM A312 - stainless steel pipe

What is a Material Test Report?
Material Test Report (MTC) is a quality assurance document generated by the mill manufacturer/process raw manufacturer and provided with the material to suppliers and fabricator. Please see type of inspection document.

Supplier
Normally, a fabricator purchase material from supplier who had stocked more type of materials and held the MTCs from mill manufacturer. It is available for submission and reviewing. So, you need to request them to send a sample MTC for review before shipping, it also avoids misunderstanding the requisition in PO and restriction of Approval’s Vendor List. Approval’s Vendor List is listed the mill manufacturer/ mill processor of some global company like TechnipFMC, Petronas, UOP, etc which limits in the specifications like country of origin, supplementary, inspection document, etc.

(sample MTC of pipe ASTM A312 type 316/316L)

ASTM A312 / A312M – Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless-Steel Pipes.

Material inspection and review its MTC are a cope of welding inspector that how to accept or reject when received MTC from supplier.

A lot of issue found when material delivery out, MTC come later such wrong heat number, wrong MTC, not comply with purchase order,…So, you should request to send MTC for reviewing before delivery.

Manufacturer and type of inspection certificates

who made product such pipe, tube, shape…

MTC shall state company’s name or workshop, location, certificate compliance.

Product markings: company’s name or company’s logo.

Trace number

Also called heat number, ladder number (L), cast number.

The trace number shall trace to all the test results of chemical analysis results, mechanical test results, NDE test results, etc.

Product markings: heat number or cast number.

Specifications and grades

Are a specification of material.

MTC shall be reported specification, grades, and year of edition.

Product markings: specifications number and material grade.

Manufacture/ Delivery condition

Is method of manufacture to form a production such hot finish or cold finish, seamless or welded.

Abbreviation marking:

SMLS Seamless,

W Welded (RT or UT)

WX Welded (100% RT)

WU Welded (100% UT)

If RT/UT was performed for welded seam, the inspection report should attach to MTC.

Dimensions

Diameter, thickness are given in ASME B36.19M

Tolerance of the wall thickness, see table 3.

Product markings: size and thickness, example NPS 8” 20S

Weight

A mass per unit length.

If specified in purchase order the marking for pipe larger than NPS 4 shall include the weight.

Mechanical properties

Tensile strength, yield strength and percentage of elongation, see table 4.

Product markings not required

Chemical analysis

See table 1, MTC may report heat analysis (H) and/or product analysis (P).

Tolerance, see ASTM A999.

Material require may require to re-verify by Positive Material Inspection (PMI), you should note that PMI with or without carbon (C) content requirement, because it is effected your cost, PMI with carbon (C) content is higher cost than without carbon (C) content.

Product markings not required

Heat treatment

All stainless steel pipes shall be furnished in the heat treatment condition. After hot or cold working to size, then steel heated to ~1100°C.

Solution annealing is rapidly cooled by quenching into water to prevent any carbides or other phases forming.

Product marking is not required.

Hydrotest or non-destructive test

Each pipe shall be subjected to the nondestructive electric test or the hydrostatic test.

Test pressures see subsection 12 and subsection 22.2 in ASTM A999.

Product marking is hydrotest valve or NDE, both.

Supplementary

As specified in the purchase order such as PMI test, complied with NACE MR0175, Intergranular grain.

Stated and certified by mill signature

Manufacturer statement of certification the product has been manufactured accordance to the specification and purchase order, etc. and endorsed by Quality department.

ASTM A36 - Material inspection and review MTC

General requirement

__See requirement in Section 4 of ASTM A6/A6M-17a

__Additional information should be included in material requisition such type of inspection document MTC 3.1 or 3.2, production test, max. carbon equivalent (CE), country of origin, approval vendor list, …

Material and manufacture

__The steel shall be killed.

Chemical composition

__Let check chemical analysis in Table 3 of ASTM A36.

__Note: product analysis tolerance in Table A of ASTM A6.

____Heat analysis: test on casting, another name heat, casing.

____Product analysis: test on production after forming.

____% C and %Mn deviation sees foot note B in Table 3 of ASTM A36.

__Sampling for chemical analysis and methods of analysis shall be in accordance with ASTM A751.

Tension test

__Tensile requirement in Table 2, you should refer to specification and compare with an MTC.

__Remarks the foot note A) B) C) D) E) in Table 2 of ASTM A36 and then refer to ASTM A6 Para. 11 to check the statement in the MTC such orientation of test sample (transverse or longitudinal).

__Test sample should verify in the MTC:

____Position of test sample: top, bottom or middle.

____Tensile test: direction, size and gauge length of sample.

__Minimum number of tension test required, see Table B in ASTM A6.

Quality

__See Para. 9 in ASTM A6: … structural products are normally furnished in the as-rolled condition and are subjected to visual inspection by the manufacturer or processor.

__Refer to product form and delivery condition in purchase order.

Permitted variations and dimensions and weight

__See Para. 12 in ASTM A6.

__Too many fake MTC modified the thickness plate by Suppler, you can find it in the MTC.

Test report

__Test reports for each heat supplied are required, see Para. 14 in ASTM A6, Identification of structural products (markings):

Plate markings

____ASTM designation: ASTM A36/A36M (year-date not required).

____Grade: (not required for A36)

____Heat number: xxxxx

____Size and thickness: 6 x 1254 x 6096 mm

____Name, brand or trademark of manufacturer: logo or tradename (NSSMC)

____Processor: ABC (stocker identification or distributor)

For structural products finished by other than the original manufacturer, the supplier of the structural product shall also provide the purchaser with a copy of the original manufacturer’s test report (Supplier shall certify true copy).

Location markings

__At least one plate of each finished plate or production.

__Other products and required marking, see Para. 18 of ASTM A6.

ASTM A234 - Material inspection and review MTC

Scopes

ASTM A234: specification for piping fitting of wrought carbon steel and alloy steel for moderate and high-temperature service.

Ordering information and general requirement sees ASTM A960.

Material
__Killed steel, forging, bars, plates, seamless or fusion-welded tubular product with filler added. “fusion-welded tubular with filler added: SAW, GTAW (filler add), GMAW”. MTC shall be cleared marking specification number, grades and date.
__If product comply another standard like, the MTC shall be stated test value, “ex. NACE MR 0175, MTC shall state hardness value, forming and heat treatment, read more in NACE MR0175 part 1, 2, 3.

Manufacture
__Forging or shaping operation by cold and hot forming.
__NDE may be performed either prior to or after forming on welded product.
__NDE reports must state in the MTC and available review by purchase.

Heat treatment
__Heat treatment shall be performed after forming, see para. 7 on ASTM A960
__ASTM A234 WPB most finished by normalizing, Annualizing.
__Other grades see section 7.0.

Chemical composition
__See table 1, It is identification by trace number, heat number, casting number, or heat code.
____L- ladle: test on casting, another name heat, casing.
____P- product: test on production after forming, see ASTM A960 for acceptance criteria.
__Carbon equivalent (CE) % = C n+ Mn/6 + (Cr+Mo+V)/5 +(Ni+Cu)/15: there are limit in the project specification and application.
__And other content limitation in specification, don’t forget see any foot notes in each table. If piping fitting formed from pipe, the MTC shall be stated “Material made from seamless pipe/welded pipe” and traceable heat number of pipe. NDE reports such RT/UT MP/PT shall attach to MTC if fitting made from welded tubular.

Mechanical properties
__See table 2 and ASTM A960.
__If tensile test on product, the MTC shall be stated sample dimension.

Hardness
__Fitting of all grades is allowed maximum 197 HB, except WP5, WP9, WPR, WP91, WP911.

Hydrostatic test
__See ASTM A960 if PO requirement.

Dimensions
__Dimension and tolerance given in ASME B16.9 for butt-weld fitting, ASTM B16.11 for threading/socket weld.

Surface quality
__See ASTM A960.

Repair by welding
__Most project prohibited, please check in PO requirement.

Certification
__See section 17.

Product marking
__It is a task of welding inspection to evaluate acceptance or rejection.
__See MSS-P-25 and ASME B16.9, B16.11.

Supplementary
__The supplementary requirements shall apply only when specified by the purchaser in the inquiry, contract, and order such as CE%, hardness, heat treatment, NDE after forming, etc.

Bolt torque calculation ASME PCC-1 2019

Bolt torque calculation, lubrication factor, and nut factor to be determined in Appendix K of ASME PCC-1 2019.

See formula (K-1) or (K-1M).
Check flange rate and bolt size in Table L-1.
Bolt stress determination in Appendix O. Normally bolt stress is approximately of 40-60% of yield strength, example ASTM A193 B7 – yield strength is 105ksi --> target bolt stress of 60% YS = 105*0.6 = 63ksi = 63x1000 = 63000 psi. Don’t worry no need to find root areas, bolt size and K factors. See Table O-3.2-1.
Calculation target bolt torque Tb – see note (b) of Table O-3.2-1 (ft-lb).
Example, See Table O-3.2-1 for Flange NPS ½”, nut factor K=0.2 (k=0.2), bolt material ASTM A193 B7 (check yield strength in Table 2 of ASME SA-193 2019 --> Bolt stress = 10560/100 = 63ksi) => Tb = 631.05 = 66 ft-lb.
Next double check determination of bolt stress see example O-4.3 in ASME PCC-1 2019.

SI Unit see Table O-3.2-1M.