(radiography, magnetic particle, ultrasonic & dye

CFCS-PROC-NDECSP-005-r03.docx NDE Contractors Scope and Procedures

Canadian Facilities Construction Services

Confidential and proprietary information of Enbridge Pipelines Inc. and its affiliates. Not for distribution or circulation by any Contractor May, 2010

NDE CONTRACTORS SCOPE AND PROCEDURES

(RADIOGRAPHY, MAGNETIC PARTICLE, ULTRASONIC & DYE PENETRANT INSPECTION)



Confidential and proprietary information of Enbridge Pipelines Inc. and its affiliates. Not for distribution or circulation by any Contractor

May, 2010

TABLE OF CONTENTS

1.0 SCOPE……………………………………………………………….. 1 2.0 PURPOSE……………………………………………………………. 1 3.0 CODES AND STANDARDS……………………………………….. 1 4.0 QUALIFICATIONS………………………………………………….. 2 5.0 SURFACE PREPARATION………………………………………... 2 6.0 SPECIFIC TECHNIQUE REQUIREMENTS……………………… 3

6.1 RADIOGRAPHY (RT)……………………………………….. 3 6.1.1 Radiographic Film 6.1.2 Intensifying Screens 6.1.3 Film Processing 6.1.4 Quality of Radiographs 6.1.5 Radiographic Density 6.1.6 Film Identification 6.1.7 Location Markers 6.1.8 Selection of Radiation Energy 6.1.9 Image Quality Indicators 6.1.10 Comparator Shims 6.1.11 Radiographic Procedure 6.1.12 Radiation Protection 6.1.13 Film Interpretation 6.1.14 Report Details 6.1.15 Specific Procedures

6.2 MAGNETIC PARTICLE INSPECTION (MT)………………. 12

6.2.1 Equipment 6.2.2 Materials 6.2.3 Medium Application 6.2.4 Magnetizing Current 6.2.5 Demagnetization 6.2.6 Indication Evaluation 6.2.7 Acceptance Criteria 6.2.8 Report Details

6.3 ULTRASONIC TESTING (UT)………………………………. 14

6.4 PENETRANT TESTING (PT)……………………………….. 14

WELD NUMBER FORMAT

APPENDIX A




May 2010 Page 1 of 14

1.0 SCOPE: This Specification has been prepared in accordance with the guidelines set forth in:

- CSA Standard Z662 Oil and Gas Pipeline Systems*

- CSA Standard W59 Welded Steel Construction*

- ASME Boiler and Pressure Vessel Code Section V*

- ASME B31.3 Process Piping*

- Company Specifications for Facility Construction*

*Latest version shall apply

This Specification applies to both qualification and production welds produced at fabrication shops, structural steel constructors, as well as compressor and pump stations.

2.0 PURPOSE:

The following document pertains to the minimum requirements needed for Non Destructive

Examination of metallic parts and more specifically of welds, in order to control the quality of the

product. The Specification details the equipment, operator, procedure, quality as well as the reporting

requirements.

3.0 CODES AND STANDARDS:

Work performed shall conform to the latest edition of the following Codes and Standards:

- ASME Boiler and Pressure Vessel Code, Section V, Non Destructive Examination and any

supplement or errata issued by ASME,

- ASME B31.3 Process Piping and any amendment, supplement or errata issued by ASME (Flaw

interpretation only),

- CSA Z662 including any amendment, supplement or errata issued by CSA,

- CSA W59 including any amendment, supplement or errata issued by CSA,

- CAN/CGSB 48.9712-2006/ISO 9712:2005,

- The current Occupational Health and Safety Standards.

Work shall be carried out in compliance with all Company Specifications, relating to Non Destructive

Examination. If a conflict arises between this Procedure and any of the above Codes and Standards,

the more stringent shall apply.





4.0 PERSONNEL QUALIFICATIONS: 4.1 All Non Destructive Testing results shall be interpreted by personnel certified in accordance

with CAN/CGSB 48.9712, Level II or Level III requirements.

4.2 All Radiographic and other NDT operations shall be followed in accordance with both the NDE

Contractor’s procedures, as well as the regulations set forth by the Canadian Nuclear Safety

Commission (CNSC).

4.3

All personnel’s valid CAN/CGSB Certifications shall be submitted as documentation prior to the start of any project, and such documentation shall be filed within the Facilities Construction Record Retention Index.

5.0 SURFACE PREPARATION:

5.1 The surface, both external and internal, must satisfy the requirements of the applicable

specifications and, if necessary, be treated so that any surface irregularity will not mask or be

confused with discontinuities. Special precautions should be taken with respect to internal

bevel presence due to misalignment, resulting in misinterpretation.

5.2 The surface finish of butt weld joints may be ground flush with the base material, or have a

smooth and reasonably uniform reinforcement in accordance with the contractual

specifications. Maximum reinforcement height is to conform to CSA Z662 requirements for

process piping components.

5.3 The surfaces of components, specifically to be examined utilizing Magnetic Particle inspection

shall be dry and free of grease, paint, water, dirt, rust, rust flakes, decarburization or any other

matter which could affect the interpretation of the test results. Surface preparation by grinding

or machining may be necessary when surface irregularities could mask indications.

5.4 Any surface preparation method which affects the chemical, metallurgical or mechanical

properties is unacceptable.





6.0 SPECIFIC TECHNIQUE REQUIREMENTS:

6.1 Radiography

6.1.1 Radiographic Film

Radiographs shall be made using industrial radiographic Type I film. Selection will be

based on achieving the required sensitivity or on contractual requirements. Film widths

shall be sufficient to depict all portions of the weld joint, including the heat affected zones

and shall provide sufficient additional space for the required IQI’s and film identification

without infringing upon the area of interest in the radiograph.

Film width shall adequately prove coverage of both sections to be joined.

6.1.2

6.1.2.1 Lead screens .005” thick front and .010” back shall be used for X-Ray, and .010”

thick front and back shall be used for Gamma-Ray radiography.

Intensifying Screens

6.1.2.2 Lead screens shall be clean and free from oils, dirt, oxide coatings and other surface

contaminants. They shall also be free of any mechanically produced defects such as

wrinkles, scratches and pits.

6.1.3

Film will be processed in accordance with the applicable manufacturer’s recommended

practice as to required chemicals, processing technique and exposure times, and to the

general recommendations of ASME, Section V, Article 22, SE-94, paragraph 23.

Film Processing

6.1.4

All radiographs shall be free of processing faults in the zone to be interpreted, unless these

faults do not hamper in any way its accurate evaluation.

Quality of Radiographs

All film marks are to be noted on the inspection report.





6.1.5

The transmitted film density through the radiographic image of the weld or area of interest

for pressure piping, shall be between 2.0 and 4.0, except for small localized areas, where

the density shall be no lower than 1.5. The transmitted film density for structural splices

shall be between 1.5 and 3.5, through the image of the weld or area of interest. The

unexposed base density of the film shall not exceed 0.30.

Radiographic Density

6.1.6

Each radiograph shall be permanently and clearly identified. This information shall not

obscure the area of interest. If this information is not interpretable, it can be permanently

identified with the use of a stick on label or permanent marker.

Film Identification (Flash)

The required information must be evident on each film:

- Company’s Entity

- Contractor Name

- Line Number, Job Number and Control Number (if applicable)

- Date work performed

- AFE Number

- Weld Identification (as per Enbridge “Q” drawings)

- Size and Thickness or Schedule

- Welder Identification

- Code/Specification

The Contractor shall supply the Radiography personnel with Enbridge’s

“Radiography Flash and Request (CFCS-032-RFR)” form or an equivalent request form

and flash sheet containing all the above details.

6.1.7

Location markers, which are to appear as radiographic images shall be placed on the part,

not on the exposure cassette. Where applicable, the location markers shall be placed in a

clockwise direction on the down-stream side of the weld, and the zero marker (identified by

a clearly written arrow) shall correspond to the 12 o’clock position. Location markers shall

indicate that the proper coverage has been obtained by having reference markers common

to two successive images, so as to establish that the entire weld has been examined.

Location Markers





6.1.8

The radiation energy employed for any radiographic technique shall achieve the density

and IQI requirements of the applicable specification. Overall radiographic sensitivity is

primarily influenced by factors such as film selection, intensifying screen selection,

geometric unsharpness, source placement, material thickness and overall film density.

Sources of radiation shall be radioisotopes or X-ray machines.

Selection of Radiation Energy

6.1.9

IQI selection shall conform to CSA Z662 for girth welds and CSA W59 for structural

splices. When considering IQI selection “Weld Thickness” shall be the nominal wall

thickness plus the maximum permissible weld crown height for that particular wall

thickness.

Image Quality Indicators

6.1.9.1 For a panoramic singe-wall exposure

technique of a girth weld, at least three IQI’s

shall be spaced equally around the weld circumference.





6.1.9.2 For a double-wall exposure

, single-wall viewing technique of a girth weld, one (1)

IQI is to be positioned within 25mm of the acceptable limits of coverage when using

small or medium cassettes. Long cassettes are to have the image of two (2) IQI’s

visible, one at each end within 25mm of the acceptable limits of coverage for each

exposure.

6.1.9.3 IQI selection and placement with respect to structural splices shall conform to CSA

W59.

6.1.10 Comparator (Undercut) Shim

The image of at least one comparator shim shall appear on each radiographic film as per CSA Z662-07 requirements

. Comparator shims are not required on structural

applications interpreted to CSA W59. Shims shall be made of material that is

radiographically similar to the material being inspected.

6.1.11

A written procedure shall be developed for each radiographic inspection technique. The

procedure shall be as per CSA Z662 and will detail the specifics of the radiographic

technique, including such things as the type and thickness of material for which the

Radiographic Procedure

procedure is suitable, the image collection and viewing system, radiation source, use of

intensifying screens, film type, the type of image quality indicators, exposure geometry,

and image storage practices.





6.1.12

6.1.12.1 Nuclear Energy Workers shall be responsible for the protection and monitoring of all

personnel working in an area where exposure to radiation is possible.

Radiation Protection

6.1.12.2 All guidelines set forth by the Non Destructive Testing Contractor, CNSC, OES and

the Department of Health shall be strictly adhered to.

6.1.13

6.1.13.1 Radiographs shall be properly dried prior to interpretation.

Film Interpretation

6.1.13.2 Film interpretation shall be performed on an illuminator that produces sufficient light

intensity so that all portion of the radiograph of the weld and base metal transmit

sufficient light to reveal the pertinent details of the radiograph.

6.1.14

A Radiographic examination report shall be written for each radiograph or group of

radiographs carried out.

Radiographic Report Details

The radiographic report shall contain or reference to, as a minimum, the following

information detailed in a clear and concise manner:

- Job/contract number (if applicable),

- Screen type and thickness,

- Number of radiographs (exposures),

- X-ray voltage or isotope used,

- X-ray machine focal spot size or isotope physical size,

- Distance from source side of radiator to weld or object being radiographed,

- Distance from source side of weld or object being radiographed to the film,

- Number of films in each film holder/cassette,

- Single or Double-wall exposure,

- Single or Double-wall viewing,

- Film type and classification,

- IQI type and size, In addition to the above details the following information shall be identified on the inspection report: - Company Entity and Contractor,

- Date work performed,





- Size and thickness or Schedule,

- AFE # and Station ID,

- Weld identification,

- Welder identification,

- Code/Specification,

- Time In/Out and Mileage.

Technician’s legible name and signature as well as certification number

MUST be identified on all NDT reports submitted.

The Contractor shall provide a suitable high-intensity viewer with sufficient capacity to illuminate radiographs of excessive density without difficulty. It is recommended that a variable-intensity

illuminator be used. Once all documentation has been submitted, the Contractor’s QC representative

as well as the Company’s representative will review the documentation and film for Quality Conformance. Interpretation of radiographs is the responsibility of the NDT Technician. Signatures

of the Contractor’s QC representative as well as the Company’s representative must be present on all copies of NDT reports. Billing sheets need only be signed by the Company’s representative.

Signatures on billing sheets must be legible so as to identify the accepting Company representative. Only original NDT reports, along with their respective radiographs, shall be submitted into the

turnover package, photo copies along with the applicable weld as-built drawing are to be included within the radiographic envelope itself.





6.1.15

Specific Radiographic Procedures

Radiographic Reports shall be outlined as follows:

6.1.15.1 Examination Standards shall be:

Structural Steel Applications CSA W59, technique and interpretation. Provisions identified in Enbridge

Facility Construction Specification Section 18, Structural Steel shall be adhered

to.

Pressure Piping (Fabrication and Site) Note: Ultrasonic evaluation may be used as an alternative to Radiography.

CSA Z662 technique, with interpretation to ASME B31.3 Normal Service as per

CSA Z662.

6.1.15.2 Pertaining to large bore welds in excess of 20”, identification on reports is to be in

increments, (0”-15”), (15”-30”) all the way to (# # -End), Metric or Imperial.

6.1.15.3 Pertaining to large bore welds in excess of 20”, reports/envelopes are to contain no

more than 3 welds worth of film.

6.1.15.4 For small bore welds, no more than 10 welds per report/envelope.

6.1.15.5 If an indication is identified as a 2 or a 3, the location of said indication shall be

identified on the inspection report. Indications identified as a (1) severity need not

have their location identified but shall be noted on the inspection report.

6.1.15.6 Welder job test shots to be on a report separate from production welds.

6.1.15.7 Company AFE number, the applicable Station Identification, as well as the

applicable Construction Work Package (CWP) number, must be documented on all

reports.

6.1.15.8 Reports to identify the “Clients” as the appropriate Company Entity, as well as the

Contractor performing the fabrication.

6.1.15.9 Reports to identify the Job Number of the Contractor performing the fabrication (if

applicable).





Inner leaves and Envelopes shall be outlined as follows: 6.1.15.10 Welds in an envelope must be the same as indicated on the X-Ray Report. Only

one report per envelope.

6.1.15.11 Film inner-leaves are to be used, one full weld per inner-leave.

6.1.15.12 Weld numbers must appear on the film sleeve that contains it.

6.1.15.13 Weld numbers shall be written on the envelopes.

6.1.15.14 The corresponding Report number shall be included on the film envelope.

6.1.15.15 Company AFE number, CWP number as well as the applicable Station

Identification must be documented on all film envelopes.

6.1.15.16 Pertaining to large bore welds in excess of 20”, reports/envelopes are to contain no

more than 3 welds worth of film. For small bore welds no more than 10 welds per

report/envelope.

6.1.15.17 Envelopes to identify the “Clients” as the appropriate Company entity as well as the

Contractor performing the Fabrication.

6.1.15.18 Envelopes to identify the job number (if applicable) of the Contractor performing the

fabrication.

6.2 Magnetic Particle Inspection

6.2.1 Equipment

A contour probe of sufficient lifting power shall be used. The lifting power for an AC-type

contour probe shall be at a minimum10lbs. (4.5kg), and for a DC-type probe the minimum

shall be 40 lbs.(18Kg) at the maximum 6”

prod spacing that will be utilized for the

examination of the test piece.

6.2.2 Materials

6.2.2.1

The color of the particles shall contrast adequately with the examined part. Colour

particles shall be either black/white contrast or florescent with blacklight. The

particles are to be suspended in either varsol or another suitable carrier.

Wet Particles





6.2.2.2 Dry Particles

When it is not applicable to use the wet particle method, the dry particle technique may be usedThe color of the particles shall contrast adequately with the examined part. The

particles shall be dry, finely divided, ferromagnetic materials of high permeability

and low retentivity. Dry powder examination shall not be carried out if the piece

temperature is greater than 600

.

oF (300

o

6.2.2.3.1

C). Additional specific requirements shall

be identified in ASTM E-709.

Contrast paint shall be used to facilitate identification of discontinuities. The area to

be examined shall demonstrate adequate coverage of the test area, the HAZ and a

portion of the parent material. Contrast paint shall be applied so as to be evenly

distributed across the inspection area.

Contrast Paint

6.2.2.3.2

A minimum light intensity of 100fc (1000Lx) is required on the surface to be

examined to ensure adequate sensitivity during the examination and evaluation of

indications.

Illumination Level

6.2.3 Medium Application

The medium shall be applied uniformly, very lightly and in small quantities. 6.2.4 Magnetizing Current

6.2.4.1 The sources of current used for magnetization shall be of a continuous or rectified

nature. As most contour probes are of an alternating current (AC), this method

shall be used for locating surface discontinuities. However, for locating deep

seated faults a direct current (DC) shall be used.

6.2.4.2 At least two separate examinations shall be performed on each area. The second

examination shall have the lines of flux running perpendicular to those of the first

examination.





6.2.5 Demagnetization

When it is determined that residual magnetization may adversely affect the test piece, the

part will be demagnetized after examination. The technique utilized for this shall be the

reversing or reducing direct current method. Verification of the results of this

demagnetization shall be accomplished with the use of a magnetic field indicator (refer to

ASME Section V, Article 7, SE-109).

6.2.6 Indication Evaluation

6.2.6.1 The surface of the test piece shall be examined both during and immediately after

the testing procedure has been applied. All indications shall be evaluated in terms

of the acceptance standards of the referencing code section.

6.2.6.2 Indications which are judged to be non-relevant shall be regarded as unacceptable

until the indications are either eliminated by surface conditioning or are re-examined

by magnetic particle or another type of nondestructive examination and the

indication is demonstrated to be non-relevant. Non-relevant indications are caused

by metallurgical discontinuities or magnetic permeability variations.

6.2.6.3 The absence of indications upon subsequent re-examination by magnetic particle

testing or another non-destructive method shall be considered as verification that

the indications were non-relevant.

6.2.6.4 When access is available, both weld surfaces (Internal and External) shall be examined

.

6.2.7 Acceptance Criteria

6.2.7.1 Welds identified on pressure containing components shall be examined in

accordance with ASME Section V, Article 7, with interpretation of results to ASME

B31.3-06.

6.2.7.2 Structural welds shall be evaluated as either statically loaded structures or cyclically

loaded structures as per CSA W59-03.





6.2.8 Magnetic Particle Examination Report

The report shall be in accordance with ASME Section V, SE-165 and shall contain the

following information:

- Company Entity and Contractor,

- Date work performed,

- Size and Thickness or Schedule,

- AFE # and Station ID,

- Weld identification,

- Welder identification,

- Code/specification,

- Time In/Out and Mileage,

- Testing Procedure used,

- Result of examination,

- Technician’s (print legibly and sign) name and certification number.

Additional details as to the location of the part tested may be required to help identify inspected

areas according to construction drawings.

6.3 Ultrasonic Testing (UT) Ultrasonic testing procedures shall be submitted and approved before starting any work.

6.4 Penetrant Testing (PT) Penetrant testing procedures shall be submitted and approved before starting any work.





APPENDIX A

WELD NUMBER FORMAT

WELD NUMBERS: AFE NUMBER LINE NUMBER DESIGNATION S - STATION M - MAINLINE U - UNIT TEST DESIGNATION X - X-RAY MP - MAGNETIC PARTICLE PT - DYE PENETRANT UT - ULTRASONIC RT - Radiographic Test WELD IDENTIFIER NUMBER (001-199) LOCATION EP – Edmonton Terminal YP – Hardisty EXAMPLE - COMPLETE NUMBER FOR WELD NDE TECHNICIAN WELD IDENTIFIER NUMBERS: - Follow flow of pipe - 001 001A 001B 002 003 003R 003R1 004 WR

0641188B01 4 S MP 001 EP

INTERMEDIATE WELDS

REPAIR WELDS

Weld Removal

(radiography, magnetic particle, ultrasonic & dye

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