ADCOP-Abu Dhabi Crude Oil Pipeline Project

Habshan-Fujairah
30.99.90.1826
HARDNESS TESTING PROCEDURE
(MPS, IPS and MOT)

EPC CONTRACTOR:

PROJECT MANAGEMENT CONSULTANT:

China Petroleum Engineering

& Construction (GROWp) Corporation
Abu Dhabi Branch
P.O. Box 127345

ILF Consulting Engineers

P.O.Box 73250
Abu Dhabi, UAE

PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT Habshan Fujairah

EPC Contractor Doc. No.: ADCOP/C013/08

DOCUMENT No.:

CONSULTING
EN GI N EERS

30-99-90-1826

PAGE:
Rev. 0

Project No: E30153

DATE:

of

09

02/07/2009

Content

Page

1.0 INTRODUCTION ............................................................................................................................................. 4

1.1 Scope .............................................................................................................................................................. 4
2.0 DEFINITION AND ABBREVIATION ............................................................................................................... 4
2.1 Definition ......................................................................................................................................................... 4
2.2 Abbreviation .................................................................................................................................................... 4
3.0 REFERENCE DOCUMENTS .......................................................................................................................... 5
3.1 International Standards ................................................................................................................................... 5
3.2 ADCO documents ........................................................................................................................................... 5
3.3 Project documents........................................................................................................................................... 5
4.0 GENERAL REQUIREMENTS ......................................................................................................................... 6
4.1 Personnel qualification .................................................................................................................................... 6
4.2 Procedure qualification test ............................................................................................................................. 6
4.3 Surface preparation ......................................................................................................................................... 6
5.0 EXAMINATION ............................................................................................................................................... 6
5.1 Methode .......................................................................................................................................................... 6
5.2 Number of test areas for circumferential welds .............................................................................................. 7
6.0 EQUIPMENT ................................................................................................................................................... 7
6.1 Equipment verification ..................................................................................................................................... 7
6.2 Maximum measurement & tolerances ............................................................................................................ 7
6.3 Test conditions................................................................................................................................................. 7
7.0 RECORDS ...................................................................................................................................................... 7
8.0 NON CONFORMITY RECORD ...................................................................................................................... 8

DOCUMENT TITLE : HARDNESS TESTING PROCEDURE

PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

Habshan - Fujairah

DOCUMENT No.:

30-99-90-1826

Project No: E30153

Page 3 of 9
Rev. 0 DATE : 02/07/2009

1.0 INTRODUCTION
The United Arab Emirates (UAE) authorities assigned International Petroleum Investment Company
(IPIC) to execute the Abu Dhabi Crude Oil Pipeline (ADCOP) project which will facilitate the
transferring of crude oil from Habshan production facilities to the Fujairah main oil terminal (MOT)
on the eastern seaboard of the UAE.
The main components of the ADCOP pipeline system are as follows:
Tie-in and manifold facility at MP-21.
48 409km pipeline from ADCO MP-21 facilities to the Fujairah Main Oil Terminal.
Main Pump Station (MPS) in Habshan area..
Intermediate Pump Station (IPS) in Sweihan
Main oil terminal (MOT) located at Fujairah
MOT loading facilities with 3 SPMs
1.1 SCOPE
This procedure describes the method which shall be used for the Hardness Testing examination on
carbon and low allow steel welds of the pump stations and the MOT loading facilities of the Abu
Dhabi Crude Oil Pipeline Project in compliance with:
ASME B31.3, Process Piping, Edition 2007

and
ASTM Code 110

The hardness measurements shall be carried out after PWHT (as applicable).

2.0 DEFINITION AND ABBREVIATION

2.1 Definition
Company

International Petroleum Investment Company ( IPIC)

Owner

Abu Dhabi Company for Onshore Oil Operations (ADCO)

Contractor

China Petroleum Construction and Engineering Company (CPECC)

May

One possible course of action

Shall/must/is to be

Required

Should

Request

2.2 Abbreviation
ADCOP

Abu Dhabi Crude Oil Pipeline

HSE

Health Safety and Environmental

HAZ

Heat affected Zone

QA/QC

Quality Assurance/Quality Control

NDT

Non Destructive Test

HT

Hardness test
DOCUMENT TITLE : HARDNESS TESTING PROCEDURE
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

Habshan - Fujairah

DOCUMENT No.:

30-99-90-1826

Project No: E30153

Page 4 of 9
Rev. 0 DATE : 02/07/2009

PMC

Project Management Consultant

PQR

Procedure Qualification Record

PQT

Procedure Qualification Test

WPS

Welding Procedure Specification

WPQ

Welding Procedure Qualification

ASNT

American Society of Nondestructive Testing

3.0 REFERENCE DOCUMENTS

3.1 International Standards
ASME B31.3

Process Piping

ASME Section V

Non Destructive Examination

ASTM E 110

Standard test method for identification hardness of metallic material

portable hardness tester.

ASNT-TC-1A

Personnel Qualification and Certification in Non-destructive Testing

DEP 30.38.01.31-Gen.

Shop and field fabrication of piping, edition 2005

3.2 ADCOs documents

30.99.12.1603

Specification for CS / SS piping Fabrication, Erection & Testing

WS 1 Rev. 2

Specification for welding inspection of shop and field fabrication Carbon

Steel process and utility piping

31.38.01.31.A

ADCO Amendments/Supplements to DEP No. 30.38.01.31-Gen

3.3 Project Documents

30-99-91-0638

Design Basis Manual

30-99-90-1672

HSE Management Plan

30-99-90-1611

Project Quality Plan

DOCUMENT TITLE : HARDNESS TESTING PROCEDURE

PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

Habshan - Fujairah

DOCUMENT No.:

30-99-90-1826

Project No: E30153

Page 5 of 9
Rev. 0 DATE : 02/07/2009

4.0 GENERAL REQUIREMENTS

4.1 Personnel qualifications
All NDT personnel shall have ASNT, PCN or equivalent Level II certificate.
ANST level II personnel shall be examined and certified by ASNT Level III examiners.
Only operators who have followed the necessary training shall perform testing.
Valid NDT certificates and CV shall be submitted to client and third party for approval, this approval shall
be submitted in writing within 3 working days to the NDT contractor.

4.2 Procedure qualification testing

A procedure qualification report shall be generated and the results documented prior to use on actual
field welds.
The qualification process shall be as follows:
a. Welds (minimum of 2 per welding procedure) containing defects and acceptable imperfections shall
be prepared from actual production pipe material samples utilizing the approved welding procedure
specification.
b. Welder qualification welds may be used.
c.

The procedure qualification welding and testing shall be witnessed and certified by the company and
no qualification testing shall be carried out without presence of company.

d. The HT procedure shall be applied and the results documented.

4.3 Surface preparation

The surfaces, on which the impression shall be made, shall be first flattened by grinding or filing and
hereafter smooth polished with sandpaper roughness 220 at the examination areas.

5.0 EXAMINATION
5.1 Methods
Test method consists of measurements taken on 5 locations, parent material on both sides of the weld,
HAZ on both sides of the weld and as close as possible to the weld and in the middle of the weld.

DOCUMENT TITLE : HARDNESS TESTING PROCEDURE

PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

Habshan - Fujairah

DOCUMENT No.:

30-99-90-1826

Project No: E30153

Page 6 of 9
Rev. 0 DATE : 02/07/2009

5.2

Number of test areas for circumferential welds

For carbon steel pipes and low alloy steel pipes with
-

diameter < 4", one test area, at 12oclock position, per circumferential weld.

diameter 4", three test areas, 120 apart per weld.

The hardness of one test location shall be determined from the average of three (3) measurements.

6.0 EQUIPMENT
Portable hardness tester Krautkramer MIC10R or Company approved and calibrated Equipment with
Vickers diamond indenter used.
Diamond pyramid 136 included angle.

6.1 Equipment verification

Prior to testing the equipment, read-out shall be verified using a reference standard.
Verification shall be performed at least three times a day.
For verification two impacts will be made on a standard test block.

6.2 Maximum measurement & tolerances

The hardness measurements shall not exceed 248HV10, there is a tolerance of max. 3% and a max.
deviation of 3.6% from the average value evaluation from 3 readings, unless ASME B31.3 table 331.1.1
specifies a lower hardness limit. Brinell hardness limits in ASME B31.3 may be converted to Vickers
hardness using ASTM E140.

6.3 Test conditions

Minimum weight of object

: 5 kg

Minimum thickness of object

: 5 mm

Test load

: 49.0 N

7.0 RECORDS
The report must contain at least the following information:

Client

Project number

Pump station

Procedure & revision

Unique weld number

equipment used

name of operator & level;

date of examination

Report Format Attached.

DOCUMENT TITLE : HARDNESS TESTING PROCEDURE
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

Habshan - Fujairah

DOCUMENT No.:

30-99-90-1826

Project No: E30153

Page 7 of 9
Rev. 0 DATE : 02/07/2009

8.0 CONTROL OF NON CONFORMITY

Non conformity shall be solved within 2 working days and shall be immediately reported to the Site NDT
project manager.

Each non conformity shall be recorded.

DOCUMENT TITLE : HARDNESS TESTING PROCEDURE

PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

Habshan - Fujairah

DOCUMENT No.:

30-99-90-1826

Project No: E30153

Page 8 of 9
Rev. 0 DATE : 02/07/2009

HARDNESS TEST REPORT

CLIENT

REPORT NO :

PROJECT : Abu Dhabi Crude Oil Pipeline Project

DATE

Drawing No :
S.No

Weld No

Location :
Type of
Equipment

Inspection Result
Value

Location
1

Average

Result

BM
HAZ
1

WM
HAZ
BM
BM
HAZ

WM
HAZ
BM
BM
HAZ

WM
HAZ
BM
BM
HAZ

WM
HAZ
BM
BM
HAZ

WM
HAZ
BM
BM

HAZ
WM
HAZ
BM

BM-Base Metal ; HAZ- Heat Affected Zone ; WM-Weld Metal

PPROVALS
Signature
Name
Date

Page 9 of 9

CONTRACTOR

TPI

Procedure : 30-99-90-1826 Rev

CLIENT