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on methods of fabrication of helically welded pipes used for transporting of combustibles. In the second one it has been given the NDT methods used during inspection
of the pipes in production plants. In the next parts it has been described the NDT
methods for steel pipes focusing first of all on visual, ultrasonic and radiographic
ones. The paper has been ended with the information about prospects of gas industry
development in Poland and in the world.
Introduction
The golden age of pipelines has come
with a permanently increasing demand for
raw materials; the excavation of which is an
enormously complicated undertaking. As of
today, the best solution related to this type
of transportation is a subterranean grid of
main pipelines made of steel pipes. Polands
gas distribution system has approximately 17 thousand kilometres of high-pressure
gas pipelines and approximately 79 thousand
kilometres of distribution network, 23 gas
pumping stations, and approximately 4 thousand 1st and 2nd degree pressure reducing and
measuring stations. A growing consumption
of energy combined with a growing demand
for energy carriers, in particular for natural
gas, shapes the development of the network of
industrial pipelines. Great distances between
the sources at which natural gas and oil are
excavated and the places of their consumption require the construction of transit pipelines characterised by very high operating
parameters, e.g. gas pipelines with a diameter of over 1000 mm and pressure of 10 MPa.
Such pipelines must be made of pipes characterised by a strength of over 690 MPa
(485MB, 555MB) and very good weldability. As a result, it is possible to observe the
development of low-alloy steels (C 0.16%,
Si 0.55%, Mn 1.9%), often with microadditions of Nb, Mo, or Ti. Such pipes are obtained by means of controller rolling referred
to as thermoplastic or thermomechanical
treatment. Pipes for the pipelines mentioned
above are produced following the regulations
contained in DIN standards or in their American (API5L) and European (EN 10208)
counterparts. Large-diameter steel line pipes
for transporting liquid and gaseous fuels are
used as the following:
seamless pipes (S), obtained by means of
hot or cold working methods,
welded pipes (W), produced by means of
electric induction welding (EW) or butt
welding (BW) as well as submerged arc
welding (SAW) with a longitudinal weld
(SAWL) or a helical weld (SAWH). Figure 1 presents the process of welding pipes
with a helical weld (two-stage). Pipes can
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This article presents non-destructive testing of thermomechanically rolled helically submerged arc welded (SAWH) pipes
L485MB and L555MB. These pipes were selected as they are typical and manufactured
in many steelworks both in Poland and overseas. Following their manufacture the pipes
undergo insulation application, usually with
polyethylene or polypropylene and are painted inside with epoxy paints.
equipment features,
supervision and how it is exercised,
applied standards, requirements and
guidelines,
systems applied for the certification of
personnel, procedures and equipment [1].
The basic NDT methods used in the production of pipes are the following:
visual testing VT,
radiographic testing of pipe ends RT,
automatic fluoroscopic testing of a whole
welded joint,
ultrasonic testing of a burden material in
the form of a strip unwound from a coil
(laminar imperfection test) UT,
automatic ultrasonic testing of a whole
welded joint UT,
manual ultrasonic testing of a welded joint
on a pipe end UT,
manual ultrasonic testing of a welded joint
being repaired UT.
In addition, in order to determine precisely the size of welding imperfections, also
other NDT methods, i.e. penetration testing
(PT) and magnetic particle testing (MT),
can be used.
The basic standard describing the selection of testing manners and assessment criteria is standard PN-EN 10208-2 Steel pipes
for pipelines for combustible fluids Technical delivery conditions Part 2: Pipes of requirements class B. The standards describing testing manners and assessment criteria
are the following:
PN-EN 10246-9 Non-destructive testing
of Steel Tubes Part 9: Automatic Ultrasonic Testing of the Weld Seam of Submerged Arc Welded Steel Tubes for the
Detection of Longitudinal and/or Transverse Imperfections;
PN-EN 10246-10 Non-destructive testing
of Steel Tubes Part 10: Radiographic
Testing of of the Weld Seam of Automatic Fusion Arc Welded Steel Tubes for the
Detection of Imperfections;
No. 3/2013
Types of imperfections
detected during pipe
manufacture
Residual magnetism
on pipe ends
Laminar imperfection
on pipe ends
Longitudinal/transverse
imperfections in welded
joint
Laminar imperfections
on pipe body
Laminar imperfections
on strip edge where
transverse weld was
made
Non-destructive testing
of weld in pipe ends
(areas not tested previously) / testing of areas
being repaired
No. 3/2013
Testing status
Obligatory
Optional
Obligatory
Optional
Optional
Obligatory
39
PN-EN ISO 10893-11 Non-destructive testing of Steel Tubes Part 11: Automated Ultrasonic Testing of the Weld Seam of Welded
Steel Tubes for the Detection of Longitudinal and/or Transverse Imperfections.
The standards of the PN-EN 10246 series
have been now replaced by the standards
of the PN-EN ISO 10893 series. The basic
product standard PN-EN 10208-2 (version in
effect) still indicates older standards as those
in effect. As a result, all the greater production plants continue to use these standards in
the manufacturing of pipes. For this reason,
in all cases this study refers to both standards
as recommended for use. As far as ultrasonic manual testing is concerned, the standards
applied are the basic standards concerned
with the manner of the ultrasonic manual
testing of welded joints and their assessment
and are not discussed in this study. A detailed
list of non-destructive tests applied in pipe
manufacture is presented in Table 1.
The residual magnetism at the ends of
each pipe, parallel in relation to the pipe axis,
should not exceed 30 G (3mT). The measurement of magnetism should be carried out on
a random basis on the butting face of the pipe
end, by means of a calibrated meter (gaussmeter) using the Hall effect or by means of
equivalent devices.
All non-destructive tests of welded joints
should follow a hydraulic test of the pipe.
No. 3/2013
In order to ensure full NDT of welded joints it is required that helically welded pipes should undergo ultrasonic testing
along their whole length. The test objective
includes both longitudinal and transverse imperfections. Ultrasonic testing should be carried out in accordance with the requirements
of standard PN-EN 10246-9 or PN-EN ISO
10893-11 [2]. As a rule, UT of pipes follows
the completion of all the main operations of
a production process. In order to ensure the
reliability of ultrasonic testing, pipes should
be sufficiently straight and free from foreign
matter.
In order to detect longitudinal and transverse imperfections, helical welds should
undergo ultrasonic testing. In both cases the
testing should be conducted in two opposite
beam propagation directions. During the
test the converter unit should remain in the
proper position in relation to a weld so that
the entire weld could be searched through. A
searching rate should not oscillate by more
than 10% than the adopted basic rate. Depending on the thickness and roughness of
the pipe surface, the frequency used in UT
should be contained within a 1 MHz15 MHz
range. The maximum width of each single
converter, measured parallel to the main
axis of the pipe, should amount to 25 mm.
By means of an ultrasonic monitor connected with a marking and/or sorting system, the
equipment should enable the classification of
pipes as accepted or rejected. If it is not possible to test welds on pipe ends by means of
automatic ultrasonic testing equipment, the
testing of pipe ends should be conducted by
the manufacturer using either manual ultrasonic testing or radiographic testing.
Ultrasonic equipment for detecting longitudinal imperfections should be calibrated by means of four longitudinal grooves,
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4. right-through hole
5. longitudinal inner grooves
A test sample should have the same nominal diameter, wall thickness, surface roughness, heat treatment state and similar acoustic properties (e.g. wave propagation velocity
and wave damping coefficient) as the pipe
being tested. The manufacturer should have
the possibility of removing the inner and outer weld run in accordance with the pipe curvature. The outer and inner grooves as well
as the datum hole should be sufficiently distant from the pipe ends and from each other
so that clearly separate indications of signals
coming from the grooves and the hole can be
obtained.
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No. 3/2013
The diameter of the drill used to make the datum hole should be selected in accordance with
Table 3. The diameter of a datum hole should
be checked and cannot exceed the nominal diameter of a drill by more than 0.2 mm.
Acceptance
level
U2
U3
U4
U5
Acceptance
level
Drill diameter
U2H
1.6
U3H
3.2
U4H
4.0
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In such a case it is possible to accept ultrasonic testing carried out at steel sheet manufacturers or carry out post-weld testing at
the pipe manufacturers, following the requirements of standard PN-EN 10246-16 or
PN-EN ISO 10893-8 and acceptance level
No. 3/2013
U2. The tests are conducted within a 15mmwide zone along both longitudinal edges of a
helical weld. In the case of transverse welds
joining the edge of a strip testing is conducted along areas adjacent to this butt weld. Requirements concerned with ultrasonic testing
of laminar imperfections in the area adjacent
to the weld are dealt with in standard PNEN 10246-15 (PN-EN ISO 10893-9) or PNEN 10246-16 (PN-EN ISO 10893-8). Single
laminar imperfections or imperfections in
groups exceeding acceptance level U2 are
not allowed [2].
Non-destructive testing of helically welded
joints on pipe ends and in areas being
repaired
45
x-rays. The use of radioscopic methods is allowed (Fig. 6), yet only in cases when the
manufacturer can demonstrate their appropriate sensitivity.
No. 3/2013
No. 3/2013
47
References
No. 3/2013
ic testing of tube ends of seamless and 11. PN-EN ISO 10893-9:2011 Non-destructive testing of steel tubes - Part 9: Autowelded steel tubes for the detection of
mated ultrasonic testing for the detection
laminar imperfections
of laminar imperfections in strip/plate
9. PN-EN ISO 10893-6:2011 Non-destrucused for the manufacture of welded steel
tive testing of steel tubes - Part 6: Ratubes
diographic testing of the weld seam of
welded steel tubes for the detection of 12. PN-EN ISO 10893-11:2011 Non-destructive testing of steel tubes - Part 11: Autoimperfections
mated ultrasonic testing of the weld seam
10. PN-EN ISO 10893-8:2011 Non-destrucof welded steel tubes for the detection of
tive testing of steel tubes - Part 8: Autolongitudinal and/or transverse imperfecmated ultrasonic testing of seamless and
tions
welded steel tubes for the detection of
laminar imperfections
No. 3/2013
49