QUALITY ASSURANCE AND CONTROL
OF STATIC AND DYNAMIC EQUIPMENT
INDEX
1.
1.1.
1.2.
1.3.
1.4.
1.5.
GENERAL ................................................. .................................................. ..................................................3
2.
ABBREVIATIONS ................................................. .................................................. .....................................4
3.
3.1.
3.2.
3.3.
3.4.
3.5.
3.6.
3.7.
3.8.
3.9.
TECHNICAL REQUIREMENTS................................................................................................................................4
4.
4.1.
4.2.
REFERENCE STANDARDS AND SPECIFICATIONS ................................................................................................14
5.
INDEX OF TABLES INCLUDED IN THIS SPECIFICATION ................................................................................16
6.
ANNEXES................................................. .................................................. .................................................. 16
Introduction ................................................................................................................................................3
Object.......................................................................................................................................................3
Order of priority ...............................................................................................................................................3
Responsibility ...........................................................................................................................................3
Units of measurement................................................. .................................................. ...................................4
Inspection by Repsol and/or its representatives ................................................................................................4
Repsol quality documentation .................................................................................................................................5
Quality of stockpiles .................................................................................................................................5
Dimensional control................................................ .................................................. ...................................6
Non-destructive testing (NDT)................................................................................................................................6
Ferrite Measurement .......................................................................................................................................11
Inspection of welding connections .................................................................................................................11
Positive identification of materials and chemical analysis ................................................................................................11
Hardness tests .................................................................................................................................................11
3.10. Impact Tests ................................................................................................................................................12
3.11. Production witnesses .......................................................................................................................................12
3.12. Pressure tests.................................................................................................................................................13
3.13. Interior surface cleaning and finishing.......................................................................................................................14
3.14. Quality dossier ................................................................................................................................................14
Repsol standards and technical specifications .................................................................................................14
Globally relevant codes and standards .................................................................................................................15
1.
GENERAL
1.1. Introduction
This document is part of the latest edition of Repsol's technical specifications, and also refers to the latest edition
of the standards and codes that are mentioned and/or applicable, as well as to what is indicated in the Basic
Design Data (DBD) that collect the specific aspects for each project and that will be transcribed to the particular
Material Requisition.
The full or partial application of this specification will be confirmed in the Basic Design Data specific to each
project.
Where this specification refers to specific paragraphs or parts of codes or standards, the latest edition of the code
or standard shall apply unless Repsol indicates the applicable revision. The indication in this specification of the
edition of the code or standard in force at the time it was drafted is intended to clearly identify the criterion to be
applied in case it has been moved or eliminated in later editions. Repsol shall be informed in writing of any
discrepancies between the edition mentioned in this specification and the latest edition of the Code or Standard.
1.2. Object
This specification defines the testing methodology required to control quality levels in the shop and field
manufacturing of static equipment such as pressure vessels, storage tanks, spheres, heat exchangers and
pressure parts of furnaces, boilers and dynamic equipment such as compressors, pumps and other machines.
Functional testing of dynamic equipment is excluded from the scope of this specification and must be included in
its corresponding specifications.
This specification shall also apply to field lines, structures and other equipment other than that indicated in the
previous paragraph, when required by the contractual conditions.
This specification makes specific reference to the ASME Code, however, when other Design, Manufacturing and
Testing Codes or Standards are specified in the project, such as EN-13445, API, etc., the application of said
associated codes or standards will replace those indicated in ASME, although, if those in this specification are
more restrictive, they must be considered as mandatory supplementary requirements compared to those of the
reference standard.
1.3. Order of priority
In case of conflict between documents, the following order of priority will prevail:
-
Mandatory local legislation and regulations (provided that more restrictive criteria are not established in the
other applicable documents).
-
Project DBD
-
This specification
-
Other referenced codes and standards
Notwithstanding the above, this discrepancy must be notified to Repsol in writing before continuing with the
design/manufacturing process.
1.4. Responsibility
Compliance with the rules and recommendations given in this specification does not exempt, either partially or
totally, the designers/suppliers from their respective responsibilities and guarantees or any other contractual
obligation.
1.5. Units of measurement
The units of measurement of the International System (SI) or the Anglo-Saxon system will be used, as defined at the
beginning of the project, although for equipment and pipe fittings, inches will be used for the measurement of
diameters and pounds for the rating of flanges. Likewise, in the case of using the International System, pressures in kg/
cm will be allowed.2.
2.
ABBREVIATIONS
The following terminology is used in this specification with the meanings indicated: AUT:.............
Automatic ultrasonic testing
END: ............Non-destructive testing
MT: ..............Magnetic particle testing
PT: ..............Liquid penetrant testing
RT: ...............X-ray test
TOFD: .........Time of Flight Diffraction
UT: ...............Ultrasonic testing
3.
TECHNICAL REQUIREMENTS
3.1. Inspection by Repsol and/or its representatives
All materials, manufacturing and testing of the equipment will be subject to inspection by Repsol and/or its
representatives, in addition to any other inspection required by the Design Codes and applicable local Laws or
Regulations.
Inspection by Repsol and/or its representatives, as well as acceptance of the inspected material or equipment, does not
exempt the Manufacturer from its responsibility to ensure compliance with the legal and contractual requirements or
from its guarantees regarding the design, materials, manufacturing and operation of the equipment.
Repsol inspectors and their representatives will have free access to the Manufacturer's and sub-suppliers'
workshops. The Manufacturer must provide the inspectors with the necessary means to carry out a correct
inspection and verify that the equipment is being manufactured in accordance with the requirements of the
Purchase Order and the legal and contractual documents.
If during the inspection of a piece of equipment an excessive number of anomalies or defects appear, the
inspector may demand an increase in the inspection level, without this fact implying any claim by the
Manufacturer.
No equipment will be prepared for shipment without written authorization from the Repsol inspector or his
representatives.
The Repsol inspector or his representatives will not issue authorization to ship equipment until they have
reviewed and accepted its corresponding manufacturing file or quality dossier, which must have been fully
prepared by the Manufacturer beforehand.
The hiring of an Official or Authorized Body by the Manufacturer for inspections and tests must have the prior
consent of Repsol.
The subcontracting of any service to comply with this specification and of the possible subcontractor must be
previously approved by Repsol or its representatives.
3.2. Repsol quality documentation
The Manufacturer must send Repsol or its representative, sufficiently in advance of the start of the works, the
following documentation:
-
Inspection point programs, which must be previously approved by Repsol or its representative.
-
Non-destructive testing and control procedures specific to each piece of equipment to be inspected.
-
Detailed procedures for the tests to be performed such as pressure testing, leaks, ferrite measurements, etc.
-
Manufacturing procedures such as: welding dossiers, heat treatment procedures, bottom shaping, etc.
-
Technical specifications for purchasing materials.
Repsol or its representative will comment on these documents, and the Manufacturer is obliged to review them as
many times as necessary until obtaining full approval of the same, and may not begin work until such approval is
obtained.
All records generated during inspections and certificates to be issued must be available for review by Repsol
inspectors or their representatives.
All equipment used to carry out the required controls, tests and trials must be properly identified and calibrated,
and their registration or certification must be available for review by Repsol inspectors or their representatives.
3.3. Quality of stockpiles
The materials to be collected for the manufacture of the equipment or components must comply with the
required quality standards and with the applicable Repsol code, standards and specifications. These materials
must be marked with the original identification data of their manufacturer and be covered by the corresponding
certificates.
In addition, the materials and their certificates shall comply with the requirements of Table IV, Material
Certificates, indicated in this specification, according to ISO 10474 or EN10204 standards.
Unless otherwise approved by Repsol, Table I, Bolt and nut qualities, indicates the quality standards for bolts and
nuts to be installed in the flanged joints of the equipment.
3a
Unless otherwise authorized by Repsol, for equipment or components that require heat treatment during
manufacturing, the Manufacturer will request certified materials in the delivery state and a simulated PWHT for
low alloys (Cr-Mo) in case repairs are necessary in the workshop or in the field. In the case of standard elements
such as flanges and pipe fittings, certification with simulated heat treatment may not be required if data on the
effect of such treatment is available, such as the Holloman-Jaffe or Larson-Miller parameter, or specific
information from steelmakers, if this has been taken into account in the stock orders for the affected materials.
The Manufacturer or engineering company will send Repsol the specific list of its potential suppliers and
subcontractors, with Repsol reserving the right to veto any of them that do not comply with the necessary
guarantees and/or that are not approved.
Material certificates shall contain all information on the condition of delivery and the tests, trials and controls
required, indicating their results and rating. They shall also indicate any other information required by the quality
standard, code and applicable standards, as well as any marks and seals that will be seen on the materials.
Materials that do not have identification marks and seals that guarantee their traceability may not be used under
any circumstances.
All materials must retain their visible identification marks throughout the manufacturing process. When a
material is to be cut and/or its original marks are not to appear on the finished equipment, these must be copied
in an appropriate position and previously, before cutting, they must be checked by the Repsol inspector or its
representative. When the equipment is to be subjected to a process that erases the marks on the materials, such
as a heat treatment, these must be copied on a drawing of the container and must also be checked by the Repsol
inspector or its representative before subjecting it to said process. All cut remains and other surplus materials
must be marked in the same way and must be retained until Repsol and/or its Representatives authorize their
disposal.
The Manufacturer's Quality Control will seal and sign the quality certificates of the collected materials as a sign
that they have been considered acceptable for the manufacture of the equipment and components to be
supplied, having previously verified that the data contained are admissible under the applicable standards and
having verified the following:
-
That the materials covered by the certificates have non-defective marks that identify them. These marks must
clearly show the manufacturer's mark.
-
That both the brands of the materials and the writing of the certificates are uniform and in the same font.
-
That he/she has original certificates and has used them to verify the authenticity of any copies that he/she
intends to submit for inspection and include in the quality dossier. His/her stamp and signature, both original,
on a copy of the certificate will mean, in addition to the approval of the data contained, the validity and prior
verification of the same.
3.4. Dimensional control
A dimensional check of the equipment, its general dimensions, orientations, arrangement and dimensions of
pipes and manholes, supports for heat insulation, fireproofing, stairs and internal and external accessories will be
carried out, checking that the tolerances indicated in the applicable standards are met. This dimensional check of
all the elements of the equipment will be carried out after the pressure test. The actual values obtained during
the dimensional check must be reflected in the quality dossier and in the "as built" drawings, which must comply
with the tolerances indicated in the applicable design code and with the standard drawing PE-C-0100.02 sheet 01,
Manufacturing tolerances
When any dimension is out of tolerance, the Manufacturer must propose the most appropriate solution to be
adopted for Repsol's approval. The repair will not be started under any circumstances before obtaining Repsol's
authorization.
3.5. Non-destructive testing (NDT)
3.5.1. Scope of NDT
The scope of the NDT will be as indicated in this specification and, in addition, as required in the equipment
drawings, in the applicable code, in the specifications of Repsol or its representatives, requests for offers or
purchase requisitions.
The Manufacturer must prepare an NDT location plan for each piece of equipment and add it to the welding
procedure or PPI, indicating all the identification data for the equipment and the positions where it has been
carried out.
3.5.2. NDT staff qualification
NDT must be performed by certified personnel in accordance with the recommendations of ASNT SNT-TC-1A or
equivalent, such as International Standards ISO 9712 or the manufacturer's own standards, provided that these
are certified and authorized by Repsol or its representatives.
3a
Both the review of the END procedures,such as the interpretation of the results, must be carried out by personnel
with a minimum qualification of Level II, in accordance with the latest edition of ASNT Recommended Practice
SNT-TC-1A or in accordance with ISO 9712, as well as demonstrating experience in these techniques.
3.5.3. NDT acceptance criteria and procedures
NDT procedures, scope maps and acceptance criteria must be approved by Repsol or its representatives, and
such examinations shall not be carried out until such approval has been obtained.
3.5.4. Visual Inspections
Visual examinations shall be conducted on the accessible exterior and interior surfaces of all welds on the
equipment.
Procedures for visual examinations shall be performed in accordance with ASME Code V, Article 9, and this
specification.
Acceptance criteria for visual examinations shall be as required in the applicable ASME code sections or
standards.
3.5.5. Magnetic Particle Testing (MT)
In ferromagnetic materials, magnetic particle inspection will be carried out in the following cases:
to)Welded joints according to Table II, Inspection of connection welds.
b)In chromium alloy steels-molybdenum All welds that for whatever reason, once accepted by Repsol, are not Xrayed or inspected by UT will be inspected by magnetic particles.
c)In chromium alloy steels-molybdenum and nickel (up to 3 1/2% Ni), in both cases of any thickness, all edges
prepared for welding shall be inspected by magnetic particles, by any procedure. With prior approval from
Repsol or its representatives, this inspection may be replaced by penetrating liquids.
The procedure to be performed in a magnetic particle examination shall be in accordance with the requirements
and methods specified in ASME V, Article 7.
Magnetic particle examination of welds shall be carried out on the outside and, if accessible, also on the inside
and shall include a strip of base metal at least 25 mm wide on each side of the weld.
The evaluation of indications and acceptance criteria shall be as required by the applicable ASME code sections or
API standards.
When the inspection is carried out at a temperature below 35 ºC, coloured or fluorescent wet magnetic particles
will be used. When the inspection is carried out at a temperature above 35 ºC, coloured or fluorescent dry
magnetic particles will be used.
The surface to be inspected by the coloured wet particle method must be coated with a thin white paint (lacquer).
Fluorescent particles must be used for the examination of internal surfaces in the absence of white light.
In nickel steels and other materials, whose residual magnetism may cause problems during welding, it must be
measured and must not be higher than before performing this test.
3.5.6. Liquid Penetrant Testing (PT).
A penetrant inspection will be performed in the following cases:
to)On edges prepared by oxycutting of sheets of any material with a thickness greater than 20 mm.
b)In areas affected by any root clean-up, except storage tanks, silos and atmospheric deposits.
c)In lifting lug welds.
d)In welds that, for any reason previously approved by Repsol, are not radiographed or inspected by UT of
stainless steels, nickel steels, carbon steels with a specified minimum breaking load greater than 48 kg/mm2
and non-ferrous materials.
and)In butt joints when they are made without separation at the root.
F)In areas affected by ground temporary attachment welds and in welding scratches or burns on sheet metal.
g)In pipe-to-shell welds, when required in Table II, Inspection of Connection Welds, of this Specification.
h)The first and last pass of stainless steel coatings deposited by welding.
Yo)In tube-to-tube plate strength welds after the root pass with GTAW and after the rest of the passes.
Liquid penetrant examination procedures shall be performed in accordance with ASME Code V, Article 6.
Penetrant liquids must meet the requirements of ASME Code V, Article 6 for sulfide and halogen content
depending on the type of material to be examined.
Weld penetrant examination shall be carried out on the outside and, if accessible, also on the inside and shall
include a strip of base metal at least 25 mm wide on each side of the weld.
Evaluation of indications and acceptance criteria shall be as required by applicable ASME code sections and/or
standards.
3.5.7. Radiographic Testing (RT)
Radiography will have the scope indicated in the sections of the ASME code and/or applicable standards, and
must also meet the following conditions:
to)All pressure welds of carbon steel equipment shall be at least spot radiographed, and 100% of welds of
equipment made of any other material shall be radiographed (in accordance with RT1 as indicated in ASME
VIII Div 1, UG-116).
b)Any weld, whether or not under pressure, that is not visible during the hydrostatic or leak test must be 100%
radiographed in the entire section that remains hidden, except for the bottoms and roofs of tanks.
c)Pipe-to-shell welds shall be radiographed in accordance with the requirements of Table II of this Specification,
Inspection of Connection Welds.
d)In addition to the above, the X-rays must be distributed so that all welders can be controlled.
For spot radiography, unless otherwise specified in the ASME Code sections and/or applicable standards, the
provisions of paragraph UW-52 of ASME VIII Div. 1 shall be taken into account, and the points shall be selected so
that at least one is located on each circumferential bead and on each longitudinal section between two adjacent
circumferential bead, with its exact position being that designated by the Inspector. In addition, all intersections
shall be radiographed.
The minimum length of the radiographic plate for each point to be radiographed will be 400 mm.
Radiographic examination procedures shall be performed in accordance with the requirements and method
specified in ASME Section V, Article 2.
The interpretation and acceptance criteria of radiographs must be carried out in accordance with the sections of the
ASME code and/or applicable standards, except that rounded and elongated indications will only be accepted if they are
isolated and do not have a dimension greater than that allowed.
Radiographic examination should preferably be performed with X-rays, although gamma rays may be used
provided the required sensitivity is obtained.
For services at temperatures below –120 ºC and for corrosive services in which the material is stainless or nonferrous steel, the use of gamma rays must be subject to Repsol's approval. The proposal must be accompanied by
a comparative report on the results obtained by X-raying a control sample with both rays.
The film should be fine or ultra-fine grain, high contrast, Class 2 or 1 per ASTM E-94. For gamma ray inspections,
only Class 1 films should be used for P-No. 3 and higher materials.
The optical density of the processed plates, whatever the type, will be between 2 and 3 for materials of uniform
thickness, and between 1.8 and 3.5 for non-uniform thickness.
The sensitivity of the films must be verified by the “Image Quality Indicator” (IQI), according to ASTM E94 or
European Standards EN 462-1.
The sensitivity shall be 2T according to Table T-276 in ASME V Edition 2015, Article 2.
The IQI should be placed on the weld bead on the source side. When this is not possible, the IQI should be placed
on the film side together with an F symbol, the sensitivity will be equivalent to the sensitivity obtained with the IQI
on the source side.
Radiographic plates shall be properly preserved by the Manufacturer for at least five years or the time required by
applicable legislation.
Radiographs of pipes with a nominal diameter of 3” or less must be performed using the elliptical projection technique.
Two exposures separated by 90º will be required.
The following information must be marked on the X-ray plates:
-
Date
-
Work order number
-
Item Number
-
Welding number
-
Position of each plate in relation to the weld number
-
Welder's Stamp
-
The repair plates will also be marked with the RN code, where N is the natural number based on the number
of times it has been repaired and consequently X-rayed in the same area.
Marks must be outside the weld image or area to be graded.
Radiographic control of all equipment requiring heat treatment shall be carried out as indicated below:
to)In carbon steel equipment that meets the conditions indicated, it may be carried out before heat treatment,
but after the heat treatment, the weld crossings or T-intersections where the initial radiographic control
revealed acceptable anomalies that are susceptible to cracking must be radiographed again. This criterion
may not be applied if, being carbon steel, it meets one or more of the following conditions:
either
either
either
Thickness equal to or greater than 50 mm.
Low temperature services where addendum ED-C-01.03 applies,Pressure vessels. Addendum for low
temperature services.
High elastic limit or high strength steels.
b)In all other cases, it will be carried out after the heat treatment, and the treatment carried out before the heat
treatment to detect and repair possible defects will not be valid for the purposes of final acceptance of the
indications.
At the manufacturer's proposal and with prior approval from Repsol, the RT inspection may be replaced by automatic UT
inspections, complying with the requirements of the design code and the provisions of section 3.5.9 of this specification.
3.5.8. Ultrasound Examination (UT)
When ultrasonic testing is required, the requirements, including rejection limits, of ASME VIII Div. 1, Mandatory
Appendix 12 shall apply, unless sections of the ASME Code and/or applicable standards indicate otherwise more
restrictive. The manufacturer must submit the complete procedure for approval to Repsol or its representatives.
Pipe-to-shell welds shall be ultrasonically examined in accordance with the requirements of Table II of this
Specification, Inspection of Connection Welds.
When applying section 3.5.7, when there is a weld subject to pressure that cannot be radiographed, this
inspection shall be carried out by ultrasound, to the same extent as that required for radiography, and in
accordance with the requirements of the applicable code for such substitution.
The execution details shall comply with the requirements of ASME Code V, Article 5.
The frequency of the transducers must be 2 or 4 MHz and the angle must be between 45° and 70°. For
thicknesses greater than 40 mm, at least two sensors with different angles must be used.
Inspection reports shall include, at a minimum, all information specified in ASME V, Article 5, paragraph T-590.
The surface will be checked for irregularities or loose particles, paint or rust layers, etc. that cause problems or
interfere with the ultrasound transmission value.
For all forged materials such as rings, flat caps, tube sheets, TEMA flanges, shaped forgings, etc., with a thickness
equal to or greater than 50 mm, 100% ultrasonic testing according to ASME SA-388 will be required upon
purchase, with the following acceptance criteria:
to)In inspection with a straight probe, any reflective defect that, either alone or together with others, gives
indications in the same plane, with total loss of reflected echo (loss >90%) and that cannot be inscribed in a
circle of 75 mm in diameter will be rejected. The presence of isolated, smaller reflectors will also be cause for
rejection, if their separation is not greater than the length of the smallest defect and if, together, they cannot
be inscribed in the circle of 75 mm in diameter.
b)In inspection with an angular probe, parts will be rejected if defects are found that give indications of greater
amplitude than that of the notches of the calibration pattern.
In equipment requiring specific test calibration blocks, these will be delivered together with the equipment and
handed over to the Inspection of the Complex where they are installed.
3.5.9. Automatic Ultrasound Examination (AUT) using Time of Flight Diffraction (TOFD) technique
When automatic ultrasonic testing is required, the requirements of ASME VIII Div.2 Ed. 2015, section 7.5.5,
including rejection limits, shall be applied, unless the applicable code sections and/or standards indicate
otherwise more restrictive.
The manufacturer must submit the complete TOFD inspection procedure for approval by Repsol or its
representatives.
The execution details shall comply with the requirements of ASME V, Mandatory Appendix III.
The system shall be designed with sufficient overlap to ensure 100% coverage of the weld and HAZ (heat affected
zone) and shall include a fully automated recording system to indicate the location of imperfections.
The extent of the test shall cover at least the volume of the weld plus one inch on each side of the weld.
When, due to the presence of lateral and back-wall waves, no defects are detected on the internal/external
surfaces, an additional technique will be proposed to cover these areas.
Inspection procedures shall include, at a minimum, all information specified in ASME V Ed. 2015, Section III-422
and the following information:
-
Description of Inspection Equipment, including transducers, couplant and calibration blocks.
-
UT Operator Qualifications.
-
The AUT procedure will contain instructions for verifying that each weld sweep provides complete coverage of
the weld with no missed areas.
-
Description of record keeping procedures
-
Calibration interval and criteria for re-examination when calibration is performed outside specified values
Inspection reports shall include, at a minimum, all information specified in ASME V Ed. 2015, Section III-490 and
the following information:
-
Evaluation of welding quality according to acceptance criteria with quantitative description of the defects
located.
-
Inspection data in electronic format (raw data).
The surface to be inspected will be checked to ensure that it does not have irregularities, paint or rust layers, etc., that
cause problems or interfere with the transmission of ultrasound.
The material for the calibration blocks shall be of the same shape and have the same material P-number as the
materials to be inspected. The condition of the surface to be inspected shall be equivalent to the condition of the
standard calibration surface. When the material of the component to be tested has a cladding/overlay coating, the
block shall be coated by the same cladding/overlay procedure used in the manufacture of that component. In
equipment requiring specific test calibration blocks, these shall be delivered together with the equipment and
delivered to the Inspection Facility where they are installed.
3a
Level II personnel indicated in chapter 3.5.2 of this specification must demonstrate experience in the TOFD
technique.
3.6. Ferrite measurement
In all welds of austenitic stainless steels and duplex/superduplex steels and in overlays with this same steel, the
ferrite content shall be measured prior to PWHT in accordance with specification ED-B-05.00General welding
requirementsand, if applicable, addendum ED-C-01.06, Pressure vessels - Addendum for vessels with metal lining.
3.7. Inspection of welding connections
Welds of pipes to the equipment casing or connections to manifolds shall be inspected in accordance with Table
II, Inspection of Connection Welds.
3.8. Positive identification of materials and chemical analysis
All alloyed components, including those deposited by welding, shall be 100% checked by portable X-ray
fluorescence spectrometry equipment (Niton XRF or similar), or by spark emission spectrography (optical
emission). Calibration, accuracy, qualification and evaluation of results shall be in accordance with API 578,
Material Verification Program for New and Existing Alloy Piping SystemsThis check will be carried out on the
components both before they are installed in the equipment and afterwards, to ensure that there have been no
errors in the identification of the materials.
The above inspection will be carried out on small areas of the components, which will have been completely
ground to remove any surface film, scale or paint.
For all metallic coatings deposited by welding (overlay) and for welds in Cr-Mo steels, chemical analyses shall be
carried out during the qualification of the coating procedure in accordance with the specifications ED-C-01.06. The
minimum thickness of the coating portion not affected by mutual dilution phenomena between it and the base
material it covers shall be 3 mm or the corrosion allowance specified in the equipment data sheet, and the total
necessary thickness of said coating shall be determined in the approval of the welding procedure.
When active fluxes are exceptionally used in submerged arc welding, chemical verification analyses shall be
carried out for each welding procedure and each production sample, and on a weld of the equipment
representative of each procedure.
The procedures and methods of chemical analysis must comply with the criteria indicated in the quality standards
of the materials to be tested and be subject to the approval of Repsol or its representatives.
Samples for chemical analysis will be taken at the equipment points selected by the Repsol inspector or his
representative.
3.9. Hardness tests
3.9.1. Qualification of procedures
For the qualification of welding procedures, Vickers hardness tests with a load of 10 kg (HV10) are required in
accordance with ASTM E384, according to the sequence indicated in specification ED-B-05.00. Hardness tests will
also be carried out on production samples on a cross section and according to a sequence similar to the above. As
a complement to these hardness tests, a macrograph will be made indicating the locations of said test.
Hardness measurements are mandatory for all materials except austenitic stainless steels and austenitic nickel
alloys unless there are special requirements due to special services.
3.9.2. Measures in production
On all equipment where hardness measurements are required in production, five Brinnell hardness tests shall be
performed, in accordance with ASTM Standard E10, for each welding procedure, including corner and pipe welds. In
addition, when intended for H service, five Brinnell hardness tests shall be performed, in accordance with ASTM Standard
E10, for each welding procedure, including corner and pipe welds.2S wet, amines or soda, as well as any other fluid likely
to cause stress corrosion, a hardness test must be carried out on the inside every 2,000 mm of circumferential weld, in
each longitudinal weld section between two circumferential welds and in pipe welds.
3.9.3. Acceptance criteria
3a
The maximum values to be obtained during the aforementioned hardness tests are indicated in Table III,
Maximum admissible hardness values, attached to this Specification, except for the special services indicated in
specification ED-C-01.04Pressure vessels. Addendum for special services,which must meet the requirements
indicated in said specification. If any of the initial measurements are higher than said maximum values,
exhaustive hardness measurements must then be carried out along the affected weld; in this case, the
Manufacturer will send, for the approval of Repsol or its representatives, the proposal to repair the section with
excessive hardness values. In said proposal, the Manufacturer must evaluate the possibility of applying a heat
treatment, or repeating it if it has already been carried out, before deciding to remove the affected welds.
The procedures and test methods used for transportable hardness testing must comply with the criteria of ASTM
E110 and be subject to approval by Repsol or its representatives.
3.10. Impact Tests
Charpy tests will be performed when required by ASME/ASTM standards for material quality or in the applicable
Repsol Design Specifications.
When Charpy testing is required, these will be V-notched and performed according to ASTM E23.
The minimum acceptable values for the Charpy V impact test will be those required by the ASME/ASTM standard
for the quality of the material and at least the following:
-
35 J for the average of the three specimens.
-
27 J for a single test tube, the other two having to give values equal to or greater than the average of the three.
In impact tests, for thicknesses below 10 mm, subsize specimens will be used in accordance with ASTM A370.
The machine used for the resilience tests must be perfectly calibrated according to ASTM E - 23, by an
organization independent of the owner of the machine. At the request of Repsol, or its Representative, the
Supplier must present the appropriate "Calibration Certificate".
3.11. Production witnesses
A production witness shall be made for each welding procedure used for category A and B joints, in the area of
greatest thickness in addition to what is required by the design code in any of the following cases:
3a
-
Equipment with post-weld heat treatment or special services according to ED-C-01.04.
-
Equipment with low temperature service to which addendum ED-C-01.03 applies.
-
High yield strength steels.
-
PQRs over 15 years old.
Each coupon will be cut into two parts; the first will be subjected to simulated PWHT and will be tested before the
equipment PWHT and the results will be sent to Repsol or its representative for approval; the second (once the
first has been approved) will accompany the equipment during the manufacturing process receiving all the real
heat treatments given in production; it will be kept by the supplier to be tested in case the PWHT record shows
differences with respect to the simulated one such as temperature, time or cooling rates. For Cr-Mo steels, the
second part of the coupon will also be tested after the final PWHT and the results will be sent for approval.
The tests to be carried out on the production samples are those included in the approval of the welding
procedures.
3.12. Pressure tests
3.12.1.Pneumatic Test
The welds of the sleeves of the pipes of equipment with internal metallic coating, as well as those of all the
reinforcements of any equipment, will be tested pneumatically in two stages, the first at a pressure of 0.2 kg/cm2
(0.2 bar) and the second at a pressure of 1 kg/cm2(1 bar), before subjecting the equipment to heat treatment, if
required, and to the final hydrostatic test. The inspection will be carried out with a leak detection liquid. After this
test, the test hole will be left uncovered.
Pneumatic tests other than those mentioned above may only be carried out with the approval of Repsol or its
representatives. The manufacturer must obtain specific written approval in order to carry out pneumatic testing
on pressure equipment or to subject it to a combination of pneumatic and hydraulic testing.
The conditions and requirements for carrying out a pneumatic test must be specified in sufficient detail and must
be subject to the approval of Repsol or its representatives.
3.12.2.Hydraulic Test
The equipment will be subjected to official and contractual pressure tests in the Manufacturer's workshop, in
accordance with the provisions of the applicable legislation and contractual documents, in the presence of
inspectors from the Official Body and Repsol and/or their representatives, respectively. Both tests may be carried
out simultaneously.
The pressure test shall be carried out with clean fresh water. When the equipment to be tested has parts of
austenitic stainless steel, the water for the test shall have a chloride content not exceeding 50 ppm. After the test,
the equipment shall be completely drained and dried with a sponge and hot air.
A graphic record of the hydraulic test in pressure and time will be available.
The pressure increase will be carried out at a rate not exceeding 1.5 kg/cm2(1.5 bar) per minute.
A 10-minute dead time will be provided if the test pressure is greater than 50 kg/cm2(50 bar), every 30 kg/cm2(30
bar), up or down.
The pressure drop will be completely controlled and the rate will not exceed 2 kg/cm2(2 bar) per minute.
Hydraulic tests may not be carried out outdoors when the ambient temperature is below 5º C. The water
temperature for the pressure test will normally be ambient temperature, and must not be less than 10ºC or more
than 50ºC. The metal temperature during the test must be at least 17ºC higher than its MDMT.
The test pressure, determined in accordance with the applicable Repsol Code, Standard and/or Design
Specification, must be maintained for at least 1 hour for every 25 mm of total thickness, and in no case will the
maintenance time be less than 1 hour.
Circumferential and longitudinal development measurements shall be taken on the equipment before, during
and after testing to verify that no residual deformations remain.
After the pressure test is completed, the equipment will be carefully emptied and dried.
The Manufacturer shall provide all the necessary means for the pressure test in its workshop, and must supply,
together with the equipment, those that due to their characteristics or special dimensions are not in current use
or standard manufacturing.
Hydraulic testing of exchangers designed to be mounted one on top of the other will be carried out with the
exchangers mounted in this arrangement.
In exchangers with plates designed for a differential pressure, the hydraulic test of the shell and tube sides will be
carried out simultaneously, ensuring that at no time are the tube plates subjected to a pressure greater than their
design differential pressure.
During field pressure testing of large volume equipment (towers, reactors, spheres, tanks, etc.) settlement and
verticality checks will be performed.
For equipment where hydraulic testing is performed at the plant, a traceability control of the materials supplied
by the plant or by the contractor (not by the equipment seller) must be carried out.
3.12.3.Leak Detection Test
When specified by Repsol or its representatives, a leak detection test must be performed with low pressure air
and/or gas. No liquid must be applied to the internal parts of the equipment before the gas leak detection test is
performed.
In welded tube-tube plate joints, whether they are resistance or sealing, leak detection tests will be carried out as
follows:
to)For carbon steel equipment without special services, an air test will be performed applying a pressure of 1 kg/
cm2(g) (1 bar (g)) before expansion. A detergent shall be used as a leak indicator when the equipment is
subjected to test pressure.
b)For all other materials and special services, a helium leak test will be performed in accordance with ASME V,
Article 10. The shell side will be pressurized with helium while the exchanger is tilted. The acceptance criterion
will be 10-4cm3/sec.
All weld leaks must be appropriately marked for repair according to your approved repair procedure.
3.13. Interior surface cleaning and finishing
Before each inspection, test or trial, the areas affected by the application of the same must be cleaned, and the
equipment must also be cleaned inside and out once all the welding has been completed. Such cleaning must
consist, at a minimum, of removing traces of water, sludge, sand, welding splashes, electrode tips and any foreign
material or marks.
After carrying out inspections, tests and trials, any remains of the products used and any possible spark marks
and stains resulting from their performance must be removed.
If a special interior surface finish is required, this will be indicated on the equipment data sheet or in the DBD.
All stainless steel overlays and welds shall be glass blasted or pickled and passivated per ASTM A380 including
free iron control per ASTM A967 Practices D or E.
3.14. Quality dossier
With each piece of equipment to be supplied and together with the manufacturing documentation required in the
applicable Repsol specifications, the Manufacturer will deliver a quality dossier containing what is indicated
therein and also the reports and/or certificates of all inspections, tests, trials and controls carried out.
4.
REFERENCE STANDARDS AND SPECIFICATIONS
4.1. Repsol standards and technical specifications
4.1.1. Design specifications
3a
ED-B-04.00
Selection of materials for special services
ED-B-05.00
General welding requirements
ED-C-01.03
Addendum for low temperature services
ED-C-01.04
Addendum for special services
ED-C-01.05
Addendum for Cr-Mo alloy steel vessels
ED-C-01.06
Addendum for containers with metallic inner coating
4.1.2. Standard plans
PE-C-0100.02 Sheet 01
Manufacturing tolerances
4.2. Globally relevant codes and standards
ASME V
Nondestructive examination
ASME VIII.
Rules for construction of Pressure Vessels
ASME SA-388
Standard Practice for Ultrasonic Examination of Steel Forgings
Material Verification Program for New and Existing Alloy Piping Systems
API 578
Materials Material Verification Program for New and Existing Alloy Piping Systems
API 582
Welding Guidelines for the Chemical, Oil, and Gas Industries
API 934-A
Materials and Fabrication of 2 1/4Cr-1Mo, 2 1/4Cr-1Mo-1/4V, 3Cr-1Mo, and 3Cr
1Mo-1/4V Steel Heavy Wall Pressure Vessels for High-temperature, High-pressure
Hydrogen Service
API 934-C
Materials and Fabrication of 1 1/4Cr-1/2Mo Steel Heavy Wall Pressure Vessels for
High-pressure Hydrogen Service Operating at or Below 825 °F (441 °C)
ASTM A262
Standard Practices for Detecting Susceptibility to Intergranular Attack in Austenitic
Stainless Steels
ASTM A370
Standard Test Methods and Definitions for Mechanical Testing of Steel Products
ASTM A380
Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts,
Equipment, and Systems
ASTM A967
Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts
ASTM E10
Standard Test Method for Brinell Hardness of Metallic Materials
ASTM E23
Standard Test Methods for Notched Bar Impact Testing of Metallic Materials
ASTM E94
Standard Guide for Radiographic Examination
ASTM E110
Standard Test Method for Identification Hardness of Metallic Materials by Portable
hardness Tester
ASTM E384
Standard Test Method for Knoop and Vickers Hardness of Materials
EN 462-1
Non-destructive testing. Image quality of X-rays
IN 10204
Metal products. Types of inspection documents.
EN 13445
Unfired pressure vessels
ISO 9712
Non-destructive testing. Qualification and certification of personnel performing nondestructive testing.
ISO 10474
Steel and steel products. Inspection documents.
SNT-TC-1A
Personnel Qualification and Certification in Nondestructive Testing
5.
6.
INDEX OF TABLES INCLUDED IN THIS SPECIFICATION
TABLE I.
ASME BOLTS AND NUTS GRADES
TABLE II.
INSPECTION OF WELDING OF CONNECTIONS TO ENCLOSURES OR MANIFOLDS.
TABLE III.
MAXIMUM ADMISSIBLE HARDNESS VALUES
TABLE IV.
MATERIAL CERTIFICATES.
ANNEXES
ANNEX I
TABLES
ANNEX I
TABLES
TABLE I. ASME BOLTS AND NUTS GRADES
Flange material
(1) (2) (3)
Temperature of
metal ºC (20)
Carbon steels
0 ÷ 400
Carbon steels for low temperature
service ASME SA-350 (5)
- 30 ÷ 0
ASME SA-105 and SA 266 Gr 2
Unions
External
Nickel steels (2.5% and 3.5% Ni)
ASME SA-350 (5)
- 100 ÷ - 30
Nickel steels (9% Ni)
ASME SA-522 (5)
- 200 ÷ - 100
Cr-Mo alloy steels
0 ÷ 520
ASME SA-182 and SA-336 (7)
- 200 ÷ 0
(without
contact
with the
fluid of
process)
Bolt (4)
SA-193 Gr .B 7
ASME
SA- 182 and
SA-336
0 ÷ 400
0 ÷ 520
520 ÷ 600
Monel ASME SB564 N 04400 (12)
Naval brass
0 ÷ 400
0 ÷ 400
Aluminum bronze
Brass aluminum
--
Carbon steels
SA-320
(A-194 Gr.7)
SA-320 Gr. L7
SA-320
(A-194 Gr. 7) (6)
SA-453 Gr. 660
CL. A or B
SA-453 Gr. 660
CL. A or B
SA-193 Gr. B16
SA-194 Gr. 7
SA-320 Gr. B8 CL.2
SA-320
(A-194 Gr.8)
SA-193 Gr. B7
Internal
(in
contact
with the
fluid of
process)
(13)
Carbon steels for low temperature
service (5)
--
Nickel steels (up to 3 ½ Ni) (5)
--
Nickel steels (up to 9 Ni) (5)
--
Cr Mo alloy steels (7)
--
Steels
stainless steel
austenitic
Monel (12)
SA-194 Gr. 2H
SA-194 Gr. 4 (18)
SA-193 Gr.B16
SA-194 Gr. 7
SA-193 Gr. B8M Cl.2
SA-453 Gr.660 (8)
SA-194 Gr. 8M
SA-193 Gr. B7
SA-193 Gr. B7
SA-193 Gr .B 7
SA-193 Gr B7M
SA-193 Gr B8 Cl 2
(14)
Unions
SA-194 Gr. 2H
SA-194 Gr. 4 (18)
SA-320 Gr. L7
SA-453 Gr. 660 (8)
Austenitic stainless steels
Nut (4) (19)
SA-320 Gr. L7
SA-320 Gr. L7
SA-453 Gr. 660
SA-193 Gr. B5,
B6 and B16 (15)
SA-194 Gr. 2H
SA-194 Gr. 4 (18)
SA-194 Gr. 2H
SA-194 Gr. 4 (18)
SA-194 Gr. 2H
SA-194 Gr 2HM
SA-194 Gr-8
SA-194 Gr. 4 (18)
(14)
SA-320
(A-194 Gr.7)
SA-320
(A-194Gr.7) (6)
SA-453 Gr. 660
SA-194 Gr. 3,
6 and 7 (15)
Tp 304
--
SA-320 Gr. 8 CL.2 (8)
Tp 316 L / 317L
Tp 321 / 347
---
SA-193 Gr. B8M (21)
SA-320
(A-194 Gr.8)
SA-194 Gr. 8M
SA-193 Gr.B8T and B8C
SA-194 Gr. 8T and 8C
Tp 304 H
---
SA-320 Gr. B8 CL.2
SA-453 Gr. 660 (8)
SF –468 N04400 (17)
SA-194 Gr. 8M
SF –467 N04400
(17)
TABLE I NOTES
1. In those cases where there may be a possibility of galvanic corrosion problems and/or significant differential
thermal expansion between the materials indicated in this table for the flanges and bolts/nuts, the material of
the bolts and nuts selected to eliminate such problems must be proposed to Repsol for approval.
2. For flange materials not included in this table, the material of the bolts and nuts will be subject to Repsol's
approval in each specific case. However, in flanged joints of cast materials or materials according to ASTM
standards, the quality of bolts and nuts will be the ones that correspond to the generic quality of the flanges
in the tables, without taking into account the ASME specification indicated for them.
3. For dissimilar flange materials, bolts and nuts of a quality corresponding to the least alloyed flange material
shall be used, after checking the tightness under service and design conditions.
4. Threading shall be performed in accordance with ANSI B1.1 Class 2A for bolts and Class 2B for nuts.
Use COARSE THREAD SERIES for diameters of 1” and smaller, 8 thread series for diameters between 1 1/8” and
3.5”, and 4-N thread series for diameters equal to or greater than 3.5”.
5. See the grades of low temperature steels normally used in ED-C-01.03
6. With additional requirement S.3.
7. See also ED-C-01.05Addendum for Cr-Mo Alloy Steels.
8. For bolts larger than 1 1/2”, ASME SA-453 Gr 660 Class A or B quality will be used.
9. Deleted
10. Deleted
11. Deleted
12. See also ED-C-01.04.
13. The screws will have a corrosion resistance comparable to that of the material inside the housing.
14. The last two materials will be applied in wet H2S service.
15. Use the grade that corresponds to the nominal composition of the following flange material:
Bolt/Nut
Up to 1 ¼ Cr ½ Mo:
B 16 / 7
Up to 5 Cr ½ Mo:
B5/3
Up to 9Cr 1 Mo:
B6/6
16. Deleted
17. It must be verified that the resistant section of this bolt material is sufficient for the service conditions.
Otherwise, study and propose to Repsol for approval the quality SF – 468 N05500 for bolts and SF – 467
N05500 for nuts.
18. SA-194 Gr. 4 quality nuts will be used in any of the following cases: flanges larger than DN
600, flanges with a thickness greater than 125 mm or bolts with a diameter of M45 or greater.
19. For the cases mentioned in note #18 and when the bolt material is other than SA-193 Gr. B7 the difference in
hardness between the bolt and the nut will be at least 50 HBW.
20. Understanding the metal temperature as the temperature of the bolt, in the absence of calculation this will be
taken as 80% of the fluid temperature if the flange is not insulated, and 100% of the fluid temperature if the
flange is thermally insulated.
21. Mo content > 2.5%. If the above is not possible, use A193 B8 MLCuN
TABLE II. INSPECTION OF WELDING OF CONNECTIONS TO ENCLOSURES OR MANIFOLDS
Equipment X-ray level (4)
Type of joint
(1)
By Points
100%
Full throttle
10% RT (2) + 10% MT (3)
100% RT (2) + 100% MT(3)
penetration
complete (5)
10% UT + 10% MT (3)
100% UT + 100%MT (3)
A fillet
10% MT (3)
100% MT (3)
At angle to
TABLE II NOTES:
1. Category D according to ASME VIII Div. 1 UW-3
2. The X-ray can be replaced by recordable ultrasound, AUT, in accordance with the provisions of section
3.5.9 and after approval by Repsol
3. Magnetic particles can be replaced by penetrating liquids in non-ferromagnetic materials.
4. In equipment with PWHT, the tests will be carried out before and after this.
5. In connections with reinforcement, the sequence will be: welding of the connection to the envelope, NDT according to the
table, welding of the reinforcement, PWHT (if applicable), NDT according to the table to the full penetration weld, MT to the fillet
weld of the reinforcement to the envelope and pneumatic test.
TABLE III. MAXIMUM ADMISSIBLE HARDNESS VALUES
Essay of
hardness
(1) (4)
About test tube (2)
HV 10 hardness
About equipment.
HB hardness
Steel Type (5) (6)
Location
from the area to
test
Base metal
ZAT (3)
Welding
Steel
carbon
Cr - Mo
Cr < 2%
Duplex
3.5% Ni
Cr > 2%
22%Cr
25%Cr
330
350
330
300
225
260
225
API 934-C
API 934-A
240
290
330
290
215
API 934-C
API 934-A
230
290
Base metal
ZAT (3)
Welding
TABLE III NOTES:
1. The difference between hardness of adjacent areas may not exceed 50 units.
2. Test specimen from the welded plates for procedure qualification, or from the production witness.
3. ZAT: Thermally affected zone.
4. For special services covered by specifications ED-B-04.00, ED-C-01.04 and for low temperature services covered by EDC-01.03, the maximum hardness values at any location will be those required in said specification and not those
indicated here.
5. For other materials follow the values suggested by API 582
6. Hardness measurement is not required on stainless steel.
3a TABLE IV. MATERIAL CERTIFICATES
P-No.
ASME IX
Inspection Certificates according to ISO 10474 / EN-10204
Properties
Metal Base
Chemical Analysis of
Mechanics of
(Chemical Properties and
Consumables
Consumables.
Mechanics)
P-No. 1 with
MDMT ≥ -46ºC
2.2(3)
2.2
3.1
Design temperature < 300 ºC
P-No. 1 with
MDMT<-46ºC
o Design temperature > 300
2.2(3)
2.2 +
screening test
3.1 (2)
ºC o > 50 mm thickness
P-No. 2, 3, 4 and 5
No. P8 (1)
No. P8 MDMT < -80ºC (1)
Duplex/Superduplex or other PNos.
2.2(3)
2.2(3)
3.1 (2)
2.2(3) with ferrite
2.2
3.1
2.2(3) with ferrite
2.2(3)
3.1 (2)
2.2(3) with ferrite (if
applicable)
2.2 +
screening test
3.1 (2)
TABLE IV NOTES:
1. For equipment with PWHT, stainless steel material will be requested with intergranular corrosion testing according to ASTM
A262 practice E.
3a
2. Tests for certificates 3.2, if required, must be requested from the DBD. They must be witnessed by a third party
(sampling and testing).
3a
3. Consumable material must be supplied by suppliers approved by Repsol.