T/PM/Q/10

MANAGEMENT PROCEDURE FOR

THE SAMPLING AND TESTING OF STEEL PIPE AND

FITTING MATERIALS USED IN GAS PIPELINES AND
PIPEWORK DESIGNED TO OPERATE AT PRESSURES
ABOVE 2 BAR.

April 2013
J964 (Rev 04/13)
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CONTENTS

Page

FOREWORD ii

BRIEF HISTORY ii

DISCLAIMER ii

MANDATORY AND NON-MANDATORY REQUIREMENTS iii

1. INTRODUCTION 1

2. REFERENCES 2

3. DEFINITIONS 2

4. PROCEDURE 2

5. MATERIALS 2

6. FACTORS AFFECTING SAFETY 2

7. REMOVAL OF COATING 3

8. CLEANING AND VISUAL EXAMINATION 3

9. MATERIAL EXAMINATION (EXPOSED AREAS) 4

10. MATERIAL EXAMINATION (STRESS CORROSION CRACKING) 4

11. HARDNESS SURVEY 4

12. REMOVAL OF MATERIAL FOR SAMPLING 4

13. REINSTATEMENT OF THE COATING AFTER SAMPLE REMOVAL 5

14. RECORDS 5

END NOTE 14

APPENDICES

A REFERENCES 6

B PROCEDURE FOR MATERIAL SAMPLING 7

C PROCEDURE FOR MATERIAL TESTING 10

D MATERIAL SAMPLE AND SITE INSPECTION REPORT 13

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FOREWORD

This Management Procedure was approved by the Gas Transmission Policy Manager and the Gas
Distribution Policy Manager in April 2013 for use by managers, engineers and supervisors throughout
National Grid Gas.

National Grid documents are revised, when necessary, by the issue of new editions. Users should ensure
that they are in possession of the latest edition by referring to the Gas Documents Library available on
infonetUK (company intranet.)

Compliance with this Document does not confer immunity from prosecution for breach of statutory or
other legal obligations.

BRIEF HISTORY
First issued as T/PM/Q/10 August 2006 EPSG/T06/1757
Revision of T/PM/Q/10 April 2013

KEY CHANGES (Identify the changes from the previous version of this document)
Section Amendments

General Title revised to add ‘testing’, general re-wording of clauses as required,

Appendix A references updated and T/PM/P/20 introduced. Nominated system
user addresses clarified.
1.2 Scope De-commisioned or redundant pipe or fittings added and re-wording of clause
1.2.2 to 1.2.5 inclusive (note now 1.2.5 removed).
5.0 Expanded background detail provided on network materials, addition of L555
grade materials and the provision of resources by the Project Manager.
6.2.1 Five year validity period for Q/10 Tech. and supervision for new Q/10 Tech’s.
7.1 The Project Engineer responsible for identifying location(s) for material
sampling.
8.4 / 11 Preparation of sample area for hardness testing moved from clause 11 and
minimum number of hardness impressions increased in clause 11.
12.1.1 Potential for cross contamination of samples highlighted.
12.5 The need for a final MPI of sampled area added.
Appendix B Includes a planning checklist. Method statement and procedure re-organised.
Appendix C Now gives greater detail for testing depending on reason for tests.
Appendix D Updated sampling and site inspection report sheet.

DISCLAIMER
This document is provided for use by National Grid and such of its contractors as are obliged by the terms
and conditions of their contracts to comply with this document. Where this document is used by any other
party it is the responsibility of that party to ensure that this document is correctly applied.

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MANDATORY AND NON-MANDATORY REQUIREMENTS

In this document:

shall: indicates a mandatory requirement.

should: indicates best practice and is the preferred option. If an alternative method is used then a
suitable and sufficient risk assessment shall be completed to show that the alternative method delivers
the same, or better, level of protection

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MANAGEMENT PROCEDURE FOR

THE SAMPLING AND TESTING OF STEEL PIPE AND
FITTINGS MATERIALS USED IN GAS PIPELINES AND
PIPEWORK DESIGNED TO OPERATE AT PRESSURES
ABOVE 2 BAR.

1. INTRODUCTION
This management procedure describes National Grid’s requirements for the sampling and subsequent
analysis of steel pipe and fittings (e.g. tee’s, bends, reducers and flanges), to establish their chemical
composition and material properties where this can not be determined from information provided by the
original material certification or through previous sampling of the material recorded on the UKOPA Fault
Database.

This management procedure shall apply to carbon steel pipelines and pipe work operating at pressures of
2 bar and above

The need to identify the grade of a material could be to support requirements for stress analysis or
qualification of a welding procedure.

1.2 Scope
1.2.1 This procedure describes three methods approved by National Grid to determine the carbon
equivalent value (CEV) and to estimate or establish the material strength and grade of a steel pipe or
fitting by the removal of a sample of the material:

i. The removal of fine cuttings of the material which are subjected to chemical analysis in
conjunction with a hardness survey of the parent pipe..

ii. The cutting out of a pipe coupon (typically by a “Hot-Tap” drilling procedure) for chemical
analysis and destructive testing

iii. The sampling or testing of de-commissioned or redundant pipe or fittings for material
validation or information purposes.

1.2.2 The preferred options are to use methods (ii) or (iii) as this permits a wider range of destructive
testing techniques to be used to objectively establish the material grade and other properties. However,
for in-service pipe work, when the original pipe or fitting material certificates are not available it will be
necessary to undertake method (i) to establish the CEV and validate the proposed welding procedure
before hot-tap welding and any subsequent retrieval of the test coupon made by under-pressure drilling.

The sampling of steel material using method (i) provides limited information. The chemical analysis test
will establish the CEV, while the measured material hardness and knowledge of the level of individual
chemical elements will allow an estimate of the material condition and grade to be made.

1.2.3 When using method (i) estimation of the grade of material from the chemical analysis shall only
be undertaken by an experienced Metallurgist. The data obtained from the chemical analysis, together
with the information to be found in material specifications, gives an excellent guide to material weldability
and a reasonable guide to the material grade, but extra care should be taken in critical applications in the
interpretation of the results.

1.2.4 The suitability of portable optical spectrometers for conducting on-site chemical analysis of pipe
and fittings have previously been reviewed by National Grid and found to be unsatisfactory. No such
devices shall be used without the prior approval of National Grid.

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2. REFERENCES
2.1 This Management Procedure makes references to the documents listed in Appendix A. Unless
otherwise specified, the latest edition of the documents, including all amendments shall apply.

3. DEFINITIONS
3.1 There are no specific definition requirements applying to this Management Procedure.

4. PROCEDURES
The detailed procedures to be adopted for material sampling and testing are given in Appendix B and C.

5. MATERIALS
5.1 Since the mid-1960’s the existing National Grid gas network has been constructed and
modified using a wide variety of pipe and fitting materials of different source, vintage and specification.

There are areas within the gas networks that will contain pipe or fittings that exhibit high CEV
compositions. Where the original material certificate is not available, the CEV of a pipe or fitting can be
established by material sampling.

In some cases older pipelines may have low toughness characteristics. Both UKT and UKD maintain a
record of transmission and distribution pipelines that have known low toughness characteristics. For
guidance on a particular pipeline it is recommended that National Grid be consulted via the contacts given
in clause 14.

5.2 Pipe supplied from the early 1970’s onwards will normally have carbon equivalent values in the
region of 0.42% or below. The newer X80 or L555 grade pipelines will have a typical CEV of around
0.44% and L555 grade induction bends a CEV of around 0.48% (material records will be available for
such pipelines). The CEV shall be calculated using the following formula:

CEV (iiw) = %C + %Mn + ( %Cr+ %Mo + %V) + (%Ni + %Cu)

6 5 15
5.3 Fittings will usually have a carbon equivalent higher than that of pipe and extra precautions (e.g
higher preheat temperature) are required when welding them.

5.4 For those pipelines where the pipe material certificate is not available and initial sampling has
been carried out to determine the CEV% and to estimate the material grade and when the pipe coupons
are not being re-used for pigging purposes, the pipe coupon will be required for analysis and mechanical
testing.

5.5 The Project Manager or Engineer responsible for the works shall ensure that resources are
made available to carry out the required material tests, that the results of the tests are recorded (see
Appendix C and D) and that appropriate arrangements are made for record archival (see T/PL/RE/1).

6. FACTORS AFFECTING SAFETY

6.1 General
6.1.1 All personnel involved in works defined by this procedure shall be required to demonstrate
competency in their assigned role.

6.1.2 This removal of steel material from an in-service pipeline or pipe work is considered to be a
non-routine operation (NRO – GDN/PM/SCO/4 and /or T/PM/SCO/94) and requires a specific procedure
and a permit to work to be approved and issued prior to the operation commencing (if operating on live
pipework the permit to work needs to cover hot works). A T/PM/Q/10 method statement and site specific
risk assessment shall be prepared / carried out and be approved by National Grid before any material
sampling begins.

6.1.3 The Authorising Engineer shall ensure that all the necessary measures to ensure a safe
operation have been taken prior to the commencement of these procedures.

All personnel shall fully understand what to do in the event of an incident occurring.

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6.1.4 The atmosphere in the vicinity of sampling operations shall be continuously monitored using
approved gas monitoring equipment to detect the presence of an explosive atmosphere or an
atmosphere that could cause asphyxiation. The atmosphere readings taken shall be recorded on the
Record of Atmosphere Test Form found in T/PR/TR/46. If such an atmosphere is detected material
sampling operations shall cease immediately until the cause is investigated and appropriate action taken.

6.2 Q/10 Technician Qualification

6.2.1 Q/10 Technicians who perform the removal of steel material for sampling purposes shall
demonstrate knowledge of this procedure and their competency in the application of the sampling
procedure using the specified tools and equipment.

The Q/10 Technician shall be assessed through the National Grid scheme for On-Site Material Testing
and if successful will be registered on the competent person database as a National Grid Q/10 Technician
for a period of five years from the date of test. Continuing competency shall be demonstrated by re-
assessment of the Q/10 Technician at the end of the validity period.

Before commencing work personnel who lack experience of working on pressurised gas pipe work or who
will implement this procedure for the first time shall be made aware of the potential risks and hazards that
could arise during this type of activity. It shall be the responsibility of a newly qualified Q/10 Technician’s
employer to provide supervision of their operative during their first material sampling operation to confirm
that the Q/10 Technician is confident in applying this procedure.

In order to demonstrate and confirm material sampling experience using this procedure the qualified Q/10
Technician may want to maintain a log of past experience detailing projects on which they have worked.

6.2.2 Personnel required to perform dressing repairs or to assess damage found during inspection
shall be qualified under the National Grid Scheme for P/11 Technician assessment.

6.3 Inspector Qualification

All non-destructive testing (NDT) personnel shall be qualified to the appropriate grade in the
BGAS/CSWIP inspector approval scheme. The Project Manager may consider the use of NDT personnel
approved to an alternative scheme as a variation to this procedure. The Project Manager shall take
guidance from the Asset Integrity Manager / Capital Delivery Inspection Team Manager with regard to
acceptable alternative approval schemes.
7. REMOVAL OF COATING
7.1 The location(s) to be sampled shall be identified by the Project Engineer and recorded on the
relevant asset drawing.

7.2 Paint or pipe coatings shall be removed from the pipe or fitting in the area to be sampled carefully
and in a safe manner. The tools and the method used shall not cause damage to the pipe or fitting
material. For example, when a hammer is used to remove coal tar enamel coatings the hammer shall
2
have a non-sparking head (e.g. copper). The area to be removed shall be equivalent to 90,000 mm (on
larger diameter pipe this equates to an area approximately 300 mm x 300 mm) and should be selected
within the top quadrant of the pipe and above the horizontal axis The area to be sampled shall be a
minimum of 50 mm from any adjacent girth, seam or attachment weld.

7.3 Coatings shall be removed using methods defined in Table 8 of T/SP/CW/5. National Grid
NGUK/PR/80 ICE sheets provide safety precautions required for the removal of existing pipe coatings
(see ICE Sheets 010, 010a and 031). Coating waste shall be disposed of in accordance with
NGUK/PM/SHE/200 and NGUK/PR/SHE/77. If any doubt exists then expert advice shall be sought.

NOTE: Certain coatings will melt and emit toxic/carcinogenic fumes when subjected to flame heating. An
assessment of potential health risks when removing coatings shall be carried out as part of the site
specific risk assessment.

8. CLEANING, SURFACE PREPARATION AND VISUAL EXAMINATION

8.1 The area of exposed material shall be thoroughly cleaned in accordance with T/SP/CW/5, to
facilitate visual inspection and non-destructive testing.

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8.2 The cleaned area shall be visually inspected to determine the presence and location of any
pipe defects (e.g. those defined under T/PM/P/11or T/PM/P/20) and seam welds. If damage is identified
work shall cease and it shall immediately be brought to the attention of the Project Engineer. If necessary,
the area to be sampled shall be relocated to avoid these features.

8.3 Prepare the pipe surface for sampling by careful sanding to bright metal finish using a hand-
held 110 V disc sander (angle grinder with sanding disc attachment) over an area equivalent to 62,500
2
mm ( for larger diameter pipes this equated to an area approximately 250 mm x 250mm). The aim shall
be to remove all surface scale, oxides and contaminants to leave a clean smooth surface. Aluminium
oxide or other appropriate sanding discs with a grade 60 grit finish is considered suitable on uniform pipe
surfaces. However in some cases other grades of sanding disc (e.g. 80 or 120 grit finish) may also be
used to provide a smoother surface profile if required.
2
8.4 A small area of the prepared surface equivalent to 900mm (approximately 30mm x 30mm)
shall be polished by hand or mechanical means to a 500 or 600 grit finish suitable for hardness testing
using a ultrasonic contact impedance type hardness tester.

9. MATERIAL EXAMINATION (EXPOSED AREA)

9.1 The cleaned area shall be subject to 100% ultrasonic examination and magnetic particle flaw
detection (MPI). This is to ensure freedom from laminations, which may prejudice the procedure, to
confirm the wall thickness of the pipe before sampling and to inspect for evidence of surface breaking
defects or stress corrosion cracking. The area to be sampled shall have a minimum wall thickness of
5mm, unless additional safety precautions necessary to sample thinner pipes have been approved in
writing by the Project Engineer.

9.2 Ultrasonic testing for the presence of laminations in pipe with a wall thickness ≥ 4.0mm shall be
in accordance with BS EN 10160.

9.3 Any lamination shall be considered unacceptable and shall be brought to the attention of the
Project Engineer prior to the procedure being continued. Any alternative location for sampling shall be
identified by the Project Engineer and recorded on the asset drawings.

9.4 MPI shall be conducted as described in BS EN ISO 9934 Parts 1, 2 and 3.

10. MATERIAL EXAMINATION (STRESS CORROSION CRACKING)

National Grid pipelines do not have a history of external stress corrosion cracking, however for
information purposes, it is required that the exposed pipe surface be examined by MPI methods. Any
stress corrosion cracking found (external surface of the pipe or the internal surface of coupon), shall be
brought to the attention of the Authorising Engineer immediately (further guidance can be found in
National Grid procedure T/PM/P/11,T/PM/P/20 and T/PM/FAULT/2). A report shall be required in all
cases of the test results (positive or negative).

11. HARDNESS SURVEY

Hardness testing shall be carried out on the prepared area (see 8.4). A minimum of ten hardness
impressions shall be made on the polished area using a calibrated Krautkramer ‘Microdur’ or GE MIC 10
portable hardness tester. Other types of hardness tester shall not be used without the approval of
National Grid.

Note: Rebound hardness testers such as the ‘Equotip’ are not suitable for testing pipe wall thickness of
the range normally found in gas distribution and transmission pipelines.

The hardness measurements taken and the average value obtained shall be recorded in Appendix D.

12. REMOVAL OF MATERIAL FOR SAMPLING

12.1 Remove fine cuttings from the pipe surface using a rotary tungsten carbide burr (Single Cut –
Round Tree Shape) in a hand-held high-speed die grinder (the carbide burr shall be clean and sharp and
uncontaminated). Keep the tool in constant motion so that an even thickness of metal of minimum depth
is removed over the prepared area, the maximum depth of metal removed shall not exceed 0.5mm.

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Prevent the formation of sharp ridges and ensure that the cuttings removed will sample the full area
prepared for material chemical analysis.

12.1.1 The Contractors method statement (see Appendix B) shall detail the procedure required to
prevent potential cross contamination between samples when a carbide burr is used to remove cuttings
from different components. Where decontamination cannot be guaranteed it is recommended that a new
clean carbide burr is used for each sample.

12.2 The use of a wheeled grinder or hand file is not permitted for this section of the procedure as
the size of cuttings will be too fine and contamination of the sample could occur.

12.3 The cuttings shall be collected so as to avoid contamination with other materials (e.g. backfill,
soil, coatings). Suitable ways of achieving this include attracting the cuttings onto a clean paper or card
placed in front of a magnet, or taping a clean, opened, polythene bag or plastic container adjacent to the
cutting area to catch the cuttings.

12.4 Once cuttings have been removed (usually 5 grams of material) they shall be transferred to a
clean sample bag and identified with the pipe details, sample location etc.

12.5 The wall thickness of the pipe shall be measured ultrasonically after sampling to confirm
adequate wall thickness for future operation, followed by a final MPI examination. The results of these
tests shall be reported to the Project Engineer and recorded in Appendix D.

13. REINSTATEMENT OF THE COATING AFTER SAMPLE REMOVAL

The pipeline protective coating shall be reinstated using an approved coating system to T/SP/PA/10 or
T/SP/CW/5 after the pipe has been sampled.

14. RECORDS.
A copy of the completed MATERIAL SAMPLE AND SITE INSPECTION REPORT provided in APPENDIX
D and any revised drawings shall be sent by the Project Engineer to the appropriate nominated system
user in order to update the pipeline records.

UK Transmission records shall be sent to: UK Distribution records shall be sent to:
GNI Integrity Manager Integrity & Engineering Manager
Asset Management Network Strategy
National Grid National Grid – Gas Distribution
National Grid House Brick Kiln Street
Warwick Technology Park Hinckley
Gallows Hill Leicestershire
Warwick LE10 0NA
Warwickshire
CV34 6DA

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APPENDIX A
REFERENCES
A.1 European And British Standards
BS EN 10208-2: Parts 1 & 2 Steel Pipes for pipelines for Combustible Fluids – Technical Delivery
Conditions

BS EN ISO 6892-1: Part 1. Metallic Materials – Tensile Testing Part 1: Method of Test at Ambient
Temperature

BS EN ISO 148 -1: Part 1. Metallic Material – Charpy Pendulum Impact Test Part 1:Test method

BS EN 10160: Ultrasonic Testing of Steel Flat Product of Thickness equal or greater

than 6 mm (Reflection Method).

BS EN ISO 9934-1: Non- Destructive Testing Magnetic Particle Testing Part 1: General
Principles

BS EN ISO 9934-2: Non- Destructive Testing Magnetic Particle Testing Part 2: Detection
Media

BS EN ISO 9934-3: Non- Destructive Testing Magnetic Particle Testing Part 3: Equipment

ISO 2566-1 Steel – Conversion of Elongation Values – Part 1. Carbon and Low Alloy
Steels

BS EN ISO 377 Steel and steel products–Location of Samples and Test Pieces for
Mechanical Testing

A.3 Industry Standards

HSG 47:2000 Avoiding Danger from Underground Services

HSG 185:1999 Health and Safety in Excavations

A.4 National Grid Documents

GDN/PM/SCO/4 Management Procedure For the Safe Control of Operations – The Control of Non
Routine Gas Supply operations
T/PM/SCO/94 Management Procedure for the Preparation, Issuing and Control of Non-Routine
Operations at Gas Transmission and LNG Storage Sites
T/PL/RE/1 Policy for the Capture, Update, and Retention of Engineering Asset Records

T/PM/P/11 Management Procedure For Inspection, Assessment And Repair Of Damaged (Non-
Leaking) Steel Pipelines Designed To Operate At Pressures Greater Than 2 bar

T/PM/P/20 Management Procedure for Inspection, Assessment and Repair of Damaged (Non
Leaking) Steel Pipelines and Pipework up to 150mm Nominal Diameter designed to
operate at pressures greater than 2 bar

T/PR/P/18 Work Procedure For Working On Pipelines Containing Defective Girth Welds Or Girth
Welds Of Unknown Quality

T/PM/SSW/2 Management Procedure For Safe Working and Development in The Vicinity Of National
Grid Gas Pipelines And Associated Installations – Requirements For National Grid Gas

T/SP/SSW/22 Specification For Safe Working In The Vicinity Of High Pressure Gas Pipelines And
Associated Installations - Requirements For Third Parties

T/SP/PA/10 Technical specification for new and maintenance painting at works and site for above
ground pipeline and plant installations.

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T/SP/CW/5 Specification for Field Applied External Coatings for Buried Pipework and Systems

T/PL/FAULT/2 Policy for the reporting and analysis of faults on Gas Transmission, Gas Distribution and
Gas supply Metering Assets

T/PR/TR/46 Work Procedure for Atmosphere Monitoring

TS-C4Gas-PIP0 v 7.5 Specification for steel pipes for pipelines Common Requirements

TS-C4Gas-PIP4 v 1.2 Specification for steel pipes for pipelines National Grid Specific Requirements

NGUK/PR/SHE/77 Environmental Guide No.1 – Management of Fixed Sites

NGUK/PR/SHE/80 Hazards, precautions and ICE sheets

NGUK/PM/SHE/200 Waste Management

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APPENDIX B
PROCEDURE FOR MATERIAL SAMPLING
B1 Planning
B1.1 General
The Procedure for material sampling shall be planned to provide safe working conditions for the
removal of the pipe or fitting material. Work shall only proceed when all authorisation and
permits are approved and issued by National Grid. The following checklist shall be used by the
Project Engineer to ensure that all necessary precautions and requirements are in place before
work proceeds.

T/PM/Q/10 Appendix B Table B.1 Planning Checklist

Item Responsibility Requirement Done

B.1 Project Identify the location from which the sample is to be taken
Engineer (e.g. marked up general arrangement drawing or
pipe/fitting).
B.2 Project Consider the need for a T/SP/P/18 Assessment of any
Engineer welds near the location.
B.3 Project Check that Q/10 Technician and the Inspection personnel
Engineer have the required approvals and that they are valid and in
date.
B.4 Q/10 Check inspection equipment calibration is in date and
Technician electrical equipment has current PAT certification.
B.5 Project
Ensure that an NRO, permit to work and all authorisations to
Manager /
proceed and are in place and signed off.
Engineer
B.6 Project Ensure conditions of the permits and risk assessments are .
Engineer & in place. Check that an inexperienced Q/10 Technician will
Q/10 be supervised (see clause 6.2.1)
Technicians
B.7 Project Check the Competent Person has the required Safe Control
Manager of Operations Authorisation.
B.8 Competent Check that at least one of the personnel on site shall have
Person the appropriate SCO training / approval (Hot Work Permit),
and shall remain on site at all times whilst the works are in
progress.

B.9 Project All personnel shall have attended a Site Safety Induction
Engineer course and be aware of the requirements of the risk
assessment and method statement.
B.10 Project Where the sample is to be taken from a buried component,
Engineer excavate sufficient area to obtain safe access/egress to and
from the location in accordance with the requirements of
HSG 47 & 185 and the method statement.
B.11 Project Excavations in close proximity to a HP Pipeline shall be
Engineer conducted in accordance with the requirements of
T/PM/SSW/2 & T/SP/SSW/22.
B.12 Project In the event that damage to the pipe or fitting is reported the
Engineer Project Engineer shall initiate the appropriate T/PM/P/11 or
T/PM/P/20 procedures.
Signature: Date:

Note: Specific project circumstances may dictate that the above items may have to be
supplemented with further requirements. In such cases they shall be identified and authorised
by the National Grid Project Engineer or Project Manager as applicable.

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B2 Method Statement for the removal of pipe or fitting material samples

B2.1 Where the material sample is to be taken from above ground pipe work that requires the use of
staging or scaffolding or the work will be carried out below ground, the working platform, pit or
excavation shall comply with the relevant National Grid safety procedures appropriate for
working at heights, in excavations or in a confined space. All safety precautions necessary shall
be identified in the method statement and be in place before a permit to work is issued to the
Competent Person.

B2.2 Dry, wind free conditions are required to permit the inspection, preparation and removal of
material without contamination of the samples. A suitable canopy shall be made available for
this purpose.

B2.3 Before and after the removal of protective pipe or fitting coatings the item shall be visually
inspected in accordance with clause 8.2 to identify any possible damage.

B2.4 Protective coatings shall be removed in accordance with clause 7 and 8.

B2.5 The method for decontamination of the rotary burr between samples shall be identified in the
contractor’s method statement (see 12.1.1).

B3 Procedure for the removal and assessment of pipe or fitting material samples

B3.1 Mechanically clean the pipe or fitting surface to bright metal finish in accordance with clause
8.3 and 8.4.

B3.2 Conduct an ultrasonic lamination check, MPI survey and wall thickness measurement in
accordance with T/PM/P/11 or T/PM/P/20.

B3.3 The area under inspection shall be checked for the presence of Stress Corrosion Cracking
(SCC) and if suspected or found, work shall cease and this shall be reported to the National
Grid Project Engineer (see 8.2).

B3.4 Following non-destructive testing clean and decontaminate the material surface thoroughly, in
accordance with clause 8.

B3.5 Carry out and record the hardness survey in accordance with clause 11.

B3.6 Ensure that the high speed, tungsten carbide rotary burr is free of ANY contamination e.g.
swarf, dirt, oil or grease (see 12.1.1. and B2.5).

B3.7 Take samples in accordance with Clause 12.3, until a minimum of 5 grams per sample have
been removed and collected into a clean receptor. The registered Q/10 Technician shall ensure
that the maximum depth of metal removed does not exceed 0.5mm.

B3.8 Avoid leaving sharp edges within or on the edge of the sample area, if present any sharp edges
shall be removed by blending to a smooth finish by the registered Q10 Technician.

B3.9 Seal the receptor and label with the site, location and a unique identifier in accordance with
clause 12.4.

B3.10 Carry out a final MPI of the area and measure the wall thickness, recording the minimum wall
thickness in the area sampled. The results of these tests shall be recorded in Appendix D.

B3.11 Repair the coating in accordance with T/SP/PA/10 or T/SP/CW/5.

B3.12 Return the permit to the issuing authority for sign off.

B3.13 Forward the sample to an approved test laboratory for full chemical analysis and testing as
appropriate.

B3.14 On receipt of the Laboratory report, issue the report to a qualified Metallurgist or Welding
Engineer for assessment of the sample test results and recommendations.

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B3.15 Complete the site inspection reports and forward a copy to the Project Manager or Project
Engineer.

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APPENDIX C
PROCEDURE FOR MATERIAL TESTING
C.1 GENERAL

C.1.1 The analysis of pipe or fitting material removed during pipeline or pipe work repair or
modification may be needed to establish the properties of a material or to confirm or
supplement existing National Grid records. This procedure details the minimum testing
requirements for steel pipe coupons retrieved during hot-tap drilling operations and pipe or
fittings that have been in-service above or below ground.

C.1.2 A chemical analysis survey shall be carried out in each case. The mechanical testing of *pipe
material shall in general be conducted in accordance with the requirements of BS EN 10208-
2,and fitting materials to a specification appropriate to the fitting type e.g. T/SP/F/1 or
T/SP/B/12. The extent, type and number of mechanical specimens to be tested shall be agreed
with National Grid prior to testing. As a minimum testing shall include the following:

o Chemical analysis

o Tensile test

o Charpy Impact tests

o Hardness test

Depending upon the nature and reason for the investigation of the material properties, other
specific types of destructive tests may be required by National Grid. In such cases the type of
specimen, method of test and test requirements will be agreed with National Grid prior to any
testing being carried out.

* Due cognisance of the additional requirements specified in TS-C4Gas-PIP0 v 7.5 and TS-
C4Gas-PIP4 v 1.2 shall be made when testing is carried out in accordance with BS EN 10208-
2.

C.2. HOT TAP COUPON

C.2.1 The level of accuracy achieved in the assessment of material strength and grade by this
sampling process will be enhanced by the number of specimens tested.

The size of the pipe coupon retrieved will determine the extent, type and size of specimens that
can be extracted for destructive testing. A coupon diameter of 180mm or greater is preferred
however, smaller coupon sizes may be used. It should be recognised that in such cases the
use of non- proportional test pieces could mean a reduced level of confidence in the test results
being achieved. Where possible the largest specimen size of each type that can be cut from
the coupon shall be tested.

C.2.2 Where the coupon contains a section of pipe seam weld any additional testing requirements for
the weld or heat affected zones shall be agreed with National Grid.

C.2. 3 The mechanical and chemical properties determined by the testing of the coupon shall be
recorded and shall be sent to the appropriate nominated system user (see clause 14 and
Appendix D) for inclusion in the National Grid Fault Database.

C.3 PIPE OR FITTING SAMPLE

C.3.1 When testing pipe and/or fittings to provide information a sufficient number of samples shall be
taken to account for variations in material type and properties.

Where a section of pipe or a fitting is removed for analysis the extent of testing shall be agreed
with National Grid before destructive tests are carried out. The type and number of tests will
depend upon the reason for the material analysis.

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C4 DESTRUCTIVE TESTING

C.4.1 Specimen preparation

The specimens shall be removed and prepared in accordance with BS EN ISO 377 or to a relevant
standard specified for the type of test.

C.4.1.1 Tensile Test Pieces

Proportional test pieces shall be used wherever possible. Rectangular test pieces that represent the full
wall thickness of the pipe shall be taken in accordance with BS EN ISO 6892-1. Transverse test pieces
shall be flattened.

If necessary, to suit small diameter coupons, subsidiary sized test pieces should be used, with the
dimensions scaled from full-sized test pieces.

Note: The specimens may be prepared from an over-size, flame-cut section but the machined, parallel
test section shall be at least 15 mm from any flame-cut edge.

Because of the small size of the test coupons only cold cutting should be used to prepare the test pieces,
in order to avoid unnecessary loss of test material.

Round or cylindrical test pieces machined from an un-flattened sample may be used by agreement with
National Grid. In such cases it is preferred that specimens are removed from the transverse direction.

Weld beads shall be ground flush, local imperfections may be removed, but mill scale should not be
removed from the test pieces.

C.4.1.2 Charpy V-notch Impact Test Pieces

Each set of impact tests must consist of three adjacent test pieces taken from a single non-flattened
sample. Charpy V-notch impact testing must be in accordance with BS EN ISO 148-1 with an additional
requirement to report the shear area of the fracture surface.

Test pieces for welds shall be taken from the weld centre line and the fusion line (s). The notch location
for the fusion line test pieces must be agreed with National Grid before testing.

The axis of the notch shall be perpendicular to the pipe surface (as shown in Figure 1).

The orientation and preferred size of the test piece shall be as shown:

Figure 1 – Position of Charpy V-notch Impact Test Specimen

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a. The greatest possible transverse width between 10 mm and 5 mm shall be machined. The
minimum outside diameter (D min) of the pipe necessary to obtain transverse test pieces is
given by

D min = (T - 5) + 756.25
T-5

where T is the wall thickness.

b. If the smallest permitted transverse test piece is not obtainable, the greatest possible
longitudinal width between 10 and 5 mm shall be used. (Fig. 1, dimension W)

Impact testing is not required if pipe or fitting dimensions are insufficient to extract longitudinal base metal
test pieces with a minimum width of 5mm. All test pieces must have their centre of strike at the mid
thickness of the pipe or fitting.

C.5. Test Methods

C.5.1 Chemical Analysis
The elements shall be determined in accordance with the methods considered in the corresponding
European Standards. Spectrographic analysis is permitted.

As a minimum, the following elements shall be reported: carbon, silicon, manganese, phosphorus,
sulphur, chromium, molybdenum, nickel, aluminium, copper, niobium, titanium, vanadium. The carbon
equivalent value (CEV) shall be calculated in accordance with clause 5.3.

C.5.2 Tensile Test

The tensile test shall be carried out in accordance with BS EN ISO 6892-1. The tensile strength (Rm), the
yield strength for 0.5 % total elongation (Rt 0.5 ) and the percentage elongation after fracture (A) shall be
determined from the sample.

The percentage elongation after fracture shall be reported with reference to a gauge length of
5.65√So (where So is the initial cross sectional area of the gauge length).

If other gauge lengths are used, the elongation referred to a gauge length of 5.65√So shall be determined
in accordance with ISO 2566-1.

NOTE. The Rt 0.5 value is considered to be approximately equivalent to the ReH or Rp 0.2 value
within the normal scatter band of test results.

In the tensile test transverse to the weld only the tensile strength (Rm) shall be determined.

C5.3 Impact test

The impact test shall be carried out in accordance with BS EN ISO 148-1 at a test temperature of 0 °C
unless otherwise specified by National Grid.

Where test pieces with a width < 10 mm are used the measured impact energy (KVp) and the cross
sectional area of the test piece (Sp) in mm² measured under the notch shall be reported. The measured
energy shall be converted to the impact energy (KV) in joules (J) using the formula:

8 x 10 x KVp
KV =
Sp

C5.4 Hardness testing

Hardness testing shall be carried out in accordance with BS EN ISO 6507-1.

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APPENDIX D
MATERIAL SAMPLE AND SITE INSPECTION REPORT

MATERIAL SAMPLE AND SITE INSPECTION Report No:

REPORT
Project: Test Date:
Location/Site Grid Ref:
Ref: Drawing No.: Item: *Pipe *Reducer *Tee *Bend
Pipe/Fitting Dia.: mm. Nominal Wall Thickness: mm.
SCC Survey: *Evident *Not Found Measured Wall Thickness: mm.
Final MPI results: Final Wall Thickness: mm.
Purpose of Test Sample: *Chemical Analysis *Material Properties
Type of test sample: *Cuttings *Coupon/Plate *Other (Specify)
* Indicate by crossing out/deleting inappropriate descriptions

Sample Material Elements CE

Identifier C Mn Cr Mo V Ni Cu S P Si Nb Ti Al %

Measured
Hardness Measured Charpy Impact size: 10 mm x mm
Sample Yield
Survey UTS
Identifier Strength 2 Test Temp. Energy
Ave. (Hv) 2 (N/mm ) % Shear Area
(N/mm ) (°C) (J)

Hardness:

U/T Lamination
MPI Report No.:
Report No.:
Metallurgical
Laboratory report No.:
laboratory
Laboratory
Address:

Telephone No.:
Estimated grade of
sample(s):
Approved Q/10
Company:
Technicians Name:

Signature: Date:

© National Grid Gas plc 2013 - All Rights Reserved

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ENDNOTE
Comments
Comments and queries regarding the technical content of this document should be directed to:

Safety and Engineering Registrar

SSR Directorate
National Grid
National Grid House
Warwick Technology Park
Gallows Hill
Warwick
CV34 6DA

Buying documents
Contractors and other users external to National Grid should direct their requests for further copies of
National Grid documents to the department or group responsible for the initial issue of their contract
documentation.

Copyright National Grid Gas plc 2013 ©, all rights reserved. No part of this publication may by reproduced
in any material form (including photocopying and restoring in any medium or electronic means and
whether or not transiently or incidentally) without the written permission of National Grid plc except in
accordance with the provisions of the Copyright, Designs and Patents Act 1988.

© National Grid Gas plc 2013 - All Rights Reserved

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