Q10
Q10
Q10
April 2013
J964 (Rev 04/13)
© National Grid Gas plc 2013 - All Rights Reserved
T/PM/Q/10
CONTENTS
Page
FOREWORD ii
BRIEF HISTORY ii
DISCLAIMER ii
1. INTRODUCTION 1
2. REFERENCES 2
3. DEFINITIONS 2
4. PROCEDURE 2
5. MATERIALS 2
7. REMOVAL OF COATING 3
14. RECORDS 5
END NOTE 14
APPENDICES
A REFERENCES 6
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
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.
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
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.
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:
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).
6.1.2 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.
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.
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.
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.
8.2 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.
9.2 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.
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.
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.
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
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 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
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.
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
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
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.
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.
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.
B2.5 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.
B3.12 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.
B3.15 Complete the site inspection reports and forward a copy to the Project Manager or Project
Engineer.
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 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.2.1 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.3.1 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.
C4 DESTRUCTIVE TESTING
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.
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.
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:
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
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.
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.
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.
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
APPENDIX D
MATERIAL SAMPLE AND SITE INSPECTION REPORT
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:
ENDNOTE
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