engineering standard guideline...

ENGINEERING STANDARD GUIDELINE ONTARIO

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SPECIALTY ENGINEERINGMATERIALS ENGINEERINGNDE-ULTRASONIC THICKNESS EVALUATION –TANKS,VESSELS, PIPING SYSTEMS

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1.0 PURPOSE

This guideline describes the minimum requirements to conduct a non-destructive evaluationin accordance with established Vale practices.

2.0 SCOPE

This specification covers the guidelines for the non-destructive evaluation to be followed forthe ultrasonic thickness of piping systems, pressure vessels, tanks and thickeners.

3.0 RESPONSIBILITY

All personnel performing the evaluation are to ensure compliance to this specification.

Any deviation from this specification must be reported to the NDE supervisor. The deviationwill be subject to VALE approval.

4.0 PREREQUISITE

Review of Safety Procedure No. 055

5.0 PERSONNEL QUALIFICATION

TSSA registered piping and Pressure vessels: Personnel qualified to C.G.S.B. 48.9712, UTlevel 1.

For all other applications: Personnel trained in the use of thickness meters.

6.0 GENERAL

6.1 SURFACE PREPARATION

All test areas are to be approximately 1 in. diameter.

Surfaces to be cleaned or ground to sound bare metal to ensure accurate and repeatablereadings. Exception: Where paint surface is tight and clean, readings can be taken over thepaint. See Photos below for example.


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Piping No grindingrequired

Grindingrequired

Tanks/Vessels

No grinding required Grinding required


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6.2 SELECTION OF TEST LOCATIONS – PIPING

Pipe sizes up to 10-inch diameter: All locations are to have 4 testareas. One at 0, 90, 180 and 270 degrees.

Pipe sizes 10 inches and above: All locations are to have 8 testareas. One at 0, 45, 90, 135, 180, 225, 270 and 315 degrees.

Test locations should be taken at every elbow and tee when reasonable.

Test locations should be taken on every section of pipe after each elbow or tee,approximately 1-inch past the welded connection or the flanged connection.

Test locations spacing for piping should be taken to give the best representation for theremaining wall thickness. e.g. Location taken every 50 or 100 feet. (Depending on linedimensions and inspection requirements and accessibility)

Long radius elbows: Test locations should be taken on the backside of these elbows.Spacing should be 1 inch apart. See attached Photo for example.

6.3 SELECTION OF TEST LOCATIONS – STORAGE TANKS

Floors: Test locations on the tank floor should be taken to give the best representation forthe remaining wall thickness. Generally test locations should be spaced a minimum of 6inches apart, taken at the 0, 90, 180 and 270 degrees and numbered sequentially. Seesection 6.5 paragraph two - “Floors” for sketch.

0

90

180

270

315 45

Flow


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Walls: Test locations on the tank walls should be taken to give the best representation for theremaining wall thickness. Usually test locations should be spaced approximately 6 inchesapart and taken at the 0, 90, 180 and 270 degrees.

Nozzles: Test locations on the tank nozzle necks are at 0, 90, 180 and 270 degree locations.See section 8.2 paragraph one and sketch below for details.

6.4 SELECTION OF TEST LOCATIONS – PRESSURE VESSELS

Shell: Test locations on the shell should be taken to give the best representation for theremaining wall thickness. A minimum of one strip of test locations should be takenapproximately 6 inches apart, starting at one head to shell circumferential weld andcontinuing to the opposite head to shell circumferential weld. See photos below forexamples.

Nozzleside view.

Nozzlefront view

0

90270

180

Tank0

90

180

Test locationstaken aroundthecircumference.

Test locationstaken around thecircumference.

Test locations taken between the head to shell welds


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Shell: One set of test locations should also be taken approximately 6 inches apart aroundthe circumference of the shell. See above photos for details.

Heads: Test locations should be taken approximately 6 inches apart. The test locations oneach head should be at 0, 90, 180, 270 degrees. See sketch below and photo for details.Test location should always start at the head to shell weld.

Nozzles: See section 6.3 paragraph 3 “Nozzles” for details.

Test location start at thehead to shell weld.

Each head


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6.5 SELECTION OF TEST LOCATIONS – THICKENERS

Shell: Test locations on the thickener shell should be taken to give the best representationfor the remaining wall thickness. Ideally test locations should be spaced approximately 6inches apart and taken at the 0, 90, 180 and 270 degrees. Test locations at thetrough/overflow portion of the shell should be taken approximately 3-inch spacing.

ShellTest locationat trough 3inches apart

Test locationbelow the troughtaken 6 inchesapart.

Locationof troughon inside.

Close up of shell wallat trough.


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Floors: Test locations on the thickener floor should be taken to give the best representationfor the remaining wall thickness. Ideally test locations should be spaced a minimum of 6inches apart and taken at the 0, 90, 180 and 270 degrees if accessible internally. See sketchbelow for details. If the floor is not accessible internally, then any exposed section of thefloor, test locations should be taken. These test locations should be spaced atapproximately 6 inches apart and numbered sequentially. See example in photos below.

Nozzles: See section 6.3 paragraph three “Nozzles” for details.

Testlocations

Top view ofThickener Floor.

0 degree

270 degrees

180 degrees.

1.01

Thickener floor at exposed locations.

90 degrees.

1.021.03

1.04

2.012.02

2.032.04

3.013.02

3.033.04

4.014.02

4.034.04


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Cones: Test locations on the thickener cone should be taken to give the best representationfor the remaining wall thickness. Ideally test locations should be spaced a minimum of 3inches apart. Four vertical strips (0, 90, 180, 270 degrees) of test location should be takenunless requested otherwise. See sketch below.

7.0 PROCEDURE

7.1 GENERAL

Test locations to be identified in a manner to allow for inspection repeatability.

When readings are taken over painted surfaces, the thickness of the paint will beautomatically removed by using the echo to echo mode on the thickness meter.

7.2 CALIBRATION OF THICKNESS METERS

Calibration blocks should have a minimum of two steps, one step below and one above thethickness range being evaluated and be of similar material of that being tested, Should ablock not be available calibration to be carried out on a mild steel block with a velocity tothickness conversion. The temperature of the calibration blocks should be at the sametemperature as the pipe system or tank being evaluated.

The instrument is to be calibrated at the start of the job and checked periodically during theevaluation.

The same couplant is used for calibration and taking thickness readings.

Thickener bottom.

Cone

Test location strips

Nozzle0, 90, 180, 270 degrees


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7.3 RECORDING OF READINGS

Data loggers. Test locations should be set up in UltraPIPE and uploaded in the data loggerprior to doing the job.

Meters without data loggers. Test locations are to be written down in the same style as thegrid being taken. See tables 1, 2 and 3 for examples.

7.4 PIPING

Drawing of the pipe system is required to detail the sample locations. Drawings of theexisting pipe systems should be available from the plant requesting the job or from theCentral Eng. drawing management system. When drawings cannot be located, a sketch ofthe piping system is to be drawn up and or photos are to be taken. Sketches and or photosshould include:

· Direction of flow when known. If direction of flow is not known then a direction will beassumed and recorded. See Figure 1.

· Sample locations numbered in sequence. See Figure 1.

· Plant North.

· At least one permanent bearing shown. Example, control room, driveway, tank, etc.See Figure 1

· Determining the location of 0 degree. To determine the location of 0 degrees, Northand direction of flow is required. See Figures 2 and 3 for location of 0 degrees foreach type of piping. Example of types - piping, elbows and tees etc.

8.0 ACCEPTANCE CRITERIA:

Vale Acceptance Criteria Piping Tolerances. Greater then 12 % wall loss from nominalrequires engineering evaluation or per UltraPIPE analytical settings.

Vale Acceptance Criteria Corrosion Tolerances for tanks and pressure vessels. 1/16”allowance from nominal wall thickness. Greater then 1/16” engineering evaluation requiredor per UltraPIPE analytical settings.


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9.0 REPORT:

The preferred method of reporting is within UltraPIPE whenever possible for alternatemethods of reporting the report shall include the following

Reference to Vale Work Order Number when applicable

Name, signature and qualification of the inspector

Date of inspection.

Reference drawing when applicable.

Equipment used.

Extent of inspected area.

Detail description of inspected items.

Procedure used.


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PIPING Table 1

NONDESTRUCTIVE THICKNESS EVALUATION

PLANT_____________________________ AREA____________________________EVALUATOR________________________ DATE____________________________INSTRUMENT_______________________ TRANSDUCER____________________CALIBRATION STEPS HIGH___ LOW___ ORIGINAL THICKNESS_____________

TAKENFROM

DWG. #PltOther

GRID # 0 90 180 270 TYPE MATERIALLOCATION SIZE DIA.12345678910111213141516171819202122232425262728


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Table 2NONDESTRUCTIVE THICKNESS EVALUATION

PLANT_____________________________ AREA____________________________EVALUATOR________________________ DATE____________________________INSTRUMENT_______________________ TRANSDUCER____________________CALIBRATION STEPS HIGH___ LOW___ ORIGINAL THICKNESS_____________

DWG. #PltOther

GRID # ReadingA

COMMENTSLOCATION SHELL WALL,

FLOOR, CONES,HEADS


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Table 3

NONDESTRUCTIVE THICKNESS EVALUATION

PLANT_____________________________ AREA____________________________EVALUATOR________________________ DATE____________________________INSTRUMENT_______________________ TRANSDUCER____________________CALIBRATION STEPS HIGH___ LOW___

DWG. #

Plt

Other

GRID # 0 90 180 270 ORIG.THICK.

MATER.LOCATION Nozzles Size.

Shell Cord

NozzlesWalls


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Figure 1. Permanent Bearing.


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Figure 2. Types of piping systems.

Top of pipe always 0 deg.

Top of pipe always 0 deg.

0

90

180

270


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Figure 3. Types of piping systems.

10.0 APPENDICES

List all appendices below:Appendix A: Revision and Transition NotesAppendix B: Keywords

11.0 ULTRAPIPE

The purpose of this section is to standardize the use of the UltraPIPE software for equipmentand piping. Standardization allows a consistent approach to the scheduling, collection, andanalysis of inspection data. This results in consistent risk determination and management,plus provides a platform for meaningful comparison of inspection results.

11.1 MASTER EQUIPMENT LIST

An equipment identifier must be entered in the Master Equipment List beforeinspection information can be stored. The Master List shows the list ofequipment for the currently selected Setting. All equipment fields should bepopulated using standard Ellipse nomenclature.


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See examples below:Plant: 22Eq/Circ ID: DSTRBN-MIXTANK11The plant number 22 is the plant number for Copper Cliff Mines in Ellipse.

This equipment is the Sand plant Mixing tank at South Mine. The EllipseEquipment number in Ellipse is: 22- DSTRBN-MIXTANK11. In UltraPIPE, theEq/Circ ID drops the plant two digit number as it is already in the Plant field.


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Piping systems that do not have a specific Ellipse equipment number should beidentified in UltraPIPE in the following manner. The Eq/Circ ID should have thebeginning of the Ellipse number of the equipment they are tied to and in additionthe line number and size in the name.

See examples below.Plant: 61Eq/Circ ID: 74-603-1121-24IN

The 74-000-603 is for the Absorbing Acid Tank. This was shortened to 74-603.The 1121 number is the line number. The 24IN is the pipe diameter.


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11.2 GENERAL CORROSION MONITORING

Design Code: Specifies the design code equations to be used forcalculating the Pressure T-Min value.

Common selections are:B31.1: Power PipingB31.3: Process PipingS8/D1: ASME Section VIII – Division I Pressure VesselsAPI 653: Atmospheric Storage Tanks

Service: Equipment Service. (Air, Acid, slurry, water, oxygen, etc.)

Class: Not currently used

Design Pressure / Temperature: Used to determine minimum wallthickness required to contain the pressure at that temperature. This maycome from a data sheet or name plate. Operating Pressure / Temp areoptional.

O / D: Specifies if Operating or Design Temperature / Pressure are to beused for Pressure T-Min calculations. “D” (Design) should always beselected.

Flange: Flange rating of critical flange on circuit or vessel. This can becalculated by UltraPIPE (See below). The critical flange is the flange ofthe lowest flange rating.(Design Temperature must be entered first.)


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TML Type: Numeric is selected because it provides maximum flexibilitywhen performing TML Copy, Data Transfer, and placing TML data ondrawings.

Corr Allow: The Corrosion Allowance field should be populated for allpiping and vessels. A zero value (0.00) is seen as a null value and NOTas an indication of zero corrosion allowance. Please see the AnalyticalSettings detail for more info on Zero Corrosion Allowance equipment.

11.2.1 TML Numbering and description

PipingFind below an example of a sketch showing an example of theUltraPIPE TML numbering system for piping:

product hold tank3rd floor

autoclave

15.01-15.04 1.01 – 1.10

4.01-4.10

FLOW

Test Locations

LEGEND

2.01-2.04

3.01-3.04

5.01-5.04

6.01-6.04

7.01-7.049.01-9.04

10.01-10.04 11.01-11.04

13.01-13.04

14.01-14.04

8.01-8.16 12.01-12.16

16.01-16.04

flow

0

90

180

270

The readings at the 0deg.on the back of the elbowsC and D should be spreadout ~ 2 ft from the centerof the elbows and shouldstop 8" from the ends ofthe elbow. When a lowreading is found, scan thearea slightly to ensure thelowest spot has beenfound.

x.01

x.04x.08

x.12x.16

Flow

2ft

8"

8"


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Tanks and VesselsFind below an example of a sketch showing an example of theUltraPIPE TML numbering system for tanks and vessels:

TML Location Description:

Piping

Examples of TML location descriptions for Piping.Location along Circumference-Type of fitting

0DEG-E90DEG-S

180DEG-R270DEG-T


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Type of fitting:E= ElbowS = StraightR= ReducerT= Tee

Equipment

Examples of TML location descriptions for Equipment.Location along Circumference/height/length-vessel component

2FT-S6FT-S

90DEG-R180DEG-BH270DEG-N3

Vessel componentTH = Top HeadBH = Bottom headNH = North HeadSH = South headS = ShellN# =Nozzle number #C= ConeR=RoofD=DrainEtc.

11.3 TML RETIREMENT THICKNESS (T-MIN)

Each TML has a Retirement Thickness (T-Min) used to determine theend of the life of the equipment or prompt a more detailed evaluation.The UltraPIPE methodology sets the TML Retirement Thickness equalto the larger (hence more conservative), of the individual Structural andPressure T-Min values.


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NOTE: The user can manually define or override the derived UltraPIPET-Min. For example, this value may come from a Fitness-for-Serviceanalysis. Any approved change made to TMIN values should be trackedby adding a “Memo” in Corrosion Monitoring

Pressure T-MinThe Pressure T-Min value is automatically calculated by UltraPIPE andrepresents the minimum wall thickness required to contain internalpressure. The Pressure T-Min value is calculated using the applicabledesign code equation, design pressure, design temperature, geometry,joint efficiency, and material code.

Structural T-MinThe Structural T-Min value represents the wall thickness required towithstand forces such as its weight, vibration, thermal expansion, wind,seismic, etc. The value can be rather subjective. This is sometimesreferred to as the “screening T-Min”.

Piping Structural T-MinIn the absence of an engineering assessment, the default valuesprovided with UltraPIPE should be used.

Vessel and Nozzle Structural T-MinAll pressure vessel and nozzle structural minimum thickness values willbe set to Nominal – Mill Tolerance (usually 12.5% for nozzles made outof pipe) - Corrosion Allowance.

Manually-Defined User Input Value

Structural T-Min (S) Vessels: Nominal – Mill Tolerance – CorrosionAllowance

Piping: Structural T-Min assigned toComponent Code

or

Pressure T-Min (P) Calculated based on B31.X, Section VIII or API650 Design Code Equations

TML RetirementThickness (T-Min)


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12.0 REFERENCE DOCUMENTATION

The following documents were used in the development of this document or haveinstructions and procedures applicable to it. They shall be used in their most recent revision.

API Publication 2201 for hot taps.Manitoba Division Memorandum - Recommendations on Piping Wear Allowances.


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13.0 REVISION AND TRANSITION NOTES

Revision notes describe: what was changed, and if applicable, why it was changed, and the plan toimplement the change, including whether changes are retroactive.Note: The revision notes are a summary of the changes and may not necessarily be a complete list.

A risk code is entered for each revision and if applicable, the revision notes will describe how riskwas addressed for the revision.RiskCode Risk Category

A This revision is a minor change and/or introduces no risk.

B Risk has been addressed for this revision by the reviewer and approver. Low risk or no new hazards identified.

C For this revision, a PHR or other risk management tool has been used to address risk and minimize hazards. Thisrisk assessment has been documented and is available through Central Engineering.

Rev Revision Notes RiskCode

Approvedby

Reviewedby

Issue DateYYYY/MM/DD

1 Document format and number changed. Previousnumber 001. A P. Belzile P. Belzile 2012/05/01

2 Added UltraPIPE section 11.0 A P. Belzile P. Belzile 2013/08/08

3 Intended changes from Rev 2 did not appear in thedocument. A P. Belzile P. Belzile 2014/02/05

4 Changed to Engineering Guideline A P. Belzile P. Belzile 2014/07/07

5 Changed to Engineering Standard Guideline A P. Belzile S. Violette 2018/01/26

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