MAJOR PROJECTS CONSTRUCTION SERVICES (PIPELINE) SPECIFICATION FOR PIPELINE CONSTRUCTION (CANADA) NON-DESTRUCTIVE TESTING CPCS-SPEC-NDT-003

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2 MAJOR PROJECTS CONSTRUCTION SERVICES (PIPELINE) SPECIFICATION FOR PIPELINE CONSTRUCTION (CANADA) NON-DESTRUCTIVE TESTING CPCS-SPEC-NDT-003 Prepared By Reviewed By Approved By Name Position Department Signature Date Denis Covey Bob Huntley Blaine Meyer Robert Hogg Stan Cichacki Surveillance Specialist Senior Construction Specialist Field Surveillance Specialist - AUT Supervisor Senior Manager MP Engineering & Construction Services Canada- Pipeline MP Engineering & Construction Services Canada- Pipeline MP Engineering & Construction Services Canada- Pipeline MP Engineering & Construction Services Canada- Pipeline MP Engineering & Construction Services Canada- Pipeline THE ORIGINAL SIGNED COPY OF THIS DOCUMENT IS RETAINED BY MP ENGINEERING AND CONSTRUCTION SERVICES. CPCS-SPEC-NDT-003 Revision 2 Page 1 of 33

3 REVISION SUMMARY Revision No. 2 Effective Date See management approval date 1 November 2011 Reason for and Description of the Change Reviewed and updated to reflect current industry standards and Company s best engineering construction practices. Reviewed and updated to reflect current industry standards and Company s best engineering construction practices. Replacement of Previous Document May 27, 2010 New document. N/A CPCS-SPEC-NDT-003 Revision 2 Page 2 of 33

4 TABLE OF CONTENTS 1 SCOPE GENERAL ACTS, REGULATIONS, LAWS, CODES AND STANDARDS GENERAL RELATED SPECIFICATIONS GENERAL DEFINITIONS GENERAL CONTRACTOR OPERATIONS GENERAL NDT SUPERVISOR TECHNICIAN (AUT/UT/MT/PT) RADIOGRAPHER EXPOSURE DEVICE OPERATOR (EDO) INSPECTION UNITS MAINLINE/POORBOY UNIT SECTION UNIT TIE-IN/REPAIR UNIT MANUAL UT HAND SCAN UNIT ADDITIONAL UNITS AND SPARE PARTS RADIOGRAPHIC INSPECTION GENERAL X-RAY GAMMA (IRIDIUM 192/SELENIUM 75) REAL TIME RADIOGRAPHIC IMAGING SYSTEMS PIPE DIAMETER RANGE LIMITATIONS RADIOGRAPHIC TESTING PROCEDURES FILM RADIOGRAPHIC QUALITY MARKING AND IDENTIFICATION OF RADIOGRAPHS PACKAGING OF RADIOGRAPHS CPCS-SPEC-NDT-003 Revision 2 Page 3 of 33

5 7.11 RADIATION SAFETY ULTRASONIC INSPECTION ULTRASONIC SYSTEM ULTRASONIC TESTING PROCEDURES RECORDING SYSTEM TRANSDUCERS REFERENCE BLOCK STANDARDS SYSTEM SET-UP CALIBRATION SCAN COUPLANT SURFACE CONDITION REFERENCE LINE MANDATORY RE-INSPECTION COATING DAMAGE EVALUATION OF INDICATIONS MAGNETIC PARTICLE TESTING MT PROCEDURES EQUIPMENT AND MATERIAL SPECIFIC APPLICATION PARAMETERS SURFACE PREPARATION MT REPORTING REQUIREMENTS LIQUID PENETRANT TESTING PT PROCEDURES EQUIPMENT AND MATERIAL SPECIFIC APPLICATION PARAMETERS SURFACE PREPARATION PT REPORTING REQUIREMENTS WELD IDENTIFICATION REPORTING PROCEDURES NDT TURNOVER PACKAGE REQUIREMENTS STANDARDS OF ACCEPTABILITY ADDITIONAL REQUIREMENTS CPCS-SPEC-NDT-003 Revision 2 Page 4 of 33

6 15.1 POLISHING EQUIPMENT TRAINING NON-DESTRUCTIVE TESTING QUALITY ASSESSMENT CPCS-SPEC-NDT-003 Revision 2 Page 5 of 33

7 1 SCOPE 1.1 General This Specification outlines the Non-Destructive Testing of pipe-to-pipe and/or pipe-tocomponent welds made using mechanized, semi-automatic or manual welding techniques for cross country pipelines. This Specification provides requirements for Radiographic, Ultrasonic, Magnetic Particle and Liquid Penetrant testing. This Specification does not apply to shop fabrication welding The Contractor shall ensure that the Non-Destructive Testing requirements set out in this Specification are complied with to the extent they are applicable in the circumstance. Except as otherwise expressly provided herein; the Contractor shall be responsible for implementing this Specification. The Contractor shall be solely responsible for ensuring that the Work is performed in strict compliance with all Environmental, Health and Safety Laws. 2 ACTS, REGULATIONS, LAWS, CODES AND STANDARDS 2.1 General The latest edition of the following Acts, Codes and Standards shall form part of this Specification. It is the Contractor s responsibility to become familiar with the latest editions of the Acts, Regulations, Laws, Codes and Standards that are necessary for the performance of the Work. These shall include but not be limited to the following: CSA Z662 Oil and Gas Pipeline Systems Where regulated by Federal Standards, the National Energy Board NEB Onshore Pipeline Regulations Alberta Pipeline Act and Regulations Other Provincial & Territories Acts, Regulations & Standards Where CSA Z662 is referenced hereafter it shall mean CSA Z662 Oil and Gas Pipeline Systems, Alberta Pipeline Act and Regulations, other Provincial and Territories Acts, Regulations and Standards and the National Energy Board Onshore Pipeline Regulations, as applicable. If there is a conflict between Acts, Regulations, Laws, Codes and Standards the most stringent requirement shall be met by the Contractor. All conflicts must be referred to Enbridge for resolution The Contractor shall comply with the requirements of Acts, Regulations, Laws, Codes and Standards in performance of the Work. 3 RELATED SPECIFICATIONS 3.1 General The NDT Contractor shall comply with the requirements of the following technical documents as referenced within CPCS-SPEC-NDT-003: ASME Boiler & Pressure Vessel Code Section V - Nondestructive Examination ASTM E94 Standard Guide for Radiographic Examination CPCS-SPEC-NDT-003 Revision 2 Page 6 of 33

8 4 DEFINITIONS 4.1 General ASTM E114 Standard Practice for Ultrasonic Pulse-Echo Straight Beam Contact Testing ASTM E273 Standard Practice for Ultrasonic Testing of the Weld Zone of Welded Pipe and Tubing ENA TS 98-2:1979 Ultrasonic Probes: Medium Frequency, Miniature Shear Wave, Angle Probes ASTM E1316 Standard Terminology for Nondestructive Examinations ASTM E1961 Standard Practice for Mechanized Ultrasonic Testing of Girth Welds using Zonal Discrimination with Focused Search Units EN Non-destructive testing Ultrasonic examination - Part 6: Time-of-flight diffraction technique as a method for detection and sizing of discontinuities CAN/CGSB Non-destructive Testing - Qualification and Certification of Personnel CSA PCP-09 Certified Exposure Device Operator (CEDO) Certification Guide ISO Non-destructive Testing Industrial radiographic film Part 1: Classification of film systems for industrial radiography ISO Non-destructive Testing Industrial radiographic film Part 2: Control of film processing by means of reference values ISO Non-destructive Testing Image quality of radiographs Part 1: Determination of the image value using wire-type image quality indicators ASTM E709 Standard Guide for Magnetic Particle Testing ASTM E165 Standard Practice for Liquid Penetrant Examination for General Industry ISO Non-destructive testing of welds - Radiographic testing - Part 2: X- and gamma-ray techniques with digital detectors Welding terms and definitions shall be in accordance with CSA Z662, ASME E1316 and the Specification as follows: AUT Automated Ultrasonic Testing Contractor - Non-Destructive Testing (NDT) Company Company Enbridge Pipelines Inc. or any of the affiliates Delay Weld - Welds that are completely radiographed or ultrasonically inspected after a minimum period of 18 hours following completion of welding Re-Shot/Re-Scan Weld - Welds or areas of welds requiring a radiographic re-shot or requiring ultrasonic re-scanning as a result of inadequate NDT quality RTR Real Time Radiography CPCS-SPEC-NDT-003 Revision 2 Page 7 of 33

9 Technician or Radiographer An NDT Technician or Radiographer certified in the applicable discipline(s) to CAN/CGSB who interprets and documents the results for a specific test Verification Weld - Welds or areas of welds that are re-radiographed or reultrasonically inspected after an initial radiographic or ultrasonic inspection to verify weld quality Welding Production All welding completed daily including all mainline, poorboy, section, field fabrication, cut-out and repair welding 5 CONTRACTOR OPERATIONS 5.1 General The Contractor shall have a documented Quality Program in place and a controlled copy of the Quality Program Manual shall be available to the Company at the place of Work. The Company may conduct an audit of the Contractor s implementation of the Quality Program. 5.2 NDT Supervisor The Contractor shall provide and designate an individual as the NDT Supervisor responsible for the direct supervision, conduct, and performance of all non-destructive project personnel and for maintaining all equipment and supplies in reliable condition. The NDT Supervisor shall work closely with the Company s Senior / Chief Welding Inspector regarding the documentation of examinations completed and shall be responsible for all reports, interpretations and evaluations NDT Supervisors shall have CGSB Level 2 or 3 Certification for the non-destructive methods used for the performance of the Work If multiple non-destructive methods are used during the performance of the work, the NDT Supervisor shall have CGSB Level 2 or 3 Certification for the non-destructive methods used for the performance of the mainline work and shall be experienced with all other methods of NDT used in the performance of the remaining Work The NDT Supervisor shall be capable of technical support for the NDT methods used for the Project. The NDT Supervisor shall be approved by the Company. The Company may require the Supervisor to demonstrate competence in operating and evaluating the results of the applicable inspection systems The NDT Supervisor, or a Company approved alternate supplied by the Contractor, shall perform documented audits to ensure that interpretations are consistent, informative and concise. Audits shall be performed as a minimum for: 100% of all rejected welds, repair welds, cut-out replacement welds, tie-in welds and final tie-in welds 100% of all AUT calibrations, including one complete set of the AUT parameters per crew per day to ensure consistency with essential AUT variables 10% of all mainline, poorboy, section and field fabrication welds All audits shall be documented and provided to the Company in a format approved by the Company as a minimum on a weekly basis. CPCS-SPEC-NDT-003 Revision 2 Page 8 of 33

10 5.2.6 The NDT Supervisor shall be assisted by a Field Clerk who is proficient in the compilation of daily and weekly NDT data and the generation of related reports. 5.3 Technician (AUT/UT/MT/PT) Technicians shall have CGSB Level 2 or Level 3 certification applicable to the NDT method performed. The Company shall evaluate the qualifications of each Technician and reserve the right to exclude those that, in the opinion of the Company, lack sufficient skills, training or experience for the Work AUT Technicians shall have CGSB Level 2 or Level 3 UT certification and receive a sufficient level of training on mechanized testing pertaining to the equipment and configurations to be examined. This training shall be documented by an in-house certifying exam AUT Technicians shall pre-qualify for pipeline weld evaluation by demonstrating their ability to detect and characterize typical weld flaw indications and interpret these according to the Project criteria. The AUT Technician shall produce an Ultrasonic Test Report documenting the complete weld assessment. The Company shall either provide qualification test pieces consisting of one or more pipe samples with defects, or provide a series of weld scans containing indications similar to those expected with the Welding Procedures. The Pre-Qualification Test shall be administered by the Contractor and may be witnessed by the Company. The results will be evaluated on overall quality, accuracy of defect assessment and compliance with these Specifications and Standards Manual UT Technicians must demonstrate their full understanding of the Manual Ultrasonic Procedure and acceptance criteria Prior to production welding the Contractor may be required to administer a technical workshop providing a clear overview of the relevant Project Procedures and acceptance criteria to all NDT Supervisors. The content shall be approved by the Company All Technicians shall be approved by the Company prior to the performance of the Work. Only Company approved Technicians are permitted to interpret Inspections. The Company shall require Technicians to demonstrate their competence in operating and evaluating the results of the Inspection System. 5.4 Radiographer Radiographers shall have CGSB Level 2 or Level 3 RT certification. The Company shall evaluate the qualifications of each Radiographer and reserves the right to exclude those that, in the opinion of the Company, lack sufficient skills, training or experience for the Work Prior to production welding, each Radiographer shall either provide a test radiograph using the technique(s) previously approved by the Company to produce a qualifying radiograph, or will evaluate a series of radiographs supplied by the Company and produce a Radiographic Test Report with a complete assessment of the weld. The Pre- Qualification Test shall be administered by the Contractor and may be witnessed by the Company. The test radiograph will be evaluated on overall quality, accuracy of defect assessment and compliance with these Specifications and Standards. CPCS-SPEC-NDT-003 Revision 2 Page 9 of 33

11 5.4.3 The Radiographer is encouraged to work in conjunction with the Senior Welding Inspector and Welding Foreman in consultation to improve welding quality and production Only Company approved qualified Radiographers are permitted to produce and interpret radiographs using Contractor supplied NDT interpretation facilities. 5.5 Exposure Device Operator (EDO) All personnel operating a radioisotope exposure device shall hold a valid CNSC Exposure Device Operator (EDO) certification. 6 INSPECTION UNITS 6.1 Mainline/Poorboy Unit A Mainline and/or Poorboy unit for the purpose of this Specification shall consist of a suitably equipped self-contained 4-wheel drive vehicle with a crew of qualified personnel of which one (1) shall be a Company approved Technician or Radiographer experienced with cross country pipeline mainline operations When radiographic testing is selected to be the principal testing method, the Mainline unit shall be equipped with, but not be limited to: X-ray or Gamma Ray internal crawler(s) Experienced crawler Operator Radiographic command source(s) Processing and drying capabilities and suitable viewing facilities Calibrated densitometer and density strip traceable to a National Standard Sufficient equipment to maintain inspection rates that can meet or exceed total daily welding production Ultrasonic testing may be selected by the Company to be the principal testing method. If ultrasonic testing is selected, the mainline unit shall be equipped with, but not be limited to, an Automated Ultrasonic Testing (AUT) system as described in this Specification The Poorboy ultrasonic or radiographic unit shall generally be equipped as outlined for a mainline unit with the exception that the manpower requirements may be less than that required for the mainline unit. 6.2 Section Unit Section units for the purpose of this Specification shall consist of a suitably equipped self-contained 4-wheel drive vehicle with a crew of two (2) personnel of which one (1) shall be a Company approved Technician or Radiographer The Section Unit shall generally be as outlined for a mainline unit but more suitably equipped for the testing of short pipe sections. 6.3 Tie-in/Repair Unit CPCS-SPEC-NDT-003 Revision 2 Page 10 of 33

12 6.3.1 Tie-in/Repair Units for the purpose of these documents shall consist of a suitably equipped, self-contained 4-wheel drive vehicle with a crew of two (2) personnel of which one(1) shall be a Company approved Technician or Radiographer The Unit shall generally be equipped with an AUT system and all calibration or reference blocks for ultrasonic test method(s) or with a portable x-ray or gamma exposure device for radiographic test method(s). The tie-in/repair crew shall be required to inspect tie-in welds and repair welds when requested by the Company AUT Tie-in/Repair Units shall be equipped with a suitably long umbilical to enable scans of accessibly difficult welds. The umbilical is deemed an essential variable which requires that the system shall be re-calibrated when a change in umbilical occurs. 6.4 Manual UT Hand Scan Unit Manual UT Hand Scan Units for the purpose of these documents shall consist of a suitably equipped self-contained 4-wheel drive vehicle with a crew of one (1) person who shall be a Company approved Technician. The Manual Hand Scan Unit may be required to inspect tie-in welds and repair welds when required by the Company. 6.5 Additional Units and Spare Parts Sufficient spare parts and/or equipment shall be provided and maintained by the Contractor to ensure consistent weld evaluation and continuity of construction. 7 RADIOGRAPHIC INSPECTION This Section outlines the requirements for Radiographic Inspection (RT) 7.1 General In the event that any film or report leaves control of the NDT Contractor, documentation of the transfer of the film and Report shall be recorded and signed by representatives of the Company and the Contractor and/or NDT Contractor The Contractor shall use only the latest "State of the Art" techniques in producing and interpreting the Radiographic Tests. Without restricting the generality of the foregoing, the following shall apply: Film shall be viewed in subdued background lighting using a viewer suitable for film with densities of up to 4.0 H&D. Under no circumstances shall a final interpretation be based on viewing wet film. All film shall be read in a dry condition. The Contractor shall provide suitable equipment for drying film immediately after developing and washing. Any radiograph which, in the Company s opinion, is of substandard quality shall be retaken at no cost to the Company. The rate of interpretation shall be in accordance with good industry practice and under no circumstance shall the interpreter be permitted to interpret radiographic film for more than two (2) consecutive hours without a 15-minute break. CPCS-SPEC-NDT-003 Revision 2 Page 11 of 33

13 7.1.3 Radiographs of repaired welds shall generally be performed by a tie-in/repair unit. Mainline units shall not normally radiograph repaired welds without Company approval The Contractor shall mark the repaired weld in a manner agreed to by the Company to indicate final acceptance of the weld repair The Contractor shall have sufficient equipment and personnel on site to maintain a production rate which ensures that any weld completed prior to 4:00 P.M. on any working day will be radiographed, interpreted and included in the Radiographic Report for that working day The Contractor shall provide at least one (1) high-intensity viewer at each film interpretation location. Equipment used to view radiographs shall provide a variable light source suitable for viewing film densities up to 4.0 H&D The Contractor shall provide one (1) high-intensity, variable light source viewer for use by the Company in the Field Office. 7.2 X-Ray X-ray exposure devices for single wall x-ray (SWX) shall be true radial beam and shall have an achievable minimum rating of 160kV/3ma X-ray exposure devices for double wall x-ray (DWX) shall have an achievable minimum rating of 200kV/5ma. 7.3 Gamma (Iridium 192/Selenium 75) Gamma Radiography may be used with prior approval of the Company Sources shall have a minimum strength of 50 curies for weld diameters greater than mm O.D. 7.4 Real Time Radiographic Imaging Systems At the option of the Company, NDT Contractor proposals for the use of non-film radiographic methods will be considered for the inspection of pipeline girth welds Radiographic Procedures and Techniques shall conform to all quality requirements detailed in the Specification and CSA Z The NDT Contractor shall be required to perform a pre-qualification process that will provide sufficient technical and comparison data to support Company approval prior to the use of the proposed imaging system or image acquisition medium. The prequalification process shall provide adequate assurance that the system is an acceptable test method for the application of pipeline girth weld defect detection The qualification procedure specified in ISO :2013 details the minimum requirements for this radiographic method which permits exposure and acquisition of digital radiographs with sensitivity equivalent to that of conventional film radiography for detection of weld imperfections Company approval of the qualification process shall be made on an individual radiographic Contractor and project specific basis. CPCS-SPEC-NDT-003 Revision 2 Page 12 of 33

14 7.5 Pipe Diameter Range Limitations Less Than 88.9 mm O.D. The radiographic technique shall be double wall gamma (DWG), ellipse or super imposed, with double wall viewing mm O.D. to mm O.D. inclusive: For diameters from to 323.9mm O.D. the radiographic technique shall be single wall exposure with single wall viewing, for mainline, poorboy and section welds and shall be double wall exposure with single wall viewing for repair, tie-in, field fabrication, and replacement welds. Double wall exposure gamma (DWG) techniques with single wall viewing shall be permitted for diameters from 88.9mm to 114.3mm OD Greater Than 323.9mm O.D. All mainline, poorboy and section welds shall be radiographed using a single wall x- ray (SWX) technique with a true radial beam x-ray exposure device. Tie-in welds, field fabrication welds and replacement welds shall be radiographed using a double wall x-ray (DWX) technique with single wall viewing. Weld repairs shall be radiographed with a double wall x-ray (DWX) technique with single wall viewing, or on approval of the Company, a single wall x-ray (SWX) technique will be permitted. 7.6 Radiographic Testing Procedures Prior to commencement of any work, the Contractor shall provide the Company with the Radiographic Procedures it proposes to use during the performance of the Work. Procedures shall be as per CSA Z662 and ASME Section V - Non-destructive Examination, paragraph T The Contractor shall demonstrate the effectiveness of its proposed Procedures as follows: The details of each proposed procedural Technique shall be submitted to the Company for approval. The submission shall include the complete results of tests and radiographs qualifying the Procedure. A radiograph shall be produced under site conditions and in the Company s presence for each proposed Procedure. Such Technique Acceptance Testing shall preferably be performed during the Pipeline Construction Contractor's Welding Procedure Qualification Tests, or similar welding, prior to the commencement of production welding. Only equipment and materials which are radiographically similar to those to be used in performing the Work shall be used for the tests. The Report of each Technique including the notation of all defects and the test radiographic film shall be submitted to the Company for approval. The Company will notify the Contractor of approval of each Procedure submitted. Any change in the CPCS-SPEC-NDT-003 Revision 2 Page 13 of 33

15 approved Procedures will necessitate the resubmission of the Procedure, as changed, subject to the conditions outlined herein. Procedures approved and accepted by the Company will form part of the Contract Document Each Radiographer shall demonstrate the ability to perform each Technique. The demonstration radiographic examination shall be performed by each Radiographer and submitted to the Company with the Daily Report. The first exposures of the project can be applied as a Technique demonstration to prevent additional work for the specific RT unit. However, two (2) film sets and reports must be produced; one (1) as Technique demonstration and one (1) as regular weld examination. 7.7 Film Radiographic film shall be classified in accordance with ISO , latest edition. The selection of Film System Class C4, as a minimum, shall apply for all welds radiographed by the X-ray method and the selection of Film System Class C3, as a minimum, shall apply for all welds radiographed by the gamma ray method The selection of film Manufacturer shall be approved by the Company prior to use Pre-packaged film may be used at the discretion of the Company and subject to prior approval If the Contractor elects to use pre-packaged film (e.g., redipack, etc.), the Contractor shall be responsible for ensuring that all garbage and excess packing material is removed daily from the Construction Right-of-Way and disposed of in accordance with the Regulations of the Authority Having Jurisdiction Film width shall be adequate to cover a minimum of 15 mm on each side of the weld cap Chemicals used for processing film shall be pre-approved by the Company and shall be used in accordance with the Manufacturer's recommendations including efficient replenishment and replacement of developer. Written schedules of actual solution changes shall be posted in the dark room at all times Film shall be processed in a manner without exposure to light or radiation and must show a fog level of not more than 0.3 H&D. This shall be verified at the beginning of each new roll/box of film and shall be done weekly per unit. The verification result shall be documented on the daily Radiographic report and the test film shall be included with the day s radiographic production film The use of density reduction solutions such as Farmers Reagent shall not be permitted Materials and processes used in film processing shall be of a quality to allow film storage without risk of deterioration for a minimum of 5 years. 7.8 Radiographic Quality Each radiograph shall conform to the requirements of CSA Z662 and supplemental Specifications herein. CPCS-SPEC-NDT-003 Revision 2 Page 14 of 33

16 7.8.2 Film density shall be H&D in the area of interest. The area of interest shall be defined as the width of the weld image plus 3-6mm from both edges of the weld cap edge to ensure inclusion of the weld HAZ The density in small localized areas, not exceeding 50.8mm in length, may be as low as 1.5 H&D. A calibrated densitometer and a density strip calibrated to a traceable National Standard shall be provided to each Radiographer to ensure that film densities are within the specified units The selection of wire type image quality indicator(s) (IQI s) shall be as described in CSA Z662 and ISO , and shall be used to measure sensitivity of the radiographic image Hole type IQI s shall not be used The placement and number of IQI(s) shall be such that the sensitivity can be measured through the area of interest and within the applicable limit of coverage. The IQI wires shall be placed perpendicular to the direction of the weld and the wires shall extend completely across the area of interest A limit of coverage is defined as the acceptable circumferential length of an individual exposure (exposure limit) as specified in the approved Radiographic Procedure Technique(s) For single wall exposure/single-wall viewing techniques where the complete weld circumference is radiographed as a single length of film, a minimum of 3 IQI s and 3 undercut comparator shims shall be placed 120 apart When multiple film holders are used for single wall exposure/single-wall viewing techniques, an image of the IQI and an image of the undercut comparator shim shall appear on each film Successive multiple films shall overlap at the adjacent ends by a minimum of 50 mm For double wall exposure/single wall viewing techniques, a minimum of 3 equally spaced exposures shall be required for 100% radiographic coverage of the weld circumference. The image of an undercut shim shall appear on each film Single and multiple film holder, double wall exposure, single wall view techniques, for pipe-to-pipe and pipe-to-component welds greater than 114.3mm OD: Each exposure requires that the IQI s be placed at both ends of the acceptable limits of coverage. The IQI s shall be placed such that the image of the essential wire is visible on the radiograph(s) within a distance no greater than 25mm from the ends of the acceptable exposure limit Single film holder, double wall exposure, single wall view techniques, for pipe-to-pipe and pipe-to-component welds 88.9mm to 114.3mm OD: Each exposure requires that an individual IQI be placed at one end of the acceptable limit of coverage. The IQI shall be placed such that the image of the essential wire is visible on the radiograph within a distance no greater than 25mm from the end of the acceptable exposure limit. CPCS-SPEC-NDT-003 Revision 2 Page 15 of 33

17 In addition to the above requirements, weld repair radiograph(s) require that at least one (1) IQI be placed adjacent to each repair area For transition welds joining unequal nominal wall thicknesses, the essential wire for each wall thickness shall be determined by the nominal wall thickness of each material plus the maximum allowable thickness of the cap reinforcement Film placement shall be such that the bottom of the weld (6 o clock position) shall not be closer than 150 mm from either of the acceptable limits of film coverage. 7.9 Marking and Identification of Radiographs Survey chainage, at 200 meter intervals, for mainline, poorboy or section Weld Numbers and for all tie-in Weld Numbers, shall be recorded on the Contractor Daily Weld Inspection Reports All film shall be clearly and accurately identified so that the location of the weld and any weld discontinuity can be quickly and accurately located. Whenever more than one(1) film is used to inspect a weld area, the identification markers shall appear on each film and each section reference marker location shall be common to 2 successive films to ensure that the entire area of concern has been examined. The markers shall be placed on the pipe on the downstream (DS) side of the weld such that the numbers on the film will read clockwise when viewed from the upstream (US) side - (DS shall be the direction of construction; US shall be opposite to the direction of construction) The Contractor shall ensure that all radiographs are clearly identified with the following: Project Title Circumferential location markers. The Contractor shall use lead numbers to identify the circumferential location of weld defects. The maximum separation for weld location markers shall be 50 mm for diameters less than or equal to 406mm O.D. and 150 mm for diameters greater than 406 mm O.D. The zero location of such markers shall correspond to the 12 o clock position (top center) on the weld. Approved image quality indicator(s) - IQI(s) Approved comparator shim(s) A unique weld number and Identification Code in accordance with the Numbering System designated by the Company 7.10 Packaging of Radiographs The Contractor shall ensure that all film is thoroughly rinsed and dried before packaging and that all film is packaged in sequential order with a copy of the signed Radiographic Test Report All completed radiographs shall be catalogued and stored in corrugated cardboard boxes supplied by the Contractor measuring 350 mm x 350 mm x 75 mm with dividers forming eight (8) cubicles along each side thus providing 64 cubicles per box. Each box shall be labeled sufficiently for ease of locating welds and identifying contents when stacked/stored Mainline radiographs shall be inserted into each cubicle in sequence starting from the left side of the first row toward the right and then from the right side of the second row CPCS-SPEC-NDT-003 Revision 2 Page 16 of 33

18 toward the left, and so on in a serpentine manner. The bottom of each cubicle shall be clearly marked with the Film Number, (i.e. Weld Number that will occupy that space), after the radiograph has been interpreted. Boxes of mainline radiographs shall be numbered sequentially Radiographs of tie-in welds shall be handled and catalogued in the same manner as mainline radiographs and stored in separate boxes. The storage boxes shall also be sequentially numbered but will have the letter "T" behind the box number Radiographs of Fabrication assembly welds shall be handled in the same manner as above and stored in separate boxes Radiographs of repaired welds, delay welds and verification welds shall be rolled with the original radiograph such that both films are stored in the same cubicle Radiographs of replaced cut-out welds shall be placed in the same cubical as the original film. If there is not enough room, then the original film may be removed and stored in a box identified as a cut-out box Clear and legible interpretation sheets shall be included inside the boxes for those films catalogued in the corresponding boxes. Each time a new box is started a new interpretation sheet shall be started as well. These sheets are to be inserted inside each box The Contractor shall supply labels for the radiographic boxes. The Contractor s Radiographers shall fill out the labels as the films are being processed and place the labels on the completed radiographic boxes. Information required will be as follows: Project Identification Range of Weld Numbers Range of chainage Dates exposed Box number Contractor s name The boxes shall be numbered sequentially starting from number Radiation Safety Radiographic practices shall comply with the relevant Acts and Codes and shall be in accordance with the requirements of CSA Z The Contractor and all personnel operating x-ray or gamma ray equipment shall be responsible for the protection of every person working with or near radiation, and for compliance with Federal, Provincial and local laws regarding radiation safety and transportation The Contractor shall submit to the Company a written Radiation Safety Plan Audible and visible warning devices shall be used by the Contractor's personnel for regular monitoring of radiation levels. CPCS-SPEC-NDT-003 Revision 2 Page 17 of 33

19 8 ULTRASONIC INSPECTION This Section outlines the requirements for Ultrasonic Inspection (UT). 8.1 Ultrasonic System Mainline girth welds, of the same nominal wall thickness, made by mechanized welding methods, and other welds as directed by the Company, shall be fully examined using a mechanized ultrasonic inspection system for 100% of the weld circumference, in accordance with the requirements of CSA Z662. The Inspection System shall be capable of locating and accurately establishing the through wall height and circumferential length of all defects, in a manner that permits the use of an acceptance criteria defined by the Company in accordance with the requirements of CSA Z662 Annex K AUT Systems and Technicians shall be qualified and approved by the Company prior to commencement of any work AUT inspection shall utilize pulse-echo and/or pitch catch lens focused transducers with zonal inspection and Time of Flight Diffraction (ToFD) Techniques The system shall provide an adequate number of inspection zones designed with sufficient beam overlap to ensure full volumetric coverage The system shall include a fully automated recording system to indicate the location of indications and the effectiveness of acoustic coupling. The system shall provide a linear A scan presentation for each channel selected The inspection channels shall allow the volume of the weld scanned to be assessed in accordance with defined inspection zones The Contractor shall provide the Company either a hard copy recording of all calibrations and weld scans or alternatively electronic PDFs of the same, on a daily basis At the completion of each Pipeline Spread the Contractor will supply two (2) copies of the original electronic data on a removable hard drive (along with viewing software) all weld scans with the interpretation of acceptability of each weld examined and the recordings of the calibration standard scans Instrument linearity shall be determined in accordance with ASME Section V, Article 4, Mandatory Appendices - Appendix I & II. A current calibration certificate shall be provided to the Company indicating the instrument linearity, which shall not deviate by more than 5% from ideal. The evaluation for linearity shall be performed a minimum of every 3 months Mapping displays (B-scan) shall be used for volumetric flaw detection and characterization Inspection shall be carried out using a mechanized system capable of maintaining production rates established by the Pipeline Construction Contractor. Manual Ultrasonic Testing may also be required for weld repairs or other welds as required by the Company. CPCS-SPEC-NDT-003 Revision 2 Page 18 of 33

20 8.2 Ultrasonic Testing Procedures Prior to the commencement of any work, the Contractor shall provide the Company with the Procedures proposed for use in the performance of the Work. Approved Procedures shall include the applicable information stated in this Specification and information stated in ASME Section V, paragraph T-421 and a description of the methodology used to investigate indications. Ultrasonic Procedures using resolvable Techniques shall include a description of the sizing curves or mathematical methods used to determine the flaw characteristics. These descriptions shall be submitted to the Company prior to any examination of production welds If Manual Ultrasonic Techniques are used to evaluate repair welds, the Manual Ultrasonic Procedures shall include the following methodology to scan repaired areas on welds as a three (3) step inspection process: Step 1: Step 2: Acceptable removal of the defect shall be confirmed by using the same AUT probe angle(s) that detected the original defect. A full volumetric scan of the repaired area shall be done. Step 3: ToFD inspection shall be performed and recorded for all weld repair area(s). ToFD image data files of weld repair areas shall be retained as permanent records Upon approval from the Company, the Procedure becomes a mandatory requirement and changes are only permitted with further approval from the Company The Company shall make available at the Contractor's request, pipe representative of the pipe to be used on the project for Procedure development and Calibration Reference Block Design. Calibration Reference Block Design shall be approved by the Company prior to use and production welding A Velocity Report, in accordance with the requirements specified in ASTM E1961, shall be completed for each pipe Manufacturer prior to production welding and submitted for approval. 8.3 Recording System The Recording or Marking System shall clearly indicate the location of imperfections relative to the top 12 o clock position of the weld with ±10.0mm accuracy (positioning shall correspond and correlate to the welding start locations). The distance from the 12 o clock position shall be measured in a clockwise direction when viewing the pipeline in the direction of construction There shall be a Record for each transducer and confirmation of the acoustic coupling for each scan, arranged on the Chart in a logical format All data channels shall be recorded in 1.0mm or less resolution, of weld circumference Each inspection channel shall be selective for pulse echo or through transmission mode, gate position, length and gain Two (2) recordable signal outputs per gate shall be available: signal height and time of flight. CPCS-SPEC-NDT-003 Revision 2 Page 19 of 33

21 8.3.6 Recording for all channels shall be 0-100% of FSH (full screen height) minimum for amplitude, transit time, mapping, and ToFD records The circumferential weld distance encoder shall be coupled directly to the pipe surface Programmed scan lengths shall be sufficient to ensure all probes travel the circumferential distance required for the pipe +100mm ToFD techniques shall be included as part of the data acquisition and shall augment but not replace pulse echo techniques, unless the ToFD display represents a potential defect that may not be fully represented by pulse echo data due to defect orientation. ToFD shall be calibrated in accordance with the requirements of EN ToFD data acquisition shall be considered part of the weld data information, with no loss of signal, amplitude or resolution over 100% of the circumference ToFD shall have a minimum frequency of 6 MHz for wall thicknesses greater than 12.0mm, and a minimum of 10 MHz for wall thicknesses less than or equal to 12.0mm The lateral wave in the ToFD display shall have an amplitude response of at least 40% FSH un-rectified The transducer angle, frequency and damping characteristics of the ToFD probes shall be selected to optimize detection and to limit the depth of the lateral wave to a maximum of 4.0mm The Contractor shall establish and document the wedge temperature range required to limit the refraction of the angle within the pipe material to a maximum of 2 from the original parameter. The wedge temperatures shall be documented prior to commencement and after completion of all inspection scans and calibrations Any deviation from the established temperature range shall be recorded and corrected. All welds inspected since the last acceptable verifications shall be re-inspected. 8.4 Transducers Each probe must be marked with the Manufacturer s name, probe type, exit point, beam angle, frequency, crystal size and shape. The transducer array design specific to the Project shall be submitted by the Contractor to the Company for approval. No transducer arrays shall be produced or used without the Company s approval Transducers shall have been certified by the Manufacturer as meeting the performance requirements of Energy Networks Association (UK) TS 98-2: All search unit probes and or shoes shall be contoured to match the curvature of the pipe surface The following transducer parameters shall be documented and provided to the Company prior to production welding, according to CSA Z662. Refracted Beam Angle Nominal Frequency Size & Shape of each crystal CPCS-SPEC-NDT-003 Revision 2 Page 20 of 33

22 Beam Size Overall Gain Index Point (conventional probes only) Manufacturer Squint Signal to Noise Ratio Wedge Material and Velocity Probe Manufacturer s data sheet Beam Size Beam size at the target is defined as the point along the beam axis where the inspection is done. The -6dB vertical dimension of the beam at the target distance shall be within 25% of the applicable height for that zone. The -6dB horizontal dimension of the beam at the target distance shall not be greater than 2 times the -6dB vertical dimension of the beam. If focused elements are being used, the target shall fall within the -6dB working range of the beam. No individual -6dB beam size shall exceed 3.5mm, excluding ToFD, transverse and volumetric transducers Beam Angle For beam angles less than or equal to 45, the measured angle shall not differ by more than 1.5 from the specified angle. For beam angles greater than 45, the measured angle shall not differ by more than 2 from the specified angle Transducer Frequencies Transducer frequencies shall be selected based on the beam size needed at the target and on defect type (i.e. planar or volumetric) Signal to Noise For all transducers, except creeping wave transducers, the noise shall be at least 20dB weaker than the signal from the reference reflector at the target distance. For creeping wave transducers, the noise shall be 16dB weaker than the signal from reference reflector at the target distance. CPCS-SPEC-NDT-003 Revision 2 Page 21 of 33

23 8.5 Reference Block Standards Reference Block Standards shall be used to qualify the testing system for field examination and to monitor on an ongoing basis the systems performance Reference Block Standards shall be manufactured from a section of Project specific pipe supplied by the Company The Company will provide the Contractor with details of the Project specific weld bevel geometry. The Contractor shall then provide a Reference Block Standard Design which must be submitted to the Company for approval prior to manufacture No design changes shall be made without prior approval from the Company A thickness validation shall also ensure that the reference block is within normal nominal pipe wall thickness variations. Minimum and maximum wall thickness shall be reported and issued to the Company with the Manufacturer s validation certification of the Reference Block Standards measured tolerances For Projects where mechanized GMAW is being used, reference blocks are required for each wall thickness Reference Blocks remain the property of the Company Acoustic velocity and attenuation shall be determined and documented with Reference Block Records The allowable velocity difference between materials shall not exceed +/- 100 meter/sec or a refracted beam angle change greater than 2 from the original parameter Reference Blocks must be manufactured by a well-established and experienced manufacturer and must be mechanically verified as to the location and the size of all Reference Block reflectors. These Reports are to be submitted to the Company prior to production welding for approval Identification of Reference Standards shall include: a permanent hard stamp serial number, diameter, wall thickness Reference Block targets shall include the following reflectors: Primary reference targets for the hot pass and fill regions shall be 2.0mm flat bottom holes (FBH). Inspection zones for the hot pass and fill zones shall be no greater than the lesser of 3.0mm or 0.25wt for CSA Z662 Annex K applications. 1.0mm deep O.D. & I.D. notches shall be machined 10.0mm long(gmaw) & 25.0mm long (SMAW) on the bevel design fusion line(s). Root and Cap notch angles shall be identical to the orientation of the bevel used in the applicable weld process. A center line through hole or notch shall be machined to verify centerline defects and to ensure gate length is sufficient to cover as a minimum 1.0mm past weld center line. CPCS-SPEC-NDT-003 Revision 2 Page 22 of 33

24 All Reference Standards shall contain a 2.0mm deep O.D. ToFD notch and a 1.0mm deep I.D. ToFD notch. ToFD notches shall be machined with a 30 nose angle to create a diffracted signal. Lateral positioning of all targets shall be such that they allow for independent signals. The beam of each transducer shall pass across its primary target without any part of the beam detecting adjacent targets during the time the primary target is in the beam. Transverse notches shall be 2.0 mm deep, measured from the pipe O.D. & I.D. surfaces and machined 10.0 mm long, and centered on the weld centerline. Primary reflectors for volumetric channels shall be mm Flat Bottomed Hole (FBH) for the upper section(s) of the weld volume. The lower section (root) shall be a 2.0mm FBH. An I.D. root notch may be used for a SMAW root Location and size of reference reflectors: Each Reference Block shall be mechanically and ultrasonically inspected, these results shall be submitted prior to any production welding. Maximum allowances shall be observed for the following reflectors. Hole Diameters Flatness of FBH +/- 0.2mm +/- 0.1mm All Angles +/- 0.5 Notch Depth Notch Length Center Position of Targets Hole Depth +/- 10% of actual notch depth +/- 10% of actual notch length +/- 0.1mm +/- 0.1mm Any Reference Block whose dimensions exceed the above tolerances shall be deemed as unacceptable Accuracy of the drilled holes and machined notches contained in the Reference Blocks shall be maintained by filling with appropriate sealant. Verification that equivalent upstream (US) and downstream (DS) reflectors are within 3dB of each other shall be completed every 90 days. 8.6 System Set-up Acoustic response shall be verified using a Company approved AUT technique At the maximum response location, the gain (db) to provide 80% FSH from the reflector shall be determined and recorded Gate Settings The length of each Detection Gate shall be set to cover a sound path which will start at a distance of not less than 5.0 mm before the weld bevel preparation for all zones with the exception of the hot pass zone which will start at a distance of not less than 3.0 mm. Gate lengths for pulse-echo channels shall end at a distance of not less than 1.0 mm past the weld zone centerline. For mapping and volumetric channels, the gate starts shall mimic the gate positions above and extend past the weld geometry. The gate length for mapping channels should be determined at the CPCS-SPEC-NDT-003 Revision 2 Page 23 of 33