BS EN 13480-5: 2002 Metallic industrial piping - Part 5: Inspection and testing(Eng)

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EN 13480-5:2002 (E)

Issue 1 (2002-05)

6.3 Performance of design review

6.3.1 System design review

A review of isometrics and/or construction drawings, including parts lists and technical schedules, shall be

performed with regard to operating conditions of the following items:

 the suitability of the material for the pressurised and un-pressurised parts including the required material

inspection documents;

 the suitability of welding procedure specifications and approvals;

 suitability of weld joint design;

 provision for appropriate in-service testing and inspection ,where necessary;

 structural stability, including supports and fixed points;

 provision and adequacy of safety devices.

The system design review shall be performed against the requirements of this European Standard.

6.3.2 Review of design calculations

The review of design calculations shall be carried out to verify that the dimensions specified meet the requirements

of EN 13480-3. The review shall also ensure that the stresses considered include pressure, temperature and that

all loads that may be applied during operating and testing have been considered.

6.3.3 Incomplete documentation

When all required data is not available at the time of the design validation, fabrication/installation may proceed

provided it shall not go beyond the applicable fabrication/installation stage, until approval is received.

6.3.4 Additional procedures/qualifications

Prior to the performance of the specific task involved, for piping class III the following shall be verified, preferably as

part of the design examination:

 Approval of welders;

 Qualification and certification of NDT personnel;

 Procedures for finishing, e.g. cleaning, painting, insulation etc.

6.4 Alternative proof of safety

If the design proposed by the manufacturer has not been prepared by a method acceptable under the requirements

of EN 13480-3, then the manufacturer shall supply all the necessary information in support of the alternative design

approach. This may consist of mathematical analysis, proof test data, operating experience or any other data the

manufacturer considers relevant to support this method of design. The documents submitted shall be reviewed to

ensure that the design of the piping is as safe as that provided by this European Standard and include the

principles given in 6.3.

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EN 13480-5:2002 (E)

Issue 1 (2002-05)

6.5 Manufacturer’s declaration of design compliance

After validation of the design has shown that the design requirements of this European Standard have been

fulfilled, the piping manufacturer shall prepare a declaration that the design is in compliance with the requirements

of this European Standard.

NOTE A specimen of the manufacturer’s declaration of design compliance is given in CEN/TR 13480-7.

A list of the relevant drawings shall be attached to the declaration.

7 In-process inspection and testing

7.1 General

Examinations and tests specified in EN 13480-5 shall be carried out by personnel trained for the method used.

European Standards or written procedures (where necessary) detailing the method and acceptance criteria shall be

available.

7.2 Materials and formed pressure retaining parts

7.2.1 General

The testing and inspection specified below shall be restricted to parts formed during the fabrication process,

especially induction bending. Formed bought out standardized parts and components shall not be a part of this

requirement.

7.2.2 Verification of material

A verification shall be performed that materials are in accordance with the specified material standard or purchase

order.

7.2.3 Verification of formed pressure retaining parts

It shall be verified that all formed pressure retaining parts comply with the specified shape and dimensional

requirements, and have received the specified finish or heat treatment.

7.2.4 Non-destructive testing of formed parts

All formed parts shall be subject to non-destructive testing.

The examination shall include, if appropriate:

 wall thickness measurements;

 dimensional checks (ovality, angle of bend etc.);

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EN 13480-5:2002 (E)

Issue 1 (2002-05)

 hardness tests;

 ultrasonic examination for volumetric (internal) imperfections in longitudinal and transversal direction;

 examination for surface or near surface imperfections (magnetic particle or penetrant examination);

 replicas of the surface structure in the tension zone (in case life monitoring is required for creep range

applications),

on each component or batch of identical components (dependent on the material and piping category).

Material, heat treatment conditions, heat treatment lot, degree of deformation shall be considered in the definition

of the batch.

7.2.5 Destructive testing of formed parts

Testing shall be performed to verify the heat treatment of the formed parts, and shall include:

 tensile test;

 hot tensile test (where items are being used in the creep range);

 notch impact test;

 micrographs (e.g. 9 % or 12 % Cr steels);

 other tests specified in EN 13480-2:2002 or in a European Standard for base material.

One set of test per cast, wall thickness range and heat treatment lot shall be performed for piping of piping

category II and III. The tests shall be performed on test pieces from the end of the component itself, or from test

pieces placed together with the components in the heat treatment furnaces.

7.3 Welding

7.3.1 Welding approvals

The following shall be verified:

 Welding procedure specifications (WPS) in accordance with EN 288-2, established for all welding activities

including tack welds and temporary attachment welds;

 Approval of all WPS to EN 13480-4.;

 Appropriate and current approval of all welders in accordance with EN 287-1 and all welding operators in

accordance with EN 1418.

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EN 13480-5:2002 (E)

Issue 1 (2002-05)

7.3.2 Inspection of welding set-up

Prior to carrying out any welding, each weld preparation shall be visually inspected. The inspection shall verify

compliance with the drawing and WPS, by ensuring the following:

 the correct materials are used;

 dimensions are within tolerance, including position, alignment, and orientation of branches, nozzles,

attachments and anchors, etc.;

 cleanliness and freedom from imperfections which may give rise to defects in the completed joint;

 nozzles, branches etc., properly fit the curvature of the pipe;

 tack welds that are to be incorporated into the final weld are free from cracks or other defects.

7.3.3 Testing and inspection during welding

The following testing and inspection shall be carried out, where appropriate, at suitable stages during the welding

operation to verify that the specified WPS is being followed for:

a) correct preheat;

b) correct welding process;

c) correct welding consumables;

d) correct electrical characteristics;

e) correct interpass temperature and cleaning;

f) other requirements of the WPS;

g) all tack welds and temporary attachments are welded in accordance with an approved WPS.

7.3.4 Inspection after welding

The following inspection shall be carried out on completion of welding:

a) examination for compliance with drawings;

b) verification that welds are correctly identified and traceable to the welder/operator;

c) verification that temporary attachments have been properly removed.

7.4 Heat treatment

For post-forming and post-weld heat treatment (PWHT), where applicable, it shall be verified by a review of the

heat treatment charts or by a hardness test, that the heat treatment carried out complies with the material

specification or to the appropriate heat treatment procedure.

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EN 13480-5:2002 (E)

Issue 1 (2002-05)

8 Non-destructive testing of welds

8.1 Application of NDT

8.1.1 General

8.1.1.1

The following shall be applicable to all welded joints:

a) Welded joints shall be visually examined in accordance with EN 970 before any other NDT is performed;

b) The area to be examined shall include the weld metal and the heat affected zones;

c) Surface examination stipulated in Table 8.2-1 shall be performed on the outer surface;

d) Where a welded joint is to be subsequently formed or heat treated, the required NDT shall be carried out on the

weld in the final condition. If a weld will not be accessible for examination after heat treatment or forming, the

parties involved shall agree on a suitable alternative;

e) NDT-method used and acceptance criteria for all NDT shall be in accordance with Table 8.4-1;

f) In case of austenitic base or filler material, the method for surface testing shall be PT.

8.1.1.2

Arc strikes and contact points with fused material shall be ground smooth and subjected to surface

examination appropriate to the material used.

8.1.1.3 Surface condition and preparation for non-destructive testing

The following criteria shall be met:

a) RT: surface dressing is required where ripples or weld surface irregularities will interfere with the interpretation

of the radiographs;

b) UT: surface dressing is required where the surfaces in contact with the probe prevent the scanning process;

c) MT: where necessary surface dressing is required to remove foreign matter to permit an accurate interpretation

of the indications.

d) PT: where necessary surface dressing is required to remove foreign matter to permit an accurate interpretation

of the indications.

NOTE Care should be taken to avoid masking of flaws by any surface dressing process.

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EN 13480-5:2002 (E)

Issue 1 (2002-05)

8.1.2 Examination of weld quality by sample inspection

Where the required extent of non-destructive testing is less than 100 %, the specified NDT techniques shall be

employed at the earliest stage practicable in the fabrication process to ensure that sound welds are achieved. The

timing shall be agreed between the parties involved. Sample joints to be examined shall be:

 randomly selected;

 representative of a group of welds.

At least one complete sample joint shall be examined over the whole circumference of the joint.

Where the number of sample joints required is small, combinations of thicker sections and smaller diameters or

thinner sections and greater diameters shall be given preference.

NOTE A group of welds is a quantity of welds, welded by one welder or welding operator, in accordance with a specific

welding procedure specification.

8.1.3 Imperfections revealed by sample inspection

When sample inspection reveals imperfections in a weld which are not acceptable to this European Standard, the

following shall apply:

a) Two additional welds of the same group shall be examined by the same method;

b) If these additional welds are acceptable, the initial weld shall be repaired or replaced and re-examined by the

original method;

c) If any one of these additional welds reveal an unacceptable imperfection, all welds in that group shall be fully

examined and, as necessary, repaired or replaced and re-examined.

The procedure illustrated in Figure 8.1-1 shall be followed.

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EN 13480-5:2002 (E)

Issue 1 (2002-05)

start

yes

Figure 8.1-1 — Flow diagram of additional testing required when imperfections have been revealed

random testing

welds

acceptable ?

test 2 additional welds

additional

welds

acce

table ?

test all welds of that group

repair tested welds with

unacceptable imperfections and

re-examine

welds

acceptable ?

end

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EN 13480-5:2002 (E)

Issue 1 (2002-05)

8.2 Circumferential butt, branch, fillet and seal welds

8.2.1 Amount of examination

The type of NDT required and its extent shall be determined in accordance with Table 8.2-1, taking into account the

piping category the piping is classified to.

The following additional conditions shall apply:

a) For piping where creep or fatigue is the controlling factor in design, it shall be assigned to piping category III

for determining the extent of NDT, irrespective of

and DN;

b) For piping in material groups 1.1, 1.2, and 8.1, in piping classes I or II, volumetric testing shall be a minimum

of 10 % of circumferential butt and branch welds irrespective of

and DN, if the piping is > DN 25 and

contains very toxic or extremely flammable fluids;

c) Where the specified NDT level is 5 %, this shall apply to the first 100 welds made. Where no unacceptable

imperfections are identified in this sample, the level of testing may be reduced to an overall level of 2 %.

However, the minimum number of welds examined shall be 5. All other requirements given in 8.1.2 shall

apply;

d) For the circumferential welds or where the calculated stresses across the weld (as determined using

EN 13480-3) are below 70 % of the nominal design stress for the design conditions, the amount of testing may

be reduced by 50 % of the values given in Table 8.2-1;

e) Piping for steam and superheated water (water at a pressure greater than 0,5 bar and at a temperature equal

to or greater than 110 C) shall be subject to the following NDT:

 where

· DN  5 000, 100 % volumetric testing of butt and branch welds;

 where

· DN  3 500, 25 % volumetric testing of butt and branch welds;

together with other testing specified in Table 8.2-1 for the combination of material, piping category and

thickness;

NOTE For piping operating at 100



C or more, at least 10 % of socket welds should be radiographed to confirm that an

adequate expansion gap has been achieved.

f) For the selection of the appropriate NDT method for volumetric testing, see Table 8.4-4.

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EN 13480-5:2002 (E)

Issue 1 (2002-05)

Table 8.2-1 — Extent of testing for circumferential, branch, fillet and seal welds

All

welds

Circumferential welds Branch welds Socket/fillet

welds

Seal welds

Surface testing Volumetric

testing

Surface testing Volumetric testing Surface testing Surface testing

Material

group

Piping Class

MT/PT

RT/UT

Branch

diameter

MT/PT

Branch

diameter

RT/UT

MT/PT

Nil

All Nil All Nil Nil

1.1

1.2

8.1

III

100

All

> DN 100 > 15 10 10

All

 30

5 10

> 30 10 10

 30

5 10

> 30 10 10

All

All Nil

All

 30

5 25

1.3, 1.4

2.1, 2.2

4.1, 4.2

8.2, 8.3

9.1, 9.2, 9.3

10.1, 10.2

III

100

> 30 10

All

> DN 100 > 15 10 All 25 All 25

 30

10 25

> 30 25 25

 30

25 25

> 30 25

25 25 25 10

 30

100 100

3.1, 3.2, 3.3

5.1, 5.2, 5.3

5.4, 6.1, 6.2,

6.3, 6.4, 7.1,

7.2, 11

III

100

> 30 100

100

All

100

All

100

All

100

All

100

Material group, see CR ISO 15608.

For the selection of the appropriate NDT-method for volumetric testing, see Table 8.4.2.

For ferritic materials preference shall be given to MT.

Additional testing for transverse defects from weld surface (see 8.4.4.2).

Only if PWHT has been carried out.

EN 13480-5:2002 (E)

Issue 1 (2002-05)

8.2.2 Dissimilar metal joints

The test methods and extent of testing for joints between ferritic and other materials (e.g. austenitic, nickel-based

alloys) shall be according to the highest material group which is applicable to the base materials.

8.3 Longitudinal welds

Longitudinal welds, except those in components made to material specifications acceptable to this European

Standard, shall be subject to the level of NDT appropriate to the joint coefficient required (see Table 8.3-1).

Table 8.3-1 — Extent of NDT for longitudinal welds

Joint coefficient

MT or PT

RT or UT

 0,7

100 0 0

0,7 <

 0,85

100 10 10

0,85 <

 1,0

100 100 100

for ferritic materials preference shall be given to MT.

see Table 8.4-3

8.4 NDT Methods

8.4.1 General

The NDT methods specified in the following clauses shall be performed in accordance with written NDT procedures,

and, where appropriate, with NDT instructions.

8.4.2 Acceptance criteria

The acceptance criteria for the NDT techniques shall follow the European Standards in Table 8.4-1. Requirements for

acceptance criteria for surface imperfections are given in Table 8.4-2 and additional requirements for acceptance

criteria for internal imperfections detected by RT are given in Table 8.4-3.

Table 8.4-1 — NDT techniques, method, acceptance criteria

NDT Technique

(abbreviation)

Method

Acceptance Criteria

Visual Examination (VT) EN 970 Table 8.4-2

Radiographic Testing (RT)

EN 1435:1997, class B

a b

EN 12517:1998

Acceptance level 2 and additional

requirements of Table 8.4-3

Ultrasonic Testing (UT)

EN 1714:1998, class B

EN 1712 :1997,

Acceptance level 2

Penetrant Testing (PT) EN 571-1 EN 1289 :1998,

Acceptance level 1

Magnetic Particle Testing (MT) EN 1290 EN 1291 :1998,

Acceptance level 1

However, the maximum area for single exposure shall correspond to the requirements of EN 1435:1997, class A.

Class A for material group 1.1, 1.2, 8.1 when piping class is I or II.

For the characterization of indications EN 1713 may be used.

Acceptance level 3 for material group 1.1, 1.2, 8.1 when piping class is I or II.