Pre-production and test programs

Working closely with the top plate and pipe mills and suppliers of subsea equipment, we advise on every aspect of pre-production and testing programs.

At pre-production meetings, Microalloying consultants:

• Review the Manufacturing Pipe Specification (MPS) and Inspection Test Plan (ITP)
• Discuss and provide input for all operations as required
• Review qualification results
• Approve MPS and ITP

We also develop special pre-production test programs for:

• API RP2Z
• Strain-based design

Process management

With our knowledge of required specifications, we can develop, analyze, inspect or manage any pipe mill or subsea process for optimal results:

• Expertise in ERW, HFIW, DSAW (straight and helical seam) and seamless pipe
• Supervision of subsea equipment including materials and functional qualification programs
• Capable of conducting qualification audits and analysis of manufacturing sources
• Development of inspection execution plans to support client specifications or requirements

Overseeing welding production

Our experts consult on the production of manual and mechanized welding specifications:

• Mainline girth weld procedures
• Repair weld procedures
• Tie-in weld procedures
• In-service welding
• Fatigue and fracture critical flowlines and risers
• Subsea infrastructure (trees, manifolds, PLETs, etc.)

Welding process management

From choice of contractor to sign off of final documentation, we can manage all welding requirements:

• Selection of welding contractor and welding equipment
• Weld procedure development and optimization
• Fabrication of girth weld qualification samples
• Weld procedure qualification testing using both API, DNV, CSA, ISO and AS code mechanical tests, and alternative acceptance criteria testing such as CTOD and SENT, as well as sour service (SS) and SS fatigue tests
• Tie-in and repair procedures
• Review and approval of weld procedures and qualification records
• Compilation of qualification records and supply of the documentation package where required

Complete NDE testing

We consult on all non-destructive procedures:

• NDE specifications including AUT, MUT, RT, MPI, DPI etc.
• Selection of NDE contractors
• Review of proposed NDE procedures
• Coordination of material for calibration block production, as required
• Fabrication of girth welds samples, with typical fabrication defects embedded (seeded defects) where required
• Coordination of AUT inspection of welds with seeded defects and supply RT of these welds as needed
• Destructive sectioning of girth weld samples
• Statistical analysis of AUT predictions, RT reports and actual measured flaw sizes
• Determination of NDE sizing errors for AUT
• Approval of NDE procedures
• Compilation of qualification records and supplying documentation package

Critical support for offshore pipelines

Review of pipeline stress analysis:

• Extreme event stress
• Fatigue stress histograms

Pipeline installation stress analysis:

• S-Lay
• J-Lay
• Reeled installation

Girth weld stress analysis:

• Hi-Lo misalignment
• Ovality
• Weld toe stress concentration

Engineering critical assessment

ECA analysis to develop girth weld flaw acceptance criteria in accordance with the following codes:

• API 1104 – Appendix A (19th and 20th Editions)
• CSA Z662 – Appendix K
• AS 2885-2
• BS 7910
• API 579

Strain-based design of pipelines:

• Qualification requirements
• Analysis and validation testing

Assess interaction with pipeline regulators.

Comprehensive management of NDE audit steps

Our consultants handle every aspect of the audit process:

• Real time independent feedback on NDE operations (AUT, MUT, RT, etc.)
• Interaction with regulatory bodies such as PHMSA to assure code compliance
• Coordination of onsite audits
• First level interaction between contractor and client on technical issues and potential change orders. This includes the technical merits of any changes, and assistance with the implementation of any mid-course corrections to equipment, consumables, procedures, etc.

Assistance to achieve compliance

We oversee the processes necessary for compliance and communication in your welding operations:

• Real time independent feedback on welding operations
• Interaction with regulatory bodies such as PHMSA to assure code compliance
• Coordination of onsite audits
• First level interaction between contractor and client on technical issues and potential change orders. This includes the technical merits of any changes, and assistance with the implementation of any mid-course corrections to equipment, consumables, procedures, etc.

Tailored to requirements

Contact your local Microalloying office for a complete list of our training services, including:

• Engineering Critical Assessment (ECA)
• Fracture mechanics
• AUT interpretation
• Welding Procedure Specification (WPS)
• Pipeline integrity
• Corrosion and corrosion control