PROCEDURE NO: PROJECT SPECIFIC PROCEDURE PSP-RESAK HTI-11 HUC REVISION NO. 0 NDE PROCEDURE (ULTRASONIC TESTING) FOR PETRONAS CARIGALI SDN BED KUALA LUMPUR, This procedure is only valid until Level ILI PCN/ASNT has sign for approval. DAYANG ENTERPRISE SDN BED Ff PCSB PREPARED BY REVIEWED BY APPROVED BY REVIEWED BY | APPROVED BY BB. | nace i © [176 (Grex | L.| Kot mA foe. | irae SEYPROCEDURE NO: NDE PROCEDURE PSP-RESAK-HTI-11 (ULTRASONIC TESTING) _ NaS Eee PAGE 10F7 TABLE OF CONTENTS SECTION DESCRIPTION PA 1.0 PURPOSE 2.0 SCOPE 3.0 REFERENCES 40 DEFINITIONS 50 PROCEDURES 5.1 Equipment 5.2 Couplant 5.3 Surface Preparation 5.4 Calibration for Testing 5.5. Sensitivity Calibration 5.6 Scanning Requirement Appendices i, Test Procedure a) UT-01 b) UT-02 °) Ur @) UT-04 ©) Ur-05 ) UT—06 2) UT-07 ii, Tubular Structure iii, Equipment Qualification iv. NDT Request Form ve UT Report (This procedure is only valid for Resak HTT)PROCEDURE NO: j NDE PROCEDURE See ei / ____ (ULTRASONIC TESTING) REVISION NO. 0 d HUC PAGE 2 OF 7 1.0 20 3.0 40 5.0 PURPOSE ‘The purpose of this procedure is to define Ultrasonic Testing (UT) technique, which are to be used for the detection, location, evaluation of defects within the weld and heat affected zone (HAZ) and the method of recording the results of the subject inspection. SCOPE ‘This testing procedure describes the requirement of technique to manual ultrasonic testing of fusion welds in ferrtic steel. The procedure is written in accordance with code and specification. The procedure covers examination of full penetration of butt weld and TK and Y connections. This service is awarded to LI Inspection and Services Sdn Bhd, REFERENCES AWS DLL - Structural Welding Code (Steel) (ASME V ~ Non Destructive Examination (NDE) PTS 50.015 - Ultrasonic Testing SNT-TC-1A - Recommended Practice for Personnel Qualification and Certification in NDT (Latest Edition) API RP-2X. ~ Recommend Practice for UT and MT of Offshore Structural Fabrication & Guidelines for Qualification of Technician, ASTM A 435 - Standard Specification for Straight Beam Ultrasonic Examination of Steel Plate ASME B 31.1 - Power Piping DEFINITIONS PROCEDURE 5.1 Equipment 5.1.1. Portable ultrasonic pulsereflection system (‘A’ scan presentation) generating frequency range of 1.0 MHz to 5.0 MHz will be used. Such instrument includes the Krautkramar USK-6, USK-7B or Sonatest Sitescan 130. (Chis procedure is only valid for Resak HTT)PROCEDURE NO : j NDE PROCEDURE PSP-RESAK-HTI-11 I (ULTRASONIC TESTING) tet on Noi UC PAGE 3 OF7 5.1.2. Probes either single or twin crystals round or square with sizes ranging 6.4mm to 25.4mmi shall be used. ‘The prob shall produce a second beam in the material being tested within +2 degrees of the following reflected angle 45*, 60° and 70°, 5.1.3 The proper functioning of the combination of the probe/UT set, check shall be arried out include:~ i. Probe Index fi, Probe Angle iii, Time Base linearity iv, Attenuator Control Linearity v. Amplitude Linearity Degree of accuracy shall be accordance with the tolerance level specified on the Equipment Qualification record sheet. 5.1.4 Viewing hoodoverthe CRT screen shall be used if ultrasonic testing to be cartied out in bright condition, 5.2 Couplant Grease, oil, water base paste (cellulose) or any other suitable couplant may be used. Same couplant shall be used in calibration and production testing, 5.3 Surface Preparation 5.3.1 The examination surface shall be free from weld spatter, scaling, pitting, inegularities, any foreign matter or thick coating which could interfere with the ultrasonic wave transmission. Grinding may be required to achieved the desired surface condition, 5.4 Calibration For Testing 5.4.1. Calibration for sensitivity and beam path distance shall be made by the operator just prior to and at the location of testing of each weld. 5.4.2 Re-calibration shall be made after a change of operator or when the electrical circuitry is disturbed in any way which includes the following : i) Battery change ii) Blectrical Outlet Change iii) Probe Change iv) Coaxil Cable Change ¥) Power Failure (This procedure is only valid for Resak HTT)PROCEDURE NO: NDE PROCEDURE PSP-RESAK-HTE-11 __ (ULTRASONIC TESTING) REVISION NO. 0 AUC PAGE 4 OF7 5.4.3 Calibration for straight beam testing of base metal adjacent to weldment shall be made by adjusting the distance calibration to present the equivalent of at least two plate thicknesses on the CRT screen, ‘The sensitivity shall be adjusted at a location free of indication so that the second back reflection from the far side of the base metal will be 50% to 70% of full screen height (FSH). Any indication that could interfere with the examination of the weld shall be recorded, 5.4.4 Time base calibration for angle beam testing shall be performed by adjusting the base to represent at least the maximum sound path distance being used. 5.5 Sensitivity Calibration Standard sensitivity for examination of production weld using Amplitude Technique shall be : {Baste sensitivity | +[ Distance Amplitude Correction +{Transfer Correction ] Basic Sensitivity 5.5.1 Reference level screen height obtained using maximum reflection from 1.5mm diameter hole in the 1.1.W, block. 5.5.2 Distance Amplitude Correction The sensitivity level shall be adjusted to provide for attenuation Joss throughout the range of sound path. 5.5.3 Transfer Correction ‘Transfer Correction may be used to accommodate ultrasonic through tight layers of paint not exceeding 10 mils (0.25mm) in thickness, (Lhis procedure is only valid for Resak HTT)PROCEDURE NO : | | NDE PROCEDURE PSP-RESAK-HTT-11 L _ (ULTRASONIC TESTING REVISION NO.0 i HUC PAGE 5 OF7 5.6 Scanning Requirement 5.6.1 When practicable scanning shall be performed at a gain setting of at least two times (i.e. +6dB) the primary reference level, 5.6.2 The rate of probe movement shall not exceed 6 inch per second. 5.63 5.6.4 Probe movement during scanning shall be combination of swivel, orbital, lateral, transverse motion and with a minimum overlapping of 10 percent of the probe dimension, The selection of probe angle for scanning different material thickness as follows : Weld Thickness Probe Angle 8mm to 12mm inclusive 70° 13mm to 25mm inclusive 60° and 70° 26mm and above 45° and 60?, supplemented by 70” for specified zone such as weld fusion zone and root. Root Scanning al root scan at stand off distance of Y skip from near root penetration face shall be carried out on full penetration constant configuration joints. Probe angles employed for critical root scan for different material thickness will be as follows :- Weld Thickness Probe Angle 8mm to 12mm inclusive 710° 13mm to 25mm inclusive 60° and 70° 26mm and above 45° and 60° (Lhis procedure is only valid for Resak HTT)PROCEDURE NO: NDE PROCEDURE PSP-RESAK-HTE-L1 (ULTRASONIC TESTING) SEI ON ETE HUC : i PAGE 6 OF 7 6.0 TESTING PROCEDURE 6.1 The entire base metal through which ultrasonic must travel to test the weld shall be tested for Jaminar reflectors using a straight beam probe. If reflectors are detected and cause total loss of back wall echo or interfere with weld scanning, its location, depth and size will be reported on the UT report and marked on the job with the use of permanent marker, 6.2 Weld and parent profile configuration will be copied by the use of wire Mimic or profile gauge. All testing of the weld shall be made in Leg I and Leg Il only if full coverage cannot be obtained in Leg 1 (within % skip distance). The probe movement must be sufficient to ensure that the centre of the beam passes over the areas of weld calculated in section 8, for the particular angle sclected. This will ensure the ‘maximum coverage, Any area of restricted test shall be recorded on the UT Report as a longth and a reason, 6.3 UT Test Procedure i) Ur-01 Butt weld accessible from one side, ii) UT-02 Butt weld accessible from both sides. iff) UT-03 Full penetration nozzic or structural comer joint, iv) UT-04 Full penctration nozzle or structural corner joint accessible from one side. y) UT-05 Full penetration T-joint accessible from both sides. vi) UT-06 Full penetration fillet in lap joint. vii) UT-07 .K-Y connection, 6.4 Defect Evaluation And Sizing 6.4.1 Alll reflections from defects will be maximized from all angels to find the best angle which is most favourable to the defect orientation, 6.4.2 Defect shall be evaluated as follows, determined by i) Flaw location ii) Defect screen presentation iii) Probe movement and manipulation if the flaw is spherical, planar or linear. (This procedure is only valid for Resak HT)‘PROCEDURE NO : NDE PROCEDURE PSP-RESAK-HTI-1L (ULTRASONIC TESTING) HUC REVISION NO. 0 PAGE 7 OF 7 6.4.3 The length of the defect shall be established by means of 6dB drop technique. ‘The height of the defect (je through thickness dimension) shall be sized by means of the 20 dB drop technique or maximum amplitude technique. 7.0 SPECIAL REQUIREMENT 7.1 Acceptance criteria of a component shall be referred to the applicable section of 6.13.1, 6.13.2 or 6.13.3. 8.0 RECORD 8.1 All test performed shall be recorded in the proper reports with the following information included : 8) Project Title/Job Number b) Weld identification ©) Weld geometry 4) Specification for acceptance ©) Equipment used 1) Result of test 2) Name, signature of tester h) Date of test (Chis procedure is only valid for Resak HTD)LI INSPECTION & SERVICES SDN.BED. LJ INSPECTION & SERVICE SDN.BHD UT PROCEDURE, JJAUTIAWS D1.1-009 REVISION - OL ULTRASONIC TESTING PROCEDURE SPECIFICATION ULTRASONIC TESTING ~ PAGE 1LI INSPECTION & SERVICES SDN.BHD LI INSPECTION & SERVICE SDN BHD UT PROCEDURE: LIAITIAWS DI.1-009 REVISION - Ot CONTENTS 1 Scope 2 Qualification of personno! 3 Equipment 4 Reference and calibration standards 5 Couplant 6 Surface preparation 7 Calibration of testing 8 Sensitivity of calibration 9 Scanning requirement 10 Testing Procedure 14 Defect evaluation and sizing 12 Reporting 13° Acceptance Criteria UT Test Procedures UT-01 Butt weld- accessible from one side UT-02_ Butt weld-accessible from both sides UT-03 Full penetration nozzle or structural comer Joint - accessible on both sides, UT-04 Full penetration nozzle- accessible from one side UT-05 Full penetration Teint UT-06 Full penetration fillet weld in lap joint UT-07 T.K-Y Connection Tubular Structure Equipment qualification check sheet Sample Of UT Report ULTRASONIC TESTING ~ PAGE 2 46 56 67 10 " 12 13 14 15-46 7LI INSPECTION & SERVICES SDNBHD LIINSPECTION & SERVICE SDN.BHD UT PROCEDURE LIAST/AWS DI. 1-009 REVISION - 01 SCOPE, This testing procedure describes the requirement of technique to manuel ultrasonic testing of fusion welds in ferritic steel. The procedure is written in accordance with AWS D1.4 ‘The procedure covers exemination of full penetration of butt weld and T, K or Y connections, 1.1 Reference Code AWS D1.1 Structural Welding Code (1996 Edition) ASME Sec. V Non- Destructive Examination (1889 Edition) SNT-TC-1A Recommended Practice for Personnel Qualification and Certification in NDT (1996 Edition) QUALIFICATION OF PERSONNEL 24 UT Practitioner shall be qualified in accordance with the LJISSB Written Practice established in compliance with SNT-TC-4A (Current Code accepted Edition Personnel Qualification and Certification In Non-Dastructive Testing) 22 UT Practitioner certified to NDT Level Il or Level Ii shall perform the test, EQUIPMENT 3.4 Portable ultrasonic pulse reflection system (‘A’ scan presentation) generating frequency range of 1.0 MHz to 5.0 MHz will be used, Such instrument includes the Krautkramer USK6, USK-78 or Sonatest Sitescan 130. 3.2 Probes either single or twin crystals round or square with sizes ranging 6.4mm 25.4mm shall be used. The probe shall produce a second beam in the material being tested within 2 degrees of the following reflected angle 45°, 60* or 70" 3.3 The proper functioning of the combination of the probe UT set, check shall be carried out include:~ Probe index ii) Probe angle iil) Time base linearity iv) Attenuator Control Linearity Vv) Amplitude Linearity, Degree of accuracy shall be in accordance with the tolerance level specified on the Equipment Qualification record sheet, 34 Viewing hood over the CRT screen shall be used if ultrasonic testing to be carried ut in bright condition, REFERENCE AND CALIBRATION STANDARDS 4.4 LLW.V4 Block Used for generat calibration, equipment checks and basic sensitivity setting for shear wave. le, the 1.6mm diameter hole at a depth 1mm. 42 |LLW. V2 (DIN 54122) Block For general distance calibration, howaver it must be referred back to the L.IW. V1 Block to determine their accuracy. } ULTRASONIC TESTING ~ PAGE 3 (WW /LI INSPECTION & SERVICES SDN. BHD LIINSPECTION & SERVICE SDN.BHD UT PROCEDURE LIASTIAWS DI. 1-009 REVISION - Ot 43 LO.WBlock ‘To be used to construct beam profiles, aistance amplitude correction curves and Provide a resolution check for shear wave probes, COUPLANT Grease, oll. water base paste (cellulose) or any other suitable couplant may be used, Same Couplant shall be used in calibration and production testing, ‘SURFACE PREPARATION he examination surface shall be free from weld spatter, scaling, pillng, regulars, any Groign matter or thick coating which could interfere with the ultrasonic wave transmieeior Grinding may be required to achieved the desired surface condition, CALIBRATION FOR TESTING 7-41 Calloration for sensitvty and beam path distance shell be made by the operator just prior to and at the location of testing of each weld, 72 Re-calbration shall be made after a change of operator or when the electrical Clrouity is disturbed in any way which includes the following: 1) Battery change ji) Electrical Outlet Change Hil) Probe Change iv) Coaxil Cable Change ¥) Power Feilure 7.3 Calibration for straight beam testing of base metal adjacent to weldment shall be made by acjusting the distance calioration to present the equivalent of at foact two plate thicknesses on the CRT screen, The Sensitivity shall be adjusted at @ location free of indication so that the second back reflection from the far skie of the base metal will be 50% to 70% of full erosn height (FSH). Any indication that could interiere with the examination of the weld shall be recorded, 7.4 Time base calibration for angle beam testing shall be performed by adjusting the base to represent at least the maximum sound path distance being used SENSITIVITY CALIBRATION Standard sensitivity for examination of production weld using Amplitude Technique shall be Basic sonsit ivity + Distance Amplitude Correction +Transfer Correction, A) Basic Sensitivity Reference level screen height obtained using maximum reflection from 1.8mm diameter hole in the LLW. block. , \LIINSPECTION & SERVICES SDN.BHD. LI INSPECTION & SERVICE SON.BHD UT PROCEDURE, LUUTIAWS DI.1-009 REVISION -01 B) c) ot 9.2 9.3 84 95 Distance Amplitude Correction ‘The sensitivity level shall be adjusted to provide for attenvation loss throughout the range of sound path Transfer Correction Transfer Correction may be used to accommodate ultrasonie through tight layers of Paint not exceeding 10 mils (0.25mm) in thickness. SCANNING REQUIREMENT When practicable scanning shall be performed at a gain setting of at least two times (ie, +6dB) the primary reference level ‘The rate of probe movement shail not exceed 6 inch per second, Probe movement during scanning shall be combination of swivel, orbital, lateral, transverse motion and with @ minimum overlapping of 10 percent of the probe dimension, ‘The selection of probe angle for scanning different material thickness as follows: Weld Thickness Probe Angi ‘&mm to 12mm inclusive 70° 13mm to 26mm inclusive 60° and 70° 26mm and above 48 ° and 60 *, supplemented by 70 ° for speaified zone such as weld fusion zone and root Root scanning A critical root scan at stand off distance of % skip from near root penetration face shall be carried out on full penetration constant configuration joints, Probe angles employed for critical root scan for different material thickness will be as follows: Wold Thickness Probe Angle ‘8mm to 12mm inclusive 70° 13mm to 25mm inclusive 60° and 70° 26mm and above 45° and 60 * 10. TESTING PROCEDURE 104 10.2 The entire base metal through which ultrasonic must travel to test the weld shall be {ested for laminar reflectors using a straight beam probe. If reflectors are detected and cause total loss of back wall echo or interfere with weld scanning, ts location, depth and size will be reported on the UT report and marked on the job with the uso ‘of permanent marker. Weld and parent profile configuration will be copied by the use of wire Mimic or Profile gauge, All testing of the weld shail be made in Leg 1 and Leg Hl onlyfit ful coverage cannot be obtained in Leg 1 (within % skip distance) / 7 | 7 ULTRASONIC TESTING — PAGE § rN ( \ \O \.