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TABLE OF CONTENTS
SECTION
DESCRIPTION
PAGE
1.0
PURPOSE
.............................................................
2.0
SCOPE
.............................................................
3.0
REFERENCES...........................................................
4.0
DEFINITIONS
..........................................................
5.0
PROCEDURES ..........................................................
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
Surface preparation.........................................
Couplant..........................................................
Ultrasonic equipment.......................................
Search Unit......................................................
Calibration........................................................
Rate of Search Unit Movement........................
Technique.........................................................
Sensitivity Level................................................
Transfer Loss....................................................
Qualification of Personnel.................................
Interpretation and Evaluation............................
Method of Defect Sizing....................................
Acceptance Criteria...........................................
Reports..............................................................
4
4
4
4
4
7
7
8
8
10
10
10
10
11
6.0
SPECIAL REQUIREMENTS...................................................
11
7.0
RECORDS...............................................................................
11
Attachment
Attachment
Attachment
Attachment
12
19
26
27
28
29
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1.0
PURPOSE
1.1
This procedure describes general requirement and techniques for the ultrasonic Ascan examination on fusion welded joint of ferritic steels for structural groove welds
and TKY joints.
1.2
This procedure utilizes angle beam or straight beam or both, depending upon the
specific weld configuration.
1.3
2.0
SCOPE
This procedure covers the personnel qualification, equipment, surface preparation,
instrument calibration, scanning technique, defect sizing, location and interpretation of
ultrasonic examination.
3.0
REFERENCES
The following codes and standards shall form parts of the requirement of this
procedure.
API RP 2X
4.0
ASME V
ASME E 164
ASTM A435
DEFINITIONS
NDT
UT
PCN
ASNT
ASME
ASTM
CSWIP
DAC
:
:
:
:
:
:
:
:
Non-destructive Testing.
Ultrasonic Testing.
Personnel Certification in Non-Destructive Testing.
American Society for Non Destructive Testing.
American Society of Mechanical Engineer.
American Society for Testing and Materials.
Certification Scheme of Welding and Inspection Personnel.
Distance Amplitude Curve.
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5.0
PROCEDURES
5.1
Surface Preparation
All scanning surface shall be free from loose scale, weld spatter, dirt and shall be of
sufficient uniform contour and smoothness that satisfactory acoustic coupling can be
maintained.
5.2
Couplant
A couplant material shall be used between the search unit and the test material. The
couplant shall be a liquid, gel or paste medium suitable for the application and
compatible with the material under test.
The maximum surface temperature when using conventional probe and couplants
shall not exceed 50C.
5.3
Ultrasonic Equipment
5.3.1
5.4
Search Unit
Straight Beam Probe :
5.5
5.4.1
5.4.2
Calibration
5.5.1
Instrument Calibration
5.5.1.1
Linearity of amplifier
The ultrasonic equipment use shall have linear vertical
presentation within 5% of the full screen height for 20% to 80%
of the calibrated screen height.
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5.5.1.2
5.5.2
5.5.2.2
5.5.2.3
5.5.2.4
5.5.2.5
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Fig 5.5 Distance Calibration of time base Block
1.5
91
100
100
perspex
100
50
25
300
Fig 5.5.2: IIW V2 Block
25
50
1.5
75
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5.6
5.7
Technique
Ultrasonic Flaw Detection shall be pulse echo straight beam or angle beam or both
with depend on joint figuration and shall be used contact method with A-scan
presentation.
Test Coverage
5.7.1
Where imperfections are detected their location and area shall be recorded.
Ultrasonic scanning shall be examined by the pulse echo technique using
straight beam probe and scanning procedure shall be in accordance to Detail
1A.
5.7.2
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5.8
Sensitivity Level
5.8.1
5.8.2
80% FSH
100% DAC
50% DAC
10
20
30
40
50
60
70
80
90
100
5.9
Transfer Loss
5.9.1
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5.9.1.1
Use two angle beam probes of the same type. One acting as
transmitter and the other as receiver.
5.9.1.2
5.9.1.3
5.9.1.4
5.9.1.5
5.9.1.6
(Transmitter)
Fixed
Receiver
(position 1)
Receiver
(position 2)
75%
50%
25%
1 Skip
2 Skip
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5.10
Qualification of Personnel
5.10.1 Ultrasonic operators shall be qualified to CSWIP 3.1, 3.2 & 3.9 or PCN Level II
Document showing evidence about the UT Operator Qualification shall be
submitted for approval.
5.10.2 Ultrasonic operators qualified SNT-TC-1A Level II shall be demonstrate their
ability throughout practical, mock up test conducted by contractor and
approved by Client.
5.11
5.12
5.11.1.1
5.11.1.2
5.11.1.3
5.13
Acceptance Criteria
Limitation of imperfections shall be evaluated as in the following code and standards.
For weldments:
API RP 2X Level C
For padeyes and lifting padeyes:
API RP 2X Level A
Discontinuities interpreted as cracks shall be unacceptable regardless length and
indication amplitudes
For laminations:
ASTM A435:
Specification for Straight Beam Ultrasonic Examination of Steel
Plate.
Acceptable laminar discontinuities within 100mm of weld areas shall be recorded.
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5.14
Reports
The ultrasonic test reports shall consist of the following information. :
Procedure use
Ultrasonic Examination Equipment
UT Personnel and level of qualification
Calibration Data
Identification and location of test area.
Map or record of indication detected or areas.
Date of examination.
Basic calibration block used.
Surface condition
Probe frequency
The format of the Ultrasonic Examination Reports is shown in the attachment. Reports
shall be accompanied with sketches of part being tested and location of indication, if
any. Welds found unacceptable shall be repaired and retested by the same ultrasonic
testing technique with results tabulated on additional report form with R1 or R2
prefixed in the same report number.
6.0
SPECIAL REQUIREMENTS
The use of corner reflector for distance calibrator is not acceptable
7.0
RECORDS
All rejectable and acceptable discontinuities having more than half (6 dB) of the
amplitude at standard sensitivity level shall be reported in the Ultrasonic Examination
Report.
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DETAIL I
1.0
The parent metal shall be examined manually by the pulse echo technique
using a compressional single or twin crystal normal probe. Probe size and
frequency shall be within 10mm to 25mm diameter and 2 MHz to 2.5 MHz.
2.0
The scanning sensitivity shall be set on the parent metal in an area free from
imperfection such that the second back wall echo (BWE) is displayed at full
screen height (100% FSH).
3.0
The parent metal shall be scanned to and fro from weld toe or fusion line to
distance of five time wall thickness (5t). Scanning may be done by zig-zag
pattern with 10% overlap and speed not more than 6 in/sec.
4.0
Any discontinuity indication that cause total loss of second back wall echo
(BWE) reflection shall be investigated. The location, depth and size of
discontinuity area shall be recorded.
Normal probe
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B. WELD EXAMINATION
1.0
The weld shall be examined manually by the pulse echo technique using
shear ware probe and compressional wave probe. Probe size and frequency
for angle probe should be 8mm x 9mm crystal size and 2 MHz to 5 MHz, while
normal probe size and frequency should within 10mm to 25mm diameter and 2
MHz to 5 MHz.
2.0
Standard sensitivity for the examination of weld shall be: Basic sensitivity +
distance amplitude correction. While scanning sensitivity shall be standard
sensitivity plus (+) scanning levels as below table.
Scanning Levels
Sound Path ** in in. (mm)
Through 2-1/2 (64mm)
> 2-1/2 through 5 (64-127mm)
> 5 through 10 (127-254mm)
> 10 through 15 (254-381mm)
Scanning Technique
3.1
3.2
All butt joint welds shall be tested from each side of the weld axis.
Corner and T-Joint weld shall be primarily tested from one side of the
weld axis only. All welds shall be tested using the applicable scanning
pattern shown in figure B1 as necessary to detect both longitudinal and
transverse flaws.
It is intended that, as a minimum, all welds be tested by passing sound
through the entire column of the weld and heat-affected zone in two
crossing direction, wherever practical.
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Weld Axis
Pattern D
Pattern E
Movement A
Movement C
Movement B
Notes :
1. Testing patterns are all symmetrical around the weld axis with the exception of pattern
D which is conducted directly over the weld axis.
2. Testing from both sides of the weld axis is to be made wherever mechanically
possible.
Figure B1 Plan View of UT Scanning Patterns
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Weld
Type
(8.0)
to
(38.1)
>38.1
to
(44.5)
IG
or F
4
IG
O F
r
5
Butt
T-
F
O
r
X
F
F
O
r
X
F
F
O
r
X
F
*
6
or
7
F
or
XF
F
O
r
X
F
IG
O
r
4
F
O
r
X
F
IG F
or O
5 r
X
F
6
or
7
F
or
XF
IG 1*
O *
r
4
IG P
or 1
3 O
r
P
3
6
or
7
P3
Corner
Electrog
as&
Electrosl
ag
Table 3.1.1
Material Thickness. in. (mm)
>44.5
>63.5
>88.9
114.3
to
to
to
to
(63.5) (88.9) (114.3) (127.0
)
>127
to
(165.1)
*
8
or
1
0
1
0
8
or
1
0
1
1
or
1
5
F
or
X
F
F
O
r
X
F
P
3
165.1
to
7(177.
8)
*
9
or
1
1
1
1
9
or
1
1
1
1
or
1
5
*
1
2
or
1
3
F
or
X
F
F
1
or 3
XF or
1
4
F
or
X
F
1
1
or
1
5
*
12
F
Or 1
XF 3
P3
177.8
to
8(203)
P
3
11
or
15
**
P3
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Receiver
Face A
x
Transmit
x
Face A
X
Face A
E
Face B
Face B
Face B
BUTT JOINT
CORNER JOINT
T-JOINT
Face A
PITCH-AND-CATCH
Ground Flush
Top
Quarter70
Middle Half -70
Bottom
1. Where possible, all examinations shall be made from Face A and in Leg 1, unless
otherwise specified in this Table.
2. Root areas of single groove weld joints which have backing not requiring removal by
contract, shall be tested in Leg 1, where possible, with Face A being that opposite the
backing. (Grinding of the weld face or testing from additional weld faces may be
necessary to permit complete scanning of the weld root.)
3. Examination in Leg II or III shall be made only to satisfy provisions of this table or when
necessary to test weld areas made inaccessible by an unground weld surface, or
interference with other portions of the weldment, or to meet the requirements of 4.2.
4. A maximum of Leg III shall be used only where thickness or geometry prevents
scanning of complete weld areas and heat affected zones in Leg 1 or Legg II
5. On tension welds in cyclically loaded structures, the top quarter of thickness shall be
tested with the final leg of sound progressing from Face B toward Face A, the bottom
quarter of thickness shall be tested with the final leg of sound progressing from Face A
toward Face B, i.e the top quarter of thickness shall be tested either from Face A in Leg II
or from Face B in Leg I at the contractors option, unless specified in the contract
documents.
6. The weld face indicated shall be ground flush before using procedure IG, 6, 8, 9, 12, 14
or 15. Face A for both connected members shall be in the same place.
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3.1.1 Legend
_____________________________________________________________________________
X
Check from Face C
G
Grind weld face flush
O
Not required
A Face
the face of the material from which the initial scanning is done (on T
and corner joints, follow
above sketches)
B Face
opposite the A face (same plate)
C Face
the face opposite the weld on the connecting member or a T-or corner
joint
*
Required only where display reference height indication of
discontinuity
is noted at the weld metal-base metal interface while searching at
scanning level with primary procedures selected form first column.
**
Use 15in. (380mm) or 20 in. (510mm) screen distance calibration
P
Pitch and catch shall be conducted for further discontinuity
evaluation in only
the middle half of the material thickness with only 45 deg or 70 deg
transducers of equal specification, both facing the weld. (Transducers
must be held in a fixture to control positioning-see sketch). Amplitude
calibration for pitch and catch is normally made by calibrating a single
search unit. When switching to dual search units for pitch and catch
inspection, there should be assurance that this calibration does not
change as a result of instrument variables.
F
Weld metal-base metal interface indications shall be further evaluated
with
either 70 deg, 60 deg or 45 deg transducer-whichever sound path is
nearest to being perpendicular to the suspected fusion surface.
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Procedure Legend
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Top Quarter
70
60
45
60
45
70G A
60B
70G A
70G A
60B
45B
70G A
45B
70G A
70G A
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DETAIL II :
Component
Material Thickness:
i.
Test surface shall be clean and smooth. Filing or light grinding (if
permitted) should be carried out on pitted surface. Paint work shall be
removed for thickness gauging.
ii.
Apply thin layer of couplant on the test point and place the probe over
the couplant. Press the probe lightly and evenly onto the test surface.
iii.
Maximised the signal to get a stable reading. Twist the probe lightly if
stable signal could not be achieved.
iv.
Record down the reading with sketch. For lamination check, at least
two signals which indicate the wall thickness should be seen.
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2.0
Component
Material
Thickness
Joint Preparation
: 8 mm and above
:
Inspection Sequence:
i.
0 degree Probe scan until 2 skips distance from weld centre line from both
side of welds.
ii.
iii.
With appropriate angle probes, scan the whole volume of the weld.
iv.
If transverse defect is detected and accurate sizing is required, grind flush the
weld cap and scan with 0 degree probes and appropriate angle probes from
flushed area. (Longitudinal Scan).
v.
vi.
vii.
viii.
All defective area shall be marked, with cross section of defective weld
marked adjacent to defective area.
ix.
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3.0
Component
Material
Thickness
8 mm and above
Joint
:
Single or double Vee/Bevel without backing strip.
Preparation
Inspection Sequence
i.
0 degree Probe- scan until 2 skips distance from weld centre line from both
sides of weld.
ii.
iii.
With appropriate angle probes, scan the whole volume of the weld.
iv.
If transverse defect is detected and accurate sizing is required, grind flush the
weld cap and scan with 0 degree probes and appropriate angle probes from
flushed area. (Longitudinal Scan).
v.
vi.
vii.
viii.
All defective areas shall be marked, with cross section of defective weld
adjacent to defective area.
ix.
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4.0
Component
Material
Thickness
Joint
Preparation
Single/Double Bevel
FACE A
0
FACE B
If accessible
FACE A
Inspection Sequence:
i.
0 degree Probe Scan until one skip distance from edge of weld on face A. If
accessible, scan from face B for laminar tearing and lack of fusion.
ii.
Root scan as per Section 5.7.2. Then scan the whole volume of weld with
other appropriate angle probes.
iii.
iv.
v.
vi.
All defective areas shall be marked, with cross section of defective weld
marked adjacent to defective area.
vii.
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5.0
Component
Material
Thickness
8 mm and above
Joint
Preparation
Single/Double Bevel
Inspection Sequence:
i.
0 degree Probe Scan until one skip distance from edge of weld on face A. If
accessible, scan from face B for laminar tearing and lack of fusion.
ii.
Root scan as per Section 5.7.2. Then scan the whole volume of weld with
other appropriate angle probes.
iii.
iv.
v.
vi.
All defective areas shall be marked, with cross section of defective weld
marked adjacent to defective area.
vii.
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6.0
Component
Material
Thickness
8 mm and above
Joint
Preparation
Single Bevel
Inspection Sequence:
i.
0 degree Probe Scan until one skip distance from edge of weld on face A. If
accessible, scan from face B for lamellar tearing and lack of fusion.
ii.
Root scan as per Section 5.7.2. Then scan the whole volume of weld with
other appropriate angle probes.
iii.
iv.
v.
Due to the curvature of the stub, small diameter probes shall be used. All
indication, high or low amplitude, within testing range shall be carefully
evaluated.
vi.
vii.
All defective areas shall be marked, with cross section of defective weld
marked adjacent to defective area.
viii.
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7.0
Component
Material
Thickness
8 mm and above
Joint
Preparation
Single Bevel
Inspection Sequence:
i.
ii.
Root scan as per Section 5.7.2. Then scan the whole volume of weld with
other appropriate angle probes.
iii.
iv.
v.
Due to the curvature of the stub, small diameter probes shall be used. All
indication, high or low amplitude, within testing range shall be carefully
evaluated.
vi.
vii.
All defective areas shall be marked, with cross section of defective weld
marked adjacent to defective area.
All scanning limitation shall be reported.
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Attachment 1 UT Lamination Check Report
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Attachment 2 Ultrasonic Testing Report (Completed Weld)
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Attachment 3 Details of Defect Findings
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