YADAVARAN Oil Field

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Table of Revised Pages

Revisions Revisions Revisions

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Table of Content

1 . SCOPE
1T 1T 1T ............................................................................................................... 4
1T

2 . REFERENCE DOCUMENTS
1T 1T 1T .......................................................................... 4
1T

3 .DEFINITIONS
1T 1T 1T .............................................................................................. 4
1T

4 . SAFETY
1T 1T 1T ............................................................................................................ 5
1T

5 . GENERAL ............................................................................................................... 5
1T 1T 1T 1T

6 . PERSONNEL
1T 1T 1T ............................................................................................. 5
1T

7 . EQUIPMENT
1T 1T 1T ................................................................................................... 6
1T

8 . SURFACE PREPRATION
1T 1T 1T .............................................................................. 7
1T

9 . EQUIPMENT CALIBRATION
1T 1T 1T ....................................................................... 8
1T

10 .SYSTEM CALIBRATION
1T 1T 1T ........................................................................... 11
1T

11 . MARKING IDENTIFICATION OF WELDS

1T 1T 1T ................................................ 12
1T

12 . ULTRASONIC EXAMINATION METHOD

1T 1T 1T ................................................... 12
1T

13 . EVALUATION
1T 1T 1T ................................................................................................ 13
1T

14 . ACCEPTANCE CRITERIA
1T 1T 1T ............................................................................. 13
1T

15 . REPORTING
1T 1T 1T ............................................................................................... 13
1T

16 . DEFECTS MARKING
1T 1T 1T .................................................................................... 13
1T

17 . EXAMINATION OF REPAIRS
1T 1T 1T .................................................................. 13
1T

18 . DOCUMENTATION
1T 1T 1T .................................................................................. 13
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1 . SCOPE
0T

This procedure details the requirements for inspection of welding by ultrasonic testing (UT) for
shop and field-fabricated piping, vessels & etc.

These requirements are established for the ultrasonic detection, location, and evaluation of
ultrasonic reflectors within the weld, heat affected zone, and adjacent material for Lamination(s).

2 . REFERENCE DOCUMENTS
0T

1) ASME Sec V, Article 5 Ultrasonic Examination for Materials & Fabrication

2) ANSI B 31.3 Chemical Plant and Petroleum Refinery piping
3) ASME Sec IX Welding Qualification
4) AWS D1.1 Steel Structural Welding Code
5) ASME Sec VIII Rules for Construction of pressure vessel

3 .DEFINITIONS
0T

CLIENT : NIOC (National Iranian Oil Company)

COMPANY : SIPC (Sinopec International Petroleum E & P

Corporation)

CONTRACTOR : JPSSK ( JAHANPARS ENGNIEERING &

CONTRUCTION COMPANY & SINOPEC
SERVICE KISH Consortium)

SUB-CONTRACTOR: The firm / corporation to which the JPSSK may in

turn Sub-contract part of the work subject to prior
approval of the Company

Work: All temporary and permanent work described in

Contract and Specifications.
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4 . SAFETY
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All local regulation and those stipulated in shall be strictly adhered.

UT set manufacturer recommendations shall be taken into consideration.
Qualified technician shall carry out the examination

5 . GENERAL
0T

5.1 Basic Principles

Ultrasonic testing is based on reflection of ultrasonic waves from the discontinuities that have
different acoustic properties with the main material.
The ultrasonic waves with frequency of 1 to 6 MHz are generated by proper probe and sent inside
the material. The flaws are detected by receiving either reflected echoes from the defects or losing
the intensity of the back wall echo. The results are observed on the screen of the test equipment.
5.2 Flaw Type
All internal flaws can be detected by this method. Welds inside defects like lack of fusion, lack of
penetration, slag, porosity, gas holes, cracks, etc. can be found by ultrasonic testing.
Besides, the lamination on both sides of welding can be detected effectively.
5.3 Application Range
Ultrasonic testing will be carried out on parts, which are required by contract and project
specification or other agreements between Company and contractor replace Radiography Test.
5.4 Limitations
5.4.1 This method shall be used mainly to detect internal flaws. Surface defects shall be tested
by other proper NDT methods.
5.4.2 This method (UT) shall not be normally used to replace radiography. Any replacement
shall be approved and documented by the Company in advance. However, UT can be used to
confirm defect location and length when wall thickness is above 12.7 mm.
5.4.3 This specification is limited to ferrite welds and ferrite pipes for laminations and other butt
weld of ferrite material. For austenitic and high nickel alloy welds, the specification will be
modified as T-542.8.5.1 article 5 ASME sec. V by agreement.

6 . PERSONNEL
0T

Non-Destructive testing and Interpretation of qualification welds and production welds shall be
performed by personnel qualified and certified in accordance with on o following items :
SNT-TC-1A (1996): ANSI recommended practice, minimum Level I or approved
equivalent. Interpretation of NDT reports shall be by an ASNT Level II or approved
equivalent.
BS EN 473 (2008) : qualification and certification of NDT personnel
CSWIP-ISO-NDT-11/93-R: requirements for employer specific certification of
personnel engaged non destructive testing in accordance with the requirements of
EN 473.
ASNT Level III will qualify and issue the certificate for UT technicians.
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7 . EQUIPMENT
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The following requirement for equipment and accessories will be considered as a minimum:
7.1 Test Instrument
A pulse-Echo, Scan type instrument capable of generating frequencies over range of at least 1 to
5 MHz equipped with calibrated gain control & sweep length control.
Instruments Type: Any equipments of a well-known manufacturer can be used by agreement.
The equipment shall have the valid traceable quality certificate. Further more the equipment shall
be checked and calibrated and documented according to the applicable reference.
7.2 Probes
The following probes can be used according to the job based on the reference code.
7.3 LONGITUDINAL WAVE PROBE
1) Single Crystal 0 4 MHz 10 or 12 mm
2) Single Crystal 0 2 MHz 10 or 12 mm
3) Twin Crystal 0 4 MHz 10 or 12 mm
4) Twin Crystal 0 2 MHz 10 or 12 mm

7.4 SHEAR WAVE PROBES

1) Single Crystal 45 4 MHz 8 x 9 mm
2) Single Crystal 60 4 MHz 8 x 9 mm
3) Single Crystal 70 4 MHz 8 x 9 mm
4) Single Crystal 45 2 MHz 8 x 9 mm
5) Single Crystal 60 2 MHz 8 x 9 mm
6) Single Crystal 70 2 MHz 8 x 9 mm
All probes shall be selected from a well-known brand and will hold data sheet and quality
certificate of the manufacturer. Other type of probes may be used with Company approval and for
specific matters.
7.5 Calibration Blocks
1. I.I.W. V1 & V2 Calibration Blocks
or
2. ASME Basic Calibration Blocks

The calibration blocks shall have the valid quality certificate.

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I.I.W V1

75 12.5
I.I.W V2

7.6 Couplant
The following materials can be used as Coupling:
a) Coupling manufactured for the purpose, or substituted by, b.c.d.e. or f.
b) Grease
c) Water based paste of cellulose gum
d) Wall paper adhesive
e) Glycerin
f) UT special gel

8 . SURFACE PREPRATION
0T

The test area and areas adjacent to the weld to be examined shall be free of all weld spatters,
loose particles, Non-adhering mill scale or any other deleterious foreign matter.
Preparation of welds for examination will be as identified in the specific ultrasonic operating
sheet..
Painted, primed or coated surfaces may be scanned as it is providing transmission of ultrasound
is reasonably constant and the transfer loss value does not exceed 6 dB.
Surface temperature shall be checked to ensure that it does exceed the Probes limitations
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9 . EQUIPMENT CALIBRATION
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The proper functioning of the equipment shall be checked and the equipment shall be calibrated
by the use of the calibration standard at the beginning of each examination, when examination
personnel are changed, and at any time that malfunctioning is suspected, as a minimum.
If during any check it is determined that the testing equipment is not functioning properly, the
entire product that has been tested since the last valid equipment calibration shall be re-
examined.

The following periodic checks of the equipment are mandatory:

9.1 Screen Height Linearity
The instrument shall provide linear vertical presentation within 5% of the full screen height for
20% to 80% of the calibrated screen height. The procedure for evaluating screen height linearity
is provided in Appendix I Article 5 ASME Section V and shall be performed at the beginning of
each period of extended use (or every 3 months, whichever is less). The results will be
documented on the form Ultrasonic Equipment Calibration Record that a sample is enclosed.
9.2 Amplitude Control Linearity
The instrument shall utilize an amplitude control accurate over its useful range to 20% of the
nominal ratio, to allow measurement of indications beyond the linear range of the vertical display
on the screen.
The procedure for evaluating amplitude control linearity is given in Appendix II of Article 5 ASME,
Section V and shall be performed at the beginning of each period of extended use (or every 3
months, whichever is less).
The result will be documented in form Ultrasonic Equipment Calibration Record.

9.3 Time Base Linearity

The time base linearity will be checked by using a normal probe on I.I.W. block V1 or V2 and
adjusting at least 4 back wall echoes on proper distances on 100 mm sweep length. This check
will be carried out at least once per month and the results will be documented on the form
Ultrasonic Equipment Calibration Record.

9.4 Basic Calibration Blocks

9.4.1 The basic calibration reflectors shall be used to establish a primary reference response of
the equipment. The basic calibration reflectors may be located either in the component material or
in a basic calibration block. The material from which the block is fabricated shall be of the same
product form and material specification or equivalent.
For examination of welds, which have been subjected to PWHT (Post Weld Heat Treatment), the
material from which the calibration block is fabricated will have received the similar PWHT
process prior to machining the reflectors.
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The surface finish of the block shall be representative of the surface finishes on the components.
The calibration block material shall be completely examined with a straight beam probe to ensure
the soundness of the material.

9.4.2 For testing materials with diameter greater than 20 inches (508 mm), a block of essentially
the same curvature or alternatively a flat basic calibration block, complying with the requirements
of ASME section v calibration block article 5 fig. T-542.2.1 shall be used.
The basic calibration block shall be curved for materials with diameters 20 inches (508 mm) or
less. A single curved basic calibration block may be used to calibrate the examination on surface
in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter.
The thickness range of the blocks will be as Fig. T542.3.5 ASME Section V Article 5.
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10 .SYSTEM CALIBRATION
0T

Each calibration shall be performed from the surface (clad or unclad) corresponding to the surface
of the component from which the examination will be performed.

10.1 Straight Beam Calibration

The calibration shall provide the following measurements (as Appendix C of Article 4 ASME
Section 5).
(a) Sweep Range Calibration
(b) Distance Amplitude Correction (DAC)

10.2 Angle Beam Calibration

The calibration shall provide the following measurements (as Appendix B of Article 4 ASME
Section 5).

(a) Sweep Range Calibration

(b) Distance Amplitude Correction (DAC)
(c) Position Calibration
(d) Echo Amplitude measurements from the surface notch in the basic calibration block.

10.3 DAC Requirements

A DAC curve is required for all pipe welds. For examination of a full wall thickness, the notches
shall be used as calibration reflectors. The angle beam shall be directed towards the calibration
reflector that yields the maximum response, setting the instrument adjustment to yield 80% of the
screen height. The search unit shall then be manipulated, without changing instrument settings, to
obtain the maximum responses from the calibration reflectors at the distance increments
necessary to generate a 3 point DAC curve. A side drilled hole may be used for initial acceptance
of a pipe weld, provided that it can be demonstrated that the hole calibration produces a
sensitivity equal or greater than the notch calibration.

10.4 DAC Exception

DAC is not required where examination is done on Non pipe material and is limited to on-half V
path in a material less than 1 inch thick, in which case the amplitude level from a single calibration
reflector shall be used.

10.5 Primary Reference Level (PRL)

PRL will be that gain setting whereby the reflectors in the applicable BCB or reference specimen
as described in part 8 above, coincide with DAC curve constructed as described in 9-1 and 9-2.
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11 . MARKING IDENTIFICATION OF WELDS

0T

Before examination, each weld shall be identified by means of an identification number on the
relevant erection drawing or on a sketch issued on site for this purpose attached to NDT request.
For each weld the reference point (Zero distance) shall be marked at a distance of at least 50 mm
from one side of the weld.

12 . ULTRASONIC EXAMINATION METHOD

0T

12.1 Examination Coverage

The volume shall be examined by moving the probe over the surface so as to scan the entire test
volume. Each pass of the probe shall overlap a minimum of 10% of the transducer dimension
perpendicular to the direction of the scan.

12.2 Straight Beam Scanning

If There Is a Problem about thickness or lamination before scanning the weldments the zone of
base metal for a minimum of 75 mm either side of the weld will be scanned by straight beam to
verify the thickness and any possible material defects such as laminations that might impair angle
beam examination of the weldments. The scanning shall be performed at a gain setting of at least
2 times the primary reference level (PRL) but evaluation shall be performed with respect to the
PRL.

12.3 Angle Beam Scanning

12.3.1 ANGLE BEAM SCANNING FOR REFLECTORS ORIENTED PARALLEL TO THWELD

The angle beam shall be directed at approximate right angle to the weld axis for 2 directions
where possible. The probe shall be manipulated so that the ultrasonic energy passes through the
required volumes of weld and adjacent base metal.
The scanning shall be performed at a gain setting at least 2 times the PRL. Evaluation shall be
performed with respect to the PRL.

12.3.2 ANGLE BEAM SCANNING FOR REFLECTORS ORIENTED TRANSVERSE TO THE WELD

The angle beam shall be directed essentially parallel to the weld axis. The search unit shall be
manipulated so that the angle beam passes through the required volumes of weld and adjacent
base metal specified by the referencing code. The scanning shall be performed at a gain setting
at least 2 times PRL. Evaluation shall be performed with respect to PRL. The probe shall be
rotated 180 and the examination will be repeated.
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13 . EVALUATION
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Any reflector which causes an indication in excess of 20% DAC shall be investigated to the extent
that it can be evaluated in terms of the acceptance standards of the referencing code. The type,
position, size and orientation of all these indications will be determined. The dimensional
evaluation of defect may be made by either 20 dB-drop method or half-value-drop method.

14 . ACCEPTANCE CRITERIA
0T

The acceptability of all evaluated discontinuities will be interpreted in accordance with the
requirements of the referencing codes as follows:
ANSI / ASME B31.3 process piping
ASME IX welding qualification
AWS D1.1 steel structural welding code
ASME VIII rules for construction of pressure vessel

15 . REPORTING
0T

The ultrasonic test status and results shall be reported on the report format provided in Appendix
A. Each report shall clearly identify the status of the weld after test when indications are reported
that means whether reportable, acceptable or reject able.

16 . DEFECTS MARKING
0T

All areas to be reject able according to the qualified UT operator, will be clearly marked on the
surface of the weld and the adjacent parent metal with indelible metal marker.

17 . EXAMINATION OF REPAIRS
0T

The extend of the examination will guarantee the satisfactory inspection of the entire cross
sectional volume of the weld and HAZ regardless of the extent of the repair. The whole length of
the repair will be examined plus 50 mm from the repair weld deposit at both ends, where possible.

18 . DOCUMENTATION
0T

All examination result shall be record as per attached format (PIP-010-1)

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