Mk-Ut-006pl Rev 1 - Ut

PT.
I\IIEGATEK KONSINDO
U ltrasonic I nspection Procedure

Doc. No MK/UT1006P1 Rev. 1 Page 1 of 20
Ultrasonic lnspection Procedure
Document No. : M[<JUT/006P1

Revision :1
PT. MEGATEK KONSINDO

Ultrasonic Inspection Procedure
Doc. No MK/UT/006PL Rev. 1 Page 2 of 20

REVISION TABLE

REVISION REVISION
PAGE PAGE PAGE REVISION
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
1
2
3
4
5
6
7
8 X
9 X
10
11
12
13 X
14
15
16
17
18
19
20

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL
Revision :1



TABLE OF CONTENTS
1. SCOPE ………………………………. 4
2. REFERENCES ………………………………. 4
3. QUALIFICATION OF PERSONNEL ………………………………. 4
4. EQUIPMENT REQUIREMENTS ………………………………. 4
5. GENERAL EXAMINATION REQUIREMENT ………………………………. 5
6. BASIC CALIBRATION BLOCK ………………………………. 7
7. CALIBRATION SYSTEM ………………………….…… 7
8. EXAMINATION OF WELDS ………………………………. 8
9. COUPLANT ………………………………. 9
10. DEFECT SIZING (LENGTH) ………………………………. 9
11. ACCEPTANCE CRITERIA ………………………………. 9
12. APPENDIX ………………………………. 9

Revision :1



1. SCOPE
This procedure details the requirements to be followed by PT. Megatek Konsindo NDT
personnel to perform Ultrasonic Inspection in accordance with the minimum
requirements of the codes & standards and the project specifications cited in clause 2.
2. REFERENCE DOCUMENTS
The following codes, standards and Client specification are used for reference in the
preparation of this procedure.
API 1104 Welding of Pipeline and Related Facility

AWS D1.1 Structural Welding Code
ASME VIII, Div. 1 Rules for Construction of Pressure Vessels
ASME IX Welding and Brazing Qualifications
ASME B31.3 Process Piping
ASME B31.8 Gas Transmission and Distribution Piping System
API 650 Welded Steel Tanks For Oil Storage
ASME V Article 5 Ultrasonic Examination Methods for Materials
ASME V SA-435 Standard Specification for Straight-Beam Ultrasonic
Examination of Steel Plates
API RP2X Recommended Practice for Ultrasonic Examination of Offshore
Structural Fabrication and Guidelines for Qualification of
Ultrasonic Technician.
MK/WP/001 Rev.4 PT. Megatek Konsindo written practice for the qualification and
certification of non destructive testing personnel.
3. PERSONNEL
All key personnel directly involved with Ultrasonic Inspection shall be qualified to one or
more of the certification schemes below and have been eye sight tested to successfully
read Jaeger J2 size letters at a distance of not less than 300mm.
ASNT American Society for Non Destructive Testing Recommended Practice
document no. SNT-TC-1A for Qualification and Certification of
nondestructive testing personnel – NDT Level II personnel.
PCN Personnel Certification in NDT Level 2 standard.
4. EQUIPMENT REQUIREMENTS
4.1 The examination shall be conducted with an ultrasonic pulse echo reflection system
generating frequencies covering the nominal range of 1 MHz to 5 MHz with a rectified ‘A’
scan display. The equipments to be used in this project is Numeric (Digital) UT sets with

Revision :1



valid calibration certificate.
4.2 The ultrasonic pulse-echo instrument shall provide linear vertical presentation within +/-
5% of full screen height for 20% to 80% of the full screen height (base line to maximum
calibrated screen height). The screen height linearity shall be measured and recorded.
Refer Appendix 1.
4.3 The ultrasonic pulse echo instrument shall utilize and amplitude control accurate over its
useful range to +/- 20% of the nominal amplitude ratio, to allow measurement of
indication beyond the linear range of the vertical display on the screen. The amplitude
control linearity shall be measured and recorded as per procedure set out in Appendix 2.
4.4 The pulse-echo instrument shall be serviced and calibrated at regular intervals at least
once a year or after each major servicing.
4.5 Frequency of normal beam probes shall be between 1 MHz to 5 MHz; with probe
diameter of 10mm to 25mm.
4.6 For angle probes (45, 60, 70) frequencies of 4 MHz with crystal size of approximately
8x9mm shall normally be used. Exit point and exact angle of beam propagation of each
individual probe shall be checked and marked before commencement of a test. Type of
probe that shall be used is 4 MHz, 8x9mm single crystal transducers for up to 50°C test
surface.
5. GENERAL EXAMINATION REQUIREMENT
5.1 Examination coverage

The area to be tested shall be examined by moving the search unit over the examination
surface to scan the entire examination area. Each pass of search unit shall overlap a
minimum of 10% of the transducer dimension perpendicular to the direction of the scan.
5.2 Rate of search unit movement

The rate of search unit movement perpendicular to the weld axis shall not exceed 4
in./sec (102mm/sec).
5.3 Scanning sensitivity level

Scanning shall be performed at a gain setting with addition of 6 dB and transfer loss
from reference level. During scanning only the gain or attenuate controls shall be
adjusted. Any adjustment of the other controls shall require re-calibration.
5.4 Transducer scanning pattern

In order to detect all possible defects, the following scanning pattern shall be utilized, as
much as weld and test specimen configuration would permit :

Revision :1



5.4.1 Transverse motion

This movement is necessary to examine the complete cross section of the weld and
heat affected zone. The extent of such movement is normally equal to the skip distance.
5.4.2 Lateral Motion

This movement should be made to scan the specified length of the welded joint. This is
combined with the traversing motion so that each successive probe displacement has an
overlap dimension not less than that 10 % of the transducer dimension.
5.4.3 Swiveling motion

During the movement both towards and away from the welded joint, the probe shall be
oscillated over an angle of 10 degrees to 15 degrees on each side of a line normal to
center of the weld.
5.4.4 Transverse scanning

The angle beam shall be directed essentially parallel (180O) to the weld axis on the
ground welds as per pattern A. When the weld reinforcement is not ground flush, the
search unit shall be directed 15O from the weld axis so the full weld section is covered as
per pattern B. Transverse discontinuities scanning technique refer appendix 5.
5.4.5 Transfer loss

Transfer loss shall be carried out along the exit of the heat affected zone area by using
two angle probes of the same frequency 4 MHz and crystal size (8x9 mm), one
transmitting and the other receiving using through transmission method through the
weld. The gain obtained in the highest amplitude shall be added into the scanning
technique.
6. BASIC CALIBRATION BLOCK
6.1 Calibration block material

The basic calibration block shall be a section of product form of the same nominal size,
schedule, and heat treatment of material specification or equivalent P-number groupings
as one of the materials being examined. The block size and reflector locations shall be
adequate to perform calibration for the beam angles used.
Where two or more base material thicknesses are involved, the calibration block
thickness shall be determined by the average thickness of weld.
6.2 Surface finish

The finish on the surface of the block shall be representative of the surface on the
component.
6.3 Block quality

The calibration block material shall be completely examined with a straight beam search

Revision :1



unit. Areas that contain indication exceeding the remaining back reflection shall be
excluded from the paths required to reach the various calibration reflectors.
6.4 Basic Calibration Reflectors. (Diameter pipe) – Fig. 3 or Fig. 5

As shown in API 1104, Fig.21A Reference Block for Manual UT.
7. CALIBRATION SYSTEM
Calibration check shall be performed before commencement of an ultrasonic testing.

When any part of the examination system is changed, a calibration check shall be made
on the basic calibration block (IIW-V1,V2 block and IOW block – Fig 1, Fig2 and Fig. 4)
to verify any change of values.
7.1 Probe index point

Obtained by directing the angle beam transducer to radius 100 mm of focal point from
V1 block. The index point pointed with the focal point when indicate the highest
amplitude. Probe index point is recorded by tape on the probe.
7.2 Straight beam transducer calibration

Calibration performed after the range (for example 50,100,150...) selection. Place
straight beam transducer on 25 mm thickness of V1 block adjusts the fine delay until
indication on exactly time base according to selected range. Calibration so completed is
to be after re-checking by 50 mm (Perspex) or 100 mm thickness of V1 block.
7.3 Resolution calibration

The far field resolving power of the test equipment can be estimated by placing normal
beam transducer on the focal point and directed to the notches of V1-IIW block. Good
resolution will be indicated if the instrument can satisfactorily separate the pips from all
three reflectors.
7.4 Angle beam transducer calibration

Calibration performed after the selection of range (100, 125,150, 175, 200). Direct angle
beam (45o, 60o, 70o) to radius 25 mm of V2 block, adjust the fine delay until indication is
on exactly time base position according to selected range. Calibration is completed after
re-checked by radius 50 mm of V2 block or radius 100 mm of V1 block.
7.5 Scanning Sensitivity for Weld Testing

For compression wave testing shall be performed with the second backwall echo from
reference standard (API 1104 Latest Edition Fig 21A) which adjusted at least 80% of full
screen height.

Revision :1



DAC curve as scanning sensitivity shall be constructed for each angle probes to be used
to API 1104 Latest Edition reference block (fig 21A) at least three point reference level
with highest point of DAC shall not be less than 80% of full screen height.

8. EXAMINATION OF WELDS
8.1 Surface preparation

The examination surfaces shall be free of irregularities, loose foreign matter, or coating,
which interfere with ultrasonic wave transmission.
8.2 Straight beam (0 probe) scanning

Straight beam (0 probe) scanning of the adjacent base metal is performed to detect
reflectors that may lie in the horizontal plane parallel to the scanning surface. Locations
and area of such reflectors shall be recorded and evaluated for acceptance or rejection
accordingly.
The minimum scanning distance shall be 4.5 inch from the weld bevel for base metal
examinations or with minimum distance 1.25 x the longest surface skip distance refer to
Appendix 4.
The acceptance of lamination defect shall be as described in ENI Specification
Document No. 02776.PLI.COR.SDS Rev. 03 TR 11.5.3 Linear Indications.
8.3 Angle beam scanning

Angle beam scanning shall be directed at approximate right angles to the weld axis from
two directions where possible. The search unit shall be manipulated so that the
ultrasonic energy passes through the required volumes of weld and adjacent base
metal.
Scanning technique shall be as per Appendix 4A.
Probe frequencies of 2MHz to 4MHz with crystal diameters of approximately 20mm
diameter or 8x9mm size shall be used. Angle of transducers include 45, 60 and 70 .
Minimum of three angle probes are to be using for each examination in addition to the
zero degree probes on parent metal.
8.4 Butt welds

Scanning of butt welds should be done within half skip and full skip distance and sketch
at 1/1 scale must be drawn. In the case of curved surfaces, the effect of curvature
should be taken into consideration in locating echo origin by reference block.
8.5 Evaluation
Any imperfection 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 and rejection standard
of the relevant code section, API 1104 Latest Edition.

Revision :1



9. COUPLANT
Methylan shall be used as couplant. The couplant used shall not be injurious to the
material to be tested or affect any post scanning surface treatment. The same couplant
shall be used for sensitivity calibration and production full penetration butt joint pipeline
inspection
10. DEFECT SIZING (LENGTH)

All reflections from weld defects shall be maximized from all angles in order to find the
best angle, which is compatible to the defect orientation. The defect echo shall be
adjusted to the screen’s height and sized in the following manner:
10.1 Compression wave

The 6dB drop method shall be used for sizing large defects. Small defects shall be
expressed as percentage amplitude of the back wall echo.
10.2 Shear wave

The 6dB drop method shall be used for sizing large defect lengths whilst the 20dB drop
method may be used for sizing small defects.
For sizing defect height, the 20dB drop method or the maximum amplitude technique
may be used.
11. ACCEPTANCE CRITERIA
The acceptance criteria shall be assessed as per ENI Specification Document No.
02776.PLI.COR.SDS Rev. 03 TR 11.5.3 Linear Indications.
12. APPENDIX
Appendix 1
Instrument Calibration Screen Height Linearity
Position an angle beam search unit so that indications can be observed from both the
1/2t and 3/4t holes in a basic calibration block. Adjust the search unit position to give a
2:1 ratio of amplitudes between the two indications, with the larger set at 80% of full
screen height.
Without moving the search unit, adjusts sensitivity (gain) to successively set at the larger
indication from 100% to 20% of full screen height, in 10% of the larger amplitude within
5% of full screen height. The settings and readings must be estimated to the nearest 1%
of full screen.
Alternatively, a straight beam search unit may be used on any calibration block which
will provided amplitude differences with sufficient signal separation to prevent
overlapping of the signals.

Revision :1



Appendix 2
Amplitude Control Linearity
Position an angle beam search unit so that the indication from 1/2t hole in basic
calibration block is peaked on the screen. With the increases and decreases in
attenuation shown in the following table, the indication must fall within the specific limits.
Other convenient reflectors from any calibration block may be used with angle or straight
beam search units. The settings and readings must be estimated to the nearest 1% of
full screen.
Indication set Indication Limits

dB change
At % of full screen % Of full screen
80 % - 6 dB 32 % to 48 %
80 % - 12 dB 16 % to 24 %
40 % + 6 dB 64 % to 96 %
20 % + 12 dB 64 % to 96 %

Revision :1



Appendix 3: Pipeline Ultrasonic Test Report
PIPELINE ULTRASONIC TEST REPORT

REPORT NO
CLIENT DATE
PROJECT PROCEDURE REFERENCE
STRUCTURE ID LOCATION
CLIENT SPEC WELD JOINT

ACCEPTANCE STANDARD SURFACE CONDITION
WELDING PROCESS TESTING TEMPERATURE
COUPLANT SCANNING TECHNIQUE

EQUIPMENT MODEL : S/N : LAMINATION CHECK

CALIBRATION CALIBRATION CHECK ANGLE TYPE S/N FREQUENCY SIZE
FOR SENSITIVE NORMAL
REFERENCE TYPE: 45o
WELD DIA. REFLECTOR 60o
SIZE: 70o

STANDARD SENSITIVITY
DISCONTINUITY
DISTANCE AMPLITUDE
TRANSDUCER ANGLE
INDICATION NUMBER
INDICATION NUMBER
BASIC SENSITIVITY
CORRECTION -dB
CORRECTION-dB
WELD NUMBER
THICKNESS
TRANSFER
MATERIAL
LEVEL -dB
LEVEL -dB
RESULT
SPHERICAL
JOINT
PLANAR
LINEAR
IDENTIFICATION
REMARK

E x a m
I N S P E C T E D B Y CONTRACTOR CLIENT CERTIFYING AUTHORITY
NAME NAME NAME NAME

SIGN SIGN SIGN SIGN
DATE DATE DATE DATE

Revision :1



CLIENT: PROJECT LOCATION:

DATE: PROJECT DESCRIPTION:
ULTRASONIC SCANNING TECHNIQUE REPORT

REFERENCE TO TEST REPORT NO:
DESCRIPTION:
Probe Detail
Remarks
Type Size Frequency

Revision :1



Appendix 4: Scanning Technique Sheet

ULTRASONIC EXAMINATION TECHNIQUE SHEET
PROJECT: TECHNIQUE:
SPECIFICATION: RANGE: CALIBRATION BLOCK:

ENI Specification Document VARIES IIW V1/V2
No. 02776.PLI.COR.SDS Rev.
03 TR 11.5.3 Linear Indications.
ACCEPTANCE CRITERIA: SENSITIVITY: COUPLANT
ENI Specification Document ASME V BLOCK
No. 02776.PLI.COR.SDS Rev.
03 TR 11.5.3 Linear Indications.
JOINT CONFIGURATION: MATERIAL/WELD TYPE: EQUIPMENT:
PIPE Carbon steel
DIAMETER & THICKNESS:
PROBES:
ANGLE TYPE – S/N FREQUENCY SIZE
0
45
60
70
OTHER
Minimum scanning distance
ADDITIONAL INFORMATION
 All Material shall be examined from one major plate

Surface.
 The Flaw echo / back wall echo technique shall be used
For sizing defect indications unless the client specifies
Otherwise.
Appendix 4A: ULTRASONIC EXAMINATION SHEET

Revision :1



PROJECT: TECHNIQUE:
SPECIFICATION: RANGE: CALIBRATION BLOCK:

API 1104 Latest Edition VARIES V1 / V2
SENSITIVITY: CALIBRATION DAC BLOCKS:
ACCEPTANCE
Fig 21A Reference Block for Fig 21A Reference Block for
CRITERIA:
Manual UT (API 1104 Latest Manual UT (API 1104 Latest
API 1104 Latest Edition
Edition) Edition)
JOINT
MATERIAL/WELD TYPE: EQUIPMENT:
CONFIGURATION:
Carbon Steel
Pipe
PROBES:
ANGLE TYPE FREQUENCY SIZE
0 TWIN 2 - 5MHz 5 to 20mm
45o SINGLE (MWB) 4 MHz 8 x 9 mm
OTHER
SCANNING DETAIL
All angle probes shall be used from the typical scanning positions below to ensure 100% full
weld body coverage. Both sides and either surface of the weld joint shall be used if accessible
ADDITIONAL INFORMATION: WELD COVERAGE:

 0Scan parent material prior to weld exam
 All welds subject to transverse scan Section Thickness Probe Angle
 Where examining along curved cross
sections adjustments must be made for 9 to 12mm 70°, 60° (single crystal)
variance in beam path distance 12 to 20mm 70°, 60°
20 to 40mm 70°, 60°,45o
Only Single crystal Maps shall be used to Greater than 40mm 70°, 60°, 45°
examine longer beam paths.


Revision :1



Appendix 5
SCANNING TECHNIQUE FOR TRANSVERSE DISCONTINUITIES
15O 15O
PATTERN A PATTERN B

Revision :1



Appendix 6
ULTRASONIC CALIBRATION BLOCKS
Figure 1
V1 Block
200 2
15 45 50 60 15
1.5 DIA
10
100
91
50
R100
30 30
5
35 0.5 100
25 23
NOTE: ALL DIMENSIONS IN MM.

Revision :1



Figure 2
IOW Calibration Block

50
(a)
13
19
25
ADDITIONAL
(OPTIONAL)
RESOLUTION HOLES 75
HOLES
SPACED AS SHOWN
IN VIEW (C) BELOW 32 10
25 35
48
83
305
(b)
22 22
22 22
(c)
10
ALL HOLES 1.5mm DIA.

4
4
2.5
2.5
NOTE: ALL DIMENSIONS IN MILLIMETRES.
BLOCK A5 DIMENSIONS.(WELDING INSTITUTE BLOCK)
19
25

Revision :1



Figure 3
API 1104 Figure 21A – Reference Block for Manual UT

Revision :1



Figure 4
V2 Block
See note 1
75
42.9
34.6
28.6
23.8
20
16.8
50 14
5 5
1.5 2.5 6
30°
R25.0
40° 50° 60° 20
See note 2
R50.0
10 70°
21.1
NOTE 1- 12.5mm or 20mm
NOTE 2- 1.5mm or 5mm 43.3
NOTE 3- All dimensions in millimetres

Revision :1



Figure 5
T T
A. L. A. L.
Typical Block Dimensions
Length L 8 in, or 8 T, whichever is greater
Minimum Arc Length A.L.

(1) for O.D. or 4 in. ( 102 mm ) or less : 270 deg.
(2) for O.D. greater than 4 in. ( 102 mm ) : the greater of 3 T
or 8 in. ( 203 mm )
Specific Notch Dimensions
Length L – 1 in. ( 25 mm ) minimum

Depth D – 10 % T with tolerance D + 10 % of depth
- 20 %
1 1
Width – /8 in. to /4 in. ( 3.2 mm to 6.4 mm )
Location – not closer than T from any block edge
FIG. T-542.8.1.1 ANGLE BEAM CALIBRATION ( PIPE WELDS )

Revision :1

Mk-Ut-006pl Rev 1 - Ut

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Mk-Ut-006pl Rev 1 - Ut

Hochgeladen von

Copyright:

Verfügbare Formate

PT.

U ltrasonic I nspection Procedure

Ultrasonic lnspection Procedure

Document No. : M[<JUT/006P1

3. QUALIFICATION OF PERSONNEL ………………………………. 4

4. EQUIPMENT REQUIREMENTS ………………………………. 4

5. GENERAL EXAMINATION REQUIREMENT ………………………………. 5

6. BASIC CALIBRATION BLOCK ………………………………. 7

7. CALIBRATION SYSTEM ………………………….…… 7

8. EXAMINATION OF WELDS ………………………………. 8

10. DEFECT SIZING (LENGTH) ………………………………. 9

11. ACCEPTANCE CRITERIA ………………………………. 9

12. APPENDIX ………………………………. 9

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL

API 1104 Welding of Pipeline and Related Facility

PCN Personnel Certification in NDT Level 2 standard.

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL

valid calibration certificate.

5. GENERAL EXAMINATION REQUIREMENT

5.1 Examination coverage

5.2 Rate of search unit movement

5.3 Scanning sensitivity level

5.4 Transducer scanning pattern

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL

5.4.1 Transverse motion

5.4.2 Lateral Motion

5.4.3 Swiveling motion

5.4.4 Transverse scanning

5.4.5 Transfer loss

6. BASIC CALIBRATION BLOCK

6.1 Calibration block material

6.2 Surface finish

6.3 Block quality

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL

6.4 Basic Calibration Reflectors. (Diameter pipe) – Fig. 3 or Fig. 5

Calibration check shall be performed before commencement of an ultrasonic testing.

7.1 Probe index point

7.2 Straight beam transducer calibration

7.3 Resolution calibration

7.4 Angle beam transducer calibration

7.5 Scanning Sensitivity for Weld Testing

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL

8.1 Surface preparation

8.2 Straight beam (0 probe) scanning

8.3 Angle beam scanning

8.4 Butt welds

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL

10. DEFECT SIZING (LENGTH)

10.1 Compression wave

10.2 Shear wave

11. ACCEPTANCE CRITERIA

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL

Indication set Indication Limits

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL

Appendix 3: Pipeline Ultrasonic Test Report

PIPELINE ULTRASONIC TEST REPORT

COUPLANT SCANNING TECHNIQUE

NAME NAME NAME NAME

DATE DATE DATE DATE

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL

CLIENT: PROJECT LOCATION:

ULTRASONIC SCANNING TECHNIQUE REPORT

GENERAL NDT PROCEDURE Document No. : MK/UT/006PL