NDT Procedure Reshadat Project Complete Rev1
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NDT procedure...
Description
NDT INSPECTION PROCEDURE Document No: RSH-C3P-00-PL-PR-2811
Rev. No.: 1
Class: 2
NDT INSPECTION PROCEDURE
CONTRACT NO.
:
TSD 90 RSHP 716
PROJECT
:
SUBMARINE PIPELINES FOR RESHADAT, ILAM-SALMAN AND ABOOZAR-NOWROOZ
COMPANY
:
IOOC
SITE
:
PERSIAN GULF, IRAN
Issued for Approval
R. Kelders E.Hajimirzaei
1
14/09/2011
Issued for Approval
R. Kelders E.Hajimirzaei
0
07/07/2011
DESCRIPTION
PRPD
CHKD
APPD
REV
DATE
(This document is the sole property of N.I.O.C; all information contained herein may neither be reproduced, used, transmitted nor in any way made public without permission of the owner)
RESHADAT
NDT INSPECTION PROCEDURE Document No: RSH-C3P-00-PL-PR-2811
Rev. No.: 1
List of NDT procedures on Reshadat Project AUT 21130 AUT Specific 11-406 AUT Specific 11-407 AUT Specific 11-408 AUT Specific 11-409 MT 11-410 MUT Lam check 11-411 MUT 11-412
-
General AUT Procedure Specific AUT Procedure 8inch Specific AUT Procedure 10inch Specific AUT Procedure 14inch Specific AUT Procedure 16inch MPI procedure MUT lamination check procedure MUT procedure
Class: 2
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Contents 1
Purpose
3
2
Scope
3
References
Inhouse documents Abbreviations Definitions
3 3 4 4
Personnel Qualifications
5
Rotoscan Operator Manipulator Operator
5 5
Rotoscan Equipment Description
5
Multi-Channel Ultrasonic Equipment Recording Scanner and Umbilical Calibration Set-up
5 6 6 6
Rotoscan Set-Up Configuration
7
Inspection Set-up Configuration Probes Used for Inspection Probe Frame Layout Parameters of Rotoscan Inspection Program Calibration Block
7 7 7 7 7
Calibration
8
General Setting of Inspection Gates Sensitivity Settings Scanning Preparation & Surface Condition
8 8 9 9
3
3.1 3.2 3.3 4
4.1 4.2 5
5.1 5.2 5.3 5.4 6
6.1 6.2 6.3 6.4 6.5 7
7.1 7.2 7.3 7.4 8 9
9.1 9.2 9.3 10
Acoustic Coupling Fluid
10
Examination
10
Calibration check Step by Step Description of a Rotoscan Examination Operational checks Interpretation of results
10.1 10.2
General Inspection result
10 11 11 12
12 12
11
Acceptance/Rejection criteria
13
12
Reporting
13
13
Examination of repairs
13
14
Storage of data
13
Attachment 1 Rotoscan site report
14
Attachment 2 Decision Flow Chart WMS
15
Attachment 3 Decision Flow Chart ECA
16
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Purpose The purpose of this procedure is to detail the set-up and methodology of all Automated Ultrasonic Examination (AUT) to determine specific circumferential ‘Weld Integrity’, this is in accordance with and following the requirements of DNV-OS-F101: 2010 The job specific parameters will be documented in an adjacent specific procedure, describing at least the following items:
2
Reference Specification Detailed project scope Inspection set-up configuration Transducer selection Probe frame layout Rotoscan parameter set-up Calibration manufacturing drawings Acceptance criteria
Scope This procedure details methods for all Automated Ultrasonic Weld Examination (via the APPLUS RTD Rotoscan System) of ferrous butt welds. The Rotoscan is an automated ultrasonic inspection system for pipeline girth welds, based upon the ‘Pulse Echo Method’, enhanced with mapping images and ‘Time of Flight Diffraction’. The weld is divided into a number of depth zones, which are each inspected by one of an array of probes. The probes are arranged such that the entire weld is examined from both sides in a single circumferential scan. The ultrasonic information is transferred to a computer for data presentation and analysis.
3
References
3.1 documents CP 31105 CP 31108 CP 31111 NL IPS 10 EN 473 SNT TC 1A
Verification procedure for ultrasonic multi-channel equipment Control Procedure of calibration blocks for Rotoscan system Verification procedure for Ultrasonic Phased Array Equipment Written Practice for the Training, Qualification, Certification and Authorization of NDT Personnel. Non-Destructive-testing – Qualification and certification of NDT personnel – General Principles Personnel Qualification and Certification in Non Destructive Testing
For all other specification references see Specific procedure.
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
3.2 Abbreviations
AUT CCW Conv CW DS ECA FBH ID LOF LOP MUT NDT OD PA PE ToFD US UT WMS
Automatic Ultrasonic Examination. Counter Clockwise Conventional Clockwise Downstream Engineering Critical Assessment. Flat Bottom Hole. Internal Diameter Lack of Fusion Lack of Penetration Manual Ultrasonic Examination. Non destructive Testing Outside Diameter Phased Array Pulse Echo Time of Flight Diffraction Upstream Ultrasonic Examination Workmanship
3.3 Definitions AUT Contractor ApplusRTD AUT Operator refers to the person responsible for all ultrasonic aspects of the inspection, recording and interpretation of results. Defect is an imperfection of sufficient magnitude to warrant rejection based on the criteria referenced by this procedure. Depth of the imperfection is the through-wall distance to the bottom of the imperfection as measured from the outside diameter of the pipe. Downstream the side of the girth weld nearest to the AUT scanner band. Go-NoGo level or Evaluation level is the level for pulse echo channels from which imperfections shall be evaluated and is used to determine imperfection length. Imperfection is a discontinuity or irregularity that is caused by the welding process and is not related to geometry indications. Indication is an ultrasonic response derived from either weld geometry or weld imperfection. Length of an imperfection will be defined if it has at least one amplitude value equal to or greater than the evaluation level. Procedure is a step-by-step description of the application of an NDT method. Rotoscan Applus RTD trade name for our AUT System. Shall is a mandatory term. Should is a recommended practice or action. Threshold level is the level for pulse echo channels from which amplitude and transit distance are recorded by the system. Through Wall Height dimensions of the imperfection will be called the “Vertical Height” of the imperfection. Upstream the side of the girth weld furthermost to the AUT scanner band.
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Personnel Qualifications
4.1 Rotoscan Operator The ultrasonic lead operator performing the examination shall: be qualified in accordance to the valid version of APPLUS RTD Written-Practice NL IPS 10 and in accordance with SNT TC 1A: 2006 and EN 473 (Level UT 2); have experience with multi-channel UT equipment; be trained and passed the Applus RTD in-house testing for Mechanised Ultrasonic Inspection course.
4.2 Manipulator Operator The manipulator operator, handling the scanner mechanism shall be trained in using AUT-manipulators to the satisfaction of the Rotoscan operator.
5
Rotoscan Equipment Description
5.1 Multi-Channel Ultrasonic Equipment A multi-channel ultrasonic flaw detector (type Rotoscan) shall be used, which provides an adequate number of inspection channels (referred to as sequences) to ensure a complete volumetric examination of the weld through thickness in one circumferential scan. Each inspection channel will provide a linear “A” scan presentation, which can be individually selected. The system meets the following minimum requirements:
5.1.1 Global Parameters Number of Sequences Main Gain Digitizer Sampling Frequency Overall System PRF Scan resolution is not set higher than
: : : : :
Specific to weld design 0 – 40 dB 50 MHz 4 kHz 1 mm
5.1.2 Gate Parameters In each sequence, the following parameters shall be selectable:
Transmitter and receiver channels numbers Programmable Gain (1 dB increments) Gate start and length (min increment 0.1mm) Delay (min increment 0.1mm) Threshold level 5% - 100% Full Screen Height (FSH) (1% increments) Recordable output selection between; Amplitude and/or Transit Distance, Mapping, ToFD and Coupling. Selection between First / Highest amplitude detection within the gated section.
5.1.3 General Electronic noise shall be lower than acoustical noise in all sequences, for the probes and sensitivities to be used during the inspection. The signal to noise ratio of each sequence during examination shall be 20 dB for shearwaves probes.
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
5.2 Recording Inspection results are presented on-line on a colour monitor. The screen layout and number of used sequences are configured to present the thickness of the weld to be examined. Distance delays are applied to the output channels to compensate for variable transducer circumferential positions. The presentation shows the following information;
Amplitude and relevant transit distance (superimposed) Mapping image sections Go – No-Go image section Coupling check section ToFD image section Circumferential position information Header section with possibility to present job specific information Time and date of inspection
5.3 Scanner and Umbilical The scanner to be used shall meet the following minimum requirements: Mechanised operation during examination. Easy and quick mounting to the guide-band. Capable of taking up a minimum of 10 individually spring loaded ultrasonic probes, of which the distances to the weld centreline can be individually set. Coupling controllable per probe, or per set. 15 up/to 45metres of cable length. The scanner is equipped with an encoder for accurate measurement of the scanner position within the pipeline circumference. Scanner speed of 40 up to 80mm/sec
5.4 Calibration Set-up The calibration set-up consists of a support, being a part of a thin wall dummy pipe of the same diameter as pipe under examination. On the support a guiding band is mounted at the same distance from the weld centreline as the guiding-band on the weld to be tested. In the support a cut-out area is present where a calibration block with the proper wall thickness is mounted which is used to monitor the ongoing system performance. The calibration block(s) to be used shall be made from a piece of project pipe, without coating and no weld included. The surface condition shall be similar to practical circumstances.
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Rotoscan Set-Up Configuration
6.1 Inspection Set-up Configuration The inspection set-up is detailed in the specific procedure. It shows the selected probe angle(s) for the selected pulse echo, tandem and ToFD technique within the zones to be examined within the given weld bevel configuration.
6.2 Probes Used for Inspection In the specific procedure the selected probes, with their parameters, which are used for the inspection are listed. All probes have a unique number for QA/QC purpose relating to the manufacturing process and tests within the APPLUS RTD probe manufacturing department. The numbers of probes used are part of the inspection parameter file within the Rotoscan inspection program.
6.3 Probe Frame Layout The probes used for inspection are positioned within a probe frame. The position of each probe in circumferential direction and its inspection function is detailed into the specific procedure.
6.4 Parameters of Rotoscan Inspection Program The parameters will be taken from the job specific calibration block. The Rotoscan operator may make adjustments to accommodate existing field conditions within the tolerances. Note: Any adjustments of parameters outside the specified tolerances shall be recorded.
6.5 Calibration Block The calibration block shall be of matching wall thickness of the item under test and contain artificial defects to install the inspection sensitivity. The block shall be designed with sufficient surface area to enable the transducer array to scan the target areas in one single pass. Reflectors for the pulse echo technique shall be flat-bottom holes and notches, which are positioned at the weld bevel. ToFD notches are used to identify the system capability to detect surface breaking indications. The calibration block shall be manufactured and tested according to Applus RTD verification procedure CP 31108. A calibration certificate shall be issued. The calibration block shall be identified with a hard stamped unique serial number. The specific procedure shows the calibration manufacturing drawings. Notes: Through-holes Ø 2mm or 5 x 1mm slots in both ends of calibration block at centre line. These reflectors are to locate weld centre position only.
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Calibration
7.1 General The ultrasonic equipment shall be electronically calibrated at least once per 12-month period (±1 week) in accordance with the valid version of Applus RTD procedure CP 31105 (Conv.) or CP 31111 (PA).
7.2 Setting of Inspection Gates 7.2.1 Pulse-Echo and Tandem channels With each transducer positioned for the peak signal response from the calibration reflector, the detection gates are to be set. The gate shall start at least 2mm, and up to 8mm (allowance for the width of heat affected zone) before the theoretical weld bevel preparation. The gate ends shall be at least 1mm after the theoretical weld centreline. All gates will be programmed to record amplitude and/or transit distance information. The gate length of the transit distance in the root channel will be extended to enable root penetration recognition.
7.2.2 Mapping Channels The mapping gate shall start at least 2mm, and up to 8mm (allowance for width of heat affected zone) before the theoretical weld bevel preparation. The gate length will be extended to enable cap reinforcement registration or to establish overtrace from adjacent mapping zones. The mapping gates in the root will be set identical to the pulse echo transit distance channels to enable the recognition of the root penetration.
7.2.3 ToFD Channel The ToFD gate should start at an appropriate distance before the arrival of the lateral wave (ca. 2mm) and should extend up to the back-wall echo and or mode converted, to achieve full cover of the wall thickness. Note: The gate settings may be altered if geometry indications dictate.
7.2.4 Coupling Channels For Conventional Set up all PE probes, with exception of ToFD and Transverse probes, shall be used for transmission US/DS coupling control
For PA set up the number of coupling channels shall be seven (7) i.e. three (3) on each side for BWE and one (1) for transmission US/DS for coupling control
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
7.3 Sensitivity Settings The equipment sensitivity (echo amplitude) for all inspection channels should be set at 80% Full Screen Height. The calibration of the inner and outer surface breaking zones is from the relevant notch and all other zones from a FBH. The sensitivity setting for mapping in the volume is on a 1.5mm FBH at 80% FSH + 14 dB but should not be so great as to cause interfering electrical or geometric noise that could be misinterpreted. The sensitivity setting for mapping in the root, as a minimum, is equal to the related pulse echo channels, increased with additional 14 dB to ensure proper detection but should not be so great as to cause interfering electrical or geometric noise that could be misinterpreted. The lateral wave (RF signal) of the TOFD channel sensitivity is set between 40% and 80% FSH. The probe distance for TOFD should be calculated at 2/3 of the wall thickness (nominal beam angle) ± 10mm.
The sensitivity for the coupling channels is established by setting the amplitude of the signal from the transmitting probe to the receiving probe to 80%FSH added with a nominal 10 dB gain and 80% FSH added with a nominal 4dB for BWE.
7.4 Scanning Preparation & Surface Condition Spiral welds or long seams have to be ground flush over the scanning area. The scanning area shall be free of weld spatter and other irregularities, which may interfere with the inspection. Adjacent to one weld side, prior to welding, over the complete circumference at a fixed distance from the nose of the weld preparation, a scribe line shall be available for the guide band position adjustment.
The client is responsible for applying the scribeline and the lead operator is responsible for the acceptance of the applied scribeline.
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Acoustic Coupling Fluid Water shall be used as acoustic coupling fluid, to be able to test welds in the range from 0°C to over lukewarm. If temperatures lower than 0°C are experienced coupling will be mixed with antifreeze and recycled. The coupling is supplied between the probe contact surface and the pipe via supply channels incorporated in the probe housing. To enable good acoustical contact between the ultrasonic probes and the pipe surface, conditions as mentioned in Section 7.4 apply.
9
Examination
9.1 Calibration check During the first number of welds a calibration scan shall be made before and after inspection of each weld. If agreed with client, the frequency of verification scans may be reduced to a minimum of one scan for each number of welds. This will be detailed in the specific procedure. Re-calibration shall be carried out if any of the following exist: The calibration of an inspection function differs more than -2 or +2dB from the previous calibration; The gate settings need to be adjusted with more than +/- 1.0mm with the previous calibration; After a weld repair; In case the calibration differs from the initial setting, outside the given tolerances, the applicable probe(s) and coupling shall be checked. If the settings have to be changed to achieve a good calibration, the welds before this calibration up to the previous calibration will be re-evaluated taking the differences in the gain and/or gate adjustment into account. Re-scanning shall be carried out from last valid calibration: After a equipment breakdown If hardware changes have to be made to scanner to achieve a valid calibration If above is applicable, the system shall not be used until 5 acceptable calibration have been performed to confirm acceptable stability. The result of each calibration scan shall be printed or converted to pdf format and stored on hard disc.
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
9.2 Step by Step Description of a Rotoscan Examination The UT-system is already calibrated and a calibration scan with a record has been made. a. Adjust guiding band on the pipe to a distance of 150mm from the marks (scribe-line, which is 40mm from the weld centre-line) and parallel to the weld. The accuracy of the band setting should be ±1mm. b. Mark a ‘0’ datum point on the top of the pipe at the 12 o’clock position.
c. Attach the scanner to the band. d. Switch on the water coupling supply. e. Locate the scanner over the top of the pipe and make sure that all probes are past the zero point and are in proper contact with the pipe surface. f. Switch on the system and automatically the weld will be scanned in a clockwise direction. g. Systems will switch off automatically after a full scan with an overlap minimum of 5cm. h. Coupling supply will be switched off as well. Check the encoder position of an indication at the start of the scan and confirm the position of that same indication in the overlap, difference in position allowed is 10mm. i. Check the inspection results on defect indications and proper coupling. Use the transit distance recording, mapping and images for validation of defect indications within the root area and proper alignment of the guiding band. j. In case of lack of coupling a second scan will be necessary. Remove the scanner from the band and attach it to the calibration block.
9.3 Operational checks Operational checks shall be performed according to the specific procedure. The execution of and the results of the operational checks shall be recorded in the system log book. The following operational checks shall be performed for every weld inspected: Reference line shall be within required tolerance and clearly marked around the pipe circumference. The scanning surface shall be free of weld spatter and other irregularities that may interfere with the movement of transducers. Physical damage and loose connections in the band. Band position shall be within a tolerance of maximum ± 1.0mm. The pipe surface temperature shall be within the required tolerance specified in the Specific Procedure.
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Once daily or at least once per shift, check: the scanner for damage and loose connections; calibration block for damage and scanning tracks; The bevel prepared at the bevelling station shall be of the specific weld bevel geometry, dimensions and tolerances shown on the drawings of the calibration block in use. Transducers shall not be rocking in the scanner and shall be in firm contact with the scanning surface. The transducers shall be firmly screwed onto the wedges. The transducer wear faces (wedges) shall be checked for scores which may cause local loss of contact. The transducer stand-off distance shall be as recorded in the set-up sheet within ± 0.5mm. The transducer case height and the difference between the protrusions of carbide tips shall be as recorded in the setup sheet within ± 0.2mm. The recording system shall clearly indicate the location of imperfections relative to the 12 o’clock position of the weld, with a ±1% accuracy or 10mm, whichever is greater.
10
Interpretation of results
10.1 General With the transit distance measurements and with the information from the Mapping and ToFD channels, visible on the result presentation, indications shall be judged whether they are from the weld geometry or defects. The coupling channels will be checked for coupling loss. Coupling loss will be registered when the through transmission signal drops below 10% FSH as long as this is above noise level. In case the coupling loss in one of the channels is longer than the shortest allowable defect length, a rescan shall be carried out. In case the cause of the coupling loss is due to the surface condition (e.g. grinding) the surface condition shall be improved (e.g. smoothing) and the weld shall be re-scanned. If this condition appears again then the client shall be informed and another available and suitable certified method of inspection (e.g. Manual UT, Radiographic Examination) shall be used.
10.2 Inspection result The inspection result should be evaluated and/or reported as follows; All indications in the pulse echo channels should be evaluated which exceed the threshold level mentioned in the acceptance criteria. Defect length in the pulse echo channels shall be measured at the Go – Nogo level as mentioned in the acceptance criteria. Linear elongated indications in the pulse echo channels with spacing less than the length of the smallest indication shall be evaluated as one continuous defect.
The interpretation sequence to be followed is visualized in Attachment 2 and 3 for the “Decision Flow Chart for WMS and ECA”.
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Acceptance/Rejection criteria For Acceptance/Rejection criteria see the project specific supplement
12
Reporting The APPLUS RTD Rotoscan site report will be used for reporting of inspection results. The following information will be documented as minimum:
Used procedure number; Project name/number; Weld No; Inspection date; Diameter; Wall thickness; Number of indications, location on circumference and location in depth; Acceptable or rejectable.
For a sample of the Rotoscan site report, see attachment 2. An example of file naming, for Mainline Weld ML 1234 ML 1234 cal Calibration scan performed prior to mainline weld ML 1234 Scan of mainline weld ML 1234 cal out Calibration scan performed at shift end.
13
Examination of repairs Repaired areas shall be inspected with the Rotoscan system that originally detected the imperfection. This inspection will demonstrate that the original imperfection is removed and that no “new” imperfections are introduced to the weld. The results from the ToFD inspection supplemented with the Mapping image will be used to interpret the repaired area. Manual UT will be used in addition to the Rotoscan inspection in accordance with approved manual UT procedures. If the repair requires a cut-out re-examination will be conducted using the Rotoscan equipment set-up for the bevel defined in the qualified project welding procedure.
14
Storage of data The raw data of each inspected weld including the parameter settings will be stored on the main hard drive (C-Drive). In addition, a back-up will be made on a second hard drive (Removable D Drive) The Date and Time function will be used to ensure that all welds scanned are accounted for. By selecting this function the date and time of each scan made becomes part of the file name, removing the chance of overwriting any file. Welds will be stored in daily directories, which will be created at 24:00 hrs each day. Operators are responsible for the daily directory on the main hard drive and shall ensure that all welds are present and readable. Each shift will store scans and calibrations in a windows folder of that date e.g. DD-MM-YYYY All calibration and weld inspection results will be printed in a compressed black-white image of the entire weld circumference after acceptable scan is completed. After completion of the pipeline project, all data (NDT, welds, repairs and calibrations) will be stored on a digital medium and presented. The official record of inspection will be the Rotoscan Site Report and will bear the original signature of the AUT Rotoscan Operator.
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Attachment 1
Rotoscan site report
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Attachment 2
Decision Flow Chart WMS
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AUT 21130 4 05-09-2011 Automatic Ultrasonic Examination General Procedure
Attachment 3
Decision Flow Chart ECA
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
SPECIFIC PROCEDURE FOR AUTOMATIC ULTRASONIC EXAMINATION Project
:
Reshadat Project
Client
:
KITO
Scope
:
Mechanized Ultrasonic Examination of girth welds Diameter : 8,625” Wall thickness : 14,3mm Wall thickness : 15,9mm Wall thickness : 18,2mm
Based on
:
DNV-OS-F 101-2010
Validity
:
This procedure is valid only for AUT-examination of girth welds up to 95°C
This procedure is valid in conjunction with the GENERAL procedure AUT 21130 latest revision
Development – Revisions Revision No. Prepared By
Date
Approved By
Date
Amendment Details
1 0
14-09-2011 01-07-2011
R. Kelders R. Kelders
14-09-2011 01-07-2011
See revision record sheet, page 2
T. Vreenegoor T. Vreenegoor
Date 14-09-2011 Address Delftweg 144, 3046 NC Rotterdam P.O. Box 10065, 3004 AB Rotterdam The Netherlands www.ApplusRTD.com
Date
14-09-2011
Date
This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without the permission of Applus RTD.
Applus RTD Benelux is the trading name of Röntgen Technische Dienst bv If this is a copy, unless otherwise specified, it is uncontrolled. You must verify the revision before use. Page 1 of 29
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Revision record sheet Revision 1
Issue date 14-09-2011
Section All General D, E and F
Description of update Added company logo’s Changed reference DNV OS F101 2007 to 2010 Updated cal block drawings, included full PIN number
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Contents 1
Purpose
4
2
Scope
4
3
Reference documents
4
4
Rotoscan Set-Up Configuration
4
Probe Frame Layout Calibration Block Gates
4 4 4
Acceptance/Rejection criteria
5
4.1 4.2 4.3 5
Attachment A: Inspection set-up configuration (will be finalised after setup)
8,625” x 14,3mm 8,625” x 15,9mm 8,625” x 18,2mm
6
6 6 6
Attachment B: Probe frame lay-out
7
Attachment C: Calibration block drawings 8,625” x 14,3mm
8
Attachment D: Calibration block drawings 8,625” x 15,9mm
15
Attachment E: Calibration block drawings 8,625” x 18,2mm
22
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Purpose The purpose of this specific procedure is to detail the actual system configuration and set-up parameters including the reference blocks for Automated Ultrasonic Examination (AUT) to determine specific circumferential ‘Weld Integrity’, this is in accordance with the requirements of DNV-OS-F 101-2010 on the Reshadat project.
2
Scope This procedure details methods for Automated Ultrasonic Weld Examination (via the APPLUS RTD Rotoscan System) of ferrous butt welds. Diameter Wall thickness
Weld Bevel
3
: : : : :
8,625” 14,3mm 15,9mm 18,2mm J-prep (Serimax)
Reference documents • General AUT Procedure AUT 21130 Latest revision • DNV-OS-F 101-2010 • CP 31111 Latest revision
4
Rotoscan Set-Up Configuration
4.1 Probe Frame Layout The probes used for inspection are positioned within a probe frame. The probe settings are visualised in Attachement A. The position of each probe in circumferential direction and its inspection function is visualised in Attachment B.
4.2 Calibration Block Detailed calibration block drawings and set ups are included in Attachment C, D and E. Production pipe will be used for Calibration Blocks.
4.3 Gates All gate lengths and settings of Pulse Echo, Tandem , Mapping, ToFD and coupling channels are a part of the “rotoscan file” and these are saved with every weld scanned.
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Acceptance/Rejection criteria The interpretation sequence to be followed is visualized in Attachment 3, the “Decision Flow Chart for ECA in the general procedure AUT 21130 latest revision. The document containing the Acceptance/Rejection criteria shall be submitted by the Client.
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment A: Inspection set-up configuration (will be finalised after setup)
8,625” x 14,3mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD 1
Notch ToFD Notch 1mm
6 MHZ comp 4 MHZ shear
65° 55°
ToFD Pulse Echo
H/I A
3 4
Upper/lower cap Fill 2 Fill 1 Hot pass
5 Vol 1 Vol 2
Root Upper mapping Lower mapping
2
Ø 3mm Ø 3mm
4MHZ shear
40°/48°
Pulse Echo
B
Ø 3mm
4MHZ shear 4MHZ shear
40°/48° 50°
Pulse Echo Pulse Echo
C D
Notch 1mm Ø 1.5mm Ø 1.5mm
4MHZ shear 4 MHZ shear 4 MHZ shear
65° 50° 50°
Pulse Echo Pulse Echo Pulse Echo
E J K
8,625” x 15,9mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD
Upper/lower
Notch ToFD
6 MHZ comp
65°
ToFD
H/I
1 2 3 4
cap Fill 2 Fill 1
Notch 1mm Ø 3mm Ø 3mm Ø 3mm
4 MHZ shear 4MHZ shear 4MHZ shear 4MHZ shear
55° 40°/48° 40°/48° 50°
Notch 1mm Ø 1.5mm
4MHZ shear 4 MHZ shear
Ø 1.5mm
5 Vol 1 Vol 2
Hot pass
Root Upper mapping Lower mapping
Pulse Pulse Pulse Pulse
Echo Echo Echo Echo
A B C D
65° 50°
Pulse Echo Pulse Echo
E J
4 MHZ shear
50°
Pulse Echo
K
8,625” x 18,2mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD 1 2 3 4 5
Upper/lower cap Fill 3 Fill 2 Fill 1 Hot pass
Notch ToFD Notch 1mm Ø 3mm Ø 3mm Ø 3mm Ø 3mm
6 MHZ comp 4 MHZ shear 4MHZ shear 4MHZ shear 4MHZ shear 4MHZ shear
65° 55° 40°/48° 40°/48° 40°/48° 50°
ToFD Pulse Echo Pulse Echo Pulse Echo Pulse Echo Pulse Echo
I/J A B C D E
6
Root Upper mapping Lower mapping
Notch 1mm Ø 1.5mm
4MHZ shear
65°
Pulse Echo
F
4 MHZ shear 4 MHZ shear
50° 50°
Pulse Echo Pulse Echo
K L
Vol 1 Vol 2
Ø 1.5mm
Page 6 of 29
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment B: Probe frame lay-out Scan direction 8’625” x 14,3mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Cap US
TOFD US
Scan direction 8’625” x 15,9mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Cap US
TOFD US
Scan direction 8’625” x 18,2mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Fill 3 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Fill 3 US
Cap US
TOFD US
Page 7 of 29
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment C: Calibration block drawings 8,625” x 14,3mm
Page 8 of 29
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment D: Calibration block drawings 8,625” x 15,9mm
Page 15 of 29
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 21 of 29
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment E: Calibration block drawings 8,625” x 18,2mm
Page 22 of 29
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: : : : : :
AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 23 of 29
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 27 of 29
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AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 28 of 29
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: : : : : :
AUT specific 11-406 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 29 of 29
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
SPECIFIC PROCEDURE FOR AUTOMATIC ULTRASONIC EXAMINATION Project
:
Reshadat Project
Client
:
KITO
Scope
:
Mechanized Ultrasonic Examination of girth welds Diameter : 10,75” Wall thickness : 12,7mm Wall thickness : 14,3mm Wall thickness : 15,9mm Wall thickness : 18,2mm
Based on
:
DNV-OS-F 101-2010
Validity
:
This procedure is valid only for AUT-examination of girth welds up to 95°C
This procedure is valid in conjunction with the GENERAL procedure AUT 21130 latest revision
Development – Revisions Revision No. Prepared By
Date
Approved By
Date
Amendment Details
1 0
14-09-2011 01-07-2011
R. Kelders R. Kelders
14-09-2011 01-07-2011
See revision record sheet, page 2
T. Vreenegoor T. Vreenegoor
Date 14-09-2011 Address Delftweg 144, 3046 NC Rotterdam P.O. Box 10065, 3004 AB Rotterdam The Netherlands www.ApplusRTD.com
Date
14-09-2011
Date
This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without the permission of Applus RTD.
Applus RTD Benelux is the trading name of Röntgen Technische Dienst bv If this is a copy, unless otherwise specified, it is uncontrolled. You must verify the revision before use. Page 1 of 38
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Revision record sheet Revision 1
Issue date 14-09-2011
Section All General C, D, E and F
Description of update Added company logo’s Changed reference DNV OS F101 2007 to 2010 Updated cal block drawings, included full PIN number
Page 2 of 38
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Contents 1
Purpose
4
2
Scope
4
3
Reference documents
4
4
Rotoscan Set-Up Configuration
4
Probe Frame Layout Calibration Block Gates
4 4 4
Acceptance/Rejection criteria
5
4.1 4.2 4.3 5
Attachment A: Inspection set-up configuration (will be finalised after setup)
10,75” x 12,7mm 10,75” x 14,3mm 10,75” x 15,9mm 10,75” x 18,2mm
6
6 6 7 7
Attachment B: Probe frame lay-out
8
Attachment C: Calibration block drawings 10,75” x 12,7mm
10
Attachment D: Calibration block drawings 10,75” x 14,3mm
17
Attachment E: Calibration block drawings 10,75” x 15,9mm
24
Attachment F: Calibration block drawings 10,75” x 18,2mm
31
Page 3 of 38
Doc Ref Revision Date Title Type Client
1
: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Purpose The purpose of this specific procedure is to detail the actual system configuration and set-up parameters including the reference blocks for Automated Ultrasonic Examination (AUT) to determine specific circumferential ‘Weld Integrity’, this is in accordance with the requirements of DNV-OS-F 101-2010 on the Reshadat project.
2
Scope This procedure details methods for Automated Ultrasonic Weld Examination (via the APPLUS RTD Rotoscan System) of ferrous butt welds. Diameter Wall thickness
Weld Bevel
3
: : : : : :
10,75” 12,7mm 14,3mm 15,9mm 18,2mm J-prep (Serimax)
Reference documents • General AUT Procedure AUT 21130 Latest revision • DNV-OS-F 101-2010 • CP 31111 Latest revision
4
Rotoscan Set-Up Configuration
4.1 Probe Frame Layout The probes used for inspection are positioned within a probe frame. The probe settings are visualised in Attachement A. The position of each probe in circumferential direction and its inspection function is visualised in Attachment B.
4.2 Calibration Block Detailed calibration block drawings and set ups are included in Attachment C, D, E and F. Production pipe will be used for Calibration Blocks.
4.3 Gates All gate lengths and settings of Pulse Echo, Tandem, Mapping, ToFD and coupling channels are a part of the “rotoscan file” and these are saved with every weld scanned.
Page 4 of 38
Doc Ref Revision Date Title Type Client
5
: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Acceptance/Rejection criteria The interpretation sequence to be followed is visualized in Attachment 3, the “Decision Flow Chart for ECA in the general procedure AUT 21130 latest revision. The document containing the Acceptance/Rejection criteria shall be submitted by the Client.
Page 5 of 38
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment A: Inspection set-up configuration (will be finalised after setup)
10,75” x 12,7mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD 1
Notch ToFD Notch 1mm
6MHZ comp 4 MHZ shear
65° 55°
ToFD Pulse Echo
H/I A
3 4
Upper/lower cap Fill 2 Fill 1 Hot pass
5 Vol 1 Vol 2
Root Upper mapping Lower mapping
2
Ø 3mm Ø 3mm
4MHZ shear
40°/48°
Pulse Echo
B
Ø 3mm
4MHZ shear 4MHZ shear
40°/48° 50°
Pulse Echo Pulse Echo
C D
Notch 1mm Ø 1.5mm Ø 1.5mm
4MHZ shear 4 MHZ shear 4 MHZ shear
65° 50° 50°
Pulse Echo Pulse Echo Pulse Echo
E J K
10,75” x 14,3mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD
Upper/lower
Notch ToFD
6 MHZ comp
65°
ToFD
H/I
1 2
cap Fill 2 Fill 1 Hot pass
Notch 1mm Ø 3mm Ø 3mm
4 MHZ shear 4MHZ shear
55° 40°/48°
Pulse Echo Pulse Echo
A B
Ø 3mm
4MHZ shear 4MHZ shear
40°/48° 50°
Pulse Echo Pulse Echo
C D
Root Upper mapping Lower mapping
Notch 1mm Ø 1.5mm
4MHZ shear 4 MHZ shear
65° 50°
Pulse Echo Pulse Echo
E J
Ø 1.5mm
4 MHZ shear
50°
Pulse Echo
K
3 4 5 Vol 1 Vol 2
Page 6 of 38
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
10,75” x 15,9mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD 1 2 3 4 5
Upper/lower cap Fill 2 Fill 1 Hot pass
Notch ToFD Notch 1mm Ø 3mm Ø 3mm Ø 3mm Notch 1mm Ø 1.5mm
6 MHZ comp 4 MHZ shear 4MHZ shear 4MHZ shear 4MHZ shear 4MHZ shear
65° 55° 40°/48° 40°/48° 50° 65°
ToFD Pulse Echo Pulse Echo Pulse Echo Pulse Echo Pulse Echo
H/I A B C D E
4 MHZ shear
50°
Pulse Echo
J
Ø 1.5mm
4 MHZ shear
50°
Pulse Echo
K
Vol 1 Vol 2
Root Upper mapping Lower mapping
10,75” x 18,2mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD 1
Notch ToFD Notch 1mm
6 MHZ comp 4 MHZ shear
65° 55°
ToFD Pulse Echo
I/J A
2
Upper/lower cap Fill 3
Ø 3mm
4MHZ shear
40°/48°
Pulse Echo
B
3
Fill 2
Ø 3mm
4MHZ shear
40°/48°
Pulse Echo
C
4 5
Fill 1 Hot pass
Ø 3mm Ø 3mm
4MHZ shear 4MHZ shear
40°/48° 50°
Pulse Echo Pulse Echo
D E
6 Vol 1 Vol 2
Root Upper mapping Lower mapping
Notch 1mm Ø 1.5mm Ø 1.5mm
4MHZ shear 4 MHZ shear 4 MHZ shear
65° 50° 50°
Pulse Echo Pulse Echo Pulse Echo
F K L
Page 7 of 38
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment B: Probe frame lay-out
Scan direction 10’75” x 12,7mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Cap US
TOFD US
Scan direction 10’75” x 14,3mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Cap US
TOFD US
Page 8 of 38
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Scan direction 10’75” x 15,9mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Cap US
TOFD US
Scan direction 10’75” x 18,2mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Fill 3 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Fill 3 US
Cap US
TOFD US
Page 9 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment C: Calibration block drawings 10,75” x 12,7mm
Page 10 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 16 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment D: Calibration block drawings 10,75” x 14,3mm
Page 17 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 18 of 38
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 23 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment E: Calibration block drawings 10,75” x 15,9mm
Page 24 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 25 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 26 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 28 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 29 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 30 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment F: Calibration block drawings 10,75” x 18,2mm
Page 31 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 32 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 35 of 38
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: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 36 of 38
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 37 of 38
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-407 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 38 of 38
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
SPECIFIC PROCEDURE FOR AUTOMATIC ULTRASONIC EXAMINATION Project
:
Reshadat Project
Client
:
KITO
Scope
:
Mechanized Ultrasonic Examination of girth welds Diameter : 14” Wall thickness : 15,9mm
Based on
:
DNV-OS-F 101-2010
Validity
:
This procedure is valid only for AUT-examination of girth welds up to 95°C
This procedure is valid in conjunction with the GENERAL procedure AUT 21130 latest revision
Development – Revisions Revision No. Prepared By
Date
Approved By
Date
Amendment Details
1 0
14-09-2011 01-07-2011
R. Kelders R. Kelders
14-09-2011 01-07-2011
See revision record sheet, page 2
T. Vreenegoor T. Vreenegoor
Date 14-09-2011 Address Delftweg 144, 3046 NC Rotterdam P.O. Box 10065, 3004 AB Rotterdam The Netherlands www.ApplusRTD.com
Date
14-09-2011
Date
This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without the permission of Applus RTD.
Applus RTD Benelux is the trading name of Röntgen Technische Dienst bv If this is a copy, unless otherwise specified, it is uncontrolled. You must verify the revision before use. Page 1 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Revision record sheet Revision 1
Issue date 14-09-2011
Section All General C
Description of update Added company logo’s Changed reference DNV OS F101 2007 to 2010 Updated cal block drawings, included full PIN number
Page 2 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Contents 1
Purpose
4
2
Scope
4
3
Reference documents
4
4
Rotoscan Set-Up Configuration
4
Probe Frame Layout Calibration Block Gates
4 4 4
Acceptance/Rejection criteria
5
4.1 4.2 4.3 5
Attachment A: Inspection set-up configuration (will be finalised after setup)
14” x 15,9mm
6
6
Attachment B: Probe frame lay-out
7
Attachment C: Calibration block drawings 14” x 15,9mm
8
Page 3 of 14
Doc Ref Revision Date Title Type Client
1
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Purpose The purpose of this specific procedure is to detail the actual system configuration and set-up parameters including the reference blocks for Automated Ultrasonic Examination (AUT) to determine specific circumferential ‘Weld Integrity’, this is in accordance with the requirements of DNV-OS-F 101-2010 on the Reshadat project.
2
Scope This procedure details methods for Automated Ultrasonic Weld Examination (via the APPLUS RTD Rotoscan System) of ferrous butt welds. Diameter Wall thickness Weld Bevel
3
: 14” : 15,9mm : J-prep (Serimax)
Reference documents • General AUT Procedure AUT 21130 Latest revision • DNV-OS-F 101-2010 • CP 31111 Latest revision
4
Rotoscan Set-Up Configuration
4.1 Probe Frame Layout The probes used for inspection are positioned within a probe frame. The probe settings are visualised in Attachement A. The position of each probe in circumferential direction and its inspection function is visualised in Attachment B.
4.2 Calibration Block Detailed calibration block drawings and set ups are included in Attachment C. Production pipe will be used for Calibration Blocks.
4.3 Gates All gate lengths and settings of Pulse Echo, Tandem , Mapping, ToFD and coupling channels are a part of the “rotoscan file” and these are saved with every weld scanned.
Page 4 of 14
Doc Ref Revision Date Title Type Client
5
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Acceptance/Rejection criteria The interpretation sequence to be followed is visualized in Attachment 3, the “Decision Flow Chart for ECA in the general procedure AUT 21130 latest revision. The document containing the Acceptance/Rejection criteria shall be submitted by the Client.
Page 5 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment A: Inspection set-up configuration (will be finalised after setup)
14” x 15,9mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD 1
Notch ToFD Notch 1mm
6 MHZ comp 4 MHZ shear
65° 55°
ToFD Pulse Echo
H/I A
3 4
Upper/lower cap Fill 2 Fill 1 Hot pass
5 Vol 1 Vol 2
Root Upper mapping Lower mapping
2
Ø 3mm Ø 3mm
4MHZ shear
40°/48°
Pulse Echo
B
Ø 3mm
4MHZ shear 4MHZ shear
40°/48° 50°
Pulse Echo Pulse Echo
C D
Notch 1mm Ø 1.5mm Ø 1.5mm
4MHZ shear 4 MHZ shear 4 MHZ shear
65° 50° 50°
Pulse Echo Pulse Echo Pulse Echo
E J K
Page 6 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment B: Probe frame lay-out
Scan direction 10’75” x 15,9mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Cap US
TOFD US
Page 7 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Attachment C: Calibration block drawings 14” x 15,9mm
Page 8 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 9 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 10 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 11 of 14
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: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 12 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 13 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-408 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Page 14 of 14
Doc Ref Revision Date Title Type Client
: : : : : :
AUT specific 11-409 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
SPECIFIC PROCEDURE FOR AUTOMATIC ULTRASONIC EXAMINATION Project
:
Reshadat Project
Client
:
KITO
Scope
:
Mechanized Ultrasonic Examination of girth welds Diameter : 16” Wall thickness : 12,7mm Wall thickness : 15,9mm Wall thickness : 20,6mm Wall thickness : 23,8mm
Based on
:
DNV-OS-F 101-2010
Validity
:
This procedure is valid only for AUT-examination of girth welds up to 95°C
This procedure is valid in conjunction with the GENERAL procedure AUT 21130 latest revision
Development – Revisions Revision No. Prepared By
Date
Approved By
Date
Amendment Details
1 0
14-09-2011 01-07-2011
R. Kelders R. Kelders
14-09-2011 01-07-2011
See revision record sheet, page 2
T. Vreenegoor T. Vreenegoor
Date 14-09-2011 Address Delftweg 144, 3046 NC Rotterdam P.O. Box 10065, 3004 AB Rotterdam The Netherlands www.ApplusRTD.com
Date
14-09-2011
Date
This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without the permission of Applus RTD.
Applus RTD Benelux is the trading name of Röntgen Technische Dienst bv If this is a copy, unless otherwise specified, it is uncontrolled. You must verify the revision before use. Page 1 of 39
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AUT specific 11-409 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Revision record sheet Revision 1
Issue date 14-09-2011
Section All General C, D, E and F
Description of update Added company logo’s Changed reference DNV OS F101 2007 to 2010 Updated cal block drawings, included full PIN number
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AUT specific 11-409 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Contents 1
Purpose
4
2
Scope
4
3
Reference documents
4
4
Rotoscan Set-Up Configuration
4
Probe Frame Layout Calibration Block Gates
4 4 4
Acceptance/Rejection criteria
5
4.1 4.2 4.3 5
Attachment A: Inspection set-up configuration (will be finalised after setup)
16” x 12,7mm 16” x 15,9mm 16” x 20,6mm 16” x 23,8mm
6
6 6 7 7
Attachment B: Probe frame lay-out
8
Attachment C: Calibration block drawings 16” x 12,7mm
10
Attachment D: Calibration block drawings 16” x 15,9mm
17
Attachment E: Calibration block drawings 16” x 20,6mm
24
Attachment F: Calibration block drawings 16” x 23,8mm
32
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AUT specific 11-409 1 14-09-2011 Automatic Ultrasonic Examination Specific Procedure KITO
Purpose The purpose of this specific procedure is to detail the actual system configuration and set-up parameters including the reference blocks for Automated Ultrasonic Examination (AUT) to determine specific circumferential ‘Weld Integrity’, this is in accordance with the requirements of DNV-OS-F 101-2010 on the Reshadat project.
2
Scope This procedure details methods for Automated Ultrasonic Weld Examination (via the APPLUS RTD Rotoscan System) of ferrous butt welds. Diameter Wall thickness
Weld Bevel
3
: : : : : :
16” 12,7mm 15,9mm 20,6mm 23,8mm J-prep (Serimax)
Reference documents • General AUT Procedure AUT 21130 Latest revision • DNV-OS-F 101-2010 • CP 31111 Latest revision
4
Rotoscan Set-Up Configuration
4.1 Probe Frame Layout The probes used for inspection are positioned within a probe frame. The probe settings are visualised in Attachement A. The position of each probe in circumferential direction and its inspection function is visualised in Attachment B.
4.2 Calibration Block Detailed calibration block drawings and set ups are included in Attachment C, D, E and F. Production pipe will be used for Calibration Blocks.
4.3 Gates All gate lengths and settings of Pulse Echo, Tandem , Mapping, ToFD and coupling channels are a part of the “rotoscan file” and these are saved with every weld scanned.
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Acceptance/Rejection criteria The interpretation sequence to be followed is visualized in Attachment 3, the “Decision Flow Chart for ECA in the general procedure AUT 21130 latest revision. The document containing the Acceptance/Rejection criteria shall be submitted by the Client.
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Attachment A: Inspection set-up configuration (will be finalised after setup)
16” x 12,7mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD 1
Notch ToFD Notch 1mm
6 MHZ comp 4 MHZ shear
65° 55°
ToFD Pulse Echo
H/I A
3 4
Upper/lower cap Fill 2 Fill 1 Hot pass
5 Vol 1 Vol 2
Root Upper mapping Lower mapping
2
Ø 3mm Ø 3mm
4MHZ shear
40°/48°
Pulse Echo
B
Ø 3mm
4MHZ shear 4MHZ shear
40°/48° 50°
Pulse Echo Pulse Echo
C D
Notch 1mm Ø 1.5mm Ø 1.5mm
4MHZ shear 4 MHZ shear 4 MHZ shear
65° 50° 50°
Pulse Echo Pulse Echo Pulse Echo
E J K
16” x 15,9mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD
Upper/lower
Notch ToFD
6 MHZ comp
65°
ToFD
H/I
1 2 3 4
cap Fill 2 Fill 1
Notch 1mm Ø 3mm Ø 3mm Ø 3mm
4 MHZ shear 4MHZ shear 4MHZ shear 4MHZ shear
55° 40°/48° 40°/48° 50°
Notch 1mm Ø 1.5mm
4MHZ shear 4 MHZ shear
Ø 1.5mm
4 MHZ shear
5 Vol 1 Vol 2
Hot pass
Root Upper mapping Lower mapping
Pulse Pulse Pulse Pulse
Echo Echo Echo Echo
A B C D
65° 50°
Pulse Echo Pulse Echo
E J
50°
Pulse Echo
K
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16” x 20,6mm Zone
Name
Reflector Cal. block
Frequency Probe
Angle
Insp. Techn
Ident.
ToFD 1 2 3 4 5
Upper/lower Cap Fill 3 Fill 2 Fill 1 Hot pass
Notch ToFD Notch 1mm Ø 3mm Ø 3mm Ø 3mm Ø 3mm
6 MHZ comp 4 MHZ shear 4MHZ shear 4MHZ shear 4MHZ shear 4MHZ shear
65° 55° 40°/46° 40°/46° 40°/46° 50°
ToFD Pulse Echo Pulse Echo Pulse Echo Pulse Echo Pulse Echo
I/J A B C D E
6 Vol 1
Root Upper mapping
Notch 1mm Ø 1.5mm
4MHZ shear 4 MHZ shear
65° 50°
Pulse Echo Pulse Echo
F K
Vol 2
Lower mapping
Ø 1.5mm
4 MHZ shear
50°
Pulse Echo
L
Frequency Probe
Angle
16” x 23,8mm Zone
Name
Reflector Cal. block
ToFD
Upper/lower
Notch ToFD
6 MHZ comp
1
Cap Fill 4
Notch 1mm Ø 3mm
4 MHZ shear 4MHZ shear
2 3 4 5
Fill 3 Fill 2 Fill 1
4MHZ shear 4MHZ shear 4MHZ shear 4MHZ shear
40°/46° 40°/46° 40°/46° 50°
Notch 1mm Ø 1.5mm
4MHZ shear 4 MHZ shear
Ø 1.5mm
4 MHZ shear
6 Vol 1 Vol 2
Hot pass
Root Upper mapping Lower mapping
Ø Ø Ø Ø
3mm 3mm 3mm 3mm
Insp. Techn
Ident.
65°
ToFD
J/K
55° 40°/46°
Pulse Echo Pulse Echo
A B
Pulse Pulse Pulse Pulse
Echo Echo Echo Echo
C D E F
65° 50°
Pulse Echo Pulse Echo
G M
50°
Pulse Echo
M
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Attachment B: Probe frame lay-out Scan direction 16” x 15,9mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Cap US
TOFD US
Scan direction 16” x 15,9mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Cap US
TOFD US
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Scan direction 16” x 20,6mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Fill 3 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Fill 3 US
Cap US
TOFD US
Scan direction 16” x 23,8mm
Root DS
Hot Pass DS
Fill 1 DS
Fill 2 DS
Fill 3 DS
Fill 4 DS
Cap DS
TOFD DS
Root US
Hot Pass US
Fill 1 US
Fill 2 US
Fill 3 US
Fill 4 US
Cap US
TOFD US
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Attachment C: Calibration block drawings 16” x 12,7mm
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Attachment D: Calibration block drawings 16” x 15,9mm
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Attachment E: Calibration block drawings 16” x 20,6mm
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Attachment F: Calibration block drawings 16” x 23,8mm
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MT 11-410 1 14-09-2011 Magnetic Examniation KITO
Procedure MAGNETIC PARTICLE EXAMINATION Project
:
Reshadat Project
Client
:
KITO
Owner
:
IOOC
NDE Contractor :
Applus RTD
Scope
:
Magnetic Particle Inspection of welds, weld bevels and repair areas
Based on
:
DNV Offshore Standard OS-F101 ed. 2010
Validity
:
This procedure is valid only for MT-examination of welds with a Surface temperature of 0°C to 50°C for wet particles and > 50° t ≤ 230°C for dry particles
Development – Revisions Revision No. Prepared By
Date
Approved By
Date
Amendment Details
1 0
14-09-2011 01-07-2011
R Kelders R Kelders
14-09-2011 01-07 -2011
See revision record sheet, page 2
Date
T. Vreenegoor T. Vreenegoor
14-09-2011
Date
14-09-2011
Date
Address Delftweg 144, 3046 NC Rotterdam P.O. Box 10065, 3004 AB Rotterdam The Netherlands www.ApplusRTD.com This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without the permission of Applus RTD.
Applus RTD Benelux is the trading name of Röntgen Technische Dienst bv If this is a copy, unless otherwise specified, it is uncontrolled. You must verify the revision before use. Page 1 of 9
Doc Ref Revision Date Title Client
: : : : :
MT 11-410 1 14-09-2011 Magnetic Examniation KITO
Revision record sheet Revision 1
Issue date 14-09-2011
Section General General
Description of update Added company logo’s Changed reference DNV OS F101 2007 to 2010
Page 2 of 9
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MT 11-410 1 14-09-2011 Magnetic Examniation KITO
Contents 1
Scope
4
2
General Requirements
4
Personnel qualifications Reference Documents Technique and materials Surface preparation Surface temperature Lighting Contrast paint
4 4 4 4 4 4 5
Equipment and Materials
5
Equipment Examination medium Black particles (wet method) Powder particles (dry method) Magnetising field adequacy Calibration of equipment
5 5 5 5 5 6
Examination
6
Method of examination Direction of magnetisation Examination coverage
6 6 6
Evaluation and Acceptance Standard
7
Evaluation of indications Acceptance standards Examination of repairs and repair grooves
7 7 8
Records
8
2.1 2.2 2.3 2.4 2.5 2.6 2.7 3
3.1 3.2 3.3 3.4 3.5 3.6 4
4.1 4.2 4.3 5
5.1 5.2 5.3 6
Attachment A : Report form
9
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MT 11-410 1 14-09-2011 Magnetic Examniation KITO
Scope This procedure describes the method to be used for magnetic particle examination on ferromagnetic material and ferromagnetic welds with yoke magnetisation in accordance with the requirements of: DNV rules for Submarine Pipeline Systems OS F101 ed. 2010.
2
General Requirements
2.1 Personnel qualifications NDE-personnel shall be qualified and certified in accordance with the valid version Applus RTD "Written Practice" NL IPS 10 for the qualification and certification of personnel, which conforms SNT-TC-1A 2006 and EN 473 Level 2. Level 1 personnel shall be assigned to NDE under the supervision of the Level 2 as. Interpretation of the results shall only be performed by Level 2 personnel as minimum.
2.2 Reference Documents Project specific reference documents will be listed in the project specific supplement to this procedure. ASNT SNT TC 1A
Recommended practice for NDT Personnel Qualification and Certification
EN 473
Non Destructive Testing – Qualification and Certification of NDT personnel
CP 31201
Calibration procedure for Electromagnetic Yoke
CP 31203
Verification & Testing Procedure for Magnetic Particle suspensions
2.3 Technique and materials The ferromagnetic particles used as an examination medium, shall be either wet or dry and shall be non-fluorescent. Yoke technique shall be used; the type of current shall be Alternating Current (AC).
2.4 Surface preparation Prior to magnetic particle examination, the surface to be examined and all adjacent areas within at least 25 mm shall be dry and free of all dirt, grease, scale, welding flux and spatter, oil or other extraneous matter that could interfere with the examination. Cleaning may be accomplished using power-brush, detergents, organic solvents, de-scaling solutions, paint removers, vapour degreasing, sand or grit blasting, or ultrasonic cleaning methods.
2.5 Surface temperature The surface temperature of the part to be examined shall be > 5˚C t ≤ 50˚C (lukewarm) for the wet method and ≤230˚C for the dry particle method.
2.6 Lighting The light intensity at the surface to be examined shall be 500 Lux. For example the intensity of 500 Lux. can be achieved with a 60 Watt bulb at a distance of 25 cm.
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2.7 Contrast paint If with the dry method the contrast between the surface and the test ink is too low, a thin layer of contrast paint must be applied on the surface. Only contrast paint submitted by ApplusRTD may be used.
3
Equipment and Materials
3.1 Equipment Alternating Current (AC) Yoke magnet shall be used.
3.2 Examination medium The ferromagnetic particles used as an examination medium, shall be either wet or dry and shall be non-fluorescent. The ferromagnetic particles used for the examination shall meet the following requirements: The colour of the particles shall provide adequate contrast with the surface being examined. The test medium shall be applied at blowing it over the surface. The blowing force shall be so, that it does not disturb or remove weakly formed indications.
3.3 Black particles (wet method) The particles shall be suspended in a suitable liquid medium. The concentration of the magnetic particles is normally checked by the use of a Sutherland Flask. A 100 ml portion of the test-medium is taken and allowed to settle for 30 minutes. The volume settling out at the bottom of the tube is indicative of the particle concentration. The recommended concentration from a 100 ml sample is from 1,2 to 2,4 ml, in accordance with Applus RTD in-house procedure CP-31203, latest revision. The temperature of the wet particle suspension and the surface of the part shall not exceed 50°C (lukewarm).
3.4 Powder particles (dry method) The dry powder ferromagnetic particles for repair grooves and/or hot areas shall be used at a surface temperature 4 dB
The setting must be corrected for the remainder of the test. The setting must be corrected and all tests carried out in the previous period must be repeated. The setting must be corrected and all indications must be retested and re-evaluated. Measure The setting must be corrected for the remainder of the test. The setting must be corrected and all tests carried out in the previous period must be repeated.
Increase in the sensitivity > 4 dB Deviation in measuring range Deviations ≤ 2 % in the measuring range Deviations > 2 % in the measuring range
4.5 Examination sensitivity Scanning sensitivity shall be reference level + 6 dB. Evaluation level shall be at normal sesitivity.
5
Examination
5.1 Parent metal examination Straight beam probes shall be used to examine the parent metal, both sides of the weld, for a minimum surface distance of 1.25x the longest angle beam surface skip distance to be scanned. After cutting pipes at least a band of 100 mm shall be examined for laminations. All partial and full beam reflectors found that may interfere with angle beam examination shall be noted on the UT report form.
5.2 Wall thickness verification After grinding of the pipe surface a wall thickness measurement shall be carried out to verify the minimum wall thickness.
5.3 Weld examination Manual UT Girth Weld examination of production pipe welds will only be used to provide a back-up examination to the primary inspection method for the specific project.
5.3.1 Longitudinal scanning Scan the weld from both sides, as indicated on attachment B, probe movement 1, 2.
5.3.2 Transverse scanning Scan the weld on both sides, as indicated on attachment B, movement 3, 4 and when surface does not allow this then probe movement 5, 6 7, 8.
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Evaluation and acceptance/rejection standard
6.1 Evaluation The indications are to be investigated by maximising the echoes with different angle probes and by rotating the probes. All indications exceeding 20% of the reference curve are to be investigated and all indications exceeding 50% of the reference curve are to be reported. Investigation is to be performed to the extent that the operator can determine the shape and location of the indication. Dimensional evaluation, either the “20 dB drop” method or maximum amplitude is to be used. Length determination the “half-value-drop” method is to be used.
6.2 Acceptance / rejection criteria According to table D-5 from DNV OS-F101 – 2007
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Test Records The manual UT Site report (see attachment C) must contain at least the following information: • • • • • • • • • • • • • • • • •
Project Client NDT Procedure number Report No & Revision No (if applicable) Test Equipment, Probes and Inspection techniques used Calibration blocks Couplant Pipe diameter, Wall thickness & Material Type Weld number Test item, Object, Parts – examined & test area % covered Surface condition and sides, from which the examination has been executed Test Results & Compliance Statement: all reflectors of imperfections, which > 50% DAC. all unacceptable indications with locations on circumference length, cross section location i.e. centreline or side-wall and depth from O.D. pipe surface. all reflectors in the base material, which restrict the examination. Technician Name and Qualification Level.
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Attachment A
Example Reference bock manual UT
The reference block shall have length and width dimensions suitable for the sound beam path for all probe types and the material dimension (s) to be tested.
Table D-1 Reference block Dimensions Material thickness (t) mm t < 25 mm 25 mm < t < 50 mm 50 mm < t < 100 mm 100 mm < t < 150mm
Thickness of reference block (T) mm 20 or t 38 or t 75 or t 125 or t
Position of side drilled hole ¼T& ½T& ¾T
Diameter of Side drilled hole mm 3.0 3.0 3.0 3.0
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Attachment B
Probe movement and direction
Test Method Scanning Position Normal probes parent material
over a distance of 2.5 WT from each side of the toe of the weld
weld metal
3 and 4 when surface allows other wise according to 5, 6, 7 and 8
Angle Probes weld metal
1 ,2 ,5,6,7,8
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Attachment C
Report form
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UT Lam Check 11- 411 1 14-09-2011 Ultrasonic Examination KITO
Procedure MANUAL ULTRASONIC EXAMINATION Project
:
Reshadat Project
Client
:
KITO
Owner
:
IOOC
NDE Contractor :
Applus RTD
Scope
:
Ultrasonic examination for laminations on pipe ends
Based on
:
DNV Offshore Standard OS-F101 ed. 2010
Validity
:
This procedure is valid only for UT-examination of welds with a surface temperature of 0° C up to 70° C.
Development - Revisions Revision No. Prepared By
0
Date
T. Vreenegoor T. Vreenegoor
14-09-2011
Date
Approved By
Date
Amendment Details
14-09-2011 01-07-2011
R. Kelders R. Kelders
14-09-2011 01-07-2011
See revision record sheet, page 2
Date
14-09-2011
Date
Address Delftweg 144, 3046 NC Rotterdam P.O. Box 10065, 3004 AB Rotterdam The Netherlands www.ApplusRTD.com This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without the permission of Applus RTD.
Applus RTD Benelux is the trading name of Röntgen Technische Dienst bv If this is a copy, unless otherwise specified, it is uncontrolled. You must verify the revision before use. Page 1 of 7
Doc Ref Revision Date Title Client
: : : : :
UT Lam Check 11- 411 1 14-09-2011 Ultrasonic Examination KITO
Revision record sheet Revision 1
Issue date 14-09-2011
Section General General
Description of update Added company logo’s Changed reference DNV OS F101 2007 to 2010
Page 2 of 7
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UT Lam Check 11- 411 1 14-09-2011 Ultrasonic Examination KITO
Contents 1
Scope
4
2
General Requirements
4
Personnel qualifications Surface preparation Reference Documents
4 4 4
Equipment and accessories
4
Equipment Probes Calibration blocks Couplant
4 4 4 5
Calibration
5
Sweep Range Sensitivity setting Calibration control
5 5 5
Examination
5
Scanning Sensitivity of examination
5 5
Evaluation and recording
6
Evaluation Acceptance criteria
6 6
Test Records
6
2.1 2.2 2.3 3
3.1 3.2 3.3 3.4 4
4.1 4.2 4.3 5
5.1 5.2 6
6.1 6.2 7
Attachment A Reportform
7
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Scope This procedure describes the method for ultrasonic examination on laminations of pipe ends on the “Reshadat Project”
2
General Requirements
2.1 Personnel qualifications NDE-personnel shall be qualified and certified in accordance with the valid version of Applus RTD Written Practice NL IPS 10, which is in conformity with the Recommended Practice SNT-TC-1A edition 2006 and EN 473. The ultrasonic examination and interpretation of the results shall be performed by qualified and certified personnel Level 2 as minimum.
2.2 Surface preparation The base material shall be cleaned by power wire brushing and filing to remove weld spatter, dirt, rust, loose scale and other irregularities that may interfere with the examination. The ultrasonic operator shall determine whether the surfaces have been adequately cleaned.
2.3 Reference Documents Project specific reference documents will be listed in the project specific supplement to this procedure. SNT TC 1A EN 473 CP 31101
3
Recommended practice for NDT Personnel Qualification and Certification Non Destructive Testing – Qualification and Certification of NDT personnel Calibration Procedure for Ultrasonic Equipment
Equipment and accessories
3.1 Equipment The examination has to be executed with pulse-echo ultrasonic equipment with A-scan presentation. This can be analogue-or digital equipment. The vertical and horizontal linearity have to be checked at least according to calibration procedure CP-31101 latest revision.
3.2 Probes The following probes shall be used for the Ultransonic examination: •
Straight beam probe: 4 MHz with crystal dimensions Ǿ10 mm
3.3 Calibration blocks •
Step wedge block 2- 20mm
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UT Lam Check 11- 411 1 14-09-2011 Ultrasonic Examination KITO
3.4 Couplant Water based couplant shall be used. The same couplant shall be used for both calibration and examination.
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Calibration
4.1 Sweep Range A step wedge block , have to be used for the sweep range calibration. The minimum sweep range has to be set at 2.5 x longest surface skip distance.
4.2 Sensitivity setting The sensitivity setting for lamination check is 2nd back wall echo of pipe under examination at 80% FSH.
4.3 Calibration control A calibration control has to be executed:
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when a part of the examination system has been changed,
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at the end of examination,
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After every 4 hours of examination.
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When examination personnel are changed.
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When there is any doubt concerning proper functioning of the equipment
Examination
5.1 Scanning The scanning of pipe ends after Weld cut-out has to be executed to find possible present reflectors. Present reflectors have to be reported. All laminations what can restrict the welding examination process shall be reported. This examination has to be executed before welding or prior to its automated ultrasonic testing.
5.2 Sensitivity of examination During scanning, the sensitivity shall be increased by at least 6 dB. Evaluation shall be performed at normal sensitivity.
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UT Lam Check 11- 411 1 14-09-2011 Ultrasonic Examination KITO
Evaluation and recording
6.1 Evaluation All reflectors, with an echo height larger than 50% DAC, shall be investigated to the extent that it can be evaluated in terms of acceptance standard. The length of reflectors found, shall be measured with the amplitude half-value method, whereby the amplitude has been decreased with 50% DAC or 50% of the maximum amplitude, the smallest value is valid. discontinuities found to be shorter than 5 mm shall be considered as "not determined with sufficient accuracy".
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6.2 Acceptance criteria No laminations or segregations shall be present during MUT lamination Testing on pipe ends.
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Test Records The manual UT Site report (see attachment C) must contain at least the following information: • • • • • • • • • • • • • • • • •
Project Client NDT Procedure number Report No & Revision No (if applicable) Test Equipment, Probes and Inspection techniques used Calibration blocks Couplant Pipe diameter, Wall thickness & Material Type Weld number Test item, Object, Parts – examined & test area % covered Surface condition and sides, from which the examination has been executed Test Results & Compliance Statement: all reflectors of imperfections, which > 50% DAC. all unacceptable indications with locations on circumference length, cross section location i.e. centreline or side-wall and depth from O.D. pipe surface. all reflectors in the base material, which restrict the examination. Technician Name and Qualification Level.
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UT Lam Check 11- 411 1 14-09-2011 Ultrasonic Examination KITO
Attachment A
Reportform
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