Wq-sj-Almco-qual-03129_ Pa and Tofd Procedure Rev A

Project:

COMPANY Doc. No.

WEST QURNA I - IRAQ

IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Contractor Job N 230009

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

1 of 40

Sub-Contract Job No. 825963

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

WEST QURNA I

PROCEDURE FOR PHASED ARRAY AND TOFD ULTRASONIC EXAMINATION M091 - ZUBAIR GATHERING SYSTEM

A Rev.

Issued for Internal Review Description

Atique-ur-Rehman

Ali Nawaz

Bilal Ashiq Bhatti

22-July-2014

Prepared

Checked

Approved

Date

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

2 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

CONTENTS CONTENTS .......................................................................................................................................................... 2 1. PURPOSE ...................................................................................................................................................... 3 2. SCOPE ........................................................................................................................................................... 3 3. APPLICABLE DOCUMENTS ..................................................................................................................... 3 4. RESPONSIBILITIES: ................................................................................................................................... 4 5. PERSONNEL QUALIFICATION ................................................................................................................ 5 6. QUALIFICATION OF TESTING PROCEDURE AND PERSONNEL ...................................................... 5 7. PREPARATION OF INSPECTION AREA .................................................................................................. 7 8. EQUIPMENT ................................................................................................................................................ 7 9. REFERENCE BLOCK PAUT ..................................................................................................................... 12 10. COUPLANT............................................................................................................................................. 18 11. PHASED ARRAY SYSTEM CALIBRATION ...................................................................................... 18 12. SYTEM CALIBRATION VERIFICATION ............................................................................................. 23 13. EXAMINATION COVERAGE AND SCANNING TECHNIQUE ....................................................... 25 14. RECORDING/EVALUATING CRITERIA & AMPLITUDE DETERMINATION .............................. 27 15. ACCEPTANCE CRIETERIA .................................................................................................................. 27 16. DOCUMENTATION ............................................................................................................................... 30 Appendix 1 .......................................................................................................................................................... 39 Appendix 2 …………………………………………………………………………………………………..40

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

1.

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

3 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

PURPOSE The purpose of this procedure is to inspect the butt weld joints of pipeline by Semi Automated Phased Array Ultrasonic Testing (PAUT) and Time of Flight Diffraction (TOFD) in lieu of Radiography Testing on West Qurna 1, Zubair Gathering System M-091 Project.

2.

SCOPE This procedure defines the approach method of MEPTS to carryout the PAUT & TOFD examination on the welded joints as per API 1104 and IQWQ-SA-LSPDS-OE-0900-C50T074Rev.0. This procedure shall be applicable for butt joints of carbon steel, Low alloy steel or Alloy steel. The PAUT and TOFD examination area shall include the volume of the weld and plus 25mm or thickness on each side of the weld. Before examining the weld joint a scan plan shall be prepared for each thickness and bevel configuration, the same shall be used for the setting the parameters for PAUT and TOFD examination. Thickness up to 25mm PAUT technique shall be used. Thickness above 25mm Combination of PAUT and TOFD shall be used. The scan plan shall contain the following information: • • • • • • • •

3.

Weld joint details ( Diameter, Thickness and Bevel Configuration ) Minimum and maximum angle selected for Sectorial or Linear scanning Focal distance Index offset from the weld centre Component coverage of weld and HAZ areas Beam direction with respect to weld centerline Search unit details: Element pitch, height & width, Number of element used Wedge refracted angle and curvature of wedge if applicable

APPLICABLE DOCUMENTS • •

API 1104 ASTM E-2491

Welding of pipeline and related Facility 2010 Standard guide for evaluating performance characteristics of Phased array ultrasonic examination.

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

•

SNT-TC-1A Ed.2006.

•

ASME Code case 181

• •

ASTM E 164 ASME SEC V Article 4

•

ASTM E-317

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

4 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

Recommended Practice for Personnel Qualification and Certification in Non-destructive Testing Use of Alternative Ultrasonic examination acceptance criteria Practice for ultrasonic examination of weldments Ultrasonic Examination Methods for welds

•

StandardPractice for Evaluating Performance Characteristics of Ultrasonic Pulse Echo Testing ASME SEC V SE 1316 The standard definitions and terms relating to UT.

•

ASME Code Case184

Use of UT of weld as an alternative to RT in ASME B31.3

•

ASTM E2700

•

ASTM E-2192

Standard practice for contact ultrasonic testing of welds Using Phased array. Guide for Planar flaw height sizing by ultrasonic testing.

•

IQWQ-FT-RSPDS-00-290302 Specification for upstream Process Piping Welding and inspection IQWQ-SJ-QPITP-0E-9623-C50T091 Quality Control Plan for Welding.

• 4.

Contractor Job N 230009

RESPONSIBILITIES: NDT Coordinator The MEPTS NDT Coordinator shall report directly to the ALMCO QA/QC Manager; shall be based at the project worksite and responsible for the day to day management of both manpower and equipment resources. The duties of the MEPTS NDT Coordinator shall include, but not limited to: • The day to day liaison with the client's site management to ensure the proper channels of communication are maintained and that work is addressed in a safe, timely and proper manner. • Coordination and direction of both equipment and manpower resources to ensure the provision of an effective and efficient service

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

5 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

• Ensuring that all MEPTS personnel are fully conversant with the level of service to be provided including familiarity with and the promotion of all safety practices and routines dictated by MEPTS and Company • Where technicians report that testing procedures or techniques are not suitable or do not produce the required test data, the NDT Coordinator shall investigate and implement the required nonconformance and corrective action routines UT Technicians • To interpret and evaluate the ultrasonic test results in accordance with this procedure and to evaluate their acceptability and to determine the fitness of the test specimen for the purpose being examined • To ensure that all ultrasonic testing are carried out in accordance with this procedure API 1104 and with the requirements of the related specifications as applicable to the project concerned • To prepare reports of ultrasonic examination after completion of test. To ensure that all equipment, techniques and consumables employed for ultrasonic testing are suitable for and are capable of producing the required inspection data.

5.

PERSONNEL QUALIFICATION Personnel performing ultrasonic examination (PAUT/TOFD) shall be qualified and certified in UT Level II as per the requirement of SNT-TC-1A or equivalent. Personnel who acquire and analyze PAUT/TOFD data shall be trained in PAUT/TOFD theory and use of the equipment. Qualification records of certified personnel shall be submitted. The performance of the approved personnel shall be able to demonstrate the following with PAUT/TOFD equipment:

•

•

a) b) c) d)

6.

Calibration of equipment Scanning of test object Characterization of flaw indication Flaw sizing & Location

QUALIFICATION OF TESTING PROCEDURE AND PERSONNEL The qualification block shall be prepared by welding and shall contain a minimum of three flaws, oriented to simulate flaws parallel to the production weld‟s fusion line as follows

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

6 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

• • • •

One surface flaw on the side of the block representing the OD surface One surface flaw on the side of the block representing the ID surface One subsurface flaw If the block can be flipped during examination, then one flaw may represent both the ID & OD surface. • The Flaw size shall be no larger than the flaw in Table 4 & 5 • Acceptable limit: acceptable performance is defined as response from the maximum allowable flaw and other flaws of interest demonstrated to exceed the reference level.

The result shall be compare with the actual dimensions. After successful evaluation the proposed PAUT and TOFD in lieu of RT will be adopted and followed on the butt weld joints.

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

7.

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

7 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

PREPARATION OF INSPECTION AREA 7.1 Surface preparation: The finished contact surface of minimum 250 mm either side of the weld should be free from weld spatters and any roughness that could interfere with free movement of the search unit or impair the transmission of ultrasonic vibrations. The weld surface should be free of irregularities that could mask or cause reflections from defect to go undetected and should merge smoothly into the adjacent base materials surface conditions. 7.2 Weld Numbering: Weld joints shall be identified with Line No and drawing No. This unique weld numbering system will be recorded as part of the file storage data. On the prepared area for inspection there will be a “A, B, C…” reference index and/or position numbers marked on the weld with paint marker arrow indicating the direction of scanning. All circumferential measurement shall be made clockwise from the zero reference position on the weld when looking in the direction of product flow.

8.

EQUIPMENT Phased Array: The ultrasonic phased array instrument shall be an Omni Scan pulse echo type and is equipped with a calibrated dB gain or attenuation control stepped in increments of 1dB or less. The equipment shall be capable of operating at frequency range of 1MHz to 10MHz. The Omni Scan contains 16 or 32 independent pulser receiver channels. The system is capable of generating the images B-scan, C-scan, S-scan (sectorial scan) along with display of A-scan. Examination personnel may use a real-time sectorial scan image during scanning to ensure that proper data has been collected. Sectorial-scan images contain signal amplitude and reflector depth information projected for the refracted angle of the ultrasonic beam. The on-board focal law generation software permits direct modification of the ultrasonic beam characteristics for performing either electronic linear scan (E-scans) or sectorial scan (Sscan). The data storing capabilities of the system requires the use of an external storage device, flash card or USB memory stick. A remote portable PC shall also be connected. In addition to data storage, the PC will also be used by the data-analysis personnel for This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

8 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

analyzing data subsequent to the completion of data collection. Data-display software compatible to that residing on the Omni Scan phased array system shall also be used for data play back. The equipment linearity shall be checked and any control which affects the equipment linearity shall be in the same position for calibration checks, linearity checks and examination. TOFD: Calibrated Ultrasonic system “Omni Sca MX / MX2, Modsonic, or “TD Focus scan or equivalent Digital flaw detector with single/dual axis encoded hand scanner” shall be used for the examination. The instrument shall be capable of operation at frequencies over the range of at least 1MHz to 15MHz and shall comply with the requirements of ASME SEC V, Article 4, Appendix III paragraph III-430.

Scanner: HSMT Flex Scanner: HSMT Flex Scanner is a small and easy to operate one axis encoded scanner for weld inspection. It can be used on plates and pipe like structures, up to 8 probes can be mounted . The Omni scan ultrasonic system will be suitably interfaced with scanner drive mechanism that moves the probes in one encoded axis. Four industrial strength magnetic wheels make it suitable to move on ferromagnetic materials (preferably used in power plant and petrochemical industries). Mechanical holders shall be used to ensure that the probe spacing is maintained at a desired index offset. The Probe motion shall be achieved using manual movement. This scanning uses a compact and mini wheel encoder with one axis encoding having a resolution of 12 steps / mm.

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Equipment Checks:

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

9 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

Linearity

Phased array ultrasonic equipment linearity shall be verified at intervals of 1year or prior to first use thereafter. The instrument linearity verification shall be recorded on the ultrasonic instrument linearity verification record. Screen Height Linearity: Couple a straight beam probe to the IIW V1 block and get multiple echoes from 25mm back wall. Select any two echoes whose amplitudes are in the ratio of 2:1 with larger echo set at 80% of full screen height. Without moving the search unit, adjust the gain to successively set the larger indication from 100% to 20% of full screen height, in 10% increments or 2 dB steps if a fine control is not available, and read the smallest indication at each setting. The reading must be 50% of the larger amplitude, within 5% of full screen height. The setting and reading must be estimated to the nearest 1% of full screen height. Amplitude Control linearity: Couple a straight beam probe to the IIW V1 block and get multiple echoes from 25mm back wall. Select any echo and note its amplitude. Reduce the gain by 6dB and read the amplitude of the same indication. It must be 50% of the initial amplitude within 20% of the nominal amplitude ratio. Perform this exercise for full range of the gain. The setting and reading must be nearest 1% of full This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

COMPANY Doc. No.

WEST QURNA I - IRAQ

IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Contractor Job N 230009

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

10 of 40

Rev.

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

screen and the readings should be as follows Table-1 Indication Set at % of Full Screen

Decibel control Change

Indication Limits %of Full

80

-6dB

32 to 48

80

-12dB

16 to 24

40

+6dB

64 to 96

20

+12dB

64 to 96

Screen

PAUT Transducers: Ultrasonic transducer configurations are specified by the technique used for the examination. 1D linear phased array probe used in this procedure may include from 10 to128 elements. The probe frequency shall be between 1 MHz and 10 MHz depending upon material type and thickness. Table- 2 Probe specifications and dimensions Part No.

A

Frequency (MHz)

Number of elements

Elevation

Pitch

(mm)

(mm)

5L 64-A2

5

64

10.0

0.6

2L 64-A2

2

64

12.0

0.75

7.5CCEV35-A15

7.5

16

10.0

0.50

PAUT Wedges: Phased array wedges should be of a design to accommodate the aforementioned phase array probes. Nominal refracted wedge angles shall be 45, 55 or 60 degrees to ensure coverage of the weld and heat affected zone. Wedges shall have provision of irrigation holes and carbides for couplant flow.

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

COMPANY Doc. No.

WEST QURNA I - IRAQ

IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Contractor Job N 230009

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

11 of 40

Wedge Specifications Part No.

Probe Type

Nominal Refracted beam angle in steel

Sweep(degree)

Probe orientation

SA2-N55S-IHC

A2

550 SW

40-70

NORMAL/

SA2-N45S-IHC

A2

450 SW

30-60

SA2-N60S

A2

600 SW

45-75

REVERSE NORMAL/ REVERSE NORMAL/ REVERSE

SA2-0L

A2

00 LW

N/A

NORMAL

TOFD Transducers & Wedges: Dia 3mm to 12mm , 2 to 10 MHz broadband TOFD probes with 45°- 70° Wedges. For TOFD scanning following table shall be used for transducer selection.

15-35 35-50 50-100

A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

Table- 3

Thickness (mm)

Rev.

Number of TOFD set- ups 1 1 2

Depthrange 0-t 0-t 0-t/2 t/2-t

Table 4 Centre Beam frequency angle(longMHz waves ℓ˚ 10-5 70-60 5-3 70-60 5-2 70-60 60-45

Element size (mm) 2-6 3-6 3-6 6-12

Beam intersection 2/3 of t 2/3 of t 1/3 of t 5/6 of t

The probes shall confirm to the following minimum requirements: a) Two probes shall be used in pitch-catch arrangements (TOFD Pair) b) Each probe in the TOFD pair shall have the same nominal frequency. c) The TOFD pair shall have the same element dimensions d) The pulse duration of the probe shall not exceed two cycles.

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

9.

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

12 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

REFERENCE BLOCK PAUT a) The basic calibration block shall be in accordance with ASME SECV Article 4, paragraph T-434.1.2 through 434.1.6. b) The block thickness shall be at ±25% of the nominal thickness of the piece to be examined. c) Side drilled holes or Notches shall be used to confirm adequate sensitivity settings. d) Materials with diameters greater than 20 inches (508 mm): For examinations in materials where the examination surface diameters is greater than 20 inches (508 mm), a block of essentially the same curvature, or alternatively a flat basic calibration block, may be used. e) Materials with diameters 20 inches (508 mm) and less: For examinations in materials where the examination surface diameter is equal to or less than 20 inches (508mm), a curved block shall be used. Except where otherwise stated, a single curved basic calibration block may be used for examinations in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter.

Fig: T 434.2.1

TABLE 5 This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Weld thickness (t) In. (mm)

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

13 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

Calibration Block Thickness (T) In (mm.)

Hole Diameter In (mm)

Upto 1” (25) Over 1” (25) through 2” (50)

3/4 (19) or t 1 ½ (38) or t

3/32 (2.5) 1/8 (3.0)

Over 2” (50) through 4” (100) Over 4” (100)

3 (75) or t

3/16 (5.0)

t+ 1 (25)

(Note 1)

Notch Dimensions In (mm) Notch Depth = 2% T Notch Width = ¼ (6.0) max Notch Length = 1 (25) min.

General Notes: Holes shall be drilled and reamed 1.5 in (38 mm)deep minimum, essentially parallel to the examination surface. For components equal to or less than 20 in.(500 mm) in diameter shall meet the requirements of para 9.0 (e). Two sets of calibration reflectors (holes , notches) oriented 90 degree from each other shall be used. Alternatively, two curved calibration blocks may be used. The tolerance for hole diameter shall be + 1/32 in. (0.8 mm). The tolerance for the hole location through the calibration block thickness (i.e. distance from the examination surface) shall be + 1/8 in (3.0 mm) For block less than ¾ in. (19 mm) in thickness, only T/2 side drilled hole and surfaces notches are required. All holes may be located on the same face (side) of the calibration block, provided care is exercised to locate all the reflectors from affecting the indication from another reflector during calibration. Notches may be in the same plane as the inline holes ( as in Figure J431 of Section V), sufficient number of holes shall be provided for both angle and straight beam calibrations at T/4 , T/2 and 3T/4 depths. Minimum notch depth shall be 1.6 % T and maximum notch depth shall be 2.2% T plus the thickness of cladding, if present. Maximum notch width is not critical . Notches may be made by EDM or with end mills up to ¼ in. (6.4 mm) in diameter. Weld thickness, t, is the nominal material thickness for welds without reinforcement or, for welds without reinforcement, the nominal material thickness plus the estimated weld This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

14 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

reinforcement not to exceed the maximum permitted by the referencing Code Section. When two or more base material thicknesses are involved, the calibration block thickness, T, shall be determined by the average thickness of the weld; alternatively, a calibration block based on greater base material thickness may be used provided the reference reflector size is based upon the average weld thickness.

Pipeline Calibration Block: Notches shall be located not closer than thickness of the part or 25mm whichever is greater, to any block edge or another notch.

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

15 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

General Notes: (a) The minimum calibration block length (L) shall be 8 in. (200 mm) or 8T, whichever is greater. (b) For OD 4 in. (100 mm) or less, the minimum arc length shall be 270 deg. For OD greater than 4 in. (100 mm), the minimum arc length shall be 8 in. (200 mm) or 3T, whichever is greater. (c) Notch depths shall be 8%T minimum to 11%T maximum. When cladding is present, notch depths on the cladding side of the block shall be increased by the cladding thickness, CT (i.e., 8%T + CT minimum to 11%T + CT maximum). Notch widths shall be 1⁄4 in. (6 mm) maximum. Notch lengths shall be 1 in. (25 mm) minimum. (d) Maximum notch width is not critical. Notches may be made with EDM or with end mills up to 1⁄4 in. (6 mm) in diameter. (e) Notch lengths shall be sufficient to provide for calibration with a minimum 3 to 1 signal-to-noise ratio.

Additional Blocks for System Calibration: In addition to the basic reference block, additional blocks may be used for system calibration. IIW V1 block and IOW block shall be used for sensitivity, velocity and wedge delay calibration.

TOFD • • • •

The basic calibration block shall be in accordance with ASME SECV Article 4, paragraphT-434.1.2 through 434.1.6. The block thickness shall be at +/- 10% of the nominal thickness of the piece to be examined for thickness up to 100mm or +/- 10mm for thickness over 100mm Side drilled holes shall be used to confirm adequate sensitivity settings. Calibration block shall be made as per ASME Sec V , Article 4,Appendix III fig. III.434.2.1 a & b.

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

16 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

17 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

18 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

Note (a)Holes shall be drilled and reamed 50 mm deep minimum, essentially parallel to examination surface. (b) Tolerance on hole dia. Shall be +/- 0.8mm and tolerance on location through the block thickness shall be +/- 3mm. (c) All holes shall be located on the same face and aligned at the centre of the face unless the indication from one reflector effects the indication from another. In this case holes may be located on opposite face of the block. When the weld is broken up into multiple zones, each zone shall have a Tz/4 and 3Tz/4 SDH, where Tz is the zone thickness. (d) A Documented Examination Strategy or scan plan shall be provided for each thickness range. The plan should show the transducer placement, movement and component coverage. The scan plan shall also include ultrasonic beam angle used, beam direction with respect to weld centreline and pipe volume examined. 10. COUPLANT Cellulose Paste, Machine Oil, Water or equivalent may be used as couplant when performing calibrations and examinations. The same couplant to be used during the examination shall be used for calibration. 11.

PHASED ARRAY SYSTEM CALIBRATION Calibration shall be performed from the surface of the calibration block which corresponds to the component surface to be examined. System calibration shall include the complete ultrasonic examination system. Screen distance calibration shall be at least 1½ “vee paths” (also known as skip) for the minimum angle that will be used during the examination, unless otherwise specified. During scanning, only the gain may be adjusted from the calibrated reference dB. Adjustment of other controls requires recalibration.

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

11.1

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

19 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

Wedge Delay Calibration

The wedge delay calibration shall be carried out for both linear scan as well as sartorial scan. The wedge delay calibration shall be carried out in true depth mode or sound path mode and done with a known reflector depth or radius. Peak up this signal from the calibration reflector and scan the phased array probe backwards through all the different angles or focal laws. Scan forward over the calibration reflector through all the refracted angles of focal laws. When the signal for all angles and focal laws lies within the threshold, the Omni scan system shall adjust all the focal laws/angles to display the reflectors true depth.

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

11.2

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

20 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

Sensitivity Calibration:

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

21 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

a Wedge Delay Calibration

The Omni scan® shall be calibrated for wedge delay and sensitivity. The sensitivity calibration shall provide the required gain adjustments for each refracted angle and sound path used. Select a calibration reflector, which is approximately one-half the thickness of the component to be examined, or Ø 1.5mm SDH on IIW V1 block. Peak up this signal from the calibration reflector or radius and scan the phased array probe backwards through all the different angles of focal laws. The Omni scan system shall calculate the required gain needed at each focal law to adjust the amount of gain required to obtain the sensitivity.

b Sensitivity Calibration

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

11.3 Time Corrected Calibration:

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

22 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

Gain

(TCG)

Time corrected gain calibration shall be used to compensate for attenuation in the material at the sound paths used during calibration and examination. To obtain the TCG calibration peak the signal from the ID notch or SDH at half skip distance and adjust the gain to obtain 80%of amplitude from the reflector. Place the phased array probe perpendicular to the notch axis. Move the phased array probe forward and backward to equal the amplitude for all the focal laws and angles and plot the first point. Move the probe to the OD notch or SDH and obtain the second point. Omni Scan users the gain compensation required due to attenuation in the sound travel and adjust the gain for all focal laws/angles. Once all the points are picked the TCG can be accepted. TCG calibration has to be carried out for all scan plans in a multi group option while using phased array probe. TCG may be plotted using IOW Blocks having 1.6 mm SDH at appropriate depth. The examination system calibration shall be stored in the Omni Scan System with electronic memory, on an external chip or data storage device. This calibration may be used at a later date provided that date provided that the system calibration is verified prior to the examination. TOFD Calibration: Set the TOFD probes on surface to be Utilized for calibration and set the gain control so that the lateral wave amplitude is from 40% to 90% of the full screen height and the noise level is less than 5 to 10% FSH. This is reference sensitivity setting. When the lateral wave is not displayed for multiple zone examination, set the gain control based solely on the noise level. 11.4 Confirmation of Sensitivity: Scan the calibration block‟s SDHs with them centered between the probes, at the reference sensitivity level set in 10.4. The SDH responses from the required zone shall be a minimum of 6 dB above the grain noise and shall be apparent in the resulting digitized grayscale display. 11.5

Encoder Calibration: This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

COMPANY Doc. No.

WEST QURNA I - IRAQ

IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

23 of 40

Sub-Contract Job No. 825963

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

Encoder shall be calibrated as per the manufacturer”s recommendations and conformed by moving a minimum distance of 20 in. (500 mm) and the displayed distance being ± 1% of the actual distance moved. In event the encoder is found to give an error of greater than ± 1%. The inspection performed for the day shall be repeated on locations where linear flaws were detected. A maximum sample spacing of 1mm shall be used between A- scan collected for thickness under 75mm and a sample spacing of up to 2mm to be used for thickness greater than 75mm. 11.6 Rate of search unit movement: Scanning speed shall be such that data drop-out is less than 2 data lines per inch (25 mm) of the linear scan length and that there are no adjacent data line skips. 12.

SYTEM CALIBRATION VERIFICATION The system calibration verification shall include the examination system. Sweep range and TCG calibration shall be verified on the appropriate calibration block or simulator block as applicable under the following conditions: • Prior to an within 24 hours of the start of a series of examinations • With any substitution of the same type and length of search unit cable • With any substitution of power using the same type source, such as a change of batteries • At least every 4 hours during examination • At the completion of series of examinations • Whenever the validity of the calibration is in doubt

Changes in Calibration:

System

The examination shall deemed to be voided if any point of the TCG decreases by 20% or 2 dB of its amplitude, or any point on the sweep line has moved more than 10% of the sweep division reading. If the situation arises, carry out a new system calibration and repeat voided examinations and re examine all indications recorded since the valid calibration verification. The change in This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

24 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

values if any shall be entered on the applicable forms.

Recalibration Any of the following conditions shall be caused for system recalibration: • Change of search unit or wedge • Change of search unit cable type or length change • Change of ultrasonic instrument • Change in examination personnel • Couplant change • Change in type of power source • When missing data lines in the display shall not exceed 5% of the scan lines to be collected, and no adjacent lines shall be missed

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

COMPANY Doc. No.

WEST QURNA I - IRAQ

IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

13.

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

25 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

EXAMINATION COVERAGE AND SCANNING TECHNIQUE • Normal Beam Examination (Conventional Technique): Prior to start of the PAUT Examination, the base metal and HAZ area shall be scanned manually with normal beam probe to locate reflectors that can limit the capability of the PAUT inspection to examine the weld volume. The gain of the instrument is adjusted such that the second back wall echo examine the weld volume. The gain the instrument is adjusted such that the second back wall echo amplitude to 80% of FSH.

Angle Beam Examination (PAUT Technique): Scanning For Reflectors Parallel To The Weld Seam:

•

The specifics of the examination volume, weld definition and location shall be identified in the scan plan. The examination volume shall cover the weld metal and a quarter from the toe the weld. This area includes the heat affected zone (HAZ). The scan plan shall demonstrated by plotting or with using a simulator the appropriate examination angles for the weld preparation bevel angles that will be used during the examination. This scan plan shall be documented to show that the examination volume was examined. This scan plan shall be a part of the final examination. Omni Scan system has the capability of using multiple-group settings to establish sector scans and E-scans for the appropriate angles to ensure complete coverage of the weld and heat affected zone. Scanning shall be performed using a line scan technique. Each line scan shall be parallel to the weld using a sectorial scan (S-scan) and/or a linear scan. Appropriate refracted angle as accepted by ASME will define the position of the arrays and hence angles. These should be detailed in the ultrasonic scan plan. A minimum of two (2) line scans shall be performed at two (2) different index points from the centre of the weld from both sides of the weld where practical to ensure coverage of the weld and heat affected zone (HAZ). Scans shall be parallel to the weld at 90º /270º scan axes and the multiple groups scanning shall involve both the above directions for complete coverage of the weld. This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

26 of 40

Rev.

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

• Reflectors Transverse to the Weld Seam. As an alternate to line scanning, a manual angle beam examination may be performed for reflectors transverse to the weld axis •

Restricted Welds:

A

Access

The welds that cannot be fully examined from two directions using angle beam technique shall also be examined if possible with straight beam technique without recording.

This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

•

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

27 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

TOFD SCANNING PROCEDURE: TOFD scans is to be performed on each weld area to ensure adequate inspection coverage. Scanning shall be carried out in clockwise direction with stating position. The examination area shall include the volume of the weld plus the lesser of 25 mm or t on each side of the weld. Each scan shall be performed with the TOFD probe array symmetrically astride the weld. The data shall be collected by moving the probes at uniform speed ensuring the probe array remains central to the weld. If offset scans are required due to the width of the weld, the initial scan to be repeated with the probes offset to one side of the weld axis and again with the offset to the opposite side of the first offset scan. The scanning speed shall be less than 500mm/min. A maximum of 5% of the total number of lines collected in one single scan may be missed but no adjacent line shall be missed. The collected data shall be presented in D-scan format i.e., vertical axis representing time/depth into the material and the horizontal axis representing distance along the weld.

14.

RECORDING/EVALUATING CRITERIA & AMPLITUDE DETERMINATION • Only Trained Level II - UT operators with hands on training Omni Scan shall calibrate and carry out UT inspection. Only personnel certified Level III in ultrasonic testing along with knowledge of phase array and Omni Scan equipment shall evaluate the results of ultrasonic examinations for acceptance. All indications that exceed 50% of reference level shall be investigated completely to determine the type of indication. When discontinuity is observed flaw sizing shall be done by 6dB drop method. Geometric Indication – Recordable ultrasonic indications, of geometric or metallurgical origin, shall be classified as such. Weld reinforcement, root geometry or variations in metallurgical structure of materials may be classified as geometric indications. Geometric Indication need not be characterized or sized.

15.

ACCEPTANCE CRIETERIA Acceptance / Rejection of ultrasonic inspection of welds shall be as per ASME code case 1812. Imperfections which produce a response greater than 20% of the reference level shall be This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.

Project:

WEST QURNA I - IRAQ

COMPANY Doc. No. IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091

Plant:

Zubair Gathering System Document Title:

Procedure for PA & TOFD Ultrasonic Examination Sub-Contract Job No. 825963

Contractor Job N 230009

Contractor Doc. No. M91-ZA-E-0xxxx

Contract No.

Sh.

W3QR-50-M091

28 of 40

Rev. A

Subcontractor Doc. WQ-SJ-ALMCO-QUAL-03129

investigated to the extent that the operator can determine the shape, identity, and location of all such imperfections and evaluate them. In any case flaw length shall not exceed 4t regardless of height for above 25mm thickness.

Flaw Acceptance for less than 25mm Thickness: A linear-type discontinuity is unacceptable if the amplitude of the indication exceeds the reference level and its length exceeds: (a) 6 mm (1⁄4 in.) for t ≤ 19 mm (3⁄4 in.) (b) t/3 for 19 mm < t ≤ 57 mm (2 1⁄4 in.) (c) 19 mm for t > 57 mm Table 6

FLAW ACCEPTANCE CRITERIA FOR SURFACE FLAWS Weld Thickness Aspect Ratio h/l 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50

< 25mm to 64mm h/t