UT MIS AWS Rev 00 TKY

INTERNATIONAL INSPECTION SERVICES LTD
Document No. : INS/MIS/AWS/UT-TKY/001

Rev:00Date:0 01.05.2013Page:1 of 1
OPERATION CONTROLS - PROCEDURE
ULTRASONIC EXAMINATION PROCEDURE
Document No. : INS/MIS/AWS/UT-TKY/001 Rev.: 00 dated 01.05.2011
Page No.: 1 of 27
This document is a property of INSPEC and for use by its authorized personnel only. Use of this Procedure by non-INSPEC Organizations is by specific agreement. This document is subject for revisions and only the latest revision stands current. Approved Master Copy of this document is filed and stored under the custody of INSPEC Technical manager. This document shall not be reproduced without the written consent of INSPEC. Controlled Distribution Copy Holders will receive current versions
INTERNATIONAL INSPECTION SERVICES LTD ULTRASONIC EXAMINATION PROCEDURE

REVISION RECORD REVISION 00 DATE 01st May 2013 DESCRIPTION New Issue
Document No. : INS/MIS/AWS/UT-TKY/001 Rev.: 00 2 of 27
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INDEX 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 SCOPE REFERENCE DOCUMENTS QUALIFICATION OF ULTRASONIC TESTING PERSONNEL EQUIPMENT COUPLING MEDIUM SURFACE CONDITION SENSITIVITY CALIBRATION BASE METAL EVALUATION SCANNING ACCEPTANCE CRITERIA DOCUMENTATION ANNEXURE 1- 7 4 4 4 5 6 6 6 9 9 9 10 12
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1.0 SCOPE 1.1 This Ultrasonic Examination procedure is to be used for the testing of T K Y tubular connection welds and heat-affected zones, when such testing is required by the referencing code. See Para 2 below. 1.2 Primarily, this procedure is intended for use on tubular TKY connections having pipe thickness 12mm & larger and pipe OD from 325mm & above with local dihedral angles 300 and more. 1.3 To use this procedure for thicknesses less than 12mm down to 8mm and for pipe diameters less than 325mm down to 219mm, a qualification test coupon shall be made and the results shall be recorded and attached as a supplement to this procedure. Refer to the supplement-1. 1.4 Any variation of this procedure with respect to essential variables shall imply re-issue of the procedure with all the variations incorporated. 1.5 This procedure shall not be used for ultrasonic examination in lieu of Radiography, unless otherwise specified or approved by client. 2.0 REFERENCE DOCUMENTS: 2.1 AWS D1.1; Section 6; Part F Para 6.27; 6.22; 6.25; 6.26 etc. 2.2 ASME SEC V Ed: 2010 2.3 ASNT SNT-TC-1A Ed: 2006 2.4 API RP 2X 2.5 INSPEC Written Practice. INSPEC/9/USN/Q1, 94 Rev 19. 3.0 PERSONNEL QUALIFICATION. 3.1 All INSPEC personnel performing Ultrasonic Examination using this Procedure shall be qualified to a minimum of Level II. 3.2 Personnel performing Examination shall have vision, with correction if necessary, to enable to read Jaeger Type No. 1 Standard Chart at a distance of not less than 12 in., and differentiate the contrast between the colors or shades of gray, and records of such vision test shall be maintained by INSPEC. Vision tests shall be conducted annually and shall be valid during examination. 3.3 Personnel conducting Ultrasonic Examination shall be competent in conducting the testing as described in this Procedure. 3.4 Wherever required, existing Personnel Qualification shall be verified for applicability as to the Code conditions.
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3.5 In addition to the above requirements, the personnel carrying out UT of TYK connections shall be required to pass additional practical tests on mock up welds on TYK weld connections. The mock up weld will be representative of the type of welds to be inspected, including a range of possible local dihedral angles and thickness to be encountered during production. Each mock up shall contain artificial or natural discontinuities that yield ultrasonic indications above or below the acceptance/ rejection criteria stated herein. Performance shall be judged on the basis of the ability of the personnel to determine the size and classification of each discontinuity with an accuracy required to accept or reject each welded joints and accurately locate each rejectable along as well as within the cross section of the weld. At least 70% of the rejectable discontinuities shall be correctly identified as rejectable. For work on non-redundant structures, all of the serious flaws those exceeding the rejectable discontinuity dimension and amplitude by a factor of two or 6 dB shall be identified, location determined and reported. 3.6 Personnel conducting Ultrasonic Examination should be aware of the safe-practice requirements during examination. 4.0 EQUIPMENT Pulse Echo Equipment: - The ultrasonic equipment shall be pulse echo type A scan suitable for use with transducers oscillating at frequencies between 1 and 6 Mhz. The equipment shall have valid calibration certificate. The test equipment shall have a calibrated gain control adjustable in discrete 1 or 2 dB steps over a range of at least 60 dB. The horizontal linearity of the test equipment shall be qualified over the full sound path distance to be used. Horizontal linearity shall be verified after 40 Hours of instrument use and shall be performed as per sec 6.30.1 of AWS D1.1 and vertical linearity in two months interval in accordance with sec 6.30.2 of AWS D1.1 The test instrument shall have internal stabilization facility, so that after warm up no variation in in response more than +/- 1 dB occurs with a supply voltage of 15% nominal or in case of battery operation. There must be an alarm or signal to indicate the reduced charge in the battery prior to complete shut off. Transducers: Transducers with following characteristics shall be used. Angle : 70, 60, 45 (within plus minus 2) and Normal (Longitudinal wave). Crystal Size: Square Inch to 1 Square Inch either round or square. Type : Single Crystal for shear wave probes. Single Crystal or Twin Crystal for compressional wave probes.
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Frequency: The nominal probe frequencies shall be 2 to 2.5 Mhz. Other probe frequencies may be used if material variable such as material grain structure or size dictates. Angle : The search unit angle shall produce a Sound beam in the material being listed within 2 of one of the following proper angle: 70, 60 or 45. Minimum 6 feet (1830 mm) and a maximum of 15 feet (4772 mm) in length with suitable connections shall be used.
Coaxial Cables: -
Calibration Blocks: IIW / V1 block shall be the standard for both distance and sensitivity calibration. Other portable blocks may be used provided the reference level sensitivity for instrument / search unit combination is adjusted to be equivalent of that achieved with IIW block. Discontinuity Plotting Aids: An array of devices are available for the ultrasonic operator to be able to plot and verify where indications are coming from, the technician may utilize the following. Magnetic strips, Electronic calculators, Mimic gauges (wire type), Soldering wire, Perspex slides, Cursors Plotting cards, Protractor, Compass, 150MM Stainless steel rulers, Measuring tapes, Indelible markers. 5.0 COUPLING MEDIUM. 5.1 Oil, Polycell jelly, grease, water or equivalent couplant that shall provide satisfactory transmission of Ultrasonic sound waves. 6.0 SURFACE CONDITION. 6.1 Scanning surface shall be free of weld spatters surface irregularities or foreign materials that might interfere with the scanning during examination. 7.0 SENSITIVITY CALIBRATION: 7.1 All calibrations and tests shall be made with the reject (clipping or suppression) control turned off. Use of the reject (clipping or suppression) control may alter the amplitude linearity of the instrument and invalidate test results. 7.2 Calibration for sensitivity and horizontal sweep (distance) shall be made by the ultrasonic operator just prior to and at the location of testing of each weld. 7.3 Calibration shall be performed at least once for each type of joints; except that for repetitive tesing of same size and configuration the calibration shall be as per the following schedule: After a change of

operators, each 30-minute maximum time interval, or when the electrical circuitry is disturbed in any way, which includes the following: (1) Transducer change (2) Battery change (3) Electrical outlet change. (4) Coaxial cable change. (5) Power outage (failure). 7.4 Calibration for straight beam testing of base metal shall be made with the search unit applied to topside of the base metal and performed as follows: 7.4.1 The horizontal sweep shall be adjusted for distance calibration to present the equivalent of at least two-plate thickness on the CRT screen. 7.4.2 The sensitivity shall be adjusted at a location free of indications so that the first back reflection from the far side of the plate will be minimum 75% of full screen height. 7.5 1) Calibration for angle beam testing shall be performed as follows. The standard sensitivity for examination of production welds using amplitude techniques shall be: Basic sensitivity + Distance amplitude correction + transfer correction. Note: The horizontal location of all screen indications is based on the location at which the left side of the trace deflection breaks the horizontal base line. 2) Basic Sensitivity: The reference level screen height shall be obtained using a 1.5mm side drilled hole from a calibration block as shown in figure K-7 of Annex K of AWS D1.1. Refer to Annexure 1. Alternately, the sensitivity can be adjusted with the 1.5mm diameter SDH on IIW V1 calibration block. This shall be the reference level (b).
3) Distance Amplitude Correction: A distance amplitude curve shall be drawn with the 1.5mm SDH at different depths/ sound paths. This will be the standard sentivity level. Distance Amplitude Correction (DAC) curves shall be constructed by the use of the amplitude from the three reference calibration holes from the applicable basic calibration block as per Attachment and shall be set up as follows: 3.1 Select the suitable range required to cover the volume of the examination. Position the search unit to produce maximum response from the hole that gives the maximnm response from the

suitable basic calibration block and adjust the amplitude to 80% ( 5%) full screen height mark the peak and note the dB required. This shall be the primary reference. 3.2 Position the search unit without changing the sensitivity (dB) to produce maximum response from the second reference hole on the screen and mark the peak. 3.3 Position the search unit without changing the sensitivity (dB) to produce maximum response from the third reference hole on the screen and mark the peak. 3.4 Connect the peaks of this amplitude and this line shall be the primary reference level. Alternately, the attenuation factor can be established by substracting 1 (25mm) from the sound path distance and multiplying the remainder by 2. This factor shall be rounded out to the neaest dB value. 4) Transfer correction: Transfer correction may be used to accommodate ultrasonic testing through tight layers of paint not exceeding 0.25mm in thickness. The surface finish of the calibration block shall be a representative of the surface finish of the component, however transfer mechanism may be used to correlate the amplitude from basic calibration block and the production material. Transfer correction shall be accomplished by using the transmission method utilizing two identical angle probes. For material thickness, less than 25.4mm at least full skip shall be used. The amplitudes of both calibration block and production material shall be evaluated at 40% of full screen and this difference shall be noted and used for the correction of the Standard Sensitivity level and this shall be the corrected Standard Sensitivity level. 5) Weld scanning of T K and Y connections shall be from the branch member surface. Refer Annexure-2. All examinations shall be performed in leg 1 & 2 only, wherever possible. For initial scanning, the sensitivity shall be increased by 12 dB more than the standard sensitivity level. However evaluation shall be performed with respect to the standard sensitivity level. 6) Optimum Angle: Indications found in the root areas of groove welds and in the fusion line of the welds shall be further evaluated with an angle, which nearest to the perpendicular of the fusion face. Calibration check for DAC:During examination calibration shall be checked for reference DAC at least once every two hours or whenever the peak drops below 20% of DAC, equipment on / off, change of technician, battery change, mal-functioning of the equipment is noticed.
7)
8.0
BASE METAL EVALUATION
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8.1 The area adjacent to the weld from which scanning is to be conducted shall be scanned with a 0 compressional probe and the thickness shall be recorded. Areas where laminar type defects are together with other reflectors that may interfere with the shear wave scan shall be reported. 8.2 A Compression probe scan shall be conducted on the continuous member of T,K and K joints prior to fit-up. Reflectors within 150mm (6 inches) of the intended weld location shall be evaluated in accordance with API RP 2X level C acceptance criteria. Cylinderical sections shall be rptated to avoid unacceptable reflectors within 150mm (6inches) of the attachment weld. SCANNING 9.1 Scanning shall be by contact method using manual, semi-automatic or automatic mechanism. Recording may be carried out using automatic alarm recording system or by manual method. Scanning shall be carried out such that entire volume of weld is tested for longitudinal and transverse discontinuities. 9.2 The volume to be scanned shall be examined by moving the search unit over the scanning surface so as to scan the entire examination volume for each required search unit.Each pass of the search unit shall overlap a minimum of 10% of the active transducer (piezoelectric element) dimension perpendicular to the direction of scan. Where mandated by code requirements, the percent minimum overlap may be increased. 9.3 Alternatively, each pass of the search unit may overlap a dimension less than the minimum beam dimension (beam spread) if the same is already known. Oscillation of the search unit is permitted provided improved coverage is demonstrated. 9.4 The pulse Repetition rate shall be small enough to assure that a signal from a reflector located at the maximum distance in the examination volume will arrive back at the search unit before the next pulse is placed on the transducer.The rate of search unit movement (scanning speed) shall not exceed 6 inch /s (152 mm/s).Scanning shall be performed from the branch connection. 9.5 Each weld joint shall be examined with sufficient probe angles to guarantee full coverage of the joint.scanning shall be done from both sides of the weld and outside surfaces where access permits if the member thickness exceeds 25mm(1 inch). Refer to API RP 2X, Paragraph 3.4.2 for UT equipment requirements. Where problem exist in coverage of a weld joint due to material, configuration, surface condition, etc; probes ofof a different frequency will be used in addition to the basic API RP 2X probe requirements. 9.6 Prior to shear wave examination, a compression probe search shall be conducted to confirm that no lamination type defects exist within the scanning surface of members at T,K and Y joint weld locations, which will mask the shear wave examination. 9.7 Prior to conducting shear wave examination, the operator shall ensure that both weld deposits and surrounding areas are sufficiently smooth to avoid spurious indications. The maximum surface correction factor is exceeded, additional surface grinding shall be performed prior to final ultrasonic examination.All flaw indications which exceeds 50% of the reference level shall be investigated and detailed in the operators report.
9.0
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10.0 DISCONTINUITY EVALUATION: 10.1 Discontinuities shall be evaluated by a combination of beam boundary and amplitude techniques. Sizes shall be given as length and height (depth dimension) or amplitude, as applicable. Amplitude shall be related to Standard calibration. 10.2 Discontinuities shall be classified as either or planer versus spherical. This can be accomplished by noting changes in amplitude as the transducer is swung in an arc centered on the reflector. 10.3 Each rejectable discontinuity shall be indicated on the weld by a mark directly over the discontinuity for its entire length and depth from the surface shall be noted on nearby base metal. 10.4 The location of discontinuities within the weld cross-section, as well as from an established reference point along the weld axis, shall be determined. 10.5 Refer to Annexure 3 for acceptance/ rejection criteria. Alternately, discontinuity evaluation may be carried on the basis of its Indication rating d which can be expressed as: d=abc where, a = Indication level. b = Reference level. c = Attenuation factor. Refer Annexure 6 for acceptance/ rejection criteria (tables 6.2 & 6.3 & 6.7). 11.0 DOCUMENTATION 11.1 Report form: A report form that clearly identifies the work and the area of inspection shall be completed by the ultrasonic technician at the time of inspection. A detailed report and sketch showing the location along the weld axis, location within the weld cross-section, size (or indication rating) extent, orientation and classification for each discontinuity shall be completed for each weld in which significant indications were observed. Reported discontinuities: When specified, discontinuities approaching rejectable size, particularly about which some doubt exists in their evaluation, shall also be reported.
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11.2

11.3 11.4 11.5 Incomplete inspection: Areas for which complete inspection was not practicable shall also be noted, along with the reason of not being tested. Unless otherwise specified, the reference point of weld and extent of rejectable indications shall also be marked physically on the work piece. UT examination conducted as per this procedure shall be reported on AWS D1.1 reporting format with standard Ultrasonic Examination report refer attached and shall contain the following information as a minimum. a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. joint identification number. Welder(s) and welding operator(s) identification(s). Welding Procedure number. Ultrasonic procedure identification number. Operator identification and signature. Sketch showing location)s) face width or amplitude above the reference level, length and location of all indications exceeding 50% of the ref.level. Date and time of welding completion and NDE. Original weld or repair. Heat treated condition or as welded. Plate Thickness. Probe angles and frequencies. Equipment identification serial numbers. The primary reference level sensitivity and transfer value. Couplant. State if hot or ambient temperature examination. Surface correction factor adopted during examination and calibration. Conclisions; accept or reject with respect to this specification
ANNEXURE 1
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ANNEXURE 2
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ANNEXURE 2
ANNEXURE 3
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ANNEXURE 4
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ANNEXURE 5 (LOCAL DIHEDRAL ANGLES)
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ANNEXURE 6
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ANNEXURE 7 SAMPLE REPORT FORMAT
INTERNATIONAL INSPECTION SERVICES LTD

P.O. BOX 96535, DUBAI, U.A.E. TEL.NO.: (9714) 3241955 FAX NO.: (9714) 3241957 E-mail: inspec@int-inspec.com Web: www.int-inspec.com
DATE : REPORT NO. : D/ PAGE : OF
Delivering it right first time
Form No.: IN-OPF-37 (AWS) Rev.00 Dt.22/12/2010
ULTRASONIC EXAMINATION REPORT

Client: Location: Drawing No.: Weld Identification: Welding process: Calibration Block No.: Damping / reject setting: PROBE TYPE Make Sr. No. Crystal Size Frequency MHz Primary Reference dB Scanning Sensitivity dB Test Range (mm) Access Limitation (if any): 0 TR 45 60 Job No. : Item ID : Project : Material Thickness: Weld joint AWS: Reference Reflectors: Quality requirements (section): Specification : 70 UT procedure & revision: Flaw Detector : Serial No.: Calibration certification No.: Base metal type & thickness: Weld Type / Configuration: Couplant brand name & type: Surface condition / Preparation: Scan Face:
Joint details: (type and geometry) Location coordinates:

Remarks: RESULT LEVEL II TECHNICIAN Name : Sign : Date : Name : Sign : Date : CLIENT REP. Name : Sign : Date :
ACCEPT REJ EC T
AI / TPI
Please see terms & conditions. This report is valid only if signed and stamped ( Numbered Stamp ) by Level III / Level II.
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UT MIS AWS Rev 00 TKY

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INTERNATIONAL INSPECTION SERVICES LTD

Document No. : INS/MIS/AWS/UT-TKY/001

OPERATION CONTROLS - PROCEDURE

ULTRASONIC EXAMINATION PROCEDURE

Document No. : INS/MIS/AWS/UT-TKY/001 Rev.: 00 dated 01.05.2011

INTERNATIONAL INSPECTION SERVICES LTD ULTRASONIC EXAMINATION PROCEDURE

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INTERNATIONAL INSPECTION SERVICES LTD ULTRASONIC EXAMINATION PROCEDURE

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INTERNATIONAL INSPECTION SERVICES LTD ULTRASONIC EXAMINATION PROCEDURE

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INTERNATIONAL INSPECTION SERVICES LTD ULTRASONIC EXAMINATION PROCEDURE

BASE METAL EVALUATION

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INTERNATIONAL INSPECTION SERVICES LTD ULTRASONIC EXAMINATION PROCEDURE

INTERNATIONAL INSPECTION SERVICES LTD

DATE : REPORT NO. : D/ PAGE : OF

Delivering it right first time

Form No.: IN-OPF-37 (AWS) Rev.00 Dt.22/12/2010

ULTRASONIC EXAMINATION REPORT

Joint details: (type and geometry) Location coordinates:

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