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ES-S-60 R4 Spec For Non Destructive Testing of Welds PDF
ES-S-60 R4 Spec For Non Destructive Testing of Welds PDF
ES-S-60
REVISIONS: All revision 4 items are marked by a vertical line in the right hand border.
Distribution list :
CONTENTS
1. INTRODUCTION ..............................................................................................................................5
1.1 SCOPE .................................................................................................................................................................... 5
1.2 DEFINITIONS, LANGUAGE AND UNITS ................................................................................................................ 5
1.3 ABBREVIATIONS .................................................................................................................................................... 5
1.4 REFERENCED SPECIFICATIONS AND STANDARDS .......................................................................................... 5
1.4.1 American Petroleum Institute. .................................................................................................... 6
1.4.2 American Society for Testing and Materials. .............................................................................. 6
1.4.3American Welding Society........................................................................................................... 6
1.4.4 British Standards . ...................................................................................................................... 6
1.4.5 Other Specifications.................................................................................................................... 6
2. METHOD OF OPERATION AND PERSONNEL QUALIFICATION ..................................................7
2.1 INTRODUCTION...................................................................................................................................................... 7
2.2 QUALITY ASSURANCE .......................................................................................................................................... 7
2.3 REPORTING............................................................................................................................................................ 7
2.4 NDT PERSONNEL .................................................................................................................................................. 7
2.4.1 NDT Co-ordinator ....................................................................................................................... 7
2.4.2 NDT Supervisor .......................................................................................................................... 7
2.4.3 NDT Operatives .......................................................................................................................... 7
2.5 QUALIFICATION OF NDT PERSONNEL ................................................................................................................ 8
2.5.1 Qualifications .............................................................................................................................. 8
2.5.2 NDT Co-ordinator ....................................................................................................................... 8
2.5.3 NDT Supervisor .......................................................................................................................... 8
2.5.4 NDT Operative............................................................................................................................ 8
3. MAGNETIC PARTICLE INSPECTION..............................................................................................9
3.1 INTRODUCTION...................................................................................................................................................... 9
3.2 MPI PROCEDURE................................................................................................................................................... 9
3.2.1 Procedure - General ................................................................................................................... 9
3.2.2 Procedure - Qualification ............................................................................................................ 9
3.3 TECHNIQUE IN GENERAL ..................................................................................................................................... 9
3.3.1 Surface Preparation.................................................................................................................... 9
3.3.2 Detecting Media.......................................................................................................................... 9
3.3.3 Magnetisation ............................................................................................................................. 9
3.3.4 Flaw Indicators and Field Strength Meters ................................................................................. 10
3.3.5 Inks ............................................................................................................................................. 10
3.4 PRACTICAL PROCEDURES................................................................................................................................... 10
3.4.1 Application of External Magnetic Field........................................................................................ 10
3.4.2 Application of Detecting Media ................................................................................................... 10
3.5 REPORTING............................................................................................................................................................ 10
3.6 CHECKS ON CONSUMABLES AND EQUIPMENT................................................................................................. 10
3.7 DEMAGNETISATION .............................................................................................................................................. 11
4. LIQUID PENETRANT TESTING.......................................................................................................12
4.1 INTRODUCTION...................................................................................................................................................... 12
4.2 PENETRANT PROCEDURES ................................................................................................................................. 12
4.3 TECHNIQUES IN GENERAL................................................................................................................................... 12
4.3.1 Penetrant - Consumables ........................................................................................................... 12
4.3.2 Approved Techniques................................................................................................................. 12
4.4 REPORTING............................................................................................................................................................ 12
4.5 CLEANING............................................................................................................................................................... 13
5. ALTERNATING CURRENT FIELD MEASUREMENT (ACFM) .........................................................14
5.1 INTRODUCTION...................................................................................................................................................... 14
5.2 NDT PERSONNEL .................................................................................................................................................. 14
5.3 EQUIPMENT............................................................................................................................................................ 14
5.3.1 Topside ....................................................................................................................................... 14
5.3.2 Sub-Sea...................................................................................................................................... 14
5.3.3 Probes ........................................................................................................................................ 14
5.3.4 Operational Test Block ............................................................................................................... 14
1. INTRODUCTION
1.1 SCOPE
This specification defines the requirements for conducting non destructive testing of welds and materials
in structural steelwork, pipelines, process piping, pressure vessels, etc., for QGPC Installations in the
Arabian Gulf.
1.2 DEFINITIONS, LANGUAGE AND UNITS
The following definitions apply throughout this specification:
EMPLOYER Shall mean QATAR GENERAL PETROLEUM CORPORATION (QGPC) or
appointed MANAGING CONSULTANT
CONTRACTOR The party which entered into contract with the EMPLOYER for the execution of
activities as mentioned in a written agreement.
The following use of language applies throughout this specification:
i) 'shall' is used where a provision is mandatory,
ii) 'should' is used where a provision is preferred,
iii) 'may' is used where alternatives are equally acceptable.
The term 'approve' as applied to the EMPLOYER is used where the EMPLOYER does not wish work
to proceed unless certain features have been agreed in writing with the CONTRACTOR. This does
not mean that all the details of a document have been considered by the EMPLOYER and does not
absolve the CONTRACTOR of his responsibilities.
All communication both documentary and spoken shall be in the English Language and all
dimensions and weights shall be in SI (Systeme International d' Unites) units.
1.3 ABBREVIATIONS
The following abbreviations are used throughout this specification:
API American Petroleum Institute
ACFM Alternating Current Field Measurement
ANSI American National Standards Institute
ASNT American Society for Non-Destructive Testing
ASTM American Society for Testing and Materials
BS British Standard
DAC Distance Amplitude Correction
IQI Image Quality Indicator
LPI Liquid Penetrant Inspection
MPI Magnetic Particle Inspection
NDT Non-Destructive Testing
PCN Personnel Certification in Non Destructive Testing
QA Quality Assurance
QC Quality Control
RT Radiographic Testing
UT Ultrasonic Testing
independent inspection agency approved by the EMPLOYERY. The EMPLOYER may audit the
performance of all NDT personnel as necessary and instruct the CONTRACTOR that he ceases to use
personnel whose performance is considered unsatisfactory.
2.5 QUALIFICATION OF NDT PERSONNEL
2.5.1 Qualifications
Either of the following qualifications shall be accepted by the EMPLOYER:
a) CSWIP/PCN Level II with a minimum of 2 years post qualifying experience.
b) ASNT recommended practice SNT-TC-1A to Level II proficiency with a minimum of 2 years
post qualifying experience.
NNo consideration shall be given to any other qualifications without the EMPLOYER’s approval.
NNDT operatives qualified in accordance with ASNT recommended practice SNT-TC-1A Level II shall
be ccertified, prior to his being acceptable for contract duties, by an ASNT Level III certifiedqualified
pperson acceptable toapproved by the EMPLOYER. The EMPLOYER at its discretion may seek
independent certification iif operational circumstances dictate.
All personnel shall be required to furnish proof of having been examined in the preceding 12 months by
a competent medical authority to prove a natural or corrected near vision acuity for reading J-1 letters on
Jaegers Standard Test Chart at a distance of not less than 300mm, a natural or corrected distance
acuity of not less than 20/40 and colour blindness to ISHIHARA for all NDT techniques iin this
specification.
2.5.2 NDT Co-ordinator
The NDT co-ordinator shall have ultrasonic or radiographic qualifications conforming to the
requirements of Clause 2.5.1. When the NDT co-ordinator takes on the function of the NDT supervisor,
the minimum qualification requirements shall be as that of the NDT supervisor.
2.5.3 NDT Supervisor
The NDT supervisor shall have full ultrasonic, radiographic, magnetic particle, and liquid penetrant and
ACFM qualifications, applicable to the scope of work given within the schemes given in Clause 2.5.1;
plus at least 5 years site experience since qualifying. NDT supervisors shall have a thorough knowledge
of the CONTRACTOR's Quality Assurance Documentation.
2.5.4 NDT Operative
The NDT operative shall have relevant qualifications in accordance with Clause 2.5.1. Further
requirements for approval of ACFM and ultrasonic operatives are specified in Clauses 5.2 and 6.2
respectively.
Variable current transformers shall be checked at agreed intervals and the results recorded. The
intensity and wavelength of black light at the surface shall be in accordance with BS 4489 or ASTM
E709. These shall be tested at intervals agreed by the EMPLOYER and the results of the test recorded.
At the beginning of each shift the lifting power of the electromagnetic yokes shall be tested and the
results of the test recorded in the calibration log. The lifting power shall exceed 4.5 Kg for the maximum
pole spacing. For permanent magnets the lifting power shall exceed 18Kg for the maximum pole
spacing, if this is greater than 75mm or 0.24Kg per millimetre of pole spacing , if this is less than 75mm.
3.7 DEMAGNETISATION
If the component to be tested exhibits residual magnetism then demagnetisation shall be carried out in
accordance with Clause 22 of BS 6072 or ASTM E709.
4.5 CLEANING
Upon completion of the examination, all tested parts shall be thoroughly cleaned to remove all traces of
the Penetrant inspection material.
1. Lloyds Register approved training course for topside operators for the inspection of tubular joints.
2. CSWIP (ACFM)
3. PCN/GEN/97 App C3B.
For sub-sea operations the diver is not required to be ACFM qualified. The diver should hold CSWIP 3.1U and must
be briefed by the ACFM operator on probe handling and scanning procedure.
For two man topside operation (e.g. rope access), the probe handler should ideally be experienced in general NDT
but is not required to be ACFM qualified. The ACFM operator must brief the probe handler on probe handling and
scanning procedures.
5.3 EQUIPMENT
ACFM is proprietary equipment of TSC Ltd, Milton Keynes, UK. Several models exist, however the most relevant for
general NDT purposes in QGPC are as follows:
5.3.1 Topside
The Crack Microguage Model U9b is the latest version of the portable unit. This unit can be battery or mains
operated. The software QFM version 2.2 should be used with this instrument. This instrument can be used in ACFM
and ACPD modes.
The U9a together with QFMv1.1 is also capable of performing ACFM and ACPD measurements.
5.3.2 Sub-Sea
The ACFM Crack Microguage Model U21R is the latest version of the subsea model. This version has been
ruggedised to withstand harsh local conditions. The unit should be used with WAMI version 4.4 or later. The
standard U21R is ACFM only.
The predecessor to the U21, the U11 is capable of performing ACFM and ACPD measurements. The software
packages WAMIv3.8 (ACFM) and QPDv1.1 (ACPD) should be used.
5.3.3 Probes
All ACFM / ACPD probes should be approved by manufacturer.
For subsea applications the removal of hard marine growth is required. This can usually be achieved using a high
pressure water jet. It is NOT necessary to clean to bright shiny metal.
5.7 TEMPERATURE
ACFM is routinely used on live plant at elevated temperatures. Special probes are available for operation at
temperatures in excess of 500ºC.
5.8 MATERIALS
ACFM can be used on magnetic and non-magnetic materials. When used on non-magnetic materials, defect
detection and signal interpretation is similar to that for magnetic materials although the display scaling may need to
be adjusted. The ACFM defect sizing routines only apply to carbon steels and the use of ACFM to size defects in
non-magnetic material requires some calibration to be conducted. The equipment manufacturers are able to offer
advice on these aspects.
6. ULTRASONIC EXAMINATION
6.1 INTRODUCTION
This section of the specification covers manual ultrasonic examination (UT) of full penetration butt
welds, structural joints and tubular intersections in thicknesses of 6mm and greater.
The ultrasonic techniques used shall be in accordance with this specification and the appropriate
construction/fabrication specification.
6.2 NDT PERSONNEL
All ultrasonic operatives shall be qualified in the relevant test category as stated below (for ASNT
Qualified Personnel this shall be in addition to their qualification) :-
a) Plate.
b) Butt weld (including longitudinal and girth weld seams in tubulars 610mm diameter and above).
c) Pipe welds.
d) Structural T-welds
e) Nozzle welds.
f) Tubular intersections.
They will be required to produce evidence of relevant site experience of at least 6 months in the 12
months preceding the date of the assignment.
6.3 EQUIPMENT
6.3.1 Flaw Detector
The A-scan flaw detector shall comply with the requirements of BS 4331 : Part 1 or ASME V, Article 4,
Section T- 431.
6.3.2 Calibration Blocks
The following test blocks shall be used by the operatives during the test:-
A2 Block (either type) )
A4 Block ) to BS 2704
A5 Block )
A7 Block ) to BS 2704
Reference Block (see Clause 6.8)
6.3.3 Ultrasonic Probes
All probes shall be marked with a unique probe identification number. The following data shall be
recorded for each probe on a separate probe sheet:-
a) Date of issue.
b) Probe manufacturer.
c) Nominal beam angle.
d) Nominal frequency.
e) Toe-in angle (twin crystal probes).
f) Size and shape of crystal.
g) Vertical plane beam profile along the 20dB lines.
h) Results and dates of mandatory probe checks (see Clause 6.4.2).
root pass, be scribed at a specific surface distance from the root face under the supervision of the
EMPLOYER. Joints requiring this reference marking will be identified by the EMPLOYER.
6.7 SENSITIVITY
6.7.1 Scanning Sensitivity
The sensitivity used for the parent material scanning shall be the primary reference sensitivity plus 6dB.
6.7.2 Reference Sensitivity
6.7.2.1 Buried Indications
The reference reflector shall be a 1.6mm diameter side drilled hole at least 22mm long in a calibration
block which corresponds to the specified thickness range. A distance-amplitude correction curve (DAC)
shall be prepared, to cover the beam path lengths between the minimum and maximum range to be
used in the test. The thickness of the block and the position of the holes shall be as stipulated in Clause
6.8.1. A correction in instrument sensitivity is required to compensate for differences between reference
standard surface roughness, contact area and acoustical attenuation characteristics.
6.7.2.2 Surface Breaking or Near Surface Defects
The reference reflectors shall be API RP 2X V-notches at least 22mm long.
6.8 REFERENCE CALIBRATION BLOCK
6.8.1 Calibration Block
Where examination involves beam path trajectory along the curved cross section of the tested part, the
reference block should represent the curvature of the tested part if either the diameter is smaller than
500mm or the thickness to diameter ratio exceeds 0.03.
A single curved reference block may be used to examine parts whose curvature is between 0.9 and 1.5
times the reference block curvature.
The thickness of the reference block shall be the same as that of the tested part, or as specified in
Table 1.
6.9 SCANNING PATTERN
Scanning patterns shall include a separate examination of weld root. Welds shall be examined for both
longitudinally and transversely orientated flaws. Submerged arc weld metal shall be examined for
o
transverse (chevron) cracking using a 45 probe positioned on the cap.
The speed of probe movement shall not exceed 100mm/sec.
6.10 DISCONTINUITY LOCATION
Where appropriate, an allowance shall be made for the effect of curvature on beam angle and sound
path distance.
6.11 FLAW SIZE EVALUATION
Flaw size assessment shall be based upon beam boundary intercept methods (6dB and 20dB drops),
and maximum amplitude technique, as necessary. Generally the 6dB technique shall be used for
measurement of defect length.
6.12 DEFECT ACCEPTANCE LEVELS
Defect acceptance criteria shall be in accordance with the referencing code, except that no cracks or
planar defects, such as lack of fusion or lack of penetration are allowed.
6.13 REPORTING OF FLAWS
All discontinuity echoes equal to or greater than the 50% reference level shall be located, sized for
length, through thickness dimension (if 3mm or greater) and recorded, giving their maximum amplitude
as a percentage of the reference level.
Reportable flaws shall be classed as follows:-
a) Cracks,
b) Inclusions,
c) Porosity,
d) Planar indications.
If a flaw is found to exceed either the reportable or rejectable acceptance criteria specified, additional
information shall be provided to identify all responses from all surfaces used to assess the defect. When
a transverse indication is found in submerged arc weld metal it shall be recorded irrespective of signal
amplitude and a second examination shall be performed by the NDT supervisor.
6.14 REPORT FORMAT
The amount of information given on a test report shall be sufficient to reproduce the test conditions and
all the relevant test parameters of the original examination.
The information provided shall include:-
a) Weld and welder identification,
b) Type of weld, weld preparation and joint geometry,
c) Material thickness,
d) Technique and procedure number,
e) Referencing code for acceptance criteria,
f) Type of ultrasonic probes and their identification number,
g) Effective probe angles on curved surfaces,
h) Type of flaw detector and couplant used,
i) Time base setting for each probe,
j) Scanning sensitivity, including transfer correction,
k) Calibration block used,
l) Any restrictions or departures from the approved procedure,
m) Sketch of the weld showing the position and dimensions of all reportable flaws,
n) Amplitude of reportable indications for each probe used in the examination.
o) Results of examination.
Prior to being submitted to the EMPLOYER, the ultrasonic reports shall be checked and endorsed by
the NDT supervisor.
Radiographs should be stored in individual plastic pockets, in an environment with temperature and
relative humidity controlled to levels recommended by the film manufacturer.
Storage of radiographs in a microfilm form shall not be acceptable.
7.5 FILM STORAGE
All unexposed films shall be stored in a clean dry place where the surrounding conditions will not
detrimentally affect the emulsion. Open packages of film should be stored in a controlled environment at
a temperature and relative humidity recommended by the film manufacturer. If there is any concern
about the condition of the unexposed film, the EMPLOYER may request that the sheets from the front
and back of each package (or a 900mm length from the front of each roll) be processed without
exposure and shall satisfy the above stated fog level.
7.6 INTERPRETATION AND REPORTING
All films shall be interpreted in the dry condition.
Prior to being submitted to the EMPLOYER for final acceptance the radiographs and radiographic
reports shall be accepted/rejected by the Radiographic Interpreter and reviewed by the
CONTRACTOR's Inspector and endorsed.
The radiographic report shall include the following information:-
a) Procedure number.
b) Radiographic number.
c) Job identification.
d) Date
e) Weld & welder identification
f) Radiographers name & qualifications
g) Interpreters name & qualifications
h) Strength of source
i) Sensitivity.
j) Density.
k) details of screens, technique and film type.
l) Results of examination.