Saudi Qtech LID Co. oo, n, GP-Q.TECH.NDT-012 cena PROCEDURE ov.02 | Oat resaote i PROCEDURE FOR ULTRASONIC EXAMINATION OF % WELD JONTS AS PEI API RP 2X Pastas SAUDI Q-TECH LTD CO. GENERAL PROCEDURE Cr Fg ere we 4] CONTROLLED PROCEDURE FOR ULTRASONIC EXAMINATION OF WELD JOINTS AS PER API RP 2X oS ( (Or. |MASTER COPY Q.TECH-QC-NDT-012 Qtech Seca ang 2 ( 10502014 @ Issuod or approval aC tease, Date Revision | Description of Revision Prepared Approved ‘This document property of SAUDI Q-TECH wio wit safequerd its rahts according to the civil and penal provisions ofthe lawSaudi Q-Teeh LID Co. oc. 9. GP-Q.TECH-NDT:O12 GENERAL PROCEDURE ev.c2 | ote teosant4 ech PROCEDURE FOR ULTRASONIC EXAIMNATION OF x WELD JOINTS AS PER APROX naiaets ISSUE & REVISION STATUS ‘SN | Revised Date Doc. No. Rev No. Change Reference Remarks wioanoT® | GPOTehNOTOIO | 0D 5 : Z| aaaaaia | GeaTennoro1 | —o1 | 2Refwence Dosis ASME 2018, Uae Eons PA TEENGTGO | oF | € Documenta (UTTHY Repo) | RPO Tech NDT-OTRE: UTTRY 3 [woman arecwccnorat2 | a2 | Documents ana Naber 2 | Roport FomatSpee Doe. 6P.Q,TECHNDTON2 GENERAL PROCEDURE v.02 | bate tensiaor4 i PROGEDURE FOR ULTRASONIC EXAMINATION OF Ny WELDUOINTS AS PER API RP 2X Purscns INDEX SCOPE AND PURPOSE REFERENCE DOCUMENTS DEFINITIONS RESPONSIBILITIES S ACTIVITIES DESCRIPTION 5.1 PERSONNEL QUALIFICATION 8.2 Equipment AND MATERIALS 6.2.1 Equipment 5.22 Probes 5.2.2 _ Couplant 5.2. EQUIPMENT CHECK AND CALIBRATION 5.2.1 Check of horizontal linearity 5.22 Range calibration 5.2.3 Distance Amplitude Correction 5.24 — Resolution evaluation 5.2.5 Calibration/Reference Blocks 5.2.5 Probe selection 5.3. PRE EXAMINATIONS 5.3.1 Awareness of Joint Details: 5.3.2 __ Test Surface Preparation: 5.4 TRANSFER VALUE CORRECTION (TIC) 5.4 SCANNING 5.5 FLAWINVESTIGATION 5.6 CALIBRATION CONFIRMATION 5.7 ACCEPTANCE -REJECTION CRITERIA 5.7.4 Level A acceptance Criteria 5.7.2 Level C Acceptance Criteria 8 DOCUMENTATION 43 Become yisvaooonaaaawae la lo le le leSaudi Q-Teeh LTD Co. Doc. a, GP-O.TECH-NDT-012 canna PRocepuRE fev. 02 | owt 1eosrote ech PROCEDURE FOR ULTRASONIC EXAMINATION OF ‘ WELD JONG AS PER APIRP 2 Pau 4. SCOPE AND PURPOSE This recommended practice (RP) for non-destructive examination (NDE) of offshore structural fabrication and guidelines for qualification of personnel contains guidance on NDE methods which have evolved from fabrication experience with offshore structures. These methods are commonly used and have found acceptance due to their reliable detection of discontinuities, This practice is applicable to ultrasonic testing of butt joints as well as T, K & Y type joints in welds using pulse ‘echo, contact and manual technique fulfiling the requirements of API RP 2 X. This procedure is applicable for all Saudi Q-Tech projects. 2, REFERENCE DOCUMENTS Oech Written Practice : GP-Q.Tech-NDI-001-1 <_ WRITTEN PRACTISE + API Recommended Practice 2X, 2004 Edition. ‘+ ASME B&PV Code Section V 2013 Edition. © SNT-TC-1A-2011 Edition + ASNT/ANSI CP — 189-2011 Edition. 3. DEFINITIONS The following terms abbreviation have been included for clarification of the CONTRACT definitions and interpretations given in the CONTRACT: NDE Non-destructive Examination ur Ultrasonic Testing aB Decibel iw International Institute Of Welding tow Institute Of Welding, FSH Full Screen Height cRT Cathode Ray Tube Te Transfer Correction Dac Distance Amplitude Correction. MHz Megahertz APL ‘American petroleum institute RP Recommended practice ASME ‘American Society for Mechanical Engineers BPV Boiler and pressure vessel code ANSI ‘American National Standard institute SDH Side Drill Hole if Thickness: D Diameter. ASNT ‘American Society for Nondestructive Test |Saudi Q-Teeb LED Co. Doo. n. GP-Q.TECH-NDT-012 GENERAL PROCEDURE +——— — rov.c2 | oat tems0%4 ech PROCEDURE FOR ULTRASONIC EXAMINATION OF s WELD JOINTS AS PER API RO 2 Paiscis 4. RESPONSIBILITIES NDT Level-ll Should be performing to set up and calibrate equipments and to interpret and evaluate the results with respect to applicable codes, standards and specification, should be thoroughly families with the scope and limitation of the qualified NDT method, and should be able to organize the test report of certified NOT methods. NDT Levelt - Should be capable of developing, qualifying and approving procedures, establishing and approving technique, interpreting codes, standards, specifications and procedures. NDT Levelll should be responsible for the NDT operations for which qualified and assigned and should be capable of interpreting and evaluating in terms of existing codes, standards, and specifications. Capable of training and examination of NOT Level-! and Level-I in the certified NOT methods. 5. ACTIVITIES DESCRIPTION 5.1 PERSONNEL QUALIFICATION ‘The examination shall be performed by at least an UT Level-ll, All interpretation of test results shall be done by a certified NDT UT Level -II API-RP-2X utilizing "mock-up" test specimens of the same configuration as the ‘actual joints to be inspected and as per written practice of SAUDI Q-TECH complying with ANS/ASNT CP-189 edition 2011 and ASNT recommended practice ASNT-TC-1A edition 2011. UT technician shall be qualified on joint-by-joint basis. 6.2 EQUIPMENT AND MATERIALS 5.24 Equipment ‘The examination shall be conducted with a pulse echo ultrasonic instrument KRAUTKRAMER USM 35, PANAMETRICS EPOCH XT or equivalent capable of generating frequencies between 1 to 10 MHz shall be used. The instrument shail be having A scan presentation. ‘The instrument shall provide a horizontal sweep with linearity within one percent of the full screen. ‘The equipment should have a calibrated gain control electrically accurate to within one decibel over a range of not less than 60 decibels. Adjustments shall be possible in increments of no more than 2 decibels per step. 5.22 Probes Longitudinal (compression) wave transducer 12.6 millimetres to 25 millimetres in diameter of @ nominal frequency 2.25 megahertz and nominal 45, 60 and 70 degree angle beam transducers of a nominal frequency of 2 megahertz to 2.25 megahertz. The oscillating elements shall be approximately square or round in shape with dimension which results in an included beam angle approximately 15 degree at 6 decibels less than the centreline maximum. High frequency transducer can also be used for reflector evaluation. The complex geometry of welded connections on offshore structures particularly T, K and Y connections, typically require the use of nominal angle transducers (i.e. 45, 60 and 70 degrees) in multiple scans of the entire circumference and almost always from the brace side of the weld only. Thick wall diagonal braces with full throated weld connections may also require the use of an 80 degree transducer to ensure that the sound beam intercepts the root area 6.2.2 Couplant ‘Commercial available couplant or cellulose glue shall be used 2s couptant. Couplants used on nickel base alloys shall not contain more than 250 ppm of sulfur. — Couplants used on austenitic stainless steel or titanium shail not contain more than 250 ppm of halides (chlorides plus fluorides) 5.2 EQuipMENT CHEGK AND CALIBRATION 5.24 Check of horizontal linearity To check the horizontal linearity of the instrument get at least five echoes depending on the range selected, from a longitudinal transducer placed on the flat surface of the IIVW block to match equal divisions on theSaudi Q-Teeh LTD Co. Dos. n. GP-Q.TECH-NDT-012 GENERAL PROCEDURE Rev.02 | Date 1670572014 qbe PROCEDURE FOR ULTRASONIC EXAMINATION OF WELD JOINTS AS PER API RP 2X Page of 13 horizontal scale of the CRT. The alignment shall start with first echo and not the initial pulse. After aligning the echoes with the scale determine the deviation of positions of each echo from the scale mark. This deviation should not exceed 4 percent of the full scale range. 5.22 Range calibration Horizontal sweep shall be calibrated for a sufficient range with the help of !IW V1 or V2 blocks which produce reflections at known distances. For plotting the DAC the sensitivity control (gain) shall be adjusted to provide 60% FSH (+ or ~ 6% FSH) from 4/16 inch (1.6mm) diameter side drilled hole in the calibration block shown in figure: 1 At least two more reflections shall be taken at different distances without changing the gain, Drawing a line connecting all three peaks will produce a DAC line. 5.2.4 Resolution evaluation Instrument-transducer combination’s resolution capabilities shall be checked using [OW & IIW V1 blocks. 5.2.5 Calibration/Reference Blocks The calibration block shall be from same material with same heat treatment, surface condition and with similar ‘metallurgical factors. Prior to fabrication, the block material shali be completely examined with a straight beam search unit. Areas that contain an indication exceeding the remaining back wall reflection shall be excluded from the beam paths required to reach the various calibration reflectors. For ultrasonic examination at level A accepiance criteria a 1/16 inch (1.6mm) side drilled hole shall be used as reference with all transducers, The thickness and length of the biock containing the dill hole shall permit evaluation of reference sensitivity at the longest metal path distance anticipated in the actual examination. The block shall be made according to the figure: 1 below. (38 mm) min | Cie Puan | "ng deep buttress notch (ex 18 mm) i See slot datas below (our blocks required) + "i 4.6 mm) hole | jemmin | | | ~esmmy~| | I+ SteT min Figure: 4 In addition to the side drilled holes empioyed for evaluation of all discontinuities in the body of the weld, two 1/16 inch (1.8mm) deep notches shall be used as reference standatd lo be used in evaluating root reflector in butt or T, Kand ¥ connections welded from one side only. The reference block for Level C examination shall contain planer reflectors compatible with the smallest reject able flaw. One reference block containing a square notch and one each with V notches for 45°, 60°, and 70°, |Saudi Q-Teeh LTD Co, ‘Doe. n. GP-G.TECH-NDT:012 conltRa PROCEDURE eve | owe wauscote een PROCEDURE FOR ULTRASONIC EXAMINATION OF s WELD COINS mo BER APINP 2X Paereiis orientations shall be made for establishing scanning sensitivity for root reflectors. In addition to notches for root reflectors a 1/16 Inch (1.6mm) diameter side drilled hole shall be made in each reference block. See figure: 2 below. 48" eae Tolerance -Angle 4 Te Tinehes — 0.001 ie me ta a 7 [cee (1.6mm) (4.12 mm) iste 7 Port = I yp / + Ha | patcoated LL cose Anteiated | cose: ‘oleae a ein eG Figure 46—Reference for Level C Examination Block Figure: 2 6.2.5 Probe selection The complex geometty of welded connections on offshore structures particularly T, K and Y connections, typically require the use of nominal angle transducers (i. 45, 60 and 70 degrees) in multiple scans of the entire circumference and almost always from the brace side of the weld only, Thick wall diagonal braces with full throated weld connections may also require the use of an 80 degree transducer to ensure that the sound beam intercepts the root area. The probe angles shall be selected in such a way that the sound beam is perpendicular to anticipated defects types including fusion line defects which again depends on the joint preparation and angle of bevel. 5.3. PRE EXAMINATIONS 5.3.4 Awareness of Joint De Prior to examination weld joints, the operator shall familiarize himself with the joint design and welding process sed. This information shall be provided by the assigned quality control inspector. 5.3.2. Test Surface Preparation: ‘The scanning area of the weld to be tested shall be free of any weld spatter, arc strikes, loose particles, non- adhering mill scale or any foreign materials that may interfere with proper performance of the test. ‘Any scanning restriction and limitations shall be noted on ultrasonic examination report. 6.4 TRANSFER VALUE CORRECTION (T/C) ‘The Transfer Value Correction shall be determined and used for all shear wave examinations to compensate for differences in surface contour, finish, coatings and acoustical attenuation characteristics. (Value over 648 to bbe reported). To ensure that accurate transfer value correction factors are obtained, signal comparisons shall only be made in the "FAR ZONE" of ultrasonic beam. Commentary: Place two identical angle probes on the calibration block or mock-up to be used, Using through transmission method maximize the amplitude to 60% FSH & note down the dB value. | | | | |Saudi Q-Tech LID Co. (Doe. a. GP-Q.TECH-NDT:012 GENERAL PROCEDURE ev.02 | Oat tosaore ech PROCEDURE FOR ULTRASONIC EXAMINATION OF s WELD OINTS AS PER APL RP 2 paisa Place the same search units on part to be examined, obtain the dB values using through transmission method at least in three locations by maximizing amplitude to 80% FSH. ‘The difference in dB between calibration block or mock-up & average of that obtained from the part to be ‘examined shall be recorded & used to adjust the standard sensitivity 8.4 SCANNING The scanning shall be 100%. The entire volume shall be examined with 2 10% overlap of the probe. The rate of search unit movement for examination shall not exceed 6 inches per second (152mmisec) unless calibration is verified at scanning speed. ‘Scanning Sensitivity level = Echo of reflector set to DAC + 6 dB #Transfer Value Correction. Primary Reference Level = Scanning Sensitivity Level -6 4B Entire area on the base metal of member from which scanning Is to be done shall be examined by fongitudinal ‘wave technique to assure freedom from laminar type flaws which could interfere with shear wave sound propagation. This examination shall be done as per Saudi G-Tech UT procedure GP-Q.Tech-NDT-006-E Examination of the weld root areas will be carried out separately from the remainder of the weld. If the probe is moved parallel to the toe of the weld at the intercept distance to the root protrusion, any change in the root geometry can be ascertained by a lateral movement on the horizontal scale of the CRT. An interruption or shift of the echo signal position indicates a change in root geometry and the presence of a discontinuity After examination of the root area, the remainder of the weld shall be scanned using a back and forth motion accompanied by e slight rotational movement. Scanning shall be done between one and one fourth times the skip distance. When the weld reinforcement extends beyond the edge of original bevel, the scanning shall be performed batween one and one haif and second skip distances of the sound beam. ‘All butt weld joints shall be examined from each side of the weld axis and both faces where accessible. Comer, T-Joint and diagonal joint shall be examined from one side of the weld axis only and both faces where accessible. ‘Scanning shall be generally performed from branch connection. a) Scanning for reflectors oriented parallel to the weld: ‘After establishing DAC the angle beam shall be directed at the weld at approximately right angles. This shall be done from two directions. The probe shall be manipulated such that the complete volume of the weld is scanned, See Figures 7, 8 and 9 b) Scanning for reflectors oriented transverse to the weld: The scanning shall be done parallel to the weld axis, If the weld is not ground flushed the probe shall be faced such that it faces nearly parallel to the weld body. See Figures 7, 8 and & Evaluation of defects shall be performed from both the branch & main member. 5.5 FLAWINVESTIGATION ‘When a flaw indication is obtained, flaw size investigation shall be done by three methods which produce useful information on sizing in following sequence. a. The amplitude comparison technique b, The beam boundary intercept technique cc. The maximum amplitude technique Length: 648 Amplitude drop method. 5.6 CALIBRATION CONFIRMATION ‘The proper functioning of the examination equipment shall be checked and the equipment shall be calibrated by the use of the calibration standard at the beginning and end of each examination, when examination personnel are changed, at an interval of 4 hours and at any time that maifunctioning is suspected, as minimum. If duting any check it is determined that the testing equipment is not functioning properly, the entire product that has been tested since the last valid equipment calibration shall be re-examined.Saudi Q-Tech LTD Co, Doc. n GP-Q.TECHNDT:O12 GENERAL PROCEDURE Rov.02 | Date 16/0512014 gto PROCEDURE FOR ULTRASONIC EXAMINATION OF WELD JOINTS AS PER API RP 2X Pages of 13 5.7 ACCEPTANCE -REJECTION CRITERIA Two Levels of acceptance criteria are defined as per the API RP 2X for specific purposes. Client specification shall govern the acceptance criteria to be implemented. 5.7.1 Level A acceptance Criteria Level A corresponds roughly to workmanship standards specified in traditional codes developed for radiography. All refiectors 6 dB smaller than the reference level (50% of DAC) may be disregarded. Reflectors above the 50% DAC line shail be further evaluated as follows. Isolated random point reflectors are acceptable. Aligned point reflectors shall be evaluated as linear reflectors. Clustered multiple reflectors with indications above the 50% DAC curve should not exceed 2/3 of the branch thickness or 3/6 inch (9.6) mm whichever is less, in any linear inch. Linear or planar reflectors whose lengths do not exceed the limits of Figure: 3 below are acceptable, except any reflector thought to be a crack, lack of fusion&. lack of penetration. lepine fin ‘i ea snsutcpricadtdees Figure: 3 Reflectors within the base metal of the main member at welds shall be evaluated as described below. Individual reflectors exceeding the limits of figure: 4 below are rejectable. Accumulated refiectors exceeding 8% of the area under the weld in 2 any 6 inch (150) mm or D2 length (whichever is less) are reject able. | | |Saud Q-Teeh LID Co, Doe. GP-Q.TECH-NDT-012 GENERAL PROCEDURE Rev.02 | Date 1670572014 lech PROCEDURE FOR ULTRASONIC EXAMINATION OF % WELD JOINTS AS PER API RP 2X Page 10 013, Reject | Ws" or TA a | ; Accumulative Loe faws ve Width, in. Individual flaws ~—- I tae} i Accept ' Any Lt ——— Va V2 1 2 4 6 or D/2 Length. in. Figure: 4 5.7.2 Level C Acceptance Criteria Level C represent experience based on fitness-for purpose oriteria which are consistent with as welded surface profiles. These criteria are specifically used for examination of welds made from outside only in tubular T, K and ¥ connections where reject able defects are subjected to visual confirmation during the weld removal repair process. All rafiectors 6 DB smaller than the reference level ie. 50% of DAC, may be disregarded. Reflectors above this limit shall be further evaluated as described below. | Isolated random spherical reflectors are acceptable, regardless of signal amplitude. Clustered multiple reflectors | with indications above the 50% DAC curve and two times the branch thickness in fength should be evaluated in terms of their encompassing width and length using the limits of figures mentioned below Reject Va" or TI4 1 ' : Accumulative | < nee flaws | < te ' | 3 ' Individual i ine flaws Se | Accept Any* bee | | L = tla We 1 2 4 Length, In. Fig: 5 internal reflectors and all other welds~ | arene Doc. n. GP-Q.TECHNDT.O12 GENERAL PROCEDURE Rev.02 | Date tesma014 ech PROCEDURE FOR ULTRASONIC EXAMINATION OF x WELD JOINTS AS PER API RP 2X Penis ; Reject fs" or T/4 LE a i ! _ Accumulative ' 1 7 flaws = a eee 1 i s ' | = Individual i i: flavs —~___ Cacnepene f16 Accept Wa 1 2 4 6orD/2 Length, in. Fig: 6 (T K and Y root defects) Cylindrical or planer reflectors whose dimensions exceed the limits of figure: 5 & 6 mentioned above (depending ‘on locations) are reject able, Reflectors within the base metal of the main member at welds shall be evaluated as mentioned below. Individual reflectors exceeding the limits of Figure: § above are reject able. Accumulated reflectors exceeding the 8% of the area under the weld in any 6 inch (150 mm) or Di2 lenath (whichever is less) are rejectable, weld not tus! wold zone Tan arse WkwEs Langitudinal flaws Scannir avian,Saudi O-Tech LTD Co, Doe. n, GP-O.TECHNDT-O12 (GENERAL PROCEDURE Rev.02 | Date 1052014 Jech PROCEDURE FOR ULTRASONIC EXAMINATION OF x WELD JOINTS AS PER APIRP 2X Page 12 of 13 round fiush wete Sry transverse longitudinal | oe 5 —_F¥ Figt'-= 30—Alternate Method for Determination of Skip Distance on Current Surfaces of aie eee th N 1, é 2 4 € 6 to 6 2 4 6 & fo Position + > Position 2 ana s S a Peston poattion Position Figure 31—Probe Manipulation tor ‘Spherical Discontinuity Figure 32—Probe Manipulation for Planar Discontinuity Figure: 9Saudi Q-Teeh LID Co. Doc. n. GP-@.TECH-NDT-012 coeNehi baodebURe fv.a2 | owe tensa0% % WELD JOINTS AS PER API RP 2X pana 6. DOCUMENTATION Results of the examination shall be recorded in the Report Format Attachment 1 “TECH RP-Q.TECH-NDT-01 UT REPORT for -Y Joints) REQUEST NO: easton TEPORTNe TBC ITE 20. DISCRIFION OF COMPONENT RXAAINED NATERIALSreeMICATION CP eth Cit Dl Aalst (Wad mb (Spt an SiaNUWACTURING CoDErACoRrEANCES STANDARD: | TESTINGMIETHOD: 3 Ane (ay el is Eo Diet Com REFERENCE, CALINRATION GAIN: BASIC CALIBRATION BLOCK VEC) V20) Step Wedge ) [REFERENCE REFLECTION SIZE : an) [SCANNING SENSITIVITY (Added ¢8): | FLAW DETECTOR MANUFACTURER MODE (a8) SrNo. SCANNING GAIN (Total AB) = RECORDING LEVEL : ‘COUPLANT: By (% Screen Height) BXTENT OF EXAMINATION = SURFACE TEMPRATURE. ‘SURFACE CONDITION Full Scan...) Partial Sean ..%) PROBE DESIGNATION ancte | sizemm | FREQUENCY REFSENSITIVITY (48) RANGE o Miz a s x Miz mm or x Mia mm 7 x Mie mm ‘ )¥ Joint ne | Draviog Ne ‘Size | WetdingNo. [Welder 1D Inspected By : Verified By : Approved By = NAME SIGNATURE DATE,