Ixar DR Unisco PKG 2 Ut 04 Rev.0

Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman

Tel: +968 24541291,Fax:+968 24541281
Email: ixaroman@gmail.com
ULTRASONIC EXAMINATION PROCEDURE

Procedure No: IXAR/DR/UNISCO/PKG-2/UT/04 Rev.0 Page No.: 1 of 18
PROJECT DUQM REFINERY PROJECT EPC Package-2
CLIENT DUQM REFINERY & PETROCHEMICAL INDUSTRIES COMPANY (DRPIC)
EPC CONTRACTOR Petrofac Samsung JV
FABRICATOR United Industrial Services Company L.L.C (UNISCO)
CONTRACT NO. CNT-1100-1000-007
DRPIC CONTRACT NO. --
NDT CONTRACTOR INDUSTRIAL X-RAY & ALLIED RADIOGRAPHERS L.L.C.
Babu Patwekar
0 21/07/2019
ASNT NDT LEVEL-III
Prepared by Reviewed Approved by
Revision Date
IXAR UNISCO Client
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TABLE OF CONTENTS
Description Page No.
Cover Page 1
Table of Contents 2
1.0 Purpose 3
2.0 Scope 3
3.0 References 3
4.0 Definitions 4
5.0 Abbreviations 4
6.0 Personnel Qualification 5
7.0 Ultrasonic Examination Procedure 5
8.0 Procedure Qualification 5
9.0 Essential and Non-Essential Variables 6
10.0 Surface Preparation 7
11.0 Equipment & Accessories 7
12.0 Calibration 8
13.0 Surface Temperature 10
14.0 Calibration Block 10
15.0 Method 10
16.0 Interpretation/Evaluation 10
17.0 Acceptance Criteria 12
18.0 Post examination cleaning 13
19.0 Documentation 13
20.0 Reporting 14
Attachment-1 Calibration Block for Piping 15
Attachment-2 Ultrasonic Examination Report for Lamination Check 16
Attachment-3 Ultrasonic Examination Report for Weld Check 17
Attachment-4 Ultrasonic Examination Technique Sheet 18
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1.0 Purpose:
The purpose of this procedure is to define the requirement for the ultrasonic examination to to
detect defects of butt weld & lamination in Carbon steel materials in process piping and
attachment.
2.0 Scope:
This procedure is applicable for manual Ultrasonic pulse echo contact method, to detect
defects of butt weld & lamination in Carbon steel materials in tank and attachment.
This procedure is applicable for above 6 inches diameter and nominal wall thickness above
6mm.
The scope, extent and stages of examination shall be as per approved QCP and NDE plan.
Before UT on production welds, technique sheet shall be approved by client
3.0 References:
1 ASME B31.3 , 2016 Edition Process Piping

ASME Sec V. Article 5,2017 Boiler and Pressure Vessel Code Nondestructive
2
Edition Examination.
3 SE-797 of ASME Sec V. Article Standard Practice For Measuring Thickness By
23,2017 Edition Manual Ultrasonic Pulse-Echo Contact Method
SA-435 of ASME Sec V. Standard Specification For Straight-Beam
4
Article 23,2017 Edition Ultrasonic Examination Of Steel Plates.
Specification For Straight-Beam Ultrasonic
5 SA 578 of ASME Sec V. Article
Examination of Rolled Steel Plates for Special
23,2017 Edition
Applications
IXAR/NDT/WP-1 Rev (Latest Written Practice for Qualification & Certification of
6
Revision) NDE Personnel
ASNT SNT TC -1A, 2006-2011 Guidelines for Personnel Qualification &
7
Edition, Certification.
8 DRP001-OUF-SPE-Q-000-507 QA QC Implementation during Construction
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9 DRP001-OUF-SPE-U-000-005 Inspection Requirements
10 DRP001-OUF-SPE-W-000-006 Specification for Welding & NDE of Pressure

Equipment’s and Piping
4.0 Definitions:
Term Definition
Client End User
Any private or public entity responsible for Detailed Engineering
Contractor and Design, Procurement, Construction and (pre-) Commissioning
of this project
A construction contractor is responsible for the day-to-day
oversight of a construction site, management of vendors and
Construction Contractor
trades, and communication of information to involved parties
throughout the course of a project.
Person or entity to whom/which the Contractor subcontracts any
Sub-Contractor
part of the service.
Is to be understood as mandatory.
Shall
An individual or collaborative enterprise that is carefully planned
Project and designed to achieve a particular aim.
Is to be understood as strongly recommended.

Should
Is to be understood as giving a freedom of choice.
May Be
5.0 Abbreviations:
NDT Non-Destructive Testing
UT Ultrasonic Testing
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
ASNT American Society of Non-Destructive Testing
API American Petroleum Institute
BPV Boiler & Pressure Vessels
ISO International Organization for Standardization
CS Carbon Steel
SS Stainless Steel
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DSS Duplex Stainless Steel

SDSS Super Duplex Stainless Steel
IXAR Industrial X-Ray & Allied Radiographers LLC
6.0 Personnel Qualification:

All personnel shall be qualified and certified to Level II in the Ultrasonic examination method
in accordance with IXARLLC written practice in compliance with ASNT-SNT-TC-1A
(2006/2011).
The Level III personnel who is qualifying NDT personnel shall pass the ASNT Level III
examination in Basic and UT method which meets the requirements specified in ASNT-SNT-
TC-1A.
Personnel performing Ultrasonic examination shall have natural or corrected near distance
acuity in at least one eye such that they are capable of reading a minimum of Jaeger No.2 or
equivalent type and size letter at a distance greater than 12”.
And also be capable of distinguishing between colours used during the examination
demonstrated by correctly reading 20 of the 24 plates of Ishihara colour vision test charts.
Vision test should be carried out annually.
The Level III shall continuously monitor the performance of UT personnel certified to Level II
and shall take corrective actions whenever the performance of UT Level II technician is not
satisfactory.
All qualification certification shall be valid (not expired).
7.0 Ultrasonic Examination Procedure:
Ultrasonic examination shall be performed in accordance with a written procedure.

The procedure shall be reviewed and endorsed by the UT ASNT Level III, prior to approval.
Ultrasonic examination shall be carried out only after the written procedure is approved by
client
.
8.0 Procedure Qualifications:
Ultrasonic examination procedure shall be qualified to the satisfaction of the company

representative to meet the requirements of the referencing code before starting of the job.
Technique sheet shall be prepared as per attached exhibit .Company approved technique
sheet shall be considered as procedure qualification record. The procedure qualification
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records shall be kept in file for auditing or for company review. The same technique variables
shall be used for production UT.
When procedure qualification is specified, a change of requirement in Essential and Non-

Essential Variables table identified as an essential variable shall require requalification of the
written procedure by demonstration.
A change of a requirement identified as a nonessential variable does not require

requalification of the written procedure.
All changes of essential or nonessential variables from those specified within the written
procedure shall require revision of, or an addendum to, the written procedure.
The extent of examination shall be specified by the project specification and by the
referencing Code Section.
9.0 Essential and Non-Essential Variables:
Non-
Sr. Essential
Requirement Essential
No. Variable
Variable
Material types and configurations to be examined,
1 Including thickness dimensions and product form Para 2.0
(Castings, Forgings, Plate, Etc.)
The Surfaces from which the examination shall be
2 Para 10.0
performed
Technique(s) (Straight beam, Angle beam, Contact,
3 Para 16.0
and/or Immersion)
Angle(s) and Mode(s) of wave propagation in the
4 Para 16.0
material
Search Unit type(s), Frequency(ies), and Element
5 Para 11.0
size(s) /Shape(s)
Special search units, wedges, shoes, or saddles,
6 NA
when used
7 Ultrasonic instrument(s) Para 11.0
Calibration [calibration block(s) and technique(s)] Para 14.0 &
8
15.0
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9 Directions and extent of scanning Para 16.0

10 Scanning (manual vs. automatic) Para 16.0
11 Method for sizing indications Para 17.0
12 Computer enhanced data acquisition, when used NA
13 Scan overlap (decrease only) Para 16.0
14 Personnel performance requirements, when required Para 6.0
15 Personnel qualification requirements Para 6.0
Surface condition (examination surface, calibration
16 Para 10.0
block)
17 Couplant: brand name or type Para 11.0
18 Post examination cleaning technique Para 19.0
Automatic alarm and/or recording equipment, when
19 applicable NA
Records, including minimum calibration data to be

20 recorded (e.g., instrument NA
settings)
10.0 Surface Preparation:
The surface from which scanning is to be achieved, should be cleared to remove all scale,
weld spatter, loose particles or any other foreign material, to assure continuous coupling
during the test. Scanning area shall be smooth.
Examination shall be performed Top Surface (Outer Surface) of the test part.
11.0 Equipment & Accessories:
Ultrasonic Flaw Detector

The equipment shall be a pulse echo A-Scan system capable of transmitting and receiving
frequencies from 1MHz to 10MHz such as USK-75, USM-35, MODOSONIC Einstein-II TFT
gauge or equivalent.
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Probes
Wave
Make Type Angle Frequency
Propagation Crystal
Dia. (mm) (MHz)
WK/ EEC
/MODOSONIC/
Lensser/ Dual Crystal 0° Longitudinal 10 mm 4/5
Krautkramer
WK/ EEC
/MODOSONIC/ Single
45° Shear 8 x 9 mm 4/5
Lensser/ Crystal
Krautkramer
EEC
/MODOSONIC/ Single
60° Shear 8 x 9 mm 4/5
Lensser/ Crystal
Krautkramer
EEC
/MODOSONIC/ Single
70° Shear 8 x 9 mm 4/5
Lensser/ Crystal
Krautkramer
Couplant
Glycerin, Oil, Oil mixed Grease, water, mixture with cellulose paste in water which permits
satisfactory transmission of ultrasonic waves will be used.
Same Couplant to be used during examination as used for calibration.
12.0 Calibration:
Instrument Performance (Only for Ultrasonic flaw detector)

Screen Height Linearity
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Hold the straight beam probe on any calibration block that provides amplitude differences,
with sufficient signal separation to prevent overlapping of the two signals.
Adjust the sensitivity (gain) so that the larger indication is set at 80% of full screen height.
Without moving the search unit, adjust sensitivity (gain) to successively set the large
indication from 100% to 20% of full screen height, in 10% increments (or 2dB steps if a fine
control is not available), and read the smaller indication at each setting.
The reading shall be 50% of the larger amplitude within 5% of full screen height.
The settings and readings shall be estimated to the nearest 1% of full screen.
ASME Section V Mandatory Appendix provides requirements for checking screen height
linearity and is applicable to ultrasonic instruments with A-scan displays.
Alternatively, a straight beam search unit may be used on any calibration block that provides
amplitude differences, with sufficient signal separation to prevent overlapping of the two
signals.
Amplitude Control Linearity

Using a normal probe, the 1.5mm dia. side drill hole in the IIW V1 block (or the ¼ t hole in the
Performance check calibration block) is peaked on the screen. With the increase and
decrease in attenuation shown in the following table, the indication must fall within the
specified limits. The settings and readings must be estimated to the nearest 1% of full screen.
Indication set at % of Full

dB Control Charge Indication limits % of Full Screen
Screen
80% - 6 dB 35 to 45%
80% - 12 dB 15 to 25%
40% + 6 dB 65 to 95%
20% + 12 dB 65 to 95%
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Primary Reference Level for Weld:

For Lamination check
For Lamination check, calibration can be done in a defect free zone of plate, make the
ultrasonic examination on either major surface of the plate.
The range shall be taken so that, minimum two (2) back wall echoes (BWE) appears on the
screen.
Maintain second back wall echoes (BWE) at least 50% Full screen Height (FSH) or the same
calibration used for thickness measurement can be done as an alternative.
For Weld check

A distance amplitude correction (DAC) curve is to be created for each angle probe to be
used during test. The curves shall be set up using the reflectors from surface notches in
the appropriate DAC reference block.
The response from far surface slot shall be set at 80% FSH and using this gain the
response from near surface slot shall be maximized and its height recorded so as to
produce DAC curve.
13.0 Surface Temperature:
The maximum surface temperature for conventional probes should not exceed 50°C. Heating
of the probe element can significantly reduce its efficiency and cause premature failure.
The temperature of object being tested and calibration block should be within ±14°C.
14.0 Calibration Block:

For Lamination
For lamination check, IIW V1, IIW V2 block and Step wedges of acoustically similar materials
(e.g. CS, SS) as the items to be examined shall be used.
For Weld Piping

Attachment-1 Calibration Block for Piping
15.0 Method:
For Lamination
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The technique shall be limited to straight beam (Longitudinal or Compressional wave) with
contact method (Manual).
Testing shall be carried out from one side of the surface, using ultrasonic pulse echo
techniques for the detection of internal imperfections.
Maximum scanning speed should not exceed 150mm / sec.
Ultrasonic thickness measurement shall be done to ensure that the wall thickness’s are within
the required tolerances prior to lamination check. Maximum and minimum value shall be
recorded.
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 minimum of 10% of the transducer (Piezoelectric Element)
dimension parallel to the direction of scan indexing.
For getting measurement of multiple echoes, gain can be set as required depending on the
echo to be considered for measurement.
Condition for Internal Imperfection

The presence of an internal imperfection is indicated by a 50% reduction or more in the signal
amplitude of the back wall echo with or without the presence of an imperfection echo, or an
increased series of multiple echoes.
For Weld
The technique shall be limited to angle beam (Shear wave) with contact method (Manual).
Testing shall be carried out from one side of the surface, using ultrasonic pulse echo
techniques for the detection of internal imperfections.
Manual ultrasonic weld testing shall be performed at a scanning sensitivity of DAC reference
sensitivity plus 6 dB minimum.
Nominal probe angle will be 45°, 60°, 70°,the weld and heat affected zone shall be
examine with a minimum of two angle probe. A third angle probe angle may be used at the
discretion of the technician or when required by the company.
The examination shall be carried out from both sides of weld axis where access permits.
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With the probe pointing at right angle to the weld axis the volume shall be examined by
moving the probes backwards and forwards to ensure complete coverage.
Angle beam Ultrasonic examination shall be done to ensure quality of full volume butt weld
within the required tolerances.
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 minimum of 10% of the transducer (Piezoelectric
Element) dimension parallel to the direction of scan indexing.
Maximum scanning speed should not exceed 150mm / sec.
16.0 Interpretation/Evaluation:
All indications that exceed 50% of DAC screen height shall be evaluated.
Evaluation sensitivity for manual ultrasonic weld testing shall be DAC reference sensitivity
plus 6 dB.
The dimension of the reflector which is being measured may be either larger or smaller than
the beam width. This can be evaluated by using 6 dB drop method for defects larger than the
crystal dia. and 20 dB drop method for defects smaller than the crystal dia.
Evaluate each area of imperfection by optimizing the echo amplitude. Move the transducer to
the edge of the imperfections until the echo height is dropped to –6dB height and mark center
of probe on pipe / plate. Repeat the process in all directions to get the shape of the
imperfections or at least in two-direction length wise, (Along the rolling direction) & width wise
(perpendicular to the rolling direction).
When the main beam is on the defect the defect signal is at its maximum. If the probe is
moved and the signal is observed until it is reduced to 10% (20dB Drop), the edge of the
beam is on the edge of the defect. Repeat the above at the other side of the defect using the
pre-constructed Beam profile and a plotting card, the defect may be sized.
17.0 Acceptance Criteria:
For Lamination check

The area under inspection shall be free from lamination.
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For Weld check

Acceptance criteria shall be as per clause 344.6.2 of ASME B31.3
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 Tw ≤ 19 mm (3⁄4 in.)
(b) Tw/3 for 19 mm < Tw ≤ 57 mm (21⁄4 in.)
(c) 19 mm for Tw > 57 mm
18.0 Post examination cleaning:

Post-examination cleaning is required and it should be done as soon as practical using a
process that does not adversely affect the part.
The cellulose paste applied on the surface shall be completely removed with a clean cotton
cloth piece.
19.0 Documentation:
For Ultrasonic examination, the following information shall be recorded on the Report
attached to this procedure.
Date of Examination
Examination personnel identity, Level and Signature
Ultrasonic Procedure Number
Ultrasonic Examination Equipment (ID & Calibration)
Search Unit Identification, Beam Angle and Cable length used
Calibration Block Identification
NDE Specification
Surface Condition
Acceptance Criteria
Wall Thickness
Identification of material
Map or record of discontinuities assessed
Conclusion, accept or reject according to specification
Drawing Number
Line / Component Number
Location
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Heat treatment condition

Couplant
20.0 Reporting:
Report shall be prepared and submitted to the inspection engineer for review and acceptance
as per appended format.
The report shall include those records indicated in Para. 19
All reports shall be signed by client/owner representative, as applicable.
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Attachment-1 Calibration Block for Piping

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Attachment-2 Ultrasonic Examination Report for Lamination Check

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Attachment-3 Ultrasonic Examination Report for Weld Check

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Attachment-4 Ultrasonic Examination Technique Sheet

Ixar DR Unisco PKG 2 Ut 04 Rev.0

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Industrial X-Ray & Allied Radiographers L.L.C.

P.O.Box 3130,P.C.111,CPO,Sultanate of Oman

ULTRASONIC EXAMINATION PROCEDURE

PROJECT DUQM REFINERY PROJECT EPC Package-2

CLIENT DUQM REFINERY & PETROCHEMICAL INDUSTRIES COMPANY (DRPIC)

EPC CONTRACTOR Petrofac Samsung JV

FABRICATOR United Industrial Services Company L.L.C (UNISCO)

CONTRACT NO. CNT-1100-1000-007

DRPIC CONTRACT NO. --

NDT CONTRACTOR INDUSTRIAL X-RAY & ALLIED RADIOGRAPHERS L.L.C.

ULTRASONIC EXAMINATION PROCEDURE

ULTRASONIC EXAMINATION PROCEDURE

Before UT on production welds, technique sheet shall be approved by client

1 ASME B31.3 , 2016 Edition Process Piping

ULTRASONIC EXAMINATION PROCEDURE

9 DRP001-OUF-SPE-U-000-005 Inspection Requirements

10 DRP001-OUF-SPE-W-000-006 Specification for Welding & NDE of Pressure

Is to be understood as strongly recommended.

ULTRASONIC EXAMINATION PROCEDURE

DSS Duplex Stainless Steel

6.0 Personnel Qualification:

All qualification certification shall be valid (not expired).

7.0 Ultrasonic Examination Procedure:

Ultrasonic examination shall be performed in accordance with a written procedure.

Ultrasonic examination procedure shall be qualified to the satisfaction of the company

ULTRASONIC EXAMINATION PROCEDURE

When procedure qualification is specified, a change of requirement in Essential and Non-

A change of a requirement identified as a nonessential variable does not require

9.0 Essential and Non-Essential Variables:

ULTRASONIC EXAMINATION PROCEDURE

9 Directions and extent of scanning Para 16.0

Records, including minimum calibration data to be

10.0 Surface Preparation:

11.0 Equipment & Accessories:

Ultrasonic Flaw Detector

ULTRASONIC EXAMINATION PROCEDURE

Instrument Performance (Only for Ultrasonic flaw detector)

ULTRASONIC EXAMINATION PROCEDURE

Amplitude Control Linearity

Indication set at % of Full

ULTRASONIC EXAMINATION PROCEDURE

Primary Reference Level for Weld:

For Weld check

13.0 Surface Temperature:

14.0 Calibration Block:

For Weld Piping

ULTRASONIC EXAMINATION PROCEDURE

Maximum scanning speed should not exceed 150mm / sec.

Condition for Internal Imperfection

ULTRASONIC EXAMINATION PROCEDURE

Maximum scanning speed should not exceed 150mm / sec.

17.0 Acceptance Criteria:

For Lamination check

ULTRASONIC EXAMINATION PROCEDURE

For Weld check

A linear-type discontinuity is unacceptable if the amplitude of the indication

(a) 6 mm (1⁄4 in.) for Tw ≤ 19 mm (3⁄4 in.)

(b) Tw/3 for 19 mm < Tw ≤ 57 mm (21⁄4 in.)

(c) 19 mm for Tw > 57 mm

18.0 Post examination cleaning:

ULTRASONIC EXAMINATION PROCEDURE

Heat treatment condition

ULTRASONIC EXAMINATION PROCEDURE