DAYANG ENTERPRISE SDN BHD

SARAWAK SHELL BERHAD

PROVISION OF TOPSIDE MAJOR MAINTENANCE

SERVICES FOR SSB/SSPC

Contract No. : CW408878

DOCUMENT TITLE : ULTRASONIC TESTING PROCEDURE

AS PER ASME SECTION V – PIPING
(CRISTAR)
DOCUMENT NO. : SMEP-2900-QA-6180-0024

DAYANG ENTERPRISE SDN BHD

SSB ACCEPTANCE
REV DOC
ISSUE DATE
CODE STATUS AUTHOR CHECKER APPROVER

NAME NAME NAME NAME DATE NAME DATE

S. Eswaran
Lee Chung
0C 06-Aug-2021 IFR (Cristar Sim Kien Beng
Khiong
NDT Level III)
S. Eswaran
Lee Chung Wan Rossle
01C 25-Apr-2022 IFR (Cristar Sim Kien Beng 03-Jun-2022
Khiong
NDT Level III)

25.04.22
13-June-2022
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REVISION STATUS

Revision Date Section Page Details of Revision

0C 06-08-2021 - - New Document

2 4 2.0 Company Requirements

Removed acceptance criteria for inspection of process
piping
4 8 4.0 Acceptance Criteria
Updated latest edition of ASME B31.3 (2020)
01C 25-04-2022
5 8 5.0 Reference
Updated latest edition of ASME B31.3 (2020)
6 9 6.0 Appendixes
Amendment for Appendix 1 to Procedure No.
CGSB/UT/003, Revision No.02
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TABLE OF CONTENT

CONTENTS PAGE NO.

1.0 PURPOSE 4

2.0 COMPANY REQUIREMENTS 4

3.0 COMPANY PIPING NDT MATRIX 4–7

4.0 ACCEPTANCE CRITERIA 8

5.0 REFERENCE 8

6.0 APPENDIXES 9

Appendix I Procedure For Ultrasonic Testing As Per ASME Section V (Piping) –

Cristar Group Sdn Bhd. (Procedure No. CGSB/UT/003, Revision No. 02)
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1.0 PURPOSE

The purpose of this procedure is to ensure the execution of Ultrasonic Testing Procedure (Piping) adhere
to the COMPANY requirements by CONTRACTOR’s appointed NDE Sub Contractor, Cristar Group Sdn.
Bhd.

2.0 COMPANY REQUIREMENTS

Ultrasonic Testing Procedure (Piping) for different type of piping materials and fluid services shall be based
on COMPANY Piping NDT Matrix (Appendix D) of SES 38.2 Rev 09 August 2020 Shop and Field
Fabrication of Piping.

For CS with CE>0.45% and thickness >19mm, Ultrasonic Testing Procedure (Piping) shall be performed
no sooner than 48 hours after completion of welding, except if entire welding by GTAW process then NDE
shall be performed no sooner than 16 hours. Any exception at offshore sites to be evaluated on case by
case basis.

Execution of this procedure shall be performed by Cristar Group Sdn Bhd based on Procedure No.
CGSB/UT/003 Revision No. 02 as attached in Appendix I.

3.0 COMPANY PIPING NDT MATRIX

Refer to below Appendix D of COMPANY SES 38.2 Shop and Field Fabrication of Piping (Rev. 09, Aug
2020), page 11 - 14 for COMPANY piping NDT matrix.

Piping NDT Matrix

Ferrite Hardness PMI
Material Pressure RT MPI DPI
Service Checks Survey Inspection
(Note 1) Rating (Note 2) (Note 4) (Note 4)
(Note 7) (Note 8) (Note 9)
CS All 100% 10% -
Closed Drain (DC) SS All 100% - 100%
DSS/
All 100% - 100%
SDSS
Drain Drilling (DD) CS 150 10% 10% -
Drain - Open CS 150 10% 10% -
Hazardous (DH)
SS 150 100% - 10%
Diesel Fuel (FD)
CS 150 100% 10%
SS All 100% - 100%
Fuel Gas (FG) DSS/
All 100% - 100%
SDSS
Instrument Air (AI)
CS 150 10% 10%
Utility Air (AU)
SS All 10% 100%
Instrument Gas (IG) DSS/
150 100% 100%
SDSS
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Piping NDT Matrix

Ferrite Hardness PMI
Material Pressure RT MPI DPI
Service Checks Survey Inspection
(Note 1) Rating (Note 2) (Note 4) (Note 4)
(Note 7) (Note 8) (Note 9)
Methanol (MT) CS All 100% 10%
CS All 100% 10%
Glycol (GL) SS All 100% 100%
DSS/
All 100% - 100%
SDSS

Chemicals:
a) Corrosion Inhibitor
(CI)
b) Pour Point
Depressent (CPD)
c) Scale Inhibitor SS All 100% 100%
(CSI)
d) LDHI (CLD)
e) MEG (CEG)
f) Biocide (CBI)
g) Nitrate (CCN)
h) Antifoam (CDF)
i) O2 Scavenger
CS 150 10% 10%
Nitrogen (NT) SS 150 100% 10%
DSS/
150 100% 100%
SDSS
Hydraulic Oil (OH) SS All 100% 100%
Lube Oil (OL)
DSS/
All 100% 100%
SDSS
CS All 100% 100%
Process (P)
SS All 100% - 100%
DSS/
All 100% - 100%
SDSS
CS All 100% 100%
Process Gas/Liquid SS All 100% - 100%
(PG) DSS/
All 100% - 100%
SDSS
CS All 100% 100%
Process Liquid (PL) SS All 100% 100% 100%
DSS/
All 100% 100% 100%
SDSS
Vent Atmosphere CS 150 10% 10%
(VA) SS 150 10% - 10%
Vent Exhaust (VE) CS 150 100% - -
Vent to Flare (VF) SS 150 100% 100%
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Piping NDT Matrix

Ferrite Hardness PMI
Material Pressure RT MPI DPI
Service Checks Survey Inspection
(Note 1) Rating (Note 2) (Note 4) (Note 4)
(Note 7) (Note 8) (Note 9)
Vent HP (VH) CS All 100% 100%
Vent LP (VL) SS All 100% 100%
SS All 100% - 100%
Service Water (WS) DSS/
All 100% - 100%
SDSS
CS All 100% 10%
Produced Water (W) SS All 100% - 100%
DSS/
All 100% - 100%
SDSS
CS 150 100% 10%
DSS/
Sea Water Service All 100% - 100%
SDSS
Titanium All 100% - 100%
SS All 100% 100%
Alkali Surfactant
Polymer (ASP) DSS/
All 100% 100%
SDSS
Acid SS All 100% 100%
Firewater Pipe CS 150 100% 10%
LTCS 150 100% 100%
Relief - Blowdown (BH) LTSS 150 100% 100%
DSS 1500* 100% 100%
Defoamer (CDF) SS 150 100% 100%
Demulsifier (CDM) SS 150 100% 100%
Hypochlorite (WSC) Titanium 150 100% 100%
LDHI - Liq SS 300 100% 100%
Waterflood/ SW
CS 1500* 100% 100%
Injection (WI)
Chemical to LDHI (CLD) DSS 10000* 100% 100%
PPD to Wellhead (CPD) DSS 10000* 100% 100%
PPD to Liq DSS 10000* 100% 100%
Dissimilar
All Services Metal All 100% - 100%
Weldments
GRVE/
(Note 5)
- GRP

Notes:
1. CS (Carbon Steel & Low Temp Carbon Steel), SS (Stainless Steel), DSS (Duplex Stainless Steel), SDSS
(Super Duplex Stainless Steel)
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2. Should welds be examined by UT in lieu of RT, then the UT procedure shall have been demonstrated to the
satisfaction of the client on a qualification block (reference block) that represents the thinnest and thickest
wall thickness to be tested. Should UT be proposed on a SS or DSS weld, then the procedure shall have
been demonstrated to the satisfaction of the client on a qualification block (reference block) made out of
similar materials and configuration, representing the thinnest wall thickness and thickest to be tested (refer
to ASME code case 2235-9 dated Oct 2005). Additional reference to ISO 22825 shall be made especially
weldment inspection involves course grain material such as Stainless Steel, Duplex etc. Suitable inspection
technique such as type of ultrasonic wave (shear or longitudinal), frequency etc shall be used. The UT
operator shall also demonstrate his competency to the satisfaction of the Company. In all of the above, the
UT technique proposed shall be of the ‘recordable’ type such as PAUT unless manual technique (pulsed
echo) at difficult areas such as nozzle, elliptical opening, and restriction of support/saddle pad is assessed
and agreed by principal.
3. Visual inspection shall be 100% for all services and materials.
4. The following shall be 100% MPI or DPI on all cases except nonmetallic line: -
a. Branch-to-run pipe welds of branch connections; and
b. Fillet welds of pipe supports, support clips, saddle plates, shoes, bracings and attachments.
5. GRP/GRE/GRVE joints shall be inspected as per manufacturer’s approved procedure. For those
GRP/GRE/GRVE/GRUP piping subject to vibration, surge or water-hammer, the joint connections shall be
laminated (butt & strap) joints. The pipe manufacturer shall provide a hydraulic design with surge or water-
hammer analysis calculation and shall be the party to fabricate, install and guarantee piping integrity in
accordance with DEP 31.40.10.19-Gen. For other joint types eg adhesive joints, GRP.GRE/GRVE/GRUP
piping shall be installed by installers with qualification certifications by the manufacturer.
6. The requirement for examination of 10 % of the welds shall mean that 10 % of the production welds shall be
randomly and independently selected throughout the fabrication period and fully examined. Refer to DEP
31.38.01.31-Gen.February 2019, 4.2 Non-Destructive Examination, 4.2.1 for details.
7. For 300 series stainless steel (SS 304 is not allowed to be used in all cases), ferrite checks shall be performed
100% on all weldments at each quadrant with a ferritescope. Acceptance criteria shall be between 3 to 8FN.
For DSS/ SDSS, several ferrite readings shall be taken 100% on all the base materials at each quadrant with
a ferrite scope. Individual readings shall be between 35% to 60%. Ferrite reading shall also be taken on all
the weld and HAZ at each quadrant. Individual readings shall be between 35% to 65% in solution annealed
weldments and 30% to 70% for welds in the as welded condition. The acceptance criteria shall be based on
the ferrite scope measurements at any single individual inspection point. The average values of ferrite scope
readings in inspection areas shall not be used to determine the acceptance criteria Detail requirement and
guideline can be referred to the latest revision of SMEP.GEN.ENG.MX.GL.0015 Guideline for Inspection of
New and Existing Duplex Stainless Steel Piping System.
8. Hardness survey for non-sour service production weld, 10% for all carbon steel and CRA listed in section
4.2.3 DEP 30.10.60.18 and this SES 38.2.
100% for all material which are sour service or toxic - acute / very toxic-chronic / very toxic - environment
(see DEP 01.00.01.30-Gen for details) and section 4 of this SES 38.2.
9. 100% PMI is mandatory for corrosion resistant alloys as per requirements of latest revision DEP 31.10.00.10.
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4.0 ACCEPTANCE CRITERIA

4.1 ASME B31.3 Acceptance Criteria Extract from ASME B31.3 Chapter VI Para 344.6.2

All welds to be examined shall be free of:-

a) Indications characterized as cracks, lack of fusion, or incomplete penetration are unacceptable

regardless of length.
b) A discontinuity is unacceptable if the amplitude of the indication exceeds the reference level and
its length exceeds:

(1) 6 mm (¼ in.) for Tw ≤ 19mm (¾ in.)

(2) Tw/3 for 19 mm (¾ in.) < Tw ≤ 57mm (2¼ in.)
(3) 19 mm (¾ in.) for Tw > 57mm (2¼ in.)

Where Tw is the nominal wall thickness, thinner of components joined by butt weld.

5.0 REFERENCE

SES 38.2 (Rev 0, Aug 2020) - Shop And Field Fabrication of Piping
SES 40.1 (Rev 03, Aug 2020) - Ultrasonic Examination
ASME B31.3 (2020) - Process Piping
ASME BPVC.V-2021 (Section V) - Non-Destructive Examination Article 4 & Article 5

6.0 APPENDIXES
Appendix I : Procedure For Ultrasonic Testing As Per ASME Section V (Piping) –
Cristar Group Sdn Bhd. (Procedure No. CGSB/UT/003, Revision No. 02)
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APPENDIX I
PROCEDURE FOR ULTRASONIC TESTING AS PER ASME SECTION V (PIPING) –
CRISTAR GROUP SDN. BHD.
(PROCEDURE NO. CGSB/UT/003, REVISION NO. 02)
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(Written in Accordance to ASME Section V)

CONTENTS

1.0 INTRODUCTION Page 4

2.0 SCOPE Page 4

3.0 PERSONNEL QUALIFICATION Page 4

4.0 PROCEDURE QUALIFICATION Page 4

5.0 SURFACE PREPARATION Page 5

6.0 EXAMINATION COVERAGE Page 5

7.0 COUPLANT Page 5

8.0 RATE OF PROBE MOVEMENT Page 5

9.0 SCANNING SENSITIVITY LEVEL Page 5

10.0 EQUIPMENT Page 6

11.0 CALIBRATION BLOCKS Page 6

12.0 PROBE Page 6

12.1 Normal Probe (Longitude Wave) Page 6

12.2 Angle Probe (Shear Wave) Page 6

12.3 Beam Spread Measurement Page 6

13.0 RESOLUTION Page 7

13.1 Normal Probe Page 7

13.2 Angle Probe Page 7

14.0 DISTANCE-AMPLITUDE-CORRECTION (DAC) Page 7

15.0 SENSITIVITY LEVEL Page 7

16.0 SWEEP RANGE CALIBRATIONS Page 7

17.0 VISUAL INSPECTION Page 7

18.0 TEST LIMITATIONS Page 7

19.0 SCANNING PROCEDURES Page 8

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19.1 Straight Beam Search Unit Page 8

19.2 Angle Beam Search Unit Page 8

19.3 Parent Metal Testing Page 8

19.4 Weld Testing Procedure Page 9

19.5 Testing of Weld Root Page 10

(Applicable for Joints Welded from One Side Only)

19.6 Testing of Weld Body Page 10

19.7 Scanning Sensitivity for Weld Root Page 10

19.8 Discontinuity Location, Sizing and Evaluation Page 11

20.0 ACCEPTANCE CRITERIA Page 13

21.0 REPORTING Page 29

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CONTENTS

Figure 1 IIW VI Block Page 17

Figure 2 IIW VI Block Page 17

Figure 3 IOW Block Page 17

Figure 4 Transducer Crystal Page 17

Figure 5 Transducer Movement Page 18

Figure 6 ASME Basic-Calibration Block Page 19

Scanning Technique No. ST01 – Single V Butt Weld Page 20

Scanning Technique No. ST02 – Double V Butt Weld Page 20

Scanning Technique No. ST03 – Single Sided Set Through Nozzle Weld Page 21

Scanning Technique No. ST04 – Double Sided Set Through Nozzle Weld Page 21

UT Technique sheet Page 23

Appendix 1 Report Sheet of Ultrasonic Testing Page 29

ATTACHMENT

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1.0 INTRODUCTION
This procedure is developed to cover the Manual Ultrasonic Testing requirements for industrial
work as carried by CRISTAR GROUP Sdn Bhd.
When required by the referencing Code Section, this testing method performed under the
following written procedure shall be demonstrated to the satisfaction of the Authorized
Inspector as per the requirements of ASME Boiler And Pressure Vessel Code Section V (2021
edition,) Article 1, Para T-150.

2.0 SCOPE
2.1 This Procedure applies to the Ultrasonic Testing of partial and/or full penetration butt
joints in the following fabrication:
a) Pressure Vessels in accordance to the requirements of ASME Section VIII Division 1
and 2.
b) Power Boiler in accordance to the requirements of ASME Section 1.
c) Power Piping in accordance to the requirements of ANSI/ASME B 31.1.
d) Chemical Plant and Petroleum Refinery Piping in accordance to the requirements
of ANSI/ASME B 31.3.
2.2 Welded joints shall be form of longitudinal and circumferential welds as in plate (rolled
or unrolled) and dish to shell, pipe to pipe, neck to neck, pipe to attachment such as
reducer, weldolet and flange.
2.3 Material type shall be of carbon or alloy steel of thickness 8.0 mm and above.
2.4 This procedure is developed to be in compliance with ASME Boiler and Pressure Vessel
Code Section V Article 4, 2019 Edition.
2.5 When specified by a referencing Code Section, the method described in this procedure
shall apply. Should there be any conflict arising between this procedure and the
referencing code section used, it shall be resolved, noted and agreed by all parties
concerned prior to commencement of the inspection.

3.0 PERSONNEL QUALIFICATION

Personnel performing Ultrasonic Testing shall be:
3.1 Level II or Level III Ultrasonic Testing technician certified in accordance with CRISTAR
GROUP Sdn Bhd. Procedure for Qualification and Certification of Non-Destructive
Personnel11 , Revision 00 according to SNT-TC-1A 2006, or
3.2 MLVK Level II or PCN/CSWIP.

3.3 The Personnel shall have at least three (3) years of working experience in Oil and Gas.

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3.4 The Personnel shall have served for at least two (2) years in the position.

3.5 The Personnel shall be certified as ASNT Level II Ultrasonic Technician. The personnel
shall perform Ultrasonic Testing and reporting of groove butt welds, full penetration
welds and node joints in structural, and UT for Thickness Gauging and Detection of
lamination for materials.

4.0 PROCEDURE QUALIFICATION

4.1 A change of a requirement in Table 1 identified an essential variable shall require re-
qualification
4.2 A change of a requirement in Table 1 identified as non-essential variable does not
require re-qualification of this procedure
4.3 A changes of essential and non-essential variables shall require revision or addendum of
this procedure

5.0 SURFACE PREPARATION

5.1 Surface through which scanning must be undertaken shall be free from spatter, scale,
loose paint dust and grit slag, irregularities and of such curvature that a free and smooth
motion of the probe is not restricted and or interfere with ultrasonic wave transmission
5.2 Surface condition shall be such that a satisfactory coupling between the probe and the
work piece can be maintained.
5.3 Where surface roughness of material differs from the basic calibration block surface
used, transfer loss or gain dB shall be added or subtracted from the reference level
obtained from the calibration block.
5.4 Accurate information of the following shall be made available from client before
commencement of testing.
a. The type of ferrite steel.
b. The joint preparation
c. Welding process
d. Detail of any repairs.

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6.0 EXAMINATION COVERAGE

6.1 Inspection area shall cover 100% of the area of interest on plates or welds including
areas where scanning is to be performed (parent metal).
6.2 Scanning shall be from all surfaces accessible such that the entire section is tested. As a
minimum, each pass of the search unit shall overlap a minimum of 10% of the
transducer dimension perpendicular to the direction of the scan.

7.0 COUPLANT
Couplant used shall be of water, light machine oil, general purpose grease or water soluble gel
(starch) depending on the test surface finish and plate temperature. The choice of couplant shall
be that when used would not be harmful, or detrimental to the part being tested or would
interfere with its subsequent processes or service requirements.

8.0 RATE OF PROBE MOVEMENT

The rate of probe movement shall not exceed 150 mm per second unless calibration is verified
at scanning speed.

9.0 SCANNING SENSITIVITY LEVEL

Scanning shall be carried out at a gain setting of at least two (2) times the reference level. During
scanning, only the gain or attenuator controls will be adjusted. Any adjustment of the other
controls shall require re-calibration.

10.0 EQUIPMENT
10.1 Ultrasonic flaw detectors shall be of Panametric Epoch III or IV, Olympus EPOCH 650,
Sonatest Sitescan D50, Krautkramer Model USK 6, 7 or equivalent for contact technique.
10.2 The instrument shall be of Pulse Echo 'A' Scan presentation type and capable of
generating frequencies over the normal range of 1 MHz to 5 MHz and capable of
presenting a clean crisp trace on the Horizontal Base Line.
10.3 Screen height linearity shall be within +/- 5 % of the full time.
10.4 Horizontal linearity shall be within +/- 2 % of the full base.
10.5 Amplitude control linearity shall be accurate over its useful range to +/- 20% of the
nominal amplitude ratio.
10.6 Gain (dB) controls shall be incorporated with fine steps of 2dB and shall be able to
display necessary amplitude sensitivity required to test.
10.7 Instrument shall be stabilized and warmed up for not less than 5 minutes prior to
performing examination.

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11.0 CALIBRATION BLOCKS

Steel Calibration Blocks shall be:
a) Step wedge of thickness ranging 2 mm to 25 mm in steps of 2 mm.
b) INTERNATIONAL INSTITUTE OF WELDING -IIW VI & V2 Blocks.
c) ASME Basic Calibration Block
d) INSTITUTE OF WELDING - IOW Resolution Block.

12.0 PROBE
Probe shall be of single crystal or twin crystal type.
12.1 Normal Probe (Longitudinal Wave)
a) Crystal size (transmitting and/or receiving - twin or single) Diameter: 10 mm to
30 mm
b) Frequency: 2 mHz to 5 mHz. Other frequencies may be used to supplement this
transducer for flaw evaluation.
12.2 Angle Probe (Shear Wave)
a) Crystal size (transmitting and/or receiving - single) Rectangular: 8 mm x 9 mm
b) Frequency: 2 mHz to 5 mHz. Other frequencies may be used to supplement this
transducer for flaw evaluation
c) Angle of refraction in steel: 45, 60 and 70 degrees
d) Angle Tolerance in steel: +- 2 degrees.
12.3 Beam Spread Measurement
Measurement of beam spread in the vertical plane of angle beam search units shall be at
a monthly basis and shall be recorded.

13.0 RESOLUTION
The combination of the probes and instrument shall be such that resolution shall meet the
following requirements.
13.1 Normal Probe
Resolution of the 85 mm, 91.0 mm and 100.0 mm notches on IIW VI block shall be
clearly discernible of the Horizontal Time Base.
13.2 Angle Probe
Resolution of the holes in the IOW Beam profile Resolution Block shall be clearly
discernible.
Note: Echo traces displayed shall be the mid range of the time base with gain set at 50%
Full Screen Height.
13.3 Other requirements with regards to instrument and system calibration shall be within

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the requirements of ASME Section V, Article 4.

13.4 Resolution check on all probes shall be carried out on a monthly basic and shall be
recorded.

14.0 DISTANCE-AMPLITUDE-CORRECTION (DAC)

DAC shall be used when determining the primary reference level and shall be plotted on the
screen face. Method shall be as recommended in ASME V Article 4 NONMANDATORY
APPENDIXES B and C.

15.0 SENSITIVITY LEVEL

Sensitivity level shall be such that primary reference level is 80% Full Screen Height obtained
from the Base Calibration Block.

16.0 SWEEP RANGE CALIBRATIONS

Test range used shall depend on the material thickness and scan technique (single traverse or
double traverse) used during testing.

17.0 VISUAL INSPECTION

The scan areas and weldment where accessible shall be visually inspected for surface
peculiarities or surface imperfections.

18.0 TEST LIMITATIONS

Where any factor occur affecting the integrity of the test results such as restricted accessibility,
unsuitable weld preparation, etc., these shall be recorded and brought to the attention of the
client.

19.0 SCANNING PROCEDURES

All weld joints including parent metal shall be tested using the applicable scanning pattern.
19.1 Straight Beam Search Unit
19.1.1 Scanning movement B: Scanning distance B shall be such that the section
covering the entire scanning zone for the subsequent weld is being tested.
19.1.2 Scanning movement C: Progression distance shall be approximately one half the
transducer widths.
19.1.3 Scanning movement D: Lateral movement for sizing of a discontinuity length to

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be used only when welds are ground flushed.

19.1.4 Movements Band C: Combined into one scanning pattern with scanning speed
not exceeding 150mm/sec. 10% overlap shall be maintained.
19.2 Angle Beam Search Unit
19.2.1 Scanning movement A : Rotational movement (rotation angle = 10 deg) for
detection of transverse discontinuities and confirmation of planar and cylindrical
discontinuities.
19.2.2 Scanning movement B: Scanning distance B shall be such that the section of
weld being tested is covered; transverse movement for determination of a
discontinuity height.
19.2.3 Scanning movement C: Progression distance C shall be approximately one-half
the transducer width.
19.2.4 Scanning movement D: For detection of transverse discontinuities and to be
used when welds are ground flush.
19.2.5 Scanning movement E: To be used when the weld reinforcement is not ground
flush. (Scanning angle = 15 deg. max.).
19.2.6 Movements A, Band C: Combined into one scanning pattern with scanning speed
less than 150mm per second. 10% overlap shall be maintained
19.3 Parent Metal Testing
19.3.1 Parent metals at attachment areas on main members regardless of thickness
and on chord member 25mm and above, shall be ultrasonically tested in
accordance with A 435/A 435.
19.3.1.1 A 100% of a major test surface shall be scanned with no less
than 10% overlap between each path.
19.3.1.2 Record all discontinuities causing complete loss of back
reflection. For materials % in (20mm) thick and over record all
indications with amplitude equal to or greater than 50% of the
initial back reflection and accompanied by 50% loss of back
reflection.
19.3.1.3 Acceptance rejection criteria shall be as per ASTM A 435 Para 6.

19.3.2 Calibration for straight beam testing of base metal shall be made with the
search unit applied to the testing surface of the parent metal and performed as
follows:
19.3.2.1 The horizontal sweep shall be adjusted for distance calibration
to present the equivalent of a least two thickness on the CRT
screen.

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19.3.2.2 The sensitivity shall be adjusted at a location free of indications

so that the first back reflection from the far side of the material
will be 50 to 75% of full screen height.
19.3.3 The entire parent metal through which ultrasound must travel to test the weld
shall be scanned with straight beam search unit in accordance with Clause 19.1
after setting the sensitivity in accordance with Clause 19.3.2.
19.3.4 If any of parent metal exhibits total loss of back reflection or an indication equal
to or greater than the original back reflection height is located in a position that
will interfere with the normal technique of scanning during subsequent weld
inspection by angle beam search unit, the practicability of an effective test shall
be determined. Otherwise, alternative scanning technique to be applied that
will ensure the maximum possible local coverage of the full cross section of the
weld shall be employed.
19.3.5 Report on the parent metal testing shall be made describing the type of flaw, its
size, location and depth from the testing surface. If no flaw is detected, a
statement that the parent metal test was satisfactorily undertaken shall be
made on the ultrasonic test report for weld testing.
19.3.6 When large reflector (discontinuity) is detected in the parent metal its length
shall be determined by employing 6 dB drop technique.
Note : Large reflector is one whose diameter/length is greater than the beam cross-
section at the testing range.
19.3.7 20 dB drop technique shall be used for the approximate size evaluation of small
reflector (discontinuity) present in the parent metal.
19.3.8 For T and corner joints in plates and beams scanning using straight beam search
unit shall also be carried out when accessible. This examination is to ensure no
under bead crack exist.
19.4 Weld Testing Procedure
19.4.1 Welds shall be tested using an angle beam search unit conforming to the
requirements of Clause 19.2 with the instrument calibrated in accordance with
Clause 19.4.2. Welds shall be tested using all angle probes 45 deg., 60 deg. or 70
deg. where applicable.
19.4.2 Calibration for angle beam testing shall be performed as follows:
19.4.2.1 The horizontal sweep shall be adjusted to represent 100mm or
200mm or actual sound path distance by using the IIW VI or V2.
19.4.2.2 The horizontal location of all screen indication is based on the
location at which the left side of the trace deflection breaks the
horizontal base line.

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19.4.2.3 Sensitivity setting - the basic or reference level sensitivity used

for flaw evaluation is attained by adjusting the calibrated gain
control of the flaw detector in accordance with guideline
outlined below:-
19.4.2.3.1 Set the search unit in position ASME Basic
Reference Block
19.4.2.3.2 Adjust the gain control until indication level
from the 1/4T hole is at approximately 80%
screen height and mark the peak on screen.
19.4.2.3.3 With set gain control as per 19.4.2.3.2 above,
mark the Peaks level from ½T and ¾ T holes.
19.4.2.3.4 Using a marker, connect the peak points of
l/4T, l/2T and 3/4T holes on the screen to form
a DAC curve.
19.5 Testing of Weld Root (Applicable for Joints Welded from One Side Only)
19.5.1 Weld Root areas shall be tested separately from the remainder of the weld by
using a 45 deg, 60 deg, or 70 deg nominal angle search unit where applicable.
The UT operator shall check that root indices are marked to provide exact
location of the root face during the ultrasonic testing and aid in differentiation
of root defects from root protrusion.
19.5.2 Scanning of weld root areas shall be made in Leg 1 (1/2 skip) except in heel
zone, when the root area is inaccessible to Leg 1, scanning made in Leg III (11/2
skip) is acceptable. However, when scanning has to be made in Leg III, only
angle beam search unit with 2 or 2.5 MHz shall be used.
19.5.3 The beam angle shall be maintained perpendicular to the axis of the weld.
19.5.4 When the generally continuous echo from the root protrusion is interrupted or
shifted in reflection position, the horizontal scale shall be expanded to include
only the region of interest to ensure that the interruption or sound path
distance shift is due to acceptable change in root geometry and not the
presence of a discontinuity.
19.6 Testing of Weld Body
19.6.1 After testing of the weld root area, the remainder of the weld is scanned as
mentioned in 19.6.2 to 19.6.4.
19.6.2 Scanning movement shall be as specified in Clause 19.2 with the search unit
oriented in a plane perpendicular to weld axis. In case of nozzles connections,
the search unit shall be oriented in a plane perpendicular to the local weld axis
rather than the brace axis.
19.6.3 The length of the transferring movement (Scanning movement B) shall be a

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surface distance equivalent to at least 1.5 times the skip distance.

19.6.4 Indication found along the fusion face of the weld shall be further evaluated
using angle beam search unit, whichever is nearest to being perpendicular to
the expected fusion face. If higher reflection amplitude is shown on the CRT, the
angle beam search unit selected shall be used to determine acceptability of the
indication and rejectable length .
19.7 Scanning sensitivity for weld root (when applicable) and weld body testing shall be basic
sensitivity + distance amplitude correction.

19.8 Discontinuity Location, Sizing, and Evaluation

19.8.1 Weld or HAZ discontinuity location in angle beam testing shall be attained by a
triangulation technique using the incident sound beam angle, a measured
surface distance to weld toe and a sound path distance obtained from the
horizontal scale of the CRT.
19.8.2 The beam boundary intercept technique shall be used to estimate the length of
discontinuity less than the width of beam spread at the discontinuity depth.
This technique shall also be used to estimate the height of a discontinuity
regardless the length is greater or less than the width of beam spread at the
discontinuity depth.
19.8.3 Discontinuity length shall be approximately by the maximum amplitude
technique. To minimize errors in the length measurements in tubular
member, actual discontinuity length shall not be obtained by measuring the
shift distance of the search unit on the curve surface instead measurement
shall be taken by plotting the sound beam at the depth of discontinuity.
19.8.4 Estimation of length or size of any discontinuity with amplitude more than half
(6 dB) the standard sensitivity level shall be performed with the gain of the
discontinuity indication adjusted to attain the standard sensitivity level prior to
determination of length or size.
19.8.5 Discontinuities shall be classified as linear or planar versus spherical, by noting
changes in the amplitude as the search unit swing in an arc centered on the
discontinuity.
19.8.6 A spherical discontinuity is one in which its length is three times its width or
less and may be round or irregular.
19.8.7 When two or more linear or planar discontinuities are not separated by at least
the length of the longer discontinuity up to the standard sensitivity level, these
discontinuities shall be considered a single linear or planar discontinuity.

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20.0 ACCEPTANCE CRITERIA

The following acceptance standards shall apply unless other standards are specified for specific
applications.
20.1 Base Metal Testing
Acceptance criteria shall be in accordance with ASME Section V Article 23, SA435/435M.
Any discontinuity indication causing a total loss of back wall reflection of which cannot
be contained within a circle, the diameter of which is 75 mm or one half plate thickness.
Whichever is greater is unacceptable.
20.2 Pressure Vessels fabricated in accordance with ASME Section VIII Division I and piping
fabricated in accordance with ASME/ ANSI B31.3 shall conform to ASME VIII Division 1
Appendix 12.
20.3 Pressure Vessels fabricated in accordance with ASME Section VIII Division 2 shall
confirm to Para 7.5.4.2.
20.4 Power Boilers fabricated in accordance with ASME Section I and piping fabricated in
accordance with ASME/ ANSI B31.1 shall conform to ASME Section I PW -52.
20.5 For Piping: ASME/ANSI B31.3 (2020) para 344.6.2

20.6 For Structural

20.6.1 Base metal:

- ASME V (2021) Article 23, SA-435 para 7.1

- AWS D1.1 (2020) para 8.19.4 and 8.25.5

20.6.2 Weldment

- AWS D1.1 (2020) Class R

20.7 All indications having one-half (6dB) or less amplitude than the sensitivity level shall be
disregarded. Indications exceeding the disregard level shall be evaluated as follows:

20.7.1 Isolated random spherical reflectors, with I in (25mm) minimum separation up

to the standard sensitivity level shall be accepted. Larger reflectors shall be
evaluated as linear reflectors.

20.7.2 Aligned spherical reflectors shall be evaluated as linear reflectors.

20.7.3 Cluster spherical reflectors having a density of more than one per square inch
(645 square millimeters) with indications above the disregard levels (projected

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area normal to the direction of applied stress, averaged over a 6 in (150mm)

length of weld) shall be rejected.

20.7.4 Linear or planar reflectors whose lengths (extent) exceed the limits of figure
9.29 shall be rejected. Additionally, root reflectors shall not exceed the limit of
Class X.

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8.19.4 Base metal. These procedures are not intended to be

employed for the procurement testing of base metals. However,
welding related discontinuities (cracking, lamellar tearing,
delaminations, etc.) in the adjacent base metal which would not
be acceptable under the provisions of this code shall be reported
to the Engineer for disposition

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8.25.5 Extent of testing. The entire base metal through which

ultrasound must travel to test the weld shall be tested for laminar
reflectors using a straight-beam search unit conforming to the
requirements of 8.21.6 and calibrated in conformance with
8.24.4. If any area of base metal exhibits total loss of back
reflection or an indication equal to or greater than the original
back reflection height is located in a position that will interfere
with the normal weld scanning procedure, its size, location, and
depth from the Face A shall be determined and reported on the
UT report, and an alternate weld scanning procedure shall be
used.

21.0 REPORTING
a) Client.
b) Date of testing.
c) Project and item reference.
d) Material - type, thickness.
e) Weld preparation, process.
f) Procedure number.
g) Couplant used.
h) Surface condition.
i) Equipment type and serial number.
j) Calibration block used.
k) Probe used.
l) Test sensitivity.
m) Technique.
n) Nature of test.
o) Acceptance criteria.
p) Results.
q) Examiner.

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TABLE 1

Essential Non Essential

Requirement Ref
Variable Variable

Material Type & configuration to be examined, including X 2.0

thickness dimensions and base material product form
(casting, pipe, plate, etc.)

The surfaces from which the examination shall be performed X 19

Technique(s) (straight beam, angle beam, contact, and/or
immersion)
Angle(s) and mode(s) of wave propagation in the material X 10
Search unit type(s), frequency (ies) and element size(s)/
X 10
shape(s)
Special search units, wedges shoes, or saddles, when used X 10 & 12
Ultrasonic instrument(s) X 10
Calibration (calibration block(s) and technique(s) X 11
Direction and extent of scanning X 19
Scanning (manual vs. automatic) X 1.0
Method of discriminating geometric from flaw indications X 19.8
Method of sizing indications X 19.8
Computer enhanced data acquisition, when used X Not in use
Scan overlap (decrease only) X 6.0
Personal performance requirement, when required X 3.0
Personal qualification requirements 3.0 X
Surface condition (examinassions surface, calibration block) 5.0 X
Couplant: brand name and type 7.0 X
Automatic alarm and/or recording equipment, when
Not in use X
applicable
Records, Including minimum calibration data to be record
12.0 X
(e.g. instrument
Settings)

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ULTRASONIC TESTING

COMPONENT : Full Penetration - T-joint - Scanning from both faces.

MATERIAL : Carbon Steel MATERIAL THICKNESS : 8mm and above
WELDING PROCESS : Fusion Welding
JOINT PREPARATION : Double Bevel
COUPLANT : Starch EQUIPMENT : Pulse Echo
CALIBRATION BLOCKS : IIW V1 and V2 blocks. ASME V Basic Calibration Block.
PROBES : Frequency Range: 2.25 to 5 Mhz PROBE SELECTION :
0 Probe : Any dimension of transducer 6 - 12 mm = 70
not to exceed 25 mm 13-25 mm = 60 and 70
Angle Probe : Transducer dimension in the Above 25 mm = 60 and 45
range of 10mm, rectangular or supplemented by 70
circular in shape.

(Either twin or single crystal may be used)

TIME BASE CALIBRATION : 0 - At least twice the test thickness.

Angle Probe - 100 mm across screen or 1 skip range whichever is greater.

SENSITIVITY SETTING : Signal from side-drilled hole and surface notch as per ASME V Fig. T-542.2.1.

CODE/SPEC. : ASME VIII Div. 1/2, Appendix 12 or ASME I Para. PW-52, 1995 Edition.

SKETCH

B
0o A

If accessible 3/4 Skip

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INSPECTION SEQUENCE

1.0 0 Probe - scan until 1 skip distance from weld on face A. If accessible, scan from B for lamellar tearing
and lack of fusion. See Para 7.5.
2.0 Root Scan - as per section 6.3. Then scan the whole volume of weld with other appropriate angle probes.
3.0 Minimum scanning level - Primary Reference Level Plus Transfer Correction plus required gain setting where
2mm high grass-signals from opposite face are observed (see section 7.1).
4.0 Defect sizing shall be carried out at Primary Reference Level Plus Transfer Correction.
5.0 Acceptance Criteria refer to ASME VIII Div. 1 Appendix 12 or ASME I Para. PW-52 (Appendix IX).
6.0 All defective areas shall be marked, with cross section of defective weld marked adjacent to defective area.
7.0 All scanning limitation shall be reported.
8.0 Acceptance indication that exceeds 50% DAC shall be recorded. See Para 7.4.

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ULTRASONIC TESTING

COMPONENT : Full Penetration - T-joint - Scanning from one face only.

MATERIAL : Carbon Steel MATERIAL THICKNESS : 8mm and above
WELDING PROCESS : Fusion Welding
JOINT PREPARATION : Double Bevel
COUPLANT : Starch EQUIPMENT : Pulse Echo
CALIBRATION BLOCKS : IIW V1 and V2 blocks. ASME V Basic Calibration Block.
PROBES : Frequency Range : 2.25 to 5 Mhz PROBE SELECTION :
0 Probe : Any dimension of transducer 6 - 12 mm = 70
not to exceed 25 mm 13-25 mm = 60 and 70
Angle Probe : Transducer dimension in the Above 25 mm = 60 and 45
range of 10mm, rectangular or supplemented by 70
circular in shape.

(Either twin or single crystal may be used)

TIME BASE CALIBRATION: 0 - At least twice the test thickness.

Angle Probe - 100 mm across screen or 1 - 1/2 skip range whichever is greater.

SENSITIVITY SETTING : Signal from side-drilled hole and surface notch as per ASME V Fig. T-542.2.1.

CODE/SPEC. : ASME VIII Div. 1/2, Appendix 12 or ASME I Para. PW-52, 1995 Edition.

SKETCH
3/4 Skip
B
0o A

0o
If accessible

INSPECTION SEQUENCE
1.0 0 Probe - scan until 1- 1/2 skip distance from weld on face A. If accessible, scan from B for lamellar tearing
and lack of fusion. See Para 7.5.
2.0 Root Scan - as per section 6.3. Then scan the whole volume of weld with other appropriate angle probes.
3.0 Minimum scanning level - Primary Reference Level Plus Transfer Correction plus required gain setting where
2mm high grass-signals from opposite face are observed (see section 7.1).

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4.0 Defect sizing shall be carried out at Primary Reference Level Plus Transfer Correction.
5.0 Acceptance Criteria refer to ASME VIII Div. 1 Appendix 12 or ASME I Para. PW-52 (Appendix IX).
6.0 All defective areas shall be marked, with cross section of defective weld marked adjacent to defective area.
7.0 All scanning limitation shall be reported.
8.0 Acceptance indication that exceeds 50% DAC shall be recorded. See Para 7.4.

ULTRASONIC TESTING

COMPONENT : T and K - Joint-Scanning from external surface of stub only.

MATERIAL : Carbon Steel MATERIAL THICKNESS : 8mm and above
WELDING PROCESS : Fusion Welding
JOINT PREPARATION : Single Bevel
COUPLANT : Starch EQUIPMENT : Pulse Echo
CALIBRATION BLOCKS : IIW V1 and V2 blocks. ASME V Basic Calibration Block.
PROBES : Frequency Range : 2.25 to 5 Mhz PROBE SELECTION :
0 Probe : Any dimension of transducer 6 - 12 mm = 70
not to exceed 25 mm 13-25 mm = 60 and 70
Angle Probe : Transducer dimension in the Above 25 mm = 60 and 45
range of 10mm, rectangular or supplemented by 70
circular in shape.
(Either twin or single crystal may be used)

TIME BASE CALIBRATION : 0 - At least twice the test thickness.

Angle Probe - 100 mm across screen or 1 - 1/2 skip range whichever is greater.

SENSITIVITY SETTING : Signal from side-drilled hole and surface notch as per ASME V Fig. T- 542.2.1.

CODE/SPEC. : ASME VIII Div. 1/2, Appendix 12 or ASME I Para. PW-52, 1995 Edition.

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SKETCH

INACCESSIBLE

CHORD MEMBER STUB-SET ON TUBULAR

BRANCH

1¼
Skip

INSPECTION SEQUENCE
1.0 0 Probe - scan until 2 skip distance on the stub surface from chord member. See Para 7.5.
2.0 Root Scan - as per section 6.3. Then scan the whole volume of weld with other appropriate angle probes.
3.0 Minimum scanning level - Primary Reference Level Plus Transfer Correction plus required gain setting where
2mm high grass-signals from opposite face are observed (see section 7.1).
4.0 Defect sizing shall be carried out at Primary Reference Level Plus Transfer Correction.
5.0 Due to the curvature of the stub, small diameter probes shall be used. All indication, high or low amplitude,
within testing range shall be carefully evaluated.
6.0 Due to joint configuration, it is fillet at the heel of T - and K - joint where full penetration is not easily
achievable. It is acceptable as long as the stub member is fully welded to the chord member.
7.0 Acceptance Criteria refer to ASME VIII Div. 1 Appendix 12 or ASME I Para. PW-52 (Appendix IX).
8.0 All defective areas shall be marked, with cross section of defective weld marked adjacent to defective area.
9.0 All scanning limitation shall be reported.
10.0 Acceptance indication that exceeds 50% DAC shall be recorded. See Para 7.4.

ULTRASONIC TESTING

COMPONENT : Y - Joint - Scanning from external and internal surface of stub.

MATERIAL : Carbon Steel MATERIAL THICKNESS : 8mm and above
WELDING PROCESS : Fusion Welding
JOINT PREPARATION : Single Bevel
COUPLANT : Starch EQUIPMENT : Pulse Echo
CALIBRATION BLOCKS : IIW V1 and V2 blocks. ASME V Basic Calibration Block.
PROBES : Frequency Range: 2.25 to 5 Mhz PROBE SELECTION :
0 Probe : Any dimension of transducer 6 - 12 mm = 70
not to exceed 25 mm 13-25 mm = 60 and 70
Angle Probe : Transducer dimension in the Above 25 mm = 60 and 45
range of 10mm, rectangular or supplemented by 70

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circular in shape.

(Either twin or single crystal may be used)

TIME BASE CALIBRATION : 0 - At least twice the test thickness.

Angle Probe - 100 mm across screen or 1 skip range whichever is greater.

SENSITIVITY SETTING : Signal from side-drilled hole and surface notch as per ASME V Fig. T-542.2.1.

CODE/SPEC. : ASME VIII Div. 1/2, Appendix 12 or ASME I Para. PW-52.

SKETCH
1½ Skip

IF ACCESSIBLE

45o ONLY

INSPECTION SEQUENCE

1.0 0 Probe - scan until 2 skip distance on the stub surface. See Para 7.5.
2.0 Root Scan - as per section 6.3. Then scan the whole volume of weld with other appropriate angle probes.
3.0 Minimum scanning level - Primary Reference Level Plus Transfer Correction plus required gain setting where
2mm high grass-signals from opposite face are observed (see section 7.1).
4.0 Defect sizing shall be carried out at Primary Reference Level Plus Transfer Correction.
5.0 Due to the curvature of the stub, small diameter probes shall be used. All indication, high or low amplitude,
within testing range shall be carefully evaluated.
6.0 Due to joint configuration, it is fillet at the heel of Y - joint where full penetration is not easily achievable. It is
acceptable as long as the stub member is fully welded to the chord member.
7.0 Acceptance Criteria refer to ASME VIII Div. 1 Appendix 12 or ASME I Para. PW-52 (Appendix IX).
8.0 All defective areas shall be marked, with cross section of defective weld marked adjacent to defective area.
9.0 All scanning limitation shall be reported.
10.0 Acceptance indication that exceeds 50% DAC shall be recorded. See Para 7.4.

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Appendix 1

ATTACHMENT
UT TEST REPORT

Page 29 of 29
 CRISTAR GROUP SDN BHD (1228739-X)
Head Quarters (Miri)
Lot 1580, Eastwood Valley Industrial Park, Jalan Miri Bypass, 98000 Miri, Sarawak.
Tel: 085-420933 / 086-310091 Fax: 085-428042 Email: info@cristargroup.com
Bintulu Branch
No.20, Jayhub Industrial Estate, Jalan Tun Hussein Onn, Lot 558 Block 32 Kemena Industrial,
97000 Bintulu, Sarawak
Labuan Branch
Lot 6875, Taman Bestari Warehouse, Kampung Patau-Patau 2, 87000 Labuan Federal Territory

ULTRASONIC TESTING FLAW DETECTION REPORT

CLIENT : REPORT NO. :
PROJECT : REQUEST NO. :
REFERENCE NO. :
PROCEDURE NO.: : TEST DATE :
ACC CRITERIA : LOCATION :

SPECIMEN DATA
MATERIAL : COUPLANT :
TESTING TEMPERATURE : WELDING PROCESS :
SURFACE CONDITION : MATERIAL THICKNESS :
ITEM INSPECTED : JOINT DETAILS :

EQUIPMENT PROBES
ULTRASONIC UNIT : FREQUENCY SIZE TRANSFER REFERENCE
ANGLE SC/TC S/NO.
SERIAL NO. : (MHz) (MM) LOSS (dB) SETTING (dB)
CALIBRATION BLOCK :
REFERENCE BLOCK :

UT DATA
CALIBRATION : SCANNING TECHNIQUE :
SENSITIVITY : SIZING TECHNIQUE LENGTH :
HEIGHT (WIDTH) :

PARENT MATERIAL
DESCRIPTION
THICKNESS LENGTH TESTED DISCONTINUITY WELDER
JOINT NO. RESULTS REMARKS
(MM) (MM) DAC% RESP. DEFECT DEPTH (MM) LENGTH (MM) NO.

REMARKS:

CRISTAR GROUP SDN BHD: VERIFIED BY: CLIENT ACCEPTANCE:

NAME: NAME: NAME:

SIGNATURE: SIGNATURE: SIGNATURE:

DATE: DATE: DATE:

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