001.17079.000076 Da0001 Rev04 A
001.17079.000076 Da0001 Rev04 A
Notes :
Cover-Page-Version-SO17079-vA5
ULTRASONIC TESTING
TITLE:
PROCEDURE - STRUCTURAL
Legend on Revision
Rev.A, Rev.B and so on shall be 04 28-April-23 Issued for review and approval Dhinesh
used “For Review and Approval”.
03 01-Nov-22 Issued for review and approval Dhinesh
02 06-Oct-22 Issued for review and approval Dhinesh
Rev.0 shall be used for
“Approved for Construction” and 01 09-Sep-22 Issued for review and approval Dhinesh
Rev.1, 2, 3 and so on for further
revision. 00 30-Jun-22 Replica document from Prosperity project Saravana
DATE : 28-April-2023
SECTION
TITLE PAGE
1.0 SCOPE 03
2.0 REFERENCES 03
5.0 COUPLANTS 03
6.0 EQUIPMENT 04
9.0 TECHNIQUE 05
10.0 CALIBRATION 06
11.0 EXAMINATION 06
13.0 EVALUATION 08
19.0 REPAIR 09
21.0 REPORTING 10
1. SCOPE
1.1 This procedure describes the ultrasonic examination of structural welds, parts, components of carbon
steels existing in range of thickness from 10mm and upto 200mm.This procedure provides the
Ultrasonic examination. Using pulse echo testing (Contact Method) of groove welds and heat
affected zone (HAZ) in Non-tubular steel structure for ONE GUYANA FPSO.
1.2 This procedure shall be prohibited for testing tube-to-tube T-, Y-, or K-connections.
1.3 All welds shall be 100% visually inspected and accepted prior to carrying out NDT.
1.4 For steel grades with SMYS < 415 MPa the testing of welds for acceptance shall be performed not
sooner than 24 hours after completion.
1.5 For steel grades with SMYS = 415 MPa, testing for acceptance shall not be performed sooner than 48
hours after completion.
1.6 Testing of shop welds shall be done prior to field installation.in all acceptance testing of PWHT parts
shall be carried out at any time after PWHT and when cooled to ambient temperature. Only the final
acceptance inspection is required to meet the 24hour / 48 hour specified hold period. On process NDE
inspection by the CONTRACTOR is not limited.
2. REFERENCES
2.1 AWS D1.1 (2020 Edition) – Structural Welding Code – Steel
2.2 ASTM E164-19 (2019 Edition) – Standard Practice for Contact Ultrasonic Testing of Weldments.
2.3 ASME Sec V :2021 – Nondestructive Examination
2.4 PECEMCPF999004 -Material & Corrosion protection Structural Steel Fabrication Supporting
Specification
2.5 PESDMCPF999003-FPSO Structural Welding & Fabrication Specification.
2.6 PECEMCPF999003-Materials - Structural Steel Fabrication - Specification
2.7 ISO 9712 – Personnel Qualification and Certification in NDT
2.8 *ABS guide for Non Destructive Inspection of Hull Welds (2020 Edition)
3 PERSONNEL
3.1 Personnel performing and evaluating ultrasonic testing shall be qualified and certified to ISO 9712
Level 2 certification schemes such as PCN, CSWIP or ISO Level II.
3.2 All the NDT Inspector involving ONE GUYANA FPSO Project works shall pass Mock Up test by SBM.”
4 SURFACE PREPARATION
4.1 The surface shall be smooth finished .The Surface condition of the material to be examined shall be
clean and free from dirt, loose scale, weld spatter, or other extraneous matter which may interfere the
transmission of Ultrasound waves into the material.
5 COUPLANTS
5.1 The couplant shall wet the surfaces of the search unit and the test piece, and eliminate any air gap
between the two.
5.2 Water, oil or cellulose gum (paste) may be used as the couplant.
5.3 The couplant used shall be the same for calibration and examination.
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6 EQUIPMENT
6.1. The examination shall be conducted with a pulse echo (“A” scan presentation) capable of generating
frequencies.
E.g. Krautkramer–USM 35X DAC, Panametrics, Sonatest or equivalent.
6.2. Screen Height Linearity. The ultrasonic instrument's screen height linearity shall be evaluated in
accordance with Appendix D.
6.3. Amplitude Control Linearity. The ultrasonic instrument's amplitude control linearity shall be evaluated
in accordance with Appendix D.
6.4. The proper functioning of the examination equipment shall be checked and the equipment shall be
calibrated by the use of calibration standard at the beginning and end of each examination, when
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examination personnel are changed, when probe, co - axial cable or battery is changed, and at any
time that malfunctioning is suspected as a minimum.
7 REFERENCE BLOCKS
Reference blocks used for equipment calibration shall be as follows
IIW (V1) Block
V2 (Din 54122) Block
IOW Beam Profile Block
Probe Selection:
9 TECHNIQUE
9.1 Scanning shall be done by Contact method using both Normal Probes (0 compression waves) and
Shear Probes (Angle probes).
9.1.1 Parent Metal Examination: This is a Mandatory requirement prior to weld examination, the testing to
be done for :
a) Location of Laminations or other internal defects which may be present that could interfere with test
results.
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b) To ascertain the actual thickness of the job. This scanning shall be done over the entire region of
the parent metal on which subsequent scanning for weld examination is to be done. A report of the
parent metal examination is to be provided stating any defects or areas of high attenuation, which
may be encountered. If no defects are encountered, a statement to this effect is to be incorporated.
9.1.2 Weld Metal Examination: The search unit over the examination surface shall be overlap a minimum
of 10% of the transducer dimension parallel to the direction of scan indexing.
10 CALIBRATION
10.1 The IIW VI or V2 Block shall be used for sweep range calibration of the equipment for both straight
beam and angle beam transducers (Refer Appendix E)
10.2 Sensitivity shall be taken from Ø1.5 hole from IIW VI block. (Refer Appendix E)
10.3 For contact examination the temperature differential between the calibration block and examination
surface shall be within 14ºC
10.4 Sensitivity setting for longitudinal probe: The sensitivity shall be adjusted at a location free of
indications so that the first back reflection from the far side of the plate will be 50% to 75% of full
screen height
10.5 Sensitivity Setting for Angle Beam Testing: Sensitivity setting for angle beam probes are adjusted by
amplifier control setting (dB setting), when angle beam directed towards 1.5 mm diameter through
hole at 15mm depth side in IIW-V1 Block, attains CRT indication at reference height level. This gain
setting (in dB) is zero reference level sensitivity (mentioned as ‘b’ on UT report). Scanning sensitivity
levels for weld scanning shall be done by increasing reference level sensitivity as tabulated below, for
statically loaded structure and cyclically loaded structure.
Upto 65mm 14 20
11 EXAMINATION
11.1 Angle Beam Testing: All UT shall be performed in accordance with AWS D1.1. Clause 8, to achieve
100% volumetric coverage. Probe selection and scanning procedure shall be in accordance with
Table 8.7 of AWS D1.1. When 100% volumetric coverage can’t be achieved by scanning from face A
on each side of the weld axis, the weldment shall be examined from face B side as well.
11.1.1 Testing angle selection for angle beam weld inspection depends on following factors
a) Weld joint type e.g., Butt, Corner, T etc.
b) Thickness and different areas of weld thickness.
c) Selection of special angles beam inspection in case where any discontinuity indication noted
at the weld metal and base metal interface which is equal to reference height
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11.1.2 All the above factors have been represented in Appendix A. All butt joint welds shall be tested from
both sides of the weld axis from the weld face sides only from which the initial scanning done. Corner
and T Joint weld shall be tested from one side of weld axis only. (For chamfering Joints Refer the
Annex-A)
11.1.3 All testing, wherever possible, shall be tested in Leg.1 (Refer Appendix A) of beam path of angle
beam. Leg 2 or Leg 3 beam path of angle beam shall be used only for weld areas inaccessible due to
ungrounded weld surface or interference with other portions of weldments.
A maximum of Leg 3 beam path recommended only when thickness or geometry prevents scanning of
complete weld areas or heat affected zones.
11.2 Indication Rating Procedure: To evaluate the indication rating (d) for any discontinuity indication, the
following procedure shall be adopted. Indication level ‘a’ for a discontinuity indication is attained by
getting the dB level as the indication is adjusted to reference level height
11.2.1 ‘b’ is zero reference level sensitivity in dB.
11.2.2 The attenuation factor ‘c’ on test report is attained by subtracting 1 inch from the sound path distance
and multiplying the remainder by 2. This factor shall be rounded to the closest significant decimal
place (0.1). Values less than 0.05 shall be reduced to the lower 0.1 and those of 0.05 or greater
increased to the higher 0.1.
11.2.3 Fractional values less than 0.5 dB shall be reduced to lower dB level and those of 0.5 or
greater increased to higher level.
11.2.4 Indication Rating‘d’ of discontinuity indication is attained by:
• For Instrument with gain in dB.
• a- b- c = d
• For Instrument with attenuation in dB.
• b- a- c = d
The indication rating shall be rounded to the nearest whole number (1 dB) value. Resulting decimal
values less than 0.5 dB shall be rounded down and those of 0.5 dB or greater shall be rounded up.
On the basis of Indication Rating of a discontinuity indication, the discontinuity severity class is
determined as in Table -8.2 and Table-8.3 in Appendix.B for statically loaded structure and cyclically
loaded structure respectively.
12 DISCONTINUITY LOCATION
Discontinuities shall be confirmed and located within the weld cross section by means probe
manipulation to maximize the response obtained, and to measure beam path lengths and distance
from established reference points.
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13 EVALUATION
13.1. The length of all reportable discontinuities shall be determined by the ‘Beam boundary’ method, i.e.
establishment of discontinuity linear extremities by the 6dB drop limits. Cross sectional heights of
reflectors and echo intensity shall initially be evaluated by the ‘Amplitude Comparison’ method to
establish status, however when cross sectional representation is required for further investigation to
identify reflectors, ‘Beam Boundary’ and/or ‘Maximum Amplitude’ shall be used to determine height
dimensions and depth positions.
b) Angle-Beam (Shear) Testing. The following procedure shall be used to determine lengths of indications
which have dB ratings more serious than for a Class D indication. The length of such indication shall be
determined by measuring the distance between the transducer centerline locations where the indication
rating amplitude drops 50% (6 dB) below the rating for the applicable discontinuity classification. This
Length shall be recorded under "discontinuity length" on the test report. Where warranted by
discontinuity amplitude, this procedure shall be repeated to determine the length of Class A, B, and C
discontinuities (Refer Appendix B).
14 SCANNING TECHNIQUES
14.1 Evaluation and assessment / characterization of indication will be carried out using the following
technique where possible.
15 FINAL ASSESSMENT
15.1. Reflectors shall be sized using those probes, which receive the optimum response. If necessary,
the defect shall be plotted with more than one probe to accurately position and size cross-sectional
height and length of the reflector.
16 RECORDING OF REFLECTORS
16.1 When specified discontinuities approaching rejectable size particularly those about which there is
some doubt in their evaluation shall be reported. All discontinuities that produce reflectors greater
than 50% of reference level shall be represented in cross section, plan view stating maximum
response level and documented in association with the corresponding report.
Each rejectable discontinuity shall be indicated on the weld by a mark directly over the discontinuity for
its entire length and draw the side view sketch with defect depth Minimum excavation length of 50mm
shall be adopted for any weld repair. Ensure the lead in and lead out of the excavation has a smooth
taper of minimum1:4. Depending on location and extent of defect, alternative excavation may be agreed
with Company
19 REPAIR
Welds found unacceptable by ultrasonic testing shall be repaired. Repaired areas shall be retested
ultrasonically.
Repair report should be indicate as "R1" first time and as "R2" second time repair.
Repair Report Represent “R” for first time and as “R1” second time repair. If it is accepted after repair
mentioned as “A”. (Applicable only for Keppel Fels).
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20 EXTENT OF NDT
The extent of welds to be inspected is stated as a percentage in Appendix Where a % lower the 100%
is stated, such as 20% volumetric examination of Primary welds, this means that 20% of weld joints on
each module or structure is required. Each selected weld joint shall then be 100% examined.
Please see Appendix G
21 REPORTING
All the ultrasonic test results shall be recorded in the Keppel Shipyard - Ultrasonic Test Report.
(Please see Appendix F).
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APPENDIX - A
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APPENDIX B
Categories 3 and 4 (Secondary and Tertiary steel)
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APPENDIX-C
Scanning Techniques:
Scanning Technique A
Scanning Technique B
Scanning Technique C
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Scanning Technique D
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Scanning Technique E
Scanning Technique F
Double Side chamfering Joints Scan as per below drawing.
Note :
- Shear Probe
- Compressional Probe
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APPENDIX - D
ULTRASONIC FLAW DETECTOR PERFORMANCE CHECK
1.0 INTRODUCTION:
This is intended to provide detailed methods and techniques for assessment and
calibration of Ultrasonic Flaw Detector, as required by this procedure Section 6.0
80 -6 dB 32 to 48
80 -12 dB 16 to 24
40 +6 dB 64 to 96
20 +12 dB 64 to 96
4.0 RECORDS:
All calibration readings shall be recorded and documented till next calibration
period and calibration block identity shall be included in the ultrasonic
calibration records.
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Date of calibration:
Calibration Due Date:
Deviation
Deviation shall be with in ±2% of Test Range
LEVEL-II
LEVEL-III
NAME NAME
DATE: DATE:
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APPENDIX – E
PROBE CHARACTERISTICS CHECK
1.0 INTRODUCTION
This has been written in order to provide detailed methods and techniques to evaluate
the Probe’s characteristics.
s
diu
Ra
m
0m
10
V1 (IIW) Block
3.2 Place shear wave probes on the IOW Beam Profile Block with the beam directed
towards the series of 5 side drilled holes. Al least 3 of the series shall be clearly
discernible.
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5.1
Figure 5.1
1.6mm hole
APPENDIX - F
ULTRASONIC TESTING REPORT
TITLE
PAGE
Project : PROSPERITY
ONE GUYANA FPSO REPORT NO :
DOC. NO.
Classification : American Bureau of Shipping (ABS) PAGE NO :
Item Tested :
Location :
Location of Defect
REV
REV DATE
04
28/04/2023
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APPENDIX - G