NDT Procedure Reshadat Project Complete Rev1

NDT INSPECTION

PROCEDURE

Document No: Rev. No.: 1 Class: 2 RSH-C3P-00-PL-PR-2811

NDT INSPECTION PROCEDURE

CONTRACT NO. : TSD 90 RSHP 716

PROJECT : SUBMARINE PIPELINES FOR RESHADAT,

ILAM-SALMAN AND ABOOZAR-NOWROOZ

COMPANY : IOOC

SITE : PERSIAN GULF, IRAN

Issued for Approval R. Kelders E.Hajimirzaei 1 14/09/2011

Issued for Approval R. Kelders E.Hajimirzaei 0 07/07/2011

DESCRIPTION PRPD CHKD APPD REV DATE

(This document is the sole property of N.I.O.C; all information contained herein may neither be reproduced, used, transmitted nor in any way made public without permission of the owner)

RESHADAT

NDT INSPECTION

PROCEDURE

Document No: Rev. No.: 1 Class: 2 RSH-C3P-00-PL-PR-2811

List of NDT procedures on Reshadat Project

AUT 21130 - General AUT Procedure AUT Specific 11-406 - Specific AUT Procedure 8inch

AUT Specific 11-407 - Specific AUT Procedure 10inch AUT Specific 11-408 - Specific AUT Procedure 14inch AUT Specific 11-409 - Specific AUT Procedure 16inch

MT 11-410 - MPI procedure MUT Lam check 11-411 - MUT lamination check procedure

MUT 11-412 - MUT procedure

Doc Ref : AUT 21130 Revision : 4 Date : 05-09-2011 Title : Automatic Ultrasonic Examination Type : General Procedure

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Contents 1 Purpose 32 Scope 33 References 3

3.1 Inhouse documents 33.2 Abbreviations 43.3 Definitions 4

4 Personnel Qualifications 54.1 Rotoscan Operator 54.2 Manipulator Operator 5

5 Rotoscan Equipment Description 55.1 Multi-Channel Ultrasonic Equipment 55.2 Recording 65.3 Scanner and Umbilical 65.4 Calibration Set-up 6

6 Rotoscan Set-Up Configuration 76.1 Inspection Set-up Configuration 76.2 Probes Used for Inspection 76.3 Probe Frame Layout 76.4 Parameters of Rotoscan Inspection Program 76.5 Calibration Block 7

7 Calibration 87.1 General 87.2 Setting of Inspection Gates 87.3 Sensitivity Settings 97.4 Scanning Preparation & Surface Condition 9

8 Acoustic Coupling Fluid 109 Examination 10

9.1 Calibration check 109.2 Step by Step Description of a Rotoscan Examination 119.3 Operational checks 11

10 Interpretation of results 1210.1 General 1210.2 Inspection result 12

11 Acceptance/Rejection criteria 1312 Reporting 1313 Examination of repairs 1314 Storage of data 13Attachment 1Rotoscan site report 14Attachment 2Decision Flow Chart WMS 15Attachment 3Decision Flow Chart ECA 16


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1 Purpose The purpose of this procedure is to detail the set-up and methodology of all Automated Ultrasonic Examination (AUT) to determine specific circumferential Weld Integrity, this is in accordance with and following the requirements of DNV-OS-F101: 2010 The job specific parameters will be documented in an adjacent specific procedure, describing at least the following items:

Reference Specification Detailed project scope Inspection set-up configuration Transducer selection Probe frame layout Rotoscan parameter set-up Calibration manufacturing drawings Acceptance criteria

2 Scope This procedure details methods for all Automated Ultrasonic Weld Examination (via the APPLUS RTD Rotoscan System) of ferrous butt welds. The Rotoscan is an automated ultrasonic inspection system for pipeline girth welds, based upon the Pulse Echo Method, enhanced with mapping images and Time of Flight Diffraction. The weld is divided into a number of depth zones, which are each inspected by one of an array of probes. The probes are arranged such that the entire weld is examined from both sides in a single circumferential scan. The ultrasonic information is transferred to a computer for data presentation and analysis.

3 References

3.1 documents CP 31105 Verification procedure for ultrasonic multi-channel equipment CP 31108 Control Procedure of calibration blocks for Rotoscan system CP 31111 Verification procedure for Ultrasonic Phased Array Equipment NL IPS 10 Written Practice for the Training, Qualification, Certification and Authorization of NDT Personnel. EN 473 Non-Destructive-testing Qualification and certification of NDT personnel General Principles SNT TC 1A Personnel Qualification and Certification in Non Destructive Testing For all other specification references see Specific procedure.


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3.2 Abbreviations AUT Automatic Ultrasonic Examination. CCW Counter Clockwise Conv Conventional CW Clockwise DS Downstream ECA Engineering Critical Assessment. FBH Flat Bottom Hole. ID Internal Diameter LOF Lack of Fusion LOP Lack of Penetration MUT Manual Ultrasonic Examination. NDT Non destructive Testing OD Outside Diameter PA Phased Array PE Pulse Echo ToFD Time of Flight Diffraction US Upstream UT Ultrasonic Examination WMS Workmanship

3.3 Definitions AUT Contractor ApplusRTD AUT Operator refers to the person responsible for all ultrasonic aspects of the inspection,

recording and interpretation of results. Defect is an imperfection of sufficient magnitude to warrant rejection based on the

criteria referenced by this procedure. Depth of the imperfection is the through-wall distance to the bottom of the imperfection

as measured from the outside diameter of the pipe. Downstream the side of the girth weld nearest to the AUT scanner band. Go-NoGo level or Evaluation level is the level for pulse echo channels from which

imperfections shall be evaluated and is used to determine imperfection length. Imperfection is a discontinuity or irregularity that is caused by the welding process and

is not related to geometry indications. Indication is an ultrasonic response derived from either weld geometry or weld

imperfection. Length of an imperfection will be defined if it has at least one amplitude value equal to or

greater than the evaluation level. Procedure is a step-by-step description of the application of an NDT method. Rotoscan Applus RTD trade name for our AUT System. Shall is a mandatory term. Should is a recommended practice or action. Threshold level is the level for pulse echo channels from which amplitude and transit

distance are recorded by the system. Through Wall Height dimensions of the imperfection will be called the Vertical Height

of the imperfection. Upstream the side of the girth weld furthermost to the AUT scanner band.


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4 Personnel Qualifications

4.1 Rotoscan Operator The ultrasonic lead operator performing the examination shall: be qualified in accordance to the valid version of APPLUS RTD Written-Practice NL IPS 10 and in accordance with SNT TC 1A: 2006 and EN 473 (Level UT 2); have experience with multi-channel UT equipment; be trained and passed the Applus RTD in-house testing for Mechanised Ultrasonic Inspection course.

4.2 Manipulator Operator The manipulator operator, handling the scanner mechanism shall be trained in using AUT-manipulators to the satisfaction of the Rotoscan operator.

5 Rotoscan Equipment Description

5.1 Multi-Channel Ultrasonic Equipment A multi-channel ultrasonic flaw detector (type Rotoscan) shall be used, which provides an adequate number of inspection channels (referred to as sequences) to ensure a complete volumetric examination of the weld through thickness in one circumferential scan. Each inspection channel will provide a linear A scan presentation, which can be individually selected. The system meets the following minimum requirements:

5.1.1 Global Parameters Number of Sequences : Specific to weld design Main Gain : 0 40 dB Digitizer Sampling Frequency : 50 MHz Overall System PRF : 4 kHz Scan resolution is not set higher than : 1 mm

5.1.2 Gate Parameters In each sequence, the following parameters shall be selectable:

Transmitter and receiver channels numbers Programmable Gain (1 dB increments) Gate start and length (min increment 0.1mm) Delay (min increment 0.1mm) Threshold level 5% - 100% Full Screen Height (FSH) (1% increments) Recordable output selection between; Amplitude and/or Transit Distance, Mapping, ToFD

and Coupling. Selection between First / Highest amplitude detection within the gated section.

5.1.3 General Electronic noise shall be lower than acoustical noise in all sequences, for the probes and

sensitivities to be used during the inspection. The signal to noise ratio of each sequence during examination shall be 20 dB for shear-

waves probes.


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5.2 Recording Inspection results are presented on-line on a colour monitor. The screen layout and number of used sequences are configured to present the thickness of the weld to be examined. Distance delays are applied to the output channels to compensate for variable transducer circumferential positions. The presentation shows the following information;

Amplitude and relevant transit distance (superimposed) Mapping image sections Go No-Go image section Coupling check section ToFD image section Circumferential position information Header section with possibility to present job specific information Time and date of inspection

5.3 Scanner and Umbilical The scanner to be used shall meet the following minimum requirements:

Mechanised operation during examination. Easy and quick mounting to the guide-band. Capable of taking up a minimum of 10 individually spring loaded ultrasonic probes, of

which the distances to the weld centreline can be individually set. Coupling controllable per probe, or per set. 15 up/to 45metres of cable length. The scanner is equipped with an encoder for accurate measurement of the scanner

position within the pipeline circumference. Scanner speed of 40 up to 80mm/sec

5.4 Calibration Set-up The calibration set-up consists of a support, being a part of a thin wall dummy pipe of the same diameter as pipe under examination. On the support a guiding band is mounted at the same distance from the weld centreline as the guiding-band on the weld to be tested. In the support a cut-out area is present where a calibration block with the proper wall thickness is mounted which is used to monitor the ongoing system performance. The calibration block(s) to be used shall be made from a piece of project pipe, without coating and no weld included. The surface condition shall be similar to practical circumstances.


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6 Rotoscan Set-Up Configuration

6.1 Inspection Set-up Configuration The inspection set-up is detailed in the specific procedure. It shows the selected probe angle(s) for the selected pulse echo, tandem and ToFD technique within the zones to be examined within the given weld bevel configuration.

6.2 Probes Used for Inspection In the specific procedure the selected probes, with their parameters, which are used for the inspection are listed. All probes have a unique number for QA/QC purpose relating to the manufacturing process and tests within the APPLUS RTD probe manufacturing department. The numbers of probes used are part of the inspection parameter file within the Rotoscan inspection program.

6.3 Probe Frame Layout The probes used for inspection are positioned within a probe frame. The position of each probe in circumferential direction and its inspection function is detailed into the specific procedure.

6.4 Parameters of Rotoscan Inspection Program The parameters will be taken from the job specific calibration block. The Rotoscan operator may make adjustments to accommodate existing field conditions within the tolerances. Note: Any adjustments of parameters outside the specified tolerances shall be recorded.

6.5 Calibration Block The calibration block shall be of matching wall thickness of the item under test and contain artificial defects to install the inspection sensitivity. The block shall be designed with sufficient surface area to enable the transducer array to scan the target areas in one single pass. Reflectors for the pulse echo technique shall be flat-bottom holes and notches, which are positioned at the weld bevel. ToFD notches are used to identify the system capability to detect surface breaking indications. The calibration block shall be manufactured and tested according to Applus RTD verification procedure CP 31108. A calibration certificate shall be issued. The calibration block shall be identified with a hard stamped unique serial number. The specific procedure shows the calibration manufacturing drawings. Notes: Through-holes 2mm or 5 x 1mm slots in both ends of calibration block at centre line. These reflectors are to locate weld centre position only.


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7 Calibration

7.1 General The ultrasonic equipment shall be electronically calibrated at least once per 12-month period (1 week) in accordance with the valid version of Applus RTD procedure CP 31105 (Conv.) or CP 31111 (PA).

7.2 Setting of Inspection Gates

7.2.1 Pulse-Echo and Tandem channels With each transducer positioned for the peak signal response from the calibration reflector, the detection gates are to be set. The gate shall start at least 2mm, and up to 8mm (allowance for the width of heat affected zone) before the theoretical weld bevel preparation. The gate ends shall be at least 1mm after the theoretical weld centreline. All gates will be programmed to record amplitude and/or transit distance information. The gate length of the transit distance in the root channel will be extended to enable root penetration recognition.

7.2.2 Mapping Channels The mapping gate shall start at least 2mm, and up to 8mm (allowance for width of heat affected zone) before the theoretical weld bevel preparation. The gate length will be extended to enable cap reinforcement registration or to establish overtrace from adjacent mapping zones. The mapping gates in the root will be set identical to the pulse echo transit distance channels to enable the recognition of the root penetration.

7.2.3 ToFD Channel The ToFD gate should start at an appropriate distance before the arrival of the lateral wave (ca. 2mm) and should extend up to the back-wall echo and or mode converted, to achieve full cover of the wall thickness. Note: The gate settings may be altered if geometry indications dictate.

7.2.4 Coupling Channels For Conventional Set up all PE probes, with exception of ToFD and Transverse probes, shall be used for transmission US/DS coupling control

For PA set up the number of coupling channels shall be seven (7) i.e. three (3) on each side for BWE and one (1) for transmission US/DS for coupling control


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7.3 Sensitivity Settings The equipment sensitivity (echo amplitude) for all inspection channels should be set at 80% Full Screen Height. The calibration of the inner and outer surface breaking zones is from the relevant notch and all other zones from a FBH. The sensitivity setting for mapping in the volume is on a 1.5mm FBH at 80% FSH + 14 dB but should not be so great as to cause interfering electrical or geometric noise that could be misinterpreted. The sensitivity setting for mapping in the root, as a minimum, is equal to the related pulse echo channels, increased with additional 14 dB to ensure proper detection but should not be so great as to cause interfering electrical or geometric noise that could be misinterpreted. The lateral wave (RF signal) of the TOFD channel sensitivity is set between 40% and 80% FSH. The probe distance for TOFD should be calculated at 2/3 of the wall thickness (nominal beam angle) 10mm.

The sensitivity for the coupling channels is established by setting the amplitude of the signal from the transmitting probe to the receiving probe to 80%FSH added with a nominal 10 dB gain and 80% FSH added with a nominal 4dB for BWE.

7.4 Scanning Preparation & Surface Condition Spiral welds or long seams have to be ground flush over the scanning area. The scanning area shall be free of weld spatter and other irregularities, which may interfere with the inspection. Adjacent to one weld side, prior to welding, over the complete circumference at a fixed distance from the nose of the weld preparation, a scribe line shall be available for the guide band position adjustment.

The client is responsible for applying the scribeline and the lead operator is responsible for the acceptance of the applied scribeline.


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8 Acoustic Coupling Fluid Water shall be used as acoustic coupling fluid, to be able to test welds in the range from 0C to over lukewarm. If temperatures lower than 0C are experienced coupling will be mixed with antifreeze and recycled. The coupling is supplied between the probe contact surface and the pipe via supply channels incorporated in the probe housing. To enable good acoustical contact between the ultrasonic probes and the pipe surface, conditions as mentioned in Section 7.4 apply.

9 Examination

9.1 Calibration check During the first number of welds a calibration scan shall be made before and after inspection of each weld. If agreed with client, the frequency of verification scans may be reduced to a minimum of one scan for each number of welds. This will be detailed in the specific procedure. Re-calibration shall be carried out if any of the following exist:

The calibration of an inspection function differs more than -2 or +2dB from the previous calibration;

The gate settings need to be adjusted with more than +/- 1.0mm with the previous calibration;

After a weld repair; In case the calibration differs from the initial setting, outside the given tolerances, the applicable probe(s) and coupling shall be checked. If the settings have to be changed to achieve a good calibration, the welds before this calibration up to the previous calibration will be re-evaluated taking the differences in the gain and/or gate adjustment into account. Re-scanning shall be carried out from last valid calibration:

After a equipment breakdown If hardware changes have to be made to scanner to achieve a valid calibration

If above is applicable, the system shall not be used until 5 acceptable calibration have been performed to confirm acceptable stability. The result of each calibration scan shall be printed or converted to pdf format and stored on hard disc.


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9.2 Step by Step Description of a Rotoscan Examination The UT-system is already calibrated and a calibration scan with a record has been made.

a. Adjust guiding band on the pipe to a distance of 150mm from the marks (scribe-line, which is 40mm from the weld centre-line) and parallel to the weld. The accuracy of the band setting should be 1mm.

b. Mark a 0 datum point on the top of the pipe at the 12 oclock position.

c. Attach the scanner to the band. d. Switch on the water coupling supply. e. Locate the scanner over the top of the pipe and make sure that all probes are past the

zero point and are in proper contact with the pipe surface. f. Switch on the system and automatically the weld will be scanned in a clockwise direction. g. Systems will switch off automatically after a full scan with an overlap minimum of 5cm. h. Coupling supply will be switched off as well. Check the encoder position of an indication

at the start of the scan and confirm the position of that same indication in the overlap, difference in position allowed is 10mm.

i. Check the inspection results on defect indications and proper coupling. Use the transit distance recording, mapping and images for validation of defect indications within the root area and proper alignment of the guiding band.

j. In case of lack of coupling a second scan will be necessary. Remove the scanner from the band and attach it to the calibration block.

9.3 Operational checks Operational checks shall be performed according to the specific procedure. The execution of and the results of the operational checks shall be recorded in the system log book. The following operational checks shall be performed for every weld inspected:

Reference line shall be within required tolerance and clearly marked around the pipe circumference.

The scanning surface shall be free of weld spatter and other irregularities that may interfere with the movement of transducers.

Physical damage and loose connections in the band. Band position shall be within a tolerance of maximum 1.0mm.

The pipe surface temperature shall be within the required tolerance specified in the Specific Procedure.


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Once daily or at least once per shift, check: the scanner for damage and loose connections; calibration block for damage and scanning tracks; The bevel prepared at the bevelling station shall be of the specific weld bevel geometry,

dimensions and tolerances shown on the drawings of the calibration block in use. Transducers shall not be rocking in the scanner and shall be in firm contact with the

scanning surface. The transducers shall be firmly screwed onto the wedges. The transducer wear faces (wedges) shall be checked for scores which may cause local loss of contact.

The transducer stand-off distance shall be as recorded in the set-up sheet within 0.5mm.

The transducer case height and the difference between the protrusions of carbide tips shall be as recorded in the setup sheet within 0.2mm.

The recording system shall clearly indicate the location of imperfections relative to the 12 oclock position of the weld, with a 1% accuracy or 10mm, whichever is greater.

10 Interpretation of results

10.1 General With the transit distance measurements and with the information from the Mapping and ToFD channels, visible on the result presentation, indications shall be judged whether they are from the weld geometry or defects. The coupling channels will be checked for coupling loss. Coupling loss will be registered when the through transmission signal drops below 10% FSH as long as this is above noise level. In case the coupling loss in one of the channels is longer than the shortest allowable defect length, a rescan shall be carried out. In case the cause of the coupling loss is due to the surface condition (e.g. grinding) the surface condition shall be improved (e.g. smoothing) and the weld shall be re-scanned. If this condition appears again then the client shall be informed and another available and suitable certified method of inspection (e.g. Manual UT, Radiographic Examination) shall be used.

10.2 Inspection result The inspection result should be evaluated and/or reported as follows;

All indications in the pulse echo channels should be evaluated which exceed the threshold level mentioned in the acceptance criteria.

Defect length in the pulse echo channels shall be measured at the Go Nogo level as mentioned in the acceptance criteria.

Linear elongated indications in the pulse echo channels with spacing less than the length of the smallest indication shall be evaluated as one continuous defect.

The interpretation sequence to be followed is visualized in Attachment 2 and 3 for the Decision Flow Chart for WMS and ECA.


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11 Acceptance/Rejection criteria For Acceptance/Rejection criteria see the project specific supplement

12 Reporting The APPLUS RTD Rotoscan site report will be used for reporting of inspection results. The following information will be documented as minimum:

Used procedure number; Project name/number; Weld No; Inspection date; Diameter; Wall thickness; Number of indications, location on circumference and location in depth; Acceptable or rejectable.

For a sample of the Rotoscan site report, see attachment 2. An example of file naming, for Mainline Weld ML 1234 ML 1234 cal Calibration scan performed prior to mainline weld ML 1234 Scan of mainline weld ML 1234 cal out Calibration scan performed at shift end.

13 Examination of repairs Repaired areas shall be inspected with the Rotoscan system that originally detected the imperfection. This inspection will demonstrate that the original imperfection is removed and that no new imperfections are introduced to the weld. The results from the ToFD inspection supplemented with the Mapping image will be used to interpret the repaired area. Manual UT will be used in addition to the Rotoscan inspection in accordance with approved manual UT procedures. If the repair requires a cut-out re-examination will be conducted using the Rotoscan equipment set-up for the bevel defined in the qualified project welding procedure.

14 Storage of data The raw data of each inspected weld including the parameter settings will be stored on the main hard drive (C-Drive). In addition, a back-up will be made on a second hard drive (Removable D Drive) The Date and Time function will be used to ensure that all welds scanned are accounted for. By selecting this function the date and time of each scan made becomes part of the file name, removing the chance of overwriting any file. Welds will be stored in daily directories, which will be created at 24:00 hrs each day. Operators are responsible for the daily directory on the main hard drive and shall ensure that all welds are present and readable. Each shift will store scans and calibrations in a windows folder of that date e.g. DD-MM-YYYY All calibration and weld inspection results will be printed in a compressed black-white image of the entire weld circumference after acceptable scan is completed. After completion of the pipeline project, all data (NDT, welds, repairs and calibrations) will be stored on a digital medium and presented. The official record of inspection will be the Rotoscan Site Report and will bear the original signature of the AUT Rotoscan Operator.


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Attachment 1 Rotoscan site report


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Attachment 2 Decision Flow Chart WMS


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Attachment 3 Decision Flow Chart ECA

Doc Ref : AUT specific 11-406 Revision : 1 Date : 14-09-2011 Title : Automatic Ultrasonic Examination

Type : Client :

Specific Procedure KITO

Applus RTD Benelux is the trading name of Rntgen Technische Dienst bv If this is a copy, unless otherwise specified, it is uncontrolled. You must verify the revision before use.

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SPECIFIC PROCEDURE FOR AUTOMATIC ULTRASONIC EXAMINATION

Project : Reshadat Project

Client : KITO Scope : Mechanized Ultrasonic Examination of girth welds Diameter : 8,625

Wall thickness : 14,3mm Wall thickness : 15,9mm Wall thickness : 18,2mm

Based on : DNV-OS-F 101-2010 Validity : This procedure is valid only for AUT-examination of girth welds up to 95C

This procedure is valid in conjunction with the GENERAL procedure AUT 21130 latest revision

Development Revisions

Revision No. Prepared By Date Approved By Date Amendment Details

1 T. Vreenegoor 14-09-2011 R. Kelders 14-09-2011 See revision record sheet, page 2

0 T. Vreenegoor 01-07-2011 R. Kelders 01-07-2011

Date 14-09-2011 Date 14-09-2011 Date

Address Delftweg 144, 3046 NC Rotterdam

P.O. Box 10065, 3004 AB Rotterdam The Netherlands www.ApplusRTD.com

This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without the permission of Applus RTD.

Doc Ref : AUT specific 11-406 Revision : 1 Date : 14-09-2011 Title : Automatic Ultrasonic Examination Type :

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Revision record sheet

Revision Issue date Section Description of update

1 14-09-2011 All Added company logos

General Changed reference DNV OS F101 2007 to 2010

D, E and F Updated cal block drawings, included full PIN number


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Contents

1 Purpose 4

2 Scope 4

3 Reference documents 4

4 Rotoscan Set-Up Configuration 4

4.1 Probe Frame Layout 4 4.2 Calibration Block 4 4.3 Gates 4

5 Acceptance/Rejection criteria 5

Attachment A: Inspection set-up configuration (will be finalised after setup) 6

8,625 x 14,3mm 6 8,625 x 15,9mm 6 8,625 x 18,2mm 6

Attachment B: Probe frame lay-out 7

Attachment C: Calibration block drawings 8,625 x 14,3mm 8

Attachment D: Calibration block drawings 8,625 x 15,9mm 15

Attachment E: Calibration block drawings 8,625 x 18,2mm 22


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1 Purpose

The purpose of this specific procedure is to detail the actual system configuration and set-up parameters including the reference blocks for Automated Ultrasonic Examination (AUT) to determine specific circumferential Weld Integrity, this is in accordance with the requirements of

DNV-OS-F 101-2010 on the Reshadat project.

2 Scope

This procedure details methods for Automated Ultrasonic Weld Examination (via the APPLUS

RTD Rotoscan System) of ferrous butt welds.

Diameter : 8,625 Wall thickness : 14,3mm : 15,9mm

: 18,2mm Weld Bevel : J-prep (Serimax)

3 Reference documents

General AUT Procedure AUT 21130 Latest revision DNV-OS-F 101-2010

CP 31111 Latest revision


4.1 Probe Frame Layout

The probes used for inspection are positioned within a probe frame. The probe settings are visualised in Attachement A.

The position of each probe in circumferential direction and its inspection function is visualised

in Attachment B.

4.2 Calibration Block

Detailed calibration block drawings and set ups are included in Attachment C, D and E.

Production pipe will be used for Calibration Blocks.

4.3 Gates

All gate lengths and settings of Pulse Echo, Tandem , Mapping, ToFD and coupling channels

are a part of the rotoscan file and these are saved with every weld scanned.


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5 Acceptance/Rejection criteria

The interpretation sequence to be followed is visualized in Attachment 3, the Decision Flow Chart for ECA in the general procedure AUT 21130 latest revision.

The document containing the Acceptance/Rejection criteria shall be submitted by the Client.


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Attachment A: Inspection set-up configuration (will be finalised after setup)

8,625 x 14,3mm

Zone

Name Reflector Cal. block

Frequency Probe

Angle Insp. Techn Ident.

ToFD Upper/lower Notch ToFD 6 MHZ comp 65 ToFD H/I

1 cap Notch 1mm 4 MHZ shear 55 Pulse Echo A

2 Fill 2 3mm 4MHZ shear 40/48 Pulse Echo B 3 Fill 1 3mm 4MHZ shear 40/48 Pulse Echo C 4 Hot pass 3mm 4MHZ shear 50 Pulse Echo D 5 Root Notch 1mm 4MHZ shear 65 Pulse Echo E

Vol 1 Upper mapping 1.5mm 4 MHZ shear 50 Pulse Echo J Vol 2 Lower mapping 1.5mm 4 MHZ shear 50 Pulse Echo K

8,625 x 15,9mm

Zone


Frequency Probe






8,625 x 18,2mm

Zone

Name Reflector

Cal. block

Frequency

Probe Angle Insp. Techn Ident.

ToFD Upper/lower Notch ToFD 6 MHZ comp 65 ToFD I/J


2 Fill 3 3mm 4MHZ shear 40/48 Pulse Echo B 3 Fill 2 3mm 4MHZ shear 40/48 Pulse Echo C 4 Fill 1 3mm 4MHZ shear 40/48 Pulse Echo D 5 Hot pass 3mm 4MHZ shear 50 Pulse Echo E 6 Root Notch 1mm 4MHZ shear 65 Pulse Echo F

Vol 1 Upper mapping 1.5mm 4 MHZ shear 50 Pulse Echo K Vol 2 Lower mapping 1.5mm 4 MHZ shear 50 Pulse Echo L


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Attachment B: Probe frame lay-out

Scan direction 8625 x 14,3mm

Cap DS

Fill 2 DS

TOFD DS

Hot

Pass DS

Fill 1 DS

Root DS

Cap US

Fill 2 US

TOFD US

Hot

Pass US

Fill 1 US

Root US


Cap

DS

Fill 2

DS

TOFD

DS

Hot Pass

DS

Fill 1

DS

Root

DS

Cap US

Fill 2 US

TOFD US

Hot

Pass US

Fill 1 US

Root US


Cap DS

Fill 3 DS

TOFD DS

Fill 1 DS

Fill 2 DS

Hot

Pass DS

Cap US

Fill 3 US

TOFD US

Fill 1 US

Fill 2 US

Hot Pass US

Root DS

Root US


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Attachment C: Calibration block drawings 8,625 x 14,3mm


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Attachment D: Calibration block drawings 8,625 x 15,9mm


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Attachment E: Calibration block drawings 8,625 x 18,2mm


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Client : KITO Scope : Mechanized Ultrasonic Examination of girth welds Diameter : 10,75


Wall thickness : 18,2mm Based on : DNV-OS-F 101-2010

Validity : This procedure is valid only for AUT-examination of girth welds up to 95C






Date 14-09-2011 Date 14-09-2011 Date

Address

Delftweg 144, 3046 NC Rotterdam P.O. Box 10065, 3004 AB Rotterdam The Netherlands www.ApplusRTD.com

This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without

the permission of Applus RTD.


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C, D, E and

F

Updated cal block drawings, included full PIN number


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Contents

1 Purpose 4

2 Scope 4






10,75 x 12,7mm 6 10,75 x 14,3mm 6 10,75 x 15,9mm 7 10,75 x 18,2mm 7


Attachment C: Calibration block drawings 10,75 x 12,7mm 10

Attachment D: Calibration block drawings 10,75 x 14,3mm 17

Attachment E: Calibration block drawings 10,75 x 15,9mm 24

Attachment F: Calibration block drawings 10,75 x 18,2mm 31


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1 Purpose



2 Scope



Diameter : 10,75 Wall thickness : 12,7mm : 14,3mm

: 15,9mm : 18,2mm Weld Bevel : J-prep (Serimax)


General AUT Procedure AUT 21130 Latest revision

DNV-OS-F 101-2010 CP 31111 Latest revision




The position of each probe in circumferential direction and its inspection function is visualised in Attachment B.


Detailed calibration block drawings and set ups are included in Attachment C, D, E and F.


4.3 Gates

All gate lengths and settings of Pulse Echo, Tandem, Mapping, ToFD and coupling channels are a part of the rotoscan file and these are saved with every weld scanned.


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10,75 x 12,7mm

Zone


Frequency Probe


ToFD Upper/lower Notch ToFD 6MHZ comp 65 ToFD H/I




10,75 x 14,3mm

Zone


Frequency Probe







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10,75 x 15,9mm

Zone


Frequency Probe






10,75 x 18,2mm

Zone


Frequency Probe







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Cap

DS

Fill 2

DS

TOFD

DS

Hot Pass

DS

Fill 1

DS

Root

DS

Cap

US

Fill 2

US

TOFD

US

Hot Pass

US

Fill 1

US

Root

US


Cap DS

Fill 2 DS

TOFD DS

Hot

Pass DS

Fill 1 DS

Root DS

Cap US

Fill 2 US

TOFD US

Hot

Pass US

Fill 1 US

Root US


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Cap DS

Fill 3 DS

TOFD DS

Fill 1 DS

Fill 2 DS

Hot Pass DS

Cap

US

Fill 3

US

TOFD

US

Fill 1

US

Fill 2

US

Hot Pass

US

Root DS

Root

US


Cap

DS

Fill 2

DS

TOFD

DS

Hot Pass

DS

Fill 1

DS

Root

DS

Cap US

Fill 2 US

TOFD US

Hot

Pass US

Fill 1 US

Root US


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Attachment C: Calibration block drawings 10,75 x 12,7mm


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Attachment D: Calibration block drawings 10,75 x 14,3mm


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Attachment E: Calibration block drawings 10,75 x 15,9mm


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Attachment F: Calibration block drawings 10,75 x 18,2mm


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Type : Client :



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Client : KITO Scope : Mechanized Ultrasonic Examination of girth welds Diameter : 14








Date 14-09-2011 Date 14-09-2011 Date

Address





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C Updated cal block drawings, included full PIN number


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Contents

1 Purpose 4

2 Scope 4






14 x 15,9mm 6


Attachment C: Calibration block drawings 14 x 15,9mm 8


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1 Purpose



2 Scope



Diameter : 14 Wall thickness : 15,9mm Weld Bevel : J-prep (Serimax)






The probes used for inspection are positioned within a probe frame. The probe settings are

visualised in Attachement A.



Detailed calibration block drawings and set ups are included in Attachment C.


4.3 Gates

All gate lengths and settings of Pulse Echo, Tandem , Mapping, ToFD and coupling channels are a part of the rotoscan file and these are saved with every weld scanned.


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14 x 15,9mm

Zone


Frequency Probe







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Cap

DS

Fill 2

DS

TOFD

DS

Hot Pass

DS

Fill 1

DS

Root

DS

Cap US

Fill 2 US

TOFD US

Hot

Pass US

Fill 1 US

Root US


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Attachment C: Calibration block drawings 14 x 15,9mm


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Type : Client :



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Client : KITO Scope : Mechanized Ultrasonic Examination of girth welds Diameter : 16









Date 14-09-2011 Date 14-09-2011 Date

Address





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C, D, E and

F

Updated cal block drawings, included full PIN number


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Contents

1 Purpose 4

2 Scope 4






16 x 12,7mm 6 16 x 15,9mm 6 16 x 20,6mm 7 16 x 23,8mm 7


Attachment C: Calibration block drawings 16 x 12,7mm 10

Attachment D: Calibration block drawings 16 x 15,9mm 17

Attachment E: Calibration block drawings 16 x 20,6mm 24

Attachment F: Calibration block drawings 16 x 23,8mm 32


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1 Purpose



2 Scope



Diameter : 16 Wall thickness : 12,7mm : 15,9mm

: 20,6mm : 23,8mm Weld Bevel : J-prep (Serimax)









Detailed calibration block drawings and set ups are included in Attachment C, D, E and F.


4.3 Gates

All gate lengths and settings of Pulse Echo, Tandem , Mapping, ToFD and coupling channels are a part of the rotoscan file and these are saved with every weld scanned.


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16 x 12,7mm

Zone


Frequency Probe






16 x 15,9mm

Zone


Frequency Probe







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16 x 20,6mm

Zone


Frequency Probe



1 Cap Notch 1mm 4 MHZ shear 55 Pulse Echo A



16 x 23,8mm

Zone

Name Reflector

Cal. block

Frequency

Probe Angle Insp. Techn Ident.

ToFD Upper/lower Notch ToFD 6 MHZ comp 65 ToFD J/K

1 Cap Notch 1mm 4 MHZ shear 55 Pulse Echo A

Fill 4 3mm 4MHZ shear 40/46 Pulse Echo B 2 Fill 3 3mm 4MHZ shear 40/46 Pulse Echo C 3 Fill 2 3mm 4MHZ shear 40/46 Pulse Echo D 4 Fill 1 3mm 4MHZ shear 40/46 Pulse Echo E 5 Hot pass 3mm 4MHZ shear 50 Pulse Echo F 6 Root Notch 1mm 4MHZ shear 65 Pulse Echo G

Vol 1 Upper mapping 1.5mm 4 MHZ shear 50 Pulse Echo M Vol 2 Lower mapping 1.5mm 4 MHZ shear 50 Pulse Echo M


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Cap DS

Fill 2 DS

TOFD DS

Hot

Pass DS

Fill 1 DS

Root DS

Cap US

Fill 2 US

TOFD US

Hot Pass US

Fill 1 US

Root US


Cap DS

Fill 2 DS

TOFD DS

Hot Pass DS

Fill 1 DS

Root DS

Cap US

Fill 2 US

TOFD US

Hot Pass US

Fill 1 US

Root US


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Cap DS

Fill 3 DS

TOFD DS

Fill 1 DS

Fill 2 DS

Hot

Pass DS

Cap US

Fill 3 US

TOFD US

Fill 1 US

Fill 2 US

Hot Pass US

Root DS

Root US


Cap DS

Fill 3 DS

TOFD DS

Fill 1 DS

Fill 2 DS

Hot

Pass DS

Cap US

Fill 3 US

TOFD US

Fill 1 US

Fill 2 US

Hot Pass US

Root DS

Root US

Fill 4 DS

Fill 4 US


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Attachment C: Calibration block drawings 16 x 12,7mm


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Attachment D: Calibration block drawings 16 x 15,9mm


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Attachment E: Calibration block drawings 16 x 20,6mm


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Attachment F: Calibration block drawings 16 x 23,8mm


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Doc Ref : MT 11-410 Revision : 1 Date : 14-09-2011 Title : Magnetic Examniation Client : KITO


Page 1 of 9

Procedure

MAGNETIC PARTICLE EXAMINATION Project : Reshadat Project Client : KITO Owner : IOOC NDE Contractor : Applus RTD Scope : Magnetic Particle Inspection of welds, weld bevels and repair areas Based on : DNV Offshore Standard OS-F101 ed. 2010 Validity : This procedure is valid only for MT-examination of welds with a Surface

temperature of 0C to 50C for wet particles and > 50 t 230C for dry particles

Development Revisions Revision No. Prepared By Date Approved By Date Amendment Details 1 T. Vreenegoor 14-09-2011 R Kelders 14-09-2011 See revision record sheet, page 2 0 T. Vreenegoor 01-07-2011 R Kelders 01-07 -2011

Date 14-09-2011 Date 14-09-2011 Date

Address Delftweg 144, 3046 NC Rotterdam P.O. Box 10065, 3004 AB Rotterdam The Netherlands www.ApplusRTD.com

This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without the permission of Applus RTD.


Page 2 of 9

Revision record sheet Revision Issue date Section Description of update

1 14-09-2011 General Added company logos General Changed reference DNV OS F101 2007 to 2010


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Contents

1 Scope 4

2 General Requirements 4

2.1 Personnel qualifications 4 2.2 Reference Documents 4 2.3 Technique and materials 4 2.4 Surface preparation 4 2.5 Surface temperature 4 2.6 Lighting 4 2.7 Contrast paint 5

3 Equipment and Materials 5

3.1 Equipment 5 3.2 Examination medium 5 3.3 Black particles (wet method) 5 3.4 Powder particles (dry method) 5 3.5 Magnetising field adequacy 5 3.6 Calibration of equipment 6

4 Examination 6

4.1 Method of examination 6 4.2 Direction of magnetisation 6 4.3 Examination coverage 6

5 Evaluation and Acceptance Standard 7

5.1 Evaluation of indications 7 5.2 Acceptance standards 7 5.3 Examination of repairs and repair grooves 8

6 Records 8

Attachment A : Report form 9


Page 4 of 9

1 Scope

This procedure describes the method to be used for magnetic particle examination on ferromagnetic material and ferromagnetic welds with yoke magnetisation in accordance with the requirements of: DNV rules for Submarine Pipeline Systems OS F101 ed. 2010.

2 General Requirements

2.1 Personnel qualifications

NDE-personnel shall be qualified and certified in accordance with the valid version Applus RTD "Written Practice" NL IPS 10 for the qualification and certification of personnel, which conforms SNT-TC-1A 2006 and EN 473 Level 2.

Level 1 personnel shall be assigned to NDE under the supervision of the Level 2 as. Interpretation of the results shall only be performed by Level 2 personnel as minimum.

2.2 Reference Documents

Project specific reference documents will be listed in the project specific supplement to this procedure.

ASNT SNT TC 1A Recommended practice for NDT Personnel Qualification and Certification

EN 473 Non Destructive Testing Qualification and Certification of NDT personnel

CP 31201 Calibration procedure for Electromagnetic Yoke

CP 31203 Verification & Testing Procedure for Magnetic Particle suspensions

2.3 Technique and materials

The ferromagnetic particles used as an examination medium, shall be either wet or dry and shall be non-fluorescent. Yoke technique shall be used; the type of current shall be Alternating Current (AC).

2.4 Surface preparation

Prior to magnetic particle examination, the surface to be examined and all adjacent areas within at least 25 mm shall be dry and free of all dirt, grease, scale, welding flux and spatter, oil or other extraneous matter that could interfere with the examination. Cleaning may be accomplished using power-brush, detergents, organic solvents, de-scaling solutions, paint removers, vapour degreasing, sand or grit blasting, or ultrasonic cleaning methods.

2.5 Surface temperature

The surface temperature of the part to be examined shall be > 5C t 50C (lukewarm) for the wet method and 230C for the dry particle method.

2.6 Lighting

The light intensity at the surface to be examined shall be 500 Lux. For example the intensity of 500 Lux. can be achieved with a 60 Watt bulb at a distance of 25 cm.


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2.7 Contrast paint

If with the dry method the contrast between the surface and the test ink is too low, a thin layer of contrast paint must be applied on the surface. Only contrast paint submitted by ApplusRTD may be used.

3 Equipment and Materials

3.1 Equipment

Alternating Current (AC) Yoke magnet shall be used.

3.2 Examination medium

The ferromagnetic particles used as an examination medium, shall be either wet or dry and shall be non-fluorescent. The ferromagnetic particles used for the examination shall meet the following requirements: The colour of the particles shall provide adequate contrast with the surface being examined. The test medium shall be applied at blowing it over the surface. The blowing force shall be so, that it does not disturb or remove weakly formed indications.

3.3 Black particles (wet method)

The particles shall be suspended in a suitable liquid medium. The concentration of the magnetic particles is normally checked by the use of a Sutherland Flask. A 100 ml portion of the test-medium is taken and allowed to settle for 30 minutes.

The volume settling out at the bottom of the tube is indicative of the particle concentration. The recommended concentration from a 100 ml sample is from 1,2 to 2,4 ml, in accordance with Applus RTD in-house procedure CP-31203, latest revision.

The temperature of the wet particle suspension and the surface of the part shall not exceed 50C (lukewarm).

3.4 Powder particles (dry method)

The dry powder ferromagnetic particles for repair grooves and/or hot areas shall be used at a surface temperature


Page 6 of 9

3.6 Calibration of equipment

Each alternating current electromagnetic yoke shall have a lifting power of at least 5kg at the maximum pole spacing that will be used.

Each alternating current electromagnetic yoke shall be calibrated at least once every 6 months according the latest revision of calibration procedure CP-31201, or whenever the equipment has been subjected to major electric repair, periodic overhaul, or damage. The lifting power of the yoke in use shall be checked at least once a day.

4 Examination

4.1 Method of examination

The test medium shall be applied at either flowing or spraying it over the surface. The spraying force shall be so, that it does not disturb or remove weakly formed indications.

Examination shall be done by the continuous method that is: the magnetising current remains on, while the examination medium is being applied and while excess of the examination medium is being removed.

4.2 Direction of magnetisation

At least two separate examinations shall be performed on each area. During the second examination, the lines of magnetic flux shall be approximately perpendicular to those used during the first examination, see figure 1.

Figure 1 shows the positions of the Yoke.

4.3 Examination coverage

All examination shall be conducted with sufficient overlap to assure 100% coverage at the required sensitivity.


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5 Evaluation and Acceptance Standard

5.1 Evaluation of indications

All indications are not necessarily imperfections however, since excessive surface roughness, magnetic permeability variations (such as at the edge of heat affected zones), etc. may produce false indications.

Any questionable or doubtful indications shall be re-examined to determine whether or not they are relevant.

All indications with dimensions 1,5 mm have to be considered relevant.

A linear indication is an indication, of which the length is larger than 3 times the width. A non-linear (rounded) indication is an indication of circular- and/or elliptical shape with a

length equal to or less than 3 times its width. Cluster indications; three or more relevant rounded indications in a line separated by

1,5mm or less, measured from edge to edge.

5.2 Acceptance standards

Acceptance criteria according to Table D3, from DNV Submarine Pipeline Systems OS F101 2010.


Page 8 of 9

If other acceptance project specific acceptance criteria are applicable this shall be provided by client.

5.3 Examination of repairs and repair grooves

Repair grooves shall be re-examined according to this pr

NDT Procedure Reshadat Project Complete Rev1

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