I.E.M.S.

ULTRASONIC EXAMINATION PROCEDURE

Code

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CINOSARTLU EXAMINATION EORUPCCOP

Owner : ENPC Main contractor : Uhde Project name : AMMONIA UREA PROJECT

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First Issue Status

23/02/2011

Ahmed Abdelrahman

23/02/2011

Mohamed Abdellateef

Rev

Description
Status Code: A = Issued for Design D = Issued for Inquiry E = Issued for Order F = Issued for Prefabrication G = Issued for Construction / Fabrication H = Issue for Work Preparation I = As- built M = General Issue

Date

Prepared

Date

Checked

Date

Approved

Acc.

CC Category Code: 1 = for approval 2 = for review 3 = for information 4 = for internal use AC Acceptance Code: 1 = approved / reviewed 2 = approved / reviewed as noted 3 = not accepted 4 = received

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CONTENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Scope
Purpose REFERENCE SPECIFICATION AND CODE PERSONNEL QUALIFICATION JOINT TYPE TEST EQUIPMENT AND MATERIALS TEST SURFACE PREPARATION EQUIPMENT CHECKS TIME BASE (DISTANCE ) CALIBRATION REFRENCE LEVELS DISTANCE AMPLITUDE CORRECTION (DAC) TRANSFER CORRECTION SCANNING SENSITIVITY REFLECTOR EVALUATION SCANNING AND SCANNING PATTERNS REPAIRS REPORTING ULTRASONIC TEST METHOD FOR WELDED JOINTS: ACCEPTANCE CRITERIA: Attached

Page 3 3 3 3 3 3-4 4 4 5 7 7 7 7 7-9 10 11 11 11-12 12 13

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1. SCOPE.

ULTRASONIC EXAMINATION PROCEDURE

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This procedure to describe and establish the requirements to performing the ultrasonic examination for the boiler activities during the execution of Ammonia Urea ENPC project
2. PURPOSE The purpose of this procedure is to ensure that all ultrasonic inspections are performed in a controlled manner and are acceptable to the project fabrication specification and controlled cods.
, .

3.

REFERENCE SPECIFICATION AND CODES AD 2000 - Merkblatt HP 5/3 DIN EN 1714 : 1997 + Al : 2002 (ULTRASONIC TESTING OF WELDED JOINTS ) CLASS B EN 1712 ACC LEVEL 2 PERSONNELQUALIFICATION. The performing ultrasonic inspections and interpreting the results shall be qualified in accordance with the requirements of EN-1714:1997+A:2002 Personal shall be qualified to an appropriate to an appropriate level in accordance with En 473 or equivalent in the relevant industrial sector. (SNT-TC-1 A, to ASNT level II)

4.

5. JOINT TYPE This procedure shall apply to the ultrasonic inspection of full penetration butt welded and Groove joints.

6. TEST EQUIPMENT AND MATERIALS 6.1 ULTRASONIC APPARATUS The ultrasonic apparatus shall have an A-scan display, utilizing the pulse-echo system and shall have an supply. Horizontal sweep linearity shall be within 1 % accuracy.The instruments shall have a calibrated gain control accurate to within 1 dB over a 60 dB range.

6.2 PROBES - Search unit frequency shall be from 2.25 MHZ to 4.0 MHZ

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Search unit type 0 deg search unit 45 deg search unit 60 deg search unit 70 deg search unit

ULTRASONIC EXAMINATION PROCEDURE

Search unit frequency 2.25 - 4.0 MHZ 2.25 - 4.0 MHZ 2.25 - 4.0 MHZ 2.25 - 4.0 MHZ Size 10 mm 8*9 mm 8*9 mm 8*9 mm

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Type Twin Single Single Single

Special search units, wedges, shoes or saddles when used Search units with contoured contact wedges may be used to aid ultrasonic coupling. 6.3 Reference Standard Blocks

IIW Reference blocks (V1&V2). Bl Reference blocks as in AD2000-Mmarkblatt-HP5/3 Appendix (1) fig. (6). 6.4 COUPLANT Wallpaper paste, oil or equivalent.
7 TEST SURFACE PREPARATION The surface (s) from which testing is to take place shall be thoroughly cleaned to remove, scale, coatings and spatter by light grinding, blasting or power brushing. The surface shall be prepared up to a distance large enough to accommodate longest probe stand off to be used during joint testing. The test surface shall be at ambient temperature when testing is performed. 8 EQUIPMENT CHECKS:

Equipment checks shall be performed using IIW and Bl standard reference blocks. Checks shall be performed at least every 4 hours of the testing and on completion of the testing and whenever a system parameter is changed.
8.1 Horizontal linearity Using the highest frequency longitudinal wave probe available on the flat surface of the IIW standard reference block and using 4 echoes- place the left hand side of the signal to coincide with consecutive horizontal scale divisions. Checks shall be performed to cover all anticipated test ranges and the maximum deviation shall not exceed 1% of full scale range. 8.2 Beam angle. Using the IIW block 100mm quadrant, maximize the echo signal by moving the probe paralle to the sides of the block .The index point directly above the quadrant center point is thin marked on the side of the probe . 8.3 Beam angle Using the IIW block 50 mm hole to check probe angles ,maximize the echo Signal and note the beam angle engraved on the block directly below the probe index point. 8.4 Transducer sensitivity Each transducer shall be capable of producing a 3/4 FSH signal from 100 mm quadrant of the IIW calibration standard with 40 dB amplification in reserve.
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9 TIME BASE (DISTANCE ) CALIBRATION: Time base calibration shall be made using the IIW reference standards. The time base shall be calibrated to accommodate the required test range. When using the IIW block, calibration of 0 probes is performed using the 25mm or 100mm Sections. When using the IIW block, calibration of angle probes is performed using the 100mm quadrant.

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10 REFRENCE LEVELS: The reference level is a distance amplitude curve (DAC - curve) for a 3 mm side-drilled hole (Reference blocks as in AD2000-Markblatt-HP5/3 Appendix (1) Fig. (6)) (Reference blocks will be samples of tested objects and same conditions) 11 DISTANCE AMPLITUDE CORRECTION (DAC): A DAC curve shall be constructed for each probe to be used during testing. The reference block, nay consist of one or more 3 mm diameter side drilled holes (Bl reference standard) The curves are constructed by plotting the peak amplitude response from one more 3 mm diameter holes in such a way that at least 3 plotting points are used to construct each curve. The beam path distances utilized shall allow curves to be constructed for all test beam path distance and ranges encountered during production. The maximum signal amplitude obtained from the shortest suitable beam path distance shall be set to 80% full screen height. This gain setting represents the standard sensitivity level to be used for testing and should be recorded for each probe. 12 TRANSFER CORRECTION: Transfer correction requirements shall be evaluated for each joint / material type to be examined in order to compare the attenuation levels of the piece under examination with that of the reference standard used to establish sensitivity levels. Two angle beam probes of the same type are directed at each other on the reference standard. Once probe is used as a transmitter, the other a receiver. At a one skip distance the signal is set at 75% full screen height and the peak plotted on a screen overlay. The probes are then positioned at a 2 skip distance without altering the instrument sensitivity and again peak is plotted. The two points are then joined to produce a line. Using the same sensitivity setting the same procedure is repeated on the member to be examined. Using the two line plots the difference in signal amplitude (attenuation) can be established for the maximum sound path distance to be used during inspection. The single skip distance shall be at least 100mm, but successive skips may be used to achieve the maximum sound path distance to be used during inspection.

The single skip distance shall be at least 100mm, but successive skips may be used to achieve the 100mm minimum, requirement.

13 SCANNING SENSITIVITY: Scanning sensitivity shall be at least standard sensitivity level plus transfer correction plus 6 dB Scanning sensitivity may be up to standard sensitivity level plus transfer correction plus 12dB when increased scanning speeds are to be used. 14 REFLECTOR EVALUATION: Defect character, size orientation and location shall be evaluated using multiple probe angles, directions and test surfaces as are permitted by the piece under examination. More than one transducer frequency may be employed during evaluation.
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14.1 DISCONTINUITY CHARACTERIZATION Discontinuity shall be characterized as either: 1. Planar : such as lack of fusion, cracks and unfazed root faces (figure 1). 2. Cylindrical: such as slag lines, hollow bead and aligned pores (figure 3). 3. Spherical : porosity (figure 2).

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14.2 DISCONTINUITY CHARACTER EVALUATION: Spherical : Discontinuity remains essentially unchanged when evaluated from any angle. Planar : Discontinuity signal amplitude is significantly higher from one angle of Incidence the signal may have multiple peaks indicating multiple faces, but will drop-off rapidly. Cylindrical : Discontinuity remains essentially the same when evaluated using different angles. 14.3 DISCONTINUITY SIZE EVALUATION: (1) AMPLITUDE COMPARISON TECHNIQUE:

This technique compares the maximum amplitude from a defect signal with that of a known artificial defect (a 3 mm 0 hole) having the same beam path distance.
(2) BEAM BOUNDARY INTERCEPT TECHNIQUES:
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* 20 dB drop technique This technique shall be applied to evaluated reflector width. This technique shall utilize prepared beam spread plots showing the 20 dB beam profile for the transducer(s) being using. The reflector signal is maximized by probe manipulation, and then the gain is adjusted to set the signal peak (1) at around 75% FSH. The gain then increased by 20 dB. The probe is moved forward until the signal returns to the same amplitude as signal peak (1) (top of reflector). The beam path distance and distance to weld reference point are recorded. The reflector signal is once again maximized at around 75% and the same procedure used with the probe moved backward (bottom of the reflector). Using the beam spread plots and the information obtained from the probe movements the discontinuity width and location can be plotted on a weld joint section drawing.

*6 dB drop technique This technique may be applied to evaluate to reflector length.

Probe manipulation is as for 20 dB drop technique, except that the probe is moved laterally towards and beyond the end points of the reflector. It may be considered that 6 dB reductions in signal amplitude occurs when half the beam is striking the reflector and therefore the beam center line is used to identify the ends of the reflector. The 20 dB drop technique shall be used to evaluate reflector length when the reflector is considered to be shorter than the cross sectional beam width at the reflector beam path distance. 14.4 DISCONTINUTY ORIENATIONA VALUATION: Transverse angular orientation evaluation is carried out using the same method as for distinguishing planer from cylindrical discontinuities. The reflector is observed using different probe angles. The angular orientation can be estimated as being essentially perpendicular to probe angle producing the greatest signal amplitude. Longitudinal orientation evaluation is carried out by maintaining a maximize discontinuity signal amplitude. 15. SCANNING AND SCANNING PATTERNS:
The complete joint including weld metal, heat effected zone and adjacent base metal shall be examined using multiple probe angles and beam path ranges as required. In all cases the technician shall attempt to examine the fusion zones using beam angles as near perpendicular to the fusion line as possible. Root areas shall be examined separately from the weld body again using multiple probe angles Double sided welds shall be examined from both faces. Butt welds shall be examined from each side of the weld axis (if accessible) The probe shall be perpendicular to the weld axis during scanning.
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The joint shall be examined by back and forth movements of the probe, while continuously rotating the probe between 6 and 10 in rapid succession Lateral probe movements shall overlap by at least 10% to ensure full test coverage.

16- REPAIRS:
Repair locations shall be identified on the joint using a permanent marker.

A sketch of the joint repair location showing the defect sectional location, Material thickness and below surface depth, shall be drawn adjacent to repair area.

17. REPORTING: Reporting shall be made on standard IEMSA ultrasonic inspection report forms. A report shall be prepared for each joint examined. Full-scale cross sectional joint sketches showing rejectable defect shall be included in the report Defect details of the examinations above disregard level shall be documented. All test restrictions shall be documented. 18. ULTRASONIC TEST METHOD FOR WELDED JOINTS: 18.1 TEST TIMING Testing shall be performed no sooner than 24 hours after weld completion. Joints shall be tests prior to an overlapping member installed. Due consideration shall be given to testing joints when the future attachment and weld out of other members in the vicinity may subsequently affect the joints soundness 18.2 PREPARATION FOR TEST: The technician shall be made aware of the welding process used. The technician shall be made aware of any root modifications, particularly in single sided joints . The technician shall be familiar with the joint geometry. Member thickness (e s) shall note from weld mark drawing. Joint identification shall be noted from weld mark drawings. The technician shall be familiar with the equipment he is using. The technician shall have performed the necessary equipment checks as listed in section 8.

The technician shall have established sensitivity levels for the probes he is using
v

18.3 PERFORMING TEST AND RECORDING RESULTS :

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A thorough visual examination shall be made to assess test surface preparation (roughness, evenness and extent) and weld profiles that may confuse ultrasonic evaluation. For complex geometries and to assist in defect location, a full size sectional drawing or drawing shall be made of the joint using profile strips etc. The root index (e s) shall be used to accurately show root face locations. The weld datum point shall be marked with marker. The technician shall establish scanning patterns and test ranges required examine the weld, HAZ and adjacent base metal. Probe / test surface coupling shall be made using wallpaper paste, oil or other suitable liquids. Calibrate the time base allowing for the required test range using a suitable reference standard (IIW) the equipments shall be calibrated whenever it is switched on or probe cable is changed. The test Surface (s) see metal' shall be checked for laminations and laminar-type flaws that may interfere with weld examination using a Longitudinal probe. Findings shall be reported. Member thickness measurements shall be noted and compared to the required member thickness. Transfer correction levels shall be established as described in section 12. Scanning sensitivity level shall be set for each probe used at between 6 to 12 dB above standard Sensitivity plus transfer correction. Scanning shall be performed as stated in section 15. From the joint member perform scan of the joint root area using (45, 60 and 70 probes) (joint geometry may restrict the use of all probe angles). From the joint member perform scan of the weld body, HAZ and adjacent base metal using two angle Probes (45 , 60 and 70 probes) From the receiver back wall perform scan of the joint using a 0 probe and other angles as required (scanning from the receiver back wall may not be possible due to access restriction). Scanning shall be performed from both sides of the weld axis for in line butt joints. Scanning shall be performed from both faces of double sided joints. Discontinuity character, orientation width, length and location within the joint cross section shall be evaluated using the techniques described in section 14, assisted by plotting cards, full size sectional sketches, overlays or other devices. Recordable indication above disregard level and below reject level shall be recorded. Reject able defect details shall be recorded and shall include probe angles and frequencies used to evaluate the defect, defect character, orientation, signal amplitude, width, length and location relative to weld datum. Defect location within the joint section shall be recorded on a full size cross sectional drawing. Repair areas shall be clearly identified using marker. A sectional sketch showing defect location within the cross section with dimensions shall be drawn adjacent to the repair area. Reporting shall be performed as described in section 16 and 17.

19. ACCEPTANCE CRITERIA:

Acceptance and rejection of discontinuities is based on discontinuity character, peak signal amplitude, width, length, and location within the joint cross section. ** Any indication equal to or exceeding the reference level (DAC) -10 dB {33% DAC) shall be Evaluated. ** Acceptance criteria stated in AD2000-Markblatt-HP5/3 paragraph 4.4 will be applied. ** Except the planer defects: not permitted.
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20. Attached: Ultrasonic examination report. Demonstration data sheet

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ULTRASONIC EXAMINATION PROCEDURE Demonstration data sheet

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Project : Ammonia Urea ENPC project Procedure : PT-BM-183-DC-0000 Surface condition : BRUSHED Examination technique : UT equipment : MSD 500 Probes :

Client : Uhde- ENPC Applicable code : EN 1714

Couplant : Soup Serial no. : FD09083003 Cables :

Equipment Check:
1) 2) 3) 4) 5) Calibration certificate. Vertical linearity (normal probe) frequency (5 MHZ). Horizontal linearity (normal probe) frequency (5 MHZ). Resolution normal probe frequency 5 MHZ and V II block. Page calibration V II.

Calibration:
1) Page range calibration. 2) DAC curve demonstration and construction by using calibration block 12.5 mm/1.5 mm target three drilled holes. 3) The angle probes for DAC curve, 60, 70 by frequency 4 MHZ. 4) The couplant and media correction db 6.

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Project : Ammonia Urea ENPC project Procedure : EN 1714 Surface condition : BRUSHED Examination technique : UT equipment :
Probe No. / Vibration Mode Frequency Size Angle Type Calibration Sheet Range Reference Echo Ref. Echo Distance Gain Damping /Reject Attenuate Correction

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Client : Uhde- ENPC Applicable code : Couplant : Serial no.

1 MHZ mm 2 3 4

No. mm mm mm dB dB

DWG/ISO: Size: JOINT DIM NO. (inch)

DISCONTINUITY THK (mm) MATERIAL CLASS PROBE

E (dB) H % L mm Q mm t mm I mm d mm D mm

RESULT

E L Q t I d D A NOTE:

REFERANCE LEVEL - H : MAX % GREATER THAN REF. LEVEL. DISTANCE OF DISCONTINUITY FROM WELD AXIS DISTANCE OF DISCONTINUITY FROM WELD AXIS DISTANCE OF DISCONTINUITY FROM PROBE CONTACT SURFACE LENGTH OF DISCONTINUITY DEPTH OF DISCONTINUITY THROUGH DEBTH OF DISCONTINUITY ACCEPTED - R : TO BE REPAIRED

IEMSA Name Sign Date

PETROJT

UHDE

ENPC

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