NATONY LIMITED RC.

105963

CLASSIFICATION STATUS: RESTRICTED

June, 2012

Document Identification FYP-NG01009296-YOKA1-QA-6050-00003

FYIP - ONSHORE COMPLETION WORKS FOR YOKRI FLOWSTATION (Contract No: NG01009269)

NON-DESTRUCTIVE TESTING

PROCEDURE

Approval:
Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Natony Limited

The Process Owner for this procedure is Quality Manager. Revision Date Description Originator Checker Approver S.N.I. Okoro

Joshua E. R01 22/06/2012 Issue For Review QAQC Engineer

Chinedu J. QAQC Cordinator

FYIP Onshore Lead

REVISION HISTORY Rev. No R01 Date of Issue 22/06/2012 Document ID/ Reason for Change Issue For Review

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TABLE OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0. SCOPE PURPOSE DEFINITIONS ABBREVIATION REFERENCE ROLES AND RESPONSIBILITIES GENERAL PROCDURE ATTACHHMENTS

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1.0

Scope This procedure sets out the quality standard specifications for the various welded joints integrity test methods that shall be applied by NATL to execute non-destructive examination of welded joints as required for the FYIP-Onshore Completion Works for Yokri Flowstation. Purpose This procedure is prepared to address and demonstrate how NATONY LIMITED intends to use quality practice instruments to carry out Non-destructive Examination of all welded joints, to meet the required quality standard. Non-destructive examination consist of Radiographic Inspection, ultra sonic or other generally accepted standard welded joints integrity evaluation methods as may be specified by the SPDC.

2.0

3.0

ABBREVIATIONS SPDC: Shell Petroleum Development Company of Nigeria Limited, the client of FYIP-Onshore Completion Works for Yokri Flowstation herewith referred to as SHELL. NATL- Natony Limited SWSI - Single wall SINGLE image DWSI - Double Wall Single Image. IQI Image Quality Indicator

4.0

Reference Documents a) b) c) d) e) f) g) ANS1/ASME B31.3 API Stand 1104 AWS D1.1 ASME Section IX Shell standard spec. 20 SPDC Radiation Safety Manual & Emergency Order C4. NATL Welding Control Plan NATL-FYIP-QSP-1501
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h) j) i.) k) l) 5.0

API 1104 Welding of Pipeline and Related Facilities ASME B313 Chemical Plant and Petroleum Refinery Piping BS 3683 Glossary of terms used in Non destructive Testing. Part 4 Ultrasonic flaw detection S 3923 Methods for Ultrasonic Examination of Welds. DEP 61.40.20.30, DEP 31. 38.01.31andDEP 30 10.60.18

RESPONSIBILITIES Project Manager He ensures adequate provision of all the resources needed for the successful execution of the work scope. He ensures that experienced and skilled persons are involved in the execution of the work scope. He is responsible for Managing HSE for these operations. Site Engineer He manages and coordinates the resources provided. Liases with QA/QC department on regular basis to ensures that all relevant parties are notified to attend the examination as well as inspection of the works.

QA/QC Engineer QA/QC Engineer shall be responsible for control and verification of the implementation of this method statement. He shall be responsible for all quality control and quality assurance functions. Safety Officer He is responsible for validity and re-validity of permit to work (PTW) before commencement of work and make it readily available on site for sighting of Shell Representative(s) and NATONY LIMITED QA/ QC team. He assists the Site Engineer to ensure that all personnel adhere to the safety rules and regulations. NDE Equipment Operators/Inspectors These are the personnel that shall be required operate the various NDE equipment that shall be used to carry out the integrity checks of welded joints and interpret the various resulting test results in this project. They would be required to demonstrate the inspection procedure capability to detect rejectable defects and the operators ability to properly interpret the indications given by the equipment.

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6.0 6.1

GENERAL PROCEDURES RADIOGRAPHIC INSPECTION

6.1.1 RADIOGRAPHIC SOURCE AND PROCEDURE STANDARD The radiographic source shall be Irridium-192 and curie strength shall be between 20 curies. The radiography procedure shall be in accordance with SPDC construction specification Section 20 part 2 and with ANSI B31.3, Process Piping and ASME Section IX. Radiography 6.2 QUALIFICATION OF RADIOGRAPHIC PROCEDURE/TEST RADIOGRAPH

6.2.1 A test weld on a pipe joint is required in the proposed radiographic procedure Qualification. This must be identified in size and material to those to be encountered in production inspection. The radiographs shall be the same using the same equipment and conditions as specified in this radiographic procedure. 6.2.2 The discontinuities shown on radiograph shall be recorded on the same report format as will be used during the production inspection. Three copies of this report, together with the test radiograph shall be submitted to the inspection agency/client who shall decide whether the procedure is satisfactory. 6.2.3 The procedure shall produce radiograph of sufficient density, clarity and contrast so that defect in the weld or in the pipe and outlines and number of wire on penetrameter (IQI) are clearly discernible. 6.3. EXTENT OF RADIOGRAPHY The extent of radiography required will be as specified in the contract documents specifications or drawings. Definition of term covering the extent of radiographic inspection shall be given in the appropriate governing piping standard. 6.4. 6.4.1 EXPOSURE GEOMETRY TECHNIQUE No 1: - Single wall SINGLE image (SWSI) For total weld examination with a single exposure, the source shall be centered

(a) and

positioned so that projected beam passes through the centre of the weld, the maximum deviation from perpendicular shall not exceed 5 degrees. (b) The minimum Source to Object Distance (SOD) shall be at least eight times the weld thickness. (c)A single film length may be used when using either one or more films; the film overlap shall not be less than 4 (10.16cm) mainly for plates.
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6.4.2 TECHNIQUE No. 2:- Double Wall Single Image. (DWSI) (a) The source shall be positioned on the outside of the pipe so that the centre of the projected beam passes through the centre of the section of the weld being examined. If necessary, the source may be off set to avoid super-imposition of weld images. The maximum amount of offset shall not exceed 5 degrees. (b) The film envelope shall be centred to the section of the weld being examined and in direct contact with the weld. Each radiograph shall have a minimum of 2 (50.8mm) overlap at each of the acceptable (readable film or diagnostic film length.) (c) Image quality indicator (IQI) shall be placed on the parent metal along the edge of the weld. The IQI shall be placed on the film side. Any pipe diameter not less than 2 uses this method. 6.4.3 TECHNIQUE No. 3:- Double Wall Double Image (DWDI). The source is off set one fifth of the SFD and the SFD is not less than 8 times the wall thickness. This is also called elliptical shot. Mainly when radiographing 1- 2 pipe diameter. The image produced is oral spherical in shape. 6.4.4 TECHNIQUE No. 4:- Single wall single image (panoramic). The source is positioned inside the pipe at the centre and the films outside the pipe. 6.5 Manual Film Processing

6.5.1 Manual film processing shall be operated according to the recommendation of the processing chemical manufacturing company. 6.5.2 Films shall be developed in approved solution for a controlled period of 4 to 5 minutes and at a temperature of 20oC + 1oC. After developing, the film shall be passed through an acid stop bath preparatory to fixing. Hardwater may be incorporated in the fixer solution. 6.5.3 Films shall be washed and dried prior to viewing and for the washing process, the temperature of the wash water shall be maintained in the range of 18 - 21oC. All films shall be washed at least 3 times using series of arranged agitating washing tanks with a minimum capacity of 25 litres each. 6.5.4 Films shall be arranged progressively from one tank to the next at five minutes intervals and each film drained thoroughly before transfer. The water in the tank should be replaced after four hours of use.

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6.5.5 Radiographs shall be processed to allow storage of film without deterioration of at least three years. The radiographs shall be free from imperfections due to processing or other defects, which could interfere with satisfactory interpretation. 6.6 Film Identification

6.6.1 All films shall be clearly identified by lead numbers, letters and/or marker so that the proper weld and any discontinuities in it can be quickly and accurately located. The client identification procedure shall be applied. 6.6.2 Whenever more than one film is used to inspect a weld, the identification markers shall appear on each film. In addition, each weld section reference marker location be common to two successive films to establish that no part of the weld shall be omitted. Lead identification tape shall be used and it ranges from 0cm-10cm-20cm-30cm100cm to any range of pipe diameter to be radio graphed. The lead tape shall be positioned on the left-hand side of the pipe so that the identification weld letters and weld numbers shall be at the right hand side of the radiograph. 6.6.3 Each weld shall be assigned a unique number by the radiographer. 6.6.4 When a weld is cut out, the replacement weld received a new tag with a new identification. 6.6.5 The image of the identification shall not interfere with the interpretation of the weld image on the radiograph. The lead letter/numbers identification shall include as a minimum the permanent identification designation, the identification of welders, weld numbers, section and all relevant information required by the clients. 6.7 Presentation of Completed Radiographs Completed radiographs shall be arranged in sequence for each weld and enclosed within an identifying envelop stating the radiograph number, weld number, project, contrast, pipe diameter, date shot, Radiographer and any other information which may be required by the client.

6.8

RADIATION PROTECTION RPS shall be fully responsible for radiation safety as indicated in the Radiation Safety Manual. Before any work begins, any employee to work with radioactive material and/or radiation machines must be given a complete understanding of the dangers involved. He must also first be thoroughly grounded in related safety procedure.

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 As needed, clear and proper warning signs must be prominently posted around the radiation area. If appropriate or called for by compliance with local regulations, other protective devices will be provided as well. Only a qualified person, responsible for radiation safety, may direct any operation involving radiation hazards. This includes both X-ray machines and radioactive sources. This qualified person is also responsible for establishing protective procedures, which assure exposure is kept at or below acceptable doses for both employees working directly in the radiation work area as well as those working near it. These procedures and routine review and/or revision of them will be based on surveys and evaluations. Whenever the radiation dosage can exceed 25% of the permissible limits, any person exposed must maintain a film badge or dosimeter pencil. Dosimeter or other indicating devices must be of the sort that not only detects but also measures accumulated dosage to which the user has been exposed. For each employee exposed to radiation, records must be kept which will document accumulated exposure at any future point. Any suspected case of over exposure must be immediately referred to a doctor, and appropriate reports filed. All radioactive materials and radiation machines must be transported, operated, stored and discarded in such a way that none receives a dose of radiation. 6.8.1 FILM INDENTIFICATION Film identification shall be including the following: Client Project Identification Line Name / Line Size Date Radiographic Position Welder No. Weld No. Spool Ref. No. Size Thickness Pipes welded with pipe axis horizontal shall have zero datum at the top of the pipe.
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6.9. 6.9.1

ULTRASONIC TEST EQUIPMENT

6.9.1.1 ULTRASONIC INSTRUMENT Only pulse signal type ultrasonic flaw detectors which incorporate A scan CRT presentation shall be used. The instrument shall be capable of fulfilling the following performance criteria:(a) Time base linearity shall not exceed + 2% deviation over CRT screen width range of 200mm. (b) Screen height linearity shall not exceed + 5% deviation of full scale reading for all values from 20 t0 80% full scale height. Amplitude control linearity shall be accurate to within + 20% of its useful range. The amplitude gain control shall have a minimum range of 60dB

(c)

To enable the performance of instruments to be monitored, each instrument shall have a unique serial number. Ultrasonic instrument shall have calibration checks carried out as detailed in table I TABLE 1 EQUIPMENT CHECKS Time Base Linearity Screen Height Linearity Amplitude Control Linearity

Frequency Daily Daily Daily.

Calibrations for time base, screen height and amplitude control linearity shall be conducted immediately prior to any ultrasonic testing Certified calibration of the ultrasonic instrument shall be performed annually with original calibration certificate held at the company head office and a photocopy held with each ultrasonic instrument. Instruments that do not meet the requirements shall be withdrawn from service until corrected.

6.9.1.2 PROBES Probes Categorization and (Specification) Table A

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Plate thickness Thickness

Probe Size (diameter or rectangular transducer of equivalent area) Compressional wave-Normal 10mm Twin crystal 20mm Twin crystal 25-30mm Single crystal 25 to 30 mm Single crystal Shear WaveAngle 8 x 9mm Single crystal 8 x 9mm Single crystal 20x22mm-Single Crystal 20x22 mm Single Crystal

Probe Frequency in MHz

Over mm 6 15 40 150

Up to including mm 15 40 150 -

4 to 5 4 to 5 2 to 4 2 to 3

The following shall be established for each probe:(a) (b) (c) An accurate probe index recheck before each ultrasonic operation Probe bean angle with an accuracy of + 2 of the nominal probe angle Probe beam profiles shall be constructed using the beam boundary technique in accordance with ASME V. See table 2

TABLE 2 CHECKS Beam Index Point Beam Angle Contact Face Flatness Beam Profile Probe Resolution FREQUENCY Daily Daily Daily Weekly Weekly

Probes Integrity Checks and Frequency Table 2. 6.9.1.3 COUPLANT The couplant used shall be capable of ensuring maximum ultrasound transmission. The couplant used shall be the same for both calibration and examination
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Cellulose paste, liquid soap, glycerin, light machine oil or suitable equivalent may be used provided they are non-injurious to materials under lest.

6.9.1.4 CALIBRATION BLOCK The following standards calibration blocks shall be used for calibration of equipment: International Institute of Welding V1 And V2 blocks Institute of Welding IOW-Beam profile block used for plotting beam profile

6.9.1.4 REFERENCE BLOCK The following reference block shall used for setting sensitivity and construction of DAC. For pressure vessels and piping the block shall be ASME BLK fig T-542.2.1 (attachment 11l.1 and 11.2) The basic calibration block shall be curved for materials with diameter 20 inches and less. A single curved basic calibration block may be used to calibrate the examination on surfaces in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter. For Pipelines, the block shall be as per API 1104. fig 22A N10 notch introduced into the a sample of the pipe to be inspected (attachment 11.3).

6.9.1.5 INFORMATION REQUIREMENTS 6.9.2 The technician shall be supplied with the following details of the item to be examined testing commences. (a) (b) (c) (d) (e) 6.9.2 Materials type Joint details Welding process P.W.H.T (it any) Any repairs carried out previous to the test

The technician shall verify the extent of examination coverage and record any limitation of the test on the inspection report

6.9.3 6.9.4

SURFACE CONDITION Surface used for testing shall be free from weld spatter, scale or other irregularities which could impair adequate acoustic coupling.
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6.9.5

Depending on the profile and condition of the weld face, dressing may be necessary to avoid the production of confusing surface signals. When the selected ultrasonic beam cannot cover the full cross section of the weld without the probe impinging up on the weld face, the weld face shall be ground smooth, or a limitation will be noted on the inspection report. CALIBRATION FOR EXAMINATION

6.9.6

6.10

6.10.1 The suppression control shall be turned off for calibration and during examination. 6.10.2 Calibration shall be conducted for sensitivity and bean path distance prior to commencement of testing. 6.10.3 Recalibration shall be carried out after a change of operator, every 30 minutes or when the electrical circuit is disturbed in any way which includes the following. 6.10.4 Calibration for straight beam testing shall encompass and preset at least two material thickness on the CRT screen. One thickness step shall be near the nominal of the range to the measured and one thickness shall be near the half the nominal. 6.10.5 Time base calibration for angle beam testing shall be adjusted to represent the maximum sound path distance covered. 6.11 MEASUREMENT OF ATTENUATION AND TRANSFER LOSS

6.11.1 Attenuation and Transfer loss measurement shall be made as follows:(a) Calibrate the time base using single angle probe (b) Two angled probes of the same nominal angle and frequency to be used for weld scanning shall be positioned, one for transmitting and one for receiving. (c) Position two probes on the DAC block to give one full skip distance, maximize the signal by adjusting the probe position and record the Gain required bring the signal to 80% full screen height. This gain (dB) is X1. (d) Reposition the probes on the DAC block to give 2 full skip distance and maximize the signal by adjusting the probes position and record the gain required to bring the signal to 80% full screen height. This gain (dB) is X2. (e) Repeat step (c) and (d) with the probe on the material under test and record the gain setting (Y1) and (Y2) respectively. (f) Plot a graph with beam path in X-axis and gain in Y-axis. Plot the points of X1,X2,Y1 and Y2 with their corresponding beam path. Connect points X1 and X2 and points Y1 and Y2 by drawing line through them and extend the line to Zero range. (g) This graph gives the attenuation and transfer loss for the selected range by giving the difference in gain between the two plotted lines.

6.12

CONSTRUCTION OF DISTANCE AMPLITUDE CORRECTION CURVE (DAC)

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a. DAC curve shall be constructed for each probe to be utilized for the examination and for each calibrated time base. b. Calibrate the time base to accommodate full testing range to be used c. Select the target holes or notch to be used for the DAC curve and adjust the probe position to obtain maximum signal height from the hole giving the highest amplitude d. Adjust the gain to give 80% full screen height signal from this hole or notch and mark the position of the signal tip on the screen e. Without altering the equipment gain, adjust the probe position to obtain maximum amplitude from each of the holes or notch in turn and mark the respective signal tip on the screen f. Join the marked points on the screen to obtain DAC curve for that particular probe g. Record the gain at which the DAC curve was plotted.

6.13

TESTING PROCEDURES

Prior to examination all specimens shall be marked with a reference datum line 6.13.1 PARENT METAL EXAMINATION a. Prior to scanning do a compressive wave probe on the parent metal to ascertain that there are no laminations (forge or roll process grain boundary layer ) defects . b. The area to be checked shall be large enough to detect laminar discontinuities that could interfere with shear wave propagation c. d. The lamination scan shall be carried out regardless of whether the parent metal has been ultrasonically tested previously During the lamination scan attenuation characteristics, material thickness and any flaws found shall be noted and recorded if necessary. Sensitivity shall be adjusted so that the second back wall reflection is 80% full screen height or first back wall @80%+6dB whichever is maximum . Evaluation of indications shall be made using the 6dB drop technique.

e.

f.

6.13.2 SHEAR WAVE EXAMINATION (a) Reference Sensitivity shall be the gain recorded for plotting DAC curve incorporating the attenuation and transfer loss correction. (b) (c) All examination shall be conducted at 6dB above reference sensitivity. The sizing of flaws shall be carried out using the beam boundary technique.
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(d) (e) (f)

Height of flaws shall be sized by the 20 dB drop techniques and length shall be sized by the 6dB drop technique. Unless otherwise specified 100% of the weld length shall be tested.

6.14

SCANNING TECHNIQUES The maximum scanning rate shall be 150mm per second.

7.15.1 Scanning techniques shall consist of: (a) (b) (c) Compression probe scan of parent material in accordance with 7.8.3 Angle beam scan of weld metal using appropriate angled probes, one of the beam angle Shall not offer more than 5 from the weld bevel preparation.

6.14.1 As a minimum each pass of the probe shall overtop a minimum of 10% of the transducer width. 6.14.2 Whenever feasible the examination shall be carried out from both sides of the weld 6.14.3 The beam shall be pointed at the weld length normally. As a minimum two (2) different angle probes shall be used. The two beam angle shall differ minimum 100 from each other. 6.14.4 Do a 450 probe shall for angled scanning of the weld to search for transverse flows. 6.15 DISCONTINUITY SIZING

6.15.1 Maximum amplitude technique shall be applicable to rough discontinuities i.e. those exhibiting subsidiary maxima, greater than 3mm in the dimension to be measured. Obtain maximum signal from discontinuity and adjust signal to 80% screen height using calibrated gain controls. Mark position of probe index on component and note angular distance 7.9.1.2 Move probe toward until last subsidiary maximum signal start to fall. Mark index and note angular distance. 7.9.1.3 Move probe backward through point as marked in 7.7.1 repeatedly taking readings 7.9.1.4 On scaled drawing of component mark relative position of probe index as determined in 7.7.1., and from angular distanced at those points determine the size and position of the discontinuity.
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7.9.2

20db drop technique shall be applicable to smooth discontinuity i.e. those where no subsidiary maxima are apart and larger than the beam width. 7.9.2.1 Determine probe index, probe angle and 20db beam profile. 7.9.2.2 Obtain maximum signal from discontinuity and adjust signal to 80% screen height using calibrated gain control. Mark position of probe index on component and note angular distance. 7.9.2.3 Reduce setting of calibrated gain control by 20db and note discontinuity signal height. 7.9.2.4 Increase setting of calibrated gain control by 20db i.e. return to setting as in 7.7.2.2. 7.9.2.5 Move probe forwards until discontinuity signal falls to same height as in 7.7.2.3. Mark probe index on component and note angular distance. 7.9.2.6. Move probe backwards through point as marked in 7.9.2.2 and repeat readings as 7.9.2.7 On scaled drawing of component mark relative positions of probe index as determined in 7.7.2.5 and 7.7.2.6 and from angular distances along 20db beam profile line determine the size and position of the discontinuity

7.10

RECORDING AND EVALUATION OF REFLECTORS 7.10.1 All discontinuities that produce reflector greater than 50% of DAG (or 20% of DAC in the event of discovery of cracks, lack of fusion or incomplete penetration) shall be recorded. Evaluation of the discontinuities shall be carried out at Reference sensitivity.

7.11

EXAMINATION OF REPAIRS 7.11.1 Repairs shall be re-examined using the same procedure utilized for the original examination. 7.11.2 The extent of the examination shall include the repaired area of the weld plus 100mm at either end of the repaired section. 7.11.3 A new report with relevant repair number, shall be written for all repaired welds retested.

7.12

POST INSPECTION CLEANING

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7.12.1 When required post cleaning shall be accomplished to remove residual inspection materials (couplant) by flushing with a solvent based cleaner then finally wiping with rags. 7.9. PENETRAMETER (Image Quality Indicator (IQI))

7.9.1. Penetrameter shall be generally of wire type and shall comply with BS 3971 (1980) or DN 54209. Penetrameter dimensions shall be appropriate to the size of the welds and penetrameter materials shall be radiographically same as the materials being tested. 7.9.2 Penetrameter sensitivity shall be such that radiography in accordance with BS 2910 will produce for the techniques listed below; Contrast not worse than. 1.5% on pipe, penetrameter on film side 7.9.3 Technique 14: examined, 7.9.4 Technique 11: 7.9.5 Technique 17: 1.8% pipe expressed in terms of the single wall shall be penetrameter on film side. 2.0% on pipe penetrameter on film side. 2.6% on pipe, penetrameter on film side.

7.9.6 Where radiography is being carried out in accordance with API 1104 or ASME V the quality level for radiography shall be at least 2% (2 - 2T). Radiographs shall also clearly display their identifying numbers and letters. 7.10 Film Processing and Printing Chemicals All chemicals for use in the developing and printing of radiographs shall be suitable for storage and use at 35oC. We use Agfa and Kodak liquid or powder for both developer and fixer. 7.11 Darkroom, Viewing and Storage Facilities

7.11.1 The darkroom, viewing and storage facilities shall be adequate in terms of size and equipment to cope with the projected work load of radiographs and shall be kept clean, dry and dust free at all time. 7.11.2 Viewing of radiographs shall be carried out under subdued lighting conditions and care shall be taken to minimize the reflection of light on the film from the viewer. 7.11.3 For examination of radiographs, viewing illuminators shall be used which will produce sufficient light intensity so that the pertinent details of the weld and base metal are clearly defined on the radiographs. 7.12 Production Radiographs All radiographs shall become property of the client.

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7.12.1 The duties and responsibilities of the radiographers with regards to radiographic activities shall include but not limited to: (a) (b) (c) Directing the performance of the radiographic work. Radiographic quality and storage. Protection against radiation or exposure, monitoring of all persons at or near radiation area.

7.12.2 Dry film interpretation shall be used. 7.12.3 Darkroom shall be large enough to accommodate film processing and viewing radiographs simultaneously. 7.12.4 Each darkroom shall have at least one film illumination that have a light source intensity and suitability controlled to allow viewing film densities up to 4.0 without damaging the film. 7.12.5 Radiographs of acceptance welds, including repairs and outs replacement welds shall be filed in numerical order. Radiographs of unacceptable welds shall be filed separately. 7.12.6 Compartmentalized boxes shall be used for filing 70mm films. Each box shall contain a grid sheet identifying the films in each compartment. The content shall be identified on the outside of each box with dates covering lowest number and highest number. 7.12.7 Film envelopes shall be used for filing sheet film. A copy of the applicable report shall be included with the film. The contents shall be identified on each envelope. 7.12.8 All packages containing radiographs shall be identified by at least the (I) date (II) radiographic unit (III) job location (IV) fabrication or line number. 7.13 Reporting

7.13.1 RADIOGRAPHIC REPORT SHEET. All weld radiographs shall be entered into radiographic report sheet with all available information. 7.13.2 The inspection agency representative signs the report sheet after interpretation. Reject and accept columns are available. 7.13.3 Daily report sheet. 7.13.4 This is optional, where the client or contractor wants the daily activities to be forwarded. Explanations are required for low production i.e., weather condition,
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inaccessibility of butt joint, inclement weather, stand by, strike action by the contractor and so on. 7.13.5 DISTRIBUTION OF REPORT 1ST copy to client, 2ND copy to contractor and 3rd copy to Inspection Agency. 7.14 Radiographic Procedure Specification Form

Project/Contract..Date Contractor Radiographic Sub-Contractor.

(a) Radiation source (b) Type of equipment *external *internal (* - Delete as necessary) *Manually operated/cable *Battery crawler device (c) Intensifying screens type Thickness front Thickness back (d) Filter type and placement (e) Geometric relationship Focal film distance Object film distance Radiation angle with respect to weld and film (Mandatory 90o for technique 8) (f) (g) (h) (i) (j) Technique number as specified in BS 2910 (*8 : *14) Film (Examples:- Kodak II ford Gevaert) Cassette type or pre-packed Chemicals Exposure time

Signed by Sub- Contractor

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Approved subject to Qualification. 7.15 Magnetic Particle Inspection Scope This Magnetic Particle inspection procedure outlines the equipment, technique, surface preparation and acceptance/rejection criteria for the examination of welded joints for Forcados Yokri Integrated Project, in accordance with applicable codes and standards. Equipment The method used is the technique utilizing an electro magnet or permanent magnet with adjustable legs to detect discontinuities that are open to the surface with a fixed pole spacing not more than 6ins. For the wet method, Magnaflux prepared Bat-Type No.7AMF black, non-fluorescent particles or equivalent are used in concentration 1.2 and 2.4ml. per 100ml. solution as recommended in S.E 138 of ASME V. For visual contrast on the work piece, white contrast paint of the type Magnaflux 9 WCP (Aerosol) or equivalent which is quick drying is used. Calibration Test: a) Magnetizing Field Adequacy Every week, it is necessary to verify the adequacy of the Magnetizing Field and the following method shall be applied: Equipment: Magnetic Flux Indicator Burmah Castro Type 1 in accordance with BS 6072 par 9.2.1. 1) 2) Lift test to ensure magnet is of required strength as per ASME V Article 7 Clause T-78. One indicator is attached to the surface of the area under examination (transparent adhesive tape is suitable). It should be aligned with its major axis in the direction of suspected discontinuities. A second indicator is attached at right angle to the first if discontinuities are suspected in all directions The component is magnetized and the Magnetic Particle Inspection Prepared Ink is then applied. Approximately 5 seconds must be allowed for particle migration and the indicator is then examined (whilst the magnetic field is applied).

3) 4) 5)

Interpretation:
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If no indications are apparent, field is too weak for inspection. When indications are clearly visible, the field is satisfactory for magnetizing high permeability materials in accordance with ASME section V. Technique: As per ASTM E 709 and /or client specification: Prior to examination, areas to be tested shall be stipulated by the client. The surface to be examined and all adjacent areas within at least one inch of examination area shall be dry and free of all dirt, grease, scale, welding flux and splatter, oil extraneous matter that may interfere with the examination. The white contrast paint shall be applied by controlled passes over the area to give a thin but opaque white layer. After preparation have been carried out, the magnetic field will be applied to the surface of the part, which does not exceed in temperature of 135 deg. F. and magnetic ink will be sprayed on to the weld area. The magnet will be applied a minimum twice in each direction at 90 deg. positions, on each section of the weld. Overlap of each test section will ensure proper magnetic coverage of the surface. The wet suspensions of particles shall be sprayed on the surface whilst the magnetizing force is present. Evaluation of Indications Discontinuities and defects will be indicated by retention of the magnetic particles. All such indications are not necessarily defects, since excessive roughness, magnetic permeability variations (such as at the edge of heat affected zones), etc., may produce similar indications. If indications are believed to be non-relevant, each type of indication shall be explored to determine if relevant linear discontinuities are present. Acceptance Criteria When magnetic particle examination is used, the procedure and technique shall be in accordance with ASTM E 709, and the standard of acceptance shall be in accordance with section 6.4 of API STD 1104. All linear discontinuities are unacceptable and shall be removed and repaired in accordance with Fthe applicable procedure. Where a linear discontinuity is removed by chipping or grinding and subsequent welding, care shall be taken to contour the surface so as to eliminate any sharp, notches or corners. If repairs are made, the repaired area shall be examined by the same method. Any indication of an imperfection, which is believed to be non-relevant shall be regarded as a defect unless on re-examination by the same method or by use of other nondestructive methods, and/or by surface conditions that no acceptable discontinuity is present. Reports A report form that clearly identifies the work and the area of inspection, equipment and consumables used, shall be completed by the NDE Technician at the time of inspection.
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A detailed report and sketch showing the location along the weld axis, location within the weld cross section, size extent, orientation, and classification for each discontinuity shall be completed for each weld in which significant indications are found. When specified, discontinuities approaching rejectable size, particularly those about which there is some doubt in their evaluation, shall also be reported. Area for which complete inspection was not practicable shall also be noted, along with the reason why. When necessary, a technique sketch will be added illustrating part geometry, magnetizing technique and area of part examination. Personnel Qualifications Personnel performing non-destructive examination shall be qualified in accordance with the current edition of American Society for Non-Destructive Examination Recommended Practice No. SNT-TC-IA and/or equivalent.

7.2

DYE PENETRANT INSPECTION Scope This Dye-penetrant inspection procedure outlines the materials, technique, surface preparation and acceptance criteria for the examination of fusion welded circumferential buff joints and plates in steel pipes, for Forcados Yokri Integrated Project, complete works in accordance with applicable codes and standards. Definition DPI, DYE PENETRANT INSPECTION: the process of NDE whereby a sp ecial liquid dye is applied to the test surface and is subsequently draw into any surface breaking discontinuities and is later drawn back out by the application of special developers to reveal such discontinuities. NDE General Dye-Penetrant examination shall be employed as specified in the contract Documents or as directed by the client or their Inspection Agency. NATONY Limited shall be responsible for the supply personnel, materials and equipment for dye-pentrant examination. The procedure to be used shall conform with client specification and in accordance with the latest edition of the following: ASME V BS 4410 Boiler and Pressure Vessel Code. Method for penetrant examination of welded or joint in metals.
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(Non-Destructive Examination)

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NDT PROCEDURE

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All procedure shall be subject to company approval prior to their use on site. Also whenever conflict arises from the specification the client recommendation shall take precedence. Personnel Qualification: Personnel employed for DPI work shall be suitably experienced and qualified to the approval of NATONY Limited and the client. SPDC. Materials All equipment and materials used in performing dye pentrant inspection shall be of a suitable type and shall be in accordance with client specification. Equipment shall be in good working order. Equipment and materials shall be handled and stored in accordance with manufacturers instructions. Materials shall not be used after the expiring date. Procedure Visual Inspection In the case of DPI of welds, all welds shall be visually inspected and accepted prior to any DPI. Penetrant Penetrant shall be of the colour contrast, solvent-removable type and shall be positively specified as being chemically suitable for use on the particular material under test. Manufacturer recommended temperature limits shall be adequate for local conditions. Developer Wet type solvent suspension developer, suitable for application by spraying shall be used. Penetrant Application Penetrant shall be applied by the use of aerosol sprays in accordance with the spray manufacturers instructions. Since penetration time is critical to the success of the examination, a time shall be established in the procedures, which will give satisfactory results for the prevailing surface temperature of the test piece. For surface temperatures outside the recommended usage range of the penetrant, a new procedure shall be qualified (Ref. To section T-660 in ASME V). After the penetration time has elapsed, excess penetrant shall be removed by wiping with a cloth or absorbent paper, repeating the operation until most traces of penetrant have been removed. The remaining traces shall be removed by wiping the surface lightly with cloth or paper moistened with solvent. To minimize removal of penetrant from discontinuities, care shall be taken to avoid the use of excess solvent. NOTE: Flushing the surface with solvent, prior to developing is prohibited. Developer Application
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Developer shall be spray applied to the entire surface of the test piece as recommended by the manufacturers. Too thin a coating may be insufficient to draw the penetrant out of discontinuities but excessive coating thickness may result in pooling and thus mask indications. NOTE: Prior to its application, the developer must be thoroughly agitated to ensure adequate dispersion of the suspended particles. Examination The type and size of any discontinuity may be difficult to evaluate if the penetrant diffuses excessively into the developer. Consequently, it is good practice to observe the surface during the application of the developer to detect the nature of any indications which tent to bleed out profusely. Final interpretation shall be made after allowing the penetrant to bleed out for up to 30 minutes. Acceptance Criteria Any indication shall be fully investigated until its nature is identified. The acceptance criteria for any imperfection revealed by DPI shall be in accordance with the relevant specifications. In the event that any repair is required to an inspected area, then the repaired area shall be re-examined by DPI. Report The Dye Penetrant Inspection Report shall be completed using the format attached. The report shall be completed in triplicate and distributed as per the Clients instruction. Natony Limited shall retain one copy. 8.0 8.1 MATERIALS AND EQUIPMENT DESCRIPTION NATONY has the responsibility for the provision of materials and equipment. The quality and sufficiency of materials and equipment provided shall be to the approval of the Inspection Agency or the client representative. Basic Requirement of materials used for Radiographic inspection are as follows:

8.2

(a) RADIATION SOURCE:- The type of Radiation source used is IR.192 Gamma Ray Tech ops container. Active dimensions, (active, diameter 3.0mm and active length 2.0mm. (b) INTENSIFYING SCREEN:- High definition lead intensifying screens shall be used for each radiograph. Film shall be placed in between the two lead screen and inserted inside a cassette. The cassette is placed back of specimen and source of radiation opposite.

(c)

FILMS: - Films shall be of type approved by the client or inspection agency. NATONY generally uses Kodak, Agfa, Fuji and Ax all medium grain film with fine density all D4. Film factor shall be 35 and above. The sizes are 7cm x 24cm, 10cm x 24cm 7cm x
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NDT PROCEDURE

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40cm, 10cm x 40cm, 7cm x 48cm. All films shall be stored in a clean, dry place where they will be not be subjected to chemical vapours or gases, excessive heat or humidity, or exposure to radiation from any radioactive source. Radiographs shall be free of fog, blemish or artefacts that interfere with their interpretation. 9.0 PERSONNEL / QUALIFICATION OF RADIOGRAPHERS. All personnel to be used for radiographic work shall be classified personnel. Radiography interpreters and radiographers shall have minimum SNT-TC-IA level II qualification or equivalent. A record of such certification shall be furnished to the client or his inspection service Agency before radiography commences. The record shall include: Background and experience record Training/course records Technical examination/basic qualification record. Doctors medical examination record. Qualification checks shall ensure that radiographic inspection personnel are properly qualified for the particular tasks undertaken. Personnel qualified solely for taking radiographs shall not be used for interpretation and vice versa.

(i) (ii) (iii) (iv)

S/No. 1 2 3 4 5

DESCRIPTION RADIO GRAPHERS SNT INTERPRETER HELPERS SAFETY OFFICER QUALITY ENGINEER

QTY X X X X X

8.

ATTACHMENTS. I. II. RADIOGRAPHIC TEST REPORT. MAGNETIC PARTICLE INSPECTION

III. DYE PENETRANT INSPECTION

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SLAG LACK OF LACK PEN OF EXCESS PEN CRATER

OTHERS

TUNGST EN CRACK

INTERPRETED / RREVIEWED BY: CONTRACTOR NAME SIGN DATE QUAL. / LEVEL SPDC / CLIENT

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ACCEPT ED REJECT ED

WALL THICKN ESS NO OF SENSITI EXPOSU VE RE

DENSIT Y UNDER CUT POROSI TY PIPING

PIPLE DIA

RADIOGRAHIC REPORT SHEET REPORT NO:. DATE:. PROJECT ENGINEER WORK ORDER NO: DRAWING NO.: TEST SPECIFICATIONS ACCEPTANCE CRITERIA SECTION NO.: CLIENT: PROJECT: LOCATION: SOURCE X-RAY TYPE TECHNIQUE: PROCESSING: IR 192Co60 Volt KV PANORAMI DWSI MANUA DEV. C L TEMP Strength Cl Curr. MA SW/SI DWDI AUTO DEV.TIME Focal Size mm PIECE FILM POSITIO OR OR N OF WELD WELD DEFECTS NO.: IDENT.

C. MI N

MAGNETIC PARTICLE INSPECTION Report no. PROJECT: CLIENT: ITEM DESCRIPTION: LOCATION: DATE OF TEST:

INSPECTION PROCEDURE NO: MAGNET TYPE: DIRECTION OF MAGNETISM: CODE APPLIED: RESULTS: PART NO IDENTIFICATION INK TYPE:

ACC

REJ

COMMENTS

INSPECTOR: DATE:
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SIGNED:

NDT PROCEDURE

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DYE PENETRANT INSPECTION Report no. PROJECT: LOCATION: CLIENT: ITEM DESCRIPTION: SURFACE CONDITION: ACCEPTANCE STANDARD: PROCEDURE NO TYPE OF PENETRANT: CLEANING: RESULTS: WELD / ITEM NO INSPECTION SOAK TIME: DEVELOPER: DATE OF TEST:

DISCRIPTION

ACC

REJ

COMMENTS

INSPECTOR: DATE:

SIGNED:

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