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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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TABLE OF CONTENTS
1.0 INTRODUCTION................................................................................................................................................... 5
2.1 Definitions............................................................................................................................................................ 5
2.2 Abbreviations ...................................................................................................................................................... 6
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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Client
PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
Revision: 00 Status :
1.0 INTRODUCTION
This document describes the methods, techniques, equipment, personnel requirements and all other details
to carry out manual ultrasonic testing on carbon steel girth welds for Baltim South West Development
Project. This procedure is applicable during welding procedure qualification testing and production stages of
the project.
2.1 Definitions
COMPANY shall mean Belayim Petroleum Company, a company having its head office at 5 El-
Mokhayem El-Dayem Street, Nasr City, Cairo, Egypt (A.R.E)
CONTRACTOR shall mean PETROLEUM MARINE SERVICES Co., a corporation existing under the
laws of Egypt and having its registered place of business at Anwar El Mofty St., Dev.
& Housing Bank - Buildings B. Right Block Nasr City, Cairo
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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2.2 Abbreviations
CS Carbon Steel
ID Inner Diameter
OD Outer Diameter
UT Ultrasonic Testing
VT Visual Testing
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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Ref CTR Document No. CPY Document No. Rev. Document Title
Last
[3] 277497-SAI-NDT-PRO-031 193602CS-QR-OP-031 PMS12 – Baltim – VT procedure
rev.
Last
[4] 277497-SAI-NDT-PRO-034 193602CS-QR-OP-032 PMS12 – Baltim – MT procedure
rev.
Last PMS12 – Baltim – Automated
[5] 277497-SAI-NDT-PRO-033 193602CS-QR-OP-033
rev. UT procedure
Calibration of non-destructive
[6] WI-SPA-ENG-WELD-024-E NA 01
testing equipment
Site manual ultrasonic
[7] WI-SPA-WELD-023-E NA 01
equipment verification procedure
Client
PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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When required, manual ultrasonic testing is performed on girth welds related to the following applications:
Client
PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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Inspection of welds for onshore prefabrication WPQT (automatic welds between pipe and forged
materials): 100% of the weld circumference.
Inspection of repaired welds for all WPQT for CS pipeline scope fo work.
If AUT calibration block is not ready, MUT may be carried on WPQT welds instead of AUT
(automatic and manual welds): 100% of the weld circumference.
Repaired welds:
MUT shall be performed on repaired weld, when a new indication is detected by AUT (TOFD) (after
excavation and repair activity) and over the repaired area only. Any detected flaw in the repaired
area shall be sentenced by MUT acceptance criteria.
Lamination check:
In case of cut-out of pipe exceeding 100mm (including re-bevelling), lamination check shall be
performed over 100mm from the new bevel.
Wall thickness check:
After grinding of pipe body, wall thickness check of ground area shall be performed.
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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This procedure is reviewed and approved by personnel qualified level 3 in UT according to ISO 9712.
Certificate of the level 3 approver is given in attachment 2.
7.0 SAFETY
Work shall be carried out using safe working practices in accordance with statutory and local requirements
and Company’s applicable safety standards.
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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9.2 Probes
Characteristics of the probes to be used are given below.
DAC blocks are manufactured from project materials (pipe or forgings), in order to cover all MUT scope of
work given in Erreur ! Source du renvoi introuvable.. They contain 3 (three) 3.0 mm SDHs located at ¼ ,
½ and ¾ of the block WT (as required in section B.315 and Table D-1 of DNV-OS-F101 / Appendix D).
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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For each application from the MUT scope of work, drawing of the specific DAC blocks are prepared.
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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If any of the above verification fails, the instrument shall be sent to the manufacturer or to a qualified lab for
corrective action.
The probe examined shall be positioned on the V1 block and shall project its beam towards the curve
R = 100 mm of the calibration block. The position of the probe corresponding to the maximum echo
displayed on the screen shall be the index point (beam emission point) for the probe.
The response from the convex surface of the 50 mm diameter cut-out in the V1 block shall be obtained and
the signal shall be maximized. The angle marked on the block coinciding with the beam emission point
marked on the probe shall be the probe angle for the selected probe.
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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For the inspection of girth weld, sensitivity calibration is performed by drawing a DAC curve using the
relevant DAC block (see section 9.4.3). DAC curve (Distance Amplitude Correction curve) is constructed to
compensate the decreasing signal amplitude received from a reflector when its distance from the probe
increases.
The DAC is based on the construction of a 3 points reference level derived from the responses of 3 reflectors
(SDH of 3.0 mm diameter).
The echo reflected from the first SDH in the reference block is maximised and the gain control regulated so
that the echo amplitude is 80% FSH. This gain setting is called the primary gain and is to be noted. Without
altering the primary gain, the probe is positioned in order to maximize the echo from the second and, then,
the third SDH. The respective echo amplitudes are marked on the screen. A line drawn through these peaks
represents the amplitude expected from a reflector of the same size at any distance from the probe.
Curves representing 33% (DAC -10dB) and 50% (DAC -6dB) of the reference sensitivity DAC curve have
also to be constructed.
Range scale shall be adjusted to cover the specific acoustic path defined in the DAC curve settings.
DAC shall be verified once per shift using the relevant DAC block.
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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If deviation is found above 2% of range scale or above 4dB of primary gain setting the examinations carried
out with the equipment over the previous period shall be repeated
Any possible difference in attenuation and surface condition between the reference block and the area to be
tested shall be checked by the transfer correction . Two angle probes of the same type as those to be
employed during the testing are to be utilized . One of the probes is to be worked as transmitter, whilst the
other acts as receiver. The first echo is maximised and it is adjusted to reach DAC curve with the aid of the
gain control. Without altering the gain setting the probes are moved to the reference block and the echo is
adjusted to reach DAC curve.
If the differences of the two gain settings are less than 2dB, correction is not required. If differences are
greater than 2dB, but smaller than 12 dB, the transfer correction shall be compensated. If transfer losses
exceed 12 dB, the reason shall be investigated and further preparation of the scanning surfaces shall be
carried out (if applicable).
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
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The surface to be examined shall be clean, dry, and free of rust, paint and other coating, oil, grease, water,
welding flux or any other impediments that could cause an improper scanning of the probe or a bad contact
between the probe and the material under examination.
When required as per section 5.0, inspection of girth weld shall be performed according to ISO 17640, with
testing level B, and Appendix D / section B.300 of DNV-OS-F101.
The whole volume of the weld and heat affected zones shall be scanned.
Weld inspection will be performed using at least 2 probe angles. The following angle probes are
recommended to be employed :
Sensitivity calibration shall be performed according to section 10.1. Inspection for longitudinal indication shall
be performed positioning the probes in positions A or B as per Figure 3. Inspection for transverse indication
shall be performed positioning the probes in positions (X and Y) or (W and Z) as per Figure 3.
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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During the scanning the primary gain will be increased by 6 dB in order to increase the sensitivity to flaws
with a difficult orientation. However, the gain shall be reduced to the primary reference level when the flaw
evaluation is carried out.
The examination shall be carried out by moving the search unit over the examination surface so as to scan
the entire volume of the weld. Each pass of the search unit shall overlap a minimum of 10% of the transducer
dimension perpendicular to the direction of the scan. Maximum probe velocity shall not exceed 150mm/sec.
As per section 5.0, if more than 100mm, including re-bevelling, is removed from pipe end, a lamination check
has to be done. In this case, lamination check shall be performed over 100mm from the new pipe end.
The inspection shall be performed using straight beam probe, calibrated on the backwall echo of the DAC
block. Each pass of the search unit shall overlap a minimum of 10% of the transducer dimension
perpendicular to the direction of the scan. Maximum probe velocity shall not exceed 150mm/sec.
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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After grinding, wall thickness check shall be performed to verify that the thickness of the ground area
remains above the minimum acceptable value.
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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All indications having signal amplitude more than 33% of the DAC shall be investigated to find the nature and
orientation of the discontinuity. This can be assessed by the responses of the reflector to the sound beam
using different probe angles and also by the lateral and transverse manipulation of the probe. It will be
permissible to use a higher amplification level (dB) for this investigation.
This procedure classifies discontinuities detected by ultrasonic testing into three groups, namely, linear,
volumetric and transverse discontinuities. Linear discontinuities are incomplete fusion/penetration, elongated
slag inclusion, copper inclusion, cracks, undercutting adjacent to cover pass or root pass and hollow bead
porosity. Volumetric discontinuities are voids, pores, single or multiple inclusions, internal concavity and
cluster porosity. A transverse discontinuity has its greater dimension across the weld. It will be adequate to
classify and record the discontinuities as linear, volumetric or transverse.
For all indications having signal amplitude more than 33% of the DAC, the length of the indication (in the
circumferential direction of the pipe/forging) shall be evaluated between the points where the echo exceeds
33% of the DAC.
Then, indications shall be confronted to the acceptance criteria based on their nature, their maximum echo
amplitude and their length (if applicable).
In the report, the length of acceptable indications with amplitude exceeding 50% of the reference curve shall
be included.
Any discontinuities causing a reflection exceeding 50% of the reference level and accompanied by a 50%
loss in amplitude of the back wall echo shall be evaluated.
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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The total length of acceptable indications with echo amplitude of DAC – 2 dB and above shall
not exceed 3 t, maximum 100 mm in any weld length of 300 mm, not more than 12% of weld
length. Any accumulation of defects in any cross section of weld that may constitute a leak path
or reduce the effective thickness of weld more than t/3 is not acceptable.
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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No indications longer than 6.4 mm in the circumferential direction and having an area greater than 100 mm²
are permitted.
Table 3 summarizes the minimum and maximum allowable wall thicknesses for each application.
Minimum Maximum
WT nominal
Application Tolerance criteria allowable allowable WT
(mm)
WT (mm) (mm)
As per Table J.4 of ref.[10]:
26” line 17.5 16.5 18.5
±1mm
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PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
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14.0 REPORTING
MUT reports that clearly identify the work areas tested and their location shall be submitted by the operator
at the time of inspection. These reports (together with any relevant sketches and/or drawings for clarification
where needed) shall be submitted to include the following information:
Name of the company and operator carrying out the testing including certification of the operator
Object and drawing references
Place and date of testing
Material type and dimensions
Post weld heat treatment, if required
Location of examined areas, type of joint
Welding process used
Surface conditions
Temperature of the object
Number of repairs if specific area repaired twice or more
Contract requirements e.g. order no., specifications, special agreements etc.
Sketch showing location and information regarding detected defects
Extent of testing
Test equipment used
Description of the parameters used for each method
Description and location of all recordable indications
Testing results with reference to acceptance level
Other information related to the specific method may be listed under each method
Client
PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
Revision: 00 Status :
Client
PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034
Revision: 00 Status :