NDT program file for AMIN project
AMIN 900KTPA Copper Captive Smelter Project
AMIN project NDT test UT program file
Document Ref. No: ACCS-PIL-QAC-NDT-002
REV NO
01
DATE
1st Submission
PIL
REMARKS
15 August 2023
PMC
AMIN
TITLE
DOC. NO.
Ultrasonic Inspection Procedure
PIL-NDT-UT01
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CONTENTS
Page
1.
PURPOSE…………………………………………………………..
1
2.
SCOPE AND APPLICATION……………………………………...
1
3.
REFERENCE DOCUMENTS……………………………………...
1
4.
SAFETY …………………………………………………………….
2
5.
EQUIPMENT AND COUPLANT………………………………….
2
6.
QUALIFICATIONOF PERSONNEL………………………………
4
7.
PROCEDURE
7.1. Surface Preparation…………….……………………………...
4
7.2. Examination Coverage………...………..……………………..
7.3. Scanning…...……………………………..……………………
7.4. Calibration…….…………………………..…………………..
4
4
5
8.
ACCEPTANCE CRITERIA……………………………………….
13
9.
ATTACHMENT ………………………………………………….
14
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Ultrasonic Inspection Procedure
PIL-NDT-UT01
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1. PURPOSE
1.1. This procedure provides a system of general instructions and specific
instructions as an aid to personnel required to perform Ultrasonic Examination
to be applied and determination to the welds, parts, components, material and
thickness of Fabrication Steel Structures.
1.2. Ultrasonic Examination shall be performed and evaluated by qualified and
certified personnel in accordance with PT. Cast Inspection and Engineering’s
written practice, WP-001, which complies with SNT – TC –1A, 2020 Edition.
2. SCOPE AND APPLICATION
2.1. Pulse Echo “A” Scan type Ultrasonic Instrument shall be employed as
specified in this procedure; each flaw detector shall carry a current calibration
certificate to a recognized standard.
2.2. Components and welds to be examined shall be identified by the Client’s
QA/QC Inspector in inspection request formats and with drawing reference.
2.3. Suppression (reject) of the CRT time base is not permitted for Weldment
Examination.
3. REFERENCE DOCUMENTS
3.1. SNT - TC - 1A
- ASNT
Recommended
Practice
for
qualification of NDT Personnel, 2020 Edition
3.2. AWS D1.1/D1.1M
- Structural Welding Code – Steel, 2020 Edition
3.3. API RP 2X
- Recommended Practice for Ultrasonic and
Magnetic Examination of Offshore Fabrication
and
Guidelines
for
Qualification
of
Technicians. Third Edition, September 2004.
3.4. PT. Cast Inspection and Engineering Batam Written
CAST/II/NDT/WP01, which complies with SNT-TC-1A, 2020 Edition.
Page 1 of 24
Practice
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4. SAFETY
- Always use PPE such as Safety shoes, hand glove, safety glass, and helmet.
- Watch out for slippery and falling apart.
- Watch out for the hazard around the areas. Stop the activities and report to client
and supervisor for unsafe working condition.
- Use fall protection equipment if working above 2 m.
- Collect all waste and put it in agreed place.
- Do not expose any lubricant, oil or test fluid to the ground.
5. EQUIPMENT AND COUPLANT
5.1. Portable pulse echoes “A” scan (rectified) presentation generating frequencies
over the nominal range of 1 MHz to 6 MHz shall be used.
5.2. Test instruments shall include internal stabilization so that after warm-up, no
variation in response greater than ±1 dB occurs with a supply voltage charge of
15% nominal or, in the case of a battery, throughout the charge operating life.
There shall be an alarm or meter to signal a drop in battery voltage prior to
instrument shutoff due to battery exhaustion.
5.3. The test instrument shall have a calibrated gain control (attenuator) adjustable
in discrete 1 or 2 dB steps over a range of at least 60 dB. The accuracy of the
attenuator setting shall be within plus or minus 1 dB.
5.4. Straight beam search unit transducer shall have an active area of not less than
½ square inches (323 square millimeters) or more than 1 square inch (645
square millimeters). The transducer shall be round or square. Transducers shall
be capable of resolving the three reflections in IIW block.
5.5. Each search unit shall be marked to clearly indicate the frequency of the
transducer, nominal angle of reflection, and index point.
5.6. Ultrasonic Technicians shall perform a number of instrument and transducer
checks.
Attenuator Accuracy
Amplifier Linearity
Equipment Resolution
Horizontal Linearity
-
weekly
weekly
weekly
weekly
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Beam angle
At the commencement and completion of each
test
Probe Index Point
Test Sensitivity Check
Daily
Check results shall be maintained for each specific contract
5.7. The search unit shall produce a sound beam in the material being tested within
plus or minus 2º of one of the following proper angles: 70 º, 60º, or 45º.
5.8. Edge distance. The dimensions of the search unit shall be such that the
distance from the leading edge of the search unit to the index point shall not
exceed 1 inch. (25 mm)
5.9. Angle beam search units shall consist of a transducer and an angle wedge. The
unit may be comprised of the two separated elements or may be an integral
unit.
5.10. The transducer frequency shall be between 2 MHz to 2.5 MHz, inclusive.
5.11. Reference blocks used for equipment calibration and calibration for testing shall
be as per bellow:
a.
b.
c.
II W / V1 Block
V2 Block
IOW Beam Profile Block
5.12. Plotting and Measuring Aids.
The following equipment shall be available to the Ultrasonic Technician as
minimum to assist weld examination.
Electronic calculators, Mimic gauges (wire type), 150 mm Stainless rulers,
Measuring tapes, indelible markers.
5.13. Couplant.
Starch or other water based cellulose paste couplant shall be used. Same
couplant shall be used in calibration and testing. Proprietary brand couplant may
also be used. Sono 600 shall be used for hot temperature inspection (315º C
max for short–term scanning and 260º C max for long – term scanning)
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6. QUALIFICATION OF PERSONNEL
Ultrasonic Examination shall be performed and evaluated by qualified and certified
personnel in Accordance with PT. Cast Inspection and Engineering Batam Written
Practice. CAST/II/NDT/WP01, which complies with SNT-TC-1A, 2020 Edition.
7. PROCEDURE
7.1. SURFACE PREPARATION
The examination surface shall be free of irregularities, loose scales, weld
spatters, paint or foreign matters which interfere with Ultrasonic Transmission.
7.2. EXAMINATION COVERAGE
7.2.1. The test shall be conducted by moving the search unit over the
examination surface so as to scan the entire volume of the weld
including the Heat Affected Zones (HAZ), as per attached scanning
techniques prior to angle probe scan.
7.2.2. Additional probes or scanning techniques may be used at the discretion
of the technician, to supplement that the stated in the specific U/T
procedure attachment.
7.2.3. The base material, on which the angle beam search unit is moving, shall
be examined with the straight beam search unit, in order to detect the
lamination and segregation that can affect the examination result.
7.2.4. When practical, the examination shall be conducted on both sides.
7.3. SCANNING
The search unit movement during scanning shall be a combination of
rotational, orbital, lateral and traversing.
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7.4. CALIBRATION
7.4.1. DETERMINATION OF ENTRY POINT OF ANGLE BEAM SEARCH
UNIT.
a. Place the search unit in position D on the V1 Block (See Fig. 1).
b. Move the search unit until the signal from the radius is
maximized. The point on the search unit which aligns with the line
on the calibration block is the point of the entry point.
Fig.1. Search Unit Positions
7.4.2. DETERMINATION OF THE ANGLE BEAM SEARCH UNIT
a.
Place the search unit in position B or C (depending on the angle
of search unit) on the V1 Block, (See Fig. 1).
b.
Maximize the signal by moving the search unit backward and
forward. When the signal is maximized, the beam angle can be
measured using the search unit Index and Engraved reference
lines on the block or physically drawing in pencil line on block
and measuring with protractor.
c.
The tolerance of Beam Angle measurement shall be  2.
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7.4.3. DETERMINATION OF HORIZONTAL LINEARITY
a.
Place the straight beam search unit in position E & G on the V1
block (see fig. 1)
b.
Bring successive back wall echoes, in turn, to A approximately
the same height (e.g., 80% full screen height).
c.
The leading edge of each echo should line up with the
appropriate gratitude line. Record any deviation, and measured
at approximately half full screen height.
d.
For range less than 255 mm (10 in.), place the search unit in
position G, and for greater than 255 mm (10 in.), place the
search unit in position E.
e.
The deviation of the base linearity shall not exceed  2% of fulltime base range.
7.4.4. DETERMINATION OF THE RESOLUTION OF STRAIGHT BEAM
SEARCH UNIT.
a.
Place the search unit in position F on the V1 block (See Fig. 1).
b.
Three signals from the 85 mm, 91 mm and 100 mm surfaces
should be clearly displayed.
7.4.5. DETERMINATION OF THE RESOLUTION OF ANGLE BEAM SEARCH
UNIT.
a.
Place the search unit in position H & I on IOW Beam Profile
Block (See Fig. 2)
b.
The signals from three of the side drilled holes should be clearly
resolved on the CRT at one time.
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Fig. 2
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7.4.6. DETERMINATION OF BEAM SPREAD IN THE VERTICAL LINE
a.
Place the search unit on surface A and B in the IOW profile
block (See Fig. 3).
Fig. 3
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Measurement of beam profile, vertical plane
Fig. 4
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In each case the position of the entry point of search unit
corresponding to maximum echo height is marked on the block.
The search unit is then moved forward and backward so that
the target is swept by the beam, the extremes of displacement
being reached when the position of the entry point of search unit
corresponds to a fall of 20 dB from maximum Echo Height (See
Fig. 4, a, b, c & d).
When the entry point in its forward position, the edge of the
target hole intercepts the lower on rear boundary of the 20 dB
reference surface, and vise versa when the search unit is in the
hid most position. The forward and backward positions on the
entry point of search unit are also marked on the block.
Similar measurements made at each target hole are used to
construct a diagram of the beam profile; figures 4a, b, and c
illustrate the plotting sequence.
b.
The reading Y (forward position) is laid off behind the beam axis
and the backward shift X in front of it. Figure 4d shows the
complete profile with target.
7.4.7. SOUND PATH DISTANCE CALIBRATION
7.4.7.1. Straight Beam Search Unit.
a.
V1 Block
The multiple signals can be set up at 25 mm, 100 mm, and
intervals by reflections of back wall. (See Fig. 1, position G,
and E).
b.
V2 Block
V2 Block can be used for calibration.
c.
The horizontal sweep shall be adjusted for distance
calibration to present the equivalent of at least two
thicknesses on the screen.
7.4.7.2. Angle Beam Search Unit.
a.
V1 Block
The multiple signals can be set up at 100 mm intervals by
the reflections between the quadrant and the notches on
the face of the block. (See Fig. 1, position D).
b.
V2 Block.
The repeated signals can be set up at 25 mm, 100 mm, 175
mm, etc, when the search unit is directed to the 25 mm
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quadrant or the repeated signals can be set up at 50 mm,
125 mm, 200 mm, etc, when the search unit is directed to
the 50 mm quadrant (see fig. 5).
c.
The distance calibration shall be made using either the 130
mm (5 in.) range or 255 mm (10 in.) range, whichever is
appropriate. The distance calibration shall be made using a
suitable range to the weldment under inspection.
Fig. 5.
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7.4.7.3. Sensitivity Calibration
a.
Non-Tubular Member
The search unit shall be set in position A on the V1 block
(see fig. 1) the maximized signal shall then be adjusted from
1,5 mm (0.06 in.) hole to attain a horizontal reference line
height indication (e.g., 80% full screen height).
b.
Tubular Member
Standard sensitivity for examination using: Amplitude
techniques shall be: Basic sensitivity + distance amplitude
correction + transfer correction.
7.4.7.4. Sensitivity Setting
a.
Distance amplitude correction curves shall be constructed by
the use of the amplitude of the three calibration holes from
the applicable basics calibration block (IOW) and shall be
set up as follows:
1.
Determine which of the three calibration holes
produces the highest amplitude and adjust this
amplitude at 80% ( 5%) of full screen height.
This is the primary reference amplitude.
2.
Position the search unit, without changing the
sensitivity with which the primary reference amplitude
was found, for maximum response from the other two
calibration holes and for angle beam method also ¾ T
hole after the beam has bounded from the opposite
surface.
3.
Mark the peaks of these amplitudes on the plastic
screen and connect these marks with a smooth line
over a length which will cover the examination range. If
the peaks drops below 20% of screen height the
amplitude shall be increased to 80% screen height and
process repeated.
This line is called the primary reference level.
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Transfer mechanism shall be used to correlate the amplitude
from the basic calibration block and the production material.
Transfer shall be accomplished by using the transmission
method and two identical angle probes. For material
thickness less than 25.4 mm at least full skip shall be used.
The amplitudes of both, calibration block and production
material shall be evaluated at 40% of full screen and this
difference shall be noted and used for the correction of the
primary reference level.
This is called the corrected primary reference level.
7.4.8. FREQUENCY OF CALIBRATION.
Re-calibration shall be made after a change of operators, each 30-minute
maximum time interval, or when the electrical circuitry is disturbed in any
way which includes the following:
a.
b.
c.
d.
e.
Search Unit Change.
Battery Change
Electrical outlet changes
Coaxial Cable Change
Power outage (failure)
7.4.9. DEFECT SIZING
The length of defect shall be evaluated using 6 dB drop method, and the
width of defect shall be evaluated by 20 dB drop method. The location of
defect shall be determined accurately and reported with an
accompanying sketch.
8.
ACCEPTANCE CRITERIA
8.1. Acceptance criteria for Statically loaded nontubular connection shall be
evaluated with subsection 8.13.1 Table 6.2 of AWS D1.1. 2020 Edition
8.2. Acceptance criteria for Cyclically loaded nontubular connection shall be
evaluated with subsection 8.13.2 Table 6.3 of AWS D1.1. 2020 Edition
8.3. Acceptance criteria for tubular connection shall be evaluated with subsection
8.13.3 Class R of AWS D1.1. 2020 Edition
8.4. Acceptance criteria for weld of T,K,Y joints tubular connection with full
penetration welds shall be evaluated as per subsection 8.13.3.2 Class X of
AWS D1.1. 2020 Edition
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9.
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ATTACHMENT
9.1. Scanning Pattern
9.2. Scanning Technique
9.3. Acceptance Criteria Table 6.2
9.4. Acceptance Criteria Table 6.3
9.5. Acceptance Criteria Class R
9.6. Acceptance Criteria Class X
9.7. Report form
9.8. Ultrasonic flaw detector performance check
9.9. Ultrasonic sensitivity daily calibration
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ATTACHMENT 1
Scanning Pattern
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ATTACHMENT 2
Scanning Technique
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ATTACHMENT 3
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ATTACHMENT 4
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ATTACHMENT 5
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ATTACHMENT 6
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ATTACHMENT 7
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ATTACHMENT 8
REPORT FORM
TITLE
FORM NO
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PIL/NDT//UT01
ULTRASONIC EXAMINATION
Project
:
Page
Report No.
Client
:
Contract Job
Location
:
Drawing No
:
Procedure No.
:
Material
Welding Process
:
:
Specification
Acceptance Criteria
:
:
Surface Condition
:
Testing Temperature
:
Joint Type
:
Face of Examination
:
UT Equipment
:
Serial No.
:
Couplant
:
Calibration Block
:
Refference
:
:
:
:
NDE Request No. :
Test date
:
:
Size
(MHz)
(mm)
Range
(dB)
Result
EVALUATION
d
(MM)
DISCONTINUITY
c
DEPTH FROM SURFACE
INDICATION RATING
b
FROM DATUM (mm)
ATTENTION FACTOR
a
POSITION
REFERENCE LEVEL
DISCONTINUITY
INDICATION LEVEL
TRANSDUCER ANGLE º
INDICATION NO
Length Tested (mm )
Weld Length ( mm )
Welder ID
Thickness ( mm )
Identification
Joint Number
DECIBELS
Reference
REMARKS
Rejected
Frequency
LENGTH (MM)
S /N
Accepted
Weld Map No.
Probes
SCANNING TECHNIQUE :
Note :
PT.PIL
Examined by
Date :
Date :
PMC/AMIN
Date :
BV
Date :
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ATTACHMENT 9
ULTRASONIC FLAW DETECTOR PERFORMANCE CHECK
TITLE
ULTRASONIC EXAMINATION
FORM NO
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EFFECTIVE DATE
PIL/NDT/UT02
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Equipment Type & Made
Serial No.
IIW Block Serial No.
Probe Type
:
Serial No.
:
Diameter/Frequency :
Date of Calibration :
Calibration Due Date :
TIME BASE LINIERITY
Block Thickness
(mm)
25
Test Range
125
1
Back Wall Echo Reading (mm)
2
3
4
Result
5
Deviation
Deviation Shall be with in ± 2 % of Test Range
SCREEN HEIGHT LINEARITY
Description
Reference Echo
100
2nd Echo
Devlation
90
80
Amplitude (In FSH %)
70
60
50
40
30
20
Result
PASS
FAIL
Deviation Shall be with in ± 5 % of FSH
AMPLITUDE CONTROL LINEARITY
Indication Set at % of FSH
dB Control Change
Required Indication Limits in
% of FSH
80
80
40
20
-6
-12
6
12
36 to 44
18 to 22
72 to 88
72 to 88
Observed Indication in % of
FSH
Legend : FSH = Full Screen Height
Tested By :
UT ASNT/ PCN LEVEL II
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Remarks
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ATTACHMENT 10
ULTRASONIC SENSITIVITY DAILY CALIBRATION
TITLE
FORM NO.
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PIL/NDT/UT03
ULTRASONIC EXAMINATION
UT DAILY CALIBRATION CHECK
PROBE DAT A
DAY
NOMINAL ACT UAL
ANGLE
ANGLE
T YPE
SERIAL
NO.
SENSIT IVIT Y
FREQ
(MHz)
SIZE
(mm)
INDEX
POINT
(mm)
IIW
AP I 5L
BS
AP I
1.5 mm
N5
3.0 mm
1/16"
NOT CH
ASME
3/32" Ø
1/8" Ø
3/16" Ø
DATE
SIGNATURE
1/4" Ø
0°
SUNDAY
45 °
60 °
70 °
0°
MONDAY
45 °
60 °
70 °
0°
T UESDAY
45 °
60 °
70 °
0°
WEDNESDAY
45 °
60 °
70 °
0°
T HURSDAY
45 °
60 °
70 °
0°
FRIDAY
45 °
60 °
70 °
0°
SAT URDAY
45 °
60 °
70 °
UT SET T YPE
:
PREPARED BY
:
SERIAL NO.
:
DAT E
:
CALIBRAT ION DAT E
:
EXPIRE DAT E
:
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