07-KU-TWK-50-QA-PRO-2162 - 0 - NDT Procedure
07-KU-TWK-50-QA-PRO-2162 - 0 - NDT Procedure
NDT Procedure
KU-TWK-50-QA-PRO-2162
License TWK
NDT Procedure
Project Title T-59 Gas injection
Wellhead
Contractor Project No. TWK-FD-33163 Contractor Doc. No. IPC-33163-07
REVISION RECORD
DNO Originated Checked Approved
Date Description
Rev. by by by
A Issued for Review SI
22Oct22 AN DY
B 10Dec22 Issued for review AN AN SI
12Jan23 SI
0 Issued for USE AN AN
Proprietary Information
This document is the property of DNO. It must NOT be reproduced or transmitted to others
without authorization from the COMPANY.
Inspection Management
Department
Revision Number ISSUED BY REVIEWED BY APPROVED BY
1 Industrial
Inspection Manager (AWS.CWS:1604001S) ISO 19011:2011 Lead Auditor
2
ASNT Level III (MT, PT, UT, RT, VT,ET) #174544
3
Chief Executive Director (CEO)- ISO 9001 Lead Auditor, , ISO 17025 Lead Assessor
Doc No: CEC[EN]-NDT/P/PT01-01 Revision No.: 03 Revision Date: 11/07/2019
CITADEL Engineering Company
AMENDMENT RECORD
INDEX
COVER PAGE 1
INDEX 2
1 PURPOSE 2
2 SCOPE 2
3 REFERENCE DOCUMENTS 3
4 DEFINITIONS 3
5 PROCEDURE 3
6 APPENDIX 12
Appendix-A ACCEPTANCE CRITERIA 13
Appendix-B DYE PENETRANT TESTING REPORT 15
1.0 PURPOSE
The purpose of this document is to provide the minimum requirements for the Dye
Penetrant Inspection of components, which will be revised as and where necessary to meet
the specific contractual specifications and requirements of a project and thus become
a project specific procedure.
2.0 SCOPE
This procedure establishes the minimum requirements for visible solvent removable
technique. The method covered in this procedure can be effectively used when performing
specific tests on welds and components and detect discontinuities that are open to the
surface of nonporous metals and other materials. Type I Method C (solvent Removable
Fluorescent Penetrant) and Type II Method C (Solvent Removable Color Contrast
Penetrant) liquid penetrant methods shall be applicable to this procedure.
The procedure is applicable only for surface temperature between 50C to 520C.
4.0 DEFINITIONS
5.0 PROCEDURE
All Personnel carrying out works to this procedure shall ensure that they follow
safe working practices in compliance with the requirements CEC’S Safety
Manual CEC[EN]-NDT/SM/01-01. In addition to that the below minimum safety
requirements shall be followed:
Penetrant materials are highly volatile, relatively toxic and may cause
skin irritation. Use adequate ventilation at all times and avoid prolonged
skin contact.
Penetrant material aerosol cans should be kept out of direct sunlight or
areas in excess of 1300F
Adequate and correct PPE to be used always, i.e. gloves, respirators
(face mask)
Ensure MSDS is available and it is read and understood by all personnel
working to this procedure
Surface condition of the part under test prior to examination: The surface to be
examined shall be free from rust, scale, paint, slag, sand, greases, oily films or
other conditions which could interfere with the examination. It shall be ensured
that the surface of the part under examination is not subjected to shot sand or
grit blasted without the approval of the client.
Penetrant materials used shall belong to the same manufacturer and family of
particular type of penetrant used.
The following family of penetrant materials shall be used:
Family of Penetrants
Method Manufacturer Penetrant Cleaner Developer
Type I
Magnaflux ZL-22A ZC-7 ZP-9E
Method C
Type II
Magnaflux SKL-SP SKC-S SKD-S2
Method C
Batch certificates for penetrant materials shall be maintained for materials used
to test nickel based alloys, austenitic stainless steels and titanium.
For nickel based alloys, sulfur content shall be limited to 1% or less residue by
weight. For austenitic stainless steels and titanium, chlorine plus fluorine content
shall be limited to 1% or less".
5.5 Temperature
It shall be ensured that the temperature of penetrant materials and the surface
of the materials to be tested shall be between 400F (50C) and 1250F (520C) for
the fluorescent liquid penetrant testing.
For the visible color contrast dye penetrant testing, the penetrant materials and
the surface of the part examined shall be from 400F (50C) t0 1250F (520C).
Where it is not practical to comply with these temperature limitations, the
procedure shall be qualified at the temperature of intended use as per Para 9.0.
5.6 Lighting
For visible solvent removable penetrant examination, adequate visible light shall
be available. It shall be a minimum of 100 foot candles (1000 lux). For
fluorescent penetrant examination, the testing shall be performed in a darkened
area with an ambient light intensity of 2 foot candles (20 lux) maximum. The
black light used shall be allowed to warm up for a minimum of 5 min. prior to use
or measurement of the intensity of the ultraviolet light emitted. The black light
intensity shall be measured with a black light meter prior to use, whenever the
light’s power source is interrupted or changed, and at the completion of the
examination or series of examinations. A minimum of 1000 micro watt/cm2 on
the surface of the part being examined shall be required. The black light
intensity shall be measured once in 4 hr., whenever the workstation is changed,
or after change of filter or bulb. The readings shall be recorded on a log sheet
and kept with the black light unit always and monitored for intensity fading
before each usage. As specified by the client, required black light level may be
as much as 4000 micro Watt/cm2 for applications such as detection of hydrogen
induced cracking.
The examiner shall be in the darkened area for at least five minutes prior to
performing fluorescent penetrant examination to enable his eyes to adapt to
dark viewing. Glass or lenses worn by examiners shall not be photosensitive.
Reflectors and filters should be checked and cleaned prior to use. Cracked or
broken filters shall not be used.
maximum of one (1) hour. The area pre-cleaned shall include at least 1"
(25mm) past both (all) sides of the area of interest.
Inspection of all welds shall include a band of base metal at least one inch
wide on each side of the weld.
Dwell Time: After application, penetrant shall remain on the surface of the
part being tested for a dwell as specified below. Care shall be taken for the
part to remain wet throughout the penetration time. If the penetrant dries on
the surface of the part, it shall be subjected to complete reprocessing
beginning with initial pre-cleaning.
Dwell Times
Product Type
Penetrant Developer
Casting and welds 10 minutes 10 minutes
Wrought Materials
extrusions, forgings, plates
20 minutes 10 minutes
etc
Allow the black light to warm up for a minimum of 5 minutes prior to its use
or measurement of the intensity of the ultraviolet light emitted.
Light meters, both visible and fluorescent (black) light meters, shall be
calibrated at least every six months or whenever the meter has been
repaired.
The black light intensity shall be measured with a calibrated black light meter
prior to use, whenever the light’s power source is interrupted or changed,
and at the completion of the examination or series of examinations and
recorded on a log sheet and shall be kept with the black light unit at all times
and monitored for intensity fading before each usage.
As specified by the client, required black light level may be as much as
4000W/cm² for applications such as detection of hydrogen induced
cracking.
The examiner shall be in the darkened area for at least five (5) minute prior
to performing the examination to enable his eyes to adapt to dark viewing.
Glass or lenses worn by examiners shall not be photosensitive.
Dwell Times
Product Type Penetrant Developer
Casting and welds 10 minutes 10 minutes
Wrought Materials
extrusions, forgings, plates
20 minutes 10 minutes
etc.
Drying: The surface of the part being examined shall be dried for at least 5
minutes before application of developer through solvent-wipes. The part
shall not be allowed to remain dry for very long periods as it may reduce the
sensitivity of operation. The surface may be dried by normal evaporation,
blotting, wiping, or forced air.
5.11 Records
The following information shall be recorded in a report format acceptable to the
client:
6.0 APPENDIX
6.1 Appendix – A Acceptance Criteria
6.2 Appendix – B Sample Report format
1. Evaluation of Indications
1.1. A linear indication is one having a length greater than three times the width.
1.2. A rounded indication is one of circular or elliptical shape with the length equal to or
less than three times the width.
These acceptance standards shall apply unless other standards are specified for
specific applications within this Division. All surfaces to be examined shall free of:
2.2. relevant rounded indications greater than 3/16 in. (4.8 mm);
2.3. four or more rounded indications in a line separated by 1/16 inch (1.6mm) or less
(edge to edge);
2.4. an indication of an imperfection may be larger than the imperfection that causes it;
however, the size of the indication is the basis for acceptance evaluation.
1. Evaluation of Indications
1.1. Mechanical discontinuities at the surface will be indicated by the retention of the
examination medium. All indications are not necessarily defects, however certain
metallurgical discontinuities and magnetic permeability variations may produce similar
indications which are not relevant to the detection of unacceptable discontinuities.
1.2. Any indication which is believed to be nonrelevant shall be reexamined to verify whether
or not actual defects are present. Surface conditioning may precede the reexamination.
Nonrelevant indications which would mask indications of defects are unacceptable.
1.3. Relevant indications are those which result from unacceptable mechanical discontinuities.
Linear indications are those indications in which the length is more than three time the
width. Rounded indications are indications which are circular or elliptical with the length
less than three times the with.
1.4. An indication of a discontinuity may be larger than the discontinuity that causes it,
however, the size of the indication and not the size of the discontinuity is the basis of
acceptance or rejection.
2. Acceptance Standards
The following relevant indications are unacceptable.
2.2. Rounded indications with dimensions greater than 3/16 in. (5.0 mm).
2.3. Four or more rounded indications in a line separated by 1/16 in. (2.0 mm) or less edge to
edge.
2.4. Ten or more rounded indications in any 6 sq in. (3870 mm2) of surface with the major
dimension of this area not to exceed 6 in. (150 mm) with the area taken in the most
unfavorable location relative to the indications being evaluated.
After a defect is thought to have been removed and prior to making weld repairs, the
area shall be examined by the same method to ensure the defect has been removed
using approved repair procedure.
6. Report
6.1. Identify all examination reports to permit positive correlation with the material or part
examined.
6.2. Identify the equipment and examination medium in sufficient detail to permit
6.3. Provide a sketch, chart, or marked-up drawing to show coverage and orientation if
necessary for clarity and/or to permit duplication of the examination.
Revision
ISSUED BY REVIEWED BY APPROVED BY
Number
Muhammad Ikram Chaitanya
Shahriyar Majlesein 3
00 Ullah 1 Vasanthavada 2 28 January, 2016
28 January, 2016 28 January, 2016
Tulasiram Poppala 1 Jinagam Chakrapani 2 Shahriyar Majlesein 3
01 01 July, 2017 01 July, 2017 01 July, 2017
Majid Faraji Shovay 1 Hamid Rabiei 2 Shahriyar Majlesein 3
02 07 November, 2019 07 November, 2019 07 November, 2019
03
Arun G. Hamid Rabiei 2 Shahriyar Majlesein 3
10 December, 2021 20 December 2021 03 January 2022
AMENDMENT RECORD
Approved by No. of
Rev. Affected Sections Description Prepared by & Date & Date pages
CHAITANYA
0 Nil First Issue VASANTHAVADA 14
24-01-2016
1 Appendix-A Added Second Issue Tulasiram Poppala 01 July, 2017 15
CEC[EN]-NDT/MPT/P/03-01 02 03
INDEX
COVER PAGE 1
INDEX 3
1 PURPOSE 4
2 SCOPE 4
3 REFERENCE DOCUMENTS 4
4 DEFINITIONS 4
5 PROCEDURE 5
6 APPENDIX 13
Appendix-A ACCEPTANCE CRITERIA 14
1.0 PURPOSE
The purpose of this document is to provide the minimum requirements for the Magnetic
Particle Examination of ferromagnetic welds/components, which will be revised as and where
necessary to meet the specific contractual specifications and requirements of a project and
thus become a project specific procedure.
2.0 SCOPE
This procedure establishes the minimum requirements for both dry and wet magneticparticle
examinations. The method covered in this procedure can be effectively used when performing
specific tests on welds and components and detect surface and subsurface discontinuities
on a variety of ferromagnetic materials.
Use of Electro Magnetic Yoke is limited to the detection of cracks at or near the surface
defects and seams, laps, cold shuts, laminations or lack of fusion in ferromagnetic materials.
Use of permanent magnets is prohibited by this procedure.
ASME V ARTICLE 7 (2020 Boiler and Pressure Vessel Code for Magnetic Particle
1
Edition) Examination
2 ASME Section VIII Div. I ASME Boiler and Pressure Vessel Code
3 ASME B31.3 ASME Code for Pressure Piping, B31 (Process Piping)
4 AWS D1.1 AWS D1.1 Structural Welding - Steel
ASNT SNT TC – 1A Recommended practice for NDT personnel Qualification
5
2020 & Certification.
Guidelines for Certification of CEC Personnel as per
6 CEC[EN]-NDT/WP/09-01
ASNT / SNT / TC / 1A
4.0 DEFINITIONS
4.1 ASME American Society for Mechanical Engineers
4.2 MPT Magnetic Particle Testing
4.3 HSE Health Safety and Environment
4.4 NDE Non-Destructive Examination
4.5 NDT Non-Destructive Testing
4.6 NDI Non-Destructive Inspection
4.8 ASNT American Society for Non-Destructive Testing
5.0 PROCEDURE
the yokes has been damaged, for its magnetizing force. Yoke’s shall be checked
daily prior to use lifting a 10 lb. (4.5 kg) weight at the maximum pole spacing that
will be used. The lifting power of yokes will be verified and recorded prior to each
shift.
Each weight shall be weighted with a scan from reputable manufacturer and
stenciled prior to first use. A weight need only be verified again if damaged in a
manner that could have caused potential loss of material.
Ultraviolet light, portable type shall be employed for wet fluorescent magnetic
particle examination.
Light meters, both visible and fluorescent(black) light meters, shall be calibrated
at least every six months or whenever the meter has been repaired. if meters have
been not used one year or more shall be done calibration being first use.
Consumables used shall belong to the same manufacturer and family or particular
type of magnetic particle used. The following family of magnetic particle materials
(or equivalent) shall be used.
The following brands of MPT consumables are approved for use in CEC.
Contrast paint shall be white in color and MPI Ink shall be black in color to provide
color contrast due to flux leakage from Inter mixing of chemicals from different
families or manufacturers is not permitted.
INSPECTION MEDIUM: The magnetic particles used for either dry or wet
magnetic particle examination techniques shall be of finely divided ferromagnetic
material of high permeability and low retentivity, free from contaminants like rust,
grease, paint, dirt or other material which might interfere
with their proper functioning. They shall be of such shape, size and color as to
provide adequate sensitivity and contrast for the intended use.
The dry method particles used shall be gray or red color. The choice of color shall
be based on maximum contrast with the part being examined.
The wet method particles used shall be either black or red color, readily available
aerosol cans. The selection of particular color, shall be one that contrast most
with the test surface. As the wet magnetic particles are finer in nature than the
particles used for dry methods, they shall be employed in the detection of smaller
discontinuities. The wet particle inspection shall also utilize fluorescent particles
which are readily available in aerosol spray cans.
5.5 Surface Temperature
Before performing, it shall be verified that the temperature of the part shall not
exceed 600 degrees F for dry particle examination or 122 degrees F for wet
particle examinations.
5.6 Lighting
For dry particle and wet non-fluorescent particle examination, adequate visible
light shall be available. It shall be a minimum of 100-foot candles (1000 lux) and
measured by lux meter daily. For fluorescent particle examination, the testing
shall be performed in a darkened area with an ambient light intensity of 2-foot
candles (20 lux) maximum. The black light used shall be allowed to warm up fora
minimum of 5 min. prior to use or measurement of the intensity of the ultraviolet
light emitted. The black light intensity shall be measured with a black light meter
prior to use, whenever the light’s power source is interrupted or changed, and at
the completion of the examination or series of examinations. A minimum of 1000
micro wall/cm2 on the surface of the part being examined shall be required. The
black light intensity shall be measured once in 4 hr., whenever the workstation is
changed, or after change of filter or bulb. The readings shall be recorded on a log
sheet and kept with the black light unit at all times and monitored for intensity
Doc No: CEC[EN]-NDT/MPT/P/03-01 Revision No.: 03 Revision Date: 11/07/2019
CITADEL Engineering Company
fading before each usage. A specified by the client, required black light level may
be as much as 4000 micro-Watt/cm2 for applications such as detection of
hydrogen induced cracking.
The examiner shall be in the darkened area for at least five minutes prior to
performing fluorescent magnetic particle examination to enable his eyes to adapt
to dark viewing. Glass or lenses worn by examiners shall not be photosensitive.
Reflectors and filters should be checked and cleaned prior to use. Cracked or
broken filters shall not be used.
Dry particles when used with alternating current for magnetization, are superior
for detection of surface cracks that are not exceptionally tight or fine.
The contour yoke leg spacing shall suit the shape of the part being tested, being
neither too close nor too far off. Pie-Shaped Magnetic Field Indicator or artificial
flawed shims shall be used in the yoke technique to determine the field strength
and direction of magnetic field. A change of essential variable shall require
requalification of the written procedure by demonstration
5.10.3Examination Coverage
.
Doc No: CEC[EN]-NDT/MPT/P/03-01 Revision No.: 03 Revision Date: 11/07/2019
CITADEL Engineering Company
5.11.4 Others
If other indications are believed to be non-relevant, at least 10% of
each type of indication shall be evaluated by removing the surface
roughness or other conditions believed to have caused the indication,
to determine if defects are present. If defects are absenting upon re-
inspection by magnetic particle examination after removal of surface
roughness, it indicates that the patterns formed were non-relevant in
nature with respect to true defects. However, if re-inspection reveals
any indications, these and all original indications shall be considered
relevant and shall be evaluated in accordance with the applicable
acceptance standards.
5.12 Demagnetization
Since the method employs the usage of alternating magnetizing current as a
magnetizing force, residual magnetism shall not be appreciable enough to subject
the part being tested for demagnetization.
When the presence of residual magnetism within the part could interfere with
subsequent processing or usage, the part shall be demagnetized.
In general demagnetization is accomplished by subjecting the part to a field
equal to or greater than that used to magnetize the part, then continuously
reversing the field direction while gradually reducing it to zero. Any of the
following methods may be adapted to parts requiring demagnetization:
Alternating-current yokes may be used for local demagnetization by placing the
poles on the surface, moving them around the area, and slowly withdrawing the
A/C yoke while it is still energized.
6.0 APPENDIX
6.1 Appendix – A Acceptance Criteria
6.2 Appendix – B Magnetic Particle Testing report format
Inspection Management
Department
Revision Number ISSUED BY REVIEWED BY APPROVED BY
Muhammad Ikram 3
Chaitanya Vasanthavada 2 Shahriyar Majlesein
00 Ullah 1
28 January, 2016
28 January, 2016
28 January, 2016
Tulasiram Poppala 1 Jinagam Chakrapani 2 Shahriyar Majlesein 3
01 01 July, 2017 01 July, 2017
01 July, 2017
Majid Faraji Shovay 1 Hamid Rabiei 2 Shahriyar Majlesein 3
02 07 November, 2019 07 November, 2019
07 November, 2019
03
AMENDMENT RECORD
CEC[EN]-NDT/PAUT/P/07-01 - 02
INDEX
COVER PAGE 1
AMMENDMENT RECORD 2
INDEX 3
1 PURPOSE 4
2 SCOPE 4
3 REFERENCE CODES AND/OR STANDARDS 4
4 PERSONNEL QUALIFICATION REQUIREMENTS 4
5 PERSONNEL SAFETY 5
6 BASIC BLOCKS 5
7 EQUIPMENT & ACCESSORIES 8
8 SURFACE PREPARATION 12
9 DATA RECORDING 17
10 DATA ANALAYSIS 17
11 FLAW EVALUATION 18
12 FLAW ACCEPTANCE CRITERIA 19
13 SCAN PLAN & WELD CONFIGURATION 27
EXAMINATION RECORDS & RECORDS
14 27
KEEPING
Appendix-A NDT SETUP BUILDER REPORT 28
PHASED ARRAY ULTRASONIC TESTING
Appendix-B 31
REPORT
1. PURPOSE
The purpose of this document is to provide the minimum requirements for testing the
components with Phased Array Ultrasonic Testing, which will be revised as and where
necessary to meet the specific contractual specifications and requirements of a
project and thus become a project specific procedure.
2. SCOPE
This procedure establishes the phased array ultrasonic examination requirements
which shall be used to examine carbon steel, Low alloy steel or Alloy steel plate and
pipe base materials and weldments. This procedure is intended to cover the method
and acceptance standard of the Semi-Automated Phased Array Ultrasonic
Examination of welding joints for piping and pipeline having outside diameter
minimum 6 inch and above and having wall thickness range minimum 6mm and
above. The examination shall be conducted using automated or semi-automated
techniques utilizing computer based data acquisition.
5. PERSONNEL SAFETY
5.1 All the personnel performing Ultrasonic examination shall take necessary personnel
protective measures in accordance with CEC Procedure for General Safety.
6. BASIC BLOCKS
6.1 Calibration Block:
The material from which the block is fabricated shall be of the same product form and
material specification or equivalent P-Number 1, 3, 4, 5A through 5C, and 15A through
15F materials are considered as one of the materials being examined. The basic
calibration block configuration and reflectors shall be as shown in Figure 1. The basic
calibration block curvature shall be in accordance with thickness, T, shall be ±25% of
the nominal thickness of the component to be examined. For examinations in
materials where the examination surface diameter is equal to or less than 20 in. (500
mm), a curved block shall be used. Except where otherwise stated in this Article, a
single curved basic calibration block may be used for examinations in the range of
curvature from 0.9 to 1.5 times the basic calibration block diameter.
General Notes:
The minimum calibration block length (L) shall be 8 in (200mm) or 8T,
whichever is Greater
For OD 4 in. (100mm) or less, the minimum arc length shall be 270 deg. For
OD greater than 4 in. (100mm), the minimum arc length shall be 8 in (200mm)
or 3 T, whichever is greater
Notch depths shall be from 8% T minimum to 11% T maximum. Notch widths
shall be ¼ in.(6mm) maximum. Notch lengths shall be 1 in. (25mm) minimum
Maximum notch width is not critical. Notches may be made with EDM or with
end mills up to ¼ in. (6mm) in diameter
Notch lengths shall be sufficient to provide for calibration with a minimum 3 to
1 signal-to-noise ratio.
6.2 Scanner Block: - System confirmation scan
The scanner block shall be scanned with the reference sensitivity settings and
reference reflector indications recorded, prior to start and at the completion of each
examination or series of examinations, when examination personnel (except for
automated equipment) are changed and if the scan plan is required to be modified.
The examination shall have deemed to be voided if any point of the TCG decreases
by 20% or 2 dB of its amplitude, or any point on the sweep line has moved more than
10% of the sweep division reading. If the situation arises, carry out a new system
calibration and repeat voided examinations and reexamine all indications recorded
since the valid calibration verification. The change in values if any shall be entered on
the applicable forms.
Note: The Basic calibration blocks can be used as Scanner blocks.
6.3 Demonstration Block and Procedure Qualification
The demonstration block material, curvature, surface finish, and heat treatment
conditions shall meet the requirements. The procedure shall have been demonstrated
to perform acceptably on a demonstration blocks. The demonstration block shall be
prepared by welding.
The demonstration block thickness shall be within 25% of the thickness to be
examined.
The weld joint geometry of the block shall be representative of the production
joint’s details.
The demonstration block shall contain a minimum of three actual planar flaws
or three EDM notches oriented to simulate flaws parallel to the production
weld’s axis and major groove faces. The flaws shall be located at or adjacent
to the block’s groove face as follows.
a. One surface flaw on the side of the block representing the OD surface.
b. One surface flaw on the side of the block representing the ID surface.
c. One subsurface flaw.
d. When the scan plan to be utilized subdivides a weld into multiple
examination zones, a minimum of one flaw per zone is required.
Flaw size of the demonstration block shall be based on the block thickness.
The Procedure demonstration shall be acceptable if only when all the flaws
are detected by the system and;
a. Recorded responses or imaged lengths as applicable exceed the specified
evaluation criteria as given in this procedure.
b. The flaws are sized as being equal to or greater than their actual size (i.e.
both length and height)
The following information shall be recorded for each demonstration block used
with this procedure. The procedure number and the details of the object for
which the procedure is qualified. The demonstration block thickness, joint
geometry and flaw data (i.e. position in block, size (length& height),
Separation from the nearest surface, category (surface or subsurface).
a. Scanning sensitivity and search unit travel speed.
b. Qualification scan data
c. Flaw sizing data.
The qualification data for each demonstration block shall be saved per
procedure being qualified and shall be available to the Inspector and Owner
along with necessary software copy to view the data.
PAUT shall be performed in accordance with this written procedure. This
written procedure is based on the essential and non-essential variables
mentioned in Table-3 and Table-3A.
The change of a requirement in Table - 3 & Table - 3A, identified as an
essential variable from the specified value or range of values shall require re-
qualification of the written procedure.
The change of a requirement in Table 3&3A, identified as non-essential
variable from the specified value or range of values do not require re-
qualification of the written procedures.
All the changes of essential or non-essential variable from the value or range
of values specified by this written procedure shall require revision.
When, due to obstruction, the weld examination can only be performed from one side
from the weld axis and the demonstration block shall contain two sets of flaws, one
set on each side of the weld axis.
7.1.3 Couplant:
Couplant shall be of a type acceptable to the client and shall be non-corrosive,
non-irritant, and easy to clean off the component and leave no residue. It may
be in the form of water with a small amount of wetting agent to enhance
consistent contact, applied by means of plastic tubing and irrigated probe
wedges, or a paste or gel applied by brush.
7.2 Phased Array system calibration:
Calibration shall be performed from the surface of the calibration block which
corresponds to the component surface to be examined. System calibrations shall
include the complete ultrasonic examination system.
Screen distance calibration shall be at least 2T + 10%T (True Depth mode) minimum.
The system calibration information shall be recorded on the ultrasonic data report
form used in Omni scan®. During scanning, only the gain may be adjusted from the
calibrated reference dB Adjustment of other controls requires recalibration.
7.2.1 Velocity calibration:
The Omni Scan shall be calibrated for the velocity with reference to the
selected material. The 100mm Radius of the V1 Block is used in the sound
path mode and multiple reflected signals are generated and by placing the
gate in the appropriate position in the two signals will automatically calibrate
the velocity and the Omni scan sets the velocity.
and focal laws lies within the threshold, the omni scan system shall adjust all
the focal laws/angles to display the reflector’s true depth.
The Sensitivity response (amplitude response) from each focal law provides a
uniform amplitude response to the calibration reflector. As the operator moves
the probe back and forth over a calibration reference reflector, unit software
would result in number of steps/mm value for the attached encoder thus giving true
length of scan. A maximum resolution of 1mm shall be set for and be used between
A-scans collected for thickness under 75mm. A 2mm resolution shall be used for
thicknesses more than and equal to 75mm. Scanning speed will be limited by
mechanical ability to maintain acoustic coupling and by the system’s electronic ability
to ensure full wave forms are captured without missing data points. Missing of data
lines shall not exceed 5% of the total acquisition with adjacent data shall not be
missed. Omni Scan equipment has the capability of rewriting the data while observed
loss of data. The encoder is retrieved back to home position whenever data is missed.
Missing data is represented by dark black lines in the C-scan display.
h. Scanning speed shall be such that data drop-out is less than 5% of the scan
length with no adjacent data line skips
i. Search unit contact must be maintained throughout the entire scan. If contact
is lost due to component geometry or obstructions, this must be noted on the
Phased.
8.6 Reflectors transverse to the weld seam
As alternate to the line scanning, a manual angle beam examination may be
performed for reflectors transverse to the weld axis. MUT result shall be reported on
the PAUT report.
Array Data Report
Save the data file under an appropriate file name which is unique for that weld only
Perform the examination from both sides of the weld, where practical, or from one
side as a minimum. All examination volume limitations shall be documented on the
report.
Phased Array Data Report
Calibration must be checked periodically as stated in the calibration requirements. If
any deviations from the last acceptable calibration are noted, all welds examined to
the last acceptable calibration shall be re-examined
Where access is restricted to a one-sided inspection for the mechanical scanner but
access allows for manual scanning of the opposite side manual scanning shall be
carried out so long as the offset requirements of the Examination Strategy are met
Where access is restricted to a one-sided inspection an additional first leg scan shall
be carried out for the detection of far side fusion defects allowable by weld geometry
for probe/beam positioning.
The specifics of the examination volume, weld definition and location shall be
identified in the scan plan. As a minimum, each linear scan of the phased array
probes shall overlap a minimum of 10% length of the probe wedge along the direction
of the scan. Details of each weld joint configuration of equal or unequal wall thickness
shall be drawn in actual scale to show full beam coverage of weld inspection and
included in the scan plans.
The scan plan shall demonstrate by plotting or with using a computer simulation the
appropriate examination angles for the weld preparation bevel angles that will be used
during the examination. This scan plan shall be documented to show that the
examination volume was examined. This scan plan shall be a part of the final
examination report.
Omni Scan® system has the capability of using multiple-group settings to establish
sector scans and E-scans for the appropriate angles to ensure complete coverage of
the weld and heat affected zone. Scanning shall be performed using a Line scan
technique. Each line scan shall be parallel to the weld using a sectorial scan (S-scan)
and /or a linear scan as shown in fig. 7.
Appropriate refracted angle as accepted by ASME will define the positions of the
arrays and hence angles. These should be detailed in the ultrasonic scan plan. A
minimum of One/two (2) line scans shall be performed from the center of the weld
from both sides of the weld where practical to ensure coverage of the weld and heat
affected zone (HAZ) depends of the thickness.
Scans shall be parallel to the weld at 90º- and 270º scan axes and the multiple groups
scanning shall involve both the above directions for complete coverage of the weld.
The speed of scanning shall be decided in combination with no of groups created in
the set-up file coupled with encoder for automated data acquisition.
For manual PAUT without assisted by an encoder, the movement shall not exceed
150mm/sec. Manual ultrasonic weld testing shall be performed at a scanning
sensitivity of DAC/TCG reference sensitivity plus 6dB minimum. All indications that
exceed 50% of DAC/TCG screen height shall be evaluated.
Evaluation sensitivity for manual ultrasonic weld testing should be DAC/TCG
reference sensitivity plus 6dB with an evaluation level for all indications at 50% of
DAC/TCG screen height.
Results of ultrasonic examination shall be reported on the Omni Scan Data Report
form used in the software. All Phased array examination data for each recordable
indication, A-, B-, C- and S-scans shall be saved as a report file.
The examiner shall record the results of the examination on the Omni Scan Data
Report Form. All recordable indications shall be documented on the examination
report. . All the columns in the report format should be completed with appropriate
data or “NA”
9. DATA RECORDING
Only Trained Level II - UT operators with hands on training Omni Scan shall calibrate
and carry out inspection. Only personnel certified Level II or III in Ultrasonic testing
along with knowledge of phased array and Omni Scan equipment shall evaluate the
results of ultrasonic examinations for acceptance.
Data shall be recorded in the unprocessed form with no thresholding.
TABLE-3
TABLE OF ESSENTIAL VARIABLES FOR QUALIFICTION OF PROCEDURE
TABLE-3A
APPENDIX-A
Report Date Report Version Setup File Name Inspection Date Inspection Version Save Mode
2015 / 04 / 08 NDT SetupBuilder 1.0R6 ITIS 30mm SCAN PLAN.wkb N/A NDT SetupBuilder 1.0R6 Setup
OmniScan Type OmniScan Serial # Module Type Module Serial # Calibration Due Data File Name
N/A N/A OMNI-PA N/A N/A N/A
Probes
Probe Probe Model Wedge Model Reverse Skew Scan Offset Index Offset PCS Pulser Connection Receiver Connection
Probe1 5L64-A2 SA2-N55S 5L64 Forward 90.0° 0.0 mm -25.0 mm N/A 1 N/A
probe2 5L64-A2 SA2-N55S 5L64 Forward 270.0° 0.0 mm 25.0 mm N/A 65 N/A
Probe1
Probe Characterization
Lower Frequency Higher Frequency Center Frequency Bandwidth (MHz) Bandwidth (%)
Setup
A:41.00 Sk:090 L:001
Beam Delay Start (True Depth) Range (True Depth) PRF Type Averaging Factor
0.0 µs N/A N/A N/A PA Linear N/A
Scale Type Scale Factor Video Filter Pretrig. Rectification Band-Pass Filter
N/A N/A N/A N/A N/A N/A
Voltage Gain Mode Wave Type Sound Velocity Pulse Width
N/A N/A PulseEcho SW 3240 m/s N/A
Calculator
Element Qty. Used First Element Last Element Resolution Wave Type Material Velocity
Probe1
Probe Characterization
Lower Frequency Higher Frequency Center Frequency Bandwidth (MHz) Bandwidth (%)
Setup
A:56.00 Sk:090 L:001
Beam Delay Start (True Depth) Range (True Depth) PRF Type Averaging Factor
0.0 µs N/A N/A N/A PA Linear N/A
Scale Type Scale Factor Video Filter Pretrig. Rectification Band-Pass Filter
N/A N/A N/A N/A N/A N/A
Voltage Gain Mode Wave Type Sound Velocity Pulse Width
N/A N/A PulseEcho SW 3240 m/s N/A
Calculator
Element Qty. Used First Element Last Element Resolution Wave Type Material Velocity
16 17 63 1 SW 3240 m/s
Start Angle Stop Angle Angle Resolution Focal Depth Law Configuration
56.0° N/A N/A 50.0 mm Linear
probe2
Probe Characterization
Lower Frequency Higher Frequency Center Frequency Bandwidth (MHz) Bandwidth (%)
Setup
A:41.00 Sk:270 L:001
Beam Delay Start (True Depth) Range (True Depth) PRF Type Averaging Factor
0.0 µs N/A N/A N/A PA Linear N/A
Scale Type Scale Factor Video Filter Pretrig. Rectification Band-Pass Filter
N/A N/A N/A N/A N/A N/A
Calculator
Element Qty. Used First Element Last Element Resolution Wave Type Material Velocity
16 1 N/A N/A SW 3240 m/s
Start Angle Stop Angle Angle Resolution Focal Depth Law Configuration
41.0° 68.0° 1.0° 50.0 mm Sectorial
probe2
Probe Characterization
Lower Frequency Higher Frequency Center Frequency Bandwidth (MHz) Bandwidth (%)
Setup
A:56.00 Sk:270 L:001
Beam Delay Start (True Depth) Range (True Depth) PRF Type Averaging Factor
0.0 µs N/A N/A N/A PA Linear N/A
Scale Type Scale Factor Video Filter Pretrig. Rectification Band-Pass Filter
N/A N/A N/A N/A N/A N/A
Voltage Gain Mode Wave Type Sound Velocity Pulse Width
N/A N/A PulseEcho SW 3240 m/s N/A
Calculator
Element Qty. Used First Element Last Element Resolution Wave Type Material Velocity
16 17 63 1 SW 3240 m/s
Start Angle Stop Angle Angle Resolution Focal Depth Law Configuration
56.0° N/A N/A 50.0 mm Linear
Part
Weld
Root Height Root Angle Land Height Land Offset Hot Pass Bevel Hot Pass Height Hot Pass Angle Fill Height Fill Angle
2.0 mm 0.0° 4.0 mm 3.0 mm V 4.0 mm 30.0° 20.0 mm 30.0°
1 Industrial
Inspection Manager (AWS.CWS:1604001S) ISO 19011:2011 Lead Auditor
2
ASNT Level III (MT, PT, UT, RT, VT,ET) #174544
3
Chief Executive Director (CEO)- ISO 9001 Lead Auditor, , ISO 17025 Lead Assessor
Amendment Record
CEC[EN]-NDT/P/02-01 02 03
INDEX
COVER PAGE 1
AMMENDMENT RECORD 2
INDEX 3
1 PURPOSE 4
2 SCOPE 4
6 APPENDIX 16
Appendix-1 Radiographic testing Report format 17
Appendix-2 Technique Sheets 18
1. PURPOSE
The purpose of this document is to provide the minimum requirements for the
radiographic examination (X-Ray & Gamma – Ray) of welds, which will be revised as
and where necessary to meet the specific contractual specifications and requirements
of a project and thus become a project specific procedure.
2. SCOPE
ASME Section-V (2019 Boiler and Pressure Vessel Code for Non-Destructive
1
Edition) Article 2 Examination
4. DEFINITIONS
5. PROCEDURE
All Personnel carrying out Radiography works to this procedure shall ensure that
they follow safe working practices in compliance with the requirements of CEC’S
Safety Manual &CEC’s Radiation Safety Manual& PTW and authorization certificate.
The welds shall be prepared only to the extent necessary that the resulting
radiographic image due to any irregularities shall not mask or be confused with the
image of any discontinuity in the weld area. The finished surface of all butt-welded
joints may be flush with base material or may have reasonably uniform crowns. If
the weld is ground flush with the adjacent base material, arrows or letter "V's" shall
be placed ¼ inch away from the edge of weld opposite to the film location markers
Doc No : CEC[EN]-NDT/P/01-01 Revision No.: 03 Revision Date: 11/07/2019
CITADEL Engineering Company
The X-ray Machine used shall have adequate voltage and radiation output. The focal
spot size shall not exceed 3 mm x 3 mm. For the verification of source size, the
manufacturer’s certificate documenting the actual physical source size shall be
acceptable.
Other Accessories:
Standard Control Units with Guide tubes for Gamma projector
Control Panel for X-ray Tubes
Power Generator for X-ray tubes
Collimator & Lead Sheets
Survey Meter
Dosimeter
Radiation Warning Placards
Cordoning Rope
Lead Markers
Indelible Markers
Measuring Tape
Elastic
Image Quality Indicator (IQI) also called Penetrameter
Dark Room Accessories & Consumables
All the Survey meters/Dosimeters/Monitoring Equipment’s shall be calibrated once in
a year and following any repair. Copy of Calibration certificate shall accompany the
equipment/survey meter at all times.
IQI shall be of wire type and shall be manufactured & identified in accordance with
the specific contractual specification requirement and appendices. Radiography
ASTM wire type IQIs are available in four sets each containing 6 wires of various
DIN wire type are three sets, each containing 7 wires of various thickness. They are
as given below:
1 ISO 7
3.20 2.50 2.00 1.60 1.25 1.00 0.80
DIAMETER OF WIRE (mm)
CORRESPONDING NUMBER 1 2 3 4 5 6 7
6 ISO 12
DIAMETER OF WIRE (mm) 1.00 0.80 0.63 0.50 0.40 0.32 0.25
CORRESPONDING NUMBER 6 7 8 9 10 11 12
10 ISO 16
DIAMETER OF WIRE (mm) 0.40 0.32 0.25 0.20 0.16 0.125 0.1
10 11 12 13 14 15 16
CORRESPONDING NUMBER
I.Q.I. selection shall be based on the nominal wall thickness of the base material
plus the reinforcement. Internal protrusions of single level welds, backing rings or
strips shall be disregarded in the selection of the required IQI wire size.
Reinforcement shall be based on estimated measurement and not actual
measurement. In general, the following shall apply:
Panoramic, Single Wall – Single image and Double wall – Single image
techniques, the required wire sizes shall be based on the single wall thickness plus
one reinforcement where such reinforcement is not ground off;
Double Wall – Double Image (Elliptical technique) – The required wire size shall
be based on two wall thickness plus one reinforcement where such reinforcement is
not ground off.
Double wall – Double image (Superimposed Technique) – The required wire size
shall be based on two wall thickness plus two reinforcements where such
reinforcements are not ground off.
For welds without reinforcement, the required wire size shall be based on the
nominal single wall thickness or double wall thickness for double wall double viewing
techniques.
Placement of IQI: The IQIs shall be placed on source side of the weld so that the
length of the wires is perpendicular to the length of the weld. In those cases where
the physical placement of IQI on the source side is not possible, the IQI shall be
placed on the film side. If the IQI is placed on the film side, it shall always
accompany a lead letter “F” at least as high as the IQI identification numbers. Only
that portion of the weld adjacent to the film when the IQI is placed on the film side of
the object being radiographed, shall be viewed for acceptance for the radiographic
technique. This includes 3 ½” and under piping. The identification numbers and,
when used, the lead letter “F” shall not be in the area of interest.
Number of IQI(s): One IQI shall represent an area within which radiographic
densities are not less than 15% from that measured through the body of the IQI. At
least one IQI shall be present on the radiograph except as noted below:
a. When film density, in the area of interest varies by more than minus 15% or
plus 30% from the density adjacent to the designated wire of a wire IQI.
b. At least one IQI image shall appear on each radiograph except for Double
wall Single image or Single wall single image techniques requiring multiple
exposures for complete inspection of weld, and where the length of the film
to be interpreted is greater than 10” two IQIs placed across the weld and
perpendicular to the weld length shall be used. One shall be within 1 inch of
the end of the film length and the other shall be at the centre of the film to be
interpreted. When the film length to be interpreted is 5inches or less, one IQI
shall be placed across the weld and perpendicular to the weld length at the
center to be interpreted.
c. If more than one IQI is used because of density requirements, one shall be
placed in the lightest area of interest and the other in the darkest area of
interest. The intervening densities on the radiograph shall be considered as
having acceptable density if the required wire is visible in each IQI.
d. For panoramic radiography involving a complete circumferential weld, four
equally spaced penetrometers at 90 intervals shall be placed.
e. When the source is placed in the axis of the circumference and a portion of
that circumference (four or more continuous locations) is radiographed
during a single exposure, at least 4 IQIs placed approximately equidistance
apart shall be used.
f. Where portions of longitudinal welds adjoining the circumferential weld are
being radiographed simultaneously with the circumferential weld, additional
IQIs shall be placed on the longitudinal welds at the ends of sections most
remote from the position of the source used to radiograph the circumferential
weld.
For Radiography performed in accordance with API 1104 and the techniques is
either DWSI or SWSI non-panoramic) at least two IQIs shall be used for each
exposure. One IQI shall be located approximately in the center of the film. The
other shall be located with the smallest wire approximately 1inch from either end of
the area of interest. Radiography of repairs shall include an IQI for each repair or
area of repair.
Materials
Required DIN IQI wire Required ASTM IQI wire
Thickness (mm)
Source Side Film side Source Side Film side
up to 6.35,
14 15 5 4
Including
over 6.35
13 14 6 5
through 9.52
over 9.52
12 13 7 6
through 12.7
over 12.7
11 12 8 7
through 19.05
over 19.05
10 11 9 8
through 25.4
over 25.4
9 10 10 9
through 38.1
over 38.1
8 9 11 10
through 50.8
over 50.8
7 8 12 11
through 63.5
over 63.5
6 7 13 12
through 101.6
5.6 FILM
Selection of films shall be determined by such factors such as the required quality
level, material type and thickness, radiation energy, source size, source to film
distance etc. The films selected shall be capable of demonstrating the required
image quality indicator (IQI) sensitivity. The films used shall conform to
ASTM/ASME specification E 94/SE94 Table 2 and be of high contrast or ultra-fine
grain, high contrast films which quality as Type I & II of ASTM E 1818-96.
Unexposed films shall be stored in such a manner that they are protected from the
effects of light, pressure, excessive heat, excessive humidity, damaging fumes,
vapors or penetrating radiation. Storage of films should be on a first in first out basis.
Intensifying screens of lead-foil type or cassette screen type shall be used. The
screens shall have a minimum thickness of 0.125 mm (0.005") both front & back.
They shall be of the same approximate dimensions as the film being used and shall
be in direct intimate contact with the film during exposure. The screens used shall
be handled carefully to avoid dents, scratches, grease or dirt. Screens rendering
non-relevant indications on radiographs shall be visually examined and discarded if
physical damage is observed. Exception is permitted when “Ready Pack or “Roll
Pack” with integral screens is used.
Film shall be loaded in the dark room under proper safe light, Filter. Films shall be
cut carefully without any damages, scratches or finger marks. Sandwich the film
between pair of screens & loaded into light tight PVC cassettes or holders. The
maximum Residual Fog level for unexposed film shall not be more than 0.3. OR
integral screens are used with ready pack roll film.
Retake of film due to scratch or other film marks shall be marked with “RT”. Welds
which are completely Cut Out and re-welded are to be identified with marks “RW”.
Unless otherwise specified in the applicable job order or contract, the geometric
unsharpness shall not exceed the following limits:
Ug = Fd/D
minimum of two exposures 90 to each other. Source to film distance will not be less
than 400 mm which being the practical limit considering the exposure time and
quality requirement.
Double Wall Single Image:
For diameter greater than 3 inches, the double wall single image technique shall be
used with at least three exposures at 120 to each other. In this technique, the
radiation penetrates through both the walls of Test Object & single image of the part
closest to the film is recorded on the Radiograph.
Double wall techniques shall be used only when single wall technique is not
practicable. Adequate Number of exposures shall be made to demonstrate the
required coverage.
The films shall be unloaded in hangers/spools carefully to avoid any marks. Films
shall be processed by manual method in accordance with CEC’s document
CEC[EN]-NDT/P/02-03.
If Automatic processing method is used for film processing manufacturers manual
shall be followed.
Viewing facilities shall provide subdued background lighting of an intensity that will
not cause troublesome reflections, shadows, or glare on the radiograph. Equipment
used to view radiographs for interpretation shall provide a variable light source
sufficient for the designated wire to be visible for the specified density range. The
viewing conditions shall be such that light from around the outer edge of the
radiograph or coming through low-density portions of the radiograph does not
interfere with interpretation.
Personnel performing radiographic interpretation shall be in the darkened area for at
least 5 min. prior to performing the interpretation to enable his eyes to adapt for dark
viewing.
the area of interest on the radiograph. If any doubt exists as to the true nature of an
indication exhibited by the film, the radiograph shall be rejected and reshot.
Film Density: The density is the quantity measurement of the degree of blackening
on the final radiograph and shall be assessed in the location of the weld.
D = log (Io / It)
Where
D Density
Io Light intensity incident on film
It Light intensity transmitted through the film
To measure the film density a calibrated Densitometer or calibrated Wedge Strip
shall be used. The Densitometer shall have a range to measure density from 0
to 4.
The Calibration of the densitometer shall be checked once in 90 days with
calibrated step wedge film or calibrated densitometer traceable to National
Standard.
Densitometer shall be calibrated at the beginning of each shift, after 8 hr. of
continuous use, or after change of apertures, whichever comes first.
The transmitted film density through the radiographic image adjacent to the
designated wire of the wire IQI and the area of interest shall be 1.8 to 4.0
radiographs made with an X-ray source and 2.0 to 3.8 for radiographs made
with a gamma-ray source.
Contrast of the film shall be adequate to manifest on the Radiograph even the
smallest thickness differential. Better the contrast better the interpretation of
discontinuity.
5.16.3 Sensitivity
5.18 REPORTS
Weld identifications
Weld Repair Documentation
Acceptance Criteria used
Source type used
Strength of source
Physical source size
Film Used (manufacturer and type/designation)
Film processing method
IQI used and required wire size to be recorded on Radiographic Testing
Report
Base material type and thickness
source-to-object distance
distance from source side of object to film
Film interpretation record shall contain as a minimum the following
information:
Disposition of each radiograph (acceptable or reject able)
If reject able, cause for rejection (slag, crack, porosity, lack of fusion,
incomplete penetration, etc.)
Surface indication verified by visual examination (grinding marks, weld
ripple, splatter, etc.)
Name and Signature of the Film interpreter with date
Name of Radiographers
6. APPENDIX
5. Make of Equipment
6. Source Strength
7. Effective dim. Source size
8. I.Q.I.Type
9. Sensitivity 2% or better
10. Technique as specified in SWSI
11. Radiation angle with respect to weld Perpendicular to the weld
and film
12. Source to film distance Center of the pipe diameter
13. Object to film distance Full contact as max. possible with weld
14. Geometric unsharpness 0.5 mm or less
15. Film type
16. Film dimensions & No of Exposures Full Circumference + 25 mm overlap on each film and one
single exposure
17. Overlap of film 25 mm
18. Diagnostic film length Depends on OD of the Pipe
19. Intensifying screens Lead
20. Screen thickness 0.125 mm Front and Back for bare Films, For Pre packed
Films as per Manufacturer
21. Maximum base fog level 0.3
22. Film density Between 2 to 3.5 in sound weld
23. Check on back scatter Yes with Letter B
24. Identification on film
25. Film processing Manual
26. Processing chemicals Kodak or Agfa
27. Acceptance Criteria
28. Reporting
29. Identification of repairs
30 Film archival life
FILM
EXPOSURE ARRANGEMENT - B
SOURCE
1.
FILM
SOURCE
2.
FILM
SOURCE
1. Elliptical Shot
FILM
SOURCE
2. Superimposed shot
FILM
LOCATION MARKING
Procedure Demonstration:
Demonstration of the density and image quality indicator (IQI) image requirements of the written
procedure on production or technique radiographs shall be considered satisfactory evidence of
compliance with that procedure.
Rounded indications:
Indications with a maximum length of three times the width or less on the radiograph are
defined as rounded indications. These indications may be circular, elliptical, conical, or
irregular in shape and may have tails. When evaluating the size of an indication, the tail
shall be included. The indication may be from any imperfection in the weld, such as
porosity, slag, or tungsten.
Image Density: Density within the image of the indication may vary and is not a criterion for
acceptance or rejection.
Relevant indications: Only those rounded indications which exceed the following
dimensions shall be considered relevant.
1. 1/10t for ‘t’ less than 1/8” (3mm)
2. 1/64” for ‘t’ from 1/8” to ¼” (3mm to 6 mm), incl.
3. 1/32” (0.8mm) for ‘t’ greater than ¼” to 2” (6mm to 50mm)
Maximum size of Rounded Indication: The maximum permissible size of any indication
shall be 1/4t, or 5/32” (4mm), whichever is smaller; except that an isolated indication
separated from an adjacent indication by 1” (25mm) or more may be 1/3t, or ¼” (6mm),
whichever is less. For ‘t’ greater than 2” (50mm) the maximum permissible size of an
isolated indication shall be increased to 3/8” (10mm).
Aligned rounded indications: Aligned rounded indications are acceptable when the
summation of the diameters of the indications is less than ‘t’ in a length of 12t. The length
of groups of aligned rounded indications and the spacing between the groups shall meet the
requirements of figure given below.
Spacing: The distance between adjacent rounded indications is not a factor in determining
acceptance or rejection, except as required for isolated indications or groups of aligned
indications.
Rounded indication Charts: The rounded indications characterized as imperfections shall
not exceed that shown in the charts (attached). The charts in figs. 4-3 through 4-8 illustrate
various types of assorted, randomly dispersed and clustered rounded indications for
different weld thicknesses greater than 1/8” (3mm). These charts represent the maximum
acceptable concentration limits for rounded indications. The charts for each thickness
range represent full-scale 6” (150mm) radiographs, and shall not be enlarged or reduced.
The distributions shown are not necessarily the patterns that may appear on the radiograph,
but are typical of the concentration and size of indications permitted.
Doc No : CEC[EN]-NDT/P/01-01 Revision No.: 03 Revision Date: 11/07/2019
CITADEL Engineering Company
Weld thickness t less than 1/8” (3mm): For ‘t’ less than 1/8” (3mm) the maximum number of
rounded indications shall not exceed 12 in a 6” (150mm) length of weld. A proportionally
fewer number of indications shall be permitted in welds less than 6” (150mm) in length.
Clustered indications: The illustrations for clustered indications show up to four times as
many indications in a local area, as than shown in the illustrations for random indications.
The length of an acceptable cluster shall not exceed the lesser of 1” (25mm) or 2t. Where
more than one cluster is present, the sum of the lengths of the clusters shall not exceed 1”
(25mm) in a 6” (150mm) length of weld.
Note: All the figures from Figure 4.2 to Figure 4.8 are from ASME code Section VIII
Division 1, Appendix 4.
For weld joints to be spot radiographed.
The acceptability of welds examined by spot radiography shall be judged by the following
standards:
1. Welds in which indications are characterized as cracks or zones of incomplete
fusion or penetration shall be unacceptable.
2. Welds in which indications are characterized as slag inclusions or cavities shall be
unacceptable if the length of any such indication is greater than 2/3 t where t is the
thickness of the weld excluding any allowable reinforcement. For a butt weld joining
two members having different thickness at the weld, t is the thinner of these two
thicknesses. If a full penetration weld includes a fillet weld, the thickness of the
throat of the fillet shall be included in t. If several indications within the above
limitations exist in line, the welds shall be judged acceptable if the sum of the
longest dimensions of all such indications is not more than t in a length of 6t (or
proportionately for radiographs shorter than 6t) and if the longest indications
considered are separated by at least 3L of acceptable weld metal where L is the
length of the longest indication. The maximum length of acceptable indications shall
be ¾” (19mm). Any such indication shorter than ¼” (6mm) shall be acceptable for
any plate thickness.
3. Rounded indications are not a factor in the acceptability of welds not required to be
fully radiographed.
ASME Section VIII Division II (addendum)
All the acceptance standards of ASME Code Section VIII Division I apply. In addition to that
Internal root weld conditions are not acceptable when the density or image brightness
change as indication in the radiograph is abrupt.
A rounded indication whose size is 1.5 mm (1/16”) shall be considered relevant for t greater
than 50 mm (2”).
ASME Section IX
Acceptance Standards:
Welder and welding operator performance test by radiography of welds in test assemblies
shall be judged unacceptable when the radiograph exhibits any imperfections in excess of
the limits specified below
a. Linear indication
1. Any type of crack or zone of incomplete fusion or penetration
2. Any elongated slag inclusion which has a length greater than
a) 1/8” (3mm) for t up to 3/8” (10mm), inclusive
b) 1/3t for t over 3/8” (10mm) to 2 ¼” (57mm)
c) ¾” (19mm) for t over 2 ¼” (57mm)
3. any group of slag inclusions in line that have an aggregate length greater than t
in a length of 12t, except when the distance between the successive
imperfections exceeds 6L where L is the length of the longest imperfection in the
group
b. Rounded Indications
a. The maximum permissible dimension for rounded indications shall be 20% of
‘t’ or 1/8” (3mm), whichever is smaller.
b. For welds in material less than 1/8” (3mm) in thickness, the maximum
number of acceptable rounded indications shall not exceed 12 in a 6”
(150mm) length of weld. A proportionately fewer number of rounded
indications shall be permitted in welds less than 6” (150mm) in length.
c. For welds in material 1/8” (3mm) or greater in thickness, the charts attached
below represent the maximum acceptable types of rounded indications
illustrated in typically clustered, assorted, and randomly dispersed
configurations. Rounded indications less than 1/32” (0.8mm) in maximum
diameter shall not be considered in the radiographic acceptance tests of
welders and welding operators in these ranges of material thickness.
ASME Section I
All the Acceptance Standards of ASME Section VIII Division I Apply.
ASME B 31.1
The following indications are not acceptable.
1. Any type of crack, or zone of incomplete fusion or penetration:
2. Any elongated indication which has length greater than
a. 1/4 in. for ‘t’ up to 3/4 in.
b. 1/3 t for ‘t’ from 3/4 in. to 2 1/4 in.
c. 3/4 in. for ‘t’ over 2 1/4 in.
where t = the thickness of the weld
3. Any group of indications in line that have an aggregate length greater than t in
a length of 12 t, except when the distance between the successive imperfections
exceeds 6L where L is the length of the longest imperfection in the group:
4. Porosity more than that specified by the acceptance standards given in Section I
of ASME Boiler & Pressure Vessel Code.
5. Root concavity when there is an abrupt change in density as indicated in the
radiograph.
More Restrictive Standard:
The above acceptance standard applies unless other more restrictive standards are
specified.
ASME B 31.3
The following table gives the details for the acceptance criteria to be applied as per
ANSI/ASME B31.3.
Inspection Management
Department
Muhammad Ikram 3
Chaitanya Vasanthavada 2 Shahriyar Majlesein
00 Ullah 1
28 January, 2016
28 January, 2016 28 January, 2016
Tulasiram Poppala 1 Jinagam Chakrapani 2 Shahriyar Majlesein 3
01 01 July, 2017 01 July, 2017 01 July, 2017
Majid Faraji Shovay 1 Hamid Rabiei 2 Shahriyar Majlesein 3
02 07 November, 2019 07 November, 2019 07 November, 2019
Arun G. Hamid Rabiei Shahriyar Majlesein
03
12 January, 2022 13 January, 2022 17 January, 2022
1 Industrial
Inspection Manager (AWS.CWS:1604001S) ISO 19011:2011 Lead Auditor
2
ASNT Level III (MT, PT, UT, RT, VT,ET) #174544
3
Chief Executive Director (CEO)- ISO 9001 Lead Auditor, , ISO 17025 Lead Assessor
Doc No: CEC[EN]-NDT/UT/P/04-01 Revision No.: 02 Revision Date: 11/07/2019
CITADEL Engineering Company
AMENDMENT RECORD
CEC[EN]-NDT/UT/P/04-01 02 03
INDEX
COVER PAGE 1
AMMENDMENT RECORD 2
INDEX 3
1 PURPOSE 4
2 SCOPE 4
3 REFERENCE CODES AND/OR STANDARDS 4
4 DEFINITIONS 4
5 PROCEDURE 5
6 APPENDIX 23
Appendix-1 Ultrasonic testing Report format 24
Appendix-2 Acceptance Criteria 25
1. PURPOSE
This procedure defines the procedures and techniques of the ultrasonic test to detect cracks
and other discontinuities, in weldments when allowed within the provisions of ASME B31.3.
This procedure shall be used in conjunction with the applicable technical and construction
specifications, drawings, codes and standards. Citadel Engineering Company will apply this
NDE procedure in conjunction with corresponding project NDE specifications for the project
after obtaining client’s approval.
2. SCOPE
This document describes the operation procedure to be followed and applied for performing
Ultrasonic Examination of the parent and complete joint penetration groove weld and HAZ of
material between the thickness of 8 mm and 200 mm inclusive in accordance with ASME B31.3
This procedure is to be used for detecting, locating and evaluating indications within the welds
and heat affected zone of carbon steel and low alloy steel. Additional specific procedures for
ultrasonic examination of special configurations, materials or technique sheets shall be
developed if and when the needs arise.
4. DEFINITIONS
5. PROCEDURE
5.1 PERSONNEL QUALIFICATION
Personnel involved in performing, interpreting and evaluating Ultrasonic examination to this
procedure shall be qualified to UT Level II minimum in accordance with CEC[EN]-NDT/WP/09-
01 which follows the requirements of Latest Editions of ASNT-SNT-TC-1A and CP 189.
UT Level II Qualified personnel are approved to use longitudinal and shear wave ultrasonic
examination.
UTT Level I qualified personnel are approved to use only longitudinal wave ultrasonic
examination.
All personnel performing UT Examination inspection shall hold a currently valid certification
All Personnel carrying out works to this procedure shall ensure that they follow safeworking
practices in compliance with the requirements CEC’S Safety Manual.
The conditions of the surface in contact with the probe shall be such that a satisfactory
coupling between the probe and the scanning surface shall be achieved.
The surface condition of the weld and the adjacent parent metal on each surface shall be such
that it does not adversely influence the weld examination. Variations across the weld shall not
exceed 1.5 mm in 50 mm length. Depending upon the profile and weld face condition, dressing
may be necessary to avoid the formation of confusing surface echoes. Weld reinforcement
shall be removed, to have a flatsurface for critical examination, if necessary.
5.4 EQUIPMENTS, CONSUMABLES & ACCESSORIES
5.4.1 Ultrasonic Flaw Detector Instrument
• The equipment shall be A-scan pulse echo type (digital or analogue) ultrasonic flaw
detector.
• The ultrasonic equipment shall be calibrated for linearity once in every 3 months for
analog instruments and every year for digital type instrumentsand prior to use,
calibration validity shall be ensured. In addition to this, the operator shall calibrate the
equipment prior to start of each day’s work and, as and when required on the job. In
case of continuous scanning, calibration shall be verified every 4 hrs. during the
examination.
• The UT instrument shall provide linear vertical presentation with ± 5% of the FSH for
20% to 80% of the calibrated screen height.
• The UT equipment shall utilize an amplitude control over its useful range to + 20% of
the nominal amplitude ratio to allow the measurement of indications beyond the linear
range of the vertical display on the screen.
5.4.2 Search Units (Probes)
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CITADEL Engineering Company
A single or dual crystal normal beam longitudinal wave probes (00), and angle beam
shear wave probes shall be used for examination.
Refracted angle in steel for angle beam probes shall be 450, 600 and 700 with
frequency of 4 MHz
Search Unit Element size (For Welds in Piping):
Dual transducer probes when used, their included angle between the beam paths
shall be such that the effective focal spot of the probe is centered in the area of
interest.
The probes with contoured contact wedges may be used for examination of such
surfaces, however in such cases; all calibration shall be performed withthe contoured
wedges to be used during the examination.
5.4.3 Calibration Blocks
• International Institute of Welding Ultrasonic Reference Block Type-I (IIW V1)
• Miniature Angle Beam Block (IIW V2)
• ASME basic calibration block (Refer to Figure 1)
• Calibration Block for Cladded Plates (Refer to Figure 2)
• Calibration Block for welds in ferritic pipes (Refer to Figure 3)
• Resolution Reference Block
• Distance and Sensitivity Block
Notches shall be located not closer than T or 1 inch (25mm), whichever isgreater, to any block edge or to
other notches.
General Notes:
(a) The minimum calibration block length (L) shall be 8 inch (200mm) or 8T, whichever is greater.
(b) For OD 4" (100mm) or less, the minimum arc length shall be 270 o. For OD greater than 4 inch
(100mm), the minimum arc length shall be 8 inch (200mm) or3T whichever is greater.
(c) Notch depth shall be from 8% T min. to 11% T max. Notch widths shall be 1/4" (6mm)
maximum. Notch length shall be 1 inch (25mm) minimum.
(d) Maximum Notch width is not critical. Notches may be made with EDM or withend mills up
to 1/4" (6mm) in diameter.
(e) Notch length shall be sufficient to provide for calibration with a minimum 3 to 1 signal-to-noise
ratio.
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CITADEL Engineering Company
5.4.4 Couplant
Commercially available couplant e.g. ZG5, Ultra gel shall be used. However, the
same couplant must be used for calibrating and for examining.
Couplant for SS shall not have more than 50ppm of halides and couplant for
nickel alloys not more than 50ppm of Sulphur.
5.4.5 Accessories
• Set the larger of the two indications at 80% of Full Screen Height (FSH).
• Without moving the search unit, adjust the gain in steps of 2 dB to successively
set the larger of the indications from 100% to 20% of FSH. Record the amplitude
of both indications. Evaluate the results in terms of the following paragraph.
• The lower amplitude must be 50% of the higher amplitude within ± 5% of FSH.
Figure A
Table 2
• Position the search unit for the maximum first indication from the ¾ T side
drilled hole. Adjust the left edge of this indication to line 6 on the screen (i.e. to
60% of sweep) with the range control.
• Repeat the range and delay control adjustment until the ¼ T and ¾ T hole
reflections start at 2 and 6 (i.e.20% and 60%).
• Position the search unit for a maximum response from the square notch on the
opposite surface. The indication will appear on line 8 (i.e. 80%).
• Now using the instrument menu enter the thickness of the job.
• Now the instrument range is calibrated with 2 divisions on the sweep equal to ¼
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CITADEL Engineering Company
T.
• This calibration shall be performed at the beginning of each examination and
verified at the end of examination
• Position the search unit for the maximum first indication from the ¼ T side drilled
hole. Adjust the left edge of this indication to line 2 on the screen (i.e. to 20% of
sweep) with the delay control.
• Position the search unit for the maximum first indication from the ¾ T side drilled
hole. Adjust the left edge of this indication to line 6 on the screen (i.e. to 60% of
sweep) with the range control.
• Repeat the range and delay control adjustment until the ¼ T and ¾ T hole
reflections start at 2 and 6 (i.e.20% and 60%).
• Position the search unit for a maximum response from the square notch on the
opposite surface. The indication will appear on line 8 (i.e. 80%)
• Now using the instrument menu enter the thickness of the job.
• Now the instrument range is calibrated with 2 divisions on the sweep equal to ¼
T. The digital depth readout is also activated.
• Position the search unit for maximum response from the hole whichgives the
highest amplitude.
• Position the search unit for the maximum indication from the otherholes and
enter those points also as DAC points.
• Position the search unit for maximum amplitude from ¾ T hole afterbouncing
from opposite face. Enter this point also into the instrument.
• Add a 1 1/2 v shear calibration for welds with single side access only. and 1 1/2
V for Full weld coverage.
• Position the search unit for maximum response from the squarenotch on the
opposite side. This should appear at sweep line 8. Mark the peak indication on
the screen.
• This indication may be 2:1 above DAC for 45 degrees probe and ½ DAC for 60
degrees. This must be taken into account while evaluating reflectors located at
or near the opposite surface.
In any case probe frequency is 4 MHz the probe refracted shear wave angles
shall be 45, 60 & 70 degrees or a combination. Probes frequency and refracted
angles shall be selected based on the contractual specification requirements.
For welds in pipes, Calibration Block for pipe welds shall be used. For pipe
joints with Diameter less than 20" curved block shall be used. A single curved
block may be used for calibration on surfaces in the range of curvature from 0.9
to 1.5 times the calibration block diameter. The thickness of the Calibration Block
shall be in accordance with Figure1. The reflectors size of the calibration block
shall be in accordance with Figure 3.
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Where two or more base material thicknesses are involved the calibration Block
thickness shall be based on the average thickness of the weld.
The material for the Blocks shall be of the same product form and equivalent P
Number grouping as one of the materials being fabricated. P Numbers 1, 3, 4, 5
being considered equivalent.
Where the component material is cladding the Calibration, Block shall be cladded
by the same procedure as the production part.
The Calibration Block must have received the minimum Tempering Treatment
required by the material specification for the type and grade. If the calibration
block contains welds other than cladding, then the block shall receive a Post
Weld Heat Treatment of at least 2 hours.
The block shall be scanned by a Straight beam search unit and any area that
contain an indication exceeding the remaining back reflection shall be excluded
from the beam path is required to reach the various reflectors.
Mark a reference line, by using scriber, parallel to the weld and at some distance
away. Mark another reference line perpendicular to this reference line. Use these
reference lines to identify and locate discontinuities.
The volume shall be examined by moving the probe over the examinationsurface
to scan the entire examination volume. Each pass of the probe shall overlap a
minimum of 10% of the transducer dimension perpendicular to the direction of
the scan.
The rate of probe movement for examination shall not exceed 6 inches/sec
(150mm/Sec).
During scanning the Reject control of the equipment shall be kept at minimum
(zero) position.
Scan the adjacent base metal to detect reflectors that might interfere with
anglebeam reflectors. Record any such reflectors.
Scan the weld and adjoining base metal (one inch on either side) after
establishing DAC.
Weld Scanning as per ASME Sec VIII Div. I / B31.3 Pipe Weld Scan:
• The sensitivity of the equipment shall be set by establishing DAC as per
Section 5.5. In addition, appropriate correction factor above DAC based on the
contractor requirements shall be given while scanning.
• The angle beam shall be directed at the weld at approximately right angles. This
shall be done from two directions if possible; the search unit shall be manipulated
such that the required volume of weld metal is scanned. Scanning shall be
carried out at two-time primary reference level. Evaluation shall be with reference
to primary reference level. Incase of one side is accessible then, calibration
examination shall be done 1 ½ V calibration scan and 1 ½ V for Full Weld
Coverage.
• The angle beam shall be directed essentially parallel to the weld axis. The search
unit shall be manipulated such that the required volume of weld metal and
adjacent base metal is scanned. Scanning shall be carried out at two time’s
primary reference level. Evaluation shall be with reference to primary reference
level. The search unit shall be rotated by 180 degrees and the scanning
repeated.
5.6.8 Recording
Recording shall be done manually. Record all indications 20% of DAC and
over as follows:
a. Position the search unit to give maximum amplitude from the reflector.
Readand record the maximum amplitude in percent of DAC.
b. Read and record the sweep reading (at the leading edge of the indication).
c. Read and record the position of the search unit with reference to the
reference line.
d. Read and record the discontinuity location echo amplitude along and
perpendicular to the weld.
e. Move the search unit towards and away from reflector until the
amplitudefalls to 20% DAC and record through thickness dimension of
discontinuity.
The record of all indications shall be made in terms of the shape, location, depth
and identity of the reflector. The record shall include a sketch of the job showing
clearly the location of all recorded indications.
• If a point on the sweep range has moved more than 10% of the sweep or more
than 5% of full sweep whichever is greater, correct the sweep range calibration
and note the correction in the examination record. All recorded indications since
the last valid calibration shall be reexamined with thecorrected calibration and
their values shall be changed in the data sheets.
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• If a point on the DAC has reduced by 20% or 2 dB of its amplitude, all data
sheets since the last calibration or calibration check shall be marked void. A
new calibration shall be made and recorded, and the area covered by the voided
data shall be re-examined.
• If a point on the DAC has increased more than 20% or 2 dB of its amplitude, all
recorded indications since the last valid calibration or calibration check shall be
reexamined with the corrected calibration and their values changed on the data
sheets.
d=a–b–c
where, a = Indication level.
b = Reference level.
c = Attenuation factor.
6. APPENDIX
6. 1 Appendix 1 - Report of Ultrasonic Examination
6. 2 Appendix 2 - Acceptance Criteria
ASME B31.3
c. ¾ in. (19.0 mm) for t over 2¼ in. (57.0 mm) where t is the
thickness of the weld being examined. If the weld joins two
members having different thicknesses at the weld, is the
thinner of these two thicknesses.