Obite TC & Ogbogu Cluster - Ultrasonic Examination Procedure For Steel Structure

OML 58 Upgrade Phase 1
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OBITE TC & OGBOGU CLUSTER-ULTRASONIC

EXAMINATION PROCEDURE FOR STEEL STRUCTURE
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OBITE TC & OGBOGU CLUSTER ULTRASONIC EXAMINATION

PROCEDURE FOR STEEL STRUCTURE
Rev.
Status
Rev. Date
Revision Memo
Issued by
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Approved by
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Issued for Review
S. Belkhede
M. Patel
L. Borri
This document has been generated by an Electronic Document System. When printed it is considered as a for information only copy. The controlled copy is the
screen version and it is the holders responsibility that he/she holds the latest valid version.
This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the Company.
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REVISION DESCRIPTION
Rev. index
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INDEX
INDEX...........................................................................................................................................................................................3
1. SCOPE AND PURPOSE..........................................................................................................................................................6
1.1. SCOPE ..................................................................................................................................................................................6
1.2. PURPOSE...............................................................................................................................................................................6
2. REFERENCE DOCUMENTS.................................................................................................................................................6
3. DEFINITIONS AND ABBREVIATIONS..............................................................................................................................7
4. PERSONNEL............................................................................................................................................................................7
4.1 ULTRASONIC OPERATOR WHO WILL PERFORM AND EVALUATE THE TEST RESULTS SHALL BE CERTIFIED TO LEVEL 2 OR 3
IN ACCORDANCE WITH NG22-280-PRC-SPD-002127:QUALIFICATION AND CERTIFICATION OF NDT PERSONNEL (WHICH
IS BASED ON ASNT-SNT-TC-1 AND EN 473), CSWIP SCHEME OR COMPANY APPROVED EQUIVALENT STANDARDS. UT
LEVEL 1 CERTIFIED PERSONNEL MAY WORK AS ASSISTANTS UNDER THE DIRECT SUPERVISION OF LEVEL 2 OR LEVEL 3
CERTIFIED PERSONNEL.................................................................................................................................................................7
4.2 THE ULTRASONIC OPERATORS ARE REQUIRED TO PASS A VISION TEST ANNUALLY. THE TEST COMPRISES OF THE ABILITY
TO READ, WITH CORRECTION IF REQUIRED TO JAEGER J2 (OR EQUIVALENT) WITH AT LEAST ONE EYE AT A DISTANCE OF 300
MM...............................................................................................................................................................................................7
4.3 ALL SUB-CONTRACTORS NDT PERSONNEL PERFORMING WORK TO THIS PROCEDURE SHALL BE SUBJECT TO A
PERFORMANCE DEMONSTRATION TEST TO DETERMINE THEIR ABILITY TO DETECT AND EVALUATE FLAWS FOUND DURING THE
EXAMINATION OF WELDS. THE PROPOSED PERFORMANCE DEMONSTRATION TEST SHALL BE PREPARED BY SPD LEVEL 3 AND
SUBMITTED TO CPY FOR APPROVAL. ALL PERFORMANCE EXAMINATION RESULTS SHALL BE EVALUATED BY SPD LEVEL 2
OR 3 CERTIFIED PERSONNEL.........................................................................................................................................................7
5. EQUIPMENT............................................................................................................................................................................8
5.1. EQUIPMENT REQUIREMENTS ...............................................................................................................................................8
5.1.1. Horizontal Linearity....................................................................................................................................................8
5.1.2. Gain Control Linearity................................................................................................................................................8
5.2. SEARCH UNITS.....................................................................................................................................................................8
5.2.1. Frequency....................................................................................................................................................................8
5.2.2. Straight Beam (Longitudinal Wave) Search Unit.....................................................................................................8
5.2.3. Angle - Beam (Transverse Wave) Search Unit............................................................................................................8
6. REFERENCE STANDARDS (BLOCKS)..............................................................................................................................8
6.1. IIW STANDARD...................................................................................................................................................................8
6.2. RESOLUTION REQUIREMENTS..............................................................................................................................................9
7. EQUIPMENT QUALIFICATION..........................................................................................................................................9
7.1.
7.2.
7.3.
7.4.
HORIZONTAL LINEARITY.....................................................................................................................................................9
GAIN CONTROL....................................................................................................................................................................9
INTERNAL REFLECTIONS......................................................................................................................................................9
CALIBRATION OF ANGLE-BEAM SEARCH UNITS.................................................................................................................9
8. CALIBRATION FOR TESTING............................................................................................................................................9

8.1. POSITION OF REJECT CONTROL............................................................................................................................................9
8.2. TECHNIQUE..........................................................................................................................................................................9
8.3. RECALIBRATION...................................................................................................................................................................9
8.4. STRAIGHT-BEAM TESTING OF BASE METAL.....................................................................................................................10
8.4.1. Sweep.........................................................................................................................................................................10
8.4.2. Sensitivity...................................................................................................................................................................10
8.5. CALIBRATION FOR ANGLE-BEAM TESTING.......................................................................................................................10
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8.5.1. Horizontal Sweep.......................................................................................................................................................10

8.5.2. Sensitivity (Zero Reference Level) Calibration.........................................................................................................10
9. TESTING PROCEDURES....................................................................................................................................................10
9.1. CLEANLINESS.....................................................................................................................................................................10
9.2. COUPLANTS .......................................................................................................................................................................10
9.3. EXTENT OF TESTING..........................................................................................................................................................10
9.4. DISCONTINUITY SIZING .....................................................................................................................................................10
9.4.1. Inaccessibility............................................................................................................................................................11
9.5. TESTING OF WELDS...........................................................................................................................................................11
9.5.1. Scanning.....................................................................................................................................................................11
9.5.2. Scanning Patterns......................................................................................................................................................11
9.5.3. Weld Joints ................................................................................................................................................................11
9.5.4. Maximum Indication..................................................................................................................................................11
9.5.5. Attenuation Factor.....................................................................................................................................................12
9.5.6. Indication Rating ......................................................................................................................................................12
9.6. BASIS FOR ACCEPTANCE OR REJECTION............................................................................................................................12
9.7. IDENTIFICATION OF REJECTED AREA.................................................................................................................................12
10. DOCUMETATION...............................................................................................................................................................12
10.1. EXAMINATION RECORDS..................................................................................................................................................12
PROCEDURE IDENTIFICATION AND REVISION;..........................................................................................................................12
ULTRASONIC INSTRUMENT IDENTIFICATION (INCLUDING MANUFACTURERS SERIAL NUMBER);............................................12
SEARCH UNIT(S) IDENTIFICATION (INCLUDING MANUFACTURERS SERIAL NUMBER, FREQUENCY, WAVE MODE, BEAM ANGLE
AND SIZE);..................................................................................................................................................................................12
COUPLANT USED, BRAND NAME OR TYPE;...............................................................................................................................12
CALIBRATION BLOCKS IDENTIFICATION;................................................................................................................................12
CALIBRATION DATA [INCLUDING TEST RANGE(S), REFERENCE REFLECTOR(S), REFERENCE LEVEL GAIN(S), TRANSFER
CORRECTION GAIN(S), SCANNING IF ANY]..................................................................................................................................12
INDICATION DATA [INDICATION RATING (S), DEPTH(S), LENGTH(S), REFERENCE DISTANCE(S) AND INDICATION TYPE(S)];...12
IDENTIFICATION AND LOCATION OF WELD;.............................................................................................................................12
SURFACE CONDITION;.............................................................................................................................................................12
MAP OR RECORD OF REJECTABLE INDICATIONS DETECTED;...................................................................................................12
AREAS OF RESTRICTED ACCESS OR INACCESSIBLE WELDS;....................................................................................................12
NAME OF EXAMINATION PERSONNEL, QUALIFICATION LEVEL;................................................................................................12
DATE OF EXAMINATION..........................................................................................................................................................12
IN GENERAL: ALL EXAMINATION REPORTS TO BE REVIEWED AND SIGNED BY CERTIFIED LEVEL 2 OR 3 PERSONNEL............12
10.2. REPORT ...........................................................................................................................................................................13
THE REPORT SHALL INCLUDE THOSE RECORDS INDICATED IN SECTION10.1 (REFER APPENDIX 6). ...................................13
11. APPENDIX............................................................................................................................................................................13
11.1. APPENDIX 1 HORIZONTAL LINEARITY PROCEDURE......................................................................................................13
11.2. APPENDIX 2 GAIN CONTROL LINEARITY .....................................................................................................................13
11.2.1. Screen Height Linearity ..........................................................................................................................................13
11.2.2. Amplitude Control Linearity....................................................................................................................................13
11.3. APPENDIX 3 INDEX POINT ..........................................................................................................................................13
11.4. APPENDIX 4 ANGLE ...................................................................................................................................................13
11.5. APPENDIX 5 INTERNAL REFLECTION ...........................................................................................................................14
11.6. APPENDIX 6 RESOLUTION STRAIGHT BEAM.................................................................................................................14
11.7. APPENDIX 7 RESOLUTION ANGLE BEAM......................................................................................................................14
11.8. APPENDIX 8 ULTRASONIC EXAMINATION REPORT.......................................................................................................15
12. FIGURES...............................................................................................................................................................................16
12.1.
12.2.
12.3.
12.4.
FIGURE 1 IIW V1 BLOCK.............................................................................................................................................16

FIGURE 2 IOW BLOCK..................................................................................................................................................16
FIGURE 3 PLAN VIEW OF UT SCANNING PATTERNS....................................................................................................17
TABLE 6.2 .......................................................................................................................................................................18
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12.5. TABLE 6.3 .......................................................................................................................................................................19

12.6. TABLE 6.7........................................................................................................................................................................20
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SCOPE AND PURPOSE

1.1.
Scope
OML58 Block, operated by TEP NG (TOTAL E&P Nigeria Ltd) is located in Nigeria, at some 75 km NorthWest from Port Harcourt and comprises OBITE Treatment Center, OGBOGU Cluster, various clusters, wells,
flow lines and pipelines.
TEP NG intends to upgrade OML 58 facilities and mainly increase gas production from 9.46 MMSm3/d up to
15.65 MMSm3/d of marketable gas.
TEP NG is also developing the project of an independent power plant (IPP) in the vicinity of the OBITE TC
(optional scope C). The IPP will be supplied with gas by a GAS SUPPLY UNIT (IPP-GSU) located nearby the
OBITE TC.
The IPP-GSU will provide a maximum of 2.5 MMSm3/d of fuel gas to the turbine generator sets located on
IPP.
The present project covers the phase 1 upgrade which includes facilities to cover the oil and gas production
profile of existing and new wells until the 31st of December 2013.
1.2.
Purpose
This procedure sets out the techniques and parameters for ultrasonic flaw detection of groove welds and
HAZ of steel structure for the thicknesses between 08mm to 200mm inclusive. This procedure is limited to
the ultrasonic testing by the pulse echo manual contact method. This procedure shall be used during the
fabrication and construction of OML 58 upgrade Project in CONTRACTORS Yards and SCNL self performed
scope at the sites. The extent of Ultrasonic Examination shall be in accordance with Para 4.2.9 of Welding
Specification for Structural Steels NG22-280-WEL-SPD-000004.
2.
REFERENCE DOCUMENTS
Doc n
NG22-280-WEL-SPD-000004
Designation
Welding Specification for Structural Steels
Contractor
NG22-280-QUA-SPD-000027
Construction Quality Control Plan
Contractor
NG22-280-QUA -SPD-000001
Project Quality Plan
Contractor
NG22-280-QUA-SPD-000024
Project Quality Policy
NG22-280-PJM-SPD-002302
NG22-280-QUA-SPD-009623
NG22-280-WEL-SPD-000001
NG22-280-PRC-SPD-002127
AWS D1.1/D1.1M:2008
Project Document Identification

Quality Control Specification For Welding
Welding Specification For Piping And Equipment
Qualification and Certification of NDT Personnel
Structural Welding Code Steel
Structural use of steelwork building- specification for
materials, fabrication and erection- Rolled and
welded section
Personnel Qualification and Certification in
Nondestructive Testing
Non-destructive testing Qualification and
certification of NDT personnel General principles
Contractor
Contractor
Contractor
Contractor
Contractor
AWS
BS 5950 Part 2: 2001

SNT-TC-1A: 2006
BS EN 473:2008
Origin
BS
ASNT
BS EN
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DEFINITIONS AND ABBREVIATIONS

PROJECT
OML 58 UPGRADE Phase 1
COMPANY (CPY)
TOTAL E&P Nigeria Limited
CONTRACTOR (CTR)
The consortium made of SAIPON snc, SCNL, PNL & DESICON

engineering (SPD).
Company that provides/supply goods and documentation and possible
associated services defined in the Purchase Order of Contractor
Authorization in writing given by COMPANY to CONTRACTOR to proceed
with the performance of a specific part of the work, without releasing in any
way CONTRACTOR from its obligations and liabilities under the contract or
at law. Approve, Approved and Approval shall be construed accordingly.
CONTRACTORS authorized representatives or members from
CONTRACTOR elected inspection agencies for the time being or from time
to time duly appointed in writing by the CONTRACTOR to act as its
representative for the purpose of the contract shall be referred to herein as
the "INSPECTOR".
Used to indicate that a provision is optional.
Used to indicate that a provision is mandatory.
SUBCONTRACTOR
Approval
Inspector
May
Shall
Should
Abbreviations
Used to indicate that a provision is not mandatory but is recommended as

good practice.
NDT - Non Destructive Testing
ASNT - American Society for Non Destructive Testing
RT - Radiographic Testing
UT - Ultrasonic Testing
MT - Magnetic Particle Testing
PT - Liquid Penetrant Testing
SCNL Saipem Contracting Nigeria Ltd.
SPD OML 58 Upgrade Phase 1 EPSCC CONTRACTOR- Construction
made of SIAPON SNC- SCNL PNL-DESICON.
4.
PERSONNEL
4.1 Ultrasonic operator who will perform and evaluate the test results shall be certified to level 2 or 3 in
accordance with NG22-280-PRC-SPD-002127:Qualification and Certification of NDT Personnel (which is
based on ASNT-SNT-TC-1 and EN 473), CSWIP scheme or company approved equivalent standards. UT
level 1 certified personnel may work as assistants under the direct supervision of Level 2 or Level 3
certified personnel.
4.2 The Ultrasonic operators are required to pass a vision test annually. The test comprises of the ability to
read, with correction if required to Jaeger J2 (or equivalent) with at least one eye at a distance of 300 mm.
4.3 All sub-contractors NDT personnel performing work to this procedure shall be subject to a performance
demonstration test to determine their ability to detect and evaluate flaws found during the examination of
welds. The proposed performance demonstration test shall be prepared by SPD Level 3 and submitted to
CPY for approval. All performance examination results shall be evaluated by SPD Level 2 or 3 certified
personnel.
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EQUIPMENT
5.1.
Equipment Requirements
Ultrasonic Testing instruments shall be pulse echo type A scan display, oscillating frequencies between
1 and 6 MHz and the display shall have the dynamic range such that a difference of 1 dB of amplitude
can be easily detected on the display. The instruments shall be stabilized 1 dB for 15% supply voltage
change or, in the case of a battery.
5.1.1.Horizontal Linearity
The horizontal linearity of the test instrument shall be within 2% of full screen width refer Appendix 1 for
procedure.
5.1.2.Gain Control Linearity
Gain control shall be calibrated in accordance with Appendix 2.
5.2.
Search Units
5.2.1.Frequency
The transducer frequency shall be between 2 5 MHz.
5.2.2.Straight Beam (Longitudinal Wave) Search Unit
Straight - Beam search units active area shall not be less than in and more than 1 in. The transducer
shall be rounded or square and shall be capable of resolving the three reflections as described in
Appendix 6.
5.2.3.Angle - Beam (Transverse Wave) Search Unit
The transducer crystal shall be square or rectangular and size can be range from 9-25mm in width and
from 8-20mm in height. The minimum width to height ratio can be 1.0 to 1.0 and the maximum width to
height ratio can be 1.2 to 1.0. The angle-beam search units shall consist of a transducer and angle
wedge. The unit may be comprised of the two separate elements or may be an integral unit.
5.2.3.1 Angles
Angle beam search unit shall produce a sound beam in the material being tested within 2 degrees of
one of the following proper angles: 45, 60, and 70 as describe in Appendix 3 & 4. The transducer shall
be clearly marked.
5.2.3.2 Internal Reflections
Maximum allowable internal reflections from the angle beam search unit shall be as described in
Appendix 5.
5.2.3.3 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 in. [25 mm].
6.
REFERENCE STANDARDS (BLOCKS)

6.1.
IIW Standard
The International Institute of Welding (IIW) UT reference block, shown in Figure 1, shall be the standard
used for both distance and sensitivity calibration. Other portable blocks may be used, provided the
reference level sensitivity for instrument/ search unit combination shall be adjusted to be the equivalent of
that achieved with the IIW Block.
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Resolution Requirements
The combination of search (angle beam) unit and instrument shall resolve three holes in the IOW
standard calibration block shown in Figure 2. Each combination of instrument search unit (shoe and
transducer) shall be checked prior to its initial use. This equipment verification shall be done initially with
each search unit and UT unit combination. The verification need not be done again provided
documentation is maintained that records the following items:
(1) UT machines make, model and serial number
(2) Search units manufacturer, type, size, angle, and serial number
(3) Date of verification and technicians name
The search unit positions are described in Appendix 7.
EQUIPMENT QUALIFICATION
7.1.
Horizontal Linearity
The horizontal linearity of the test instrument shall be re-qualified at two months intervals. The
qualification procedure shall be in conformance with Appendix 1.
7.2.
Gain Control
The instruments gain control shall be checked for correct calibration at two months intervals in
conformance with Appendix -2.
7.3.
Internal Reflections
Maximum internal reflections from each search unit shall be verified at a maximum time interval of 40
hours of instrument use in conformance with Appendix 3.
7.4.
Calibration of Angle-Beam Search Units

With the use of an approved calibration block, each angle beam search unit shall be checked after each
eight hours of use to determine that the contact face is flat, that the sound entry point is correct, and that
the beam angle is within the allowed plus or minus 2 tolerance in conformance with Appendix 3 and 4.
Search units which do not meet these requirements shall be corrected or replaced.
8.
CALIBRATION FOR TESTING

8.1.
Position of Reject Control

All calibrations and tests shall be made with the reject (clipping or suppression) control turned off. Use of
the reject (clipping or suppression) control may alter the amplitude linearity of the instrument and
invalidate test results.
8.2.
Technique
Calibration for sensitivity and horizontal sweep (distance) shall be made by the UT operator just prior to
and at the location of testing of each weld.
8.3.
Recalibration
Recalibration shall be made after a change of operators, each two-hour maximum time interval, or when
the electrical circuitry is disturbed in any way which includes the following:
(1) Change of operator
(2) Transducer change
(3) Battery change
(4) Electrical outlet change
(5) Coaxial cable change
(6) Power outage (failure)
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Straight-Beam Testing of Base Metal

Calibration for straight-beam testing of base metal shall be made with the search unit applied to Face A
of the base metal and performed as follows:
8.4.1.Sweep
The horizontal sweep shall be adjusted for distance calibration to present the equivalent of at least two
plate thicknesses on the display.
8.4.2.Sensitivity
The sensitivity shall be adjusted at a location free of indications so that the first back reflection from the
far side of the plate will be 50% to 75% of full screen height.
8.5.
Calibration for Angle-Beam Testing

Calibration for angle-beam testing shall be performed as follows:
8.5.1.Horizontal Sweep
The horizontal sweep shall be adjusted to represent the actual sound-path distance by using the IIW
block or alternatively other portable blocks may be used. Select the proper scale so that the sound can
pass through the entire volume of the weld and HAZ.
8.5.2.Sensitivity (Zero Reference Level) Calibration
The zero reference level sensitivity used for discontinuity evaluation (b) shall be attained by adjusting
the calibrated gain control. Set the search unit in position A on the IIW block (any angle), and maximized
the signal amplitude from 1.59mm diameter hole at 40% to 60% of FSH by using the gain control. Note
the decibel as the Reference Level b. Other alternative method may be used for setting the Zero
Reference Level.
9.
TESTING PROCEDURES
9.1.
Cleanliness
All surfaces to which a search unit is applied shall be free of weld spatter, dirt, grease, oil (other than that
used as a couplant), paint, and loose scale and shall have a contour allowing intimate coupling.
9.2.
Couplants
A couplant material shall be used between the search unit and the test material. The couplant shall be
either glycerin or cellulose gum and water mixture of a suitable consistency. A wetting agent may be
added if needed. Light machine oil may be used for couplant on calibration blocks.
9.3.
Extent of Testing
The entire base metal through which ultrasound must travel to test the weld shall be tested for laminar
reflectors using a straight-beam search unit. If any area of base metal exhibits total loss of back reflection
or an indication equal to or greater than the original back reflection height is located in a position that will
interfere with the normal weld scanning procedure, its size, location, and depth from the A face shall be
determined and reported on the UT report, and an alternate weld scanning procedure shall be used.
9.4.
Discontinuity Sizing
(a) Straight Beam
The reflector size evaluation shall be done by 6dB drop method. Position the search unit at the center of
the reflector and move the search unit until amplitude drops by 50%. Mark the centre of the search unit
for the reflector boundaries.
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(b) Angle-Beam
The length of discontinuity shall be determined by measuring the distance between the transducer
centreline locations where the indication rating amplitude drops by 50% (6 dB).
9.4.1.Inaccessibility
If part of a weld is inaccessible to testing in conformance with the requirements of Table 6.7, due to
laminar content recorded in conformance with 9.3, the testing shall be conducted using one or more of
the following alternative procedures as necessary to attain full weld coverage:
(1) Weld surface(s) shall be ground flush in conformance with Para 5.24.4.1of AWS D1.1;
(2) Testing from Faces A and B shall be performed;
(3) Other search unit angles shall be used.
9.5.
Testing of Welds
Welds shall be tested using the angle as shown in Table 6.7. Following calibration and during testing, the
only instrument adjustment allowed is the sensitivity level adjustment with the calibrated gain control.
9.5.1.Scanning
The gain (dB) shall be increased from the reference level for weld scanning in conformance with Table
6.2 or 6.3, as applicable testing angle and scanning procedure shall be in conformance with those shown
in Table 6.7.
9.5.2.Scanning Patterns
a.
Longitudinal Discontinuities
(1)
Scanning Movement A. Rotation angle a = 10.
(2)
Scanning Movement B
Scanning distance b shall be such that the section of weld being tested is
covered.
(3)
Scanning Movement C
Progression distance c shall be approximately one-half the transducer width.
Note: movements A, B, and C may be combined into one scanning pattern.
b.
Transverse Discontinuities
Ground Welds: Scanning pattern D shall be used when welds are ground flush.
Unground Welds: Scanning pattern E shall be used when the weld reinforcement is not ground flush.
Scanning angle e = 15 max.
Note: The scanning pattern shall cover the full weld section.
(1)
ESW or EGW Welds (Additional Scanning Pattern): Scanning Pattern E, Search unit rotation
angle e between 45 and 60
Note: The scanning pattern shall cover the full weld section.
9.5.3.Weld Joints
All butt joint welds shall be tested from each side of the weld axis.
Corner and T-joint welds shall be primarily tested from one side of the weld axis only. All welds shall be
tested using the applicable scanning pattern or patterns shown in Figure 3 as necessary to detect both
longitudinal and transverse discontinuities. It is intended that, as a minimum, all welds be tested by
passing sound through the entire volume of the weld and the HAZ in two crossing directions, wherever
practical.
9.5.4.Maximum Indication
When a discontinuity indication appears on the screen, the maximum attainable indication from the
discontinuity shall be adjusted to produce amplitude on the display. This adjustment shall be made with
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the calibrated gain control, and the instrument reading in decibels shall be used as the Indication Level,
a, for calculating the Indication Rating, d, as shown in the test report.
9.5.5.Attenuation Factor
The Attenuation Factor, c, on the test report shall be attained by subtracting 1 in. [25 mm] from the
sound-path distance and multiplying the remainder by 2. This factor shall be rounded out to the nearest
dB value. Fractional values less than 0.5 dB shall be reduced to the lower dB level and those of 0.5 dB or
greater increased to the higher level.
9.5.6.Indication Rating
The Indication Rating, d, in the UT Report, represents the algebraic difference in decibels between the
indication level and the reference level with correction for attenuation as indicated in the following
expressions:
Instruments with gain in dB:
abc=d
9.6.
Basis for Acceptance or Rejection

Each weld discontinuity shall be accepted or rejected on the basis of its indication rating and its length, in
conformance with Table 6.2 for statically loaded structures or Table 6.3 for cyclically loaded structures,
whichever is applicable.
9.7.
Identification of Rejected Area

Each unacceptable discontinuity shall be indicated on the weld by a mark directly over the discontinuity
for its entire length. The depth from the surface and indication rating shall be noted on nearby base
metal.
10. DOCUMETATION
10.1.
Examination Records
For each ultrasonic examination, the following information shall be recorded:
Procedure identification and revision;
Ultrasonic instrument identification (including manufacturers serial number);
Search unit(s) identification (including manufacturers serial number, frequency, wave mode, beam angle
and size);
Couplant used, brand name or type;
Calibration blocks identification;
Calibration data [including test range(s), reference reflector(s), reference level gain(s), transfer correction
gain(s), scanning if any].
Indication data [indication rating (s), depth(s), length(s), reference distance(s) and indication type(s)];
Identification and location of weld;
Surface condition;
Map or record of rejectable indications detected;
Areas of restricted access or inaccessible welds;
Name of examination personnel, qualification level;
Date of examination.
In General: All examination reports to be reviewed and signed by certified level 2 or 3 personnel.
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Report
The report shall include those records indicated in Section10.1 (Refer Appendix 6).
11. APPENDIX
11.1.
Appendix 1 Horizontal Linearity Procedure

Note: Since this qualification procedure is performed with a straight beam search unit which produces
longitudinal waves with a sound velocity of almost double that of shear waves, it is necessary to double
the shear wave distance ranges to be used in applying this procedure.
(1) A straight beam search unit shall be coupled in position: E on the IIW block (Figure 1)
(2) A minimum of 11 back reflections in the qualification range being certified shall be attained.
(3) The first back reflection shall be adjusted to zero division of horizontal scale of display and eleventh
back reflection shall be adjusted to 10th division of division of horizontal scale of display with use of
the distance calibration and zero delay adjustments.
(4) Each indication shall be adjusted to reference level with the gain control for horizontal location
examination.
(5) Each intermediate trace deflection location shall be corrected within 2% of the screen width.
11.2.
Appendix 2 Gain Control Linearity
11.2.1. Screen Height Linearity

1. Position the straight beam search unit in position F on IIW block (see figure 1).
2. Obtain two indications from the steps on the screen so that the amplitudes are in the ratio of 2:1.
3. Adjust the gain so that the larger indication is set at 80% of Full Screen Height (FSH) and smaller is set
at 40% of FSH.
4. Without moving the probe, adjust the gain to successfully set the larger indication from 80% to 20% of
FSH, in 10% increments (or 2 dB steps if a fine control is not available), and read the smaller indication
at each setting.
5. The reading shall be 50% of the larger amplitude, within 5% of FSH. The settings and readings shall be
estimated to the nearest 1% of FSH.
11.2.2. Amplitude Control Linearity
1. Position the straight beam search unit in position E on IIW block to obtain a back reflection from
100mm thickness (see figure 1).
2. Adjust the gain as shown in the following table.
3. The indication shall be within the specified limits.
4. The settings and readings shall be estimated to the nearest 1% of FSH.
Indication set at % of FSH
dB Control Change
Indication Limits % of FSH
80%
6
32 to 48%
80%
12
16 to 24%
40%
+6
64 to 96%
20%
+12
64 to 96%
11.3.
Appendix 3 Index Point
The transducer sound entry point (index point) shall be located or checked by the following procedure:
(1) The transducer shall be set in position D on the IIW block.
(2) The transducer shall be moved until the signal from the radius is maximized. The point on the
transducer which aligns with the radius line on the calibration block is the point of sound entry
11.4.
Appendix 4 Angle
The transducer sound-path angle shall be checked or determined by one of the following procedures:
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(1) The transducer shall be set in position B on IIW block for angles 40 through 60, or in position C on
IIW block for angles 60 through 70 (see Figure 1).
(2) For the selected angle, the transducer shall be moved back and forth over the line indicative of the
transducer angle until the signal from the radius is maximized.
The sound entry point on the transducer shall be compared with the angle mark on the calibration block
(tolerance 2).
11.5.
(1)
(2)
(3)
(4)
Appendix 5 Internal Reflection

Calibrate the equipment in conformance with 8.5.
Remove the search unit from the calibration block without changing any other equipment adjustments.
Increase the calibrated gain 20 dB more sensitive than reference level.
The screen area beyond 1/2 in. [12 mm] sound path and above reference level height shall be free of
any indication.
11.6.
Appendix 6 Resolution Straight Beam

(1) The transducer shall be set in position F on the IIW block.
(2) Transducer and instrument shall resolve all three distances.
11.7.
Appendix 7 Resolution Angle Beam

The resolution shall be evaluated with the instrument controls set at normal test settings and with
indications from the holes brought to mid screen height.
(1) The transducer shall be set on block IOW position Q for 70 angle, position R for 60 angle, or
position S for 45 angle.
(2) Transducer and instrument shall resolve the three test holes, at least to the extent of distinguishing
the peaks of the indications from the three holes.
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Appendix 8 Ultrasonic Examination Report

JOB
TOTAL E&P NIGERIA LIMITED
UNIT
REPORT N.
PLANT LOCATION:
QC CODE
PROGRESS N.
PROJECT: OML 58 UPGRADE PHASE-1 PROJECT

ITP REF.
ULTRASONIC EXAMINATION REPORT

TAG/ITEM
Page
ENGINEERING DOCUMENT. N.
CODE/SPECIFICATION
Search Unit
of
S/N
Angle (Deg.)
Exam. Technique:
Flaw Detector:
Serial No.:
0
Single/TR
Certificate. No.:
Type
Freq.(MHz)
Material Specification:
Ref. Level (dB)
Weld type:
Process:
Couplant:
Ref. Cal. Block No.
Scanning
Sensitivity dB)
Limitations:
Test Range (mm)
Drg. No. / Line

No.
Weld No.
45
Single
60
Single
Ind.
Length
(mm)
Ref.
Distance
70
Single
Transfer
Correction (dB)
Surface Condition:
S/N
PROCEDURE N.
Welder
No.
Dia. ()
Thk.
(mm)
Ind. Depth
(mm)
Indication
rating
Result (1)
Remarks:
(1) A = Acceptable
NA = Not acceptable
Inspection Notification Reference
RFI No.
Issue Date:
Notes:
NDT Contractor
Company
Name
Name
Name
Signature
Signature
Signature
Date
Date
Date
Form Code: MDT.WL.CDQ.0143 Sh. 01/Rev. 00.07
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12. FIGURES
12.1.
Figure 1 IIW V1 Block
12.2.
Figure 2 IOW Block
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Figure 3 Plan View of UT Scanning Patterns
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Table 6.2
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Table 6.3
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Table 6.7
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END OF DOCUMENT
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OML 58 Upgrade Phase 1