procedure

PT.SEPEKTRA MEGAH SEMESTA

TECHNICAL TESTING & INSPECTIONUltrasonic Examination Procedure for Structural Steel

Quality Procedure

Revision : 00

Issued : 28 January, 2008Page 1 of 39

PT. SPEKTRA MEGAH SEMESTAULTRASONIC TESTING

PROCEDURE

(Based on API 1104)Proc. No. : SMS-603-PT-003

Revision: 1

Date: October 19, 2010

Page No.: 13 of 13

Revision

No.DateDescriptionApproved byReviewed byPrepared by

1

October 19, 2010First Issue

Daftar Isi / Table of Content

Par.UraianPar.DescriptionPage

1Ruang lingkup1SCOPE3

2Referensi2REFERENCES3

3Personel3PERSONNEL3

4Peralatan/asesoris4EQUIPMENT / ACCESSORIES3

5Persiapan Permukaan5SURFACE PREPARATION5

6Metode pengujian6TESTING METHOD6

7Couplant7COUPLANT6

8Kalibrasi range8SWEEP RANGE CALIBRATION6

9Sensitiviti9SENSITIVITY6

10Kalibrasi jarak amplitude10DISTANCE AMPLITUDE CALIBRATION7

11Teknik scanning11SCANNING TECHNIQUES7

12Pola scanning12SCANNING PATTERN7

13Pengukuran13SIZING8

14Temperature pengujian14TESTING TEMPERATURE8

15Kriteria keberterimaan15ACCEPTANCE CRITERIA8

16Pelaporan16REPORTING12

1Ruang lingkup1SCOPE

a.Procedure ini sebagai petunjuk dan standard keberterimaan untuk pengujian ultrasonic kontak untuk pengelasan pada pipaa.This procedure provides the requirements and acceptance standards for the contact ultrasonic examination for production welds on piping.

b.Prosedur ini terdiri dari versi Inggris dan Indonesia, jika ada konflik antara keduanya maka versi Inggris yang dipakaib.This procedure consists of English and Indonesian versions, should there is conflict between these versions the English version shall govern.

2Referensi2REFERENCES

2.1API 1104, Welding of Pipeline and Related Facilities2.1API 1104, Welding of Pipeline and Related Facilities

2.2ASME BPV Section V, Article 4 and 52.2ASME BPV Section V, Article 4 and 5

2.3ASTM E114 - Standard Practice for Ultrasonic Pulse - Echo Straight Beam Examination by Contact Method2.3ASTM E114 - Standard Practice for Ultrasonic Pulse - Echo Straight Beam Examination by Contact Method

2.4PT. Spektra Megah Semestas (SMS) Written Practice Procedure No.: SMS-601-P-001.2.4PT. Spektra Megah Semestas (SMS) Written Practice Procedure No.: SMS-601-P-001.

3Personel3PERSONNEL

3.1Personel yang melakukan pengujian harud dikualifikasi berdasarkan written practice PT. Spektra Megah Semesta no: SMS-601-P-0013.1Personnel conducting the examination shall be qualified in accordance with PT. Sepektra Megah Semestas written practice no: SMS-601-P-001.

3.2Personel yang menentukan keberterimaan sesuai persyaratan prosedur iniharus level II atau III3.2Personnel determining the acceptability to the requirements of this procedure shall be Level II or Level III.

4Peralatan/asesoris4EQUIPMENT / ACCESSORIES

4.1Ultrasonic Flaw Detector Krautkramer USK-7 atau mirip boleh digunakan, konektor BNC atau Lemo 1 tersambung dalam unit peralatan.4.1Ultrasonic Flaw Detector Krautkramer USK-7 or similar may used, BNC or Lemo 1 connectors attached in Unit.

4.2Ukuran transduser: maksimum x (probe sudut) dan 1 (probe normal)4.2Transducers Size : Maximum 1/2 x 1/2 (Angle Probe) and 1 (Normal Probe)

4.3Tipe probe4.3Type of Probe :

Straight Beam: MB 2-E atau MB 4-E atau setara untuk ketebalan sampai dengan 1 (25.4 mm) dan lebih.MSEB 2-E atau MSEB 4-E untuk ketebalan sampai 1 (25.4 mm) atau setara. Straight Beam :MB 2-E or MB 4-E or Equivalent for thickness up to 1 (25.4 mm) and more.MSEB 2-E or MSEB 4-E for thickness up to 1 (25.4 mm) or Equivalent.

Angle beam: Angle Beam :

a. MWB 450 - 2 MHz sampai 4 MHz atau setara

b. MWB 600 - 2 MHz sampai 4 MHz atau setara

c. MWB 700 - 2 MHz samapi 4 MHz atau setara

d. Untuk ketebalan sampai 1 (25.4 mm) dua probe sudut 600 dan 700 harus digunakan,

e. Untuk ketebalan lebih 1 (25.4 mm) tiga probe 450 , 600 dan 700 harus digunakan..a. MWB 450 - 2 MHz To 4 MHz or Equivalent

b. MWB 600 - 2 MHz To 4 MHz or Equivalent

c. MWB 700 - 2 MHz T0 4 MHz or Equivalent

d. For thickness up to 1 (25.4 mm) two angle probes 600 and 700 shall be used,

e. For thickness greater than 1 (25.4 mm) three angle probes 450 , 600 and 700 shall be used.

4.4Acuan standard block4.4Reference Standard Block :

Blok IIW V1 & V2, blok profile API 1104 (lihat gambar 22A API 1104) seperti dibawah:IIW Ultrasonic Reference Block V1 & V2 API 1104 Beam Profile Block (See Figures 22A of API 1104) as below :

SHAPE \* MERGEFORMAT

Dimensions :

T : Nominal Pipe wall thickness

N: Notch depth = 10% of notch depth

A: 2 in. (50 mm) minimum length

B: 0.125 in. (3.2 mm) maximum notch widh

C: 11.35 T plus 2 in. (50 mm) minimum width

D: 3.1 in. (80 mm) minimum width

E: 1. in. (25 mm) minimum notch length

R1: Out side radius of pipe

R2: Radius of inside notch = R1 minus 0.9 T

R3: Radius of outside notch R1 minus 0.10 T

Figure 22A of API 1104 Reference Block for Manual UT

4.5Kabel: MPKL atau setara4.5Cables : MPKL or equivalent

5Persiapan Permukaan5SURFACE PREPARATION

Permukaan dimana transduser ditempatkan harus bebas dari spatter, scale, karat dan cat dimana dapat mengganggu transmisi gelombang ultrasonic.

Permukaaan lasan harus cukup rata untuk menghindari gangguan terhadap pengujian. Lasan harus dipersiapkan sesuai yang diperlukan dalam pengujian.Surface where transducer is placed shall be free of weld spatter, scale, rust and painting that might interfere with transmission ultrasonic waves.

Weld surface shall be adequately smooth to prevent interferes with the examination. The weld shall be prepared as needed to permit examination.

6Metode pengujian6TESTING METHOD

Metode kontak langsungContact Method

7Couplant7COUPLANT

CMC / Methylant, Light Oil Machine / S. A. E 40 atau Grease.CMC / Methylant, Light Oil Machine / S. A. E 40 or Grease.

8Kalibrasi range8SWEEP RANGE CALIBRATION

Penentuan range dengan menggunakan blok IIW V1 dan V2 untuk menentukan range sound path actual 2 leg + reinforcement specimen. Pengaturan sweep length dan sweep delay untuk mendapatkan lokasi pulsa secara tepat pada garis dasar dari CRT (Cathode Ray Tube)Determine Range with use IIW V1 and V2 Block to a designated range of Actual Sound Path 2 Legs + Reinforcement of Test Specimen. Adjust Sweep Length and Sweep Delay to obtain an exact pulse location on base line of CRT (Cathode Ray Tube).

9Sensitiviti9SENSITIVITY

Semua kedudukan unit harus ditetapkan sedikitnya 80% full screen height (FSH) dari notch dalam (sensitivity level) + dB transfer nilai koreksi = reference level.All seats unit shall be established at least 80% of Full Screen Height (FSH) of inside notch (Sensitivity Level) + dB Transfer Correction Value = Reference level.

Pengujian lasan dengan ultrasonic manual harus dilakukan dengan sensitivity scanning 100% DAC (100 % reference level) ditambah minimum 6 dB.

Semua indikasi yang melebihi 50% DAC harus dievaluasi.Manual Ultrasonic weld testing shall be performed at a scanning sensitivity of 100% DAC (100% Reference Level) plus 6 dB minimum.

All indications that exceed 50% of DAC shall be evaluated.

SHAPE \* MERGEFORMAT

Figure 22B of API 1104 Establishing Distance Amplitude Correction

SHAPE \* MERGEFORMAT

Figure 22C of API 1104 Transfer Correction Value Procedure

10Kalibrasi jarak amplitude10DISTANCE AMPLITUDE CALIBRATION

Screen height linearityScreen Height Linearity.

Peralatan ultrasonic harus memberikan presentasi vertical linear dalam + 5% full screen height (FSH) sekurangnya 80% pada screen height terkalibrasi (garis dasar sampai titik maksimum screen terkalibrasiThe ultrasonic instrument shall provide linear vertical presentation within + 5% of the Full Screen Height (FSH) for at least 80% at the calibrated screen height (base line to maximum calibrated screen point (s)).

Amplitude Control LinearityAmplitude Control Linearity.

Instrumen ultrasonik harus menggunakan kontrol amplitudo, secara akurat selama rentang pengunaan sampai + 20% dari rasio amplitudo nominal, untuk memungkinkan pengukuran indikasi di luar rentang linier dari tampilan vertikal di layarThe ultrasonic instrument shall utilize an amplitude control, accurate over useful range to + 20% of the nominal amplitude ratio, to allow measurement of indication beyond the linear range of the vertical display on the screen.

11Teknik scanning11SCANNING TECHNIQUES

Straight Beam Straight Beam :

Harus memadai untuk menyediakan cakupan 100% pada sensitivitas pemeriksaan seragam area yang diperiksaShall be adequate to provide 100% coverage at uniform examination sensitivity of area being examined.

Angle BeamAngle Beam :

Scan seluruh volume pengujianScan the entire examined volume.

12Pola scanning12SCANNING PATTERN

12.1Gerakan pola scanning untuk mendeteksi diskontinuitas longitudinal adalah dari 2 sisi permukaan daerah las dan juga dari permukaan dalam jika bisa diakses, harus sejajar dengan sumbu las dan rotasi maksimum sudut 10 derajat dari garis normal probe ke sumbu pengelasan diperbolehkan12.1Scanning pattern movement to detect longitudinal discontinuities is from 2 surface sides of weld area and also from inside surface if accessible, it shall be parallel to the centreline of weld and rotation angle maximum 10 degrees from normal line of probe to centreline of weld is permitted.

12.2Pola rotasi sudut probe maksimum 15 derajat untuk menemukan diskontinuitas melintang12.2Rotation angle probe pattern is maximum 15 degrees to locate transverse discontinuities.

12.3Overlap scanning probe maksimum 10 %, rata rata kecepatan scanning probe maksimum 150 mm/second.12.3Scanning probe overlap is minimum 10%, the scanning rate of probe is maximum 150 mm / second.

13Pengukuran13SIZING

13.1Kedalaman: Sound Path (SP) Indication x Cosine Used Angle of Probe (1 Leg) atau 2T - (SP x Cosine Used Angle of Probe) untuk 2 Legs.13.1Depth : Sound Path (SP) Indication x Cosine Used Angle of Probe (1 Leg) or 2T - (SP x Cosine Used Angle of Probe) for 2 Legs.

13.2Jarak indeks probe ke indikasi: SP x Sine Used Angle of Probe13.2Distance of Probe Index to Indication : SP x Sine Used Angle of Probe

13.3Panjang: 6 dB Amplitude drops13.3Length : 6 dB Amplitude drops.

14Temperature pengujian14TESTING TEMPERATURE

Temperature ruangan maksimum sampai 1250CAmbient temperature up to 1250 C max.

15Kriteria keberterimaan15ACCEPTANCE CRITERIA

15.1Klasifikasi indikasi15.1Classification of Indication

15.1.1Indikasi yang dihasilkan oleh pengujian ultrasonik belum tentu defect.Perubahan geometri lasan karena alignment offset ujung pipa berbatasan, perubahan dalam profil penguatan pengelasan dari root IDdan O.D. capping, chamfering internal, dan gelombang konversi mode ultrasonik karena kondisi tersebut dapat menyebabkan indikasi geometris yang mirip dengan yang disebabkan oleh ketidaksempurnaan lasan tetapi yang tidak relevan dengan penerimaan15.1.1Indications produced by ultrasonic testing are not necessarily defects. Change in the weld geometry due to alignment offset of abutting pipe ends, changes in weld reinforcement profile of I.D. root and O.D. capping passes, internal chamfering, and ultrasonic wave mode conversion due to such conditions may cause geometric indications that are similar to those cause by weld imperfections but that are not relevant to acceptability.

15.1.2Indikasi linier didefinisikan sebagai indikasi dengan ukuran terbesar dalam arah panjang lasan.Tipikal indikasi linier dapat disebabkan oleh, tetapi tidak terbatas pada jenis berikut ketidaksempurnaan; inadequate penetration without high-low ( IP ), inadequate penetration due to high low ( IPD ), inadequate cross penetration ( ICP ), incomplete fusion ( IF ), incomplete fusion due to cold lap ( IFD ), elongated slag inclusion ( ESI ), cracks (C), undercutting adjacent to the over pass ( EU ) or root pass ( IU ), and hollow bead porosity ( HB )15.1.2Linear indications are defined as indications with their greatest dimension in the weld length direction. Typical linear indications may be caused by, but are not limited to the following types of imperfection; inadequate penetration without high-low ( IP ), inadequate penetration due to high low ( IPD ), inadequate cross penetration ( ICP ), incomplete fusion ( IF ), incomplete fusion due to cold lap ( IFD ), elongated slag inclusion ( ESI ), cracks (C), undercutting adjacent to the over pass ( EU ) or root pass ( IU ), and hollow bead porosity ( HB ).

15.1.3indikasi Transverse didefinisikan sebagai indikasi dengan ukuran terbesar di las.indikasi melintang Tipikal dapat disebabkan oleh, tetapi tidak terbatas, untuk jenis berikut ketidaksempurnaan: cracks ( C ), isolated slag, inclusions ( ISI ), and incomplete fusion due to cold lap ( IFD ) at start/stops in the weld passes. 15.1.3Transverse indications are defined as indications with their greatest dimension across the weld. Typical transverse indications may be caused by, but are not limited, to the following types of imperfections: cracks ( C ), isolated slag, inclusions ( ISI ), and incomplete fusion due to cold lap ( IFD ) at start/stops in the weld passes.

15.1.4indikasi volumetrik didefinisikan sebagai indikasi tiga-dimensi.indikasi tersebut dapat disebabkan oleh satu atau beberapa inklusi atau pori-pori.Rongga terisi sebagian, pori-pori, start/stop di pass lasan mungkin disebabkan indikasi yang lebih besar dalam arah melintang dibandingkan dari arah panjang lasan.Tipikal indikasi volumetrik dapat disebabkan oleh, tetapi tidak terbatas pada jenis berikut ketidaksempurnaan: internal concavity ( IC ), burn-through ( BT ), isolated slag inclusion ( ISI ), porosity ( P ), and cluster porosity ( CP ).15.1.4Volumetric indications are defined as three-dimensional indications. Such indications may be caused by single or multiple inclusions void or pores. Partially filled voids, pores, at start/stops in weld pass may caused larger indications in the transverse direction than in the weld length direction. Typical volumetric indications may be caused by, but are not limited to the following types of imperfections: internal concavity ( IC ), burn-through ( BT ), isolated slag inclusion ( ISI ), porosity ( P ), and cluster porosity ( CP ).

15.1.5indikasi yang relevan adalah yang disebabkan oleh ketidaksempurnaan.Indikasi relevan harus dievaluasi pada tingkat evaluasi yang diberikan dalam 11.4.7 dengan standar keberterimaan yang diberikan dalam 15.2.15.1.5Relevant indications are those caused by imperfections. Relevant indications shall be evaluated at the evaluation level given in 11.4.7 to the acceptance standards given in 15.2.

Catatan: bila ada keraguan tentang jenis ketidaksempurnaan yang diungkapkan oleh indikasi, verifikasi dapat diperoleh dengan menggunakan metode pengujian non-destruktif lain.Note: when doubt exist about the type of imperfection being disclosed by an indication, verification may be obtained by using other non-destructive testing methods.

15.2Standard keberterimaan15.2Acceptance Standards

15.2.1Indikasi harus dianggap defect bila beberapa kondisi berikut ada:15.2.1Indications shall be considered defects should any of the following conditions exist:

a. Indikasi yang dipastikan crack (C)b. Indikasi individu dengan dimensi ketinggian vertikal (through-wall) ditentukan lebih besar dari satu seperempat dari ketebalan dinding

c. Indikasi multiple di lokasi keliling yang sama dengan jumlah ) dimensi ketinggian vertikal (through wall lebih dari satu setengah tebal dindinga. Indications determined to be cracks (C)

b. Individual indications with vertical height (through wall) dimension determined to be greater than one quarter of the wall thickness.

c. Multiple indications at the same circumferential location with a summed vertical height (through wall) dimension exceeding one half the wall thickness

15.2.2Indikasi linear surface (LS) (selain crack) diinterpret terbuka di permukaan LD. atau O.D. harus dianggap defect bila beberapa kondisi ada:15.2.2Linear surface (LS) indications ( other than cracks )interpreted to be open to the LD. or O.D. surface shall be considered defects should any of the following conditions exist:

a. Panjang agregat indikasi LS dalam setiap 12 in (300 mm) kontinu panjang lasan melebihi 1 in (25 mm).b. Panjang aggregate indikasi LS melebihi 8% panjang lasan.a. The aggregate length of LS indications in any continuous 12 in. (300 mm) length of weld exceeds 1 in. ( 25 mm ).

b. The aggregate length of LS Indications exceeds 8% of the weld length.

15.2.3Linear dimakamkan (LB) indikasi (selain retak) ditafsirkan bawah permukaan dalam las dan tidak LD.atau O.D.permukaan dihubungkan harus dianggap cacat bila salah satu kondisi berikut ada:15.2.3Linear buried ( LB ) indications ( other than cracks ) interpreted to be subsurface within the weld and not LD. or O.D. surface connected shall be considered defects should any of the following conditions exist:

a. Panjang agregat indikasi LB dalam setiap 12 in (300) kontinu panjang lasan melebihi 2 in (50 mm)

b. Panjang agregat indikasi LB melebihi 8 % panjang lasan.a. The aggregate length of LB indications in any continuous 12 in. (300 mm) length of weld exceeds 2 in. (50 mm).

b. The aggregate length of LB indications exceeds 8 % of the weld length.

15.2.4Indikasi melintang (T) (selain retak) harus dipertimbangkan volumetrik dan dievaluasi menggunakan kriteria untuk indikasi volumetrik.Huruf T harus digunakan untuk ditunjuk semua laporan indikasi melintang.15.2.4Transverse (T) indications (other than cracks) shall be considered volumetric and evaluated using the criteria for volumetric indications. The letter T shall be used to designated all reported transverse indications.

15.2.5Indikasi volumetrik cluster (VC) harus dipertimbangkan sebagai defect jika ukuran maksimum dari indikasi VC melebihi inci (13 mm).15.2.5Volumetric cluster (VC) indications shall be considered defects when the maximum dimension of VC indications exceeds in. ( 13 mm ).

15.2.6Indikasi Volumetrik Individu (VI) harus dipertimbangkan sebagai defect jika ukuran maksimum V1 indikasi melebihi 1 / 8 inci (3 mm)15.2.6Volumetric Individual ( VI ) indications shall be considered defects when the maximum dimension of V1 indications exceeds 1/8 in. (3 mm).

15.2.7Indikasi Volumetric root (VR) diinterpret terbuka sampai I.D. permukaan harus dipertimbangkan sebagai defect bila kondisi berikut ada:15.2.7Volumetric root (VR) indications interpreted to be open to the I.D. surface shall be considered defects should any of the following conditions exist:

a. Dimensi maksimum indikasi VR melebihi in (6 mm) atau nominal tebal dinding, mana yang terkecil

b. Panjang total indikasi VR melebihi in (13 mm) dalam panjang kontinu 12 in (300 mm)a. The maximum dimension of VR indications exceeds in ( 6 mm ) or the nominal wall thickness, whichever is less.

b. The total length of VR indications exceeds in. ( 13 mm ) in any continuous 12 in. ( 300 mm ) length.

15.2.8Setiap akumulasi indikasi relevan (AR) harus dianggap sebagai defect ketika salah satu kondisi berikut ada:15.2.8Any accumulation of relevant indications ( AR ) shall be considered a defect when any of the following conditions exist:

a. Panjang agregat indikasi diatas tingkat evaluasi melebihi 2 in (50 mm) pada setiap panjang 12 inci (300 mm) lasanb. Panjang agregat indikasi diatas tingkat evaluasi melebihi 8% panjang lasana. The aggregate length of indication above evaluation level exceeds 2 in. (50 mm) in any 12 in. (300 mm) length of weld.

b. The aggregate length of indications above evaluation level exceeds 8% of the weld length.

16Pelaporan16REPORTING

Hasil pengujian ultrasonic harus dilaporkan kedalam format laporan PT Spektra Megah SemestaUltrasonic flaw detection result should be reported in the form of PT. SPEKTRA MEGAH SEMESTA Ultrasonic Examination Report. (Appendix -1).

ULTRASONIC EXAMINATION REPORT

Job/Contract No.:Work Order No. :Report No. :

P r o j e c t:

L o c a t i o n: Drawing No. :

C u s t o m e r :

UT Equipment: Serial No. :

Surface Condition: Welded Ground FlushOther ( )

C o u p l a n t: Oil Grease Other ( )

Calibration Block : BCB IIW V1 Other ( )

Face of Examination: Face A Face B Face C ( )

Welding Process: GTAW SMAW Other ( )

Test Range : Procedure No. :

Scanning Technique :

Probe Identification: Applicable Code :

IdentificationProbe AngleFrequencyD e s i b e l sRecord of DiscontinuityResultRemark

Scanning LevelReference LevelTransfer of LossesScreen Height, %Length (mm)Angular DistanceSurface DistanceDiscontinuity TypeAcceptedRejected

Discontinuity Type : Cr = crack IF = Incomplete Fusion IP = Incomplete Penetration EL = Elongated Ind.

Examined ByReviewed / Witnessed byAuthorized Inspector

Date : NDE Level

Date :

Date :

B

A

End view

R3

R1

R2

E

C

D

N

N

T

A

B

Notch Block Side View