ut procedure otc

8/10/2019 UT Procedure OTC

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National Iranian Gas Company

IGAT V Booster Gas Compressor Stations

Document Title Document No.

PHASE AREA TRAIN/UNIT DIS DOC SEQ REVUT Procedure

SPY 3 0000 CM PR 212 00

Page 1 of 34

NATIONAL IRANIAN GAS COMPANY

IGAT V Booster Gas Compressor Station

DOCUMENT TITLE:

UT PROCEDURE

SPY-3-0000-CM-PR-212

A. M. P. K. A. M. M. A. T. 24 Aug '06 D00 For Information

5GCS EP MCAUTHOR CHECK QA

AUTHORIZED APPROVED

DATE OF

ISSUEREV.

PURPOSE OF

ISSUE


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CONTENTS

Page

1 Scope 4

2 Reference 4

3 Responsibility 4

4 Qualification of personnel 5

5 General requirement 5

6 Equipment and accessories 6

7 Calibration blocks and reference specimens 12

8 Distance calibration 16

9 Distance amplitude correction 16

10 Primary reference level and scanning sensitivity 17

11 Transfer value correction 1712 Application UT examination 18

13 Parent metal evaluation 18

14 Inspection of welds 18

15 Discontinuity localization and size evaluation 21

16 Post cleaning 22

17 Acceptance standards 22

18 Defect marking and examination of repair 2219 Reporting 23

20 Appendices 23


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1. Scope

1.1. This procedure covers requirements for ultrasonic examination for fabrication &

erection of piping and steel structure full penetration welds in ferrite materials,

usually minimum thickness of 5/16 inch (8mm) to be fabricated for IGAT V Booster

Gas Compressor Stations, contract No. 180502.

1.2. The purpose of ultrasonic examination is to determine and evaluate the severity of

internal discontinuities in welds and base metal. This procedure describes the

general requirements for ultrasonic testing of full penetration welds in ferrite

materials, usually minimum thickness of 5/16 inch (8mm).

2. References

2.1. ASME Sec. V : Nondestructive Examination

2.2. ASME E164, A578, Nondestructive Examination (vol.03-03, 01-03)

2.3. ASME B31.3 : Process Piping

2.4. AWS D1.1 : Structural Welding Code

2.5. ASNT SNT-TC-1A : Recommended practice for NDT personnel qualification and

certification

2.6. Project Specification : 602-000-PI-SP-010, 602-000-ST-SP-001

3. Responsibility

3.1. The QC engineer shall be responsible for cooperate with sub-contractor for NDE


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work.

3.2. The sub-contractor shall be responsible for managing of general NDE work.

3.3. The QA/QC Manager or his designee of Subcontractor shall be responsible for

control of NDE sub-contractor and documents related to the NDE.

4. Qualification of Personnel

4.1. Personnel performing examination to this procedure shall be qualified as level II or

III in accordance with ASNT SNT-TC-1A Recommended practice for NDT

personnel qualification and certification or equivalent in PCN / CSWIP certification

systems.

4.2. Only Level II or Level III personnel shall interpret and evaluation test results to

determine acceptability.

5. General requirements

5.1. Surface preparation

5.1.1. The area adjacent to the weld to be examined shall be free of all weld

spatters, loose particles, non-adhering mill scale or any other foreign matter

that would interface with the free movement of search unit or with the

transmission of ultrasound into the test part.

5.1.2. Preparation of welds for examination will be identified in the specific

ultrasonic operating technique sheet.

5.1.3. Painted, primed or coated surfaces cannot be scanned.

5.2. Examination Coverage


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5.2.1. Welds shall be examined by moving the search unit over the examination

surface so as to scan the entire volume.

5.2.2. The search unit will be moved laterally in zigzag pattern ensuring that the

forward movement is perpendicular to the weld axis and overlap by at least

10%.

5.3. The rate of search unit movement for examination shall not exceed 152mm/sec1

unless calibration is verified at scanning speed.

5.4. Recording of indication level shall be made in respect to the reference level.

5.5. Information furnished to the NDE Subcontractor shall clearly identify the drawing

No., materials category, thickness, weld No., welder(s), location and length of

welds to be examined. A copy of the weld procedure applicable to each specific

joint being examined shall be made available for the operators review, prior to

commencement of the examination.

6. Equipment and accessories

The following equipment and accessories will be considered as a minimum to fulfill the

requirements of this procedure and will be available to all technicians. The calibration

certificate for the UT equipment, and the certificate of conformity for UT probes,

calibration blocks are to be available on site for verification by certifying authority. and

company.

6.1. The examination shall be conducted with a pulse-echo ultrasonic instrument,

capable of generating, receiving and presenting the relevant pulses on a screen in

the frequency range from 1 to 6 MHz. (e.g. Krautkramer USK6, USK7, USN 50 and

1Refer to ASME Sec. V, Art V


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USN 52or equivalent). Instruments operating at other frequencies may be used if

equal or better sensitivity can be demonstrated and documented.

6.1.1. Equipment qualification and calibration

The operator shall carry out the following checks for calibration:

6.1.2. Any of the above checks found to be out of tolerance should be cause for

system repair followed by full re-calibration of affected points.

Checks Frequency Ref. Documents

Amplitude control

linearity

At least once a

month

ASME Sec.V, Para

T533

Screen height

linearity

At least once a

month

ASME Sec.V, Para

T533

Horizontal linearity At least once a

month

ASME E 164

Internal reflection At least once a

week

ASME E 164

Resolution At least once a

week

ASME E 164

6.1.3. The result of such calibration should be signed by contractor and certifying

authority and should be maintained for reference in the NDT department and

available for Company inspection as required.

6.2. Transducers

The following transducer or equivalent shall be used.


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6.2.1. Longitudinal wave search units

Type Angle Frequency Crystal size Make of Probe

Single crystal O 4 MHz 10 mm dia Kraut Kramer

Twin crystal O 4 MHz 3.5 x 10 mm Kraut Kramer

Single crystal O 2 MHz 10 mm dia Kraut Kramer

Twin crystal O 2 MHz 3.5 x 10mm Kraut Kramer

6.2.2. Shear wave search units

Type Angle Frequency Crystal size Make of Probe

Single crystal 45 2 MHz 10 mm dia Kraut Kramer




Single crystal 60 4 MHz 8 x 9 mm Kraut Kramer


6.3. Calibration and reference blocks6.3.1. STB-A1, IIW Type 1 (Fig. 1) or IIW Type 2 block (Fig. 2)

6.3.2. IIW miniature block (Fig. 3) or STB-A3 (Fig. 4)

6.3.3. ASME basic calibration block (Fig. 5, 7)

6.3.4. IOW as calibration block


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Fig. 1 STB-A1, IIW Type 1 Block

Fig. 2 STB-A2, IIW Type 2 Block


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Fig. 3 IIW Miniature Block


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Fig. 4 STB-A3 Block

6.3.5. A suitable couplant such as water based paste of cellulose gum, wall paper

adhesive or coupling paste having good wetting characteristics should be used

between the transducer and examination surface. The same couplant shall be

used for calibration and examination.


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7. Calibration blocks and reference specimens

7.1. Material

7.1.1. Material from which respective calibration blocks and reference specimens

are fabricated will be of the same product form and material specification or

equivalent. The calibration block material will be completely examined with a

straight beam search unit to ensure freedom from reflectors that exceed the

back wall echo.

7.1.2. For the examination for weldments which have been subjected to post weld

heat treatment the material from which the calibration block is fabricated will

have received a similar PWHT process, and also a post weld heat treatment of

at least 2 hr, if the calibration block contains weld prior to machine the

reflectors.

7.1.3. When calibration block have not received heat treatment, transfer method

shall be used to correlate the responses from the basic calibration block and

component. Transfer is accomplished by noting the difference between

responses received from the same reference reflector in the basic calibration

block and in the component and correcting for the difference.

7.2. The surface finish of the calibration blocks will be as representative of the surface

finish of the components as far as possible with suitable surface preparation or

treatment, as practical, to simulate testing conditions.

7.3. Reference specimens for testing the welds (ASME Basic Calibration Blocks)

7.3.1. For examination in materials where examination surface diameter is greater

than 20 inches, a flat basic calibration block, complying with the requirements

indicated on figure 5 will be used. Reflectors will have side-drilled holes and


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surface notches oriented parallel to the longitudinal axis of annuals reference

specimen.

7.3.2. For examination in material where the examination surface is 20 inches or

less, curved annuals basic reference specimen will be used. The size and

location of the surface notches and diameter of range covered by each blocks

will be as shown in fig. 6 and 7.

7.3.3. A single reference specimen may be used to calibrate for examination on

component surfaces in the ranges of curvature from 0.9 to 1.5 times the basic

reference specimen diameter. Basic reference specimen thickness ranges will

be as stipulated in figure 5. These specimens could be a section pipe of the

same nominal size as one of the components being tested i.e. as off cut pipe

being used in fabrication.


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Weld Thickness Basic CalibrationBlock Thickness

Hole Diameter Notch Size

1 in or less 3/4in. or t 3/32in.

Over 1in. through 2in. 1 1/2in. or t 1/8in.

Over 2in. through 4in. 3in. or t 3/16in.




Over 10in. t1in. [See note 6]

Width=1/8in. to 1/4in.

Depth= 2%T or 0.04in.

Whichever is greater, into

the base metal.

Length= 2in. min.

Notes:

a) Holes shall be drilled and reamed a minimum of 1-1/2in. deep, essentially parallel to the examinationsurface.

b) Curved surfaces: for curved surface, two curved blocks, one for each representative curvature or twosets of calibration reflectors orientated 90 deg. from each other shall be used.

c) Notches may be provided as required. The tolerance for hole diameter shall be 1/32in. The toleranceon notch depth shall be +10% and -20%. The tolerance on hole location through the thickness shall be1/8in.

d) For each increase in thickness on 2in. or fraction thereof over 10in., the hole diameter shall increase1/16in.

Fig. 5 ASME Basic Calibration Block


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Fig. 6 Ratio limits for curved surfaces

Fig. 7 Angel beam calibration block dimension (Pipe welds)


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8. Distance calibration

The CRT will be calibrated for range using the international institute of welding STB-A1,

type 1, 2 and STB-A3 calibration blocks, in the relationship of time versus distance

(beam path length).

9. Distance amplitude correction (DAC curve)

9.1. For sensitivity calibration during all weld examination (Straight or Angle beam),

DAC curves will be constructed for every search unit to be utilized at each

particular range. Block used for DAC construction will be selected as appropriate

from those as specified in para. 7.3.

9.2. DAC curves will be constructed as follow.

9.2.1. Place the probe on the calibration block to obtain a reflection from the hole

that produces the greatest response.

9.2.2. Maximize the indication by manipulation and adjust to approx. 80% screen

height using the calibration gain control. Make a mark on the CRT at the peak

of the indication using an indelible fine tipped felt marker.

9.2.3. Points representing 20 % and 50 % of the primary gain are also to be

constructed. Repeat b) and c) using reflections from every reflector that can be

obtained within the beam length of the test range to be used, including those

reflections obtained from skip, if the sound path is more than probes specific

near field range.

9.2.4. Connect all points marked (minimum 3 points) with a smooth curving line,

this line will be referenced to as the DAC curve the respective probe used and

will apply for that particular material and configuration (or part geometry) only.


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9.2.5. DAC curves will be directly marked as the CRT time base screen cover with

an indelible ink marker or superimposed using clear plastic, polyester or

Perspex overlap. The DAC curve fail to search a level of at least 23 % of full

screen height at the limit of its range, as represented on the time base,

sufficient supplementary gain should be added to attain this level and the DAC

adjusted accordingly.

10. Primary reference level and scanning sensi tiv ity

10.1. The primary reference level will be that gain setting whereby reflectors in the

applicable basic calibration block or reference specimen as described in para. 7.3

above, coincide with DAC curve constructed as described in para. 9.0 above. The

primary reference level will be corrected for differences in surface character and

attenuation between the basic reference block and the actual item under

examination by method, as described in para. 11 herein.

10.2. Sensitivity settings for parent material examination with 0 compression wave will

be that dB value where by the first back wall echo of the material reaches 80 % of

full screen height, DAC curves will not apply for evaluation during this application.

Scanning will be carried out at the same setting according to ASTM A578.

11. Transfer value correction

11.1. Transfer value will be determined and used for all shear wave examination to

compensate for differences in surface contour, finish, coating, and acoustical

attenuation characteristics. This exercise will be performed for each nominal angle

of refraction to be utilized for examination. To ensure that accurate transfer value

correction factors are obtained, signal comparison will only be made in the far

field area of the ultrasonic beam.

11.2. Transfer correction will be measured with the following way;


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11.2.1. Construct the DAC as per para. 9.0.

11.2.2. Using the primary search unit as the transmitter and a similar search unit as

a receiver, position both on the basic calibration block facing each other, in a

pitch and catches arrangement with the instrument in the dual transducer

mode.

11.2.3. Maximize the indication and adjust the gain to allow the indication to peak

at the DAC curve. Note the gain value.

11.2.4. Repeat steps a), b) and c) above on the component to be examined. The

difference in gain values is the transfer value. This value may be positive or

negative and adjustments will be made to the sensitivity settings accordingly

and should be recorded in all the reports.

12. Appl ication of UT Examination

12.1. The applicable specification are 602-000-PI-SP-010 and 602-000-ST-SP-001

12.2. When RT is required and is not practicable UT plus MT may be considered as an

alternative subject to COMPANY approval.

12.3. UT may be substituted for RT where it is impractical to obtain an interpretable

radiograph, subject to COMPANY review and approval.

13. Parent metal evaluation

13.1. Thickness measurement

13.1.1. Any member from which scanning is to be conducted shall first be scanned

with a 0compression probe to establish the thickness. These results will be

recorded.

13.1.2. Any areas of significant thickness variation, which could possibly affect

calculation, will be highlighted, recorded and reported.

13.2. Parent metal examination


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13.2.1. The scanning of the adjacent base metal shall be performed to detect

reflectors that might affect interpretation of angle beam results, and is not to be

used as an acceptance-rejection examination. Locations and areas of such

reflectors shall be recorded.

13.2.2. Ultrasonic examination within pipe end and shall be carried out according to

ASTM A578. Any discontinuity (e.g. lamination) causing a reflection echo

exceeding 50 % and accompanied by a 50 % loss of back reflection shall be

considered as reject when the discontinuity area exceeds 100 mm.

14. Inspection of welds

14.1. General

14.1.1. A minimum of two different probe angles should always be applied (see

table 2) this is in addition to the straight beam probe required as per para. 12.

14.1.2. For butt joint welds, the examination shall be made from both sides of the

weld axis from the accessible surface, wherever possible.

14.1.3. Upon discovering suspect indications both orbital and rotational scan will be

carried out to evaluate the characteristics of the reflector.

14.1.4. Time base ranges as specified may be suitably readjusted by the operator in

localized areas to highlight suspect deflections and subsequently assist in echo

evaluation.

14.1.5. The normal scanning is carried out with at least 6 dB increased gain level,

and that all defects sizes will be evaluated at a non-increased level.


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14.2. Longitudinal scanning

14.2.1. Scanning for longitudinal discontinuities in the weld body will be carried out

with the angle beam at approximately right angles to the weld axis, from two

directions whenever possible. Nominal angles of reflection to achieve this are

stated in table 2.

14.3. Transverse scanning

14.3.1. Scanning for discontinuities oriented transverse to the weld will be carried

out with the angle beam directed essentially parallel to the weld. For scanning

of transverse defects, it should be considered to scan on the weld cap itself,

which if necessary, must be ground flat. The search unit will be manipulated so

that the angle beam energy passes through the required volumes of weld and

adjacent base metal.

14.3.2. A transverse scan will be carried out on all welds scheduled for ultrasonic

examination.

14.3.3. Nominal angles of reflection to achieve this are stated in table 2. The

exception of the above will be when the search unit is scanning essentially as

tangent over curved surfaces of 20 diameter or less.


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Table 2

8 - 25.4 mm 25.4 - 50.8 mm 50.8 - 65 mm

45HSD

FSD

N/A

N/A

A(36 72)

A(72 144)

A(72 92)

A(144 184)

60HSD

FSD

N/A

A(32 102)

A(51 102)

A(102 203)

A(102 130)

N/A

70 HSDFSD

N/AA(47 148)

A(74 148)N/A

A(148 190)N/A

0HSD

FSD

N/A

A

N/A

A

A

A

Note) HSD: Half sonic distance / FSD: Full sonic distance, A: Applicable / N/A: Not applicable

15. Discont inui ty localization and s ize evaluation

15.1. Discontinuities will be confirmed and located within the weld cross section by

means of a probe manipulation to maximize the response obtained and to measure

beam path lengths and distance from established reference points. Location

reflectors may be aided by the use of trigonometry, electronic calculators and

ultrasonic plotting slides. The use of these additional tools will not be mandatory.

15.2. Evaluation

15.2.1. The corrected primary gain (primary reference level + transfer correction) is

to be increased by 6 dB for defect detection.

15.2.2. All discontinuities that produce reflectors at or grater than 20 % of DAC

when searching at the increased gain level as above, are to be subject to

defect size evaluation at non-increased gain level (i.e. with 6dB decrease).

These imperfections shall be investigated to determine the shape, identity, and

location.


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15.2.3. Dimensional evaluation of indication is made using either the 20 dB drop

method or the half value drop method.

15.2.4. Also each indication producing an echo, which exceeds 50 % of the

reference curve, is to be reported and its evaluated size as above checked for

acceptability.

16. Post cleaning

upon the completion of the examination, the surfaces shall be thoroughly cleaned by

wiping with a suitable one as required to remove all traces of couplant.

17. Acceptance standards

Acceptance criteria for piping welding shall be as per ASME B31.1 para. 344.6.2 and

for steel structure welding shall be as per AWS D1.1 section 6 part C.

18. Defect marking and examination of repair

18.1. All areas deemed to be rejectable that require repairing, will be clearly and

unambiguously marked up on the surface of the weld and the adjacent parent

material with indelible metal markers.

18.2. The extent of examination will guarantee the satisfactory inspection of the entire

cross sectional volume of weld and HAZ regardless of the extent of repair. The

whole length of repair will be examined plus 50 mm from the repair weld deposit at

the both ends where possible.

18.3. During repair examination, taking into consideration the nature, position and

extent of the original defect and the position of new fusion faces created by the

repair.


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19. Report ing

19.1. The report attached here after shall be reviewed and signed by TPA.

19.2. QC engineer shall maintain UT reports

20. Appendices

20.1. Appendix 1: Specific UT technique sheets

20.2. Appendix 2: Calibration report of Ultrasonic instrument

20.3. Appendix 3: Examination report

20.4. Appendix 4 Detail of Ultrasonic Examination Report


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Appendix 1: Specif ic UT technique sheets

Technique 1

1. Joint Type: Butt Joint

2. Thickness (T): T 8~25.4mm similar thickness, plate and pipe (dia. > 20inch)

3. Probe

a. 0 4MHz

b. 60 4MHz

c. 70 4MHz

4. Range

a. 0~50mm

b. 0~100mm scanning with 0-1 skip

c. 0~100mm scanning with 0-1/2 skip

5. Scanning Sensitivity

a. Echo off first back reflection adjusted to 80% full screen height

b. , c Echo off 2.4mm dia. Side drilled hole set to DAC + additional 6db +

additional 2db transfer correction

Note) Additional 6db to be removed for evaluation purpose

6. Sizing Method: Length #6db amplitude drop, depth and height (width) #20db drop

7. Scanning Patterns


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Technique 2

1 Joint Type: Butt Joint

2 Thickness (T): T 25.4~50.8mm similar thickness, plate and pipe (dia. > 20inch)

3 Probe

a. 0 4MHz

b. 45 4MHz

c. 60 4MHz

d. 70 2MHz

4 Range

a. 0~50mm


c. 0~100mm scanning with 0-1 skip

d. 0~150mm scanning with 0-1/2 skip

5 Scanning Sensitivity


b. , c, d Echo off 3.2mm dia. Side drilled hole set to DAC + additional 6db +

additional transfer correction


6 Sizing Method: Length #6db amplitude drop, depth and height (width) #20db drop

7 Scanning Patterns


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Technique 3


2 Thickness (T): 50.8mm ~ 65mm

3 Probe

a. 0 2MHz

b. 45 2MHz

c. 60 2MHz

d. 70 2MHz

4 Range

a. 0~50mm










7 Scanning Patterns


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Technique 4

1 Joint Type: Tee or Branch Joint

2 Thickness (T): T 8~25.4mm similar thickness, plate and pipe (dia. > 20inch)

3 Probe

a. 0 4MHz

b. 60 4MHz

c. 70 4MHz

4 Range

a. 0~50mm









7 Scanning Patterns


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Technique 5


2 Thickness (T): 25.4mm ~ 50.8mm

3 Probe

a. 0 4MHz

b. 45 4MHz

c. 60 4MHz

d. 70 2MHz

4 Range

a. 0~50mm










7 Scanning Patterns


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Technique 6


2 Thickness (T): 50.8mm ~ 65mm

3 Probe

a. 0 2MHz

b. 45 2MHz

c. 60 2MHz

d. 70 2MHz

4 Range

a. 0~50mm










7 Scanning Patterns


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Technique 8


2 Thickness (T): T 8~25.4mm similar thickness, plate and pipe (dia. 20inch)

3 Probe

a. 0 4MHz

b. 60 4MHz

c. 70 4MHz

4 Range

a. 0~50mm









7 Scanning Patterns


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Technique 8


2 Thickness (T): T 44.45mm similar thickness, plate and pipe (dia. = 20inch)

3 Probe

a. 0 4MHz

b. 45 4MHz

c. 60 4MHz

d. 70 2MHz

4 Range

a. 0~50mm










7 Scanning Patterns


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Appendix 2 Cal ibrat ion report of ULTRASONIC instrument

INSTRUMENT TYPE:

I. D. No. :CALIBRATION RECORD UNIT

Sr. No. :

Type Marker

TRANSDUCERFrequency Size Sr. No.

2. SCREEN HEIGHT LINEARITY

ScreenHeight

Linearity

100%FSH ---------------%FSH90%FSH ---------------%FSH80%FSH ---------------%FSH70%FSH ---------------%FSH60%FSH ---------------%FSH

50%FSH ---------------%FSH40%FSH ---------------%FSH30%FSH ---------------%FSH20%FSH ---------------%FSH

3. AMPLITUDE CONTROL LINEARITY

AmplitudeControlLinearity

80%FSH-6dB ----------------------%FSH (32-48)80%FSH-12dB ----------------------%FSH (16-24)40%FSH-6dB ----------------------%FSH (64-96)20%FSH-12dB ----------------------%FSH (64-95)

4. HORIZONTAL LINERARITY

1) Range-100mm

Liner scale (a)25 (b)50 (c)75 (d)100 Echo position (a) (b) (c) (d)

2) Range-200mm

Liner scale (a)25 (b)50 (c)75 (d)100 (e)125 (f)150 (g)175 (h)200

Echo position (a) (b) (c) (d) (e) (f) (g) (h)

Examined byLevel Date

Approved byLevel Date

FORM CM-PR-212-01 Rev. 00


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Appendix 3 Ul trasonic Examinat ion Report

ITP NO. :

REPORT NO. :FIELD INSPECTION REPORT

DATE :

INSPECTION TYPE: WORK NO.:

ITEM NO. :

LOCATION :ULTRASONIC EXAMINATION

SIGNATURE1

INSPECTION NOTICE NO. : COMPANY CONTRACTOR SUBCONTR.

COMPANY'S INSPECTOR : / / / / / /

CONTRACTOR INSPECTOR :

SUBCONTRACTOR'S INSPECTOR :

PROCEDURE METHOD :

ACCEPTANCE CRITERIA :

MATERIAL : THICKNESS:

METHOD : PROBE SIZE:

MEDIUM : FREQUENCY:

ANGLE:MAKER & TYPE OF MACHINE:

DWG N0. JOINT NO. WELDER NO. RESULT ACC REP C-O

ACC : ACCEPT EP : EXCESS PENETRATION

REP : REPAIR IP : INCOMPLETED PENETRATION

C-O : CUT-OUT LF : LACK OF FUSION

C : CRACK S : SLAG INCLUSION

P : POROSITY ND : NO DEFECT

ABBREVIATIONS

* SEE ATTACHED SHEET (DETAILED ULTRASONIC EXAMINATION RECORD)1- To be signed if Accepted by all parties

LEGEND: ACC.: ACCEPT REJ.: REJECT N/A: Not Applicable FORM:QA-QA-51-06 1/2 Rev. 01


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Appendix 4 Detail of Ult rasonic Examinat ion Report

ITP NO. :

REPORT NO. :FIELD INSPECTION REPORT

DATE :

DETAILED ULTRASONIC EXAMINATION REPORT

DWG NO.JOINT

NOt DISTANCE W L D d

LENGTH OF

INDICATION

COMMENTS2

2- Reason of Rejection and to be Signed by Refuser