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H1058-DOC-MQC-0145-UT Piping RevB

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H1058-DOC-MQC-0145-UT Piping RevB

     H1058 Bohai Phase II Shanghai Waigaoqiao Development Shipbuilding Co. Ltd.

    SWS No. :H1058-DOC-MQC-0145 FPSO Hull Project 上海外高桥造船有限公司

    COPC No.:K1-11P-SBA-Q-QMS-0000135 CONTRACT NO. BB-1119-I

    Document Description;

    Ultrasonic Test Procedure For Piping

    Number of Status Revision Date Written by Checked by Approved by Pages

    FRC A 2005-12-8 34 Ni Yumin Zhang Xiaoda Wang Qi FRC B 2006-1-5 34 Ni Yumin Zhang Xiaoda Wang Qi

Status Code:

    AFC Accepted For Construction IFA Issued For Approval AFD Accepted For Design IFC Issued For Construction AFE Accepted For Estimate IFD Issued For Design APP Approved IFU Issued For Use ASB As Built INFO Issued For Information Only BID Issued For Bid PHA HAZOP

    DEVLP Accepted For Development PHA1 HAZID

    DRAFT N/A No Revision Applied PHA2 HAZID Level 2 FCA For Client Acceptance PO Issued For Purchase FCC For Construction Comments PRELIM Preliminary FPU For Project Use REF Reference Only FRC For Review & Comments RFQ Request For Quote ICE Issued For Cost Estimate VOID Issued For Void

Revision Explanation:

The documents submitted by SWS to COPC for review and comment will bear the alphabetical

    revision labels i.e. A, B, C. Once the documents are released as “Approved for Construction” the

    label will change to numeric i.e. 0, 1, 2, etc.

     Bohai Phase II Development

    FPSO Hull Project

    CONTENTS

    1.0 PURPOSE

    2.0 SCOPE

    3.0 RESPONSIBILITY

    4.0 DEFINATION

    5.0 SAFETY

    6.0 SPECIAL RESOURCES

    7.0 PROCEDURES

    7.1 PERSONNEL QUALIFICATION

    7.2 THE EXTENT OF NDT

    7.3 REPORT FORM

    7.4 EQUIPMENT

    7.5 CALIBRATION AND REFERNECE BLOCKS

    7.6 CALIBRATION FOR TESTING

    7.7 TESTING PROCEDURE

    7.8 DISCONTINUITY EVALUATION

    7.9 REPORTING

    7.10 GENERAL REQUIREMENT

    7.11 ACCEPTANCE CRITERIA

    8.0 REFERENCE STANDARD

    9.0 ATTACHMNENT

    APPENDIX A SPECIFIC ULTRASONIC TESTING TECHNIQUE SHEET

    APPENDIX B ULTRASONIC TESTING REPORT

    APPENDIX C ULTRASONIC EQUIPMENT CALIBRATION PROCEDURE

    APPENDIX D ULTRASONIC EQUIPMENT CALIBRATION REPORT

    SWS No.: H1058-DOC-MQC-0145 Ultrasonic Test Procedure For Piping Issued Date: 5-Jan-2006

    COPC No.: K1-11P-SBA-Q-QMS-0000135 Rev B Page 2 of 34

     Bohai Phase II Development

    FPSO Hull Project

    1.0 PURPOSE

    This procedure is established to ensure that Ultrasonic testing undertaken by SWS meet the requirements of COPC Specification, DNV Standards where applicable. 2.0 SCOPE

    This procedure covers the methods, techniques and acceptance standards for Ultrasonic Testing (UT) of piping for carbon steel marine system, machinery system, marine machinery system and hydrocarbon offloading system fabrication on Bohai Phase II FPSO hull development project.

    UT may be applied in lieu of radiographic testing when the conditions are such that a comparable level of weld quality is assured and subject to COPC & DNV approval.

3.0 RESPONSIBILITY

     The SWS QC Engineer is responsible for revision and implementation of this

    procedure.

     The SWS Senior Inspector coordinates with COPC & DNV when their

    verification are required per the approved ITP.

     The SWS NDE Supervisor is responsible for preparation and ensures

    procedure is strictly followed by all technicians.

     The SWS Construction Engineer/Supervisor is responsible for preparing test

    surface, proper scaffolding, adequate lighting etc.

    4.0 DEFINATION

    NDT - Non Destructive Testing

    UT - Ultrasonic Testing

    CS - Carbon Steel

    5.0 SAFETY

    UT shall be performed in comformance with all applicable approved safety procedure. 6.0 SPECIAL RESOURCES

    Subcontractor may be engaged for performing radiographic testing, all work perform by subcontractor to follow project approved procedures.

    SWS No.: H1058-DOC-MQC-0145 Ultrasonic Test Procedure For Piping Issued Date: 5-Jan-2006

    COPC No.: K1-11P-SBA-Q-QMS-0000135 Rev B Page 3 of 34

     Bohai Phase II Development

    FPSO Hull Project

    7.0 PROCEDURES

    7.1 PERSONNEL QUALIFICATION

    Personnel performing the UT testing shall be qualified and certified to UT Level II or III in accordance with the requirements of SNT-TC-1A recommended practice or equivalent qualifications issued by recognized authority or organization that is approved by DNV & COPC.

    A register shall be provided with Names, Qualification dates, Certification Nos., Operator Nos., Expiry dates for all NDT operators including sub-contractor. COPC/DNV shall approve all NDT operators prior to work commencement. Further evaluation of the NDT operators may be required by oral, written, practical examination to the satisfaction of the COPC representative. 7.2 THE EXTENT OF NDT

    NDT shall be performed accordingly to below DNV & COPC approved procedure -

    058-DOC-MQC-0096 - Extent of piping NDT, that base on DNV-OS-D101 B500

    Non Destructive Testing Table B4 and Piping Specification

    K1-11P-SAA-P-SP-0000001.

     7.3 REPORT FORM

    Refer Appendix B Ultrasonic Testing report

     7.4 EQUIPMENT

    1) Ultrasonic examination equipment is to:

    a) Be applicable for the pulse echo technique and for the double-probe technique.

    b) Covers as a minimum the frequency range from 2 to 6 MHz.

    c) Have a calibrated gain regulator with minimum 2db per step over a range of at

    least 60dbB.

    d) Have a flat screen accessible from the front for direct plotting of reference

    curves or equipped with automatic calibration or DAC (Distance Amplitude

    Curve) display presentation.

    e) Echoes with amplitudes of 5% of full screen height shall be clearly detectable

    under test conditions.

    f) The horizontal linearity of the test instrument shall be qualified within 1% over

    the full sound path distance to be used in testing.

    g) Include straight beam transducers and angle beam transducers of 45?, 60?

    and 70?.

    SWS No.: H1058-DOC-MQC-0145 Ultrasonic Test Procedure For Piping Issued Date: 5-Jan-2006

    COPC No.: K1-11P-SBA-Q-QMS-0000135 Rev B Page 4 of 34

     Bohai Phase II Development

    FPSO Hull Project

    2) Probe Probes as a straight beam probes 0 degree and angle beam probes of 45, 60 and 70 degree. The selection of probe shall be in accordance with client specification and actual WPS (thickness, welding bevel, etc.)

    a) Straight beam probe

    ; Straight beam probes shall be round in shape and shall have an active

    area of not less than 10 mm in diameter nor more than 25 mm in

    diameter maximum.

    The frequency shall be between 2 to 5 MHz.

    ; Probes of other sizes and frequencies may be used provided they are

    qualified as described in AWS D1.1/ASME code and approved by client. b) Angle beam probe

    ; A probe with a transducer element in size from 8 to 15 mm in width and 9

    to 15 mm in height operating at 2 to 5 MHz shall be mostly used in

    accordance with the code’s recommendations.

    ; The probe shall produce a sound beam in the material being tested within

    2 degrees of one of the following proper angles: 45, 60 and 70 degrees.

    The actual angle shall be checked or verified during calibration for testing

    and reported on the applicable test report.

    ; Each probe shall be clearly marked to indicate the frequency of the

    transducer, nominal angle of reflection and index point. Probes of other

    sizes and frequencies may be used provided they are qualified as

    described in ASME V and approved by client.

    ; The resolution of the angle probe shall be evaluated with the instrument

    controls set at normal test settings and with indications from the holes

    brought to mid-screen height. Resolution shall be sufficient to distinguish

    at least the peaks of indications from the three holes.

    c) Periodic Calibration

    The instrument shall be periodically checked in accordance with the appendix

    C “Calibration of Ultrasonic Equipment”. Calibration of the ultrasonic

    equipment shall be carried out whenever has been out of function for any

    reason including on and off and whenever there is any doubt concerning

    proper functioning of the equipment.

    All ultrasonic flaw detectors shall be calibrated by a recognized test authority

    yearly.

    SWS No.: H1058-DOC-MQC-0145 Ultrasonic Test Procedure For Piping Issued Date: 5-Jan-2006

    COPC No.: K1-11P-SBA-Q-QMS-0000135 Rev B Page 5 of 34

     Bohai Phase II Development

    FPSO Hull Project

    7.4 CALIBRATION AND REFERENCE BLOCKS

    IIW or ISO calibration blocks (ie. V1, V2 etc) shall be used for the calibration of range and for angle determination.

    Basic Calibration block described as per ASME V T-542.2.1 Basic Calibration Block for welds in Wrought and Cast Ferritic Product Forms, Excluding Pipe & T-542.8.1 for Ferritic Welds in Ferritic Pipe, for gain calibration and constructing of reference curve. The reference block material shall be fabricated from the same product form and material specification or equivalent P-number grouping as the material being examined. The surface finish of the calibration block shall be representative of the surface finish of the piping.

    A side-drilled hole may be used for initial acceptance of a pipe weld, provided that it can demonstrated that the hole calibration produces a sensitivity equal to or greater than the notch calibration.

    The basic calibration block shall be curved for materials with diameter 20in (508mm) and less. A single curved basic calibration block may be used to calibrate the examination on surfaces in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter.

    7.5 CALIBRATION FOR TESTING

    Calibration for sensitivity and horizontal sweep range shall be made by the ultrasonic technician just prior to and at the location of testing of each weld. For this purpose, the reject (suppression) control shall be turned off. Calibration for Straight Beam Testing

    Calibration for straight beam testing of base metal shall be made with the probe applied to Face A of the base metal and performed as follows.

    a) Sweep Range

    The horizontal sweep shall be adjusted for distance calibration to present the equivalent of at least two (2 back wall echoes) plate thickness on the CRT screen. b) Reference Sensitivity Level

    The sensitivity shall be adjusted at a location free of indication so that the first back reflection from the side of the plate will be 80 to 100% of full screen height.

    SWS No.: H1058-DOC-MQC-0145 Ultrasonic Test Procedure For Piping Issued Date: 5-Jan-2006

    COPC No.: K1-11P-SBA-Q-QMS-0000135 Rev B Page 6 of 34

     Bohai Phase II Development

    FPSO Hull Project

    Calibration for Angle Beam Testing

    a) Sweep Range

    Sweep range calibration shall include as a minimum the entire sound path distance to be used during the specific testing by using the IIW block

    b) Standard Sensitivity Level (Corrected Primary Gain)

    Standard sensitivity for testing of production welds shall be the Basic Sensitivity Level. Correction for distance by a Distance-Amplitude-Correction Curve established with the Reference Block and modified by Transfer Correction.

    c) Basic Sensitivity Level (Primary Gain)

    Reference level screen height shall be obtained using maximum reflection from the diameter hole in the Reference Block.

    The amplitude from the reflectors in reference block shall be adjusted to 100% DAC. In addition to the side-drilled holes employed for evaluation of all discontinuities in the body of the weld.

    d) Distance Amplitude Correction (DAC)

    The Reference Level shall be adjusted to provide for attenuation loss throughout the range of sound path to be used, by DAC curve.

    The reference block shall be used and curves which are 100%, 50% and 20% of reference curve are to be constructed as follows:

e) Transfer Correction

    a) The reference level shall be adjusted to compensate for the differences in

    surface character and attenuation between the reference block and the

    material being tested, by means of the double probe technique.

    b) A transfer correction shall be performed and recorded once for each welded

    SWS No.: H1058-DOC-MQC-0145 Ultrasonic Test Procedure For Piping Issued Date: 5-Jan-2006

    COPC No.: K1-11P-SBA-Q-QMS-0000135 Rev B Page 7 of 34

     Bohai Phase II Development

    FPSO Hull Project

    joint to be tested using part of the test surface exhibiting the roughest

    condition, except for repetitive testing of the same materials, size and

    configuration, in which case a transfer correction shall be performed at the

    beginning of every shift by the ultrasonic operator. Calibration surfaces shall

    closely match that of the test surface to minimize corrections required. 7.6 TESTING PROCEDURE

    1) Surface Preparation The surfaces of welds and base metal shall be prepared as follows: a) Contact surfaces shall be free of weld spatter and any condition that might

    interfere with free movement of the search unit or impair coupling of ultrasonic

    vibrations to and from the material examined.

    b) Finished weld surfaces shall be adequate to prevent interference with

    interpretation of the examination.

    c) Surfaces of the calibration reference blocks shall be of a similar finish to the

    part under examination.

    2) Couplant

    a) A couplant material shall be used between the search unit and the test

    material. The couplant shall be paste. A wetting agent may be added if

    needed. Couplant use for testing and calibration shall be the same. 3) Scanning Procedure

    a) Straight Beam Technique and Scanning

    ; At the time of test and prior to angle beam scanning of the weld, the

    entire base metal through which sound will pass during angle beam

    testing (determined by maximum surface distance required from the weld

    for the required skip distance) shall be scanned for laminar reflectors or

    inclusions which might interfere with the examination. Locations and

    areas of such reflectors shall be recorded.

    ; Where conditions are found to interfere with angle beam testing,

    alternate scanning method or other NDT methods shall be employed. b) Angle Beam Technique and Scanning

    ; General

    The technician shall be given the following information before weld

    testing is commenced, and choice of angle(s) of refraction for scanning

    weld body and reinforcement shall depend on the following factors:

     Type of ferritic steel.

     Groove type used.

     Characteristics and orientation of defects likely to occur i.e., the

    SWS No.: H1058-DOC-MQC-0145 Ultrasonic Test Procedure For Piping Issued Date: 5-Jan-2006

    COPC No.: K1-11P-SBA-Q-QMS-0000135 Rev B Page 8 of 34

     Bohai Phase II Development

    FPSO Hull Project

    welding process (WPS)

     Type of weld joint configuration to be tested i.e., the applicable range

    of diameter and thickness.

    ; Accurate profiles shall be taken with wire type profile gauges or, if joint

    angle is acute, a suitably pliable material able to maintain its shape under

    normal conditions.

    ; Angle beam scanning

    The angle beam shall be directed at approximate right angles to the weld

    axis from two directions where possible. The search unit shall be

    manipulated to scan the entire volume of the weld and adjacent base

    metal. The sensitivity shall be increased by 12 dB above the standard

    sensitivity level (basic sensitivity +distance amplitude correction +transfer

    correction). Evaluation shall be performed with respect to the standard

    sensitivity level.

    ; The angle beam shall also be directed essentially parallel to the weld axis.

    The search unit shall be manipulated to scan the entire volume of the

    weld and adjacent base metal.

    c) Selection of Probes

     The nominal frequency shall be 2.5 to 5 MHz, unless variables, such

    as fabrication material grain structure require the use of other

    frequencies to assure adequate penetration or better resolution.

     Indications found in the root areas of groove welds in butt joints and

    along the fusion face of all welds shall be further evaluated with 70,

    60, or 45 deg. angles, whichever is nearest to being perpendicular to

    the expected fusion face.

    d) Scanning coverage

    The weld shall normally be examined from both sides and the testing is to include the area adjacent to the weld. Scanning speed shall not exceed 150mm per second and a 10% overlap shall be maintained.

    e) Indication Investigation

    For evaluation of flaw indications a reference curve shall be established. The curve shall be plotted on the instrument screen. Imperfections, which produce a response greater than 20% of the reference level shall be investigated to the extent that the operator can determine the shape, identity and location of

    SWS No.: H1058-DOC-MQC-0145 Ultrasonic Test Procedure For Piping Issued Date: 5-Jan-2006

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     Bohai Phase II Development

    FPSO Hull Project

    all such imperfection and evaluate them in terms of the acceptance criteria

    The indications shall be investigated by maximizing the echoes by rotating the

    probes and by using different angle probes with DAC curves. All defects

    exceeding the acceptance criteria shall be reported.

    7.8 DISCONTINUITY EVALUATION

    1) General

    a) Once a reflector has been found by scanning wherever >20% DAC reference

    curve, it shall be carefully evaluated to determine the following characteristics,

    as required for application of the acceptance criteria and for reporting:

    ; Location from an established reference point.

    ; Location within the weld cross section.

    ; Sizes - i.e., length along the weld axis and width (height dimension) as

    seen in the weld cross section, or amplitude relative to reference level.

    ; Type and Orientation - i.e., classify as linear, planar or spherical reflectors.

    If planar, the orientation of the plane relative to the brace or chord side

    fusion boundaries.

     b) Discontinuities shall be evaluated by use of a combination of Beam Boundary

     and Maximum Amplitude Techniques.

    2) Defect Size Determination

    The following technique shall apply to determine the defect size.

    a) The length of the discontinuity shall be obtained by recording the location

    along the length of weld as determined by 50% of Reference Level (6dB drop)

    for each end of the reflector.

    b) If the length of discontinuity is smaller than the beam spread, sizing shall be

    made by beginning outside of the discontinuity and moving the transducer

    toward the area of discontinuity until an indication on the screen/display

    begins to form. The leading edge of the search unit at this point is indicative of

    the edge of the discontinuity.

    c) The width (height) of the discontinuity shall be determined by either 20dB

    drop or maximum amplitude technique, or both.

    d) Discontinuities approaching unacceptable size, particularly those about which

    are some doubt in their evaluation, shall also be reported.

    7.9 REPORTING

    Report turn around time shall be within 2 working days. After signed by all parties, SWS No.: H1058-DOC-MQC-0145 Ultrasonic Test Procedure For Piping Issued Date: 5-Jan-2006

    COPC No.: K1-11P-SBA-Q-QMS-0000135 Rev B Page 10 of 34

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