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DANGOTE FERTILIZER LIMITED ReAE ENiro eae NIGERIA COMMENTS SHEET From: QA/QC Department To: PARESA Spa. C. Franco: enne Att. tor Mr. Patrick Osemeka . Ce: Mr. Rocco Sainato 1. Reviewed with comment Mr. Paolo Marin | 2. Reviewed with no comment Ryo oc ninaan 3. Approved Date 10-08-2016 I SNe Document No, [Ree Description Cote | PROCEDURE FOR PHASED | ARRAY ULTRASONIC. 3 ‘ KARINDTIPAUT-O1 2 aga ELTA SERBAN STERE Welding Engineer Coordinator Dangote Ferilizer Project Saipem Contracting Wi, Ltd, Z PARESA INDUSTRIAL CRAY & ALLIED ae c= 7 RADIOGRAPHERS NIGERIA LTD. DANGOTE ie PROCEDURE FOR : DAAR | CNE | 2 RAY ULTRASONIC TESTING ssipem “=== _| OF WELD JOINTS FOR AMMONIA TANK DocNo: IXAR/NDT/PAUT-01 Date: 5/08/2016 Project: Ammonia & Urea Fertilizer Complex ae Owner: Mis Dangote Fertilizer Company Lid (DFL) Page No. : 10728 EPC = Mis Saipem Location: Nigeria Contractor: Paresa PROCEDURE FOR PHASED ARRAY ULTRASONIC TESTING OF WELD JOINTS 2 | 21072016 | FoRREVEy COMMENTS INCORPORATED a 1 | 0287206. | cio eae APPROVAL. ISSUE FOR 0 | 02.08.2016 REVIEW & | COMMENTS: NAME THANGARAJU | RAJESHPERUMAL | P.OSEMEKA | § SERBAN Rev. | Issue Date | Reason for issue Prepared By | Checked By Approved | ~ Approved IXAR (ASNT Levelt By By L (PARESA) | (SAIPEM) | DocNo: IXARINDI/PAUT-O1 INDUSTRIAL X-RAY & ALLIED RADIOGRAPHERS NIGERIA LTD. PROCEDURE FOR: PHASED ARRAY ULTRASONIC TESTING ‘OF WELD JOINTS FOR AMMONIA TANK 30101 Project: Ammonia & Urea Fertlizer Complox | Owner: Ws Dangote Fertizer Company Lid (OFL)- EPC : Mis Saipem Contractor: Paresa REVISION CONTROL SHEET Location: Nigeria iS [Sr.No | RevNo Issue Date Description Reason for Issue Issue for Review / 1 0 02/06/2016 - ‘Comments 7 Comments incorporated 2 i peni7i2016: - & Issued for construction 3 BD 05.08.2016 New issue For Review & approval INDUSTRIAL X-RAY & ALLIED RADIOGRAPHERS NIGERIA LTD. DANGOTE PROCEDURE FOR S PHASED ARRAY ULTRASONIC TES” ‘ING wapem OF WELD JOINTS FOR AMMONIA TANK 307-01 DocNo: IXAR/NDT/PAUT-01 Date: 5/08/2016 Project: Ammonia & Urea Fertilizer Complex bap Quner: M/s Dangote Fertiizer Company Ltd (DFL) Page No. : 3 of 28 EPC : Mis Saipem a Location: Nigeria Contractor: Paresa INDEX ‘Clause No] Name of Clause Page No, 1.0 | PURPOSE 4 2.0 REFERENCE DOCUMENTS 4 3.0” [DEFINITIONS 4 4.0 | QUALIFICATION OF UT PERSONNEL 4 | 50 APPLICATION 5 6.0 GENERAL REQUIREMENTS: 6 | 70 EQUIPMENT 67 80 | BASIC CALIBRATION BLOCKS 7 9.0 | CALIBRATION PROCEDURE 10-15 10.0 | CALIBRATION VERIFICATION 16-17 _ 11.0 | SCAN PLAN SET-UP 18 | 120 | APPLICATION OF SCANNING 18 13.0 | SCANNING OVERLAP AND SPEED 8 140 | RE-EXAMINATION 8 15.0 | EVALUTION OF USING THE TOMO VIEWER 19 PROGRAM 16.0 [RECORDS 20 17.0 [ACCEPTANCE STANDARD 2436 76.0 | REPAIR REQUIREMENT 7 19.0 | REPORTS & RECORDS 2 | 200 | ATTACHMENTS 28-28 PARESA INDUSTRIAL X-RAY & ALLIED ie & ios RADIOGRAPHERS NIGERIALTD. | pact Sve — PROCEDURE FO! i : IXAR PI RAY ULi NIG TESTING saipem “==> | OF WELD JOINTS FOR AMMONIA FANE | 30-T-9 DocNo: IXAR/NDT/PAUT-01 Date: 5/08/2016 Project: Ammonia 8. Urea Fertilizer Complex Fa Co Owner: Mis Dangote Fertilizer Company Ltd. {DFL) Page No. : 4 of 28 EPC : Mis Saipem Location: Nigeria | Contractor: Paresa 1.0 PURPOSE, his procedure describes the Phased Ary Ultrasonic examination (PAUT) method for ultrasonic wal ae aton of welds, heat effected zones, and adjacent materials of Ammoria Tank, Item 30-T-1 as Wel as the butt welds of Piping nozzles, if the diameters are feasible, in. DANGOTE Fertilizer Project, Nigeria, ‘This procedure covers the inspection of butt welds satisfying the following conditions + Minimum Thickness 10 mm (Base metal nominal thickness) + Material ~ Low Alloy Steel ASTM A537, CL.1 (P No.1 Gr No.2) 2.0 Reference Documents a) Contract document b) Approved QCP/ITP ©) SAIPEM Specification SPC. WL.CK.0390 Rev 4 @) ASME B 31.3, Case-181 Ed.2012 ©) ASME Sec IX Ed. 2013. f) ASME Sec V Article 4. 9) API 650 fn) ASME Sec VIII Div.1 (Mandatory Appendix 12) ) SNT-TC-1A ~ Recommended Practice for NDT Personnel qualification, 1) 90-2A-E-09609 “QA Requirements for construction contracon K) 00-24 E-09610 “QC Requirements for construction contractor” )) PARESA/PA UTWELD/DEMO/01 3.0 Definitions UT : Ultrasonic Testing QcPiTP: : Quality control plan / Inspection test plan 4.0 Qualification of UT Personnel AS a minimum al personnel conducting UT shall be certified to level - Il in accordance with ASNT document SNT-TC-1A or equivalent, Personnel Performing PAUT shall have minimum six months experience in the application & usage of PAUT method & equipment. Wines and evaluation of examination shall only be carried out by an SNT-TC-14 level — Il qualified Personnel. The person has to demonstrate the scan plan on the calibration block, RADIOGRAPHERS NIGERIALTD. | pancOre - CPARESA INDUSTRIAL XRAY & ALLIED ae PROCEDURE FOR a. DXAg | ENE | euasep akeay ULTRASONIC TestING seipem ‘OF WELD JOINTS FOR AMMONIA TANK | 30-T-01 | DocNo: IXARINDT/PAUT-01 Date: 5/08/2016 Project: Ammonia & Urea Fertilizer Complex et ‘Owner: M/s Dangote Fertilizer Company Ltd (DFL) Page No. : 5 of 28 EPC : Mis Saipem Location: Nigeria Contractor: Paresa Level Ill person is required to check and approve the written procedure. Independent qualified level III has to give final approval of the inspection of the welds by signing on the PAUT reports. 6.0 Application: Main objective of this procedure is to describe computerized semi-automated “Phased Array” technique for location and evaluation of defects in the volume of the weld and adjacent parent matetial (Lesser of Tin. orton each side of the weld), For material thickness 8 in. (200 mm) or less, the ultrasonic examination area shall include the volume of the weld, plus the lesser of 1 in. (25 mm) or t on each side of the weld. Altematively, examination volume may be reduced to include the actual heat affected zone (HAZ) plus 6mm of bese material beyond the heat affected zone on each side of the weld, provided the extent of the weld HAZ is measured and documented during the weld qualification process and the ultrasonic transducer. Positioning and scanning device is controlled using reference mark to ensure that the actual HAZ plus an additional 6 mm of base metal is examined. Examination shall be conducted from outside of weld surface so that 100% (full) volume of weld is Covered. If there is evidence showing that not 100% (full) volume of weld is scanned, more than one directions of scanning will be taken in consideration. 6.0 General Requirement 6.1 Surface Preparation 6.1.1 Contact Surfaces ~ The finished contact surface should be free from weld spatter and any roughness that would interfere with free movement of the search unit or impair the transmission of ultrasound, 6.1.2 Weld Surfaces — Weld surface shall have uniform & smooth weld ripples through out circumference of weld or weld reinforcement shall be ground smooth flush to the base metal height. 6.1.3 Temperature — The maximum surface temperature to be scanned should not exceed 50°C. The surface temperature shall be within +/- 14°C of the reference block temperature when the calibration was performed. 6.1.4 Conditions which do not meet these requirements shall be recorded as limitations on the Ultrasonic Examination Report (Phased Array), INDUSTRIAL X-RAY & ALLIED ] a RADIOGRAPHERS NIGERIA LTD. DANGOTE PROCEDURE FOR pi ARRAY ULTRASONIC TESTII oer. WELD JOINTS Fi IMONIA TANK 30-T-01 DocNo: IXAR/NDT/PAUT-01 Date: 5/08/2016 Project: Ammonia & Urea Fertlizer Complex Rev Go Owner: M/s Dangote Fertilizer Company Lta,(DFL) Page No. : 6 of 28 EPG : Mis Saipem Location: Nigeria _ [ Contractor: Paresa 7.0 Equipment:- 7.1 Phased Array UT Machine (ex. OMNISCAN MX2) shall be used for examination. it shall be quipped with a calibrated dB gain of attenuation control stepped in increments of 2dB or less, capable of generating and displaying sectorial-scan (also called an $-scan) images, which can be stored and recalled for subsequent review. Use a realtime sectional-scan image during scanning to assure that proper data has been collected Sectorial-scan images contain signal amplitude and reflector depth information projected for the refracted angle of the ultrasonic beam. Images produced by A-, B-, C- and sectorial-scan images are a useful aid in evaluation. The use of an external storage device, flash card, or USB memory stick is useful aid in examination data saving INSTRUMENT INSTRUMENT MODEL ‘SOFTWARE VERSION MAKE OLYMPUS OMNISCAN-MX2 WITH PA MODULE 4.3 or latest 7.2, Search Unit (Probe) ‘The phased array search unit frequency shall be 2.25 or § MHz due to material type and thicknesses range. ‘The phased array search unit configuration shall be used 16, 32 or 64 elements. (See to Table 1.) ‘Table 4. Probe Specification & Dimensiot Part no Frequency(MHiz)[ No. of elements | Elevation(mm) Piteh(mm) | 2.25L64-A12 2.25 64 40 0.60 1 SL64.A12 5 64 10 oso | 7.3. Wedges: Phased atray wedges shall be of a design to accommodate phased array search unit Nominal refracted-wedge angles shall be used 45, 55, 60 or 70 degrees to ensure coverage of the weld and heat affected zone. (See to Table 2.) a ‘SPARESA INDUSTRIAL X-RAY & ALLIED es ee RADIOGRAPHERS NIGERIALTD. | pancore i, PROCEDURE FOR a DMAR | TNE | Pxasen aRRAY ULTRASONIC TESTING ssipem = | OF WELD JOINTS FOR AMMONIA TANK 30-704 DocNo: XARINDTIPAUTOT Date: 5082076 4 Project: Ammonia & Urea Fertilizer Complex no ‘Owner. Mis Dangote Fertilizer Company Lta (DEL) Page No: 7 of28 EPC = Mis Saipem Location: Nigeria (Contractor: Paresa ‘Table 2. Wedge Specification & Dimension Nominal Sweep Probe Part no Probe type | Refracted beam ‘angle neice’ | (degree) | orientation ‘SA12-N55S-IHC Az 55° SW 35-70 cients SAT2-NGSS- = Normal / AQD(6.625,8.625,10.75812.75) p12 eu pale Reverse 7.4. Encoder ‘The encoder shall be used quadrature type signal. The quadrature type is recommended by manufacturer. { callbration check shall be performed at intervais not to exceed one month or prior to fist use Rereafter, by moving the encoder a minimum distance of 20 in. (500 mmr). The display distance shall be within +1% of the actual distance moved. 7.5. Couplant Couplants shall be used in order to provide optimum wetting, transmission of ultrasound, resistance to corrosion, viscosity and removal characteristics & which permits satisfactory transmission of ultrasori¢ waves. (@) Water or glycerin(75% purity) or oll mixed with grease shall be used to couple search units to the surface being scanned (b) Application of liquid on weld surfaces shall be done by fine nylon brush only during weld scanning, (©) Coupiants materials used for examination shall be the same as used for the Calibration, 8. Basic Calibration Block:- 8-1 Piping Calibration Blocks (for butt welds of Piping, Piping Nozzles or other tubular welds) [Fhe basic calibration block configuration and reflectors shall be as shown in Fig.1. The basic calibration lock shall be a section of pipe of the same nominal size and schedule. The block size and reflector locations shall be adequate to perform calibration for the Phased Array Probe used. ‘The calibration block shall meet the following requirements of Figure 1 and Notes: Fig. 1 (as per ASME Code, Section V, Article 4) INDUSTRIAL CRAY & ALLIED rs ep RADIOGRAPHERS NIGERIALTD. | pancore PROCEDURE FoR . KAR PHASED ARRAY ULTRASONIC TESTING saipem OF WELD JOINTS FOR AMMONIA TANK 307-01 @ | DocNo: IKARINDT/PAUT-O1 Dale! 5108016 Project Ammonia & Urea Fertilizer Complex — o [i Tz I Owner: M/s Dangote Ferliizer Company Ltd (OFL) Page No. 8 of 28 EPC : Mis Saipem Location: Nigeria Contractor: Paresa a Notches shall be located not closer than T or 1 in (25 mm), whichever is greater, to any block edge or to other notches. GENERAL NOTES. {a) The minimum calibration block fength (L) shall be & in. (200 mm) or 8T, whichever is greater. (b) For OD 4 in, (100 mm) or less, the imum are length shall be 270 deg. For OD greater than 4 in, (100mm), the minimum are length shail be 8 in, (200 mm) or 3T, whichever is greater. (©) Notch depths shall be trom 8% T minimum to 11% T maximum. Notch widths shall be 1/4 in. (6 mm) maximum. Notch lengths shall be 1 in. (25 mm) minimum. (d) Maximum notch width is not critical, (e) Notch lengths shall be sufficient to Provide for calibration with a noise ratio, imum 3 10 1 signal-to- 8.2 Plate Calibration Blocks Reference block shall be made with thickness and side-drilled and shall be used for gain calibration and Construction of reference curves, The reference block shall normally be manufactured from the same material examined and have the dimensions approved as shown in fig.2. INDUSTRIAL CRAY & ALLIED rs RADIOGRAPHERS NIGERIALTD. | pancore PROCEDURE FOR PHASED ARRAY ULTRASONIC TESTING saipem F WELD JOINTS FOR AMMONIA TAI 30-104 DocNo: IKARINDTIPAUT.O7 Dale: STOBROT Project: Ammonia & Urea Fertilizer Complex ae ‘Guner Wis Dangote Feriizer Company LaF) Page No.6 of 26 EPC : Mis Saipem ae Location: Nigeria Contractor: Paresa Fig. 2 (As per ASME Code, Section V, Article 4) sen Ping cao ack SSS Nastia | Las 3x Tanck Notes: (1) Minimum dimension Weld Thickness (t) | Basic Calibration Block Thickness (T) Hole Diameter 1” (25mm) or Less 4%" (19mm) ort 3/32" GENERAL NOTES: (a) Holes shall be drilled and reamed 1.5in. (38mm) deep minimum, parallel to the examination surface () For blocks less than % in. (19mm) thickness, only the % T side-drilled hole and surface notches are required (¢) Maximum notch width is not critical (d) Weld thickness, ‘t’, is the nominal material thickness for welds without reinforcement. For welds with reinforcement *t’is the nominal material thickness plus the estimated weld reinforcement, inside the acceptable range. 9.1 Sensitivity Calibration for plate ‘The reference sensitivity shall be established and TCG curves constructed for Phased array Probe with 64 elements and 45°,60°,70° angles covering the full examination range using then appropriate sensitivity calibration reference block INDUSTRIAL XRAY & ALLIED a RADIOGRAPHERS NIGERIALTD. | pancOre PROCEDURE FOR ; PHASED ARRAY ULTRASONIC TESTING saipem ‘OF WELD JOINTS FOR AMMONIA TANK 307-01 DocNo: IKARINDTIPAUT-OI Date: 5/08/2016 Project: Ammonia & Urea Fertilizer Complex EI | Owner: Mis Dangote Fertilizer Company Ul (OFL) Page No: 10 0128 EPC : Mis Saipem Location: Nigeria Contractor: Paresa For internal reflectors, the primary calibration reflector (the side drilled hole used to establish the reference sensitivity) shall not be to a depth corresponding to less than % the nominal thickness of item to be examined. The picked signal from the primary calibration reflector shall be set at 80% FSH marked on the instrument screen. Without further adjustment of the instrument's setting, the peaked signal height from progressively deeper reflector shall be marked on the screen. The points shall then be connected to construct the TCG ALL TCG curves shall be constructed using at least three Points when possible 9.2 Sensitivity Calibration for piping The reference Sensitivity shall be established and TCG curves constructed for Phased array probe with 64 elements and 35° to 70° angles covering the full examination range using then appropriate sensitivity calibration reference block The reference block used for sound path calibration shall be of the same material as the weld to be examined, Without changing the equipment settings, the search unit shall be placed to obtain reflections from SDH at 1/4, 1/2 and 37/4, System calibration verification shall include the entire examination system. Sweep range and TCG calibration shall be verified on the appropriate calibration block under the following conditions; 1) Prior to and within 24 hours of the start of a series of examinations. 2) With any substitution of the same type and length of search-unit cable. 3) With any substitution of power using the same type source, such as a change of batteries. 4) Atthe completion of a series of examination. 5) Whenever the validity of the calibration is in doubt. 9.3 System Calibration Changes:- Perform the following if any point on the TCG decrease by 20% or 2 d8 of its amplitude, or any Point on the sweep line has moved more than 10 % of the sweep division reading. 1) Void all examinations performed after the last valid calibration verification. 2) Conduct a new system calibration. 3) Repeat voided examination. ia. | OPARESA INDUSTRIAL X-RAY & ALLIED ry “Se RADIOGRAPHIERS NIGERIA LD. | DANGOTE inh BROCEDURETOR ag & e DAR | CAE | euasen array ULTRASONIC TESTI ssipem = LD JOINTS FOR AMMONIA TANK 30-101 | DocNo: IXARINDTIPAUT-01 Date: 5/08/2076 Project: Ammonia & Urea Fertilizer Complex , o | Owner: Ms Dangote Feriizer Company Ltd (OL) Page No: 11 of 28 EPC : Mis Saipem " Location: Nigeria Contractor Paresa Perform the following if any point on the TCG has increased more than 20 % or 2 dB of its amplitude: 1) Correct the system calibration 2) Re-examine ail indications recorded since the last valid calibration verification. 9.4 Re-Calibration:- Any of the following conditions shall be cause for system recalibration: 1) Search unit transducer or: wedge change. 2) Search unit cable or length change. 3) Ultrasonic instrument change. 4) Change in examination personnel. 5) Change in type of power source. 9.5. Calibration for Examination:- Establishment of the minimum screen range shall be depended upon wedge profile with phased array probe. in all cases the screen range shall also be sufficient to ensure coverage of the through member for non-butt joint -Calibration for PA probe and wedge- 2) It shall be selected the type of probe and wedge, material specification for being tested, 2) It shall be selected the type of scan linear scan or sector scan. Fig. 3- The type of Wedge and Probe INDUSTRIAL XRAY & ALLIED ry RADIOGRAPHERS NIGERIALTD. | nancore PROCEDURE FOR aS PHASED ARRAY ULTRASONIC TESTING saipem ‘OF WELD J FOR AMMONIA TANK 307-01 ‘DocNo: IXARINDT/PAUT-O1 Date: 5/08/2076 Project: Ammonia & Urea Fertiizer Complex ae ne I ‘Owner: M/s Dangote Fertilizer Company Lid.(DFL) . Page No. : 12 of 28 EPC : Mis Saipem Location: Nigeria Contractor: Paresa Linear Scan’ ‘Sector Scan Fig. 4— Type of Scan 3) It shall be selected how many transducer will produce ultrasonic beam, which transducer will ‘send the first beam. 4) Select the wave form whether LS or SW. 5) Choose the focus depth. 6) Choose the range of angle to be used. 7) Change the viewer monitor to A-S scan. 8) Adjust the sweep range to appear the reflection echo on the screen; the reference level shall be FSH 80% to adjust the gain. 9) It may be selected the filter with using frequency band width of transducer. 10) Calibration of Sound Velocity. A. Put the probe on the standard block as below Fig. 5 Fig. 5 Calibration of Sound Velocity B. Adjust the sound velocity with setting up Grade A to the 50R the reflection echo and Gate B to the 100 R the echo. ~PARESA INDUSTRIAL X-RAY & ALLIED & : RADIOGRAPHERSNIGERIALTD. | pactore Ma PROCEDURE FOR DXAR | TNE | PHASED ARRAY ULTRASONIC TESTING & Eaipers “=== | QOFWELD JOINTS FOR AMMONIA TANK 30-T-01 DocNo: IXARINDT/PAUTO4 Date: S006 Project’ Ammonia & Urea Fertilizer Complex ae zal Owner: M/s Dangote Fertilizer Company Lid (OFL) Page No 130f 28 EPC: Mis Saipem Location: Nigeria Contractor Paresa Fig. 6 The Screen of Adjusting Sound Velocity 11) Calibration of Wedge delay. ‘A. Put the probe on the standard block as below Fig.7 Fig. 7 Calibration of Wedge B. Select the Sound Path, Wedge Mode and Adjust Wedge Delay. C. Adjust the 60 R reflection echo into the Gate range, afier putting the probe on the 50 R locations as the Fig. & Fig. 8 Adjusting Gate Calibration D. Control the 50 R reflections Curva into the guide line by moving the Probe, Ifthe refection curve is out of guide line, re-calibration shall be performed. INDUSTRIAL X-RAY & ALLIED ry ] RADIOGRAPHERS NIGERIALTD. | pancore PROCEDURE FOR & PHASED ARRAY ULTRASONIC TESTING ews ‘OF WELD JOINTS FOR AMMONIA TANK 30-101 DocNo: IKAR/NDT/PAUT-07 Date: 5/08/2016 Rev Project: Ammonia & Urea Fertilizer Complex te Te ‘Owner: Mis Dangote Fertiizer Company Le(DFL) Page No. : 14 of 28 EPC : Mis Saipem [Location: Nigeria Contractor: Paresa. 7 _] Fig. 9 Screen of Wedge Calibration 12) Calibrate the Width of Beam Spreading, A. Put the probe on the standard block to aim the side drilled hole for getting the reflection echo as below FIG.10 FIG. 10 Calibration of the Width of Beam Spreading. B. Control the SDH reflections echo into the guide line by moving the Probe .If the reflection echo is out ‘5% of guide line, re-calibration shall be performed, Fig, 11 Calibration for the Beam Spreading of Probe. INDUSTRIAL CRAY & ALLIED rs RADIOGRAPHERS NIGERIALTD. | panaoTe en m= PHASED ARRAY ULTRASONIC TESTING saipem ‘OF WELD JOINTS FOR AMMONIA TAN! 30-1-04 DocNo: IXARINDI/PAUT-01 Date: 57082016 Project Ammonia & Urea Fertilizer Complex ae Bost Owner: Mis Dangote Fertilizer Company Ltd (DFL)___ - Page No. : 15 of 26 a [ EPC : Mis Saipem Location: Nigeria Contractor: Paresa I 10.0 Scanning Technique:- 1) Scanning shall be performed using a Line-scan technique (also called LAST-Line Analysis Scanning Technique). Each line scan shall be parallel fo the weld using a linear scan with 64 elements 2) A minimum line scans shall be performed at index points from the canter of the weld from both sides of the weld where practical to ensure coverage of the weld and heat affected zone. 8) For thicker materials with nominal wall thickness Line Scan shall be performed to the degree to cover the required volume of weld and base material. If Line Scan could not cover whole weldment multiple line scan shail be used. 4) Scans shall be parallel to the weld at 90°/270" skew angle. 5) Perform the examination from both sides of the weld, where practical, or from one side as a minimum. 6) Supporting tools shall be fixed with a magnetic chuck. Sample Beam Profile for Thickness of Welding Weld width : 1 inet: Scan plan showing the refracted angles at index point. 2 RADIOGRAPHERS NIGERIA LTD. aoa = PROCEDURE FOR & DXA | CNE | PHASED ARRAY ULTRASONIC TESTING oaees = LD JOINTS FOR AMMONIA TANK 2 CPARESA INDUSTRIAL X-RAY & ALLIED | 30-T-01 DecNo: XARINDTIPAUT-01 _ [Bale 570872016 Project Ammonia & Urea Fertilizer Complex fe 1 - Owner: Mis Dangote Fertilizer Company Ua (DEL) Page No. 16 of 28 EPC = Mis Saipem Location: Nigeria Contractor: Paresa 1 i Specimen thi EE 4 3.3imehes | Skew angle from Weld C, : 270° Weld widele = 1 imetr ‘Scan plan showing the refracted angles at index point-3 2° Index paint \ Specimen 1 | thickness: Stew 11 : Weld C2 90 bt} ae ‘Scan plan showing the refracted angles at index point-4 10.1. Examination Coverage 2) The specifics of the examination volume, weld identification, and location shall be identified in the scan plan. 2B Al ot amiation volume shall cover the weld metal and includes the hear affected zone(HAZ) 3) All butt joint welds shall be tested from one side as. minimum of the weld axis & (If required) both side of the weld axis (see also 5.0 — last paragraph). 41. Scan Plan Set-up:- she scan plan shall demonstrate by plotting the appropriate examination anglo for the weld preparation bevel angles (for example, from 30° to 60° or from 45° to 70°) that wil be used during the exananation ‘A scan plan shall be used taking in consideration the profile of each weld and selected wedges. 1) The scan plan shall ensure complete coverage of the weld and heat affected zone. INDUSTRIAL CRAY & ALLIED RADIOGRAPHERS NIGERIALTD. | pacccGre PROCEDURE FOR HASED ARRAY ULTRASONIC TESTING saipem INTS FOR AMMONIA TANK 30-T-01 DocNo: KARINDTIPAUT-01 Date: 5/0807 Project Ammonia & Urea Fertiizer Complex oT | Gener: Mis Dangote Fertilizer Company Ltd (OF) Page No: 17 of 28 EPC : Mis Saipem Location: Nigeria Contractor: Paresa 2) 70 determine the required examination volume and scan area, profiles shall be taken in account (on ‘each profile at the top-dead-center ~ the beginning of the area to be scanned), as a minimum, 3) The set-up of scanning resolution on equipment shall be used in order fo get a minimum detecting size less than allowable size of acceptance criteria, {reliable defect detection and sizing is based on scan pattems with specific functional combinations between the scanner movement and the phased array beam direction, a) Data acquisition shall be triggered by encoder position. b) The examination shall be Performed as the probe carrier is moved by Auto Scanning (Fig.11) or manual, but the movement is. encoded; data is acquired based on encoder resolution, ©) For plate butt welds shall be used basically a linear scan with 64 channels and can be used 16 channels elements probe. A linear scan is one is Scanning Sequence, which uses only one position encoder to determine the position of the acquisition 11.1 Selection of wedges and Gate set-up: According to the Profle with wedgo type selection of wedge and gate setting shall cover the weld metal include HAZ. 12. Application of scanning: 2) For Vertical, Horizontal, T-cross welding shall be applied PA Technique. 2) For Horizontal, T-cross welding can be applied Manual UT, too (if thickness range allows). 9) For T-cross welding an additional RT is recommended Apply Manual UT for Transverse flaw detection (phased Array probe parallels ‘welding line) 5) Sometime can be applied O°probe, INDUSTRIAL XRAY & ALLIED _ RADIOGRAPHERS NIGERIALTD. | pancore PROCEDURE FOR 7 PHASED ARRAY ULTRASONIC TESTING ssipem ‘OF WELD JOINTS FOR AMMONIA TANK | 30-101 DocNo: IKARINDTIPAUT-01 Date! SOOT Project: Ammonia & Urea Fertilizer Complex fous or ‘Owner: Wis Dangote Feriizer Company Utd (OFT) Page No, 16 of 28 EPC : M/s Saipem Location: Nigeria Contractor: Paresa 13. SCANNING OVERLAP AND SPEED: For each 5000mm scan length 25 mm scan overtap shall be done in case of scanning in two or more Parts. Scanning speed shall be such that data drop-out is less than 2 data lines per inch (25 mm) of the linear scan length and that there are no adjacent data line skips, For E-scan techniques, overlap between adjacent active apertures (Le., aperture incremental change) Shall be a minimum of 50% of the effective aperture height. For S-scan techniques. the angular sweep incremental change shall be a maximum of 1* of sufficient to assure 50% beam overlap. When multiple linear scans are required to cover the required volume of weld and base. material, overlap between adjacent linear scans shall be a minimum of 10% of the effective aperture height for E- Scans or beam width for S-scans different skews, different scanning types, different inspection areas, and other parameters. Sampling Step less than ‘Imm of Examination Thickness, 14, RE-EXAMINATION:- 1) An examined item with one or more defects (imperfections of a type or magnitude exceeding the ‘acceptance criteria of this procedure) shail be repairad or replaced; and the new work shall be fe~ Gxamined by the same method, to the extent, by the same acceptance criteria as required for the original work. 18. EVALUATION OF USING THE TOMO-VIEWER PROGRAM:- TomoView™ is Olympus NDT software for phased array and ultrasonic data viewing. This software gives the capability to load data files generated by TomoView or OmniScan® PA and UT sofware, ‘TomoVIEWER software runs on Microsoft® Windows® 2000 or XP operating systems. 1) The Tomo-viewer program shall be used interpretation of acquisition data. 2) The interpretation data shall be included of location (from X., Y-), length, depths and amplitude for making result report. 9) A request of customer, these data from displayed equipment may be attached the result report. INDUSTRIAL X-RAY & ALLIED rs RADIOGRAPHERS NIGERIALTD. | pancore PROCEDURE FOR 4 PHASED ARRAY ULTRASONIC TESTING saipem OF WELD JOINTS FOR AMMONIA TANK 30-T-01 DocNo: IXARINDT/PAUT-01 Date: 5/08/2016 Project: Ammonia & Urea Fertilizer Complex ey TET ‘Owner: Wis Dangote Fertilizer Company Ltd (FL) Page No. 19 of 28 EPC : Mis Saipem Location: Nigeria Contractor: Paresa Tamoliew offers advanced post-processing of OnuniScan data. Wlstrated here: weld ovedlay, eudtiple sector scans, imdtibeam C-ecans, and merging of A-scan with Fop and End ews (the laticr with rebound dtaptay). 46.RECORD :- 1) Once a discontinuity has been found by scanning and determined to be rejectable the following characteristics shall be shown on the report. 2) Weld datum point 3) Location and length along the weld axis 4) Location within the weld cross section 5) Height & length of the defects. 8) Orientation of discontinuities ~show in sketch relative to the weld fusion boundaries 7) For all welds examined, the examiner shall mark with indelible marker on the work-piece either “ UT. OK" or “UT REJECT", his name, and date. In case of rejection, he shail also mark the datum point and the position ofthe defects, 8) The ultrasonic examiner shall complete a report form, which clearly identifies the weld or weld seam and the area of examination, at the time of examination. Evaluation of retested repaired weld areas ‘must be tabulated on a line of the report form. INDUSTRIAL GRAY & ALLIED ae RADIOGRAPHERS NIGERIALTD, | pancore PROCEDURE FOR PHASED ARRAY ULTRASONIC TESTING seipem ‘OF WELD JOINTS FOR AMMONIA TANK 30-01 DocNo: IXARINDTIPAUT-07 Date: 5/08/2016 Project: Ammonia & Urea Fertilizer Complex 7 c= 1 Owner Mis Dangote Ferilizer Company Ltd (DFL) ‘ Page No: 20 of 28 EPC : Mis Saipem [ Location: Nigeria Contractor: Paresa iH 17. ACCEPTANCE STANDARD:- 17.4 Piping Acceptance Standard: 17.142) As per ASME B31.3 344.62 Acceptance Criteria: A linear type discontinuity is unacceptable if the amplitude of the indication exceeds the reference level and its length exceeds as below (1) V4 in. (6 mm) fort up to 34 in. (19 mm); (2) V8t for t over 34 in. (over 19 mm); 17.1(b) Project Specification: SPC.WL.CK.0390 (Attachment. Il for Welding class 1 & 2):- CPARESA INDUSTRIAL X-RAY & ALLIED ep RADIOGRAPHERS NIGERIA LTD. DANGOTE a Te KAR PHASED ARRAY ULTRASONIC TESTING saipem ‘OF WELD JOINTS FOR AMMONIA TANK 30-701 DocNo: IXARINDIW/PAUT-O1 A Date: 5/08/2016 Project: Ammonia & Urea Fertilizer Complex es 1 Owner: M/s Dangote Fertilizer Company Ltd. (DFL) Page No_: 21 of 28 | EPC : Mis Saipem Location: Nigeria Contractor: Parese F ATTACHMENT E NDE TECHNIQUE, AFPLICABLE STANDARDS AND ACCEPTANCE CRITERIA SUMMARY TABLE, FOR WELDING CLASS 1 £2 [ APPLICABLE STANDARDS. accertance corena_ | Resign Coae sign Cade Mowe a DestTRUCTIVE | = EXAMINATION | ASmEB 313 Et 13860 a= | eeszasa (ABBREVIATIONS) | ASME 31.9 g z Z35) nolEcomintin | ASHI coe | B28) enscase mn ‘Sat V, Aaiie ENo?O BES) leech 323 | | auc ery 32/822 | | a= [32 (ectewmntle | Sect, Anite 2 exis | 821222) ovose Seana Clee | 33/258) Acc lett Ubrssonic ASHE DIY Code g2/ 3 | a Set, arse< exw | 32) 3 | even | | emen | a8) 2 | actect2 quid Penetrant ‘ASRIE BEY Coge 32/,53 Ecominaon (PT) Ste ee | er | ee [aed ater a 88 [0 28) exam a |e ASHE BPY Dose E obs | Magnetic Panicie = 2 ze go ena cae ‘Seat V,Aeite exw | Bs 888) “Sone ur) [*- | 5 | INDUSTRIAL XRAY & ALLIED ry RADIOGRAPHERS NIGERIALTD. | pancore PROCEDURE FOR & PHASED ARRAY ULTRASONIC TESTING OF WELD JOINTS FOR AMMONIA TANK 30-T-01 DacNor KARINDTIPAUT. 07 ; Dale: S/0BI2075 Project: Ammonia & Urea Fertilizer Complex aoe ‘Owner Ws Dangote Fariiizer Company Ltd (DFL) Page No,: 22 01 28 EPC : Mis Saipem Location: Nigeria Contractor: Paresa 7.4(6). Project Specification: SPC. WL.CK.0390 (Attachment: Ill for Welding class 3 & 4) :- AT TACHIUENET 8 NOG TECHMIOUE APPLICABLE STANDARDS AND ANCE CRITERIA SUMMARY TADLE On welomes Cees a APPLICABLE STANDARDS ACCEPTANCE Cerrenia . ‘Design Gade ca a. lasl es euree | $E gE euro | is | | g= ze mare g2)| BES EN iso 5817 ve | ge| 223 Lees) 2] #,. mise | BS) fas excrsw-t owen | Se) p53 ee Lowel 2X } — | eur | BS emir | ‘Class A. BS Ace. Level 3 a3 - S lez Leenraicatin = Zar Liquis Penerrane B | 2282 | ener cnam, See |eeeeges | on | 2 EEEEE et Set ances | @ [SEB B25si loco 2 2 ication = ere z 432.5 |= wear | smeprvcoe | cue | 2 |ELdEE oe | ene | } iia l | BESS & [ovis mc toes 17.1(d). ASME 31.3 CODE CASE 181: Flaw Evaluation for Welds with Thicknesses over 25mm (1) Dimensions. The dimensions of the flaw(s) shall be determined by the rectangle that fully contains. the area of the flaw(s). (Refer to Fig. 1. below) (@) The length, of the flaw shall be drawn parallel to the inside pressure-retaining surface of the ‘component. (b) The height, h, of the flaw shall be drawn normal to the inside pressure-retalning surface of the component. INDUSTRIAL X-RAY & ALLIED ry RADIOGRAPHERS NIGERIALTD. | pancore PROCEDURE FOR & PHASED ARRAY ULTRASONIC TESTING satpem OF WELD JOINTS FOR AMMONIA TANK 30-T-01 DocNo: IXAR/NDT/PAUT-O1 Date: 5/08/2016 Project Ammonia & ea Feiler Complex os | Owner: Mis Dangote Ferilizer Company Lid (DFL) Page No. : 23 of 28 EPC : Mis Saipem - Location: Nigeria | Contractor: Paresa (©) The flaw shall be characterized as a surface or subsurface flaw, as shown in Fig. 1 (4) A subsurface indication shall be considered as a surface flaw if the separation (S in Fig. 1 below) of the indication from the nearest surface of the component is equal to or less than half the through-wall dimension [h in Fig. 1 below, sketch (b)] of the subsurface indication (2) Multiple Flaws (2) Discontinuous flaws that are oriented primarily in parallel planes shall be considered to tie in a single plane if the distance between the adjacent planes is equal to or less than 13mm. (0.50in.) or 0.5t,whichever is less. (©) Ifthe space between two flaws aligned along the axis of weld is less than the height of the flaw of greater height, the two flaws shall be considered a single flaw. (0) Ifthe space between two flaws aligned in the through-thickness dimension is less than the height of the flaw of greater height, the two flaws shall be considered a single flaw. (@) Flaw Acceptance Criteria. Flaws shall be evaluated against the applicable acceptance criteria of Table 1 or Table 2, except that flaw length () shall not exceed 4t, regardless of flaw height (h) or the calculated aspect ratio. INDUSTRIAL XRAY & ALLIED rs RADIOGRAPHERS NIGERIALTD. | paneGre PROCEDURE FOR s {ED ARRAY ULTRASONIC TESTIN xelpem OF WELD JOINTS FOR AMMONIA TANK 30:1.01 DocNe: KARINDTPAUT-O1 Date: SO0S2016 Project: Ammonia & Urea Fertiizer Complex ot Teall Guwmer:Iiis Dangote Fetilizer Company Ud (DFT) Page No: 24 of 28 EPC : Mls Saipom Location: Nigeria Contractor: Paresa an Golew ism) 836 036 ‘ment. for 8 buit joint joining two Meme heving Gticeeer thickness at the joint. ¢ is the miner of the two theckeee es inined. a 3 full penetiaion weld includes & they ene we Pies throor imension of the filet meld shall be ticlated calculaved hi+ down tO the nearest 0.05 mErement valee (© Feuisrmesiae thianess[eeld tekietnes benween 4 mm GENERAL NOTES. a) t= thickness of the weit excluding any allomanle reinforce SELL Ses fe ne tam memes hac otros Ipined. H 2 full penetration weld includes Siler eid ae fictive thioat dimension of ie Het meld snsi be shcded > Scpect ratio init) uoed may be derermaned ty rouncig the (0 for inarmedtate thickness * fweid thicknesses between G4 rom ‘Bnet 100 toe C25 ins ad 39 OH Coen ear nee RADIOGRAPHERS NIGERIALTD. | pantore = PROCEDURE FOR s DMAR | TNE | PHased ARRAY ULTRASONIC TesTING saipem => OF WELD JOINTS FOR AMMONIA TANK 30-T-01 Z CPARESA INDUSTRIAL X-RAY & ALLIED DoeNo: ARINDTIPAUTDA ____ | Dale 582076 Project: Ammonia & Urea Fertilizer Complex :t fantom - ‘Owner: Wis Dangote Ferilizer Company Ltd (DFL) Page No: 26 of 28 EPC : Mis Saipem ~ [Lecation: Contractor: Paresa 17.2 Non Piping Acceptance Standard: 17.2.1 Flaw Evaluation and interpretation- Flaws shail be evaluated for acceptance using the applicable criteria of Tables U-1 OF Mandatory Appendix U given in API 650 with the following additional requirements: 17.2.2 Surface flaws - Unless the UT data confirms that a flaw is not surface connected it shall be considered a surface connected flaw and itis unacceptable unless a surface examination is performed any one of the following examination techniques. 8) Magnetic Particle examination (MT) OR Liquid Penetrant Testing 17.3.3 Multiple flaws - 17.9.3.1 Discontinuous flaws that are oriented primarily in parallel planes shall be Considered a singular planar flaw if the distance between the adjacent planes is equal to or less than % inch. 17.9.32 If the space between the two flaws aligned along the axis of the weld is less than two times the length of the longer of the two, then the two flaws shall be considered a single flaw. 17.9.3.3 If the space between the two flaws aligned in the thru thickness direction is less than two times the height of the larger flaw of the two ,the two flaws shall be considered a single flaw. SPARESA INDUSTRIAL X-RAY & ALLIED ae

es fa [eons 78 + ee ax | om | oi) | som | aay | asm | om | aan Wisieawam {9 x a * i Lm | wx | wim | wan | cisw | aan | oa | eam | een en NM chs ay Abe ceercement, For 3 ha wed ineny metho ning diene Mack ae melt se thinner af thet SA ace fa tae doen accept a sats he Koes ms ae a sy say the MITA chaser tion imssaions of U2 18. REPAIR REQUIREMENTS: Repair shall be examined by the same ‘Acceptability of repairs shall be determined by the same acceptance standards. 19. REPORTS AND RECORDS:- 1) Examination of Reports A teport of the examinations shall be made. the report shall include a record indication the Weld(s) or volume examined (this may ba marked-up sketched), the location of each recorded reflector and the identification of the operator who carried out each examination or part thereof as detailed in attachments. 2) Calibration Records 'nstrument calibrations in accordance with 6, 7 shall be included in the ultrasonic calibration records. Ultrasonic examination system calibration requirements in accordance with 12 and ‘calibration block identity shall be included in the ultrasonic calibration records. 3) Examination Records For each ultrasonic examination the following information should be identified and recorded, a) Procedul Procedure used for the detection of the discontinuities, PARESA INDUSTRIAL XRAY & ALLIED rs SQ . RADIOGRAPHERS NIGERIA LTD. DANGOTE = PROCEDURE FOR & DA HASED ARRAY ULTRASONIC TESTING saipem “== | OFWELD JOINTS FOR AMMONIA TANK 30-17-01 DocNo: IXARINDT/PAUT-O1 Dae, 5/08/2076 Project: Ammonia & Urea Fertilizer Complex a = 4 [27-7 J Owner: Mis Dangote Fertilizer Company Ltd (DFL) Page No. : 27 of 28 EPC : Mis Salpem Location: Nigeria Contractor: Paresa ) Ultrasonic examination system (equipment) ; ©) Examination personnel identity and level: 4) Calibration sheet identity; ©) Identification and location of weld or volume scanned: #) Surface from which examination is conducted; 2) Map or record of indications detected or areas clear, fh) Date and time examinations were performed; )) Couplant }) Basic calibration blocks identification; ) Surface condition; ') Frequency; tm) Search Unit Type, element size and number, and pitch and gap dimensions 1) Focal low parameters, including angle, focal depth, and elements used 4) Evaluation Record Records Of any evaluations of indications shall be maintained and documented as requited by the referencing Code section. 20. ATTACHMENTS: ~ _PAUT Report (Format Code : IMAR/PAUT-01) INDUSTRIAL X-RAY & ALLIED rs RADIOGRAPHERS NIGERIALTD. | paneore PROCEDURE FOR SS PHASED ARRAY ULTRASONIC TESTING seipem ‘OF WELD JOINTS FOR AMMONIA TANK 30-101 DocNe: XARINDTPAUT-O7 - Date: S0B207E | Project Ammonia & Urea Fertilizer Complex STZ i ‘Owner: iis Dangote Ferilizer Company Ltd (OFT) Page No. 28 0f 28 EPC : Mis Saipem Location: Nigeria Contactor Paresa poeee IKARcas SEMI AUTOMATIC PHASED ARRAY(PA) | vancore = ULTRASONIC INSPECTION REPORT saipem x Date: | Project Report no: Client: - Location: Description: Maternal: Tank No: Welding Process: | | Test Specification: Weld Configuration: ‘Scan Plan: Procedure/Rev No: _| Type of scan&Scanner: EQUIPMENT DETAILS | Scanning Side: Instrument Serial No: ‘Scanning Surface/Surface Condition: Instrument Model: | Instrument Manufacturer: Basic Calibration 1D Thickness: Probe Sr.No: Reference Reflector(mm)/ Amplitude: x [Software version: robe Frequency: | index Offset: ‘Scanning overiapy T Reference level G5: | Cabla Length 7 Data Sampling spacing’ | Scanning Speed: Probe angle(s): Coupiant RECORDABLE INDICATIONS i | [ re [vomve. | waserno [SEES Tu, [ Sea | OSB] OE | TO Tome Tne | moc [I t | Lees: ACACCEP TABLE: R=TO BE REPAIRED © = ewGEDDED, S= SURFACE. Reviewed/Witnessed by ReviewediWitnessed by OPERATOR (Level PARESA ‘SAIPEM NOTLEVEL AWE [ SIGNATURE : DATE | NOTE: Geometic indication determined from weld reinforcement or Root Geomely IXAR/PAUT-01