QUALITY CONTROL PROCEDURE

SUBJECT ULTRASONIC PROCEDURE for THICKNESS MEASUREMENT

PROCEDURE No. AMSYCO 500–5–1

REVISION NO. 07

DATE OF FIRST ISSUE APRIL 03, 1997

DISTRIBUTION OF CONTROL COPIES

PROJECT SAMAC MMA-PMMA PROJECT

CONTRACT

COPY # 1 AK and Partners Company Limited

COPY # 2 CTCI ARABIA LTD. & CTCI CORPORATION

COPY # 3 N/A

REVISION DATE
01 April 10, 1997
02 April 19,2004
03 July 18, 2006
04 July 15, 2007
05 January 12, 2010
06 January 11, 2012
07 December 29, 2012
 Procedure No. : AMSYCO 500-5-1
First Issue Date : April 03, 1997
Revision No. : 07
Revision Date : December 29, 2012
TITLE: ULTRASONIC PROCEDURE for
Page 1 of 7
Thickness, Corrosion and Lamination Measurement

TABLE OF CONTENTS

1. SCOPE

2. REFERENCE

3. PERSONNEL QUALIFICATION

4. SURFACE CONDITION

5. COUPLANT

6. EQUIPMENT

7. PROBES

8. GENERAL EXAMINATION REQUIREMENTS

9. BASIC CALIBRATION(S)

10. EXAMINATION

11. POST CLEANING

12. ACCEPTANCE STANDARDS

13. DOCUMENTATION

ATTACHMENT

ATTACHMENT-1 REPORT FORMAT

 Procedure No. : AMSYCO 500-5-1
First Issue Date : April 03, 1997
Revision No. : 07
Revision Date : December 29, 2012
TITLE: ULTRASONIC PROCEDURE for
Page 2 of 7
Thickness, Corrosion and Lamination Measurement

1. SCOPE

1.1. This procedure describes the general instructions for manual Ultrasonic Corrosion Scanning
and Thickness Gauging of base materials in plates, tubings, pipes, tanks, vessels, castings and
forgings having a nominal wall thickness of 2.0 mm to 150 mm (6 in.) in accordance with the
referenced Codes and Standards.

2. REFERENCE

2.1. ASME Boiler and Pressure Vessel Code, Section V (2010 ed., 11 a.)

2.2. ANSI/ASNT CP-189 NDT Personnel Qualification and Certification (2006 ed.)

2.3. SE-797 Standard Practice for Thickness Measurement by manual contact ultrasonic method

2.4. ASME Section I Rules for Construction of Power Boiler (2010 ed., 11 a.)

2.5. ASME Section VIII, Div.1 Rules for Construction of Pressure Vessels (2010 ed., 11 a.)

2.6. ASME B31.1 Power Piping (2010 ed.)

2.7. ASME B31.3 Process Piping (2010 ed.)

2.8. ASME B31.4 Liquid Transportation Systems for Hydrocarbons (2009 ed.)

2.9. ASME B31.8 Gas Transmission and Distribution Piping Systems (2010 ed.)

2.10. API 1104 Standard for Welding pipelines and Related Facilities (20th ed. 2005)

2.11. API 650 Welded Steel tanks for Oil Storage (11th ed. 2007, 2009 a.)

2.12. API 620 Design and Construction of Large, Welded, Low-Pressure Storage
Tanks (11th ed. 2008)

2.13. API Spec 5L Specification for Line Pipe (44th ed.)

3. PERSONNEL QUALIFICATION

3.1. All personnel performing and reporting the results of the Ultrasonic Thickness Measurements
shall be qualified and certified to Ultrasonic Testing Level-II or Ultrasonic Thickness Testing
Level-II in accordance with written practice AMSYCO 101-001, Rev. 09 dated January 6, 2010
(Training Manual AMSYCO TP-1) prepared in accordance with ASNT CP-189 (2006 ed.).

4. SURFACE CONDITION

4.1. All testing surfaces shall be clean and free of scale, dirt, grease, paint, weld spatter or other
foreign material that could interfere with test results.

4.2. Excessive surfaces roughness or scratches can produce signals that interfere with the test and
shall be ground smooth.

4.3. Where coatings interfere with the UTT examination, the coating shall be removed and
recorded in the report.
 Procedure No. : AMSYCO 500-5-1
First Issue Date : April 03, 1997
Revision No. : 07
Revision Date : December 29, 2012
TITLE: ULTRASONIC PROCEDURE for
Page 3 of 7
Thickness, Corrosion and Lamination Measurement

5. COUPLANT

5.1. Couplant having good wetting characteristics such as motor oil SAE No. 20 or No. 40, glycerine,
pine oil, Ultra gel-II, cellulose gum or water shall be used.

Whenever the temperature of the pipe is above ambient, a high temperature couplant of the
following type from Krautkramer or equivalent shall be used:
ZGT Multigrade Couplant Temperature Range -30°C to +250°C
ZGM High Temperature Couplant, Temperature +200°C to +600°C

5.2. Couplants may not be comparable to one another. Same couplant shall be used for calibration
and examination.

5.3. Rust inhibitors, softeners and wetting agents may be added to the couplant.

5.4. Couplant selection shall depend on chemical compatibility with the surface and the temperature
of the specimen. For nickel base alloys, sulfur content shall be limited to 250 ppm. For austenitic
stainless or titanium, halides (chlorides + fluorides) shall be limited to 250 ppm.

6. EQUIPMENT

6.1. Any one of the following equipment shall be used for thickness measurement in accordance
with this procedure:

Pulse-echo type A-scan Ultrasonic Equipment (flaw detectors) capable of generating

frequencies in the range of 1~10 MHz, Krautkramer, USM 35X DAC or Olympus-EPOCH XT.

or

Ultrasonic Thickness meter with A-scan display, Krautkramer, Model DMS2E.

Instrument manufacturer’s operating instructions shall be available to the operator.

6.2. Equipment shall be calibrated every 3 months for analog type and one year for digital type in
accordance with the manufacturer’s recommendations.

6.3. Thickness measurement equipment (DMS2E) shall not be used for Corrosion and
Lamination scanning.

6.4. Frequency (A-scan Equipment): The scanning and measurement shall be conducted with an
ultrasonic, pulsed reflection system generating frequency of 1~5 MHz. Other frequencies may
be used if equal or better sensitivity can be demonstrated.

6.5. Screen Height Linearity: The ultrasonic instrument shall provide linear vertical presentation
within ±5% of the full screen height for 20% to 80% of the calibrated screen height (base line
maximum calibrated screen points).

6.6. Amplitude Control Linearity

The ultrasonic instrument shall utilize an amplitude control accurate over its useful range to
±20% of the nominal amplitude ratio to allow measurement of indications beyond the linear
range of the vertical display on the screen.
 Procedure No. : AMSYCO 500-5-1
First Issue Date : April 03, 1997
Revision No. : 07
Revision Date : December 29, 2012
TITLE: ULTRASONIC PROCEDURE for
Page 4 of 7
Thickness, Corrosion and Lamination Measurement

6.7. Horizontal Linearity

The horizontal linearity of the instrument shall be within 2% of full scale.

7. PROBES

7.1. The probes used shall be of the following size and frequency. Manufacturer’s data sheet shall
be verified for compatibility with the read out equipment and model for use in the operating
range with the temperature of the part and cable used:

Compressional 0°, 1~5 MHz, 5~25 mm Ø, Single/Twin crystal for A-scan equipment
Twin probe 0°, 1~5 MHz, 10 mm Ø, Model D790 for high temperature up to (500°C) 932°F

8. GENERAL EXAMINATION REQUIREMENTS

8.1. Examination Coverage – The volume shall be examined by moving the probe unit over the
examination surface so as to scan the entire examination volume. Each pass of the probe unit
shall overlap a minimum of 10% of the probe.

8.2. Rate of Search Unit Movements – The rate of probe unit movement for examination shall not
exceed 6 inches/second unless calibration is verified at scanning speed.

8.3. Method – The examination shall be performed by the direct contact method.

9. BASIC CALIBRATION(S)

9.1. The proper functioning of the system shall be checked and the calibration of the equipment shall
be verified at the beginning and end of each shift; every four (4) hours during the examination;
when any personnel and or equipment change; and at any time that malfunctioning is
suspected.

9.2. The calibration blocks shall have a sound velocity within ±5% of the material to be tested. When
absolute precision is required calibration shall be performed on blocks made of the same
material being tested or on known thickness values of the specimen.

9.3. The equipment shall be calibrated using a two-point calibration range that overlaps the
expected measurement range, i.e., select a calibration block or step wedge thickness
value greater than the maximum expected measurement value and a calibration block or
step wedge value less than the expected measurement value.

9.4. All calibration values shall be within ±0.002 inch of the known thickness value.

9.5. If at the end of the shift the instrument has drifted more than 0.002 inches consideration should
be given to retaking all of the measurements since the last calibration.

9.6. Button-type calibration blocks, on the front of some ultrasonic thickness gauges, shall not be
used for calibration.
 Procedure No. : AMSYCO 500-5-1
First Issue Date : April 03, 1997
Revision No. : 07
Revision Date : December 29, 2012
TITLE: ULTRASONIC PROCEDURE for
Page 5 of 7
Thickness, Corrosion and Lamination Measurement

10. EXAMINATION

Surface Preparation: Discretion should be used when evaluating the cleaning requirements of each
application, as many corrosion-monitoring applications require readings to be taken in the same
condition, i.e., coated, as when originally measured.

The extent, type, and data reporting needs of the examination shall be determined by the inspector
and communicated to the NDT examiner prior to the test.

10.1. Thickness Measurement with A-scan display

Normal probe with single element: The display start is synchronized with the initial pulse. A
minimum of two thicknesses that covers the range of thickness to be measured shall be used.
The single crystal normal probe is placed on the material of known thickness and the full screen
is adjusted to the convenient range by taking echoes and using the sweep and delay control of
the instrument. The readings shall be verified by using lesser thickness to improve the accuracy.

Normal probe with twin crystal: In case of using the twin crystal, the step wedge or V1
representing the range of thickness to be measured with at least two thicknesses is used. Place
the probe on a lower thickness and adjust the backwall echo to the division corresponding to the
thickness on the screen. Then place the probe on the higher thickness and adjust the range
control to bring the backwall echo to the required division of the screen, repeat the same till the
screen is adjusted for both the thickness. The calibration of the screen is verified using a
thickness in between. Measurement of the thickness shall then be made on the job and
recorded.

10.2. Thickness Measurement at High Surface Temperature

Thickness measurement at high temperature shall be done by specially designed probes,
assemblies and couplants. Equipment, couplant, cable and probes are selected as per the
manufacturer’s recommendations.

Note: For high-temperature measurements, couplant should always be applied to the face of the
probe, not the hot part.

The measured thickness at high temperature will be more than the actual thickness by a factor
of about 1% per 55°C (131°F). Thus if the instrument was standardized on a block at 35°C, and
if the temperature of the surface reading was 145°C, the reading should be reduced by 2%.

The calibration of the equipment is made on the block at ambient temperature. Then the
measurement is made on the job and the temperature difference between the block and the job
is found. Temperature correction shall be performed for material thickness greater than 1 inch
for temperatures below 32°F and over 215°F as follows:

Ta = Tm x [1.007 – (0.0001 X Temp)]

where:
Ta = actual thickness of the part
Tm = measured thickness of the part
Temp = surface temperature in °F

11. POST CLEANING

11.1. All water based couplant shall be completely removed from the specimen, i.e., wiped with a
dry absorbent cloth or paper towel, fresh water, etc.
 Procedure No. : AMSYCO 500-5-1
First Issue Date : April 03, 1997
Revision No. : 07
Revision Date : December 29, 2012
TITLE: ULTRASONIC PROCEDURE for
Page 6 of 7
Thickness, Corrosion and Lamination Measurement

12. ACCEPTANCE STANDARDS

12.1. The acceptance criteria for thickness of the pipes shall be based on the applicable Codes and
Standards as required by the client.

13. DOCUMENTATION

13.1. A record of inspection itemizing test conditions and findings shall be maintained on report form
“Ultrasonic Testing Report” (Attachment-1) and made available to the customer or inspection
agency concerned. A copy of this procedure shall be readily available with the NDT personnel
performing these functions.

13.2. The following minimum data shall be recorded at the time of each test:

13.2.1. procedure identification and revision

13.2.2. model no. and type of instrument (including serial number)

13.2.3. size, frequency, and type of search unit used

13.2.4. surface preparation and couplant

13.2.5. calibration blocks

13.2.6. identification and location of material measurements

13.2.7. surface from which examination is conducted

13.2.8. maximum and minimum thickness measurements

13.2.9. personnel data, certification level

13.2.10. date examinations were performed

 Procedure No. : AMSYCO 500-5-1
First Issue Date : April 03, 1997
Revision No. : 07
Revision Date : December 29, 2012
TITLE: ULTRASONIC PROCEDURE for
Page 7 of 7
Thickness, Corrosion and Lamination Measurement

Attachment -1