Oil and Natural Gas Corporation Ltd.

EPCIC for the Integrated Requirement of SPS and SURF for

NELP Block KG-DWN 98/2

CONSORTIUM PROJECT NO.: (if any) Page:

MANUAL ULTRASONIC TESTING 1 of 17
PROCEDURE
DOCUMENT NO: K07NL17002-M00- Rev.1
QU-A-PRC-00054

Oil and Natural Gas Corporation Ltd.

EPCIC for the Integrated Requirement of SPS and SURF for
NELP Block KG-DWN 98/2

EPCI Contract No.

EOA/MM/SURF-SPS/K07NL17002/2018

MANUAL ULTRASONIC TESTING PROCEDURE

No. of Pages ( Including Cover Page ) : 17
ONGC/Consultant Approval ONGC/Consultant Review

1 Approved
Consultant Signature
2 Accepted with Comments, Resubmit,
Name
Work may proceed
3 Rejected, Resubmit, Work May Not Date
Proceed
4 Information only, Reviewed Not
Required, Work May Proceed
ONGC Signature
Name (ONGC)
Date

Note: Approval/ Review by PMC/OWNER/Engineering Consultant shall not absolve the CONTRACTOR of his CONTRACTUAL obligations.
CONTRACTOR is fully responsible for complying with the requirement of the CONTRACT & other relevant documents & codes / standards.
Acceptance of any document shall not be interpreted as permitting any deviation & shall in no way relieve / absolve the CONTRACTOR of
his CONTRACTUAL obligations under the terms of the CONTRACT, for correct design & execution of works.

1 02-Aug-2019 PA DMM PG IFC

Rev No Date By Checked Approved Issue Purpose

 Oil and Natural Gas Corporation Ltd.
EPCIC for the Integrated Requirement of SPS and SURF for
NELP Block KG-DWN 98/2

CONSORTIUM PROJECT NO.: (if any) Page:

MANUAL ULTRASONIC TESTING 2 of 17
PROCEDURE
DOCUMENT NO: K07NL17002-M00- Rev.1
QU-A-PRC-00054

VERSION RECORD SHEET

Revision Revision Date Purpose List of updated/modified

sections if any
04-July-2019
0 Issued for Review -

1 02-Aug-2019 Issued for Construction

HOLD LIST

No Section Description

REMARKS – This Document shall be read in conjunction with APPLUS Rtd - Doc Ref : UT 19 510
Revision: 2 – Title: MANUAL ULTRASONIC TESTING PROCEDURE
 Doc Ref : UT 19 510
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Date : 02-08-2019
Title : Manual Ultrasonic Testing Procedure
Project : KG-DWN 98/2

MANUAL ULTRASONIC TESTING PROCEDURE

Project : KG-DWN 98/2

Contractor : McDermott

Company : Oil and Natural Gas Corporation Ltd.

Scope : Manual Ultrasonic Testing of welds including thickness, lamination and repair areas.

Based on : DNVGL-ST-F101: 2017 and Client specific document 402020-01391D-01-SY-CRT-0001

.

Validity : This procedure is valid only for Manual Ultrasonic Testing of material with a surface
temperature up to 60°C

Development – Revisions
Revision No. Prepared By Date Approved By Date Amendment Details

2 G. Vermeer 02-08-2019 E. van Kessel 02-08-2019 DNV comment included.

1 N. Brasser 04-07-2019 T. Cornelissen 04-07-2019
0 N. Brasser 26-06-2019 T. Cornelissen 26-06-2019

Prepared by: Reviewed / Approved by:

Date: 02-08-2019 Date: 02-08-2019 Date:
Address
Delftweg 144, 3046 NC Rotterdam
P.O. Box 10065, 3004 AB Rotterdam
The Netherlands
www.ApplusRTD.com
This publication is the intellectual property of Applus+ RTD and may not be used in whole or in part for any purpose other than the
business of Applus+ RTD and may not be used for the business of the recipient and may not be passed to any other person without
the permission of Applus+ RTD.

Applus+ RTD Global Project Services

If this is a copy, unless otherwise specified, it is uncontrolled. You must verify the revision before use.
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Contents
1 Purpose 5
2 Scope 5
3 References 5
Applus+ RTD Documents 5
Codes and Standards 5
Pipeline Contractor / Company Specific Documents 5
Abbreviations and Definitions 5
4 Personnel Qualifications 6
5 Safety 6
6 Equipment 7
Ultrasonic Flaw Detector 7
Periodical Verifications 7
Probes 7
International Calibration Block 8
Project Specific Reference Block 8
Couplant 8
7 Calibration 9
Calibration Control 9
Time Base Calibration 9
Reference Sensitivity 10
Transfer Correction 10
Scanning Sensitivity 10
Signal to Noise Ratio 10
8 Testing 11
Surface Preparation 11
Probe Movement, Direction and Scanning Speed 11
Probe Angles 11
Parent Material Testing 11
Weld Testing 11
9 Acceptance Criteria 12
10 Reporting 12
Project Specific Reference Block 13
Reference Block PIN: 2019|8.625|12.7|137762-MUT-301 13
Reference Block PIN: 2019|15|20.6|137762-MUT-302 14
Probe Movement and Direction 15
Example of Report 16
Acceptance Criteria 17

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1 Purpose
The purpose of this procedure is to detail the methodology used for the Ultrasonic Testing (UT), based on the
requirements of Pipeline contractor / Company specific documents No. 2020-01391D-01-SY-CRT-0001 and the
Offshore Standard DNVGL-ST-F101: 2017 during the KG-DWN 98/2 Project.

2 Scope
This procedure details the methods for UT of welds including thickness measurement, lamination check and
repair areas of the Carbon steel pipes, diameter 6” up to 24” and wall thickness between 10 mm up to 25 mm.

3 References
Applus+ RTD Documents
• PIPL-12.03.0004 Rev.0 Control Procedure for Ultrasonic Flaw Detectors.
• NL-10 Written practice for the training, qualification, certification and authorization
of NDT personnel.

Codes and Standards

• DNVGL-ST-F101: 2017 Submarine Pipeline Systems.
• ISO 17640: 2013 Non-destructive testing of welds – Ultrasonic testing – Techniques, testing
levels and assessment.
• ISO 16811: 2014 Non-destructive testing – Ultrasonic examination – sensitivity and
range setting
• ISO 9712: 2012 General requirements for qualification of NDT personnel.

Pipeline Contractor / Company Specific Documents

• 402020-01391D-01-SY-CRT-0001 General Requirements for Welding and Non-Destructive Testing
– SURF & SPS.
• 402020-01391-01-QA-CRT-0001 General Requirements for Quality Assurance and Quality control.

Abbreviations and Definitions

• BWE Back-Wall Echo.
• Calibration of the Manual Ultrasonic Testing equipment is performed on calibration blocks for linearity
checking, sweep range.
• Calibration Blocks blocks with known dimensions and material sound velocities as defined by
International and European standards for the ultrasonic testing.
• Company shall mean owner and shall include their engineering agencies, inspectors and other authorized
representatives.
• DAC Distance Amplitude Correction. Is the Electronic change of amplification to provide equal amplitude
from equal reflectors at different depths.
• DAC Curve a curve constructed from the peak amplitude responses from reflectors of equal area at
different distances in the same material.
• Defect is an imperfection of sufficient magnitude to warrant rejection based on the criteria referenced by
this procedure.
• Depth of the imperfection is the through-wall distance of the imperfection as measured from the OD of
the pipe, with the highest amplitude.
• Evaluation level is the pulse-echo level from which imperfections should be evaluated.
• FSH Full Screen Height.
• HAZ Heat Affected Zone.
• ID Inside Diameter.
• Indication is evidence obtained by non-destructive testing.
• Imperfection is a discontinuity or irregularity that is caused by the welding process and is not related to
weld profile indications.
• May is a verbal form used to indicate a course of action permissible within the limits of the procedure.
• NDT Non Destructive Testing.

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• Shall is a mandatory term, from which no deviation is permitted.

• Should indicates that among several possibilities, one is recommended as particularly suitable, without
mentioning or excluding others, or that a certain course of action is preferred but not necessarily required.
• Stacked Imperfection consists of multiple discrete imperfections in different weld passes occurring at
the same circumferential location.
• OD Outside Diameter.
• Pipeline Contractor is company fabricating pipeline.
• PPE Personal Protection Equipment.
• Procedure is a step-by-step description of the application of a NDT method.
• Reference Reflector is a known dimension relative to the UT set-up required sensitivity.
• Reference Sensitivity is the initial sensitivity applied to any reference reflector as applicable.
• Reference Block is made out of project specific pipe material under inspection with the inclusion of known
reference reflectors relevant to the required sensitivity.
• Repair is any rework on a completed weld that requires welding to correct a fault in the weld that has
been discovered by visual or non-destructive testing and is beyond the limits of acceptability.
• Scanning Sensitivity is the sensitivity level at which the material is tested (reference + additional gain
as specified).
• SDH Side Drilled Hole.
• SMLS Seamless.
• Stacked Imperfection consists of multiple discrete imperfections in different weld passes occurring at
the same circumferential location.
• Through Wall Height dimensions of the imperfection will be called the “Vertical Height” of the
imperfection.
• UT Ultrasonic Testing.
• UT Contractor shall mean “Applus+ RTD”.
• UT Personnel/Operator refers to the person responsible for all aspects of the inspection, recording and
interpretation of result
• WPS is Welding Procedure Specification.

4 Personnel Qualifications
Personnel shall be qualified in accordance to Applus+ RTD regional “Written Practice” for the training,
qualification, certification and authorization of NDT Personnel.
Only personnel qualified to UT Level 2 as minimum, ISO 9712 shall interpret the test results.

5 Safety
All work shall be performed in accordance with Applus+ RTD safety policies including all national, local safety
rules and regulations including any Client Specific Health and Safety programs. All personnel shall be aware
that they have a responsibility to work safely and prevent others working in an unsafe manner.
All portable electronic equipment shall be electrically tested in accordance with Applus+ RTD/Client
regulations.
The equipment is non-intrinsically safe and the data acquisition unit can be damaged by water. Both these
points shall be taken into account when planning or performing data collection.
Batteries shall not be replaced in any area of live plant or where gas or other explosive materials may be
present.
All technicians shall wear proper PPE in the manner that they were designed to be used. Any defective PPE
shall be replaced immediately.
Information regarding the Applus+ RTD occupational Health and Safety program can be obtained from the
Project Health and Safety Management Plan.

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6 Equipment
Ultrasonic Flaw Detector
An ultrasonic flaw detector with a DAC curve facility, with valid verification report according to the control
procedure PIPL-12.03.0004, and shall have the following minimum capabilities:
• Be applicable for the pulse echo technique and for the double probe technique.
• Cover as a minimum the frequency range from 1 to 6 MHz.
• Have a calibrated gain regulator with maximum 2 dB per step over a range of at least 60 dB.
• Have a flat screen accessible from the front for direct plotting of reference curves or be equipped with
digital DAC- display presentation of user-defined curves.
• Allow echoes with amplitudes of 5% of FSH to be clearly detectable under test conditions.

Periodical Verifications
The Amplitude Control, Screen Height and Time Base Linearity shall be checked for correct verification at the
beginning of each period of extended use or every 3 months, whichever is less according to the control
procedure PIPL-12.03.0004.

Probes
All probes shall be checked before and after use and at approximately four-hourly intervals for correct angles,
beam alignment and surface. Probes not in compliance to the requirements described in section 7.1 of this
procedure shall be corrected or withdrawn from service.

6.3.1 Angled Beam Shear Wave Probes

For material thickness ≤ 25 mm a 45°, 60° and 70° with a Frequency of 4MHz, dimension ~ 10 mm probes
shall be used.
Transverse testing should be performed with the 45°/60° probe.

6.3.2 Straight Beam Longitudinal Wave Probes

For material thickness < 60 mm a Twin crystal 0º with a Frequency of 4MHz, dimension ~ 10 mm probes shall
be used.

6.3.3 Adaptation of Probes to Curved Surfaces

The gap between the test surface and the bottom of the probe shoe shall not be greater than 0.5 mm.
For cylindrical or spherical surfaces the requirement will normally be met when the following equation is
fulfilled:
D ≥ 15 A
Where:
D = the diameter in millimeters of the curved surface.
A = the dimension in millimeters of the probe shoe in the direction of scanning.
If this requirement cannot be obtained the probe shoe shall be adapted to the surface and the sensitivity and
time base shall be set accordingly.

6.3.4 Co-axial Cable

The co-axial cables shall be maintained in good condition and connections shall be protected by shrink-
wrapping. The cables shall be between two and three metres in length.

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International Calibration Block

The International Institute of Welding (IIW) or EN ISO calibration blocks (No. 1 and or No2) shall be used for
sweep range calibration and angle determination.

Project Specific Reference Block

Project specific reference block(s) shall be used for construction a DAC and sensitivity settings.
For project specific reference block design, refer to Attachment – A.
For wall thicknesses from 10 mm up to 15 mm reference block with PIN No. 2019-8.625-12.7-137762-MUT-
301 shall be used.
For wall thicknesses from 15 mm up to 25 mm reference block with PIN No. 2019-15-20.6-137762-MUT-302
shall be used.

Couplant
Water or Ultrasonic Gel shall be used as couplant and the same coupling medium is to be used for both
calibration and testing.
Manufacturers data sheets/COSHH sheets shall be available upon request, ensuring that the couplant utilized
will have no detrimental effect to the pipe material or the MUT Operator and that all traces of couplant utilized
will be removed post inspection works.

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7 Calibration
Calibration Control
Interval
Before and after use and at approximately four-hourly intervals, the range scale, probe angle and primary gain
must be checked and confirmed. Checks shall also be carried out whenever a system parameter is changed or
changes in the equivalent settings are suspected.
Correction
If deviation is found to be larger than 2% of range scale, or 4 dB of primary gain setting or 2° of nominal
probe angle, the equipment shall be re-calibrated and the testing carried out with the equipment over the
previous period shall be repeated. Re-calibration shall be performed whenever the equipment has been out
function for any reason including on-off and whenever there is any doubt concerning proper function of the
equipment.

Time Base Calibration

The International Institute of Welding (IIW) or EN ISO calibration blocks (No. 1 and or No2) shall be used for
establishing the probe exit point, determination of the nominal beam angle and the zero offset:
Probe exit point
The transducer is positioned on the calibration block and moved parallel to the sides of the block until the
maximum echo is obtained from the curved quadrant. The transducer index point is then directly above the
centre of the quadrant (refer to Figure 1). This point should be marked with a scribe on the side of the
transducer.

Figure 1 Determination of probe exit point

Determination of nominal beam angle (+/- 2°)
Using the IIW block, obtain a maximized echo signal from the 1.5 mm diameter hole. When the echo is at a
maximum, the angle can be determined with the values as shown in the figure below filled in in the following
formula (refer to Figure 2):
Tan α = (Z4+X-35) / 15.

Figure 2 Determination of probe exit point

Zero offset
Calibrating of the radius for angled probes and through thickness for 0º probes of known distance (100 mm /
25 mm) determine the zero offset.
Initial sweep range setting
Set the screen range for shear wave probes to cover a minimum of 1½ skip distance.

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Reference Sensitivity
The angled beam probes sensitivity shall be based on a minimum of a 3-point reference level DAC, ensuring
the whole weld volume is inspected.
The initial sensitivity setting shall be established over half skip distance by obtaining a minimum response of
80% FSH from the SDH. Without changing this sensitivity setting, obtain maximum amplitudes from the SDHs
between half and full skip distance. Mark the peaks of each maximized echo on the screen.
Connect the screen marks to provide the DAC.
If only one side of the weld is accessible for testing, the reference sensitivity shall be increase with 6dB.

7.3.1 Establishing Reference Curves

The timebase is first calibrated to accommodate the maximum sound path length to be used, and the gain is
adjusted so that the echoes from the series of reflectors fall within 20% and 80% of FSH. In the case of angle
probes, the reflectors may be used in either the 0 to ½ skip, or ½ to 1 skip positions.
The DAC must be constructed so that the range covers the required beam path for testing of the complete
weld volume.
The first point of DAC shall be selected such that the distance in sound path from the probe index to the drilled
hole is not less than 0.6 N where N is the near field length of the relevant probe.
The position of the tip of each maximized echo, at a constant gain setting, is then marked on the screen, and
the DAC drawn through the points.
If the difference in height between the largest and smallest echoes exceeds the range 20% to 80% FSH, the
line shall be split, and separate curves plotted at different gain settings (see Figure 3). The difference in gain
between the two curves shall be recorded on the screen.
The gain setting used for plotting the DAC may be referenced to the echo from some other reflector, e.g. in
the case of flat probes to either the 100mm radius quadrant, or the 3 mm diameter hole in Calibration Block
No. 1. This will enable the gain to be reset, in future, without the use of the reference block.

Figure 3 Screen of ultrasonic instrument showing a split DAC

Transfer Correction
Due to the use of a project specific reference block a transfer correction is not required.

Scanning Sensitivity
Scanning sensitivity shall be reference sensitivity (section 7.3) + 6 dB (additional scanning sensitivity).
For the evaluation of an in imperfection the +6 dB (additional scanning sensitivity) shall be removed.

Signal to Noise Ratio

• Electronic noise shall be lower than acoustical noise in all sequences.
• For probes, the acoustical noise should be at least 16 dB weaker than the reference signal from the
reference reflector.

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8 Testing
Surface Preparation
The temperature difference during calibration and testing shall be within +/- 14°C. Temperature of the object
under testing shall not exceed 60°C.
The base material, both sides of the weld, shall be cleaned by either power wire brushing and/or filing to
remove all weld spatters, dirt, rust, loose scale and other irregularities that may interfere with the testing. The
ultrasonic operator shall determine whether the surfaces have been adequately cleaned.

Probe Movement, Direction and Scanning Speed

Probe movements, directions and scanning speeds are documented in Attachment - B and shall be followed.

Probe Angles
The probe angles to be chosen shall be according the DNVGL-ST-F101, table D-2 as shown below.

Parent Material Testing

Calibrate the flaw detector screen range to 50mm or appropriate screen range using the straight beam (0°)
probe.
The reference sensitivity for this testing shall be performed 2nd BWE from the relevant reference block
adjusted to at least 75% FSH.
A straight beam (0°) probe shall be used to examine the parent metal, both sides of the weld, for a minimum
surface distance of 1½x the longest angle beam surface skip distance to be scanned. This shall be carried out
prior to inspection by any angle probes. All partial and full beam reflectors found that may interfere with angle
beam testing shall be noted on the UT Report (refer to Attachment C).

Weld Testing
Using the probes detailed in section 6.3 and following sections 6 to 8 investigate any relevant indications
exceeding 20% DAC reference curve (evaluation level).
All indications exceeding 20% of the DAC reference curve are to be evaluated and all indications exceeding
50% DAC are to be reported. Investigation is to be performed to the extent that the operator can determine
the shape and location of the indication.
Ultrasonic inspection must be considered from all surfaces i.e. ID and OD where possible. Weld configurations
may exist where access for ultrasonics is restricted i.e. flange welds, the UT report must clearly identify these
ultrasonic restriction(s).
Indication length evaluation:
• Establish the maximum amplitude on the indication,
• Move the probe parallel with the weld until the amplitude drops to the evaluation level (DAC -6dB) and
mark position,
• Establish the maximum amplitude on the indication,
• Move the probe parallel with the weld until the amplitude drops on the other side of the indication to the
evaluation level (DAC -6dB) height and mark position,
• The indication length is the distance between the marked points.
Weld configurations may exist where access for ultrasonic is restricted i.e. flange welds, the UT Report must
clearly identify these ultrasonic restriction(s). Ultrasonic inspection must be considered from all surfaces i.e.
ID and OD.

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9 Acceptance Criteria
The acceptance criteria shall be according DNVGL-ST-F101, table D-6 as shown in Attachment D.

10 Reporting
For each inspection all information shown on the report format in Attachment - C shall be recorded.

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Project Specific Reference Block

Reference Block PIN: 2019|8.625|12.7|137762-MUT-301

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Reference Block PIN: 2019|15|20.6|137762-MUT-302

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Probe Movement and Direction

Movement A : Rotation angle a is approximately 10º.

Movement B : Scanning distance b shall be such, that the entire weld volume and adjacent
base material is examined.
Movement C : Distance c shall overlap a minimum of 10% of the transducer dimension
` perpendicular to the direction of the scan.
Movement D : Scanning pattern for transverse reflectors (45º probe in two directions) if cap is
flushed.
Movement E : Scanning pattern for transverse, when the weld-surface is too rough
(unflushed), rotation angle is approximately 15º (from two sides of the weld).
Note:
Movement A, B and C are combined in one probe movement.
The choice of scanning speed shall take into consideration the pulse repetition frequency and the ability of the
operator to recognize or of the instrument to record signals.

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Example of Report

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Acceptance Criteria

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