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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Document No.: POS-WHP-E1-Q-P-0007

AlphaNDT/ PTSC POS REV. NO.

DATE

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23.3.20

PREPARED BY NAME

D.X.M

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DATE 20.3.20

CHECKED BY NAME

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JVPC APPROVED BY NAME

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CHECKED BY NAME

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APPROVED BY NAME

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 1 of 35 Date: 23/3/2020

REVISION RECORD SHEET NO.

REV. NO.

CONTENT OF REVISION

DATE OF REVISION

1

0

Issued for Approval

23.03.2020

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PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 2 of 35 Date: 23/3/2020

TABLE OF CONTENTS SECTION

DESCRIPTION

PAGE

1.0

SCOPE ................................................................................................................................................................. 3

2.0

DEFINITIONS AND ABBREVIATIONS ............................................................................................. 4

3.0

REFERENCE.................................................................................................................................................... 4

4.0

ESSENTIAL VARIABLES OF PROCEDURE .................................................................................. 4

5.0

PERSONNEL QUALIFICATION ........................................................................................................... 6

6.0

EQUIPMENT.................................................................................................................................................... 6

7.0

CALIBRATION BLOCK ............................................................................................................................ 9

8.0

TECHNIQUES ............................................................................................................................................... 12

9.0

CALIBRATION ............................................................................................................................................. 13

10.0 EXAMINATION............................................................................................................................................ 20 11.0 SIZING METHOD OF FLAW LENGTH. ......................................................................................... 21 12.0 SIZING METHOD OF FLAW HEIGHT ............................................................................................ 22 13.0 DISCRIMINATION GEOMETRIC OF FLAW INDICATIONS ............................................. 23 14.0 SCAN PLAN .................................................................................................................................................... 27 15.0 PROCEDURE QUALIFICATION ........................................................................................................ 27 16.0 RECORDING/EVALUATION LEVEL .............................................................................................. 27 17.0 ACCEPTANCE CRITERIA ..................................................................................................................... 28 18.0 DOCUMENTATION ................................................................................................................................... 29 19.0 RECORDS ........................................................................................................................................................ 30 APPENDIX 1 - PAUT REPORT .......................................................................................................................... 32 APPENDIX 2– ACCEPTANCE CRITERIA IN ACCORDANCE WITH TABLE K341.3.2 .......................................................................................................................................................................... 34

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Revision No.: 0

1.0

Page 3 of 35 Date: 23/3/2020

SCOPE -

This procedure provides the requirements for phased array ultrasonic examination using Olympus NDT Omniscan MX or MX2 Phased Array System utilizing an auto or semiauto scanner for the examination of welds in process piping.

-

This procedure is prepared in accordance with ASME V Article 4, Mandatory Appendix VII “Ultrasonic Examination Requirements for a Workmanship Based Acceptance Criteria”, and ASME B31.3 for welded joint.

-

This procedure also shall comply in with ASME Section VIII, Division 3, KE-301 and KE-302 for high pressure component.

-

This procedure shall be used for detecting, locating and evaluating indications within the welds and heat affected zone using the contact inspection technique for carbon steel and alloy steel with material with as list below.

-

For locations where PAUT probes will be inaccessible due to the welding joint space limitation, RT will be used. Table 1: List of piping joints No.

OD Inch

Thickness mm

Configuration

Material

Pipe to pipe & pipe to fitting

ASTM A106 Gr.B/ ASTM A234 Gr.WPB/ ASTM A105

Pipe to pipe & pipe to fitting

ASTM A106 Gr.B/ ASTM A234 Gr.WPB/ ASTM A105

Pipe to pipe & pipe to fitting

ASTM A106 Gr.B/ ASTM A234 Gr.WPB/ ASTM A105

pipe to pipe & pipe to fitting

ASTM A106 Gr.B/ ASTM A234 Gr.WPB/ ASTM A105

pipe to pipe & pipe to fitting pipe to pipe & pipe to fitting

ASTM A106 Gr.B/ ASTM A234 Gr.WPB/ ASTM A105 ASTM A106 Gr.B/ ASTM A234 Gr.WPB/ ASTM A105

SCH STD 1

2"

SCH 160 SCH XXS SCH STD SCH 120 SCH 160 SCH STD SCH 120 SCH XXS SCH STD SCH 120 SCH 160

2

3"

3

4"

4

6"

5

8"

SCH STD

6

14"

SCH STD

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2.0

3.0

4.0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 4 of 35 Date: 23/3/2020

DEFINITIONS AND ABBREVIATIONS -

UT: Ultrasonic Testing

-

ASME: American Society of Mechanical Engineers

-

TCG: Time-Corrected Gain

REFERENCE -

ASME Section V, Article 1 and Article 4, 2017 edition.

-

TQ No.:0009.

-

ASME B31.3 2016 Edition;

-

ASME Section VIII, div. 3 2017 edition

-

ASME Section V, Article 23, 2017 edition, SE2491 Guide for Evaluating Performance Characteristics of Phased-Array Ultrasonic Testing Instruments and Systems

-

SNT-TC-1A, 2016 edition;

-

SNT-TC-1A, 2006 edition;

-

ISO 9712, 2012: Non Destructive Testing-Qualification and Certification of NDT Personnel

-

AlphaNDT’s Written Practice No: 8408-30-01 Rev.08E.

ESSENTIAL VARIABLES OF PROCEDURE Essential variables of this Phased Array Ultrasonic Examination Procedure will be as per the descriptions on the table 2 below: This procedure shall be re-qualified whenever there is a change in one or more essential variable.

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PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Revision No.: 0

Page 5 of 35 Date: 23/3/2020

Table 2: essential variables Nonessential Variabl e

Procedure Paragraph No.

Remark

X

…

Table 1

Butt welded

The surfaces from which the examination shall be performed

X

…

9.4

…

3

Technique(s) straight beam, angle beam, contact, and/or immersion)

X

…

7.0

…

4

Angle(s) and mode(s) of wave propagation in the material

X

…

7.0

…

5

Search unit size(s)/shape(s)

X

…

Table 4

…

6

Special search unit, wedge, shoes or saddles, when used

X

…

Table 4

…

7

Ultrasonic instrument(s)

X

…

1.1, 5.1

Omni MX2

8

Calibration (calibration block(s) and technique(s)

X

…

Table 5

ASME Block

9

Direction and extent of scanning

X

…

9.3

…

10

Scanning (manual vs. automatic)

X

…

1.1, 5.6

Manual/ Auto/ Semi Auto

11

Method for discrimination geometric from flaw indications

X

…

12.0;

…

12

Method for sizing indications

X

…

10.0; 11.0

…

13

Computer enhance data acquisition, when use

X

…

5.4

Tomoview software

14

Scan overlap (decrease only)

X

…

9.0

Minimum 50mm

15

Personnel performance requirements, when required

X

…

4.0

…

16

Personnel qualification requirements

…

X

…

…

17

Surface condition (examination surface, calibration block)

…

X

…

…

18

Couplant: brand name or type

…

X

…

…

19

Automatic alarm and/or recording equipment, when applicable

…

X

…

…

20

Records, including minimum calibration data to be recorded (e.g., instrument settings)

…

X

…

…

21

Scan plan

X

...

13.0

…

22

Computer software

X

...

5.4

…

23

Scanning technique (automated vs. semi automated)

X

...

Table 6

…

24

Flaw characterization methodology

X

…

12.0

…

Flaw sizing (length, height) methodology

X

…

10.0; 11.0

…

Essential Variable

No.

Requirement

1

Weld configurations to be examined, including thickness dimensions and base material product form (pipe, plate, etc)

2

25

type(s),

frequency(ies),

and element

Scan

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5.0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

26

Search unit mechanical fixturing device (manufacturer and model)

X

27

Scanner adhering and guiding mechanism

X

...

Page 6 of 35 Date: 23/3/2020 7.0

Olympus

…

…

PERSONNEL QUALIFICATION The test will be carried out and results shall be evaluated and reported by the phased array ultrasonic technicians qualified and certified as level II or level III in accordance with AlphaNDT’s Written Practice, Document No: 8408-30-01, Rev. 08E or Certify body in accordance with ISO 9712 as BINDT, TWI… Only qualified UT personnel trained in the use of the equipment and who have demonstrated the ability to properly acquire examination data, shall conduct production scans. Personnel who analyze and interpret the collected data shall be a Level II or III who have documented training in the use of the equipment and software used.

6.0

EQUIPMENT

6.1

PHASED ARRAY INSTRUMENT. -

OLYMPUS MX AND MX2 as specification as table 3 shall be used.

Table 3: PHASED ARRAY EQUIMENT MAINFRAME AND PHASED ARRAY MODULE SPECIFICATIONS Overall dimensions (W x H x D) General Weight

Data Storage

I/O Ports

Storage devices Data file size USB ports Audio alarm Video output Ethernet Encoder

I/O Lines

Digital input Digital output Acquisition on/off switch Power output line Alarms Analog output

325 mm x 235 mm x 130 mm (12.8 in. x 9.3 in. x 5.1 in.) 3.2 kg (7 lb), no module and one battery SDHC card*, most standard USB storage devices, or fast Ethernet. *Lexar® brand memory cards are recommended for optimized results. 300 MB 3 Yes Video out (SVGA) 10/100 Mbps 2-axis encoder line (quadrature, up, down, or clock/direction) 4 digital TTL inputs, 5 V 4 digital TTL outputs, 5 V, 15 mA Remote acquisition enabled TTL, 5 V 5 V, 500 mA power output line (short-circuit protected) 3 TTL, 5 V, 15 mA 2 analog outputs (12 bits) ±5 V in 10 kΩ

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Display

PHASED ARRAY ULTRASONIC TESTING PROCEDURE Pace input Display size Resolution Brightness Number of colors Type Battery type

Power Supply

Number of batteries

5 V TTL pace input 26.4 cm (10.4 in.) (diagonal) 800 pixels x 600 pixels 700 cd/m2 16 million TFT LCD 1 or 2 (battery chamber accommodates two hotswappable batteries) Minimum 7 hours with two batteries

Operating temperature range Storage temperature range Relative humidity Ingress Protection Rating Shockproof rating MXU 4.1R8 and later MXU 4.0 and later

MX2 Module Compatibility MXU 3.1 and MXU 4.1R12 and later

6.2

Date: 23/3/2020

Smart Li-ion battery

Battery life

Environmental Specifications

Page 7 of 35

-10 °C to 45 °C (14 ºF to 113 ºF) -20 °C to 60 °C (-4 ºF to 140 ºF) with batteries -20 °C to 70 °C (-4 ºF to 158 ºF) without batteries Max. 70% RH at 45°C noncondensing Designed for IP66 Drop-tested according to MIL-STD-810G 516.6 OMNI-M2-PA32128PR OMNI-M2-PA1664 OMNI-M2-PA16128 OMNI-M2-PA32128 OMNI-M2-UT-2CH OMNI-M-UT-8CH

PHASED ARRAY PROBES and Wedges Probes and Wedges specification as table 4 shall be used. Table 4: Probes and Wedges No.

Probe

Wedge

Range Thickness(mm)

Curvature Wedge OD (inch)

Technique

Material

1

A12

SA12-N55S-IHC

9~70

2 inches to Flat

Haftskip + Fullskip

CS

2

A15

3~12

2 inches to Flat

Haftskip + Fullskip

CS

3

A17

19~120

4.5 inches to Flat

Haftskip

SS/DL/CS

4

A27

19~120

4.5 inches to Flat

Haftskip

SS/DL/CS

5

A32

10~120

2 inches to Flat

Haftskip + Fullskip

CS

SA15-N60S-IH 7.5/10CCEV3516 SA17-DN80L0IHC SA27-DNCRIHC SA32-N55S-IHC

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6.3

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 8 of 35 Date: 23/3/2020

SOFTWARE ANALYSIS Tomoview software - processed data analysis and display techniques are used in conjunction with automatic or semi-automatic scanning mechanisms to produce two and threedimensional images of flaws, which provides an enhanced capability for examining critical components and structures. Computer processes may be used to quantitatively evaluate the type, size, shape, location, and orientation of flaws detected. Table 4: Software Analysis Specification Feature Metric and Imperial Units Multi-group Combined Display (PA, UT, and TOFD) Ability to Zoom in/out in Display Predefined Weld Overlay Display Selectable Information Groups (Readings) Offline Data Management and Processing Indication Table Tools Built-in Report Generator (Customizable) Ability to Modify/Create Color Palette Offline Thickness C-Scan Tool Offline TOFD Calibration TOFD Lateral Wave Synchronization Tool TOFD Lateral Wave Removal Tool TOFD SAFT Tool Volumetric Merge Tool (Automatic or Manual) Software Gain Adjustment Custom Layouts (Creation and Saving) Zone Tool for Statistical Measurements 3D Cursor Ability to Open Multiple Files Simultaneously Data File Merging C-Scan Data Merging Signal to Noise Ratio (SNR) Analysis Tool Binarizer Processing Tool Matrix Filters Tool Backwall Following C-Scan Tool Hysteresis Correction Ability to Export Data Group in .txt File FFT Calculation Microsoft Excel® Exchanges for Custom Readings Acoustic Field Simulation (AFiSiMO) Polar View Display A-Scan Resynchronization Tool

TomoView Analysis                                 

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6.4

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 9 of 35 Date: 23/3/2020

COUPLANT The couplant used is water, cellulose paste or grease

6.5

SCANNING MECHANISMS Auto or semi-auto scanner shall be used.

7.0

CALIBRATION BLOCK

7.1

REFLECTORS Side drill hole or EDM notches shall be used in Calibration block

7.2

BLOCK MATERIALS and BLOCK CURVATURE. The material from which the block is fabricated shall be of the same product form and material specification or equivalent P-Number grouping as one of the materials being examined. For the purposes of this paragraph, P-Nos. 1, 3, 4, 5A through 5C, and 15A through 15F materials are considered equivalent. Materials With Diameters Greater Than 20 in. (500 mm). For examinations in materials where the examination surface diameter is greater than 20 in. (500 mm), a flat basic calibration block, shall be used.

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PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 11 of 35 Date: 23/3/2020

Materials With Diameters 20 in. (500 mm) and Less. For examinations in materials where the examination surface diameter is equal to or less than 20 in. (500 mm), a curved block shall be used. Except where otherwise stated in this Article, a single curved basic calibration block may be used for examinations in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter.

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PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Revision No.: 0

Page 12 of 35 Date: 23/3/2020

Block Thickness, T, shall be ±25% of the nominal thickness of the component to be examined. The block size and reflector locations shall be adequate to perform calibrations for the beam angle(s) and distance range(s) to be used. 7.3

SURFACE FINISH The finish on the scanning surfaces of the block shall be representative of the scanning surface finishes on the component to be examined. Otherwise, transfer correction shall consider performance if difference surface between calibration block and production in accordance with ASME B31.3.

8.0

TECHNIQUES -

Angle beam longitudinal waves, where both refracted longitudinal and shear waves are present in the material under examination. Dual matrix probes with high refract angle shall be used (Dual Matrix A17 and A27 probes of Olympus Manufacturer).

-

Angle beam shear waves, where incident angles in wedges produce only refracted shear waves in the material under examination are generally termed angle beam examinations. (linear A12, A32 and A15 probes shall be used of Olympus Manufacturer)

-

Detail of beam angle, mode of wave propagation in material shall be detailed in Table 6 and plan scan Table 6: PAUT Technique Scan Plan

Thickne ss (mm)

Configu ration

Probe

Wedge

Technique

3 ~ 12

Pipe to Pipe

7.5CCEVA15

SA15N60S-IH 7.5

Shearwave

3 ~ 12

Pipe to Fitting

7.5CCEVA15

SA15N60S-IH 7.5

Shearwave

9 ~ 16

Pipe to Pipe

5L64A12

SA12N55SIHC

Shearwave

Group 1 (Haftskip)

Group 2 (Fullskip)

Group 3 (1.1/2 skip) -

-

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PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 13 of 35 Date: 23/3/2020

9 ~ 16

Pipe to Fitting

5L64A12

SA12N55SIHC

Shearwave

16 ~ 50

Pipe to Pipe

5L64A12

SA12N55SIHC

Shearwave

-

5L64A12

SA12N55SIHC

Shearwave

-

DMA27

SA27DNCRIHC

Longitudinalwave

16 ~ 50

9.0 No 1 2 3 4 5 6 7 8 9.1

Pipe to Fitting

-

-

CALIBRATION Type of Calibration Encoder Velocity Wedge Angle corrected gain (ACG) Time correction gain (TCG) Screen Height Linearity Amplitude Control Linearity Element Check

Frequency 4 hours or has changed 4 hours or has changed 4 hours or has changed 4 hours or has changed 4 hours or has changed Weekly weekly Weekly

Remark As Cal. Confirmation para. 9.8 As Cal. Confirmation para. 9.8 As Cal. Confirmation para. 9.8 As Cal. Confirmation para. 9.8

ENCODER CALIBRATION A calibration check shall be performed at intervals not to exceed one month or prior to first use thereafter, by moving the encoder a minimum distance of 20 in. (500 mm). The display distance shall be within 1% of the actual distance moved.

9.2

VELOCITY CALIBRATION

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9.3

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 14 of 35 Date: 23/3/2020

-

The velocity calibration wizard use Radius option for measuring the velocity of a component that are compatible with both shear and longitudinal beams.

-

This options require 2 reflectors (radius) at known positions

-

Select Wizard for Velocity Calibration

-

Select Echo Type radius and enter the values for radius 1 and 2.

-

Adjust the gain for a signal and ensure that neither target 1 or 2 is saturated.

-

Adjust the range over the targets.

-

Set the gate A start, width, and threshold over thickness 1.

-

Select Get Position. The time of flight position of thickness 1 is recorded

-

Set the gate A start, width, and threshold over thickness 2.

-

Select Get Position. The time of flight position of thickness 2 is recorded and the velocity will be calculated

WEDGE CALIBRATION -

Inputting the wedge, probe, and component parameters correctly into the group set up wizard is the most accurate means of arriving at the correct wedge delay.

-

Enter the wedge delay calibration wizard

-

Select Echo Type Radius

-

Select the last angle to be used in the calibration

-

Set the position of gate A to cover the radius

-

Select Clear Envelope and move the probe across the calibration block passing each focal law through the 100mm radius maximum amplitude position

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9.4

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 15 of 35 Date: 23/3/2020

-

After selecting calibrate, move the probe over the block again passing each focal law through the 100mm radius maximum amplitude position to verify that the wedge delay was modified correctly.

-

If the wedge delay calibration was successful the new white envelope trace will be contained within the tolerance window indicating all focal laws are detecting the 100mm radius +/- 1mm.

-

Calibrate can be selected repeatedly improving the calibration until the white envelope trace is contained within the +/- 1mm tolerance

SENSITIVITY CALIBRATION (Angle Corrected Gain (ACG)) -

After completing the group setup wizard process, position the probe so that the calibration target can be seen in the S-scan.

-

Enter the reference amplitude. (default 80%) All focal laws will be adjusted to this amplitude by addition of a focal law gain offset after sensitivity wizard completion.

-

Enter tolerance of 5%. The tolerance is a visual indicator for amplitude verification after the sensitivity calibration correction

-

Select the last focal law to be calibrated for sensitivity. When there are no obstructions from corners or adjacent calibration targets the entire sector scan can be calibrated at one time

-

Set the start and width of gate A to ensure that the calibration target can be detected by all focal laws in the S-scan.

-

Set the gate A threshold as low as possible to ensure the last focal law can be detected. Gate thresholds below approximately 10% may have an amplitude error beyond the tolerance when the focal law gain offset is calculated to correct to 80%.

-

Gain compensation is a tool that is used to ease calibration, The longer the sound path to the calibration target, the more gain is added

-

Move the probe across the calibration block with consistent pressure and coupling.

-

As the calibration target travels through the gate of each focal law the green envelope records the maximum amplitude detected.

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9.5

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 16 of 35 Date: 23/3/2020

-

The MX2 will calculate the required gain offset in dB for each focal law to correct to 80%. Focal laws with amplitude over 80% but less than 100% will receive a negative gain offset.

-

Successful sensitivity calibration of the S-scan is visualized by repeating the probe movement over the calibration block with all focal laws corrected to 80% amplitude within the tolerance.

-

If any focal law is over 100% after calibration the complete process must be repeated by selecting Restart. Saturated focal laws cannot be corrected.

-

Calibrate may be selected repeatedly until all laws are within tolerance.

TIME CORRECTION GAIN (TCG) CALIBRATION -

The targets used for TCG calibration should cover the entire range of the area of interest for the inspection and specified in the work procedure.

-

Enter the reference amplitude. (default 80%) All focal laws will be adjusted to this amplitude by addition of a TCG gain offset for that point

-

Enter tolerance. The tolerance is a visual indicator for amplitude verification after the sensitivity calibration correction

-

Set the gate A start position just before the first SDH in the S-scan.

-

Enter the reference amplitude. (Typically 80%)

-

Select set to 80%. This will automatically adjust the amplitude of the signal in gate A to 80% by adjusting the general gain.

-

Select the last focal law to be calibrated for the TCG point.

-

Adjust the general gain if needed. Unlike the sensitivity calibration, the TCG wizard will not allow any point over 80% amplitude to be corrected.

-

Adjust the start and range to ensure sufficient range for all required TCG points to be detected by all focal laws in the S-scan.

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9.6

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 17 of 35 Date: 23/3/2020

-

Set the start and width of gate A to ensure that the calibration target can be detected by all focal laws in the S-scan.

-

Set the gate A threshold as low as possible to ensure the last focal law can be detected. Gate thresholds below approximately 10% may have an amplitude error beyond the tolerance when the focal law gain offset is calculated to correct to 80%

-

Move the probe across the calibration block with consistent pressure and coupling.

-

As the calibration target travels through the gate of each focal law the green envelope records the maximum amplitude.

-

Successful TCG sensitivity calibration of the S-scan is visualized by repeating the probe movement over the calibration block with all focal laws corrected to 80% amplitude within the tolerance

-

If any focal law is over 100% after calibration the complete process must be repeated by selecting Restart. Saturated focal laws cannot be corrected

INSTRUMENT LINEARITY CHECKS 9.6.1

Screen Height Linearity

-

Position a search unit on a calibration block to obtain indications from the two calibration reflectors.

-

Alternatively, a straight beam search unit may be used on any calibration block that will provide amplitude differences with sufficient signal separation to prevent overlapping of the two signals.

-

Adjust the search unit position to give a 2:1 ratio between the two indications, with the larger indication set at 80% of full screen height (FSH) and the smaller indication at 40% of FSH.

-

Without moving the search unit set the larger indication to 100% of FSH; record the amplitude of the smaller indication, estimated to the nearest 1% of FSH.

-

Successively set the larger indication from 100% to 20% of FSH in 10% increments (or 2 dB steps if a fine control is not available); observe and record the smaller indication estimated to the nearest 1% of FSH at each setting. The reading must be 50% of the larger amplitude within +5% of FSH.

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

9.6.2

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 18 of 35 Date: 23/3/2020

Amplitude Control Linearity

-

Position a search unit on a calibration block to obtain maximum amplitude from a calibration reflector.

-

As a minimum, the amplitude control linearity shall be performed to document linearity at both ends of the gain range being used with the equipment.

-

Without moving the search unit, set the indication to the required percent of FSH and increase or decrease the dB as specified on the Ultrasonic Instrument Linearity Verification. The estimated signal shall be recorded to the nearest 1% of FSH and shall fall within the limits 9.6.3

Element Check

-

Connect the phased array probe to be tested to the phased-array ultrasonic instrument and remove any delay line or refracting wedge from the probe.

-

Acoustically couple the probe to the 25-mm thickness of an IIW (International Institute of Welding) block with a uniform layer of couplant.

-

Configure an electronic scan consisting of one element that is stepped along one element at a time for the total number of elements in the array. (This should ensure that the pulser-receiver number 1 is used in each focal law or if the channel is selectable it should be the same channel used for each element). Set the pulser parameters to optimize the response for the nominal frequency of the probe array and establish a pulse-echo response from the block backwall or waterpath to 80 % display height for each element in the probe.

-

Observe the A-scan display for each elemen signal amplitude for each element. Results may be recorded on a table similar to that in Table 1.

-

The number of inactive elements allowed should be based on performance of other capabilities such as focusing and steering as of the focal laws being used. if more than 25 % of the elements in a probe are inactive, sensitivity and steering capabilities may be compromised. Similarly, the number of adjacent elements allowed to be inactive should be determined by the steering and electronic raster resolution required by the application.

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Revision No.: 0

Element

1

2

3

4

5

6

7

8

9

10

…

…

Page 19 of 35 Date: 23/3/2020

59

61

62

63

64

Gain Active inactive Table 7: Probe Element Activity Chart

9.7

TEMPERATURE OF CALIBRATION. -

9.8

The temperature differential between the calibration block and examination surfaces shall be within 25°F (14°C). For immersion examination, the couplant temperature for calibration shall be within 25°F (14°C) of the couplant temperature for examination.

CALIBRATION CONFIRMATION 9.8.1

System Changes. When any part of the examination system is changed, a calibration check shall be made on the basic calibration block to verify that distance range points and sensitivity setting(s) satisfy the requirements of 8.8.3.

9.8.2

Calibration Checks. A calibration check on at least one of the reflectors in the basic calibration block or a check using a simulator shall be performed at the completion of each examination or series of similar examinations, and when examination personnel (except for automated equipment) are changed. The distance range and sensitivity values recorded shall satisfy the requirements 9.8.3.

9.8.3

Confirmation Acceptance Values. a. Distance Range Points. If any distance range point has moved on the sweep line by more than 10% of the distance reading or 5% of full sweep, whichever is greater, correct the distance range calibration and note the correction in the examination record. All recorded indications since the last valid calibration or calibration check shall be reexamined and their values shall be changed on the data sheets or re-recorded. b. Sensitivity Settings. If any sensitivity setting has changed by more than 20% or 2 dB of its amplitude, correct the sensitivity calibration and note the correction in the examination record. If the sensitivity setting has decreased, all data sheets since the last valid calibration check shall be marked void and the area covered by the voided data shall be re-examined. If the sensitivity setting has increased, all recorded indications since the last valid calibration or calibration check shall be reexamined and their values shall be changed on the data sheets or re-recorded.

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

9.9

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 20 of 35 Date: 23/3/2020

TRANSFER CORRECTION. When the block material is not of the same product form or has not received the same heat treatment, it may be used provided it meets all other block requirements and a transfer correction for acoustical property differences is used. Transfer correction shall be determined by noting the difference between the signal response, using the same transducers and wedges to be used in the examination, received from either (1) the corresponding reference reflector (same type and dimensions) in the basic calibration block and in the component to be examined, or (2) two search units positioned in the same orientation on the basic calibration block and component to be examined. The examination sensitivity shall be adjusted for the difference.

10.0

EXAMINATION

10.1

EXAMINATION COVERAGE. The examined shall be scanned using a linear scanning technique with an encoder. Each linear scan shall be parallel to the weld axis at a constant standoff distance with the beam oriented perpendicular to the weld axis. (a) The search unit shall be maintained at a fixed distance from the weld axis by a fixed guide or mechanical means. b) The examination angle(s) for E-scan and range of angles for S-scan shall be appropriate for the joint to be examined. (c) 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. (d) For E-scan techniques, overlap between adjacent active apertures (i.e., aperture incremental change) shall be a minimum of 50% of the effective aperture height. (e) For S-scan techniques, the angular sweep incremental change shall be a maximum of 1 deg. or sufficient to assure 50% beam overlap. (f) 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 (g) When multi scans are required to cover full length of weld, overlap of scanning shall be 50 mm or larger.

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

10.2

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 21 of 35 Date: 23/3/2020

SCANNING SENSITIVITY LEVEL. The scanning sensitivity level shall be set a minimum of 6 dB higher than the reference level gain setting. 10.2.1 Scan from both side The angle beam shall be directed at approximate right angles to the weld axis from both sides of the weld (i.e., from two directions) on the same surface when possible. 10.2.2 Scan from one side /Inaccessible Welds Welds that cannot be examined from at least one side using the angle beam technique shall also be examined. These areas of Inaccessible welds shall be noted in the examination report.

10.3

SURFACE PREPARATION 10.3.1 Base Metal The base metal on each side of the weld shall be free of weld spatter, surface irregularities, or foreign matter that might interfere with the examination. 10.3.2 Weld Metal Where the weld surface interferes with the examination, it shall be prepared for the permission of the examination by grinding or suitable method.

10.4

POST-EXAMINATION CLEANING

11.0

The couplant or any contaminations have to clean after completion work. SIZING METHOD of FLAW LENGTH. Flaw lengths parallel to the surface can be measured from the distance encoded D or C-scan images using amplitude 6dB drop techniques by placing the vertical cursors on the extents of the flaw displayed on the D- or C-scan display. (Figure 1)

Figure 1: Flaw Length Sizing

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

12.0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 22 of 35 Date: 23/3/2020

SIZING METHOD OF FLAW HEIGHT Flaw height normal to the surface can be measured from the B-, E-, or S-scan images using amplitude drop or tip diffraction techniques. (a) Using amplitude drop techniques, the horizontal cursors are placed on the displayed flaws upper and lower extents. Figure 2 shows an example of cursors used for height sizing with the amplitude drop technique. (b) Using tip diffraction techniques the horizontal cursors are placed on the upper and lower tip signals of the displayed flaw. Figure 3 shows an example of cursors used for height sizing with the tip diffraction technique.

Figure 2: Scan Showing Flaw Height Sizing Using Amplitude Drop Technique and theHorizontal Cursors on the B-Scan Display

Figure 3: Flaw Height Sizing Using Top Diffraction Technique and the Horizontal Cursors on the S-Scan Display

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0 GENERAL NOTE:

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Date: 23/3/2020

The two arrows in the A-scan at left show the relevant signals for

13.0

measurement. DISCRIMINATION GEOMETRIC OF FLAW INDICATIONS

13.1

ID (INSIDE DIAMETER) CONNECTED CRACK -

Page 23 of 35

These typically show multiple facets and edges visible in the A-scan and S-scan. There is a distinct start and stop on the A-scan, and a significant echo-dynamic travel to the signal as the probe is moved in and out from the weld (if the crack has significant vertical extent). The reflector is usually detectable and can be plotted from both sides of the weld. The reflector should plot to the correct I.D. depth reference or depth reading, as shown in Figure 4.

-

Figure 4: S-Scan of I.D. Connected Crack 13.2

LACK OF SIDEWALL FUSION -

LOF (Lack of Fusion) plots correctly on the weld fusion line, either through geometrical plotting or via weld overlays. There may be a significantly different response from each side of the weld. LOF is usually detected by several of the angles in an S-scan from the same position. The A-scan shows a fast rise and fall time with short pulse duration indicative of a planar flaw. There are no multiple facets or tips. Skewing the probe slightly does not produce multiple peaks or jagged facets as in a crack. There may be mode converted multiple signals that rise and fall together and maintain equal separation. Figure 5 shows an example.

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 24 of 35 Date: 23/3/2020

Figure 5: E-Scan of LOF in Midwall 13.3

POROSITY. -

Porosity shows multiple signal responses, varying in amplitude and position. The signals plot correctly to the weld volume. The signals’ start and stop positions blend with the background at low amplitude. The A-scan slow rise and fall time with long pulse duration is indicative of a non-planar flaw. Porosity may or may not be detected from both sides of the weld, butshould be similar from both sides. Figure 6 shows an example of porosity.

Figure 6: S-Scan of Porosity, Showing Multiple Reflectors

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

13.4

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 25 of 35 Date: 23/3/2020

OD (Outside Diameter) Toe Crack. -

Toe cracks typically show multiple facets and edges visible in the A-scan and S-scan. There is significant echo-dynamic travel to the signal as the probe is moved in and out from the weld. The reflector is usually detectable and can be plotted from at the correct O.D. depth reference line or depth reading. Normally, toe cracks are best characterized on S-scans and lower angle Escan channels. Figure 7 shows an example.

Figure 7: O.D. Toe Crack Detected Using S-Scan 13.5

INCOMPLETE PENETRATION. -

Incomplete Penetration (IP) typically shows high amplitude signals with significant echo-dynamic travel or travel over the I.D. skip line. IP will typically respond and plot from both sides of the weld in common weld geometries near centerline reference indicators. Generally, IP is detected on all channels, with highest amplitude on a high angle E-scan. The A-scan shows a fast rise and fall time with short pulse duration indicative of a planar flaw. Figure 8 shows an IP signal.

-

Note that IP must be addressed relative to the weld bevel. For example, a double V weld will have IP in the midwall, whereas a single V bevel will be surface-breaking. However, the rise-fall time of the signal is similar to that for toe cracks and other root defects. This requires extra care on the part of the operator. Note that incomplete penetration can look similar to surface lack of sidewall fusion.

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 26 of 35 Date: 23/3/2020

Figure 8 IP Signal on S-Scan, Positioned on Root 13.6

SLAG -

Slag typically shows multiple facets and edges visible in the A-scan and S-scan. The Ascan shows a slow rise and fall time with long pulse duration, indicative of a non-planar flaw. Typically slag shows lower amplitude than planar flaws, and may be difficult to distinguish from porosity, or from some smaller planar defects. Slag is typically detectable from both sides, can be plotted from both sides of the weld and is often best characterized using an S-scan. A slag reflector will typically plot to the correct depth area and reference lines that coincide to the weld volume. Figure 9 shows an example.

Figure 9: Slag Displayed as a Midwall Defect on S-Scan

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

14.0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Page 27 of 35 Date: 23/3/2020

SCAN PLAN -

15.0

A scan plan (documented examination strategy) shall be provided showing search unit placement and movement that provides a standardized and repeatable methodology for the examination. All information of scan plan shall be showed in prior demonstration.

PROCEDURE QUALIFICATION The demonstration block as following requirement. -

Preparation. A demonstration block shall be prepared by welding.

-

Demonstration thickness and diameter shall be performed as list below.

-

Flaw Type: Flaws type of demonstration block shall be including: Lack of fusion, Lack of Penetration, Crack, Slag and porosity for each thickness and diameter of pipe.

16.0

RECORDING/EVALUATION LEVEL

16.1

EVALUATION OF LAMINAR REFLECTORS -

16.2

Reflectors evaluated as laminar reflectors in the base material which interfere with the scanning of the examination volume shall require the scan plan to be modified such that the maximum feasible volume is examined and shall be noted in the record of the examination EVALUATION OF WELDED REFLECTORS

16.3

All indications greater than 20% of the reference level shall be investigated to the extent that they can be evaluated in terms of the acceptance criteria of the ASME B31.3 2016. SUPPLEMENTAL MANUAL TECHNIQUES

-

Flaws detected during the automated or semi-automated scan may be alternatively evaluated, if applicable, by supplemental manual techniques.

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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17.0

ACCEPTANCE CRITERIA

17.1

For high pressure piping welds and severe critical service, apply ASME B31.3 Ed 2016 Table K341.3.2. as Appendix 2.

17.2

For other welds: Acceptance criterial shall accordance with ASME B31.3 2016 para. 344.6.2 as below: -

The discontinuity is unacceptable if interpreted as crack, lack of fusion, lack of penetration. For Tw ≥ 6mm A linear-type discontinuity is unacceptable if the amplitude of the indication exceeds the reference level and its length exceeds: (1) 6 mm (1⁄4 in.) for Tw ≤ 19 mm (3⁄4 in.) (2) Tw/3 for 19 mm < Tw ≤ 57 mm (21⁄4 in.) (3) 19 mm (3⁄4 in.) for Tw > 57 mm (21⁄4 in.)

-

For Tw < 6 mm, the indication exceeds 10% reference level shall be reject regardless of length.

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

18.0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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DOCUMENTATION -

Results of ultrasonic examination shall be reported on the Phased Array and examination report sheet. All Phased Array examination data, A-scans, B, C, D, and S Scans shall be saved as a digital encoded recording.

-

The Ultrasonic Profile, Ultrasonic Calibration, and Ultrasonic Instrument Linearity verification (if applicable) shall be considered part of the examination report, assigned the NDT Report Log Numbers, and page numbered appropriately.

-

All NDT procedure qualification documentation shall be maintained as quality control record.

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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19.0

RECORDS

19.1

Phased array ultrasonic examination results shall be recorded in the attached form by certified personnel who perform the ultrasonic examination.

19.2

For each Phased Array Ultrasonic examination, the following information shall be recorded: a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. s. t. u. v.

w. x.

y. z. aa. bb.

Date of the examination name and/or identity and certification level (if applicable) for personnel performing the examination Identification of the weld, part, or component examined including weld number, serial number, or other identifier Examination method, technique, procedure Identification, and revision ultrasonic instrument identification (including manufacturer's serial number); search unit(s) identification(including manufacturer's serial number, frequency, and size); beam angle(s) used; couplant used, brand name or type: search unit cable(s) used, type and length: special equipment when used (search units, wedges, shoes, automatic scanning equipment, recording equipment, etc.); computerized program identification and revision when used; calibration block identification; simulation block(s) and electronic simulator(s) identification when used; instrument reference level gain and, if used, damp calibration data [including reference reflector(s), indication amplitude(s), and distance reading(s)]; data correlating simulation block(s) and electronic simulator(s), when used, with initial calibration; identification and location of weld or volume scanned; surface(s) from which examination was conducted, including surface condition; map or record of rejectable indications detected or areas cleared; areas of restricted access or inaccessible welds; examination personnel identity and, when required by referencing Code Section, qualification level; date and time examinations were performed. Items (b) through (m) may be included in a separate calibration record provided the calibration record identification is included in the examination record. search unit element size, number, and pitch and gap dimensions focal law parameters, including, as applicable, angle or angular range, focal depth and plane, element numbers used, angular or element incremental change, and start and stop element numbers or start element number wedge natural refracted angle scan plan scanner and adhering and guiding mechanism indication data [i.e., position in weld, length, and characterization (e.g., crack, lack of fusion, lack of penetration, or inclusion)]

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

cc. dd.

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the final display processing levels supplemental manual technique(s) indication data, if applicable [same information as (y)]

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

Revision No.: 0

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APPENDIX 1 - PAUT REPORT

PHASED ARRAY ULTRASONIC EXAMINATION REPORT Project Name:

Procedure No.:

Report No:

Client Name:

Acceptance Standard:

Request No:

Items:

PKG No:

Page :

Instrument Identification:

ISO No.:

Calibration data: Computerized Program:

S/N: Probe

1

2

3

4

Calibration Block:

Model/ Manufacturer Serial No.

Weld Preparation:

Cable Type

Scan Technique:

Cable Length

WPS No.

Aperture

Material type:

Frequency (MHz)

Transverse Examined:

Refracted Wedge

Parent Metal Examined:

Element quantity

Date of Inspection:

Sensitivity (dB)

-

Couplant :

Surface Condition:

After PWHT:

EVALUATION Weld Identification Joint/ Weld No.

Detail of defect (mm) Welder No.

ABBREVIATION

Dia.(mm)/ Thick.(mm)

Length

Depth

Amp.

Type

ACC: Accepted

REJ: Reject

LP: Lack of Penetration

CP: CLUSTER POROSITY

LF: Lack of Fusion

SI: Slag Inclusion

ALPHANDT Name :

Location

Judgment

POS

ACC

C : CRACK

JVPC

C.A

Name :

Name :

Name :

Signature :

Signature :

Signature :

Date :

Date :

Date :

Qualification : Signature : Date :

Remark s

REJ

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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ANALYSIS VIEW TOP-C Report No.

1) Root 2) Body 3) 1 1/2 Skip

1) Root

2) Body

3) 1.1/2 SKIP

ISO No.: Joint No.:

Page

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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APPENDIX 2– ACCEPTANCE CRITERIA IN ACCORDANCE WITH TABLE K341.3.2

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PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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APPENDIX 3 – DEMONSTRATION REPORT 3.1 PURPOSE Determine detect ability of phased array for weld with t < 6mm 3.2 TECHNICAL Demonstration is perform following procedure POS-WHP-E1-Q-P-0007 and scan plan. PAUT Demonstration report as below:

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PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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RANG DONG FIELD DEVELOPMENT PROVISIONS OF GAS LIFT SEPARATION SYSTEM FOR RENTAL AT WHP-E1 Document No.: POS-WHP-E1-Q-P-0007 Revision No.: 0

PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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PHASED ARRAY ULTRASONIC TESTING PROCEDURE

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