PROJECT PART D PARADIP NUMALIGARH CRUDE OIL PIPELINE OF NRL

PROJECT NO
CLIENT NUMALIGARH REFINERIES LTD.
ENGG. CONSULTANT ENGINEERS INDIA LIMITED. (EIL)
CONTRACTOR ADVANCE INFRASTRUCTURES PVT. LTD
NDT AGENCY INSPECTION TECHNOLOGY( Intec)

JOB PROCEDURE
FOR

MANUALY ULTRASONIC TESTING

For Review Name

0 5/04/2023 & Approval &
Sign IT AIPL EIL NRL
PREPARED & CHECKED REVIEW & REVIEW &
REV DATE DESCRIPTION
BY APPROVED BY APPROVED BY
 CONTENTS

Sr.No. DESCRIPTION PAGE No.

1 Purpose 02

2 Scope 02

3 Reference 02

4 Equipments & Materials 02

5 Manpower 03

6 Methodology 03

7 Health, Safety & Environment 06

8
Documentation 06

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1. Purpose

This procedure is used to detect internal discontinuity of Girth welds of Mainline, Tie In, repair

and bevel ends of pipe made at site in Part D of Paradip Numaligarh Crude Oil Pipeline Project

of NRL.

The purpose of this work instruction is to lay guidelines and requirements and to establish a

method or a system to control the Manual Ultrasonic Test inspection activity and to be Use in

Paradip Numaligarh Crude Oil Pipeline Project part D, by AIPL for executing the Project.

Pipeline Diameter: 26"

Pipeline Wall Thickness :

Pipe Specification : API 5L Gr. X70

2. Scope

This scope covers the Manual Ultrasonic Testing of girth welds in Mainline, Tie-In, Lamination

check of pipe bevels & Repair configurations for 26" line pipes for PNCPL Part D.

3. References

 EIL.SPEC.-6-71-0051 REV 04
 ASME-B31.8
 API 1104
 ASME Sec. V
 ASTM E 428
 AST SNT TC – 1A

4.PERSONAL QUALIFICATION:
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 The qualification of the NDT inspector to carry out this testing will be minimum ASNT level II or

Company's level II in accordance with Company's written practice which is in accordance to

ASNT SNT TC 1A & ANSI CP 189.

4.1 Equipments & Accessories:

 Ultrasonic Flow Detector, A Scan Type. Meeting the requirement of EIL / NRL Specification.
 Suitable Miniature Probes. (TR Probe, Angle Probe 70⁰) Miniature Probes.
 Matching Cables.
 Couplant – Grease, Oil / Water.
 Drawing & Gauging Tools.

5.Methodology:

The ultrasonic inspection procedure shall be approved by the NRL/EIL. This specification test

consists in testing (under normal operating conditions) weld made according to the same

production procedure, where there are typical defects the test intends to detect.

 TEST PROCEDURE :

The surface with the probe coming into contact shall be free of metal spatter, dirt, iron oxide

and scales of any type, therefore it shall be necessary to clean a strip at least 50mm wide on

both sides of the weld with steel-wire brushes and anyhow the cleaned strip must be at least

wide enough to allow one and a half skip examination. Circumferential welds shall be inspected

from both sides using angles probes.

If, during the test, echoes of doubtful origin appear, it shall be necessary to inspect a convenient

area on the pipe surface, close to the weld, with a straight beam transducer in order to check

whether any manufacturing defects are present which could have interfered with the Ultrasonic

beam.

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 ULTRASONIC INSTRUMENTS:

The Ultrasonic instrument/Equipments:

Shall be pulse echo type, able to generate, receive and display on the screen a Cathode Ray Tube

(CRT), pulse at frequencies between 1 and 6 MHz the useful part of the CRT screens shall be at

least 70mm wide and at least 50mm high. Shall have variable amplification, with steps of 1 or 2

db over a range of a least 60DB.

The regulations control shall be accurate to within ± 1 DB and this accuracy shall be certified by

the instrument manufacturer.

May be powered by a battery or an electric generator. In the first case, the autonomy of

operation (endurance) of the instrument shall be sufficient to carry on working without frequent

interruptions, and the instrument shall be equipped with an automatic switch which switches if

off when the battery runs down in the second case, there must be a voltage stabilizing devices

with a tolerance of ± 2 volts

PROBES: The probes used shall have dimension frequencies and a refraction angle suited to

the type of steel, the thickness of the pipeline and to the joint design.

 REFRENCE SAMPLE PIECES:

The efficiency of the equipment used, the effective refraction angle of the probe and the

beam output point, shall be checked using a V1 and V2 sample Block, IIW type or the

calibration block ASTM E-428.

 CALIBRATION:

The calibration qualification of the testing procedure shall be done as per API 1104 (Fig 22A).

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 OTHER EQUIPMENT :

The use of rules calibrated in centimeters, attached if possible to the probe, for the precise

location of the position of welding defects, is recommended. Defect location is effected by

measuring the projection distance between the probe output and the reflecting surface. The

operators carrying out the tests shall have, besides the probing instrument, tools for

cleaning the pipe surface (file,brushes etc.) .as well as the coupling liquid or paste

appropriate for the temperature of the section to be examined.

 EVALUATION OF INDICATIONS :

Each time that echoes from the weld bead appear during production testing, the instrument

amplification shall be altered to coincide with the reference amplifications and the probe

shall be moved until maximum response is obtained, paying attention all the time to the

probe-tube coupling.

 STANDARD & REFERENCE BLOCKS :

I.I.W V1 and / or I.I.W V2, IOW Block, Step wedge, and Notch Block for D.A.C.as per the

attached drawing.Fig. 1A.

Calibration block shall be the same material and thickness of line pipe.

 CALIBRATION OF ULTRASONIC FLAW DETECTOR :

The calibration of the UFD shall be carried out in accordance with ASME section V Article 5 or

specific written procedure for its vertical & horizontal linearity once in every operation or after

repair of UFD whichever is earlier.

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 In addition, Amplitude control corrections, Beam spread, index point, Beam angle & Resolution

will be and the Type, Method & Frequency will be as per approved procedure Qualification.

 DISTANCE AMPLITUDE CORRECTION CURVE (D.A.C. CURVE) :

Following steps shall be carried out to obtain a DAC curve for angle probe. See fig. 1 a & 1 b.

After finding Beam Index and Probe angle (±2degree).

Calibrate the screen range as required beam path using IIW VI or V2 standard block.

Apply couplant to Notch through reference block.

Take echo from ID Notch at 80 % (±5 %) maximize and mark.

Note down the Db.

Repeat the same OD Notch & ID Notch and mark.

Draw the curve connecting three points from Echo leg & Connect to draw a curve.

Calibration block material shall be same as pipe material (API 5L Gr. X70 PSL 2 ).

 SURFACE CONDITION :

All surfaces shall be cleaned and free of scale, dirt, grease, paint, spatter or any other foreign

materials. Surface shall be smooth to carry out effective test for at least 50mm wide on both

sides of weld. If surface is not smooth as reference block, Db correction shall be done. Cleaned

strip must by at least wide enough to allow 1 1/2 skip Examination. If surface is not smooth as

reference block, DB correction shall be done.

 PROBE SELECTION :

The combination of probes in addition to normal probes shall be selected as per spec if

requirement or as per thickness of the pipe, equipment or structures.

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 THICKNESS RANGES PROBE COMBINATIONS,

5 mm to 10 mm TR, 60 & 70 degree

above 10 mm to 25 mm Normal, 45 & 60 degree, Miniature Probes.

above 25 mm 45⁰ & 60⁰ degree, Normal Probe.

 SCANNING :

100% area shall be scanned by all selected probes both sides of the welds using longitudinal and

shear wave probe adding +6db. Length of scanning shall be minimum of ½ Beam Path to 1½ %

Beam Path on both side of weld. Scanning speed will be maintained ≤ 150mm/sec.

In case of only parent metal inspection, normal/TR scanning shall be carried out.

 PROCEDURE :

Inspection of weld on both sides by using longitudinal & Shear wave probes.

 LONGITUDINAL WAVE PROBE :

With reference to second back wall echo 80 % of full screen height, scanning shall be carried out

before and after weld on base metal to confirm any inherent or after weld discontinuity. During

scanning with longitudinal wave probe, full contact and echo height shall be maintained. Area of

scanning shall be at least 1 / 2 Beam Path to 1½ % Beam Path on both side of pipe weld with

minimum 50mm.This scanning will reveal discontinuity with major surface parallel to scanning

surface. The bevels ends of pup piece for Tie-in joints will be scanned for a minimum length of

50mm each side for lamination check after welding the pup piece to the pipe. Calibration blocks

range 0-50mm.

 CALIBRATION BLOCKS RANGE 0-50 mm

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 A calibration block shall be made on actual pipe curvature on thickness wise with pre machine

defects for quick check.

The defect shall be on ½ to 1½.

 SHEAR WAVE PROBE :

With respect to DAC, scanning shall be carried out on both sides of weld half skip/Full skip with

minimum of 2 different angle probes to determine discontinuity within the weld, HAZ & Base

metal. Calibration Block range 0-100mm.Scanning shall cover at least skip distance ½ to 1½ skip.

 PERIODIC CHECK OF SCREEN CALIBRATION :

Calibration of screen shall be checked prior to any inspection run, prior equipment shut down

and at least in each 4 hours during continuous equipment operation.

FIGURES : -

Finger 1.a

ID OD ID

Notch of 3.2mm width and N 10 (+ 10% depth)

(Refer Figure 22A of API 1104 -20th edition.)

Figure 1.b

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 Figure 2.a 0o TR PROBE 0o TR PROBE

50 mm 50mm

Figure 2.b Both side –Scanning with45 o / 70&60o

½ V Beam Path 1V Beam Path

 INTERPRETATION OF RESULTS :

Each time the' echo from the weld bead appear during Production testing the instrument

amplification shall be altered to coincide with the reference(after reducing 6 db amplifications

and the probe shall be moved until maximum echo height is obtained, Due care shall be taken

to maintain good contact, of the probe with the material surface.

• In case, the height of the indication is equal to or greater than that of the reference echo, the

indication shall be evaluated according to the EIL spec. If the indication has been detected by

radiographic and or visual examination, the dimensions shall be judged according to the type of

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 examination, which detects the greater indication. Echoes that are between 50% and 100% of

reference line, if the operator has good reasons to suspect that the returns are caused by

unfavorably oriented cracks, he shall inform to the client.

• All the indications that are equal or greater than rejection level, established during calibration,

as described in acceptance/rejection as per API 1104 and EIL specification of this procedure or

agreed by client's inspector, shall be considered representing defects and may be cause of

rejection or repair of the weld or base metal.

Moreover, when there is an indication, which is to be repaired, such defect shall be removed for

a length corresponding to the one where no more return echo is given.

 ACCEPTANCE OR REJECTION CRITERIA :

Acceptance or rejection criteria shall be in accordance with API 1104 latest edition and EIL

specification. All defect location shall be marked & recorded for repairing

 RETEST :
Retest of repaired area will be carried out in accordance with this procedure.

6. HEALTH, SAFETY & ENVIRONMENT

 Machine operator/supervisor involved shall be an experienced person.
 It is to be noted that the special care to be adopted against snake / insects bite.
 PPE shall be used.
 Only trained rigging personnel to be deployed for this activity.
 Vehicular traffic to be diverted if required
 Personnel around the machine (if any) should be cautious about overhead utility & falling
objects.
 During the movement of earth moving equipment the operator should blow horn to
caution the people around.
 All Measuring & Test Equipment used shall be calibrated.
 All lifting devices & Tools used shall be tested & TC duly submitted to owner.

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  First Aid Box shall be available at site for all times.
 Check out the existing pipeline markers and pipeline path.

7.DOCUMENTATION

Inspection & Test Plan: As per EIL

Inspection Report : As per EIl

Standard operating procedure (SOP) shall be strictly followed

In case of conflict between procedure and specification, the specification shall govern.

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