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Subject :
TASDID OFFSHORE
DEVELOPMENT COMPANY
Project No. :
-2-88-4164
Date :
RSH-C3P-00-PL-PR-4121-D2
No. of Pages:
15/04/2013
29
D2
D2
IFA
15/04/2013
H.Y
A.GH
A.GH
D1
IFA
16/09/2012
H.Y
M.S
A.GH
D0
IFC
03/08/2012
S.P
M.S
A.GH
Rev
Description
Date
Prepared
Checked
Approved
Company
Category:
1-For Approval
2-For Review
All Right Reserved
3-For Information
Date
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
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DOCUMENT NO.
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TABLE OF CONTENTS
1.0
INTRODUCTION...............................................................................................................5
1.1
PROJECT DESCRIPTION.................................................................................................................................. 5
1.2
1.3
DEFINITIONS ................................................................................................................................................. 6
1.4
2.0
PERSONNEL QUALIFICATION..7
3.0
GENERAL.........................................................................................................................7
3.1
3.2
3.3
3.4
Equipment .................................................................................................................................................... 7
3.5
Couplant ....................................................................................................................................................... 8
3.6
4.0
4.1
4.2
Resolution....................................................................................................................................................12
5.0
SYSTEM CALIBRATION................................................................................................... 12
5.1
5.2
5.3
6.0
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
Page: 4 of 29
7.0
SCANNING .................................................................................................................... 17
7.1
7.2
7.3
7.4
Evaluation....................................................................................................................................................17
8.0
ACCEPTANCE CRITERIA.................................................................................................. 18
9.0
RECORDS ...................................................................................................................... 18
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
1.0
1.1
Page: 5 of 29
INTRODUCTION
PROJECT DESCRIPTION
Iranian Offshore Oil COMPANY (IOOC) intends to renovate and further develop the
Reshadat oil fields through execution of the Reshadat Renovation and Development project.
The Reshadat Field, formerly called Rostam, is located in the Persian Gulf 110kms southwest of Lavan Island at approximate co-ordinates of 25o 56 17 N, 52o 54 17 E at R4 and
25o 54 26 N, 52o 54 42 E at R7 drilling platforms.
The Reshadat Field will comprise of one satellite wellhead platform (W0) and a central
complex at R4 consisting of a wellhead platform, (W4) replacing the existing R4 drilling
platform, a production platform (P4) a living quarter platform (Q4) and a flare platform (F4).
The satellite wellhead platform (W0) will be a new platform located approximately 1.2 km
south of the former R7 complex. This platform normally will not be a manned wellhead
platform housing both oil production and water injection wells, drilled using a jack-up rig.
All W0 wellhead produced untreated three phase fluid will be sent via a new 16 subsea
pipeline to the P4 production platform for processing. One 8 test line will also be provided
between W0 and P4 to allow wells on W0 to be tested in the test separator on P4. Injection
water for W0 will be generated on P4 and sent to W0 via a new 10 water injection line. A
new wellhead platform (W4) will be installed and bridge-linked to P4. The W4 drilling
facilities will be used to drill both oil production and water injection wells. Oil produced will
flow over a bridge connecting the W4 platform to the production platform (P4) for
processing. Injection water will be produced on the P4 platform and pumped over the bridge
to the injection wells on W4. Two three-phase production separators will be installed on the
new P4 platform. Production from the W0 platform will flow to one production separator,
and production from the W4 platform will flow to the other. Oil from P4 production
separators will be pumped to Lavan Island using the new 16 export pipeline which about
1100m of this line will be onshore. The associated gas will be compressed at P4 compression
facilities and will be sent to KPP platform via a new 10 gas export pipeline. The flare
platform (F4) is also bridge linked to the P4 platform. This platform will be used to safely
burn any hydrocarbon vapors released as a result of operating the P4 production facilities. In
addition two subsea Power and Control cables will be installed between the new Production
platform P4 and the new Wellhead platform W0. They will be installed within individual Jtubes
.
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
1.2
Page: 6 of 29
SCOPE OF DOCUMENT
This procedure is to govern both straight and angle beam technique with contact method
of the ultrasonic examination for butt and branch welds in platform piping.
This procedure is applied to full penetration welds, heat affected zone, and adjacent
material in wrought and cast forms including pipes, fittings, but excluding pressure
vessels. ultrasonic testing can be implemented in lieu of radiographic testing in offshore
where the welds can not be tested with RT.
1.3
DEFINITIONS
The following abbreviations are used in this document:
IOOC
TASDID
D2
1.4
EPCI
PROJECT
Shall
May
Should
SUBCONTRACTOR
VENDOR
TPA
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
Page: 7 of 29
ASTM A578 Straight beam ultrasonic examination of plain and clad steel plates for
special applications.
2.0
PERSONNEL QUALIFICATION
NDT operator shall be qualified to level II of the relevant PCN standard or SNT-TC-1A.
SNT qualification will only be acceptable if they have been of awarded by an independent
THIRD PARTY AGENCY.
Responsibility
QC Manager shall be responsible for the implementation and control of this procedure.
NDT Level 2 Examiner shall be responsible for performing the tests and interpretation of
the radiographs with respect to this procedure and preparing the test reports.
3.0
General
3.1
Examination Coverage
The volume shall be examined by moving the search unit over the examination surface so
as to scan the entire examination volume.
Each pass of the search unit shall overlap a minimum of 10% of the transducer dimension
perpendicular to the direction of the scan.
3.2
3.3
Scanning Sensitivity
Scanning shall be performed at a gain setting at least two times the reference level, which
is the primary reference response corrected for distance by the DAC curve in accordance
with paragraph 5.2.
3.4
Equipment
a) The ultrasonic test instrument shall be the pulse-echo type. It shall generate,
receive and present on a CRT screen pulses in the frequency range from 1 to 10
MHZ.
b) The instrument shall provide a horizontal sweep with linearity within 1% of the
full screen range.
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
Page: 8 of 29
Couplant
A suitable liquid couplant such as reagent grade glycerin or machine oil shall be used to
couple search units to the surface being scanned.
Couplant materials used for examination shall be the same as used for the calibration.
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
3.6
Page: 9 of 29
Surface Preparation
Base metal & Weld 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.
Prior to conducting ultrasonic examination the contractor shall ensure that the weld
deposit and surrounding area are sufficiently smooth to avoid false or misleading defect
indications.
Where the weld surface interferes with the examination, the weld shall be prepared as
needed to permit the examination.
All components and welds to undergo ultrasonic test shall be at ambient temperature.
4.0
4.1
Instrument Calibration
Routine checks on the performance of instrumentation
a) The ultrasonic instrument shall be checked periodically for the screen height
linearity the amplitude control linearity (dB Accuracy) and the time base linearity
in accordance with the applicable calibration procedures as outlined in this
procedure.
b) Frequency shall be checked before use and every 3 month intervals use thereafter
in addition to the 3 monthly calibration of ultrasonic flaw detectors, annual
calibration by an independent body traceable to national / international standards
shall be performs.
c) All assessment checks shall be carried out with instrument suppression reject
controls off or at zero.
d) The reports of these assessment tests shall be recorded on calibration record sheet
shown in appendix-A Basic instrument calibration sheet
e) All instrument qualification records shall be reviewed and approved by an NDE
level III technician before the instrument is permitted to be used. The records
shall be kept in the NDE office.
Screen Height Linearity (Amplitude 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.
To verify the ability of the ultrasonic instrument to meet this linearity requirement.
a) Set a straight beam probe in position A (Fig.1) on the square (buttress) notch of
IIW block.
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
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b) Adjust the probe position to give a 2:1 ratio of amplitudes between the two
indications, with the larger set at 80% of full screen height.
c) Without moving the probe, adjust sensitivity (gain) to successively set the larger
indication from 100% to 20% of full screen height, in 10% increments (or 2dB
steps if a fine control is not available), And read the smaller indication at each
setting.
d) The reading must be 50% of larger amplitude, within 5% of full screen height.
e) The settings and readings must be estimated to the nearest 1% of full screen.
DOCUMENT NO.
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Indication Limits
% of Full Screen
80%
-6 dB
32 to 48%
80%
-12 dB
16 to 24%
40%
+6 dB
64 to 96%
20%
+12 dB
64 to 96%
DOCUMENT NO.
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Page: 12 of 29
f) Express the deviations from linearity as a percentage of the time base range
between the first and fifth back reflections displayed. (Maximum acceptable= 1%)
g) Report using a range of 250 mm
4.2
Resolution
Resolution of the combined electronic instrument and probe shall proved on IOW
(Institute of welding) and IIW (International institute of welding) standard blocks to
determine whether reflectors in close proximity to each other can be indicated clearly and
separately. The following method shall be used.
Straight beam probes
The straight beam probe shall resolve the reflectors at a range of 85mm (2mm slit),
91mm and 100mm (flat surface) of the IIW block (IIW-A1)
Angle Beam Probes
The angle probe shall resolve the three(3) hole at 2.5mm spacing for high frequencies
(usually of 4 Mhz and higher), or the two (2) holes at 4mm specing for IOW frequencies
(2 Mhz) of the IOW beam profile block in Fig. 3.
5.0
System Calibration
5.1
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
Page: 13 of 29
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 material being
examined.
For welds in ferrite pipe, the basic calibration block shall be a section of pipe of the same
nominal size, schedule, heat treatment, and material specification or equivalent PNumber grouping of the material being examined.
The sizes of the basic calibration block and locations of the calibration reflectors shall be
as shown in Fig. 4 and 5. The surface finish shall be representative of the surface of the
piping, as per ASME V.
Distance Amplitude Correction (DAC)
5.2
5.3
Calibration Confirmation
Any change in the instrument, transducer, connecting cables, couplant, operator, or power
supply shall require re-verification of calibration for the system.
Calibration shall be verified at regular intervals, four hours maximum throughout the
examination period.
If during any calibration verification it is determined that the equipment is not properly
functioning and readjustment is required, all of the product that has been tested since the
last valid calibration or calibration check shall be reexamined with the corrected
calibration.
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If during any of the function checks , it is determined that the equipment is not
function properly and within the limits then following steps shall be taken .
All of the checks shall be carried out and documented as soon as possible for
failures.
other
Equipments shall not be used until receiving required repair / adjustments and issuance
of a new calibration certificate.
If find a equipment out of calibration all of the joints tested by it since last valid check
shall be reexamined.
DOCUMENT NO.
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DOCUMENT NO.
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DOCUMENT NO.
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6.0
Page: 17 of 29
7.0
Scanning
7.1
Scanning Extent
Wherever feasible, the scanning of the examination volume shall be carried out from both
sides of the weld on the same surface. Where configuration or sdjacent parts of the
component are such that scanning from both sides is feasible, this fact shall be included
in the report of examination. In addition, Company will be informed of restricted access
situations.
7.2
7.3
7.4
Evaluation
All indications which produce a response greater than 20% of the reference level shall be
investigated to the extent that the operator can determine the shape, identity, and location
of all such reflectors and evaluate them in terms of the acceptance standards given in
DOCUMENT NO.
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para. 8. In addition, all indications which produce a response greater than 50% of the
reference level shall be recorded.
When linear indications are detected and in excess of 20% DAC and positive defect type
interpretation cannot be ascertained, one of the following options shall be adopted:
Check with radiography if adequate. (Or MT if appears to be surface breaking access
permitting).
Consider the indication as a crack.
This does not apply to spot reflectors; therefore sizing further investigation (ie
supplementary NDT, flushing off cap, modifying technique to suit, etc.) should be carried
out before rejection. Alternate sizing techniques such as 20 dB drop and / or maximum
amplitude may be used as appropriate.
8.0
D2
Acceptance Criteria
Acceptance criteria for piping are in accordance with table 1 of this procedure. for
pipeline are in accordance with table 9 of BS 4515-1 standard .
9.0
Records
The results shall be recorded in the attached form by the certified personnel who perform
the Ultrasonic examination.
Identification of repairs or retest
First repairs shall be identified as R1, second repairs R2 etc report identification shall
indicate repair status i.e., R1 shall be identified as (report no.), Suffix A, R2, Suffix B.
Additional testing without repair will be identified on the report suffixed as (Report no.),
-1, -2 etc.
DOCUMENT NO.
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Defects
Max. Allowable
Not Allowed
Solid
Slag inclusions
Inclusions
Profile
Defects
1) Isolated
2) Grouped
As isolated pores.
Copper inclusions
Root concavity
DOCUMENT NO.
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INTERNAL REFLECTION
Ultrasonic Unit Model :
Search Unit Size
Type :
Frequency :
Calibration Date :
Interval :
Method :
Block Serial No. :
Reort No. :
Serial No. :
Result:
Equipment Is :
Acceptable For Use
Recalibration Due Date :
Calibrated By :
Location Of Calibration :
Name :
Date :
Sign :
DOCUMENT NO.
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Peport No. :
Serial No. :
Type :
Frequency :
Calibration Date :
Interval :
Method :
Block Serial No. :
Nummber Of Row
Range
Display Height
Reading
Reading Error
Accuracy Required :
Equipment Is :
Name :
Date :
Sign :
DOCUMENT NO.
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Report No. :
Serial No. :
Frequency :
Type:
Calibration Date :
Interval :
Method :
Block Serial No. :
NUMBER OF
ROW
10
dB READING
DISPLAY
HEIGHT
CORRECTED
READING
dB ERROR
COLLECTIVE dB
ERROR
Accuracy Required:
Average % :
Equipment Is :
11
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DOCUMENT NO.
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DOCUMENT NO.
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1) Angle beam scanning for reflector oriented transverse to the weld. The angle
beam shall be directed essentially parallel to the weld axis. The search unit shall
be manipulated so that the angle beam passes through the required volumes of
weld and adjacent base metal specified by the referencing code section. The
scanning shall be performed at a gain setting at two time's primary reference level.
Evaluation shall be performed with respect to the primary reference level. The
search unit shall be rotated 180 deg. And the examination repeated.
2) Evaluation Any imperfection which causes an indication in excess of 20% DAC
shall be investigated to the extent that it can be evaluated in terms of the
acceptance standards of the referencing code section.
All welds require a transverse scan.
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
Thick. Range
8 25 mm
Page: 26 of 29
Used Probe
Range
0 - 100 mm
70
0 - 200 mm
60
0 - 125 mm
0 - 100 mm
70
0 - 400 mm
60
0 - 200 mm
45
0 - 200 mm
25 50 mm
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
Thick. Range
8 25 mm
Page: 27 of 29
Used Probe
Range
0 - 100 mm
70
0 - 200 mm
60
0 - 125 mm
0 - 100 mm
70
0 - 400 mm
60
0 - 200 mm
45
0 - 200 mm
25 50 mm
DOCUMENT NO.
RSH-C3P-00-PL-PR-4121-D2
Page: 28 of 29
0,45 scanning outside surface from main member run pipe or header only.
Thick. Range
8 25 mm
Used Probe
Range
0 - 100 mm
70
0 - 200 mm
60
0 - 125 mm
0 - 100 mm
70
0 - 400 mm
60
0 - 200 mm
45
0 - 200 mm
25 50 mm
ULTRASONIC
EXAMINATION REPORT
LINE No:
Report No:
DWG NO:
Report Date:
Code/Standard:
Examination Date:
Procedure No. :
Req. No :
Rev.:
Welding Process:
Material:
Test Block:
Maker
PROBE
SPECIFICATION
Equipment:
Serial No:
Couplant:
Transfer Correction :
1
2
3
4
As Machined
Weld No.
WPS
Welders Dia
(Inch)
ID
SDH
Wall
Thk.
(mm)
FBH
SMAW
Model
GTAW
Freq.
(MHz)
Angle
Size
(mm)
0
45
60
70
Other
As Ground
Pulse-Echo
NOTCH
B/REF.
Discontinuity & Evaluation
TestedL
ength Location Length
(mm)
(mm)
Type
of
Width Depth
(mm) (mm) Defect
Other
Result
Acc
Rej
1
2
3
4
5
6
7
Sketch:
mm
Remarks:
NDT Co.
TASDID
TPA
Name:
Name:
Name:
Name:
Date:
Date:
Date:
Date:
Sign
Sign
Sign
Sign
IOOC
ODS-QC-T-108