Aut Proceedure

Stolt Offshore
SANTOS LTD CASINO DEVELOPMENT OFFSHORE INSTALLATION Contract Number: 651008 RTD Automated Ultrasonic Testing SAC-CTN-00251
Originator Checker Approver

0.1 Version
: : :
RTD Grant Milne Harry Johnson

May.31.05 Issue Date
Sub Contractor Senior Project Engineer Project Technical Manager
Issued For IDC Reason for Issue
Prepared by
Checked by
Approved by
Customer Approval
Number : UT-05530 Revision : A Date Page : 30.05.2005 : 1 of 41
(Ref RTD-Steeltest Proc. RTDST-TP-UT-45)

AUTOMATIC ULTRASONIC TESTING PROCEDURE
Copyright RTD
Rntgen Technische Dienst bv Delftweg 144, 3046 NC ROTTERDAM
Project Owner Pipeline contractor UT contractor Scope
: : : : :
Santos Casino Project Santos Stolt Offshore Rntgen Technische Dienst bv Mechanised Ultrasonic Inspection of Diameter : Pipe 12" Wall thickness : 18.1 and 22.2 mm Material : SML 450 IPD DNV OS-F101 2000 This procedure is valid only for UT-examination of welds with a surface temperature up to 95C.
Based on Validity
: :
30.05.2005 Approval Level III RTD Approval Approval
Rev.N Date o

Copyright RTD
2003
Rntgen Technische Dienst bv
This document has been produced by Rntgen Technische Dienst bv (RTD). Each copy is controlled and remains property of RTD. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without the prior permission of:
Rntgen Technische Dienst bv
Inquiries can be directed to; Rntgen Technische Dienst bv Delftweg 144, P.O box 10065 3004 AB Rotterdam The Netherlands Phone : +31 10 2088208 Fax : +31 10 4158022 E-mail : rtd@rtd.nl

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Content
1.0 2.0 3.0 4.0 Purpose Scope Reference Specifications Rotoscan Equipment Description 4.1 4.2 4.3 4.4 5.0 Multi-channel Ultrasonic Equipment Recording Scanner and Umbilical Calibration Set-up
Rotoscan Set-Up Configuration 5.1 5.2 5.3 5.4 Inspection Set-Up Configuration Probe Configuration Probe Frame Layout Calibration Block
6.0
Equipment Calibration 6.1 6.2 6.3 6.4 General Setting of Inspection Gates Sensitivity Settings Scanning Preparation & Surface Conditions
7.0 8.0
Acoustic Coupling Fluid Examination 8.1 8.2 8.3 Calibration Check Step by Step description of Rotoscan Examination Verification circumferential position

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9.0
Interpretation of Results 9.1 9.2 9.3 General Reportable Indications Sizing
10.0
Acceptance/Rejection Criteria 10.1 Repairs
11.0 12.0
Reporting Personnel Qualifications 12.1 The Rotoscan Operator 12.2 The Manipulator Operator
Attachment 1 : Attachment 2 : Attachment 3 : Attachment 4 : Attachment 5 : Attachment 6 : Attachment 7 :
Inspection Set-up Configuration Transducer Selection Calibration Manufacturing Drawings Rotoscan Cover sheet Report Rotoscan Site Report Reportable indication sheet Gain settings calibration record

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1.0
Purpose The purpose of this procedure is to determine Weld Acceptability during the pipeline construction of 12" Line-pipe of the "Santos Casino Pipeline Project" as required.
2.0
Scope This procedure details methods for Automated Ultrasonic Weld Inspection (via the RTD Rotoscan Unit) of pipeline girth welds. The Rotoscan is an automated ultrasonic inspection system for pipeline girth welds, based upon the Pulse Echo Method, enhanced with mapping images and Time of Flight Diffraction. The weld is divided into a number of depth zones which are each inspected by one of an array of probes. The probes are arranged such that the entire weld is examined from both sides in a single circumferential scan. The ultrasonic information is transferred to a computer for data presentation and analysis. Inspection results are stored on harddisc ( incl. backup removable harddisc ) and a hardcopy of each weld is printed in a compressed black & white image covering the pipe circumference. After completion of pipeline inspection, all data will be stored on CDROM or DVD and presented to client. This procedure is valid for following welds: Diameter : 12 Wall thickness: 18.1 and 22.2 mm Weld bevel : J-prep Material : SML 450 IPD

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3.0
Reference Specifications Pipelines Gas and Liquid Petroleum Part 2 Welding Submarine Pipeline Systems Offshore Standard Society of Non destructive Testing Technical Council European Norm General requirements for the competence of testing and calibration laboratories Calibration check procedure for ultrasonic multi-channel equipment Control Procedure of calibration blocks for Rotoscan system
Manual UT procedure for weld repairs RTD Written Practise
AS 2885.2 2002 DNV-OS-F101- 2000 SNT TC 1A - 1996 EN 473 AS ISO/IEC 17025 1999 RTD CP 31105 Rev 4 RTD CP 31108 Rev 1 UT-05531 latest Rev A-512 Rev 3
4.0 4.1
Rotoscan Equipment Description Multichannel ultrasonic equipment A multichannel ultrasonic flaw detector shall be used, type Rotoscan, which provides an adequate number of inspection channels (referred to as sequences) to ensure a complete volumetric examination of the weld through thickness in one circumferential scan. Each inspection channel will provide a linear A scan presentation, which can individually selected. The system meets the following minimum requirements:
4.1.1 Global parameters Number of Sequences Main Gain Digitiser Sampling Frequency Overall System P.R.F : 32 : 0 40 dB : 50 MHz : 4 kHz

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4.1.2 Gate Parameters In each sequence, the following parameters shall be selectable: Transmitter and Receiver channel 1- 32 Gain 0 - 40 dB ( 2dB increments ) Gate start and length. ( min increment 0,1mm ) Delay ( mm ) Threshold level 5% - 100% Full Screen Height ( FSH ). Recordable output selection between; Amplitude and/or Transit distance, Mapping, TOFD and Coupling. Selection between First / Highest amplitude detection within gated section 4.1.3 General 4.2 Electronic noise shall be lower than acoustical noise in all sequences, for the probes and sensitivities to be used during the inspection. The signal to noise ratio of each sequence during examination shall be at least 20 dB for shear waves probes. The signal to noise ratio for TOFD probes, measured on the 2mm calibration block notch in the root, shall be at least 12 dB
Recording Inspection results are presented on-line on a 20" colour monitor. The screen layout and number of used sequences are configured to present the thickness of the weld to be examined. Distance delays are applied to the output channels to compensate for variable transducer circumferential positions. The presentation shows the following information; Amplitude and relevant transit distance (superimposed ) Mapping image sections Go-Nogo image section Coupling check section TOFD image section Circumferential position information Header section with possibility to present job specific information Time and date of inspection
The raw data of each inspected weld will be stored on a hard disc. In addition a back-up will be made on an removable hard disc. Inspection files can be reviewed at any time. The inspection results will be printed in a compressed black-white image of the weld circumference.

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4.3
Scanner and Umbilical The scanner to be used shall meet the following requirements: Automated operation during examination, however manual operation may be permitted as detailed in section 8.2 part F . Easy and quick mounting to the guideband. Capable of taking up a minimum of 10 individually spring loaded ultrasonic probes, of which the distances to the weld centreline can individually be set. Coupling controllable per probe, or per set. 15-45 metres of cable length. The scanner is equipped with an encoder for accurate measurement of the scanner position within the pipeline circumference. Minimum speed of 40 mm/sec Maximum speed of 80 mm/sec
4.4
Calibration Set-up The calibration Set-up consists of a pipe piece, being a part of thin wall 12" pipe. On the support a guiding band is mounted at the same distance from the weld centreline as the guidance band on the weld to be tested. In the pipe piece a cut-out area is present where a calibration block with the proper wall thickness as pipe under test, is mounted which is used to monitor the ongoing system performance. The calibration block(s) to be used shall be made from original piece of pipe, without coating and no weld included.
5.0 5.1
Rotoscan Set-up Configuration Inspection Set-up Configuration The inspection set-up is visualised in Attachment 1.It shows the selected probe angle(s) for the selected pulse echo, tandem and TOFD technique within the zones to be examined within the given weldbevel configuration.

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5.2
Probe Configuration In Attachment 2 the selected probes with their parameters are listed which are used for the inspection. All probes have an unique number for QA/QC purpose relating to the manufacturing process and tests within the RTD probe manufacturing department. The numbers of probes used are part of the inspection parameter file within the Rotoscan inspection program.
5.3
Probe Frame Layout The probes used for inspection are positioned within a probe frame.
5.4
Calibration block The calibration block shall be of matching wall thickness of the item under test and contain artificial defects to install the inspection sensitivity. The block shall be designed with sufficient surface area to enable the transducer array to scan the target areas in one single pass. Reflectors for the pulse echo technique shall be flat-bottom holes and notches, which are positioned at the weldbevel. TOFD notches are used to identify the system capability to detect surface breaking indications. The calibration block shall be manufactured and tested according to procedure CP-31108. The calibration block shall be identified with a hard stamped unique serial number. Attachment 3 shows the calibration manufacturing drawings. Notes: * * * Through-holes 2mm in both ends of calibration block at centre line. These reflectors are to locate weld centre position only. Notches, are to indicate the weldbevel position. TOFD notches are used to identify surface breaking indications.
6.0 6.1
Equipment Calibration General The ultrasonic equipment shall be electronically calibrated at least once per 3- month period according calibration procedure to CP-31105 latest revision.

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6.2
Setting of Inspection Gates Pulse echo and Tandem channels With each transducer positioned for the peak signal response from the calibration reflector the detection gates are to be set. The gate shall start 2-8 mm ( allowance for width of heat affected zone ) before the theoretical weld bevel preparation. The gate ends shall be after the theoretical weld centreline. All gates will be programmed to record amplitude and/or transit distance information. The gate length of the transit distance in the root channel will be extended to enable root penetration registration and for the amplitude sequence the gate shall end at the position of the root TOFD notch. Mapping channels The mapping gates in the body of the weld starts 2-8 mm (allowance for width of heat affected zone) before the theoretical weld bevel preparation. The gate length will be extended to enable cap reinforcement registration. The mapping gates in the root will be set identical to the pulse echo transit distance channels to enable the registration of the root penetration. TOFD channel The TOFD gate start will be set 3 mm before the arrival of the lateral wave and should extend up to and including the first back-wall echo, to achieve full cover of wall thickness. Note: The gate settings may be altered if geometry indications dictate. If gate settings are changed the client should be informed.
6.3
Sensitivity Settings With each transducer positioned for the peak signal response from the calibration reflector ( flat bottom holes ) the detection gates are to be set. In this position the probe holder is fixed to the probe frame. The equipment sensitivity ( echo amplitude ) for all inspection channels shall be set at 80% Full Screen Height. Calibration of surface breaking zones to be done using the 1 mm notches, for the embedded zones a 3mm FBH.

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Mapping channels in the body of the weld will be used to detect the presents of porosity , and in addition to identify the position of the weld cap reinforcement for pattern recognition purpose. The sensitivity setting is on a 1.5mm FBH at 80% FSH + 6 dB but should not be so great as to cause interfering electrical or geometric noise that could be misinterpreted. Mapping channels in the root will be used to identify the position of the root penetration for pattern recognition purpose. The sensitivity as a minimum is equal to the related pulse echo channels, increased with additional 8dB to ensure proper detection but should not be so great as to cause interfering electrical or geometric noise that could be misinterpreted. The lateral wave (RF signal) of the TOFD channel sensitivity is set at 40% FSH. The probe distance for TOFD should be calculated at 2/3 of the wall thickness (nominal beam angle) 10mm. 6.4 Scanning Preparation & Surface Condition The scanning area shall be free of weld spatters and other irregularities which may interfere with the inspection. Adjacent to one weld side, prior to welding, over the complete circumference at a fixed distance from the nose of the weld preparation, a scribeline shall be available for guidance band position adjustment. The distance from this scribeline to the weld centre-line should be 40mm with an accuracy of 1mm. Transition welds shall be machined, to match the thinnest wall thickness over a width of at least 150mm.

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7.0
Acoustic Coupling Fluid Tap water shall be used as acoustic coupling fluid, to be able to test welds in the range up to 95C. The coupling is supplied between probe contact surface and the pipe via supply channels incorporated in the probe housing. To enable good acoustical contact between the ultrasonic probes and the pipe surface, conditions as mentioned under 6.4 apply.
8.0 8.1
Examination Calibration check During the first 10 welds a calibration scan shall be made for every inspected weld. Thereafter the frequency of calibration is reduced to a minimum of one calibration every five welds. The calibration scan shall be performed every weld during slow-lay of the pipeline. Slow-lay is defined as one weld every two hours The Gain settings calibration record (attachment 7) shall be filled out twice per shift after being done for the first 10 welds. A re-calibration shall be carried out if; * * * The calibration of an inspection function differs more than - 3 or + 2 dB from the previous calibration. The gate settings need to be adjusted when they deviate more than +/0.25 mm with the previous calibration. After a weld repair. The print-out of the calibration run shall become part of the repair. After equipment breakdown If there is any reason to assume that a mechanical impact or other event occur.
In case the calibration differs from the initial setting, outside the given tolerances, the applicable probe(s) and coupling shall be checked. If the calibration has to be changed, the welds before this calibration up to the previous calibration will be re-evaluated taking the differences in the gain and/or gate adjustment into account. The result of each calibration scan shall be printed, tabulated and stored on harddisc.

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8.2
Step by Step Description of a Rotoscan Examination Before starting the step by step description the UT-system is already calibrated and a calibration scan with a record has been made. a. Adjust guiding band on the pipe to a distance of 110mm from the marks (scribe-line, which is 40mm from the weld centre-line) and parallel to the weld. The accuracy of the band setting should be 1mm. Scanner Operator will mark zero-point on the 12 o clock position of the pipe. Switch on coupling supply . Locate the scanner over the top of the pipe and make sure that all probes are past the zero point and are in proper contact with the pipe surface. Attach the scanner to the band. As long as cooling water is vaporising ( surface temperature >100) scanner shall not be attached to the band.. Switch on system and automatically the weld will be scanned in clockwise direction. In the event of a drive motor failure, the probe frame may be manually driven provided that the weld scan integrity is not compromised. This may be proven by an acceptable comparison of the last automated calibration scan to the first manual calibration scan. This is envisaged to be temporary measure and best efforts will be made to repair and re-install the automatic drive system. Systems and coupling supply will switch off automatically after a full scan with an overlap of minimum 5 cm. Check the inspection results on defect indications and proper coupling. Use the transit distance recording and mapping and images for validation of defect indications within the root area and proper alignment of the guiding band. In case of lack of coupling a second scan will be necessary. Remove the scanner from the band and attach it to the calibration block.
b. c. d.
e.
f.
g. h.
i.

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8.3
Verification circumferential position The accuracy of the circumference, measured by the system, should be checked by comparison of indications (defects or geometrical) in the overlap of the system. The tolerance is 10mm. This check should be done at least once every five welds
9.0 9.1
Interpretation of results General With the transit distance measurements and with the information from the Mapping and TOFD channels visible on the result presentation, indications shall be judged whether they are from the weld geometry or defects. The coupling channels shall be checked for couplant loss. Action shall be taken if one of the following events occur. Couplant loss length is greater than the smallest allowable defect in the acceptance criteria. In case an indication is present in the TOFD channel in a position of couplant loss a re-scan shall be required. If couplant loss persists in the zone of the indication in the TOFD, the indication shall be validated by manual UT. In case an indication is present in the PE channel experiencing loss of couplant directly adjacent to the length where couplant was lost, a rescan shall be required.
9.2
Reportable indications The inspection result should be evaluated and/or reported as follows ; To be agreed This shall be performed off-line. The report format is given in attachment 6 This is intended to give a measure of the overall weld quality and allow feedback to the welding foreman.

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9.3 9.3.1
Sizing Length Sizing The beginning and end of the defect shall be determined from the points where the signal falls below 40%FSH either side of the indication If a resolvable TOFD indication is seen without an associated pulse echo amplitude >40%FSH, then the defect length shall be determined for the resolvable part of the image. This is the only instance where length shall be measured by TOFD.
For the length measurement of porosity mapping channel shall be used. The length of the porosity is defined as the start of the cluster to the end of the cluster in circumferential direction. 9.3.2 Height Sizing The height of an indication shall be measured by PE (pulse/Echo). Sizing curves shall be used where 80%FSH = 2,5mm defect height for the embedded zones and 80% FSH= 1.2mm for the surface breaking zones. If the indication can be resolved by TOFD (clear separation between upper and lower diffraction tip) the measured defect height by TOFD shall apply. The methodology is summarised in the AUT Defect Height Evaluation Flow Chart (see page 17).

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9.3.3
Sizing of porosity When white points (> 40%FSH) are present in the mapping channels. Porosity shall be evaluated using the mapping channel(s). The height of the porosity is defined as distance between start and end of the porosity along the sound axis divided by the cos (), where is the probe angle. For the height of the porosity see following table: Measured cluster size along the sound beam (mapping) in mm 2 3 4 5 6 7 8 9 10 11 12 13 Reportable height in mm 1.5 2.3 3.1 3.8 4.6 5.4 6.1 6.9 7.7 8.4 9.2 10

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9.3.4 AUT DEFECT HEIGHT EVALUATION FLOW CHART

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9.3.6 Interaction rules Defects shall be assessed for interaction as follows: Horizontal Interaction. If the distance between the two adjacent defects at the same depth (within 3mm in the vertical plane i.e. 1 pass thickness) or the same or adjacent pulse echo channel is less than the length of the smaller of the two defects assessed by pulse echo, then the defects shall be treated as a single continuous defect. Vertical interaction: If the distance between the two adjacent defects is less than the height of the smaller of the two defects, then the defects shall be treated as a single defect. The vertical interaction of defects shall be assessed using TOFD where a clearly resolvable TOFD image is seen. Where the individual defects cannot be resolved by TOFD the separation between adjacent single diffraction tips shall be at least 2mm i.e. the maximum assumed height of a non resolvable indication. Otherwise the defects are assumed to interact and shall be treated as a single defect. 10.0 Acceptance/Rejection criteria See AUT acceptance criteria Document number; To be agreed 10.1 Repairs In the event of a repair the weld should be scanned with the AUT system after the repair is finished to prove the defect has been removed. If the weld repair extends beyond 2mm of the original weld bevel manual UT shall be performed for the whole repaired area. New indications in the repaired area shall be verified by manual UT (see procedure UT 05-531 latest Rev).

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11.0
Reporting At commencement of the project we shall issue a covering UT Report ( see attachment 4) with all parameters of the system that shall not change throughout the project. Then on a daily basis throughout the project, a Rotoscan site report will be issued for reporting of daily test results with the following information; Project and RTD project number Weld No; Date; Diameter; Wall thickness; Number of indications, location on circumference, length and location in depth; Acceptable ( C-comply) or rejected (DNC- does not comply).
For a sample of the Rotoscan site report, see attachment 5 The following set-up for a filename will be used during pipelay. Example of filename for weld 1234. 1234 1234C 1234R1 1234R1C 12.0 Scan of mainline or double joint weld Calibration scan performed before scanning weld 1234 Scan of weld 1234 after repair Calibration scan performed before scanning weld 1234R1
Personnel qualifications All NDE personnel must be able to speak the English language.
12.1
The Rotoscan operator The ultrasonic lead operator performing the examination shall: Be qualified in accordance to RTD written-practice A-512 which conforms to SNT-TC-1A 1996 and EN-473 (level II). Has experience with multichannel UT-equipment; Be trained and passed the RTD in-house testing for Mechanised Ultrasonic Inspection.
12.2
The Manipulator operator The manipulator operator, handling of scanner mechanism shall: Be trained in using mechanised UT-manipulator to satisfaction of Rotoscan operator

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Attachment 1
Inspection Set-up Configuration

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Attachment 2: Transducer Selection Example; Will be updated after arrival cal blocks Calibration Block 18.1 and 22.2mm (J-prep) Zone Z1 Z2 Z3 Z4 Z5 Z6 Reflectors Cal. block Notch 15x1x2 Notch 15x2x1 FBH 3 mm FBH 3 mm FBH 3 mm FBH 2 mm Notch 15x1x2 Notch 15x2x1 Frequency probe 4 MHz 6 MHz 4 MHz 4 Mhz 4 MHz 4 MHz 4 MHz 6 Mhz Angle 55 65 Tx 40 Rx 46 Tx 40 Rx 46 Tx 40 Rx 46 50 60 65 Inspec.tech. Pulse Echo TOFD Tandem Tandem Tandem Pulse Echo Pulse Echo TOFD Crystal 10 x 13 mm 6 mm Tx 10 mm Rx 12 x 14 mm Tx 10 mm Rx 12 x 16 mm Tx 11 mm Rx 12 mm 13 x 16 mm 10 x 15 mm 6 mm Ident. E G A B C D F H

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Attachment 3
Calibration manufacturing drawings

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Attachment 4
Rotoscan Cover Sheet report

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Attachment 5
Rotoscan report

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Attachment 6
Reportable indication sheet

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Attachment 7
Gain settings calibration record

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Stolt Offshore

Originator Checker Approver

RTD Grant Milne Harry Johnson

Sub Contractor Senior Project Engineer Project Technical Manager

Issued For IDC Reason for Issue

Number : UT-05530 Revision : A Date Page : 30.05.2005 : 1 of 41

(Ref RTD-Steeltest Proc. RTDST-TP-UT-45)

Rntgen Technische Dienst bv Delftweg 144, 3046 NC ROTTERDAM

Project Owner Pipeline contractor UT contractor Scope

30.05.2005 Approval Level III RTD Approval Approval

Number : UT-05530 Revision : A Date Page : 30.05.2005 : 2 of 41

(Ref RTD-Steeltest Proc. RTDST-TP-UT-45)

Rntgen Technische Dienst bv Delftweg 144, 3046 NC ROTTERDAM

Rntgen Technische Dienst bv

Rntgen Technische Dienst bv

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Interpretation of Results 9.1 9.2 9.3 General Reportable Indications Sizing

Acceptance/Rejection Criteria 10.1 Repairs

Attachment 1 : Attachment 2 : Attachment 3 : Attachment 4 : Attachment 5 : Attachment 6 : Attachment 7 :

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9.3.4 AUT DEFECT HEIGHT EVALUATION FLOW CHART