Exploration and Production Malaysia Inc.

GENERAL SPECIFICATION

NO. 20-1-3
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE

Document Revision Record

Revision Document System System Next Review

Date Approver
No. Custodian Administrator Owner Date
2 Sept. 2002 ZAT MI JLS GEM Sept. 2007

Attention

• This document is for ExxonMobil Use Only. It is valid for use until next revision is available.

• Refer to Summary Data Sheet for the details of changes in this revision.

• Users may apply for access to electronic copy of the document in LAN at:
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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

TABLE OF CONTENTS

1.0 SCOPE............................................................................................................................. 2

2.0 GENERAL ...................................................................................................................... 2

3.0 ABBREVIATIONS......................................................................................................... 3

4.0 QUALITY CONTROL PROGRAM ............................................................................. 3

5.0 INSPECTION PERSONNEL QUALIFICATIONS AND REQUIREMENTS .......... 5

5.1 The Written Practice................................................................................................. 5
5.4 NDT Instructor......................................................................................................... 5
5.5 UT Level II Inspector............................................................................................... 6
5.6 Radiograph Interpreter.............................................................................................. 6
5.7 Welding Inspector .................................................................................................... 6
5.8 Hardness Testing...................................................................................................... 6

6.0 NON-DESTRUCTIVE TESTING PROCEDURE ....................................................... 6

6.2 Radiographic Testing (RT)........................................................................................ 6
6.3 Ultrasonic Testing (UT)............................................................................................. 8
6.4 Liquid Dye Penetant Testing (PT).............................................................................. 9
6.5 Magnetic Particle Testing (MT)............................................................................... 10

7.0 NON DESTRUCTIVE TESTING METHODS .......................................................... 11

7.1 General .................................................................................................................. 11
7.2 Radiographic Testing (RT)...................................................................................... 11
7.3 Ultrasonic Testing (UT)........................................................................................... 14
7.4 Liquid Dye Penetant Testing (PT)............................................................................ 16
7.5 Magnetic Particle Testing (MT)............................................................................... 16
7.6 Visual Inspection.................................................................................................... 18
7.7 Hardness Testing.................................................................................................... 19

8.0 DOCUMENTATION ................................................................................................... 19

APPENDICES
1 Summaries for NDT Personnel Qualification Requirements
2 Radiograph Transfer Record (FORM A)
3 NDT Requirement for Documentation Structural & Piping

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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

1.0 SCOPE

1.1 The specification covers mandatory requirements governing Quality Assurance programs,
visual inspection, non-destructive testing and completion of Quality Control documentation for
weldments made during structural, piping and vessel fabrication.

1.2 This specification does not cover pipeline fabrication, cladding / sheathing of components or
source inspection of purchase equipment.

2.0 GENERAL

2.1 Latest revision of the following codes/specification/standards shall be used together with this
specification.

GS 0-4-0 - Common Requirements and Specifications

IP 3-18-1 - Piping Fabrication Shop or Field
IP 18-10-1 - Additional Requirements for Materials
IP 20-1-1 - Inspection Of Equipment And Materials
IP 20-1-3 - Quality Programs
AWS D1.1 - Structural Welding Code
ANSI B31.3 - Chemical Plant And Petroleum Refinery Piping
ANSI B31.8 - Gas Transmission And Distribution Piping Systems
ASME Section V - Non-Destructive Examination
ASME Section VIII - Rules for Construction of Pressure (Division I and Division II)
Vessels
ASME Section IX - Welding and Brazing Qualifications
ASTM Standards - All Standards adopted by AWS D1.1 and ASME
DIN-54109 - Non-Destructive Testing: Image Quality of Radiographs,
Concepts, Image Quality Indicators, Determination of Image
Quality Value.
ASNT-TC-1A - Recommended Practice for Training, Qualification and
Certification of NDT Personnel
ASNT-CP-189 - ASNT Standard for Qualification and Certification Of NDT
Personnel.
AELB Act 1984 - Atomic Energy Licensing Act 1984
ISO 9712 - Non-Destructive Testing - Qualification and Certification of
Personnel

2.2 The requirements of this specification augment those in the related codes. Where in conflict
with any mandated code, specification or standard, the more stringent requirements
prescribed shall be met.

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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

2.3 If in the opinion of EMEPMI reasonable doubt exists as to the quality achieved in a critical
component, EMEPMI reserves the right, at own cost to examine at any time by any means
any component of the work supplied under this specification. In the event of discrepancy
being detected, EMEPMI reserves the right to reject any of the supplied NDT reports and
request competent retest per code OR increase in sampling, at Contractor's expense.

2.4 The decision of the EMEPMI representative regarding concessional acceptance of any
essential requirement, shall be final and binding. Such concessional acceptance by EMEPMI
shall not relieve Contractor of warranties for the work.

2.5 Deviation and exception from this GS or applicable code/standards and contract adopted
shall be approved by EMEPMI through the project management of change.

3.0 ABBREVIATIONS

Abbreviations used in this specification are as follows:

ACCP - ASNT Central Certification Program.

AELB - Atomic Energy Licensing Board of Malaysia
(LPTA - Lembaga Perlesenan Tenaga Atom)
ANSI - American National Standards Institute
ASTM - American Society for Testing and Materials
ASNT - American Society for Non-Destructive Testing
ASME - American Society of Mechanical Engineers
AWS - American Welding Society
AWS CWI - AWS Certified Weld Inspector
CSWIP - Certification Scheme for Weld Inspection Personnel (U.K)
DIN - Deutsches Institut für Normung (Germany)
EMEPMI - ExxonMobil Exploration and Production Malaysia, Inc.
GS - General Specification
MLVK - Majlis Latihan Vokasional Kebangsaan, Malaysia
MT / MPI - Magnetic Particle Testing
NDT - Non-Destructive Testing
PT/DP - Liquid Dye Penetrant Testing
PCN - Personnel Certification in NDT (UK)
RT - Radiographic Testing
UT - Ultrasonic Testing

4.0 QUALITY CONTROL PROGRAM

4.1 Contractor shall submit for EMEPMI approval an inspection plan and flowcharts for the
various fabrication activities and extent of inspections to be covered by all relevant parties.
The extent of inspection activities shall be denoted as follows:

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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

H - "Hold" point inspection which indicates Contractor mandatory requirement to

fully and adequately confirm compliance in any area of inspection.
Endorsement is required prior to proceed with the next fabrication activity.

W - "Witness" point inspection to be performed by Contractor on a

selective/partial or random basis as determine on its critically or other basis of
determined need.

S - "Surveillance" inspection which indicate surveillance and general monitoring of

Contractor work in-progress.

V/R - " Verify" or "Review" inspection which indicate review or verification of

inspection reports by Contractor including associated QC Documentation.

The responsibilities to the inspection shall be the sole responsibility of Contractor, which
exclude the subcontractor.

4.2 A Quality Control Manual shall be prepared and submitted to EMEPMI for appraisal prior to
commencement of work. The appraised manual shall provide a basis for quality control and
shall be adhered to during work.

The manual shall cover procedures and systems for all stages of work including, but not
limited to, the following items:

a) Material Control: Contractor shall establish systems, procedures and keep records to
identify where all tubulars, plates and pipes are located in the completed structure,
piping and vessel so that the material can be traced back to mill certificates.

b) Welding Control: Contractor shall establish systems to monitor issue of consumables,

identify weld joint inspection and NDT status, identify welders and Welding Procedure
Specification (WPS) and sequences used, monitor welding parameters, preheat, post
weld heat treatment (PWHT), welder qualification and performance, etc.

c) NDT Operation: Contractor shall provide documented evidence on training and

certification of personnel, procedures for testing methods to be used, radiation safety
and emergency procedure, etc.

d) Miscellaneous Procedures: Procedures for processing of non-conformity and rejection,

performing dimensional checks, rectification of distorted items, etc.

e) Samples of all forms to be used in recording performing the quality control inspection
and monitoring work performed.

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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

5.0 INSPECTION PERSONNEL QUALIFICATIONS AND REQUIREMENTS

5.1 The Written Practice

5.1.1 Contractor shall establish a Written Practice for the training and certification of NDT
personnel. The level of competence, eligibility for certification and training/experience shall be
in accordance with ISO-9712. Other acceptable training and certification schemes are ASNT
Recommended Practice No.: SNT-TC-1A, ANSI/ASNT CP-189 and ACCP. Other
scheme and national standard is acceptable provided the criteria are equivalent to the above
standards approved by Contractor.

5.1.2 The Written Practice shall be approved by Contractor’s Company NDT Level III Personnel
and appraised by EMEPMI who reserves the right to audit the certification practice and
documentation. All activities pertaining to the certification shall be documented and maintained
in file.

5.1.3 The Company NDT Level III Personnel shall possess valid certification and the necessary
experience and appointed by Contractor. He or she shall manage the training and certification
systems.

5.2 When outside NDT services are engaged, Contractor’s Written Practice shall govern. All
personnel to be assigned in the project shall be approved and certified by Contractor and
appraised by EMEPMI prior to commencement of work.

Where the Written Practice and personnel certification of the outside NDT services vendor
are to be used, Contractor shall approve and endorsed these documents. It is the
responsibility of Contractor to ensure that these documents complied with the contractual and
project specification requirements and the NDT personnel has the necessary skill and
experience specific to the project. Competency assessment may be by examination or with
examination waived and all decision shall be documented.

5.3 EMEPMI reserves the right to assess the proficiency of each NDT operator, especially the
UT and RT technicians, through production tests or mock-up tests. Contractor is to prepare
the mock-up test piece for this testing purpose at no cost to EMEPMI. Final acceptance shall
be at the discretion of EMEPMI.

5.4 NDT Instructor

NDT Instructor shall meet the requirements of ANSI/ASNT CP-189. NDT Instructor who
performs hands-on demonstration shall possess NDT Level II for at least five years.

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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

5.5 UT Level II Inspector

The minimum practical experience for UT Level II is three years relevant to the job.

5.6 Radiograph Interpreter

Radiograph interpreter shall be an experienced radiographer with at least three years at RT

Level II relevant to the job. The radiograph interpreter shall possess valid qualification to
ASNT Level II or CSWIP 3.4. He shall be a person that is independent from the party that
performing the radiography works.

5.7 Welding Inspector

The minimum qualification for Welding Inspector who performs visual weld inspection and
evaluate for acceptance and rejection of works and materials shall be CSWIP 3.1 or AWS
CAWI.

5.8 Hardness Testing

Inspector who performs hardness testing shall be qualified to Level II in any of the NDT
methods and have the knowledge and skill to operate the hardness testing machine and
attended classroom or on the job training on the subject. The training to be appraised by
EMEPMI.

Refer to Appendix 1 for summary of personnel requirements.

6.0 NON-DESTRUCTIVE TESTING PROCEDURE

6.1 This section specifies the requirements for NDT procedure qualification and acceptance
criteria. Additional requirements specific to the NDT methods were also stipulated. Any
contractual requirement shall be complied in addition to this GS.

6.2 Radiographic Testing (RT)

6.2.1 This section provides the minimum requirements for film RT on welds and materials.

6.2.2 Contractor shall establish an industrial radiation safety program and emergency procedure.
As a minimum, the requirements of Atomic Energy Licensing Act of Malaysia, ACT 304 -
1984 shall be complied for personnel monitoring, area monitoring, equipment handling,
storage, usage, licensing etc.

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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

6.2.3 The supplier shall maintain written operating and emergency procedure for handling of
radioactive sources. This procedure shall be annually revised and updated to meet
governmental regulations and covers individual exposure to excess radiation, control access to
radiation areas, sources of radiation, procedures in the event of an accident, personnel
training, transportation and storage of resources.

6.2.4 Upon EMEPMI approval of the radiographic procedure, Contractor shall conduct a
procedure qualification test for each technique to be used and witnessed by EMEPMI or their
designated representative to prove the adequacy of the procedure to satisfy the following
requirements: sensitivity; density; contrast; and, geometrical unsharpness.

The test shall consist of the following:

i. Double Wall Double Image (DWDI) Technique is limited to 100mm.

ii. Double Wall Single Image (DWSI) Technique at and above 100mm.

iii. Single Wall Single Image (SWSI) Technique

Each method of imaging shall be assessed by at least:

• Thinnest wall thickness of plate or beam joint to be used in production.

• Thickest wall thickness of plate or beam joint to be used in production.

The film shall be identified with a radiographic image with the letters, PQF (Procedure
Qualification Film) and suitable letters to represent technique being used.

6.2.5 Single source of either X-ray or Gamma ray shall be used. Radioisotopes acceptable for the
works are Selenium 75 (Se-75), Iridium-192 (Ir-192) and Cobalt-60. Typical test thickness
range for Se-75 is 6.0 mm to 30.0 mm of carbon steel. In any case, the requirement of
ASME Section V shall be complied.

6.2.6 Wire type IQI as per DIN-54109 or equivalent may be used.

6.2.7 Film density shall be measured through the image of the body of the whole type IQI, or
adjacent to the designated wire of a wire type IQI on the area of interest. It the measured
density of the radiograph varies by more than minus 15% or plus 30% within the
minimum/maximum allowable density ranges specified in ASME Section V, than an additional
IQI shall be placed for each exceptional area or areas and the radiograph retaken. Additional
radiograph (s) shall be taken if the requirement of ASME Section V cannot be complied.

6.2.8 IQI selection and sensitivity requirements shall be based on single-wall thickness plus weld
reinforcement for all exposure technique. The maximum allowable weld reinforcement

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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

allowable by the governing code shall be used. Physical measurement of weld reinforcement is
not necessary. The requirement of ASME Section V, paragraph T-276 shall be complied.

6.2.9 Acceptance criteria for welds quality

Radiographs shall be interpreted to the applicable codes. When random requirement is
specified, the interpretation shall follow the 100% RT requirements.

a) Piping - ASME B31.3, Table 341.3.2 as per serve cyclic conditions.

b) Structural - AWS D1.1 paragraph 6.12.1 for statically loaded non-tubular

connection and paragraph 6.12.3.for tubular connection.

c) Pressure Vessel - ASME Section VIII Div. 1 or 2

6.2.10 Any exception shall be approved by EMEPMI before commencement of works.

6.3 Ultrasonic Testing (UT)

6.3.1 This section provides the minimum requirements for manual, contact UT on welds above 6.0
mm thick.

6.3.2 The Written Procedures and UT techniques shall comply with:

Structural Welds. - AWS D1.1, Section 6 part C and F

Piping. - ASME Section V Article 4 and 5.

Pressure Vessel. - ASME Section V Article 4 and 5.

6.3.3 Water based medium shall be used as UT couplant. Oil, grease or similar products is not
permitted. Prior EMEPMI is necessary if such product is to be used.

6.3.4 Transfer correction due to scanning surface finish and condition shall be determined
physically.

6.3.5 The length of flaw should be determined by the 6dB-drop technique. The size/height of flaw
should be determined by amplitude comparison or maximum amplitude techniques. For 6dB
drop technique, the primary reference level or distance amplitude correction (DAC) curve
shall be used as reference.

6.3.6 Scanning with angle beam probe for flaw oriented transverse to the longitudinal axis of the
weld shall be carried under the following circumstances:

a) Weld deposited by submerged arc welding process regardless of thickness.

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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

b) Chrome-molly alloy materials.

c) For base metal thickness 38.0 mm and greater.
d) Whenever transverse flaw is suspected.

6.3.7 Supplementary UT examination using two 45o angle beam probes held mechanically in tandem
shall be performed under the following circumstances:

a) Base metal thickness 100mm and greater

b) Chrome-molly alloys materials.
c) When the bevel angle of the weld preparation is 15o or less.
d) Whenever vertical flaw is suspected.

6.3.8 Computerized / mechanized UT, UT on stainless steel, duplex stainless steel or other coarse
grain materials shall be approved by EMEPMI before commencement of works.

6.3.9 Contractor shall establish a procedure for defect marking, identification, reporting and
identification of the area that has been UT.

6.3.10 Acceptance criteria for UT:

a) Structural welds, non-tubular and tubular - AWS D1.1, Section 6 part C and F
Note: Class X is not applicable for all instances.

b) Pipings - Applicable code and contractual requirement

c) Pressure Vessel - ASME Section VIII Div. 1 or 2

d) Cladding – ASTM A578/SA – Acceptance level B

6.4 Liquid Dye Penetant Testing (PT)

6.4.1 This section provides the minimum requirements for liquid dye penetant testing. Solvent-
removable color contrast or solvent-removable fluorescent penetrant techniques shall be used.

6.4.2 The written procedures and PT technique shall comply with the requirements of ASME
Section V Article 6.

6.4.3 The chemicals use in PT shall comply with the requirements of ASME Section V for chemical
compositions and contamination.

6.4.4 Preapproved brands of chemicals are ARDROX, MAGNAFLUX and ELY. Other brands
may be used upon approval from EMEPMI.

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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

6.4.5 All indication shall be evaluated based on the size of the indication and not the physical size of
the discontinuity.

6.4.6 Acceptance criteria for PT:

Structural Welds - AWS D1.1 paragraph 6.10

Piping - ASME B31.3

Pressure Vessel - ASME Section VIII Div. 1 or 2

6.5 Magnetic Particle Testing (MT)

6.5.1 This section provides the minimum requirements for continuous magnetization, color contrast
or fluorescent, wet or dry magnetic particles technique.

6.5.2 The written procedures and PT technique shall comply with the requirements of ASME
Section V Article 7.

6.5.3 Enamel spray paint, which provides very smooth finish, shall not be used as the white contrast
paint in color contrast technique. Only specific paint for the purpose shall be used.

6.5.4 Dry particle technique shall be used only when the test surface is above 50 o C.

6.5.5 Alternating Current (AC) or Half-Wave-Direct-Current (HWDC) magnetic yoke, which

comply with the requirements of ASME Section V Article 7, shall be used. Approval from
EMEPMI is necessary when permanent magnet or other magnetizing source is to be used.
Demagnetization is not necessary.

6.5.6 At least one inch on both sides of the welds or area of interest shall be tested together with
the area of interest.

6.5.7 All indication shall be evaluated based on the size of the indication and not the physical size of
the discontinuity.

6.5.8 Reporting information shall be as required by the applicable code.

6.5.9 Acceptance criteria for MT:

Structural Welds - AWS D1.1 paragraph 6.10

Piping - ASME B31.3

Pressure Vessel - ASME Section VIII Div. 1 or 2

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 GENERAL SPECIFICATION
NON-DESTRUCTIVE TESTING AT CONSTRUCTION SITE
Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

7.0 NON DESTRUCTIVE TESTING METHODS

7.1 General

7.1.1 Welds that are subjected to percentage NDT shall be selected by EMEPMI and based on
random basis. The selected welds shall be 100% tested for the whole circumferential in case
of girth butt welds.

7.1.2 All additional cost due to examination of welds described in para 2.3 and 6.1.5 shall be by
contractor.

7.1.3 All NDT requirements specified for high yield strength materials (Y.S. 345 MPa/50 Ksi and
greater) shall be performed after a minimum of 48 hours have elapsed since weld completion.

7.1.4 The extent of NDT requirement as a minimum shall be per table shows in Appendix 3.

7.1.5 All structural steel members shall be visually inspected prior to and after welding to make
certain that it meets the requirements of AWS D1.1 Sections 5 and 6, as applicable.

7.2 Radiographic Testing (RT)

This section specifies the general requirements for radiographic inspection of butt welds in
pressure vessels, structures and piping.

7.2.1 Personnel performing radiography shall comply with all governmental and plant radiation
safety regulations. Updated regulations of Atomic Energy Licensing Act of Malaysia, 1984
shall be complied with, when radiography is performed in Malaysia.

7.2.3 Radiographic inspections of piping shall be carried out in accordance with the requirements of
ANSI B31.3 and the following:

a) For hydrocarbon service in ANSI 600# and higher pressure piping, butt welds
including butted welded branch connection shall be subjected to 100% radiography
examination. In lower pressure service butt welds shall have a minimum of 10%
radiographic examination.

b) All socket welds shall have a minimum of 20% RT for gap-a-let verification. Remaining
welds or weld portion not selected for RT shall be subjected to MPI for welding
workmanship.

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 GENERAL SPECIFICATION
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Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

c) Welds or weld portion that cannot be examined by radiography shall be UT plus MP

inspected. Where weld configuration precludes the use of UT, the weld portion shall be
examined by MPI. Subjected to EMEPMI prior approval via STQ (Site Technical
Queries)

d) All onsite welding of field erected spool(s) shall be subjected to 100% radiography
inspection except for onsite welding of spools for service air, potable water and open
drain system where minimum of 20% shall be selected for radiography.

e) When defect(s) is/are detected in any single weld selected under percentage NDT, the
extent of the defect shall be explored and corrected. Two additional joints/ spots
welded by the same welder shall be selected (penalty) for NDT. When either or both
of the two additional/spots is/are found to be defective, the entire batch of welds per
isometric welded by the same welder shall be subjected to 100% NDT.

7.2.5 All cost for percentage NDT, including additional requirements that may be requested by
EMEPMI, shall be to contractor’s expense.

7.2.6 Radiography procedures utilizing gamma ray shall have film quality as specified herein with
respect to its contrast, density, sensitivity, and geometric unsharpness in production welds. In
the event the cross sectional thickness provide insufficient source to film distance or due to
other factors affecting quality of radiographic film, the subjected weld shall be subjected to
UT and MPI in addition to radiography. The use of stronger source of radioisotope such as
Cobalt 60 requires the Ministry of Health prior approval.

7.2.6.1 Sensitivity of 2% or better for gamma ray shall be maintained for all radiographic films utilizing
wire penetrameters. For thin wall (6mm & less) utilizing Double Wall Double Image or
Double Wall Single Image techniques, or in cases where complexity of application arises, the
sensitivity of maximum 3% is acceptable. However if 3% sensibility cannot be achieved
maximum sensitivity will be determined by performing Procedure Qualification Film (PQF).

7.2.6.2 The Geometric Unsharpness [Ug] shall not exceed 0.508 mm (0.020in) for thickness below
50mm (2 in) or 0.762mm (0.030 in) for thickness of 50mm (2 in) through 76mm (3 in). For
76mm (3 in) to 102mm (4 in) wall thickness, the geometric unsharpeness shall be not greater
than 1.0 mm (0.040 in).

7.2.6.3 The minimum and maximum transmitted film density at the area of interest for single film
viewing shall be 2.0 and 4.0 H & D respectively. The density shall be measured either by
comparison with a calibrated densitometer or a calibrated density strip.

7.2.6.4 When radiography is carried out in a direction that may create back scattering, lead sheets
shall be placed behind the film cassette to reduce or cut-off such scatter. A lead letter 'B' of
1.6mm (1/16 in) thickness by 12mm (1/2 in) height shall be placed on the back of the film
cassette. If the lead letter `B' appears on the radiograph as a lighter image than the

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Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

background, protection from back scatter is insufficient. A new exposure shall be taken with
additional backings.

7.2.7 Radiographic Test Equipment and Materials

7.2.7.1 ASTM E94 Type 1 film shall be used for radiography of stainless steel, copper-nickel,
titanium, high nickel duplex stainless steel & all alloys materials. ASTM E94 Type 1 film shall
also be used for carbon steel welded joints that are subjected to PWHT.

7.2.7.2 All radiography films shall have archival life of 5 years.

7.2.7.3 Film cassettes and screens shall not interfere with film interpretation. Use of slat screens
intensification requires specific approval by EMEPMI.

7.2.7.4 Film width shall be sufficient to depict all portions of the weld joint, including the heat affected
zone, and shall provide sufficient additional space for identification location markers and IQI
without infringing upon the area of interest. The film length shall be sufficient to cover the area
of interest and at least 13mm beyond the projected edge, on either side.

7.2.7.5 Each film shall contain identification and location markers with the following information as a
minimum:

a) Project Number / Job No.

b) Equipment No. / Line No.
c) Part / Joint No.
d) Date of radiography
e) Radiograph Identification Number
f) Weld Identification of repair for repaired weld, i.e. R1, R2.
g) Weld Number
h) Penetrameter location marker (F for film side)
i) Welder identification

7.2.7.6 High Intensity industrial radiograph illuminator with foot-switch, calibrated black and white
transmission digital densitometer, low power magnifying lens and applicable indication
Interpretation aids (such as, ASTM Reference Radiographs, ASME Rounded Indication
Charts) shall be used to suit film density interpretation 2.5 to 4.0.

7.2.8 Transmittal

7.2.8.1 Contractor shall be responsible for the care, packaging storage of RT film for up to 12
months after the completion contract. Transfer of all required project radiographic film from
worksite storage and files to EMEPMI in Kuala Lumpur.

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 GENERAL SPECIFICATION
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Exploration and Production Malaysia Inc.
Production Projects Department GS 20-1-3

7.2.8.2 Contractor shall provide shipping container(s) for transferring boxes of film, which has been
individually, wrapped/packaged and identified, shall be packed in heavy-duty cardboard
boxes per specific category film for welds or others. Film shall further be placed in some
chronological order, i.e., numerically or by date of film exposure. The numbers of films per
box shall be such that film is not packed so tightly as to create crimps or pressure marks on
film from worksite to EMEPMI in Kuala Lumpur. The shipping container shall be made of
sheet metal, heavy plastic or similar material with maximum outside dimensions of 534 mm
(21 in) long by 432mm (17 in) wide by 330 mm(13 in) high. When selecting the shipping
container, Contractor shall consider the protection of film from damage or loss during the
transfer cause by fire, water and unsecured container latch impact/crushing.

7.2.8.3 Each shipping container shall be lined with a suitable plastic or polyethylene sheet for film
storage. Closure of the protective sheeting shall be accomplished with moisture proof
industrial adhesive. Each shipping container shall have its content printed on both front and
backside of the container. Printing shall be legible and with waterproof marking material.

7.2.8.4 The responsibility for the proper transfer of radiographic film from worksite to EMEPMI
office shall rest with Contractor. A formal document of transfer as per Appendix 2 shall be
fully documented and signed on site by Contractor and the EMEPMI Representative attesting
to the content of the container prior to shipping to EMEPMI office Kuala Lumpur.

7.3 Ultrasonic Testing (UT)

7.3.1 This section outlines the general requirements for the ultrasonic testing of groove butt-welds,
full penetration fillet welds and node joints in structural, pressure vessels. Also UT for
thickness gauging and detection of lamination in materials for EMEPMI projects.

7.3.2 The UT Inspector as per ASME Section V Article 5 shall carry out routine calibration of UT
instrument. The calibration shall be witnessed by EMEPMI and the calibration documented.
If any of the instrument function linearity is found to be unacceptable, works that have been
UT since last calibration shall be considered void and to be re-UT with calibrated instrument.

It is not necessary for the instrument manufacturer or a third party to perform the calibration
unless there is a malfunction and the equipment been repaired.

7.3.3 All materials 38 mm and above shall be ultrasonically examined in accordance with ASTM
A578 Level C at areas where branch members will be attached. The area shall be examined
by straight beam technique 100% along and on either side of the branch member projected
line of intersection. The coverage shall be a band at least 150 mm wide.

7.3.4 Before conducting angle beam examination on welding, the base material through which angle
beam will travel shall be tested for laminar reflectors in accordance with ASME Section V,
SA 435 / SA 435-M.

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7.3.5 Jacket launch cradle sections shall be randomly examined with a minimum of 10% coverage.
However, the welds joining launch cradles to launch legs shall be 100% examined.

7.3.6 Except lamination check, UT shall be followed by MPI.

7.3.7 When examination of T-, Y-, and K- connections tubular structures is to be performed, the
operator shall also meet "Personnel" requirement as per para 6.27.2 of AWS D1.1.

7.3.8 Equipment and Reference Blocks

7.3.8.1 Calibration and Reference Blocks shall be used to prove defect detection tolerance
appropriate to the construction code required such as AWS, ASME, API 1104. One of the
following shall be used at the beginning and end of each inspection assignment.

- IIW V1 Block
- IIW V2 Block
- IOW Beam Profile Block
- RC - Resolution Block as per AWS D1.1 (Figure 6.23)
- Blocks in accordance with the specified code like the Basic Calibration Block as per
Figure T542.2.1 of ASME Section V Article 5 and DSC, DC and SC blocks as
shown in Figure K-1 in AWS D1.1.

Customized blocks may be used if it can be demonstrated that it can meet the required defect
sensitivity and acceptable to EMEPMI.

7.3.9 Identification of Examination Area

7.3.9.1 A uniform system for identification of examined area or components shall be employed. This
shall include all pertinent information necessary for accurate tracing and shall be included in
the report.

7.3.9.2 Each weld and examination area shall be located and identified by a system of reference
points marked on the component. The system shall permit identification of each weld
centerline and designation of regular intervals along the length of the weld.

7.3.10 Examination Records

Each ultrasonic examination shall be serially numbered and reported using the Ultrasonic
Examination Report form, appropriate to the applicable code. Reporting information shall
include, but not limited to the following:

a) Limitation/constraints in carrying out UT, if any.

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b) Evaluation record, describing the size, location, nature and acceptability of all relevant
indications.

7.4 Liquid Dye Penetant Testing (PT)

7.4.1 At least 50 mm (1.0 in) on both sides of the welds or area of interest shall be tested together
with the area of interest.

7.4.2 Water based products are required unless approved by EMEPMI representative. Only
solvent removable type, florescent or non-florescent of penetrant shall be used based on a
need for the application and if subjected to EMEPMI approval.

7.4.3 When examining nickel-base alloys, austenitic stainless steels or titanium, the penetrants,
solvents, cleaning agents and developers shall meet the requirements of ASME Section V,
para T625 (a) or (b), as applicable.

7.4.4 The test surface shall be closely monitored during developer application and dwell time in
order to detect small indications that may release large amount of penetrant and become
obscured before dwell time is complete. Final interpretation shall be made within 30 minutes
after the developer dwell time is complete.

7.4.5 Each dye penetrant examination shall be serially numbered and reported in the format for
Dye Penetrant Examination Report. The report shall contain, as a minimum, the following
information:

i) Project
ii) Part identification, description and examination coverage
iii) Date of examination
iv) Penetrant, solvent and developer used
v) Surface preparation
vi) Evaluation Report describing the location, type and size of indications observed,
sketches, if necessary
vii) Acceptance criteria, Inspection result;
viii) Inspector's signature, name and certification level.

7.5 Magnetic Particle Testing (MT)

7.5.1 This spection outlines the minimum requirements for the magnetic particle testing to detect
surface and subsurface discontinuities in materials and product forms for EMEPMI projects.

7.5.2 Magnetizing equipment shall be properly grounded to avoid electrical shock hazard. Plant
electrical safety rules shall be followed when wiring equipment for field used.

7.5.3 Test Equipment and Materials

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7.5.3.1 Magnetic Field Source

DC electromagnetic magnetizing yokes are preferred for detection of very fine, surface
discontinuities. AC yokes shall not be used for detecting subsurface discontinuities. AC and
DC probes shall not be used unless approved by EMEPMI.
Contractor shall conduct Yoke Lifting Force Test on the same material as the test part to
demonstrate that the requirement of E709 is met.

7.5.3.2 White Contrast Paint

A thin layer of white contrast paint shall be applied on the examination area whenever
practical to do so.

7.5.3.3 Dry Method Magnetic Particles

In cases where Dry Method Magnetic Particles examination is employed to control distortion
of work piece [e.g. Welding of tubular column ring stiffeners], the dry powder used for this
purpose must be able to provide optimum contrast to the surface temperature of the welded
sections.

7.5.4 Inspection Procedure

7.5.4.1 At least two separate examinations shall be performed on each test area. During the second
examination, the yoke axis shall be approximately 90º to its position during the first
examination.

7.5.4.2 Pole spacing shall be limited to 50mm to 200mm. Coverage is limited to a maximum distance
of one fourth of the pole spacing on either side of a line joining the two poles. Overlapping of
the pole spacing shall be at least 25mm.

7.5.4.3 When using electromagnetic yokes, the magnetizing current shall remain on while the magnetic
particles are applied and excess is allowed to drain.

7.5.4.4 Sufficient time for indication formation and observation shall be allowed between successive
magnetization cycles.

7.5.4.5 For non-florescent examination, the test area shall be examined for indications under natural
or artificial white light of minimum intensity 500Lux.

7.5.5 Evaluation

7.5.5.1 Flux leakage fields that are not attributed to discontinuities can produce false indications.
Non-relevant indications shall be regarded as unacceptable until the indication is either

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eliminated by surface conditioning, or demonstrated to be non-relevant by re-examination

using the same or a different NDT technique.

7.5.5.2 All relevant indications shall be evaluated in accordance with applicable acceptance standards
specified in design documents, codes or the approved specific procedure for the item being
examined.

7.5.6 Reporting

7.5.6.1 All magnetic particle examinations shall be reported in the "Magnetic Particles Examination
Report". The report shall contain, as a minimum, the following information:

i) Project
ii) Date of inspection
iii) Examination Procedure reference
iv) Applicable code, standard or design documents
v) Part identification, description and material type, examination coverage
vi) Surface preparation/precleaning
vii) Magnetizing equipment type, make
viii) Magnetic particle and contrast paint - manufacturer
ix) Magnetization technique, pole spacing, direction - add sketches if necessary
x) Method of particle application
xi) Inspection results, description of indications including type, location, size and number;
sketches if necessary
xii) Interpretation and evaluation record
xiii) Inspector's signature, name and certification level

7.5.7 Demagnetization

7.5.7.1 When required by EMEPMI, in situations where residual magnetization can adversely affect
subsequent welding or manufacturing processes, examined components shall be demagnetized
by the supplier by any of the following means:

i) Decreasing AC technique - permeability less

ii) Reversing DC technique
iii) Fast removal of AC coil - for small parts

7.6 Visual Inspection

7.6.1 All joints in piping shall be visually inspected before and after weld completion. Criteria
established for acceptable weld geometry and limitations on imperfections in welds shall be
that specified in ANSI B31.3, and following requirements.

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7.6.1.1 Root bead of joints such as elbows, flanges, tees, etc. where internal is accessible for
inspection shall be visually accepted prior to depositing fill and cap passes.
7.6.1.2 Width of the weld shall be slightly greater than the width of the bevel. It's recommended that
the bead shall extend a minimum of 1.6 mm on each side of the bevel.

7.6.1.3 For reinforcement, the bead shall extend not be less than 1.0 mm or more than 3.0 mm above
parent metal.

7.6.1.4 Penetration of weld shall extend the full depth of the pipe wall, including both the
beveled and straight portions. The internal surface of root bead shall be free from "whiskers"
or "icicles".

7.6.1.5 The cap and other beads shall be smooth in appearance and shall contain no valleys or
indentations on the crest or at the edge. Deposited metal shall be free from folds, cold shuts,
gas holes, or other defects. Upon completion of the weld, all oxide, porosity and slag on and
around the weld shall be removed to allow proper inspection and application of coatings.

7.7 Hardness Testing

7.7.1 Hardness testing in addition to contracted/code requirement shall be carried out on primary
weld joints that are subjected to PWHT.

7.7.2 Acceptable Brinell hardness shall not exceed 225 BHN. The test shall be carried out
separately on base metal, weld metal and the heat-affected zone.

7.7.3 Portable POLDI Brinell hardness tester may be used providing that the diameter of the
indentation ball is between 7mm to 10mm, and the hardness of the reference bar is within
±2.5 percent of the maximum hardness.

7.7.4 Alternative portable hardness tester that uses conversion tables may be used upon approval
from EMEPMI and converted to Brinell provided it is less than 220BHN. On thin material
where the material is subjected to vibration, portable hardness tester based on
dynamic/rebound principle shall not be used unless the works can be properly rested

8.0 DOCUMENTATION

8.1 The required completion documentation shall consist of at least the following:

8.1.1 Material Summary records and relevant mill certificates, receiving inspection report
verification records etc.

8.1.2 Welding summary records and relevant WPS, WPQT, welder certificates, performance
records, weld rejection statistics, joint fit-up, visual, NDT reports, repair records, PWHT etc.

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8.1.3 Non-Conformance reports, Corrective Action Requests, EMEPMI rejection / release notice
and contractor's site queries.

8.1.4 Inspection Daily Log

8.1.5 I& E Precommissioning Records

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APPENDIX 1

Summaries for NDT personnel qualification requirements.

NDT METHOD/LEVEL QUALIFICATION MINIMUM EXPERIENCE

(Additional)
1) Company NDT Level ISO 9712 Level 3 or Five years experience as NDT
III ASNT/ACCP/CP-189 Level III Level 2/II with or without current
NDT Level II Certification in the
NDT method to be practiced.
2) Radiographer ISO 9712 Level 2 or Licensed by AELB
ASNT/ACCP/CP-189 Level II
3) Radiograph Interpreter ISO 9712 Level 2, or 36 months as RT Level II
ASNT/ACCP/CP-189 Level II radiographer.
4) UT Inspector ISO 9712 Level 2 or 36 months of relevant experience.
ASNT/ACCP/CP-189 Level II
5) Liquid Dye Penetrant ISO 9712 Level 2 or -
Inspector ASNT/ACCP/CP-189 Level II
6) Magnetic Particle ISO 9712 Level 2 or -
Inspector ASNT/ACCP/CP-189 Level II
7) Hardness testing Level II in any NDT method. Training on the use of instrument
and application.

Note:

1) ISO 9712 denotes different Levels of qualification by 1, 2 and 3 where as ASNT uses I, II and
III
2) It is the sole discretion of Contractor/employer to certify a NDT inspector who has been
certified under other schemes like PCN and MLVK to NDT Level II in accordance to the
Written Practice if the requirements can be fulfilled. The certification can be with or without
examination and the decision has to be documented subject to EMEPMI acceptance.
3) MINIMUM EXPERIENCE (ADDITIONAL) above is additional experience required in
addition to the experience stipulated in the Written Practice.

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APPENDIX 2

RADIOGRAPH TRANSFER RECORD (FORM A)

TRANSFER FROM: TO: EMEPMI DPD QUALITY

CONTROL

CONTRACT NO:

PROJECT AND/OR PLATFORM IDENTIFICATION:

DEPARTMENT: DEVELOPMENT PROJECTS

BOX NO. DIVISION: CONSTRUCTION SERVICES DIV

FILE SOURCE:

DATE:

RADIOGRAPH COMMENTS / REMARK

QUANTITY WELD NUMBER PARTICULARS OF RADIOGRAPHIC FILM / REPAIRS / ETC

PREPARED & CHECKED BY: CHECKED BY: RECEIVED BY:

CONTRACTOR EMEPMI CS / RE EMEPMI QC SUPERVISOR

NAME: NAME: NAME:

SIGNATURE: SIGNATURE: SIGNATURE:

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APPENDIX 3

Following are the NDE requirements for structural, piping and pressure vessels. Refer also to relevant
codes, drawing, contract and specification minimum requirements.

No. CATEGORY NON-DESTRUCTIVE METHODS

RT UT+MT MT PT

A) STRUCTURALJACKET AND JACKET CAP

Fabricated Tubulars (full pen welds)

Butt welds - jackets legs, piles, conductors 100%
Butt welds - primary braces 100%
Butt welds - Other 10%
Transition can long seam welds 100%
Tubular long seam welds 10%

Beam Splices
Box beam butt welds 100%
Fabricated Beams 100%
Deck Beams 100%

Tubular TKY full pen welds

Vertical framing/Primary elevations & Column rows 100%
Members attached to above 100%
Primary braces attached to launch legs 100%
Members attached to fabricated box beams 100%
Knee braces 100%
Members attached to tubular joint cans in horizontal elevation 100%
Misc. attachments, except as above 10% 10% (not
UT’d)
Other full pen T-connections
Fabricated box beams 100%
Flange welds beam T-connection (major) 100%
Flange welds beam T-connection (minor) 10%
Box beam stiffeners 100%
Internal/external ring stiffeners 100%
Leveling padeye 100%
Pulling lugs 100%
Beams/plates attached to legs 100% 100% (after I/O)
Jacket launch cradle to jacket legs 100% 10% (not UT’d)
Jacket launch cradle-other 10%

Fillet Welds
Internal/external ring stiffeners-MT cleared 10% 100%
Internal/external ring stiffeners-MT failed 100% 100%
Other, to jacket and jacket cap legs 100%
All other 10%

Others
All backgouge areas 100%

B) INTEGRATED DECK

Fabricated Tubulars (full pen welds)

Butt welds - deck legs 100%
Butt welds - primary braces 100%

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Butt welds - Other 10%

Transition can long seam welds 100%
Tubular long seam welds 10%

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APPENDIX 3 (continued)

No. CATEGORY NON-DESTRUCTIVE METHODS

RT UT+MT MT PT

B) INTEGRATED DECK (cont'd)

Beam Splices
Box beam butt welds 100%
Fabricated Beams 100%
Deck Beams 100%

Tubular TKY full pen welds

Vertical framing/Primary elevations & Column rows 100%
Members attached to above 100%
Members attached to fabricated box beams 100%
Knee braces 100%
Members attached to tubular joint cans in horizontal elevation 100%
Misc. attachments, except as above 10% 10% (not
UT’d)
Other full pen T-connections
Fabricated box beams 100%
Flange welds beam T-connection (major) 100%
Flange welds beam T-connection (minor) 10%
Box beam stiffeners 100%
Internal/external ring stiffeners 100%
Leveling padeye 100%
Pulling lugs 100%
Lifting padeyes, Lift Trunnion 100%
Beams/plates attached to legs 100%

Fillet Welds
Internal/external ring stiffeners-MT cleared 10% 100%
Internal/external ring stiffeners-MT failed 100% 100%
Other, to deck legs/columns 100%
All other 10%

Others
All backgouge areas 100%

C) MODULES, QUARTERS, & HELIDECKS

Full Penetration Welds

Horizontal beams, vertical & diagonal truss members 100%
Flange welds beam T-connection (major) 100%
Flange welds beam T-connection (minor) 10%
Haunch/box beam butt weld 100%
Plate butt welds 50%
Internal stiffeners – box beams 100%
External stiffeners – girders, haunch, box beams 100%
Ring stiffeners 100%
Flare/vent hinge turnings, Padeyes, Lift Trunnion 100%
Tie-downs 10% 90%
Other 10% 10%(not
UT’d)
Fillet Welds

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Internal/external ring stiffeners – MT cleared 10% 100%

Internal/external ring stiffeners – MT failed 100% 100%
Trusses/Columns 100%
All other 10%

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APPENDIX 3 (continued)

No. CATEGORY NON-DESTRUCTIVE METHODS

RT UT+MT MT PT

C) MODULES, QUARTERS, & HELIDECKS (cont'd)

Beam Splices
Box beam butt welds 100%
Fabricated Beams 100%
Deck Beams 100%

D) FLARE/VENT BOOMS & BRIDGES

Full Penetration
Hinge sections to chord 100%
TKY tubular connections 100%
Tiedowns 10% 10%(not
Butt joints for Splices 100% 10% UT’d)
Other 10% (not
UT’d)
Fillets Welds
Any 10% 10%(not
UT’d)

E) CRANE PEDESTALS

Fabricated Tubulars
Crane Pedestal long seam welds 100%
Crane Pedestal to module/supports 100%
Circumfrential weld 100%
Cone adapter 100%

Other Full Penetration Welds

T-connection to deck/beams 100%
Boom sections main framing 100%
Attachment welds to crane pedestal 10%*
Mask 10% 100%
Boom sections pin connections 100%
Lifting Lugs, Monorail, hoisting 100% * Based on crane manufacturer’s
engineering practices

Fillets Welds
TKY boom braces fillet weld 10% *
Other fillet welds e.g. (cabin, deck, engine housing etc) 10%

F) MISCELLANEOUS
Sea Fastening 100%
Piping Support Beams for Load Carrying Members 100%
Piping Support Non Load Carrying Members/Pipe Rack 10%
Fillet Welds not subject to MT (ex gussets, ladders, grating sprts) 100%

G) WELD REPAIRS
As per original weld requirement

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General
Grooves-flame cut, or by back gouging 100%
Attachment welds, after grinding smooth 100%
Arc strikes, after repair/grinding smooth 100%

H) OTHERS
All backgouge areas 100%

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APPENDIX 3 (continued)

No. CATEGORY NON-DESTRUCTIVE METHODS

RT UT+MT MT PT FE

I) PIPING 100%

Carbon Steel
Butt welds including branch connections < 300# Rating 10%
Butt welds including branch connections >300# Rating 100%
Socket welds 20% 100%
PWHT welded joints 100%

Austenitic Stainless Steel

Butt welds including branch connection <300# Rating 10%
Butt welds including branch connections >300# Rating 100%
Socket welds 20% 100%

Duplex Stainless Steel

End/bevel prep 100%
Root and Cap 100%
Butt welds including branch connections-all ratings 100%
Socket welds 100%

Copper-Nickel
Butt Welds :-
First 10 welds 100% * Rejection requires return to next
Second 10 welds 50% higher inspection level.
Third 20 welds 10%
(or 2 joints for every 50 joints welded)
Balance 2%

Socket Welds 20%

Slip-On-Flanges - Internal 100%
- External 20%

All other corrosion resistant alloy 100%

Miscellaneous
Non pressure containing fillet weld and butt welds 10%

Repair welds
General As per original weld requirement
Grooves – flame cut or back gouging 100%
Fabrication aid, attachment welds, arc strike and tack weld 100%

J) PRESSURE VESSEL

Refer GS 5-1-1 and IP 5-1-1 for NDT requirement for

pressure vessel. No additional requirement in this
specification.

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APPENDIX 3 (continued)

Note: -

1) Joints that cannot being inspected by RT shall be inspected using UT+MT/PT. If the joint can not
be UT due to weld configuration, progressive MT or PT shall be required upon approval of
EMEPMI representative.

2) When progressive examination is invoked at the discretion of EMEPMI, the following guide shall be
followed:-

a) When random or spot examination of as single weld or weld lot/per ISO discloses welding that
does not comply with the specified acceptance criteria, two additional examinations of equal
extent to the original examination shall be taken of the same weld or weld lot at location
specified by EMEPMI.

b) If either of the two additional examination do not meet the acceptance criteria, the entire length
of weld or weld lot represented by original examination shall be rejected. The entire length of
weld or weld lot shall be examined and areas not meeting the acceptance criteria shall be
repaired.

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