1744 - UT PROCEDURE (For Final) PDF [PDF]

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Engineering & construction

ULTRASONIC TEST PROCEDURE Document No. DES-1744-QA&QC-04 Purchase Order No.: Equipment/Material: Stack

REV

DATE

DESCRIPTION

00

11-9-2013

FOR FINAL/ CERTIFIED

A

12/02/2013

Issued for client review

B

22/07/2012

Issued for client review

PREPARED

CHECKED

RONAK MEHTA RONAK MEHTA

RONAK MEHTA RONAK MEHTA

DESCON ENGINEERING FZE

APPROVED

SAKET KUMAR SAKET KUMAR

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TABLE OF CONTENTS S.NO

CONTENT

1. SCOPE 2. REFERENCE 3. PERSONAL QUALIFICATION 4. SURFACE CONDITION 5. EQUIPMENT 6. SCREEN HEIGHT AND AMPLITUDE CONTROL LINERITY 7. SEARCH UNITS / PROBES 8. COUPLANT 9. EXAMINATION COVERAGE AND RATE OF PROBE 10. TECHNIQUE FOR EXAMINATION OF PLATES 11. TECHNIQUE FOR EXAMINATION OF FORGING 12. TECHNIQUE FOR EXAMINATION OF WELDS 13. WELD METAL OVER LAY

CLADDING

14. REFERENCE POINTS FOR EXAMINATION 15. LOCATION AND CONFIRMATION OF IMPERFACTIONS 16. CHARACTERIZATION AND SIZING OF IMPERFACTION 17. TECHNIQUE SHEET 18. ACCEPTANCE CRETIRA 19. POST EXAMINATION CLEANING TECHNIQUE 20. REPORTS AND EXAMINATIONS RECORDS TABLE – 1 [PROCEDURE REQUIREMENTS OF AN ULTRASONIC EXAMINATION] ATTACHMENT -1[GUIDANCE NOTES FOR PROBE SELECTION] ATTACHMENT -2[BASIC CALIBRATION BLOCK] ATTACHMENT -3[BASIC CALIBRATION BLOCK FOR PIPES] ATTACHMENT -4[GUIDANCE NOTES FOR EXAMINATION OF WELDS] ATTACHMENT -5[ALTERNATE CALIBRATION BLOCK FOR WELD METAL OVERLAY] ATTACHMENT -6[TECHNIQUE SHEET FOR ULTRASONIC EXAMINATION] ATTACHMENT -7[ACCEPTANCE CRITERIA FOR ULTRASONIC EXAMINATION] ATTACHMENT -8[ULTRASONIC EXAMINATION REPORT] ATTACHMENT -9[NOZZLE DETAIL –SINGLE & DOUBLE BEVEL WELD]

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SCOPE This procedure describes the method for ultrasonic examination of plates, forging and butt / fillet weld single or double groove for carbon and low alloy steels up to a maximum thickness of 200 mm in plates (shell) /pipe to shell/ head, including austenitic/ ferritic weld metal overlay cladding.

2.0

REFERENCES      

3.0

ASME Sec VIII Div 1 and 2 Edition 2011 Addenda 2011a ASME Sec. I Edition 2011 Addenda 2011a ASME Sec V Article 4 & 5 Edition 2011 Addenda 2011a Saudi Aramco Specification No :SAEP-1146 32-SAMSS-004 32-SAMSS-029

PERSONNEL QUALIFICATION 3.1

Ultrasonic Testing shall be performed by Level I or II and results evaluated by Level II or III qualified as per DESCON written practice.

3.2

If sub-contracted, their personnel shall be qualified to the Levels as specified above (except Level III) as per the sub-contractors written practice. Qualification of these personnel shall be verified and approved by the DESCON Level III. Personnel Qualification: Shall be in accordance with the ASNT SNT-TC-1A 2006, per ASME Section V, T-120. (1), note No. 3, and ASME Section VIII, Div. 1, Table U3.Table U-3 of ASME Section VIII Division. Testing shall be performed by personnel certified in accordance with the requirements of ASNT SNT-TC-1A, 2006 edition per adopted by latest addenda of ASME/ANSI B31.1,

4.0

SURFACE CONDITION 4.1

5.0

The surface from which examination is required to be conducted shall be free from rust, loose scales, weld spatters etc. to enable smooth movement of the search units on the surfaces.

EQUIPMENT 5.1

The examination shall be conducted with a pulse echo ultrasonic instrument having AScan display and which is capable of generating frequencies in the range of at least 1MHz to 5MHz & shall be equipped with a stepped gain control in units of 2dB or less.

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5.2

The proper functioning of the instrument shall be checked at least one of the reflectors in the basic calibration block or calibration standards/ block specified below at the beginning and end of each examination or series of similar examinations, every 4 hour during the examination, whenever examination personnel are changed and at any time when malfunctioning is suspected. If during any check it is observed that the instrument is not functioning properly, all examination carried out since the last valid calibration shall be repeated.

5.3

If the instrument has damping control, it may be used if it does not reduce the sensitivity of the examination. The reject control shall remain in “OFF” position for all examinations.

SCREEN HEIGHT AND AMPLITUDE CONTROL LINEARITY 6.1

The ultrasonic instrument shall provide linear vertical presentation within ± 5% of the full screen height for 20% to 80% of the calibrated screen height. The settings and reading shall be estimated to the nearest 1% of full screen.

6.2

The ultrasonic instrument shall utilize an amplitude control accurate over its useful range to ± 20% of the normal amplitude ratio, to allow measurement of indications beyond the linear range of the vertical display on the screen.

6.3

The above checks shall be carried out for each ultrasonic instrument at the beginning of each period of extended use or 3 months, whichever is less. The checks shall be carried out as per Appendix I and II of Article 4 of applicable ASME Sec V. For digital type instruments the above checks shall be carried out at the interval of one year or prior to first use thereafter.

SEARCH UNITS/PROBES 7.1

A single or dual transducer probes shall be used for examination.

7.2

For plates, forging and welds, minimum of 2.25MHz frequency probes shall be used for examination. For castings, frequency of 1MHz shall be used for examination. However other lower frequencies may also be used for evaluation purpose if equal or better sensitivity can be demonstrated and recorded or when the production material grain structure require the use of other frequencies to assure adequate penetration and better resolution.

7.3

The probes with contoured contact wedges may be used for examination of such surfaces, however in such cases; all calibration shall be performed with the contoured wedges to be used during the examination.

7.4

The angle probes shall be checked for angle of beam and the exit point using IIW-V1 block and records of such checks shall be kept. If the angle of beam or the exit point varies from the original, it shall be suitably marked on the probes.

7.5

Guidelines for the selection of probe are given the Attachment 1.

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8.2

10.0

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COUPLANT 8.1

9.0

ULTRASONIC TEST PROCEDURE

The couplant, including additives, shall not be detrimental to the material being examined. Couplants used on nickel base alloys shall not contain more than 250 ppm of sulfur

8.3

Couplants used on austenitic stainless steel, duplex stainless steel or titanium shall not contain more than 250ppm of halides (chlorides plus fluorides).

8.4

Same type of couplant shall be used for calibration and examination.

EXAMINATION COVERAGE AND RATE OF PROBE MOVEMENT 9.1

Total area / volume which need to be examined shall be scanned by moving the search unit over the surface so as cover the entire examination area. Each pass of the probe shall overlap a minimum of 10% of the transducer dimension perpendicular to the direction of the scan.

9.2

The rate of probe movement for examination shall not exceed 6 in./sec. (150 mm/sec)

9.3

During scanning the Reject control of the equipment shall be kept at zero position.

TECHNIQUE FOR EXAMINATION OF PLATES 10.1

When required, the plates shall be examined using normal beam probes in accordance with the requirement of SA-435/SA-435M,SA-577/SA-577M, SA 578 / SA578M and as supplemented by the referencing Code section / agreed standard.

10.2

The sweep range and distance amplitude calibration shall be in accordance with SA 435 or SA 578 and as supplemented by the referencing Code section/agreed standard.

10.3

The examination, coverage, recording, acceptance criteria and reporting shall be in accordance with SA 435 or SA 578 and as supplemented by the referencing Code section/agreed standard.

TECHNIQUE FOR EXAMINATION OF FORGING AND BARS

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11.1

When required, the forging and bars shall be examined in accordance with the requirements of SA-388/SA-388M and as supplemented by the referencing Code section/agreed standard.

11.2

The sweep range and distance amplitude calibration shall be in accordance with SA388/SA-388M or SA-745/SA-745M and as supplemented by the referencing Code section/agreed standard.

11.3

All forging and bars shall be examined by straight-beam probes examination technique. Ring forging and other hollow forging shall, in addition, shall be examined using angle beam probes in two circumferential and axial directions, if OD to ID ratio is less than 2 and length of forging is more than 2 inches.

11.4

Ring forgings made to fine grain melting practices and used for vessel shell sections shall be also examined by the angle beam examination technique in two axial directions.

TECHNIQUE FOR EXAMINATION OF WELDS 12.1

GENERAL 12.1.1 12.1.2

12.1.3 12.1.4

12.2

The following paragraphs describe the technique for ultrasonic examination of full penetration welds. These requirements are applicable for ultrasonic detection, location and evaluation of ultrasonic reflectors within the weld, heat affected zone and adjacent material. Guidelines for the examination of welds are given in the (Attachment 4). Applicable Technique sheets for the welds are identified & the technique sheet shall be attached along with the procedure.

BASIC CALIBRATION BLOCKS 12.2.1

The basic calibration blocks shall be used to establish the primary reference response of the equipment. An alternate reflector(s) may be used provided that the alternate reflector(s) produces the sensitivity equal to or greater than the specified reflectors.

12.2.2

The material from which the block is fabricated shall be of the same product form, and material specification or equivalent P-number grouping as one of the materials being examined. For the purpose of this section, P-numbers 1, 3, 4 and 5 are considered equivalent.

12.2.3

Where the component material is clad, the block shall be clad by using same weld procedure as the production part. The calibration block shall receive at least the minimum tempering treatment required by the material specification for the type & grade and a

12.2.4

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12.3

12.4

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component weld is heat treated at the time of examination if the calibration block contains weld other than cladding. The finish on the surfaces of the block shall be representative of the surface finish of the components and the block material shall be completely examined with normal beam method for indications exceeding the remaining back reflection so that such areas can be excluded from the beam path required to reach the calibration reflectors.

12.2.6

Each calibration block shall be identified by a unique number and details of block regarding product form, heat treatment and other details shall be kept.

12.2.7

The dimensions and the reflectors shall be in accordance with figure given in Attachment 2 of this procedure.

12.2.8

The temperature difference between calibration block and examination surface shall be within 25degree F (14 degree C).

DIAMETER OF MATERIAL UNDER EXAMINATION 12.3.1

For examination in materials where the examination surface diameter is more than 20in. (508mm), a flat or curved calibration block shall be used.

12.3.2

For materials with diameters 20in. (508mm) and less, the basic calibration block shall be curved. A curved calibration block may be used to calibrate the examination on surfaces in the range of 0.9 to 1.5 times the basic calibration block diameter.

SWEEP RANGE CALIBRATION 12.4.1

For normal beam examination, the sweep range calibration shall be carried out using back reflection from the basic calibration block for the measured thickness. The ¼t hole indication shall be delay controlled positioned to ¼ of the sweep range. Alternatively, IIW-V1 block may also be used for the sweep range calibration.

12.4.2

For angle beam examination, sweep range shall be calibrated using basic calibration block to indicate 2 divisions of the total sweep equal ¼t. Alternatively, IIW-V2 block shall be used for sweep range calibration for angle beam examination.

12.5 SENSITIVITY SETTING: DISTANCE AMPLITUDE CORRECTION (DAC) CURVE 12.5.1 The distance amplitude correction curve for normal beam and angle beam examination shall be established using ¼ t, ½ t and ¾ t holes on the Basic calibration block and by using following method:   

Position for maximum response from the hole, which gives highest amplitude. Adjust the sensitivity control to provide an 80% of full screen indication from the hole Mark the peak of the indication on the screen with a suitable marker.

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Without changing the sensitivity setting, position the search unit for maximum response from at least two other holes at different depths and marks the points. Also manipulate the search unit for maximum response from a bottom notch and mark the point. Connect the screen marks and extend through the thickness to provide the distance amplitude curve.

12.5.2

The sensitivity setting for DAC shall be the Primary Reference Level (PRL) for examination.

12.5.3

In case of piping weld, separate DAC shall be established for both axial and circumferential notches by using basic calibration block shown in the Attachment 3.

CALIBRATION CHECK 12.6.1 When any part of the examination system is changed, a calibration check shall be made on the basic calibration block to verify that distance range points and sensitivity settings have not been changed beyond limits. 12.6.2

A calibration check on at least one of the basic reflectors shall be made at the finish of each examination, or by series of similar examinations, 4 hours during the examination and when examination personnel are changed.

12.6.3

If a point on the DAC curve has moved on the sweep line more than 10% of the sweep reading or 5% of the full sweep or the DAC curve has decreased 20% or 2dB of its amplitude, all data sheets since the last calibration shall be marked void. A new calibration shall be made and recorded and the area covered by the void data shall be re-examined. If the DAC curve has increased more than 20% or 2dB of its amplitude, all recorded indications since last valid calibration shall be re-examined with the corrected calibration and recorded.

12.6.4

When the referencing Code section requires the detection and evaluation of all indications exceeding 20 % of DAC, the gain should be increased an additional amount so that no calibration reflector indication is less than 40% FSH. As an alternate, the scanning sensitivity level may be set at 14 dB higher than the reference level gain setting. With this increase in dB reference DAC becomes 20% DAC.

12.6.5

System Changes. When any part of the examination system is changed, a calibration check shall be made on the basic calibration to verify that distance range points and sensitivity setting (s) satisfy the requirements of 12.6.7.

12.6.6

Calibration Checks. A calibration check on the least one of the reflectors in the basic calibration block or a check using a similar shall be performed at the completion of each examination or series of examinations, and when examination personnel (except for automated equipment) are changed. The distance range and sensitivity values recorded shall satisfy the requirements 12.6.7.

12.6.7

Confirmation Acceptance Values

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Distance Range Points If any distance range point has moved on the sweep line by more than 10% of the distance reading or 5% of full sweep, whichever is greater, correct the distance range calibration and note the correction in the examination record. All recorded indications since the last valid calibration or calibration check shall be reexamined and their values shall be changed on the data sheets or re-recorded. Sensitivity Settings If any sensitivity setting has changed by more than 20% or 2 dB of its amplitude, correct the sensitivity calibration and note the correction in the examination record. If the sensitivity setting has decreased, all data sheets since the last valid calibration check shall be marked void and the area covered by the voided data shall be reexamined. If the sensitivity setting has increased, all recorded indications since the last valid calibration or calibration check shall be reexamined and their values shall be changed on the data sheets or re-recorded. 12.7

NORMAL BEAM SCANNING 12.7.1

Scan the adjacent base metal for at least one full skip distance (of the angle beam probe) from the weld, on the surface from (at least single surface) which the examination is to be performed to detect the reflectors that might affect the interpretation of angle beam result. Record the location and areas of such reflectors; however these indications shall not be used for acceptance or rejection.

12.7.2

Scan the weld by normal beam probe to the extent possible. This scanning shall be performed at the gain setting of at least two times the PRL (6dB more than the PRL dB setting). Evaluation shall be performed with respect to PRL.

12.7.3

The normal probe scanning over the weld surface (dressed smooth reasonably) is performed for following type of indications:

  

Measure the depth of any excessive root penetration or root concavity. Determine the presence and extent of any lack of fusion into the backing metal. Detect any lack of inter run fusion or other favorably oriented imperfections in

the weld. 12.8

ANGLE BEAM SCANNING 12.8.1 The angle beam shall be directed at approximately right angle to the weld axis from two directions where possible to detect linear and non-linear imperfections, which are predominately longitudinal with respect to the weld axis. 12.8.2 The most critical part of the examination is that for in imperfections lying along the fusion faces, such as lack of side wall fusion or HAZ cracking. Other imperfections like crack or slag inclusion have a more random orientation. 12.8.3 For reflectors oriented transverse to the weld, the angle beam shall be directed parallel to the weld axis. The search unit shall be manipulated so that ultrasonic energy passes through the required volume of the weld and the adjacent base metal.

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The search unit shall be rotated 180 degree and the examination repeated. Transverse imperfections are usually planar in nature. For critical examination, weld reinforcement shall be ground flush with the base metal. 12.8.4 When weld cap is not machined or ground flat, the examination shall be performed from the base metal on both sides of the weld cap in both weld axis direction from at least single surface. 12.8.5 For angle beam scanning, selection of probe angle and knowledge of weld geometry is very important. Guidance for selection of probe is given in Attachment no.1 to this procedure. 12.8.6 The probe shall be manipulated so that the ultrasonic energy passes through the required volume of weld and adjacent base metal. This scanning shall be performed at the gain setting of at least two times the PRL (6dB more than the PRL dB setting). Evaluation shall be performed with respect to PRL. 12.8.7 Guidance for scanning butt welds is given in Attachment no. 3 to this procedure. 12.8.8 Restricted Access Welds: Welds that cannot be fully examined from two directions using the angle beam technique shall also be examined, if possible with a straight beam technique. These areas of restricted access shall be noted in the examination report. 12.8.9 Inaccessible Welds: Welds that cannot be examined from at least one side using the angle beam technique shall be noted in the examination report. For flange welds, the weld may be examined with a straight beam or low angle longitudinal waves from the flange face provided the examination volume can be covered. 12.9

EVALUATION

12.9.1 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 sections or agreed standard. 12.10 Technique 12.10.1 Each type of Ultrasonic examination shall have a Technique sheet (Attachment 6) with the details of all the essential variables applicable for that technique. These technique sheets shall be qualified by performing actual demonstration for the range of variables. 12.10.2 Any change in the essential variable (Refer Table 1) shall require requalification, re-demonstration and revision of that technique sheet attached to this procedure. 12.10.3 Any change in the non-essential variable (Refer Table 1) shall require revision in the respective technique sheets attached to this procedure.

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12.11 EXAMINATION OF NOZZLES SIDE WELD FUSION ZONE AND / OR ADJACENT NOZZLE PARENT METAL Ultrasonic Examination will be performed to examine the nozzle side weld fusion zone / or the adjacent nozzle parent metal with a straight beam technique from the inside surface of the nozzle. The full circumference of the nozzle shall be scanned to cover the entire nozzle side fusion zone of the weld plus 1inch beyond the toes. The search unit may be moved either circumferentially around or axially across the examination zone. The screen range shall cover as a minimum 1.1times the full thickness of the nozzle wall thickness. 12.11.1 Calibration Block The calibration block configuration shall be as shown in the below fig.12.1.If the internal surface of the nozzle is clad the ID of the calibration shall be also claded. The calibration block thickness shall be maximum thickness of nozzle wall adjacent to the nozzle weld plus 19mm. For Examination of nozzles with an inside diameter equal to or less than 20 inch the contact surface of the calibration block shall have the same curvature with in 0.9 to 1.5 times the diameter as described in below fig12.2. The calibration reflector shall be side drilled hole(s) as described in attachment 2. If only the nozzle side fusion zone to be examined then only a single side drilled hole at the nozzle wall thickness need to be used. Single Hole Technique: The response from single side drilled hole shall be set at 80 % ±5 % of the full screen height. Multiple Holes Technique: The straight beam shall be directed toward the calibration reflector reflector that yields the maximum response. The gain control shall be set so that this response is 80% ±5 % of the full screen height. This shall be primary reference level. The search unit shall be then manipulated without changing instrument setting.

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FIG 12.1 CALIBARTION BLOCK FOR NOZZLES SIDE WELD FUSION ZONE AND / OR ADJACENT NOZZLE PARENT METAL

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Fig. 12.2 RATIO LIMITS FOR CURVED SURFACES

13.0 WELD METAL OVERLAY CLADDING 13.1 The following paragraphs describe the techniques for ultrasonic examination weld metal overlay cladding to determine the lack of bonding or flaws in the cladding. 13.1.1 For weld metal overlay clad utilizing technique one Dual search units using an angled pitch –catch (probes) shall be used. The included angle between the beam paths shall be such that the effective focal spot of the search unit is centered in the area of interest. 13.1.2 The calibration block clad by same welding procedure, as the production part shall be used. The surface condition shall be representative of the production part. Either a side drill hole or flat bottom hole shall be used for calibration. Refer Attachment 5 & 6 for the calibration blocks. The thickness of the weld

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overlay shall be at least as thick as that to be examined and base metal shall be at least twice the thickness of cladding. 13.1.3 When examination is performed from the base metal side, the thickness of the base material shall be within 1” (25 mm) of the calibration block thickness. 13.1.4 Calibration shall be done by placing the probe on the calibration block and manipulating the probe for the maximum response from the calibration hole. The gain control shall be set so that this response is 80% ± 5% of the full screen. This shall be the PRL for examination. 13.1.5 For Technique one :The examination shall be performed from the clad surface, with the plane separating the elements of dual probe shall be parallel to the axis of the weld bead and the probe shall be moved perpendicular to the weld direction. 13.1.6 For Technique two: The examination may be performed from the clad or unclad surface; the probe can be moved perpendicular or parallel to the weld direction. 13.1.7 The scanning shall be done at minimum 6dB+PRL and evaluation shall be performed at PRL

13.2

EVALUATION 13.2.1

14.0

REFERENCE POINTS FOR EXAMINATION 14.1

15.0

In order to enable the position of possible imperfections to be accurately identified within the component or weld, reference points shall be marked on the component. Alternatively a sketch which can provide the above information shall be provided.

LOCATION AND CONFIRMATION OF IMPERFECTIONS 15.1

16.0

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 sections or agreed standard.

The position of the suspect imperfection shall be accurately determined in relation to the weld cross section or component geometry from the range of signals along the time base, beam angle and the position and orientation of the probe and in relation to the reference point. Having initially located the apparent imperfection position, this shall be confirmed from the second side/surface of the weld/component and/or by the use of different beam angle. This will ensure that the indication is not from a normal geometrical feature of the weld or caused by wave mode change.

CHARACTERIZATION AND SIZING OF IMPERFECTIONS 16.1

Sizing of the imperfections shall be carried out at a range not exceeding the half skip position. The length shall be determined by 6dB drop method or 20 dB beam profile

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method. The cross section dimension shall be determined by 20 dB beam profile method.

17.0

16.2

Imperfections shall be characterized by observing their echo dynamic pattern as the probes are scanned in two directions, across and along the imperfection. Variation in signal amplitude with swivel and orbital scan shall also be used for characterization.

16.3   

Imperfections shall be characterized as one of the following: Volumetric, rounded indications (e.g. porosity) Volumetric, linear indications (e.g. slag inclusion) Planer indication (e.g. crack or lack of fusion)

TECHNIQUE SHEET 17.1

Each type of Ultrasonic examination shall have a Technique sheet (Attachment 6) with the details of all the essential variables applicable for that technique. These technique sheets shall be qualified by performing actual demonstration for the range of variables.

17.2

Any change in the essential variable shall require re-qualification, re-demonstration and revision of that technique sheet attached to this procedure.

17.3

Any change in the non-essential variable shall require revision in the respective technique sheets attached to this procedure.

18.0 ACCEPTANCE CRITERIA 18.1

19.0

The acceptance criteria shall as per Attachment 7.

POST EXAMINATION CLEANING TECHNIQUE Post examination cleaning shall be done as soon as practical after the completion of Ultrasonic Examination of Welds and Material in such a way that will not put adverse effect on the material inspected.

20.0 REPORTS AND EXAMINATION RECORDS 20.1 The imperfections, which are required to be reported & their evaluation shall be recorded on Ultrasonic Examination Report (refer Attachment 8) 20.2 The calibration record for the instrument shall be maintained. The calibration blocks used shall be referred in the ultrasonic examination report.

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TABLE 1 PROCEDURE REQUIREMENTS OF AN ULTRASONIC EXAMINATION S. NO. 01

02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20

REQUIREMENTS Weld Configuration to be examined, including thickness dimensions and base material product from (pipe, plate etc) The surface from which the examination shall be performed Technique (S) (Straight beam, angle beam, contact, and/or immersion) Angle (s) and mode(s) of wave propagation in the material Search unit type (s), frequency (ies), and element size (s) / shape (s) Special unit search units, wedges, shoes or saddles, when used Ultrasonic instrument (s) Calibration ( Calibration block (s) and technique (s) Direction and extent of scanning Scanning (manual vs automatic) Method for discriminating geometric from flaw indications Method for sizing indications Computer enhanced data acquisition, when used Scan overlap (decrease only) Personnel performance requirements, when required Personnel Qualification Requirements Surface Condition (Examination surface, Calibration block) Couplant : Brand name or type Automatic alarm and or recording equipment, when applicable Records, including minimum calibration data to be recorded (eg.Instrument setting)

ESSENTIAL VARIABLE

NONESSENTIAL VARIABLES

PROEDURE REFERENCE CLAUSE NO:

X

Cl. 1.1

X

Cl.12.7.1 12.8.4

X

Cl. 12.7 & 12.8

X

Attachment 1

X

Cl. 7.0

X

N.A

X

X X

Cl. 5.0 Cl. 14.2 , 14.6 , 15.0 Cl. 14.7& 14.8 Cl. 14.7 & 14.8

X

Cl. 14.0 & 15.0

X

Cl. 16.0

X

N.A

X

Cl. 9.1

X

N.A

X

X

Cl. 3.0

X

Cl. 4.0 & 12.2

X

Cl. 8.0

X

N.A

X

Cl. 14.0

&

N.A. = Not applicable Note: when the procedure qualification is specified by the referencing code section, a change of requirements listed in Table-1 identified as essential variables from the specified value, or range of values shall require requalification of this written Procedure. A change of a requirements identified as non-essential variable from the specified value or range of values, does not require requalification of this written Procedure.

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ATTACHMENT NO. 4 GUIDANCE NOTES FOR EXAMINATION OF WELDS

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ATTACHMENT 05 ALTERNATE CALIBRATION BLOCK FOR WELD METAL OVERLAY (TECHNIQUE ONE)

C la d d in g

(TECHNIQUE ONE)

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TECHNIQUE TWO

C la d d in g

1

8 in . ( 3 m m )f la t b o tto m h o le d rille d to c la d in te rfa c e . t o l e r a n c e = + / -1 6 4 i n . ( 0 . 4 m m )

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ATTACHMENT NO. 6 Technique Sheet No:

TECHNIQUE SHEET FOR ULTRASONIC EXAMINATION

VARIABLES

Procedure :________________Revision : 0

TYPE

RANGE / VALUE

CERTIFICATE OF QUALIFICATION This is to certified that this technique sheet along with the procedure TWI - 957 Rev. A has been qualified and demostrated for the range of variables specified. Certified By ( LEVEL - III) SIGN NAME DATE

Witnessed By : AI

No

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Attachment – 7 ACCEPTANCE CRITERIA FOR ULTRASONIC EXAMINATION 1.0

REFERENCING CODE: 1.1 1.2 1.3 1.4

2.0

ASME Sec I APPENDIX – PW -52 ASME Sec VIII Div.1 APPENDIX-12 ASME Sec VIII Div.2 Para 7.5.4 ASME B 31.1 PARA 136.4.6

ACCEPTANCE-REJECTION STANDARD

2.1 Standards shall apply unless other standards are specified for specific applications within this Division. 2.2

Imperfections 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 imperfections and evaluate them in terms of the acceptance standards given in (a) and (b) below. a) Indications characterized as cracks, lack of fusion, or incomplete penetration are unacceptable regardless of length. b) Other imperfections are unacceptable if the indications exceed the reference level amplitude and have lengths which exceed: 1) ¼ in. (6 mm) for t up to ¾ in. (19 mm); 2) 1/3 t for t from ¾ in. to 2 ¼ in. (19 mm to 57 mm); 3) ¾ in. (19 mm) for t over 2 ¼ in. (57 mm) Where t is the thickness of the weld excluding any allowable reinforcement for a butt weld joining two members having different thicknesses at the weld, t is the thinner of these two thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be included in t.

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Attachment – 9

Vessel to nozzles joints shall be checked for any defect both from external and internal surfaces as described in above figure (1),(2) and (4) technique shall be used for scanning. Also if applicable nozzle neck joint will also be scanned with technique (3).