1744 -ut procedure (for final)

8/10/2019 1744 -Ut Procedure (for Final)

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WASIT SRU & UTILITIES PROJECT,PACKAGE # 3

Doc. No.

DES-1744-QA&QC-04Descon Engineering FZE.ULTRASONIC TEST

PROCEDURE Rev. 00 Page1of27

Engineering & construction

ULTRASONIC TEST PROCEDURE

Document No. DES-1744-QA&QC-04

Purchase Order No.:

Equipment/Material: Stack

REV DATE DESCRIPTION PREPARED CHECKED APPROVED

00 11-9-2013 FOR FINAL/ CERTIFIED

A 12/02/2013 Issued for client reviewRONAK

MEHTA

RONAK

MEHTA

SAKET

KUMARB 22/07/2012 Issued for client review

RONAKMEHTA

RONAKMEHTA

SAKETKUMAR

DESCON ENGINEERING FZE


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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 / PROBES8. 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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QUALITY CONTROL PROCEDURE

FOR

ULTRASONIC EXAMINATION


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1.0 SCOPE

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

2.0 REFERENCES

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

3.0 PERSONNEL QUALIFICATION

3.1 Ultrasonic Testing shall be performed by Level I or II and results evaluated by Level IIor 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 thesepersonnel shall be verified and approved by the DESCON Level III.

Personnel Qualification: Shall be in accordance with the ASNT SNT-TC-1A 2006, perASME Section V, T-120. (1), note No. 3, and ASME Section VIII, Div. 1, Table U-3.Table U-3 of ASME Section VIII Division.Testing shall be performed by personnel certified in accordance with the requirementsof ASNT SNT-TC-1A, 2006 edition per adopted by latest addenda of ASME/ANSIB31.1,

4.0 SURFACE CONDITION

4.1 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 thesurfaces.

5.0 EQUIPMENT

5.1 The examination shall be conducted with a pulse echo ultrasonic instrument having A-Scan display and which is capable of generating frequencies in the range of at least1MHz to 5MHz & shall be equipped with a stepped gain control in units of 2dB or less.


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PROCEDURE Rev. 00 Page5of275.2 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 hourduring the examination, whenever examination personnel are changed and at any timewhen malfunctioning is suspected. If during any check it is observed that the instrumentis not functioning properly, all examination carried out since the last valid calibrationshall be repeated.

5.3 If the instrument has damping control, it may be used if it does not reduce thesensitivity of the examination. The reject control shall remain in OFF position for allexaminations.

6.0 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 andreading shall be estimated to the nearest 1% of full screen.

6.2 The ultrasonic instrument shall utilize an amplitude control accurate over its usefulrange to 20% of the normal amplitude ratio, to allow measurement of indicationsbeyond 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 ofeach period of extended use or 3 months, whichever is less. The checks shall becarried out as per Appendix I and II of Article 4 of applicable ASME Sec V. For digitaltype instruments the above checks shall be carried out at the interval of one year orprior to first use thereafter.

7.0 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 forexamination. For castings, frequency of 1MHz shall be used for examination. Howeverother lower frequencies may also be used for evaluation purpose if equal or bettersensitivity can be demonstrated and recorded or when the production material grainstructure require the use of other frequencies to assure adequate penetration andbetter 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 contouredwedges to be used during the examination.

7.4 The angle probes shall be checked for angle of beam and the exit point using IIW-V1block and records of such checks shall be kept. If the angle of beam or the exit pointvaries 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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PROCEDURE Rev. 00 Page6of278.0 COUPLANT

8.1 The couplant, including additives, shall not be detrimental to the material beingexamined.

8.2 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 notcontain more than 250ppm of halides (chlorides plus fluorides).

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

9.0 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 probeshall overlap a minimum of 10% of the transducer dimension perpendicular to thedirection 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.

10.0 TECHNIQUE FOR EXAMINATION OF PLATES

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

10.2 The sweep range and distance amplitude calibration shall be in accordance with SA435 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 inaccordance with SA 435 or SA 578 and as supplemented by the referencing Codesection/agreed standard.

11.0 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 Codesection/agreed standard.

11.2 The sweep range and distance amplitude calibration shall be in accordance with SA-388/SA-388M or SA-745/SA-745M and as supplemented by the referencing Codesection/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 anglebeam probes in two circumferential and axial directions, if OD to ID ratio is less than 2and length of forging is more than 2 inches.

11.4 Ring forgings made to fine grain melting practices and used for vessel shell sectionsshall be also examined by the angle beam examination technique in two axialdirections.

12.0 TECHNIQUE FOR EXAMINATION OF WELDS

12.1 GENERAL

12.1.1 The following paragraphs describe the technique for ultrasonic examinationof full penetration welds.

12.1.2 These requirements are applicable for ultrasonic detection, location andevaluation of ultrasonic reflectors within the weld, heat affected zone andadjacent material.

12.1.3 Guidelines for the examination of welds are given in the (Attachment 4).

12.1.4 Applicable Technique sheets for the welds are identified & the techniquesheet shall be attached along with the procedure.

12.2 BASIC CALIBRATION BLOCKS

12.2.1 The basic calibration blocks shall be used to establish the primary referenceresponse of the equipment. An alternate reflector(s) may be used providedthat the alternate reflector(s) produces the sensitivity equal to or greaterthan the specified reflectors.

12.2.2 The material from which the block is fabricated shall be of the same productform, and material specification or equivalent P-number grouping as one ofthe materials being examined. For the purpose of this section, P-numbers1, 3, 4 and 5 are considered equivalent.

12.2.3 Where the component material is clad, the block shall be clad by usingsame weld procedure as the production part.

12.2.4 The calibration block shall receive at least the minimum temperingtreatment required by the material specification for the type & grade and a


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PROCEDURE Rev. 00 Page8of27component weld is heat treated at the time of examination if the calibrationblock contains weld other than cladding.

12.2.5 The finish on the surfaces of the block shall be representative of the surfacefinish of the components and the block material shall be completelyexamined with normal beam method for indications exceeding theremaining back reflection so that such areas can be excluded from thebeam path required to reach the calibration reflectors.

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

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

12.2.8 The temperature difference between calibration block and examination

surface shall be within 25degree F (14 degree C).

12.3 DIAMETER OF MATERIAL UNDER EXAMINATION

12.3.1 For examination in materials where the examination surface diameter ismore 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 calibrationblock shall be curved. A curved calibration block may be used to calibratethe examination on surfaces in the range of 0.9 to 1.5 times the basiccalibration block diameter.

12.4 SWEEP RANGE CALIBRATION

12.4.1 For normal beam examination, the sweep range calibration shall be carriedout using back reflection from the basic calibration block for the measuredthickness. The t hole indication shall be delay controlled positioned to of the sweep range. Alternatively, IIW-V1 block may also be used for thesweep range calibration.

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

12.5 SENSITIVITY SETTING: DISTANCE AMPLITUDE CORRECTION (DAC) CURVE12.5.1 The distance amplitude correction curve for normal beam and angle beam

examination shall be established using t, t and t holes on the Basiccalibration 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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PROCEDURE Rev. 00 Page9of27 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 andmark 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 andcircumferential notches by using basic calibration block shown in theAttachment 3.

12.6 CALIBRATION CHECK

12.6.1 When any part of the examination system is changed, a calibration check shallbe made on the basic calibration block to verify that distance range pointsand 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 atthe finish of each examination, or by series of similar examinations, 4 hoursduring 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% ofthe sweep reading or 5% of the full sweep or the DAC curve has decreased20% 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 areacovered by the void data shall be re-examined. If the DAC curve hasincreased more than 20% or 2dB of its amplitude, all recorded indicationssince last valid calibration shall be re-examined with the corrected calibrationand recorded.

12.6.4 When the referencing Code section requires the detection and evaluation ofall indications exceeding 20 % of DAC, the gain should be increased anadditional amount so that no calibration reflector indication is less than 40%FSH. As an alternate, the scanning sensitivity level may be set at 14 dBhigher than the reference level gain setting. With this increase in dBreference 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 distancerange 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 inthe basic calibration block or a check using a similar shall be performed atthe completion of each examination or series of examinations, and whenexamination personnel (except for automated equipment) are changed. Thedistance range and sensitivity values recorded shall satisfy the requirements12.6.7.

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, whicheveris greater, correct the distance range calibration and note the correction inthe examination record. All recorded indications since the last validcalibration or calibration check shall be reexamined and their values shall bechanged 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 thecorrection in the examination record. If the sensitivity setting has decreased,all data sheets since the last valid calibration check shall be marked void andthe area covered by the voided data shall be reexamined. If the sensitivitysetting has increased, all recorded indications since the last valid calibrationor calibration check shall be reexamined and their values shall be changedon 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 anglebeam probe) from the weld, on the surface from (at least single surface)which the examination is to be performed to detect the reflectors that mightaffect the interpretation of angle beam result. Record the location and areasof such reflectors; however these indications shall not be used foracceptance or rejection.

12.7.2 Scan the weld by normal beam probe to the extent possible. This scanningshall be performed at the gain setting of at least two times the PRL (6dBmore 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 smoothreasonably) 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 axisfrom two directions where possible to detect linear and non-linear imperfections, whichare predominately longitudinal with respect to the weld axis.12.8.2 The most critical part of the examination is that for in imperfections lyingalong the fusion faces, such as lack of side wall fusion or HAZ cracking. Otherimperfections 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 directedparallel to the weld axis. The search unit shall be manipulated so that ultrasonicenergy passes through the required volume of the weld and the adjacent base metal.


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PROCEDURE Rev. 00 Page11of27The 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 performedfrom the base metal on both sides of the weld cap in both weld axis direction from atleast single surface.

12.8.5 For angle beam scanning, selection of probe angle and knowledge of weld geometryis very important. Guidance for selection of probe is given in Attachment no.1 to thisprocedure.

12.8.6 The probe shall be manipulated so that the ultrasonic energy passes through therequired volume of weld and adjacent base metal. This scanning shall be performed atthe 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 beamtechnique shall also be examined, if possible with a straight beam technique. Theseareas 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 techniqueshall 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 theexamination volume can be covered.

12.9 EVALUATION

12.9.1 Any imperfection which causes an indication in excess of 20% DAC shall beinvestigated to the extent that it can be, evaluated in terms of the acceptancestandards of the referencing Code sections or agreed standard.

12.10 Technique

12.10.1 Each type of Ultrasonic examination shall have a Technique sheet (Attachment6) with the details of all the essential variables applicable for that technique. Thesetechnique sheets shall be qualified by performing actual demonstration for the range ofvariables.

12.10.2 Any change in the essential variable (Refer Table 1) shall require re-qualification, re-demonstration and revision of that technique sheet attached to thisprocedure.

12.10.3 Any change in the non-essential variable (Refer Table 1) shall require revisionin the respective technique sheets attached to this procedure.


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PROCEDURE Rev. 00 Page12of2712.11 EXAMINATION OF NOZZLES SIDE WELD FUSION ZONE AND / OR ADJACENTNOZZLE PARENT METAL

Ultrasonic Examination will be performed to examine the nozzle side weld fusion zone / or theadjacent nozzle parent metal with a straight beam technique from the inside surface of thenozzle.The full circumference of the nozzle shall be scanned to cover the entire nozzle side fusionzone of the weld plus 1inch beyond the toes. The search unit may be moved eithercircumferentially around or axially across the examination zone. The screen range shall coveras a minimum 1.1times the full thickness of the nozzle wall thickness.

12.11.1 Calibration BlockThe calibration block configuration shall be as shown in the below fig.12.1.If the internalsurface 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 contactsurface of the calibration block shall have the same curvature with in 0.9 to 1.5 times thediameter as described in below fig12.2.The calibration reflector shall be side drilled hole(s) as described in attachment 2. If only thenozzle side fusion zone to be examined then only a single side drilled hole at the nozzle wallthickness 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 themaximum response. The gain control shall be set so that this response is 80% 5 % of the fullscreen height. This shall be primary reference level. The search unit shall be then manipulatedwithout changing instrument setting.


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PROCEDURE Rev. 00 Page13of27FIG 12.1 CALIBARTION BLOCK FOR NOZZLES SIDE WELD FUSION ZONE AND / OR

ADJACENT NOZZLE PARENT METAL


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PROCEDURE Rev. 00 Page14of27Fig. 12.2 RATIO LIMITS FOR CURVED SURFACES

13.0 WELD METAL OVERLAY CLADDING

13.1 The following paragraphs describe the techniques for ultrasonic examination weldmetal 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 anangled pitch catch (probes) shall be used. The included angle between thebeam paths shall be such that the effective focal spot of the search unit iscentered in the area of interest.

13.1.2 The calibration block clad by same welding procedure, as the production partshall be used. The surface condition shall be representative of the productionpart. 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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PROCEDURE Rev. 00 Page15of27overlay shall be at least as thick as that to be examined and base metal shallbe at least twice the thickness of cladding.

13.1.3 When examination is performed from the base metal side, the thickness of thebase 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 andmanipulating 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 fullscreen. 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 theaxis of the weld bead and the probe shall be moved perpendicular to the welddirection.

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 Any imperfection which causes an indication in excess of 20% DAC shall beinvestigated to the extent that it can be, evaluated in terms of theacceptance standards of the referencing Code sections or agreed standard.

14.0 REFERENCE POINTS FOR EXAMINATION

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

15.0 LOCATION AND CONFIRMATION OF IMPERFECTIONS

15.1 The position of the suspect imperfection shall be accurately determined in relation tothe weld cross section or component geometry from the range of signals along the timebase, beam angle and the position and orientation of the probe and in relation to thereference 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 ofdifferent beam angle. This will ensure that the indication is not from a normalgeometrical feature of the weld or caused by wave mode change.

16.0 CHARACTERIZATION AND SIZING OF IMPERFECTIONS

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


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PROCEDURE Rev. 00 Page16of27method. The cross section dimension shall be determined by 20 dB beam profilemethod.

16.2 Imperfections shall be characterized by observing their echo dynamic pattern as theprobes are scanned in two directions, across and along the imperfection. Variation insignal 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)

17.0 TECHNIQUE SHEET

17.1 Each type of Ultrasonic examination shall have a Technique sheet (Attachment 6) withthe details of all the essential variables applicable for that technique. These techniquesheets 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 andrevision of that technique sheet attached to this procedure.

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

18.0 ACCEPTANCE CRITERIA

18.1 The acceptance criteria shall as per Attachment 7.

19.0 POST EXAMINATION CLEANING TECHNIQUE

Post examination cleaning shall be done as soon as practical after the completion of UltrasonicExamination of Welds and Material in such a way that will not put adverse effect on thematerial inspected.

20.0 REPORTS AND EXAMINATION RECORDS

20.1 The imperfections, which are required to be reported & their evaluation shall berecorded on Ultrasonic Examination Report (refer Attachment 8)

20.2 The calibration record for the instrument shall be maintained. The calibration blocks usedshall be referred in the ultrasonic examination report.


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PROCEDURE Rev. 00 Page17of27TABLE 1

PROCEDURE REQUIREMENTS OF AN ULTRASONIC EXAMINATION

S. NO. REQUIREMENTSESSENTIALVARIABLE

NON-ESSENTIALVARIABLES

PROEDUREREFERENCECLAUSE NO:

01 Weld Configuration to be examined, includingthickness dimensions and base materialproduct from (pipe, plate etc)

X Cl. 1.1

02 The surface from which the examination shallbe performed

XCl.12.7.1 &12.8.4

03 Technique (S) (Straight beam, angle beam,contact, and/or immersion)

X Cl. 12.7 & 12.8

04 Angle (s) and mode(s) of wave propagationin the material

X Attachment 1

05 Search unit type (s), frequency (ies), and

element size (s) / shape (s)

X Cl. 7.0

06 Special unit search units, wedges, shoes orsaddles, when used

X N.A

07 Ultrasonic instrument (s) X Cl. 5.0

08 Calibration ( Calibration block (s) andtechnique (s)

XCl. 14.2 , 14.6 ,15.0

09 Direction and extent of scanning X Cl. 14.7& 14.8

10 Scanning (manual vs automatic) X Cl. 14.7 & 14.8

11 Method for discriminating geometric from flawindications

X Cl. 14.0 & 15.0

12 Method for sizing indications X Cl. 16.0

13 Computer enhanced data acquisition, whenused

X N.A

14 Scan overlap (decrease only) X Cl. 9.1

15 Personnel performance requirements, whenrequired

X N.A

16 Personnel Qualification Requirements X Cl. 3.0

17 Surface Condition (Examination surface,Calibration block)

X Cl. 4.0 & 12.2

18 Couplant : Brand name or type X Cl. 8.0

19 Automatic alarm and or recording equipment,when applicable

X N.A

20 Records, including minimum calibration datato be recorded (eg.Instrument setting)

X Cl. 14.0

N.A. = Not applicableNote: 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 ofvalues shall require requalification of this written Procedure. A change of a requirements identifiedas non-essential variable from the specified value or range of values, does not requirerequalification of this written Procedure.


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ATTACHMENT NO. 4GUIDANCE NOTES FOR EXAMINATION OF WELDS


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PROCEDURE Rev. 00 Page22of27ATTACHMENT 05

ALTERNATE CALIBRATION BLOCK FOR WELD METAL OVERLAY(TECHNIQUE ONE)

C l ad d i n g

(TECHNIQUE ONE)


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TECHNIQUE TWO

18 i n . (3 m m ) f la t b o t to m h o l e

d r i l l e d t o c l a d i n t e r f a c e .

t o l e r a n c e = + / -1 6 4 i n . ( 0 .4 m m )

C l a d d i n g


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PROCEDURE Rev. 00 Page24of27ATTACHMENT NO. 6

Technique Sheet No:TECHNIQUE SHEET FOR

ULTRASONIC EXAMINATION Procedure No:________________Revision : 0

VARIABLES TYPE RANGE / VALUE

CERTIFICATE OF QUALIFICATIONThis is to certified that this technique sheet along with the procedure TWI - 957 Rev. A has beenqualified and demostrated for the range of variables specified.

Certified By ( LEVEL - III) Witnessed By :AI

SIGN

NAME

DATE


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PROCEDURE Rev. 00 Page25of27At tachment 7

ACCEPTANCE CRITERIA FOR ULTRASONIC EXAMINATION

1.0 REFERENCING CODE:

1.1 ASME Sec I APPENDIX PW -521.2 ASME Sec VIII Div.1 APPENDIX-121.3 ASME Sec VIII Div.2 Para 7.5.41.4 ASME B 31.1 PARA 136.4.6

2.0 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 beinvestigated to the extent that the operator can determine the shape, identity, and location ofall 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 areunacceptable regardless of length.

b) Other imperfections are unacceptable if the indications exceed the reference levelamplitude and have lengths which exceed:

1) in. (6 mm) for t up to in. (19 mm);2) 1/3 t for t from in. to 2 in. (19 mm to 57 mm);3) in. (19 mm) for t over 2 in. (57 mm)

Where t is the thickness of the weld excluding any allowable reinforcement for a butt weldjoining two members having different thicknesses at the weld, t is the thinner of these twothicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of thefillet shall be included in t.


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At tachment 8


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PROCEDURE Rev. 00 Page27of27At tachment 9

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

1744 -ut procedure (for final)

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