Ultra Sonic Testing

7/27/2019 Ultra Sonic Testing

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PROJECT TITLE:

RELIANCE

JAMNAGAR EXPORT REFINERYPROJECT

VENDORS NAME: KH Petrotec

DOCUMENTTITLE:

ULTRASONIC TESTING PROCEDURE

VENDORS DOCUMENT NO: KH-USZ-UT-002

VENDORS REVISION NO: 00

Reliance JERP

Supplier Document ReviewPermission to proceed does not constitute acceptance or approval of Design Detail, Calculations, Analysis, Test Methods orMaterials developed OR selected by SUPPLIER, and does NOT relieve SUPPLIER from FULL compliance with Contractual

Obligations

1 Work May Proceed

2aRevise & Resubmit. Work mayProceed subject to incorpor ation of changes

2bRevise - Work may Proceed do notresubmit until final

3 Revise & Resubmit. Work may not Proceed

4 Review Not Required. Work may Proceed

By: Date:

Discipline: Mechanical

Equipment No. ALL ITEMS (COMMON)

MR No.

M V V L 0 2

Job No PO No Unit No

Cat. No Seq. No Rev No.

25194 U S Z M V V L 0 2 L A C 0 0 0 J 0 2 0 0 0 1 0 0


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PAGE 1 OF 11KH-USZ-UT-002 Process Specification

Rev.No 0

KH Petrotec A4 (210297 m/m)

Title ULTRASONIC TESTING PROCEDURE

PROJECT NAME : RELIANCE JERP

P.O N.o : 25194-USZ-MVVL02-LAC

BECHTEL DOCUMENT NO. : 25194-USZ-MVVL02-LAC-000-J02-0001

APPLICABLE EQUIPMENT : ALL RELATED TO THIS P.O No.

- Contents -

1.0 Scope

2.0 Applicable Codes and Standards

3.0 Qualification of Personnel

4.0 General Requirements

5.0 Calibration

6.0 Examination Procedure

7.0 Acceptance Standards

8.0 Records

0 Dec.28,06 First Issue W. J. CHANG W. J. CHANG

NDE Level NDE LevelREV

NO. DATE (DESCRIPTION)PREPARED BY REV'D & APP'D BY

Approved by

Customer

I, the under signed, certify that this procedure has been written in accordance with therequirement of ASME section , T- 150.

NDE Mgr.


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1.0 SCOPE

1.1 This procedure described the ultrasonic examination procedure of manufacturing and checking raw

material of pressure vessels in accordance with the contract and technical specifications for JERP

Project.

1.2 The application of this procedure is limited straight beam and angle beam method of ultrasonically

testing the welded joints, heat affected zone and adjacent base material using manual, contact and

pulse-echo ultrasonic techniques.

1.3 This procedure is not permitted in lieu of Radiographic Test of welds and limited to use as follows;

1.3.1 Confirming defect position of weld seams for repair

1.3.2 Category D joint, if applicable

1.3.3 Raw material of plate exceed 20mm and forging exceed 75 mm

1.3.4 Manual UT is applicable for 1.3.1 & 1.3.2, and auto scanning method for 1.3.3.

2.0 APPLICABLE CODES AND STANDARDS

2.1 ASME Code section.; Nondestructive examination (2004 Ed. + 2005 Add.)2.2 ASME Code section. Div 1 ; Rules for construction of pressure vessels (2004 Ed. + 2005 Add.)2.3 ASNT, SNT-TC-1A

2.4 In case of conflicting requirements among the referenced codes(AMSE Code, section ),Owners requirements and this procedure, the most stringent requirements shall govern.

3.0 QUALIFICATION OF PERSONNEL

Personnel performing examination to this specification shall be qualified and certified as Level orhigher, which meet the requirements of SNT-TC-1A and ASME Code.

The personnel responsible to the KHPT reviewing and approving ultrasonic examination results shall

be a certified Level III accordance with ASNT TC 1A. For ASNT certifications Level III

examiners shall be certified directly by ASNT through written examination.

4.0 GENERAL REQUIREMENTS

4.1 Equipment

4.1.1 Pulse-echo, A-scope presentation type ultrasonic equipment shall be used. All equipment shall be

equipped with gain or attenuation control. All instruments shall be calibrated for the examination

specified herein and shall be capable of meeting the requirements of screen height linearity and

amplitude control linearity in paragraph 5.1. USK-7S, USN-52R and USD-10 of KRAUTKRAEMER

Co. or equivalents may be used for this examination.

4.1.2 The equipment shall be capable of generating at test frequency within the range 1 MHz to 5 MHz and

equipped with a stepped gain control calibrated in units of 2.0 dB or less.

4.1.3 The ultrasonic search units in the following table or equivalent shall be used.


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Mode Frequency ModelMajor size

(mm)

Reference

Angle

Longitudinal

wave2 MHz

KRAUTKRAMER

B2S-N, MB2S-N

B4S-N, MB4S-N

Dia. 24

Dia. 100 deg.

2 MHzWB 45, 60 or 70

MWB 45, 60 or 70

20 X 22

8 X 9Shear wave

4 MHzWB 45, 60 or 70

MWB 45, 60 or 70

20 X 22

8 X 9

45, 60, 70 deg.

Search unit of other sizes, frequencies, and other refraction angles may be used to assure

adequate penetration or better resolution.

4.2 CouplantSuitable liquid, such as machine oil, glycerin or water, shall be used as a couplant.

4.3 Examination Coverage

The volume shall be examined by moving the search unit over the examination surface so as to scan

the entire examination volume. Each pass of the search unit shall overlap a minimum of 10 % of

the transducer (piezo-electric element) dimension perpendicular to the direction of the scan.

4.4 Rate of Search unit Movement

The rate of search unit movement for examination shall not exceed 150 mm/sec. unless calibration is

verified at the scanning speed.

4.5 Surface Preparation

4.5.1 The base metal on each side of the weld shall be free of weld spatter, surface irregularities, loose

foreign matter or coatings that might interfere with the examination.

4.5.2 When the weld surface interferes with the examination, the weld shall be prepared as needed to

permit examination. Preparation of as welded by grinding or machining may be required where

surface irregularities would mask indications of unacceptable discontinuities.

4.6 Calibration Reference Standards (Reference block)

4.6.1 Basic calibration reflectors

The basic calibration reflectors shall be used to establish a primary reference response of the

equipment. The basic calibration reflectors may be located either in the component material or in a

basic calibration block.

4.6.2 Basic calibration block

(1) The material from which the block is fabricated shall be of the same product form and material

specification or equivalent P-No, grouping as one of the material being examined. For the purpose

of this Para. P-No. 1,3,4 and 5 materials are considered equivalent.(2) Fig.1 and Fig.1-1 show the block configurations and thickness with hole sizes and locations.


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(3) For examinations in welds where the examination surface diameter is greater than 508 mm, a flat

basic calibration block shall be used. If the welds with diameter 508 mm or less, a single curved

basic calibration block may be used to calibrate the examination on surface in the range ofcurvature from 0.9-1.5 times the basic calibration block diameter.

5.0 CALIBRATION

5.1 Instrument Calibration

The basic calibration block to be used in instrument calibration is described on Fig.1.

5.1.1 Screen height linearity (See Fig. 2)

The ultrasonic instrument shall provide linear vertical presentation within 5 % of the full screenheight for at least 80 % of the calibrated screen height.

(1) Position a search unit as shown in fig. 2, so that indications from both the T/2 and 3T/4 holes in a

basic calibration block can be observed.

(2) Adjust the search unit position to give a 2:1 ratio of amplitudes between the two indications, with

the larger set at 80 % of full screen height.

(3) Without moving the search unit, adjust sensitivity to successively set the larger indication from

100 % to 20 % of full screen height, in 2 dB steps, and read the smaller indication of each setting.

(4) The reading must be 50 % of the larger amplitude, within 5 % of full screen height. The settingsand readings must be estimated to the nearest 1 % of full screen.

(5) This shall be checked and recorded every three months.

5.1.2 Amplitude control linearity (See fig.2)

The ultrasonic instrument shall utilize an amplitude control, accurate over its useful range to 20%of the nominal amplitude ratio, to allow display on the screen.

(1) To verify the accuracy of the amplitude control of the ultrasonic instrument, position a search unit

as shown in Fig. 2 so that the indication from the T/2 hole in a basic calibration block is peaked onthe screen.

(2) With the increases and decreases in attenuation shown in the following table, the indication must

fall within the specified limits.

Indication set

(% of full screen)dB control change

Indication limits

(% of full screen)

80 %

80 %

40 %

20 %

- 6 dB

- 12dB

+ 6 dB

+ 12dB

32 to 48 %

16 to 24 %

64 to 96 %

64 to 96 %


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(3) Other convenient reflectors from any calibration block may be used with angle or straight beam

search units. The settings and readings must be estimated to the nearest 1 % of screen.(4) This shall be checked and recorded every three months.

5.2 System Calibration

The ultrasonic system shall be calibrated according to following explanation.

5.2.1 Angle beam calibration.

5.2.1.1 Sweep range calibration (See Fig.3)

(1) Position the search unit for the maximum first indication from the T/4 side drilled hole and

adjust the left edge of this indication to line 2 on the screen with the delay control.

(2) Position the search unit for the maximum indication from the 3T/4 hole and adjust the left edge

of this indication to line 6 on the screen with the range control.

(3) Repeat delay and range control adjustments until the T/4 and 3T/4 hole reflection start at sweep

lines 2 and 6.

(4) Position the search unit for maximum response from the square notch on the opposite surface.

The indication will appear near sweep line 8.

(5) Two divisions on the sweep equal T/4.

5.2.1.2 Distance Amplitude Correction (See Fig. 4)

(1) Position the search unit for maximum response from the hole which gives the highest amplitude.

(2) Adjust the sensitivity control to provide an 80 % (

5% full screen height ) of full screenindication from the hole. Mark the peak of the indication on the screen.

(3) Position the search unit for maximum response from another hole indications.

(4) Mark the peak of the indication on the screen.

(5) Position the search unit for maximum response from each second and third hole indication and

mark the peaks on the screen.

(6) Position the search unit for maximum amplitude from the 3T/4 hole indication after the beam

has bounced from the opposite surface. The indication should appear at sweep line 10. Mark

the peak on the screen for the 5T/4 position.

(7) Connect the screen marks and extend through the thickness to provide the distance amplitude

curve for the side-drilled holes.

5.2.2 Straight beam calibration

5.2.2.1 Sweep range calibration (See Fig.5)

(1) Position the search unit for the maximum first indication from the 1/4T side drilled hole.

Adjust the left edge of this indication to line 2 on the screen with the delay control.

(2) Position the search unit for the maximum indication from 3/4T hole. Adjust the left edge of

this indication to line 6 on the screen with the range control.

(2) Repeat delay and range control adjustments until 1/4T and 3/4T hole reflection start at sweep

line 2 and 6.


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5.2.2.2 Distance-Amplitude correction (See Fig. 6)

(1) Position for maximum response from the hole which give the highest amplitude.

(2) Adjust the sensitivity control to provide an 80%(5% of full screen height) of full screenindication from the hole. Mark the peak of the indication on the screen with a grease pencil or

other suitable marker.

(3) Position the search unit for maximum response from another hole indication.

(4) Mark the peak of the indication on the screen.

(5) Position the search unit for maximum amplitude from the third hole indication and mark the

peak on the screen.

(6) Connect the screen marks and extend through the thickness to provide the distance-amplitude

curve for the side-drilled holes.

5.2.2.3 Ferritic welds in pipe

The basic calibration block for weldments shall be made in accordance with Fig. T-542.8.1.1 of

ASME Code section .article 5.

5.2.2.4 Distance-amplitude correction (DAC) for Angle beam calibration

A DAC curve is required for all pipe welds. For examination of a full wall thickness, the notches

shall be used as calibration reflectors. The angle beam shall be directed toward the calibration

reflector that yields maximum response, setting the instrument adjustment to 80% of screen

height. The search unit shall then be manipulated, without changing instrument settings, to

obtain the maximum response from the calibration reflectors at the distance increments

necessary to generate a 3-point DAC curve.

Angle beam scanning of pipe weld shall be performed according to the requirement in Para.6.2

and 6.3.

5.2.2.5 Distance-amplitude correction (DAC) for straight beam calibration

Straight beam examination shall be calibrated on the side drilled holes in the basic calibration

block. Straight beam scanning of pipe weld shall be performed according to the requirement in

Para.6.1.

6.0 EXAMINATION PROCEDURE

6.1 Straight Beam

The scanning of the adjacent base metal shall be performed to detect reflectors that might affect

interpretation of angle beam result, and is not to be used as an acceptance rejection examination.

Locations and areas of such reflector shall be record. The weld and base metal shall be scanned,

where required by the referencing Code Section to the extent possible with the straight beam search

unit. The scanning shall be performed at a gain setting of at least two times the primary reference

level. Evaluation shall be performed with respect to the primary reference level.

6.2 Angle Beam Scanning for Reflectors Oriented Parallel to the Weld.

The angle beam shall be directed at approximate right angles to the weld axis from two directions

where possible. The search unit shall be manipulated so that the ultrasonic energy passes through

the required volumes of weld and adjacent base metal.

The scanning shall be performed at again setting at least two times the primary reference level.Evaluation shall be performed with respect to the primary reference level.


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6.3 Angle Beam Scanning for Reflectors Oriented Transverse to the Weld.

The angle beam shall be directed essentially parallel to the weld axis. The search unit shall be

manipulated so that the angle beam passes through the required volumes of weld and adjacent basemetal specified by the referencing Code section. The scanning shall be performed at a gain setting at

least two times the primary reference level. Evaluation shall be performed with respect to the

primary reference level. The search unit shall be rotated 180 deg. and the examination repeated.

7.0 ACCEPTANCE STANDARDS

7.1 All imperfections which produce an amplitude 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 following acceptance standards.

7.2 Imperfections that are interpreted to be crack, lack of fusion, or incomplete penetration are

unacceptance regardless of length.

7.3 All other linear type imperfections are unacceptable if the amplitude exceeds the reference level and

the length of the imperfection exceeds the following:

(1) 1/4 in. (6.0mm) for T up to 3/4 in. (19.0mm).

(2) 1/3 T for from 3/4 in. (19.0mm) to 2 1/4 in. (57.0mm).

(3) 3/4 in. (19.0mm) for T over 2 1/4 in. (57.0mm).

Where T is the thickness of the weld excluding any allowable reinforcement. For a butt weld

joining two members having different thickness 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 the

fillet shall be included in T.

8.0 RECORDS

Examination report shall include the information below, as minimum.

(a) procedure.

(b) ultrasonic examination system(equipment).

(c) examination personnel identify and level.

(d) calibration sheet identifies.

(e) identification and location of weld or volume scanned.(f) surface from which examination is conducted

(g) map or record of indication detected or areas clear.

(h) date and examination were performed.

(i) couplant

(j) basic calibration block identification

(k) surface condition.

(l) frequency.

(m) special equipment.


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Fig. 1 Basic Calibration Block

Basic Calibration Hole

Weld Thicknesst(mm) Block Thickness T(mm) Diameter(mm) Notch Size (mm)

25.4 or less 19.05mm ort 2.38mm With = 3.175 to 6.35Over 25.4 through 50.8 38.1 ort 3.175

Over 50.8 through 101.6 76.2 ort 4.76 Depth = 2% T or 1.016

Over 101.6 through 152.4 127 ort 6.35 whichever is greater

Over 152.4 through 203.2 177.8 ort 7.93 into the base metal.

Over 203.2 through 254 228.6 ort 9.5

Over 254 t 25.4 Note (1) Length = 50.8 min.GENERAL NOTE:

(a) Holes shall be drilled and reamed a minimum of 1-1/2in. (38mm ) deep, essentially parallel to the

examination surface.

(b) Alternatively, the block may be constructed as shown in Article 4, Appendix J, Fig.-10.

(c) Curved surfaces: for curved surfaces, two curved blocks, one for each representative curvature:

or two sets of calibration reflectors oriented 90 deg. From each other shall be used.(d) Notches may be provided as required.

(e) The tolerance for hole diameter shall be 1/32in.(0.79mm) The tolerance on notch depth shall be+10 and 20%. The tolerance on hole location through the thickness shall be 1/8in.(3.175mm)

NOTE :

(1) For each increase in weld thickness of 2in.(50.8mm) or fraction thereof over 10in.(254mm), the hole

diameter shall increase 1/16in.(1.6mm)


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Fig. 1-1 Basic Calibration Block for pipe welds

Typical block dimensions

Length L 8 in. or 8T, whichever is greater

Minimum Arc Length A.L

(1) for O.D. 4in. or less : 270 deg.

(2) for O.D. greater than 4in. : the greater of 3T or 8in.

Specific Notch Dimensions

Length L ------ 1 in. minimum

Depth D ---- 10% T with tolerance D +10%/-20% of Depth

Width ------ 1/8 in. to 1/4in.

Location ----- not closer than T from any block edge

FIG. 2 LINEARITY

FIG.3 SWEEP RANGE


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FIG. 4 SENSITIVITY AND DISTANCE-AMPLITUDE CORRECTION

FIG. 5 SWEEP RANGE

FIG. 6

SENSITIVITY AND DISTANCE-AMPLITUDE CORRECTION


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