Job Procedure For Ultrasonic Testing Of Welds: Document No: Rev Issue Date Prepared By: Reviewed By: Approved By

Job Procedure for Ultrasonic Testing of welds

Document No:

Rev

Issue Date

Prepared by:

Reviewed by:

Approved by:

Name & Signature: Vipin Kumar

Name & Signature: Prakriti Samanta

Name & Signature: Ganesh Babu

Date: 28.12.2017

Date: 28.12.2017

Date: 28.12.2017

28.12.2017 QHSE/P11/CNDT/JP46/U T-API 650

06

Job Procedure for Ultrasonic Testing Of welds

INDEX Sl No.

Description of Content

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Annexure I Annexure II Annexure III

Annexure IV Annexure V

Purpose Scope Reference Documents Performance Demonstration Personnel Qualification Testing Method Test Equipment and Auxiliaries Surface Condition and Preparation Couplant Calibration Blocks QC of Test Equipment General Calibration Requirements System Calibrations Calibration Confirmations Examination Evaluation of geometric indications Sizing of indications Evaluation for Acceptance Documentation and Reporting of Results Final Cleaning Safety ANNEXURE

Page #

4 4 4 5 5 5 5 6 7 7 8 8 9 12 14 18 19 19 19 21 21

Linearity Checks - 22 Sample Acceptance Criteria - 24 Sample Report Format - 25 TECHNIQUE SHEET & CALIBRATION BLOCK Technique Sheet Calibration Block

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Job Procedure for Ultrasonic Testing Of welds

AMENDMENT RECORD Revision No.

Date of Amendment

Section / Checklist Amended

06

28 Dec 2017

Sec

26 Dec 2016

05

Name Amendment Details Reviewed

Approved

Section changes

Prakriti Samanta

Ganesh Babu

Sec 2, 18& Annexure III

Section - 2, 18& Annexure III

Prakriti Samanta

Ganesh Babu

All

Overall formatting and old Procedure Reference No. Aries/UFT/API 650/03 changed to new number P 11/CNDT/JP46 UT-API 650

Prakriti Samanta

Ganesh Babu

04

03 Jan 2016

03

27 Jul 2015

Revised

Ganesh Babu

Ramasamy

02

21.04.2014

Revised

Ganesh Babu

Ramasamy

01

10.10.2013

Revised

Ganesh Babu

Ramasamy

00

03 .05. 2013

Initial Issue

Ganesh Babu

Ramasamy

All

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Job Procedure for Ultrasonic Testing Of welds

1.

Purpose The purpose of this procedure is to describe the minimum requirement in carrying out Ultrasonic Examination of Storage Tank welds.

2.

Scope: Ultrasonic Examination is an effective means for determination of thicknesses as well as detecting planar and volumetric discontinuities. This Non-destructive Examination Procedure details the minimum requirements for conducting Ultrasonic Examination of welded joints, associated heat affected zone and base metal. This Procedure shall not be used in lieu of radiography. This Procedure is primarily intended for application on welds and adjacent heat affected zone made of steel or ferrite materials; however, the Procedure may be applied to welds and HAZ made of other materials and base metal product forms subject

to

the

qualification by satisfactory demonstration and revision of the procedure. This Procedure can be used on weld thick nesses varying between 8 mm and 150 mm (of steel). The extent of examination shall be as per applicable construction-Code requirements / project specifications and client directives. Typical types of discontinuities that can be detected by this method are cracks, incomplete fusion,

incomplete penetration,

undercut,

burn-through,

misalignment,

excessive/

overlap,

inadequate

porosity,

root-concavity,

reinforcement, laminations,

inclusions. 3.

Reference Documents:

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3.1.1. ASME Section V Edition-2017 3.1.2.

ASME Section VIII Division 1 & 2 Ed-2017

3.1.3.

ASNT SNT TC 1A Edition-2011 &2016

6

3.1.4. API 653-5TH Edition 2014-Tank Inspection, Repair, Alteration 3.1.5. API 650 -12th Edition-Welded Tanks for Oil Storage 3.1.6. ASME-BPVC-Section I –Edition 2017 3.1.7. Aries-NDT-GQP-01-Rev 10– Aries Written Practice

4.

Performance demonstration:

4.1.

When required by referencing Code Section or per Client requirements, performance demonstration shall be carried out and documented as report with the variables used. Copies of such reports shall be maintained by ARIES.

4.2.

A ‘Certification Statement’ stating satisfactory demonstration and qualification of the procedure with respect to the variables stated therein, either incorporated in procedure demonstration record or as a separate sheet shall be attached to the procedure.

5.

Personnel Qualification:

5.1

All ARIES personnel performing Ultrasonic Examination using this Procedure shall be qualified to a minimum of UT Level II as per ASNT document No. SNT-TC-IA. Accordance with Aries written practice of NDT-GQP-01; Rev.10.

5.2

Personnel conducting Radiographic Examination shall have vision, corrected or uncorrected to enable to read Jaeger Type No. 1 Standard Chart at a distance of not less than 300mm, and is capable of distinguishing and differentiating contrast between colors or shades of gray used. Vision tests shall be conducted annually and be current during examination.

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6

Job Procedure for Ultrasonic Testing Of welds

5.3

Personnel conducting Ultrasonic Examination should be aware of the safe-practice requirements during examination.

6

Testing Method:

6.1

Manual contact method using pulse-echo-type of ultrasonic instrument with a ‘A’ scan presentation and with system calibration using Distance Amplitude Techniques, with Normal & Angle Beam Probes employing Compressional & Shear Waves

7

Test Equipment and Auxiliaries:

7.1

The pulse-echo type instrument shall be capable of operation at frequencies over the range of at least 1 MHz to 5 MHz and shall be equipped with a stepped gain control in units of 2.0 dB or less.

7.2

The equipment shall have facilities to work with both combined and, separate transmitter/receiver probes.

7.2.1

The

recommended

equipment

models

include

USM

35/36

manufactured

by

KRAUTKRAMER. Or Epoch 600,650 by Olympus Application of this procedure for other instrument/ types shall be subject to qualification and revision of this procedure. 7.3

Search Units (Transducers) shall be either Single Crystal or Twin Crystal types. The nominal frequency shall be from 1 MHz to 5 MHz

7.4

The search units’ materials & construction shall be capable of producing either longitudinal or shear waves into the test component. Generally designated normal (0°) probes should be capable of producing longitudinal waves into test component while angle probes should be capable of producing refracted shear waves in to test component at angles 45°, 60°, and 70° (in steel).

7.5

The nominal cross-section sizes of normal probes shall be between diameters 10 mm to 25 mm, while the cross-section sizes of angle probes shall be 8 mm x 9 mm to 20 mm x 22

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mm. 7.6

Co-axial cables connecting search units with the equipment shall be of length between 1.5m. & 4m and shall have end adapters capable of secured connections at ends; where, required adopters of various types shall be used to secure connectivity.

7.7 8 8.1

8.2

Auxiliary test aids would include tape strips & rulers, calculators, mimic gauges, Perspex slides, plot cards, marking aids. Surface condition & preparation: Satisfactory results are usually obtained when the surface of the component is in as-rolled, as-welded, as-cast or as-forged condition. Surface preparation may be necessary by grinding, machining or other methods, where surface irregularities could affect proper scanning or affect test results by causing excessive surface reflections or noise. Prior to examination, all areas to be scanned shall be free of all dirt, paint, loose particles, loose mill scale, temporary attachments or any obstructive materials that could interfere with the examination.

9

Couplant:

9.1

Couplants are liquids or pastes used to eliminate the air gap between the transducer and the test surface to assure maximum ultrasound transmission. The couplants will normally be a wetting agent (polycel) in water, liquid soap, sodium CMC or any other suitable couplant medium. Glycerin, light machine oil or grease may also be used.

9.2

The couplant should be selected so that its viscosity is appropriate for the surface finish of the material surface to be examined (Examination of rough surfaces generally requires high viscosity couplant).

Temperature of the material surface can change the couplant’s

viscosity. 9.3

The couplant, including additives, shall not be detrimental to the material being examined.

9.3.1

Where, during examination, it may come in contact with nickel base alloys, the couplant shall not contain more than 250 ppm of sulfur. In cases where it may come in contact with stainless steel or titanium, the couplant shall not contain more than 250 ppm of halides (chlorides plus fluorides).

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Job Procedure for Ultrasonic Testing Of welds

9.4

Couplant used for calibration shall be the same proposed for use during examination

10

Calibration Blocks:

10.1

IIW – V1 Calibration Block, V2 (miniature) Calibration Block shall be used for distance calibration

10.2

IIW / IOW Standard blocks shall be used for equipment checks.

10.3

IIW Block shall be used for evaluating sensitivity, sweep linearity, transducer index point and angle.

10.4

IOW Standard block shall be used for establishing shear wave beam characteristics, profiles, to check accuracy of beam index and angle obtained for measurements on the large hole of IIW block, for assessment of the resolution characteristics of instrument-transducer combinations.

10.5 ASME Non-Piping Calibration Block shall be used for Distance Amplitude Correction (DAC) curves. For piping upto 20” dia piping calibration blocks shall be used

10.6

Where specific calibration blocks are mandated by Code or client requirements, the same shall be used for calibration and instrument set-up.

10.6.1 Examples of such calibration blocks are the Non-piping Calibration Blocks as per J-431 of ASME Section V, Non-Piping Calibration Blocks as per T-434.2.1, Calibration Block for Pipe as per T-434.3, Cladding Calibration Blocks as per T-434.4.1, T-434.4.2.1, T434.4.2.2, T-434.4.3.

11

QC of Test Equipment:

11.1

Instrument Linearity Checks:

11.1.1 Screen Height Linearity and Amplitude Control Linearity of the equipment shall be periodically evaluated; such periodicity shall be at intervals not to exceed three months or prior to first use thereafter. Results of such evaluations shall be recorded and records Doc. Ref.: QHSE/P11/CNDT/JP46/UT-API 650 Job Procedure for Ultrasonic Testing | Rev No: 06 | Date: 28.12.2017

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maintained. 11.1.2 The procedures for linearity checks shall be as detailed in Mandatory annexure I

12

General Calibration Requirements:

12.1

Calibrations shall include the complete ultrasonic system and shall be performed prior to use of the system in the thickness range under examination

12.2

Calibrations shall be performed from the surface (clad or unclad; convex or concave) corresponding to the surface of the component from which examination will be performed.

12.3

Same contact wedges to be used during the examination shall be used for calibration.

12.4

Any instrument control, which affects instrument linearity (e.g. filters, reject, or clipping), shall be in the same position for calibration, calibration checks, instrument linearity checks, and examination.

12.4.1 If the instrument has a damping control, it may be used if it does not reduce Sensitivity of examination. 12.4.2 The reject control shall be in the “off” position for all examinations, unless it can be demonstrated that it does not affect the linearity of the examination. 12.5

The temperature differential between calibration block and examination surfaces shall be within 14°C (25°F). Heat Treatment. The calibration block shall receive at least the minimum tempering treatment required by the material specification for the type and grade. If the calibration block contains welds other than cladding, and the component weld at the time of the examination has been heat treated, the block shall receive the same heat treatment. Surface Finish. The finish on the scanning surfaces of the block shall be representative of the scanning surface finishes on the component to be examined. Block Curvature. Materials with Diameters Greater Than 20 in. (500 mm). For examinations in materials where the examination surface diameter is greater than 20 in. (500 mm), a block of essentially the same curvature, or alternatively, a flat basic calibration block, may be used. Materials with Diameters 20 in. (500 mm) and Less. For examinations in materials where the examination surface diameter is equal to or less than 20 in. (500 mm), a curved block shall be used. Except where otherwise stated in this Article, a single curved basic

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calibration block may be used for examinations in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter. For example, an 8 in. (200 mm) diameter block may be used to calibrate for examinations on surfaces in the range of curvature from 7.2 in. to 12 in. (180 mm to 300 mm) in diameter. The curvature range from 0.94 in. to 20 in. (24 mm to 500 mm) in diameter requires six curved blocks as shown in Figure-2 (Fig T434.1.7.2 ASME Sec-V Article-4) for any thickness range. Alternative for Convex Surface. As an alternative to the requirements in block curvature when examining from the convex surface by the straight beam contact technique, may be used 13 13.1 13.1.1

System Calibrations: Angle Beam Calibration: The Non-Piping Calibration Block (as per ASME V T434.2.1) shall be used. Where necessitated

by

Code

requirements,

appropriate

other Calibration blocks shall be

used. 13.1.2

The calibration shall provide the following measurements:

13.1.2.1 Distance range calibration 13.1.2.2 Distance-amplitude correction 13.1.2.3 13.1.3 13.1.3.1

Echo amplitude measurement from the surface notch in the basic Calibration block. Distance Amplitude Correction (DAC) Curves: The Distance Amplitude Correction (DAC) curves shall be constructed by using amplitude from (minimum three reference) holes of the Non-piping calibration block or piping calibration block as detailed below:

13.1.3.2

Select the range required to cover the volume of examination. Position the search unit to produce maximum response from the SDH or the notch, which gives the highest amplitude.

13.1.3.3

Adjust the sensitivity (gain) control to provide an indication of 80% (±5%) of full screen height (FSH). This is the primary reference. Mark the peak of the indication on the screen.

13.1.3.4

Position the search unit without changing the sensitivity (dB) to produce maximum

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response from another SDH and mark the peak of the indication on the screen. 13.1.3.5

Position the search unit for maximum amplitude from third SDH and mark the peak on the screen.

13.1.3.6

Position the search unit for maximum amplitude from the ¾ T SDH after the beam has bounced from the opposite surface. The indication should appear near the sweep line. Mark the peak on the screen for the 5/4 T Position

13.1.3.7

Connect all the screen marks for the SDHs to provide the distance-amplitude curve (DAC) and this line shall be the primary reference level.

13.1.4

Calibration correction for Perpendicular reflectors at opposite surface:

13.1.4.1

Notch Indication: Position the search unit for maximum amplitude from the notch on the opposite surface. Mark the peak of the indication with an “X” on the screen.

13.1.4.2

45° vs. 60°: The opposite surface notch may give an indication 2 to 1 above DAC for a 45° shear wave, but only ½ DAC for a 60° shear wave. Therefore, the indications from the notch shall be considered when evaluating reflectors at the opposite surface.

13.2

Straight (Normal) Beam Calibration:

13.2.1

The calibration shall provide the following measurements:

13.2.1.1

Distance range calibration

13.2.1.2

Distance-amplitude correction

13.2.2

Distance Amplitude Correction (DAC) Curves:

13.2.2.1

The Distance Amplitude Correction (DAC) curves shall be constructed by using amplitude from (minimum three reference) holes of the calibration block as detailed below:

13.2.2.1.1

Select the range required to cover the volume of examination.

13.2.2.1.2

Position the search unit to produce maximum response from the SDH, which gives

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the highest amplitude. 13.2.2.1.3

Adjust the sensitivity (gain) control to provide an indication of 80% (±5%) of full screen height (FSH). This is the primary reference. Mark the peak of the indication on the screen

13.2.2.1.4

Position the search unit without changing the sensitivity (dB) to produce maximum response from another SDH and mark the peak of the indication on the screen.

13.2.2.1.5

Position the search unit for maximum amplitude from third SDH and mark the peak on the screen.

13.2.2.1.6

Connect all the screen marks for the SDHs to provide the distance-amplitude curve (DAC) and this line shall be the primary reference level.

14

Calibration Confirmations:

14.1

System Changes: When any part of the examination system is changed or probe cable is changed, a calibration check shall be made on the basic calibration block to verify that distance range points and sensitivity setting(s) satisfy the requirements in 14.1.1 & 14.1.2. Calibration check shall be on change of operator, after each 30 min. of operation, or on disturbance

for

electrical

circuit.

Disturbance to electrical circuit would include

transducer changes, change of co-axial cable, change of battery, change of electrical outlet, machine “on” / “off”, or power outage. 14.1.1 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. 14.1.2 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 Doc. Ref.: QHSE/P11/CNDT/JP46/UT-API 650 Job Procedure for Ultrasonic Testing | Rev No: 06 | Date: 28.12.2017

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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. 14.2

Periodic Examination Checks:

14.2.1 A calibration check on at least one of the basic reflectors in the basic calibration block or a check using a simulator shall be made: 14.2.1.1 At the finish of each examination or series of similar examination, 14.2.1.2 Every 4 hr. during the examination, and 14.2.1.3 When examination personnel are changed. 14.2.2 The distance range points and sensitivity setting(s) recorded shall satisfy the requirements of 14.1.1 & 14.1.2 14.3

Simulator Checks:

14.3.1 Any simulator checks that are used shall be correlated with the original calibration on the basic calibration block during the original calibration. 14.3.2 The simulator checks may use different type of calibration reflectors or blocks (such as IIW) and/or electronic simulation. 14.3.3 The simulation used shall be identifiable on the calibration sheet(s). 14.3.4 The simulator check shall be made on the entire examination system. The entire system does not have to be checked in one operation; however, for its check, the search unit shall be connected to the ultrasonic instrument and checked against a calibration reflector. 14.3.5 Accuracy of the simulator checks shall be confirmed, using the basic Calibration block, at the conclusion of each period of extended use, or every three months, whichever is less. 14.4 Shear wave transducers shall be checked after every 8 hours for correct angle and flat surface condition. 14.5

The dimension of the search unit shall be such that the distance from the leading edge of search unit to the index point shall not exceed 25 mm.

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14.6

Beam angle in the material being tested shall be determined to an accuracy of ± 2° from the nominal angles.

14.7

Transducer units, which do not meet necessary requirements, shall be corrected or withdrawn from service.

15

Examination:

15.1 General Requirements: 15.1.1 The volume to be scanned shall be examined by moving the search unit over the scanning surface so as to scan the entire examination volume for each required search unit. 15.1.2 Each pass of the search unit shall overlap a minimum of 10% of the active transducer (piezoelectric element) dimension perpendicular to the direction of scan. Where mandated by Code requirements, the percent minimum overlap may be increased. 15.1.3 Alternatively, each pass of the search unit may overlap a dimension less than the minimum beam dimension (beam spread) if the same is already known. Oscillation of the search unit is permitted provided improved coverage is demonstrated. 15.1.4 The Pulse Repetition Rate shall be small enough to assure that a signal from a reflector located at the maximum distance in the examination volume will arrive back at the search unit before the next pulse is placed on the transducer. 15.1.5 The rate of search unit movement (scanning speed) shall not exceed 6 in. /s (152 mm/s). 15.2

Scanning:

15.2.1 The scanning sensitivity level shall be set a minimum of 6 dB higher than the reference level gain setting. 15.2.2 The temperature differential between the test surface and that of the calibration block shall be less than 25° F. 15.3

Weld Joint Scanning:

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15.3.1 Weld Joints shall be scanned with an angle beam search unit in both parallel and transverse directions (4 scans) to the weld axis. 15.3.2 Before performing the angle beam examinations, a straight beam exa mination shall be performed on the volume of base material through which the angle beams will travel to locate any reflectors that can limit the ability of the angle beam to examine the weld volume. 15.3.3 Beam Angle: The search unit and beam angle selected shall be appropriate for the configuration being examined and shall be capable of detecting the calibration reflectors, over the required angle beam path. 15.3.4 Reflectors Parallel to the Weld Seam: The angle beam shall be directed at approximate right angles to the weld axis from both sides of the weld (i.e. from two directions) on the same surface when possible. The search unit shall be manipulated so that the ultrasonic energy passes through the required volume of weld and adjacent base material. 14.3.5 Reflectors Transverse to the Weld Seam: The angle beam shall be directed essentially parallel to the weld axis. The search unit shall be manipulated so that the ultrasonic energy passes through the required volume of weld and adjacent base material. The search unit shall be rotated 180° and the examination repeated. 15.3.6 Restricted Access Welds: Welds that cannot be fully examined from two directions using the angle beam technique (e.g. corner and tee joints) shall also be examined, if possible, with a straight beam technique. 15.3.6.1 These areas of restricted access shall be noted in the examination report. 15.3.7 Inaccessible Welds: Welds that cannot be examined from at least one side (edge) 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.

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Calibration for Piping; Using the Piping Calibration Block ( Fig. 4) the angle beam shall be directed toward the calibration reflector that yields the maximum response. The gain control shall be set so that this response is 80%± 5% of full screen height. This shall be the primary reference level .The search unit shall then be manipulated , without changing the instrument settings , to obtain the maximum responses from the calibration reflectors at the distance increment necessary to generate a three point distance amplitude correction ( DAC ) curve( see Fig. 11).

a. Separate calibration shall be established for both the axial and circumferential notches. These calibrations shall establish both the distance range calibration and the distance amplitude correction. MISCELLANEOUS REQUIREMENTS IDENTIFICATION OF WELD EXAMINATION AREAS a. Weld Locations. Weld locations and their identification shall be recorded on a weld map or in an identification plan. b. Marking. If welds are to be permanently marked, low stress stamps and/or vibratooling may be used. Markings applied after final stress relief of the component shall not be any deeper than 3/64 in. (1.2 mm). c. Reference System. Each weld shall be located and identified by a system of reference points. The system shall permit identification of each weld center line and designation of regular intervals along the length of the weld. TECHNIQUES The techniques described in this Procedure are intended for applications where either single or dual element search units are used to produce: a. normal incident longitudinal wave beams for what are generally termed straight beam examinations or Doc. Ref.: QHSE/P11/CNDT/JP46/UT-API 650 Job Procedure for Ultrasonic Testing | Rev No: 06 | Date: 28.12.2017

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b. Angle beam longitudinal waves, where both refracted longitudinal and shear waves are present in the material under examination. When used for thickness measurement or clad examination, these examinations are generally considered to be straight beam examinations. When used for weld examinations, they are generally termed angle beam examinations or c. Angle beam shear waves, where incident angles in wedges produce only refracted shear waves in the material under examination are generally termed angle beam examinations. Contact or immersion techniques may be used. Base materials and/or welds with metallurgical structures producing variable attenuations may require that longitudinal angle beams are used instead of shear waves. Additionally, computerized imaging techniques may enhance the detectability and evaluation of indications. Other techniques or technology which can be demonstrated to produce equivalent or better examination sensitivity and detectability using search units with more than two transducer elements may be used. Nozzle Side Weld Fusion Zone and/or Adjacent Nozzle Parent Metal Calibration Blocks. Calibration Block. (a) Configuration. The calibration block configuration shall be as shown in Figure-10 (Figure T-434.5.1 of ASME Sec V Article-4). The block size and reflector locations shall be adequate to perform calibrations to cover the nozzle side weld fusion zone and/or the adjacent nozzle parent metal. If the internal surface of the nozzle is clad before the examination, the ID surface of the calibration block shall be clad. (b) Block Thickness. The calibration block shall be the maximum thickness of the nozzle wall adjacent to the nozzle weld plus 3/4 in. (19 mm). (c) Curvature. For examinations of nozzles with an inside diameter (I.D.) equal to or less than 20 in. (500 mm), the contact surface of the calibration block shall have the same curvature or be within the range of 0.9 to 1.5 times the diameter as detailed in Figure-2 (Figure T-434.1.7.2 of ASME Sec V Article-4). (d) Calibration Reflectors. The calibration reflectors shall be side-drilled hole(s) that are in accordance with the requirements of Figure-3 (Figure T-434.2.1 of ASME Sec V Article-4) for the nozzle wall thickness. (e) Alternative Blocks. Alternative calibration blocks may be used for similar types of examinations provided the sound path distance(s) to the block’s reflector(s) is (are) within 1/4 in. (6 mm) of what is required and the side drilled hole(s) is (are) the same or a smaller diameter than what is required 15.4 Cladding Techniques:

Calibration for Cladding a. Calibration for Technique One; ·

Calibration shall be performed using the calibration block shown in Fig.5. The search unit

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shall be positioned for the maximum response from the calibration reflector. The gain shall be set so that this response is 80% ± 5% of full screen height. This shall the primary reference level. b. Calibration for Technique Two; ·

Calibration shall be performed using the calibration block shown in Fig.6. The search unit shall be positioned for the maximum response of the first resolvable indication from the bottom of the calibration reflector. The gain shall be set so that this response is 80% ± 5% of full screen height. This shall the primary reference level.

c. Calibration for Side Weld Fusion Zone and/or Adjacent Nozzle Parent Metal; ·

Single hole ; the response from a single side drilled hole shall be set at 80% ± 5% full screen height. This is the primary reference level.

d. Multiples holes ; ·

The etright beam shall be directed toward the calibration reflector that yield the maximum response. The gain control shall be set so that this response is 80%±55 of full screen height. This shall be the primary reference level. The search unit shall then be manipulated ,whitout changing instrument settings , to obtain the maximum responses from the other hole position(s) to generate a DAC curve.

16

Evaluation and Discrimination of Geometric Indications:

16.1

Generally, certain metallurgical discontinuities and geometric conditions may produce indications that are not relevant.

16.1.1 Classification of an indication as geometric shall be through the following steps: 16.1.1.1 Interpret the area containing the reflector in accordance with the applicable examination procedure. 16.1.1.2 Plot and verify the reflector coordinates. Prepare a cross-sectional sketch showing the reflector position and surface discontinuities such as root and counter bore. 16.1.1.3 Review fabrication or weld preparation drawings. 16.1.1.4 If necessary, other ultrasonic techniques or nondestructive examination methods may be

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applied in determining a reflector’s true position, size and orientation.

16.2

All indications greater than 20 % of the reference level shall be investigated to the extent that they can be evaluated in terms of the acceptance criteria of the referencing Code.

16.3

Reflectors evaluated as laminar reflectors in base material, which interfere with

the

scanning of examination volumes, shall require the angle beam examination technique to be modified such that the maximum feasible volume is examined, and shall be noted in the record of the examination. 16.4

Reflector dimensions exceeding the referencing Code Section requirements may be evaluated to any alternative standards provided by the referencing Code Section.

16.5

This Procedure contains sample acceptance standards as per ASME Section VIII Division I (Refer Non-Mandatory Annexure IV)

17

Sizing of Indications:

17.1

All indications considered to be record able shall be sized for their length extension by 6 Db drop (50% amplitude drop) method.

17.2

Other methods of sizing of indications may be used subject to subject to satisfactory demonstration for qualification and revision of the procedure.

18

Evaluation for Acceptance:

18.1

All non-rejectable indications shall be recorded, as specified by any referencing Code Section or client requirement.

18.2

Rejectable indications shall be recorded. As a minimum, the type of indication (i.e. crack, non-fusion, slag, etc.), location, and extent (i.e. length) shall be recorded.

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18.3

Acceptance criteria used shall be documented in the NDE Report.

19

Documentation & reporting of results.( Ref:Aries/UT/01 Rev 03)

19.1

For each Ultrasonic Examination as per this Procedure, the following minimum information shall be recorded and suitably addressed in the relevant ARIES Report (Refer Non- Mandatory Annexure III):

19.1.1 Client / Project / Job details 19.1.2 Location 19.1.3 Procedure Identification and Revision 19.1.4 Ultrasonic Instrument identification (Make / Serial No.) 19.1.5 Search unit identification 19.1.5.1 Make / Serial No. 19.1.5.2 Frequency 19.1.5.3 Size 19.1.6 Beam Angles Used 19.1.7 Search unit cable, type & length: 19.1.8 Special equipment (like wedges, shoes etc, when used): 19.1.9 Calibration block identification: 19.1.10 Simulation blocks identification (when used) 18.1.11 Instrument reference level gain 19.1.12 Damping and Reject settings (when used): 19.1.13Calibration data (including reference reflectors, indication amplitudes & Distance) Doc. Ref.: QHSE/P11/CNDT/JP46/UT-API 650 Job Procedure for Ultrasonic Testing | Rev No: 06 | Date: 28.12.2017

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19.1.14 Data correlating simulation blocks (when used) with initial calibration 19.1.15 Weld Configuration, thickness & dimensional details of Base metal 19.1.16 Identification and location or weld or volume scanned 18.1.17 Couplant brand name or type used: 18.1.18 Surface condition of examination location 19.1.19 Surface from which examination was conducted 19.1.20 Record of rejectable indications detected or areas cleared 19.1.21Record of all reflections from uncorrected areas having responses greater than 50% of the reference level. (See Annexure II). 19.1.22 Areas of restricted access or inaccessible welds 19.1.23 Examination personnel identity and qualification level 19.1.24 Examination date and time. 19.1.25 Accept / Reject status (as appropriate & applicable) 19.2

Items 18.1.4 through 18.1.14 may be included in a separate calibration record, Provided the calibration record identification is included in the Examination Record. 19.3 All such reports shall be maintained by ARIES and copies provided to Client. 20

21

Final cleaning: Whenever required, after completion of Examination, couplants such as polycel paste shall be cleaned using water. Couplants such as glycerin / oil / grease shall be cleaned utilizing suitable solvent remover. Such cleaning agents shall not produce any detrimental effect to the test component. Safety:

21.1 All inspection personnel shall be responsible for compliance with applicable safety rules in the use of Test materials. 21.2 Some of the Calibration blocks used in Ultrasonic Testing are fairly heavy in weight, having square edges. They may be become slippery due to usage of couplants and will need to be carefully handled.

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21.3 Some test materials such as couplants may cause skin irritation. Use adequate ventilation at all times and avoids prolonged skin contact. 21.4 Test materials shall never be heated above the recommended temperature limits prescribed by the manufacturer. 21.5 The test system has electrical input for the Test equipment and safe practices should be followed to avoid any electrical shocks.

ANNEXURE I LINEARITY CHECKS

Fig. MA II-1

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Screen Height Linearity: Position an angle beam search unit on a calibration block similar to that shown in Fig. MA II-1 so that indications from both the ½ and ¾ T holes give a 2:1 ratio of amplitudes between the two indications. Adjust the sensitivity (gain) so that the larger indication is set at 80% of full screen height (FSH). Without moving the search unit, adjust sensitivity (gain) to successively set the larger indication from 100% to 20% of full screen height, in 10% increments (or 2 dB steps if a fine control is not available), and read the smaller Indication at each setting. The reading shall be 50% of the larger amplitude, within 5% of FSH. The settings and readings shall be estimated to the nearest 1% of full screen. Alternatively, a straight beam search unit may be used on any calibration bloc that provides amplitude differences, with sufficient signal separation to prevent overlapping of the two signals. Amplitude Control Linearity: Position an angle beam search unit on a basic calibration block, as shown in Fig. MA II-1 so that the indication from the ½T side-drilled hole is peaked on the screen. Adjust the sensitivity (gain) as shown in the following table. The indication shall fall within the specified limits. Alternatively, any other convenient reflector from any calibration block may be used with angle or straight beam search units. The settings and readings shall be estimated to the nearest 1 % of full screen.

Indication Set at % of Full

dB Control Change

Indication of Full Screen Limits

Screen

%

80 %

-6 dB

32 to 48 %

80 %

-12 dB

16 to 24 %

40 %

+6 dB

64 to 96 %

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Job Procedure for Ultrasonic Testing Of welds

20 %

+12 dB

64 to 96 %

ANNEXURE II Acceptance Criteria (Note: Information provided in this annexure is for guidance only; users are encouraged to refer the relevant standards / codes for specific acceptance criteria. These acceptance criteria apply unless other more restrictive standards are specified for specific materials or applications within the Code Sections / Divisions) ASME Section VIII (As per Appendix 12) 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 acceptance standards given below: Indications characterized as Crack, Lack of Fusion, or Incomplete Penetration is unacceptable regardless of length other imperfections whose indications exceed the reference level and which have their length exceeding the following are unacceptable: ¼” (6 mm) for t up to ¾” (19 mm) t/3 for t from ¾” to 2¼” (19 mm to 57 mm) ¾” for t over 2¼” (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 .

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Annexure III Sample Report Format 6

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Technique sheet-01 BUTT WELD – SINGLE “V” Scanning Pattern

a. Parent Metal Examination Scanning Positions

:

1 & 2 over 2.5 times the parent Metal thickness each side of the weld toes.

Thickness Range Sensitivity

: 8mm to 20 mm OR Single V Butt welds : Sensitivity setting shall be SDH for straight beam probe (Single /Twin) when used for discontinuity detection of weld metal. BWE shall be used for base metal scanning only for laminar discontinuity.

Probes

: 0° - 2 MHz to 2.5 MHz T/C or S/C

b. Weld Metal Examination: Scanning Pattern

: 10% Overlapping Scans

Probes

Scanning Options

0°

HAZ (1&2)

70°, 60°&45°

1&2

Scanning Sensitivity II’nd BWE set to 80%+6 dB Reference side drilled hole set to 80%FSH (DAC)

Sizing Technique

: 6 dB drop, max amplitude and similar recognized technique.

Scanning dB

: Reference dB +TC+6dB

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Job Procedure for Ultrasonic Testing Of welds

Annexure I

Technique sheet-02

BUTT WELD – Double “V” Scanning Pattern

a. Parent Metal Examination

Scanning Positions

:

1 & 2or 3 & 4 over 2.5 times the parent Metal thickness each side of the weld toes.

Thickness Range Sensitivity

: 20mm OR 25mm and above Double V Butt weld : Sensitivity setting shall be SDH for straight beam probe (Single /Twin) when used for discontinuity detection of weld metal. BWE shall be used for base metal scanning only for laminar discontinuity.

Probes

: 0° - 2 MHz to 2.5 MHz T/C or S/C

b. Weld Metal Examination: Scanning Pattern

: 10% Overlapping Scans

Probes

Scanning Options

0°

1& 2

Scanning Sensitivity

II’nd BWE set to 80%+6 dB

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Job Procedure for Ultrasonic Testing Of welds

70°,45°&60°

1 &2/3&4

Reference side drilled hole set to 80%FSH(DAC)

Sizing Technique

: 6 dB drop / max amplitude or similar recognized technique.

Scanning dB

: Reference+TC+6dB

Annexure I

Technique sheet-03 T- WELD – (Single Bevel T) Scanning Pattern

a. Parent Metal Examination

Scanning Positions

:

1 over 2.5 times the parent Metal thickness each side of the weld toes.

Thickness Range

Sensitivity

Probes

: 8mm to 20mm OR 25mm Single Bevel T weld

: Sensitivity setting shall be SDH for straight beam probe (Single /Twin) when used for discontinuity detection of weld metal. BWE shall be used for base metal scanning only for laminar discontinuity. : 0° - 2 MHz to 2.5 MHz T/C or S/C

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b. Weld Metal Examination: Scanning Pattern

: 10% Overlapping Scans

Probes

Scanning Options

0°

1

0°

2 (if required)

70°45°&60°

1

Sizing Technique Scanning dB

Scanning Sensitivity II’nd BWE set to 80%+6 dB

Reference side drilled hole set to 80%FSH

Reference side drilled hole set to 80%FSH (DAC)

: 6 dB drop / max amplitude or similar recognized technique. : Reference+TC+6dB Annexure I

Technique sheet-04 T- WELD – (Double Bevel T) Scanning Pattern

a. Parent Metal Examination

Scanning Positions

:

1 & 2 over 2.5 times the parent Metal thickness each side of the weld toes.

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Thickness Range Sensitivity

: Above 20mm OR 25mm Double Bevel T weld : Sensitivity setting shall be SDH for straight beam probe (Single /Twin) when used for discontinuity detection of weld metal. BWE shall be used for base metal scanning only for laminar discontinuity.

Probes

: 0° - 2 MHz to 2.5 MHz T/C or S/C

b. Weld Metal Examination: Scanning Pattern

: 10% Overlapping Scans

Probes 0°

Scanning Options 1

0°

3 (if required)

70°, 45°&60°

1&2

Scanning Sensitivity II’nd BWE set to 80%+6 dB

Reference side drilled hole set to 80%FSH

Reference side drilled hole set to 80%FSH (DAC)

Sizing Technique

: 6 dB drop / max amplitude or similar recognized technique.

Scanning dB

: Reference+TC+6dB

ANNEXURE-V

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Ultrasonic Testing Procedure for welds

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Ultrasonic Testing Procedure for welds

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Ultrasonic Testing Procedure for welds

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Ultrasonic Testing Procedure for welds

Nozzle Side weld Fusion and/or Adjacent Nozzle Parent Metal Calibration Block a. Configuration. The calibration block configuration shall be as shown in Fig. 10. The block size and the reflector location shall be adequate to perform calibartions to cover the nozzle side weld fusion zone and/or the adjacent nozzle parent metal. If the internal surface of the nozzle is clad before the eamination , the ID surface of the calibration block shall be clad. b. Block Thickness The calibration block shall be the maximum thickness of the nozzle wall adjacent to the nozzle weld plus ¾ in.( 19 mm). c. Curvature. For examination of nozzles with an inside diameter (ID) equal oe less than 20 in. (500 mm) , the contact surface of the calibration block shall have the same curvature or be within the range of 0.9 to 1.5 times the diameteras detailed in Fig.2. d. Calibration Reflectors. The calibration reflectors shall be side-drilled hole (s) that are in accordance with the requirements of the Fig. 3 for the nozzle wall thickness.

e. The number of the holes depends upon the requrement for the examination. If only the nozzle side fusion zone is to be examined , shall be used a single hole drilled at the nozzle wall thickness.

Doc. Ref.: ARIES-UFT-API650-173 Job Procedure for Ultrasonic Testing | Rev No: 0 | Date: 10.12.2017

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