Procedure For Ultrasonic Tesing Of Butt Weld Joints In Structure Dfps/sspl/qac/sop-007 Rev.00

D F Power Systems Pvt. Ltd.,

Document No.DFPS/SSPL/ QAC/SP-007

Revision No: 00 Date of Revision:12/11/2 010

Title : Procedure For Ultrasonic Testing Of Butt Weld Joints In Structure

PROCEDURE FOR ULTRASONIC TESING OF BUTT WELD JOINTS IN STRUCTURE DFPS/SSPL/QAC/SOP-007 REV.00

SALASAR STEEL & POWER LTD., (1X65 MW)

Prepared By: MR. JAY PAL

Reviewed By: MR.JAVID

Signature:

Signature:

Approved By: MR.VAKA MURTHY

Copy No:

Signature:

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Page 1 of 7

D F Power Systems Pvt. Ltd.,

Document No.DFPS/SSPL/ QAC/SP-007

Revision No: 00 Date of Revision:12/11/2 010 Page 2 of 7

Title : Procedure For Ultrasonic Testing Of Butt Weld Joints In Structure Issued By: MR.

Issued to: Name: Designation:

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REVISION HISTORY Rev. No.

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REFERENCE DOCUMENTS Document Number ASME Section V AWS D 1.1 1.0

Document Title Non Destructive Examination Structure welding code

PURPOSE This defines a general procedure for Ultrasonic testing of but weld joint in structure of Salaya power Project.

2.0

SCOPE This procedure shall be employed for the Ultrasonic examination of the Weld joints in structure weld joints.

3.0 Definitions and Acronyms ASME dB IIW NDT UT

American Society for Mechanical Engineers. Decibel International Institute of welding Non Destructive Testing Ultrasonic Testing

D F Power Systems Pvt. Ltd.,

Document No.DFPS/SSPL/ QAC/SP-007

Revision No: 00 Date of Revision:12/11/2 010

Title : Procedure For Ultrasonic Testing Of Butt Weld Joints In Structure SDH UFD DAC SNT-TC-1A

Page 3 of 7

Side Drill Hole Ultrasonic Flaw Detector Distance Amplitude Curve Society of Non destructive Testing

4.0 FLOW CHART

VISUAL INSPECTION & RELEASE FOR TESTING

SURFACE PREPARATION & CLEANING

EQUIPMENT / PROBE SELECTION

CALIBRATION OF EQUIPMENT WITH STANDARD BLOCKS

WELD JOINT SCANNING AND RESULT RECORDING / REPORTING/POST CLEANING

ACCEPTALE

RELEASE FOR FURTHER ACTIVITIES

RECTIFICATION AS PER CODE

UN ACCEPTABLE

D F Power Systems Pvt. Ltd.,

Document No.DFPS/SSPL/ QAC/SP-007

Revision No: 00 Date of Revision:12/11/2 010

Title : Procedure For Ultrasonic Testing Of Butt Weld Joints In Structure

5.0

PROCEDURE

5.1

EQUIPMENT

Page 4 of 7

The equipment used shall be pulse echo reflection type with A-Scan display. a) Frequency range b) Calibration gain control c) Horizontal linearity d) Vertical linearity 6.2

: 0.5 - 15 MHz : 0 - 80 dB step : + 1% over the F.S.R. of CRT : ± 5% over the F.S.R. of CRT

PROBE 4 MHz, 8x9 mm active size, 450 angle probe. 4 MHz, 8x9 mm active size, 600 angle probe. 4 MHz, 8x9 mm active size, 700 angle probe. However, angle probe shall be selected based on job thickness.

6.3

COUPLANT Water or Oil shall be used as couplant. The couplant used for calibration shall be used for the actual job.

6.4

CALIBRATION BLOCK Calibration shall be carried out on standard Blocks (V-1 & V-2) and if necessary calibration shall be done on similar sections to be tested.

6.5

SURFACE CONDITION All surfaces shall be clean and free from scale, dirt, spatters or any other conditions that will interfere with the test result.

D F Power Systems Pvt. Ltd.,

Document No.DFPS/SSPL/ QAC/SP-007

Title : Procedure For Ultrasonic Testing Of Butt Weld Joints In Structure 6.6

Revision No: 00 Date of Revision:12/11/2 010 Page 5 of 7

Scanning Method The sketch pf annexure 1 show’s scanning method of different types of structure weld joints configuration. However the other points are also to be taken care of while scanning the structure joints.

6.7

Scanning with TR probes Prior to angle beam scanning area from where angle beam scanning to be carried out are to be marked. T/R probe scanning to be carried out on the marked area to identify any reflector, which may interfere during beam scanning.

6.8

Examination Coverage The weld 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 10% of the transducer dimension perpendicular to the director of the direction of the scan. The shear probes which produces beam of an angle of 45 to 70 degrees in the examination medium shall be used. The beam angle dependent on the thickness and weld geometry. The recommended beam angles for different thickness are given below or code recommended angle probe shall be used. Thickness Up to 38 mm

Beam angle 70 degree

Above 38 mm

45/60/70 degree

Scan plan for UT examination shall be prepared as per the geometry of the job to ensure that the complete weld & HAZ area is covered during the scanning of weld joint. For butt joints the scanning limits ½ to 11/2 skip distance from both sides or as per the job requirement. For partial penetration weld joint scanning shall be carried out as per the required specification. For complicated geometries of the weld joints the scanning pattern shall be designed to cover the area of interest of the weld metals. 6.9

SCANNING dB

D F Power Systems Pvt. Ltd.,

Document No.DFPS/SSPL/ QAC/SP-007

Title : Procedure For Ultrasonic Testing Of Butt Weld Joints In Structure

Revision No: 00 Date of Revision:12/11/2 010 Page 6 of 7

All angle beam scanning to be carried out at reference level and of added gain as per the AWS D1.1 code requirements. 6.10

RECORDING & ACCEPTANCE The recording of indication shall be made with respect to the reference level. Acceptance criteria for defect evaluation of structure steel welding shall be as per sec. 6.13.1 Table 6.2 & sec. 6.13.2 Table 6.3 of AWS D1.1.

6.11

Evaluation of indication Any indication shall be evaluated at reference level. All indication will be investigated to the extent that the inspector can determine shape, identity and location. All indication detected with one probe may be further evaluated if required, using an appropriate combination of angle probes so that nature orientation and length can be accurately and discontinuity type can be established. The discontinuities shall be sized using 6db drop method and maximum amplitude technique. Wherever required, plotting to be carried out on the graph paper to decide the nature and location of the defect.

6.11

Evaluation of repair weld Wherever weld repair have been carried out, the soundness of the weld/job shall be confirmed by repeating the UT examination as per the procedure.

6.12

Post cleaning Couplant (grease/oil) applied to the job surface for UT examination shall be cleaned by respective NDT agency after completion of the cotton waste / cloth.

6.12

PERSONNEL QUALIFICATION The personnel carrying out the test shall be qualified as ASNT in accordance with the requirements of SNT-TC-1A of 1996 edition.

7.0

REPORTS AND RECORDS:

D F Power Systems Pvt. Ltd.,

Document No.DFPS/SSPL/ QAC/SP-007

Title : Procedure For Ultrasonic Testing Of Butt Weld Joints In Structure

Revision No: 00 Date of Revision:12/11/2 010 Page 7 of 7

The result of Ultrasonic examination shall be recorded on the approved format (DFPS/SSPL/QAC/FM-023) and shall be signed by all concerned as per approved ITP.