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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

CONTENTS:

1.0 PURPOSE 2.0 SCOPE 3.0 REFERENCES 4.0 INSPECTION PERSONNEL 5.0 UT EQUIPMENTS 6.0 CALIBRATION FOR TESTING 7.0 TESTING PROCEDURE 8.0 ACCEPTANCE & REJECTION CRITERIA 9.0 ATTACHMENTS.

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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

1.0

PURPOSE: The purpose of this procedure is to provide sufficient guidelines to operators, examiners, inspectors, and engineers etc. to apply ULTRASONIC TEST method correctly and efficiently as a Non-Destructive Test tool for determination of discontinuities in welds. 2.0 SCOPE:

The Scope of this procedure covers all structural steel column welds (Build-up Sections) which are likely to be fabricated at job site/shop of MSQ Up gradation Project, Panipat Refinery, Panipat, Haryana. This procedure will be valid for Plate-toPlate welded joint only. Thickness of structural members varies from 10 mm to 50 mm. Material Spec IS 2062 Gr. A/B. & IS 2002 Gr. II 3.0 REFERENCE: AWS D1.1, Sec 6 SNT-TC-1A of ASNT. 4.0 INSPECTION PERSONNEL Ultrasonic Testing shall be performed by NDT Level II personnel in accordance with SNT-TC-1A. NDT qualification shall include demonstration of ability to apply the rules of the AWS D 1.1 code in the accurate detection and disposition of discontinuities. 5.0 5.1 UT EQUIPMENTS Basic Unit The UT equipment shall be the pulse echo type suitable for use with transducers oscillating at frequencies between 1 and 6 MHz. The display shall be an A scan rectified video trace.

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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

The Horizontal linearity of the test instrument shall be qualified over the full sound path distance to be used in testing in conformance with 6.30.1 of AWS D1.1. The instruments gain control shall meet the requirement of 6.22.4 and shall be checked for correct calibration at 2 month intervals in conformance with 6.30.2. 5.2 5.3 PROBES / SEARCH UNITS Ultrasonic search unit with frequency 1 4 MHz shall be used.

5.2.1 TYPE OF SEARCH UNITS 5.2.1.1Straight beam (Longitudinal wave) search unit transducers shall have an active area of 10 mm dia crystal size. 5.2.1.2Angle beam search units crystal shall be 8 x 9 mm rectangular. The search unit shall produce a sound beam in the material being tested within plus or minus 2o. If one of the following proper angles: 70o, 60o or 45o. The dimensions of the search unit shall be such that distance from the leading edge of the search unit to the index point shall not exceed 1. 5.3 Resolution For straight beam search unit, the transducer shall be set in position F on the IIW block as specified in the AWS D1.1. Transducer and instrument shall resolve all three distances. For angle beam search unit, RC block shall be used as per clause no. 6.29.2.5. 5.4 Internal Reflection: Angle beam search unit shall meet the criterion of clause 6.24.3. Internal reflection check shall be verified at a maximum time interval of 40 hours of instrument use as per clause 6.30.3.

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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING 5.4 Probe Parameters Type 0o Normal beam Probe Angle Probe 45o, 60o, 70o Angle probe Frequency of probes 6.0 6.1 CALIBRATION FOR TESTING Calibration of Base Unit The detector until shall be calibrated by an approved Third party yearly or after any major repair or service done to the equipment. In addition to this, the equipment qualification shall be performed as per AWS D 1.1 clause. All calibrations and tests shall be made with the reject control turned off. 6.2 Daily Calibration Tests The Operator shall carry out and keep record of daily calibration checks of the following: Time-base linearity Gain Sensitivity Probe Index Calibration of Angle Beam search units shall be done with the use of an approved calibration block, each angle-beam search unit shall be checked after each eight hours of use to determine that the contact face is flat, the sound entry point is correct and the beam angle is within allowed tolerance. 8mm X 9mm crystal 2MHz to 4MHz. Size 10 mm dia
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING 6.3 Calibration of Time Base Time base and range calibration shall be set to accurately cover the entire ultrasonic beam distance for each probe selected for examination of the sample, using basic calibration blocks with artificial or defect reflectors at the commencement of each job or probe change. examination. 6.4 Reference Calibration Blocks The International Institute of Welding (IIW V1 & V2) UT reference block shall be the standard used for both distance calibration and IIW V1 block shall be used for sensitivity calibration. Other portable blocks may be used provided the reference level sensitivity for instrument / search unit combination shall be adjusted to be the equivalent of that achieved with the IIW block. The use of a corner reflector for calibration purpose shall be prohibited. 6.5 Beam Index for Angle Probe The angle probe is positioned in the V1 block to obtain maximum echo for 100mm radius. The index point is verified with the marking in the calibration block. 6.6 Straight Beam Calibration Sweep The horizontal sweep shall be adjusted for distance calibration to present the equivalent of at least two plate thicknesses on the display. Sensitivity The sensitivity shall be adjusted at a location free of indications so that the first back reflection will be 50 to 75% of full screen height. 6.7 Angle Beam Calibration Sweep The horizontal sweep distance shall be adjusted to represent the actual sound path distance by using the IIW block. The distance calibration shall be made using either the 5 in (152mm) scale or 10 In. (250mm) scale on the display, whichever is appropriate. If, however, the joint The calibration shall be checked frequently throughout the
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

configuration or thickness prevents full examination of the weld at either of these settings, the distance calibration shall be made using 15 in. or 20 in. (400mm or 500mm) scale as required. Amplitude or Sensitivity The Transducer shall be set in a position on the IIW V1 block to the indication from the 1.5mm hole to attain a horizontal reference-line height indication. The maximum decibel reading obtained shall be used as the Reference Level. b. Calibration for sensitivity and horizontal sweep shall be made by the UT operator just prior to and at the location of testing each weld. Recalibration shall be made after a change of operators, each 30 minute maximum time interval, or when the electrical circuit is disturbed in any way which includes the following: 1. Transducer change 2. Battery change 3. Electrical outlet change 4. Coaxial cable change 5. Power outage (failure). 6.8 INFORMATION TO OPERATOR The following information shall be provided to the operator before start of test. Material type grade & form (cast, rolled, forged etc.) Joint preparation details The welding process Details of the previous reports Details of any post weld heat treatment Differing thickness Mis-match & non-alignment

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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING Referencing code section 6.9 SURFACE CONDITION The weld and adjacent parent material to the extent of examination shall be kept free of slag, scale, paint, rust and weld spatter. Any temporary attachment, which might cause restriction to scanning, shall be removed. Surface condition of the weld shall be as weld condition. 7.0 7.1 TESTING PROCEDURE Couplants Mixture of grease and oil shall be used as Couplant. Special emphasis shall be given for post cleaning using cleaner. 7.2 Testing of Welds. 7.2.1 Welds shall be tested using an angle beam search unit as shown in Table 6.7 of AWS D1.1. The testing angle and scanning procedure shall be in conformance with the above-referred Table. (See attachment) 7.2.2 All butt joint welds shall be tested from each side of weld axis. All welds shall be tested using the applicable scanning patterns as per the referred standard to detect both longitudinal and transverse discontinuities. 7.2.3 Scanning plan shall be prepared for each type and thickness of weld joint. 7.3 Extent of Testing The entire base metal through which ultrasound must travel to test the weld shall be tested for laminar reflectors using a traight-beam search unit. If any area of base metal exhibits total loss of back reflection or an indication equal to or grater than the original back reflection height is located in a position that will interface with the normal weld scanning procedure, its size, location, and depth from the A face (see
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

Annex 1) shall be determined and reported on the UT report, and an alternate weld scanning procedure shall be used. 7.3. Indication Level a When a discontinuity indication appears on the screen, the maximum attainable indication from the discontinuity shall be adjusted to produce a horizontal reference level trace deflection on the screen. The adjustment shall be made with the calibrated gain control, and the instrument reading in decibels shall be used as the Indication Level, a, for calculating the Indication Rating, d. 7.4 Attenuation Factor, c The Attenuation factor, c shall be attained by subtracting 1 in. (25mm) from the sound path distance and multiplying the remainder by 2. This factor shall be rounded out to the nearest dB value. 7.5 Indication Rating, d. The Indication Rating, d represents the algebraic difference in decibels between the indication level and the reference level with correction for attenuation as indicated in the following expressions: Instruments with gain in dB: a b c = d. 7.6 Basis for Acceptance or Rejection. Each weld discontinuity shall be accepted or rejected on the basis of its indication rating and its length in conformance with Acceptance Criteria mentioned. Only those discontinuities which are unacceptable need be recorded on the test report. 7.7 Size Evaluation Procedure Straight Beam Testing The approximate size evaluation of the reflector shall be made by beginning outside of the discontinuity and moving the transducer toward the area of the discontinuity until the indication on the display begins to form. The leading edge of the search unit at this point is indicative of the edge of the discontinuity.

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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

Angle Beam Testing The following procedure shall be used to determine lengths of indications which have dB ratings more serious than for a Class D indication as per Acc Criteria. The length of such indication shall be determined by measuring the distance between the transducer centreline locations where the indication rating amplitude drops 50% (6dB) below the rating for the applicable discontinuity classification. 7.8 Inaccessibility If part of a weld is inaccessible to testing with the requirements mentioned in the table 6.7 of AWS D1.1 due to laminar content, the testing shall be conducted using one or more of the following alternative procedures as necessary to attain full weld coverage. 8.0 Weld surface(s) shall be ground flush Testing from Both sides. (Face A & Face B) Other search unit angles shall be used.

Other scanning patterns can also be used. (See sr. no. 3 of Annex 1) ACCEPTANCE & REJECTION CRITERIA The applicable Acceptance & rejection criterion is as per Table 6.3 of AWS D1.1. (See attachment). 9.0 ATTACHMENTS Annex 1 - Details of Job Thickness, Weld joints, and Scanning patterns / methods. Annex 2 Table 6.7 of AWS D1.1 for selection of Testing Angle. Annex 3 - Acceptance & Rejection Criteria, Table 6.3 of AWS D1.1. 10.0 DOCUMENTATION The records of test reports shall be maintained in the format no. LT/MSQ//UT/025 Rev. 00.

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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

ANNEX 1 - Details of Job Thickness, Weld joints, and Scanning patterns / methods. 1. For Job Thickness 10 & 12mm. Angle of Probe 70o, Freq. of Probe 2MHz.
Single side scanning for Single V 60o Butt Joint up to Full Beam path (1 V)

Full Beam Path (1 V)

Half Beam path ( V path)

Face A

Face B

2. For Job Thickness 20, 25 & 32m-m. Angle of Probe 70o, Freq. of Probe 2MHz.

Double side scanning for Double V 60o Butt Joint. Up to half bem path on both sides ( V)

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LARSEN & TOUBRO LIMITED MSQ UP GRADATION (EPCC 1) PROJECT

PROCEDURE FOR ULTRASONIC TESTING
DATE:-05..11.07 REV.NO.- 0 PROCEDURE NO.LT/MSQ/P/UT/011

3. When the Web plate joint fitted with Flange plate, Scanning to be done as per the below sketch for web & flange joining area.

Flange Plate

Normal Probe

Angle Probe

Web Plate

Web Plate to Web Plate Joint

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