RELIANCE

PROJECT TITLE:

JAMNAGAR EXPORT REFINERY PROJECT

KH Petrotec

VENDORS NAME:

DOCUMENT TITLE:
VENDORS DOCUMENT NO: VENDORS REVISION NO:

ULTRASONIC TESTING PROCEDURE

KH-USZ-UT-002 00

Reliance JERP

Supplier Document Review

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

Work May Proceed Revise & Resubmit. Work may Proceed subject to incorporation of changes Revise & Resubmit. Work may not Proceed Revise - Work may Proceed do not resubmit until final

2a

2b

Review Not Required. Work may Proceed

By:

Date:

Discipline:

Mechanical ALL ITEMS (COMMON)

MR No.

Equipment 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

LAC

0 0 0

J 0 2

0 0 0 1

0 0

KH-USZ-UT-002

Process Specification

PAGE Rev.No

1 OF 11 0

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 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Scope Applicable Codes and Standards Qualification of Personnel General Requirements Calibration Examination Procedure Acceptance Standards Records

0
REV NO.

Dec.28,06

First Issue

W. J. CHANG NDE Level

W. J. CHANG NDE Level REV'D & APP'D BY

DATE

(DESCRIPTION)

PREPARED BY

Approved by Customer

I, the under signed, certify that this procedure has been written in accordance with the requirement of ASME section , T- 150. NDE Mgr. KH Petrotec
A4 (210297 m/m)

KH-USZ-UT-002

Process Specification

PAGE Rev.No

2 OF 11 0

1.0 1.1

SCOPE 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. 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.

1.2

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 or higher, 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.

KH Petrotec

A4 (210297 m/m)

KH-USZ-UT-002

Process Specification
Frequency Model Major size (mm)

PAGE Rev.No

3 OF 11 0

Mode Longitudinal wave

Reference Angle

KRAUTKRAMER Dia. 24 2 MHz B2S-N, MB2S-N 0 deg. Dia. 10 B4S-N, MB4S-N WB 45, 60 or 70 20 X 22 2 MHz MWB 45, 60 or 70 8X9 Shear wave 45, 60, 70 deg. WB 45, 60 or 70 20 X 22 4 MHz MWB 45, 60 or 70 8X9 Search unit of other sizes, frequencies, and other refraction angles may be used to assure adequate penetration or better resolution. 4.2 Couplant Suitable liquid, such as machine oil, glycerin or water, shall be used as a couplant. 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. 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. Surface Preparation

4.3

4.4

4.5

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.

KH Petrotec

A4 (210297 m/m)

KH-USZ-UT-002

Process Specification

PAGE Rev.No

4 OF 11 0

(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 of curvature from 0.9-1.5 times the basic calibration block diameter. 5.0 5.1 CALIBRATION 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 screen height 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 settings and 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 on the 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) 80 % 80 % 40 % 20 % Indication limits (% of full screen) 32 to 48 % 16 to 24 % 64 to 96 % 64 to 96 %
A4 (210297 m/m)

dB control change - 6 dB - 12dB + 6 dB + 12dB KH Petrotec

KH-USZ-UT-002

Process Specification

PAGE Rev.No

5 OF 11 0

(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 screen indication 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.

KH Petrotec

A4 (210297 m/m)

KH-USZ-UT-002

Process Specification

PAGE Rev.No

6 OF 11 0

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 screen indication 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 6.1 EXAMINATION PROCEDURE 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. 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.

6.2

KH Petrotec

A4 (210297 m/m)

KH-USZ-UT-002

Process Specification

PAGE Rev.No

7 OF 11 0

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 base metal 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. ACCEPTANCE STANDARDS 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. Imperfections that are interpreted to be crack, lack of fusion, or incomplete penetration are unacceptance regardless of length. 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 two thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be included in T.

7.0 7.1

7.2

7.3

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.

KH Petrotec

A4 (210297 m/m)

KH-USZ-UT-002

Process Specification

PAGE Rev.No

8 OF 11 0

Fig. 1

Basic Calibration Block

Weld Thickness t(mm) 25.4 or less Over 25.4 through 50.8 Over 50.8 through 101.6 Over 101.6 through 152.4 Over 152.4 through 203.2 Over 203.2 through 254 Over 254

Basic Calibration Block Thickness T(mm) 19.05mm or t 38.1 or t 76.2 or t 127 or t 177.8 or t 228.6 or t t 25.4

Hole Diameter(mm) 2.38mm 3.175 4.76 6.35 7.93 9.5 Note (1)

Notch Size (mm) With = 3.175 to 6.35 Depth = 2% T or 1.016 whichever is greater into the base metal. 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)

KH Petrotec

A4 (210297 m/m)

KH-USZ-UT-002

Process Specification

PAGE Rev.No

9 OF 11 0

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

KH Petrotec

A4 (210297 m/m)

KH-USZ-UT-002

Process Specification

PAGE Rev.No

10 OF 11 0

FIG. 4 SENSITIVITY AND DISTANCE-AMPLITUDE CORRECTION

FIG. 5 SWEEP RANGE

FIG. 6 SENSITIVITY AND DISTANCE-AMPLITUDE CORRECTION

KH Petrotec

A4 (210297 m/m)

KH-USZ-UT-002

Process Specification

PAGE Rev.No

11 OF 11 0

ATTACH

KH Petrotec

A4 (210297 m/m)