PROCEDURE FOR ULTRASONIC

TEST OF PIPING
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Project Details

PROJECT MECHANICAL AND PIPING COMPOSITE WORKS AT

MANGALORE, HPCL PROJECT.
CLIENT HINDUSTAN PETROLEUM CORPORATION LIMITED

PMC WORLEY SERVICES INDIA PRIVATE LTD

CONTRACTOR NARMADA OFFSHORE CONSTRUCTIONS PVT. LTD.

Approved for
00 Prakash Jha Khirod Kumar Giri
Construction

REV DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

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Table of Contents

Sl nos. Descriptions Page nos.

1.0 PROJECT......................................................................................3

2.0 SCOPE…………………………………………………......................3

3.0 PURPOSE……………………………………………………………...3

4.0 REFERENCE………………………………………………................3

5.0 ABBREVIATION……………….…………......................................4

6.0 QUALIFICATION OF PERSONNEL AND PROCEDURE …........4

7.0 INSTRUMENT, PROBE AND CALIBRATION BLOCK................4

8.0 SURFACE PREPARATION ………………………………….......9

9.0 COUPLING AGENT……………………………………………….9

10.0 EXAMINATION……………………………….……………….…..9

11.0 IMPERFECTION EVALUATION & ACCEPT CRITERIA…...12

12.0 INSPECTION REPAIR AND RESULT……………………………..12

13.0 RECORD AND DOCUMENT………………………………..…......13

14.0 HSE……………………………………………………………….…...13

15.0 APPENDICES/FORMATS………………………………………..…13

1.0 PROJECT
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Mechanical and Piping composite works at Mangalore, HPCL Project.

2.0 SCOPE
This procedure provides technical information and describes steps necessary to ensure a
Complete and accurate manual pre-service ultrasonic examination of full penetration butt weld
Joints, tee joints, branch connection joints and adjacent base materials of equipment / pipe
welds. This procedure is applicable for ferrous materials,

3.0 PURPOSE
This procedure is used to defect internal discontinuities of objects. The discontinuities parallel to
the scanning surface are the must ones favorably aligned for detection.

4.0 REFERENCE
ASTM E 164 Standard Practices for Ultrasonic Contact Examination of Weldments

API 1104 Welding of Pipelines and Related Facilities

ASME Section V Non-Destructive Examination

ASNT RP SNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing.

ASTM E317 Standard Practice for Evaluating Performance Characteristics of Ultrasonic

Pulse-Echo Testing Instruments and Systems without the Use of Electronic
Measurement Instruments

ASTM E428 Standard Practice for Fabrication and Control of Steel Reference Blocks
Used in Ultrasonic Examination.

5.0 ABBREVIATION

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DAC Distance Amplitude Correction Curve

EL E Evaluation Line
FBH Flat Bottom Hole
FSH Full Screen Height
NDT Non-Destructive Testing
RL Reject Line
SL Size Line
UT Ultrasonic Testing

6.0 QUALIFICATION OF PERSONNEL AND PROCEDURE

All UT personnel shall hold certification issued by American Society for Nondestructive Testing
(ASNT). UT personnel validation test shall be carried out by Reliance to verify their capabilities to
perform to the requirements of the qualified procedure and then approved by HPCL. NDT UT
level II certified personnel in ultrasonic shall calibrate equipment, perform the test interpret the
test results and evaluate the result per the acceptance / rejection criteria. This procedure shall be
demonstrated on site production welds with actual discontinuities confirmed by RT.

7.0 INSTRUMENT, PROBE AND CALIBRATION BLOCK

7.1 Ultrasonic Instrument

7.1.1 Ultrasonic Equipment / Instrument Requirements

Shall be pulse echo type, able to generate, receive and display on the CRT screen, pulse at
frequencies between 1 and 6 MHz The useful part of the CRT screen shall be at least 70mm
wide and 50mm high.

Shall have variable amplifications, with steps of 1 or 2 dB over a range of at least 60 dB

The regulation control shall be accurate to within ±1 dB and this accuracy shall be certified by
instrument manufacturer. Calibration certificate shall be submitted to HPCL.

May be powered by a battery or an electronic generator.In the first case the instrument shall be
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equipped with automatic switch which switches it of where the battery runs down. In the second
case there must be a voltage stabilizing device with a tolerance of ± 2 volts.

The efficiency of the equipment / instrument used, the effective refraction angle of the probe and
the beam output point shall be checked using a calibration block as per ASTM E-428.

Calibration certificate of the instrument shall be submitted to HPCL for review.

7.1 Probe

• Working Frequency 1MHz to 6MHz,

• Front Distance 12mm, to be verified and marked
• Effective Element Area <_96mm,
• Probe Angle 45°, 60 °, 70°,appropriate size
• The horizontal deviation angle of the main beam is less than 2 degrees.
• The vertical direction of the main signal shall be clear peak.
• Probe angle shall be suitable for different weld geometric configuration, Minimum two no. of
angle probes and a straight probe to be used for scanning.
• The probe used shall have dimensions, frequencies and a refraction angle suited to the type
of steel, the diameter and the thickness of the pipe and to the point design. The efficiency of
the equipment used, the effective refraction angle of the probe and the beam output point
shall be checked using a calibration block as per ASTME-428.

7.2 Checking & Calibration of Equipment:-

The proper functioning of the examination equipment shall be checked and the equipment
shall be calibrated by use of the calibration standards at the beginning and end of each
examination, where examination personnel are changed, at any time malfunctioning is
suspected, as a minimum. If during the check it is determined that the testing equipment
carried out has been tested since the last valid equipment calibrated shall be re-examined

7.2.1 System Performance

a) Linearity verification: - Manual contact method using pulse echo type of ultrasonic instrument
with A-scan representation and with system calibration using DA tech with normal and angle

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beam probe employing compression & share wave working frequency at least 1 mHz to
6 mHz.

b) Screen height linearity:-

Screen height linearity shall be checked with straight beam probe. Couple a straight beam probe
to IIW VI block and get multiple echoes from 5 mm back wall select any two echoes whose
amplitude are in the ratio of 2:1 with larger echoes set at 80% of full screen height, without
moving the probe adjust the gain successively set the larger indication from 100% to 20% of full
screen height, In increments of 10% or 2dB steps if a fine gain control is not available and read
the smaller indication at each setting. The reading must be 50% of the larger amplitude, with is
5% of full screen height. The settings and readings must be estimated to the nearest 1% of
FSH. The Procedure for calibrating screen height linearity shall be performed at the beginning of
each period of extended use or every three months which ever in less.

c) Horizontal linearity:-

Horizontal linearity shall be checked with straight beam probe. Couple a straight beam probe
to IIW VI block and get multiple echoes from 25mm back wall. Select 1 st and 5th echoes
reflections shall be adjusted to their proper location with use of range and delay adjustment.
Each intermediate reflection location shall be corrected within 2% of the screen width.

d) Amplitude Control Linearity:-

Amplitude control linearity shall be checked with straight beam probe. Couple at angle beam
probe to IIW VI block and get multiple echoes from 100mm quadrant. Select any echo and
note its amplitude with decreases and increase of the gain by 6 dB and 12 dB and read the
amplitude of the same indication. They must be 50% of the initial amplitude wit in 10% of the
nominal amplitude ration perform this exercise for the full range of the gain. The settings and
readings must be estimated to the nearest 1% of full screen and the readings shall be as
shown in the following table. The Procedure for calibrating screen height linearity shall be
performed at the beginning of each period of extended use or every three months which ever
in less

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AMPLITUDE CONTROL LINEARITY

Indication Set at % of full Indication limits % of full screen

dB control change
screen height height
80% -6 dB 36 to 44
80% -12 dB 18 to 22
40% + 6 dB 72 to 88
20% + 12 dB 72 to 88

7.3 Calibration block

Select IIWV1 and IIWV2 shall be used for sweep range calibration with ASME SEC V.

See the following figure:

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Reference Block for manual Ultrasonic Testing

Search Unit: - Depending on the application following transducers shall be weld.

i) Single / Dual straight beam search unit.
ii) Angle beam search units ( 45°, 60°, 70° & 80°) having frequency : 1-6 mHz.
iii) Cable: Co-axial cable shall be used with Lemo/ mini Lemo or Lemo to Micro
dot co-machine.

a) IIW, V1, V2 blocks shall be used for screen distance range calibration, beam exit point & actual
angle of probe.

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b) Step wedge block shall be used for calibration of TR probe used for thickness measurement.

8.0 SURFACE PREPARATION

Weld that are being examined using ultrasonic shall be prepared to provide a sufficiently smooth
and regular area for scanning to be undertaken. The area shall extend at least the full skip
distance required, and shall be free of any irregularities such as spatter, grinding or chipping
mark scale etc., which may under the scanning pattern or cause confusion in the interpretation
of the resultant display in excessive noise.

9.0 COUPLING AGENT

The coupling agent should be well transparent and suitably fluidized. The agent used could not be
dangerous to either person or material (Non-corrosive). No residue should remain on the pipe
surface after the liquid has evaporated.
Glycerin, light machine oil or grease maybe used as a coupling agent.
When normal probe and coupling agent are used the test surface temperature shall not exceed
50 degree Centigrade.
Same couplant will be used in calibration and during the examination.
The couplant must be removed after examination by means of wiping with a cloth with the help
of solvent / detergent.

10.0 EXAMINATION

10.1 Lamination Check:

Before angle beam examination, a lamination check/scan shall be done using normal
probe to verify whether back echoes material. This scan shall cover as much as
practical of volume through which, later angle beam will pass. The area of loss of back
reflection shall be recorded.

10.2 Angle beam:-

For flows parallel to the weld, using 45° angle probe, scan from both sides of the welds
as far as possible In addition to 45° probe, other angle (60° & 70°) shall be used based
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on weld configuration . Examination shall be done by moving the probe back & fourth
perpendicular to the weld line in order to cover weld area & HAZ at least between ½
beam paths & 1 ½ beam path of the sound beam.

For flaws perpendicular to the weld, examination shall be conducted by moving the
search unit back & fourth parallel to weld on the surface or on the adjacent base metal
with little angulations with the sound beam directed in to the weld. Then line length of
the weld and adjacent base metal shall be scanned and the scan shall be repeated at
180° opposite direction. During scanning the gain shall be 200% of primary reference
level (in 6 dB + DAC gain).

Angle beam calibration: - The Calibration shall provide the following measurement
1) Distance range calibration
2) Distance amplitude
3) Echo amplitude measurement from the surface notch in the
basic calibration block.
10.3 DAC PREPARATION

DAC shall be prepared by using angle probe, taking in to consideration the probe index and the
weld edge distance. First point at 80% FSH ± 5% shall be established other two points shall be
drawn based on the reference block or notch.

DAC for longitudinal weld scanning shall be made from circumferential notch with 45° & 70°
angles probes to detect defect parallel to weld axis. From longitudinal notch, DAC is to be made
from 45° angle probe to detect transverse to weld axis.
Every NDT contractor shall established the DAC on the standards reference block/notch and get
it approved by authorized representative of HPCL before starting examination on the actual job.

Procedure Qualification: Procedure qualification test shall be performed to the satisfaction of the
HPCL before starting of the work. HPCL shall witness qualification test and PQR record shall be
maintained. Any changes in essential variables as per ASME Sec V must be required.

10.4 Calibration of the DAC curve

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Calibrate the scanning scale and the DAC curve on the Reference calibration block, No less than
three points, before inspecting.
The temperature difference between the probe/Reference calibration block and the weld shall be
within 14 Centigrade in calibration.
Re-calibration shall be done at every four hours as well as at the start and end of each shift and
when examination personnel are changed.
Scanning-line calibration: If back reflection amplitude deviates 10% from the calibrated point
scale or 5% of full scale (whichever is less), readjust scanning-line. For the imperfections that
have been recorded after the latest calibration, its location parameter shall be re-decided and
corrected.

Sensitivity Calibration:-
If the amplitude decreases 2dB or 20% than the DAC curve. Re-adjust sensitivity and re-
inspected all inspected welds from last calibration. If the amplitude increases 2dB or 20% than
the DAC curve, Re-adjust sensitivity. For the record imperfections after latest calibration, the size
and parameters of imperfections shall be re-measured and interpreted. The temperature
difference between the reference calibration block and the welds shall be 14°C. Recalibration
shall be verified at every 4 hours as weld at the start and end of each shift and when examination
personnel are changed.

10.5 Sensitivity adjustment

Manual ultrasonic weld testing shall be performed at a scanning sensitivity of DAC reference
sensitivity plus 6 dB minimum. All indications that exceed 50% of DAC screen height shall be
evaluated.
Evaluation sensitivity for manual ultrasonic weld testing should be DAC reference sensitivity plus
6 dB with an evaluation level for all indications at 50% of DAC screen height.
After the reference sensitivity, scanning sensitivity, and evaluation sensitivity and levels have
been established, they shall be qualified, and then incorporated into the final procedure and in
the final qualification report.

10.6 Scanning mode

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The probe is vertical to the weld centerline and does zigzag scanning. To detect the transverse
defect in the weld and the HAZ, do the lateral scan with oblique angle. Scanning speed shall be
confirmed according to the speed used in procedure qualification test. The adjacent probe
movement interval shall ensure 10% of the Imperfection Sizing: When the peak of the indication,
interpreted to be flaw shall be sized till the amplitude is down to EL. Any other indications shall be
sized by half-value method or tip half- value method.
Imperfection positioning: a. circumferential; b. length; c. Depth in the direction of diameter;
d. Position in the axis.
Mention separately normal beam scanning and angle beam scanning.

Fig-6.4-1 Scanning Area and Inspection Fig-6.4-2 Scanning Mode

Area

11.0 IMPERFECTION EVALUATION & ACCEPT CRITERIA

MUT results will be interpreted and evaluated by UT Level II or Level III personnel.
Evaluate all discontinuities indications (exclude crack). According to ASME - B31.4 / B31.3.

12.0 INSPECTION RESULT AND REPAIR

When doubt exits about the type of imperfection being disclosed by an indication, verification may
be obtained by other NDT methods.
The inspection of the repaired weld will follow the same procedure. Owner reserve the right to
request NOCPL to perform RT to verify or supplement UT result.
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13.0 RECORD AND DOCUMENTS

In UT Report the following information of the defect shall be recorded: Weld No., circumferential
position, length, depth to the O.D. surface and the type of defect (linear, planer or volumetric).
Evaluation & repair should be recorded. This shall be supported by print out of defect signals
wherever applicable. UT Report Record should be signed & verified by level II or III personnel and
transfer to the HPCL for approval.
Report & relative information should be kept properly till hand-over to the HPCL.

14.0 HEALTH SAFTEY & ENVIRONMENT:

The approved procedure for Health, Safety & Environment shall be followed during the
execution.
A safety restricted zone shall be defined and marked off with red and white paintings.

Only authorized personnel as defined /identified shall be allowed within the test area.
No stage of activity shall progress without the specific clearance of the Activity In-charge.
Proper lightning arrangement shall be done at site. All electrical circuits, wiring, circuit board
etc. shall be checked for electrical hazard.

Precautions: - When working on A/C current see that earthing is proper (otherwise probe may
give shock). Use of excess Oil/Couplant shall be avoided.

15.0 APPENDICES/FORMATS:

Inspection Test Plan for Piping Ultrasonic Test NOCPL /MPCW/HPCL/ITP-0

IR for Ultrasonic Test of Piping NOCPL /MPCW/HPCL/IR-0

Note: In case of any conflict between the requirements of this procedure and HPCL
Specification the later shall govern.

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