Sub Vendor Document Review Cover Sheet

PROJECT NAME: HPCL-RESIDUE UP-GRADATION FACILITY (RUF) FOR

VISAKH REFINERY MODERNIZATION PROJECT (VRMP)

OWNER: HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL)

VENDOR HEURTEY PETROCHEM INDIA PVT LTD

SUB-VENDOR NAME ONSHORE CONSTRUCTION CO.PVT LTD
HPIP CLIENT L&T HYDROCARBON ENGINEERING

PMC ENGINEERS INDIA LIMITED (EIL)

HPIP PROJECT CODE NI120004

Radiant Section Fabrication Heater No.

HEATER TAG No. 504-F-101, 504-F-102, 504-F-103,504-F-301,504-F-302,
504-F-401 & 504-F-701

FIRED HEATER PACKAGE - HEATER FABRICATED

DESCRIPTION
COMPONENTS (NON PRESSURE PARTS)

ULTRASONIC EXAMINATION PROCEDURE FOR

DOCUMENT TITLE STRUCTURAL STEEL WELD
OCCPL DOCUMENT NUMBER OCCPL/HPIP/L&T/UT/0002 Rev : 0
CLIENT DOCUMENT
NUMBER

Status Approval Code Code Description

NO COMMENTS. PROCEED WITH MANUFACTURE/FABRICATION AS PER THE
1 DOCUMENT.
2 PROCEED WITH MANUFACTURE/FABRICATION AS PER COMMENTED
DOCUMENT. REVISED DOCUMENT REQUIRED
3 DOCUMENT DOES NOT CONFORM TO BASIC REQUIREMENTS AS MARKED.
RESUBMIT FOR REVIEW
DOCUMENT IS RETAINED FOR RECORDS. PROCEED WITH
R
MANUFACTURE/FABRICATION
V VOID

REV DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

0 13.01.2021 FIRST ISSUE RM RK
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ULTRASONIC TESTING PROCEDURE OF STRUCTURAL

WELD

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CONTENTS

1. SCOPE

2. REFERENCE

3. PROCEDURE

4. EVALUATION OF INDICATION

5. ACCEPTANCE CRITERIA

6. POST CLEANING

7. RECORD

8. ATTACHMENT (Annexure I, II )

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1 SCOPE:

The purpose of this procedure is to provide the guide lines for the Ultrasonic Testing of
Non-Pressure Part weld using conventional manual pulse echo.

This procedure shall apply on applicable weld joints as per drawing requirement
& I nspection Test Plan

This procedure is applicable for The Structural Steel fabrication of the Heater Components
includes structural steel welds (As per LOI Scope ). RADIANT SECTION & CONVECTION
STRUCTURAL FABRICATION HEATER No.504-F-101, 504-F-102, 504-F-103, 504-F-301,
504-F-302, 504-F-401 & 504-F-701

2 REFERENCE:

 AWS D1.1/D1.1M Part C, D & F – 2020

 ASNT -SNT- TC-1A - 2006: Personnel Qualification and Certification in
Non- destructive Testing
 ASME SEC V -2019 Non Destructive Examination
 6-17-0002 Rev.6: Standard specification for steel work of fired heater and APH
 6-17-0001 Rev.5: Standard specification for Execution of fired heater and APH
 Approved Inspection Test Plan & Approved Drawings

3 PROCEDURE:

3.1 Equipment
ULTRASONIC FLAW DETECTOR (UFD)

The ultrasonic examination shall be conducted with a pulse echo ultrasonic instrument
capable of generating frequencies over the range of 1MHz to 6MHz & shall be
equipped with a stepped gain control in units of 2.0dB or less. ( Refer ASME SEC V
Clause T-431 ). The time base must be linear within approx. 1% of full screen width
over the maximum calibrated range used. The screen height amplitude control linearity
shall be verified. The ultrasonic flaw detector shall have valid calibration status.
Equipment shall be calibrated for vertical & horizontal linearity etc. on IIW V1 & V2
blocks as per ( Appendix –I & II ) ASME Sec-V Article 4.

SCREEN HEIGHT LINEARITY

Position an angle beam search unit on a calibration block, as shown in Fig. I. so

that indications from both the 1⁄2 and 3⁄4T holes give a 2:1 ratio of amplitudes

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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 block 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. I so that
the indication from the 1⁄2T 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
Indication Set at % of Full dB Control Change Indication limits
Screen Change
% of Full Screen
80% -6 dB 35 to 45%
80% -12 dB 15 to 25%
40% +6 dB 65 to 95%
20% +12 dB 65 to 95%

The settings and readings shall be estimated to the nearest 1% of full screen.

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3.2 The probe details are as follows

For straight beam inspection, TR (Transmitter & Receiver) probes

having 5 mm to 10 mm crystal diameter with frequency of 2 to 5 MHz shall be used.
Normal probe can also be used for straight beam inspection, for detection of any
reflector in the base metal

3.3 Couplant

The couplant shall be preferably be a manufactured gel produced for this purpose.
However this may be substituted by oil or oil & grease mixture or other suitable
medium that is not toxic or corrosive. The couplant must be removed after examination
by means of wiping with a cloth or with the help of solvent.

3.4 Surface Preparation

The base metal on either side of the weld shall be free from weld spatter, surface
irregularities, or foreign matter that might interfere with the weld examination. The
weld surface under examination shall be prepared to a smooth profile with a section flat
at the top of weld to enable good contact with probe to permit examination. In case of
spiral & longitudinal weld joints, the top surface of weld shall be flushed & both the
sides of the weld joint shall be ground to smooth surface (150 mm length) for the
examination.
When both sides scanning is not possible, then in that case , at least one side scanning
shall be carried out
Surface temperatures shall not exceed 50°C / subject to couplant and probe service
Condition
3.5 UT Operator

Personnel qualified and certified as Level II can perform, evaluate and report the results
of the examination. Personnel performing Ultrasonic testing shall be qualified and
certified NDE Personnel based on SNT- TC- 1A Edition 2006.

3.6 DAC Preparation

No Point on the DAC curve shall be less than 20% of full screen height (FSH ). When
any portion of the DAC curve will fall below 20% FSH a split DAC shall be used. The
First Calibration reflector on the second DAC shall start at 80% ± 5% FSH. When

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reflector single-to-noise ratio precludes effective indication evaluation &

characterization a split DAC should not be used

NDE agency shall establish the DAC on the standard reference block for his scope of
job before starting examination on the actual job.

3.7 Calibration block and method ( For Non-Piping Job )

Basic Calibration Block : The basic Calibration block configuration & reflectors as
shown in ( Attachment Figure T-434.2.1). The block size and reflectors locations shall
be adequate to perform calibration for beam angle(s) and distance range(s) to be used.

Alternate Calibration Block : Alternatively Calibration Block may be constructed as

per ASME Sec V Article 4 Non-Mandatory Appendix J Figure J-431.

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3.8 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 angle beam scanning is to
identify any reflector which may interfere during angle beam scanning.

3.9 Examination coverage

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.
Each Pass of the search unit shall overlap a minimum of 10% of the transducer
dimension parallel to the direction of scan indexing.

Scanning Sensitivity Level

a) Non-Distance Amplitude Techniques: The level of gain used for scanning
shall be appropriate for the configuration being examined and shall be capable of
detecting the calibration reflectors at the maximum scanning speed.
b) Surface Preparation: When the base material or weld surface interferes with the
examination, the base material or weld shall be prepared as needed to permit the
examination

When the Referencing Code Section requires the detection and evaluation of all
indications exceeding 20% DAC, the gain should be increased an additional amount so
that no calibration reflector indication is less than 40% FSH. As an alternate, the
scanning sensitivity level may be set at 6dB higher than the reference level gain
setting. (This additional gain makes the reference DAC curve a 20% DAC curve so
that indications exceeding 20% DAC may be easily identified and evaluated.).

4 EVALUATION OF INDICATION:

Each weld discontinuity shall be accepted or rejected on the basis of its indication
rating and its length, in conformance with AWS D1.1:2020 Table 8.2 for statically
loaded structures or AWS D1.1 Table 8.3 for cyclically loaded structures, whichever is
applicable.

Attenuation Factor: The “Attenuation Factor, “c,” on the test report shall be attained
by subtracting 1 in. [25 mm] from the sound-path distance and multiplying the
remainder by 2. This factor shall be rounded out to the nearest dB value. Fractional
values less than 1/2 dB shall be reduced to the lower dB level and those of 1/2 dB or
greater increased to the higher level.

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Discontinuity Size Evaluation:

Length
The length of indication shall be determined by measuring the distance between the
probe centerline locations where the indication rating amplitude drops 50% (6 dB)
below the rating for the applicable classification. This length shall be recorded
under "discontinuity length" on the test report.

Height
The discontinuity height (depth dimension) should be determined using the
following methods: (i) The indication height should be maximized by moving the
search unit to and from the discontinuity in accordance with A o. The indication
height should be adjusted to a known value (e.g.,60% of full screen height FSH).

(ii)The search unit should move towards the discontinuity until the indication height
begins to drop rapidly and continuously towards the base line. The location of the
leading (left) edge of the indication at location B in Figure S.l2 in relation to the
display horizontal base line scale should be noted. A 0.10 inch (2.5mm) division scale
or metric scale should be used

5 ACCEPTANCE CRITERIA:

5.1 Acceptance Criteria

Acceptance criteria for defect evaluation of structural steel welding shall be as per
AWS D1.1:2020. Clause 8.13.1, Table 8.2 & 8.3 and refer attached (Annexure 1)

5.2 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 POST CLEANING:

Couplant (grease/oil) applied to the job surface for UT examination shall be

cleaned after completion of the testing by cotton waste / cloth.

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7 RECORD:

Inspection record for inspected welds shall be maintained in attached approved format.

8 ATTACHMENT:

1) Annexure –I : UT acceptance criteria (Table – 8.2,8.3).

2) Annexure – II UT report Sample

Annexure -I

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Annexure II

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