ML20151W302
| ML20151W302 | |
| Person / Time | |
|---|---|
| Site: | Limerick  |
| Issue date: | 04/10/1987 |
| From: | Matthew Mitchell BECHTEL POWER CORP. |
| To: | |
| Shared Package | |
| ML20151W267 | List: |
| References | |
| UT-FERRITIC, NUDOCS 8808240033 | |
| Download: ML20151W302 (27) | |
Text
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BECHTEL CONSTRUCTION, INC.
(,,) MANUAL ULTRASONIC EXAMINATION PROCEDURE FOR FERRITIC STEEL PIPING WELDS UT-FERRITIC April 10, 1987 REVISION 10 Date -
MATERIALS AND QUALITY' SERVICES Prepared and Approved // Md/ / A//dh7 Authortzed for use by hDE Levellli Exa iner 'D4te Reviewed MM.Z!:h g u f
Approved ~ ##M<rw/n- e Manager of Construction ' D6te " ~~
Mahrger, M&QJ te V
(FOR LIMERICK ONLY)
TABLE OF CONTENTS 1.0 SCOPE APR 2 01987n s;)
2.0 REFERENCES
BECHTEL
,1 (g i 3.0 GENERAL REQUIREMENTS 4.0 CALIBRATId ,,+
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7.0 EVALUATION PTANCE CRITERIA 8.0 DOCUMENTATION AND RECORDS kgo Yet. 9 44. 0#
10 ;04710/87) Incorporate FCR No. LP-825 2.z. n ad /s. hat.nr +9sAr 9 l 01/09/87) Incorporate FCR Nos. LP-424 and ME-123
'8 ; 09/29786.' Incorporate FCR No._ LP-325 7 l 08/29/86; Incorporate Client Comments 5 l 05/15/86) Inccrporate Client Comments 04/24/86; 5 Incorporate Client Comments 4 . 04/15/86 Include fitting-to-fitting examination and incorporate project comments 3 3 ; 02/12/86' ,
Incorporate Client Comments
- 01/16/86' p 2 Incorporate Client Requirements g 1 .
11/20/85; General Revision 0 110/10/85) Initial Issue 1 NO.}DATE I REVISONS
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s Docu men t N7. UT-FERRITIC Rev.10 (Limarick Projset Only) Page 2 cf 27
, *0. SCOPE 1.1 This procedure specifies the minimum requirements for OD surf ace, manual
,r w contact ultrasonic examination of full penetration butt welds and adjacent base
(_,) metal in ferritic steel piping systems, 0.2 to 6.0 inches in nominal wall thickness.
1.2 Configuration types include pipe-to pipe, pipe-to- fi t t ing, fitting-to-fitting, pipe-to-safe end and longitudinal welds.
1.3 Alternate examination techniques may be used as provided by IRA-2240 of Reference 2.1.
2.0 REFERENCES
2.1 ASME Boiler and Pressure Vessel Code,Section XI, 1980 Fdition through Winter 1981 Addenda.
2.2 American Society for Nondestructive Testing, Recommended Practice SNT-TC-1A, 1980 Edition.
2.3 Bechtel Construction Procedure CP-W-4, Preservice Inspection of Nuclear Piping Systems.
3.0 CENERAL REQUIREMENTS -
3.1 Pe rsonne l 3.1.1 Bechtel NOE Personnel shall be certified and certification records
(,s)
maintained in accordance with Bechtel's NDE Certification Standards, NEPQ 1 and NEPQ 2.
3.1.2 Subcontractor NDE Personnel shall be certified in accordance with their NDE Personnel Certification Procedure, which shall meet the requirements of the American Society of Nondestructive Testing's Recommended Practice No. SNT-TC-1A, 1980 Edition as well as ASME Boiler and Pressure Vessel Code,Section XI,1980 Edition through Winter 1981 Addenda.
3.1.3 Complete certification records for the NDE Subcontractor's NDE personnel plus the Level III that certified the individual, shall be aubmitted to the designated Bechtel individual prior to performing final Acceptance examination.
Complete certification records for each individual shall be maintained on file at the jobsite.
3.2 Equipmen t 3.2.1 A pulse-echo ultrasonic instrument with an A-scan presentation shall be used. The inst rument shall be equipped with a stepped gain control calibrated in units of 2 dB or less. The instrument shall be capable of generating and receiving frequencies of.1.00 to 5.00 MHz. Manufacture r's recommended mE maintenance checks of ultrasonic instruments shall be performed annually.
8k p 3.2.2 Search units may contain either single or dual transducer elements.
gg 3.2.2.1 Transducers shall have a nominal frequency range of 1.0 to 5.00 Mht.
l Document N,, UT-FERRITIC Rev.10 (Limirick Projcet only) prge 3 of 27
, 3.2.2.2 C;ntr:11y, ccximua nominal transducer dimensions for circular, square, or rectangular active elements shall conform to the following:
m Nominal Material
,)
- Th ickne s s Transducer Size
- 1/4" or less 1/4" x 1/4" or 1/4" Round 1/4" to 1/2" 1/4" x 1/4" or 1/4" Round to 1/2" x 1/2" or 1/2" Round 1/2" and above 1/2" x 1/2" or 1/2" Round to 1" Round
- For dual element transducers, the dimension applies to one of the two elements.
NOTE: Other transducers may be used provided a code calibration is d'cumented.
3.2.3 Search unit cables shall be of the coaxial type.
- 3.2.4 angle. Wedges shall be used to produce shear waves at a nominal 45-degree Other angles may be used for evaluation of an indication, or where wall thickness or geometric ccnfiguration impedes effective use of a 45 degree angle beam for examination. Additional wedges which produce refracted longitudinal
[s'~)
waves at a nominal 45-degree angle may be utilized for examination of fitting side velds.
3.2.4.1 Variables such as weld preparation, weld crown width, or physical i interference may preclude obtaining two directional coverage of the examination volume with 1/2 V-path examination from both sides of weld. If this interference occurs, the beam path shall be increased to obtain two direction coverage of the examination volume. Alternatively, the interference may be eliminated by one or more of the following:
1) reducing the dimension of the wedge edge-to-beam entry point
- 2) reducing search unit size
- 3) increasing the beam angle
- 4) conditioning the veld surface.
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Document N% tJT-FERRITIC Rev.10 (Limerlek Project only) PTRe 4 Ff 27
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I h n # &g FIGURE 1 3.2.4.2 shall reeetWhen examination is limited to 1/2 V path, dimension A in Figure 1 the following criteria:
- 1) 0.93t for 0 = 45'
- 2) 1.6t for 0 = 60'
- 3) 2.5t for 0 = 70' .
3.2.4.3 Calibration shall be done with the contact wedges used during the examination.
3.2.5 Couplants O) 3.2.5.1 Any commercially available couplant may be used to couple the transducer to the part during calibration and examination. 1he same couplant shall be used during both processes.
3.2.5.2 Couplants shall be certified for total sulfur and halogen content in accordance with ASTM D-129-64 and 1,-808-63, respectively. The total residual halogens and sulfur shall not exceed 1 percent by weight, respectively.
3.2.6 Basic Calibration Block 3.2.6.1 Calibration blocks shall be made from material of the same nominal diameter and nominal vall thickness or pipe schedule as the component to be examined.
3.2.5.2 Material Specification 1)
The calibration blocks shall be fabricated from one of the materials specified for the components being joined by the veld.
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, 2) Where the examination is to be performed from only one side of the joint, the calibration block material shall be the same
$D specification as the material on that side of the joint.
P 89 e.
Docueent the UT-FERRITIC Rev.10 (Limarick Projems unty) Page 5 et 27
- 3) If catorial cf the scme specification is not available, material of similar chemical analysis, tensile properties, and
_ metallurgical structure may be used as approved by PECo.
()_ 3.2.6.3 The finish on the block surfaces shall be representative of the surf ace finish of the component to be examined.
- 3. 2 . 6. 4 The calibration blocks shall contain circumferential1y and longitudinally oriented notches no greater than 1/4-inch wide and 1- to 2-inches long on the ID and OD surfaces. The sides of the notches shall be perpendicular to the ent ry surf ace (Figure 2).
3.2.6.5 Surf ace notch depths shall conform to Table 1 below:
TABLE 1 Nominal Pipe Wall Thickness (t) Notch Depth (D)* Tolerance Carbon Steel - less than 0.312 inch 0.10 t + 0.00 ne
+ 10 percent Carbon Steel - 0.312 to 6.0 inches 0.104 t - 0.009 t2 - 20 percent
- Notch depth in base material (excluding cladding) 3.2.6.6 The calibration blocks shall contain holes to be used during straight beam and one-half V-path angle beam calibrations. The holes shall be drilled
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t parallel to the length axis in the end surface of the pipe calibration block.
Tor nominal thickness greater than 0.5 inch, a minimum of two holes, each of the same diameter (Table 2), located at 1/4t and 3/4t, shall be used. For nominal thickness equal to or less than 0.5 inch, a minimum of one hole, located at 1/2t shall be used.
3.2.6.7 Hole diameters shall conform to the Table 2 below:
TABLE 2 Basic Calibration Hole Weld Thickness (t) Block Thickness (T) Diameter 1 in. or less 3/4 in. or t 3/32 in.
Over 1 in. through 2 in. 1-1/2 in. or t 1/8 in.
Over 2 in. through 4 in. 3 in, or t 3/16 in.
Over 4 in. through 6 in. 5 in. or t 1/4 in.
NOTES :
c3 (1) Holes shall be drilled and reamed a minimum of 1-1/2 inches j 5, "
deep, essentially parallel to the examination surface and
, perpendicular to the examination beam direction while
{} . meeting the requirements of paragraph 3.2.6.6.
- 9 t
Docusent tio. UT-FERRITIC Rey,10 (!.imarick Projset Only) Page 6 ef 27
' (2) Tha tolcrancs for holo diamstor shall be o 1/32 inch. The tolerance on hole location through the thickness shall be
+ 1/8 inch.
l 3.2.6.8 calibration reflectors shall be positioned in the block in such a manner that, when the search unit is maximited on the reflector, the centerline of the search unit is greater than 3/4 inch from the adjacent side of the block.
3.2.6.9 Additional reflectors may be installed provided they do not interfere with establishing the primary reference level.
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mE EN FIGURE 2. Recornended Pipe Basic Calibration Block NOTE: Alternate block design and layout may be used,
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Document No. UT-FERRITIC Rev.10 (Lim: rick Proj0ct Only) pag, 8 ct 27 3 . 2 . _7 Reference blocks such as an IIW or a Rompas may be used fort
- 1) search unit beam exit point location (n) 2) angle verification
- 3) sweep range calibration
- 4) system calibration checks provided the block is fabricated from acoustically similar material.
4.0 CALIBRATION 4.1 Inst rument Calibration 4.1.1 Instrument calibration for screen height and amplitude control linearities shall be verified prior to the start of each day's examinattuns.
4.1.2 Screen Height Linearity 4.1.2.1 The ultrasonic instrument shall provide screen height linearity within 5 percent of full range for at least 80 percent of the full screen height (FSH)
(baseline to maximum calibrated screen points).
4.1.2.2 To verify the capability of the ultrasonic instrument to meet the linearity requirements, position a search unit as shown in Figure 3 so that -
echoes can be observed from any two reflectors in a calibration block.
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gg, o FIGURE 3. Linearity 4.1.2.3 Adjust the search unit position to give a 2:1 ratio of amplitudes between the two echoes, with the larger set at 80 percent of full screen height.
Without moving the search unit, adjust only the calibrated gain control to successively set the larger echo froin 100 percent to 20 percent of TSH, in 10 percent increments (or 2 dB steps if a fine control is not available), and read the amplitude of the smaller echo at each setting. The reading shall be mE 50 percent of the larger amplitude, within 5 percent of FSH. The settings and p readings shall be estimated to the nearest 1 percent of full screen.
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Document !!o, UT-FERRITIC Rav,10 (Limerick Probet Only) Page 9 cf 27 4.1.3 Amplitude Cont rol Linearity
-3 4.1.3.1
') The ultrasonic instrument shall utilize an amplitude control, accurate over its useful range to + 20 percent of the nominal amplitude ratio, to allow rnessurement screen. of indications beyond the linear range of the vertical display on the 4.1.3.2 To verify the accuracy of the amplitude control in the ultrasonic instrument, as required in paragraph 4.1.3.1, position a search unit so that an echo from one reflector in a calibration block is peaked on the screen, k'ith the '
increases fall within and the decreases specified limits. in gain (dB) shown in Table 3, the echo amplitude shall l
TABLE 3 SPECIFIED LIMITS FOR ECHO AMPLITUDE Indication Set Indication Limits, at Percent dB Control Percent of of Full Screen Change (1) Full Screen 80 percent - 6 dB 32 to 48 percent 80 percent - 12 dB 16 to 24 percent 40 percent + 6 dB 64 to 96 percent 20 percent + 12 dB 64 to 96 percent
- l NOTE:
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(1) Minus denotes decrease in amplitude; plus denotes increase.
Convenient reflectors from any calibration block may be used with angle or straight beam search units.
The settings and readings shall be estimated to the 1
nearest 1 percent of full screen.
4.1.4 Screen height and amplitude control linearity verification shall be documented in the appropriate blocks on the Ultrasonic Calibration Report, MQ S-013.
4.1.5 Instruments that do not meet the requirements of paragraphs 4.1.2 or 4.1.3 shall not be used.
l 4.2 Search Unit Calibration I
_4.2.1 Prior to performing system calibration (4.3), the search unit beam exit point shall be determined and marked on the wedge. In addition, the beam angle shall be determined and documented in the "measured angle" block on the Ultrasonic Calibration Report, HQS-013. This shall be verified using one of the
, reference blocks described in paragraph 3.2.7.
E Ie 9
Document No. UT-FERRITIC Rev.10 (Limerick Proicet only) Page 10 cf 27 4.3 System Calibration 4.3.1 Ceneral Requirements 4.3.1.1 A complete ultrasonic examination system calibration establishing the DAC curve shall be performed and the data documented appropriately on the Ult rasonic Calibration Report , MQS-013 each day prior to the examination.
b 3.1. 2 Calibration shall include the complete ultrasonic examination system.
Any change in search units, shoes, couplants, cables, ultrasonic instruments, recording devices, or any other parts of the examination system shall be cause for a calibration check. The initial and final calibration shall be performed on the basic calibration block. Intermediate calibration checks may be performed in the same manner as the initial calibration or as an alternate as described in paragraph 4. 7.
4.3.1.3 The maximum calibration indications shall be obtained with the sound beam oriented essentially perpendicular o the axis of the calibration reflector.
The centerline of the search unit shall be at least 3/4 inch from the nearest side of the block. (Rotation of the beam into a corner formed by the reflector and the side of the block may produce a higher amplitude signal at a longer beam path; this beam path shall not be used for calibration.)
4.3.1.4 Calibration shall be performed from the surface (clad or unclad) of the calibration block that corresponds to the component surface te be examined.
- 4.3.1.5 The temperature of the calibration block surface shall be within 25'T of the temperature of the examination surfaces. These temperatures and r.he
('] serial number of the temperature measuring device shall be documented in the v appropriate blocks on the Ultrasonic Calibration Report, MQS-013.
4.3.2 System Calibration Check 4.3.2.1 A system calibration check, which is the verification of the instrument sensitivity and sweep range calibration, shall be performed and documented on the Ultrasonic Calibration Report, HQS-013.
- 1) at the start and finish of each examination,
- 2) with any change in the examination equipment (instruments, recording instruments, search units, shoes, couplants, or cables),
- 3) with any change in examination personnel,
- 4) at least every twelve hours during system use,
- 5) at any time when, in the opinion of the operator, there is doubt as to the validity of the calibration.
4.3.2.2 If any point on the DAC curve has decreased more than 20 percent or 2 dB of its amplitude, all data sheets since the last calibration check shall be marked void. A new calibration shall be made and recorded, and the voided examination areas shall be reexamined, o
mR 4.3.2.3 ,
any point on the DAC curve has increased more than 20 percent or k'i 2 dB of its amplitude, recorded indications taken since the last valid
- g. calibration or calibration check may be reexamined with the correct calibration and their values changed on the data sheets, e9 u
Document lh. UT-FERRITIC x y,10 (1.imarick Projset only) p.g, 11 rf 27 4.3.2.4 If any point on the DAC curve has moved on the sweep line more than 10 percent of the sweep division reading, correct the sweep range calibration es and note the correction in the examination record. If recordable reflectors are
(
'" ) noted on the data sheets, those data sheets shall be voided, a new calibration shall be recorded, and the examination areas shall be reexamined.
4_. 3. 2 . 5 Pulse shape (dampening), noise suppression (reject), and filter controla shall be at the same position during examination, calibration (verification), and system linearity checks. Adjusting or changing these controls while the instrument is calibrated for an examination is prohibited.
The mininsum or "off" position is the recommended position for these controls.
4.4 St raight Beam Calibration 4.4.1 The sweep shall be calibrated to obtain a linear display throughout the entire examination range utilizing a reference block.
4.4.2 Sensitivity Calibration for Weld and Code-Required Volume 4.4.2.1 For calibration blocks which contain 1/4t and 3/4t side drilled holes:
- 1) Position the search unit to display the response from the 3/4t hole. Adjust the gain to provide an 80 percent of full screen height signal. His is the primary reference level.
response on the screen.
Mark this .
- 2) Draw a straight horizontal line on the screen through the p thickness of the part. his is the DAC line.
U 3) Without changing the gain, note the sweep position and amplitude of the 1/4t hole response if possible.
4.4.2.2 For calibration blocks which contain only a 1/2t hole:
- 1) Position the search unit to obtain the maximum response from the 1/2t hole. Adjust the gain to provide an 30 percent of full scresn height signal, nis is the primary reference level. Mark the response on the screen.
- 2) Draw a straight horizontal line on the screen through the thickness of the part. B is is the DAC line.
4.4.3 0-Degree Calibration for Base Metal Examination Brough Which Angle Beams Shall Pass 4.4.3.1 Position the search unit on the component being examined in the area of base metal through which the angle beam will pass. Adjust the gain until the back reflection is at 80 percent FSH; this is the reference sensitivity for base metal examination. Record this gain on the calibration data sheet.
m Po 4.5 Angle Beam Calibration 84 n' 4.5.1 When the weld crown is not ground flush, angle beam search units, as E practical, shall meet the requirements of paragraph 3.2.4.1 to ensure full g coverage of the veld root area.
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Document No. UT-FERRITIC Ray.10 (Lim rick Project Only) page 12 cf 27 4.5.2 Angle beam coalibration of the ultrasonic system sweep shall be
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performed 3.2.7). %e using the basic calibration block or reference block (paragraph ij sweep shall, as a minimum, incorporate the entire examination volume, and may be established as follows:
- 4. 5. 2.1 Place the angle beam transducer on the block so that the ultrasonic beam is airned at the applicable reflector (s) . Use the specified metal path distances in the applicable reference block (paragraph 3.2.7) or calculate and use the metal path distance for each reflector in the basic calibration block.
- 4. 5.2.2 Maximize the return signals and adjust the sweep and range controls to position them on the sweep at convenient increments to include the required examination volume.
- 4. 5. 2. 3 manner.
A one-half V-path calibration shall be performed in the following We shape of the DAC curve shall be generated using the axial 1/4-t and 3/4-t side dcilled holes in a basic calibration block. When the calibration block only contains a 1/2t hole, che shape of the DAC curve shall be generated using the reflections from the hole at the 1/4 V path and 3/4 V path positions.
In either case, the maximum hole response is set to 80 percent of the calibrated screen height. B is response shall be obtained with the transducer aligned so that the beam is perpendicular to the SDH's (to prevent possible erroneous corner responses) and at least 3/4 inch from the adjacent side of the block, ne DAC shall be clearly marked on the CRT screen and smoothly extrapolated to cover the full examination range.
The 5/4 t hole response may be used as an aid for extrapolation. Sensitivity is obtained by using the gain control to adjust the peaked one-half V-notch response to the DAC curve. The DAC and notch n response shall also be recorded on the Calibration Report form. he DAC curve
(~) corrected for the notch sensitivity is the primary reference level (lX) for all velds except fitting side welds (paragraph 4.7).
- 4. 5. 2.4 For metal paths greater than one-half V-path, calibration shall be performed using either the circumferential or axial ID and OD notches. De shape of the DAC curve shall be generated by placing the angle beam transducer on the OD surface of the basic calibration block and obtaining a response from the ID notch at the one-half V-path position. Manipulate the transducer until the response is maximized on the CRT screen. Adjust the gain control to bring this signal to 80 percent FSH. Mark its amplitude and sweep position on the CRT screen. Without changing the gain, move the transducer away from the notch until a signal is obtained from the same notch at the one-and-one-half V path position. Manipulate the transducer to maximize this signal and mark its sweep and anplitude position on the CRT screen. Obtain the reflected signal from the OD notch at the full V path position. Manipulate the transducer to maximize this signal and mark its sweep and amplitude position on the CRT screen. Draw a smooth line through the three points. nis is the primary reference level (1X) for all welds except fitting side welds (paragraph 4.7).
4.6 Should any point on the DAC fall below 20% FSH, that response shall be increased to 20% FSH and the previous signal response shall be remeasured and recorded. his is the reference sensitivity for a secondary DAC.
mE he shape and 8k elope of both DACs shall be recorded on the Ultrasonic Calibration Report.
g' 4.7 For fitting side welds, the primary reference level shall be the x distance aeplitude curve (DAC) initially obtained directly from the calibration g block as described in paragraph 4.5.2.3 or 4.5.2.4, plus any sensitivity sE
Document No. UT-FERRITIC Rev.10 (I.imorick ProJ:c t only) Prge_13 cf 27 ccrrecti n which cay he r: quired as a result of the acoustic compatibility correction techniques described in paragraphs 4.7.1 through 4.7.3.3 below.
- 4. 7.1 E_) Acoustic compatibility correction for angle beam examinations shall be axial directionusing accomplished theapplicable).
(where thru-transmission technique and shall be performed in the sides of the circumferential piping weld.This technique shall be performed on both
- 4. 7.2 If the two sides of the circumferential weld require different amounts of gain for acoustic compatibility correction, the amount of gain required for each side of the weld shall be added to that side during examinations.
4.7.3 The method for determining the acoustical compatibility correction is dependent on the type of examination and calibration performed. The following methods shall be employed as appropriate.
- 4. 7. 3.1 Acoustic compatibility for 1/2 V-path calibration and exemination:
1)
Adjust the screen for a minimum of one full V path presentation.
2)
Position the search units on the OD surface of the calibration block and through themaximize material. the received signs 1 after one full V path
- 3) Adjust the sensitivity controls to produce a signal amplitude of 80 percent FSH.
- 4) Record this sensitivity on the data sheet.
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$) Using the same equipment, position the search units on the OD surface of the examination component.
- 6) Using the sensitivity recorded in step 4 above, maximize the received signal af ter one full-V through the material thickness.
- 7) If the amplitude of the received signal is different from 80 percent FSM, change the sensitivity to bring the signal amplitude to 80 percent FSH.
- 8) Record this change in dB on the data sheet.
9)
If the sensitivity increase or decrease recorded in step (8) is more than 4dB, the Lead PSI Technician shall be notified prior to completion of the examination. Final disposition for completion of the examination will be by a Bechtel Level III.
- 4. 7.3. 2 Acoustic compatibility for one V path calibration and examination:
1)
Adjust the screen for a minimum of two full V paths presentation.
mE 2) 8Os Position the search units on the OD surface of the calibration block and maximize the received signal af ter two full V paths n' through the material.
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Docuee n t Mo, UT-FERRITIC Rev.10 (Lim 2 rick Proj:et only) Page 14 cf 27 3)
Adjust the sensitivity controls to produce a signal amplitude of 80 percent FSH.
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- 4) Record this sensitivity on the data sheet.
- 5) Using the same equipment, position the search units on the CD surface of the examination component.
- 6) Using the sensitivity recorded in step (4) above, maximize the received signal af ter two full V paths through the material thickness.
- 7) If the amplitude of the received signal is different than 80 percent FSH, change the sensitivity to bring the signal amplitude to 80 percent FSH.
- 8) Record this change in dB on the data sheet.
- 9) If the sensitivity increase or decrease recorded in step (8) is more than 4dB, the Lead PSI Technician shall be notified prior to completion of the examination. Final disposition for completion of the examination will be by a Bechtel Level III.
4.7.3.3 Acoustic compatibility for 1-1/2 V-path calibration and examination:
- 1) Adjust the screen for a minimum of two full V paths presentation.
r3 2) Positiun the search unit on the OD surf ace of the calibration ti block and maximize the received signal after one full V path through the material thickness.
- 3) Adjust the sensitivity controls to produce a signal amplitude of 80 percent FSH.
- 4) Record this sensitivity on the data sheet.
- 5) Maximize the signal after two full V paths through the calibration block thickness.
- 6) Record the amplitude of the received signal on the data sheet.
- 7) Using the same equipment used above, position the search units or the OD surf ace of the examination component.
- 8) Using the sensitivity from step (4) above, maximite the received signal after one full V-path through the material thickness.
- 9) If the amplitude of the received signal is different than 80 percent FSH, change the sensitivity to bring the signal amplitude to 80 percent FSH.
mE 84 10) Record this change in dB on the data sheet.
f-e9 .
Document Ho, UT-FERR1 TIC Rev310 (Limrick project only) Page 15 of 27
- 11) Without changing the sensitivity and where accessibility on the y
component allows, maximize the received signal af ter two full V paths through the component thickness.
1
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12)
If this signal is different than that recorded in step (6) above, change the sensitivity to bring the component amplitude response level to the amplitude response level of the calibration block.
- 13) Record this change in dB on the data sheet.
- 14) If the sensitivity changes in steps (10) and (13) above total more than 6dB, the Lead PSI Technician shall be notified prior to completion of the examination. Final disposition for completion l l
of the examination will be by a Bechtel Level III.
4.8 Initial and intermediate calibration checks may be performed using one ;
of the reference blocks described in paragraph 3.2.7 provided the following is '
documented in the appropriate blocas on the Ultrasonic Calibration Report.
HQS-013:
- 1) Reference block type / serial number, e.g., Rompas S/N #953608.
- 2) Reference reflector used.
- 3) Cain setting establishing the signal peak amplitude if different from primary response.
- 4) Horizontal sweep position of lef t side of signal base.
4.9 As a minimum, the following data shall be recorded on a calibration data sheet (Form HQS-013):
1) calibration sheet identification and date of calibration;
- 2) names of examination personnel;
- 3) examination procedure number and revision;
- 4) basic calibration and reference block identification;
- 5) ultrasonic instrument identification and serial number;
- 6) beam angle, couplant, and mode of wave propagation in the material;
- 7) orientation of search unit with respect to the pipe (longitudinal or circumferential);
- 8) search unit identification -- frequency, sire, and manufacturer's serial number; mE 9) special search units, wedges, shoe type, or saddle's 8h identification, if used; k* 10) search unit cable type and length; E
2a
Document lio. UT-FERRITIC Rev.10 (Linerick Projset ontv) Page_16 of 27
- 11) times of initial calibration and subsequent calibration checks;
- 12) amplitudes and sweep readings obtained from the calibration
) reflectors.
- 13) temperature measuring device serial number and temperatures of the calibration block (s) and part examined.
NOTE:
If an elect ronic DAC curve is being used, a second record shall be made of the resultant amplitudes and sweep readings obtained from the calibration reflectors.
5.0 EXAMINATION 5.1 Surf ace Conditions 5.1.1 The examination surf ace shall be free of irregularities, loose material, or coatings that interfere with ultrasonic wave transmission.
5.2 Scanning Sensitivity 5.2.1 Straight Beam / Angle Beam - Scanning sensitivity shall be at least 5 dB above the primary reference level. In some cases, this sensitivity may not f.e adequate; then the gain setting shall be adjusted to obtain a 10 percent FSH ID .
noise level and in no case shall the average noise level exceed 30 percent FSH.
5.3 Scanning Speed f")
U 5.3.1 Scanning speed shall not exceed 6 inches per second.
5.4 Cove rage 5.4.1 Scan the examination volume with the sound beam overlapping each scan by at least 10% of the transducer dimension measured perpendicular to the scan path.
5.4.2 Examination volume: The inner 1/3t of the weld and adjacent base metal volume for 1/4 inch on each side of the weld crown, as shown in Figure 4.
5.4.2.1 For Class 1 welds, the examination volumes shown in Figure 4 shall, to the extent practicable, be extended to include the full through-wall thickness.
5.5 Scanning for Reflectors - in the Weld and Code-Required Volume / Base Metal - Straight Beam 5.5.1 To the extent possible, scanning of the veld and adjacent base metal shall be performed to detect reflectors that might affect interpretation of angle beam results. This scan is not to be used as an acceptance-rejection examination when performed per paragraph 4.4.3. For the weld and Code-required volume each indication that exceeds 50 percent of reference, and for base metal examination, mE each indication that exceeds the remaining back reflection, the peak location and 8A extremities to the 50 percent maximum amplitude level shall be documented as n' , "possible interfering conditions" on the Ultrasonic Examination Data Report, E HQS-014 2
2a
D cument No. UT-FERRITIC Rev.10 (Limerick Project Only) Pago 17 cf 27 5.5.2 In addition to the requirements in paragraph 5.5.1, the material .
thickness shall be monitored. The thickness and location of the lowest wall l thickness shall be documented on the Ultrasonic Examination Data Report, MQS-014 (q / 5. 6 Scanning for Reflectors - Angle Beam
- 5. 6.1 beam perperd
- n. angle beam examination for reflectors parallel to the weld (angle to weld) shall be performed by a full V-pa d from one side or a ona -ha1
- from two sides of the weld, where practicable. ne examination volume s nned in two beam path directions. A suffier ently long examinati .h may be used to provide this coverage, i.e. , one-half P pat h and full \ m a only one side of the weld.
- 5. 6. 2, ,
s e beam examination for reflectors transverse to the weld (angle beam parallel to weld) shall be performed on the weld c rown on a single scan path to examine the weld root by one-half V path in two directions along the weld.
- 5. 6. 3 The search unit shall be continuously oscillated approximately 20 degrees to the lef t and right to aid in detecting reflectors oriented in a direction not normally expected. If oscillation is not possible, the sound beam nall be overlapped (paragraph 5.4.1) at least 50 percent.
- 5. 6. 4 _
For examination of branch connections, the most sensitive reference level (either the response from the circumferential or axial notch) may be used to scan the entire weld. However, if any recordable indications are observed, -
then the appropriate reference level must be used for recording purposes, as shown in Figure 5.
I 5.7 Any obstruction or other condition preventing full coverage of the
' E mination volume shall be documented on the Ultrasonic Examination Data Report, MQS-014 and an Incomplete Examination Report (IER).
6.0 EXAMINATION RECORDING REQUIREMENTS
{
6.1 Indication Recording 6.1.1 All indications 50 percent of DAC or greater at reference sensitivity shall be recorded at the referenced sensitivity level.
6.1.2 Any indication suspected to be a crack, lack of fusion or incomplete penetration shall be recorded regardless of amplitude.
6.1.3 All indications recorded per the requirements of 6.1.1 and 6.1.2 shall be investigated to the extent necessary to determine the shape, identity, and location of the reflector.
6.2 Examination Documentation 6.2.1 The following data shall be recorded on the Ultrasonic Examination Data Report (Form HQS-014):
SA 1) Data sheet identification, date and time period of examination.
.J 2) Npes and certified levels of examination personnel.
!G e
1
D2cument th. UT-FERRITIC Rev. 10 (Liuerick Projset Only)Page 18 of 27
- 3) Examination procedure (s) and revision (s).
- 4) Applicable calibration report number.
]m')
- 5) Identification of weld examined.
- 6) Surface from which examination was conducted.
- 7) Record of indications (or of volume free of indicat.*ons).
6.2.2 For each weld which is free of any recordable indications, the data report shall state "No Recordable Indications".
6_.2.3 For each indication that equals or exceeds 50 percent of DAC, the following shall be recorded:
6.2.3.1 Peak amplitude dB setting when adjusted to the DAC (Ind, dB at DAC),
sweep reading (MP - metal path), search unit position (S.U. POS), search unit location (S.U. LOC), and sound beam direction, i.e., axial upe,tream or downstream (US or DS). (Abbreviations correspond with Form MQS-014 block headings.)
6.2.3.2 Search unit positions and locations perpendicular to the reficctor at the location of the peak amplitude and locations parallel to the reflector at the points where the reflector amplitude equals: .
(7 2) d 50 percent of IAC and 100 percent of DAC for reflectors that equal or exceed 100 pa.rcent of DAC.
6.2.3.3 For indications that are recorded to the requirements of 6.2.3 that can be determined to be related and intermittent, the requirements of 6.2.3.1 need only be recorded for the peak amplitude of the related family of indications.
6.2.4 For indications suspected to be cracks, lack of fusion or incomplete penetration, the applicable requirements of paragraphs 6.2.3.1 and 6.2.3.2 shall be met except search unit positions and locations shall also be recorded at the points where the reflector amplitude equals 50 percent of the maximum amplitude.
6.2.5 For indications that are recorded to the requirements of paragraph 6.2.3.1 and additional information is generated during evaluation (paragraph 7.0) that information shall be recorded or referenced on Form MQS-014.
6.3 Reference System A 6.3.1 The search unit location and position will be measured and recorded in accordance with Figure 5.
A 6.3.2 The recording shall be the distance to the beam exit point of the mE search unit from (whichever is appropriate):
EN
- 1) The point of the datum Vee in the direction it is pointing et oC
- u. a
3 Dscument Nm. UT-FERRITIC Re v. 10 (Literick Projtet only) pag, 19 ef
- 27
- 2) The weld centerline
,- , 3) The intersection of the corresponding circetferential weld 6.3.3 All position and location recordings shall be to the nearest 0.050 of an inch.
6.4 Weld Volume Profile 6.4.1 A weld volume profile shall be established for all indications recorded per the requirements of paragraphs 5.5.1, 6.1.1 ar.d/or 6.1.2. Intermittent related indications determined to be of the same origin (i.e. geometrical) need only have a single weld volume profile at the location of the peak amplitude of the composite indication.
6.4.1.1 At the position of maximum amplitude along each indication, the general OD contour of the weld and component surface shall be profiled by applying a pin gage to the weld and/or component surface. The pin sage contour measurement shall be continuous along the area to be profiled. An OD profile shall cover the weld and a sufficient distance of base metal to cover 1 inch beyond the search unit position, where possible. Outside diameter profiles shall be conducted by placing the pin gage on the OD surface of the weld and adjacent component material and applying pressure to obtain a contour. One tooth of the pin gage may be raised when profiling. This raised tooth (over the weld centerline) may ,
be used as a reference to assure overlapping and continuity in the OD profile.
After forming the contour and establishing the elevated gage tooth reference, this section of the OD contour shall be traced off the pin gage contour and the process repeated until the area of interest is completely profiled.
[N- 6.4.1.2 An ultrasonic A-scan instrument shall be used to conduct thickness measurements in the same location and direction as the OD profiles. These thickness measurements shall be recorded in approximately 0.2-inch increments with respect to the OD surface. Locations of thickness changes shall be identified in relation to a specific datum point. Alternate reference points may be used as required. Inside diameter profiles are established by connecting the recorded thickness measurement pointe and drawing a continuous line equal to the length of the ultrasonic scan and OD profile.
6.4.1.3 All thickness / profile data shall be drawn on the Form MQS-015 and attached to the applicable Ultrasonic Examination Data Report, Form MQS-014. In addition, all reflectors recorded per paragraph 5.5.1, 6.1.1 and/or 6.1.2 shall be plotted onto the profile at their appropriate locations.
7.0 EVALUATION AND ACCEPTANCE CRITERIA 7.1 All recorded indication data shall be evaluated by the Lead PSI Technician or M&QS designated acting Lead PSI Technician.
l 7.1.1 Any additional examinations that are performed to further evaluats a recorded indication shall be properly documented on Forms HQS-013, MQS-014 and
!mE MQS-015, as applicable.
' E ?i
'd 7.1.1.1 A description of the examination technique used shall be included on I the Ultrasonic Examination Data Report, Form MQS-014.
l2 a'..:
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. 1
. l D!cume n t No. UT-FERRITIC Rev.10 (Limerick Proimet only) P:21 20 af 27
, 7.1.1._2_ The additional Ultrasonic Examination Data Report shall be cross referenced with the Ultrasonic Examination Data Report originally documenting the indication using the Exam Report Numbers.
n ;
k) m 7.1.2 The following steps shai. oe applied when evaluating any indication recorded per the requirements of 6.1.1 and 6.1.2:
7.1. 2 .1 Verify that all examination documentation is complete in accordance with Section 6.2 and that each indication is plotted in accordance with paragraph
- 6. 4 .1. 3 .
7.1.2.2 drawings.
Review the fabrication and weld specifications and/or end preparation 7.1.2.3 Interpret the indication from the area containing the reflector in accordance with the applicable procedure or by visual inspection.
7.1. 2 . 4 As an option, other NDE methods or techniques such as alternate UT beam angles, UT profiling or radiography may be used.
7.1.2.5 The basis for classifying the origin of an indication as geometrical or metallurgical shall be recorded on the Ultrasonic Examination Data Report (Form HQS-014) .
7;_. 2 All recorded indications that equal or exceed 100 percent of DAC and
- not determined to be geometrical or metallurgical shall be evsluated in accordance with Article IRA-3000 of Reference 2.1. The examination results are then compared to the acceptance standards of Table 4 or Table 5, as applicable.
() 7.2.1 Any evaluated indication that exceeds the allowable limits or can be determined to be a crack, lack of fusion or incomplete penetration shall be designated as rejectable on the Ultrasonic Examination Data Report, Form HQS-014, and shall be further documented on a Nonconformance Report (NCR) and submitted to the client for final evaluation and disposition.
8.0 DOCUHINTATION AND RECORDS 8.1 Ultrasonic calibration data shall be documented on Form HQS-013.
8.2 Indication recording shall be documented on Form HQS-014.
8.3 Material thickness and contour profiling shall be documented on Form MQS-015.
8.4 Examination reports shall be reviewed by the Lead PSI Technician for completeness and conformity to the requiremente of this procedure.
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p F ra MQS-003 Rg l, 3/80 O o - -
TABLE 4 O a
c ALLOWABLE PLANAR INDICATIONS S 3
r+
Material: Ferritic steels that meet the requirements of NB-2300 and y the specified minimum yield strength of 50 kai or less at 100*F
- C e
volumetrk Esamensteen Method, Nominal Wat: Thickness,' ' t, in. {
m 0.312 :o 1.0 2.0 :o 3.0 4 0 and over "
Aspect Sartace $
- urface s Surface Se6 surface Surface Sutnurface Surface natie' Inscatiest, Indution'* Sutnerface Surface Inscatiesq, Inecation Inrhcation, Indmation Indication, Sutnurface elf e ft, % e st, % la w . son Indecation, Indmation '*
o f t, % oft, % o f t, % o f t, % o f t, % o f t, % ett, % ett, %
hm av Enamination 0.00 7.4 9.2Y 67 8.4 Y 5.7 7.2 Y 47 0 05 7.9 96Y 58Y 3.7 4.6Y 7.2 83Y 62 7.SY 0.10 83 SO 6.lY 40 4.8 Y 10.4 Y 7.9 9.5Y 0.13 68 8.1Y 5.5 6 6Y 9.6 ll.SY 8.8 4.3 5.2Y 0.20 9.6 II.SY 9.9 10.SY 7.5 9 0Y 61 7.)Y 48 58Y g
II.8Y 8.4 10.lY 6.9 4 0.25 9.6 11.SY 8.2 Y 54 6.SY 9.9 !!.8Y 9.5 ll.4Y ,
0.30 9.6 ll.SY 78 9.) Y 61 0.35 9.6 II.SY 9.9 II.8Y 9.5 ll.4Y 88 10.5Y 6.9 7.) Y 8.2Y 9.9 II.8Y 95 11.4Y 0.40 9.6 !!.5Y 88 II .8Y 69 9 3Y 9.9 II.8Y 9.5 11.4Y c*
0.45 9.6 II.SY 88 II.8Y 6.9 0.50 96 9.9 11.8Y 9.5 11.4Y 88 118Y 6.9 10 4 Y y 11.57 9.9 11.8 Y 9.5 II.6Y ID 11.4 Y 88 1I .8 Y 6.9 11.6Y .'.
legervice Esamination n
0 00 11.1 138Y 10.0 W 12.6Y 8.5 10 SY 0.05 11.8 7.0 8.7Y 5.5 0.10 13.0 14.4 Y 15.6Y 10.8 11.8 13.0Y 9.3 11.2 Y 7.5 9. l Y 60 6.9Y 7.2 Y y ,
14.2 Y 10.2 !?.1Y o 0.15 14.4 17.2Y 83 9.9Y 64 133 15.7 Y 7.8 Y 0.20 14.4 17.2Y le 8 173Y 11.2 13.5Y 9.1 10.9 F 7.2 8.7 Y 7
n 12.6 15. l Y 10.3 0.25 14.4 17.2Y 14.8 12.)Y 8.1 91Y "
17JY 14.2 17.1Y 0.30 14.4 17.2Y 14.8 113 13.9Y 9.1 10.9Y 17.7Y 0.35 14.4 17.2Y 14.8 173Y 14.2 17.l Y 13.2 15.7Y 10.3 12.)Y 14.2 17.1Y 13.2 0.40 14.4 17.7 Y 0.45 14 4 17.2Y 17.2Y 14.8 l e.8 173Y 14.2 17.1Y 13 2 173Y 10.3 10.3 13.9Y 15 6Y b
IFJr 14.2 17.1Y 0.50 13.2 14.4 17.2Y 14.8 17.7Y I4.2 17.1Y 13.2 l y,7y 17.Y/
10.) 17.4 Y g 10.3 3 7.4 Y N 8 DOTES: .re t13 For latermeggiate flan aspect ratios o ff and thickness t, linrar interpola* ion is prembyble. M (2) t is nomenal wall ttuchness or actual wall th.cnness as determined by U T esam. nation t)) The total depth of a sutnurface endicatoon is 2a. .
O 443 Y = 15 /el/to Iri - 3 lo. If Y < 0 4, the flaw indication is efassified as a surface ind cation. If Y > 10 v$e Y = 10..
M M
D!cument Ns. UT-FERRITIC Rev.10 (Limarick Project Only) Pega 22 cf 27 4 f%
w/
TABLE S ALLOWABLE LAMINAR INDICATIONS Nominal Pipe Wall Laminar Area Thickness, t, in, so in.
0.625 and less 1.25 2.0 4.0 6.0 12.0
- NOTES:
(1) Area of a laminar indication is defined in subarticle IWA-3360 of reference 2.1.
(2) Linear interpolation with respect to nominal pipe wall thickness is permis-sible to determine intermediate value of allowable laminar area. Refer to subarticle IWA-3200(c) of reference 2.1.
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-= i n in. + -
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Re v.
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Para 24 et 27 Cire Cal./ Parallel ccan Position Datum. measurements taken from Location from s f
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co rding bran ch wel d indi ca tion s Quadrant Parallel Refl -------------------------------
---.---------------------------- ectors Transverse Reflectors
, A+C Cire. Calibration ,
mR Perpendicular scan Ax Cali'> ration Parallel scan E.n .
, B+D
- Ax Calibration Perpendicular scan Cire. Calibration Parallel scan E
&,M FIGURE. 5.
- Branch Connection Weld scanning Requirements
Docueent N u UT-FERRITIC Rev.10 (Limerick Project Only) pag 3 25 at 27 Uttaa50nts cAilga AtlDa a(pont T Tent el alIKmit neio7 D o. ,
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