. | Procedure .No.: L&T- L & T-THI Consortium mm | punsruveerocnr -IHI Trev. 00 | Datel9.1120 PROCEDURE FOR ULTRASONIC EXAMINATION 8 or WELDS Page | of 12 customer Mumbai Metropolitan Reion Development Authority (MMRDA) PROJECT Mumba! Trans Harbour Lik project Package-1 Construction of 10.380 long beige section (C110 000 CHI 10-380 across the Mumbai Bay Including Sewri Interchange ENGINEER AECOM - PADECO - DAR AL HANDSAH -TY LIN Consortium CONTRACTOR: L&T=1HT Consort REVISION STATUS 0 [nas RGavea ow), Rev.No.| Dare UTLevel Udvevet (NDE Lev PREPARED BY CHEEKED BY APPROVED BY Revision 0 Page Lof 12 Procedure No. L&’T-IHV/MTHL/P/PROCIUT 087| L& T-IHI Consortium poe | VMTHLIP UPROCIU’ No.: L&T @ -JHI == ee | bael9.1120 PROCEDURE FOR ULTRASONIC EXAMINATION qo See Page 2 of 12 Tho Tern Tage 1 aspains ; 2 [rates 2 [see 3 7 ren Da 5 [haa 5 6 ‘Equipment & Material . 3 7 Couplant im - + eta = 3 Retro Bio as oe 7 it fear 3 2 | Baan nia 5; a i Tt Ren Rep 7 T3—| Reine AUT Aes on ia aly at Naw er J — 10 Cmts) a od a a 3 1 A) TereNo-LATIHIMTHLPLPROCUT —Revdond Ped 2 088L & T-IHI Consortium roe “THI me te | Page 3 of 12 3.0 Scope 3.1 This procedure describes the requirement for ultrasonic examination of BUTT welds in Ferrite Steel materials by direct contact Pulse echo reflection method. This Procedure is applicable to material thickness Smm to $0 40 Reference Documents 4.1.18 4260 Edition 2004- Recommended Practice For Ultrasonic Testing of BUTT welds in Feritie Stee. 42. AWS DIL, Edition 2015- Clause 6 Inspection 43 ASNT-SNT-TC-1A-201 - Recommended Practice for Personnel Qualification 5.0. Personnel 5.1 Personnel involved in conducting the test, recording the result & evaluating the same against applicable acceptance standards shall be certified toa least ASNT Level-Il.Level-I person may be used as Assistants 5.2 AIL'NDE personnel shall be given annual vision examination and capable of reading Jaeger Number 2 or equivalent letters at nt less than 30cm for near vision acuity either corected or natural 60 Equipment & Material 6.41 Ultrasonic Flaw Detector:- ‘A’ sean pulse-echo system equipment such as Modsonic Einstein-l DGS/TPT or equivalent approved equipment shal be use. 62 The ultrasonic equipments shall be capable of producing, receiving and displaying high frequency acoustic pulses over the nominal range of | to 5 MHz, and shall be of pulse reflection type. Other frequencies may ‘be used, if equal to better sensitivity ean be demonstrated. 63 The ultrasonic equipment and probes shall be capable of being used without difficulty in the temperature range of -10 10 + 50 degree Celsius. 64 The ultrsonic equipment shall be adjusted for sweep range and calibrated prior to inspection as deseribed in IS 12666, 6.5. Equipment Linearity: ‘The instrument calibration for linearity shall be performed at the beginning ofeach period of v extended use ot every 3 months whichever Is less as follows, i. Sereen height linearity: Couple a straight beam probe to the LW Vi block and get rultiple echoes from 25mm back wall. Select any two echoes whose amplitudes are in the ratio of 2: with larger echo set at 80% of full screen height. Without moving the search unit adjust the fain to successively setthe larger indication from 100% to 20% of full screen height, in 10% increments or 2dB steps if a fine control is not available, and read the smaller indication at each setting. 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 height. i Amplitude control linearity: Couple an angle beam probe to IW VI block and get multiple echoes from 100mm quadrant. Select any echo and note its amplitude. Reduce the gnin by 6¢B and read the amplitude ofthe same indication. It must be 50% of the initial amplitude within 10% of the ‘nominal amplitude ratio, Perform this exercise for full range ofthe gain . The settings and readings must be estimated to the nearest 19% of full sereen and the readings should be as follows. Procedure No. L&T-IHUMTHLIPPROC/UT Revision 0 Page 3 of 12 andy 0899 THI Rev:00 | Date:l9.11.20 Procedure No.: LaT- IHUMTHL/P VPROCIUT L & T-IHI Consortium PROCEDURE FOR ULTRASONIC EXAMINATION 8 a Page 4 of 12 [Tnaeatin seat Yonge oF Ta IB Contr change | Tatton Lis Yonge a all nae erecn hele wo 8 Teak fa rm Tete ra eB i096 2 sa etieds 660 Search Unit- 66:1 1 Aahear wave probe which produces an Angle of 480 10700 Inthe examination medium i normally ved The selection ofthe beam angle is dependent on thickness and geometry of the weld. The selection of angle is as per the below table. SR NO. THICKNESS mm BEAM ANGLE Degree] 1 Up 10.30 70, | ‘Over 3010 50 oO. 1 3 ‘Over 50 ss 662. 1) Probes with a beam angle less than 45 Degree and more than 70 Degree be used. If the geometry of the ‘weld is more adoptable tothe chosen beam angle. "The nominal equency shall be inthe range of 2 to 5 MHz Unless variables such as production materi ‘use of other frequencies to asaure adequate penetration or better resolution. 6.7 Reference/Calibration Block= 62.1 IIW Block Type “VI": This block Is used to verify the emission point of Ultrasonic beam, probe angle, beam spread & equipment linearity. This block ean also be used for time base calibration 6.12. IIW Block Type “V2": This block is used to verify the emission point of Ultrasonic beam & for time base calibration. 643 Basie Calibration Blocks -Table-1 Procedure No. L&T-IHUMTHLPI/PROCIUT Revision 0 Page 4 of 12 yee 030L & T-IHI Consortium _| nuaravevpaccur -JHI | batsl9 1120 procepuns For uutrasonicexaminarion [82° _ |g ] Procedure .No.: L&T- OF WELDS facut pane ete = | 674 7 Notch Size-— Width = 3.2 meno 6 4 men, Depth 2 percent of Tot 1 Om, whichever grader into the Bae ata, Length ST me 1) The basic calibration reflectors shall be used to establish a primary reference response of the equipment. 1i) The material from which the block is fabricate shall be of the same product form, that is pate, forging ber, tubes ect.and material specification, having similar acoustic properties of the finished component ‘When two of more base material thickness are involved, the calibration block thicknesses shall be ‘determined by the average thickness of wel. ii) The temperature difference between the examination and_ the calibration shall be within 14 degre. Coup Cellulose, Paste (wall paper paste), Glycerin, light machine Oil. A satisfactory couplant having wetting properties to permit the transmission of mechanical vibrations between the probe and material under test shall be used Procedure No. L&T-IHVMTHLPU/PROCIUT Revision 0 Page $ of 12 {A woh 091i Procedure No.: L&T- L & T—IHI Consortium : LHUMITHLP /PROCIUT -JHI....... a freon | Dao PROCEDURE FOR ULTRASONIC EXAMINATION 6 | OF wETs Page 6 of 12 8 Surface Preparation i) Thetest surface and an area covering the entire scanning area on either side of the tet surface shall be free of dirt, prease, rust, int, weld spatter and other extraneous matter which may interfere with the effectiveness of the test ii) The weld ripples or weld surface irregularities shall be removed by any suitable mechanical means to sueh a degree that the resulting ultrasonic examination from any remaining irregulartics cannot mask ‘any objectionable defects The finished surface of the reinforcement should merge smoothly into the surface ofthe adjacent base material. ii) The volume ofthe base material through which the sound will travel in Angle beam examination shall be completely scanned with straight beam search unit usually of 2 MHz frequency to detect and record reflection which might affect interpretation of angle beam result. iv) Dual Probes may be employed in plate of thickness 5 mm to 12 mm for detestion of reflectors. 9.0 Examination Coverage and Scanning Method snce Amplitude Correction (DAC)-Angle Beam Scanning- For Thickness above-25 mm “The Angle beam probe shall be directed towards the basic calibration reflectors inthe calibration block, The centerline of probe shall not points towards the comers ofthe hole. The sound beam shal be oriented perpendicular tothe axis ofthe side drilled holes. The probe shall be positioned to get highest amplitude, The Sensitivity contros shall be adjusted to get indication from SDH at 80 percent of FSH. The peak ofthe indication is marked on the CRT sereen. The probes are positioned on the other node positions covering the expected examination range. The corresponding peaks are marked on the CRT screen. The peaks are joined bya smooth line whose length cover the examination range to generate DAC curve i) For Thickness 25 mm or less {A single calibration reflector shall be located at $0 percent T thickness ofthe calibration block. No DAC curve need to establish ,The signal amplitude obtained from the reflector is kept as the reference amplitude level for testing, Procedure No. LT-IHIMTHLPUIPROCIUT Revision 0 Page 6 of 12 an) 092; Procedure .No.: L&T: L & T-THI Consortium IHUMTHLPYPROCIUT Rev: 00 | Date:t9.11.20 PROCEDURE FOR ULTRASONIC EXAMINATION ~ | 18, OF WELDS . | Page 7 of 12 Fig2 SALINE HOLES ano Norenes useo Foe ANGLE BEAM CALIBRATION IREELECIORS Moves [i 10 Beate * fect 3" AMPLITUDE 60 iNPeRcENT 40. 20 i) Angle beam examination less than 10 mm weld thickness shall be carried out from both side of the weld on the same surface. The total width ofthe scanning zone shall be equal to twice the skip distance. {v) For weld thickness 10 mm to 100 mm ,the angle beam examination shall be done from both sides ofthe weld on the same surface whenever practicable the scanning zone being the full skip distance 9.1. Scanning for reflectors oriented parallel to the Welds ‘The angle beam shall be directed right angles to the weld axis from two direction where possible. The probe shall be manipulated so thatthe ultrasonic energy passes through the required volume of the welds and adjacent base metal ‘The scanning shall be performed ata gain setting of 6db above the reference level, Evaluation shall be perform with respect to primary reference level 9.11 Scanning for reflectors oriented Transverse to the Welds ‘The angle beam shal be directed parle! angles othe weld axis. The probe shall be manipulated so thatthe ultrasonic energy passes through the required volume of the welds and adjacent base metal The seanning shall be performed at again setting of 6b above the reference level. Evaluation shall be performed with respect to primary reference evel. The probe shall be rotated 180 degree and the examination repented 4) For straight beam examination, the probe is positioned for maximum response from the hole that gives the highest amplitude. The sensitivity control is adjusted to get 80 percent of FSH. The probe is positioned to get Procedure No, L&T-IHUMTHLPUPROC/UT Revision 0 Page 7 of 12 EY 033L & T-IHI Consortium besa oniateiaeril mnmieimar | @)-1HI Ren 00 | Basa PROCEDURE YOR ULTHABOMC EAMRATION is orca Page 8 of 12 [( sserinum esponse fom another ole and peak of the oles ae marked on he soeen. The peaks are coonened and extended through the thickness to provide the distance amplitude curve fromthe side drilled hoes. if) For straight beam examination the probe is positioned directly on the weld surface of the examination materia. ‘The weld shall be scan along and across the width of the weld inclusive of adjacent heat affected zone to its entire volume. Penetration is verified by back reflection amplitude, ii) The scanning shall be performed ata gain setting 6 db above the reference level .Evaluation shall be performed atthe primary reference level 10.1 Examination Procedure ') The volume of the weld shall be examined by moving the probe over the examination surface so as to sean the entire examination volume. Each pass of the probe shall overlap a minimum of 10 percent of the transducer dimensions perpendicular tothe direction of sean. ii) The rate of probe moment of examination shall nt exceeds | SOmmis, ii) During movement both towards and away from the welded joints of flat /near flat surface the probe shall be oscillated over an angle 10 to 15 degree on each side of a line ofthe weld. 11.0 Evaluation of Indications 11.1 Each weld discontinuity shall be evaluated on the basis of ts length in conformance with Table 6.2 of AWS Di. for statistically loaded structures. Indication rating shall be determined by using the following formula. 4 ‘b—e (Where a = indication level, b= reference level, attenuation factor.) 11.2 When a discontinuity indication appests on the sereen, maximum attainable indication from discontinuity shall be adjusted to produce «horizontal reference level trace deflection on the display. The dB reading, shall be used an indication lev! 113 Attenuation factor shal be attsined by subtracting 1 in (25mm) from the sound path distance and rultiplying the reminder by 2 for US Customary Units or by 0.08 for SI Units This factor shall be rounded ‘out to nearest dB, 11.4 Discontinuity size evaluation shall be as per Clause 629 of AWS DILL 120 Acceptance Criteria AWS D1.I Section 6, para 6.13.2 and Table 6:3 forthe welds of Cyelically Loaded Non-Tubular connections. Procedure No. L&T-IHUMTHL/P/PROCIUT Page 8 of 12 ny 094: Procedure .No.: L&T L & T—IHI Consortium a | IHVMTHLPYPROCIUT. @)-TH roo masneonccmmane [eo [Seon] PROCEDURE FOR ULTRASONIC EXAMINATION 18 | OF WELDS Page 9 of 12 13.0 Recording/Reporting ‘Written reports shall be completed on the approved form and shall include all relevant information such as ‘equipment, basic calibration and reference blocks, probes (frequency and angle), couplant material and surface condition, material and thickness of component.ID and location of weld or volume examined, location of each recorded indication, 1D and level of UT personnel, date and time of examination, surface from which examination is conducted The report shall be submitted the designated personnel as soon as possible after inspection is completed, Only rejectable discontinuities need to be recorded on the report, Each rejectable discontinuity shall be marked on the weld directly over the discontinuity for its entire length. The depth and each indication rating shal also be noted on nearby base metal Repaired area shall be noted on the report and the report and the result of the re-examination for the repaired area shall be recorded & indicated as indication number with R1, R2, R3 on the new line on the ‘original report or report number with R number for addtional report. All the restrictions that limit the effectiveness ofthe examination shall be noted on the report. Procedure No. LAT-IHUMTHLPU/PROCIUT Revision 0 Page 9 of 12 (as) 095: Procedure ‘No.: LAT- L & T-THI Consortium oer IBUMTHLPYPRO rT OF WELDS | . oa Date:19.17.20 | Q)-THN | cerenapupectnnenen Page 10 of 12 ANNEXURE-A Table 6.3 UT Acceptance-Rejection Criteria (Cyciically Loaded Nontubular Connections) (se¢ 6.13.2 and C-6.26.5) Wel Se mines nee Vn Ang M6 3M hh tngh MLR a 22a ough s > tough Orscentaiy) 15-20) [3 S100 eon Seriya _—— ——— Cas, ele ow os fw ow [sok a WR Wk | ak Rk Rk uA [tomer ter | tes owes toner | tomer tower owes | her iner we ’ ols 3 = Sa tcl ghee cao Z | fis ears oS 2 0) a 0 | a 7 ae eae os ao! ye # W]e os ¢ ee Sep kup | dep kp em | Bp kup Rep up "een ot ea hae eee note ane la Ban aici fe pared yt 3 eg he ght rd tye awn te tt Sh scott cated ty eat ct keg of contest was see hn Hehehe vive Clos Bare vseanvy ale ere et dnc 1 HC ul pa ta bes a2 orm neh sg pty ae en oa ban sce che ag a8 tie of CH ae rsh a deen Sra sche dried 1 Th dla pt seed 4 Race ce wel ras shale cee an tay to he esigab 48 eat tg, a steko sd eo tx fe oat na 9 he ena ou edly ted iti el rb 32 Procedure No, Lé IHUMTHLIPVPROC/UT Revision 0 Page 10 of 12 096—————— OOS L & T-THI Consortium TProcedure Nostat- | IAVMTHL/PUPROCIUT ate: 9.11.2 - Rev: 00 OF WELDS at le Page 11 of 12 ANNEXURE-B Chg a ‘Ney vac this ey thal rect calle eth ‘Scanning Levels Chis ines aims : nal ek rc So a Ace tt Chan ye seri nS mal > Apidos capa ov nga , i mals ese ae 1K alah Ap s-13e Yen a 4 i aed 18 Chee Dfmm Jcomnntes p15 (290-380 a nid th cace tl sgl epson oe ai Fvln onan cio. 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