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PROCEDURE FOR ULTRASONIC EXAMINATION

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PROCEDURE FOR ULTRASONIC EXAMINATION (382.5MW UNOSUGEN CCPP-UNOSUGEN FLASH TANK)

TABLE OF CONTENTS

0.1 Revision Rev ision Table 1.0 SCOPE 2.0 APPLICABLE CODES AND STANDARDS 3.0 QUALIFICATION OF PERSONNEL 4.0 GENERAL REQUIREMENTS 5.0 CALIBRATION 6.0 EXAMINATION EVALUATION LEVEL 7.0 EVALUATION I NDICATION ION 8.0 RECORDING OF INDICAT

9.0 ACCEPTANCE STANDARDS 10.0 RECORDS Attachment 1 :

0

REV NO.

2010.12.07

DATE

Form of Examination Report

First Issue

(DESCRIPTION)

S.R. LIM

M.K. SHIN

J. W. IM

Q.A. DEPT

Q.A. DEPT

Level III

PREPARED BY

REVIEWED BY

APPROVED BY

HANYANG INSPECTION & ENGINEERING,LTD.

HY-QF-003(Rev.1)2005.12.26.승인 (A4) 210mm X 297mm

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0.1 Revision Table Rev. No./Date

Reasons of Revision

Contents of Revision

0 / 2010.12.07

First Issue

First Issue



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1.0 SCOPE 1.1 This procedure describes the requirements and techniques for ultrasonic testing of ferrous materials and their welds for fabricated pressure vessel and piping within the range of 0.2in. (5.0mm) to 8 in. (203mm) in plate thickness using direct contact method. 1.2 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.

2.0 APPLICABLE CODES AND STANDARDS 2.1 ASME Code Section V (2007 Edition + 2009 Addenda) 2.2 ASME Code Section VIII Div1(2007 Edition+ 2009 Addenda) 2.3 SNT-TC-1A (2006 Edition)

3.0 QUALIFICATION OF PERSONNEL 3.1 Personnel performing examination to this specification shall be qualified and certified as Level II or higher in accordance with HIE written practice, HY-QP-06-03, which meet the requirements of SNT-TC-1A (2006 Edition).

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. EPOCH-4B or equivalent shall 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.



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4.1.3 The ultrasonic search units in the following table or equivalent shall be used.

Mode

Frequency

Model

Element Size(㎜)/ Shape

Shear wave

2 or 4 MHz

MWB 45,60 & 70

8 X 9 / rectangle

Longitudinal Wave

1 ~ 5 MHz

BS or MBS

Ø25 or Ø 10 /

circle

Angle(

)

˚

Remark

45,60 ,70

or equivalent shall be used

0

or equivalent shall be used

4.2 Couplant 4.2.1 As coupling media, oil, glycerol or water-based paste may be used, on condition that it is compatible with the material of the part under examination. 4.2.2. The same media shall be used for both examination and calibration. 4.3 Calibration Blocks 4.3.1 General 4.3.1.1 Reflectors Known reflectors (i.e., side drilled holes, flat bottom holes, notches, etc.) shall be used to establish a primary reference response of the equipment. 4.3.1.2 Material 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. P-No. 1, 3, 4, 5A through 5C, and 15A through 15F materials are considered equivalent. 4.3.1.3 Surface Finish The finish on the scanning surfaces of the block shall be representative of the scanning surface finishes on the component to be examined. 4.3.1.4 Block Curvature (Except for Piping) (1)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. (2) A calibration block having the greater base material thickness may be used provided the HANYANG INSPECTION & ENGINEERING,LTD.


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reference reflector size is based upon the average or smaller. 4.3.1.5 Non-Piping Calibration Blocks The basic calibration block configuration and reflectors shall be as shown Fig.1. 4.3.1.6 Piping Calibration Blocks The basic calibration block configuration and reflectors shall be as shown Fig.2. The basic calibration block shall be a section of pipe of the same nominal size and schedule.

5.0 CALIBRATION 5.1 Instrument Linearity Checks The basic calibration block to be used in instrument calibration is described on Fig. 1. 5.1.1 Screen height linearity The ultrasonic instrument shall provide linear vertical presentation within ±5 % of the full screen height for at least 80 % of the calibrated screen height. This shall be checked and recorded every three months for analog type instruments and one year for digital instruments. 5.1.2 Amplitude control linearity 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. This shall be checked and recorded every three months for analog type instruments and one year for digital instruments.

5.2 System Calibration The ultrasonic system shall be calibrated according to following explanation. 5.2.1 Angle beam calibration for Non-piping Calibration shall be performed utilizing the calibration block shown in Fig.1.

5.2.1.1 Sweep Range Calibration 5.2.1.1.1 IIW Block IIW reference blocks may be used to calibration the sweep range displayed on the instrument screen. (1) Search Unit Adjustment. Position the search unit for the maximum indication from the 4 in. (100

) radius while

rotating it side to side to also maximize the second reflector indication. (2) Delay and Range Control Adjustments. HANYANG INSPECTION & ENGINEERING,LTD.


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Without moving the search unit, adjust the range and delay controls so that the indications start at their respective metal path distances. (3) Repeat Adjustments. Repeat delay and range control adjustments until the two indications are at their proper metal path on the screen. (4) Sweep Readings. Two divisions on the sweep now equal 1/5 of the screen range selected.

5.2.1.1.2 Side Drilled Holes (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 f 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 for Side Dril led Holes Primary reference Level (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.



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6.0 EXAMINATION 6.1 Direction and Extent of Scanning (a)The scanning shall be directed to the weld from in & outside surface in possible. Each pass of the search unit shall overlap a minimum of 10% of the active transducer (piezo-electric element) dimension perpendicular to the direction of the scan. (b)The volume to be examined shall be scanned by shear wave (45, 60, 70 deg.) if accessible. 6.2 Rate of Search unit Movement Scanning method : manual scanning. The rate of search unit movement for examination shall not exceed 150 mm/sec.

6.3 Surface Preparation 6.3.1 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. 6.3.2 When the weld surface interferes with the examination, the weld shall be prepared as needed to permit examination. Preparation of as welded by grinding may be required where surface irregularities would mask indications of unacceptable discontinuities.

6.4 Scanning Sensitivity Level The scanning sensitivity level shall be set a minimum of 6

higher than the reference level

gain setting.

6.5 Angle Beam Scanning Technique Welds in non-piping and piping shall be scanned to detect a defects in the weld as following scanning technique and methods. 6.5.1 Reflectors parallel to the weld. The angle beam shall be directed at approximate right angles to the weld axis from both sides of the weld (i.e., from two directions) on the same surface when possible.

The search unit shall be

manipulated so that the ultrasonic energy passes through the required volumes of weld and adjacent base metal. 6.5.2 Reflectors 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 material . The search unit shall be rotated 180 deg. and the examination repeated. HANYANG INSPECTION & ENGINEERING,LTD.


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6.6 Restricted Access Welds Welds that cannot be fully examined from two directions using the angle beam technique(e.g., corner and tee joints) shall also be examined, if possible, with a straight beam technique. These areas of restricted access shall be noted in the examination report.

6.7 Inaccessible Welds Welds that cannot be examined from at least on side (edge) using the angle beam technique shall be noted in the examination report. For flange welds, the weld may be examined with a straight beam or low angle longitudinal waves from the flange face provided the examination volume can be coved.

6.8 Sizing method The length of the reflector shall be obtained by recording the position and location along the length of weld as determined by 6drop of DAC for each end of the reflector

6.9 Methods for discriminating geometric from flaw indications Indications should be characterized as follows;

- Spherical(individual pores and widely spaced porosity, nonlongated slag) - Cylindrical (elongated slag, aligned pores of porosity, hollow beads) - Planar(incomplete fusion, inadequate joint penetration, cracks) 6.9.1 The following methods should be used for determining basic discontinuity characteristics. 6.9.1.1 Spherical Sound is reflected equally in all directions. Indications remains basically unchanged as the search unit is moved around the spherical indications. 6.9.1.2 Cylindrical Sound is reflected equally in one direction but is changed in other direction. Indications remains basically unchanged when the search unit is moved in one direction but is drastically changed when moved in other directions. 6.9.1.3 Planar Sound is reflected at its maximum from only one angle of incidence with one plane. Indication is changed with any angular movement of the search unit. Indications from cracks typically have multiple peaks as results of the many discontinuity HANYANG INSPECTION & ENGINEERING,LTD.


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facets usually present.

7.0 EVALUATION LEVEL 7.1 Distance Amplitude Technique All indications greater than 20% of reference level shall be investigated to the extent that they can be evaluated in terms of the acceptance criteria.

7.2 Laminar Reflectors Reflectors evaluated as laminar reflectors in base material which interfere with the scanning of examination volumes shall require the angle beam examination technique to be modified such that the maximum feasible volume is examined, and shall be noted in the record of the examination.

8.0 RECORDING OF INDICATION 8.1 Non-Rejectable Indications Non-rejectable indications shall be recorded in the report. 8.2 Rejectable Indications Rejectable indications shall be recorded. As a minimum, the type of indication (i.e., crack, non-fusion, slag etc.), location, and extent(i.e., Length) shall be recorded. 8.3 The examiner shall maintain a record of all reflections from uncorrected areas having responses that exceed 50% of the reference level. This record shall locate each area, the response level, the dimensions, the depth below the surface, and the classification.

9.0 ACCEPTANCE STANDARDS (ASME Sec VIII Div.1 App12) 9.1 Weld that are shown by ultrasonic examination to have discontinuities which produce an indication greater than 20 % of the reference level shall be investigated to the extent that the operator can determine the shape, identity, and location so that they may evaluate each discontinuity for acceptance in accordance with 9.1.1 and 9.1.2 below. 9.1.1 Indications characterized as cracks, lack of fusion, or incomplete penetration are unacceptable HANYANG INSPECTION & ENGINEERING,LTD.


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regardless of length. 9.1.2 Other imperfections are unacceptable if the amplitude exceeds the reference level and the length of the imperfection exceeds the following: (1) 1/4 in. (6.0 mm ) for t up to 3/4 in. (19.0 mm ). (2) 1/3 t for from 3/4 in. (19.0mm) to 2 1/4 in. (57.0 mm ). (3) 3/4 in. (19.0 mm ) for t over 2 1/4 in. (57.0 mm ).

where t is the thickness of the weld excluding any allowable reinforcement. For a butt weld joining two members having different thicknesses at the weld, t is the thinner of these two thickness. If a full penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be include in t.

10.0 RECORDS Examination report shall include the information below, as minimum. (a) procedure identification and revision; (b) Ultrasonic instrument identification(including manufacturer’s serial number); (c) Such unit(s) identification (including manufacturer’s serial number, frequency, and size); (d) beam angle(s) used; (e) couplant used, brand name or type; (f) search unit cable(s) used, type and length; (g) Special equipment, when used (search units, wedges, shoes, automatic scanning equipment, recording equipment, etc.) ; (h) Computerized program identification and revision, when used; (i) calibration block identification; (j) Simulation block(s) and electronic simulator(s) identification, when used; (k) Instrument reference level gain and, if used, damping and reject setting(s); (l) Calibration data [including reference reflector(s), indication amplitude(s), and distance reading(s)]; (m) data correlating simulation block(s) and electronic simulator(s), when used, with initial calibration (n) identification of material or volume scanned (o) surface(s) from which examination was conducted, including surface condition (p) Map or record of rejectable indications detected or areas cleared; (q) areas of restricted access or inaccessible areas; HANYANG INSPECTION & ENGINEERING,LTD.


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(r) examination personnel identity and, when required by referencing Code Section, qualification level; (s) date of examinations.



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Basic Calibration Block for Non - Piping

Weld Thickness t(mm) Up to 25mm Over 25 through 50 Over 50 through 100 Over 100

Basic Calibration Block Thickness T(mm) 19 mm or t 38 or t 75 or t

T ± 25mm

Hole

Diameter(mm) Notch Size (mm) Width 6mm max. 2.5mm Depth = 2% T 3 Length = 25mm min. 5 **

** For each increase in weld thickness of 2in.(50mm), or fraction thereof over 4 in.(100mm), the hole diameter shall increase 1/16 in.(1.5mm). GENERAL NOTE: (a) Holes shall be drilled and reamed a minimum of 1.5in. (38mm) deep minimum, essentially parallel to the examination surface. (b) For components equal to or less 20 in. (500mm) in diameter, calibration block diameter shall meet the requirement of T-434.1.7.2. Two sets of calibration reflectors (holes, notches) oriented 90 deg from each other shall be used. Alternatively, two curved calibration block may be used. (c) The tolerance for hole diameter shall be ±1/32in.(0.8mm) The tolerance for hole location through the calibration blocks thickness(i.e., distance from the examination surface) shall be ±1/8in.(3. mm) (d) For block less than 3/4in.(19mm) in thickness, only the 1/2T side-drilled hole and surface notches are required. (e) All holes may be located on the same face (side) of the calibration block provided care is exercised to locate all the reflectors (holes, notches) to prevent one reflector from affecting the indication from another reflector during calibration. Notchs may be also be in the same plane HANYANG INSPECTION & ENGINEERING,LTD.


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as the inline holes (See Appendix J, FIG J-431, a sufficient number of holes shall be provided for both angle and straight beam calibration at the 1/4T, 1/2T and 3/4T depths. (f) Notch depths shall be 1.6%T minimum to 2.2%T maximum. When cladding is present, notch depth on the cladding side of the block shall be increased by the cladding thickness, CT (i.e, 1.6%T + CT minimum to 2.2%T + CT maximum) (g) Maximum notch width is not critical. Notches may be made by EDM or with mills up to 1/4 in.(6.4mm) in diameter. (h) Weld thickness, t, is the nominal material thickness for welds without reinforcement or, for welds with reinforcement, the nominal material thickness plus the estimated weld reinforcement not to exceed the maximum permitted by the referencing Code section. When two or more base material thickness are involved, the calibration block thickness, T, shall be determined by average thickness of the weld; alternatively a calibration block based on the greater base material thickness may be used provided the reference reflector size is based upon the average weld thickness

Fig. 2

Basic Calibration Block for Piping

* Notches shall be located not closer than T or 1 in. (25 mm), whichever is greater, to any block edge or to other notches. (a) The minimum calibration block length (L) shall be 8 in. (200 mm) or 8T, whichever is greater. (b) For OD 4 in. (102 mm) or less, the minimum arc length shall be 270 deg. For OD greater than 4 in. (102 mm), the minimum arc length shall be 8 in. (203 mm) or 3T, whichever is greater. (c)Notch depths shall be from 8% T minimum to 11% T maximum. When cladding is present, notch depths on the cladding side of the block shall be increased by the cladding thickness, CT (i.e.,8%T + CT minimum to 11%T+CTmaxmum). Notch widths shall be 1/4 in. (6 mm) maximum. Notch lengths shall be 1 in. (25 mm) minimum. (d) Maximum notch width is not critical. Notches may be made by EDM or with mills up to 1/4 in.(6mm) in diameter. (e) Notch length shall be sufficient to provide for calibration with a minimum 3 to 1 signal to noise ratio. HANYANG INSPECTION & ENGINEERING,LTD.


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Attachment 1. Form of Examination Report (A)



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Attachment 1. Form of Examination Report (B)



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