JOB PROCEDURE P.

013753
MANUAL ULTRASONIC TESTING D 11095
010

TORRENT GAS PRIVATE LIMITED

VENDOR LOGO

CITY GAS DISTRIBUTION PROJECT

IRCA LOGO

TRACTEBEL ENGINEERING PVT. LTD.

JOB PROCEDURE
MANUAL ULTRASONIC TESTING

DOC. NO. P.013753 D 11095 010

0 21.06.2019 Issued For Client Approval Anuj Soni Akash Dhobi Pintu Patel
Rev. Date Description Prepared by Checked by Approved by

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JOB PROCEDURE P.013753

MANUAL ULTRASONIC D 11095
TESTING 010

TABLE OF CONTENT

1. PURPOSE .........................................................................................................................................3
2. SCOPE..............................................................................................................................................3
3. REFERENCES ....................................................................................................................................3
4. EQUIPMENT, CONSUMABLES & ACCESSORIES ...............................................................................3
5. PERSONNEL QUALIFICATION ..........................................................................................................3
6. SPECIFICATION FOR ULTRASONIC TESTING PROCEDURE: QUALIFICATION ...................................3
7. TEST PROCEDURE ...........................................................................................................................4
8. REFERENCE BLOCKS ........................................................................................................................4
9. CALIBIRATION OF ULTRASONIC FLAW DETECTOR..........................................................................4
10. DISTANCE AMPLITUDE CORRECTION CURVE (D.A.C. CURVE) ....................................................5
11. SURFACE CONDITION ..................................................................................................................5
12. PROBE SELECTION .......................................................................................................................5
13. SCANNING ...................................................................................................................................5
14. AMPLIFICATION DURING PRODUCTION TESTING ......................................................................5
15. PROCEDURE ................................................................................................................................5
16. PERODIC CHECK OF SCREEN CALIBIRATION................................................................................6
17. INTERPRETATION OF RESULTS ....................................................................................................6
18. EVALUATION OF INDICATIONS GIVEN BY ULTRASONIC TESTS ...................................................6
19. ACCEPTANCE OR REJECTION CRITERIA .......................................................................................6
20. RETEST .........................................................................................................................................7
21. OTHER EQUIPMENT ....................................................................................................................7
22. REPORTING .................................................................................................................................7
23. HEALTH SAFETY AND ENVIRONMENT:........................................................................................7
24. FIGURES .......................................................................................................................................7

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MANUAL ULTRASONIC D 11095
TESTING 010

1. PURPOSE

This procedure is used to detect internal discontinuities of weld in gas pipeline. The discontinuities
parallel to the scanning surface are the most ones favorably aligned for detection during the Execution
of Steel Pipeline Construction.

2. SCOPE

This is a general procedure, which describes Examination of weld of pipelines, by using Ultrasonic flaw
detector with pulse echo contact beam method for diameter 6”φ, 8”φ , 12”φ & 16”φ welded joints
which are using of girth weld, all repaired portions of weld joint, weld joints of crossing, weld joint of
tie-in, and all golden joints. The UT shall be done at all above joints after the x-ray film interpretation.
This procedure is useful for examination of welds of single wall of pipes. The welds are single ’V’ Butt
welds.

3. REFERENCES

 Specification No.: Tender specification.

 ASME Sec. V – latest edition
 API 1104 - latest edition
 ASNT SNTC- 1A/ ANSI CP-189

4. EQUIPMENT, CONSUMABLES & ACCESSORIES

 Ultrasonic Flaw Detector, A scan type, meeting the requirements of T- 530 of article 5 of ASME
Section V.
 Suitable Miniature And Large Probes (Normal Probe, TR Probe, Angle Probes of 45°, 60° & 70°)
 Matching Cables
 Suitable Couplant
 Scale and Paint Marker
 Drawing & Gauging Tool

5. PERSONNEL QUALIFICATION

The qualification of the NDT inspector to carry out this testing shall be minimum ASNT level II & / or
Company’s level II in accordance with Company’s Written Practice which is in accordance to ASNT SNT
TC 1A & / ANSI CP 189.

6. SPECIFICATION FOR ULTRASONIC TESTING PROCEDURE: QUALIFICATION

Before work begins, the Contractor shall present a specification describing the proposed procedure
qualification and calibration methodology.

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MANUAL ULTRASONIC D 11095
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This specification shall state, as an indication only but not limited to the following information:

 Type of LT Equipment used

 Details for calibration
 Type and dimensions of transducers
 Frequency range
 Coupling medium
 Inspection technique
 Record details
 Reference to the welding procedure where it is intended to adopt the weld location.
 Temperature range of the joints to be inspected.

The ultrasonic inspection procedure shall be approved by the PMC/Client. This specification test
consists in testing (under normal operating conditions) some Contractors welds made according to the
same production procedure, where there are typical defects the test intends to detect.

This test shall be conducted in the presence of the Client.

7. TEST PROCEDURE

Circumferential welds shall be inspected from both sides using angled probes.

If, during the test, echoes of doubtful origin appear, it shall be necessary to inspect a convenient area
on the pipe surface, close to the weld, with a straight beam transducer in order to check whether any
manufacturing defects are present which could have interfered with the ultrasonic beam.

The equipment shall include but not be limited to the following

 Ultrasonic equipment and coupling medium
 Sample sections for calibration of instruments
 Equipment for cleaning of surface to be examined
 Rules calibrated in centimeters for exact location of the position of defects.

8. REFERENCE BLOCKS

 The efficiency of the equipment used, the effective refraction angle of the probe, and the beam
output point, shall be checked using a V1 and V2 sample block, IIW type or the calibration block
ASTM E-428.
 Notch Block for D.A.C. as shown in figure 1.(as per API-1104)

9. CALIBIRATION OF ULTRASONIC FLAW DETECTOR

The calibration of the UFD shall be carried out in accordance with ASME section V Article 5 or specific
written procedure for its vertical & horizontal linearity once in every six months or after repair of UFD
whichever is earlier.

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In addition, Amplitude control corrections, Beam spread, index point, Beam angle & Resolution will be
checked.

10. DISTANCE AMPLITUDE CORRECTION CURVE (D.A.C. CURVE)

 Following steps shall be carried out to obtain a DAC curve for angle probe. See figure 1 (B).
 Calibrate the screen range as required beam path using V1 or V2 standard block.
 Apply Couplant to notched bar with through and through hole (3.2 mm) reference block.
 Take echo from hole maximize at 80%, (±5%) and mark.
 Note down the dB.
 Repeat the same for OD Notch & ID Notch & mark. (As per API-1104, figure -3)
 Draw the curve connecting three points.

11. SURFACE CONDITION

All surfaces shall be clean and free of scale, dirt, grease, paint, spatters or any other foreign materials.
Surface shall be smooth to carry out effective test for at least 50 mm wide on both side of weld. Any
how the cleaned strip must be at least wide enough to allow 11/2 skip examination. If surface is not
smooth as reference block, dB correction shall be done.

12. PROBE SELECTION

The combination of probes in addition to normal probes shall be selected as per specific requirement
or as per thickness of the pipe.

13. SCANNING
Hundred percent areas shall be done at 6db gain (it shall be set at reference standard) and scanned on
both side of the welds using longitudinal and shear wave probes. Length of scanning shall be minimum
of ½ Beam Path to 1 ½ Beam Path on the both side of weld. See figure 3.

14. AMPLIFICATION DURING PRODUCTION TESTING

The amplification during production testing shall be obtained by adding 2-6 dB (according to the
surface condition of the pipe and its cleanness) to the reference amplification.

15. PROCEDURE

Unless otherwise specified, inspect the weld on both sides by using longitudinal & shear wave probes.

 LONGITUDINAL WAVE PROBE

With reference to first back wall echo 80% + 5%, scanning shall be carried out before and after weld on
base metal to confirm any inherent or after weld discontinuity. During scanning with longitudinal wave
probe, full contact and echo height shall be maintained. Area of scanning shall be at least ½ Beam Path
to 1 ½ Beam path on the both side of pipe weld. This scanning will reveal discontinuity with major
surface parallel to scanning surface.
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MANUAL ULTRASONIC D 11095
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 SHEAR WAVE PROBE

With respect to DAC, Scanning shall be carried out on both sides of weld to determine discontinuity
within the weld & base metal, which are not parallel to scanning surface, Both the probes be scanned
individually on both the sides. Scanning shall cover at least ½ Beam Path to 1 ½ Beam Path of beam
path. Unless & otherwise specified, circumferential direction scanning shall be carried out on base
metal.

16. PERODIC CHECK OF SCREEN CALIBIRATION

Calibration of screen shall be checked prior to any inspection run, prior to equipment shut down and at
least in each 4 hours during continuous equipment operation.

17. INTERPRETATION OF RESULTS

All indications that are equal to or greater than rejection level, established during calibration, as
described in acceptance / rejection criteria in section 14 of this procedure or agreed by client’s
inspector, shall be considered representing defects and may be cause of rejection repair of the weld or
base metal. Each time echoes from the weld bead appear during production testing. The amplification
shall be attended the co-inside with the reference (after reducing 6 db) amplification, and the probe
shall be oscillated and removed until maximum response is obtained, paying attention all the time to
the probe tube coupling.

18. EVALUATION OF INDICATIONS GIVEN BY ULTRASONIC TESTS

Each time that echoes from the weld head appear during production testing, the instrument
amplification shall be altered to coincide with the reference amplifications and the probe shall be
moved until maximum response is obtained, paying attention all the time to the probe-tube coupling.

If under these conditions, the height of the defect echo is equal to or greater than the reference echo,
the defect shall be evaluated according to Client Specification. If the defect has also been detected by
the radiographic and/or visual examination, the dimensions shall be judged according to the type of
examination which detects the greater defect. Returns which are less than 50% of the reference echo
will not be considered. If returns are above 50% but lower than 100% of the reference echo, and if the
operator has good reasons to suspect that the returns are caused by unfavorably oriented cracks, he
shall inform the PMC/Client. Moreover, when there is a defect to be repaired, such defect shall be
removed for a length corresponding to the one where no more return echo is given.

19. ACCEPTANCE OR REJECTION CRITERIA

Acceptance or rejection criteria shall be in accordance with API 1104 or as per specified in Client
specification. All defect location shall be marked & / or recorded for repairing.
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20. RETEST

Retest of the repaired area shall be carried out in accordance this procedure.

21. OTHER EQUIPMENT

The use of rules calibrated in centimeters, attached if possible to the probe, for the precise location of
the position of welding defects, is recommended. Defect location is effected by measuring the
projection distance between the probe output and the reflecting surface.

The operators carrying out the tests shall have, besides the probing instrument, tools for cleaning the
pipe surface (tiles, brushes, etc.) as well as the coupling liquid or paste appropriate for the
temperature of the section to be examined.

22. REPORTING

All details of inspection and results of inspection shall be documented in Report and shall be signed by
NDT inspector, TPIA and Client.

Note:-
In case of any conflict between the requirements of this procedure and that of CLIENT standard
specification, the requirement of CLIENT Specification shall govern.

23. HEALTH SAFETY AND ENVIRONMENT:

WARNING: Electrical equipment shall not be operated in areas where combustible gases or vapors may
be present, unless the equipment is explosion-proof.
If instrument is operated using AC power, use a grounded power cord.
Turn power OFF before connecting or disconnecting transducer cable or power cable

24. FIGURES

Figure:1(A)

Notch of 3.2 mm width and n10(10% depth)

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MANUAL ULTRASONIC D 11095
TESTING 010

(reference figure 22a of API 1104-19Edition)

0 ID OD ID

Figure:1(B)
½ NORMAL PROBES

/TR PROBE 1V

Figure:1(C)

25. DOCUMENTATION:

FORMAT 1 : Inspection Test Plan ITP-CON-F-10 UT

FORMAT 2 : Inspection Report IR-CON-F-10 UT

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