Uhde India - PVtools

GENERAL ENGINEERING SPECIFICATIONNON - DESTRUCTIVE TESTINGESA-AD6 (M)Page2.2Test conditions and requirements2.2.1Normal operating conditions:2of172.2.1.A For plates having thickness 40 mm If specified in the DDS or IDS, Ultrasonictest of the whole surface according to SA-435, scanning grid 225 mm.The manufacturer shall test the zones of longitudinal, circumferential and nozzlewelds with a width equal to plate thickness or minimum 50 mm.2.2.1BFor plates having thicknesses 20 to 40 mm (both inclusive):If specified in the DDS or IDS, Ultrasonic test of the whole surface according toSA 435, scanning grid 225 mm.The manufacturer shall test the zones of longitudinal, circumferential and nozzlewelds with a width equal to plate thickness or minimum 50 mm.2.2.1.1Acceptance Standard:The acceptance standards are in accordance with SA-435 Section 6.2.2.2Operating conditions according to ESA-AD3 (M):Ultrasonic test according to SA-578 except the scanning grid shall be 100 mm.The zones of longitudinal, circumferential and nozzle welds shall be tested by themanufacturer with a width equal to plate thickness or minimum 50 mm.2.2.2.1Acceptance Standard:The acceptance standards are in accordance with the requirements of SA-578quality level B and supplementary requirements S 2.1 imposed, except that themaximum acceptable encompassed diameter circle for discontinuities shall be35 mm, and for scanning of weld edges the maximum acceptable encompasseddiameter circle for discontinuities shall be 11 mm.2.3Test reportThe results of ultrasonic tests and the test conditions shall be recorded in an inspection test certificate.2.4Personnel QualificationMaster Document Rev.01 2008The manufacturer shall certify that the personnel performing ultrasonic examination has been qualified to SNT-TC-1A ( "Personnel Qualification and Certification inNon destructive Testing" published by American Society for NDT) or an approvedequivalent.3.0Ultrasonic test (UT) of forgings3.1ScopeThis specification covers the requirements for ultrasonic tests of forgings made ofcarbon or low-alloyed steel and applies to the tests specified in the ESA, DDS orIDS.H:\AP 0 21.09 0 General\GES\PRESSURE VESSEL GES\ESA-AD6 (M).doc

GENERAL ENGINEERING SPECIFICATIONNON - DESTRUCTIVE TESTINGESA-AD6 (M)Page3.2Test conditions and requirements3.2.1Test specification: SA-388.3.2.2Date of test:3of17The test shall be carried out after the heat treatment if called for by Material specification.3.2.3Test surfaces:The surfaces to be tested shall be prepared according to SA-388, Section 6.3.2.4Normal operating conditions:All surfaces shall be tested according to SA-388. The whole cross section of theforging shall be scanned. In addition forgings for tubesheets shall be scanned by theAngle probe method on the side where the tubes are welded to the tubesheet. Thescanning depth shall be 20 mm of the machined tubesheet.The same method shall be used for concave fillets which are susceptible to localstress, e.g. in transitions from tubesheet to shell.3.2.5Operating conditions according to ESA-AD3 (M):The test shall correspond to 3.2.4. Moreover, the fluid side(s) of the tubesheets shallbe scanned by Angle probe method. The scanning depth shall be 10 % of the thickness of the machined tubesheet sections.3.3Admissible defectsMaster Document Rev.01 2008The following conditions are considered rejectable:3.3.1Straight beam examination:3.3.1.1Complete loss of back reflection not associated with forging configurations or surfaceand accompanied by an indication of discontinuity. For this purpose a back reflection less than 5% of full screen height shall be considered complete loss of back reflection.3.3.1.2Indications whose amplitude equals or exceeds that of the back reflection established in an indication free area of the forging.3.3.1.3One or more indications equal in amplitude to that of the applicable reference hole,when properly corrected for distance.3.3.1.4For twin probe examination indications showing an amplitude equal or exceeding thereference amplitude of 6.4 mm flat bottom hole.3.3.2Angle beam examination:Discontinuities which results in indications exceeding the amplitude of the referencenotch or the amplitude reference line.3.3.3The vessel manufacturer shall provide any details for above examination to the forging manufacturer.H:\AP 0 21.09 0 General\GES\PRESSURE VESSEL GES\ESA-AD6 (M).doc

GENERAL ENGINEERING SPECIFICATIONNON - DESTRUCTIVE TESTINGESA-AD6 (M)Page3.44of17Recording levelThe recording level shall be 6 dB below the admissible echo level. Indications exceeding the recording level shall be recorded.3.5RecordingThe report of the ultrasonic inspection shall be in compliance with SA-388, Section 8and 9.In addition the following shall be recorded:3.6a)Indications exceeding the calibration back reflection.b)For twin probe examination indications exceeding 50% of the amplitudeof 6.4 mm diameter reference hole.c)For angle beam examination of weld edges or weld joining areas indicationsof discontinuities exceeding 25% of the amplitude of the reference line.Personnel QualificationThe manufacturer shall certify that the personnel performing ultrasonic examinationhas been qualified to SNT-TC-1A (" Personnel Qualification and Certification in Nondestructive Testing" published by American Society for NDT) or an approved equivalent.4.0Ultrasonic Test (UT) of cladding4.1ScopeThis specification covers the requirements for ultrasonic tests of rolled, explosionbonded and deposit weld cladding and applies to the tests indicated in the ESA,DDS or IDS.4.2Test conditions and requirements4.2.1Test according to SA-578.4.2.2Date of test:The test shall be carried out after forming i.e. after rolling the shell sections or pressing the heads. If the test is performed according to ESA-AD3 (M), it shall take placeafter the final heat treatment. For weld overlays in the case that PWHT is requiredbefore the application of the final layer, the 1st layer also to be scanned after thePWHT.Master Document Rev.01 20084.2.3Test surfaces:The surfaces to be tested shall be prepared such that the probe is supported properly. However, the surface condition shall ensure the echo reflection ratio specifiedunder 4.2.4.4.2.4Calibration of sensitivity:The calibration block shall comply with SA-578. It shall be clad by the same procedure as the test specimen.H:\AP 0 21.09 0 General\GES\PRESSURE VESSEL GES\ESA-AD6 (M).doc

GENERAL ENGINEERING SPECIFICATIONNON - DESTRUCTIVE TESTINGESA-AD6 (M)Page5of17The difference between the echo level to be recorded and the indication shall bemin. 6 dB.4.2.5The dimension of a defect shall be determined according to Section 5 of SA 578.4.3Test of rolled or explosion-bonded claddingThe material shall be tested for lack of bond between cladding and base metal bymeans of straight-beam probe according to SA-578.4.3.1Normal Operating Conditions:Surface shall be scanned according to a grid of 225 x 225 mm. 100% of the weldedges shall be scanned, the test zone width being 50 mm. Tubesheets shall be100% scanned.In the case of clad sections where components intended for load transmission arewelded to the structure, the scanning width shall be 150 mm from the weld. The testshall take place prior to and after welding.4.3.1.1Admissible defects:According to SA-578 Acceptance Standard-Level B with the following additions:A defect shall be considered as individual defect if the distance to the adjacent defect is greater as described in SA-578 paragraph 8.Plates which have lack of bond of 5% referred to the overall surface shall be rejected.Individual defects with a surface of maximum 20 cm² shall be repaired by welding. Ifrequired, the manufacturer shall submit a valid process qualification and a certificatefor the repair method of the component in question. After the pressure test, the repaired sections shall be subjected to ultrasonic and dye penetration test. Repairwelding shall be in accordance with the requirements of SA-264 paragraph 14.Tubesheets for heat exchanger, lack of bonds which have a surface of 10 cm2shall be inadmissible. For 10 cm2, repair procedure shall be discussed on a case tocase basis with Uhde. The outer zones of the cladding shall not have any continuouslack of bond from the bore hole to the perimeter.4.3.2Operating conditions according to ESA-AD3 (M):The surfaces shall be tested according to a grid of 100 x 100 mm. 100% of theweld edges shall be scanned, the test zone width being 50 mm. Tubesheets shall be100% scanned.Master Document Rev.01 20084.3.2.1Admissible defects:According to SA-578 Acceptance level S 7 with the following additions:Defects with lack of bond and with a surface area of 1cm² shall be inadmissible.Moreover, the requirements according to 4.3.1.1 shall apply if more stringent thanlevel S 7. Admissible defects for the base metal shall be in accordance to 2.2.2.1.4.4Test of weld overlaysThe test shall be performed by means of a straight beam probe according to ASMESec. V, Article 4, T-473.1.H:\AP 0 21.09 0 General\GES\PRESSURE VESSEL GES\ESA-AD6 (M).doc

GENERAL ENGINEERING SPECIFICATIONNON - DESTRUCTIVE TESTINGESA-AD6 (M)Page6of17Tests to be carried out by means of TR probe for longitudinal waves using the anglebeam method shall be agreed upon in writing with the Purchaser.4.4.1Normal operating conditions:25% of the surface shall be scanned. In the case of strip overlay welding, the overlapping sections shall be tested. Tubesheets shall be 100% scanned.4.4.1.1Admissible defects:Indications exceeding the echo level of the calibration reflector by 50% and 100%shall be recorded.Defects causing indications above the echo level of the calibration reflector shall beinadmissible.Systematic defects such as pores, scale rocks, lack of fusion, etc. are inadmissibleand shall be repaired irrespective of the size of the defects listed above.For tubesheets, outer zone of the cladding shall not have any continuous lack atbond from the bore hole to the perimeter.4.4.2Operating conditions according to ESA-AD3 (M):100% of the surface shall be scanned.4.4.2.1Admissible defects:The requirements according to 4.4.1.1 shall apply.4.5Test ReportThe test report shall comply with SA-578 paragraph 13.4.6Personnel QualificationThe manufacturer shall certify that the personnel performing ultrasonic examinationhas been qualified to SNT-TC-1A ("Personnel Qualification and Certification in Nondestructive Testing" published by American Society for NDT) or an approved equivalent.5.0Ultrasonic test (UT) of welds5.1ScopeMaster Document Rev.01 2008This specification covers the requirements for ultrasonic tests of ferritic steel weldsand applies to the tests indicated in the ESA, DDS or IDS.5.2Test conditions and requirements5.2.1Test specification:ASME Section V and ASME Section VIII5.2.2Date of test:If heat treatment is specified, the test shall be carried out after the last heattreatment or, if specifically requested in DDS or IDS after the pressure test.H:\AP 0 21.09 0 General\GES\PRESSURE VESSEL GES\ESA-AD6 (M).doc

GENERAL ENGINEERING SPECIFICATIONNON - DESTRUCTIVE TESTINGESA-AD6 (M)Page5.2.37of17Calibration of Instruments:Master Document Rev.01 2008The methods shall meet the requirements of ASME, Section V, Article 4. Othertechniques may be used if approved by the purchaser.5.2.3.1For pressure vessels, basic calibration block shall be in accordance with ASME Section V, Article 4, T-434. The Alternate Block T-434.2.4 shown in Appendix JFig. J-431 shall be used. For pipe welds, basic calibration block shall be in accordance with T-434.3, Fig. 434.3 and T-464.5.2.3.2For straight beam examination the gain control shall be set to 80% of full screen bybasic calibration block at 3/4 T hole.5.2.3.3For angle beam examination the calibration shall meet the requirementsASME, Section V, Article 4, Appendix B as a general technique.5.2.3.4In addition the distance amplitude correction curve (DAC) shall be adjusted insuch a way, that the grain control is set 80% of full screen by basic calibration blockat the 1/4 T hole. Position the search unit for maximum responses from the nextholes and connect the peaks of the indications on the screen. Because of the loss ofsensitivity by scanning of thicker plates start with a second DAC curve for 3/4 T holeby similar 80% screen height of the grain control and note the dB increase whichis necessary to achieve the same sensitivity as for the 1/4 T hole.5.2.4Scanning Requirements:5.2.4.1Plates around connection holes shall be ultrasonically tested. This is to be done priorto beveling, using the normal beam technique over a continuous annular band atleast 75 mm (3-in) wide around the opening in the plate.5.2.4.2The adjacent base metal to the weld joint shall be scanned according to ASME, Section V, Article 4, T-472.5.2.4.3The weld shall be scanned for reflectors oriented parallel to the weld accordingto ASME, Section V, Article 4, T-471, T-472 and Article 4, I-471, I-472 and I-473with two different beam angles.5.2.4.4The weld shall be scanned for reflectors oriented transverse to the weld according toASME, Section V, Article 4, T-471, T-472.1.3 and Article 4, I-471, I-472, I-473.Where the weld surface interferes with the examination, the weld surface shall beprepared as needed to permit the examination.5.2.4.5To examine nozzle welds exceeding 150 mm (6-in) internal diameter to shellplates exceeding 38 mm thickness an additional scan shall be done from thebore of a set-through nozzle or the inner shell surface of a set-off nozzle with thestraight beam technique.5.2.5Welds on pipes shall be examined according to the requirements of ASME, SectionV, Article 4, T-434.3, T-464.5.2.6Weld seams thicker than 75 mm (3-in) may be divided in sections of max. 60 mmthickness for scanning and evaluation to ensure optimal testing sensitivity for thewhole thickness. Wherever possible the scanning shall be done from the inside andthe outside surface.5.2.7Welds for non-pressure attachments as for lifting lugs and lifting trunnions to thevessel shall be ultrasonically inspected from the opposite side of the plate or forging.The final inspection shall be done after the post weld heat treatment of the welds.H:\AP 0 21.09 0 General\GES\PRESSURE VESSEL GES\ESA-AD6 (M).docof

GENERAL ENGINEERING SPECIFICATIONNON - DESTRUCTIVE TESTINGESA-AD6 (M)Page5.38of17MarkingEach weld and examination area shall be located and identified by a system of reference points placed on the component or in a sketch. An example is given in ASME,Section V, Article 4, Appendix A.5.4RecordingRecord all reflectors that produce a response equal to or exceeding 50% of DACcurve. The length of the reflector shall be obtained by measurement according toASME, Section V, Article 4, T-470 and T-480. The Report of examination shall contain the information required by ASME, Section V, Article 4, T-490, T-491, T- 492and T-493 and the Pressure Vessel Code, Section VIII, Div. 1, App. 12 and Div. 2,Article 7.5.4.1.5.5Acceptance Standard5.5.1The Standard for unacceptable discontinuities shall be in accordance with the requirements of ASME, Section VIII, and Div. 1, Appendix 12 or Div. 2, Article 7.5.4.1,except for weld edges the Standard shall be according to 2.2.2.1.5.5.2Repairs to correct weld defects shall be made in accordance with approved repairwelding procedure.5.5.3The Inspector shall be informed of all major repair work prior to commencing repair.Major repairs are defined as follows:5.6(a)A repair which requires the excavation of base material to a depthexceeding 3/8 inches (10 mm) or one-half the base material thickness,whichever is the smaller.(b)A repair which requires welding and the area exceeds 6 square inches(39 cm²) at any spot.(c)A re-repair which requires welding after excavation of the repairedpart of the base material and weld metal.(d)A repair which requires welding after PWHT.Test reportThe results of ultrasonic tests and the test conditions shall be recorded in an inspection test certificate. See also 5.4.Master Document Rev.01 20085.7Personnel QualificationThe manufacturer shall certify that the personnel performing ultrasonic examination has been qualified to SNT-TC-1A (" Personnel Qualification and Certification inNon-destructive Testing" published by American Society for NDT) or an approvedequivalent.6.0Radiographic test (RT) of welds6.1ScopeThis specification covers the requirements for radiographic tests of welds and applies to the tests indicated in the ESA, DDS or IDS.H:\AP 0 21.09 0 General\GES\PRESSURE VESSEL GES\ESA-AD6 (M).doc

GENERAL ENGINEERING SPECIFICATIONNON - DESTRUCTIVE TESTINGESA-AD6 (M)Page6.2Test conditions and requirements6.2.1Test specification:9of17All welded joints to be examined as specified in the Uhde Specification shall betested in accordance with the requirements in ASME, Section V, Article 1 andArticle 2 and Subsection B, Article 22, SE-94, T-277, T-280 and Section VIII Div. 1,UW 51, UW52 and Div. 2 Part 7, 7.5.3.6.2.2Date of test:If post-weld heat treatment is specified, the radiographic test shall be performed afterthe last heat treatment. If radiographic and ultrasonic tests are required, the RT canbe carried out after welding and the UT after the last heat treatment.6.2.3Surface Preparation:The finished surface of the butt-welded joints may be flush with the base material orhave reinforcements not exceeding the limits specified in ASME, Section VIII, Div. 1,UW 35 and Div.2, Part 6, 6.2.4.1 (d) and will meet the requirements in ASME, Section V, Article 2 T-222.6.2.4Selection of Energy of Radiation - Film Type:The energy of radiation shall be selected according to the requirements in ASME,Section V, Article 2, T-272. Radiographs shall be made using film type SE-1815Table X1.1 with the requirements in ASME, Section V, SE-94 Table 1 and 2 as aguide.6.2.5Radiographic Density:The transmitted film density shall be in the ranges according to ASME, Section V, Article 2, T-282.1. If the density varies more than that allowed, then an additionalpenetrameter shall be used for each exceptional area. For joints between plates ofdifferent wall thicknesses one radiograph with allowable density range for eachthickness shall be taken.6.2.6Shims under Penetrameter:A shim of material radiographically similar to the weld metal shall be placed underthe penetrameter if the reinforcement is not removed. Selection of the shims shallbe according to ASME, Section V, Art

PRESSURE VESSELS DOCUMENT NO. 6481-MQ-UGS-0001 PAGE 2 REV. 0 . 3. REFERENCE UHDE STANDARDS Standard No. Part Title Issue Dt UN 2000-01 1(M) VESSELS & EQUIPMENT: PRESSURE VESSELS GENERAL SPECIFICATION 08-2008 UN 2000-01 3(M) VESSELS & EQUIPMENT: FIELD FABRICATION GENERAL SPECIFICATION 08-2008 . and Uhde Std. UN 2000-01 Part 1 (M). (ii) This .