KAY BOUVET ENGINEERING LIMITED Revision 0

Date 10.06.2017
ULTRASONIC EXAMINATION PROCEDURE FOR Total Pages 7 Nos.
STEEL FORGINGS Page No. Page 1 of 7

CONTROL SHEET

PROCEDURE NO. : KBE/02.12.22/QCS/UT/COM/0001/00

CUSTOMER : NUCLEAR POWER CORPORATION OF INDIA LTD.

PROJECT : TUBE BUNDLE FOR BLEED CONDENSER

PO NO. : CMM/OPS/55-33-9-3056/e-PO/15409 Dt. 15/03/2017

KBEL JOB NO. : 02.12.22

Sr. Rev. No. /

Description of Revision No. of Pages
No. With Date

00
1 New Issue 7
dt. 10.06.2017

PROCEDURE NO. : KBE/02.12.22/QCS/UT/COM/0001/00

 KAY BOUVET ENGINEERING LIMITED Revision 0
Date 10.06.2017
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For Kay Bouvet Engineering Limited

Signature

Name Sachin Kadam Mujaffar Shaikh

Date

Prepared by Checked by Approved by

For Nuclear Power Corporation of India Ltd

PROCEDURE NO. : KBE/02.12.22/QCS/UT/COM/0001/00

 KAY BOUVET ENGINEERING LIMITED Revision 0
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1. Scope

This practice covers the examination procedures for the contact, pulse-echo ultrasonic
examination of steel forgings required for Tube Bundle of Bleed Condenser ( Tube Sheet,
Channel Cover & Nozzles ) by the straight beam techniques. The straight beam techniques
include utilization of the DGS (Distance Gain-Size)

2. Reference

2.1 ASTM A388/SA 388

2.2 SNT-TC-1A
2.3 NPCIL Specification PP-E-2037

3. NDT Personnel Qualification

3.1 The personnel performing Ultrasonic examination should be qualified and certified as
per written procedure in line with the ASNT recommended practice SNT-TC -1A.
3.2 Calibration and scanning shall be done by at least level I under supervision of NDT
Level II or NDT Level III.
3.3 However interpretation and evaluation of indications shall be done by NDT Level II/III.

4. Equipment

4.1 The instrument shall be pulse echo type and shall be equipped with a stepped gain
control calibrated in the units of 2.0 dB or less. The system shall have a minimum
capability for examining at frequencies from 0.5MHz to 6MHz.
4.2 The ultrasonic instrument shall provide linear presentation (within 5%) for at least 75%
of screen height (sweep line to top of screen) the 5% linearity referred to descriptive of
the screen presentation of amplitude.
4.3 Search Units :
4.3.1 Straight Beam Probe : Freq. 0.5 - 5 MHz, Size - 10mm, 24mm
4.3.2 Other search units may be used for evaluating and pinpointing indications.

5. Couplant

5.1 Couplant having a good wetting ability should be used.

5.2 Couplant such as SAE No. 20 or SAE No. 30 Motor oil, grease may be used.
5.3 Same couplant shall be used for calibration as well as for testing.

6. Surface Condition

6.1 The surface of the Tube Sheet forging to be examined shall be free of loose scale, paint,
dirt etc.
6.2 The surface roughness of scanning surfaces shall not exceed 6.35 m.

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7. Reject
7.1 This control is also called suppression in some instruments and shall be maintained
in the minimum position (or OFF position, if available) throughout the examination.

8. Procedure

8.1 General
8.1.1 As far as practicable, subject the entire volume of the Tube Sheet forging to ultrasonic
examination.
8.1.2 Perform the ultrasonic examination after heat treatment for mechanical properties but
prior to drilling holes, cutting keyways, tapers, grooves, or machining sections to
contour.
8.1.3 To ensure complete coverage of the forging volume, index the search unit with at least
15 % overlap with each pass.
8.1.4 For manual scanning, do not exceed a scanning rate of 150 mm/s.
8.1.5 If possible, scan Tube Sheet forgings in two perpendicular directions.
8.1.6 Scan Tube Sheet forgings using a straight beam technique from at least one flat face
and radially from the circumference, whenever practicable.

8.2 Straight-Beam Examination

8.2.1 For straight-beam examination use a nominal 2-4MHz search unit whenever
practicable. Other frequencies may be used if desirable for better resolution,
penetrability, or delectability of flaws.
8.2.2 Establish the instrument sensitivity by, reference-block technique, or DGS method

A) Reference-block technique

a) Calibration blocks shall be of the same material specification and heat treatment as
applicable to the test object. However, where the actual forging material belongs to P1
(Refer ASME Sec. IX), use of calibration block made of mild steel is permitted,
provided the block is made from forged material. The surface finish at the entry
surface of the calibration block should be similar to that of the test object. Prior to
machining the block, the raw material shall be ultrasonic examination checked and
shall be adequately defect free.
The hole diameter shall be 6 mm. The holes shall be machined truly flat bottomed,
preferably by end milling.
The diameter of the calibration blocks and block length shall be as shown in the
Table1 & Fig.1

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Fig. 1 : Standard Reference block

Table 1 : Dimensions of Reference Block

Hole Diameter Metal Distance B Overall Length C Diameter D

mm mm mm mm

6 25 45 50
6 50 70 50
6 75 95 50
6 150 170 75
6 200 220 100
6 250 270 125
6 300 320 125
6 350 370 125

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b) Sensitivity Calibration

i) Setting the primary reference level

At a suitable gain setting find out which hole provides the highest response. Set the
amplitude of this echo to between 70% FSH and 80% FSH using the gain control. This
is the reference gain and should not be changed.

ii) Drawing the DAC curve

Use the instrument screen as a graph. At the metal path corresponding to the first
hole (which gives highest response), mark the maximized amplitude of the echo.
Repeat this for all the other holes. Draw a smooth line through the points so obtained.
This is the distance amplitude correction (DAC) curve.

c) Recording and Evaluation

Scan at a gain value higher than the above reference gain by 6 dB.
Recording & Evaluation shall be done at reference gain for
Any indication whose amplitude equals or exceeds 50% of the established DAC
i) Travelling, clustered or continuous indications that have amplitudes equal to or
greater than 25% of the DAC curve.
ii) any reduction in back reflection (associated with a discontinuity indication)
exceeding 20% of the calibration back reflection. Evaluate the amplitude of each
indication by comparison with the height of the DAC curve at the same metal path
as the indication and report it as a percentage of DAC.

d) Acceptance Level

Indications of following nature shall cause for rejection

i) Any indication whose amplitude exceeds 100% of the established DAC curve,
ii) Travelling, clustered or continuous indications that have amplitudes equal to or
greater than 50% of the DAC curve.
iii) Reduction in black reflection exceeding 50% not associated with geometric
configuration are unacceptable.

B) DGS Method
a) Prior to use of DGS scale, verify that the DGS overlay matches the transducer can
be size and frequency.
b) Accuracy of overlay can be verified by reference blocks.
c) Overlays are to be serialized to match the ultrasonic transducer and pulse echo
testing systems that they are utilized with.
d) Insert the overlay on the CRT screen. Ensure the DGS scale base line coincides with
the sweep line of the CRT screen.
e) Place the transducer on the test piece. Adjust the gain to make the first back wall
echo appear clearly on CRT screen. Using delay and sweep control shift the screen
pattern so that, the leading edge of the initial pulse is on the zero of DGS scale

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and the back wall echo is on the DGS scale value corresponding to the thickness of
bar/billet/bloom.

f) Adjust the gain so that back wall echo matches the height of DGS reference slope
within 1db. Once adjusted increase the gain by the dB shown on DGS scale for
the reference slope.
g) Instrument is now calibrated and the flaw size that can be readily detected can be
directly read from the CRT screen. These flaw sizes are equivalent to that Flat
bottom hole reflector that can be used as a reference point.
h) In built DGS scale of the Ultrasonic Flaw Detector can be used.

i) Recording and Evaluation

Scan at a gain value higher than the above reference gain by 6 dB.
Recording & Evaluation shall be done at reference gain for
Any indication whose amplitude equals or exceeds 50% of the established DGS
i) Travelling, clustered or continuous indications that have amplitudes equal to
or greater than 25% of the DGS curve.
ii) any reduction in back reflection (associated with a discontinuity indication)
exceeding 20% of the calibration back reflection. Evaluate the amplitude of
each indication by comparison with the height of the DGS curve at the same
metal path as the indication and report it as a percentage of DGS curve.
j) Acceptance Level
Indications of following nature shall cause for rejection
i) Any indication whose amplitude exceeds 100% of the DGS curve,
ii) Travelling, clustered or continuous indications that have amplitudes equal to
or greater than 50% of the DGS curve.
iii) Reduction in black reflection exceeding 50% not associated with geometric
configuration are unacceptable.

9 Report
The following data shall be reported to format
a) Test procedure including make and model of instrument, test frequency, transducer
type, and transducer active element size and couplant used.
b) Technique used for examination. For example DGS or Reference blocks technique.
c) Acceptance standard.
d) Heat Identification number, size and surface condition of test piece.
e) All the recordable indications along with the length and area.
f) Date of performance of examination, name and signature of NDT person performing
the examination and approving of results.

PROCEDURE NO. : KBE/02.12.22/QCS/UT/COM/0001/00