Ut - Bhe Nde Nu 700mw RH RT Rev 00 Latest Ut Procedure 14-02-2014

BHARAT HEAVY ELECTRICALS LIMITED BHE:NDE:NU:700MW:RH:UT
TIRUCHIRAPPALLI-620014 REV:01
NON-DESTRUCTIVE TESTING Date: 01-08-2014
DEPT.-2350 ULTRASONIC EXAMINATION PROCEDURE Page 01 of 17
PROCEDURE FOR ULTRASONIC EXAMINATION OF WELDS
REACTOR HEADER ASSEMBLIES FOR KAPP-03 & 04 AND RAPP-07 & 08
APPLICABLE W.O. No: D-139 to 142
APPLICABLE P.O. No: i) CMM/FTP/23-33-1-1042/PO/ 6027 AND

ii) CMM/FTP/23-33-1-1042/PO/6373
DILIP KUMAR SINGH

PREPARED BY ENGINEER/NDTL
Level-II
T. V. SUBASH
REVIEWED BY MANAGER/NDTL
Level-II
T. GURUNATHAN
APPROVED BY HOD/AGM/NDTL
Level-III
N. SUBRAMANIAN
REVIEWED BY HEAD/QA
M/s NPCIL/QS,TRICHY
APPROVED BY
M/s NPCIL, MUMBAI
REV. REASON FOR REVISION DATE (DD-MM-YYYY)
01 Revised for 5% NOTCH depth 01-08-2.14
00 First Issue 16-11-2013

LIST OF CONTENTS:
1. Scope……………………………………………………………………03
2. Reference Documents………………………………………………….03
3. Personnel Qualification………………………………………………..03
4. Extent of Examination………………………………………………...03
5. Stage of Examination………………………………………………….05
6. Surface Condition……………………………………………………...05
7. Equipment……………………………………………..……………….05
8. Examination Medium and Couplant…………………………………06
9. Calibration……………………………………………………………..06
10. Examination Area……………………………………………..……….08
11. Scanning Details………………………………………………………..09
12. Recording and Evaluation…………………………………………….09
13. Examination Instructions……………………………………………..12
14. Acceptance Standards……………………………………………........13
15. Examination Records………………………………………………….13
16. Reports……………………………………………………………….....13
17. Post Test Cleaning……………………………………………………..13
APPENDIX-I, II & III

LIST OF TABLES:
1. TABLE-01: Recording Level Depending on Nominal Wall Thickness (t)……...14
2. TABLE-02: Reference Blocks for Ultrasonic Examination of Reactor Header
Assembly …………………………...15
3. TABLE-03: List of Technique Sheet for Ultrasonic Examination of Reactor
Header Assembly ……………………………………………...16
APPENDIX-IV
1. Report Format …………........................................................................17

1.0 SCOPE:
This procedure describes and defines the requirement of the

equipment, calibration, Inspection procedure and acceptance
standards for the Ultrasonic Examinations of Reactor Header
Assemblies for the Primary Coolant System of 700 MWe PHWR
for KAPP-3&4 & RAPP-7&8 projects.
2.0 REFERENCE DOCUMENTS:
This procedure in accordance and complies with following Codes,

Standards and Documents:
i) ASME Section III-Division-1-Sub-Section-NB
ii) ASME Section V-Non Destructive Examinations
iii) 33117/PC-E-286 Section–C of Technical Specification for
Reactor Header Assemblies and
iv) SNT-TC-1A.
3.0 PERSONNEL QUALIFICATIONS:
Personnel performing examinations in accordance with this

procedure shall be qualified and certified in accordance with SNT-
TC-1A and NB-5520 requirements. Testing shall be performed by
Level-I or Level-II. Interpretation shall be done by Level-II/Level-
III personnel only.
4.0 EXETENT OF EXAMINATION:
4.1 Pressure boundary butt welds of Category A, B, C & D

which require Ultrasonic Examination as per ASME Sec III
NB 5000 shall be subjected to Ultrasonic Test as per this
procedure.
4.2 In addition to the Non-Destructive Examinations specified in

ASME section III-NB this procedure calls for Ultrasonic
Examinations for all butt welds and corner welds attaching
nozzles of all sizes on Header and Feeder Pipes.
4.3 So, all pressure retaining butt and corner welds irrespective
of their sizes shall be examined by Ultrasonic Test in
accordance with ASME Section III-Division-1-Sub-Section-
NB, ASME Section V-Non Destructive Examinations and
Sub-Sections 7.6 of Section-C of Tender Document
(33117/PC-E-286).
4.4 Ultrasonic examinations shall also cover extent possible

adequate area of base metal beneath the weld deposited and
weld metal in pressure retaining and attachment joints
(especially corner welds) to detect any cracks, lack of fusion
/ bonding or Laminar defects etc.
4.5 Full penetration corner welded joints of category C & D shall

be subjected to Ultrasonic examination as per this procedure.
4.6 Attachment welds on pressure retraining walls shall be

subjected to an ultrasonic examination as per this procedure.
4.7 The discontinuity indications from within base metal shall be

evaluated as per acceptance standards applicable to base
metal product forms.
4.8 Heat Treatment Condition:
As a rule, the acceptance examination shall take place after

the Final Heat Treatment of the respective weld. This
assumes that no reduction in accessibility or any other
hindrance to the examination of the weld to the fullest
required sensitivity has occurred due to production progress
at this stage. In the event of restrictions to the examination
after heat treatment, proceed as specified in section 12.6.2.
5.0 STAGE OF EXAMINATION:
Ultrasonic Examinations will be performed before HT and shall be

performed after final Post Weld Heat Treatment (PWHT). If any
weld and adjoining surfaces which are not accessible after PWHT
will be examined and concluded prior to the PWHT.
Ultrasonic examination shall be carried out prior to Hydrostatic

Test. However, weld joint between Headers to Dished End (Joint.
No. 01 & 02 of each Header assembly) shall be re-examined after
hydrostatic test.
6.0 SURFACE CONDITION:
Surfaces to be examined shall be clean and free from scale, oil,

grease, machining marks, heavy paint and other foreign matter that
could adversely affect inspection sensitivity or the interpretation of
indications. Cleaner used to degrease and prepare the surfaces shall
not be detrimental to the material, the surface finish or the detection
media.
The roughness of the surfaces shall not exceed 250 µin. (6µm).
The weld surfaces should be finished such that they cannot mask or
confused with reflections from defects and should merge smoothly
into the surface of the adjacent base materials.
7.0 EQUIPMENT:
UT Apparatus:
The following UT equipment or instruments with similar

characteristics shall be used:
Manufacturer Type –Manual -A scan
Krautkramer: USN 52R (Digital) / USL32/ Site scan 250(Digital).
Olympus: Epoch 600 (Digital)
The Equipment shall be of the Pulse echo contact type with
calibrated gain control of linear characteristics. The scanning
frequencies will range from 2 to 5 MHz minimum.
8.0 EXAMINATION MEDIUM AND COUPLANT:
The couplant including additives shall not be detrimental to the

surfaces being examined.
9.0 CALIBRATION:
9.1.0 Instruments:
For digital type instruments, the requirements of the following

paragraph 9.1.1 & 9.1.2 and ASTM E317 shall be met at intervals
not exceeding one year and for analog type instruments the
requirements of the following paragraph 9.1.1 & 9.1.2 and ASTM
E317 shall be met at an intervals at least once in a year.
9.1.1Screen Height Linearity:
The Ultrasonic Instrument’s screen height linearity shall be

evaluated in accordance with Mandatory Appendix I of ASME-V,
Article 4, at least once in a year.
9.1.2 Amplitude Control Linearity:
The Ultrasonic Instrument’s amplitude control linearity shall be

evaluated in accordance with Mandatory Appendix II of ASME-V,
Article 4, at least once in a year.
9.1.3 Horizontal Linearity:
Horizontal linearity check of instrument shall be as per Cl.6.2of

ASTM E-317, at least once in a year.
9.1.4 Resolution:
Resolution shall be checked with IIW-V1 block having depths 85,

91&100mm.
The instruments and the probes should be calibrated before starting
the examination and after any adjustment or change of equipment
or personnel carrying out these operations.
9.1.5 Search Unit (Angle Beam):
Prior to use, the angle beam probes shall be verified using

calibration block to determine the correct angle and beam exit point
of the search unit.
9.2.0 Calibration/Reference Block/specimen:
The reference block shall be manufactured from material of the

same composition, diameter, thickness and surface condition and
heat treatment conditions as of the material which is to be
examined.
Reference Calibration Block for Angle–Beam & Straight - Beam

scanning shall be made in accordance with TABLE-2 of Appendix
II. With concurrence of M/s NPCIL, other standard reference holes/
notches may also be employed for setting the sensitivity provided
no higher recording heights than those stated in Table 1 are
produced by them.
9.2.1 Sensitivity Calibration Method:
Based on response of applicable (as per table-1) notches/side drilled

holes/ flat bottom holes available in applicable reference
block/specimen DAC (reference level) curve shall be made. The
DAC (reference level) curve shall be established as per approved
applicable examination technique sheet (Table-3).
9.3.0 Calibration Confirmation:
9.3.1 System Changes: When any part of the examination system is

changed, a calibration check shall be performed on the calibration
block to verify the distance range points and sensitivity settings to
meet the requirements of 9.3.2 & 9.3.3.
9.3.2 If any distance range point has moved on the sweep line by more
than 10% of the distance reading or 5% of full sweep (whichever is
greater), correct the distance range calibration and note the
correction in the examination record. All recorded indications since
the last valid calibration or calibration check shall be re-examined
and their values shall be changed on the data sheets or re-recorded.
9.3.3 If any sensitivity setting has changed by more than 20% or 2 dB of

its amplitude, correct the sensitivity calibration and note the
correction in the examination record. If the sensitivity setting has
decreased, all data sheets since the last valid calibration or
calibration check shall be marked void and the area covered by the
voided data shall be re-examined. If the sensitivity setting has
increased, all recorded indications since the last valid calibration or
calibration check shall be re-examined and their values shall be
changed on the data sheets or re-recorded.
9.3.4 Calibration Checks: A calibration check on at least one of the

reflectors in the calibration block shall be performed at the
completion of each examination or series of similar examinations
and when examination personnel are changed. The distance range
and sensitivity values recorded shall meet the requirements of 9.3.2
& 9.3.3.
10.0 EXAMINATION AREA:
The complete weld metal and extent possible adjacent zones of

base material beneath or on either side of the weld irrespective of
their sizes shall be examined. Each pass of the search unit shall
have overlap a minimum of 10% of the transducer /search unit
dimensions parallel to the direction of scanning. Oscillation of the
search unit is permitted if it can be demonstrated that overlapping
coverage is provided. Scanning speed shall not exceed 150mm/sec.
11.0 SCANNING DETAILS:
11.1 SCANNING DIRECTIONS:
11.1.1 The scanning directions shall be taken as per approved

applicable examination technique sheet (Table-3).
11.1.3 If any deviation from the above, examination will be done

with concurrence of M/s NPCIL.
11.2 SCANNING ANGLE AND FREQUENCIES:
11.2.1 The scanning angles and frequencies shall be taken as per

approved applicable examination technique sheet (Table-3).
11.2.2 If any deviation from the above, examination will be done with
concurrence of M/s NPCIL.
12.0 EVALUTION, SCANNING SENSITIVITY RECORDING:
12.1 General Evaluation:
12.1.1 Indications that are determined to originate from surface

discontinuities such as surface step and counter-bore shall be
classified as spurious indications.
12.1.2 To classify an indication as geometrical indications, reflected

coordinates are to be verified for surface discontinuities such
as root surface step and counter-bore.
12.2 RECORDING:
12.2.1 All echo indications other than those caused by the geometry
of the component in the examination area shall be recorded if
their amplitudes reach or exceed the reference level of 50%
and stated in Table 1 for reference holes / notches
perpendicular to the sound beam.
12.3 Evaluation Level:
12.3.1 All indications greater than the reference level (DAC) shall
be investigated to the extent that they can be evaluated in
terms of the identity, shape and locations of all such
indications and it will be characterize for their nature and
type. Finally evaluation shall be done in terms of acceptance
standards as given in Para. 14.0.
12.3.2 The Evaluation shall be performed with reference level given

in TABLE-01. If the nature, location and accumulation of
indications suggest a welding discontinuities like excess
penetration, root concavity at root side etc. and in that case of
indications which are greater than applicable reference level
will be evaluated and accepted based on case to case
evaluation standard agreed upon between M/s BHEL and
M/s NPCIL. In all such cases, all echo indications due to
welding discontinuities like excess penetration, root
concavity at root side etc. shall be jointly evaluated by M/s
BHEL and M/s NPCIL.
If required, the doubtful/suspected area will be re-examined

by radiography preferably with single image viewing in such
a way the doubtful/suspected region is covered in film side
of the radiograph. Based on radiograph, all echo indications
due to welding discontinuities like excess penetration, root
concavity at root side etc. shall be jointly evaluated by M/s
BHEL and M/s NPCIL. Also if required, root visual
examination by boroscope / videoscope shall be carried out
to ensure that the indications are due to root discontinuities
within the acceptable limit.
12.4 Scanning Sensitivity:
Scanning sensitivity level shall be set 6dB higher than the

reference level (DAC) gain setting.
12.5 Transfer Correction:
Angle beam search units will be subjected to calibrating for

the angle deviations, if required.
12.6.0 Examination under restricted conditions:
12.6.1 If it is difficult to carry out complete ultrasonic examination

of the weld fully complying with the examination procedures
mentioned above, throughout the production, suitable special
probes shall be employed to detect the flaws in the welded
areas likely to missed.
12.6.2 For welds on which the examination is not possible after
final heat treatment due to assembly restrictions the
following shall be applicable.
Examination shall be performed in full specified or agreed

extent in the condition existing after completion of welding
operations (as far as possible during production sequence).
However after the intermediate stress relief heat treated
condition, examination shall be carried out according to
Para11.1. This shall form the first integral part of the
acceptance examination. After final Heat treatment, the
Second integral part of acceptance examination shall further
be conducted to the maximum extent, in according with
Para11.1.
13.0 EXAMINATION INSTRUCTIONS:
All examination (except demonstration) shall be done in

accordance specific technique sheets (detailed written
instructions for the complete extent of examinations) based
on the requirements of this specification. In these
examination instructions/technique sheets, method and extent
will be stated in correlation with the individual examination
area. The Instructions/technique sheet will be approved by
M/s NPCIL / QS.
The examination instructions shall provide at least the

following information as given in para 13.1:
13.1 Content of Ultrasonic Examination instructions/technique sheet:
Type of Equipment, stimulation of search units,

scanning directions correlated to the particular examination
area, if necessary illustrated by means of sketches.
Method for discontinuity size determination, if necessary by
means of sketches of basic calibration block correlated to the
particular examination area, Calibration method and
explanation on examination technique, recording level for
indications and further information for reporting.
List of technique sheets is available in Table -3 of Appendix III

14.0 ACCEPATANCE STANDARDS:
14.1 All indications shall be examined in terms of the acceptance

Standards given in Para 14.2.
14.2 Products shall not be acceptable if indications of echoes are

higher than DAC (or reference level) when UT inspected in
straight and angle beam.
14.3 Indications characterized as cracks, lack of fusion, or
incomplete penetration are unacceptable regardless of length.
15.0 EXAMINATION RECORDS:
For each ultrasonic examination, the following information

shall be identified and recorded:
 Procedure with Rev. No. & Technique sheet No.;
 Ultrasonic Examination System (Equipment, Probes,
Couplant etc.);
 Examination Personnel Identity and Level;
 Scanning and Calibration Sketch;
 Map and Record of Indications Detected;
 Identification of Component, Date of Examinations;
 Basic Calibration Blocks Identification;
16.0 REPORTS:
After the examination, the reporting of the results in sample

format (enclosed in Appendix IV) of examination shall be
done with dully signed & reviewed by responsible technical
representative Level II or Level III.
17.0 POST TEST CLEANING:
After completion of the examination, interpretation and

reporting the component shall be thoroughly cleaned with
suitable technique to prevent the occurrence of rust and /or
corrosion after inspection.
APPENDIX-I
TABLE-1
Recording Level Depending on Nominal Wall Thickness (t)
For Straight Beam Scanning
Nominal Wall Thickness (t) Diameter of the FBH (Flat Bottom Hole)
Sl. No.
(in mm unit) (in mm unit)
1 t≤100 2
2 100<t≤200 3
3 t>200 4
For Angle Beam Examination
It shall be rectangular-Notch as per below mentioned dimension
Notch Dimension:
i) 3mm Wide X 12mm Long X 0.05(5% of t) of t (3mm Max.) Deep for feeder pipe
weld joints.
ii) 3mm Wide X 12mm Long X 0.02 of t (1.43mm Max.) Deep for dished end weld joints.
Where,
T is the nominal thickness of the examining product.
Note: For Dished End Joint (approx. 65 mm thickness-Joint No. 01 and 02) apart from
the notch, Side Drilled Hole = Φ4.5±0.8mm shall also be taken as reference.
APPENDIX II
TABLE-2
List of Applicable Reference Block/Specimen:
Rev. Applicable for - NB/OD (in Notch/FBH/SDH
Sl. No. BLOCK NO. Drawing NO. Description
NO. MM) SIZE Size
ID NOTCH
1 RH17 4-RH-25 00 20NB Axial Scanning for ID
Depth=0.25
OD NOTCH
2 RH18 4-RH-26 00 20NB Axial Scanning for OD
Depth=0.25
ID NOTCH Circumferential Scanning for
3 RH2A 3-RH-11A 3 20NB
Depth=0.15 ID&OD
OD NOTCH circumferential Scanning for
4 RH2B 3-RH-11B 3 20NB
Depth=0.15 OD
5 RH3 3-RH-12 0 20NB FBH(ø) = 2mm Straight Beam Examination
ID&OD NOTCH
6 RH19 4-RH-27 00 50NB Axial Scanning For 50NB
Depth =0.45
ID&OD NOTCH Circumferential Scanning for
7 RH25 4-RH-33 00 50NB & 65NB
Depth=0.45 ID&OD
8 RH6 3-RH-15 2 50NB & 65NB FBH(ø) = 2mm Straight Beam Examination
ID&OD NOTCH Axial Scanning For 65NB
9 RH20 4-RH-28 00 65NB
Depth =0.50 (L=25.4mm)
ID&OD NOTCH Axial Scanning For 65NB
10 RH21 4-RH-29 00 65NB
Depth =0.50 (L=8.3mm)
ID&OD NOTCH
Depth =0.68
ID&OD NOTCH
Depth =0.68
ID&OD NOTCH Circumferential Scanning for
13 RH24 4-RH-32 00 100NB
Depth=0.68 ID&OD
14 RH10 3-RH-18 2 100NB FBH(ø) = 2mm Straight Beam Examination
ID&OD NOTCH
15 RH11 3-RH-19 2 457 OD Axial Scanning
Depth =1.30
16 RH12A 3-RH-20A 2 457 OD FBH(ø) = 2mm Straight Beam Examination
17 RH12B 3-RH-20B 2 457 OD FBH(ø) = 2mm Straight Beam Examination

ID&OD NOTCH Circumferential Scanning For
18 RH13 3-RH-21 2 457 OD
Depth =1.30 ID&OD
19 RH14A 3-RH-22 A 0 457 OD SDH - Φ4.5mm For Circumferential Scanning
20 RH14B 3-RH-22B 0 457 OD SDH -Φ 4.5mm For Axial Scanning
3/8” inch instrumentation Before final drilling stage.

21 RH15 3-RH-23 0 SDH =Φ 1.5mm
nozzle to 100 NB pipe :For Axial Scanning
After drilling stage:3/8” inch
After drilling stage.
22 RH16 3-RH-24 0 instrumentation nozzle to SDH =Φ 1.5mm
:For Axial Scanning
100 NB pipe
APPENDIX III
Table-3
List of Technique Sheet
Sl. Tech. Rev Joint
No. Applicable Size
No. Sheet no. Annexure
1 01 Dished end joints A
2 02A 50NB straight feeder pipe (at 180° orientation) B
50NB bent feeder pipe
3 02B (at 135⁰/225⁰ orientation)
C
4 03A 65NB straight feeder pipe (at 180° orientation) D
65NB bent feeder pipe with 25.5 mm straight
5 03B portion E
(at 135⁰/225⁰ orientation)
65NB bent feeder pipe with 8.1 mm straight
6 03C portion F
(at 135⁰/225⁰ orientation)
20NB
7 04A (Header with 20NB Bend Pipe and G1 & G2
20 NB pipe with end cap butt weld)
8 04B 20NB fittings joints (Tee/Elbow to feeder pipe) H
20NB fittings joints (elbow with tee butt joints)
9 04C Only applicable for work order I
D140-D142
10 05A 100NB straight feeder pipe (at 180° orientation) J
100NB bent feeder pipe
11 05B (at 135⁰/225⁰ orientation)
K
100/65/50NB coupling Joint after welding and
12 06A before drilling
L, M, N
100/65/50NB coupling Joint after welding with
13 06B drilling
L, M, N
14 06C 100/65/50NB coupling Joint after PWHT L, M, N
Note: Kindly refer the specific examination technique sheets and joint annexure for
detailed joint and examination details.
APPENDIX-IV
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BHARAT HEAVY ELECTRICALS LIMITED BHE:NDE:NU:700MW:RH:UT

NON-DESTRUCTIVE TESTING Date: 01-08-2014

DEPT.-2350 ULTRASONIC EXAMINATION PROCEDURE Page 01 of 17

PROCEDURE FOR ULTRASONIC EXAMINATION OF WELDS

REACTOR HEADER ASSEMBLIES FOR KAPP-03 & 04 AND RAPP-07 & 08

APPLICABLE W.O. No: D-139 to 142

APPLICABLE P.O. No: i) CMM/FTP/23-33-1-1042/PO/ 6027 AND

DILIP KUMAR SINGH

REV. REASON FOR REVISION DATE (DD-MM-YYYY)

01 Revised for 5% NOTCH depth 01-08-2.14

00 First Issue 16-11-2013

NON-DESTRUCTIVE TESTING Date: 01-08-2014

DEPT.-2350 ULTRASONIC EXAMINATION PROCEDURE Page 02 of 17

APPENDIX-I, II & III

1. Report Format …………........................................................................17

NON-DESTRUCTIVE TESTING Date: 01-08-2014

DEPT.-2350 ULTRASONIC EXAMINATION PROCEDURE Page 03 of 17

This procedure describes and defines the requirement of the

2.0 REFERENCE DOCUMENTS:

This procedure in accordance and complies with following Codes,

3.0 PERSONNEL QUALIFICATIONS:

Personnel performing examinations in accordance with this

4.0 EXETENT OF EXAMINATION:

4.1 Pressure boundary butt welds of Category A, B, C & D

4.2 In addition to the Non-Destructive Examinations specified in

NON-DESTRUCTIVE TESTING Date: 01-08-2014

DEPT.-2350 ULTRASONIC EXAMINATION PROCEDURE Page 04 of 17

4.4 Ultrasonic examinations shall also cover extent possible

4.5 Full penetration corner welded joints of category C & D shall

4.6 Attachment welds on pressure retraining walls shall be

4.7 The discontinuity indications from within base metal shall be

4.8 Heat Treatment Condition:

As a rule, the acceptance examination shall take place after

NON-DESTRUCTIVE TESTING Date: 01-08-2014

DEPT.-2350 ULTRASONIC EXAMINATION PROCEDURE Page 05 of 17

5.0 STAGE OF EXAMINATION:

Ultrasonic Examinations will be performed before HT and shall be

Ultrasonic examination shall be carried out prior to Hydrostatic

6.0 SURFACE CONDITION:

Surfaces to be examined shall be clean and free from scale, oil,

The following UT equipment or instruments with similar

NON-DESTRUCTIVE TESTING Date: 01-08-2014

DEPT.-2350 ULTRASONIC EXAMINATION PROCEDURE Page 06 of 17

8.0 EXAMINATION MEDIUM AND COUPLANT:

The couplant including additives shall not be detrimental to the

For digital type instruments, the requirements of the following

9.1.1Screen Height Linearity:

The Ultrasonic Instrument’s screen height linearity shall be

9.1.2 Amplitude Control Linearity:

The Ultrasonic Instrument’s amplitude control linearity shall be

9.1.3 Horizontal Linearity:

Horizontal linearity check of instrument shall be as per Cl.6.2of

Resolution shall be checked with IIW-V1 block having depths 85,

NON-DESTRUCTIVE TESTING Date: 01-08-2014

DEPT.-2350 ULTRASONIC EXAMINATION PROCEDURE Page 07 of 17

9.1.5 Search Unit (Angle Beam):

Prior to use, the angle beam probes shall be verified using

9.2.0 Calibration/Reference Block/specimen:

The reference block shall be manufactured from material of the