DOCUMENT NAME: Standard Procedure for

PAUT of Carbon Steel, Alloy Steel Boiler &

Stainless Steel Tube Weld Joints
PROCEDURE –PAUT/02/2024, Rev 02

Doc Date Description Prepared Checked Approved

Rev By: By: By:
Mr. Babloo Khan
2 04/06/2024 Initial Issue
ASNT LEVEL- II

Page 1 of 34
 TABLE OF CONTENT

1.0 PURPOSE 3
2.0 SCOPE 3
3.0 SAFETY 3
4.0 REFERENCE 3
5.0 DEFINITION 3
6.0 PERSONNEL REQUIREMENTS 4
7.0 SYSTEM REQUIREMENTS 4
8.0 INSPECTION VOLUME COVERAGE REQUIREMENTS 6
9.0 EQUIPMENT SETUP 7
10.0 CALIBRATION 8
11.0 PRE-INSPECTION REQUIREMENT 9
12.0 INSPECTION REQUIREMENT 11
13.0 DATA ANALYSIS 12
14.0 ACCEPTANCE CRITERIA 14
15.0 REPORT 14
16.0 PROCEDURE QUALIFICATION / PERFORMANCE DEMONSTRATION 14
17.0 NON-COMPLIANCE STATEMENT 14

FIGURE-1 TYPICAL CALIBRATION BLOCK 16

FIGURE-2 TYPICAL SCANNER 16
FIGURE-3 TYPICAL CHARACTERIZATION 17

TABLE-1 CALIBRATION BLOCK 18

TABLE-2 REPORT CHECK LIST 19
TABLE-3 VARIABLES INVOLVED IN PROCEDURE QUALIFICATION 20

APPENDIX-A: PAUT ON BOILER TUBES 22

APPENDIX-B: TYPICAL TECHNIQUE SHEET 24

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APPENDIX-C: TYPICAL REPORT 27

PURPOSE
The purpose of this procedure is to define methodology and requirements of contact encoded
Phased Array Ultrasonic Testing (PAUT) using 1-D linear array probe in pulse-echo mode to
cover inspection of weld volume and its heat affected zone (HAZ).

SCOPE
Technique described within this procedure is to detect and size the dimensions of discontinuities
in inspection volume of circumferential boiler tube weld joints.

Power Boiler tube weld joints with nominal diameter equal to 51mm or Power boiler tube weld
joints with wall thickness equal to 5mm is performed as contractual weld examination.
(Refer to Appendix A)

This procedure is applied in conjunction with appropriate technique sheet. All technique sheets
shall be approved by Level 3 personnel prior to its implementation on production welds

SAFETY
All personnel shall have responsibility to themselves and other persons with regard to safety and
shall ensure that site facilities are adequate with regard to lighting, ventilation, scaffolding
etc. prior to commencement of operations.

Risk Assessments where ever required shall be completed prior to work and shall be reviewed at
daily tool box meetings.

REFERENCES
The following documents shall be referred in conjunction with this procedure

• ASME Boiler and Pressure Vessel Code Section V, Article 4 (2015)

• ASME Boiler and Pressure Vessel Code Section I, Power Boilers (2015)
• SNT-TC-1A (2016), Recommended practice for Certification of NDT personnel
• ISO 9712, Non-destructive testing – qualification and certification of NDT personnel
(2012)

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 DEFINITIONS
Phased Array Ultrasonic Testing/Examination (PAUT): Phased array ultrasonic testing is a
technique for volumetric assessment and flaw detection in metal objects. Phased array
consists of a number of ultrasonic elements arranged in a single probe (transducer). The
multiple elements are used to create an array of ultrasonic beams. The beams can be
“steered” to optimize the orientation of the beam to the object being studied, which
increases the probability of detection. The beams can be scanned over the object in order
to produce an image. By adjusting the individual elements electronically, the beams also
can be focused to yield more clear and less uncertain results. Portable phased array
ultrasonic instruments offer advantages over conventional single-element ultrasonic,
particularly in automated testing of welds. Operating in scanning mode and using the
electronic focusing capabilities of these systems, phased array ultrasonic is more definitive
and significantly faster than single-element systems.

Technique Sheet / Scan Plan: Technique Sheet or Scan Plan is detailed information required for
examination applicable to weld joints. The technique sheet is designed to be definitive and
shall include data pertaining to the weld configuration. This data may include the probe(s)
and wedge type required, steering angles required, number of groups required, PRF, filter,
averaging, and index offset. The technique sheet is required in addition to the procedure as
it contains the specifics related to a given design weld joint configuration.

6.0 PERSONNEL REQUIREMENTS

The personnel performing PAUT data acquisition shall be an ASNT or PCN PAUT Level 2
Alternatively, personnel (Scanner Technician) trained in the use of the equipment and who
have demonstrated the ability to properly acquire examination data shall conduct
production scan under the direct supervision of appropriate PAUT Level 2 personnel. The
personnel performing PAUT data analysis shall be at least a PCN PAUT Level 2.
Inspection Personnel may be assessed by client inspector to evaluate their performance
and familiarization with equipment and techniques used in accordance with this
procedure. Additional training shall be provided to the extent deemed necessary by the
NDT Level 3.

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SYSTEM REQUIREMENTS
EQUIPMENT
OMNISCAN MX / MX2 16:128 or 32:128 module equipment is proposed to be used.

SOFTWARE
Omni PC software shall be used for analysis, reporting and defect sizing.

SEARCH UNITS & CABLES

Phased array search units with frequency of 5-10 MHz with capability of generating 35 to
75 degrees ultrasonic beams shall be employed. Appropriate Axial outside diameter (AOD)
wedges shall be used for adaptability to geometry of the tube surface.
Cables shall not exceed 10 meters length. The cables, extensions, Y-adapter and pre-
amplifier used shall be same while performing calibration and examination.
SCANNER
Cobra scanner or equivalent miniature scanner is to be used. A typical scanner is illustrated
in Figure-2.
Scanner shall have encoding scanning capability with probe adjustable facility to achieve
required probe index offset. Scanner shall maintain fixed probe index offset throughout its
entire scan distance to achieve the planned results.
COUPLANT
Water or equivalent is recommended as couplant for the examination. Couplant used for
examination and calibration shall be same. For probe and wedge coupling, a thick ultra-gel
or equivalent shall be used to facilitate proper coupling and transmission. Before each
shift, proper coupling between probe and wedge by replacing/replenishing the couplant
shall be ensured.

CALIBRATION BLOCK
Calibration block shall be manufactured using a material acoustically similar to that of
piping. Calibration block is to be used as scanner block. Thickness shall be within lesser of
6mm or 25% of the thickness of material thickness to be examined. Scanner block shall be

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 with curvature that complies with wedge manufacturer’s recommended range of curvature
for the appropriate Axial outside Diameter (AOD) wedge used on piping for inspection.

Side drill hole (SDH) / notch shall be used as reference reflector. Notch depth shall be 8%T
minimum to 11%T maximum, where T is nominal block thickness. Notch length shall be
minimum 25mm or shall be sufficient to provide for a calibration with a minimum 3 to 1
signal-to-noise ratio. Notch width shall be 3mm or shall be sufficient to provide for a
calibration with a minimum 3 to 1 signal-to-noise ratio.

Reference sensitivity of inspection during system confirmation scan shall be based on

notch. Calibration block may be also used as scanner block provided it includes the specific
requirements of scanner block. Typical calibration block is illustrated in Figure-1.
Calibration blocks are listed in Table-1.

TECHNIQUE SHEET
Inspection personnel shall select an appropriate technique sheet for the required
inspection job and create setup files accordingly. The following constitute the primary
details which are included in the technique sheet.
 Technique of examination
 Instrument model and software
 Material velocity & geometry of part to be inspected
 probe frequency, pitch
 Wedge type and angle
 Scanner
 Pulsar voltage
 No. of groups. number of elements, start and stop element, angle range angle step
 UT range, Focal depth
 Index offset

Each technique sheet shall be specific for each weld configuration and used in conjunction
with this procedure. Whenever there is change in type of wedge and probe, a new
technique sheet shall be prepared and validated. A typical technique sheet is provided in
Appendix-B.

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INSPECTION VOLUME COVERAGE REQUIREMENT
The following constitute the inspection volume coverage requirement.
 The required volume of weld (entire weld region and its HAZ) to be examined shall be
scanned using a linear scanning (one-line) technique with encoding.
 Each linear scan shall be parallel to weld axis at a constant standoff distance with
tolerance of ±1mm and beam oriented perpendicular to the weld axis.
 For all possible welds to cover the sub-surface of welds, the angles shall be selected
appropriate to the joint to be examined. The maximum deviation of beam angle and
bevel angle shall not exceed ±100 BIA (Bevel Incidence Angle).
 In general the scan plan is prepared in such a way to cover ID region in the angle range
of 650 – 750. The OD region is covered in the angle range of 400 - 600
 For restricted access welds, the examination angles should be selected with maximum
possible extent optimum for the joint to be examined.
 For E-Scan techniques, overlap between adjacent active apertures shall be a minimum
of 50% of the effective aperture height. For S-Scan techniques, the angular sweep
incremental change shall be a maximum of 10 or sufficient to assure 50% beam
overlap.
 When multiple linear scans are required to cover the entire volume of weld and base
material, overlap between adjacent linear scans shall be a minimum of 10% of the
effective aperture height for E-scans or beam width for S-scans.
 A-Scan data shall be recorded from the area of interest in an unprocessed form with no
thresholding, at a minimum digitization rate of 5 times the frequency of the search unit.
 Scan resolution shall be a maximum of 1mm.

EQUIPMENT SETUP
PHASED ARRAY
Material velocity shall be selected as longitudinal wave for L-wave inspection and
transverse wave for S-wave inspection. Focal depth may be selected to close to the area of
interest.
True depth mode shall be selected. The range start and width shall be selected such that it
slightly exceeds the region of interest, and to avoid the coverage of unwanted portions to

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 keep acquisition speed optimum. The following constitute the recommended equipment
settings.

 Pulse voltage - high

 Pulse width - optimum
 Rectification - full wave
 Reject filter - off
 Filter - 7.5MHz
 PRF - optimum
 Averaging - 1
 Digitizer - 100MHz
 Points quantity - 320
 Video filter - off

Gain shall be selected to achieve required FSH response from the calibration reflector for
all focal laws. Gate threshold shall be 20% of TCG and shall cover the region of interest.
Pulse echo configuration shall be selected according to inspection requirements. Data
sample size shall be 8 bit. Acquisition rate and pulse repetition rate shall be optimum to
avoid ghost echoes and data loss.

SCANNER
Maximum scan speed shall not exceed 150mm/sec. Scanning speed shall be such that data
drop-out is less than 2 data lines per inch (25 mm) of the linear scan length and that there
are no adjacent data line skips.

10.0 CALIBRATION
EQUIPMENT
The equipment shall be calibrated annually by the OEM to ensure its performance or
whenever a repair is required, whichever comes first.

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DEAD ELEMENT CHECK
There shall not be more than one dead element among the elements in the probe which
are involved in the firing sequence for the focal laws for the appropriate technique sheet.
Dead element check of probes shall be performed by placing probe (without any wedge)
directly on a V1 block with focal law parameters selection including linear sector 0 0 , first
element , last element and element quantity ‘1’. If any missing back wall response appears
on any focal law then the element shall be deemed as not working.
Dead element check shall be performed prior to each use as a daily check or whenever a
discrepancy arises on its functionality. If an adaptor/splitter is used for inspection, dead
element check shall be performed using the same configuration.

CALIBRATION RECORDS
All the calibration output shall be documented and maintained. All calibration which is to
be recorded in interval of prior to each use shall be documented in appropriate NDT Pre-
calibration report for every shift. Rest of the calibration shall be documented in
appropriate individual calibration report.

ENCODER CALIBRATION
Encoder shall be calibrated at least to a distance of 500mm or entire scan length that is to
be inspected. Encoders shall be verified prior to each use as a daily check. Encoder
calibration error shall be within 1% of the actual distance moved.

SETUP FILE CALIBRATION

Velocity calibration shall be performed using notch/SDH on the corresponding calibration
block. Alternatively, velocity value may be determined using a zero degree single crystal
shear wave probe on the calibration block and may be considered for examination of
production welds. Wedge delay calibration shall be performed using notch/SDH on the
corresponding approved calibration block. Measured depth shall be within ±1 mm of the
actual thickness. Sensitivity calibration shall be performed for all focal laws against
notch/SDH in corresponding approved calibration block to provide uniform amplitude
(within ±2.5% FSH).

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 TCG calibration for all focal laws shall be performed to provide measurement of distance
and amplitude correction over the sound path employed in its region of interest. TCG shall
be performed using the calibration reflectors (notch/SDH) and corresponding to the
approved calibration block. TCG points shall be selected to cover the entire region of
interest. Gain compensation may be used to avoid over saturation.

PRE INSPECTION (PRODUCTION SCAN) REQUIREMENTS

WELD IDENTIFICATION AND SCAN REFERENCE

All the welds to be examined shall be identified with a unique identification number on the
job by client representative and same shall be provided through a NDT request. Inspection
personnel shall ensure the weld identification number on the job and NDT request are
identical.
Inspection personnel shall mark zero reference (Scan Start) and scan direction on the part
using marker. Scan direction shall be as instructed by client representative. If required,
client may make a permanent stamp of zero reference and scan direction on the part for
future use.

WELD CENTER LINE

Weld center line shall be identified based on weld edges or by appropriate part drawing
sheet. It’s under the scope of Client to provide proper markings.

SURFACE PREPARATION
Surface preparation shall be under the scope of client. All the production welds to be
examined are through probe placement from the outer surface of the tubing adjacent to
the weld and hence probe placement surface shall be free of irregularities and
contaminates such as spatter, paint, rust and mill scale etc., that may negatively impact the
ultrasonic scanning at the area of probe contact.
Visual check shall be performed by inspection personnel on the weld surface for any visual
discontinuities or other contaminations on the weld and HAZ region at the location of
probe placement area prior to scanner placement for data collection.

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 Any such areas shall be noted and reported.

THICKNESS AND LAMINATION CHECK

Scan surface shall be ultrasonically verified for its thickness by the inspection personnel
and the measured thickness shall be within ±1mm of specified thickness.
Lamination check on scan surface shall be under the scope of the client. Inspection
personnel shall verify with the client representative and ensure that lamination check
report is with satisfactory results.

TRANSFER LOSS CORRECTION

Transfer loss correction (TCL) is not required is not required if the calibration block is with
same surface condition, made with same material and received minimum tempering heat
treatment for the grade of the part to be tested.
Otherwise, TCL is recommended to estimate using the appropriate probe used for
inspection. If any difference is observed between the value obtained on the basic
calibration block and the test piece, then the primary reference (TCG Gain reference) shall
be modified to the required transfer correction and this shall be noted in the report.

TEMPERATURE CONTROL
The maximum surface temperature shall not be more than 500 Celsius to perform inspection.
The temperature difference between the calibration block and the job shall be within ±14°
C. If any discrepancy is observed, the temperature may be measured using an appropriate
calibrated measuring instrument and recorded for both the calibration block and the job.
When both calibration block and job are located in an area of controlled temperature or
located in an area were ambient temperature gradients are constant, then the
temperature validation is not required.

DISCREPANCIES IN SITE REQUIREMENT

If any discrepancy is observed during the task including job identification, weld center line,
clearance check around the scan circumference, surface preparation check, job thickness
check and lamination check then inspection personnel shall report to client inspector or
equivalent and follow-up for further actions.

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 If any other discrepancy including non-compliance with specified parameters of technique
sheet is observed, then inspection personnel shall report to level 3 in-charge and follow up
for further action.

INSPECTION (PRODUCTION SCAN) REQUIREMENTS

SYSTEM CONFIRMATION SCAN
System confirmation scan shall be performed to record the SDH indications on the
calibration block (Fig-1) to verify the distance range point and sensitivity setting.
The system confirmation scan shall be performed,
 prior to each examination or series of similar examinations (Pre-Cal)
 after the completion of each examination or series of similar examinations (Post-Cal)
 whenever discrepancy occurs
 whenever examination personnel are changed
 whenever technique sheet selection is changed
 whenever the technique sheet parameter is required to be modified

Full system calibration (velocity, wedge, sensitivity, TCG in the initial setup) shall be
performed whichever occurs earlier from below:
 Every 30 days
 Whenever probe/wedge or any interface electronic function is changed Whenever

fault is noticed in the setup file.

SENSITIVITY
During Pre-Cal scan of PAUT, the reflector amplitude response shall be set at 80% ±2.5%
FSH at any angle and corresponding dB shall be maintained as reference dB.
During Post-Cal scan of PAUT, if the reflector amplitude response is observed to be less
than 77.5% FSH at any angle, then the dB shall be increased to achieve a minimum of 80%
±2.5% FSH at any angle and all the joints shall be rescanned.

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RANGE
During pre-cal scan, distance range point shall not exceed 10% of the distance reading on
the sweep line or 5% of full sweep, whichever is greater.
During post-cal scan, 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 accordingly and the correction shall be noted in inspection
record. All recorded indications since the last valid calibration shall be reexamined and
their values shall be changed on the inspection record or re-recorded.

DATA COLLECTION
System confirmation scan (Pre-Cal) shall be performed prior to data collection of
corresponding production welds and frequency shall be as specified in clause 12.1.
Data collection shall be performed as described in the appropriate technique sheet as
individual data acquisition or collective data acquisition. Scanning of production welds shall
be performed with reference dB.
Scan area shall cover the entire circumference and scan overlap shall be 25 mm. Scan
resolutions, tolerance of probe positioning (Index offset) from weld centerline and scan
speed as specified in clause 9.0.
System confirmation scan (Post-Cal) shall be performed at the completion of data
collection of corresponding production scan and frequency shall be as specified in clause
12.1.

Each data file shall be saved with the name of the joint identification as provided by client
in the NDT request. All data files including calibration data shall be regularly backed-up in
appropriate storage media.
Inspection personnel shall ensure the integrity of acquired data that it is saved in proper
file name and it does not have any data loss and coupling loss. After scanning the scan
surface shall be cleaned properly (Post Cleaning).

ONE SIDED INSPECTION

Inspection job where two sided inspection is not feasible, welds shall be inspected from
one sided according to the appropriate technique sheet specified for one-sided approach.

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 The suspected region shall be further examined by flush grinding the weld cap along the
circumference with overlap of maximum one inch on either side of the suspected location.
If the weld cap cannot be flushed, then evaluation of the opposite side bevel portion of
weld shall be performed at additional dB as specified in appropriate technique sheet to
detect the suspected relevant signal.
DATA ANALYSIS

REQUIREMENTS
Each pre-cal and post-cal data shall be analyzed for the following.
 amplitude level of ultrasonic echo from reference reflector
 position of reference echo signal in both horizontal axis and vertical axis
 volume coverage in depth and width
 signal-to-noise ratio

Each weld scan data shall be analyzed in the following sequence.

 data quality (coupling loss, missed scan lines etc.,)
 identification of relevant indication
 characterization (Slag, crack etc.,)
 sizing (location, length, depth and height of relevant indication)
 evaluation (against acceptance criteria)

Weld scan data of the entire scan length with its examination volume extent shall be
considered for analysis.

NON-RELEVANT INDICATION
Signals which are determined to be from a metallurgical interface (such as weld to base
metal interface) or geometrical conditions (such as corner profile reflection) are classified
as geometric reflectors. Such reflectors are not required to be compared with the
allowable indications criteria. The presence of geometric reflectors may be confirmed by
reviewing the fabrication drawings of the weld preparation or by the previous inspection
records or by supplemental inspection techniques.

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 When the indication analyzed as inconclusive, it shall be cross-verified using manual UT or
surface NDE as applicable and concluded accordingly.

RELEVANT INDICATION
The indications other than non-relevant indications are considered as relevant indication.
Weld overlay shall be established, prior to starting analysis. Display of A-scan, B-Scan, S-
scan and C-Scans shall be used.
Any relevant indication exceeds the amplitude of 20% of reference level shall be evaluated
for acceptance criteria. If any discrepancy arises, re-scan with appropriate focus using
manual PAUT may be performed to establish confirmation. Based on the outcome,
characterization and size estimation (length, depth, height) shall be performed
CHARACTERIZATION
Relevant indications need to be characterized. Characterization is to be based on pattern
and volumetric position of indication. The typical indications with probable nature are
illustrated in Figure-3.

SIZING
Location and length of relevant indication shall be evaluated from B or C-scan. Depth and
height of relevant indication shall be evaluated from S-Scan. 6dB drop method shall be
used for unsaturated signal response and maximum amplitude method shall be used for
saturated signal response.

14.0 ACCEPTANCE CRITERIA

Acceptance shall be as per paragraph PW-52.3 of ASME BPVC Section I.
Any dis-continuity interpreted as crack, lack of fusion or lack of penetration is unacceptable
regardless of its length.
Other dis-continuities are unacceptable if the amplitude of the indication exceeds the
reference level and its length 1/3 of thickness.

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15.0 REPORT
The inspection report shall be prepared to describe the work done and the results of
examination. The inspection report shall cover the requirements of ASME Sec V, Art 4.
Report requirements are listed in Table-2 which may serve as a check list. A typical report
format is illustrated in Appendix-C.

16.0 PROCEDURE QUALIFICATION / PERFORMANCE DEMONSTRATION

This procedure shall be qualified to assure the data parameters selected, calibration
technique employed, technique or scan plan selected, equipment and software selection
ensure detectability of flaws.
Procedure and vendor qualification shall be under the scope of the client. It shall be
performed by conducting a practical test on the client's appropriate seeded defect weld
coupon.
Essential and non-essential variables of procedure qualification are listed in Table-3. Any
changes to non-essential variables shall not be cause for re-qualification of the procedure.

NON COMPLIANCE STATEMENT

If any or part of this document cannot be implied due to what so ever reason, stop further
inspection and report immediately to Level III/Technical Manager for review, evaluation and
further disposition.
Level 3/Technical manager shall review with customer or affected parties and propose the
alternate solution. All the proposed and revised procedure shall be documented for review
and audit.

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 Figure-1: Typical calibration (Scanner) Block

Figure-2: Typical scanner

COBRA SCANNER

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 Figure-3: Typical characterization

Root crack Toe crack

Lack of root fusion Lack of side wall fusion

Incomplete penetration

Cluster of pores

Slag inclusion

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TABLES

Table-1: List of calibration block

Sl. Block ID Configuration Material Repair area

1 1 Dia 33.4 x thk 6.1 SA213T22 +

S-26NIP(SH Platen Front
SA213T22
Inlet Header) +
S-27(SH PLATEN FRONT
COILS)

2 3 Dia 50.8 x thk 7.62 SA213T91 +

S-27(SH Platen Front Coils) +
SA213T91
S-27TO(SH Platen Front
Outlet Terminal Tubes)

3 4 Dia 44.75 x thk 7.11 SA213T91 +

S-27(SH Platen Front Coils) +
SA213T91
S-27TO(SH Platen Front
Outlet Terminal Tubes)

4 5 Dia 38.1 thk 6.6 SA213T12 +

S-09(BP Extd Side Floor
SA213T12
Outlet Header) +
S-09D(BP Equalizing Line)

5 6 Dia 50.8 x thk 8.64 SA213T12 +

S-11(L&R)(Backpass side wall
SA213T12
inlet header) + S-
12U(L&R)(Backpass Side
Upper Panels

6 11 Dia 54 Thic 9.14 SA213T12 +

S-14(BP Lower Front Header)
SA213T22
+
S-15L(Backpass Lower Front
Wall Panel)

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7 15 Dia 57.16xTHICK9.6 SA213T22 +
S-17(BP Lower Rear Header)
SA213T22
+
S-20L(BP Lower Rear Wall
Panel)

8 16 Dia 38.1XTHICK 6.6 SA213T22 +

S-26NIP(SH Platen Front
SA213T22
Inlet Header) +
S-27(SH PLATEN FRONT
COILS

9 7 Dia 57.15Xthk 9.6 SA213T91 +

S-27TO(SH Platen Front
SA213T91
Outlet Terminal Tubes)
+
S-28(SH Platen Front Outlet
Header)

10 8 Dia 42.4X thk 7.1 SA213T91 +

S-27TO(SH Platen Front
SA213T91
Outlet Terminal Tubes)
+
S-28(SH Platen Front Outlet
Header)
Issued by: Asst. Manager- Quality Assurance File No. LAB_NDT_LY_SOP_18 Issued on: 15/03/2023 Amendment No:00

11 19 Dia 38.1 x thk 6.6 SA213T91 +

S-27TO(SH Platen Front
SA213T91
Outlet Terminal Tubes)
+
S-28(SH Platen Front Outlet
Header)

12 23 Dia 33.4X Thick 6.1 SA213T91 +

S-27TO(SH Platen Front
SA213T91
Outlet Terminal Tubes)
+
S-28(SH Platen Front Outlet
Header)

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13 26 Dia 57.15 x thk 7.62 SA213T91 +
S-32(SH Platen Rear Inlet
SA213T91
Header) +
S-33TI-1(SH Platen Rear Inlet
Terminal Tubes)

14 2 Dia 48.3X6.6 SA213T91 +

S-32(SH Platen Rear Inlet
SA213T91
Header) +
S-33TI-2TO3(SH Platen
Rear Inlet Terminal Tubes)

15 20 Dia 38.1X Thick 5.6 SA213T91 +

S-32(SH Platen Rear Inlet
SA213T91
Header) +
S-33TI-4TO13(SH Platen
Rear Inlet Terminal Tubes)

16 21 Dia 33.4x tiick 6.1 SA213T91 +

S-32(SH Platen Rear Inlet
SA213T91
Header) +
S-33TI-14TO17(SH
Platen Rear Inlet Terminal
Tubes)

17 25 Dia 57.15 x thk7.62 SA213T91 +

S-33TI-1(SH Platen Rear Inlet
SA182F91
Terminal Tubes) + S-33-1(SH
Platen Rear Coils)

18 30 Dia 48.3 x thk6.6 SA213T91 +

S-33TI-2TO3(SH Platen
SA182F91
Rear Inlet Terminal Tubes) +
S-33-2TO3(SH Platen
Rear Coils)

19 31 Dia 38.1 x thk 5.6 SA213T91 +

S-33TI-4TO13(SH Platen
SA182F91
Rear Inlet Terminal Tubes) +
S-33-4TO13(SH Platen
Rear Coils)

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20 9 Dia 33.4 x thk 6.1 SA213T91 +
S-33TI-4TO13(SH Platen
SA182F91
Rear Inlet Terminal Tubes) +
S-33-4TO14(SH Platen
Rear Coils)

21 10 Dia 50.8 x thk 8.64

SA213UNSS304 S-33-1 (SH Platen Rear Coils)
32 + +
SA213UNSS304 S-33TO-1 (SH Platen
32 Rear Outlet Terminal Tubes)

22 12 Dia 44.45 x thk 7.62 SA213TP347H +

S-33-2 to 17 (SH Platen Rear
SA213TP347H
Coils) +
S-33TO-2 to 17 (SH
Platen Rear Outlet Terminal
Tubes)

23 13 Dia 57.15 x thk 8.64 SA213T91 +

S-33TO-1(SH Platen
SA213T91
Rear Outlet Terminal Tubes)
+
S-34(SH Platen Rear Outlet
Header

24 14 Dia 42.4 x thk6.1 SA213T91 +

S-33TO-2TO6(SH Platen
SA213T91
Rear Outlet Terminal Tubes)
+
S-34(SH Platen Rear Outlet
Header)

25 39 SA213UNSS304
Dia50.8 x thick 4.5 R_13TO (Finish RH Outlet
32 +
Terminal Tubes)
Dia44.45 x thick 4.5 SA213UNSS304
+
32
R-14 (Finish RH Outlet
Header)

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26 18 Dia 57 x thk3.8/thk 3.8 SA213T91 +
S-33TO-1(SH Platen
SA213T91
Rear Outlet Terminal Tubes)
+
S-34(SH Platen Rear Outlet
Header)

27 22 Dia 33.4 x thk6.1 SA213T91 +

S-33TO-12TO17(SH
SA213T91
Platen Rear Outlet Terminal
Tubes) +
S-34(SH Platen Rear Outlet
Header)

28 24 Dia 44.5 x thk 6.1 SA213T91 +

S-38(Finish Superheater Inlet
SA213T91
Header) +
S-39TI(Finish SH Inlet
Terminal Tubes)

29 29 Dia 38.1 x thk5.6 SA213T91 +

S-33TO-7TO11(SH
SA213T91
Platen Rear Outlet Terminal
Tubes) +
S-34(SH Platen Rear Outlet
Header)

30 27 Dia 44.5 x thick 7.62,8.1 SA213UNSS304 S-39-1&2(Finish Superheater

32 + coils ) + S-39M-8&7(Finish
SA213UNSS304 Superheater Inter coils
32 )
31 27A Dia 44.5 x thick 8.13 , 7.6 , S-40-(Finish Superheatercoils ) + S-
SA213UNSS304
8.64 6.1 40TO-(Finish SH
32 +
Outlet Term Tube)
SA213UNSS304
32

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32 28 Dia 50.8 x thick 9.14, 7.6 7.11 SA213T22 +
S-9A(FURNACE ARCH
SA213T22
SUPPPORT INLET HEADER) + S-44(Fluid
cooled spacer
tubes )
33 29 Dia 38.1 x thick 8.13 SA213T22 +
-08X(Furn Rear Spiral To Vert
SA213T22
Transition Panel) +
F-11(Furn rear arch panel)
34 30 Dia 63.5 x thick 12.7 SA213T22 +
E-08TO(Econ Terminal
SA213T12
Hanger Tubes ) +
E-09(Econ Outlet Header )
35 31 Dia 44.45 x thick 7.1 SA210GRC +
E-06TO(Econ Outlet Terminal
SA106GRC
Tubes) + E-07(Econ Junction
Headers NPL)
36 32 Dia 69.85 x thick 4.57 SA213T11 +
SA213T11
R-03-1(LTRH Inlet header
nipple ) + R04TI(LTRH Inlet
Terminal Tubes)
37 33 Dia 50.8 x thick 8.13 SA213T91 +
SA213T91
R-07 TO 2 to 6(LTRH Outlet header
Terminal tubes +
R-08(LTRH Outlet Header)
38 34 Dia 63.5 x thick 5.08 SA213T22 + R12 (Finish RH Inlet Header)
SA213T22 +R_13TI (Finish RH Inlet
Terminal Tubes)
39 35 Dia 50.8 x thick 4.0 SA213T22 +
R12 (Finish RH Inlet Header)
SA213T22
+ R_13TI(Finish RH Inlet
Terminal Tubes)
40 36 Dia 44.45 x thick 5.0 SA213T22 + R12 (Finish RH Inlet Header) +
SA213T22 R_13TI (Finish RH Inlet Terminal
Tubes)
41 37 Dia 76.2 x thick 4.57, 4 SA213TP347H +
R_13TI-1-1 (Finish RH Inlet
SA213TP347H
Terminal Tubes) + R_13_1 1(Finish RH
coils)

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42 38 Dia 63.5 x thick 4 SA213UNSS304 R_13TO (Finish RH Outlet
32 + Terminal Tubes)
SA213UNSS304 +
32 R-13_2 to R-13_12
(Finish RH coils)

43 SS-01 Dia 44.45 x thick 7.62 SA213TP347 S-38(Finish Super heater Inlet Header)

44 SS-02 Dia 50.8 x thick 8.64 SA213UNSS304 S-40(Finish SH Outlet Term Tube+
S41Finish Super heater Outlet Header)

Table-2: Report check list

ASME
Sl.No. Reference Description Report Reference

1 T-490 Procedure identification and revision yes

2 T-490 Ultrasonic instrument identification Yes

3 T-490 Search unit identification, cable type and length Yes [Tech. Sheet]
4 T-490 Beam Angle Yes [Tech. Sheet]
5 T-490 Couplant name yes
6 T-490 Special equipment (Scanner) yes

7 T-490 Computerized program identification and revision Yes [Tech. Sheet]

8 T-490 Calibration block identification yes
9 T-490 Simulation block identification and data Not applicable
10 T-490 Calibration data yes
11 T-490 Identification of weld yes
12 T-490 Surface condition yes
13 T-490 Record of rejectable indication yes
14 T-490 Areas of restricted access yes
15 T-490 Examination personnel identity and qualification yes
16 T-490 Date of examination yes

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 17 V-492 Search unit parameters and wedge natural angle Yes [Tech. Sheet]
18 V-492 Focal law parameters and scan plan Yes [Tech. Sheet]
19 VII-492 Scan Plan Yes [Tech. Sheet]
20 VII-492 Scanner with adhering and guiding mechanism yes
21 VII-492 Indication data and display processing yes
22 VII-492 Supplemental manual technique yes

Table-3: Essential & Non-Essential variables

Essential Nonessential
S/No Description of Variable Variable Value / Range of Values
. Variable
Weld configuration to be examined,
including thickness range dimensions and Refer to Technique Sheet
1 √
base material product form (pipe, plate, etc.) parameter
Surfaces from which the examination shall be
2 √ Clause 11.4
performed
Refer to Technique Sheet
3 Ultrasonic Techniques √
Parameter
Angles and mode of wave propagation in the Refer to Technique Sheet
4 √
material parameter
Search unit type(s), frequency, and
Refer to Technique Sheet
5 element size/ shape, wedges , special √
parameter
search unit (if used),
Ultrasonic Instrument manufacturer and Refer to Technique Sheet
6 √
Instrument software parameter
Calibration [calibration block(s) and
7 √ Clause 7.6
technique(s)]
8 Directions and extent of scanning √ Clause 11.1
Refer to Technique Sheet
9 Scanning technique √
parameter
Method for discriminating geometric from
10 √ Clause 13.2
flaw indications
11 Flaw characterization and sizing methodology √ Clause 13.0

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 Computer enhanced data acquisition, when
12 √ Clause 13.3
used
13 Scan overlap (decrease only) √ Clause 12.2
Personnel performance requirements, when
14 √ Clause 6.0
required
15 Personnel qualification requirements √ Clause 6.0
Surface condition (examination surface,
16 × Clause 11.4
calibration block)
17 Couplant: brand name or type × Clause 7.5
18 Post Cleaning × Clause 12.2
19 Instrument settings × Clause 9.0
Search unit (element pitch, size, number and Refer to Technique Sheet
20 √
gap dimensions) parameter
Refer to Technique Sheet
21 Focal range √
parameter
Virtual aperture (number of elements, Refer to Technique Sheet
22 √
element width and effective height) parameter
Refer to Technique Sheet
23 Wedge natural refracted angle √
parameter
Refer to Technique Sheet
24 Scan Plan √
parameter
E-Scan (Rastering angle, element start, Refer to Technique Sheet
25 √
element stop, number of element step) parameter
S-Scan (Sweep angular range, sweep Refer to Technique Sheet
26 √
increment, aperture elements) parameter
APPENDIX-A: PAUT ON BOILER TUBES

ASME BPVC Section I, Rules for construction of power boilers

“Required volumetric examination of welded butt joints"

Subjected to Furnace
Not subjected to Furnace radiant heat
Butt weld type radiant heat

Contains Steam/Water Contains Water Contains Steam

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 Circumferential
> NPS 10 (DN 250) or
welds in pipes, > NPS 4 (DN 100) or > NPS 16 (DN 400) or
> 1 1/8 in. (29 mm)
tubes, and > 1/2 in. (13 mm) thick > 15/8 in. (41 mm) thick
thick
headers

However Code also specifies that for welds with thickness less than 13mm (Radiographic) RT shall
be used. Using (Ultrasonic) UT in lieu of RT for thickness less than or equal to 13mm and nominal
diameter of less than or equal to 100mm is beyond the scope of the ASME BPVC Sec I code
requirement.

Hence with reference to clause PW-11.1, the examination and acceptance standards for required
scope shall be a matter of prior agreement between the owner and the service provider.

Although Conventional RT is widely used for boiler tube weld inspection, there are apparent safety
hazards & space constraints inside the boiler. RT being a positive method for detecting porosity,
inclusions, and voids in the interior of welds often fails to detect the planar defects like cracks, lack
of fusions which are a greater concern for serviceability. Due to the safety and financial
consequences associated with tube leaks, it is general industrial practice that most of the reputed
boiler owners perform volumetric examination to determine the quality of weld.

In the recent years with the technological advancements, UT technology with true scale imaging
capability proved to be a viable replacement of RT. Efficient and powerful Phased array ultrasonic
testing (PAUT) technique backed with low profile scanner and probes offers a better and complete
UT solution for boiler tube weld inspection. Several studies were conducted to understand the
qualitative and quantitate feasibility of PAUT in lieu of RT which demonstrated increased
probability of detection and productivity with negligible safety hazards. [See References]

Within the past decade, numerous industry codes have begun to incorporate PAUT as a viable
mean for volumetric inspection of welds of wall thickness less than or equal to 13mm.
• ASME B31 code case 189, Use of alternative ultrasonic examination acceptance criteria
in ASME B31.1
• ASME B31 code case 186, Use of alternative ultrasonic examination acceptance criteria
in ASME B31.12

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 • ASME B31 code case 181-2, Use of alternative ultrasonic examination acceptance
criteria in ASME B31.3
• ASME BPVC code case N-659-2, Use of ultrasonic examination in lieu of radiography for
weld examination, Section III, Division 1, Section III, Division 3
• ASME BPVC code case N-713, Ultrasonic examination in lieu of radiography, Section XI
– Division 1
• ASME BPVC Section VIII Division-2 7.5.5, Rules for construction of pressure vessels,
Alternative rules, Ultrasonic examination used in lieu of radiographic examination
• AWS D1.1 Clause 6 Part G, Structural welding code - Steel, Inspection, Other
examination methods
• API 620 Annex U, Design and construction of large, welded, low pressure storage tanks,
Ultrasonic examination in lieu of radiography
• API 650 Annex U, Welded tanks for oil storage, Ultrasonic examination in lieu of
radiography

References:
1. “Replacement of Radiography with Ultrasonics for the Non-destructive Inspection of
Welds – Evaluation of Technical Gaps – An Interim Report” Studies conducted by
Pacific Northwest National Laboratory (PNNL) based in Washington for the U.S.
Nuclear Regulatory Commission in 2010 has concluded UT as a feasible replacement of
RT given the guidelines for interchangeability of UT in lieu of RT are established in
standard codes.

2. “Phased array UT application for Boiler tube inspection in Manufacturing and In

service”
– by Anandamurugan S & Siva Sankar Y of GE inspection Technologies.

3. “Serviceability Based Examinations of Boiler tube Butt weds” – by John L Arnold,

Marshal Clark & Allen Porter

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 APPENDIX-B: TYPICAL TECHNIQUE SHEET
Scan Type Two Sided (Jireh/Cobra scanner)
Phased Array Ultrasonic Testing (PAUT)
Reference Code ASME B31.1
APPLICABILITY (as welded condition) [For more details, please refer appropriate welding specification]
Job Tube OD Thickness (mm) Weld Configuration Tube Material
circumferential weld
3” 10 Single V CS
(Two side access)
BEVEL DRAWING

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PAUT: Gr-1

PAUT: Gr-2

PAUT: Gr-3

PAUT: Gr-4

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PAUT: Complete Scan

Note:
1) Weld centerline shall be marked or referred by client.
2) Client shall confirm any prior check (lamination etc.), if any.
3) Response from notch in dynamic calibration block shall not be less than 80% FSH.
4) Scanning and Evaluation dB shall be performed at reference level or as per client’s recommendation.
5) Acceptance criteria shall be as per the referencing procedure.
6) Save data as per client’s recommendation.
Prepared By: Reviewed & Approved By: Client Representative

Date:
APPENDIX-C: TYPICAL SAMPLE REPORT
PROJECT NAME DATE OF INSPECTION
CLIENT DATE OF REPORT
JOB DETAILS:
WELD TYPE OD & THK
JOB No. DRAWING REF.

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MATERIAL SCAN SURFACE TEMP. / PWHT
EQUIPMENTDETAILS: (For further details, please refer Technique sheet)
EQUIPMENT &Sl.No. SOFTWARE
PROBE &Sl.No. SCANNER
ENCODER TYPE ENCODER RESOLUTION

APPENDIX-C: TYPICALSAMPLE REPORT (CONTD.)

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