CHAPTER 14 Inspection and Testing Source: Photographs courtesy of National Weld 14.1 GENERAL 141.1 Owner/Engineer Because the amount and type of nondestructive testing required sting requirements determined early during the design stage, Testing and inspec- tion alone do not ensure the integrity of the penstock. They provide only additional assurance that the completed penstock does in fact conform fo the engineer's considerations. fects the basic design, ust be 14.12 Contractor ‘The supplier, fabricator, and installer are responsible for ‘quality control programs that provide the degree of qual- ity controVquality assurance required by the project speci= fications. Inspection and testing must be documented (see Corp.: reproduced with permission, ‘Chapter 16). Inspection by the owner or the engineer does not relieve the fabricator or installer of the responsibility of conforming to the project specifications, 14.2 SHOP OK FIELD INSPECTION Penstock components are subject to inspection at the place of fabrication and/or installation. The inspector must be allowed to view any oF all of the operations au to report forms and test results, such as radiographs, 14.2.1 In-Process Inspection Before the start of manufacture, the inspector must review the wsting requirements of the specification and the appli= cable codes and standards for tolerances, 163164 STEEL PENSTOCKS 4142.11 In-Process Inspections of Fabrication \n- process inspections must include the following where appli- cable: 1. Review of the purchase order and specification docu- ‘ment requirements for materials, fabrication, weld- ing, examination, testing, marking, tagging, cleaning, painting, and preparation for shipment. Review of the suppliers’ quality assurance programs. for conformance with the project specifications and discussions with the suppliers” personnel about the ‘quality verification activities to be performed during the course of the assignment. -w of the shop drawings and other vendor docu- ‘that require submittal before fabrication, in- jon that they have been approved by the engineer, are properly stamped, and released for fabrica 4. Review of mill test reports for alll materials used in the fabrication of the penstock sections to verify that the materials are in compliance with the specification ‘und applicable ASTM standards for chemical com- position, mechanical properties, and Charpy impact tests, if applicable 5. Verification that the pressure and attachment material identification, heat number, and thickness correspond with the certified mill test reports provided for the project. In addition, the owner may request the certi- fied mill test reports for other materials. Copies of Certified mill test reports must be available for inclu- sion inthe project file ©. Verinication that welding procedures and welders have been qualified and are approved in accordance with the requirements of the specification, drawings, ‘and applicable codes and standards. This step may require an in-process review of the welding proce dure specification (WPS) and supporting procedure ‘qualification record (PQR) for conformance with the specification, drawings, and applicable codes and standards, particularly if there were design or person- nel changes after the original submissions. Welders and welding operators must have current Certifications and must be able to produce acceptably sound welds with the processes, materials, and weld ing procedures to be used in production, 7. Verification that welding electrodes, filler materials, and fluxes are identifiable, in compliance with the ap- plicable WPSs, and properly stored and maintained in a clean and dry environment. 8. Check of all in-process welding for conformance to approved welding procedures, drawings, and appli- cable codes. This check includes all welding parame- ters, preheat, and interpass temperature requirements. 9. Where welding repairs are required, verification that the contractor has an approved repair and inspection procedure and follow-up testing plan to ensure sat- isfactory defect removal and welding of the affected 10. Check of the plate edges. 11. Inspection of shell courses for concentricity and roundness and verify that the fi-up gaps of longitudi- nal and circumferential joints are within the tolerances, given by the specifications. 12, Inspection of the various parts of the penstock to en- sure that all appurtenances have been provided and that the projections and orientations are in accor- dance with approved shop drawings. 13, The inspector's witnessing of nondestructive exami- nation (NDE) of materials or welds (spotscheck) on. ‘random basis or as specified by the purchase order and review of the required radiographic film to ensure that there are no indications exceeding the limitations, specitied by the applicable codes and standards. 14, The inspector's verification that any required preheat or postweld heat treatment has been performed in ac~ cordance with the approved procedures. The inspec- tor must obtain copies of time-temperature charts of cach stress-relieving operation for inclusion in the project file, 15, For elbows, measurement of each chord to ensure dat he units are fabricated as specified and ive the desired radi 16. For wye branches, verification of branch angle(s), projection, and orientation. 17. For couplings and mechanical expansion joints, re- view for compliance with the project specifications of the mill test reports provided for the couplings and gasket materials; documentation of NDE (if required). Couplings and gaskets must be checked for physical damage, and dimension checks must be made to ver= ify compliance with the drawings. The longitudinal or spiral seam welds on both ends of the penstock see tions must have been ground flush in accordance with the project specifications and drawing requirements. 14.212 Coating and Lining Inspection Requirements When corrosion protection, internal lining, oF external sur- face coating is required inthe project specifications, a careful spection for strict compliance with the project specifica- tions, referenced standards, and Chapter 10 of this manual is mandatory. Details of inspection procedures for coating ‘materials and their application are given in Chapter 10. 14.2.2 Final Shop Inspection Refare shipment, final shop inspections must he completed 1, Ensure that required test reports, as-built drawings, and other documentation generated during the fabrica- tion of the penstock are complete and available.166 STEEL PENSTOCKS Film must be marked with the date, owner's project num- ber, contract number, piece or section number, and weld number. Procedures must include an identification system ty between the radiographic film and the weld examined, as well as clear location of weld defects. Radiographs and interpretation reports must be submitted to the owner for permanent retention. Acceptance standards for welded joints examined by radiography must be in accordance with Paragraph UW 91 ‘or UW $2 of ASME (20108). Defects disclosed by radiography and determined unac- ‘ceptable in accordance with the project specifications must be repaired and reradiographed. 14.32 Ultrasonic Examination UT and acceptance standards for welds other than spiral welds must be in accordance with Paragraph UW 53 and Appendix 12 of ASME (20106), For spiral-welded pipe used in penstocks, ultrasonic test procedures and acceptance stan- ‘dards must be in accordance with API (2009). 14.3.3 Magnetic Particle Examination MT techniques are described in Article 7 of ASME (20103) ‘and in ASTM (2008). Acceptance criteria must conform to the requirements of Appendix 6 of ASME (2010b). 14.34 Liquid Penetrant Examination Liquid penetrant examination (PT) procedures mast conform to the requirements of ASME (2010a), Acceptance criteria ‘must conform to the requirements of Appendix B of ASME, (20106). 14.35 Visual Examination Visual examination (VT) procedures must conform 0 the requirements of ASME (2010). “The following visual indie Cracks; Undercut on surface greater than 1/32 in. deep: Lack of fusion on the surface; Incomplete penetration’ Convexity of fillet weld surface greater than 10% of the longer leg plus 0.03 in.; Concavity in groove welds: Concavity in fillet welds greater than 1/16 in.: and 8, Fillet weld size less than indicated or greater than 1.25 times the minimum indicated fillet leg length, Disclosed defects that are determined unacceptable in be repeicest and reexamined. 14.3.6 Areas Requiring Special Consideration 1. Where required by the project specifications or the weld procedure, weld bevel preparation in wye branches and penstocks must undergo magnetic par- ticle examination (MT) before welding. Laminations ‘and other linear defeets must be repaired in accor- dance with Paragraph 9.4 of ASTM (2011). 2. C-ginders used for reinforcement of wye hranches are subjected to through-thickness loading where the shell plates are welded to them. If the plate has Jaminations in the loaded area, lamellar tearing can occur. The likelihood of this defect occurring in- creases with plate thickness, Therefore, C-girder plates exceeding I in. in thickness must undergo ul- trasonic examination (UT) in the area within 6 in. of the shell-to-C-girder weld. UT and evaluation must comply with ASTM (2007), with the addi tional requirement that the 6-in. band adjacent to the weld area must undergo 100% UT. Any defect that shows a loss of back reflection that cannot be con- tained within w I-in-diameter circle is unacceptable. Laminations must be repaired in accordance with Paragraph 9.4 of ASTM (2011). Shell-to-bar joints in wye branches must also be examined for lamina- sions in a similar manner. Exposed edges of C-girders must undergo MT after postweld heat treatment 3. After postweld heat treatment, if required, weld sur- faces must undergo MT in accordance with Appendix 6 of ASME (2010b). If, in the opinion of the inspector, major repalrs are required, stress relief again may De required after repairs 14.4 HYDROSTATIC TESTING 144.1 General Hydrostatic testing is not a mandatory requirement for pea stocks. The need for hydrostatic testing is determined by the engincer and included in the project specifications. The following should be considered in determining the need for hydrostatic tests 1, Site location, automatic shut-off systems, and head; 2. Risk to the public and damage to property in the event ofa failures 3. Structural complexity (complicated weldments, such fas wye branches, may warrant testing to verify their fabrication). The engineer may consider 100% RT or UT, and MT in lieu of hydrostatic testing; and 4, ‘The extent and type of NDE performed in the shop and. field. HEALD Component Testing Pipe: for witered teats may be hydrostatically tested before making mitered cuts.