NTPC LIMITED

(A GOVERNMENT OF INDIA ENTERPRISES)

SSC VINDHYACHAL

SCOPE OF WORK

10.10 INSPECTION OF JOINTS DURING O/H: PHASED ARRAY ULTRASONIC TESTING (PAUT) IN BOILER DURING UNIT
O/H
1. Agency has to arrange all equipments and skilled for Phased array Ultrasonic Testing (PAUT) of high pressure boiler
tube joints during Unit O/H & a detailed report showing all the inspection findings has to be submitted to NTPC in
prescribed format.
2. Necessary Power supply, scaffolding platforms, lighting, and manpower assistance for cleaning of boiler tubes at
location shall be arranged by NTPC as per site requirements.
3. Agency may have to carry out Phased array Inspection on Boiler tubes during unit O/H of sizes varying from OD
30mm to 70 mm and thickness ranging from 3.6 mm to 14 mm. Tube materials are of Carbon Steel, Alloy Steel (SA 213
Gr T11, SA 213 Gr T22 & SA 213 Gr T91 or equivalent) & Stainless Steel (SA 213 Gr TP321H & SA 213 Gr TP347H or
equivalent) grade.
4. Phased Array Ultrasonic Testing / inspection for circumferential weld joint inspection of boiler tubes (Waterwall,
superheater, reheater & other tubes, as identified by station) is to be carried out for assessment of the weld joints. For
waterwall tubes, portion of weld on fireside will only be tested with probes/wedges dismantled from the scanner.
5. Test System: For PAUT inspection of boiler tubes, service provider agency will bring the PAUT equipment &
accessories with following or higher capability:
(i) PAUT equipment: 16:128 or higher configuration,
(a) Weld inspection features including setting up of weld profile
(b) Multi grouping capability
(c) Capability of using two UTPA probes simultaneously. Necessary adapter/splitter (if required) for attaching two probes
for simultaneously working should be available for inspection.
(e) Operation with battery
(f) A-scan, B-Scan, C-scan, S-Scan, Linear scan, Sectorial scan
(g) Calibration: Velocity, Wedge Delay, Sensitivity, TCG, DAC, Encoder calibration features
(h) Data analysis and report building
(i) Encoder recognition

(ii)Probes: At least two numbers of low profile suitable PAUT probes of 7.5-10 MHz frequency, 16-32 element with more
than 2 meters of cable length. The probes shall have couplant supply mechanism for passage of couplant (water to be
used in this case) to test surface. A water irrigation channel along with water storage container & pressure mechanism
for providing continuous couplant (water) to the probe during testing.
(iii)Wedges: Specially designed wedges to fit in the above probes and having refractive angle of 50 to 60-degree shear
wave in steel. Wedges should have suitable contour to fit with around 25-100 mm outer diameter tubes.
(iv)Scanner: A manual/automated scanner capable for scanning of around 25-100 mm outer diameters tubes. The
scanner shall have encoder with it for precise data acquisition. The scanner shall be able to hold two low profile phased
array probes and wedges, as mentioned above, for complete inspection of the weld in one rotation of the scanner. The
design of scanner, probe & wedges shall allow complete inspection of circumferential weld on tube having gap of more
than 15 mm with any adjacent tubes, supports and structures etc.
6. Manpower: Inspection/service provider agency shall depute two persons with minimum UT Level-2
qualification/certification from PCN, CSWIP, ASNT and ISNT. Also at least one person should have sufficient training (at
least 5 days) in PAUT for operation, data analysis and interpretation of signal/data acquired. The necessary
document/certificate for above to be produced to station.
7. Test plan:
(a) The agency shall submit the written inspection procedure for PAUT of boiler tube weld joints. Scan plan
(linear/sectorial) shall cover the entire volume of the weld for inspection and should mention parameters, like thickness,
OD, Index offset, weld profile, probe, wedge, scan angles etc. There shall be minimum one sectorial scan for one probe.
Total minimum two groups for two probes, positioned at 90 & 270 degree. Angle step shall be 0.5 degree.
(b) Calibration: velocity, wedge delay, sensitivity, TCG, encoder calibration shall be performed before inspection.
Reference block: Tubes with similar diameter & wall thickness (within 10%) and circumferential notches/grooves
(detailed below) shall be used as reference block. The Reference block should have length not less than 200 mm. It
should have two circumferential grooves/notches (one each on ID & OD) having depth of 10% wall thickness, 1 to 1.5
mm width and length between 25 to 50 mm. These two grooves should be located at opposite ends of the tube. The
notches should be separated from adjacent tube edge by about 50 mm. The length of reference block and location of
reflectors (notches/grooves) should comply the requirement of calibration for angle beams. In case tube for preparation
of reference block is not provided by NTPC, the inspection agency has to arrange it.
(c) Data storage: The calibration data and inspection data should be stored in the equipment and should be available for
verification to NTPC Personnel. Inspection data file is to be stored by giving identifiable marking for reporting &
interpretation.

(d) Test Results: The test results for each tested tube should provide information on type of defects (like Lack of
penetration, porosity, Lack of Fusion etc.), their location, length, height, depth etc. The final report with above
information to be given in an excel sheet along with PAUT inspection data file & images for all the tested tubes.
8. Surface preparation & access to test area: NTPC will provide suitable arrangement (scaffolding etc.) for safe access to
test locations. Also surface cleaning /buffing on weld regions of tube, lighting (hand lamp etc. as required) would be
within the scope of NPTC.

10.20 MOBILISATION CHARGES:

1. Agency scope include deployment of requisite manpower and equipment’s as per scope of work specified above.
2. Payment for mobilization charges shall be done on the basis of no. of overhauling’s for which agency has mobilized its
PAUT testing equipment’s and technician at site as per instruction of EIC. Expected no of mobilizations during the
contract period are 07 nos.
B) TERMS AND CONDITIONS:
1. The bidder should report at site with his team as required by Engineer-in charge at least one day in advance during
unit shut down. Start date of job at site shall be communicated 7 days in advance.
2. Site testing completion period is 07 to 10 days for each unit. During this period accommodation subject to availability
may be provided to technicians in NTPC hostel / guest house on chargeable basis.
4. Contract Period shall be 12 months( Tentative date of start shall be 7 days from the date of LOA )
5. Defect liability period is nil.
6. Interim Reports shall be submitted daily on site as job progresses.
7. As the job is of intermittent in nature, where employees are not permanently deployed at site, no "HR NOC" shall be
applicable for this contract.
C) SPECIAL TERMS AND CONDITIONS RELATED TO SAFETY:
1. The bidder shall ensure safety in work place by the people and method applied for the job. Personal protective
devices like safety helmets, safety belts, etc. shall be arranged by the bidder. It shall be responsibility of the bidder to
take adequate insurance for the people and works of overhauling & shutdown are not affected.
2. Contractor has to strictly follow the safety regulations for safe working of men and equipments, working at high
elevations and scaffolding.
3. Contractor shall be fully responsible for the safety of his workmen and equipment. He should clearly understand that
safety of men at work is as important as the work itself. The contractor shall ensure the safety of highest standard by his
entire work force. Besides the various statutory requirements prescribed to ensure safety, special attention is here by
drawn to the following safety precautions in particular.
4. GENERAL SAFETY PRECAUTIONS:
a) All persons deployed by contractor should be medically fit.
b) All persons must wear ISI marked safety helmet, ISI marked safety shoes and use other personal protective
equipment like dust mask, safety belt, hand gloves, grinding goggles and fire restrained clothing’s as deemed necessary.
c)Violation of any safety norms shall draw the penalty as per the safety clauses of NTPC.
5. SAFETY PRECAUTIONS RELATED TO WORKING AT HEIGHTS:
a. All workers working at a height of more than two meters of any other location fall from where is likely to cause
injuries should use safety belts (of ISI marked full body harness type only).
b. For working at height, the contractor and his workers must take up the job only when the contractor is assured of the
safety of his workers.

6. SAFETY TRAINING: Contractor shall ensure that all of his workmen deployed for the work have compulsorily
undergone safety training at safety dept. or elsewhere organized by safety dept. Before and after the start of work,
Safety training is being organized by safety dept. from time to time.

Bill of Quantity

SL NO Description Unit Qty

PHASED ARRAY INSPECTION DURING O/H

10.10 INSPECTION OF JOINTS DURING O/H 3,500 NO
10.20 MOBILISATION CHARGES 7 NO