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Ultrasonic Examination Procedure
Document No :
Rev.No Date Revision Details Prepared and Authorized
Approved by Signature
01. 20.01.18 Ultrasonic Flaw Engr. Md. Amit
Detection Hasan
CONTENTS
1. Purpose
2. Scope
3. Personnel Qualification
4. Equipment
5. Calibration
6. Examination Requirements
7. Examination Procedure
8. Evaluation of Indications and Acceptance Criteria
9. Removal of Defects
10. Records
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1 Purpose
The purpose of this procedure is to describe the methods of performing ultrasonic examination of
weldments in accordance with ASME Code requirements.
2 Scope
This procedure meets the requirement of ASME Code Section I, V and VIII Div. 1, ASME B31.1 &
ASME B31.3.
3 Personnel Qualification
3.1 All personnel performing Ultrasonic Examination according to this procedure shall be
qualified as per the requirements of procedure for Qualification & Certification of NDT
personnel, which meets the minimum requirements of SNT-TC-1A.
3.2 Certified UT Level I may operate equipment and perform ultrasonic testing under the
direct supervision of UT Level II.
3.3 The Radiographic Examination shall be carried out under the guidance or supervision of
a certified NDT Level II or level III individual.
4 Equipment
4.1 UT Equipment :
The Ultrasonic Test equipment shall be of the pulse-echo type. It shall generate, receive and
present on a cathode-ray tube screen pulses in frequency range from 1 to 6 (MHz). The presentation on
the CRT screen shall be the "Video" type and characterized by a clean, crisp trace. It shall be equipped
with a stepped gain control calibrated in units of 2 dB or less. It shall be able to work with both combined
and separated transmitter and receiver probe. The following make and models or equivalent can be used:
a) Modasonic Model Einstein-II DGS
4.1.1 Screen height linearity
The ultrasonic instrument shall provide a linear vertical presentation within ±5% of the full screen height
for 20% to 80% of the calibrated screen height (baseline to maximum calibrated screen points)
Amplitude control Linearity
The ultrasonic instrument shall utilize and amplitude control accurate over its useful range to ±20% of the
nominal amplitude ratio to allow measurement of indications beyond the linear range of vertical display
on the screen. Horizontal Linearity
The ultrasonic instrument shall provide a horizontal linearity within ±1% over the whole range.
The procedure for evaluation horizontal linearity, screen height linearity and amplitude control linearity
shall be as mentioned in Calibration section of this procedure.
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4.2 Probes :
The probes to be used shall have the following characteristics:
a) Probe unit may contain either single or dual probe elements.
o
b) Angle: O0, 450, 60 , 650 and 70o probe.
c) Frequency: 2 to 5 MHZ
d) Crystal size (mm) : 8X9 to 20X22 for angle probes; Diameter 10 to 25 for normal probes.
Probes with contoured contact wedges may be used to aid ultrasonic coupling. In such cases, calibration
shall be done with the contact wedges used during the examination.
The sizes and frequencies other than stated in (b) and (c) above may be used to assure adequate
penetration or better resolution.
4.3 Couplant :
4.3.1 A couplant which causes acoustic coupling between the transducer and the part being examined
shall be used. The same couplant used during calibration shall be used for examination. Any of the
following couplants may be used :
Grease
Oil
Water
Cellulose powder dissolved in water.
Other couplants which cause satisfactory acoustic coupling may be used when approved by the
NDT Level III.
4.3.2 The couplant including additives, shall not be detrimental to the material being examined.
a) Couplants used on nickel base alloys shall not contain more than 250 ppm of sulfur.
b) Couplants used on austenitic stainless steel or titanium shall not contain more than 250
ppm of halides (chlorides plus fluorides)
5 Calibration
5.1a Check Of Calibration:
The check of calibration during examination shall be carried out in the following cases:
Whenever the equipment is turned on.
When an element of system (cable, probe) is changed.
When the operators change during examination
Whenever there is any doubt concerning proper functioning of equipment.
A new calibration shall be made, and all the inspected area since the last valid calibration shall be
Re-examined, if at calibration check it is verified that:
A point of the D.A.C. curve has moved on the sweep line more than 10% of the sweep division
Reading.
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A point on the D.A.C. curve has decreased more than 20% or 2dB of its amplitude. If a point of
The D.A.C. curve has increased more than 20% or 2dB of its amplitude, all recorded indications
Since the last valid calibration shall be evaluated again and their values shall be changed on the
Reports.
5.1b Screen Height Linearity Check :
To verify the ability of the ultrasonic instrument to meet the linearity requirement, position an angle beam
search unit as shown in Fig. I-1 so that indications can be observed from both the ½ and ¾T holes in a
basic calibration block. Adjust the search unit position to give a 2:1 ratio of amplitudes between the two
indications, with the larger set at 80% of full screen height. Without moving the search unit, adjust
sensitivity (gain) to successively set the larger indication form 100% to 20% of full screen height, in 10%
increments (or 2 dB steps if a fine control is not available), and read the smaller indication at each setting.
The reading must be 50% of the larger amplitude, within 5% of full screen height. The settings and
readings must be estimated to the nearest 1% of full screen. Alternatively, a straight beam search unit may
be used on any calibration block which will provide amplitude differences, with sufficient signal
separation to prevent overlapping of the two signals.
5.1c Amplitude Control Linearity Check:
To verify the accuracy of the amplitude control of the ultrasonic instrument, position an angle beam
search unit as shown in Fig I-1 so that the indication from the ½T hole in a basic calibration block is
peaked on the screen. With the increases and decreases in attenuation shown in the following table, the
indication must fall within the specified limits. Other convenient reflectors from any calibration block
may be used with angle or straight beam search units.
Indication set at % of Control Change Indication Limits % of Full
Full Screen dB Screen
80% - 6 dB 32 to 48%
80% -12 dB 16 to 24%
40% +6 dB 64 to 96%
20% +12 dB 64 to 96%
The settings and readings must be estimated to the nearest 1% of full screen.
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5.1d Horizontal Linearity Check
Measuring range from 0 to 100mm
Place the probe on the IIW V1 block as shown in Figure 5.2.1. Make adjustments to get four signals on
the screen as shown in Figure 5.2.2. Check and record the actual position of each back reflection.
Measuring range from 0 to 250mm
Make adjustments to get 10 signals on screen as shown in figure 5.2.3. Check and record the actual
position of each back reflection.
Measuring range from 0 to 500 mm
Place the probe on IIW V1 Block as shown in Figure 5.2.4 and adjust 5 signals on the screen as shown in
Figure 5.2.5. Check and record the actual position of each back reflection.
Admissible Deviation
Deviation between actual location of each back reflection and required location shall be within +/-1% of
full scale.
Figure 5.1.1 Figure 5.1.2
Figure 5.1.3
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Figure 5.1.4 Figure 5.1.5
5.2 Equipment Calibration
5.2.1 Calibration Standards
5.2.1.1 IIW V1 / V2 blocks (See Figure 1) Use for Distance Calibration, linearity checks, angle checks
and index point.
Basic Calibration Block Use for amplitude calibration (See Figure 2)
5.2.2 Basic Calibration Block
The basic calibration reflectors shall be used to establish a primary reference response of the
equipment.
Calibration block material
The material from which the block is fabricated shall be of the same product form, and material
specification or equivalent P-number grouping as the material(s) being examined. P-numbers 1,3,4 and
5 materials are considered equivalent for this purpose. Calibration blocks for dissimilar metals welds,
the material selection shall be based on the material on the side of the weld from which the
examination will be conducted. If the examination will be conducted from both sides, calibration
reflectors shall be provided in both materials.
Calibration Block Thickness
When two or more base material thickness are involved, the calibration block thickness shall be
determined by the average thickness of the weld.
Calibration block surface finish
The finish on the surfaces on the block shall be representative of the surface finishes on the components
to be examined.
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Heat Treatment
The calibration block shall receive at least the minimum tempering treatment required by the material
specification for ;the type and grade and also a postweld heat treatment of at least 2 hours if the
calibration block contains welds other than cladding.
Basic Calibration Reflectors
The side of a hole drilled with its axis parallel to the examination surface is the basic calibration
reflector. A square notch shall also be used. The reflecting surface of the notches shall be
perpendicular to the block surface.
Curved Test surfaces
Materials with diameters greater than 508 mm
For examination in materials where the examination surface diameter is greater than 508 mm, a block of
essentially the same curvature or alternatively, a flat basic calibration block, shall be used.
Materials with diameters 508mm or less
For examination in materials where the examination surface diameter is 508 mm and less, the basic
calibration block shall be curved. A single curved basic calibration block may be used to calibrate for the
examination on surfaces in the range of curvature from 09 to 1.5 times the basic calibration block
diameter.
Angle Beam Calibration
The calibration shall provide the following measurement
Check of Probe Angle
Calibration of Range Scale
Calibration of Amplitude
Probe Angle Check
The probe shall be positioned on the IIW V1 or V2 block to verify the exact location of the probe index
and true probe angle. The difference between the nominal and true probe angle shall not exceed 2
degrees.
Calibration of Range Scale
The range scale calibration shall be made with IIW V1 or V2 Block
IIW V1 Block – Place the probe with the beam direction towards 25mm radius (See Fig. 3). The 1 st echo
indication comes after the beam travels 25mm and the 2 nd indication comes after the beam travels
150mm (i.e. an additional travel of 125mm). Bring the 1 st indication to position 1.67 on the horizontal
scale using the delay control. Adjust the range (fine) Control to place the 2 nd indication at position 10.
The scale from 0-10 CRT now corresponds to 0-150mm on steel.
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IIW V2 Block – Place the probe with the beam direction towards 25mm radius (See Figure 4). The 1 st
indication comes after the beam travels 25mm and the 2nd indication comes after an additional travel of
75mm i.e. a total of 100mm. Using the delay control position the 1 st indication at 2.5and with the range
control position the 2nd indication at 10. The scale from 0-10 on CRT now corresponds to 0-100mm on
steel.
Distance Amplitude Correction (DAC) Construction (See Figure 5)
‘Reject Control’ of the equipment shall be set in ‘OFF’ condition.
Position the probe for maximum response from 1/4T hole and adjust the gain setting to provide an
indication height of 80% (±5% of full screen height) and mark the peak of the indication on the screen.
Position the probe for maximum response from 1/2 t hole and mark the peak of the indication on the
screen
Position the probe for maximum response from 3/4T hole and mark the peak of the indication on the
screen.
Connect the screen marks for the side-drilled holes to provide the distance amplitude curve.
Record probe data and equipment settings. The amplification is called “Primary Gain”
5.2.3.4 When an electronic distance amplitude correction device is used, the primary reference
response shall be equalized at a nominal constant screen height of between 40% to 80% of full screen
height over the distance range or employed in the examination.
Straight Beam Calibration
The calibration shall provide the following:
Calibration of range scale
Calibration of amplitude.
Calibration of range scale
The range scale calibration can be made using IIW-V1 calibration block thickness (25mm or 100mm),
IIW-V2 calibration block thickness (12.5mm or 20mm) or ASTM basic calibration side drilled holes
reflection block.
IIW-V1 Block : Place the probe on the IIW V1 block as shown in Figure 6. with the delay and range
controls make adjustments to get four indications on the screen. Now the scale from 0-10 on CRT
corresponds to 0-100mm on steel. Similarly by getting 10 indications, the screen will represent 0-250
mm on steel.
To set a range of 0-500 mm, place the probe on the 100mm side of the IIW V1 block. Get five
indications on the screen. Now the scale from 0-10 on CRT corresponds to 0-500 mm on steel.
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5.2.4.2 Distance amplitude correction for normal probes (See Fig. 7).
1) Position for maximum response from the hole which gives the highest amplitude.
2) Adjust the sensitivity control to provide an 80% ( 5% of full screen height) of full screen height.
Mark the peak on the screen.
3) Position the probe for maximum response from another hole indication. Mark the peak on the screen.
4) Position the probe for maximum amplitude from the third hole indication and mark the peak on the
screen.
Connect the peaks and extend through to provide the DAC curve.
Examination Requirements
6.1 Examination Coverage
The volume shall be examined by moving the search unit over the examination surface so as to scan the
entire examination volume. Each pass of the probe shall overlap a maximum 0f 50% of the probe (piezo-
electric element dimension perpendicular to the direction of the scan).
For weld testing, scanning shall be done from both the sides of same face of material. In case both the
sides of same face are inaccessible, the information shall be recorded in the report
The entire volume of the weld needs to be covered, if necessary two or more angle beams need to be used
to ensure full volume coverage.
Scanning of plate for lamination using straight beam probe
For plate lamination testing, using straight beam probe, the area to be tested shall be scanned in grid
pattern. The grid dimensions shall be 225mm width by 225 mm breadth unless otherwise previously
specified and agreed with the client.
Rate of Probe Movements
The rate of search unit movement for examination shall not exceed 150 mm / second.
Scanning Sensitivity
Scanning shall be performed at a gain setting at least two times the reference level and recording of
indications (evaluation) shall be made with respect to the reference level.
Scanning surface
The test surface shall be free of irregularities; loose foreign matter or coatings, which may interfere with
ultrasonic wave transmission. The scanning surface shall be free of weld spatter, dirt and corrosion
products. Forged or rolled surfaces having reasonably smooth surfaces are acceptable.
Identification of item
The client shall supply sufficient information to the technician enabling the item for testing to be
identified. Datum locations shall be clearly marked.
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6.7 Determination Of Surface Compensation
Before starting the examination any possible differences in attenuation and surface character between
the calibration block and the material to be inspected are to be checked as shown in Fig. 10. The
difference in dB, is to be added to the “primary gain”. the gain so corrected is called “Corrected Primary
Gain”. The gain correction shall be 6 dB max.
EXAMINATION PROCEDURE
6.3 Inspection of Weld:
The weld joint and H.A.Z. shall be 100% examined.
As a rule the inspection shall be performed as follows:
a) Before starting the examination with angle probe it is required to investigate the scanning area with
longitudinal probe to verify the possible presence of laminar indication which can interfere with the
examination of welds. Record all areas giving indications equal to or greater than the remaining back
reflection. Where laminar reflectors interfere with the angle beam scanning, the angle beam technique
shall be modified to examine the maximum feasible volume, within the specified examination volume.
The examination for planar reflectors shall be performed on the entire volume of weld (when possible)
and adjacent base material. Record all reflectors that produce a response equal to or greater than 20%
of the distance amplitude correction.
b) During the scanning increase the gain setting value by 6 dB, the evaluation of the indication shall be
performed by placing the gain setting at true value (for defect evaluation the magnification used during
scanning 6 dB shall be removed).
c) Scanning overlap shall be approximately 50% of the transducer active element dimensions.
d) For detection of longitudinal defects the probe shall be placed on parent metal in such a way that the
sound beam is always normal to the weld axis. During the scanning the probe shall be angulated or
skewed 5 to 10 in the horizontal plane (See Figure No. 8).
e) For detection of transverse defect the probe shall be placed along side the weld connection so that
the beam sound form a shallow angle with the center line of the weld connection (See Fig. 9). If the weld
surface assures a sufficient coupling, the probes shall be placed directly on the weld.
f) Figures 8A, B shows scanning positions for butt welds with thickness up to 80mm and above 80mm
respectively. Figure 9 A, B shows scanning positions for set-on and set-in nozzles respectively. Figures
10A, B show scanning positions for T and corner joints respectively.
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7. Evaluation of Indications and Acceptance Criteria
Imperfections which produce a response greater than 20% of the reference level shall be investigated to
the extent that their shape, identity and location can be determined and evaluated in terms of
acceptance standards given below as per ASME Code Section I, Section VIII, Div. 1 & Div. 2 and B31.1.
1) Indications characterized as cracks, lack of fusion, or incomplete penetration are unacceptable
regardless of length.
2) Other imperfections are unacceptable if the indications exceed the reference level amplitude and
have lengths which exceed.
a) 1/4 in (6mm) for t up to 3/4 in (19mm).
b) 1/3t in for t from ¾ to 2 1/4 in (19 to 57mm).
c) 3/4 in (19mm) for t over 2 1/4 in (57mm)
Where t is the thickness of weld excluding any reinforcement. For a butt weld joining two members
having different thickness at the weld, t is the thinner of these thickness.
If a full penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be included in
8 Removal of Defects
Indications or discontinuities in excess of acceptance limits shall be removed by mechanical means and
repaired by qualified welding procedure wherever necessary. The repaired area shall be re-inspected
using the procedure according to this specification.
9 Records
The ultrasonic examination shall be documented by the ultrasonic inspector on the Ultrasonic Testing
Report Form
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Figure 2, Basic Calibration Block
Figure 3
Figure 4
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Figure 5
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Figure 6
Figure 7
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Figure 8
Figure 9
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Figure 10
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Figure 11
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Figure 12
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Figure 13
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