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PROCEDURE FOR ULTRASONIC TESTING

BUTT WELDS

Rev No Issue Date Prepared By Reviewed By Approved By Client

00 S. Manoj
Chithambaranath

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CONTENTS

Sl. No Description Page Ref #

1. SCOPE 03
2. REFERENCE DOCUMENTS 03
3. PERSONNEL QUALIFICATION 03
4. NON COMPLIANCE 03
5. GENERAL REQUIREMENTS 03
6. EQUIPMENT 04
7. SURFACE PREPARATION 04
8. INSTRUMENT CALIBRATION 05
9. SYSTEM BEAM CALIBRATION 06
10. TECHNIQUE 09
11. CONDUCTING THE TEST 11
12. CHARACTERIZATION OF DISCONTINUTIES 12
13. DETERMINATION OF SURFACE OMPENSATION 13
14. INSPECTION PROCEDURE 10 & 14
15. POST EXAMINATION CLEANING 15
16. EVALUATION OF INDICATIONS 15
17. ACCEPTANCE CRITERIA 16
18. SAFETY REQUIREMENTS 17
19. ATTACHMENTS & FIGURES 17
20. SAMPLE REPORT FORMAT 21

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1. SCOPE

This procedure covers minimum requirements to perform the ultrasonic examination for
detecting, locating and evaluating indications the flaws on both base metals and welds using the
contact inspection technique of thickness over mm.

2. REFERENCE DOCUMENTS

ASME SEC V – 2017 Edition

ASME B 31.3- Edition-2016
EN473 /ISO9712:2012 -NDT-Qualification and Certification of Personnel
EN1330-4 Non-destructive Testing Terminology Part-4: Terms used in ultrasonic testing
EN 23279:2010 Non-destructive examination of welds Ultrasonic examination characterization of
imperfections in weld.
EN 11666:2010 Non-destructive examination of welds Ultrasonic examination of welded joints
acceptance levels.
EN 17640:2010 Non-destructive examination of welds joints, Ultrasonic examination of welded
joints
EN 16810:2014 Non-destructive testing Ultrasonic examination Part 1: General principles Non
destructive testing Ultrasonic examination Part 2: Sensitivity and Range settings.

3. PERSONNEL QUALIFICATION

ISO 9712 Level II personnel shall perform UT inspection and Level II personnel shall be
qualified and certified in accordance with ISO 9712 recommended practice.

4. NON COMPLIANCE

If any of test area could not be tested due to inaccessibility, surface condamination and
temperature condition, it to be indicated in the UT report.

5. GENERAL EXAMINATION REQUIREMENTS

5.1. EXAMINATION COVERAGE

Each pass of the search unit shall overlap a minimum 10% of the transducer (piezoelectric
element) dimension perpendicular to the direction of the scan

5.2 RATE OF SEARCH UNIT MOVEMENT

The rate of search unit movement for examination shall not exceed 6 in. /sec (150mm /
Sec) unless calibration is verified at scanning speed.
5.3 RECORDING SENSITIVITY LEVEL

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The recording of indication shall be made with respect to the reference level.

5.4 TEMPRATURE

The temperature difference between the calibration block and examination surface shall
be within 25°F (14°C).

5.5 CONTACT WEDGES.

The same contact wedges to be used during the examination shall be used for calibration.

6. EQUIPMENT

6.1 ULTRASONIC FLAW DETECTOR

Ultrasonic flaw detector (Krautkramer USM 36 or Epoch 600 or equivalent) is the Pulse
echo type utilizing A—Scan presentation capable of transmitting and receiving
frequencies from 1 MHZ to 5 MHZ equipped with gain control steps 2 dB or less.

6.2 PROBES

The probes shall be electrically compatible to the flaw detector having various sizes and
configurations as below.

a) Angles: 0°, 45°, 60°, 70°

b) Frequency: 1 to 5 MHz
c) Crystal size: The circular transducer elements shall not greater than 1 1/8 inch
diameter and the rectangular shall not greater than 3/4inch X 1 inch wide.

6.3 COUPLING MEDIUM

The coupling medium shall be a suitable mixture of glycerine, grease, oil, water or
cellulose powder. Couplant materials used for examination shall be the same as used for
the calibration. The couplant shall produce maximum acoustic transmission between
Probe face and material under examination.

7. SURFACE PREPARATION

7.1 BASE METAL

The base metal on each side of the weld shall be free of weld spatter, surface
irregularities, of foreign matter that might interfere with the examination. Surface
preparation is necessary to ensure that the entire volume of the weld is scanned with the
required angle probe.

7.2 WELD METAL

Welds which are to be ultrasonically examined shall be prepared to the extent necessary
to provide a sufficiently smooth and regular area to allow satisfactory distance required

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and shall free of any irregularities such as spatter, grinding or chipping marks, dust, dirt or
any foreign matter that might interfere with the examination.

7.3 DISCONTINUITY SOUGHT

The evaluation of indications shall be performed on indications detected by

testing performed in accordance with EN 17640.

The setting reference level shall be a distance amplitude curve (DAC) for a
3mm diameter side drilled hole.

Evaluation level of an indication equal to or exceeding the reference level –

10dB (33%DAC) shall be evaluated.

Recording level of all indication equal to or exceeding the reference level –

6dB (50% DAC) shall be evaluated.

8. INSTRUMENT CALIBRATION

The ultrasonic instrument shall be calibrated (Screen height and amplitude control
linearity) three months once for analog type instruments and one year for digital type
instruments, or prior to first use thereafter as per ASME V article.4 Sec-T.460.

`8.1 SCREEN HEIGHT LINEARITY

 Couple the V1 block (IIW) to the search unit (Normal Probe) as shown in
Attachment-1. Adjust the instrument gain, sweep delay and sweep range controls
to display multiple back wall echo pattern.

 Select two back wall echoes which bear 2:1 ratio of amplitudes. The larger one is
considered as first indication and the smaller one is second indication. Adjust the
instrument gain such that the height of the first indication is at 100% full screen.
Note the height of second indication and record the % of screen height.

 Adjust the instrument gain to reduce the height of first indication of 100% full
screen to 90% of full screen. Note the height of second indication and record.
Reduce the height of first indication in steps of 10% of full screen height up to
20% of full screen height and each time note the height of the second indication
and record the % of screen height.


In each step the reading must be 50% of the larger amplitude within 5% of full
screen height. The procedure for calibrating screen height linearity shall be
performed at the beginning of each period of extended use or every three month
whichever is less.
8.2 AMPLITUDE CONTROL LINEARITY

Couple the V1 block (IIW) to the search unit (Normal Probe) as shown in Attachment-1.
Adjust the instrument gain, sweep delay and sweep range control to display four non-
interfering back reflections.

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Further adjust the sweep delay and sweep controls to position the leading edge of first and
third back reflection on accurately on 25% and 75% divisions of horizontal sweep scales
respectively.

Select the first back wall indication. Adjust the instrument gain such that the height of that
back wall indication is at 80% of full screen. Reduce 6 dB gain, observe the height of the
indication in % full screen height and record. Further reduce 6dB, observe the height of
that indication.

Set the height of the second indication at 40% of full screen by using instrument gain
control. Increase 6 dB gain, observe the indication's height in % of full screen height and
record.

Set the height of the third back wall indication at 20% of full screen by adjusting
instrument gain. Increase 12 dB. Note the height of the indication in % of full screen and
record.

Indication set at full dB control changer Indication limits %

screen 80% full
screen
100% +2dB Above 95%
80% Ref dB Not Less Than 80%
40% -6dB <35% to >45%
20% -12dB <15% to >25%

9. SYSTEM CALIBRATION

The system calibration during examination shall be carried out in the following cases:
- At beginning and end of each examination.
- When an element of system (cable, probe) is changed
- When the operators change during examination
- Whenever there is any doubt concerning proper functioning of

9.1 BASIC CALIBRATION BLOCK

The basic calibration reflectors shall be used to establish a primary reference response of
the equipment. The basic calibration reflectors may be located either in the component
material or in a basic calibration block (as shown in fig.1).

a) The material from which the block is fabricated shall be of the same product form
and material specification or equivalent P-Number grouping as one of the material
being examined.

b) For examinations in materials where the examination surface diameter is greater

than 500mm a flat basic calibration block shall be used as per Sec.

9.2 BLOCK CURVATURE

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9.2.1 MATERIALS WITH DIAMETER GREATER THAN 20 INCHES (NON PIPING)

For examination of materials where the examination surface diameter is greater than 20" a
block of essentially the same curvature or alternatively, a flat basic calibration block, shall
be used

9.2.2 MATERIALS WITH DIAMETERS 20" AND LESS (PIPING)

The basic calibration block shall be curved for materials with diameters 20" and less.
Except where otherwise stated in this procedure, a single curved basic calibration block
may be used to calibrate the examination on surfaces in the range of curvature from 0.9 to
1.5 times the basic calibration block diameter.

Calibration reflectors shall be longitudinal and with circumference notches in both the
inner and outer surfaces. The sizes and locations of the calibrationreflectors are shown in
fig - 2.

9.3 NON-PIPING CALIBRATION BLOCKS

For other than pipe welds the basic calibration reflectors as shown in figure 1.

9.4 RANGE SETTING (Fig 3 & 4)

For straight beam range shall be set such that the screen displays at least 2 backwall
echoes using V1 or V2 Blocks.

For angle beam testing, the range shall be calibrated using V1 or V2 Blocks to cover at
least one full skip distance for each angle Probe being used to ensure that entire volume of
the weld covered during scanning.

The range shall be checked at least once in 4 hours and every time when changes made in
system parameter such as search unit change, test thickness change, operator change etc.

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 the recorded indications since the
last valid calibration or calibration check shall be re-examined and their values shall be
changed on the data sheet or re-rerecorded

Fig- 3 (Range Setting – Normal Probe )

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9.5 DISTANCE AMPLITUDE CORRECTION CURVES (DAC Fig 5 & 6)

DAC Curve is required to be generated for prior to the weld scanning by angle beam
technique. Distance amplitude correction curves shall be constructed for each angle probe
employed for weld examination.

The basic calibration block is used for this purpose. Reflectors selected for establishing
the DAC curve include those located at T/4, T/2 and 3T/4 depths (where T is the
thickness of the block). Calibrate Screen range equal to full skip distance for the Part
being tested by using V1 or V2 blocks.

Position the angle beam probe on surface of basic calibration block such that its beam
path is directing towards the first reflector (T/4). Adjust the sensitivity control (dB) to
provide maximum echo peak to 80% full screen height. Mark the Peak at 80% on the
CRT Screen.

Without changing the gain setting of the Instrument, Position the angle beam probe basic
reference block to get maximum echo amplitude from T/2 depth reflector. Mark the peak
of the echo on the screen. Without changing the gain setting of the instrument, Position
the angle beam Probe on basic calibration block to get maximum echo amplitude from
3T/4 depth. Mark the Peak of the echo on the screen. Join these marking of the CRT
Screen to obtain DAC Curve.

The first point on the DAC Curve is set by adjusting the response of the first reflector to
80% of full screen height. Subsequent points are determined by plotting the response from
the other selected reflectors as applicable. A smooth curve is drawn through the plotted
points to give the DAC Curve.

Electronic DAC Curve generation is permitted if it is verified on the basic calibration

blocks

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10. TECHNIQUE

10.1 General

This technique utilizes the reflected or diffracted signal from any interface of interest within the
object under examination. This signal is characterized by its amplitude and position along the
time base; the latter related to the distance between the reflector and the probe. The location of
the reflector is determined from the knowledge of its distance, the direction of sound propagation,
and the position of the probe it is recommended that the signal amplitude be measured by
comparison with either:

a) a distance amplitude correction (DAC) curve, or a series of DAC curves, obtained by using
artificial reflectors (side drilled holes, flat-bottomed holes or notches etc.) within one or more
reference blocks;

b) an equivalent reflector diagram (DGS system);

c) echoes from suitable notches; or

d) echoes from large planar reflectors perpendicular to the acoustic axis (e g. back wall echo
These techniques are described in EN 16811.

In order to obtain further information about the shape and size of reflectors, other techniques may
be used. Such techniques are based, for example on variations in signal amplitude with movement
of the probe, measurement of sound path or frequency analysis.

Ultrasonic examinations shall be performed in accordance with EN 16810 with the addition of the
following clauses.

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10.2 Manual scan path

During angle probe scanning (as illustrated in figure 1) a slight swiveling movement up to a angle
of 10deg on either side of the nominal beam direction may be applied to the probe

10.3 Examination for imperfections perpendicular to the examination surface

Subsurface planar imperfections perpendicular to the examination surface are difficult to detect
with single angle probe techniques. For such imperfections specific examination techniques
should be considered, particularly for welds in thicker materials. Use of these examination
techniques shall be by agreement between the contracting parties.

10.4 Location of indications

The location of all indications shall be defined by reference to a co-ordinate system, e.g. as shown
in figure XY. A point on the examination surface shall be selected as the origin for these
measurements. Where examination is carried out from more than one surface reference points
shall be established on each surface. In this case care shall be taken to establish a positional
relationship between all reference points used, so that the absolute location of all indications can
be established from any nominated reference point. In the case of circumferential welds this may
require the establishment of the inner and outer reference points prior to assembly for welding.

10.5 Evaluation of indications

All relevant indications above the evaluation level shall be assessed in accordance with EN 17640
clauses 12.5.2 (I,e given below) to 12.5.4.

Maximum echo amplitude The echo amplitude shal be maximized by probe movement and
recorded in relation to the agreed reference level

10.6 Indication length

The length of the indication, in either the longitudinal or transverse direction shall, where
possible, be determined using the technique specified in the acceptance levels standard or the 6
dB drop tip location technique, unless otherwise agreed.

10.7 Indication height

Indication height measurement shall be carried out by agreement only. If applicable, the
following method shall be used: Where possible, for imperfections which generate more than one
distinct peak in the received signal when scanned in the through-thickness direction, the height
(h) shall be measured by a probe movement technique. It is recommended that when an indication
has a measured height of 3 mm and above, the indication height is recorded. However, other
higher threshold heights for recording may be agreed upon.

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10.8 Characterization of imperfections

Imperfections shall be characterized only by agreement between the contracting parties, or when
necessary to meet the requirements of the specified acceptance levels.

DAC DRAWING PROCEDURE IS GVEN IN THE APPENDIX – III

11. CONDUCTING THE TEST

11.1 General

Quality requirements for welded joints are mainly associated with the material, welding process
and service conditions. To accommodate all of these requirements this standard specifies four
examination levels (A, B, C and D).

From examination level A to examination level Can increasing probability of detection will be
achieved by an increasing examination coverage e g number of scans, surface dressing. The
examination level D may be agreed for special application using a written procedure which shall
take into account the general requirements of this standard.

In general the examination levels are related to quality levels (e.g. EN 25817). The appropriate
examination level may be specified by standards for examination of welds (e.g. EN 12062) product
standards or other documents. When EN 12062 is specified the recommended examination levels
are as given in table

Recommended examination levels

Examination level Quality level in EN

25817

A C

B B

C By agreement

D Special application

Specific requirements for examination levels A to C are given for various types of joints in annex
A. It should be noted that the joint types shown are ideal examples only and where actual weld
conditions or accessibility do not conform exactly to those shown, the examination technique
shall be modified to satisfy the general requirements of this standard and the specific examination
level required. For these cases a written test procedure shall be prepared.

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11. 2. Examination coverage

Scanning shall be carried out in accordance with the requirements of the referencing document(s).
These requirements shall include the areá to be scanned and the scanning direction, and can
include the type, size, frequency and beam angle of the probe s) to be used.

11.3. Overlap and scanning speed

Overlap

For a 100 % examination, the interval between two successive scan lines shall not be greater than
the -6 dB beam width at any depth within the examination volume

Scanning speed

The choice of scanning speed shall take into consideration the pulse repetition frequency and the
ability of the operator to recognize or of the instrument to record signals In semi-automatic or
automatic examination, the maximum scanning speed (Vmax) is determined by the passage of a
reference block beneath the probe, or is calculated from the following equation:

VMAX = DxFREP/N (mm/s)

Where

d is the minimum beam width at p6 dB, in millimeters (mm) as applicable for the examination;

frep is the pulse repetition frequency in hertz (Hz);

n is the number of consecutive signals of an indication before alarm.

11.4 Evaluation and recording levels

The evaluation and recording levels are defined in relevant standards. When these levels are not
defined, the values applied during the examination shall be included in the examination report.

11.5 Pulse echo technique

If the amplitude of an echo exceeds the evaluation level, the signal shall be evaluated against the
acceptance criteria.

12. CHARACTERISATION OF DISCONTINUITIES

Characterization of a discontinuity involves the determination of those features which are

necessary for its evaluation with respect to known acceptance criteria.

Characterization of a discontinuity may include

a) Determination of basic ultrasonic parameters (echo height, time of flight)

b) Determination of its basic shape and orientation,

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c) Sizing, this may take the form of either:

The measurement of one or more dimensions (orarea/volume), within the limitations of the
methods; or the measurement of some agreed parameter e.g. echo height, where this is taken as
representative of its physical size.

d) Location e.g the proximity to the surface or to other discontinuities

e) Determination of any other parameters or characteristics that may be necessary for complete
evaluation

f) Assessment of probable nature, e.g. crack or inclusion, where adequate knowledge of the test
object and its manufacturing history makes this feasible

Where the examination of a test objects in accordance with the principles of EN 583-1:1998
yields sufficient data on the discontinuity. For its evaluation against the applicable acceptance
criteria, no further characterization is necessary.

The techniques used for characterization shall be specified in conjunction with the applicable
acceptance criteria.

Characterization of imperfections using Pulse echo technique

- The imperfections are characterized by at least:

- their location in the object (x, y and z co-ordinates);
- Their reflectivity determined by measuring the maximum amplitude of the echo by one of
the methods described in EN 16811.
Supplementary characteristics can also be determined, such as:

- orientation;
- size determined by 6 dB drop technique, or other probe movement techniques;
- planar or non-planar characteristic.

13. DETERMINATION OF SURFACE COMPENSATION

The different in single amplitude between the calibration block and test component due to
test surface roughness shall be compensated by use of transverse correction values. The
thickness of the block and the job should be equal.

1. Transfer gain correction shall be provided for coupling losses and losses due to beam
divergence.

2. After the time base calibration for through transmission technique, two similar angle
beams are to be connected to the instrument. One as transmitter and other as receiver

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3. The transmitter and receiver probe should be kept on the basic calibration block ( scan
"Al") and the probe distance should be adjusted to obtain maximum transmission level

4. The gain setting should be adjusted to 80% of full screen height on the basic calibration
block surface( scan " Al")

5. Note the dB level setting for the scan "Al"

6. The same two probes should be placed on the test surface (scan "A2"), Probe distance
to be adjusted to get maximum transmission signal.

7. The transfer correction B = "Al" — "A2".

8. The ”B” correction factor shall be added to initial gain settings.

14. INSPECTION PROCEDURE

14.1 SCANNING

Wherever feasible, the scanning of the examination volume shall be carried out from both
sides of the weld on the same surface. Where configuration or adjacent parts of the
component are such that scanning from both sides is not feasible, this fact shall be
included in the report of examination.

For typical scanning technique please refer fig. 7 to 9.

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14.2 STRAIGHT BEAM PROBE SCANNING

The scanning of adjacent base metal shall be performed to detect reflector that might
affect interpretation of angle beam result. Location and areas of such reflectors shall be
recorded. Scanning with straight beam probe verifies the material thickness and locates
any laminar type defects exist in the material

The weld and base metal shall be scanned, where required by the referencing code
section, to the extent possible with the straight beam search unit. The scanning shall be
performed at a gain setting of at least 2 times the primary reference level. Evaluation shall
be performed with respect to the primary reference level.

14.3 ANGLE BEAM SCANNING FOR REFLECTOR ORIENTED PARALLEL TO THE

WELD.

The angle beam shall be directed at approximately right angle to the weld axis from two
directions where possible. The search unit shall be manipulated so that the ultrasonic
energy passes through the entire volumes of weld and the adjacent base metal. The
scanning shall be performed at a gain setting at least two times the primary reference
level. Evaluation shall be performed with respect to the primary reference level.

14.4 ANGLE BEAM SCANNING FOR REFLECTOR ORIENTED TRANSVERSE TO THE

WELD.

The angle beam shall be directed essentially parallel to the weld axis. The search unit
shall be manipulated so that the angle beam passes through the required volumes of weld
and adjacent base metal specified by the referencing code section. The scanning shall be
performed at a gain setting at least two times the primary reference level. Evaluation shall
be performed with respect to the primary reference level. The search unit shall be rotated
180 deg and the examination repeated. The scan distance shall be minimum of 1.25 times
skip distance. Interfering reflectors shall be recorded.

14.5 EXAMINATION OF REPAIR WELDS

The repaired welds shall be redo as per this procedure and it should be included in the
report of UT examination.

15. POST EXAMINATION CLEANING

The Post examination cleaning shall be carried out as soon as the examination of the Part
is completed using dust free cloth and by solvent cleaner that not adversely affect the Part.

16. EVALUATION
16.1 Any imperfection which causes an indication in excess of 20% DAC shall be
investigated to the extent that it can be evaluated in term of the acceptance
standards.

16.2 Certain metallurgical discontinuities, heat affected zones and geometric conditions
may produce non relevant indications. The identity, maximum amplitude, location
and extent of reflector causing above problems shall be verified with the reflector

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coordinate. Other NDT methods also may be use to verify the geometric non
relevant indications.

16.3 Evaluation Procedure (6dB Drop Method)

Indications giving response greater than 50% DAC at the primary reference level
shall be recorded regardless of the dimensions.

Indications giving a response greater than 20% of primary reference level shall be
subjected to investigation. Such investigation may include examination with
alternative angles and search units. If investigation reveals that the response
originates from harmful discontinuities such as crack or fusion type discontinuities,
the same will be recorded. If the echo height from the flaw is more than Primary
reference level, mark the location and move the probe towards the boundary of the
flaw until the maximum flaw echo is reduced by 6 dB (i.e. 50%), Mark the new
location of which indicates the location flaw edge. .similarly move the probe from
the location of the Max flaw echo to other side till the echo drops to 50% of Max
flow echo. Mark the location of the Probe which gives other edge of the flaw. So
the centre of the probe shall then be assumed to be over the discontinuity boundary.

The discontinuity area shall then be scanned to localize the boundary of distance.
Measure the length of the defect.

17. ACCEPTANCE CRITERIA:

17.1 Acceptance criteria shall be in accordance with ASME B 31.3 Clause 344.6.2 and
ASME SEC VIII DIV 1, Appendix12

17.2 Indications characterized as cracks, lack of fusion, or incomplete penetrations are

unacceptable regardless of length.

17.3 Other imperfections are unacceptable if the indications exceed the reference level
amplitude and have lengths which exceed:

1) 1/4 inch (6mm) for up to 3/4 inch (19mm).

2) 1/3 t for t from 3/4 inch(19mm) to 21/4 inch (57mm).

3) 3/4 inch (19mm) for t over 21/4 inch (57mm).

Where "t" is the thickness of the weld excluding any of allowable reinforcement. For a
butt weld joining two numbers having different thickness at the weld, "t" is the thinner of
these two thicknesses. If a full penetration weld includes a fillet weld, the thickness of the
throat of the fillet shall be included on "t".

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18. SAFETY REQUIREMENTS

Prior to commencement of any activity, all personnel involved on the job shall attend the
project HSE Induction training.

` 19. ATTACHMENTS & FIGURES

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20. SAMPLE REPORT

Sketch Details
Period of examination / Location
Date
Job No Drawing No
Clients order No. Procedure No MI/UT/2015/001
Id. No. Material
Supplementary Information (without liability)
Equipment Used PWHT With Backing
BSR ASR
W/o Backing
Comp.probes Angle probes
Type B: Type 70 deg 60 deg 45 deg
Crystal dimension Crystal
mm
dimension/Freq
Freq MHz /MHz True angle
Sensitivity setting Sensitivity setting
Basic self ~ref.curve Basic self
dB dB dB dB dB
~ref.curve
Transfer Correction Transfer
dB dB dB dB dB
Correction
Extra when scanning Extra when
dB dB dB dB dB
scanning
Total dB dB Total dB dB dB
DAC :Diam = 3 mm , range = 0 -125mm
Calibration Block Reference Block
Probe check Couplant
Operator check of ultrasonic probes carried out
Acceptance criteria ASME B 31.3 Clause 344.6.2 and ASME SEC VIII DIV 1, Appendix12
Sl.No. Joint No Welder ID Material Thick Length Bevel Weld process Acc Rej Remarks
1.
2.
3.
4.
5.
Comments:

Company Company Name Third Party Client

Name:
Sig:
Date:

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