RAWABI INDUSTRIAL SUPPORT SERVICES

_____________________________________________________________________________________

QUALITY CONTROL PROCEDURE

Subject

Engineering Procedure for Radiographic

Examinations of Weld Joints

Procedure Number

RISS/EP/UT-01

Revision Number

08

Date of first issue

01st February 2004

Distribution of control copies

project

Manifa upstream onshore pipelines

contract

*******

Copy No 1

Petrojet

Copy No 2
Revision Summary
Revision
00
01
02
03
04
05
06
07
08

Date
1 February 2004
22nd July 2004
06th August 2006
st

14th July 2007

01st November 2009
02nd January 2010
26th January 2010

1st June 2012

08th May 2013

Procedure Approvals
Reviewed by

Approved by

Yazeed Qundos
QA/QC Manager

Mukesh Kumar Bhatt

ASNT NDT Level III

______________________________________________________________________

RAWABI INDUSTRIAL SUPPORT

SERVICES CO. LTD.

RISS/ EP/ UT-01

ENGINEERING PROCEDURE FOR ULTRASONIC EXAMINATION OF

WELD JOINTS
Revision No
00
01
02
03
04
05
06
07
08

Date of Issue
st
01 February 2004
nd
22 July 2004
th
06 August 2006
th
14 July 2007
st
01 November 2009
nd
02 January 2010
nd
02 July 2010
st
01 June 2012
th
08 May 2013

Total Pages
Page

: Fourteen (14)
: 1 of 14

Prepared By

Reviewed By

Approved By

Name

Mohammad Shaban

Yazeed Qudnos

Mukesh Kumar Bhatt

Designation

NDT Coordinator

QA/QC Manager

ASNT NDT Level III

Signature

RAWABI INDUSTRIAL SUPPORT SERVICES

ENGINEERING PROCEDURE FOR ULTRASONIC EXAMINATION OF WELD
JOINTS.
TABLE OF CONTENTS:

Procedure Control No.

RISS/EP/UT-01

Issue Date
Revision
Page

Page

Revision Summary
1. Scope
2. Applicable Documents and References
3. Personnel Qualification
4. Equipment and Materials
5. Calibration and Instrument linearity check
6. Scanning and examination sequence
7. Evaluation, location and confirmation of imperfections

3
4
4
4
4
5
10
12

Acceptance and Rejection Criteria

13

Exhibit-1: Report Format

14

01/02/2004
8
2 of 14

RAWABI INDUSTRIAL SUPPORT SERVICES

ENGINEERING PROCEDURE FOR ULTRASONIC EXAMINATION OF WELD
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Procedure Control No.

RISS/EP/UT-01

Issue Date
Revision
Page

01/02/2004
8
3 of 14

REVISION SUMMARY:
Rev.

Para No.
All Pages
4.0
5.1 & 5.2

5.3.1 & 5.3.2

5
6

5.4
7.5
7.8
2.0
4.0
9.0
1.0,2.0, 3.0
4.1 & 4.2
5.4
7.0
8.0
Fig B & C
Exhibit -1
All
2.0
4.1,4.2 & 4.3
5.0
6.0
7.0
8.0
Fig B
All
1
1
2
4.1

4.3
5.2.1
5.2.5

Exhibit-1
3

Changes
Page numbers changed
Permissible tolerance criteria added
Calibration interval added
General Technique for angle beam and straight beam calibration with fig A-1 &
A-2 added
Fig A-3 added for sensitivity and DAC curve
Scanning speed added
Calibration conformation completely revised
Reviewed as per latest edition and addenda of codes
Equipment and material specified
Scope of interpretation and evaluation defined
Amended as per latest edition and addenda of codes
Specific usage of probe and couplant specified
DAC and scanning sensitivity elaborated
Test sequence elaborated in 7.1.2, 7.2, 7.5, 7.5.2, 7.7 & 7.8
Reporting details elaborated
Amended as per ASME Sec V
Report format amended as per ASME Sec V
Pages renumbered
Amended as per latest code and addenda
Description of Equipment, probes and couplant amended
Instrument calibration method and sequence revisited
Scanning sequence amended
Flaw evaluation and reporting method amended
Acceptance criteria reviewed
Point h added
Code revisions added
Scope modified
Scope modified
References Updated
Adding 4.1.4 The equipment should be ready to be used along with single
crystal or double crystal probes.
Redefining Couplant requirements
Adding 5.2.1 Calibration General Requirements
Changing sensitivity check to Interim calibration check and adding points
5.2.5.1,2,3
Report format revised
UT Level-I may perform the test under supervision of UT Level-II

Procedure Control No.

RISS/EP/UT-01

RAWABI INDUSTRIAL SUPPORT SERVICES

ENGINEERING PROCEDURE FOR ULTRASONIC EXAMINATION OF WELD
JOINTS.

Issue Date
Revision
Page

01/02/2004
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4 of 14

1- SCOPE
This practice describes the method for ultrasonic testing of butt joints in ferrite welds in product form of
plates and pipes using angle beam shear waves pulse echo, contact and manual technique emitted by
rectangular piezoelectric probes/materials. The applicable thicknesses are from 6mm up to 100 mm
(Inclusive). For higher thicknesses procedure shall be qualified separately.
2- APPLICABLE DOCUMENTS AND REFERENCES
a. ASME B&PV code Section V. 2010 Edition addenda 2011
b. ASME B&PV code Section VIII Division I & II 2010 Edition addenda 2011
c. ASME B&PV code Section IX 2010 Edition addenda 2011
d. ASME/ANSI B31.1 2010 Edition
e. ASME/ANSI B31.3 2010 Edition
f. API 1104 2005 Edition addenda 2008
g. Client Specifications and Procedures.
3- PERSONNEL QUALIFICATION
Personnel performing ultrasonic testing shall be qualified as per the written practice of Rawabi Industrial
Support Services complying with ANSI/ASNT CP-189 (Latest 2006) and ASNT recommended practice
SNT-TC-1A (2006) as UT-Level II, and UT Level-I may perform the test under supervision of UT Level-II
In addition, any related additional certification requested by client shall be obtained.

EQUIPMENT AND MATERIALS

4.1 EQUIPMENT
4.1.1. The examination shall be conducted using a pulse echo ultrasonic instrument having A-Scan
display and which is capable of generating sound with frequencies in the range of at least 1
MHz to 5 MHz.
4.1.2. The ultrasonic instrument shall be equipped with a stepped gain control in units of 2.0 dB or
less.
4.1.3. The damping control shall not reduce the sensitivity of the examination. The reject control
shall be in off position during calibration and examination.
4.1.4. The equipment should be ready to be used along with single crystal or double crystal probes.
4.2 PROBES
4.2.1. The nominal frequency shall be from 1 MHz to 5 MHZ unless variables such as production
materials grain structure, requires the use of other frequency to assure adequate penetration
or better resolution. Search units with contoured wedge may be used to aid UT coupling.
4.2.2. The selection of the probe angle shall be as paragraph 6 below.
4.2.3. Probes shall be free from internal noise in the beam path distance and at the working
sensitivity used for the weld examination.
4.2.4. Angle probes shall be checked for angle of the beam and the exit point using IIW-V1 or V2
block. Any variation in the angle of the beam or exit point from the original shall be marked on
the probe for reference.

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Procedure Control No.

RISS/EP/UT-01

Issue Date
Revision
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01/02/2004
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5 of 14

4.3 COUPLANT
4.3.1. Couplant shall be selected based on surface finish of test piece, direction of the test piece
(vertical or decline), temperature of test surface, no possibility for chemical reaction with the
test piece and possibility of post cleaning.
4.3.2. Based on 4.3.1 Oil, grease or wall paper paste may be used as couplant between probe and
examination surface.
4.3.3. Couplants used on nickel base alloys shall not contain more than 250PPM of sulfur.
4.3.4. Couplants used on austenitic stainless steel or titanium shall not contain more than 250PPM
of halides (Chlorides plus fluorides).
4- CALIBRATION AND INSTRUMENT LINEARITY CHECKS
5.1 INSTRUMENT LINEARITY CHECKS
The below checks (5.1.1 and 5.1.2) shall be carried out for each ultrasonic instrument every one
year or prior to first use.
5.1.1 SCREEN HEIGHT LINEARITY: The ultrasonic instrument shall provide linear vertical
presentation within + 5% of full screen height for 20% to 80% of the calibrated screen height.

Position an angle beam transducer as shown in the below Figure-5.1 such that
indications can be obtained from the T and T holes in the basic calibration block.
Adjust the position of the search unit to give 2:1 ratio of amplitude between the two
indications.

Set the larger of the two indications at 80% of full screen height (FSH) without moving the
search unit adjust the gain in 2 dB to successively set the larger of the indications from
100% to 20% of FSH. Record the amplitude of both indications. The lower amplitude
must be 50% of the higher amplitude within 5% of FSH.
Figure-5.1

5.1.2 AMPLITUDE CONTROL LINEARITY: The ultrasonic instrument shall utilize an amplitude
control accurate within + 20% of the normal amplitude ratio over its useful range, to allow
measurement of indications beyond the linear range of the vertical display on the screen.

RAWABI INDUSTRIAL SUPPORT SERVICES

ENGINEERING PROCEDURE FOR ULTRASONIC EXAMINATION OF WELD
JOINTS.

Procedure Control No.

RISS/EP/UT-01

Issue Date
Revision
Page

01/02/2004
8
6 of 14

Position an angle beam transducer as shown in Figure-5.1, such that the indication
obtained from the hole in the basic calibration block is peaked on the screen.

Increase/ decrease the dB as shown in the below table-5.1.

Table-5.1

Se. #
1
2
3
4

Indication set at % of FSH

80
80
40
20

dB Control Change
-6
-12
6
12

Indication limits % of FSH.

32 to 48
16 to 24
64 to 96
64 to 96

5.2 CALIBRATION
5.2.1

Calibration General Requirements

5.2.1.1. Calibration shall be performed prior to daily use. Calibration shall include Sweep
Range Calibration (Described in 5.2.3) and Distance Amplitude Correction
(Described in 5.2.4).
5.2.1.2. The following conditions and items which will be used during examination should
be the same during calibration: Ultrasonic System, Calibration Surface, Couplant,
Contact Wedges and Instrument Controls which affects linearity.
5.2.1.3. Temperature differential between the calibration block and examination test piece
shall not exceed 14C.
5.2.1.4. Calibration parameters should be re-checked and re-verified (Interim calibration
check) as described on paragraph 5.2.5 on this procedure.

5.2.2 Basic Calibration Blocks

5.2.2.1. General Requirements of the Calibration Blocks:
5.2.2.2. The calibration block shall be from same material with same heat treatment,
surface condition, with similar metallurgical factors and cladding. Prior to
fabrication, the block material shall be completely examined with a straight beam
search unit. Areas that contain an indication exceeding the remaining back wall
reflection shall be excluded from the beam paths required to reach the various
calibration reflectors.
5.2.2.3. Where two dissimilar thicknesses are involved the calibration block shall be based
on the average thickness of the weld. The material of the blocks shall be of the
same product form and specification or equivalent P Number grouping as one of
the materials being fabricated. P number 1, 3, 4,5A through 5C and 15A through
15F shall be considered equivalent.
5.2.2.4. For dissimilar materials, the 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 on both
materials. Where the component material is clad, the calibration block shall be clad
be the same procedure as the production part
5.2.2.5. For non piping weld joints, Basic Calibration Block shall be used. The design of this
calibration block should be as shown below,

RAWABI INDUSTRIAL SUPPORT SERVICES

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Procedure Control No.

RISS/EP/UT-01

Issue Date
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Figure-5.2: Basic Calibration Block Design

Table-5.2: Minimum Dimension

Weld Thickness (t) Inch(mm)
Up to 1(25)
Over 1(25) through 2(50)
Over 2(50) through 4(100)
Over 4(100)

Calibration Block Thickness (T) Inch(mm)

(19) or t
1
1 /2(38) or t
3(75) or t
t + 1(25)

Hole Diameter Inch(mm)

3
/32(2.5)
1
/8(3)
3
/16(5)
[Note (1)]

Table-5.3: Notch Dimensions in Inch (mm)

Depth
Width
Length

2%T
1
/6(6) max.
1(25) min.

GENERAL NOTES
a.

Holes shall be drilled and reamed 1.5 inch (38mm) deep minimum, essentially parallel to the examination surface.

b.

For components equal to or less than 20 inch (500mm) in diameter, a curved block shall be used. A single curved block shall be used
for examinations in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter. Two sets of calibration reflectors
(holes, notches) oriented 90 degree from each other shall be used. Alternatively, two curved calibration blocks may be used.

c.

The tolerance for hole diameter shall be + 1/32 inch (0.8mm). the tolerance for hole location through the calibration block thickness
(i.e. distance from the examination surface) shall be + 1/8 inch (3mm).

d.

For blocks less than inch (19mm) in thickness, only the T side drilled hole and surface notches are required.

e.

All holes may be located on the same face (side) of the calibration block, provided care is exercised to locate all the reflectors (holes,
notches) to prevent one reflector from affecting the indication from another reflector during calibration. Notches may also be in the
same plane as the inline holes. A sufficient number of holes shall be provided for both angle and straight beam calibrations at the T,
1/2T, and 3/4T depths.

f.

Minimum notch depth shall be 1.6%T and maximum depth shall be 2.2%T plus the thickness of cladding, if present.

g.

Maximum notch width is not critical. Notches may be made by EDM or with end mills up to inch (6.4mm) in diameter.

h.

Weld thickness, t, is the nominal material thickness for welds without reinforcement or, for welds with reinforcement, the nominal
material thickness plus the estimated weld reinforcement not to exceed the maximum permitted by the referencing code. When two or
more base material thicknesses are involved, the calibration block thickness, T, shall be determined by the average thickness of the
weld; alternatively, a calibration block based on the greater base material thickness may be used provided the reference reflector size
is based upon the average weld thickness.

i.

For each increase in weld thickness of 2 inch (50mm) or fraction thereof over 4 inch (100mm), the hole diameter shall increase 1/16
inch (1.5mm).

Procedure Control No.

RISS/EP/UT-01

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5.2.2.6. Piping Calibration Blocks:

5.2.2.1.1.

For piping welds in Pressure Vessels above 20 in OD the Basic

Calibration Block described in 5.2.2.5.

5.2.2.1.2.

For Piping welds in Pressure vessels less than or equal to 20 in OD,

a curved block shall be used. The description and design of this
calibration block should be as shown below. Except where otherwise
stated in this procedure a single curved basic calibration block may be
used for examinations in the range of curvature from 0.9 to 1.5 times
the basic calibration block diameter.

Figure-5.3: Calibration Block Design for Pipe Welds

Notches shall be located not closer than T or 1 in. (25 mm), whichever is greater, to any block edge or to other
notches.
GENERAL NOTES:
a.

The minimum calibration block length (L) shall be 8 in. (200 mm) or 8 T, whichever is greater.

b.

For OD 4 in. (lO0 mm) or less, the minimum arc length shall be 270 deg. For OD greater than 4 in. (lO0 mm), the minimum arc
length shall be 8 in. (200 mm) or 3 T, whichever is greater.

c.

Notch depths shall be from 8% T minimum to 11% T maximum. Notch widths shall be in. (6 mm) maximum. Notch lengths shall
be 1 in. (25 mm) minimum.

d.

Maximum notch width is not critical. Notches may be made with EDM or with end mills up to in. (6 mm) in diameter.

e.

Notch lengths shall be sufficient to provide for calibration with a minimum 3 to 1 signal-to-noise ratio.

Procedure Control No.

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5.2.3 Sweep Range Calibration:

5.2.3.1. Sweep Range Calibration shall be performed using Side Drilled Holes on the Basic
Calibration Blocks described on 5.2.2 on this procedure, IIW block or V2 block.
5.2.3.2. For angle beam examination the required sweep range shall be adjusted using a
basic calibration block to indicate at least 3 divisions of the total sweep equal to t.
Personnel can use any combination of the Side Drilled Holes (SDH) to calibrate the
Sweep range. At least one of the selected SDH shall be hit by the second leg of the
sound beam.
Figure-5.4: Example of Combination to Calibrate the Sweep Range

5.2.4 Distance Amplitude Correction:

The distance amplitude correction curve for angel beam examination shall be established
1
1
3
using /4t, /2t and /4t hole on the basic calibration block described in Figure-5.2.
For plotting the DAC, the sensitivity control (gain) shall be adjusted to provide 80% FSH (+ or
5% FSH) from the hole which gives the highest response. The point shall be marked on the
screen. Without changing the sensitivity setting, the search unit shall be positioned for
maximum response from remaining two other holes at different depths and the points shall be
marked. A curve shall be drawn connecting all three points.
This sensitivity setting for the DAC shall be primary reference level for examination.
As the referencing code section requires the detection and evaluation of all indications
exceeding 20% DAC, the gain should be increased by an additional amount so that no
calibration reflector indication is less than 40% FSH. As an alternative, the scanning
sensitivity level may be set at 14db higher than the reference level gain setting. (This
additional gain makes reference DAC curve a 20% DAC curve so that indications exceeding
20% DAC may be easily identified and evaluated.
5.2.5 Interim Calibration Check:
5.2.5.1.

The calibration of the system used for the examination shall be re-verified and rechecked for any changes on Sweep Range Points and Sensitivity settings. If any
changes occurred, those changes shall not exceed the limits mentioned on
paragraph 5.2.5.5.

5.2.5.2.

The Calibration check shall be performed by the operator at:

5.2.5.1.1.

Change of any part of the system used for examination change.

5.2.5.1.2.

At change of job scope.

5.2.5.1.3.

When the personnel (operator) is changed.

Procedure Control No.

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5.2.5.3.

The personnel (operator) can perform the calibration check by using the Basic
Calibration Block.

5.2.5.4.

Calibration Check can be performed on at least one reflector from the Basic blocks
described on 5.2.5.3 above.

5.2.5.5.

Limit of changes in Sweep Range and Sensitivity: 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, the distance range calibration shall be corrected in
noted in the examination record. All recorded indications since last valid calibration
check shall be re-examined and their values shall be re-recorded on the data
sheets.
If sensitivity settings have changed more than 20% or 2 dB of its amplitude, the
sensitivity calibration shall be corrected and noted the correction in the examination
record. If the sensitivity setting has decreased, all data sheets since the last valid
calibration check shall be marked void and the area covered by the voided data
shall be reexamined. If the sensitivity setting has increased, all recorded indications
since the last valid calibration or calibration check shall be reexamined and their
values shall be changed on the data sheets or re-recorded.

5- SCANNING AND EXAMINATION SEQUENCE

6.1

SURFACE PREPARATION
It shall be checked that all surface from which scanning is to be done are free from loose scale or
lightly adhering matter, weld spatter, roughness etc. and any unsatisfactory surface condition found
should be rectified.

6.2

Recommended selection of probe angle with reference to thickness is given below in table-6.1;
however other angles can be used if found suitable for the configuration.
Table-6.1: Selection of probe angle based on tested job thickness
BUTT WELD THICKNESS (mm)
< 12

Angle

Primary
70

Top 1/4
70

12 to 38
Primary
70 or 60

Top 1/4
45 or 60

38 to 63
Primary
70, 60 or 45

Top 1/4
45 or 60

63 to 127
Primary
60 or 45

Top 1/4
45 or 60

127 to 200
Primary
60 or 45

Top 1/4
45

6.3

Mark a reference line or establish a datum on the inspection location so as to use this as a
reference for marking the discontinuities location.

6.4

The scanning shall be 100%. The entire volume shall be examined with a 10% overlap of the probe.
The rate of search unit movement for examination shall not exceed 6 inches per second
(152mm/sec) unless calibration is verified at scanning speed.

6.5

The adjacent base metal shall be scanned with straight beam angle to detect reflectors that might
interfere with angle beam reflections and hence shall be taken care during subsequent scanning.

6.6

For angle beam scanning, sensitivity level shall be set at a minimum of 6 dB higher than the
primary reference level gain. The angle beam shall be directed at the weld at approximately right
angles. This shall be done from two directions. The probe shall be manipulated such that the
complete volume of the weld is scanned. Refer Figures-6.1, 6.2.

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Procedure Control No.

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Figure-6.1

Figure-6.2

6.7

For reflectors oriented transverse to the weld the scanning shall be done parallel to the weld axis. If
the weld is not ground flushed the probe shall be manipulated such that it faces nearly parallel to
the weld body. The search unit shall be manipulated so that the ultrasonic energy passes through
the required volume of weld and adjacent base material. The search unit shall be rotated 180 deg
and the examination repeated. If the weld cap is not or ground flat, the examination shall be
performed from the base metal on both sides of the weld cap in both weld axis directions. Refer
Figures-6.1, 6.2.

6.8

When a flaw indication is obtained whose height exceeds 20% of DAC curve, efforts shall be made
to obtain maximum possible information about the flaw by manipulating the probe around the defect
and observing the behavior of the echo.

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6.9

Procedure Control No.

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The extent of the defect perpendicular to the scanning direction shall be judged by the 6dbreduction method. If the extent thus obtained is equal to or less than the probe width, then this
estimate is not reliable and the defect length shall be recorded as equal to the probe width.

6.10 Welds that cannot be fully examined from two directions using the angle beam technique (e.g.,
corner and tee joints) shall also be examined, if possible, with a straight beam technique. These
areas of restricted access shall be noted in the examination report.
6.11 Welds that cannot be examined from at least one side (edge) using the angle beam technique shall
be noted in the examination report. For flange welds, the weld may be examined with a straight
beam or low angle longitudinal waves from the flange face provided the examination volume can be
covered.
6- EVALUATION, AND REPORTING OF IMPERFECTIONS
7.1

Personnel shall use the report format described on Appendix-a of this procedure.

7.2

In order to enable the positioning of possible discontinuity to be accurately identified within the
component or weld, reference points shall be marked on the component. Alternatively a sketch,
which can provide the above information

7.3

All reflectors coordinates and locations shall be plotted on a cross section sketch. All recorded
indications shall be reported. The report shall also contain the calculated location of the flaws as
well as remarks about the type of the flaw.

7.4

Any imperfection which causes an indication in excess of 20% DAC shall be investigated to the
extent that it can be evaluated in terms of the acceptance standards of the referencing code
sections or agreed standard.

7.5

Examination areas mentioned on in Paragraphs 6.10 and 6.11 shall be noted on the examination
report.

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Procedure Control No.

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Appendix-a: Acceptance and Rejection Criteria as per ASME Sec-VIII, Div-1:

Imperfection which produces a response greater than 20% of the reference level shall be investigated to the
extent that the operator can identify the shape, Identity, location and evaluate them in terms of acceptance
given below.
1) Indication characterized as crack, lack of fusion or lack of penetration is unacceptable
regardless of length.
2) Other imperfections are unacceptable if the indication exceeds the reference level and have
length, which exceeds:

(6mm) for t up to (19mm)

1/3t for t from to 2 (19mm to 57mm)

for t over 2 (57mm)

t: Is the thickness of the weld excluding any allowable reinforcement. For butt welds joining two members
have 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 indicated in t.

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Exhibit-1: Report Format

Procedure Control No.

RISS/EP/UT-01

Issue Date
Revision
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01/02/2004
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14 of 14