MECHATHERM SERVICES (1) PVT. LTD. - BHOSARI, 411 026 PROCEDURE FOR ULTRASONIC TEST AND —_ [DOC NO: MS/UT-01 ACCEPTANCE STANDARD FOR FORGED BARS FOR NUTS. (BACK REFLECTION TECHNIQUE ) REV No: 0 pr: 13-09-2014 1.0 el 2.0 24 2:2, 2.3 3.0 3.1 3.2 3.3 34 3.5 4.0 41 4.2 5.0 6.0 6.1 6.2 6.3 SCOPE This document details the Ultrasonic Examination Procedure and Acceptance Standards for component Nuts forged proof machined round bars 90mm 0/Dia. x 600mm long for 10 Nuts ( M48 x 4.5P - Finish Size 85mm O/Dia. x 40mm I/D - 55mm long). Project - Air and Water Accumulator (NPCIL) MATERIAL: ASTM A194 Gr. 7 / AISI 4140. EQUIPMENTS: Flaw detector: EEC EX-10/ EEC-PX-20/MODISONIC-EINSTEIN-II/EQUIVALENT Probe : 1 To 5 MHz Couplant : Oil REFERENCE DOCUMENTS: Ultrasonic Examination Methods for Materials - ASME Sec V, Article 5 Specification for Ultrasonic Examination of Heavy Steel Forging - SA 388/ SA388M Performance Checks of Instrument Procedure MS/UT-02 Recommended Practice for Non-destructive Personnel Qualification and Certification SNT-TC-1A, Supplement C - Ultrasonic Testing. Construction Code of Acceptance ASME Sec III - NC 2541 QUALIFICATION LEVEL (ASNT / ISNT) Personnel conducting the ultrasonic examination in accordance with this specification shall be qualified to Level I or II. Personnel evaluating the ultrasonic examination shall be qualified to Level II or Level IIT. ULTRASONIC TECHNIQUE Back Reflection Technique. First echo from back surface of the bar shall be adjusted to 75 +/- 5% of the full screen height (FSH) of the CRT. Note down the gain. The nominal value of 80% FSH is here after called as Reference gain. Acceptance criteria shall be as per Para 9.0 GENERAL REQUIREMENTS The shaft shall be proof machined at the time of examination. The surface roughness of exterior finishes shall not exceed 6 microns. Probe movement for scanning shall be circumferential. The overlap, which would be axial, shall be at least 15% of the probe diameter Scanning speed shall not exceed 150 mm/second MS/UT-01 REV 0 DT 13-09-2014 PAGE 1 OF 3MECHATHERM SERVICES (1) PVT. LTD. - BHOSARI, 411 026 6.4 For Scanning purpose Gain shall be raised 6 dB. All evaluation shall be conducted at a Reference Gain. 7.0 RECORDING 7.1. Individual indication equal to or exceeding 10% of the back reflection from an adjacent area free from indications. 7.2. An indication that is continuous on the same plane regardless of amplitude and found over an area larger than twice the diameter of the search unit. The extent of such an indication shall be accurately measured along with variation in amplitudes of reflections. 7.2.1 Planar indications shall be considered continuous over a plane if they have a major axis greater than 25mm. In recording these indications, corrections must be made for beam divergence at the estimated flaw depth. 7.3. Discontinuity indications equal to or exceeding 5% of the back reflection. 7.3.1 Traveling indications are here in defined as indications whose leading edge moves a distance equivalent to 25 mm or more of metal depth with movement of the search unit over the surface of the bar. 7.3.2 A cluster of indications is defined as five or more indications located in a volume representing a 50 mm or smaller cube in the bar. 7.4 Reduction in back reflection exceeding 20% of the original measured in increments of 10%. 7.5 Amplitudes of record able indications in increments of 10%. 8.0 REPORT 8.1 All record able indications shall be reported. Unacceptable indications shall be clearly marked in the report. The report shall contain all data which will be needed for re-examination and re-evaluation of the bar, when so needed. 8.2 Zoning of Bar for Acceptance Peripheral Zone ~ Portion of Bar, outside a core area of 40 mm I/D is defined as the Peripheral Zone. (M48 x 4.5P Nut, minor diameter 40 mm to be drilled and bored). Core Zone ~ The core area 40mm diameter from centre. 8.3 Location of Indication All report able or unacceptable indications shall be recorded with reference to a key diagram which gives the position of each indication as axial distance from a reference end, angular distance clockwise from a reference mark, as viewed from the reference end and the radial depth of the indication. The reference mark shall be a unique existing stamp or preferably, a special identification provided for the purpose and shall be detailed in the report, 8.4 Information Required in the Report The following indications details are required, not necessarily in the following format or sequence. 1. Execution Order No. and Date of Examination MS/UT-01 REV 0 DT 13-09-2014 PAGE 2 OF 3MECHATHERM SERVICES (I) PVT. LTD. - BHOSARI, 411 026 8.5 a. b. ch 2. Description of Component 3. Customer and Customer Order No. 4. Material Specification and Identification 5. Shaft Diameter and Length 6. Details of Scan - Instrument Make and Model - Calibration Status References = Probe Make and Model - Couplant Description = Record able Indications - Unacceptable Indications - Reference Marking Information for reporting = _ Name of Operator, Name of Evaluating Engineer If indications of an unacceptable or record able nature are present, this Information shall be clearly stated by a separate written statement Report Forms (UTO1-01) Report forms meeting the requirements of these Specifications are to be prepared, The forms should permit efficient, unambiguous and complete recording of all test parameters as well as of test results. ACCEPTANCE CRITERIA The following indications are not acceptable. All the defects causing reduction in back wall echo to less than 50% of the reference level. All the defects with longitudinal direction found on peripheral zone (within 40mm and 90mm Diameter. The following indications are acceptable. Periphery Zone - All the defects which height of reference reflection is less than 25% of back reflection. - All the defects which height of reference reflection is above 25% of back reflection and which length Is less than 1/5D i.e. 18mm. Core Zone ~ All the defects, since core is to be drilled and bore to 40mm I/D. NOTES The defect length is that found with the half defect reflection method. The minimum distance between two defects must be at least 2D. “D" is the diameter under examination. 10.0 RECORDS OF REVISION: REV JREVISION [DETAILS OF REVISION | PREPARED. "APPROVED BY INO. [DATE | MEGHATHE! KAY BOUVET. 0 [13-09-2014 Se M. L. KHATRI ISNT UT LEVEL I -Fos-2014 PAGE 3 OF 3 SFULTRASONIC TEST REPORT Work. Order No. : Date: ‘Type of Product Customer Customer Order No. DETAILS OF TEST 1.0 MATERIAL: 2.0 EQUIPMENTS : 2.1 Equipment 22 Probe : Frequency - Size - Type — 2.3 Couplant —: Oil 3.0 REFERENCE CALIBRATION BLOCK : IW V1 Block / Range 4.0 PROCEDURE ? 41 STANDARD - ASME Sec V, SA — 388, Procedure MS/UT-01, Quality Assurance Plan. 4.2 SENSITIVITY SETTING — Back wall echo at 75 + /-5% of full screen height. For scanning purpose 6 dB sensitivity shall be raised.ie. + 6= dB. 5.0 RECORDS: Scanning done for full volume. No flaw observed which exceeds 20% of CRT. No reduction in back wall echo 50% of reference level. 6.0 ACCEPTANCE STANDARD — : 6.1 The defects giving echo height of more than 20% of total CRT screen height shall be treated as unacceptable, 6.2 Also defects causing reduction in back wall echo to less than 50% of the reference level shall be treated as unacceptable. 70 REPORT: 7.1 Shafts found ultrasonically satisfactory — material is acceptable. 7.2. Following discontinuities / defects observed and evaluation is as follows — TESTEDBY REVIEWED / WITNESSED BY AUTHORISED SIGNATORY UTo1-o1MACHATHERM SERVICES (1) PVT. LTD. - BHOSARI, PUNE 411 026 PROCEDURE FOR PERFORMANCE CHECKS OF [DOC NO: MS/UT-02 ULTRASONIC FLAW DETECTOR IREV NO: 0 [DT: 13-09-2014 1.0 SCOPE: 1.1 This document details the Performance Checks of Ultrasonic Flaw Detector in terms of Instruments Linearity checks (Screen Height Linearity, Amplitude Control Linearity and Time base Linearity) 2.0 REFERENCE DOCUMENTS: 2.1 Ultrasonic Examination Methods for Materials - ASME Sec V, Article 5 2.2 Equipment Calibration - ASME Sec V, Article 5, T-560 3.0 CALIBRATION FREQUENCY: 3.1 3 Months or prior to first use. There after reports shall be maintained. 4,0 CALIBRATION (INSTRUMENTS LINEARITY CHECKS) 4.1 SCREEN HEIGHT LINEARITY Use any convenient probe. Set the Suppression or Reject control to minimum (or Off if available) which value shall be left undisturbed throughout. Pick up any two Indications from any convenient test piece or block which can readily be maintained stable. The amplitude of the two indications must be adjusted such as to provide a ratio of 1:2 between indication heights. That is, one echo must be twice the height of the other. It is immaterial which echo appears first on the time base. In order to obtain this condition, one method is to obtain a stepped block (i.e., ‘one with two distinct thicknesses) and scan it from the un-stepped flat side. On scanning the zone of thickness change, two echoes, back wall echoes from the two thicknesses, will be obtained, By selecting an appropriate probe position, the two echoes can be set at any amplitude ration to each other, in this case, 1:2 or 2:1. Another suitable method can be to use an angle beam block with side drilled holes or notches, where any two of these reflectors or any one of these and a corner reflector can be adjusted to the required ratio. Using Gain control set the amplitude of the bigger of the two echoes to 80% full screen height (FSH). Without permitting probe movement; read just any of the above controls to change the amplitude of the larger echo successively from 10% to 20% in steps of 10% FSH. Record the amplitude of the smaller echo in each case. This value must be within 5% FSH of half the bigger echo, rounded off to the nearest 1% FSH. For example, for the case of the bigger echo being at 60%, the smaller echo must be within the range of 30% +/- 5% of FSH, i.e., between 25 and 35% FSH. 4,2 AMPLITUDE CONTROL LINEARITY Use any convenient probe. Set the Suppression or Reject control to minimum (or Off if available) which value shall be left undisturbed throughout. Pick up any two MS/UT-02 REV 0 DT 13-09-2014 PAGE 1 OF 3MACHATHERM SERVICES (I) PVT. LTD. - BHOSARI, PUNE 411 026 indications from any convenient test piece or block which can readily be maintained stable. Using Gain Control set the amplitude of the chosen echo to 80% full screen height. Only the Gain control shall be adjusted further. Without permitting probe movement, change the Gain by +/- 6 dB and /or 12 dB, and record the amplitudes. The table below gives the requirements. Tnitial set of value ‘Acceptance limit of of amplitude acon el eng resulting amplitude 80 -6qB 36 to 44 % 80 -12dB 18 to 22 % 40 $648 72 to 88 % 20 +12 dB 72 to 88 % This must be 50% and 25% of the original setting, within 10%; i.e. 36 to 44% and 18 to 22% respectively. Values outside these call for instrument rectification. 4.3 TIME BASE LINEARITY This parameter shall be checked at or near range values corresponding to those of the shaft step diameters. In the following descriptions, the percentage values refer to the time-base, 0% and 100% being the left and right hand extreme graduations. Select a block of uniform thickness of approximately one-fifth of the range to be checked. Use any convenient normal beam probe, and suitable settings for control setting other than those related to the time-base. Calibrate the instrument time-base to five times this thickness, by positioning the second back wall echo to 40% and the third back wall echo to 60% of the screen. This would require adjustment to Range, Material Calibration or Velocity and Delay controls. Lock all of these controls other than Delay. Using Delay, shift the second back wall echo to a selected screen division, and record the position of the next echo, i.e., the third back wall echo. Selected screen divisions shall be zero, 20%, 40%, 60%, and 80%. The expected reading shall, in each case, be obviously 20% larger than the selected screen division. In each case the permissible error from expected reading shall be within 2% of the time- base. In instruments with a total of 50 divisions for the time-base, this, will correspond to one such small division. In many instruments, the display does not extend beyond the final time-base mark. In such cases, the check of the last point shall be done in reverse, by shifting the third back wall to the last mark and reading the position of the second back wall echo. Specifically in the case of the initial or last portions of the time-base, twice the error of 2% i.e., 4% may be permitted. This however, is conditional on checks of MS/UT-02 REV 0 DT 13-09-2014 PAGE 2 OF 3MACHATHERM SERVICES (I) PVT. LTD. - BHOSARI, PUNE 411 026 the 5 to 25% or 75 to 95% or both respectively, additionally being done and the results being within 2%, and in instruments with 2% as the small division size, these values may be changed to 6 to 26% and 76 to 96% respectively. Values outside these call for instrument rectification. 5.0 REPORTING Performance check records of Ultrasonic Flow Detector (UFD) shall be maintained as per UTO2-01. 6.0 RECORDS OF REVISION: REV] REVISION | DETAILS OF REVISION | PREPARED BY | APPROVED BY NO. DATE MECHATHER| KAY BOUVET 0 [13-09-2014] New issue M. L. KHATRI ISNT UT LEVEL UL M/UT-02 REV 0 DT 13-09-2014 PAGE 3 OF 3PERFORMANCE CHECK RECORDS OF ULTRASONIC FLAW DETECTOR (UFD) Date: Page 1 T | EQUIPMENT: 2 | CALIBRATION PROCEDURE: MS/0T02,_ FREQUENCY :3 MONTHS 3 | SCREEN HEIGHT LINEARITY Probe: Make- Frequency- Mz Size Type Couplant: Oil ma Reference Stepped Calibration Block g a} ee Range ‘him, Gain fo gel two echoes an ratio of 1-2 or 2:1 with biguer of the two echoes to 80% full sereen height (f3h): | 4B ‘Without permitting probe movement, readjust Gain to change amplitude of the larger echo successively from 100% to 20% in steps of 10% fh Gain Bigger Echo ‘Smaller Echo Amplitude Remarks B Amplitude Yah 96 fh ‘Acceptance Limits ‘Actual 100 45.55 90 40-50 80 35-45 70. 30-40 oo 25.35 50 20-30 a0 15.25 30 10-20 20 05-15 Remarks: 4 | AMPLITUDE CONTROL LINEARITY rabe and Reference Calibration Block same as serial no. 3 above, Range? Tam, Gain fo set the amplitude of the chosen echo at mm 0 80% full screen height (fsh): dB, 40% fh: dB, 20% fh: dB Without permitting probe movement, change the Gain by +/- 6 dB and/or 12 dB, and record the amplitude. Initial Set Value Gain Control [___ Resulting Amplitude Remarks of Amplitude ‘Change [Acceptance ‘Actual Limits 80% = 6d 36 10 44%, 80% 712 4B TB to 22%, 40%. =6 dB 7210 98% 20% Fi2dB | 7210 88%. Remarks: Contd,Page 2 3 TIME-BASE LINEARITY Probe: Make- Frequency. MHz Size- Type Couplant: Git ‘Reference Calibration Block: IIW VI Block, 25 mm thickness faces ‘Range: 125 mm, — Position the second back wall echo to 40% and the third back wall echo to 60% of the soreen. This would require adjustment to Range, Material Calibration or Velocity and Delay controls. Lock all of these controls other than Delay. Using Delay, shif the second back wall echo to a selected screen division, and record the position of the next echo, ic. the third back wall echo. Selected screen divisions shall be zero, 20%, 40%, 60%, and 80%, The expected reading shall in each case, be obviously 20% larger than the selected screen division, In many instruments, the display does not extend beyond the final time-base mark. In such cases, the check of the last point shall be done in reverse, by shifting the third back wall to the last mark and reading the position of | the second back wall echo. Specifically in the case ofthe initial or last portions of the time-base, twice the error of 2% i.e., 4% may be permitted. This however, is conditional on checks of the $ to 25% or 75 to 95% or both respectively, additionally being done and the results being within 2%, and in instruments with 296 as the small division size, these values may be changed to 6 to 26% and 76 to 96% respectively. Position of Second Position of Third Back Wall Echo Remarks Back Wall Echo Selected Screen Division Expected Screen] Actual Sereen Division. % Division. % | _ 0 20 20 40 40 60 60 80 80 100 NOTE: Actual reading shall be within 2% of the time base. Remarks: CALIBRATED BY uTo2-01