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QUALITY CONTROL PROCEDURE Doc No.

QCP/GEN/UT/001

Rev. 00
Date 1.11.17
DEE DEVELOPMENT PROCEDURE FOR MANUAL ULTRASONIC
ENGINEERS LTD EXAMINATION OF PIPES AND TUBES Page Page 1 of 4

1.0 SCOPE
This procedure establishes requirements for Ultrasonic Testing (UT) of Seamless
Tubular materials (pipes and tubes) by manual, contact pulse echo method. This is
applicable for ferritic and austenitic steel tubular products of 12 mm OD and larger
size.

2.0 REFERENCE
This procedure is based on the following
a) ASME Section V, Article 5 (2010 Edition)
b) SE-213, Standard practice for Ultrasonic Examination of metal pipe and tubing.
c) PP-P-1981 Rev. 2, Requirements for Ultrasonic Examination procedures.
d) ASME-Sec-III-NB, NC, 2010, Rules for construction of Nuclear Reactor
Components.

3.0 EQUIPMENT & ACCESSORIES


3.1 UT Equipment
A pulse-echo UT instrument capable of generating frequencies from 2 MHz to 5 MHz
shall be used. Screen height linearity and Amplitude control linearity shall be checked
before starting any job as per Annexure 3.
3.2 Probe
Depending on the application following transducers shall be used.
a) Dual Crystal (TR) Probe for thickness check
b) Angle beam probes: 45
Probe frequency: 2 to 5 MHz.
3.3 Reference and Calibration blocks
a) IIW V1, V2 blocks shall be used for screen distance range calibration, beam exit
point and measurement of actual angle of probe.
b) Step wedge block shall be used for calibration of TR probe used for thickness
measurement.
c) Ref. Calibration notches shall be used to establish primary reference level/
Distance amplitude correction curve for examination & evaluation.

4.0 COUPLANT
Oil, grease, glycerine, water or cellulose paste shall be used as couplant. Select a
suitable couplant based on the surface conditions and orientation; roughness and non-
horizontal conditions require a more viscous couplant. Any requirements for
protection of the material under test, such as for sulphur and halogen content, shall be
met by the couplant. E.g. couplants used on nickel base alloys shall not contain more
than 25 ppm of sulphur and those used on austenitic stainless steel or titanium shall
not contain more than 25ppm of halides (chlorides plus fluorides).
5.0 SURFACE CONDITION
The scanning surface shall be neat & clean, free of dirt, scale, and grease paint and
other foreign materials. The surface finish shall be better than 3 Dm. Excessive surface
roughness and scratches which interferes with free movement of search unit shall be
removed.

6.0 PERSONNEL QUALIFICATION


QUALITY CONTROL PROCEDURE Doc No. QCP/GEN/UT/001

Rev. 00
Date 1.11.17
DEE DEVELOPMENT PROCEDURE FOR MANUAL ULTRASONIC
ENGINEERS LTD EXAMINATION OF PIPES AND TUBES Page Page 2 of 4

Scanning shall be carried out by personnel qualified by the ISNT or the ASNT to UT
Level I or higher. Verification of calibration, scanning, analysis of indications and
reporting shall be by personnel qualified by the ISNT or the ASNT to UT Level II or
higher. The Head of the QA Unit may conduct evaluation tests to check the
theoretical and practical capability of the personnel performing UT.
7.0 SCAN DIRECTIONS
Circumferential scanning in both directions are mandatory. As a supplementary
requirement longitudinal scanning also may be required by referencing document, such
as NB-2550.
7.1 The maximum rate of probe (search unit) movement shall be established by moving
the probe on the calibration block for which the amplitude from reflector notch shall be at
least 50% of the reference amplitude when picked up at a distance of full vee path for
outer notch and be not less than 60% of the reference amplitude when at a distance of
vee path for inside notch. However scanning speed shall be less than 150 mm / sec.
Minimum overlap shall be 10% of probe size. Signal to Noise ratio shall be at least
3:1when the notch is picked up by the search unit and also during scanning.

8.0 CALIBRATION
Reference standard shall be of the same nominal diameter and thickness and the same
nominal composition and heat treatment as the material being examined and should be
of sufficient length to establish efficient calibration facility and the maximum scanning
speed as defined in Cl 7.1 above.

The search unit shall be 45 (in steel) angle probe of size 10 mm or smaller (such as the
98 rectangular size of the MWB series of M/s Krautkramer)

For circumferential scanning, the reference standard shall have axial rectangular
notches on the inside and outside surfaces. Their length shall be 25 mm or less, width
not to exceed 1.6 mm, and a depth not greater than the larger of 0.1 mm or 5 % of the
nominal wall thickness.

For axial scanning the reference standard shall have a transverse (circumferential) notch
on the inner and outer surfaces. Dimensions of the transverse notches shall be same as
that of longitudinal notches.

Using the calibration standard adjust the equipment to produce clearly identifiable
indications from both the inner and outer surface notches. The relative response from
the inner and outer surface notches shall be as nearly equal as possible by probe
selection. Use the lesser of the two responses to establish the rejection level. On large
diameter or heavy wall pipe and tubing, if the inner and outer surface notch amplitude
cannot be made equal because of test metal distance and inside diameter curvature,
make DAC curve using inner and outer surface notches to establish separate rejection
levels for flaws clearly identifiable as located at the inner and outer surfaces.

A sketch of the Calibration Block is provided as below:


QUALITY CONTROL PROCEDURE Doc No. QCP/GEN/UT/001

Rev. 00
Date 1.11.17
DEE DEVELOPMENT PROCEDURE FOR MANUAL ULTRASONIC
ENGINEERS LTD EXAMINATION OF PIPES AND TUBES Page Page 3 of 4

9.0 EXAMINATION
Examination shall be conducted on the finished product, unless otherwise the
referencing code calls for an intermediate scanning. Scanning shall be done at +6 dB
above calibration dB, and recording / evaluation shall be carried out at calibration /
reference db.

10.0 ACCEPTANCE CRITERIA


All indications that are equal to or greater than the rejection level established during
calibration shall be considered unacceptable.

11.0 CHECKING CALIBRATION OF EQUIPMENT


Calibrations, DAC shall be verified:
a) At the start of examination
QUALITY CONTROL PROCEDURE Doc No. QCP/GEN/UT/001

Rev. 00
Date 1.11.17
DEE DEVELOPMENT PROCEDURE FOR MANUAL ULTRASONIC
ENGINEERS LTD EXAMINATION OF PIPES AND TUBES Page Page 4 of 4

b) At least every 4 hrs during examination.


c) At the finish of the examination.
d) At any time that malfunctioning is suspected. If during any check, equipment is to be
not functioning properly all the products that has been checked since last valid
equipment calibration shall be re-examined
e) Substitution of any of the following:
Search unit, cable, power source, couplant, UT instrument, and operator.

12.0 REPORTING

The report shall include at least the following information:


Identification of the material, type, size, lot, heat.
Identification of the examination equipment and accessories.
Name & Qualifications of UT operator and reviewing Engineer.
Details of examination technique, including examination speed and testing
frequency.
Description of the calibration standard with sketches, including the actual
(measured) dimensions of the artificial discontinuities.
Description of the distance amplitude correction procedure if used
Examination results and method of eliminating defects
13.0 POST EXAMINATION CLEANING
After the examination the test surface shall be thoroughly cleaned free from grease, oil
etc. using dry cloth, acetone etc.