Attest Inspection LLC, 11515 Carson Avenue Pearland, Texas 77584

Table of Contents
Section Page No.

1.0 Purpose and Scope ....................................................... 2

2.0 References .................................................................... 2
3.0 Personnel Qualifications ................................................ 2
4.0 Ultrasonic Equipment and Materials .............................. 3
5.0 Examination Surface ..................................................... 4
6.0 Calibration Procedure .................................................... 4
7.0 Method of Examination .................................................. 6
8.0 Special Technique Consideration .................................. 6
9.0 Post Cleaning ................................................................ 8
10.0 Examination Report ....................................................... 9
11.0 Acceptance Criteria ....................................................... 9
Table 2 ........................................................................ 10
Figure 1 ....................................................................... 11
Table 3 ........................................................................ 11
Figure 2 ....................................................................... 12
Figure 3 ....................................................................... 12
Table 4 ........................................................................ 12
NDE UT Report ........................................................... 13
UT Instrument Verification Report ................................ 14

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1.0 PURPOSE AND SCOPE

1.1 This procedure establishes the requirements for Manual Ultrasonic

Thickness Measurement of materials and will be applied when Ultrasonic
Thickness Measurement is required in accordance with ASME Section V,
Article 5 by the referencing Code. This procedure will be used in
conjunction with applicable client specifications.

1.2 This procedure will be used whenever manual ultrasonic thickness

measurements per the requirements of ASME are specified.

1.3 Ultrasonic examination shall be performed in accordance with a written

procedure which shall, as a minimum, contain the requirements found in
Table 1.0.

Table 1.0
Variables of an Ultrasonic Examination Procedure

Essential Nonessential
Requirement Variable Variable
Material types and configurations to be examined, including thickness dimensions and product form
(casting, forgings, plates, etc.). X
Personnel qualification requirements. X
Personnel performance requirements, when required. X
The surfaces from which the examination shall be performed. X
Surface condition (examination surface, calibration block). X
Couplant: brand or type. X
Technique(s) (straight beam, angle beam, contact, and/or immersion). X
Angle(s) and mode(s) of wave propagation in the material. X
Search unit type(s), frequency (ies), and element size(s) shape(s). X
Special search units, wedges, shoes or saddles, when used. X
Ultrasonic instrument(s). X
Calibration [calibration block(s) and technique(s)]. X
Directions and extent of scanning. X
Automatic alarm and/or recording equipment, when applicable. X
Scanning (manual vs. automatic). X
Computer enhanced data acquisition, when used. X
Records, including minimum calibration data to be recorded (e.g., instrument settings). X
Scan overlap (decrease only) X

1.4 When procedure qualification is specified, a change of a requirement in

Table 1.0 identified as an essential variable from the specified value, or
range of values, shall require requalification of the written procedure.

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1.5 A change of requirement identified as a nonessential variable from the

specified value, or range of values, does not does not require
requalification of the written procedure.

1.6 All changes of essential or nonessential variables from the value, or range
of values, specified by the written procedure shall require revision, or an
addendum to, the written procedure.

2.0 REFERENCES

2.1 The latest revision, or revision stated in the contract, of the following
referenced documents is applicable to and /or form the basis of this
procedure:
2.1.1 ASME Boiler and Pressure Vessel Code, Section V “Nondestructive
Examination” (July 2003)
2.1.2 ASTM E-114 “Recommended Practice for Ultrasonic Pulse-Echo
Straight-Beam Testing by the Contact Method (2001)
2.1.3 ASTM E-317 “Standard Practice for Evaluating Performance
Characteristics of Ultrasonic Pulse-Echo Testing Systems without
the Use of Electronic Measuring Instruments” (1997).
21..4 ASTM E-797 “Standard Practice for Measuring Thickness by
Manual Ultrasonic Pulse-Echo Contact Method” (2001)
2.1.5 AES NDE-QC-1 “Qualification and Certification of Nondestructive
Examination Personnel”.
2.1.6 ASNT SNT-TC-1A (2001), CP-189 (2001), and ACCP (Revision3,
November 1997).

2.2 This procedure will be superceded only when an equal or more stringent
requirement is specified by the customer’s purchase order or contract and
is approved by the ATT Corporate Level III.

3.0 PERSONNEL QUALIFICATION

3.1 Personnel performing Ultrasonic Thickness Measurement will be certified

to at least Level I Ultrasonic Examination (UT) in accordance with
procedure ATT NDE-QC-1 "Qualification and Certification of
Nondestructive Examination Personnel".

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3.2 A subcontractor may use their Qualification and Certification procedures

when approved by the ATT Corporate Level III and meeting the
requirements of Section 2.1.6.

3.3 UT Level I, II, and lIl personnel may perform all operations necessary in
accordance with this procedure to process the objects being examined.
Except that Level I personnel shall receive the necessary supervision and
guidance from certified UT Level II or Level III personnel.

3.4 Interpretation and evaluation of ultrasonic examination results will only be

accomplished by personnel certified as UT Level II or lIl.

4.0 ULTRASONIC EQUIPMENT AND MATERIALS

4.1 The following are the requirements for the Ultrasonic Thickness
Measurement Examination Equipment
4.1.1 The instrument shall be of the pulse-echo type and must have a
CRT or digital and CRT display.
4.1.2 The instrument’s horizontal limit and linearity, Paragraph 8.4,
screen height linearity, paragraph 8.5 and amplitude control
linearity, paragraph 8.6, shall be verified every 3 months or prior to
first use thereafter.
4.1.3 The instrument shall be calibrated at intervals no longer than 12
months to reference standards traceable to the National Institute of
Standards and Technologies (NIST) and meet or exceed the
manufacturer’s tolerances and specifications.4.1.4. Any frequency
and size search unit may be selected as long as it is capable of
resolving the thickness range being measured, provided that it
meets the manufacturer’s recommendations and client
specifications.
4.1.5 The search unit may be single element, delay line, or dual element
contact transducers.
4.1.5.1 Search unit selected shall have sufficient crystal to surface
contact to produce stable readings. On smaller diameter
pipe, 3.50” and less, a small diameter search unit or curved
standoff shoe may be required.

4.2 Couplant may be water, glycerin, cellulose gel (gum), oil, grease or
specially formulated commercially available materials.
4.2.1 Inhibitors and/or wetting agents may be used.
4.2.2 The chemical interaction or the corrosive nature of any couplant with
the material(s) being examined will be considered when making the
choice of couplant.

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4.3 The reference standards material from which the block is fabricated shall
be of the same product form, material specification or equivalent P-
Number grouping, and heat treatment as the material being examined.
The finish on the scanning surface of the block shall be representative fo
the scanning surface on the material to be examined and:
4.3.1 Shall have at least three steps:
4.3.1.1 The thinner step shall have a thickness within +10% of the
value stated in the column marked “Lower step” of table 2 for
the thickness range to be tested.
4.3.1.2 The thicker step shall have a thickness within +10% of the
value stated in the column marked “Upper step” of table 2
for the thickness range to be tested.
4.3.1.3 The third step and the minimum thickness to be tested shall
fall within the “Objective Thickness Range” and between the
thin and thick calibration steps. The third step shall be
machined with a flat bottomed hole in accordance with figure
1 and table 2.
4.3.2 The physical dimensions will be within + 1% of the nominal
thickness of the step.
4.3.2.1 The measurement of the steps will be performed with a
calibrated mechanical instrument, traceable to NIST.

5.0 EXAMINATION SURFACE

5.1 Surfaces will be uniform and free of loose scale and paint, discontinuities
such as pits or gouges, weld spatter, dirt, or other foreign matter which
may adversely affect test results.
5.1.1 Tightly adhering paint, scale or coatings do not necessarily need to
be removed for testing if they present uniform attenuation
characteristics.

5.2 Surfaces may be ground, sanded, wire brushed, scraped, or otherwise

prepared for examination purposes when necessary.

5.3 In areas where severe pitting is experienced and where surface

preparation is not recommended, readings will be taken on high areas and
pit depth will be measured by mechanical depth gauges. As an alternate,
an ultrasonic pencil tip probe may be used if the customer desires.

6.0 CALIBRATION PROCEDURE

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6.1 The proper functioning of the examination equipment will be checked and
the equipment will be calibrated by use of the reference standard, as
described in paragraph 4.3, at:
6.1.1 The beginning and end of each examination;
6.1.2 When examination personnel are changed;
6.1.3 Anytime that a malfunction or improper operation is suspected (i.e.,
unusually high or low readings);
6.1.4 When search units are changed;
6.1.5 When new batteries are installed or electrical outlet is changed;
6.1.6 When equipment operating from one power source is changed to
another power source or experiences power failure.

6.2 If, during a calibration, it is determined that the examination equipment is

not functioning properly or it is found to be out of calibration, all of the
measurements since the last valid equipment calibration will be retaken.

6.3 Calibration shall be accomplished using the same couplant as that to be

used when measurements are being taken.
6.3.1 When special form high temperature couplant is being used, a
different couplant may be used for calibration.
6.3.2 The temperature of the calibration block shall be within + 25° F of
the test specimen.

NOTE
All ultrasonic measurements shall be made at a threshold setting of
20 %FSH.

6.4 Calibration shall be established with three known thickness.

6.4.1 Determine the objective thickness from table 3
6.4.2 Place the transducer on the thin step and adjust the instrument to
read the step within + .001 inch of the actual step thickness.
6.4.3 Place the transducer on the thick step and adjust the instrument to
read the step within + .001 inch of the actual step thickness.
6.4.4 Repeat 6.4.2 and 6.4.3 until the instrument reads both steps within
the + .001 inch tolerance without further adjustment.
6.4.5 Ultrasonically measure the objective thickness. The thickness shall
be within + .001 inch of its actual thickness.

6.5 Gain transfer shall be established in the following manner:

6.5.1 Place the transducer on the reference calibration thickness closest
to the corresponding material thickness being examined. Note
signal strength and gain control setting.

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6.5.2 Place the transducer on the test material in an area with a uniform
back-wall reflection free from any indications and representative of
sound material.
6.5.3 Observe the signal level and adjust the gain control to produce the
same signal height or response as noted from the calibration block.
Note the gain control setting.
6.5.4 Subtract the gain control value in 6.5.1 from that in 6.5.3. This
number (positive or negative) is the gain transfer.

6.6 Scanning sensitivity.

6.6.1 Place the transducer on the object step and maximize the response
from the flat bottom hole. Observe the signal level and adjust the
gain control to produce a signal that is 80% FSH.
6.6.2 Repeat the steps in paragraph 6.4 and verify the system meets the
required tolerance.
6.6.3 Add the gain transfer amount (6.5.4) to the reference setting (6.6.1).
This is the gain control sensitivity setting for scanning.

6.7 All calibrations shall be recorded. The setup parameters used, including
gain, percent screen height setting, time of calibration and the
identification of the operator performing the calibration.

7.0 METHOD OF EXAMINATION

7.1 Couplant may be applied to the search unit or directly on the component
being examined.

7.2 The extent of the examination and the location of the readings will comply
with the referencing code and the customer requirements.
7.2.1 Readings may be taken at randomly selected locations or taken in
specified grid patterns as required.

7.3 Scanning speeds will not exceed a rate of 6 in./ sec.

8.0 SPECIAL TECHNIQUE CONSIDERATIONS

8.1 Dual transducer element search units are inherently nonlinear for
thickness measurements less than 0.125".
8.1.1 If measurements below 0.125" must be made with dual transducer
element search units, calibration must be accomplished with at
least 3 thickness steps below 0.125" within the range of the
expected readings. Additionally the proposed technique shall be in

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accordance with manufacturer’s recommendations and applicable

client specifications.

8.2 When testing steel at elevated temperatures, above 200°F and up to

1000°F, specially designed search units and couplant shall be used.

NOTE
To compensate for reading errors due to elevated temperatures the following
shall be used. The apparent thickness reading obtained from steel walls having
elevated temperatures is high (too thick) by a factor of about 1% per 100°F.
Thus, if the instrument was calibrated on a piece of similar materials at 68° F,
and if the reading was obtained with a surface temperature of 860° F, the
apparent reading should be reduced by 8%.

8.3 Consideration must be given to the back-wall echo during testing.

8.3.1 When encountering wall thinning due to corrosion, the roughening
of the back surface can affect the amplitude and shape of the back-
wall echo. Such a change in the back-wall echo should be noted.
8.3.2 When encountering wall thinning caused by erosion, the back wall
echo might disappear as the sharply-angled far surface reflects the
incident wave away from the transducer. If the back wall echo
disappears for this or any other reason, such as abrupt thinning into
the near surface region, the cause will be investigated with shear
wave transducers or other inspection technique, as appropriate.
Such a disappearance of the back-wall echo can indicate a critical
degree of thinning and must be explored until the reason for such a
loss of signal is defined.
8.3.3 Indications being displayed at or near the back-wall may be
absorbed into the back-wall signal and initially appear to be the
inner diameter (ID) connected. Interpretation shall be performed at
lower gain settings to determine if two separate signals exist. A
lower amplitude signal in front of a higher amplitude back-wall
signal may indicate a near ID inclusion. If any question exists, the
area shall be investigated with a shear wave search unit to
determine if an ID corner trap exists between the indication and the
back-wall.

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8.4 Horizontal limit and linearity

8.4.1 Couple a longitudinal transducer, 2.25 to 5.0 MHz, to an IIW block
(or equivalent thickness) as not to intercept any test holes (figure
2). The couplant used must provide stable indications during the
measurements.

NOTE
All multiple positioning and position measurements shall be made with the
respective back-reflection set at 50% of full screen height.

8.4.2 Adjust the instrument gain, sweep-delay, and sweep-length controls

to display eleven non-interfering back reflections. Further adjust the
sweep controls to position the leading edge of the third and ninth
back reflections at 20% and 80% horizontal screen divisions
respectively.
8.4.3 Read and record each scale position on a UT Instrument
Verification Report form (attached) and plot. Record greatest
linearity error in % of full horizontal scale.
8.4.4 Horizontal limit is given by the maximum available trace length
falling within the CRT gradticule lines expressed in linear units
(inches or millimeters). Unless otherwise noted this is also
assumed to represent 100% full screen. Failure to obtain full-scale
deflection may indicate an equipment malfunction.
8.4.5 Record all data and conformance on a UT Instrument Verification
Report form (attached).

8.5 Screen height linearity

8.5.1 Couple a longitudinal transducer, 2.25 to 5.0 MHz, to a distance
sensitivity (DS) block (or equivalent) so that indications from the 2
inch and 4 inch back-reflection can be observed (figure 3 position
A).
8.5.2 Adjust the search unit position to give a 2:1 ratio of amplitude
between the two indications.
8.5.3 With the larger set at 80% of full screen height (FSH), and without
moving the search unit, adjust gain to successively set the larger
indication from 100% to 20% of full screen height in 10%
increments.
8.5.4 Read the smaller indication at each setting. The smaller reading
must be 50% of the larger reading amplitude, within 5% of FSH.
The settings and readings must be estimated to the nearest 1% of
FSH.
8.5.5 Record all data and conformance on a UT Instrument Verification
Report form (attached).

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8.6 Amplitude control linearity

8.6.1 Couple a longitudinal transducer, 2.25 to 5.0 MHz, to a DS block (or
equivalent) so that the 4 inch back-reflection is peaked on the
screen (figure 3 position B).
8.6.2 With an increase and decrease in gain, as shown in table 3, the
indication must fall within the specified limits.
8.6.3 Record conformance on a UT Instrument Verification Report form
(attached 1).

9.0 POST CLEANING

9.1 Immediately upon completion of the examination, the couplant shall be

removed by a suitable cleaning method.
9.1.1 The considerations of paragraph 4.2.2 shall also apply for the
cleaning agents.

10.0 EXAMINATION REPORT

10.1 The following data will be recorded as a minimum for future reference at
the time of each examination and included in the report:
10.1.1 Part number identification;
10.1.2 Operator's name and certification level:
10.1.3 Instrument description, make, model, serial number; and NIST
traceable calibration due date;
10.1.4 Setup - couplant, cable type and length;
10.1.5 Search unit description - type, size, frequency, special
shoes;
10.1.6 Reference standards, size, and material types;
10.1.7 Record required instrument settings;
10.1.8 Scanning method and any limitations;
10.1.9 Each thickness measurement and its location;
10.1.10 Reference to this procedure.

11.0 ACCEPTANCE STANDARDS

11.1 Acceptance or rejection of a component will be based on customer

requirements, and/or the minimum design thickness allowed by the
referencing code.

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Objective
Maximum Thickness Minimum
lower Step Target Upper Step

.03” Up to .125” incl. .20”

.10” over .125” through .375” .50”
.10” over .375” through .50” .625”
.25” over .50” through .750” .90”
.50” over .750” through 1.00” 1.30”
.50” over 1.00” through 1.25” 1.60”
.75” over 1.25” through 1.50” 1.90”
1.00” over 1.50” through 1.75” 2.15”
1.00” over 1.75” through 2.00” 2.50”
1.00” over 2.00” through 2.25” 2.80”
1.50” over 2.25” through 2.50” 2.90”
1.50” over 2.50” through 2.75” 3.00”
2.00” over 2.75” through 3.00” 3.50”
2.00” over 3.00” through 3.25” 3.75”
2.00” over 3.25” through 3.50” 4.00”
2.00” over 3.50” through 3.75” 4.25”
2.00” over 3.75” through 4.00” 4.50”
2.00” over 4.00” through 4.25” 4.75”

Table 3
Thickness Testing Reference Table
for
Lower, Target, and Upper Bracket Ranges.

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1 ni chm ni

FBH d aim e et rs ni
a cco rdan ce w iht
tab el 2 3 ni chm ni

Figure 1
Calibration Standard

Flat Bottom
Material Thickness Hole Dia. +1/32 in.

Up to 1 in. 1/16 in.

Over 1 to 2 in. 1/8 in.
Over 2 to 3 in. 3/16 in.
Over 3 to 4 in. 5/16 in.
Over 4 in. 3/8 in.

GENERAL NOTE:
Flat bottom holes machined to a minimum depth of 1/8 inch
parallel to the transducer contact surface.

Table 2
Flat Bottom Hole Requirements

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0 0
60 70

Figure 2

A B

2"

4"

2"

Figure 3

Indication Set at dB Control Indication Limits

% of Full Screen Change % of Full 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%
Table 4

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Date:
INSTRUMENT MAKE: INSTRUMENT MODEL INSTRUMENT SERICAL #: CAL DUE DATE:

ULTRASONIC INSTRUMENT VERIFICATION REPORT

COUPLANT and BATCH #: CABLE TYPE: CABLE LENGTH: REFERENCE BLOCK:

TRANSDUCER TYPE: TRANSDUCER SIZE: TRANSDUCER FREQUENCY: TRANSDUCER SERIAL #:

HORIZONTAL LIMIT AND LINEARITY

11
Ideal
10 Linearity Line
9

8
BACK GREATES ERROR ______
REFLECTION # 7 (% FULL HORIZONTAL SCALE)
6

1
0 10 20 30 40 50 60 70 80 90
100
POSITION OF SIGNAL ON SWEEP TRACE - % FULL SCALE

SCREEN HEIGHT LINEARITY

2” Response 4” Response % Error
AMPLITUDE CONTROL LINEARITY
100 INDICATION SET AT dB CONTROL INDICATION LIMITS INDICATION SET AT
% FULL SCREEN CHANGE % FULL SCREEN % FULL SCREEN
90
80 -6 dB 32 – 48%
80 80 -12 dB 16 – 24%
70 40 +6 dB 64 – 96%
60 20 +12 dB 64 – 96%
50
This system meets the requirements for Horizontal Limit
40 and linearity, screen height linearity and Amplitude Control
Linearity as stated in ASME Section V Article 4.
30
Technician: Level:
20

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