DN Wind Systems India Pvt. LTD.: Ultrasonic Procedure FOR Wind Mill Tower

DN WIND SYSTEMS INDIA PVT. LTD.
PROCEDURE FOR ULTRASONIC TESTING

DOCUMENT NO.- DN / WP / 003 PAGE NO. - 1 OF 23
REV. NO.- 00 REV. DATE- 19/03/2009
ULTRASONIC PROCEDURE
FOR
WIND MILL TOWER
PREPARED BY APPROVED BY AUTHORISED BY

REV. NO.- 00 REV. DATE- 19/03/2009
INDEX
SR.NO. DESCRIPTION PAGE NO.
1.0 PURPOSE 3/23
2.0 SCOPE 3/23
3.0 REFERENCE DOCUMENTS 3/23
4.0 PERSONNEL QUALIFICATION 4/23
5.0 EQUIPMENT & ACCESSORIES 4/23
6.0 CALIBRATION 4/23
6.1 CALIBRATION OF ULTRASONIC FLAW DETECTOR 4/23
6.2 CALIBRATION AND REFERANCE BLOCKS 5/23
7.0 DAC CURVE 5/23
8.0 SURFACE CONDITION 9/23
9.0 COUPLANT 9/23
10.0 PROBE SELECTION 9/23
10.1 ADAPTION OF PROBE TO FLAT SURFACE 9/23
10.2 ADAPTION OF PROBE TO CURVED SCANNING 10/23
SURFACE
11.0 SCANNING 10/23
12.0 EXAMINATION OF BASE METAL 11/23
13.0 WELD EXAMINATION 11/23
13.1 LONGITUDINAL WAVE PROBE 11/23
13.2 SHEAR WAVE PROBE 12/23
14.0 PERIODIC CHECK OF SCREEN CALIBRATION 12/23
15.0 INTERPRETATION OF RESULTS 12/23
16.0 ACCEPTANCE OR REJECTION CRITERIA 12/23
17.0 RETEST 13/23
18.0 REPORTING 13/23
19.0 SAFETY 13/23
20.0 SPECIFIC ULTRASONIC TESTING PROCEDURE 15/23
21.0 FIGURES 16/23
22.0 U.T.REPORT FORMAT 23/23

REV. NO.- 00 REV. DATE- 19/03/2009
1.0 PURPOSE
This procedure is intended to detect internal discontinuities of

Objects. The discontinuities parallel to the scanning surface are
the most ones favorably aligned for detection.
2.0 SCOPE
This procedure is for windmill tower. These procedures are

applicable to in process & final operation of-
1) Shell plate 22 mm & above.
2) Forged Flanges – 100 %
3) Weld after PWHT (Base Ring & Door Frame)
4) Top flange to shell segment sec. I
5) All seams of flange to shell.
6) Bottom flange to shell.
7) Welding Defects & repairs there in.-
3.0 REFERENCE DOCUMENTS
 ASME Section V - Article 4, 5 and 23

 EN 1714
 SEP 1921
 ASNT SNT – TC – 1A
 ANSI CP 189 OR EN 473
 SI’s Safety Procedure HSE

REV. NO.- 00 REV. DATE- 19/03/2009
4.0 PERSONNEL QUALIFICATION –
Qualification of NDT operator to carry out this testing shall be

minimum ASNT Level II & in accordance with documents ASNT
SNT – TC – 1A and ANSI CP 189 OR EN 473.
5.0 EQUIPMENT & ACCESSORIES –
A) Ultrasonic Flaw Detector, ESM 2M – EEC MAKE OR

Equivalent, A scan type, meeting the requirement of T –530
of Article 5 of ASME Section V
B) Suitable Miniature And Large Probes.
(Normal Probe 10 mm Ø,24mm Ø, TR Probe 10 mm Ø,
Angle Probe of 45º, 60º & 70º Crystal size 8 X9 mm of 4MHz)
C) Connecting cables.
D) Suitable Couplant.
i) Starch, Cellulose, Gum / Poly cell, (for
welding & Steel Plates)
ii) Oil, Grease (For Flanges)
E) Drawing & Gauging Tools
6.0 CALIBRATION–
6.1 CALIBRATION OF ULTRASONIC FLAW DETECTOR –
The calibration of the UFD shall be carried out in

accordance with ASME section V Article 5 or specific
written procedure for its vertical & horizontal linearity once
in every six months or after repair of UFD whichever is
earlier. In addition, Amplitude control corrections, Beam
spread, Index point, Beam angle & Resolution will be
checked.

REV. NO.- 00 REV. DATE- 19/03/2009
6.2 CALIBRATION AND REFERNCE BLOCKS –
The following calibration blocks shall be used for

calibration purposes.
 IIW V1 AND / OR IIW V2 Calibration Block,

 Step Wedge,
 Side drilled hole Block for D.A.C.
 Notch Block for D.A.C.
 Reference mock up Block
7.0 DISTANCE AMPLITUDE CORRECTION CURVE

(D.A.C. CURVE) –
DAC curve shall be made for every angle beam search unit to
be used for each particular range set for reference during all
weldment examination. DAC curve shall be constructed by
using 3 mm side drilled hole as mentioned in method 1 of
paragraph 10.2 of BS EN 1714.
The DAC Curve shall be constructed by connecting the 3 peak

indication points obtained from the side drilled holes of
reference blocks by maintaining the first peak height at 80%
screen height
. This shall be the reference level.
Once the DAC Curve is made, transfer correction shall be done

as given below:
When separate blocks are used for establishing reference

levels a measurement shall be made of the transfer difference
Between test object and DAC block at a representative
Number of locations. Suitable techniques as described in
Sec6.5 of EN 583-2 shall be used for transfer correction
REV. NO.- 00 REV. DATE- 19/03/2009
adjustment.
Scanning shall be done along paths approximately

perpendicular to the weld axis.
Whilst scanning the probes shall be swiveled about its

average movement direction to detect discontinuities which
may be oriented unfavorably.
The scanning speed shall not exceed 150 mm per second

along the traverse paths.
For detecting discontinuities perpendicular to the weld axis,

angle beam scans shall be conducted approximately parallel
to the weld axis, angle beam scans shall be conducted
approximately parallel to the weld axis clockwise and anti-
clockwise.
Guidelines given in Annex A, figures A.1 to A.6 and the

corresponding tables A.1 to A.6 of BS EN 1714 are to be used
as guidelines for scanning various types of weld or item
configurations.
The test sensitivity shall be set by maximizing the echo from

sensitivity block standard holes reflector in the DAC reference
block and adjusting the gain to bring the peak of the echo up
to the DAC
The gain shall then be increased by transfer correction at the

appropriate sound path length if it has not been incorporated
in the DAC itself.
The gain is reduced or increased as per reference level is set

for specified scanning.

REV. NO.- 00 REV. DATE- 19/03/2009
The sizing of the defect shall be in accordance with 6 db

amplitude drop OR 20 db amplitude technique.
Defect locations shall be identified by the exact and physical
location of the transducer by use of trigonometric calculations,
skip distance and the beam path lengths (1 st or 2nd Leg). Refer
to figure 1 for details.
Figure 1
SAW welds of above 25 mm thick shall be scanned for any

Chevron cracks parallel to weld near HAZ Area on both sides.

REV. NO.- 00 REV. DATE- 19/03/2009
Moving the probe parallel to the weld seam as shown in

Figure 2 below shall do detection of longitudinal imperfections.
FIGURE 2 : Example of examination volume to be covered when

scanning for longitudinal indications
Note: BS 3923 recommends scanning level be +14 dB. However, when a 3 mm SDH is
used for DAC, +6 dB increase during scanning will give sufficient enough to give a
reasonable assurance that all significant discontinuities are detected.

REV. NO.- 00 REV. DATE- 19/03/2009
8.0 SURFACE CONDITION –
All surfaces shall be clean and free of scale, dirt, grease, paint,
spatter or any other foreign materials. Surface shall be smooth to
carry out effective test.
9.0 COUPLANT –
Water for Plates.
Water based paste of cellulose gum ( poly gel ) shall be used

for the scanning purposes. ( For weld scanning)
Oil, Grease for flanges.
10.0 PROBE SELECTION –
10.1 ADAPTION OF PROBES TO FLAT SURFACES -
The combination of probes in addition to normal probes shall

be selected as per specific requirement or as per thickness
of the plates.
THICKNESS RANGES PROBES COMBINATIONS

10 mm to 20 mm TR, 45º & 70º
Above 20 mm Normal, 45º & 60º

REV. NO.- 00 REV. DATE- 19/03/2009
10.2 ADAPTION OF PROBES TO CURVED SCANNING

SURFACES -
The gap between the test surface and bottom of the

probe shoe shall not be greater than 0.5 mm. For
cylindrical surfaces this requirement will normally be met
when the following equation is fulfilled:
D ≥ 15 a
where
D is the diameter of the component
a is the dimension of the probe shoe in the
direction of testing ( in mm ).
11.0 SCANNING –
Hundred percent area shall be scanned by all selected probes

both side of the welds using longitudinal and shear wave
probes. Length of scanning shall be minimum of ½ Beam path
to 1½ Beam path on the both side of weld.
In plate inspection, normal scanning (by 10 mm dia.probe) shall

be carried out.

REV. NO.- 00 REV. DATE- 19/03/2009
12.0 EXAMINATION OF BASE METAL -
By using a 0º compressional wave transducer the base metal

8” wide on either side of the weldment shall be examined to
check for any laminar types of defects, which may interfere with
the shear wave testing of the weld. Guidelines given in
paragraph 9 of BS EN 1714 are used for parent metal
examination.
The parent metal, in the scanning zone area, shall be examined

with straight beam probes prior to or after welding, unless it can
be demonstrated that the angle probe examination of the weld
will not be influenced by the presence of the imperfections or
high attenuation.
Where imperfections are found their influence on the proposed

angle beam examination shall be assessed and if necessary,
the technique adjusted correspondingly.
13.0 WELD EXAMINATION -
Unless other wise specified inspect the weld on both side by

using longitudinal & shear wave probes.
13.1 LONGITUDINAL WAVE PROBE-
With reference to first back wall echo 80 % ± 5 %,

Scanning shall be carried out before and after weld on
base metal to confirm any inherent or after weld
discontinuities. During scanning with longitudinal wave
probe, full contact and echo height shall be maintained.
Area of scanning shall be at least HAZ to 1½ Beam Path

REV. NO.- 00 REV. DATE- 19/03/2009
on the both side of the weld. This scanning will reveal

discontinuity with major surface parallel to
scanning surface.
13.2 SHEAR WAVE PROBE –
With respect to DAC, scanning shall be carried out on

both sides of weld to determine discontinuity within the
weld & base metal, which are not parallel to scanning
surface. Both the probes shall be scanned individually on
both the side. Scanning shall cover at least ½ Beam Path
to 1½ Beam Path of beam path. Unless & otherwise
specified, circumferential direction scanning shall be
carried out on base metal.
14.0 PERIODIC CHECK OF SCREEN CALIBRATION -
Calibration of screen shall be checked prior to any inspection

run, prior equivalent shut down and at least in each 4 hours
during continuous equipment operation.
15.0 INTERPRETATION OF RESULTS –
All indications that are equal to or greater than rejection level,

established during calibration, as described in acceptance /
rejection criteria in SECTION 17 of this procedure shall be
consider representing defects and may be cause of rejection or
repair of the weld or base metal.
16.0 ACCEPTANCE OR REJECTION CRITERIA –
Acceptance criteria shall be as defined in TABLE A of the

Project Specification or in accordance to AWS D1.1
EN 1712 /1714 .
Repair of unacceptable weld defects shall be carried out in
accordance with the denoted specification following which the

REV. NO.- 00 REV. DATE- 19/03/2009
repair area shall be retested ultrasonically and an additional

report submitted on the finding.
TABLE A
ULTRASONIC TESTING ACCEPTANCE CRITERIA
DEFECT TYPE ACCEPTANCE LEVEL
a) Indications greater than 100% of the reference
curve shall reported and limited to a maximum
length of t/3 or 20 mm, whichever is the lesser.
Three Dimensional b) Indications less than 100 % but greater than
defects (i.e. slag, porosity) 50 % of the reference curve shall be reported,
and limited to a maximum length of 2t or 50
mm, whichever is lesser.
c) Indications less than 50% of the reference
curves are acceptable.
a) Not acceptable if the indications exceed the
reference curve, or lie within 6 mm of either
surface, regardless of amplitude.
Two dimensional defects b) Indications more than 6 mm from either
other than Cracks (i.e. surface which are less than 100 % but greater
Lack of side wall fusion, than 50 % of the reference curve shall be
Lack of inter-run fusion.) reported, and limited to a maximum length of
t/3 or 20 mm, whichever is the lesser.
c) Indications more than 6 mm from either
surface which are less than 50 % of the
reference curve are acceptable.
Cracks or Suspected Not acceptable
cracks
Incomplete penetration or
lack of root fusion in single Not acceptable
sided welds.
Single point reflectors: If separated by a distance of 25 mm or greater,
(Indications which show acceptable regardless of amplitude. If separated by
Pattern I behaviour in both less than 25mm, indications with an amplitude
directions, as per greater than 100 % of the reference curve shall be

REV. NO.- 00 REV. DATE- 19/03/2009
BS 3923 Appendix L ) reported.
17.0 RETEST –
Retest of the repaired area shall be carried out in accordance to

this procedure & Acceptance Criteria.
18.0 REPORTING –
All details of inspection and results of inspection shall be

documented in Report Format and shall be signed by NDT
inspector and client’s representative.
19.0 SAFETY –
All SI’s employed UT operators, trainees and their assistants

shall follow the safety rules in accordance to SI’s HSE Guide.
Under any circumstances, no one is allowed to violate the

safety requirements.

REV. NO.- 00 REV. DATE- 19/03/2009
20.0 SPECIFIC ULTRASONIC TESTING PROCEDURE -
SPECIFIC UT PROCEDURE
1 Material Ferritic Carbon Steel
2 Weld Details: Double “v”, back weld single “v”, full
penetration T- joints or partial penetration joint.
3 Joint Type Butt, full penetration and partial penetration welds
4 Thickness Range 14 mm to 75 mm
5 Probes 1) 2.5 MHZ, 20 mm S/C
ii) eec MWB 45 4 MHZ, 10 mm dia. S/C
iii) eec MWB 60 4 MHZ, 10 mm dia. S/C
iv) eecMWB 70 4 MHZ, 10 mm dia. S/C
6 Flaw Detector USK-7 (or) EEC - EX 10 or equivalent
7 Ranges 0 – 150 and 0 – 200 mm
8 Scanning Sensitivity i) Echo off 3 mm dia. side drilled hole set to DAC +
Transfer correction + 6 db
9 Sizing methods Length = 6 db amplitude drop
Depth & Height (width) -20 db drop / Max. amplitude
or combination of both.
10 Couplant Cellulose Paste
12 Acceptance Criteria As per Table 6 / SA 578 Level B, SEP 1921
13 Testing Temperature Ambient

REV. NO.- 00 REV. DATE- 19/03/2009
21 FIGURES –
A ) FLANGES –
Having Diameter from Ø2800 mm to 1488 mm
SECTION A A

REV. NO.- 00 REV. DATE- 19/03/2009
B) BOTTOM FLANGE -
60

REV. NO.- 00 REV. DATE- 19/03/2009
C ) WELDING JOINTS –
2 -3 mm
2-3 mm

REV. NO.- 00 REV. DATE- 19/03/2009
D) FLANGE TO SHELL -

REV. NO.- 00 REV. DATE- 19/03/2009
E ) BOTTOM FLANGE TO SHELL -

REV. NO.- 00 REV. DATE- 19/03/2009
F) TOP FLANGE TO SHELL -

REV. NO.- 00 REV. DATE- 19/03/2009
G) DOOR FRAME -
R675
R424
R303
40 mm
H ) DOOR FRAME TO SHELL -
U.T.TEST REPORT FORMAT

REV. NO.- 00 REV. DATE- 19/03/2009
SHRENIK INDUSTRIES,(ENGG. DIV.)

MAJALE
ULTRASONIC TEST REPORT
REPORT NO. - DATE -
CUSTOMER LOCATION- COMPONENT –
PROJECT – MATERIAL –
JOB NO. – WELD PROCESS –
DRG. NO. – DIMENSIONS-
FLAW DETECTOR – TRANSDUCERS : TECHNIQUE –
DATE OF CALIBRATION- NORMAL – PULSE ECHO CONTACT –
SURFACE CONDITION – ANGLE – A-SCAN PRESENTATION
COUPLANT – T/R -
SPECIFICATION – ACC / REJ. STANDARD- CALIBRATION STANDARD
SCANNING SENSITIVITY : REF. TRANSFER TOTAL

NOMAL PROBE : dB dB dB
ANGLE PROBE
RESULTS : DESCRIPTION OBSERVATION REMARKS
ULTRASONIC TECHNICIAN WITNESSED BY SI TPL

NAME – NAME – NAME –
SIGN – SIGN - SIGN -

DN Wind Systems India Pvt. LTD.: Ultrasonic Procedure FOR Wind Mill Tower

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DN WIND SYSTEMS INDIA PVT. LTD.

PROCEDURE FOR ULTRASONIC TESTING

WIND MILL TOWER

PREPARED BY APPROVED BY AUTHORISED BY

PREPARED BY APPROVED BY AUTHORISED BY

This procedure is intended to detect internal discontinuities of

This procedure is for windmill tower. These procedures are

3.0 REFERENCE DOCUMENTS

 ASME Section V - Article 4, 5 and 23

 ANSI CP 189 OR EN 473

 SI’s Safety Procedure HSE

PREPARED BY APPROVED BY AUTHORISED BY

4.0 PERSONNEL QUALIFICATION –

Qualification of NDT operator to carry out this testing shall be

5.0 EQUIPMENT & ACCESSORIES –

A) Ultrasonic Flaw Detector, ESM 2M – EEC MAKE OR

6.1 CALIBRATION OF ULTRASONIC FLAW DETECTOR –

The calibration of the UFD shall be carried out in

PREPARED BY APPROVED BY AUTHORISED BY

6.2 CALIBRATION AND REFERNCE BLOCKS –

The following calibration blocks shall be used for

 IIW V1 AND / OR IIW V2 Calibration Block,

7.0 DISTANCE AMPLITUDE CORRECTION CURVE

The DAC Curve shall be constructed by connecting the 3 peak

Once the DAC Curve is made, transfer correction shall be done

When separate blocks are used for establishing reference

Scanning shall be done along paths approximately

Whilst scanning the probes shall be swiveled about its

The scanning speed shall not exceed 150 mm per second

For detecting discontinuities perpendicular to the weld axis,

Guidelines given in Annex A, figures A.1 to A.6 and the

The test sensitivity shall be set by maximizing the echo from

The gain shall then be increased by transfer correction at the

The gain is reduced or increased as per reference level is set

PREPARED BY APPROVED BY AUTHORISED BY

The sizing of the defect shall be in accordance with 6 db

SAW welds of above 25 mm thick shall be scanned for any

PREPARED BY APPROVED BY AUTHORISED BY

Moving the probe parallel to the weld seam as shown in

FIGURE 2 : Example of examination volume to be covered when

PREPARED BY APPROVED BY AUTHORISED BY

8.0 SURFACE CONDITION –

Water for Plates.

Water based paste of cellulose gum ( poly gel ) shall be used

Oil, Grease for flanges.

10.0 PROBE SELECTION –

10.1 ADAPTION OF PROBES TO FLAT SURFACES -

The combination of probes in addition to normal probes shall

THICKNESS RANGES PROBES COMBINATIONS

PREPARED BY APPROVED BY AUTHORISED BY

10.2 ADAPTION OF PROBES TO CURVED SCANNING

The gap between the test surface and bottom of the

Hundred percent area shall be scanned by all selected probes

In plate inspection, normal scanning (by 10 mm dia.probe) shall

PREPARED BY APPROVED BY AUTHORISED BY

12.0 EXAMINATION OF BASE METAL -

By using a 0º compressional wave transducer the base metal

The parent metal, in the scanning zone area, shall be examined

Where imperfections are found their influence on the proposed

13.0 WELD EXAMINATION -

Unless other wise specified inspect the weld on both side by

13.1 LONGITUDINAL WAVE PROBE-

With reference to first back wall echo 80 % ± 5 %,