QUALTECH

ULTRASONIC EXAMINATION PROCEDURE

Doc. No. Page Revision Date

: QUAL/UT/001 : 1 of 10 : 00 : 25.04.05

1.0

SCOPE: This procedure explains the requirements for manual pulse echo contact method of ultrasonic examination of butt joints in carbon and low alloy steel, plates, pipe / tube and pressure vessels.

2.0 REFERENCE: ASME SEC. V ARTICLE 4 ASME SEC. VIII Div. I APPENDIX 12
3.0

PERSONNEL QUALIFICATION: Personnel performing ultrasonic examination shall be qualified to Level II in accordance with QUALTECH ’s written practice for qualification and certification for NDT Personnel NDT/WP/001.

4.0 EQUIPMENT: 4.1 The examination shall be conducted with pulse echo ultrasonic equipment that generates frequencies over the range of 1MHz to 5MHz. The equipment model microscan EX–10, make EEC, Modsonic Einstin-I or equivalent satisfying the above requirements shall be used. The equipment shall have valid calibration and stickered mentioning the date of expiry.

4.2

5.0 PROBES: 5.1 5.2 Search units shall contain single crystal transducers. For straight beam examination longitudinal wave probes (0°) shall be used. For angle beam examination shear wave probes of 45° shall generally be used and atleast one probe of other angles up to 70° shall be used appropriate to the configuration being examined. Groove angle and thickness shall be considered in selecting the probe angle other than 45° For straight beam examination, the crystal dimensions shall be selected in the range of 10 mm to 25 mm. For angle beam examination, the crystal dimensions shall be selected appropriate to the contact available with examination surface and will generally be 8x9 mm or 20x22 mm. Probes of frequencies between 2 MHz and 4 MHz shall be used for both straight beam and angle beam examination.

5.3

5.4

6.0 SURFACE CONDITION: 6.1 6.2 The finished contact surface shall be free from weld spatter and surface irregularities which will impair the free movement of the search unit. The weld reinforcement shall be ground flush smooth with adjacent base material, if required.

The reference blocks manufactured in house. Nos. 4 and 5 are considered equivalent) as one of the material being examined. a curved basic reference block shall be used.0 COUPLANT: Grease-oil mix shall be used as couplant.7 mm. Reference blocks for dissimilar metal welds.QUALTECH ULTRASONIC EXAMINATION PROCEDURE Doc. Reference blocks shall receive atleast the minimum tempering treatment required by the material specification for the type and grade.1 Basic Reference Block: The basic reference reflectors shall be used to establish a primary reference response of the equipment. Couplant used on nickel base alloys shall not contain more than 250 ppm of sulfur.6 8.8 .2 8.7 8.Number grouping (P. require transfer correction to be calculated.0 CALIBRATION OF EQUIPMENT: 8. Page Revision Date : QUAL/UT/001 : 2 of 10 : 00 : 25. When the component has flat surfaces or curved surface with a diameter greater than 20 inches.5 8.04.05 7. The components to be tested can have a curvature between 0. If the examination will be conducted from both sides. 8. Couplants used on austenitic stainless steel or titanium shall not contain more than 250 ppm of halides (Chlorides plus fluorides). calibration reflectors shall be provided in both materials.1. The couplant used for the examination shall be the same as that used for calibration. Variation in component configuration and surface finish. the material selection shall be based on the material on the side of the weld from which the examination will be conducted. Areas that contain an indication exceeding the remaining back reflection shall not be used as block material. a flat basic reference block shall be used. No.9 to 1. 8.1). shall be inspected and certified by NDT Level III. (Figure . The thickness and the location and size of holes in the basic reference block to be used shall be as indicated in the Figure .3 When two or more base material thicknesses are involved. When the component is curved and has a diameter less than 20 inches.4 8. The finish on the surface of the reference block shall be representative of the surface finish on the component. 8. 1. 3. The reference block material shall be completely examined with a straight beam search unit. the reference block thickness shall be determined by the average thickness of the weld. The material from which the block is fabricated shall be of the same product form and material specifications or equivalent P . Notched reference blocks shall only be used for thickness less than 12.5 times of basic reference block diameter.

When calibrated using notched specimen. 8.0 EXAMINATION SURFACE: 10. at the beginning and finish of each examination or series of similar examinations.1 For straight beam examination the weld and base material shall be scanned progressively along and across the weld surface to the extent possible from at least one surface of the part.3 A calibration check on atleast one of the basic reflections in the basic calibration block shall be made to ensure proper functioning of the equipment.1.04.3 Distance . The sensitivity (in dB) used for DAC shall be evaluation sensitivity or reference level. 8. The peak marks of the indications from the side drilled holes are connected to provide distance amplitude curve. ¾T holes and T+¼T hole after the beam has bounced from the opposite surface. The peak of the indication is marked on the screen with a glass marking pencil. 8.2. the probe is positioned for maximum response from the ½T. . 10. 8. The peak of the indication is marked on the screen with a glass marking pencil. indication form the root notch is brought to 80% of screen height and the sensitivity level is noted. the probe is positioned for maximum response from the other two hole indications and their peaks marked on the screen.Amplitude Correction: The probe is positioned for maximum response from the hole that gives the highest amplitude and set to 80% (±5%) full screen height.5 Transfer correction if any obtained.QUALTECH ULTRASONIC EXAMINATION PROCEDURE Doc.2 Technique for Angle Beam Calibration: 8.2. No.1. every 4 hours during the examination and when examination personnel are changed.2 Distance . 8.05 9.4 8.2. Page Revision Date : QUAL/UT/001 : 3 of 10 : 00 : 25. 8.1 The sweep range for straight beam is set on the equipment using the IIW V1 block. ½T and ¾T shall be used. Without disturbing the sensitivity controls of the unit.V1 and V2 blocks. shall be added to test / evaluation sensitivity.0 CALIBRATION TECHNIQUES: 8. The gain is adjusted to provide an 80% ± 5% of full screen indication from the ¼T hole. Without disturbing the settings.Amplitude Correction (DAC): To construct a DAC a basic calibration block having drilled holes at ¼T.1 Technique for Straight Beam Calibration: 8. The screen marks are connected and extended through the thickness to provide the distance amplitude curve using side drilled holes.2 The sweep range is selected and the equipment is calibrated to the selected range using IIW .1 The basic calibration block shall be used for distance amplitude correction and position calibration.

12.2. The probe shall be rotated at 180° and examination shall be repeated. For butt joints the angle beam shall be directed essentially parallel to the weld axis.QUALTECH ULTRASONIC EXAMINATION PROCEDURE Doc. The probe shall be manipulated so that the angle beam passes through required volumes of the weld and adjacent base metal. shall verify the sweep range calibration and distance amplitude correction. No. However evaluation of indications shall be performed at the primary reference level.4) The angle beam shall be directed at 90° to the weld axis. from two directions where possible. In any case the rate of probe movement for examination shall not exceed 150mm per second. Sweep Range Correction: If a point on the DAC curve has moved on the sweep line more than 10% of the sweep reading or 5% of full sweep whichever is greater.04. Each pass of the probes shall overlap a minimum of 10% of the crystal element dimension perpendicular to the direction of the scan. During scanning.2 Defects Transverse to Weld (Figure -5) : For detection of transverse defects the weld shall be examined using 45 deg. Page Revision Date : QUAL/UT/001 : 4 of 10 : 00 : 25.0 CALIBRATION CONFIRMATION: A calibration check as discussed in 8.2.0 SCANNING SENSITIVITY: Scanning sensitivity shall be a minimum of +6dB above the reference level.1 .0 12. EXAMINATION COVERAGE : For the angle beam examination the entire volume of the weld inclusive of adjacent base metal shall be examined by moving the probe over the examination surface.05 10. All recorded indications since the last valid calibration or calibration check shall be re-examined with the corrected calibration and the value changed.3. the sweep range calibration shall be corrected. 11.2 Angle Beam Scanning: 10. 10. 12.1 Defects Parallel to the Weld: (Figure . the probes shall be moved to and fro with swiveling action of 10° to 15° on either side with overlap between successive scanning. The probes shall be manipulated so that the ultrasonic energy passes through the required volumes of the weld and adjacent base material. angle beam probe.

04.1 Details of inspection of original weld and repaired area shall be recorded in Attachment .1 Cracks. 16.2 Other imperfections are unacceptable if the indication exceeds the reference level amplitude and lengths which exceeds the following : ¼ inch for t up to ¾ inch 1/3 t for t from ¾ inch to 2¼ inches ¾ inch for t over 2 ¼ inches. and evaluate them in terms of paragraph 14.0 REPORT: No.0 ACCEPTANCE STANDARD: length. 17. lack of fusion. t is the thinner of these two thicknesses. Where t is the thickness of the weld being examined. If the weld joints two members having different thickness at the weld. or incomplete penetration are unacceptable regardless of After the examination is completed the couplant applied on the surface shall be removed to the pre-inspection condition. 17. Page Revision Date : QUAL/UT/001 : 5 of 10 : 00 : 25.2 DAC Correction: If a point on the DAC curve has changed 20% or 2dB of its amplitude.QUALTECH ULTRASONIC EXAMINATION PROCEDURE Doc. identity. 13.0 14. No. 15.0 EVALUATION: Imperfections that cause an indication greater than 20% of the reference level shall be investigated to the extent that the ultrasonic examination personnel can determine their shape. 17.2 Recording all reflections from uncorrected areas having responses that exceed 50% of reference level shall be made.05 12. and location.0 POST CLEANING: 14. all recorded indications since the last valid calibration check shall be re-examined with the corrected calibration. 14. 1.0 REPAIR & RETEST: Repaired weld regions shall be ultrasonically re-examined by the same procedure used for original testing.

Date of Test Time of Test Calibration Block Reference Block Normal: Calibration Range Search Unit Size Frequency Couplant Angle: Normal Angle Size / Length Type of Discontinuity Disposition For QUALTECH Witnessed by Sign: Name: Date: Sign: Name: Date: . Job Identification Referenc e Scanning Report No.05 Attachment 1 ULTRASONIC TESTING REPORT FORMAT QUALTECH QUALTECH ULTRASONIC TESTING REPORT Client Job Description Drawing No. Gain Calibration Verification Sl.QUALTECH ULTRASONIC EXAMINATION PROCEDURE Doc. No. Material Thickness Procedure No.04. No. Surface condition Equipment Model Serial No. Page Revision Date : QUAL/UT/001 : 6 of 10 : 00 : 25.

e. (3. The tolerance for hole location through the calibration block thickness (i. Alternatively. or fraction thereof over 4 in. (1.2 mm). (102 mm). notches) oriented 90 deg from each other shall be used.4) max.8) ** Notch Dimensions in.04. (38 mm) deep minimum. (mm) ¾ (19) or t 1 ½ (38) or t 3 (76) or t Hole Diameter in.2% T plus the thickness of cladding.2) 3/16 (4. (c) The tolerance for hole diameter shall be + 1/32 in. two sets of calibration reflectors (holes.4) 1/8 (3.QUALTECH ULTRASONIC EXAMINATION PROCEDURE Doc. (0. Notch Length = 1 (25) min. (mm) Notch Depth = 2% T Notch Width = ¼ (6. (d) All three holes may be located on the same face (side) of the calibration block provided care is exercised to locate the holes far enough apart to prevent one hole from masking the indication of another hole during calibration. (mm) 3/32 (2. (51mm). Page Revision Date : QUAL/UT/001 : 7 of 10 : 00 : 25. essentially parallel to the examination surface. if present.8 mm). t + 1 (25) ** For each increase in weld thickness of 2 in. No. (b) For curved surfaces. two curved calibration blocks may be used.. the hole diameter shall increase 1/16 in. distance from the examination surface) shall be + 1/8 in. GENERAL NOTES: (a) Holes shall be drilled and reamed 1.05 Weld Thickness (t) in. FIG (1) NON – PIPING CALIBRATION BLOCKS .6 mm).6% T and maximum notch depth shall be 2. (mm) Up to 1 (25) Over 1 (25) through 2 (51) Over 2 (51) through 4 (102) Over 4 (102) Calibration Block Thickness(T) in. (e) Minimum notch depth shall be 1.5 in.

No. whichever is greater.QUALTECH ULTRASONIC EXAMINATION PROCEDURE Doc. (203 mm) or 8T. (102 mm). (25mm). Page Revision Date : QUAL/UT/001 : 8 of 10 : 00 : 25.4 mm) maximum. GENERAL NOTES: (a) The minimum calibration block length (L) shall be 8 in. (c) Notch depths shall be from 8% T minimum to 11% T maximum. (6. to any block edge or to other notches. (203 mm) or 3T. For OD greater than 4 in. Notch widths shall be ¼ in. (b) For OD 4 in.05 * Notches shall be located not closer than T or 1 in. whichever is greater. Notch lengths shall be 1 in. the minimum arc length shall be 8 in. (102 mm) or less. (25 mm) minimum. Fig 1(A) CALIBRATION BLOCK FOR PIPE . whichever is greater.04. the minimum arc length shall be 270 deg.

QUALTECH ULTRASONIC EXAMINATION PROCEDURE Doc. 1(B) – CURVED BASIC REFERENCE BLOCK .04. Page Revision Date : QUAL/UT/001 : 9 of 10 : 00 : 25. No.05 FIG.

No.QUALTECH ULTRASONIC EXAMINATION PROCEDURE Doc.04. Page Revision Date : QUAL/UT/001 : 10 of 10 : 00 : 25.1 S ID E -2 F IG (5 ) S C A N N IN G D IR E C T IO N S F O R A N G L E B E A M .05 C /L W E L D M a x o v e rla p S K IP D IS T E X A M IN A T IO N C O V E R A G E F IG (4 ) S C A N N IN G T E C H N IQ U E W ELD S ID E .

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