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X-008064
S. GURESH 13 FEB 2018
APPROVED BY DATE 16
PAGE 2 OF 16
S. JOHNSON 13 FEB 2018
1.0 PURPOSE
This Inspection Method describes the methodology for Ultrasonic Examination using manual
and semi-automatic techniques by the contact and immersion longitudinal wave method and
angle beam methods on wrought materials. This Inspection Method meets the requirements of
ASTM A 388, ASME Section V, Article 5, DNVGL-RP-0034 and ASTM E1001 using referenced
calibration reflectors and an A-scan presentation as a minimum.
2.0 REFERENCES
The latest edition of the Standards and References cited were utilized in the current release of
this inspection method. Changes to a standard or reference that are determined to affect
product quality or services shall be cause for revision of this document.
2.1 ASTM A 388 Standard Practice for Ultrasonic Examination of
Steel Forgings
2.2 ASTM E 317 Standard Practice for Evaluating Performance
Characteristics of Ultrasonic Pulse- Echo Testing
Instruments and Systems without the Use of
Electronic Measurement Instruments
2.3 ASTM E 428 Standard Practice for Fabrication and Control of
Metal, Other than Aluminum, Reference Blocks
Used in Ultrasonic Testing
2.4 ASME Section V, Article 5 Ultrasonic Examination Method for Materials
2.5 ASNT Recommended Personnel Qualification and Certification in
Practice No. SNT-TC-1A Nondestructive Testing
2.6 ISO 9712 Non-destructive Testing, Qualification and
Certification of NDT Personnel – General
Principals
2.7 ASTM E 1001 Standard Practice for Detection and Evaluation of
Discontinuities by the Immersed Pulse-Echo
Ultrasonic Method Using Longitudinal Waves
3.0 PERSONNEL
3.1 All personnel performing examinations in accordance with this specification shall be
qualified and certified in accordance with a written practice that complies with ASNT
SNT-TC-1 A, or ISO 9712, or equivalent. Supplemental requirements may be imposed
on the Inspection Plan (IP).
3.2 Level I personnel shall be qualified to properly perform specific calibrations, specific non-
destructive testing, and specific evaluations for acceptance or rejection determinations
under direct supervision from a certified Level II or III and to record the results. Selection
of test method or technique and interpretation and evaluation of test results to codes
and/or standards shall be performed by Level II or III personnel.
3.3 Level II personnel shall be qualified to set-up and calibrate equipment and to interpret
and evaluate results with respect to codes, standards and specifications. Level II
personnel shall be able to organize and report results of non-destructive tests and to
provide training and guidance to Trainees and Level I personnel.
3.4 Records of certified personnel shall be maintained.
PROPERTY OF PREPARED BY DATE REVISION
X-008064
S. GURESH 13 FEB 2018
APPROVED BY DATE 16
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S. JOHNSON 13 FEB 2018
4.0 DEFINITIONS
4.1 Indication Levels (clusters): Five or more indications in a volume representing a 2
inch (50mm) or smaller cube in the forging.
4.2 Individual Indications: Single indications showing a decrease in amplitude as the
search unit is moved in any direction from the position of maximum amplitude and which
are too small to be considered traveling or planar.
4.3 Planar Indications: Indications shall be considered continuous over a plane if they
have a major axis greater than 1 inch (25mm) or twice the major dimension of the
transducer, whichever is greater, and do not travel.
4.4 Traveling Indications: Indications whose leading edge moves a distance equivalent to
1 inch (25mm) or more of metal.
4.5 Effective Beam Diameter: That distance through which a search unit can be traversed
across a calibration reflector so that the corresponding echo amplitude is at least one
half (-6 dB) of the maximum amplitude. The effective beam diameter is not a
characteristic of the search unit alone, but is dependent on the propagating medium,
distance to the discontinuity, reflector geometry, etc.
4.6 Scan Index: The length of the step created by indexing the scan of the search unit over
the part, which is continuously scanning in one direction, then stepping in the direction
perpendicular to the scan or making a linear advance per rotation (pitch) for rotary scan
of cylindrical parts. The allowable scan index should be correlated with the search unit
effective beam diameter to ensure full coverage of the part.
4.7 Transfer: A change in scanning gain to compensate for differences in attenuation of the
reference standard and the component of material being inspected.
5.0 EQUIPMENT
5.1 General
5.1.1 An ultrasonic pulsed reflection type instrument shall be used for these
inspections. The system shall have a minimum capability for examining at
frequencies from 1 to 5 MHz for the contact methods except as otherwise
noted. Other frequencies may be used if equal or better sensitivity can be
obtained.
5.1.2 The instrument shall have basic calibration performed at least every twelve
months per ASTM E 317, or whenever maintenance is performed which affects
the function of the instrument.
5.1.3 The instrument shall provide linear vertical presentation within +5% for a
minimum of 75% of the screen height (sweep line to top of screen). The 5 %
linearity referred to is descriptive of the screen presentation amplitude.
5.2 Immersion
5.2.1 The instrument shall have a pulser of sufficient voltage, repetition rate and
wave shape to provide total volume coverage at the desired scanning speed as
established using calibration reflectors.
5.2.2 For automated immersion examination of parts or material with regular shape
and parallel surfaces, such as plate, machined bar stock, and forgings, an
audible alarm or recording equipment should be used.
PROPERTY OF PREPARED BY DATE REVISION
X-008064
S. GURESH 13 FEB 2018
APPROVED BY DATE 16
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S. JOHNSON 13 FEB 2018
10.0 TESTING
10.1 As far as practical, the entire volume of each part shall be examined after heat treatment
for mechanical properties, excluding any post weld heat treatment, but prior to drilling,
cutting, tapering, or machining contours that limit effective interpretation of the
examination results. Because of local configurations it may not be possible to examine
some sections.
10.2 Materials shall be scanned from 2 perpendicular directions from all accessible surfaces
to examine the entire volume. Forgings which cannot be examined axially using the
straight beam technique shall be scanned with the angle beam technique in both axial
directions. Scanning speed shall not exceed a rate of 6 inches (152 mm) per second for
contact testing. For semi-automated scanning, adjust scanning speed or instrument
repetition rate, or both, to permit detection of the smallest calibration reflector referenced
in the specification and to allow visual detection or recording/alarming device to function.
At no time shall the scanning speed or index rate exceed the speed or index at which an
acceptable calibration was made.
10.3 For rings and hollow cylindrical forgings (see 9.3 and Note 1) scans shall be performed
in both the circumferential and the longitudinal directions. The longitudinal scan shall be
performed in both directions. For the circumferential scan direction, the scan shall be
performed in both the clockwise and counter-clockwise direction.
10.4 To assure complete coverage of the forging volume, index the search unit with at least
15% overlap with each pass.
10.5 Scanning shall be performed at a gain setting at least two times (+6 dB) the primary
reference level. Background noise levels caused by material composition or processing
greater than 50 % of the recordable level will be reported.
10.6 During examination the back reflection shall be monitored where possible for any
significant reduction in amplitude. Reduction in back reflection may indicate not only the
presence of a discontinuity, but also non-parallel front and back surfaces, or local
variations of attenuation in the forging. In the case of an area showing 50% or more loss
of back reflection where the back reflection can be monitored, further surface
conditioning shall be accomplished to help determine whether the loss of back reflection
is caused by surface conditioning or other factors.
10.7 For those areas of a particular part where it is not possible to conduct the ultrasonic
straight beam examination from two perpendicular surfaces (excluding radius locations)
an additional ultrasonic examination from other accessible surfaces will be required. The
additional ultrasonic examination shall be a straight beam or an angle beam shear
(transverse) wave technique. Note that the angle beam technique can only be used
when the OD to ID ratio is less than 2, and when the axial length is greater than 2 inches
(50 mm).
NOTE 2: High sensitivity levels are not usually employed when inspecting austenitic
steel forgings due to attendant high level of “noise” or “hash” caused by coarse grain
structure.
10.8 Evaluation
The operator shall investigate all indications above the visible noise level to determine
cause. All indications shall be evaluated with the gain setting at the calibration reference
level.
PROPERTY OF PREPARED BY DATE REVISION
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S. GURESH 13 FEB 2018
APPROVED BY DATE 16
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10.9 Recording
Record all indications which do not meet the acceptance criteria required for the
material. Additionally indications identified below shall be recorded.
10.9.1 Straight Beam Examination:
A. Indications equal to or exceeding 100% of the reference amplitude.
B. Length of indications which are planar, traveling, or clustered. Determine
the location of the edges and the major and minor axes using the half-
amplitude (6dB drop) technique.
C. Variation in depth or planar area, or both, of traveling indications.
D. Volume occupied by indication levels and the amplitude range.
10.9.2 Angle- Beam Examination:
A. Indications equal to or exceeding 50% of the indication from the reference
line.
B. Indications where an amplitude reference line cannot be generated, record
indications equal to or exceeding 50% of the reference notch.
C. Length of indications which are linear, planar, traveling, or clustered.
Determine the location of the edges and the major and minor axes using
the half-amplitude (6dB drop) technique.
11.0 DOCUMENTATION
11.1 Following completion of examination, an Ultrasonic Examination Report shall be
prepared to include the following information:
11.1.1 Identification of the items examined (Part Number, Revision level, Serial
Number, Purchase Order, Sales Order, Production Order, Lot Number, and
company, if other than Cameron, as applicable).
11.1.2 All recordable indications.
11.1.3 The location of recordable indications. A drawing shall be used showing the
physical outline of the forging including dimensions of all areas, if any, not
inspected due to geometric configuration, the item identification number and
the axial, radial and circumferential distribution of recordable ultrasonic
indications.
11.1.4 The specification or Inspection Method and revision to which the examination
was performed as well as the acceptance criteria, method, couplant, transducer
size, transducer type, transducer frequency, beam angle, mode of
transmission, surface preparation, calibration block, instrument reference level
gain etc.
11.1.5 The Ultrasonic Instrument (including serial number)
11.1.6 The inspector's signature and level of certification in accordance with
requirements described in Section 3.0.
11.1.7 Date examination was performed.
11.1.8 The names and employers of any witnesses to the examination.
PROPERTY OF PREPARED BY DATE REVISION
X-008064
S. GURESH 13 FEB 2018
APPROVED BY DATE 16
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S. JOHNSON 13 FEB 2018
FIGURE 1 A
FIGURE 1 B
FIGURE 2
Basic Immersion Setup
FIGURE 3
Typical Distance-Amplitude Curve
PROPERTY OF PREPARED BY DATE REVISION
X-008064
S. GURESH 13 FEB 2018
APPROVED BY DATE 16
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S. JOHNSON 13 FEB 2018
FIGURE 4
FIGURE 5
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X-008064
S. GURESH 13 FEB 2018
APPROVED BY DATE 16
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S. JOHNSON 13 FEB 2018
FIGURE 6
Curvature Correction Factor
PROPERTY OF PREPARED BY DATE REVISION
X-008064
S. GURESH 13 FEB 2018
APPROVED BY DATE 16
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S. JOHNSON 13 FEB 2018
TABLE 1
Distance Amplitude Reference Block-Metal Path
TABLE 2
Reference Block-Metal path Selection in Near Field