NDT Corrosion Control Services Co.

Dammam – Saudi Arabia Date: 26th June 2023

ULTRASONIC EXAMINATION PROCEDURE

INDEX
SL# CONTENT PAGE NO

1 Scope 3
2 Referenece Standard 3
3 General Requirement 3
3.1 Inspection Witness 3
3.2 NDT Personnels 3
3.3 Essentia and Non-essentail variables 3
4 Ultrasonic Examination Technique and Requirement 4
4.1 General Exmanination Requirements 4
5 Equipment, Accessoroes and Couplant 5
5.1 A- Scan Ultrasonic Flaw Detector 5
5.2 Probe/Search Units 5
5.3 Calibration Blocks 5
5.4 Reference Blocks 6
5.5 Couplant 11
6 Equipment Calibration 11
6.1 Gain Control Linearity 11
6.2 Time base or Horizontal Linearity 11
6.3 Range Calibration 12
6.4 Probe Angle 12
7 Distance Amplitude Correction (DAC) Using Angle Beam 13
8 Transfers Correction 13
9 Examiantion Procedure 14
9.1 Surface Preparation 14
9.2 Scanning 14
10 Examination as per AWS D1.1 16
11 Evaluation 18
12 Accetance Criteria 18
13 Safety Precautions 22
14 Post Examination Cleaning 22
15 Reporting 22
Attachment 1 – UT Report Format 23

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Document Revision History

1 00 26th June “23 Singupuram Joseph Initial Issue

Narayana Cherian
Sl. No Rev No Date Prepared By Reviewed By Comments

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1 SCOPE

This standard prescribes the method of testing and inspection of welds examination by Ultrasonic
direct contact reflection method. This method is applicable to Ferritic steel of thickness over 6
mm. It covers technique to be employed at normal temperature; care shall therefore be taken
to ensure that the temperature of the test piece is not above the temperature for which the
probe manufacture recommanded.
2 REFERENCE STANDARD

1. ANSI/ASME-V Article 4 & 5 – 2021 Edition

2. ANSI/ASME B 31.3 – 2020 Edition
3. ANSI/ASME B 31.1 - 2020 Edition
4. ANSI/ASME SEC.VIII DIV. I & II – 2021 Edition
5. AWS D1.1 2020 Edition
6. API-1104 – 2020 Edition
7. SA-435 latest Edition
8. SA-388 latest Edition
9. SAEP 1142 18th February 2020 Edition – Qualification of non-saudi Aramco NDT Personnel.
10. ASNT/ANSI CP-189 – 2020 Edition
11. NDT/CERT/01(Written Practice document for NDE Personnel Qualifcation)
3 GENERAL REQUIREMENT

Personnel performing UT examination must be qualified and certified in accordance with

NDT/CERT/01 NDTCCS (latest revision). All work shall be performed by Saudi ARAMCO approved
Technician; and work shall be in accordance with Saudi Aramco specs and standards.
3.1 INSPECTION WITNESS
Client inspection representatives, at their option, witness all or part of ultrasonic examination at
any time and place during and after fabrication and may, as deemed necessary, establish
witness as a hold point prior to or during the test.
3.2 NDT PERSONNEL
The examination shall be performed by at least an UT Level -II All interpretation of test results shall
be done by a certified NDT Level -II Technician. Personnel performing ultrasonic examination
must be qualified and certified in accordance with company’s written practice NDT/CERT/01
(latest revision), ANSI/ASNT CP-189. The client inspection unit representative may, at his option,
require the technicians to validate their certification by submitting to qualification test
administered by client NDE Level III.
3.3 Essential and non-essential variables
Any changes identified as essential variable vide ASME Section V Art 4; Table T-421, reproduced
below, shall require re-qualification of the written procedure by demonstration. A change of a
requirement identified as a non-essential variable does not require re qualification of the written
procedure.
Table T – 421: Requirement for Ultrasonic Examination Procedure

Essential Non-Essential
Requirement
Variable Variable

Weld configuration to be examined, including thickness

X --
dimensions and base material product form (pipe, plate etc.)
The surfaces from which the examination shall be performed X --
Technique(s) (straight beam, angle beam, contact, and/or
X --
immersion)
Angle(s) and mode(s) of wave propagation in the material X --
Search unit type(s), frequency(s), and element size(s)/ shape(s) X --

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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 --
Scanning (manual vs., automatic) X --
Method for discriminating geometric from flow indications X --
Method for sizing indications X --
Computer enhanced data acquisition, when used X --
Scan overlap (decrease only) X --
Personnel performance requirements, when required X --
Personnel qualification requirements -- X
Surface condition (examination surface, calibration block) -- X
Couplant: brand name or type -- X
Post examination cleaning technique -- X
Automatic alarm and/ or recording equipment, when
-- X
applicable
Record, including minimum calibration data to be recorded
-- X
(e.g., instrument settings)

4 ULTRASONIC EXAMINATION TECHNIQUE REQUIREMENTS

Ultrasonic examination technique record containing the essential elements shall be maintained.
1. Weld and/or material types and configuration to be examined including thickness
dimensions, and product from (casting, forging, plate etc.)
2. The surface or surfaces from which the examination shall be performed.
3. Surface condition.
4. Couplant, brand name, or types.
5. Technique (straight beam, angled beam, contact or immersion.
6. Angles and mode (s) of wave proposition in material.
7. Search unit type, frequency (ices), and transducer size(s)
8. Special search units, wedges, shoes, or saddles.
9. Ultrasonic instrument type(s).
10. Description of calibration: blocks and technique.
11. Directions and extent of scanning.
12. Data to be recorded and method of recording (manual or mechanized).
13. Automatic alarm and recording equipment, or both.
14. Rotary, revolving or scanning.
15. Post-examination cleaning.
4.1 GENERAL EXAMINATION REQUIREMENTS
EXAMINATION COVERAGE
Each pass of the search unit shall overlap a minimum 10% of the transducer (piezoelectric
element) dimension perpendicular to the direction of the scan.
RATE OF SEARCH UNIT MOVEMENT
The rate of search unit movement for examination shall not exceed 6 in./sec. unless calibration
is verified at scanning speed.
RECORDING SENSITIVITY LEVEL
The recording of indication shall be made with respect to the reference level.
5 EQUIPMENT, ACCESSORIES AND COUPLANT

5.1 A-SCAN ULTRASONIC FLAW DETECTOR

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The ultrasonic equipment shall be pulse echo type ‘A’ scan suitable for use with transducers
oscillating at frequencies between 1 and 6 MHz the equipment shall have valid calibration
certificate equipment must be calibrated at least every 12 months. The equipment shall be
equipped with a flat screen accessible from the front for direct plotting of Distance Amplitude
Curves (DAC) and shall be able to clearly distinguish echoes with amplitudes of 5% of FSH. If the
instrument has a damping control, it may be used if it does not reduce the sensitivity of the
examination. The reject control shall be in the “off” position for all the examinations. Following
instruments can be used for the ultrasonic examinations.
OLYMPUS EPOCH XT, EPOCH 600, GE USM-35, USM-36, USM Go, USM Go + or equivalent and the
instrument shall be equipped with a stepped gain control calibrated in units of 2 dB or less .
5.2 PROBE OR SEARCH UNIT
Probes used for testing of the welds in Carbon steel, C-Mn steel and alloy steels shall be straight
beam (Single or twin crystal) and angle shear wave of 45º, 60º and 70º. The nominal frequency
shall be 1 MHz to 5 MHz unless variables, such as production material grain structure, require the
use of other frequencies to assure adequate penetration or better resolution. Search units with
contoured contact wedges may be used to aid ultrasonic coupling.
An angle shall be selected as appropriate for the configuration being examined.
The instrument, when required because of the technique being used, shall have both send and
receive jacks for operation of dual search units or a single search unit with send and receive
transducers.
5.3 CALIBRATION BLOCKS
The IIW (V1 & V2) or ISO blocks (A2 & A4), see in given below figure. shall be used for the
calibration of range scale and for angle determination. These calibration blocks shall preferably
have the same acoustic properties as the material to be tested.

Figure: 5.3 Calibration blocks

5.4 REFERENCE BLOCKS

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Reference blocks shall be made with thickness and side –drilled holes, as Attachment. The
reference block shall normally be manufactured from the actual material tested and have
approved dimensions.
Table 5.4: Reference block requirements
Thickness of Thickness Diameter of hole (mm) Distance of hole from one
material to be of block surface (mm)
examined (mm) (mm)
Up to 25 t 19 or T Ø 2.5 T/4, T/2 and 3T/4. Additional
25< t ≤ 50 38 or T Ø3 holes are allowed and
50 < t ≤ 100 75 or T Ø5 recommended.
t > 100 ± 25 of T For each increase in weld
thickness of 2 in. (50 mm)
or fraction thereof over 4
in. (100 mm), the hole
diameter shall increase
1/16 in. (1.5 mm).

Table 5.4 (b) Notch Dimensions In (mm)

Notch Depth Notch Width Notch Length

1.6 % of T or 2.2 % T 1/6 (6) Max 1 (25)

Figure: 5.4 (a) Non Piping Reference or/and Calibration Block ( setting DAC)
General Requirements:
Holes shall be drilled and reamed 1.5 in. (38 mm) deep minimum essentially parallel to the
examination surface.
For components equal to or less than 20 in. (500 mm) in diameter, calibration block diameter
shall meet the requirements of 13.3.3. Two sets of calibration reflectors (holes, notches)
oriented 90 deg. From each other shall be used. Alternately two curved calibration blocks
may be used.
The tolerance for the hole diameter shall be ± 1/32 in. (0.8 mm). The tolerance for hole
location through the calibration block thickness (distance from the examination surface)
shall be ±1/8 in. (3 mm).

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For blocks less than ¾ in. (19 mm) in thickness, only the ½ T side drilled hole and surface
notches are required.
All holes may be located on the same face (side) of the calibration block, provided care is
exercised to locate all the reflectors (holes, notches) to prevent one reflector from affecting
the indication from another reflector during calibration. Notches may also in the same plane
as the inline holes., Enough holes shall be provided for both angle and straight beam
calibration ¼ T, ½T and ¾ T depths.
When cladding is present, notch depth on the cladding side of the block shall be increased
by the cladding thickness, CT (i.e.,1.6 % T+ CT minimum to 2.2%T + CT maximum).
Maximum notch width is not critical. Notches may be made by EDM or with end mills up to
¼ in. (6.4 mm) in diameter.
Weld thickness t is the nominal material thickness for welds without reinforcement or for welds
with reinforcement, the nominal material thickness plus the estimated weld reinforcement
not to exceed the maximum permitted by the referencing code section. When two or more
base material thicknesses are involved, the calibration block thickness, T shall be determined
by the average thickness of the weld; alternatively, a calibration block based on the greater
base material thickness may be used provided the reference reflector size is based upon the
average weld thickness.
NOTES:
1. Minimum dimension
2. For each increase in weld thickness of 2 in.(50 mm) or fraction thereof over 4 in.( 100 mm),
the hole diameter shall increase 1/16 in(1.5 mm)

Figure: 5.4 (b) Piping Reference or/and Calibration Block ( setting DAC)
General Requirements:

a) The minimum calibration block length, L, shall be 8 in. (200 mm) or 8T, whichever is greater.
b) For O.D. 4 in. (100 mm) or less, the minimum arc length shall be 75% of the circumference. For
O.D. greater than 4 in. (100 mm), the minimum arc length shall be 8 in. (200 mm) or 3T,
whichever is greater.
c) Notch depths shall be from 8% T minimum to 11% T maximum. When cladding is present,
notch depths on the cladding side of the block shall be increased by the cladding thickness,
CT (i.e., 8% T + CT minimum to 11% T + CT maximum). Notch widths shall be 1/4 in. (6 mm)
maximum. Notch lengths shall be 1 in. (25 mm) minimum.
d) Maximum notch width is not critical. Notches may be made with EDM or with end mills up to
1/4 in. (6 mm) in diameter.

e) Notch lengths shall be sufficient to provide for calibration with a minimum 3 to 1 signal-to-
noise ratio.

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f) Two blocks shall be used when a weld joining two different thicknesses of material is
examined and a single block.
g) When a flat block is used as permitted by T-434.1.7.1 of ASME Section V article 4, the two axial
notches may be omitted and the block width may be reduced to 4 in. (100 mm), provided
the I.D. and O.D. notches are placed on opposite examination surfaces of the block. When
cladding is not present, only one notch is required provided each examination surface is
accessible during calibrations.
NOTE:
(1) Notches shall be located not closer than 1/2T or 1/2 in. (13 mm), whichever is greater, to any
block edge or to other notches.

Figure: 5.4 (c) Ratio Limits for Curved Surfaces

Nozzle Side Weld Fusion Zone and/or Adjacent Nozzle Parent Metal Calibration Blocks.
Calibration Block.
(a)Configuration. The calibration block configuration shall be as shown in Figure 5.4 (d). The block
size and reflector locations shall be adequate to perform calibrations to cover the nozzle side
weld fusion zone and/or the adjacent nozzle parent metal. If the internal surface of
thenozzleiscladbeforetheexamination,theIDsurfaceof the calibration block shall be clad.
(b) Block Thickness. The calibration block shall be the maximum thickness of the nozzle wall
adjacent to the nozzle weld plus 3/4 in. (19 mm).
(c) Curvature. For examinations of nozzles with an inside diameter (I.D.) equal to or less than 20
in. (500 mm), the contact surface of the calibration block shall have the same curvature or be
within the range of 0.9 to 1.5 times the diameter as detailed in Figure 5.4 (c).
(d) Calibration Reflectors. The calibration reflectors shall be side-drilled hole(s) that are in
accordance with the requirements of Figure 5.4 (a) for the nozzle wall thickness.
(e) Alternative Blocks. Alternative calibration blocks may be used for similar types of
examinations provided the sound path distance(s) to the block’s reflector(s) is (are) within 1/4 in.

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(6mm)of what is required and the side drilled hole(s) is (are) the same or a smaller diameter than
what is required.
Calibration Block for Straight Beam Examination of Nozzle Side Weld Fusion Zone and/or Adjacent
Nozzle Parent Meta;

Figure 5.4 (D): Calibration Block for Straight Beam Examination of Nozzle Side Weld Fusion Zone
and/or Adjacent Nozzle Parent Meta;

Calibration Block Wall

Hole Location, 5/8T Hole Location, 3/4T Hole Location, 7/8T
Thickness, in. (mm)

> 2 (50) through 3 (75) … X …

> 3 (75) X X X

Figure 5.4 (d): NozzleSideWeldFusionZoneand/orAdjacent Nozzle Parent Metal Calibration

Blocks.
Calibration For Nozzle Side Weld Fusion Zone And/Or Adjacent Nozzle Parent Metal
The number of calibration holes used depends upon the requirements for the examination. If only
the nozzle side fusion zone is to be examined, then only a single sidedrilled hole at the nozzle wall
thickness needs to be used.
(a) Single Hole. The response from a single side drilled hole shall be set at 80% ± 5% of full screen
height. This is the primary reference level.
(b) Multiple Holes. The straight beam shall be directed toward the calibration reflector that yields
the maximum response. The gain control shall be set so that this response is 80% ± 5% of full
screen height. This shall be the primary reference level. The search unit shall then be
manipulated, without changing instrument settings, toobtain the maximumresponses
fromthe other holeposition(s) to generate a distance–amplitude correction (DAC) curve.

REFEREBCE BLAOCK AS PER API 1104 (SETTING SENSITIVITY LEVEL)

Manual ultrasonic testing sensitivity shall be based on a two- or three-point reference level
(i.e., DAC or TCG) derived from an N10 notch introduced into a sample of the pipe to be
inspected (see Figure 5.5 a and Figure 5.5 b).
The highest point of the DAC/TCG shall not be less than 80 % of full screen height. The
reference standard shall also be used to determine the actual sound beam velocity,
refracted angle, and sound path distance in the pipe material to be inspected.

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Unknown velocity and refracted angle shall be determined when welds in pipe of different
chemistry specifications, wall thickness, diameter or from more than one pipe and rolling or
piercing manufacturer are to be inspected.
This may be accomplished by using two probes of the same nominal angle and frequency
with the probes directed toward one another. When a difference is noted in velocity, angle,
or sound path distance, another reference standard shall be made from the different pipe
material.
For automated ultrasonic testing and when required by the company for manual ultrasonic
testing, flat bottom holes shall be machined into a sample of the pipe to be inspected.

This sample shall be used as calibration reflectors in addition to the N10 notches at the inside
and outside surfaces. The diameter of each flat bottom hole should be approximately equal
to the thickness of one welding fill pass.

The flat reflecting surface of each hole shall be installed at the same angle and position as
the weld joint preparation for each fill pass required by the welding procedure. Additionally,
planar reflectors or flat bottom holes shall be installed at the weld centre line position with
their flat reflecting surfaces vertical to the weld.

All reflectors should be spaced apart so that no two will be within the beam spread of one
probe simultaneously.

For testing on other than new construction, a pipe sample of the same grade, wall
thickness, and OD as the pipe to be inspected shall be used to make the reference
standard.

A transfer technique using probes of the same nominal angles and frequencies to be
used for inspection shall be carried out to determine actual full skip distance, actual
refracted angle, and attenuation in the material to be inspected (see Figure 5.5 c).

Figure 5.5 a: Reference block for Manual UT

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Figure 5.5 b: Establishing, Reference Angle and Velocity

Figure 5.5 c: Transfer Procedure

5.5 COUPLANT
Polycell glue / Oil/ Grease/ Glycerine/UCA 2M/Sonagel etc. Couplant used on nickel or
austenitic stainless base alloys shall not contain more than 250ppm of sulfur.
For any high Temparature components clinet should be supply couplant whch is applicable for
the testing. clinet should be take care supplied couplant doest not have any affect with the Test
componants.
6 EQUIPMENT CALIBRATION

6.1 GAIN CONTROL LNEARITY

The ultrasonic instrument shall provide linear vertical presentation within +/-5% of the
full screen height for 20% to 80% of the calibrated screen height. The screen height
linearity evaluation shall be met with intervals not to exceed three months for analog
type instruments and one year for digital type instruments, prior to first use. During
Inspection Technicians shall be varify gain control linearity every 4 hours.
Table: 6.2
Indication limit of % full screen
Gain [dB] Expected screen height [%]
Height (%)
+2 101 Not Less than 95
0 80 Reference Line
- 6 dB 40 37% to 43
- 12 dB 20 17 to 23
-18 dB 10 8 to 12
6.2 TIME BASE OR HORIZONTAL LNEARITY

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Horizontal linearity of the time base shall be checked by using IIW -V1 block. The length of the
time base chosen shall be appropriate to the part to be tested. The time base shall be adjusted
to at least four multiple echoes from the IIW block by using single crystal normal beam transducer
or angle beam transducer. The multiple echoes shall be adjusted in such a way that the leading
edges of the second echo and the last but one coincides with the required major divisions of
the horizontal time base scale. The equipment suppression level shall be set at ‘0’ level while
performing the horizontal time base linearity check. When measuring their position against the
amplitude, the echoes shall be brought to the same amplitude height preferably 80% of FSH. The
time base shall be considered non-linear, if the deviation of any of the amplitude position
exceeds ± 2% of the selected range or one minor sub-division. This time base linearity shall be
verified, at the start of each working shift or/and every 4hours.
Further any variation on the position of echo with ≤2 % of full screen width, setting shall be
corrected before testing is continued. If the Echo position exceeds 2% of full screen width setting
shall be corrected and testing carried out with the equipment over the previous period shall be
repeated.
6.3 RANGE CALIBRATION
The calibration of the range scale with straight beam probe is to be carried out with an IIW
calibration block, a V1 calibration block or on a defect free area of the material to be tested.
The range scale is to be selected such that there are always at least 2 back-wall echoes
(reflections) on the screen. Figure 8.1shows typical calibration in range 0-100 mm, 0-200 mm, and
0-500 mm for straight beam probes. The calibration of angle beam probes is to be carried out
on an IIW or V2 calibration block. The range is to be selected to cover minimum 1.25 x full skip
distance. Required skip distance (S) is depending on the object thickness and can be calculated
as follows:
S = 2Ttanθ where T = Thickness of object to be tested, θ= probe angle and S= Skip Distance
BP = T/Cosθ where BP= Beam Path
6.4 PROBE ANGLE
The probe index is to be determined by placing the probe as shown in Figure 6.4 (a) and
maximizing the echo against the cylinder surface with radius 100 mm (IIW) or 50 mm (V2), the
echo height is adjusted to about 80% if FSH. The probe index can now be read off against the
mark on the calibration block and marked off on the probe. The probe angle is to be checked
on the IIW block using the index found. The echo from the circular Perspex reflector is maximized
and put at 80% of FSH. The probe angle can now be read off on the calibration block against
the engraved center point, see Figure 6.4 (b).

Figurre: 6.4 (a): Probe Index Figure: 6.4 (b): Probe Angle

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7 DISTANCE AMPLITUDE CORRECTION (DAC) USING ANGLE BEAM

Position the search unit for maximum response from the ¼ T hole. Adjust the sensitivity control to
provide an 80% of FSH echo from the hole. Record the peak of the indication on the screen.
Record the gain setting, which will be considered as primary reference level.
Position the search unit for maximum response from ½ T hole without changing the instrument
settings and record the peak of the indication on the screen.
Position the search unit for maximum response from the ¾ T hole without changing the instrument
settings and recoed the peak of the indication on the screen.
Position the search unit for maximum response from the ¾ T hole without changing the instrument
settings after half skip and mark the peak of the indication on the screen.
Connect the screen marks to provide a distance amplitude curve (DAC) for each search unit to
be used in testing.
When DAC has been set up it is recommended to draw two additional curves, 20% and 50% of
DAC, on the screen. see Figure 7.

¼T ½T
¾T

Figure: 7 Angle beam DAC curve

8 TRANSFER CORRECTION

Any possible difference in attenuation and surface character between the calibration block
and the object to be tested are to be checked in the following ways: Two angle probes of the
same type as those to be utilized during the testing are to be used. The probes are placed on
the object to be tested as shown in Figure 8. One of the probe works as transmitter and the other
as the receiver. The first echo is maximized and with the aid of gain control it is adjusted to reach
the DAC. The gain setting is noted. Without altering this gain setting the probes are moved to
calibration block. The echo is adjusted to reach the DAC and gain setting is noted. Any
difference in echo amplitude between the two materials can now be determined with the aid
of gain control. If the differences are less than 2 dB, correction is not required. If the differences
are more than 2 dB but less than 12 dB they shall be compensated.

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Figure 8: Transfer correction.

9 EXAMINATION PROCEDURE

9.1 SURFACE PREPARATION

BASE METAL
The base metal on each side of the weld shall be free of weld spatter, surface irregularities, of
foreign matter that might interfere with the examination. Surface preparation is necessary to
ensure that the entire volume of the weld is scanned with the required angle probe.
WELD METAL
Where the weld surface interferes with the examination, the weld shall be prepared as needed
to permit examination.
9.2 SCANNING
The volume of weld and adjacent base material (volume on either side of the weld seam) that
is to be examined shall be scanned by straight and angle beam probes.
STRAIGHT BEAM
The scanning of adjacent base metal shall be performed to detect reflector that might affect
interpretation of angle beam result. Location and areas of such reflectors shall be recorded.
The weld and base metal shall be scanned, where required by the referencing code section, to
the extent possible with the scaning zone untill angle beam search unit. The scanning shall be
performed at a gain setting of at least 2 times the primary reference level. Evaluation shall be
performed with respect to the primary reference level.
9.2.1 ANGLE BEAM SCANNING ON BUTT WELDED PALTES, PIPES, Nozzle AND ‘T’ JOINTS
The angle beam shall be directed at approximately right angle to the weld axis from two
direction where possible. The search unit shall be manipulated so that the ultrasonic energy
passes through the entire volumes of weld and the adjacent base metal. The scanning shall be
performed at a gain setting at least two times the primary reference level. Evaluation shall be
performed with respect to the primary reference level.
Where possible the welds are to be tested from on surface of the plate and from both sides
of the weld connection. The angle probe is placed on the parent material in such a way that
the sound beam is normal to the weld. The probe is to be moved forwards and backwards in the
scanning area of 1.25 x S. during this movement the probe is to be continuously turned to 5-10º

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in the horizontal plane, as intimated on Figure 9.2.2 For plate thickness greater than 70 mm it may
be necessary to scan from both surfaces and all four side of the weld.
The probe is to be moved forwards and backwards in the scanning area of 1.25 x S. of U bevel
as shown in figure 9.2.2 B.
Testing of Butt Plate, Pipe, Nozzle (D-Catogory) and T-joints:
The examination of T joint with ½ V or K groove and But welded half V and double V jojnts, sahll
be carried out the scaning as possible shown in below figures.

Figure 9.2.2 : scaning of Butt Plate, Pipe, T-joint Nozzle (D-Category):

½ SD

1.25 SD

Figure 9.2.2 B U Bevel weld configuration

9.2.2 NOZZLE SIDE WELD FUSION ZONE AND/ OR ADJACENT NOZZLE PARENT METAL
Search Unit Location.
When the referencing Code Section specifies that an ultrasonic examination be performed to
examine either the nozzle side weld fusion zone and/or the adjacent nozzle parent metal, a
straight beam examination shall be conducted from the inside nozzle surface.
Examination.
The full circumference of the nozzle shall be scanned to cover the entire nozzle side fusion zone
of the weld plus 1 in. (25 mm) beyond the weld toes. The search unit may be moved either
circumferentially around or axially across the examination zone. The screen range shall cover as
a minimum, 1.1timesthefullthicknessofthenozzlewall.Nozzlesthat cannot be fully examined (e.g.,
restricted access that preventshand placement ofthe search unit)shall be noted in the
examination report.

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10 EXAMINATION AS PER AWS D1.1

10.1 CALIBARTION FOR TESTING

All calibrations and tests shall be made with the reject (clipping or suppression) control turned
off. Use of the reject (clipping or suppression) control may alter the amplitude linearity of the
instrument and invalidate test results.
Calibration for sensitivity and horizontal sweep (distance) shall be made by the ultrasonic
operator just prior to and at the location of testing of each weld.
Recalibration shall be made after a change of operators, each 30-minute maximum time
interval, or when the electrical circuitry is disturbed in any way, which includes the following:
Transducer change, Battery change, Electrical outlet change, Coaxial cable change and Power
outage (failure).
10.2 CALIBARTION FOR STRAIGHT BEAM TESTING OF BASE METAL SHALL BE MADE WITH SEARCH
UNIT APPLIED TO TOPSIDE OF THE BASE METAL AND PEROFRMED AS FOLLOW.
The horizontal sweep shall be adjusted for distance calibration to present the equivalent of at
least two-plate thickness on the CRT screen.
The sensitivity shall be adjusted at a location free of indications so that the first back
reflection from the far side of the plate will be minimum 75% of full screen height.
10.3 CALIBARTION FOR ANGLE BEAM TESTING SHALL BE PERFORMED AS FOLLOW.
The horizontal sweep shall be adjusted to represent the actual sound path distance by using
the IIW block or alternative blocks. The distance calibration shall be made using either the
125mm scale or 250mm scale on the CRT screen, whichever is appropriate. If, however, the joint
configuration or thickness prevents full examination of the weld at either of these settings, the
distance calibration shall be made using 500mm scale as required.
Note: The horizontal location of all screen indications is based on the location at which the left
side of the trace deflection breaks the horizontal base line.
The zero reference level sensitivity used for flaw evaluation is attained by adjusting the
calibrated gain control (attenuator) of the flaw detector, so that a maximized horizontal
reference level trace deflection results on the CRT screen.
Welds shall be tested using an angle beam search unit using the angle as shown in Table
8.7 attached. Following calibration and during testing, the only instrument adjustment permitted
is the sensitivity level adjustment with the calibrated gain control (attenuator). The reject
(clipping or suppression) control shall be turned off. Sensitivity shall be increased from the
reference level for weld scanning in accordance with Tables 8.2 or 8.3 (see attached) as
applicable.
The testing angle and scanning procedure shall be in accordance with those shown in Table
8.7 (see attached).
All butt joint welds shall be tested from each side of the weld axis. Corner and T-joint welds
shall be primarily tested from one side of the weld axis only. All welds shall be tested using the
applicable scanning pattern exhibit as necessary to detect both longitudinal and transverse
flaws. It is intended that, as a minimum, passing sound through the entire volume of the weld
and the heat-affected zone in two crossing directions test all welds, wherever practical.
10.4 INDICATION RATING METHOD.
The transducer shall be set in the position of IIW so that the maximum reflection from 1.59 mm
hole is received. The maximized signal shall then be adjusted to attain a horizontal reference
line height indication.
The maximum decibal reading shall be used as the reference level, “b” in the calculation of the
indication rating.

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Indication rating, d = a-b-c

Where “a” – Instrument reading in decibels, when the indication from the discontinuity is
adjusted to the amplitude source as the indication from 1.59mm Ф hole at primary reference
level.
“c”- Attenuation factor is attained by subtracting 1 inch (25mm) from the sound – path distance
and multiplying the remainder by 2. The factor shall be rounded out to the nearest dB value.
10.5 SCANNING
Scanning shall be by contact method using manual, semi-automatic or automatic mechanism.
Recording may be carried out using automatic alarm recording system or by manual method.
Scanning shall be carried out such that entire volume of weld is tested for longitudinal and
transverse discontinuities.
The volume to be scanned shall be examined by moving the search unit over the scanning
surface so as to scan the entire examination volume for each required search unit.
Each pass of the search unit shall overlap a minimum of 10% of the active transducer
(piezoelectric element) dimension perpendicular to the direction of scan. Where mandated by
code requirements, the percent minimum overlap may be increased.
Alternatively, each pass of the search unit may overlap a dimension less than the minimum
beam dimension (beam spread) if the same is already known. Oscillation of the search unit is
permitted provided improved coverage is demonstrated.
The pulse Repetition rate shall be small enough to assure that a signal from a reflector
located at the maximum distance in the examination volume will arrive back at the search unit
before the next pulse is placed on the transducer.
The rate of search unit movement (scanning speed) shall not exceed 6 inch /s (152 mm/s)
Scanning shall be performed from the branch connection.

FIGURE 10.5 – PLAN VIEW OF UT SCANNING PATTERNS

General Notes:
• Testing patterns are all symmetrical around the weld axis except for pattern D, which shall
be conducted directly over the weld axis.
• Testing from both sides of the weld axis shall be made wherever mechanically possible.

10.6 FLAW SIZE EVALUATION PROCEDURES

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Straight (longitudinal) Beam Testing:

The size of lamellar discontinuities is not always easily determined, especially those that are
smaller than the transducer size. When the discontinuity is larger than the transducer, a full loss of
back reflection will occur and a 6 dB loss of amplitude and measurement to the centerline of
the transducer is usually reliable for determining flaw edges. However, the approximate size
evaluation of those reflectors, which are smaller than the transducer, must be made by
beginning outside of the discontinuity with equipment calibrated as per this procedure and
moving the transducer toward the area of discontinuity until an indication on the screen begins
to form. The leading edge of the search unit at this point is indicative of the edge of the
discontinuity.
Angle Beam (Shear) Testing:
The following procedure shall be used to determine lengths of indications, which have dB ratings
more serious than for a Class D indication. The length of such indication shall be determined by
measuring the distance between the transducer centerline locations where the indication rating
amplitude drops 50% (6dB) below the rating for the applicable flaw classification. This length
shall be recorded under “discontinuity length” on the test report. Where warranted by flaw
amplitude, this procedure shall be repeated to determine the length of Class A,B and C flaws.

10.7 WELD DISCONTINUITY CHARACTERIZATION METHODS

Discontinuities shall be characterized as follows:
Spherical (individual pores and widely spaced porosity, nonelongated slag) – Sound is reflected
equally in all directions. Indication remains basically unchanged as the search unit is moved
around the spherical discontinuity.
Cylindrical (elongated slag, aligned pores of porosity, hollow beads) – Sound is reflected equally
in one direction but is changed in other directions. Indication remains basically unchanged when
the search unit is moved in one direction but is drastically changed when moved in other
directions.
Planar (incomplete fusion, inadequate joint penetration, cracks) - Sound is reflected at its
maximum from only one angle of incidence with one plane.Indication is changed with any
angular movement of the search unit. Indicationsc from cracks typically have multiple peaks as
a result of the many discontinuity facets usually present.

10.8 ACCEPTANCE CRITERIA AND TEST FREQUENCY.

Each weld discontinuity shall be accepted or rejected on the basis of its indication rating and
its length, in accordance with A W S D 1 . 1 table 8.2 and 8.3 for statically or cyclically
loaded structures respectively.
Each reject able discontinuity shall be indicated on the weld by a mark directly over the
discontinuity for its entire length and depth from the surface shall be noted on nearby base
metal.
Evaluation of the defects shall be performed from both the branch and the main branch.
10% testing on CJP Groove butt welds of total Qty –full weld length.
11 EVALUATION

Any imperfection which causes an indication in excess of 20% DAC shall be investigated to the
extent that it can be evaluated in term of the acceptance standards as per acceptance
standard.
12 ACCEPTANCE CRITERIA

During the examiantion all evaluated discontinuties shall be accept and rejected based below
standaed.

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12.1 ASME SEC VIII DIV I APPENDIX -12

Indications characterized as cracks, lack of fusion, or incomplete penetration are
unacceptable regardless of length.
Other imperfections are unacceptable if the indications exceed the reference level amplitude
and have lengths which exceed:
1) ¼ inch (6 mm) for t up to ¾ inch(19 mm).
2) 1/3 t for t from ¾ inch to 2¼ inch.(19 mm to 57 mm)
3) ¾ inch(19 mm) for t over 2¼ inch.(57 mm)
Where t is the thickness of the weld excluding any allowable reinforcement. For a butt weld
joining two numbers having different thickness at the weld, t is the thinner of these two
thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the fillet
shall be included on t.

12.2 ASME B31.3:

Acceptance criteria shall be as described in (a)
(a) A linear type discontinuity is unacceptable if the amplitude of the indication exceeds the
reference level and its length exceeds-
1. 6 mm (¼ inch) for Tw ≤ 19 mm (¾ inch)
2. Tw /3 for 19 mm < Tw ≤ 57 mm (2¼ inch)
3. 19 mm (¾ inch) for Tw > 57 mm(2¼ inch)

12.3 AWS D1.1

General Notes:
• Class B and C discontinuities shall be separated by at least 2L, L being the length of the longer
discontinuity, except that when two or more such discontinuities are not separated by at
least2L, but the combined length of discontinuities and their separation distance is equal to
or less than the maximum allowable length under the provisions of Class B or C, the
discontinuity shall be considered a single acceptable discontinuity.
• Class B and C discontinuities shall not begin at a distance less than 2L from weld ends carrying
primary tensile stress, L being the discontinuity length.
• Discontinuities detected at “scanning level “in the root face area of CJP double groove weld
joints shall be evaluated using an indicating rating 4 dB more sensitive than described in
6.26.6.5 when such welds are designated as” tension welds “ on the drawing ( subtract 4 dB

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from the indication rating “d”). This shall not apply if the weld joint is back gouged to sound
metal to remove the root face and MT used to verify that the root face has been removed.
• ESW or EGW s: discontinuities detected at “scanning level” which exceed 2 in. [50 mm] in
length shall be suspected as being piping porosity and shall be further evaluated with
radiography.
• For indications that remain on the display as the search unit is moved, refer to 8.13.1. (AWS
D1.1)
Note:
1. Weld thickness shall be defined as the nominal thickness of the thinner of the two parts being
joined.

General Notes:
Class B and C discontinuities shall be separated by at least 2L, L being the length of the longer
discontinuity, ,except that when two or more such discontinuities are not separated by at least
2L, but the combined length of discontinuities and their separation distance is equal to or less
than the maximum allowable length under the provisions of Class B or C, the discontinuity shall
be considered a single acceptable discontinuity.
Class B and C discontinuities shall not begin at a distance less than 2L from weld ends carrying
primary tensile stress, L being the discontinuity length.

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Discontinuities detected at “scanning level “in the root face area of CJP double groove weld
joints shall be evaluated using an indicating rating 4 dB more sensitive than described in 6.26.6.5
when such welds are designated as” tension welds “ on the drawing ( subtract 4 dB from the
indication rating “d”). This shall not apply if the weld joint is back gouged to sound metal to
remove the root face and MT used to verify that the root face has been removed.
ESW or EGW s: discontinuities detected at “scanning level” which exceed 2 in. [50 mm] in length
shall be suspected as being piping porosity and shall be further evaluated with radiography.
For indications that remain on the display as the search unit is moved, refer to 8.13.2.1.(AWS D1.1)
Note: 2 -- Weld thickness shall be defined as the nominal thickness of the thinner of the two parts
being joined.

12.4 API 1104

Indication shall be considering defects should any of the following conditions exist:

A. Indication determined to be cracks,

B. Individual indications with a vertical height dimension determined to be
greater than one quarter of wall thickness.
C. Multiple indications at the same circumferential location with a summed
vertical height dimension exceeding one quarter the wall thickness.

Linear Surface (LS) Indications:

a. The aggregate length of LS indications in any continuous 12 in. (300 mm) length of
weld exceeds 1 in. (25 mm),
b. The aggregate length of LS Indications exceeds 8 % of the weld length
Linear Buried (Lb) Indications
LB indications (other than cracks) interpreted to be subsurface within the weld and not
ID or OD surface connected shall be considered defects should any of the following
conditions exist:
a) the aggregate length of LB indications in any continuous 12 in. (300 mm) length
of weld exceeds 2 in. (50 mm),
b) the aggregate length of LB indications exceeds 8 % of the weld length.
Transverse (T) Indications
T indications (other than cracks) shall be considered volumetric and
evaluated using the criteria for volumetric indications. The letter T shall be
used to designate all reported transverse indications.

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Volumetric Cluster (Vc) Indications

VC indications shall be considered defects when the maximum dimension of VC
indications exceeds 1/2 in. (13 mm).
Volumetric Individual (VI) Indications
VI indications shall be considered defects when the maximum dimension of VI
indications exceeds 1/8 in. (3 mm).
Volumetric Root (VR) Indications
VR indications interpreted to be open to the ID surface shalt be considered
defects should any of the following conditions exist:
a) the maximum dimension of VR indications exceeds 1/4 in. (6 mm) or the
specified wall thickness, whichever is less.
b) the total length of VR indications exceeds 1/2 in. (13 mm} in any continuous
12 in. {300 mm) length.
13 SAFETY PRECAUTIONS

Inspection personnel involved in Ultrasonic Testing should take safety precautions and follow the
Safety Procedures, work permit, site and regulatory requirment should be during the exmiantion.
14 POST EXAMINATION CLEANING

Inspetion involved personnels, post cleaning must be done after the completion upon the
exmiantion.
15 REPORTING

All recorded and Rejected indications should be record, Attachment 1 given UT Weld scanning
report format.

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ATTACHMENT1: ULTRASONIC EXAMINATION TEST REPORT

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