P 11 CNDT JP41 Ut-Aws D1.1 Rev 07

Job Procedure for Ultrasonic Testing
As per AWS D1.1
Document
Rev Issue Date Prepared by: Reviewed by: Approved by:
No:
Name & Signature: Name & Signature: Name & Signature:
Vipin Kumar Prakriti Samanta Ganesh Babu M
QHSE/P
11/CNDT/JP41 07 14.01.2022
/UT-AWS D1.1
Date: 14.01.2022 Date: 14.01.2022 Date: 14.01.2022

As per AWS D1.1
CONTENTS
Section Description Page No.
AMENDMENT RECORD 3
1. SCOPE 4
2. REFERENCE DOCUMENTS 4
3. QUALIFICATION OF ULTRASONIC TESTING PERSONNEL 4
4. EQUIPMENT 5
5. COUPLING MEDIUM 6
6. SURFACE CONDITION 7
7. CALIBRATION FOR TESTING 7
8. BASE METAL EVALUATION 9
9. SCANNING 9
10. ACCEPTANCE CRITERIA 11
11. DOCUMENTATION 11
12 SAFETY 12
12. ACCEPTANCE CRITERIA AS PER AWS D1.1(Attachment- I-II) 13-14
13. SAMPLE REPORT FORMAT(Attachment -III) 15
14. TECHNIQUE SHEET (Attachment -IV) 16
15. SCANNING PATTERN (Attachment -V) 22
Doc. Ref.: QHSE/P 11/CNDT/JP41/UT-AWS D1.1 Job Procedure for Ultrasonic Testing AWS D1.1 | Rev No: 07 | Date: 14.01.2022 Page 2 of 22
As per AWS D1.1
AMENDMENT RECORD
Section / Name
Rev. Date of
Checklist Amendment Details
No. Amendment Reviewed Approved
Amended
Revised. 2,
Prakriti
07 14 Jan 2022 10, Attach- Revised. 2, 10, Attach-I, II, IV Ganesh Babu
Samanta
I, II, IV
Section: 2,
4, 7.6, Revised. 2, 4, 7.6, Attach-I, II, Prakriti
06 15 Feb 2021 Ganesh Babu
Attach-I, II, IV Samanta
IV
Prakriti
05 30 Dec 2019 Section: 2 Revised. Ganesh Babu
Samanta
Section: 3.6,
Section: 3.6, 4, 5, 7.3, 9 & Fig. Prakriti
04 18 Mar 2018 4, 5, 7.3, 9 Ganesh Babu
6.15 Scanning Pattern. Samanta
& Fig. 6.15
Sec: 2, 9,
10, 11, Section: 2, 9, 10, 11, Attach- I, Prakriti
03 28 Dec 2017 Ganesh Babu
Attach-I, III III, IV & Overall formatting Samanta
& IV
Prakriti
02 26 Dec 2016 All Section: 2 & 13 Ganesh Babu
Samanta
Overall formatting and old
Procedure Reference No.
Aries/UFD/D1.1/20 changed to Prakriti
01 03 Jan 2016 All new number Ganesh Babu
Samanta
P 11/CNDT/JP41 UT-AWS
D1.1
Ganesh
00 20 July 2015 All Initial Issue Ramasamy
Babu
As per AWS D1.1
1.0 SCOPE
1.1 This Ultrasonic Examination procedures are to be used for the testing of groove
welds and heat affected zones between the thickness of 5/16” (8.0mm) and 8”
(200mm) when such testing is required.
1.2 For thicknesses less than 8 mm or greater than 200 mm, separate examination
procedure is to be adopted.
1.3 During testing of electro slag weld or electro gas weld, if any piping porosity is
suspected, that should be supplemented by Radiographic examination.
1.4 Any variation of this procedure with respect to essential variables shall imply re-
issue of the procedure with all the variations incorporated.
2.0 REFERENCE DOCUMENTS:
Aries shall use the latest editions for the following;

7
The following documents are referred:
· AWS D1.1- 2020

· ASME SEC V- 2021
· Personnel Qualification SNT-TC-1A- 2016 & 2020
· Aries Written Practice document - QHSE/P11/CNDT/WP/P01
3.0 PERSONNEL QUALIFICATION.
3.1 All ARIES personnel performing Ultrasonic Examination using this Procedure shall
be qualified to a minimum of ASNT Level II or as qualified by the Aries Written
Practice
3.2 Personnel performing Examination shall have vision, with correction if necessary, to
enable to read Jaeger Type No. 1 Standard Chart at a distance of not less than 12 in.,
and differentiate the contrast between the colors or shades of gray, and records of
such vision test shall be maintained by ARIES. Vision tests shall be conducted
annually and shall be valid during examination.
3.3 Personnel conducting Ultrasonic Examination shall be competent in conducting the
testing as described in this Procedure.
As per AWS D1.1
3.4 Wherever required, existing Personnel Qualification shall be verified for

applicability as to the Code conditions.
3.5 Personnel conducting Ultrasonic Examination should be aware of the safe-practice
requirements during examination.
3.6 Operator shall be qualified to AWS D1.1 clause 8.20 requirements with the Client
witness.
4.0 EQUIPMENT
Pulse Echo Equipment: - 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. The test equipment shall have a calibrated
gain control adjustable in discrete 1 or 2 dB steps over a range of at least 60 dB
The horizontal linearity of the test equipment shall be qualified over the full sound path
distance to be used. Horizontal linearity shall be verified after 40 Hours of instrument use
and shall be performed as per sec 8.28.1 of AWS D1.1 and vertical linearity in two months
interval in accordance with sec 8.28.2 of AWS D1.1
The test instrument shall have internal stabilization facility, so that after warm up no
variation in response more than +/- 1 dB occurs with a supply voltage of 15% nominal or in
case of battery operation. There must be an alarm or signal to indicate the reduced charge in
the battery prior to complete shut off.
Equipment Requirements: - The ultrasonic apparatus to be used shall be pulse echo type
and able to work with both combined and separated transmitter and receiver probe.
The following ultrasonic apparatus having frequency range from 0.5 to 10.0 MHz may be
used.
Krautkramer- USK 7 / USK 6 / USK 7B / USN 50 / USN 52 / USM 22 / USM 25/ USM
36/USM 35 DAC/ USM Go/ USM 33/Olympus-Epoch 600/ Epoch 650
Transducers: - Transducers with following characteristics shall be used. Angle: 70°, 60°, 45°
(within plus minus 2°) and Normal (Longitudinal wave).
As per AWS D1.1
Crystal Size: Straight-beam Search unit transducers ½ Square Inch to 1 Square Inch either
round or square.
Type: Single Crystal for shear wave probes.

Single Crystal or Twin Crystal for compressional wave probes.
Frequency: The nominal probe frequencies shall be 2 to 2.5 MHz
Other probe frequencies may be used if material variable such as material grain structure or
size dictates.
Angle: The search unit angle shall produce a Sound beam in the material being listed within
±2º of one of the following proper angle: 70º, 60º or 45º.
The Transducer crystal shall be square or rectangular in shape and may vary from 15mm to
25mm in width and in height 15mm to 20mm.
Coaxial Cables: - Minimum 6 feet (1830 mm) and a maximum of 15feet (4772 mm) in
length with suitable connections shall be used.
Calibration Blocks: - IIW / V1/V2block shall be the standard for both distance and
sensitivity calibration. Other portable blocks may be used provided the reference level
sensitivity for instrument / search unit combination is adjusted to be equivalent of that
achieved with IIW block.
Discontinuity Plotting Aids: - An array of devices are available for the ultrasonic
operator to be able to plot and verify where indications are coming from, the technician
may utilize the following.
Magnetic strips, Electronic calculators, Mimic gauges (wire type), Soldering wire,
Perspex slides, Cursors
Plotting cards, Protractor, Compass, 150MM Stainless steel rulers, measuring tapes, indelible
markers.
As per AWS D1.1
5.0 COUPLING MEDIUM.
Oil, Poly cell jelly, grease, water or equivalent Couplant that shall provide satisfactory
transmission of Ultrasonic sound waves. The same Couplant shall be used for calibration
and during inspection of production welds.
6.0 SURFACE CONDITION.

Scanning surface shall be free of weld spatters surface irregularities or foreign
materials that might interfere with the scanning during examination.
7.0 CALIBRATION FOR TESTING.

7.1 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.
7.2 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.
7.3 RESOLUTION REQUIREMENTS.
The combination of search unit and instrument shall resolve three holes using by
IOW Block. The transducer shall be set on IOW Block for 70°, 60°, and 45°
angle. The resolution shall be evaluated with the instrument controls set at normal
test settings and with indications from the holes brought to mid screen height.
Resolution shall be sufficient to distinguish at least the peaks of indications from
the three holes. Each combination of instrument search unit (shoe and transducer)
shall be checked prior to its initial use. This equipment verification shall be done
initially with each search unit and UT unit combination. The verification need not
be done again provided documentation is maintained that records the following
items:
· UT machine’s make, model and serial number
· Search unit’s manufacturer, type, size, angle, and serial number

· Date of verification and technician’s name
As per AWS D1.1
7.4 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:
(1) Transducer change
(2) Battery change
(3) Electrical outlet change
(4) Coaxial cable change
(5) Power outage (failure).
7.5 Calibration for straight beam testing of base metal shall be made with the search
unit applied to topside of the base metal and performed as follows:
7.5.1 The horizontal sweep shall be adjusted for distance calibration to present
the equivalent of at least two-plate thickness on the CRT screen.
7.5.2 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.
7.6 Calibration for angle beam testing shall be performed as follows.
1) 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.
2) 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.
As per AWS D1.1
3) Welds shall be tested using an angle beam search unit using the angle as shown
in Table 8.7Attached. 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.
4) The testing angle and scanning procedure shall be in accordance with those
shown in Table 8.7 (see attached).
5) 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.
6) 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 decibel reading shall be used as the reference level,
“b” in the calculation of the indication rating.
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 Ȃ 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.
As per AWS D1.1
8.0 BASE METAL EVALUATION

The area adjacent to the weld from which scanning is to be conducted shall be
scanned with a 0° compressional probe and the thickness shall be recorded. Areas
where laminar type defects are together with other reflectors that may interfere with
the shear wave scan shall be reported.
9.0 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. The operator should be X- line marking on weld center to
specify the location of discontinuities (refer Attachment IV)
9.1 Longitudinal Discontinuities:
· Scanning Movement A. Rotation angle a = 10°.
· Scanning Movement B. Scanning distance b shall be such that the section of
weld being tested is covered.
· Scanning Movement C. Progression distance c shall be approximately one-
half the transducer width.
NOTE: Movements A, B, and C may be combined into one scanning pattern.
9.2 Transverse Discontinuities:
· Ground Welds. Scanning pattern D shall be used when welds are ground
flush.
· Unground Welds. Scanning pattern E shall be used when the weld
reinforcement is not ground flush. Scanning angle e = 15° max.
NOTE: The scanning pattern shall cover the full weld section.
· ESW or EGW Welds (Additional Scanning Pattern). Scanning Pattern E
Search unit rotation angle e between 45° and 60°.
Scanning shall be carried out such that entire volume of weld is tested for
longitudinal and transverse discontinuities. (Refer: Attachment V, Fig: 8.15)
As per AWS D1.1
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 (150
mm/s) Scanning shall be performed from the branch connection.
10.0 ACCEPTANCE CRITERIA.
10.1 Each weld discontinuity shall be accepted or rejected on the basis of its indication
rating and its length, in accordance with AWS D1.1 for statically or cyclically
7
loaded structures respectively (Refer: Attachment -I & II).
10.2 Each rejected 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
10.3 Evaluation of the defects shall be performed from both the branch and the main
branch.
11.0 DOCUMENTATION
UT examination conducted as per this procedure shall be reported on AWS D1.1
reporting format with standard Ultrasonic Examination report refer attached and
shall contain the following information as a minimum.
a. Client
b. Job No.
c. Procedure no
d. Location
As per AWS D1.1
e. Drawing /Line
e. Repair
f. Date
g. Weld Type
h. Flaw detector type, Serial No.
i. Probe, Frequency, Sensitivity, Transfer Correction
j. Technician’s Name with personnel qualification and signature. k. Test limitations
/ Restrictions.
12.0 SAFETY:
All Personnel shall have responsibility to themselves and other persons with regard
to safety and shall ensure that site facilities are adequate with regard to lighting,
scaffolding prior to commencement of Operations. All NDT personnel shall be
following Aries Safety Practice or the site HSE regulation.
As per AWS D1.1
Attachment – I Acceptance Criteria as per AWS D1.1 Table 8.2

7
As per AWS D1.1
Attachment – II Acceptance Criteria as per AWS D1.1 Table 8.3
As per AWS D1.1
Attachment -III Sample Report format
As per AWS D1.1
Attachment -IV Technique Sheet
As per AWS D1.1
As per AWS D1.1
Annexure IV
Technique sheet-01
BUTT WELD – SINGLE “V” Scanning Pattern

Technique sheet-02
a. Parent Metal Examination
Scanning Positions : 1 & 2 over 2.5 times the parent

Metal thickness each side of the weld toes.
Thickness Range : 8mm to 20mm Single V Butt welds

Sensitivity : Sensitivity setting shall be 1.6mmSDH for straight beam probe
(Single /Twin) when used for discontinuity detection of weld metal.
BWE shall be used for base metal scanning only for laminar discontinuity.
Probes : 0° - 2 MHz to 2.5 MHz T/C or S/C
b. Weld Metal Examination:
Scanning Pattern : 10% Overlapping Scans
Probes Scanning Options Scanning Sensitivity
0° HAZ (1&2) II’nd BWE set to 80%+6 dB
70° 1&2 1.6mm Reference side drilled hole set to 50%FSH
Sizing Technique : 6 dB drop, max amplitude and similar recognized technique.
Scanning dB : Refer attachment I & II AWS D1.1 Table 8.2 / 8.3.
Note: 45°&60° Angle Beam not required as Per Code Specification Ref: attachment I & II AWS D1.1 Table 8.2 / 8.3.
As per AWS D1.1
Annexure IV
Technique sheet-02
BUTT WELD – Double “V” Scanning Pattern
Scanning Positions : 1 & 2or 3 & 4 over 2.5 times the parent
Thickness Range : 20mm and above Double V Butt weld

0° 1& 2 II’nd BWE set to 80%+6 dB
70° 1 &2/3&4 1.6mm Reference side drilled hole set to 50%FSH
Sizing Technique : 6 dB drop / max amplitude or similar recognized technique.
As per AWS D1.1
Annexure IV
Technique sheet-03
T- WELD – (Single Bevel T) Scanning Pattern
Scanning Positions : 1 over 2.5 times the parent

Thickness Range : 8mm to 20mm Single Bevel T weld

0° 1 II’nd BWE set to 80%+6 dB
0° 2 (if required) 1.6mm Reference side drilled hole set to 80%FSH
70° 1 1.6mm Reference side drilled hole set to 50%FSH

As per AWS D1.1
Annexure IV
Technique sheet-04
T- WELD – (Double Bevel T) Scanning Pattern
Scanning Positions : 1 & 2 over 2.5 times the parent

Thickness Range : Above 20mm Double Bevel T weld


0° 1 II’nd BWE set to 80%+6 dB
0° 3 (if required) 1.6mm Reference side drilled hole set to 80%FSH
70° 1&2 1.6mm Reference side drilled hole set to 50%FSH
As per AWS D1.1
Attachment -V Scanning Pattern

P 11 CNDT JP41 Ut-Aws D1.1 Rev 07

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Job Procedure for Ultrasonic Testing

As per AWS D1.1

Date: 14.01.2022 Date: 14.01.2022 Date: 14.01.2022

Section Description Page No.

3. QUALIFICATION OF ULTRASONIC TESTING PERSONNEL 4

7. CALIBRATION FOR TESTING 7

8. BASE METAL EVALUATION 9

10. ACCEPTANCE CRITERIA 11

12. ACCEPTANCE CRITERIA AS PER AWS D1.1(Attachment- I-II) 13-14

13. SAMPLE REPORT FORMAT(Attachment -III) 15

14. TECHNIQUE SHEET (Attachment -IV) 16

15. SCANNING PATTERN (Attachment -V) 22

2.0 REFERENCE DOCUMENTS:

Aries shall use the latest editions for the following;

· AWS D1.1- 2020

3.0 PERSONNEL QUALIFICATION.

3.4 Wherever required, existing Personnel Qualification shall be verified for

Type: Single Crystal for shear wave probes.

Frequency: The nominal probe frequencies shall be 2 to 2.5 MHz

5.0 COUPLING MEDIUM.

6.0 SURFACE CONDITION.

7.0 CALIBRATION FOR TESTING.

· Search unit’s manufacturer, type, size, angle, and serial number

6) Indication rating method:

8.0 BASE METAL EVALUATION

Attachment – I Acceptance Criteria as per AWS D1.1 Table 8.2

Attachment – II Acceptance Criteria as per AWS D1.1 Table 8.3

Attachment -III Sample Report format

Attachment -IV Technique Sheet

BUTT WELD – SINGLE “V” Scanning Pattern

a. Parent Metal Examination

Scanning Positions : 1 & 2 over 2.5 times the parent

Thickness Range : 8mm to 20mm Single V Butt welds

Probes : 0° - 2 MHz to 2.5 MHz T/C or S/C

b. Weld Metal Examination:

Scanning Pattern : 10% Overlapping Scans

Probes Scanning Options Scanning Sensitivity

0° HAZ (1&2) II’nd BWE set to 80%+6 dB

70° 1&2 1.6mm Reference side drilled hole set to 50%FSH

Sizing Technique : 6 dB drop, max amplitude and similar recognized technique.

Scanning dB : Refer attachment I & II AWS D1.1 Table 8.2 / 8.3.

BUTT WELD – Double “V” Scanning Pattern

a. Parent Metal Examination

Thickness Range : 20mm and above Double V Butt weld

Probes : 0° - 2 MHz to 2.5 MHz T/C or S/C

b. Weld Metal Examination:

Scanning Pattern : 10% Overlapping Scans

Probes Scanning Options Scanning Sensitivity

0° 1& 2 II’nd BWE set to 80%+6 dB

70° 1 &2/3&4 1.6mm Reference side drilled hole set to 50%FSH

Sizing Technique : 6 dB drop / max amplitude or similar recognized technique.

Scanning dB : Refer attachment I & II AWS D1.1 Table 6.2 / 6.3.

a. Parent Metal Examination

Scanning Positions : 1 over 2.5 times the parent

Thickness Range : 8mm to 20mm Single Bevel T weld

Sensitivity : Sensitivity setting shall be 1.6mmSDH for straight beam probe

Probes : 0° - 2 MHz to 2.5 MHz T/C or S/C

b. Weld Metal Examination:

Scanning Pattern : 10% Overlapping Scans

Probes Scanning Options Scanning Sensitivity

0° 1 II’nd BWE set to 80%+6 dB

0° 2 (if required) 1.6mm Reference side drilled hole set to 80%FSH

70° 1 1.6mm Reference side drilled hole set to 50%FSH