UT FLAW DETECTION PROCEDURE

REVISIONS
Revision Date Nature of modification
0 10/08/23 Initial compilation
1 25/05/23 General Improvement
2 25/5/23 General Improvement

AUTHORIZATION
Stage Names and Titles Company Signature Date

Prepared by: Rixon Maranan : NDT Level II NINONENA

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Approved by: Alain Simplice Gan : NDT Level III NINONENA
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Authorized by: George Ogbeche: Managing Director NINONENA
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CONTENT

Title Page
1. Purpose 3
2. Scope. 3
3. References. 3
4. Related documentation. 3
5. Definitions. 3
6. Responsibilities 4
7. Personnel Qualification 4
8. Safety 5
9. Equipment and Consumables 5
10. Operating Procedure 8
10.1 Area of Interest 8
10.2 Surface Condition 8
10.3 System Calibration 8
10.4 Examination (Scanning) 11
10.5 Interpretation and Evaluation 13
10.6 Final Cleaning 13
10.7 Repair 13
11. Records 14
12. Annexes 14
Annex A (A1 to A3) DAC Blocks 15
Annex B UT Report Form 17
Annex C (C1 to C6) Scanning sequences per type of joint 18
Annex D (D1 and D2) DAC plotting and transfer loss determination 22
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1. Purpose
This procedure describes the operative mode and acceptance levels to be followed when carrying out the
Ultrasonic test on parent materials, butt welds, and weld build up on ferritic welds or components.

2. Scope
This procedure is applicable to test welds or components whenever ASME V is called upon.

It refers to the detection, location and evaluation of reflectors within the weld, the Heat Affected Zone and
adjacent material on full penetration ferritic welds of plates or pipes with thickness ranging between 0.250 to 6
in (6 mm to 150 mm). In addition, for pipe, surface diameter shall be equal or greater than 4 in (100 mm).

Note: Whenever actual conditions are different from what is specified herein or the application of this
procedure is not possible, The NDT crew shall stop the job, report to the NINONENA NDT supervisor, and
wait for instructions before any continuation of the job.

3. References

 SNT-TC-1A, 2006: The ASNT recommended Practice for Qualification and Certification of NDT
personnel;
 ASME V, Article 4 and Article 5: Articles devoted to “Ultrasonic Testing”

 BS 3923-Part 1: Ultrasonic examination of welds

4. Related Documentation
 UT Report Form;
 NINONENA Written Practice for Qualification and Certification of NDT Personnel n°
NINONENA/GAS/SOP/09/008.

5. Definitions
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NINONENA: NINONENA Engineering Services (The Employer);

NDT: Non Destructive Testing;

ASNT: The American Society of Non Destructive Testing;

ASME: American Society of Mechanical Engineers;

BS: British Standard;

SNT-TC-1A: The ASNT (American Society for Non-destructive Testing) recommended Practice for
Qualification of NDT personnel;

UT: Ultrasonic Testing;

DAC: Distance Amplitude Correction

PRL: Primary Reference Level

6. Responsibilities

NINONENA:
- Perform the job as requested by the Client and in conformance with this procedure (i.e. use qualified
personnel, appropriate equipment, follow safety regulations);
- Issue on time deliverables (i.e. Reports, drawings, and images).

The Client:
- Provide and/or specify Codes and Standards to apply;
- Determine the Extent of examination and/or Areas to test;
- Provide relevant information related to the component to test (i.e. drawings, material, sizes, and
schedule; DAC block or Calibration block of the material to test);
- Issue Permit to Work

7. Personnel Qualification

- All personnel entitled to use this procedure shall be qualified and certified in conformance with
NINONENA written practice N° NINONENA/GAS/SOP/09/008; which is in accordance with The
ASNT’s recommended practice SNT TC 1A (2006 Edition).
- Level 2 or Level 3 will perform the test, report, interpret and evaluate results as directed by applicable
Codes and specifications.
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- Level 1 personnel will only perform specific Testing operations as per written instructions and under
adequate supervision of level 2 or Level 3 personnel.

8. Safety

- Basic safety regulation shall be followed, especially the use of Personnel Protective Equipment such as
Safety boot, coverall, helmet, etc;
- For jobs to be performed at a height higher than 2 meters, the use of convenient access means
associated with convenient fall arrest is mandatory;
- For specific job site, a joint meeting with Client representative shall be necessary for “Job safety
Analysis” that will conduct to the issuance of “Permit to Work”; then, eventually, specific safety
equipment will be used/worn and additional care will to taken during operations.

9. Equipment and Consumables

9.1. UT Flaw Detector

A Pulse-Echo, digital instrument, with an “A” scan presentation and an operating frequency between 1.0
MHz to 5.0 MHz shall be used.

The instrument shall be linear in accordance with ASME V, article 5, Section T532 and T533. A valid
calibration certificate shall be issued for the flaw detector used.

Screen height linearity:

The ultrasonic instrument shall provide linear vertical presentation within approximately ±5% of the
Full Screen Height for 20% to 80% of the calibrated screen height (base line to maximum calibrated
screen point/s). This shall be performed at the beginning of each period of extended use (or every 3
months, whichever is less). The procedure for evaluating screen height linearity is provided in ASME V,
article 5, Appendix I.

Amplitude Control Linearity:

The ultrasonic instrument shall utilize an amplitude control accurate over its useful range to
approximately ±20% of the nominal amplitude ratio (±20% of the expected echo’s peak), to allow
measurement of indications beyond the linear range of the vertical display on the screen. This shall be
performed at the beginning of each period of extended use (or every 3 months, whichever is less). The
procedure for evaluating amplitude control linearity is provided in ASME V, article 5, Appendix II.

Type used: Manufacturer: Sonatest (UK) – Model: Sitescan 150.

9.2. Search Units

9.2.1. Transducer frequency:

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A frequency range of 2.25 MHz to 5.00 MHz can be employed for both angle (shear wave) and straight
beam (longitudinal wave) testing. Depending on the acoustic properties of the material to test, the
highest frequency transducer that allow appropriate penetration will be employed.

9.2.2. Transducer size

A minimum of ¼ in (6.4mm) diameter or ¼ inch square to a maximum of 1 inch (25mm) square or 1 ⅛
(28,6mm) diameter shall be used for both angle and straight beam transducers. Similar rectangular probe
sizes will be acceptable.

9.2.3. Transducer Angles/Type

- For straight beam testing, a 0° probe may contains either single or dual transducer elements.
- The nominal beam angle of 45º shall be used but other angles may be used where appropriate for
the configuration being examined angle probe shall be used for shear wave testing.

9.2.4. Transducer Types

- Twin crystal straight beam transducer to be used if Thickness ≤ 1in (25mm).
- Single crystal straight beam transducer to be used if Thickness >1in (25mm).
- Only single crystal angle transducer shall be used.

9.2.5. Contact wedges

Search units with contoured may be used to aid ultrasonic coupling. Calibration shall be done with the
contact wedges used during the examination.

Types used: Manufacturer: Phoenix – Model: hereunder:

Single normal probe Phoenix SC 4-10 Model : SC 4-10

Twin normal probe Phoenix TC 4-10 Model : TC 4-10
Single 45° angle probe Phoenix GSW 4-45 (8x9) Model : GSW 4-45
Single 60° angle probe Phoenix GSW 4-60 (8x9) Model : GSW 4-60
Single 70° angle probe Phoenix GSW 4-70 (8x9) Model : GSW 4-70

9.3. Transducer cables

Transducer cables shall be approximately 64 inches – 80 inches (1.6m – 2.0m) in length and shall be free
of any leakage.

9.4. Couplant
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A liquid or semi liquid shall be required. The couplant used shall not be injurious to the material being
tested. Water, oil, grease or cellulose paste can be used for a couplant. The same coupling medium shall
be used for both calibration and examination.

9.5. Reference/Calibration Blocks.

9.5.1. International Institute of Welding (IIW) V1 and V2 Blocks (also called respectively A2 and
A4 Blocks): These blocks are used for distance calibration, for determination of some
characteristics of the ultrasonic examination system, and for evaluation of its performance.

9.5.2. Beam Calibration Block (also called A5): It is used to draw the beam profile of each probe.

9.5.3. Flat Basic Distance Amplitude Correction (DAC) Blocks (see in annex A): These are used in
the thickness range concerned for sensitivity calibration for flat surfaces or surfaces with
diameter greater than 508 mm (20 in).

Refer to Notes 1 and 2 of the next paragraph for detailed specifications for the block.

9.5.4. Curved Basic Distance Amplitude Correction (DAC) Blocks (see in annex A): These are used
in the thickness range concerned for sensitivity calibration for curved surfaces.

Note 1:
- For materials with the inspection surface diameter greater than 508 mm (20 in.), the
calibration block will be curved, and essentially with the same curvature. Alternatively, a
Flat Basic Distance Block specified in 9.5.3 or a General purpose DAC block specified in
9.5.5 can be used.
- For materials with the inspection surface diameter equal to 508 mm (20 in.) or less, the
calibration block will be curved. A calibration block can be used to calibrate the
inspection of surfaces with diameters between 0.9 and 1.5 times the block diameter.

Note 2:
- The material from which the calibration block is fabricated will be of an equivalent P-
Number, according to ASME IX, to that of the material to be examined. P-Numbers 1, 3, 4
and 5 are considered equivalent.
- For dissimilar metal welds, the selection of the calibration block material will be made in
terms of the material from the side of the weld from which the inspection is conducted.
When it is conducted from both sides, calibration blocks of both materials are used.
- When there is two or more base material thicknesses involved, the block thickness is
determined by the average thickness of the weld.
- The calibration block will receive the same tempering treatment required by the Material
Specification for the corresponding type and grade.
- Where the component material is clad, the block will be clad by the same welding
Procedure, as production part.
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- The finish on the surfaces of the block will be representative of the surface finishes of the
parts to be examined.
- The calibration block material will be completely examined with a straight beam search
unit. Areas that contain an indication exceeding the remaining back reflection will be
excluded from the beam paths required to reach the various calibration reflectors.

9.5.5. General Purpose Distance Amplitude Correction (DAC) block (see annex A3): made from low
attenuation steel, after some corrections, it may be used as alternate for sensitivity calibration.
It will be used for correction due both to attenuation and surface condition differences. It could
be used for examining flat surfaces or surface with diameter greater than 508 mm

10. Operating Procedure

10.1. Area of Interest

Unless otherwise specified, the areas of interest shall be the weld itself, its Heat Affected Zone (HAZ),
and adjacent surfaces.

10.2. Surface Condition/Preparation

The base metal on each side of the weld shall be free of weld spatter, surface irregularities, or foreign
matter that might interfere with the examination. The temperature of the examination and basic
calibration block surfaces shall be within 25°F (14°C).

10.3. System Calibration

Calibration shall include the complete ultrasonic examination system. Each calibration shall be
performed from the surface (clad or unclad) corresponding to the surface of the component from which
the examination will be performed.

Calibration will be performed prior to the use of the system in thickness range under examination.

10.3.1. Distance Calibration

The calibration is carried out by means of the standard blocks indicated in 5.4.1, and consists for digital
UT equipment, of introducing the correct delay inside the probe (“Zero” of the probe) and velocity of the
sound inside the material. The “Zero” of the probe is known prior to the testing and the velocity of the
sound is determined by aiming on the standard blocks one reflector with known position.
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10.3.2. Sensitivity Calibration

Reflectors on the appropriate Distance-Amplitude-Correction Block among those listed in 9.5 will be
used to draw the DAC curve as described in 10.3.3.1.b. The curve will be used as reference for
evaluation of echoes, provided it is adjusted by appropriate correction factor to account specific aspects
i.e. difference in block shape and material, probe work face, etc.

10.3.3. Probe Calibration: Points and Techniques

10.3.3.1. Angle Beam.

The calibration is done according to ASME V, article 4, Appendix B; and shall provide the
following measurements:

a) Sweep range calibration:

Using the delay, and range controls, the sweep range shall be set as follows:

When examination is to be done only with the first leg (Half Skip), the range shall be in minimum:
[0 to Half Skip + Quarter Skip]

When examination is to be done with both first and second leg (Half Skip and Full Skip), the range
shall be in minimum: [0 to Full Skip + Quarter Skip]

When examination is to be done only with the second leg (between Half Skip and Full Skip), the
range shall be in minimum: [Half Skip - Quarter Skip to Half Skip + Quarter Skip]

b) Distance – Amplitude – Correction:

As per annex D1, using the Reflectors on the appropriate Distance-Amplitude-Correction Block
among those listed in 9.5, this is what must be done:

- Consider the reflector which gives the highest amplitude indication, and adjust the
sensitivity (gain) until it reaches 80% (approximately) of the full screen height.
Record as Reference.
- Without varying the gain, search for the maximum amplitudes that can be
obtained by the other reflectors and record the echo.
- Acknowledge the end of echo recording, and the Distance-Amplitude Correction
(DAC) curve is drawn and will be taken as reference level.
- When using angle beam search units, the indication of the notch on the opposite
surface must also be recorded.
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To avoid the corner effect of the hole and wall, the search unit must in all cases be perpendicular to
the reflector axis, and the centre of the search unit will be located at least 38 mm. from the lateral
end of the part.

c) Correction factor to account differences in attenuation and surface condition:

This will be done as shown on Annex D2, alternatively on the General Purpose DAC block
(points called A) and the material under test (points called B) by using two 45° angle probe
facing each other operating as separate transmitter and receiver.

- Calibrate the time base using one the 45° angle probe.
- Position the two probes facing each other to get the V path, maximize the echo by
adjusting the probes and set the gain to put the echo at 80 FSH; record the first
point (Sound path and gain).
- Position the two probes facing each other to get the VV then the VVV paths,
proceed as above to record the second and the third point.
- With three points got from each component, plot their respective curves and
extrapolate them to zero range.
- The transfer loss at the work range is G2-G1

d) Position calibration: Necessary to link sound path to the depth of the reflector. This calibration is
not necessary for digital UT flaw detector with trigonometric calculator when the actual probe
angle is known. The UT flaw detector would help to locate the reflector.

e) Echo amplitude measurement from the surface notch in the basic calibration block: It is used as
reference when evaluating planar reflector at the opposite surface (depth = T).

f) When an electronic distance amplitude correction device is used, the primary reference response
may be equalized at a nominal constant screen height at/or between 40 to 80% of full screen
height over the distance range to be employed in the examination (Time Corrected Gain or TCG).

10.3.3.2. Straight Beam.

The calibration is done according to ASME V, article 4, Appendix C; and shall provide the
following measurements:

a) Sweep range calibration (similar to angle beam practice).

Using the delay, and range controls, the sweep range shall be in minimum: [0 to T + T/4]

b) Distance – amplitude correction (similar to angle beam practice).

c) Correction factor to account differences in attenuation and surface condition

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This will be done alternatively on the General Purpose DAC block (points called A) and the
material under test (points called B) with the normal probe to use during the test.

- Calibrate the time base.

- Position the probe on the DAC block to obtain a series of back walk echoes A1,
A2, A3, A4, etc.
- Note the gain setting (in dB) required to bring each echo up to 80% FSH, the
position of the echo in mm, and plot these values as per curve A in Annex D2.
- Reposition the probe on the material under test to equally obtain a series of back
wall echo B1, B2, B3, B4, etc. And repeat the step above plotting curve B.
- Extrapolate them to zero range.
- The transfer loss at the work range is G2-G1

d) When an electronic distance amplitude correction device is used, the primary reference response
may be equalized at a nominal constant screen height at/or between 40 to 80% of full screen
height over the distance range to be employed in the examination (Time Corrected Gain or TCG).

10.3.4. Calibration Confirmation /Check

A calibration confirmation of the system shall be performed prior to use in the thickness range under
examination. A calibration check shall verify the sweep range calibration and Distance – Amplitude –
Correction.

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, the sweep range calibration shall be
corrected and the correction noted in the examination record. All recorded indications since the last valid
calibration or calibration check shall be voided and the related area re-examined with the corrected
calibration.

DAC Correction:
If a point on the Distance – Amplitude Correction (DAC) curve has decreased 20% or 2 dB of its
amplitude, a new calibration shall be made and recorded, all recorded indications since the last valid
calibration or calibration check shall be voided and the related area re-examined with the corrected
calibration.
If any point of the Distance – Amplitude Correction (DAC) curve has increased more than 20% or 2 dB
of its amplitude, a new calibration shall be made and recorded, all recorded indications since the last
valid calibration or calibration check shall be re-examined with the corrected calibration and their values
shall be consequently changed.

10.4. Examination (Scanning)

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10.4.1. General

- The search unit displacement speed will be less than 150 mm/sec (6 in/sec).
- The sweep of the search unit will be made allowing a 10% minimum overlap of the working
dimension of the search unit.

10.4.2. Preliminary Examination of Parent Materials

Before conducting the examination, a straight beam search applied from one or both side (s) of
the base material area through which the ultrasonic beam passes during the examination. If
scanning from only one side or if the material thickness is 1 inch (25mm) or less a twin crystal
transducer shall be used. This examination is meant to locate reflectors that can affect the
interpretation of the inspection results obtained by later search units.

This is done by positioning the probe in an area free from imperfection such that the 2nd back
wall echo (2nd BWE) is at 80% of full screen height (FSH); and scanning the appropriate surface
of parent material. Any area producing a loss of the back wall echo of – 6dB or more, or
producing an unexpected echo greater than 50% FSH would be recorded and marked.

Consequently, alternatives ways should be found to ensure the 100% examination of the area of
interest; if not, this should be marked on the report as limitation.

10.4.3. Examination of the weld

The scanning of weld and base metal shall be performed at a gain setting of at least two times
(+6dB) the primary reference level plus or minus applicable corrections. Evaluation shall be
performed with respect to the primary reference level plus or minus applicable corrections.

Near field considerations shall be taken into account.

The weld, together with its adjacent base material, will be inspected in these aspects: extension,
search units, and position, according to the indications of Annex C (C1 to C6).

10.4.3.1. Critical Root Examination

This technique shall be done using the half - skip method and the beam targeting the centreline of the weld
at the weld root. It is recommended to place a guide bar or strip to ensure that the transducer is kept at the
constant distance from the weld centreline.

A 45° angle probe will be used, unless because of the weld cap, its beam cannot be directed to the access to
the centreline of the weld at the weld root. Then a 60° angle probe would be used
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The probe shall be moved continuously along the weld and all echoes that occur at more or less the path
distance calculated for the weld root shall be investigated. All observed echoes shall be maximised by
moving the transducer forward/backward to determine its position and depth.

Notes:

The DAC curve is not convenient for evaluating these echoes; instead the amplitude got from the surface
notch in the basic calibration block will be used.

This technique shall be used from both sides of the weld. The capability of this technique is severely
reduced when scanning is possible from one side only. This shall be recorded as a limitation on the
ultrasonic report.

10.1.1.1. Weld body examination for longitudinal reflector

45°, 60°, and 70° angle probe will be used. If practical because the weld is ground flushed and etc, a
straight beam probe would also be used.

The angle beam shall be directed at approximate right angles to the weld axis from two directions where
possible. The search unit shall be manipulated so that the ultrasonic energy passes through the required
volumes of weld and 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.

Note:

Particular attention is to be taken for detecting lack of side wall fusion that produces a peculiar echo
when stroke at right angle by the UT beam.

10.1.1.2. Weld body examination for transverse reflector

A 70° angle probe will be used.

The angle beam shall be directed essentially parallel to the weld axis. The search unit shall be
manipulated so that the angle beam passes through the required volumes of weld and 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. The search unit shall be
rotated 180 deg. and the examination repeated.
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10.5. Interpretation and Evaluation

For examination using a Distance–Amplitude Correction curve (DAC), any reflector which causes an
indication in excess of 20% of DAC (DAC + 2dB) shall be investigated in order to determine their
shape, dimensions and location, to the extent that it can be evaluated in terms of the applicable
Acceptance and Rejection criteria.

Imperfection sizing will be a 6 dB drop technique for along the length of the weld and maximum
amplitude technique on the transverse direction.

10.6. Final Cleaning

Once the evaluation has been made, and the results have been recorded, if the completion of the test can
interfere with later fabrication stages or working conditions, the part will be cleaned by using suitable
means to ensure a complete removal of the couplant to prevent later corrosion.

10.7. Repairs

To be performed as per applicable codes and Standards

11. Records

Report
Reporting of test shall be done on the standard ultrasonic report sheet (see Annex B for typical ultrasonic
report).

Map
For complex geometry, a map shall be drawn so that the proper weld and any discontinuity in it can be
quickly and accurately located.

Distribution
Report and map (s) if applicable will be transmitted to Client. NINONENA will keep copies for archiving
purposes

12. Annexes
A. Flat, Curved and General purpose Distance-Amplitude-Correction Blocks
B. Ultrasonic Report Form
C. Scanning sequences per type of joint
D. DAC plotting and Correction factor to account differences in attenuation and surface condition
E. Applicable Acceptance/Rejection Criteria (to be provided by the client on a case to case basis)
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Annex A1: Flat Basic Distance Amplitude Correction (DAC) Blocks

Annex A2: Curved Basic Distance Amplitude Correction (DAC) Blocks

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Annex A3: General Purpose Distance Amplitude Correction (DAC) Blocks

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Annex B
Ultrasonic Testing report
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Annex C1: Scanning of butt weld in plate or pipe

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Annex C2: Set-on connections. Branch welds

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Annex C3: Set-through nozzle welds. Single-sided

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Annex C4: Set-through nozzle welds. Double-sided

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Annex C5: Structural T-joint

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Annex C6: Cruciform-joint

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Annex D1: Distance – Amplitude – Correction (DAC) plotting

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Annex D2: Transfer loss (Correction factor to account differences in attenuation and surface condition)