PROCEDURE NO.

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PROCEDURE FOR ULTRASONIC OF REV. NO. 00

WELD EXAMINATION DATE : 01.04.2021
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ULTRASONIC EXAMINATION OF WELDS

1.0 SCOPE:

This procedure describes the requirements for ultrasonic examination of full

penetration welds in wrought carbon steel materials (rolled, drawn, forged or
extruded) up to 8mm to 200 mm thickness.

2.0 PERSONNEL QUALIFICATION REQUIREMENT:

Certified Personnel in UT-I, UT-II method in accordance with ASNT document SNT-TC-
1A.( Edition 2006 ). UT-Level-I is authorized to perform necessary operations. UT-
Level-II is authorized to perform necessary operations including interpretation and
evaluation.

3.0 REFERENCING DOCUMENTS

ASME Section VIII Division 1 (Edition 2007)

ASME Section V (Edition 2007)

4.0 APPLICATION:
The principle objective of the technique described herein is the detection, location
and evaluation of defects within the weld, heat effected zone and also in the
adjacent base material. The weld shall be examined by angle beam method
wherever practical. The scanning shall be carried out manually by contact method.
All welds shall be examined from both the sides of the weld form a single surface or
a combination of surfaces so that full volume of the weld is covered. Where
geometry of the assembly does not allow examination from both sides, one of the
alternatives of (a), and (b) may be used.

(a) Combination of angle beam & straight beam.

(b) Angle beam from one side of the weld using two different beam angles.

Special wedges, shoes or saddles may be used as and when needed depending on
the scanning surface / curvature of scanning surface and scanning techniques used.

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Post examination cleaning of the test surface shall be carried out as and when it is
necessary.
5.0 EQUIPMENT

5.1 APPARATUS

A pulse-echo-type of ultrasonic instrument shall be used. The instrument shall be

capable of operation at frequencies over the range of at least 1 MHZ to 5 MHZ and
shall be equipped with a stepped gain control in units of 2.0 dB or less. 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
examinations, unless it can be demonstrated that it does not affect the linearity of
the examination. The instrument shall have both send and receive jacks for
operation of dual search units or a single search unit with send and receive
transducers.

5.1.1 SCREEN HEIGHT LINEARITY:

Position an angle beam search unit on a calibration block, so that indications from
both the ½ and 3/4T holes give a 2:1 ratio of amplitudes between the two
indications. Adjust the sensitivity (gain) so that the larger echo set at 80% of full
screen height. Without moving the search unit, adjust the gain to successively set
the larger indication from 100% to 20% of full screen height, in 10% increments (or
2dB steps if a fine control is not available), and read the smaller indication at each
setting. The reading must be 50% of the larger amplitude, within 5% of full screen
height. The setting and readings must be estimated to nearest 1% of full screen
height.

5.1.2 AMPLITUDE CONTROL LINEARITY:

Position an angle beam search unit on a calibration block, so that indication from
the 1/2T side-drilled hole is peaked on the screen. Select any echo and note its
amplitude. Reduce the gain by 6 dB and read the amplitude of same indication. It
must be 50% of the initial amplitude within 20% of the nominal amplitude ratio.
Perform this exercise for full range of the gain. The settings and readings must be
estimated to the nearest 1% of full screen and the readings shall be as shown in the
table.

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Indication set at % of dB control change Indication limits % of full

full screen height screen height
80% -6dB 32 to 48%
80% -12dB 16 to 24%
40% +6dB 64 to 96%
20% +12dB 64 to 96%

6.0 SEARCH UNITS :

Single or dual element search units operating between nominal frequency shall be
from 1 MHz to 5 MHz

7.0 COUPLANT

Grease, oil, water or any other similar material which permits satisfactory
transmission of ultrasonic waves. However same couplant shall be used for
calibration as well as testing.

8.0 TEST SURFACE PREPARTION

8.1 BASE METAL

The base metal on each side of weld shall be free of weld spatters, surface
irregularities or foreign matter that might interface with the examination.

8.2 WELD METAL

Where the weld surface interface with the examination, the weld shall be prepared
as needed to permit the examination.

9.0 BASIC CALIBRATION BLOCK

The basic calibration block as per fig. T-434.2.1. for contact examination, the
temperature differential between the calibration block and examination surfaces
shall be within 14 0C.

9.1 MATERIAL:

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(a) Similar Metal Welds.:-The material from which the block is fabricated shall be of
the same product form and material specifications or equivalent P- number
grouping as one of the materials being examined. P- Nos. 1,3,4 and 5 materials are
considered equivalent.
(b) Dissimilar Metal Welds.:- The material selection shall be based on the material
on the side of the weld from which the examination will be conducted. If the
examination will be conducted from both sides, calibration reflectors shall be
provided in both materials.

9.2 ANGLE BEAM METHOD

9.2.1 BEAM ANGLE

An angle shall be selected as appropriate for the weld configuration being

examined.

9.2.2 DISTANCE AMPLITUDE CORRECTION (DAC)

(a) Position for maximum response from the hole, which gives the highest
amplitude.

(b) Adjust the sensitivity control to provide an 80 % (± 5% of full screen height) of

full screen indication from the hole. Mark the peak of the indication on the
screen.

(c) This gain setting shall be refereed as Primary Reference Level.

(d) Without changing the gain setting, position the search unit for maximum
response for another hole indication. Mark the peak of the indication on the
screen.

(e) Position the search unit for maximum amplitude from the third hole
indication and mark the peak of the indication on the screen.
(f) Connect the screen marks to provide the distance amplitude curve.

(g) DAC curve shall be generated for each probe to be used in testing.

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9.2.3 STRAIGHT BEAM METHOD

9.2.3.1 DISTANCE AMPLITUDE CORRECTION (DAC)

(a) Position for maximum response from the hole which gives the highest
amplitude.

(b) Adjust the sensitivity control to provide an 80% (±5% of full screen height) of
full screen indication from the hole. Mark the peak of the indication on the
screen.

(c) This gain setting shall be referred as Primary Reference Level.

(d) Without changing the gain setting, position the search unit for maximum
response from another hole indication. Mark the peak of the indication on
the screen.
(e) Position the search unit for maximum amplitude from the third hole
indication and mark the peak of the indication on the screen.

(f) Connect the screen marks and extended through the thickness to provide the
distance – amplitude curve for the side – drilled holes.

(g) DAC curve shall be generated for each probe to be used in testing.

9.2.3.2 RECALIBARTION

Calibration shall be re-established on at least one of the basic reflectors in the basic
calibration block or by using a simulator in the finish of each examination or series of
similar examinations, every 4 hrs during the examination, and when examination
personnel are changed, whichever occurs earlier.

10.0 SCANNING

10.1 STRAIGHT BEAM

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10.1.1 The scanning of the adjacent base material shall be performed to detect reflectors
that might affect interpretation of angle beam results. The result of this scanning is
not to be used for acceptance or rejection of the weld. Location and areas of such
reflectors shall be recorded.

10.1.2 The weld and base metal shall be scanned, where required by the referencing code
section to the extent possible with the straight beam search unit. The scanning
shall be performed at a gain setting of at least two times the primary reference
level. Evaluation shall be performed with respect to the primary reference level.

10.2 ANGLE BEAM

10.2.1 SCANNING FOR REFLECTORS ORINTED PARALLEL TO THE WELD

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

The scanning shall be performed at a gain setting of at least two times the primary
reference level. Evaluation shall be performed with respect to the primary reference
level.

10.2.2 SCANNING FOR REFLECTORS ORIENTED TRANSVERSE TO THE

WELD

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 the weld and the adjacent weld metal. The scanning shall be performed
at a gain setting at least two times the primary reference level. The search unit shall
be rotated 180 deg. And the examined shall be repeated.

10.3 SCANNING FOR RESTRICTED ACCESS WELDS :

Welds that cannot be fully examined from two directions using the angle beam
Technique (e.g. Corner and Tee joints) shall be also examined, if possible, with a
Straight beam technique. These areas of restricted access shall be noted in the

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Examination report.

10.4 INACCESSIBLE WELDS:

Welds that cannot be examined from at least one side (edge) using the angle beam
technique shall be noted in the examination report.

10.5 SCANNING OVERLAP AND SPEED

Each pass of the search unit shall overlap a minimum of 10% of the active
transducer (piezoelectric element) dimension perpendicular to the direction of the
scan. The rate of search unit movement (scanning speed) shall not exceed 6 inch per
second (152 mm/S).

11.0 EVALUATION

GENERAL

It is recognized that not all ultrasonic reflectors indicates flaws, since certain
metallurgical discontinuities and geometrical conditions may produce indications
that are not relevant. Included in this category are plate segregates in the heat-
affected zone that becomes reflective after fabrication. Under straight beam
examination, these may appear as spot or line indications. Under angle beam
examination, indications that are determined to originate from surface conditions
(such as weld root geometry) or variations in metallurgical structure in austenitic
materials may be classified as geometric indications. The identity, maximum
amplitude, location, and extent of reflector causing a geometrical indication shall be
recorded. The following steps shall be taken to classify an indication as geometric

(a) Interpret the area containing the reflector in accordance with the applicable
examination procedure.

(b) Plot and verify the reflector coordinates. Prepare a cross-sectional sketch
showing the reflector position and surface discontinuities such as root and counter
bore.

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(c) Review fabrication or weld preparation drawings, other ultrasonic techniques or

nondestructive methods may be helpful in determining a reflector’s true position,
size and orientation.

12.0 SIZING OF DISCONTINUITY

Discontinuity shall be sized as follows:

(a) Maximize the response echo and centered on this portion, search unit shall
be moved in all directions, till the response of indication is reduced to 50% of
its original echo height.

(b) Mark two points on either side, and evaluate the maximum length of
separation between two such points.

(c) This maximum distance shall be considered as defect size.

13.0 ACCEPTANCE / REJECTION STANDARD

(a) Indications characterized as cracks, lack of fusion or incomplete penetration,

are unacceptable regardless of length.

(b) Other imperfections are unacceptable if the indications exceed the ref.
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 (19 mm) to 2 1/4 inch (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 members having different thickness at the weld, t
is the thinner of the two thicknesses. If a full penetration weld includes a fillet
weld, the thickness of the throat of the fillet shall be included in t.

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14.0 EXAMINATION OF REPAIRS

All repaired areas shall be re-examined by the same procedure as used for the
original detection of the discontinuity.

15.0 REPORT OF EXAMINATION

A report of the examination shall be made as per format and shall contain weld
details, technique followed, setting used and all reflections from uncorrected areas
having responses, which exceeds 50% of the primary reference level. This record
shall locate each area, the response level, the dimensions, the depth below the
surface, and the classification.

If the amplitude exceeds the DAC after increasing 6 dB, the indication shall be
considered as exceeding 50% of DAC.

In addition, a record of repaired areas shall be noted as well as the results of the
reexamination of the repaired areas.

BASIC CALIBRATION BLOCK

Based on fig. T-434.2.1 ASME Section V, Article 4

Basic Calibration
Hole
Weld thickness, t, Block Thickness,
Diameter
mm T,
Inch (mm)
mm

25mm or less 19 or t 2.5

Over 25 through 51 38 or t 3.0

Over 51 through 100 75 or t 5.0

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Over 100 t ± (25) Note 1

Note 1:- For each increase in weld thickness of 50mm or fraction thereof over 100mm, the
hole diameter shall increase 1.5mm.

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GENERAL NOTES

(a) Holes shall be drilled and reamed 1.5-inch (38 mm) deep minimum, essentially parallel
to the examination surface.

(b) For curved surfaces, two sets of calibration reflectors (holes, notches) oriented 90
degree from each other shall be used. Alternatively, two curved calibration blocks may
be used.

(c) The tolerances for hole diameter shall be ± 1/32 inch (0.8 mm). The tolerance for hole
location through the calibration block thickness (i.e, distance from the examination
surface) shall be ± 1/8 inch (3.2 mm) .

(d) All three holes may be located on the same face (side) of the calibration block provided
care is exercised to locate the holes far enough apart to prevent one hole from masking
the indication of another hole during calibration.

(e) Prior to fabrication, the block material shall be completely examined with a straight
beam search unit. Areas that contain an indication exceeding the remaining back-wall
reflection shall be excluded from the beam paths required to reach the various
calibration reflectors.

(f) Surface finish of the block shall be representative of the surface finish on the
components.

(g) The basic calibration block shall be curved for materials with diameters 20 inch (508
mm) and less.

(h) The material from which block is fabricated, shall be of the same product form and
material specification or equivalent P- No. groupings ( P- Nos. 1, 3, 4 and 5 materials are
considered equivalent)

(i) Where two or more base material thickness are involved the calibration block thickness
shall be determined by the average thickness of the weld.

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(j) For calibration blocks for dissimilar metal welds, the block material shall be based on
the material from which the testing shall be carried out. If the testing is to be carried
out from both sides’ calibration reflectors shall be provided in both materials.

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