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    IRIS UT NDE Procedure Rev 2

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    19 views25 pages

    4.0 Ultrasonic Procedures (Rev 2)

    Uploaded by

    keroppifrog647
    IRIS UT NDE Procedure Rev 2

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    NDE Procedures Manual 4.0 Ultrasonic Procedures Cover Page 40 Ultrasonic Procedure | { | ISSUE DATE: PREPARED BY: REVIEWED BY: APPROVED BY: Re-Affirmed March, 2010 Gordon Robertson Gordon Schultz Gordon Robertson NDE Procedures Manual ‘4.0 Ultrasonic Procedures IRD NST Table of Contents DATE: __Re-Affimad, March 2010 ___REVISION#: _2___APPROVEDEY: _GR___—Paye2of28 40 Ultrasonic Standards and Procedures 44 Scope 42 Safety Requirements and Precautions 43 Personnel Qualifications | 44 General Procedure Requirements 45 Equipment and Consumables 451 Instrument Requirements 452 Search Units 453 Cables 454 Couplant 455 Calibration Blocks 46 Calibration, Verification, and Certification 46.1 Ultrasonic Flaw Detectors 482 Search Units (Transducers) 47 Surface Preparation | 48 ion, General Examination Coverage Pulse Repittion Rate Rate of Search Unit Movement Straight Beam Sensitivity Primary Angle Beam Sensitivity ‘Scanning Sensitivity Recording Sensitivity Level | Surface / Material Attenuation Transfer Calibration Blocks Calibration Confirmation 49 Examination of Materials | 491 Scope 492 Plate 4.9.3 Forgings and Bars (Except Boling Material) 494 Castings (Restricted to Carbon Steel and Low Alloy Ste!) 495 Tubular Products 498 Boling Material 48.7 Straight Beam Testing 498 Thickness Measurement 499 Immersion Testing 4.10 Examination of Welds | 4401 Scope 4402 Testing Procedures 440.3 Sizing Of Discontinuties, 4.11 Post Cleaning 412 Acceptance / Rejection Criteria 413 Records and Reporting 4.14 Ultrasonic Examination Techniques NDE Procedures Manual 4.0 Ultrasonic Procedures References. DATE: Re-Affirmed, March 2010 REVISION#: 2 __APPROVEDBY:_GR__ Page 3 of 25. References Uniess otherwise stated reference documents are the atest published editions) ASME V ARTICLE 1 General Requirements ASME V ARTICLE 4 Ultrasonic Examination Methods for Welds ASME V ARTICLE 5 Ultrasonic Examination for Materials ASME V ARTICLE 23 Ultrasonic Standards ASME VII! Ultrasonic Examination ASME B31.1 Power Piping ASME B31.3 Process Piping ASTM Section Three Volume 3.03 Nondestructive Testing ‘API.620 Design and Construction of Large, Welded, Low-Pressure, Storage Tanks API 650 Welded Steel Tanks for Oil Storage AWS D1.1/D1.1M Structural Welding Code CAN/CGSB-48.9712 Qualification and Certification of Nondestructive Testing Personnel ASNT/SNT-TC-1A_ Qualification and Certification of Nondestructive Testing Personnel IRISNDT Automated Ultrasonic Procedures IRISNDT Ultrasonic Thickness Measurement Procedure IRISNDT Quality Assurance Manual IRISNDT Personnel Certification Manual (Work Practice) NDE Procedures Manual A BANID ee DATE: 4.0 44 42 Re-Affirmed, March 2010. REVISION#: 2 APPROVED BY: _GR___ Page 40f25 Ultrasonic Standards and Procedures Scope ‘This procedure is proposed for nondestructive examination by ultrasonic techniques. It is recognized that the effectiveness of any nondestructive examination program is limited by the capabilities of the procedure, the equipment available, and by those persons who are responsible for, and cary out, the procedure. “The procedure is to be used when no other specific code or standard is referenced, and / or where specific test parameters of examination are not stipulated, The procedure will be used forthe ultrasonic inspection of components primarily by the hand scan method and for the detection of cracks, voids and non-metallic discontinuities and other linear and non-linear discontinuities in welds, parts, components and materials. The procedure may also be used in thickness determination of materials ‘The procedure is not primarily intended to be used for the full examination of austenitictype welds or with automated ultrasonic examination, computerized imaging or digital acquisitioning equipment and techniques. IRISNDT has additional specife procedures and techniques for such examinations, Those procedures. and techniques may reference this procedure where common aspects exist and / or to reduce unneccesary duplication, Safety Requirements and Precautions All IRISNDT safe work practices and procedures, customer safe work practices and procedures and all legislated safely acts and regulations must be followed, Examination procedures are often carried out in hazardous environments. Personnel involved in ultrasonic examination may be exposed to a number of hazards including: ‘+ Materials and concentrates - Consult Material Safety Data Sheets (MSDS) for material properties, precautionary measures, personal protective equipment and first aid measures for any hazardous materials being used. + Fires / Explosion -. Some ultrasonic consumables may have the potential for starting a fre or ‘explosion, Assess the environment you are working in and know the flammability and explosive properties (from Material Safety Data Sheets) of the products you are using so that appropriate Precautions can be taken. Utrasonic instruments are generally not intrinsically safe and work in live plants should be carried out under a hot work Permit + Falls - Examination is often cartied out from ladders, scaffolding or atop of large structures. Proper safe work practices must be followed and proper fall protection must be in place in all cases. ‘+ Environment - Identity the hazards in the work area and take appropriate steps to eliminate them or contro ‘+ Wet ficors - Consumables and / or water often results in wet floors, which present a slipping hazard, Walch footing and keep work areas dry whenever possible. ‘+ Shitting or dropping of equipment ~ The body and body members can be crushed or caught in or under equipment. Improper liting can cause back injury. Use proper safe work practices for iting and handing, + Hazard Assessment (JHA) - Pre-job hazards assessments are to be completed and all potential hazards controlled prior to starting a project. IRIS NDT NDE Procedures Manual ‘4.0 Ultrasonic Procedures DATE: ___Re-Affirmed, March 2010 REVISION#: 2 APPROVED BY: GR. Page 5 of 25 43 Personnel Qualifications 434 Examinations Examinations may be performed by personnel certified in ultrasonic examination to a minimum of Level | CANICGSB-48.9712 and /or Level | IRISNDT SNT-TC-1A (written practice). Where the examination is carried out by personnel certified in ultrasonic examination to Level | CAN/CGSB. 48.9712 and / of Level | IRISNDT SNT-TC-1A (vwriten practice), the technician will be responsible only for the recording of results, classifying results in terms of written criteria and reporting results, 43.2 Interpretation and Evaluation of Results The interpretation and evaluation of results in accordance with applicable codes and specifications shall be performed and the reports signed by personnel certiied to a minimum Level ll CAN/CGSB 48.9712 and / or Level Il IRISNDT SNT-TC-1A (written practice). 433 Code Specific Qualification Requirements. Where specified by code NDE personnel collecting and analyzing UT data may have to demonstrate thelr ablity to perform an acceptable examination using written procedures. The procedures themselves may have to be demonstrated to yield acceptable results when applied to a specified test piece or calibration block, 44 General Procedure Requirements Witten Procedure Requirements When required by code, ultrasonic examination shall be performed in accordance with a written procedure. Each procedure shall include, as a minimum, the following information as applicable: ‘+ Weld and / or material types and configurations to be examined, including thickness dimensions, and product form (casting, forging, plate, eta); the surface of surfaces from which the examination shal be performed: {echnique(s) (straight beam, angle beam, contact and / or immersion); ‘angles and mode(s) of wave propagation inthe material search unit type, frequency(jes), and transducer size(s) special search units, wedges, shoes or saddles, and type; ultrasonic instrument type(s) calibration (blocks and techniques); directions and extent of scanning; scanning (manual vs. automatic) ‘method for discriminating geometric from flaw indications; method for sizing indications; computer enhanced data acquisition, when used; scan overlap; personnel performance requirements when required: personne! qualifcation requirements; surface condition (examination surface, calibration bloc); type of couplant; ‘automatic alarm and recording equipment, or both and rotating, revolving or scanning mechanisms; records, including minimum calibration data tobe recorded (e.g. insttument setings) post examination cleaning, if required. NDE Procedures Manual 4.0 Ultrasonic Procedures REVISION: 2 APPROVED BY: _GR Page 6 of 25 DATE: Re-Affirmed, March 2010 45 Equipment and Consumables 454 Instrument Requirements, ‘A pulse-echo-type of ultrasonic instrument shall be used. The instrument shall be capable of operation at frequencies over the range of atleast 1 MHz to 5MHz and shall be equipped with a stepped gain contol in units ‘of 2.0 dB or less. Ifthe instrument has a damping control, it may be used ift 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, when required by the technique shall have both send and receive jacks for dual search unit or a single search unit with send and receive transducers, Uttrasonic thickness testing instruments shall conform with the requirements of section 4.9.8 of this document. 452 Search Units ‘The nominal frequency shall be from 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 ‘may be either single or dual transducer (crystal) elements. Search units with contoured contact wedges may be sed fo aid ultrasonic coupling. The angle, frequency, and size of ultrasonic transducer used will be dependant lupon test variables such as material thickness, material type, part configuration, avalable test surface, maximum allowable flaw size, flaw orientation, etc. The type of transducer may also be specified by the referencing code or specification or may be matched to the instrument as with thickness measuring instruments, 453 Cables. Cables and connectors shall be checked prior to and frequently during inspections for fraying, damage or pinching which may affect the transmission of signals between the instrument and transducer. Damaged or ‘suspect cables shall be replaced. When cables are replaced sensitivity recalibration shall be performed. Cable lengths shall be kept as short as is reasonable to stil allow efficient testing to be carried out, 454 Couplant A suitable couplant shall be utilized, usually a liquid or semi-iquid, between the transducer face and the ‘examination surface. This is to permit the transmission of ultrasound from the transducer into the material under fest. Typical couplants include water, cellulose paste, oll and grease or commercial products. Corrosion inhibitors and / or welting agents may be needed to permit improved wetting of the material surface, Commercially manufactured products designed specifically for use as ultrasonic couplant will have an ‘accompanying data sheet. Data sheets should contain the following information: manufacturers name: type / grade of couplant; manufacturers batch number, | specifications to which manufactured: date of manufacture, The couplant including additives shall not be detrimental to the material being examined and shall meet applicable specifications when required by a referencing code, 2) Couplants used in nickel based alloys shall not contain more than 250ppm of sulphur. b) Couplants used on austenitic stainless steel or titanium shall not contain more than 250ppm of halides (chlorides plus fuorides) Upon receipt, commercially manufactured couplant shall be assigned an IRISNDT batch number; this number, along with the manufacturers batch number wil be recorded on IRISNOT specified form. “The same couplant to be used during the examination shall be used for calibration and verifeation, NDE Procedures Manual [Pd b SINGS ge DATE: Re-Affirmed, March 2010 REVISION #: PROVED BY: GR_ Page 7 of 25 455 Calibration Blocks 45.5.4 Is permissible in certain circumstances, to use the material itself as an adequate method establishing the height ofthe back wall echo for reference during a fongitudinal examination. Typical calibration blocks include: International Institute of Welding Block (IW Block); ASME Basic Calibration Blocks; ASTM Reference Blocks Basic Set (or equivalent) area amplitude or distance amplitude; IOW Beam Profile Block: DCS oF Kidney Block; Other calibration blocks as specified by referencing codes or specifications, 4.5.52 Reference Standards for Calibration Blocks Known reflectors (ie. side dled holes, fat bottom holes, notches, etc) shall be used to establish primary reference levels on the equipment. ‘The material from which the block is fabricated shall be of the same product form, and material specification or equivalent P-Number grouping as one of the materials being examined, For the Purpose of this paragraph, P-Nos. 1, 3, 4, and 5 materials are considered equivalent 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-wallrefiection shall be excluded from the beams paths required to reach the various calibration reflectors. When the component material is clad or heat-treated, the block shall be clad or heat-treated by the ‘same procedure as the production part, if possible. ‘The surface finish of the reference block shall be a representation of the scanning surface finish of the material under examination ‘Where two or more base thicknesses are involved the calibration block thickness shall be determined by the average thickness of the weld or by selecting a calibration block representative of the greater material thickness with reference reflector size based on the average or smaller weld thickness, For dissimilar metals the material selection shall be based on the material on the side of the weld {rom which the examination will be conducted. If the examination will be conducted from both sides, calibration reflectors shall be provided in both materials, 48.53 Calibration Block Curvatures (Except for Piping) For examinations of materials where the diameter is greater than 20° (608mm), a block of similar curvature or a flat block may be used. For those materials where the curvature is less than 20° (508mm), a curved block shall be used. Except where otherwise stated by the code a single curved block may be used for examinations with a curvature range of 0.9 to 1.5 times the block diameter. When examining from a convex surface by the straight beam contact technique, ASME V Ariicle 4 Non-Manatory Appendix G may be used. 45.54 Calibration Blocks, Piping Calibration blocks for piping shall be as specified in the code or specification and shall be a section of pipe of the same nominal size and schedule. The block size and reflector locations shall be adequate to perform calibration for the angle to be used. The basic calibration block configuration and reflectors shall be as shown ASME V Article 4 Fig, T-434.3, 4555 Calibration Blocks, Overiay or Clad Calibration blocks for clad material shall be constructed as specified by the relevant code or specification. Either side driled holes or flat bottom holes may be used. The thickness of the weld overlay on the calibration block shall be at least as thick as the weld overlay or cladding material to be examined. The base material thickness shall be atleast twice the thickness of the cladding. NDE Procedures Manual 4.0 Ultrasonic Procedures IRIS NDT DATE: Re-Affirmed, March 2010 REVISION#: 2 APPROVED BY: GR Page 8 of 25, 4.656 Tubular Product Calibration Blocks ‘+ Calibration reflectors shall be longitudinal notches and shall have a length not to exceed 25 mm (1 in) 2 width not to exceed 1.6 mm (1/16 in), and a depth not to exceed 0.10 mm (0,004 in) or 5% of the ‘nominal wall thickness, whichever is larger. The calibration block shall be long enough to simulate the handling of the product being examined through the examination equipment, 455.7 Casting Calibration Blocks + Calibration blocks shall be the same thickness +/-25% as the casting to be examined. 4558 Boling Calibration Blocks ‘+ Botting material calibration blocks shall be in accordance with ASME V Asticle 5 T-534.3 and shall be Used for straight beam examination. "Botting" as used in ths Article isan alLincusive term for any type of threaded fastener that may be used in a pressure boundary bolted flange joint assembly such a8 a bolt, stud, studbolt, cap screw, etc. NDE Procedures Manual LPSd PINGS == DATE: 46 464 46.44 4612 46.13 4614 Re-Afirmed, March 2010 REVISION#: 2 APPROVED BY: GR Page 9 of 25 Calibration, Verification, and Certification of Equipment Uttrasonic Instruments Ultrasonic instruments shall be verified for acceptable Screen Height Linearity, Amplitude Control Linearily These verifications shall be carried out at intervals of no greater than 3 months forall flaw detector instruments, as specified in the specification, or after any maintenance work, or whenever the integrity of the machine is in doubt ‘The verification date shall be recorded on tags securely affixed to each flaw detector. Results of verification shall be recorded on IRISNDT specified forms, which will be kept on file in the calibration log. Contractor's calibration records shall be kept on file along with IRISNDT specified form in calibration log NOTE: CSA W59 requires Horizontal Linearity be verified in accordance with ASTM ES17 every 40 hours of use and Amplitude Linearity to be performed in accordance with ASTM E317 every 2 months. ‘Screen Height Linearity ‘Screen Height Linearity verifeation in accordance with ASME T-461 (Mandatory Appendix |) Position an angle beam search unit on a basic calibration block so that the indications can be observed from both the 1/2 and 2/4 T holes. Adjust the search unit position to give a 2:1 ratio of amplitudes between the two indications, with the larger set at 80% of fll screen height. Without moving the search unit, adjust the sensitivity to successively set the larger indication from 100% to 20% of full scteen height in 10% increments (or 2 48 steps if fine contol is not avaliable), and read the small indication at each setting, The reading ofthe smaller amplitude shall be 50% of the larger amplitude, within 5% of full screen height. The settings and readings shall, be estimated tothe nearest 1% of full screen height. Alternatively, a straight beam search unt may be used on any calibration block, which wil provide amplitude differences with suffcient signal separation to prevent overlapping ofthe two signals, ‘Amplitude Control Linearity Amplitude Control Linearity verification in accordance with ASME T-461 (Mandatory Append I). Position an angle beam search unit so that the indication from the 1/2 T hole in a basic calibration biock is peaked on the screen. With the increases and decreases in attenuation as shown in the following table, the indications shall fall within the specified limits. Other convenient reflectors from any calforation block may be used with either an angle or stright beam search unit, Indication Set at 8 Control Indication Limits %otFull Screen Change Swot Full Screen 80% -68 3210 48% 80% -1248 16 10.24% 40% +608 64 10 96% 20% +1248 6410 90% ‘The setings and readings shall be estimated to the nearest 1% of fll screen. Horizontal Limit and Linearity (only where required by governing specification or code) Horizontal Limit and Linearity verification in accordance with ASTM E 317. ‘Adjust the flaw detector gain, sweep-delay and sweep length controls to display eleven non-interfering back: wall reflections, (positioning the first reflection at, or near, zero on the timebase). Set the amplitude of each back- Feflection at 60% screen height before measurement of its position. Further, adjust the sweep contrals to Position the leading edge of the third and ninth reflections at 2nd and 8th scale divisions respectively (with each set, in tur, at 50% screen height). After the 3rd and 8th back reflections are positioned accurately on the 2nd ‘and 8th divisions as described, read and record the scale positions of each other multiple (when set at 60% ‘screen height). Test results shall show the percentage of error maximum allowable Is 5% of screen width NDE Procedures Manual 4.0 Ultrasonic Procedures a DATE: Re-Affimed, March 2010____REVISION#: 2 _APPROVED BY: GR Page 10 of 25 482 Search Units (Transducers) Upon receipt, all documentation attesting to transducer characteristics (Je. signal waveform and frequency response as per ASTM E1066) shall be reviewed and fled in the applicable equipment log. All transducers will, as a minimum, have the following checks carried out prior fo each use: + exit point Position the transducer on the IW block and move parallel to the sides of the calibration block until the ‘maximum reflection is obtained from the 100 mm (4 in) radius. The transducer index point is then directly above the centre ofthe radius and shall be marked on the side ofthe transducer. + beam angle Place the transducer on the IIW block and maximize the reflection of the 50 mm (2 in) diameter or 1.8 mm (1/16 in) diameter hole. The angle is indicated by the engraved numbers on the side ofthe block at the point directly below the index mark. ‘Transducer / flaw detector systems should have the following checks carried out when the integrity of the system is in question or whenever required by referencing codes or specications: + beam spread; + resolution; + signal to noise ratio, ‘These calibrations shall be measured and recorded on IRISNDT specified forms, which will be Kept on file in the calibration log, The data sheets for the transducers shall be kept in the calibration log with the above forms, 47 Surface Preparation ‘The scanning surfaces shall be free of irregularities, lose foreign matter, extreme roughness or coatings, which interfere with the ultrasonic wave transmission. When the base material or weld surface interferes with the ‘examination the base material or weld shall be prepared as needed to permit examination. NDE Procedures Manual TRAN DATE:_ 48 4a4 482 483 484 485 486 4864 4862 487 Re-Affirmed, March 2010 REVISION#: 2 APPROVED BY: GR ___Page 11 of 26 Examination, General Examination Coverage Unless otherwise specified, the entire volume shall be examined by moving the search unit over the ‘examination surface such that each pass of the search unit shall overlap a minimum of 10% of the transducer dimension (or as othenwise specified) perpendicular to the direction of the scan. Oscillation of the search unit is permitted ifit can be demonstrated that overlapping coverage is provided, Pulse Repittion Rate ‘The pulse repitition rate shall be small enough to assure that a signal from a reflector located at the maximum distance in the examination volume wil artive back at the search unit before the next pulse Is placed on the transducer. Rate of Search Unit Movement ‘The rate of search unit movement for examination shail not exceed 150 mm (6 in) / second, unless calibration is verified at scanning speed, Straight Beam Sensitvty ‘The examination sensitivity calibration shall be performed as detailed in the specified code or standard, For ‘contact examination, the temperature differential between the calibration block and examination surfaces shall bbe within 25°F (14°C), Primary Sensitivity, Angle Beams. ‘The examination sensitivity caliration shall be performed as detailed in the specified code or standard. For contact examination, the temperature differential between the calibration block and examination surfaces shall be within 25°F (14°C), If not otherwise specified, the applicable ASME Basic Calibration Block (ASME Section V Article 4) shall be used for sensitivity calibration. The examination sensitivity shall be established on 80% of full screen height amplitude from the side-drilled inole producing the largest response. ‘The distance amplitude correction (DAC) curve, shall be constructed by utiizing the responses from the side driled hole, vee, or square notch reflectors in the angle beam reference block covering the examination distance range in the material to be examined. Scanning Sensitivity Distance Amplitude Techniques ‘The sensitivity seting for examination shall be set at 6 dB above the reference level. The 6 dB shall be removed before determining the acceptance / rejection of a discontinuity indication based on the reference level ‘When the referencing code requires the evaluation of indications exceeding 20% DAC the gain should be increased an additional amount s0 that no calibration reflector indication is less than 40% FSH. Alternately the ‘scanning sensitivity may set 14dB higher than the reference level setting. The additional gain makes the reference DAC curve a 20% DAC curve and any indications exceeding 20% DAC may be more easily identified and evaluated. Non-Distance Amplitude Techniques The level of gain used shall be appropriate for the configuration being examined and shall be capable of detecting the calibration reflectors at the maximum scanning speed. Recording Sensitivity Level For both manual and mechanized examinations, recording of indications shall be made with the gain set at the reference sensitivity. I R ] 54 IN [DS NDE Procedures Manual | eee | DATE: 488 489 48.10 4am Re-Affirmed, March 2010 REVISION#: 2 APPROVED BY: GR ___ Page 12 0f 25 ‘Surface / Material Attenuation Transfer When the material and / or finish of the work piece do not match those of the calibration block, a transfer mechanism may be used, where allowed by the referencing code, to compensate for the response of the instrument. To complete this transfer mechanism, use two probes of the same angle and frequency in the transmit / receive mode. Compare the signal received with the probes on the work piece and on the callration block. Apply the correction, if any, to the distance amplitude correction curve. The difference in gain shall be referred to as the transfer correction, Calibration Blocks Calibration blocks shall conform with the requirements of section 4.55 or as specified in the referencing code or standard. Basic Calibration Blocks shall conform with the requirements of ASME Section V Alice 4. Sweep Range Calibration calibration blocks are availabe to calibrate instrument sweep / range. In all cases ensure the calibration is linear and uses as much of the screen width as possible to improve the accuracy of distance ‘measurements. Examples of sweep / range calibration - Position the transducer on the top surface of lIW block. Move the probe to obtain the maximum signal from the 100 mm (4 in) radius. Depending on the model of the calibration block, there will be @ second signal corresponding to 200 mm (8 in) or 225 mm (9 in). Adjust the equipment for graticule coincidence of the first and second echo and repeat signals as required to obtain the desired Calibration range. Altematively, the DC or MAB calibration block can be utiized which will give signals at 25 mm (1 in) and 100 mm (4 in) oF 60 mm (2 in) and 125 mm (5 in). Adjust the equipment for graticule coincidence of the first and second echo and repeat signals as required to obtain the desired calibration range. Calibration Confirmation Uttrasonic flaw detectors shall be allowed fo warm up before calibration Is attempted and the examination of parts or products commences. When any part of the examination system is changed, a calibration check shall be made on the calibration block to verify that distance range points and sensitivity setting(s) meet the requirements below. A calibration check (on atleast one of the basic reflectors in the basic calibration block or a check using a simulator shall be carried Cut at the end of the examination, with intermittent calibration being carried out at least every four hours, or ‘when personnel change but not less than once per shift any distance range point has moved on the sweep line by more than 10% of the distance reading or 5% of full sweep, whichever is greater, correct the distance range calibration and note the correction in the report. All recorded indications since the last valid calibration or calibration check shall be reexamined and their values ‘shall be changed on the reports or re-recorded, If the sensitvty settings have changed by more than 20% or 2 dB of its amplitude, the senstivity calibration shall be corrected. Where the sensilvily has decreased all areas tested from the last valid calibration shall be retested. Should the sensitivity have increased only a re-evaluation of recorded indications need be completed, ‘Angle Beam Calibration Adjustment for Coarse Grain Materials ‘Where examination of materials with high alloy, Nickel alloy, dissimilar weld metals or course grain materials ‘and weldments is required, a verification shall be carried out to ensure adequate sensitivity can be achieved through the entire area to be examined, Two methods of verifiyng this sensitivity are specified below. ‘The prefered method is to fabricate a test block using the material / weldment combination to be examined and locating side driled holes of a size and position as specified in the govering code or specification in the block. The holes shall be placed in such a manner that will ensure when setting the primary sensitivity level the Ultrasound will pass through the entire weldment and heat affected zone before interacting withthe reflector. ‘As an altemate, a transfer correction may be carried out, when allowed by the governing code or specification, as detailed in section 48.8, except that when the probes are placed on the work piece they shall be placed in such a manner that the ultrasound will pass through the volume of the weld. Should a reduction in the signal amplitude be indicated additional dB shall be added to bring the amplitude level to that level achieved on the calibration block and the difference noted. This additional dB shall then be added to the primary angle beam sensitivity and shall not be removed when evaluating reflectors. Should the correction show a decrease in amplitude no dB shall be removed from the primary angle beam sensitivity level. IRIS NST DATE: 49 494 492 498 494 NDE Procedures Manual ] 4.0 Ultrasonic Procedures —_J Re-Affimed, March 2010 ___—REVISION#: 2 APPROVED BY: GR Page 130f25 Ultrasonic Examination of Materials Scope ‘This paragraph describes the requirements forthe ultrasonic examination used by qualified technicians for the inspection of materials such as plate, forgings and bars. The paragraph describes the examination method{s) used for the detection, location and evaluation of ultrasonic reflectors within the volume of the materials) and includes thickness measurement. These methods are to be used where no other specific code or standard is referenced, and / or where specific test parameters of examination are not stipulated ‘The referencing code section shall be consulted for specific requirements forthe following personne! qualifications; procedure requirements / demonstration, qualification; ‘examination system characteristics; retention and control of calibration blocks; extent of examination and / or volume to be scanned: acceptance standards; retention of records; report requirements. Plate Procedures and methods used for the ultrasonic examination of plate shall be carried out in accordance with the latest edition of the following ASME / ASTM standards with amendments if applicable: ASME V SA-436/435M Straight Beam Examination of Steel Plate for Pressure Vessels ASME V SB-548 Straight Beam Examination of Aluminium Alloy Plate for Pressure Vessels, ASME V SA-577577M ‘Angle Beam Examination of Steel Plate 2" (5 cm) Thick and Less ‘ASME V SA-578/578M ‘Straight Beam Examination of Carbon and Alloy Steel Plate In-service examination of cladding excluding weld metal overlay cladding shall be carried out in accordance with ASME V SA-578/578M, Forgings and Bars (Except Bolting Material) Procedures and methods used for the ultrasonic examination of forgings and bars shall be carried out in accordance with the latest edition of the following ASME / ASTM standards with amendments if applicable: ASME V SA.388/388M Examination of Heavy Stee! Forgings ‘ASME V SA-745/745M Examination of Austinetic Stee! Forgings All forgings and bars shall be examined by the straight-beam technique. In addition ring and hollow forgings shall also be examined by angle-beam techniques in two circumferential directions unless thickness or {geometrical configurations make angle-beam examination impractical. In addition ring forgings used for vessel shell sections shal! also be examined by angle-beam examination in two axial directions, Castings (Restricted To Carbon And Low Alloy Steels) Procedures and methods used forthe ultrasonic exatnination of castings shall be carried out in accordance with the latest edition of the folowing ASME / ASTM standards with amendments if applicable: ‘ASME V SA-609/600M Examination of Carbon and Low-Alloy Steel Castings ‘A supplementary angle-beam examination shall be performed if castings or areas of castings where back- reflection cannot be maintained during straight ~beam examination, or where the angle between the front and back surfaces of the casting exceeds 15 degrees, TET RINISS ge DATE: Re-Affimed, March 2010____-REVISION#:_2. APPROVEDBY: GR Page 14 0f25 495 498 497 498 499 NDE Procedures Manual Tubular Products Procedures and methods used for the ultrasonic examination of tubular products shall be carried out in accordance with the latest ecition ofthe following ASME / ASTM standards with amendments if applicable: ASME V SE-213 Examination of Metal Pipe and Tubing ASME V SE-273 Examination of Longitudinal Welded Pipe and Tubing Bolting Material Procedures and methods used for the ultrasonic examination of bolting material shall be carried out in ‘accordance with the latest edition ofthe following ASME / ASTM standards with amendments if applicable; see ASME V Alicle 5 7571.5: ASME V SA-388/388M Examination of Heavy Stee! Forgings In-service examination of bolting shall be cartied out in accordance with ASME V Article , Mandatory Appendix W. Straight Beam Testing Procedures and methods used for the straight-beam ultrasonic examination of materials shall be in accordance with the latest edition ofthe following ASME / ASTM standards: ASME V SE-114 ‘Standard Practice for Straight Beam Testing by the Contact Method Thickness Measurement Procedures and methods and ultrasonic instruments used for the ultrasonic thickness measurement of new ‘materials and components oF in-service materials and components shall be carried out in accordance with the latest edition of the folowing ASME / ASTM standards with amendments if applicable: ASME V SE-797.2, ‘Thickness Measurement by Manual Contact Method Ultrasonic instruments used in thickness measurement shall conform with the calibration requirements of section 4.6.1.1 except that only Horizontal Limit and Linearity need be carried out in accordance with section 4.6.1.4 and only on an annual basis or after any maintenance work, or whenever the integrity ofthe instrument is in doubt Immersion Testing Procedures and methods used for the ultrasonic examination of materials shall be in accordance with the latest edition ofthe following ASME / ASTM standards with amendments if applicable: ASME V SE-214 Immersed Ultrasonic Examination by the Reflection Method Using Pulsed Longitudinal Waves ASTM E 1001-90 Detection and Evaluation of Discontinuities by the Immersed Pulse-Echo Uttrasonic Method Using Longitudinal Waves, Lad ANID 4402 440.24 4102.2 41023 41024 4102.8 NDE Procedures Manual 4.0 Ultrasonic Procedures Re-Affimed, March 2010 ___REVISION#: 2 APPROVED BY: GR Page 15 of 25, Weld Examination Techniques Scope ‘This paragraph describes the method of ultrasonic inspection used by qualified technicians for the inspection of ‘welded joints in material over 0.2" (6 mm) in thickness. This procedure Is established for the detection, location ‘and evaluation of ultrasonic reflectors within the weld, heat affected zone, and adjacent parent material. This Procedure is to be used when no other specific code or standard is referenced, and / or where specific test parameters of examination are not stipulated, Testing Procedures Distance - Amplitude Correction Construct a distance amplitude correction curve by ullzing the responses from the basic calibration holes of the calibration block suited for the thickness of material being examined. Set the equipment up on the basic calibration block hole, which gives the greatest response (i.e. 1/4 T, 1/2 T, of 3/4 T hole in the basic calibration block). Set the response at 80% screen height. This is the “primary reference level’. Without changing the gain, place the search unit so that similar responses can be obtained from side dled holes at different depths and ‘sound path distance, which will cover the complete examination volume. Mark the corresponding responses on the screen or on the clear fim fixed in place covering the screen. The points will than be joined up by a smooth line which will then give the Distance Amplitude Correction (DAC) curve for that particular transducer in that range and for that material thickness. Discontinuity Evaluation Sensitivity ‘The sensitivity for discontinuity evaluation is the primary reference level. Scanning is carried out at twice the primary reference level (+6db) or as otherwise stated in the referencing code, ‘Scanning Pattems Prior to the start of an examination, a reference point shall be marked on the weld using @ paint marker or crayon, The direction of the examination shall also be indicated. This reference point shall be given on the Ultrasonic examination report and any indications shall be located in inches or millimetres from this point in the direction indicated Lamination Scanning Examination for laminations or inclusions in the parent material that may interfere with the angle bean scanning of the weld shall be carried out prior to the angle beam scanning in all instances, The examination shall as a ‘minimum cover a width, which is equivalent to the material through which the ultrasonic angle beam is to pass. ‘Scanning for laminar reflectors shall be performed at a gain setting that gives an intial reflection amplitude of 80% +/- 5% of full screen height from the back-wall reflector of the component. When the examination is performed from the tapered surface at a transition in thickness of the component, angie beam longitudinal waves traveling essentially perpendicular to the back surface may be used to maintain the back reflection, Evaluation of Straight Beam, Laminar Reflectors Reflectors which are determined may interfere with the scanning examination shall require the angle beam examination technique to be modified such that the maximum feasible volume is examined and this shall be recorded in the report Pd FANT EDS DATE: 4.1026 44027 4102.8 NDE Procedures Manual ‘4.0 Ultrasonic Procedures Re-Affimed, March 2010___REVISION# _2___APPROVEDBY:_GR__Page 16 of 25 Recording of Straight Beam, Laminar Reflectors Record all areas giving indications equal to or greater than the remaining back reflection that may interfere with the angle beam technique. Record laminar reflectors in all areas where one or more discontinuities produce a Continuous total loss of back reflection accompanied by continuous indications in the same plane. Specify the screen display reading giving depth from the surface, location from reference line of each search unit position, and the recordable extent ofthe indication for each area scanned. Record all reflectors that produce a response equel to or greater than 60% of the back-wall reflector and the search unit position and location dimensions to the nearest 5 mm (0.2 in). Record data for end points as determined by 50% of back wall reflector loss method. Clad interface and back wall reflections need not be recorded, ‘Angle Beam Scanning The volume to be scanned shall be examined with angle beam search units directed both at right angles to the ‘weld axis and along the weld axis. Wherever possible, each examination shall be performed by: 8) scanning the weld from opposite directions of the same face for reflectors parallel to the weld axis; ) scanning parallel to the weld and from opposite directions for transverse reflectors such that the Ultrasonic energy passes through the required volume of weld and material Oscillation ofthe search unit is permitted if it can be demonstrated that overlapping coverage is provided. If the weld cap is not ground flat the examination for transverse reflectors shall be performed from the base ‘material on both sides of the wold cap in in both weld axis directions, ‘These examinations shall be conducted using a minimum of one of the folowing nominal beam angles: 45°, 60° ‘and 70°, unless another angle is specified. The examination shall be conducted from each direction, The adjacent base metal in the examination volume shall be scanned by two angle beams, but need not be completely scanned by both angle beams from both directions; any combination of two angle beams will satisfy the requirements. ‘A method of acourately determining reflector position within the volume of the examination area shall be used. Tris will assist in both differentiating from reflectors created by geometric conditions and will increase the ‘accuracy of positioning discontinuities within the examination area. The prefered method(s) is the use of a scale

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