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PROCEDURE NO. : GIPREV. NO : DATE : No. of Pages: 1/ 21 UT-015 0 20.09.2004 TITL ULTRASONIC TESTING PROCEDURE E:

TABLE OF CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 SCOPE REFERENCE DOCUMENTS GENERAL REQUIREMENTS EXAMINATION EVALUATIONS AND RECORDING OF RESULTS RECORDS ATTACHMENTS:
DIAGRAM FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 4-1 FIGURE 5 FIGURE 6 FIGURE 7 FIGUE 8 Basic Calibration Standard Ratio Limits for Curved Surfaces Angle Beam Calibration Block (Pipe Welds) Sweep Range Sweep Range 1 Screen Height and Amplitude Control Linearity Planar Reflectors Common Reference Reflectors Sensitivity and Distance Amplitude Correction

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PROCEDURE NO. : GIPREV. NO : DATE : No. of Pages: 2/ 21 UT-015 0 20.09.2004 TITL ULTRASONIC TESTING PROCEDURE E:
1.0 SCOPE
1.1 This procedure describes the method and requirements for the performance of ultrasonic examination in welds, parts, components, materials and thickness determination.

2.0

REFERENCE DOCUMENTS
2.1 This procedure has been developed using the following documents as reference:

(1)
(2)

(3) (4)
(5)

ASME B&PV Code Section V, Nondestructive Examination. 2001 Edition ASME Section 1 ASME VIII ASME B31.1 & B31.3 RWTUV Middle East based on ASNT SNT-TC-1A 2001 Edition

3.0

GENERAL REQUIREMENTS
3.1 PERSONNEL 3.1.1 Personnel performing examinations to the requirements of this procedure shall be qualified and certified in accordance with RWTUV Middle East procedure for Qualification and Certification of Nondestructive Examination Personnel. supervision of certified NDE Level II and Level III. Only certified NDE Level II or NDE Level III personnel shall interpret and evaluate examination results.

3.1.2 Certified NDE Level I can do specific calibration and examination with the

3.2

EQUIPMENT
3.2.1 3.2.2 A pulse echo type instrument shall be used with capabilities of generating frequencies over the nominal range of 1 MHz to 5MHz. The instrument shall be equipped with stepped gain control, calibrated in units of 2 dB or less. Instruments operating at other frequencies may be used if equal or better sensitivity is demonstrated and documented. Instruments using battery power shall be equipped with a low voltage-warning device.

3.2.3

3.2.4 3.2.5 3.2.6

Instrument shall provide a linear vertical presentation and amplitude control accuracy over its useful range and meet other calibration procedure requirements as per calibration plan. Ultrasonic instrument shall provide linear vertical presentation within 5% of full screen height at least 80% of the screen height. (see figure 5) Instrument shall provide an amplitude control accurate over its useful range to 20% of the amplitude ratio to allow measurement of indications beyond the linear range of vertical display on the

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screen.

3.2.7

Instrument s screen height and amplitude control linearity shall be calibrated at the beginning of period of extended use or every three (3) months whichever is less.

3.3

SEARCH UNITS:
3.3.1 Straight beam transducers shall have an active crystal area not less than 1/4 square inch and not greater than 1 square inch. The frequency shall be 2.25 MHz unless such variables as grain structure require other frequencies for better penetration and resolution. Angle beam transducers shall have an active crystal area of not less than 1/4 square inch and not greater than 13/16 inch by 1 inch. The frequency shall be 2 -4 MHZ unless such variables as grain structure requires other frequencies for better penetration and resolution. 45 should be primarily used for examination. However, other angles may be used when part geometry or configurations require the use of other angles such as 60 and/or 70.

3.3.2

3.3.3

3.4

COUPLANT
3.4.1 Couplant shall be of any material having good wetting characteristics that will provide for the transmission of ultrasound from the search unit to the test material and from the test material to the search unit. When examining nickel base alloys, couplant shall not contain more than 250 pm of sulphur while for austenitic stainless steel or titanium, couplant shall not exceed a content of 250 pm of halides (chlorides + fluorides).

3.5

CALIBRATION STANDARDS
3.5.1 Calibration Blocks: Basic Calibration Block for construction of DAC Curve, IIW V1 Block, V2 Miniature block shall be used for sound path distance and range calibration. Calibration standards shall be made of the same material, product form, material specifications and / or P number grouping as the item being examined. For the purpose of definition P, P 1,P3, P4 and P5 materials are considered acceptable. For calibration standards for dissimilar metals, the material selection shall be based on side of the weld of which the exam is being performed. If the exam is being performed from on both sides of the weld, a calibration standard representing both materials shall be used.

3.5.2

3.5.3

3.5.3.1 Calibration reflectors shall be made in both materials. 3.5.4 3.5.5 Where two or more base metal thicknesses are involved, the calibration standard shall be determined by an average of both thicknesses. The standard shall receive the same heat treatment as the material specification

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used for the item being examined. The post heat treatment shall be a minimum of 2 hours if the standard contains weld(s) other than cladding. 3.5.6 3.5.7 The finish on the surfaces of the block shall be representative of the surface finishes on the components. A block of essentially the same curvature or alternatively a basic calibration block shall be used for examinations in materials where examination surface in diameter is greater than 20 in. (508 mm) See Fig 1. A single curved basic calibration standard may be used to calibrate on surfaces in the range of curvature from 0 .9 to 1.5 times the basic calibration standard diameter. For an example, an 8-inch diameter curved standard may be used to calibrate diameters of pipe ranging from 7.2 inches to 12 inches in diameter. An example of ranges is further defined in Figure 2. Calibration standard configuration requirements are shown in Figure 3. Any standards used must be configured to the specifications shown.

3.5.8

3.5.9

3.5.10 Independent of the calibration standards noted above, if the client provides other standards to calibrate with, they should be noted and considered acceptable.

3.5.11
4.0

The temperature of the calibration standard must be within 25F of the item being examined.

EXAMINATION
4.1 SURFACE CONDITION 4.1.1 The surface of the item being examined shall be free from scale, excessive rust, weld spatter, paint, surface roughness or any extraneous matter that would interfere with the free movement of the transducer or effect the coupling of the transducer to the item being examined. 4.1.2 The final prepared surface shall be accepted by the Authorized inspector to assure the item is sufficiently cleaned enough to prevent non-relevant or false indications. 4.2 ACCESSIBILITY 4.2.1 Final surface preparation shall include an area from the toe of the weld back to a point such that full volumetric inspection is possible. 4.2.2 The volume of base material through which ultrasound will travel in angle beam examination shall be scanned with a straight beam search unit. Any reflectors found that could interfere or affect the interpretation of angle beam examination results shall be recorded as to the area and location of the indication.

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4.2.3 Any indication that is observed during this scan shall not be considered acceptable or rejectable, but should be noted on the examination report for further client evaluation. 4.3 SWEEP RANGE CALIBRATION OF STRAIGHT BEAM 4.3.1 Position the search unit for the maximum first indication from 1/4 t side drilled hole as shown in Fig. 4.1. 4.3.2 Adjust the leading edge of this indication to the second major screen division on the screen with the delay control. 4.3.3 Position the search unit for the maximum indication from the 3/4 t hole. Adjust this signal such that the leading edge of the signal is at the sixth major screen division on the screen with the range control. 4.3.4 Repeat the steps in paragraphs 4.3.1 through 4.3.3 with the delay and range control adjustments until the 1/4 t ands 3/4 t hole reflections start at sweep lines 2 and 6. See Figure 4.1 for actual presentation display. 4.4 DISTANCE AMPLITUDE CORRECTION FOR STRAIGHT BEAM 4.4.1 Position the search unit for maximum response from the hole, which gives the highest amplitude. 4.4.2 Adjust the sensitivity or gain control to provide a 80% ( 5% of FSH) of full screen indication from the hole. This shall be considered the reference dB level. 4.4.3 Mark the peak of the indication on the screen with a grease pencil or other suitable marker. (make sure the marking can be removed after the inspection is complete). 4.4.4 Position the search unit for maximum response from another hole indication and mark the peak of the indication on the screen. 4.4.5 Position the search unit for maximum amplitude from the third hole indication and mark the peak on the screen. 4.4.6 Position the search unit for maximum amplitude from the t hole indication after the beam has bound from the opposite surface. The indication should appear at sweep line 10. mark the peak on the screen for 5/4t position 4.4.7 Connect the points marked on the screen with a smooth curve, extending the curve to cover the full thickness of the weld. Reference Figure 5 for actual presentation display. This the primary reference level DAC curve for performing straight beam examination.

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4.5 ANGLE BEAM CALIBRATION
4.5.1 Position the search unit for the maximum first indication from 1/4 t side drilled hole. See Figure 4. 4.5.2 Adjust the leading edge of this indication to the second major screen division on the screen with the delay control. 4.5.3 Position the search unit for the maximum indication from the 3/4 t hole. Adjust this signal such that the leading edge of the signal is at the sixth major screen division on the screen with the range control. 4.5.4 range control lines 2 and 6. 4.5.5 Repeat the steps in paragraphs 4.5.2 through 4.5.4 with the delay and djustments until the 1/4 t and 3/4 t hole reflections start at sweep Reference Figure 4 for actual presentation display.

Position the search unit for the maximum response from the square notch on the opposite surface. The indication should appear at or near sweep division 8. Two divisions on the sweep equal 1/4 t.

4.6

DISTANCE AMPLITUDE CORRECTION FROM THE CLAD SIDE

4.6.1 Position the search unit for maximum response from the hole, which gives the highest amplitude. 4.6.2 Adjust the gain control to provide an 80% 5% FSH of full screen indication from the hole. This shall be considered the reference dB level. 4.6.3 Mark the peak of the indication on the screen with a grease pencil or other suitable marker. (Make sure the marker used can be removed after the inspection is complete). 4.6.4 4.6.5 Position the search unit for maximum response from another hole indication. Mark the peak of the indication on the screen.

4.6.6 and

Position the search unit for maximum response from the third hole indication mark the peak on the screen. 4.6.7 Position the search unit for maximum amplitude from the 3/4 t hole indication after the beam has bounced back from the opposite surface. This indication should appear at sweep division 10. Mark the peak on the screen for the 5/4 t position.

4.6.8 Connect the points marked on the screen with a smooth curve extending the full length of the screen. See Figure 7 for actual screen presentation display. For calibration for perpendicular reflectors at the opposite surface, See Figure 8.

4.7

DISTANCE AMPLITUDE CORRECTION FROM THE UNCLAD SIDE

4.7.1 From the clad side of the block, determine the dB change in amplitude between the 3/4 t and 5/4 t positions. 4.7.2 From the unclad side, repeat the steps noted in paragraphs 4.6.1 through

4.6.8. 4.7.3 To determine the amplitude for the 5/4 t hole, position the search unit for maximum amplitude from the 3/4 t hole. Decrease the gain control (dB) by the number of dB noted in 4.7.4. Mark the height of this signal amplitude at sweep line 10 (5/4 t). 4.7.5 Connect the screen marks to provide the distance amplitude curve. This will permit evaluation of indications down to the clad surface, which should be at or near sweep division 8.

4.7.6

For calibration correction for perpendicular planar reflectors near the opposite surface, the 45 angle beam shear wave reflects well from a corner reflector. However, mode conversion and redirection of reflection occurs to part of the beam when 60 angle beam shear wave hits the same reflector. This problem also exists to a lesser degree throughout the 50 to 70 angle beam shear wave range. 4.7.6.1 Position the search unit for maximum amplitude from the surface X mark the peak of the indication on the screen near sweep line 8. See Figure 6. 4.7.6.2 The opposite surface square notch may give an indication 2 to 1 above DAC at 45 and DAC at 60. Therefore, the indications from the square notch must be considered when evaluating. See Figure 6.

4.8

DISTANCE AMPLITUDE CORRECTION FROM NON-CLAD MATERIAL

4.8.1 For distance amplitude correction on non-clad materials follow the steps outlined in paragraphs 4.6.1 through 4.6.8.

4.9

CALIBRATIONS FOR EXAMINATIONS WHERE CALIBRATION STANDARDS ARE NOT AVAILABLE OR FOR SINGLE SIDED EXAMS WITH CLIENT APPROVAL
4.9.1 When permitted by the client, if calibration standards are not available for the curvature or thickness of the item being examined or where single side exams are required due to geometry, the following may apply; a) b) Position the search unit on the item being examined. Adjust the gain to obtain a signal of 10% of FSH.

c)

d) 4.9.2

Adjust the delay and range controls to position the roll of the signal at the fifth major division on the screen. This should allow enough screen to see the entire area of interest in the first and second leg of the sound beam path. Scan the item as further defined in this procedure.

The only evaluation of indications will be that of signal characterization. No amplitude- based evaluations can be performed using this method of examination. 4.9.3 Other alternate calibrations may be used proved they meet the minimum sensitivity levels defined in the procedure, are documented on the report and done so with client approval. 4.9.4 All reject or dampening controls should be in the off position. If these options are employed, they shall be used during the calibration of the instrument as well as throughout the examination process and so noted on the examination / calibration report. 4.10 CALIBRATION CHECKS 4.10.1 The calibration of the instrument will be checked using the same combination of variables used during the initial calibration as follows: a) b) couplants, the instrument c) d) At the start and finish of each examination With any change of variables such as transducers, cables, shoes, or any other item that could effect the calibration of With any change of personnel At least every four hours of continuous use

4.10.2 If any point on the DAC curve has changed in amplitude of 20% or 2 dB, all data taken during the time since the last calibration shall be considered invalid. 4.10.3 If any point on the DAC curve has moved more than 10% of the sweep position reading documented during the initial calibration, all data shall be considered invalid. 4.10.4 If the differences noted in paragraphs 4.10. 2 and 4.10.3 have occurred, the instrument shall be recalibrated in accordance with the original calibration requirements and the inspection shall be performed again. 4.10.5 Recalibration shall be done if there is any change of operation, transducer, coaxial cable, transducer, battery, couplant and examiner.

4.11 dB TRANSFER METHOD

4.11.1 When the basic calibration standard do mot match as required in the material being examined, transfer methods shall be used to correlate the responses from the basic calibration standard and from the item being examined. 4.11.2 Transfer is accomplished by noting the difference between responses received from the same reference reflector in the basic calibration standard and in the item being examined and correcting for the difference. 4.11.3 The reference reflector may be a V-notch see Figure 7 , an angle beam search unit acting as a reflector, or any other reflector which will aid in accomplishing the transfer.

4.11.4 The transfer shall be used at the following times; a) examined. b) feet of c) examined. For pipe sizes 2 inches and under, once in every 10 welded joints For sizes over 2 inches through pipe size 18 inch, once in every 5 weld examined. For pipe sizes greater than 18 inches, once for each welded joint NOTE: Each type of material, each size and thickness shall be considered separately in applying the transfer method. In addition, the transfer method shall be used at least twice on each type of weld joint.

4.12 SCANNING FOR STRAIGHT BEAM TECHNIQUE

4.12.1 Scanning of the adjacent base metal shall be performed to detect reflectors that could interfere with the interpretation of the angle beam examination. 4.12.2 This scan is not intended to be used as an acceptance or rejection of the base metal area. However, all reflectors found should be recorded on the examination report. 4.12.3 The entire base metal area that will be subject to coverage with an angle beam search unit shall be examined to the extent possible with the straight beam search unit. 4.12.4 The scanning shall be performed at a gain setting of at least twice the primary reference level (6 dB). 4.12.5 Evaluation shall be performed at the primary reference level.

4.13

SCANNING FOR ANGLE BEAM TECHNIQUE

4.13.1 When scanning for reflectors that are parallel to the weld, the angle beam shall directed at approximate right angles to the weld axis from two directions where possible.

4.13.2 When scanning for reflectors that are transverse to the weld, the angle beam shall directed essentially parallel to the weld axis. 4.13.3 The search unit shall be manipulated or oscillated so that the sound passes through the required volume of weld to be examined as well as the adjacent base metal.

4.13.4 The search unit shall be rotated 180, and the examination repeated.
4.13.5 The scanning level shall be performed at a gain setting of at least twice the primary reference level (6 dB). 4.13.6 Evaluation shall be performed with reference to the primary reference level.

4.14

OVERLAP
4.14.1 Each pass of the search unit in the scanning pattern shall overlap the preceeding pass by a minimum of 15% of the width of the active crystal size.

4.15

RATE OF SCANNING

4.15.1 The rate of scanning shall not exceed 6 inches per second.

5.0

EVALUATION AND RECORDING OF RESULTS

5.1 EVALUATION OF INDICATIONS 5.1.1 Any imperfection that causes an indication in excess of 20% DAC shall be investigated to the extent that is can be evaluated in terms of the acceptance criteria defined in this procedure. Evaluation shall always be performed at the primary reference level. The flaw evaluation is estimated on 6 dB drop method. Any complete loss of back reflection not caused by poor coupling shall be recorded and investigated. 5.1.2 The primary reference level for straight beam or angle beam is the primary reference response corrected by the DAC curve. 5.1.3 All reflections from uncorrected areas having responses that exceed 50% of the reference level shall be recorded. 5.1.4 When required, the locations of unacceptable indications will be marked on the test surface.

5.1.5

Independent of the requirements in the acceptance criteria noted, any imperfections that are characterized by signal representation to be cracks, incomplete fusion or incomplete penetration shall be unacceptable regardless of discontinuity or amplitude reference.

5.2 ACCEPTANCE CRITERIA 5.2.1

ASME Section 1, ASME Section VIII, Division 1, ANSI/ASME B 31.1 & B 31.3 And any other codes and standards as applicable per client and specification evaluated as being cracks, lack of fusion or incomplete penetration are unacceptable regardless of length.

5.2.2 Discontinuities

5.2.2.1 Discontinuities are considered unacceptable if the amplitude exceeds the reference level and exceed the following lengths;
a) b) c) 1/4 inch for thickness up to 3/4 inch. 1/3 t for t from 3/4 inch to 2 1/4 inches 3/4 inch for t over 2 1/4 inches

NOTE: ASME Section I, ASME B31.1 & ASME B31.3 Where t is the thickness of the weld being examined. If the weld joins two members having different thicknesses at the weld, t is the thinner of these two thicknesses. ASME VIII Division I Where t is the thickness of weld being examined. If the weld joins 2 members having different thicknesses as the weld, t is considered the thinner of these 2 areas. If a full penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be included in t.

5.2.3 Other acceptance criteria may apply as specified by the client.

6.0

RECORDS

6.1 A report shall be completed for each examination. Any interpretation that is doubtful or if differences in interpretation exist, the interpretation shall be resolved by consultation with the responsible NDE Level III. Reports Typical to that shown in Example 1 should be used. If reports other than that shown are used, they shall contain as a minimum, the information required by the client specification noted in Example 1 and should be approved by the client.

7.0

DIAGRAM (See following page)

ULTRASONIC INSPECTION

Longitudinal/Straight Beam Calibration

Shear/ Angle Beam Calibration

Surface Preparation / PreCleaning

Calibration

Index Point Determination (for Shear only)

Distance Calibration (Range)

( Straight Beam only beam )

Resolution Setting

Sensitivity Setting

Scanning & Examination

Angle beam checking (Shear only)

Evaluation & Records

Repairs & Re-examination

Records

FIGURE 1 Basic Calibration Block

FIGURE 2 Ratio Limits For Curved Surfaces

GENERAL NOTES: (a) Plot examination surface of basic calibration block on diagonal (45 deg.) line. (b) Draw horizontal line through that point from the 9/10 to the 1-1/2 limit line. (c) The ends of this line read on the horizontal scale give the range of examination surface diameters, which may be examined with a system calibrated on this block. (d) Thickness range requirements shall also be satisfied.

Examination Surface Diameter, in.

FIGURE 3 Angle Beam Calibration Block (Pipe Welds)

Figure4.0

Figure 4.1 Sweep Range

Figure 5 - Screen Height and Amplitude Control Linearity

Indication Set at % of full screen db Control Change Indication Limits % of full Screen

80% -6 dB 32 to 48% 80% -12dB 16 to 24% 40% +6 dB 64 to 96% 20% +12dB 64 to 96% The settings & readings must be estimated to the nearest 1% of full screen.

FIGURE 6 Planar Reflectors

Figure 7 - Common Reference Reflectors

Figure 8 Sensitivity and Distance Amplitude Correction

Figure 9 Position Depth and Beam Path