MIDHANI PAUT PROCEDURE - Latest

Procedure
MISHRA DHATU NIGAM LIMITED

MIDHANI /ANDT/PAUT/01
Date 14-03-2020
STANDARD PROCEDURE FOR PHASED ARRAY Page Page 1 of 20
ULTRASONIC EXAMINATION
STANDARD PROCEDURE FOR PHASED ARRAY
ULTRASONICEXAMINATION.
PREPARED BY REVIEWED BY APPROVED BY
RONANKI RAVIKUMAR
ASNT NDT LEVEL III
MIDHANI
Procedure
Date 14-03-2020
REVISION CONTROL SHEET
Rev. No. Issue Date Section Changes Made
00 14-03-2020 NA First Issue
TABLE OF CONTENTS
S.No DESCRIPTION PAGE NO.

COVER PAGE
REVISION CONTROL SHEET
COMMENT HISTORY
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCE DOCUMENTS
4.0 DEFINITIONS AND ABBREVIATIONS
5.0 PERSONNEL QUALIFICATION REQUIREMENTS

Procedure
Date 14-03-2020
6.0 BASIC BLOCK

7.0 EQUIPMENT AND ACCESSORIES
8.0 Phased array System calibration
9.0 Calibration Check
10.0 SURFACE PREPARATION
11.0 DATA RECODING
12.0 DATA ANALYSIS
13.0 Acceptance Criteria
14.0 SCAN PLAN
15.0 RECODING
Procedure
Date 14-03-2020
1. PURPOSE
The purpose of this procedure is to inspect the MDN 250 Plates of VSSC by Manual raster
scan Angle beam Phased Array Ultrasonic Testing (PAUT).
2. SCOPE
This procedure establishes the phased array ultrasonic examination requirements which shall be
used to examine MDN -250 Plates . This procedure is intended to cover the method and
acceptance standard of the Phased Array Ultrasonic Examination of plates having wall
thickness range minimum 7.7- 8.2 mm . The examination shall be conducted using Manual
Angle beam techniques utilizing computer based data acquisition. The Olympus MX2 machine
shall be used with operating temperature of 45°C maximum.
3. REFERENCE DOCUMENTS:
Current edition of the following documents are referred
 ASTM E-2491 Standard guide for evaluating performance
characteristics of Phased array ultrasonic examination
AMS 2632B - Inspection, Ultrasonic, of Thin Materials, 0.50 Inch (12.7 mm)
and Under in Cross-Sectional Thickness
4. DEFINITIONS AND ABBREVIATIONS
Band pass Filtering: A function of the receiver circuit in most modern UT and PAUT
equipment designed to filter out unwanted returned sound frequencies outside of that used for
sound wave generation. The frequencies of sound on return are of much broader range than the
range of frequencies put into the test piece.
Procedure
Date 14-03-2020
Channel: A send/receive circuit in the phased array unit. The number of channels dictates the
maximum number of elements that the phased array unit can support as a whole.
Dead Elements: Individual elements that is no longer functional due to broken cables,
connectors or element failure. This can also include elements with sub-par performance
Element: An individual crystal (piezo-composite material) within a phased array probe.
Encoded: Using an encoder.
Encoder: A device, normally in the form of a wheel that records probe position for computer
analysis for an automatic data acquisition system.
Encoding: Using an encoder.
Focal Law: A phased array operational file defining search unit elements and time delays for
transmitted and received signals.
FSH: Full screen height.

Imaging Views: Images defined by different plane views between the ultrasonic path
(ultrasonic axis), beam movement (index axis), and probe movement (scan axis).
Phased Array Probe: A probe made up of several piezoelectric elements individually

connected so that the signals they transmit or receive may be treated separately or combined as
desired. The elements can be pulsed individually, simultaneously, or in a certain pattern relative
to each other to create the desired beam angles or scan pattern.
Pitch: The center to center distance between two successive phased array probe elements.
S-Scan: The S-scan beam movement is a set of focal laws that provides a fan-like series of
beams through a defined range of angles using the same set of elements.
Procedure
Date 14-03-2020
Scan Plan: A document specifying key process elements such as equipment detail, focal law
settings and probe positions as necessary to complete an examination; also depicts plate
coverage.
Time Corrected Gain (TCG): A calibration technique in which the search unit computes the
dB gain difference needed to balance standard calibration reflectors (side drilled holes) at
various material depths at one set screen amplitude.
Virtual Probe Aperture (VPA): The number of elements in a phased array probe used for
generating one A scan...This is also called active aperture.
5. PERSONNEL QUALIFICATION REQUIREMENTS

Personnel performing Examination in accordance with this procedure shall be qualified and
certified to ASNT/ISNT Level II in conventional UT .
Only VSSC approved Level II - UT operators with hands on training on Omniscan
MX2 shall calibrate , carry out inspection & shall evaluate the results of ultrasonic
examinations for acceptance.
All the personnel performing Ultrasonic examination shall take necessary personnel
protective measures in accordance with INAT Procedure for General Safety.Technicians
shall adhere to any additional Safety requirement specified/requested by client.
6. BASIC BLOCKS
Calibration Block:
The material from which the block is prepared shall be of the same product ( MDN 250 )
Ref block thickness, SDH details, FBH / notch details, metal distance details ?)…to be added
7. EQUIPMENT AND ACCESSORIES

Procedure
Date 14-03-2020
7.1 General Equipment:
The Phased Array instrument shall be calibrated annually, Olympus –MX-2 is a pulse
echo type and is equipped with a calibrated dB gain or attenuation control stepped in
increments of 0.5dB. The system is capable of generating the images B-scan, C-scan,
S-scan (sectorial scan) along with display of A-scan. The scan plan is generated using
software called NDT Setup Builder (Latest version)& Interpretation is done with
software (Latest Version). Examination personnel may use a real-time sectorial scan
image during scanning to ensure that proper data has been collected. Sectorial-scan
images contain signal amplitude and reflector depth information projected for the
refracted angle of the ultrasonic beam. The data storing capabilities of the system requires
the use of an external storage device, flash card or USB memory stick. A remote
portable PC can also be connected.
In addition to data storage, the Personnel computer will also be used by operator to
analyze the data using OMNIPC software. Data-display software compatible to that
residing on the Omni Scan phased array system shall also be used for data play back.
7.1.1 Transducers:
Ultrasonic transducer configurations are specified by the technique used for the
examination. The probe frequency shall be between 5 MHz and 7.5 MHz
For current scanning of maraging steel plate ( MDN 250) , we are using –
16 element, Linear array, 5MHz, 0.6mm pitch Probe (5L16-A10) shall be

used
7.1.2 Wedges:
Wedge with 55 º angle & compatible with A10 probe shall be used Nominal
refracted wedge angles shall be 39 -57 degrees in maraging steel plates to ensure
full coverage . Wedges shall have provision of irrigation holes and carbides
for couplant flow.
For current scanning SA10-N55S wedge shall be used with 5L16-A10 Probe
Procedure
Date 14-03-2020
7.1.3 Couplant :
Couplant shall be non-corrosive, non-irritant, and easy to clean off the
component and should be approved by VSSC
8. SCAN PLAN
Type of scan : Sectorial (Shear wave)
Angle : 39 to 57 º (equivalent to 45 to 70 º in mild steel) with angle step as

1 º maximum
Aperture : 16 element with pitch 0.6mm
First element: 1 Last Element: 16
Individual angle PRF (I) : 200 Hz min
Overall sectorial scan PRF : I x no of angles min
9. Phased Array system calibration:

Calibration shall be performed using the reference block which shall be from the same
material and heat treatment condition that of job to be examined. System calibrations shall
include the complete ultrasonic examination system.
Range shall be at least 3T (True Depth mode) minimum. The system calibration
information shall be recorded on the ultrasonic data report form used in MX-2 machine
During scanning, only the gain may be adjusted from the calibrated reference dB.
Adjustment of other controls requires recalibration.
The following calibrations (Velocity, Wedge delay, Sensitivity & TCG) shall be carried
out for PAUT scanning as described below
Procedure
Date 14-03-2020
9.1Velocity calibration:
The machine should be calibrated for the velocity with reference to the selected
material. 2 Back Wall Echo (BWE) from the actual MDN 250 –Reference block
is used and by placing the gate in the appropriate position in the two signals will
automatically calibrate the velocity and that machine sets the velocity. Or check
the actual velocity of material with Conventional Olympus UT machine and feed
in the Machine
Figure2: Velocity Calibration for S-scans
9.2 Wedge delay calibration:

In PAUT probe with angle wedge, wedge delay (probe delay) will differ for each angle and
correspondingly the depth of the defects will also differ. Wedge delay calibration adjusts the
delay for each angle such that constant depth is maintained for all the angles.
The wedge delay calibration shall be carried out for both linear scan as well as sectorial scan. The
wedge delay calibration shall be carried out in true depth mode and done using a 0.5 mm x 6.4
mm SDH at T/2 depth on the same reference block. SDH shall be at least 60mm away from the
reference block edge Peak up this signal from the SDH reflector and scan the phased array probe
back and forth with minor swiveling, through all the different angles or focal laws. Perform
Procedure
Date 14-03-2020
calibration till the SDH depth is within +/- 0.5 mm tolerance for all the focal laws.
Due to repeated use of the wedge, there can be variation in wedge delay. Hence, it is necessary to
verify the depth of SDH on reference block before scanning every time. In case of variation > +/- 0.5
mm, all calibrations (wedge delay, sensitivity & TCG) shall be repeated.
Figure 3: wedge delay calibration

Note:- Section wise Wedge delay calibration shall be avoided. However, if distortion of images
between two sections is not evident after calibration, this is acceptable.
8.3 Sensitivity calibration (Angle Corrected Gain):

Sensitivity calibration provides the required gain adjustments for each refracted angle w.r.to same
reference reflector. SDH of size Ø0.5x6.4 mm shall be used for sensitivity calibration. Pickup this
signal from the calibration reflector and scan the phased array probe backwards through all the
different angles of focal laws, with very minor swiveling so that echo is maximized.
Procedure
Date 14-03-2020
Figure4: Sensitivity Calibration.

The Sensitivity response (amplitude response) from each focal law providesa
uniform amplitude response to the calibration reflector. As the operator moves
the probe back and forth over a calibration reference reflector, During this
calibration, software automatically adjusts gain to the prescribed amplitude of
80% with +5% tolerance limit for all the angles. The horizontal scale is the
Virtual Probe Aperture (VPA) which defines the group of elements i.e. focal law
that is sequenced in the scan.
Note :- Section wise sensitivity calibration shall be avoided. However, if distortion of images
between two sections is not evident after calibration, this is acceptable.
9.4 Time corrected Gain (TCG)calibration:

Time corrected gain calibration is used to compensate for attenuation in the material w.r.to various
sound paths used during calibration and examination. F notch shall be used for TCG calibration.
Before starting calibration ensure that the notch is properly cleaned with suitable cleaning agent.
TCG calibration shall be done for each half skip interval stating from ½ skip to 2 ½ skip.
Place the phased array probe perpendicular to the notch axis and pick the signal from the F-
notch at half skip distance and adjust the gain to obtain at least 20% amplitude in the highest
angle. Move the phased array probe forward and backward and pick up the amplitude for all the
focal laws / angles. Press calibrate and the machine will set all the focal laws / angles to 80%
Procedure
Date 14-03-2020
±5% (However it is recommended to achieve ±2.5% tolerance). Move the probe on F- notch
and repeat the same procedure to obtain the points up to 2 ½ skip . Once all the points are added ,
TCG can be accepted. TCG calibration has to be carried out for all scan plans in a multi group
option while using phased array probe. The calibration setup file shall be stored in the MX-2
System with appropriate name.
Re-check all the points to ensure that all angles at all skips are at 80% and within ±5%
tolerance
Calibration check
The calibration shall becheck is required in below cases:
1. Before start the PAUT Examination
2. When the operator changes
3. Change in thickness (±15% of calibrated thickness)
4. Every 4 Hours
5. After repair of the equipment
6. After completion the examination
In case of variations in wedge delay / TCG beyond acceptance limit, all calibrations (wedge delay,
sensitivity & TCG) shall be repeated.
9 SURFACE PREPARATION
9.1 Contact surfaces
The finished contact surface should be free from spatter and any roughness that could
interfere with free movement of the scanning unit or the transmission of ultrasonic
vibrations. Surface roughness shall be < 3.2 microns as per AMS 2632
10Transfer Loss Correction MEASUREMENT

TLC shall be measured by conventional method and the same shall be added in PAUT
during scanning.
Procedure
Date 14-03-2020
11SCANNING
Scan area ? Overalap?

Scanning speed ?
Add 10.4dB after drawing TCG ?

directions of scan?
Swivelling of +/-15 º ?
Scaning dB = TCG dB + TLC + 10.4
Gate shall be set to 80% Alarm shall be set t
12 SIGNAL TO NOISE RATIO

At scanning dB (TCG + TLC + 10.4), Signal to noise ratio of minimum 6dB is required
for angles 39 to 52 º (M250 refracted angle). For angle 53º and above, S/N ratio shall not be
the criteria for rejection of a plate. However, any distinct indication, other than general noise
shall be considered for analysis as per specification.
Note: 1) 39º in M250 is equivalent to 45º in mild steel
2) 52º in M250 is equivalent to 60º in mild steel
13 DATA RECORDING
Only certified Level II UT personal along with knowledge of phased array shall evaluate the
results of ultrasonic examinations for acceptance.
Data shall be recorded in the unprocessed form with no thresholding.
Since scanning is manual, 100% data recording is not possible. However, in case of any
recordable or rejetcable indications are observed, the same shall be saved in either encoded
mode or time scan mode. However saving shall be done after getting the maximum amplitude
irrespective of any angle.
Procedure
Date 14-03-2020
If defect length, width & height is required then encoder shall be used for data recording
along the defective area. During this data recording , it shall be ensured that probe is oriented in
a direction in which maximum amplitude of the defect is obtained.
The following Defect parameters shall be reported
Parameter Source Technique

Location To be measured
Depth From A Scan Manual PAUT
Amplitude From A Scan
Length * From C Scan
Width * From C Scan Encoded PAUT
Height * From S Scan
* if required only
12 FLAW ACCEPTANCE CRITERIA

The Acceptance/ rejection criteria for angle beam scanning of MDN 250 Plates (M22, P22,)
shall be as per AMS 2632B and VSSC recommendations as below
 60 % of F -Notch for single defects

 30 % of F-Notch for multiple & Linear defects
13 DATA ANALYSIS
Definition for single / multiple / linear indications ?
14.1 Single indications

 Ensure TLC + 4.4 dB is added to TCG dB
 At this dB any single indications exceeding 80% of FSH (TCG) is rejectable.
 At this dB any single indications exceeding 40% of FSH is recordable.
14.2 Mutiple indications

Procedure
Date 14-03-2020

 At this dB any multiple indications exceeding 80% of FSH (TCG) is rejectable.
 At this dB any multiple indications exceeding 40% of FSH is recordable.
14.3 Linear indications

 At this dB any linear indications (Length > 6.4mm) exceeding 80% of FSH (TCG) is
rejectable.
 At this dB any Linear indications (Length > 6.4mm) exceeding 40% of FSH is
recordable.
However the above indications shall be cross verified with the reference block to take
care of the variations occurring due to tolerances set during calibration.
13.1.2 check for the backwall loss by adjusting gate to only backwall
13.1.3 rescan if backwall loss is visible in C-scan
13.1.4 Put the gate over the range ( avoiding the back wall)
13.1.5 any defect amplitude measurement shall be done manually with reference block
13.1.6 save the maximum amplitude signal (These 5 points are applicable for normal
beam auto scan only. So these points need be mentioned in manual angle beam
PAUT)
.
13.2 Alternatively, other techniques or NDE methods may be used to classify an indication as
geometric (e.g., alternative beam angles)..
TABLE-3
TABLE OF ESSENTIAL VARIABLES FOR QUALIFICTION OF PROCEDURE
Procedure
Date 14-03-2020
Sr. Requirements Essential Non-Essential
No. Variable Variables
Material Configuration to be examined, including thickness
1 X
dimensions and base material product form (pipe, plate etc)
2 The surface from which the examination shall be performed X
3 Instrument setting and scanning data X
Technique(s) ( Straight beam, angle beam, contact, and / or
4 X
immersion )
5 Angle (s) and mode(s) of wave propagation in the material X
Search unit type (s), frequency (ies), and element size (s) /
6 X
shape (s)
Special unit search units, wedges, shoes or saddles, when
7 X
used
8 Ultrasonic instrument (s) X
9 Instrument Software X
10 Calibration ( Calibration block (s) and technique (s) X
11 Direction, Selection and extent of scanning X
12 Scanning (manual vs. automatic) X
13 Scanning Speed X
14 Method for discriminating geometric from flaw indications X
15 Method for sizing indications ( length & Height ) X
16 Computer enhanced data acquisition, when used X
17 Scan overlap (decrease only) X
18 Personnel Qualification Requirements X
19 Surface Condition (Examination surface, Calibration block) X
20 Couplant : Brand name or type X
Automatic alarm and or recording equipment, when
21 X
applicable
Records, including minimum calibration data to be recorded
21 X
(eg.Instrument setting)
22 Personnel Performance requirements (when required) X
Search unit mechanical fixturing device(manufacturer and
23 X
model)
24 Scanner and adhering and guiding mechanism X
14 SCAN PLAN CONFIGURATION
 See attachment –I for Scan Plan

 See attachment –II for SDH calibration Block
Procedure
Date 14-03-2020
 See attachment -III for F-Notch DAC Block
 See attachment IV- Normal UT report of Defective plate (K2593G)
15 REPORTING
Sample PAUT report – as per ATTACHMENT 3 (please attach a sample report)
Recordable indications to be added in the report by using add indication option.
For each ultrasonic examination,

 A CD/DVD containing all the raw data and calibration scans shall be furnished to
the proponent with final report and the same shall be retained for the duration of the
contract.
ATTCHMENT 2- PAUT CALIBRATION BLOCK METROLOGY REPORT ( SDH-0.5mm x 6.4 SDH )

Procedure
Date 14-03-2020
ATTCHMENT 3- PAUT DAC CALIBRATION BLOCK METROLOGY REPORT ( F-Notch )

Procedure
Date 14-03-2020
Procedure
Date 14-03-2020
ATTCHMENT 4- Sample defect location map

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Procedure

MISHRA DHATU NIGAM LIMITED

STANDARD PROCEDURE FOR PHASED ARRAY

PREPARED BY REVIEWED BY APPROVED BY

REVISION CONTROL SHEET

Rev. No. Issue Date Section Changes Made

00 14-03-2020 NA First Issue

S.No DESCRIPTION PAGE NO.

5.0 PERSONNEL QUALIFICATION REQUIREMENTS

6.0 BASIC BLOCK

4. DEFINITIONS AND ABBREVIATIONS

Element: An individual crystal (piezo-composite material) within a phased array probe.

Encoded: Using an encoder.

Encoding: Using an encoder.

FSH: Full screen height.

Phased Array Probe: A probe made up of several piezoelectric elements individually

5. PERSONNEL QUALIFICATION REQUIREMENTS

7. EQUIPMENT AND ACCESSORIES

16 element, Linear array, 5MHz, 0.6mm pitch Probe (5L16-A10) shall be

Angle : 39 to 57 º (equivalent to 45 to 70 º in mild steel) with angle step as

Aperture : 16 element with pitch 0.6mm

First element: 1 Last Element: 16

Individual angle PRF (I) : 200 Hz min

Overall sectorial scan PRF : I x no of angles min

9. Phased Array system calibration:

Figure2: Velocity Calibration for S-scans

9.2 Wedge delay calibration:

Figure 3: wedge delay calibration

8.3 Sensitivity calibration (Angle Corrected Gain):

Figure4: Sensitivity Calibration.

9.4 Time corrected Gain (TCG)calibration:

10Transfer Loss Correction MEASUREMENT

Scan area ? Overalap?

Add 10.4dB after drawing TCG ?

12 SIGNAL TO NOISE RATIO

Note: 1) 39º in M250 is equivalent to 45º in mild steel

2) 52º in M250 is equivalent to 60º in mild steel

Data shall be recorded in the unprocessed form with no thresholding.

The following Defect parameters shall be reported

Parameter Source Technique

12 FLAW ACCEPTANCE CRITERIA

 60 % of F -Notch for single defects

Definition for single / multiple / linear indications ?

14.1 Single indications

14.2 Mutiple indications

 Ensure TLC + 10.4 dB is added to TCG dB

14.3 Linear indications

14 SCAN PLAN CONFIGURATION

 See attachment –I for Scan Plan

For each ultrasonic examination,

ATTCHMENT 2- PAUT CALIBRATION BLOCK METROLOGY REPORT ( SDH-0.5mm x 6.4 SDH )

ATTCHMENT 3- PAUT DAC CALIBRATION BLOCK METROLOGY REPORT ( F-Notch )

ATTCHMENT 4- Sample defect location map

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