Doc. MNS/UT/O1 ULTRASONIC TESTING PROCEDURE Revision ° FOR WELDS Date Wlesiz0 8 Page dof i0 MASTER NDT SOLUTIONS ULTRASONIC TESTING PROCEDURE FOR WELD DOCUMENT NO. : MNS/UT/01, Rev. 0 DATE OF ISSUE | REVISION DETAILS OF REVISION FIRST ISSUE | ceed Cs Ravi TALEKAR NDT LEVEL II (UT,MT,PT,VT) AMDT LEVEL ps SS aa % CRAVE R TALEKAR) e PALEKAR) SPENT UTDoe. MNS/UT/O4 ULTRASONIC TESTING PROCEDURE Revision ° FOR WELDS Date Page 20f 10 MASTER NDT SOLUTIONS 4.0 SCOPE 1.1 This document describes the application of the non-destructive testing method of Ultrasonic testing by the pulse-echo, direct contact technique. 1.2 Thickness ranges from 10 mm to 200mm. Materials shall be carbon steels and shall be used for ultrasonic examination of welds. 1.3 Weld types and configurations to be examined include groove butt welds (circumferential and longitudinal) and other full penetration welds (such as; nozzle to shell welds) 2.0 REFERENCE DOCUMENTS Applicable edition & addenda of the following: 2.1 ASME Section V Article 4, 2.2 ASME Section Vill Div.1 UW 53 & Appendix 12. 2.3 SNT-TC-1A 3.0 PERSONNEL QUALIFICATION 3.1 Personnel involved in conducting the test, recording results and evaluating the same against applicable acceptance standards shall be certified to at least Level Il_as per MNS Written Practice. 4.0 EQUIPMENT 4.1 Pulse Echo type Ultrasonic instrument shall be used. Instrument shall be capable of operation at frequencies over the range of at least 1 to 5 MHz. 4.2 Ultrasonic instrument shall be equipped with a stepped gain control in units of 2.0 dB or less. 4.3. Reject control shall be in off position for all examination and calibration. 4.4 Damping control, Automatic alarm & recording equipment, Computer enhanced data acquisition, Electronic distance - amplitude correction shall not be used. * 4.8 Only. calib nnn flaw detector shall be used for testing, 4.6. Following’Ultrasonic Flaw Detector - Portable, Battery-operated, Pulse-Echo type with A-scan presentation is acceptableDoc. MNs/uT/o2 | ULTRASONIC TESTING PROCEDURE Revision ° FOR WELDS Date Page Zof10 | MASTER NDT SOLUTIONS: dee 5.0 51 5.2 5.3 6.0 61 62 8.3 7.0 7A 8.0 8.1 Make: Modsonic Model: Einstein II - TFT or Einstein DGS Other brands and models may be used provided that their operating characteristics are satisfactorily demonstrated to be at least equal to or better than those of the models listed above. SEARCH UNITS: (FREQUENCY, ANGLE, SIZE) ‘Search units with nominal frequency of 1 MHz to 5 MHz shall be used unjess variables such as production material grain structure require use of other frequencies to assure adequate penetration or better resolution. Both Angle Beam (Shear Waves) and Straight beam (Longitudinal Waves of either single crystal or dual crystal shall be used as applicable. For Weld Metal Overlay Cladding , Dual element, straight beam search units using an angled pitch-catch technique shall be used. The included angle between the search Unit's elements shall be such that the effective focal spot distance is centred in the area of interest. 48 and 60 / 70 degree search units (Shear waves) shall be used depending upon joint configuration, such that beam of Ultrasound impinges on major portion of bevel angle perpendicularly as far as practicable. ‘Angle beam Search unit size of 1/4 inch to 1.0 inch either rectangular or square shall be used. Straight beam search unit size shalll be 1.0-inch square. Special search units, wedges, Shoes or saddles shall not be used COUPLANT The couplant shall be water-soluble cellulose paste. Other couplants which may be used include glycerine, light diesel oil and light grease Couplant used on Nickel base alloys shall not contain more than 250 ppm of sulphur. Couplants used on Austenitic Stainless steels or Titanium shall not contain more than 250ppm of halides (chloride + fluorides) SURFACE PREPARATION The test surface and an area covering the entire scanning area on either side of the test surface shall be free of dirt, grease, rust, lint, weld spatter and other extraneous matter which may interfere with the effectiveness of the test. CALIBRATION BLOCKS General Requirements,Doe. MNS/UT/OL ULTRASONIC TESTING PROCEDURE Revision ° FOR WELDS Date Page 4of 10 MASTER NDT SOLUTIONS 9.0 9.4 8.1.1. Known reflectors like side-drilled holes (SDH), flat bottom holes (FBH), Notches etc, shall be used to establish primary reference responses. 8.1.2. Material: The material from which block is fabricated shall be of the same product form, and material specification or equivalent P- No. Grouping as one of the materials being examined. 8.1.3 For the purpose of Ultrasonic examination P- Nos. 1,3,4,5A through 5C and 16A through 15C materials are considered equivalent. 8.1.4 Quality: Prior to fabrication, the block material shall be completely examined with straight beam search unit. Areas that containing an indication exceeding back wall refiection shall be excluded from the beam paths required to reach the various calibration reflectors, 8.1.6 Heat Treatment: Calibration block shall receive at least the minimum tempering treatment required by the material specification for the type and grade. If the calibration block contains welds other than cladding, and the component weld at the time of examination has been heat treated, the block shall receive the same heat treatment. 8.1.7 Surface Finish: Finish on the scanning surfaces of block shall be representative of scanning surface finishes on the component to be scanned. 8.1.8 Block Curvature: Block of essentially same curvature or alternatively flat basic calibration block may be used, BASIC CALIBRATION BLOCK Basic calibration blocks for piping, cladding & welds with flat surfaces & curved surfaces, shall be used as per Annexure A of this procedure. 10.0 CALIBRATION 10.1 General Calibration Requirements: 10.1.1 Calibration Surface: Calibration shall be performed from the surface corresponding to the surface of component from which examination will be performed, 10.1.2 Couplant ‘The same Couplant to be used during examination shall be used for calibration. 10.1.3 Instrument Controls :Any control, which affects instrument linearity (e.g Filter, Reject,clipping) shall be in the same position for calibration, Calibration checks, instrument linearity check, and examination 10.1.4 Temperature: Temperature differential between the calibration block and examination surface shall be within 25° F (14° C)Doc. MNS/UT/O1 ULTRASONIC TESTING PROCEDURE Revision ° FOR WELDS Date | Page| Sof 40 MASTER NDT SOLUTIONS 11.0 EXAMINATION 11.1 General Examination Requirements. 11.1.1 Examination Coverage: The volume to be scanned shall be examined by moving the search unit over the scanning surface so as to scan the entire examination volume for each required search unit. Each pass of search unit shall overlap a minimum of 10% of the active transducer dimension perpendicular to the direction of scanning. 11.1.2 Pulse Repetition Rate: The pulse repetition rate shall be small enough to assure that a signal from a reflector located at maximum distance in the examination volume will arrive back at the search unit before the next pulse is placed on the transducer. Above system is in built in the instrument. 11.1.3 Rate of Search Unit Movement: The rate of search unit (scanning speed) shall not exceed Ginch/second (150 mm per second) unless 11.1.4 Scanning Sensitivity Level a) Distance Amplitude Technique : The scanning sensitivity level shall be set at a minimum of 6 dB higher than the reference level gain setting (DAC). b) Surface Preparation: When the base material or weld surface interferes with examination, the base material or weld shall be prepared as needed to permit the examination. 14.1.5 Scanning Technique by angle beam. a) Manual scanning shall be performed. b) Before performing angle beam examinations, a straight beam ‘examination shall be performed on the volume of base material through which angle beam will travel to locate any reflectors that can limit the ability of angle beam to examine the weld volume. c) Weld joints shall be scanned with an angle beam search unit in both parallel and transverse direction (4 scans) to the weld axis, d) When discontinuity is observed sizing shall be done by 6 dB drop method 11.1.6 Angle Beam technique:Doe MNS/UT/OL ULTRASONIC TESTING PROCEDURE Revision ° FOR WELDS Date Page 6 of 10 MASTER NDT SOLUTIONS 12.0 12.4 a) Beam Angle: The Search unit beam angle selected shall be appropriate for the configuration being examined and shall be capable of detecting the calibration reflectors, over the required beam angle path. b) Reflector parallel to the weld Seam: The angle beam shall be directed at approximate right angle to the weld axis from both sides of the weld (ie. from two directions ) on the same surface when possible. The Search unit shall be manipulated so that the Ultrasonic sound energy passes through required volume of weld and adjacent base material. ©) Reflector Transverse to the weld Seam: (1) Scanning With Weld Reinforcement. If the weld cap is not machined or ground flat, the examination shall be performed from the base material on both sides of the weld cap. While scanning parallel to the weld axis, the angle beam shall be directed from 0 deg to 60 deg with respect to the weld axis in both axial directions, with the angle beam passing through the required examination volume. (2) Scanning Without Weld Reinforcement. If the weld cap is machined or ground flat, the examination shall be performed on the weld. While scanning, the angle beam shall be directed essentially Parallel to the weld axis in both axial directions. The search unit shall be manipulated so that the angle beam passes through the required examination volume d) Single-Sided Access Welds. Welds that cannot be fully examined from two directions per 13.1.6 b using the angle beam technique shall also be examined to the maximum extent possible with a straight beam technique applied from an adjacent base material surface. This may be applicable to vessel corner and tee joints, nozzle and manway neck to shell or head joints, pipe to fittings, or branch connections. The area(s) of single-sided access ang, if applicable, the extent of the limit coverage shall be noted in the examination report ) Inaccessible welds: The weld that cannot be examined from at least one side ( Edge ) using angle beam technique shall be noted in the examination report. EVALUATION General: Geometric Indications: geometric indications like surface conditions, Segregates in HAZ, Weld root, attachments which act as reflectors shall be recorded with respect to Identification, maximum amplitude, Location.Doe. MNS/UT/o1 | ULTRASONIC TESTING PROCEDURE Revision ° FOR WELDS Date Page | 70f 40 MASTER NDT SOLUTIONS 12.2 Evaluation Level: Distance Amplitude Technique: Imperfections which produce a response greater than 20% of the reference level shall be investigated to the extent that the operator can determine the shape, identity and location of all such imperfections. 13.0 ACCEPTANCE CRITERIA: Following acceptance criteria shall be applicable for ultrasonic examination of welds & clads as per ASME Sec.|, Sec. Vill Div. 1 a) Indications characterized as Cracks, Lack of fusion, Incomplete penetration are un acceptable regardless of length. b) Other imperfections are Unacceptable if the indication exceeds the reference level amplitude and have length which exceeds 1) 6 mm for tup to % in. (19 mm) 2) 1/3 tto t from % in. To 2% in. (19 mm to 57 mm) 3) 3/4 in. (19 mm) for t over 2% (57 mm), ‘Where tis thickness of weld excluding any allowable reinforcement. For a butt weld joining two members having different thicknesses at the weld, tis 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. 14.0 POST EXAMINATION CLEANING 14.1. Post examination cleaning shall be done as soon as practical after evaluation and documentation using a process that does not adversely affect the part.. 15.0 DOCUMENTATION 15.1. Recording Indications 16.1. 1Non Rejectable Indications : Non Rejectable indications producing response greater than 50% of primary reference level shall be recorded 15.1.2 Rejectable Indications : Rejectable indications shall be recorded with respect to type of indication ( Crack, Slag, lack of fusion ), Location and length.Doc. MNS/UT/O4 ULTRASONIC TESTING PROCEDURE Revision ° FOR WELDS Date Page 8 of 10 MASTER NDT SOLUTIONS 15.2 Examination Records 16.2.1 Ultrasonic Examination Report shall be prepared by at least NDE Level II and shall contain information as follows a) Procedure Number and Revision. b) Ultrasonic instrument identification and manufacturer's Sr. No ©) Search Unit Identification (Including manufactures Sr. No frequency and size. d) Beam angle(s) used. e) Couplant used, brand name or type. f) Special equipments when used. 9) Search unit cable (s) used, type and length. h) Calibration Block Identification. i) Instrument reference gain and if used, damping and reject setting, i) Calibration data ( Including reference reflector(s), indication amplitude(s) and distance reading(s) ) k) Identification and location of weld or Volume scanned. 1) Surfaces) from which examination was conducted, including surface condition m) Record of rejectable indications detected or area cleared. n) Area of restricted access or inaccessible welds. ©) Examination person Identity and Qualification Level. p) Date and time of Examination performedDoc. MNS/UT/O1 ULTRASONIC TESTING PROCEDURE Revision ° FOR WELDS Date Page 4 of 10 MASTER NDT SOLUTIONS ANNEXURE A CALIBRATION BLOCKS 1.0 Non piping calibration block: 1.1 Materials having curvature more than 20° (500 mm) or more Block of * essentially same curvature or alternatively flat basic calibration block ( Fig. 1) may be used Bint 1150 sim) Dm ‘ip wiath Length Cladding if (present) Figure 4 * Minimum dimension. GENERAL NOTES: Mr Minimum dimensions (13mm) In (150 mom) “Thickness (a) Holes shall be drilled and reamed 1.5 in. (38 mm) deep minimum, essentially parallel to the examination surface (b) For components equal to or less than 20 in. (500 mm) in diameter, calibration block diameter shall meet the requirements of 1.2. ‘Two sets of calibration reflectors (holes, notches) oriented 90 deg from each other shall be used. Alternatively, two curved calibration blocks may be used (c) The tolerance for hole diameter shall be + 12 in. (0.8 mm). The tolerance for hole location through the calibration block thickness (i,e.distance from the examination surface) shall be + 18 in. (3 mm).Doc. MNS/UT/O1 ULTRASONIC TESTING PROCEDURE Revision ° FOR WELDS Date Page 10 of 10 MASTER NDT SOLUTIONS (d) For blocks less than 34 in. (19 mm) in thickness, only the 1/2T side-drilled hole and surface notches are required. (e) All holes may be located on the same face (side) of the calibration block, provided care is exercised to locate all the reflectors (holes, notches) to prevent one reflector from affecting the indication from another reflector during calibration. Sufficient number of holes shall be provided for both angle and straight beam calibrations at the V4T, 12T, and ¥4T depths. (f) When cladding is present, notch depth on the cladding side of the block shall be increased by the cladding thickness, CT (i.e. 1.6% T + CT minimum to 2.2% T + CT maximum) (g) Maximum notch width is not critical. Notches may be made by EDM or with end mills up to 4 in. (6.4 mm) in diameter. (h) Weld thickness, t, is the nominal material thickness for welds without reinforcement or, for welds with reinforcement, the nominal material thickness plus the estimated weld reinforcement not to exceed the maximum permitted by the referencing Code Section. When two or more base material thicknesses are involved, the calibration block thickness, T, shall be determined by the average thickness of the weld; alternatively, a calibration block based on the greater base material thickness may be used provided the reference reflector size is based upon the average weld thickness. NOTE. (1) For each increase in weld thickness of 2 in. (50 mm) or fraction thereof over 4 in. (100 mm), the hole diameter shall increase 16 in. (1.5 mm). TABLE -1 Basic Calibration Weld Thickness (t) Hole Diameter Block Thickness (T) aD Up to 1” (25) or Less %(19) ort 332 (25) Over 7" through 2° 1% (38) ort 118" (3) Over 2" through 4” 3°(75) ort 3/16" (5) \_Over 4" (100) through 6” t+ 1 (25) Note (1) above 1.2Materials having with diameters 20" (500 mm) or less a curved block shall be used. A single curved basic calibration block may be used for the ‘examinations in the range 0.9 times to 1.5 times of the basic calibration block diameter.