Build the block:

Before a good calibration block is made, the fabricator will need a drawing
that accurately describes all the dimensions that will be required to machine
the targets in the block. The person designing the technique must have, not
only, knowledge of the ultrasonic requirements (zones, client special target
requests, sensitivities required, etc.), but also some knowledge of how the
machinist must prepare the piece for machining. The initial design of the
calibration block is usually done prior to the material being available for
machining. The design then uses the nominal wall thickness provided by the
client However, there is usually a wall thickness tolerance in pipe that can be
upwards of 10% of the nominal, This can have a very significant effect on the
target-hole placement, E.g., if a pipe was nominally 20mm thick and the
sample provided from the client was actually 19mm thick, the spacing of the
targets will not conform to the drawings, if the machinist uses the design
dimensions for the 20mm wall thickness. It is critical that, after the sample is
received for the fabrication of the calibration blocks, the AUT company must
check the actual thickness and make the necessary changes to the drawing
that will be used by the machinist.

Initially, calibration blocks were cut roughly to shape, using band saws; then the overall
dimensions refined using milling machines. The "blank" was then mounted in a jig and the targets
made using end-mill cutters. More recently, some machine shops have fabricated the targets using
Electric Discharge Machining (EDM), also referred to as "spark erosion" machining. Depending
on the machine shop capabilities, they might use a combination of the two methods for preparing
the targets The operator responsible for designing the calibration block should be aware of the
method that will be used, as it might affect the shape that is used for the "blank". Moreover, the
machinist should be made aware of the nature of the pipe being used.

Most shops using end mill cutters will remove a portion of the pipe; and having cut the outer
dimensions to that specified on the drawing, will then fix the blank into a jig. But the handling of a
section cut from a pipe presents a few challenges. Pipe made from plate can be roll formed with a
long, Double Submerged Arc Welded (DSAW) seam or it can be made by a spiral rolling system,
where the plate is rolled in a twisting fashion and the edges welded together. After the pipe is
formed there is a residual stress in the steel and when a section of the pipe is removed, it tries to
recover its original flat shape. The distortion that results will be different for long or spiral seamed
pipe. Themachinist must be prepared to correct for the distortion with a suitably made jig, If not
done, the measurements made on the drawing, where "flat conditions of a pipe surface are
assumed, will not exist on the actual blank and significant errors in angles and depths can result.
In most cases, the calibration block cannot be made from a complete pipe cylinder. The scanning
head cannot, however, move over the Zed block alone, because the probes are unsupported on the
cut-out regions and there is no room to mount the guide-band on the unsupported Zed block. This
requires that the calibration block be mounted in a section of pipe with an opening, matching the
dimensions of the block. The common term developed for this mounting section of pipe is the
"dummy”. This need not be the same material or thickness as the calibration block; it needs only
to be the same diameter and have dimensions suitable to hold the calibration block.
Figure 2-10 shows a dummy, with the calibration block mounted on the side of a
truck, with the scanning band in place and the scanner mounted on the block, Figure
5-5 shows a top view of a Zed shaped calibration block fixed in the dummy. Typically
the block is tack welded into place and the edges where the probes move from the
dummy to the calibration block are filled with epoxies that allow a smooth transition
of the probes from one surface to the next. This ensures that the probe edges do not
get caught on the transition edges thereby causing the probes to flip or stutter. A white
line is overlaid on the image in Figure 5-5 to indicate the approximate outline of the
calibration block Markings along the upper edge of the image are typical of those
used by the operators to assist in locating the targets so they can position the probes in
front of the appropriate target when optimizing signals during static calibrations.
Some of the targets are clearly visible on the outer surface. Indicated are the TOFD,
OD and transverse notches.
Not clearly seen on the image in Figure 5-5, are some of the FBH targets. The targets
should have a protective plug at their entrance, typically epoxy or silicon sealants, that
are secure but removable. These are used to prevent water ingress. Water presents two
problems in calibration blocks. If it collects in the hole, surface tension will prevent it
from being easily removed. Corrosion will eventually make the flat-bottom surface
irregular thereby reducing the reflectivity of the surface. Aswell, water on the flat-
bottom surface means that the high acoustic impedance difference, that was present at
the time of assessment in the lab, when no water was present, is reduced. Typically a
steel air interface signal is reduced by about 2dB when water replaces the air. Both
conditions result in the operator having to add gain to the system to maintain an 80%
response for the acceptable calibration for reference level.
The same treatment cannot be made for the shallow notches. If epoxy or silicon
sealants make a good contact on the intended reflecting surface these targets will also
have reduced acoustic impedance as sound pressure is coupled into the plugging
material. The shallow notches should therefore be left open, but periodically checked
during a project, to ensure that corrosion is not allowed to form. Surface access to the
notches is relatively good, so a small toothbrush and some toothpaste (weak abrasive)
can be used to maintain a clean reflecting surface. For long projects the FBHs can be
similarly maintained. We noted above that the plugging materials should be
removable. FBH maintenance would involve removing the plugs and using a small
flat-ended dowel that fits inside the hole. A small amount of weak abrasive (like
toothpaste), on the end of the dowel, can be used as the dowel is spun between the
fingers, while gently pressing the dowel into the holes. The holes would then be
rinsed, dried and re-plugged.
Calibration and verification
Calibration
The reference plate is used for initial calibration and for regular checks on proper
equipment settings and probe condition. The plate is scanned at full inspection speed
to create conditions identical to those during weld inspection.

Green indications on the analog record obtained from the reference reflectors indicate
that the echo amplitude is within tight limits. Amplitudes obtained from the reference
reflectors should be within set limits, typically ± 2 dB. Records are stored along with
the corresponding calibration tables, which are generated automatically.

Amplitudes of artificial defects in adjacent zones should differ preferably 12 dB. This
zone resolution to be achieved by proper beam characteristics (angle and beam
width).
Overall sensitivity of the ultrasonic system should remain within specified tight
tolerance limits. Traditionally, this calibration consistency is monitored by frequent
mandatory checks. Results are stored and presented in a graphical presentation which
is part of the report to the client. In the future, one more feature might be added to
RTD’s AUT equipment, the so called “Automatic Calibration Check” or ACC.