PROCEDURE FOR ULTRASONIC EXAMINATION OF WELDE JOINTS

PROCEDURE No.: ASIPL/UT-PROCEDURE/2023/02

1 20/11/2023 -- 0 13 Prepared By Approved By

Sr. No. Date Details Revision Pages

Tushar Patel
1.0 SCOPE
1.1. This procedure covers the requirements for Ultrasonic Examination of Welded joints,
Heat affected zone, base metal and other pressure parts of Pressure Vessels by pulse
echo contact method. This procedure shall be used for the weld joints and materials of
pressure vessels which configuration, thickness and other Ultrasonic Testing variables
are described as per the Annexure 1 to 3.
1.2. Ultrasonic test of all Pressure containing welds shall be performed from OD of the
vessel at least 24 hours after completion of welding and before PWHT (Note: for
purposes of the UT exam, piping welds are excluded; i.e., the welds to be examined are
the shell longitudinal seams, shell circumferential seams and nozzle-to-head welds) .
1.3. Reference:
1.3.1. ASME Sec. V – Non Destructive Examination (Ed.2015)
1.3.2. ASME Sec. VIII Div. 1 – Rules for construction of Pressure Vessel (Ed.2015)
1.3.3.ASME Sec. IX – Welding and Brazing Qualifications (Ed.2015)

2.0 Qualifications of Personnel

2.1 The certified NDT Level II (UT) and or NDT Level III (UT) as per written practice, Latest
revision which is in line with SNT – TC- 1A shall conduct ultrasonic testing.
2.2 Interpretation and Evaluation shall be carried out by NDT Level II (UT) or NDT Level III
(UT) as per written practice, Latest revision which is in line with SNT – TC- 1A shall
conduct ultrasonic testing.
2.3 All new technique shall be developed under the supervision of NDT Level-III.

3.0 Application

Main objective of this procedure is to describe different techniques for location and
evaluation of defects within the weld, HAZ of weld and adjacent parent material by using
normal and angle beam probes. Examination shall be conducted from one or both sides of
weld surfaces or from combination of surfaces so that full volume of weld is covered. Where
geometry of the assembly does not allow examination from both sides any one of the
alternatives as mentioned below shall be used.
3.1 Combination of angle beam and straight beam.
3.2 Straight beam in two directions at 90 deg to each other.
3.3 Angle beam from one side of the weld using two different beam angles.
3.4 Special wedges, shoes or saddles may be used as and when needed depending on the
scanning surface/curvature of scanning surface and scanning techniques used. Post
examination cleaning of the test surface shall be carried out if this requirement is
mentioned in customer’s specification.
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4.0 Equipment

4.1Apparatus
Following models of UFD and other makes shall be used.
MODSONIC Einstein-2 TFT
MODSONIC Einstein-2 PLUS
Other equivalent apparatus can be used after approval by NDT Level – III.

For digital UFD shall be equipped with a stepped gain control in units of 2.0 dB or less.
Screen height linearity and amplitude control linearity shall be within 5% and 20% of FSH
respectively.
Calibration interval shall not be exceed three month for analog type instruments and one
year for digital type instruments, or prior to first use thereafter.
4.2 Probes
Frequency and size of the probe shall be selected depending upon thickness and acoustic
properties of the material to be tested as described in Annexure 1 to 3. Angle shall be
selected in such away that it hits the major reflecting surface approximately in right
angles.
Probe having refracted beam angle of 45° /60° / 70° with frequency ranging from 1 MHz
to 5 MHz for welds and longitudinal wave straight beam probes with frequency ranging
from 1 MHz to 5 MHz shall be used.
4.3 Couplant
Couplant shall be Cellulose Paste, grease, oil, water or any other similar material which
permits satisfactory transmission of ultrasonic waves. Same couplant shall be used for
calibration as well as for testing.
4.4 Basic Calibration Block
4.4.1 The standard calibration blocks e.g. IIW V 1 and V2 blocks shall be used for sweep
range calibration.
4.4.2 The basic calibration block and the reference reflectors shall be as shown in figure T-
434.2.1 for non-piping, Fig. T-434.3 for piping and Fig. T -434.5.1 for nozzles side
weld fusion zone of Article 4 of ASME Sec V and general notes.
4.4.3 For contact examination, the temperature differential between the calibration block
and examination surfaces shall be within 25°F (14°C).
For piping calibration block thickness ‘T’ shall be + 25% of the nominal thickness of the
component to be examined.

4.4.4 Nozzle Side Weld Fusion Zone and / or Adjacent Nozzle Parent Metal Calibration
Blocks:
Configuration: The calibration block configuration shall be as shown in Fig. T-434.5.1.
The block size and reflector locations shall be adequate to perform calibrations to cover
the nozzle side weld fusion zone and/or the adjacent nozzle parent metal. If the internal
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 surface of the nozzle is clad before the examination, the ID surface of the calibration
block shall be clad.

(b) Block Thickness. The calibration block shall be the maximum thickness of the nozzle
wall adjacent to the nozzle weld plus 3⁄4 in. (19 mm).

5.0 Test Surface Preparation

5.1Base Metal
The base metal on each side of weld shall be free of weld spatters, surface irregularities or
foreign matters that might interfere with the examination. (Minimum 100 mm or 3 times
of Thickness whichever is greater on either side of weld joint.) This base metal surface
preparation shall be carried out with minor grinding or wire brushing to the satisfaction of
NDT Inspector.
5.2Weld Metal
Where the weld surface interferes with the examination, the weld shall be prepared as
needed to permit the examination.

6.0 Calibration
6.1 Frequency
The nominal frequency shall be 2 MHz to 4 MHz unless variables such as material grain
structure require the use of other frequencies to ensure adequate penetration or better
resolution.
Refer attached Annexure 1 to 3 for specific technique and detailed scan plans for
various thickness Ranges for Straight beam and Angle Beam method.

6.2 Angle Beam Method

6.2.1 Beam Angle
An angle shall be selected as appropriate for the configuration being examined.
Refer attached Annexure 1 to 3 for specific detail.
6.2.2 Distance Amplitude Correction Curve (DAC)
a. Position the search unit for maximum response from the ¼ T hole on reference
calibration block.
b. Adjust the sensitivity control to provide and 80% of FSH echo form the hole. This
is a primary reference level. Mark the peak of the indication on the screen. Do
not change dB after this setting during drawing DAC.
c. Position the search unit for maximum response from ½ T hole and mark the peak
of the indication on the screen.
d. Position the search unit for maximum response from the ¾ T hole and mark the
peak of the indication on the screen.
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 e. Position the search unit for maximum response from ¾ T hole after half skip and
mark the peak of the indication on the screen.
f. Connect the screen marks to provide a distance amplitude curve.

6.2.3 Calibration correction for Planer reflector Perpendicular to the Examination

surface at or near the opposite surface position the search unit for maximum
amplitude from the square notch on the opposite surface. Mark the peak of
the indication on the screen.

6.3 Straight Beam Method

6.3.1 Distance Amplitude correction Curve (DAC)
a. Position for maximum response from the ¼ T hole.
b. Adjust the sensitivity control to provide an 80% FSH echo from the hole. This is a
primary reference level. Mark the peak on the screen. Do not change dB after
this setting during drawing DAC.
c. Position the search unit for maximum response from ½ T hole and mark the peak
on the screen.
d. Position the search unit for maximum response from ¾ T hole and mark the peak
on the screen.
e. Connect the screen marks and extend through the thickness to provide the
distance amplitude curve.
6.3.2 Recalibration
System Changes: When any part of the examination system is changed, a calibration
check shall be made on the basic calibration block to verify that distance range
points and sensitivity settings.
Calibration shall be re-established on at least one of the basic reflectors in the basic
calibration block or by using a simulator at the finish of each examination or series
of similar examinations, every 4 hours during the examination, and when
examination personnel are changed. After ultrasonic examination the instrument
and the technique shall be recalibrated, if Calibration is off then the examinations
between the calibration shall be repeated.
6.4 Distance Amplitude Correction Curve (DAC) for piping calibration block:
6.4.1 Distance Amplitude correction Curve (DAC)
a. The angle beam shall be directed towards the calibration reflector that gives
maximum response from the ID notch.
b. Adjust the sensitivity control to provide an 80% FSH echo + 5% from the ID notch.
This is a primary reference level. Mark the peak on the screen. Do not change dB
after this setting during drawing DAC.
c. Position the search unit for maximum response from OD notch and mark the peak
on the screen.
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 d. Position the search units for maximum response from ID notch at 1½ skip and mark
the peak on the screen.
e. Connect the screen marks and extend through the thickness to provide the
distance amplitude curve.
6.4.2 Calibration for Nozzle side Weld Fusion Zone and / or Adjacent Nozzle Parent Metal:
6.4.2.1 The number of calibration holes used depends upon the requirements for
the examination. If only the nozzle side fusion zone is to be examined, then
only a single side drilled hole at the nozzle wall thickness needs to be used.
6.4.2.2 Single Hole: The response from a single side-drilled hole shall be set at 80%
±5% of full screen height. This is the primary reference level.
6.3.2.3 Multiple Holes. The straight beam shall be directed toward the calibration
reflector that yields the maximum response. The gain control shall be set so
that this response is 80% ±5% of full screen height. This shall be the primary
reference level. The search unit shall then be manipulated, without
changing instrument settings, to obtain the maximum responses from the
other hole position(s) to generate a distance-amplitude correction (DAC)
curve.

7.0 Examination

7.1 Straight Beam

7.1.1 The scanning of adjacent base material shall be performed to detect reflectors that
might affect interpretation of angle beam results and is not to be used for
acceptance or rejection of the weld. Location and areas of such reflectors shall be
recorded.
7.1.2 Whenever straight beam examination is part of the weld testing, the scanning shall
be performed at a gain setting of +12 dB of the primary reference level. Evaluation
shall be performed at the primary reference levels.
7.2 Angle Beam
7.2.1 Scanning for reflectors oriented parallel to the weld:
The angle beam shall be directed approximately at right angles to the weld axis from
two directions wherever possible. The search unit shall be manipulated so that the
ultrasonic energy passes through the required volumes of the weld, HAZ and
adjacent base metal. The scanning shall be performed at a gain setting of + 6 dB of
the primary reference level. (Note: The scanning sensitivity may set to +14 dB of
primary Level. This additional gain makes the reference DAC curve a 20% DAC curve
so that indications exceeding 20% DAC may be easily identified and evaluated.)
Evaluation shall be performed with respect to the primary reference level.
7.2.2 Scanning for reflectors oriented transverse to the weld:
The angle beam shall be directed essentially parallel to the weld axis. The search
unit shall be manipulated so that the ultrasonic energy passes through the required
volume of the weld and the adjacent weld metal. The unit to be rotated 180 deg and
the examination repeated. If the weld cap is not machined or ground flat, the
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 examination shall be performed from the base metal on both sides of the weld cap
in both weld axis directions.
The scanning shall be performed at a gain setting of + 14 dB of the primary
reference level. This additional gain makes the reference DAC curve a 20% DAC
curve so that indications exceeding 20% DAC may be easily identified and evaluated.
The search unit shall be rotated 180 deg and the examination shall be repeated.

7.2.3 Scanning for restricted access welds:

Welds that cannot be fully examined from two directions using the angle beam
technique (e.g. corner and tee joints) shall be also examined, if possible, with a
straight beam technique. These areas of restricted access shall be noted in the
examination report.
7.2.4 Inaccessible Welds:
Welds that cannot be examined from at least one side (edge) using the angle beam
technique shall be noted in the examination report. For flange weld, the weld may
be examined with a straight beam or low angle longitudinal wave from the flange
face provided the examination volume can be covered.
7.3 Each pass of the search unit shall overlap a minimum of 10% of the transducer
(piezoelectric element) dimension parallel to the direction of the scan. The rate of search
unit movement (scanning speed) shall not exceed 6 inch/sec. (150 mm/sec.).

8.0 Evaluation

8.1 Geometric Indication:

Under angle beam examination, indications that are determined to originate from surface
conditions (such as weld root geometry) or variations in metallurgical structure in austenitic
materials (such as the automatic-to-manual weld clad interface) may be classified as
geometric indications. The identity, maximum amplitude, location, and extent of reflector
causing a geometric indication shall be recorded.
The following steps shall be taken to classify an indication as geometric:
(a) Interpret the area containing the reflector in accordance with the applicable
examination procedure.
(b) Plot and verify the reflector coordinates. Prepare a cross-sectional sketch showing the
reflector position and surface discontinuities such as root and counter bore.
(c) Review fabrication or weld preparation drawings. Other ultrasonic techniques or
nondestructive examination methods may be helpful in determining a reflector’s true
position, size, and orientation.
8.2 Any imperfection that causes an indication in excess of 20% of DAC shall be investigated to
the extent that it can be evaluated in terms of acceptance or rejection standards given
below.
The length of discontinuity shall be measured by 6 dB drop method.
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9.0 Acceptance\Rejection Criteria as per ASME SEC.VIII, DIV.I

9.1.1 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 and evaluate them in terms of the acceptance
standards given in (a) and (b) below.
(a) Indications characterized as cracks, lack of fusion, or incomplete penetrations are
unacceptable regardless of length.
(b) Other imperfections are unacceptable if the indications exceed the reference level
amplitude and have lengths which exceed:
(1)
1⁄4 in. (6 mm) for t up to 3⁄4 in. (19 mm);
(2)
1⁄3t for t from 3⁄4 in. to 21⁄4 in. (19 mm to 57 mm);
(3) 3⁄4 in. (19 mm) for t over 21⁄4 in. (57 mm).
Where, “t” is the thickness of the weld excluding any allowable reinforcement. For a butt
weld joining two members having different thicknesses at the weld, t is the thinner of
these two thicknesses. If a full penetration weld includes a fillet weld, the thickness of
the throat of the fillet shall be included in t.

10.0 Examination of Repairs

All repaired areas shall be re-examined by the same procedure as used for the original
detection of the discontinuity.

11.0 Report of Examination

A report of the examination shall be made and shall contain weld details, technique followed,
settings used and all reflections from uncorrected areas having responses which exceeds 50%
of the reference level.
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12.0 Requirement of an Ultrasonic Examination Procedure.

Requirement Essential Non essential Reference to

Variable Variable Procedure Para.
Weld configurations to be examined, including thickness X --- Annexure 1 to 3
Dimensions and base material product form (pipe, plate, etc.)
The surfaces from which the examination shall be performed X --- Annexure 1 to 3
Technique(s) (straight beam, angle beam, contact, and/or X --- Annexure 1 to 3
immersion)
Angle(s) and mode(s) of wave propagation in the material X --- Annexure 1 to 3
Search unit type(s), frequency(ies), and element size(s)/shape(s) X --- Annexure 1 to 3
Special search units, wedges, shoes, or saddles, when used X --- Not Applicable
Ultrasonic instrument(s) X --- Para. 4.1
Calibration [calibration block(s) and technique(s)] X --- Para. 4.4, 6.0, and
Fig. T-434.2.1,
T-434.5.1
Directions and extent of scanning X --- Para. 7 & Annexure
1 to 3
Scanning (manual vs. automatic) X --- Para. 7
Method for discriminating geometric from flaw indications X --- Para. 8.1
Method for sizing indications X --- Para. 8.2
Scan overlap (decrease only) X --- Para 7.3
Personnel performance requirements, when required X --- Not applicable
Personnel qualification requirements X Para. 2.0
Surface condition (examination surface, calibration block) X Para. 5.0
Couplant: brand name or type X Para. 4.3
Records, including minimum calibration data to be recorded X Para. 11.0
(e.g., instrument
settings)

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 Based on figure T-434.2.1, Article 4 of ASME Section V (Non piping Basic Calibration Block)

Weld Thickness (t), in. Calibration Block Thickness (T), in. Hole Diameter in. Notch Dimensions, in. (mm)
(mm) (mm) (mm)
Up to 1 (25) ¾ (19) or t 3/32 (2.5) Notch depth = 2% T
Over 1 (25) through 2 1 ½ (38) or t 1/8 (3) Notch width = ¼ (6) max.
(50)
Over 2 (50) through 4 3 (75) or t 3/16 (5) Notch length = 1 (25) min.
(100)
Over 4 (100) t  1 (25) [Note (1)]
* Minimum dimension.
GENERAL NOTES:
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, a single curved calibration block may be used for examination
in the range of curvature from 0.9 to 1.5 times the basic calibration block. 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 be  1/32 in. (0.8 mm). The tolerance for hole location through the calibration block thickness
(i.e., distance from the examination surface) shall be  1/8 in. (3 mm).
d) For blocks less than ¾ in. (19 mm) is 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. Notches may also
be in the same plane as the inline holes. A sufficient number of holes shall be provided for both angles and straight beam
calibrations at the 1/4T, 1/2T, and 3/4T depths.
f) Minimum notch depth shall be 1.6%T and maximum notch depth shall be 2.2%T plus the thickness of cladding, if present.
g) Maximum notch width is not critical. Notches may be made by EDM or with end mills up to ¼ in. (6.4 mm) in diameter.
h) Surface finish of the block shall be representative of the surface finish on the components.
i) The material from which block is fabricated, shall be of the same product form and material specification or equivalent P -
No groupings. (P Nos. 1, 3, 4 and 5 materials are considered equivalent).
j) Where two or more base material thickness are involved the calibration block thickness shall be determined by the average
thickness of the weld.
k) For calibration blocks for dissimilar metal welds, the block material shall be based on the material from which the testing shall be
carried out. If the testing is to be carried out from both sides calibration reflectors shall be provided in both materials.
l) Where block thickness (1” spans two of the weld thickness ranges, the blocks used shall be acceptable in those portions of each
thickness range covered by 1”.
m) Post cleaning of couplant shall be ensured after completion of testing.
n) The calibration block material shall receive at least the minimum tempering treatment required by the material specification for
the type and grade.
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
1/10in.
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 (1.5 mm)

Piping Calibration Block

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Page 12 of 15
 Note: These UT technique sheets are prepared to show the scan plan for mentioned thickness ranges as a
general UT procedure. UT Demonstration for each weld joint with all applicable essential variables
shall be done as per project requirement and this procedure shall be used in conjunction with
demonstration report.

Annexure 1
Shell to Shell (Long Seam & Circ. Seam)

*Notes:
(1) Provided accessibility of scanning from O/S or I/S on either side of weld ensuring full weld volume
and HAZ is being covered.
(2) Demonstrated thickness = 48 mm.
Product Form: Plate
 Page 13 of 15

Crystal Frequency Angle Wave Mode Scanning

Size MHz (degree) Longitudinal (L)/ Direction
Transverse(T)
24 mm Ø 4 0 L 1 (On HAZ + Base Metal on either side of weld)
20 x 22 mm 4 45 T 4, 5

20 x 22 mm 4 60 T 4, 5

20 x 22 mm 4 70 T 4, 5

8 x 9 mm 4 45 T 2, 3 (Scanning for Transverse indication in two

direction at 180° opposite)

Scanning Technique Contact Manual BUTT WELDS

Scanning Detail As shown in fig. OUTSIDE
Recordable Indication At Reference ≥ 50% DAC 4 1 2/3 5
Gain
Scanning Sensitivity +6 dB
Basic Calibration Block 1 V 1 / V 2 (IIW) T

Basic Calibration Block 2 FIG. T – 434.2.1

38 mm Thick or ‘T’
(3 mm Φ SDH) 4 5
INSIDE
Couplant Cellulose Paste
Shell L/S & C/S (48mm)
 Annexure 2
Shell to D ’End (Circ. Seam)
Crystal Frequency Angle Wave Mode Scanning
Size MHz (degree) Longitudinal (L)/ Direction
Transverse(T)
24 mm Ø 4 0 L 1 (On HAZ + Base Metal on either side of weld)
20 x 22 mm 4 45 T 4, 5

20 x 22 mm 4 60 T 4, 5

20 x 22 mm 4 70 T 4, 5

8 x 9 mm 4 45 T 2, 3 (Scanning for Transverse indication in two

direction at 180° opposite)

Scanning Technique Contact Manual BUTT WELDS

Scanning Detail As shown in fig. OUTSIDE
Recordable Indication At Reference ≥ 50% DAC 4 1 2/3
Gain
Scanning Sensitivity +6 dB
Basic Calibration Block 1 V 1 / V 2 (IIW) T
Basic Calibration Block 2 FIG. T – 434.2.1
38 mm Thick or ‘T’
(3 mm Φ SDH) 4 5
Couplant Cellulose Paste INSIDE

*Notes:
(1) Provided accessibility of scanning from O/S or I/S on either side of weld ensuring full weld volume
and HAZ is being covered.
(2) Demonstrated thickness = 48 mm.
Product Form: Plate

Page 14 of 15
 Annexure 3
Nozzle (SRN Forging) # Head

Scanning Technique Contact Manual

Scanning Detail As shown in fig.
Recordable Indication At ≥ 50% DAC
Reference Gain NOZZLE ID
Scanning Sensitivity +6 dB
Basic Calibration Block 1 V 1 / V 2 (IIW) Head
Basic Calibration Block 2 FIG. T – 434.2.1 4 1
38 mm Thick or ‘T’
(3 mm Φ SDH)
6
Couplant Cellulose Paste

5 2/3 1

Nozzle (SRN Forging) # Head

*Notes:
(1) Provided accessibility of scanning from O/S or I/S or either side of weld ensuring full weld volume
and HAZ is being covered.
(2) Demonstrated thickness = 54 mm (Plate).
 Page 15 of 15

Wave Mode
Crystal Frequency Angle Scanning
Longitudinal (L)
Size MHz (degree) Direction
Transverse(T)
24 mm Ø 4 0 L 1, (On HAZ + Base Metal on either side of weld)
6 (From ID of Nozzle for Side wall Lack of Fusion)
20 x 22 mm 4 45 T 4, 5

20 x 22 mm 4 60 T 4, 5

20 x 22 mm 4 70 T 4, 5

8 x 9 mm 4 45 T 2, 3 (Scanning for Transverse indication in two

direction at 180° opposite)
Product Form: Plate for Head.
Forging for Nozzle
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