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Ultrasonic Test Procedure: Rev. Date Prepared by Reviewed Approved

This document outlines the procedure for ultrasonic testing of stainless steel welded pipes to detect discontinuities. It specifies that testing be performed by certified level II or III personnel using pulse-echo ultrasonic equipment operating between 1-10 MHz. The procedure describes calibration requirements including linearity checks and use of a calibration block matching the pipe dimensions. It provides acceptance criteria for indications, requiring investigation of reflections exceeding 20% of the reference level and rejection of welds with discontinuities like cracks or those exceeding certain size limits based on pipe thickness. A scan plan and equipment details are also included.

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269 views8 pages

Ultrasonic Test Procedure: Rev. Date Prepared by Reviewed Approved

This document outlines the procedure for ultrasonic testing of stainless steel welded pipes to detect discontinuities. It specifies that testing be performed by certified level II or III personnel using pulse-echo ultrasonic equipment operating between 1-10 MHz. The procedure describes calibration requirements including linearity checks and use of a calibration block matching the pipe dimensions. It provides acceptance criteria for indications, requiring investigation of reflections exceeding 20% of the reference level and rejection of welds with discontinuities like cracks or those exceeding certain size limits based on pipe thickness. A scan plan and equipment details are also included.

Uploaded by

kevin desai
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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ULTRASONIC TEST PROCEDURE

10/02/2019 JAY PATEL HEMANT DESAI

Rev. Date Prepared By Reviewed Approved


1.0 ULTRASONIC EXAMINATION OF WELDS
This procedure describes the requirements for ultrasonic examination of
detecting discontinuities in Stainless steel welded pipe and tubing having outside
diameters approximately 1⁄2 in. (12.7 mm) and larger

2.0 PERSONNEL REQUIREMENT

Certified UT Level II Or III personnel in accordance with ASNT SNT TC-


1A.Reportto be approved by Level III.

3.0 APPLICABLE CODES, STANDARDS AND SPECIFICATIONS


ASME Sect. V, Article 4,5 & Article 23
Referencing code ASME SEC VIII DIV 1
Applicable Edition and Addenda for above codes shall be the same as used in
job construction.

3.0 PROPOGATION OF SOUND

A pulsed ultrasonic angle beam by means of surface contact method shall be


used.Fig. 1 Illustrates the characteristic angle beam ultrasound entry into the
wall of a welded pipe or tube in the axial direction to search for transverse
discontinuities using a single search unit.

FIG. 1 AXIAL PROPOGATION OF SOUND

OF SOUND IN A PIPE OR TUBE WALL


4.0 EQUIPMENT
4.1 APPARATUS:

A pulse Echo-Type Of Ultrasonic instrument shall be used. The Instrument Shall Be


Capable of Operating at Frequencies Over The Range Of 1MHZ To 10 MHZ And Shall
Be equipment with a stepped gain control unit of 2.0 dB or less. If The instrument has
damping control, it shall not be used. The reject control shall be in OFF Position for all
examination. If in any case damping and reject setting has been used it shall be
mentioned in the report. only Calibrated pulse-echo type of ultrasonic flaw detector
shall be used for testing. Calibration shall be done as per 4.2 and 4.3 to Check screen
height linearity and amplitude control linearity at the beginning of each period of
extended use or every three months, whichever is less. Level III Approved Equipments
Of different make can also be used.

MAKE Model
EEC DS 322 OR EQUIVALENT
MODSONIC EINSTEIN II TFT, EINSTEIN II PLUS,
EIENSTEIN II DGS OR EQUIVALENT

4.2 Screen Height Linearity:

The Ultrasonic Instrument Shell provide linear vertical presentation within 5% of the full
screen height for at least 80% of the calibrated screen height (base line to maximum
calibrated screen points). Couple a straight beam probe to the IIW – V1 block and get
multiple echoes from 25mm back wall. Select any two echoes whose amplitudes are in
the ratio of 2:1 with larger echo set at 80% of full screen height. Without moving the
search unite, adjust the gain to successively set the larger indication from 100% to
20% of full screen height, in 10% increments or 2dB steps if a line control is not
available, and read the smaller indication at each setting. The reading must be 50% of
the larger amplitude, within 5% of the full screen height. The setting and readings must
be estimated to the 1% of full screen height.

4.3 Amplitude Control Linearity:

The ultrasonic instrument shall utilize an amplitude control, accurate over its useful
range to +20% of the nominal amplitude ratio, to allow measurement of indication
beyond the linear range of the vertical display on the screen. Couple an angle beam
probe to IIW – V1 block and get multiple echoes from 100mm quadrant. Select an
echoes and note its amplitude. Reduce the gain by 6dB and read the amplitude of the
same indication. It must be 50% of the initial amplitude within 20% of the nominal
amplitude ratio. Perform the exercise for full screen and readings should be as follow,
refer TABLE – 1 below.
TABLE – 1

Indication set at % of dB Control Change Indication limits % of


FSH FSH

80 -6 dB 32 to 48
80 -12 dB 16 to 24
40 +6 dB 64 to 96
20 +12 dB 64 to 96

5.0 CALIBRATION BLOCK FOR PIPE :


The basic calibration block configuration and reflectors shall be as shown in
Fig.2. The basic calibration block shall be a section of pipe of the same nominal
size 19 mm OD and 1.6 MM Thickness. The block size and reflector locations shall
be adequate to perform calibration for the beam angles used.

FIG. 2 CALIBRATION BLOCK FOR PIPE


* Notches shall be located not closer than T or 1 in. (25 mm), whichever is
greater, to any block edge or to other notches.
5.1 GENERAL NOTES
(a) The minimum calibration block length (L) shall be 8 in. (200 mm) or 8T,
whichever is greater.
(b) For OD 4 in. (100 mm) or less, the minimum arc length shall be 270
deg. For OD greater than 4 in. (100 mm), the minimum arc length shall
be 8 in. (200 mm) or 3T, whichever is greater.
(c) Notch depths shall be 8%T minimum to 11%T maximum. When cladding
is present, notch depths on the cladding side of the block shall be
increased by the cladding thickness, CT (i.e., 8%T + CT minimum to
11%T + CT maximum). Notch widths shall be 1⁄4 in. (6 mm) maximum.
Notch lengths shall be 1 in. (25 mm) minimum.
(d) Maximum notch width is not critical. Notches may be made with EDM or
with end mills up to 1⁄4 in. (6 mm) in diameter.
(e) Notch lengths shall be sufficient to provide for calibration with a
minimum 3 to 1 signal-to-noise ratio.

5.2 PROBES:
Transverse wave angle beam 45 ° Single probe.
EEC Make : 3x 4 mm size Frequency 4 MHz

5.3 COUPLANT:
Grease, oil, water or any other similar material which permits satisfactory
transmission of ultrasonic waves. However same couplant shall be used for
calibration as well as for testing.

6.0 TEST SURFACE PREPARATION

6.1 BASE 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.

6.2 WELD METAL:


The weld surface interferes with the examination; the weld shall be
prepared as needed to permit the examination.

7.0 CALIBRATION FOR PIPING BLOCK

7.1 BEAM ANGLE


An 45 deg angle shall be selected as appropriate for the configuration being
examined. More details refer Probe detals and Scan plan.
7.2 DISTANCE AMPLITUDE CORRECTION (DAC):
The angle 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 from Notch. This shall be the primary reference level..
calibrations shall be established for circumferential notches. These calibrations
shall establish both the distance range calibration and the distance amplitude
correction.

7.3 RECALIBRATION:
Calibration shall be re-established on at least one of the basic reflector in
the basic calibration block or by using a simulator at the finish of each
examination or series of similar examinations. Every 4 hrs during the
examination, and when examination personnel changed.

8.0 EVALUATION

1) Evaluation shall be performed by Level II and III.


2) Any reflector which causes an indication in excess of 20% of DAC shall be
investigated to the extent that it can be evaluated in terms of the acceptance
standard para. 11.

9.0 ACCEPTANCE / REJECTION STANDARDS

Welds that are shown by ultrasonic examination to have discontinuities


which produce an indication greater than 20% of the reference level shall be
investigated to the extent that ultrasonic examination personnel can determine
their shape, identity, and location so that they may evaluate each discontinuity
for acceptance in accordance with 1), 2) below.

1) Discontinuities evaluated as being cracks, lack of fusion, or incomplete


penetration are unacceptable regardless of length.

2) Other discontinuities are unacceptable if the indication exceeds the reference


level and their length exceeds the following :

(a) 1/4 in.(6.0mm) for t up to 3/4 in.(19.0mm)


(b) 1/3t for t from 3/4 in.(19.0mm) to 2 1/4 in.(57.0mm)
(c) 3/4 in.(19.0mm) for t over 2 1/4 in.(57.0mm)

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.

10.0 EXAMINATION OF REPAIRS

Repair shall be examined by the same procedure used for detection of the
discontinuities. Acceptability of repairs shall be determined by the same
acceptance standards.

11.0 REPORT OF EXAMINATION

Report of the examination shall be made as per the company standard


format and shall contain weld details, technique followed, settings used and all
reflections from Directed areas having responses which exceeds 50% of the
reference level.

SEARCH UNIT DETAILS AND SCAN PLAN

TYPE MAKE DOUBLE ANGLE FREQ. MODE


CRYSTAL SIZE /SINGLE
AM45454 4L
WB EEC 3X 4 MM SINGLE 45° 4 MHZ TRANSVERSE

mB452E SEARCH UNITS * BUTT WELD


SCANNING
DIRECTION
AM 45 - 4
3 X 4 MM

1 √
2 √

THICKNESS 2.77 TO
4.77 Diameter 19.05 mm
REPORT NO. :

TEST DATE :

ULTRASONIC EXAMINATION AND CALIBRATION REPORT


INSPECTION AGENCY:
CUSTOMER: CALIBRATION SHEET NO. :
JOB DESCRIPTION : PART SIZE:
MATERIAL SPECIFICATION : SPECIFICATION : PART DRG. NO. :
IDENTIFICATION MARKS : QUANTYTI:
APPLICABLE CODE AND SPECIFICATION : UT PROCEDURE NO. :
EQUIPMENT :  EE EX-10  KRAUTKRAMER EQUIPMENT SERIAL NO :
SEARCH UNIT :  EEC  KRAUTKRAMER  MODSONIC TRANSDUCER SERIAL NO :
CRYSTAL
REFRACTION WAVE RANGE REF-
DIMENSION / FREQUENCY
TESTTYPE ANGLE MODE M.M. GANE(dB)
ARRGT.




COUPLANT  WATER  GREASE  OIL  PASTE 
EXAMINATION SYSTEM CALIBRATION RECORD
EQUIPMENT CALIBRATION SHEET NO. : RECORDABLE SIZE :
BASIC CAL. BLOCK : REF. REFLECTOR :
REF. SENSITIVITY LEVEL :
RECORDABLE INDICATION AT REF.
SCANNING SENSITIVITY LEVEL : SENSITIVITY:

SURFACE CONDITION : SURFACE FROM WHICH MATL. EXAMINED :


STAGE OF EXAMINATION : EXTENT OF EXAMINATION :
TEST RESULT:

Note:
EXAMINED BY
WITNESSED BY REVIWED BY
(UTLEVEL II)
SIGNATURE
NAME
DATE

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