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Dammam, Saudi Arabia. 11 TH SEPTEMBER 2006

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DOCUMENT CHANGES
The changes in this revision over Rev 0 of this procedure are stated in red letter as follows:

M-520 GENERAL REQUIREMENTS

All work shall be performed by Saudi Aramco approved Technician; and

work shall be in accordance with Saudi Aramco specs and standards.
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INDEX

CONTENTS PAGE NO.

M-510 SCOPE 1.

M-511 REFERENCE STANDARDS 1.

M-520 GENERAL REQUIREMENTS 1.

M-521 INSPECTION WITNESS 1.

M-522 NDT PERSONNEL 1.

M-523 ULTRASONIC EXAMINATION TECHNIQUE 1

REQUIREMENT.

M-524 GENERAL EQUIPMENT REQUIREMENTS 2.

M-524.1 EXAMINATION COVERAGE 2.

M-524.2 RATE OF SEARCH UNIT MOVEMENT 2.

M-524.3 RECORDING SENSITIVITY LEVEL 2.

M-530 EQUIPMENT AND SUPPLIES 2.

M-530.1 FREQUENCY 2.

M-530.2 COUPLANT 3.

M-531 SCREEN HEIGHT LINEARITY 3.

M-532 AMPLITUDE CONTROL LINEARITY 3.

M-533 CHECKING AND CALIBRATION OF EQUIPMENT 3.

M-534 SEARCH UNITS 3.

M-540 APPLICATION 3.
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INDEX
CONTENTS PAGE NO

M-541 WELDS 3.
M-541.1 EQUIPMENT 4.
M-541.2 CALIBRATION 4.

M-542 CALIBRATION 5.

M-542.1 STRAIGHT BEAM CALIBRATION 5.

M-542.2 ANGLE BEAM CALIBRATION 6.
M-542.3 CALIBRATION CONFORMATION 7.

M-550 EXAMINATION PROCEDURE 8.

M-551 SURFACE PREPARATION 8.

M-552 SCANNING 8.

M-553 EVALUATION 9.

M-554 ACCEPTANCE CRITERIA 9.

M-555 POST EXAMINATION CLEANING 10.

M-560 REPORTS & RECORDS 10.

FIG 1 BASIC CALIBRATION BLOCK 11.

FIG 2 ANGLE BEAM CALIBRATION (PIPE WELDS) 12.

FIG 3 STRAIGHT BEAM CALIBRATION 13.
(SWEEP RANGE)

FIG 4 STRAIGHT BEAM (SENSITIVITY & 13.

DISTANCE AMPLITUDE CORRECTION)

FIG 5 ANGLE BEAM CALIBRATION (SWEEP RANGE) 14.

FIG 6 ANGLE BEAM (SENSITIVITY & DAC) 14.

FIG 7 SCANNING METHOD 15.

FIG 8 SCANNING PATTERN 16.

ULTRASONIC EXAMINATION REPORT 17

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ULTRASONIC EXAMINATION PROCEDURE

M-510 SCOPE

This standard prescribes the method of testing and inspection of welds by

Ultrasonic direct contact reflection method. This method is applicable to
Ferritic steel of thickness over 5 mm. It covers technique to be employed at
normal temperature; care shall therefore be taken to ensure that the
temperature of the test piece is not above the temperature for which the
probe is designed.

M-511 REFERENCE STANDARD

1. ANSI/ASME-V Article 4 & 5 – 2004 Edition

2. ANSI/ASME B 31.3 – 2004 Edition
3. ANSI/ASME B 31.4 - 2002 Edition
3. ANSI/ASME SEC.VIII DIV. I & II – 2004 Edition
4. API-1104 – 2005 Edition
5. SNT-TC-1A – 2001 Edition
6. ASNT/ANSI CP-189 – 2001 Edition
7 NDT/CERT/01 Rev.3 – 2006 Edition (CERTIFICATION MANUAL)

M-520 GENERAL REQUIREMENTS

All work shall be performed by Saudi Aramco approved Technician; and

work shall be in accordance with Saudi Aramco specs and standards.

M-521 INSPECTION WITNESS

Client inspection representatives, at their option, witness all or part of

ultrasonic examination at any time and place during and after fabrication and
may, as deemed necessary, establish witness as a hold point prior to or
during the test.

M-522 NDT PERSONNEL

The examination shall be performed by at least an UT Level-II All

interpretation of test results shall be done by a certified NDT Level-II
Technician. Personnel performing ultrasonic examination must be qualified
and certified in accordance with company’s written practice NDT/CERT/01
Rev.3, ANSI/ASNT CP-189. The client inspection unit representative may, at
his option, require the technicians to validate their certification by
submitting to qualification test administered by client NDE Level III.

M-523 ULTRASONIC EXAMINATION TECHNIQUE REQUIREMENTS

Ultrasonic examination technique record containing the essential elements

shall be maintained.

a) Weld and/or material types and configuration to be examined

including thickness dimensions, and product from (casting, forging,
plate etc.)

b) The surface or surfaces from which the examination shall be performed.

c) Surface condition.
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ULTRASONIC EXAMINATION PROCEDURE

d) Couplant, brand name, or types.

e) Technique (straight beam, angled beam, contact or immersion.

f) Angles and mode (s) of wave proposition in material.

g) Search unit type, frequency (ies), and transducer size(s)

h) Special search units, wedges, shoes or saddles.

i) Ultrasonic instrument type(s).

j) Description of calibration : blocks and technique.

k) Directions and extent of scanning.

l) Data to be recorded and method of recording (manual or mechanized).

m) Automatic alarm and recording equipment, or both.

n) Rotary, revolving or scanning.

o) Post-examination cleaning.

M-524 GENERAL EXAMINATION REQUIREMENTS

M-524.1 EXAMINATION COVERAGE

Each pass of the search unit shall overlap a minimum 10% of the transducer
(piezoelectric element) dimension perpendicular to the direction of the scan.

M-524.2 RATE OF SEARCH UNIT MOVEMENT

The rate of search unit movement for examination shall not exceed 6
in./sec. unless calibration is verified at scanning speed.

M-524.3 RECORDING SENSITIVITY LEVEL

The recording of indication shall be made with respect to the reference

level.

M-530 EQUIPMENT AND SUPPLIES

M-530.1 FREQUENCY

The examination shall be conducted with a pulse echo ultrasonic instrument

KRAUTKRAMER USM 50, USM 50L USN 20, USN 25, PANAMETRICS EPOCH
IIIB, SONATEST SITESCAN 140 or equivalent capable of generating
frequencies over the ranges of at least 1 MHz to 5 MHz or equivalent and the
instrument shall be equipped with a stepped gain control calibrated in units
of 2 dB or less.

M-530.2 COUPLANT

Polycell glue / Oil/ Grease/ Glycerine

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ULTRASONIC EXAMINATION PROCEDURE

M-531 SCREEN HEIGHT LINEARITY

The ultrasonic instrument shall provide linear vertical presentation

within +/-5% of the full screen height for 20% to 80% of the calibrated
screen height. The procedure for calibrating screen height linearity shall
be performed at the beginning of each period of extended use or every three
month whichever is less. (Refer procedure WI 111-1for calibrating UT
systems).

M-532 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. The procedure for calibrating amplitude control linearity shall
be performed at the beginning of each period of extended use (or every 3
month whichever is less). (Refer procedure WI 111-1 ).

M-533 CHECKING AND CALIBRATION OF EQUIPMENT

The proper functioning of the examination equipment shall be checked and

the equipment shall be calibrated by use of the calibration standard at the
beginning and end of each examination; when examination personnel are
changed; at any time malfunctioning is suspected, as a minimum. If during
the check it is determined that the testing equipment is not functioning
properly, all the product that has been tested since the last valid equipment
calibration shall be reexamined.

M-534 SEARCH UNITS

Frequencies : 2.25 MHz - 5 MHz; Angle :0°,45°,60°, 70° (± 2°)

Size: 10, 8 x 9 mm.

a) Search unit may contain either single or dual transducer elements.

b) Search units with contoured contact wedges may be used to aid

ultrasonic coupling. Calibration shall be done with the contact wedges
used during the examination.

M-540 APPLICATION

M-541 WELDS

These paragraphs describes the requirements for ultrasonic examination of

full penetration welds in wrought (rolled, drawn, forged, or extruded) and
cast material.

These requirements are established for the ultrasonic detection, location,

and evaluation of ultrasonic reflector within the weld, heat affected zone,
and the adjacent material.
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ULTRASONIC EXAMINATION PROCEDURE

M-541.1 EQUIPMENT

The requirement of the equipment shall be in accordance with M-530.

M-541.2 CALIBRATION

M-541.2.1 BASIC CALIBRATION BLOCK

The basic calibration reflectors shall be used to establish a primary

reference response of the equipment. The basic calibration reflectors
may be located either in the component material or in a basic
calibration block (as shown in fig.1).

The reference block shall have following characteristics:

a) Block material shall be of the same product form, material

specification or P- number grouping and with same acoustic
properties to the material to be inspected.

b) Block surface shall be as much as possible representative to the

member which is to be inspected. The reference block shown in
figure 1 may be used for the construction of DAC curve and for
evaluation of internal reflectors and planner reflectors.

c) The calibration block material shall be completely examined

with a straight beam search unit. Areas that contain an
indication exceeding the remaining back reflection shall be
excluded from the beam paths required to reach the various
calibration reflectors.

d) For ferritic welds in ferritic pipe the basic calibration block for
weldments shall be a section of pipe of the same nominal size,
schedule, heat treatment, and material specification or
equivalent P-number grouping as one of the materials being
examined. For the purpose of this procedure P-Nos 1, 3, 4 & 5
materials are considered equivalent. The block size and
reflector locations shall be adequate to perform calibration for
the beam angles used. The surface finish of the calibration
block shall be representative of the surface finish of the piping.

M-541.2.2 MATERIALS WITH DIAMETER GREATER THAN

20 INCHES.

For examination of materials where the examination surface

diameter is greater than 20" a block of essentially the same
curvature or alternatively, a flat basic calibration block, shall
be used.
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ULTRASONIC EXAMINATION PROCEDURE

M-541.2.3 MATERIALS WITH DIAMETERS 20" AND LESS.

The basic calibration block shall be curved for materials with

diameters 20" and less. Except where otherwise stated in this
procedure, a single curved basic calibration block may be used
to calibrate the examination on surfaces in the range of
curvature from 0.9 to 1.5 times the basic calibration block
diameter. The curvature range form 0.94" to 20" diameter
requires 6 block curvature as indicated in Fig.2 for any
thickness range. When side-drilled holes are to be used for
calibration, the block shall be as shown in Fig.1.

M-541.2.4 BASIC CALIBRATION REFLECTORS

a) For Pipe Welds:

Calibration reflectors shall be longitudinal and with circumference

notches in both the inner and outer surfaces. The sizes and locations
of the calibration reflectors are shown in fig. 2.

When side drilled holes are to be used the block shall be as shown in
fig. 1.

b) For welds other that pipe welds the basic calibration reflectors
are as shown in figure 1.

M-542 CALIBRATION

M-542.1 STRAIGHT BEAM CALIBRATION

The calibration shall provide the following requirements:

a) Sweep range calibration.

b) Distance-amplitude correction.

When an electronic distance-amplitude correction device is used, the primary

reference shall be equalized on the basic calibration block at a screen height
between 40% and 80% of full screen height over the distance range to be
employed in the examination.

M-542.1.1 SWEEP RANGE CALIBRATION

Calibrate the Sweep range to cover the area of interest required for the
examination. The following is an example using the basic calibration block
side drilled holes.

a) Position the search unit for the maximum first indication from the ¼T
side-drilled hole. Adjust the left edge of this indication to line 2 on
the screen with the delay control (see fig. 3)
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ULTRASONIC EXAMINATION PROCEDURE

b) Position in search unit for the maximum indication from 3/4T hole.
Adjust the left edge of this indication to line 6 (or other for
convenient measurement) on the screen with the range control.

c) Repeat delay and range control adjustments until the ¼T and 3/4 T
hole reflections start at sweep lines as indicated above.

542.1.2 DISTANCE AMPLITUDE CORRECTION (DAC)

a) Position for maximum response from the hole which gives the highest
amplitude. See fig. 4.

b) Adjust the sensitivity control to provide an 80% (± 5% of full screen

height) of full screen indication from the hole. Mark the peak of the
indication on the screen with a grease pencil or other suitable marker.

c) Position the search unit for maximum response from another hole
indication.

d) Mark the peak of the indication on the screen.

e) Position the search unit for maximum amplitude from the third hole
indication and mark the peak on the screen.

f) Connect the screen marks and extend through the thickness to provide
the distance-amplitude correction curve for the side drilled holes.

M-542.2 ANGLE BEAM CALIBRATION

Perform each calibration from the surface corresponding to the surface of the
component from which the examination will be performed.

M-542.2.1 SWEEP RANGE CALIBRATION (SEE FIG. 5)

Calibrate the sweep range to cover the area of interest required

for the examination. The following is an example using the basic
calibration block side drilled holes.

a) Position the search unit for the maximum first indication from
the ¼ T side drilled hole. Adjust the left edge of this indication
to line 1 on the screen with the delay control.
b) Position the search unit for the maximum first indication from
the ½T side drilled hole. Adjust the left edge of this indication
to line 2 on the screen with the delay control.
c) Position the search unit for maximum response from the square
notch on line opposite surface. The indication will appear near
sweep line 4.

d) Position the search unit for maximum indication from 1½ T.

Adjust the left edge of this indication to line 6 on the screen
with the range control.

e) Position the search unit for maximum response from the square
notch on the upper surface. The indication will appear near
sweep line 8.
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f) One division on the sweep equals to ¼ T.

M-542.2.2 DISTANCE-AMPLITUDE CORRECTION

(PRIMARY REFERENCE LEVEL)

a) Position the search unit for maximum response from the hole
which gives the highest amplitude.

b) Adjust the sensitivity control to provide and 80% (±5% of full

screen height) of full screen indication from the hole. Mark the
peak of line indication an line the screen.

c) Position the search unit for maximum response from another

hole indication.

d) Mark the peak of the indication on the screen.

e) Position the search unit for maximum amplitude from the third
hole indication and mark the peak on the screen.

f) Position the search unit for maximum amplitude from the ½T

Hole indication after the beam has bounced from the opposite
surface. The indication should appear at sweep line 6. Mark the
peak on the screen for 1 1/4 T position.

g) Connect the screen marks for the side drilled holes to provide the
distance-amplitude curve. Extend the curve to completely cover
the total area of interest.

M-542.3 CALIBRATION CONFIRMATION

Calibration shall be performed prior to use of the system in the thickness range
under examination. A calibration check shall verify the sweep range and
distance amplitude correction as defined in M-542.3.1 AND M-542.3.2.

M-542.3.1 SWEEP RANGE CORRECTION

If a point on the DAC curve has moved on the sweep line more than
10% of the sweep reading or 5% of full sweep, whichever is greater,
correct the sweep range calibration and not the correction in the
examination record. If reflectors are recorded on the data sheets,
those data sheets shall be voided and a new calibration shall be
recorded. All recorded indications since the last valid calibration or
calibration check shall be reexamined with the corrected calibration
and their values shall be changed on the data sheets.
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ULTRASONIC EXAMINATION PROCEDURE

M-542.3.2 DAC CORRECTION

If any point on the distance amplitude correction (DAC) curve has

decreased 20% or 2 dB of its amplitude, all data sheets since the last
calibration of calibration check shall be marked void. A new
calibration shall be made and recorded and the voided examination
areas shall be reexamined. It any point on the distance-amplitude
correction (DAC) curve has increased more than 20% of 2 dB of its
amplitude, all recorded indications since the last valid calibration or
calibration check shall be evaluated with the corrected calibration and
their values shall be changed on the data sheets.

M-550 EXAMINATION PROCEDURE

M-551 SURFACE PREPARATION

M-551.1 BASE METAL

The base metal on each side of the weld shall be free of weld spatter, surface
irregularities, of foreign matter that night interfere with the examination.
Surface preparation is necessary to ensure that the entire volume of the weld is
scanned with the required angle probe.

M-551.2 WELD METAL

Where the weld surface interfere with the examination, the weld shall be
prepared as needed to permit examination.

M-552 SCANNING

The volume of weld and adjacent base material (volume on either side of the
weld seam) that is to be examined shall be scanned by straight and angle beam
techniques. For typical scanning technique please refer fig. 7 & 8.

M-552.1 STRAIGHT BEAM

The scanning of adjacent base metal shall be performed to detect reflector that
might affect interpretation of angle beam result. Location and areas of such
reflectors shall be recorded.

M-552.2

The weld and base metal shall be scanned, where required by the referencing
code section, to the extent possible with the straight beam search unit. The
scanning shall be performed at a gain setting of at least 2 times the primary
reference level. Evaluation shall be performed with respect to the primary
reference level.
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ULTRASONIC EXAMINATION PROCEDURE

M-552.3 ANGLE BEAM SCANNING FOR REFLECTOR ORIENTED

PARALLEL TO THE WELD.

The angle beam shall be directed at approximately right angle to the weld axis
from two direction where possible. The search unit shall be manipulated so that
the ultrasonic energy passes. Through the entire volumes of weld and the
adjacent base metal. The scanning shall be performed at a gain setting at least
two times the primary reference level. Evaluation shall be performed with
respect to the primary reference level.

M-552.4 ANGLE BEAM SCANNING FOR REFLECTOR 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 angle beam passes through the
required volumes of weld and adjacent base metal specified by the referencing
code section. The scanning shall be performed at a gain setting at least
two times the primary reference level. Evaluation shall be performed with
respect to the primary reference level. The search unit shall be rotated 180 deg.
And the examination repeated.

M-553 EVALUATION

Any imperfection which causes an indication in excess of 20% DAC shall be

investigated to the extent that it can be evaluated in term of the acceptance
standards as per M-554.

M-554 ACCEPTANCE CRITERIA

M-554.1 Indications characterized as cracks, lack of fusion, or incomplete

penetration are unacceptable regardless of length.

M-554.2 Other imperfections are unacceptable if the indications exceed the

reference level amplitude and have lengths which exceed:

1) ¼ inch for t up to ¾ inch.

2) 1/3 t for t from ¾ inch to 2¼ inch.

3) ¾ inch for t over 2¼ inch.

Where t is the thickness of the weld excluding any allowable

reinforcement. For a butt weld joining two numbers having different
thickness 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 on t.
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ULTRASONIC EXAMINATION PROCEDURE

M-555 POST EXAMINATION CLEANING

Remove couplant as much as possible with clean rags.

M-560 REPORTS & RECORDS

M-560.1 A report of the examination shall be made. The report shall include a
record indicating the weld(s) of volume examined, the location of each
recorder reflector, and the identification of the operator who carried
out each examination or part there of.
See a typical sample on page 17.

M-560.2 RECORD

M-560.2.1 All unacceptable indications.

M-560.2.2 Repairs and results of re-examination.

M-560.2.3 All uncorrected areas which showed responses exceeding 50% DAC
with the area, the response level, the dimensions, the depth and
acceptable rejection classification.

M-560.2.4 All weld areas not completely examination due to stiffness,

attachments, etc. or restricted access and identify restriction.
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1
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ULTRASONIC EXAMINATION PROCEDURE

NDT & CORROSION CONTROL SERVICES

C.R. 2050006867, P.O. Box 322, Dammam - 31411, K.S.A. -
Tel. +966-3-8468328,8417464 Fax: 8468353 - E-mail: [email protected]

ULTRASONIC EXAMINATION REPORT

REQUESTED BY & DATE J.O.NO. / BI.NO CUSTOMER REPORT NO. DATE

TIME OF
NAME OF TECHNICIAN PLACE OF INSPECTION INSPECTION DATE OF INSPECTION

DESCRIPTION OF COMPONENT EXAMINED

MATERIALSPECIFICATION THICKNESS SIZE IDENTIFICATION MARKS

TESTING METHOD
MANUFACTURING CODE ACCEPTANCE STANDARD

REFERENCE CALIBRATION BLOCKS REFERENCE REFLECTION SIZE

SCANNING
SCALE REFERENCE SENSITIVITY SENSITIVITY RECORDING LEVEL

FLAW DETECTOR MANUFACTURER/MODEL COUPLANT

PROBE DESIGNATION ANGLE SIZE FREQUENCY

EXAMINATION
STATE OF EXAMINATION EXTENT OF EXAMINATION SURFACE SURFACE CONDITION

TEST RESULTS:

INSPECTOR CLIENT ULTRASONIC TECHNICIAN