D F Power Systems Pvt.

Document Revision No: 00

No.DFPS/SSPL/ Date of
Ltd., QAC/SP-007 Revision:12/11/2
010

Title : Procedure For Ultrasonic Testing Of Butt Weld Page 1 of 7

Joints In Structure

PROCEDURE FOR
ULTRASONIC TESING OF
BUTT WELD JOINTS IN STRUCTURE

DFPS/SSPL/QAC/SOP-007 REV.00

SALASAR STEEL & POWER LTD.,

(1X65 MW)

Prepared By: MR. JAY PAL Reviewed By: MR.JAVID

Signature: Signature:
Approved By: MR.VAKA MURTHY Copy No:

Signature: Date of Issue:

 D F Power Systems Pvt. Document Revision No: 00
No.DFPS/SSPL/ Date of
Ltd., QAC/SP-007 Revision:12/11/2
010

Title : Procedure For Ultrasonic Testing Of Butt Weld Page 2 of 7

Joints In Structure

Issued By: MR. Issued to: Date:

Name:
Signature Designation:

REVISION HISTORY
Rev. Date of
Description of Change Author Reviewer
No. Revision

REFERENCE DOCUMENTS
Document Number Document Title
ASME Section V Non Destructive Examination
AWS D 1.1 Structure welding code

1.0 PURPOSE

This defines a general procedure for Ultrasonic testing of but weld joint in
structure of Salaya power Project.

2.0 SCOPE

This procedure shall be employed for the Ultrasonic examination of the Weld
joints in structure weld joints.

3.0 Definitions and Acronyms

ASME American Society for Mechanical Engineers.

dB Decibel
IIW International Institute of welding
NDT Non Destructive Testing
UT Ultrasonic Testing
 D F Power Systems Pvt. Document Revision No: 00
No.DFPS/SSPL/ Date of
Ltd., QAC/SP-007 Revision:12/11/2
010

Title : Procedure For Ultrasonic Testing Of Butt Weld Page 3 of 7

Joints In Structure
SDH Side Drill Hole
UFD Ultrasonic Flaw Detector
DAC Distance Amplitude Curve
SNT-TC-1A Society of Non destructive Testing

4.0 FLOW CHART

VISUAL INSPECTION &

RELEASE FOR TESTING

SURFACE PREPARATION &

CLEANING

EQUIPMENT / PROBE
SELECTION

CALIBRATION OF
EQUIPMENT WITH RECTIFICATION
STANDARD BLOCKS AS PER CODE

WELD JOINT SCANNING

AND RESULT RECORDING /
REPORTING/POST UN ACCEPTABLE
CLEANING

ACCEPTALE

RELEASE FOR FURTHER

ACTIVITIES
 D F Power Systems Pvt. Document Revision No: 00
No.DFPS/SSPL/ Date of
Ltd., QAC/SP-007 Revision:12/11/2
010

Title : Procedure For Ultrasonic Testing Of Butt Weld Page 4 of 7

Joints In Structure

5.0 PROCEDURE

5.1 EQUIPMENT

The equipment used shall be pulse echo reflection type with A-Scan
display.

a) Frequency range : 0.5 - 15 MHz

b) Calibration gain control : 0 - 80 dB step
c) Horizontal linearity : + 1% over the F.S.R. of CRT
d) Vertical linearity : ± 5% over the F.S.R. of CRT

6.2 PROBE

4 MHz, 8x9 mm active size, 450 angle probe.

4 MHz, 8x9 mm active size, 600 angle probe.
4 MHz, 8x9 mm active size, 700 angle probe.

However, angle probe shall be selected based on job thickness.

6.3 COUPLANT

Water or Oil shall be used as couplant. The couplant used for calibration
shall be used for the actual job.

6.4 CALIBRATION BLOCK

Calibration shall be carried out on standard Blocks (V-1 & V-2) and if
necessary calibration shall be done on similar sections to be tested.

6.5 SURFACE CONDITION

All surfaces shall be clean and free from scale, dirt, spatters or any other
conditions that will interfere with the test result.
 D F Power Systems Pvt. Document Revision No: 00
No.DFPS/SSPL/ Date of
Ltd., QAC/SP-007 Revision:12/11/2
010

Title : Procedure For Ultrasonic Testing Of Butt Weld Page 5 of 7

Joints In Structure

6.6 Scanning Method

The sketch pf annexure 1 show’s scanning method of different types of

structure weld joints configuration. However the other points are also to be
taken care of while scanning the structure joints.

6.7 Scanning with TR probes

Prior to angle beam scanning area from where angle beam scanning to be
carried out are to be marked. T/R probe scanning to be carried out on the
marked area to identify any reflector, which may interfere during beam
scanning.

6.8 Examination Coverage

The weld volume shall be examined by moving the search unit over the
examination surface so as to scan the entire examination volume. Each
pass of the search unit shall overlap a minimum 10% of the transducer
dimension perpendicular to the director of the direction of the scan. The
shear probes which produces beam of an angle of 45 to 70 degrees in the
examination medium shall be used. The beam angle dependent on the
thickness and weld geometry. The recommended beam angles for
different thickness are given below or code recommended angle probe
shall be used.

Thickness Beam angle

Up to 38 mm 70 degree

Above 38 mm 45/60/70 degree

Scan plan for UT examination shall be prepared as per the geometry of

the job to ensure that the complete weld & HAZ area is covered during the
scanning of weld joint. For butt joints the scanning limits ½ to 11/2 skip
distance from both sides or as per the job requirement. For partial
penetration weld joint scanning shall be carried out as per the required
specification. For complicated geometries of the weld joints the scanning
pattern shall be designed to cover the area of interest of the weld metals.

6.9 SCANNING dB
 D F Power Systems Pvt. Document Revision No: 00
No.DFPS/SSPL/ Date of
Ltd., QAC/SP-007 Revision:12/11/2
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Title : Procedure For Ultrasonic Testing Of Butt Weld Page 6 of 7

Joints In Structure
All angle beam scanning to be carried out at reference level and of added
gain as per the AWS D1.1 code requirements.

6.10 RECORDING & ACCEPTANCE

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

Acceptance criteria for defect evaluation of structure steel welding shall be

as per sec. 6.13.1 Table 6.2 & sec. 6.13.2 Table 6.3 of AWS D1.1.

6.11 Evaluation of indication

Any indication shall be evaluated at reference level. All indication will be
investigated to the extent that the inspector can determine shape, identity
and location. All indication detected with one probe may be further
evaluated if required, using an appropriate combination of angle probes so
that nature orientation and length can be accurately and discontinuity type
can be established. The discontinuities shall be sized using 6db drop
method and maximum amplitude technique. Wherever required, plotting to
be carried out on the graph paper to decide the nature and location of the
defect.

6.11 Evaluation of repair weld

Wherever weld repair have been carried out, the soundness of the
weld/job shall be confirmed by repeating the UT examination as per the
procedure.

6.12 Post cleaning

Couplant (grease/oil) applied to the job surface for UT examination shall

be cleaned by respective NDT agency after completion of the cotton waste
/ cloth.

6.12 PERSONNEL QUALIFICATION

The personnel carrying out the test shall be qualified as ASNT in

accordance with the requirements of SNT-TC-1A of 1996 edition.

7.0 REPORTS AND RECORDS:

 D F Power Systems Pvt. Document Revision No: 00
No.DFPS/SSPL/ Date of
Ltd., QAC/SP-007 Revision:12/11/2
010

Title : Procedure For Ultrasonic Testing Of Butt Weld Page 7 of 7

Joints In Structure
The result of Ultrasonic examination shall be recorded on the approved
format (DFPS/SSPL/QAC/FM-023) and shall be signed by all concerned as
per approved ITP.