Doc. No.

: QUAL/UT/001
ULTRASONIC EXAMINATION Page : 1 of 10
QUALTECH
PROCEDURE Revision : 00
Date : 25.04.05

1.0 SCOPE:

This procedure explains the requirements for manual pulse echo contact method of
ultrasonic examination of butt joints in carbon and low alloy steel, plates, pipe / tube
and pressure vessels.

2.0 REFERENCE:

ASME SEC. V ARTICLE 4

ASME SEC. VIII Div. I APPENDIX 12

3.0 PERSONNEL QUALIFICATION:

Personnel performing ultrasonic examination shall be qualified to Level II
in accordance with QUALTECH ’s written practice for qualification and certification
for NDT Personnel NDT/WP/001.

4.0 EQUIPMENT:
4.1 The examination shall be conducted with pulse echo ultrasonic equipment that
generates frequencies over the range of 1MHz to 5MHz. The equipment model
microscan EX–10, make EEC, Modsonic Einstin-I or equivalent satisfying the above
requirements shall be used.

4.2 The equipment shall have valid calibration and stickered mentioning the date of
expiry.

5.0 PROBES:
5.1 Search units shall contain single crystal transducers.

5.2 For straight beam examination longitudinal wave probes (0°) shall be used. For
angle beam examination shear wave probes of 45° shall generally be used and
atleast one probe of other angles up to 70° shall be used appropriate to the
configuration being examined. Groove angle and thickness shall be considered in
selecting the probe angle other than 45°

5.3 For straight beam examination, the crystal dimensions shall be selected in the range
of 10 mm to 25 mm. For angle beam examination, the crystal dimensions shall be
selected appropriate to the contact available with examination surface and will
generally be 8x9 mm or 20x22 mm.

5.4 Probes of frequencies between 2 MHz and 4 MHz shall be used for both straight
beam and angle beam examination.

6.0 SURFACE CONDITION:

6.1 The finished contact surface shall be free from weld spatter and surface irregularities
which will impair the free movement of the search unit.

6.2 The weld reinforcement shall be ground flush smooth with adjacent base material, if
required.
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QUALTECH
PROCEDURE Revision : 00
Date : 25.04.05

7.0 COUPLANT:
Grease-oil mix shall be used as couplant. The couplant used for the examination
shall be the same as that used for calibration.
Couplant used on nickel base alloys shall not contain more than 250 ppm of sulfur.

Couplants used on austenitic stainless steel or titanium shall not contain more than
250 ppm of halides (Chlorides plus fluorides).

8.0 CALIBRATION OF EQUIPMENT:

8.1 Basic Reference Block:

The basic reference reflectors shall be used to establish a primary reference

response of the equipment. The material from which the block is fabricated shall be of
the same product form and material specifications or equivalent P - Number grouping
(P. Nos. 1, 3, 4 and 5 are considered equivalent) as one of the material being
examined.
Reference blocks for dissimilar metal welds, the material selection shall be based on
the material on the side of the weld from which the examination will be conducted. If
the examination will be conducted from both sides, calibration reflectors shall be
provided in both materials.

Reference blocks shall receive atleast the minimum tempering treatment required by
the material specification for the type and grade.

8.2 When two or more base material thicknesses are involved, the reference block
thickness shall be determined by the average thickness of the weld.

8.3 The thickness and the location and size of holes in the basic reference block to be
used shall be as indicated in the Figure - 1. Notched reference blocks shall only be
used for thickness less than 12.7 mm.

8.4 The finish on the surface of the reference block shall be representative of the surface
finish on the component. Variation in component configuration and surface finish,
require transfer correction to be calculated.

8.5 The reference block material shall be completely examined with a straight beam
search unit. Areas that contain an indication exceeding the remaining back reflection
shall not be used as block material.

8.6 When the component has flat surfaces or curved surface with a diameter greater than
20 inches, a flat basic reference block shall be used. (Figure - 1).

8.7 When the component is curved and has a diameter less than 20 inches, a curved
basic reference block shall be used. The components to be tested can have a
curvature between 0.9 to 1.5 times of basic reference block diameter.

8.8 The reference blocks manufactured in house, shall be inspected and certified by NDT
Level III.
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ULTRASONIC EXAMINATION Page : 3 of 10
QUALTECH
PROCEDURE Revision : 00
Date : 25.04.05

9.0 CALIBRATION TECHNIQUES:

8.1 Technique for Straight Beam Calibration:

8.1.1 The sweep range for straight beam is set on the equipment using the IIW V1 block.

8.1.2 Distance - Amplitude Correction: The probe is positioned for maximum response
from the hole that gives the highest amplitude and set to 80% (±5%) full screen
height. The peak of the indication is marked on the screen with a glass marking
pencil. Without disturbing the sensitivity controls of the unit, the probe is positioned
for maximum response from the other two hole indications and their peaks marked
on the screen.
The screen marks are connected and extended through the thickness to provide the
distance amplitude curve using side drilled holes.

8.2 Technique for Angle Beam Calibration:

8.2.1 The basic calibration block shall be used for distance amplitude correction and
position calibration.

8.2.2 The sweep range is selected and the equipment is calibrated to the selected
range using IIW - V1 and V2 blocks.

8.2.3 Distance - Amplitude Correction (DAC): To construct a DAC a basic calibration

block having drilled holes at ¼T, ½T and ¾T shall be used. The gain is adjusted to
provide an 80% ± 5% of full screen indication from the ¼T hole.

The peak of the indication is marked on the screen with a glass marking pencil.
Without disturbing the settings, the probe is positioned for maximum response from
the ½T, ¾T holes and T+¼T hole after the beam has bounced from the opposite
surface. The peak marks of the indications from the side drilled holes are connected
to provide distance amplitude curve.

When calibrated using notched specimen, indication form the root notch is brought
to 80% of screen height and the sensitivity level is noted.

8.3 A calibration check on atleast one of the basic reflections in the basic
calibration block shall be made to ensure proper functioning of the equipment, at the
beginning and finish of each examination or series of similar examinations, every 4
hours during the examination and when examination personnel are changed.

8.4 The sensitivity (in dB) used for DAC shall be evaluation sensitivity or reference level.

8.5 Transfer correction if any obtained, shall be added to test / evaluation sensitivity.

10.0 EXAMINATION SURFACE:

10.1 For straight beam examination the weld and base material shall be scanned
progressively along and across the weld surface to the extent possible from at least
one surface of the part.
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QUALTECH
PROCEDURE Revision : 00
Date : 25.04.05

10.2 Angle Beam Scanning:

10.2.1 Defects Parallel to the Weld: (Figure - 4)

The angle beam shall be directed at 90° to the weld axis, from two directions where
possible. The probes shall be manipulated so that the ultrasonic energy passes
through the required volumes of the weld and adjacent base material.

10.2.2 Defects Transverse to Weld (Figure -5) :

For detection of transverse defects the weld shall be examined using 45 deg.
angle beam probe.
For butt joints the angle beam shall be directed essentially parallel to the weld
axis. The probe shall be manipulated so that the angle beam passes through
required volumes of the weld and adjacent base metal. The probe shall be rotated at
180° and examination shall be repeated.

11.0 SCANNING SENSITIVITY:

Scanning sensitivity shall be a minimum of +6dB above the reference
level. However evaluation of indications shall be performed at the primary
reference level.

12.0 EXAMINATION COVERAGE :

For the angle beam examination the entire volume of the
weld inclusive of adjacent base metal shall be examined by moving the probe over
the examination surface.

During scanning, the probes shall be moved to and fro with swiveling action of
10° to 15° on either side with overlap between successive scanning.

Each pass of the probes shall overlap a minimum of 10% of the crystal element
dimension perpendicular to the direction of the scan.

In any case the rate of probe movement for examination shall not exceed 150mm
per second.

12.0 CALIBRATION CONFIRMATION:

A calibration check as discussed in 8.3, shall verify the sweep range calibration and
distance amplitude correction.

12.1 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, the sweep range calibration
shall be corrected. All recorded indications since the last valid calibration or
calibration check shall be re-examined with the corrected calibration and the value
changed.
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QUALTECH
PROCEDURE Revision : 00
Date : 25.04.05

12.2 DAC Correction:

If a point on the DAC curve has changed 20% or 2dB of its amplitude, all recorded
indications since the last valid calibration check shall be re-examined with the
corrected calibration.

13.0 EVALUATION:
Imperfections that cause an indication greater than 20% of the reference
level shall be investigated to the extent that the ultrasonic examination personnel
can determine their shape, identity, and location, and evaluate them in terms of
paragraph 14.0

14.0 ACCEPTANCE STANDARD:

14.1 Cracks, lack of fusion, or incomplete penetration are unacceptable regardless of

length.

14.2 Other imperfections are unacceptable if the indication exceeds the reference level
amplitude and lengths which exceeds the following :
¼ inch for t up to ¾ inch
1/3 t for t from ¾ inch to 2¼ inches
¾ inch for t over 2 ¼ inches.

Where t is the thickness of the weld being examined. If the weld joints two members
having different thickness at the weld, t is the thinner of these two thicknesses.

15.0 POST CLEANING:

After the examination is completed the couplant applied on the surface shall be
removed to the pre-inspection condition.

16.0 REPAIR & RETEST:

Repaired weld regions shall be ultrasonically re-examined by the same
procedure used for original testing.

17.0 REPORT:

17.1 Details of inspection of original weld and repaired area shall be recorded in Attachment
No. 1.

17.2 Recording all reflections from uncorrected areas having responses that exceed 50%
of reference level shall be made.
 Doc. No. : QUAL/UT/001
ULTRASONIC EXAMINATION Page : 6 of 10
QUALTECH
PROCEDURE Revision : 00
Date : 25.04.05

Attachment 1 ULTRASONIC TESTING REPORT FORMAT

QUALTECH QUALTECH

ULTRASONIC TESTING REPORT

Client Report No.
Job Description Date of Test
Drawing No. Time of Test
Material Calibration Block
Thickness Reference Block
Procedure No. Normal:
Surface Calibration Range Angle:
condition
Equipment Search Unit Normal Angle
Model Size
Serial No. Frequency
Referenc Scanning Couplant
Gain e

Calibration
Verification

Sl. Size /
Job Identification Type of Discontinuity Disposition
No. Length

For QUALTECH Witnessed by

Sign: Sign:
Name: Name:
Date: Date:
 Doc. No. : QUAL/UT/001
ULTRASONIC EXAMINATION Page : 7 of 10
QUALTECH
PROCEDURE Revision : 00
Date : 25.04.05

Calibration Hole
Weld Thickness (t) Block Diameter Notch Dimensions
in. (mm) Thickness(T) in. (mm) in. (mm)
in. (mm)
Up to 1 (25) ¾ (19) or t 3/32 (2.4)
Notch Depth = 2% T
Over 1 (25) through 2 1 ½ (38) or t 1/8 (3.2)
Notch Width = ¼ (6.4)
(51)
max.
Over 2 (51) through 4 3 (76) or t 3/16 (4.8)
Notch Length = 1 (25)
(102)
min.
Over 4 (102) t + 1 (25) **

** For each increase in weld thickness of 2 in. (51mm), or fraction thereof over 4 in. (102
mm), the hole diameter shall increase 1/16 in. (1.6 mm).

GENERAL NOTES:
(a) Holes shall be drilled and reamed 1.5 in. (38 mm) deep minimum, essentially
parallel to the examination surface.
(b) For curved surfaces, 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 shall 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. (3.2 mm).
(d) All three holes may be located on the same face (side) of the calibration block
provided care is exercised to locate the holes far enough apart to prevent one hole
from masking the indication of another hole during calibration.
(e) Minimum notch depth shall be 1.6% T and maximum notch depth shall be 2.2% T
plus the thickness of cladding, if present.

FIG (1) NON – PIPING CALIBRATION BLOCKS

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QUALTECH
PROCEDURE Revision : 00
Date : 25.04.05

* Notches shall be located not closer than T or 1 in. (25mm), whichever is greater, to any
block edge or to other notches.

GENERAL NOTES:
(a) The minimum calibration block length (L) shall be 8 in. (203 mm) or 8T, whichever is
greater.

(b) For OD 4 in. (102 mm) or less, the minimum arc length shall be 270 deg. For OD
greater than
4 in. (102 mm), the minimum arc length shall be 8 in. (203 mm) or 3T, whichever is
greater.

(c) Notch depths shall be from 8% T minimum to 11% T maximum. Notch widths shall
be ¼ in. (6.4 mm) maximum. Notch lengths shall be 1 in. (25 mm) minimum.

Fig 1(A) CALIBRATION BLOCK FOR PIPE

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QUALTECH
PROCEDURE Revision : 00
Date : 25.04.05

FIG. 1(B) – CURVED BASIC REFERENCE BLOCK

 Doc. No. : QUAL/UT/001
ULTRASONIC EXAMINATION Page : 10 of 10
QUALTECH
PROCEDURE Revision : 00
Date : 25.04.05

C /L W E L D

M a x o v e rla p

S K IP D IS T

E X A M IN A T IO N C O V E R A G E

F IG (4 ) S C A N N IN G T E C H N IQ U E

W ELD

S ID E - 1 S ID E -2

F IG (5 ) S C A N N IN G D IR E C T IO N S F O R A N G L E B E A M