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TS -UT-12

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EXAMINATION PROCEDURE ~ __ 0 _
I Date. 01/04/2017

ULTRASONIC EXAMINATION
PROCEDURE
(Issue 2)

ThIS is to certify that this procedure has been demonstrated to the satisfaction of the A. I. in accordance
with the requirements of T-1S0 of ASME Sec. V within the range of essential variables as detailed on
demonstration record included in the supplement to this procedure.

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INDEX
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1.0 Scope

2.0 References

3.0 Definitions

4.0 Responsibilities

5.0 Procedure

6.0 Attachments
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1. SCOPE:
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1.1 This Procedure describes the requirements for contact manual ultrasonic examination methods to be
employed for the examination of full penetration Welded Joints, heat affected zone and adjacent
material; fabricated in wrought rolled, drawn, forged, or extruded ferritic products, including pressure
vessels, power boilers and pipes.

1.2 This procedure is to cover the method to be employed for ultrasonic examination of plate and pipe
welds in steel having a parent material thickness of 10 mm or greater.

1.3 This procedure shall be demonstrated prior to use to the satisfaction of the Authorized Inspector in
accordance with the requirements of T-150, ASME Code Sec. V. The procedure demonstration
record shall be attached to this procedure.

1.4 A change of a requirement in Table T-421, identified as an essential variable from the specified value
or range of values shall require requalification of this procedure by demonstration. A change of a
requirement identified as a nonessential variable from the specified value or range of values does not
require requalification of the written procedure. All changes of essential or nonessential variables
from the specified value or range of values specified within this procedure shall require revision of
this procedure.

2. REFERENCES:
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2.1 ASME Boiler & Pressure Vessel Code Section V – Non Destructive Examination, Edition 2015.

2.2 ASME Boiler & Pressure Vessel Code Section I – Power Boilers, Edition 2015, for acceptance
criteria.

2.3 ASME Boiler & Pressure Vessel Code Section VIII Div. 1, Edition 2015, for acceptance criteria.

2.4 ASME B31.1 Edition 2012, Power Piping for acceptance criteria.

2.5 National Board Inspection Code, NBIC, edition 2015.

2.6 Client’s specification requirements for acceptance criteria.

3.1 TS Written Practice (Training, Qualification & Certification for NDE Personnel).

NOTE: In case of conflict between Code requirements and Client’s specifications, Code requirements shall
prevail.

3. DEFINITIONS:
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3.1 NDE: Non-Destructive Examination.

3.2 ASNT: American Society for Non-Destructive Testing.

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3.3 DAC: Distance Amplitude Correction.

4. RESPONSIBILITIES:
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4.1 The NDE Examiner shall be responsible for conducting and reporting the results of examination in
accordance with the ASME - B & PV applicable Code Section and Client’s specifications,
whichever is more restrictive.

5. PROCEDURE:
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5.1 Personnel Qualifications:

5.1.1 All personnel involved in Ultrasonic Examinations shall be qualified in accordance with the
requirements TS Written Practice (Training, Qualification & Certification for NDE Personnel).

5.1.2 When the written practice is revised, the certification of NDE personnel remains valid to
the requirements of the previous revision until the expiry date of the personnel qualification
certificate; then, recertification to the requirements of the new revision is required.

5.1.3 The certification of personnel shall be checked by the Quality Control Manager or NDE
Level III prior to work commencement.

5.1.4 Evaluation and reporting of examination results shall be done by at least a level II or III
certified NDE personnel.

5.2 Equipment:

5.2.1 Ultrasonic examination equipment shall be of the pulse echo type utilizing “A” scan
presentation, capable of generating and receiving frequencies between 1 and 5 MHz as a
minimum and shall be capable of recording UT data including the scanning positions.

5.2.2 The flaw detector shall be calibrated in accordance with the relevant calibration procedure.
A certificate of conformance shall accompany each flaw detector.

5.2.3 The ultrasonic instrument shall provide linear vertical presentation within ± 5% of the full
screen height (FSH) for 20% to 80% FSH. The procedure for evaluating screen height
linearity is carried out as per ASME section V, article 4, appendix I.

5.2.4 The ultrasonic instrument shall utilize an amplitude control accurate over its useful range
to 20% of the nominal amplitude ratio, to allow measurement of indications beyond the
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linear range of the vertical display on the screen. The procedure for evaluating amplitude
control linearity shall be performed as per code section V, Article 4, appendix II.

5.2.5 The requirements of 5.2.3 and 5.2.4 above; shall be met at intervals not to exceed three
months for analogue type instruments and one year for digital type instrument, or prior to
first use thereafter.

5.2.6 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 setting (s)
satisfy the requirements of T-467.3.

5.2.7 The ultrasonic examination equipment shall be checked for proper functioning and shall be
calibrated using the calibration procedure at the beginning and end of each examination,
when examination personnel are changed, and at any time that malfunctioning is
suspected, as a minimum. If during any check, it is determined that the examination
equipment is not functioning properly, all of the product that has been examined since the
last valid equipment calibration shall be re-examined.

5.3 Materials:

5.3.1 Search units shall be electrically matched to the flaw detector.

5.3.2 Search units shall be in the frequency range 1 MHz to 5 MHz and be free of noise and
internal reflections. Twin or single transducer elements may be used dependent upon the
configuration of weld under examination.

5.3.3 Search units with contoured contact wedges may be used to aid the ultrasonic coupling.
Calibration shall be done with the contact wedges used during the examination.

5.3.4 Each flaw detector shall have a full set of search units with cables; the search units shall
be of type, size and frequency, as required by the governing specification.

5.3.5 Calibration blocks shall include but not be limited to ASME non-piping Calibration Block
Fig. T-434.2.1, Piping Calibration Block Fig. T-434.3, or IIW-V2 with the flaw detector.
The operator shall also have access to IIW-V1, and such others that may be required
to ensure compliance with regard to calibration of flaw detector and probe
characteristics, e.g. beam angle, beam profile, exit point (index). etc.

5.3.6 For Nozzle Side Weld Fusion Zone and/or Adjacent Nozzle Parent Metal calibration
block shall be as shown in Figure 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 surface of the nozzle is clad before the
examination, the ID surface of the calibration block shall be clad
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5.3.7 Calibration Block Material shall be of the same product form, and material specification or
equivalent P-Number grouping as one of the materials being examined. For the purpose of
this procedure P-Numbers 1, 3, 4, 5A through 5C, and 15A through 15F materials are
considered equivalent. The calibration block shall have the same heat treatment
specification for the type and grade and also have the same surface finish.

5.3.8 For dissimilar metal welds, the calibration block 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.

5.3.9 Where the component material is clad and the cladding is a factor during examination,
the block shall be clad to the component clad nominal thickness ±1/8 in. (3 mm).
Deposition of clad shall be by the same method (i.e., roll-bonded, manual weld
deposited, automatic wire deposited, or automatic strip deposited) as used to clad the
component to be examined. When the cladding method is not known or the method of
cladding used on the component is impractical for block cladding, deposition of clad
may be by the manual method.

5.3.10 The calibration block shall receive at least the minimum tempering treatment required by the
material specification for the type and grade. If the calibration block contains welds other
than cladding, and the component weld at the time of examination has been heat treated,
the block shall receive the same heat treatment.

5.3.11 Measurements of beam spread for scan indexing limits shall be taken only when required by
a referencing code section. Beam spread angles shall be measured once for a search unit
wedge combination in the calculated far field at the beginning of each period of extended
use, or every 3 months, whichever is less.

5.3.12 Angles shall be measured accurate to ± 2º of the nominal (45º, 60º or 70º) for individual
search units.

5.3.13 Search units with worn faces shall not be used.

5.3.14 Couplant shall be used to give the maximum acoustic transmission between the probe face
and the material under examination.

5.3.15 The couplant, including additives, shall not be detrimental to the material being
examined.

5.3.16 Couplants used on nickel base alloys shall not contain more than 250 ppm of sulfur.

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

5.4 Surface Condition:

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5.4.1 Welds that are being examined using ultrasound shall be prepared to provide a sufficiently
smooth and regular area for scanning to be undertaken. The area shall extend at least the
full skip distance required, and shall be free of any irregularities such as spatter, grinding
or chipping marks scale, etc., which may hinder the scanning pattern or cause confusion in
the interpretation of the resultant display i.e. excessive surface noise.

5.5 Technical Information:

5.5.1 Prior to commencement of examination, the following information shall be obtained:

 Type of material.
 Joint configuration.
 Welding Process.
 Other information that may have a bearing on the inspection e.g. post weld heat
treatment, etc.

5.6 Examination Procedure:

5.6.1 For examinations in materials where the examination surface diameter is greater than 20 in.
(500 mm), a block of essentially the same curvature shall be used, or alternatively, a flat
basic calibration block, may be used, provided that, gain correction shall be adjusted as
described in code section V, Article 4, Appendix A.

5.6.2 For examination in materials where the examination surface diameter is 20 in. (500 mm), or
less, the calibration block shall be curved. Except where otherwise stated in the reference
code, 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.

5.6.3 The scanning requirements of this procedure are based on the use of at least two probes of
differing angles (one longitudinal zero angle and the other is angle probe) from each side
of the weld.

5.6.4 The scanning sensitivity level shall be set a minimum of 6 dB higher than the reference
level gain setting or, when a semi-automatic or automatic technique is used, it may be set
at the reference level.

5.6.5 For contact examination, the temperature differential between the calibration block
and examination surfaces shall be within 14° C.

5.6.6 Calibration
5.6.6.1 Straight Beam Calibration (0° Probe):
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(A) The equipment is calibrated using a straight beam probe for a suitable
range for the thickness of material being examined. A minimum of two
back wall echoes from the material under test be noted during the
examination.

(B) A Distance Amplitude Correction curve (DAC curve) shall be produced

using the appropriate calibration block. The gain control is adjusted to
produce a response of 80% full screen height and the screen is marked.
The probe is then re-positioned to give the maximized response for each
of the remaining holes. At each maximized position, mark the position of
maximum response on the screen.

Connect the screen marks to produce the DAC curve. This gain setting is
the primary reference level.

5.6.6.2 Angle Beam Calibration:

(A) The equipment is calibrated for a suitable range for the beam path length
required to satisfactorily complete the examination, (i.e. Full Skip
Distance).

(B) Produce a DAC curve in accordance with paragraph 5.6.5.1(B).

(C) No point on the DAC curve shall be less than 20% of full screen
height (FSH). When any portion of the DAC curve will fall below
20% FSH, a split DAC shall be used. The first calibration reflector
on the second DAC shall start at 80% ± 5% FSH. When reflector
signal-to-noise ratio precludes effective indication evaluation and
characterization, a split DAC should not be used.

5.6.6.3 System Calibration:

System calibration shall be carried out at the commencement of and at 4 hourly

intervals during, the inspection and on completion of an inspection.

If during the calibration confirmation the sweep range of the DAC curve has
changed by the following tolerances:

 Sweep Range:

If a point of the DAC curve has moved on the time base by more than
10% of its original time base position.

 DAC Curve:
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If a point on DAC curve has changed by ± 20% or 2 dB from its original

amplitude.
Then the following action shall be taken:

 Sweep Range:

The calibration shall be corrected with a note of the correction being made
on the report. If any signals have been recorded, all recorded indications
shall be re-examined with the corrected calibration and their values
corrected accordingly on the report.
 DAC Curve:

If any point on the DAC curve has decreased by 20% or 2 dB all recorded
data since the last valid calibration shall be marked void. A new DAC
curve shall be produced with a note to this effect on the report and the
voided are as shall be re-examined. If any point on the DAC Curve has
increased following the production of the new DAC curve. A note of this
shall be made on the report.

5.6.7 Inspection Technique

5.6.7.1 Parent Metal Examination

Prior to any examination of the weldments, the parent material shall be

examined. A compression wave 0 examination will be carried out for a minimum
of 3 in. (75 mm) either side of the weld to locate any flaws in the parent material
and to determine its thickness.

5.6.7.2 Weld Examination. Plate and Pipe Welds

A critical root scan shall be carried out from both sides of the weld, with at least
one angle probe directed essentially perpendicular to the weld axis so as to
distinguish between root variations and the existence of root cracks or crack-like
defects. This may be done where practicable with the aid of a magnetic strip
placed so that the distance from the probe index to the root will be constant. The
body and fusion faces of the weld shall then be examined using a continuous
scanning raster from both sides of the weld between the weld center line or the
cap edge whichever is appropriate and full skip plus the cap width using at least
two probes of differing angles.

5.6.7 Scanning

5.6.7.1 Datum:
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A datum reference point shall be clearly marked on the work-piece and shall be
marked with the weld identification. The datum shall be used for a reference for
locating defects, and the reporting of defects.

5.6.7.2 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.

5.6.7.3 Angle beam 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.

5.6.7.4 The angle beam shall be directed at approximate right angles to the weld axis
from two directions where possible to detect discontinuities oriented parallel to
the weld axis.
5.6.7.5 The angle beam shall be directed essentially parallel to the weld axis and shall
be manipulated so that the angle beam passes through the required volumes of
weld and adjacent base metal specified by the referencing code in order to
detect discontinuities oriented transverse to the weld axis.
The search unit shall be rotated 180º and the examination shall be repeated.

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

5.6.7.7 Oscillation of the search unit is permitted if it can be demonstrated that

overlapping coverage is provided.

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

5.7 Defect Evaluation And Sizing

5.7.1 Certain Metallurgical and geometric conditions may produce indications that are not
relevant, 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:

5.7.1.1 Interpret the area containing the reflector in accordance with this procedure.

5.7.1.2 Plot and verify the reflector coordinates. Prepare cross sectional sketch showing
the reflector position and surface discontinuities such are root and counter bore.

5.7.1.3 Review fabrication of weld preparation drawings.

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5.7.1.4 Use another ultrasonic techniques or NDE methods as appropriate to determine

reflector’s true position, size, and orientation.

5.7.2 Any imperfection which causes an indication in excess of 20% DAC shall be investigated to
the extent that it can be evaluated in terms of the acceptance standards of the referencing
code section. The indication shall be investigated to:
 Confirm its existence.
 Determine its location with reference to the established datum points.
 Determine its size.
 Determine its nature.
This investigation may require scanning from other positions and with different probes. It is highly
subjective in its nature and should be carried out with extreme care.
The recommended sizing techniques are as follows:
 Defect Length
Use the 6 dB drop technique, marking the probe centre at the defect end points.
 Through Thickness Dimension
Use the 20 dB technique in conjunction with an adjustable flaw location slide
The recording levels and rejection levels shall be in accordance with the referencing Code or
standard.
All defects shall be assessed in accordance with the requirements of the applicable referencing
Code Section.
5.8 Reporting
5.8.1 Upon completion of the examination the examiner shall prepare an examination report, for
each weld or area of weld examined, using the Company report from. All restrictions which
limit the effectiveness of the test must be recorded.

5.8.2 Rejectable indications shall be recorded. As a minimum, the type of indication (i.e.,
crack, non-fusion, slag, etc.), location, and extent (i.e., length) shall be recorded.
Nonmandatory Appendices D and K provide general recording examples for angle and
straight beam search units. Other techniques may be used.

5.8.3 All reflectors greater than 50% of the reference level shall be reported and shall be
described with regard to size, shape, location and probable identity/classification.

5.8.4 In addition, sketches and drawings shall be prepared to support written descriptions.

5.8.5 The following information shall be included in the report.

5.8.5.1 Unique report number.

5.8.5.2 Material and grade.
5.8.5.3 Weld preparation and process.
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5.8.5.4 Welder identification.

5.8.5.5 Surface preparations.
5.8.5.6 procedure identification and revision;
5.8.5.7 ultrasonic instrument identification (including manufacturer’s serial number);
5.8.5.8 search unit(s) identification (including manufacturer’s serial number,
frequency, and size);
5.8.5.9 beam angle(s) used;
5.8.5.10 couplant used, brand name or type;
5.8.5.11 search unit cable(s) used, type and length;
5.8.5.12 special equipment when used (search units, wedges, shoes, automatic
scanning equipment, recording equipment, etc.);
5.8.5.13 computerized program identification and revision when used;
5.8.5.14 calibration block identification;
5.8.5.15 simulation block(s) and electronic simulator(s) identification when used;
5.8.5.16 instrument reference level gain and, if used, damping and reject setting(s);
5.8.5.17 calibration data [including reference reflector(s), indication amplitude(s), and
distance reading(s)];
5.8.5.18 simulation block(s) and electronic simulator(s) identification when used;
5.8.5.19 data correlating simulation block(s) and electronic simulator(s), when used,
with initial calibration;
5.8.5.20 identification and location of weld or volume scanned;
5.8.5.21 surface(s) from which examination was conducted, including surface
condition;
5.8.5.22 map or record of rejectable indications detected or areas cleared;
5.8.5.23 areas of restricted access or inaccessible welds;
5.8.5.24 examination personnel identity and, when required by referencing Code
Section, qualification level;
5.8.5.25 Date of examination.
5.8.5.26 Inspection and acceptance criteria.
5.8.5.27 Calibration sheet identity.

Items 5.8.5.7 through 5.8.5.19 may be included in a separate calibration record provided the
calibration record identification is included in the examination record.

5.9 Acceptance Criteria:

5.9.1 Acceptance criteria shall be as specified in the referencing Code section or as specified by
the Client, whichever is more restrictive.
♦ ASME Code, Section I, PW-52. 3
♦ ASME Code, Section VIII-DIV. 1 mandatory appendix 12.
♦ ASME B31.1 chapter VI Para. 136.4.6

5.10 Post Examination Cleaning:

5.10.1 After examination, parts shall be cleaned and traces of the couplant used shall be removed
from the surface by using suitable cleaners.
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6. ATTACHMENTS:
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6.1 Ultrasonic Examination Report.

6.2 Ultrasonic Calibration Record.
6.3 Procedure Demonstration Record.
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Check List for Compliance with ASME Sec. V, Article 4 Essential variables

Sr.
No. PROCEDURE VARIABLES TYPE OF VARIABLE Ref. Paragraph

Weld configuration to be examind,including thickness dinensions and

1 base material product form(pipe,plate) Essential 5.5.1

The Surface form which the Examination shal be performed

2 Essential 5.4.1

3 Tehnique (s)(straight beam, angle,contact andorimmartion Essential 5.6.7

4 Angle(s)and mode of wave propgationin material Essential 5.6.3
5 Search unit ype(s).fequency and element size Essential 5.3.2-5.3.4
Essential N.A
6 Special search unite .wedge shose. Or saddle

7 Ultrasonic instrument Essential 5.2.3-5.2.4

8 Calibration block(S)and technique Essential 5.3.5 theough 5.3.8
9 Direction and extend of scanning Essential 5.6.7.4
10 Scanning (manual vs.automatic) Essential 1.1
11 Method for discriminating geometric from flaw indication 5.7.2
12 Method for sizing indication 5.7.2
13 Computer enhanced data acquisitionwhen used Essential N.A

Scan overlap (decrease only)

14 Essential 5.6.7.6

15 Personnel performance requirment ,when required Essential N.A

5.1
16 Personnel qualification requirment Nonessential
5.4
17 Surface condation (examination surface, calpbration block) Nonessential
5.3.15
18 Couplant: brand name or type Nonessential
Post examination cleaning technique 5.10
19 Nonessential
Automatic alarm and or recording equpment,when required N/A
20 Nonessential
Record, including minimum calibration data to be recorded
21 (e.g.instroment setting) Nonessential N/A