ULTRASONIC EXAMINATION PROCEDURE

BY : YUDHA ZEN
 PROCEDURE FOR ULTRASONIC EXAMINATION OF WELDS

TABLE OF CONTENTS

1.0 SCOPE……………………………………………………………………………….

2.0 REFERENCE………………………………………………………………………..

3.0 SAFETY AND PRECAUTION HAZARD

IDENTIFICATION…………………………………………………………………..

4.0 PERSONNEL QUALIFICATION………………………………………………….

5.0 EQUIPMENT REQUIREMENTS………………………………………………….

6.0 GENERAL EXAMINATION REQUIREMENTS…………………………………

7.0 BASIC CALIBRATION BLOCK………………………………………………….

8.0 SYSTEM CALIBRATION AND CALIBRATION

CONFIRMATION…………………………………………………………………..

9.0 EXAMINATION OF WELDS………………………………….…………………..

10.0 COUPLANT…………………………………………………….…………………..

11.0 DEFECT SIZING (LENGTH)………………………………….…………………..

12.0 ACCEPTANCE CRITERIA………………………………………………………..

13.0 REPORTING………………………………………………………………………..

14.0 APPENDIX………………………………………………………………………….
1.0 SCOPE

This procedure establishes the requirement for pulse echo ultrasonic examination to
evaluate full penetration welds in steel plates, beams, turbulars and pipes. The general
requirement will be conditional to examination of all welds whilst specific changes may
be deemed necessary to suit particular dimension, geometry and material of specific
welds.

2.0 REFERENCE

ASME Section V : 2004 Edition.

ASME B31.3 : 2004 Edition , 2003 Addendum.
ASTM A 435 : Lamination Check – 2002 Edition.

3.0 SAFETY PRECAUTION AND HAZARD IDENTIFICATION

All Personnel performing UT Shall be fully aware of the potential site working hazard
and take the necessary safety precaution during the time and inspection. E.g. Working
at height, confine spaces, etc.

4.0 PERSONNEL QUALIFICATION

Ultrasonic Inspector shall be qualified to the following:

Personnel having PCN / CSWIP Level II shall be engaged on the job.

5.0 EQUIPMENT REQUIREMENT

5.1 The examination shall be conducted with an ultrasonic pulse reflection system
generating frequencies covering the nominal range of 1 MHz to 5 MHz with a
rectified ‘A’ scan display. Such equipment includes the Krautkramer USK 7.

5.2 The ultrasonic pulse-echo instrument shall provide linear vertical presentation
within +/- 5% of the full screen height for 20% to 80% of the full screen height
(base line to maximum calibrated screen height). The screen height linearity shall
be measured and recorded as per procedure set out in Appendix 1.
 5.3 The ultrasonic pulse echo 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 amplitude control linearity shall be measured and recorded as per
procedure set out in Appendix 2.

5.4 The pulse-echo instrument shall be calibrated weekly and the calibration results
filed using the format shown in Appendix 5. The equipment shall be serviced with
respect to its service manual at least once a year.

Equipment shall be checked at the beginning and end of each examination, when
examination personnel are exchanged or at anytime when malfunctioning
suspected.

5.5 Frequency of straight beam probes shall be between 1 MHz

to 5 MHz, with diameters 10mm to 25mm size. A4MHz 20mm diameter probe
shall normally be used.

5.6 For angle probes, frequencies of 2 MHz to 4 MHz with crystal size of
approximately 20mm shall normally be used. Exit point and exact angle of beam
propagation of each individual probe shall be checked and marked before
commencement of a test. Type of probes used shall include Krautkramer MWB
series.

6.0 GENERAL EXAMINATION REQUIREMENT

6.1 Examination Coverage

The area to be tested shall be examined by moving the search unit over the
examination surface so as to scan the entire examination volume. As a
minimum, each pass of search unit shall overlap a minimum of 10% the
transducer dimension perpendicular to the direction of the scan.

6.2 Rate of Search Unit Movement

The rate of search unit movement shall not exceed 6 in/sec (153mm/sec)
unless calibration is verified at scanning speed.

6.3 Scanning Sensitivity Level

Scanning shall be performed at a gain setting at least two times the

reference level. During scanning, only the gain or attenuator controls will be
adjusted. Any adjustment of the other controls shall require recalibration.

6.4 Transducer Scanning Pattern

The examination volume shall be scanned with angle beam probes directed
 both at right angles to the weld axis and along the weld axis. In order to
detect all possible defects, the following scanning pattern shall be utilized
as much as weld and test specimen configuration would permit.

6.4.1 Transverse Motion

This movement is necessary to examine the complete cross

section of the weld and heat affected zone. The extent of such
movement is normally equal to the skip distance.

6.4.2 Lateral Motion

This movement should be made to scan the specified length of the

welded joint. This is combined with the traversing motion so that
each successive probe displacement has an overlap dimension not
less than that stated in 5.1 above.

6.4.3 Swiveling Motion

During the movement both towards and away from the welded joint the
probe shall be done at an angle not exceeding 15 degrees from the
weld axis from both directions and sides of the weld.

6.4.4 Transverse Scanning

On cases where transverse defects in the weld is to be detected,

scanning shall be done at an angle not exceeding 15 degrees from the
weld axis from both directions and sides of the weld.

Alternatively, the weld surface may be dressed flush with the parent
metal and a transverse scan be performed over the weld surface along
the weld axis.

6.5 Transfer Correction

In the event calibration is not performed on an off-cut of the component to be

tested, it will be deemed necessary to determine the difference in gain setting
necessary to compensate for transfer loss. This can be obtained from the
amplitude difference between the signals obtained from the edge of the
calibration block and from the edge of the component with similar thickness.
7.0 BASIC CALIBRATION BLOCK

7.1 Calibration Block Material

The basic calibration block shall be a section of product form of the same
nominal size, schedule, heat treatment of material specification or
equivalent P-Number groupings as one of the materials being examined.
The block size and reflector locations shall be adequate to perform
calibration for the beam angles used. For calibration blocks for dissimilar
metal welds, the material selection shall be used on the side of the weld
from which the examination will be conducted.

If examination will be conducted from both sides, calibration reflectors shall

be conducted from both sides, calibration reflectors shall be provided in
both materials. Where two or more base material thickness are involved,
the calibration block thickness shall be determined by the average thickness
shall be determined by the average thickness of the weld.

7.2 Clad

Where the component materials are cladded, the block shall be cladded by
the same method as the production part.

7.3 Surface Finish

The finish on the surface of the block shall be representative of the surface
on the components.

7.4 Block Quality

The calibration block material shall be completely examined with a straight

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

7.5 Basic Calibration Reflectors

The calibration block and reflector configurations shall be as specified in

T441.1.1 in Article 4 and T542.2.1 in Article 5 of ASME V (2004), according
to their thickness and diameter (in the case of pipe) as stated. Additional
reflectors may be installed; these reflectors shall not interfere with
establishing the primary reference.

7.6 Materials with diameters greater than 508mm

For examination of materials where the examination surface diameter is

greater than 508mm, a block of essentially the same curvature, or
alternatively a flat basic calibration block, shall be used.
 7.7 Material with diameters less than 508mm.

The basic calibration block shall be curved for materials with diameters 20”
and less. 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.

8.0 SYSTEM CALIBRATION AND CALIBRATION CONFIRMATION

8.1 System Calibration

Calibration shall include the complete ultrasonic examination system. The

original calibration shall be performed on the basic calibration blocks as per
ASME Section V, Article 4, Appendix B.

8.2 Calibration Check

Calibration check shall be performed before commencement of a test.

When any part of the examination system is changed, a calibration check
shall be made on the basic calibration block to verify any change of values.

Such changes may include:

1. Changes of transducer or cable

2. Change of power source
3. Manipulation of on/off switch
4. Manipulation of any other settings on the equipment with exception to
the gain setting.

8.3 Sweep Range Correction

If a point on the DAC curve has moved on the sweep line more that 10% of the
sweep reading or 5% of full sweep, whichever is greater, the sweep range
calibration shall be noted and corrected. All recorded indications since the last
valid calibration check shall be re-examined with corrected calibration and their
values shall be changed on the data sheets.

8.4 DAC Correction

If a point on the DAC curve has decreased 20% or 2 Db of its amplitude, all
data sheets since the last calibration check shall be marked void. A new
calibration shall be made and recorded and the area covered by the voided
data shall be re-examined. If any point of the DAC curve has increased more
than 20% or 2 Db of its amplitude all recorded indications since the last valid
calibration and their values shall be changed on the data sheets.
9.0 EXAMINATION OF WELDS

9.1 Surface Preparation

The base metal on each side of the weld shall be free of weld spatter, surface
irregularities or foreign matter that might interfere with the examination.

9.2 Straight Beam Scanning

Straight beam scanning of the adjacent base metal shall be performed to

detect reflectors that may lie in the horizontal plane parallel to the scanning
surface. Locations and area of such reflectors shall be recorded and
evaluated for acceptance and rejection accordingly.

9.3 Angle Beam Scanning

Angle beam scanning shall be directed at approximate right angles to the

weld axis from two directions where possible. The search unit shall be
manipulated so that the ultrasonic energy passes through the required
volumes of weld and adjacent base metal.

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. Transducers angle include 45, 60, 70 degrees. A minimum
of three angle probes are to be used for each examination in addition to the
zero degree probe on parent metal. (where specimen thickness allows).

9.4 Butt Welds

Scanning of butt welds should be done within half skip and full distance. In
the case of curve surfaces, the effect of curvature should be taken into
consideration in locating echo origin.

9.5 Nozzle Welds (Full Penetration)

Nozzle orientation and weld configuration should be studied to understand

the shift in echoes due to change on geometry . Test should be performed
from more than one scanning face if possible. In the case of large diameter
nozzles, scan should be performed also from the nozzle internal.

9.6 Evaluation

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
– rejection standard of the relevant code section.

10.0 COUPLANT

Grease, light oil or cellulose paste shall be used as couplant. The couplant used
shall not be injurious to the material to be tested or disturb post scanning surface
treatment. The same couplant shall be used for sensitivity calibration and production
test.
11.0 DEFECT SIZING (LENGTH)

All reflections from weld defects will be maximized from all angles to find the best
angle which is compatible to the defect orientation. The defect echo will be adjusted
to the screen’s graticule. The defect echo will be adjusted to the screen’s graticule
height and sized in the following manner:

11.1 Compressional Wave

The 6 Db drop method shall be used for sizing large defects. Small defects
shall be expressed as a percentage amplitude of the back wall echo.

11.2 Shearwave

The 6 Db drop method shall be used for sizing large defects lengths whilst
the 20 Db drop method may be used for sizing small defects. For sizing
defect height, the 20 Db drop method or the maximum amplitude technique
may be used.

12.0 ACCEPTANCE CRITERIA

The acceptance / rejection criteria shall be as per Appendix 9 of ASME VIII

Div. 1 / ASME B31.3 for Piping, 2004 Edition,
ASTM A 435 for Lamination Check - 2002 Edition.
13.0 REPORTING

13.1 All tests performed shall be recorded in proper reports with the following
information included :

i. Project Title

ii. Weld Identification and Spool No and Line No

iii. Weld Geometry

iv. Ultrasonic Procedure No.

v. Specification for Acceptance

vi. Equipment Used

vii. Frequency Range

viii. Couplant

ix. Basic Calibration Blocks

x. Result of Test

xi. Name and Signature

xii. Date of Test

xiii. Material Tested (Type).

13.2 Any defects found shall be recorded with the following information included :

i. Location of Defect

ii. Size of Defect

iii. Defect Type Assessment

14.0 APPENDIX

APPENDIX 1 : INSTRUMENT CALIBRATION

APPENDIX 2 : AMPLITUDE CONTROL LINEARITY

APPENDIX 3 : ULTRASONIC EXAMINATION REPORT

APPENDIX 4 : TEST PROCEDURE

APPENDIX 5 : CALIBRATION FORMAT FOR ULTRASONIC FLAW

DETECTOR
 APPENDIX 1

INSTRUMENT CALIBRATION

A. Screen Height Linearity

Position an angle beam search unit so that indications can be observed from both the ½ t
and ¾ t holes in a basic calibration block. Adjust the search unit position to give a 2 : 1 ratio
of amplitudes between the two indications, with the larger set at 80% of full screen height.
Without moving the search unit adjust sensitivity (gain) to successively set at the larger
indication from 100% to 20% of full screen height, in 10% increments (or 2 dB steps) and
read the smaller indication at each setting. The reading must be 50% of the larger amplitude
within 5% of full screen height. The settings and readings must be estimated to the nearest
1% of full screen. Alternatively, a straight beam search unit may be used on any calibration
block which will provide amplitude differences, with sufficient signal separation to prevent
overlapping of the signals.
 APPENDIX 2

Amplitude Control Linearity

Position and angle beam search unit so that the indication from ½ t hole in basic calibration
block is peaked on the screen. With the increases and decreases in attenuation shown in
the following table, the indication must fall within the specific limits. Other convenient
reflectors from any calibration block may be used with angle or straight beam search units.
The settings and readings must be estimated to the nearest 1% of full screen.

Indication Set At % dB Indication Limits %

of Full Screen Change of Full Screen
------------------------- ---------- --------------------------

80% - 6 dB 32% to 48%

80% - 12 dB 16% to 24%

40% + 6 dB 64% to 96%

20% + 12dB 64% to 96%

 APPENDIX 3

Refer Attached Report format

 APPENDIX 4 SHT. 1 0F 8

TEST PROCEDURE NO : UTP -01

70º,60º, 45º 70º,60º, 45º

0º Comp. Probe Shear Probe Shear Probe

Whichever is
applicable

NOT ACCESSIBLE

TYPE OF WELD : BUTT WELD ( ACCESSIBLE FROM ONE SIDES)

THICKNESS BELOW 25mm min of 8mm ABOVE 25

PROBE DETAILS 0º Compressional . 0º Compressional .
*
70º,60º,45ºShear. 70º,60º,45ºShear.

SCANNING HALF SKIP & FULL SKIP

RANGE

* Note :
As per specimen thickness
 APPENDIX 4 SHT. 2 0F 8

TEST PROCEDURE NO : UTP - 02

0º Comp. Probe
70º,60º, 45º 70º,60º, 45º
Shear Probe Shear Probe

70º,60º, 45º 70º,60º, 45º

Shear Probe Shear Probe

TYPE OF WELD : BUTT WELD ( ACCESSIBLE FROM BOTH SIDES)

THICKNESS BELOW 25mm min of 8mm ABOVE 25

PROBE DETAILS 0º Compressional . 0º Compressional .
70º,60º,45ºShear. * 70º,60º,45ºShear.

SCANNING HALF SKIP & FULL SKIP

RANGE

* Note :
As per specimen thickness
 APPENDIX 4 SHT. 3 0F 8

TEST PROCEDURE NO : UTP – 03

70º,60º, 45º
Shear Probe

0º Comp. Probe 70º,60º, 45º

Shear Probe
0º Comp. Probe

70º,60º, 45º
Shear Probe

TYPE OF WELD : FULL PENETRATION NOZZLE WELD

THICKNESS BELOW 25mm ABOVE 25mm
PROBE DETAILS 0º Compressional . 0º Compressional .
*
70º,60º,45ºShear. 70º,60º,45ºShear.

SCANNING HALF SKIP

RANGE

* Note :
As per specimen thickness
 APPENDIX 4 SHT. 4 0F 8

TEST PROCEDURE NO : UTP – 03

NOT
ACCESSIBLE

NOT
ACCESSIBLE

TEE JOINT and NOZZLE

TYPE OF WELD
(Accessible From One Side)

PROBE DETAILS 70 °, 60 °, 45 ° and 0 °

SCANNING RANGE FULL SKIP & HALF SKIP

 APPENDIX 4 SHT. 5 0F 8

TEST PROCEDURE NO: UTP - 04

( NOT
ACCESSIBLE)

0º Comp. Probe 70º,60º, 45º

Shear Probe)

(NOT ACCESSIBLE)

TYPE OF WELD : FULL PENETRATION NOZZLE WELD

THICKNESS BELOW 25mm ABOVE 25mm
PROBE DETAILS 0º Compressional . 0º Compressional .
*
70º,60º,45ºShear. 70º,60º,45ºShear.

SCANNING HALF SKIP & FULL SKIP

RANGE

* Note :
As per specimen thickness
 APPENDIX 4 SHT. 6 OF 8

TEST PROCEDURE NO.: UTP – 04

TYPE OF WELD TEE JOINT and NOZZLE

(Accessible From Both Sides)

PROBE DETAILS 70  , 60 , 45 and 0

SCANNING RANGE FULL SKIP & HALF SKIP

 APPENDIX 4 SHT. 7 OF 8

TEST PROCEDURE NO.: UTP – 05

Tubular Internal
(Not Accessible)

Tubular Internal
(Not Accessible)

Tubular Internal
(Not Accessible)

Tubular Internal
(Not Accessible)

TYPE OF WELD TKY TUBULAR JOINTS

(Not Accessible From Internal Surface)

PROBE DETAILS 70  , 60 , 45 and 0

SCANNING RANGE FULL SKIP & HALF SKIP

 APPENDIX 4 SHT. 8 OF 8

TEST PROCEDURE NO.: UTP - 06

TYPE OF WELD TKY NON TUBULAR

(Accessible From Both Sides)

PROBE DETAILS 70  , 60 , 45 and 0

SCANNING RANGE FULL SKIP & HALF SKIP

 APPENDIX 5 SHT. 1 OF 2

CALIBRATION PROCEDURE FOR TIME BASE LINEARITY:

1) Calibrate the screen for the test range of 125mm using single crystal transducer
and IIW-VI Block.

2) Place the probe on 25mm thickness side and read the back wall echoes. Adjust
so that the 1st and 5th back wall echo coincide with graticule line the CRT
screen.

3) Bring successful back wall echoes to approximately 80 FSH.

Record any deviation.

4) The percentage of error is calculated based on actual reading and the expected
reading.

5) The error should not exceed ± 2% of test range.

TIME BASE LINEARITY :

BACK WALL ECHO

TEST BLOCK READINDS RESULT
RANGE THICKNESS (mm)
125 (mm)
1 2 3 4 5

Calculated Reading

Actual Reading

Deviation
 APPENDIX 5

ROUTINE OPERATOR CHECKS ON THE PERFORMANCE

OF ULTRASONIC FLAW DETECTORS.

JOB LOCATION : EMPLOYER:

CHECK SHEET FOR WEEK ENDING: DATE CARRIED OUT:
FLAW DETECTOR MAKE:
MAKERS SERIAL NO. : TYPE :

NOTE : ALL RESULTS MUST BE RECORD

TEST TOLERANCE RANGE RESULT PASS/FAIL
Time base Linearity ± 2%
+ 2dB Not less than
95% f.s.h
Attenuator Accuracy 0 dB -
(Datum point 80% -6dB 35% to 45%
f.s.h) f.s.h
-18 dB 8% to 12%
f.s.h
-24dB to be visible
above
base line
Difference between Main
smaller Signal
signal and 1/2 larger 100%
signal
height to be better 80%
than 5%
f.s.h or 60%
height(whichever is
less) 40%
20%
Equipment All three echoes to Probes
Resolution be used
clearly resolved
Maximum Minimum of 3 echoes
Penetrative
Power

Signature of Operator :____________________________

Name of Operator:________________________