1 Purpose

The purpose of this procedure is to describe the methods of performing ultrasonic

examination of weldments in accordance with ASME Code requirements.

2 Scope

This procedure meets the requirement of ASME Code Section I, V and VIII Div.1,
ASME B31.3, ASME B31.1 & API 1104.

3 Personnel Qualification

3.1 All personnel performing Ultrasonic Examination according to this

procedure shall be qualified as per the requirements of SNT-TC-1A.
3.2 Certified UT Level I may operate equipment and perform ultrasonic testing
under the direct supervision of UT Level II.

3.3 The Ultrasonic Examination shall be carried out under the guidance or
supervision of a certified NDT Level II or level III individual.

4 Equipment

4.1 UT Equipment:

The Ultrasonic Test equipment shall be of the pulse-echo type. It shall

generate, receive and present on a cathode-ray tube screen pulses in
frequency range from 1 to 6 (MHz). The presentation on the CRT screen shall
be the "Video" type and characterized by a clean, crisp trace. It shall be
equipped with a stepped gain control calibrated in units of 2 dB or less. It
shall be able to work with both combined and separated transmitter and
receiver probe. The following make and models or equivalent can be used:
a) Krautkramer Model 22 B
b) Panametric EPOCH LT or equivalent
4.1.1 Screen height linearity
The ultrasonic instrument shall provide a linear vertical presentation
within ±5% of the full screen height for 20% to 80% of the calibrated
screen height (baseline to maximum calibrated screen points)
4.1.2 Amplitude control Linearity
The ultrasonic instrument shall utilize and amplitude control accurate
over its useful range to ±20% of the nominal amplitude ratio to allow
measurement of indications beyond the linear range of vertical display
on the screen.
 4.1.3 Horizontal Linearity
The ultrasonic instrument shall provide a horizontal linearity within
±1% over the whole range.
The procedure for evaluation horizontal linearity, screen height linearity and
amplitude control linearity shall be as mentioned in Calibration section of this
procedure.

4.2 Probes :

The probes to be used shall have the following characteristics :

a) Probe unit may contain either single or dual probe elements.

o o o o
b) Angle : O , 45 , 60 and 70 probe.
c) Frequency : 2 to 5 MHZ
d) Crystal size (mm) : 8X9 to 20X22 for angle probes;
Diameter 10 to 25 for normal probes.
e) Probes with contoured contact wedges may be used to aid ultrasonic
coupling. In such cases, calibration shall be done with the contact
wedges used during the examination.
f) The sizes and frequencies other than stated in (b) and (c) above may
be used to assure adequate penetration or better resolution.

4.3 Couplant :

4.3.1A couplant which causes acoustic coupling between the transducer and
the part being examined shall be used. The same couplant used during
calibration shall be used for examination. Any of the following couplants
may be used :

 Grease
 Oil
 Water
 Cellulose powder dissolved in water.

 Other couplants which cause satisfactory acoustic coupling may be

used when approved by the NDT Level III.
4.3.2The couplant including additives, shall not be detrimental to the material
being examined.
a) Couplants used on nickel base alloys shall not contain more than
250ppm of sulfur.
b) Couplants used on austenitic stainless steel or titanium shall not
contain more than 250 ppm of halides (chlorides plus fluorides)

5 Calibration

5.1a Check Of Calibration :

 The check of calibration during examination shall be carried out in the
following cases:

 Whenever the equipment is turned on.

 When an element of system (cable, probe) is changed.
 when the operators change during examination
 whenever there is any doubt concerning proper functioning of
equipment.
A new calibration shall be made, and all the inspected area since the last
valid calibration shall be re-examined, if at calibration check it is verified that:

 a point of the D.A.C. curve has moved on the sweep line more than 10%
of the sweep division reading.
 a point on the D.A.C. curve has decreased more than 20% or 2dB of its
amplitude.
 If a point of the D.A.C. curve has increased more than 20% or 2dB of its
amplitude, all recorded indications since the last valid calibration shall
be evaluated again and their values shall be changed on the reports.

5.1b Screen Height Linearity Check :

To verify the ability of the ultrasonic instrument to meet the linearity

requirement, position an angle beam search unit as shown in Fig. I-1 so that
indications can be observed from both the ½ and ¾T 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 the larger indication form 100% to 20% of full screen height,
in 10% increments (or 2 dB steps if a fine control is not available), 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 two
signals.
5.1c Amplitude Control Linearity Check :

To verify the accuracy of the amplitude control of the ultrasonic instrument,

position an angle beam search unit as shown in Fig I-1 so that the indication
from the ½T hole in a 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 specified limits. Other convenient reflectors
from any calibration block may be used with angle or straight beam search
units.

Indication set at % Control Change Indication Limits % of Full

of Full Screen dB Screen
80% - 6 dB 32 to 48%
80% -12 dB 16 to 24%
40% +6 dB 64 to 96%
20% +12 dB 64 to 96%

The settings and readings must be estimated to the nearest 1% of full screen.

5.1d Horizontal Linearity Check

Measuring range from 0 to 100mm

Place the probe on the IIW V1 block as shown in Figure 5.2.1. Make
adjustments to get four signals on the screen as shown in Figure 5.2.2.
Check and record the actual position of each back reflection.
Measuring range from 0 to 250mm
Make adjustments to get 10 signals on screen as shown in figure 5.2.3.
Check and record the actual position of each back reflection.
Measuring range from 0 to 500 mm
Place the probe on IIW V1 Block as shown in Figure 5.2.4 and adjust 5 signals
on the screen as shown in Figure 5.2.5. Check and record the actual position
of each back reflection.

Admissible Deviation
Deviation between actual location of each back reflection and required
location shall be within +/-1% of full scale.
 Figure 5.1.1 Figure 5.1.2

Figure 5.1.3

Figure 5.1.4
Figure 5.1.5

5.2 Equipment Calibration

5.2.1 Calibration Standards

5.2.1.1 IIW V1 / V2 blocks (See Figure 1)
Use for Distance Calibration, linearity checks, angle checks and index point.
5.2.1.2 Basic Calibration Block
Use for amplitude calibration (See Figure 2)
5.2.2 Basic Calibration Block
The basic calibration reflectors shall be used to establish a primary reference
response of the equipment.
 5.2.2.1 Calibration block material
The material from which the block is fabricated shall be of the same
product form, and material specification or equivalent P-number
grouping as the material(s) being examined. P-numbers 1,3,4 and 5
materials are considered equivalent for this purpose. Calibration
blocks for dissimilar metals 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.
5.2.2.2 Calibration Block Thickness
When two or more base material thickness are involved, the
calibration block thickness shall be determined by the average
thickness of the weld.
5.2.2.3 Calibration block surface finish
The finish on the surfaces on the block shall be representative of the
surface finishes on the components to be examined.
5.2.2.4 Heat Treatment
The calibration block shall receive at least the minimum tempering
treatment required by the material specification for ;the type and
grade and also a postweld heat treatment of at least 2 hours if the
calibration block contains welds other than cladding.
5.2.2.5 Basic Calibration Reflectors
The side of a hole drilled with its axis parallel to the examination
surface is the basic calibration reflector. A square notch shall also be
used. The reflecting surface of the notches shall be perpendicular to
the block surface.
5.2.2.6 Curved Test surfaces
a) Materials with diameters greater than 508 mm
For examination in materials where the examination surface
diameter is greater than 508 mm, a block of essentially the same
curvature or alternatively, a flat basic calibration block, shall be
used.
b) Materials with diameters 508mm or less
For examination in materials where the examination surface
diameter is 508 mm and less, the basic calibration block shall be
curved. A single curved basic calibration block may be used to
calibrate for the examination on surfaces in the range of curvature
from 09 to 1.5 times the basic calibration block diameter.

5.2.3 Angle Beam Calibration

The calibration shall provide the following measurement
- Check of Probe Angle
- Calibration of Range Scale
- Calibration of Amplitude
5.2.3.1 Probe Angle Check
The probe shall be positioned on the IIW V1 or V2 block to verify the
exact location of the probe index and true probe angle. The difference
between the nominal and true probe angle shall not exceed 2 degrees.
5.2.3.2 Calibration of Range Scale
The range scale calibration shall be made with IIW V1 or V2 Block
IIW V1 Block – Place the probe with the beam direction towards 25mm
st
radius (See Fig. 3). The 1 echo indication comes after the beam travels
 nd
25mm and the 2 indication comes after the beam travels 150mm (i.e. an
st
additional travel of 125mm). Bring the 1 indication to position 1.67 on the
horizontal scale using the delay control. Adjust the range (fine) Control to
nd
place the 2 indication at position 10. The scale from 0-10 CRT now
corresponds to 0-150mm on steel.
IIW V2 Block – Place the probe with the beam direction towards 25mm
st
radius (See Figure 4). The 1 indication comes after the beam travels 25mm
nd
and the 2 indication comes after an additional travel of 75mm i.e. a total of
st
100mm. Using the delay control position the 1 indication at 2.5and with the
nd
range control position the 2 indication at 10. The scale from 0-10 on CRT
now corresponds to 0-100mm on steel.

5.2.3.3 Distance Amplitude Correction (DAC) Construction (See Figure

5)
‘Reject Control’ of the equipment shall be set in ‘OFF’ condition.
1. Position the probe for maximum response from 1/4T
hole and adjust the gain setting to provide an indication
height of 80% (±5% of full screen height) and mark the
peak of the indication on the screen.
2. Position the probe for maximum response from 1/2 t
hole and mark the peak of the indication on the screen
3. Position the probe for maximum response from 3/4T
hole and mark the peak of the indication on the screen.
4. Connect the screen marks for the side-drilled holes to
provide the distance amplitude curve.
5. Record probe data and equipment settings. The
amplification is called “Primary Gain”

5.2.3.4When an electronic distance amplitude correction device is used,

the primary reference response shall be equalized at a nominal
constant screen height of between 40% to 80% of full screen height
over the distance range or employed in the examination.

5.2.4 Straight Beam Calibration

The calibration shall provide the following:
- Calibration of range scale
- Calibration of amplitude.
5.2.4.1 Calibration of range scale
The range scale calibration can be made using IIW-V1 calibration block
thickness (25mm or 100mm), IIW-V2 calibration block thickness
(12.5mm or 20mm) or ASTM basic calibration side drilled holes
reflection block.
IIW-V1 Block : Place the probe on the IIW V1 block as shown in Figure
6. with the delay and range controls make adjustments to get four
indications on the screen. Now the scale from 0-10 on CRT
corresponds to 0-100mm on steel. Similarly by getting 10 indications,
the screen will represent 0-250 mm on steel.
To set a range of 0-500 mm, place the probe on the 100mm side of
the IIW V1 block. Get five indications on the screen. Now the scale
from 0-10 on CRT corresponds to 0-500 mm on steel.

5.2.4.2 Distance amplitude correction for normal probes (See Fig. 7).
 1) Position for maximum response from the hole which gives the
highest amplitude.

2) Adjust the sensitivity control to provide an 80% ( 5% of full

screen height) of full screen height. Mark the peak on the screen.

3) Position the probe for maximum response from another hole

indication. Mark the peak on the screen.

4) Position the probe for maximum amplitude from the third hole
indication and mark the peak on the screen.

5) Connect the peaks and extend through to provide the DAC curve.

6. Examination Requirements
6.1 Examination Coverage
The 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
probe shall overlap a maximum 0f 50% of the probe (piezo-electric element
dimension perpendicular to the direction of the scan).
For weld testing, scanning shall be done from both the sides of same face of
material. In case both the sides of same face are inaccessible, the information shall
be recorded in the report
The entire volume of the weld needs to be covered, if necessary two or more
angle beams need to be used to ensure full volume coverage.
6.2 Scanning of plate for lamination using straight beam probe
For plate lamination testing, using straight beam probe, the area to be tested
shall be scanned in grid pattern. The grid dimensions shall be 225mm width
by 225 mm breadth unless otherwise previously specified and agreed with the
client.
6.3 Rate of Probe Movements
The rate of search unit movement for examination shall not exceed 150 mm /
second.
6.4 Scanning Sensitivity
Scanning shall be performed at a gain setting at least two times the reference
level and recording of indications (evaluation) shall be made with respect to
the reference level.
6.5 Scanning surface
The test surface shall be free of irregularities; loose foreign matter or
coatings, which may interfere with ultrasonic wave transmission. The
scanning surface shall be free of weld spatter, dirt and corrosion products.
Forged or rolled surfaces having reasonably smooth surfaces are acceptable.
6.6 Identification of item
The client shall supply sufficient information to the technician enabling the
item for testing to be identified. Datum locations shall be clearly marked.
6.7 Determination Of Surface Compensation
Before starting the examination any possible differences in attenuation and
surface character between the calibration block and the material to be
inspected are to be checked as shown in Fig. 10. The difference in dB, is to be
added to the “primary gain”. the gain so corrected is called “Corrected
Primary Gain”. The gain correction shall be 6 dB max.
7.0 EXAMINATION PROCEDURE

6.3 Inspection Of Weld :

The weld joint and H.A.Z. shall be 100% examined.
As a rule the inspection shall be performed as follows:

a) Before starting the examination with angle probe it is required to

investigate the scanning area with longitudinal probe to verify the
possible presence of laminar indication which can interfere with the
examination of welds. Record all areas giving indications equal to or
greater than the remaining back reflection. Where laminar reflectors
interfere with the angle beam scanning, the angle beam technique
shall be modified to examine the maximum feasible volume, within
the specified examination volume. The examination for planar
reflectors shall be performed on the entire volume of weld (when
possible) and adjacent base material.Record all reflectors that
produce a response equal to or greater than 20% of the distance
amplitude correction.

b) During the scanning increase the gain setting value by 6 dB, the
evaluation of the indication shall be performed by placing the gain
setting at true value (for defect evaluation the magnification used
during scanning 6 dB shall be removed).

c) Scanning overlap shall be approximately 50% of the transducer active

element dimensions.

d) For detection of longitudinal defects the probe shall be placed on

parent metal in such a way that the sound beam is always normal to
the weld axis. During the scanning the probe shall be angulated or
skewed  5 to 10 in the horizontal plane (See Figure No. 8).

e) For detection of transverse defect the probe shall be placed along side
the weld connection so that the beam sound form a shallow angle
with the center line of the weld connection (See Fig. 9). If the weld
surface assures a sufficient coupling, the probes shall be placed
directly on the weld.

f) Figures 8A, B shows scanning positions for butt welds with thickness
up to 80mm and above 80mm respectively. Figure 9 A, B shows
scanning positions for set-on and set-in nozzles respectively. Figures
10A, B show scanning positions for T and corner joints respectively.

7 Evaluation Of Indications And Acceptance Criteria

Imperfections which produce a response greater than 20% of the reference level
shall be investigated to the extent that their shape, identity and location can be
determined and evaluated in terms of acceptance standards given below as per
ASME Code Section I, Section VIII, Div. 1 & Div. 2 and B31.1.
 1) Indications characterized as cracks, lack of fusion, or incomplete
penetration is unacceptable regardless of length.

2) Other imperfections are unacceptable if the indications exceed the

reference level amplitude and have lengths which exceed.

a) 1/4 in (6mm) for t up to 3/4 in (19mm).

b) 1/3t in for t from ¾ to 2 1/4 in (19 to 57mm).

c) 3/4 in for t over 2 1/4 in (57mm)

Where t is the thickness of weld excluding any reinforcement. For a

butt weld joining two members having different thickness at the weld,
t is the thinner of these thickness.

If a full penetration weld includes a fillet weld, the thickness of the

throat of the fillet shall be included in t

8 Removal Of Defects

Indications or discontinuities in excess of acceptance limits shall be removed by

mechanical means and repaired by qualified welding procedure wherever necessary.
The repaired area shall be re-inspected using the procedure according to this
specification.

9 Records

The ultrasonic examination shall be documented by the ultrasonic inspector on the

Ultrasonic Testing Report Form
Figure 2, Basic Calibration Block
Figure 3

Figure 4
Figure 5
Figure 6

Figure 7

Figure 8
Figure 9

Figure 10