PROCEDURE FOR ULTRASONIC EXAMINATION OF CLAD PLATES,
CLIENT: M/s,EXPLOFAB METALS (I) PVT LTD.
Anumaspally village,Kadthal.
PROCEDURE NO.:SNIS/UT/SA 578/1/Rev:0
INITIAL ISSUE DATE:
REVISION NO.;
CLIENT COMMENT INCORPORATED:
PREPARED/APPROVED BY.
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PROCEDURE NO:SNIS/UT/SA 578 ISSUED DATE:
Sr. No. Index: Page No.
1 Scope 3
2 Personnel Requirements 3
3 Applicable Documents 3
4 Equipment’s 3
5 Procedure Qualification & Demonstration 4
6 Surface Preparation 4
7 Calibration 4
8 Scanning 5
9 Recording 5
10 Acceptance Criteria 6
11 Reporting 7
Annexure1: Requirement OF Ultrasonic Testing Procedure 8
Annexure2: Ultrasonic Examination Report 9
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PROCEDURE NO:SNIS/UT/SA 578/1 ISSUED DATE:
1. Scope:
This procedure describes the requirements for ultrasonic Examination & Acceptance standard for formed
Clad plates or carbon steel /base plate or alloy steel of 10mm thickness & above. Straight Beam contact
Ultrasonic examination to be carried out to detect internal discontinuities parallel o rolled surfaces & also lack
of bond between clad & base material by pulse echo A scan method.
2. Personal Requirements:
2.1 Personnel employed for performing Ultrasonic Testing examination shall be certified to NDT Level II
(ULTROSONIC Testing) as per written practice SNIS-WP-001.Rev.0 which is in line with SNT-TC-1A.or
ASNT’S Recommended practice SNT TC 1A.
2.2 Personnel employed for Interpretation/evaluation shall be certified to NDE Level-II (Ultrasonic) /NDE levl
III (Ultrasonic) as per written practice SNIS-WP-001.Rev.0.or ASNT’S Recommended practice SNT TC 1A.
3. Appli8cable Documents:
3.1 SNT-TC-1A (2006 edition) & SNIS Written practice SNIS –WP-00.
3.2 ASME Section V Article 5 (2017 Edition)
3.3 ASME Section V Article 23 – SA 578 (2017 Edition)
3.4 ASME Section II PARTS A SA – 263, SA-264, and SA 265. (2017 Edition)
4. Equipments:
Ultrasonic Flaw Detector
Analog or Digital A scan Pulse echo (0.5MHz To 5MHz)
Following flaw detectors shall be used with valid calibration.
MODSONIC MAKE – Digital – Einstein – II or TFT/DGS/TFT or Equivation
4.1.1 Equipment Linearity: Equipment linearity shall be checked before use and record shall be maintained.
The ultrasonic instrument’s screen height linearity shall be evaluated in accordance with mandatory
Appendix I of ASME Sec V Article 4,Latest Edition. The ultrasonic instrument’s amplitude control linearity
shall be evaluated in accordance with mandatory Appendix II,of ASME Sec V Article 4,Latest edition.
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4.2 Search Unit: (EEC/Modsonic make or equivalent 1 to 5 MHz)
24mm Dia,2-4MHz,Straight Beam Probe Long Mode
24mm Dia,2-4MHz,Twin Crystal Probe Long Mode
10mm Dia,2-4MHz,Straight Beam Probe Long Mode
10mm Dia,2-4MHz, Twin Crystal Probe Long Mode
4.3 Couplant : Water or equivalent
4.4 Calibration Blok:
IIW VI Block or IIW V2, Material Steel 1018.
Flat bottom hole Reference Calibration Block as per ASME Section V Article 4 Figure T 434.4.3
See Annexure3 for block details. For clad bond examination, calibration block clad shall be deposited
by the same procedure as the production part. The surface condition shall be representative of the
cladding on the production part
5. Procedure Qualification& Demonstration:
Procedure of Ultrasonic examination shall be demonstrated to the satisfaction of A I on test specimen.
If the change in value of range of values of any of essentials specified in Annexure-1, the procedure shall be re
qualified and re demonstrated to A1. The change of requirements specified non- essential variable does not required
re qualification of written procedure.
All change of essential variables from the value or range of value specified in written procedure requires revision or,
Or an addendum to, of the written procedures.
Annexure 1 : attached with this procedure for Essential- Nonessential
6. Surface Preparation:
Surface shall be free of surface irregularities or foreign matters like dirt, rust, oil, grease etc. that might interfere with
examination. Surface shall be sufficiently clean and smooth to maintain a first back wall Reflection from the opposite
side of plate at least 80% of full scale during scanning.
7. Calibration:
Basic Calibration shall fiedoneby using HW V1, orV2 blocks, & properrangesettingtoget
minimumtwobackwal1echoesonscreen.Forprimaryreferencelevelgainsettingshallbeadjustedso that first back
wall echo shall be adjusted to 80% of(Full Screen Height) FSH.
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PROCEDURE NO:SNIS/UT/SA 578/1 ISSUED DATE:
8, Scanning: Manual Scanning.
a. Scanning shall be done 100 % coverage of clad plates with 10% Overlap. (SA 578 Supplementary
requirement — 1) (S-D)
b. An additional path shall be scanned on 2” (50 mm) with along the edges of Plates,
c. Scanning shall be carried from clad side for cladded plates.
d. During thescanning firstreflection from back surface should be maintain 50% offull screen height. f, e.
Ifdiscontinuityconditionobser edduringscanning,setthe firstbackreflectionfrom sound area
(back surface) 75 + 5% offull screen height, & maintainthis setting during evaluation of
discontinuity indication
9, Recording: (6 dB drop Method shall be used for sizing of defects)
i. Record all discontinuities causing total loss of back wall echoes.
ii. Where recordable indications were observed the true boundaries shall be established by moving
thetransduceraway from the center of the discontinuity until the height of back reflection & discontinuity
indications are equal. Mark the plate at apointequivalenttothe center of transducer. Repeat the
operation to establish the boundaries.
iii. DefinitionofNon-bond, the cladding shall be interpretedtobe unbonded whenthereis complete
lossofbackreflectionaccompanied byanechoindicationfromtheplaneofinterface oftheclad & backing
steel. Areawithin 1 in.(25 mm)ofcutedgeontheplatethatcontain indicationsexceeding 50% ofthe back
reflectionatthebond interface shall be considered to be unbounded.
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10.0 Acceptance Standards:
101.1, Acceptance for Base Metal.(Carbon/Alloysteel)/clad plate):-Acceptancecriteriaforbasemeta1shallbeSA
578 Level —B & Quality Level Class 1 of SA 264.
SA 578 Level-C: Any area where one or more discontinuities produce a continuous total loss of back reflection
accompanied by continuous indications on the same plane(within5%ofplatethickness) that cannot be
encompassed within a I-in. [25-mm] diameter circle is unacceptable.
10,1,2 Acceptance for clad Metal:-
Acceptance criteria for clad plates as per ASME Sec — II Part A SA 263, 264, 265
Class 1:-Nosingleunbondedareaexceeding1 in. [25 mm] in its longest dimension with total unbounded area not to
exceed 1% of the total cladded surface area.
11.0 Reporting:
Annexure 2 - Ultrasonic Examination Report
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Annexure - 1
REQUIREMENT OF ULTRASONIC TESTING PROCEDURE:
(Table T -522 ASME Sec. V Article S)
Requirement Essential Non-essential Reference to
Variable Variable Procedure Para,
Material type and configurations to be examined, including X -- Para. 1.
thickness dimensions and product form (casting, forgin ;,
plate, etc)
Personal qualification requirements - X Para2.1&2.2
Personal performance requirements, when required Para2.1&2.2
The surface lrom which the examination shall be X Para. 7. c
performed.
Surface condition (examination surface, calibration block) X Para. S.
Couplant: brand name or type X Para. 4.3
Technique (s) (straight beam, angle beam, contact, and/or X Para. 1.
immersion )
Angles(s) and mode(s) of wave propagation in the material X Para. 1. & 4.2
Search unit type(s), frequency(ies), and element X
size(s)/shape(s)
Special search units, wedges, shoes, or saddles, when used X N.A
Ultrasonic Instniment(s) X Para. 4. I
Calibration (calibration block(s)and technique(s) X Para. 6.
Direction o1 extent scanning X i'ara. 7 a.b.c
Automatic alarm and/or recording equipment, when X N.A.
applicable x
Scanning(manual vs. automatic) Para 7.
Method for sizing indications Para 8.
Computer enhanced data acquisition, when used N.A.
Records, including minimum calibration data to be X Para lI.
recorded (e.g. instrument settings)
Scan overlap(decrease only) Para 7.a
N.A.-Not Applicable.
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Annexure 3
Reference Calibration Block
(Flat Bottom Hole Block Details)
Figure - 1
Calibration for Technique two calibrations shall be performed utilizing the calibration block shown in Figure 1 -
above.
The search unit shall be positioned for the maximum response from the calibration reflector. When a side- drilled
Role is used for calibration, the plane separating the elements of the dual element search unit shall be positioned
parallel to the axis of the hole. The gain control shall be set so that this response is 80%±5% of full screen height.
This shall be the primary reference level.
The basic calibration block configuration and reflectors shall be as shown in Figure 1. A flat bottom hole drilled to
the weld/base metal interface shall be used. This hole may be drilled from the base material or weld metal overlay
cladding side. The thickness of the weld metal overlay cladding shall be at least as thick as that to be examined.
The thickness of the base metal shall be within 1 in.(25 mm)of the calibration block thickness when the
examination is performed from the base material surface. The thickness of the base material on the calibration block
shall be at least twice the thickness of the weld metal overlay cladding when the examination is performed from the
weld metal overlay cladding surface.
