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IOP-UTE-2016019-1
ULTRASONIC EXAMINATION
INSTRUCTION FOR
THICKNESS UP TO 6 mm

Project: AL BAYT Stadium

Client: GSIC JV

Revision matrix

0 30/09/2017 Nali M. D’Anna E. D’Anna E.

Rev. Date Issued Checked Approved
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TABLE OF CONTENT
1. SCOPE ............................................................................................................. 3
2. REFERENCE DOCUMENTS ............................................................................ 3
3. PERSONNEL QUALIFICATION ...................................................................... 3
4. EXTENT OF EXAMINATION ............................................................................ 3
5. TIME OF EXAMINATION ................................................................................. 4
6. SURFACE CONDITIONS ................................................................................. 4
7. COUPLANT ...................................................................................................... 4
8. ULTRASONIC EQUIPMENT ............................................................................ 4
9. EXAMINATION FOR FULL PENETRATION WELDS EXAMINATION............ 5
10. ACCEPTANCE STANDARD .......................................................................... 10
11. REPAIR .......................................................................................................... 12
12. ULTRASONIC TEST REPORT ...................................................................... 12
ATTACHMENT N. 1 .............................................................................................. 16
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1. SCOPE

This procedure is intended for the manual ultrasonic pulse echo technique examination of
groove welds and HAZ on butt welds in ferritic steel having thickness between 6 mm
and 8 mm inclusive and for the dimensioning of indications by means of comparison with
Acceptance Standards.

2. REFERENCE DOCUMENTS

• EN ISO 17640 : Ultrasonic Examination of welded joints. Non-destructive testing

of welds – Ultrasonic testing
• EN ISO 11666 : Acceptance levels Non-destructive testing of welds – Ultrasonic
testing
• EN ISO 23279 : Characterization of indications in welds
• EN 473 : Qualification and Certification of NDT Personnel.
• ISO 9712 : Qualification and Certification of NDT Personnel.
• EN 12668 All parts : Characterization and verification of ultrasonic examination
equipment

3. PERSONNEL QUALIFICATION

Examination shall be carried out by NDE examiners holding a level II or III qualification in
accordance with the following document:
• EN 473
• ISO 9712
The personnel employed for the execution of NDE Examination shall have an annual
vision test to assure:
• Near vision acuity: the examination should ensure natural or corrected near
distance acuity such that they are capable of reading standard J-1 letters on
standard Jaeger test type charts or Times Roman No.4,5 (having a height of
1,6mm) or equivalent characters to a distance of not less than 30 cm with one or
both eyes. Equivalent near vision tests are acceptable
• Color contrast differentiation: the examination should demonstrate the capability of
distinguishing and differentiating contrast among colors or shades of gray (reading
of Ishiara test or equivalent)

4. EXTENT OF EXAMINATION

From outside on 100% of longitudinal pipe welds after weld completion have to be
examined: full skip from both sides of weld.
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Ultrasonic examination shall include weld and parent material for at least 10 mm on each
side of the weld or heat affected zone (HAZ), whichever is greater.
The base metal adjacent to the weld, to the extent having width of the scanning area for
angle probes, have to be examined with straight beam for laminations and transverse
defects that could interfere with examination of the weld.

5. TIME OF EXAMINATION

Ultrasonic Examination shall be carried out at least 12 hours following completing of

welding.

6. SURFACE CONDITIONS

The surface to be inspected shall be cleaned from any dirt, scales, slag and any other
contaminations which may interfere with the scanning or interpretation of the results.
Base material surface adjacent to the weld, shall be prepared to a distance at least
allowing the full skip scanning of the shallowest angle transducer on either side of the
weld: shall be free of weld spatter, rust or other foreign particles which could interfere with
probe coupling and this could be obtained by sandblasting or light grinding.
“As welded” weld surface condition is acceptable to perform correctly the examination.
If undercuts, imperfect shape, incorrect weld toe or other surface discontinuities are
clearly visible before examination start, these shall be removed with adequate operations
(grinding, welding etc.).

7. COUPLANT

Glycerin, gel, special paste or other similar products may be used. The total chlorine and
sulphur content shall be less than 1000 ppm.
Usually Cimolai uses C.G.M. type U-49 or Sichozell, made by Henkel, which shall be
mixed with water (dilution Approx 1:40). Similar products could be otherwise used,
providing the couplant used during examination is the one used for calibration.

8. ULTRASONIC EQUIPMENT

Instrument.
The UT instrument shall be the pulse-echo type suitable for use with transducers
oscillating at frequencies between 1 and 6 MHz. The display shall be an “A” scan rectified
video trace.
A pulse-echo instrument calibrated annually by a qualified vendor, in accordance with
ASTM E 317 or EN12668-1 shall be employed. Moreover, recorded linearity checks for
ultrasonic equipment according with Appendix A, should be carried out at the beginning of
each period of extended use but not more than every 3 months.
The linearity of the time base shall be within 2% over the whole range, i.e. the echoes do
not deviate by more than 2% of the time base range from their true position. The amplifier
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shall be linear to an accuracy of ±1 dB at any point within the range 20% to 80% full
screen height.
Cimolai normally uses one or more of the following equipments, but other equivalent
could be used if properly calibrated in accordance to the herein listed requirements:
• GE Model USM GO Advanced GE Model USN 60 SW
• KRAUTKRAMER Model USK7 B Krautkramer
• OLYMPUS Model EPOCH 600

Probes
The following probes are used for the scope, but others could be used if equivalent or for
a better evaluation and characterization of indications:

FREQUENCY BEAM ANGLE CRYSTAL SIZE Wave

TRADE MARK MANUFACTURER
(MHz) (degree) (mm) Type

MSEB4 Krautkramer 4 0 Dual 3.5 x 10 Compression

MWB 70-4 Krautkramer 4 70 Single Shear
MWB 45-4 Krautkramer 4 45 Single Shear

Ultrasonic equipment checks

Other equipment checks, in addition to those previous indicated, shall be performed in as
per the following table, in accordance to EN12668-3. This checks doesn’t need to be
recorded

Check Frequency
Linearity of timebase Weekly
Linearity of equipment gain Weekly
Probe index Daily
Beam angle Daily
Physical state and external aspects Daily
Sensitivity and signal-to-noise ratio Weekly
Pulse duration Weekly

9. EXAMINATION FOR FULL PENETRATION WELDS EXAMINATION

Calibration of range scale and angle determination

The IIW or ISO calibration blocks (K1 or K2; No.1 Reference block of EN12223, or No.2
Reference block of EN 27963), shall be used for calibration of range scale and for angle
determination. These calibration blocks shall preferably have the same acoustic
properties as the material to be tested. The range (scale) shall be determined depending
of thicknesses under testing and shall be appropriate so that to assure the entire volume
of weld has been examined.
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Reference blocks for calibration of amplification for testing of welds.

For testing of welds, sensitivity setting for the weld examination shall be referred to a
Distance/Amplitude Correction (DAC) curve obtained on here following described
reference blocks.
20 20 20

1 mm 3
8 mm
1 mm 5

Sensitivity calibration block 8 mm thickness, 30 mm wide with:

• notch for 70° probe setting;
• SDH Ø2 mm, 20 mm deep for 45° probe setting, valid for 6 mm thickness too.

0,5 mm
6 mm

1 mm

Sensitivity calibration block 6 mm thickness, 30 mm wide with:

• notch for 70° probe setting;

The reference blocks to be used shall be manufactured from the actual material
examined (metal type and heat treatment condition), traceable to a material certificate.

Construction of reference curve, DAC

Straight beam probes:

For testing of weld connections using straight beam probes the Ø2 mm side drilled hole
(SDH) in the 8 mm thickness reference block is to be used for gain setting. In order to
have relevant DAC, the curve must be established as indicated here following.

1° eco DAC
80%

8 mm 1° eco
2° eco
0

2° eco
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Angle probes:
Following description of angle probes setting of reference DAC, by mean of the Ø2 mm
side drilled hole (SDH) and 1 mm notch in the 8 mm thickness reference block and 0,5x1
mm notch in the 6 mm thickness reference block.

8 mm thickness block 2°eco 1°eco

70° 45°

70° 3°eco 45° 45° 2°eco

1°eco

80%
DAC
70° DAC
1° 2° 45°
3°
1°
2°

6 mm thickness block 2°eco

70°

70° 1°eco

The echo reflected from the drilled hole in the applicable reference block, is maximized
and the gain control regulated so that the echo amplitude is 80% of full screen height
(FSH).
This gain setting is called the primary gain and is to be noted. Without altering the
primary gain, the probe is positioned in various skip distances and the respective echo
amplitudes are marked on the screen.
These points are connected with a smooth line with a length, which covers the required
scanning area. This is the reference curve (DAC).
The first point of DAC must be selected so that the distance in sound path from the
probe index to the drilled hole is not less than 0.6 N where N is the near field length of
the relevant probe.

When DAC has been set up it is recommended to draw two additional curves, 33% and
50% of DAC, on the screen. Where DAC by excessive sound paths falls to below 25% of
FSH the gain in this area is to be increased and a new DAC must be established, see
figure below
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Transfer correction:

When calibration is not carried out on the piece itself or where reference block is not
representative of the surface condition of the part to be examined, any possible
difference in attenuation and surface character between the reference block and the
object to be tested are to be checked and the DAC curve corrected by transfer correction
value determined as follows:
Two angle probes of the same type as those to be utilized during the testing are to be
used. The probes are placed on the object to be tested. One of the probes works as a
transmitter probe, whilst the other acts as receiver. The first echo is maximized and with
the aid of the gain control it is adjusted to reach DAC. The gain setting is noted. Without
altering this gain setting the probes are moved to the reference block. The echo is
adjusted to reach DAC and the gain setting is noted. Any difference in echo amplitude
between the two materials can now be determined with the aid of the gain control.
Transfer correction shall be carried out considering the following requirements:
• if the differences are less than 2 dB, correction is not required
• if the differences are greater than 2 dB but smaller than 12 dB they shall be
compensate for
• if transfer losses exceed 12 dB, the reason shall be considered and further
preparation of the scanning surface shall be carried out, if applicable.
When there are no apparent reasons for high correction values, the attenuation, at
various locations on the test object shall be measured. Where it is found to vary
significantly, corrective actions must be considered.
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The calibration of range scale with straight beam probe is to be carried out with an IIW
calibration block, a K2 calibration block or on a defect free area of the material to be
tested. The range scale is to be selected such that there are always at least 2 back-wall
echoes (reflections) on the screen.
At approximately four-hourly intervals the range scale, probe angle and primary gain must
be checked and corrected. Checks shall also be carried out whenever a system
parameter is changed or changes in the equivalent settings are suspected.

Calibration time:

Calibration shall be performed, prior to use of the system, in the thickness range under
examination. As applicable the calibration shall provide the following measurements:
sweep range calibration and Distance Amplitude Correction.

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, sensitivity setting,
beam index point, true angle probe satisfy the requirements of the Code. During testing
of the weld, the noise level excluding spurious surface conditions, shall remain at least
12 dB below the evaluation level.
At approximately four-hourly intervals the range scale, probe angle and primary gain must
be checked and corrected. Checks shall also be carried out whenever a system
parameter is changed or changes in the equivalent settings are suspected.
If deviation is found to be >2% of range scale, > 4dB of primary gain setting or >2° of
nominal angle probe, the examination carried out with the equipment over the previous
period shall be repeated.

Testing:
Scanning is made adding 6 dB to the amplification obtained during DAC construction,
while evaluation is made at the amplification obtained during DAC construction.
Lateral movement of the probe should assure an overlap greater that 10% of previously
inspected area and scan speed should be no faster than 150 mm/s.
Here following a scan plan of a typical weld having thickness less than 8 mm, up to 6
mm, with or without backing.

70° 70°

2° 2°

1°

70° 45° 70°

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1°
Base material close to the weld have to be inspected first, in order to reveal possible
imperfections, which might influence the angle probe testing.
The whole of the area (1.5 × S) which will transfer ultrasound when using angle probes
shall be tested. The gain setting shall be calibrated on a defect free place on the parent
material. The second back wall echo shall be set to 80% of FSH Imperfections with a
cross section larger than the sound beam (loss of back wall echo) shall be reported. The
extent of the imperfections is measured with the aid of the 6 dB-drop method when
complete loss of back wall echo occurs.

The weld has to be examined in accordance to the following acceptance criteria:

• Quality level in accordance to ISO5817 : Level B
• Above indicate ISO5817 Level B require that UT examination shall be made at
least in accordance with EN ISO 17640 testing level B
• Above indicate ISO5817 Level B require that applicable UT examination
acceptance criteria shall be in accordance with EN ISO 11666 level 2

based in the here following settings:

• Primary reference level. Primary reference level is DAC + Transfer Correction
• Scanning sensitivity. Scanning sensitivity is Primary reference level + 6 dB

Evaluation of discontinuities shall be performed with respect to the primary reference

level.

Discontinuity Size Measurement:

The length of the imperfections is to be evaluated by maximizing the echo amplitude in
the middle of the defect. Subsequently, the probe is traversed towards the edge of the
imperfection until the echo amplitude has dropped to the evaluation level -10 dB (33% of
DAC) The centre of the probe is then marked off as the edge of the imperfection. This
length shall be recorded under “discontinuity length” on the test report.

10. ACCEPTANCE STANDARD

Four levels as defined in ISO 17640 are used:
• Reference level
• Evaluation level
• Recording level (4dB below the acceptance level)
• Acceptance level

The Acceptance Criteria for welds shall comply with EN ISO 5817 lev B, so EN ISO
11666 lev. 2 shall be used (see figure A.3 extracted from EN ISO 11666) with the
following additions: all imperfections from which the reflected echo amplitude exceeds
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the evaluation level shall be characterized and all those that are characterized as planar
(e.g. cracks, lack of fusion, incomplete penetration) shall be rejected
Grouping of indications and cumulative length of indications are assessed according to
EN 11666:2011 par 5.4 and 5.5

Characterization of indications
Characterization of indications are based on echo amplitude – (stage 1 and 2) and
directional reflectivity criteria (stage 3) given in ISO 23279:
• Low amplitudes (stage 1): An indication having echo amplitude lower than the
evaluation level is not significant and shall not be characterized.
• High amplitude (stage 2): An indication having echo amplitude that is at least
equal to the reference level plus 6 dB is a planar defect.
• Directional reflectivity criteria (stage 3): By comparing the maximum echo
amplitude from an indication using two probe angles having different refraction
angles of more than 10° the difference shall be more than 9 dB. When comparing
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the amplitude from a shear wave angle probe and a compression wave normal
probe, the difference shall be more than 15 dB.

11. REPAIR

All repairs shall be carried out in accordance with established procedures.

Repair By Welding
Before repair welding, the defects shall be completely removed. Each unacceptable
discontinuity shall be marked on the weld over the discontinuity for its entire length
directly. The depth from the surface and indication rating shall be marked on base metal
right next to the defect.
The excavated area shall have smooth transitions to the metal surface and allow good
access for both NDT after excavation and subsequent repair welding. After excavation,
complete removal of the defects shall be confirmed by MT or PT. PWHT shall be
performed after repair if specified for the original weld. The excavated groove shall
extend minimum 25 mm behind both start and end of defect, measured at defect depth.
Defects spaced less than 100 mm shall be repaired as one continuous defect.
After repair welding the complete weld (i.e. the repaired area plus at least 50 mm on
each side) shall be subjected at least to the same NDT as specified for the original weld.
Repair welding may only be carried out once in the same area: the second require
customer involvement.

Re-welding
Re-welding shall be performed in accordance with the procedures and WPS utilized for
the original weld, and includes complete removal of the original weld and HAZ

12. ULTRASONIC TEST REPORT

A report which clearly identifies the work and the area of inspection shall be completed
by the UT operator at the time of inspection. Examination results for each weld shall be
reported on the Ultrasonic Examination Report Form. The Ultrasonic Examination
Report (sample form) is enclosed as Attachment 1 to this procedure: any change or
update to this form, does not invalidate this procedure as long all therein information
are maintained.
The report shall be signed by the Quality Control Manager and when required by the
Client’s Inspector and other Authority Testing.
The report form for welds that are acceptable need only contain sufficient information to
identify the weld, the operator (signature), and the acceptability of the weld.
When a defect shall be identified and repair shall be required, the relevant report
issued at completion of the inspection operation will have to record both inspections
prior and after the repair of the defect.
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Evaluation of retested repaired weld areas shall be tabulated on a new line on the
report form. If the original report form is used, an R1, R2, ...Rn shall prefix the
indication number. If additional report forms are used, the R number shall prefix the
report number.
All NDT shall be properly documented in such a way that the performed testing can be
easily retraced at a later stage. The reports shall identify the unacceptable defects
present in the tested area, and a conclusive statement as to whether the weld satisfies
the acceptance criteria or not.
The report shall include a reference to the applicable standard, NDT procedure and
acceptance criteria. In addition, as a minimum, the following information must be given
or easily retrievable from therein included information:
• object and drawing references
• place and date of examination
• material type and dimensions
• post weld heat treatment, if required
• location of examined areas, type of joint
• welding process used
• name and certification level of the operator carrying out the testing
• surface conditions
• temperature of the object
• contract requirements e.g. order no., specifications, special agreements etc.
• sketch showing location and information regarding detected defects
• extent of testing
• test equipment used
• description of the parameters used for each method
• description and location of all recordable indications
• examination results with reference to acceptance level.
• number of repairs to be specified in the report, such as once or twice repairs in
the same area.
• probes, type and frequency
• identification of reference blocks used
• couplant medium
• reporting level, if different from acceptance level
• calibration range
• scanning technique, half skip or full skip scanning.
• surface compensation/transfer correction
• defect type (At least defined as Spherical, Volume or Planar

The report shall be such that there is no doubt about what is tested, where it has been
carried out and give a clear and exact description of reportable defect location.
The format of report is not a reason for rejection as long all above indicated information
are included and any change induced by addition doesn’t be considered a rejection of
those already issued
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APPENDIX- A
Check of Screen Height Linearity
To verify the ability of the ultrasonic instrument to meet the linearity, as required in
paragraph 8, position an angle beam search unit as shown in the Fig. 2 so that indication
can be observed from both the 1/2 and 3/4T 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 from 100% to 20% of full screen height, in
increments (of 2 dB steps 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
setting 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.
Check of Amplitude Control Linearity
To verify the accuracy of the amplitude control of the ultrasonic instruments, as required
in paragraph 8, position an angle beam search unit as shown in Fig. 1 so that the
indication from the 1/2T 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 specified limits base. Other convenient reflectors from any calibration block
may be used with angle or straight beam search units.

Indication limits %
Indication set dB control
Test n° of full screen
at % of full screen change
(+20%)
1 80% -6 dB 32 to 48%
2 80% -12 dB 16 to 24%
3 40% +6 dB 64 to 96%
4 20% +12 dB 64 to 96%

The setting and reading must be estimated to the nearest 1% of full screen.
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ATTACHMENT N. 1