NDT Corrosion Control Services Co.

Dammam – Saudi Arabia Date: 15th Aug 2023

ULTRASONIC EXAMINATION PROCEDURE

INDEX
SL# CONTENT PAGE NO
1 Scope 2
2 Referenece Standard 2
3 General Requirement 2
3.1 Inspection Witness 2
3.2 NDT Personnels 2
3.3 Essentia and Non-essentail variables 2
4 Ultrasonic Examination Technique and Requirement 3
4.1 General Exmanination Requirements 3
5 Equipment, Accessoroes and Couplant 3
5.1 A- Scan Ultrasonic Flaw Detector 4
5.2 Probe/Search Units 4
5.3 Calibration Blocks 4
5.4 Reference Blocks 4
5.5 Couplant 8
6 Equipment Calibration 9
6.1 Gain Control Linearity 9
6.2 Time base or Horizontal Linearity 9
6.3 Range Calibration 9
6.4 Probe Angle 9
7 Distance Amplitude Correction (DAC) Using Angle Beam 10
8 Transfers Correction 11
9 Examiantion Procedure 11
9.1 Surface Preparation 11
9.2 Scanning 11
10 Examination as per AWS D1.1 13
11 Evaluation 15
12 Accetance Criteria 16
13 Safety Precautions 18
14 Post Examination Cleaning 18
Reporting 18
Attachment 1 – UT Report Format 19

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ULTRASONIC EXAMINATION PROCEDURE

1 SCOPE

This standard prescribes the method of testing and inspection of welds by Ultrasonic direct
contact reflection method. This method is applicable to Ferritic steel of thickness over 6 mm.
It covers technique to be employed at normal temperature; care shall therefore be taken to
ensure that the temperature of the test piece is not above the temperature for which the
probe manufacture recommanded.
2 REFERENCE STANDARD

1. ANSI/ASME-V Article 4 & 5 – 2021 Edition - ASME Code for Nondestructive Examination.
2. ANSI/ASME B 31.3 – 2022 Edition - ASME code for process piping.
3. ANSI/ASME B 31.1 – 2022 Edition - ASME Code for Power Piping.
4. ANSI/ASME SEC.VIII DIV. I & II – 2021 Edition - Rules for Construction of Pressure Vessels.
5. AWS D1.1 2020 Edition - AWS code for Structural Steel welding.
6. API-650 12th Edition Addendum 3
7. API -620 12th Edition Addendum 2
8. API 653 2018 Edition
9. SA-435 2019 Edition
10. SA-388 2019 Edition
11. JERES-W-11 REV04 - Welding Requirement for on-Plot Piping
12. ASNT/ANSI CP-189 – 2020 Edition - ASNT Standard for Qualification and Certificaiton of
Nondestructive Testing Personnel.
13. NDT/CERT/01 Latest Edition (Written Practice document for NDE Personnel Qualifcation)
3 GENERAL REQUIREMENT

Personnel performing UT examination must be qualified and certified in accordance with

NDT/CERT/01 NDT CCS (latest revision). All work shall be performed by SATORP approved
Technician; and work shall be in accordance with SATORP specs and standards.
3.1 INSPECTION WITNESS
Client inspection representatives, at their option, witness all or part of ultrasonic examination
at any time and place during and after fabrication and may, as deemed necessary, establish
witness as a hold point prior to or during the test.
3.2 NDT PERSONNEL
The examination shall be performed by at least an NDT UT Level -II All interpretation of test
results shall be done by a certified NDT Level -II Technician. Personnel performing ultrasonic
examination must be qualified and certified in accordance with company’s written practice
NDT/CERT/01 (latest revision), ANSI/ASNT CP-189 2020 Edition. The client inspection unit
representative may, at his option, require the technicians to validate their certification by
submitting to qualification test administered by client NDE Level III.

3.3 ESSENTIAL AND NON-ESSENTIAL VARIABLES

Any changes identified as essential variable vide ASME Section V Art 4; Table T-421,
reproduced below, shall require re-qualification of the written procedure by demonstration.
A change of a requirement identified as a non-essential variable does not require re
qualification of the written procedure.
Table T – 421: Requirement for Ultrasonic Examination Procedure
Essential Non-Essential
Requirement
Variable Variable
Weld configuration to be examined, including thickness
X --
dimensions and base material product form (pipe, plate etc.)
The surfaces from which the examination shall be performed X --

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Technique(s) (straight beam, angle beam, contact, and/or

X --
immersion)
Angle(s) and mode(s) of wave propagation in the material X --
Search unit type(s), frequency(s), and element size(s)/ shape(s) X --
Special search units’ wedges, shoes, or saddles, when used X --
Ultrasonic instrument(s) X --
Calibration (calibration block(s) and technique(s) X --
Directions and extent of scanning X --
Scanning (manual vs., automatic) X --
Method for discriminating geometric from flow indications X --
Method for sizing indications X --
Computer enhanced data acquisition, when used X --
Scan overlap (decrease only) X --
Personnel performance requirements, when required X --
Personnel qualification requirements -- X
Surface condition (examination surface, calibration block) -- X
Couplant: brand name or type -- X
Post examination cleaning technique -- X
Automatic alarm and/ or recording equipment, when
-- X
applicable
Record, including minimum calibration data to be recorded
-- X
(e.g., instrument settings)

4 ULTRASONIC EXAMINATION TECHNIQUE REQUIREMENTS

Ultrasonic examination technique record containing the essential elements shall be

maintained.
1. Weld and/or material types and configuration to be examined including thickness
dimensions, and product from (casting, forging, plate etc.)
2. The surface or surfaces from which the examination shall be performed.
3. Surface condition.
4. Couplant, brand name, or types.
5. Technique (straight beam, angled beam, contact or immersion.
6. Angles and mode (s) of wave proposition in material.
7. Search unit type, frequency (ices), and transducer size(s)
8. Special search units, wedges, shoes, or saddles.
9. Ultrasonic instrument type(s).
10. Description of calibration: blocks and technique.
11. Directions and extent of scanning.
12. Data to be recorded and method of recording (manual or mechanized).
13. Automatic alarm and recording equipment, or both.
14. Rotary, revolving or scanning.
15. Post-examination cleaning.

4.1 GENERAL EXAMINATION REQUIREMENTS

EXAMINATION COVERAGE
Each pass of the search unit shall overlap a minimum 10% of the transducer (piezoelectric
element) dimension perpendicular to the direction of the scan.
RATE OF SEARCH UNIT MOVEMENT
The rate of search unit movement for examination shall not exceed 6 in./sec. unless
calibration is verified at scanning speed.

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ULTRASONIC EXAMINATION PROCEDURE

RECORDING SENSITIVITY LEVEL

The recording of indication shall be made with respect to the reference level.
5 EQUIPMENT, ACCESSORIES AND COUPLANT

5.1 A-SCAN ULTRASONIC FLAW DETECTOR

The ultrasonic equipment shall be pulse echo type ‘A’ scan suitable for use with transducers
oscillating at frequencies between 1 and 6 MHz The equipment shall have valid calibration
certificate equipment must be calibrated at least every 12 months. The equipment shall be
equipped with a flat screen accessible from the front for direct plotting of Distance Amplitude
Curves (DAC) and shall be able to clearly distinguish echoes with amplitudes of 5% of FSH. If
the instrument has a damping control, it may be used if it does not reduce the sensitivity of
the examination. The reject control shall be in the “off” position for all the examinations.
Following instruments can be used for the ultrasonic examinations.
OLYMPUS EPOCH XT, EPOCH 600, GE USM-35, USM-36, USM Go, USM Go + or equivalent and
the instrument shall be equipped with a stepped gain control calibrated in units of 2 dB or
less.
5.2 PROBE OR SEARCH UNIT
Probes used for testing of the welds in Carbon steel, C-Mn steel and alloy steels shall be straight
beam (Single or twin crystal) and angle shear wave of 45º, 60º and 70º. The nominal frequency
shall be 1 MHz to 6 MHz unless variables, such as production material grain structure, require
the use of other frequencies to assure adequate penetration or better resolution. Search units
with contoured contact wedges may be used to aid ultrasonic coupling. An angle shall be
selected as appropriate for the configuration being examined.
5.3 CALIBRATION BLOCKS
The IIW (V1 & V2) or ISO blocks (A2 & A4), see in given below figure. shall be used for the
calibration of range scale and for angle determination. These calibration blocks shall
preferably have the same acoustic properties as the material to be tested.

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ULTRASONIC EXAMINATION PROCEDURE

Figure: 5.3 Calibration blocks

5.4 REFERENCE BLOCKS
Reference blocks shall be made with thickness and side –drilled holes, as Attachment. The
reference block shall normally be manufactured from the actual material tested and have
approved dimensions.
Table 5.4: Reference block requirements
Thickness of Thickness Diameter of hole (mm) Distance of hole from one
material to be of block surface (mm)
examined (mm) (mm)
Up to 25 t 19 or T Ø 2.5 T/4, T/2 and 3T/4. Additional
25< t ≤ 50 38 or T Ø3 holes are allowed and
50 < t ≤ 100 75 or T Ø5 recommended.
t > 100 ± 25 of T For each increase in weld
thickness of 2 in. (50 mm)
or fraction thereof over 4
in. (100 mm), the hole
diameter shall increase
1/16 in. (1.5 mm).

Table 5.4 (b) Notch Dimensions In (mm)

Notch Depth Notch Width Notch Length

1.6 % of T or 2.2 % T 1/6 (6) Max 1 (25)

Figure: 5.4 (a) Non Piping Reference or/and Calibration Block ( setting DAC)
General Requirements:
Holes shall be drilled and reamed 1.5 in. (38 mm) deep minimum essentially parallel to the
examination surface.
For components equal to or less than 20 in. (500 mm) in diameter, calibration block
diameter shall meet the requirements of 13.3.3. Two sets of calibration reflectors (holes,
notches) oriented 90 deg. From each other shall be used. Alternately two curved
calibration blocks may be used.

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The tolerance for the hole diameter shall be ± 1/32 in. (0.8 mm). The tolerance for hole
location through the calibration block thickness (distance from the examination surface)
shall be ±1/8 in. (3 mm).
For blocks less than ¾ in. (19 mm) in thickness, only the ½ T side drilled hole and surface
notches are required.
All holes may be located on the same face (side) of the calibration block, provided care
is exercised to locate all the reflectors (holes, notches) to prevent one reflector from
affecting the indication from another reflector during calibration. Notches may also in the
same plane as the inline holes., A sufficient number of holes shall be provided for both
angle and straight beam calibration ¼ T, ½T and ¾ T depths.
When cladding is present, notch depth on the cladding side of the block shall be
increased by the cladding thickness, CT (i.e.1.6 % T+ CT minimum to 2.2%T + CT maximum).
Maximum notch width is not critical. Notches may be made by EDM or with end mills up
to ¼ in.(6.4 mm) in diameter.
Weld thickness t is the nominal material thickness for welds without reinforcement or for
welds with reinforcement, the nominal material thickness plus the estimated weld
reinforcement not to exceed the maximum permitted by the referencing code section.
When two or more base material thicknesses are involved, the calibration block thickness
, T shall be determined by the average thickness of the weld; alternatively, a calibration
block based on the greater base material thickness may be used provided the reference
reflector size is based upon the average weld thickness.
NOTES:
1. Minimum dimension
2. For each increase in weld thickness of 2 in.(50 mm) or fraction thereof over 4 in.( 100
mm), the hole diameter shall increase 1/16 in(1.5 mm)

Figure: 5.4 (b) Piping Reference or/and Calibration Block ( setting DAC)
General Requirements:

a) The minimum calibration block length, L, shall be 8 in. (200 mm) or 8T, whichever is greater.
b) For O.D. 4 in. (100 mm) or less, the minimum arc length shall be 75% of the circumference.
For O.D. greater than 4 in. (100 mm), the minimum arc length shall be 8 in. (200 mm) or 3T,
whichever is greater.
c) Notch depths shall be from 8% T minimum to 11% T maximum. When cladding is present,
notch depths on the cladding side of the block shall be increased by the cladding
thickness, CT (i.e., 8% T + CT minimum to 11% T + CT maximum). Notch widths shall be 1/4 in.
(6 mm) maximum. Notch lengths shall be 1 in. (25 mm) minimum.

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d) Maximum notch width is not critical. Notches may be made with EDM or with end mills up
to 1/4 in. (6 mm) in diameter.
e) Notch lengths shall be sufficient to provide for calibration with a minimum 3 to 1 signal-to-
noise ratio.
f) Two blocks shall be used when a weld joining two different thicknesses of material is
examined and a single block
g) When a flat block is used as permitted by T-434.1.7.1 of ASME Section V article 4, the two
axial notches may be omitted and the block width may be reduced to 4 in. (100 mm),
provided the I.D. and O.D. notches are placed on opposite examination surfaces of the
block. When cladding is not present, only one notch is required provided each
examination surface is accessible during calibrations.
NOTE:
(1) Notches shall be located not closer than 1/2T or 1/2 in. (13 mm), whichever is greater, to any
block edge or to other notches.

Figure: 5.4 (c) Ratio Limits for Curved Surfaces

NozzleSideWeldFusionZoneand/orAdjacent Nozzle Parent Metal Calibration Blocks.
Calibration Block.
(a)Configuration. The calibration block configuration shall be as shown in Figure 5.4 (d). 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 thenozzleiscladbeforetheexamination,theIDsurfaceof the calibration block shall be clad.
(b) Block Thickness. The calibration block shall be the maximum thickness of the nozzle wall
adjacent to the nozzle weld plus 3/4 in. (19 mm).
(c) Curvature. For examinations of nozzles with an inside diameter (I.D.) equal to or less than
20 in. (500 mm), the contact surface of the calibration block shall have the same curvature
or be within the range of 0.9 to 1.5 times the diameter as detailed in Figure 5.4 (c).
(d) Calibration Reflectors. The calibration reflectors shall be side-drilled hole(s) that are in
accordance with the requirements of Figure 5.4 (a) for the nozzle wall thickness. (e) Alternative

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Blocks. Alternative calibration blocks may be used for similar types of examinations provided
the sound path distance(s) to the block’s reflector(s) is (are) within 1/4 in. (6mm)of what is
required and the side drilled hole(s) is (are) the same or a smaller diameter than what is
required.
Calibration Block for Straight Beam Examination of Nozzle Side Weld Fusion Zone and/or Adjacent
Nozzle Parent Meta;

Figure 5.4 (D): Calibration Block for Straight Beam Examination of Nozzle Side Weld Fusion
Zone and/or Adjacent Nozzle Parent Meta;

Calibration Block Wall

Hole Location, 5/8T Hole Location, 3/4T Hole Location, 7/8T
Thickness, in. (mm)

> 2 (50) through 3 (75) … X …

> 3 (75) X X X

Figure 5.4 (d): NozzleSideWeldFusionZoneand/orAdjacent Nozzle Parent Metal Calibration

Blocks.
Calibration For Nozzle Side Weld Fusion Zone And/Or Adjacent Nozzle Parent Metal
Thenumberofcalibrationholesuseddependsuponthe requirements for the examination. If only
the nozzle side fusion zone is to be examined, then only a single sidedrilled hole at the nozzle
wall thickness needs to be used.
(a) Single Hole. The response from a single side drilled hole shall be set at 80% ± 5% of full
screen height. This is the primary reference level.
(b) Multiple Holes. The straight beam shall be directed toward the calibration reflector that
yields the maximum response. 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 search unit shall then
be manipulated, without changing instrument settings, toobtain the maximumresponses
fromthe other holeposition(s) to generate a distance–amplitude correction (DAC) curve.

5.5 COUPLANT
Polycell glue / Oil/ Grease/ Glycerine/UCA 2M/Sonagel etc. Couplant used on nickel or
austenitic stainless base alloys shall not contain more than 250ppm of sulfur.
For any high Temparature components clinet should be supply couplant whch is applicable
for the testing. clinet should be take care supplied couplant doest not have any affect with
the Test componants.

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6 EQUIPMENT CALIBRATION

6.1 GAIN CONTROL LNEARITY

The ultrasonic instrument shall provide linear vertical presentation within +/-5% of
the full screen height for 20% to 80% of the calibrated screen height. The screen
height linearity evaluation shall be met with intervals not to exceed three months
for analog type instruments and one year for digital type instruments, prior to first
use. During Inspection Technicians shall be varify gain control linearity every 4
hours.
Table: 6.2
Indication limit of % full screen
Gain [dB] Indication Set at % of Full Screen
Height
-6 80 35-45
-12 80 15-25
+6 40 65-95
+12 10 65-95
6.2 TIME BASE OR HORIZONTAL LNEARITY
Horizontal linearity of the time base shall be checked by using IIW -V1 block. The length of the
time base chosen shall be appropriate to the part to be tested. The time base shall be
adjusted to at least four multiple echoes from the IIW block by using single crystal normal
beam transducer or angle beam transducer. The multiple echoes shall be adjusted in such a
way that the leading edges of the second echo and the last but one coincides with the
required major divisions of the horizontal time base scale. The equipment suppression level
shall be set at ‘0’ level while performing the horizontal time base linearity check. When
measuring their position against the amplitude, the echoes shall be brought to the same
amplitude height preferably 80% of FSH. The time base shall be considered non-linear, if the
deviation of any of the amplitude position exceeds ± 2% of the selected range or one minor
sub-division. This time base linearity shall be verified, at the start of each working shift or/and
every 4hours.
Further any variation on the position of echo with ≤2 % of full screen width, setting shall be
corrected before testing is continued. If the Echo position exceeds 2% of full screen width
setting shall be corrected and testing carried out with the equipment over the previous period
shall be repeated.
6.3 RANGE CALIBRATION
The calibration of the range scale with straight beam probe is to be carried out with an IIW
calibration block, a V1 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. Figure 8.1shows typical calibration in range 0-100 mm, 0-200 mm,
and 0-500 mm for straight beam probes. The calibration of angle beam probes is to be carried
out on an IIW or V2 calibration block. The range is to be selected in order to cover minimum
1.25 x full skip distance. Required skip distance (S) is depending on the object thickness and
can be calculated as follows:
S = 2Ttanθ where T = Thickness of object to be tested, θ= probe angle and S= Skip Distance
BP = T/Cosθ where BP= Beam Path
6.4 PROBE ANGLE
The probe index is to be determined by placing the probe as shown in Figure 6.4 (a) and
maximizing the echo against the cylinder surface with radius 100 mm (IIW) or 50 mm (V2), the
echo height is adjusted to about 80% if FSH. The probe index can now be read off against the
mark on the calibration block and marked off on the probe. The probe angle is to be checked
on the IIW block using the index found. The echo from the circular Perspex reflector is

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maximized and put at 80% of FSH. The probe angle can now be read off on the calibration
block against the engraved center point, see Figure 6.4 (b).

Figurre: 6.4 (a): Probe Index Figure: 6.4 (b): Probe Angle
7 DISTANCE AMPLITUDE CORRECTION (DAC) USING ANGLE BEAM

Position the search unit for maximum response from the ¼ T hole. Adjust the sensitivity control
to provide an 80% of FSH echo from the hole. Record the peak of the indication on the screen.
Record the gain setting, which will be considered as primary reference level.
Position the search unit for maximum response from ½ T hole without changing the instrument
settings and record the peak of the indication on the screen.
Position the search unit for maximum response from the ¾ T hole without changing the
instrument settings and recoed the peak of the indication on the screen.
Position the search unit for maximum response from the ¾ T hole without changing the
instrument settings after half skip and mark the peak of the indication on the screen.
Connect the screen marks to provide a distance amplitude curve (DAC) for each search unit
to be used in testing.
When DAC has been set up it is recommended to draw two additional curves, 20% and 50%
of DAC, on the screen. see Figure 7.

¼T ½T
¾T

Figure: 7 Angle beam DAC curve

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ULTRASONIC EXAMINATION PROCEDURE

8 TRANSFER CORRECTION

Any possible difference in attenuation and surface character between the calibration block
and the object to be tested are to be checked in the following ways: 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 as shown in Figure 8. One of the probe works as transmitter and
the other as the receiver. The first echo is maximized and with the aid of gain control it is
adjusted to reach the DAC. The gain setting is noted. Without altering this gain setting the
probes are moved to calibration block. The echo is adjusted to reach the DAC and gain
setting is noted. Any difference in echo amplitude between the two materials can now be
determined with the aid of gain control. If the differences are less than 2 dB, correction is not
required. If the differences are more than 2 dB but less than 12 dB they shall be compensated.

Figure 8: Transfer correction.

9 EXAMINATION PROCEDURE

9.1 SURFACE PREPARATION

BASE METAL
The base metal on each side of the weld shall be free of weld spatter, surface irregularities, of
foreign matter that might interfere with the examination. Surface preparation is necessary to
ensure that the entire volume of the weld is scanned with the required angle probe.
WELD METAL
Where the weld surface interferes with the examination, the weld shall be prepared as
needed to permit examination.

9.2 SCANNING
The volume of weld and adjacent base material (volume on either side of the weld seam)
that is to be examined shall be scanned by straight and angle beam probes.
STRAIGHT BEAM
The scanning of adjacent base metal shall be performed to detect reflector that might affect
interpretation of angle beam result. Location and areas of such reflectors shall be recorded.
The weld and base metal shall be scanned, where required by the referencing code section,
to the extent possible with the scaning zone untill angle beam search unit. The scanning shall

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be performed at a gain setting of at least 2 times the primary reference level. Evaluation shall
be performed with respect to the primary reference level.
9.2.1 ANGLE BEAM SCANNING ON BUTT WELDED PALTES, PIPES, Nozzle AND ‘T’ JOINTS
The angle beam shall be directed at approximately right angle to the weld axis from two
direction where possible. The search unit shall be manipulated so that the ultrasonic energy
passes through the entire volumes of weld and the adjacent base metal. The 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.
Where possible the welds are to be tested from on surface of the plate and from both sides
of the weld connection. The angle probe is placed on the parent material in such a way that
the sound beam is normal to the weld. The probe is to be moved forwards and backwards in
the scanning area of 1.25 x S. during this movement the probe is to be continuously turned to
5-10º in the horizontal plane, as intimated on Figure 9.2.2 For plate thickness greater than 70
mm it may be necessary to scan from both surfaces and all four side of the weld.
Testing of Butt Plate, Pipe, Nozzle (D-Catogory) and T-joints:
The examination of T joint with ½ V or K groove and But welded half V and double V jojnts,
sahll be carried out the scaning as possible shown in below figures.

Figure 9.2.2 : scaning of Butt Plate, Pipe, T-joint Nozzle (D-Category):

9.2.2 NOZZLE SIDE WELD FUSION ZONE AND/ OR ADJACENT NOZZLE PARENT METAL
Search Unit Location.
When the referencing Code Section specifies that an ultrasonic examination be performed
to examine either the nozzle side weld fusion zone and/or the adjacent nozzle parent metal,
a straight beam examination shall be conducted from the inside nozzle surface.
Examination.
The full circumference of the nozzle shall be scanned to cover the entire nozzle side fusion
zone of the weld plus 1 in. (25 mm) beyond the weld toes. The search unit may be moved
either circumferentially around or axially across the examination zone. The screen range shall
cover as a minimum, 1.1timesthefullthicknessofthenozzlewall.Nozzlesthat cannot be fully
examined (e.g., restricted access that preventshand placement ofthe search unit)shall be
noted in the examination report.

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10 EXAMINATION AS PER AWS D1.1

10.1 CALIBARTION FOR TESTING

All calibrations and tests shall be made with the reject (clipping or suppression) control turned
off. Use of the reject (clipping or suppression) control may alter the amplitude linearity of the
instrument and invalidate test results.
Calibration for sensitivity and horizontal sweep (distance) shall be made by the ultrasonic
operator just prior to and at the location of testing of each weld.
Recalibration shall be made after a change of operators, each 30-minute maximum
time interval, or when the electrical circuitry is disturbed in any way, which includes the
following: Transducer change, Battery change, Electrical outlet change, Coaxial cable
change and Power outage (failure).
10.2 CALIBARTION FOR STRAIGHT BEAM TESTING OF BASE METAL SHALL BE MADE WITH SEARCH
UNIT APPLIED TO TOPSIDE OF THE BASE METAL AND PEROFRMED AS FOLLOW.
The horizontal sweep shall be adjusted for distance calibration to present the equivalent of
at least two-plate thickness on the CRT screen.
The sensitivity shall be adjusted at a location free of indications so that the first back
reflection from the far side of the plate will be minimum 75% of full screen height.
10.3 CALIBARTION FOR ANGLE BEAM TESTING SHALL BE PERFORMED AS FOLLOW.
The horizontal sweep shall be adjusted to represent the actual sound path distance by using
the IIW block or alternative blocks. The distance calibration shall be made using either the
125mm scale or 250mm scale on the CRT screen, whichever is appropriate. If, however, the
joint configuration or thickness prevents full examination of the weld at either of these
settings, the distance calibration shall be made using 500mm scale as required.
Note: The horizontal location of all screen indications is based on the location at which the
left side of the trace deflection breaks the horizontal base line.
The zero reference level sensitivity used for flaw evaluation is attained by adjusting the
calibrated gain control (attenuator) of the flaw detector, so that a maximized horizontal
reference level trace deflection results on the CRT screen.
Welds shall be tested using an angle beam search unit using the angle as shown in Table
8.7 attached. Following calibration and during testing, the only instrument adjustment
permitted is the sensitivity level adjustment with the calibrated gain control (attenuator). The
reject (clipping or suppression) control shall be turned off. Sensitivity shall be increased from
the reference level for weld scanning in accordance with Tables 8.2 or 8.3 (see attached) as
applicable.
The testing angle and scanning procedure shall be in accordance with those shown in
Table 8.7 (see attached).
All butt joint welds shall be tested from each side of the weld axis. Corner and T-joint welds
shall be primarily tested from one side of the weld axis only. All welds shall be tested using the
applicable scanning pattern exhibit as necessary to detect both longitudinal and transverse
flaws. It is intended that, as a minimum, passing sound through the entire volume of the weld
and the heat-affected zone in two crossing directions test all welds, wherever practical.
10.4 INDICATION RATING METHOD.
The transducer shall be set in the position of IIW so that the maximum reflection from 1.59
mm hole is received. The maximized signal shall then be adjusted to attain a horizontal
reference line height indication.
The maximum decibal reading shall be used as the reference level, “b” in the calculation of
the indication rating.

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Indication rating, d = a-b-c

Where “a” – Instrument reading in decibels, when the indication from the discontinuity is
adjusted to the amplitude source as the indication from 1.59mm Ф hole at primary reference
level.
“c”- Attenuation factor is attained by subtracting 1 inch (25mm) from the sound – path
distance and multiplying the remainder by 2. The factor shall be rounded out to the nearest
dB value.

10.5 SCANNING
Scanning shall be by contact method using manual, semi-automatic or automatic
mechanism. Recording may be carried out using automatic alarm recording system or by
manual method. Scanning shall be carried out such that entire volume of weld is tested for
longitudinal and transverse discontinuities.
The volume to be scanned shall be examined by moving the search unit over the scanning
surface so as to scan the entire examination volume for each required search unit.
Each pass of the search unit shall overlap a minimum of 10% of the active transducer
(piezoelectric element) dimension perpendicular to the direction of scan. Where mandated
by code requirements, the percent minimum overlap may be increased.
Alternatively, each pass of the search unit may overlap a dimension less than the minimum
beam dimension (beam spread) if the same is already known. Oscillation of the search unit is
permitted provided improved coverage is demonstrated.
The pulse Repetition rate shall be small enough to assure that a signal from a reflector
located at the maximum distance in the examination volume will arrive back at the search
unit before the next pulse is placed on the transducer.
The rate of search unit movement (scanning speed) shall not exceed 6 inch /s (152 mm/s)
Scanning shall be performed from the branch connection.

FIGURE 10.5 – PLAN VIEW OF UT SCANNING PATTERNS

General Notes:
• Testing patterns are all symmetrical around the weld axis with the exception
of pattern D, which shall be conducted directly over the weld axis.

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• Testing from both sides of the weld axis shall be made wherever
mechanically possible.

10.6 FLAW SIZE EVALUATION PROCEDURES

Straight (longitudinal) Beam Testing:
The size of lamellar discontinuities is not always easily determined, especially those that are
smaller than the transducer size. When the discontinuity is larger than the transducer, a full loss
of back reflection will occur and a 6 dB loss of amplitude and measurement to the centerline
of the transducer is usually reliable for determining flaw edges. However, the approximate size
evaluation of those reflectors, which are smaller than the transducer, must be made by
beginning outside of the discontinuity with equipment calibrated as per this procedure and
moving the transducer toward the area of discontinuity until an indication on the screen
begins to form. The leading edge of the search unit at this point is indicative of the edge of
the discontinuity.
Angle Beam (Shear) Testing:
The following procedure shall be used to determine lengths of indications, which have dB
ratings more serious than for a Class D indication. The length of such indication shall be
determined by measuring the distance between the transducer centerline locations where
the indication rating amplitude drops 50% (6dB) below the rating for the applicable flaw
classification. This length shall be recorded under “discontinuity length” on the test report.
Where warranted by flaw amplitude, this procedure shall be repeated to determine the
length of Class A,B and C flaws.

10.7 WELD DISCONTINUITY CHARACTERIZATION METHODS

Discontinuities shall be characterized as follows:
Spherical (individual pores and widely spaced porosity, nonelongated slag) – Sound is
reflected equally in all directions. Indication remains basically unchanged as the search unit
is moved around the spherical discontinuity.
Cylindrical (elongated slag, aligned pores of porosity, hollow beads) – Sound is reflected
equally in one direction but is changed in other directions. Indication remains basically
unchanged when the search unit is moved in one direction but is drastically changed
when moved in other directions.
Planar (incomplete fusion, inadequate joint penetration, cracks) - Sound is reflected at its
maximum from only one angle of incidence with one plane.Indication is changed with any
angular movement of the search unit. Indicationsc from cracks typically have multiple peaks
as a result of the many discontinuity facets usually present.

10.8 ACCEPTANCE CRITERIA AND TEST FREQUENCY.

Each weld discontinuity shall be accepted or rejected on the basis of its indication rating
and its length, in accordance with A W S D 1 . 1 table 8.2 and 8.3 for statically or
cyclically loaded structures respectively.
Each reject able discontinuity shall be indicated on the weld by a mark directly over the
discontinuity for its entire length and depth from the surface shall be noted on nearby base
metal.Evaluation of the defects shall be performed from both the branch and the main
branch.
10% testing on CJP Groove butt welds of total Qty –full weld length.
11 EVALUATION

Any imperfection which causes an indication in excess of 20% DAC shall be investigated to
the extent that it can be evaluated in term of the acceptance standards as per acceptance
standard.

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12 ACCEPTANCE CRITERIA

During the examiantion all evaluated discontinuties shall be accept and rejected based
below standaed.

12.1 ASME SEC VIII DIV I APPENDIX -12

Indications characterized as cracks, lack of fusion, or incomplete penetration
are unacceptable regardless of length.
Other imperfections are unacceptable if the indications exceed the reference level
amplitude and have lengths which exceed:
1) ¼ inch (6 mm) for t up to ¾ inch(19 mm).
2) 1/3 t for t from ¾ inch to 2¼ inch.(19 mm to 57 mm)
3) ¾ inch(19 mm) for t over 2¼ inch.(57 mm)
Where t is the thickness of the weld excluding any allowable reinforcement. For a butt weld
joining two numbers having different thickness at the weld, t is the thinner of these two
thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the
fillet shall be included on t.

12.2 ASME B31.3:

Acceptance criteria shall be as described in (a)
(a) A linear type discontinuity is unacceptable if the amplitude of the indication exceeds the
reference level and its length exceeds-
1. 6 mm (¼ inch) for Tw ≤ 19 mm (¾ inch)
2. Tw /3 for 19 mm < Tw ≤ 57 mm (2¼ inch)
3. 19 mm (¾ inch) for Tw > 57 mm(2¼ inch)

12.3 AWS D1.1

General Notes:
• Class B and C discontinuities shall be separated by at least 2L, L being the length of the
longer discontinuity, except that when two or more such discontinuities are not separated
by at least2L, but the combined length of discontinuities and their separation distance is
equal to or less than the maximum allowable length under the provisions of Class B or C,
the discontinuity shall be considered a single acceptable discontinuity.

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• Class B and C discontinuities shall not begin at a distance less than 2L from weld ends
carrying primary tensile stress, L being the discontinuity length.
• Discontinuities detected at “scanning level “in the root face area of CJP double groove
weld joints shall be evaluated using an indicating rating 4 dB more sensitive than
described in 6.26.6.5 when such welds are designated as” tension welds “ on the drawing
( subtract 4 dB from the indication rating “d”). This shall not apply if the weld joint is back
gouged to sound metal to remove the root face and MT used to verify that the root face
has been removed.
• ESW or EGW s: discontinuities detected at “scanning level” which exceed 2 in. [50 mm] in
length shall be suspected as being piping porosity and shall be further evaluated with
radiography.
• For indications that remain on the display as the search unit is moved, refer to 8.13.1. (AWS
D1.1)
Note:
1. Weld thickness shall be defined as the nominal thickness of the thinner of the two parts
being joined.

General Notes:
Class B and C discontinuities shall be separated by at least 2L, L being the length of the longer
discontinuity, ,except that when two or more such discontinuities are not separated by at
least 2L, but the combined length of discontinuities and their separation distance is equal to

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or less than the maximum allowable length under the provisions of Class B or C, the
discontinuity shall be considered a single acceptable discontinuity.
Class B and C discontinuities shall not begin at a distance less than 2L from weld ends carrying
primary tensile stress, L being the discontinuity length.
Discontinuities detected at “scanning level “in the root face area of CJP double groove weld
joints shall be evaluated using an indicating rating 4 dB more sensitive than described in
6.26.6.5 when such welds are designated as” tension welds “ on the drawing ( subtract 4 dB
from the indication rating “d”). This shall not apply if the weld joint is back gouged to sound
metal to remove the root face and MT used to verify that the root face has been removed.
ESW or EGW s: discontinuities detected at “scanning level” which exceed 2 in. [50 mm] in
length shall be suspected as being piping porosity and shall be further evaluated with
radiography.
For indications that remain on the display as the search unit is moved, refer to 8.13.2.1.(AWS
D1.1)
Note: 2 -- Weld thickness shall be defined as the nominal thickness of the thinner of the two
parts being joined.

13 SAFETY PRECAUTIONS

Inspection personnel involved in Ultrasonic Testing should take safety precautions and follow
the Safety Procedures, work permit, site and regulatory requirment should be during the
exmiantion.
14 POST EXAMINATION CLEANING

Inspetion involved personnels, post cleaning must be done after the completion upon the
exmiantion.
15 REPORTING

All recorded and Rejected indications should be record, Attachment 1 given UT Weld
scanning report format.

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ATTACHMENT1: ULTRASONIC EXAMINATION TEST REPORT

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