PROCEDURE FOR PHASED ARRAY ULTRASONIC

EXAMINATION OF BUTT WELDS

Procedure No: NDT/PAUT/01

Revision No:00
Issued on: 08/07/2013

Prepared By
Reviewed By
Approved By

Revision History Details

Revision No. Revised on Reason for revision
00 -- Initial Issue
 PART 1 GENERAL

1. Scope

The scope of this procedure covers the inspection of 30mm single V carbon steel
butt welds using SMAW welding process. This procedure is made in accordance
with ASME SEC V and with ASME SEC VIII div 1 as acceptance criteria.

2. Document Control

Document No. NDT/PAUT/01

Revision No. 00
Issue No. Initial Issue
Prepared By
Reviewed By
Approved By

3. Normative References
The following referenced documents are referred to prepare this procedure
S.No Standard Description Edition
1 EN473 Qualification and certification of NDT Personnel Latest
2 EN583-1 Non Destructive Testing-Ultrasonic Examination Latest
part1:General Principles
3 ASME Sec.V Boiler and Pressure Vessel Code Non destructive Latest
Article 4 testing
3 ASME Sec.VIII Boiler and Pressure Vessel Code fabrication of Latest
Div 1 pressure vessels
4 EN1714 Non Destructive examination of welds – Ultrasonic Latest
examination of welded Joints

4. Abbreviations and Terminology

A). PAUT: Phased Array Ultrasonic Testing
B). HAZ : Heat Affected Zone
C). TCG: Time Corrected Gain
D). Focal Law: The set of delays and amplifications applied to a group of elements
required to generate a specific beam.
E). E-Scan: The same focal law and delay is multiplexed across a group of active
elements; scanning is performed at a constant angle and along with the passed array
probe length (aperture). This is equivalent to a conventional ultrasonic transducer
performing a raster scan for corrosion mapping or shear wave inspection.
F). S-Scan: (also called azimuthal or sectorial scanning): the beam is moved through a
sweep range of angles using the same elements.

5. Non-Compliance
Non-conforming products shall be dealt through the proper identification and
segregation mechanism ie. Shall be clearly identified with a marker and the area
retested after attending the repair. Repair scans shall include 50mm of scan length
beyond the repair area limits and the files and reports with be marked as R1. If for
any reason this procedure cannot be complied, the controlling NDT supervisor shall
be informed and if necessary further guidance sort.

PART 2 NDT PERSONNEL

6. Personnel
The qualification requirements for NDT personnel shall be in accordance with
ASNT SNTC -1A.
Also all technician shall meet the minimum vision requirement as per ASNT
SNTC-1A

7. Safety
PPE’s must be worn all time at the time of inspection.
All technicians must be aware of regulations and requirements of both local and
international safety standards.
All personnel carrying out the work as per this procedure shall have had a
sufficient safety training and shall comply with all company safe working
practices including the use of PPE as instructed.

PART 3 EQUIPMENT AND CONSUMABLES

8. PAUT equipment Requirements
Contain 16/64 independent pulse echo channels
Ability to display A,B,C and S scan images
Search Unit(Transducers and wedges) type to be used based on material and
thickness. For 30mm thick carbon steel butt weld we can choose 5L64A12
probe and SA12 N55S wedge for scanning.
Have attenuation (gain) control stepped in increments of 2 dB or less
Capable of operation at frequency of 5 MHz

9. Couplant
For mixing and use during inspection only potable water shall be used.
For temperature above 50-degree Celsius high temperature couplant shall be
used. The same type of couplant shall be used during the examination and
calibration. Oil or water type couplant can be used for performing calibrations
and examinations.

10 Encoder
The encoder shall be capable of permitting a scan resolution of 1.0 mm as a
minimum for 30mm thickness job.
The encoder shall be capable of tracking probe movement and
position on one axis of travel as a minimum.
The maximum scan speed shall not exceed 150 mm per second.

11. Calibration Reference Blocks

The calibration block is used to establish velocity, wedge delay, sensitivity and
to construct a time corrected gain (TCG).
The calibration block(s) for setting beam position and sensitivity shall use
sections of plate of approximately the same dimensional and acoustic
characteristics as that being inspected.
Calibration block design shall be in accordance with ASME Section V Art.4.

12. Equipment Checks

PAUT equipment shall be calibrated each year.
PAUT Equipment used in the application of this procedure shall comply with
the requirements of EN12668-1, EN12668-2 & EN12668-3.
 PART 4 TEST PIECE
13. Test Piece Surface Preparation
Scan surfaces of the calibration block shall be of a condition similar to the plate
being inspected. It shall be free of rust, scale, greese or any other material that
would impede ultrasound from being coupled into the metal.
Weld Surfaces - the weld surface should be free of irregularities that could mask
or cause reflections from defects to go undetected and should merge smoothly
into the adjacent base materials
Conditions which do not meet these requirements shall be recorded as
limitations on the Phased Array Data Report
The PAUT system shall be capable of use on scanning surfaces of a wide range
of Temperatures ranging from 0-50 c.

14. Test Volume

The test area shall include the full volume and also the heat affected zone
(HAZ). The heat affected zone shall include at least t/4 on either side of the
weld volume unless the actual extent of the HAZ has been determined and
recorded during the welding process.
The parent metal through which the sound beam travels shall be examined with
a straight beam focal law to detect imperfections or high attenuation.

15. Datum points

In order to ensure the repeatability of testing a permanent reference system
shall be applied. Each component shall be clearly identified by use of hard
stamping. The identification shall be unique to the component and be traceable
to the welding procedure and material details. The stamped marking shall be
placed such that the marking shall not be in an area where the probe shoes shall
be in contact with the parent material. In order to accomplish this, the NDT
TOFD supervisor shall mark the probe contact prior to scanning. Typically, the
component identification shall contain the component number, weld number.
In addition to this scan start position shall be indicated on the component using
a permanent marker or hard stamp start position and scanning direction shall be
established based on the weld identification reference points.
All defective areas shall be marked with reference to the above datum.
If reports are required, the scan file shall be clearly be designated with the
component and weld identification followed by R1,R2 etc for repairs (R1-Repair
1, R2-Repair2). In addition to the above requirements if client advise us to
maintain the identification system as per their procedure the same shall be
adhered.
PART 5 PERFORMANCE OF THE TEST
16. Phased Array Technique
The UT-Phased Array Technique is a process wherein UT data are generated by
controlled incremental variation of the ultrasonic beam angle in the azimuthal
or lateral direction while scanning the object under examination. This process
offers an advantage over processes using conventional search units with fixed
beam angles because it acquires considerably more information about the
reflecting object by using more aspect angles in direct impingement.
17. Pulse Echo Method
It is an inspection method in which the presence and position of a reflector are
indicated by the echo amplitude and time

18. Semi-Automated Method

It is a technique of ultrasonic examination performed with equipment and
search units that are mechanically mounted and guided, manually assisted
(driven), and which may be manually adjusted by the technician. The
equipment used to perform the examinations is capable of recording the
ultrasonic response data, including the scanning positions, by means of integral
encoding devices such that imaging of the acquired data can be performed.

19. Sectorial Scan

Also termed an S-scan or azimuthal scan. This may refer to either the beam
movement or the data display. As a data display it is a 2D view of all A-scans
from a specific set of elements corrected for delay and refracted angle. When
used to refer to the beam movement it refers to the set of focal laws that sweeps
a defined range of angles using the same set of elements.
20. Linear Scanning
Also termed line scanning is defined as a single pass scan of the search unit
parallel to the weld axis at a fixed stand-off distance.

21. Scan Plan

A documented examination strategy that provides a standardized and repeatable
methodology for weld examinations. The scan plan displays cross-sectional joint
geometry, extent of coverage, clad or overlay (if present), Heat Affected Zone
(HAZ) extent, search unit size(s) and frequency(ies), beam plots of all angles
used, search unit(s) position in relation to the weld centerline [Probe Center
Spacing (PCS) in the case of Time of Flight Diffraction (TOFD)], and if
applicable, zonal coverage overlap.

22.Requirments Of A Phased Array Linear Scanning Examination Procedure

Using Linear Arrays
Requirements Essential Nonessential
(As Applicable) Variable Variable

Search unit(s) X ...

(element pitch, size, number,
and gap dimensions)

Focal range(s) X ...

(identify plane, depth, or
sound path as applicable)

Virtual aperture size(s) X ...

(number of elements, element
width, and effective height
[Note (1)]

Wedge natural refracted angle X ...

Scan plan X ...

Weld axis reference point ... X
Marking

Additional E-scan requirements:

Rastering angle(s) X ...

Aperture start and stop element X ...

numbers

Aperture incremental change(s) X ...

(number of elements stepped)

Additional S-scan requirements:

Sweep angular range(s) X ...

Angular sweep increment X ...

(incremental angle change,
deg)

Aperture element numbers X ...

(first and last

23. Procedure Qualification

When procedure qualification is specified by the referencing Code Section, a
change of a requirement in an essential variable from the specified value, or
range of values, shall require requalification of the written procedure. A change
of a requirement identified as a nonessential variable from the specified value,
or range of values, does not require requalification of the written procedure. All
changes of essential or nonessential variables from the value, or range of values,
specified by the written procedure shall require revision of, or an addendum to,
the written procedure.

System Calibration

24. Velocity Calibration

Velocity calibration shall be done using 100mm Radius of the V1 Block. Place
the gate in the multiple reflected signals, the two signals selection will
automatically calibrate the velocity.

25. Wedge Delay Calibration

The wedge delay calibration is carried out using 3mm side drilled hole block.
The wedge delay calibration shall be carried out in true depth mode and done
with a known reflector depth.
Scan the phased array probe back ward and forward through all the different
angles or focal laws.
When the signal for all angles and focal laws lies within the threshold, the
system shall adjust all the focal laws/angles to display the reflector’s true depth.

26. Sensitivity Calibration

The sensitivity calibration is carried out using 3mm side drilled hole block.
The sensitivity calibration shall provide the required gain adjustments for each
refracted angle and sound path used. Peak up this signal from the calibration
reflector and scan the phased array probe back wards through all the different
angles or focal laws. Scan forward over the calibration reflector through all the
refracted angles of focal laws. The System shall calculate the required gain
needed at each focal law to adjust the amount of gain required to obtain the
sensitivity.

27. Time Corrected Gain Calibration(TCG)

The TCG calibration is carried out using 3mm side drilled hole block.
The reflectors shall be selected for at least 3 holes preferably <T, T to 2T, >2T
where T is the thickness of job. Time corrected gain calibration shall be used to
compensate for attenuation in the material at the sound paths used during
calibration and examination. To obtain the TCG calibration peak the signal
from the ID notch on the reference block. Move the phased array probe forward
and backward to equal the amplitude for all the focal laws and angles and plot
the first point(<T). Repeat the process with T to 2T and > 2T. TCG calibration
has to be carried out for all scan plans in a multi group option while using
phased array probe.
28. Encoder Calibration
Encoder is used to record the Scan data which is hooked to the scanner.
Encoder calibration shall be carried out for step resolution for data acquisition.
The encoder shall be connected to the Omni Scan equipment and the
calibration wizard shall be used to calibrate the encoder. Through the menu
wizard set up, all the parameters are fed and the encoder is made to scroll on a
pre determined known length. After reaching from position A to B as shown
below the calibration shall be accepted by presetting the origin and the length
of travel. This would result in no of steps/mm value for the attached encoder
thus giving true length of scan. A maximum resolution of 1mm shall be set for
and be used between A-scans collected for thickness under 30mm.
29. Conducting The Test:
Scan plan shall be developed using the selected probe and the wedge to ensure
the adequate coverage and the proper technique is used which gives maximum
probability of detection. Scanning sensitivity shall be 6 dB above the reference
level used to create the TCG calibration. A mechanical scanner shall be used
wherever possible to ensure the probe travels in a straight line along the weld
axis, ensuring the search unit index offset distance does not change at any point
throughout the scan.A dual probe configuration shall be used wherever possible,
with the second probe on the opposite side of the weld. An encoder must be
used wherever possible to record all A-scan data from all parallel scans
Place the search unit at the starting position of the scan, with the search unit
directing sound essentially perpendicular to the weld axis. The front of the
search unit shall be set at the correct offset distance from the weld centerline, as
define in the Scan Plan. If a different offset distance is used, it is to be noted on
the Phased Array Examination Report. Move the search unit alongside the weld
with the encoder active and recording. The scan speed shall not exceed 150
mm/s. Scan the complete length of the weld. Scanning speed shall be such that
data drop-out is less than 5% of the scan length with no adjacent data line skips.
Search unit contact must be maintained throughout the entire scan. If contact is
lost due to component geometry or obstructions, this must be noted on the
Phased Array Data Report. Save the data file under an appropriate file name
which is unique for that weld only. Calibration must be checked periodically as
stated in the calibration requirements. If any deviations from the last acceptable
calibration are noted, all welds examined to the last acceptable calibration shall
be re-examined

30. Documentation
PA results shall be presented in A,B,C,D or S form with the horizontal axis of
the image representing the distance along the weld axis and the vertical axis of
the image representing the through wall dimension. Once all datable indication
data has been collected, viewing and sizing shall be carried out using the
applicable cursors on the PA unit or saved and analyzed on remote PC using
Tomoview software associated with Omni scan equipment.

PART 6 Acceptance Criteria

All Indications assessed as flaws having an amplitude response greater than or
equal to -6 of the reference level shall be assessed
When using this procedure with a semi automated scan the assessment shall be
made using the cursors on C-scan display of the acquired data measuring to the
encoded scan positions where the peak response drops to 20% screen height of
reference scanning level
The location of the reported flaw shall be recorded indicating:
a)Flaw start with respect to the datum
b)Flaw offset from the weld centerline
c)Depth of the flaw from the test surface
Flaws greater than the allowed lengths indicated in the Acceptance criteria (eg.
ASME CC2235) shall be considered rejectable and notified to the client along
with the marking.
Only EN 473 Level II or III shall analyse or interpret the PAUT Results.
PART 7 POST TEST PROCEDURE

Any labels or segregation done to ease the examination shall be cleaned and
restored. If protective coating is removed from the job before examination the same
shall be notified to the client or coated as per client requirement if applicable. The
material under testing shall be cleaned by the suitable means to remove the
couplant from the surface of the object and dried in the suitable temperature and the
client shall be notified for the safe customer property handling.
 PART 8 PRODUCTION OF THE TEST REPORT

The Test report shall include a reference to this document and shall give as a
minimum the following information:

Information relating to object under test

a) Identification of object under test
b) Dimensions including wall thickness
c) Material type and product form
d) Geometrical configuration
e) Location of welded joints examined
f) Reference to welding process and heat treatment
g) Surface condition and temperature
h) Stage of manufacture
Information relating to equipment
a) manufacturer and type of PAUT equipment including scanning
mechanisms with identification numbers if required
b) manufacturer, type, frequency, element size and beam angles of
probes with identification numbers if required
c) details of reference block (s) with identification numbers if
required
d) type of couplant used
Information relating to test technique
a) examination level and reference to a written test instruction, if
required
b) purpose and extent of test
c) details of datum and co-ordinate systems
d) details of TOFD set-ups
e) method and values used for range and sensitivity settings
f) details of signal averaging and scan increment setting
g) details of offset scans, if required
h) access limitations and deviations from this document
Information relating to test results
a) TOFD images of at least those locations where relevant indications
have been detected
b) Acceptance criteria applied
c) Tabulated data recording the classification, location and size of
relevant indications and results of evaluation
d) Date of test
e) Names, signature and certification of personnel