Ut procedure general

AMIGOS TECHNICAL SERVICES (S) PTE LTDOPERATING PROCEDURE

ULTRASONIC TESTING

NDE PROCEDURE -GENERAL

SUBJECT: ULTRASONIC TESTING

AMIGOS TECHNICAL SERVICES (S) PTE LTD

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PREPARED BY APPROVED

Name:

Signature:

Date :

Name: J. AFFANDI

Signature:

Date :

REVISION STATUS:

S.NO REVISION No. DATE DESCRIPTION1 FIRST ISSUE

STANDARD PRACTICE INSTRUCTIONS/OPERATING PROCEDURES CONTAINED IN THE COMPANY QUALITY ASSURANCE SYSTEM ARE CONTROLLED BY THE QUALITY ASSURANCE MANAGER AND MAY NOT BE IN ANY WAY REVISED OR AMENDED WITHOUT HIS AUTHORITY.

The signatures above indicate Review and Authorization of all the numbered pages in this Standard Document.

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CONTENTS

1. SCOPE

2. REFERENCE DOCUMENT

3. QUALIFICATIONS

4. RESPONSIBILITIES

5. PROCEDURES

6. REPORTING

7. ACCEPTANCE CRITERIA

8. ATTACHMENTS

9. DOCUMENTS

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ABBREVIATION

API - AMERICAN PETROLEUM INSTITUTE

AWS - AMERICAN WELDING SOCIETY

ASME - AMERICAN SOCIETY OF MECHANICAL ENGINEERS

ASTM - AMERICAN SOCIETY FOR TESTING MATERIALS

ASNT - AMERICAN SOCIETY FOR NON DESTRUCTIVE TESTING

MHz - MEGA HERTZ

IOW - INTERNATIONAL ORGANIZATION OF WELDING

IIW - INTERNATIONAL INSTITUTE OF WELDING

DAC - DISTANCE AMPLITUDE CORRECTION

FSH - FULL SCREEN HEIGHT

dB - DECIBELL

CRT - CATHODE RAY TUBE

HAZ - HEAT AFFECTED ZONE

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1.0 SCOPE

This procedure is prepared to inspect base metal and fusion welded butt joints in ferritic steel by Manual Ultrasonic Method.

2.0 REFERENCE DOCUMENTS

2.1 ASME Section V- Article-4, 5 & 23 (2007 Edition ) –

Boiler and Pressure Vessel Code

2.2 ASME /ANSI B31.3 (2008 edition) –

Chemical Plant and Petroleum Refinery Piping

2.3 AWS-D 1.1 (2008 edition) – Structural Welding Code

3.0 QUALIFICATIONS

3.1 The Personnel who carry out Ultrasonic Testing shall be qualified Level-II as per SNT-TC-1A (2006).

3.2 Alternately a level-1 qualification is acceptable, provided the work is carried out under the direct supervision of a qualified Level-2 Technician. him.

4.0 RESPONSIBILITIES

An Ultrasonic Operator / UT Technician shall be responsible for performing ultrasonic examination according to this procedure.

5.0 PROCEDURES

5.1 EQUIPMENT

5.1.1 Ultrasonic Flaw Detector shall be Portable; Pulse echo unit with rectified A – Scan display. (E.g. Krautkramer–USK6, USK7, USK7D or equivalent).

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5.1.2 Straight Beam search units shall be of standard manufacturer, either twin or single crystal with a nominal frequency of 4 MHz-5 MHz for less than 50 mm job thickness and 2.0 -2.5 MHz for job more than 50 mm job thickness, crystal diameter of 10 – 25mm.

5.1.3 Angle Beam search units shall be of standard manufacturer, either twin or single crystal with a nominal frequency of 4 MHz-5 MHz for less than 50 mm job thickness and 2.0 -2.5 MHz for job more than 50 mm, crystal dimensions of 8x9mm or 10mmØ.

5.2 REFERENCE BLOCKS

5.2.1 Reference blocks used for equipment calibration shall be as follows5.2.2 IIW or V1 Block5.2.3 V2 (Din 54122) Block5.2.4 IOW Beam Profile Block5.2.5 Basic Calibration Block of ASME Section-V, Article-5

5.3 COUPLANT5.3.1 A suitable coupling medium for acoustic transmission is required. 5.3.2 Glycerin, light machine oil, cellulose paste, non-corrosive gel or

equivalent may be used.5.3.3 Suitable high temperature grease shall be used as a couplant when doing

high temperature testing.

5.4 CALIBRATION OF EQUIPMENT

5.4.1 Manufacturers certificate of calibration shall be available with each new flaw detection unit. Annual re-calibration and certification shall be carried out by manufacturers agent or recommended third parties.

5.4.2. In addition to the above, the ultrasonic operator shall carry out following equipment checks prior to conducting any test.

Time base linearity Equipment Performance checks as per Attachment-IScreen Height

LinearityAmplifier linearityProbe resolutionProbe Index Probe characteristics check as per

Attachment-II

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5.4.3 A record for all equipment checks shall be maintained in the standard format.

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5.5 SURFACE CONDITION

5.5.1 Scanning surface shall be smooth, clean and free of scale, spatter, pitting, paint or any imperfection that might impair the coupling between the probe and the work piece.

5.5.2 Dressing of weld profile may be carried out to eliminate or resolve confusing surface echoes/mode conversions.

5.5.3 Where it is otherwise impossible for the ultrasonic beam to interrogate the full cross-section of the weld, the weld profile shall be dressed smooth.

5.6 TRANSFER CORRECTION

5.6.1 Transfer correction shall be carried out to compensate for differences in surface condition and material composition between calibration block and test component. It is a requirement to determine a transfer correction factor and adjust basic sensitivity prior to any test. It shall be carried out as follows:

5.6.2 Connect two – shear wave probes of same angle, type to the UFD in transmitter & Receiver mode.

5.6.3 Position the probes on the basic calibration block facing each other. 5.6.4 Maximize the Full skip distance echo and keep it at 80% of full screen

height (Refer Fig.5.1). Mark the signal on the UFD screen.5.6.5 Reposition the probes in order to get the double skip distance echo and

maximize it (Refer Fig.5.2). Mark the signal on the screen.5.6.6 Join the two points together in a straight line marked across the screen

(Refer Fig.5.3).5.6.7 Without altering the gain control setting, transfer the probes to the surface

of the test piece. Using the same method described above, obtain peaked signals at full and double skip distances. Join the peaks together in a straight line on the flaw detector screen.

5.6.8 The difference in dB between the two lines at comparable time base range represents the transfer correction factor.

5.6.9 The transfer correction factor shall be added to the primary reference level prior to the commencement of examination.

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Sketches for Transfer Correction Factor

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Full skip distance

Transmit Receive

Figure 5.1

Double skip distance

Transmit Receive

Figure 5.2

80%FSHLine 1

Line 2

Test piece at Full Skip

Basic Cal. Blockat Full Skip

Test piece at Double Skip

Basic Cal. Blockat Double Skip

TCF

Figure 5.3




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5.7 BEAM PATH CALIBRATION, SENSITIVITY SETTING AND DAC

5.7.1 Beam path Calibration and sensitivity setting shall be made by the ultrasonic operator at the work location, immediately prior to he commencement of test.

5.7.2 Straight beam calibration shall be made to display at least two back wall echoes on the CRT screen.

5.7.3 Straight beam sensitivity shall be adjusted such that the first back wall echo is set at 80% FSH.

5.7.4 Angle beam calibration shall be made for the beam path length that is sufficient to ensure complete coverage of weld. This may vary from 0-0.5 Skip Beam Path to 1.5 Skip Beam Path depends up on accessibility for scanning.

5.7.5 Angle beam sensitivity shall be set using a DAC curve in accordance with the requirements of the applicable code as described in the attachment-III. Scanning sensitivity shall be 6 dB above the primary sensitivity.

5.7.6 The flaw detector unit shall have minimum 20dB gain in reserve above basic sensitivity.

5.7.7 Recalibration of beam path shall be made every 30 minutes during testing, after any change of probe, coaxial cable or battery, or after any change of work location.

5.7.8 Suppression control shall be off during calibration.

5.8 TEST PROCEDURE

5.8.1 Straight beam examination shall be carried out on the base metal to ensure that the angle beam scanning area is free of lamination or any imperfections that might interfere with the angle beam test.

5.8.2 Any area of base metal with indications excess or equal to back wall echo or any area in which the back wall echo is completely lost shall be reported.

5.8.3 Straight beam examination of attachment welds shall be carried out where access is possible.

5.8.4 Scanning patterns for angle beam probes shall be established in accordance with size and geometry of the test joint. Selection of probe angles and scanning surface shall be designed to achieve optimum coverage of weld metal volume.

5.8.5 Scanning patterns for each joint type shall be specified in a technique sheet appended to this procedure.

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5.8.6 Probe movement during scans shall be a combination of lateral and traversing actions. Each scan shall overlap by at least 10%. Rotational and orbital probe movements shall be used for assessment of indications.

5.8.7 Transverse scanning shall be carried out from weld cap if possible. Alternately scanning shall be done on the parent metal adjacent to weld at an angle of <15° to the weld axis.

5.8.8 The rate of search unit movement (scanning speed) shall not exceed 150 mm per second

5.9 EVALUATION OF INDICATIONS

5.9.1 All assessment and evaluation of indications shall be carried out with primary reference level after deducting 6dB scanning sensitivity.

5.9.2 Care should be taken to ensure only relevant indications are reported as discontinuities.

5.9.3 Cross-sectional size of discontinuities shall be determined using 20dB drop technique or maximum amplitude drop technique.

5.9.4 Length of discontinuities shall be determined using 6dB drop method.5.9.5 The type of discontinuity (i.e., Planar/Cylindrical /Spherical /Linear) shall

be evaluated by noting signal response to various scans and various angles.

5.9.6 A reference zero datum mark shall be made on the work piece surface. All rejectable discontinuities shall be marked relative to zero datum.

5.10 EXAMINATION OF REPAIRS

5.10.1 Repairs shall be re-examined using the same procedure used for the original examination.

5.10.2 The extent of examination shall include the repaired area plus 100mm at either end.

5.10.3 A new report, with relevant repair number, shall be written for all repaired welds retested.

5.11 POST INSPECTION CLEANING

5.11.1 When required, post inspection cleaning shall be accomplished to remove residual inspection materials (couplant) by flushing with a solvent based cleaner then finally wiping with rags.

5.12 SAFETY

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5.12.1 Care shall be exercised during inspection with due regard to safety and the fact that the standard Ultrasonic Flaw Detectors used by the company are NOT considered intrinsically safe and also Permits shall be required for hazardous areas.

6.0 REPORTING

6.1 Reporting requirements shall be as specified by the Client or the Contract Document.

6.2 All examination results shall be reported in standard format.6.3 A sketch depicting cross-sectional area and circumferential location shall be made

for all rejectable discontinuities.6.4 All restricted areas that are not scanned with complete coverage shall be reported

with full explanation of restriction.

7.0 ACCEPTANCE CRITERIA

7.1 The acceptance criteria shall be in accordance with client’s requirements.7.2 However, unless otherwise specified the minimum acceptance criteria shall be in

accordance with the latest editions of the following documents:

i) AWS D1.1 (2008 Edition) - For Structural Steel Work

ii) ASME B31.3 (2008 Edition) - For Process Piping

iii) ASME Section-VIII Div.1 & 2 (2007 Edition) –

For Pressure Vessels

iv) API 1104(2005) - For Pipelines

8.0 ATTACHMENTS

I - Equipment Performance CheckII - Probe Characteristics CheckIII - Construction of DAC Curve

9.0 DOCUMENTS

9.1 Technique sheet UT-T 001Technique sheet UT-T 002Technique sheet - UT-T 003Ultrasonic Examination Report

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Sketch Format for Ultrasonic Examination Report

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ATTACHMENT-I

ULTRASONIC FLAW DETECTOR PERFORMANCE CHECK

1.0 INTRODUCTION

This is intended to provide detailed methods and techniques for assessment and calibration of Ultrasonic Flaw Detector, as required by UT-01 Section 8.2.

2.0 TYPE OF EQUIPMENT:

As defined by section 5.0 of UT-01.

3.0 CALIBRATION PROCEDURE:

The instrument calibration shall be performed every 40 hours as per Asme Sec V

3.1 Horizontal LinearityCalibrate the screen for the test range of 125mm using Single Crystal Transducer and IIW Block. Place the probe on 25mm thickness side and read the back wall echoes. The Percentage of error is calculated based on actual reading and the expected reading. The error should not exceed ±2% of Test Range.

3.2 Screen Height LinearityA straight beam probe is coupled with the IIW (V1) block to get multiple echoes from 25mm back wall. Select any two echoes whose amplitudes are in the ratio of 2:1 with larger echo set at 80% of full screen height. Adjust the gain successively without moving search unit and set the larger indication from 100% to 20% of full screen height in 10% increments or 2dB steps if a fine control is not available. Read the smaller indication at each setting. The settings and readings must be estimated to the nearest 1% of full screen height. Deviation should not exceed ±5% of Full Screen Height.

Alternately, a straight beam search unit shall be used on any calibration block, which will provide amplitude differences with sufficient signal separation to prevent overlapping of the two signals.

3.3 Amplitude Control LinearityCouple the angle beam search unit to IIW (V1) block and get multiple echoes from 25 mm thickness side. Select any echo and note its amplitude. Reduce the gain by 6dB and read the

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amplitude of the same indication. It must be 50% of the initial amplitude within ±10% of the nominal amplitude ratio. Perform this exercise for full range of Gain.

The settings and readings must be estimated to the nearest 1% of full screen and the readings should fall within the limits of following table.

Other convenient reflectors from any calibration block shall be used with straight or angle beam search units.

Indication Set at % of Full Screen Height

dB Control Change Indication Limits % of Full Screen Height

80 -6 dB 36 to 4480 -12 dB 18 to 2240 +6 dB 72 to 8820 +12 dB 72 to 88

4.0 RECORDS:

All calibration readings shall be recorded and documented till next calibration period and calibration block identity shall be included in the ultrasonic calibration records.

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ATTACHMENT – II

PROBE CHARACTERISTICS CHECK

1.0 INTRODUCTION

This has been written in order to provide detailed methods and techniques to evaluate the Probe’s characteristics.

2.0 TYPE OF PROBES & EQUIPMENT

As defined by section 5.0 of UT-01.

3.0 PROBE CHARACTERISTICS

3.1 Probe Resolution3.1.1 Place 0° compression probe on the V1 (IIW) Block as shown in the figure 1. The

echoes from the bottom of the milled slot at 85mm and from the steps at 91mm and 100mm shall be clearly discernible on the screen.

3.1.2 Place shear wave probes on the IOW Beam Profile Block with the beam directed towards the series of 5 side drilled holes. Al least 3 of the series shall be clearly discernible.

3.2 Probe IndexPlace shear wave probe on the V1 (IIW) block’s 100mm quadrant side as shown in the figure 2 and maximize the eco from the quadrant. Hold the probe and measure the distance (d) from block edge to probe edge.

The probe index = (100 – d) mm.For example, if ‘d’ is 86mm, then

Probe index = 100-86=14mm.This distance shall be transferred to the probe.

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Figure1

100mm Radius

V1 (IIW) Block

Figure 2100mm

d

V1 (IIW) Block




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3.3 Probe Angle Place the shear wave probe on the V1 Block as shown in the figure 3 and maximize the echo from 1.6mm hole.

Note the beam path and Probe angle is calculated using formula:Probe Angle = Cos-1(15/Beam Path)

3.4 20dB Beam Profile 3.4.1 Position the shear wave probe on the IOW block with the beam directed at a selected

1.6mm hole and maximize the signal by moving probe backwards and forwards. Hold the probe in the maximized position and adjust gain control to give 100% FSH. Make a mark1 on the block, which corresponds with the probe index point (see Fig. 4)

3.4.2 Move the probe gently forward until the signal height form the target hole has dropped to 10% FSH (i.e. 20dB). Hold the probe in this position and mark2 the probe index position on the block. (See Fig. 5)

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Figure 3

1.6m

m h

ole

V1 (IIW Block) – Probe Angle

Figure 4

Lead ing ed ge

Trailing Ed geBeam Centre

Mark at maximized pos it io n

Prob e movementto maximize s ignal

Ho rizontals tand-o ff

IOW Block




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3.4.3 Move the probe gently backward such that the signal goes back to maximum then falls away again to 10% FSH. Hold the probe in this position and mark3 the probe index position on the block. (See Fig.6)

3.4.4 Transfer the measurements of hole depth and probe stand off for each of three marks onto a flaw location slide or suitable plotting system.

3.4.5 Repeat the above steps for three other target holes at different depths.3.4.6 Complete the beam angle and profile plot by joining relevant points on the plotting

system. (See Fig.7)

4.0 CHECKLIST

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Figure 5

20 dB Trailing Edge

Mark the p rob e indexat 10 % s ig nal height

Mo ve p ro be fo rward unt ilSignal height d rop s to 1 0%

Figure 6

20 d BLead ing Ed ge

Mark the p ro b e ind exat 10% s ignal heig ht

Move p ro b e backward untilSig nal heig ht d ro p s to 1 0 %

Fig.7

Hole 1

Hole 2

Hole 3

Hole 4

Hole depth

Horizontal stand-off

Mark2 Mark1 Mark3

IndexPoint

Beam Profile Plotting




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All probe characteristics shall be entered in to the Probe Characteristics Checklist format: -: FORMAT/UT/CAL-02

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UFD Model : Date of Testing :Serial No :

CHECKLIST FOR PROBE CHARACTERISTICS

Item No Checklist Item Tolerance ResultAccept Reject

1 Resolution - 0° Probe 3 Clearly defined indications

Resolution (Angle Probe) 3 Clearly defined indications

2 Probe Index 25 mm maximum from the edge

3 Probe Angle45°60°70°

±2°

4 Beam Profile(Leading/trailing edge)

45°60°70°

FORMAT/UT/CAL-02

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x

x

x

Point 180% FSH

Point 2

Point 3

Time Base

Am

plitu

de




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ATTACHMENT-III

1.0 INTRODUCTIONThis illustration is written to provide technical detail for the construction of Distance Amplitude Correction (DAC) Curves as required by this written procedure.

2.0 EQUIPMENTAs defined by section 5.0 of UT-01.

3.0 BLOCKS3.1 IOW Block for structural steel work weldments3.2 ASME Section-V – Basic Calibration Block for Pressure Vessels/Process Piping

4.0 METHODS4.1 Select a hole in the calibration block which falls out side of the Probe’s near zone. The

near zone length is calculated using the formula:

N = D2F /4V

where, N = Length of near zone (mm)D = Crystal diameter (mm)F = Frequency (MHz)V = Velocity (103m/s)

4.2 Position the probe on the block and pick up the signal from selected target hole. 4.3 Maximize the signal by manipulation of probe. 4.4 Adjust the gain and keep the maximized signal at 80% FSH and mark the signal peak

on the screen. 4.5 Without further alteration select two more holes at suitable beam path to cover the

entire range/ thickness of the test material. Maximize the echoes by probe manipulation and mark the respective signal peaks on the screen.

4.6 Join together all the three points plotted on the screen to generate a DAC curve. (See Fig.1)

Figure 1

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HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD

ULTRASONIC TESTING PROCEDURE

GENERAL PROCEDURE

DOC No. : HT-UT-01REVISION : 9.0DATE : 03.07.2009

TECHNIQUE SHEET – 1:

SCANNING TECHNIQUE FOR BUTT WELDS

a) Welds with single side access:

]

Angle Thickness Scan leg Surface Examination0° all n/a 1 & 2 Lamination check on Parent metal45° ≥25mm half 1 & 2 Root and lower weld volume

full skip 1 & 2 Upper weld volume and fusion faces60° 10-25mm half skip 1 & 2 Root, lower weld volume and fusion faces

>25mm full skip 1 & 2 Upper weld volume and fusion faces70° 10-25mm half skip 1 & 2 Root, lower weld volume and fusion faces

all half skip 1 & 2 Transverse scan of weld. (if cap is flushed tosmooth, scanning may be carried out from the weld surface)

2.0 Welds with double side access:

Angle Thickness Scan leg Surface Examination0° all n/a 1 & 2 Lamination check on Parent metal45° ≥25mm half 1,2,3 &4 Root and lower weld volume60° ≥10mm half skip 1,2,3 &4 Root, lower weld volume and fusion faces

full skip 1,2,3 &4 Transverse scan of weld. (if cap is flushed tosmooth, scanning may be carried out from the weld surface)

70° 10-25mm half skip 1,2,3 &4 Root, lower weld volume and fusion faces

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half skip

Full Skip+ 1/2 Cap

Surface 1 Surface 2

half skip

half skip half skip

half skip

Surface 4

Surface 2

Surface 3

Surface 1



GENERAL PROCEDURE


TECHNIQUE SHEET – 2:

SCANNING TECHNIQUE FOR FULL PENETRATION / NOZZLE WELDS

a) Nozzle with ‘Set through’ or full penetration T-Joints:

Scan 1 0° Lamination check on parent metalScan 2/3 45°/60°/70° shear wave scanning for weld volume, root, HAZ and fusion faces

at ½ skipScan 3 - 0° scan for fusion at main member side and lamellar tearing in main member.

b) Nozzle or branch attachment ‘set-on’

Scan 1 0° Lamination check on the parent metal.Scan 2 45°, 60° scan for weld volume, fusion faces & HAZ at half and full skip

distance.Scan 3 60°, 70° scan for root at half skip.Scan 4 0° scan on main member to check main member side fusion, HAZ, Lamellar

tearing (if surface is accessible).Scan 5 If scan 2 & 3 is restricted due to non accessibility, a 45° scan for weld and

fusion at full skip shall be carried out.

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Scan 4

Sca

n 1

- 0

º

Sca

n 2

-45

º/6

0º/

70

º

Sca

n 3

-45

º/6

0º/

70

º

Scan 4

Scan 5

Sca

n 1,

2, &

3

Ful

l ski

p half

skip



GENERAL PROCEDURE


TECHNIQUE SHEET - 03:SCANNING TECHNIQUE FOR TKY JOINTS:

Scanning detail1. All scans to be carried out from branch member surface.2. 0° scan for lamination check on scan surface.3. 45°, 60°, 70° angle beam scan of weld metal at half and full skip as permitted by material thickness and

weld geometry.4. Local dihedral angle and weld geometry varies point to point. Therefore beam axis should be kept

perpendicular to the weld during angle beam scanning.

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Toe zoneTransit ion

zone

Heel zone

MAIN MEMBER

BRANCHMEMBER

Scanning perpendicularto weld at all locations

Section through Toe zone

Mai

n m

embe

r

Scan surface

Full skipHalf skip

Mai

n m

embe

r

Scan surface

Full skipHalf skip

Section through Heel zone

Section through Transition zone

Scan surface



GENERAL PROCEDURE


ULTRASONIC TESTING REPORT FORMATE

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GENERAL PROCEDURE


ULTRASONIC TEST SKETCH

SKETCH

PROJECT TITLE : REPORT NO :

Joint Identification Length / mm Depth / mm Width / mm Defect Type Remarks

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Ut procedure general

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