Professional Documents
Culture Documents
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DATE
REF DOC.
ATS-UT-001
REVISION
0.0
PREPARED BY
APPROVED
Name:
Name: J. AFFANDI
Signature:
Signature:
Date :
Date :
REVISION STATUS:
S.NO
1
REVISION No.
DATE
DESCRIPTION
FIRST ISSUE
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ATS-UT-001
DATE
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0.0
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
AWS
- MEGA HERTZ
IOW
IIW
DAC
FSH
dB
- DECIBELL
CRT
HAZ
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1.0
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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
2.2
2.3
3.0
QUALIFICATIONS
3.1
3.2
4.0
The Personnel who carry out Ultrasonic Testing shall be qualified Level-II as per
SNT-TC-1A (2006).
Alternately a level-1 qualification is acceptable, provided the work is carried out
under the direct supervision of a qualified Level-2 Technician.
him.
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. KrautkramerUSK6, USK7, USK7D or equivalent).
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5.1.2
5.1.3
5.2
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REFERENCE BLOCKS
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.3
COUPLANT
5.3.1 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
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
Screen Height
Linearity
Amplifier linearity
Probe resolution
Probe Index
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5.4.3
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5.5
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SURFACE CONDITION
5.5.1
5.5.2
5.5.3
5.6
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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.
Dressing of weld profile may be carried out to eliminate or resolve
confusing surface echoes/mode conversions.
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.
TRANSFER CORRECTION
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.6.6
5.6.7
5.6.8
5.6.9
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Receive
Figure 5.1
Transmit
Receive
80%FSH
Line 1
Line 2
TCF
T est piece at
Full Skip
Basic Cal. Block
at Full Skip
Figure 5.3
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5.7
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5.7.5
5.7.6
5.7.7
5.7.8
5.8
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TEST PROCEDURE
5.8.1
5.8.2
5.8.3
5.8.4
5.8.5
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.
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.
Straight beam examination of attachment welds shall be carried out where
access is possible.
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.
Scanning patterns for each joint type shall be specified in a technique
sheet appended to this procedure.
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5.8.6
5.8.7
5.8.8
5.9
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EVALUATION OF INDICATIONS
5.9.1
5.9.2
5.9.3
5.9.4
5.9.5
5.9.6
5.10
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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
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
6.2
6.3
6.4
7.0
ACCEPTANCE CRITERIA
7.1
7.2
8.0
ATTACHMENTS
I - Equipment Performance Check
II - Probe Characteristics Check
III - Construction of DAC Curve
9.0
DOCUMENTS
9.1
Technique sheet UT-T 001
Technique sheet UT-T 002
Technique sheet - UT-T 003
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:
CALIBRATION PROCEDURE:
The instrument calibration shall be performed every 40 hours as per Asme Sec V
3.1
Horizontal Linearity
Calibrate 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 Linearity
A 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 Linearity
Couple 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
80
80
40
20
4.0
dB Control Change
-6 dB
-12 dB
+6 dB
+12 dB
Indication Limits % of
Full Screen Height
36 to 44
18 to 22
72 to 88
72 to 88
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
Probes characteristics.
2.0
PROBE CHARACTERISTICS
3.1
3.1.1
Probe Resolution
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.
Figure1
V1 (IIW) Block
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 Index
Place shear wave probe on the V1 (IIW) blocks 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.
Figure 2
100mm
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.
1.6mm hole
Figure 3
Leading edge
BeamCentre
Trailing Edge
IOW Block
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 mark 2 the probe index
position on the block. (See Fig. 5)
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Figure 5
M ove probe forward until
Signal height drops to 10%
M ark the probe index
at 10%signal height
20 dB Trailing Edge
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)
Figure 6
M ove probe backward until
Signal height drops to 10%
M ark the probe index
at 10%signal height
20 dB
Leading Edge
3.4.4
3.4.5
3.4.6
Transfer the measurements of hole depth and probe stand off for each of three marks
onto a flaw location slide or suitable plotting system.
Repeat the above steps for three other target holes at different depths.
Complete the beam angle and profile plot by joining relevant points on the plotting
system. (See Fig.7)
Fig.7
Horizontal stand-off
Index
Point
Hole 1
H o le de pth
Hole 2
Hole 3
Hole 4
CHECKLIST
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All probe characteristics shall be entered in to the Probe Characteristics Checklist format: -:
FORMAT/UT/CAL-02
Page 20 of 23
UFD Model
Serial No
:
:
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Checklist Item
Tolerance
Resolution - 0 Probe
3 Clearly defined
indications
3 Clearly defined
indications
25 mm maximum
from the edge
2
Probe Index
Probe Angle
45
60
70
Beam Profile
(Leading/trailing edge)
45
60
70
Result
Accept
Reject
FORMAT/UT/CAL-02
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ATTACHMENT-III
1.0
INTRODUCTION
This illustration is written to provide technical detail for the construction of Distance
Amplitude Correction (DAC) Curves as required by this written procedure.
2.0
EQUIPMENT
As defined by section 5.0 of UT-01.
3.0
3.1
3.2
BLOCKS
IOW Block for structural steel work weldments
ASME Section-V Basic Calibration Block for Pressure Vessels/Process Piping
4.0
4.1
METHODS
Select a hole in the calibration block which falls out side of the Probes near zone. The
near zone length is calculated using the formula:
N = D2F /4V
4.5
4.6
Position the probe on the block and pick up the signal from selected target hole.
Maximize the signal by manipulation of probe.
Adjust the gain and keep the maximized signal at 80% FSH and mark the signal peak
on the screen.
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.
Join together all the three points plotted on the screen to generate a DAC curve. (See
Fig.1)
80% FSH
A
m
p
litu
d
e
4.2
4.3
4.4
Figure 1
Point 1
x
Point 2
x
x
Point 3
Time Base
Page 22 of 23
DOC No.
: HT-UT-01
REVISION : 9.0
DATE
: 03.07.2009
TECHNIQUE SHEET 1:
SCANNING TECHNIQUE FOR BUTT WELDS
a) Welds with single side access:
Full Skip
+ 1/2 Cap
half skip
Surface 1
Surface 2
]
Angle
0
45
Thickness
all
25mm
60
10-25mm
>25mm
10-25mm
all
70
2.0
Scan leg
n/a
half
full skip
half skip
full skip
half skip
half skip
Surface
1&2
1&2
1&2
1&2
1&2
1&2
1&2
Examination
Lamination check on Parent metal
Root and lower weld volume
Upper weld volume and fusion faces
Root, lower weld volume and fusion faces
Upper weld volume and fusion faces
Root, lower weld volume and fusion faces
Transverse scan of weld. (if cap is flushed to
smooth, scanning may be carried out from the weld
surface)
half skip
Surface 1
Surface 2
Surface 3
Surface 4
half skip
half skip
Angle
0
45
60
Thickness
all
25mm
10mm
Scan leg
n/a
half
half skip
full skip
Surface
1&2
1,2,3 &4
1,2,3 &4
1,2,3 &4
70
10-25mm
half skip
1,2,3 &4
Examination
Lamination check on Parent metal
Root and lower weld volume
Root, lower weld volume and fusion faces
Transverse scan of weld. (if cap is flushed to
smooth, scanning may be carried out from the
weld surface)
Root, lower weld volume and fusion faces
Page 23 of 27
DOC No.
: HT-UT-01
REVISION : 9.0
DATE
: 03.07.2009
GENERAL PROCEDURE
TECHNIQUE SHEET 2:
SCANNING TECHNIQUE FOR FULL PENETRATION / NOZZLE WELDS
a) Nozzle with Set through or full penetration T-Joints:
Scan 1
Scan 2/3
Scan 3 -
S
c
a
n3
-4
5
/6
0
/7
0
S
c
a
n2
-4
5
/6
0
/7
0
S
c
a
n1-0
Scan 4
Scan 1
Scan 2
Scan 3
Scan 4
Scan 5
S
c
a
n1
,2
, &3
h
a
lf s
k
ip
F
u
ll s
k
ip
Scan 5
DOC No.
: HT-UT-01
REVISION : 9.0
DATE
: 03.07.2009
GENERAL PROCEDURE
BRANCH
MEMBER
Scanning perpendicular
to weld at all locations
Heel zone
T oe zone
T ransition
zone
MAIN MEMBER
Section through
Heel zone
M
a
i
n
m
e
m
b
e
r
Scan surface
Scanning detail
1.
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.
Page 25 of 27
DOC No.
: HT-UT-01
REVISION : 9.0
DATE
: 03.07.2009
GENERAL PROCEDURE
Page 26 of 27
DOC No.
: HT-UT-01
REVISION : 9.0
DATE
: 03.07.2009
SKETCH
PROJECT TITLE :
Joint Identification
REPORT NO :
Length / mm
Depth / mm
Width / mm
Page 27 of 27