ULTRASONIC TESTING

NON-DESTRUCTIVE TESTING PROCEDURE

Universal Testing Laboratory & Inspection Inc.

 TABLE OF CONTENTS

1 Scope…………………………………………………………………………… 1
2 References……………………………………………………………………. 1
3 Personnel Qualification…………………………………………………… 1
4 Equipment and Materials………………………………………………… 2
4.1 Ultrasonic Test Unit…………………………………………………………………. 2
4.2 Ultrasonic Search Unit / Probes………………………………………………. 3
4.3 Calibration Block………………………………………………………………………. 3
4.4 Couplant…………………………………………………………………………………… 4
5 Ultrasonic Performance Check…………………………………………. 4
Calibration Procedure
5.1 Frequency of Check…………………………………………………………………. 4
5.2 Performance of Ultrasonic Test Unit……………………………………….. 5
5.3 Performance Monitoring of
Ultrasonic Search Unit…………………………………………………………….. 9
6 Procedure……………………………………………………………………… 11
6.1 Configuration of Materials……………………………………………………….. 11
6.2 Surface Preparation…………………………………………………………………. 11
6.3 Examination Area…………………………………………………………………….. 12
6.4 Technique…………………………………………………………………………………. 12
6.5 Scanning…………………………………………………………………………………… 13
7 Evaluating of Indication………………………………………………….. 14
8 Acceptance Criteria………………………………………………………… 15
9 Examination of Repair…………………………………………………….. 16
10 Reports…………………………………………………………………………. 16

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1 SCOPE

1.1 This specification provides a system of general conditions and specific

instructions as an aid to personnel required to perform Ultrasonic
Testing Examination.

1.2 This guide contains all the basic technical and methodological
requirements for Ultrasonic examination of welds, parts, components,
materials and thickness determination.

1.3 Appendices of this procedure maybe amended, replaced or additional

appendices added without revision to this procedure provided the NDE
Level III duly approves them.

2 REFERENCES

API 1104 - Welding of Pipelines & Related Facilities

ANSI/AWS D1.1 - Structural Welding Code – Steel
ASME Section V - Ultrasonic Examination Methods for Materials
and Fabrication
ASME Section 8 Div. 1

3 PERSONNEL QUALIFICATION

3.1 The examiner shall have been qualified in accordance with the
requirements of the ASNT recommended practice SNT-TC-1A latest
edition and certified as an NDE Level I and II Ultrasonic Testing
Examination method.

3.2 The examiner shall have an annual vision test with correction if
necessary, equivalent to 20/30 for distance and is able to read Jaeger
type No. 2 Standard Chart at a distance not less than twelve (12”)
inches. He shall be capable of distinguishing and differentiating contrast
between colours.

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4 EQUIPMENT AND MATERIALS

4.1 Ultrasonic Test Unit

A Pulse-echo “A” Scan rectified video presentation shall be used

with gain control or attenuation control calibrated in steps of not
greater than 2 dB. The Ultrasonic test unit shall have both single
and double transducer function and shall have flat screen which
makes viewed at varying angels without distortion of the time
base.

4.1.1 Frequency

The examination shall be conducted with frequency range

of at least 1.0 to 10 MHz unless otherwise specified by
the applicable code.

4.1.2 Screen Height Linearity

The ultrasonic instrument shall provide linear vertical

presentation within ± 5 % of the full screen height for
20% to 80% of the calibrated screen height.

4.1.3 Amplitude Control Linearity

The Ultrasonic instrument shall utilize an amplitude

control accurate over its useful range to ± 20% of the
nominal amplitude ratio to allow measurement of
indication beyond the linear range of the vertical display
on the screen.

Tolerance:

Indication Set @ % FSH dB Control Change Indication Limits % of FSH

80% -6 dB 32 – 48%
80% -12 dB 16 – 24%
40% +6 dB 64 – 96%
20% +12dB 64 – 96%

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 4.2 Ultrasonic Search Units/Probes

Search units may contain either a single or dual transducer elements.

Probe frequency, refracted angle, and crystal size shall be clearly
marked on the probe exterior.

4.2.1 Frequency

Search units shall have a nominal frequency of 2.25 MHz unless variables
such as grain structure require the use of other frequencies to assure
adequate penetration and resolution.

4.2.2 Search Units Shoes

a) Search unit shoes maybe used to maintain adequate

sound penetration or to produce the proper sound angle
on to the test material. Shoes for curved surfaces shall
have the same nominal radius of curvature at the test
specimen.
b) All probes shall be examined for physical damage and
excessive shoe wear prior to use.
c) Shoe flatness hall be determined by putting the probes
against a relatively flat surface. Check for concavity and
convexity along and across the probe axis.

4.3 Calibration Blocks

The International Institute of Welding (IIW) ultrasonic reference block

shall be the standard used for both distance and sensitivity calibration.
Other portable block maybe used, provided the reference level sensitivity
for instrument / search unit combination is adjusted to the equivalent of
that achieved with the IIW Block.

4.4 Couplant

A Couplant having good wetting properties shall be used. The Couplant

must be compatible with temperature of the test specimen.

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5 Ultrasonic Performance Check/Calibration Procedure

5.1 Frequency of Check

Description Frequency of Check

Ultrasonic Test Unit
• Time base linearity Weekly
• Equipment gain control
Monthly
attenuator
• Equipment gain control
Monthly
attenuator
• Probe/test unit combine
Weekly
resolution
• Maximum Penetrative
Weekly
Power

Ultrasonic Search • Beam Exit Points Initial calibration and prior

Units/Probes to testing of individual
component
• Probe refracted angle Weekly, or when the
refracted angle varies from
1° from the previous
• Distance amplitude Before commencement and
correction curve every completion of the
working shift

• Transfer correction Before commencement of

each component

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5.2 Performance of Ultrasonic Test Units

5.2.1 Time Base Linearity Check

1. Place a compressional wave probe on IIW-VI Block (25 mm) or

IIW-V2 Block (12.5 mm) to obtain a minimum of 5 backwall
echoes indications coincides with the appropriate graticule scale
lines.

2. Bring the successive backwall echo in turn to approximately the

same height (e.g. 80% full screen height). The leading edge of
each echo should line up with the appropriate graticule scale
lines.

3. Record any deviation from linearity and express the deviation as

percentage of the time base range.

4. Repeat steps above using 10 backwall echoes.

5.2.2 Equipment Gain Control/Attenuator Accuracy Check

1. Position a compressional wave probe on IOW Beam Profile Block

to obtain indication from 25 mm deep, 1.5 mm Ø side drilled
hole.

2. Adjust the gain control to set the signal to 80% full screen
height (slight probe manipulation maybe necessary to achieve
this exact signal height) and note the value of the calibrated
gain control (dB). Adjust the calibrated gain control to increase
the gain by 2 dB. The signal should increase to full screen height
(100%). Restore the gain to its original value and then reduce it
to further 6 dB. The signal should fall to 40% full screen height.
Reduce the gain control by further 12 dB. The signal should fall
to 5% full screen height.

Tolerance:
The difference between the smaller signal and half of the larger
signal shall not exceed 5% of the full screen height.

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 5.2.3 Equipment Amplifier Linearity Check

1. Position a compressional wave probe to obtain indication from

the 25 mm deep, 1.5 mm Ø side drilled hole together with the
indication from the backwall of the IOW beam profile block.

2. With the “gain control” and probe manipulation adjust the

backwall indication to 80% FSH and the indication from the hole
to 40% FSH without further change in the signal height ratio.
Set the larger signal to 100%, 60%, 40% and 20% FSH with
the use of equipment gain control and at each setting. Note the
height of the signal from the hole.

5.2.4 Checking of Probe/Test Unit Combined Resolution

5.2.4.1 Compression Wave Probe

1. Place a compressional wave probe at Position “A” (Fig. 1),

three (3) signals from 85 mm to 91 mm and 100 mm
surface should be clearly display.

2. Position at “B” and “C” to determine the near surface

resolution of the dead zone of the probe. If the reflection
from the Perspex disc at 10 mm © and 5 mm (b0 could
not be displayed it should be noted that reflectors within
that region (dead zone) would not be detected.

Fig.1

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 5.2.4.2 Shear Wave Probe

1. Place a shear wave angle probe on position “A” or “B”. The

signal from the side-drilled holes should be distinguishably
displayed (refer to fig 2 below).

2. Near surface resolution of shear wave angle probe can be

determined by using block with simulated side drilled hole near
the surface.

Tolerance:

The signal amplitude of subsequent signals should be clearly separated as indicated in Fig. 3

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5.2.5 Assessment of Maximum Penetrative Power

This check can only be used as an indication of maximum penetrative

power by direct comparison of different unit i.e. flaw detectors and or
probes. Two zero degree compressional wave probes shall be used for
the assessment, one low frequency and high frequency for
comparison.

1. The probe shall be placed at position “A” on the IIW Calibration

Block (See sketch in Fig. 4)

2. The control shall be set to give maximum gain and maximum

pulse energy.

3. Determine the number of multiple echoes obtained from the

bottom of the plastic insert in the block and the amplitudes of
the echoes.

4. At least three echoes should obtain with the use of 2 to 2.25

MHz probes.

5. At least two echoes should be obtained with the use of 4 to 5

MHz probes.

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 5.3 Performance Monitoring of Ultrasonic Search Unit

This section describes the method, which will be use by the Ultrasonic
Technician for checking the performance of ultrasonic search unit
prior to utilization.

5.3.1 Locating Beam Exit Point

1. Position the angle probe on the IIW-VI or IIW-V2 calibration

blocks to obtain the maximized signal from the 100 mm radius
(IIW-VI) or 25-mm/50 mm radius (IIW_V2) curve.

2. Mark with indelible marker the point on both sides of the probes
that coincides with the datum line on the calibration block.

3. Repeat this procedure for all probes to be used.

4. The beam exit point shall be marked as accurately as possible

since all physical measurement will be made from this point.

5.3.2 Determination of Prove Refracted Angle

1. Place the angle probe in the approximate position of the angle

scribed on the IIW-V1 or IIW-V2 calibration block that
corresponds to the nominal angle of the probe being tested.

2. Maximized the signal from the reference hole and adjust as

necessary.

3. Correlate the probe index point as indicated in 4.1 to the

corresponding scribed graduation on the calibration block to
determine exact angle of the main beam axis.

4. Probe actual angle shall be within ± 2° of the designed angle.

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 5.3.3 Distance Amplitude Correction

DAC Curve shall be constructed for each probe to be employed for

weldment examination, as applicable using the IOW beam profile
block.

1. Position the probe on the block to obtain the maximized signal

from the 1.5 mm hole nearest to the surface.

2. Adjust the signal to approximately 80% of FSH using the

calibrated gain control. Mark the peak of this indication on the
CRT screen by using an indelible fine tipped felt marker.

3. Repeat 4.3.1 and 4.3.2 using the signals of every 1.5 mm Ø

hole within the beam path-length of the test range to be used.

4. Connect all points marked with a smooth curving line. This line
will be referred to as DAC curve for a particular probe.

Note:

• DAC curve may be marked directly over the CRT screen cover or superimposed
using a clear plastic or Perspex overlays.

• If any point of the DAC has deviated by ± 2 dB of its amplitude, a new DAC
curve shall be reconstructed and the previous one are voided.

5.3.4 Transfer Correction

The difference in signal amplitude between the reference block and the
test surface roughness, contour, coating and acoustical attenuation
characteristics shall be compensated by the use of transfer correction
method.

1. Measurement of this value is achieved by using two angle beam

probes of the same type; one acting as transmitter and the
other as a receiver with the test unit set to dual mode. Position
the probe on the reference blocks directed at each other to
obtain the maximum signal at full skip distance.

2. Adjust the maximized signal to approximately 75% of full screen

height with the use of the calibrated gain control. Mark the peak
of this signal over the CRT screen cover or transparent overlay
and take note of the dB gain value.

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 3. Without alternating the test unit sensitivity, reposition the
probes to obtain a maximized signal at two skip distance and
mark the peak of this signal on the screen cover or on the same
transparent overlay used on paragraph 2.

4. Draw a straight line connecting the set of peaks obtained. This

line represents the reference line in determining the transfer
correction to be used in the test component.

5. Repeat Par 1 on the test component and align the peak of the
maximized signal with the line established in Par 4. The
resultant figure shall be used as the transfer correction value.
This value shall be added to the reference level prior to
examination of the test component. Note that this value maybe
positive or negative.

6 PROCEDURE

6.1 Configuration of Materials

Prior to examination weld and other material types should be

examined including thickness dimension, and product form such as
casting, forging plate etc.

6.2 Surface Preparation

The finish contract surface shall be free from weld spatter, roughness,
or any particles that would interfere with free movement of the probe
or impair the transmission of ultrasonic vibration. The weld surface
shall be sufficiently finished so as to prevent non-relevant indication
from masking or interfering with interpretation of discontinuities.

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6.3 Examination Area

6.3.1 The volume of base metal through which ultrasound will travel in angle
beam examination shall scanned using the straight beam method. If any
reflectors are detected that could interfere with the interpretation of angle
beam examination results, one of the alternate examination methods
specified in Par 6.3.2 shall be used to examined the weld and heat affected
zone for which angle beam examination is masked or partially masked.

6.3.2 The weld shall be examined for discontinuities within the weld and
adjacent heat affected zone. This examination shall be performed using
the angle beam method from two directions. In cases where geometry or
inability of the test specimen to allow transmission of ultrasound makes
the angle beam examination from both sides of the weld impractical, either
a combination of angle beam or straight beam in two directions at 90° to
each other shall be used.

6.3.3 Base material shall not be accepted or rejected on the results of the base
materials scanned specified in Par 6.3.1. The areas are to be noted on the
examination report.

6.4 Techniques

6.4.1 Straight Beam Calibration

A change in operator, power supply, search units, frequency, cable,

couplant and other components shall require a recalibration of the
system.

The calibration shall be done prior to examination, after each four

(4) hours of the work, and at the completion of the examination.

A basic calibration block shall be used for sweep range calibration.

A Distance Amplitude Correction Curve (DAC) need not be

constructed when the thickness of materials is less than one (1)
inch.

For materials one inch thick and greater, a DAC shall be

constructed.

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 6.4.2 Angle Beam Calibration

The beam angle in the production material shall be in the range of

40 to 75° inclusive.

The general calibration requirements in 6.4.1 are applicable (1-3).

A DAC curve shall be used.

6.5 Scanning

6.5.1 Straight Beam Scanning

• The scanning pattern for straight beam examination shall be, to

move the search unit along and across a sufficient contact area of
the test specimen so as to scan the entire volume of the weld and
heat affected zone.

• The scanning shall be performing at a gain setting of at least two

(2x) times the primary reference level. Evaluation shall be
performing with respect to the primary reference level.

• When rejectable indication is detected, a map of drawing shall be

prepared showing the location and the depth of indication.

6.5.2 Angle Beam Scanning

• To scan for discontinuities parallel to the weld using the angle beam
method, the search unit shall be placed on the surface with the
sound beam at the right angle to the centerline of the weld.

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 • The search unit shall be manipulated laterally and longitudinally so
that the sound beam passes through the entire volume of the weld
and heat affected zone from both sides of the weld.

• Scan the examination volume with search unit overlapping each

scan by at least 10% of the search unit dimension measured
perpendicular to the direction of scan.

• The rate of scanning shall not exceed six (6) inches per second.

7 EVALUATION OF INDICATION

All indication, which produces a response greater than 20% of the reference
level, shall be investigated to the extent that the operator can determine the
shape, identity and location of all such reflectors and evaluate them in terms of
the acceptable standards of the applicable code.

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8 ACCEPTANCE CRITERIA

Acceptance Criteria for Ultrasonic Inspection

CODE REJECTION CRITERIA

See par. 9.6 p 27-28
API 1104

AWS D1.1 For Statically Loaded Structure:

See Table 6.2
For Cyclically/Dynamically Loaded Structure;
See Table 6.3
ANSI/ASME B31.3 See Table 341.3.2A & 341.3.2B
Supplementary:
a) Linear type discontinuities are unacceptable if the
amplitude exceeds the reference level and f the length
exceeds:
1) ¼ in. for t< ¾ in.
2) 1/3t for ¾ t <2 ¼ in.
3) ¾ in for t > 2 ¼ in.
ASME Section VIII Appendix 12 a) Indications characterized as cracks, lack of fusion, or
incomplete penetrations are unacceptable regardless of
length.
b) Other imperfection are unacceptable if the indication
exceeds the reference level amplitude and have length
which exceed:
1) ¼ in. for t up to ¾ in.;
2) 1/3T for t from ¾ in. to 2 ¼ in.
3) ¾ in. for t over 2 ¼ in.

Note: Where t is the thickness of the weld excluding any allowable

reinforcement.

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9 EXAMINATION OF REPAIR

Repair shall be re-examined by the same procedure used for the original
examination.

10 REPORTS

An Ultrasonic Examination Records shall be filled out and if the material or weld
is unacceptable a “non-conformance Report” shall be made and the inspector
shall mark the portion to be repaired.

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