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You cn change yout ad preferences anytime, arnigorm Seer nr aa Thc PREPARED BY [APPROVED Name Nam: J.AFPANDI Siew smnce [s80——[aresioxse fours Joeman Pat 28CONTENTS quaLariextioNs NCCHPEANCECRITERIS Paget 28PAGE NDE PROCEDURE -GENERAL were pare SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD REFDOG. | REVISION oo ATS-UT-001 ABBREVIATION ADL» 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. Miz MEGA HERTZ JOW INTERNATIONAL ORGANIZATION OF WELDING IW INTERNATIONAL INSTITUTE OF WELDING DAC - DISTANCE AMPLITUDE CORRECTION FSH FULL SCREEN HEIGHT DECIBEL RT -CATHODE RAY TURE HAZ - HEAT AFFECTED ZONE Page 3 of 23NDE PROCEDURE -GENERAL ieee pare SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD REFDOG. | REVISION oo 10 20 30 40 50 PAGE ATS-UT-001 SCOPE, This procedure is prepared to inspect base metal and fusion welded butt joints in ferrtic steel by Manual Ultrasonic Method. REFERENCE DOCUMENTS 2.1 ASME Section V- Article-4, 5 & 23 (2007 Euition ) Boiler and Pressure Vessel Code 2.2. ASME/ANSIBS13 (2008 edition) — Chemical Plant and Petroloum Refinery Piping 2.3. AWS-D 1.1 (2008 edition) — Structural Welding Code QUALIFICATIONS: 3.1 The Personnel who earry out Ultrasonic Testing shall be qualified Level-II as per SNT-TC-1A (2006). 3.2. Altemately a level-I qualification is acceptable, provided the work is cartied 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. PROCEDURES 5.1 EQUIPMENT 5.1.1 Ultrasonic Flaw Detector shall be Portable; Pulse echo unit with rectified A Scan display. (Eg. Krauthramer-USK6, USK7, USK7D or equivalent). Page 4 of 23PAGE NDE PROCEDURE -GENERAL were pare SUBJECT: ULTRASONIC TESTING - AMIGOS TECHNICAL SERVICES (S) PTE LTD REFDOG. | REVISION oo ATS-UT-001 5.1.2. Straight Beam search units shall be of standard manufacturer, either twin 582 53 or single crystal with a nominal frequency of 4 MHz-5 MH2 for less than ‘50 mm job thickness and 2.0 -2.5 MHz for job more than $0 mm job thickness, erystal diameter of 10— 25mm. 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 SO ‘mm job thickness and 2,0 -2.5 MHz for job more than 50 mm, crystal dimensions of $x9mm or LOmm0. REFERENCE BLOCKS 5.2.1 Reference blocks used for equipment calibration shall be as follows 5.2.2 UW or V1 Block 52.3 V2.(Din 54122) Block 5.24 10W Beam Profile Block 5.2.5 Basic Calibration Block of ASME Section-V, Article-5 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 CALIBRATION OF EQUIPMENT S54. 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 partes, In addition to the above, the ultrasonic operator shall carry out following equipment checks prior to conducting any test “Time base linear Equipment Performance checks as per Sereen Height Attachment-T Linearity Amplifier Tinear Probe resolution Probe Index. Probe characteristics check as per Attachment-II Page 5 of 23NDE PROCEDURE -GENERAL SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (8) PTE LTD PAGE pate corns wEFpo, | REVIION ATSUrOO1 5.4.3 A record for all equipment checks shall be maintained in the format Page 6 of 23PAGE NDE PROCEDURE -GENERAL rere pare SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD REFDOG. | REVISION oo ATS-UT-001 55 SURFACE CONDITION 56 5.5.1 Seanning surface shall be smooth, clean and free of seale, 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 itis 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 Transfer correction shall be carried out to compensate for differences in surface condition and material composition between calibration block and test component. It 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. 5.64 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 sereen, 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 ina straight line marked across the sereen (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 fall and double skip distances. Join the peaks together in a straight line on the flaw detector sereen, 5.68 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, Page 7 of 23PAGE NDE PROCEDURE -GENERAL ware pare SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD REFDOG. | REVISION oo ATS-UT-001 5 er ‘i Transmit mes | ruts aie Figure 5.1 Transmit Figure 8.2 <—— _ Double skip distance Receiv Test pee tf Ful Sip Fl Skip Figure $3 asic Cal. Block asic Cal, Bek ‘at Doble Skip Test pce at Dove Sip Page 8 of 23PAGE NDE PROCEDURE -GENERAL sare pare SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD REFDOG. | REVISION oo ATS-UT-001 57 BEAM PATH CALIBRATION, SENSITIVITY SETTING AND DAC 572 $13 574 518 516 ExAd 578 Beam path Calibration and sensitivity setting shall be made by the ultrasonic operator at the work location, immediately prior to he commencement of test. Straight beam calibration shall be made to display at least two back wall echoes on the CRT screen. Straight beam sensitivity shall be adjusted such that the first back wall echo is set at 80% FSH. Angle beam calibration shall be made for the beam path Length that 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 Angle beam sensitivity shall be set using a DAC curve in accordance with the requirements of the applicable eode as described in the attachment-II. Scanning sensitivity shall be 6 dB above the primary sensitivity The flaw detector unit shall have minimum 204B gain in reserve above basic sensitivity 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. Suppression control shall be off during calibration, TEST PROCEDURE 582 583 584 585 ‘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 er equal to back wall echo forany 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. Page 9 of 23NDE PROCEDURE -GENERAL noes pare SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD REFDOG. | REVISION PAGE oo ATS-UT-001 SL 812 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 ax The rate of search unit movement (scanning speed) shall not exceed 150 ‘mum per second, EVALUATION OF INDICATIONS 5.9.1 All assessment and evaluation of indications shall be carried out with primary reference level after deducting 6¢B 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 usi drop technique or maximum amplitude drop technique. 5.9.4 Length of discontinuities shall be determined using 648 drop method. 5.9.5. The type of discontinuity (i. 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, 2048 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. POST INSPECTION CLEANING S.IL.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. SAFETY Page 10 of 23NDE PROCEDURE -GENERAL noes pare SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD REFDOG. | REVISION PAGE oo ATS-UT-001 60 10 80 90 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 arcas, 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. 64 Allrestricted areas that are not scanned with complete coverage shall be reported ‘with full explanation of restriction, 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, i) ASME Section-VIII Div.1 & 2 2007 Edition) For Pressure Vessels iv) API 11042005) - For Pipelines ATTACHMENTS 1 - Equipment Performance Check IL- Probe Characteristics Check II - Construction of DAC Curve DOCUMENTS 9.1 Technique sheet UT-T O01 ‘Technique sheet UT-T 002 ‘Technique sheet - UT-T 003 Ultrasonic Examination Report Page 11 of 23NDE PROCEDURE -GENERAL SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (8) PTE LTD PAGE pate woras weFpoc, | REVITON ATSUrOO1 ‘Sketch Format for Ultrasonic Examination Report Page 12 of 23PAGE NDE PROCEDURE -GENERAL we bare SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (8) PTE LTD REPDoc. | REVISION ATS-UT-001 bia ATTACHMENT-1 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-O1 3.0 CALIBRATION PROCEDURE: ‘The instrument calibration shall be performed every 40 hours as per Asme See V 3.1. Horizontal Linearity Calibrate the screen forthe test range of 12Smm using Single Crystal Transducer and IW Block. Place the probe on 25mm thickness side and read the back wall echoes, The Percentage of error is ealeulated based on actual reading and the expected reading. The error should not exceed 42% of Test Range. 32 Sereen Height Linearity ‘A straight beam probe is coupled with the IW (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 sereen 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 cach setting. The settings and readings must be estimated to the nearest 1% of full screen height. Deviation should not exc! 45% of Full Seren Height ‘Altomately, 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 IW (V1) block and get multiple echoes from 25. mm. thickness side, Select any echo and note its amplitude. Reduce the gain by 64B and read the Page 13 of 23PAGE NDE PROCEDURE -GENERAL Date, SUBJECT: ULTRASONIC TESTING HOES AMIGOS TECHNICAL SERVICES (8) PTE LTD REFDOC. | REVISION ATS.UT-001 bia ‘amplitude of the same indication, It must be $0% 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 sereen and the rea should fall within the limits of following table. ings Other convenient reflectors from any calibration block shall be used with straight or angle beam. search units Indication Set at % of | dB Control Change | Indication Limits % of Full Sercen Height FullScreen Height 80 ma T6104 30 =12 6B Tst022 40 sda 721088 20 =o T1088 40 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. Page 14 of 23NDE PROCEDURE -GENERAL SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (8) PTE LTD. PAGE 1S OF 23 DATE REVISION REF DOC. a ATS-UT-001PAGE NDE PROCEDURE -GENERAL ora DATE SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD. REF DOC. ATS-UT-001 ATTACHMENT - PROBE CHARACTERISTICS CHECK, 1.0 INTRODUCTION This has been written in order to provide detailed methods and techniques to evaluate the Probe’s characteri 20 TYPE OF PROBES & EQUIPMENT As defined by section 5.0 of UT-O1. 3.0 PROBE CHARACTERISTICS 31 Probe Resolution 3.1.1 Place 0° compression probe on the VI (IW) 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. Pa VI(IW) Block 3.1.2 Place shear wave probes on the OW Beam Profile Block with the beam directed towards the series of S side drilled holes. Al least 3 of the series shall be clearly discernible. 3.2 Probe Index Place shear wave probe on the V1 (IW) block’s 100mm quadrant side as shown in the figure 2 tnd 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. Figure 2 For example, if ‘dis 86mm, then Probe index = 100-86=14mm. This distance shall be transferred to the probe. VI (IW) Block Page 16 of 23,PAGE NDE PROCEDURE -GENERAL nora DATE SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD. REF DOC. REVISION 7 00 ATS-UT-001 Page 17 of 23,22 Probe Angle 9 ‘V4 (UW Bl) Probe Anse Nolethe ba ph and Pie ane cake wing om Tre age "Con (Been ah "un ne ada te stg ng ee cb an Hd fee ne mca osion ad ais gnc tghe WGI Mk ‘ont la whch crepe whe pnbelnsex pam wep 8 Latta 4142 Meth rte gy vd und ei i fa htt i i doped Pre 180828NDE PROCEDURE -GENERAL SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD. PAGE DATE worn erpoc. REVISION AIS-Ur-01 Figure 5 2040 Trg Edge Markiheprobelnies ove probe forward unt 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 position on the block. (See Fig.6) is position and mark’ the probe index Figure 6 SF Setup drpate 10% 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 Suen Fa) Fig.7 [ae sam ProiePting 40° CHECKLIST Page 19 of 23,PAGE NDE PROCEDURE -GENERAL worn DATE SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD. REF DOC. REVISION 7 00 ATS-UT-001 Al probe characteristics shall be entered in to the Probe Characteristics Checklist format: ~ FORMATIUT/CAL-02 Page 20 of 23,NDE PROCEDURE -GENERAL nee DATE SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (8) PTE LTD REFDOG, | REVISION ATSUT-001 UFD Model Date of Testin; Serial No CHECKLIST FOR PROBE CHARACTERISTICS Tiem No | Checklist lem Tolerance Result ‘Accept | 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 Angle 2° 45° oe 70° 4 Beam Profile (Leading/trailing edge) 45° oe 70° FORMATIUTICALE Page 21 of 23,PAGE NDE PROCEDURE -GENERAL DATE 220F 23 SUBJECT: ULTRASONIC TESTING AMIGOS TECHNICAL SERVICES (S) PTE LTD. REVISION 00 ATTACHMENT- 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-O1 3.0 BLOCKS 3.1 LOW Block for structural steel work weldments 3.2. ASME Section-V — Basie Calibration Block for Pressure Vessels/Process Piping 4.0 METHODS 4.1 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= DF AV where, N= Length of near zone (mm) D= Crystal diameter (mm) F = Frequency (MHz) V~ Velocity (10%n/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. 44 Adjustthe 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 centre 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 sereen to generate a DAC curve, (See Fig.l) Point 1 80% FSH Point 2 g he Poti 3 Figure 1 Time Base Page 22 of 23,HI-TECH NDI INSPECTION SERVICES (8) PTE. LTD DOCNe, |: HT-UT-OL ULTRASONIC TESTING PROCEDURE DATE GENERAL PROCEDURE. TECHNIQUE SHEET- SCANNING TECHNIQUE FOR BUTT WELDS ieee a Li ESL le aaa NR Angle Thickness Scam leg ° all a Lamination check on Parent metal 4° 225mm halt 1a2 Root an lower weld volume full skip 142 Upper weld volume and fusion faces 60° hal skip 1&2 Root, lower weld volume and fusion faces tl skip 1a? Upper weld volume and fusion faces 70° hal skip 182 Root, lower weld volume and fusion faces hal skip 1&2 ‘Transverse scan of wel, (ieap is Mushed to smooth, scanning may be carried out from the weld surface) 20 Welds with double side access: ° wa 182 Lamination check on Parent ct as halt Root and lower weld volume Co hal skip Root, lower weld volume and fasion faces full skip 123 44 ‘Tranverse scan of weld. (ieap i Mushed smooth, seanning may be earied out fom the ‘weld surfuee) 70% 10-25mm al skip Root, lower weld volume and fasion faces Page 23 of 27HI-TECH NDI INSPECTION SERVICES (8) PTE. LTD. ULTRASONIC TESTING PROCEDURE GENERAL PROCEDURE. TECHNIQUE SHEET - SCANNI 3 TECHNIQUE FOR FULL PENETRATION / NOZZLE WELDS, a) Nozzle wit “Set through’ or full penetration T-Join Sean 1 (0° Lamination check on parent metal Scan 2/3 45°/60°/70° shear wave scanning for weld volume, root, HAZ and fusion faces at 4 skip Scan 3 0° scan for fusion at main member side and lamellar tearing in main member. b) Nozzle o branch attachment ‘set-on’ Sean 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. Sean 3 {60°, 70? sean for root at half skip. Sean 4 0° scan on main member to check main member side fusion, HAZ, Lamellar tearing (if surface is accessible). Scan 5 Ifscan 2 & 3 is restricted due to non accessibility, a 45° scan for weld and fusion at full skip shall be carried out. Page 24 of 27HI-TECH NDI INSPECTION SERVICES (8) PTE. LTD. DOC No, HT-UT-OL ULTRASONIC TESTING PROCEDURE DATE GENERAL PROCEDURE. TECHNIQUE SHEET - 03: SCANNING TECHNIQUE FOR TRY JOI ‘Section through Heel zone ‘Section through Transition zone ‘All cans tobe curried out from branch member surfees, 2.0 scan fr lamination check on sean surface 45, 60°, 70" angle beam scan of weld metal a half and fll skip as permitted by mera thickness ant weld geometry 4. Local dihedral anele and weld geomety varies point to point. Therefore beam axis should be kept perpendicular tothe weld during angle bears scanning Page 25 of 27HI-TECH NDI INSPECTION SERVICES (8) PTE. LTD. GENERAL PROCEDURE. Page 26 of 27HI-TECH NDI INSPECTION SERVICES (8) PTE. LID DOCNe, |: HT-UT-OL ULTRASONIC TESTING PROCEDURE DATE GENERAL PROCEDURE. ULTRASONIC TEST SKETCH PROJECT TITLE: REPORT NO: Joint Identification | Length/mm | Depth/mm | Width/mm | Defect Type | Remarks Page 27 of 27 Upcoming SideShare Loading in 5 10627