Procedure : OPS-PR-BSUT-029A10

Initial Issue Date : 20-Nov-11

Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 1 of 16
WELDS

Company Name
GLOBAL INSPECTION SERVICES W.L.L.

Mailing Address P. O. Box 22410

DOHA – QATAR

Telephone + (974) 4460 4550

Fax + (974) 4460 4054

Email technical.qa@gismea.com

Document Title ULTRASONIC EXAMINATION OF WELDS

Document Ref. # OPS-PR-BSUT-029A10 Rev - 00

Client

Contract #

Project Description

Revised to comply with Shammy S. N. M.R. Sarath Babu

01 12-May-12
BS EN ISO 17640 Technical Support ASNT NDT Level III
(184206)

00 20-Nov-11 Initial Issue Anup Nair M.R. Sarath Babu

Technical Support Asst. ASNT NDT Level III
(184206)

Revision Date Revision Details Prepared By Reviewed and Approved By

GLOBAL INSPECTION SERVICES

 Procedure : OPS-PR-BSUT-029A10
Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 2 of 16
WELDS

CONTENTS

1. SCOPE
2. REFERENCE
3. PERSONNEL QUALIFICATION
4. DEFINITIONS AND SYMBOLS
5. SURFACE CONDITION
6. COUPLANT
7. BASIC CALIBRATION BLOCK(S): GENERAL EXAMINATION REQUIREMENTS
8. CALIBRATION CONFIRMATION
9. EXAMINATION OF PARENT MATERIAL
10. EXAMINATION OF WELDS
11. ACCEPTANCE STANDARDS
12. DOCUMENTATION

ATTACHMENT

ATTACHMENT - I REPORT FORMAT

ATTACHMENT - II GENERAL TECHNIQUES FOR ANGLE BEAM CALIBRATIONS

ATTACHMENT - III TECHNIQUE SHEET – EXAMINATION LEVEL B

ATTACHMENT - IV ACCEPTANCE CRITERIA QCS 2007 SECTION 16 TABLE 5.2

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 Procedure : OPS-PR-BSUT-029A10
Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 3 of 16
WELDS

1. SCOPE:

1.1. This procedure describes the method, technique and acceptance standards to be employed
for the Manual Ultrasonic Examination of full penetration butt weld, structural welds and
tubular intersection welds in wrought (rolled, forged, extruded or drawn) materials to detect
01
weld discontinuities by contact method at temperatures from 0 °C to 60 °C

1.2. This procedure utilizes angle beam or straight beam, or both, depending upon the specific
configuration. This procedure is intended to be used on thicknesses of 8 mm and above.

01 1.3. The testing shall be carried out using reference level to technique 1 of BS EN ISO 17640
(evaluation based primarily on length and echo amplitude of the signal indication), evaluation
level -14 db from reference level and testing level B (ATTACHMENT –III).

1.4. The procedure accepts personnel’s qualified in accordance with SNT-TC-1A to do testing
01 instead of EN 473 or ISO 9712 as required by BS EN ISO 17640.

2. REFERENCE:

01 2.1. BS EN ISO 17640 Non- destructive testing of welded joints – Ultrasonic testing

2.2. BS EN ISO 17635 Non-destructive testing of welds. General rules for metallic materials

2.3. SNT-TC-1A Recommended practice for Personnel Qualification

3. PERSONNEL QUALIFICATION:

3.1. All personnel performing and evaluating Ultrasonic Examination shall be qualified and certified
Level II in accordance with GLOBAL INSPECTION SERVICES (hereinafter called GIS) Written
Practice OPS-PR-WP-014, prepared in accordance with SNT – TC – 1A, of ASNT.

GLOBAL INSPECTION SERVICES

 Procedure : OPS-PR-BSUT-029A10
Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 4 of 16
WELDS

4. DEFINITIONS AND SYMBOLS;

4.1. Indications shall be considered to be either longitudinal or transverse, depending on

the direction of their major dimension with respect to the weld axis.

Symbol Quantity Unit

t Thickness of parent material (thinnest part) mm
DDSR Diameter of a disc shaped reflector mm
DSDH Diameter of a side-drilled hole mm
L Length of the indication mm
h Extension of the indication in depth direction mm
x Position of the indication in the longitudinal direction mm
y Position of the indication in the transverse direction mm
z Position of the indication in depth mm
lz Projected length of the indication in depth mm
lx Projected length of the indication in the x-direction mm
ly Projected length of the indication in the y-direction mm
p Full skip distance mm

5. SURFACE CONDITION:

5.1. All surfaces from which the weld is scanned shall be clean and free of loose scale, dirt, grease,
paint or other foreign material that could interfere with interpretation of test results.

5.2. The waviness of the test surface shall not result in a gap between the probe and test surface
greater than 0.5mm.

6. COUPLANT:

6.1. Couplants having good wetting characteristics such as motor oil, glycerin, pine oil, Ultragel II,
cellulose gum or water shall be used. Rust inhibitors, softeners and wetting agents may be
added to the couplant.

6.2. Couplants may not be comparable to one another. Same couplant shall be used for calibration
and examination.

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 Procedure : OPS-PR-BSUT-029A10
Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 5 of 16
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7. EQUIPMENT:

7.1. The examination shall be conducted with an ultrasonic pulse-echo type equipment capable of
01 operating at frequencies over the range of at least 1 MHz to 5 MHz and shall be equipped with
a stepped gain control in units of 2.0 dB or less. The equipment shall comply with the
requirements of EN 12668 (all parts)

A pulse-echo type of Ultrasonic Instrument like Krautkrammer USK 7, USM 35, Penametrics
Epouch - series or equivalent shall be used for this examination

7.2. Search Unit:

7.3.1 The transducer frequency shall be between 2 to 5 MHz unless variables, such as
material grain structure, require the use of other frequencies to assure adequate
penetration or better resolution. Search units with contoured contact wedges may be
used to aid ultrasonic coupling. The angle beam transducers used shall be 45°, 60°, or
70° with an accuracy of ±2°.

Frequencies of 1 Mhz may be used for testing at long sound paths where the material
shows attenuation is above average.

Adaption of probes to curved scanning surfaces:

ƒ The gap between test surface and probe bottom (wedge) shall not be greater
than 0.5 mm.
ƒ For cylindrical or spherical surfaces this requirement will normally be met when
the following equation is fulfilled

o g = a 2/ D
o Where “D” is the diameter of the component (mm), “a” is the dimension
of probe shoe in the direction of testing (mm)
ƒ Curved probe shoes shall be used when above requirement is not met.

01 7.3.2 Crystal size for weld examination range from 6 mm to 12 mm or rectangular elements
of equivalent area. For ranges greater than 100 mm for normal beam probes and
greater than 200 mm for angle beam probes, an element size of 12 mm to 24 mm shall
be used.

7.3.3 The shape of the element shall be rounded for straight beam and rectangular for angle
beam transducers.

8. GENERAL EXAMINATION REQUIREMENTS:

8.1. Examination Coverage - The test volume shall include entire weld and at least 10 mm on each
side of the weld or the width of the heat affected zone, whichever is greater. The volume shall
be examined by moving the search unit over the scanning surface so as to scan the entire
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 Procedure : OPS-PR-BSUT-029A10
Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 6 of 16
WELDS
examination volume for each required search unit. Each pass of the search unit shall overlap
a minimum of 50% of the transducer (piezo-electric element) dimension perpendicular to the
weld axis.

8.2. Rate of Search Unit movements - The rate of search unit movement for examination shall not
exceed 100mm/second unless calibration is verified at scanning speed.

8.3. Probe manipulation – During angle probe scanning, a slight swiveling movement up to an
angle of 10° on either side of nominal beam direction shall be applied to the probe.

8.4. Transfer Correction – A suitable transfer correction technique shall be utilized. If the difference
is less than 2 db, correction is not required. If the differences are greater than 2 db but smaller
than 12 db, they shall be compensated. Over 12 db transfer loss, the reason for transfer
correction shall be considered and further preparation of the scanning surfaces shall be carried
out, if required.

8.5. Method - The examination shall be performed by the direct contact methods.

8.6. Reference point – A reference point shall be marked on the weld/testing surface. All the
measurement shall be made in respect to this reference point

9. BASIC CALIBRATION BLOCK(S):

9.1. The basic calibration reflectors shall be used to establish a primary reference response of the
equipment. The basic calibration reflectors may be located either in the component material or
in a basic calibration block.

9.2. The calibration block reflector shall be a 3 mm diameter side drilled hole (SDH). The calibration
01
block reflector shall be located at least 25mm away from any edges (edges of block and edges
of other SDH). The length of the calibration block reflector shall be greater than the width of the
sound beam measured at -20 dB.

9.3. Selection of the block thickness and reflectors shall be in accordance with below table for the
range of weld thickness.

9.3.1. A general purpose block of uniform low attenuation and specified surface
finish, and having a thickness within ±10 % of the test object; or
9.3.2. A block of the same acoustic properties, surface finish, shape and curvature
as the test object.

Note: If 9.3.1 is used, correction for any differences in attenuation, curvature

and coupling losses may be necessary before the Distance Amplitude Curve
can be directly applied.

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 Procedure : OPS-PR-BSUT-029A10
Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 7 of 16
WELDS

10. CALIBRATION CONFIRMATION:

10.1. Setting of range and sensitivity shall be carried out prior to each test. Calibration check to
confirm range and sensitivity settings shall be performed at least every 4 hours and on
completion of the testing. Checks should also be carried out whenever a system parameter
is changed or changes in the equipment are suspected.

10.2. If deviations are found during these checks the corrections given in the below table shall be
carried out.

SENSITIVITY
1 Deviations ≤ 4 dB The setting shall be corrected before the testing is
continued
2 Reduction of the sensitivity > 4 dB Setting shall be corrected and all testing carried
out with the equipment over the previous period
shall be repeated
3 Increase in sensitivity > 4 dB Setting shall be corrected and all recorded
indications shall be re-tested

RANGE
1 Deviations ≤ 2 % of the range The setting shall be corrected before testing is
continued

2 Deviations > 2 % of the range Setting shall be corrected and testing carried out
with the equipment over the previous period shall
be repeated

11. EXAMINATION OF PARENT MATERIAL:

11.1. Prior to any shear wave examination, the entire surface under angle probe movement shall
be first scanned with a longitudinal wave probe in order to confirm the thickness and to
ensure that the scanning surface is free from any laminations or other laminar type flaws
which could interfere with the shear wave examination.

11.2. The scanning of the adjacent base metal shall be performed to detect reflectors that might
affect interpretation of angle beam results and is not to be used as an acceptance-rejection
examination. Locations and areas of such reflectors shall be recorded.

11.3. When the weld surface is flush grounded or smoothed, it is recommended to perform
scanning over the weld using longitudinal wave probe to detect root and internal reflectors.

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 Procedure : OPS-PR-BSUT-029A10
Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
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11.4. The scanning shall be performed at a gain setting of at least two times the primary reference
level. Evaluation shall be performed with respect to the primary reference level.

11.5. If any areas of significant thickness variation which could affect flaw location and sizing are
located, they shall be noted on the report.

12. EXAMINATION OF WELDS

Weld joints shall be scanned with an angle beam search unit in both parallel and transverse
directions to the weld axis, wherever possible. Attachment-III shall be referred for information on
scanning directions and sides.

12.1. Beam angle:

The search unit shall be of 45 deg or an angle appropriate for the configuration being
examined and shall be capable of detecting the calibration reflectors, over the required angle
beam path. When two angle probes are used, one of the angle shall be as normal
(perpendicular) as possible to weld fusion face. The difference between both angles shall be
not less than 10 deg.

12.2. Reflectors Parallel to weld seam

Angle beam scanning shall be carried out on both sides of weld with search unit pointing
towards the weld and moving perpendicularly with swiveling movement up to an angle of 10
deg to the welds. The search unit shall be manipulated so that the ultrasonic energy passes
thru entire weld and adjacent base metal.

12.3. Reflectors transverse to weld

Angle beam scanning shall be carried out by moving the search unit parallel to the weld.
After completing one full rotation of scanning (eg. clockwise), the search unit shall be rotated
to 180° and the examination repeated (eg. Anticlockwise). In case the weld cap is not
machined or ground flushed, the examination shall be carried out from the base metal on
both sides of weld cap.

12.4. Restricted weld access

When weld/joint configuration limits scanning from two directions (eg. Corner, tee joints)
using angle beam technique, shall be scanned with straight beam technique to the cover
entire weld area. Such restricted areas shall be recorded in the examination report.

12.5. Signal to Noise Ratio

During the scanning the noise level shall remain at least 12 db below the below the
evaluation level.

12.6. Evaluation:
Any imperfection which causes an indication in excess of 20% DAC shall be investigated to
the extent that it can be evaluated in terms of the acceptance standards shown in Para 13.0.
The echo amplitude shall be maximized by probe movement and recorded in relation to the
reference level.

12.7. Sizing:
The length of all reportable indications shall be measured using the 6 dB drop method. The
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 Procedure : OPS-PR-BSUT-029A10
Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 9 of 16
WELDS
discontinuity indication shall be maximized and the amplitude noted. Move the probe to both
sides until the amplitude drops to half. The location where the amplitude falls to half shall be
noted.

12.8. Location:
An allowance shall be made for effect of curvature on beam angle and sound path distance.
The location of all indications shall be defined by reference of co-ordinate system.

13. ACCEPTANCE STANDARDS:

13.1. The acceptance criteria based on the applicable Codes and Standards as required and
specified in the project specification or by client.

01 13.2. Acceptance criteria for examinations shall be QCS 2007 Table 5.2 (given in Appendix IV) or
BS EN ISO 11666.

14. DOCUMENTATION:

14.1. Recording Indications:

14.1.1. All discontinuity echo’s equal to or greater than 20 % of reference level shall be
located, sized for length.

14.1.2. Rejectable Indications shall be recorded. As a minimum, the type of indication (i.e.,
crack, non-fusion, slag, etc), location, and extent (i.e., length) shall be recorded.

14.2. A record of inspection itemizing test conditions and findings shall be maintained on form
“Report of Ultrasonic Examination” (Attachment - I) and made available to the customer or
inspection agency concerned. A copy of this procedure specification shall be readily
available to the NDT personnel performing these functions.

14.3. Areas not covered due to scanning limitations shall be recorded including the detail of
obstruction whether it is temporary or permanent.

14.4. The following minimum data shall be recorded at the time of each test:

14.4.1. procedure identification and revision;

14.4.2. ultrasonic instrument identification (including serial number);
14.4.3. search unit(s) identification (serial number, frequency, and size);
14.4.4. beam angle(s) used;
14.4.5. instrument reference level gain and, if used, damping and reject setting(s);
14.4.6. Calibration data and time base setting for each probes;
14.4.7. Scanning Sensitivity, including transfer correction;
14.4.8. Calibration block used;
14.4.9. identification & location of weld or volume scanned;
14.4.10. surface from which examination is conducted, including surface condition;
14.4.11. Any restrictions or departures from approved procedure;
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Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 10 of 16
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14.4.12. Sketch of the weld showing the position and dimensions of all reportable flaws:
14.4.13. map or record of indications detected or areas clear;
14.4.14. areas of restricted access or inaccessible welds;
14.4.15. couplant, brand name or type;
14.4.16. basic calibration block identification;
14.4.17. examination personnel identity and qualification level;
14.4.18. place date examinations were performed.

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Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
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ATTACHMENT – I

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 Procedure : OPS-PR-BSUT-029A10
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Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 12 of 16
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ATTACHMENT – II

This Appendix provides general techniques for Angle beam Range calibration using A1 block, alternatively A2
block or SDH block may be used.

SWEEP RANGE CALIBRATION

a) Position the search unit for the maximum first indication from the 4” inch (100 mm) radius while side to
side to also maximize the second reflector indication.
b) Without moving the search unit, adjust the range and delay controls so that the indication start at their
respective metal path distance.
c) Repeat the delay and range control adjustments until the two screen indication are at their proper metal
path on the screen

SENSITIVITY AND DISTANCE-AMPLITUDE CORRECTION -SDH

(a) Position the search unit for maximum response from the hole which gives the highest amplitude

(b) Adjust the sensitivity control to provide an 80% (± 5%) of full screen height. Mark the peak of the indication
on the screen.

(c) Position the search unit for maximum response from another SDH.

(d) Mark the peak of the indication on the screen.

(e) Position the search unit for maximum amplitude from the third SDH and mark the peak on the screen.

(f) Position the search unit for maximum amplitude from the ¾T SDH after the beam has bounced from the
opposite surface. The indication should appear near sweep line 10. Mark the peak on the screen for the ¾T
position.

(g) Connect the screen marks for the SDHs to provide the distance-amplitude curve.

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Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 13 of 16
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ATTACHMENT – III

ULTRASONIC EXAMINATION LEVEL B

BUTT JOINTS IN PLATE AND PIPE

1. Side 1
2. Top view
3. Side 2
4. Side view
5. Scanning zone width (SZW) related to skip distance p
Whenever possible, all scans shall be carried out from both sides (1 and 2)

No. of  Scanning zone 
Probe  Total no 
Thickness of parent material  probe  width (skip  Notes 
position  of scans 
angles  distance) 
8 ≤ t < 15  1  A or B  1.25 p  2  1 
15 ≤ t < 40  2  A or B  1.25 p  4  ‐ 
40 ≤ t <60  2  A or B  1.25 p  4  ‐ 
60≤ to ≤ 100  2  A or B  1.25 p  4  ‐ 
Notes 
1‐ If only access from one side two angles shall be used 
 
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Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
TITLE: ULTRASONIC EXAMINATION OF Page 14 of 16
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STRUCTURAL T – JOINTS

Scanning  Scanning 
No. of  zone  zone  Total 
Probe  Probe 
Thickness of parent material  probe  width  width  no of  Notes 
position  position
angles  (skip  (skip  scans 
distance)  distance) 
8 ≤ t < 15  1  A or B  1.25 p  C1   ‐  2 
15 ≤ t < 40  1  A & B  1.25 p  C1  c  3 
40≤ to ≤ 100  2  A & B  0.25 p  C1  c  5 
Notes:
1. To be substituted by tandem technique from A or B if C is not possible.

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Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
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Appendix – IV
ACCEPTANCE CRITERIA – QCS 2007 — Table 5.2

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Initial Issue Date : 20-Nov-11
Rev. No. : 01
Revised Date : 12-May-12
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