LV-104B-98 RECOMMENDED PRACITCE FOR ULTRASONIC

EXAMINATION OF BUTT WELDS IN FERRITIC STEEL

1. SCOPE

1.1 This recommended practice is applicable to ultrasonic testing of butt welds in ferritic
steel with thickness 20 mm to 100 mm.

2. TEST EQUIPMENT REQUIREMENTS

2.0 The following general requirements shall be met as a minimum performance

specification for the ultrasonic flaw detection apparatus and accessories.

2.1 The presentation on the cathode ray tube shall be of A-scan type.

2.2 The equipment shall permit testing at frequencies from 0.5MHz 10MHz.

2.3 The flaw detector shall be substantially linear upto 75 +/- 5% of full screen height.

2.4 The amplifier shall be substantially linear upto 75 +/- 5% of full screen height. The
dynamic range of the equipment shall be at least 20 dB.

2.5 The deviation in time base linearity shall not exceed 1% over full length of the
graticule scale. The full length of the CRT shall be capable of presenting a metal path
length of at least 500mm of steel at shear wave velocities.

2.6 Probes should be free from internal noise in the beam path distance and at the
working sensitivity used for the weld examination.

2.7 The equipment should have facility for the following systems of operation viz. (a)
the probe acting as both transmitter and receiver and (b) two probes one transmitting and
the other receiving.

3. PREPARATIONS FOR EXAMINATION

3.1 It shall be checked that all surfaces from which scanning is to be done are free from
loose scales or lightly adhering matter. Weld spatter, roughness etc. and any
unsatisfactory surface condition found should be rectified. Surface roughness exceeding
230 micro inch shall not be permitted.

3.2 The volume of the parent metal through which the ultrasonic beam will pass during
the ultrasonic examination of the weld shall be checked by normal beam technique using
a probe having a frequency between 2 and 4 MHz and size not exceeding 25 mm. The

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sensitivity for this scan shall be adjusted to give first back surface echo from a detect
free area upto 80% of full screen height. All defects found shall be recorded. The
influence of these defects on the ultrasonic examination shall be considered and
appropriate action taken during examination of the weld and evaluation of the results.

3.3 A visual examination of the weld shall be carried out and visible defects and shape of
the weld shall be recorded e.g. surface curvature, degree or root penetration, presence of
backing ring. Extent of weld re-inforcement, presence of under-cuts, alignment of parts
etc.

4. PROBE PARAMETERS

4.1 No dimension of the piezo-electric crystal in the probes selected shall exceed 25 mm.
In the case of rectangular crystals, the length to width ratio of the crystal shall not exceed
1.2. Beam angle selected shall be as per table 4.1. To detect lack of fusion along weld
edge preparation, an additional scan with beam angle such that it strikes the postulated
lack of fusion perpendicularly, within +/- 10 degrees, shall be carried out. This additional
scan applies only to thicknesses exceeding 25mm.

Note : If geometry of the test object does not permit the use of angles stipulated in Table
4.1, other angles can be used, and this fact shall be mentioned in the report.

5. SETTING OF SENSITIVITY

5.1 The sensitivity of the apparatus for the examination shall be set by drawing a distance
amplitude correction (DAC) curve using the reference block made as per Fig. 207. DAC
is not required for normal beam inspection of thickness upto and inclusive of 25 mm.

5.2 The reference blocks shall have same nominal composition, heat treatment and
thickness as the plates to be tested. The test surface finish of the reference block shall be
comparable but no better than the item to be examined.

Note : If the test surface finish is better than the surface finish of the item to be
examined, an appropriate transfer finish of the item to be examined, an appropriate
transfer correction shall be applied.

6. SCANNING PROCEDURE

6.1 The entire volume of weld material along with heat affected zone shall be scanned by
the second leg of the V-path as shown in Fig. 208. If the weld re-inforcement and the
probe size will not permit this, the volume of interest as defined above shall be scanned

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by the third leg of the V-path (Fig 208). The area over which the scanning should be done
to satisfy either of the above conditions, whichever is applicable, shall be clearly marked
on the surface before scanning is started.

Note: For the purposes of this recommended practice, heat affected zone is defined as
that part of the parent metal extending from the weld fusion line upto a distance of 10
mm or half the thickness whichever is less.

6.2 Wherever possible, the weld shall be scanned from both sides of the same surface or
from both surfaces on the same side (Fig. 209)

6.3 The volume of material of interest shall be scanned by moving the probe
systematically over the surface, the ultrasonic beam being propagated perpendicular to
the weld seam. An overlap of at least 15% shall be given between successive scan paths.

6.4 Additional scan for double-V welds: An additional tandem scan, using a separate
transmitter and a separate receiver shall be done specifically aimed at the root in the
double-V weld (Fig 210) if thickness exceeds 50 mm.

6.5 Additional scan for transverse defects: If the material or welding process used make
the weld probe to transverse cracking, an additional scan to detect them shall be carried
out.

6.5.1 In the case when the weld crown is ground flush with the parent metal, the probe
shall be moved on the weld crown aiming the ultrasonic beam parallel to the weld seam
(Fig 211).

6.5.2 If the weld crown is not ground flush, the probe shall be moved over the parent
metal, close and parallel to the weld seam, with the beam slightly inclined towards the
weld (Fig. 211). This angle of inclination shall not exceed 10 degrees.

6.5.3 This additional scan for transverse defects shall be carried out only if specifically
stipulated in the contract.

7. FLAW INVESTIGATION

7.1 When a flaw indication is obtained whose height exceeds 20% of DAC curve, efforts
shall be made to obtain maximum possible information about the flaw by manipulating
the probe around the defect and observing the behaviour of the echo.

7.2 The extent of the defect perpendicular to the scanning direction shall be judged by the
‘6dB reduction method.’ If the extent thus obtained is equal or less than the probe width,

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then this estimate is not reliable and the defect length shall be recorded as equal to the
probe width.

Note: For defects whose length is less than the probe width, special investigations using
the DGS method may be employed.

8. RECORDING

8.1 All flaws, interpreted to be planar in nature (e.g. cracks, lack of fusion etc.) shall be
recorded, irrespective of their echo amplitude.

8.2 All indications, other than those covered by Para 8.1 above, whose heights exceed
50% of the DAC curve shall be recorded.

9. ACCEPTANCE CIRTERIA

9.1 All indications interpreted to be from planar defects (cracks, lack of fusion etc.) shall
be unacceptable irrespective of echo amplitude.

9.2 Linear indications (not due to planar defects) are unacceptable if their echo amplitude
exceeds DAC, or if their length exceeds 30 mm.

9.3 Other indications are unacceptable if their echo amplitude exceeds 300% of DAC.

10. REPORTING

10.1 All recordable indications shall be reported. The report shall also contain the
calculated locations of the flaws as well as remarks about the type of each flaw and their
acceptability.

TABLE 4.1

Thickness (mm) Beam angle

From upto (degrees)
0 15 70 or 60
15 50 60 or 45
50 100 45

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QP-49L
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40 mm ( min )

100 mm (min.)
40 mm
(min )

x = T/2 for T  25 mm
= T/4 for T > 25 mm
T = t  0.1 t
t = nominal thickness of test object
d = 3mm for t  40 mm ‘d’ shall be increased by 1mm for every additional 20mm or
part there of ‘t’.

FIG 207: Reference Block For Weld Ultrasonic Testing

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 B A

Scanning by the first leg of V -Path

A
B

SCANNING BY THE SECOND LEG OF V - PATH

B A

FIG 208: SCANNING BY DIFFERENT LEGS OF V-PATH

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SURFACE 1 SIDE A SURFACE 1 SIDE B

SURFACE 2 SIDE A SURFACE 2 SIDE B

FIG 209A: DEFINITION OF SURFACES AND SIDES

FIG 209B FOUR POSSIBLE COMBINATION FOR SCANNING

DIRECTIONS (PARA 6.2)

FIG 209: SCANNING SCH EAES

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FIG 210 TANDEM SCAN FOR DOUBLE E-V WELDS

WELD GROUND FLUSH

PROBE

FIG 211 A

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 PROBE WELD UN GROUND

FIG 211 SCANNING FOR TRANSVERSE FLAWS

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1. A flaw detector has a calibrated gain of 100dB. When the echo from the
100mm radius of the V-1 block is adjusted to 75% of full screen height,
the gain setting is 40dB. . The gain reserve is:
a. Not enough even for thickness upto 50mm
b. Enough for thickness upto 50mm only
c. Enough for thickness upto 100mm
d. Not a consideration as per the document

2. Circumferential butt weds in some cylindrical vessels are to be

inspected by UT. The given document is applicable to which of the
following vessels?
a. Ferritic steel, 150mm OD, 130mm ID.
b. Ferritic steel, 1000mm OD, 750mm ID
c. Austenitic steel 150mm OD, 130mm ID
d. All of the above
e. None of the above

3. Scanning area adjacent to the weld has a surface roughness of

250microinches rms. Which of the following statement is true?
a. The surface roughness acceptable for UT
b. The surface roughness is to be improved for UT
c. The surface roughness is acceptable for UT, only if frequencies less
than 2 MHz are employed
d. Onone of the above statements can be derived from the document.

4. A weld as shown in fig 049-D04 is to be inspected ultrasonically using

beam angles
a. 45 degrees or 60 degrees
b. 45 degrees or 60 degrees, and 80 degrees.
c. 45 degrees or 60 degrees, and 70 degrees.
d. None of the above is true.

5. Pre-scan of parent metal by normal beam shows a defect of size 100m x

75mm at a distance of 75mm from weld centre-line. Which of the
following statements is true?
a. The defect is cause for rejection
b. The defect is acceptable provided that it is not a crack
c. The defect should be recorded
d. The defect needs further investigation to determine its type
e. The defect is acceptable provided it will not interfere with the UT
examination of the weld.

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6. The reference black has a surface finish of 250 microinches. The actual
job has surface finish of 125 microinches. Transfer correction (to
compensate for variation surface roughness)
a. Should be applied
b. Should not be applied
c. Need not be applied
d. Should be applied only if a thin couplant is used.

7. Scanning for detection of transverse defects

a. Should always be done
b. Should be done only if it is mentioned in the contract.
c. Should be done only if the weld crown is ground flush
d. Is not mentioned in the document

8. An angle probe of outer dimensions 30mm length, 20mm width and

20mm height is used. A defect is judged to be having a length of 15mm
by 6dB reduction method. Which of the following is true?
a. The defect length should be recorded as 15mm
b. The defect length should be recorded as less than 20mm
c. The defect length should be recorded as equal to 20mm
d. The defect length should be recorded as equal to 30mm
e. The defect size should be evaluated b DGS method

9. A weld should be examined by scanning from

a. One side of two surfaces
b. Two sides of one surface
c. Tow sides of two surfaces
d. Either a or b
e. Both surfaces

10. To inspect a 40mm thick weld, a reference block 44mm thick having a
4mm dia side-drilled-hole was fabricated. The block was rejected by the
third part inspector. The reason was
a. The thickness of the block was not acceptable
b. The diameter of the side-drilled-hole was not acceptable
c. Both a and b
d. Neither a nor b

11. A reference block was made with the side–drilled hole having a length
of 50 mm. The block is
a. acceptable
b. not acceptable
c. acceptable, only for transverse scanning
d. not acceptable, if inspection is to be done before heat-treatment

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12. A flaw detector can represent maximum of 1 metre of ferritic steel at
longitudinal wave velocity. This equipment is
a. acceptable
b. not acceptable
c. acceptable provided maximum metal path length during inspection
suing shear wave is 250 mm
d. acceptable, if so agreed to between the contracting parties

13. For scanning the weld by the second leg of the V-path, the best way of
drawing DAC will be by taking points at
a. 1/8 V, 3/8 V and 5/8 V paths
b. 3/8 V, 5/8 V and 7/8 V paths
c. 5/8 V, 7/8 V and 9/8 V paths
d. 3/8 V, 5/8 V, 7/8 V and 9/8 V paths

14. Tandem scan is needed

a. Whenever the weld is a double-V weld
b. Only when root defects are suspected to be present in a double-V weld
c. Only when specifically stipulated in the contract
d. Only when transverse cracks are to be detected
e. None of the above statements is true

15. The frequency of the probe used for inspecting the weld shall
a. Be 2.25 MHz, unless otherwise specified
b. Depend on the thickness of job under test
c. Depend on the angle used
d. Depend on the acceptance standards applicable
e. None of the above statements is true

16. This document is applicable to:

a. Butt welds in ferritic steel plates 15 mm thick
b. Tee-welds in ferritic steel plates 50 mm thick
c. Butt welds in austenitic stainless steel plates 15 mm thick
d. Tee welds in austenitic stainless steel plates 50 mm thick
e. None of the above

17. An ultrasonic flaw detector with an amplifier bandwidth of 1 – 10 MHz is:

a. acceptable
b. not acceptable
c. acceptable, only if the flaw detector is battery operated
d. not acceptable because 10 MHz should not be used on welds

18. The use of an angle beam probe with crystal size of 15mm x 12mm is:
a. permissible
b. not permissible
c. permissible only for inspection on flat surfaces
d. permissible only for detecting transverse defects

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19. For welds in 50 mm thick plates, the extent of heat affected zone shall
be taken as:
a. 10 mm
b. 25 mm
c. 50 mm
d. None of the above

20. For detecting transverse cracks in a flush-ground weld, one should use
a. Procedure shown in fig. 210
b. Procedure shown in fig. 211–A
c. Procedure shown in fig. 211–B
d. Any of the above [a], [b] or [c]
e. Either [b] or [c]

21. A lack of fusion whose echo amplitude is 40% of DAC

a. is acceptable
b. is not acceptable
c. is acceptable provided its length does not exceed 30mm
d. none of the above conclusions can be arrived at from the document

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 O49L – ANSWERS

Questions Answers

1 C

2 E

3 A

4 A

5 C

6 C

7 B

8 C

9 D

10 B

11 A

12 A

13 D

14 E

15 E

16 E

17 B

18 B

19 A

20 B

21 B

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