PROCEDURE FOR PHASED_ARRAY_ULTRASONIC

TESTING

Serial
Description Page No#
No#
1 PURPOSE 3
2 GENERAL 3
2.1 SCOP 3
2.2 Procedure Qualification 3
2.3 PERSONNEL QUALIFICATION 3
2.4 NON-COMPLIANCE STATEMENT 4
2.5 EQUIPMENT 4
2.6 EXAMINATION Coverage 4
2.7 DATA RECORDING AND CAPTURE 5
2.8 DATA ANALYSIS 5
2.9 FLAW EVALUATION 5
2.10 FLAW ACCEPTANCE CRITERIA 5-9
2.11 SURFACE CONDITION 10
2.12 CALIBRATION, REFERENCE &DEMONSTRATION
10
BLOCKS
2.13 ENCODER CALIBRATION 10
2.14 Scanning 10
2.15 Couplant 10
2.16 HSE 11
3 Performance of the test 11
3.1 SCAN PLAN 11
3.2 DATA VISUALIZATION 11
3.3 CALIBRATION 11-12
3.4 FLAW SIZING TECHNIQUES 12-17
4 Attachment 18
4.1 Equipment list 18
4.2 Linearity Verification Report 19
4.3 Scan Plan Index Sheet 20
4.4 Scan Plane Techniques Sheet 21
4.5 Test report 22-23
Table of Contents
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1. PURPOSE:
a) To established and maintain documented system to control all documents and data that related to the
requirement of ISO 9001:2015, OHSAS 45001 and ISO 14001:2015 standard.
b) To ensure that only the most recent revision of documents is available to appropriate personnel.
c) To control that document requiring changes are revised and received the required approvals.

2 GENERAL
2.1 SCOPE
This Non-Destructive procedure establishes PAUT requirement examination of
carbon steel and alloy steel pipe welded joints. This procedure is intended to
cover the method and acceptance standard of the PAUT examination of
circumferential piping welded joint (pipe to pipe, pipe to fitting, fitting to
fitting) according to:
ASME B31.1 2020 edition- Appendix O not R (USE OF ALTERNATIVE
ULTRASONICACCEPTANCE CRITERIA)
Section V, Article 4, Mandatory Appendix VIII,
Section V, Article 4, Mandatory Appendix V
Procedure qualification shall meet the requirements of Section V, Article 4,
Mandatory Appendix IX.
2.2 Procedure Qualification
 Personnel, procedures, and equipment used to collect and analyze UT data shall
demonstrated their ability to perform an acceptable examination using test blocks.
 Test Blocks used for the calibration and qualification / demonstration shall be verified
and certified by an independent 3rd Party laboratory accepted by PCIHBV.
2.3 PERSONNEL QUALIFICATION
 Personnel performing nondestructive examination to the requirements of
Appendix R shall be qualified and certified in the ultrasonic testing method in
accordance with a procedure as described in ASME Section V, Article 1, T-
120(e) or (f).
 Setup and scanning of welds shall be performed by personnel certified as UT
(PAUT) Level II or III).
 PAUT personnel shall meet the requirements (certified) at least Level II of ISO 9712 or
equivalent and shall be subjected to and pass the Blind (Mock-Up) Test witnessed by the
PAUT Level III.
 Only Level II/III personnel that have been subjected to and pass Mock-Up Test shall perform
PAUT examination, analyze the data and interpret the results
 Interpretation and evaluation of data shall be performed by UT (PAUT) Level II or III
personnel
 Final PAUT data, records, and reports prepared by the qualified PAUT Level II and
endorsed by PAUT Level III.
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2.3.1 Responsibility
 Subcontractor to carry out NDT activities according to the approved
Procedure.
 Subcontractor shall be responsible for the administration of qualification of
NDT examiners.
2.4 NON-COMPLIANCE STATEMENT
 The NDT operator shall strictly follow the guideline and instructions of this
procedure during Examination for the given material and thickness range. In
case he/she can find that the requirement of this procedure fully or partially
cannot meet, the operator should stop the examination activity immediately till
issues are sorted out and inform the supervisor or responsible NDT level II or
III for further action.
2.5 EQUIPMENT
 A mechanical guided scanner capable of maintaining a fixed and consistent
search unit position relative to the weld centerline shall be used.
 Sona test VEO+ equipment shall be used.
 Manual or electrical couplant delivery system
2.6 EXAMINATION Coverage
 The examination area shall include the volume of the weld, plus the lesser of
25 mm or Tw of adjacent base metal on each side of the weld. Alternatively, the
examination volume may be reduced to include the actual heat affected zone
(HAZ) plus 6 mm of base material beyond the heat affected zone on each side
of the weld, provided the extent of the weld HAZ is measured and documented.
 The examination angle(s) for E-scan and range of angles for S-scan shall be
appropriate for the joint to be examined.
 Scanning speed shall be such that data drop-out is less than 2 data lines per
25mm of the linear scan length and that there are no adjacent data line skips.
 For E-scan techniques, overlap between adjacent active apertures (i.e.,
aperture incremental change) shall be a minimum of 50% of the effective
aperture height.
 For S-scan techniques, the angular sweep incremental change shall be a
maximum of 1deg or sufficient to as-sure 50% beam overlap.
 When multiple linear scans are required to cover the required volume of weld
and base material, overlap between adjacent linear scans shall be a minimum
of 10% of the effective aperture height for E-scans or beam width for S-scans.
 The minimum overlap between adjacent scans shall be 25mm.
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2.7 DATA RECORDING AND CAPTURE

 A-scan data shall be recorded for the area of interest in an unprocessed form
with no thresholding, at a minimum digitization rate of five times the
examination frequency, and recording increments of a maximum of
 1 mm for material < 75 mm thick
 2 mm for material ≥ 75 mm thick
2.8 DATA ANALYSIS
 Reflectors exceeding the limits of below shall be investigated to determine
whether the indication originates from a flaw or is a geometric indication.
 The location, amplitude, and extent of all reflectors that produce response
greater than 20% of the reference level shall be evaluated.
2.9 FLAW EVALUATION

2.9.1 Dimensions
 The dimensions of the flaw(s) shall be determined by the rectangle that fully
contains the area of the flaw(s). Refer to Fig. R307.
 The length, lF, of the flaw shall be drawn parallel to the inside pressure-
retaining surface of the component.
 The height, hF, of the flaw shall be drawn normal to the inside pressure-
retaining surface of the component.
 The flaw shall be characterized as a surface or subsurface flaw, as shown in
Fig. R307.
 A subsurface flaw shall be considered as a surface flaw if the separation (S F in
Fig. R307) of the flaw from the nearest surface of the component is equal to or
less than half the through-wall dimension [hF in Fig. R307, illustration (b)] of
the subsurface flaw.

2.9.2 Multiple Flaws

 Discontinuous flaws that are oriented primarily in parallel planes shall be
considered to lie in a single plane if the distance between the adjacent planes
is equal to or less than 13 mm or 0.5Tw, whichever is less.
 If the space between two flaws aligned along the axis of weld is less than the
height of the flaw of greater height, the two flaws shall be considered a single
flaw.
 If the space between two flaws aligned in the through-thickness dimension is
less than the height of the flaw of greater height, the two flaws shall be
considered a single flaw.
2.10 FLAW ACCEPTANCE CRITERIA
 Discontinuity evaluated as Crack, Incomplete fusion and incomplete
penetration is not acceptable regardless of length.
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 For all thicknesses less than 25 mm. A Slag or porosity discontinuity is

unacceptable if the amplitude of the indication exceeds the reference level and
its length exceeds
6 mm for Tw ≥ 19 mm
Tw/3 for 19 mm Tw 25 mm

 For all thickness equal to or greater than 25 mm flaws shall be evaluated using
the applicable criteria of Table R308.1 or Table R308.2. Regardless of flaw
height or aspect ratio, flaw length shall not exceed 4Tw.
 To check and add on the acceptance criteria for Piping/Tank as required by the Power
Generation pr
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2.11 SURFACE CONDITION

 The parent metal on each side of the weld shall be free of weld spatter, surface
irregularities or foreign matter that might interfere with the angle beam
examination area, over a distance of 2S i.e., Probe Centre Spacing (PCS) This
applies also when the cap width or its irregularities disturb the probe
coupling. When the cap is flushed, the transition with the surface of the parent
metal shall be smooth. Visual Inspection of the Joint shall be carried out by
Inspectors prior to the filling of the request form Technique
 Depending on the required sensitivity class, Seam weld reinforcement may
have to be machined flush on one or both sides of the weld. For Special NDE,
the weld reinforcement that is accessible shall be machined to provide a
roughness not to exceed 125 RMS.

2.12 CALIBRATION, REFERENCE &DEMONSTRATION BLOCKS

 The standard calibration blocks e.g. IIW V1 and V2 shall be used for sweep
range calibration and determining probe characteristics. The sensitivity
setting shall be done using ASME basic calibration block and the reference
reflectors are modified for PAUT as per ASME sec V
2.13 ENCODER CALIBRATION
 Encoders shall be calibrated per the manufacturer’s recommendations and
confirmed by moving a minimum distance of 500mm and the displayed distance
being ±1% of the actual distance Moved Directions and extent of scanning.
 A calibration check shall be performed at intervals not to exceed one month or
prior to first use.
2.14 Scanning
 The scan plan shall demonstrate by plotting or by using a computer simulation
that the examination angles are appropriate for the configuration being
examined, and that the required volume of the weld and adjacent base material
is covered. Butt welds should be examined from both side of the weld and
preferably from the bevel opening side (when access permits).
 When two sides of weld joint are accessible, weld joint shall be scan with full
cover sectorial scan from both side of weld.
 When one side of weld joint is accessible, weld joint shall be scan with
sectorial and E-scan if required. The area(s) of single-sided access and, if
applicable, the extent of the limit coverage shall be noted in the examination
report.
 Fitting to fitting joint shall be scan after flushing the weld cap.
2.15 Couplant
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 The same couplant to be used during calibration shall be used for the
examination.

2.16 HSE
 All Personnel shall be responsible for compliance with applicable safety rules
in the use of test materials.
 Some of calibration blocks in ultrasonic testing are fairly heavy in weight,
having square edges; they may be becoming slippery due to usage of couplant
and will need to be carefully handled.
 Some test materials such as couplant may cause skin irritation. Use adequate
ventilation at all times and avoids prolonged skin contact.
 Test materials shall never be heated above the recommended temperature
limits prescribed by the manufacturer.
 The test system has electrical input for the test equipment and safe practice
should be followed to avoid any electrical shocks.

3 Performance of the test

3.1 SCAN PLA SCAN PLA
 A scan plan (documented examination strategy) shall be provided showing
search unit placement and movement that provides a standardized and
repeatable methodology for the examination. In addition to the information
in ASME Sec V TableV-421, the scan
3.2 DATA VISUALIZATION
 PAUT has the ability to image the data in the same format as conventional
ultrasonic A scans, and time or distance encoded B-scan, D-scan, and C-scans.
(See Figure P-421-2.)

3.3 CALIBRATION

3.3.1 INSTRUMENT LINEARITY CHECKS

 Amplitude Control Linearity. The ultrasonic instrument’s amplitude control
linearity shall be evaluated in accordance with Mandatory Appendix II for
each pulsar-receiver circuit and se2491.
3.3.2 GENERAL CALIBRATION REQUIREMENTS
 Focal Law. The focal law to be used during the examination shall be used for
calibration.
 Beam Calibration. All individual beams used in the examination shall be
calibrated to provide measurement of distance and amplitude correction over
the sound path employed in the examination
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3.3.3 SENSITIVITY BLOCK CURVATURE AND THICKNESS

 A block shall be fabricated meeting the requirements of ASME T-434.1 and
Figure T-434.2.1 & T-434.3.1- T-434.3.1.
 Materials With Diameters Greater Than 20in.(500mm) . For examinations in
materials where the examination surface diameter is greater than 20in.
(500mm) , a block of essentially the same curvature, or alternatively, or
alternatively, a special PAUT TCG with 3mm SDH or a flat basic calibration
block, may be used.
 Materials With Diameters 20in.(500mm) and Less. For examinations in
materials where the examination surface diameter is equal to or less than
20in.(500mm) ,a curved block shall be used. A single curved basic calibration
block may be used for examinations in the range of curvature from 0.9 to1 .5
times the basic calibration block diameter for any thickness range.
 Calibration block thickness, T, shall be within the lesser of 6mm or 25% of the
material thickness to be examined.
 TCG shall be used for evaluation.

3.4 FLAW SIZING TECHNIQUES

 Flaw sizing can be performed using a variety of industry accepted techniques,
such as amplitude drop (e. g.,-6dB Drop) techniques and/or tip diffraction
techniques. Different flaw types may require different sizing techniques.
 Flaw Length. Flaw lengths parallel to the surface can be measured from the
distance encoded D- or C-scan images using amplitude drop techniques by
placing the vertical cursors on the extents of the flaw displayed on the D-or C-
scan display. Figure P-452.1 shows an example of cursors used for length
sizing.
 Flaw Height. Flaw height normal to the surface can be measured from the B- ,
E-, or S-scan images using amplitude drop or tip diffraction techniques.
 Using amplitude drop techniques, the horizontal cursors are placed on the
displayed flaws upper and lower extents. Figure P-452 .2-1 shows an example
of cursors used for height sizing with the amplitude drop technique.
 Using tip diffraction techniques the horizontal cursors are placed on the upper
and lower tip signals of the displayed flaw. FigureP-452 .2-2 shows an
example of cursors used for height sizing with the tip diffraction technique.
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4 Attachment
4.1 Equipment list

Project equipment requirement

Equipment Manufacturer Model Decryption
PAUT Flaw detector Sonatest VEO+ 32-64PR LEMO
PA Transducers Sonatest X3PE2.2M48E0.8PIX500 PA Probe 2.25 MHz 48 element 0.8 mm pitch
PA Wedge Sonatest X3-SB57-N0L-IHC X3 Wedge 0 degree (25 mm)
PA Wedge Sonatest X3-SB57-N60S-IHC X3 Wedge 60 degree SW flat
PA Curved Wedge Sonatest X3-SB57-N60S-IHC X3 Curved Wedges for Circumferential Weld for 12-16 and 24 Dia
in Pipes
Scanner Phoenix AE-MAGMAN-PA-6 MagMan 6PA-2 PAUT probe cradles and 4 TOFD Standard Tool-
posts- Irrigation manifold and tubing- Waterproof spring-loaded
encoder wired-
Couplant delivery system
Keyboard and mouse

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Linearity Verification Report

Location: Date:
Operator: Signature: Verified By: Signature:
Instrument: Couplant:
Pulsar Voltage (V): Pulse Duration (ns): Receiver (band): Receiver smoothing:
Digitization Frequency (MHz): Averaging:
Display Height Linearity: Amplitude Control Linearity:
Small Actual Actual Range Allowed Range
Large (%) Small Allowed Range (%) Ind.Height dB
100 47-53 40 +1 42-47
90 42-48 40 +2 48-52
80 40 40 40 +4 60-66
70 32-38 40 +6 77-83
60 27-33 40 -6 47-53
50 22-28
40 17-23
30 12-13
20 7-13
10 2-8
Amplitude Control linearity Channel Results: (Note any channels that do not fall in the allowed range)
Dead Element check: (For 32 Element Probe).
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Gain
condition
Element 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Gain
condition
Time-Base Linearity (for 25-mm IIW block)
Multiple 1 2 3 4 5 6 7 8 9 10
Thickness 25 50 75 100 125 150 175 200 225 250
Measured Interval
Allowed deviation ±0.5 mm(Yes/No)
If more than 25 % of the elements in a probe are inactive, sensitivity and steering capabilities should be compromised.
The number of adjacent elements allowed to be inactive should be determined by the steering and electronic raster resolution
required by the application.
Checked By Approved By
Name:

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PAUT
Technique Sheet
Plant Technique Sheet No Rev Date

Description of Scan Plan Calibration Reflector Used Equipment No

Row Item Explanation

1 Material
Inspection Thickness Inspection Dia.
2 Cal. Block Thickness Cal. Block Dia.
Applicable Range THK Applicable Range
3 Type of Joint
4 Type of Inspection

5 Offset Distance 1 Offset Distance 2

6 Probe / Wedge(PA)
7 Couplant Used
8 Cal. Block
9 Demo. Block
10 Set Up File Name

i)
ii)

11 Reference Gain iii)

iv)
12 Scanner Used
13 Remarks if any
Prepared By Checked By Approved By

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