ULTRASONIC EXAMINATION PROCEDURE

TABLE OF CONTENTS

1.0 SCOPE

2.0 REFERENCES

3.0 PERSONNEL

4.0 GENERAL

5.0 INSTRUMENT CALIBRATION

6.0 SYSTEM CALIBRATION

7.0 SCANNING

8.0 POST-EXAMINATION CLEANING

9.0 ACCEPTANCE STANDARDS

10.0 RECORDS

1.0 SCOPE
 ULTRASONIC EXAMINATION PROCEDURE

1.1 This procedure covers both angle and straight beam technique with contact method of the
ultrasonic examination of ferrite steel materials and weldments for tanks, pipes and pressure
vessels. This procedure covers plates with thickness equal and greater than 8 mm and pipes with
diameters 20 in.(500 ) and less.

1.2 This procedure is provided for evaluating ultrasonic reflectors within the welds, heat affected
zone, and adjacent material of full penetration welds in wrought and cast materials.
1.3 The requirements not specifically described on this procedure shall comply with ASME
Section V. and the referencing Code Sections.
1.4 For proper examination before starting any ultrasonic examination of a welded joint, the
ultrasonic operator shall have the following essential information.
(1) Material spec. & grade.
(2) Type of groove / joint configuration for welds.
(3) Thickness dimension and product form (plate, forging, etc.)
(4) Type of welding process and, if possible, process data.

2.0 REFERENCES

2.1 ASME Sec. I Boiler And Pressure Vessel

2.2 ASME Sec. V Non Destructive Examination for boiler and pressure vessel
2.3 ASME Sec. VIII Div.1 & Div.2 Rules for Construction of Pressure Vessels
2.4 ASME B31.1 Power Piping
2.5 Operator's specification requirements for acceptance criteria.

3.0 PERSONNEL

3.1 Personnel who perform this examination shall be qualified and certified in accordance with
the Written Practice for the qualification and certification of personnel, according to ASNT ,ISO or
equivalents.
3.2 Only qualified and certified Level II or Level III personnel shall make determinations as
to the acceptability of this examination results.

4.0 GENERAL
 ULTRASONIC EXAMINATION PROCEDURE

4.1 Examination Coverage

The volume to be scanned shall be examined by moving the search unit over the examination
surface so as to scan the entire examination volume for each required search unit. Each pass of
the search unit shall overlap a minimum of 10% of the transducer(piezoelectric element)
dimension parallel to the direction of scan indexing.
4.2 Rate of Search Unit Movement
The rate of search unit movement shall not exceed 6 in. (150 ) per second.
4.3 Equipment
4.3.1 A pulse-echo type of ultrasonic instrument shall be used. The instrument shall be capable
of operation 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 dB or less.
If the instrument has a damping control, it may be used if it does not reduce the sensitivity of the
examination. The reject control shall be in the off” position for all examinations, unless it can be
demonstrated that it does not affect the linearity of the examination.

4.3.2 Search Units

The search unit shall be selected according to the following tables

(1) Straight beam

Material Thickness Type Element Size Freq.(MHz)

(2) Angle beam

Material Thickness Type Element Size Freq.(MHz) Angle in Material

■Note : Search units of other size, angles and frequencies may be used if desirable for better resolution,
penetrability, or detectability of indications.
 ULTRASONIC EXAMINATION PROCEDURE

4.4 Couplant

4.4.1 A suitable liquid couplant such as (e.g. gel, oil, or grease) which is capable of conducting

ultrasound between the ultrasonic transducer and the surface of material to be tested.
4.4.2 Couplants materials used for examination shall be the same as used for the calibration.
4.5 Surface Preparation
4.5.1 Base Metal
The base metal on each side of the weld shall be free of weld spatter, surface irregularities, or
foreign matter that might interfere with the examination.
4.5.2 Weld Metal
Where the weld surface interferes with the examination, it shall be prepared for the permission of
the examination by grinding or suitable method.
4.5.3 Calibration Surface
Calibrations shall be performed from the surface (convex or concave) corresponding to the
surface of the component from which the examination will be performed.
4.6 Temperature
For contact examination, the temperature differential between the calibration block and
examination surfaces shall be within 25℉(14℃).

5.0 INSTRUMENT CALIBRATION

The ultrasonic instrument shall be checked periodically for screen height linearity and the
amplitude control linearity in accordance with applicable calibration procedure.

6.0 SYSTEM CALIBRATION

6.1 Basic Calibration Block

The basic calibration reflectors shall be used to establish a primary reference response of the
equipment and to construct a distance correction curve.

6.1.1 Block Materials

 ULTRASONIC EXAMINATION PROCEDURE

The material from which the block is fabricated shall be of the same product form, and material
specification of equivalent P-number grouping as one of the material being examined.

6.1.2 Non-Piping Calibration Blocks

(a) Basic Calibration Block

The basic calibration block configuration and reflectors shall be as shown in Fig.1
1.The block size and reflector locations shall be adequate to perform calibrations for the beam
angle(s) and distance range(s) to be used.

(b) Block Thickness

When two or more base material thicknesses are involved, the calibration block thickness shall
be determined by the average thickness of the weld. Alternatively, a calibration block having the
greater base material thickness may be used provided the reference reflector size is based upon
the average or smaller weld thickness. calibration block having the greater base material
thickness may be used provided the reference reflector size is based upon the average or
smaller weld thickness.

(c) Block Range of Use

When the block thickness ±1 in. (25 ) spans two weld thickness ranges as shown in Fig. 1, the
block’s use shall be acceptable in those portions of each thickness range covered by 1 in. (25 ) of
the calibration block’s thickness. As an example, a calibration block with a thickness of 11/2 in. (38
mm) could be used for weld thicknesses of 0.5 in. (13 mm) to 2.5 in. (64 mm).

6.1.3 Piping Calibration Blocks

The basic calibration block configuration and reflectors shall be as shown in Fig. 2. The basic
calibration block curvature shall be in accordance with Para. 6.1.4. Thickness, T, shall be ±25%
of nominal thickness of component to be examined. The block size and reflector locations shall
be adequate to perform calibration for the beam angles used.
6.1.4 Block Curvature
 ULTRASONIC EXAMINATION PROCEDURE

For examinations in materials where the examination surface diameter is equal to or less than 20
in. (500 mm), a curved block shall be used. Except where otherwise stated in this Article, a single
curved basic calibration block may be used for examinations in the range of curvature from 0.9 to
1.5 times the basic calibration block diameter. For example, an 8 in (200 mm) diameter block
may be used to calibrate for examinations on surfaces in the range of curvature from 7.2 in. to 12
in. (180 mm to 300 mm) in diameter. The curvature range from 0.94 in. to 20 in. (24 mm to 500
mm) in diameter requires 6 curved blocks as shown in Fig. 3 for any thickness range.

6.2 Calibration for Examination

6.2.1 Straight Beam Method
(1) Calibration for Base Metal Examination
(a) Sweep Range Calibration
The horizontal sweep range shall be adjusted for distance calibration to present the equivalent of
at least two plate thickness on the CRT/LCD screen.
(b) Reference Sensitivity Calibration
The reference level shall be adjusted from the first back wall echo to 80% ±5% of full screen
height.
(2) Calibration for Weld Examination
For weld examination with straight beam probes, distance range calibration and reference
sensitivity calibration shall be as for angle beam method. (Construction of DAC based on proper
selection of side-drilled hole from the reference block.)
6.2.2 Angle Beam Method
(1) Sweep Range Calibration
Horizontal sweep range calibration shall include as a minimum the entire sound path distance to
be used during the specific testing by using the llW block. The minimum sound path distance
shall be calculated based upon one full skip distance with a maximum probe angle to be used. In
all cases the distance range shall be sufficient to ensure coverage of the through member for all
weld joints.
(2) Standard Sensitivity Level
Standard sensitivity for testing of production welds shall be the basic sensitivity level corrected
for distance by a Distance-Amplitude-Correction Curve established with the reference block and
modified by transfer correction.
(3) Basic Sensitivity Level
 ULTRASONIC EXAMINATION PROCEDURE

Reference level screen height shall be obtained using maximum reflection from the side drilled
holes in the reference block as described in paragraph 6.1 of this procedure. The amplitude shall
be adjusted to 80% ±5% of full screen height.
(4) Distance Amplitude Correction (DAC)
The reference level shall be adjusted to provide for attenuation loss throughout the range of
sound path to be used, by three-point distance amplitude correction (DAC) curve. The block
configuration shall be used and curves which are 100%, 50% and 20% of reference curve are to
be constructed.
(5) Notch Indication
Position the search unit for maximum amplitude from the notch on the opposite surface. Mark the
peak of the indication with an "X" on the screen.

Calibration for Piping (using Notches) - Reference level

(a) Position the search unit for maximum response from the notch which gives the highest
amplitude.
(b) Adjust the sensitivity (gain) control to provide an indication of 80% (±5%) of full screen height
(FSH). Mark the peak of the indication on the screen.
(c) Without changing the gain, position the search unit for maximum response from another
notch.
(d) Mark the peak of the indication on the screen.
(e) Position the search unit for maximum amplitude from the remaining notch at its
Half Vee, Full Vee or 3/2 Vee beam paths and mark the peak on the screen.
(f) Connect the screen marks for the notches to provide the distance amplitude
curve (DAC).
6.3 Calibration Confirmation
6.3.1 System Changes
When any part of the examination system is changed, a calibration check shall be made on the
basic calibration block to verify that distance range points and sensitivity setting(s) satisfy the
requirements of 6.3.3.
6.3.2 Calibration Checks
A calibration check on at least one of the basic reflectors in the basic calibration block or a check
using a simulator shall be performed at the completion of each examination or series of similar
examination, and when examination personnel(except for automated equipment) are changed.
the distance range and sensitivity values recorded shall satisfy the requirements para. 6.3.3.
 ULTRASONIC EXAMINATION PROCEDURE

Interim calibration checks between the required initial calibration and final calibration check shall
be performed every 4hr during examination.

6.3.3 Confirmation Acceptance Values

(a) Distance Range Points
If the distance range point for the deepest reflector used in the calibration has moved by more
than 10% of the distance reading or 5% of full sweep, whichever is greater, correct the distance
range calibration and note the correction in the examination record. All recorded indications since
the last valid calibration or calibration check shall be reexamined and their values shall be
changed on the data sheets or rerecorded.
(b) Sensitivity Settings
If the sensitivity setting for the deepest reflector used in the calibration has changed by less than
4 dB, compensate for the difference when performing the data analysis and note the correction
in the examination record. If the sensitivity setting has changed by more than 4 dB, the
examination shall be repeated.
7.0 Scanning
The scanning sensitivity level shall be set a minimum of 6 dB higher than the reference level gain
setting.
7.1 Scanning Extent:
Any imperfection which considered as the indication during scanning shall be investigated to the
all the direction of the weld in other that it can be evaluated by operator.
7.2 Straight Beam Scanning:
7.2.1 When the straight beam scanning of weld is required, the weld and base metal shall be
scanned to the extent possible with the straight beam search unit.
7.2.2 Before performing the angle beam examinations, a straight beam examination shall be
performed on the volume of base material through which the angle beams will travel to locate any
reflectors that can limit the ability of the angle beam to examine the weld volume.
7.3 Angle Beam Scanning:
7.3.1 Beam Angle:
The search unit and beam angle selected shall be 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.
7.3.2 Reflectors Parallel to the Weld Seam.
 ULTRASONIC EXAMINATION PROCEDURE

The angle beam shall be directed at approximate right angles to the weld axis from both sides of
the weld (i.e., from two directions) on the same surface when possible. The search unit shall be
manipulated so that the ultrasonic energy passes through the required volume of weld and
adjacent base material.

7.3.3 Reflectors Transverse to the Weld Seam.

(a) Scanning With Weld Reinforcement. If the weld cap is not machined or ground flat, the
examination shall be performed from the base material on both sides of the weld cap. While
scanning parallel to the weld axis, the angle beam shall be directed from 0 deg to 60 deg with
respect to the weld axis in both axial directions, with the angle beam passing through the
required examination volume.
(b) Scanning Without Weld Reinforcement. If the weld cap is machined or ground flat, the
examination shall be performed on the weld. While scanning, the angle beam shall be directed
essentially parallel to the weld axis in both axial directions. The search unit shall be manipulated
so that the angle beam passes through the required examination volume.

7.3.4 Restricted Access Welds.

Welds that cannot be fully examined from two directions using the angle beam technique(e.g.,
corner and tee joint) shall also be examined, if possible, with a straight beam technique. These
areas of restricted access shall be noted in the examination report.

7.4 Evaluation
7.4.1 All indications which produce 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 them in terms of the acceptance standards given in para. 9.
7.4.2 In addition, all indications which produce a response greater than 20% of the reference
level shall be recorded.
7.4.3 The indicated defect length (sizing) shall be determined by locating the points at each end
at which the echo height drops minus (-) 6dB, and measuring between the points from the center
of the probe at one end to the center of the probe at the other end.

8.0 POST-EXAMINATION CLEANING

 ULTRASONIC EXAMINATION PROCEDURE

When post-examination cleaning is required by the procedure, it should be conducted as soon as

practical after evaluation and documentation using a process that does not adversely affect the
part.

9.0 ACCEPTANCE STANDARDS

9.1 ASME Sec.VIII Div.1 UW-53 : Appendix 12 and ASME Sec VIII Div.2 : para. 9-320: ART 9-3
and ASME B31.1b Chapter VI 136.4 and ASME Sec.I PW-52.3 All imperfections which produce a
response greater than 20% of the reference level shall be investigated to the extent that the
operator can determine the sharp, identity, and location of all such imperfections and evaluate
them in terms of the acceptance standards given in para. 9.1 and 9.2 below
9.1 Indications characterized as cracks, lack of fusion, or incomplete penetration are
unacceptable regardless of length.
9.2 Other imperfections are unacceptable if the indications exceed the reference level
amplitude and have lengths exceed
(1) 1/4 in. (6 ) for t up to 3/4 in. (19 ) inclusive
(2) 1/3 t for t from 3/4 in. (19 ) to 2-1/4 in. (57 ) inclusive
(3) 3/4 in. (19 ) for t over 2 1/4 in. (57 ).
Where t is the thickness of the weld excluding any allowable reinforcement. For a butt weld
joining two members having different thicknesses at the weld, t is the thinner of these two
thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the fillet
shall be included in t.

10.0 RECORDS
Ultrasonic examination results shall be recorded in the attached form by certified personnel who
performs the ultrasonic examination. For each ultrasonic examination, the following information
shall be recorded:
(a) procedure identification and revision;
(b) ultrasonic instrument identification (including manufacturer's serial number);
(c) search unit(s) identification (including manufacturer's serial number, frequency, and size);
(d) beam angle(s) used;
(e) couplant used, name or type;
(f) search unit cable(s) used, type and length;
(a) procedure identification and revision;
(b) ultrasonic instrument identification (including manufacturer’s serial number);
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(c) search unit(s) identification (including manufacturer's serial number, frequency, and size);
(d) beam angle(s) used;
(e) couplant used, brand name or type;
(f) search unit cable(s) used, type and length;
(g) special equipment when used (search units, wedges, shoes, automatic scanning equipment,
recording equipment, etc.);
(h) computerized program identification and revision when used;
(i) calibration block identification;
(j) simulation block(s) and electronic simulator(s) identification when used;
(k) instrument reference level gain and, if used, damping and reject setting(s);
(l) calibration data [including reference reflector(s), indication amplitude(s), and distance
reading(s)];
(m) data correlating simulation block(s) and electronic simulator(s), when used, with initial
calibration;
(n) identification and location of weld or volume scanned;
(o) surface(s) from which examination was conducted, including surface condition;
(p) map or record of rejectable indications detected or areas cleared;
(q) areas of restricted access or inaccessible welds;
(r) examination personnel identity and, when required
by referencing Code Section, qualification level;
(s) date of examination.
Items (b) through (m) may be included in a separate calibration record provided the calibration
record identification is included in the examination record.
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Fig. 1 Non-Piping Calibration Blocks ( T-434.2.1 of ASME Sec.V )

Weld Thickness (t), in. (mm) Calibration Block Thickness (T), Hole Diameter, in.(mm)
in. (mm)
Up to 1 (25) 3/4 (19) or t 3/32 (2.5)
Over 1 (25) through 2 (50) 11/2 (38) or t 1/8 (3)
Over 2 (50) through 4 (100) 3 (75) or t 3/16 (5)
Over 4 (100) t ±1 (25) [Note (2)]

NOTE:
(1) Minimum dimension
(2) For each increase in weld thickness of 2 in.(50 mm) or fraction thereof over 4 in.(100 mm),
the hole diameter shall increase 1/16 in.(1.5 mm)
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Fig. 2 Calibration Block for Pipe ( T-434.3-1 of ASME Sec.V )

NOTES :
NOTE: (1) Notches shall be located not closer than ½T or ½ in.(13 mm), whichever is greater, to
any block edge or to other notches

Fig. 3 RATIO LIMITS FOR CURVED SURFACE