ULTRASONIC EXAMINATION OF STRUCTURAL

TUBULAR BUTT & TKY WELD JOINTS

ULTRASONIC EXAMINATION OF STRUCTURAL

TUBULAR BUTT & TKY WELD JOINTS

Procedure No. INSP-UT-

Rev Description Prepared By: Reviewed By: Approved By: Date

0 Initial Release Priyesh Maurya 12th Feb 2013

Signat
ure

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 TABLE OF CONTENTS

1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 RESPONSIBILITIES
4.1 Safety
4.2 Personnel
4.3 Supervision
5.0 MISCELLANEOUS REQUIREMENTS
5.1 Identification and Datum Points
5.2 Surface preparation
5.3 Extent of Inspection
6.0 EQUIPMENT & ANCILLARY
6.1 Equipment Requirement
6.2 Probe Selection
6.3 Couplant
6.4 Calibration and reference blocks
7.0 EQUIPMENT SPECIFICATION
7.1 Equipment Function Tests
7.2 Equipment Function Tests Parameters
8.0 EQUIPMENT CALIBRATION
9.0 WELD EXAMINATION
9.1 Parent Metal Scan
9.2 Weld Scanning
10.0 ACCEPTANCE CRITERIA
11.0 REPORTING
12.0 POST – CLEANING
13.0 RESTRICTIONS
14.0 DOCUMENTS
15.0 RECORDS
APPENDIX 1 - Client Based Acceptance and Reference Standards.

1.0 PURPOSE

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1.1 The purpose of this procedure is to:

• Provide the Customer and Verifying Bodies with a documented procedure for
the execution of ultrasonic examination for detection of discontinuities.

• Provide NDT personnel with a general procedure which addresses the

activities associated with the ultrasonic examination for detection of
discontinuities.

1.2 Prior to commencement of any inspection, PRETECT shall inform NDT

personnel of the scope of work ahead. Inspectors shall ensure that they are
familiar with the instruction and procedural requirements of work to b e undertaken,
and that all relevant information, documented or otherwise, is made available to
facilitate job completion.

2.0 SCOPE

2.1 This procedure is a general procedure that describes manual UT method A-

scan display for ultrasonic examination of structural tubular complete joint
penetration groove Butt & TKY joints welded from one side without backing

2.2 This procedure is limited to diameters of 325 mm and larger, thicknesses of 12 mm

and above, and local dihedral angles of 30° or greater.
(Weld joints configuration out of above limit may be tested if client agrees for use of
this procedure for the inspection.)

2.3 When required by a client or contract, job specific technique sheets shall be
compiled to address any applicable parameters that may differ from this
procedure. These job specific technique sheets shall be issued prior to
Commencement of work.

3.0 REFERENCES

3.1 The following documents are applicable to meet the general or specific
industry requirement. Note that this procedure refers to the latest revision of these documents.

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 • BS EN ISO 9712:2012 – General Criteria for Certification and Qualification of
NDT Personnel.
• SNT-TC-1A: 2016 - Recommended Practice Qualification and Certification of
NDT Personnel.
• ASME BPV Code 2017 Section V - Non- Destructive Testing. Article 4 and
Article 23.
• AWS D1.1/D1.1M:2015 – Structural Welding Code—Steel.
• API RP 2X- Recommended Practice for Ultrasonic and Magnetic Examination of
Offshore Structural Fabrication and Guidelines for Qualification of Technicians
• ASTM E 1316: 16a -Terminology for Non-Destructive Examinations.
• INSP-UT-P001-TS-001 – 018 Standard Technique Sheets.
• INSP-CWP-P001 Company Written Practice in Accordance with SNT-TC-1A.
• INSP-EET-P001 Eye Examination Test Procedure.
• INSP-RA-UT-002 Risk Assessment – Ultrasonic Inspection.
• Health and Safety at Work etc. Act 1974.
• The Management of Health and Safety at Work Regulations 1999.
• Control of Substances Hazardous to Health Regulations 2002.
(All above documents shall be based on the latest revision)

Note: Other standards which may be necessary as part of the client requirements will
be detailed on a relevant Technique Sheet and in Appendix 1 without further
amendments to the text of the main procedure.

4.0 RESPONSIBILITIES

4.1 Safety

4.1.1 Where deemed necessary, all technicians performing ultrasonic testing

shall wear, prior to and during inspection, safety glasses, safety boots, safety
coveralls and gloves as a minimum.

4.1.2 All technicians shall be familiar with and comply with current legislation, industry
standards and Company Safety Procedures relative to their operations.

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4.2 Personnel

4.2.1 All technicians performing ultrasonic inspection shall be trained, experienced and
currently certified in UT to Level II as per company written practice INSP-CWP-
P001, BS EN 9712, SNT-TC-1A or equivalent in weld sector.

4.2.2 In addition to above the technician performing ultrasound testing shall have TKY
configuration weld joint certification as per AWS D1.1/ API RP 2X or as per BS EN
9712

4.2.2 All technicians performing ultrasonic inspection shall have passed a near acuity
eye examination in accordance with the Company Eye Test Examination
procedure, INSP-EET-P001. Records of such eye examinations shall be recorded
and kept on personnel files.

4.3 Supervision

4.3.1. Supervisors are to apply Quality Control procedures, check and sign off completed
work packs and reports, ensure that the work has been completed satisfactory
and carried out in accordance with relevant procedures.

5.0 MISCELLANEOUS REQUIREMENTS

5.1 Identification and Datum Points

5.1.1 All material inspected shall have evidence of a unique number for traceability as
determined by the client.

5.1.2 A datum point shall be clearly marked by means of paint, halogen free marker
pen, tape or other means acceptable by the client in order to identify the areas
where indications or discontinuities may be present and to ensure the
repeatability of test results for the future location of defects.

5.1.3 In the event of any material being found defective a detailed drawing will be
provided. The item shall be identified as rejected and clearly marked using a

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 halogen free marking pen or similar that will not affect the use of the component or
prejudice any subsequent testing.

5.2 Surface Preparation

5.2.1 All areas under inspection shall be clean, dry and free from all contaminants
and /or foreign matter that may affect the sensitivity of the test.

5.2.2 Mechanical cleaning operations must be carefully managed so as not to damage

the surfaces of inspection

5.2.3 Welds are mainly tested in the ‘as welded’ condition and the profile may be
dressed where it interferes with the interpretation of the trace.

5.3 Extent of Inspection

5.3.1 All areas to be inspected should be identified on a request for inspection provided
by the client.

5.3.2 The areas of examination will include weld and parent material for at least 10mm
from weld toe or width of the heat affected zone, whichever is greater.

5.3.3 The parent material shall be inspected along the full length of the weld for a
distance back from the weld equal to the maximum scanning distance to be used
for the subsequent angle probe examination.

6.0 EQUIPMENT & ANCILLARY

6.1 Equipment Requirement

6.1.1 The UT instrument shall be the pulse echo type suitable for use with transducers
oscillating at frequencies between 1 and 5 megahertz. The display shall be an “A”
scan rectified display.

6.1.2 Permanent graticule markings shall be used for both range and amplitude.

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6.1.3 Flaw detectors shall be calibrated annually to ensure performance to manufacturing
tolerances

6.1.4 The examination shall be carried out manually using the pulse-echo method with
direct contract coupling

6.2 Probe Selection

6.2.1 Probes t o be used shall be compatible with the flaw detectors in use and shall be
in the operating frequency range 1 – 5 MHz.

6.2.2 The ultrasonic technician shall select the appropriate probes for the configuration of
weld taking into account influencing factors.

6.2.3 All probes used shall be recorded on the test report.

6.2.4 Where required by the client or contract, additional or alternative requirements may
be applicable. These shall be detailed or referred to on a job specific technique
sheet.

6.3 Couplant

6.3.1 Coupling shall normally be achieved using proprietary couplants where surface
temperatures are less than 50°C.

6.3.2 In the case of high temperatures, special high temperature couplants may be
used in conjunction with high temperature probes.

6.3.3 If there are no specific requirements cellulose paste shall be used and no further
reference made to couplant.

6.4 Calibration and reference blocks

6.4.1 Calibration and reference blocks shall be used in accordance with AWS D1.1. IIW V1
block shall be use as calibration block and IOW block shall be used as reference
block.

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6.4.2 The probes and test blocks used during calibration shall be maintained at a

temperature within ± 14o C of that of the joint(s) to be examined.

6.4.3 Other reference blocks to be used for setting sensitivity with prior approval from
client.

7.0 EQUIPMENT SPECIFICATION

7.1 Equipment Function Tests

7.1.1 The technician conducting ultrasonic examination shall carry out a functional
check on a daily basis or prior to starting work. Tests shall be designed to ensure
the proper functioning of both the main and ancillary equipment in order to reveal
discrepancies in either or both. An updated record of all checks carried out shall be
kept on file within the Company’s Quality Assurance System.

7.1.2 A visual inspection shall be carried out on a daily basis on all equipment to
be used to check for mechanical damage and / or wear that may interfere with the
integrity and performance during examination. Checks should include, but are
not limited to, the following:

• Test equipment - Check for visual damage to graticule or casing and

controls
• Probes - Check for shoe wear and damage to cable connections /
terminals
• Co-axial Leads - Check for any breakages and connection point wear
• Calibration Blocks - Check for physical damage
• Reference Blocks - Check for physical damage

7.1.3 All equipment should be function tested prior to commencement of contract work
at the periods listed in Table 1 below, where all results shall be recorded on an
Ultrasonic Equipment Function Checks Form INSP-UT-F001 D and held on file.
7.4 Equipment Function Tests Parameters
UT Equipment Function test Requirements shall be as per the below table.

Table-1 (UT Equipment Qualification and Calibration Requirements

UT Equipment Qualification and Calibration Requirements

Type of qualification Minimum Frequency

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 or Calibration Activity
Horizontal Linearity 2 months
Instruments
Gain Control/dB Accuracy 2 months

Equipment Internal Reflections 40 hours of usea

Qualification Search Units Angle Beam Search Units
Procedures 8 hours of usea
(Index Point, Angle)

Straight Beam (for Resolution (Angle Beam) Prior to initial useb

Base Material Testing) Resolution (Straight Beam) Prior to initial useb

Straight Beam (for Range

Base Material Testing) Sensitivity
Range Just prior to and at
the location of the
Calibration
Sensitivity first weld testedc
for Testing Angle Beams
Index Point
Angle
Straight Beam and
Recalibration 2 hoursd
Angle Beam
a
Must be performed for each search unit.
b
Must be performed for each combination of search unit (transducer and shoe) and
instrument prior to initial use.
c
After sensitivity and sweep (distance) are met the condition for recalibration
requirements of 8.4 shall apply.
d
Or when electrical circuitry is disturbed in any way which includes the following:
(1) Transducer Change
(2) Battery Change
(3) Electrical outlet change
(4) Coaxial cable change
(5) Power outage (failure)

7.2.1 Horizontal Linearity:

(NOTE: Since this qualification procedure is performed with a straight beam search
unit which produces longitudinal waves with a sound velocity of almost double that
of shear waves, it is necessary to double the shear wave distance ranges to be
used in applying this procedure.)

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 (1) A straight-beam search unit shall be coupled to the IIW type block As
necessary to attain five back reflections in the qualification range being
certified.
(2) The first and fifth back reflections shall be adjusted to their proper locations with
use of the distance calibration and zero delay adjustments.
(3) Each indication shall be adjusted to reference level with the gain or attenuation
control for horizontal location examination.
(4) Each intermediate trace deflection location shall be correct within 2% of the
screen width.

7.2.2 Gain Control / dB Accuracy:

Position a straight beam on the IIW V1 block so that reflection from 1st BWE is peaked
up is peaked on the screen. Adjust the sensitivity (gain) as shown in the following
table. The indication shall fall within the specified limits.

Table-2

The settings and readings shall be estimated to the nearest 1% of full screen.

7.2.3 Internal Reflections

(1) Calibrate the equipment in for angle beam

(2) Remove the search unit from the calibration block without changing any other
equipment adjustments.
(3) Increase the calibrated gain or attenuation 20 dB more sensitive than
reference level.
(4) The screen area beyond 1/2 in [12 mm] sound path and above reference level
height shall be free of any indication.

7.2.4 Index Point. The transducer sound entry point (index point) shall be located or

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 checked by the following procedure:
(1) The transducer shall be set in position D on the IIW type block as shown in
fig-1 below.
(2) The transducer shall be moved until the signal from the radius is maximized.
The point on the transducer which aligns with the radius line on the calibration
block is the point of sound entry.

Fig-1: Probe position for equipment check

7.2.5 Angle. The transducer sound-path angle shall be checked or determined by one of
the following procedures:

(1) The transducer shall be set in position B on IIW type block for angles 40°
through 60°, or in position C on IIW type block for angles 60° through 70° (see
Fig-1).

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 (2) For the selected angle, the transducer shall be moved back and forth over the
line indicative of the transducer angle until the signal from the radius is
maximized. The sound entry point on the transducer shall be compared with
the angle mark on the calibration block (tolerance ± 2°)

7.2.6 Resolution Requirements.

7.2.6.1 Straight Beam:

(1) The transducer shall be set in position F on the IIW type block (fig-1)
(2) Transducer and instrument shall resolve all three distances.

7.2.6.2 Angle Beam

The combination of search unit and instrument shall resolve three holes in the RC
resolution reference test block shown in (Fig-2)

(1) The transducer shall be set on resolution block RC position Q for 70° angle,
position R for 60° angle, or position S for 45° angle.
(2) Transducer and instrument shall resolve the three test holes, at least to the
extent of distinguishing the peaks of the indications from the three holes.
The resolution shall be evaluated with the instrument controls set at normal test
settings and with indications from the holes brought to mid-screen height.
Resolution shall be sufficient to distinguish at least the peaks of indications from
the three holes. Use of the RC resolution reference block for calibration shall be
prohibited. Each combination of instrument search unit (shoe and transducer) shall
be checked prior to its initial use. This equipment verification shall be done initially
with each search unit and UT unit combination. The verification need not be done
again provided documentation is maintained that records the following items:
(1) UT machine’s make, model and serial number
(2) Search unit’s manufacturer, type, size, angle, and serial number
(3) Date of verification and technician’s name
8.0 EQUIPMENT CALIBRATION

8.1 Only equipment that holds current valid calibration certification to National or
International Standards shall be used when performing ultrasonic inspection.
Calibration information shall be identified on the equipment by tags, stickers or by
any other approved method.

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8.2 Records of calibration shall be kept / controlled / filed in an easily retrievable
manner.

8.3 Calibration of main equipment shall be carried out every 12 months by approved
personnel, unless otherwise agreed by contracting parties.

8.4 Range and Sensitivity Settings

Range and sensitivity settings shall be established in accordance with ASME

Section V Article 4 prior to each examination and re-confirmed at the following
stages:

• At least every 4hrs during testing.

• Any change in equipment.
• Any change in the test parameters or personnel.
• Where changes in the equivalent settings are suspected.
• At the end of each inspection.

8.4.1 Range Calibration

Range (distance) calibration shall include, as a minimum, the entire sound path
distance to be used during the specific examination.

8.4.1.1 Straight Beam:

(1) The transducer shall be set in position G on the IIW type block (Fig-1 :)
(2) The instrument shall be adjusted to produce indications at 25 mm, 50 mm, 75
mm & 100 mm on the display.

8.4.1.2 Angle Beam:

The transducer shall be set in position D on an IIW type block (any angle) (fig-1). The
instrument shall then be adjusted to attain one indication at 100 mm and
a second indication at 200 mm or 225 mm on the display.

8.4.2 Sensitivity Calibration

8.4.2.1 Straight Beam

Unless otherwise specified by the client or contract, sensitivity of 1st Back Wall Echo
(BWE) to 80% of full screen height shall be applied.

8.4.2.1 Angle Beam

8.4.2.1 DAC Curve shall be plotted on the IOW block (fig-2)

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8.4.2.2 Unless otherwise specified by a client or contract the method used by PRETECT
shall be the DAC curve. The constructed curve forms the primary reference level.

8.4.2.3 Any differences between the DAC reference block and the material under test
shall be corrected as detailed in Attenuation and Transfer Loss section.

Fig-2: Reference Block: Institute of Welding (IOW) Block

8.4.3 Sensitivity Level

Unless otherwise specified by the client or contract, the sensitivities or scanning

levels are defined as follows:

8.4.3.1 Primary Reference Level – the value (in dB) at which the DAC
was plotted from a particular reference block
8.4.3.2 Evaluation Level (Standard Sensitivity) – the ‘Primary Reference
Level’ +/- a n y t r a n s f e r correction factors (in dB)
8.4.3.3 Scanning L e v e l – t h i s is the ‘ s e a r c h ’ or ‘scanning’ sensitivity. The
minimum gain is 6dB above the ‘Evaluation Level’

9.0 WELD EXAMINATION

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9.1 Parent Metal Scan

9.1.1 Prior to the examination of the weld the parent metal on either side of
the weld, where accessible, shall be examined using a compression
wave probe.
9.1.2 This test is to locate any laminar type flaws in the parent metal which
may interfere with or restrict the subsequent test.

9.2 Weld Scanning

9.2.1 All Tubular butt joint welds shall be tested from each side of the weld axis. All
welds shall be tested using the applicable scanning pattern or patterns shown
in Figure-3 as necessary to detect both longitudinal and transverse
discontinuities. It is intended that, as a minimum, all welds be tested by passing
sound through the entire volume of the weld and the HAZ in two crossing
directions, wherever practical.
(Note: Scanning pattern D shall be used when welds are ground flush. Scanning
pattern E shall be used when the weld reinforcement is not ground flush
Scanning angle e = 15° max.)

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Fig-3: Plan view of UT Scanning Patterns: Tubular Butt Weld

9.2.2 Weld scanning of T-, Y-, and K-connections shall be performed from the branch
member surface (fig-4). All examinations shall be made in leg I and II where
possible. For initial scanning, the sensitivity shall be increased by minimum 6
dB for the maximum sound path. Indication evaluation shall be performed with
reference to the evaluation level.

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Fig-4: Scanning Technique: Tubular TKY Configuration weld Joints

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 9.2.3 The majority of welds presently tested by PRETECT are in the ‘as welded’
condition and so the technique details the testing parameters required
covering this type of weld.

9.2.4 The crystal path overlap shall be at least 10% of each previous path to ensure
that the area under examination is completely covered.

9.3 Technique Sheets

9.3.1 If the client does not request job specific technique sheets, PRETECT shall apply
this procedure in conjunction with the appropriate standard technique s h e e t s
(INSP-UT-P001-TS001 – 018). These are based on the requirements of AWS
D1.1 / API RP 2X

9.3.2 Where required by client / contract, job specific technique sheets shall be
compiled and issued to address any differing parameters that may be applicable.
These technique sheets will be placed in Appendix 1, and m u s t be read in
conjunction with this procedure.

9.3.3 Job specific technique sheets shall be compiled and/or approved by personnel
qualified to at least Level II in the appropriate method, sector and category of the
product to be examined.

9.3.4 Job specific technique sheets shall be completed in the Company approved
format, issued with a form number and controlled by the Project Manager.

10.0 ACCEPTANCE CRITERIA

10.1 If job specific Acceptance criteria not mentioned, following acceptance criteria
may be used as reference for the acceptance or rejection of the component
under inspection.

10.2 Class R (Applicable When UT is Used as an Alternate to RT).

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 All indications having one-half (6 dB) or less amplitude than the evaluation
sensitivity level shall be disregarded. Indications exceeding the disregard level shall
be evaluated as follows:

10.2.1 Isolated random spherical reflectors, with 25 mm minimum separation up to the

evaluation sensitivity level shall be accepted. Larger reflectors shall be evaluated as
linear reflectors.

10.2.2 Aligned spherical reflectors shall be evaluated as linear reflectors.

10.2.3 Clustered spherical reflectors having a density of more than one per square inch
[645 square millimeters] with indications above the disregard levels (projected area
normal to the direction of applied stress, averaged over a 6 in [150 mm] length of
weld) shall be rejected.
10.2.4 Linear or planar reflectors whose lengths (extent) exceed the limits of Fig-4 (a) &
4(b) shall be rejected. Additionally, root reflectors shall not exceed the limits of
Class X.

Fig-4 (a): Class-R Indication

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 Fig-4 (b): Class-R Indication

10.3 Class X (Experience-Based, Fitness for- Purpose Criteria Applicable to T-, Y-, and
K Connections in Structures with Notch-Tough Weldments).

All indications having half (6 dB) or less amplitude than the evaluation sensitivity
level shall be disregarded. Indications exceeding the disregard level shall be
evaluated as follows:
10.3.1 Spherical reflectors shall be as described in Class R, except that any indications
within the following limits for linear or planar shall be acceptable.
10.3.1 Linear or planar reflectors shall be evaluated by means of beam boundary
techniques (6dB drop), and those whose dimensions exceeded the limits of Fig-5

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 (a) & (b) shall be rejected. The root area shall be defined as that lying within 6 mm
or tw/4, whichever is greater.
Note: 1. Aligned discontinuities separated by less than (L1 + L2)/2 and parallel
discontinuities separated by less than (H1 + H2)/2 shall be evaluated as
continuous.
2. Accumulative discontinuities shall be evaluated over 6 in [150 mm] or D/2 length of
weld (whichever is less), where tube diameter = D.

Fig-5 (a): Class-X Indication (T-, Y-, & K-Root Discontinuities)

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 Fig-5 (b): Class-X Indication (Internal Reflectors and all Other Welds)

Note: Discontinuities that are within H or tw/6 of the outside surface shall be sized as if
extending to the surface of the weld.

11.0 Reporting

11.1 If the client has not requested a specific report format, on completion of
Ultrasonic Inspection, a detailed report shall be completed using the standard
Ultrasonic Inspection Report form, INSP-UT-F001A and will include essential data
as follows as a minimum:

• Customer
• Job Number
• Item number

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 • Component or Weld Identification
• Material Type - Surface Condition
• Material Nominal Thickness
• Couplant used
• Probe Details
• Sensitivity Settings
• Scanning Sensitivity
• Calibration and Reference Blocks
• Calibration Ranges
• Recording Levels
• Test Procedure Number
• Date of Inspection
• Technician’s Signature and Qualifications
• Equipment Used
• Results / Sentencing / Rework

11.2 Specific report formats may be requested by various clients and may be
attached to this procedure as an attachment in Appendix 1.

11.3 Reporting Results - all indications shall be considered to be relevant until

proved otherwise.

11.4 A concise report including sketches and or photographs where necessary will
be submitted to the client on completion of each inspection or otherwise as
instructed.

11.5 Acceptance criteria will be in accordance with the relevant reference

document specified by the client.

11.6 The reporting of an ultrasonic examination will give sufficient information to

enable a repeat inspection to be undertaken where required.

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11.7 Additional report formats may be attached to this procedure as an attachment and
will be controlled by the Project Manager. Additional report formats may be
compiled within Appendix 1.

12.0 Post – Cleaning

12.2 Post cleaning shall be carried out on the material under inspection. Care shall
be taken to ensure that the surface is clean, dry and free from all contaminants
which may be harmful to the surface under inspection.

12.3 Parts shall be protected from corrosion or damage as required.

12.4 Disposal of all cleaning materials and aerosol canisters shall be in accordance
with manufacturer or work-site safety regulations.

13.0 RESTRICTIONS

13.1 Any restrictions to the technician carrying out this procedure, or in its application,
shall be reported to the supervisor and client as soon as possible.

13.2 The client shall approve any deviation from this procedure prior to application.

13.3 All amendments to this procedure shall be recorded.

14.0 DOCUMENTS

INSP-UT-F001A Ultrasonic Inspection Report Form

INSP-UT-F001B Ultrasonic Inspection Report Data Continuation Sheet
INSP-UT-F001C Ultrasonic Inspection Report Continuation Sheet
INSP-UT-F001D Ultrasonic Equipment Function Test Report
INSP-UT-F001E Ultrasonic Instrument Linearity Verification Form

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15.0 RECORDS

This section details the requirements for retention of records on completion of work.

Document Responsible Holder Retention Period

Ultrasonic Inspection Reports / Project Engineer or

5 Years
Continuation Sheets Base Supervisor

Ultrasonic Equipment Function Test Project Engineer or

Report Base Supervisor 5 Years

Project Engineer or
Technique Sheets 5 Years
Base Supervisor

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 ULTRASONIC EXAMINATION OF WELDS

APPENDIX 1 - CLIENT BASED ACCEPTANCE AND REFERENCE STANDARDS

This section is included to allow details of specific Client requirements to be placed in this
document.

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