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ATS-UT-001
CONTENTS
1. SCOPE
2. REFERENCE DOCUMENT
3. QUALIFICATIONS
4. RESPONSIBILITIES
5. PROCEDURES
6. REPORTING
7. ACCEPTANCE CRITERIA
8. ATTACHMENTS
9. DOCUMENTS
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ABBREVIATION
dB - DECIBELL
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1.0 SCOPE
This procedure is prepared to inspect base metal and fusion welded butt joints in ferritic
steel by Manual Ultrasonic Method.
3.1 The Personnel who carry out Ultrasonic Testing shall be qualified Level-II as per
SNT-TC-1A (2006).
3.2 Alternately a level-1 qualification is acceptable, provided the work is carried out
under the direct supervision of a qualified Level-2 Technician.
him.
4.0 RESPONSIBILITIES
5.0 PROCEDURES
5.1 EQUIPMENT
5.1.1 Ultrasonic Flaw Detector shall be Portable; Pulse echo unit with rectified
A Scan display. (E.g. KrautkramerUSK6, USK7, USK7D or equivalent).
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5.1.2 Straight Beam search units shall be of standard manufacturer, either twin
or single crystal with a nominal frequency of 4 MHz-5 MHz for less than
50 mm job thickness and 2.0 -2.5 MHz for job more than 50 mm job
thickness, crystal diameter of 10 25mm.
5.1.3 Angle Beam search units shall be of standard manufacturer, either twin or
single crystal with a nominal frequency of 4 MHz-5 MHz for less than 50
mm job thickness and 2.0 -2.5 MHz for job more than 50 mm, crystal
dimensions of 8x9mm or 10mm.
5.3 COUPLANT
5.3.1 A suitable coupling medium for acoustic transmission is required.
5.3.2 Glycerin, light machine oil, cellulose paste, non-corrosive gel or
equivalent may be used.
5.3.3 Suitable high temperature grease shall be used as a couplant when doing
high temperature testing.
5.4.2. In addition to the above, the ultrasonic operator shall carry out following
equipment checks prior to conducting any test.
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5.4.3 A record for all equipment checks shall be maintained in the standard
format.
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5.5.1 Scanning surface shall be smooth, clean and free of scale, spatter, pitting,
paint or any imperfection that might impair the coupling between the
probe and the work piece.
5.5.2 Dressing of weld profile may be carried out to eliminate or resolve
confusing surface echoes/mode conversions.
5.5.3 Where it is otherwise impossible for the ultrasonic beam to interrogate the
full cross-section of the weld, the weld profile shall be dressed smooth.
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Figure 5.1
Transmit Receive
Line 1
80%FSH
Line 2
TCF
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5.7.1 Beam path Calibration and sensitivity setting shall be made by the
ultrasonic operator at the work location, immediately prior to he
commencement of test.
5.7.2 Straight beam calibration shall be made to display at least two back wall
echoes on the CRT screen.
5.7.3 Straight beam sensitivity shall be adjusted such that the first back wall
echo is set at 80% FSH.
5.7.4 Angle beam calibration shall be made for the beam path length that is
sufficient to ensure complete coverage of weld. This may vary from 0-0.5
Skip Beam Path to 1.5 Skip Beam Path depends up on accessibility for
scanning.
5.7.5 Angle beam sensitivity shall be set using a DAC curve in accordance with
the requirements of the applicable code as described in the attachment-III.
Scanning sensitivity shall be 6 dB above the primary sensitivity.
5.7.6 The flaw detector unit shall have minimum 20dB gain in reserve above
basic sensitivity.
5.7.7 Recalibration of beam path shall be made every 30 minutes during testing,
after any change of probe, coaxial cable or battery, or after any change of
work location.
5.7.8 Suppression control shall be off during calibration.
5.8.1 Straight beam examination shall be carried out on the base metal to ensure
that the angle beam scanning area is free of lamination or any
imperfections that might interfere with the angle beam test.
5.8.2 Any area of base metal with indications excess or equal to back wall echo
or any area in which the back wall echo is completely lost shall be
reported.
5.8.3 Straight beam examination of attachment welds shall be carried out where
access is possible.
5.8.4 Scanning patterns for angle beam probes shall be established in
accordance with size and geometry of the test joint. Selection of probe
angles and scanning surface shall be designed to achieve optimum
coverage of weld metal volume.
5.8.5 Scanning patterns for each joint type shall be specified in a technique
sheet appended to this procedure.
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5.9.1 All assessment and evaluation of indications shall be carried out with
primary reference level after deducting 6dB scanning sensitivity.
5.9.2 Care should be taken to ensure only relevant indications are reported as
discontinuities.
5.9.3 Cross-sectional size of discontinuities shall be determined using 20dB
drop technique or maximum amplitude drop technique.
5.9.4 Length of discontinuities shall be determined using 6dB drop method.
5.9.5 The type of discontinuity (i.e., Planar/Cylindrical /Spherical /Linear) shall
be evaluated by noting signal response to various scans and various
angles.
5.9.6 A reference zero datum mark shall be made on the work piece surface. All
rejectable discontinuities shall be marked relative to zero datum.
5.10.1 Repairs shall be re-examined using the same procedure used for the
original examination.
5.10.2 The extent of examination shall include the repaired area plus 100mm at
either end.
5.10.3 A new report, with relevant repair number, shall be written for all repaired
welds retested.
5.12 SAFETY
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5.12.1 Care shall be exercised during inspection with due regard to safety and the
fact that the standard Ultrasonic Flaw Detectors used by the company are
NOT considered intrinsically safe and also Permits shall be required for
hazardous areas.
6.0 REPORTING
8.0 ATTACHMENTS
9.0 DOCUMENTS
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ATTACHMENT-I
1.0 INTRODUCTION
This is intended to provide detailed methods and techniques for assessment and calibration of
Ultrasonic Flaw Detector, as required by UT-01 Section 8.2.
The instrument calibration shall be performed every 40 hours as per Asme Sec V
Alternately, a straight beam search unit shall be used on any calibration block, which will
provide amplitude differences with sufficient signal separation to prevent overlapping of the two
signals.
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amplitude of the same indication. It must be 50% of the initial amplitude within 10% of the
nominal amplitude ratio. Perform this exercise for full range of Gain.
The settings and readings must be estimated to the nearest 1% of full screen and the readings
should fall within the limits of following table.
Other convenient reflectors from any calibration block shall be used with straight or angle beam
search units.
4.0 RECORDS:
All calibration readings shall be recorded and documented till next calibration period and
calibration block identity shall be included in the ultrasonic calibration records.
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ATTACHMENT II
1.0 INTRODUCTION
This has been written in order to provide detailed methods and techniques to evaluate the
Probes characteristics.
s
diu
Ra
0 mm
10
V1 (IIW) Block
3.1.2 Place shear wave probes on the IOW Beam Profile Block with the beam directed
towards the series of 5 side drilled holes. Al least 3 of the series shall be clearly
discernible.
V1 (IIW) Block
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Figure 3
1.6mm hole
V1 (IIW Block) Probe Angle
Note the beam path and Probe angle is calculated using formula:
Probe Angle = Cos-1(15/Beam Path)
Figure 4
Ho rizo ntal
s t and -o ff
Pro b e mo vement
t o maximize s ig nal
Beam Cent re
Trailing Ed g e
IOW Block
3.4.2 Move the probe gently forward until the signal height form the target hole has dropped
to 10% FSH (i.e. 20dB). Hold the probe in this position and mark 2 the probe index
position on the block. (See Fig. 5)
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Figure 5
Mo ve p ro b e fo rward unt il
Sig nal heig ht d ro p s t o 1 0 %
2 0 d B Trailing Ed g e
3.4.3 Move the probe gently backward such that the signal goes back to maximum then falls
away again to 10% FSH. Hold the probe in this position and mark3 the probe index
position on the block. (See Fig.6)
Figure 6
M o ve p ro b e b ackward until
Sig nal heig ht d ro p s to 1 0 %
M ark t he p ro b e ind ex
at 1 0 % s ig nal heig ht
20 dB
Lead ing Ed g e
3.4.4 Transfer the measurements of hole depth and probe stand off for each of three marks
onto a flaw location slide or suitable plotting system.
3.4.5 Repeat the above steps for three other target holes at different depths.
3.4.6 Complete the beam angle and profile plot by joining relevant points on the plotting
system. (See Fig.7)
Fig.7
Horizontal stand-off
Index
Point
Mark 2 Mark 1 Mark 3
Hole 1
Hole 2
Hole depth
Hole 3
Hole 4
4.0 CHECKLIST
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All probe characteristics shall be entered in to the Probe Characteristics Checklist format: -:
FORMAT/UT/CAL-02
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ATTACHMENT-III
1.0 INTRODUCTION
This illustration is written to provide technical detail for the construction of Distance
Amplitude Correction (DAC) Curves as required by this written procedure.
2.0 EQUIPMENT
As defined by section 5.0 of UT-01.
3.0 BLOCKS
3.1 IOW Block for structural steel work weldments
3.2 ASME Section-V Basic Calibration Block for Pressure Vessels/Process Piping
4.0 METHODS
4.1 Select a hole in the calibration block which falls out side of the Probes near zone. The
near zone length is calculated using the formula:
N = D2F /4V
4.2 Position the probe on the block and pick up the signal from selected target hole.
4.3 Maximize the signal by manipulation of probe.
4.4 Adjust the gain and keep the maximized signal at 80% FSH and mark the signal peak
on the screen.
4.5 Without further alteration select two more holes at suitable beam path to cover the
entire range/ thickness of the test material. Maximize the echoes by probe manipulation
and mark the respective signal peaks on the screen.
4.6 Join together all the three points plotted on the screen to generate a DAC curve. (See
Fig.1)
Point 1
80% FSH x
Amplitude
Point 2
x
x
Point 3
Figure 1
Time Base
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HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD DOC No. : HT-UT-01
REVISION : 9.0
ULTRASONIC TESTING PROCEDURE DATE : 03.07.2009
GENERAL PROCEDURE
TECHNIQUE SHEET 1:
Surface 1 Surface 2
Surface 3 Surface 4
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HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD DOC No. : HT-UT-01
REVISION : 9.0
ULTRASONIC TESTING PROCEDURE DATE : 03.07.2009
GENERAL PROCEDURE
TECHNIQUE SHEET 2:
Scan 3-45/60/70
Scan 4
Scan 5
half skip
Full skip
Scan 1, 2, & 3
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HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD DOC No. : HT-UT-01
REVISION : 9.0
ULTRASONIC TESTING PROCEDURE DATE : 03.07.2009
GENERAL PROCEDURE
BRANCH
MEMBER
Scanning perpendicular
to weld at all locations
Fu
Ha ll s
lf s k ip
Sca kip
ns
urf
ace
Scan surface
Scanning detail
1. All scans to be carried out from branch member surface.
2. 0 scan for lamination check on scan surface.
3. 45, 60, 70 angle beam scan of weld metal at half and full skip as permitted by material thickness and
weld geometry.
4. Local dihedral angle and weld geometry varies point to point. Therefore beam axis should be kept
perpendicular to the weld during angle beam scanning.
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HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD DOC No. : HT-UT-01
REVISION : 9.0
ULTRASONIC TESTING PROCEDURE DATE : 03.07.2009
GENERAL PROCEDURE
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HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD DOC No. : HT-UT-01
REVISION : 9.0
ULTRASONIC TESTING PROCEDURE DATE : 03.07.2009
GENERAL PROCEDURE
SKETCH
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