Input: 400 TPD MSW

Output: 14 TPD CBG

Location: Bhopal, Madhya Pradesh

TITLE: TITLE: PROCEDURE FOR ULTRASONIC DOC NO :

TESTING REV NO :0
PAGE : 1 of 17

DRG. CATEGORY
R/A A REVIEW CODE

DOCUMENT STATUS
Review Code 1 - No Comments / Approved
Review Code 2 - Proceed with Manufacture/Fabrication as per
commented Document.
Revised document required.
Review Code 3 - Document does not confirm to the Basic
requirements as marked.
Resubmit for review
Review Code R - Retained for Records / Information
Review Code V - Void

NOTE: THIS REVIEW / APPROVAL DOES NOT RELIEVE THE VENDOR/MANUFACTURER OF THE FULL RESPONSIBILITY
FOR THE DESIGN, ENGINEERING, DIMENSION, PERFORMANCE, OVERALL GUARANTEE, APPLICABLE CODES &
STANDARDS, REGULATIONS AND THE REQUIREMENTS SPECIFIED IN TENDER.

ULTRASONIC TESTING
12.09.2023 PAWAN.A.SONONE
0 PROCEDURE
REV DATE DESCRIPTION PREPARED BY REVIEWED APPROVED
 1.0 Scope:

1.1 This procedure covers the technique and acceptance standards which shall be used for the
ultrasonic examination of groove Single ‘V’ & Double ‘V’ butt welds in ferritic wrought
and cast materials, of thickness 10 mm and above for Non-piping jobs with or without
clad of any diameter.

1.2 This procedure is in conformance with the requirements of ASME Sec. V Article 4, Sec.
VIII Div.1, & 2 Ed 2007, Ad 2009 and Sec. I Ed 2007, Ad2009.
1.3 The extent of examination shall be as per QAP or Drawing.

2.0 Procedure Qualification:

2.1 This procedure shall be demonstrated to the satisfaction of AUTHORISED INSPECTOR
(AI) as per ASME Sec.V para T-150. When procedure qualification is specified following
(para 2.2 to 2.5) shall be applicable.

2.2 This written procedure is based on the essential and non-essential variables
Mentioned in Table 1.

2.3 The change of a requirement in Table 1, identified as an essential variable from the
Specified
Value or range of values shall require re-qualification of the written procedure
2.4 The change of a requirement in Table 1, identified as non-essential variable from the
Specified value or range of values do not require re-qualification of the written
procedures.

2.5 All the changes of essential or non-essential variable from the value or range of values
Specified by this written procedure shall require revision. Of or an addendum to the
written procedure.

3.0 Personnel Requirements:

3.1 The personnel employed for Ultrasonic examination shall be at least Level II certified as
per the FFIL written practice based on SNT-TC-1A.
4.0 Equipment:

4.1 The pulse echo type ultrasonic instrument shall be used.

4.2 The instrument shall be capable of generating frequencies over the range of at least 1 MHz
to 5 MHz.

4.3 Ultrasonic instrument shall be equipped with a stepped gain control in units up to 2dB
or less.
4.4 If the instrument has damping control, it may be used if it does not reduce the
sensitivity of the examination.

4.5 The reject control shall be in the off position for all examinations and calibration.

4.6.1 The instrument , when required because of the technique being used, shall have both
send and receive jacks for operation of dual search units or a single search unit with
send and receive transducers.

5.0 Search Unit: (Frequency, Angle, Size)

5.1 Search units with nominal frequency of 1MHz to 5MHz shall be used unless variables
such as production material grain structure require the use of other frequencies to
assure adequate penetration or better resolution.

5.2 Both angle beam (shear waves) and straight beam (longitudinal) either single or dual
crystal shall be used as applicable.

5.3 45° or an angle appropriate for the configuration being examined and shall be capable
Of detecting the calibration reflectors, over the required angle beam path.

5.4 Special search units, shoes or saddles shall not be used.

5.5 The search units with wedges may be used for curved surfaces.
6.0 Couplant:

6.1 A suitable couplant such as oil and grease, mixture, water or cellulose gel having good
wettability and required viscosity shall be used. However, the same couplant that is
used for the calibration shall be used during the actual examination.
6.2 The couplant including the additive shall not be detrimental to the material being
examined.
6.3 Control of contaminants:
6.3.1 Couplants used on nickel based alloys shall not contain more than 250 ppm of sulphur.
6.3.2 Couplants used on austenitic stainless steel or titanium shall not contain more than
25 ppm of halides (chlorides plus fluorides).

7.0 Calibration Blocks:

7.1 General Requirements:
The known reflectors i.e. side drill holes, notches shall be used to establish
Primary reference response (DAC).

7.1.1 Material
(a) Similar Metals Welds. The material from which surface the block is fabricated shall
be of the same product form, and material specification or equivalent P-number
grouping as one of the materials being examined. For this purposes of this paragraph,
P-Nos. 1, 3, 4, & 5A through 5C, and 15A through 15F materials are considered
equivalent.
(b) Dissimilar Metals Welds. The material selection shall be based on the material on
the side of the weld from which the examination will be conducted. If the examination
will be conducted from both sides, calibration reflectors shall be provided in both
materials.

7.1.2 Quality
Prior to fabrication, the block material shall be completely examined with
A straight beam search unit. Areas that contain an indication exceeding the remaining
Back wall reflection shall be excluded from the beam paths required to reach the
Various calibration reflectors.
7.1.3 Cladding:
When the component material is clad, the block shall be clad by the same welding
Procedure as the production part. It is desirable to have component materials which
Have been clad before the drop outs or prolongations are removed. When the
cladding
Is Deposited using an automatic welding process, and, if due to block size, the
automatic
Welding process is impractical, deposition of clad may be by the manual method.

7.1.4 Heat Treatment:

The calibration block shall receive at least the minimum tempering treatment required
The material specification for the type and grade. If the calibration block contains
Welds other than cladding, and the component weld at the time of examination has
Been heat treated, the block shall receive the same heat treatment.

7.1.5 Surface Finish:

The finish on the scanning surfaces of the block shall be representative of the surface
Finishes on the component to be examined.

7.1.6 Block Curvature:

a) Materials with diameters greater than 20 inches (500 mm): For examinations
in materials where the examination surface diameters is greater than 20 inches (508
mm), a block of essentially the same curvature, or alternatively a flat basic calibration
block, may be used.

b) Materials with diameters 20 inches (500 mm) and less: For examinations in
materials where the examination surface diameter is equal to or less than 20 inches
(500mm), 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.

7.1.7 Basic Calibration Block:

a) Basic calibration block configuration & reflectors shown in Fig.1 shall be used. The
block size & reflector locations shall be adequate to perform calibration for the
beam angles used.

b) Depending upon thickness of the material to be tested the proper block shall be
used.
 c) When two or more base material thicknesses are involved, 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 provide
the reference reflector size is based upon the average or smaller weld thickness.

d) When the block thickness Plus/Minus (+/-) 1 inch spans two weld thickness range as
shown in figure 1, the block’s use shall be acceptable in those portions of each
thickness range covered by 1 inch (25 mm).

e) Alternatively, the block may be constructed as shown in appendix 1 of article 4 of

ASME section V (Fig. J-431).

8 Identification of Weld Examination Areas:

8.0 Weld locations: Weld location and their identification shall be recorded as a weld seam
chart (Weld Plan).

8.2 Marking: If welds are to be permanently marked low stress stamps and or vibratooling
May be used. Markings applied after final stress relief of the component shall
Not be deeper than 3/64” (1.2 mm).
8.3 Reference System: Each weld shall be located and identified by system of reference
points
As 1, 2, and 3….or A, B, C….. The system shall permit identification of each weld center
line
And designation of regular intervals along the length of the weld.
The interval shall not be more than 300 mm.
9.0 Calibration:
9.1 Instrument linearity:
Instrument linearity shall be checked as per procedure No.GDJ/QA/UT- 1

9.2 General calibration requirements:

9.2.1 Ultrasonic system: Calibration shall include the complete ultrasonic system as per
Para and shall be performed prior to use of the system in the thickness range under
Examination.

9.2.2 Calibration surface: Calibration shall be performed from the surface (clad or unclad,
convex or concave) corresponding to the surface of the component from which the
examination will be performed.

9.2.3 Couplant: The same couplant to be used during the examination shall be used for
calibration.

9.2.4 Contact wedges: The same contact wedges to be used during the examination shall be
used for calibration

9.2.5 Instrument Controls: Any control which affects instrument linearity (damping, reject
etc.) shall be in the same position for calibration, calibration checks, instrument
linearity checks and examination.

9.2.6 Temperature: For contact examination, the temperature differential between the
calibration block and examination surfaces shall be within 25°F (14°C)

9.3 System calibration for DAC Technique:

9.3.1 Calibration Block(s):

Calibrations shall be performed utilizing the calibration block as shown in figure 1.

9.3.2 Techniques :
 Following techniques of calibration for angle beam & straight beam shall be used .

9.3.3 Angle beam calibration:

9.3.3.1 Distance Range Calibration :

Distance range calibration shall be done by using IIW V1 or V2 standard reference

block by adjusting delay control and range control.

9.3.3.2 Distance Amplitude Correction (DAC) :

The angle beam shall be towards the calibration

Reflector that yields the maximum response in the area of interest. The gain control
shall
Be Set so that this response is 80% +/- 5% of full screen height. This shall be the primary
Reference level. The search unit shall be manipulated, without changing instrument
Setting To obtain the maximum responses from the other calibration reflectors at their
Beam To obtain the maximum responses from the other calibration reflectors at their
Beam path to generate the distance amplitude correction (DAC) curve. These
calibration shall establish both the distance range calibration and the distance
amplitude correction.

9.3.3.3 Echo Amplitude Measurement from the surface Notch in the Basic
Calibration Block:
Notch Indication: Position the search unit for maximum amplitude from the notch on
the
Opposite surface .Mark the peak of the of the indication with an “X” on the screen .

9.3.4 Straight Beam Calibration:

9.3.4.1 Distance range:
Distance range calibration shall be done by using IIW V1 or V2 standard reference block
By adjusting delay control and range control.

9.3.4.2 (A) - Position the search unit for the maximum indication from the SDH, which gives the
Highest indication.
(b) - Adjust the sensitivity (gain) control to provide an 80% (+ 5%) of FSH indication.
 This is the primary reference level. Mark the peak of this indication on the screen.

(c) - Position the search unit for maximum indication from another SDH.

(d) - Mark the peak of the indication on the screen.

(e) - Position the search unit for maximum indication from the third SDH and mark the
Peak on the screen.

(f) - Connect the screen marks for the SDHs and extend through the thickness to
provide
The distance amplitude curve.

9.3.4.3 When an electronic distance amplitude correction device is used, the primary reference
Response (DAC) shall be equalized at the nominal constant screen height at or between
40 To 80 % of full screen height over the distance range to be employed in the
Examination.

10.0 Calibration confirmation:

10.1 System Changes :- When any part of the examination system is changed, calibration
check shall be made on the basic calibration block to verify that the distance range
points and sensitivity setting(s) satisfy the requirement of 10.3

10.2 Periodic Examination Checks:- A calibration check on at least one of the reflectors in the
basic calibration block or a check using simulator shall be performed at the completion
of each examination or series of similar examination, and when examination personnel
are changed .

10.3 Confirmation Acceptance Values:

10.3.1 Distance Range Points:

If any distance range point has moved on sweep line 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 examination record.
All recorded indications since the last valid calibration or calibration check shall be
 Re-examined and their values shall be changed on data sheet or rerecorded.

10.3.2 Sensitivity Settings:

If any sensitivity setting has changed by more than 20% or 2 dB of its amplitude,
Correct the sensitivity calibration and note the correction in examination record.
If the sensitivity setting has decreased, all data sheets since the last valid calibration
Shall be marked void and area covered by the voided data shall be re-examined.
If the sensitivity setting has increased, all recorded indications since the last valid
Calibration or calibration check shall be re-examined and their values shall be
Changed on the data sheets or re-recorded.

11.0 Examination
11.1 General Examination Requirements:
11.1.1 Examination Coverage

The volume to be scanned shall be examined by moving the search unit over the
scanning
Surface so as to scan the entire examination volume for each required search unit.

a) Each pass of search unit shall overlap a minimum of 10% of the active transducer
(Piezoelectric element) dimension parallel to the direction of scan. As an alternative if
the sound beam dimension parallel to the direction of scan indexing is measured in
accordance with beam spread measurement rules each pass of the search unit may
provide overlap of the minimum beam dimension determined.
11.1.2 Pulse Repetition Rate:
The Pulse repetition rate shall be small enough to assure that a signal from a
Reflector located at the maximum distance in the examination volume will
Arrive back at the search unit before the next pulse is placed on the transducer.
The above system is in-built in the instrument.

11.1.3 Rate of search unit movement:

11.1.4
 The rate of search unit (scanning speed) shall not exceed 6inch/second
(150 mm per second)
11.1.5 Scanning Sensitivity Level:

a) Distance Amplitude Technique:

The scanning sensitivity level shall be set at a minimum of 6 dB higher than the
Reference level (DAC) gain setting. To detect & evaluate the indication above 20% of
DAC the gain should be increase an additional amount so that no calibration reflector
Indication is less than 40% of FSH. As an alternative the scanning sensitivity level may
Be
Set at 14dB higher than the reference level gain setting.

b) Surface Preparation:
When the base material or weld surface interferes with the examination, the base
Material or weld shall be prepared as needed to permit the examination.

11.2 Scanning Technique:

a) Manual pulse echo contact scanning technique shall be performed.
b) Before performing the angle beam examinations, a straight beam examination shall
Be performed on the volume of base material through which angle beams will travel
To locate any reflectors that can limit the ability of angle beam to examine the well
Locate any reflectors that can limit the ability of angle beam to examine the weld
Volume.

c) When discontinuity is observed sizing shall be done by 6 dB drop method.

11.3 Reflectors parallel to the weld seam :

11.3.1 The angle beam shall be directed at approximate right angle to the weld axis, from
both
Sides of the weld (from two directions) on the same surface when possible. The
search
Unit shall be manipulated so that the ultrasound energy passes through the required
Volume of the weld and adjacent base material.
11.4 Reflectors transverse to the weld seam:

11.4.1 The angle beam shall be directed essentially parallel to weld axis. The search unit shall
be manipulated so that the ultrasound energy passes through the required volume of
weld and adjacent base material. The search unit shall be rotated 180 deg and
examination repeated. When weld cap is not machined or ground flat the examination
shall be performed from the base metal as both sides of the weld cap in both weld axis
direction.

11.5 Restricted Access Welds:

11.5.1 The welds that cannot be fully examined from two directions using angle beam
technique, shall also be examined if possible with straight beam technique. These
areas of restricted access shall be noted in the examination report.

11.6 Inaccessible Welds

11.6.1 The welds that cannot be examined from at least one side (edge) using the angle
beam technique shall be noted in examination report. For Flange welds, the weld may
be examined with a straight Beam or low Angle Longitudinal waves from the Flange
Face provided the examination volume can be covered.

12.0 Evaluation
12.1 General
a) Geometric Indications: Indications that are determined to originate from surface
conditions, HAZ, weld root, attachments, which act as reflectors shall be recorded with
respect to identification, maximum amplitude, location & length.
b) Following steps shall be taken to classify an indication as geometric.
i) Interpret the area containing the reflector as per applicable examination procedure.
ii) Plot and verify the reflector co-ordinates. Prepare cross sectional sketch showing
Reflector position and surface discontinuities.
iii) Review fabrication drawing
iv) Use any other NDT method to determine the true position, size and orientation of
the reflector.
 12.2 . Evaluation Level

12.2.1 Distance Amplitude Technique

Unless otherwise specified following acceptance criteria shall be applicable:

Imperfections which cause a response greater than 20% of DAC shall be investigated
to the extent that the operator can determine shape, location and identify all such
imperfections and evaluate them in terms of the acceptance standards given below (a)
& (b)
a) Indications characterized as cracks, lack of fusion or incomplete penetration, they are
Unacceptable regardless of length.

b)Other imperfections are unacceptable if the indications exceed reference level

amplitude (DAC) and imperfection have lengths which exceed ;

 1/4" (6mm) for t up to 3/4" (19mm).

 t/3 for (t) up to 3/4" (19mm) to 2 1/4" (57mm) inclusive.
 3/4" (19mm) for t over 2 1/4" (57 mm).
 Where’t’ is the thickness of the weld excluding any allowable reinforcement.

12.2.2 Evaluation for Laminar Reflectors:

Reflectors evaluated as laminar reflectors in base material which interfere with the
scanning of examination volumes shall require the angle beam examination technique
to be modified such that the maximum feasible volume is examined and shall be noted
in the record of the examination report.

12.2.3 Post-examination Cleaning

Post –examination cleaning shall be performed by any suitable method to remove the
Couplant from the surface examined to the extent possible.

13.0 Documentation

13.1 Recording
13.1.1 Non-Reject able Indications

Godrej shall maintain record of all reflections from uncorrected areas having responses
that
Exceed 50% of the reference level (DAC). This record shall locate each area, the
response
Level, the dimensions, the depth below the surface and the classification.

13.1.2 Rejectable Indications

Reject able indications shall be recorded. As a minimum, the type of indication

(Crack,non-fusion,slag etc.), location and extent (length) shall be recorded.

14.0 Examination Records:

14.1 For each Ultrasonic examination, following information shall be recorded.

a) Procedure Number and Revision.

b) Ultrasonic instrument identification and manufacturer’s Sr. No.
c) Search Unit(s) Identification (including manufactures Sr. No., 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’s 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).
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 qualification Level.
 s) Date and time of Examination performed.

15.0 Reporting:

15.1 The Report shall contain all the information required by para 13.0 & 14.0.

15.2 The report shall be filed and maintained in accordance with Godrej Quality Manual.

TABLE 1
PROCEDURE REQUIREMENTS OF AN ULTRASONIC EXAMINATION

SR.NO REQUIREMENTS ESSENTIAL NON- PROEDURE

VARIABLE ESSENTIAL REFERENCE
VARIABLES CLAUSE NO:

01 Weld Configuration to be examined, X Cl. 1.1

including thickness dimensions and
base material product from (pipe, plate
etc)

02 The surface from which the X Cl.9.2.2

examination shall be performed

03 Technique (S) (Straight beam, angle X Cl. 9.3.2

beam, contact, and/or immersion)

04 Angle (s) and mode(s) of wave X Cl. 5.3

propagation in the material

05 Search unit type (s), frequency (ies), X Cl. 5.1, 5.2,

and element size (s) / shape (s) 5.4

06 Special unit search units, wedges, X Cl. 5.5 & 5.6

shoes or saddles, when used

07 Ultrasonic instrument (s) X Cl. 4.0 & 9.0

08 Calibration ( Calibration block (s) and X Cl. 7.0

technique (s)
09 Direction and extent of scanning X Cl. 1.3& 11.2

10 Scanning (manual vs automatic) X Cl. 11.2a

11 Method for discriminating geometric X Cl. 12.1

from flaw indications

12 Method for sizing indications X Cl. 11.2d

13 Computer enhanced data acquisition, X Cl. 4.7

when used

14 Scan overlap (decrease only) X Cl. 11.1.1a

15 Personnel performance requirements, X Cl. 2.1

when required

16 Personnel Qualification Requirements X Cl. 3.0

17 Surface Condition (Examination X Cl. 7.1.5

surface, Calibration block)

18 Couplant : Brand name or type X Cl. 6.0

19 Automatic alarm and or recording X Cl. 4.6

equipment, when applicable

20 Records, including minimum X Cl. 14.0

calibration data to be recorded
(eg.Instrument setting)

FIG - 1
 Width = ¼ (6 mm) max. And Length = 3 x Thickness
Weld thickness (t) Calibration Block Hole Notch Dimensions
In. (mm) Thickness (T) Diameter In (mm)
In (mm.) In (mm)
Upto 1” (25) 3/4 (19) or t 3/32 (2.5) Notch Depth = 2% T
Over 1” (25) through 2” (50) 1 ½ (38) or t 1/8 (3.0) Notch Width = ¼ (6.0) max
Over 2” (50) through 4” 3 (75) or t 3/16 (5.0) Notch Length = 1 (25) min.
(100)
Over 4” (100) t+ 1 (25) (Note 1)
General Notes:
a) Holes shall be drilled and reamed 1.5 in (38 mm) deep minimum, essentially parallel to the examination surface.
b) For components equal to or less than 20 in.(500 mm) in diameter, calibration block diameter shall meet the
requirements of para 7.1.6 (b). Two sets of calibration reflectors (holes, notches) oriented 90 degree from each other
shall be used. Alternatively, two curved calibration blocks may be used.
c) The tolerance for hole diameter shall be + 1/32 in. (0.8 mm). The tolerance for the hole location through the
calibration block thickness (i.e. distance from the examination surface) shall be + 1/8 in (3.0 mm)
d) For block less than ¾ in. (19 mm) in thickness, only T/2 side drilled hole and surfaces notches are required.
e) All holes may be located on the same face (side) of the calibration block, provided care is exercised to locate all the
reflectors (holes, notches) to prevent one reflector from affecting the indication from another reflector during
calibration. Notches may be in the same plane as the inline holes (as in Figure J- 431 of Section V), sufficient
number of holes shall be provided for both angle and straight beam calibrations at T/4, T/2 and 3T/4 depths.
f) Notch depths shall be 1.6%T minimum to 2.2%T maximum. When cladding is present, notch depth on the cladding
side of the block shall be increased by the cladding thickness, CT (i.e., 1.6%T+CT minimum to 2.2%T+CT
maximum).
g) Maximum notch width is not critical. Notches may be made by EDM or with end mills up to ¼ in. (6.4 mm) in
diameter.
h) Weld thickness, t, is the nominal material thickness for welds without reinforcement or, for welds without
reinforcement, the nominal material thickness plus the estimated weld reinforcement not to exceed the maximum
permitted by the referencing Code Section. When two or more base material thicknesses are involved, the calibration
block thickness, T, shall be determined by the average thickness of the weld; alternatively, a calibration block based
on greater base material thickness may be used provided the reference reflector size is based upon the average weld
thickness.
NOTE:
1) For each increase in weld thickness of 2 in. (50 mm), or fraction thereof over 4 in. (100 mm), the hole
Checked & Approved By Checked & Approved By
MM ENVIRO PVTLTD. ( GPS RENEWABLES)