Corporate Partner ASNT NDT LEVEL II Specific Examination arAsstech ENGINEERS PRIVATE LIMITED (AN ISO 9001:2008 CERTIFIED COMPANY) Website: vrnw.armstechtraining.in E-mail: [email protected] Helpline: 9495923365|9846798904|8086678999ULTRASONIC WELD TESTING PROCEDURE 1.0 SCOPE This Ultrasonic Testing Procedure covers the Ultrasonic Testing of materials, welds, and fabricated components at Onshore and Offshore. 2.0 REFERENCES: Latest edition of the following documents shall be referred. ‘a, ASME Section V, 2010 Edition bb. QP Standard ES-S-60 . QP-STD-R- 002, Rev. 1 d. QP Standard ES-S-20 e. ASME B31. 3, 2008 Edition £, AWS D1.1, 2010 Edition 9. ASNT SNT-TC-1A, 2011 Edition hh. ANSI/ASNT CP-105, 2011 Edition 2.1 Acceptance Criteria a) ES.5.14.00 10 Table 6 b) ES-S'20 Table 8.8.1 ©) ASME B 31.3 ) ASME Section V 3.0 PERSONNEL 3.1 Qualification Personnel conducting Urasonic Testing shall be qualified to ASNT Level I as per SNT-TC-1A and PPI Written Practice. All personnel shall be examined for their vision acuity and have the approval of Customer before ‘Commencement of work. 3.2 Safety Personnel shall have the responsibility of safety to themselves and to others. They shall ensure that the lighting, Ventilation and scaffolding facilites at the work site dre adequate, before commencement of work. 4.0 EQUIPMENT AND MATERIALS 4.1 Flaw Detector The Ultrasonic Flaw Detector capable of operating in the pulse echo mode with A-scan display, KRAUTKRAMER USM 25 and USM 35with valid calibration shall be used. 4.2 Probes A range of probes covering but not limited to the following minimum requirements should be available. a) 2- 5 MHz, Standard and miniature size, single and twin crystal Compression Probes b) 2-4 MHz, Miniature, single and twin crystal Shear Wave Probes ot” 45°, 60 and 70° 4.3 Couplant ‘A suitably approved paste, poly cel, shall be used. 4.4 Calibration ‘The range of equipment shall be calibrated in accordance with requirements of applicable sections of AWS D1.1 for structural welds and ASME Section \ Article 5, T530 for ASME scope of welds and ES- $-60 for all applications. ¢4.5 Range Setting 2a) For straight beam testing, the range shall be set such that it encompasses at least two back wall echoes. b) For angle beam testing, the range shal be set to cover atleast 1.25 times the half beam path. €) The range shall be checked every time the machine is switched off or a change made in system parameters such as search unit change, test thickness change, operator change etc. if the machine is not switched off, it shall be checked at least once in 4 hours of operation. 4.6 Sensitivity Setting a) Primary Reference Level This is set on the basic calibration block with the response from the first reference reflector adjusted to 80% of the full screen height. Adjustment for variances in coupling conditions and or material characteristics shall be done by comparing echo responses on the calibration block with similar response from the test object. The correction required to compensate such variances is termed as transfer correction. 'b) Scanning Sensitivity The scanning shall be conducted at a sensitnity setting of at least 6 d8 gain setting greater than the primary reference level, including transfer correction. 4.7 Distance Amplitude Correction (DAC) Curve 2) ADAC Curve shall be generated for all the welds to be tested. The basic calibration shall be used for this purpose. Reflectors-selected for establishing the DAC curve includes those located at 7/4, T/2 and 3T/4 (where T represents the thickness of the block). The first point on the DAC is set by adjusting the response of the first reflector to 80% of the full secret height. Subsequent points are determined by plotting the response from other selected reflectors as applicable. A smooth curve is drawn through the plotted points to give the DAC curve. b) Electronic DAC curve generation is permitted provided itis verified on the basic calibration block. 4.8 Examination Coverage a) The entire volume to be tested shall be covered by moving the probe over the scanning surface. Each pass of the search unit shall overlap the previous pass by at least 10% of the transducer dimension perpendicular to the scanning direction. ) The scanning speed of the search unit shall not exceed 152 mm per second unless the calibration is verified at the scanning speed. 5.0 PERFORMANCE MONITORING CHECKS ON ULTRASONIC EQUIPMENT 5.1 Flaw Detector 5.1.1. The following equipment checks shall be carried out at the intervals specified below and recorded in a form for Performance check record for ultrasonic flaw detector (sample form attached). a) Time base calibration at every change of probes, of location, after each switching on of the instrument and every half hour. 'b) Time base linearity, screen height linearity to be checked prior to start of the job every day and amplifier linearity to be checked after 40 hours of operation, or once in a working week, whichever is the shortest period. 5.1.2 Guide lines for time based linearity check. {) Place a compression wave probe on 2 25 mm IIW Vi or 12.5 mm V2 calibration block to obtain a minim of five back wall echoes. Adjust the time base so that the first and the last back wall echo indication coincides with the appropriate scale marks, ) Bring successive back wall echoes in turn to approximately the same height (e.g. 80% FSH). ©) The leading edge of each echo should line up/break the time base line at the appropriate graticule line. Record any deviation from ideal position with respective echoes at 80% setting, d) Express the deviation from linearity as a percentage of the time base range between the first and the last back wall echoes displayed. ) Repeat using a range of 250 mm or over. Tolerance: Deviation up to and including + 2% are acceptable.5.2 Probes The results and dates of the probe performance tests as specified below shall be recorded in a form for Performance ‘check record for ultrasonic flaw detector (sample form attached) a) Every working shift or every 8 hours of operation whichever is shorter: Probe index (# 1 mm), Beam Angle (+ 2 degree change maximum), Beam width in vertical plane (+ 2 mm), Beam alignment - squint (with in 5 degrees) 'b) Every week or every 40 hours of operation, whichever is shorter: Resolution, Overall Gain ©) Complete beam profile shall be checked and re - drawn at least once in a working week or whenever a significant change of index, beam angle, squint or width indicates that it may be required. . Note: All tests shall be carried out with the noise suppression circuitry switched off. 6.0 EXAMINATION PROCEDURE 6.1 Surface Preparation Al surfaces shall be free of weld spatter, dirt, grease, oil, paint, loose scale and shall have 2 contour permitting intimate coupling, 6.2 Examination Examination shall be carried out in accordance with the applicable sections of AWS D1.1 for structural welds, ASME Section V for ASME scope of welds and ES-S-60 for all welds. Note: For difficult geometries, test limitations shall be fully noted in the report. 6.2 Examination Coverage a) The volume of the weld shall be examined by moving the search unit over the test surface ‘$0 as to scan the entire weld. A separate examination shall be carried out for the weld root. b) Scanning overiap shall be to 15% of the transducer width, ©) The 0’ degree parent metal scan shall cover a minimum distance equivalent to the maximum distance traverses during angle beam scanning of the weld. 4) Scanning speed shall be 152 mm per second maximum, 6.4 Preparation for Examination ‘The Ultrasonic operator shall make himself thoroughly familiar with the edge preparation geometry by reference to the specification and the construction/erection/fabrication and isometric drawings. 6.5 Techniques and extents of scanning a) Straight beam technique : ‘Ths technique is used for the thickness determination and for checking scanning areas for laminar or other detectable discontinuities, which could interfere with the ultrasonic beam whilst conducting angle beam scanning b) Angle beam technique This shall be used for all welds and other configurations to detect and evaluate discontinuities which are not parallel to the test surface. Extent of scanning includes all areas covering up to 1.5 times the beam full V path for the given thickness, The scanning direction shall be approximately perpendicular to the weld axis along the scanning surface. The search Unit shall be manipulated such that the ultrasonic energy passes through the required volumes of weld metal and adjacent parent material. The scanning shall be performed at a given setting at least twice the primary reference level ‘Angle beam scanning shall be done with the search unit being swiveled approximately +10° along the scan path to detect discontinuities which are otherwise unfavorably oriented. Angle beam scanning for reflectors oriented parallel to the weld, the angle beam shall be directed at approximately to the weld axis from two directions where possible, ‘The search unit shall be manipulated such that the ultrasonic energy passes the required volume of weld metal and adjacent parent material. The scanning shall be performed at again setting at least twice the primary reference level. .6.6 Ultrasonic Standards 2) Ultrasonic examination of Heavy Steel Forgings shall be carried out in accordance with ASTM A 338 /ASME SA 338 standard. b) Ultrasonic examination of Steel Plates shall be carried out in accordance with ASTM A 435 ASME SA 435 or ASTM A 577 / ASME SA 577 standard, ©) Utrasonic examination of Plain and Clad Stee! Plates shall be carried out in accordance vith ASTM A578 / ASME SA 578 standard, 4) Ultrasonic examination of Castings, Carbon low - alloy and martensitic Steel shall be carried out in accordance with ASTM A 609 / ASME SA 609 standard. €) Ultrasonic examination of Metal Pipe and Tubing shall be carried out in accordance with ASTM A 213 /ASME SA 213 standard. £) Ultrasonic examination of Longitudinal welded Pipe and Tubing shall be carried out in accordance with ASTM A 273 / ASME SA 273 standard. 4) Ultrasonic examination of Thickness measurement shall be caried out in accordance with ASTM A 787 / ASME SA 797 standard. 7.0 ULTRASONIC TEST TECHNIQUES Ultrasonic examination of weld shall be carried out in accordance with the following techniques: 1. Ultrasonic Test Technique 1 - Butt Welds Single Groove Preparation 2. Ultrasonic Test Technique 2 - Butt Welds Double Groove Preparation 3. Ultrasonic Test Technique 3 - T,K,¥ Complete Penetration 4. Ultrasonic Test Technique 4 - Tee Butt Welds Incomplete Penetration 5. Uitrasonic Test Technique § - Butt Welds Set through, including Nozzles 6. Ultrasonic Test Technique 6 - Butt Welds Set on, including Nozzles. CODES AND STANDARDS ‘SECTION VIII DIVISION 1 ASME B31.1 POWER PIPING ASME B31.3 PROCESS PIPING RECORDING INDICATIONS Non - Rejectable Indications 'Non - Rejectable indications shall be recorded as specified by the referencing Code Section. Rejectable Indications Rejectable indications shall be recorded. As a minimum, the type of indication (i.e. crack, lamination, inclusion, etc.) location and extent (ie., length) shall be recorded. ASME SECTION VIII, DIVISION 1 Acceptance and Rejection Standards Imperfection which produces a response greater than 20% of the reference level shall be investigated to the extent that the operator can identify the shape, size, location and evaluate them in terms of acceptance given below: 1. Indication characterized as crack, lack of fusion or incomplete penetration is unacceptable regardless of length.2 Other imperfections are unacceptable ifthe indication exceeds the reference level and have length, which exceed; 6 mm (1/4 in.) for t up to 19 mm (3/4 in.) 18 t for t from 19 mm to 57 mm (34 in. to 2 ¥e in.) 19 mm (3/4 i.) fort over 57 mm (2 % in.) Where tis the thickness of the weld excluding any allowable reinforcement. For butt welds joining two- members have different thickness at the weld, tis the thinner of these two thicknesses. IF a full penetration weld includes a fillet weld the thickness of the throat of the filet shall be indicated in t. ‘ASME B31.1 POWER PIPING ‘Acceptance standards ‘Welds that are shown by ultrasonic examination to have discontinuities which ( produce an indication greater than 20% of the reference level shall be investigated to the extent that ultrasonic examination personnel can determine their shape, identity and location so that they may evaluated each discontinuity for acceptance in accordance with B.1 ‘and B2 below- (6.1) discontinuities evaluated as being cracks, lack of fusion, or incomplete penetration are unacceptable regardless of their length. (B.2) other discontinuities are unacceptable if the indication exceeds the reference ( level and their length exceeds the following © B21 % in (6.0 mm) for t up to % in (19mm). © B22 1/3 t for from % in (19mm) to 2 % in (57 mm). * B23 % in (19 mm) for t over 2 % in (57 mm) Where t Is the thickness of the weld being examined g if the weld joins two members having different thicknesses at the weld, tis the thinner of these two thicknesses.ASNT NDT LEVEL IT ULTRASONIC WELD TESTING ‘SPECIFIC EXAMINATION QUESTION PAPER REFERANCE NO. AEPL/RI-S/01. 1. According to ASME section VIII, which of the following indication is unacceptable regardless of length? A. crack D. all of the above B. lack of fusion E. both A and C C. lack of penetration 2. To check lamination in 20 mm thick plate, what minimum range would be set in UT machine? A. 20 mm ¢. 60 mm 8.40 mm . 100 mm 3, According to the specification, the scanning speed of probe A. shall not be more than 100 mm/s . shall not be more than 500 mm/s B, shall not be more than 152 mm/s D. any of the above 4, Nominal frequency of the longitudinal wave probe shall be A.1-5 MHz C.1-2.25 MHz B.1-2MHz D.2-5 MHz 5. The procedure requires at least ___ of the overlap of the probe beam to ensure full coverage of the area, A. 2% ©. 10% 8.5% D. 20% 6. The tolerance for time based linearity of UT equipment shall be A. within 1% . within 5% B. within 29% D. within 10% 7. Which of the following statement is true’? ‘A the scanning shall be conducted at a sensitivity setting of at least 6 dB gain setting greater than the primary reference level, excluding transfer correction. B, the scanning shall be conducted at a sensitivity setting of at least 6 dB gain setting greater than the primary reference level, including transfer correction. . the scanning shall be conducted at a sensitivity setting of at least 12 dB gain setting greater than the primary reference level, including transfer correction. D. none of the above . For angle beam testing, the range shall be set to cover at least 1.25 times the half beam path. the range shall be set to cover at least 1.5 times the half beam path. the range shall be set to cover at least 1.75 times the half beam path. the range shall be set to cover at least 2 times the half beam path. ). Parental metal shall be the examined using: 0° probe . 60° probe 45° probe D. 70° probe10. In a plate, full skip distance can be calculated fro ingle of sound beam refraction, zm which of the following formula. (Where, t = plate thickness, © and v = sound velocity) A, S= (2 t/tan © 11. Which of the following ultrasor ‘A. Modsonic Einstein II TFT B. Krautkramer USM 25 . Olympus Epoch 600 42. UT shall be as per ASME BPVC SECTION V _ flaw detector shall 413. Which of the following shall be used for ti D.S=2vsin® E, none of the above I be used for testing as per this procedure? D. Krautkramer USM 35 E. both Bor D D. attide 5 . none of the above ime based linearity check? A IIW V1 BLOCK B, TIW V2 BLOCK 414. What is the maximum allowed angle vari D. both A&B E. all of the above jation for angle probes? A. +/- 1 degrees B, +/- 2 degrees 15, Resolution shall be checked B. before start of each shift 16. Applicable code for structural welds is 1B, ASME BPVC SECTION VIII 17. Swiveling of angle beam search unit while scanning A. +/- 10 degrees B, +/- 15 degrees 18, Imperfections which produce a signal greater than C. +/-3 degrees . no tolerance allowed for probe angle every 40 hours of operation. D. the shorter of A and C D. API 1104 E, none of the above shall be C. 41-5 degrees . no limit for swiveling __ of the reference level shall be investigated. D. 80% E. 100% ower piping inspection, An indication was identified as slag with a length of 14mm. The ‘the pipe is 40 mm. The indication is__? weld thickness of 20. Ultrasonic thickness measurement shall be carried C. rejectable D. irrelevant ‘out in accordance with _? C. ASTM A273 D. ASTM A737