Ultrasonic Testing of Weld Joints (Pe-Ut and Aut)

Reliance
Procedure For
Ultrasonic Testing of Weld Joints
(PE-UT and AUT)
EPCMD-2-QM00-JEP-ME-031
01
05.05.2014
Issued for Implementation
ASR
PKD
SNS
00
31.08.2012
Issued for Implementation
PKD
KSS / EMK
SNS
Rev
Date
Revision
Prepared
By
Checked
By
Approved
By
Reliance
Contents
1. Purpose ...3
2. Scope .3
3. References .3
4. Abbreviations and Terms ....3
5. Responsibilities ..4
6. Methodology .4
7. Records
....14
The following technique sheets shall be used for PEUT.

Technique sheet 1 - Pipe to pipe joint equal thickness
Technique sheet 2 Pipe to fittings/ Pipe to pipe joint unequal thickness
Technique sheet 3 Set on nozzle
Technique sheet 4 Set in nozzle
Technique sheet 5 Tangential nozzle
Technique sheet 6 Dollar plate nozzle
Technique sheet 7 Set in through nozzle
ASME Section VIII Div-1 Appendix 12
EPCMD-2-QM00-JEP-ME-031, Rev:01
Confidential Reliance. All rights reserved
Page 2 of 22
Reliance
1.
Purpose
The purpose of this document is to provide the guide lines for the Ultrasonic Testing
of the pipe weld using conventional manual pulse echo and automated phase array.
2.
Scope
The scope of this procedure covers the Ultrasonic testing of
i.
Nozzle branch weld joints of equipment by PE-UT

Nozzles from 2 NB and above (including Set-In and Set-On type), where shell
thickness of the vessel / column is sufficient for testing.
ii.
iii
Butt welds of pipes By PE-UT

a.
Pipe welds of size 2 NB and above
b.
Pipe thickness from 5.4 mm and above.
Butt welds of pipes By PA-UT

a.
Pipe welds of size 8 NB and above
b.
Pipe thickness from 6 mm and above
This procedure may be used for the testing of the weld joints in on line service
having liquid / gases in the pipe line and is applicable for CS, AS and SS material
for all the jobs in Reliance Projects.
3.
References
ASME Sec VIII Div. I
Rules for Construction of Pressure Vessel
ASME B31.3
Process Piping
ASME B31.1
Power Piping
ASME Sec. V
Non-destructive Examination
Code Case 2235-9
Use of UT in Lieu of Radiography
CEN/TS 14751
Use of TOFD for examination of weld
EPCMD-2-QM00-GUI-ME-002
Guidelines for Surface Preparation for UT.
EPCMD-2-QM00-TCR-ME-007
Technical Requirement for UT Services
EPCMD-2-QM00-FMT-ME-025
Format for PE Ultrasonic Testing Report
EPCMD-2-QM00-FMT-ME-231. Format for MUT/AUT scan plan
4.
Abbreviations and Terms

ASME
American Society of Mechanical Engineers
AUT
Automated Ultrasonic Testing
DAC
Distance Amplitude Curve
dB
Decibel
DTA
Domestic Tariff Area
HAZ
Heat Affected Zone
HOD
Head of the Department
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Reliance
IIW
International Institute of Welding
JERP
Jamnagar Export Refinery Project
MUT
Manual Ultrasonic Testing
NDT
Non Destructive Testing
PE UT
Pulse Echo Ultrasonic Testing
PA UT
Phased Array Ultrasonic testing
QMD
Quality Management Department
SNT-TC-1A
Society of Non-destructive Testing
TCG
Time Corrected Gain
TR
Transmitter and Receiver
TOFD
5.
Time of Flight Diffraction Technique
UFD
Ultrasonic Flaw Detector
UT
Ultrasonic Testing
Responsibilities
Construction Managers/Engineer in Charges is responsible for implementing this

procedure in their area.
HOD, QMD is responsible for maintaining this procedure.
DCC is the custodian of this document.
6.
Methodology
6.1
UT Equipment and Its Accessories ( PE-UT )
6.1.1
Equipment: Ultrasonic Flaw Detector (UFD)

Any ultrasonic flaw detector capable of operating in the pulse-echo mode having
DAC facility and minimum 100 memories with recording facility shall be used.
The instrument shall be capable of operation at frequencies at the range of 1 MHz
to 5 MHz and shall be equipped with a stepped gain control in steps of 1.0 dB or
less. The time base must be linear within approx. 1% of full screen width over the
maximum calibrated range used. The screen height amplitude control linearity shall
be verified. The ultrasonic flaw detector shall have valid calibration status.
Equipment shall be calibrated for vertical and horizontal linearity etc. on IIW V1 and
V2 blocks as per AppendixI and II of Article - 4 of ASME Sec-V.
The UFD shall be selected from the following manufacturer.
Panamatrics
Kraut Kramer
Sonatest
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Reliance
Omniscan
The use of any other models of UFDs, than the recommended as above, shall have
prior approval from engineer-in-charge.
6.1.2
Probes
Probes used with UFD shall be selected from the following manufacturers,
6.1.3
Panamatrics
Kraut Kramer
Sonatest
The probe details are as follows,

For straight beam inspection, TR (Transmitter and Receiver) probes having 5 mm to
10 mm crystal diameter with frequency of 2 to 5 MHz shall be used. Normal probe
can also be used for straight beam inspection, provided the thickness of the job is
more than 20 mm.
For angle beam inspection, normal beam probes (5 mm dia. crystal) mounted on
Contour shoe or probes having 8 X 9 mm crystal size, of different angles shall be
used.
Probe/Shoe
Selection of angle/shoes
Pipe
Dia
Probe Size
Parallel to weld
axis
Circumferential
to weld axis
2"
5-8 mm
45,70,(shoe)
45 (shoe)
5-8 mm
3"
5-8 mm
45,70,(shoe)
45 (shoe)
5-8 mm
4"
5-8 mm
45,70,(shoe)
45 (shoe)
5-8 and mm
6"
89 and
5mm
45,70
89mm
Flat shoe 45,
5-8 and 10 mm
> 8"
89mm
45,60/70
89mm
89mm
10 mm
TR
Probe
For set on nozzle, the above table shall be followed.

For set in nozzle, the scanning shall be carried out by 8 X 9 mm crystal size probes.
6.1.4
Couplant
The couplant shall be a manufactured gel product, oil or cellulose paste or other
suitable medium (oil and grease mixture ) which is non toxic and non corrosive. The
couplant must be removed after examination by means of wiping with a cloth with
the help of solvent / detergent.
6.1.5
Standard Blocks
6.1.5.1
For piping job the basic calibration block shall be a section of pipe of same nominal
size, schedule, heat treated, equivalent P number material (as per clause T-434. of
ASME Sec. V).
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Notches shall be prepared on outer as well as on inner surface of the pipe as
specified in fig. T 434.3 of ASME Sec. V. DAC shall be drawn with 3 points.
6.1.5.2
6.1.6
For non piping job, (above 20 diameter non piping welds), the
reference block
shall be used from the same job or a flat basic calibration block as per clause
T - 434.1.7.1. The reference block for non piping welds having diameter equal to
or less than 20dia., shall have curved calibration block and shall be used to scan
the jobs having curvature at the range of 0.9 to 1.5 times the basic calibration
blocks diameter. Non piping calibration blocks shall be as per T- 434.2 and cladding
calibration blocks as per T- 434.4.
UFD Operator
All the technicians shall under go a selection test and qualify the same prior to the
deployment on the job as per Procedure for the selection of UT technicians.
(EPCMD-2-QM00-JEP-ME-038).
6.1.7
Inspection / Scanning Method
6.1.7.1
Preparation of Job Surface

The base metal on either side of the weld shall be free from weld spatter, surface
irregularities, or foreign matter that might interfere with the weld examination. The
weld surface under examination shall be prepared to a smooth profile with a section
flat at the top of weld to enable good contact with probe to permit examination for
pipe sizes 10 inch and below. For pipe sizes 12 Inch dia and above no grinding is to
be carried out to make weld joint flat at top.
In case of spiral and longitudinal weld joints, the top surface as well as protrusion
of of weld shall be flushed and both the sides of the weld joint shall be ground to
smooth surface (150 mm length) for the examination. The surface for UT shall be
prepared as per
EPCMD-2-QM00-GUI-ME-002 Guideline for surface
preparation for Ultrasonic Testing.
6.1.7.2
When both sides scanning is not possible, then in that case, at least one side
scanning shall be carried out.
6.1.7.3
For identification of weld joints the optical letter V to be punched on the base
metal at 12 o clock position turning 90 degree (symbolic shown as > ) on the top
of the weld joint and shall be considered as the reference point ( >) or zero point.
All the recordable indications (print outs) shall be given with reference to zero point
in the UT report. Punching and marking on the weld joint shall be done by the NDT
Contractor. Reference points shall be hard punched on CS and AS joints and SS
joints shall be marked with permanent marker.
6.1.7.4
Surface temperatures shall not exceed 50C / subject to couplant and probe service
condition.
6.1.8
DAC Preparation.
6.1.8.1
DAC shall be prepared by using angle probes, taking into consideration the probe
index and the weld edge distance. First point at 80% FSH 5% shall be
established other two points shall be drawn based on the reference block (SDH or
notch).
6.1.8.2
DAC for longitudinal weld scanning shall be made from circumferential notch with
45 and 70 angle probes to detect defect parallel to weld axis. From longitudinal
notch, DAC is to be made from 45 angle probe to detect defect transverse to weld
axis.
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6.1.8.3
Every NDE contractor shall establish the DAC on the standard reference block for
his scope of job and get it approved by authorized representative of Reliance before
starting examination on the actual job. Reliance NDT Coordinator shall maintain a
latest list of standard reference block.
6.1.9
Time base calibration range
6.1.9.1
Angle probe: Calibration range shall be selected as per the job requirement.
6.1.9.2
TR or normal probe: Calibration range shall be selected as per the job requirement.
6.1.10
Sensitivity
6.1.10.1
TR Probe: 1st Back Wall Echo to 80% of FSH
6.1.10.2
Angle probe: First point of DAC shall be set to 80 % of FSH.
6.1.10.3
Scan Plan: Before actual scanning, scan plan shall be developed by the operator
and shall be approved by Reliance Engineer. The scan plan data shall be recorded in
Form: EPCMD-2-QM00-FMT-ME-231.
6.1.11
Examination: The weld joints shall be examined as follows,
6.1.11.1
TR probe: Before performing the angle beam examination, a straight beam

examination shall be performed on the volume of base material through which the
angle beam will travel to locate any reflectors that can limit the ability of the angle
beam to examine the weld volume.
Both side of the weld joint (up to two skip of the max probe angle to be used) and
top weld shall be scanned with TR probes to identify any reflectors which may
interfere during angle beam scanning. Scanning shall be carried out in zigzag and
weaving motion to ensure the compete coverage of the surface.
6.1.11.2
Angle beam probe: (To detect defect parallel to weld axis): All
welds
shall
be
scanned with two different angle beam probes. Angle of the probe is selected based
on the actual job thickness by preparing the weld geometry drawing and the
scanning location /areas. One angle probe is 450 and other angle is selected based
on the base material thickness (90-t, where t is the thickness of the pipe). However
for thickness <15 mm, 70 angle probe shall be used.
6.1.11.3
Angle beam probe (To detect defect transverse to weld axis): Scanning shall be
carried out from the top of the weld reinforcement for the pipes having sizes 10
Inch or less (ground flat to ensure the proper contact) parallel to weld axis. The
probes shall be moved throughout the pipe circumference in such a way that the
entire volume of the weld is covered. Scanning shall be done clockwise and shall be
repeated in anticlockwise direction. Only 45 angle probe shall be used for this
purpose.
For pipe of sizes 12 Inch dia or more, angle beam scanning to detect defect
transverse to weld axis, the examination shall be performed from the base metal on
both side of the weld cap in both weld axis direction, if the weld cap is not
machined or ground flat, with the help of a scanner where two 45 degree miniature
probes are used. One probe used as transmitter and other probe is used as
receiver.
6.1.12
Scanning overlap
Each fresh scan shall have an overlap of 10% of the crystal size over the previous
Scan.
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6.1.13
Scanning speed
The probes shall be moved throughout the pipe circumference at a suitable
speed but not more than 150 mm / Sec.
6.1.14
Scanning Sensitivity
6.1.14.1
Angle probe: Ref. dB of DAC + 14dB as per Article T- 481 of ASME Sec V or as
per the job requirement.
6.1.14.2
TR and normal probe: Ref. dB for 80 % BWE + 6dB.
6.1.15
Evaluation
6.1.15.1
Evaluation shall be done at reference level.
6.1.15.2
In case of TR and Normal probe, the indications longer than 40 % of the

reference level shall be investigated to extent that they can be evaluated.
6.1.15.3
In case of angle probe, all indications equal to or in excess of 20% of the primary
reference level shall be investigated in order to determine their shape, size, identity
and location.
6.1.15.4
In case of angle probe, any imperfection which produce a response above 50% of
reference level shall be recorded from the uncorrected area with reference from
the reference point marked on the joint.
6.1.15.5
All indications detected with one probe shall be further evaluated using appropriate
combination of probe angle (from other side of the weld joint) so that length,
depth and orientation can be accurately determined and the type of discontinuity
can be established.
6.1.15.6
All discontinuity shall be sized using 6 dB drop method.
6.1.15.7
Where ever the indications exceeds the acceptance standard , graph to be plotted
based on probe location to determine shape, size, identity and location of the
defect. Interpretation shall be carried out at reference sensitivity level (dB).
6.2
AUT Equipment and Its Accessories (AUT)
6.2.1
Operator Qualification
All the technicians shall under go a selection test and qualify the same prior to
the deployment on the job as per Procedure for the selection of UT technicians.
(EPCMD-2-QM00-JEP-ME-038).
6.2.2
Ultrasonic Phased Array Instrument
6.2.2.1
The ultrasonic Phased Array instrument shall be pulse echo type and shall be
equipped with a calibrated dB gain or attenuation control stepped in increments of
1dB or less. The system shall be capable of generating and displaying linear scan
and sector scan images, which can be digitally stored and recalled for subsequent
review.
6.2.2.2
The instrument shall be capable of operation at frequencies over the range of

1 MHz to 15 MHz .The phased array system shall provide a variety of analysis
capabilities including. A scan display and parameters read out associated with
software courser along with images produced by B, C, D and Sectorial scan.
6.2.2.3
Examination Personnel shall use a real-time linear and or sector scan image with
B / C / D / Sectorial scan presentation during scanning to ensure that proper data
has been collected.
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6.2.2.4
The Phased Array system shall be capable of using an external storage device.
A remote portable PC may be used for this purpose.
6.2.2.5
In addition to external data storage, the PC shall also be used by the Data analysis
personnel for analyzing data subsequent to the completion of data collection.
6.2.2.6
Instruments screen height linearity and amplitude control linearity shall be

verified as per AppendixI and II of Article - 4 of ASME Sec-V.
6.2.2.7
Any control, which affects the instrument linearity (e.g. Reject) shall be in the off or
minimum position during instrument calibration, system calibration and
examination.
6.2.3
Probe Selection
Phased Array Probe configuration shall be suitable for the inspection of the job.
Phased Array Probe frequency shall be either 1 to 5 MHz or as per the job
requirements.
6.2.4
Couplant
Water, Glycerin or Cellulosic gel equivalent oil grease mixture may be used as
couplant when performing calibration and examinations. Water pump may be used
if required.
6.2.5
Standard Block
The calibration block shall be prepared as per ASME Sec V Fig T-434.2.1 and
T-434.3. IIW Blocks shall be used for time base calibrations. Multiple reference
blocks for calibration may also be used as per the requirements of AUT system.
6.2.6
Phased Array System Calibration
6.2.6.1
Calibration shall be performed from the surface of the calibration block which
corresponds to the component surface to be examined.
6.2.6.2
System calibration shall include the complete ultrasonic examination system. Time
base calibration shall be suitable for the beam paths which will be used during the
examination, unless otherwise specified.
6.2.6.3
The calibration information shall be recorded on the Ultrasonic Calibration system.

During scanning, only reference sensitivity and scan sensitivity gain may be
adjusted during examination. Adjustment of other controls shall require
recalibration.
6.2.6.4
Calibration of computer imaging shall be conducted in such a manner that gain

levels are optimized for data acquisition and imaging purpose and also to establish
scanning and or flaw detection / sizing sensitivity level.
6.2.7
Focal Law Verification
6.2.7.1
Verification that the input information is correct and that the phased array system
is working properly shall be checked as follows.
6.2.7.2
Select the Angle Cursor and adjust its position so that is displays A-scan
information for the 450 angle of refraction or the minimum angle that will be used
in the Sector Scan.
6.2.7.3
Using the 4-inch (100 mm) radius of the IIW block, peak the signal shown
A-scan display.
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on the
Reliance
Note: Although the sector scan may indicate different amplitude responses form
other angles. Only use the A-scan response associated with the 450 angle or
minimum angle used for propagation.
6.2.7.4
Mark the beam exit point, on the transducer wedge. This beam exit location is only
valid for the particular angle of propagation.
6.2.7.5
Using the primary angle of beam exit locator, measure the actual angle of
propagation by peaking the response in the A scan display using the plexi-glass
insert as indicated on the IIW block using the beam exit point location.
6.2.8
Time Based Verification
6.2.8.1
Position the Angle cursor and adjust its position so that it displays A-scan
information for the angle, used for refraction.
6.2.8.2
Place the transducer so that reflections from 2 inch (50mm) and 4-inch (100mm)
radius reflectors on the IIW block are peaked and observed individually on the
A-scan display.
6.2.8.3
Using the A-scan Cursors, measure the distance between the 2 and 4-inch signals
markings. This result shall be 2 0.1 inches.
6.2.8.4
If the measured separation between the signals is too large (grater than 2.1 inch)
decrease the Shear Velocity parameter under the Part Setup Menu. Similarly, if the
measured distance is too short (less than 1.9 inch), increase the velocity value.
Repeat adjustment until an acceptable value is achieved.
6.2.8.5
With the transducer remaining in the peaked position, measure the beam path of
the four-inch radius reflector using a cursor in the A-scan display.
6.2.8.6
The value should measure to be 4 0.1 inches. If this measurement is less than
3.9 inches, increase the value of the Delay parameter until the measurement is
correct. If this value is grater than 4.1 inch, decrease the Delay parameter until the
measurement is correct.
6.2.9
Sensitivity and Wedge Delay Calibration
6.2.9.1
The Phased array instrument shall be calibrated for Sensitivity and Wedge Delay as
per the requirements.
6.2.9.2
The Sensitivity Calibration will provide the required gain adjustment for each
refracted angle and sound path used.
6.2.9.3
Select a calibration reflector within the zone of material to be examined.
6.2.9.4
Peak up this signal from the calibration reflector and scan by the phased array
probe through all the different angles or focal laws.
6.2.9.5
Scan back over the calibration reflector through all the refracted angles or
laws.
6.2.9.6
The phased array system will calculate the required gain needed at each focal law
to adjust the required amplitude needed.
6.2.9.7
The Wedge Delay Calibration shall be calibrated for True Depth for the reflector
with the angles used in calibration.
6.2.10
Preparation of DAC / TCG
focal
A Distance Amplitude Correction (DAC) Curve or a Time Corrected Gain (TCG) shall
be used to calibrate for attenuation in the material at the sound paths utilized
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during calibration
documented.
6.2.11
and
examination.
This
shall
be
digitally
recorded
and
Storage of System Calibration

Ultrasonic System Calibration shall be checked prior to the start of examination.
6.2.12
System Calibration Verification
6.2.12.1
Sweep range and DAC / TCG

calibration shall be verified on the appropriate
calibration block or simulator block, as applicable under the various conditions.
6.2.12.2
With any substitution of power utilized the same type of source (e.g. a change
batteries).
6.2.12.3
Whenever the validity of the calibration is in doubt.
6.2.13
System Calibration Changes
6.2.13.1
Perform the following if any point of the DAC curve has decreased 20% or 2 dB of
its amplitude, or any point on the sweep line has moved more than 10% of the
sweep division reading.
6.2.13.2
Void all examinations performed after the last valid calibration verification.
6.2.13.3
Conduct a new system calibration if required.
6.2.13.4
Repeat all void examinations.
6.2.13.5
Perform the following if any point on the DAC curve has increased more than 20%
or 2 dB of its amplitude.
6.2.13.6
Correct the existing system calibration if required.
6.2.14
Recalibration
6.2.14.1
Any of the following conditions shall be caused for system recalibration.
6.2.14.2
Search unit transducer change.
6.2.14.3
Ultrasonic accessories change.
6.2.14.4
Couplant change.
6.2.15
Preparation of Scanning Surface
6.2.15.1
Scanning surface should be free from weld spatter, foreign materials and any
irregularities that would interfere with the free movement of the search unit.
of
The weld surface under examination shall be prepared to a smooth profile with a
section flat at the top of weld to enable good contact with probe to permit
examination.
receiver.
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In case of spiral and longitudinal weld joints, the top surface as well as protrusion
of weld shall be flushed and both the sides of the weld joint shall be ground to
smooth surface (150 mm (length ) for the examination.
6.2.15.2
Surface temperature shall not exceed 500 C / subject to couplant and probe service
temperature.
6.2.15.3
Surface preparation shall be as per EPCMD-2-QM00-GUI-ME-002, Guidelines for

surface preparation for ultrasonic testing.
6.2.16
Examination Coverage and Scanning Technique
6.2.16.1
Before actual scanning, scan plan shall be developed by the operator and shall be
approved by Reliance Engineer. The scan plan data shall be recorded in Form:
EPCMD-2-QM00-FMT-ME-231.
6.2.16.2
The specific of the weld volume, weld identification and location shall be identified.
6.2.16.3
The examination volume shall the weld metal and 1 inch from the toe of the weld
both sides. This area includes the heat-affected zone.
6.2.16.4
To determine the required examination volume and scan

taken for each weld.
6.2.16.5
Scanning shall be performed using a Linear or sectorial Scan Technique. Each

Linear scan shall be parallel to the weld using a Sector Phased Array Scan or
Electronic Scan.
6.2.16.6
Two linear scans shall be performed from the center of the weld from both sides if
required to ensure the weld and HAZ coverage. In case of pipe to fitting joint, two
scan shall be carried out from one side.
6.2.16.7
For thicker materials, multiple liner scans shall be performed to the degree to cover
the required volume of weld and base metal.
6.2.16.8
Scans shall be parallel to the weld using the linear scans both side of the weld axis.
6.2.16.9
The rate of search unit movement shall be limited to a maximum of 3 inches per
second for welds unless calibration has been verified at a higher speed.
area, profiles may be
6.2.16.10 Perform the examination from both sides of the weld, where practical, or from one
side as a minimum.
6.2.16.11 To detect the defects transverse to weld axis, scanning shall be carried out from the
top of the weld reinforcement (ground flat to ensure the proper contact) parallel to
weld axis. The probes shall be moved throughout the pipe circumference in such a
way that the entire volume of the weld is covered. Scanning shall be done clockwise
and shall be repeated in anticlockwise direction. Only 45 angle probe shall be used
for this purpose.
receiver.
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6.2.17
Evaluation
6.2.17.1
Flaw Signal amplitude shall be measured as a percentage of DAC or TCG by

adjusting gain (dB) control or by color code related to amplitude (White up to 20%,
Blue 20-50%, Yellow 50-65%, Orange 65-80%, Red above 80%) on, B, C or S
scan display.
6.2.17.2
Flow sizing shall be performed by 6 dB drop method or by information given by

A, B, C and S scan display using calibrated encoder.
6.2.17.3
Flow location shall be measured by using information given by A, B, C and S scan

display. Evaluation shall be done as per datum marking.
6.2.17.4
All indication equal to or in excess of 20% of the reference level shall

investigated in order to determine their shape, size, identity and location.
6.2.17.5
Any imperfection producing a response above 50% of reference level shall be

recorded in the data / report from uncorrected area.
6.2.17.6
If any imperfection produces a response above reference level, length of that

imperfection shall be measured and evaluated as pre ASME Sec VIII Div. 1,
Appendix 12.
6.2.18.
Examination Record
be
Computerized image technique shall have the following data / information recorded
in the system.
6.2.18.1
Computerized program identification and revision if any.
6.2.18.2
Equipment details and
6.2.18.3
Details of Transducers and wedges used.
6.2.18.4
Mode and modes of wave propagation used in different setting.
6.2.18.5
Calibration blocks identification.
6.2.18.6
SDH dia. / Notch details and orientation (longitudinal or circumferential) in

calibration blocks.
6.2.18.7
Validation blocks details.
6.2.18.8
Instrument setting and scanning data.
6.2.18.9
Calibration data.
Serial no.
6.2.18.10 Identification of the job with details.

6.2.18.11 Surface from which job was conducted including surface condition.
6.2.18.12 Evaluation record of the indications detected and their locations.
6.2.18.13 Area of restricted access or inaccessible areas.
6.2.18.14 Examination personnel identity and qualification level.
6.2.18.15 Test results.
6.2.18.16 Date and Time of examination.
6.3
Acceptance Criteria
Acceptance criteria for nozzle welds and piping welds shall be as per:
ASME Sec VIII Div. I. Appendix 12.
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6.4
Evaluation of Repair welds

Wherever weld repairs have been carried, the repaired area shall be ultrasonically
examined by the same procedure followed during original weld examination.
6.5
Post cleaning
Couplant (grease / oil) applied to weld joint for ultrasonic examination shall be
cleaned properly after completion of the examination by respective NDT agencies.
The couplant must be removed after examination by means of wiping with a cloth
and with the help of solvent / detergent.
7.
Record
7.1
UFD Print out of indication / reports and or graph plotting to be attached along
with the test report for repair. The report shall be in the form of data in the soft
form or hard copy as per the requirements.
7.2
Any obstruction of scanning coverage or not accessibility for scanning shall be

recorded in report Form: EPCMD-2-QM00-FMT-ME-025 / approved format of NDE
agency.
Page 14 of 22
Reliance
PE-UT Technique Sheet No. 1
Weld joint
: Pipe to pipe joint of equal thickness.

(Circumferential / Longitudinal / Spiral weld joints)
Fit up data
: Datum mark on (pipes) both side of the weld.
Surface preparation
: Weld top shall be ground flat.
Diameter
: 2 inch NB and above
Detail of Probe and shoes : As given in the following table

Frequency
: 4 MHz for CS/AS up to 25 mm thk. and

2 MHz above 25 mm thk. 2 MHz for SS
Probe/Shoe
Angle of probe/shoe
Pipe Dia
Probe Size
Parallel to weld
axis
Circumferential
to weld axis
TR
Probe
2"
3"
5-8 mm
5-8 mm
45,70, (shoe)
45, 70, (shoe)
45 (shoe)
45 (shoe)
5-8 mm
5-8 mm
4"
5-8 mm
45, 70, (shoe)
45 (shoe)
5-8 mm
6"
89 and
5 mm
Flat shoe 45,
5-8 and
10 mm
> 8"
89 mm
45, 70
89 mm
45, 60/70
89 mm
89 mm
10 mm
Scanning technique
(a)
TR probe scanning shall be carried on the area where angle beam scanning is to be
carried out. The both side of the weld joint (up to two skip of the max angle probe to
be used) and top weld shall be scanned with TR probes to identify any reflectors
which may interfere during angle beam scanning.
(b)
Angle beam Scanning(to detect defect parallel to weld axis) to be carried from both
side of the weld side from to 1 skip distance or 1 to 2 skip distance depending
upon the requirement .
(c)
Angle beam Scanning (to detect defect transverse to weld axis) to be carried out as
detailed in clause no. 6.1.11.3 of this procedure.
Note: DAC range to be verified with by 1:1 graph plotting.
Page 15 of 22
Reliance
Weld joint Type
: (1). Pipe to fitting and, (2). pipe of unequal thickness joint.
Fit up data
: For Type (1). Datum mark on pipe

For Type (2). Datum mark on (pipes) both side of the weld.
Surface preparation : Weld top shall be ground flat.

Diameter
Probe and shoes
: As given in the following table
Frequency

Pipe
Dia
Probe
Size
58mm
58mm
58mm
89 and
5mm
2"
3"
4"
6"
> 8"
Probe/Shoe
Angle of probe/shoe
TR
Probe
Parallel to weld
axis
Circumferential
to weld axis
45,70,(shoe)
45 (shoe)
5-8 mm
45,70,(shoe)
45 (shoe)
5-8 mm
45,70,(shoe)
45 (shoe)
5-8 mm
45,70 89mm
Flat shoe 45,
5-8 and 10 mm
45,60/70
89mm
89mm
10 mm
89mm
Scanning technique
(a) TR probe scanning shall be carried out on one side of the joint on the area where
angle beam scanning is to be carried out.. The scanning to be carried on the
surface ( up to two skip of the max probe angle ) to be used, top weld and heat
effected zone of the fitting side to identify any reflectors which may interfere
during angle beam scanning from
(1) Pipe side in case of pipe to fitting joint
(2) Pipe with lower thickness in case of pipe to pipe joint of unequal thickness
(b)
(c)
(d)
Angle beam scanning (to detect defect parallel to weld axis) to be carried out from
HAZ of fitting side to other side of weld up to 1 skip distance or 1 to 2 skip
distance depending on the requirement.
Angle beam Scanning (to detect defect transverse to weld axis) to be carried from
top of the weld as detailed in clause no. 6.1.11.3 of this procedure.
Scanning shall not be done from the thicker pipe or fitting side where inside
tapering has been carried out.

Page 16 of 22
Reliance
Weld joint
: Set-On nozzle
Fit up data
: Datum mark on Nozzle side
Thickness
: 5.4 mm and above
Surface preparation
: Welds shall be ground flat.
Diameter
Probe and shoe
: As given in the following table
Frequency

Pipe Dia
2"
3"
4"
6"
> 8"
Probe
Size
5-8mm
5-8mm
5-8mm
89 and
5mm
89mm
Probe/Shoe
Angle of probe/shoe
Parallel to weld
axis
Circumferential
to weld axis
45,70,(shoe)
45,70,(shoe)
45,70,(shoe)
45 (shoe)
45 (shoe)
45 (shoe)
45,70 89mm
Flat shoe 45,
45,60/70
89mm
89mm
TR
Probe
5-8 mm
5-8 mm
5-8 mm
5-8 and 10
mm
10 mm
Scanning technique
(a) TR probe scanning to be carried out on branch nozzle to identify any reflectors
which may interfere during angle beam scanning. In addition to that, TR probes
scanning to be carried out from equipment in side on the weld joint wherever
possible.
(b) Angle beam scanning (to detect defect parallel to weld axis) to be carried out with
two angle beam probes from to 2 skip distance based on the requirement
of the branch nozzle...
(c) Angle beam Scanning (to detect defect transverse to weld axis) to be carried
from top of the weld as clause no. 6.1.11.3 of this procedure.

Page 17 of 22
Reliance
Weld joint
: Set-In nozzle
Fit up data
: Datum mark on shell side.
Surface preparation : Weld shall be ground flat.

Thickness
: 9 mm and above
Dia. of the nozzle
Probe
: TR probe -10 / 5 - 8 mm crystal dia.

Normal probe 5-8 mm crystal dia.
Angle beam probe 45and 60/ 70.
Frequency

Scanning technique
(a) TR probe scanning from nozzle inside and from shell inside/outside on the weld to
cover entire weld volume. Also on shell side up to datum marking to identify any
reflectors which may interfere during angle beam scanning.
(b) Angle beam scanning (to detect defect parallel to weld axis) to be carried out
from shell inside or out side from skip distance to 1 skip distance as per
datum marking.
(c) Angle beam scanning (to detect defect transverse to weld axis) to be carried from
Page 18 of 22
Reliance
Weld joint
Fit up data
Tangential nozzle
Datum mark on shell side .
Surface preparation :
Weld shall be ground flat.
Thickness
9 mm and above
Dia of the nozzle
2 inch NB and above
Probe
TR probe 10/5-8 mm Dia,

Normal probe 5-8 mm Dia
Frequency
4 MHz. For CS and AS up to 25 mm thk and

Scanning technique
(a) TR probe scanning from nozzle inside and from shell inside/outside on the weld to
cover entire weld volume. Also on shell side up to datum marking to identify any
reflectors which may interfere during angle beam scanning.
(b) Angle beam scanning (to detect defect parallel to weld axis) to be carried out either
from shell inside or out side from skip distance to 3 skip distance based on
the requirements to cover the total weld volume and as per datum marking.
top of the weld as detailed in clause no. 6.1.11.3
of this procedure.
Note: DAC range to be verified with 1:1 graph plotting.
Page 19 of 22
Reliance
Weld joint
Dollar plate type nozzle
Fit up data
Datum mark on shell side .
Thickness
9mm and above
Dia of the nozzle
2 inch NB and above
Probe
TR probe 10 /5-8 mm crystal Dia,

Normal probe 5-8 mm crystal Dia
Frequency

Scanning technique
(a) TR probe scanning from Dollar plate nozzle up to the weld and from shell inside or
outside, top of the weld and heat effected zone to cover entire weld volume to
identify any reflectors which may interfere during angle beam scanning.
(b) Angle beam scanning (to detect defect parallel to weld axis) to be carried out
either from shell inside or out side from skip distance to 1 skip distance as per
requirement.
top of the weld as detailed in clause no. 6.1.11.3
of this procedure.
Page 20 of 22
Reliance
Weld joint
Set in through nozzle
Fit up data
Datum mark on shell side
Thickness
9mm and above
Dia of the nozzle
2 inch NB and above
Probe
TR probe 10/5-8 mm crystal Dia,

Normal probe 5-8 mm crystal Dia
Angle beam probe 45 and 60/ 70.
Frequency

2 MHz above 25 mm thk. 2 MHz fo SS
Scanning technique:
(a) TR probe scanning from nozzle inside to cover entire weld volume. Also from shell
inside or outside up to datum marking to identify any reflectors which may
interfere during angle beam scanning.
(b) Angle beam scanning (to detect defect parallel to weld axis) to be carried out at
right angle to the weld axis on shell side with two angle beam probes from to 1
skip distance based on the requirement.
(c) Angle beam Scanning ( to detect defect transverse to weld axis) to be carried from
Page 21 of 22
Reliance
Page 22 of 22

Ultrasonic Testing of Weld Joints (Pe-Ut and Aut)

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Ultrasonic Testing of Weld Joints (Pe-Ut and Aut)

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Reliance

Issued for Implementation

Issued for Implementation

The following technique sheets shall be used for PEUT.

Nozzle branch weld joints of equipment by PE-UT

Butt welds of pipes By PE-UT

Pipe welds of size 2 NB and above

Pipe thickness from 5.4 mm and above.

Butt welds of pipes By PA-UT

Pipe welds of size 8 NB and above

Pipe thickness from 6 mm and above

Rules for Construction of Pressure Vessel

Code Case 2235-9

Use of UT in Lieu of Radiography

Use of TOFD for examination of weld

Guidelines for Surface Preparation for UT.

Technical Requirement for UT Services

Format for PE Ultrasonic Testing Report

EPCMD-2-QM00-FMT-ME-231. Format for MUT/AUT scan plan

Abbreviations and Terms

American Society of Mechanical Engineers

Automated Ultrasonic Testing

Distance Amplitude Curve

Domestic Tariff Area

Heat Affected Zone

Head of the Department

International Institute of Welding

Jamnagar Export Refinery Project

Manual Ultrasonic Testing

Non Destructive Testing

Pulse Echo Ultrasonic Testing

Phased Array Ultrasonic testing

Quality Management Department

Society of Non-destructive Testing

Time Corrected Gain

Transmitter and Receiver

Time of Flight Diffraction Technique

Ultrasonic Flaw Detector

Construction Managers/Engineer in Charges is responsible for implementing this

HOD, QMD is responsible for maintaining this procedure.

DCC is the custodian of this document.

UT Equipment and Its Accessories ( PE-UT )

Equipment: Ultrasonic Flaw Detector (UFD)

The probe details are as follows,

Flat shoe 45,

For set on nozzle, the above table shall be followed.

Inspection / Scanning Method

Preparation of Job Surface

Time base calibration range

TR Probe: 1st Back Wall Echo to 80% of FSH

Angle probe: First point of DAC shall be set to 80 % of FSH.

Examination: The weld joints shall be examined as follows,

TR probe: Before performing the angle beam examination, a straight beam

TR and normal probe: Ref. dB for 80 % BWE + 6dB.

Evaluation shall be done at reference level.

In case of TR and Normal probe, the indications longer than 40 % of the

All discontinuity shall be sized using 6 dB drop method.

AUT Equipment and Its Accessories (AUT)

Ultrasonic Phased Array Instrument

The instrument shall be capable of operation at frequencies over the range of

Instruments screen height linearity and amplitude control linearity shall be

Phased Array System Calibration

The calibration information shall be recorded on the Ultrasonic Calibration system.