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SKIPL /QC/P – 01
PREPARED BY CHECKED BY
APPROVED BY
1. PURPOSE
The purpose of this procedure is to establish and maintain documented
procedure to ensure that manual ultrasonic examination of welded joints, plates and
HAZ (heat affected zone) is carried out to get desired quality steel structures.
Thickness Range for which UT to be followed –
2. SCOPE
The ultrasonic examination described in this procedure is applicable to the
butt joints of the Structural Steels welded in the Fabrication Yard (field splicing). Also
this method can be applied to the butt/single V groove joints of structures, pipe
supports, T, K & Y joints of Loading Platform with approved technique sheet and
proper demonstration of technique.
UT shall be of Digital recordable Type.
3. REFERENCES/STANDARDS USED
AWS D 1.1,2010 – Structural welding code – Steel.
ASME Boiler and Pressure Vessel Code Sec V 2007 for Nondestructive
Examination article 5.
ASTM SA-578 2002 Specification for Straight-Beam Ultrasonic Examination of
Plain and Clad Steel Plates for Special Applications
4. RESPONSIBILITY
Personal performing ultrasonic examination shall be responsible for preparing
examination report and shall be responsible for performing Calibration & evaluation of
indication during the examination of weld
5. PERSONNEL QUALIFICATION
Inspection personnel shall be experienced, qualified Level II as per ASNT SNT-
TC-1A 2006 edition
6. SAFETY
Before application, the examiner shall be familiar with relevant regulations
covering health safety and hazardous substances, both local and statutory,
appropriate test method.
7. STAGE OF EXAMINATION
After Visual examination of respective area. UT will be carried out after PWHT.
8. TECHNIQUE
9. METHOD OF EXAMINATION
10. EQUIPMENT –
Straight – beam (Longitudinal wave) search unit transducers shall have an active
area of not less than 323 square millimeters nor more than 645 square millimeters. The
Transducers shall have good resolution.
Type: Ultrasonic flaw detector, make-Modsonic, model-Einstein II
TFT & shall be of Digital type.
Cable: Coaxial cable with lemo to mini lemo connector of length
1.5m to 2.5m shall be used.
Search Unit: Angle probes with +/- 20 tolerance of 700, 600, 450(4
MHz 8 X 9 mm) Normal probe (2 MHz 24mm Dia) and T/R (2 MHz
20mm Dia) probe, size and frequencies shall be used accordingly,
which ever applicable. Transducer frequency shall be between 2 to
2.5 MHz for angle probes.
A. Horizontal Linearity
B. Gain Control
UT unit in longitudinal mode and in shear mode shall be calibrated, using IIW blocks.
Distance calibration
Amplitude
Resolution
Horizontal linearity
Gain control
B. In shear mode, the following are to be checked as per clause 6.29.2 of AWS D
1.1 :
Index point
Angle
Distance calibration
Amplitude
Resolution
IIW V1, V 2 and Standard Calibration blocks are used for range calculation
as well as for calibration for weld and plate scanning.
Measure the part thickness. From this thickness skip distance is calculated.
The skip distance is the area where scanning is done with the proper angle
transducer.
Skip distance = Thickness X tan (probe angle)
Table 6.7* of AWS D 1.1 2010, will list the transducer angles and face needed
to test the weld.
Calculate the full sound path. This is determined by the material thickness
and transducer angle.
The Horizontal sweep shall be adjusted for distance calibration to present the
equivalent of at least two plate thicknesses on the display.
Choose the appropriate screen range in order to see a minimum sound path
of two legs. Adjust the ultrasonic machine to obtain the proper screen range.
Determine the exit point of the transducer. Peak the signal on the ultrasonic
machine and verify that the index point on the plastic wedge matches the calibration
block. The angle of the transducer will need to be verified. It shall be within plus or
minus 2 degrees of the required angle.
The amplitude of a known size block will be adjusted from 50-75% full screen
height. The Db will be recorded as the reference level “b”
.
15. CALIBRATION FREQUENCY
Mark the end of the skip distance from the edge of the heat affected zone
(HAZ). A lamination scan will be performed in the area where the angle beam
inspection will take place. This scan is performed with a straight beam transducer.
Perform a lamination scan from face “A” with at least two plate thicknesses on
the display. The first back wall reflection shall be 50 to 75% full screen height.
All butt joint welds shall be tested from each side of the weld axis.
If any area of the base metal shows a total loss of back wall reflection, or if an
indication is equal or greater to the back wall reflection, the size and location and
depth will be reported. Move the transducer in all directions until the amplitude of the
signal is reduced by 50%. Mark the center of the transducer. The distance between
the centres will be the length of discontinuity.
Angle beam Scanning level is based on sound path distance. If Table 6.2* of
AWS D1.1 2010, (Statically loaded non tubular connections) are tested, the following
scanning levels will be used.
Above Zero
>2.5” to 5” (65-125mm) 19
For Cyclically loaded Nontubular connections the following scanning level will be
used.
Above Zero
>2.5” to 5” (65-125mm 25
If any reportable indications are observed calculate the surface distance and
depth in order to determine if the signal is located in the weld. Move the transducer
in all directions in order to peak the signal from the discontinuity. Record the “Sound
Path”.
Increase or decrease the dB until the screen height from the discontinuity is
equal to the reference level based on reflectors. Record the dB under indication
level “a”.
Find attenuation factor “c” by following method Subtract one inch from the
sound path distance and multiply the remainder by two(in SI unit subtract 25mm and
multiply it by 0.08). This number will be rounded to the nearest whole number. If the
number is less than 0.5 dB it will be lowered to the nearest whole number. If the
number is 0.5 or greater, it will be increased to the nearest whole number.
Use Table 6.2* of AWS D1.1 2010 to find out in which class discontinuity belongs to.
Class A (large discontinuity)
Any indication in this category having a length greater than ¾” shall be rejected.
Any indication in this category having a length greater than 2” shall be rejected.
A) Column & Girders: Cyclically Loaded Non tubular connections, refer 6.13.2
1) Welds subject to stress under any condition of loading shall confirm to the
requirements of Table 6.3 of AWS D1.1.
3)
REVISION : 00
PROCEDURE FOR ULTRASONIC EXAMINATION
DATE : 01.02.2013
OF STRUCTURE
The plate surface shall be sufficiently clean and smooth to maintain a first
reflection from the opposite side of the plate at least 50%of full scale during
scanning. Test shall be performed using direct contact method using suitable
Couplant such as water, soluble oil or glycerine. Scanning shall be continuous
perpendicular grid lines on nominal 9 in.(225mm) centres. Measure the lines from
center or one corner of the plate with an additional path within 2 inch (50mm) of all
edges of the plate on the searching surface. When a discontinuity condition is
observed during general scanning adjust the instrument to produce a first reflection
from the opposite side of a sound area of the plate of 75+/- 5% of full scale. Maintain
this instrument setting during evaluation of the discontinuity condition.
18.1 Recording
Record all discontinuities causing complete loss of back reflection. For plates
20mm thick and over, record all indications with amplitudes equal to or greater than
50% of the initial back reflection and accompanied by a 50% loss of back reflection.
When recordable conditions are detected along a given grid line the entire surface
area of the squares adjacent to this indication shall be scanned.
STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P – 01
Any area where one or more discontinuities produce a continuous total loss of
back reflection accompanied by continuous indications on the same plane that
cannot be encompassed within a circle whose diameter is 3 inch (75mm) or ½ of the
plate thickness, whichever is greater, is unacceptable. In addition two or more
discontinuities smaller than 3inch(75mm) shall be un acceptable unless separated by
a minimum distance equal to the greatest diameter of the larger discontinuity or
unless they may be collectively encompassed by the circle described above.
19. REPORTS
The operator will prepare a report on the approved ultrasonic examination format as
attached. It shall show position, extent of test, operating parameters at the time of
examination and indication size if detected, identity and extent of any imperfections
whichever is applicable. If welds are rejected, the report shall accurately identify the