STEEL KONNECT (INDIA) PVT. LTD.

SKIPL /QC/P – 01

PROCEDURE MANUAL PAGE : 1 OF 16

PROCEDURE FOR ULTRASONIC EXAMINATION REVISION : 00

OF STRUCTURE DATE : 01.02.2013

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 –

For Plates – Beyond 40 mm Thickness

Butt weld – Beyond 32 mm Thickness

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

STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P – 01

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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

Pulse echo technique. A scan.

9. METHOD OF EXAMINATION

Longitudinal and shear beam contact method

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.

STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P – 01

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 Couplant: A Couplant material shall be used between the search

unit and the test material. The Couplant shall be either glycerine or
cellulose gum and water mixture of suitable consistency. Couplant
used for calibration & testing shall be same.
Equipment shall have a calibrated gain control adjustable to 1 or 2 db step. The
accuracy of the gain setting shall be within +/- 1db

11. SURFACE PREPARATION

Scanning surface shall be free form loose scale, weld spatter and any other
foreign matter that may interfere with the examination. Light grinding of weld caps
may be required to facilitate scanning requirements.
Surface temperature shall not exceed 50OC when using conventional probes.

12. INSTRUMENT CALIBRATION

Vertical & Horizontal linearity, Sensitivity, Penetration and Resolution of
equipments using is checked once in a year and those calibration certificates are
available with machine itself. However, calibration shall be carried out in the
presence of DCW Inspector prior to starting examination.
Recalibration shall be done under the following conditions:
1) Change of Operator.
2) Probe change.
3) Coaxial cable change.
4) Power failure.
5) Electrical outlet change.
1. EQUIPMENT QUALIFICATION

A. Horizontal Linearity

a) Horizontal linearity shall be prequalified at 2 months interval in each of

distance range where equipment shall be used.

b) The procedure to be followed for qualification / requalification shall be as per

clause 6.30.1 of AWS D 1.1.

STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P – 01

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B. Gain Control

a) Instrument’s gain control / attenuator shall be verified at 2 months interval for

correct calibration at two month’s interval.

b) Procedure to be followed for verification shall be as per clause 6.30.2 of AWS

D 1.1.

2. CALIBRATION OF UT UNIT WITH IIW BLOCK

UT unit in longitudinal mode and in shear mode shall be calibrated, using IIW blocks.

A. In longitudinal mode, the following are to be checked as per clause 6.29.1 of

AWS D 1.1

 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

 Approach distance of search unit

13. CALIBRATION BLOCKS

IIW V1, V 2 and Standard Calibration blocks are used for range calculation
as well as for calibration for weld and plate scanning.

STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P – 01

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14. CALIBRATION PROCEDURE

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.

Sound path = Thickness / cos (probe 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.

The distance and sensitivity calibration block (DSC), miniature calibration

block or rumpus block (V 2), IIW (V 1) block can be used for calibration.

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

Machine shall be calibrated at starting of each shift and whenever system

raise doubt about its efficiency.

STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P – 01

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* See Attachments for Table 6.7

16. TEST PROCEDURE

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.

1) Probe swelling of 100 shall be given during scanning.

2) The boundary of the laminar discontinuities shall be found by 6 db drop

method.

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

Sound Path (in) Reference, dB

0.0” to 2.5” (65mm) 14

>2.5” to 5” (65-125mm) 19

> 5” to 10” (125 – 250mm) 29

> 10” to 15” (250 – 380mm) 39

STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P – 01

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PROCEDURE FOR ULTRASONIC EXAMINATION REVISION : 00

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For Cyclically loaded Nontubular connections the following scanning level will be
used.

Above Zero

Sound Path (in) Reference, dB

0.0” to 2.5” (65mm) 20

>2.5” to 5” (65-125mm 25

> 5” to 10” (125 – 250mm) 35

> 10” to 15” (250 – 380mm) 45

The scanning pattern shall be in zigzag motion perpendicular to weld.

 To ensure coverage of the required volume, an overlapping of 10% of the pitch

between adjacent scan lines of the probe shall be provided.

The scanning speed during operation shall not exceed 150mm/6 inch per Sec.
* See Attachments
for Table 6.2

17. ACCEPTANCE CRITERIA as per AWS D1.1 2010

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.

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The indication rating is calculated by taking the “Indication level” minus

“Reference level” minus “Attenuation factor”. a-b-c =d, where “d” is the indication
rating.

Length of discontinuity can be done by following way. Maximize the signal

amplitude from the discontinuity. Slide the transducer parallel with the weld until the
signal amplitude has reduced by 50%. Mark the location next to the weld aligned
with the center of the transducer. Perform this procedure in both directions.

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 shall be rejected regardless of length

Class B (medium discontinuity)

Any indication in this category having a length greater than ¾” shall be rejected.

Class C (small discontinuity)

Any indication in this category having a length greater than 2” shall be rejected.

Class D (minor discontinuity)

Any indication in this category shall be accepted regardless of length or location in

the weld.

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.

2) Welds subject to compressive stress shall confirm to the requirements of

Table 6.2 of AWS D1.1.

3)

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DATE : 01.02.2013
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B) Horizontal Bracings – Pipe Bracings: Tubular connections, Refer 6.13.3 Class

R

1) Acceptance criteria for UT shall be as provided in contract documents. Class R

or Class X or both may be incorporated by reference. Amplitude based
acceptance criteria as given by 6.13.1 may also be used for groove welds in butt
joints in tubing 600mm in diameter and over, provided all relevant provisions of
clause 6 part F of AWS D1.1 are followed. However, these amplitude criteria shall
not be applied to tubular T, Y, K connections.

* See Attachments for Table 6.2

18. PLATE SCANNING PROCEDURE

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

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18.2 Acceptance Standards- Level B

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

that are considered rejectable or reportable as per specifications/standards

whichever is applicable. If welds are rejected, the report shall accurately identify the

size, nature and extent of the defect area.

All reports shall be sentenced in one of the following manners:

 No reportable indication- Acceptable.

 Reportable indication as noted – Acceptable.
 Reject.
20. CLEANING AFTER TEST

All Couplant materials shall be removed on completion of the test using

portable water wash / solvents and cloths.

STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P – 01

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Prepared By Reviewed By Approved By

Engineer QC Head QA&C Management Representative