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Approval
Electronic: PDM Flow
Documentation Type: Title: process:
DTPD Prepared: MOYARZABAL
Deliverable: Verified: MCC
Ultrasonic Inspection of tower section
weldings BMVAHNOVEANU/
D02 Approved: JMUZQUIZA LEVEL III
in NDT
The present document, its content, its annexes and/or amendments (the “Document”) has been drawn up by GAMESA CORPORACIÓN TECNOLÓGICA, S.A. (“Gamesa”) for
information purposes only, and contains private and confidential information regarding Gamesa and its subsidiaries (the “Company”), directed exclusively to its addressee.
Therefore it must not be disclosed, published or distributed, partially or totally, without the prior written consent of Gamesa, and in any case expressly indicating the fact that
Gamesa is the owner of all the intellectual property. All the content of the Document, whether it is texts, images, brands, trademarks, combination of colours or any other element,
its structure and design, the selection and way of presenting the information, are protected by intellectual and industrial property rights owned by Gamesa, that the addressee of
the Document must respect. In particular (notwithstanding the general confidentiality obligation), the addressee shall not reproduce (except for private use), copy, transform,
distribute or publish to any other third party, any of the information, totally or partially.

INDEX

1 INTRODUCTION .................................................................................................................2
1.1 Scope ................................................................................................................................. 2
2 REFERENCES .....................................................................................................................2
2.1 Normative references............................................................................................................ 2
3 PERSONNEL QUALIFICATION ..............................................................................................2
4 EQUIPMENT AND MATERIAL FOR THE INSPECTION..............................................................2
4.1 Equipment........................................................................................................................... 2
4.2 Transducers......................................................................................................................... 3
4.3 Coupling.............................................................................................................................. 3
5 TEST CONDITIONS.............................................................................................................3
6 GAUGING BLOCKS ..............................................................................................................3
7 GAUGING...........................................................................................................................4
7.1 Gauging of the time base ...................................................................................................... 4
7.2 Gauging sensitivity ............................................................................................................... 4
7.3 Frequency of gauging ........................................................................................................... 5
8 TEST PROCEDURE ..............................................................................................................5
8.1 Base metal examination ........................................................................................................ 5
8.2 Angular beam examination .................................................................................................... 6
9 ASSESSING THE INDICATIONS............................................................................................6
10 ACCEPTANCE CRITERIA ......................................................................................................7
10.1 Generalities ......................................................................................................................... 7
10.2 Aligned and grouped indications........................................................................................... 10
10.3 Accumulative length of the acceptable indications .................................................................. 10
11 INSPECTION REPORT ....................................................................................................... 11
11.1 Generalities ....................................................................................................................... 11
11.2 Inspection Report template ................................................................................................. 12
12 ANNEXES ......................................................................................................................... 14
12.1 Annex I: Basic calibration gauging block ............................................................................... 14
12.2 Annex II: Time base linearity............................................................................................... 14
12.3 Annex III: Screen height linearity......................................................................................... 15
12.4 Annex IV: Amplitude control linearity.................................................................................... 16

RECORD OF CHANGES

Rev. Date Author Description

00 17/03/09 MOYARZABAL The present document replaces EQ219004.

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Title: Ultrasonic Inspection of tower section weldings

1 INTRODUCTION

1.1 SCOPE

This instruction defines the method to follow for the ultrasonic examination of full penetration welded joints
(butt weld or fillet weld) in ferrous or low-alloy materials with thicknesses of between 8 and 100 mm, as used
in the construction of wind towers in keeping with the indications of Gamesa.

Likewise, it defines the acceptance and rejection criteria of the indications detected in the aforementioned
ultrasound test, based mainly on the echo amplitude and length of the said indications.

This instruction may be used to test weldings with thicknesses of over 100 mm or with partial penetration,
provided there is prior agreement between the manufacturer and Gamesa.

2 REFERENCES

2.1 NORMATIVE REFERENCES

The following documents are invoked as part of this specification and must be fulfilled to the extent defined.
Unless specifically over-ruled by the inclusion of a date, or an issue letter or code, the latest issue shall
always apply.

Number Title
EN 473 Non-destructive testing. Qualification and certification of NDT personnel. General principles

SNT-TC-1 A Non-Destructive Testing

EN 25817 Arc-welded joints in steel. Guidance on quality levels for imperfections

Non-destructive examination of welds. Ultrasonic examination of welded joints. Acceptance
EN 1712
levels
EN 1714 Non destructive testing of welded joints. Ultrasonic testing of welded joints

EN 583-2 Non-Destructive Testing - Ultrasonic Examination - Part 2: Sensitivity and Range Setting

3 PERSONNEL QUALIFICATION

Personnel in charge of ultrasonic test inspection shall be in possession of the certificate of qualification Level
II issued by following standards:
• EN 473
• SNT – TC – 1A

Gamesa will have access to such documentation if required.

4 EQUIPMENT AND MATERIAL FOR THE INSPECTION

4.1 EQUIPMENT

The ultrasound equipment shall use the impulse-echo technique, with a minimum range of frequencies of
between 1 and 5 MHz and with A-scan on-screen graphic display.

Preferably, equipment by Krautkramer, Panametrics or similar will be used.

Equipment must have a time-base linearity ≤ 2% of the width of the screen (see Annex I, point 12.1)

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Height linearity of indications on screen shall have a deviation of ± 5% of the total height of the screen (see
Annex II, point 12.2).

Attenuation control shall show a linearity with a tolerance of ± 20% of the nominal value, according to Annex
III (point 12.3).

4.2 TRANSDUCERS

4.2.1 Normal beam transducer

These shall have a nominal frequency of 4 MHz with an oscillator diameter of 24 mm for monocrystal feelers
and of 6 x 20 for bicrystal feelers, although other oscillator diameters and frequencies can be used when
characteristics such as the grain size and thickness or others so require, or in order to ensure adequate
penetration, improved resolution or appropriate accessibility throughout the volume of the zone under test.

4.2.2 Angular beam transducer

These shall have a nominal frequency of 4 MHz and an oscillator size of 8 x 9 mm, although other oscillator
sizes and frequencies can be used when characteristics such as the grain size and thickness or others so
require, or in order to ensure adequate penetration, improved resolution or appropriate accessibility
throughout the volume of the welding under test.

Angular transducers of 45º, 60º and 70º will be used.

4.3 COUPLING

The ultrasound gel coupling agent shall be cellulose water, water, oil, vaseline or any other product which
ensures correct acoustic coupling and which can be easily eliminated.

For both the block calibration and piece inspection the same coupling agent must be used.

5 TEST CONDITIONS

The inspection shall be carried out in a zone in which no work which may interfere in the correct working of
the equipment is being carried out.

The surface areas of the base material to which the transducer is to be applied must be free from any
projections, irregularities, grease or any other substances which may interfere in the normal carrying out of
the inspection.

The surface areas of the welding must be finished in such a way that they do not result in indications which
interfere with the interpretation of the echoes. The said surface areas must, therefore, have a smooth
transition with the metal base, without any holes, gaps or ledges.

Whenever necessary, any inappropriate zones must be corrected using a file, emery or similar.

When working outside, the inspection zones must be protected from external cold and heat and rainwater.

6 GAUGING BLOCKS

The blocks shall be manufactured using the same material, or equivalent, as that examined, and shall have
the same treatment and superficial finishing as the material under test.

The characteristics of the mentioned blocks (thicknesses, lengths, boreholes, etc) are shown in Figure 4.

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Gauging blocks shall include basic reflectors in order to establish the primary reference response of the
equipment. The said reflectors shall be boreholes of 3 mm in diameter, located at least at t/4, t/2 and 3t/4,
in which t is the gauge block thickness as shown in Figure 5.

7 GAUGING

7.1 GAUGING OF THE TIME BASE

7.1.1 Normal incidence

V1 and V2 type blocks shall be used, gauging the equipment in sound runs.

The chosen field shall be in line with the thickness of the sheet to be examined and shall allow the on-screen
display of at least 2 background echoes for monocrystal transducers and 1 echo for bicrystals.

7.1.2 Angular incidence

V1 and V2 type blocks shall be used, gauging the equipment in sound runs.

The chosen field shall be in line with the thickness of the welding to be examined and shall be in excess of
the skip distance, allowing the on-screen display of at least 2 echoes.

The real beam output point and the real feeler angle shall be checked in all the transducers using the V1 and
V2 type blocks.

Deviations in excess of 2º are unacceptable.

7.2 GAUGING SENSITIVITY

With the angular transducers, the sensitivity will be calculated using the 3 mm boreholes of the gauge block
(Figure 6). The transducer will be positioned in such a way as to obtain the maximum indication of the
borehole which gives the greatest echo amplitude (¼ t or ½ t), with the said indication at 80% of the total
height of the screen. The number of decibels indicated at this moment on the device controls will constitute
the basic reference level.

The transducer will then be positioned in order to obtain the maximum indications of the other boreholes,
including the one corresponding to 5/4 t.

The DAC curve obtained will provide the basic reference sensitivity level. The said curve will cover the
appropriate range of the time base.

If the difference between maximum and minimum echos is outside the 20%-80% range of the total screen
height (TSH), the line must be divided, and separated curves must be used, with different gain adjusting.

The gain difference between curves must be recorded in the screen (see example of Figure 1).

Make sure to check for possible transfer losses. The maximum compensation shall be 4 db.

The reference level must be constituted by the basic reference level, compensated with transference losses.

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Figure 1. Ultrasonic control device screen showing a divided DAC curve

7.3 FREQUENCY OF GAUGING

The said gaugings should be checked at the start and end of each working day, every four test hours, every
time the cable, transducer, battery, protective base or operator is changed, or whenever there are doubts
with regards to the reliability of the results.

If, during the mentioned checking, deviations are detected, the following corrections must be done:

SENSIBILITY
1 Deviations ≤ 2 dB Adjustment must be corrected before continuing with the exam.
Sensibility reduction > Adjustment must be corrected and all the previous exams made with
2
2 dB. the equipment must be repeated.
Aumento de Adjustment must be corrected and all the recorded indications must be
3
sensibilidad > 2 dB. examined again.
TIME BASE ( RANGE )
Deviations ≤ 2% of
1 Adjustment must be corrected before going on with the exam
the range
Deviations > 2% of Adjustment must be corrected and all the previous exams made with
2
the range the equipment must be repeated

8 TEST PROCEDURE

8.1 BASE METAL EXAMINATION

The metal base is on both sides of the welding, in an area sufficient to cover the angular transducer run,
must be examined (100% examination) using a straight beam transducer in order to detect imperfections
which can produce interference in the angular transducer test, assessing the level of influence of each
imperfection with regards to the aforementioned angular beam examination and, if necessary, adjusting the
techniques properly.

During the test, overlapping ≥ 10% of probe diameter must be assured.

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If the carrying out of the ultrasound examination is seriously affected, consider other inspection methods
(e.g. radiographies).

8.2 ANGULAR BEAM EXAMINATION

The transducers shall be chosen in line with the thickness, design and geometry of the welded joints, in
keeping with the following orientations:

8 ≤ thickness ≤ 15 mm thickness ⇒ angle of 70º

15 < thickness ≤ 40 mm thickness ⇒ angle of 60º and 70º

40 < thickness ⇒ angle 45º and 60º.

The said parameters may vary in keeping with the above-mentioned (thickness, design and geometry of the
welding), in order to guarantee ultrasound beam access throughout the volume of the welding under test.

In the case of joints with different thicknesses, the thickness considered shall be the lesser of the two.

The test shall be carried out from the both sides and faces of the welding, provided that it is possible.

The examination will work with an amplification of + 12 db on the reference level.

In order to detect longitudinal defects, the sound beam will be directed perpendicularly to the axis of the
welding and the transducer will be manipulated in such a way that the ultrasound beam covers the totality of
the welding and of the thermically affected zone.
During the said movement, the transducer will carry out small oscillations (between 0ºC and 10ºC with
regards to that perpendicular to the axis of the welding).

In order to detect transverse defects, the transducer shall be positioned as parallel as possible to the
longitudinal axis of the welding, whilst guaranteeing the penetrability of the ultrasound beam in the said
welding.

In both the tests to detect longitudinal indications and transverse indications, the indications will be displayed
in their true magnitude (maximum echo amplitude), for which the necessary inspection conditions (angle,
frequency and size of the transducer; position and orientation of the transducer in the welding with regards
to the situation and orientation of the indication; etc.) should be achieved, filing down the excess thickness
of the welding if necessary.

The exploration speed shall not be in excess of 6 " / s (152 mm/ s).

During the test, overlapping ≥ 10% of probe width must be assured.

9 ASSESSING THE INDICATIONS

All indications with echo amplitudes in excess of 20% ( - 14 db) of the reference level will be investigated in
order to determine their shape, dimensions and situation.

The length of the indication should be determined by measuring the distance throughout the length on which
the echo amplitude is above the assessment level.

The indications are assessed as longitudinal or transversal depending on the orientation of the greater
dimension. When this distinction cannot be clearly made, the indication should be classified as transversal if
the echo amplitude obtained during the examination of the transversal indications exceeds the echo
amplitude obtained during the examination of the longitudinal indications by 2 db or more.

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Those indications which, due to the geometry of the welding, cannot be displayed in their maximum echo
amplitude, including when the said amplitude does not exceed the assessment level, must be put
through additional tests, filing down the welding both on the inside and outside whenever necessary, using
transducers of different angles, sizes and frequencies, and including the tandem technique whenever
possible. The assessment of the indication must be based on the echo amplitude and length measured in the
transducer with which the maximum response is obtained.

The transversal indications with echo amplitudes equal to or in excess of the assessment level should be
classified by way of additional ultrasound exploration, radiography or other examination methods in order to
determine their nature.

The indications detected using the tandem technique (longitudinal and transversal) should be researched in-
depth if their echo amplitudes exceed the recording level. Additional radiography or ultrasound examinations
need to be carried out in order to determine the type and size of the imperfections.

10 ACCEPTANCE CRITERIA

10.1 GENERALITIES

All discontinuities interpreted as cracks, incorrect casting or incomplete penetration are unacceptable
regardless of their size and echo amplitude.

All other discontinuities are governed by the acceptance criteria indicated in Tables 1, 2 and Figures 2, 3.

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Thicknesses: 8 mm ≤ t<
< 15 mm
Length of the indication Maximum echo amplitude
L (mm) allowed
L ≤ t Reference level - 6 db

L > t Reference level - 12 db.

Table 1: Range of thicknesses 8mm ≤ t < 15 mm

Figure 2: Range of thicknesses 8mm ≤ t < 15 mm

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Thicknesses: 15 mm ≤ t ≤ 100 mm

Length of the indication L (mm) Maximum echo amplitude allowed

L ≤ 0,5 t Reference level

0,5 t < L ≤ t Reference level - 6 db.

L > t Reference level - 12 db.

Table 2. Range of thicknesses 15 mm ≤ t ≤ 100 mm.

Figure 3. Range of thicknesses 15 mm ≤ t ≤ 100 mm

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10.2 ALIGNED AND GROUPED INDICATIONS

The aligned indications should be considered continuous if they are separated by a distance, dx, less than
twice the length of the longest indication. The total or combined length needs to be checked against the
appropriate acceptance levels.

The aligned indications must satisfy the following:

dy ≤ 5 mm , dz ≤ 5 mm , see Figure 4.

The adjacent indications grouped together in this manner must not be used for other groups with additional
indications. Only isolated indications should be grouped together.

Once grouped together, all the indications registered and accepted in the same section and the same depth
(dz ≤ 5 mm) should be separated by a distance dy >10 mm. The indications in the same lateral position
(dy ≤ 5 mm) should be separated by a distance dz >10 mm. Adjacent indications with distances less than dy
and dz are unacceptable.

Figure 4. Geometrical configurations for grouped indications

10.3 ACCUMULATIVE LENGTH OF THE ACCEPTABLE INDICATIONS

For any length of welding equal to 6t, the maximum accumulative length of each of the acceptable
indications above the registration levels must not exceed 20% of this length.

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11 INSPECTION REPORT

11.1 GENERALITIES

Inspection document shall report, at least, the following data:

- Procedure

- Customer and manufacturer

- Ultrasound equipment

- Identity and level of the examination staff

- Identification and location of the examined welding

- Registration of the repaired areas, along with the re-examination results for the said repaired areas

- Date and place on which examination was carried out

- Coupling agent

- Identification of the gauge block

- Superficial condition

- Frequencies

- Fields

- Transducers used

In addition to the rejectable indications, all acceptable indications for which the echo amplitude exceeds the
acceptance / rejection level shall be registered.

All the indications reflected in the report shall be recorded in such a manner that they can be located at any
moment during or after the production process.

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11.2 INSPECTION REPORT TEMPLATE

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12 ANNEXES

12.1 ANNEX I: BASIC CALIBRATION GAUGING BLOCK

Figure 5. Basic gauging block.

Welding thickness (t) Block thickness Diameter of boreholes (mm)

8 mm ≤ t ≤ 25 mm 18 mm or t 3
25 mm < t ≤ 50 mm 38 mm or t 3
50 mm < t ≤ 100 mm 75 mm or t 3
Length of the boreholes: 38 mm minimum

- This block, known as flat block, is used for surface areas whose curvature corresponds to a diameter in
excess of 20 inches.
- In order to correctly display the DAC curve, depending on the thickness and the characteristics of the
equipment to be used, additional boreholes shall be used (same diameter and length as those indicated),
located at different depths of the gauge block (e.g. 1/8t) and in places which do not interfere with the
basic drill holes (t/2 of the corresponding side and at its corresponding depth).

12.2 ANNEX II: TIME BASE LINEARITY

With a longitudinal wave transducer a sequence of multiple echo is represented, with 5 bottom echo coming
from a free-of-laminations sample, chosen by the range of depth to be checked. (Checking of the linearity
would be carried out for the commonly used depth ranges.

The first bottom echo will be placed in the 2.0 div,esc position (horizontal scale of 10 divisions of the screen)
with an echo amplitude of the 40% of the screen.

Next, the fourth bottom echo will be placed at the 40% of the height of the screen too, and adjusted exactly
to de 8,0 division of the scale.

Once these two adjustments have been made, the second, the third and the fifth bottom echos are adjusted
at the 40% of the height of the screen, one after the other and the deviation of the echo position from its
correct position is determined and registered (divisions 4,0; 6,0 and 10,0 respectively).

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The greater deviation is called the “deviation of linearity of the time base” and is expressed as a percentage
of the total width of the graphic (screen).

A deviation less or equal to 2% of the total width of the screen is allowed.

12.3 ANNEX III: SCREEN HEIGHT LINEARITY

Oscillations in the signal in the vertical direction of the screen must be linear, at least, in a 80% of its useful
height. This height will be fixed taking as an origin the base line of the screen.

To verify this characteristic, a transducer will be positioned, as shown in Figure 6 so that indications can be
observed from both the ½ and 3/4T holes in a basic calibration block. Adjust the search unit position to give
a 2:1 ratio of amplitudes between the two indications, with the larger set at 80% of full screen height.
Without moving the search unit, adjust sensitivity (gain) to successively set the larger indication from 100%
to 20% of full screen height, in 10% increments (or 2 dB steps if a fine control is not available), and read the
smaller indication at each setting. The reading must be 50% of the larger amplitude, within 5% of full screen
height.

The test must be done for each frequency of the transducers to be used.

This verification can be made with longitudinal wave transducers, too, provided that two echos, in a
proportion of 2:1 between them, can be detected.

Figure 6. Verification of the linearity of the height of the indications of the screen.

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12.4 ANNEX IV: AMPLITUDE CONTROL LINEARITY

To verify the linearity of the amplitude control of the ultrasonic instrument, an angular transducer will be
positioned, as shown in Figure 7, so that the indication from the ½T hole in a basic calibration block is
peaked on the screen. With the increases and decreases in attenuation shown in the following table, the
indication must fall within the specified limits, in % of the total height of the screen.

This verification can be made with longitudinal wave transducers, too.

Figure 7. Verification of the linearity of the amplitude control

Limits of the indication in

Percentage of the heigth Decibeles of change in the
percentage of the screen
reached by the indication attenuation control
height
80 -6 32 - 48
80 -12 16 - 24
40 +6 64 - 96
20 +12 64 - 96

Table 3. Linearity of the amplitude control

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