NSCL Doc. No.

1055-NSCPL-PR-UT-01
PROCEDURE FOR Revision 0
ULTRASONIC
Date 30.11.2019
EXAMINATION
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NEO STRUCTO CONSTRUCTION PRIVATE

LIMITED

PROCEDURE FOR

ULTRASONIC TESTING

Revision History

0 30.11.19 Initial Issue Viral Prajapati G.K.Verma Binoy Shaw

Rev. Prepared By Reviewed By Approved By

Date Description
No. (NDE Level II) (NDE Level III)
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CONTENTS
Sr.No Description Page No

1 Scope 3

2 Reference 3

3 Personnel Qualification 3

4 Application 3

5 Equipment 4

6 Search Unit 5

7 Couplant 5

8 Basic Calibration Block 6

9 Identification of weld examination area 7

10 Surface Preparation 7

11 General Calibration Requirements 7

12 System Calibration for Distance Amplitude 7

13 Calibration Conformation 8

14 Examination 9
15 Technique 10
16 Evaluation 11
17 Acceptance Standard 12
18 Examination of Repairs 14
19 Procedure Re-qualification 14
20 Report of the Examination 14
21 Post Examination Cleaning 15
22 Essential Variables 17
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1.0 SCOPE

This procedure shall be applicable for Examination of butt weld and base plate
by Ultrasonic method.

2.0 REFERENCE:

 ASME Section V. ED: 2017

 AWS D1.1 ED:2015
 SNT TC 1A (Applicable Edition)
 4058-XZ-SW-00OO000103

3.0 PERSONNEL QUALIFICATION

3.1 The personnel employed for conducting the examinations shall be qualified to
Level – II according to SNT-TC 1A.
3.2 Interpretation of the results of ultrasonic test examination shall be performed
by either Level II or Level III individuals qualified and certified as per SNT-TC-
1A.
3.3 When the referencing code section doesn’t specify qualifications or does not
reference directly Article 1 of ASME Sec V, qualification of personnel shall only
involve a satisfactory demonstration of competence in the established procedure.
Such qualified NDE personnel shall be employed for conducting the examination
in that procedure only.

4.0 APPLICATION
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4.1 The principle objective of this procedure and technique described herein is
the detection, location and evaluation of discontinuities within weld, heat
affected zone and also in the adjacent base material.
4.2 The weld shall be examined by angle beam method decide the exact job. All
welds shall be examined from both the sides of weld from an outer surface decide
the exact combination of surfaces so that full volume of the weld is covered.
4.3 Where geometry of the assembly does not allow examination from both sides, then
any of the following alternatives may be used:
Combination of angle beam (mode of wave propagation in material -shear
wave) and straight beam, (mode of wave propagation in material-longitudinal
wave)

5.0 EQUIPMENT

5.1 A pulse echo type of ultrasonic instrument shall be used. The instrument shall be
capable of operation at frequencies over the range of at least 1 MHz to 5 MHz and
shall be equipped with a stepped gain control in units of 2.0dB or less.

5.2 If instrument has a damping control, it may be used if it does not reduce the
sensitivity of the examination. The reject control shall be in the ‘off’ position for all
examinations, unless it can be demonstrated that it does not affect the linearity of
the examination.
5.3 Linearity Checking:
5.3.1 Analog Equipment: The requirements of screen height linearity &
amplitude control linearity shall be checked at intervals not to exceeding
three months; if equipment is not in use for3 months then it shall be
checked before use and record shall be maintained.
5.3.2 Digital Equipment: The requirement of screen height linearity & amplitude
control linearity shall be checked at intervals not to exceeding one year; if
equipment is not in use for one year then it shall be checked before use and
record shall be maintained.
5.3.3 The ultrasonic instrument’s screen height linearity shall be evaluated in
accordance with mandatory Appendix I of ASME Sec V Article 4.The
ultrasonic instrument shall provide linear vertical presentation within ±5 of
the full screen height for at least (larger indication is set) 80% of the
calibrated screen height(base line to maximum calibrated screen point(s)
5.3.4 The ultrasonic instrument’s amplitude control linearity shall be evaluated
in accordance with mandatory Appendix II, of ASME Sec V Article 4.
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The ultrasonic instrument shall utilize an amplitude control, adjust the

sensitivity (gain) as per given table. The indication shall fall within the
specified limit. The setting and reading must be of 1% full screen.

INDICATION LIMITS %
INDICATION SET AT % dB CONTROL
OF FULL SCREEN
OF FULL SCREEN CHANGE
HEIGHT
80 -6dB 35 to 45
80 -12dB 15 to 25
40 +6dB 65 to 95
20 +12dB 65 to 95
accura
5.3.5 T

horizontal linearity of the test instrument shall be qualified over the full
sound path distance to be used. The horizontal linearity of the test instrument
shall be requalified at two month intervals in each of the distance ranges that
the instrument will be used.
The horizontal sweep shall be adjusted for distance calibration to
present the equivalent of at least two plate thicknesses on the display.
The sensivity shall be adjusted at a location free of indications so that
the first backwall reflection from the far side of the plate will be 50% to
75% of full screen height.

6.0 SEARCH UNIT

6.1 Search unit (transducer) consists of piezoelectric crystals in combination

With wearing surface or shoe shall be used. Both straight beam and angle
beam search units are used for testing and may contain either single or
twin crystals as one dedicated to transmit and the other to receive.
6.2 Single crystal or dual-crystal ( shall be 10mm and 25 mm diameter
respectively for straight beam and 8x9mm for angle beam) search unit
containing both transmitting and receiving crystal with frequency of 1 to 5
MHz shall be used when examining the parent metal.
6.3 Each weld shall be examined with at least two different probe 60 &
70°angles of operating frequencies between 1 to 5 MHz.
6.4 The selection of probe angle shall dependent on the weld geometry and the
judgment of the operator, but shall be in accordance with the scanning
technique employed
6.5 Measurements of beam spread for scan indexing shall be taken only when
required by referencing code section.
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6.6 Measurements of angle beam search units shall be performed

once for a search unit wedge combination in the calculated far
field at the beginning of each period of extended use. A
technique for beam spread shall be in accordance with ASME
SEC V Article 4 & 5
6.7 make of search unit shall be same as equipment or shall be compatible

7.0 COUPLANT

7.1 Starch which permits satisfactory transmission of Ultrasonic Waves shall be used as
couplant However, same couplant shall be used for calibration as well as testing.

7.1 Couplant used on nickel base alloys shall not contain more than 250 PPM of sulfur.

7.2 Couplants used on austenitic stainless steel or titanium shall not contain more than
250 PPM of halides (Chlorides plus Fluorides).

8.0 BASIC CALIBRATION BLOCK

8.1 Reflectors: Known reflectors shall be selected as per job requirement i.e. weld or
material velocity (i.e., side drilled holes, flat bottom holes, notches etc.) shall be
used to establish primary reference, responses of the equipment.
8.2 Material: The material from which the block is fabricated shall be of the same
product form, same material specification or equivalent P Number grouping (heat
treatment shall be same material) as one of the materials being examined. For the
purposes of this procedure P Nos. 1, 3, 4 & 5 materials are considered equivalent.
The calibration block shall receive at least the minimum tempering required by the
material specification for the type and grade. If the calibration block contain welds
other than cladding, and the component weld at time of examination has been heat
treated, the block shall receive the same heat treatment.
8.3 Quality: Prior to fabrication, the block material shall be completely examined with
a straight beam search unit. Areas that contain an indication exceeding the
remaining back wall reflection shall be excluded from the beam paths required
reach various calibration reflectors.
8.4 Surface Finish: The finish on the scanning surfaces of the block shall be
representative of the scanning surface finishes on the component to be examined.
8.5 Calibration Block:
Annexure1 (shall be as per actual requirement) shows block configuration
with hole size and location each weld thickness on the component must be
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represented by a block having a thickness relative to the component weld.

Where the block thickness is ±1 inch (25mm) spans two of the weld
thickness range shown in the figure, the block’s use shall be acceptable in
those portion of each thickness range covered by 1 inch (25mm).The hole
diameter shall be in accordance with the thickness of the block. Where two
or more base material thickness is involved, the calibration block thickness
shall be sufficient to contain the entire examination beam path. The hole
shall be drilled to a depth of 1-1/2 Inch (38mm) minimum but where
possible the depth shall be 2 inches (51mm)
8.6 Alternative blocks: Existing calibration blocks may be used for similar types of
examination provided the sound path distance(s) to the block’s reflector(s) is(are)
within ¼ in. (6mm) of what is required and the side-drilled hole(s) is(are) the same
or a smaller diameter than what is required

9.0 IDENTIFICATION OF WELD EXAMINATION AREAS:

9.1 Weld Locations: Weld locations and their identification shall be recorded on a weld
map or in an identification plan.

9.2 Marking: If welds are to be permanently marked, low stress stamps may be used.
Markings applied after final stress relief of the component shall not be deeper than
3
/64 in. (1.2mm).
9.3 Reference System: Each weld shall be located and identified by a system of
reference points. The system shall permit identification of each weld center line and
designation of regular intervals along the length of the weld.

10.0 SURFACE PREPARATION

10.1 Base Metal: The base metal on each side of weld shall be free of weld spatters,
surface irregularities, or foreign matters that might interfere with the examination.
10.2 Weld Metal: Where the weld metal interferes with the examination, the weld shall
be prepared as needed to permit the Ultrasonic Examination.

11.0 GENERAL CALIBRATION REQUIERMENTS

11.1 Ultrasonic system: Calibration shall include the complete ultrasonic system and
shall be performed prior to use of the system in the thickness range under
examination. Calibrations shall be performed from the surface corresponding to the
surface of the component from which examination will be performed.
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11.2 Examination shall be performed with same couplant, same contact wedges,
and same instrument controls which affects the linearity, used for
calibrations. The temperature differential between the calibration block and
examination surface shall be within 14 deg C.
11.3 Calibration surface: Calibrations shall be performed from the surface (clad or
unclad; convex or concave) corresponding to the surface of the component from
which the examination will be performed.

12.0 SYSTEM CALIBRATION FOR DISTANCE AMPLITUDE TECHNIQUES

12.1 Calibration blocks: Calibrations shall be performed using the standard calibration
block e.g. IIW V1/V2 shall be used

12.2 Technique:
12.2.1 The angle beam shall be directed towards the calibration reflector that
yields maximum response in area of interest.
12.2.2 Adjust the sensitivity control to provide an 80% ± 5% of FSH echo from the
hole. Mark the peak indication on the screen.
12.2.3 Without changing gain control, manipulate the search unit for
maximum response from other calibration reflectors at their beam paths to
generate the distance amplitude correction (DAC) curve.
12.2.4 These calibrations shall establish both the distance range calibration and
the distance amplitude correction.
12.3 Angle beam calibration:
12.3.1 As applicable, calibration shall provide the following information.
(a) Distance range calibration
(b) Distance amplitude correction in area of interest
(c) Echo amplitude measurement from the surface notch in the basic
calibration block.
12.3.2 When an electronic distance-amplitude correction device is used, the
primary reference responses from the basic calibration block shall be
equalized over the distance range to be employed in the examination. The
response equalization line shall be at a screen height of 40% to 80% of full
screen height
12.4 Straight beam calibration:
12.4.1 As applicable, calibration shall provide the following information.
(a) Distance range calibration
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(b) Distance amplitude correction in area of interest

12.4.2 When an electronic distance-amplitude correction device is
used, the primary reference responses from the basic
calibration block shall be equalized over the distance range to
be employed in the examination. The response equalization line shall be at
a screen height of 40% to 80% of full screen height.

13.0 CALIBRATION CONFIRMATION

13.1 System Changes: When any part of the examination system is changed, a
calibration check shall be made on the basic calibration block to verify that distance
range points and sensitivity settings satisfy the requirement of clauses 13.3 & 13.4

13.2 Periodic Examination Checks: A calibration check on at least one of the basic
reflectors in the basic calibration block or a check using a simulator shall be made at
the finish of each examination or series of similar examinations, and when
examination personnel are changed. Distance range points and sensitivity settings
shall satisfy the requirements of 13.3 & 13.4
13.3 Distance Range Points: If any distance range point has moved on the sweep line by
more than 10% of the distance reading or 5% of full sweep, whichever is grater,
correct the distance range calibration and note the correction in the examination
record. All recorded indications since the last valid calibration or calibration check
shall be re–examined and their values shall be changed on the data sheets or re–
recorded.
13.4 Sensitivity Settings: If any sensitivity setting has changed by more than 20% or
2dB of its amplitude, correct the sensitivity calibration and note the correction in
the examination record. If the sensitivity setting has decreased, all data sheets since
the last valid calibration check shall be marked void and the area covered by the
voided data shall be re–examined. If the sensitivity setting has increased, all
recorded indications since the last valid calibration or calibration check shall be re–
examined and their values shall be changed on the data sheets or re–recorded.

14.0 EXAMINATION

14.1 Scanning of the adjacent base metal by normal beam shall be performed to detect
reflectors that might affect interpretation of angle beam results and is not to be used
for acceptance or rejection of weld. Location and areas of such reflectors shall be
recorded.
14.2 Examination Coverage: The volume to be scanned shall be examined by moving the
search unit over the scanning surface so as to scan the entire examination volume
for each required search unit. Each pass of the search unit shall overlap a minimum
of 10% of the active transducer dimension (piezoelectric element) parallel to the
direction of scan indexing.
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14.3 Oscillation of the search unit is permitted if it can be demonstrated that

overlapping coverage is provided. The rate of search unit movement shall
not exceed 150mm/s (6in/s).
14.4 Scanning Sensitivity Level: Distance amplitude technique the scanning
sensitivity level shall be set a minimum of 6dB higher than the reference level gain
setting. The gain shall be increased to the extent that no calibration reflector
indications are less than 40%FSH.

15.0 TECHNIQUE:

15.1 Weld Joint Distance Amplitude Technique: When the referencing Code section
specifies a distance amplitude technique, weld joints shall be scanned with an
angle beam search unit in both parallel and transverse directions (4 scans) to the
weld axis. Before performing the angle beam examinations, a straight beam
examination shall be performed on the volume of base material through which the
angle beams will travel to locate any reflectors that can limit the ability of the angle
beam to examine the weld volume.
15.1.1 Angle Beam Technique
(a). Beam Angle: The search unit and beam angle selected shall be 45
degree or an angle appropriate for the configuration being examined
and shall be capable of detecting the calibration reflectors, over the
required angle beam path.
(b). Reflectors Parallel to the Weld Seam: The angle beam shall be directed
at approximate right angle to the weld axis from both sides of the weld
on the same surface when possible. The search unit shall be
manipulated so that the ultrasonic energy passes through the required
volume of weld and adjacent base material.
(c). Reflectors Transverse to the Weld Seam: The angle beam shall be
directed essentially parallel to the weld axis. The search unit shall be
manipulated so that the ultrasonic energy passes through the required
volume of weld and adjacent base material. The search unit shall be
rotated 180° and the examination repeated. If the weld cap is not
machined or ground flat, the examination shall be performed from base
metal on both side of the weld cap in both weld axis directions
(d). Restricted Access Welds: Welds that cannot be fully examined from
two directions using the angle beam technique (e.g., Corner and Tee
joints) shall also be examined, if possible, with a straight beam
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technique. These areas of restricted access shall be noted in the

examination report.
(e). Inaccessible Welds: Welds that cannot be examined from at least one
side (edge) using the angle beam technique shall be noted in the
examination report.
15.1.2 Straight Beam Technique:
Whenever Straight Beam examination is part of the weld testing the scanning
shall be performed at a gain setting of at least two times the primary
reference level. Evaluation shall be performed at primary levels.
15.1.3 Discontinuity sizing shall be done as per 6dB drop method.

16.0 EVALUATION:

16.1 Evaluation of indication due to geometrical origin shall be done as follows:

16.1.1 Interpret the area containing the reflector in accordance with the applicable
examination procedure. If indication is near surface damp the area with
couplant
16.1.2 Plot and verify the reflector coordinates. Prepare a cross-sectional sketch
showing the reflector position and surface discontinuities such as root and
counter bore.
16.1.3 Review Fabrication or weld preparation drawings. Other ultrasonic
techniques or non destructive examination methods may be helpful in
determining a reflector’s true position, size and orientation.
16.1.4 The identity, maximum amplitude, locations and extent of reflector causing
a geometric indication shall be recorded.

16.2 Evaluation of indication other than geometrical origin shall be as follows:

16.2.1 Any imperfection that causes an indication in excess of 20% of DAC shall be
investigated to the extent that it can be evaluated in terms of acceptance or
rejection criteria given in the reference code which is stated below.
16.3 Recordable Indication: All reflectors from uncorrected areas having responses that
exceed 50% of reference level shall be recorded. This record shall locate each area,
the response level, the dimension, the depth below the surface & classifications.
16.4 Evaluation Level:
16.2.2 Distance Amplitude Techniques: All indications greater than 20% of the
reference level shall be investigated to the extent that they can be evaluated
in terms of the acceptance criteria of the referencing Code Section.
16.2.3 Non Distance Amplitude Techniques: All indications longer than 40% of the
rejectable flaw size shall be investigated to the extent that they can be
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evaluated in terms of the acceptance criteria of the referencing

Code Section
16.2.4 Evaluation of Laminar Reflectors: Reflectors evaluated as
laminar reflector in the base material which interfere with the
scanning of examination volumes shall require the angle beam examination
technique to be modified such that the maximum feasible volume is
examined, and shall be noted in the record of the examination.
16.2.5 Alternative Evaluations: Reflector dimensions exceeding the referencing
Code Section requirements may be evaluated to any alternative standards
provided by the referencing Code Section.

17.0 ACCEPTANCE / REJECTION STANDARD:

Acceptance criteria shall follow as per approved drawing / applicable code.

17.1 Following acceptance criteria meets the requirement of ASME Sec VIII. Div. 1
Appendix-12:
17.1.1 Discontinuities are unacceptable if the amplitude exceeds the reference
level and have a length which exceeds the following:
a) 6mm for T up to 19 mm
b) 1/3 T for T from 19mm to 57mm
c) 19mm for T over 57mm
Where T is the thickness (excluding any allowable reinforcement) of the
weld being examined. If the weld joins two members having different
thickness at the weld, T is the thinner of the two thicknesses.
17.2 Where discontinuities are interpreted to be cracks, lack of fusion or
incomplete penetration, they are unacceptable regardless of discontinuity size
or signal amplitude.
17.3 Acceptance Criteria as per AWS D1.1 Clause No. 6.12
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18.0 EXAMINATION OF REPAIRS:

All repaired areas shall be re–examined by the same procedure as used for the
original detection of the discontinuity.

19.0 PROCEDURE RE–QUALIFICATION:

If there is any change in value of any essential or non essential procedure shall be
revised, if there is any change in essential variables the procedure shall be re-
qualified.

20.0 REPORT OF THE EXAMINATION:

20.1Recording indications:

17.3.1 Non-rejectable indication: Non-rejectable indications shall be recorded as

specified by the referencing Code Section.
17.3.2 Rejectable indication: Reject able indications shall be recorded. As a
minimum, the type of indication (i.e. crack, non fusion, slag etc)., location
and extent (i.e. length) shall be recorded. No mandatory Appendices D and
K provide general recording examples for angle and straight beam search
units. Other techniques may be used.
20.2 Examination Records: For each ultrasonic examination, the following information
shall be recorded:
(a) Procedure identification and revision;
(b) Ultrasonic instrument identification (including manufacturer’s serial number);
(c) Search unit(s) identification (including manufacturer’s serial number,
frequency, and size);
(d) Beam angle(s) used;
(e) Couplant used, brand name or type;
(f) Search unit cable(s) used, type and length;
(g) Special equipment when used (search units, wedges, shoes, automatic
Scanning equipment, recording equipment etc).
(h) Computerized program identification and revision when used;
(i) Calibration block identification;
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(j) Simulation block(s) and electronic simulator(s) identification when

used;
(k) Instrument reference level gain and, if used, damping and reject
setting(s);
(l) Calibration data [including reference reflector(s), indication amplitude(s) and
distance reading(s)];
(m) Data correlating simulation block(s) and electronic simulator(s), when used,
with initial calibration;
(n) Identification and location of weld or volume scanned;
(o) Surface from which examination was conducted, including surface condition;
(p) Map or record of rejectable indication detected or area cleared;
(q) Areas of restricted access or inaccessible welds;
(r) Examination personnel identity and, when required by referencing Code
Section, qualification level;
(s) Date of examination. Note:- Items (b) through (m) may be included in a separate
calibration record provided the calibration record identification is included in
the examination record.
20.3 Report: A report of the examinations shall be made. The report shall include those
records. The report shall be filed and maintained in accordance with the
referencing Code section. Exhibit No: ND-03 R1 shall be used for reporting the
examination results.
20.4 Storage Media: Storage media for computerized scanning data and viewing
software shall be capable of securely storing and retrieving data for the time period
specified by the referencing Code section

21.0POST-EXAMINATION CLEANING

When Post Examination cleaning is required, it shall be done as soon as practical

after evaluation and documentation using a process that does not adversely affect the
part.
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ANNEXURE-I
NON-PIPING CALIBRATION BLOCK
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REQUIREMENT ESSENTIAL NON

ESSENTIAL CLAUSE NO
SL.
NO.
1 Weld configurations to be examined, including thickness
X -- 1.0
dimensions and base material product form (pipe, plate, etc.)
2 The surface from which the examination shall be performed X -- 4.0
Technique(s) (straight beam, angle beam, contact, and/or
3 immersion) X -- 4.0

4 Angle(s) and mode(s) of wave propagation in the material X -- 1.0

Search unit type(s), frequency (ies), and element
5 X -- 6.0
size(s)/shape(s)
6 Special search units, wedges, shoes, or saddles, when used X -- 4.0

7 Ultrasonic instrument(s) X -- 5.0

8.0,11.0,12.0,13.
8 Calibration [calibration block(s) and technique(s)] X --
0
9 Directions and extent of scanning X -- 14.0

10 Scanning (manual vs. automatic) X -- 4.0

11 Method for discriminating geometric from flaw indications X -- 16.1

12 Method for sizing indications X -- 16.2

13 Computer enhanced data acquisition, when used X -- NA

14 Scan overlap (decrease only) X -- 14.2

15 Personnel performance requirements, when required X -- 3.3

16 Personnel qualification requirements -- X 3.0

17 Surface condition (examination surface, calibration block) -- X 8.0,10.0

18 Couplant: brand name or type -- X 7.0

19 Post examination cleaning technique -- X 21.0

Automatic alarm and/or recording equipment, when
20 -- X NA
applicable
Records, including minimum calibration data to be recorded
21 (e.g., instrument settings) -- X 20.0

NOTE:
1. Any change in above described Essential Variable would require Re Demonstration of NDE
Procedures.
2. Any change in Non Essential Variables may be addressed by incorporating required change and
revising existing procedure without Re Demonstration.
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Appendix –I (Essential Variables)

NEO STRUCTO CONSTRUCTION PRIVATE LIMITED

ULTRASONIC EXAMINATION REPORT

REPORT NO: DATE: REQUEST NO

JOB NO PROJECT NO. DRAWING NO.

ACCEPTANCE
PROCEDURE & REV.NO. . CLIENT
STANDARD
ULTRASONIC
MODEL/SR. NO INSPECTION/TPI
EUQIPMENT MARK
CALIBRATION BASIC CLIBRATION
MATERIAL SPEC
REFLECTOR BLOCK
STAGE OF
REF. GRAIN LEVEL SCANING GRAIN LEVEL
INSPECTION
EXAMINATION SURFACE
TEST RANGE
TECHNIQUE CONDITION

Thick
Sr. Joint Welder ness Remar
Job Identification Size. Prob Observ Result
No. No. No. (mm) PRL ks
e ation
.

Note : PRL (PRIMARY REFERENCE LEVEL)

APPROVED
EXAMINED BY WITNESSED/APPROVED/REVIEWED BY
(LEVEL II/II) BY (LEVEL
II/III) TPI PMC/CLIENT CA AI
NAME

SIGN
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DATE
Exhibit No: ND-03 Rev-0