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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
Procedure For
Manual & Phased Array Ultrasonic Weld
Examination
00 25/02/2019
Dibyendu Bera S.K.Roy L&T CFCL
ASNT Level-II ASNT Level-III
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
Contents
1. Scope ................................................................................................................................................. 3
2. Reference Documents ....................................................................................................................... 3
3. Definitions ......................................................................................................................................... 3
4. Personnel Qualifications .................................................................................................................... 3
5. Equipment ..................................................................................................................... 3
6. Genearl Requirements ……………………………………………………………………………. 5
7. Basic Calibration block/Scanner block/Demonstration block ........................................................... 6
8. Calibration Block ........................................................................................................................ 6
9. Scanner block ........................................................................................................................ 6
10. Demonstration Block & Procedure Qualification................................................................................6
11. Encoder Calibration & Confirmation ……………………………………….. .................................. 6
12. Examination Area .......................................................................................................................... 6
13. Calibration Procedure ......................................................................................................................... 6
14. Scanning ............................................................................................................................. 7
15. Identification of weld …………………………………………………………………………… 10
16. Data Recording ............................................................................................................................. 10
17. Flaw Category ................................................................................. 10
18. Evaluation ……………………………………………………………………………………. 10
19. Acceptance Criteria .......................................................................................................................... 12
20. Data Interpretation ……………………………………………………………………………… 13
21. Examination Record& Report ................................................................................ 14
22. Post Cleaning ................................................................................................................................... 14
Table-1 ........................................................................................................................................................... 13
Table-2............................................................................................................................................................ 15
Table-2A.......................................................................................................................................................... 16
Annexure-I ................................................................................................................................................ 17
Annexure-II ................................................................................................................................................. 21
Annexure –III ……………………………………………………………………………………………… 22
Annexure –IV ………………………………………………………………………………………………..23
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
1. SCOPE:
1.1. This procedure describes the method of Ultrasonic examination of Butt welds of Outlet Nozzle
to Reducer joint using Phased array S scan & Manual Ultrasonic Examination by RTD Probe in
CFCL, Gadepan, Kota
1.2. Material grade : SA508 GR. 3 Class I & SB564 UNS NG08899
1.3. Weld Material : NiCr3 GTAW, NiCrFe2 - SMAW
1.4. Dia and Thickness : 22” and 42mm & 52mm of Nozzle & Reducer respectively.
2. REFERENCE DOCUMENTS:
3. DEFINITIONS:
3.1. PAUT Phased array Ultrasonic Examination
3.2. A Scan Amplitude based Scan
3.3. FSH Full Screen Height
4. PERSONNEL QUALIFICATIONS:
4.1. All personnel performing ultrasonic examination, final evaluation and reporting of test results
in accordance with this procedure shall meet the following minimum qualification requirements:
Personnel certified in Ultrasonic Examination as Level II or III in accordance with the IXAR
Written Practice IXAR-NDE-WP-10 which is prepared as per the guidelines of SNT-TC-1A-
2006 Edition.
4.2 Personnel performing scanning and acquire data shall be trained in the use of the equipment.
They shall demonstrate their ability to acquire examination data.
4.3 Personnel who analyze and interpret the acquired data shall be trained in the use of the equipment
and software used.
4.4 The training records of all the persons performing scanning, data acquisition, analyze and
interpretation shall be documented.
4.5 All the persons performing the scanning, data acquisition, analyze and interpretation shall
participate in the procedure qualification demonstration using demonstration block and
calibration block which shall be demonstrated to inspector/client. Test result shall be evaluated
independently by Level II or Level III.
4.6 Personnel performing scanning, acquiring data analyze and interpreting the collected data may
be trained by the manufacturer of the equipment or by a NDE Level III who already trained in
the use of equipment to acquire data, analyze and interpret the collected data using the software.
5. Equipment
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PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
5.1. The instrument shall provide a linear ‘A’ scan presentation for both setting up scan parameters
and for signal analysis. Instrument linearity shall be such that accuracy of the indicated
amplitude and time is within ±5% of the actual full scale amplitude and time. The ultrasonic
pulser may provide excitation voltage by tone burst, unipolar or bipolar square wave. Receiver
gain control shall be available to adjust the signal amplitude in increments of 1dB or less.
Preamplifiers may be used in the system. Analog to digital conversion of waveforms shall have
sampling rates at least four times the nominal frequency of the probe. When digital processing
is to be carried out on the raw data, this shall be increased to eight times the nominal frequency
of the probe. Instrument linearity checks shall be performed at intervals not to exceed one year.
5.2 Calibrated Ultrasonic system “OMNI SCAN MX2 32: 128 PR Digital flaw detector with single
axis encoded automated / semi automated scanner shall be used for the testing. Data Analysis
software OMNIPC/ TOMOVIEW shall be used for and post processing of data.
5.3 Equipment Linearity Checks:
PAUT & Manual ultrasonic equipment linearity shall be verified at intervals of 1year or prior to first
use thereafter. The instrument linearity verification shall be recorded on the ultrasonic instrument
linearity verification record.
5.3.1 Screen Height Linearity:
Couple a straight beam probe to the IIW V1 block and get multiple echoes from 25mm back
wall. Select any two echoes whose amplitudes are in the ratio of 2:1 with larger echo set at
80% of full screen height. Without moving the search unit, adjust the 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 smallest indication at each setting. The reading
must be 50% of the larger amplitude, within 5% of full screen height. The setting and reading
must be estimated to the nearest 1% of full screen height.
5.3.2 Amplitude Control linearity:
Couple a straight beam probe to the IIW V1 block and get multiple echoes from 25mm back
wall. Select any echo and note its amplitude. Reduce the gain by 6dB and read the amplitude
of the same indication. It must be 50% of the initial amplitude within 20% of the nominal
amplitude ratio. Perform this exercise for full range of the gain. The setting and reading must
be nearest 1% of full screen and the readings should be as follows
Table-1
Indication Set at % of Decibel control Indication Limits % of Full
Full Screen Change Screen
80 -6dB 32 to 48
80 -12dB 16 to 24
40 +6dB 64 to 96
20 +12dB 64 to 96
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
5.4 Transducers:
Phased Array – Olympus make A27 4MHz DMA ( Longitudinal Mode) 2(2X16) 1,3 mm pitch
Manual - Modsonics make or Equivalent RTD Make Probe 2(10-15 dia.) 2 MHz
45°,60°,70° FD 10 ,45°FD 30, 60°FD54 & Creep Wave
5.5 PA Wedges:
Phased array wedges should be of a design to accommodate the aforementioned phase array probes.
Nominal refracted wedge angles shall be such that to ensure coverage of the weld and heat
affected zone. Wedges shall have provision of irrigation holes and carbides for couplant
flow. The wave mode of propagation shall be longitudinal wave in the material.
Table- 3
Wedge Specifications
5.6 A couplant shall be used which provides optimum wetting, transmission of ultrasound, resistance to
corrosion, viscosity and removal characteristics. For this inspection couplant shall be water/sonotec
ultragel -II. The same couplant shall be used for both calibration and examination. Water
conditioner may be added to improve wettability and corrosive resistance property and the halides
shall be less than 250ppm.
6.1 Surface preparation – The scanning surface finishes on the component to be examined is
required such that it will maintain acoustical contact of the search unit. The finish on the
scanning surfaces of the block shall be representative of the scanning surface finishes on the
component to be examined. The base metal on each side of the weld shall be free of weld
spatters, surface irregularities or foreign matters that might interfere with the examination.
6.2 Weld surface shall have uniform & weld reinforcement shall be ground smooth flush to the
base metal height.
6.3 Temperature – The maximum surface temperature to be scanned should not exceed 50 ͦ C.
Surface temperature shall be within ±14 ͦ C of the reference block temperature when the
Calibration was performed.
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
7.2 Scanner Block: Scanner block is used to check the system confirmation at regular intervals as
described in clause 8 of this procedure. Either this block may be made separately or the basic
calibration block may be used for this.
7.3 Demonstration block: Demonstration block is a block containing artificial flaws and used to qualify
the procedure as described in Annexure-III of this procedure.
9.1 Calibration
The positional encoder which is placed on scanner shall be calibrated by moving
a minimum distance of 20 inch(500mm) and displayed distance being ±1% of the actual
distance moved.
9.2 Confirmation
A calibration check shall be performed at intervals not to exceed one month or prior to first use
thereafter.
10.1 The PAUT examination area shall cover the full volume of weld, plus the HAZ area. Each weld
shall be designated a unique identification numbers and this numbers shall be documented and
recorded.
10.2 A scan plan for each thickness and bevel angle shall be made to ensure weld coverage and
additional area as per clause 12.1. The scan plan shall contain all the beam angles used in virtual
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
probe aperture (VPA) in PAUT examination to cover weld examination area. All the scan plans
shall be documented as addenda to this procedure.
10.3.1 Re-examination of the weld shall be done under the following conditions.
- Any changes which exceeds the limits in calibration set ups.
- When missing data lines in the display shall not exceed two scan lines per 25mm
length scanned and no adjacent lines shall be missed
- When scan length is less than the actual length of weld seam.
- Loss of couplant .
10.4.1.3 S.S Weld Scanning.: As the grain structure is coarse it is difficult with normal shear
wave angle beam , so for this dual matrix longitudinal shear wave angle beam shall be used for
weld scanning. Apart from this 80⁰ creep wave also shall be used to cover the entire weld
volume scanning from OD/ outside.
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
Page 8 of 23
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
13.1 Weld Location: Weld location and identification such as part number, seam number shall be
recorded.
13.2 Marking: If welds are to be permanently marked, hard number punch/ vibro etching can be
used. Marking after final stress relief of the component shall not be deeper than 1.2mm.
15. Evaluation
15.1 The operator shall determine whether the indication is originated from a flaw or is a
geometric indication. The a/t ratio shall be verified for the acceptance for the indication,
which is originated from the flaw. If it is from the flaw it shall be recorded.
15.2 To acquire additional information of the flaw inspection with manual angle beam
examinations/ method may be performed.
15.3 Geometric Indication - Recordable ultrasonic indications, of geometric or metallurgical
origin, shall be classified as such. Weld reinforcement, root geometry or variations in
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
15.8 Initial data evaluation shall be carried out using the unprocessed data only.
A flaw shall be considered a surface flaw if the separation of the flaw from the
nearest surface of the component is equal to or less than half of the through
dimensional height of the flaw.
15.9 The dimension of the flaw shall be determined by the rectangle that fully contains
the area of the flaw.
Discontinuous flaws shall be considered a singular planar flaw if the distance between adjacent
flaws is equal to or less than S.
Discontinuous flaws that are oriented primarily in parallel planes shall be considered a singular
planar flaw if the distance between adjacent planes is equal to or less than 12.7mm.
Discontinuous flaws that are coplanar and nonaligned in the through wall thickness direction of
the component shall be considered a singular planar flaw if the distance between adjacent flaws
is equal to or less than S. .(S is the distance from the nearest surface.)
Discontinuous flaws that are coplanar in the through wall thickness direction within two parallel
planes 12.7mm apart (i.e., normal to the pressure retaining surface of the component) are
unacceptable if the additive flaw depth dimension of the flaws exceeds the limit.
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
Notes :
1) “l ” is length of the defect
2) “a “ is the height of the surface defect
3) “2a” is the height of the sub-surface defect
4) “S” separation of indication from nearest surface.
5) “t” thickness of the weld excluding any allowable reinforcement.
16.1.1 Surface flaws - Unless the UT data confirms that a flaw is not surface connected it shall not be
considered a surface connected flaw and it is unacceptable unless a surface examination is
performed any one of the following examination techniques.
a) Magnetic Particle examination (MT) in accordance with paragraph 7.5.6 of ASME
Sec.VIII Div.2
b) Liquid penetrant examination (PT) in accordance with paragraph 7.5.7 of ASME Sec.VIII
Div.2
16.1.2 Multiple flaws –
16.1.3 Discontinuous flaws shall be considered a singular planar flaw if the distance
between adjacent flaws is equal to or less than S as shown in Figure in Annexure-I.
16.1.4 Discontinuous flaws that are oriented primarily in parallel planes shall be Considered
a singular planar flaw if the distance between the adjacent planes is equal to or
less than ½ inch. Refer to Figure in Annexure -I.
16.1.5 Discontinuous flaws that is coplanar and non-aligned in the through-wall Thickness
direction of the component shall be considered a singular planar flaw if the
distance between adjacent flaws is equal to or less than S as shown in Figure in
Annexure-I
16.1.6 Discontinuous flaws that is coplanar in the through-wall direction within two
Parallel planes ½ inch apart (i.e., normal to the pressure-retaining surface of the
component) are unacceptable if the additive flaw depth dimension of other flaws
exceeds those shown in Figure in Annexure –I.
16.1.7 Subsurface flaws - Flaw length (l) shall not exceed 4t.
16.2 Acceptance shall be as per ASME Sec. VIII Div.2. Indications shall be measured as aspect
ratio (a/l) and acceptance / rejection shall be as per Table-1 given below. For definitions of
surface and subsurface flaws and their separation follow as per ANNEXURE-I Flaw size shall
not be larger than the flaws in the table mentioned below.
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DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
(a) t is the thickness of the weld excluding any allowable reinforcement. For a butt weld joining
two members having different thickness at the weld, t is the thinner of these two thicknesses.
(b) For intermediate flaw aspect ratio a/l and thickness t (21/2 in< t < 4 in.) linear interpolation is
permissible.
16.3 For Manual UT
16.3.1 For Butt Welds/ Nozzle Welds .
Acceptance / Rejection standard shall be as per ASME Section VIII Div –2, as stated
below:
i. Discontinuities are unacceptable if the amplitude exceeds reference level
and discontinuities have length which exceeds 1/3 rd of weld thickness or 19 mm
whichever is smaller.
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
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NDE PROCEDURE
PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
Table-2
PROCEDURE REQUIREMENTS OF AN ULTRASONIC EXAMINATION
NON- PROEDURE
ESSENTIAL
Sr. No. REQUIREMENTS ESSENTIAL REFERENCE
VARIABLE
VARIABLES CLAUSE NO:
Weld Configuration to be examined, including
1 thickness dimensions and base material product form X CL 1.1.1
(pipe, plate etc)
The surface from which the examination shall be
2 X CL 10.4.1.3
performed
3 Instrument setting and scanning data X CL 11 & 14
Technique(s) ( Straight beam, angle beam, contact,
4 X CL1.1
and / or immersion )
Angle (s) and mode(s) of wave propagation in the
5 X CL 5.4
material
Search unit type (s), frequency (ies), and element size
6 X CL 5.4
(s) / shape (s)
Special unit search units, wedges, shoes or saddles,
7 X NA
when used
8 Ultrasonic instrument (s) X Cl. 5.4
9 Instrument Software X Cl. 5.4
10 Calibration ( Calibration block (s) and technique (s) X Annexure II
11 Direction, Selection and extent of scanning X Cl. 12
12 Scanning (manual vs. automatic) X Cl. 12
13 Scanning Speed X Cl.12.2
Method for discriminating geometric from flaw
14 X Cl.15
indications
15 Method for sizing indications ( length & Height ) X Cl. 15
16 Computer enhanced data acquisition, when used X Cl. 15
17 Scan overlap (decrease only) X Cl. 12
18 Personnel Qualification Requirements X Cl. 4
Surface Condition (Examination surface, Calibration
19 X
block)
20 Couplant : Brand name or type X
Automatic alarm and or recording equipment, when
21 X
applicable
Records, including minimum calibration data to be
21 X
recorded (eg.Instrument setting)
22 Personnel Performance requirements (when required) X X
Search unit mechanical fixturing device(manufacturer
23 X X
and model)
24 Scanner and adhering and guiding mechanism X
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DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
TABLE-2A
NON- PROEDURE
ESSENTIAL
Sr. No. REQUIREMENTS ESSENTIAL REFERENCE
VARIABLE
VARIABLES CLAUSE NO:
Search unit(s)
1 X
(element pitch, size, number, gap dimensions)
Focal range(s)
2 X Scan Plan
(identify plane, depth, or sound path as applicable)
Virtual aperture size (s)
3 (number of elements, element width, and effective X Scan Plan
height) (Note (1))
4 Wedge natural refracted angle X Scan Plan
5 Scan Plan X Attached
Data sampling spacing X Cl 14
6 Additional E-scan requirements:
Rastering angle(s) X N.A
Aperture start and stop element numbers X N.A
Aperture incremental change(s)
7 X N.A
(number of elements stepped)
8 Additional S-scan requirements:
Sweep angular range(s) X Scan Plan
Angular sweep increment (incremental angle change,
X Scan Plan
deg)
9 Aperture element number (first and last) X Scan Plan
Note(1): Effective height is the distance measured from the outside edge of the first element to last element
used in focal law.
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PROCEDURE FOR MANUAL & PHASED ARRAY ULTRASONIC EXAMINATION
DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
ANNEXURE-I
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DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
ANNEXURE-I Contd.
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DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
ANNEXURE I Contd.
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ANNEXURE-I Contd.
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DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
ANNEXURE -II
CALIBRATION BLOCK
1
2
52MM
P22 3 S.S.
4
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DOCUMENT NO.: IXAR/CFCL/2019/PAUT-02 REV.0 DATE: 25.02.2019
ANNEXURE-III
DEMONSTRATION BLOCK
500 mm
50 mm v 50 mm
100 mm 200 mm 100 mm
400 mm
1 2 3 4
DIMENSION OF FLAWS
ANNEXURE - IV
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