Ultrasonic Phased Array Procedure

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AM
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Title: Ultrasonic Contact Phased Array Examination
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Cover Page
PROJECT
CONTRACT
COPY # 1
COPY # 2
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Revision record :
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Date
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1. Originator
Ed Trotter
Specialized Equipment
Division Manager
ASNT Level III UT # XXXX
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Changes Made
First Issue
Doc. Approver
Tae Young Shin
2.Reviewer
Keith Baldam
3. Approving Officer
Tae Young Shin
NDT and VID Division Manager
General Manager
ASNT Level III UT #11863
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Table of Contents
Cover Page................................................................................................................................... 1
1.0
Scope................................................................................................................................. 3
2.0
General Requirements ....................................................................................................... 3
3.0
Weld Configuration, Materials and Forms .......................................................................... 4
4.0
Ultrasonic Instrumentation ................................................................................................. 5
5.0
Examination ....................................................................................................................... 8
6.0
Procedure Qualification and Reference Calibration Blocks .............................................. 14
7.0
Acceptance / Rejection Criteria ........................................................................................ 14
8.0
Records and Report ......................................................................................................... 15
Drawing 1: Amplitude Reference Level Blocks ........................................................................... 17
Appendix A (Page 1 of 10).......................................................................................................... 18
Appendix A (Page 10 of 10)........................................................................................................ 27
Appendix B: Specific Instructions and Report Form (Page 1 of 5) .............................................. 28
Appendix C (Page 1 of 8) ........................................................................................................... 29
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1.0 Scope
1.1. This procedure is used for the Ultrasonic examination of Welds and the dimensioning of
indications for comparison with standards established in the acceptance/rejection criteria
included in this document.
1.2. The following information is included in this procedure:
1.2.1.
Personnel Qualification/Certification requirements
1.2.2.
Procedure Qualification/Demonstration requirements
1.2.3.
Instrumentation characteristics and requirements
1.2.4.
Calibration Blocks
1.2.5.
Extent of examination and examination volume
1.2.6.
Acceptance/Rejection criteria
1.2.7.
Documentation, records and marking requirements
1.2.8.
Report requirements
2.0 General Requirements

2.1. This procedure is Qualified and Demonstrated within specific parameters; this information
is clearly defined in this procedure any deviation within the specific ranges, limits or
specifications regarding the following Essential Variables will require additional
Qualification/Demonstration of this test procedure:
2.1.1.
Personnel Qualification/Certification and performance requirements
2.1.2.
Weld Configuration, material PClass, thickness, dimensions and material product

form.
2.1.3.
Techniques (straight beam, angle beam, contact, etc.). Manual, Semiautomated

(encoded in passive axis), fully automated method
2.1.4.
Angles, angle range and wave mode propagation
2.1.5.
Transducer, wedges, sizes, number of crystals, frequency, shape. Surface condition

and coupling requirements
2.1.6.
Ultrasonic Instrument characteristics. Instrument setup and recording requirements
2.1.7.
Calibration technique and Calibration block description and characteristics
2.1.8.
Scanning technique, overlapping, surface from which the examination will be

performed, directions and extent of scanning.
2.1.9.
Method for sizing indications.
2.1.10. Discrimination between geometric and flaw indications, indications sizing technique
2.2. Reference Documents
2.2.1.
ASME B31.1 2007, Chapter VI Inspection, Examination and Testing; Par:

136.4.6 Ultrasonic Examination.
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2.2.2.
ASME B31.3 2007, Chapter VI Inspection, Examination and Testing; Par:

136.4.6
2.2.3.
ASME Code for Boilers and Pressure Vessels, Section V, 2007
2.3. Personnel Qualification/Certification Requirements

2.3.1.
A Level II UT ASNT Certified inspector in ultrasonics is required to perform this test.

The NDE personnel collecting and analysis UT data shall have demonstrated their
ability to perform an acceptable examination using this procedure.
2.3.2.
The AMSYCO Written Practice for Personnel Qualification and Certification in Non
Destructive Testing shall be used as a reference.
2.3.3.
Specific qualification requiring a minimum of 24 hrs of Phase Array Instrumentation

training is required.
2.3.4.
A Level III ASNT certified inspector will review and assure the quality of the
inspection results. The final data package shall be reviewed by a UT Level III
individual.
3.0 Weld Configuration, Materials and Forms

3.1. This procedure can be used for welds with a maximum thickness of 5 inches on the base
metal.
3.2. Materials included in Pclass numbers 1, 3, 4, 5A and 5X are considered equivalent. This
procedure cannot be used for high alloy and high nickel materials.
3.3. Two sets of calibration blocks are required:
3.3.1.
Basic Calibration Blocks: These blocks are used for general instrument calibration
and performance verification. The manufacturer of Omniscan has a specific
sequence for calibration of the instrument. This information is included in Appendix
A of this document. The blocks required for this general instrument calibration are
the IIW type blocks and side drill hole blocks as described in that appendix.
3.3.2.
Reference Calibration Block: Piping calibration blocks (See figure from T434.3 at
Drawing 1) of the same nominal size and schedule shall be used. Alternatively, the
Basic Calibration block (Drawing 1) and provisions of T434.1.7 may be used where
it is demonstrated that sidedrilled hole sensitivity is equal to or greater than that of
the ID and OD notches. This demonstration shall be documented and on a probe
specific basis.
3.4. Prior to start the inspection the following information is required:

3.4.1.
Base material nominal thickness
3.4.2.
Diameter, curvature and other geometric configuration characteristics
3.4.3.
Obstructions and other accessories located from the weld center line within 6 times
the thickness of the base material.
3.4.4.
Bevel dimensions, shape and angles.
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3.4.5.
Root characteristics, including the presence of backing strips, counter bore and
geometry.
3.4.6.
Welding technique
3.4.7.
Root and Hot passes NDE inspection requirements, inspection results and repairs.
4.0 Ultrasonic Instrumentation

The ultrasonic examination shall be performed using a device employing automatic computer
based data acquisition. Data is recorded in unprocessed form. A complete data set with no gating,
filtering, theresholding for the response in the examination volume shall be included.
4.1. Instrument
4.1.1.
This procedure is specific for the Phase Array Instrument manufactured by RD

Tech, Model Omniscan.
4.1.2.
The Omniscan software used for this service will be revision 2.0R2 or newer. This
needs to be compatible with the AMSYCOS license for operation of the TOMO
VIEW PostAnalysis software.
4.2. Analysis Software

4.2.1.
The analysis of the data will be performed using the RDTech, TOMOVIEW 2.4 or
newer, installed in a Laptop computer.
4.2.2.
In order to analyze this data, the files will be transferred to this computer at the end
of inspection of every weld, or with the frequency and conditions indicated later in
this Procedure.
4.3. Transducer
4.3.1.
A 16 element (or higher) phase array transducer will be used for this test. Model
and Serial number will be recorded in the Specific Instructions, See Appendix B.
4.4. Encoder, Scanner and Transducer Mounting

4.4.1.
A semiautomated technique, encoding the passive axis of the transducer will be

used for this test. The maximum resolution for encoding position will be 0.039.
4.4.2.
The encoder will be calibrated so that the accuracy shall be within 1% per 20
inches of scanning length.
4.4.3.
The transducer will be mounted in such a manner that probe spacing from the weld
centerline will be maintained. An automated or semiautomated device (carriage,
sledge, cradle, etc.) appropriate for component geometry and capable of ensuring
accurate x and y coordinate movement shall be used. Circumferential movement of
the apparatus can be manually assisted.
4.4.4.
The encoded Olympus HSPXY01 semiautomated scanner will be used for

examinations.
4.5. Transducer Frequency

4.5.1.
5 MHz will be used for base materials with thickness not exceeding 1.0 inches.
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4.5.2.
2 MHz will be used for base materials from 1.0 to 6.0 inches.
4.5.3.
This procedure cannot be used for material base exceeding 6 inches.
4.6. Wedge: A 45 or 60 Wedge can be used for this inspection. Angular shear waves are
produced and used for this inspection.
4.7. Wedge Shape: For parts with diameters below 20 in diameter; wedge shaping is allowed to
help on the coupling and transducer stability, using carbide inserts to provide stability to the
wedge can also be used. The same wedge design, and/or carbide insert positions should
be used for the qualification of the test procedure.
4.8. Phase Array Technique and Angle Interval
4.8.1.
This procedure requires the use of SScan and/or LScan techniques and views.
A, B, and CScans are also used for the detection and sizing of flaws.
4.8.2.
The technique used in this procedure is not based in amplitude for the detection or
flaw sizing. Other techniques are used for this purpose as described later.
4.8.3.
DAC and other amplitude based references are not allowed for detection or sizing.
4.8.4.
The instrument will be calibrated in Sensitivity and Delay for a interval not
exceeding 35 to Any restriction on the angle interval calibration will be considered
on the design of the specific scanning technique, and included in the Specific
Instructions as described later.
4.9. Surface Condition and Coupling

4.9.1.
The area within 4 times the thickness of the base material from the weld center line
has to be free from spattering, loose materials, and other surface condition that will
prevent the transducer from getting and keeping acoustic coupling.
4.9.2.
The material used for coupling will provide enough wetability to avoid any air
bubbles to build in the shoe/material interface.
4.9.3.
The coupling product should not be detrimental to the material being examined
4.9.4.
The Brand name and grade of the couplant used will be recorded in the report for
this service.
4.9.5.
Coupling between the transducer and the wedge shall be visually checked every 4
hours.
4.10. Instrument Calibration.

4.10.1. Instrument Calibration and SetUp
4.10.1.1. The RDTech Omniscan instrument requires specific calibration sequences as
indicated by the manufacturer to insure that the system is performing within
the design specifications. The Complete calibration sequence specified in the
Instrument Operating Manual will be used for this calibration. This calibration
includes the Screen High Linearity check and the Amplitude Control Linearity
checks.
4.10.1.2. A SetUp file will be constructed for each focallength.
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4.10.1.3. Appendix A is attached to this procedure showing the applicable pages of

the Omniscan Operation Manual indicating the sequence for calibration.
4.10.1.4. The focal distance will be selected as calculated at 1.0 times the pipe
thickness. This calibration will be used for scanning at the ID, midwall and
OD indications.
4.10.1.5. The Full Instrument Calibration will be performed:
a) Before every shift
b) If the transducer or transducer wedge are replaced.
4.10.2. Instrument Calibration Record: The instrument calibration setup will be recorded in
the Omniscan media. The file name used will contain the following characters:
C2_SETUP_####.OPS
Where:
C2: Weld Identification number
#### is a sequential number
This name will be kept in the test Log Book.
4.10.3. Instrument Calibration Verification
4.10.3.1. This verification will be used as reference for Instrument Calibration and
instrument verification only. Other techniques not based in amplitude will be
used for the detection and sizing of flaws as described later.
4.10.3.2. A calibration verification will be performed:
a) Every four (4) hours
b) When changing inspectors
4.10.3.3. The calibration verification sequence includes:
a) Distance/range calibration verification using the IIW block 4 inches
circumference side. For this verification, change the Screen Rulers to
Half path.
b) Verification of operation on all the angles intervals and positioning. The
0.060 hole located in the IIW block will be used for. For this verification,
return the Screen Rulers to Truth Depth.
c) Verification of reference amplitude using the Amplitude Reference Level
Block and reflector(s) used for this setting.
4.10.4. Instrument Recording
4.10.4.1. The instrument will be set to record every AScan obtained for all angles and
encoder positions. This information will be used for postprocessing and
future reference.
4.10.4.2. A file name for each scan will be used. The scan designation shall include:
ID7777USP1####.OPD
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Where:
ID7777: Is the weld identification number as indicated by the Customer
US or DS: Upstream or Downstream, as explained in Paragraph 5.64
P1: Scan Position Sequence
####: Scan serial number.
NOTE: These names will be kept in the log book.
4.10.4.3. Those scans that are considered Valid will be marked as OK, the scans
that will not be used for analysis will be marked as N/G, not good. This will
be stated in the Comments column of the Scans Table.
4.10.4.4. Data BackUp: The data files and setup files will be backedup in other media
every weld. The backup data will be kept in two different media at the same
time.
5.0 Examination
5.1.
Specific Instructions: Specific instructions (scan plans) will be prepared and submitted for
review and approval prior to examinations.
5.1.1.
This information will be included to the documentation presented in Appendix B.
5.1.2.
Appendix B Is the form that will be used for the specific instructions for each weld.
This form includes all the information necessary to perform the weld inspection in
accordance with this Test Procedure.
5.1.3.
Specific instructions for each weld will be specified before the start of the inspection.
5.1.4.
The specific instructions will cover details regarding the weld and bevel geometry,
part geometry, diameters and other information that is used for the specific
examination on each weld.
5.1.5.
These specific instructions will be obtained from: Calculations, plotting and

simulation.
5.1.6.
The specific instructions are part of this procedure and will be Qualified under then
Procedure Qualification program.
5.1.7.
The following information and other discussed previously will be included in those
instructions:
5.2. Examination Coverage Volume

5.2.1.
The ultrasonic examination shall include the volume of the weld plus the heat
affected zone.
5.2.2.
The weld should be inspected in both sides, unless obstruction or inaccessibility

prevents the inspection from one side. In this case, this situation shall be discussed
and approved by the customer or the Quality Assurance personnel from the
customer.
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5.2.3.
The scan plan drawing [crosssection] will need to show complete coverage and
include material type(P# is OK), beam plots, refracted angles, probe index spacing
(from weld centerline), overlap, frequencies, thickness, crosssection geometry,
weld joint configuration and dimensions, weld crown width and profile, two
directional beam coverage (minimum), and location of calibration reflectors.
5.2.4.
The scan plan will be used to define the transducer positions to the weld centerline
and be included in the Specific Instructions. This document will be attached to the
Specific Instructions document presented in Appendix B.
5.3. Ultrasonic Scanning Technique

5.3.1.
Straight Beam Inspection: The volume of metal that will be used to transmit sound
from either side of the weld will be examined to detect planar reflectors or other
inclusions that may prevent the efficient transmission of the sound in these areas.
5.3.2.
Reflectors Parallel to the Weld Seam: The welds will be scanned to detect any flaws
that are located parallel to the weld center line within the examination coverage
volume.
5.3.3.
Reflectors Transverse to the Weld Seam:
5.3.3.1.
The welds will be scanned to detect any flaws that are located transversal to
the weld center line within the examination coverage volume.
5.3.3.2.
The ultrasonic transducer shall be aimed parallel to the weld centerline. The
transducer will be manipulated so that the ultrasonic beam passthrough all
the examination volume and adjacent base metal. Scanning shall be done in
two directions 180. to each other and on both sides of the weld to the extent
possible. Areas blocked by geometric condition shall be examined at least
one direction. Any indication detected will be sized with the techniques
indicated later and compared with the Acceptance/Rejection criteria included
in this test procedure.
5.4. Fusion Face, Bevel Angle and Ultrasonic Incidence Angle

5.4.1.
It is considered that the maximum intensity of ultrasound reflection will happen

when the flaw is oriented perpendicular to the ultrasonic beam, and within 5 of that
direction.
5.4.2.
Using Phase Array technologies allows for increasing the probability of detection
based on the presence of sound in a diverse interval of angles interrogating the
weld.
5.4.3.
It is also clear that fusion lines, inclusions and other flaws are oriented primarily in
the same angle as the weld bevel face.
5.4.4.
Plotting or simulation of the weld shall be used to ensure that 100% of the volume of
the weld and the HAZ are inspected.
5.4.5.
With this consideration the following ultrasonic technique will be used:
5.4.5.1.
Considering the bevel design two or more SScans or LScans will be

obtained on either side of the weld, by moving the transducer parallel to the
weld center line at specific distances.
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5.4.5.2.
Plotting or simulation of the weld geometry shall be used to calculate what is

the angle, range and distance from the weld center line to obtain maximum
amplitude reflection from flaws located at the fusion face surface, root and
weld crown.
5.4.5.3.
The fusion face inspected shall not be more that the area covered by an
interval of 5 from the calculated maximum amplitude angle.
5.4.5.4.
It is expected that for thickness of 1.5 inches or less at least 2 scans will be
necessary and 3 or more will be necessary for thickness of more than 1.5
inches.
5.4.5.5.
The crown of the weld shall be inspected using the smallest angle that allows
the shortest sound path in a fullskip (i.e. 4055).
5.4.5.6.
The root and the midwall of the weld shall be inspected with the angle that on
the first leg reaches the area with the shortest sound path. (i.e. 5065).
5.4.5.7.
If crown obstructions prevents from getting a complete volume coverage of

the midwall section, then a twoleg inspection with the shortest sound path
shall be used.
5.5. Angular Interval for Each Scan

5.5.1.
The phase array instrument is calibrated for SScan angular aperture within 35 to
70, as indicated in the specific instructions for each weld design. Using this angular
interval will increase the probability of detection of flaws within the weld and the
HAZ.
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5.5.2.
5.5.2 Special attention will be placed to those angles that are expected to produce
maximum amplitude from reflectors located at the fusion face, crown toe cracks or
weld root flaws.
5.5.3.
The angular interval must ensure that 100% of the volume and the HAZ are
interrogated.
5.5.4.
Presentations type: A, B, and C are used in conjunction with SScans and L

Scans to obtain the highest quality information and increase the flaws probability of
detection when compared with the Acceptance/Rejection Criteria indicated later in
this procedure.
5.6. Scan Designation and Sequence

5.6.1.
The Specific instructions will indicate the number and position of the Scans
performed on each weld.
5.6.2.
Information regarding the length of each scan and file designation will also be
included in that document.
5.6.3.
A zero and scan direction stamp will be premarked on the welds to inspect, and will
be used as reference start point for all measurements and for scanning direction.
The symbol used will be:
>
5.6.4.
The zero marking will be designated as 12:00 oclock position. The Index and Scan
definitions indicated will be used as references for indication and scans positions
and directions. Forward or Downstream and Backward or UpStream direction are
defined as follows:
5.6.5.
If an obstruction is present on the scan transducer path, stop and save the file at the
point before the obstruction and continue after the obstruction. The names of both
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files and the distance between the stop and the start will be documented and
included.
5.7. Scanning Sensitivity Level, DAC Curve and Discontinuity Detection
5.7.1.
A Reference Calibration Block will be used to set a Reference Level.
5.7.2.
Piping calibration blocks (See figure from T434.3 at Drawing 1) of the same
nominal size and schedule shall be used. Alternatively, the Basic Calibration block
(Drawing 1) and provisions of T434.1.7 may be used where it is demonstrated that
sidedrilled hole sensitivity is equal to or greater than that of the ID and OD notches.
This demonstration shall be documented and on a probespecific basis.
5.7.3.
The calibration block shall comply with the dimensions and characteristics included
in the Table, General Notes and Note included in Drawing 1.
5.7.4.
A DAC Curve shall be established using the reflectors included in the Basic
Calibration Block. The angle beam shall be directed toward the calibration reflector
that yields the maximum response, and the instrument shall be set to obtain an 80%
of full screen height indication. This shall be the reference level.
5.7.5.
The transducer then shall be manipulated to obtain without changing instrument

settings to obtain the maximum responses from the other calibration reflectors to
generate a DAC curve.
5.7.6.
This calibration shall establish the sweep range and the distance amplitude
correction.
5.7.7.
The examination coverage volume will be scanned with a Hardware Gain (Hard
Gain) at Reference Level plus no more than 6 dB. The detection analysis in TOMO
VIEW will be performed with gain at Reference Level plus at least 6 db more gain,
but not more than 14 db of Software Gain (Soft Gain) than the reference gain used
during the actual scanning.
5.7.8.
This process is intended for the detection of discontinuities, both relevant (flaws)
and nonrelevant (geometric, metallurgical).
5.7.9.
Sizing of these discontinuities will be performed using the methods indicated later.
5.8. Indications Record

5.8.1.
All indications that produced reflection exceeding 20% of the Reference Level shall
be recorded and investigated.
5.8.2.
Ultrasonic indications of geometric and metallurgical origin shall be classified as

follows:
5.8.2.1.
Indications determined to originate from the surface configuration.
5.8.2.2.
Indications produced by variation on the metallurgical structure of the

materials.
NOTE: The following steps should be taken to classify an indication as geometric:

5.8.2.3.
Interpret the area containing the reflector in accordance with the Notes and
Recommendations included in APPENDIX C.
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5.8.2.4.
Plot and verify the reflector coordinates on the weld geometry.
5.8.2.5.
Review fabrication or weld preparation drawings.
5.8.2.6.
Alternatively other NDE methods may be applied to classify an indication as

geometric.
5.8.3.
Indications determined not to be from geometric or metallurgical origin and

exceeding 20% of the DAC Reference Level will be considered relevant. Relevant
indications shall be sized and characterized to obtain the following information:
a) Determine if it is a Crack, Lack of Fusion or a Lack of Penetration
b) Reflectivity compared to the DAC curve used as Reference Level
c) Length of indication
5.8.3.1.
5.8.3.1 To determine the characteristics of the indication APPENDIX C

includes a series of techniques based on:
a) Echodynamics
b) Amplitude Behavior
c) Weld position
These methods shall be used to determine if any indication is a crack, lack or
fusion or lack of penetration, regardless of its length.
5.8.3.2.
For length measurement the following technique shall be used:
5.8.3.3.
Length, measured parallel to the surface, designated as l, using the

following techniques:
a)
Instrument SetUp: gate length and positioning are required for flaw
detection and sizing of indications. The starting position of the gate will
have to include all parts of the first leg data excluding the wedge noise
which shows up in the initial part of the first leg. The gate should also
include the information up to half way of the third leg. This way we get
information about what is happening in the entire metal path and no
indication will be lost.
b)
Analysis: The analysis will be done by a combined analysis of the Cscan

and the Sector or Linear scan views and also by obtaining any additional
information from the Ascan. For sizing it is necessary to locate the
extreme dimensions of the indication. In many cases, the root or OD
indications might be masked by some reflections of the root or cap.
These reflections, although do not occur in the same time frame, can
overlap over the flaw indications in the Cscan. This will mean an obvious
compromise in the length of the indication. The method to overcome this
is to scan along the length of the Cscan and look for a maximum
indication of the flaw in the sector scan. Then, gate out this dimension of
the flaw only in the sector scan. This will provide us with indications only
from the flaw helping the sizing procedure greatly.
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c)
(CAUTION) Encoder Positioning: It is important to note the encoder

position at the start of each scan. Also care should be taken to ensure
the encoder slippage is minimum. This can be verified by checking the
length of the scan at the end of each scan and comparing that to the
actual circumference that had to be scanned. Identifying the correct
starting and ending position of the flaw is important for any rework to be
done. The encoder accuracy shall be within 1% per 20 inches of
scanning length.
d)
Flaw Length Sizing: For deeper ID/OD indications: The amplitude fall off
is gradual for a while and then drops off suddenly. The sudden dropoff
points are going to be the ends of the indication.
For Shallow ID/OD indications: In this case, the energy of the beam
hitting the flaw is not very high. Hence, the amplitude response is not
going to follow the profile of the indication. In this case, the amplitude
change will be gradual. The sizing will be taken to the end of the visible
indication or a 20% amplitude change in the signal.
For MidWall indications: The sizing of the length will be treated in a
similar fashion to the sizing of the deep and shallow ID/OD indications.
6.0 Procedure Qualification and Reference Calibration Blocks

6.1. This Procedure including the Specific Instructions will be qualified to assure that
discontinuities located on the ID, OD surface as well as in the subsurface of the weld are
detected and sized correctly.
6.2. Calibration blocks prepared by welding or hot isostatic process will contain indications
located on the ID, OD and midwall.
6.3. The calibration blocks shall be examined in accordance with the Ultrasonic procedure and
specific instructions.
6.4. The Procedure shall demonstrate to perform acceptably on the calibration blocks.
7.0 Acceptance / Rejection Criteria
7.1. Welds that are shown to have discontinuities which produce an amplitude greater than
20% of the Reference Level shall be investigated to determine their shape, identity and
location so that each indication may be evaluated for acceptance in accordance with (7.1)
and (7.2).
7.2. Any indication from cracking, lack of fusion or lack of penetration will be considered
rejectable regardless of length.
7.3. Any other indication that exceeding the DAC Reference Level will be considered
rejectable if additionally has the following characteristics:
7.3.1.
For thickness (t) up to , the indication length is more than
7.3.2.
For thickness (t) from up to 2.5 the indication length is more than t/3
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7.3.3.
For thickness above 2.5 the indication length is more than 0.750.
7.3.4.
NOTE: If the weld joins two members having different thicknesses at the weld, t is
the thinner of these thicknesses.
8.0 Records and Report

8.1. Test Log: A book will be prepared for each weld. All the drawings, specific instructions,
forms, inspection results and other documentation and records will be maintained in this
book. All calibration and calibration verification records will be maintained in this book.
8.2. Test Report: Appendix B Includes the form that will be used for the report of the
examination. The inspector must generate a Report per Weld including as a minimum:
8.2.1.
Identification of Job/Project/ Service; Date and Time of Data Acquisition; Date of

Data Analysis.
8.2.2.
Personnel and Certification Level
8.2.3.
Procedure ID and revision
8.2.4.
Search unit ID, s/n, type, frequency, and element size and number, couplant type.
8.2.5.
Search unit cable used, type, and length
8.2.6.
Special equipment used i.e. Scanner manufacturer and model, Data acquisition
increment
8.2.7.
Omniscan software version, Setup file names
8.2.8.
Data analysis (Tomoview) software name and version
8.2.9.
Calibration simulator information, if used
8.2.10. Reference level gain for all applicable scans.

8.2.11. Calibration data including reference reflectors, indication amplitude(s), and distance
reading(s). Calibration block identification and calibration records
8.2.12. Focal law parameters, including as applicable, angular range, focal depth, element
numbers used, angular incremental change, and wedge angle.
8.2.13. Scanning surface from which the examination was conducted, surface condition,
number of positions and distances to weld centerline, scanning sequence, files
names used to save Data Files.
8.2.14. Scan plan [crosssection] will need to show complete coverage and include material
identification, beam plots, refracted angles, probe index spacing (from weld
centerline), overlap, frequencies, thickness, crosssection geometry, weld joint
configuration and dimensions, weld crown width and profile, twodirectional or
multiple beam coverage.
8.2.15. Details of restricted access or inaccessible welds.
8.2.16. Map or record of indications detected, including dimensions, positions and
characterization, as well as any other pertinent information. Accepted or Rejected.
8.2.17. Comments
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8.3. Deliverables: The report formats are included as Appendix B on this procedure.
8.3.1.
A handwritten Report will be generated for each weld, and will be delivered to the
customer indicating the position of rejectable indications, if any.
8.3.2.
The rejectable indications will be marked on the surface of pipe with a paintpen
showing their position and length.
8.4. Data BackUp

8.4.1.
The data and setup files will be transferred to a PCComputer harddisk every
weld.
8.4.2.
The data and setup files and any other electronic documentation will be backedup
in a external harddisk drive or stick memory.
8.4.3.
All the data and documents will be stored in a external harddisk for permanent
storage. Two copies will be made. The customer will receive a copy and
AMSYCO'S will retain the other copy.
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Appendix C (Page 1 of 8)
Identifications of flaws in the welded joint can be performed based in three independent criteria or
by combination of either technique.
These techniques are:
Echodynamics and echo behavior
Amplitude expected and flaw orientation
Position of the flaw within the weld.
The following tables have descriptions for each one of these techniques:
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Figure 3: Weld areas identification and flaw position.
Notes on Positions and flaw characteristics when evaluated with UT

Nonfusion at Root: Several variations can occur.
Lack of Penetration: The internal welding head did not fire or sputtered. No metal is deposited.
Ideally this presents 2 smooth root faces, however, welders have been known to see this from the
outside and the Hot Pass bug can be run over the area twice. This can cause some metal to
penetrate and reduce the surface area of nonfused root face.
Nonfusion at Root:
Misalignment: Due to misalignment of the internal head or high low conditions, one side of the
root bevel may not get metal deposited on it. The Main Figure shows a missed edge on the right
side of the weld. Undercut, shown on the left, is the depression caused by melting of the parent
metal next to the weld edge. It would need to be very deep to detect but we could not reasonably
see a difference between U/C (U/C=undercut) and a missed edge.
Non-fusion Root:
Nonfusion Root: It may be possible for the root bead to be placed symmetrically but due to oil or
arc redirection, an area of the parent metal does not get melted to fuse with the weld puddle. The
bead will appear acceptable on the inside surface but nonfusion still exists. Although it does not
appear to be surface breaking it is considered a surface defect.
Nonfusion Root:
Nonfusion Root and LCP: If a condition of High Low exists or debris is caught between the root
bead and corner of the weld prep. at the land area, the nonfusion may span 2 zones. Such a flaw is
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difficult to evaluate as one or another condition. If seen mostly by the LCP probe it is called LCP
and if seen mostly with the Root probe but with some LCP component it is called a Root indication.
LCP:
Lack of Cross Penetration both identifies the defect and is the term used to identify the zone at the
weld land area. This can be associated with the internal welding machine not depositing the bead
deep enough, the hot pass weld not penetrating deep enough or is often associated with conditions
of high low. With welder problems the condition may be more symmetric (seen with approximately
equal length and amplitude upstream and downstream) whereas high low conditions could cause
one side to be more pronounced that the other. The adjacent channels (Root and hot pass 1) are
usually examined to see if the LCP extends inwards or outwards.
Nonfusion
Hot Pass:
With its 45 orientation, the hot pass bevel was a difficult problem for radiographic testing. Due to
the surface length of this area it has been divided into 2 zones, hot pass 1 and hot pass 2. UT
signals here are clear and due to the large angular difference between the 45 hot pass bevel and
the 90 LCP below it and the 85 Fill above, signals from the hot pass zone are not confused with
adjacent zone defects. (If they were detectable by RT these would have been called LFSS).
Lack of Fusion Fill 1:
The sources of this defect are the same as for any nonfusion defect in the fill passes. Fill 1 non
fusion is often associated with the corner where the hot pass bevel and the fill bevel meets.
Lack of Fusion Fill 2 and 3:
This defect can be simple sidewall nonfusion, or it may have a component of cold lap to the Fill 1
pass. In light wall pipe only 2 fill pass probes are used to cover the Fill 1, Fill 2 and Cap passes.
Undercut, if deeper than 1 mm would occur in the Fill 2 zone as well. The operator cannot
discriminate where the nonfusion exists. This must be determined by the hand scanner who would
have to plot any defects called for repair. If during the manual evaluation no undercut is seen it is
assumed the flaw is subsurface. For heavier wall pipe where 3 or 4 fills are required the concerns
are the same as for fills 1 & 2.
Stacked Defects:
When a welder stops a weld in the middle of the process (to clean a cup or clear bad wire, etc.,
they must then restart the weld in the same area. If the arc stutters or the stop was not properly
cleaned out a vertical component will be seen that can extend to 2 or more zones. If the chart
indicates the situation exists on 3 or more adjacent zones, it is recommended to investigate further
using manual ultrasonics even if length is less than 25mm.
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Burnthrough:
This occurs when the heat of the melt is sufficient to weaken the weld metal laid down previously
and pokes through thereby removing a volume of metal from the inside surface of the weld/pipe.
The amount of material may be very small, typically 56 mm diameter and only be sufficient to
remove the bead surface. This would produce little or no indication on the root probe channel.
However, if the situation is more pronounced, metal could be removed from the hot pass and bead
as well as material from the parent metal. This would be seen on Root, LCP and 1 or 2 hot pass
zones. Associated with this stacked indication would be an arrival time sooner than the normal non
fusion and some degree of symmetry.
Porosity:
Caused by gasification of impurities on the weld prep. surface or by loss of shielding gas, porosity
is seen by the standard probes in the Root and LCP zones. For fill and hot pass occurring porosity,
a special probe is incorporated into the system. Signals will typically have irregular amplitudes in
the amplitude gates and irregular arrival times in the time gates although with such short time
intervals as exist in the Root and LCP this is more difficult to see.
Some symmetry is often noted and if the porosity is heavy, the geometry signal seen from the weld
surface will be reduced or even eliminated.
Porosity Bead (See image part: Root Bead Porosity)
Porosity Fill
(See image part: Typical Porosity)
Centerline Cracking:
If too much weld metal is deposited too quickly the heat gradient in the weld nugget will cause
shrinkage cracking to occur as it solidifies (also called solidification cracking or shrinkage cracking).
This is not likely to occur in the root pass but may occur in any pass made from the outside
surface. As this is likely to pass right through the weld nugget its amplitude is usually large and
symmetry exists. On a radiograph the crack edges are very fine and may not show clearly, it would
then be misinterpreted as LCP as it is approximately centered.
Geometry HighLow:
Not a defect, high low is a geometry condition caused by ovality or poor mechanical fit. Care must
be taken by the operator to ensure the indications originating from this are not called for repair.
However, this condition can cause genuine defects and the two must be discernible. Large
differences in root transit times are usually an indication of high low.
Bead Offset (or wander):
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Internal welding is performed using 6 welding heads arranged to align with the weld centerline. If
not correctly set one or more heads will deviate from the central position. This may be a head
starting on one side and crossing the centerline or it may be a head that moves straight but is offset
upstream or downstream. Root transit time indicates this condition.
Other Transition (counterbore):
To allow heavy wall and light wall pipe to be joined the heavy wall pipe is counter bored to the
same thickness as the light wall. If the counter bore is made as a taper the counter bored side
cannot be UT inspected as the skip angles are no longer correct. If the counter bore is parallel
inspection is possible but ovality may result in some areas being thicker than they should be.
These results in the gated regions being incorrect for the sound path traveled.

Ultrasonic Phased Array Procedure

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Ultrasonic Phased Array Procedure

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Procedure No.

First Issue Date

Title: Ultrasonic Contact Phased Array Examination

NDT and VID Division Manager

Personnel Qualification/Certification requirements

Procedure Qualification/Demonstration requirements

Instrumentation characteristics and requirements

Extent of examination and examination volume

Documentation, records and marking requirements

2.0 General Requirements

Personnel Qualification/Certification and performance requirements

Weld Configuration, material PClass, thickness, dimensions and material product

Techniques (straight beam, angle beam, contact, etc.). Manual, Semiautomated

Angles, angle range and wave mode propagation

Transducer, wedges, sizes, number of crystals, frequency, shape. Surface condition

Ultrasonic Instrument characteristics. Instrument setup and recording requirements

Calibration technique and Calibration block description and characteristics

Scanning technique, overlapping, surface from which the examination will be

Method for sizing indications.

ASME B31.1 2007, Chapter VI Inspection, Examination and Testing; Par:

Title: Ultrasonic Contact Phased Array Examination

ASME B31.3 2007, Chapter VI Inspection, Examination and Testing; Par:

ASME Code for Boilers and Pressure Vessels, Section V, 2007

2.3. Personnel Qualification/Certification Requirements

A Level II UT ASNT Certified inspector in ultrasonics is required to perform this test.

Specific qualification requiring a minimum of 24 hrs of Phase Array Instrumentation

3.0 Weld Configuration, Materials and Forms

3.4. Prior to start the inspection the following information is required:

Base material nominal thickness

Diameter, curvature and other geometric configuration characteristics

Bevel dimensions, shape and angles.

4.0 Ultrasonic Instrumentation

This procedure is specific for the Phase Array Instrument manufactured by RD

4.2. Analysis Software

4.4. Encoder, Scanner and Transducer Mounting

A semiautomated technique, encoding the passive axis of the transducer will be

The encoded Olympus HSPXY01 semiautomated scanner will be used for

4.5. Transducer Frequency

This procedure cannot be used for material base exceeding 6 inches.

4.9. Surface Condition and Coupling

4.10. Instrument Calibration.

4.10.1.3. Appendix A is attached to this procedure showing the applicable pages of

This information will be included to the documentation presented in Appendix B.

These specific instructions will be obtained from: Calculations, plotting and

5.2. Examination Coverage Volume

The weld should be inspected in both sides, unless obstruction or inaccessibility

5.3. Ultrasonic Scanning Technique

Reflectors Transverse to the Weld Seam:

5.4. Fusion Face, Bevel Angle and Ultrasonic Incidence Angle

It is considered that the maximum intensity of ultrasound reflection will happen

With this consideration the following ultrasonic technique will be used:

Considering the bevel design two or more SScans or LScans will be

Plotting or simulation of the weld geometry shall be used to calculate what is

If crown obstructions prevents from getting a complete volume coverage of

5.5. Angular Interval for Each Scan

Presentations type: A, B, and C are used in conjunction with SScans and L

5.6. Scan Designation and Sequence

A Reference Calibration Block will be used to set a Reference Level.

The transducer then shall be manipulated to obtain without changing instrument

5.8. Indications Record

Ultrasonic indications of geometric and metallurgical origin shall be classified as

Indications determined to originate from the surface configuration.