Reliance

Procedure For
Ultrasonic Testing of Weld Joints
of Structures

EPCMD-2-QM00-JEP-ME-040

00

31.08.2012

Issued for Implementation

PKD

KSS / EMK

SNS

Rev

Date

Revision

Prepared
By

Checked
By

Approved
By

Reliance
Contents
1.

Purpose ...3

2.

Scope .3

3.

References .3

4.

Abbreviations and Terms 3

5.

Responsibilities ..4

6.

Methodology 4

7.

Record ..7
1.

Scanning sheet of various weld configuration for structural job.

2.

UT Acceptance Rejection criteria .Table -6.2 & 6.3 of AWS D1.1

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1.

Purpose
The purpose of the procedure is to provide guide line to carry out UT in structural jobs
in line with the procedures, specifications, code & the job requirements.

2.

Scope
The scope of this document is limited to UT of groove welds of structural jobs having
thickness ranging from 8mm to 200mm (incl.) at Reliance Refinery complex at
Jamnagar.

3.

4.

5.

Reference

AWS D1.1

ASME Section V

BS 5950

SNT-TC-1A

EPCMD-2-QM00-JEP-ME-038 : Procedure for selection of UT Technician

Abbreviations And Terms

ASME

American Society for Mechanical Engineers

dB

Decibel

DCC

Document Control Centre

HOD

Head of the Department

IIW

International Institute of Welding

NDT

Non Destructive Testing

QMD

Quality Management Department

SNT-TC-1A

Society of Non-destructive Testing

T/R probe

Transmitter Receiver probe

UFD

Ultrasonic Flaw Detector

UT

Ultrasonic Testing

Responsibilities

Construction Managers/Engineer in Charges is responsible for implementing this

procedure in their area.

HOD, QMD is responsible for maintaining this procedure.

DCC is the custodian of this document.

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6.

Methodology

6.1

Equipment
The ultrasonic examination shall be conducted with a pulse echo ultrasonic instrument
capable of generating frequencies over the range of 1MHz to 6MHz. The ultrasonic
instrument shall provide linear vertical presentation within 5% of the full screen
height for 20% to 80% of the calibrated screen height. The ultrasonic instrument shall
utilize amplitude control linearity over its useful range to 20% of the nominal
amplitude ratio to allow measurement of indications beyond the linear range of
vertical display on the screen. The instrument shall be equipped with a stepped gain
control calibrated in units of 2.0 dB or less.
In order to make the ultrasonic test result as permanent record, it is recommended to
use flaw detector with recording facilities .The Ultrasonic testing equipment & probes
shall be selected from the following manufacturer which are approved by the Reliance.

6.2

1.

Panametrics

2.

Krautkramer

3.

Sonatest

4.

Omniscan

Probe
The probe may contain either single or dual crystal. The search units with contoured
contact wedges may be used to aid ultrasonic coupling. Calibration shall be done with
the contact wedges to be used during the examination.
The transducer frequency shall be between 2 and 2.5 MHz, inclusive. and size shall be
as per the job requirement. For UT of Tubular T, Y and K connections higher
frequencies up to 6 MHz may be used.
The angle of probe shall be 45, 60 and 70 degree or as per the job requirement.

6.3

Couplant
The couplant shall be preferably be a manufactured cellulosic gel produced for this
purpose. However this may be substituted by oil or oil & grease mixture

or other

suitable medium that is not toxic or corrosive. The couplant must be removed after
examination by means of wiping with a cloth or with the help of solvent.
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6.4

Surface Preparation
The scanning surface shall be free from loose scale, weld spatter and any other
foreign matter that may interfere with the examination. In case of single V /double V
butt joint weld caps shall be ground flush to facilitate scanning from the top of the
weld, if required.

6.5

Calibration blocks
V1 block of IIW shall be used for distance & sensitivity calibration as per AWS D1.1
requirements.

6.6

UFD Operator
All the technicians shall undergo a selection test and qualify the same prior to the
deployment on the job as per Procedure for the selection of UT technicians EPCMD-2-QM00-JEP-ME-038.

6.7

Scanning method
The sketch of annexure I shows scanning method of different types of structural weld
joint configuration. However the other points are also to be taken care of while
scanning the structural joints.

6.8

Scanning with TR probes

Prior to angle beam scanning, area from where angle beam scanning to be carried out
are to be marked. T/R probe scanning to be carried out on the marked area to identify
any reflector which may interfere during angle beam scanning.

6.9

Examination coverage
The weld

volume shall be examined by moving the search unit over the examination

surface so as to scan the entire examination volume. Each pass of the search unit
shall overlap a minimum of 10% of the transducer dimension perpendicular to the
direction of the scan. The shear probes which produces beam of an angle of 45 to 70
degrees in the examination medium shall be used. The beam angle dependent on the
thickness and weld geometry. The recommended beam angles for different thickness
are given below or code recommended angle probe shall be used.
Thickness

Beam angle

Up to 38 mm

70 degree

Above 38 mm

45 / 60 / 70 degree

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Scan plan for UT examination shall be prepared as per the geometry of the job to
ensure that the complete weld metal & HAZ area is covered during the scanning of
weld joint. For butt joints the scanning limits shall be from to 1 1/2 skip distance
from both the sides or as per the job requirements. For partial penetration weld joints
scanning shall be done to cover the weld metal excluding the root area. For
complicated geometries of the weld joints the scanning pattern shall be designed to
cover the area of interest of the weld metals.

6.10

Rate of search unit movements

The rate of search unit movement for examination shall not exceed 6 in/sec.
(152mm/sec).

6.11

Recording Sensitivity level

The recording of indication shall be made with respect to the reference level.

6.12

Scanning dB
All angle beam scanning to be carried out at reference level and of added gain as per
the AWS D1.1 code requirements.

6.13

Evaluation of indication
Any indication shall be evaluated at reference level. All indications will be investigated
to the extent that the inspector can determine shape, size, identity and location. All
indications detected with one probe may be further evaluated if required; using an
appropriate combination of angle probes so that nature, depth, orientation and length
can be accurately determined and discontinuity type can be established. The
discontinuities shall be sized using 6 db drop method and maximum amplitude
technique. Where ever required, plotting to be carried out on the graph paper to
decide the nature and location of the defect.

6.14

Acceptance criteria
Acceptance criteria for defect evaluation of structural steel for non-tubular connection
welding shall be as per Sec 6.13.1 Table 6.2 & Sec 6.13.2 Table 6.3 of AWS D1.1 for
statically loaded & cyclically loaded structure respectively. For tubular connection
acceptance criteria shall be as per Sec 6.13.3. of AWS D1.1.

6.15

Evaluation of repair weld

Where ever weld repair have been carried out, the soundness of the weld/job shall be
confirmed by repeating the UT examination as per the procedure.

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6.16

Post cleaning
Couplant (grease/oil), cellulosic paste applied to the job surface for UT examination
shall be cleaned by respective NDT agency after completion of the testing by cotton
waste / cloth.

7.

Record
Report shall be prepared in the format EPCMD-2-QM00-FMT-ME-025 / approved
format of NDE agency. In case of repair, print out of repair area along with
sketches/graph plotting showing exact location of repair shall be given.

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P3
P2

P1

P2

P1

P2

P1

P3

P1

P2

P2
2

P2

P1 Scanning with T/R probe up to 2 skip distance

P2 Scanning with required angle probe to cover entire weld
volume.
P3 Scanning from top of the weld to detect transverse
defect.

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P1 Scanning with TR
probe

P2

P2 Scanning with 45 /
60/70 to cover the total
weld volume.

P1

P3

P3 Scanning with 45 /
60/70 to cover the total
weld volume.
Scanning zone of P2/P3 are
also to be scan by T/R
probes.
Scanning to be carried out
either from P2 or from P3
side.

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P1

P2

P3

P1- Scanning with TR probe & angle

probe
P2- Scanning with 45 / 60 /70
to cover entire weld volume.
P3- Scanning with 45 / 60 /70
to cover entire weld volume
Scanning zone of P2/P3 are also to
be scan by T/R probes.
Scanning to be carried out either
from P2 or from P3 side.

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Scanning 0 to 1 skip with 45 /

60/70 probe from all the side
to cover entire weld volume.
Scanning zone are also to be
scan by T/R probes.

P
pP
P

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