Wq-sj-Almco-qual-03129 - Pa and Tofd Procedure Rev A

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IQWQ-SJ-KPZZZ-0E-0xxxx-C50M091
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230009
Zubair Gathering System

Document Title:
Procedure for PA & TOFD Ultrasonic

Examination
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WQ-SJ-ALMCO-QUAL-03129
WEST QURNA I
PROCEDURE
FOR PHASED ARRAY AND TOFD
ULTRASONIC EXAMINATION
M091 - ZUBAIR GATHERING SYSTEM
A
Rev.
Issued for Internal Review

Description
Atique-ur-Rehman
Ali Nawaz
Bilal Ashiq Bhatti
22-July-2014
Prepared
Checked
Approved
Date
This document is the property of ALMCO who will safeguard its rights according to the civil and penal provisions of the law.
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CONTENTS
CONTENTS .......................................................................................................................................................... 2
1. PURPOSE ...................................................................................................................................................... 3
2. SCOPE ........................................................................................................................................................... 3
3. APPLICABLE DOCUMENTS ..................................................................................................................... 3
4. RESPONSIBILITIES: ................................................................................................................................... 4
5. PERSONNEL QUALIFICATION ................................................................................................................ 5
6. QUALIFICATION OF TESTING PROCEDURE AND PERSONNEL ...................................................... 5
7. PREPARATION OF INSPECTION AREA .................................................................................................. 7
8. EQUIPMENT ................................................................................................................................................ 7
9. REFERENCE BLOCK PAUT ..................................................................................................................... 12
10.
COUPLANT............................................................................................................................................. 18
11.
PHASED ARRAY SYSTEM CALIBRATION ...................................................................................... 18
12.
SYTEM CALIBRATION VERIFICATION ............................................................................................. 23
13.
EXAMINATION COVERAGE AND SCANNING TECHNIQUE ....................................................... 25
14.
RECORDING/EVALUATING CRITERIA & AMPLITUDE DETERMINATION .............................. 27
15.
ACCEPTANCE CRIETERIA .................................................................................................................. 27
16.
DOCUMENTATION ............................................................................................................................... 30
Appendix 1 .......................................................................................................................................................... 39
Appendix 2 ..40
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PURPOSE
The purpose of this procedure is to inspect the butt weld joints of pipeline by Semi Automated
Phased Array Ultrasonic Testing (PAUT) and Time of Flight Diffraction (TOFD) in lieu of
Radiography Testing on West Qurna 1, Zubair Gathering System M-091 Project.
2.
SCOPE
This procedure defines the approach method of MEPTS to carryout the PAUT & TOFD
examination on the welded joints as per API 1104 and IQWQ-SA-LSPDS-OE-0900-C50T074Rev.0. This procedure shall be applicable for butt joints of carbon steel, Low alloy steel or
Alloy steel. The PAUT and TOFD examination area shall include the volume of the weld and
plus 25mm or thickness on each side of the weld. Before examining the weld joint a scan
plan shall be prepared for each thickness and bevel configuration, the same shall be used for
the setting the parameters for PAUT and TOFD examination. Thickness up to 25mm
PAUT technique shall be used. Thickness above 25mm Combination of PAUT and TOFD
shall be used.
The scan plan shall contain the following information:
3.
Weld joint details ( Diameter, Thickness and Bevel Configuration )

Minimum and maximum angle selected for Sectorial or Linear scanning
Focal distance
Index offset from the weld centre
Component coverage of weld and HAZ areas
Beam direction with respect to weld centerline
Search unit details: Element pitch, height & width, Number of element used
Wedge refracted angle and curvature of wedge if applicable
APPLICABLE DOCUMENTS
API 1104
ASTM E-2491
Welding of pipeline and related Facility 2010

Standard guide for evaluating performance characteristics
of Phased array ultrasonic examination.
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SNT-TC-1A Ed.2006.
ASME Code case 181
ASTM E 164
ASME SEC V Article 4
ASTM E-317
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Recommended Practice for Personnel Qualification and

Certification in Non-destructive Testing
Use of Alternative Ultrasonic examination acceptance
criteria
Practice for ultrasonic examination of weldments
Ultrasonic Examination Methods for welds
StandardPractice
for
Evaluating
Performance
Characteristics
of Ultrasonic Pulse Echo Testing
ASME SEC V SE 1316
The standard definitions and terms relating to UT.
ASME Code Case184
Use of UT of weld as an alternative to RT in ASME B31.3
ASTM E2700
ASTM E-2192
Standard practice for contact ultrasonic testing of welds

Using Phased array.
Guide for Planar flaw height sizing by ultrasonic testing.
IQWQ-FT-RSPDS-00-290302 Specification for upstream Process Piping Welding and

inspection
IQWQ-SJ-QPITP-0E-9623-C50T091 Quality Control Plan for Welding.
4.
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RESPONSIBILITIES:
NDT Coordinator
The MEPTS NDT Coordinator shall report directly to the ALMCO QA/QC Manager; shall be
based at the project worksite and responsible for the day to day management of both
manpower and equipment resources. The duties of the MEPTS NDT Coordinator shall
include, but not limited to:
The day to day liaison with the client's site management to ensure the proper channels
of communication are maintained and that work is addressed in a safe, timely and
proper manner.
Coordination and direction of both equipment and manpower resources to ensure the provision of
an effective and efficient service
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Ensuring that all MEPTS personnel are fully conversant with the level of service to be provided
including familiarity with and the promotion of all safety practices and routines dictated by
MEPTS and Company
Where technicians report that testing procedures or techniques are not suitable or do not produce
the required test data, the NDT Coordinator shall investigate and implement the required nonconformance and corrective action routines
UT Technicians
To interpret and evaluate the ultrasonic test results in accordance with this procedure
and to evaluate their acceptability and to determine the fitness of the test specimen for
the purpose being examined
To ensure that all ultrasonic testing are carried out in accordance with this procedure API 1104
and with the requirements of the related specifications as applicable to the project concerned
To prepare reports of ultrasonic examination after completion of test.
To ensure that all equipment, techniques and consumables employed for ultrasonic testing are
suitable for and are capable of producing the required inspection data.
5.
PERSONNEL QUALIFICATION
Personnel performing ultrasonic examination (PAUT/TOFD) shall be qualified and
certified in UT Level II as per the requirement of SNT-TC-1A or equivalent.
Personnel who acquire and analyze PAUT/TOFD data shall be trained in PAUT/TOFD
theory and use of the equipment. Qualification records of certified personnel shall be
submitted. The performance of the approved personnel shall be able to demonstrate the
following with PAUT/TOFD equipment:
a)
b)
c)
d)
6.
Calibration of equipment
Scanning of test object
Characterization of flaw indication
Flaw sizing & Location
QUALIFICATION OF TESTING PROCEDURE AND PERSONNEL

The qualification block shall be prepared by welding and shall contain a minimum of three
flaws, oriented to simulate flaws parallel to the production welds fusion line as follows
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One surface flaw on the side of the block representing the OD surface
One surface flaw on the side of the block representing the ID surface
One subsurface flaw
If the block can be flipped during examination, then one flaw may represent
both the ID & OD surface.
The Flaw size shall be no larger than the flaw in Table 4 & 5
Acceptable limit: acceptable performance is defined as response from the
maximum allowable flaw and other flaws of interest demonstrated to exceed the
reference level.
The result shall be compare with the actual dimensions. After successful evaluation the proposed
PAUT and TOFD in lieu of RT will be adopted and followed on the butt weld joints.
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PREPARATION OF INSPECTION AREA

7.1 Surface preparation:
The finished contact surface of minimum 250 mm either side of the weld should be free from
weld spatters and any roughness that could interfere with free movement of the search unit or
impair the transmission of ultrasonic vibrations. The weld surface should be free of
irregularities that could mask or cause reflections from defect to go undetected and should
merge smoothly into the adjacent base materials surface conditions.
7.2 Weld Numbering:
Weld joints shall be identified with Line No and drawing No. This unique weld numbering
system will be recorded as part of the file storage data. On the prepared area for inspection there
will be a A, B, C reference index and/or position numbers marked on the weld with paint
marker arrow indicating the direction of scanning. All circumferential measurement shall be
made clockwise from the zero reference position on the weld when looking in the direction
of product flow.
8.
EQUIPMENT
Phased Array: The ultrasonic phased array instrument shall be an Omni Scan pulse echo type
and is equipped with a calibrated dB gain or attenuation control stepped in increments of 1dB or
less. The equipment shall be capable of operating at frequency range of 1MHz to 10MHz. The
Omni Scan contains 16 or 32 independent pulser receiver channels. The system is capable of
generating the images B-scan, C-scan, S-scan (sectorial scan) along with display of A-scan.
Examination personnel may use a real-time sectorial scan image during scanning to ensure that
proper data has been collected. Sectorial-scan images contain signal amplitude and reflector
depth information projected for the refracted angle of the ultrasonic beam.
The on-board focal law generation software permits direct modification of the ultrasonic
beam characteristics for performing either electronic linear scan (E-scans) or sectorial scan (Sscan).
The data storing capabilities of the system requires the use of an external storage device, flash card
or USB memory stick. A remote portable PC shall also be connected.
In addition to data storage, the PC will also be used by the data-analysis personnel for
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analyzing data subsequent to the completion of data collection. Data-display software

compatible to that residing on the Omni Scan phased array system shall also be used for data
play back.
The equipment linearity shall be checked and any control which affects the equipment linearity shall
be in the same position for calibration checks, linearity checks and examination.
TOFD: Calibrated Ultrasonic system Omni Sca MX / MX2, Modsonic, or TD Focus scan or
equivalent Digital flaw detector with single/dual axis encoded hand scanner shall be used for the
examination.
The instrument shall be capable of operation at frequencies over the range of at least 1MHz
to 15MHz and shall comply with the requirements of ASME SEC V, Article 4, Appendix III
paragraph III-430.
Scanner: HSMT
Flex Scanner:
HSMT Flex Scanner is a small and easy to operate one axis encoded scanner for weld inspection.
It can be used on plates and pipe like structures, up to 8 probes can be mounted . The Omni
scan ultrasonic system will be suitably interfaced with scanner drive mechanism that moves the
probes in one encoded axis. Four industrial strength magnetic wheels make it suitable to move
on ferromagnetic materials (preferably used in power plant and petrochemical industries).
Mechanical holders shall be used to ensure that the probe spacing is maintained at a desired
index offset. The Probe motion shall be achieved using manual movement.
This scanning uses a compact and mini wheel encoder with one axis encoding having a resolution
of 12 steps / mm.
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Linearity
Phased array 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.
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.
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
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screen and the readings should be as follows

Table-1
Indication Set at % of
Full Screen
Decibel control
Change
Indication Limits %of Full
80
-6dB
32 to 48
80
-12dB
16 to 24
40
+6dB
64 to 96
20
+12dB
64 to 96
Screen
PAUT Transducers:
Ultrasonic transducer configurations are specified by the technique used for the examination. 1D
linear phased array probe used in this procedure may include from 10 to128 elements. The
probe frequency shall be between 1 MHz and 10 MHz depending upon material type and
thickness.
Table- 2 Probe specifications and dimensions
Part No.
Frequency
(MHz)
Number of
elements
Elevation
Pitch
(mm)
(mm)
5L 64-A2
64
10.0
0.6
2L 64-A2
64
12.0
0.75
7.5CCEV35-A15
7.5
16
10.0
0.50
PAUT Wedges:
Phased array wedges should be of a design to accommodate the aforementioned phase array
probes. Nominal refracted wedge angles shall be 45, 55 or 60 degrees to ensure coverage of the
weld and heat affected zone. Wedges shall have provision of irrigation holes and carbides
for couplant flow.
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Wedge Specifications
Part No.
Probe
Type
Nominal Refracted
beam angle in steel
Sweep(degree)
Probe
orientation
SA2-N55S-IHC
A2
550 SW
40-70
NORMAL/
SA2-N45S-IHC
A2
450 SW
30-60
SA2-N60S
A2
600 SW
45-75
REVERSE
NORMAL/
REVERSE
NORMAL/
REVERSE
SA2-0L
A2
00 LW
N/A
NORMAL
TOFD Transducers & Wedges: Dia 3mm to 12mm , 2 to 10 MHz broadband TOFD probes with
45- 70 Wedges. For TOFD scanning following table shall be used for transducer selection.
15-35
35-50
50-100
Subcontractor Doc.
Table- 3
Thickness
(mm)
Rev.
Number
of TOFD
set- ups
1
1
2
Depthrange
0-t
0-t
0-t/2
t/2-t
Table 4
Centre
Beam
frequency
angle(longMHz
waves
10-5
70-60
5-3
70-60
5-2
70-60
60-45
Element
size
(mm)
2-6
3-6
3-6
6-12
Beam
intersection
2/3 of t
2/3 of t
1/3 of t
5/6 of t
The probes shall confirm to the following minimum requirements:

a) Two probes shall be used in pitch-catch arrangements (TOFD Pair)
b) Each probe in the TOFD pair shall have the same nominal frequency.
c) The TOFD pair shall have the same element dimensions
d) The pulse duration of the probe shall not exceed two cycles.
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REFERENCE
BLOCK PAUT
a) The basic calibration block shall be in accordance with ASME SECV Article 4, paragraph
T-434.1.2 through 434.1.6.
b) The block thickness shall be at 25% of the nominal thickness of the piece to be examined.
c) Side drilled holes or Notches shall be used to confirm adequate sensitivity settings.
d) Materials with diameters greater than 20 inches (508 mm): For examinations in materials
where the examination surface diameters is greater than 20 inches (508 mm), a block of
essentially the same curvature, or alternatively a flat basic calibration block, may be used.
e) Materials with diameters 20 inches (508 mm) and less: For examinations in materials
where the examination surface diameter is equal to or less than 20 inches (508mm), a curved
block shall be used. Except where otherwise stated, a single curved basic calibration block may
be used for examinations in the range of curvature from 0.9 to 1.5 times the basic calibration
block diameter.
Fig: T 434.2.1
TABLE 5
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Weld thickness (t)

In. (mm)
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Calibration Block
Thickness (T)
In (mm.)
Hole Diameter
In (mm)
Upto 1 (25)
Over 1 (25) through
2 (50)
3/4 (19) or t
1 (38) or t
3/32 (2.5)
1/8 (3.0)
Over 2 (50) through

4 (100)
Over 4 (100)
3 (75) or t
3/16 (5.0)
t+ 1 (25)
(Note 1)
Notch Dimensions
In (mm)
Notch Depth = 2% T
Notch Width = (6.0)
max
Notch Length = 1 (25)
min.
General Notes:
Holes shall be drilled and reamed 1.5 in (38 mm)deep minimum, essentially parallel to the
examination surface.
For components equal to or less than 20 in.(500 mm) in diameter shall meet the
requirements of para 9.0 (e). Two sets of calibration reflectors (holes , notches) oriented
90 degree from each other shall be used. Alternatively, two curved calibration blocks may
be used.
The tolerance for hole diameter shall be + 1/32 in. (0.8 mm). The tolerance for the hole
location through the calibration block thickness (i.e. distance from the examination
surface) shall be + 1/8 in (3.0 mm)
For block less than in. (19 mm) in thickness, only T/2 side drilled hole and surfaces
notches are required.
All holes may be located on the same face (side) of the calibration block, provided care is
exercised to locate all the reflectors from affecting the indication from another reflector
during calibration. Notches may be in the same plane as the inline holes ( as in Figure J431 of Section V), sufficient number of holes shall be provided for both angle and straight
beam calibrations at T/4 , T/2 and 3T/4 depths.
Minimum notch depth shall be 1.6 % T and maximum notch depth shall be 2.2% T plus the
thickness of cladding, if present.
Maximum notch width is not critical . Notches may be made by EDM or with end mills up
to in. (6.4 mm) in diameter.
Weld thickness, t, is the nominal material thickness for welds without reinforcement or, for
welds without reinforcement, the nominal material thickness plus the estimated weld
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reinforcement not to exceed the maximum permitted by the referencing Code Section.
When two or more base material thicknesses are involved, the calibration block thickness,
T, shall be determined by the average thickness of the weld; alternatively, a calibration
block based on greater base material thickness may be used provided the reference
reflector size is based upon the average weld thickness.
Pipeline Calibration Block:

Notches shall be located not closer than thickness of the part or 25mm whichever is greater, to any
block edge or another notch.
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General Notes:
(a) The minimum calibration block length (L) shall be 8 in. (200 mm) or 8T, whichever is greater.
(b) For OD 4 in. (100 mm) or less, the minimum arc length shall be 270 deg. For OD greater than 4
in. (100 mm), the minimum arc length shall be 8 in. (200 mm) or 3T, whichever is greater.
(c) Notch depths shall be 8%T minimum to 11%T maximum. When cladding is present, notch
depths on the cladding side of the block shall be increased by the cladding thickness, CT (i.e., 8%T +
CT minimum to 11%T + CT maximum). Notch widths shall be 14 in. (6 mm) maximum. Notch
lengths shall be 1 in. (25 mm) minimum.
(d) Maximum notch width is not critical. Notches may be made with EDM or with end mills up to
14 in. (6 mm) in diameter.
(e) Notch lengths shall be sufficient to provide for calibration with a minimum 3 to 1 signal-to-noise
ratio.
Additional Blocks for System

Calibration:
In addition to the basic reference block, additional blocks may be used for system calibration.
IIW V1 block and IOW block shall be used for sensitivity, velocity and wedge delay calibration.
TOFD
The basic calibration block shall be in accordance with ASME SECV Article 4,
paragraphT-434.1.2 through 434.1.6.
The block thickness shall be at +/- 10% of the nominal thickness of the piece to be examined
for thickness up to 100mm or +/- 10mm for thickness over 100mm
Side drilled holes shall be used to confirm adequate sensitivity settings.
Calibration block shall be made as per ASME Sec V , Article 4,Appendix III fig. III.434.2.1
a & b.
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Note
(a)Holes shall be drilled and reamed 50 mm deep minimum, essentially parallel to
examination surface.
(b) Tolerance on hole dia. Shall be +/- 0.8mm and tolerance on location through the block
thickness shall be +/- 3mm.
(c) All holes shall be located on the same face and aligned at the centre of the face unless
the indication from one reflector effects the indication from another. In this case holes
may be located on opposite face of the block.
When the weld is broken up into multiple zones, each zone shall have a Tz/4 and 3Tz/4
SDH, where Tz is the zone thickness.
(d) A Documented Examination Strategy or scan plan shall be provided for each thickness
range.
The plan should show the transducer placement, movement and component coverage. The
scan plan shall also include ultrasonic beam angle used, beam direction with respect to weld
centreline and pipe volume examined.
10. COUPLANT
Cellulose Paste, Machine Oil, Water or equivalent may be used as couplant when
performing calibrations and examinations. The same couplant to be used during the examination
shall be used for calibration.
11.
PHASED ARRAY SYSTEM CALIBRATION

Calibration shall be performed from the surface of the calibration block which corresponds
to the component surface to be examined. System calibration shall include the complete
ultrasonic examination system. Screen distance calibration shall be at least 1 vee
paths (also known as skip) for the minimum angle that will be used during the
examination, unless otherwise specified. During scanning,
only the
gain
may
be
adjusted
from the calibrated reference dB. Adjustment of other controls requires
recalibration.
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Wedge Delay Calibration
The wedge delay calibration shall be carried out for both linear scan as well as sartorial scan.
The wedge delay calibration shall be carried out in true depth mode or sound path mode and done
with a known reflector depth or radius. Peak up this signal from the calibration reflector and
scan the phased array probe backwards through all the different angles or focal laws.
Scan forward over the calibration reflector through all the refracted angles of focal laws.
When the signal for all angles and focal laws lies within the threshold, the Omni scan system
shall adjust all the focal laws/angles to display the reflectors true depth.
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Sensitivity Calibration:
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a Wedge Delay Calibration
The Omni scan shall be calibrated for wedge delay and sensitivity. The sensitivity
calibration shall provide the required gain adjustments for each refracted angle and sound
path used. Select a calibration reflector, which is approximately one-half the thickness of the
component to be examined, or 1.5mm SDH on IIW V1 block. Peak up this
signal from the calibration reflector or radius and scan the phased array probe backwards
through all the different angles of focal laws. The Omni scan system shall calculate the required
gain needed at each focal law to adjust the amount of gain required to obtain the sensitivity.
b Sensitivity Calibration
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11.3 Time Corrected

Calibration:
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Gain
(TCG)
Time corrected gain calibration shall be used to compensate for attenuation in the material at
the sound paths used during calibration and examination. To obtain the TCG calibration peak
the signal from the ID notch or SDH at half skip distance and adjust the gain to obtain
80%of amplitude from the reflector. Place the phased array probe perpendicular to the notch
axis. Move the phased array probe forward and backward to equal the amplitude for all the focal
laws and angles and plot the first point. Move the probe to the OD notch or SDH and obtain
the second point. Omni Scan users the gain compensation required due to attenuation in the
sound travel and adjust the gain for all focal laws/angles.
Once all the points are picked the TCG can be accepted. TCG calibration has to be carried out for
all scan plans in a multi group option while using phased array probe. TCG may be plotted using
IOW Blocks having 1.6 mm SDH at appropriate depth.
The examination system calibration shall be stored in the Omni Scan System with electronic
memory, on an external chip or data storage device. This calibration may be used at a later date
provided that date provided that the system calibration is verified prior to the examination.
TOFD Calibration:
Set the TOFD probes on surface to be Utilized for calibration and set the gain control so that the
lateral wave amplitude is from 40% to 90% of the full screen height and the noise level is less
than 5 to 10% FSH. This is reference sensitivity setting. When the lateral wave is not displayed
for multiple zone examination, set the gain control based solely on the noise level.
11.4
Confirmation of Sensitivity:
Scan the calibration blocks SDHs with them centered between the probes, at the reference
sensitivity level set in 10.4.
The SDH responses from the required zone shall be a minimum of 6 dB above the grain noise
and shall be apparent in the resulting digitized grayscale display.
11.5
Encoder Calibration:
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Encoder shall be calibrated as per the manufacturers recommendations and conformed by

moving a minimum distance of 20 in. (500 mm) and the displayed distance being 1% of
the actual distance moved. In event the encoder is found to give an error of greater than
1%. The inspection performed for the day shall be repeated on locations where linear flaws
were detected.
A maximum sample spacing of 1mm shall be used between A- scan collected for thickness under
75mm and a sample spacing of up to 2mm to be used for thickness greater than 75mm.
11.6
Rate of search unit movement:
Scanning speed shall be such that data drop-out is less than 2 data lines per inch (25 mm) of
the linear scan length and that there are no adjacent data line skips.
12.
SYTEM CALIBRATION VERIFICATION

The system calibration verification shall include the examination system. Sweep range and
TCG calibration shall be verified on the appropriate calibration block or simulator block as
applicable under the following conditions:
Prior to an within 24 hours of the start of a series of examinations
With any substitution of the same type and length of search unit cable
With any substitution of power using the same type source, such as a change
of batteries
At least every 4 hours during examination
At the completion of series of examinations
Whenever the validity of the calibration is in doubt
Changes
in
Calibration:
System
The examination shall deemed to be voided if any point of the TCG decreases by 20% or 2 dB of
its amplitude, or any point on the sweep line has moved more than 10% of the sweep division
reading. If the situation arises, carry out a new system calibration and repeat voided examinations
and re examine all indications recorded since the valid calibration verification. The change in
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values if any shall be entered on the applicable forms.
Recalibration
Any of the following conditions shall be caused for system recalibration:
Change of search unit or wedge
Change of search unit cable type or length change
Change of ultrasonic instrument
Change in examination personnel
Couplant change
Change in type of power source
When missing data lines in the display shall not exceed 5% of the scan lines to be collected, and
no adjacent lines shall be missed
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EXAMINATION COVERAGE AND SCANNING TECHNIQUE
Normal Beam Examination (Conventional Technique): Prior to start of the PAUT

Examination, the base metal and HAZ area shall be scanned manually with normal beam probe
to locate reflectors that can limit the capability of the PAUT inspection to examine the weld
volume. The gain of the instrument is adjusted such that the second back wall echo examine the
weld volume. The gain the instrument is adjusted such that the second back wall echo
amplitude to 80% of FSH.
Angle Beam Examination (PAUT Technique): Scanning For

Reflectors Parallel To The Weld Seam:
The specifics of the examination volume, weld definition and location shall be identified in the
scan plan. The examination volume shall cover the weld metal and a quarter from the toe the weld.
This area includes the heat affected zone (HAZ).
The scan plan shall demonstrated by plotting or with using a simulator the appropriate
examination angles for the weld preparation bevel angles that will be used during the
examination. This scan plan shall be documented to show that the examination volume was
examined. This scan plan shall be a part of the final examination.
Omni Scan system has the capability of using multiple-group settings to establish sector
scans and E-scans for the appropriate angles to ensure complete coverage of the weld and heat
affected zone.
Scanning shall be performed using a line scan technique. Each line scan shall be parallel to the
weld using a sectorial scan (S-scan) and/or a linear scan.
Appropriate refracted angle as accepted by ASME will define the position of the arrays and
hence angles. These should be detailed in the ultrasonic scan plan.
A minimum of two (2) line scans shall be performed at two (2) different index points from the
centre of the weld from both sides of the weld where practical to ensure coverage of the weld and
heat affected zone (HAZ).
Scans shall be parallel to the weld at 90 /270 scan axes and the multiple groups scanning shall
involve both the above directions for complete coverage of the weld.
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Reflectors Transverse to the Weld Seam. As an alternate to line scanning, a manual angle
beam examination may be performed for reflectors transverse to the weld axis
Restricted
Welds:
Access
The welds that cannot be fully examined from two directions using angle beam technique shall
also be examined if possible with straight beam technique without recording.
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TOFD SCANNING PROCEDURE:

TOFD scans is to be performed on each weld area to ensure adequate inspection coverage.
Scanning shall be carried out in clockwise direction with stating position. The examination
area shall include the volume of the weld plus the lesser of 25 mm or t on each side of the weld.
Each scan shall be performed with the TOFD probe array symmetrically astride the weld.
The data shall be collected by moving the probes at uniform speed ensuring the probe array
remains central to the weld. If offset scans are required due to the width of the weld, the initial
scan to be repeated with the probes offset to one side of the weld axis and again with the
offset to the opposite side of the first offset scan.
The scanning speed shall be less than 500mm/min. A maximum of 5% of the total number of
lines collected in one single scan may be missed but no adjacent line shall be missed.
The collected data shall be presented in D-scan format i.e., vertical axis representing time/depth
into the material and the horizontal axis representing distance along the weld.
14.
RECORDING/EVALUATING CRITERIA & AMPLITUDE DETERMINATION
Only Trained Level II - UT operators with hands on training Omni Scan shall calibrate
and carry out UT inspection. Only personnel certified Level III in ultrasonic testing along
with knowledge of phase array and Omni Scan equipment shall evaluate the results of
ultrasonic examinations for acceptance. All indications that exceed 50% of reference level shall
be investigated completely to determine the type of indication. When discontinuity is observed
flaw sizing shall be done by 6dB drop method.
Geometric Indication Recordable ultrasonic indications, of geometric or metallurgical origin,
shall be classified as such. Weld reinforcement, root geometry or variations in metallurgical
structure of materials may be classified as geometric indications. Geometric Indication need not
be characterized or sized.
15.
ACCEPTANCE CRIETERIA
Acceptance / Rejection of ultrasonic inspection of welds shall be as per ASME code case 1812. Imperfections which produce a response greater than 20% of the reference level shall be
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investigated to the extent that the operator can determine the shape, identity, and location of
all such imperfections and evaluate them. In any case flaw length shall not exceed 4t regardless
of height for above 25mm thickness.
Flaw Acceptance for less than 25mm Thickness:

A linear-type discontinuity is unacceptable if the amplitude of the indication exceeds the
reference level and its length exceeds:
(a) 6 mm (14 in.) for t 19 mm (34 in.)
(b) t/3 for 19 mm < t 57 mm (2 14 in.)
(c) 19 mm for t > 57 mm
Table 6
FLAW ACCEPTANCE CRITERIA FOR SURFACE FLAWS

Weld Thickness
Aspect
Ratio
h/l
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
< 25mm to 64mm

h/t
<0.031
<0.033
<0.036
<0.041
<0.047
<0.055
<0.064
<0.074
<0.083
<0.085
<0.087
< 100mm to
300mm
h/t
<0.019
<0.020
<0.022
<0.025
<0.028
<0.033
<0.038
<0.044
<0.050
<0.051
<0.052
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Table 6
FLAW ACCEPTANCE CRITERIA FOR SUBSURFACE FLAWS

Weld Thickness
Aspect
Ratio
h/l
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
< 25mm to 64mm

h/t
<0.068
<0.076
<0.086
<0.098
<0.114
<0.132
<0.156
<0.180
<0.210
<0.246
<0.286
< 100mm to
300mm
h/t
<0.040
<0.044
<0.050
<0.058
<0.066
<0.076
<0.088
<0.102
<0.116
<0.134
<0.152
General Notes:
(a)- t = 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 thickness. If a
full penetration weld includes a fillet weld , the thickness of the throat of the fillet weld shall
be included in t
(b)- A subsurface indication shall be considered as a surface flaw (S in fig. 1) of the indication from
the near surface of the component is equal to or less than through thickness dimension.
(c) - For intermediate thickness t ( weld thickness between 64mm and 100mm ) linear interpolation is
required to obtain h/t values.
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DOCUMENTATION
Results of ultrasonic examination shall be reported on the Omni Scan Data Report. All
Phased array data shall be documented on the examination report. All the columns in the
report format should be completed with appropriate data or NA
Ultrasonic Procedure number.
Date of examination.
Examination personnel Identity, level and signature.
Ultrasonic examination equipment.
Calibration Identity.
Weld identification and location.
Welding process.
Surface condition.
Acceptance criteria.
Wall thickness and diameter of weld examined.
Original or repair weld.
Map or record of discontinuities assessed.
Conclusion-accept or reject according to specification.
Search Unit type, element size and element number.
Focal low parameters including pitch, gap dimension, angle, focal depth and element used
Search unit type, element size and number, and pitch and gap dimensions
Focal law parameters, including as applicable, angle, focal depth, element no. used, range
of elements, element incremental change, angular range, and angle incremental change.
Wedge angle
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Appendix 1
TABLE OF ESSENTIAL VARIABLES FOR QUALIFICTION OF PROCEDURE
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