Test Procedure

Ultrasonic Examination of
austenitic and austenitic-
ferritic stainless steel
forgings.
TCR ADV/GEA/TM - 43
Rev. 00

Prepared by Sandeep S Singh

Paresh Haribhakti
Authorized by
Managing Director, TCR Advanced

Date : 20/06/2017
 TCRADV/GEA/TM 43, Rev 00
20.06.2017

Ultrasonic Examination of austenitic and ferritic stainless steel forgings

TABLE OF CONTENTS

1. SCOPE 2

2. REFERENCING DOCUMENTS 2

3. DEFINITION & SYMBOLS 2

4. REQUIREMENT FOR PERSONNEL AND EQUIPMENT 3

5. PREPARATION OF SCANNING SURFACE 3

6. RANGE AND SENSITIVITY SETTING 4

7. ROUTINE CALIBRATION AND CHECKING 7

8. TESTING TECHNIQUE 7

9. EXAMINATION 8

10. CLASSIFICATION OF DISCONTINUITIES 9

11. RECORDING AND ACCEPTANCE LEVELS 11

12. TEST REPORT FORMAT 13

13. RECORD OF REVISIONS 14

14. ANNEXURE 1 15

15. ANNEXURE 2 16

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1. SCOPE
This procedure is used to carry out manual Ultrasonic Testing, using pulse echo contact technique with A-
Scan presentation for forgings manufactured from austenitic and austenitic-ferritic stainless steels.

2. REFERENCING DOCUMENTS
BS EN 10228-4:1999
BSEN 1712, 1713, 1714
BSEN 583-1,2,4,5.
BS EN 473
BSEN 12223

3. DEFINITION & SYMBOLS

SYMBOLS QUANTITY UNIT

UFD Ultrasonic Flaw Detector -

DAC Distance Amplitude correction -

Diameter mm

t Thickness of parent material mm

DDSR Diameter of a disc shaped reflector mm

DSDH Diameter of Side drilled hole mm

l Length of indication mm

h Extension of the indication in depth direction mm

x Position of the indication in the longitudinal direction mm

y Position of the indication in the transverse direction mm

z Position of the indication in depth mm

lz Projected length of the indication in depth mm

lx Projected length of the indication in the x-direction mm

ly Projected length of the indication in the y-direction mm

p Full skip distance mm

Table 1
4. REQUIREMENT FOR PERSONNEL AND EQUIPMENT
4.1) Personnel Qualification

4.1.1) The person who performs the Ultrasonic Testing shall be minimum Level 2
qualified from BS EN 473 or equivalent in the relevant industrial sector or NDT
Level II as per SNT-TC-1A.

4.2) Equipment

4.2.1) The flaw detector shall feature A-scan presentation and shall conform to the
requirements of EN 12668-1.

4.3) Probe Parameters

4.3.1) The frequency shall be within range 0.5MHz to 6MHz, and shall be selected to
comply with specified acceptance levels.
4.3.2) Search units with crystal size 10 mm to 24 mm diameter for straight beam, for
near surface examination twin crystal probes shall be used.
4.3.3) 8x9 mm or 20x22 mm for angle probe shall be used. Shear wave probe beam
angles shall be in the range from 35 to 70.

5. PREPARATION OF SCANNING SURFACE

6.1) Surfaces to be scanned shall be free from paint, non-adhering scale, dry Couplant, surface
irregularities or any other substance which could reduce coupling efficiency, hinder the free
movement of the probe or cause errors in interpretation

6.2) In the machined condition, for testing to quality classes 1 and 2, a surface finish
corresponding to a roughness Ra 12.5 mm shall be produced and for testing of quality
class 3, a surface finish corresponding to a roughness Ra 6.3 mm shall be produced.

6.3) Where forgings are supplied in the as-forged surface condition they shall be considered
acceptable providing the specified quality class can be achieved. When it is not practical
to perform a comprehensive examination on as-forged surfaces, shot blasting, sand
blasting or surface grinding shall be used to ensure that acoustic coupling can be
maintained.
6. RANGE AND SENSITIVITY SETTING
6.1) General

6.1.1) Details of the calibration block are given in Annexure 1.

6.1.2) Check to conform these settings shall be performed at least every 8 hours and on
completion of the testing.
6.1.3) Check shall also be carried out whenever a system parameter is changed or
changes in the equipment settings are suspected.
6.1.4) If deviations are found during these checks the corrections shall be carried out.
6.2) Reference Blocks

6.2.1) The surface condition of the reference block shall be representative of the surface
condition of the part to be examined.

6.2.2) The reference block shall contain at least three reflectors covering the entire depth
range under examination.

6.2.3) The reference block shall be manufactured from one of the following:
a) an excess length of the part to be examined, or b) a part of the same material
and with the same heat treatment condition as the part to be examined; or c) a
part having similar acoustic properties to the part to be examined.

6.2.4) For normal probes distance amplitude curve (DAC) technique, based upon the use
of flat bottomed holes. Details of the reference block is given in annexure 2.

6.2.5) For shear-wave probes, DAC technique using 3mm side drilled hole shall be used to
establish sensitivity for scanning. Details of the reference block is given in annexure
2.

6.3) DAC

A DAC reference block is required having a series of reflectors at different sound

Path distances over the time base range to be used for the test. Details of the
spacing and minimum size of block and reflectors are given in annex 2.

6.3.1 The DAC reference block shall be either:

1) A general purpose block of uniform low attenuation and specified surface finish,
and having a thickness within 10 % of the test object; or

2) A block of the same acoustic properties, surface finish, shape and curvature as
the test object.
 6.3.2 Preparation of a Distance Amplitude Curve

The distance amplitude curve shall be either shown directly on the screen of the
instrument, or plotted on a separate graph, as described below. This may be supported by
electronic means. When using equipment with Time Controlled Gain, TCG, (also known as
Swept Gain,) gain will be controlled such that the DAC will become a straight horizontal
line.

6.3.2.1 Plotting on screen

The time base is first calibrated to accommodate the maximum sound path length to be
used, and the gain is adjusted so that the echoes from the series of reflectors fall within
20 % and 80 % of full screen height (FSH). In the case of angle probes, the reflectors may
be used in either the 0 to skip, or to 1 skip positions.

The position of the tip of each maximized echo, at a constant gain setting, is then marked
on the screen, and the Distance Amplitude Curve drawn through the points.

If the difference in height between the largest and smallest echoes exceeds the range 20
% to 80 % FSH, the line shall be split, and separate curves plotted at different gain settings
(see Figure 1). The difference in gain between the two curves shall be recorded on the
screen.

The gain setting used for plotting the DAC may be referenced to the echo from some other
reflector, e.g. in the case of flat probes to either the 100 mm radius quadrant, or the 3 mm
diameter hole in Calibration Block No. 1. This will enable the gain to be reset, in future,
without the use of the reference block.

Figure 1 Screen of ultrasonic instrument showing a split Distance Amplitude Curve (DAC)
6.3.2.2 Plotting on a separate graph

The general procedure is similar to technique 6.3.2.1 except that the maximized echo
from each reflector is adjusted to the same height (generally 80 % FSH) and the gain
setting noted and plotted against the sound path length on a separate graph.

6.3.3 Evaluation of signals using a Distance Amplitude Curve

6.3.3.1 Setting the test sensitivity

The test sensitivity shall be set by maximizing the echo from one of the reference
reflectors in the DAC reference block and adjusting the gain to bring the peak of the echo up
to the DAC.

6.3.3.2 Measurement of echo height

The height of any echo, which requires to be evaluated, is adjusted using the calibrated
gain control, to bring it to the DAC, and recorded in terms of the increase or decrease in
gain setting compared to the original value at which the DAC was plotted. If not already
incorporated in the DAC, appropriate values for transfer correction shall be added if
necessary.

Evaluation of the resulting echo height difference is as follows:

Where the gain setting has required to be increased from the original value by x dB, the
echo height is assigned a value (reference level - x) dB. Where the gain setting has required
to be decreased from the original value by y dB, the echo height is assigned a value
(reference level + y) dB.

6.3.4 Evaluation of signals using a reference height

In this method the discontinuity echo is compared to the echo from a reference reflector
having the same or larger sound path length. The two signals are set to equal screen
height (i.e. the reference height), using gain settings Vu and Vr, respectively. The
reference height shall be within 40 % and 90 % FSH. The echo height difference, Hu,
shall then be
calculated using equation: Hu = Vr _ Vu
7. ROUTINE CALIBRATION AND CHECKING
Table 2

Sr. no. Title Frequency of checking

1 Linearity of time base Weekly*

2 Linearity of equipment gain Weekly*

3 Probe Index Daily

4 Beam Angle Daily

5 Physical state and external aspects Daily

6 Pulse duration Weekly*

NOTE To simplify the recording of weekly checks it may be more convenient

for the user to perform them each time the equipment is used.

For detailed procedure of routine calibration and checking refer EN 126688 - 3

8. TESTING TECHNIQUE
8.1) General

8.1.1) Ultrasonic testing shall be performed in accordance with the following clauses.

8.2) Coupling Media

8.2.1) Water (with or without corrosion inhibitor or softener), grease, oil, glycerol
and water-cellulose paste.

8.2.2) The characteristics of the coupling medium shall remain constant throughout the
verification, calibration operation and the examination. It shall be suitable for the
temperature range in which it will be used. If the constancy of the characteristics
cannot be guaranteed between calibration & examination, a transfer correction
may be applied.

8.2.3) After the examination is completed, the coupling medium shall be removed
by wiping with cloth.
 8.3) Calibration Blocks

8.3.1) For calibration blocks refer annexure 1.

8.4) Manual Scan path

8.4.1) During angle probe scanning (as illustrated in figure 1) a swiveling movement up
to an angle of 10 on either side of the nominal beam direction may be applied
to the probe.

8.5) Scanning and Coverage

100% scanning coverage shall be performed over the surfaces specified in Table 3 and 4.

9. EXAMINATION

9.1) Examination Coverage

Scanning coverage with normal probes

Scan 100% around 360on the outer cylindrical surface and on

lateral surface.

100% means at least 10% probe overlap between consecutive

probe traverses.
Fig. 2a

Table 3.

Scanning coverage with shear wave probes

a. Scan in both circumferential directions over 100 % on

the outer cylindrical surface.

b. Additional scanning coverage may be carried out if

required.
Fig. 2b

Table 4
 9.2) Overlap and Scanning

Speed 9.2.1) Overlap

9.2.1.1) For a 100% examination, the interval between two successive scan lines
shall not be greater than the -6dB beam width at any depth within the
examination volume.

9.2.2) Scanning Speed

9.2.2.1) The scanning speed shall be accordance with the ability of the operator
to recognize signals. In any case the scanning speed shall not exceed 100
mm per second.

10. CLASSIFICATION OF DISCONTINUITIES

Discontinuities shall be classified according to their echodynamic patterns as follows:

a) Point discontinuity
Echodynamic pattern 1 and/or dimension equal to or less than the -6 dB beam width (see Figure 3a).

b) Extended discontinuity
Echodynamic pattern 2 and/or dimension greater than the -6 dB width (see Figure 3b).

c) Isolated discontinuities
The distance d, between points corresponding to the maxima of the indications of adjacent
discontinuities exceeds 40 mm (see Figure 3c).

d) Grouped discontinuities
The distance d, between points corresponding to the maxima of the indications of adjacent
discontinuities is less than or equal to 40 mm (see Figure 3d).
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11. RECORDING AND ACCEPTANCE LEVELS
Table 5: Quality classes recording and acceptance criteria for normal probes 1)
Forging thickness t Recording level Isolated discontinuities Extended or grouped
in mm. deq2) mm deq2) Discontinuities deq2)
mm mm
Quality class 1
t75 >5 8 5
75<T250 >8 11 8
250<T400 >14 19 14
t > 400 Indication with a Indication with a total loss of backwall echo. A total loss
80% reduction of backwall echo is to be considered when its amplitude
of backwall echo becomes less than 5% of its initial value measured near
the indication or less than or equal to grass
Quality class 2
t 75 >3 5 3
75 < t 250 >5 8 5
250 < T 400 >8 11 8
400<T600 >11 15 11
t > 600 Indication with a Indication with a total loss of backwall echo. A total loss
80% reduction of backwall echo is to be considered when its amplitude
of backwall echo becomes less than 5% of its initial value measured near
the indication or less than or equal to grass
Quality class 3
t < 75 >2 3 2
75 < t 250 >3 5 3
250 < t 400 >5 8 5
400 < t 600 >8 11 8
t>600 Indication with a 80% Indication with a total loss of backwall echo. A
reduction of backwall total loss of backwall echo is to be considered
echo when its amplitude becomes less than 5% of its
initial value measured near the indication or
less than or equal to grass
1) Reflector diameter shall not be interpreted as representing the dimension of the discontinuity
which caused the echo.
2) deq = Equivalent diameter of flat-bottomed hole.
Table 6: Recording and acceptance criteria for shear wave probes for DAC technique 1)2)3)
Forging thickness Nominal test Recording level
mm frequency Acceptance criteria for
MHz % Isolated Extended or
discontinuities grouped
% discontinuities
%

t75 1 30 60 30

2 50 100 50

t75 1 50 100 50

2 100 200 100

250<T400< td 1 100 200 100

2 200 400 200

1) Based on 3 mm diameter side-drilled holes.
2) A DAC based on 3 mm diameter side drilled holes shall be constructed for each frequency of
probe used.
3) The indication amplitude in dB, relative to the DAC, is given in table 7.

DAC % Amplitude of indication relative to DAC dB

25 -12
30 -10
50 -6
60 -4
100 0
200 +6
400 +12
Table 7
 12. TEST REPORT FORMAT
ULTRASONIC INSPECTION REPORT
Report No.:- Date :
INSP. AGENCY:
CUSTOMER : JOB NO.: DRG. NO.:
SKETCH NO.:
JOB DESCRIPTION : Attached

REFERENCE STANDARD:- UT PROCEDURE No. :-

TEMPERATURE :- Ambient COUPLANT :- paper paste

FLAW DETECTOR:- Modsonic SURFACE CONDITION :-

MATERIAL SPECIFICATION DIMENSION

EQUIPMENT MODEL :- EXAMINATION SYSTEM :- DATE OF EXAMINATION:-

SR No.
AREA TESTED :- Weld Joints
CALIBRATION BLOCK DETAILS:-

REFERENCE LEVEL:- TR Probe : - When indication of first back wall Echo was set at 80% FSH
Angle probe:-DAC plotted using calibration pipe sample
DEFECT REPORT LEVEL: TR Probe:- Any Planner discontinuity observed, Angle probe:- Any discontinuity
indication amplitude exceeding 50% of Reference level.
DESCRIPTION OF ITEMS :
RANGE
SR. No. COMPONENT PROBE REF. LEVEL
(mm)

1
-:Observation :-

Remarks: - WITNESSED BY AUTHORIZED SIGNATURE

EXAMINED BY
INSPECTION AGENCY For, TCR

SIGNATURE

Mr. [NAME]
NAME ASNT level II UT,
Surveyor
DATE
13. RECORD OF REVISIONS

Revisions incorporated
Revision Date of Reasons for
Revision Nature of Revisions
No. Revision Revisions
Section Page
14. ANNEXURE 1
15. ANNEXURE 2