JIMAH East PAUT Procedure - Rev.0 - 14062017 PDF

KPG SYNERGY SDN BHD
DOCUMENT COVERSHEET
TITLE: NON-DESTRUCTIVE TESTING PROCEDURE
PHASED ARRAY ULTRASONIC INSPECTION
DOCUMENT NO: NDT-03-04-UT
PROJECT: JIMAH EAST POWER PLANT
CLIENT: EQUATOR ENGINEERING SDN BHD
CURRENT REVISION: 0
DOCUMENT STATUS RECORD

PREPARATION APPROVAL FOR USE
REV No. NAME DATE SIGNATURE NAME DATE SIGNATURE
0 KL Leong 23rd Apr 2016 Jeffrey C. 23rd Apr 2016
REVISION CHANGE RECORD
REV No. DESCRIPTION SECTION

00 Issued for review and comment All
KPG SYNERGY SDN BHD DOC. NO.: NDT-03-04-UT-REV. 0
PHASED ARRAY ULTRASONIC TESTING PROCEDURE PROJECT: JIMAH EAST
TABLE OF CONTENTS
1.0 SCOPE
2.0 OVERVIEW
3.0 REFERENCES
4.0 DEFINITION
5.0 PERSONNEL
6.0 PROCEDURE
6.1 Scanning Technique
6.2 Equipment
6.3 Probes
6.4 Encoders
6.5 Couplant
6.6 Standard Calibration Blocks
6.7 Qualification/Demo Blocks
6.8 Phased Array System Calibration
6.9 Focal Law Verification
6.10Time Base Verification
6.11Sensitivity and Wedge Delay Calibration – Phased Array
6.12Storage of System Calibration
6.13System Verification Calibration
6.14System Calibration Changes
6.15Recalibration
6.16Preparation of Scanning Surfaces
6.17Examination Coverage and Scanning Technique
6.18Evaluation
6.19Acceptance Criteria
6.20NDT of Repaired Welds
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6.21Examination Record
6.22Reporting
APPENDIXES
Appendix I – Weld Test Methods – General Set UP for Weld Testing

Ultrasonic Examination of Welded Joints: PA-002
Appendix II – Reporting Format
Appendix III – Worksheets
Appendix IV – Calibration and Qualification Blocks for Phased Array
Appendix V – Scan Plan Summary
Appendix VI – Manual UT procedure – NDT-01-04-UT Rev. 0
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1.0 SCOPE
The purpose of this procedure is to establish and implement the Guided Encoded Phased Array Ultrasonic
Testing and Time of Flight Diffraction examination technique, including interpretation of results to determine
acceptability of the welds for all Carbon & Alloy steel butt welds of thickness from 50 mm to 150mm of
Jimah East Power Plant Project, Malaysia.
1.1 UT sensitivity setting – The calibration block shall be prepared in accordance with T-434.2.2 of
ASME V as per Fig. T-434.2.1
1.2 ASME V (2015) – Appendix IX – Procedure Qualification for Flaw Sizing and Categorization
1.3 ASME V (2015) – Mandatory Appendix VIII –Ultrasonic Requirements for a Fracture Mechanics
Based Acceptance Criteria
1.4 Acceptance Criteria – ASME B31.1 (2014) – Code Case 189
2.0 OVERVIEW
2.1 The AGR/TD Focus Scan is a 128 multi-channel ultrasonic data collection and analysis system utilised
for the inspection of girth welds in pipelines, pipings and vessels. The use of high-speed multiplexing
and phased array probe technology allows numerous inspection angles in pulse echo, pitch and catch
modes to be used seemingly simultaneously. Focused beams allow small specific areas of the weld to
be examined and defects to be accurately located and sized. A scan utilising all selected beam angles
is recorded every 1 mm along the weld length at a scanning speed of approximately 10-30 mm per
second.
2.2 Data is displayed in real time in various display and chart format that allows the weld fusion face and
volume to be presented symmetrically either side of the weld centreline. Couplant efficiency is also
monitored by any lost in data in the C-scan display for PAUT. The complete scanned data plus the set-
up and scanning parameters is stored on the hard drive of the system computer
2.3 TOFD Technique is employed to detect and size any mid-wall flaws and only applicable for wall
thickness above 12mm and of even thickness on both sizes of the weld. TOFD will also be used for
testing restricted areas such as gamma plugs and complemented with manual UT using shear and
creep wave probes.
3.0 REFERENCES
3.1 SNT-TC-1A – 2006: Recommended Practice

3.2 KPG/QP/018 – KPG Qualification and Certification of Personnel – Written Practice
3.3 ASME V ART 4 (2015) – Ultrasonic Examination Methods for Welds
3.4 ASME B31.1 (2010) – Power Piping
3.5 ISO9712-2012 – Non Destructive Testing – Qualification and Certification of NDT Personnel
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4.0 DEFINITION
4.1 AUT Automated ultrasonic testing as performed using the KPG AUT phased array
system.
4.2 Calibration Correlation of the Ultrasonic System responses with calibration reflectors
4.3 Calibration A reflector with a dimensioned surface which is used to provide an accurately
Reflector reproducible reference level.
4.4 Defects One of more flaws whose aggregate size, shape, orientation, location or
properties do not meet specified acceptance criteria and are rejectable.
4.5 FBH Flat-bottomed hole.
4.6 FSH Full Screen Height
4.7 Gate The pertinent section of the ultrasonic beams travel where the data is collected
and recorded.
4.8 HAZ Heat Affected Zone
4.9 HP Hot Pass
4.10 ID Internal Diameter or Internal surface of the pipe zones on the same side of the
weld
4.11 Linear Scan The ability to use a series of single linear pass along the weld at a fixed angle to
give the coverage required without any probe movement.
4.12 NDT/NDE Non Destructive Testing
4.13 OD External Diameter or External surface of the pipe
4.14 PE Conventional Pulse Echo channel using single crystal probes.
4.15 Phased array A method of producing multiple probe angles and wave forms from a single
Probe containing multiple elements fired in discrete sequences (linear array).
4.16 PAUT Phased Array Ultrasonic Testing
4.17 PWHT Post Weld Heat Treatment
4.18 SAUT Semi-Automated Ultrasonic Testing – manually manipulated encoder scanning
4.19 SDH Side Drilled Hole
4.20 Set up file A computer file that contains all the necessary data to allow an PAUT weld
inspection to be carried out. Set up files are project, pipe size, thickness and
weld geometry specific.
4.21 Sectorial Scan The ability to scan a complete sector of the volume and at different singles
without any probe movement.
4.22 Sensitivity Measure of the level of response from a discontinuity by a NDE
4.23 SNT-TC-1A Qualification and certification of NDT personnel - General principles and
guidelines.
4.24 TRL Transmit – Receive Longitudinal (probes or technique)
4.25 UT Pulse Echo Ultrasonic Testing
4.26 WT Wall Thickness
5.0 PERSONNEL
Personnel responsible for performing ultrasonic testing shall be certified to ISO 9712-2012 by an
accredited certification body such as PCN scheme conducted by the British Institute of Non Destructive
Testing. Inspection, testing and report in shall only be carried out by PCN Level II approved personnel.
All personnel shall meet visual and color acuity as per KPG Written Practice KPG/QP/018 and vision
acuity shall be valid during the period inspection is been performed.
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6.0 PROCEDURES
6.1 SCANNING TECHNIQUE
6.1.1 Only approved Scan Plans and procedures shall be used for the project. Any changes in Scan
Plan will be submitted to Client for approval before it can be used for PAUT inspection. Weld
Identification will be provided by contractor as per construction drawings.
6.2 EQUIPMENT
The equipment and probes to be used on this project is listed in Table 1 below:
Table 1: Equipment and Probes List.

Manufacturer Type Element Pitch Frequency Size (mm) Materials Tested
(mm) (MHz) 50mm to 110mm
Technology Data Acquisition Unit 64/128 N/A 0.5 - 25 360x300x86mm Carbon & Alloy
Design (AGR) 7 Kg Steel
SIUI/Doppler PAUT Probes 64 1.0 5 69mm x20mm Carbon & Alloy
Steel
SIUI/Doppler PAUT Probes 32 0.8/0.5 5 37mm x20mm Carbon & Alloy
Steel
Doppler PAUT Probes TRL 32 1.0 4 42mm x 20mm Carbon & Alloy
Steel
KPG Wedge PAUT Probe Wedges-SB85 N/A N/A N/A 85mmx 40mm – Carbon & Alloy
55deg. Shear Steel
55deg. Shear Steel
55deg. Shear Steel
SIUI TOFD Probes 3mm dia. N/A 5 10mm x 30mm Carbon & Alloy
Steel
SIUI Pulse Echo – TRL Probes -800 10x10 N/A 4 30mmx 30mm x Carbon & Alloy
40mm Steel
Jireh Remote Controlled Scanner - N/A N/A N/A 215x275x82mm Carbon & Alloy
Industries Navic 8Kg Steel
Jireh Semi-Automated N/A N/A N/A 215x275x82mm Carbon & Alloy
Industries Mechanized Scanner - Rotix 5Kg Steel
KPG AUT Remote Controlled N/A N/A N/A 325 x375x325mm Carbon & Alloy
Scanner Motorised Scanner for CW 15Kg Steel
6.2.1 ULTRASONIC PHASED ARRAY INSTRUMENT
6.2.1.1 The Ultrasonic Phased Array instrument shall be Manufacturer: Technical Design Model: Focus
Scan 64/128 pulse echo type and shall be equipped with a calibrated dB gain or attenuation
control stepped in increments of 1dB or less. The system shall be capable of generating and
displaying linear scan & sectorial or Stripchart scan images, which can be stored and recalled for
subsequent review. AGR Software 19.11 and above can be used.
6.2.1.2 The instrument shall be capable of operation at frequencies over the range of 1MHz TO 15MHz.
The Phased Array system should provide a variety of analysis capabilities including A-scan
display and parameter readout associated with software. Images produced by B, C, D, Sectorial
Scan and Linear Scan images will be used in combination to aid in evaluation.
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6.2.1.3 Examination Personnel shall use a real-time linear & sector scan image with a combination of
A,B,C,D, S scan presentation during scanning to assure that proper data has been collected. A
Sector scan images contain signal amplitude and reflector depth information projected for the
refracted angle of the ultrasonic beam backup with linear scan for root, cap and centre of weld will
be the base of the Phase Array scans. TOFD shall be used as a supplementary method to PAUT.
6.2.1.4 The AGR Phased Array system has on-board focal law generation software that permits direct
modification to ultrasonic beam characteristics. The AGR Phased Array system uses an internal
storage device as well as external storage using a pen drive or external hard disk.
6.2.1.5 In addition to external data storage, a PC shall also be used by the Data Analysis Personnel for
analysing data subsequent to the completion of data collection.
6.2.1.6 Instruments screen height linearity and amplitude control linearity shall be verified as per ASME
Sec-V SE 2491
6.2.1.7 Any control, which affects the instrument linearity, shall be in the off or minimum position for
instrument calibration, system calibration and examination.
6.2.1.8 The equipment will have current calibration certification in accordance with SE 2491. The
equipment is designed to meet or exceed the screen height and distance linearity requirements
detailed within ASME V SE 2491. Calibration periods shall be 12 months.
6.2.2 PRESENTATION
6.2.2.1 The presentation shall be A-Scan, B-Scan, C-Scan, D-Scan, (Sectorial) S-Scan, Linear Scan.
Depth, Range, Amplitude, Angle, Channel, and Distance in real time.
6.2.2.2 User definable panel configuration for data images. View data from multiple channels individually
or overlayed.
6.2.2.3 Corrected Skip overlay
6.2.2.4 User definable weld overlays
6.2.2.5 Defect sizing by cursors or echo dynamics
6.2.3 ATTENUATOR
6.2.3.1 The Instrument shall be equipped with a stepped gain control calibrated in units of 1dB or less.
6.2.4 TIME BASE
6.2.4.1 The time base shall be linear.
6.2.4.2 The deviation of the time base shall not exceed 2% of the screen width.
6.2.5 SCREEN HEIGHT LINEARITY
6.2.5.1 The ultrasonic instrument shall provide linear vertical presentation within +/- 5% of the full screen
height for 20% to 80% of the calibrated screen height.
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6.2.6 GAIN CONTROL LINEARITY
6.2.6.1 The ultrasonic instrument shall utilize an amplitude control accurate over its useful range to +/- 20%
of the normal amplitude ratio.
6.3 PROBES
6.3.1 Phased Array Probe & wedge configuration shall be suitable for the inspection of Carbon & Alloy
steel material; diameter & thicknesses. Phased Array Probe frequency shall be 5MHz, 64
elements, 1.0mm pitch. Manufacturer: SIUI or Doppler. 5MHz will be used for normal testing and
2.0 – 2.5MHz shall be used for high attenuation materials. Shoes/wedges of various sizes based
on material curvature or profile shall be used. Supplementary PAUT probes of 32 element, 1.0mm
0.8mm or 0.5mm pitch may be used for restricted areas. Table 1 gives a summary of the probes to
be used.
6.3.2 The probes will held in a probe holder scanning assembly with an encoded motorised scanner
which is guided along the centre of the weld or datum reference point with a laser tracker.
6.3.3 Two Phased array probes will be used to produce multiple angles and sound transmission modes
required to examine the weld. These probes will be utilised to produce the beam angles necessary
to test the weld in either or both pulse echo and pitch and catch modes.
6.3.4 A dedicated TOFD 5MHz (3mm dia.) probe assembly comprising of transmitter and receiver probes
will be used to assist in the validation of defects detected by PAUT for Carbon & Alloy steel. Phased
Array probes shall not be used to generate TOFD and act as dedicated TOFD probes.
6.3.5 For wall thickness from 51mm to 125mm, two pairs of TOFD probes will be used. However the
number of TOFD probes to be used will be determined by the lateral wave dead zone. If there is
not more than 1.0mm difference in the lateral dead zone between the 2 sets of TOFD probes, only
one TOFD probes pair will be used.
6.3.6 For wall thickness from 125mm to 150mm, three pairs of TOFD probes will be used. However the
number of TOFD probes to be used will be determined by the lateral wave dead zone. If there is
not more than 1.0mm difference in the lateral dead zone between the 3 sets of TOFD probes, only
two TOFD probes pair will be used.
6.4 ENCODERS
6.4.1 Encoders shall be used for all scans and no free hand scanning is allowed unless client approval
is granted for such scans. Encoders will be manual or motor driven and the resolution of the
encoder is set at 1.0mm. The positioning of the encoder is capable of accuracy better than +/-
10mm over the total scan length. Encoder Calibration will be made on the scanned test piece
based on the circumferential references and count bits rating. This will be recorded and kept in the
scan file.
6.4.2 Positional Encoder Check - The positional encoder shall be moved through a measured distance
of 20 in. (500 mm). The system read-out shall be within 1% of the measured distance. Encoders
failing this check shall be re-calibrated and this check repeated.
6.5 COUPLANT
6.5.1 Water will be used as couplant when performing calibration and examinations. Water pump shall
be used for water couplant if a water source capable of generating the required pressure is not
available on site.
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6.6 STANDARD CALIBRATION BLOCKS
6.6.1 Project specific calibration blocks will be used as per Appendix IV.
Wall Thickness Diameter of Side Drill Holes Notched (ID and OD) Positions
25mm to 50mm 3.0mm 2% of WT 1/4t, 1/2t, ¾ t
51mm to 100mm 5.0mm 2% of WT 1/4t, 1/2t, 3/4t
100mm to 150mm 6.4mm 2% of WT 1/4t, 1/2t, 3/4t
6.6.2 Calibration Blocks of various thicknesses should be available to cover the thickness indicated and
+/- 25% of the thickness range of the calibration block thickness.
6.6.3 For calibration blocks of all diameters, the diameter of the calibration block that can be used shall
be within 0.9 to 1.5 times the calibration block diameter on top of the thickness range for materials
with diameters less than 500mm. (T-434.1.7) For examination in materials with diameters equal to
or greater than 500 mm, a block of essentially the same curvature, or alternatively, a flat basic
calibration block, may be used.
6.6.4 The calibration and scanner block as per ASME V, Mandatory Appendix VIII 434.2.4 is combined
into one block as per drawing in Appendix IV.
6.6.5 Multiple reference blocks for calibration may also be used as per the requirements of PA system.
Special calibration blocks may be manufactured to meet calibration requirements if required.
Client to supply material for the manufacturing of calibration blocks to specification.
6.7 QUALIFICATION BLOCKS
6.7.1 The PAUT Scan Plan shall demonstrate sufficient sensitivity on a Qualification Block as define in
Code Case 189 (ASME V Art. 4 Mandatory Appendix IX) that sensitivity is achieved. If the
sensitivity is not achievable, different SDH of smaller diameters shall be used subject to client
approval. This new sensitivity will be demonstrated again on the Qualification Block to meet Code
acceptable performance.
6.7.2 Acceptable performance is defined as the detection of all the flaws in the demonstration block and
(a) recorded responses or imaged lengths, as applicable, exceed the specified evaluation
criteria of the procedure.
(b) the flaws are sized as being equal to or greater than their actual size (i.e., both length
and height)
(c) the flaws are properly categorized (i.e., surface or subsurface)
6.8 PHASED ARRAY SYSTEM CALIBRATION

6.8.1 Calibration shall be performed from the surface of the calibration block which corresponds to the
component surface to be examined. Temperature of the job shall be less than 60 0C. Surface shall
be smooth.
6.8.2 System calibration shall include the complete ultrasonic examination system.
6.8.3 Time base calibration: Calibration shall be suitable for the beam paths which will be used during
the examination.
6.8.4 The calibration information shall be recorded on the Ultrasonic Calibration system. During
scanning, no other adjustment will be made to the system setup. During examination adjustment
of other controls shall require recalibration.
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6.8.5 Calibration on standard calibration blocks will use flat wedges. For calibration with axial or
circumferential curved wedges, custom calibration blocks will be used. If no custom calibrations
blocks are available, calibration will be made on standard flat calibration blocks but the wedge
centre of first element height (Z) for the flat wedges and curve wedges will be the same when
measured from the centreline of the wedges. This will ensure that the focal laws for the phased
array will not be compromised. However the calibration will need to be verified and additional of
6dB will be added to compensate for beam divergence.
6.8.6 Element Balancing: The Operation of all elements of the transducer has to be checked if any
material is malfunctioning or any dead element. This is accomplished by “Balance Elements”. If any
element is not working then proper correction in calibration has to be done to compensate the
element and the probe can be used or the probe has to be replaced. Any element out by more
than +/- 12dB will be checked and disabled. If more than 10% of the total elements are dead or if
two adjacent elements are found to be not working, the probe will have to be replaced. Element
balancing is carried out on a backwall echo with 00 wedges or without any wedges. Note that TD
Focus Scan system use Element Balancing to ensure that each element generate the same energy
of ultrasound (by electronic compensation) apart from checking the working of the elements, which
is different from other manufacturer.
6.8.7 If during Element Balancing, it is suspect that one of the element is not working properly or inactive,
an image scan as per ASME-2491 Article 23 A3. will be carried out to determine and confirm the
inactive element(s).
6.8.8 Element Verification: To check that there is no dead element or pulser of the DAU, all the elements
in the probe will be triggered one element at a time with A-scan display, the element/channel will
be toggle from the first to the last element. Any dead element will display a loss of transmission
pulse. Further verification if probe or DAU is defective will be carried out by switching probes with
connector channel and reverse of triggering sequence. If the probe/DAU performance do not meet
6.8.6 above, then Element Balancing, will be carried out.
6.8.9 Calibration of computer imaging shall be conducted in such a manner that gain levels are optimized
for data acquisition and imaging purpose and also to establish scanning and or flaw detection/
sizing sensitivity level.
6.8.10 Instrument Linearity check should be as per ASME-2491 Art 23 A7. This will be carried out weekly
and record need to be maintained.
6.8.11 Coverage of the ultrasound has to be checked in ESBeamTool or any other equivalent simulation
software considering weld profile, probe and wedge combination and scan access of job prior to
selection of beams. A hard or soft copy of the scan plan shall be with the operator during scanning
/ Interpretation and evaluation.
6.9 FOCAL LAW VERIFICATION (Note: Subject to availability of block as per Appendix IV)
6.9.1 The transmission and reception of ultrasonic waves of a given angle of incidence is a function of
time delays calculated by focal laws using the information provided to the phased array system.
Verification that the input information is correct and that the phased array system is working
properly must be checked.
6.9.2 Using the 3 SDHs at different depths, peak the signal shown on the A-scan display using the
sectorial or linear scans display in the base/parent material.
6.9.3 The 3 SDHs should be at the correct depth and position. A tolerance of +/- 2.0mm or +/- 5%
whichever is greater is accepted for horizontal and vertical offset.
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6.9.4 The 3 SDHs should also show sensitivity settings at approximately 80% FSH reference level (RL)
with a tolerance of +/- 2dB (RL shall be between 63.5% to 100% FSH).
6.10 TIME BASE VERIFICATION
6.10.1 Position the Angle Cursor and adjust its position so that it displays A-scan information for the 45 0
angle of refraction.
6.10.2 Place the transducer so that reflections from both the 100mm and 200mm radius reflectors on the
IIW V1/K1 block are peaked and observed on the A-scan display.
6.10.3 Using the A-scan Cursors, measure the distance between the 100mm and 200mm signals. This
result shall be ± 2mm.
6.10.4 If the measured separation between the signals is too large (greater than 102mm), decrease the
Shear Velocity parameter under the Global Setup Menu. Similarly, if the measured distance is too
short (less than 98mm), increase the velocity value. Repeat adjustment until an acceptable value
is achieved.
6.10.5 With the transducer remaining in the peaked position, measure the metal path of the 100mm radius
reflector using a cursor in the A-scan display.
6.10.6 The value should measure to be 100 ± 2mm. If this measurement is less than 98mm, increase the
value of the Delay parameter until the measurement is correct. If this value is greater than 102mm,
decrease the Delay parameter until the measurement is correct.
6.10.7 Alternatively, the velocity of the specimen can be measured using the time measurement of the
instrument and using a venier calliper with accuracy of +/- 0.01mm to measure the thickness and
the velocity will be computed by V = Distance/Time.
6.11 SENSITIVITY AND WEDGE DELAY CALIBRATION – PHASED ARRAY

The Phased array system shall be calibrated for Sensitivity and Wedge Delay as per the
requirement using the Calibration software or using the A-scan display.
6.11.1 Probe Delay Calibration:
6.11.1.1 Enter Calibration Wizard for Probe Delay. This will automatically measure the delay for each focal
law to a calibration target. Once measurement is complete, each focal law is shifted in time so that
the signal from the calibration target appears in the correct place.
6.11.1.2 Manual Probe Delay Calibration: Using A-scan display, activate “cursor” and “persist”. Use the V1
Block at 100mm and 200mm range as reference for flat wedges. For curved wedges, use the
customised calibration block notches or SDH as reference. Set probe delay in Hardware Collection
to “0.00”. Adjust first known distance echo to maximum height. Place yellow cursor on the peak of
the echo. Type in “known distance” and “enter”. Activate Probe Delay Button. The software will
make the adjustment for the delay automatically. Verify the accuracy of the probe delay by typing
“second known distance” for the blue cursor. The blue cursor should appear on the “second known
distance” echo.
6.11.1.3 Focal Law Balancing for Sectorial Scans: If Calibration Wizard for Probe Delay is not used. The
sectorial beams need to be balanced for the different angles and sensitivity. This is carried out
using Focal Law Balancing and using a SDH as a reference. After Focal Law Balancing, activate
the Focal Law Balancing button.
6.11.1.4 The Wedge Delay Calibration shall be calibrated for True Depth with the angles used in calibration
+/- 2.0mm accuracy is required for all focal laws.
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6.11.2 Time Corrected Gain (TCG)
A Time Corrected Gain (TCG) shall be used to calibrate for attenuation in the material at the sound
paths utilized during calibration and examination. It should be at least a 3 point TCG. This shall be
digitally recorded and documented. The TCG function is similar to the DAC of a manual UT
equipment. No TCG is required for gate length less than 20mm.
6.11.2.1 Calibration Wizard for TCG per Focal Law Group: Measurements are taken from calibration
targets (normally side drilled holes) for each focal law group, and for multiple sound paths (depths).
The software then calculates a TCG curve for each focal law, thus a constant amplitude response
should be seen for every focal law at varying sound paths.
6.11.2.2 The Sensitivity Calibration will provide the required gain adjustment for each refracted angle
and sound path used.
6.11.2.3 Select a calibration reflector within the zone of material to be examined or use the Calibration
Block with the 3 SDH for TCG calibration. Set the number of TCG points for calibration. A minimum
of three points to be used.
6.11.2.4 Set the depth and leg values (skip path) in the TCG dialog box.
6.11.2.5 Move probe over the calibration block 1st target and set it to 80-90% FSH.
6.11.2.6 Start the calibration procedure and ensure good coupling and skew angle to optimise the signal.
Move the probe over the SDH for Pass 1 and Pass 2. The average will be computed for the 1 st
target.
6.11.2.7 Repeat for the 2nd Target and subsequent targets until the process is completed.
6.11.2.8 Once all points have been calibrated, TCG test mode is automatically entered.
6.11.2.9 Move the probe over each target to view the echo dynamics for each Focal Law and table for
the Focal Law will be populated.
6.11.2.10 Complete all the targets and save the setup. This completes the TCG process.
6.11.2.11 The Phased array system will calculate the required gain needed at each focal law to adjust the
amount needed +/- 5% echo height of all focal laws to be maintained.
Table 2 -Scanning and reporting threshold for each detection channel for PAUT Setup
Channel Name Calibration Evaluation Threshold Measurement Scanning Sensitivity Level
Standard (FSH) Level (Sizing) Threshold of (Ref = 80% FSH)
(of Reference Level (RL)) Peak Echo Height Carbon & Alloy Steel
˃ 25mm WT
Root & Cap Linear 80%FSH/ 5mm 20% for linear 50% for Height Reference Level +0dB
Channels SDHs indications 50% for Length
Linear Fusion 80%FSH/ 5mm 20% for linear 50% for Height Reference Level +0dB
Zone Scan SDHs indications 50% for Length
Sectorial Scan 80%FSH/ 5mm 20% for linear 50% for Height Reference Level +0dB
SDHs indications 50% for Length
*Note: 1) Transfer Loss (TL) will be determined by PE or PAUT probes of similar frequency – Refer to Appendix VI
2) SDHs for thickness above 100mm shall use 6.4mm SDH as Reference Level.
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6.11.3 Manual Setup for TCG
6.11.3.1 In certain cases, manual TCG setting is prefer over the TCG Calibration Wizard.
6.11.3.2 Activate manual TCG from the Hardware Collection. Select the number of TCG points to
be used. A minimum of 3 points is recommended. In case the gate is too short (less than
30mm) for 2 or 3 points TCG, then only one point is used to set the sensitivity correctly.
No TCG is required to be activated.
6.11.3.3 Place the probe (after probe delay and focal law balancing setup) on the reference block
with SDHs and adjust the echo height to the sensitivity required by the specification or
procedure.
6.11.3.4 Adjust the echoes for all the SDHs and note the dB and differences. This information is
manually input into the TCG setup in the Hardware Collection. The TCG for that focal law
group is setup and ready for testing.
6.12 SENSITIVITY SETTINGS – TIME OF FLIGHT DIFFRACTION (TOFD)
6.12.1 For each probe pair setup, the reference sensitivity level shall be set based on the lateral wave
amplitude from 40% to 80% FSH and noise level is less than 5% to 10% FSH.
6.12.2 If SDH is used for verification and sensitivity setting, the amplitude from the SDH will be set at
FSH of the calibration block.
6.12.3 For multiple zones examinations when the lateral wave is not displayed, or barely discernible, the
sensitivity will be set based on the noise (grass) level from 5% to 10% FSH. This noise (grass)
level sensitivity will not be less than the sensitivity set on zone with lateral wave settings if the
probe frequency is the same.
6.12.4 The side drilled holes (SDH) response from the respective zones shall be 6dB of more than the
noise (grass) level and shall be discernible in the digitized grey scale display.
6.12.5 The above sensitivity setting may be verified through the detection of artificial reflectors in
qualification block or calibration blocks.
6.12.6 Pre-amplifiers shall be used to reduce noise level for coarse grain or thick wall scanning.
6.13 STORAGE OF SYSTEM CALIBRATION

6.13.1 The examination system calibration may be stored in the Phased Array System with electronic
memory or on an external chip or data storage device. This calibration shall be checked prior to the
start of examination of each shift and after each break and shall be recorded in report.
6.14 SYSTEM VERIFICATION CALIBRATION
6.14.1 Sweep range and TCG calibration shall be verified on the appropriate calibration block or simulator
block, (IIW or same calibration block) as applicable, under the following conditions:
6.14.1.1 With any substitution of probe or operator.

6.14.1.2 Whenever the validity of the calibration is in doubt.
6.14.1.3 Whenever the beginning and end of a shift
6.14.1.4 Whenever there is a long break in examination during a shift.
Page 13 of 62
6.15 SYSTEM CALIBRATION CHANGES

6.15.1 Perform the following if any point of the TCG has decreased 20% or 2 dB of its amplitude, or any
point on the sweep line has moved more than 10% of the sweep division reading.
6.15.1.1 Void all examinations performed after the last valid calibration verification.
6.15.1.2 Conduct a new system calibration if required.
6.15.1.3 Repeat all voided examinations.
6.15.1.4 Perform the following if any point on the TCG has increased more than 20% or 2 dB of its
amplitude. Correct the system calibration if required.
6.16 RECALIBRATION
6.16.1 Any of the following conditions shall be caused for system recalibration:
6.16.1.1 Search unit transducer or wedge change
6.16.1.2 Change in probe cable length.
6.16.1.3 Ultrasonic accessories change
6.16.1.4 Couplant change
6.16.1.5 Change in operator
6.17 PREPARATION OF SCANNING SURFACES
6.17.1 Scanning surface should be free from surface defects, foreign materials, paint and any roughness
that would interfere with the free movement of the search unit. The scanning surface should be
smooth, that is, less than 25 micron roughness.
6.17.2 The surface temperature shall not exceed +/- 140C of calibration block temperature subject to
couplant and probe service temperature.(T 462.6)
6.17.3 Reflectors evaluated as laminar reflectors in the base material which interfere with the scanning
of the examination volume shall require the scan plan to be modified such that the maximum
feasible volume is examined and shall be noted in the record of the examination (T-493).
6.17.4 All T-section of Longitudinal and Circumferential Welds shall be grounded flush inside and
outside of the piles to facilitate scanning for the PAUT Probes. A minimum distance of 175mm
(or more depending on the thickness) for the T-joint shall be grounded flush. Any restrictions to
scanning shall be reported.
6.17.5 When necessary welds cap will be ground flushed to facilitate scanning for the PAUT Probes if
required. Spot dressing of the cap may be required to verify any root defects using 00
compression probes and measurement of defects height.
6.17.6 Weld caps shall be flushed for single sided scans.
6.18 EXAMINATION COVERAGE AND SCANNING TECHNIQUE
6.18.1 The specifics of the weld volume, weld identification, location and weld maps shall be identified and
recorded with reference to Project Drawing.
6.18.2 The examination volume shall be weld metal and areas on either side of the weld heat affected
zones. HAZ is defined as 10mm from the side of the weld.
6.18.3 To determine the required examination volume and scan area, profiles may be taken on each weld
and thickness and plot with weld simulation software like ESBeamtool to ensure coverage and
probe/wedge matching.
Page 14 of 62
6.18.4 Scanning shall be performed using a combination of Linear and/or Sectorial Technique. Each
sectorial or linear scan shall be parallel to the weld using a Sector Phased Array Scan or Electronic
Scan. To ensure coverage two probes of similar setup will be used to scan on both sides of the
weld simultaneously.
6.18.5 For thicker materials, multiple scans may be performed to the degree to cover the required volume
of weld material.
6.18.6 The rate of search unit movement shall be limited to a maximum of 30mm per second for welds
unless calibration has been verified at a higher speed.
6.18.7 Encoders shall be used to assist in the positioning of the probes and for plotting of the Phase Array
beams and TOFD. The resolution will be set to 1.0mm step.
6.18.8 If encoders are used, they will be calibrated to ensure that each millimetre of probe travel will be
equivalent to the full multi-probe data collected for all focal law for sectorial and or linear scans.
6.18.9 At least 100mm of overlap at both ends of the weld is required when scanning adjacent welds or
long welds.
6.18.10 For circumferential weld, at least 100mm of overlap is required at the start point of the weld.
6.18.11 Additional use of TRL Compression Wave creep wave and 700 Shear Wave is used to complement
PAUT, for single sided scans.
6.18.12 Additional use of PAUT TRL Compression Wave Probes maybe used for single sided scans when
the cap is flushed.
6.18.13 Scanning for Transverse Imperfections shall be carried out using manual 45 0 or 600 angle probes
orientated at approximately 150 to the weld axis for double sided scans.
6.18.14 Scanning for Transverse Imperfections shall be carried out using manual 45 0 or 600 angle probes
orientated at approximately 00 to the weld axis for single sided scans with the cap flushed.
6.19 EVALUATION
6.19.1 Flaw Signal amplitude shall be measured as a percentage of TCG by adjusting gain (dB) control
or by colour code related to amplitude (white up to 10%,Blue 11%-15%, Green16%-40%, Yellow
40%-63%; Orange 64%-99%,Red above 99%) on D, C or S scan display.
6.19.2 For carbon steel materials greater than 25.0mm, evaluation will be based on ASME B31.1 (2014)
Code Case 189 Table 2 and Table 3. TOFD shall be used as the primary height and depth
measurement when the TOFD top and bottom tip signals are distinct for height measurement.
PAUT of all multi-groups shall be used for evaluation of surface related defects and for height
measurement when the top and bottom tip signals of TOFD are not distinct. The maximum height
from the PAUT multi-groups or single tip measured TOFD shall be used. PAUT of all multi-groups
and TOFD will be used for length measurements. In the event there is a difference in length
measurements from TOFD and PAUT multi-groups, the largest sized length measurement shall be
used.6.19.3 Flaw sizing shall be performed by 6dB drop method of the peak echo for its length
by information given in A & C scan display using calibrated encoder, and 6dB drop method of the
peak echo for its height by information given in A, D & S scan display.
6.19.3 All indication equal to or in excess of 20% of the reference level shall be investigated in order to
determine their shape, size, identity and location.
Page 15 of 62
6.19.4 Any imperfection producing a response above 50% of reference level shall be recorded in the
data/report.
6.19.5 Indication of geometric or metallurgical origin will be verified from linear scans of specific areas
such as root, cap, fusion zone and centreline of the phased array system. Additional verification
by manual scanning may also be required for confirmation purposes. These indications will be
noted and recorded.
6.19.6 Where there is a transition thickness, the thickness of the thinner base material shall be the basis
for evaluation.
6.19.7 A subsurface indication shall be considered as a surface ﬂaw if separation of the indication from
the nearest surface of the component is equal to or less than half the through thickness dimension
of the subsurface indication.
6.19.8 Indication Interaction Rules is defined as indications close to one another shall be considered as
one defect or surface connecting as described in 6.20 (2) Multiple Discontinuities.
Page 16 of 62
6.19.9 “Code Case -189” Interpretation Methodology

The following flow chart will be used as a guide to the interpretation of “ECA” acceptance criteria
based on height and length only.
PAUT - Scan for Discontinuities

Scanned Data Is the Quality
Yes in US and DS S-Scans
Acceptable?
Scroll Top to Bottom
If Discontinuities - Compare
Rescan No Multi Groups and Choose
Maximum Echo Group.
Measure height for
acceptance criteria
TOFD - Scan for Discontinuities. Subsurface Root and Cap

Scroll Left to Right. Check TOFD Defects; Size Defects; Size
discontinuities for distinct top and Height with Height from
bottom signals and size length Echo Dynamic surface to
using 6dB drop 6dB drop
̑̑ Signal not distinct: Measure

̑ Distinct Signals – Size for
height using TOFD and use height relative to surfaces or
this as primary height for use PAUT height
acceptance criteria
Compare heights from TOFD and

Accept/Reject PAUT and choose maximum height
for acceptance criteria
Compare lengths from TOFD and Size Length using 6dB drop
PAUT and choose maximum length of peak amplitude of Multi
for acceptance criteria Groups and choose
maximum length**
** Note: For single sided scans, refer to specific technique sheets for length sizing.
Page 17 of 62
6.20 ACCEPTANCE CRITERIA
The acceptance criteria shall be based on ASME B31.1 – Code Case 189 – Table 2 and 3
1) The graphs below are used for evaluation of the acceptance criteria based on the Code Case.
Note that the thickness of the materials will be inserted into this Excel format for the actual
acceptance and rejection level which will be plotted by the formulas. This Excel format will be part
of the Scan Plan for materials greater than 25mm WT.
2) Multiple Discontinuities
(-a) Discontinuous indications that are oriented primarily in parallel planes shall be considered to lie
in a single plane if the distance between the adjacent planes is equal to or less than 13mm(0.50
in.) or 0.5t, whichever is less.
(-b) If the space between two indications aligned along the axis of weld is less than the height of
the indication of greater height, the two discontinuities shall be considered a single discontinuity.
(-c) If the space between two indications aligned in the through-thickness dimension is less than
the height of the indication of greater height, the two indications shall be considered a single
discontinuity.
3) Discontinuity Acceptance Criteria. Discontinuities hall be evaluated using the applicable criteria of
Table 2 or 3, with the following additional requirement:
Regardless of discontinuity height or aspect ratio, discontinuity length shall not exceed 4t.
Page 18 of 62
Sample Evaluation Table for Thickness of 75mm as per Table 2 and 3
6.21 NDT TESTING OF REPAIRED WELDS
6.21.1 NDT of repaired welds shall conform to the requirements of approved Inspection Test Plan of the
project.
6.22 EXAMINATION RECORD
6.22.1 Computerized image technique shall have the following data / information recorded in the system
as per sample format agreed to by client prior to project commencement.
6.22.2 A print out of indication/ reports and or graph plotting to be attached along with the test report for
repair. The report shall be in the form of data in soft copy or hard copy.
6.22.3 Any obstruction of scanning coverage or not accessibility for scanning or any restriction shall record
on the report.
6.23 REPORTING
6.22.1 Upon completion of the examination a completed test report will be submitted to the client and/or
certifying authority. This report shall be the standard reporting format as included in Appendix III.
All relevant information as required by the report shall be completed and signed by an authorized
person.
Page 19 of 62
APPENDIX I
WELD TEST METHODS

General Set Up for Weld Testing:
PARENT METAL EXAMINATION – Pulse Echo (If applicable)

Scanning Positions: Both sides of the weld up to 6T distance.
Scanning Pattern: Overlapping Scans
Sensitivity: 2nd Back Wall Echo at 80% to Full Screen Height
Probes: 0 degrees Pulse Echo probes
WELD METAL EXAMINATION
Phased Array:
Scanning Positions: Scan on Both sides of the weld at a fixed distance.
Scanning Pattern: D-scan parallel to the weld axis
Focal Laws: Sectorial Scans, Linear Scans for fusion face, Linear Scans for Cap, Root and
Centerline
Sensitivity: 3.0mm, 5.0mm or 6.4mm SDH to 80% FSH as per Code requirements.
Probes: Phased Array probes with relevant wedges
Evaluation Sensitivity: 20% above reference level
Sizing Technique: 6dB drop method of Peak Echo
TOFD:
Scanning Positions: Scan on Both sides of weld at fixed distance
Scanning Pattern: D-Scan parallel to weld axis
Sensitivity: Lateral Wave set to 50-80% of FSH; Alternatively Grass Level 5-10% of FSH
Probes: TOFD Probes with relevant wedges
Evaluation: Any abnormality in standard display and confirm with PA
Sizing technique: Parabolic Cursors after calibration of linear depth.
Pulse Echo (Transverse Scan):

Scanning Positions: Scan on both sides of the weld at fixed distance and approximately 15 0 to weld
axis. Scan both directions on top of the weld at approx. 00 to weld axis for single
side scans.
Scanning Pattern: 00 for single side scans & 150 for both side scans from both directions of the weld..
Sensitivity: 1mm notch of calibration block to 80% FSH + 6dB
Probes: Pulse Echo probes with relevant wedges of 45 0 or 600
Evaluation Sensitivity: 20% of reference level
Sizing technique: 6dB drop method
Creep Wave (TRL Compression Wave) Scan (complement Single Side/Restricted Scanning):
Scanning Positions: Scan on Both sides of weld at fixed distance near to toe of cap or across cap.
Scanning Pattern: D-Scan parallel to weld axis
Scanning Sensitivity: 1.0mm notch to 80% of FSH at 25mm from probe face.
Probes: Twin Crystal Compression Wave probes 80 - 83 deg.
Evaluation: Any echo greater than 50% of reference level will be investigated.
Sizing technique: 6dB drop method
Page 20 of 62
Ultrasonic Inspection Test Method – 01-02 – Double Sided Scans
Technique No: T/ASME/PA/01-02/50-150/DS Rev.0

Client: Equator Engineering Sdn Bhd KPG Job/IRO No:
Project: Jimah East Power Plant Client Job No:
Application: Welds in Plate and Pipes Operator Qualifications: PCN Level II
Technique In Accordance with: ASME V Art 4
Acceptance Criteria: Boiler Pipings – ASME I – Code Case 2235; Non-boiler pipings – ASME B31.1 Code Case 189
Item/Weld: 50-150mm Double V Butt Welds
Thickness Range: 50-150+/- 2mm Material: Carbon & Alloy Steel
EQUIPMENT CALIBRATION
Calibration Block: V1 and V2 Reference Block: 5mm SDH; Specific Block
Probes: Phase Array 64 element x 1.0mm Pitch 5MHz
Wave Type Angle (deg) Sensitivity Type of Scan Skew Direction
Shear 37-65 5mm SDH to 80% FSH Sectorial 1 – Full Skip 0 & 180
Shear 39 / 40 5mm SDH to 80% FSH Linear Lower 100 fusion – P&C 0 & 180
0
Shear 48 /34 5mm SDH to 80% FSH Linear Upper 10 fusion – P&C 0 & 180
Shear 34/36 5mm SDH to 80% FSH Linear to Cap 0 & 180
0
Shear 50 5mm SDH to 80% FSH Linear to 37.5 Fusion (180) 180
Shear 58.5 5mm SDH to 80% FSH Linear to 37.50 Fusion (0) 180
Sensitivity: 5mm hole plus attenuation factor plus scanning dB
Probes: TOFD – 5 or 7.5 MHz – Sensitivity – lateral Wave 40-80% FSH or 10% of grass level
TECHNIQUE DETAILS
Additional Instruction:
 Note any restriction on the test report.
 Transverse Scan will be carried out manually using single probe at approximately 15 0 adjacent to the probe axis
 Scan Plan valid for the thickness and bevel indicated. Any changes in thickness will require a new scan plan
 Scan Plan Summary and Detail to be provided prior to inspection for the particular thickness.
 Scan plan angles and coverage will depends on the Thickness of the material inspected and will be submiited for
approval before inspection is carried out.
Originator: KL Leong Client: Principal/Third Party:
ASNT Level III - #25071
PCN Level 3 UT, PAUT, TOFD - #326793
Page 21 of 62
Ultrasonic Inspection Test Method – 01-03 – Single Sided Scans (Sample Only)
Technique No: T/ASME/PA/01-03/75/SS Rev. 0

Client: Equator Engineering Sdn Bhd KPG Job No:
Project: Jimah East Power Plant Client Job No:
Application: Welds in Plate and Pipes and Fittings Operator Qualifications: PCN Level II
Technique In Accordance with: ASME V Art 4
Acceptance Criteria: Boiler Pipings – ASME I – Code Case 2235; Non-boiler pipings – ASME B31.1 Code Case 189
Item/Weld: 50-150mm Butt Welds (Pipe to tee, flanges, elbows or valves)
Thickness Range: 50-150mm +/- 2mm Material: Carbon & Alloy Steel
EQUIPMENT CALIBRATION
Calibration Block: V1 and V2 Reference Block: 5mm SDH dia. hole; Specific Block
Probes: Phase Array 64 element x 0.6mm Pitch 5MHz
Wave Type Angle (deg) Sensitivity Type of Scan Skew Direction
Shear 37-65 5mm SDH to 80% FSH Sectorial 1 – Full Skip 180
Shear 39 / 40 5mm SDH to 80% FSH Linear Lower 100 fusion – P&C 180
0
Shear 48 /34 5mm SDH to 80% FSH Linear Upper 10 fusion – P&C 180
Shear 34/36 5mm SDH to 80% FSH Linear to Cap 180
0
Probe: TRL PE Creep Wave : Sensitivity: 1mm notch plus scanning dB
Probes: TOFD 5MHz 3mm dia. 450 & 600 Wedge – where accessible for PCS.
Wave Type Angle (deg) Sensitivity Type of Scan Focal Depth (%)
Compression 60 60-80% FSH Lateral Wave Non Parallel Y mm (30-40%)
Compression 45 5-10% FSH Grass Level Non Parallel X mm (80-90%)
TECHNIQUE DETAILS
Additional Instruction:
 All caps shall be flushed prior to inspection.
 Note any restriction on the test report.
 Scan from one side from half skip to one and a half skip distance.
 Transverse Scan will be carried out manually using single probe at 0 0 on the cap
 Scan Plan valid for the thickness indicated. Any changes in thickness will require a new scan plan
 Scan Plan Summary and Detail is available on request for the particular thickness.
Originator: KL Leong Client: Principal/Third Party:
ASNT Level III - #25071
PCN Level 3 UT, PAUT, TOFD - #326793
Page 22 of 62
APPENDIX II
REPORTING FORMAT
1.0 - Report
Page 23 of 62
APPENDIX III
WORKSHEETS
Page 24 of 62
APPENDIX IV – Calibration and Qualification Blocks (Sample Only)
A – 60mm WT – Top View
A- 60mm WT – Side View
APPENDIX V
Page 25 of 62
SCAN PLAN SUMMARY:
Please refer to specific Scan Plan for various thicknesses and profiles.
 The Scan plan is specific for the thickness mentioned. If a different thickness outside the range of +/-
5mm is to be tested, a new Scan plan will be planned onsite to ensure proper test coverage. The Scan
Plan will be recorded in hard and soft copy for reference and traceability.
 New Scan plans will be required for any changes in weld configuration for example from V bevel to J
bevel.
 New Scan plans will be required for any fittings, flanges, valves, bends, and slopes and will be drawn to
scale to ensure proper coverage and scanning technique.
 The technique sheets are a guide for the coverage for the calibration blocks used as reference and their
range of thickness as per ASME V Art 4 2015 requirements.
 Once the validation is successfully completed, based on any changes made to scan plan (if any), the
final approval for the procedure shall be made
1. Technique Sheet: TS-01-02-75-75mm-DS Rev.0

3. Technique Sheet: TS-01-03-75-75mm-SS-01 Rev.0
Page 26 of 62
1. Scan Plan: Technique Sheet: TS-01-02-75-75mm-DS Rev.0
Scan Plan: 75mm – 75mm WT

Inspection Layout
Piece
Shear Compression
Thickness Width Length Index Offset Material
Velocity Velocity
75mm 450mm 100mm 0mm Steel 1020 3.24mm/µs 5.89mm/µs
HAZ: 19.04% HAZ Width: 10mm
Page 27 of 62
Weld
Region Angle Height Gap
Upper Fill 10° 53.4mm
Fill 37.5° 17mm
Hot Pass - V-Type 37.5° 3mm
Root 1.6mm 3mm
Cap Height Width Overlap
Top 2mm 62.52mm 5mm
Bottom 2mm 13mm 5mm
Phased Array Probe: PA Probe 1
Index Offset: -127mm Scan Offset: 0mm Mirrored: False
Wedge: KPG SB85

Velocity Primary Offset Height 1st Element Length Width Angle
2.33mm/µs 81mm 7.7mm 85mm 40mm 36.2o
Transducer: Doppler 5L64-01.0X10-B7

Total Aperture: 64mm Number of Elements: 64 Element Pitch: 1mm
Page 28 of 62
Sectorial Beamset 1
Law Config.: Sectorial Wave Type: Shear
Element First Min Max Angle

Focus
Qty Element Angle Angle Steps
16 27 39o 68o 1o None
Linear Beamset 1
Law Config.: Linear Wave Type: Shear
Element First Last Number Refracted

Focus
Qty Element Element of Beams Angle
16 1 40 13 53o None
Linear Beamset 2

Focus
16 1 30 8 42.5o None
Page 29 of 62
Linear Beamset 3

Focus
16 21 64 15 52.5o None
TOFD Probe: TOFD Probe 60
Crossover Depth PCS Index Offset Scan Offset Elevation Refracted Angle
37mm 128.17mm 0mm 60mm 0mm 60o
Wedge:
Length Width Exit Point
20.95mm 20mm 8.4mm
Page 30 of 62
Transducer:
Shape Diameter Frequency Length Width
Round 3mm 5Mhz 10mm 10mm
63mm 126mm 0mm 90mm 0mm 45o
Wedge:
20.95mm 20mm 8.4mm
Transducer:
Page 31 of 62
Index Offset: 127mm Scan Offset: 0mm Mirrored: True
Wedge: KPG SB85

2.33mm/µs 81mm 7.7mm 85mm 40mm 36.2o

Sectorial Beamset 1 Beamset

Focus
16 27 39o 68o 1o None
Page 32 of 62
Linear Beamset 1

Focus
16 1 40 13 53o None
Linear Beamset 2

Focus
16 1 30 8 42.5o None
Linear Beamset 3

Focus
16 21 64 15 52.5o None
Page 33 of 62
Scan Plan: 145-145mm WT
Inspection Layout
Piece
Shear Compression
Velocity Velocity
Page 34 of 62
Weld
Fill 37.5° 17mm
Root 1.6mm 3mm
Top 2mm 87.21mm 5mm
Bottom 2mm 13mm 5mm
Phased Array Probe: PA Probe Shear 1
Wedge: KPG SB85

2.33mm/µs 81mm 7.7mm 85mm 40mm 36.2o

Page 35 of 62
Sectorial Beamset 1

Focus
16 27 44o 65o 1o None
Linear Beamset 1

Focus
16 1 64 17 53o None
Linear Beamset 3

Focus
17 1 62 16 50.5o None
Phased Array Probe: PA Probe -Com - 1
Page 36 of 62
Wedge: TRL60
2.32mm/µs 48mm 13mm 57mm 40mm 20o
Transducer: TRL 32*1.0- D51

Sectorial Beamset 1
Law Config.: Sectorial Wave Type: Longitudinal

Focus
16 1 73o 85o 1o None
Phased Array Probe: PA Probe - Com - 2
Wedge: TRL60
2.32mm/µs 48mm 13mm 57mm 40mm 20o
Page 37 of 62

Sectorial Beamset 1

Focus
16 1 74o 84o 0.67o None
Wedge: KPG SB85

2.33mm/µs 81mm 7.7mm 85mm 40mm 36.2o

Page 38 of 62
Sectorial Beamset 1

Focus
16 27 44o 65o 1o None
Linear Beamset 1

Focus
16 1 64 17 53o None
Linear Beamset 3

Focus
17 1 62 16 50.5o None
Page 39 of 62
Wedge: TRL60
2.32mm/µs 48mm 13mm 57mm 40mm 20o

Sectorial Beamset 1

Focus
16 1 73o 85o 1o None
Wedge: TRL60
2.32mm/µs 48mm 13mm 57mm 40mm 20o
Page 40 of 62

Sectorial Beamset 1

Focus
16 1 74o 84o 0.67o None
TOFD Probe: TOFD Probe 1 - 60
35mm 121.24mm 0mm 40mm 0mm 60o
Wedge:
20.95mm 20mm 8.4mm
Page 41 of 62
Transducer:
Wedge:
20.95mm 20mm 8.4mm
Transducer:
Page 42 of 62
Scan
Crossover Depth PCS Index Offset Elevation Refracted Angle
Offset
125mm 250mm 0mm 80mm 0mm 45o
Wedge:
20.95mm 20mm 8.4mm
Transducer:
Conventional Probe: UT Probe 1 - Creep
Index Offset: -70mm Scan Offset: 180mm Beam Angle: 83º Compression
Page 43 of 62
Wedge:
33mm 30mm 16mm
Transducer:
Index Offset: 70mm Scan Offset: 180mm Beam Angle: 83º Compression
Wedge:
33mm 30mm 16mm
Transducer:
Page 44 of 62
Scan Plan: 75mm WT –Single Side
Inspection Layout
Piece
Shear Compression
Velocity Velocity
Page 45 of 62
Weld
Fill 37.5° 17mm
Root 1.6mm 3mm
Top 2mm 62.52mm 5mm
Bottom 2mm 13mm 5mm
Wedge: KPG SB85

2.33mm/µs 81mm 7.7mm 85mm 40mm 36.2o

Page 46 of 62
Sectorial Beamset 1

Focus
16 27 39o 68o 1o None
Linear Beamset 1

Focus
16 1 40 13 53o None
Linear Beamset 2

Focus
16 1 30 8 42.5o None
Page 47 of 62
Linear Beamset 3

Focus
16 21 64 15 52.5o None
Linear Beamset 4

Focus
16 1 64 17 76o None
Phased Array Probe: PA Probe - 2
Page 48 of 62
Wedge:
2.34mm/µs 42mm 14mm 52mm 40mm 20o

Sectorial Beamset 1

Focus
16 1 72o 85o 0.65o None
Linear Beamset 1
Law Config.: Linear Wave Type: Longitudinal

Focus
14 1 32 10 50.5o None
Page 49 of 62
Linear Beamset 1

Focus
14 1 32 10 55.5o None
37mm 128.17mm 0mm 60mm 0mm 60o
Wedge:
20.95mm 20mm 8.4mm
Transducer:
Page 50 of 62
Wedge:
20.95mm 20mm 8.4mm
Transducer:
Conventional Probe: UT Probe
Index Offset: -59mm Scan Offset: 0mm Beam Angle: 83º Longitudinal
Page 51 of 62
Wedge:
33mm 30mm 16mm
Transducer:
Conventional Probe: UT Probe
Index Offset: 59mm Scan Offset: 0mm Beam Angle: 83º Longitudinal
Wedge:
33mm 30mm 16mm
Transducer:
Page 52 of 62
Scan Plan: 145mm WT – Single Side
Inspection Layout
Piece
Shear Compression
Velocity Velocity
Page 53 of 62
Weld
Fill 37.5° 17mm
Root 1.6mm 3mm
Top 2mm 87.21mm 5mm
Bottom 2mm 13mm 5mm
Wedge: KPG SB85

2.33mm/µs 81mm 7.7mm 85mm 40mm 36.2o

Page 54 of 62
Sectorial Beamset 1

Focus
16 27 44o 65o 1o None
Linear Beamset 1

Focus
16 1 64 17 53o None
Linear Beamset 3

Focus
17 1 62 16 50.5o None
Page 55 of 62
Linear Beamset 3

Focus
16 1 64 17 62o None
Wedge:
2.34mm/µs 42mm 14mm 52mm 40mm 20o

Page 56 of 62
Sectorial Beamset 1

Focus
16 1 73o 85o 1o None
Sectorial Beamset 2

Focus
16 1 45o 65o 1o None
Wedge:
2.34mm/µs 42mm 14mm 52mm 40mm 20o
Page 57 of 62

Sectorial Beamset 1

Focus
16 1 74o 84o 0.67o None
Sectorial Beamset 2

Focus
16 1 48o 70o 1o None
Page 58 of 62
Wedge: TRL60
2.32mm/µs 48mm 13mm 57mm 40mm 20o

Sectorial Beamset 1

Focus
16 1 67o 85o 1o None
Sectorial Beamset 2 Beamset

Focus
16 1 45o 70o 0.81o None
35mm 121.24mm 0mm 40mm 0mm 60o
Page 59 of 62
Wedge:
20.95mm 20mm 8.4mm
Transducer:
Page 60 of 62
Wedge:
20.95mm 20mm 8.4mm
Transducer:
Index Offset: -70mm Scan Offset: 180mm Beam Angle: 85º Shear
Wedge:
33mm 30mm 16mm
Transducer:
Index Offset: 70mm Scan Offset: 180mm Beam Angle: 85º Shear
Page 61 of 62
Wedge:
33mm 30mm 16mm
Transducer:
Page 62 of 62

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TITLE: NON-DESTRUCTIVE TESTING PROCEDURE

PHASED ARRAY ULTRASONIC INSPECTION

DOCUMENT NO: NDT-03-04-UT

PROJECT: JIMAH EAST POWER PLANT

CLIENT: EQUATOR ENGINEERING SDN BHD

DOCUMENT STATUS RECORD

REVISION CHANGE RECORD

REV No. DESCRIPTION SECTION

6.1 Scanning Technique

6.6 Standard Calibration Blocks

6.7 Qualification/Demo Blocks

6.8 Phased Array System Calibration

6.9 Focal Law Verification

6.10Time Base Verification

6.11Sensitivity and Wedge Delay Calibration – Phased Array

6.12Storage of System Calibration

6.13System Verification Calibration

6.14System Calibration Changes

6.16Preparation of Scanning Surfaces

6.17Examination Coverage and Scanning Technique

6.20NDT of Repaired Welds

Appendix I – Weld Test Methods – General Set UP for Weld Testing

Appendix II – Reporting Format

Appendix III – Worksheets

Appendix IV – Calibration and Qualification Blocks for Phased Array

Appendix V – Scan Plan Summary

Appendix VI – Manual UT procedure – NDT-01-04-UT Rev. 0

3.1 SNT-TC-1A – 2006: Recommended Practice

6.1 SCANNING TECHNIQUE

Table 1: Equipment and Probes List.

6.2.1 ULTRASONIC PHASED ARRAY INSTRUMENT

6.2.2.3 Corrected Skip overlay

6.2.2.4 User definable weld overlays

6.2.2.5 Defect sizing by cursors or echo dynamics

6.2.4 TIME BASE

6.2.4.1 The time base shall be linear.

6.2.5 SCREEN HEIGHT LINEARITY

6.2.6 GAIN CONTROL LINEARITY

6.6 STANDARD CALIBRATION BLOCKS

25mm to 50mm 3.0mm 2% of WT 1/4t, 1/2t, ¾ t

51mm to 100mm 5.0mm 2% of WT 1/4t, 1/2t, 3/4t

100mm to 150mm 6.4mm 2% of WT 1/4t, 1/2t, 3/4t

6.7 QUALIFICATION BLOCKS

6.8 PHASED ARRAY SYSTEM CALIBRATION

6.10 TIME BASE VERIFICATION

6.11 SENSITIVITY AND WEDGE DELAY CALIBRATION – PHASED ARRAY

6.11.2 Time Corrected Gain (TCG)

6.11.3 Manual Setup for TCG

6.12 SENSITIVITY SETTINGS – TIME OF FLIGHT DIFFRACTION (TOFD)

6.13 STORAGE OF SYSTEM CALIBRATION

6.14 SYSTEM VERIFICATION CALIBRATION

6.14.1.1 With any substitution of probe or operator.

6.15 SYSTEM CALIBRATION CHANGES

6.17 PREPARATION OF SCANNING SURFACES

6.17.6 Weld caps shall be flushed for single sided scans.

6.18 EXAMINATION COVERAGE AND SCANNING TECHNIQUE

6.19.9 “Code Case -189” Interpretation Methodology

PAUT - Scan for Discontinuities

TOFD - Scan for Discontinuities. Subsurface Root and Cap

̑̑ Signal not distinct: Measure

Compare heights from TOFD and