ULTRASONIC THICKNESS

MEASUREMENT
PROCEDURE
No.06/MAT-UTG/IGF/2018

Revision: 00

Made by Reviewed by Approved by

Name : Ira Roni Yuda Name : Irwan Name : Muhammad Jahid Akbar
Position : Material Test Technician Position : Inspector Leader Position : President Director
Date : Date : Date :
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 2of 15

1.0 PURPOSE AND SCOPE

1.1 This procedure establishes the requirements for Manual Ultrasonic Thickness
Measurement of materials and will be applied when Ultrasonic Thickness
Measurement is required in accordance with ASME Section V, Article 5 by the
referencing Code. This procedure will be used in conjunction with applicable
client specifications.
1.2 This procedure will be used whenever manual ultrasonic thickness measurements
per the requirements of ASME are specified.
1.3 Ultrasonic examination shall be performed in accordance with a written
procedure which shall, as a minimum, contain the requirements found in Table
1.0.

Table 1.0
Variables of an Ultrasonic Examination Procedure

1.4 When procedure qualification is specified, a change of a requirement in Table

1.0 identified as an essential variable from the specified value, or range of values,
shall require requalification of the written procedure.
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 3of 15

1.5 A change of requirement identified as a nonessential variable from the specified

value, or range of values, does not does not require requalification of the written
procedure.
1.6 All changes of essential or nonessential variables from the value, or range of values,
specified by the written procedure shall require revision, or an addendum to, the
written procedure.

2.0 REFERENCES
2.1 The latest revision, or revision stated in the contract, of the following referenced
documents is applicable to and /or form the basis of this procedure:
2.1.1 ASME Boiler and Pressure Vessel Code, Section V “Nondestructive
Examination”
2.1.2 ASTM E-114 “Recommended Practice for Ultrasonic Pulse-Echo Straight-
Beam Testing by the Contact Method
2.1.3 ASTM E-317 “Standard Practice for Evaluating Performance
Characteristics of Ultrasonic Pulse-Echo Testing Systems without the Use
of Electronic Measuring Instruments”.
21..4 ASTM E-797 “Standard Practice for Measuring Thickness by Manual
Ultrasonic Pulse-Echo Contact Method”
2.1.5 ASNT SNT-TC-1A, CP-189.

3.0 PERSONNEL QUALIFICATION

3.1 Personnel performing Ultrasonic Thickness Measurement will be certified to at
least Level II Ultrasonic Examination (UT) or Thickness Measurement Limited.

4.0 ULTRASONIC EQUIPMENT AND MATERIALS

4.1 The following are the requirements for the Ultrasonic Thickness Measurement
Examination Equipment
4.1.1 The instrument shall be of the pulse-echo type and must have a CRT or
digital and CRT display.
4.1.2 The instrument’s horizontal limit and linearity, Paragraph 8.4, screen height
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 4of 15

linearity, paragraph 8.5 and amplitude control linearity, paragraph 8.6, shall
be verified every 3 months or prior to first use thereafter.
4.1.3 The instrument shall be calibrated at intervals no longer than 12 months to
reference standards traceable to the National Institute of Standards and
Technologies (NIST) and meet or exceed the manufacturer’s tolerances and
specifications.4.1.4. Any frequency and size search unit may be selected as
long as it is capable of resolving the thickness range being measured,
provided that it meets the manufacturer’s recommendations and client
specifications.
4.1.5 The search unit may be single element, delay line, or dual element contact
transducers.
4.1.5.1 Search unit selected shall have sufficient crystal to surface contact
to produce stable readings. On smaller diameter pipe, 3.50” and less,
a small diameter search unit or curved standoff shoe may be
required.
4.2 Couplant may be water, glycerin, oil, grease or specially formulated commercially
available materials.
4.2.1 Inhibitors and/or wetting agents may be used.
4.2.2 The chemical interaction or the corrosive nature of any couplant with the
material(s) being examined will be considered when making the choice of
couplant.
4.3 The reference standards material from which the block is fabricated shall be of the
same product form, material specification or equivalent P- Number grouping, and
heat treatment as the material being examined. The finish on the scanning surface
of the block shall be representative fo the scanning surface on the material to be
examined and:
4.3.1 Shall have at least three steps:
4.3.1.1 The thinner step shall have a thickness within +10% of the value
stated in the column marked “Lower step” of table 2 for the
thickness range to be tested.
4.3.1.2 The thicker step shall have a thickness within +10% of the value
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 5of 15

stated in the column marked “Upper step” of table 2 for the

thickness range to be tested.
4.3.1.3 The third step and the minimum thickness to be tested shall fall
within the “Objective Thickness Range” and between the thin and
thick calibration steps. The third step shall be machined with a flat
bottomed hole in accordance with figure 1 and table 2.
4.3.2 The physical dimensions will be within + 1% of the nominal thickness of
the step.
4.3.2.1 The measurement of the steps will be performed with a
calibrated mechanical instrument, traceable to NIST.

5.0 EXAMINATION SURFACE

5.1 Surfaces will be uniform and free of loose scale and paint, discontinuities such as
pits or gouges, weld spatter, dirt, or other foreign matter which may adversely affect
test results.
5.1.1 Tightly adhering paint, scale or coatings do not necessarily need to be
removed for testing if they present uniform attenuation characteristics.
5.2 Surfaces may be ground, sanded, wire brushed, scraped, or otherwise prepared for
examination purposes when necessary.
5.3 In areas where severe pitting is experienced and where surface preparation is not
recommended, readings will be taken on high areas and pit depth will be measured
by mechanical depth gauges. As an alternate, an ultrasonic pencil tip probe may be
used if the customer desires.

6.0 CALIBRATION PROCEDURE

6.1 The proper functioning of the examination equipment will be checked and the
equipment will be calibrated by use of the reference standard, as described in
paragraph 4.3, at:
6.1.1 The beginning and end of each examination;
6.1.2 When examination personnel are changed;
6.1.3 Anytime that a malfunction or improper operation is suspected (i.e.,
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 6of 15

unusually high or low readings);

6.1.4 When search units are changed;
6.1.5 When new batteries are installed or electrical outlet is changed;
6.1.6 When equipment operating from one power source is changed to another
power source or experiences power failure.
6.2 If, during a calibration, it is determined that the examination equipment is not
functioning properly or it is found to be out of calibration, all of the measurements
since the last valid equipment calibration will be retaken.
6.3 Calibration shall be accomplished using the same couplant as that to be used when
measurements are being taken.
6.3.1 When special form high temperature couplant is being used, a different
couplant may be used for calibration.
6.3.2 The temperature of the calibration block shall be within + 25° F of the test
specimen.
NOTE
All ultrasonic measurements shall be made at a threshold setting of 20
%FSH.
6.4 Calibration shall be established with three known thickness.
6.4.1 Determine the objective thickness from table 3
6.4.2 Place the transducer on the thin step and adjust the instrument to read the
step within + .001 inch of the actual step thickness.
6.4.3 Place the transducer on the thick step and adjust the instrument to read the
step within + .001 inch of the actual step thickness.
6.4.4 Repeat 6.4.2 and 6.4.3 until the instrument reads both steps within the +
.001 inch tolerance without further adjustment.
6.4.5 Ultrasonically measure the objective thickness. The thickness shall be
within + .001 inch of its actual thickness.
6.5 Gain transfer shall be established in the following manner:
6.5.1 Place the transducer on the reference calibration thickness closest to the
corresponding material thickness being examined. Note signal strength and
gain control setting.
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 7of 15

6.5.2 Place the transducer on the test material in an area with a uniform back-wall
reflection free from any indications and representative of sound material.
6.5.3 Observe the signal level and adjust the gain control to produce the same
signal height or response as noted from the calibration block. Note the gain
control setting.
6.5.4 Subtract the gain control value in 6.5.1 from that in 6.5.3. This number
(positive or negative) is the gain transfer.
6.6 Scanning sensitivity.
6.6.1 Place the transducer on the object step and maximize the response from the
flat bottom hole. Observe the signal level and adjust the gain control to
produce a signal that is 80% FSH.
6.6.2 Repeat the steps in paragraph 6.4 and verify the system meets the required
tolerance.
6.6.3 Add the gain transfer amount (6.5.4) to the reference setting (6.6.1). This is
the gain control sensitivity setting for scanning.
6.7 All calibrations shall be recorded. The setup parameters used, including gain,
percent screen height setting, time of calibration and the identification of the
operator performing the calibration.

7.0 METHOD OF EXAMINATION

7.1 Couplant may be applied to the search unit or directly on the component being
examined.
7.2 The extent of the examination and the location of the readings will comply with the
referencing code and the customer requirements.
7.2.1 Readings may be taken at randomly selected locations or taken in specified
grid patterns as required.
7.3 Scanning speeds will not exceed a rate of 6 in./ sec.

8.0 SPECIAL TECHNIQUE CONSIDERATIONS

8.1 Dual transducer element search units are inherently nonlinear for thickness
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 8of 15

measurements less than 0.125".

8.1.1 If measurements below 0.125" must be made with dual transducer element
search units, calibration must be accomplished with at least 3 thickness
steps below 0.125" within the range of the expected readings. Additionally
the proposed technique shall be in accordance with manufacturer’s
recommendations and applicable client specifications.
8.2 When testing steel at elevated temperatures, above 200°F and up to 1000°F,
specially designed search units and couplant shall be used.
NOTE
To compensate for reading errors due to elevated temperatures the following shall be used.
The apparent thickness reading obtained from steel walls having elevated temperatures is
high (too thick) by a factor of about 1% per 100°F. Thus, if the instrument was calibrated
on a piece of similar materials at 68° F, and if the reading was obtained with a surface
temperature of 860° F, the apparent reading should be reduced by 8%.

8.3 Consideration must be given to the back-wall echo during testing.

8.3.1 When encountering wall thinning due to corrosion, the roughening of the
back surface can affect the amplitude and shape of the back- wall echo.
Such a change in the back-wall echo should be noted.
8.3.2 When encountering wall thinning caused by erosion, the back wall echo
might disappear as the sharply-angled far surface reflects the incident wave
away from the transducer. If the back wall echo disappears for this or any
other reason, such as abrupt thinning into the near surface region, the cause
will be investigated with shear wave transducers or other inspection
technique, as appropriate. Such a disappearance of the back-wall echo can
indicate a critical degree of thinning and must be explored until the reason
for such a loss of signal is defined.
8.3.3 Indications being displayed at or near the back-wall may be absorbed into
the back-wall signal and initially appear to be the inner diameter (ID)
connected. Interpretation shall be performed at lower gain settings to
determine if two separate signals exist. A lower amplitude signal in front of
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 9of 15

a higher amplitude back-wall signal may indicate a near ID inclusion. If any

question exists, the area shall be investigated with a shear wave search unit
to determine if an ID corner trap exists between the indication and the back-
wall.
8.4 Horizontal limit and linearity
8.4.1 Couple a longitudinal transducer, 2.25 to 5.0 MHz, to an IIW block (or
equivalent thickness) as not to intercept any test holes (figure 2). The
couplant used must provide stable indications during the measurements.
NOTE
All multiple positioning and position measurements shall be made with the
respective back-reflection set at 50% of full screen height.

8.4.2 Adjust the instrument gain, sweep-delay, and sweep-length controls to

display eleven non-interfering back reflections. Further adjust the sweep
controls to position the leading edge of the third and ninth back reflections
at 20% and 80% horizontal screen divisions respectively.
8.4.3 Read and record each scale position on a UT Instrument Verification Report
form (attached) and plot. Record greatest linearity error in % of full
horizontal scale.
8.4.4 Horizontal limit is given by the maximum available trace length falling
within the CRT gradticule lines expressed in linear units (inches or
millimeters). Unless otherwise noted this is also assumed to represent
100% full screen. Failure to obtain full-scale deflection may indicate an
equipment malfunction.
8.4.5 Record all data and conformance on a UT Instrument Verification Report
form (attached).
8.5 Screen height linearity
8.5.1 Couple a longitudinal transducer, 2.25 to 5.0 MHz, to a distance sensitivity
(DS) block (or equivalent) so that indications from the 2 inch and 4 inch
back-reflection can be observed (figure 3 position A).
8.5.2 Adjust the search unit position to give a 2:1 ratio of amplitude between the
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 10of 15

two indications.
8.5.3 With the larger set at 80% of full screen height (FSH), and without moving
the search unit, adjust gain to successively set the larger indication from
100% to 20% of full screen height in 10% increments.
8.5.4 Read the smaller indication at each setting. The smaller reading must be
50% of the larger reading amplitude, within 5% of FSH. The settings and
readings must be estimated to the nearest 1% of FSH.
8.5.5 Record all data and conformance on a UT Instrument Verification Report
form (attached).
8.6 Amplitude control linearity
8.6.1 Couple a longitudinal transducer, 2.25 to 5.0 MHz, to a DS block (or
equivalent) so that the 4 inch back-reflection is peaked on the screen (figure
3 position B).
8.6.2 With an increase and decrease in gain, as shown in table 3, the indication
must fall within the specified limits.
8.6.3 Record conformance on a UT Instrument Verification Report form
(attached 1).

9.0 POST CLEANING

9.1 Immediately upon completion of the examination, the couplant shall be removed
by a suitable cleaning method.
9.1.1 The considerations of paragraph 4.2.2 shall also apply for the cleaning
agents.

10.0 EXAMINATION REPORT

10.1 The following data will be recorded as a minimum for future reference at the time
of each examination and included in the report:
10.1.1 Part number identification;
10.1.2 Operator's name and certification level:
10.1.3 Instrument description, make, model, serial number; and NIST traceable
calibration due date;
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 11of 15

10.1.4 Setup - couplant, cable type and length;

10.1.5 Search unit description - type, size, frequency, special
shoes;
10.1.6 Reference standards, size, and material types;
10.1.7 Record required instrument settings;
10.1.8 Scanning method and any limitations;
10.1.9 Each thickness measurement and its location;
10.1.10 Reference to this procedure.
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 12of 15

11.0 ACCEPTANCE STANDARDS

11.1 Acceptance or rejection of a component will be based on customer requirements,

and/or the minimum design thickness allowed by the referencing code.

Objective
Maximum Thickness Minimum
lower Step Target Upper Step
.03” Up to .125” incl. .20”
.10” over .125” through .375” .50”
.10” over .375” through .50” .625”
.25” over .50” through .750” .90”
.50” over .750” through 1.00” 1.30”
.50” over 1.00” through 1.25” 1.60”
.75” over 1.25” through 1.50” 1.90”
1.00” over 1.50” through 1.75” 2.15”
1.00” over 1.75” through 2.00” 2.50”
1.00” over 2.00” through 2.25” 2.80”
1.50” over 2.25” through 2.50” 2.90”
1.50” over 2.50” through 2.75” 3.00”
2.00” over 2.75” through 3.00” 3.50”
2.00” over 3.00” through 3.25” 3.75”
2.00” over 3.25” through 3.50” 4.00”
2.00” over 3.50” through 3.75” 4.25”
2.00” over 3.75” through 4.00” 4.50”
2.00” over 4.00” through 4.25” 4.75”

Table 3
Thickness Testing Reference Table for
Lower, Target, and Upper Bracket Ranges.
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 13of 15
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 14of 15
 ULTRASONIC THICKNESS No.06/MAT-UTG/IGF/2018
MEASUREMENT PROCEDURE Revision 00
Page 15of 15