Geecy Industrial Services Pvt. Ltd.

Standard Operating Procedure

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Geecy Industrial Services Pvt. Ltd.
Standard Operating Procedure

Contents

Section No. Title

1. Purpose

2. Scope

3. Personnel Qualification

4. Reference Documents

5. Surface condition

6. Equipment

7. Calibration

8. Sensitivity

9. Distance Amplitude Correction (DAC)

10. Transfer Correction

11. Scanning procedure

12. Discontinuity Location, Evaluation & Recording

13. Sizing of Imperfections

14. Recording of Indications

15. Acceptance Criteria

16. Repairs

17. Reporting

18. Ultrasonic Examination Report Format (Sample)

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Geecy Industrial Services Pvt. Ltd.
Standard Operating Procedure

1 Purpose

1.1 Purpose of this procedure is to ensure the quality of welded steel joints by Ultrasonic pulsed
echo contact beam examination method

2 Scope

2.1 This procedure details the general requirements for the use of straight and angled beam
pulse echo ultrasonic examination units for testing of steel welds

2.2 The test is performed manually by Ascan,pulse echo contact method. Through transmission
or pitch catch method are not within the scope of this procedure.

2.3 Electronic alarms and suppression /reject controls are not utilized

3 Personal Qualification

3.1 The qualification of personnel is as stipulated in the internal written practice as given
inTraining & Certification Manual GISPL/OM /01

3.2 As a minimum all personnel conducting Ultrasonic test are qualified to level –II

3.3 All qualification certification are current

4 Referenced Documents

4.1 ASME Sec.V.Boiler& Pressure Vessel code

4.2 ANSI B 31.3-code for Chemical plant & petroleum Refinery Piping

4.3 ANSI B 31.1 power piping

4.4 Geecy Training & Certification Manual GISPL/OM/01

4.5 All referred documents shall be current

5 Surface Condition

5.1 The surface from which scanning is performed, is cleaned to remove all scale, weld spatter,
loose particles or any other deleterious foreign material, to assure continuous coupling during
examination

5.2 Uniformly coated, primed or painted surfaces can be scanned as it is, provided transmission
of ultrasound is reasonably constant and the transfer correction value does not exceed 6 dB

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Geecy Industrial Services Pvt. Ltd.
Standard Operating Procedure

6 Equipment

6.1 Ultrasonic instrument used is A scan pulsed reflection type Flaw Detector - EEC, Model - Ex
– 10, EEC- Model DS 322 digiscan

6.2 Probes used are:- Normal beam – single & double crystal, single crystal angle beam
Frequency – 1 to 5 MHz, Normal beam Crystal Size – 25 mm Dia or 12.5 TR probe, 8x9
mm size angle probe 45˚, 60º, 70

7 Calibration

7.1 The recommended Configuration for an IIW calibration block (VI) and miniature calibration
block (V2) is as shown in sketch 1 & 2

7.2 Each technician performs instrument and probe checks. This includes beam angle check
screen height linearity, amplitude control linearity, horizontal linearity every three months

7.3 Range and other calibrations are done prior to the start of each working shift or at minimum
4 hrs. interval whichever is earlier

7.4 Acceptance criteria for linearity is in accordance with ASME sec .V Article 4 mandatory
Appendix

7.5 Normal beam

Normal beam range Calibration is done using an IIW VI or V2 block. The calibrated range is such
that at least two back wall echoes from the parent metal near to the weld are visible on the CRT
screen

7.6 Angle Beam Range Calibration

An IIW V1 or V2 block is used for range calibration. The range for angle beam calibration is
determined from the angle of the probe used for testing and the maximum beam path covered. Ie,
for scanning up to half –skip distance, the range is at least equal to half beam path; for scanning up
to full skip distance , the range is at least equal to full beam path and so on.

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vt. Ltd
d.
Sttandard Operatiing Proc
cedure

V 1 Block

V 2 Blockk

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Geecy Industrial Services Pvt. Ltd.
Standard Operating Procedure
8 Sensitivity

8.1 Normal beam - The second back wall echo form the parent metal is kept at 80% of full
screen height. The corresponding “dB” added with surface correction, if applicable, as the reference
sensitivity for normal beam scanning. Discontinuities are evaluated by comparing their echo height
at this reference sensitivity

8.2 Angle Beam – DAC is drawn as stated below

9 Distance Amplitude Correction

9.1 DAC curves are made for each variation in combination of probe angle & frequency orwhen
changing to probe / machine of different manufacturer or series. The reference
block is used for DAC curve construction as shown below

The material from which the block is fabricated shall be of the same product form, and material
specification or equivalent P-Number grouping as one of the material being examined.For the
purpose of this procedure P-Nos. 1, 3, 4 and 5 are considered equivalent).

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Gee
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Test Block for DAC

C curve of F
Flat surface
es (above 20
0” diameterr pipes)

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9.2 The referencce sensitivitty for angle e beam sca anning is e established through a Distance
A
Amplitude Coorrection currve (DAAC).AA special calibration blocck according
g to the requ
uirements
off Sec.V, Article 5 is useed for prepa
aring a dista
ance amplitu ude correctiion curve. The
T basic
ca
alibration blo
ock containss Side drille
ed Holes (SDDH) and No otches, the selection
s of which is
go
overned by a specific test procedure. The DA AC Block iss acousticallly similar too the test
m
material

DAC curv
ves are consstructed as follows
f

9.2.1 Place the probe on

o the calibra
ation block to
o obtain a re
eflection from
m the notch.

9.2.2 Maximmize the inddication by manipulatin ng Adjust inndication ap

pproximatelyy to 80%
een height using the
ofscre e gain con ntrol. Make e a mark on the CRT C (or
slide/transparencyy)at the peakk of this indication. Note
e the gain

9.2.3 Repea at step (ii), without

w distu
urbing the gain,
g using rreflection at least from two
t other
differe
ent beam patth length, wiithin the testt range to be
e used

9.2.4 Conne
ect all pointss marked, w with a smoo oth curving line. This lin
ne referred to
t as the
DAC curve.
c This is
s called as reference
r levvel

9.3 The calibratio

on reflectorss for Pipe W
Weld are longgitudinal and
d with circum
mferential no
otches on
bo
oth the inner and outer surfaces.
s Se
ee figure below

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10 T
Transfer C
Correction

10.1 A transfer correction valuue is determ mined for all shear wavee examinatio on to compe ensate for
difference
es in surfacee contour, finish, coating
g and acousstical propertties. This va
alue is determ
mined for
each anggle used, Ulttrasonic freq
quency, size and make of o probe musst be identiccal

10.2 Proce
edure

A correcction in instru
ument senssitivity is req
quired to com
mpensate fo or Difference
es between n the ref-
erence standard
s and the test su
urface at the ustical attenuation
e contact arrea and anyy other acou
characteeristic.

Measureement is ach hieved by employing too angle beamm probes off the same type,
t one accting as
a transm
mitters and th
he other as receiver. The two transsducers are
e placed initially at one skip dis-
tance an
nd the respoonse is adjusted to 75%%. Note the dB”
d X.”

The samme step is re

epeated on the
t test obje
ect and dB “Y” d to bring response to 7
“ required 75% is
noted.

Transferr correction is the differe

ence betwe
een “ X” and “Y”.

11 S
Scanning P
Procedure
e

11.1 Scanning for discontinuitties is carried out with th

he angle be
eams at approximately rightangle
r
to xis. The scanning is don
o the weld ax ne from two directions
d where possible

11.2 A the three angles

All a viz. 45°,
4 60° & 70
0° are utilize
ed for testing
g.

11.3 The search unit

u is moved d in a zig-za
ag pattern with
w an overlap of 10%. The scannin
ng speed
do
oes not exce
eed 6” per second

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Geecy Industrial Services Pvt. Ltd.
Standard Operating Procedure
11.4 Scanning is done continuously from weld toe up to 1½ skip distance on both sides of the
weld

11.5 Reference sensitivity is added with 6 db during scanning, which is deducted at the event
evaluation of indications

11.6 The joint is indexed suitably and marked on the adjacent parent metal to identify the
direction in which scanning is progressed.

12 Discontinuity Location, Evaluation & Recording

12.1 Location - Discontinuities once confirmed are positioned within the weld cross section
by manipulating the probe to get maximum response, measure beam path length
and distance from established reference point. A graphical plotting card may be employed
to determine the sound beam path in the member and provides all details for locating
the defect

12.2 Evaluation -The length of all reportable discontinuities are determined by 6 dB drop
method. Reflectors/discontinuities are sized using those probes which receive maximum response

12.3 Characterization - The discontinuities are characterized as

12.3.1 Spherical - Like single pores, spaced porosity, cluster porosity

12.3.2 Cylindrical - Like hollow beads, slag, slag lines

12.3.3 Planar - Like lack of fusion, unfused root faces, crack

13 Sizing of imperfections

13.1 Imperfections are sized by 6 dB drop method which is described below

13.1.1 Method: Maximize the response form the defect and adjust to 80% full screen height

13.1.2 Move the probe towards the left till the indication height reduces to 50% of
initialheight. Mark the probe center on the job. Repeat the same step for probe
positiontowards right

13.1.3 The distance between the two probe centers M give the length of the Defect

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cedure

14 R
Recording of Indications

14.1 All discontinu

A uities that produce
p reflection at orr greater th
han 50% DA
AC are porttrayed in
fu
ullscale cros
ss section and
a representative plan
n view and documented d along with
h the UT
R
Report

15 A
Acceptanc
ce Criteria
a

The acce
eptance crite
eria as per th
he ANSI B 31.3

A linea
ar type discontinuity is unacceptable if the amp
plitude of the indication exceeds
el and its length exceedss:
the refference leve

● 6 mm (1/4 in) for Tw ≤ 19mm ((3/4 in)

● Tw /3 for
f 19 mm < Tw ≤ 57 mm m (21/4 in)
● 19 mmm for Tw> 577 mm

Where Twis
i the weld thickness + allowable
a reiinforcement.

16 R
Repairs

All the reepaired welds are reste ed as per thhis procedure. Test rep
ports of repa
air welds arre clearly
identified
d R1,R2etc .a
as first repair, second re
epair etc

17 R
Reporting
All Tests conducted in accordancce with this p
procedure are reported o
on a standard test reporrt.

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 Geecy Industrial Services Pvt. Ltd.
Standard Operating Procedure
ULTRASONIC EXAMINATION REPORT
Customers name
Contract No.
(with brief address)
Location of work site Contact person
UT Report No. Date of Testing

Standard Instrument & Sr. No.

Acceptance criteria Calibration status
Procedure/Tech. sheet No. Coupling media
Extent of coverage Surface condition Free of scale and clean

Job Sr.
Job Description Material Nominal Dimension Qty.
No.

Setting of time base

Search unit Setting of sensitivity

(%reference level)

(%reference level)
range

Recording level
Rejection level
Job Sr. No.

Max. beam path

Gain (dB) (Ref)

Reference block

(SDH / Notch
Search unit /

(dB) (if any)

Beam index

range (mm)
Beam angle

Calibration
Time base

correction
Reflector

Scan dB
in mm)
(mm)

block

Add
type

Position and orientation of

Result Evaluation
indications
Search unit / type
Indication No.

Transverse defect
Beam path (mm)
Job Sr. No.

Not Acceptable
% of reference
Distance from

Refer
surface (mm)

length (mm)
Depth from

Long. Defect
Point (mm)

Indication

Acceptable
coupling

sketches
level
ref.

attached

Note: 1. Calibration printout attached 2. Material accepted & stamped as:

Tested by Reviewed by
Customer Surveyor
ASNT UT LV- II ASNT UT LV-II
Sign &
Date
Name
GISPL/F/UT/01 Rev. 2.00

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