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RONAK
MEHTA
RONAK
MEHTA
SAKET
KUMAR
B 22/07/2012 Issued
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5.1 The examination shall be conducted with a pulse echo ultrasonic instrument having AScan
display and which is capable of generating frequencies in the range of at least
1MHz to 5MHz & shall be equipped with a stepped gain control in units of 2dB or less.
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examined.
8.2 Couplants used on nickel base alloys shall not contain more than 250 ppm of sulfur
8.3 Couplants used on austenitic stainless steel, duplex stainless steel or titanium shall not
contain more than 250ppm of halides (chlorides plus fluorides).
8.4 Same type of couplant shall be used for calibration and examination.
9.0 EXAMINATION COVERAGE AND RATE OF PROBE MOVEMENT
9.1 Total area / volume which need to be examined shall be scanned by moving the search
unit over the surface so as cover the entire examination area. Each pass of the probe
shall overlap a minimum of 10% of the transducer dimension perpendicular to the
direction of the scan.
9.2 The rate of probe movement for examination shall not exceed 6 in./sec. (150 mm/sec)
9.3 During scanning the Reject control of the equipment shall be kept at zero position.
10.0 TECHNIQUE FOR EXAMINATION OF PLATES
10.1 When required, the plates shall be examined using normal beam probes in
accordance with the requirement of SA-435/SA-435M,SA-577/SA-577M, SA 578 / SA578M and as supplemented by the referencing Code section / agreed standard.
10.2 The sweep range and distance amplitude calibration shall be in accordance with SA
435 or SA 578 and as supplemented by the referencing Code section/agreed standard.
10.3 The examination, coverage, recording, acceptance criteria and reporting shall be in
accordance with SA 435 or SA 578 and as supplemented by the referencing Code
section/agreed standard.
11.0 TECHNIQUE FOR EXAMINATION OF FORGING AND BARS
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Adjust the sensitivity control to provide an 80% of full screen indication from the
hole
Mark the peak of the indication on the screen with a suitable marker.
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Without changing the sensitivity setting, position the search unit for maximum
response from at least two other holes at different depths and marks the points.
Also manipulate the search unit for maximum response from a bottom notch and
mark the point.
Connect the screen marks and extend through the thickness to provide the
distance amplitude curve.
12.5.2 The sensitivity setting for DAC shall be the Primary Reference Level (PRL)
for examination.
12.5.3 In case of piping weld, separate DAC shall be established for both axial and
circumferential notches by using basic calibration block shown in the
Attachment 3.
12.6 CALIBRATION CHECK
12.6.1 When any part of the examination system is changed, a calibration check shall
be made on the basic calibration block to verify that distance range points
and sensitivity settings have not been changed beyond limits.
12.6.2 A calibration check on at least one of the basic reflectors shall be made at
the finish of each examination, or by series of similar examinations, 4 hours
during the examination and when examination personnel are changed.
12.6.3 If a point on the DAC curve has moved on the sweep line more than 10% of
the sweep reading or 5% of the full sweep or the DAC curve has decreased
20% or 2dB of its amplitude, all data sheets since the last calibration shall be
marked void. A new calibration shall be made and recorded and the area
covered by the void data shall be re-examined. If the DAC curve has
increased more than 20% or 2dB of its amplitude, all recorded indications
since last valid calibration shall be re-examined with the corrected calibration
and recorded.
12.6.4 When the referencing Code section requires the detection and evaluation of
all indications exceeding 20 % of DAC, the gain should be increased an
additional amount so that no calibration reflector indication is less than 40%
FSH. As an alternate, the scanning sensitivity level may be set at 14 dB
higher than the reference level gain setting. With this increase in dB
reference DAC becomes 20% DAC.
12.6.5 System Changes. When any part of the examination system is changed, a
calibration check shall be made on the basic calibration to verify that distance
range points and sensitivity setting (s) satisfy the requirements of 12.6.7.
12.6.6 Calibration Checks. A calibration check on the least one of the reflectors in
the basic calibration block or a check using a similar shall be performed at
the completion of each examination or series of examinations, and when
examination personnel (except for automated equipment) are changed. The
distance range and sensitivity values recorded shall satisfy the requirements
12.6.7.
12.6.7 Confirmation Acceptance Values
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12.8.4 When weld cap is not machined or ground flat, the examination shall be performed
from the base metal on both sides of the weld cap in both weld axis direction from at
least single surface.
12.8.5 For angle beam scanning, selection of probe angle and knowledge of weld geometry
is very important. Guidance for selection of probe is given in Attachment no.1 to this
procedure.
12.8.6 The probe shall be manipulated so that the ultrasonic energy passes through the
required volume of weld and adjacent base metal. This scanning shall be performed at
the gain setting of at least two times the PRL (6dB more than the PRL dB setting).
Evaluation shall be performed with respect to PRL.
12.8.7 Guidance for scanning butt welds is given in Attachment no. 3 to this procedure.
12.8.8 Restricted Access Welds:
Welds that cannot be fully examined from two directions using the angle beam
technique shall also be examined, if possible with a straight beam technique. These
areas of restricted access shall be noted in the examination report.
12.8.9 Inaccessible Welds:
Welds that cannot be examined from at least one side using the angle beam technique
shall be noted in the examination report. For flange welds, the weld may be examined
with a straight beam or low angle longitudinal waves from the flange face provided the
examination volume can be covered.
12.9 EVALUATION
12.9.1 Any imperfection which causes an indication in excess of 20% DAC shall be
investigated to the extent that it can be, evaluated in terms of the acceptance
standards of the referencing Code sections or agreed standard.
12.10 Technique
12.10.1 Each type of Ultrasonic examination shall have a Technique sheet (Attachment
6) with the details of all the essential variables applicable for that technique. These
technique sheets shall be qualified by performing actual demonstration for the range of
variables.
12.10.2 Any change in the essential variable (Refer Table 1) shall require requalification,
re-demonstration and revision of that technique sheet attached to this
procedure.
12.10.3 Any change in the non-essential variable (Refer Table 1) shall require revision
in the respective technique sheets attached to this procedure.
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13.1.5 For Technique one :The examination shall be performed from the clad surface,
with the plane separating the elements of dual probe shall be parallel to the
axis of the weld bead and the probe shall be moved perpendicular to the weld
direction.
13.1.6 For Technique two: The examination may be performed from the clad or unclad
surface; the probe can be moved perpendicular or parallel to the weld direction.
13.1.7 The scanning shall be done at minimum 6dB+PRL and evaluation shall be
performed at PRL
13.2 EVALUATION
13.2.1 Any imperfection which causes an indication in excess of 20% DAC shall be
investigated to the extent that it can be, evaluated in terms of the
acceptance standards of the referencing Code sections or agreed standard.
14.0 REFERENCE POINTS FOR EXAMINATION
14.1 In order to enable the position of possible imperfections to be accurately identified
within the component or weld, reference points shall be marked on the component.
Alternatively a sketch which can provide the above information shall be provided.
15.0 LOCATION AND CONFIRMATION OF IMPERFECTIONS
15.1 The position of the suspect imperfection shall be accurately determined in relation to
the weld cross section or component geometry from the range of signals along the time
base, beam angle and the position and orientation of the probe and in relation to the
reference point. Having initially located the apparent imperfection position, this shall be
confirmed from the second side/surface of the weld/component and/or by the use of
different beam angle. This will ensure that the indication is not from a normal
geometrical feature of the weld or caused by wave mode change.
16.0 CHARACTERIZATION AND SIZING OF IMPERFECTIONS
16.1 Sizing of the imperfections shall be carried out at a range not exceeding the half skip
position. The length shall be determined by 6dB drop method or 20 dB beam profile
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Post examination cleaning shall be done as soon as practical after the completion of Ultrasonic
Examination of Welds and Material in such a way that will not put adverse effect on the
material inspected.
20.0 REPORTS AND EXAMINATION RECORDS
20.1 The imperfections, which are required to be reported & their evaluation shall be
recorded on Ultrasonic Examination Report (refer Attachment 8)
20.2 The calibration record for the instrument shall be maintained. The calibration blocks used
shall be referred in the ultrasonic examination report.
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(TECHNIQUE ONE)
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C la d d in g
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