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EVERSENDAI CONSTRUCTION PRIVATELIMITED

Plot No:B7, B8 & B18 GK Industrial park,

Reddimangudi siruganur village,

Trichy -621105.

STATISCTICAL LOADED STRUCTURE ULTRASONIC TESTING

PROCEDURE OF T, K & Y JOINTS:-

Prepared By Reviewed By Verified & Guided by Approved By

Level III

Mr.Jalil (EVS) Mr. Vadivel (EVS) Mr. Sivakumar ( EVS)

Mr. Narasimhan (EVS) Mr. Manikandan (EVS)

MAG NDT MAG NDT

Date: 08.05.2018 Rev: 00 Report No : ECPL/AWS/UT/001

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INDEX

1) PURPOSE

2) SCOPE

3) REFERENSE CODE

4) EQUIPMENT & MACHINERIES

5) TEST PIECE SIZE & DEFCET INDUCED DETAILS

6) ULTRASONIC TEST PROCEDURE

7) TEST RESULTS & ACCEPTANCE CRITERIA

8) SAMPLE PHOTOS

9) ACTUAL TEST REPORTS & RESULT AND DECLARATION

1) Purpose:-

Now a day T, K & Y shape type of steel structure project works are very common in construction
steel structure & composite structure type of projects.

DATE: 08.05.2018 REV:0 REPORT NO: ECPL/AWS/UT/001

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To make of this complicated structure, the steel fabrication weld quality requirements are very
stringent. The test of complexity weld quality is the main part and which required additional skill of
the ultrasonic test operator.

Hence T, K & Y shape type of steel joint connection is to be performed; the operator shall be
required to demonstrate his ability to apply special technique is required for such examination.

The practical tests for this purpose, here we have prepared one mock up / sample weldment which
represents the weld type, angle of actual weld and its thickness and joint configuration of the
structure is encountered in production using of this mock up as applicable and qualified procedures.

2) Scope: -

The procedure and standards is specifically uses for statistical loaded structure consists of rolled
beams & columns (UB and UC) for to connect of T, K & Y shape weld joint configured structure.

The applicable thickness limitation is 8mm and above of the thickness and up to 200 mm thick of the
member.

The performance shall be judged on the basis of the ability of the operator to determine the size and
classification of each discontinuity with accuracy required to accept or reject through this mock up
evaluation. The welding operator skill shall be confirmed through this mock up test then the
operator shall engage for actual production test inspection.

The ultrasonic test operator shall find out at least 90 % of the known defects which is induced by us.
Then only the operator is eligible and allow for T, K & Y type joints in our premises.

3) Normative References:-

AWS D 1.1 2015

ASME Sec V

Established WPS

4) Testing operator basic qualification & Equipment requirements:-

The ultrasonic testing operator shall be qualified by any one of the ASNT Level II or ISNT Level II of
UT operator certificate and his past experience shall be verified in order perform of test of the weld
component.

The Equipment shall confirmed by NABL accredited calibrated certificate in order to perform of test
purpose.

Standard calibrations block.

5) Defect Induced location & Size Details:-

The structural joint mock – up which has been identified by three joint configurations.

DATE: 08.05.2018 REV:0 REPORT NO: ECPL/AWS/UT/001

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T, K & Y Shape joint:-

Figure 1

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Figure 2

Defect information of PART A at Details-1

It has further split in to three parts. One flange represent a1, the web part
represent a2 & the another flange which represent a3.

PART A ; a1
Nomenclature of Joints:-

Shape of the Joint: - “K” Shape

Groove Joint Configuration: - Single Bevel

Groove Angle: - 45 Degree

Root Face: - 3MM

Root Gap: - 3MM

DATE: 08.05.2018 REV:0 REPORT NO: ECPL/AWS/UT/001

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Defect Size & Location:-

Total Weld Length -372MM

Known / Induced Repair Length-90MM (Flange)

Depth:-15MM

Size: - 90X4MM

Actual welding process (Not induced) Defect: - If any, this shall confirm with actual report.

Top View

Figure 3

PART A a2- Slag.

Nomenclature of Joints:-

Shape of the Joint: - K Type Joint

Joint Configuration: - Single Bevel

Groove Angle: - 45 Degree

Root Face: - 3mm

Root Gap: - 3mm

Defect Size & Location:-

Total Weld Length -460mm

Known / Induced Repair Length-100MM (Web)

Depth:-13mm

Size: - 100X4mm

Actual welding process (Not induced) Defect: - If any, this shall confirm with actual report.

Top View

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Figure 4

PART A a3- Slag.

Nomenclature of Joints:-

Shape of the Joint: - K Type Joint

Joint Configuration: - Single Bevel

Groove Angle: - 45 Degree

Root Face: - 3mm

Root Gap: - 3mm

Defect Size & Location:-

Total Weld Length is 372 mm

Known / Induced repair length-100MM (flange)

Depth:-23MM

Size: - 80X3MM

Actual welding process (Not induced) Defect: - If any, this shall confirm with actual report.

DATE: 08.05.2018 REV:0 REPORT NO: ECPL/AWS/UT/001

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Top View

Figure 5

PART B; b1 & Detail 2

Nomenclature of Joints:-

B1-Porosity.

Shape of the Joint: - K Type Joint

Joint Configuration: - Single Bevel

Groove Angle: - 45 Degree

Root Face: - 3mm

Root Gap: - 3mm

Defect Size & Location:-

Total Weld Length -372 MM

Known / Induced Repair Length-100MM (Flange)

Depth:-15MM

Size: - 100X5MM

Actual welding process (Not induced) Defect: - If any, this shall confirm with actual report.

Top View

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Figure 6

PART B; b2 at Detail 2
Nomenclature of Joints:-

B2-Pin Hole.

Shape of the Joint: - K Type Joint

Joint Configuration: - Single Bevel

Groove Angle: - 45 Degree

Root Face: - 3MM

Root Gap: - 3MM

Total Weld Length is 460mm

Defect Size & Location:-

Known / Induced Repair Length-50MM (Web)

Depth:-10MM

Size: - 50X3MM

Actual welding process (Not induced) Defect: - If any, this shall confirm with actual report.

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Top View

Figure 7

PART B; b3 at Detail 2
Nomenclature of Joints:-

B3- Lake Of Side Wall Fusion.

Shape of the Joint: - K Type Joint

Joint Configuration: - Single Bevel

Groove Angle: - 45 Degree

Root Face: - 3mm

Root Gap: - 3mm

Defect Size & Location:-

Total weld length -372 MM

Known / Induced Repair Length-60MM (Flange)

Depth:-13mm

Size: - 60X4mm

Top View

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Figure 8

PART C; c1 at Detail 3
Nomenclature of Joints:-

Shape of the Joint: - T Type Joint

Joint Configuration: - Single Bevel

Groove Angle: - 45 Degree

Root Face: - 3mm

Root Gap: - 3mm

Defect Size & Location:-

Total Weld Length -340 MM

Known / Induced Repair Length-00MM (Web)

Depth: - 00 mm

Size 00X00 mm

Actual welding process (Not induced) Defect: - If any, this shall confirm with actual report.

DATE: 08.05.2018 REV:0 REPORT NO: ECPL/AWS/UT/001

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Top View

Figure 9

PART C; c2 at Detail 3
Nomenclature of Joints:-

C2- Cluster Porosity/Side Wall Fusion

Shape of the Joint: - T Type Joint

Joint Configuration: - Single Bevel

Groove Angle: - 45 Degree

Root Face: - 3mm

Root Gap: - 3mm

Defect Size & Location:-

Total Weld Length -179 mm/179mm

Known / Induced Repair Length-50mm /50mm (Flange)

Depth: - 15mm/15mm

Size:-50X6MM/50X4MM

Actual welding process (Not induced) Defect: - If any, this shall confirm with actual report.

Top View

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Figure 10

PART C; c3 at Detail 3
Nomenclature of Joints:-

C3- Slag/ Lack of Fusion

Shape of the Joint: - T Type Joint

Joint Configuration: - Single Bevel

Groove Angle: - 45 Degree

Root Face: - 3mm

Root Gap: - 3mm

Defect Size & Location:-

Total Weld Length 179 MM/179MM.

Known / Induced Repair Length-50MM/50MM (Flange)

Depth: - 20 mm/23 mm

Size:-50X5MM/50X4 mm

Actual welding process (Not induced) Defect: - If any, this shall confirm with actual report.

Top View

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Figure 11

7) Ultrasonic Test Procedure for T, K & Y Joints & Acceptance criteria

1) The alternative acceptance procedure is being used for only T, K & Y type of joint configured weld
and it shall be approved by engineer.

2) Wherever accessible the member shall be scanned properly by two to three sides with required
angle probe (60° & 70°) half and full skip method.

3) If need zero probe shall be used for ensure of Root defects.

4) All UT shall be performed in conformance with a written procedure which shall contain a
minimum of the following information regarding the UT method and examination techniques.

5) The UT operator shall qualify through this procedure & the evaluated result shall meet at least 90
% of our own / identified defects in that mock up piece.

6) Acceptance / rejection criteria are being followed as per AWS D1.1 recommended Table Q1
requirements.

7) To measure the quality of the equipment they are verified by the measurement system
(24,14MM, THICKNESS).

8) Its range is set 100mm according to 25mm, 14mm thickness.

9) The examination shall be conducted with a pulse echo Technique ultrasonic instrument capable of
generating frequencies over the range of at least 0.5MHz to 6MHz.

10) The Ultrasonic instrument shall provide linear vertical presentation within ±5% of the full screen
height for 20% to 80% of the calibrated screen height [base line to maximum calibrated screen
point(s)].

11) The temperature of the calibration block and the examination materials shall be within 25o F (
14 o C ) or each other

12) Adjust the sensitivity ( or equivalent control ) to provide an 80% (±5% full screen height ) of full
screen height(FSH) indication from the hole.

13) Scanning sensitivity level shall be at least 6 dB above the reference level.

14) The Cuplant shall be made from materials that will not damage the material under examination.

DATE: 08.05.2018 REV:0 REPORT NO: ECPL/AWS/UT/001

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Figure 12

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Figure 13

1) Cracks, lack of fusion, or incomplete penetration are unacceptable regardless of length.

2) Other imperfections are unacceptable if the indication exceeds the reference level amplitude and
lengths which exceeds the following.
¼ inch for t up to ¾ inch
1/3 t for t from ¾ inch to 2¼ inches
¾ inch for t over 2 ¼ inches.

3) Where t is the thickness of the weld being examined. If the weld joints two members having
different thickness at the weld, t is the thinner of these two thicknesses.)

4) The depend up on client acceptance- rejection standard may be change as per

job requirement.

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8) SAMPLE PHOTOS

Part –A
Identification-a1
Total Weld Length-372MM
UN Known / Induced
Repair Length-90MM
DepthMM-10-12MM
Length Size-60MM
DEFECT- Porosity .

Part –A
Identification-a1
Total Weld Length-372MM
UN Known / Induced
Repair Length-90MM
Depth=13-14MM
Length Size-40MM
DEFECT- Slag

Part –A
Identification-a2
Total Weld Length-460MM
UN Known / Induced
Repair Length-100MM
Depth=7-9MM
Length Size-200MM
DEFECT- Slag

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Part –A
Identification-a3
Total Weld Length-372MM
UN Known / Induced
Repair Length-100MM
Depth=10-11MM
Length Size-45MM
DEFECT- Slag

Part –A
Identification-a3
Total Weld Length-372MM
UN Known / Induced
Repair Length-100MM
Depth=11-12MM
Length Size-80MM
DEFECT- Slag

Part –A
Identification-a3
Total Weld Length-372MM
UN Known / Induced
Repair Length-100MM
Depth=13-14MM
Length Size-20MM
DEFECT -Spot indication

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Part –B
Identification-B1
Total Weld Length-372MM
UN Known / Induced
Repair Length-100MM
Depth=10-11MM
Length Size-15MM
DEFECT - Cluster porosity

Part –B
Identification-B1
Total Weld Length-372MM
UN Known / Induced
Repair Length-100MM
Depth=12-13MM
Length Size-20MM
DEFECT – Side wall fusion

Part –B
Identification-B1
Total Weld Length-372MM
UN Known / Induced
Repair Length-100MM
Depth=15-16MM
Length Size-20MM
DEFECT – Lack of fusion

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Part –B
Identification-B1
Total Weld Length-372MM
UN Known / Induced
Repair Length-90MM
Depth=14-15MM
Length Size-30MM
DEFECT – Slag

Part –B
Identification-B2
Total Weld Length-372MM
UN Known / Induced
Repair Length-50MM
Depth=8-10MM
Length Size-30MM
DEFECT – Slag

Part –B
Identification-B3
Total Weld Length-372MM
UN Known / Induced
Repair Length-60MM
Depth=13-14MM
Length Size-60MM
DEFECT – Slag

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Part –B
Identification-B3
Total Weld Length-372MM
UN Known / Induced
Repair Length-60MM
Depth=12-13MM
Length Size-120MM
DEFECT – Side wall fusion

Part –c
Identification-c1
No Significant defects

Part –C
Identification-C2
Total Weld Length-179MM
UN Known / Induced
Repair Length-50MM
Depth=19-20MM
Length Size-100MM
DEFECT – Slag

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Part –C
Identification-C2
Total Weld Length-179MM
UN Known / Induced
Repair Length-50MM
Depth=14-16MM
Length Size-60MM
DEFECT – Slag

Part –C
Identification-C3
Total Weld Length-179MM
UN Known / Induced
Repair Length-50MM
Depth=18-20MM
Length Size-100MM
DEFECT – Lack of fusion

Part –C
Identification-C3
Total Weld Length-179MM
UN Known / Induced
Repair Length-50MM
Depth=16-17MM
Length Size-60MM
DEFECT – Slag

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9) ACTUAL TEST RESULT & ITS CONFIRMSTION

Defect table & acceptance criteria shall make for reference.

Page 1 of 1

Project: Mock Up Piece Report No. ECPL/AWS/UT/001 Weld I.D. Ecpl/w/788

Thickness 24x12 Class A UT Procedure No: 01 Technique: Pulso Echo

UT Instrument: Modosonic Einstein -II Dgs_ Search Unit: No: MBW 60 N4

Angle 70° Freq: 4mhz Size: 8x9mm

RESULT (identifies and describes each discontinuity)

NDT Tech: Dhinesh Aravinth.T Contractor: Mag Integrity_Resources

Date Of Examined: 08.05.2018 Approved _____________________

Date:

Approved:___________

DATE: 08.05.2018 REV:0 REPORT NO: ECPL/AWS/UT/001