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ULTRASONIC EXAMINATION PROCEDURE

Doc No.: ABC/NDT/UT-AWS-01. Rev:01

PREPARED APPROVED CLIENT

UT Level II NDT Level III

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CHANGE RECORDS (In one revision)

Rev. Date Description revision Page

01 [Link].21 First issue
02 [Link].24 Second issue

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CONTENT
SECTION DESCRIPTION PAGE

1 SCOPE 4

2 REFERENCE 4

3 QUALIFICATION OF PERSONNEL 4

4 ULTRASONIC EQUIPMENT 5

5 CALIBRATION AND CHECKING 6

6 TEST PROCEDURE 7

7 EVALUATION 11

8 IDENTIFICATION OF REJECTED AREA 13

9 REPAIR 13

10 RECORD AND REPORT 14

APPENDIX (1- 4)

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1. SCOPE
This procedure defines the conditions for ultrasonic examination of groove welds and HAZs
between the thicknesses of 8 mm and 200 mm inclusive in accordance with AWS D1.1. For
thicknesses less than 8 mm or greater than 200 mm, the examination shall be performed by other
procedure which conformance with Annex K of AWS D1.1.
This procedure shall be prohibited for testing tube-to-tube T-, Y-, or K-connections.
Variations in testing procedure, equipment, and acceptance standards not included in this
procedure may be used with the approval of the Engineer or Client. Such variations include other
thicknesses, weld geometries, transducer sizes, frequencies, couplant, painted surfaces, testing
techniques, etc. Such approved variations shall be recorded in the contract records.
Whenever a discontinuity of planar type defect detected, detailed evaluation shall be done by
other means such as alternative ultrasonic techniques, radiography, grinding or gouging for visual
inspection, etc…as an option of Client.
This procedure is not intended to be employed for the procurement testing of base metals.
However, welding related discontinuities (cracking, lamellar tearing, delamination, etc.) in the
adjacent base metal which would not be acceptable under the provisions of AWS D1.1 shall be
reported to the Engineer for disposition.
2. REFERENCES
- AWS D1.1 Structural Welding Code Steel, 2020 Edition;
- ASNT Recommended Practice for Personnel Qualification and Certification in Non-
Destructive Testing No. SNT-TC-1A 2020;
- ABC-TR-01, Rev 00: ABC Written Practice
3. QUALIFICATION OF PERSONNEL
- Individuals who perform Ultrasonic Examination shall be qualified and certified in
accordance with ABC Written Practice, Document No.: ABC-TR-01, Rev 00, which is based
on the ASNT Recommended Practice No.: SNT-TC-1A, 2020.
Individuals who perform Ultrasonic Testing (UT) shall be qualified for:
- NDT Level II or
- NDT Level I working under NDT Level II
- Other national/ international qualified and certified scheme programs which are recognized and
approved by the Customer

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4. ULTRASONIC EQUIPMENT:
4.1 Test Blocks:
❖ The I.I.W. V1 Test Block shall be used for both distance (time base) and
sensitivity calibration (see Appendix 1 for IIW V1 Block).
❖ AWS D1.1 RC Blocks may be used to evaluate resolution of the system of
combination of search unit and instrument (see Appendix 2, RC Block).
4.2 Ultrasonic instrument:
4.2.1 Flaw detector
❖ It shall be the pulse echo type and suitable for use with transducers oscillating at
frequencies between 1 and 6 MHz
❖ The display shall be an “A” scan rectified video trace
❖ Its performance characteristics shall be qualified properly following the
procedure attached (Appendix 3)
❖ The following types may be used:
− EPOCH 600
− STRESSTEL FLAWMIKE
− KRAUTKRAMER USM 35
− Or other makes / model equivalent
4.2.2 Search Unit
The transducer frequency shall be between 2 and 2.5 MHz, inclusive
- Straight-Beam (Longitudinal Wave) Search Units. Straight-beam (longitudinal wave) search
unit transducers shall have an active area of not less than 1/2 square inches [323 square
millimeters] nor more than 1 square inch [645 square millimeters]. The transducer shall be round
or square
- Angle-Beam Search Units. Angle-beam search units shall consist of a transducer and an angle
wedge. The unit may be comprised of the two separate elements or may be an integral unit. The
transducer crystal shall be square or rectangular in shape and may vary from 5/8 in. to 1 in. [15
to 25 mm] in width and from 5/8 to 13/16 in. [15 to 20 mm] in height. The maximum width to
height ratio shall be 1.2 to 1.0, and the minimum width-to-height ratio shall be 1.0 to 1.0. The
search unit shall produce a sound beam in the material being tested within plus or minus 2° of
one of the following proper angles: 70°, 60°, or 45°
4.2.3 Couplant:
A couplant material shall be used between the search unit and the test material. It shall be either
glycerin or cellulose gum and water mixture of a suitable consistency or some industrial types of
grease provided they do not affect or damage test material.

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5. CALIBRATION AND CHECKING

▪ All calibration and tests shall be made with the reject control turned off.
▪ Calibration for distance and sensitivity shall be made by the ultrasonic
operators/technicians just prior to and at the location of testing of each weld.
▪ Checking / Recalibration shall be made after a change of operators, each 30 minutes
maximum time interval, or when the electrical circuitry is disturbed in any way which
includes the following:
- Transducer change
- Battery change
- Electrical outlet change
- Coaxial cable change
- Power outage (failure)
▪ Calibration for straight – beam testing of base metal shall be made with:
- Horizontal sweep adjusted to present the equivalent of at least two base
metal thickness on the display, and
- Sensitivity adjusted at a location free of indication so that the first back
reflection from the far side of the base metal will be 80% of full screen
height.
▪ Calibration for angle beam testing of weld shall be made with:
− Refracted angle is checked/verified by using the I.I.W (Block V1)
as shown in Figure 2 (position B and C).
− Horizontal sweep is adjusted to present the actual sound-path
distance by using the IIW block V1 (Figure 2- position D), and
− Zero Reference level sensitivity attained by adjusting the gain
control of the flaw detector so that a maximized horizontal trace deflection results on
the display of 50% of full screen height by using IIW V1 block shown in Figure 2
(position A).

Figure 02

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The maximum decibel reading obtained shall be used as Reference Level b for calculating and
evaluating discontinuity for Reject / Acceptance.
6. TEST PROCEDURE:
6.A.1 PREPARATION PRIOR TO EXAMINATION
❖ Prior to attempting evaluation of a weld in the structure, the following information are
known:
- Weld profile (Design and actual)
- Nominal and actual thickness
❖ A final visual inspection of the weld shall be performed for detection of undercut,
incomplete fill or excess roughness which would interfere with a meaningful ultrasonic
examination.
❖ All surfaces to which a search unit is applied shall be free of weld spatter, dirt, grease, oil
(other than that used as a couplant), paint, and loose scale and shall be contour permitting
intimate coupling.
❖ “X” line for flaw location shall be marked the test face of the weld in a direction parallel
to the weld axis. Distance from X is used in describing the location of a weld discontinuity
in a direction perpendicular to the weld reference line. Unless it is zero, plus or minus sign
must accompany it.
❖ “Y” line accompanied with a weld identification number shall be clearly marked on the
base metal adjacent to the weld that is ultrasonically tested this marking is used for the
following aims:
• Weld identification
• Identification of face A (see Figure 3)

Figure 3

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• Distance measurements and direction (+ or -)

• Location measurement from weld ends or edges. Distance from Y is used in describing the
location of a weld discontinuity in a direction parallel to the weld reference line. This is attained
by measuring the distance from the “Y” end of the weld to the beginning of said discontinuity (see
Figure 4).

Figure 4

6.A.2 EXAMINATION
6.A.2.1 Base metal Testing
❖ The entire base metal through which ultrasound must travel to test the weld shall be
tested for laminar reflectors using a straight – beam.
If any area of base metal total loss of back reflection or an indication equal to or greater than
the original back reflection height is located in a position that will interfere with the normal
weld scanning procedure, its size, location, and depth from the A face shall be determined and
reported on the ultrasonic test report, and an alternate weld scanning procedure shall be used.
❖ The reflector size evaluation procedure shall be 6dB-drop method when the
discontinuity is larger than the transducer.
❖ In the case of discontinuity is smaller than transducer, 20dB-drop method may be used.
❖ If part of a weld is inaccessible to testing due to laminar content, the testing shall be
conducted using one or more of the following alternative procedures as necessary to
attain full weld coverage:
- Weld surface shall be ground flush in accordance with Company’s specification.
- Or Testing from Faces A and B shall be performed
- Or Other search unit angles shall be used.

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6A2-2 Testing of welds:

❖ Selection of Probes:
- The testing angle shall be as shown in Table 1 below.
Reference is based upon AWS D1.1- Table 8.7 "Testing Angle".
❖ All welds shall be tested using the applicable scanning patterns shown in Figure 5 below
to detect both longitudinal and transverse flaws.

General Notes:
• Testing patterns are all symmetrical around the weld axis with the exception of pattern D,
which shall be conducted directly over the weld axis.
• Testing from both sides of the weld axis shall be made wherever mechanically possible.
Figure 5—Plan View of UT Scanning Patterns

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Table 1 : PROBE SELECTION - TESTING PROBE

Probe Selection based on Weld Types

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Legend:
• X - Check from Face C G- Grind weld face flush O- Not required
• * - Required only where display reference height indication of discontinuity is noted at the weld metal-
base metal interface
• ** - Use 15 in [400 mm] or 20 in [500 mm] screen distance calibration.
• P- Pitch and catch shall be conducted for further discontinuity evaluation in only the middle half of the
material thickness with only 45° or 70° transducers of equal specification, both facing the weld.
(Transducers must be held in a fixture to control positioning-see sketch.) Amplitude calibration for
pitch and catch is normally made by calibrating a single search unit. When switching to dual search
units for pitch and catch inspection, there should be assurance that this calibration does not change as
a result of instrument variables.
• F - Weld metal-base metal interface indications shall be further evaluated with either 70°, 60°, or 45°
transducer - whichever sound path is nearest to being perpendicular to the suspected fusion surface.
• Face A - the face of the material from which the initial scanning is done (on T-and comer joints, follow
above sketches).
• Face B - opposite Face A (same plate).
• Face C - the face opposite the weld on the connecting member or a T-or corner joint.
❖ It is a good practice that all welds should be tested by passing sound through the entire volume
of the weld and the heat – affected zone in two crossing directions, wherever practical.
❖ When a discontinuity indication appears on the screen, the maximum attainable indication from
the discontinuity shall be adjusted to produce a horizontal reference level trace deflection on the
display - 50% of full height screen. This adjustment shall be made with the gain control, and the
instrument reading in decibels shall be used as the “Indication Level, a ”.
❖ Attenuation Factor C that is used for attenuation correction is attained by subtracting 25 mm
from the sound – path distance and multiplying the remainder by 0.0787.
❖ This factor shall be rounded out to the nearest dB value. Fractional values less than 0.5 dB shall
be reduced to the lower dB level and those of 0.5 or greater increased to the higher level.
❖ Indicate on Rating (d) is determined by following expression:
d=a–b–c
❖ The length of flaws shall be determined by using 6dB-drop method or 20dB-drop method.

7. EVALUATION
Each weld discontinuity shall be accepted or rejected on the basis of its indication rating (d)
and its length, in accordance with table 8.2 for Statically Loaded Nontubular Connection and
Cyclically Loaded Nontubular Connection in Compressions; Table 8.3 for Cyclically Loaded
Nontubular Connection in Tension.

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Table 8.2
Ultrasonic Acceptance-Rejection Criteria- for Statically Loaded Nontubular Connection and
Cyclically Loaded Nontubular Connection in Compressions

Notes:
1. Class B and C discontinuities shall be separated by at least 2L. L being the length of the longer
discontinuity, except that when two or more such discontinuities are not separated by at least 2L, but
the combined length of discontinuities and their separation distance is equal to or less than the
maximum allowable length under the provisions of Class B or C the discontinuities shall be considered
a single acceptable flaw.
2. Class B and C discontinuities shall not begin at a distance less than 2L from the end of the weld,
L being the discontinuity length.
3. Discontinuities detected at “scanning level” in the root face area of complete joint penetration
double groove weld joints shall be evaluated using an indicating rating 4dB more sensitive than
described in Chapter 6 of this procedure when such welds are designated as “tension weld” on the
drawing (subtract 4 dB from the indication rating “d”)
4. ESW or EGW: Discontinuities detected at “scanning level” which exceed 2 in. [50 mm] in length
shall be suspected as being piping porosity and shall be further evaluated with radiography
5. For indications that remain on the display as the search unit is removed, refer to 8.13.1 of AWS
D1.1, 2020.
* Weld thickness shall be defined as the nominal thickness of the thinner of the two parts being joined,
given in mm

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Table 8.3 Ultrasonic Acceptance - Rejection Criteria - Cyclically Loaded Nontubular

connection in Tension

Notes:
1. Class B and C discontinuities shall be separated by at least 2L, L being the length of the longer
discontinuity, except that when two or more such discontinuities are not separated by at least 2L, but
the combined length of discontinuities and their separation distance is equal to or less than the
maximum allowable length under the provisions of Class B or C, the discontinuity shall be considered
a single acceptable discontinuity.
2. Class B and C discontinuities shall not begin at a distance less than 2L from weld ends carrying
primary tensile stress, L being the discontinuity length.
3. Discontinuities detected at “scanning level” in the root face area of CJP double groove weld joints
shall be evaluated using an indicating rating 4 dB more sensitive than described in [Link] when such

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welds are designated as “tension welds” on the drawing (subtract 4 dB from the indication rating “d”).
This shall not apply if the weld joint is back gouged to sound metal to remove the root face and MT
used to verify that the root face has been removed.
4. For indications that remain on the display as the search unit is moved, refer to [Link] of AWS
D1.1, 2020.
* Weld thickness shall be defined as the nominal thickness of the thinner of the two parts being joined,
given in mm

8. IDENTIFICATION OF REJECTED AREA

Each rejectable discontinuity shall be indicated on the weld by a mark directly over the
discontinuity for its entire length. The depth from the surface and indication rating (d) shall be
noted on nearby base metal.

9. REPAIR
Welds found unacceptable by ultrasonic testing shall be repaired by methods Company approved.
Repaired areas shall be retested ultrasonically with results on additional report forms and the R
number shall prefix the report number.
10. RECORD AND REPORT
For welds designed as being “Fracture Critical”, acceptable ratings that are within 6dB,
inclusive, of the minimum rejectable shall be recorded on the test report.
The report sample is shown in Sample of UT Report attached.

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APPENDIX 1

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APPENDIX 2

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APPENDIX 3

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APPENDIX 4
Report no. :
ULTRASONIC TESTING Date :
REPORT Page :

Project : Reported to : :

Item : Quality requirements - section no. :

Equipment Transducer 00 450 600 700 Examination Conditions

Manufacturer : Manufacturer Weld ID :

Model : Model Weld joint * :

Serial : Serial Welding process :

Cal. Date : Frequency (MHz) Material :

Cable used : Size (mm) Thickness :

Cal. Block : Range (mm) Technique :

Ref. Block : Ref. Level (dB) Scaninng Level :

E
EXAMINATION RESUILT
PL

DECIBELS DISCONTINUITY
Transducer angle

Attenuation

Distance
Depth from "A"
Indication

Indication
Reference
Indication No.

Discontinuity
Leg (I/II/III)

Remarks
factor
From Face

Sound path
M

evaluation
level

level

level

From X *

From Y *
Line No.

surace *
Length

a b c d
SA

* Note :

We, the undersigned, certify that the statements in this record are correct and that the test welds were prepared
in conformance with the requirements of AWS D1.1/D1.1M, 2020 Structural Welding Code - Steel.
SQC CONTRACTOR OWNER
Date: Date: Date:
Examined by: Signature: Signature:

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