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ULTRASONIC EXAMINATION PROCEDURE
Doc No. NDE-IN-UT-EN-01 Rev. 00
PREPARED
APPROVED
CLIENT
NDT Level III
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CONTENTS
SECTION
DESCRIPTION
PAGE
1
INTRODUCTION
3
2
SCOPE
3
3
APPLIED STANDARDS AND VALID DOCUMENTS
3
4
QUALIFICATION AND CERTIFICATION OF
INSPECTION PERSONNEL
3
5
EQUIPMENTS AND MATERIALS
3
6
COUPLANT
5
7
TESTING VOLUME
5
8
PREPARATION
OF
SCANNING
EXAMINATION OF PARENT MATERIAL
9
RANGE AND SENSITIVITY SETTINGS
7
10
RANGE SETTING
8
11
EXAMINATION AND ACCEPTANCE CRITERIA
9
12
EXAMINATION TECHNIQUE
12
13
SCANNING POSITIONS
15
14
MARKINGS
17
15
TEST REPORT
17
ZONES,
6
APPENDIX 1: ULTRASONIC EXAMINATION REPORT
19
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1.
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INTRODUCTION
This procedure is developed to cover the general requirements for Ultrasonic Examination
services provided and carried out by NDE Center according to EN 1090.
When required by the referencing specification, this examination performance under the
following written procedure shall be demonstrated to the satisfaction of the owner’s.
2. SCOPE
This procedure applies to the ultrasonic testing of full penetration ferritic steel welds, with
thicknesses from 8 mm up to 100 mm, to enable the acceptance levels 2.
3. APPLIED STANDARDS AND VALID DOCUMENTS
-
Project Specification
-
EN 473 Qualification and certification of NDT personnel – General principles
-
ISO 9712 Non-destructive testing - Qualification and certification of NDT personnel
-
TCVN 5868 Non-destructive testing - Qualification and certification of personnel
-
EN 1090 Execution of steel structures and aluminium structures
-
EN 12062 Non-destructive examination of welds General rules for metallic materials
-
EN 1714 Non-destructive testing of welded joints — Ultrasonic testing of welded joints
-
EN 1712 Non-destructive testing of welds — Ultrasonic testing of welded joints —
Acceptance levels
-
EN 25817 Arc-welded joints in steel – Guidance on quality levels for imperfections
(ISO 5817 : 1992)
-
EN 583-2 Non-destructive testing. Ultrasonic examination. Sensitivity and range setting
4. QUALIFICATION AND CERTIFICATION OF INSPECTION PERSONNEL
The personnel performing for testing must, as a minimum requirement, be in possession of
a valid Level 2 competence Certificate as defined in EN 473 or ISO 9712 or the
corresponding National standard TCVN 5868 or equivalent standard at an appropriate level
in the relevant industrial sector.
5. EQUIPMENTS AND MATERIALS
5.1. Equipments
Any equipment used in conjunction with this standard shall comply with the requirements
of relevant European Standards. Prior to the publication of an EN standard related to the
subject, the corresponding national standards may be used.
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The UT instruments, GE USM 35X DAC or Olympus Epoch 600 or equivalent shall be
used.
5.2. Probes
5.2.1. Test frequency
The frequency shall be within the range 2 MHz to 5 MHz, and shall be selected to comply
with the specified acceptance levels.
Frequencies of approximately 1 MHz may be used for testing at long sound paths where
the material shows above average attenuation.
5.2.2. Angles of incidence
When testing is carried out with transverse waves and techniques that require the
ultrasonic beam to be reflected from an opposite surface, care shall be taken to ensure that
the angle between the beam and the normal to the opposite reflecting surface is between
35° and 70°. Where more than one probe angle is used, at least one of the angle probes
used shall conform with this requirement. One of the probe angles used shall ensure that
the weld fusion faces are examined at, or as near as possible to, normal incidence. When
the use of two or more probe angles is specified, the difference between the nominal beam
angles shall be 10° or greater.
Angles of incidence at the probe and opposite reflecting surface, when curved, may be
determined by drawing a sectional view of the weld or in accordance with the techniques
given in EN 583-2. Where angles of incidence cannot be determined as specified by this
International Standard, the testing report shall contain a comprehensive description of the
scans used and the extent of any incomplete coverage caused, together with an explanation
of the difficulties encountered.
5.2.3. Element size
The element size shall be chosen according to the ultrasonic path to be used and the
frequency.
The smaller the element, the smaller the length and width of the near field, and the larger
the beam spread in the far field at a given frequency.
Small probes having 6 mm to 12 mm diameter elements (or rectangular elements of
equivalent area) are therefore most useful when working at short beam path ranges. For
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longer ranges, i.e. greater than 100 mm for single normal beam probes and greater than
200 mm for angle beam probes, an element size of 12 mm to 24 mm is more suitable.
5.2.4. Adaptation of probes to curved scanning surfaces
The gap between the test surface and bottom of the probe shoe shall not be greater than 0,5
mm. For cylindrical or spherical surfaces this requirement will normally be met when the
following equation is fulfilled:
D ≥ 15 a (1)
Where:
D - is the diameter of the component (in mm);
a - is the dimension of the probe shoe in the direction of testing (in mm).
If this requirement cannot be met the probe shoe shall be adapted to the surface and the
sensitivity and range shall be set accordingly.
6. COUPLANT
The couplant that shall not be detrimental to the material being examined, such as
cellulose paste or oil/grease are used.
The coupling medium used for range and sensitivity setting and for the test shall be the
same.
7. TESTING VOLUME
The testing volume (see Figure 1) is defined as the zone which includes weld and parent
material for at least 10 mm on each side of the weld, or the width of the heat-affected zone,
whichever is greater.
In all cases, scanning shall cover the whole testing volume. If individual sections of this
volume cannot be covered in at least one scanning direction, or if the angles of incidence
with the opposite surface do not meet the requirements, alternative or supplementary
ultrasonic techniques or other non-destructive techniques shall be agreed upon. This may,
in some cases, require removal of the weld reinforcement.
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8. PREPARATION OF SCANNING
MATERIAL
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ZONES, EXAMINATION OF PARENT
8.1. Preparation of scanning surfaces
Scanning surfaces shall be wide enough to permit the testing volume (see Figure 1) to be
fully covered. Alternatively, the width of the scanning surfaces may be smaller if
equivalent coverage of the testing volume can be achieved by scanning from both the
upper and the lower surface of the joint.
Scanning surfaces shall be even and free from foreign matter likely to interfere with probe
coupling (e.g. rust, loose scale, weld spatter, notches, grooves). Waviness of the test
surface shall not result in a gap between the probe and test surfaces greater than 0,5 mm.
These requirements shall be ensured by dressing if necessary. Local variations in surface
contour, e.g. along the edge of the weld, which result in a gap beneath the probe of up to 1
mm, can only be permitted if at least one additional probe angle is employed from the
affected side at the weld. This additional scanning is necessary to compensate for the
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reduced weld coverage that will occur with a gap of this dimension.
Scanning surfaces and surfaces from which the sound beam is reflected shall allow
undisturbed coupling and reflection.
8.2. Parent metal testing
The parent metal, in the scanning zone area (see Figure 1), shall be examined with straight
beam probes prior to or after welding, unless it can be demonstrated (e.g. previous testing
during the fabrication process) that the angle probe testing of the weld is not influenced by
the presence of the imperfections or high attenuation.
Where imperfections are found, their influence on the proposed angle beam testing shall be
assessed and, if necessary, the techniques adjusted correspondingly. When satisfactory
coverage by ultrasonic testing is seriously affected, other inspection techniques (e.g.
radiography) shall be considered.
9. RANGE AND SENSITIVITY SETTINGS
9.1. General
Setting of range and sensitivity shall be carried out prior to each testing in accordance with
this International Standard and EN 583-2, taking the influence of temperature into account.
The temperature difference during range and sensitivity setting and during the test shall be
within 15 °C.
Checks to confirm these settings shall be performed at least every 4h and on completion of
the testing. Checks shall also be carried out whenever a system parameter is changed or
changes in the equivalent settings are suspected.
If deviations are found during these checks, the corrections given in Table 1 shall be
carried out.
Table 1- Sensitivity and range corrections
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10. RANGE SETTING
Time base setting shall be carried out with two reference echoes having a known time or
distance interval between them. Depending on the intended calibration, the respective
sound paths, depths, projection distances, or shortened projection distances shall be
known.
For the examination of ferritic steels the use of Calibration Block No.1 or Calibration
Block No.2, as specified in EN 12223 and EN 27963 respectively, is recommended. If a
reference block or the test object itself is used for calibration, faces opposite to the test
surface or appropriate reflectors at different known sound path lengths may be used as
applicable.
Either reference blocks shall have a sound velocity within ±5 % of that of the test object,
or correction for the velocity difference shall be made.
10.1. Reference for sensitivity setting
Method 1: The reference is a distance-amplitude curve (DAC) for side-drilled holes of
diameter 3 mm shall be used for sensitivity setting.
The length of the side-drilled holes and notches shall be greater than the width of the
sound beam measured at -20 dB.
10.2. Evaluation level
All indications equal to or exceeding the following shall be evaluated:
The evaluation level for Method 1: Reference level -10 dB (33 % DAC)
10.3. Transfer correction
When separate blocks are used for establishing reference levels, a measurement shall be
made of the transfer differences, between test object and block, at a representative number
of locations. Suitable techniques are described in EN 583-2.
If the differences are less than 2 dB, correction is not required.
If the differences are greater than 2 dB but smaller than 12 dB, they shall be compensated
for.
If transfer losses exceed 12 dB, the reason shall be considered and further preparation of
the scanning surfaces shall be carried out, if applicable.
When there are no apparent reasons for high correction values, the attenuation, at various
locations on the test object, shall be measured and, where it is found to vary significantly,
corrective actions shall be considered.
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11. EXAMINATION AND ACCEPTANCE CRITERIA
The recording level and acceptance criteria defined in EN 1712 shall apply for assessment.
The acceptance levels shall be related to the testing techniques (testing levels) as defined in
EN 1714. Acceptance level 2 will normally require at least testing level B. Any other
relationship between acceptance levels and testing levels shall be defined by specification.
When recording levels are not otherwise specified, the following values shall be used:
Recording level for method 1:
- Acceptance level 2: reference level - 6 dB (50 % DAC)
Indications are to be evaluated as longitudinal or transverse depending on the orientation of
their major dimension. Where this distinction cannot be clearly made, the indication shall
be classified as transverse if the echo amplitude obtained during the testing of transverse
indications exceeds the echo amplitude obtained during the testing for longitudinal
indications by 2 dB or more.
Evaluation of indications may include discrimination between different imperfection types
if defined in a specification. In such case, the characterization as a planar indication may be
used as the primary discrimination of an acceptable or rejectable indication. In this case all
indications with echo amplitude above the evaluation level shall be characterized, and all
that are characterized as planar shall be rejected.
11.1. Longitudinal indications
All indications with echo amplitudes and lengths exceeding the following limits are
unacceptable:
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Figure 2 – Acceptance level 2 for method 1
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Table 2 – Acceptance level 2 for method 1
Any indication with a length exceeding t, for the thickness range of 8 mm t < 15 mm, or t/2
or 20 mm, whichever is the larger, for all other thickness ranges, shall be subject to further
testing using additional probe angle(s), including the tandem technique where applicable.
The final evaluation shall be based on the echo amplitude and length measured at the angle
giving the maximum response.
11.2. Transverse indications
All indications exceeding the limits stated in 11.1 are unacceptable.
Transverse indications with echo amplitudes equal to or exceeding the evaluation level shall
be classified by additional ultrasonic scanning, radiography or other testing method to
determine their nature. Only indications that are isolated (i.e. maximum three per metre),
whose length is less than 10 mm, are acceptable if they are planar. If they are non-planar the
acceptance level for longitudinal indications shall apply.
11.3. Linearly aligned and grouped indications
Linearly aligned indications shall be considered as continuous if they are separated by a
distance, dx, of less than twice the length of the longest indication. The total, combined
length shall then be assessed against appropriate acceptance levels.
Linearly aligned indications shall satisfy the following:
dy ≤ 5 mm, dz ≤ 5 mm, see Figure 3
Adjacent indications grouped in this way shall not be used for further grouping with
additional indications. Only discrete indications shall be subject to grouping.
After grouping, any recorded and accepted indications in the same cross-section and depth
position (dz ≤ 5 mm) shall be separated by a distance dy > 10 mm. Indications in the same
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lateral position (dy ≤ 5 mm) shall be separated by a distance dz > 10 mm. Adjacent
indications with smaller distances dy and dz are not acceptable.
Figure 3 – Geometric configurations for grouped indications
11.4. Cumulative length of acceptable indications
For any length of weld equal to 6t, the maximum cumulative length of all individually
acceptable indications above the recording levels shall not exceed 20 % of this length for
acceptance level 2.
12. EXAMINATION TECHNIQUE
12.1. Examination coverage
Scanning shall be carried out in accordance with the requirements of the referencing
document(s). These requirements shall include the area to be scanned and the scanning
direction, and can include the type, size, frequency and beam angle of the probe(s) to be
used.
12.2. Testing levels
Quality requirements for welded joints are mainly associated with the material, welding
process and service conditions. To accommodate all of these requirements this procedure
specifies testing levels B.
From testing level B an increasing probability of detection will be achieved by an
increasing testing coverage e.g. number of scans, surface dressing.
12.3. Overlap and scanning speed
12.3.1 Overlap
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For a 100 % examination, the interval between two successive scan lines shall not be
greater than the -6 dB beam width at any depth within the examination volume.
12.3.2 Scanning speed
The choice of scanning speed shall take into consideration the pulse repetition frequency
and the ability of the operator to recognize or of the instrument to record signals.
12.4. Evaluation and recording levels
The evaluation and recording levels are defined in relevant standards. When these levels
are not defined, the values applied during the examination shall be included in the
examination report.
For Pulse echo technique: If the amplitude of an echo exceeds the evaluation level, the
signal shall be evaluated against the acceptance criteria.
12.5. Manual scan path
During angle probe scanning (as illustrated in Figure 1), a slight swivelling movement up
to an angle of approximately 10° on either side of the nominal beam direction shall be
applied to the probe.
12.6. Location of indications
The location of all indications shall be defined by reference to a coordinate system, e.g. as
shown in Figure 4. A point on the testing surface shall be selected as the origin for these
measurements.
Where testing is carried out from more than one surface, reference points shall be
established on each surface. In this case, care shall be taken to establish a positional
relationship between all reference points used, so that the absolute location of all
indications can be established from any nominated reference point.
In the case of circumferential welds, this may require the establishment of the inner and
outer reference points prior to assembly for welding.
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Figure 4 - Coordinate system for defining the location of indications
12.7. Evaluation of indications
12.7.1. General
All relevant indications above the evaluation level shall be assessed in accordance with
12.7.2 to 12.7.3.
12.7.2. Maximum echo amplitude
The echo amplitude shall be maximized by probe movement and recorded in relation to the
reference level.
12.7.3. Indication length
The length of the indication, in either the longitudinal or transverse direction (lx, ly), shall,
where possible, be determined using the technique specified in the acceptance levels
standard, unless otherwise agreed.
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13. SCANNING POSITIONS
Key for tables:
L-scan:
N-scan:
T-scan:
p:
SZW:
scan for longitudinal indications using angle beam probes.
scan using straight beam probe.
scan for transverse indications using angle beam probes.
full skip distance.
scanning zone width.
Figure 5 – Butt joints in plates and pipes
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Table 3 – Butt joints in plates and pipes
Figure 6 – Structural T-joints
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Table 4 – Structural T-joints
14. MARKINGS
The tested components are to be permanently marked with a test stamp in the area
stipulated on the drawing, so that their testing status is clearly identifiable at all times.
15. TEST REPORT
A test report is to be issued which must contain the following as a minimum
requirement:
a) Reference to this Test Specification
b) Identification of the test specimen (e.g. designation, drawing number, ID number,
weld seam, etc.)
c) Specifications of the ultrasonic probes(type, dimensions, frequency) and the device
d) Test conditions (condition of scanning zone, coupling medium, test plan, device
settings)
e) Testing Scope
f) Location of scanning zones
g) Probe positions applied
h) Setting range
i) Type and values of sensitivity setting, reference heights
j) Results of tests performed on the parent material
k) Test results
l) Name and qualifications of test personnel
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m) Name and qualifications of test supervisor
n) Test location
o) Date of the test
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APPENDIX 1: ULTRASONIC EXAMINATION REPORT
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