Ultrasonic Testing Procedure for Welds

LARSEN & TOUBRO LIMITED
PAGE NO.- 1 OF 11
DATE:-05..11.07
MSQ UP GRADATION (EPCC 1)
PROJECT
REV.NO.- 0
PROCEDURE FOR ULTRASONIC
TESTING
PROCEDURE NO.-
LT/MSQ/P/UT/011

CONTENTS:
1.0 PURPOSE
.0 SCOPE
!.0 REFERENCES
".0 INSPECTION PERSONNEL
5.0 UT EQUIPMENTS
#.0 CALIBRATION FOR TESTING
7.0 TESTING PROCEDURE
$.0 ACCEPTANCE & REJECTION CRITERIA
%.0 ATTAC&MENTS.

APPROVED B' L & T REVIE(ED ) APPROVED B' JACOBS
PAGE NO.- 2 OF 11
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1.0 PURPOSE:
The purpose of this procedure is to provide sufficient guidelines to operators,
examiners, inspectors, and engineers etc. to apply ULTRASONIC TEST method
correctly and efficiently as a Non-Destructive Test tool for determination of
discontinuities in welds.
.0 SCOPE:
The Scope of this procedure covers all structural steel column welds !uild-up
Sections" which are li#ely to $e fa$ricated at %o$ site&shop of 'S( )p gradation
*ro%ect, *anipat +efinery, *anipat, ,aryana. This procedure will $e valid for *late-to-
*late welded %oint only. Thic#ness of structural mem$ers varies from -. mm to /.
mm. 'aterial Spec 0 1S 2.32 4r. 5&!. 6 1S 2..2 4r. 11
3.0 REFERENCE:
57S D-.-, Sec 3
SNT-T8--5 of 5SNT.
4.0 INSPECTION PERSONNEL
)ltrasonic Testing shall $e performed $y NDT 9evel 11 personnel in accordance with
SNT-T8--5. NDT :ualification shall include demonstration of a$ility to apply the rules
of the 57S D -.- code in the accurate detection and disposition of discontinuities.
5.0 UT EQUIPMENTS
5.1 Basic Unit
The )T e:uipment shall $e the pulse echo type suita$le for use with transducers
oscillating at fre:uencies $etween - and 3 ',;. The display shall $e an 5 scan
rectified video trace.
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The ,ori;ontal linearity of the test instrument shall $e :ualified over the full sound
path distance to $e used in testing in conformance with 3.<..- of 57S D-.-.
The instrument=s gain control shall meet the re:uirement of 3.22.> and shall $e
chec#ed for correct cali$ration at 2 month intervals in conformance with 3.<..2.
5.2 PROBES SEARC! UNITS
5.3 )ltrasonic search unit with fre:uency - 0 > ',; shall $e used.
5.2.1 T"PE OF SEARC! UNITS
5.2.1.1Straight $eam 9ongitudinal wave" search unit transducers shall have an active area
of -. mm dia crystal si;e.
5.2.1.25ngle $eam search units crystal shall $e ? x @ mm rectangular. The search unit shall
produce a sound $eam in the material $eing tested within plus or minus 2
o
. 1f one of
the following proper anglesA B.
o
, 3.
o
or >/
o
. The dimensions of the search unit shall
$e such that distance from the leading edge of the search unit to the index point shall
not exceed -.
5.3 R#s$%&ti$n
Cor straight $eam search unit, the transducer shall $e set in position DC= on the 117
$loc# as specified in the 57S D-.-. Transducer and instrument shall resolve all three
distances. Cor angle $eam search unit, +8 $loc# shall $e used as per clause no.
3.2@.2./.
5.4 Int#'na% R#(%#cti$n:
5ngle $eam search unit shall meet the criterion of clause 3.2>.<. 1nternal reflection
chec# shall $e verified at a maximum time interval of >. hours of instrument use as
per clause 3.<..<.
PAGE NO.- 4 OF 11
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5.4 *ro$e *arameters
T)*# Si+#
.
o
Normal $eam *ro$e -. mm dia
5ngle *ro$e
>/
o
, 3.
o
, B.
o
5ngle pro$e ?mm E @mm crystal
Cre:uency of pro$es 2',; to >',;.
,.0 CALIBRATION FOR TESTIN-
,.1 Ca%i.'ati$n $( Bas# Unit
The detector until shall $e cali$rated $y an approved Third party yearly or after any
ma%or repair or service done to the e:uipment. 1n addition to this, the e:uipment
:ualification shall $e performed as per 57S D -.- clauseFFFFF.
5ll cali$rations and tests shall $e made with the re%ect control turned off.
,.2 /ai%) Ca%i.'ati$n T#sts
The Gperator shall carry out and #eep record of daily cali$ration chec#s of the
followingA
Time-$ase linearity
4ain
Sensitivity
*ro$e 1ndex
8ali$ration of 5ngle !eam search units shall $e done with the use of an approved
cali$ration $loc#, each angle-$eam search unit shall $e chec#ed after each eight
hours of use to determine that the contact face is flat, the sound entry point is correct
and the $eam angle is within allowed tolerance.
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,.3Ca%i.'ati$n $( Ti0# Bas#
Time $ase and range cali$ration shall $e set to accurately cover the entire ultrasonic
$eam distance for each pro$e selected for examination of the sample, using $asic
cali$ration $loc#s with artificial or defect reflectors at the commencement of each %o$
or pro$e change. The cali$ration shall $e chec#ed fre:uently throughout the
examination.
,.4R#(#'#nc# Ca%i.'ati$n B%$c1s
The 1nternational 1nstitute of 7elding 117 0 H- 6 H2" )T reference $loc# shall $e the
standard used for $oth distance cali$ration and 117 0 H- $loc# shall $e used for
sensitivity cali$ration. Gther porta$le $loc#s may $e used provided the reference
level sensitivity for instrument & search unit com$ination shall $e ad%usted to $e the
e:uivalent of that achieved with the 117 $loc#. The use of a corner reflector for
cali$ration purpose shall $e prohi$ited.
,.5B#a0 In2#3 ($' An4%# P'$.#
The angle pro$e is positioned in the H- $loc# to o$tain maximum echo for -..mm
radius. The index point is verified with the mar#ing in the cali$ration $loc#.
,.,St'ai45t B#a0 Ca%i.'ati$n
S6##* 7 The hori;ontal sweep shall $e ad%usted for distance cali$ration to present
the e:uivalent of at least two plate thic#nesses on the display.
S#nsiti8it) 7 The sensitivity shall $e ad%usted at a location free of indications so that
the first $ac# reflection will $e /. to B/I of full screen height.
,.9An4%# B#a0 Ca%i.'ati$n
S6##* 7 The hori;ontal sweep distance shall $e ad%usted to represent the actual
sound path distance $y using the 117 $loc#.
The distance cali$ration shall $e made using either the / in -/2mm" scale or -. 1n.
2/.mm" scale on the display, whichever is appropriate. 1f, however, the %oint
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configuration or thic#ness prevents full examination of the weld at either of these
settings, the distance cali$ration shall $e made using -/ in. or 2. in. >..mm or
/..mm" scale as re:uired.
A0*%it&2# $' S#nsiti8it) 7 The Transducer shall $e set in a position on the 117 H-
$loc# to the indication from the -./mm hole to attain a hori;ontal reference-line height
indication. The maximum deci$el reading o$tained shall $e used as the :R#(#'#nc#
L#8#%. ..
8ali$ration for sensitivity and hori;ontal sweep shall $e made $y the )T operator %ust
prior to and at the location of testing each weld.
+ecali$ration shall $e made after a change of operators, each <. minute maximum
time interval, or when the electrical circuit is distur$ed in any way which includes the
followingA
-. Transducer change
2. !attery change
<. Jlectrical outlet change
>. 8oaxial ca$le change
/. *ower outage failure".
,.;INFORMATION TO OPERATOR
The following information shall $e provided to the operator $efore start of test.
'aterial type grade 6 form cast, rolled, forged etc."
Koint preparation details
The welding process
Details of the previous reports
Details of any post weld heat treatment
Differing thic#ness
'is-match 6 non-alignment
PAGE NO.- 7 OF 11
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+eferencing code section
,.<SURFACE CON/ITION
The weld and ad%acent parent material to the extent of examination shall $e #ept free
of slag, scale, paint, rust and weld spatter.
5ny temporary attachment, which might cause restriction to scanning, shall $e
removed.
Surface condition of the weld shall $e as weld condition.
9.0 TESTIN- PROCE/URE
9.1 C$&*%ants
'ixture of grease and oil shall $e used as 8ouplant. Special emphasis shall $e given
for post cleaning using cleaner.
9.2T#stin4 $( =#%2s.
9.2.1 7elds shall $e tested using an angle $eam search unit as shown in Ta$le 3.B of
57S D-.-. The testing angle and scanning procedure shall $e in conformance with
the a$ove-referred Ta$le. See attachment"
9.2.2 5ll $utt %oint welds shall $e tested from each side of weld axis. 5ll welds shall $e
tested using the applica$le scanning patterns as per the referred standard to detect
$oth longitudinal and transverse discontinuities.
9.2.3 Scanning plan shall $e prepared for each type and thic#ness of weld %oint.
9.3 E3t#nt $( T#stin4
The entire $ase metal through which ultrasound must travel to test the weld shall $e
tested for laminar reflectors using a traight-$eam search unit. 1f any area of $ase
metal exhi$its total loss of $ac# reflection or an indication e:ual to or grater than the
original $ac# reflection height is located in a position that will interface with the
normal weld scanning procedure, its si;e, location, and depth from the 5 face see
PAGE NO.- 8 OF 11
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5nnex -" shall $e determined and reported on the )T report, and an alternate weld
scanning procedure shall $e used.
9.3. In2icati$n L#8#% >a?
7hen a discontinuity indication appears on the screen, the maximum attaina$le
indication from the discontinuity shall $e ad%usted to produce a hori;ontal reference
level trace deflection on the screen. The ad%ustment shall $e made with the cali$rated
gain control, and the instrument reading in deci$els shall $e used as the In2icati$n
L#8#%@ a?@ for calculating the :In2icati$n Ratin4@ 2?.
9.4 Att#n&ati$n Fact$'@ c
The 5ttenuation factor, c shall $e attained $y su$tracting - in. 2/mm" from the
sound path distance and multiplying the remainder $y 2. This factor shall $e rounded
out to the nearest d! value.
9.5 In2icati$n Ratin4@ 2.
The 1ndication +ating, d represents the alge$raic difference in deci$els $etween the
indication level and the reference level with correction for attenuation as indicated in
the following expressionsA
1nstruments with gain in d!A a 0 $ 0 c L d.
9., Basis ($' Acc#*tanc# $' R#A#cti$n.
Jach weld discontinuity shall $e accepted or re%ected on the $asis of its indication
rating and its length in conformance with 5cceptance 8riteria mentioned. Gnly those
discontinuities which are unaccepta$le need $e recorded on the test report.
9.9Si+# E8a%&ati$n P'$c#2&'#
St'ai45t B#a0 T#stin4 7 The approximate si;e evaluation of the reflector shall $e
made $y $eginning outside of the discontinuity and moving the transducer toward the
area of the discontinuity until the indication on the display $egins to form. The leading
edge of the search unit at this point is indicative of the edge of the discontinuity.
PAGE NO.- 9 OF 11
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PROCEDURE NO.-
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An4%# B#a0 T#stin4 7 The following procedure shall $e used to determine lengths
of indications which have d! ratings more serious than for a 8lass D indication as per
5cc 8riteria. The length of such indication shall $e determined $y measuring the
distance $etween the transducer centreline locations where the indication rating
amplitude drops /.I 3d!" $elow the rating for the applica$le discontinuity
classification.
9.; Inacc#ssi.i%it)
1f part of a weld is inaccessi$le to testing with the re:uirements mentioned in the
ta$le 3.B of 57S D-.- due to laminar content, the testing shall $e conducted using
one or more of the following alternative procedures as necessary to attain full weld
coverage.
7eld surfaces" shall $e ground flush
Testing from !oth sides. Cace 5 6 Cace !"
Gther search unit angles shall $e used.
Gther scanning patterns can also $e used. See sr. no. < of 5nnex -"
;.0 ACCEPTANCE B RECECTION CRITERIA
The applica$le 5cceptance 6 re%ection criterion is as per Ta$le 3.< of 57S D-.-.
See attachment".
<.0 ATTAC!MENTS
Ann#3 1 D Details of Ko$ Thic#ness, 7eld %oints, and Scanning patterns & methods.
Ann#3 2 7 Ta$le 3.B of 57S D-.- for selection of Testing 5ngle.
Ann#3 3 D 5cceptance 6 +e%ection 8riteria, Ta$le 3.< of 57S D-.-.
10.0 /OCUMENTATION
The records of test reports shall $e maintained in the format no. LTMSQUT025
R#8. 00.
Single side scanning f! Single "
60
#$%% &in% $' % F$ll #ea(

'a%) *1 "+
,$-le side scanning f! ,$-le " 60

#$%% &in%. U' % )alf -e( 'a%) n -%)
sides */ "+
PAGE NO.- 10 OF 11
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ANNEE 1 D /#tai%s $( C$. T5ic1n#ss@ =#%2 A$ints@ an2 Scannin4 *att#'ns 0#t5$2s.
1. F$' C$. T5ic1n#ss 10 B 1200. An4%# $( P'$.# 7 90
$
@ F'#F. $( P'$.# 7 2M!+.
2. F$' C$. T5ic1n#ss 20@ 25 B 320D0. An4%# $( P'$.# 7 90
$
@ F'#F. $( P'$.# 7 2M!+.
Face #
Face 0
F$ll #ea( Pa%) *1 "+
1alf #ea( 'a%) */ " 'a%)+
PAGE NO.- 11 OF 11
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3. =5#n t5# =#. *%at# A$int (itt#2 6it5 F%an4# *%at#@ Scannin4 t$ .# 2$n# as *#' t5#
.#%$6 s1#tc5 ($' 6#. B (%an4# A$inin4 a'#a.
Flange Pla%e
2e- Pla%e
2e- Pla%e % 2e-
Pla%e &in%
3!(al
P!-e
0ngle P!-e

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