Procedure for Ultrasonic Examination

for Lamination Check and Thickness

Measurement

CONTENTS

1.0 SCOPE.....................................................................................................................................4

2.0 REFERENCES...........................................................................................................................4

3.0 PERSONNEL............................................................................................................................4

4.0 PROCEDURE QUALIFICATION.................................................................................................5

5.0 EQUIPMENT...........................................................................................................................6

6.0 PROBES...................................................................................................................................6

7.0 COUPLANT..............................................................................................................................6

8.0 SURFACE PREPARATION.........................................................................................................6

9.0 Technique...............................................................................................................................6

10.0 CALIBRATION..........................................................................................................................6

11.0 METHOD.................................................................................................................................8

12.0 EVALUATION OF IMPERFECTIONS.........................................................................................9

13.0 ACCEPTANCE CRITERIA..........................................................................................................9

14.0 POST CLEANING......................................................................................................................9

15.0 REPORT...................................................................................................................................9

16.0 Appendix-I (Screen Height Linearity)....................................................................................10

Attachment-I..............................................................................................................................11
Attachment-II.............................................................................................................................12
Attachment-III...........................................................................................................................13
1.0 SCOPE

1.1 This procedure specifies the minimum requirements for the Ultrasonic Examination for lamination
check and thickness measurement for 1&1/8” forging welded area after the flash grinding .

2.0 REFERENCES

ASME Sec V Art.5 Ed. 2017 : Ultrasonic Examination Methods for Materials
ASME V Art. 23 SE-797 Ed. 2017 : Standard Practice For Measuring Thickness By Manual Ultrasonic
Pulse-Echo Contact Method
ASME V Art. 23 SA-435 Ed. 2017 : Standard Specification For Straight-Beam Ultrasonic Examination Of
Steel Plates
3.0 PERSONNEL

3.1 Personnel performing ultrasonic examination shall be qualified and certified level II as per with ASNT
SNT-TC-1A (Ed. 2006 / 2011).

3.2 The company approved level III NDT engineer shall continuously monitor the performance of NDE
personnel certified to ASNT Level II and shall take corrective measures whenever the performance
of ASNT Level II technicians is not satisfactory.

3.3 Personnel performing Ultrasonic Examination, shall have vision with correction if necessary, to enable
him to read a Jaeger Type No. 2 Standard Chart at a distance of not less than 12 in. (300 mm), and is
capable of distinguishing and differentiating contrast between colors used. These requirements shall
be checked annually.

4.0 PROCEDURE QUALIFICATION

4.1 Procedure Qualification test shall be performed in the presence of Company Authority to meet the
requirements of the referencing Code and project specification.

4.2 Any change of a requirement in Table 1. Identified as an essential variable from the specified value,
or range of values, shall require requalification of the written procedure. A change of a requirement
identified as a nonessential variable from the specified value, or range of values, does not require
requalification of the written procedure. All changes of essential or nonessential variables from the
value, or ranger of values, specified by the written procedure shall require revision of, or an
addendum to, the written procedure.

Table1. Requirements of an Ultrasonic Examination Procedure

Sl. Essential Nonessential

No. Requirement
Variable Variable
Material types and configurations to be examined, including Cl. 1.0 through
1. --
 thickness dimensions and product form (casting, forgings, pipe, plate, Cl.1.2
etc.)
2. The surfaces from which the examination shall be performed Cl. 8.0 --
3. Technique(s) (straight beam, angle beam, contact, and/or immersion) Cl. 9.0 --
4. Angle(s) and mode(s) of wave propagation in the material Cl. 9.0 --
5. Search unit type(s), frequency(ies), and element size(s)/shape(s) Cl. 6.1 --
6. Special search units, wedges, shoes, or saddles, when used N/A --
7. Ultrasonic instrument(s) Cl. 5.1 --
Cl. 10.2 & --
8. Calibration [calibration block(s) and technique(s)] Cl. 10.3
9. Directions and extent of scanning Cl. 11.7 --
10. Scanning (manual vs. automatic) Cl. 9.0 --
11. Method for sizing indications Cl. 12.0 --
12. Computer enhanced data acquisition, when use N/A --
13. Scan overlap (decrease only) Cl. 11.7 --
14. Personnel performance requirements , when required Cl. 3.0 --
15. Personnel qualification requirement -- Cl. 3.1
16. Surface condition (examination surface, calibration block) -- Cl. 8.0
17. Couplant: brand name or type -- Cl. 7.0
18. Post Examination Cleaning technique -- Cl. 14.0
19. Automatic alarm and/or recording equipment, when applicable -- N/A
Records, including minimum calibration data to be recorded --
20. N/A
(e.g., instrument settings)

5.0 EQUIPMENT

5.1 To check lamination the Ultrasonic equipment shall be a flaw detector to provide a check on the validity
of the electronic measurement by revealing measurement variables, such as internal discontinuities, or
echo- strength variations, which might result in inaccurate readings. The equipment shall be a pulse
echo A- Scan system capable of transmitting and receiving frequencies from 1MHz to 10MHz such as
USK-75, USN-52, Sonatest Site Scan 130, D10, D10+, D20, D50 Alfa gauge, Olympus 38 DL Plus,
USM GO, GSM GO or equivalent.

7.0 COUPLANT

Couplant used will be Glycerin / Water 1:2 parts or a mixture of cellulose paste in water, to enable
good acoustic coupling, between the probes and the inspection surface. Couplant used for calibration
and job shall have the same acoustic properties.

8.0 SURFACE PREPARATION

The material examined shall be free from surface irregularities, dust, paint, dirt, grease, or any
foreign matter, that might interfere with the examination.
9.0 TECHNIQUE

The technique shall be limited to straight beam (Longitudinal or Compressional wave) with contact
method (Manual).

10.0 CALIBRATION

10.1 Instrument Performance (Only for Ultrasonic flaw detector)

10.1.1 Screen Height Linearity

Hold the straight beam probe on any calibration block that provides amplitude differences, with sufficient
signal separation to prevent overlapping of the two signals
Adjust the sensitivity (gain) so that the larger indication is set at 80% of full screen height. Without moving the
search unit, adjust sensitivity (gain) to successively set the large indication from 100% to 20% of full screen
height, in 10% increments (or 2dB steps if a fine control is not available), and read the smaller indication at each
setting.

The reading shall be 50% of the larger amplitude within 5% of full screen

height. The settings and readings shall be estimated to the nearest 1% of full

screen.

10.1.2.1 Amplitude Control Linearity

Using a normal probe, the 1.5mm dia. side drill hole in the IIW V1 block (or the ¼ t hole in the
Performance check calibration block) is peaked on the screen. With the increase and decrease in
attenuation shown in the following table, the indication must fall within the specified limits. The
settings and readings must be estimated to the nearest 1% of full screen.

Indication set at % of Full dB Control Charge Indication limits % of Full

Screen Screen
80% -6dB 35 to 45%
80% -12dB 15 to 25%
40% +6dB 65 to 95%
20% +12dB 65 to 95%

10.2 Calibration Blocks

10.2.1 Calibration blocks

For thickness measurement check, IIW V1, IIW V2 block or step wedge of acoustically similar
materials (e.g. CS, SS, DSS) as the items to be examined shall be used.

For Lamination check, calibration can be done in a defect free zone of plate or the same calibration
used for thickness measurement can be done as an alternative.

10.2.2 Temperature

For contact examination, the temperature differential between the calibration block and examination
surfaces shall be within 25°F (14°C).

10.3 Calibration Procedure

Calibration shall be done as follows;

a) For lamination check, calibration can be done as an alternative to below calibration method on the
plate to be inspected.
 b) For thickness measurement, calibration shall be done using IIW V1 or V2 blocks using minimum four
(4) echoes; first echo (echo 1) of V2 block shall be set to 12.5mm and fourth echo (echo 4) shall be
set to 50mm and the actual values shall be recorded. Care shall be taken to verify that values match
as far as possible these values. In similar way calibration can be done on V1 block or with a
greater number of echoes.

11.0 METHOD

11.1 For lamination check, the range shall be taken so that, minimum two (2) back wall echoes (BWE)
appears on the screen.
11.2 For thickness measurement, the range shall be taken so that, the back wall echo (BWE) shall appear
on the screen as follows;

I. Minimum eight (8) back wall echoes (BWE) for thickness less than equal to 10mm.
II. Minimum four (4) back wall echoes (BWE) for thickness greater than 10mm.

11.2.1 Thickness Measurement and Records

Thickness measurement shall be carried out on the part surface, specified by the manufacturer or
client representative. Each location shall be checked and the measured value shall be recorded.

11.3 Testing shall be carried out from one side of the surface, using ultrasonic pulse echo techniques for
the detection of internal imperfections.

11.4 Maximum scanning speed should not exceed 150mm / sec.

11.5 Adjust the sensitivity of the equipment such that the first back wall echoes from a satisfactory area
of material is set at 80% full screen height.

11.6 Ultrasonic thickness measurement shall be done to ensure that the wall thickness’s are within the
required tolerances prior to lamination check. Maximum and minimum value shall be recorded.

11.7 The volume to be scanned shall be examined by moving the search unit over the scanning surface so as
to scan the entire examination volume for each required search unit. Each pass of the search unit
shall overlap minimum of 10% of the transducer (Piezoelectric Element) dimension parallel to the
direction of scan indexing.

11.8 For getting measurement of multiple echoes, gain can be set as required depending on the echo to
be considered for measurement.

11.9 Condition for Internal Imperfection

The presence of an internal imperfection is indicated by a 50% reduction or more in the signal
amplitude of the back wall echo with or without the presence of an imperfection echo, or an
increased series of multiple echoes.
12.0 EVALUATION OF IMPERFECTIONS

12.1 The dimension of the reflector which is being measured may be either larger or smaller than the
beam width. This can be evaluated by using 6 dB drop method for defects larger than the crystal dia.
and 20 dB drop method for defects smaller than the crystal dia.

12.2 Evaluate each area of imperfection by optimizing the echo amplitude. Move the transducer to the edge
of the imperfections until the echo height is dropped to –6dB height and mark center of probe on
pipe / plate. Repeat the process in all directions to get the shape of the imperfections or at least in
two-direction length wise, (Along the rolling direction) & width wise (perpendicular to the rolling
direction).

12.3 When the main beam is on the defect the defect signal is at its maximum. If the probe is moved and
the signal is observed until it is reduced to 10% (20dB Drop), the edge of the beam is on the edge
of the defect. Repeat the above at the other side of the defect using the pre-constructed Beam
profile and a plotting card, the defect may be sized.

13.0 ACCEPTANCE CRITERIA

13.1 Nozzle Cut area and foot print area shall be lamination free.

13.2 For thickness measurement, unacceptable if the thickness is below the minimum specified value as
per design code.
14.0 POST CLEANING

After completion of inspection, the cellulose paste applied on the surface shall be completely removed
with a clean cotton cloth piece.

15.0 REPORT

The test report shall include but not limited to the following information

1) Ultrasonic Procedure Number

2) Date of Examination
3) Examination personnel identity, Level and Signature
4) Ultrasonic Examination Equipment (ID & Calibration)
5) NDE Specification
6) Surface Condition and Heat Treatment Condition.
7) Acceptance Criteria
8) Wall Thickness
9) Map or record of discontinuities assessed
10) Conclusion, accept or reject according to specification
11) Drawing Number
12) Line / Component Number
13) Location
16.0 APPENDIX-I (SCREEN HEIGHT LINEARITY)

16.1 Scope

This Mandatory Appendix provides requirements for checking screen height linearity and is applicable to
ultrasonic instruments with A-scan displays.

16.1.1 Miscellaneous Requirements

1. Position an angle beam search unit on a calibration block, as shown in Fig.1 so that indications from
both the 1/2 and 3/4T holes give a 2:1 ratio of amplitudes between the two indications.
2. Adjust the sensitivity (gain) so that the larger indication is set at 80% of full screen height.
3. Without moving the search unit, adjust sensitivity (gain) to successively set the large indication from
100% to 20% of full screen height, in 10% increments (or 2dB steps if a fine control is not
available), and read the smaller indication at each setting.
4. The reading shall be 50% of the larger amplitude within 5% of full screen height.
5. The settings and readings shall be estimated to the nearest 1% of full screen.
6. Alternatively, a straight beam search unit may be used on any calibration block that provides
amplitude differences, with sufficient signal separation to prevent overlapping of the two signals.

Fig.1. Linearity