GRP - PM.QA.04A - Prosedur Ultra Sonic Test (AWS) - Update

PLATE SERVICE CENTER
Document No. GRP.PM.QA.04A

QUALITY PROCEDURE Revision 01
Issued May 14, 2020
Title : Ultrasonic Testing (In accordance with AWS D1.1/D1.1M- Page 1 of 16
2020) Department QA/QC
REVISION NOTE
Date Revision Paragraph
Prepared By Approved By
RIYANTO SAENAL A. RAPI

ASNT UT LEVEL II ASNT NDT LEVEL III
ID. 145 394
Date : 14th May 2020 Date : 14th May 2020
Issued May 14, 2020
TABLE OF CONTENT
SECTION CONTENT PAGE

1. SCOPE...................................................................................................................................................3
2. REFERENCE......................................................................................................................................3
3. PERSONNEL QUALIFICATION AND RESPONSIBILITY............................................3
4. EQUIPMENT......................................................................................................................................3
5. STANDARDIZATION AND CALIBRATION.......................................................................4
6. SURFACE CONDITION................................................................................................................5
7. SELECTION OF ANGLE PROBE..............................................................................................5
8. SCANNING AND DEFECT EVALUATION..........................................................................5
9. ULTRASONIC TESTING PROCEDURE.................................................................................6
10. RE-EXAMINATION OF REPAIRED AREAS.......................................................................6
11. REPORTING.......................................................................................................................................6
12. ACCEPTANCE CRITERIA..........................................................................................................6
APPENDIX I.........................................................................................................................................................7
TRANSFER CORRECTION.............................................................................................................................7
APPENDIX II..........................................................................................................................................................8
ACCEPTANCE CRITERIA AS PER AWS D1.1.......................................................................................8
APPENDIX III......................................................................................................................................................10
TECHNIQUE SHEET: LAMINATION CHECK......................................................................................10
APPENDIX IV......................................................................................................................................................12
TECHNIQUE SHEET: STRUCTURAL BUTT JOINT, T JOINT & CORNER JOINT..............12
Issued May 14, 2020
1. SCOPE
1.1. This testing procedure provide the technical information and detailed steps necessary to ensure
a complete and repeatable ultrasonic testing of welds.
1.2. This Procedure is comply with the recommendation of AWS D1.1 Ultrasonic Testing Only
Non Tubular Conection & Tubular Joint with diameter 24” and greater.
2. REFERENCE
2.1. AWS D1.1, 2020 Edition
2.2. ASME BPV Section V Article 4 and 5 – 2019 (As Complimentary)
2.3. ASTM A 435 Standard Specification for Straight Beam Ultrasonic Examination of Steel Plate
3. PERSONNEL QUALIFICATION AND RESPONSIBILITY

3.1. Personnel performing the ultrasonic testing shall be qualified in compliance/in accordance with
ASNT-TC-1A in Ultrasonic Testing Level II
3.2. UT operator qualified to NDT level I may perform thickness gauging. He is allowed to perform
flaw detection only under the supervision of the NDT level II or Level III Technician and as
per approved testing procedure.
4. EQUIPMENT
4.1. Portable pulse echo 'A' scan (rectified) presentation units with test frequency range of 1.0 MHz
to 6.0 MHz will be used. It shall be equipped with a stepped gain control calibrated in units of
2.0 dB or less.
4.2. Probes, either single or twin crystals, with polarized ceramic crystals shall be used. No
dimension of the crystals shall exceed 25.0 mm (1.0 inch), The angle of angle beam probe shall
be between 45 to 70 within the test material.
4.3. Reference block used for equipment’s calibration and standardization shall be one or more of
the following :
i IIW VI Block, Distance Sensitivity Calibration Block
ii IIW V2 (DIN 54122) Block, Distance Sensitivity Calibration Block
The proper functioning of the these block shall be of similar material as the test components
and meet the requirement of the governing code specification.
4.4. Viewing (light) hood over the CRT screen shall be used if ultrasonic testing is to be carried out
in bright condition.
4.5. Couplants like grease, oil, wall paper paste (cellulose) and other water based couplant may be
use as coupling medium. Same couplant shall be used in calibration and production testing.
High temperature grease shall be used for couplant for examination on surface with
temperature of more than 50o C.
4.6. Temperature of calibration block shall be within range actual on the test specimen or calculate
due to temperature deviation to reference level.
Issued May 14, 2020
5. STANDARDIZATION AND CALIBRATION

The pulse echo instrument shall be serviced and calibrated at regular intervals at least one a year.
Performance check of Ultrasonic Test units and probes shall be checked for the performance
periodically.
Minimum frequency of calibration and standardization are listed below :
5.1. ULTRASONIC TEST UNIT

 Horizontal Linearity
Frequency of Calibration:
The horizontal linearity of the test instrument shall be requalified at two-month interval in
each of the distance ranges that the instrument will be used.
 Distance Calibration of Time Base
This calibration shall be verified:
i) At the start of a series of testing.
ii) With any substitution of probe/cable.
iii) With any substitution of power source.
iv) At least every 4 hours during testing.
v) At the finish of testing
vi) At any time, when in the opinion of the UT operator, there is doubt as to the
validity of the calibration.
 Gain / Attenuator Control Accuracy
Frequency of Checking:
Re-calibration is necessary at least every two month or when maintenance service is
carried out on the test equipment’s,
 Internal Angle Beam Reflection and Calibration
This will depend on the rate of probe wear due to usage and to the roughness of the teasing
surface. When a probe is in continuous use, check shall be carried out every four hours or
daily before production test and the new angle shall be used for all evaluations.
 Probe – Equipment Combined Resolution
The resolution check of probe unit combined shall be carried out for new probe, when
index/angle has changed or at least once a month.
Issued May 14, 2020
5.2. ULTRASONIC SEARCH UNIT / PROBE

 Probe index point of shear (angle) wave probe
This will depend on the rate of probe wear due to usage and to the roughness of the testing
surface. When a probe is in continuous use, daily check or at least every four hours is
required
 Internal Reflector
Initial Calibration, after every change of shoe and weekly thereafter
6. SURFACE CONDITION
6.1. The surface where scanning is to be carried out shall be free of scale, weld spatters, pitting,
thick coating and other irregularities which may interfere in the transmission of sound wave.
7. SELECTION OF ANGLE PROBE

7.1. Angle probes of frequency 2.0 MHz to 2.5 MHz are to be used, with nominal angle of 45 deg,
60 deg, and 70 deg, plus or minus 2 deg.
7.2. The choice of angle probes for scanning different material thickness are as follows :
8 mm to 38 mm : 70 deg
Above 38 mm : 45 deg, 60 deg, 70 deg.
7.3. Root Scanning
A critical root scan at stand-off distance of 1/2 skip from near root penetration face shall be
carried out on all full penetration joints. Probe of 70 deg nominal angle is recommended for
critical root scanning for all thickness as described in technique sheets.
Take not for tubular, 70 deg angle beam may not reach the bore and other appropriate angle
should be used.
8. SCANNING AND DEFECT EVALUATION

8.1. Welds shall be tested using an angle beam search unit as shown in AWS D1.1, 2020 Table 8.7.
8.2. Prior to any examination of the weldment, the parent material shall be examined with a
compression wave 0 o for a minimum of 25 mm either side of weld to locate any flaws in the
parent material and to determine its thickness. For the thickness up to 30 mm, a twin crystal
probe shall be used. For thickness over 30 mm, a single crystal probe shall be used. Ultrasonic
examination of welds are detailed in the procedure technique sheet as attached.
8.3. When practicable, scanning shall be performed at a minimum gain setting of two times (i.e.
+6db) the primary reference level, at scanning speed not to exceed 6 inches (152.4 mm) per
second. Preferably to adjust the gain control until 2mm grass signal from opposite face is
observed.
8.4. Probe movement during scanning shall be a combination of rotational, orbital, lateral, and
traversing actions and with a minimum overlapping of 50 % the probe dimension.
Issued May 14, 2020
8.5. The length of discontinuity shall be determined by 6dB (1:2) drop technique.
8.6. The cross section of discontinuity shall be sized with 20 dB (1:10) drop method or maximum
amplitude technique or a combination of both if required.
8.7. Reporting of defective areas shall be referred to a zero datum and the weld center line for
constant configuration and defective area physically marked adjacent to the defective weld.
9. ULTRASONIC TESTING PROCEDURE

9.1. Ultrasonic testing procedure/technique of welds are detailed in the procedure technique sheet.
Testing procedure will be developed for specific job when required. Refer to attached,
technique sheets.
10. RE-EXAMINATION OF REPAIRED AREAS

10.1. Repaired areas shall be reexamined taking into consideration the new fusion zone created by
the excavation and the position of the original defect
10.2. The whole length of the repaired areas shall be reexamined plus 50 mm from both ends where
possible
11. REPORTING
11.1. The Client shall receive copies of approved reports generated in accordance with this
procedure. The report shall be counter signed by the Client.
11.2. Reports shall contain full details of test restriction and procedure deviation wherever
applicable.
11.3. Copies of the above reports shall be retained and filed by PT. GUNUNG RAJA PAKSI
12. ACCEPTANCE CRITERIA

Acceptance or rejection of a component shall be interpreted according to the applicable code or
specification:
12.1. AWS D1.1, 2020 Clause 8, Table 8.2 for Statically Loaded Non-tubular Connection and
Cyclically Loaded Non-tubular Connection in Compression.
12.2. AWS D1.1, 2020 Clause 8, Table 8.3 for Cyclically Loaded Non-tubular
Connection in Tension.
Issued May 14, 2020
APPENDIX I
TRANSFER CORRECTION
1.0 GENERAL.
1.1 There is a difference in instrument sensitivity between the reference block and test
component due to test roughness, contact area, component temperature and
acoustical characteristic. A correction in instrument sensitivity is required to
compensate for these difference (transfer correction) and is described below.
75%
Line R
50 %
25 % F
2.0. PROCEDURE
2.1 Use two angle beam probes of the same type. One acting as transmitter and the
other as receiver with the test unit set to dual mode.
2.2 Place the probe in tandem directed at each other on the reference block at one skip
distance and maximized the signal to 75 % . Note down the gain (dB)
2.3 Mark on the screen the peak of the maximized signal.
2.4 Reposition the probe without altering the test unit sensitivity to achieve peak signal
at two skip distance repeat step 2.3 and join the two marks to obtain line R.
2.5 On the surface of the test component, carry out step 2.2 at the same gain (dB)
setting.
Increase or decrease the maximize signal peak (line F as shown above) as to bring
it to line R.
Note down the gain (dB) difference.
2.6 The difference in gain (dB) in step 2.2 and step 2.5 is the transfer correction and
has to be added or subtracted to the primary reference sensitivity level prior to
scanning.
2.7 The first skip distance has to be greater than four inches or other wise the
successive skip distance should be employed
Issued May 14, 2020
APPENDIX II
UT ACCEPTANCE-REJECTION CRITERIA AS PER AWS D1.1/D1.1M-2020
Issued May 14, 2020
Issued May 14, 2020
APPENDIX III
TECHNIQUE SHEET: LAMINATION CHECK
MATERIAL : Carbon Steel

MATERIAL THICKNESS : 6 mm and above
JOINT PREPARATION : N.A
WELDING PROCESS : N.A
EQUIPMENT : Pulse Echo, A-scan Presentation, Digital thickness meter.
COUPLANT : Cellulose and water mixture
CALIBRATION BLOCKS : Step wedge or calibration block of at least one half of test material
thickness
PROBE SELECTION : Frequency range - 1.0 to 6.0 MHz
Zero degree probe - any dimension of transducer but not
to exceed 25mm, single or twin
crystal.
Angle probe - Not Applicable
TESTING TEMPERATURE : AMBIENT
TIME BASE CALIBRATION: At least twice the test material thickness
SENSITIVITY SETTING : First backwall echo to 50% to 75% FSH.

Not applicable for digital or other portable thickness meter.
dB SCANNING : dB Sensitivity Setting + 6 dB
CODE / SPECIFICATION : Client Specification or Client’s Advice

SCANNING SKETCH
0
t
Pate
Issued May 14, 2020
INSPECTION SEQUENCE:
1. Test surface shall be cleaned and smooth as practically allowed. Filling or light grinding
(if permitted) should be carried out on rusted and pitted surface. Paint work shall be
removed for thickness gauging.
2. Apply thin layer of couplant on the test surface and place the probe over the couplant.
Press the probe lightly and evenly into the test surface.
3. Maximized the signal to get a stable reading (digital meter) twist the probe lightly if stable
signal could not be achieved.
4. Record down the reading with sketch. For lamination check at least two signals which
indicate the wall thickness should be seen.
5. Special couplant, probe housing and technique will be detailed if testing to be carried out
on hot surface above 50  C.
6. Defect sizing shall be carried out at primary reference level plus transfer correction not be
achieved.
Issued May 14, 2020
APPENDIX IV
TECHNIQUE SHEET: STRUCTURAL BUTT JOINT, T JOINT & CORNER JOINT
MATERIAL : Carbon Steel

MATERIAL THICKNESS : 8mm and above
JOINT PREPARATION : Single-V or bevel, full penetration weld, with or without backing
strip.
WELDING PROCESS : Fusion Welding
EQUIPMENT : Pulse Echo, A-Scan presentation
COUPLANT : Cellulose wallpaper paste and water solution, starch solution or
any water based solution may be used.
CALIBRATION BLOCK : IIW V1 and V2 blocks, as applicable.
PROBE SELECTION : Frequency range - 2.0 to 2.5 MHz
Zero degree probe - any dimension of transducer not to
exceed 25 mm
Angle probe - transducer dimension in the range
of 10mm rectangular or circular in
shape.
Material thickness - 8mm to 38mm : 70 deg
Above 38mm : 45, 60 and 70 deg.
TESTING TEMPERATURE : Ambient.
TIME BASE CALIBRATION : Zero degree probe - At least twice the material thick.
: Angle probe - 100 mm across screen or 1-1/2 skip range
whichever is greater.
SENSITIVITY SETTING : Zero degree probe - 1st backwall echo set to 50% to 75%
FSH.
: Angle probe - Echo of 1.5 mm diameter side drill hole in
IIW V1 Block set to 40% to 60% FSH + dB Transfer
Correction
dB SCANNING of Angle Beam : dB Sensitivity Setting 1.5 mm diameter side drill hole IIW
V1 Block + dB Transfer Correction + dB Scanning level
(Non Tubular Joints)
DEFECT EVALUATION : - Weld discontinuity shall be evaluated on the basic of its

indication rating (d) and its length, in accordance with AWS
D1.1 – 2020, Table 8.2 for statically loaded structures and
Table 8.3 for cyclically loaded structures.
- Indication Rating (d) = a –b – c
a. Indication Level = Maximum height pulse indication on
screen at adjusted
Issued May 14, 2020
b. Reverence Level = Echo of 1.5mm diameter side drill hole

in IIW V1Block set to 40% to 60% FSH.
c. Attenuation Factor = ((Sound Path Discontinuity / 25) -1)
x 2, if value less the lower level and those of ½ dB shall
be rounded out to the lower level and those of ½ or
greater
CODE/SPECIFICATION : See section 12 of this procedure specification.
SCANNING SKETCH BUTT JOINT

FIGURE 1
Face A
0 0 Angle probe
Face B
 Compressions scan of parent materials, both side of weld.

 This Technique is also applicable for double V preparation.
 Weld, root and body scan both faces A and B at ½ skip technique.
 If face A or face B is inaccessible, scanning from face A or face B shall be at full skip
Issued May 14, 2020
SCANNING SKETCH T-JOINT DOUBLE BEVEL

FIGURE 2
Face A Face B
Face C

 If face A or face B is inaccessible, scanning from face A or face B shall be at full skip.
 Compressions scan at face C, if accessible, for weld metal – parent metal interface.
SCANNING SKETCH SINGLE BEVEL

FIGURE 3
Face A Face B
Face C

 If face A or face B is inaccessible, scanning from face A or face B shall be at full skip.
 Compressions scan at face C, if accessible, for weld metal – parent metal interface
Issued May 14, 2020
SCANNING SKETCH CORNER JOINT

FIGURE 4
Face A
Angle Probe 0
Face C
0
Face B

 Weld, root and body scan both face A and B at ½ skip technique.
 If face A or face B is inaccessible, scanning from face A or Face B shall be at full skip.
SCANNING SKETCH CORNER JOINT WITH BACKING PLATE

FIGURE 5
Face A
Angle Probe 0
Face C
0
Face B
Backing Plate

 Weld, root and body scan both face A and B at ½ skip technique.
 If face A or face B is inaccessible, scanning from face A or Face B shall be at full skip.
Issued May 14, 2020
INSPECTION’S SEQUENCE.
1. Zero degree probe scan of the parent material at least 2 skip distance from the weld center
line.Scan both sides of the weld parent material. this will determine the material thickness
and will detect internal reflector which might affect interpretation of angle beam results.
Location and areas of such reflector should be reported.
2. Root scanning - as per section 7.3
3. With appropriate angle probes, scan the whole volume of the welds. See scanning sketch
on this technique sheet.
4. Minimum scanning level - primary reference level plus transfer correction plus required
gain setting where 2 mm high grass signals from the opposite face are observed.
5. Defect sizing shall be carried out at primary reference level plus transfer correction.
Acceptance criteria should be referred back to client's requirements. It should be specific.
6. Defective areas shall be marked and recorded in a simple sketch of cross-section of the
weld indicating defect depth, position and orientation reckoned from reference datum
point.
7. Written report should be generated on weld tested. Rejectable discontinuity shall be shown
in full cross-sectional profile. All scanning limitations and restrictions shall be reported

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PLATE SERVICE CENTER

Document No. GRP.PM.QA.04A

Date Revision Paragraph

RIYANTO SAENAL A. RAPI

SECTION CONTENT PAGE

3. PERSONNEL QUALIFICATION AND RESPONSIBILITY

5. STANDARDIZATION AND CALIBRATION

5.1. ULTRASONIC TEST UNIT

5.2. ULTRASONIC SEARCH UNIT / PROBE

7. SELECTION OF ANGLE PROBE

8. SCANNING AND DEFECT EVALUATION

9. ULTRASONIC TESTING PROCEDURE

10. RE-EXAMINATION OF REPAIRED AREAS

12. ACCEPTANCE CRITERIA

MATERIAL : Carbon Steel

TESTING TEMPERATURE : AMBIENT

TIME BASE CALIBRATION: At least twice the test material thickness

SENSITIVITY SETTING : First backwall echo to 50% to 75% FSH.

dB SCANNING : dB Sensitivity Setting + 6 dB

CODE / SPECIFICATION : Client Specification or Client’s Advice

MATERIAL : Carbon Steel

TESTING TEMPERATURE : Ambient.

DEFECT EVALUATION : - Weld discontinuity shall be evaluated on the basic of its

b. Reverence Level = Echo of 1.5mm diameter side drill hole

CODE/SPECIFICATION : See section 12 of this procedure specification.

SCANNING SKETCH BUTT JOINT

 Compressions scan of parent materials, both side of weld.

SCANNING SKETCH T-JOINT DOUBLE BEVEL

 Compressions scan of parent materials, both side of weld.

SCANNING SKETCH SINGLE BEVEL

 Compressions scan of parent materials, both side of weld.

SCANNING SKETCH CORNER JOINT

 Compressions scan of parent materials, both side of weld.

SCANNING SKETCH CORNER JOINT WITH BACKING PLATE

 Compressions scan of parent materials, both side of weld.

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