WRITTEN INSTRUCTION FOR ULTRASONIC EXAMINATION OF A

DOUBLE V BUTT WELD IN 40 mm THICK MILD STEEL PLATE

Document Reference: UT/WI/001 Issue: 1 Revision: 0

Written By (Name): G. Masding

Written By (Signature):
Date: 03 June 2005

Approved By (Name): M. Spicer

Written By (Signature):
Date: 03 June 2005

Purpose of Test:

To detect all significant defects within the weld body and heat affected
zone.

Safety:

Appropriate personal protective equipment is to be worn. Where a

permit to work system is in operation it shall be strictly adhered to.

Personnel:

All personnel working in accordance with this written instruction shall

be qualified, as a minimum, to EN 473 Ultrasonic Practitioner level 1
(welds).

Equipment:

Krautkramer USK 7a or equivalent: an ultrasonic flawdetector having

A-scan presentation & suitable for operation with ultrasonic probes in
the frequency range 1 to 6 MHz.

Couplant Ultragel II or equivalent; the couplant used for calibration

shall be the same as that used for testing

Wells Krautkramer CD10/5 or equivalent: 5 MHz 10 mm diameter

twin crystal zero degree compression probe.

Wells Krautkramer SMAP45/4 or equivalent: 4 MHz 10 mm diameter

45 single crystal shear wave probe.

Wells Krautkramer SMAP60/4 or equivalent: 4 MHz 10 mm diameter

60 single crystal shear wave probe.

Wells Krautkramer SMAP70/4 or equivalent: 4 MHz 10 mm diameter

70 single crystal shear wave probe.

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Calibration block: BS EN 12223 Calibration block No. 1

Calibration block: BS EN 27963 Calibration block No. 2

IOW beam spread block

Mild steel reference block conforming to figure 1 below

Figure 1: Mild steel reference block

Product Area To Be Tested:

100% of the weld volume and heat affected zone shall be tested. For
the purposes of inspection the heat affected zone shall be considered to
extend 10 mm each side of the weld cap.

Test Conditions:

Ultrasonic testing shall be performed after final heat treatment. The

parent material each side of the weld cap shall be free from weld
spatter, millscale, corrosion products, paint and any irregularity or
error of form that could hinder angle probe scanning.

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Equipment Checks

1. Timebase linearity. The time base shall be linear to within 2% of

screen width. Place the zero degree probe on the large surface of
calibration block No. 1. Adjust the range control to obtain 6 back
wall echoes. Adjust the range and delay controls such that the first
echo is aligned with the graticule position zero and the sixth echo
is aligned with the graticule position 10. Record the positions of
echoes 2, 3, 4 and 5; they should align with graticule positions 2, 4,
6 and 8. If there is an error exceeding 2% of screen width report to
the supervisor.

2. Amplifier linearity. The amplifier shall be linear within the limits

given below. If the equipment fails to meet this requirement report
to the supervisor. First make certain that the reject control is
switched off then, using any convenient probe, obtain a signal
from the 1.5 mm side drilled hole in calibration block No. 1. Use
the gain control to set this signal to 80% full screen height then
perform the steps listed below.

Add 2 dB the resulting signal height should exceed 101% of full

screen height.

Subtract 2 dB the signal should return to 80% full screen height.

Subtract 6 dB the resulting signal height should be between 37%

and 43% of full screen height.

Subtract a further 6 dB the resulting signal height should be

between 17% and 23% of full screen height.

Subtract a further 6 dB the resulting signal height should be

between 8% and 12% of full screen height.

Subtract 4 dB the resulting signal height should be visible, but

below 8% of full screen height.

3. Probe index. For all shear wave probes the probe index point shall
be checked by maximising the signal from the 100 mm quadrant of
calibration block No. 1. This shall be checked again on
completion of testing and shall be repeatable 2 mm.

4. Beam profile. For all shear wave probes the 20 dB beam profile
shall be plotted using the echoes from a minimum of 3 off 1.5 mm
side drilled holes at appropriate depths in the IOW block. This
shall be checked again after testing and shall be repeatable 1.5.
The refracted angle of all shear wave probes shall be within 2 of
the nominal probe angle.

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Calibration

1) Zero degree scan of the parent material. The zero degree probe
shall be calibrated for a range of 0 to 100 mm using calibration
block No. 1 or No. 2. Scanning sensitivity shall be set on the test
material and shall be second backwall echo to full screen height.

2) The scanning range for the 45 and 60 shear wave search scans
shall be 0 to 100 mm. The scanning range for the 70 shear wave
search scans shall be 0 to 200 mm. The scanning range for
shearwave probes shall be set using calibration block no. 2 or No.1
as appropriate. Using the 3 mm side drilled holes in the reference
block a DAC shall be plotted to cover for scanning up to the half
skip range and the reference gain shall be noted. On completion of
inspection reference sensitivity shall be checked. If the reference
gain is found to have increased by more than 4 dB all testing shall
be repeated. If the reference gain is found to have decreased by
more than 4 dB all recorded defects shall be re-evaluated.

3) Minimum scanning sensitivity for shear wave scanning shall be

reference sensitivity + 14 dB.

4) Transfer correction shall not be applied.

5) On completion of testing all traces of couplant shall be removed

and a light coat of oil shall be applied as a preservative.

Detailed Instructions For Application Of The Test

1. The parent material up to a distance of at least 140 mm (enough to

cover the 70 half skip distance) each side of the weld cap shall be
scanned to confirm thickness and freedom from significant laminar
discontinuities. If laminations are found, report to the supervisor.

2. The weld fusion faces, the heat affected zone and the weld volume
shall be scanned for longitudinal reflectors using the 60 and 70
probes as shown in figure 2. Overlap between adjacent scans to be
at least 20% of the probe shoe width.

3. The weld volume and heat affected zone shall be scanned for
longitudinal reflectors using the 45 probe as shown in figure 2.
Overlap between adjacent scans to be at least 20% of the probe
shoe width.

4. The weld volume and heat affected zone shall be scanned for
transverse reflectors using the 70 probe as shown in figure 2.
Overlap between adjacent scans to be at least 40% of the probe
shoe width.

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Non-Conformance Statement

In the event that the technician is unable to perform this examination

fully in accordance with this written instruction he shall stop all work
and report to the supervisor.

Recording and Classifying Results

1. For shear wave scans all reflectors giving rise to indications which
equal or exceed the DAC at the minimum scanning sensitivity
shall be investigated.

2. All investigable reflectors which are judged to be planar in nature

shall be recorded.

3. All investigable reflectors which are judged to be volumetric in

nature and with a dimension sizeable by probe movement shall be
recorded.

4. All recordable indications shall be recorded by means of a

dimensioned sketch.

5. All welds containing recordable indications shall be labelled and

segregated to the designated quarantine area.

Reporting Results

For each completed weld the operator shall prepare a report using the
standard reporting format.

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Figure 2: Scanning

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