Kuwait International Industrial Laboratory
& Inspection Services (KIL)
Quality Control Procedure
ULTRASONIC INSPECTION
QCP- KIL-02A Rev.1
1 24/01/09 PRASANTH.S
Rev Date Comments Prepared By Checked By Approved by
Kuwait International Industrial Laboratory & Inspection
Services (KIL)
ULTRASONIC INSPECTION
QCP- KIL-02A Rev. 1
CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 GENERAL
5.0 PERSONNEL
6.0 EQUIPMENT
7.0 PRE-TEST
8.0 GENERAL TEST
9.0 CALIBRATION FOR TESTING
10.0 TESTING
11.0 EVALUATION
12.0 RECORDS
APPENDIX CALIBRATION FOR TESTING
ATTACHMENT UT REPORT FORM
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Kuwait International Industrial Laboratory & Inspection
Services (KIL)
ULTRASONIC INSPECTION
QCP- KIL-02A Rev. 1
1.0 PURPOSE
This test instruction sets forth the minimum requirements for execution of ultrasonic testing
to ANSI / AWS D1.1, Structural Welding Code - Steel and similar codes.
2.0 SCOPE
2.1 This instruction describes the requirements for the ultrasonic testing of welded joints
in accordance with specifications requiring ANSI / AWS D1.1 quality requirements.
2.2 Definitions shall be as stated in AWS. D1.1 Section 6, Inspection.
2.3 Unless specifically stated all the requirements of ANSI / AWS D1.1 shall be
observed.
3.0 REFERENCES
The following documents shall be referred to in conjunction with this instruction: -
Written Practice for training, qualification, and certification of NDT personnel (SNT-
TC-1A, 2001),
ASNT SNT-TC-1A, Recommended Practice for NDT Personnel
ANSI / ASNT CP 189, ASNT Standard for Qualification and Certification of NDT Personnel
ANSI/AWS D1.1, Structural Welding Code - Steel
4.0 GENERAL
At the time of testing technicians shall have in their possession copies of the acceptance
criteria as mandated by the job specification. If excerpts of the actual code are provided,
necessary annotation shall be made to clarify any requirements that may be subject to
interpretation.
5.0 PERSONNEL
Personnel shall be qualified to written practice as prepared in accordance with ASNT SNT-
TC-1A. Personnel with other qualification such as PCN or ACCP may use this instruction
with specific written approval of appropriate Client representative.
6.0 EQUIPMENT
6.1 The ultrasonic flaw detector shall be of the pulse-echo type having A-scan presentation
and shall have a valid calibration certificate, battery voltage meter or alarm, minimum 2dB
steps over a minimum 60dB range, with screen showing easily discernible changes of
minimum 2dB.
Valid certificate of calibration/test shall be not more than two months previous to date of
use, and shall confirm horizontal linearity, dB accuracy, and resolution were within the
parameters described in ANSI / AWS D1.1 at time of certification.
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QCP- KIL-02A Rev. 1
6.2 The nominal frequency of probes shall be in the range of 2 to 6 MHz and may be of
twin or single crystal type. Each probe shall be clearly marked with frequency,
nominal angle, and index point. Straight beam probes shall have an active area from
323 mm² (½ in²) to 645mm² (1 in²). Angle beam probe crystal(s) shall be square or
rectangular in shape and may vary from 16 to 25mm (5/8 to 1 in) in width and from
16 to 21mm (5/8 to 13/16 in) in height. Ratio of height to width shall be from 1:1 to
1.2:1. Sound beam paths shall be within ± 2° of probe nominal angles of 45°/60°/70°.
Other probes may be used, subject to achieving ANSI / AWS D1.1 sensitivity and
resolution requirements, only with clients written approval.
6.4 Reference standard (calibration block) shall be the IIW V1 reference block, standard
Reflector shall be the 1.59mm (0.06in) hole in it.
6.5 Alternatively 1.59mm (0.06 in.) side drilled hole blocks can be used to establish
distance amplitude correction (DAC).
6.6 Couplant can be any suitable viscous liquid compatible acoustically with the test item.
Consideration shall be given to effects of couplant to subsequent operations and service.
7.0 PRE-TEST
7.1 The Client shall supply sufficient information to the technician enabling the item for
examination to be uniquely identified.
7.2 Datum locations shall be clearly marked.
7.3 The examination surface shall be free of weld spatter, dirt, grease, oil (other than that
used as a couplant), paint and loose scale and shall have a contour permitting intimate
coupling.
7.4 Equipment shall be qualified for use with this procedure. Requalification shall be
undertaken at not more than the prescribed intervals.
7.4.1 Horizontal linearity shall be requalified after each 40 hours use in all distance ranges
used under this procedure.
7.4.2 Gain control calibration, as at item 6.1 above, shall be checked at two-month
intervals.
7.4.3 Maximum internal reflections of probes shall be verified with each 40 hours use.
7.4.4 Angle beam probes shall be checked after each 8 hours use for flat contact face,
correct index marking, and angle with ± 2° of nominal. Probes not meeting these
requirements shall be corrected or replaced.
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7.4.5 Flaw detector/angle probe combinations shall resolve three holes in the resolution
block (RC or IOW BCB) at normal test settings. Verification of it shall be done with each 40
hours use.
Instruction for the above equipment qualification is in Appendix.
8.0 GENERAL TEST
8.1 The complete parent material and weld examination shall be executed in accordance
with
relevant KIL technique instructions.
8.2 Variation from this procedure shall only be undertaken with the appropriate client
representative’s prior written approval. Each variation shall be noted on the ultrasonic
report and a relevant test techniques instruction produced, if required.
8.3 For testing welded joints, a straight beam probe shall be used to test for laminar
reflectors the appropriate accessible volume through which angle beam sound paths will
traverse.
8.4 Numbers and angle of angle beam probes which shall be used to test the weld is as
given in AWS D1.1 Table 6.6, the choice of angles being dependent on variables such as
material thickness, access, and weld configuration.
8.5 Scanning movements shall not exceed 150mm (6 in) per second, and each subsequent
pass shall overlap the preceding scan by not less than 10% and preferably 50%.
9.0 CALIBRATION FOR TESTING (refer to appendix for details)
9.1 Calibration for testing shall be made with suppression (reject) off, by the test technician
just prior to and at the test location. Recalibration shall be made for each weld, after a
change of operators, each 30-minute maximum time interval, or when the electrical circuitry
is disturbed.
9.2 Calibration for sensitivity and horizontal sweep (distance) shall be made by the
ultrasonic
operator just prior to and at the locations of testing of each weld. Distance amplitude
correction (DAC) curves shall be made for each flaw detector/probe combination.
9.3 Reference sensitivity shall be basic sensitivity from standard reflector, with DAC, plus
transfer correction.
10.0 TESTING
10.1 Testing techniques for different geometry are shown in AWS D1.1Annex K, Figure K-
8.
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10.2 It is intended that as a minimum requirement all welds tested have the sound beam
pass through the entire weld and heat affected zone in two crossing directions, for
longitudinal and for transverse flaws.
10.3 Scanning level setting shall be standard sensitivity plus approximately 6 to 12 dB or as
required to verify sound penetration from indications of surface reflections.
11.0 EVALUATION
Flaw size evaluation shall be performed with reference to the standard sensitivity except if
higher or lower sensitivity is more appropriate for determining the maximum discontinuity
size (height and length). If unless otherwise specified, the evaluation shall be as follows: -
11.1 Straight beam testing
When the discontinuity is large than the probe, a full loss of back reflection will occur. A6dB
loss of amplitude and measurement to the probe centre line shall determine the
discontinuity edge.
Discontinuities smaller than the probe shall be sized by moving the probe towards the
discontinuity until an indication on the screen begins to form. The leading edge of the probe
is determined as the edge of the discontinuity.
11.2 Angle beam testing
Discontinuity height and depth shall be determined using a maximum amplitude method.
Discontinuity length shall be determined by the 6dB drop method.
11.3 Acceptance criteria
In the absence of specified criteria, the acceptance / rejection criteria in AWS D1.1 Annex
K, Table K1 shall apply.
12.0 RECORDS
12.1 For each test performed the following information shall be identified (where available)
and included on the report.
a) Client
b) Construction code / client specification
c) Test specification / technique
d) Job description
e) Test item identification
f) Material type and condition
g) Welded joint type
h) Attenuation correction factor
i) Couplant
j) Ultrasonic equipment type, serial number, and calibration certification
k) Details of probes, including sensitivity and scanning levels
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Kuwait International Industrial Laboratory & Inspection
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QCP- KIL-02A Rev. 1
l) Calibration block types
m) Test and/or access restrictions
n) Test results
o) Technician
p) Date of test
12.2 Transducer details shall include the type, crystal dimensions, nominal angles and
frequencies. The evaluation sensitivity level shall be included. The scanning sensitivity
shall be in accordance with item 10.3 herein.
12.3 The test results shall include details (when available) of the item under test, welded
joint or piece tested, welding operator identification and the outcome of the test as detailed
in item 11.3 herein.
12.4 Recordable discontinuities, those reflectors having maximised indications less than
standard sensitivity level (SSL) and above disregard level (DRL) shall have the following
information noted.
a) Test number
b) Discontinuity type
c) Length of reflector
d) Width of reflector
e) Reference height of reflector
f) Location to datum of reflector
g) Assessment as per 11.3 above
h) Sketches of reflector cross - sections and / or location drawings.
At Client's direction, those reflectors having maximised indications not less than standard
sensitivity level (SSL) minus 6dB shall be deemed recordable discontinuities.
12.5 The reference height of the reflector may be recorded as plus or minus dB relative to
the DAC or percentage DAC curve, i.e. plus 6dB means a reflector is 6dB greater (twice
the height) than the DAC and 50% DAC represents a reflector of a value minus 6dB (half
the DAC).
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Kuwait International Industrial Laboratory & Inspection
Services (KIL)
ULTRASONIC INSPECTION
QCP- KIL-02A Rev. 1
CALIBRATION FOR TESTING
6.0 EQUIPMENT CALIBRATION
6.1 Calibration blocks
The basic calibration reflectors shall be used to establish a primary reference response of the equipment.
6.1.1 Calibration block material
The material from which the block is fabricated shall be of the same product form, and material specification
or equivalent P-number grouping as the material(s) being examined. Calibration blocks for dissimilar metal
welds, the material selection shall be based on the material on the side of the weld from which the
examination will be conducted
6.1.2 Calibration block thickness
When two or more base material thickness are involved, the calibration block thickness shall be
determined by the average thickness of the weld
6.1.3 Calibration block surface finish
The finish on the surfaces of the block shall be representative of the surface finishes on the components
to be examined.
6.1.4 Basic calibration reflector
The basic calibration reflectors may be located either in the component material or in a basic calibration
block.
Basic calibration block detail
(Reference to ASME Section V, T- 534.2.1)
Basic calibration
block thickness
Weld thickness Hole diameter Notch size, mm
(T)mm
(t) mm mm
Width = 3.2 to
25 or less 19 or t 2.4 6.4Depth = 2% T or
0.1, whichever is
Over 25 to 51 38 or t 3.2 greater in to the
base material
Over 51 to 102 76 or t 4.8
Length = 51
Over 102 up to and 127 or t 6.4
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incl. 152
6.1.5 Curved test surfaces
a) Materials with diameters greater than 508 mm
For examination in materials where the examination surface diameter is greater than 508 mm, a block of
essentially the same curvature, or alternatively, a flat basic calibration block, shall be used.
b) Materials with diameters 508 mm or less
For examination in materials where the examination surface diameter is 508 mm and less, the basic
calibration block shall be curved. A single curved basic
calibration block may be used to calibrate for the examination on surfaces in the range of curvature from
0.9 to 1.5 times the basic calibration block diameter.
6.2 System calibration
Calibration shall include the complete ultrasonic examination system. The original calibration must be
performed on the basic calibration block. Checks shall be made to verify the sweep range calibration and
distance amplitude correction. Checks shall include the entire examination system.
6.2.1 Angle beam calibration
The calibration shall provide the following measurements:
[Link] Sweep range calibration
Sweep range calibration shall be performed using minimum two reflections from the quadrant IIW–V1 or
IIW–V2 calibration block to calibrate the sweep range.
Example 1:
To achieve 0 to 100 mm range using IIW-V1 calibration block:
a) Position the angle beam probe towards the 100 mm quadrant and maximise the echo response by
moving the probe front and back parallel to the sides of the calibration block, without any angulations.
(Rotation of the beam into the corner formed by the hole and the side of the block may produce higher
amplitude at a longer beam path; this beam path shall not be used for calibration).
b) To start with, adjust the initial echo at zero division on the screen.
c) Adjust the first back reflection to tenth division
d) By using delay control bring first back reflection to zero division of screen
e) Set the second back reflection at tenth division of the screen by adjusting both range and delay
controls
f) Using only delay control, bring the first back reflection to zero scale position (the initial response need
not coincide with zero position of the scale).
g) Now the tenth scale division of the screen represents 100 mm metal path in steel.
Example 2:
To achieve 0 to 100 mm range using IIW-V2 calibration block
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QCP- KIL-02A Rev. 1
a) Position the angle beam probe towards the 25 mm or 50 mm quadrant and maximise the echo
response by moving the probe front and back parallel to the sides of the calibration block, without any
angulations, to
avoid beam reflecting from the corner of the block.
b) To start with, adjust the initial echo at zero division on the screen.
c) Set the first and second back reflections to 2.5 and tenth scale divisions for the probe position towards
25 mm quadrant by adjusting both range and delay controls. Then for verifying the calibrations keep the
probe
towards 50 mm. Now the first back reflection shall be at fifth scale division.
d) Now the tenth division of the screen represents the 100 mm steel metal path distance.
[Link] Distance amplitude correction (DAC)
‘Reject control’ of the equipment shall be set in ‘OFF’ condition.
a) Position the probe for maximum response from ¼ T hole and adjust the gain setting to provide an
indication height of 80% (± 5% of full screen height) and mark the peak of the indication on the screen
b) Position the probe for maximum response from ½ T hole and mark the peak of the indication on the
screen
c) Position the probe for maximum response from ¾ T hole and mark the peak of the indication on the
screen.
d) Connect the screen marks for the side-drilled holes to provide the distance amplitude curve.
e) Record probe data and equipment settings.
[Link] When an electronic distance amplitude correction device is used, the primary reference response
shall be equalised at a nominal constant screen height of between 40% to 80% of full screen height over
the distance range or employed in the examination.
6.2.2 Straight beam calibration
The calibration shall provide the following measurements:
[Link] Sweep range calibration
For sweep range calibration IIW-V1 calibration block thickness (25 mm or 100 mm), IIW-V2 calibration
block thickness (12.5 mm or 20 mm) or ASTM basic calibration side drilled holes reflection can be used.
Example 3 - Calibration of 100 mm using IIW-V1 block 25 mm thick
a) To start with, adjust the initial echo at zero division on the screen
b) Position the straight beam probe on the IIW-V1 block 25 mm thick side and maximise the first
reflection.
c) Adjust the first, second, third and fourth back reflections to 2.5, 5.0, 7.5 and tenth scale divisions by
using range and delay controls.
d) Now the tenth division of the screen represents the 100 mm metal path distance in steel.
6.3 Calibration confirmation
Calibration confirmation shall be performed prior to use of the system in the thickness range under
examination. A calibration check shall verify the sweep range calibration and distance amplitude
correction.
6.3.1 Sweep range calibration
If any point on the DAC curve has moved on the sweep line more than 10% of the sweep division reading,
correct the sweep range calibration and note the correction in the examination record. If recordable
reflectors are noted on the data sheets, those data sheets shall be voided, a new calibration shall be
recorded, and the voided examinations shall be repeated
6.3.2 DAC curve
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QCP- KIL-02A Rev. 1
If any point on the distance-amplitude correction (DAC) curve has decreased 20% or 2 dB of its
amplitude, all data sheets since the last calibration or calibration check shall be marked void. A new
calibration shall be made and recorded and the voided examination areas shall be re-examined. If any
point on the distance-amplitude correction (DAC) curve has increased by more than 20% or 2 dB of its
amplitude, all recorded indications since the last valid calibration or calibration check shall be evaluated
with the corrected calibration, and their values shall be changed on the data sheets.
6.4 Calibration check on basic calibration block
A calibration check on at least three of the basic reflectors in the basic calibration block shall be made at
the finish of each examination. Interim calibration checks may be made as above or on the three required
pulses from the electronic simulator every 12-hours during the examination and whenever examination
personnel are changed.
1.0 LONGITUDINAL MODE
1.1 Distance calibration
The probe shall be set in position G on IIW V1 block, the instrument adjusted to produce
indications at 25/ 50/ 100mm etc. on the screen.
1.2 Amplitude
The probe shall be set in position G on the IIW V1 block, the gain adjusted until the
maximised indication from the first back wall echo (FBWE) attains 50 to 75% full screen
height (FSH).
1.3 Resolution
The probe shall be set in position F on the IIW V1 block and shall resolve all three
distances.
2.0 SHEAR WAVE MODE
2.1 Index point
The probe shall be set in position D on the IIW V1 block, and move to maximise response
from the radius. The point on the probe (both sides) that aligns with the radius line on the
block is the index point.
2.2 Probe sound angle
The probe shall be set in position B on the IIW V1 block for angles 40° through 60°, or be
set in position C on the IIW V1 block for angles 60° through 70°, and moved to maximise
response from the perspex insert. The index point shall be compared with the angle mark
on the block (tolerance ± 2° of nominal).
2.3 Distance calibration
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The probe shall be set in position D on the IIW V1 block (any angle), and moved to
maximise response from the radius, the instrument shall be adjusted to produce indications
at 100 and 200mm or 4 and 8 in on the screen.
2.4 Sensitivity (amplitude)
The probe shall be set in position A on the IIW V1 block (any angle), the maximised signal
from the 1.5mm (0.06 in) hole adjusted to attain a horizontal reference line height
indication. The maximum dB reading obtained shall be the basic sensitivity. DAC -
Standard reflectors as 1.5mm(0.06in) side drilled hole located at the minimum, middle and
maximum depths below the surface to be used for examination shall be used in
accordance with the figure attached. Indications shall be maximised and a DAC
established.
2.5 Resolution
The probe shall be set on the RC block in position Q for 70°, in position R for 60°, and in
position S for 45° angle, the flaw detector/probe combination shall resolve the three test
holes to the extent of distinguishing the peaks of the indications from three test holes.
Alternately IOW calibration block may be used to check resolution of the shear wave angle
beam probe.
2.6 Approach distance of probe
The minimum allowable distance between the toe of the probe and the edge of the IIW V1
block (probe stand off distance minus the distance from toe to index) shall be: -
for 70° probe, 50mm (2 in)
for 60° probe, 37mm (2 ½ in)
for 45° probe, 25mm (1 in)
3.0 ALTERNATIVE METHODS
As an alternative each calibration above may be made on other calibration blocks in a
similar
manner to those above, as follows: -
3.1 The IIW V2 block may be used for: -
Longitudinal wave mode - distance
amplitude
Shear wave mode index
angle
distance
amplitude
3.2 The IOW BCB block may be used for: -
distance calibration
amplitude calibration
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resolution check
3.3 Other blocks of similar material, finish, and essential tolerances may be used provided
that calibration shall be proven to attain outcome as above. Essential tolerance is defined
as any dimension or characteristic affecting the sound beam behaviour during the
particular calibration.
3.4 Other methods may be used provided that calibrations are proven to attain out comes
as above.
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