Document No.

: NT/G/UT/AWS
Revision No. : 4
Issued No. : 1
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Issued Date : 30 December 2021

TESTING PROCEDURE

ULTRASONIC TESTING

APPROVAL
NAME DESIGNATION DATE
AUTHORITY

Operations
Prepared by 30/12/2021
Director

Mohd Diah Baba

Reviewed and
NDT Level III 30/12/2021
Approved by

Saharudin Kambari

THIS DOCUMENT PRESCRIBES COMPANY PRACTICE AND IS FOR INTERNAL USE ONLY. IT SHALL NOT BE REPRODUCED IN WHOLE OR IN PARTS
OR RELEASED TO A THIRD PARTY WITHOUT PRIOR CONSENT FROM THE HEAD OF RESPONSIBLE DIVISION
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ULTRASONIC TESTING

CLAUSE TABLE OF CONTENTS PAGE

1.0 Scope 1

2.0 Reference Code and Standard 1

3.0 Types of Welds 1

4.0 Qualification of Personnel 1

5.0 Surface Preparation 1

6.0 Couplant 2

7.0 Ultrasonic Equipment 2

8.0 Search Unit 2

9.0 Calibration 2

10.0 Rate of Search Unit Movement 3

11.0 Scanning Technique 3

12.0 Transfer Loss 4

13.0 Interpretation 5

14.0 Evaluation 5

15.0 Acceptance 5

16.0 Reports 6

UT Examination Report Format Attachment 1

Ultrasonic Scanning for Non – Tubular Connections Appendix 1

Ultrasonic Testing on Tubular Butt Weld and T-Y-K Connection Appendix 2

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ULTRASONIC TESTING

1.0 Scope
1.1 This procedure describes general requirement and techniques for the ultrasonic A-scan examination
on fusion welded joint of ferritic steels.
1.2 This procedure utilizes angle beam or straight beam or both, depending upon the specific weld
configuration.
1.3 This procedure covers for weld configuration in non-tubular butt weld and tubular T, Y and K –
Connection & butt weld joint.

2.0 Reference Codes and Standards

The following codes and standards shall form parts of the requirement of this procedure whichever is
applicable.

2.1 AWS D1.1 (2020 Edition): Structural Welding Code – Steel.

2.2 ASTM A435 (2017 Edition): Specification for Straight Beam Ultrasonic Examination of Steel Plate.
2.3 ASME Section V (2021 Edition): Non-Destructive Examination – Article 5.

3.0 Types of Welds

3.1 Non-tubular butt weld for material thickness 8mm and above.
3.2 Non-tubular butt weld and tubular T, Y and K – Connection & butt weld joint for material thickness 8
mm & above and tube diameter 4” (100mm) & above.

4.0 Qualification of Personnel

4.1 Ultrasonic operators shall be qualified and certified as Level II in accordance to ASNT SNT-TC-1A
and Nusantara Technologies written practice. Document showing evidence about the UT Operator
Qualification shall be submitted for approval.
4.2 Ultrasonic operators qualified ASNT Level II shall be demonstrate their ability throughout practical,
mock up test conducted by contractor and approved by Client.

5.0 Surface Preparation

All scanning surface shall be free from loose scale, weld spatter, dirt and shall be of sufficient uniform
contour and smoothness that satisfactory acoustic coupling can be maintained.

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6.0 Couplant
A couplant material shall be used between the search unit and the test material. The couplant shall be a
liquid, gel or paste medium suitable for the application and compatible with the material under test.

The maximum surface temperature when using conventional probe and couplants shall not exceed 50°C.

7.0 Ultrasonic Equipment

A-Scan flaw detector - manually operated.
 Krautkramer Ultrasonic Flaw Detector (Model: USM 35X DAC, USM GO or USM GO+).
 SIUI Ultrasonic Flaw Detector (Model: CTS 9005).
 Olympus Ultrasonic Flaw Detector (Model: Epoch XT).

8.0 Search Unit

8.1 Straight Beam Probe
Longitudinal wave; Straight beam, search unit (probe) transducers may be single crystal or double
crystal transducers. The frequency of transducers shall be within 2 MHz to 2.25 MHz and the size
shall be within 12.5 mm and 25mm diameter.

8.2 Angle Beam Probe

Shear wave; Angle beam search unit (probe) transducers shall have frequency within 2 MHz to 2.55
MHz.

The probe crystal shall be square or rectangular in shape and may vary from 15 mm to 25 mm in
width and 15 mm to 20 mm in height.

However for low thickness material or Tubular butt weld and T-K & Y connection smaller probe size
may use such as 8 mm x 9 mm and the probes may have frequency within 2 MHz to 6 MHz.

Probe angle shall be 45 degree, 60 degree and 70 degree with plus or minus 2 degree.

9.0 Calibration
9.1 Instrument Calibration
9.1.1 Linearity of amplifier
The ultrasonic equipment use shall have linear vertical presentation within ± 5 % of the full
screen height for 20 % to 80 % of the calibrated screen height.

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9.1.2 Linearity of Time Base

The ultrasonic equipment use shall have linearity of the time base within 2 % over the whole
range, i.e. the echoes do not deviate by more than 2 % of the time base range from their
true position.

9.2 Calibration of search unit

9.2.1 Angle beam calibration
The calibration shall provide the following measurement:
a. Sweep range calibration
b. Probe Angle
c. Probe Index

9.2.2 Straight Beam Calibration

The calibration shall provide the following measurement:
a. Sweep range calibration
The calibration of search unit should be made using VI Block or V2 Block. The
frequency of calibration shall be performed daily or prior to perform any testing.

9.2.3 Calibration and Reference Block

The reference block used for equipment calibration shall be as follows:
a. IIW VI Calibration Block.
b. IIW V2 Calibration Block.
c. The Welding Institute U.K (I.O.W) Beam profile with BS 4331: Part 3
d. Reference Blocks according to the specified code.
e. The standard reflector shall be a 1.5 mm diameter side drilled hole.

10.0 Rate of Search Unit Movement

The rate of search unit (probe) movement for examination shall not exceed 6 in/sec (150 mm/sec). Each
pass of the search unit shall overlap a minimum of 10 % of the transducer dimension perpendicular to the
direction of the scan.

11.0 Scanning Technique

The weld metal shall be scan for longitudinal imperfections and transverse imperfections.

11.1 Non-tubular butt weld

Ultrasonic scanning shall be examined by the pulse echo technique as in Appendix 1.

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11.2 Tubular butt weld and tubular T, Y and K – Connection

Ultrasonic scanning shall be examined by the pulse echo technique as in Appendix 2.

12.0 Transfer Loss

There is a difference in instrument sensitivity between the reference block and test component due to test
surface roughness, contact area, component temperature and acoustical attenuation characteristic. A
correction in instrument sensitivity is required to compensate for these differences and is described below.
12.1 Use two angle beam probes of the same type. One acting as transmitter and the other as receiver.
12.2 Placed at the probes in-tandem on the reference block at one skip distance and maximize the signal
to 75%. Note down the gain (dB).
12.3 Mark on the screen or on a graphical paper the peak of the maximized signal.
12.4 Reposition the probes to achieve peak signal at two-skip distance and maximize the signal to 75%.
Note down the gain (dB).
12.5 Third point may be acquired with third skip with follow the above step.
12.6 On the surface of test component, carry out step 12.2 & 12.3 and record the gain (dB). Increase or
decrease the signal where the peak is on line R and note down the gain (dB) difference.
12.7 The difference in dB gain of the instrument in line R and line R2 at relevant beam path is the transfer
correction that has to be added or subtracted during sizing of defects.

Line R for reference block material

Gain setting (dB) ir 80% full screen height echo

B3

Transmitter probe Receiving pobe

A B1 B2 B3 Line R2 for
B2 materials under
test
A3

B1
A2

A1
1skip 2 skip 3 skip

Beam path range (mm)

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13.0 Interpretation
It is recognized that not all ultrasonic reflectors indicate flaws, since certain metallurgical discontinuities
and geometric conditions may produce indications that are not relevant. The following steps shall be taken
to classify the indication:

13.1 The identity, maximum amplitude, location, and extent of reflector indication.
13.2 Plot and verify and reflector coordinates. Prepare a cross-sectional sketch of weld configuration
which showing the reflector position such as discontinuities, surface or root reflector.
13.3 Analyze the echo heights and pattern.

14.0 Evaluation
14.1 Indication evaluation
Imperfection which produce a response greater than 50 % DAC or less amplitude than the standard
sensitivity level (SSL) shall be investigated to the extent that the operator can determine the shape,
identity and location of all imperfections and evaluate them in acceptance standards Para 18.0.

All indications having half (6 dB) i.e. 50 % DAC or less amplitude than the standard sensitivity level
(SSL) regard for shall be disregarded.

14.2 Method of sizing indications

The sizing of indications (reflectors) shall be estimated with 6 dB drop method for the length and
height (width) of defects. Other methods of sizing such as maximum amplitude technique or 20 dB
drops may be used for sizing of defects height (width).

15.0 Acceptance
Limitation of imperfections shall be evaluated as in the following code and standards.

15.1 For Non-tubular butt weld (AWS D1.1 Edition 2020)

 Table 8.2: UT Acceptance-Rejection Criteria (Statically Loaded Non-tubular Connections and
Cyclically Loaded Non-tubular Connections in Compression).
 Table 8.3: UT Acceptance-Rejection Criteria (Cyclically Loaded Non-tubular Connections in
Tension).

15.2 For Non-tubular butt weld and tubular T, Y and K – Connection & butt weld joint (AWS D1.1 Edition
2020)
 UT Acceptance-Rejection Criteria shall be Class R or Class X or both.

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16.0 Reports
The ultrasonic test reports shall consist of the following information:
 Procedure use.
 Ultrasonic Examination Equipment.
 UT Personnel and level of qualification.
 Calibration Data.
 Identification and location of test area.
 Map or record of indication detected or areas.
 Date of examination.
 Basic calibration block used.
 Surface condition.
 Probe frequency.

The format of the Ultrasonic Examination Reports was shown as in the Attachment 1.

Reports shall be accompanied with sketches of part being tested and location of indication, if any.

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 Attachment 1

Page No. :
Our Ref. : ULTRASONIC EXAMINATION
REPORT Report No. :

Client : Ultrasonic Equipment :

Cable Type / Length :

Project :
Couplant :

Location : Calibration Block :

Material : Procedure No. :

Thickness : Examination Standard :

Surface Condition : Acceptance Standard :

Welding Process : Examination Date :

Probe Parameter :
Serial No. Beam Angle Frequency Size PRE Level Tr. Loss Scanning Range

Sensitivity Setting :
Angle Probes : Set Reference Level at 80% FSH from mm Ø reflector of block mm.
Normal Probes : Set 1st BWE at 100 % FSH.

No. Joint Reference Interpretation Result Remark

NDT Operator : Reviewed By Client : Reviewed By Client’s Rep :

Signature : Signature : Signature :
Name : Name : Name of Client’s Rep. :
Date : Date : Date :

NUSANTARA TECHNOLOGIES SDN BHD (187753-D)

Metrology & NDT Division: No. 9, Jalan Sungai Jerluh 32/196, Seksyen 32, Bukit Kemuning, 40460 Shah Alam, Selangor Darul Ehsan, Malaysia. Tel: 603-5525 1766 Fax: 603-5525 2766
Kemaman Branch: K-7206, Kawasan Perindustrian Jakar II, 24000 Kemaman, Terengganu Darul Iman, Malaysia. Tel: 019-389 9768 Fax: 609-859 3129
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Appendix 1: Ultrasonic Scanning for Non – Tubular Connections

Ultrasonic Flaw Detection shall be pulse echo straight beam or angle beam or both with depend on joint
figuration and shall be used contact method with A-scan presentation.

1.0 Scope
This UT scanning technique and acceptance shall be used for groove welds and HAZs between
the thicknesses of 8 mm and 200 mm inclusive.

2.0 Calibration
2.1 Range
Range (distance) calibration shall include, as a minimum, the entire sound path distance to
be used during the specific examination. This may be adjusted to represent either the sound-
path travel or the surface distance is displayed along the instrument horizontal scale.

2.2 Sensitivity Calibration

Standard sensitivity for examination of production welds using amplitude techniques shall be:
basic sensitivity + distant amplitude correction + transfer correction.

2.3 Basic Sensitivity

Reference level screen height can be obtained using maximum reflection from the 1.5 mm
diameter hole in the IIW type block or other block which results in the same basic calibration
sensitivity.

Get the maximum reflection from 1.5 mm hole and plus transfer correction and establish
horizontal reference-line height indication for sensitivities setting.

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Appendix 1: Ultrasonic Scanning for Non – Tubular Connections

100% FSH

80% FSH

Horizontal reference –
line height indication

Figure 2.0 – Sensitivity setting on 1.5 mm diameter hole in IIW Block

When a discontinuity indication appears on the screen, the maximum attainable indication
from the discontinuity shall be adjusted to produce a horizontal reference level trace
deflection on the display. The instrument reading in decibels shall be used as the “Indication
Level”, “a” for calculating the “Indication Rating", “d” as state below.

Indication Rating (d) = a – b – c

Where a - Indication of Discontinuity Level

b - Reference Level or Basic Sensitivity
c - Attenuation Factor

Attenuation Factor (c) = 2 (BPL – 1)

Where BPL - Beam Path Length (Unit in inches)

The indication rating shall be rounded to the nearest whole number (1 dB) value. Resulting
decimal values less than 0.5 dB shall be rounded down and those of 0.5 dB or greater shall
be rounded up.

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Appendix 1: Ultrasonic Scanning for Non – Tubular Connections

3.0 Test Coverage

3.1 Parent Metal Examination
Prior to examine the actual weld joint, the entire base metal through which ultrasound must
travel to test the weld shall be tested for laminar reflectors using a straight-beam.

If any area of base metal exhibits total loss of back reflection or an indication equal to or
greater than the original back reflection height is located in a position that will interfere with
the normal weld scanning procedure, its size, location, and depth from the Face A shall be
determined and reported on the UT report, and an alternate weld scanning procedure shall
be used.

3.2 Weld Metal Examination

The weld metal shall be examined with the angle beam probes in accordance to the material
thickness as descript in Table A1-1.

Table A1-1: UT Testing Angle

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Appendix 1: Ultrasonic Scanning for Non – Tubular Connections

Table A1-1: UT Testing Angle

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Appendix 1: Ultrasonic Scanning for Non – Tubular Connections

Table A1-1: UT Testing Angle

3.3 Scanning Patterns

The examination of the weld metal shall use the scanning pattern as Figure A1-1.

3.3.1 For Longitudinal Discontinuities

Use an angle probe and scan the weld as follows:

Move the probe to and fro toward the weld as scanning movement B. Continue
scanning along the entire weld as scanning movement C. During scanning use
scanning movement A by rotating the probe at an angle a = 10°.

Scanning Movement C. Progression distance c shall be approximately one-half the

transducer width.

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3.3.2 For Transverse Discontinuities

When the weld is ground welds, ultrasonic examination shall use Scanning pattern
D, where the angle probe is scan direct on the along weld.

While for unground welds, scanning pattern E shall be used and scanning angle (θ =
15° max).

Figure A1-1: Plan View of UT Scanning Pattern

 Testing patterns are all symmetrical around the weld axis with the exception of
pattern D which is conducted directly over the weld axis.
 Testing from both sides of the weld axis is to be made wherever mechanically
possible.

4.0 Acceptance Criteria

Each weld discontinuity acceptance shall be on the basis of its indication rating and its length, in
conformance with AWS D1.1 Table 8.2 for statically loaded structures or Table 8.3 for cyclically
loaded structures, whichever is applicable.

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Appendix 1: Ultrasonic Scanning for Non – Tubular Connections

Only those discontinuities which are unacceptable need be recorded on the test report, except that
for welds designated in the contract documents as being “Fracture Critical,” acceptable ratings that
are within 6 dB, inclusive, of the minimum unacceptable rating shall be recorded on the test report.

AWS D1.1 Edition 2020 Table 8.2: UT Acceptance-Rejection Criteria (Statically Loaded Non-tubular
Connections and Cyclically Loaded Non-tubular Connections in Compression)

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AWS D1.1 Edition 2020 Table 8.3: UT Acceptance-Rejection Criteria (Cyclically Loaded Non-
tubular Connections in Tension)

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Appendix 2: Ultrasonic Testing on Tubular Butt Weld and T-Y-K Connection

1.0 Scope
This UT scanning technique and acceptance shall be used for groove welds in butt joints in tubing
less than 24 in [600 mm] in diameter and T-Y-K Connection. While for groove welds in butt joints in
tubing 24 in [600 mm] in diameter and over, UT scanning technique and acceptance in Non-
Tubular Connection may be used.

2.0 Calibration
2.1 Range
Range (distance) calibration shall include, as a minimum, the entire sound path distance to
be used during the specific examination. This may be adjusted to represent either the sound-
path travel or the surface distance is displayed along the instrument horizontal scale.

2.2 Sensitivity Calibration

Standard sensitivity for examination of production welds using amplitude techniques shall be:
basic sensitivity + distant amplitude correction + transfer correction.

2.3 Basic Sensitivity

Reference level screen height can be obtained using maximum reflection from the 1.5 mm
diameter hole in the IIW type block or other block which results in the same basic calibration
sensitivity.

2.4 Distance Amplitude Correction (DAC). The sensitivity level shall be adjusted to provide for
attenuation loss throughout the range of sound path to be used by either distance amplitude
correction curves or electronic means.

DAC curve may be constructed from the trace point (peak) of the reflector echo. Standard
reflectors may locate at the minimum, middle, and maximum depths below the surface to be
used for examination. Indications should be maximized and a DAC established or electronic
methods used to locate the display indications which represent the standard reflector at the
various depths selected.

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The DAC should be adjusted, based upon the results of the transfer correction. The
sensitivity calibration methods described herein are not essential when actual discontinuity
size (height and length) is required. In this case, it is only necessary to maintain sufficient
sensitivity throughout the part being examined so that all discontinuities are found and
properly evaluated.

6dB

100% DAC
SSL

50% DAC

DRL

Figure 2.4 – Distance Amplitude Correction Curve

Note:
i. The display screen may be marked to show SSL established during sensitivity
calibration with the DRL located 6 dB below.
ii. SSL = Standard Sensitivity Level.
iii. DRL = Disregarded Level.

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Appendix 2: Ultrasonic Testing on Tubular Butt Weld and T-Y-K Connection

3.0 Test Coverage

3.1 Parent Metal Examination
Prior to examine the actual weld joint, the entire base metal through which ultrasound must
travel to test the weld shall be tested for laminar reflectors using a straight-beam.

If any area of base metal exhibits total loss of back reflection or an indication equal to or
greater than the original back reflection height is located in a position that will interfere with
the normal weld scanning procedure, its size, location, and depth from the Face A shall be
determined and reported on the UT report, and an alternate weld scanning procedure shall
be used.

3.2 Weld Metal Examination

3.2.1 Tubular Butt-Weld
The weld metal shall be examined with the angle beam probes in accordance to the
material thickness as descript in Table 3.2.1.

Table 3.2.1: Probe selection for UT Scanning on Tubular Butt-Weld

Material Thickness Probe (θº) Scan Area Scanning Distance
70 Weld Top Leg II
6 to 25 mm 70 Weld Center Leg I or Leg II
70 Root Leg I
60 Weld Top Leg II
> 25 to 50mm 70 Weld Center Leg I
70 Root Leg I
45 Weld Top Leg II
> 50 to 100mm 60 Weld Center Leg I
60 Root Leg I

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Appendix 2: Ultrasonic Testing on Tubular Butt Weld and T-Y-K Connection

Figure 3.2.1 – UT Scanning on Tubular Butt-Weld

i. Select an angle probe as descript in Table 3.2.1.

ii. Calibrate the time base with the range cover the beam path length for the
thickness of examination component. Set the sensitive and DAC from 1.5mm
side drill hole. Scanning dB may be increase 12 dB from reference level.
iii. Perform root scanning by using leg I or leg II distance path as illustrated in
Figure 3.2.1. Move the probe along the weld by maintaining the beam
direction perpendicular to the weld axis.
iv. Perform weld body scanning by using leg II distance path. Move the probe to
and fro from haft-skip distance to full skip distance and continue move the
probe along the weld by maintaining the beam direction perpendicular to the
weld axis as illustrated in Figure 3.2.1.
v. UT scanning should be performing from each side of weld axis.
vi. Discontinuities indication shall be interpreted and evaluated as clause 4.0 for
acceptance criteria.

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Appendix 2: Ultrasonic Testing on Tubular Butt Weld and T-Y-K Connection

3.2.2 Tubular T-Y-K Connection

The weld metal shall be examined with the angle beam probes in accordance to the
material thickness as descript in Table 3.2.2.

Table 3.2.2: Probe selection for Tubular T-Y-K Connection.

Material Thickness Probe (θº) Scan Area Scanning Distance
70 & 60 Weld Top Leg II or Leg III
6 to 25 mm 70 Weld Center Leg I or Leg II
70 Root Leg I
60 Weld Top Leg II
> 25 to 50mm 70 Weld Center Leg I
70 & 45 Root Leg I
45 Weld Top Leg II
> 50 to 100mm 60 & 70 Weld Center Leg I
60 & 45 Root Leg I

i. Select an angle probe as descript in Table 3.2.2. Perform root scanning by

using leg I or leg III distance path at section 1, 2 & 3 as illustrated in Figure
3.2.2. Move the probe along the weld by maintaining the beam direction
perpendicular to the weld axis.
ii. Perform weld body scanning by using leg II distance path at section 1, 2 & 3
as illustrated in in Figure 3.2.2. Move the probe to and fro from haft-skip
distance to full skip distance and continue move the probe along the weld by
maintaining the beam direction perpendicular to the weld axis.
iii. Use multiple probes angle as descript in Table 3.2.2, to cover the scanning
area on the root and weld body.

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Appendix 2: Ultrasonic Testing on Tubular Butt Weld and T-Y-K Connection

Figure 3.2.2 – UT Scanning on Tubular T-Y-K Connection.

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4.0 Acceptance Criteria

4.1 For UT are used as an Alternate to RT the acceptance shall follow Class R.
Indications exceeding the disregard level shall be evaluated as follows:
4.1.1 Isolated random spherical reflectors, with 1 in [25 mm] minimum separation up to the
standard sensitivity level shall be accepted. Larger reflectors shall be evaluated as
linear reflectors.
4.1.2 Aligned spherical reflectors shall be evaluated as linear reflectors.
4.1.3 Clustered spherical reflectors having a density of more than one per square inch
[645 square millimeters] with indications above the disregard levels (projected area
normal to the direction of applied stress, averaged over a 6 in [150 mm] length of
weld) shall be rejected.
4.1.4 Linear or planar reflectors whose lengths (extent) exceed the limits of Figure 4.1.4
shall be rejected. Additionally, root reflectors shall not exceed the limits of Class R.

a
Internal linear or planar reflectors above standard sensitivity.
b
Minor reflectors (above di regard level up to and including standard sensitivity). Adjacent reflectors
separated by less than their average length shall be treated as continuous.
Figure 4.1.4 – Class R Indications

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a
Root area discontinuities falling outside theoretical weld are to be disregarded.
Figure 4.1.4 – Class R Indications

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Appendix 2: Ultrasonic Testing on Tubular Butt Weld and T-Y-K Connection

4.2 UT is used for Experience-Based, Fitness for Purpose Criteria Applicable to TYK-
Connections in Structures with Notch-Tough Weldments, the acceptance shall follow Class
X.
Indications exceeding the disregard level shall be evaluated as follows:
4.2.1 Spherical reflectors shall be as described in Class X, except that any indications
within the following limits for linear or planar shall be acceptable.
4.2.2 Linear or planar reflectors shall be evaluated by means of beam boundary
techniques, and those whose dimensions exceeded the limits of Figure 4.2.2 shall be
rejected.
4.2.3 The root area shall be defined as that lying within 1 /4 in [6 mm] or t w / 4, whichever
is greater, of the root of the theoretical weld.

Figure 4.2.2 – Class X Indications

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Appendix 2: Ultrasonic Testing on Tubular Butt Weld and T-Y-K Connection

Figure 4.2.2 – Class X Indications

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