TITLE:

SUBIC DRYDOCK CORPORATION

ULTRASONIC TESTING PROCEDURE

Document No.: Revision No.: Issue No.:

TEST MEMORANDUM
Ref. No. : SB - 001/TM-56

Vessel Name
Hull Number Work Item Number System / Component : Location Contract Number Description of Test

:
: :

: : : Ultrasonic Test

1.0 OBJECTIVE: To objective of the Ultrasonic Test method stated in this test-memo is for detecting the presence of discontinuities on ships structural and machinery steel forging parts/components to ensure material soundness and good workmanship. 2.0 OBJECTIVE: -To ensure material soundness and good workmanship. -To satisfy all the customers requirements performing NDT inspection. 3.0 GENERAL REQUIREMENTS
3.1 PERSONNEL 3.1.1Personnel performing examinations to the requirements of this procedure shall be qualified and certified in accordance with PNS - ISO 9712 , written practice, guidelines & procedure for Qualification and Certification of Nondestructive Examination Personnel. They will be required to produce evidence of relevant site experience of at least 6 months in the 12 months preceding the date of the assignment. 3.1.2 Only personnel certified as NDE Level II or NDE Level III shall interpret and

Effective Date: January 16, 2012

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TITLE:
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ULTRASONIC TESTING PROCEDURE

evaluate examination results.

Document No.: Revision No.: Issue No.:

3.2

EQUIPMENT 3.2.1 3.2.2 A pulse echo type instrument shall be used with capabilities of generating frequencies over the nominal range of 1 MHz to 5MHz. The instrument shall be equipped with stepped gain control, calibrated in units of 2dB or less. Instruments operating at other frequencies may be used if equal or better sensitivity is demonstrated and documented. Instruments using battery power shall be equipped with a low voltage-warning device. Instrument shall provide a linear vertical presentation and amplitude control accuracy over its useful range and meet other calibration procedure requirements as per calibration plan. Ultrasonic instrument shall provide linear vertical presentation 5% of the screen height at least 80% of the screen height. (see figure 5) Instrument linearity shall be calibrated every (3) months whichever is less. Instrument shall utilize an amplitude control accurate over its useful range to 20% of the amplitude ratio to allow measurement of indications beyond the linear range of vertical display on the screen. The A-scan flaw detector shall comply with the requirements of ASME V, Article 4, section T-431.

3.2.3 3.2.4

3.2.5 3.2.6 3.2.7

3.3

SEARCH UNITS 3.3.1 Straight beam transducers shall have an active crystal area not less than 1/4 inch and not greater than 1 square inch. The frequency shall be 2.25 MHz unless such variables as grain structure require other frequencies for better penetration and resolution. Angle beam transducers shall have an active crystal area of not less than 1/4 inch and not greater than 13/16 inch by 1 inch. The frequency shall be 2 -4 MHZ unless such variables as grain structure requires other frequencies for better penetration and resolution. Angle beam transducer shall have an active crystal area of not less than inch and not greater than 13/16 inch by 1 inch. The frequency shall be 2-4 MHz unless such variables as grain structure require other frequencies for better penetration and resolution. 45 degrees -should be primarily used for examination. However, other angles may be used when part geometry or configurations require the use of other angles such as 60 degree and/or 70 degree. Effective Date: January 16, 2012 Page 2 of 11

3.3.2

3.3.3

3.3.4

TITLE:
SUBIC DRYDOCK CORPORATION

ULTRASONIC TESTING PROCEDURE

Document No.: Revision No.: Issue No.:

3.3.5

Transducers may be equipped with wedges of different angles to maintain adequate sound penetration or proper sound beam angles in the test material. Wedges for curved surfaces, when used, shall have an appropriate radius of curvature for the material being examined. All search units shall conform with the requirement stipulated on ES-S-60 QP Specification, Clause 6.3.2, 6.3.3, 6.3.3.1, 6.3.3.2, 6.3.3.3 and 6.4.2

3.3.6 3.4

COUPLANT 3.4.1 Couplant shall be any material having good wetting characteristics that will provide for the transmission of ultrasound from the search unit to the test material and from the test material to the search unit. When examining nickel base alloys, austenitic stainless steel or titanium, couplant materials shall not exceed a content of 1% by weight with sulphur, chlorine and fluorine.

3.5

CALIBRATION STANDARDS 3.5.1 3.5.2 Calibration Blocks: Basic Calibration Block for construction of DAC Curve, IIW V1 Block, V2 Miniature block shall be used for sound path distance and range calibration Calibration standards shall be made of the same material, product form, material specifications and / or P number grouping as the item being examined. For the purpose of definition P, P 1,P3, P4 and P5 materials are considered acceptable For calibration standards for dissimilar metals, the material selection shall be based on side of the weld of which the exam is being performed. If the exam is being performed from on both sides of the weld, a calibration standard representing both materials shall be used Calibration reflectors shall be made in both materials Where two or more base metal thicknesses are involved, the calibration shall be determined by an average of both thicknesses standard

3.5.3

3.5.4 3.5.5 3.5.6 3.5.7

When inspecting materials with clad surfaces; the standard shall be clad by the same process as the item being examined The standard shall receive the same heat treatment as the material specification used for the item being examined. The post heat treatment shall be a minimum of 2 hours if the standard contains welds other than cladding The surface condition of the standard shall be representative of the surface condition of the item being examined The standard shall be examined by a straight beam search unit. Areas that contain indications exceeding the back reflection shall be excluded from the beam paths required to reach the various calibration reflectors

3.5.8 3.5.9

3.5.10 Basic reference reflectors are cylindrical hole drilled into one side of the block Effective Date: January 16, 2012 Page 3 of 11

TITLE:
SUBIC DRYDOCK CORPORATION

ULTRASONIC TESTING PROCEDURE

Document No.: Revision No.: Issue No.:

and at least 40mm deep. Their diameter shall be of 2 mm. The location and number of holes are determined by the first hole at a depth 10 mm from the contact surface, facing the second one 10 mm and following the 15 mm 3.5.11 A single curved basic calibration standard may be used to calibrate on surfaces in the range of curvature from 0 .9 to 1.5 times the basic calibration standard diameter. For an example, an 8-inch diameter curved standard may be used to calibrate diameters of pipe ranging from 7.2 inches to 12 inches in diameter. An example of ranges is further defined in Figure 2 3.5.12 Calibration standard configuration requirements are shown in Figure 3. Any standards used must be configured to the specifications shown 3.5.13 Independent of the calibration standards noted above, if the client provides other standards to calibrate with, they should be noted and considered acceptable 3.5.14 The temperature of the calibration standard must be within 25 F of the item being examined 3.5.15 Additional to these, calibration blocks shall conform to the ES-S-60 QP Specification, Clause 6.32 and Clause 6.8

4.0

EXAMINATION
4.1 SURFACE CONDITION 4.1.1 The surface of the item being examined shall be free from scale, excessive rust, weld spatter, paint, surface roughness or any extraneous matter that would interfere with the free movement of the transducer or effect the coupling of the transducer to the item being examined. The final prepared surface shall be accepted by the inspector to assure the item is sufficiently cleaned enough to prevent non-relevant or false indications.

4.1.2

4.2

ACCESSIBILITY 4.2.1 4.2.2 Final surface preparation shall include an area from the toe of the weld back to a point such that full volumetric inspection is possible. The volume of base material through which ultrasound will travel in angle beam examination shall be scanned with a straight beam search unit. Any reflectors found that could interfere or affect the interpretation of angle beam examination results shall be recorded as to the area and location of the indication. Any indication that is observed during this scan shall not be considered

4.2.3

Effective Date: January 16, 2012

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TITLE:
SUBIC DRYDOCK CORPORATION

ULTRASONIC TESTING PROCEDURE

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acceptable or rejected, but should be noted on the examination report for further client evaluation. 4.3 STRAIGHT BEAM CALIBRATION 4.3.1 4.3.2 4.3.3 Position the search unit for the maximum first indication from 1/4 t side drilled hole. Adjust the leading edge of this indication to the second major screen division on the screen with the delay control. Position the search unit for the maximum indication from the 3/4 t hole. Adjust this signal such that the leading edge of the signal is at the sixth major screen division on the screen with the range control. Repeat the steps in paragraphs 4.3.1 through 4.3.3 with the delay and range control adjustments until the 1/4 t and 3/4 t hole reflections start at sweep lines 2 and 6. Reference Figure 4 for actual presentation display.

4.3.4

4.4

DISTANCE AMPLITUDE CORRECTION 4.4.1 4.4.2 4.4.3 Position the search unit for maximum response from the hole, which gives the highest amplitude. Adjust the sensitivity or gain control to provide a 80% ( 5% of FSH) of full screen indication from the hole. This shall be considered the reference dB level. Marks the peak of the indication on the screen with a grease pencil or other suitable marker. (make sure the marker used can be removed after the inspection is complete). Position the search unit for maximum response from another hole indication and mark the peak of the indication on the screen. Position the search unit for maximum amplitude from the third hole indication and mark the peak on the screen. Position the search unit for maximum amplitude from the t hole indication after the beam has bound from the opposite surface. The indication should appear at sweep line 10. mark the peak on the screen for 5/4t position Connect the points marked on the screen with a smooth curve, extending the curve to cover the full thickness of the weld. Reference Figure 5 for actual presentation display. This the primary reference level DAC curve for performing straight beam examination.

4.4.4 4.4.5 4.4.6

4.4.7

4.5

ANGLE BEAM CALIBRATION 4.5.1 The sweep range may be calibrated in terms of units of metal path, projected surface distance or actual depth to the reflector as shown in Figure 6. The particular method of examination may be selected according to the preference of the inspector. Effective Date: January 16, 2012 Page 5 of 11

TITLE:
SUBIC DRYDOCK CORPORATION

ULTRASONIC TESTING PROCEDURE

Document No.: Revision No.: Issue No.:

4.5.2 4.5.3 4.5.4

Position the search unit for the maximum first indication from 1/4 t side drilled hole. Adjust the leading edge of this indication to the second major screen on the screen with the delay control. division

Position the search unit for the maximum indication from the 3/4 t hole. Adjust this signal such that the leading edge of the signal is at the sixth major screen division on the screen with the range control. Repeat the steps in paragraphs 4.5.2 through 4.5.4 with the delay and range control adjustments until the 1/4 t and 3/4 t hole reflections start at sweep lines 2 and 6. Reference Figure 6 for actual presentation display. Position the search unit for the maximum response from the square notch on the opposite surface. The indication should appear at or near sweep division 8. Two divisions on the sweep equal 1/4 t.

4.5.5

4.5.6

4.6

DISTANCE AMPLITUDE CORRECTION FROM THE CLAD SIDE 4.6.1 4.6.2 4.6.3 Position the search unit for maximum response from the hole, which gives the highest amplitude. Adjust the gain control to provide an 80% 5% FSH of full screen from the hole. This shall be considered the reference dB level. indication

Mark the peak of the indication on the screen with a grease pencil or other suitable marker. (Make sure the marker used can be removed after the inspection is complete). Position the search unit for maximum response from another hole indication. Mark the peak of the indication on the screen. Position the search unit for maximum response from the third hole indication and mark the peak on the screen. Position the search unit for maximum amplitude from the 3/4 t hole indication after the beam has bounced back from the opposite surface. This indication should appear at sweep division 10. Mark the peak on the screen for the 5/4 t position. Connect the points marked on the screen with a smooth curve extending the full length of the screen. Reference Figure 7 for actual screen presentation display. For calibration for perpendicular reflectors at the opposite surface, Reference Figure 8.

4.6.4 4.6.5 4.6.6 4.6.7

4.6.8

4.7

DISTANCE AMPLITUDE CORRECTION FROM THE UNCLAD SIDE 4.7.1 From the clad side of the block, determine the dB change in amplitude between the 3/4 t and 5/4 t positions. Effective Date: January 16, 2012 Page 6 of 11

TITLE:
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ULTRASONIC TESTING PROCEDURE

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4.7.2 4.6.8. 4.7.3

From the unclad side, repeat the steps noted in paragraphs 4.6.1 through To determine the amplitude for the 5/4 t hole, position the search unit for maximum amplitude from the 3/4 t hole. Decrease the gain control (dB) by the number of dB noted in 4.7.1. Mark the height of this signal amplitude at sweep line 10 (5/4 t). Connect the screen marks to provide the distance amplitude curve. This will permit evaluation of indications down to the clad surface, which should be at or near sweep division 8. For calibration for perpendicular planar reflectors near the opposite surface Reference Figure 6.

4.7.4

4.7.5 4.8

DISTANCE AMPLITUDE CORRECTION FROM NON-CLAD MATERIAL 4.8.1 For distance amplitude correction on non-clad materials follow the steps outlined in paragraphs 4.6.1 through 4.6.8.

4.9

CALIBRATIONS FOR EXAMINATIONS WHERE CALIBRATION STANDARDS ARE NOT AVAILABLE OR FOR SINGLE SIDED EXAMS WITH CUSTOMER APPROVAL 4.9.1 When permitted by the client, if calibration standards are not available for the curvature or thickness of the item being examined or where single side exams are required due to geometry, the following may apply; a) b) c) Position the search unit on the item being examined. Adjust the gain to obtain a signal of 10% of FSH. Adjust the delay and range controls to position the roll of the signal at the fifth major division on the screen. This should allow enough screen to see the entire area of interest in the first and second leg of the sound beam path. Scan the item as further defined in this procedure.

d) 4.9.2

The only evaluation of indications will be that of signal characterization. No amplitude-based evaluations can be performed using this method of examination. Other alternate calibrations may be used proved they meet the minimum sensitivity levels defined in the procedure, are documented on the report and done so with client approval. All reject or dampening controls should be in the off position. If these options are employed, they shall be used during the calibration of the instrument as well as throughout the examination process and so noted on the examination / calibration report.

4.9.3

4.9.4

4.10

CALIBRATION CHECKS Effective Date: January 16, 2012

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TITLE:
SUBIC DRYDOCK CORPORATION

ULTRASONIC TESTING PROCEDURE

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4.10.1

The calibration of the instrument will be checked using the same combination of variables used during the initial calibration as follows: a) b) c) d) At the start and finish of each examination With any change of variables such as transducers, cables, shoes, complaints, or any other item that could affect the calibration of the instrument With any change of personnel At least every four hours of continuous use

4.10.2

If any point on the DAC curve has changed in amplitude of 20% or 2 dB, all data taken during the time since the last accurate calibration shall be considered invalid. If any point on the DAC curve has moved more than 10% of the sweep position reading documented during the initial calibration, all data shall be considered invalid. If the differences noted in paragraphs 4.10. 2 and 4.10.3 have occurred, the instrument shall be recalibrated in accordance with the original calibration requirements and the inspection shall be performed again. Recalibration shall be done if there is any change of operation, transducer, coaxial cable, Transducer, battery, complaint and examiner.

4.10.3

4.10.4

4.10.5 4.11

dB TRANSFER METHOD 4.11.1 When the basic calibration standard has not received the same heat treatment as required in the material being examined, transfer methods shall be used to correlate the responses from the basic calibration standard and from the item being examined. Transfer is accomplished by noting the difference between responses received from the same reference reflector in the basic calibration standard and in the item being examined and correcting for the difference. The reference reflector may be a V-notch, (which must subsequently removed) an angle beam search unit acting as a reflector, or any other reflector which will aid in accomplishing the transfer. The transfer shall be used at the following times; a) b) c) For pipe sizes 2 inches and under, once in every 10 welded joints examined. For sizes over 2 inches through pipe size 18 inch, once in every 5 feet of weld examined. For pipe sizes greater than 18 inches, once for each welded joint examined. NOTE: Each type of material, each size and thickness shall be Effective Date: January 16, 2012 Page 8 of 11

4.11.2

4.11.3

4.11.4

TITLE:
SUBIC DRYDOCK CORPORATION

ULTRASONIC TESTING PROCEDURE

Document No.: Revision No.: Issue No.:

considered separately in applying the transfer method. In addition, the transfer method shall be used at least twice on each type of weld joint. 4.12 SCANNING FOR STRAIGHT BEAM TECHNIQUE 4.12.1 4.12.2 Scanning of the adjacent base metal shall be performed to detect reflectors that could interfere with the interpretation of the angle beam examination. This scan is not intended to be used as an acceptance or rejection of the base metal area. However, all reflectors found should be recorded on the examination report. The entire base metal area that will be subject to coverage with an angle beam search unit shall be examined to the extent possible with the straight beam search unit. The scanning shall be performed at a gain setting of at least + 6dB of the primary reference level. Evaluation shall be performed at the primary reference level. 4.13 SCANNING FOR ANGLE BEAM TECHNIQUE 4.13.1 When scanning for reflectors that are parallel to the weld, the angle beam shall direct at approximate right angles to the weld axis from two directions where possible. 4.13.2 When scanning for reflectors that are transverse to the weld, the angle beam shall direct essentially parallel to the weld axis. 4.13.3 The search unit shall be manipulated or oscillated so that the sound passes through the required volume of weld to be examined as well as the adjacent base metal. 4.13.4 The search unit shall be rotated 180, and the examination repeated.

4.12.3

4.12.4

4.13.5 The scanning level shall be performed at a gain setting of at least +6dB of the primary reference level. 4.13.6 4.14 Evaluation shall be performed with reference to the primary reference level.

OVERLAP 4.14.1 Each pass of the search unit in the scanning pattern shall overlap the preceding pass by a minimum of 10% of the width of the active crystal size.

4.15

RATE OF SCANNING 4.15.1 The speed rate of scanning shall not exceed 100mm per second.

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TITLE:
SUBIC DRYDOCK CORPORATION

ULTRASONIC TESTING PROCEDURE

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5.0

EVALUATION AND RECORDING OF TEST RESULTS

5.1 EVALUATION OF INDICATIONS 5.1.1 Flaw size assessment shall be based upon beam boundary intercept methods (6dB and 20dB drops), and maximum amplitude technique, as necessary. Generally the 6dB technique shall be used for measurement of defect length. The primary reference level for straight beam or angle beam is the primary reference response corrected by the DAC curve. When required, the locations of unacceptable indications will be marked on the test surface. Independent of the requirements in the acceptance criteria noted, any imperfections that are characterized by signal representation to be cracks, incomplete fusion or incomplete penetration shall be unacceptable regardless of discontinuity or amplitude reference.

5.1.2 5.1.3 5.1.4

5.2

ACCEPTANCE CRITERIA

5.2.1 IACS No. 20, Non-Destructive Testing of ship hull steel welds - Table 5 or other approved customer variance.

6.0

RECORDS
6.1 A report shall be completed for each examination. Any interpretation that is doubtful or if differences in interpretation exist, the interpretation shall be resolved by consultation with the responsible NDE Level II. Reports Typical to than shown in sample should be used. If reports other than that shown are used, they shall contain as a minimum, the information required by the client specification noted in Example 1 and should be approved by the client. The information provided shall include: Weld and welder identification Type of weld, weld preparation and joint geometry Material thickness Technique and procedure number Referencing code for acceptance criteria Type of ultrasonic probes and their identification number Effective probe angles on curved surfaces Type of flaw detector and complaint used Time based setting for each probe Scanning sensitivity, including transfer correction Calibration block used

6.2

Effective Date: January 16, 2012

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TITLE:
SUBIC DRYDOCK CORPORATION

ULTRASONIC TESTING PROCEDURE

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Any restrictions or departures from the approval procedure Sketch of the weld showing the position and dimensions of all reportable flaws Amplitude of reportable indications for each probe used in examination Results of examination

Prior to being submitted to the Customer, the ultrasonic reports shall be checked and endorsed by the NDT supervisor.

7.0

REFERENCE DOCUMENTS (Latest Edition & Revision)

7.1 This procedure has been developed using the following documents as reference: API RP 2X ASME V ASTM E164 ASTM A435 ASNT-TC-1A PCN/W/UT/190 Ultrasonic Examination of Offshore Structural Fabrication and Guidelines for Qualification of Ultrasonic Technicians Non-Destructive Examination Standard Practice for Ultrasonic Contact Examination of Weldments Straight Beam Ultrasonic Examination of Steel Plates. Personnel Qualification and Certification in Non Destructive Testing Requirements for the Certification of Personnel engaged in the Ultrasonic Testing of Fusion welded Ferritic Steels in thickness of 6mm and above.

IACS No. 20

Non-Destructive Testing of ship hull steel welds - Table 5

Effective Date: January 16, 2012

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