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ULTRASONIC EXAMINATION OF ASTM A‐182 Gr. 321 BARS FOR ECIL
1.0 Scope:
This procedure covers standard recommended practice for ultrasonic testing of solid bars after solution
annealing by contact method.
2.0 MATERIAL AND SIZES:
ASTM A‐182 Gr. 321 bars of sizes 33,66,85,124,240 & 280mm.
3.0 FORM AND STAGES:
Forged / Rolled Bars ‐ Raw material stage after heat treatment / proof machining.
4.0 REFERENCE STANDARDS:
This specification meets the requirement of:
1. ECIL Specs.
2. ASME Boiler & Pressure Vessel Code Section V
3. ASME SA‐745m
4. ASTM E317
5. ASTM E428
6. SNT‐TC‐1A
7. ASME SA‐388
5.0 EQUIPMENT:
Type : ECC Make DS322, MODSONIC Make Einstein II or Equivalent.
Frequency range : 1.0 / 5.0 MHz ( ECC Make / MODSONIC Make )
Depth Range : Up to 5‐meter max.
Probe Size : 10 mm 24 mm Dia, ( ECC Make / MODSONIC Make )
20 X 22 mm / 8 X 9 mm, 45 Deg. (ECC make)
Testing Method : Pulse echo contact method
6.0 PERSONNEL QUALIFICATION:
Personnel performing and evaluating the inspection in accordance with this specification shall be
qualified to at least Level‐II as per
i) BIS ‐ 13805‐2004(1SNT)
ii) SNT‐TC‐1A.
7.0 CALIBRATION OF EQUIPMENT:
7.1 Equipment requirements
The ultrasonic equipment should satisfy the following minimum requirement and Purchaser’s approval
where necessary.
7.1.1 The ultrasonic flaw detector shall be of the pulse‐echo type having A‐scan presentation, capable of
generating frequencies over the range of at least 1 to 5 MHz with a valid calibration certificate
Instrument operating at other frequencies may be used if demonstrated and documented.
7.1.2 Equipment linearity
Screen height linearity and amplitude control linearity shall be met at intervals not to exceed three
month for analogue type instrument and one year for digital type instrument.
a) Screen height linearity
The ultrasonic instrument shall provide linear vertical presentation within ± 5% of the full screen height
for 20% to 80% of the calibrated screen height (base line to maximum calibrated screen points) and the
procedure shall be per ASTM E .317 requirement.
Screen height linearity verification method.
I. Position an angle beam on as calibration block so that indication from the ½ and 3/4 T holes
gives a 2:1 ratio of amplitudes between the two indications. As shown in annexure ‐ 4
II. Adjust the gain so that the larger indication is set at 80% of full screen height (FSH). Without
moving the search unit adjust the gain to successively set the larger indication from 100% to
20% of full screen height in 2 dB increments and read the smaller indication at each setting.
III. The reading shall be 50% of the larger amplitude within 5% of FSH.
IV. Alternately the equipment manufacturer's certification confirming the equipment screen height
Linearity is acceptable.
b) Amplitude control linearity
The ultrasonic instrument shall utilize an amplitude control accurate over its useful range to + 20% of
the nominal amplitude ratio, to allow measurement of indications beyond the linear range of the
vertical display on the screen.
Amplitude control linearity Method.
I. Position an angle beam search unit on a basis calibration block so that the indication from the
1/2 T side drilled hole is peaked on the screen.
II. When adjusting the gain, the indications shall fall within the specified limits as given below:
Indication at % full screen Amplitude Control change Indication limits of
(dB) full screen (%)
80 ‐6 32‐48
80 ‐12 16‐24
40 +6 64‐96
20 +12 64‐96
c) Sweep linearity check
Method to check sweep linearity check
i. Get 10 multiple echoes from the 25 mm metal distance of IIW VI block.
II. By adjusting the range and delay controls to position the leading edge of the 2nd back‐ Wall echo on
main scale divisions 2nd and 8th.
III. In the above setting none of the other echoes should deviate from the main scale divisions by more
than ±1 small scale division of the scale.
d) Alternately the equipment manufacturer's certification confirming the above linearity requirements
in (a), (b) and (c) is acceptable.
7.2 Calibration Check Frequency:
The proper functioning of the equipment and the equipment calibration shall be verified by the use of a
calibration standard, as a minimum, at the following stages:
a) Beginning and end of each examination
b) When examination personnel are changed
c) Every 4 hours during the examination
d) At any time the malfunctioning is suspected
e) When any part of the examination system is suspected
During the calibration check, if it is determined that the testing equipment is not functioning properly or
need recalibration the action shall be as per paragraph 7.1.2
7.3 Calibration check
A calibration check shall verify the sweep range calibration and distance‐amplitude correction.
7.3.1 Check for Sweep range (Distance range check)
a) If any change in the sweep line more than 10% of the sweep division reading or 5% of full sweep
whichever is greater, correct the sweep range calibration and note the correction in the examination
reports.
b) If recordable indications are noted on the examination report, those reports shall be voided, a new
calibration shall be recorded, and the voided examinations shall be repeated.
7.3.2 Check for amplitude calibration (DAC curve‐Reference Block Detail annexure‐2)
a) 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 block shall be marked void. A new
calibration shall be made and recorded and the voided examination areas shall be re‐examined.
b) If any point on the distance‐amplitude correction curve (DAC) 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 examination reports.
7.4 Couplant
(a) A suitable couplant such as SAE 40 or grease with oil having good wetting characteristics shall be
used between the transducer and the examination surface.
(b) The same couplant shall be used for calibration and examination.
8.0 CALIBRATION BLOCKS
8.1 General requirements
8.1.1 Calibration reflectors
The basic calibration reflectors (side drilled holes. flat bottom holes or notches) shall be used to
establish a primary reference response of the equipment.
8.1.2 Calibration block material
Shall be same as Job being examined in terms of acoustic properties.
8.1.3 Calibration block quality
Prior to fabrication, the calibration block material shall be completely examined with a straight beam
search unit.
8.1.4 Calibration block surface finish
The finish on the surfaces of the block shall be representative of the surface inches on the components
to be examined.
8.1.5 Calibration block dimensional tolerance
a) Calibration block metal path distance represents the greater metal travel of the part under
examination with in ± 25 mm
b) Calibration block flat bottom hole diameter tolerance ± 0.03 mm
c) Calibration block flat bottom hole depth tolerance ± 1.6 mm
8.1.6 Curved test surfaces
a) Material with diameter greater than 500mm
For examination in materials where the examination surface diameter is greater than 500 mm, a block of
essentially the same curvature, or alternatively, a flat basic calibration block, shall be used.
b) Materials with diameters 500 mm or less
For examination in materials where the examination surface diameter is 500 mm and less, the basic
calibration block shall be curved. A single curved basic calibration block may be used for examinations in
the range of curvature from0.9 to 1.5 times the basic calibration block diameter.
8.2 calibration blocks for Bars up to 100 mm diameter
Calibration block will be from actual job; Refer annexure ‐ 2 & 3 (Model UT reference block sketch for
straight and angle scanning). Calibration block drawing and Dimensional inspection Report shall be
attached to UT report for all sizes.
9.0 NORMAL BEAM EXAMINATION:
9.1 Normal beam probe requirement
9.2 Normal beam probe calibration
Calibration shall include the complete ultrasonic examination system. The initial calibration must be
performed on the basic calibration block. Checks shall be made to verify the correctness of sweep range
calibration and distance amplitude correction
9.2.1 Normal beam calibration reflectors
a) Calibration reflectors for Bars using Normal beam radial direction and pancakes using thickness and
axial direction testing Calibration reflector shall be a flat bottom hole and the "Hole diameter
"determined by the applicable diameters as detailed below
Forged/Rolled Bar Diameter Acceptance based on FBH hole diameter (mm)
Dia.< 60 mm Dia. Φ 2 mm
Dia.> 60 mm Dia. Φ 3 mm
9.2.2 Normal beam sweep range calibration
For sweep range calibration any one of the following calibration block can be used
* IIW‐V1 calibration block metal distance 25 mm or 100mm.
* IIW‐V2 calibration block metal distance 12.5mm
EXAMPLE 1 ‐ Calibration of 100 mm using IIW‐V1 block 25 mm thick
a) To start with, adjust the initial eco at approximate zero division on the screen
b) Position the straight beam probe on the IIW‐VI block 25 mm thick side and maximize the first
reflection.
c) Adjust the first, second, third and fourth reflections to 2.5. 5.0. 7.5 and scale division by using range
and delay controls.
d) Now the tenth division of the screen represents the 100 mm metal path distance in steel.
9.2.3 Normal beam Amplitude calibration
Distance Amplitude curve calibration (DAC method)
For material thickness up to 600 mm can be tested using DAC method and following are the steps in
constructing the DAC curve;
a) Maximize the amplitude from the calibration reference reflector as per 9.2.1 of applicable
specimen diameter and from the metal path distance representing 1/4 T (or diameter). Mark the
peak amplitude in the screen.
b) Maximize the amplitude from calibration reflector as above for the metal path distances
representing 1/2 T and 3/4T (or diameter) of the specimen and mark the peak amplitude in the
screen.
c) Join all the three points, by a smooth curve this curve represents (the reference level for the
specimen of specified reflector as in 9.2.1 (a).
d) Note down the equipment details such as range and the amplification in dB, the probe details.
The DAC curve drawn is valid for the equipment, probe, set range and set amplitude.
e) Calibration to 1/2 thickness test material distance may be used provided. Examinations from
two opposing surface are made.
9.2.4 Normal beam scanning
a) Scanning speed by manual shall not exceed 150mm per second with an overlap of minimum 10% of
probe diameter between the scans and 100% coverage wherever possible.
b) The scanning for bars and pancakes shall be in radial (Sound beam parallel to the radius) and axial
(Sound beam parallel to axis) directions.
c) The scanning surface roughness shall not exceed 6 um unless otherwise specified.
d) The scanning level shall be +6db minimum to the reference level db and the evaluation of indications
shall be at reference level only.
e) Discontinuity sizing shall be performed by using 6db drop method.
f) Apply transfer loss correction:‐
1) If there is difference in curvature of calibration block and job.
2) Difference in acoustic properties of calibration block and job.
10.0 ANGLE BEAM EXAMINATION
10.1 Angle beam probe requirement
a) Angle beam probe shall have a nominal sizes of 10 to 20 mm diameter or "8X9" mm to"14X14"' mm
rectangle crystal of construction and refracted beam angle of 30° to 70° in the test material with
frequencies 1 to 5 MHz of quartz or piezoelectric material may be used.
b) For circumferential scanning of the bar diameters 100 mm and less, a suitable contour shoe shall be
fixed with the probe to ensure the proper contact with the specimen curvature and better sound
transmission into the specimen.
c) Subminiature probes can be used for angle beam scanning with wedge attachment for small pats of
closed die forgings.
10.2 Angle Beam Calibration
Angle beam calibration consists of sweep range & amplitude calibration. Sweep range calibration shall
be carried out using IIW‐Vl Block or IIW‐ V2 Block quadrant curvatures and amplitude calibration using
appropriate reference notch.
10.2.1 Angle Beam Calibration reflectors (annexure‐3)
Calibration reflectors for bars using angle beam axial & circumferential scanning, and for pancake angle
beam axial scanning shall be as below –
Angle beam Calibration notch details
Notch shape Notch depth Notch length Notch location
Bars: Rectangular with 3% of the Bar diameter 25 mm maximum So as to have no
width not greater than = ±5%depth tolerance surface length interference with each
twice its depth or 60° other as shown in
minimum to 70° (annexure‐3)
maximum
included angle with ‘V’
10.2.2 Angle beam probe 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 2 ; To calibrate 0 to 100 mm range using IIW‐VI calibration block:
a) Position the angle beam towards the 100 mm quadrant and maximize the echo response by
moving the probe front and back parallel to the sides of the calibration block, without any
angulations (Angulations of the probe from parallelism to block edge may‐produce higher
amplitude at a longer beam path; this beam bath shall not be used for calibration)
b) To stat with adjust the initial echo at approximate zero division on the screen.
c) Adjust the first back reflection, from the 100 mm quadrant to tenth division.
d) By using delay control bring first back reflection to exact zero division of the screen.
e) Set the second back reflection from the 100 mm quadrant at tenth division of the screen, by
adjusting both range and delay controls, while the first back wall still positioned at exact zero
division.
f) Using only delay control, bring the first back reflection to tenth 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.
10.2.3 Angle beam amplitude calibration for bars
(A) Construction of DAC curve using circumferential notch for axial scanning
a) Determine the response from the opposite side (half‐node approach) and scan notch side (full
node approach ‐ by rotating the specimen to 180 degree position) with the search unit
positioned to produce the maximum response from each notch.
b) Adjust the sensitivity of the ultrasonic equipment so that the indication from the notch at the
greatest test metal distance is at least 13 mm seep‐to‐peak.
c) Draw a straight line connecting the peaks of the response obtained from the inside and outside
diameter notches. This shall be the primary reference line for axial scanning using full node.
(B) Construction of primary reference line using axial notch for circumferential scanning. For
circumferential scanning curvature shoe may be required suitable to the specimen diameter to
achieve better contact.
a) The probe is positioned so that the sound enters the specimen, in circumferential approach, to
get reflection from the axial direction notch and maximize the indication.
b) Adjust the sensitivity of the instrument so that the indication from the‐axial notch is at least
13mm sweep to peek in magnitude.
c) This shall be the primary reference for the circumferential scanning.
10.2.4 Angle beam Scanning
Apply transfer loss correction:
1) If there is difference in curvature of calibration block and Job
2) Difference in acoustic properties of calibration block and job
11.0 PRE‐EXAMINATION REQUIREMENTS AND EXAMINATION STAGES:
11.1 The supplier shall give sufficient details for job identification and other require information’s about
the job for performing the ultrasonic examination. The bars shall be machined to provide cylindrical
surfaces for radial examination and the ends of the bars shall be machined perpendicular to the axis of
the bar for the axial examination. The surface roughness of exterior finishes shall not exceed 6 µm.
11.2 The test surface shall be free of irregularities; loose foreign matter, which may interfere with
ultrasonic energy transmission. Where required, the test surface may be prepared by buffing or grinding
to improve the sound transmission.
11.3 Examination stages:
11.3.1 Forgings
Forging after heat treatment and proof machining shall be examined by normal beam scanning
as per paragraph 9.0 and by angle beam scanning as per paragraph 10.0 above.
12.0 INTERPRETATION AND EVALUATION:
12.1 Consideration during interpretation
(a) Coarse‐grained austenitic material frequently display sweep noise, particularly when an
examination is performed at high sensitivities: For this reason it is important to critically scrutinize
reportable and reject able indications to determine whether they result from defects or gain structure.
(b) During back‐reflection examination, loss of back reflection results not only from internal
discontinuities but also from coarse or not uniform grain structure , variations in coupling, non parallel
reflecting surfaces, and other factors that must be considered before concluding that the loss of back
reflection is due to discontinuities.
12.2 Acceptance criteria
a) For straight beam:
Indication equal to or greater than reference level is unacceptable.
Indication equal or above 50% of reference shall level be recorded. Length of the indication shall
be recorded by 6 dB drop method.
Indication distinct from the normal noise level & traveling to the left or right on the screen with
movement of the transducer 25 mm or more over the surface of the bar are unacceptable. Two
recordable indication shall be separated by at least the major dimension of the longer
discontinuity otherwise they will consider as single discontinuity shall be evaluated as per 25
mm limit.
If BWE amplitude falls by 50% or more of original amplitude will be unacceptable unless
otherwise it is proved that this is not because of defect.
b) For Angle Beam:
A bar containing a discontinuity that results in an indication exceeding the amplitude of the
reference line is subject to rejection.
Record discontinuity indications equal to or exceeding 50% of the indication from the reference
line. Recordable indications having length more than 25 mm are unacceptable. As per ECIL
Specifications –
13.0 DOCUMENTATION:
All work shall be reported in UT report ‐ Annexure – 1.
13.1 Recorded /rejected reflectors shall have the following information recorded:
a) Job serial number
b) Maximum percent of discontinuity indication in respect to the reference line or indication height
with % of loss of back‐wall for cases based on back‐reflection method.
c) Length of the reflector based on 6 dB drop method.
d) Depth of the Reflector from the Test Surface.
e) Position of the Reflector.
f) The Reference level based on which the indication is assessed.
g) Where required sketches of reflector cross‐sectional positions &/or location drawings.
13.2 Report :‐ ( Refer Format enclosed)
The report shall include the following:‐
Specification to which the examination was performed.
The frequency of search unit.
Size of the search unit.
Surface finish of the job under examination.
Make & Model of instrument.
Couplant used
Percentage of the area scanned.
Direction of scanning.
Material examined.
Heat no/Job identification no.
Job thickness & dimensions examined.
Range calibrated for each scanning.
Gain in dB.
Calibration block identification or details.
Inspector signature with level of qualification.
Procedure no.
Acceptance reference reflector ( FBH Size/Notch dimensions)
Result of examination.
DAC details like beam path, echo height for all the point used for drawing DAC. Range used &.
gain selling.
14.0 INDEX OF ANNEXURES:
Annexure‐1 UT report format (Empty format)
Annexure‐2 Normal beam calibration block for bars.
Annexure‐3 Angle beam probe calibration block bars.
Annexure‐4 Vertical linearity check.
Annexure – 1
UT REPORT FORMAT (Sample)
COMPANY NAME :
ULTRASONIC EXAMINATION REPORT
CUSTOMER :ECIL
REPORT NO: DATE :
JOB/BAR ID : SHEET 1 OF 1
PART NO : BAR DIAMETER
PROCEDURE NO : UT OPERATOR'S NAME &
MATERIAL : SIGNATURE
Ref. PROCEDURE of ECIL :
REFERENCE BLOCK DIM
PRODUCT FORM :
INSPECTION REPORT NO
EXTENT OF EXAMINATIONS :
DAC GAIN GAIN
PROBE CRYSTAL PROBE WAVE JOB RFF ECHO SCANING
FREQ RANGE BEAM DAC SCANED
TYPE DIMN ANGLE MODE DIM BLOCK HTS DIRECTION
PATH TC dB
REFERENCE OF SHEETS FOR RECORDABLE INDICATIONS
COUPLANT SURFACE CONDITION
SCANNING SPEED
EXAMINATION EVALUATION No recordable indication observed SIGNATURE / DATE
EXAMINATION AGENCY ACCEPTED / REPAIR
REMARK
ECIL ‐ QUALITY CONTROL ACCEPTED / REPAIR
REMARK
QS ‐ BARC ACCEPTED / REPAIR
REMARK
Annexure – 2
NORMAL BEAM DAC CALIBRATION BLOCK DETAILS
Details of the Reference Block:
Flat bottom hole diameter:
Ø 3mm for Diameter > 60mm
Ø 2mm for Diameter < 60mm
Block Sketch:
L (Actual Length)
D/4
D/2
3D/4
D
(Actual Diameter)
1 2 3
75% 50% 25%
Page‐16
Annexure – 3
ANGLE BEAM CALIBRATION BLOCK NOTCH DETAILS
Block Sketch:
L (Actual Length)
Circumferential Notch
Axial Notch
D
(Actual Diameter)
A B C
Notch Depth: 3% of thickness with ±5% of depth tolerance.
A – Axial notch distance from edge.
B – Axial notch length.
C – Circumferential notch distance from edge.
D – Diameter of the block.
Annexure – 4
VERTICAL & HORIZONTAL LINEARITY CHEACK OF UT MACHINE
A. Vertical Linearity:‐
1. Calibrate the UFD to 100 mm range by using IIW – block.
2. Couple the probe to 25 mm thickness of IIW – block.
st
3. Set the 1 echo to 100% full screen height & record Reference Gain (RG).
4. Reduce the gain in steps of two dB & record.
RG ‐ 0 100% ‐
B. Horizontal Linearity –
1. Calibrate the UFD to 250 mm by using IIW – block.
2. Couple the probe to 25 mm side of the block.
3. Ten echoes at a distance of 25 mm each will be displayed.
4. If the leading edge of the echoes match the respective scale divisions within ±1%,then the
UFD is horizontally linear.
Result: OK / NOT OK