standard inspection procedure for ultrasonic thickness measurement (repaired)

7/17/2019 Standard Inspection Procedure for Ultrasonic Thickness Measurement (Repaired)

http://slidepdf.com/reader/full/standard-inspection-procedure-for-ultrasonic-thickness-measurement-repaired 1/16

Inspection Procedure for Ultrasonic ThicknessMeasurement

Table of Contents

Section Page No.

1.0 Purpose and Scope ....................................................... 2

2.0 References .................................................................... 23.0 Personnel Qualifications ................................................ 2

4.0 Ultrasonic Equipment and aterials .............................. 3

!.0 E"amination Surface ..................................................... 4

#.0 $ali%ration Procedure .................................................... 4

&.0 et'od of E"amination .................................................. #(.0 Special )ec'nique $onsideration .................................. #

*.0 Post $leaning ................................................................ (

10.0 E"amination Report ....................................................... *

11.0 +cceptance $riteria ....................................................... *)a%le 2 ........................................................................ 10

,igure 1 ....................................................................... 11)a%le 3 ........................................................................ 11

,igure 2 ....................................................................... 12

,igure 3 ....................................................................... 12

)a%le 4 ........................................................................ 12

N-E U) Report ........................................................... 13

U) nstrument /erification Report ................................ 14



1.0 PURPOSE AND SCOPE

1.1 )'is procedure esta%lis'es t'e requirements for anual Ultrasonic )'icness

easurement of materials and ill %e applied 'en Ultrasonic )'icness easurement is

required in accordance it' +SE Section / +rticle ! % t'e referencing $ode. )'is

procedure ill %e used in conunction it' applica%le client specifications.

1.2 )'is procedure ill %e used 'ene5er manual ultrasonic t'icness measurements per

t'e requirements of +SE are specified.

1.3 Ultrasonic e"amination s'all %e performed in accordance it' a ritten procedure

'ic' s'all as a minimum contain t'e requirements found in )a%le 1.0.

Table 1.0Va ria ble s of a n Ult ra sonic E xa mination

Proce dre

Requirement

Essential

/aria%le

Nonessential

/aria%le

aterial tpes and configurations to %e e"amined including t'icness dimensions and product form

6casting forgings plates etc.7.

Personnel qualification requirements.

Personnel performance requirements 'en required.

)'e surfaces from 'ic' t'e e"amination s'all %e performed.

Surface condition 6e"amination surface cali%ration %loc7.

$ouplant8 %rand or tpe.

)ec'nique6s7 6straig't %eam angle %eam contact and9or immersion7.

+ngle6s7 and mode6s7 of a5e propagation in t'e material.Searc' unit tpe6s7 frequenc 6ies7 and element si:e6s7 s'ape6s7.

Special searc' units edges s'oes or saddles 'en used.

Ultrasonic instrument6s7.

$ali%ration ;cali%ration %loc6s7 and tec'nique6s7<.

-irections and e"tent of scanning.

+utomatic alarm and9or recording equipment 'en applica%le.

Scanning 6manual 5s. automatic7.

$omputer en'anced data acquisition 'en used.

Records including minimum cali%ration data to %e recorded 6e.g. instrument settings7.

Scan o5erlap 6decrease onl7

=

=

=

=

==

=

=

=

=

=

=

=

=

=

=

=

=

1.4 >'en procedure qualification is specified a c'ange of a requirement in )a%le 1.0

identified as an essential 5aria%le from t'e specified 5alue or range of 5alues s'all

require requalification of t'e ritten procedure.

1.! + c'ange of requirement identified as a nonessential 5aria%le from t'e specified

5alue or range of 5alues does not does not require requalification of t'e ritten

procedure.



1.# +ll c'anges of essential or nonessential 5aria%les from t'e 5alue or range of

5alues specified % t'e ritten procedure s'all require re5ision or an addendum to t'e

ritten procedure.

!.0 RE"ERENCES

2.1 )'e latest re5ision or re5ision stated in t'e contract of t'e folloing referenced

documents is applica%le to and 9or form t'e %asis of t'is procedure8

2.1.1 +SE ?oiler and Pressure /essel $ode Section / @NonAdestructi5e E"aminationB

6Cul 20037

2.1.2 +S) EA114 @Recommended Practice for Ultrasonic PulseAEc'o Straig'tA?eam

)esting % t'e $ontact et'od 620017

2.1.3 +S) EA31& @Standard Practice for E5aluating Performance $'aracteristics of

Ultrasonic PulseAEc'o )esting Sstems it'out t'e Use of Electronic easuring

nstrumentsB 61**&7.

21.4 +S) EA&*& @Standard Practice for easuring )'icness % anual Ultrasonic

PulseAEc'o $ontact et'odB 620017

2.1.! +ES N-EAQ$A1 @Qualification and $ertification of NonAdestructi5e E"aminationPersonnelB.

2.1.# +SN) SN)A)$A1+ 620017 $PA1(* 620017 and +$$P 6Re5ision3 No5em%er 1**&7.

2.2 )'is procedure ill %e superseded onl 'en an equal or more stringent requirement

is specified % t'e customerDs purc'ase order or contract and is appro5ed % t'e +))

$orporate e5el .

#.0 PERSONNE$ %UA$&"&CAT&ON

3.1 Personnel performing Ultrasonic )'icness easurement ill %e certified to at least

e5el Ultrasonic E"amination 6U)7 in accordance it' procedure +)) N-EAQ$A1

FQualification and $ertification of NonAdestructi5e E"amination PersonnelF.



3.2 + su%contractor ma use t'eir Qualification and $ertification procedures 'en

appro5ed % t'e +)) $orporate e5el and meeting t'e requirements of Section 2.1.#.

3.3 U) e5el and ll personnel ma perform all operations necessar in accordance

it' t'is procedure to process t'e o%ects %eing e"amined. E"cept t'at e5el personnel

s'all recei5e t'e necessar super5ision and guidance from certified U) e5el or e5el

personnel.

3.4 nterpretation and e5aluation of ultrasonic e"amination results ill onl %e

accomplis'ed % personnel certified as U) e5el or ll.

'.0 U$TRASON&C E%U&P(ENT AND (ATER&A$S

4.1 )'e folloing are t'e requirements for t'e Ultrasonic )'icness

easurement E"amination Equipment.

4.1.1 )'e instrument s'all %e of t'e pulseAec'o tpe and must 'a5e a $R) or digital and

$R) displa.

4.1.2 )'e instrumentDs 'ori:ontal limit and linearit Paragrap' (.4 screen 'eig't

linearit paragrap' (.! and amplitude control linearit paragrap' (.# s'all %e 5erified

e5er 3 mont's or prior to first use t'ereafter.

4.1.3 )'e instrument s'all %e cali%rated at inter5als no longer t'an 12 mont's to reference

standards tracea%le to t'e National nstitute of Standards and )ec'nologies 6NS)7 and

meet or e"ceed t'e manufacturerDs tolerances and specifications.

4.1.4 +n frequenc and si:e searc' unit ma %e selected as long as it is capa%le of

resol5ing t'e t'icness range %eing measured pro5ided t'at it meets t'e manufacturerDs

recommendations and client specifications.

4.1.! )'e searc' unit ma %e single element dela line or dual element contact

transducers.

4.1.!.1 Searc' unit selected s'all 'a5e sufficient crstal to surface contact to produce

sta%le readings. Gn smaller diameter pipe 3.!0B and less a small diameter searc' unit or

cur5ed standoff s'oe ma %e required.

4.2 $ouplant ma %e ater glcerine cellulose gel 6gum7 oil grease or speciall

formulated commerciall a5aila%le materials.

4.2.1 n'i%itors and9or etting agents ma %e used.

4.2.2 )'e c'emical interaction or t'e corrosi5e nature of an couplant it' t'e material6s7

%eing e"amined ill %e considered 'en maing t'e c'oice of couplant.



4.3 )'e reference standards material from 'ic' t'e %loc is fa%ricated s'all %e of t'e

same product form material specification or equi5alent PA Num%er grouping and 'eat

treatment as t'e material %eing e"amined. )'e finis' on t'e scanning surface of t'e %loc

s'all %e representati5e for t'e scanning surface on t'e material to %e e"amined and8

4.3.1 S'all 'a5e at least t'ree steps8

4.3.1.1 )'e t'inner step s'all 'a5e a t'icness it'in H10I of t'e 5alue stated in t'e

column mared @oer stepB of ta%le 2 for t'e t'icness range to %e tested.

4.3.1.2 )'e t'icer step s'all 'a5e a t'icness it'in H10I of t'e 5alue stated in t'e

column mared @Upper stepB of ta%le 2 for t'e t'icness range to %e tested.

4.3.1.3 )'e t'ird step and t'e minimum t'icness to %e tested s'all fall it'in t'e

@G%ecti5e )'icness RangeB and %eteen t'e t'in and t'ic cali%ration steps. )'e t'ird

step s'all %e mac'ined it' a flat %ottomed 'ole in accordance it' figure 1 and ta%le 2.

4.3.2 )'e p'sical dimensions ill %e it'in H 1I of t'e nominal t'icness of t'e

step.

4.3.2.1 )'e measurement of t'e steps ill %e performed it' a cali%rated mec'anical

instrument tracea%le to NS).

).0 E*A(&NAT&ON SUR"ACE

!.1 Surfaces ill %e uniform and free of loose scale and paint discontinuities suc' as

pits or gouges eld spatter dirt or ot'er foreign matter 'ic' ma ad5ersel affect test

results.

!.1.1 )ig'tl ad'ering paint scale or coatings do not necessaril need to %e remo5ed for

testing if t'e present uniform attenuation c'aracteristics.

!.2 Surfaces ma %e ground sanded ire %rus'ed scraped or ot'erise prepared for

e"amination purposes 'en necessar.

!.3 n areas 'ere se5ere pitting is e"perienced and 'ere surface preparation is

not recommended readings ill %e taen on 'ig' areas and pit dept' ill %e measured %mec'anical dept' gauges. +s an alternate an ultrasonic pencil tip pro%e ma %e used if

t'e customer desires.



+.0 CA$&,RAT&ON PROCEDURE

#.1 )'e proper functioning of t'e e"amination equipment ill %e c'eced and t'e

equipment ill %e cali%rated % use of t'e reference standard as descri%ed in paragrap'

4.3 at8

#.1.1 )'e %eginning and end of eac' e"aminationJ

#.1.2 >'en e"amination personnel are c'angedJ

#.1.3 +ntime t'at a malfunction or improper operation is suspected 6i.e. unusuall 'ig'

or lo readings7J

#.1.4 >'en searc' units are c'angedJ

#.1.! >'en ne %atteries are installed or electrical outlet is c'angedJ

#.1.# >'en equipment operating from one poer source is c'anged to anot'er poer

source or e"periences poer failure.

#.2 f during a cali%ration it is determined t'at t'e e"amination equipment is not

functioning properl or it is found to %e out of cali%ration all of t'e measurements since

t'e last 5alid equipment cali%ration ill %e retaen.

#.3 $ali%ration s'all %e accomplis'ed using t'e same couplant as t'at to %e used 'en

measurements are %eing taen.

#.3.1 >'en special form 'ig' temperature couplant is %eing used a different couplant

ma %e used for cali%ration.

#.3.2 )'e temperature of t'e cali%ration %loc s'all %e it'in H 2!K , of t'e test specimen.

NOTE

+ll ultrasonic measurements s'all %e made at a t'res'old setting of 20 I,SL.

#.4 $ali%ration s'all %e esta%lis'ed it' t'ree non t'icness.

#.4.1 -etermine t'e o%ecti5e t'icness from ta%le 3

#.4.2 Place t'e transducer on t'e t'in step and adust t'e instrument to read t'e step

it'in H .001 inc' of t'e actual step t'icness.

#.4.3 Place t'e transducer on t'e t'ic step and adust t'e instrument to read t'e step

it'in H .001 inc' of t'e actual step t'icness.

#.4.4 Repeat #.4.2 and #.4.3 until t'e instrument reads %ot' steps it'in t'e H .001 inc'

tolerance it'out furt'er adustment.



#.4.! Ultrasonicall measure t'e o%ecti5e t'icness. )'e t'icness s'all %e it'in H .001

inc' of its actual t'icness.

#.! Main transfer s'all %e esta%lis'ed in t'e folloing manner8

#.!.1 Place t'e transducer on t'e reference cali%ration t'icness closest to t'e

corresponding material t'icness %eing e"amined. Note signal strengt' and gain control

setting.

#.!.2 Place t'e transducer on t'e test material in an area it' a uniform %acAall

reflection free from an indications and representati5e of sound material.

#.!.3 G%ser5e t'e signal le5el and adust t'e gain control to produce t'e same signal

'eig't or response as noted from t'e cali%ration %loc. Note t'e gain control setting.

#.!.4 Su%tract t'e gain control 5alue in #.!.1 from t'at in #.!.3. )'is num%er 6positi5e or negati5e7 is t'e gain transfer.

#.# Scanning sensiti5it.

#.#.1 Place t'e transducer on t'e o%ect step and ma"imi:e t'e response from t'e flat

%ottom 'ole. G%ser5e t'e signal le5el and adust t'e gain control to produce a signal t'at

is (0I ,SL.

#.#.2 Repeat t'e steps in paragrap' #.4 and 5erif t'e sstem meets t'e required

tolerance.

#.#.3 +dd t'e gain transfer amount 6#.!.47 to t'e reference setting 6#.#.17.

)'is is t'e gain control sensiti5it setting for scanning.

#.& +ll cali%rations s'all %e recorded. )'e setup parameters used including gain

percent screen 'eig't setting time of cali%ration and t'e identification of t'e

operator performing t'e cali%ration.

-.0 (ETOD O" E*A(&NAT&ON

&.1 $ouplant ma %e applied to t'e searc' unit or directl on t'e component %einge"amined.

&.2 )'e e"tent of t'e e"amination and t'e location of t'e readings ill compl it' t'e

referencing code and t'e customer requirements.

&.2.1 Readings ma %e taen at randoml selected locations or taen in specified grid

patterns as required.

&.3 Scanning speeds ill not e"ceed a rate of # in.9 sec.



/.0 SPEC&A$ TECN&%UE CONS&DERAT&ONS

(.1 -ual transducer element searc' units are in'erentl nonlinear for t'icnessmeasurements less t'an 0.12!F.

(.1.1 f measurements %elo 0.12!F must %e made it' dual transducer element searc'

units cali%ration must %e accomplis'ed it' at least 3 t'icness steps %elo 0.12!F it'in

t'e range of t'e e"pected readings. +dditionall t'e proposed tec'nique s'all %e in

accordance it' manufacturerDs recommendations and applica%le client specifications.

(.2 >'en testing steel at ele5ated temperatures a%o5e 200K, and up to 1000K,

speciall designed searc' units and couplant s'all %e used.

NOTE

)o compensate for reading errors due to ele5ated temperatures t'e folloing s'all %e

used. )'e apparent t'icness reading o%tained from steel alls 'a5ing ele5ated

temperatures is 'ig' 6too t'ic7 % a factor of a%out 1I per 100K,. )'us if t'e instrument

as cali%rated on a piece of similar materials at #(K , and if t'e reading as o%tained

it' a surface temperature of (#0K , t'e apparent reading s'ould %e reduced % (I.

(.3 $onsideration must %e gi5en to t'e %acAall ec'o during testing.

(.3.1 >'en encountering all t'inning due to corrosion t'e roug'ening of t'e %ac

surface can affect t'e amplitude and s'ape of t'e %acA all ec'o. Suc' a c'ange in t'e

%acAall ec'o s'ould %e noted.

(.3.2 >'en encountering all t'inning caused % erosion t'e %ac all ec'o mig't

disappear as t'e s'arplAangled far surface reflects t'e incident a5e aa from t'e

transducer. f t'e %ac all ec'o disappears for t'is or an ot'er reason suc' as a%rupt

t'inning into t'e near surface region t'e cause ill %e in5estigated it' s'ear a5e

transducers or ot'er inspection tec'nique as appropriate. Suc' a disappearance of t'e

%acAall ec'o can indicate a critical degree of t'inning and must %e e"plored until t'e

reason for suc' a loss of signal is defined.

(.3.3 ndications %eing displaed at or near t'e %acAall ma %e a%sor%ed into t'e

%acAall signal and initiall appear to %e t'e inner diameter 6-7 connected. nterpretation

s'all %e performed at loer gain settings to determine if to separate signals e"ist. +

loer amplitude signal in front of a 'ig'er amplitude %acAall signal ma indicate a near

- inclusion. f an question e"ists t'e area s'all %e in5estigated it' a s'ear a5e

searc' unit to determine if an - corner trap e"ists %eteen t'e indication and t'e %acA

all.



(.4 Lori:ontal limit and linearit

(.4.1 $ouple a longitudinal transducer 2.2! to !.0 L: to an > %loc 6or equi5alent

t'icness7 as not to intercept an test 'oles 6figure

27. )'e couplant used must pro5ide sta%le indications during t'e measurements.

NOTE

+ll multiple positioning and position measurements s'all %e made it' t'e respecti5e

%acAreflection set at !0I of full screen 'eig't.

(.4.2 +dust t'e instrument gain seepAdela and seepAlengt' controls to displa

ele5en nonAinterfering %ac reflections. ,urt'er adust t'e seep controls to position t'e

leading edge of t'e t'ird and nint' %ac reflections at 20I and (0I 'ori:ontal screen

di5isions respecti5el.

(.4.3 Read and record eac' scale position on a U) nstrument /erification Report

form 6attac'ed7 and plot. Record greatest linearit error in I of full 'ori:ontal scale.

(.4.4 Lori:ontal limit is gi5en % t'e ma"imum a5aila%le trace lengt' falling it'in t'e $R)

gradticule lines e"pressed in linear units 6inc'es or millimetres7. Unless ot'erise

noted t'is is also assumed to represent 100I full screen. ,ailure to o%tain fullAscale

deflection ma indicate an equipment malfunction.

(.4.! Record all data and conformance on a U) nstrument /erification Report form

6attac'ed7.

(.! Screen 'eig't linearit

(.!.1 $ouple a longitudinal transducer 2.2! to !.0 L: to a distance sensiti5it 6-S7

%loc 6or equi5alent7 so t'at indications from t'e 2 inc' and 4 inc' %acAreflection can %e

o%ser5ed 6figure 3 position +7.

(.!.2 +dust t'e searc' unit position to gi5e a 281 ratio of amplitude %eteen t'e to

indications.

(.!.3 >it' t'e larger set at (0I of full screen 'eig't 6,SL7 and it'out mo5ing t'e

searc' unit adust gain to successi5el set t'e larger indication from 100I to 20I of full

screen 'eig't in 10I increments.

(.!.4 Read t'e smaller indication at eac' setting. )'e smaller reading must %e !0I of t'e

larger reading amplitude it'in !I of ,SL. )'e settings and readings must %e estimated

to t'e nearest 1I of ,SL.

(.!.! Record all data and conformance on a U) nstrument /erification Report form

6attac'ed7



(.# +mplitude control linearit

(.#.1 $ouple a longitudinal transducer 2.2! to !.0 L: to a -S %loc 6or equi5alent7 so

t'at t'e 4 inc' %acAreflection is peaed on t'e screen 6figure 3 position ?7.

(.#.2 >it' an increase and decrease in gain as s'on in ta%le 3 t'e indication must fall

it'in t'e specified limits.

(.#.3 Record conformance on a U) nstrument /erification Report form 6attac'ed 17.

.0 POST C$EAN&N

*.1 mmediatel upon completion of t'e e"amination t'e couplant s'all %e remo5ed %

a suita%le cleaning met'od.

*.1.1 )'e considerations of paragrap' 4.2.2 s'all also appl for t'e cleaning agents.

10.0 E*A(&NAT&ON REPORT

10.1 )'e folloing data ill %e recorded as a minimum for future reference at t'e time of

eac' e"amination and included in t'e report8

10.1.1 Part num%er identificationJ

10.1.2 Gperators name and certification le5el8

10.1.3 nstrument description mae model serial num%erJ and NS) )racea%le

cali%ration due dateJ

10.1.4 Setup A couplant ca%le tpe and lengt'J

10.1.! Searc' unit description A tpe si:e frequenc special s'oesJ

10.1.# Reference standards si:e and material tpesJ

10.1.& Record required instrument settingsJ

10.1.( Scanning met'od and an limitationsJ

10.1.* Eac' t'icness measurement and its locationJ

10.1.10 Reference to t'is procedure.



11.0 ACCEPTANCE STANDARDS

11.1 +cceptance or reection of a component ill %e %ased on customer requirements

and9or t'e minimum design t'icness alloed % t'e referencing code.

(aximm T2ic3ness (inimm

lo4er Ste5 Tar6et U55er Ste5

.03B Up to .12!B incl. .20B

.10B o5er .12!B t'roug' .3&!B .!0B

.10B o5er .3&!B t'roug' .!0B .#2!B

.2!B o5er .!0B t'roug' .&!0B .*0B

.!0B o5er .&!0B t'roug' 1.00B 1.30B

.!0B o5er 1.00B t'roug' 1.2!B 1.#0B

.&!B o5er 1.2!B t'roug' 1.!0B 1.*0B

1.00B o5er 1.!0B t'roug' 1.&!B 2.1!B

1.00B o5er 1.&!B t'roug' 2.00B 2.!0B

1.00B o5er 2.00B t'roug' 2.2!B 2.(0B

1.!0B o5er 2.2!B t'roug' 2.!0B 2.*0B

1.!0B o5er 2.!0B t'roug' 2.&!B 3.00B

2.00B o5er 2.&!B t'roug' 3.00B 3.!0B

2.00B o5er 3.00B t'roug' 3.2!B 3.&!B2.00B o5er 3.2!B t'roug' 3.!0B 4.00B

2.00B o5er 3.!0B t'roug' 3.&!B 4.2!B

2.00B o5er 3.&!B t'roug' 4.00B 4.!0B

2.00B o5er 4.00B t'roug' 4.2!B 4.&!B

Table #

T2ic3ness Testin6 Reference Table for

$o4er7 Tar6et7 and U55er ,rac3et Ran6es.



"i6re 1Calibration Standard

,lat ?ottomaterial )'icness Lole -ia. H1932 in.

Up to 1 in. 191# in.

G5er 1 to 2 in. 19( in.G5er 2 to 3 in. 391# in.G5er 3 to 4 in. !91# in.G5er 4 in. 39( in.

MENER+ NG)E8,lat %ottom 'oles mac'ined to a minimum dept' of 19( inc'parallel to t'e transducer contact surface.

Table !"l a t , o t t om ole R e 8i re m e n t s



"i6re !

"i6re #



&ndication Set at d, Control &ndication $imits

9 of "ll Screen C2an6e 9 of "ll Screen

/09 :+ d, #! 9 to '/9

/09 :1! d, 1+9 to !'9

'09 ;+ d, +'9 to +9

!09 ;1! d, +'9 to +9

Table '



100

*0

(0

&0

#0

!0

40

30

20

-ate8

NS)RUEN) +OE8 NS)RUEN) G-E NS)RUEN) SER$+ 8 $+ -UE -+)E8

U$TRASON&C &NSTRU(ENT VER&"&CAT&ON REPORT

$GUP+N) and ?+)$L 8 $+?E )PE8 $+?E ENM)L8 RE,EREN$E ?G$O8

)R+NS-U$ER )PE8 )R+NS-U$ER SE8 )R+NS-U$ER ,REQUEN$8 )R+NS-U$ER SER+ 8

?+$ORE,E$)GN

OR&<ONTA$ $&(&T AND $&NEAR&T=

11

10

*

(

&

#

!

4

3

2

1

0 10 20 30 40 !0 #0 &0 (0 *0

100PGS)GN G, SMN+ GN S>EEP )R+$E A I ,U S$+E

dealinearit ine

MRE+)ES ERRGR6I ,U LGRGN)+ S$+E7

SCREEN E&T $&NEAR&T=!> Res5onse '> Res5onse 9 Error

A(P$&TUDE CONTRO$ $&NEAR&T=

N-$+)GN SE) +)I ,U S$REEN

d? $GN)RG$L+NME

&ND&CAT&ON $&(&TS9 "U$$ SCREEN

N-$+)GN SE) +)I ,U S$REEN



)'is sstem meets t'e requirements for Lori:ontal imitand linearit screen 'eig't linearit and +mplitude $ontrolinearit as stated in +SE Section / +rticle 4.

)ec'nician8 e5el8

(0 A# d? 32 4(I

(0 A12 d? 1# 24I

40 H# d? #4 *#I

20 H12 d? #4 *#I

standard inspection procedure for ultrasonic thickness measurement (repaired)

Documents