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AMIGOS TECHNICAL SERVICES (S) PTE LTD
OPERATING PROCEDURE
ULTRASONIC TESTING
DATE
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ATS-UT-001
REVISION
0.0
PREPARED BY APPROVED
Name:
Signature:
Date :
Name: J. AFFANDI
Signature:
Date :
REVISION STATUS:
S.NO REVISION No. DATE DESCRIPTION
1 FIRST ISSUE
STANDARD PRACTICE INSTRUCTIONS/OPERATING PROCEDURES CONTAINED IN
THE COMPANY QUALITY ASSURANCE SYSTEM ARE CONTROLLED BY THE
QUALITY ASSURANCE MANAGER AND MAY NOT BE IN ANY WAY REVISED OR
AMENDED WITHOUT HIS AUTHORITY.
The signatures above indicate Review and Authorization of all the numbered pages in this Standard
Document.
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CONTENTS
1. SCOPE
2. REFERENCE DOCUMENT
3. QUALIFICATIONS
4. RESPONSIBILITIES
5. PROCEDURES
6. REPORTING
7. ACCEPTANCE CRITERIA
8. ATTACHMENTS
9. DOCUMENTS
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ABBREVIATION
API - AMERICAN PETROLEUM INSTITUTE
AWS - AMERICAN WELDING SOCIETY
ASME - AMERICAN SOCIETY OF MECHANICAL ENGINEERS
ASTM - AMERICAN SOCIETY FOR TESTING MATERIALS
ASNT - AMERICAN SOCIETY FOR NON DESTRUCTIVE TESTING
MHz - MEGA HERTZ
IOW - INTERNATIONAL ORGANIZATION OF WELDING
IIW - INTERNATIONAL INSTITUTE OF WELDING
DAC - DISTANCE AMPLITUDE CORRECTION
FSH - FULL SCREEN HEIGHT
dB - DECIBELL
CRT - CATHODE RAY TUBE
HAZ - HEAT AFFECTED ZONE
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1.0 SCOPE
This procedure is prepared to inspect base metal and fusion welded butt joints in ferritic
steel by Manual Ultrasonic Method.
2.0 REFERENCE DOCUMENTS
2.1 ASME Section V- Article-4, 5 & 23 (2007 Edition ) –
Boiler and Pressure Vessel Code
2.2 ASME /ANSI B31.3 (2008 edition) –
Chemical Plant and Petroleum Refinery Piping
2.3 AWS-D 1.1 (2008 edition) – Structural Welding Code
3.0 QUALIFICATIONS
3.1 The Personnel who carry out Ultrasonic Testing shall be qualified Level-II as per
SNT-TC-1A (2006).
3.2 Alternately a level-1 qualification is acceptable, provided the work is carried out
under the direct supervision of a qualified Level-2 Technician.
him.
4.0 RESPONSIBILITIES
An Ultrasonic Operator / UT Technician shall be responsible for performing ultrasonic
examination according to this procedure.
5.0 PROCEDURES
5.1 EQUIPMENT
5.1.1 Ultrasonic Flaw Detector shall be Portable; Pulse echo unit with rectified
A – Scan display. (E.g. Krautkramer–USK6, USK7, USK7D or equivalent).
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5.1.2 Straight Beam search units shall be of standard manufacturer, either twin
or single crystal with a nominal frequency of 4 MHz-5 MHz for less than
50 mm job thickness and 2.0 -2.5 MHz for job more than 50 mm job
thickness, crystal diameter of 10 – 25mm.
5.1.3 Angle Beam search units shall be of standard manufacturer, either twin or
single crystal with a nominal frequency of 4 MHz-5 MHz for less than 50
mm job thickness and 2.0 -2.5 MHz for job more than 50 mm, crystal
dimensions of 8x9mm or 10mmØ.
5.2 REFERENCE BLOCKS
5.2.1 Reference blocks used for equipment calibration shall be as follows
5.2.2 IIW or V1 Block
5.2.3 V2 (Din 54122) Block
5.2.4 IOW Beam Profile Block
5.2.5 Basic Calibration Block of ASME Section-V, Article-5
5.3 COUPLANT
5.3.1 A suitable coupling medium for acoustic transmission is required.
5.3.2 Glycerin, light machine oil, cellulose paste, non-corrosive gel or
equivalent may be used.
5.3.3 Suitable high temperature grease shall be used as a couplant when doing
high temperature testing.
5.4 CALIBRATION OF EQUIPMENT
5.4.1 Manufacturers certificate of calibration shall be available with each new
flaw detection unit. Annual re-calibration and certification shall be carried
out by manufacturers agent or recommended third parties.
5.4.2. In addition to the above, the ultrasonic operator shall carry out following
equipment checks prior to conducting any test.
Time base linearity Equipment Performance checks as per
Screen Height Attachment-I
Linearity
Amplifier linearity
Probe resolution
Probe Index Probe characteristics check as per
Attachment-II
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5.4.3 A record for all equipment checks shall be maintained in the standard
format.
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5.5 SURFACE CONDITION
5.5.1 Scanning surface shall be smooth, clean and free of scale, spatter, pitting,
paint or any imperfection that might impair the coupling between the
probe and the work piece.
5.5.2 Dressing of weld profile may be carried out to eliminate or resolve
confusing surface echoes/mode conversions.
5.5.3 Where it is otherwise impossible for the ultrasonic beam to interrogate the
full cross-section of the weld, the weld profile shall be dressed smooth.
5.6 TRANSFER CORRECTION
5.6.1 Transfer correction shall be carried out to compensate for differences in
surface condition and material composition between calibration block and
test component. It is a requirement to determine a transfer correction
factor and adjust basic sensitivity prior to any test. It shall be carried out as
follows:
5.6.2 Connect two – shear wave probes of same angle, type to the UFD in
transmitter & Receiver mode.
5.6.3 Position the probes on the basic calibration block facing each other.
5.6.4 Maximize the Full skip distance echo and keep it at 80% of full screen
height (Refer Fig.5.1). Mark the signal on the UFD screen.
5.6.5 Reposition the probes in order to get the double skip distance echo and
maximize it (Refer Fig.5.2). Mark the signal on the screen.
5.6.6 Join the two points together in a straight line marked across the screen
(Refer Fig.5.3).
5.6.7 Without altering the gain control setting, transfer the probes to the surface
of the test piece. Using the same method described above, obtain peaked
signals at full and double skip distances. Join the peaks together in a
straight line on the flaw detector screen.
5.6.8 The difference in dB between the two lines at comparable time base range
represents the transfer correction factor.
5.6.9 The transfer correction factor shall be added to the primary reference level
prior to the commencement of examination.
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Sketches for Transfer Correction Factor
Transmit Receive
Page 8 of 23
Transmit Receive
Full skip distance
Figure 5.1
Double skip distance
Figure 5.2
80%FSH
Line 1
Line 2
Test piece at
Full Skip
Basic Cal. Block
at Full Skip
Basic Cal. Block
at Double Skip
Test piece at
Double Skip
TCF
Figure 5.3

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5.7 BEAM PATH CALIBRATION, SENSITIVITY SETTING AND DAC
5.7.1 Beam path Calibration and sensitivity setting shall be made by the
ultrasonic operator at the work location, immediately prior to he
commencement of test.
5.7.2 Straight beam calibration shall be made to display at least two back wall
echoes on the CRT screen.
5.7.3 Straight beam sensitivity shall be adjusted such that the first back wall
echo is set at 80% FSH.
5.7.4 Angle beam calibration shall be made for the beam path length that is
sufficient to ensure complete coverage of weld. This may vary from 0-0.5
Skip Beam Path to 1.5 Skip Beam Path depends up on accessibility for
scanning.
5.7.5 Angle beam sensitivity shall be set using a DAC curve in accordance with
the requirements of the applicable code as described in the attachment-III.
Scanning sensitivity shall be 6 dB above the primary sensitivity.
5.7.6 The flaw detector unit shall have minimum 20dB gain in reserve above
basic sensitivity.
5.7.7 Recalibration of beam path shall be made every 30 minutes during testing,
after any change of probe, coaxial cable or battery, or after any change of
work location.
5.7.8 Suppression control shall be off during calibration.
5.8 TEST PROCEDURE
5.8.1 Straight beam examination shall be carried out on the base metal to ensure
that the angle beam scanning area is free of lamination or any
imperfections that might interfere with the angle beam test.
5.8.2 Any area of base metal with indications excess or equal to back wall echo
or any area in which the back wall echo is completely lost shall be
reported.
5.8.3 Straight beam examination of attachment welds shall be carried out where
access is possible.
5.8.4 Scanning patterns for angle beam probes shall be established in
accordance with size and geometry of the test joint. Selection of probe
angles and scanning surface shall be designed to achieve optimum
coverage of weld metal volume.
5.8.5 Scanning patterns for each joint type shall be specified in a technique
sheet appended to this procedure.
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5.8.6 Probe movement during scans shall be a combination of lateral and
traversing actions. Each scan shall overlap by at least 10%. Rotational and
orbital probe movements shall be used for assessment of indications.
5.8.7 Transverse scanning shall be carried out from weld cap if possible.
Alternately scanning shall be done on the parent metal adjacent to weld at
an angle of <15° to the weld axis.
5.8.8 The rate of search unit movement (scanning speed) shall not exceed 150
mm per second
5.9 EVALUATION OF INDICATIONS
5.9.1 All assessment and evaluation of indications shall be carried out with
primary reference level after deducting 6dB scanning sensitivity.
5.9.2 Care should be taken to ensure only relevant indications are reported as
discontinuities.
5.9.3 Cross-sectional size of discontinuities shall be determined using 20dB
drop technique or maximum amplitude drop technique.
5.9.4 Length of discontinuities shall be determined using 6dB drop method.
5.9.5 The type of discontinuity (i.e., Planar/Cylindrical /Spherical /Linear) shall
be evaluated by noting signal response to various scans and various
angles.
5.9.6 A reference zero datum mark shall be made on the work piece surface. All
rejectable discontinuities shall be marked relative to zero datum.
5.10 EXAMINATION OF REPAIRS
5.10.1 Repairs shall be re-examined using the same procedure used for the
original examination.
5.10.2 The extent of examination shall include the repaired area plus 100mm at
either end.
5.10.3 A new report, with relevant repair number, shall be written for all repaired
welds retested.
5.11 POST INSPECTION CLEANING
5.11.1 When required, post inspection cleaning shall be accomplished to remove
residual inspection materials (couplant) by flushing with a solvent based
cleaner then finally wiping with rags.
5.12 SAFETY
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5.12.1 Care shall be exercised during inspection with due regard to safety and the
fact that the standard Ultrasonic Flaw Detectors used by the company are
NOT considered intrinsically safe and also Permits shall be required for
hazardous areas.
6.0 REPORTING
6.1 Reporting requirements shall be as specified by the Client or the Contract
Document.
6.2 All examination results shall be reported in standard format.
6.3 A sketch depicting cross-sectional area and circumferential location shall be made
for all rejectable discontinuities.
6.4 All restricted areas that are not scanned with complete coverage shall be reported
with full explanation of restriction.
7.0 ACCEPTANCE CRITERIA
7.1 The acceptance criteria shall be in accordance with client’s requirements.
7.2 However, unless otherwise specified the minimum acceptance criteria shall be in
accordance with the latest editions of the following documents:
i) AWS D1.1 (2008 Edition) - For Structural Steel Work
ii) ASME B31.3 (2008 Edition) - For Process Piping
iii) ASME Section-VIII Div.1 & 2 (2007 Edition) –
For Pressure Vessels
iv) API 1104(2005) - For Pipelines
8.0 ATTACHMENTS
I - Equipment Performance Check
II - Probe Characteristics Check
III - Construction of DAC Curve
9.0 DOCUMENTS
9.1 Technique sheet UT-T 001
Technique sheet UT-T 002
Technique sheet - UT-T 003
Ultrasonic Examination Report
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Sketch Format for Ultrasonic Examination Report
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ATTACHMENT-I
ULTRASONIC FLAW DETECTOR PERFORMANCE CHECK
1.0 INTRODUCTION
This is intended to provide detailed methods and techniques for assessment and calibration of
Ultrasonic Flaw Detector, as required by UT-01 Section 8.2.
2.0 TYPE OF EQUIPMENT:
As defined by section 5.0 of UT-01.
3.0 CALIBRATION PROCEDURE:
The instrument calibration shall be performed every 40 hours as per Asme Sec V
3.1 Horizontal Linearity
Calibrate the screen for the test range of 125mm using Single Crystal Transducer and IIW Block.
Place the probe on 25mm thickness side and read the back wall echoes. The Percentage of error
is calculated based on actual reading and the expected reading. The error should not exceed ±2%
of Test Range.
3.2 Screen Height Linearity
A straight beam probe is coupled with the IIW (V1) block to get multiple echoes from 25mm
back wall. Select any two echoes whose amplitudes are in the ratio of 2:1 with larger echo set at
80% of full screen height. Adjust the gain successively without moving search unit and set the
larger indication from 100% to 20% of full screen height in 10% increments or 2dB steps if a
fine control is not available. Read the smaller indication at each setting. The settings and
readings must be estimated to the nearest 1% of full screen height. Deviation should not exceed
±5% of Full Screen Height.
Alternately, a straight beam search unit shall be used on any calibration block, which will
provide amplitude differences with sufficient signal separation to prevent overlapping of the two
signals.
3.3 Amplitude Control Linearity
Couple the angle beam search unit to IIW (V1) block and get multiple echoes from 25 mm
thickness side. Select any echo and note its amplitude. Reduce the gain by 6dB and read the
Page 13 of 23

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amplitude of the same indication. It must be 50% of the initial amplitude within ±10% of the
nominal amplitude ratio. Perform this exercise for full range of Gain.
The settings and readings must be estimated to the nearest 1% of full screen and the readings
should fall within the limits of following table.
Other convenient reflectors from any calibration block shall be used with straight or angle beam
search units.
Indication Set at % of
Full Screen Height
dB Control Change Indication Limits % of
Full Screen Height
80 -6 dB 36 to 44
80 -12 dB 18 to 22
40 +6 dB 72 to 88
20 +12 dB 72 to 88
4.0 RECORDS:
All calibration readings shall be recorded and documented till next calibration period and
calibration block identity shall be included in the ultrasonic calibration records.
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ATTACHMENT – II
PROBE CHARACTERISTICS CHECK
1.0 INTRODUCTION
This has been written in order to provide detailed methods and techniques to evaluate the
Probe’s characteristics.
2.0 TYPE OF PROBES & EQUIPMENT
As defined by section 5.0 of UT-01.
3.0 PROBE CHARACTERISTICS
3.1 Probe Resolution
3.1.1 Place 0° compression probe on the V1 (IIW) Block as shown in the figure 1. The
echoes from the bottom of the milled slot at 85mm and from the steps at 91mm and
100mm shall be clearly discernible on the screen.
3.1.2 Place shear wave probes on the IOW Beam Profile Block with the beam directed
towards the series of 5 side drilled holes. Al least 3 of the series shall be clearly
discernible.
3.2 Probe Index
Place shear wave probe on the V1 (IIW) block’s 100mm quadrant side as shown in the figure 2
and maximize the eco from the quadrant. Hold the probe and measure the distance (d) from
block edge to probe edge.
The probe index = (100 – d) mm.
For example, if ‘d’ is 86mm, then
Probe index = 100-86=14mm.
This distance shall be transferred to the probe.
Page 16 of 23
Figure1
100mm Radius
V1 (IIW) Block
Figure 2
100mm
d
V1 (IIW) Block

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3.3 Probe Angle
Place the shear wave probe on the V1 Block as shown in the figure 3 and maximize the echo
from 1.6mm hole.
Note the beam path and Probe angle is calculated using formula:
Probe Angle = Cos-1(15/Beam Path)
3.4 20dB Beam Profile
3.4.1 Position the shear wave probe on the IOW block with the beam directed at a selected
1.6mm hole and maximize the signal by moving probe backwards and forwards. Hold
the probe in the maximized position and adjust gain control to give 100% FSH. Make a
mark1 on the block, which corresponds with the probe index point (see Fig. 4)
Prob e movement
to maximize s ignal
3.4.2 Move the probe gently forward until the signal height form the target hole has dropped
to 10% FSH (i.e. 20dB). Hold the probe in this position and mark2 the probe index
position on the block. (See Fig. 5)
Page 18 of 23
Figure 3
1.6mm hole
V1 (IIW Block) – Probe Angle
Figure 4
Leading ed ge
Beam Centre Trailing Ed ge
Mark at maximized pos itio n
Ho rizontal
stand-off
IOW Block

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Mo ve pro be forward until
Signal height drop s to 1 0%
3.4.3 Move the probe gently backward such that the signal goes back to maximum then falls
away again to 10% FSH. Hold the probe in this position and mark3 the probe index
position on the block. (See Fig.6)
Move p ro b e b ackward until
Sig nal heig ht d ro p s to 1 0%
3.4.4 Transfer the measurements of hole depth and probe stand off for each of three marks
onto a flaw location slide or suitable plotting system.
3.4.5 Repeat the above steps for three other target holes at different depths.
3.4.6 Complete the beam angle and profile plot by joining relevant points on the plotting
system. (See Fig.7)
4.0 CHECKLIST
Page 19 of 23
Figure 5
20 dB Trailing Edge
Mark the p rob e index
at 10% s ig nal height
Figure 6
20 dB
Lead ing Ed ge
Mark the p ro b e ind ex
at 10% s ignal heig ht
Fig.7
Hole 1
Hole 2
Hole 3
Hole 4
Hole depth
Horizontal stand-off
Mark2 Mark1 Mark3
Index
Point
Beam Profile Plotting

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All probe characteristics shall be entered in to the Probe Characteristics Checklist format: -:
FORMAT/UT/CAL-02
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UFD Model : Date of Testing :
Serial No :
CHECKLIST FOR PROBE CHARACTERISTICS
Item No Checklist Item Tolerance Result
Accept Reject
1 Resolution - 0° Probe 3 Clearly defined
indications
Resolution (Angle Probe) 3 Clearly defined
indications
2 Probe Index 25 mm maximum
from the edge
3 Probe Angle
45°
60°
70°
±2°
4 Beam Profile
(Leading/trailing edge)
45°
60°
70°
FORMAT/UT/CAL-02
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x
x
x
Point 1
80% FSH
Point 2
Point 3
Time Base
Amplitude
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ATTACHMENT-III
1.0 INTRODUCTION
This illustration is written to provide technical detail for the construction of Distance
Amplitude Correction (DAC) Curves as required by this written procedure.
2.0 EQUIPMENT
As defined by section 5.0 of UT-01.
3.0 BLOCKS
3.1 IOW Block for structural steel work weldments
3.2 ASME Section-V – Basic Calibration Block for Pressure Vessels/Process Piping
4.0 METHODS
4.1 Select a hole in the calibration block which falls out side of the Probe’s near zone. The
near zone length is calculated using the formula:
N = D2F /4V
where, N = Length of near zone (mm)
D = Crystal diameter (mm)
F = Frequency (MHz)
V = Velocity (103m/s)
4.2 Position the probe on the block and pick up the signal from selected target hole.
4.3 Maximize the signal by manipulation of probe.
4.4 Adjust the gain and keep the maximized signal at 80% FSH and mark the signal peak
on the screen.
4.5 Without further alteration select two more holes at suitable beam path to cover the
entire range/ thickness of the test material. Maximize the echoes by probe manipulation
and mark the respective signal peaks on the screen.
4.6 Join together all the three points plotted on the screen to generate a DAC curve. (See
Fig.1)
Figure 1
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23.
HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD
ULTRASONIC TESTING PROCEDURE
GENERAL PROCEDURE
DOC No. : HT-UT-01
REVISION : 9.0
DATE : 03.07.2009
TECHNIQUE SHEET – 1:
SCANNING TECHNIQUE FOR BUTT WELDS
a) Welds with single side access:
]
Angle Thickness Scan leg Surface Examination
0° all n/a 1 & 2 Lamination check on Parent metal
45° ³25mm half 1 & 2 Root and lower weld volume
full skip 1 & 2 Upper weld volume and fusion faces
60° 10-25mm half skip 1 & 2 Root, lower weld volume and fusion faces
>25mm full skip 1 & 2 Upper weld volume and fusion faces
70° 10-25mm half skip 1 & 2 Root, lower weld volume and fusion faces
all half skip 1 & 2 Transverse scan of weld. (if cap is flushed to
smooth, scanning may be carried out from the weld
surface)
2.0 Welds with double side access:
half skip
Surface 2
Surface 4
Surface 1
Surface 3
Angle Thickness Scan leg Surface Examination
0° all n/a 1 & 2 Lamination check on Parent metal
45° ³25mm half 1,2,3 &4 Root and lower weld volume
60° ³10mm half skip 1,2,3 &4 Root, lower weld volume and fusion faces
full skip 1,2,3 &4 Transverse scan of weld. (if cap is flushed to
smooth, scanning may be carried out from the
weld surface)
70° 10-25mm half skip 1,2,3 &4 Root, lower weld volume and fusion faces
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half skip
Full Skip
+ 1/2 Cap
Surface 1 Surface 2
half skip
half skip half skip

24.
HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD
ULTRASONIC TESTING PROCEDURE
GENERAL PROCEDURE
DOC No. : HT-UT-01
REVISION : 9.0
DATE : 03.07.2009
TECHNIQUE SHEET – 2:
SCANNING TECHNIQUE FOR FULL PENETRATION / NOZZLE WELDS
a) Nozzle with ‘Set through’ or full penetration T-Joints:
Scan 1 0° Lamination check on parent metal
Scan 2/3 45°/60°/70° shear wave scanning for weld volume, root, HAZ and fusion faces
at ½ skip
Scan 3 - 0° scan for fusion at main member side and lamellar tearing in main member.
b) Nozzle or branch attachment ‘set-on’
Scan 1 0° Lamination check on the parent metal.
Scan 2 45°, 60° scan for weld volume, fusion faces & HAZ at half and full skip
distance.
Scan 3 60°, 70° scan for root at half skip.
Scan 4 0° scan on main member to check main member side fusion, HAZ, Lamellar
tearing (if surface is accessible).
Scan 5 If scan 2 & 3 is restricted due to non accessibility, a 45° scan for weld and
fusion at full skip shall be carried out.
Page 24 of 27
Scan 4
Scan 1 - 0º
Scan 2-45º/60º/70º
Scan 3-45º/60º/70º
Scan 4
Scan 5
Scan 1, 2, & 3
Full skip
half skip

25.
HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD
ULTRASONIC TESTING PROCEDURE
GENERAL PROCEDURE
DOC No. : HT-UT-01
REVISION : 9.0
DATE : 03.07.2009
TECHNIQUE SHEET - 03:
SCANNING TECHNIQUE FOR TKY JOINTS:
Scanning detail
1. All scans to be carried out from branch member surface.
2. 0° scan for lamination check on scan surface.
3. 45°, 60°, 70° angle beam scan of weld metal at half and full skip as permitted by material thickness and
weld geometry.
4. Local dihedral angle and weld geometry varies point to point. Therefore beam axis should be kept
perpendicular to the weld during angle beam scanning.
Page 25 of 27
Toe zone
Transition
zone
Heel zone
MAIN MEMBER
BRANCH
MEMBER
Scanning perpendicular
to weld at all locations
Section through Toe zone
Main member
Scan surface
Full skip
Half skip
Section through
Heel zone
Section through Transition zone
Scan surface

26.
HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD
ULTRASONIC TESTING PROCEDURE
GENERAL PROCEDURE
DOC No. : HT-UT-01
REVISION : 9.0
DATE : 03.07.2009
ULTRASONIC TESTING REPORT FORMATE
Page 26 of 27

27.
HI-TECH NDT INSPECTION SERVICES (S) PTE. LTD
ULTRASONIC TESTING PROCEDURE
GENERAL PROCEDURE
DOC No. : HT-UT-01
REVISION : 9.0
DATE : 03.07.2009
ULTRASONIC TEST SKETCH
SKETCH
PROJECT TITLE : REPORT NO :
Joint Identification Length / mm Depth / mm Width / mm Defect Type Remarks
Page 27 of 27