The document outlines the requirements and procedures for ultrasonic examination methods

specifically for welds, as specified in the ASME Boiler and Pressure Vessel Code.

Ultrasonic Examination Methods for Welds

This article outlines the requirements and procedures for ultrasonic examination of welds as per
referencing code sections.

Ultrasonic examination procedures must comply with specific requirements outlined in the
referencing code section.

Key areas include personnel qualification, procedure requirements, examination system

Definitions of terms are provided in Article 1, Mandatory Appendix I.

General Requirements for Ultrasonic Examination

This section emphasizes the integration of general requirements with specific ultrasonic
examination protocols.

Special provisions exist for coarse grain materials and computerized imaging techniques.

Mandatory appendices detail various advanced techniques such as Time of Flight Diffraction
(TOFD) and phased array methods.

Written Procedure Requirements for Ultrasonic Examination

This section specifies the need for a written procedure for ultrasonic examinations.

Written procedures must include requirements listed in Table T-421 or relevant appendices.

Changes in essential variables require requalification of the written procedure, while nonessential
changes do not.

Equipment Requirements for Ultrasonic Examination

This section details the necessary equipment for conducting ultrasonic examinations.

A pulse-echo-type ultrasonic instrument must operate between 1 MHz to 5 MHz.

Instruments should have stepped gain control and may include damping control if it does not
affect sensitivity.

Search Units Specifications for Ultrasonic Examination

This section outlines the specifications for search units used in ultrasonic examinations.

Search units must operate within a frequency range of 1 MHz to 5 MHz.

Contoured contact wedges are required for curved components with diameters less than 14
inches.
Couplant Requirements for Ultrasonic Examination

This section discusses the requirements for couplants used during ultrasonic examinations.

Couplants must not harm the material being examined and should meet specific contaminant
limits.

For nickel base alloys, sulfur content must not exceed 250 ppm; for austenitic stainless steel,
halides must not exceed 250 ppm.

Calibration Blocks for Ultrasonic Examination

This section describes the requirements for calibration blocks used in ultrasonic examinations.

Calibration blocks must use specified reflectors to establish primary reference responses.

The material for blocks should match the product form and specification of the materials being
examined.

Miscellaneous Requirements for Weld Examination

This section covers additional requirements for identifying and marking weld examination areas.

Weld locations must be recorded on a weld map or identification plan.

Permanent markings should not exceed 1.2 mm in depth after final stress relief.

Techniques for Ultrasonic Examination

This section outlines various techniques for conducting ultrasonic examinations.

Techniques include manual, nonautomated, semiautomated, and automated scanning.

The choice of technique may depend on the specific application and material characteristics.

Calibration Requirements for Ultrasonic Examination

This section details the calibration requirements for ultrasonic examination instruments.

Instruments must undergo linearity checks at specified intervals (every three months for analog,
annually for digital).

Calibration must include the complete ultrasonic system and be performed using the same
couplant and contact wedges as during examination.

Instrument Controls and Calibration Requirements

This section outlines the necessary controls and calibration procedures for ultrasonic
instruments to ensure accurate measurements.

Controls affecting instrument linearity must remain unchanged during calibration and checks.

Temperature differentials for calibration and examination must be within 25°F (14°C).
Distance-Amplitude Correction (DAC) curves must not fall below 20% of full screen height; a split
DAC is required if this occurs.

Calibration Procedures for Nonpiping

This section details the calibration methods for ultrasonic testing systems not related to piping.

Calibration blocks must be used as specified in Figure T-434.2.1.

Angle beam calibrations should achieve a response of 80% ± 5% of full screen height.

Straight beam calibration must also establish distance range and DAC.

Calibration Procedures for Piping

This section describes the calibration requirements specifically for piping applications.

Calibration blocks must be utilized as shown in Figures T-434.3-1 and T-434.3-2.

Angle beam calibration requires separate calibrations for axial and circumferential notches.

Straight beam calibration must establish both distance range and DAC.

Calibration for Weld Metal Overlay Cladding

This section specifies calibration techniques for weld metal overlay cladding examinations.

Calibration blocks shown in Figures T-434.4.1 and T-434.4.3 must be used.

Gain control should be set to achieve 80% ± 5% of full screen height for maximum response.

Calibration for Nozzle Side Weld Fusion Zone

This section outlines the calibration requirements for examining nozzle side weld fusion zones.

A single side-drilled hole is sufficient for examining the fusion zone.

Multiple holes require the gain control to be set at 80% ± 5% of full screen height.

Calibration Confirmation Procedures

This section emphasizes the importance of confirming calibration after system changes.

Calibration checks must be performed after any system changes or personnel changes.

Simulator checks should correlate with original calibration and be verified regularly.

General Examination Requirements

This section provides guidelines for conducting ultrasonic examinations.

The scanning volume must be fully covered with a minimum 10% overlap.
The scanning speed should not exceed 6 in./s (150 mm/s) unless specific conditions are met.

Weld Joint Distance-Amplitude Technique

This section describes the scanning techniques for weld joints using distance-amplitude
methods.

Angle beam search units must be used in both parallel and transverse directions to the weld axis.

A straight beam examination is required before angle beam examinations.

Angle Beam Technique for Welds

This section details the angle beam examination techniques for welds.

The search unit must be positioned at 45 degrees or an appropriate angle for the configuration.

Scanning must be performed from both sides of the weld when possible.

Evaluation of Indications

This section outlines the evaluation process for ultrasonic indications.

All indications greater than 20% of the reference level must be investigated.

Nonrejectable indications must be recorded as specified by the referencing Code Section.

Documentation and Reporting Requirements

This section specifies the documentation needed for ultrasonic examinations.

Examination records must include instrument identification, search unit details, and calibration
data.

A report must be filed and maintained according to the referencing Code Section.

Mandatory Appendices Overview

This section summarizes the mandatory appendices related to ultrasonic examination

Appendices cover various aspects such as amplitude control linearity, TOFD techniques, phased
array techniques, and workmanship-based acceptance criteria.

Each appendix provides specific requirements for calibration, examination, and documentation.

Written Procedure Requirements for Ultrasonic Techniques

The procedures for ultrasonic examination must be detailed and qualified according to
established techniques.

Procedures must be detailed for the applicable ultrasonic technique.

Only qualified personnel trained in the equipment and techniques can conduct production scans.

Personnel Qualifications for Ultrasonic Testing

Qualified personnel are essential for conducting ultrasonic examinations and interpreting data.

Only Level II or Level III personnel with documented training can approve setups and analyze
data.

Personnel must have participated in technique qualification or demonstration without

Employer's written practice must address training and demonstration requirements.

Equipment and Instrument Requirements

Ultrasonic examinations must utilize specific equipment and instruments to ensure accuracy and
reliability.

Automated or semi-automated scanning systems with computer-based data acquisition are

Manual examination for transverse reflectors is allowed unless specified otherwise.

Search units must match the nominal frequency used in qualification.

Calibration Blocks and Verification Methods

Calibration blocks are critical for verifying scan plans and examination calibration.

Scanner blocks must meet specific thickness and reflector requirements.

Simulator checks must be performed before and after examinations to ensure accuracy.

Search unit position verification is necessary to maintain consistent probe positioning.

Examination Coverage and Sensitivity Levels

Examinations must cover specified volumes and maintain qualified sensitivity levels.

The entire volume to be scanned must adhere to the established scan plan.

The rate of search unit movement must not exceed qualified limits.

Scanning sensitivity levels must meet or exceed those established during qualification.

Evaluation of Indications and Flaws

Indications from ultrasonic examinations must be evaluated according to specific criteria.

Indications longer than specified lengths must be evaluated against acceptance criteria.
Flaws must be categorized as surface or subsurface based on their proximity to the nearest
surface.

Final flaw evaluations should occur after all display parameter adjustments are completed.

Documentation and Examination Records

Comprehensive documentation is required for all ultrasonic examinations and evaluations.

Examination records must include scan plans, indication data, and instrument settings.

All original scanning data must be saved electronically for future reference.

Documentation must also include details of any supplemental manual techniques used.

Procedure Qualification Requirements for Flaw Sizing

Specific requirements exist for qualifying ultrasonic examination procedures for flaw sizing and
categorization.

Procedures must be qualified when flaw sizing and categorization are specified.

Demonstration blocks must contain actual flaws to simulate production welds.

Qualification data must be saved and available for review by inspectors.

Ultrasonic Examination of High-Density Polyethylene

Requirements for examining butt fusion welds in HDPE pipe using ultrasonic techniques are
outlined.

Examination must follow a written procedure that includes specific requirements.

A scan plan must detail search unit placement and movement for standardized methodology.

Equipment must meet specific frequency and performance criteria for effective examination.

Full Matrix Capture Ultrasonic Technique

The full matrix capture technique is essential for examinations based on fracture-mechanics
acceptance criteria.

A written procedure must outline essential variables and scanning methodologies.

Personnel must be qualified to perform data reconstruction and analysis.

Calibration blocks and reference standards are necessary for accurate examination results.

Sweep Range Delay and Sensitivity Correction

This section discusses the calibration and sensitivity adjustments necessary for ultrasonic
testing using angle beam examination.
Staggered holes are utilized for straight beam reflectors calibration.

Sensitivity and distance-amplitude correction (DAC) curves are essential for accurate
measurements.

The DAC curve is used to evaluate reflector indications based on their amplitude responses.

Angle Beam Examination Data Recording

This section provides guidelines for recording data during angle beam examinations of welds.

The appendix outlines methods for documenting reflector dimensions and identities.

Reflector indications producing responses greater than 20% of the DAC curve must be identified.

Length measurements of reflectors are taken perpendicular to the scanning direction.

Reflector Identification and Measurement Techniques

This section details the requirements for identifying and measuring reflectors during ultrasonic
examinations.

Reflectors with amplitudes greater than 20% of DAC must be identified and measured.

Flaw sizing techniques must be qualified and demonstrated for accurate measurements.

Documentation of search unit location and position is crucial for accurate data recording.

Documentation and Data Recording Examples

This section illustrates how to document ultrasonic examination data effectively.

A sample data record is provided for various indications, including their amplitudes and
dimensions.

The search unit's location and position are recorded relative to the weld axis.

Length and through-wall dimensions are calculated based on the recorded data.

Computerized Imaging Techniques Overview

This section outlines the requirements for computerized imaging techniques in ultrasonic
testing.

Computerized imaging techniques must meet basic instrument requirements and be qualified for
flaw detection.

Procedures should define test frequency, signal processing techniques, and image interpretation
guidelines.

Dimensional scaling features must be included to relate imaged features to actual component
dimensions.
Calibration and Examination Requirements

This section discusses the calibration processes and examination requirements for ultrasonic
testing.

Calibration must optimize gain levels for data acquisition and imaging.

Lateral resolution and depth discrimination blocks are necessary for verifying ultrasonic imaging
systems.

Examination requirements vary based on reflector types and dimensions.

Full Matrix Capture (FMC) Examination Techniques

This section describes the full matrix capture technique for ultrasonic examinations.

FMC involves capturing a full matrix of time-domain signals for image reconstruction.

The elementary total focusing method (TFM) is a common method for image reconstruction.

Equipment selection and search unit design are critical for achieving optimal imaging results.

Examination of Welds Using Angle Beam Search Units

This section outlines the examination of welds using angle beam search units.

Nominal angles of 45 deg, 60 deg, and 70 deg are typically used for weld examinations.

Each pass of the search unit must overlap a minimum of 50% of the active transducer
dimension.

Exceptions for angle usage are provided for specific weld types and configurations.

Alternative Calibration Block Configuration

This section provides guidance on using alternative calibration blocks for ultrasonic testing.

Basic calibration blocks must establish a primary reference response for distance-amplitude
correction.

The material for calibration blocks should match the component being examined.

Calibration reflectors must be accurately positioned to ensure effective calibration.

Calibration of Round Bottom Holes

Round bottom holes are drilled as per specific code requirements for beam spread
measurements.

Round bottom holes are drilled only when required by a referencing code section for beam
spread measurements.

The technique of B-60 is utilized for these measurements.

The T/2 hole can be positioned at 1.5 times the basic calibration block diameter.

A flat calibration block can be used if the curvature radius exceeds the critical radius defined in
Article 4.

Calibration Blocks for Welds in Small Diameter Materials

Curved calibration blocks are essential for examining welds in materials with diameters of 20
inches or less.

Basic calibration blocks must be curved for materials with diameters of 20 in. (500 mm) or less.

A single curved block can calibrate surfaces with curvature ranging from 0.9 to 1.5 times the
block diameter.

An example includes using an 8 in. (200 mm) diameter block for calibrating surfaces from 7.2 in.
to 12 in. (180 mm to 300 mm).

Six block curvatures are required for curvature ranges from 0.94 in. to 20 in. (24 mm to 500 mm).

Recording Straight Beam Examination Data

This section outlines the method for recording data during straight beam examinations for
planar reflectors.

Data should be obtained from successive scans with a maximum increment of 90% of the
transducer dimension (10% overlap).

Record all reflectors producing a response equal to or greater than 50% of the distance-
amplitude correction (DAC).

Clad interface and back wall reflections do not need to be recorded.

All search unit positions and location dimensions must be recorded to the nearest tenth of an
inch.

TOFD Sizing Demonstration Methodology

The methodology for demonstrating the accuracy of a UT system in sizing surface machined
notches is provided.

The demonstration block must match the desired material and shape for accuracy.

It should contain at least three notches machined to depths of T/4, T/2, and 3T/4.

Additional notches may be necessary based on block thickness and examination zones.

The block material must be examined to ensure no interfering reflectors are present before
machining notches.
Calibration and System Checks for TOFD

Calibration and system checks are crucial for ensuring accurate TOFD measurements.

The system must be calibrated according to the procedure being demonstrated.

A positional encoder check must confirm the system read-out is within 1% of the measured
distance.

A thickness check should ensure the distance between the lateral wave and first back-wall signal
is within ±0.02 in. (±0.5 mm) of the block's measured thickness.

Evaluation of TOFD Images

This section aids in interpreting TOFD ultrasonic images for flaw detection and sizing.

TOFD images are displayed as grayscale images of digitized A-scans, showing lateral wave and
backwall signals.

The phase information in TOFD images is crucial for identifying signals and determining depth
measurements.

Various flaw types can be identified, including point flaws, inside far-surface-breaking flaws, and
midwall flaws.

Measurement tools for flaw heights and lengths are provided, with specific techniques for
measuring depth and length using hyperbolic cursors.

Documentation Requirements for TOFD Demonstration

Documentation of the TOFD demonstration is essential for accuracy and traceability.

The demonstration report must include computerized program identification, wave propagation
modes, and block configuration.

Notch depths, lengths, and orientations must be documented.

Instrument settings and scanning data should be recorded, along with accuracy results.