6
Owner: ONEOK Hydrocarbon, LP
Package: 103044-VSL-01A
Hugh K. Howerton
Name Antonio Dilay
ASNT Level III - 5921
Signature
Revision History
Revision No.: 0
Initial issue
Revision No.: 1 Revised para 1.4, 3.1, 4.0 and removed all references and requirements for pipe.
Revision No.: 2 Revised 1.1, 2.1, 2.3, 4.0, 5.1, 13.0 per customer comments
Revision No.: 6
2.1 and 2.1 Updated to 2017 and added reference to Appendix 12
2.3 Updated to 2016
Page 41. Added Sample Ultrasonic Report
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TABLE OF CONTENTS
PAGE
1.0 Scope 4
2.0 References 4
3.0 Personnel 4
5.0 Equipment 5
8.0 Techniques 15
10.0 Examination 27
13.0 Documentation 38
14.0 Report 40
1.0 SCOPE
1.1 This procedure covers the general procedure and requirements for ultrasonic
examination of plate weldments, using the contact method, as required by ASME
Boiler and Pressure Vessel Code, Sections V and VIII.
1.3 This procedure is certified to meet the minimum requirements of paragraph T-150 of
the ASME Section V Code.
1.4 This procedure is does not apply to welds for which UT is to be substituted for RT.
This procedure is for manual UT and does not meet CC 2235-9.
2.0 REFERENCES
2.2 2017 ASME Section VIII – Rules for Construction of Pressure Vessels, Division 1
Mandatory Appendix 12 – Ultrasonic Examination of Welds (UT)
2.3 2016 ASNT Recommend Practice No. SNT-TC-1A – Personnel Qualification and
Certification in Nondestructive Testing
3.0 PERSONNEL
3.2 NDT Level II or III personnel may perform the examination and evaluate the results.
The procedure applies to carbon steel and low alloy steel plate weldments, with a
thickness between ¼ inch (6.35 mm) and 8 inch (203mm). The welds are full fusion butt
welds, welded from one or both sides.
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5.0 EQUIPMENT
of operation at frequencies over the range of at least 1 MHz to 5 MHz and shall be
equipped with a stepped gain control, it may be used if it does not reduce the sensitivity of
the examination. The reject control shall be in the “off” position for all examinations,
unless it can be demonstrated that it does not affect the linearity of the examination.
Typical ultrasonic instruments which may be used are: Epoch 2, Epoch 3, Epoch 4, USM-
2, USK-7, USIP-11, USN-25, USN-50, USN-52, USN-58, USN-60 or equal.
The instrument, when required because of the technique being used, shall have both send
and receive jacks for operation of dual search units or a single search unit with send and
receive transducers.
5.1 Search Units: The sizes below are in US units. Equivalent sizes in metric units may
be used. Angle beam search units may be in one piece or affixed to Lucite or
bakelite wedges.
5.1.1 The frequency shall be from 1 MHz to 5 MHz unless variables, such as
5.1.2 The size of the probe to be used shall be determined by the ability to calibrate
on the reference block and the shape of the area to be scanned i.e. joint
5.2 Couplant
5.2.1 The couplant, including additives, shall not be detrimental to the material being
examined. The couplants used on nickel based alloys shall not contain more
than 250 ppm sulfur and couplants used on austenitic stainless steels or
titanium shall not contain more than 250 ppm of halides (chlorine plus
fluorides).
5.2.2 Typical couplants to be used are: cellulose gum mixed with water, Exosen,
5.2.3 The same couplant used for calibration shall be used for the actual
examination.
6.1 General
6.1.1 Reflectors
Known reflectors (i.e., side drilled holes, flat bottom holes, notches, etc.) shall
6.1.2 Material
The material from which the block is fabricated shall be of the same product
6.1.3 Quality
6.1.4 Cladding
When the component material is clad, the block shall be clad by the same
welding procedure as the production part. It is desirable to have component
materials which have been clad before the drop outs or prolongations are
The calibration block shall receive at least the minimum tempering treatment
required by the material specification for the type and grade. If the calibration
block contains weld other than cladding, and the component weld at the time
of the examination has been heat treated, the block shall receive the same
heat treatment.
The finish on the scanning surfaces of the block shall be representative of the
scanning surface finishes on the component to be examined.
thickness range.
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6.1.7.3 Flat Calibration Block Used for Convex Surface Greater Than 20 Inch
Diameter
a. Search units with a frequency of 2.25 MHz are acceptable for all
than 20 inches.
When the block thickness ± 1 inch (25 mm) spans two welds
overlay interface shall be used. This hole may be drilled from the
base material or weld overlay side. The thickness of the weld
7.2 Marking
If welds are to be permanently marked, low stress stamps and/or vibra-tooling may
be used. Marking applied after final stress relief of the component shall not be any
7.2.1.1 For layout of vessel and nozzles: Unless specified by the customer,
for horizontal vessels, from the inlet end of the vessel. The
examination surfaces shall be identified as above, below, north,
c) For Longitudinal Welds, the reference points shall be laid out from
starting from the bottom of the longitudinal weld for vertical vessels
d) For Nozzle to Vessel Welds, the 0 shall be at the top of the nozzle
8.0 TECHNIQUES
8.1 The techniques described in this procedure are intended for applications where either
8.1.1 Normal incident longitudinal wave beams for what are generally termed
straight beam examinations or
8.1.2 Angle beam longitudinal waves, where both refracted longitudinal and shear
waves are present in the material under examination. When used for
examinations, they are generally termed angle beam examinations. For this
8.3 Longitudinal angle beams will not be used in lieu of shear waves.
The requirements of Section 9.1.1 and 9.1.2 shall be met at intervals not to exceed
three (3) months or prior to first use thereafter.
9.1.1 Screen Height Linearity Check: The ultrasonic instrument shall provide linear
vertical presentation within +
_ 5% of the full screen height for 20% to 80% of
the full screen height.
indication can be observed from both the 1/2 and 3/4T holes in a
basic calibration block.
or
9.1.1.2 Adjust the search unit (either angle or straight) position to give a 2:1
ratio of amplitudes between the two indications, with the larger set at
9.1.1.3 Next, without moving the search unit, adjust sensitivity (gain) to
successively set the larger indication from 100% to 20% of full screen
height, in 10% increments or 2dB steps if a fine control is not
9.1.1.4 The smaller reading must be 50% of the larger amplitude, within 5%
of full screen height. See Figure 10. (Settings and readings must be
estimated to the nearest 1% of full screen height.)
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9.1.2.1 Position an angle beam search unit, as shown in Figure 8, so that the
indication from the 1/2T hole in a basic calibration block is peaked on
the screen.
or
the indication must fall within the specified limits. (The settings and
readings must be estimated to the nearest 1% of full screen height.)
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examination.
9.2.3 Couplant
The same couplant to be used during the examination shall be used for
calibration.
The same contact wedges to be used during the examination shall be used for
calibration.
Any control which affects instrument linearity (e.g., filters, reject, or clipping)
9.2.6 Auto-DAC:
notch responses shall be equalized between 40 and 80% of full screen height
9.2.6 Temperature
9.3 Calibration
9.3.1.3 It must be demonstrated that the entire examination volume and the
required metal path is covered by the DAC and that all points on the
DAC have amplitudes of at least 20% FSH. A double DAC or
examination volume.
Calibrate the sweep range to cover the area of interest required for the
examination. The following is an example using the basic calibration block
side drilled holes. A full node examination is required for welds in the
unwelded condition. A half node examination may be used if the weld is
9.3.2.1 Position the search unit for the maximum first indication from the 1/4T
side drilled hole. Adjust the left edge of this indication to line 2 (or
9.3.2.2 Position the search unit for the maximum indication from 3/4T hole.
Adjust the left edge of this indication to line 6 (or other for convenient
9.3.2.3 Repeat delay and range control adjustments until the 1/4T and 3/4T
hole reflections start at sweep lines as indicated above.
9.3.3 Angle Beam DAC for Unclad Material or from the Clad Side of Clad Material
NOTE: A DAC is not required where the examination is limited to one-half vee
path in a material less than 1 inch (25mm) thick, in which case the
amplitude level from a single calibration reflector (1/2T hole) can be
used.
9.3.3.1 Position the search unit for maximum response from the hole which
gives the highest amplitude. See Figure 13. For an example of a full
9.3.3.2 Adjust the sensitivity control to provide an 80% ( 5% of full screen
height) of full screen indication from the hole. Mark the peak of the
indication on the screen.
9.3.3.3 Position the search unit for maximum response from another hole
indication.
9.3.3.5 Position the search unit for maximum amplitude from the third hole
9.3.3.6 Position the search unit for maximum amplitude from the 3/4T hole
indication after the beam has bounced from the opposite surface.
Mark the peak on the screen for the 5/4T position.
9.3.3.7 Connect the screen marks for the side drilled holes to provide the
distance-amplitude correction curve.
9.3.4 Angle Beam DAC from the Unclad Side of Clad Material
NOTE: A DAC is not required where the examination is limited to one-half vee
path in a material less than 1 inch (25mm) thick, in which case the
amplitude level from a single calibration reflector (1/2T hole) can be
used.
9.3.4.1 From the clad side of the block, determine the dB change in amplitude
between the 3/4T and the 5/4T positions.
9.3.4.2 From the unclad side, perform systems calibrations as noted in 9.3.3.1
through 9.3.3.7.
9.3.4.3 To determine the amplitude for the 5/4T hole, position the search unit
for maximum amplitude from the 3/4T hole. Decrease the signal
Calibrate the sweep range to cover the area of interest required for the
examination. The following is an example using the basic calibration block
9.3.5.1 Position the search unit for the maximum first indication from the 1/4T
side drilled hole. Adjust the left edge of this indication to line 2 (or
9.3.5.2 Position the search unit for the maximum indication from 3/4T hole.
Adjust the left edge of this indication to line 6 (or other for convenient
9.3.5.3 Repeat delay and range control adjustments until the 1/4T and 3/4T
hole reflections start at sweep lines as indicated above.
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9.3.6.1 Position for maximum response from the hole which gives the highest
9.3.6.2 Adjust the sensitivity control to provide an 80% ( 5% of full screen
height) of full screen indication from the hole. Mark the peak of the
indication on the screen with a grease pencil or other suitable marker.
9.3.6.3 Position the search unit for maximum response from another hole
indication.
9.3.6.5 Position the search unit for maximum amplitude from the third hole
9.3.6.6 Connect the screen marks and extend through the thickness to
provide the distance-amplitude correction curve for the side drilled
holes.
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Angle Beam Calibration. The angle beam shall be directed toward the
calibration reflector that yields the maximum response. The gain control shall
be set so that this response is 80% ± 5% of full screen height. This shall be
the primary reference level.
resolvable indication from the bottom of the calibration reflector. The gain
shall be set so that this response is 80% ± 5% of full screen height. This shall
9.4.3.1 The search unit shall be positioned for maximum response from the
reflector, which gives the highest amplitude.
9.4.3.2 The gain shall be set so that this response is 80% ±5% of full screen
height. This shall be the primary reference level. Mark the peak of
the indication on the screen.
9.4.3.3 Without changing the instrument settings, position the search unit
for maximum response from each of the other reflectors and mark
9.4.3.4 Connect the screen marks for each reflector to provide a DAC
curve.
shall be made on the basic calibration block to verify that distance range
points and sensitivity setting(s) satisfy the requirements of Section 9.5.3.
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Any simulator checks that are used shall be correlated with the
original calibration on the basic calibration block during the original
whichever is less.
If any distance range point has moved on the sweep line by more
or re-recorded.
decreased, all data sheets since the last valid calibration check
shall be marked void and the area covered by the voided data
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10.0 EXAMINATION
10.1 Clean contact surfaces of weld spatter, dirt, rust, grease and any roughness that will
interfere with the free movement of the search unit or would prevent the transmission
of ultrasonic vibrations.
10.1.2 Utilizing either an angle or straight beam search unit, perform an instrument
10.1.3 The signature of the operator and/or evaluator on the report documents
10.2.1 Select a straight beam search unit with a nominal frequency of 2.25 MHz*.
*NOTE: The nominal frequency shall be 2.25 MHz unless variables such as
10.2.2 Calibrate the system (ultrasonic instrument, co-axial cable and search unit) so
that a back reflection from the opposite side of a sound indication free area of
the plate will produce a minimum of 75% of full screen height indication.
10.2.3 When any part of the examination system is changed, perform a calibration
check on a sound indication free area of the plate to verify that amplitude
values have not varied from that specified in 9.3 through 9.5.
10.2.5 Increase the gain a minimum of two times (+6dB) calibration sensitivity for
10.2.6 Scan manually at a speed not to exceed 6 inches (152mm) per second.
10.2.7 With the straight beam search unit examine the adjacent base metal through
which the angle beam sound path will travel during the weld examination in
order to detect reflectors that might affect interpretation of the angle beam
results.
10.2.8 Manually scan the base metal by moving the transducer progressively along
and across the contact area overlapping search unit passes a minimum of
10% so the entire area is covered. See Figure 21.
10.2.9 Mark on the material or part the location and areas of all reflectors exceeding
50% of the first back reflection. This initial base metal straight beam
examination is not to be used as an acceptance/ rejection examination.
Evaluation of indications shall be at the amplitude (gain) setting per 9.3.6.
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10.3.1 Select a search unit with a nominal frequency of 2.25 MHz*, and a lucite
wedge so that the beam angle in the production material shall be in the range
of 40o to 75o inclusive with respect to the perpendicular to the contact surface.
The 45o, 60o or 70o angle selected shall be the one that produces a sound
path that is closest to being perpendicular to the weld prep beveled surfaces.
*NOTE: The nominal frequency shall be 2.25 MHz unless variables such as
10.3.3 Calibrate the system (ultrasonic instrument, co-axial cable and search unit) as
outlined in 9.3. When any part of the examination system is changed, perform
a calibration check on the basic calibration block to verify that calibration
points on the sweep and distance amplitude correction values recorded satisfy
10.3.4 Perform a calibration check on at least one of the basic reflectors in the basic
10.3.5 Increase the gain a minimum of two times (+6dB) calibration sensitivity for
10.3.6 Scan manually at a speed not to exceed 6 inches (152mm) per second. In
addition to the weld volume, scan an adjacent amount of base material, the
greater of ½ inch or ½ T.
10.3.7 For the detection of reflectors oriented parallel to the weld axis progress in a
general direction parallel to the weld axis, with the angle search unit beam
path directed approximately 90 o to the weld axis. Move the search unit closer
to, and over the weld if ground flush, and further away from the weld while
continuously rotating the transducer wedge approximately 15 o alternately to
each side. Overlap search unit passes a minimum of 10% to ensure complete
coverage of the examination zone. See Figure 22.
10.3.8 Repeat step 10.3.7 from the opposite side of the weld (180o) if possible. See
Figure 22.
Figure 22 - Example of Angle Beam Scanning of a Double Butt Weld at Right Angles to
10.3.8 For the detection of reflectors oriented transverse to the weld axis perform
another angle beam examination, with the same angle used in 10.3.6 and
10.3.7 with the beam path directed essentially parallel to the weld axis. See
Figure 23. If the weld surface is sufficiently smooth, scan on the weld.
10.3.9 Repeat step 10.3.8 from the same side of the weld axis but with the search
unit beam path directed in the opposite direction (180 o). See Figure 23.
10.3.10 If the weld reinforcement is not sufficiently smooth for scanning on the weld
and the weld reinforcement is wider than 3/4 inch (19mm), repeat 10.3.8 and
10.3.9 on the plate surface on the opposite side of the weld axis.
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Figure 23 - Example of Angle Beam Scanning of a Double Butt Weld Essentially Parallel
For geometric conditions that prevent angle beam examination from two directions to
the weld as specified in 10.3.7, examine the weld with a combination of angle beam
and straight beam. See Figure 24. If conditions still prevent examination from two
directions, coverage of the weld from one direction shall be acceptable.
10.5.1 Select a straight beam search unit with a nominal frequency of 2.25 MHz.
The nominal frequency shall be 2.25 MHz unless variables such as production
material grain structure require the use of other frequencies to assure
adequate resolution.
10.5.3 Calibrate the system (ultrasonic instrument, co-axial cable and search unit) as
outlined in 9.3. When any part of the examination system is changed, perform
a calibration check on the basic calibration block to verify that calibration
points on the sweep and distance amplitude correction values recorded satisfy
10.5.4 Perform a system calibration check on at least one of the basic reflectors in
the basic calibration block or perform a check using a simulator at the
completion of each examination or series of similar examinations, every four
(4) hours during the examination and when examination personnel (except for
10.5.5 Increase the gain a minimum of two times (+6dB) calibration sensitivity for
10.5.6 Scan manually at a speed not to exceed 6 inches (152mm) per second. In
addition to the weld volume, scan an adjacent amount of base material, the
greater of ½ inch or ½ T.
11.1.1 Any reflector which causes an indication in excess of 20% DAC, at reference
sensitivity, shall be investigated to the extent necessary to provide accurate
characterization, identity and location. All such indications shall be evaluated
in terms of the acceptance criteria of the referencing Code Section.
11.1.2 During examination, the sweep range may be adjusted for indication
discrimination and characterization. Final recording of indications shall be
done utilizing the sweep and DAC settings established during calibration.
11.2.1 Flaw Indications – All indications produced by reflectors within the volume to
be examined, regardless of amplitude, that cannot be clearly attributed to the
geometry of the weld configuration (counterbore, root, metallurgical
i. Interpret the areas containing the reflector in accordance with the Flaw
Indications (11.3.1) or the Geometric or Metallurgical Indications
ii. Plot and verify the reflector coordinates. Prepare a cross section
sketch showing the reflector position and surface discontinuities such
as root condition, weld reinforcement.
11.3.1 Flaw indications – All suspected flaw indications shall be investigated and
evaluated taking into account the following indication characteristics. These
characteristics should not be considered as mandatory criteria for classifying
indications as defects, but are listed as significant points of interest for the
examiner to consider during evaluation of suspect areas.
a. The indication had a signal-to-noise ratio greater than 2:1 with defined
start and end points. This characteristic can be supported by observing
c. The indication can be detected with multiple search unit angles and a
higher angle providing comparable or greater signal responses. This
along the length of the weld and by scanning with an adequate reference
reflector (inside surface notch or equivalent).
observing other areas along the length of the part and by scanning along
the length of the indication laterally.
tangential scans.
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k. For axial indications, the indications(s) can be confirmed from the opposite
direction. This characteristic is dependent upon indication orientation and
may not always be available.
m. For components where access is limited to a single side of the weld, the
following additional information shall be considered:
ii. For suspect far side indications, several search unit angles should be
evaluated to optimize the response.
b. The indication provides additional responses, which occur from the same
scan position, but at different sweep positions (multiples) along the length
of the weld. This may be a sign of mode-converted shear wave signals
may require an increase in the time base size (increased range) in order
c. The indication can be seen across the entire length of the scan, either
d. When examining with a higher angle search unit, the amplitude response
is lower or not detected. This characteristic should consider localized
thickness and contour information to ensure that he search unit angles
h. The signal responses are consistent from each side of the weld for axial
c. Evaluate the indication signal amplitude response from each side of the
weld, if possible. Observe if the signal response appears due to weld
d. Evaluate the ultrasonic responses from each side of the weld in both
flawed and unflawed regions. Attempt to identify standard benchmark
responses (i.e. weld root, weld noise, weld counterbore, etc.) and flaw
All indications greater than 20% of the reference level shall be investigated to the
extent that they can be evaluated in terms of the acceptance criteria of the
referencing Code Section. See Section 11.0.
Reflectors evaluated as laminar reflectors in base material which interfere with the
scanning of examination volumes shall require the angle beam examination
technique to be modified such that the maximum feasible volume is examined, and
shall be noted in the record of examination of Section 13.0.
The length of the imperfection shall be the transducer travel from 50% of maximum
amplitude, through maximum, to 50% of maximum, measuring from the centerline
of transducer to the centerline of transducer.
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12.5 Evaluate all indications in accordance with the applicable acceptance criteria of
ASME Sections VIII. Portions of the weld that are interpreted by ultrasonic
12.5.2 Other linear type imperfections if the amplitude exceeds the DAC Curve
and the imperfection length exceeds the following:
Where t is the thickness of the weld being examined excluding any allowable
reinforcement. If the weld joins two members having different thicknesses at the
weld, t is the thinner of these two thicknesses. If a full penetration weld includes a
fillet weld, the thickness of the throat of the fillet shall be included in t.
12.5.3 The length of the imperfection shall be the transducer travel from 50% of
maximum amplitude, through maximum, to 50% of maximum, measuring
All visible sign of couplant shall be removed from the examination surfaces.
14.0 DOCUMENTION
shall be recorded.
14.0 REPORT
14.1 General
A report of the ultrasonic examination shall be made. The report shall include
those records indicated in Sections 12.0 and 13.0. The report shall be filed and
maintained in accordance with the referencing Code Section.
The Manufacturer shall prepare a report of the ultrasonic examination and a copy
of this report shall be retained by the Manufacturer until the Manufacturer’s Data
Report has been signed by the Inspector. The report shall contain the information
required by ASME Section V. In addition, a record of repaired areas shall be
noted as well as the results of the reexamination of the repaired areas. The
Manufacturer shall also maintain a record of all reflections from uncorrected areas
having responses that exceed 50% of the reference level. This record shall locate
each area, the response level, the dimensions, the depth below the surface, and
the classification.
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