Professional Documents
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Document No.
SAL-TECH-SOP-TOFD & PA-0102015
Customer
Client
Contractor
Sub-Contractor
Project No.
05th December
2015
Page 2 of 49
ISSUE 1, Rev.0
THIS OPERATING PROCEDURE IS CONTROLLED BY THE SIEVERT ARABIA LIMITED AND MAY NOT BE
AMENDED, REVISED OR ALTERED IN ANY OTHER WAY WITHOUT THE CONSENT OF THAT COMPANY.
THE SIGNATURES BELOW AUTHORISE ALL PAGES OF THIS PROCEDURE FOR USE FROM THE DATE OF
APPROVAL SHOWN
ISSUE
REVISION
DATE
REMARKS
Initial Issue
NAME
POSITION
Prepared by
Bechan Barai
ASNT NDT Level II
05 th December 2015
05 th December 2015
SIGNATURE
DATE
Item
Comment
Document No.
SAL-TECH-SOP-TOFD & PA-0102015
ISSUE 1, Rev.0
Resolution
05th December
2015
Page 3 of 49
Document No.
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2015
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CONTENTS
1.0
SCOPE: .
2.0
PURPOSE:
3.0
REFERENCE: ..
4.0
SAFETY: .
5.0
PERSONNEL QUALIFICATION:
6.0
SURFACE PREPARATION: .
7.0
7.1
7.2
10
7.3
11
8.0
12
9.0
COUPLANT: ..
12
10.0
CALIBRATION BLOCKS:
12
11.0
QUALIFICATION BLOCKS:
16
12.0
CALIBRATION: ....
19
12.1
EQUIPMENT CALIBRATION: .
19
12.2
ENCODER CALIBRATION: .
23
12.3
23
12.4
25
12.5
TCG CALIBRATION..
26
13.0
CALIBRATION CONFIRMATION: .
27
14.0
SCAN PLAN: ..
28
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15.0
28
16.0
30
17.0
ACCEPTANCE CRITERIA: ..
37
18.0
REPORTING: .
38
41
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1.0 SCOPE
This procedure describes the requirement and application of automated Time of Flight
Diffraction (TOFD) examination for detection and evaluation of discontinuities within weld
metal and heat affected zone of weld joints, and TOFD dead zones shall be covered by
Phased array method for deaerator. Final inspection shall be after PWHT in general
arrangement for deaerator. This procedure, when used in combination with specified scan
plan is applicable for single V groove joints configuration and thickness range as per table
given below. Work to this procedure will be in compliance with ASME Sec VIII Div 2.This
procedure is applicable for both circumferential and longitudinal weld seams.
Job no.
Joint No.
Material
Thickness
Joint
configuration
Welding
Process
301-01
SA 516 Gr 70
N
20,24,25 &
28mm
Single V
SAW +
SMAW
301-02 TO
05
SA 516 Gr 70
N
22,24,25 &
28mm
Single V
SAW +
SMAW
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2.0 PURPOSE
This procedure shall apply to the general aspect of ultrasonic examination of welds using
TOFD technique along with Phased array and Omniscan equipment coupled with
WeldROVER or HSMT X-03 (in areas inaccessible to WeldROVER Scanner). Main
objective of this procedure is to
Give the details of the equipment used and extent of volume coverage.
Since the qualification of this procedure is unique to the Omniscan equipment, this procedure
is not valid with any other instrument.
TOFD Sensitivity to near surface indications may be enhanced by using; higher frequency
probes, smaller PCS (Probe Center Separation), Lateral wave straightening or subtraction
algorithms.
3.0 REFERENCE
The following documents shall be referred in conjunction with this procedure:
ASME Sec VIII, Division 2 (2013), Rules for Construction of Pressure Vessels.
Omniscan Manual
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4.0 SAFETY
All personnel are responsible for ensuring that they, as well as their fellow employees
perform their job in a safe and professional manner, while adhering to the safety guidelines
laid out in safety manual SAL-HS-CP-GSE. In addition they will also adhere to any statutory
and local safety requirements along with any Client / Project specific safety requirements.
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Generally it is assumed that parent material has been tested using normal beam for planar
flaw e.g. lamination, during various stages of fabrication. If the same not documented then
prior to start of the TOFD & PA inspection, the base metal and HAZ area shall be scanned
using normal beam probe to locate reflectors that can limit the capability of the TOFD & PA
inspection to examine the weld volume.
Weld Identification:
Weld joints shall be identified with Weld Seam No. This unique weld numbering system will
be recorded as part of the file storage data. On the prepared area for inspection there will be a
zero reference index and/or position numbers marked on the weld with paint marker arrow
indicating the direction of scanning.
All circumferential measurement shall be made clockwise from the zero reference
position on the weld when looking in the direction of product flow. For vertical long
seams scanning shall start from bottom side of the shell towards topside.
The data storing capabilities of the system requires the use of an external storage device, flash
card or USB memory stick. In addition to data storage, the PC will also be used by the dataanalysis personnel for analyzing data subsequent to the completion of data collection. Datadisplay and analysis software (Tomoview 2.7R6 or higher version) compatible to that residing
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on the Omni Scan phased array system shall also be used for data play back. Tomoview 2.7R6
It is a powerful and versatile package that will be utilized for offline analysis of previous
acquired data files.
7.20SCANNER DETAIL
WeldROVER
Weld ROVER (Fig. 2 (c)) is a small and easy to operate one
axis encoded, motorized scanner. It can be used on plates and
pipe like structures with up to 6 probes (depends on OD/ID of
the pipe).
Figure 2 (c)WeldRover
HSMT-X03(Fig 2(d)) Scanner is a one axis encoded, semiautomated scanner. This scanner can hold up to 10 probes for
either
phased
array or
conventional
UT.
The
basic
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Figure 2 (f)
TOFD Probes & Wedges
Hole
Dia
(mm)
20 to < 25
2.5
Number
Depthof
range
TOFD
(mm)
set-ups
1
25 to < 28
0-t
Frequency
(MHz)
5-10
Wedgeangle
50-70
Element
size
(mm)
3-6
Beam
intersection
2/3t
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This procedure uses the following probes and wedges for Phased Array
PA Probe
Frequency
Number of
Elements
Active
Aperture
Elevation
Element
Size
Supportive Wedge
5L64 A2
5 MHz
64
38.4 mm
10 mm
0.60 mm
5L32 A5
5 MHz
32
19.2 mm
10 mm
0.60mm
9.0 COUPLANT
Acoustic coupling shall be obtained by using a medium (oil, grease, cellulose, water) suitable
for the purpose. Temperature of the part to be scanned shall be taken into considerations while
selecting the couplant. An environmentally safe wetting agent, such as water (up to 50oC) will
be required to promote acoustic coupling, however, no residue will remain on the work-piece
surface after the water has been evaporated. During examination same couplant shall be used as
during calibration.
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prolongation or material of the same specification product form. The calibration block shall
receive the same heat treatment as the part to be tested. The surface of the calibration, at no time
shall be inferior to that of the component. When the component material to be examined is clad,
the block shall be clad by the same welding process as the production part.
Two Cal blocks shall be used to scan different thickness varies from 20mm to 28mm.
alternatively, a thicker block may be utilized provided reflector size is based on the thickness to
be examined and an adequate number of SDHs exist to comply with basic calibration block.
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The basic calibration block configuration and reflector shall be as shown in figure 3 & 4
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Note :
1) All dimensions are in mm.
2) Runner plates shall be attached after drilling and notch preparation.
3) Notch width shall be 3mm
Tolerance on hole dia. Shall be +/- 0.8mm and tolerance on location through the block
thickness shall be +/- 3mm
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2.
3.
In case the block can be flipped during UT examination then one flaw may represent both ID
and OD surfaces.
When due to obstruction the weld examination can only be performed from one side of the
weld axis, the qualification block shall contain two sets of flaws, one set on each side of the
weld axis.
Flaw size shall be based on the qualification block thickness and shall be no longer than that
specified by Referencing code Section. For this work flaw size is based on
Maximum acceptable flaw height for material thickness as per ASME SECTION VIII
DIVISION 2
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Qualification block shall be scanned and the qualification data saved as per the procedure and
shall be available to the inspector.
Flaws shall be sized and categorized in accordance with the written procedure being
qualified.
Automated and semi-automated acceptance performance criteria is defined as the
detection of all the flaws in the demonstration block and
a) Recorded responses or imaged lengths, as applicable, exceed the specified evaluation
criteria of the procedure
b) The flaws are sized as being equal to or greater than their actual size (i.e., both length and
height)
c) The flaws are properly categorized (i.e., surface or subsurface)
Supplemental manual technique(s) (For Transverse Reflectors) acceptable performance
criteria is defined as the demonstration blocks flaws being
a) Sized as being equal to or greater than their actual size (i.e., both length and height)
b) Properly categorized (i.e., surface or subsurface)
Demonstration Block Record
The following information shall be recorded:
a) The information specified by the procedure being qualified
b) Demonstration block thickness, joint geometry including any cladding or weld overlays,
and flaw data [i.e., position in block, size (length and height)], separation distance to
nearest surface, category (surface or subsurface)
c) Scanning sensitivity and search unit travel speed
d) Qualification scan data
e) Flaw sizing data [same information as flaw data in]
The basic qualification block configuration and reflector shall be as shown below. Notch
width shall be 3 mm. All dimensions are in mm. Runner plates shall be attached after notch
preparation
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12.0 CALIBRATION
12.10 EQUIPMENT CALIBRATION
Due to the digital control nature of TOFD& PA instruments and also due to the fact that
multiple pulser and receivers are used, instruments are subject to screen height and amplitude
control linearity checks. Linearity checks shall be as per section T-461.1 & 461.2 (Mandatory
appendix I & II) of ASME Section V, Article 4. The results of these checks are recorded in
the ultrasonic instrument linearity forms and are kept as a part of the inspection record. OR
Linearity checks may be performed as per manufacturers standard practice. In this case a
template of verification sheet or a mention regarding manufacturer calibration shall be
provided. Instrument linearity checks are conducted on a twelve month cycle.
Prior to the start of shift operator need to carry out an element check and ensure that probe is
in working condition and ensure that no more than 10% of elements are inactive and no two
adjacent elements are inactive. Ensure the proper couplant between the probe and wedge.
Once data is collected make sure that data missing lines do not exceed the allowable limit.
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2) Increase the gain using the receiver gain adjustment to obtain 100% of full screen height
of the larger response. The height of the lower response is recorded at this gain setting as
a percentage of full screen height.
3) The height of the higher response is reduced in 10% steps to 10% of full screen height
and the height of the second response is recorded for each step.
4) Return the larger signal to 80% to ensure that the smaller signal has not drifted from its
original 40% level due to coupling variation. Repeat the test if variation of the second
signal is greater than 41% or less than 39% FSH.
5) For an acceptable tolerance, the response from the two reflectors should bear a 2 to 1
relationship to within 3% of full screen height throughout the range 10% to 100% (99%
if 100% is saturation) of full screen height.
6) The results are recorded on an instrument linearity form.
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the reference and measurement cursors determine the interval between each
normal
pulser and receiver, a method from element to element and any differences are
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attributable to the probe itself. To ensure channel is selected to address each element.
2) Any Phased Array Probe that has greater than 25% defective element of the usable
aperture should be replaced with a new probe.
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TOFD
After initial UT parameter and PCS setting for the given weld configuration and weld
thickness, an inspection pass is performed on the calibration block and a location is chosen in
the B-scan image by choosing the data cursor, where the lateral wave and Back wall signal is
seen. The velocity and wedge delay calibration is performed by choosing the ultrasound
reference cursor (Ur) on the lateral wave and place the TOFD (Tr) value as 0. Place the
ultrasound measurement cursor (Um) on the phase reversal amplitude of the back wall signal
and place the TOFD (Tm) value part thickness. Accept calibration and the TOFD
calibration shows the value of the part thickness in the B-scan display. In case, if the part is
divided into multiple zones where back wall or lateral wave or both may not be available,
calibration can be performed using SDHs at known depth.
Phased Array
Compensation for delay in the wedge is required so as to ensure that indications detected are
poisoned correctly. The wedge delay calibration shall be carried out for both linear scan and
as well as sectorial scan. The velocity & wedge delay calibration can be carried out in sound
path (using 50mm, 100mm radius of V1 block) mode or true depth (using SDHs) mode with
known reflector having fixed sound path or depth respectively. Peak up this signal from the
calibration reflector and scan the phased array probe backwards through all the different
angles or focal laws. Scan forward over the calibration reflector through all the refracted
angles of focal laws. When the signal for all angles and focal laws lies within the threshold,
Omniscan system dynamically adjusts delay setting to correctly indicate radius (depth).
Figure (11) shows the screen display during wedge delay calibration.
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12.4SENSITIVITY CALIBRATION
TOFD
The maximum diffraction efficiency occurs when the included angle is about 120o the probes
should be arranged such that beam centre lines intersect at about this angle (approximately at
2/3 of the zone thickness). The time window and PCS shall be set to those values that will be
used in subsequent examination. The time window should start at least 1s prior to the time
of arrival of the lateral wave, and should at least be extended up to the first back wall echo
with allowance for thickness and mismatch variation. Useful data can be obtained from mode
converted signals so it is recommended that the time window recorded also includes the time
of arrival of the first mode converted backwall echo signal.
Sensitivity calibration shall be performed on the calibration block or on the test object itself.
Set the TOFD probes on the surface to be utilized for calibration and set the gain control so
that the lateral wave amplitude is from 40% to 90% of the full screen height(FSH) and the
noise (grass) level is less than 5% to 10% FSH. This is the reference sensitivity. For multiple
zone examinations when the lateral wave is not displayed, or barely discernible, set the gain
control based solely on the noise (grass) level.
Phased Array
Variation between electronics of pulsers and receivers and variation between probe elements
results in small gain variation from one focal law to the next. Also the variation in path
distance in both wedge and steel will result in some focal laws requiring more gain. So to
compensate for this Omniscan shall be calibrated for sensitivity, which can be carried out
dynamically. The sensitivity calibration shall provide the required gain adjustments for each
refracted angle and sound path used. Select a calibration reflector, which is within the zone of
material to be examined. Peak up this signal from the calibration reflector and scan the
phased array probe backwards through all the different angles or focal laws. Scan forward
over the calibration reflector through all the refracted angles of focal laws. The Omniscan
System calculates the required gain needed at each focal law to adjust the amount of gain
required to obtain the sensitivity.
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Figure 12 illustrates the example of special screen feature used to ensure the sensitivity
(amplitude response) from each focal law. All focal laws provide a uniform amplitude
response to the calibration reflector. As the operator moves the probe back and forth over a
calibration reference reflector, unit software automatically adjusts gain to the prescribed
amplitude 80% with +5% tolerance limit. The horizontal scale is the virtual probe aperture
(VPA) which defines the group of elements i.e. focal law that is sequenced in the scan. These
focal laws are either linear or sectorial depending on whether E-scan of S-scans is being
calibrated.
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for each focal law at 80% FSH. Omniscan uses the gain compensation required due to
attenuation in the sound travel and adjust the gain for all focal laws/angles. Once all the
points are picked the TCG can be accepted. TCG calibration has to be carried out for all scan
plans in a multi group option while using phased array probe. The examination system
calibration shall be stored in the Omni scan System with electronic memory, on an external
chip or data storage device. This calibration may be used at a later date provided that the
system calibration is verified prior to the examination. A complete ultrasonic system
calibration shall be performed at least once prior to the examination.
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14.0SCAN PLAN
A documented examination strategy shall be provided showing search unit placement and
movement that provides a standardized and repeatable methodology for the examination.
Scan plan shall include beam angles and direction with respect to the weld axis reference
point, weld geometry and number of zones.
Scan plan provides clear view of scanning, helping to clearly convey weld coverage, HAZ
coverage and probe position, in addition to critical dimensions. The beamset parameters
dialog displays a visual representation of the transducer elements that are used to form the
beamset. Varying the focus of the beam is the capability of TOFD &PAinstrument, but
generally focusing is not the norm for weld inspection.
Beam spread visualization allows you to more accurately see the beam coverage and near
field visualization ensures that any focusing being performed is within the near field. True
Depth, Projection and Half Path focus types can be visualized in the workspace and
documented as a technique report. These all is achieved with the help of ESbeam software
tool. The scan plan for inspection of full volume of given weld geometry and thickness are
given in Annexure: 1
Note: Scan plan given below may require modification based on the actual field conditions to
achieve optimum inspection results. Such improvements are applicable provided it has been
demonstrated successfully on the qualification block.
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2) The ultrasonic transducer positioning and scanning device is controlled using a reference
mark (paint or low stress stamp adjacent to the weld)
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wave forms are captured without missing data points. Scanning speed shall not exceed that
qualified. Missing of data lines shall not exceed 5% of the total acquisition with adjacent data
shall not be missed. Omni Scan equipment has the capability of rewriting the data while
observed loss of data. The encoder is retrieved back to home position whenever data is
missed. Missing data is represented by black lines in the display. Between two consecutive
scans there should be an overlap of 50 mm. Repaired weld area shall be rescanned with an
overlap of minimum 50mm at the start and end of the scan.
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Relevant Indications
Signals that are determined to result from welding flaws will be assessed according to the
acceptance criteria in ASME Sec VIII Div2.For PA, flaw sizing shall be performed using -6
dB Drop technique. Flaw length parallel to the surface can be measured from the distance
encoded D- or C-scan images using amplitude drop techniques by placing vertical cursors on
the extents of the flaw displayed on the D- or C- scan display. Flaw height normal to the
surface can be measured from the B-, E-, or S-scan images using amplitude drop techniques.
Using amplitude drop techniques, the horizontal cursors are placed on the displayed flaws
upper and lower extents.
For TOFD, flaw lengths parallel to the surface can be measured from the TOFD image by fitting
hyperbolic cursors to the ends of the flaws. Flaw height perpendicular to the surface can be
measured from the TOFD image by fitting cursors on the top and bottom tip signals. A sizing
procedure qualified by performance demonstration will be used to assess all indications
interpreted to be flaws.
TomoView software should be used for further processing (e.g. lateral wave synchronization,
lateral wave removal and to apply soft gains) which enhances the interpretation of the
discontinuities.
Size & Category
Dimensions of the flaw shall be determined by rectangle that fully contains the area of the flaw.
Length of the flaw is the dimension of the rectangle parallel to pressure retaining surface, and
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the height of the flaw is the dimension of rectangle perpendicular to the pressure retaining
surface.
Flaws shall be characterized as being surface or subsurface based on their separation from the
nearest component surface:
1.
If space is equal to or less than one half of the height of the flaw than flaw shall be
categorized as surface flaw.
2. If space is greater than one half of the height of the flaw than flaw shall be categorized as
subsurface flaw.
Surface Indications
S <d
S>a
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flaw open to the surface, and is unacceptable unless surface examination is performed. If the
flaw is surface connected, the requirements above still apply. However, in no case shall the flaw
exceed the acceptance criteria in this Division for the material employed. Acceptance surface
examination techniques are as follows:
(1)
Magnetic particle examination (MT) in accordance with ASME 2013 SECTION VIII,
VIII,
Figure 15: Multiple Planar Flaws Oriented in a Plane Normal to the Pressure Retaining
Surface
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i.
Discontinuous flaws shall be considered a singular planar flaw if the distance between
adjacent flaws is equal to or less than the dimension S as shown in Figure (15).
ii.
Discontinuous flaws that are oriented primarily in parallel planes shall be considered a
singular planar flaw if the distance between the adjacent planes is equal to or less than 13
mm. (see Figure 16).
iii.
Discontinuous flaws that are coplanar and nonaligned in the through-wall thickness
direction of the component shall be considered a singular planar flaw if the distance
between adjacent flaws is equal to or less than S as shown in Figure 17.
iv.
For Subsurface Flaws the flaw length shall not exceed 4t.
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Figure 17: Non-Aligned Coplanar Flaws in a Plane Normal to the Pressure Retaining
Surface
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Sample Scan image Showing Flaw Length Sizing Using Amplitude Drop Technique
Flaw Height
Flaw height normal to the surfacecan be measured from the B-, E-, or S-scan images
using amplitude drop
Using amplitude drop techniques, the horizontalcursors are placed on the displayed flaws
upper and lowerextents.
Sample Scan image Showing Flaw Height Sizing Using Amplitude Drop Technique
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Flaw Acceptance Criteria for Inch (13mm) to less than 1 inch (25mm) Thick Weld
a/t
Surface Flaw
0.087
0.143
.025 In (6.4mm)
GENERAL NOTES:
(a) The parameter t is the thickness of the weld excluding any allowable reinforcement, and
the parameter l is the length of the flaw. For a butt weld joining two members having
different thickness at the weld, t is the thinner of these two thicknesses. If a full penetration
weld includes a fillet weld, then the thickness of the throat of the fillet weld shall be included
in t .
(b) A subsurface indication shall be considered as a surface flaw if the separation (S in Figure
13) of the indication from the nearest surface of the component is equal to or less than half
the through dimension (2d in Figure 14) of the subsurface indication.
(c) The acceptance limits specified here are based upon workmanship considerations and are
not necessarily intended for use in evaluating flaws identified after the vessel has gone into
service.
(d) The length (l) of the flaw shall be drawn parallel to the inside pressure-retaining surface
of the component.
(e) The depth of the flaw shall be drawn normal to the inside pressure retaining surface and
shall be denoted as a for a surface flaw or 2a for a subsurface flaw.
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GENERAL NOTES:
(a) The parameter t is the thickness of the weld excluding any allowable reinforcement, and
the parameter l is the length of the flaw. For a butt weld joining two members having
different thickness at the weld, t is the thinner of these two thicknesses. If a full penetration
weld includes a fillet weld, then the thickness of the throat of the fillet weld shall be included
in t .
(b) A subsurface indication shall be considered as a surface flaw if the separation (S in Figure
10) of the indication from the nearest surface of the component is equal to or less than half
the through dimension (2d in Figure 14) of the subsurface indication.
(c) The acceptance limits specified here are based upon workmanship considerations and are
not necessarily intended for use in evaluating flaws identified after the vessel has gone into
service.
(d) For intermediate flaw aspect ratio a/l and thickness t (64 mm (2 in.) < t < 100 mm (4
in.)), linear interpolation is permissible.
(e) If the acceptance criteria in this table results in a flaw length, l , less than 6.4 mm (0.25
in.), a value of 6.4 mm (0.25 in.) may be used.
(f) For materials exceeding 655 MPa (95 ksi) ultimate tensile strength, the use of this table is
limited to a thickness of 200 mm (8 in.).
18.0 REPORTING
The following data shall be reported in the final report
a. Procedure identification and revision.
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Annexure: 1
SCAN PLAN DETAILS
Surface of scanning : OD
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Surface of scanning : ID
Note:- scanning from ID surface shall be done when scanning from OD surface is not
possible.
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SURFACE OF SCANNING : OD
Scan Plan for 301-01 : CS1 & CS5
Thickness:25-20MM SHELL-DISH (A2 & A5)
Scan Plan for 301-01 : CS2 TO CS4 & LS1 TO LS4 & 301-02 TO 05 :
CS2 & LS1 TO LS2
Thickness: 25MM SHELL-SHELL
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Scan Plan for 301-01 : CS7 TO CS10 & LS5 TO LS9 & 301-02 TO 05 :
CS5, CS6 & LS3 TO LS5
Thickness:28MM SHELL-SHELL
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SURFACE OF SCANNING : ID
Scan Plan for 301-01 : CS1 & CS5
Thickness:25-20MM SHELL-DISH (A2 & A5)
Scan Plan for 301-01 : CS2 TO CS4 & LS1 TO LS4 & 301-02 TO 05 :
CS2 & LS1 TO LS2
Thickness:25MM SHELL-SHELL
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Scan Plan for 301-01: CS7 TO CS10 & LS5 TO LS9 & 301-02 TO 05:
CS5, CS6 & LS3 TO LS5
Thickness:28MM SHELL-SHELL
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Transverse Scanning
The angle beam shall be directed essentially parallelto the weld axis. The search unit shall be
manipulatedso that the ultrasonic energy passes through the requiredvolume of weld and adjacent
base material. The searchunit shall be rotated 180 deg and the examination repeated.
If the weld cap is not machined or ground flat, theexamination shall be performed from the base
metal onboth sides of the weld cap in both weld axis directions.