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While it is recognized that phased array technology is becoming more widespread and
popular within various industries, it has not yet been specifically addressed by the
AWS. The following document was written to satisfy customer requests. Its purpose is
to serve as a guideline to align the Phasor XS with the current methodology prescribed
in Clause 6, Part F, of the AWS D1.1, 2008 Code.
This is achievable due to the well-established fact that an array transducer with the
same physical properties of size, shape, and frequency, as a conventional monolithic
transducer, will have identical acoustic properties.
This document has been produced in typical procedure format, for the sake of
familiarity. As such, it is intended as a guideline only.
Page 2 of 40
Table of contents
SECTION PAGE
1. Scope 3
2. References 3
3. Personnel 4
4. Equipment 4
5. Calibration 6
6. Examination 13
Annex D: Drawings 37
Page 3 of 40
1. Scope
1.1. This procedure describes the use of the Phasor XS utilizing the sectorial and
A-scan views. For the detection and interpretation of discontinuities in groove
type welds and the associated heat affected zones (HAZ). Applicable part
thickness range is from 5/16” to 8” inclusive of material thickness as prescribed
by Part F of the AWS D1.1 – 2008 code. (herein referenced as “the code”)
1.2. Limitations
1.2.1. This procedure is not intended for the inspection of tube-to-tube (tubular)
T, Y, K connections
1.2.2. This procedure is not intended for the inspection of base material.
However, discontinuities discovered in the adjacent base material shall be
reported to the Owner / Engineer for disposition.
1.2.4. For discrepancies between this procedure, and the code, the code shall
hold precedence.
2. References
2.1. American Welding Society – AWS D1.1 Structural Welding Code Steel
3. Personnel
3.2. Personnel performing exams shall be a certified level I, II, or a level III who has
taken, and passed a Level II Practical certification test.
3.2.1. Level I personnel shall only perform exams under the direct supervision
of a level II, or III, and shall not independently (1) conduct exams, (2)
interpret exam results, or (3) write a report of exam results.
3.3. All personnel conducting exams in accordance with this procedure shall
demonstrate proficiency by successfully passing a general, specific and
practical exam administered by a level III, or a Level II so designated by a level
III, and applying the methodology of this procedure and the rules of AWS D1.1.
4. Equipment
4.1.1. For compliance with Sec. 6.22 of the AWS code, reference the Phasor
Owner’s Manual for the technical specifications.
4.4. Any suitable couplant material of glycerin type, or a cellulose gum and water
mixture shall be used between the search unit and base material. A wetting
agent may be added to improve consistency. Light machine oil or equivalent
may be used for coupling on calibration blocks.
Page 6 of 40
5. Calibration
5.1. General
5.1.2. A transducer element, cable, and coupling check shall be made prior to
an exam or series of exams, and again at the completion of an exam or
series of exams, but not to exceed intervals of 8 hours, and at any time of
suspected system irregularity. Reference Annex C for equipment
programming, and guidance.
5.1.3. The “primary” testing angle used for calibration shall be selected from
table 5.1
5.1.4. Calibration shall be performed with the Phasor set up in accordance with
table(s) 5.2, or 5.3.
5.1.5. Calibration intervals for sensitivity and horizontal sweep shall be made
by the operator at the location of each weld being tested, and at intervals
not to exceed 30 minutes as testing proceeds.
a) Change of personnel.
5.2.1. With the Phasor programmed in accordance with Table 5.2, place the
search unit on face “A” and adjust the leg function such that 2 plate
thicknesses are displayed on the screen.
5.2.2. For sensitivity, place the search unit at a location on the base material
that is free of discontinuities. Adjust the gain control to display the first back
reflection at 50% to 75% of amplitude. (A%A reading in the results
window).
5.3.1. A linear screen range shall be achieved to represent the actual sound
path in metal. The following method describes the use of the IIW2
reference block. However any suitable block described in 4.3 may be used.
5.3.2. Using the primary testing angle, and with the Phasor programmed in
accordance with Table 5.3, adjust the instrument to achieve a linear screen
range as follows:
5.3.2.2. Adjust the leg function to display the 2” and 4” radius on the
screen, maximizing the signal(s) amplitude. (NOTE: For this
process, the “Material Thickness” function may also be adjusted.
However, prior to examinations, the “Material Thickness” function
shall be returned to the actual component thickness as prescribed
in Table 5.3.)
5.3.2.3. Place the beam cursor on the primary testing angle to ensure the
readings in the “Results” windows are for this angle.
Page 8 of 40
5.3.2.4. In the CAL submenu (HOME > PART > CAL) adjust the gates to
surround where the beam cursor intersects the reflection from the
4” radius. (NOTE: the gates may also need to be narrowed.)
Maximize the signal response from the 4” radii by adjusting the
probe position. Adjust the gain such that the amplitude response
reads less than 100% in the A%A results window. Adjust the
VELOCITY S until the SA reading in the results window reads 4”.
5.3.3. With the Phasor programmed in accordance with table 5.3, adjust the
DbD gain control such that the response from the 0.060” hole, when the
search unit is placed at position A from Annex D Drawing 1, is maximized
with the primary testing angle from Table 5.1, to display a resulting
amplitude in the A%A between 40% to 60%. The resulting DbD setting is
the “zero reference level” and shall be recorded on the Ultrasonic Test
Report Table 7.1 under “Reference level (b)”.
(NOTE: The reference level may also be achieved by using only one side
of the gain in the Phasor. DbA or DbD. In this case toggle the “steps” key
to display the gain being used in the “home” screen. To activate the “Level
above reference” function, press and hold the orange key next to the gain
sub-menu box. In either case it is important to note the sum of all gain
applied above reference.
Page 9 of 40
Table 5.1
Page 10 of 40
Table 5.2
PROBE MENU
(Sub-menu) (Tab) (Value)
PRB DAT Dialog Probe Load Def
Frequency 2.3 MHz
Number of Elements 16
PRB GEO
Pitch 0.040
Elevation 0.650
WDGE DAT Element 1 Position Low end
Velocity .1086 in/µs
Wedge Front 0.000
WDGE GEO
Offset Z 1.00 (Annex C)
Angle 0.0 deg
OFFSET Origin Offset 0.000
PART MENU
(Sub-menu) (Tab) (Value)
PLAN Material Thickness “Enter material thickness”
CAL “ as described in section 5.2”
SCAN MENU
(Sub-menu) (Tab) (Value)
Type Linear
ELECTRNC Focal Point Unfocused
Wave Type Longitudinal
Angle Start 0.0 deg
SCN PATT Angle Stop 0.0 deg
Angle Step 1.0 deg
Number of Steps 1
First Element 1
APERTURE
Aperture Size 16
Aperture Step 1
DISPLAY MENU
(Sub-menu) (Tab) (Value)
View Mode Frame
VIEW Angle corrected On
Data Source Amp A
BACKGRND Color Leg On
Reading 1 Beam
Reading 2 A%A “Readings may be
RESULTS1
Reading 3 SA displayed in any order”
Reading 4 PA
UT MENU
(Sub-menu) (Tab) (Value)
Display Start Material
Base Display Delay 0.000 in
Leg 2.3
Voltage 150V
Pulser Width 220ns
PRF Value “set to maximum”
Frequency 2MHz
Receiver
Ascan Rectify Fullwave
Gate select Gate A
GATEMODE Logic Positive
Gate Display On
Page 12 of 40
Table 5.3
PROBE MENU
(Sub-menu) (Tab) (Value)
PRB DAT Dialog Probe Load Def
Frequency 2.3 MHz
Number of Elements 16
PRB GEO
Pitch 0.040
Elevation 0.650
WDGE DAT Element 1 Position Low end
Velocity .1086 in/µs
Wedge Front 0.711
WDGE GEO
Offset Z 0.435 (Annex C)
Angle 47.5 deg
OFFSET Origin Offset 0.000
PART MENU
(Sub-menu) (Tab) (Value)
PLAN Material Thickness “Enter material thickness”
CAL “ as described in section 5.3”
SCAN MENU
(Sub-menu) (Tab) (Value)
Type Sector
ELECTRNC Focal Point Unfocused
Wave Type Shear
Angle Start 35.0 deg
“minimum”
SCN PATT Angle Stop 70.0 deg
Angle Step 1.0 deg
Number of Steps 1
First Element 1
APERTURE
Aperture Size 16
Aperture Step 1
DISPLAY MENU
(Sub-menu) (Tab) (Value)
View Mode Frame
VIEW Angle corrected On
Data Source Amp A
BACKGRND Color Leg On
Reading 1 Beam
Reading 2 A%A “Readings may be
RESULTS1
Reading 3 SA displayed in any order”
Reading 4 PA
UT MENU
(Sub-menu) (Tab) (Value)
Display Start Material
Base Display Delay 0.000 in
Leg 2.3
Voltage 150V
Pulser Width 220ns
PRF Value “set to maximum”
Frequency 2MHz
Receiver
Ascan Rectify Fullwave
Gate select Gate A
GATEMODE Logic Positive
Gate Display On
Page 13 of 40
6. Examination
6.1. General
6.1.1. An “X” line for flaw location shall be marked on the test face of the
weldament in a direction parallel to the weld axis. The location distance
perpendicular to the weld axis is based on the dimensional figures on the
detail drawing and usually falls on the centerline of the butt welds, and
always falls on the near face of the connecting member of T and corner
welds, the face opposite Face C. (see Table 5.1 for Face descriptions.)
a) Weld identification,
b) Identification of Face A,
6.1.3. A couplant described in 4.4 shall be used between the search unit and
scanning surface.
6.1.4. All surfaces to which the search unit(s) is applied shall be free of weld
spatter, dirt, grease, oil, paint, loose scale, or any material/condition which
would prevent the transmission of ultrasound, and shall have a contour
allowing intimate coupling.
Page 14 of 40
6.2.1. The entire volume of base metal through which ultrasound must travel to
examine the weld shall be examined for laminar reflectors utilizing the
straight beam search unit calibrated in section 5.2. If any area of base
material exhibits a total loss of back wall reflection or displays an indication
equal to, or greater than the original back wall reflection height, and is
located such that it’s presence will interfere with the transmission of the
ultrasound for the weld inspection, it’s size, location, and depth from the A
Face shall be determined and reported on the ultrasonic test report, and an
alternate weld scanning procedure shall be used.
6.2.1.1. When the indication is larger than the search unit a full loss of the
back wall reflection will usually occur. By sliding the search unit off
the indication until a 50% drop in amplitude from the indication is
realized, and then by measuring to the centerline of the search
unit, is generally reliable for determining the edges of the
indication.
6.3.1. Welds shall be tested with the search unit described in Section 4.2, and
calibrated in Section 5.3. Following calibration, and during testing, the
only instrument adjustment permitted is the sensitivity level (gain)
setting.
6.4.2. All butt welds shall be examined from each side of the weld axis. Corner
and T welds shall be primarily tested from one side of the weld axis only.
All Welds shall be examined using the applicable scanning pattern, or
patterns as shown in Figure 6.4, as necessary to detect both longitudinal
and transverse discontinuities.
6.4.3.2. Scanning Movement “B”, Scanning Distance “b” shall be such that
the full section of the weld is being examined with the primary
angle from Section 5.3.
6.4.4. To detect transverse defects, cover the full weld section with one of the
following movements from Figure 6.4
Page 16 of 40
6.4.5. For electroslag or electrogas welds, use Scanning Pattern “E”, with the
search unit rotation angle “e” between 45deg. to 60deg.
Page 17 of 40
Table 6.4
Scanning Patterns
Page 18 of 40
7.2. The “Attenuation Factor, c,” in the ultrasonic test report shall be attained by
subtracting 1 inch of sound path (SA in the results window) from the
distance to the indication and multiplying the remainder by 2, and rounded to
the nearest dB value.
7.3. The “Indication Rating, d,” in the ultrasonic test report represents the
algebraic difference in decibels between the indication level with correction
for attenuation as indicated by the following expression:
Gain in dB: a – c =d
NOTE: Traditionally the indication level “a” is the sum of all gain applied. For
the purpose of this document the indication level is expressed as the amount of
gain OVER the reference gain. Therefore the equation will be “a – c = d”, and
NOT “a – b – c = d”
7.4. Lengths of indications with ratings more severe than Class D shall be
determined by measuring the distance between the transducer centerline
locations where the indication drops 50% in amplitude (6dB) below the
rating for the applicable flaw classification. The length shall be recorded as
“discontinuity length” on the ultrasonic test report.
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7.5. Each weld discontinuity shall be accepted or rejected on the basis of its
indication rating, and its length in conformance with the applicable Table
7.5A or 7.5B. Only those indications that are found to be unacceptable need
be recorded on the test report. The exception being those welds identified in
the contractual documents as being “fracture critical”. Fracture critical welds,
which are within 6dB inclusive of the minimal unacceptable rating, shall be
included on the test report.
7.7. Retesting of welds that have been repaired shall be documented on a new
line in the ultrasonic report, if the original is used, and shall be designated by
an “R” prefix in the indication number. If additional report forms are used, the
“R” designation shall prefix the report number, and / or the weld number, or
any such manner that clearly identifies the weld as being previously
repaired.
Page 20 of 40
Table 7.1
Ultrasonic Report Form
Page 21 of 40
Table 7.5A
Table 7.5B
AWS D1.1 STRUCTURAL WELDING CODE – STEEL
Annex A
dB accuracy procedure
1. dB Accuracy Procedure.
Note: In order to attain the required accuracy (+ 1%) in reading the indication
height, the Display must be graduated vertically at 2% intervals at horizontal
midscreen. These graduations shall be placed on the Display between 60%
and 100% of screen height. This may be done with use of a graduated
transparent screen overlay. If this overlay is applied as a permanent part of
the ultrasonic unit, care should be taken that the overlay does not obscure
normal testing displays.
(2) Adjust the distance calibration so that the first 2 inch back
reflection indication (hereafter called "the indication") is at
horizontal mid-screen.
(4) Move the search unit toward position U, until the indication
is at exactly 40% screen height.
(5) Increase the sound amplitude 6dB with the calibrated gain
or attenuation control. The indication level theoretically
should be exactly 80% screen height.
(7) Move the search unit further toward position U, until the
indication is exactly 40% screen height.
(11) Apply the information from Rows "a" and "b" to the below
referenced equation (Section 2. Annex A) or the
nomograph (Form A.2) to calculate the corrected dB.
(13) Subtract Row "c" value from Row "a" value and apply the
difference in Row "d", dB error. These values may be
either positive or negative and should be noted with a plus
sign "+" or a minus sign "-".
(16) Apply the dB information from Row "e" (Form A.1) vertically
and dB reading from Row "a" (Form A.1) horizontally as X
and Y coordinates for plotting a dB curve on Form A.2.
2. Decibel Equation.
The following equation shall be used to calculate decibels:
%
dB = 20 x log + dB
2
%
2 1
%1 = Row “b”
Form A.1
Ultrasonic Unit Calibration Report Form
Supplemental Instructions:
Start with the lowest dB level that you can obtain a 40 percent display height indication from. Add 6 dB's and
record this dB reading in “Row A” and display height “Row B” as the starting points on the tabulation chart.
After recording these values in “Rows A and B”, slide the transducer to obtain a new 40 percent display
height. Without moving the transducer add 6 dBs and record the new dB reading and the new display height in
“Rows A and B”. Repeat this step as many times as the unit allows.
Find the average % screen values from “Row B” by disregarding the first 3 and the last 3 tabulations. Use
this as %2 in calculating the corrected reading.
dB1 is Row A
dB2 is Row C
The dB Error "Row D" is established by subtracting “Row C" from “Row A": (A - C = D).
The Collective dB Error "Row E" is established by starting with the dB Error "Row D" nearest to 0.0,
collectively add the dB Error “Row D” values horizontally, placing the sub-totals in “Row E".
Moving horizontally, left and right from the Average % line, find the span in which the largest and smallest
Collective dB Error figures remain at or below 2 dB. Count the number of horizontal spaces of movement,
subtract one, and multiply the remainder by six. This dB value is the acceptable range of the unit.
In order to establish the acceptable range graphically, Form D-9 from AWS D1.1 may be used as follows:
(1) Apply the collective dB Error “Row E” values vertically on the horizontal offset coinciding with the dB reading
values from "Row A".
(3) Apply a 2 dB high horizontal window over this curve positioned vertically so that the longest section is
completely encompassed within the 2 dB Error height.
(4) This window length represents the acceptable dB range of the unit.
Page 27 of 40
NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13
Row A dB READING
Row D dB ERROR
Equipment is: Acceptable for Use Not Acceptable for Use Recalibration Due Date:
Form A.2
dB Accuracy Evaluation Report Form
Annex B
Horizontal Linearity, Internal Reflectors, and Resolution
The use of a 10 in. [250 mm] screen calibration in shear wave would
require a 20 in. [500 mm] screen calibration for this qualification procedure.
The following procedure shall be used for instrument certification:
(1) Couple a straight beam search unit meeting the requirements
of paragraph 4.2 to the DS block (Drawing D.1 in Position U).
(2) To attain a 20 in. [500 mm] screen calibration, adjust the first
and fifth back reflections to their proper locations with use of
the distance calibration and zero delay adjustments.
(2) Remove the search unit from the calibration block without
changing any other equipment adjustments.
(4) The screen area beyond 1/2 in. [12 mm] sound path and
above reference level height shall be free of any indication.
Page 30 of 40
3. Resolution Requirements.
3.1 The combination of search unit and instrument shall resolve three holes
in the RC resolution reference test block shown in Drawing D.1, or D.3.
The search unit position(s) from Drawing D.1 are as follows:
3.2 The resolution shall be evaluated with the instrument controls set at
normal test settings and with indications from the holes brought to
midscreen height. Resolution shall be sufficient to distinguish at least
the peaks of indications from the three holes. Use of the RC resolution
reference block for calibration shall be prohibited. Each combination of
instrument search unit (shoe and transducer) shall be checked prior to
its initial use. This equipment verification shall be done initially with
each search unit and UT unit combination. The verification need not be
done again provided documentation is maintained that records the
following items:
Form B.1
Ultrasonic Unit Calibration Report Form B.1
Horizontal linearity :
Internal Reflections:
Remove search unit from block without changing any equipment settings
Is the CRT screen area beyond 1/2" sound path and above reference level height free of
any indications? Yes: No:___
Equipment Status:
As Found As Adjusted
Form B.2
Ultrasonic Unit Resolution Report Form B.2
TRANSDUCERS:
Annex C
Search unit check
PROBE MENU
(Sub-menu) (tab) (value)
Number of elements 16
Probe Geometry
Pitch 0.040”
Wedge Dat Elem 1 Pos Low End
Offset “Z” 0
Wedge Geometry
Angle 0
Offset Probe Delay 0.000µs
PART MENU
(Sub-menu) (tab) (value)
Part Velocity L .1080 in/us
SCAN MENU
(Sub-menu) (tab) (value)
Type Linear
Electronic Focal Point Unfocused
Wave Type Longitudinal
Scan Pattern Angle Start 0.0 deg
Number of Steps 16
First Element 1
Aperture
Aperture Size 1
Aperture Step 1
DISPLAY MENU
(Sub-menu) (tab) (value)
View Angle Corrected On
Reading 1 P%A
Reading 2 PSA
Results1
Reading 3 Beam
Reading 4 SA
UT MENU
(Sub-menu) (tab) (value)
Base Display Delay 0.0
Voltage 150V
Pulser
Width 220ns
Receiver Frequency 2MHz
Gate mode TOF mode Flank
Page 35 of 40
The pattern created is the result of firing each individual element in sequence,
and the “step like” slope that is created is due to the different thickness in
wedge material, or delay, beneath each element.
Page 36 of 40
Material thickness and leg functions must be adjusted to your wedge in order
to display the “step pattern” on the screen.
The A gate must frame the wedge echoes.
The gain must be high enough so that the P%A reading is the result of the
first element being barely > 100% FSH.
Position the beam cursor to the last element so that it is reading in the SA.
1) Z = (9.14mm + 13.60mm) /2
2) Z = (22.74mm) /2
3) Z = 11.37mm
Specified value 11.5mm → Measured value 11.37mm
Page 37 of 40
Annex D
Drawings
Drawing D.1
Page 38 of 40
Drawing D.2
Page 39 of 40
Drawing D.3
Page 40 of 40
Drawing D.4