DOCUMENT No.

: T Q I 78

REV. No. 0 DATE: 15.12.2003

INSPECTION INSTRUCTIONS
PAGE 1 OF 10

ULTRASONIC INSPECTION OF WELDS EXTENT OF INSPECTION

AND ACCEPTANCE CRITERIA AS PER AWS-D1.1

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0 15.12.2003 First Issue

REV. NO. DATE BRIEF RECORD OF REVISIONS

PREPARED BY : HEAD - QA APPROVED BY : CHIEF - QUALITY SERVICES

SIGNATURE : SIGNATURE :

NAME : NAME : G. SREENIVASA RAO

 DOCUMENT No. : T Q I 78
ULTRASONIC INSPECTION OF WELDS REV. No. 0 DATE: 15.12.2003
EXTENT OF INSPECTION & ACCEPTANCE
CRITERIA AS PER AWS-D1.1 PAGE 2 OF 10

1.0 SCOPE

This document covers the extent of ultrasonic inspection and acceptance

criteria as per AWS D-1.1.

2.0 REFERENCE

AWS D-1.1-1996 structural welding code (Section6, part-C).

3.0 EXTENT OF ULTRASONIC INSPECTION

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3.1 Tubular connections and staticllay and cyclically loaded non-tubular
connections.

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3.1.1 For complete joint penetration groove welds, welded from one side
without backing, the entire length of all completed tubular production

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welds shall be examined by either radiography or ultrasonic testing.

3.1.2
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For all other weld joints, the requirement of ultrasonic inspection shall be

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as indicated in the relevant contract/ fabrication drawings.

3.1.3
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The weld joints shall have been inspected visually and found acceptable

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prior to ultrasonic inspection.

4.0
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ACCEPTANCE CRITERIA

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4.1

4.1.1 UN
Statically loaded non-tubular connections

The welds that are subject to ultrasonic testing, in addition to visual

inspection, shall be acceptable, if they melt requirements of Table 6.2
(Annexure-I).

4.1.2 For complete joint penetration web-to-flange welds, acceptance of

discontinuities detected by scanning movements other than scanning
pattern E may be based on weld thickness equal to the actual web
thickness plus 1 in.(25mm)

4.1.2.1 Discontinuities detected by scanning pattern E shall be evaluated to the

criteria of Table 6.2 (Annexure-I) for actual web thickness.

4.1.2.2 Ultrasonically tested welds are evaluated on the basis of a discontinuity

reflecting ultrasound in proportion to its effect on the integrity of the weld.

4.1.2.3 Indications of discontinuities that remain on the display as the search unit
is moved towards and away from the discontinuity (scanning movement
b) may be indicative of planar discontinuities with significant through -
throat dimension.
 DOCUMENT No. : T Q I 78
ULTRASONIC INSPECTION OF WELDS REV. No. 0 DATE: 15.12.2003
EXTENT OF INSPECTION & ACCEPTANCE
CRITERIA AS PER AWS-D1.1 PAGE 3 OF 10

4.1.2.4 Since the major reflecting surface of the most critical discontinuities is
oriented a minimum of 200 (for a 700 search unit) to 450 (for a 450 search
unit) from perpendicular to the sound beam, amplitude evaluation (dB
rating) does not permit reliable disposition.

4.1.2.5 When indications exhibiting these planar characteristics are present at

scanning sensitivity, a more detailed evaluation of the discontinuity by
other means shall be required. (eg. Alternate ultrasonic techniques,
radiography, grinding or gouging for visual inspection etc.).

4.2 Cyclically loaded non-tubular connections

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4.2.1 Welds that are subject to ultrasonic testing in addition to visual inspection

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are acceptable if they meet the following requirements.

4.2.1.1 Welds subject to tensile stress under any condition of loading shall

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conform to the requirements of Table 6.3 (Annexure-II).

4.2.1.2
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Welds subject to compressive stress shall conform to the requirements of
Table 6.2 (Annexure-I).
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4.2.2 Indications
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4.2.2.1
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Ultrasonically tested welds are evaluated on the basis of a discontinuity

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reflecting ultrasound in proportion to its effect on the integrity of the weld.

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4.2.2.2

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Indications of discontinuities that remain on the display as the search unit
is moved towards and away from the discontinuity (scanning movement
b) may be indicative of planar discontinuities with significant through
throat dimension.

4.2.2.3 As the orientation of such discontinuities relative to the sound beam

deviates from the perpendicular, dB ratings which do not permit direct
reliable evaluation of the welded joint integrity may result.

4.2.2.4 When the indications that exhibit these planar characteristics are present
at scanning sensitivity, a more detailed evaluation of the discontinuity by
other means may be required (eg. alternate ultrasonic techniques,
radiography, grinding or gauging for visual inspection etc.)

4.2.2.5 Scanning

4.2.2.5.1 Complete joint penetration web-to-flange welds shall conform to the

requirements of Table 6.2 (Annexure-I), and acceptance for
discontinuities detected by scanning movements other than scanning
pattern E may be based on a weld thickness equal to the actual web
thickness plus 1 in. (25 mm). Discontinuities detected by scanning pattern
E shall be evaluated to the criteria of 4.2 for the actual web thickness.
 DOCUMENT No. : T Q I 78
ULTRASONIC INSPECTION OF WELDS REV. No. 0 DATE: 15.12.2003
EXTENT OF INSPECTION & ACCEPTANCE
CRITERIA AS PER AWS-D1.1 PAGE 4 OF 10

4.2.2.5.2 When such web-to-flange welds are subject to calculated tensile stress
normal to weld, they shall be so designated on the design drawings and
shall conform to the requirements to Table 6.3 (Annexure-II).

4.3 Tubular connections

4.3.1 Acceptance criteria for ultrasonic testing shall be as provided in contract

documents. Class R or Class X, or both may be incorporated by
reference.

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4.3.1.1 Amplitude based acceptance criteria as given for statically loaded non-
tubular connections (Refer 4.1) may also be used for groove welds in butt

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joints in tubing 24 in. (610 mm) in diameter and over, provided all relevant
provisions of section 6, part F (i.e) ultrasonic testing of groove welds
(procedures and standards) is followed. However, these amplitude criteria

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shall not be applied to tubular T-, Y-, and K-connections.

4.3.2
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Class R (Applicable when UT is used as an alternate to RT)

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4.3.2.1
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All indications having one half (6 dB) or less amplitude than the standard

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sensitivity level, shall be disregarded. However, the requirements

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indicated in 4.4.2 shall be ensured.

4.3.2.2
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Indications exceeding the disregard level shall be evaluated as follows:

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a)

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Isolated random spherical reflectors, with 1 in. (25mm) minimum
separation upto the standard sensitivity level shall be accepted.
Larger reflectors shall be evaluated as linear reflectors.

b) Aligned spherical reflectors shall be evaluated as linear reflectors.

c) Clustered spherical reflectors having a density of more than one per

square inch (645 square milli meters) with indications above the
disregard levels (projected area normal to the direction of applied
stress, averaged over a 6 in. (150 mm) length of weld) shall be
rejected.

d) Linear or planar reflectors whose lengths (extent) exceed the limits

of figure 6.7 (Annexure-III) shall be rejected. Additionally, root
reflectors shall not exceed the limits of class X.

4.4 Class X (Experience-based, fitness- for purpose criteria applicable to T-

, Y-, and K- connections in redundant structures with notch tough
weldments)

4.4.1 All indications having half (6 dB) or less amplitude than the standard
sensitivity level shall be disregarded.
 DOCUMENT No. : T Q I 78
ULTRASONIC INSPECTION OF WELDS REV. No. 0 DATE: 15.12.2003
EXTENT OF INSPECTION & ACCEPTANCE
CRITERIA AS PER AWS-D1.1 PAGE 5 OF 10

4.4.2 However, indications found in the root areas of groove welds, in butt joints
and along the fusion face of all welds shall be further evaluated with either
700, 600 or 450 search angle, whichever is nearest to being perpendicular
to the expected fusion face.

4.4.3 Indications exceeding the disregarded level shall be evaluated as follows.

i) Spherical reflectors shall be as described in class R, (Para 3.2

above) except that any indications within the following limits for
linear or planar are acceptable.

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ii) Linear or planar reflectors shall be evaluated by means of beam
boundary techniques, and those whose dimensions exceeded the

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limits of figure 6.8 (Annexure-IV) shall be rejected. The root area
shall be defined as that laying within in. (6mm) or tw/4,
whichever is greater, of the root of the theoretical weld.

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 DOCUMENT No. : T Q I 78
ULTRASONIC INSPECTION OF WELDS REV. No. 0 DATE: 15.12.2003
EXTENT OF INSPECTION & ACCEPTANCE
CRITERIA AS PER AWS-D1.1 PAGE 6 OF 10

Annexure I

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 DOCUMENT No. : T Q I 78
ULTRASONIC INSPECTION OF WELDS REV. No. 0 DATE: 15.12.2003
EXTENT OF INSPECTION & ACCEPTANCE
CRITERIA AS PER AWS-D1.1 PAGE 7 OF 10

Annexure II

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 DOCUMENT No. : T Q I 78
ULTRASONIC INSPECTION OF WELDS REV. No. 0 DATE: 15.12.2003
EXTENT OF INSPECTION & ACCEPTANCE
CRITERIA AS PER AWS-D1.1 PAGE 8 OF 10

Annexure III

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 DOCUMENT No. : T Q I 78
ULTRASONIC INSPECTION OF WELDS REV. No. 0 DATE: 15.12.2003
EXTENT OF INSPECTION & ACCEPTANCE
CRITERIA AS PER AWS-D1.1 PAGE 9 OF 10

Annexure III

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 DOCUMENT No. : T Q I 78
ULTRASONIC INSPECTION OF WELDS REV. No. 0 DATE: 15.12.2003
EXTENT OF INSPECTION & ACCEPTANCE
CRITERIA AS PER AWS-D1.1 PAGE 10 OF 10

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