REVISION CONTROL Revision Number & Date
Changes
Remarks -
INDEX Clause Re!!! % ' ( . / 1 2 %3 %% %'
Des"ri#tion o Content
$age Re!
S"o#e Reeren"e Do"uments $ersonal Test E)ui#ment an* +u,iliaries Sura"e Con*ition an* $re#aration Cou#lant Calibration 0lo"k Calibration Interval E)ui#ment Controls Calibration $ro"e*ure Do"umentation Saet4
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+nne,ure - %
%(
%! S"o#e5 %!%! This #ro"e*ure *es"ribes routine "alibration o ultrasoni" la6 *ete"tors using "onventional #ulse e"ho metho* or the *ete"tion an* evaluation o la6s in metalli" "om#onents an* #ro*u"t orms! %!'! Onl4 #ulse-e"ho +-s"an t4#e instruments base* on #ie7o-ele"tri" #rin"i#le o generating an* re"eiving soun* 6aves have been "overe*! 0oth the +nalogue an* *igital out #ut e)ui#ments are in the s"o#e o this #ro"e*ure! 8o6ever9 this #ro"e*ure ma4 be use* or other t4#es o instruments e! g! 0-s"an an* C-s"an t4#es9 i #ermitte* b4 the relevant "o*es: s#e"ii"ations an* sub;e"t to an4 a**itional re)uirement state* therein! %!(! This #ro"e*ure shall not be use* or "alibration o ultrasoni" la6 *ete"tors 6ith soun* generation an* re"e#tion base* on other #rin"i#les like S4ntheti" +#erture o"using9 E<+T9 $hase* +rra49 To=D et"! %!! The #ro"e*ure *es"ribe* here is limite* to the verii"ation o linearit4 an* "alibration o +-s"an t4#e *is#la4! Calibration o ele"tri"al "om#onents is not un*er the #urvie6 o this #ro"e*ure an* shall not be use* or that #ur#ose! '! Reeren"e Do"uments5 '!% The ollo6ing *o"uments are reerre*5 '!%!% '!%!' '!%!( '!%! '!%! '!%!. (
+S
< E (%/! +S
$ersonnel5 (!% +ll #ersonnel #erorming "alibration o @T e)ui#ment using this #ro"e*ure shall be )ualiie* to a minimum o Level II! AReer '!%!.B (!' $ersonnel #erorming E,amination shall have vision9 6ith "orre"tion i ne"essar49 to enable to rea* aeger T4#e No! ' Stan*ar* Chart at a *istan"e o not less than (33mm9 an* *ierentiate the "ontrast bet6een the "olors and sha*es o gra49 an* re"or*s o su"h vision test shall be maintaine* b4 "om#an4! Vision tests shall be "on*u"te* annuall4 an* be "urrent *uring e,amination! (!( Ea"h "alibration o ultrasoni" e)ui#ment shall be 6itnesse* an* a##rove* b4 a NDT Level III in the
relevant metho*! (! $ersonnel "on*u"ting @ltrasoni" E,amination shoul* be a6are o the sae-#ra"ti"e re)uirements *uring e,amination!
Test E)ui#ment an* +u,iliaries5 !% The #ulse-e"ho t4#e instrument "a#able o o#eration at re)uen"ies over the range o at least % <87 to <87 an* e)ui##e* 6ith a ste##e* gain "ontrol in units o '!3 *0 or less are sub;e"t to the "alibration on annual basis! !' Sear"h @nits ATrans*u"ersB shall be either Single Cr4stal or T6in Cr4stal t4#es! The nominal re)uen"4 shall be rom % <87 to <87 !( The sear"h units materials & "onstru"tion shall be "a#able o #ro*u"ing either longitu*inal or shear 6aves into the test "om#onent! enerall4 *esignate* normal A3 B #robes shoul* be "a#able o #ro*u"ing longitu*inal 6aves into test "om#onen t 6hile angle #robes shoul* be "a#able o #ro*u"ing rera"te* shear 6aves in to test "om#onent at angles 9 .3 9 an* /3 Ain steelB! °
°
°
°
! The nominal "ross-se"tion si7es o normal #robes shall be bet6een *iameters %3 mm to ' mm9 6hile the "ross-se"tion si7es o angle #robes shall be 1 mm , 2 mm to '3 mm , '' mm! ! Co-a,ial "ables "onne"ting sear"h units 6ith the e)ui#ment shall be o length bet6een %!m! & m! an* shall have en* a*a#ters "a#able o se"ure* "onne"tions at en*s? 6here9 re)uire* a*o#ters o various t4#es shall be use* to se"ure "onne"tivit4!
Sura"e "on*ition & #re#aration5 !% +s the "alibration blo"k use* or the #ur#ose o instrument "alibration is integrall4 atta"he* to the #robe su##lie* or "alibration9 sura"e #re#aration is not re)uire*! !' In "ases9 6here a se#arate "alibration not integrall4 atta"he* is use*9 the sura"e shall be #re#are* in su"h a 6a4 that areas to be s"anne* shall be ree o all *irt9 #aint9 loose #arti"les9 loose mill-s"ale9 tem#orar4 atta"hments or an4 obstru"tive materials that "oul* interere 6ith the e,amination!
.
Cou#lant5 .!% Cou#lants are not re)uire* 6hen using integrall4 atta"he* blo"ks! .!' =or non-integral blo"ks9 "ou#lants are use* to eliminate the air ga# bet6een the trans*u"er an* the test sura"e to assure ma,imum ultrasoun* transmission! The "ou#lants 6ill normall4 be a 6etting agent A#ol4"elB in 6ater9 li)ui* soa#9 so*ium C
.!( The "ou#lant shoul* be sele"te* so that its vis"osit4 is a##ro#riate or the sura"e inish o the material sura"e to be e,amine* AE,amination o rough sura"es generall4 re)uires high vis"osit4 "ou#lantB! Tem#erature o the material sura"e "an "hange the "ou#lants vis"osit4! /
Calibration 0lo"ks5 /!% Integrall4 atta"he* blo"k5 N (3 "alibration stan*ar*5 +luminium blo"k o 1mm long an* (1!mm *iameter ASoli* "4lin*ri"al sha#eB atta"he* to a 'mm *iameter '<87 longitu*inal 6ave trans*u"er shall be use*! This blo"k an* #robe assembl4 is su##lie* b4 Frautkrammer9 manua"turer o ultrasoni" la6 *ete"tors! Reer to igure %! /!' Other "alibration blo"ks like IIG V% or IOG stan*ar* blo"ks ma4 be use*! Reer to igure ' or blo"k *etails!
1! Calibration interval5 S"reen 8eight Linearit4 an* +m#litu*e Control Linearit4 o the e)ui#ment shall be #erio*i"all4 evaluate*? su"h #erio*i"it4 shall be at intervals not to e,"ee* three months or +nalogue t4#e instruments an* one 4ear or Digital t4#e instruments or #rior to irst use thereater! Results o su"h evaluations shall be re"or*e* an* re"or*s to be maintaine*!
2! E)ui#ment "ontrols5 2!%
+n4 instrument "ontrol9 6hi"h ae"ts instrument linearit4 Ae!g! ilters9 re;e"t9 or "li##ingB9 shall be in the same #osition or "alibration9 "alibration "he"ks9 instrument linearit4 "he"ks9 an* e,amination! I the instrument has a *am#ing "ontrol9 it ma4 be use* i it *oes not re*u"e sensitivit4 o e,amination!
2!' The re;e"t "ontrol shall be in the Ho #osition or all e,aminations9 unless it "an be *emonstrate* that it *oes not ae"t the linearit4 o the e,amination! %3! Calibration $ro"e*ure5 %3!% 8ori7ontal linearit45 @sing N(3 "alibration blo"k5 $la"e the trans*u"er blo"k assembl4 to the @T instrument so"ket! Fee# the *istan"e range to 33mm! +*;ust #robe *ela4 to mark the irst e"ho rom 3mm o steel A1mm o +lB!
%3!' Verti"al Linearit45 @sing N(3 "alibration blo"k5 $la"e the trans*u"er blo"k assembl4 to the @T instrument so"ket! Fee# the *istan"e range to '33mm! Choose an4 t6o e"ho 6ho make almost '5% ratio! In"rease the gain in ' *0 ste#s rom '3J =S8 o the highest e"ho to 13J =S8 o the highest! The in"rease o the lo6est e"ho shall be in the same #ro#ortion so that the ratio bet6een the t6o is 6ithin K J o '5%! @sing the IIG V% blo"k9 kee# the #robe at #osition AbB as sho6n in igure (! Change the instrument *istan"e range to '33mm9 so that ' sets o ba"k 6all e"hoes "an be vie6e* "an be seen in the *is#la4! =ollo6 the same #ro"e*ure state* above! +lternatel49 $osition an angle beam sear"h unit on a "alibration blo"k similar to that sho6n in =ig! so that in*i"ations rom both the an* M T holes give a '5% ratio o am#litu*es bet6een the t6o in*i"ations! +*;ust the sensitivit4 AgainB so that the larger in*i"ation is set at 13J o ull s"reen height A=S8B! Githout moving the sear"h unit9 a*;ust sensitivit4 AgainB to su""essivel4 set the larger in*i"ation rom %33J to '3J o ull s"reen height9 in %3J in"rements Aor ' *0 ste#s i a ine "ontrol is not availableB9 an* rea* the smaller in*i"ation at ea"h setting! The rea*ing shall be 3J o the larger am#litu*e9 6ithin J o =S8! The settings an* rea*ings shall be estimate* to the nearest %J o ull s"reen! %3!( +m#litu*e Control Linearit45 @sing N(3 "alibration blo"k5 $la"e the trans*u"er blo"k assembl4 to the @T instrument so"ket! Fee# the *istan"e range to '33mm! Choose an4 e"ho rom the ba"k 6all! In"rease the gain in . *0 ste#s rom '3J =S8 o the highest e"ho to 13J =S8 o the highest! Similarl49 *e"rease the instrument gain b4 .*0 ste#s rom 13J to '3J =S8! The resulting values shall be 6ithin the range as given the ollo6ing table! @sing the IIG V% blo"k9 kee# the #robe at #osition A"B as sho6n in igure (! Change the instrument *istan"e range to %33mm! =ollo6 the same #ro"e*ure state* above! +lternatel49 #osition an angle beam sear"h unit on a basi" "alibration blo"k9 as sho6n in =ig! so that the in*i"ation rom the T si*e-*rille* hole is #eake* on the s"reen! +*;ust the sensitivit4 AgainB as sho6n in the ollo6ing table! The in*i"ation shall all 6ithin the s#e"iie* limits! +lternativel49 an4 other "onvenient rele"tor rom an4 "alibration blo"k ma4 be use* 6ith angle or straight beam sear"h units! The settings an* rea*ings shall be estimate* to the nearest % J o ull s"reen!
Srl no!
In*i"ation set at J o ull s"reen
3% 3' 3( 3 3
13 3 '3 3 13
*0 "ontrol "hange 33 -. *0 -%' *0 K. *0 K%'*0
In*i"ation limits J o ull s"reen (' to 1J %. to 'J (' to 1J . to 2.J
Deviation
Remarks
%%! Do"umentation %%!%
=or ea"h @ltrasoni" e)ui#ment "alibration as #er this $ro"e*ure9 the ollo6ing minimum inormation shall be re"or*e* an* suitabl4 a**resse* in the relevant Re#ort AReer +nne,ure IB5 %%!%!% %%!%!' %%!%!( %%!%! %%!%! %%!%!. %%!%!/ %%!%!1 %%!%!2 %%!%!%3
$ro"e*ure I*entii"ation an* Revision @ltrasoni" Instrument i*entii"ation A
%'! Saet45 %'!% +ll ins#e"tion #ersonnel shall be res#onsible or "om#lian"e 6ith a##li"able saet4 rules in the use o Test materials! %'!' Some o the Calibration blo"ks use* in @ltrasoni" Testing are airl4 heav4 in 6eight9 having s)uare e*ges! The4 ma4 be be"ome sli##er4 *ue to usage o "ou#lants an* 6ill nee* to be "areull4 han*le*! %'!(
Some test materials su"h as "ou#lants ma4 "ause skin irritation! @se a*e)uate ventilation at all times an* avoi*s #rolonge* skin "onta"t!
%'!
Test materials shall never be heate* above the re"ommen*e* tem#erature limits #res"ribe* b4 the manua"turer!
%'!
The test s4stem has ele"tri"al in#ut or the Test e)ui#ment an* sae #ra"ti"es shoul* be ollo6e* to avoi* an4 ele"tri"al sho"ks!
(1!mm *ia!
$robe
1 mm length Figure – 1 N(3 "alibration stan*ar* blo"k
Figure – 2
(a) & (c)
'mm
(33mm
'33mm
%33 1 2%
(b)
Figure – 3
NOTES: 1. Probe position (a): Horionta! !inearit". 2. Probe position (b): #ertica! !inearit". 3. Probe position (c): $%p!itue contro! !inearit".
Figure – '
$NNE*E – 1 Calibration certificate no.
1. E+uip%ent etai!s: , Instrument Model no.
Make
Serial no.
2. *e-erence ocu%ents: , a! +S
Serial no. Date:
Measured deviation Tolerance Remarks See se"tion + K:- J See se"tion 0 J See se"tion C iven at C Nil Nil Next calibration date:
This is to "erti4 that the above instrument bearing serial no! has been "alibrate* in a""or*an"e 6ith the re)uirements o +S
+##rove* b45
Name5
Name5
Date5
Date5
$. nstru%ent #ertica! inearit":
Calibration blo"k5 N(3 Instrument5 Calibration reeren"e5 3mm thi"k blo"k? longitu*inal 6ave s#ee*5 2'3m:s! Srl no! 3% 3' 3( 3 3 3. 3/
Instrument ain A*0B '.! '! ''! '3! %1! %.! %!
E"ho 8eight + AJB /2 . % 3 (' '. '3
E"ho height 0 AJB (1 (' ' '3 %. %( %3
Ratio
Remarks OF OF OF OF OF OF OF
0. nstru%ent Horionta! inearit":
Calibration blo"k5 N(3 Instrument5 @S< ( A('21aB Calibration reeren"e5 3mm thi"k blo"k? longitu*inal 6ave s#ee*5 2'3m:s! Srl no! 3% 3' 3( 3 3
Range AmmB '3 '3 '3 '3 '3
E"ho no! % ' (
Dieren"e
Deviation
Remarks
C.Amplitude Control Linearity: Calibration blo"k5 N(3 Instrument5 Calibration reeren"e5 3mm thi"k blo"k? Longitu*inal 6ave s#ee*5 2'3m:s! Srl no!
In*i"ation set at J o ull s"reen
3% 3' 3( 3 3
13 3 '3 3 13
*0 "ontrol "hange 33 -. *0 -%' *0 K. *0 K%'*0
In*i"ation limits J o ull s"reen (' to 1J %. to 'J (' to 1J . to 2.J
Deviation
K'!J KJ KJ K'!J
Remarks
OF OF OF OF
