THE DOW CHEMICAL COMPANY ENGINEERING SPECIFICATION

MATERIALS G8S-5070-01
GLOBAL 03-DEC-2002
Page 1 of 12
Ultrasonic Thickness Measurement

1 Overview

1.1 Scope

This practice describes requirements for using ultrasonic pulse-echo

instruments with digital thickness readouts to measure thicknesses.
This practice is applicable to any material in which ultrasonic waves
will propagate at a constant velocity throughout the material and from
which back reflections can be obtained and resolved.

1.2 Codes

This practice meets the requirements of Section V of the ASME Boiler

and Pressure Vessel Code.

1.3 References

Use the latest edition of the following codes, standards, guidelines

and references:

ASME Boiler and Pressure Vessel Code

• Section V, Nondestructive Examination

• Section IX, Welding and Brazing Qualifications

ASNT
• SNT-TC-1A, Personnel Qualification and Certification in
Nondestructive Testing

1.5 Definitions

ASME: American Society of Mechanical Engineers.

ASNT: American Society for Nondestructive Testing.

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MATERIALS G8S-5070-01
GLOBAL 03-DEC-2002
Page 2 of 12

2 Personnel Qualification

2.1 Dow personnel

Dow personnel who perform ultrasonic thickness measurements (UTT) in

accordance with this standard shall be qualified and certified in
accordance with the requirements of G8S-5001-00.

2.2 Non-Dow personnel

Non-Dow personnel who perform ultrasonic thickness measurements in

accordance with this standard shall be certified to NDT Level II UT or
UTT, or NDT Level III UT, in accordance with their employer's written
practice. The employer's written practice shall comply with the
requirements published in ASNT Recommended Practice No. SNT-TC-1A.

2.3 Assistants

Noncertified personnel may be utilized to assist with ultrasonic

thickness measurements provided the work performed is under the direct
supervision of a Level II UT or UTT, or Level III UT.

3 Equipment

3.1 Instrument

The ultrasonic instrument shall be a pulse-echo type with a digital

thickness readout. An A-scan presentation is recommended.

When measurements are to be made through coatings (e.g., paint), the

ultrasonic instrument shall be capable of measuring thickness through
coatings without the coating thickness affecting the measurement (some
thickness gage manufacturers refer to this as multiple echo or echo-to-
echo measurement capability).

3.2 Search Unit

Search units shall be designed to be used with the ultrasonic

instrument specified in Article 3.1. A delay line type search unit
designed for high temperature applications is permitted and may be
required when the surface temperature of the equipment being examined
exceeds 200°F (93°C). Special shoes may be used to improve ultrasonic
coupling (e.g., when measuring the wall thickness of small diameter
tubing).

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MATERIALS G8S-5070-01
GLOBAL 03-DEC-2002
Page 3 of 12

3.3 Couplant

A couplant having good wetting characteristics (e.g., glycerin, water,

oil, etc.) shall be used.

Couplants used on austenitic stainless steel or titanium shall not

contain more than 250 ppm of halides (chlorides plus fluorides) and
couplants used on nickel base alloys shall not contain more than 250
ppm of sulphur.

A commercial high temperature couplant is permitted and may be required

when the surface temperature of the equipment being examined exceeds
200°F (93°C).

3.4 Calibration Block

Calibration blocks shall be of the same material specification (e.g.,

SA-312) or P-number grouping as the equipment being examined, and shall
have known thicknesses (or steps).

Note: P-Number 1, 3, 4, and 5 are considered equivalent (see Section

IX of the ASME Boiler and Pressure Vessel Code for P-Numbers).

Alternative: The equipment to be examined may be used for calibration

provided known thicknesses can be verified by physical measurement
(e.g., by a micrometer).

The surface finish of calibration blocks shall be similar to the

equipment being examined.

When clad equipment is examined, calibration shall be performed on

known thicknesses of the clad equipment. When this is impractical,
calibration block material shall be based on the backing material.

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MATERIALS G8S-5070-01
GLOBAL 03-DEC-2002
Page 4 of 12

4 Calibration

The instrument manufacturer’s instructions shall be followed for setting

instrument controls during calibration.

The ultrasonic instrument shall be calibrated by measuring two or more

calibration block steps (or known thicknesses) selected as follows:

Step Action
1. Measure one calibration block step (known thickness) that is not more
than 102% of the minimum thickness to be measured.
2. Measure one calibration block step (known thickness) that is not less
than 98% of the maximum thickness to be measured.
3. When using a dual element transducer to measure thicknesses less than
0.1 inch, measure additional calibration block steps (known
thicknesses) such that each thickness measurement under 0.1 inch (2.5
mm) will be within ± 0.016 inch (± 0.4 mm) of a measured calibration
block step.
4. Adjust the instrument to obtain measurements within ± 0.001 inch (± 0.03
mm) or ± 0.2%, whichever is larger, of the calibration block step
(known thickness). When three or more calibration block steps are
required (because of Step 3), the calibration measurement tolerance may
be limited to the two thickest calibration block steps; the remaining
(thinner) calibration block step(s) are used to verify any dual-element
transducer error for thin measurements.

4.1 Calibration Block Temperature

During calibration, the temperature of calibration blocks (when used)

shall be within ± 25°F (± 14°C) of the surface to be examined;
calibration blocks may be heated or cooled to meet this requirement
(see Article 5.5).

4.2 Calibration Verification

Calibration shall be performed before and after examination, and at

intervals not to exceed 2 hours during examination.

When a calibration produces thickness measurements outside the

tolerance allowed by Article 4, a new calibration shall be performed
and all thickness measurements since the last valid calibration shall
be repeated.

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THE DOW CHEMICAL COMPANY ENGINEERING SPECIFICATION
MATERIALS G8S-5070-01
GLOBAL 03-DEC-2002
Page 5 of 12

5 Examination

5.1 Thickness Measurement Locations

Locations for thickness measurements shall be as specified by the

equipment owner and/or vessel inspector.

When thickness measurements are to be used in the determination or

monitoring of uniform corrosion rates, G8S-5070-12 may be used as a
guide in selecting locations for thickness. Care shall be exercised
such that subsequent measurements are taken at the same locations as
previous measurements. When measurement locations are permanently
marked on equipment, they shall be marked in a way that is not
detrimental to the equipment (includes protective coatings).

5.2 Thickness Measurement of Coated Equipment

When taking thickness measurements on coated equipment, the coating

shall not be removed (see Article 3.1) unless specified by the
equipment owner.

5.3 Measuring Thicknesses

Thickness measurements shall be taken as follows:

Step Action
1. Obtain the nominal thickness(es) of the equipment to be measured
from drawings, equipment specifications, or the equipment owner.
2. Obtain the acceptance (screening) criteria from the equipment
owner.
3. Obtain previous thickness measurements data for the equipment to
be measured, if available.
4. Measure the thickness at a location specified by Article 5.1 and
compare with the expected thickness from Step 1 or Step 3.
5. If an unusual thickness change is encountered, recheck the
instrument calibration, then scan the surrounding area to confirm
actual metal loss, or the presence of discontinuities (e.g.,
lamination) or geometric reflectors (an A-scan presentation is
helpful for identifying discontinuities; check equipment drawings
for locations of possible geometric reflectors).
6. Repeat the measurement and record if the measurement is the same
as Step 5.
7. If the measurement in Steps 5 and 6 differ, take a third
measurement, and record the lowest.
8. When unacceptable corrosion or metal loss is found, obtain the
data required in Figure 1 through Figure 4.
9. Repeat Step 4 through Step 8 until thickness measurements have
been made at all locations specified by Article 5.1.

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GLOBAL 03-DEC-2002
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5.4 Temperature Correction

When measuring thicknesses of carbon steel, stainless steel, or nickel

alloy equipment at cold or elevated temperatures, the ± 25°F (± 14°C)
calibration block temperature limit of Article 4.1 may be exceeded
provided that the following thickness measurement correction is made:

1. Elevated temperature: Reduce each thickness measurement by 1% for

each 100°F (56°C) difference between the calibration block and
examination surface temperature.

2. Cold temperature: Increase each thickness measurement by 1% for

each 100°F (56°C) difference between the calibration block and
examination surface temperature.

Example: If the instrument is calibrated on calibration blocks at 70°F

(21°C) and thickness measurements are taken on equipment with a surface
temperature of 320°F (160°C), each measurement taken at 320°F (160°C)
must be reduced by 2-1/2%. Thus, a measurement of 0.320 inch (8.13 mm)
would become 0.312 inch (7.92 mm) after correction.

6 Acceptance Standards

Thickness measurements shall be compared with the acceptance (screening)

criteria provided by the equipment owner and/or inspector.

All unacceptable thickness measurements shall be brought to the attention of

the equipment owner for further evaluation and reconciliation. The location
of all unacceptable areas shall be positively identified (e.g., via a plan-
view sketch) and shall be fully explained in sufficient detail to permit
evaluation by the equipment owner and/or inspector (also see Article 5.3,
Step 8 for unacceptable corroded areas).

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THE DOW CHEMICAL COMPANY ENGINEERING SPECIFICATION
MATERIALS G8S-5070-01
GLOBAL 03-DEC-2002
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7 Reports

An examination report should be made and shall include the following:

1. Identification of examined equipment.

2. Examination procedure and revision.
3. Identification of calibration blocks.
4. Ultrasonic instrument identification and manufacturer's serial number.
5. Search unit identification and serial number.
6. Couplant type.
7. Special shoes, if used.
8. Times of initial calibration and calibration verifications.
9. Surfaces(s) from which the examination is conducted including surface conditio
10. Examination results (i.e., thickness measurements).
11. Data required by Article 5.3, Step 8 for unacceptable corroded areas.
12. A map showing measurement locations and locations where measurements could not
13. Acceptance (screening) criteria.
14. Date of examination.
15. Names and certification levels of examination personnel.

Note: When thickness measurements indicate metal loss, the report shall
indicate whether the metal loss is external or internal, general or pitting,
etc.

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MATERIALS G8S-5070-01
GLOBAL 03-DEC-2002
Page 8 of 12
Figure 1: Data to be Obtained for Unacceptable Corroded or Thinned
Areas

lo n g itu d in al
a x is o f
t min β
cylin d er
t min
A
c

s
B s

tm m
c A

A: Localized Flaw1 B: Groove-Type Flaw1

gw
gl

t min gr
tm m
t min
tm m

Section A - A (see Sketch B) Section B - B (see Sketch B)

tmin = required thickness (obtain tmin from applicable equipment drawing or from
design engineer)
Note 1: For corroded areas in non-cylindrical components (or components
without a similar axis such as a conical section), include a sketch showing
the orientation of the corroded area(s).

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GLOBAL 03-DEC-2002
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Specific Information to Obtain for Unacceptable Corroded or Thinned Areas

c = critical* circumferential dimension s = critical* longitudinal dimension
(see below) (see below)
β = orientation of groove with respect gr = radius at bottom of groove
to centerline
gl = critical* length of groove (see gw = critical* width of groove
below)
tmm = minimum measured thickness tam = average measured thickness (not
illustrated)
* Critical dimensions are the maximum dimensions over which the material
thickness is less than the required thickness. Dimension c (critical
circumferential dimension) is not required for corroded or thinned areas in the
shells of flat bottom storage tanks except for the lower half of the bottom
shell course.

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GLOBAL 03-DEC-2002
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Figure 2: Distances to be Measured and Recorded for Pipe

LL

LS LS

L DL DS
L

DB

LL
LB

Branch Connections Pipe Supports

Pipe Reducers

Measure, Sketch, & Record:

Distances between adjacent corroded areas and from corroded areas to adjacent structural
discontinuities (e.g., reducers, ells, tees, branch connections, pipe supports, etc.).
Note: Distance measurement is with respect to the portion of the corroded area that is less
than the minimum required thickness (illustrated by the dashes in the corroded area sketches).

Do Not Sketch & Record:

1. Distances to adjacent branc h connections that exceed 1 branch pipe diameter (L B > D B ).
2. D istances to ad jacent corroded areas or structural discontinuities (excluding branch
connections) that exceed 1/2 pipe diameter (L S > 1/2D S or L L > 1 /2D L ).

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MATERIALS G8S-5070-01
GLOBAL 03-DEC-2002
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Figure 3: Distances to be Measured and Recorded for Vessels

Stiffening Rings, Body Flanges,

Internal Support Rings, etc.

Nozzles, Manways, Other Openings

LS

Measure, Sketch, & Record:

Distances between adjacent corroded
DN
areas and from corroded areas to
adjacent structural discontinuities
(e.g., nozzles, conical transitions,
stiffening rings, skirts, etc.).
LN Note: Distance measurement is with
LS respect to the portion of the corroded
area that is less than the minim um
required thickness (illustrated by the
dashes in the corrode d area sketches).
DS
Do Not Sketch & Record:
1. Distances to ad jacent nozzles
DL
or other opening that exceed
1 nozzle diameter (L N > D N).
2. D istances to adjacent corroded
areas or structural discontinuities
LL (excludes nozzles or openings)
LL
that exceed 1/4 vessel diameter
(L S > 1/4D S or L L > 1/4D L).

L
L

LL
Vessel Supports
(skirts, lugs, saddles, etc.)

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Figure 4: Distances to be Measured and Recorded for Tanks

Botto m Shell Course-to-2nd Sh ell Course W eld

(Distance from this corroded area to

the shell-to-bottom jun ction exceeds
1/2 of the bottom shell coures height.)

Nozzles, Ma nways,
& Other Openings

Corroded Area
on Bottom
L DN

1/2 of Bottom Shell She ll-to-Bottom

LB Course Height
LB LN Junction

Measure, Sketch, & Record:

Distances between adjacent corroded areas, from corroded areas to adjacent nozzles, and from
corroded areas to the tank shell-to-bottom junction.
N ote: Distance measurement is with respect to the portion of the corroded area that is less than
the minimum required thickness (illustrated by the dashes in the corroded area sketches).

Do Not Sketch & Record:

1. Distances to adjacent nozzles or other openings that exceed 1 nozzle diameter (L N > D N).
2. D istances to the shell-to-bottom junction (LB) that exceed 1/2 the bottom shell course height.
3. D istances to adjacent corroded areas (L) that exceed 5 feet (1.5 m).

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