ULTRASONIC PROCEDURE

1. Purpose :

To describe a nondestructive procedure that is capable of determining the degree of interface

bonding between babbit alloy and its base metal of babbit lined bearing. This procedure use pulse
echo method during ultrasonic testing.

2. Scope :

This test procedure just used for babbit lined bearing that support heavy duty operation at power
plant particularly at PT. PJB or other power generation outside PT. PJB generally. Supplied customer
spesification (especially from OEM) always take precedence over this procedure. If there is no
spesification from supplied customer, this procedure must be accomplished mandatory.

3. Procedure :

Equipment :

3.1 Ultrasonic flaw detector :

PT. PJB has 2 (two) ultrasonic flaw detector as listed below :

1. Krautkramer USN 52

2. Krautkramer USN 58 L

These instrument is pulse echo type which can be used in single and dual element transducers.
Normal transducer with frequency which vary from 2,25 MHz, 4 MHz untill 6 MHz and a
diameter from 5 mm and not greater than 10 mm.

3.2 Ultrasonic Couplant :

Many couplant can be used, such as grease, machine oil, and its combination. Couplant will be
of a suitable viscosity to allow for consistent, accurate readings between the transducer and
bearing surface being tested.

3.3 Reference Block :

Reference “A” is steel block with laminated two layer as described below :

Thin layer is fully babbited and backing metal is base metal of babbit lined. Un-bonded portion
can shown with hacthing line localized and others is bonded portion. This two different area will
allow for accurate setting of the sensitivity of the ultrasonic unit.
 Fig. 1. Reference block A

Other reference block is :

Operator Qualification :

3.4 All ultrasonic testing will be performed by level I or level II technician as qualified by ASNT-TC-1A
certification. All ultrasonic testing result will be reviewed by level II or above according to highest
functional job state. And all final result will become a part of individuals quality record life.

Testing :

3.5 All bearing which has been machined more than 48000 hours must be inspected by ultrasonic
testing. It can accomplished during major inspection or overhaul period. Make sure that bearing is
completely cold and safe to perform ultrasonic testing. Because in warm or hot surface can give
inaccurate result, and may cause damage on transducer. In other case, where is bearing repaired
frequently, ultrasonic testing must be performed scheduled

3.6 Ultrasonic test unit should have the sensitivity set to a reference block that is comparable in Babbitt
thickness to the Babbitt thickness on the bearing being tested. The test block should have bonded and
un-bonded areas.

3.7 Set the damping and reject controls to the minimum

3.8 Place the transducer on bonded area, and set to the gain control to project an image similar to
Figure 2. It may be necessary to adjust the damping control or reject control to eliminate noise at this
point. The echo at bond line should be at 80% of FSH ( Full Screen Height ). Move the transducer to the
un-bonded area and observe the difference on the display.

IP IF BR

Fig. 2. Bonded area on ultrasonic pulse echo display

Note :

IP = Initial pulse

IF = Interference between babbitt and base metal

BR = Back reflection ( commonly known as backwall)

3.9 Move the transducer to the bearing to be tested and locate an area to observe a back reflection
(backwall). It may be necessary to adjust the gain control so that the initial bond line echo is 80% of FSH.

Note : If the bearing made from cast iron, it maybe rather difficult, if not impossible to get a back
reflection.
3.10 Un-bonded areas will appear as shown in Figure 3. These areas will be determined by a comparison
between the bond line display given by the bearing and the reference block. The area directly under the
centerline of the transducer shall be the area under evaluation.

IP IF
Multiple IF

Fig. 3. Un-bonded area on ultrasonic pulse echo display

Note :

IP = Initial pulse

IF = Interference between babbitt and base metal ( it has multiple IF due to repeating pulse IF)

ACCEPTANCE STANDARD

3.11 Bearing with indication exceeding the following criteria are not acceptable.

1. Any single un-bonded area greater than 5% of the total Babbitt surface.

2. When applicable, the load area (bottom area 1/3 of bearing), of horisontally installed bearings having
any single un-bonded area greater than 5% of the total load area.

3. Any un-bonded area within 1/2 ” of any interference area or any high pressure oil lift holes.

4. Customer spesification and contract requirements always supercede these.

DISPOSITION

1. Bearing that show no indication in excess of those given in section 3.11 shall be accepted.

2. Any bearing requiring re-babbitting shall be inspected after repair have been completed.
RECORDS & REPORT

1. Final UT reports will become part of permanent overhaul report which be keep and arranged by
planning and controlling officer.

2. The final UT report shall contain manufacturer’s identification number, testing technician’s signature,
inspection date, inspection procedure, transducer frequency, instrument type, size of transducer used,
un-bonded localized maps (if found on ultrasonic testing), and location of repaired areas.

3. A continuous loss of back reflection greater than 50% over any single area exceeding 1% to the
babbitted area shall be mapped and recorded.