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HI-TECH NDT INSPECTIONS SERVICES (S) PTE. LTD.

DOCUMENT TITLE

ULTRASONIC PHASED ARRAY INSPECTION PROCEDURE FOR

PIPE WELD JOINTS

DOCUMENT NUMBER

HT PAUT-ASME-01

Description Name Signature

PREPARED
M.SATHIASEELAN
& PCN NDT LEVEL II-UT/PAUT
REVIEWED BY

S.ESWARAN
APPROVED BY ASNT NDT LEVEL III
RT/UT/MT/PT/ET/VT
TECHNICAL MANAGER
REVISION STATUS

S.No ISSUE NO REVISION No. DATE DESCRIPTION

1 1 0.0 20.04.2011 REVISED

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TABLE OF CONTENTS

1.0 PURPOSE
3
2.0 SCOPE
3
3.0 REFERENCES
3
4.0 ULTRASONIC PHASED ARRAY EXAMINATION EQUIPMENT
3
5.0 PHASED ARRAY INSTRUMENT LINEARITY
5
6.0 PHASED ARRAY PROBE ELEMENT OPERABILITY VERIFICATION
6
7.0 PHASED ARRAY SYSTEM CALIBRATION
6
8.0 SURFACE PREPARATION
10
9.0 EXAMINATION COVERAGE AND SCANNING TECHNIQUE
11
10.0 RECORDING AND AMPLITUDE DETERMINATION
12
11.0 REPORT OF EXAMINATION
14
12.0 POST EXAMINATION CLEANING
15
13.0 DOCUMENTATION
15
APPENDICES
17
APPENDIX-1: PHASED ARRAY SCAN PLANS- FULL VOLUMETRIC COVERAGE PIPE TO PIPE
WELDS ....................................................................................................................................................................
APPENDIX-2 : TYPICAL GRAPHICAL SCAN PLAN FOR PIPE WELDS...............................................................
APPENDIX-3 : BASIC CALIBRATION BLOCK.............................................................................................................
APPENDIX-4 : PHASED ARRAY CALIBRATION & QUALIFICATION BLOCK.....................................................
APPENDIX-5 : ACCEPTANCE CRITERIA -ASME SEC VIII DIV.1.............................................................................
APPENDIX- 6: SAMPLE PAUT INSPECTION REPORT.............................................................................................

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1.0 PURPOSE
1.1 This procedure provides requirements for Semi-Automatic OR fully
automated with encoded Ultrasonic Examination of pipe welds and base
materials using Phased Array.
1.2 Project specific procedures complying with ASME Sec VIII DIV 1
requirements are attached in the Appendices.

2.0 SCOPE
2.1 This procedure establishes the specific phased array ultrasonic examination
requirements that shall be used to examine Carbon & Alloy Steel pipe to
pipe welds prior to or after Post Weld Heat Treatment (PWHT).
2.2 This procedure is applicable for welds that are 8.0 mm and above in
thickness with outer diameter (OD) from 4 inch and above.
2.3 This procedure is designed to demonstrate the Olympus NDT Omni Scan
Phased Array System used in this procedure as qualified UT System in
accordance with the ASME Sec VIII DIV.1.
2.4 A non-blind test shall be used as a Performance Demonstration for the
Omni Scan Phased Array System.
2.5 The Phased Array Scan Plan for each demonstration is outlined in the
Appendix 2 &4 with specific requirements for this job .

3.0 REFERENCES
3.1 ASME Sec VIII Division 1: Rules for construction of pressure vessel.
3.2 ASME Boiler and Pressure Vessel Code, Section V, Article 4, Edition 2010.
3.3 ASME Code for Pressure Piping, B31.3 (Latest Edition)
3.4 BV Rules Part B Ch 12 Section 1
3.5 HT-WP-01 (2010) - Company written practice for qualification and
Certification of NDE personnel.

4.0 ULTRASONIC PHASED ARRAY EXAMINATION EQUIPMENT


4.1 The ultrasonic Phased Array instrument shall be an Omni Scan pulse echo type
and shall be equipped with a calibrated dB gain or attenuation control stepped in
increments of 2 dB or less. The Omni Scan contains 16 or 32 independent
pulser/receiver channels. The system is capable of generating and displaying
sector scan images, which can be stored and recalled for subsequent review.

4.2 Phased Array Equipment details:

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Equipment OMNI SCAN MX


Data Acquisition System Olympus - Omniscan MX
16:128PA & 32:128PA
Phased Array Software Omniscan MXU-2.0R12
PA Probe with cable 5L64- A12
llatesthigher
Wedge SA12-N55S SA12-N55S

4.3 Examination personnel may use a real-time sector scan (also called an S-Scan)
image during scanning to assure that proper data has been collected. Sector scan
images contain signal amplitude and reflector depth information projected for the
refracted angle of the ultrasonic beam. The Omni Scan Phased Array system
provides a variety of analysis capabilities including A-scan display and parameter
readout associated with software cursors. Images produced by B, C and Sectorial
Scan images are a useful aid in evaluation.
4.4 The Omni Scan Phased Array system has on-board focal law generation
software that permits direct modification to ultrasonic beam characteristics. The
Omni Scan Phased Array System requires the use of an external storage device, or
flash card or USB memory Stick. A remote portable PC connected via Ethernet
may be used for this purpose.
4.5 In addition to data storage, the PC will also be used by the Data Analysis
Personnel for analyzing data subsequent to the completion of data collection.
Data display software compatible to that residing on the Omni Scan Phased Array
System will also be used on the remote PC for data playback. Reference the
manufacturer operating manuals for instrument operation specifics.
4.6 Any control, which affects the instrument linearity (e.g., Reject) shall be in the
off or minimum position for instrument calibration, system calibration and
examination.
4.7 If any control (e.g., filters, averaging, pulse duration, etc.) are used in
calibration, then these controls shall not be adjusted afterwards since they may
affect the Omni Scan System Calibration.
4.8 The Ultrasonic Phased Array System shall be calibrated for linearity in
accordance with Paragraph 5.0.
4.9 Ultragel II, Sonotrace 40, Sonatech, glycerine, diluted Wall paper paste,
water or equivalent may be used as couplant when performing calibrations and
examinations.
4.10 The same couplant material used for calibration shall be used for
examinations.
4.11 Ultrasonic transducer configurations are specified by the technique used
for examination. Linear Phased Array Probe configurations may include from 10 to
128 elements.
4.12 The Phased Array probe frequency shall be between 2 and 10 MHz
depending upon material type, thickness.

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4.13 Phased Array Wedges should be of a design to accommodate the


aforementioned Phased Array Probes. Nominal refracted wedge angles shall be
45, 55, 60 or 70 degree to ensure coverage of the weld and heat affected zone
(HAZ).
4.14 An encoder interfaced with the Phased Array instrument may be used to
track the Phased Array Probe movement. The encoder shall be calibrated by
moving a minimum distance of 500mm and the distance recorded shall be within
+/- 1% of actual distance moved. After the initial verification, further verification
shall be performed not exceeding one month from the first test and the same test
shall be repeated.
5.0 PHASED ARRAY INSTRUMENT LINEARITY
5.1 Ultrasonic instrument linearity shall be verified at the beginning and end of
each series of examinations not to exceed 3 months.
5.2 The instrument linearity verification shall be recorded on the Ultrasonic
Instrument Linearity Verification (Form 1).
5.2.1 Screen Height Linearity
5.2.1.1 Position a search unit on a calibration block to obtain
indications from the two calibration reflectors.
5.2.1.2 Alternatively, a straight-beam search unit may be used on
any calibration block that will provide amplitude differences
with sufficient signal separation to prevent overlapping of the
two signals.
5.2.1.3 Adjust the search unit position to give a 2:1 ratio between
the two indications, with the larger indication set at 80% of
full screen height (FSH) and the smaller indication at 40% of
FSH.
5.2.1.4 Without moving the search unit set the larger indication
to 100% of FSH; record the amplitude of the smaller
indication, estimated to the nearest 1% of FSH.
5.2.1.5 Successively set the larger indication from 100% to 20%
of FSH in 10% increments (or 2 dB steps if a fine control is not
available); observe and record the smaller indication
estimated to the nearest 1% of FSH at each setting. The
reading must be 50% of the larger amplitude within +5% of
FSH.
5.2.2 AMPLITUDE CONTROL LINEARITY
5.2.2.1 Position a search unit on a calibration block to obtain
maximum amplitude from a calibration reflector.

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5.2.2.2 As a minimum, the amplitude control linearity shall be


performed to document linearity at both ends of the gain
range being used with the equipment.
5.2.2.3 Without moving the search unit, set the indication to the
required percent of FSH and increase or decrease the dB as
specified on the Ultrasonic Instrument Linearity Verification
(Form 1). The estimated signal shall be recorded to the
nearest 1% of FSH and shall fall within the limits specified on
Form 1.

6.0 PHASED ARRAY PROBE ELEMENT OPERABILITY VERIFICATION


6.1 The Phased Array Probe shall be checked for element performance
whenever the examiner suspects an element operability problem. Each
phased array probe must be checked to determine each elements ability to
transmit and receive ultrasonic energy.
6.2 This Operability Verification verifies performance of each
transmitter/receiver module, and cable conductivity for each channel. Any
Phased Array Probe that has greater than 25% defective elements of the
useable aperture should be replaced with a new probe. However, if an
effective calibration is performed then the probe may not be considered
defective.
7.0 PHASED ARRAY SYSTEM CALIBRATION
7.1 Calibration shall be performed from the surface of the calibration block
which corresponds to the component surface to be examined.
7.2 System calibration shall include the complete ultrasonic examination
system. Screen distance calibration shall be at least 1 and vee paths for
the minimum angle that will be used during the examination, unless
otherwise specified.
7.3 The system calibration information shall be recorded on the Ultrasonic Data
Report Form utilized in the Omni Scan. During scanning, only the gain may
be adjusted from the calibrated Reference dB. Adjustment of other controls
shall require recalibration.
7.4 Focal law Verification
7.4.1 The transmission and reception of ultrasonic waves of a given
angle of incidence is a function of time delays calculated by focal
laws using the information provided to the phased array system.
Verification that the input information is correct and that the
phased array system is working properly must be checked.
7.4.2 Select the Angle Beam Cursor and adjust its position so that it
displays A-scan information for the 45 angle of refraction or the
minimum angle that will be used in the Sector Scan.
7.4.3 Using the 100mm radius on the IIW block, peak the signal shown
on the A-scan display. Note: Although the sector scan may

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indicate higher amplitude responses from other angles, only use


the A-scan response associated with the45 angle of propagation.
7.4.4 Indicate on the transducer wedge, the beam exit point. This
beam exit location is only valid for the 45 angle of propagation.
7.4.5 Using the primary angle of beam refraction exit location, measure
the actual angle of propagation by peaking the response in the A-
scan display using the plexi-glass insert on the IIW block. Record the
actual angle of propagation as indicated on the IIW block using the
beam exit point location.
7.4.6 If the measured angle of propagation is 45 +/- 2, then critical
focal law parameters are correct.
7.4.7 If the measured angle of propagation is outside the allowable
tolerance(45 +/-2), then all transducer and setup parameters must
be reviewed for accuracy. If these parameters are correct, then check
the shear wave velocity value used for the material. If this is correct,
then small adjustments must be made to the transducer wedge
velocity entry. If the measured angle is too high, then the wedge
velocity must be increased slightly, and repeated. Similarly, if the
measured angle is too low, then the wedge velocity parameter must
be lowered and repeated until the measured angle is within
tolerance.

7.5 Time Base Verification


7.5.1 Position the Angle Cursor and adjust its position so that it displays
A-scan information for the 45 angle of refraction.
7.5.2 Place the transducer so that reflections from both the 50 mm and
100 mm radius reflectors on the IIW block are peaked and observed
simultaneously on the A-scan display.
7.5.3 Using the A-scan Cursors, measure the distance between the 50
mm and 100 mm signals. This result shall be 50 + 2.5mm.
7.5.4 If the measured separation between the signals is too large
(greater than 52.5 mm), decrease the Shear Velocity parameter
under the Part Setup Menu. Similarly, if the measured distance is too
short (less than 47.5 mm), increase the velocity value. Repeat
adjustment until an acceptable value is achieved.

7.5.5 With the transducer remaining in the peaked position, measure


the metal path of the 100 mm radius reflector using a cursor in the
A-scan Display.

7.5.6 The value should measure to be 100 +/- 2.5 mm. If this
measurement is less than 97.5 mm, increase the value of the Delay
parameter until the measurement is correct. If this value is greater
than 102.5 mm, decrease the Delay parameter until the
measurement is correct. The requirements for focal law verification,
time base verification and sensitivity adjustments are listed below.
Instrument linearity verification and ultrasonic beam spread is not
required.

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7.5.7 As an alternative, other calibration blocks may be used to perform


the Time Base or Wedge Delay calibration.

7.6 Sensitivity And Wedge Delay Calibration


7.6.1 The Omni Scan shall be calibrated for Wedge Delay and
Sensitivity.
7.6.2 The Wedge Delay Calibration shall be calibrated for True Depth
with the angles used in calibration.
7.6.3 The Sensitivity Calibration will provide the required gain
adjustments for each refracted angle and sound path used.
7.6.4 Select a calibration reflector which is approximately one half the
thicknesses of the component to be examined, or within the zone of
material to be examined.
7.6.4.1 Peak up this signal from the calibration reflector and scan
the phased array probe backwards through all the different
angles or focal laws.
7.6.4.2 Scan forward over the calibration reflector through all the
refracted angles or focal laws.
7.6.4.3 The Omni Scan system will calculate the required gain
needed at each focal law to adjust the amount needed
7.7 A Time Corrected Gain (TCG) calibration shall be used to compensate for
attenuation in the material at the sound paths utilized during calibration
and examination.
7.8 As an alternative, DAC may be used for electronic Scans (E-Scans) of
specific angles, e.g., 45, 60 or 70 degrees.
7.9 The examination system calibration may be stored in the Omni Scan
System with electronic memory or on an external chip or data storage
device. This calibration may be used at a later date provided the system
calibration is verified prior to examination.
7.10 A complete Ultrasonic System Calibration shall be performed at least once
prior to the examination.
7.11 Temperature Requirements
The basic calibration block temperature shall be within 25 degrees F (14
deg. C) of the component temperature.
7.12 System Calibration Verification
7.12.1 System calibration verification shall include the entire
examination system. Sweep range and TCG calibration shall be
verified on the project specific Qualification block under the following
conditions:

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7.12.2 Prior to and within 24 hours of the start of a series of


examinations
7.12.3 With any substitution of the same type and length of search unit
cable.
7.12.4 With any substitution of power utilizing the same type source
(e.g., a change of batteries)
7.12.5 At least every 12 hours during the examination.
7.12.6 At the completion of a series of examinations.
7.12.7 Whenever the validity of the calibration is in doubt.
7.12.8 A simulator block (e.g., IIW block, miniature DSC) may be used for
the entire exam system calibration verifications
7.12.9 The initial system calibration shall be made using a basic
calibration block. Whenever possible, the final system calibration
verification should be made using the basic calibration block.
7.12.10 CALIBRATION/QUALIFICATION BLOCKS FOR CODE CASE 181
7.12.10.1 For the validation of calibration a project specific
Qualification block shall be made to meet the ASME SecV
requirements. See Appendix 5.
7.12.10.2 The procedure shall be demonstrated to perform
acceptably on this Qualification block with required
reflectors in accordance with ASME Code Case 181. The
blocks shall be prepared by welding or made from material
having the same or equivalent P number grouping and
having ultrasonically the same characteristics and shall
contain a minimum of three flaws, orientated to simulate
flaws parallel to the production welds fusion lines as follows.
i) One surface flaw on the side of the block
representing the pipe OD surface.
ii) One surface flaw on the side of the block
representing the pipe ID surface.
iii) One Subsurface flaw
7.12.10.3 In addition to the requirements of ASME Sec VIII, the
blocks shall also have side drill holes representing various
zones in accordance with Article 4 of ASME Section V
The minimum requirements of the reference blocks are the
following:
i) Shall be made of same material as the weld under
inspection with regard to sound, velocity, grain noise
and surface condition.

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ii) The wall thickness shall be equal or up to 1 greater


than the nominal wall thickness of the weld under
inspection.
iii) The width and the length scanning surface shall be
adequate to allow probe movement over the reference
reflectors.
iv) The surface conditions shall be representative of the
material surfaces to be examined.
v) The block shall also be heat treated the same as the
pipe to pipe weld condition (if any).
vi) A dynamic calibration is performed on multiple
reflectors moving the probes from one end of the block
to the other.

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7.13 System Calibration Changes


7.13.1 Perform the following if any point on the TCG decreases by 20% or
2 dB of its amplitude, or any point on the sweep line has moved
more than 10% of the sweep division reading.
7.13.2 Void all examinations performed after the last valid calibration
verification.
7.13.3 Conduct a new system calibration.
7.13.4 Repeat voided examinations.
7.13.5 Perform the following if any point on the TCG has increased more
than 20% or 2 dB of its amplitude:
7.13.5.1 Correct the system calibration.
7.13.5.2 Re-examine all indications recorded since the last valid
calibration verification.
7.13.5.3 Enter proper values on the applicable forms.
7.14 Re-calibration
7.14.1 Any of the following conditions shall be cause for system
recalibration:
7.14.1.1 Search unit transducer or wedge change
7.14.1.2 Search unit cable type or length change
7.14.1.3 Ultrasonic instrument change
7.14.1.4 Change in examination personnel
7.14.1.5 Couplant change
7.14.1.6 Change in type of power source
8.0 SURFACE PREPARATION
8.1 Contact Surfaces - the finished contact surface should be free from weld
spatter and any roughness that would interfere with free movement of the
search unit or impair the transmission of ultrasonic vibrations.
8.2 Weld Surfaces - the weld surface should be free of irregularities that
could mask or cause reflections from defects to go undetected and should
merge smoothly into the adjacent base materials.
8.3 Conditions which do not meet these requirements shall be recorded as
limitations on the Ultrasonic Examination Data Report Form.
8.4 Testing of Base Material & Transverse Defects :
8.4.1 Following inspection shall be considered when appropriate prior to
PA scanning:

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8.4.2 Prior to PA inspection, the detection for lamination or inclusion in


the base material need not be foreseen, when this has already
been carried out by the plate manufacturer or the fabricator when
plates are cut. However, when laminar defects are suspected, the
entire base metal through which ultrasound must travel to test
the weld shall be tested for laminar reflectors using a straight-
beam search unit.
8.4.3 To ensure the coverage for the detection of transverse defects,
transverse notches shall be introduced as depicted on the
Qualification block (See appendix4). These transverse notches
(both Cap and the Root) shall be detected by the PA technique
during the calibration / validation exercise. Satisfactory detection
of the transverse notches will ensure sufficient coverage.
8.4.4 Alternatively, manual scanning with shear waves 70 or 60 may
be substituted for the detection of transverse defects. The 70 or
60 angle beam shall be directed essentially parallel to the weld
axis. The search unit shall be manipulated so that the ultrasonic
energy passes through the required volume of weld and adjacent
base material. The search unit shall be rotated 180 degree and
the examination shall be repeated. Wherever, the weld cap is not
machined or ground flat, the examination shall be performed from
the base metal on both sides of the weld cap in both weld axis
directions.
9.0 EXAMINATION COVERAGE AND SCANNING TECHNIQUE
9.1 The specifics of the examination volume, weld identification and location
shall be identified in the Scan Plan.
9.2 The examination volume shall cover the weld metal and HAZ plus 6 mm
minimum of base material is examined from the toe of the weld. This area
includes the heat affected zone or HAZ.
9.3 The Scan Plan shall demonstrate by plotting or with using a computer
simulation the appropriate examination angles for the weld prep bevel
angles (e.g., 35 to 60 degrees or 55 to 70 degrees) that will be used during
the examination. This Scan Plan shall be documented to show the
examination volume was examined. This Scan Plan shall be a part of the
Final Examination Report.
9.4 The Omni Scan may use Multi-Groups to establish Sector Scans and E-
Scans for the appropriate angles as identified in Paragraph 9.3 to ensure
complete coverage of the weld and heat affected zone.
9.5 To determine the required examination volume and scan area, profiles may
be taken on each weld. Profile data will consist of ultrasonic thickness
measurements and outside surface contours using a contour gage.
Thickness measurements should be taken at a maximum interval of
approximately 1/4 inch and should cover the material volume to be
examined and recorded. The "T" dimension shall be the nominal wall

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thickness. Alternatively, computer simulations with appropriate software


can by used to plot the Weld profile.
9.6 Scanning shall be performed using a Line Scan Technique. Each Line scan
shall be parallel to the weld using a Sector Scan, (S-Scan) and/or Electronic
Scan, (E-Scan).
9.7 Appropriate refracted angles as accepted by ASME will define the positions
of the arrays, and hence the angles. These should be detailed in the
Ultrasonic Scan Plan.
9.8 A minimum of two (2) line scans shall be performed at two (2) different
index points from the center of the weld from both sides of the weld where
practical to ensure coverage of the weld and heat affected zone, (HAZ).
9.9 Scans shall be parallel to the weld at Skew 90 and 270 scan axes (where
accessible).
9.10 Raster scanning will aid in Flaw Characterization.
9.11 The rate of search unit movement shall be limited to a maximum of 50 mm
per second for Pipe to pipe circumferential welds unless calibration has
been verified at a higher speed.
9.12 Perform the examination from both sides of the weld, where practical, or
from one side as a minimum. All examination volume limitations shall be
documented on the Ultrasonic Examination Data Report Form.
9.13 The entire examination volume comprising the weld and adjacent base
metal shall be examined with the beam parallel to the weld on either side
of the weld where accessible, in two directions, i.e., clockwise and counter
clockwise. Phased Array Wedges contoured to the radius of the pipe may be
used in the examination to ensure proper contact.
9.14 Full A-Scan & S-Scan data shall be recorded and stored when using
encoders.

10.0 RECORDING AND AMPLITUDE DETERMINATION


10.1 Data shall be recorded in unprocessed form. A complete data set with no
gating, filtering, or threshold shall be included in the data record.
10.2 All reflectors that exceed 20% of DAC or TCG shall be investigated to the
extent to determine the type of reflector.
10.3 Indications that exceed 50% of DAC or TCG and determined to be of
geometric or metallurgical origin shall be recorded.
10.4 The position and location of indications shall be recorded.
10.5 Geometric Indication - Recordable ultrasonic indications, of geometric or
metallurgical origin, shall be classified as such. Weld reinforcement, root
geometry or variations in metallurgical structure of materials (such as
cladding to base metal interface) may be classified as geometric
indications, and
10.5.1 Need not be characterized or sized.
10.5.2 Need not be compared to allowable flaw acceptance criteria.

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10.5.3 The maximum length and location shall be recorded. For example:
100mm length, one inch above the weld centre line, on the inside
surface, from 90 to 95 degrees.
10.6 The following steps shall be taken in order to classify an indication to be of
geometric or metallurgical origin:
10.6.1 Interpret the area containing the reflector in accordance with the
applicable examination instruction;
10.6.2 Plot and verify the reflector coordinates, provide a cross-sectional
display showing the reflector position and surface discontinuity such
as root or counter bore.
10.6.3 Review fabrication or weld prep drawings when accessible.
10.6.4 All recordable indications shall be resolved to determine the
shape, identity, and location of the reflector. Final evaluation and
disposition of the indication is the responsibility of owner/user of the
component to be examined.
10.6.5 Amplitude Determination - Signal amplitude shall be measured as
a percent of the calibrated DAC or TCG.
10.6.6 The appropriate Code or Specification shall be used to determine
final acceptance of the weld inspection using the Omni Scan.
10.7 Flaw Sizing
10.7.1 Reflectors determined to be flaws shall be sized in accordance
with a procedure demonstrated to size similar flaws at similar
material depths. Alternatively, a flaw may be sized by manual
techniques that have been demonstrated on the calibration block
10.7.2 LENGTH - The length of the flaw shall be drawn parallel to the
inside pressure retaining surface.
10.7.3 HEIGHT (DEPTH) - the depth of the flaw as the dimension drawn
normal to the inside pressure retaining surface
10.7.4 DEPTH - The true depth of an indication is the dimension
measured from OD surface of the pipe to the top of the indication.
10.8 Flaw Evaluation
10.8.1 Flaws shall be evaluated in accordance with Appendix 12 of
Section VIII, Division 1.

10.9 Repair weld


10.9.1All Indication identified by Phased Array and checked by manual UT
and found not acceptable in accordance with applicable code will
have to be repaired and re-checked. After repair, a length of weld
(each side of the repair) equal to 500 mm shall be also reexamined.

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11.0 REPORT OF EXAMINATION


11.1 The following items shall be reported in the examination report and this
report shall be retained for a period of 5 years.
a) Procedure identification and revision;
b) Ultrasonic instrument identification(including manufacturer's
serial number);
c) Search unit(s) identification (including manufacturer's serial
number, frequency and size);
d) Beam angle(s) used;
e) Couplant used, brand name or type;
f) Search unit cable(s) used, type and length;
g) Special equipment when used (search units, wedges, shoes,
automatic scanning equipment, recording equipment, etc.);
h) Computerized program identification and revision when used;
i) Calibration block identification;
j) Simulation block(s) and electronic simulator(s), identification
when used;
k) Instrument reference level gain and, if used, damping and
reject setting(s);
l) Calibration data [including reference reflector(s), indication
amplitude(s). and distance reading(s)];
m) Data correlating simulation block(s) and electronic
simulator(s), when used with initial calibration;
n) Identification and location of weld or volume scanned;
o) Surface(s) from which examination was conducted, including
surface condition;
p) Map or record of rejectable indications or non-rejectable
indications with >=50% reference level detected or area cleared;
q) Areas of restricted access or inaccessible welds;
r) Examination personnel identity and, when required by
referencing Code Section, qualification level;
s) Date of examination;
11.2 A table of all investigated indications shall be provided in a report which
includes location and all analysis criteria (See Appendix 5 for Phased Array
summary report format).
11.3 The final data package shall be reviewed by a UT level III individual. The
review shall include:
a) The ultrasonic data record
b) Data interpretations

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c) Flaw evaluations /characterizations performed by another qualified Level


II or III individual. The data review may be performed by another
individual from the same organization.
12.0 POST EXAMINATION CLEANING
The remaining couplant shall be wiped from the surface at the completion
of the
examination.

13.0 DOCUMENTATION
13.1 Results of ultrasonic examination shall be reported on the PA UT Report
Form shown in the appendix. All Phased Array examination data for each
recordable indication, A-scans, B, C, and S Scans shall be saved as a Report
File and recorded on a CD/DVD.
13.2 The examiner shall record the results of the examination on the PA
Summary Report from (Appendix 6). All recordable indications shall be
documented on the examination report. All blocks should be completed
with the appropriate data or "NA".
13.3 The Ultrasonic Scan Plan, Ultrasonic Calibration, and Ultrasonic Instrument
Linearity verification (if required) shall be considered part of the
examination report.

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SAMPLE ULTRASONIC INSTRUMENT LINEARITY VERIFICATION - FORM

ULTRASONIC INSTRUMENT LINEARITY VERIFICATION

INSTRUMENT MANUFACTURER MODEL NUMBER RECORD NO.

CALIBRATION BLOCK NO. INITIAL DATE FINAL DATE

SCREEN HEIGHT
AMPLITUDE CONTROL LINEARITY
LINEARITY
INSTRUMENT WITH INDICATION dB INDICATION ACTUAL % OF FULL SCREEN **
FINE dB CONTROL LIMITS % OF
SET AT % OF CONTROL FULL SCREEN
CHANGE HI GAIN LOW GAIN
FULL SCREEN SETTING
SETTING
FIRST SECON INITIAL FINAL INITIAL FINAL
D
SIGNAL SIGNAL
IN % IN % ____dB ____d ____d ____dB
*
B B

100 100
90 90
80 -6Db 32 TO 48
80 40 80 40
70 80 -12 Db 16 TO 24 70 80 -12 Db
60 60
50 40 +6 Db 64 TO 96 50 40 +6 Db
40 40
30 20 +12 dB 64 TO 96 30 20 +12
20 20
*READING MUST BE 50% OF FIRST SIGNAL AMPLITUDE WITHIN 5% OF FULL SCREEN HEIGHT.

COMMENTS:

INSPECTOR CERT LEVEL DATE SUPV/LEVEL III REVIEW

INSPECTOR CERT LEVEL DATE DATE

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APPENDICES

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APPENDIX-1 : PHASED ARRAY SCAN PLANS- FULL VOLUMETRIC COVERAGE PIPE TO PIPE WELDS

PHASED ARRAY SCAN PLAN - PIPE TO PIPE WELDS

Index Offset (mm)


S.No Freq. No.of
WT Weld Probes & Angle Angle First Last Focus
1 ID (mm) No.of PA Groups Technique (Mhz Elements
(mm) Seam Wedges Coverage Step Element Element Depth (mm)
) used Skew 90 Skew
(-) 270 (+)
50 -70
S.No Pipe to G1 Sectorial 1 16 1 64 50 mm 12 12
5L64A12+SA SW
2 Various 12 mm pipe 5
12-N55S-IHC 45-65
weld G2 1 16 40 55 50 mm 12 12
Sectorial SW
50 -70
G1 Sectorial 0.5 16 44 61 50 mm 9 9
9.53 5L64A12+SA12 SW
5
mm -N55S-IHC
G2 Linear 1 16 31 N.A 50 mm 9 9
60

Note:

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APPENDIX-2 : TYPICAL GRAPHICAL SCAN PLAN FOR PIPE TO PIPE


WELDS

I) Scanning From OD

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Phased Array Probe Details

Wedge: SA12-N55S-IHC
Primary Height 1st Widt
Velocity Length Angle
Offset Element h

40m
2.33mm/s 56.8mm 11.02mm 68.53mm 36o
m

Transducer: 5L64-A12
Total Aperture: 38.4mm Number of Elements: 64 Element Pitch: 0.6mm

Sectorial Beamset (Group-1)

Law Config.: sectorial Wave


Type: Shear First Min Max Angle Focus
Element Angle Angle Steps Depth
Element
Qty
16 41 50o 70o 1.00o 50mm

Sectorial Beamset (Group-2)

Law Config.: Sectorial Wave Type:


Shear First Min Max Angle Focus
Element Angle Angle Steps Depth
Element
Qty
16 47 45o 65o 1.0o 50mm

APPENDIX-3 : PIPING CALIBRATION BLOCK

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APPENDIX-4 : QUALIFICATION BLOCK- DIMENSIONS OF


QUALIFICATION REFLECTORS

75 mm

Side drilled Hole ID Notch OD Notch


Weld CL
Length=38 mm, size=2.5
Length=38 mm, size=2.5 mm
mm

CL

T/4 Side drilled Hole

T/2 Side drilled Hole


19 mm
3T/4 Side drilled Hole

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APPENDIX- 5 : ACCEPTANCE CRITERIA ASME B 31.3


APPENDIX 12

APPENDIX -6 PAUT INSPECTION SAMPLE REPORT

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