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I Phased Array Insl!ection NBTC-OP/TS26

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Phased Array Inspection Procedure

Document No: NBTC-OP/TS26

Revision No 0
(

Prepared &
Rev. No Date Revision Details
Approved By

Issued For
0 24-01-2016
Approval

NDT Level III

G. SURENDRANATH
ASNT NOT LEVEL III(RT,UT,MT.PtVT,ET)
Cert No.: 149498
IAEA LEVEL Ill (UT)
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Table of Contents
Para No. Description

1. Scope
2. Purpose
3. Definition s
4. Applicable Codes and Acceptance std.
(
5. Personnel Qualification
6. Preparation of examination surface
7. Equipment required
8. Ultrasound Equipment calibration
9. UT Calibration Standards
10. Acquisition and Analysis
11. Reporting
12. Inspection Report format
13. Scan Plan and Calibration block
(
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Phased Array Insuection NBTC-OPffS26
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1. SCOPE:
This Procedure describes the requirement for Phased array Ultrasonic Testing on Longitudinal and
circumferential butt weld joints and Heat Affected Zone of Aluminum Silo Panel

This procedure describes the requirement and application techniques for both detection and sizing
of discontinuities.

2. PURPOSE
In this document, how to make an acquisition using Phased array probe placed on one side of the
weld, is explained.
(
Following this, the weld zones to be inspected by each of the probes shall be listed and identified.

Parameters and Scan plan ( refer page 10 - Fig.2) used for setting up the acquisition unit with the
hand scanner is listed.

A scan of the Calibration Block manufactured with side drill holes shall be carried out (as
detailed in Page 10 - Fig 1). This block shall also be used for sensitivity settings and for creating
acceptance criteria.

3.DEFINITIONS

AUT : Automated Ultrasonic Testing

SDH : Side Drill Hole
NBTC: Naser Al-Baddah and Partner General Trading and Contracting Co.
ASME: American Society of Mechanical Engineers
( PAUT :Phased Array Ultrasonic Testing
IIW :International Institute ofWelding

4. APPLICABLE CODES & SPECIFICATIONS

ASME sec V Article 4 Ultrasonic Examination Methods for Welds

ASME SE-2700 Standard Practice for Contact Ultrasonic Testing of Welds Using
Phased Arrays .

5. PERSONNEL QUALIFICATION

5.1All personnel performing Ultrasonic Examination according to this procedure shall be qualified
to level II as per the requirements of NBTC procedure for Qualification & Certification of NDT
personnel, Doc. No. NBTC-OPffS04, which meets the minimum requirements ofSNT-TC-lA.
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5.2 The accuracy and completeness of an examination report is verified only by qualified level II
or level III operators.
5.3 Additionally the operators shall be trained by the Original Equipment Manufacturer or by
NBTC NDT Level III in UT for carrying out Phased Array examinations.

6. PREPARATION OF EXAMINATION SURFACE

a) Surface preparation

The finished contact surface shall be minimum 5 times of the weld thickness on either side of
the weld seam and should be free from weld spatters and any roughness that could interfere
( with free movement of the search unit or impair the transmission of ultrasonic vibrations. The
weld surface should be free of irregularities that could mask or cause reflections from defect
to go undetected and shall be smooth cleaned with power wire brush or sand paper wheel
grinder. The weld should merge smoothly into the adjacent base material. Surface conditions
which do not meet these requirement shall be recorded as limitations on the ultrasonic
examination data report form.

b) Normal beam Examination

Prior to start of the of the examination the scanning area (Probe resting area) of the base metal
and HAZ on either side of weld shall be scanned manually with normal beam probe to locate
reflectors or localized lamination that could limit the capability of the phased array inspection
to examine the weld volume. TD Handy Scan equipment pulse echo channel shall be used for
this inspection.

c) Weld Marking and Inspection area location

( Weld joints shall be identified with Joint No. , Thickness for each weld joint offered for
AUT Examinations.

100% of Marked areas of the weld ( 10% of total weld length) shall be scanned .

7. EQUIPMENT REQUIRED

a) Ultrasonic Test Instrument

TD Handy Scan from AGR Technology Design UK capable of operating in Pulse Echo, Phased
array mode.
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Phased Array ultrasonic search units will operate at a frequency 5 MHz. The choice of aperture
element selection, point/stride, focusing depth, and angle control will be determined by the pertinent
parameters for the approved technique.

5L64- A2 64 element 0.6mm pitch Phased Array Probes Olympus make

Laptop with Superview Software Version 18.03

Soft key Dongle for offline analysis

(
encoder cable (# ADTX 004A)

encoder (#ACUX-240A)

calibration block support runner plate.

Aluminum Calibration Block with SDH

a) Data Acquisition Software

TD Super View version 18.03- It is a powerful and versatile package that manages the
acquisition of ultrasonic signals combined with real-time imaging and as well as offline analysis
of previously acquired scan files.
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b) Couplant

Acoustic coupling shall be maintained by using a medium suitable for the purpose. The Paper paste
and water mixture shall be used. Same couplant shall be used during calibration and weld testing.

8.:._ULTRASONIC EQUIPMENT CALIBRATION

A. Positional Encoder Check

Encoder is used to record the distance along with scan data which is fixed to the scanner. Encoder
calibration shall be carried out for step resolution for data acquisition. The encoder shall be
connected to the TD Scan equipment and calibration procedure detailed in section 18 of this
procedure. The system readout shall be within+/- 1% of measured distance. Encoder failing this
check shall be recalibrated and check repeated. AUT Technician should check encoder calibration
at the start of each shift.

9. UT CALIBRATION STANDARDS

A. General requirement for calibration blocks Calibration standard purpose

Calibration standards shall be used to qualify the inspection system for field inspection and to
monitor, on an ongoing basis, the system's performance.

Temperature
For Contact examination, the temperature differential between the calibration block and the
examination surfaces shall be within 25 F(14 C)
( Surface Finish:
The surface finish of calibration blocks should be same as the work surface. Calibration blocks for
phased array pulse echo coverage will conform to calibration block as per ASME Section V Article 4
recommendations. Reflectors must be provided in the calibration block to establish sensitivity and
volume coverage.

Material

Calibration Standards shall be manufactured from material used for fabrication of aluminum silo
as supplied by Client.

Calibration Blocks:

Certified IIW VI block (Carbon Steel) shall be utilized to calibrate the phased array probes for probe
delay, range, element balancing and angle.
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ASME calibration block#1 Thickness of the calibration block shall be within +/- 10% the thickness
of the weld. ( page 10 - Fig. 1)

ACQUISITION AND ANALYSIS

Phased Array probes is placed on one side of the weld with distance from weld centre as per scan
plan in one line scan.

The 40-70 degree sectorial array beams from 16 elements will progress up to 32 elements with
( aperture of 16 elements at a time. The target of this beam with a sweep from 40 to 70 degree is the
entire section of the weld. This is linked to channel1.

SENSITIVITY

Sensitivity Settings: The echo height for PA probes beaming at 45-70 shall be adjusted and the
required gain be set. Reference reflector is SDH from the calibration Block.

The echo height from the reference reflector be set to 80% in order to generate clear cut color ramp.
The 15 mm calibration block has 2.5 mm SDH drilled Y2 T and% T.

This block for sensitivity calibration can be used for weld thickness range 9-16 mm.
For equalizing the echo height of reference reflector at different beam path distance
TCG is adapted. This means the echo height remains same irrespective of changing beam path for
the same size reference reflector. Focal Law balancing is done to ensure a constant echo height from
the reference reflector positioned at different beam path distance within the weld beam coverage.
(
ANALYSIS AND ACCEPTANCE

Acceptance Criteria

Acceptance Criteria Shall be as given below (as per. Client's requirement).

. Vessels and The required examination volume (see Article 5.1) shall be free of:
Tanks
1. Cracks, incomplete fusion, and incomplete penetration.
2. Other imperfections whose indication amplitudes exceed the reference level
(DAC curve) and whose lengths exceed:
a. 1/4 inch (6 mm) fort less than 3/4 inch (19 mm).

b. 1/3t fort from 3/4 inch (19 mm) through 2.25 inches (57 mm).

c. 3/4 inch (19 mm) fort over 2.25 inches (57 mm).
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Any echo crossing 80% of the gate threshold and exceeding the acceptance standard length is
unacceptable.

To exactly know the position of defects in the weld so generated in the color ramp, Weld overlay
can be recalled and superimposed over the color map.The individual cursors when moved over the
defects can exactly give the depth, widthand the distance from the weld datum or reference point.
Two cursors are provided to exactly measure the length and width of the defect.
The defect in terms of top View(C Scan) Side View(S Scan) and end view (Bscan) can easily be
evaluated.
(
REPORTING
Report shall be submitted in the attached format. Recorded scan data can be analysed offline using
Dongle Key.

(
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Phased Array Insl!ection NBTC-OP/TS26
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Phased Array Ins:uection NBTC-OP!TS26
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SCAN PLAN AND CALffiRATION BLOCK

WEDGE

1 20mm r SL64A2

S t o 16.5 IT'm

SCAN PLAN- SECTORAL SCAN

Figure 2

ALUMINUM CALIBRATION BLOCK

75 mm
n ,...
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I u
O.SThole

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0

0 .75T hole

Figure 1