OLYMPUS Automated Ultrasonic Testing for Pipeline Girth Welds A Handbook E. A. Ginzel 4 ni fAudorneted Ulirasonic Testing for Pipeline Girth Welds: A Handbook Series coordinator, Noél Dubé Technical reviewer and adviser: D: Michael D. C. Moles (Olympus NDT) Layout, graphics, editing, proofreeding, and indexing; Technical Communications Service, Olyngus NDT Published by: Olympus NDT, 48 Woerd Avenue, Waltham, MA 02453, USA Marketing and distribution: Olympus NDT This guideline and the products and programs it describes are protected by the Copyright Act of Canada, by laws of other countries, and by international treaties, and therefore may not be reproduced in whele or in part, whether for esle ov not, without the pélor written consent from Material Rescarch Institute, Under copyright law, copying includes translation into another language or fornat. ‘The information contained in this document is subject to charge or revision without notice RD Tech part number: DUMGO70A, © 2006 by Clympas NDT All rights reserved, Published 2008, Printed in Canada ISBN 0-9735933-2-6 Notice To the best af our knowledge, the information in this publication is accurate; however, the Publisher does not assume any responsibility or liability for the accuracy or completeness of, or consequences arising from, such information. 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History — Early Days ..... . 1.1 Early Ideas... 1.2 The Introduction of Mechanised Welding ...... 1.3 UT Adaptations to the Mechanised Hee 1.4 Probe Design Changes ........ ea 3 Mechanised UT Enters the Computer Age Lé Standardising Concepts References to Chapter 1... 15 Zones—How to Keep Them Apart 2.1 Principles of the Zonal Technique ... 2.2 Beam Control . 22.1 Beam Spot Size 222 Beam Angle References ta Chapter 2 Beam Angles—Designing a Technique Defining Fusion Zones and Volumetric Zones .. Volumetric Detection 3 Some Transverse Ideas Adding TOFD ........... 5 SMAW and SAW here Vertical Dee References to Chapter 3 .. Ee Wa au +. Calibration—How to Set Up the Targets .. 4.1 Block Drawings and What the Machinist Needs to Know 2 Acoustic Ouality Check . 3 Surface Condition rences to Chapter 4 eoma Table of Contents5. System Requirements — Aap pentand Display? 5.1 Scanner Head .. 5.2 Data Acquisition Units $3 Displays .. 54 Records ..... References to Chapter 5 6. Making a Good Calibration .. 6.1 A Review of Target: 6.1.1 Zonal Targets 612 Volumetric Targets 6.13 Transverse and TOFD Notches . 6.14 Various Calibration Aspects 6.2 Limitations on Calibration Quality 63 Characteristics of a Good Calibrati References to Chapter 6 7. Project Preparation and Pre-Project Benning References to Chapter 7.. 8. Qualification—Systems, Operators, and Techniques . 8.1 What Is Required and Is It Reasonable? ........ 8.1.1 Testing at Elevated Temperature 8.1.2 Repeatability with Guide Band Movement 8.1.3 Accuracy in Circumferential Positioaing/Location 8.1.4 Repeatability with Scanner Orientation (Upside Dawn 8.1.5 Detection Level on an Unwelded Bevel .. 8.1.6 Coupling Check—Alarm Levels Verified (TR and PE) 8.17 Repeatability with Scan Direction 8.1.8 Clearance Tes .... 8.1.9 Probability of Detection and Sizin; 8.1.10 Accuracy in Height and lengih cans 8.1.11 Other Equipment Tests .. 8.2 Operator Qualificatons . 83 In Summary . References to Chapter 8 se Interpretation ..... 9.1 What Is Evaluated? 9.2. Evaluation Thresholds .. 93 Flaws .... 93.1 Misfire ...... 9.3.2 Undercut ...... 9.3.3 Shrinkage Cracks vi Table of Contents9.34 Porosity 176 9.35 Cold Lap .. Ud 3.4 Geomexy 178 9.4.1 Root . 179 9.4.2 Cap Geometry 182 9.5 False or Overtrace Signals. What are they? 184 9.6 Examples of AUT Indications 186 OT TYR eestor . 187 Lack of Fusion Root .. Lack of Fusion Midwall Lack of Fusion Cap . Centreline Crack. Root Porosity .. Fill Porosity Burn Through ‘ Geometry: High-Low Cap Geometry 9.7.10 False Signal 9.3 Special Flaws 9.8.1 Transverse Cracks 9.82 Copper 9.83 General 9.9 What to Do with Volumetric and TOFD Data 9.10 Computer-Assisted Positioning ..... References to Chapter 9... i 976 O77 978 w79 10. Acceptance Criteria ... 10.1 Workmanship 10.1.1 API 1104 .. 10.1.2 AS 2885.2 ... 10.1.3 CSA 2662 210 ia 10.1.4 ISO 13847 ...... : . 213 10.1.5 DNV OS FIO) .... é le 24 10.1.6 General Considerations in Workmanship Acceptance Criteria for AUT . 217 ole. . 215 - 226 228 23) 10.2 ECA-Based Acceptance Criteria 10.2.1 The Principles of Engineering Critical Assessment 10.2.2 API and BS Rules .. 10.2.3 Generic Acceptance Criteria References to Chapter 10 . 11. AUT Sizing and PODs 1 Sizing “Techniques” Amplitude Techniques Table of Contents vi12, 13. Appendix A: Beam Size Tables .. viii 11.2.1 Simple Zone Sizing 11.2.2 Amplitude Corrected Zone Sizing 11.2.3 Amplitude Corrected Zone Sizing with Overtrace Allowance 11.2.4 Amplitude Comparisons with Zone Characterisation .. 11.2.5 Beam Boundary by dB Drop .... 11.3 Temporal Techniques .. 11.3.1 TOFD .. 11.3.2 Backscatter 11.4 Amplitude Sizing Comparison . 11.5 POD and POS. 11.6 Statistical Techniques 17 Precision and Accuracy 11.8 Summary ... References to Chapter ie Great Expectations and Mythologies 12.1 Procedure Policies 12.2 Audit Guidelines 12.3 The Operator's Log .. 12.4 Wall Thickness Variation Eff 12.5 AUT Myths . References to Chapter 12 Applications ., 13.1 Pipeline Land Lay 13.2 Offshore Projects 133 Offshore Spoolbase 13.4 Dual-Product Longitudinal Seam 135 Non-Pipeline Applications of the Zonal Technique 13.6 Future of AUT 13.7 Phased Arrays 13,71 Seamless 13.7.2 Inspections on Thick Section Risers 13,7.3 1.5D Arrays for Improved Sizing in Risers and Tendons .. 13,74 Focusing for Small Diameter Pipes 13.7.5 Short Cutback 13.7.6 Clad Pipe ..... 13.7.7 Portable Phased Array Units 13.8 Conclusions = References to Chapter 3 ‘Table of ContentsAppendix B; Beam Size Approximations from Calibration SCAMS sessesescesersesanenne esenenrerenaenetseee Appendix C: Suggested cy C1 CRC Bevel...... 2 CRC Techniques C3 SMAW Single Vee Bevel of 60° (Manual Welding) soscientares OS Appendix D: Statistical Comcepts .....secreecesersneron D.1 Comparing Samples eeu 2 The Significance of ignificance D3 A Tail of a Curve .. A Probability .... iography of Appendix : “Statistical Concepts” Glossary of Terms and Abbreviations ......::::ss:ssseuesssseesiees 34 sees OF List of Figures . List of Tables Index .... Table of Contents i