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Ultrasonic Inspection Procedure: Gary E. Kinter Asnt Level Iii Ut 2-5-2013
Ultrasonic Inspection Procedure: Gary E. Kinter Asnt Level Iii Ut 2-5-2013
PROCEDURE
Author
Approved By
Revision No.
Name
Gary E. Kinter
Reviewed By
APPROVAL
Function
ASNT Level III UT
REVISION HISTORY
Approved By
Date
2-5-2013
Signature
Date
Signature
INDEX
1.0
SCOPE
2.0
DESCRIPTION
3.0
APPLICATION DOCUMENT
4.0
PERSONNEL
5.0
EQUIPMENT
5.1
APPARATUS
5.2
SEARCH UNIT
5.3
COUPLANT
5.4
5.5
5.6
CALIBRATION
6.0
PROCESS
6.2
APPLICATION
6.3
ANGLE BEAM
6.4
6.5
6.6
EXAMINATION PROCEDURE
6.7
7.0
ACCEPTANCE STANDARD
8.0
A.
REPORTS
2.0
SCOPE
1.1
This procedure covers the requirement for Ultrasonic examination of any welded
material of any size, shape, thickness or configuration capable of conducting
sound as may be required by the client specification and by various codes under
which a component, or system is being designed and manufactured.
1.2
EDEMAC certifies that this document meets the minimum requirements of the
ASME section V. Article V. and any other code or specification reference methods
of Ultrasonic examination as defined by ASME section V. Articles
DESCRIPTION
2.1
2.2
3.0
APPLICABLE DOCUMENTS
3.1
The following documents are made a part of this procedure to the extent specified.
American Society of Mechanical Engineer (ASME)
Section
I
Power Boiler
Section
VIII
Pressure
American National Standard Institute (ANSI)
B31.1
Power Piping
B31.3
Chemical plat / Petroleum Refinery Piping
American Society for Testing and Material (ASTM)
E 164 Standard Method for Contact Inspection of Welding
American Society for Non- Destructive Testing (ASNT)
SNT-TC 1A NDT Personnel Qualification and certification
EDEMAC SERVICES
QA Examiner Personnel Qualification and Certification
4.0
PERSONNEL
4.1
4.2
4.3
5.0
5.2
5.3
EQUIPMENT
5.1
a.
b.
SEARCH UNIT
5.2.1 Straight beam transducers shall have to nominal frequency or 2.25
MHZ unless variables such as grain structure material thickness etc.
require the used of other frequencies
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
COUPLANT
5.3.1
5.4
a.
b.
5.5
c.
d.
5.6
CALIBRATION
5.6.1 Calibration of the probes for beam angle is required on the IIW
(International Institute of Welding) test block or other approved alternative
(for example the V2 block) at least daily calibration of the flaw detector
time base and amplification shall be carried out before examining each
weld.
6.0
PROCESS
6.1
SURFACE PREPARATION
6.1.1 Contact surface the finished contact surface shall be free
from weld spatter and any roughness that would interfere with free
movement of the search unit or impair the transmission of Ultrasonic
Vibration.
6.1.2
6.1.3
Base Material: The volume of base material through which the sound will
travel in angle beam examination shall be completely scanned with a
straight beam search unit to detect reflectors which might affect
interpretation of angle beam results. This is not intended as an acceptance
reflection examination.
6.2
APPLICATION
6.2.1 The principal objective of the method given herein is the detection,
location and evaluation of defects within the weld and heat affected zones.
The welds shall be examined by the angle beam method where practical.
In the examination of weldments where geometry or the condition
described in 6.1.3 does not allow angle examination from both sides of the
weld from single surface or a combination of surface, either a combination
of angle beam and straight beam or straight beam in two (2) directions at
90 degrees to each other shall be used.
6.3
Determination of Curves:
Distance amplitude correction curves shall
be constructed by utilizing responses from the basic calibration described
in 5.5. The first point on the curve is obtained by placing the search unit
as near as possible, but not less that 3/8 vee-path or 2-in whichever is less
from the calibration hole and positioning for maximum response.
b.
The gain control is then set so this response is 80 percent of full screen on
the cathode ray tube (CRT) This is the primary reference response.
c.
Without chaining the gain, the search unit shall be placed similarly at other
position covering the expected examination distance range, and the
corresponding response marked or the CRT screen.
d.
These points are joined by a smooth line whose length should cover the
examination range. See figure 5.
6.3.2
6.3.3
The Search unit is positioned for maximum response from the notch in the
basic calibration block and response reading is recorded. Then the search
unit is positioned for maximum response from the notch in the test
material to be examined and this response reading is also recorded.
The original distance amplitude correction curve can now be used for
signal amplitude rejection of flaws.
Connect the second angle search unit to the receive connection of the
instrument and switch on the calibration block and manipulate the two
search units until a maximum response is shown on the CRT mark this
level on the CRT
The transit and receive search units are then placed on the production
material so that the sound beam travels from the single transmit search
unit through the material and into the receiver unit. It is again necessary to
peak in the response and mark the level on the CRT.
As with the V-notch method, correct the response from the test material
by adding or subtracting attenuation (db). Following disconnection of the
receive search unit and switching of the instrument back to the pulse-echo
method, the distance-amplitude correction curve originally drawn on the
CRT screen is satisfactory for use as a signal amplitude rejection level.
6.4
Piping: The transfer method shall be used as a minimum once for each
welded joint for pipe size 10 inches in diameter and over, once for each 5
feet of weld for pipe less than 10 inches in diameter.
6.4.3
6.4.4
b.
6.4.5
6.5
Two search units technique: Technique using two search units may
be used to detect lack of penetration in double welded butt joints.
6.6
b.
c.
EXAMINATION PROCEDURE
6.6.1. Scanning Motion: The weld shall be examined by moving the
search unit progressively along and across a sufficient contact area
so as to scan the entire weld
6.6.2
6.6.4
6.6.5
6.7
7.0
ACCEPTANCE STANDARDS
7.1
7.2
a.
b.
Note: Where this the thickness of the weld being examined, if a weld
joins two members having different thickness at the weld, this the
thinner of these two thickness.
7.3
7.4
EXAMINATION OF REPAIRS:
7.4.1 Repairs shall be re-examined by the same procedure used
for original detection of the discontinuity
7.5
ACCEPTANCE STANDARD
7.5.1 Defects shall be identified primarily by accurate
positioning of the source of the echo in the weld cross section, and
their approximate orientation determined by comparing the echoes
received from each. When the examination show indication of a
defect the following shall apply.
a.
b.
c.
7.5.2
a.
b.
Any amount of incomplete fusion between the root and the level as
defined by API 1104 shall be unacceptable
c.
REPORTS
8.1
Ultrasonic examination Inspection Report shall be filled out
completely by qualified personnel and the report shall be signed by
the certified inspector.
8.2
8.3
A test report shall be issued for each weld with all the relevant
data, including but not limited to the following
a.
Report number
b.
Weld number
c.
d.
Material thickness
e.
Couplant
f.
g.
Calibration technique
h.
Surface condition
i.
Name of Operator
j.
Acceptance Code
k.
l.
DSG
SCOPE
The scope of work describe in this page spelt out requirement necessary for the corrosion
monitory wall thickness examination of vessel, process lines and facilities.
QUALIFICATION OF PERSONNEL
a.
ULTRASONIC INSPECTION
Inspector shall hold a current certificate of proficiency in ultrasonic issued by a national
recognized certification scheme for non- destructive testing (ASNT) shall be used for the
purpose of qualification of personnel. Alternatives qualifications shall only be deemed
acceptable with the prior consent of the client and / or inspecting authority.
EQUIPMENT AND MATERIAL
a.
Ultrasonic flow detectors with a well define A- scan present
b.
c.
ULRASONIC PROBES
10mm to 25mm crystal diameter probes shall be used a frequency 2 MH Z to 5 MHZ. The
types of probe required depend on the thickness of the material being examined.
TYPES OF PROBE
i)
Angel probe
ii)
Normal probe
iii)
Transmit probe
PROBE SENSITIVITY
Compression Wave Probe Longitudes
A minimum of 40dB of gain shall be in reserve when the first back wall echo from the
dimension of the IIW/I block is set at 100% full screen height.
ii)
RESOLUTION OF PROBES
Sheave Wave Probe:
IOW beam spread block shall be used to assess resolution. This should be done
accordance to the acceptance standard.
COMPRESION WAVE PROBES
Resolution shall be assessed using the IIWV/I calibration shall be considered acceptance
when the three echoes at 100mm, 91mm and 85mm are clearly defined.
BEAM PROFILE
The beam spread of probes shall be established using the I0W block and 20dB drop
method and beam profile recording on the tracing paper or clear Perspex.
OTHER EQUIPMENT
Calibrated Rule
Tape measure
Welding Gauge
Flaw light location plotting board
THICKNESS SURVEY OF PIPING
Isometric drawing is usually employed in representing pipelines with particular reference
to welds, valves, pumps, flanges and cap ends. The position of each measurement point
clearly marked and referenced to the nearest up weld, value etc.
MEASUREMENT
a.
Vertical piping work and pipe work inclined at 450 to horizontal:
Four measurements shall be made around the circumference of the pipe located at
plat- form North and South (or East and West) and top and bottom of pipe.
Top
East
North
West
North - west
South
VERTICAL
South
Bottom
HORIZONTAL
b.
Horizontal Reading: Requirement with pipe work inclined at 45 0
horizontally, see sketches above.
Other methods of measurement include ultrasonic reading. The procedure for method
forms the basis for the data management system and is specific for the individuals
piping items.
A grid scan at 100% can be carried out as suspect area of piping with evidence of
gross corrosion or significance loss wall thickness.
South West
North East
VERTICAL
Outside
Bottom
Top
HORIZONTAL
Inside
South West
VERTICAL
HORIZONTAL
OUTSIDE
INSIDE
BOTTOM
HORIZONTAL
1.
2.
3.
Tee Pieces
Measurement position on head of T1 in centre, 1 offset 900 each of centre
Reading procedure D
7
6
5
MI 18
4
3
2
1
VESSEL
ULTRASONIC VESSELWALL
THICKNESS SURVEY
Equipment description
Tag no _______________Location __________ flow sheet no _______________
Nominal thickness (mm)
Corrosion Allowance (mm)
Minimum Acceptance thickness (mm)
READING PROCEDURE E
11
12
10
9
8
7
3
6
5
Weld root scan pipe over 8 carry out weld root scans with sheave / compression probes as
appropriate expected is report minimum thickness for 12 quadrants
Reading Procedure
END CAP
(3)
Reading to be taken
(4)
Measurement around the circumstance adjacent to the weld, 1 measurement at the end
cap
REPORT NO.
REQUEST NO.
DATE OF TEST
ACC. CRETERIA
PROCEDURE NO.
CALIBRATION BLOCK
WELD TYPE
OTHER DETAILS
COUPLANT
PERSONNEL
MATERIAL
SURFACE CONDITION
EQUIPMENT TYPE
SERIAL NO.
SENSITIVITY:
ANGEL
FREQUENCY
MHZ
PROBE
SIZE
PRIMARY
REF. LEVEL
TRANSFER
CORRECTION
SCANNING
LEVEL
TOTAL
(dB)
COMMENTS:
EDEMAC SERVICES
CLIENT
NAME:
NAME:.
NAME:
DATE:.
DATE:..
DATE:..
SIGN:.
SIGN:
SIGN:
8.0
ILLUSTRATION OF SCANNING
TECHNIQUES
A.
DETAILS
A OR B
DETAIL D
DETAIL B
DETAILS
C OR D
(A)
00 compression probe scan on parent metal to check for laminations and to verify wall
thicknesses
(B)
Angle probe scan (minimum of 3 probes- 450, 600, 700) from weld cap to full skip
distance plus weld cap width for coverage.
(C)
DETAIL A
DETAIL B
DETAIL C
DETAIL D
ALTERNATE DETAIL D
(A)
00 compression probe scan on parent metal to check for laminations and to verify wall
thicknesses
(B)
Angle probe scan (minimum of 3 probes- 450, 600, 700) from weld cap to full skip
distance plus weld cap width for coverage.
(C)
C.
(A)
00 compression probe scan on parent metal to check for laminations and to verify wall
thicknesses
(B)
Angle probe scan (minimum of 3 probes- 450, 600, 700) from weld cap to full skip
distance plus weld cap width for full coverage.
D.
(A)
00 compression probe scan on parent metal to check for laminations and to verify wall
thicknesses
(B)
Angle probe scan (minimum of 3 probes- 450, 600, 700) from weld cap to full skip
distance plus weld cap width for full coverage.
E.
TYPICAL T WELD
(A)
00 compression probe scan on parent metal to check for laminations and to verify wall
thicknesses
(B)
Angle probe scan (minimum of 3 probes- 450, 600, 700) from weld cap to full skip
distance plus weld cap width for full coverage.
(C)
00 compression probe scan on face X to check for fusion defects (when accessible)
(D)