RAJASTHAN NORTHERN AREA DEVELOPMENT PROJECT MANGALA FIELD DEVELOPMENT PHASED ARRAY (UT) TESTING JCT-105-MPX-Q-PRO-0003 Kj Ci | 28-16-2010 | ISSUED FOR CONSTRUCTION | SURFSHTNAIKER | GISWAJITIT RVSMANI AT] 0082010 ISSUED FOR REVIEW BINUI BISWAJITH RVSMANT Rev Date Purpose of osu Prepared By ‘Checked By ‘Approved By SCT-105-MPX-Q-PRO-0003 REV-CI Pape 1 0F 12PHASED ARRAY (UT) TESTING IXAR CONTENT 10 INTRODUCTION 11 Scope 2.0 REFERENCES 3 30 PERSONAL QUALIFICATION 3 40 SUMMARY OF PRACTICE, 4 50 APPARATUS: 5 SA TRANSDUCERS s 82 WEDGES 6 60 REFERENCE BLOCKS ‘6 6.1 ADDITIONAL BLOCKS FOR SYSTEM CALIBRATION 6 7.0 PHASED ARRAY SYSTEM CALIBRATION ‘ 0 SENSITIVITY CALIBRATION 1 9.0 WEDGE DELAY CALIBRATION ’ 10.0. TIME CORRECTED GAIN CALIBRATION 1 110 SYSTEM CALIBRATION VERIFICATION 8 (20 CHANGES INSYSTEM CALIBRATION 8 130 RECALIBRATION o (40 SURFACE PRPERATION ’ 150. EXAMINATION COVERAGE AND SCANNING TECUNIQUE, . 16.0 PRE INSPECTION 0 170 RECORDINGIE VALUATION CRITERI 1 18.9 DOCUMENTATION " 19.0 ACCEPTANCE CRITERIA 2 SCT-10S-MP.0-PH0.000%.1 evr Page 20012PHASED ARRAY ( UT } TESTING ZS 1, INTRODUCTION 1.1 SCOPE This procedure establishes the phased array ultrasonic examination which shall be used to examine carbon steel/stainless steel plate and pipe base materials and weldments. This procedure is intended to cover the method and acceptance standard of the manual phased array ultrasonic examination of welding joints for piping having outside diameter mm 4 inch to 24 inch and having wall thickness ranges from 6mm to 40 mm. 2, REFERENCE DOCUMENTS ASME-B31.3,American Society of Mechanica! Engineers Code for process Piping ASTM E-2491 Standard guide for evaluating performance characteristics of Phased Array Ultrasonic Examination. ASME SEC VIII, DIV 1, APP.4 DNV - OS - F101, 2007 API 1104 ASME B 31.1 3. PERSONNAL QUALIFICATION Non- destructive testing (NDT LEVEL l/III) personnel shall be qualified In accordance with a recognized NDT personnel qualification practice or Standard such as ANSI/ASNT-CP-[89, SNT-TC-1A, MIL-STD-410, BIS 13805 or a similar document. Records of NDT Personnel Certification shall be submitted to CEIL for records. SCTAOS-MPX-Q-PROAOOR-CL REVCI Page 3of 12yy r PHASED ARRAY ( UT ) TESTING ZS 4, SUMMARY OF PRACTICE Phased array ultrasonic examination is one of the computerized imaging techniques. ‘The ut-Phased Array Technique is a process wherein UT data are generated by controlled incremental variation of the ultrasonic beam angle in the azimuthal or literal direction while scanning the object under examination. ‘This process offera an advantage over processes using conventional search units with fixed beam angles in direct impingement. Each phased array search unit consists of a series of individually wired transducer element on a wedge that are activated separately using a pre-sclectable time delay pattern. With a linear delay time between transmitter pulses, an inclined sound field is generated. Varying the angle of refraction requires a variation of the linear distribution of the delay time. Depending on the search unit design, it is possible to electronically vary either the angle on incidence of the lateral/skew angle. In receiving mode, acoustic energy is received by the elements and the signals undergo a summation process utilizing the same time delay pattern as was used during transmission. Flaw sizing is normally performed measuring the vertical extent ( incase of crack } or the cross sectional distance ( incase of volumetric /planer flaws } at the dB level once the flaw has been isolated and the image normalized. Tandem sizing and analysis used techniques similar to pulse echo but provides image that are easier to interpret since specular reflection is used for defects oriented perpendicular surface. For cracks and planer defects, the result should be verified using crack-tip-diffraction signals from the upper and lower ends of the flaw , since the phased array approach using topographic reconstruction is most sensitive to flaw tip indications and is able to give a clear reconstruction image of these refraction phenomena. As with other techniques, the phased array process assumes isotropic and homogenous material whose acoustic velocity is constant and accurately known, ICT-IOS-MPX-Q-PRO-GOO-C1 revel Page 408 12es | PHASED ARRAY ( UT ) TESTING Z> 5.0 APPARATUS The ultrasonic phased array instrument shall be an Omni Scan®, a pulse echo type and is equipped with a calibrated dB gain or attenuation control stepped in increments of 2dB or less. The Omni Scan contains 16 or 32 independent pulser/receiver channels. The system is capable of generating the images B-scan, C-scan, S-scan ( Sectorial scan ) along with display of A-scan Examination personnel may use a real-time sectorial scan image during scanning to ensure that proper data has been collected. Sectorial-scan images contain signal amplitude and reflector depth information projected for the refracted angle of the ultrasonic beam. The on-board focal law generation software permits direct modification of the ultrasonic beam characteristics for performing either electronic linear scan (E-scans) or sectorial scan (S-scan) ‘The data storing capabilities of the system requires the use of an external storage device, flash card or USB memory stick. A remote portable PC shall also be connected 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 shall aiso be used for data play back 5.1 TRANSDUCERS Ultrasonic transducer configurations are specified by the technique used for the examination. 1D linear phased array probe used in this procedure may include from 10 to 128 elements. The probe frequency shall be between 2 MHz and 10 MHz depending upon material type and thickness. This procedure uses a phased array probe with 5 Mhz frequency with 64 elements with a pitch of 0.6mm. ICTAOSMPXQ-PRO-6003-C1 REVeI Page Sof 12Zs PHASED ARRAY ( UT ) TESTING E> 5.2 WEDGES Phased array wedges should be of a design to accommodate the aforementioned phase array probes. Nominal refracted wedge angles shall be 45, 55, 60 or 70 degrees to ensure coverage of the weld and heat affected zone. Wedges shall have provision of irrigation holes and carbides for couplant flow. 6.0 REFERENCE BLOCK ‘The reference block shall be manufactured from the same pipe material of specification and wall thickness. Two square buttress notches shall be placed as shown in figure T-542.8, 1.1 of Article 5, ASME Sec V. The calibration reference standard dimensional details are shown in the same figure 6.1 ADDITIONAL BLOCKS FOR SYSTEM CALIBRATION In addition to the basic reference block, additional blocks shall be used for system calibration. IW V1 block and IOW block shall be used for sensitivity, velocity and wedge calibration. PHASED ARREY SYSTEM CALIBRATION Calibration shall be performed from the surface of the calibration block which corresponds to the component surface to be examined. System calibration shall include the complete ultrasonic examination system. Screen distance calibration shall be atleast 1% “vee paths” (also known as skip) for the minimum angle that will be used during the examination, unless otherwise specified. The system calibration information shall be recorded on the ultrasonic data report form used in Omniscan®. During scanning, only the gain may be adjusted from the calibrated reference dB. Adjustment of other controls requires recalibration. JCT-105-440X-Q-PRO-0003-C1 REVCI Page 60f 12PHASED ARRAY ( UT ) TESTING > 8. SENSITIVITY CALIBRATION The Omniscan® shall be calibrated for wedge delay and sensitivity ‘The sensitivity calibration shall provide the required gain adjustments for each refracted angle and sound path used. Select a calibration reflector, which is approximately one-half the thickness of the component to be examined, or within the zone of the material to be examined, Peak up this signal from the calibration reflector and scan the phased array probe backwards through all the different angles of focal laws. The Omniscan system shall calculate the required gain needed at each focal law to adjust the amount of gain required to obtain the sensitivity. 9. WEDGE DELAY CALIBRATION ‘The wedge delay calibration shall be carried out for both linear scan as well as sectoral scan. The wedge delay calibration shall be carried out in true depth mode and done with a known reflector depth. Peak up this signal from the calibration reflector and scan the phased array probe backwards through all the different angles or focal laws. Scan forward over the calibration reflector through all the refracted angles of focal laws. When the signal for all angles and focal laws lies within the threshold, the omni scan system shall adjust all the focal laws/angles to display the reflector’s true depth. 10. TIME CORRECTED GAIN CALIBRATION Time corrected gain calibration shall be used to compensate for attenuation in the material at the sound paths used during calibration and examination. To obtain the TCG calibration peak the signal from the ID notch at half skip distance and adjust the gain to obtain 80% of amplitude from the reflector. Place the phased array probe perpendicular to the notch axis. Move the phased array probe forward and backward to equal the amplitude for all the focal laws and angles and plot the first point. Move the probe to the OD notch and obtain the second point. Omni Scan users the gain compensation required due to attenuation in the sound travel and adjust the JCTH105-MPX-Q-PRO-O003-C1 Rever Page 7 of 12aa PHASED ARRAY ( UT ) TESTING E> gain for all focal laws/angles. Once again the phased array probe is moved to the ID notch and located at a skip distance equal to 1.5 skip distance and repeat the same procedure as carried out in obtaining the first and second point. Once all the points are picked the TCG can be accepted. TCG calibration has to be carried out for all scan plans in a multi group option while using phased array probe. TCG may be plotted using IOW Blocks having 1.6 mm SDH at appropriate depth. The examination system calibration shall be stored in the Omni Scan System with electronic memory, on an external chip or data storage device. This calibration may be used at a later date provided that date provided that the system calibration is verified prior to the examination. 11. SYSTEM CALIBRATION VERIFICATION The system calibration verification shall include the examination system Sweep range and TCG calibration shall be verified on the appropriate calibration block or simulatior block as applicable under the following condition: * Prior to an with in 24 hours of the start of a series of examinations * With any substitution of the same (ype and length of search unit cable + With any substitution of power using the same type sources, such as a change of batteries * At least every 12 hours during examination * At the completion of series of examinations * Wherever the validity of the calibration is in doubt 12, CHANGES IN SYSTEM CALIBRATION The examination shall deemed to be voided if any point of 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. if the situation arises, carry out a new system calibration and repeat voided examinations and re examine all indications recorded since the valid calibration verification. The change in values if any shall be entered on the applicable forms. ICTLOSMPX-O-PRO-LB0I-CI REVer Page Bof 12wk PHASED ARRAY ( UT ) TESTING es> 13, RECALIBRATION Any of the following conditions shall be caused for system recalibration: * Changes of search unit or wedge * Changes of search unit cable type or length changes + Changes of ultrasonic instrument * Changes in examination personnel * Couplant change * Change in type of power source 14. SURFACE PREPRATION Contact surfaces: The finished contact surface should be free from weld spatter and any roughness that could interfere with tree movement of the search unit or the transmission of ultrasonic vibrations. Weld surfaces: The weld surface should be free of irregularities that could mask or cause reflections from defect to go undetected and should merge smoothly in to the adjacent base materials. Surface conditions, which do not meet these requirements, shall be recorded as limitations on the ultrasonic examination data report form. 15. EXAMINATION COVERAGE AND SCANNING TECHNIQUE ‘The specifics of the examination volume, weld definition and location shall be identified in the scan plan. The examination volume shall cover the weld metal and a quarter from the toe the weld. This area includes the heat affected zone (HAZ). The scan plan shall demonstrated by plotting or with using a simulator the appropriate examination angles for the weld preparation bevel angles that will be used during the examination. This scan plan shall be documented to show that the examination volume was examined. This scan plan shall be a part of the final examination. ICTIOS-MPX-Q-PRO.1003.01, REVCI Page 9of 12PHASED ARRAY ( UT ) TESTING Ss Omni Scan system has the capability of using multiple-group settings to establish sector scans and E-scans for the appropriate angles to ensure complete coverage of the weld and heat affected zone Scanning shall be performed using a line scan technique. Each line scan shall be parallel to the weld using a sectorial scan (S-scan) and/or a linear scan Appropriate refracted angle as accepted by ASME will define the position of the arrays and hence angles. These should be detailed in the ultrasonic scan plan. A minimum of two (2) line scans shall be performed at two (2) different index points from the centre of the weld from both sides of the weld where practical to ensure coverage of the weld and heat affected zone (HAZ) Scans shall be parallel to the weld at 90° and 270° scan axes and the multiple groups scanning shall involve both the above directions for complete coverage of the weld. Manual ultrasonic weld testing shall be performed at a scanning sensitivity of DAC/TCG reference sensitivity plus 6 dB minimum. All indications at 50% of DAC/TCG screen height. Evaluation sensitivity for manual ultrasonic weld testing should be DAC/TCG reference sensitivity plus 64B with an evaluation level for all indications at 50% of DAC/TCG screen height. After the reference sensitivity, and evaluation sensitivity and levels have been established, they shall be qualified, and then incorporated into the final procedure and in the final qualification report 16. PRE INSPECTION Prior to start array examination, the weld base metal and HAZ area shall be scanned manually with normal beam probe to locate reflectors that can limit the capability of the phased array inspection to examine the weld volume. The gain of the instrument is adjusted such that the second back wall echo examine the weld volume. The gain the instrument is adjusted such that the second back wall echo amplitude to 80% of FSH. Omni Scan equipments conventional UT channel shall be used for this inspection. ICT-105-MPX-Q-PRO-OO03-C1 Reve Page ot 12wa PHASED ARRAY ( UT ) TESTING Ss 17, RECORDING/EVALUATING CRITERIA & AMPLITUDE DETERMINATION Only Trained Level Il - UT operators with hands on training Omni Scan shall calibrate and carry out UT inspection. Only personnel certified Level II or II in ultrasonic testing along with knowledge of phase array and Omni Scan equipment shall evaluate the results of ultrasonic examinations for acceptance. All reflectors that exceed 50% of DAC/TCG shall be investigated completely to determine the type of reflector. Signals which are determined to result from geometrical reflectors. Such reflectors shall not be considered as flaw indications or compared with allowable with allowable indication standards. 18, DOCUMENTATION Results Scan Data Report form used in the software. All Phased shall be documented on the examination report. All the columns in the report format should be completed with appropriate data or ‘NA’ The ultrasonic scan plan, ultrasonic calibration and ultrasonic instrument linearly verification (if required) shall be considered of ultrasonic examination shall be reported on the Omni part of examination report * Clients name & address * Information about the equipments used for testing * Date and place of inspection «Test system calibration * Inspection sammary * Objects reference number * Comments * Signature of the inspection personnel. JCT-105-MPX-Q-PRO-0003-C1 Revel Page Hof 12PHASED ARRAY ( UT ) TESTING ES 19, ACCEPTANCE CRIETERIA | Refer : ASME B 31.1 Para 344.6.2 ) The following indications shall be considered as defects : 1) A linear type of discontinuity is unacceptable if the amplitude of the indication exceeds the Reference level and if its length exceed 6mm for weld thickness Tw < 19mm Tw/3 for weld thickness > 19mm to < 57mm Tw means the thinner wall thickness of the two joining members 2) Rounded type of discontinuity is unacceptable if the ampulitude of the indication exceeds the reference level and size & distribution of these indications is more than that given in App 4 of the ASME Sec VIII DIV Las enclosed in Annexure Number 1. ICTHOS-MPX-QPRO-LHDLT Revel Page 12 oF #2