RUSSINDO GROUP CORPORATION

Jalan Ampi No.09, Air Dingin, Simpang Tiga

Pekanbaru, Riau, Indonesia 28284
Tel > (+62) 761 8442592
Fax > (+62) 761 8442592
email > info@russindo.com
www.russindo.com

STANDARD OPERATION PROCEDURE

FOR INTERNAL ROTATING INSPECTION
SYSTEM

Document No : 032/OPD/III/17
Rev :0
Date : 21st March 2017
Issue Number :1

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No. Rev 00
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FOR INTERNAL ROTATING Page 2 of 11
INSPECTION SYSTEM

DOCUMENT APPROVAL SHEET

Title STANDARD OPERATION PROCEDURE FOR

INTERNAL ROTATING INSPECTION SYSTEM

Prepared by

TRI DHARMA PUTRA

ASNT NDT LEVEL II

Reviewed & Approved by

SATWAN SINGH
ASNT NDT LEVEL III

Approved by
ADITYA ROMAS
PRESIDENT DIRECTOR

REVISION RECORD

Approvals
Issue No Date Revision
Originator Checked Approved
1 21/03/2017 0

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INSPECTION SYSTEM

TABLE OF CONTENTS

SECTION TITLE

1 Purpose

2 Scope

3 Reference

4 Personnel Qualification Requirements

5 Equipment Safety

6 Tube Details

7 Inspection Principle

8 Equipment Description and Setup

9 Software

10 Iris Probe

11 Preparation of Calibration Standard

12 Tube Cleanliness

13 Testing Procedures

14 Documentation

15 Acceptance Criteria

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INSPECTION SYSTEM

1.0 PURPOSE

This document describes the prosedures to be followed during Ultrasonic Internal Rotating
Inspection System ( IRIS ) on Heat Exchangers, Air Fin Coolers and Boiler tubes by using R/D
TechMS5800

2.0 SCOPE

This scope outlines the Inspection Principles, Equipment used, Testing Procedures and the
preparations prior to IRIS inspection

It also covers the basic qualification of NDT inspection and safety rules and regulation during
the inspection

A sample report of the inspection conducted on a Heat Exchanger

3.0 REFERENCE

R/D-TECH MS5800 manual

4.0 PERSONNEL QUALIFICATION REQUIREMENTS

IRIS Interperter: He shall be a graduate and certified by R/D-TECH and with a minimum of 3
years field experience in IRIS data collection and analysis

IRIS Inspector: He shall be a graduate / Diploma holder in science or Engineering with a

minimum of 2 years experience in IRIS data collection and analysis

IRIS Asseistan: He shall be responsible for probe pulling at side. The IRIS Inspector will train
the IRIS Assistan

5.0 EQUIPMENT SAFETY

Equipment shall be grounded properly while inspection. The power socket for the equipmnet
shall be matched with the plant power socket. And this power point should not allow sharing
with other activities such as grinding, welding and compressor because it would damage the
equipment and data collection.

Preesurized clean water supply is required because this system uses water as a couplant and
also for rotating turbine

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INSPECTION SYSTEM

6.0 TUBE DETAILS

Preparation: Prior to the IRIS inspection, the IRIS inspector must have all the relevant
information about the unit that going to be inspected. For instants the dimentions of the tubes,
history of the unit, number of tubes and the orientation the tubes, the cleanlines, and the location
of the heat exchanger must be known.

Data collection and Reporting: This involves the setup of IRIS equipment. Data collection and
analysis will be done as using the correct parameter

7.0 INSPECTION PRINCIPLE

The IRIS inspection principle is based on pulse-echo detection. A high frequency tranducer
producing ultrasonic wave that propagates into water. This ultrasonic wave will turn into
normal incidence beam on the inner diameter by the 45o mirror, which is mounted in the turbine
(Figure.1). While the turbine rotates 360o, the tranducer collects the front and back wall echoes
which are digitally processed, and calculate the probe delay, tube OD and ID, and tube wall
thicknes

Figure.1 IRIS Inspection Principle and IRIS Data

8.0 EQUIPMENT DESCRIPTION AND SETUP

8.1 IRIS Equipment: MS5800

8.2 MS5800 with RFET module
8.3 A laptop computer with Multi View software
8.4 Appropriate transdures and cables for tube inspection
8.5 A water pump and a water filter. Water pump is required if the water
pressureis less than 40psi
8.6 The voltage requirement for the MS5800 system is: 240V/50Hz

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INSPECTION SYSTEM

9.0 SOFTWARE

Multi View Version 6.0 Rev 8 is the R/D Tech software used for inspection and analysis. It has
three of modes

1) Setup Mode
The setup mode is used for all setup operation such as RFET, IRIS and MFL, Multi View
environment setup, calibration setup, and analysis setup. Data acquisition can be done in
the setup mode to perfome the probe calibration

2) Inspection Mode
The inspection mode is designed to perfome inspections using a predefined filing system

3) Analysis Mode
The analysis mode is used to load and data files for analysis purposes

10.0 IRIS PROBE and TURBINE

IRIS probe are in various frequecies: 15MHz and 10MHz. The frequency selection is based on
the thickness of a material. For example 19.05 mm OD with 2.11 mm Thickness tube requires
15MHz probe. IRIS probes usually mounted with a hydraulic turbine (Figure.2)

Figure.2 IRIS Probe Assembly

The list below show the sizes of centering device and turbines

Extra Small Centering Device 11.4 mm to 17.8 mm ID

Small Centering Device 17.8 mm to 25.4 mm ID
Medium Centering Device 23.4 mm to 41.9 mm ID
Large Centering Device 25.6 mm to 76.2 mm ID

Turbine -12 mm < 31.75 mm OD

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Turbine -17 mm > 31.75 mm OD

11.0 PREPARATION OF A CALIBRATION STANDARD

Calibration Standard is very important. It must be of the same material, diameter, and thickness
as the tube to be inspected. Figure.3 show a calibration standard with artificial flaws. Wall lose
can be a through hole, round bottom, flat bottom hole, circumferentiel grooves and one-side
flaws, a long flaw, a short flaw, and a taper or pitting. Diameter of a pitting or trough hole in a
calibration tube is usually the tube wall thickness or 1.5 times tube wall thickness

Calibration is always perfomed in the lap prior to leaving for the inspection. The same
calibration will be repeated at the side to confirm that the equipment does not experience any
frequency interference or other unwanted noisy signals.

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Figure.3 Calibration Standard

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12.0 TUBE CLEANLINSS

The internal tube must be very clean in order for the turbine to rotate smoothly and collect good
data. Good cleaning will avoid scattering ultrasonic signals. Besides that, pressurized clean
water is required to rotate the turbine. Hydro blast, abrasive blasting or bio blasting can achieve
good internal tube cleaning

13.0 TESTING PROCEDURES

13.1 Numbering the tube bundle

Usually the numbering process of a tube bundle is based on the drawing provided by
the client. Otherwise, row run horizontally ( from left to right) and columns run
vertically (from top to bottom)

13.2 Setting Up MS5800

13.2.1 First setup the equipment with all the necessary parameters and
connection. Then load the particular calibration file from the setup wizard
to perform the side job. Then adjust the gain parameters to obtain good
signal on the A-Scan

13.2.2 Input client’s name, inspection date, and unit number for the reporting
purpose

13.2.3 Input the tube identification: Rows, Column numbers

14.0 DOCUMENTATION

Once the data acquisition is completed, a preliminary report will be prepared. This
preliminary report is given to the client before the inspection team leaving the plant. It
contains details of the tubes that were tested and along with a tube sheet diagram.

The following page the a sample of a preliminary report

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INSPECTION SYSTEM

PRELIMINARY IRIS INSPECTION REPORT

CLIENT :........................
UNIT NO:..........................

REPORT REFERENCE: CIT/....../....../PR........... DATE:..../...../.....

Name / ID. Of Exchanger / Boiler

Total Tubes In Unit
No. Of Tubes Inspected
Tube Material / Dimension

Scanning Direction

Row No. Tube No. Wall Remaining Remarks

For: ................................... For Client:..................................

......................................... ............................................

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FINAL REPORT

A detailed final report of inspection of the heat exchanger that was inspected will be presented
with in two weeks. This report contains a tube sheet diagram, which illustrates all the tubes
with color codes. A sample waveform of tubes (Figure.3) with wall loss also will be included.

15.0 ACCEPTANCE CRITERIA

The inspection results shall be reported as in percentage wall loss values. The acceptance
orrejection criteria of a tube bundles are based on the requirement of the client.

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