NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . .

CP-136: API-650 Code Annex-U Requirements for Ultrasonic

Examination in lieu of Radiography

1. Engr.Sangili Gunasekaran, 2.Miteshkumar Panchal, 3. D.M.Tripathi, 4.

S.S.Murugan
More info about this article: http://www.ndt.net/?id=25729

1 & 2. Heavy Engineering Industries & Shipbuilding Co. K.S.C (Public) (HEISCO)-Kuwait
3. Alghanim international- Kuwait
4. Integral Services Co. (ISCO) - Kuwait
sangili.gunasekaran@heisco.com

ABSTRACT
We at HEISCO constructed total 75 No’s of various oil storage tanks as per API-650 Code of
construction. As per API-650 code requirements all vertical weld seams of 25 mm and above shell
thickness 100% RT (Radiography Testing) is required, however customer specification is asking to
perform 100% RT for 19mm and above shell thickness. For all vertical weld joints having thickness
10mm and above we proposed TOFD (Time of Flight Diffraction) technique instead of RT. Radial
annular joints with backing strip also 100% AUT (Automated Ultrasonic Testing) carried out instead of
100% RT.

In Kuwait only 50 Curie (Ir-192: Source) is permitted for industrial Radiography. It takes more time for
RT shooting for heavy wall thickness. Radiography progress is not enough to meet the Construction
schedule due to low Curie source and limited work permit time. To overcome above issues, TOFD
technique (as per API-650 Annex-U Requirements) proposed and accepted by client.

This paper explains about TOFD procedure, scan plans, calibration & demonstration blocks, personal
qualification and training, Interpretation and evaluation etc. TOFD shows Higher Probability of
Detection (POD) and faster result compared to RT Technique.

Keywords: Non-destructive Examination (NDE), Radiography Testing (RT), Ultrasonic Testing (UT),
TOFD (Time of Flight Diffraction), AUT (Automated Ultrasonic Testing), Curie, Probability of Detection
(POD) etc.
2 NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . .

CP-136: API-650 Code Annex-U Requirements for Ultrasonic

Examination in lieu of Radiography

1. Engr.Sangili Gunasekaran, 2.Miteshkumar Panchal, 3. D.M.Tripathi, 4.

S.S.Murugan
1 & 2. Heavy Engineering Industries & Shipbuilding Co. K.S.C (Public) (HEISCO)-Kuwait
3. Alghanim international- Kuwait
4. Integral Services Co. (ISCO) - Kuwait
sangili.gunasekaran@heisco.com

1.0 Introduction:
We at HEISCO constructed total 75 No’s of various oil storage tanks as per API-650 Code of
construction. As per API-650 code requirements all vertical weld seams of 25 mm and above shell
thickness 100% RT (Radiography Testing) is required, however customer specification is asking to
perform 100% RT for 19mm and above shell thickness. For all vertical weld joints having thickness
10mm and above we proposed TOFD (Time of Flight Diffraction) technique instead of RT. Radial
annular joints with backing strip also 100% AUT (Automated Ultrasonic Testing) carried out instead of
100% RT.

In Kuwait only 50 Curie (Ir-192: Source) is permitted for industrial Radiography. It takes more time for
RT shooting for heavy wall thickness. Radiography progress is not enough to meet the Construction
schedule due to low Curie source and limited work permit time. To overcome above issues, TOFD
technique (as per API-650 Annex-U Requirements) proposed and accepted by client.

2.0 Body of Knowledge:

This paper explains about basic, TOFD procedure, scan plans, calibration & demonstration blocks,
personal qualification and training, Interpretation and evaluation etc. TOFD shows Higher Probability
of Detection (POD) and faster result compared to RT Technique.
2.1 Basic principle of TOFD:
 Time-Of-Flight Diffraction (TOFD) relies on the diffraction of ultrasonic energies from 'corners'
and 'ends' of internal structures (primarily defects) in a component being tested.
 The basic configuration for TOFD technique consists of a separate ultrasonic transmitter and
receiver.
 After emission of a compressional wave from a transmitter, the first signal to arrive at the
receiver is lateral wave through upper surface.
 In the absence of defects the second signal to arrive at the receiver is the back wall echo.
 The diffracted signal generated at the upper tip of a defect will arrive before the signal
generated at the lower tip of a defect.
2.1.1 TOFD Advantages:
♦ Diffracted rather than reflected signals
♦ Longitudinal waves
♦ B-scan type imaging (side view)
♦ Accurate sizing capability (height)
♦ Fast scanning
♦ Interpretation of defects
♦ Less sensitive to defect orientation
2.1.2 TOFD Limitations:
♦ Blind area - near surface, back wall
♦ Weak signals
♦ Flaw classification limitation
♦ Interpretation of defects
♦ Sensitive to grain noise
 NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . . 3

Basic Principle set up: Figure -2

2.2 TOFD procedure:

 Personnel qualification –NDT level-II/III: AUT Performing by minium NDT level -2 and final
interprepation and final data evalaution by only NDT level -3. NDT level -2 In TOFD Technique
training hour is 40 and minium experience in technique is 160 Hour with prerequstic basic in
Ultrasonic Level -2
 Principle – Diffracted signal
 Equipment –OMNI MX2
 Probe selection
 Wedge selection
 Data acquisition unit
 Calibration block and demonstration block preparation
2.2.1 Calibration TOFD procedure:
 Sensitivity setting and confirmation
 Width coverage
 Encoder calibration -500 mm long (- or +5 mm)
 Thickness check and gate setting
 Scan plan and scanning
 Interpretation and evaluation
 Reporting
4 NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . .

2.2.2 Comparison of X-rays and Gamma Rays: Table-1

2.2.3 Site Photo- Figure-3

2.3 Scan Plans-Samples 70 Deg and 60 Deg. (Figure-4, 5 &6)

 NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . . 5

2.4 Calibration and Demonstration/Qualification- Samples

Figure-7 Calibration Block Image. (31.2 mm block with 70 degree, 5 MHz Probe):

Figure-8 Qualification Block Image: (70 degree, 6 mm Dia, 5 MHz Probe):

6 NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . .

Table-2 Indication Table for Qualification and Demonstration of 32 mm block:

Target X- Value Probe Depth Length Height Surface / Remarks
No Angle Subsurface
26.24-
1
116-127 70˚ 28.69
11 2.45 Sub surface Acceptable
15.54-
2
166-197 70˚ 19.27
31 3.73 Sub surface Not accept
15.86-
3
218-244 70˚ 19.19
26 3.33 Sub surface Not accept
10.31-
4
316-338 70˚ 13.69
22 3.39 Sub surface Not accept

The TOFD examination as per procedure has been satisfactorily qualified based on the
comparison between actual induced flaw and detected flaw with calibration and qualification
blocks.

The technique used in capable of determined the induced flaw and has been evaluated sized
and reported satisfactorily, hence the technique used per the procedure shall be accepted.

Qualification and Calibration Blocks were scanned at site.

Table-3 Probe Details:

Make Diameter Frequency Wave Type Technique

Phoenix 5MHz
10mm Longitudinal Wave TOFD
Phoenix 10MHz

Table -4 Wedge Details:

Make Wedge Angle Type of Wave in Wedge

Phoenix 60˚ 60˚ Compressional wave
70˚ 70˚ Compressional wave

Table-5: Comparison of AUT and RT

SL. AUT (TOFD) RT

No
1 Qualification demonstration on a Established techniques are used and
representative mock up with at least 3 straightforward. Every time no
representative fabrication flaws including qualification/demonstration is required.
planer flaws.

2 High probability of detection based on 2 % of job thickness is sensitivity for RT and

more precise engineering evaluation workmanship/characterization basis

3 AUT planar –through wall thickness A poor technique to detect surface cracks and other
detection is easy planar defects in welds(Crack/LOP/LOF)

4 No radiation hazards and it can Safety hazards and dark room facility set up
performed at any time without any
protection measures

5 Interpretation & final evaluation by NDT Minimum NDT level-II

LEVEL-III
 NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . . 7

Repair rate:
Total weld Length scanned: 4548 meter
Repair rejected length : 1.44 meter
% of Repair : 1.0

2.5 Interpretation and evaluation:

2.5.1 Measuring Flaw length:
Flaw lengths parallel to the surface can be measured from the TOFD Image by fitting hyperbolic
cursors to the ends of the flaws.
Figure-9:

2.5.2 Measuring Flaw Depth:

Flaw height perpendicular to the surface can be measured from the TOFD Image by fitting
cursors on the top and bottom tip signals.

Figure-10:
8 NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . .

Figure-11:

Figure-12

Figure-13
 NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . . 9

Figure-14

Figure-15

Figure-16
10 NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . .

Figure-17:

Figure -18

Table-6 Acceptance Criteria :

 NDE2019, 028, v1: ’CP-136: API-650 Code Annex-U Requirements for Ultrasonic Exami . . . 11

2.5.3 Legends: TOFD (Time of Flight Diffraction), AUT (Automated Ultrasonic Testing), Higher
Probability of Detection (POD), Non-destructive Examination (NDE), Radiography Testing (RT),
NDT- Non-destructive Testing

3.0 Conclusion:
 TOFD shows Higher Probability of Detection (POD) and faster result compared to RT
Technique.
 No radiation hazard and we can work parallel construction work as well as NDE- AUT works.

4.0 Reference

 ASME SEC-V Article -4 Non Destructive Examination.

 API-620 Appendix-U : Ultrasonic examination in lieu of Radiography
 Client specification
 Olympus OMNI MX2 training course materials