ACUREN Group Inc.
Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
TABLE OF CONTENTS 1.0
SCOPE
3
2.0
STANDARDS AND SPECIF ICATIONS
3
3.0
QUALIFICATIONS OF PERSONNEL
3
4.0
SAFETY
3
5.0
DEFINITIONS AND TERMINOLOGY
4
6.0
EQUIPMENT AND APPARATUS
4
6.1 Equipment Requirements
4
6.2 Cleanliness and Handling
5
6.3 Inspection Materials
5
6.4 Operational Requirements
5
7.0
TECHNICAL HAZARDS
5
8.0
GENERAL PROCEDURE
7
8.1
Surface Preparation
7
8.2
Identification of Examination areas
8
8.3
Examination Coverage
9
8.4
Examination Process
10
8.5
Interpretation and Evaluation
11
8.6
Defect Sizing
12
8.7
Marking
13
9.0
ACCEPTANCE CRITERIA
14
10.0
POST CLEANING
14
11.0
REPORTS AND RECORDS
14
12.0
NONCOMPLIANCE
15
Revision Date:
October 10, 2007
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ACUREN Group Inc.
Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
1.0
2.0
SCOPE
1.1
This procedure outlines the requirements of an Ultrasonic Thickness Measurement Survey.
1.2
This procedure also indicates a numbering convention to be followed during surveys and sets a reporting standard for the final report.
STANDARDS AND SPECIFICATIONS
2.1
This procedure is in conjunction with the following codes: a) ASME Section V Article 4 and 5 b) ASTM Standard E317.
3.0
4.0
QUALIFICATIONS OF PERSONNEL
3.1
Techniques and procedure for UT corrosion surveys are to be carried out by technicians with a minimum certification of CGSB or SNT Level I.
3.2
A minimum certification to CGSB and SNT Level II shall carry out all final interpretation.
SAFETY
4.1
All personnel must follow the Acuren safety policies as outlined in Acuren’s Safety Manual.
4.2
All personnel utilizing this procedure must have WHMIS training.
4.3
Take precautions when reaching over “Steam Tracer” lines. Wrist protectors are required.
4.4
Some areas where measurements are to be taken may be in high heat zones. Personnel must take extra precautions when entering these areas.
4.5
Equipment must have secure hand and waist straps to ensure units are not dropped. Extreme care is to be taken when handling calibration step blocks, couplant and probes to ensure they are not dropped.
4.6
Disposal or cleanup of waste examination materials shall conform to Federal, Provincial and Municipal Environmental Regulations and Company policy.
4.7
Follow all manufacturer instructions and precautionary statements.
4.8
Workplace hazard assessments must identify and/or mitigate the potential hazards prior to commencing work.
Revision Date:
October 10, 2007
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ACUREN Group Inc.
Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
5.0
DEFINITIONS & TERMINOLOGY
a) ASTM – American Society of Testing Materials. b) ASME – American Society of Mechanical Engineers. c) CGSB – Canadian General Standards Board. d) FSH – Full Screen Height. e) MHz – Megahertz. f)
NDE – No n-destructive Examination.
g) SNT- Society of Non-destructive Testing. h) Contact Method – refers to contact of the transducer with the part.
6.0
i)
Straight Beam – where the angle of pulse from the transducer is zero degrees. Mode of propagation is longitudinal wave.
j)
Search Unit – transducer or probe.
EQUIPMENT AND APPARATUS
6.1
Equipment Requirements a) UT Set •
Datalogger capable of A-Scan representation.
−
Panametrics 36DL+, 37DL+ or equivalent.
b) Probes (Transducers) •
Panametrics D790 and D798 or other suitable probes.
c) Calibration Blocks •
•
•
0.100” to 0.500” Stainless steel and carbon steel with traceable certification. 0.600” to 1.00” Stainless steel and carbon steel with traceable certification. Metric calibration blocks may also be used at the client’s request.
d) Couplant •
Use the appropriate co uplant for the range of temperature.
e) Supplies •
tape measures – flexible, heat resistant
•
‘Pyromarkers’
•
Squeeze bottles for couplant application.
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October 10, 2007
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Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
•
Scrapers.
•
Wire brushes.
•
Clipboards and office supplies.
f) PPE
6.2
•
Fire-retardant coveralls.
•
Heavy clothing for winter work.
•
Suitable hearing protection.
•
Safety glasses.
•
Full Face shield when buffing .
•
Hard Hat, Steel-toed boots, leather gloves.
•
Wrist protectors.
Calibration a) Typical for 36DL+ and 37DL+ or equivalent. b) Determine the pipe nominal thickness and material, then calibrate on a range of thickness values appropriate to the nominal pipe thickness. A minimum of two points is required for calibrations. One at the upper limit and one at the lower limit. c) The search unit shall be calibrated at a similar temperature as the pipe to be inspected. This shall be accomplished by placing the calibration block on the part and allowing the calibration block to achieve the same temperature as the test piece. Calibrations will be carried out using a small amount of the same couplant that is to be used during the procedure.
NOTE
Failure to comply with temperature difference during calibration will result in measurement errors due to the velocity changes that occur at different temperatures. d) Wipe the probe end clean and press [Zero ] often to compensate for temperature drift. e) Check the calibration frequently (see tips for improving transducer longevity).
Revision Date:
October 10, 2007
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ACUREN Group Inc.
Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
7.0
TECHNICAL HAZARDS
7.1
It is critical to know the material grade and type prior to performing ultrasonic examination. Velocities and acoustic attenuation change with types of materials and calibrations must be done on the same material standards as those being examined. Accuracy is dependent upon actual dimensional measurements to standards.
7.2
Special attention must be given on curved or contoured surfaces to ensure consistent ultrasonic beam entry angle and adequate coupling.
7.3
Search units must be periodically checked for characteristics as per ASTM E164 or the referencing code section. These include beam spread, index points, angle verification, near field and far field resolution.
7.4
Any damage to the ultrasonic instrument requires re-calibration.
7.5
Steps To Ensure Transducer Longevity a) UT Set •
Always keep the download and recharging port clean and protected, either by keeping the cap in place when unit is being used or, if cap becomes lost/damaged, by using electrician’s tape to protect the port.
b) High Temperature Applications •
Ensure the surface temperature of the test piece does not exceed the maximum specified temperature for the transducer.
•
Use couplant rated for the temperature of the test material.
•
Limit transducer contact time to 5 seconds.
•
Never let transducer get too hot to hold.
•
If transducer gets hot:
•
•
•
−
Allow transducer to air cool or,
−
Dip transducer in water to cool.
Re-zero transducer frequently with the tip dry to compensate for temperature drift. Avoid dragging transducer cable across hot pipe and/or place a protective sleeve on the cable. Armored cables are also available and should be used if possible. High temperature dual transducers have delay lines made of thermally tolerant materials, but with continuous exposure to high temperatures, the inside of the probe will heat to a point where the bonds will fail, destroying the transducer.
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October 10, 2007
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Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
c) Surface Conditions •
•
•
•
•
Develop a technique of applying a transducer with the least possible pressure. When scanning an area, do so with the lightest pressure possible. Clean any loose debris (flaking paint, rust, scale, and dirt) from the specimen with a wire brush or file. When dealing with a rough surface, an effort should be made to smooth the surface roughness. On some rough surfaces, the use of gel or grease rather than a liquid couplant will help transmit sound energy into the test piece.
NOTE
If a surface is rough and it is difficult to obtain a reading, it is unlikely that grinding the transducer into the surface will improve the situation. When the transducer surface becomes worn, the efficiency of the transducer will diminish due to the fact that thick couplant layers may build up between the delay elements of the transducer and the surface. Alternatively, the gage may have difficulty in performing “do zero”. If these conditions develop, resurfacing of the transducer face may be necessary. d) Transducer Positioning/Alignment •
•
8.0
On small diameter cylindrical surfaces, such as pipes, hold the transducer so that the crystal division bar visible on the probe face is aligned perpendicular to the centre axis of the pipe. When scanning an area, data should be taken at increments no greater than half the diameter of the transducer to insure that nothing is missed.
GENERAL PROCEDURE
8.1
Supervisor Responsibilities a) Supplying the required number of technicians, the data clerk and the lead technician. b) Understanding the job scope and any previously identified trouble areas or trends before commencing the survey. c) Keeping the lines of communication with the Project Supervisor during the duration of the survey.
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October 10, 2007
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Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
8.2
Client Requirements a) The following are tasks to be completed by client representati ves prior to Acuren Personnel arriving on site. •
Supply isometric drawings for every line to be surveyed.
•
Identify the line contents and hazard (s) level(s) of each line.
•
Identify the survey locations on the isometric drawings.
•
Label the direction of flow on every isometric drawing.
•
Provide the operating temperature for every line to be surveyed.
•
•
•
8.3
Identify any non-standard material types on isometric drawings (i.e. Hastalloy). Co-ordinate the scaffolding and insulation removal. Establish a liaison between the Lead Technician and the Scaffolding and Insulator Foremen to enable smooth and efficient co-ordination during inspection.
Personnel a) The number of Acuren personnel will be based upon the survey scope and duration. b) The duties of the data clerk shall inc lude but are not limited to: •
Input data as it comes in from the field.
•
Update or create new drawings as required.
•
Ensure final report is in proper format at job completion
c) Lead Technician (either CGSB UT Level II or experienced CGSB UT Level I) shall be responsible for the following: •
•
•
•
•
Ensuring the project runs smoothly including job set-up, equipment maintenance and supplies. Obtaining the line contents and hazard(s) level(s) for each line. Review previous surveys when accessible and familiarize self to job scope and trends. Act as liaison with Client Area Inspector(s) and provide daily updates of progress. Ensure that the organization system records survey completions, rework requirements and their progress and that the system is kept current.
•
Review all downloaded readings.
•
Have all questionable readings re-checked and verified.
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October 10, 2007
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Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
•
•
Perform a random audit on 10% of thickness readings for each technician. Report thickness readings taken during audit in the final report to the client.
•
Sign off completed survey locations.
•
Review a ll correspondence with Client Area Inspector(s).
•
Perform ultrasonic thickness testing in field.
•
Organize daily toolbox meetings.
•
Ensure all equipment is calibrated.
d) UT Technicians (minimum requirement CGSB UT Level I): •
Set up the UT data logger and numbering convention as outlined in later sections.
•
Perform ultrasonic thickness testing in field.
•
Ensure readings are accurate to minimize re-checks.
•
Perform re -checks of other technicians when requested by Lead Technician.
•
Aid in creating, uploading and downloading of data.
•
Participate in all facets regarding safety program meetings.
e) Supervisor:
8.4
•
Peer review of final report document before issuing to the Client.
•
Ensure duties of above personnel are carried out.
•
Act as a resource for any problems that occur.
Preparation a) Review all Isometric drawings for flow direction and clear identification of locations to be surveyed. b) The Lead Technician shall discuss the following with the client representative: •
Work Permit procedure.
•
Number of locations.
•
Criteria for what is considered an area of concern.
•
Schedule for completion of work and priorities.
•
When they would like final reports: i.e. as they are completed or at the end of the job.
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October 10, 2007
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ACUREN Group Inc.
Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
•
8.5
At what intervals they would like to receive progress reports.
Data Acquisition a) Set up the UT set and data numbering convention as explained in this technique or as requested by the client. b) Make a drawing of the area ensuring that both the direction of flow and the numbering convention are identified. c) Using a data logger perform the initial thickness measurement survey. d) Review the data on the instrument prior to leaving the location to ensure that no data points have been missed. If the data appears to be incomplete, perform additional data logging for any remaining survey locations. e) Automated methods of obtaining thickness information (i.e. UT B-Scan and C-scan) may be employed when requested by the client.
8.6
Data Review and Reporting a) The Lead technician shall review the data for any low areas or erroneous data and identify any areas that need to be re-logged or confirmed.
NOTE
The data must be reviewed within two days of the initial survey or as required by the client . b) If any areas are to be rechecked the lead technician will assign a different technician than the one who performed the initial survey to remeasure the areas of concern. NOTE
This must be done within 3 days of the initial survey or as required by the client. c) If the review did not reveal any low areas the field report will be prepared for each survey site location. d) A field copy of the survey report shall be printed given to the client area representative. NOTE
The final report shall be completed as soon as possible, and it must be within 5 days of the initial survey or as required by the client . e) All applicable updates and new drawings to the corrosion surveys shall be carried out by Acuren Group Inc. Revision Date:
October 10, 2007
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Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
8.7
Data Logging a) Setting up a Matrix •
Looking in the direction of flow, the grids start at the upstream side of the initial circumferential weld and progress alphabetically as the bands move downstream.
b) Location of Measurement Bands •
•
•
•
•
The second axis for the matrix shall make up the numeric portion of the alphanumeric grid and is also referenced to the direction of flow. Each grid is made up of a series of readings in the center of each 2.54 cm (1”) square on the outside of the pipe. The grid placement may be determined by the client (i.e. top of the pipe, bottom of the pipe outside of the elbow, inside of the elbow, etc.). When Acuren is determining the grid locations they shall be:
−
for pipe – start on top at zero
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for elbows – outside of bend
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for tees – center of straight side
The client may employ a method of permanently marking the pipe to ensure consistency, repeatability and accuracy of future thickness surveys. The method of permanently marking the pipe shall be the responsibility of the client. The direction of numbering is determined by the direction of flow. The grid squares shall be designated alphanumerically as follows:
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The grid squares shall be designated along the longitudinal axis numerically
−
The grid squares shall be designated circumferentially with letters of the alphabet.
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October 10, 2007
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Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
c)
The grid size s will be different for each size of pipe. •
For pipe ranging in size from 2.54 cm (1”) to 35.56 cm (14”) shall be 2.54 x 2.54 cm (1”x 1”) squares. The grid shall start 2.54 cm (1”) after the closest upstream weld (see fig.1) and continue for a longitudinal distance designated by the client.
Figure 1
•
For pipe ranging from 40.64 cm (16”) to 76.2 cm (30”), a 5.08 cm by 5.08 cm (2” x 2”) square grid shall used. The grid shall start 2.54 cm (1”) after the closest upstream weld (see fig. 2) and continue for a longitudinal distance designated by the client.
Figure 2
•
For piping ranging from 86.36 cm (34”) to 132.08 cm (52”), a 7.62 by 7.62 cm (3” x 3”) square grid shall used. The grid shall start 2.54 cm (1”) after the closest upstream weld (see fig. 3) and continue for a longitudinal distance designated by the client.
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October 10, 2007
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Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
Figure 3 d) Set up a table with the numerical grid designation as column headings and the alpha designation as row headings. For Example, an NPS 4 standard wall pipe would have a 1 x 12 grid for a total of 12 thickness readings and the grid would be as shown table 2. 1
2
3
4
5
6
7
8
9
10
11
12
A
Table 2 NOTE
It is important to maintain the above convention for naming both columns and rows even if a portion of the grid is not accessible. For example, if there was no access to Column 3 of Table 2, all other areas would be inspected and no data would be entered in Column 3. Make note in the report the reason for no data in that location (i.e. A – nozzle, B – restricted access, etc.). 8.8
Data Logger ID and Excel File Naming Conventions a) It is important to follow a logical convention in naming the data logger files. The name should contain information regarding the plant name, isometric drawing, and inspection point. b) The Panametrics matrix maker allows the first 8 characters for naming the file, using numbers and letters. c) Following the ID Name, is a delimiter, then the first column, another delimiter, followed by the first row. d) Name the file with the plant number, the isometric drawing number, followed by weld number designated by the client or from existing ISO drawings.
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ACUREN Group Inc.
Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
e) Example: In the isometric sketch shown in Figure 4, 15-2 FB-003, 13-1 is the plant number, and FB-003 is the Drawing ID number. f)
If we surveyed the “T” location the closest upstream weld is “01”, the data logger file should be 131FB3-01.
g) If for some reason 8 characters are not sufficient to follow this convention, ensure that the data entry clerk is informed right away so that the file can be renamed after downloading to conform to the proper naming convention.
Figure 4 8.9
Care of Equipment a) In order to ensure accurate thickness measurements and reliable inspection results, equipment must be properly maintained. b) Keep the unit clean and protect from the environment. c) Follow the manufacturer’s manual for routine care and maintenance. d) Equipment to be red tagged if unit is not operating properly and returned to the Acuren Repair Facility in Edmonton.
9.0
ACCEPTANCE CRITERIA
9.1 10.0
The client shall determine the acceptance criteria.
POST CLEANING
10.1 If necessary final cleaning shall be accomplished with an approved manufacturer’s cleaner or a cleaner approved by the referencing code section or customer specification.
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October 10, 2007
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Technical Procedure No. UT-0030 GENERAL THICKNESS MEASUREMENT SURVEYS
11.0
REPORTS AND RECORDS
11.1 The report of results for each location surveyed shall include but not limited to the following information: a) Plant number. b) Isometric drawing number. c) Location identifier. d) Component name (i.e. elbow, tee, reducer, etc.) e) Diameter of component surveyed. f)
Nominal wall thickness.
g) Material. h) Pipe temperature at time of examination. i) j)
Operator name and certification number. Survey date.
k) Data logger serial number. l)
Calibration due date.
m) Transducer type and serial number, and length of cables. n) Calibration block material, size and reference serial number. o) Sketch of the component with direction of flow and location of thickness grid. p) The minimum reading and grid location. q)
The maximum reading and grid location.
r) The survey data. 12.0
NONCOMPLIANCE
12.1
All items of non-compliance will be dealt with according to the Acuren Quality Management System, and a report shall be generated on nonconformance items to address any problems that may occur.
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October 10, 2007
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