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Stork Cooperheat

PHASED ARRAY ULTRASONIC PROCEDURE DUPLEX STAINLESS STEEL BUTTWELDED ASME B31.3 PROCESS FIREMAIN PIPING FOR THE PETROFAC EL MERK ALGERIA PROJECT Client

PETROFAC

NDT Contractor

Stork Cooperheat

Project

EL Merk Central Processing Facility

Location

EL Merk- Algeria

Cooperheat Job No

14-004387

Cooperheat Procedure No

14-004387-PA-UT_DUPSS_PETROFAC_ALGERIA

reviewed by: DCM

sign:

authorized authoriz ed by: SC

sign:

14-004387-PA-UT_DUPSS_PETROFAC_ALGERIA Revision 02, issued: 20-02-2015 , page 2 of 31

Stork Cooperheat

PHASED ARRAY ULTRASONIC PROCEDURE DUPLEX STAINLESS STEEL BUTTWELDED ASME B31.3 PROCESS FIREMAIN PIPING FOR THE PETROFAC EL MERK ALGERIA PROJECT Client

PETROFAC

NDT Contractor

Stork Cooperheat

Project

EL Merk Central Processing Facility

Location

EL Merk- Algeria

Cooperheat Job No

14-004387

Cooperheat Procedure No

14-004387-PA-UT_DUPSS_PETROFAC_ALGERIA

reviewed by: DCM

sign:

authorized authoriz ed by: SC

sign:


Stork Cooperheat

REVISION NUMBER

DATE

SUMMARY

1

20-02-2015

SCAN PLANS, AREA OF INTEREST, CALIBRATION/ VALIDATION BLOCK DRAWINGS, DRAWINGS, AREA OF INTEREST SCAN RANGE, DATUM CONVENTION


Stork Cooperheat CONTENTS DESCRIPTION

PAGE

COVER PAGE

1

REVISION

2

CONTENTS

3

SECTION 1.0

INTRODUCTION

4

2.0

PURPOSE AND SCOPE

4

3.0

REFERENCES AND DEFINITIONS

5

4.0

PERSONNEL QUALIFICATION

6

5.0

PREPARATION OF EXAMINATION AREA

6

6.0

EQUIPMENT

7

7.0

CALIBRATION

11

8.0

EXAMINATION AND RECORDING CRITERIA

17

9.0

ACCEPTANCE CRITERIA

21

10.0

DATA STORAGE

21

11.0

REPORTING

22

12.0

SCAN PLANS

23

ATTACHMENTS APPENDIX 1: PHASED ARRAY TECHNIQUE SHEET APPENDIX 2: AUT REPORT FORMAT APPENDIX 3: DATA ASSESSMENT SHEET APPENDIX 4: WELD GEOMETRY DETAILS


Stork Cooperheat 1.0

INTRODUCTION This procedure defines the requirements of semi-automated and manually encoded Phased Array ultrasonic examination of Duplex Stainless Steel Fire main Process Pressure Piping Butt welded seam welds for El Merk Central Processing Facility located in the People’s Democratic Republic of Algeria. This Phased Array procedure shall be qualified for use on Duplex Stainless Steel (*ASTM A790 UNS S31803 & PIPE EFW - DUPLEX SS ASTM A928 UNS S31803 CL1) 2” (50mm) through to 16” (400mm) Firemain Line Piping between the thicknesses of 2.77mm to 4.78mm thickness. *For the purposes of this procedure the various DSS material grades are to be treated as acoustically equal. The Phased Array scanning associated with this procedure is intended to be used with Skews 0 and 180 degree probes to complete each circumferential weld intended for inspection concerning pipe fittings only. Scan coverage is to include 100% of the buttwelded associated region from the edge of bevel prep either side of the weld up to 20mm into the parent material. This area shall be deemed the area of interest for the detection of in-service discontinuities. Any reference to the term weld shall be for reference purposes only. As noted above the area of interest is the HAZ and Parent material as defined and further referenced in this procedure. Where elbows and fittings are present scanning shall be performed to one side pipe section of the configuration.

2.0

PURPOSE AND SCOPE The scope of inspection is to determine, identify and sentence pitting indications as described in introduction using the latest revision of ASME B31.3 Chapter VI Process Piping as a guideline only. Sentencing of flaws shall be performed as per clients specific requirements (refer section 9). This procedure defines the requirements of semi-automated and manually encoded Phased Array contact ultrasonic examination of welds. This procedure shall be specific to the Duplex Stainless Steel material grade ultrasonic inspection of HAZ and Parent Material using the Phased Array techniques and equipment. These aspects include; • • • • • • •

monitoring the performance of the equipment configuring the display and data acquisition parameters calibration of time base and sensitivity description of the recording criteria identification and layout of the components to be tested surface conditions required details of the equipment used and the volumes covered

Details of the scanning shall be found in the associated technique sheets. This procedure is applicable to semi automated and manually encoded ultrasonic examination of in-service “welded” (HAZ and Parent Material) components. Provisions are incorporated into this procedure and the special adaptations unique to their implementation are described in this procedure and the associated standard practices referenced by this procedure. Since the qualification of this procedure and associated standard practices and techniques is unique to the TD Handy Scan instrument, this procedure is not valid with any other instrument.


Stork Cooperheat This procedure is valid for only those techniques that are identified and are recorded in the latest revision of this procedure. This procedure intends to cover the Phased Array scanning performed from the external Firemain pipe surface with PAUT scanning coverage from both sides of the weld. The following PAUT Firemain piping buttweld list is intended to be the minimum requirements to be completed. Below list is not exhaustive and may be adjusted to suit site conditions and inspection findings;

Summary for Joints for PAUT S No

Diameter of pipe

1 2 3 4 5 6 7 8 9

Dia 2''NB Dia 3''NB Dia 4''NB Dia 6''NB

Duplex Duplex Duplex Duplex

Material Specification

Material thickness

No of Joints

stainless steel Grade S31803 stainless steel Grade S31803 stainless steel Grade S31803 stainless steel Grade S31803

2.77MM 3.05MM 3.05MM 3.76MM

16 43 69 96

Dia 8''NB

Duplex stainless steel Grade S31803

3.05MM

42

Dia 10''NB Dia 12''NB Dia 14''NB

Duplex stainless steel Grade S31803 Duplex stainless steel Grade S31803 Duplex stainless steel Grade S31803

4.19MM 4.57MM 4.78MM

23 327 89

Dia 16''NB

Duplex stainless steel Grade S31803

4.78MM

67

Total Joints

772 No’s

3.0

REFERENCES AND DEFINITIONS

3.1

The following documents shall be referenced with this procedure: GSOP5003, Written Practice for Training, Qualification and Certification of NDT Personnel to ASNT SNT-TC-1A GSOP5004, Procedure for Training, Qualification and Certification of NDT Personnel to CP189 EN 473, Qualification and Certification of NDT Personnel EN ISO 22825:2006: Ultrasonic Testing of welds in austenitic st eels and nickel-based alloys ASNT SNT-TC-1A, Recommended Practice for Training, Qualification and Certification of NDT Personnel ASNT CP-189, ASNT Standard for Training, Qualification and Certification of NDT Personnel ASME Section V ART IV, UT Examination of Welds. ASME B31.3, Chapter VI 2010 Pressure Piping

3.2

Definitions and Abbreviations Client ASTM ASME BS / EN ToFD PAUT PE

PETROFAC American Society for Testing Materials American Society of Mechanical Engineers British Standards / European Norms Time of Flight Diffraction Phased Array Ultrasonic Inspection Pulse Echo Ultrasonic Conventional


Stork Cooperheat

A-SCAN - An ultrasonic waveform plotted as amplitude with respect to distance. It may be rectified or unrectified. B-SCAN - A two dimensional ultrasonic waveform plotted as reflector depth or distance with respect to beam position, also known as side view. CALIBRATION - A procedure that standardizes responses. ELEMENT - One of the individual parts of which a composite entity is made up. DEAD ELEMENT - One of the individual parts of which a composite entity is made up that is no longer operational. FOCAL LAW - The programmed pattern of time delays applied to pulsing and receiving from individual elements of an array transducer in order to steer and/or focus the resulting sound beam and responses. Defined as the phased array set-up file controlling the search element time delays, and all parameters making up their specific ultrasonic fi le. PHASED ARRAY - An ultrasonic technique utilizing multi element probes. TIME CORRECTED GAIN (TCG) – An electronically generated correction for depth in relation to amplitude used to equalize responses from a know size reflector at different depths. SECTORAL SCAN - A phased array scan configuration using a range of angles that are focused and steered. LINEAR SCAN - A single angle scan configuration producing a single angle from multiple elements

4.0

PERSONNEL QUALIFICATION

4.1

Personnel shall be qualified in accordance with Cooperheat Written Practice as referenced in item 3.0 above.

4.2

All personnel involved in the interpretation and analysis of Phased Array scans shall be certified to a minimum of Level 2 in ultrasonic weld inspection as well as level II in specific Phased array in accordance with ASNT-SNT-TC1A and/or ISO 9712 or EN473.

4.3

Level 3 is responsible for procedure development, validation exercises, preparation of technique sheets data and report review and is generally not site based.

5.1

Surface Preparation The scanning area shall be rendered free of dirt, loose scale, weld splatter, machining particles, or corrosion products. Where the surface cannot be made suitable for ultrasonic inspection by light brushing and wiping, the Client representative and Cooperheat shall be advised. The base material or weld shall be prepared as needed to permit examination.

5.2

Weld Marking and Inspection Area Location Numbers allocated to welds being examined shall designate inspection areas.


Stork Cooperheat Each weld designated for inspection shall be marked with a reference index and/or position numbers marked on the examination surface during initial examination. This shall include a method for identifying the location of the weld centreline. Permanent stamping should only be carried out when approved in writing by the client and should be carried out with low stress stamps with a depth less than 1.0mm. Datum convention as follows: • • •

Horizontal pipework - Zero datum at top dead centre , clockwise in direction of flow Vertical pipework - Zero datum at plant north , clockwise in direction of flow Pipe spools – Zero datum shall be as marked

The actual datum convention may vary based on site conditions and shall be subject to change by means of a written variation instruction from the client. Sketches and Drawings should be used to aid in uniquely identifying the welds marked up for inspection. Firemain Line Piping noted for Inspection to be supplied b y TPSA prior to site activities. 6.0

EQUIPMENT

6.1

Essential and Non-Essential variables

Requirement:

Essential / Non Essential:

Clause Number:

Essential

12.0 Scan Plans + Appendix 4

The surfaces from which the examination shall be performed

Essential

2.0 Purpose and scope

Technique (s) (straight beam, angle beam, contact and or immersion.

Essential

6.2.2 Search Units + *Appendix 1

Angle (s) and mode (s) of wave propogation in the material

Essential

6.2.2 Search Units

Search unit type(s), frequency (ies), and element size(s)/shape(s), pitch and gap dimensions

Essential

6.2.2 Search Units

Focal Range identifying plane, depth or sound path

Essential

12.0 Scan Plans

Virtual Aperture Size (number of elements, effective height, and element width.

Essential

6.2.2 Search Units

Wedge Angle

Essential

6.2.2 Search Units

Special search units, wedges, shoes, or saddles when used

Essential

6.2.2 Search Units

E-Scan: Range of elements used and element incremental change

Essential

12.0 Scan Plans

S- Scan: Angular range used and angle incremental change

Essential

12.0 Scan Plans

Weld configuration to be examined, including thickness dimensions and base material product form (Plate, Pipe, etc)


Stork Cooperheat Requirement:

Essential / Non Essential:

Clause Number: 6.2.1 Ultrasonic Test Instrument 6.2.4 Calibration Blocks

Ultrasonic instrument(s)

Essential

Calibration {calibration block(s) and Techniques(s)}

Essential

Directions and extent of scanning

Essential

12.0 Scan Plans

Scanning (manual vs automatic)

Essential

2.0 Purpose and scope

Method for discriminating geometric from flaw indications

Essential

8.2 Non Relevant Indications

Method for sizing indications

Essential

8.6 Sizing of Defects

Computer enhanced data acquisition, when used

Essential

Scan overlap

Essential

Personnel performance requirements, when required

6.2.1 Ultrasonic Test Instrument 8.4.2 Scanning normal to weld.

Non Essential

6.2.5 Validation Blocks

Surface condition (examination surface, calibration block)

Non Essential

5.1 Scanning Surface + 6.2.4 Calibration Blocks

Couplant : Brand name or type

Non Essential

6.2.3 Couplant

Automatic alarm and /or recording equipment, when applicable

Non Essential

NA

Records, including minimum calibration data to be recorded (eg: instrument settings).

Non Essential

10.0 Data Storage

* Technique sheets to be completed as per the requirements of each pipe dimensions nominated for inspection as per ASME requirements detailing phased array angles, focal range and depth, and sound path.

6.2

Examination Equipment

6.2.1

Ultrasonic Test Instruments This procedure shall use the 32/64 Element TD Handy Scan (Software Version 19.00 or higher) phased array/ ToFD ultrasonic inspection unit exclusively. The ultrasonic flaw detection instrument shall be used in the Phased Array (pulse echo) mode with an A-Scan presentation used for calibration. Unit display shall be capable of composite A- Scan, B- Scan, C- Scan, D- Scan, and S- Scan formats. The instrument is equipped with a stepped gain control calibrated in units of 1dB or less. The equipment is capable of amplitude control over its useful range and Time Corrected Gain (TCG) shall be used in lieu of a simple Distance Amplitude Correction (DAC) curve. The Phased Array/ ToFD equipment shall be capable of recording and saving all inspection data for offline analysis to be performed. The data is to include set-up parameters of the transducer(s), positional “offsets” and technique type and encoder output values.


Stork Cooperheat 6.2.2

Search Units Nominated Transducer Required

Probe ID

Frequency

10L32-A10/ SA10-N55S VPA= 9.92mm 10L32-A10/ SA10-0L VPA= 9.92mm 6.2.3

10Mhz

10Mhz

Element Dimensions 32 x 0.31mm (Active Aperture) x 10.00mm (Passive Aperture) (Linear Array) 32 x 0.31mm (Active Aperture) x 10.0mm (Passive Aperture) x (Linear Array)

Wedge Details 40º through 82º Shear Wave Sectorial Scan. (Thickness Based) Roof Angle= 36º 0º Compression Wave Linear Scan. (Thickness Based) Roof Angle= 0º

Couplant A suitable Couplant having good wetting characteristics shall be used between probe and examination surface. The Couplant shall not be detrimental to the material bei ng examined. Same type of couplant shall be used for calibration and examination.

6.2.4

Sensitivity and Range setting Calibration Blocks Weld inspections using the TD Handy Scan shall be calibrated using as appropriate Duplex Stainless Steel calibration blocks and which have been subjected to minimum heat treatment required by the material specification. The surface of calibration blocks is finished to approximately 10 micron Ra. At no time shall the calibration block surface be inferior to the test piece surface. Prior to fabrication, the block material shall be completely examined with a straight beam search unit. Areas that contain an indication exceeding the remaining back-wall reflection shall be excluded from the beam paths required to reach the various calibration reflectors.


Stork Cooperheat Calibration block for both Range and Sensitivity shall be f rom the 1 Block as detailed below. (A) Phased Array (Pulse Echo) Calibration Block

Table 1 Ultrasonic Reference Block Requirements

6.2.5 Validation Blocks The validation blocks shall be prepared as per the requirements specific to this procedure. Refer below for further details The following table notes the Validation Blocks to be fabricated: Note: Notches fabricated in below Validation blocks shall include Calibration notches to be used as initial setups. S No

Diameter of pipe

1 2 3 4

Dia 2''NB Dia 4''NB Dia 8''NB Dia 14''NB

Material Specification Duplex Duplex Duplex Duplex

Material thickness

stainless steel Grade S31803 stainless steel Grade S31803 stainless steel Grade S31803 stainless steel Grade S31803

2.77MM 3.05MM 3.76MM 4.38MM

Validation Block Drawings;


Stork Cooperheat


Stork Cooperheat Validation Block Details ��

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Validation/ Calibration Block Images; 14” x 4.3mm

8” x 3.6mm

4” x 4.0mm

2” x 2.77mm

7.0

CALIBRATION

7.1 7.1.1

Equipment Calibration Instrument Linearity Checks


Stork Cooperheat All instruments are subject to the following linearity checks before use. Details of the steps involved in the set-up of equipment for calibration can be found in the Standard Guide for Use of TD Handy Scan. The results of these checks are recorded in the Ultrasonic instrument Linearity Report forms (see standard practice for Verification of TD Handy Scan Linearity Performance) and are kept as part of the Inspection Record. Instrument Linearity Checks are conducted: a) on initial receipt of equipment b) at the commencement of an inspection campaign c) on a twelve month cycle d) after any electronic repair or physical damage e) or for any other reason deemed appropriate at intervals less than 12 months 7.1.2

Screen height Linearity The AGR Handyscan instrument shall provide vertical amplitude presentation linear to within +/-3% of full screen height over the range 10% to 100%. For an acceptable tolerance, the responses from the two reflectors shall bear a 2 to 1 relationship to within +/-3% of full screen height throughout the range 10% to 100% of full screen height. The results are recorded on the Ultrasonic Instrument Linearity Form.

7.1.3

Search Unit Checks Because the TD Handy Scan ultrasonic instrument is a phased array instrument many of the parameters associated with standard single element probes such as exit point and nominal angle do not apply. Standard Practice for Verification of Performance of Probes used with TD Handy Scan will be used as appropriate to assess the suitability of the probe and focal laws applied to phased array probes. Search unit Checks are conducted: a) on initial receipt of equipment b) at the commencement of an inspection campaign c) on a one month cycle d) after any electronic repair or physical damage e) or for any other reason deemed appropriate at intervals less than 1 month.

7.2

Sweep Calibration Range From each of the fabricated Duplex Stainless Steel blocks a Sweep calibration shall be performed using the following sequence • • •

• • • •

Reset the wedge delay to zero Enter the probe angle (35 degrees, lowest angle utilized) Measure the thickness of Calibration Block using either a vernier or a calibrated digital thickness meter. Couple the phased array probe/ wedge combination to the Notched calibration block Maximise the internal Notch (half skip) echo to 80% screen height Position curser 1 on the peak of this signal( figure 1) In curser 2 test box click and enter the beam path of the reflector block radius. ( figure

2) • •

Click the ‘SET P-DEL’ button. The new delay will be transferred to the wedge delay box ( figure 3)


Stork Cooperheat •

•

Confirm of the calibration to be performed by maximizing the external notch (full skip) to 80% and measuring the distance, the measurement should fall within 2% of the actual distance. Close the screen, wedge delay and calibration is now set.

Figure 1

Figure 2


Stork Cooperheat

Figure 3 7.3

Calibration TCG Sensitivity 7.3.1: The Following Diagram and Table notes the TCG Notches to be used to perform the Sensitivity calibration. Each point to use the minimum angle (for this procedure 55°) across the sectorial beam spread with the signal at each point maximized at 80% Full screen Height. One x Notch, to be used to complete TCG points as detailed below. Calibration Points Point 1 Notch

Notch Skip Distance Thickness Thickness (Half Skip)

Initial Sensitiviy Setting as per ASME

Final Setting on :Leaking Site Weld Multiple Peaks from Pipe Pinhole sample weld.

Point 1 (Half Skip) Note: Scanning was performed to pin holed site weld with sensitivities adjusted to suit detection of actual sample piece for final sensitivities used.

7.3.2: The TCG Points shall be performed from the minimum beam distance full thickness (Half Skip) Notch.


Stork Cooperheat 7.3.5 The fundamental criterion for the evaluation of the existence of an ultrasonic examination indication is the amplitude of the indication in relation to a specified reference level. The reference level is established during calibration of the test instrument on the sensitivity calibration block and set so that the amplitude from the applicable holes are set to 80% full screen height using TCG. Notch conforming to ASME shall then be scanned to ensure compliance. 7.4

Calibration Confirmation 7.4.1 A system calibration confirmation shall be used to verify the sweep range calibration and TCG curve at the start and finish of each examination and at a minimum of once each day during an examination session using t he appropriate calibration block 7.4.2 Any change in search units, couplant, cables, ultrasonic instruments, personnel or other parts of the examination system is cause for a calibration check. 7.4.3 If either point along the time base using the TCG has decreased by greater than 2 dB in amplitude, all recorded data sheets since the last calibration check are marked void. A new calibration is made and recorded and the voided examination areas reexamined. a) If any point along the time base using the TCG has increased by greater than 2 dB in amplitude, only recorded indications taken since the last valid calibration check need be re-examined with the correct calibration and their values changed on the data sheets or files rescanned. b) If during system confirmation of calibration, any point on the time base has moved on the sweep line more than 5% of the total base line, correct the sweep range calibration. If recordable reflectors are noted on the data sheets, these data sheets are voided, a new calibration is recorded and the voided examination is repeated.

The TD HandyScan is calibrated for each examination specified on a detailed technique sheet for both range and signal amplitude.

7.5

Temperature Control For contact examination, the temperature differential between the calibration block and the examination surface shall be within +/-10C°.

7.6

Encoding Semi- Automated scanning shall use position encoders that are verified to provide position accuracy of scans within +/-5mm (1%) in 500mm of scan length. All encoders shall be verified daily to be correctly calibrated. Moving the scanning apparatus over a fixed distance (e.g. 500mm Minimum) and comparing the start and end readings is sufficient to verify the calibration of the encoder. All encoded distances recorded by the data acquisition system shall be accurate to within 5mm over 500mm of actual travel. Encoders failing to maintain this tolerance shall be re-calibrated. All semi-automated scanning shall be position encoded at sampling intervals of 1mm.

8.0 EXAMINATION AND RECORDING CRITERIA



Inspection Area Each inspection area is identified with a unique "weld" number. The width of the inspection area extends beyond the point of maximum width of the final Firemain weld preparation for a minimum distance of 50mm which comprises the main arear of inspection interest. The range gating of the PAUT data collection shall be 3 x shear wave skip distances. This distance shall ensure complete coverage of the heat affected zones and up to 20.00mm of parent metal either side of weld. The weld zone, HAZ and Parent material which is defined as the weld and the base metal up to 20 mm (Heat Affected Zone - HAZ), from the edge of the final weld preparation, as illustrated in Figure 1 is defined as the area of Inspection Interest. The base material on either side of the inspection area of Firemain pipe welds need not be examined for laminations that would interfere with shear wave examination if these materials have been inspected for laminar inclusions at some previous stage in fabrication. .

Figure 1

Weld Profile Showing Inspection Area (Light Red) and associated Weld Zone

Datum Convention Datum points shall be performed prior to commencement of data collection and marked on the work surface to ensure accuracy and repeatability. The datum convention as per Fig. 1shall be followed.

Direction of Flow

Fig 1 Datum Convention The datum for scans on horizontal pipe sections shall be Top Dead Centre.


Stork Cooperheat The datum for vertical pipe sections shall be at North. Where circumferential and/or longitudinal pipe welds are visible these shall be recorded and included in the datum reference information.

8.2

Non-Relevant Indications Signals which are determined to result from welding discontinuities, metallurgical discontinuities and / or geometrical conditions (such as weld root geometry, or weld to base metal interface) are classified as geometric reflectors .Such reflectors are not characterised as indications nor compared with the allowable indications criteria. The presence of geometric reflectors is confirmed either by reviewing the fabrication drawings of the weld preparation, the previous inspection records or by supplemental inspection. Every root indication shall be carefully examined to ensure it is not masking a relevant indication such as Pitting indications. The position of the reflector shall be carefully examined, indications on the probe side of the root centreline shall be deemed defect indications and characterised as such, defects on the far side of the root centreline shall be assumed to be geometric in nature and further confirmed by the probe on the other side of the weld centreline. All scan types can be used to assist in interpretation and shall include, TOP (C), Side (B), (A) and (S) scan displays. Every “root”, “HAZ” and “PM” indication shall be carefully examined to determine its nature (Welding, Pitting or Geometrical indication).

8.3

Recording a) General TD Handy Scan Phased Array ultrasonic instrument is a digital instrument. Analogue to Digital Conversion will be at a rate suitable to ensure that the recorded peak signal is within 1dB of the analogue peak. This shall be considered achieved when the digitisation rate is set to at least 5 times the nominal frequency of the probe used. Actual digitisation settings shall be specified in the Technique. b) Sequence of Examination Reporting The Site Examination Record is a record prepared by the ultrasonic technician containing the data pertaining to an examination of a particular weld. This is the raw data collected in the TD-Scan software. The Ultrasonic Inspection Data Record Sheet is the official source of ultrasonic records on which observed reflectors are plotted, and all inspection results are permanently recorded. This form will include weld number, technique number, project information, minimum thickness noted and the status of the inspection (accept/reject) with pertinent indications noted if repairs are required. . The site examination record data file shall be kept on file with the Ultrasonic Inspection Data Record Sheet.


Stork Cooperheat

8.4

Detailed Examination and Recording Sequence

8.4.1

Thickness Measurements Thickness Measurements - Weld Inspection At the examination site, the ultrasonic operator takes an initial thickness measurement. The thickness is compared to the thickness indicated on the detailed technique to confirm that the technique and related range settings are applicable. This thickness assessment may be made using a separate zero degree probe with TD Handy Scan unit or as part of any required scan results from a 0°scan.

8.4.2

Scanning Normal to the Weld (Axial Scan) The probe is directed at 90° to the weld centre line and mechanically moved so that the ultrasonic beam passes through all of the inspection area. This is accomplished by an electronic raster or Shear S-scan. This shall be considered the Initial scan of the HAZ and Parent Material Where possible, the weld is scanned from both sides of the same surface. The speed of scanning is such as to ensure that coupling and data acquisition integrity is maintained. Data recorded will ensure encoded samples along the weld are at 1mm intervals and not greater than 5% of data points shall be missed in a weld scan with not more than 3 adjacent samples missing in a single scan, with minimum scan overlap between adjacent scans to be 25mm.

Typical Scan Coverage per Nominated weld earmarked for Inspection.

Coverage 100% circumferenti ally around pipe at HAZ + Parent Material adjacent Weld prep 20mm Width Scan, Coverage 100% circumferentially around pipe

Scan 2

Scan 1

Coverage 100% circumferent ially around pipe at HAZ + Parent Material adjacent Weld prep

Scan 3

20mm Width Scan, Coverage 100% circumferentially around pipe


Stork Cooperheat

8.4.3

Scanning Adjacent to the Weld (Compression Wave Scan adjacent Weld) The probe is situated directly adjacent the buttwelded seam with the PAUT beam covering the area directly adjacent the weld cap edge for 20mm, either side of the weld bevel preparation. This is accomplished by a compression wave Linear-scan. This shall be considered the second scan (comprising of two Linear scans to cover the intended 20mm area either side) of the HAZ and Parent Material. Where possible, the area of interest is scanned from both sides of the same surface. The scanning shall be performed with 2 x offsets per weld Skew at 0mm from weld edge and 10mm from weld edge, circumferentially around pipe. For the 10mm offset scan a guide edge shall be used to ensure correct offset distance. All scanning shall be performed manually encoded. The speed of scanning is such as to ensure that coupling and data acquisition integrity is maintained. Data recorded will ensure encoded samples along the weld are at 1mm intervals and not greater than 5% of data points shall be missed in a weld scan with not more than 3 adjacent samples missing in a single scan, with minimum scan overlap between adjacent scans to be 25mm.

8.5 Recording 8.5.1

All A-scan waveforms shall be recorded using a digitisation not less than 5 times the nominal frequency of the probe. Recording shall be in the form of an “SCN” data file and evaluation of the scan results shall be made using A- Scan, B-scan, S-scan and C-scan and D- Scan projections with colour pallets that allow the operator to discriminate between signals above or below the evaluation threshold.

8.5.2

Reflectors that produce a response within the area of interest and are deemed to be a discontinuity shall be classified, sized and recorded noting the location in reference to the fixed datum point. The investigation shall interpret whether the indication originates from a flaw or is a geometric indication. When the reflector is determined to be a flaw, the flaw shall be evaluated as per acceptance criteria below (Section 9.0).

8.5.3

The dimensions of the flaw shall be defined by the rectangle that fully contains the area of the flaw. The length (l) of the flaw shall be drawn parallel to the inside pressure retaining surface. •

If the space between two flaws aligned along the axis of weld is less than two times the length of the longer of the two, the two flaws shall be considered a singular flaw.

The AGR Handy Scan has an internal memory capacity of 2 0 GB which caters for inspection scans involving large memory files. Where required an external hard drive may be fitted to increase the storage capacity. 8.6

Sizing of Defects Sizing shall be carried out using the following te chnique Length by 6dB drop. Sizing for length shall be carried out using a c ombination of A-Scan and C-Scan displays. The peak amplitude shall be taken from each end of the defect and the ref erence cursers shall be re-located to the -6dB boundary at each end. The length of the defect shall be recorded and a screen image of the def ect saved with the cursers in the -6dB locations


Stork Cooperheat A screen snap shall be made with the cursers in the measuring positions.

9.0

ACCEPTANCE CRITERIA All Pitting type indications ar e to be evaluated and recoded. All indications deemed to be pitting indications in the area of interest are Unacceptable. All unacceptable indications are to be recording in the Defect Assessment sheet with associated PAUT screen snaps detailing depth and location relative to the fixed datum point. Note: Welding indications are not intended to be evaluated.

10.0

DATA STORAGE

10.1

Once data has been collected it should be given a unique name.

10.2

If data, which has been collected and saved on the system, is required for archiving then the files shall be copied onto the final storage medium being an external hard drive with a minimum storage capacity of 100GB. Three copies should be taken, one as the archive, one as the back up and one should be given to the Client representative, this HDD should be backed up daily (end of shift) for client review to be performed.

10.3

Once copied the data shall be re-assessed to check that it has been copied correctly.

10.4

The storage mediums shall be given a unique serial number, which is registered in the data logbook.

10.5

Once the data has been checked the original files can be removed from the system's disk.

10.6

The archive disk and backup disk shall be stored in two separate storage cabinets.

10.7

At the completion of the contract, one full set of UT data, and copies of all final reports shall be stored to an external hard drive and shall be presented to Client as part of the final report.

11.0

REPORTING After each inspection an Inspection Report shall be prepared. This report describes the work done, the equipment used, the qualification of the inspection personnel and the results. Additional inspection results (if any) are also reported and alternate methods of inspection described. The final report for each weld shall include; a) b) c) d) e) f) g) h) i) j) k)

Project name, contract details Procedure and technique identification Equipment used (UT instrument, probes, cables, manipulators, couplant) Computer programme identification and version Instrument gain settings sensitivity or reference target Weld Identification Scan Surface Record of rejectable indications locations or areas cleared Areas of restricted access Personnel and their qualifications Date and Time of the examination



SCAN PLANS

SA10 Phased Array Probes, above Ø2.0” through to Ø16.0” Pressure Piping- Scan Plans


Stork Cooperheat 3.05mm Scan 1 (Below Scan Plan to suit 2.77mm thickness and 3.77mm thickness variations)

Probe/Wedge

Offset

Pipe/ Thickness

Sectorial Scan

Focussing (Far Wall)

Gates: Start/ Length

10L32 A10/ SA10 N55S

-12.0mm

2.77mm/ 3.05mm/ 3.77mm

40°to 82°

True Depth 3.0mm

6.0mm/ 28.0mm

10L32 A10/ SA10 N55S

-12.0mm

2.77mm/ 3.05mm/ 3.77mm

40°to 82°

True Depth 3.0mm

6.0mm/ 28.0mm

3.05mm Scan 2 (Below Scan Plan to suit 2.77mm thickness and 3.77mm thickness variations) to cover the required 20mm scan width.

Scan 2


Stork Cooperheat

Scan 3

Probe/Wedge

Offset

Pipe/ Thickness

Linear Scan

10L32-A10/ SA10- 0L

0mm + 10mm

4.19mm/ 4.57mm/ 4.78mm

0°

10L32-A10/ SA10- 0L

0mm + 10mm

4.19mm/ 4.57mm/ 4.78mm

0°

Gates: Start/ Length 1) 65mm/ 1.3mm 2) 2mm- 9mm 3) 65mm/ 1.3mm 4) 2mm- 9mm

4.78mm Scan 1 (Below Scan Plan to suit 4.19mm thickness and 4.57mm thickness variations)

Probe/Wedge

Offset

Pipe/ Thickness

Sectorial Scan

Focussing (Far Wall)

Gates: Start/ Length

10L32 A10/ SA10 N55S

-12.0mm

4.19mm/ 4.57mm/ 4.78mm

40°to 80°

True Depth 5.0mm

6.0mm/ 28.0mm

10L32 A10/ SA10 N55S

-12.0mm

4.19mm/ 4.57mm/ 4.78mm

40°to 80°

True Depth 5.0mm

6.0mm/ 28.0mm


Stork Cooperheat 4.78mm Scan 2 + 3 (Below Scan Plan to suit 4.19mm thickness and 4.57mm thickness variations) to cover the required 20mm scan width.

Scan 2

Scan 3

Probe/Wedge

Offset

Pipe/ Thickness

Linear Scan

10L32-A10/ SA10- 0L

0mm + 10mm

4.19mm/ 4.57mm/ 4.78mm

0°

10L32-A10/ SA10- 0L

0mm + 10mm

4.19mm/ 4.57mm/ 4.78mm

0°

Gates: Start/ Length 5) 65mm/ 1.3mm 6) 2mm- 9mm 7) 65mm/ 1.3mm 8) 2mm- 9mm

Notes: Above scan plans are based on proposed phased array probe to wedge combinations for various pipe si zes nominated for inspection. Wedges to be shaped to suit weld cap contour to allow for PAUT Linear scanning to be performed up to the weld edge. Scan 2 shall be performed with wedge contoured over weld cap. Linear Strip scanning to ensure correct offset for scan 3 shall require guide to run against side of PAU T wedge.


Stork Cooperheat Appendix 1: PAUT Technique Sheet PAUT Technique Sheet- Shear Sectorial Weld Scanning Report No.: 14-004387- Various

Procedure No.: 14-004387-PA-UT_DUPSS_PETROFAC

Technique Sheet No.: 14-004387/ 001

Client: Petrofac Enquiry No.: 14-004387

Project: Firemain System- MIC evaluation Unit No.: Firemain System

Contract No.: 14-004387 Material: Duplex Stainless Steel

Stage of Manufacture: In- Service

Thickness: 2.77mm through to 4.78mm

Acceptance Criteria: Record Relevant Indications

Equipment Checks. Check Screen Height Linearity

Frequency Monthly

Check Time Base Linearity

Amplitude Control Linearity

Monthly

Storage Device Test

Probe Details/Serial No

10L32 A10

Frequency Monthly

Check Scanner Calibration Axis X

Daily

Daily

Scanner Calibration Axis Y

Daily

Wedge Details/ Serial No

Frequency

A10- N55S- 5L32- IHC

Phased Array Parameters. HT Voltage

50V

PRF

2500-5000Hz

Pulse Width

50ns

Sample Rate

33.33Mhz

Averaging

Off

Bits/ Sample

8

Array Geometry

Linear

Wave Type

Shear

Probe Delay

22.27 (16”)

Skew

0°-180°

Horizontal Offset

12mm

Vertical Offset

NA

Sectorial Phased Array Focal Laws

Phased Array Focal Law Tx

Phased Array Focal Law Rx

Angle Control Min

40

First Active

1

First Active

1

Angle Control Max

82

No of Active

32

No of Active

32

Separation

1

Idx Points/Stride

1/1

Idx Points/Stride

1/1

Linear Phased Array Focal Laws



Angle Control Min

NA

First Active

NA

First Active

NA

Angle Control Max

NA

No of Active

NA

No of Active

NA

Seperation

NA

Idx Points/Stride

NA

Idx Points/Stride

NA

Band Pass Filters

Gate 1

Gate 2

Probe Centre Freq.

10Mhz

Start

6

Start

NA

Rectifier

Full Wave

Width

28

Width

NA

Filter Mode

6MHZ

Threshold

40%

Threshold

NA

FLB Enabled/Disabled

-

DAC/TCG On/Off

TD Superview (Group 1)

On. TCG Single Skip 36db base, + 6db TCG 1 @ 8mm


Panel Layout

1

Panel Layout

NA

Sub Panel Layout

5

Sub Panel Layout

NA

B-Scan Direction

Secondary

B-Scan Direction

NA

Phased Array Wedge Parameters First Element at

Front

First Element Height

6.80mm

First Element to Diffuser

20mm

Roof Angle

36

Wedge Velocity

2330m/s

First Element to Front

20mm

Additional Evaluations. Evaluation Type

Offline

Additional Phased Array Scans

Evaluation free run as required.

Online Max Speed Details

300

Details of deviations from the procedure: Technician: Dean Mason

NDT Engineer:

Client:

Signature:

Signature:

Signature:

Date: 20-02-2104

Date

Date


Stork Cooperheat

PAUT Technique Sheet- Compression Linear Scanning Report No.: 14-004387- Various Client: Petrofac

Procedure No.: 14-004387-PA-UT_DUPSS_PETROFAC Project: Firemain System- MIC evaluation

Technique Sheet No.: 14-004387/ 001 Contract No.: 14-004387

Enquiry No.: 14-004387

Unit No.: Firemain System

Material: Duplex Stainless Steel

Stage of Manufacture: In- Service

Thickness: 2.77mm through to 4.78mm

Acceptance Criteria: Record Relevant Indications

Equipment Checks. Check Screen Height Linearity

Frequency Monthly

Check Time Base Linearity

Frequency Monthly

Check Scanner Calibration Axis X

Daily

Amplitude Control Linearity

Monthly

Storage Device Test

Daily

Scanner Calibration Axis Y

Daily

Probe Details/Serial No

10L32 A10

Wedge Details/ Serial No

Frequency

A10- N0L- 5L32- IHC

Phased Array Parameters. HT Voltage

50V

PRF

5000Hz

Pulse Width

50ns

Sample Rate

33.33hz

Averaging

off

Bits/ Sample

8 b/s

Array Geometry

Linear

Wave Type

Compression

Probe Delay

0mm (Trigger Gating used)

Skew

0°-180°

Horizontal Offset

0mm + 10mm

Vertical Offset

NA

Sectorial Phased Array Focal Laws



Angle Control Min

NA

First Active

NA

First Active

NA

Angle Control Max

NA

No of Active

NA

No of Active

NA

Seperation

NA

Idx Points/Stride

NA

Idx Points/Stride

NA

Linear Phased Array Focal Laws



Angle Control Min

0°

First Active

1

First Active

1

Angle Control Max

0°

No of Active

4

No of Active

4

Separation

1

Idx Points/Stride

28

Idx Points/Stride

28

Band Pass Filters

Gate 1

Gate 2

Probe Centre Freq.

10Mhz

Start

65mm

Start

1.3mm

Rectifier

Full

Width

2.06mm

Width

8.95mm

Filter Mode

10Mhz

Threshold

48%

Threshold

30%

FLB Enabled/Disabled

-

DAC/TCG On/Off

Off



Panel Layout

1

Panel Layout

NA

Sub Panel Layout

5

Sub Panel Layout

NA

B-Scan Direction

Secondary

B-Scan Direction

NA

Phased Array Wedge Parameters First Element at

20mm

First Element Height

20mm

First Element to Diffuser

20mm

Roof Angle

NA

Wedge Velocity

2330m/s

First Element to Front

20mm

Additional Evaluations. Evaluation Type

Offline

Additional Phased Array Scans

Evaluation free run as required, Focus not required due to thickness.

Online Max Speed Details

NA

Details of deviations from the procedure: Technician: Dean Mason

NDT Engineer:

Client:

Signature:

Signature:

Signature:

Date: 20-02-2104

Date

Date


Stork Cooperheat

Appendix 2: Mechanized UT Data Collection Form Client:

Job No:

Report No:

Project No:

Order No:

Site/ Location:

Part No:

Drawing No:

Object Tested:

Extent of Test:

Procedure:

Engineer/ Technician:

Material:

Thickness:

Equip. Type:

Equip. Serial:

Probe Frequency:

Scanner Type:

Scanner Serial No:

Probe Serial No:

Probe Diameter:

Calibration Block:

Weld No:

Scan ID:

Area

Gain

PCS

Comments


Stork Cooperheat Appendix 3: Assessment Sheet

Client:

Order no.:

Project:

Site / location:

Plant Equip ID

Weld / Part no.

Scan ID

Indication no.

Indication type

Cooperheat job no.: Report no.: Start

Length

Depth

Name:

Title and Level:

Signature:

Date:

Date of test: Indication height

Comments: Clients Signature:

Clients Title:


Stork Cooperheat

Appendix 4: PAUT Analysis (Area of Interest) Strip Scan Corrosion Mapping Area of Interest for Analysis

PAUT Superview setup to detail at best 2 x Backwall echoes in “A” “B” or “S” Scan images. Analysis to be concentrated st nd between 1 to 2 backwall echoes with re-confirmation st made between interface and 1 backwall echo as detailed. “C” Scan may include Amplitude

Minimum wall thickness

Comments

Elm Pul Qa Prc 0004 r2

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