WORK PROCEDURE FOR PHASED ARRAY AUT INSPECTIONS
INDEX
S.NO ITEM PAGE
1.0 Scope
2.0 Reference documents
3.0 Personnel Qualification
4.0 Summary of Practice
5.0 Apparatus
5.1 Transducer & Encoder
5.2 Wedges
6.0 Reference Block
6.1 Additional block for system calibration
7.0 PA system calibration
8.0 Recalibration
9.0 Surface Preparation
10.0 Recording / Evaluation
11.0 Documentation
12.0 Acceptance Criteria
Sample Report Format
1.0 SCOPE
This procedure establishes the generic phased array ultrasonic examination
requirements which shall be used to examine corrosion mapping (wall thickness
loss) of a section of 24 inch TNP lines for SPDC.
2.0 REFERENCE DOCUMENTS:
ASME Sec V –
1 Article 4 ASME Code for Non Destructive testing
(Latest Edition)
Standard specification for Straight-beam
2 ASME Sec V – SA435 ultrasonic examination of steel plates
Standard Practice for Ultrasonic Pulse-echo
3 ASME Sec V-
SE-114 straight beam examination by contact method
Guide lines for Personnel Qualification &
4 ASNT SNT TC – 1A
Certification.
5 WP/SIPL/017/2000 Sievert’s Manual for General safety
6 WP/SIPL/001/2006 Sievert’s Written Practice
3.0 PERSONNEL QUALIFICATION:
Nondestructive testing (NDT Level II) personnel shall be qualified in
accordance with a nationally recognized NDT personnel qualification
practice or standard such as ANSI/ASNT-CP-189, SNT-TC-1A, or a similar
document.
4.0 SIGNIFICANCE AND USE
4.1 SUMMARY OF PRACTICE
The UT-Phased array Technique is a process wherein active area of probe
can be adjusted for thin wall thickness measurements. UT data are
generated by controlled incremental variation of lateral direction while
scanning the object under examination. This process offers an advantage
over processes using conventional search units with fixed active area
whereas in phased array the active area can be adjusted. Each phased array
search unit consists of a series of individually wired transducer elements
on a wedge that are activated separately using a pre-selectable time delay
pattern. With a linear delay time between transmitter pulses, a normal
sound field is generated. 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 by measuring the vertical extent (in case of cracks) or
the cross sectional distance (in the case of volumetric/planar flaws) at the
6dB levels once the flaw has been isolated and the image normalized. As
with other techniques, the phased array process assumes isotropic and
homogeneous material whose acoustic velocity is constant and accurately
known.
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
independent pulser /receiver channels. The system is capable of generating
the following images B-scan, C-scan along with display of A-scan.
Scanner shall be Olympus- HSMT Flex® with Magnetic wheels.
5.1 TRANSDUCER & ENCODER
Ultrasonic transducer configurations are specified by the technique used for the
examination. 1D linear phased array probe used in this procedure may include
64mm elements activated by 8 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.
In built Encoder with HSMT Flex shall be used which is well compatible with the
Omniscan. Mouse scanner or Miniwheel Encoder shall be used in the places
where scanner is inaccessible.
5.2 WEDGES
Phased array wedges should be of a design to accommodate the
aforementioned phased array probes. The wedge shall be 0 degree to
ensure coverage of the inspection zone. Wedges shall have provision of
irrigation holes and carbides for couplant flow.
6.0 REFERENCE BLOCK
The reference block shall be of the similar material specification or equivalent
to part material under examination and shall cover the inspection thickness
range.
6.1 ADDITIONAL BLOCKS FOR SYSTEM CALIBRATAION
In addition to the basic reference block, additional blocks shall be used for
system calibration. I.I.W V1 / V2 or Step Wedge may also be used for range,
sensitivity, velocity, and wedge calibration.
7.0
PHASED ARRAY SYSTEM CALIBRATION
Calibration shall be performed on the reference block having appropriate
reference thicknesses. The screen range shall be set to receive minimum two
back wall echo of the object to be tested. System calibration shall include the
complete ultrasonic examination system. The system calibration
informationshall 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.
8.0 RECALIBRATION
Any of the following conditions shall be cause for system recalibration:
Change of search unit or wedge
Change of search unit cable type or length change
Change of ultrasonic instrument
Change in examination personnel
Couplant change
Change in type of power source
9.0 SURFACE PREPARATION
The surfaces of the material to be examined shall be free of any irregularities
such as scale, dirt, grease, paint, spatters or any other foreign material. Surface
shall be smooth enough to carry out the examination effectively.
Surface conditions, which do not meet these requirements, shall be
recorded as limitations on the ultrasonic examination data report form
10.0 RECORDING/ EVALUATION
The Trained NDT Level II - UT operators with hands on training Omni Scan
shall calibrate and carry out UT inspection. Only personnel certified Level II
or III in Ultrasonic testing along with knowledge of phased array and Omni
Scan equipment shall evaluate the results of ultrasonic examinations for
acceptance.
11.0 DOCUMENTATION
Results of ultrasonic examination shall be reported on the Omni Scan Data
Report form used in the software. All Phased array examination data for
each recordable indication, A-, B- and C-scans shall be saved as a report.
The examiner shall record the results of the examination on the Omni Scan
Data Report Form. All recordable indications shall be documented on the
examination report.
The ultrasonic scan plan, ultrasonic calibration and ultrasonic instrument
linearity verification (if required) shall be considered part of examination
report
Client’s name and address
Information about the equipments used for testing
Date and place of inspection
Test system calibration
Inspection summary
Object reference number
Comments
Signature of the inspection personnel.
12.0 ACCEPTANCE CRITERIA
As per the client specification.
13.0 REPORT FORMAT
The results will be interpreted as wall thickness loss (or nominal wall thickness) over the circumferential
and axial length and same will be tabulated as shown below
