General Procedure For AUT
General Procedure For AUT
General Procedure For AUT
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14-C-053-AUT
PIPL-06.01.0001
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08-04-2014
Automated Ultrasonic Testing
General Procedure
Development Revisions
Revision No. Prepared By
0
M.Wilson
1
M.Wilson
2
M.Wilson
Date
5th July 2012
2nd Feb 2013
10th Apr 2013
Approved By
J.van der Ent
J.van der Ent
J.van der Ent
3
4
M.Wilson
M.Wilson
th
09 Apr 2014
th
09 Apr 2014
Date
5th July 2012
2nd Feb 2013
10th Apr 2013
31st Jan 2014
09th Apr 2014
Amendment Details
6.1,6.3,6.7,7.2.8,7.3.2,7.3.3,7.7,
9.2, Attachment 3
Contents list
Lay-out and 7.3.3
This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the
business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without
the permission of Applus RTD.
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14-C-053-AUT
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Automated Ultrasonic Testing
General Procedure
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14-C-053-AUT
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Automated Ultrasonic Testing
General Procedure
Contents
1
Introduction
Scope
References
3.1
3.2
3.3
3.4
3.5
Internal Documents
Codes and Standards
Pipeline Contractor / Company Specific Documents
Abbreviations
Definitions
4
4
4
4
5
Personnel Qualifications
4.1
4.2
6
6
5.1
5.2
5.3
5.4
5.5
6
7
7
7
7
6.1
6.2
6.3
6.4
6.5
6.6
6.7
8
8
8
8
8
9
9
Equipment Settings
7.1
7.2
7.3
7.4
7.5
7.6
7.7
General
Setting of Inspection Gates
Sensitivity Settings
Scanning Preparation & Surface Condition
Reference Line
Datum Point
Acoustic Coupling Fluid
9
10
11
12
12
12
12
8.1
8.2
8.3
9.1
9.2
9.3
General
Coupling Criteria
Imperfection length, Depth and Height
Examination
Interpretation of results
10
11
11.1
11.2
12
12
13
13
14
14
14
14
Acceptance/Rejection Criteria
15
Repairs
15
15
15
12
Reporting
16
13
Storage of data
16
Attachment 1
17
Attachment 2
18
Attachment 3
19
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14-C-053-AUT
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Automated Ultrasonic Testing
General Procedure
Introduction
Applus RTD provides a field-proven Automated Ultrasonic Testing (AUT) system, trademarked as Rotoscan . The
system was developed for the inspection of girth welds during construction of pipelines, both on and offshore. High
inspection speed, instantaneous recording of inspection results utilizing phased array and /or conventional probe
technology that characterize Rotoscan.
The purpose of this procedure is to describe generic system configurations and methodology of Applus RTD AUT
inspection process, to determine weld integrity.
The project parameters will be documented in a Specific Procedure(s) which shall accompany this document,
describing as a minimum the following items:
x Reference Specification(s).
x Probe frame layout.
x Rotoscan parameter set-up.
x Detailed project scope (Dia, WT, WPS).
x Reference block manufacturing drawings.
x Inspection set-up configuration.
x Probe selection.
x Acceptance criteria.
Note: Deviation or alternations of the processes defined within this core procedure require the approval of the
Applus RTD AUT Technical Authority.
Scope
The Rotoscan inspection system is based upon the Pulse Echo Method, enhanced with mapping images and
Time of Flight Diffraction. The weld is divided into a number of depth zones, which are each inspected by one or
more probes or array. The probes / array are arranged such that the entire weld is examined from both sides in a
circumferential scan. The ultrasonic information is transferred to a computer for data presentation, analysis and
storage.
References
3.4 Abbreviations
AUT
Conv
DS
FBH
MUT
OD
PE
ToFD
UT
UPS
DIA
FSH
PCS
CCW
CW
ECA
ID
NDT
PA
PRF
US
WMS
WPS
WT
HAZ
SCR
Counter Clockwise
Clockwise
Engineering Critical Assessment
Internal Diameter
Nondestructive Testing
Phased Array
Pulse Repetition Frequency
Upstream
Workmanship
Welding Procedure Specification
Wall Thickness
Heat Affected Zone
Steel Catenary Riser
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3.5
14-C-053-AUT
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Automated Ultrasonic Testing
General Procedure
Definitions
x
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Automated Ultrasonic Testing
General Procedure
Personnel Qualifications
Be qualified in accordance with the Applus RTD Written Practice, specific to the region.
Only accredited personnel qualified to level II or Level III UT (applicable certification body is referenced in
the Project Specific Procedure(s)) shall interpret the test results.
Be trained and passed the Applus RTD Rotoscan in-house course for Automated Ultrasonic Testing.
If required, be trained and passed Applus RTD in-house course(s) for specific advanced techniques, SCR as
example.
5.1.1 Software
Applus RTD Rotoscan software version 5 or higher.
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General Procedure
5.2 Recording
Inspection results are presented on-line with a colour monitor. The screen layout and number of used sequences
are configured to present the thickness of the weld to be examined. Distance delays are applied to the output
channels to compensate for variable probe circumferential positioning therefore achieving a coherent display
presentation.
The following information is presented:
x Pulse echo channels section (US/DS), recording amplitude and relevant transit distance (superimposed).
x All channel mapping section (US/DS), digitized pulse echo image converted into colour/mapping pattern.
x Mapping image sections (US/DS), digitized pulse echo images for pattern recognition purposes of cap
reinforcement and root penetration.
x Go/No-Go image section.
x Coupling check section.
x ToFD image section / ToFD View.
x Circumferential position information.
x Header section with possibility to present job specific information.
x Time and date of inspection.
x Indication mark-up.
x Wall Thickness recording check (if applicable).
x Wedge Temperature (if applicable).
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Automated Ultrasonic Testing
General Procedure
Transverse flaw probes should be integrated in the AUT inspection system in the following cases;
i.
In specific welding processes where the likelihood of transverse cracking occurs (i.e. SMAW).
ii.
Is specified in the applicable standard and/or client specification not being waived by Company.
b.
Creep Wave should be integrated in the AUT inspection system in the following cases;
Fatigue sensitive welds having weld cap reinforcement that may interfere with defect detection
capability using full skip inspection functions.
ii.
Is specified in the applicable standard and/or client specification not being waived by Company.
i.
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Automated Ultrasonic Testing
General Procedure
WPS
x Tolerances on bevel outside the relevant WPS in relation to Reference Standard.
x Changes in type of consumable or alternations within the WPS that may affect the validity of the Reference
block(s) if manufactured to include a project specific weld.
Notes: Through-holes 2 mm or 5 x 1 mm slots in both ends of calibration block at centreline are to locate weld
centre position only.
Equipment Settings
7.1 General
The ultrasonic equipment shall be electronically calibrated in accordance with the relevant valid version of Applus
RTD control procedure for verification. This shall be referenced in the Project Specific Procedure(s).
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General Procedure
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General Procedure
+20-40% FSH
20-40% FSH
In cases when use of the lateral wave is not applicable, e.g. surface conditions and steep beam angles, the
amplitude of the back wall signal shall be set at between 12 to 24 dB above FSH.
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General Procedure
The PCS for ToFD should be calculated at 2/3 of the wall thickness (nominal beam angle). The ToFD display on the
calibration scan shall demonstrate the ability to detect the smallest applicable root notch with a response at least 6
dB greater than adjacent grain noise.
Examination
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The result of each calibration scan may be printed or converted to pdf format and be stored on hard drive(s). Each
calibration will have the same number as the next corresponding weld with the applicable defined designation,
(example, Cal) as a postfix. Calibration performed at the end of a shift or after weld repairs shall use the same
number as the last weld inspected with the defined designation, (example, CalOut) as a postfix.
Calibrations are performed in the same direction and at the same nominal speed as the weld.
Calibration Frequency At the start of every shift and at intervals not exceeding one hour or ten consecutive
welds, or whichever comes first and at the conclusion of every shift, unless otherwise defined in the Project Specific
Procedure(s).
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General Procedure
Interpretation of results
9.1 General
With the transit distance measurements and information from the Mapping and ToFD channels visible on the result
presentation, indications shall be judged whether they are from the weld geometry or weld imperfections.
Indications produced by ultrasonic testing may or may not be imperfections. Changes in the weld geometry due to
misalignment, cap profile, root penetration, internal chamfering and ultrasonic wave mode conversion may cause
geometric indications similar to those caused by weld imperfections but that are not relevant to acceptability.
9.3.1 Length
All indications in the pulse echo channels shall be evaluated which exceed the threshold level as defined in the
Project Specific Procedure(s).
Defect length in the pulse echo channels shall be measured at the Evaluation (Go/No-Go level as defined in the
Project Specific Procedure(s). The AUT Operator shall take lateral beam spread into account in defect evaluation as
shown in Figure 3 below. All beam spread calculations shall be performed at the Evaluation (Go/No-Go) level as
defined within the Project Specific Procedure(s) from echo dynamics derived from the calibration scan.
Defect Length
Threshold Level
Figure 3
Note: If two indications are spaced closer than the width of the beam, the lateral beam spread correction must be
conservative. That is, the beam spread correction can be applied to one indication or partly to both indications, but
the total beam spread cannot be applied separately to both defects.
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9.3.2
14-C-053-AUT
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Automated Ultrasonic Testing
General Procedure
Depth
Defect depth from OD surface will be established using ToFD. Where no clear ToFD signal is evident, depth shall be
established using pulse echo channels.
An Interzonal imperfection is defined as a single flaw, which is seen by adjacent channels. To be considered
Interzonal, the echo dynamics and the circumferential positioning should be similar. In the case of Interzonal
imperfections, only the imperfection and not the overtraces of the imperfection are to be sized. Where the echo
dynamics differ, the imperfection will be considered larger than the beam or stacked and reported as such. In all
channels mapping it can determined whether the indication is a single or multiple flaw by checking the following:
1.
2.
3.
The interpretation sequence to be followed is visualized in Attachment 2 and 3, Decision Flow Chart for WMS and
ECA.
9.3.3 Height
Determine the height of the indication in the applicable pulse echo channel(s). Where the indication is present in
more than one PE channel (adjacent), it shall be established whether indications are derived from Single or
Multiple imperfections. In cases where it has been established that (1) defect is present in more than one
channels, the overall height needs to be measured taking into account relevant over trace values taken from the
previous calibration.
If there are resolvable ToFD (clear diffraction Upper and Lower tip) signals for the indication, then the ToFD
measurement for height shall be used.
The interpretation sequence to be followed is visualized in Attachment 2 and 3, Decision Flow Chart for WMS and
ECA.
9.3.4 Interaction
The interaction rules within the relevant Standard / Code applicable to the Project, or specifically defined by
Contractor / Company shall be taken into account when determining overall imperfection length or height. The
interaction shall be defined within the Project Specific Procedure(s).
Where possible the (Code dependant) interaction module of the software should be used to determine imperfection
interaction.
10 Acceptance/Rejection Criteria
The Acceptance/Rejection criteria shall be defined by the Pipeline Contractor or Company. This may be included as
an addendum to the Project Specific Procedure(s) or issued as a separate document by the Contractor.
11 Repairs
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12 Reporting
The Applus RTD Rotoscan site report, as shown in Attachment 1, shall be used for reporting of inspection results.
The following information will be documented as minimum:
x Used procedure number;
x Project name/number;
x Weld No;
x Inspection date;
x Diameter;
x Wall thickness;
x Number of indications, location on circumference and location in depth;
x Acceptable or Rejectable.
An example of file naming, for Mainline Weld ML 1234;
x ML 1234 Cal
: Calibration scan performed prior to mainline weld
x ML 1234
: Scan of mainline weld
x ML 1234 CalOut : Calibration scan performed at shift end.
The naming and numbering system for weld files will be determined at project commencement in cooperation with
the Contractor / Company.
13 Storage of data
The raw data of each inspected weld including the parameter settings shall be stored on the main hard drive (CDrive). In addition, a full back-up shall be made on a second removable hard drive.
The Date and Time function shall be used to ensure that all welds scanned are accounted for. By selecting this
function the date and time of each scan made becomes part of the file name, removing the chance of overwriting
any file.
Welds shall be stored in directories which will be created every 24hrs. Operators are responsible for the daily
directory on the main hard drive and shall ensure that all welds are present and readable.
All calibration and weld inspection results should be printed in a compressed black-white image of the entire weld
circumference after an acceptable scan is completed or saved to PDF.
After completion of the pipeline project, all data (NDT, welds, repairs and calibrations) will be stored on a digital
medium, including a viewer program and presented to Client.
The official record of inspection shall be the Applus RTD Rotoscan Site Report (or other if specified by Client) and
shall bear the original signature of the AUT Applus RTD Rotoscan Operator.
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General Procedure
Attachment 1
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General Procedure
Attachment 2
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General Procedure
Attachment 3