SGS Qatar PAUT Rpocedure [PDF]

Zitiervorschau

(SGS QATAR WLL - INDIV)

PROCEDURE FOR ULTRASONIC PHASED ARRAY EXAMINATION (Welds & Base Materials)

DOC. No. SGSQA - INDIV - SOP - 009

20052019 Date

00 Rev. No.

Issued for Implementation

Tejas Chandegra

Adil Bari

Description

Prepared

Reviewed By

Arsalan ul Haq ASNT NDT Level III Approved By (Technically)

Jahangir Zia Approved By

TECHNICAL PROCEDURE

SGS Qatar WLL - INDIV

PROCEDURE FOR ULTRASONIC PHASED ARRAY EXAMINATION (Welds & Base Materials)

Page : 2 of 35 Issue date : 20.05.2019 Doc. No.:SGSQA-INDIVSOP-009 Revision no. : 00 Author : Tejas Chandegra Approved by: Arsalan Ul Haq

CONTENTS 1.

PURPOSE ......................................................................................................................................... 4

2.

SCOPE .............................................................................................................................................. 4

3.

REFERENCE AND/OR RELEVANT DOCUMENTS ............................................................................ 4

4.

GENERAL.......................................................................................................................................... 4

5.

RESPONSIBILITIES .......................................................................................................................... 5

6.

ACTIVITIES ....................................................................................................................................... 5

6.1

Personnel Qualifications ..................................................................................................................... 5

6.2

Technical Data ................................................................................................................................... 6

6.3

Equipment & Accessories. .................................................................................................................. 6

6.3.1

Equipment .......................................................................................................................................... 6

6.3.2

Phased Array Search Units & Wedges. .............................................................................................. 6

6.3.3

Couplant ............................................................................................................................................ 7

6.3.4

Scanning And Adhering And Guiding Mechanism ............................................................................... 7

6.3.5

Calibration Blocks............................................................................................................................... 8

6.4

Execution Of The Examination ..........................................................................................................13

6.4.1

Annual Calibration Of The Equipment ................................................................................................13

6.4.2

Element Check ..................................................................................................................................13

6.4.3

Scan Plan .........................................................................................................................................13

6.4.4

Calibration Procedure. .......................................................................................................................16

6.5

Examination. .....................................................................................................................................17

6.5.2

Surface Preparation .......................................................................................................................18

6.5.3

Identification Of Weld Examination Areas. .........................................................................................18

6.5.4

Scanning Of Base Material ................................................................................................................18

6.5.5

Scan Speed Of Probes ......................................................................................................................18

6.5.6

Data Acquisition ................................................................................................................................18

6.5.7

Scanning. ..........................................................................................................................................19

6.6

Data Evaluation .................................................................................................................................19

6.6.1

Characterization ................................................................................................................................19

6.6.2

Geometric Indications ........................................................................................................................19

6.6.3

Flaw Sizing........................................................................................................................................20

6.7

Post Examination Cleaning................................................................................................................21

6.8

Acceptance Criteria ...........................................................................................................................21

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PROCEDURE FOR ULTRASONIC PHASED ARRAY EXAMINATION (Welds & Base Materials)

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List of Tables Table 1. Phased Array Personel Qualification Requirements .......................................................................... 5 Table 2; SGS Phased Array Equipment list .................................................................................................... 6 Table 3 Probes and Wedges Detail ................................................................................................................ 7 Table 4: List Of Scanners............................................................................................................................... 7 Table 5; Through Wall Height Measurement .................................................................................................20 Table 6 Flaw Acceptance Criteria for Welds Between Thicknesses of 6 mm (1/4 in.) and < 13 mm (1/2 in.) ...26 Table 7 : Flaw Acceptance Criteria for Welds With a Thickness Between 13 mm (1/2 in.) and Less Than 25 mm ...............................................................................................................................................................26 Table 8 : Flaw Acceptance Criteria for Welds With Thickness Between 25 mm (1 in.) and Less Than or Equal to 300 mm ....................................................................................................................................................26

List of Figures Figure 1:- TCG Block for Non Piping .............................................................................................................. 9 Figure 2: Piping TCG Calibration block..........................................................................................................10 Figure 3: Alternative Piping TCG Calibration block ........................................................................................11 Figure 4: Scanner Block ................................................................................................................................12 Figure 5: Examination Sequence ..................................................................................................................13 Figure 6: Butt welds. .....................................................................................................................................14 Figure 7: THICK BUTT WELDS (S- AND E-SCANS) Butt welds should be examined from both sides of the weld and preferably from the bevel opening side (when access permits). ......................................................14 Figure 8: CORNER WELDS (COMBINED S- AND E-SCANS). ......................................................................14 Figure 9: T-weld examinations ......................................................................................................................15 Figure 10: TEE WELDS (FROM FLANGE OPPOSITE WEB) .......................................................................15 Figure 11: Weld reference Marking ...............................................................................................................18 Figure 13: Surface and Subsurface Flaws .....................................................................................................22 Figure 12 Single Indications ..........................................................................................................................22 Figure 14: Non-Aligned Coplanar Flaws in a Plane Normal to the Pressure Retaining Surface ......................23 Figure 15 : Multiple Planar Flaws Oriented in a Plane Normal to the Pressure Retaining Surface ..................24 Figure 16: Multiple Aligned Planar Flaws .......................................................................................................25

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TECHNICAL PROCEDURE PROCEDURE FOR ULTRASONIC PHASED ARRAY EXAMINATION (Welds & Base Materials)

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Page : 4 of 35 Issue date : 20.05.2019 Doc. No.:SGSQA-INDIVSOP-009 Revision no. : 00 Author : Tejas Chandegra Approved by: Arsalan Ul Haq

1. PURPOSE This documents provides procedural requirements for the manual and encoded examination of welds and base materials using Phased Array advanced ultrasonic technique.

2. SCOPE 1. a. b. c.

This procedure is applicable for phased array examination of carbon steel and alloy steel in accordance with ASME Sec V-Article-4 & 5: 2017. Groove Welds of Pressure vessels, Piping/Pipeline, Tanks and boiler tubes. Product forms - Weldments & Plates

2. ➢ ➢ ➢

Following conditions are applicable for these examinations wall thickness range ≥ 6.0 mm to 300 mm Scanning surface OD ≥ 4 “and above Temperature < 70 oC In any other cases procedure qualification is required.

3. This procedure is applicable for personnel performance demonstration and procedure qualification purpose whenever required by referencing code in conformance to ASME Sec V Article 4. 4. For other product forms like forgings and castings, this procedure may also be used for general examinations requirements. Requirements specific to these product forms shall be fulfilled additionally in conformance to referencing standards.

3. REFERENCE AND/OR RELEVANT DOCUMENTS • • • • • • • • • • •

ASME Boiler and Pressure Vessel Code Sec I ;2015 Rules for Construction of Power Boilers ASME Boiler and Pressure Vessel Code Sec V ;2019 Non Destructive Examination ASME Boiler and Pressure Vessel Code Sec VIII Div I & II ;2019 Non Destructive Examination SGSQA-IND-CWP-001– SGS Written practice in accordance with ASNT’s document SNT-TC-1A;2006 & 2011 ASME B31 Code for Pressure Piping ; 2014 ASME Code Case 2235-13 SNT-TC 1A CP/189 - Recommended practice for the qualification and certification of Non-destructive testing; 2006 & 2011 ASTM E-2700, Standard Practice for Contact Ultrasonic Testing of Welds using Phased Array ASTM E 2491, Guide for Evaluating Performance Characteristics of Phased-Array Ultrasonic Testing Instruments and Systems Equipment Manuals ASTM A 388: ASTM standard reference for Ultrasonic Examination of Steel Forgings ASTM A 609 ; ASTM Standard for Castings

4. GENERAL Abbreviations •

ASME:

-

American Society of Mechanical Engineers

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TECHNICAL PROCEDURE PROCEDURE FOR ULTRASONIC PHASED ARRAY EXAMINATION (Welds & Base Materials)

SGS Qatar WLL - INDIV

• • • • • • • • •

ASNT: BCB DAC NDT: PA SNT-TC-1A TCG UT HAZ

-

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American Society for Non Destructive Testing Basic calibration block Distance amplitude correction Non-Destructive Testing Phased Array Qualification & Certification of NDT Personnel Time Corrected Gain Ultrasonic Testing Heat Affected Zone

5. RESPONSIBILITIES PERSONNEL NDT Level III

Operator

6.

RESPONSIBILITY Develops, qualifies, and approves procedures, establishes and approves techniques,, interpreting codes, standards, specifications, and procedure; He shall be responsible for NDT operations for which qualified and assigned. He is responsible for approving scan plan and data evaluations. Complies with this procedure. Understand client specific requirements and acceptance criteria Reports any exceptions if encountered

ACTIVITIES

6.1 PERSONNEL QUALIFICATIONS The personnel performing Phased array with below mentioned examination scope shall be qualified in accordance with SGS written practice SGSQA-IND-CWP-001 conforming the requirements of SNT-TC-1A ; 2006 & 2011. Table-1 elaborates personnel qualification requirements for phased array examinations. Table 1. Phased Array Personnel Qualification Requirements EXAMINATION SCOPE

QUALIFICATION OPERATOR

Procedure & Scan Plan approval

ASNT Level III UT having PA Level II Certifications

Data collection Data Interpretation & evaluation

Phased array Level 2 or UT Level II who have demonstrated the ability to properly acquire examination data Phased array Level 2 or UT Level II/ who have documented training in the use of the equipment and software used.

Personnel shall be periodically examined for performance evaluation at least every two years and for performance demonstration whenever required by referencing code .

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PROCEDURE FOR ULTRASONIC PHASED ARRAY EXAMINATION (Welds & Base Materials)

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6.2 TECHNICAL DATA In advance of the weld inspection the client has to supply at least the following technical data: 1. 2. 3. 4. 5. 6. 7. 8.

Scope of the inspection: Weld Details: Surface condition and temperature: Heat treatment (if applicable): Type of material: Size of test object (diameter and schedule/wall thickness): Drawing: Accessibility

6.3 EQUIPMENT & ACCESSORIES. 6.3.1

EQUIPMENT

➢ To perform an inspection, an ultrasonic device shall be used which is capable to activate Phased Array transducer elements simultaneously or sequentially. The system shall consist of an automated, data-acquisition program, to generate and collect Linear and Sectorial-scans, to store it on disk. Equipment list is shown in Table-2. ➢ The phased array system shall have a means of data storage for archiving scan data. An External storage device, flash card or USB memory stick can be used for data storage ➢ The equipment it selves or separate analysis software shall make it possible to analyze the original data by means of A, B, C, D and S-scan presentation of the data, after finalizing the scan. ➢ The phased array system shall be standardized for amplitude and height linearity in accordance with Annex-A & B. Table 2; SGS Phased Array Equipment list

6.3.2 • • •

Manufacturer

Model

Connections/ Software Versions Active Elements

Technology Design

Handy-scan

64/32

TD 19.11

Olympus

Omni scan MX2

128/32

TomoView 2.10 or Later Omni PC 4.2 or later

Olympus

Omni scan MX2

128/16

TomoView 2.10 or Later Omni PC 4.2 or later

GE

Phasor XS

128/16

UT Rhythm 4.0

PHASED ARRAY SEARCH UNITS & WEDGES.

Probes and wedges mentioned in Table-3 shall be used for Phased array examinations. All probes have Omni Scan connector with a cable length of 2.5 meter. For simultaneous use of two PA probes , Y adapter splitter shall be used. For automated and semi automated scanning, there should exist irrigation holes for water injection.

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•

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Refracting wedges used on curved surfaces shall require contouring to match the surface curvature if the curvature causes a gap between the wedge and examination surface exceeding 0.5mm at any point.

Table 3 Probes and Wedges Detail

Make

Model

Type

Freq.

No

of Pitch

Wedges

Elements

Olympus

5L16-A1

Linear

5 MHz

16

0.75

SA1-0L

0O Longitudinal

SA1-N60S

60o Shear wave

SA1-N60L

60o longitudinal 0O Longitudinal 55o Shear wave 60o longitudinal 0O Longitudinal 55o Shear wave 60o longitudinal 0O Longitudinal 60o longitudinal 55o Shear wave 60o Shear wave

Olympus

2.25L64-A2

Linear

2.25 MHz

64

0.75

Olympus

5L64- A2

Linear

5 MHz

64

0.60

Olympus

5L16- A3

Linear

5 MHz

16

1.2

Olympus

2.25L16-A4 7.5CCEV35A15

Linear

2.25 MHz

16

2

SA2-0L SA2-N55S SA2-N60L SA2-0L SA2-N55S SA2-N60L SA3-0L SA2-N60L SA4-N55S

Linear

7.5 MHz

16

0.5

SA15N60

Olympus

Wedges Natural refracted angle

6.3.3 COUPLANT The couplant including additives shall not be detrimental to the material being examined. Couplants used on nickel base alloys shall not contain more than 250ppm of sulfur. Couplants used on Austenitic Stainless Steel shall not contain more than 250 ppm of halides (chlorides plus fluorides). Glycerine, water, grease, motor oil etc can be used as couplant. For rough surfaces high viscous couplants are recommended to be used. 6.3.4 SCANNING AND ADHERING AND GUIDING MECHANISM Automatic, Semi-automatic and handheld scanners that can accommodate all necessary accessories for scanning can be used. Following scanners are being used for automated or semi-automated examinations. Arrangements shall be made to adhere and guide the probe during scanning e.g. hand held, mechanical or magnetic. Table 4: List of Scanners

Manufacturer Jireh Industries Jireh Industries AUT Solutions Phoenix ISL Olympus Olympus

Model Navic ODI Nano Scanner Magman Pipe Scanner Cobra Scanner

Type Automatic Semi Automatic Semi Automatic Semi Automatic Semi Automatic Semi Automatic

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6.3.5

PROCEDURE FOR ULTRASONIC PHASED ARRAY EXAMINATION (Welds & Base Materials)

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CALIBRATION BLOCKS

6.3.5.1 General ➢ Calibration block shall be of the same product form and material specification or equivalent P-Number grouping as one of the materials being examined. ➢ The finish on the scanning surfaces of the block shall be representative of the scanning surface finishes on the component to be examined. ➢ For examinations in materials where the examination surface diameter is greater than 500mm, a block of essentially the same curvature, or alternatively, a flat basic calibration block, may be used. ➢ For examinations in materials where the examination surface diameter is equal to or less than 500 mm, a curved block shall be used. Except where otherwise stated in this procedure, a single curved basic calibration block may be used for examinations in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter. ➢ Alternative reflectors for calibration may be used provided that its sensitivity exceeds that of that dictated by this document. 6.3.5.2 Velocity & Wedge Delay Calibration Block. Any of the calibration blocks mentioned below shall be used for distance calibration, verifying angles (Focal Laws), and theoretical wedge index point, assessing sensitivity, sweep linearity and elements checks. • IIW-V1 Block • DC Block • PACS Block • Any other standard block with required specific reflectors & equivalent material properties. 6.3.5.3 NON PIPING TCG Calibration Block For non piping welds examination below mentioned block shall be used for TCG calibration. Alternatively PACS block or any other block may be used if all mandatory requirements regarding material, thickness and reflectors size are fulfilled.

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Figure 1:- TCG Block for Non Piping GENERAL NOTES: (a) Holes shall be drilled and reamed 1.5 in. (38 mm) deep minimum, essentially parallel to the examination surface. (b) The tolerance for hole diameter shall be ±1/32 in. (0.8 mm). The tolerance for hole location through the calibration block thickness (i.e. distance from the examination surface) shall be ±1/8 in. (3 mm).

(c) (d) (e) (f)

For blocks less than 3/4 in. (19 mm) in thickness, only the 1/2T side drilled hole and surface notches are required. All holes may be located on the same face (side) of the calibration block, provided care is exercised to locate all the reflectors (holes, notches) to prevent one reflector from affecting the indication from another reflector during calibration. Maximum notch width is not critical. Notches may be made by EDM or with end mills up to 1/4 in. (6.4 mm) in diameter.

Weld thickness, t, is the nominal material thickness for welds without reinforcement or, for welds with reinforcement, the nominal material thickness plus the estimated weld reinforcement not to exceed the maximum permitted by the referencing Code Section. When two or more base material thicknesses are involved, the calibration block thickness, T, shall be determined by the average thickness of the weld; alternatively, a calibration block based on the greater base material thickness may be used provided the reference reflector size is based upon the average weld thickness. For each increase in weld thickness of 2 in. (50 mm) or fraction thereof over 100 mm, the hole diameter shall increase 1.5 mm. NOTES: (1) Minimum dimension. (2) For each increase in weld thickness of 2 in. (50 mm) or fraction thereof over 100 mm, the hole diameter shall increase 1.5 mm.

6.3.5.4 PIPING TCG Calibration Block For piping welds examination below mentioned block in Figure-2 shall be used for TCG calibration. Thickness of block shall be ± 25% of nominal thickness of component to be examined.

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Figure 2: Piping TCG Calibration block 1

Notches shall not closer then T or 1 Inch. (25mm), whichever is a greater, to any block edge or other notch.

General Notes: • The minimum calibration block length (L) shall be 8 Inch. (200mm) or 8T whichever is greater. • For OD 4 Inch. (100mm) or less, the minimum arc length shall be 270 deg. For OD greater than 4 Inch. (100mm) the minimum arc length shall be 8 Inch. (200mm) or 3T whichever is greater. • Notch depth shall be 8% T minimum to 11% T maximum. Notch width shall be 1/4 Inch. (6mm) maximum. Notch length shall be 1 Inch. (25mm) minimum. • Maximum notch width is not critical. Notches may be made with EDM or with end mills up to ¼ Inch. (6mm) in diameter.

•

Notch length shall be sufficient to provide for calibration with a minimum 3 to 1 signal-to-noise ratio.

Alternatively calibration block mentioned in Figure-3 may also be use.

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Figure 3: Alternative Piping TCG Calibration block GENERAL NOTES: (a) For blocks less than 19 mm in thickness, only the 1/2T side drilled hole is required.. (b) Inclusion of notches is optional. Notches as shown in Figure -2 may be utilized in conjunction with this calibration block. (c) Notch depths shall be from 8% T minimum to 11% T maximum. Notch widths shall be 1/4 in. (6 mm) maximum. Notch lengths shall be 1 in. (25 mm) minimum. (d) Notches may be made with EDM or with end mills up to 1/4 in. (6 mm) in diameter. (e) Notch lengths shall be sufficient to provide for calibration with a minimum 3 to 1 signal-to-noise ratio. (f) Notches shall be located not closer than T or 11/2 in. (38 mm), whichever is greater, to any block edge or to other notches. NOTES: (1) Length and arc shall be adequate to provide required angle beam calibration. (2) Side-drilled hole diameter, length, and tolerance shall be in accordance with Figure-1

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6.3.5.5 Calibration Block for Corrosion Mapping and C Scanning Phased array step wedge block , TCG calibration block or block with flat bottom holes shall be used for sensitivity setting depending on suspected discontinuities. For C scanning specific to embedded defects , back wall reflection method may be used by setting sensitivity on test specimen. 6.3.5.6 Scanner Block (Reference Block) Reference block shall have thickness within the lesser of 1/4 in. (6 mm) or 25% of the material thickness to be examined. The number and position of the side-drilled holes shall be adequate to confirm the sensitivity setting of each probe as positioned per the scan plan in the scanner. The reference block (Figure-4) shall has all the specified reference reflectors required per Figure-1 & figure -2 for non-piping and piping components respectively. Reference block dimensions must be such that scanner can easily be accommodated on. For non-piping side drilled holes shall be used for reference scanning. For piping components side drilled holes are not critical, only notches at ID and OD are required. Notches simulating lack of side wall fusion on both sides should also be incorporated in reference block whenever scanning from one side of weld is accessible.

Figure 4: Scanner Block 6.3.5.7 Demonstration Blocks A demonstration block shall be prepared by welding. The demonstration block shall be within 25% of the thickness to be examined. For welds joining two different thicknesses of material, demonstration block thickness shall be based on the thinner of the two materials. The demonstration block’s weld joint geometry shall be representative of the production joint’s details. Unless specified otherwise by the referencing Code Section, the demonstration block shall contain a minimum of three actual planar flaws or three EDM notches oriented to simulate flaws parallel to the production weld’s axis and major groove faces. The flaws shall be located at or adjacent to the block’s groove faces as follows:

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(a) one surface flaw on the side of the block representing the component O.D. surface (b) one surface flaw on the side of the block representing the component I.D. surface (c) one subsurface flaw Demonstration block flaw sizes shall be based on the demonstration block thickness and shall be no larger than that specified by the referencing Code Section (a maximum acceptable flaw height for material less than 1 in. (25 mm) thick, or (b) 0.25 aspect ratio acceptable flaw for material equal to or greater than 1 in. (25 mm) thick based on the demonstration block thickness.

6.4 EXECUTION OF THE EXAMINATION Examination procedural steps are summarized in below figure

Equipment Check

Scan Plan

Calibration

Reference Scan

Equipment setting & Marking

Scanning & Data Acquisition

Evaluation & Reprting

Figure 5: Examination Sequence

6.4.1 Annual Calibration Of The Equipment Prior to the inspection the operator has to check if the used equipment has a valid calibration (sticker) conform mandatory requirements of ASME Sec V Article 4. Equipment without a valid calibration status will not be used. Procedure for these equipment calibrations are covered in Annex-A. Equipment calibration by manufacturer shall be considered an alternative if all mandatory requirements of this document are fulfilled. 6.4.2 Element Check This assessment is used to determine that all elements of the phased array probe are active and of uniform acoustic energy. The Phased Array Transducer Element Check shall be performed whenever the inspector suspects transducer operability, and At a minimum of at least each six month. Procedure for element check is described in Annex-B. 6.4.3 Scan Plan Phased array scanning procedures for welds shall be established using scan plans that indicate the required stand-off positions for the probe to ensure volume coverage required and appropriate beam angles. The ultrasonic examination area should include the volume of the weld, plus 50 mm (2 in.) on each side of the weld for material thickness greater than 200 mm (8 in.). For material thickness 200 mm (8 in.) or less, the ultrasonic examination area should include the volume of the weld, plus the lesser of 25 mm (1 in.) or t on each side of the weld. ES Beam Tool software shall be used for determining the focal laws generation for examination of specific joint configurations and HAZ and shall be part of reporting. Scan plan shall be approved by Level III, Following considerations shall be taken for scan plan development.

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Weld Examination ➢ Actual Weld configuration shall be known for accurate determinations of scanning parameters. In case if required joint details are not provided then assumed geometry shall be reported. Below mentioned are general examples of different configuration and respective scan plans. Scan plan for 30 mm butt joint and shell to nozzle joint is shown in Annex-5 & 6 respectively.

Figure 6: Butt welds should be examined from both sides of the weld and preferably from the bevel opening side (when access permits).

Figure 7: THICK BUTT WELDS (S- AND E-SCANS) Butt welds should be examined from both sides of the weld and preferably from the bevel opening side (when access permits).

Figure 8: CORNER WELDS (COMBINED S- AND E-SCANS) Corner welds are to be addressed using a combination of angle beams and straight beams. The preferred probe placement for the angle beam is on the surface where the weld bevel opening occurs. For double Vee welds, angle beam examinations should be carried out from both surfaces when access permits. In most cases, the surface from which the straight beam is used needs no further examination using angle beams.

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Figure 9: T-weld examinations may be treated similarly to butt welds. For thin sections, it may be possible to use a single stand-off

Figure 10: TEE WELDS (FROM FLANGE OPPOSITE WEB) When access permits, the preferred technique for T-weld examinations is from the plate opposite the web. A combination of 0 deg E-scans, and angled compression and shear modes from each direction provides the best approach for flaw detection along the fusion faces of the weld.

➢ The examination angle(s) for E-scan and range of angles for S-scan shall be appropriate for the joint to be examined. ➢ Scan plan shall be developed such that unfocussed beams cover entire weld and HAZ area. Focused beams (Focal range, Focal depth etc) may be utilized for detail interpretation and characterization of detected discontinuities or for some specific application e.g lack of cladding bonding or lack of side wall fusion determinations. ➢ Angular range for sectrorial scan shall be no more than ±20o off from natural refracted angle ➢ For S-scan techniques, the angular sweep incremental change shall be a maximum of 1 deg or sufficient to assure 50% beam overlap. ➢ For E-scan techniques, overlap between adjacent active apertures (i.e., aperture incremental change) shall be a minimum of 50% of the effective aperture height. ➢ For single and double sided weld scanning S-Scan or E- Scan shall be selected such that bevel incidence angle does not vary by ± 10o at weld fusion boundary. ➢ When multiple linear scans are required to cover the required volume of weld and base material, overlap between adjacent linear scans shall be a minimum of 10% of the effective aperture height for E-scans or beam width for S-scans. ➢ For thickness less than 1 inch single sectorial scan can be used provided focal laws hit fusion boundary by no more than 10o variation .

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➢ For thichness ≥ 1 “ multiple sectorial scans and/or multiple E S scans at appropriate angle shall be used. ➢ Standoff or focal laws shall be adjusted such that generated focal law of 60 o ±5o shear wave fire beyond the root to avoid mode conversion associated with 600 shear wave. ➢ For manual raster scanning, minimum to maximum stand offs distance shall be determined and focal laws used shall be reported. Corrosion Mapping ➢ Scan plan for E-scan at 0O shall contain number of active elements, element incremental change, active aperture size, element start and end element. ➢ Aperture size shall be adjusted based on thickess, beam spread and total number of elements. ➢ Active aperture of 25% of thickness may be used as a rule of thumb to avoid attenuation due to excessive beam spread. ➢ Longitudinal angle sectorial scan may be used for detection of suspected damage mechanism. ➢ For E-scan techniques, overlap between adjacent active apertures (i.e., aperture incremental change) shall be a minimum of 50% of the effective aperture height. If for some reason it is not practical or possible (due to obstacles near the weld or unexpected excessive weld cap width etc.) the operator is allowed to adjust the setup. The scan-plan shall be changed accordingly and attached to the inspection report. 6.4.4 CALIBRATION PROCEDURE. 6.4.4.1 General Calibration Requirements. ➢ The focal law to be used during the examination shall be used for calibration. ➢ All individual beams used in the examination shall be calibrated to provide measurement of distance and amplitude correction over the sound path employed in the examination. ➢ Surface of calibration block shall resemble that of actual component. Else transfer loss shall be incorporated in scanning sensitivity. ➢ Temperature of the calibration block shall be with in 14 oC of the component to be examined. 6.4.4.2 Calibration For each active group or channel, a probe delay calibration, TCG (Time Corrected Gain) calibration and Sensitivity calibration need to be performed. 6.4.4.3 Velocity & Wedge delay calibration The probe delay calibration has to be performed to determine the delay in the wedge prior to inspection with each set-up. This shall be done using the radius of a V1 , V2 , DC or PACS block.

6.4.4.4 TCG Calibration. For the PA setup, to achieve equal sensitivity for each focal law and at each depth a TCG-calibration (time corrected gain) will be performed using the specified blocks in 6.3.5 ➢ TCG shall be performed according to operation manual of different equipment. ➢ At least three reflectors shall be fired with phased array beam in the useful range. ➢ For E-Scans, flat bottom holes or side drilled holes at different depths may be used for TCG calibration. In such case customized block may be designed in accordance to client specification or reference documents. Else only back reflection based sensitivity calibration or focal law balancing would be enough.

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6.4.4.5 Encoder Calibration. ➢ Encoder calibration shall be performed by moving it to known distance and calibrate it according to operational manual. ➢ Calibration check shall be performed at intervals not to exceed one month or prior to first use thereafter, by moving the encoder a minimum distance of 20 in. (500 mm). The display distance shall be within 1% of the actual distance moved. ➢ Alternatively encoder resolution value may also be directly used as specified in user manual. 6.4.4.6 Sensitivity Reference Scan ➢ A reference scan over the scanner block shall be performed to demonstrate accurate sensitivity and coverage over the volume to be inspected. The sensitivity reference scan is performed on PA reference blocks (Figure-4). ➢ In case one or more reflectors are not visible, an extra scan or channel shall be made with optimum angle for detection of the desired reference reflector, using the same sensitivity. In this case a new scan plan shall be created and submitted to the level 3 for approval. The additional scan-plan shall be attached to the examination report and the procedure. ➢ For single sided inspections it is important that the reference scan is from one side of the centerline, to prove sufficient coverage and detection of flaws at both sides of bevel. In case one or more reflectors are not visible an extra scan or channel shall be made with optimum angle for detection of the desired reference reflector, using the same sensitivity. Minimum two different offset scans shall be performed in case of single sided inspections depending upon approved scan plan.. The sensitivity reference scans have to be performed: ✓ Prior to inspection with each set-up. ✓ During inspection after changing a probe and/or cable or battery. ✓ After 4 hours of inspection using the same setup. ✓ After finishing the inspection using a certain setup. The deviation between the measured sound path and the actual sound path may not exceed 10% of the distance reading or 5% of full sweep, whichever is greater, correct the distance range calibration and note the correction in the examination record. All recorded indications since the last valid calibration or calibration check shall be reexamined and their values shall be changed on the data sheets or re-recorded. If the amplitudes of the follow up reference scans deviates 2 dB or less from the initial reference scan, no further action is required and the setting may be corrected by the software. If the deviation is more than 2 dB, the system needs to be checked for malfunctioning components (e.g. element check), sensitivity calibration need to be redone and all tests carried out since the last valid check shall be repeated.

6.5 EXAMINATION. 6.5.1 Examination Techniques. The procedure explained in this document is applicable to the following raster and encoded linear examination techniques using linear array probe. 1) Single (fixed angle) is a focal law applied to a specific set of active elements for a constant angle beam, emulating a conventional single element probe.

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2) E-scan (also termed an electronic raster scan) is a single focal law multiplexed, across a grouping of active elements, for a constant angle beam stepped along the phased array probe length in defined incremental steps not more than two elements. 3) S-scan (also called a Sector, Sectorial, or Azimuthal scan) is the set of focal laws that provides a fanlike series of beams through a defined range of angles using the same set of elements. A sweep range shall not be greater than ± 200 of the refracted angle in specimen either normal or angle. In all phased Array examination techniques, probes are in direct contact with surface.

6.5.2 Surface Preparation The surface of the materials to be examined shall be cleaned and free from extraneous material such as loose scales, paint, irregular surface, and spatters or other foreign material that could interfere with the interpretation of the result. When the base material or weld surface interferes with the examination, the base material or weld shall be prepared as needed to permit the examination.

6.5.3

Identification of weld Examination Areas & Reference Marking

Each weld shall be located and identified by a system of reference points. Weld centerline shall be marked along with reference line markings for standoff distance(s) on scanning side(s). . The system shall permit identification of each weld centerline and designation of regular intervals along the length of the weld in clock wise direction. A general system for layout is shown in figure 1. An overlap of 50 mm min is required in each consecutive scans.

Figure 11: (LHS)Weld reference Marking (RHS) Phased Array Probe Skews (For Omni scan Equipment X & Y are 90 & 270 respectively whereas for TD Handy Scan X & Y are 0 & 180 respectively)

6.5.4

Scanning of base material

The area of the base material through which the sound will travel should be completely scanned with a straight-beam search unit to detect reflectors that might affect the interpretation of angle-beam results by obstructing the sound beam. Consideration must be given to these reflectors during interpretation of weld examination results, but their detection is not necessarily a basis for rejection of the base material.

6.5.5

SCAN SPEED OF PROBES

The scanning speed shall be chosen such that satisfactory images are generated. The scanning speed depends on averaging, scan increment, digitalization frequency, volume to be inspected and pulse repetition frequency. Missing scan lines are an indication that the scanning speed was too high. Scanning speed shall be such that data drop-out is less than 2 data lines per inch (25 mm) of the linear scan length and that there are no adjacent data line skips.

6.5.6

Data Acquisition

A-scan data shall be recorded for the area of interest in an unprocessed form with no thresholding, at a minimum digitization rate of five times the examination frequency, and recording increments of a maximum of

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▪ 0.04 in. (1 mm) for material < 3 in. (75 mm) thick ▪ 0.08 in. (2 mm) for material ≥ 3 in. (75 mm) thick. For encoded scan data shall be stored for each segment separately and the scan file shall contain that information. Data acquisited shall be analysed using softwares mentioned in 6.3.1 Table-2. Enhanced data processing features of respective softwares may be used for effective data interpretation and analysis including soft gain, scans merging, Palette colour adjustment etc.

6.5.7

Scanning.

➢ Typically scanning is carried out from the surfaces where the plate has been machined with the weld bevel. ➢ Where scanning is to be performed along the top or across this weld, the weld reinforcement may be ground to provide a flat scanning surface. The extent of examination shall be suitable to examine the volume of the weld plus the heat affected zone unless otherwise specified. ➢ Scanning may be by manual probe motion or automated or semi-automated motion. ➢ For manual scanning the primary scan pattern is a raster motion with the beam directed essentially perpendicular to the weld axis. The distance forward and backward that the probe is moved is determined by the scan plan to ensure full volume coverage. ➢ For manual scanning using phased arrays examination personnel shall use a real-time S-scan or B-scan display during scanning to monitor for coupling quality and signals exceeding the evaluation threshold ➢ For automated or semi-automated scanning the probe will be used with a positional encoder for each axis in which probe motion is required at a stand off distance maintained by using scanner. 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. Any other alternative Guide mechanisms may be used to ensure that the probe moves at a fixed distance from the weld centreline ➢ For transverse scanning The search unit is aimed essentially parallel to the weld centre line and moved along the weld so that the ultrasonic beam passes through the weld zone. Scanning is done in two directions essentially 180° to each other. Swiveling of the probe is not possible when using shaped wedges. As an alternate to line scanning, a manual angle beam examination may be performed for reflectors transverse to the weld axis.

6.6 DATA EVALUATION Upon completion of a scan, the unprocessed data shall be automatically digitally stored and data evaluation shall be offline.

6.6.1

CHARACTERIZATION

For workmanship based criteria, all reflectors exceeding 20% of the reference level shall be investigated to determine whether the reflection is caused by geometric indication or by a flaw (relevant or non-relevant). In case a reflection is determined as a flaw, then it shall be characterized (Crack, LOP, LOF, Pore, alignment fault & Slag etc.) based on depth, location, echodynamic and echo patterns and sized as per section 6.6.3. For fracture mechanics based evaluation indications shall be classified as surface or subsurface in accordance with 6.8.1 (see Figures 12,13,14,15,16).

6.6.2

GEOMETRIC INDICATIONS

Indications of geometric and metallurgical origin, which are determined to originate from surface configurations, (such as weld reinforcement or root geometry) shall be classified as geometrical and non relevant indications. This type of indications shall not be reported, but in case if it cannot be proven that the indication is geometric, then the reflection shall be considered as a flaw.

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Following steps shall apply for the verification of geometrical indications: ✓ A weld overlay shall be made for the applicable weld bevel configuration and wall thickness ✓ Determination of the actual position of the indication in combination with the weld overlay ✓ Determining whether it is a geometric indication or not by the position and shape of the indication

6.6.3

FLAW SIZING

Flaw sizing can be performed using a variety of industry accepted techniques, such as amplitude drop (e.g.6 dB or 20 dB Drop) techniques and/or tip diffraction techniques. Tip diffraction technique may be used for crack through-wall height sizing.

6.6.3.1 Flaw Length. Flaw lengths parallel to the surface can be measured from the distance encoded C-scan images using amplitude drop . In case the length of the indication is longer than the passive aperture, then the 6 dB drop method shall be used. If the length of indication is shorter than the passive aperture, then the 3 dB drop method shall be used.

6.6.3.2 Flaw Height. Flaw height normal to the surface can be measured from the B-, E-, or S-scan images using amplitude drop or tip diffraction techniques. The height of the indications shall be measured with the tip diffraction technique whenever possible. In case there’s no tip diffraction signal present, then the height shall be measured using the cursors in combination with the 3 dB amplitude drop method. (a) For amplitude base sizing See Table-5

(b) Using tip diffraction techniques the horizontal cursors are placed on the upper and lower tip signals of the displayed flaw. Table 5; Through Wall Height Measurement

Height is measured from top Root defects (lack of Surface Breaking Defects to bottom at -3 dB penetration) height is Actual Height = Projected measured from cross- height/2 point of indications to bottom of weld overlay

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6.7 POST EXAMINATION CLEANING Whenever required , it should be conducted as soon as practical after evaluation and documentation using cotton rags or a process that does not adversely affect the part.

6.8 ACCEPTANCE CRITERIA 6.8.1 Workmanship Criteria Imperfections which produce a response greater than 20% of the reference level shall be investigated to the extent that the operator can determine the shape, identity, and location of all such imperfections and evaluate them in terms of the acceptance standards given in (a) and (b) below. (a) Indications characterized as cracks, lack of fusion, or incomplete penetration are unacceptable regardless of length. (b) Other imperfections are unacceptable if the indications exceed the reference level amplitude and have lengths which exceed: (1) 1/4 in. (6 mm) for t up to 3/4 in. (19 mm); (2) 1/3t for t from 3/4 in. to 21/4 in. (19 mm to 57 mm); (3) 3/4 in. (19 mm) for t over 21/4 in. (57 mm). where t is the thickness of the weld excluding any allowable reinforcement. For a butt weld joining two members having different thicknesses at the weld, t is the thinner of these two thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be included in t .

6.8.2 Fracture Mechanics Based Criteria (Engineering Critical based Assessment) Flaw Sizing. The dimensions of the flaw shall be determined by the rectangle that fully contains the area of the flaw, and the flaw shall be classified as either a surface or subsurface flaw (see Figures 12,13,14,15,16). (a) The length, l , of the flaw shall be drawn parallel to the inside pressure-retaining surface of the component. (b) The measured flaw through-wall dimension shall be drawn normal to the inside pressure retaining surface and shall be defined as a for a surface flaw or 2a for a subsurface flaw. (c) Subsurface flaw(s) close to a surface shall be considered surface flaw(s) if the distance between the flaw and the nearest surface is equal to or less than one-half the flaw through-wall dimension, as shown in Figures 7.11 through 7.15.

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Surface

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Sub Surface

Figure 12 Single Indications

Figure 13: Surface and Subsurface Flaws

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Figure 14: Non-Aligned Coplanar Flaws in a Plane Normal to the Pressure Retaining Surface

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Figure 15 : Multiple Planar Flaws Oriented in a Plane Normal to the Pressure Retaining Surface

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Figure 16: Multiple Aligned Planar Flaws

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Flaws shall be evaluated for acceptance using the applicable criteria of Tables 4, 5, 6, , and 7 with the following additional requirements. (a) For surface connected flaws, the measured through-wall dimension, a, shall be compared to the value of a as determined from the applicable flaw acceptance criteria tables. (b) For subsurface flaws, the measured through-wall dimension, 2a, shall be compared to twice the value of a as determined from the applicable flaw acceptance criteria tables. Table 6 Flaw Acceptance Criteria for Welds Between Thicknesses of 6 mm (1/4 in.) and < 13 mm (1/2 in.)

Table 7 : Flaw Acceptance Criteria for Welds With a Thickness Between 13 mm (1/2 in.) and Less Than 25 mm

Table 8 : Flaw Acceptance Criteria for Welds With Thickness Between 25 mm (1 in.) and Less Than or Equal to 300 mm

6.8 EXAMINATION RECORDS AND REPORT. For each ultrasonic examination, the following information shall be identified and recorded as a minimum: a) Procedure identification and revision b) Ultrasonic examination system (equipment identification and serial no) c) Search unit identification including type, serial no, number and element size, pitch and gap dimensions. d) Focal law parameters, including angle, focal depth and elements used

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e) f) g) h) i) j) k) l) m) n) o) p) q) r) s)

Beam angles used for both linear and sectorial scans Couplant used, brand name or type Search unit cables used, type and length Computerized programme identification and revision, if any Calibration block identification Equipment reference gain Damping and reject setting whenever used Calibration data (including reference reflector, indication amplitudes and distance reading) Identification and location of welds or volume scanned Surface from which examination conducted Map or record of indications detected or areas cleared Areas of restricted access or inaccessible welds Examination personnel identity and level if required by referencing code section Date of examination All system calibration, settings and phased array ultrasonic examination raw data shall be electronically recorded, stored and handed over to contractor/ client for permanent archival t) Non-rejectable indications shall be recorded as per referencing code section u) Rejectable indications shall be recorded as a minimum, the type of indication (surface, embedded etc), location and extent shall be recorded. v) The report shall include a record indicating the weld(s) or volume examined, and the location of each reflector w) The report shall be filed and maintained in accordance with the referencing code section

7.

ANNEXES. Annex I: Equipment Calibration Procedure Annex II: Phased Array Probe Element Check Annex III: Phased Array Report Annex IV: Equipment Calibration Sheet Annex-V : Scan Plan for 30 mm Butt Weld Annex-VI: Scan Plan for Nozzle to Shell Joint

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Annex-1 Equipment Calibration Procedure 1. Element Check. This assessment is used to determine that all elements of the phased array probe are active and of uniform acoustic energy. Because, during normal operation in a timed sequence, each of the elements is addressed by a separate pulser and receiver, a method must be used that ensures the electronic performance of the phased-array instrument is identical from element to element and any differences are attributable to the probe itself. To ensure that any variation of element performance is due only to probe construction, a single pulser- receiver channel is selected to address each element. The Phased Array Transducer Element Check shall be performed: • • • • • •

•

• • •

Prior to using any new search unit, Whenever the inspector suspects transducer operability, and At a minimum of at least once per month. Connect the phased array probe to be tested to the phased-array ultrasonic instrument and remove any delay line or refracting wedge from the probe. Acoustically couple the probe to any acoustically sound piece of material with a unirofrm thickness, with a uniform layer of couplant. Configure an electronic scan consisting of one element that is stepped along one element at a time for the total number of elements in the array. (This should ensure that the pulserreceiver number 1 is used in each focal law or if the channel is selectable it should be the same channel used for each element). Set the pulser parameters to optimize the response for the nominal frequency of the probe array and establish a pulse-echo response from the block back wall to 80 % display height for each element in the probe. Observe the A-scan display for each element in the array and record the receiver gain required to achieve the 80 % signal amplitude for each element. Results shall be recorded on form “SP-PATM-01Phased Array Probe Element Check Form”. Note and record any elements that do not provide a backwall signal (inactive e l e m e n t s ). Results shall be recorded on form “SP-PATM-01Phased Array Probe Element Check Form”. Data collected is used to assess probe uniformity and functionality. The receiver gain to provide an 80 % response for each element should be within a range of +/-6 dB of each other.

2. Time-Base Linearity (Horizontal Linearity). • Configure the phased array instrument to display an A-scan presentation. • Select any compression wave probe and configure the phased-array instrument to display a range suitable to obtain at least ten multiple back reflections from a block of a known thickness.

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•

• • •

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With the probe coupled to the block and the A-scan displaying 10 clearly defined multiples, the display software is used to assess the interval between adjacent back wall signals. Acoustic velocity of the test block is entered into the display software and the display configured to read out in distance (thickness). Using the reference and measurement cursors determine the interval between each multiple and record the interval of the first 10 multiples. Acceptable linearity on the multiples shall not exceed +/-0.5 mm for a steel plate.

3. Display Height Linearity. With the phased array instrument connected to a probe (shear or longitudinal) and coupled to any block that will produce two signals as shown in Figure 1, adjust the probe such that the amplitude of the two signals are at 80 % and 40 % of the display screen height.

Figure 1: Display Height Linearity •

Increase the gain using the receiver gain adjustment to obtain 100 % of full screen height of the larger response. The height of the lower response is recorded at this gain setting as a percentage of full screen height.

•

The height of the higher response is reduced in 10 % steps to 10 % of full screen height and the height of the second response is recorded for each step.

•

Return the larger signal to 80 % to ensure that the smaller signal has not drifted from its original 40 % level due to coupling variation. Repeat the test if variation of the second signal is greater than 41 % or less than 39 % FSH. For an acceptable tolerance, the responses from the two reflectors should bear a 2 to1 relationship to within +/-3 %of full screen height throughout the range 10 % to 100% (99 % if 100 % is saturation) of full screen height.

•

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4. Amplitude Control Linearity. • A 16 or 32/128 phased-array instrument has 16 or 32 respectively pulsers and receivers that are used to address up to 128 elements. Each of the pulser-receiver components must be checked to determine the linearity of the instrument amplification capabilities. • Select a flat (normal incidence) linear array phased array probe having at least as many elements as the phased array ultrasonic instrument has pulsers. (i.e. A 16 or 32 element probe must be used for a 16 or 32/128 phased array instrument) • Using this probe, configure the phased-array ultrasonic instrument to have a linear scan. Each focal law will consist of one element and the scan will start at element number 1 and end at the element number that corresponds to the number of pulsers in the phasedarray instrument. (i.e. Linear scan, start element of 1, element quantity of 1, last element of 16 ot 32, angle of 0) • Couple the probe to a suitable surface to obtain a pulse-echo response from each focal law. • Select Channel 1 of the pulser-receivers of the phased-array instrument. Using the A- scan display, monitor the response from the selected target. Adjust the gain to bring the signal to 40 % screen height. • Add gain to the receiver in the increments of 1 dB, then 2 dB, then 4 dB and then 6 dB. Remove the gain added after each increment to ensure that the signal has returned to 40 % display height. Record the actual height of the signal as a percentage of the display height. • Adjust the signal to 100 % display height, remove 6-dB gain and record the actual height of the signal as a percentage of the display height. • Signal amplitudes should fall within a range of +/-3 % of the display height required in the allowed height range (as seen on form “SP-PATM-01 Phased Array Instrument Linearity Checks”). • Repeat the sequence from 6.4.5 to 6.4.8 for all other pulser-receiver channels.

Annex-II: PA Probe Element Check

AMPLITUDE (%)

Probe 1

2

3

4

5

Checking Date 6 7 8 9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

262

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

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Annex-III PHASED ARRAY REPORT

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Annex-IV: Equipment Calibration Sheet LINEARITY VERFICATION REPORT FORM Location: Date: Operation: Signature: Instrument: Couplant: Pulser Vlotag (V): Receiver(band): Receiver smoothing: Digtization Frequency (MHZ): Averaging: Display Height Linearity Amplitude Control Linearity Large (%) Small Allowed Range Small Actual Ind. Height dB Allowed Range (%) 100 45-53 40 +1 42-47 90 42-48 40 +2 48-52 80 40 40 40 +4 60-66 70 32-38 40 +6 77-83 60 27-33 40 -6 47-53 50 22-28 40 17-23 30 12-18 20 7-13 10 2-8 Amplitude Control Linearity Channel Results: (Note any channels that do not fall in the allowed range) Channel (Add more if required for 32 or 64 pulser-reciever units) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

17

18

19

20

21

22

23

Time Base Linearity (for 25 –mm IIW blocks) Multiple 1 2 Thickness 25 50 Measured Interval Allowed deviation ±0.5 mm (Yes/No)

24

3 75

25

4 100

26

5 125

27

28

6 150

29

7 175

30

8 200

31

9 225

16

32

10 250

Confidential: Not to be copied without the permission of the Services Head (Industrial Services)

TECHNICAL PROCEDURE

SGS Qatar WLL - INDIV

PROCEDURE FOR ULTRASONIC PHASED ARRAY EXAMINATION (Welds & Base Materials)

Page : 33 of 35 Issue date : 20.05.2019 Doc. No.:SGSQA-INDIVSOP-009 Revision no. : 00 Author : Tejas Chandegra Approved by: Arsalan Ul Haq

Annex-V SCAN PLAN FOR 30 mm BUTT WELD with one side Access

Confidential: Not to be copied without the permission of the Services Head (Industrial Services)

TECHNICAL PROCEDURE

SGS Qatar WLL - INDIV

PROCEDURE FOR ULTRASONIC PHASED ARRAY EXAMINATION (Welds & Base Materials)

Page : 34 of 35 Issue date : 20.05.2019 Doc. No.:SGSQA-INDIVSOP-009 Revision no. : 00 Author : Tejas Chandegra Approved by: Arsalan Ul Haq

Annex-V: SCAN PLAN FOR 30 mm Nozzle to Shell Joint

Confidential: Not to be copied without the permission of the Services Head (Industrial Services)

TECHNICAL PROCEDURE

SGS Qatar WLL - INDIV

PROCEDURE FOR ULTRASONIC PHASED ARRAY EXAMINATION (Welds & Base Materials)

Page : 35 of 35 Issue date : 20.05.2019 Doc. No.:SGSQA-INDIVSOP-009 Revision no. : 00 Author : Tejas Chandegra Approved by: Arsalan Ul Haq

Confidential: Not to be copied without the permission of the Services Head (Industrial Services)