006 Procedure Phased Array
006 Procedure Phased Array
Nidhin Venkatesh
Rev. Rev. Date Description Prepared By Reviewed By Approved By
ASIC OFFSHORE & MARINE SDN.BHD. Lot G02-G07, Level 3,
Platinum Sentral, Jalan Stesen Sentral 2, Kuala Lumpur Sentral 50470 Kuala Lumpur,
MALAYSIA Tel.: (+603) 2721 2183 | Fax: (+603) 2721 2184 | Website: www.asicoffshore.com
INDEX
DESCRIPTION PAGE
COVER PAGE
CONTENTS 2
SECTION
1.0 INTRODUCTION 3
1.0 INTRODUCTION
This procedure defines the requirements of semi-automated and manually encoded Phased Array
ultrasonic examination Seam Welds +1.6 mm of adjacent parent material.
- ASNT SNT-TC-1A, Recommended Practice for Training, Qualification and Certification of NOT
Personnel, 2011
- ASNT CP-189, ASNT Standard for Training, Qualification and Certification of NOT Personnel, 2011
- API 5L Specification for Line Pipe Forty Fifth Edition, 2012
- ASME Section V Art IV, Non-destructive Examination, 2013
3.2
Definitions and Abbreviations
ASTM
American Society for Testing Materials
ASME
American Society of Mechanical Engineers
API
American Petroleum Institute
BS/ EN
British Standards/ European Norms
PA
Phased Array Ultrasonic Inspection
PE
Pulse Echo Ultrasonic Conventional
ASIC OFFSHORE & MARINE SDN.BHD. Lot G02-G07, Level 3,
Platinum Sentral, Jalan Stesen Sentral 2, Kuala Lumpur Sentral 50470 Kuala Lumpur,
MALAYSIA Tel.: (+603) 2721 2183 | Fax: (+603) 2721 2184 | Website: www.asicoffshore.com
A-SCAN - An ultrasonic waveform plotted as amplitude with respect to 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 file.
PHASED ARRAY - An ultrasonic technique utilizing multi element probes for electronic scanning.
TIME CORRECTED GAIN (TCG) - An electronically generated correction for depth in relation to
amplitude used to equalize responses from a known 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
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 ASICS shall be advised. The base material or weld
shall be prepared as needed to permit examination.
Each weld designated for inspection shall be marked with a reference index and/or position numbers
marked on the examination surface during initial examination. If welds are to be permanently marked,
low stress stamps or vibra-tools may be used such that the marks are not deeper than 1mm.
Longitudinal Weld measurements shall run from a zero reference position as marked prior to
inspection. Refer below for Schematic of typical layout of datum’s.
Sketches and Drawings should be used to aid in uniquely identifying the welds marked up for
inspection.
Datum points shall be consistent for all of the Welds designated for Phased Array inspection.
ASIC OFFSHORE & MARINE SDN.BHD. Lot G02-G07, Level 3,
Platinum Sentral, Jalan Stesen Sentral 2, Kuala Lumpur Sentral 50470 Kuala Lumpur,
MALAYSIA Tel.: (+603) 2721 2183 | Fax: (+603) 2721 2184 | Website: www.asicoffshore.com
6.0 EQUIPMENT
This procedure shall use the 32/128 Element omni Scan phased array ultrasonic inspection unit
exclusively. The ultrasonic flaw detection instrument shall be used in the pulse echo or pitch-catch
mode with an A-Scan presentation used for calibration. Unit display shall be capable of composite B
Scan, C- Scan, 0- Scan, and S- Scan formats.
ASIC OFFSHORE & MARINE SDN.BHD. Lot G02-G07, Level 3,
Platinum Sentral, Jalan Stesen Sentral 2, Kuala Lumpur Sentral 50470 Kuala Lumpur,
MALAYSIA Tel.: (+603) 2721 2183 | Fax: (+603) 2721 2184 | Website: www.asicoffshore.com
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 (DAG) curve.
The Phased Array equipment shall be capable of recording and saving all inspection data for offline
analysis to be performed.
The HSMT scanners are capable of acquiring data using multiple transducers, it is configured to allow
each pair of transducers to acquire and transfer the data to the omni scan system. The data is to
include set-up parameters of the transducer(s), positional "offsets" and technique type, scanner
movement and encoder output values. HSMT scanners shall be used with chain guide to ensure
correct offsets are maintained during each scan performed.
Search units used for weld examinations shall operate at a frequency between 2 MHz and 1 O MHz.
either phased array or single element probes may be used. Phased array linear array configurations
shall have 16 elements or more having element width of 6mm to 15mm. Element spacing will be
search unit design specific and based on the calculations for element pitch to provide beam steering of
+/- 20°. For typical shear wave applications, the phased array probe will be placed on a refracting
wedge of suitable material and refracting angle as to be compatible with the requirement to provide
beam steering of +/- 20°.
Phased Array Angles outside Manufacturers Specification may be used but must be detailed in the
Specific Technique Sheet and Validated with specific Blocks.
6.2.3 Couplant
A suitable Couplant such as Polygell or water having good wetting characteristics shall be used
between probe and examination surface. The Couplant shall not be detrimental to the material being
examined.
Same type of couplant shall be used for calibration and examination.
Weld inspections using the OmniScan MX2 shall be calibrated using standard calibration blocks and
blocks fabricated from material that is acoustically similar to that being inspected and which has 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.
Calibration blocks are of 2 types i.e. range setting calibration blocks and sensitivity setting calibration
blocks.
Other range setting blocks may be used provided they are demonstrated to provide the accuracy
required for the materials examined.
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.
ASIC OFFSHORE & MARINE SDN.BHD. Lot G02-G07, Level 3,
Platinum Sentral, Jalan Stesen Sentral 2, Kuala Lumpur Sentral 50470 Kuala Lumpur,
MALAYSIA Tel.: (+603) 2721 2183 | Fax: (+603) 2721 2184 | Website: www.asicoffshore.com
As per API 5L the Sensitivity setting (Notch N5) shall be as follows; Depth maximum 5%t (±15%) with
minimum wall thickness of (0.3mm ±0.005mm), width 1.0mm Maximum and a length of 50mm
Maximum.
7.0 CALIBRATION
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 OmniScan. The
results of these checks are recorded in the Ultrasonic Instrument Linearity Report forms (see standard
practice for Verification of OmniScan MX2 Linearity Performance) and are kept as part of the Inspection
Record.
7.1.1.1 Screen Height Linearity - The OmniScan instrument shall provide vertical amplitude presentation linear
to within+/- 3% of full screen height over the range 10% to 100% of full screen height. The method for
evaluating screen height linearity is outlined in standard practice for Verification of OmniScan Linearity
Performance.
7.1.1.2 Amplitude Control Linearity (Calibrated Gain Control) - The accuracy of amplitude control on the omni
Scan instrument is verified. The method for evaluating amplitude control linearity is outlined in standard
practice for Verification of omni Scan Linearity Performance.
7.1.1.3 Sweep Range Linearity (Horizontal Linearity) - The ultrasonic instrument must provide sweep range
linearity accurate to +/-2% of the total base line. The method for evaluating sweep range linearity is
outlined in standard practice for Verification of Omni Scan Linearity Performance.
Because the Omni 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. As
well, probes using curved wedges to fit the diameter of pipes, and components will not permit
measurements of nominal angle and exit points using the standard calibration blocks (IIW and DIN-54)
as they cannot be used on flat surfaces. Standard Practice for Verification of Performance of Probes
ASIC OFFSHORE & MARINE SDN.BHD. Lot G02-G07, Level 3,
Platinum Sentral, Jalan Stesen Sentral 2, Kuala Lumpur Sentral 50470 Kuala Lumpur,
MALAYSIA Tel.: (+603) 2721 2183 | Fax: (+603) 2721 2184 | Website: www.asicoffshore.com
used with omni Scan will be used as appropriate to assess the suitability of the probe and focal laws
applied to phased array probes. Guidance for Probe Performance is also found in this Standard
Practice for assessment of single element probes when used with the omni Scan phased array
ultrasonic instrument.
The OmniScan is calibrated for each examination specified on the detailed technique for both range
and signal amplitude.
a) Range setting for both shear and longitudinal wave examination is detailed in Standard Practice for
Setting Range using Omni Scan.
b) Time Corrected Gain is applied as detailed in Standard Practice for Distance Amplitude Correction
using Omni Scan.
A system calibration confirmation shall be used to verify the sweep range calibration and DAC and or
TCG curve at the start and finish of each examination and at a minimum of once each day during an
examination session using the appropriate calibration block
Any change in search units, shoes, couplants, cables, ultrasonic instruments, personnel or other parts
of the examination system is cause for a calibration check.
a) The sensitivity control settings are adjusted to match those recorded for the calibrated reference
sensitivity of the middle focal law of a single angle Phased Array scanning technique or the single
element probe for non-phased array probe applications.
b) The search unit is positioned to detect the first and last points on the TCG/DAC using the reference
reflectors on the appropriate basic calibration block. The maximum signal response amplitudes and
horizontal sweep positions are observed.
c) If either point along the time base using the TCG/DAC 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 re-examined.
d) If any point along the time base using the TCG/DAC 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.
e) 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.
Loss of sound transmission due to surface geometry, or surface condition (roughness or coatings), can
be compensated using a transfer value. Transfer value shall be determined using Standard Practice for
Determining Acoustic Compatibility using omni Scan, if required, based on acoustic differences
between calibration specimen and component for inspection.
Any difference between the transfer value obtained on the basic calibration block and the test piece is
added to the Primary Reference and this noted in the report. If a negative dB value results from the
transfer value determination, no adjustment to the primary Reference shall be made.
For contact examination, the temperature differential between the calibration block and the examination
0
surface shall be within +/-15C •
Instrument Controls
Any controls affecting the linearity of the instrument shall be in the same position for calibration,
calibration checks, instrument linearity checks and examinations.
7.7 Encoding
Automated scanning shall use position encoders that are verified to provide position accuracy of scans
within +/-1mm in 100mm of scan length. All encoders shall be verified daily to be correctly calibrated.
Moving the scanning apparatus over a fixed distance (e.g. 150mm) 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 2mm over 100mm of actual travel. Encoders failing
to maintain this tolerance shall be re-calibrated.
Each weld configuration has its own individual technique that describes in detail the type and extent of
the examination. Techniques will be described using the format detailed in Standard Practice for
Technique Layout and omni Scan parameters.
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 weld preparation for a minimum distance of
one-half the material thickness or 25 mm, whichever is less.
The weld zone is defined as the weld and the base metal up to 1.6mm (Heat Affected Zone - HAZ),
from the edge of the final weld preparation, as illustrated in Figure 1. The base material on either side
of the inspection area of 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.
When required overlapping manual raster scanning shall be performed ensuring 20% overlap as a
minimum.
Final Scan Plan layouts may be adjusted based on site weld configuration.
ASIC OFFSHORE & MARINE SDN.BHD. Lot G02-G07, Level 3,
Platinum Sentral, Jalan Stesen Sentral 2, Kuala Lumpur Sentral 50470 Kuala Lumpur,
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Non-Relevant Indications
Signals which are determined to result from 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 characterized as indications nor compared with allowable indication standards.
They are clearly identified, located, and recorded in the Inspection Record for future reference.
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 results. PA scanning
may be used to aid in discriminating between flaws and geometric reflectors where surface scanning
areas permit. When PA is carried out, guidance on its use shall follow the instructions in BS7706.
Every "root" indication shall be carefully examined to determine its nature (crack/ LOF /LOP/
geometrical).
Manual or Semi- Automated Phased Array Sectorial axial scanning (0° and 180°) shall be performed to
the entire weld length subject for inspection. Restrictions due to geometries and surroundings shall be
reported.
8.1.4 Recording
a) General
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 API 5L notch is set to 100% full screen height at the required
beam path distance.
Omni 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 digitization rate is set to at least 5
times the nominal frequency of the probe used 1. Actual digitization settings shall be specified in the
Technique.
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 2 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, and the status of the inspection
(accept/reject) with pertinent indications noted if repairs are required. Images of the unacceptable
indications shall form part of the inspection report. Snaps in the form of one or all of the following
"S", "C" and "D" scan images incorporated with weld overlays shall note the location of the
unacceptable indication. Refer appendix 4 for Typical Images required.
The site examination record data file shall be kept on file with the Ultrasonic Inspection Data
Record Sheet.
The examination equipment shall be calibrated as described in item 8.0 herein to verify linearity and set
range and sensitivity.
Calibration checks are performed when required as outlined in item 8.0 herein.
Scanning of all welds is performed at a gain setting equal to the Primary Reference Sensitivity of API
5L notch at 100% +6db as a minimum. A compensation value of 4db between the coated and uncoated
pipe surface is to be used.
The probe is directed at 90° to the weld center line and mechanically or manually moved so that the
ultrasonic beam passes through all of the inspection area. This is accomplished by an electronic raster
or S-scan. 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.
All A-scan waveforms shall be recorded using a digitization not less than 5 times the nominal frequency
of the probe. Recording shall be in the form of a data file and evaluation of the scan results shall be
made using B-scan or S-scan and C-scan projections with color pallets that allow the operator to
discriminate between signals above or below the evaluation threshold.
Only reflectors that produce a response greater than 100% above the reference level shall be
recordable as per API 5L.
The dimensions of the flaw shall be defined by the rectangle that fully contains the area of the flaw. The
length (I) of the flaw shall be drawn parallel to the inside pressure retaining surface.
If the space between the surface and the flaw through wall thickness direction is less than one half the
measured height of the flaw, then the flaw shall be characterized as a surface flaw with the height
extending to the surface of the material.
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.
ASIC OFFSHORE & MARINE SDN.BHD. Lot G02-G07, Level 3,
Platinum Sentral, Jalan Stesen Sentral 2, Kuala Lumpur Sentral 50470 Kuala Lumpur,
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The omni Scan has an internal memory capacity of 20 Gigabytes which caters for inspection scans
involving large memory files. Where required an external hard drive may be fitted to increase the
storage capacity.
A Phased Array Ultrasonic signal that produces a signal greater than the acceptance limit given in
Table 3 below shall be considered an Imperfection.
Flaw dimensions shall be evaluated for acceptance using the criteria of table 3 below.
10 DATA STORAGE
10.0 Once data has been collected it should be given a unique name.
10.1 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 60MB. Two copies should be taken, one as the archive and one as the backup.
10.2 Once copied the data shall be re-assessed to check that it has been copied correctly.
10.3 The storage medium shall be given a unique serial number, which is registered in the data logbook.
10.4 Once the data has been checked the original files can be removed from the system's disk.
10.5 The archive disk and backup disk shall be stored in two separate storage cabinets.
10.6 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.
Weld Dimensions:
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12.0 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.