DOCUMENT QUALITE PQ-END-PAUT-C001

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GENERAL PROCEDURE FOR PHASED ARRAY CORROSION

MAPPING WITH THE OMNISCAN MX2 SYSTEM USING
SCANNER

0 27-11-2023 Issued for Review O. Kellil M. Baba Amer

Rev Date Description Revision Prepared by Reviewed by Approved by

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Contents

1. Introduction..........................................................................................................................................4

2. Reference Documents .........................................................................................................................4

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

4. Equipment............................................................................................................................................5

4.1. Temperature......................................................................................................................................5

4.2. Scanner..............................................................................................................................................5

4.3. Apparatus .........................................................................................................................................6

4.4. Couplant...........................................................................................................................................6

4.5. Equipment Check .............................................................................................................................6

4.6. Screen Height Linearity.....................................................................................................................6

4.7. Amplitude Control Linearity ............................................................................................................7

4.8. Time Base Linearity ..........................................................................................................................8

5. General Requirements ........................................................................................................................8

6. Calibration and Settings.......................................................................................................................9

6.1. Calibration Block ..............................................................................................................................9

6.2. Straight Beam Probe.........................................................................................................................9

6.3. Sensitivity setting ...........................................................................................................................10

6.4. General Settings..............................................................................................................................10

6.5. Velocity Calibration.........................................................................................................................10

6.6. Wedge Delay Calibration.................................................................................................................10

6.7. Sensitivity Calibration .....................................................................................................................10

6.8. TCG Calibration ...............................................................................................................................11

6.9. Calibration Check ............................................................................................................................11

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6.10. Probe Element ...............................................................................................................................11

6.11. Encoder Calibration ........................................................................................................................11

7. Examination Coverage & Scanning ......................................................................................................12

8. Datum Points ......................................................................................................................................12

9. Test Details .........................................................................................................................................12

10. Evaluation .........................................................................................................................................13

11. Acceptance Criteria ..........................................................................................................................13

12. Reporting .........................................................................................................................................13

13. Safety Requirements ........................................................................................................................20

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1. Introduction
This procedure describes the general requirements for performing scanner or Manual encoded phased
Array Ultrasonic Inspection for quality assessments of pressure vessel, piping & storage tanks in
compliance with the specific code requirements.

2. Reference Documents
VMW-2-OP-007 Rev.6 - Velosi's Procedure for Ultrasonic Inspection and Calibration of Ultrasonic Flaw
Detector

SNT-TC-1A-2011 - Recommended Practice No. SNT-TC-1A - Non-Destructive

Testing, 2011 Edition

ASME Section V (2015) - Non-destructive Examination.

ASME SEC VIII Div. 1 ED 2015 - Rules for construction of pressure vessels

ASME SEC VIII Div. 2 ED 2015 - Alternate Rules for construction of pressure vessels

ASME B31.3 ED 2014 - Process Piping

ASME Sec V, Article 23, SE-2700

(2013 Edition) - Standard Practice for Contact Ultrasonic Testing of Welds Using

Phased Arrays

ASME B31.3 (2014 Edition) - Process Piping

ASME B31.3 CASE 181

(2014 Edition) - Use of Alternative Ultrasonic Examination Acceptance Criteria

in ASME B31.3.

L3-MYS-028(Rev0) - Ultrasonic Testing Procedure for Weld Inspection

Other related code cases would be referred to the specific inspection method.

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3. Personnel Qualifications
The work shall be performed by two technicians, both with the following qualification as a minimum: 1)
UT NDT Level II (ASNT/PCN/CSWIP) 2) UT NDT Level I (ASNT/PCN/CSWIP) UT Level II Inspector will carry
out the data capturing, data verification and evaluation with a minimum additional training of 40 hours
using the equipment and the associated software. The personnel shall be able to demonstrate their
ability to correctly use the equipment in compliance with this procedure.

4. Equipment
EQUIPMENT PROBE WEDGE SOFTWARE SCANNER ENCODER
OLYMPUS EQUIPMENT:
OmniScan MX2 MXU 4.3 POST
32/128 PROCESSING:
TOMOVIEW
2.10 or
relevant

All equipment shall be checked for satisfactory performance prior to deployment and use. The
equipment has sampling rate (A-scan) at least 6 times the nominal probe frequency and above than
100MHZ. The equipment shall be calibrated on an annual basis and record of calibration shall be always
kept for reference.

4.1. Temperature

The surface temperature of the material under examination shall be in the range of 0 – 50 ◦C.

4.2. Scanner

Semi-automated scanner shall use for pipes with correct adapter based on the curvature.

4.3. Apparatus

Interpretation of inspection data shall be performed using OMNIPC software or machine itself. ES Beam
Tool or setup builder shall be used as a tool to determine coverage of interest area (scan plan).

4.4. Couplant

The coupling medium to be used shall be chosen to suit the test surface conditions, profile &
temperature.

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A water-based cellulose paste or an ISG approved proprietary ultrasonic couplant shall be used unless it
is deemed to be more convenient or effective to use an alternative substance such as oil, grease or
gelatin-based compound.

The same couplant shall be used for both calibration and subsequent testing on surfaces 50°C (122° F) or
less.

Test surfaces with higher temperatures will require an approved high-temperature couplant (or grease)
and be used in conjunction with high temperature probes as appropriate

4.5. Equipment Check

Ultrasonic equipment used for the phased array testing should be in accordance with the requirements
of ASME Section V article 4 where applicable. Deviation and tolerance shall be within the criteria
mentioned in this standard, any deviation exceeding the tolerance, the equipment shall not be used. The
equipment thus used must be calibrated at 12 months interval.

4.6. Screen Height Linearity

Screen height linearity shall be checked as per ASME Sec.V, Article 4, and clause T- 461.1. Position an
angle beam search unit on a calibration block, as shown in Fig 1 so that indications from both the ½ and
¾ T Holes give a 2:1 ratio of amplitudes between the two indications. Adjust the sensitivity (gain) so that
the larger indication is set at 80% of full screen height (FSH). Without moving the search unit, adjust the
gain to successively set the larger indication from 100% to 20% of full screen height, in 10% increments
(or 2dB steps if a fine control is not available), and read the smaller indication at each setting. The
reading shall be 50% of the larger amplitude, within 5% of full screen height. The setting and readings
must be estimated to nearest 1% of full screen height. Alternatively, a straight beam search unit may be
used on any calibration block that provides amplitude differences, with sufficient signal separation to
prevent overlapping of the two signals

Figure 1: Linearity

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4.7. Amplitude Control Linearity

Amplitude control linearity shall be checked as per ASME Sec.V, clause T-461.2. Couple an angle beam
probe to IIW – V1 block and get multiple echoes from 100mm quadrant. Select any echo and note its
amplitude. Reduce the gain by 6 dB and read the amplitude of same indication. It must be 50% of the
initial amplitude within 20 % of the nominal amplitude ratio. Perform this exercise for full range of the
gain.

The settings and readings must be estimated to the nearest 1% of full screen and the readings shall be as
shown in the following table. The Amplitude control linearity shall be checked for each pulser receiver
circuit.

AMPLITUDE CONTROL LINEARITY

INDICATION SET AT % OF FULL dB CONTROL CHANGE INDICATION LIMITS % OF FULL

SCREEN HEIGHT SCREEN HEIGHT
80 % - 6 dB 32 to 48 %
80 % -12 dB 16 to 24 %
40 % + 6 dB 64 to 96 %
20 % +12 dB 64 to 96 %

4.8. Time Base Linearity

Configure the phased array instrument to display an A-Scan presentation using a 10 in range. Select any

longitudinal (compression) wave probe and configure the phased- array instrument to display a range
obtaining at least ten multiple back reflections from the 1 in wall thickness of the calibration block. With
the probe coupled to the block and the A-Scan displaying 10 clearly defined multiples as illustrated in
Figure below, use the display software to assess the interval between adjacent backwall signals.
Determine the acoustic velocity of the test block by calibration, enter the acoustic velocity in the display
software, and configure the display to read out in thickness / distance.

Using the reference and measurement cursors, determine the interval between each multiple and record
the interval of first 10 multiples. Each trace deflection shall be correct within 2% of the screen width.

5. General Requirements

The authorization to work at each location is the responsibility of the client. However, the inspection
personnel must ensure that the client’s safety regulations are adhered to at all times.

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The instrumentation included in this procedure is not intrinsically safe and thus should only be deployed
in a hazardous environment under the client’s permit to work system. Access, scaffolding, lighting, shade
etc. should be addressed prior to the start of the inspection.

All inspection surfaces should be free from loose scale, rust, weld spatter, indentations or any other
surface condition, which may affect the free passage of the probes over the surface or interfere with the
transmission of the ultrasound into the material. Long seam and circumferential seam intersections shall
be ground flushed to accommodate scanner/probe movement and sound transmission. If the long seam
and circumferential seam intersections unable to ground flush due to some reasons the inaccessible area
shall be highlighted in the inspection report.

Transfer correction may be used to compensate for the sound energy difference between the calibration
blocks and production welds due to weld geometry and scanning surface. All weld cap to be ground flush
to facilitate PAUT for Ferrite steel (if required based on circumstance).

The senior operator should be satisfied with the surface that it does not affect properties of the material
and it does not degrade the ultrasonic signals as affect the integrity of the examination.

Prior to commencement of the project/ job the following information should be agreed between the
contracting parties:

• The system for classification and/ or acceptance of flaws

• Technician's qualification papers

6. Calibration and Settings

Calibration details will be generated by the Omni-scan MX2 software and will be attached together with
the final inspection report.

6.1. Calibration Block

Calibration blocks and Reference block used for equipment calibration and standardization shall be one
or more of the followings: -

a) Step wedge

b) TCG block

The calibration block is made as per ASME SEC V satisfying the minimum requirement as follows:

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6.2. Straight Beam Probe

Calibration sensitivity shall be with reference to 1st back wall echo to 75% at full screen height at the
respective calibration block and scanning sensitivity with reference to 2nd back wall echo to 75% at full
screen height on surface adjacent to the weld. Any finding will be reported to the client / owner.

6.3. Sensitivity setting

If any sensitivity setting has changed by more than 20% or 2 dB of its amplitude, correct the sensitivity
calibration and note the correction in the examination record. If the sensitivity setting has decreased, all
data sheets since the last valid calibration check shall be marked void and the area covered by the voided
data shall be re-examined, if the sensitivity setting has increased, all recorded indications since the last
valid calibration or the calibration check shall be re-examined and their values shall be changed on the
data sheets or re- recorded. (As per T467.3.2)

6.4. General Settings

Straight beam and angle beam shall be calibrated as per ASME Sec V. Carbon Steel: Using V1/ V2 /
reference block correctly set material velocity:

• Longitudinal Wave: 0 deg probe

• Shear Wave: Angle Beam probe

6.5. Velocity Calibration

The velocity of the signal is to be calibrated at (Tolerance of ±5%):

i. Carbon steel at 3240mm/s (shear)& 5920mm/s (Compressional)

ii. Stainless steel at 3130mm/s (shear)& 5800mm/s (Compressional)

6.6. Wedge Delay Calibration

The delay resulting from the signal through the wedge is to be calibrated. The total wedge delay is
adjusted if needed, in order to reduce a systematic depth, offset of the reflectors, if any.

6.7. Sensitivity Calibration

Sensitivity calibration normalizes the gain for all focal laws so that it produces signal with similar
amplitude for the reference reflector.

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6.8. TCG Calibration (manual TCG recommended )

TCG calibration is designed to equalize the amplitude of all A-scans or focal laws in the group over the
sound path range with a series of calibration targets. The TCG calibration uses the same interface as the
sensitivity calibration with the exception that it does not allow a negative gain correction and it can be
used on successive Calibration targets by moving gate A to the next target. TCG calibration shall be
perform using calibration block which is make in accordance with ASME requirements.

As per 1.2.2, TCG shall be set at 80% full screen height as per image below

6.9. Calibration Check

Calibration check shall be performed before commencement of a test. When any part of the examination

system is changed, a calibration block check shall be made on the calibration block to verify any changes
of values. Such Changes may include:

a) Changes of probe

b) Power Failure

c) Manipulation of any other settings on the equipment with the exception to the

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6.10. Probe Element

1. Connect the probe.

2. Configure an electronic scan along on element at a time for the total number of elements in the array.

3. Set the pulser parameters to optimize the response for the nominal frequency of the probe.

4. Establish a pulse-echo response from the back wall echo to 80% FSH of each element.

5. Observe display and record the gain required to achieve 80% FSH for each element.

6. Ensure not more than 10% element is inactive or 2 adjacent elements.

7. Ensure amplitude response change is not more than ±3dB.examination and all measurements shall be
in millimeters. The NDT personnel should specify specific datum reference point.

6.11. Encoder Calibration

Mini wheel encoder or other suitable encoder shall be calibrated prior to inspection. Calibration is to be
carried out on a 300mm up to 500mm length. The deviation of the distance shall not exceed ±1%.
Scanning speed shall not exceed 150mm/s with a resolution of 1mm.

7. Examination Coverage & Scanning

Scanning speed shall be chosen such that satisfactory images are generated. The scanning speed is
dependent on the scan increment, signal averaging, pulse-repetition frequency, data acquisition
frequency and the volume to be inspected. If the weld is scan in more than one part, an overlap of at
least 50mm between the adjacent scans is required. The same overlap is required for the end of the last
scan and the start of the first scan when circumference weld is scanned.

Scan plan is to be generated by using the ESBeam Tool. The operator has to design and document the
correct probe position, elements, angle and other related details in order to get a full coverage of the
weld. The owner or client has to provide all related details such as dimension and specification of the
weld in order for the operator to generate a scan plan.

8. Datum Points
In order to enable the position of defects to be permanently and accurately identified within the
component cross section and along its length, an agreed method of referencing based upon the inherent
features of the component or associated elements shall be provided. A reference to the location of all
datum locations shall be included in the report and as agreed with client. All locations shall be clearly
marked on the component surface prior to examination and all measurements shall be in millimeters.

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The NDT personnel should specify specific datum reference point. Example, for circumferential seam the
datum should started at 0° of clockwise and length of the circumferential seam must be included inside
report.

9. Test Details
i) Place the magnetic strip (reference line) on weld parallel from the weld center line

ii) Apply couplant to the scan area/ continues water supply

iii) Press start scan and manually move the probe.

iv) Ensure data has no missed lines and save the data

v) Inspection coverage will cover of the volume and 50mm of adjacent parent material.

10. Evaluation
The evaluation can be carried out in two ways; Online analysis using the software installed in the
OmniScan MX2 and/ or Offline analysis using the Omnipc post processing software on a note book. As
per normal practice, all data will be recorded during inspection time and Offline analysis would be
carried out using the post processing software and to report any findings by end of the working shift

 The location, amplitude and extent of reflectors that produce a response greater than 20% of the
reference level shall be investigated.
 The cross section of defect shall be sized with 20dB (1:10) drop technique or maximum
amplitude technique or a combination of both. The length of defects shall be determined by 6dB
(1:2) drop technique.
 Sizing Of Discontinuity:
1. Flaws shall be sized in accordance with a procedure demonstrated. Sizing of discontinuity
(location, length, through thickness dimension) shall be done using equipment software on the
captured image of discontinuity as mentioned in the sketch below. Amplitude drop method at
the ends of the discontinuities shall be used for sizing of the same. Data cursor can be moved on
the indication and with the help of a scan, amplitude method at the ends of discontinuities can
be done for sizing of the indication.
2. If the indication is saturated skull method maybe applied. Indication length can be calculated by
placing two cursors as shown below on C scan image and similarly through thickness height can
be calculated by placing two cursors as shown below on S scan image. The length and through
thickness measurement facility available in software itself which is described above (Same shall
be demonstrated).

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 f) The following steps shall be taken to classify an indication as geometric:

1. Interpret the area containing the reflector in accordance with the application examination
procedure.
2. Plot & verify by calculation/ manual inspection the reflector coordinates. Comparison with the S
Scan from the flaw unit CRT screen.
3. Review of the fabrication / weld preparation drawing.
4. Other UT technique or NDT examination methods may be helpful to locate the true position/size
& orientation.

 Flaws shall be sized in accordance with a procedure demonstrated to size similar flaws at similar
material depths. Alternatively, a flaw may be sized by supplemental manual technique so long as
it has been qualified by the demonstration above. The dimensions of the flaw shall be
determined by the rectangle that fully contains the area of the flaw. The length (l) of the flaw
shall be drawn parallel to the inside pressure- retaining surface of the component.

11. Acceptance Criteria

All evaluation shall be carried out with the gain setting at reference level, any imperfection that produce
an amplitude greater than 20% of the reference level shall be investigated to the extent the operator can
determine the shape, identify, and location of all such imperfections and evaluation them.

12. Reporting
The inspection report should include information as per ASME Sec V T-490. Refer to Appendix II - Typical
Inspection Report.

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APPENDIX I: SET-UP OF EQUIPMENT

The scanner and the instrument must be properly connected and set up to enable inspection.

1.1 Setting up an Instrument Using a USB Key

You can load a predefined inspection-parameter setup from the supplied USB key into your OmniScan
instrument. Or, if the predefined setups are not suitable for your requirements, you can create a new
setup. To set up an instrument using a USB key

● Load the setup from the USB key:

a) Use a computer to transfer the setup from the supplied USB key to the OmniScan instrument’s SDHC
memory card.

b) Insert the SDHC card into the OmniScan and then turn it on.

c) Select the setup.

1.2 Setting up an Instrument Using the Interface

Most common setups can be easily created by following the instructions in the User’s Manual for your
OmniScan instrument. The instructions below are specific to the scanner, and should not be considered
complete.

1.2.2 scanner Corrosion Mapping System – Mechanical Setup

The scanner Phased Array System is designed to perform corrosion mapping in two possible
configurations:

 Manual Encoded One Line Scans (1 axis)

 Semi-Automated Encoded Multiple Line Scans (2 axis)

Probe Installation

 Ensure that the probe is installed into the scanner where element number 1 is positioned
correctly for the C-scan that will be created. The normal position for this is 1-64 left to right
when scanning forward as pictured.
 The Index axis will increment in the direction below indicated by the green arrow. (1mm focal
law resolution and 61mm total width) , and its all about the probe the you work with it .

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 The Scan axis will increment below in the direction indicated by the blue arrow at the resolution
entered into the Omniscan.
 Loosen the knob (pictured at right), apply light pressure on the probe to ensure the foam seal is
secure against the inspection surface and tighten the knob.
 The phased array probe will align parallel and level with the pipe when secured with the one-
knob patent pending probe carriage.
 Minor differences in the water column due to the scanner “Crabbing” will not affect thickness
readings when the interface gate (Yellow) is set to A-scan Syncro I

2. Preparation for Inspection

In addition to the setup detailed in “Setup of Equipment” , before you begin inspecting you must also
clean the inspection surface and set up the instrument parameters. It is recommended that you also
mark the scan lines.

2.1 Drop Precautions

Be sure to observe the following precautions when handling the scanner. To prevent injury and
equipment damage when operating the scanner at heights 2 meters or higher above ground or floor
level, secure it with a lanyard that is held taut. Wear appropriate safety shoes that protect your feet in
case you accidentally drop the unit during handling.

Also ensure the inspection surface is free of rust, debris, or obstructions, and is continuously
ferromagnetic so that magnetic wheels remain attached to the surface.

2.2 Cleaning the Inspection Surface

The inspection surface must be free of scaling and other obstructions. A smooth surface helps maintain
the water column and extends the life of the wedge’s foam gasket that rubs against the surface during
inspection. This attach doing by the client

To avoid the risk of injury, wear appropriate work gloves and safety glasses when cleaning the inspection
surface using scrapers, metal brushes, or other cleaning tools.

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To clean the inspection surface:

1. Carefully use an appropriate metal scraper, chisel, or file to remove scaling, protruding metal, or weld
residue on the surface, without affecting the structural integrity and curvature of the surface.

2. Use a metal brush to remove any remaining loose material on the surface.

PROBE ELEMENT CHECK

Equipment Sr. No Date

Probe Sr. No. Probe Frequency
Couplant Total elements
Db (minimum) Db(maximum)

1. Connect the phased-array probe to the phased-array ultrasonic instrument.

2. Connect below delay line wedge to the probe: -

2.1 SA14-0L

2.2 Thickness: ...mm

2.3 Material: ….

3. Configure an electronic scan consisting of is stepped along one element at a time for the total number
of elements in the array. (This should ensure that the pulser-receiver number 1 is used in each focal law
or:

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 or water path to 80% display height for each element in the
probe.

4. 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 maybe recorded on a table similar to that in Table 1.

5. No more than 10% element inactive or 2 adjacent elements.

6. Amplitude response change not more than ±3Db.

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Table 1

PROBE ELEMENT ACTIVITY CHART: ENTER RECEIVER GAIN FOR 80% FSH

Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22
Gain
Active
([sqcap)]
Inactive

Element 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Gain
Active
([sqcap)
]
Inactive

Element 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Gain
Active
([sqcap)
]
Inactive

Element 61 62 63 64
Gain
Active
([sqcap)]
Inactive

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13. Safety Requirements

The supervising technician is to ascertain the risk to health and safety prior to the commencement of
inspection or prior to entering areas that may present such a risk. He shall make himself aware of all
hazards and take all appropriate steps to ensure that these risks are minimized or removed. All personnel
shall follow the procedures, instructions and signs made available for safety purposes.

Special safety equipment is to be a prerequisite to any works carried out in areas considered to be
hazardous. All safety equipment is to be checked in-date and in working order by the supervising
technician immediately prior to entering such hazardous areas. Intrinsically safe equipment shall be used
in areas considered of high explosive risk and all proper safety precautions for this situation must be
complied with in full. All the stained rags and papers shall be promptly removed from test area and
disposed according to local regulations; Due care shall be taken when the work is carried out in confined
space.

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