HOW TO CARRY OUT NDE? Instructor : Bhaskara Rao Gurram © 2008 Canadoil Group © Marketing www.canadoilgroup.com

Brief Training Module on Non Destructive Examination Welcome to RSO Brief Training Module on Non Destructive Examination In Cpipe

COMMON MATERIAL/ WELD DEFECTS

Typical Double sided butt weld joint Weld metal Heat affected zone (HAZ) Pipe wall parent plate Weld cap Toe crack Undercut lamination HAZ crack 9 Slag Lack of root fusion Isolated porosity Lack of side wall fusion. Cluster porosity

NDE in Cpipe Direct visual testing Penetrant testing Ultrasonic testing Digital Radiography Magnetic particle testing

Visual Testing -100% seam weld and pipe body NDE- API 5L-2004 edition Visual Testing -100% seam weld and pipe body 100% UT check for welds -longitudinal/transverse defects. Weld / body repairs need PT in addition to RT as required by specification. SAW pipes both ends of the pipes shall be performed 200 mm Xray Examination. Weld or body repairs to be examined by MT in addition to UT/XRay.

Visual Testing -100% seam weld and pipe body NDE- ASTM pipes( A 671,672, 358, 691 etc) Visual Testing -100% seam weld and pipe body 100% UT check for welds -longitudinal/transverse defects. Weld / body repairs need PT in addition to RT as required by specification. 100% RT as required by specification. Some classes do not require RT( class 13). Weld/ body repairs NDT by MT in addition to Xray.

VT VT is visual testing. Direct or indirect visual Need vision test as per ASNT SNT TC 1A. Need adequate lighting. Need skill and training. Need to use templates, gauges. Most codes demand 100% VT of welds and surfaces. More details on VT – ref to ASME Sec V.

API –Visual inspection requirements API products -Direct visual exam of welds and product surfaces Type of discontinuities to be inspected for each pipe as per API 5L OFF SET OF PALTE EDGES OUT OF LINE WELD BEAD CRACKS, SWEATS AND LEAKS LAMINATION ARC BURNS UNDERCUTS UNDERFIL- NEGATIVE REINFORCEMENT HARD SPOTS DENTS DISTORTION/ DEFORMATION IRREGULAR WELD PROFILE

VT Hard spot Weld visual Pipe end bevel Pipe body Heat treatment Plate inspection Edge milling Hard spot VT Final visual Pipe forming hydro test

PENETRANT TESTING Needed for weld repair as per ASTM standards PT is done as per the customer specification requirements on weld or prepared bevels. Mostly SS, Copper alloy, Nickel and clad welds are PT requested by customers in Cpipe product ranges. When in doubt or weld cracks repairs PT is done to confirm the surface defects. PT in Cpipe is visible method, solvent removable and water washable type. PT can be done after removal of arc burns.

PT – COLOR CONTRAST TECHNIQUE (SOLVENT REMOVABLE AND WATER WASHABLE) Bevel Back gouging Weld PT Plate Clad pipe PT

UT UT is 100% for API 5L products. Weld UT is not required for ASTM products for A 671,672 and A 358 or A 691. UT is done on full body as per customer requirements. UT of bevels is done for min 2 inches wide from end as per customer requirements. UT is done either manual or Auto. UT is done after weld repairs in Cpipe. UT is done for plate lamination checks either by grid or full as required. UT is Lamination checks are done for steel plate or clad steel plate in Cpipe. UT is when required done for full pipe body after pipe manufacturing at final inspection for alloy steel grades.

BLOCK DIAGRAM: ULTRASONIC INSTRUMENT amplifier work piece probe horizontal sweep clock pulser IP BE screen

MANUAL PLATE LAMINATION CHECKS (UT) Very slow process, as per A 435 or A 578, Need to perform outdoors, need calibration each shift.

ULTRASONIC TEST – EXAMINATION (WELD AND PIPE BEVEL) Auto UT Defect confirmation Weld UT Pipe ends UT Calibration UT Calibration clad disbond

UT CALIBRATION BLOCKS IIW US1 block V2 block Bottom drilled hole block

PIPES BODY UT ( LAMINATION AND CLAD DISBONDING CHECK) Pulsed Echo UT Phased Array UT

PIPE WELDS AND BODY CHECKS USING AUTO UT

PIPE WELDS AND BODY CHECKS USING AUTO UT

AUTOMATIC UT TESTING OF PIPE Max 12m pipe length, 60mm max thick, 16-60inch dia pipes. speed – 2 minutes/ pipe. Defect locations are marked for manual UT confirmation, Ends are done MUT as AUT has some limitations. Manual UT of AUT marked locations.

RADIOGRAPHY Required by API 5L and ASTM specifications. RT is done using Film or film less( digital). RT is using Xray or Gamma ray sources. RT is done for API 5L pipes ( ends 200mm) and ASTM pipes as required by product specifications( full or spot). RT personnel and facility is controlled by statutory body of Thailand for personnel radiation exposure and hazard extent. RT involves multi stages – shooting, developing film, evaluations. Radiation safety and handling of source, film is the key aspect of Radiography productivity and quality.

- + RADIOGRAPHY X-RAY PRODUCTION KV TRANSFORMER mA X - R A Y S CURRENT CATHODE ELECTRONS TUNGUSTEN TARGET COPPER HOODED ANODE X-RAYS TUBES OIL COOLER INLET OIL COOLER OUTLET CURRENT 0 - 10 mA RADIOGRAPHY TRANSFORMER KV mA GLASS TUBE VACCUAM X - R A Y S

FILM RADIOGRAPHY SOURCE X-RAYS / GAMMA RAYS WELD IQI JOB FILM SCREEN CASSETTE HOLDER FILM SCREEN

RT SHOOTING AND EVALUATION- FILM RT RT using FRT machine Film evaluation Developed RT film RT by manual Xray equipment

PARAMETER CONTROL IN RT

DIGITAL RADIOGRAPHY TESTING Digital RT station RT of Pipe long seam weld Digital image of weld

MT Magnetic particle testing is done for repair welds as per standard. MT is some time done on body for alloy steel plates after bending or rolling. MT of bevels is done when requested by customer. MT is done on arc burns when after removal. MT is visible, dry or wet method using electro magnets.

MAGNETIC PARTICLE TESTING MT of pipe bevel ends MT of long seam bevels Weld seam MT Pipe body MT Weld seam defects in MT

QUALIFICATION AND CERTIFICATION By standard ASNT SNT TC 1A-2001 Mandatory by product code and specification. Formal training, examination and practical test. Codes and specifications demand minimum Level I, Level II in each method.

RSO TRAINING Process capability Dia Thickness Pipes per shift NDT CAPABILITY MATRIX Process capability Dia Thickness Pipes per shift Critical paths VT of welds <24inch dia All thickness 50 pipes/shift Inspection ext surfaces, random insp. >24inch 16 pipes/shift Inside and outside, random insp. AUT <16inch dia 16-60inch Nil 50 pipes /shift Not capable. Capable and 10min, each pipe AUT+ confirm Manual UT+ Ends 200mm manual UT. General : AUT need calibration pipe each MO, each item. Preparation of cal pipe 3 shifts, calibration each shift one hr FRT- API 5L <18inch, >18inch 25mm max 50mm max 30 pipes/shift Pipe both ends Xray, developing and evaluation simultaneously. Note: calibration each shift FRT- ASTM <18inch 4 pipes /shift 10 pipes/shift Double wall technique, 100 % xray Single wall technique, 100% Xray Note: Calibration each shift DRT ASTM Max 20mm Max 40mm 16 pipes /shift 8 pipes/ shift Only process inspection and repair pipes Note: Calibration each shift. PT All dia Clad plates All thick 5 plates / shift MT Pipe bevels all thickness 6 pipes / shift 30 pipes/ shift

ASTM Vs API 5L - impact on pipe delivery and productivity/pipe cost Mfr activity API 5L ASTM Remarks Handling of pipes Less critical Critical Handling is doubled than API due to PWHT, sand blasting, extensive sizing, careful handling is necessary due to less tolerance in thickness reduction, handling hot pipes cause local dents, sizing is more than API. Pipe /weld visual Required RF is less critical for API 5L pipes, surface VT ASTM more rejections. Weld UT 100% Not reqd. API 5L pipes - Auto UT, ASTM pipes - manual UT/ DRT for ASTM slow process. RT Only ends Mostly 100% RT is slow for ASTM pipes, Cost saving is high for API 5L pipes. PT of welds NR Need for repair welds PT of bevels Not required by specification. MT of welds Option to use on low alloy steels, weld bevels & weld repairs. Heat treatment SR Cl 22 NR is slow process, low productivity. dimensions vary largely. Sizing time more than API 5L pipes. Max 1-6 pipes/ 5 hours Heat treatment – NR Cl 32 Slow, need positive allowance in pipe thickness, sizing is slow, Need sandblasting all pipes due to lot of scale formation. Max 1-6 pipes/ 5 hours Weld repairs More repairs compare to API 5L pipes due to weld Radiographic quality. Re RT of weld repairs increase pipe movement and handling damages. Hydro test No significant difference. Mechanical testing 300ft/ heat 60ft/heat API pipes Significant cost and time saving compare to ASTM. Nearly 8 times costly than API 5l pipes. Beveling No significant difference between ASTM and ASTM. Sizing More critical Straightness every 3 m check- max 3.2mm for ASTM, API 5L 0.2%(max 24mm in 12m length). ASTM pipes 5-8 times slow than API pipes. Finishing Thickness negative tolerance is 0.3mm below nominal, API allows 8-10% negative tolerance. More rejections for ASTM pipes. QC cycle time More tolerance Tolerance is limited Extensive dimension check, rework due to straightness failures( 3.2mm max in 3m), local deviations due to weld repair, sizing errors.

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