Insert date here Presentation to 4 th PANI 3 Management Committee PANI 3 Results – Ultrasonic Results

Overall Results Overall % FDF Per Defect Min41.67 Average64.70 Max86.67 Std. Dev.13.16

Individual Defect Results Max87% 69%

Individual Defect Results Min42% 60%53%

De-Brief Data Overall Observations Must be able to understand the ultrasonic implications of the geometry Methodology (see next slide) Even the better performing operators can mis-characterise an indication

De-Brief Data - Methodology Systematic way of working to achieve the aims of the procedure Review procedure and obtain clarification Once decided on methodology –stick to it –Plotted out weld toes & unfused land on pipe with 0° probe –Completed 0° scans on outside of pipe –Completed angle beams on disc –Resolve all geometrical indications and record all recordable inds. –All recordable indications evaluated –Comprehensive report produced By methodical approach weld can be split into zones to simplify

De-Brief Data Details from the Signal Amplitude? Most used for recordable / non recordable –6% correctly characterised on basis of amplitude Echo Shape (Echo Static)? Rough cracks appear easier to characterise –13% correctly characterised on shape Position? 91% correctly positioned indications in x-section –Scale drawings? Echo Dynamic? Surface breaking cracks appear easier –32% correctly characterised on probe movement Persistence? 100% reported length – Geometrics identified by persistence all way around & pattern.

De-Brief Data Process Overall deduction from main detection probe? –46% correctly characterised on main probe –Cracks flaw most correctly characterised Sentencing on the basis of main detection probe? –54% would sentence, 46% would not Test with subsequent probes? –80% would use other probes Apply IF-THEN logic? –44% not familiar with the term, 80% would use other probes but only 29 % thought which probe to use. Throw away information? See above.

Theoretical Questions 16 Questions – Each given to 5 operators – 80 Answers

Question 15 The graph shown below has been plotted to calculate the Transfer Correction between a reference block (DAC Block) and the material under test. Line A – B shows the line plotted from the reference block. Line C – E shows the line plotted from the material under test. Line C – D is parallel to line A – B and is separated from it by X dB. What effect does the difference X dB represent? At Position 1 on the Range axis the difference between line C – D and the line C – E is Y dB. What effect does the difference Y dB represent?

Question 15 - Average Mark 3.2 The graph shown below has been plotted to calculate the Transfer Correction between a reference block (DAC Block) and the material under test. Line A – B shows the line plotted from the reference block. Line C – E shows the line plotted from the material under test. Line C – D is parallel to line A – B and is separated from it by X dB. What effect does the difference X dB represent? Transfer Correction At Position 1 on the Range axis the difference between line C – D and the line C – E is Y dB. What effect does the difference Y dB represent? Attenuation in the component

Question 12 The equipment used in Ultrasonic Inspections is controlled under Company quality systems to ensure correct functionality. Describe what checks should be made on a Flaw Detector Annually ? Weekly ? Daily ? Describe what checks should be made on Probes: Weekly ? Daily ? During an Ultrasonic Inspection when are Equipment Calibrations performed?. What Documentation would substantiate the Equipment Calibrations? How would you know you were working to the correct issue of an Ultrasonic Inspection Procedure?

Question 12 – Average Mark 4.4 The equipment used in Ultrasonic Inspections is controlled under Company quality systems to ensure correct functionality. Describe what checks should be made on a Flaw Detector Annually ? Full calibration Weekly ? Linearity of the time base, Linearity of the equipment gain Daily ? Sensitivity and signal to noise ratio Describe what checks should be made on Probes: Weekly ? Beam Profile Daily ? Probe index, Beam Angle, Beam Alignment During an Ultrasonic Inspection when are Equipment Calibrations performed? At the start and end of an inspection and shift. What Documentation would substantiate the Equipment Calibrations? Calibration Certificates How would you know you were working to the correct issue of an Ultrasonic Inspection Procedure? From the Quality Plan

Question 1 Consider the defect shown in the diagram below. The weld is a single V with a fusion face of 30°. The weld cap and weld root are in the as welded state. The defect is a LOSWF defect. Describe how you would detect the LOSWF defect. Describe the signals you would expect to see with each probe you would use. Write your answers below and draw diagrams as required.

Question 1 – Average Mark ° beam on the full skip will hit the defect at normal incidence and the echo will plot out beyond the backwall. Type 2 echo dynamic. At half skip the 60° beam will be reflected down to the backwall and back up the same path. The signal will plot out beyond the position of the defect. Type 2 echo dynamic. – Not aware of this possibility A 45° beam at full skip may pick up the top & bottom tip response. Type 3b dynamic. A 70° beam at half skip may pick up the top & bottom tip responses Type 3b dynamic.

Conclusions Different ways of applying same procedure Methodical approach most effective Understanding of geometry important Reporting inconsistent Knowledge gaps prevent extraction of best information