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

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

3. COMMON MATERIAL/ WELD DEFECTS

4. 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

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

6. 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.

7. 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.

8. 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.

9. 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

10. 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

11. 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.

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

13. 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.

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

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

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

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

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

19. PIPE WELDS AND BODY CHECKS USING AUTO UT

20. PIPE WELDS AND BODY CHECKS USING AUTO UT

21. 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.

22. 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.

23. - + 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 mA
RADIOGRAPHY
TRANSFORMER KV mA
GLASS TUBE
VACCUAM
X R A Y S

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

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

26. PARAMETER CONTROL IN RT

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

28. 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.

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

30. 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.

31. 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

32. 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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