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ULTRASONIC-TOFD INSPECTION
FOR HDPE PIPE CONSTRUCTION
SPECIFICATION
DOCUMENT NO. 240K-C2-CS-50-006
REV. 0T
05 November 2012
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2.
3.
4.
5.
6.
7.
8.
9.
GENERAL...................................................................................................................................................... 5
1.1 Summary ..........................................................................................................................................5
1.2 References .......................................................................................................................................6
1.3 Site Conditions .................................................................................................................................7
TESTING AND INTERPRETATION ............................................................................................................. 7
2.1 General .............................................................................................................................................7
2.2 Welds to be tested............................................................................................................................7
2.3 Interpretation of Test ........................................................................................................................8
QUALIFICATION OF TECHNICIANS........................................................................................................... 8
3.1 Qualified Personnel ..........................................................................................................................8
3.2 Technician Level Requirement .........................................................................................................9
3.3 Record of Qualification .....................................................................................................................9
3.4 Technician Evaluation ......................................................................................................................9
3.5 Other Qualifications and Requirements ...........................................................................................9
UT-TOFD EQUIPMENT................................................................................................................................. 9
4.1 Approved Ultrasonic-TOFD Equipment............................................................................................9
4.2 Ultrasonic Probe Selection .............................................................................................................10
4.3 Ultrasonic-TOFD Equipment Parameters.......................................................................................10
4.4 Ultrasonic-TOFD Scanning Mechanism .........................................................................................11
EQUIPMENT SET-UP AND CALIBRATION PROCEDURES ................................................................... 11
5.1 General ...........................................................................................................................................11
5.2 Calibration Blocks Standards .........................................................................................................11
5.3 Verification of Calibration................................................................................................................12
5.4 Couplants........................................................................................................................................12
5.5 Equipment Maintenance.................................................................................................................12
WELD PREPARATION AND INSPECTION TECHNIQUES ..................................................................... 12
6.1 Accessibility and Pipe Surface Condition .......................................................................................12
6.2 Pre-Test Data Requirements..........................................................................................................13
6.3 Examination of Parent Material Flaws............................................................................................13
6.4 Acoustic Comparison Prior to Weld Examination...........................................................................13
6.5 Scanning Examination Procedures ................................................................................................13
6.6 Discontinuity and Flaw Evaluation..................................................................................................14
6.7 Characterization of Flaws ...............................................................................................................14
6.8 Re-testing of Repaired Defects or Welds .......................................................................................15
ACCEPTANCE CRITERIA & REPORTING ............................................................................................... 15
7.1 Acceptance Criteria ........................................................................................................................15
7.2 Reports and Identification of Defects .............................................................................................17
7.3 Content of Final End-of-Job Examination Report...........................................................................17
GENERAL SAFETY PROGRAM................................................................................................................ 18
8.1 General Safety Program.................................................................................................................18
8.2 Reporting Accidents .......................................................................................................................18
ATTACHMENTS.......................................................................................................................................... 18
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1.
GENERAL
1.1
Summary
A.
B.
Scope of Specification
1.
This specification defines the general requirements, techniques, and equipment for nondestructive Ultrasonic time of flight diffraction (UT-TOFD) inspection of high density
polyethylene (HDPE) butt fusion welds in pipeline service.
2.
This specification defines the use of sound waves to inspect butt fusion welds of HDPE
pipe to identify and size internal fusion joint defects, such as: voids, cracks, discontinuities,
foreign particles, etc. Utilizing this technique, production welds can be field-tested nondestructively to determine overall weld-joint quality.
3.
This specification provides guidelines for the set-up and calibration of equipment for the
two- probe (pitch-catch technique) TOFD examination technique.
Terminology
The following terms are defined as stated, unless otherwise indicated:
1.
2.
B-Scan Scan that shows the data collected when scanning the probe pair in the direction
of the beam transversely across a weld or flaw.
3.
D-Scan Scan that shows the data collected when scanning the probe pair normal to the
direction of the beam along a weld or flaw.
4.
Back wall echo Echo due to the wave reflected from the rear surface.
5.
Butt-weld Fusion Bonding A joint in which the prepared ends of the HDPE pipe are
heated against a hot plate to the desired temperature, which allows for the ends to be
fused together via application of external pressure.
6.
7.
Construction Contractor Shall refer to the company performing fusion bonding and
installation of HDPE pipe.
8.
9.
10.
Lateral wave Wave that runs directly between the two UT-TOFD probes.
11.
Manufacturer Unless otherwise noted, the company or organization that produces HDPE
pipe that has been approved for use for this project.
12.
13.
14.
Socket Fusion Bonding A joint in which the joining surfaces of the components are
heated, and the joint is made by inserting one component into the other.
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D.
This specification does not address the requirements for inspection of any types of HDPE
fusion joints other than butt fusion, such as socket fusion or saddle fusion.
2.
Echo amplitude is not used quantitatively by the TOFD technique when characterizing butt
fusion flaws. Amplitude-based flaw sizing, conventionally used for pulse-echo ultrasonic
inspection, is invalid for the TOFD analysis technique and not discussed within this
specification.
Related Documents
The following documents prescribe items of related work:
240K-C2-CS-50-005
240K-C2-DC-10-002
240K-C2-SP-50-001
Coordinate Work prescribed by this specification with work prescribed by the above listed
specifications.
1.2
References
The publications listed below form part of this specification. Referenced publications within this
specification shall be the latest revision and addendum in effect as of October 1, 2011, unless
otherwise specified; and applicable parts of the referenced publications shall become a part of this
specification as if fully included. Except as modified by the requirements specified herein or the details
of the drawings, work included in this specification shall conform to the applicable provisions of these
publications.
ASME
ASNT
ASTM
BSI
Process Piping
BS EN583-6
Non-destructive Testing Ultrasonic Examination Part 6: Time-ofFlight Diffraction Technique as a Method for Detection and Sizing of
Discontinuities
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Site Conditions
Refer to Section 1.1.D, Related Documents.
2.
2.2
General
A.
When performing UT-TOFD examination using this specification, it is necessary, for purpose of
having an accurate record, that the Construction Contractor provides essential information to the
Inspection Technician performing the test. This information identifies the items being tested. The
Technician, for his part, must provide information for the record that supports the validity of the
test.
B.
Information required to identify the items being tested includes the project or contract number,
the name/tag number of the component, and the weld joint configuration: weld size and location.
C.
Verification of the validity of the test requires the recording of the Technician's name and level,
and a copy of the Technician's certification.
D.
Welds to be tested
A.
UT-TOFD shall be used to randomly inspect production fusion welds. When random UT-TOFD
examination (i.e. examination frequency is less than 100%) is specified by Companys Quality
Manager, it shall be based on a progressive sampling criterion, as detailed in Fig. 1.
B.
In addition, when the Inspection Contractor is brought on site during construction of the pipeline,
the first production weld of each crew, at the beginning of each shift, shall be subjected to UTTOFD to verify good operating equipment, environmental conditions, etc. If a weld fails, welding
by that crew and fusion machine shall be suspended. Faults that caused the failure shall be
corrected to the satisfaction of both the Construction Contractor and Companys quality manager
before welding by this crew and machine can resume.
C.
The random weld inspection frequency shall be in accordance with Piping Line Class
Specification 240K-C2 SP 50 001 Attachment 5 Heat & Inspection Summary. The Construction
Contractor shall not know the sequence of weld inspections ahead of time.
D.
A weld shall fail UT-TOFD inspection if it is labelled either CAT 1 or CAT 2 by the Inspection
Contractor as per the acceptance criteria in Section 7 of this specification. Labelling the failed
weld as CAT 1 or CAT 2 indicates the relative severity of the defects present.
E.
This method shall only be used to detect butt fusion defects for which it has been developed and
qualified. This specification does not address the requirements for inspection of any other types
of HDPE fusion joints, such as socket fusion or saddle fusion.
F.
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PASS
FAIL
INSPECT
ONE WELD
PASS
FAIL
SUSPEND
FUSION &
INVESTIGATE
see NOTE 4
See NOTE 1
CONTINUE
FUSIONS &
INSPECTIONS
PASS
FAIL
see NOTE 2,3
STOP
FUSION
EXAMINE ALL
REMAINING
UNINSPECTED
WELDS
See NOTE 1
INSPECT
TWO WELDS
NOTES:
1) IF > 2 UN-INSPECTED WELDS REMAIN FROM THE LAST INSPECTION, EXAMINE 2 WELDS AT RANDOM. IF 1 UN-INSPECTED WELD REMAINS
FROM LAST INSPECTION, THEN EXAMINE THAT ONE WELD.
2) THE RANDOM WELD INSPECTION FREQUENCY SHALL BE DETERMINED PER PIPING LINE CLASS SPECIFICATION C-SP-50-001 ATTACHMENT 5.
IF < 5 UN-INSPECTED WELDS REMAIN FROM THE LAST INSPECTION, EXAMINE 1 WELD AT RANDOM.
3) THE FUSION WELDING CONTRACTOR SHALL NOT KNOW THE RANDOM WELD INSPECTION SEQUENCE IN ADVANCE.
4) IF A FUSION CREW IS SUSPENDED DUE TO INSPECTION FAILURES, THE EQUIPMENT, SPECIFICATIONS, QUALIFICATIONS, AND
PROCEDURES SHALL BE AUDITED BY THE BUYER'S QUALITY MANAGER.
3.
Interpretation of Test
A.
If the Construction Contractor differs with the Technician's interpretation, the Technician's
interpretation is assumed correct until, and unless, the Construction Contractor decides a review
is required.
B.
The Construction Contractor may arrange for a second test at his own expense. If the
Construction Contractor decides not to repeat the test, the Technician's interpretation stands and
a repair, if required, shall be made on that basis.
C.
If a second test is preformed, the results of both tests shall be submitted to the Companys
Quality Manager for evaluation.
QUALIFICATION OF TECHNICIANS
3.1
Qualified Personnel
A.
B.
The record for personnel performing ultrasonic-TOFD inspection and interpretation shall include:
1.
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3.2
2.
3.
4.
5.
6.
Date of certification
3.3
3.4
3.5
4.
Record of Qualification
A.
The Inspection Contractor shall provide a record of qualification for each Technician and
assistant to the Company, for approval, prior to commencing work.
B.
The record of qualification for each Technician and assistant shall be complete with the name of
the agency or person giving qualification, date of qualification, and a description of all
procedures for which he/she is current. This record shall highlight any special training and
previous HDPE inspection work experience.
Technician Evaluation
A.
If the qualification records are incomplete, illegible, or are otherwise questionable, the
Technician will be required to provide further evidence of qualification.
B.
The Company or Construction Contractor may, if it has reason to question qualification or vision,
require any certified Technician to demonstrate an examination. If requested, the Technician
shall perform calibration testing and interpret the result under the observation of the Company.
Only Technicians and Inspection Contractors that are experienced with UT-TOFD examination of
HDPE butt fusion welds are acceptable. Validation of this experience may be required.
B.
The Technician must be familiar with the TOFD techniques required to reliably detect and
accurately size fusion flaws common to HDPE butt fusion welds including, but not limited to;
contaminants, voids, cracks, discontinuities, lack of fusion (cold fusion), and lack of penetration.
UT-TOFD EQUIPMENT
4.1
The ultrasonic-TOFD equipment shall be in compliance with Paragraph 5.1 of BS7706 and
Paragraph 6.1 of BS EN583-6.
B.
The ultrasonic flaw detector shall be of such dimensions and weight that it is easily portable by
one person without requiring mechanical assistance.
C.
The acceptable equipment for UT-TOFD examination is the RTD Porta-TOFD, or approved
alternate.
D.
All butt fusion joints will be inspected utilizing the Porta-TOFD Scooter scanning mechanism, or
approved alternate, to ensure consistent and reproducible inspection results.
E.
The flaw detector may be powered by an external power supply, such as a portable generator or
batteries. Power source stabilization, either built-in or external, must accommodate input voltage
fluctuations of at least 10% without affecting the performance characteristics of the flaw
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The probe selection and configuration shall be selected as to maximize the overall accuracy, the
signal-to-noise ratio, and the coverage of the region of interest.
B.
As per BS EN583-6, the probes used for TOFD detection shall meet the following minimum
requirements:
Number of probes: 2 (transmitter and receiver)
2.
Wave mode: Compression wave (the use of shear waves must be agreed by both
Company and Inspection Contractor)
3.
Frequency Tolerance: both probes shall have the same center frequency within 20% of
nominal.
4.
Pulse repetition: shall be set such that no interference between signals from successive
transmission pulses occurs.
C.
D.
The probe type used shall be at incident angle of 55 to 65 and the probe crystal diameter shall
be 0.5 (12.7 mm).
E.
The probe separation shall be based on the pipe diameter and thickness of the weld to be
examined and shall be determined by the Technician.
F.
4.3
1.
1.
The probe separation and inspection techniques shall be used such that, to maximize the
diffraction efficiency, the included angle of the probe beam axes at any existing flaw tip
shall be approximately 120.
2.
The probes shall be arranged so that the imagined beam centerline intersects the region at
the appropriate depth where the flaws are anticipated, at the above-mentioned angle.
Deviations of more than -35 or +45 from this value result in weak diffracted echoes and
shall not be used.
The beam width shall cover 90% (minimum) to 100% of the entire cross-section of interest and
ensure that all flaws are resolved.
The linearity of the amplifier shall be 5% over a range from 0% to 75% of the upper vertical
limit, and a signal set to this height should remain clearly visible when it is decreased by 24 dB.
B.
The amplifier linearity shall be determined on the reference block in accordance with ASTM
E317 and shall be recorded and kept on file.
C.
The flaw detector shall have a calibrated gain control with 2 dB maximum increments over a
range of 0 to at least 60 dB.
D.
The TOFD inspection equipment must operate such that the signal/noise ratio is not less than +6
dB for the HDPE pipe material. For example, set the equipment noise suppression and gain
such that the signal recorded from the arrival of the lateral wave indication is at least 6 dB higher
in amplitude than the electronic noise that existed, in that same region, prior to the lateral wave.
E.
The scan resolution setting is recommended to record, at-least, one A-scan per millimetre of
probe displacement.
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4.4
5.
F.
Signals shall be digitized with a sampling rate that is at least four (4) times the nominal probe
frequency. The acceptable normal setting shall be 100MHz.
G.
The amplitude and time base linearity calibration shall be performed in accordance with
equipment manufacturer recommendations prior to commencing work and once every three (3)
month period thereafter.
The scanning mechanism shall maintain a constant distance and alignment between the index
points of the two probes, as per the requirements of Section 4.2. The scanning mechanism shall
be manually driven and be guided via a suitable guiding mechanism (steel band, belt, etc.)
around the entire pipe circumference. Guiding accuracy between the center reference line (e.g.
butt fusion bead) and the probe indexes shall be within 10%.
B.
The ultrasonic search units shall be clearly marked to show normal frequency, angle of
refraction, and beam index point.
C.
The ultrasonic search units shall be free from internal noise over the beam path distance and at
the highest sensitivity level used for weld examination.
D.
The scanning mechanism internal encoder for the positioning data shall be calibrated as per
equipment manufacturer recommendations. There shall be no deviations greater than 5%
between the recorded and actual displacement.
5.2
General
A.
Each calibration test must include both the A-Scan and TOFD image (D-scan) that is digitally
recorded for verification of equipment settings. Each calibration test shall have a calibration
number and the results of each test are to be electronically saved and recorded (e.g. CD-ROM)
with the time, date, & all weld tag number(s) subsequently examined.
B.
Calibration block standards shall be manufactured from material same as the HDPE pipe and be
used to establish sensitivity levels, the effects of attenuation, probe power requirements, qualify
the examination system for field examination, and to monitor the systems performance on an
ongoing basis.
Calibration blocks will be required to establish flaw identification sensitivity levels, and therefore,
differentiate between acceptable and defective fusion welds.
B.
The calibration blocks shall contain artificial diffracting defects and calibration reflectors to verify
the sensitivity level of the TOFD equipment. Each calibration block shall have the following
artificial defects (note: T = Wall Thickness):
1.
2.
Side drilled hole, 2.00mm (0.079) diameter, located at half T (i.e. 50%T)
3.
Vertical drilled hole, 3.175mm (1/8) diameter, drilled from inside surface to depth of 75%T
C.
The temperature of the calibration block shall be within 10C of the pipe temperature during field
calibration.
D.
The thickness of the pipe to be inspected shall not be less than 90% of the calibration block
thickness.
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The Inspection Contractor shall provide a Calibration Block Selection Matrix suitable for the pipe
IPS and SDR used for this project. This Matrix is subject to Company approval.
F.
Reference Table 1 for an example of acceptable calibration blocks as a function of pipe wall
thickness.
Calibration
Block Tag
Testable
Existing Pipe
Thickness
NPS 24 SDR 17
36 mm (1.412)
55 to 652.25Mhz
68.6 mm (2.7")
20 mm (0.8) to
38 mm (1.5)
NPS 26 SDR 11
60 mm (2.364)
55 to 652.25Mhz
119.4 mm (4.7")
38.1 mm (1.5) to
63.5 mm (2.5)
NPS 28 SDR 9
79 mm (3.11)
55 to 652.25Mhz
175.3 mm (6.9")
63.6 mm (2.5) to
83.9 mm (3.3)
90.5 mm (3.56)
55 to 652.25 Mhz
175.3 mm (6.9")
84 mm (3.3) to
101.5 mm (4)
G.
5.3
Calibration block for porosity (using phased array or B-scan Technology) shall be manufactured
from HDPE pipe and shall contain a minimum of 5 perforations for each drill bit diameter at 5
different depths in order to cover the thickness of the pipe.
Verification of Calibration
The TOFD equipment calibration shall be verified every ten (10) weld examinations, or every four (4)
hours during breaks in the examination, whichever occurs sooner. The inspection system calibration
must be verified for new pipes of different nominal diameter and/or thickness.
5.4
5.5
Couplants
A.
The couplant approved by the Company is potable water. The couplant used to calibrate must
be the same as used to test.
B.
C.
An environmentally friendly anti-freeze agent may be required to ensure that the couplant does
not freeze when inspection is done at temperatures below 0C. After inspection is completed, the
anti-freeze agent must be removed from the pipe surface by rinsing thoroughly with potable
water.
Equipment Maintenance
The electronic performance of the flaw detector shall be checked for alignment in accordance with the
equipment manufacturer's specification prior to use of the equipment for the first time on site and after
any repair or major adjustment, and at least once every 90 days.
6.
Welds and the surface adjacent to the welds to be tested shall be uncovered, accessible, and
not coated with any material that would be detrimental to UT-TOFD inspection.
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6.3
Some non-abrasive surface cleaning may be required to provide suitable conditions for UT
TOFD inspection.
Any weld or pipe irregularity that affects the TOFD inspection (e.g., alignment, mechanical
indentions, undercut, excessive weld build up, etc.) shall be recorded.
B.
Should any repairs to the butt fusion joint be required, the ultrasonic examination shall not
commence until after all repairs have been completed and visually accepted.
After each random weld examination, the parent material at either side of the weld approximately
300 mm (12 inch) shall also be scanned.
B.
Possible conditions or imperfections that may be identified in the parent material during the weld
inspection are noted below:
1.
2.
3.
Porosity*
*Phased array or B-Scan technology shall be used for detection of this defect. Sensitivity
and resolution shall be sent to 0.5mm or better.
C.
6.4
4.
Crack-like defect
5.
Lamination or inclusions
Such findings or any other indications of poor parent material quality, as indicated by the
acceptance criteria of Section 7, must be noted and documented.
6.5
Prior to inspection, the UT-TOFD Technician shall complete an approved, detailed technique
sketch for each type of butt fusion joint to be inspected.
B.
The approved flaw-locating equipment must be utilized in accordance with the operating
instructions of the equipment manufacturer. To produce reliable and reproducible results, the
Porta-TOFD Scooter, or approved alternate, will be used along the entire length of the butt
fusion weld. If necessary, the Inspection Contractor must modify the Porta-TOFD Scooter, or
approved alternate, to function properly and accurately on non-magnetic HDPE material.
C.
D.
Using the approved TOFD equipment the initial D-Scan shall be in compliance with the following
requirements:
1.
2.
Probes movement along the centerline of the weld zone shall be in a single circumferential
direction.
3.
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6.6
4.
5.
During the initial D-scan the Porta-TOFD, or approved alternate, software must also
simultaneously record an A-Scan image for comparison.
E.
A second scan direction (B-Scan) can be used with the transducer moved in the direction of the
beam to better characterize any flaws located during the D-Scan (when required).
F.
Scanning sensitivity must be the same as that defined for the calibration block standard, with a
signal-to-noise ratio of 6 dB.
G.
The scanning speed shall not exceed 150 mm/sec (6 lineal inches per second) unless it can be
demonstrated that the required sensitivity levels can be maintained at greater speeds.
Discontinuity evaluation shall be performed at the sensitivity level required by this specification,
and shall be in accordance with the following:
1.
2.
B.
6.7
b.
Length (x)
c.
d.
Type of discontinuity:
(1)
Embedded
(2)
Bottom-Surface Breaking
(3)
Top-Surface Breaking
(4)
Through-wall
(5)
Point Reflector
The location of the imperfection shall be marked on the pipe and the imperfection shall be
permanently marked electronically via the Porta-TOFD, or approved alternate, software.
Characterization of Flaws
A.
In order to characterize a flaw/imperfection, an indication resolvable in the D-, A-, & B-Scan shall
be classified as described below:
1.
Embedded Discontinuities
An indication with both an upper-tip and low-tip diffraction that is a measurable distance
away from both the inner and outer pipe surface
2.
3.
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Through-wall Discontinuities
An indication that interrupts, weakens, and/or shifts both the lateral wave and back wall
echo and appears to cover the entire cross-section thickness (ignoring the protrusion of the
weld bead) shall be considered a through-wall discontinuity.
5.
Point Reflector
An indication consisting of only an apparent upper-tip with no interruption of the back wall
echo or, respectively, only a lower-tip with no interruption of the lateral wave, shall be
labelled an imperfection with no height, and therefore, a point reflector.
B.
6.8
Check for couplant loss whenever there is an interruption of the back-wall echo or weakening of
the lateral wave. The indications in the lateral wave or back-wall echo can be weak and care
must be taken to not misinterpret the TOFD examination results.
7.
Acceptance Criteria
A.
Special consideration shall be given by an experienced Technician while interpreting the TOFD
results to accurately locate and identify fabrication induced fusion flaws such as lack of fusion,
incomplete penetration, and foreign particles that occur in HDPE.
B.
By comparing the results of the D-, B- & A-Scan to the acceptance standards, below, the butt
fusion weld joint will be judged acceptable or not acceptable. Based on the relative severity of
the defects, the failed welds will also be categorized.
C.
The acceptance criterion given as per ASME B31.3, Table A341.3.2 (see Fig 2) shall be used
when evaluating butt fusion welds; unfilled or un-bonded areas in the joint are not acceptable.
Any embedded, bottom-surface breaking, top-surface breaking, or through-wall discontinuity that
is interpreted to be gross lack of fusion or incomplete penetration are unacceptable regardless of
length.
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Imperfections that are not interpreted as areas of gross lack of fusion or incomplete penetration
may or may not be grounds for rejection of the weld. Any dimension of an identified point
reflector, indication, or crack-like defect shall not be larger than the critical flaw size.
1.
For wall thickness less than 25.4mm (1): critical flaw size is one-third (1/3) the wall
thickness.
2.
For wall thickness greater than 25.4mm (1): critical flaw size is 9.5mm (0.375).
NOTE!!! The critical flaw size is subject to verification by the Company once final pipe
diameters and wall thicknesses (i.e. IPS and SDR combinations) for the project are
confirmed.
E.
The presence of multiple indications (point reflections, incomplete fusion, cracks) shall result in
weld failure. The failed welds shall also be categorized based on the Weld Severity Ranking
Criteria in Table 2:
Table 2-UT-TOFD Examination - Weld Severity Ranking Criteria
Defect Type
CAT 1
1 - 6PR
7PR
X
X
IF
IF+PR
C+PR
Loss of LW and/or BE
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CAT 2
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Point Reflector
Incomplete Fusion
Crack
Lateral wave
Back wall Echo
Point Reflector
1.
2.
A weld identified as Category 2 contains major defects and shall be removed at discretion
of Companys Quality Manager.
F.
If a fusion weld fails examination, regardless of the defects and the weld severity ranking
category, the Construction Contractor and Company shall be notified immediately since this will
affect weld production, as per the requirements of Section 2.2.
G.
2.
Size of each pore shall be 1 mm or smaller.
Both criteria shall be met for pipe and fitting to be accepted.
7.2
7.3
The Inspection Contractor shall mark all welds that have been ultrasonically examined and
accepted with green paint. All welds requiring repair shall be marked with red paint; the weld
severity category shall be identified. The marking shall be done in such a manner so as to
enable the Company and Construction Contractor to easily determine the status of the welds on
the pipeline.
B.
The Inspection Contractor shall maintain, on Company approved report forms, an individual weld
report and a daily log of all welds inspected (see Attachment 1 and Attachment 2 for acceptable
sample forms). Any Inspection Contractor report form is to be submitted for approval prior to
beginning the Work.
C.
An individual electronic file shall be kept for each weld inspected. All weld reports shall be stored
on CD ROM media and catalogued such that they may be referenced at a later date. The
electronic file of each defective weld shall have electronic markers that indicate and describe the
presence of each defect identified.
The Inspection Contractor shall prepare a final end-of-job examination report. The report is to
contain the following for each individual butt fusion joint:
1.
2.
Date
3.
4.
Examination results
5.
Defect Characterization
a.
The size, quantity, and location of all relevant indications shall be recorded.
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8.
Sketches and TOFD images shall be provided with the report showing the location,
direction, and frequency of indications.
c.
6.
7.
8.
SAFETY REQUIREMENTS
8.2
9.
b.
The Inspection Contractor shall provide the Construction Contractor and Company a copy of
their internal safety program.
B.
The Construction Contractor will provide the Companys safety procedures to the Inspection
Contractor. The Inspection Contractor shall attend all applicable on-site safety orientations and
meetings.
Reporting Accidents
A.
B.
A lost time accident will be followed by a written report. This report will describe the accident and
any steps taken to avoid a reoccurrence.
ATTACHMENTS
Attachment 1
Attachment 2
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LINE NUMBER:
PIPE
NPS/
THICKNESS:
WELD LOCATION:
INSPECTION
STANDARD:
TOFD REPORT
IMAGE NO.:
&
UT EQUIPMENT
NO.:
MODEL
TRANSDUCER MTG.:
CALIBRATION
NO.
UT EQUIPMENT
NO.:
SERIAL
TRANSDUCER SIZE:
CALIBRATION
BLOCK TEMP.:
INDICATION
POSITION
Y, Z, & DEPTH)
PAGE 1 OF 1
ACCEPTANCE
STANDARD:
SCANNING METHOD:
COUPLANT
ADDITIVE(S):
AND
BATCH NUMBER:
TYPE OF INSPECTION:
FLAW DETECTION
THICKNESS
TYPE OF REFLECTOR
CALIBRATION BLOCK
NPS,
DR,
AND
THICKNESS:
SIDE
HOLE
PIPE TEMP.:
DIMENSIONS (X,
DATE:
TRANSDUCER S/N:
DR/
NDE PROCEDURE
NO.:
DEFECT
CODE
DEFECT
TYPE
TRANSDUCER
FREQUE
CY:
ACCEPT
VERTICAL
HOLE
NOTCH
SHOE ANGLE:
0 DEG.
55 DEG.
65 DEG.
70 DEG.
1.0 MHz
2.25 MHz
OTHER
REJECT
WELD CATEGORY
DEFECT CODE
C-
CRACK
IP -
INCOMPLETE
PENETRATION
IF LA -
INCOMPLETE
FUSION
LAMINATION
P-
POROSITY
O-
OTHER SPECIFY
EMBEDDED
BSB -
PR -
POINT REFLECTOR
TW -
BOTTOM-SURFACE
BREAKING
THROUGH-WALL
TSB -
TOP-SURFACE
BREAKING
THICKNESS
ACCEPT
REJECT
RECORED
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WELD
NO.
LINE NO.
IPS
SDR
CALIBRATION
BLOCK NO.
AREA:_______________________
VIUSAL
INSPECTION
PASS
FAIL
TOFD
INSPECTION
PASS
WELD CAT.
DATE: _____________________
REMARKS
FAIL
ULTRASONIC-TOFD INSPECTOR
DATE
__________________
COMPANY REPRESENTATIVE
PAGE
DATE
OF ___
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ESPECIFICACIN DE
CONSTRUCCIN DE INSPECCIN
ULTRASNICA-TOFD PARA
TUBERAS HDPE
DOCUMENTO NO. 240K-C2-CS-50-006
REV. 0T
05 Noviembre 2012
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Autor
Kevin McConville
Kevin McConville
Rob Dawson
Rob Dawson
Rob Dawson
Fecha Rev.
12Oct11
09Nov11
01May12
17May12
05Nov12
Nueva Edicin
Aprobaciones Fluor
Director de Proyecto
N/A
Gerente de Ingeniera
N/A
Gerente de rea
N/A
Jefe de Procesos
N/A
N/A
Revisor
N/A
Autor
N/A
Aprobaciones SMCV
Gerente de Ingeniera
Descripcin de la Revisin
Emitido para Revisin Combinada
Emitido para Revisin del Cliente
Emitido para Aprobacin
Emitido para Construccin
Emitido para Construccin Translated by Tescup,
tracked changes by Gabriela Cespedes
Fecha
Fecha
N/A
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2.
3.
4.
5.
6.
7.
8.
9.
GENERAL...................................................................................................................................................... 5
1.1 Resumen ..........................................................................................................................................5
1.2 Referencias.......................................................................................................................................6
1.3 Condiciones de campo .....................................................................................................................7
INTERPRETACIN Y PRUEBAS ................................................................................................................ 7
2.1 General .............................................................................................................................................7
2.2 Soldaduras que sern probadas ......................................................................................................7
2.3 Interpretacin de la prueba...............................................................................................................8
CAPACITACIN DE TCNICOS ................................................................................................................. 8
3.1 Personal Calificado...........................................................................................................................8
3.2 Nivel Tcnico requerido....................................................................................................................9
3.3 Registro de calificacin.....................................................................................................................9
3.4 Evaluacin Del Tcnico ....................................................................................................................9
3.5 Otros Requerimientos y Calificaciones ............................................................................................9
EQUIPO UT-TOFD ........................................................................................................................................ 9
4.1 Equipo Ultrasnico-TOFD Aprobado................................................................................................9
4.2 Seleccin de la sonda Ultrasnica .................................................................................................10
4.3 Parmetros Del Equipo Ultrasnica-TOFD ....................................................................................10
4.4 Mecanismo de Escaneo Ultrasnica-TOFD ...................................................................................11
PROCEDIMIENTO DE CONFIGURACIN Y CALIBRACIN DE EQUIPO ............................................ 11
5.1 General ...........................................................................................................................................11
5.2 Normas de los Bloques de Calibracin ..........................................................................................11
5.3 Verificacin de Calibracin .............................................................................................................12
5.4 Acopladores....................................................................................................................................12
5.5 Mantenimiento del Equipo ..............................................................................................................13
TCNICAS DE PREPARACIN E INSPECCIN DE SOLDADORAS.................................................... 13
6.1 Accesibilidad y Condiciones de la superficie de Tuberas .............................................................13
6.2 Requerimiento de Datos previo a la Prueba ..................................................................................13
6.3 Examen de Defectos en Material matriz ........................................................................................13
6.4 Comparacin Acstica previa al Examen de soldaduras...............................................................14
6.5 Procedimiento de prueba de exploracin.......................................................................................14
6.6 Evaluacin de Defectos y Discontinuidad ......................................................................................14
6.7 Caracterizacin de Defectos ..........................................................................................................15
6.8 Re-Anlisis de los defectos Reparados o Soldaduras ...................................................................15
CRITERIOS DE ACEPTACIN Y PRESENTACIN DE INFORMES...................................................... 16
7.1 Criterios de Aceptacin ..................................................................................................................16
7.2 Reporte e identificacin de los defectos.........................................................................................17
7.3 Contenido del informe final de evaluacin de fin de trabajo ..........................................................18
PROGRAMA GENERAL DE SEGURIDAD ............................................................................................... 18
8.1 Programa General de Seguridad....................................................................................................18
8.2 Notificacin de Accidentes .............................................................................................................18
ANEXOS ...................................................................................................................................................... 19
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1.
GENERAL
1.1
Resumen
A.
B.
Alcance de la especificacin
1.
Esta especificacin define los requisitos generales, tcnicas y equipos para la inspeccin
no destructiva ultrasnica por Difraccin de Tiempo de Vuelo (UT-TOFD) en soldaduras de
fusin a tope de polietileno de alta densidad (HDPE) en el servicio de tuberas.
2.
3.
Esta especificacin establece pautas para la puesta a punto y calibracin de equipos para
la tcnica de exploracin TOFD de dos sondas (emisin y recepcin).
Terminologa
Los trminos siguientes se definen como se indica, a menos que se indique lo contrario:
1.
2.
B-Scan Escaneo que muestra los datos recogidos durante la exploracin del par de
sonda en la direccin del haz transversal a travs de la soldadura o defecto.
3.
D-Scan Escaneo que muestra los datos recogidos durante la exploracin del par normal
de sonda a la direccin del haz a lo largo de la soldadura o defecto.
4.
Eco por pared posterior Eco debido a la onda reflejada desde la superficie posterior.
5.
Unin de soldadura por fusin a tope una union en la cual los extremos preparados de la
tubera de polietileno de alta densidad se calientan contra una placa caliente a la
temperatura deseada, lo que permite que en los extremos se fusionen a travs de la
aplicacin de presin extrema.
6.
7.
8.
9.
10.
Onda Lateral Onda que se ejecuta entre las dos sondas UT-TOFD.
11.
12.
Unin de Monturas por Fusin Una unin en la que se utiliza una placa calefactora
contorneada para calentar simultneamente la base de la curva del accesorio montante y
un rea correspondiente de la superficie de tubera a la temperatura requerida para
permitir la fusin completa tras la aplicacin de una presin externa.
13.
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C.
D.
14.
Unin de Socket por Fusin - Una unin en la que las superficies de unin de los
componentes se calientan, y la unin se hace insertando un componente dentro del otro.
15.
Trabajo no Incluido
1.
2.
Documentos Relacionados
Los siguientes documentos describen los elementos de trabajo relacionados:
Especificacin de Construccin para el Ensamblaje en
240K-C2-CS-50-005
Campo de Tuberas de polietileno de alta densidad.
240K-C2-DC-10-002
240K-C2-SP-50-001
Coordinar los trabajos prescritos en esta especificacin con el trabajo establecido por las
especificaciones antes mencionadas.
1.2
Referencias
Las publicaciones listadas a continuacin forman parte de esta especificacin. La versin de las
publicaciones de referencia dentro de esta especificacin deber ser la ms reciente y los addendum
vigentes desde el 1 de octubre de 2011, a menos que se especifique lo contrario; y las partes
aplicables de las publicaciones de referencia se convertirn en parte de esta especificacin, como si
estuvieran totalmente incluidas. Salvo lo dispuesto por los requerimientos especificados en este
documento o por los detalles de planos, los trabajos incluidos en esta especificacin se adecuarn a
las disposiciones aplicables de estas publicaciones.
ASME
ASNT
ASTM
BSI
Tuberas de Proceso
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1.3
Condiciones de campo
Consultar la Seccin 1.1D - Documentos Relacionados.
2.
INTERPRETACIN Y PRUEBAS
2.1
2.2
General
A.
Con esta especificacin al realizar el examen (UT-TOFD), es necesario, para tener un registro
exacto, que el contratista de construccin proporcione informacin esencial para que el tcnico
de inspeccin realize la prueba. Esta informacin identifica los elementos que se estn
probando. El tcnico por su parte debe proporcionar informacin para el registro que apoya la
validez de la prueba.
B.
La informacin necesaria para identificar los elementos que se estn probando incluye el
nmero de proyecto o contrato, el nombre/nmero de etiqueta del componente y la
configuracin de la soldadura en conjunto: tamao de la soldadura y la ubicacin.
C.
La verificacin de validez de la prueba requiere el registro del nombre del tcnico y el nivel, y
una copia de la certificacin del tcnico.
D.
UT-TOFD se utiliza para inspeccionar las soldaduras por fusin de produccin de forma
aleatoria, cuando el examen aleatorio UT-TOFD (es decir, la frecuencia de examinacin es
menor al 100%) esta especificado por el administrador de calidad de la compaa, este se debe
basar en un criterio de muestreo progresivo, segn se detalla en la Fig. 1.
B.
C.
D.
Una soldadura fallar la inspeccin UT-TOFD si est etiquetada ya sea CAT1 o CAT2 por parte
del contratista de inspeccin de a cuerdo con los criterios de aceptacin de la Seccin 7 de
esta especificacin. El etiquetado de la soldadura con falla como CAT1 o CAT2 indica la
gravedad relativa de los defectos que presenta.
E.
Este mtodo solo se utiliza para detectar defectos de fusin a tope para el que se ha
desarrollado y calificado. Esta especificacin no aborda los requisitos de inspeccin de
cualquier otro tipo de uniones de fusin de HDPE, como la fusin a socket o fusin de montura.
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PASS
PASA
CORRECT
FAULTS
CORREGIR
FALLAS
ENINEL
FUSION DE
EQUIPMENT
EQUIPO
FUSIN / /
PROCEDURE
PROCEDIMIENTO
FAIL
FALLA
N=1
INSPECCIONAR
INSPECT
UNA
ONE WELD
SOLDADURA
PASS
PASA
FALLA
FAIL
SUSPEND
SUSPENDER
FUSION
FUSIN E &
INVESTIGAR
INVESTIGATE
Ver NOTA 4
see NOTE 4
VER NOTA 1
See NOTE 1
CONTINA
CONTINUE
FUSIN
&
FUSIONS
INSPECC.&
INSPECTIONS
PASA
PASS
INSPECCIN
ALEATORIA
DE
RANDOM WELD
INSPECTION
SOLDADURAS
NOTA
see Ver
NOTE
2,3 2,3
FAIL
FALLA
DETENER
STOP
FUSIN
FUSION
VER NOTA 1
See NOTE 1
TODAS LAS
SOLDADURAS
ALL WELDS
PASANPASS
INSPECCIONAR
DOS
INSPECT
SOLDADURAS
TWO WELDS
EXAMINAR
TODAS LAS
EXAMINE ALL
SOLDADURAS
REMAINING
RESTANTES SIN
UNINSPECTED
INSPECCIONAR
WELDS
UNA
AMBAS
ONE
OROBOTH
FAIL
FALLA
NOTAS:
1)
SI 2, LAS SOLDADURAS RESTANTES QUE NO HAN SIDO INSPECCIONADAS EN LA LTIMA INSPECCIN, EXAMINAR 2
NOTES:
SOLDADURAS ALEATORIAMENTE. SI ES 1 SOLDADURA RESTANTE NO INSPECCIONADA EN LA LTIMA INSPECCIN, EXAMINAR
DICHA SOLDADURA.
1) IF > 2 UN-INSPECTED
WELDS REMAIN FROM THE LAST INSPECTION, EXAMINE 2 WELDS AT RANDOM. IF 1 UN-INSPECTED WELD REMAINS
2) LAST
LA FRECUENCIA
DE INSPECCIN
ALEATORIA
DE SOLDADURAS DEBERN SER DETERMINADAS POR LA ESPECIFICACIN DE
FROM
INSPECTION, THEN
EXAMINE THAT
ONE WELD.
CLASE DE LNEA DE TUBERAS C-SP-50-001 ANEXO 5. SI < 5 SOLDADURAS RESTANTES QUE NO HAN SIDO INSPECCIONADAS EN
LA LTIMA INSPECCIN, EXAMINAR UNA SOLDADURA ALEATORIAMENTE.
2) THE RANDOM WELD INSPECTION FREQUENCY SHALL BE DETERMINED PER PIPING LINE CLASS SPECIFICATION C-SP-50-001 ATTACHMENT 5.
3)
EL CONTRATISTA DE SOLDADURA DE FUSIN NO DEBER CONOCER PREVIAMENTE LA SECUENCIA DE INSPECCIN ALEATORIA
IF < 5 UN-INSPECTED WELDS REMAIN FROM THE LAST INSPECTION, EXAMINE 1 WELD AT RANDOM.
DE SOLDADURAS.
4)
SI EL EQUIPO DE FUSIN ES SUSPENDIDO DEBIDO A FALLAS EN LA INSPECCIN, EL EQUIPO, ESPECIFICACIONES,
3) THE FUSION
WELDING CONTRACTOR
SHALL NOT
KNOW THE
WELD
INSPECTION
SEQUENCE
IN ADVANCE.
CALIFICACIONES
Y PROCEDIMIENTOS
DEBERN
SERRANDOM
AUDITADAS
POR
EL GERENTE
DE CALIDAD
DEL COMPRADOR.
4) IF A FUSION CREW IS SUSPENDED DUE TO INSPECTION FAILURES, THE EQUIPMENT, SPECIFICATIONS, QUALIFICATIONS, AND
PROCEDURES SHALL BE AUDITED BY THE BUYER'S QUALITY MANAGER.
Figura 1 Diagrama de Flujo Muestreo Progresivo para la Inspeccin de Examinacin por UT-TOFD
2.3
3.
Interpretacin de la prueba
A.
B.
El contratista de construccin podr disponer de una segunda prueba por su propia cuenta. Si el
contratista de construccin decide no repetir la prueba, la interpretacin del tcnico se asume y
si es necesario se har una reparacin sobre esa base.
C.
Si se realiza una segunda prueba, los resultados de ambas pruebas se presentaran al Director
de Calidad de la Compaa para su evaluacin.
CAPACITACIN DE TCNICOS
3.1
Personal Calificado
A.
Los tcnicos que realizaran la inspeccin TOFD deber estar certificado de acuerdo con SNTTC-1A o un equivalente.
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3.2
2.
3.
4.
5.
6.
Fecha de Certificacin
3.3
3.4
3.5
4.
Registro de calificacin
A.
B.
B.
Solo los Tcnicos y los Contratistas de inspeccin que tienen experencia con la examinacin
UT-TOFD de soldaduras de fusin a tope de polietileno de alta densidad son aceptables. La
validacin de la experiencia puede ser necesaria.
B.
El Tcnico debe de estar familiarizado con las tcnicas TOFD necesarias para detectar de
forma fiable y con precisin los defectos de fusin de tamao comn en soldaduras de fusin a
tope HDPE incluyendo pero no limitando, los contaminantes, los huecos, las grietas,
discontinuidades, la falta de fusin (fusin fra) y la falta de penetracin.
EQUIPO UT-TOFD
4.1
B.
El detector de fallas ultrasnico ser de dimensiones y peso fcilmente transportables por una
persona sin necesidad de asistencia mecnica.
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4.2
C.
D.
E.
El detector de fallas puede ser alimentado por una fuente de energa externa, tal como por un
generador porttil o bateras. La estabilizacin de la fuente de energa, ya sea integrado o
externo, debe adaptare a las fluctuaciones de voltaje de entrada por lo menos 10% sin afectar
las caractersticas de rendimiento del detector de fallas. Si se utilizan bateras, deben tener
capacidad, o bateras de repuesto deben ser cargadas y estar disponibles, de tal manera que el
tcnico no espere para recargar cuando exista una necesidad de inspeccin.
B.
De acuerdo con BS EN583-6, las sondas utilizadas para la inspeccin TOFD debern cumplir
con los siguientes requerimientos mnimos:
Nmero de sondas: 2 (trasmisor y receptor)
2.
El modo de onda: Comprensin de onda (el uso de ondas de corte deber ser acordada
por la Compaa y Contratista de inspeccin)
3.
4.
C.
Las sondas debern funcionar a una frecuencia estndar nominal de 2.25 MHz.
D.
E.
F.
4.3
1.
1.
La separacin de la sonda y la inspeccin tcnica ser usado de tal manera que, para
maximizar la eficiencia de difraccin, el ngulo incluido de ejes del haz de la sonda en
cualquier falla existente sea aproximadamente de 120.
2.
Las sondas se dispondrn de manera que la lnea central imaginaria del haz intersecte la
zona a una profundidad apropiada donde los defectos se prevn, en el ngulo antes
mencionado. Las desviaciones de ms de -35 o +45 para este valor resultan en ecos
dbiles de difraccin y no se utilizaran.
El ancho del haz deber cubrir el 90% (mnimo) hasta el 100% de la seccin transversal de
inters y garantizar que todos los defectos se resuelvan.
La linealidad del amplificador ser 5% sobre un rango de 0% a 75% del lmite vertical superior
y una seal establecida a esta altura debe permanecer claramente visible cuando se disminuye
en 24 dB.
B.
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4.4
5.
C.
D.
El equipo de inspeccin TOFD debe operar de tal manera que la relacin seal/ruido no sea
menor que 6 dB para el material de la tubera de HDPE. Por ejemplo, establezcer la supresin y
ganancia de ruidos en el equipo de tal manera que la seal grabada desde la llegada de
indicacin de onda lateral sea al menos de 6 dB mayor en amplitud que el ruido electrnico
existente, en la misma zona, antes de la onda lateral.
E.
F.
Las seales de digitalizacin sern digitalizadas con una frecuencia de muestreo que es al
menos cuatro (4) veces la frecuencia de la sonda. El ajuste normal aceptable ser 100MHz.
G.
El mecanismo de barrido deber mantener una distancia constante y alineacin entre los puntos
ndices de las dos sondas, segn los requisitos del punto 4.2. El mecanismo de barrido deber
ser impulsado manualmente y guiado mediante un mecanismo gua adecuado (banda de acero,
cinturn, etc.) alrededor de la circunferencia del tubo. La precisin de gua entre la lnea central
de referencia (por ejemplo, cordn de fusin a tope) y los ndices de la sonda deben estar
dentro de 10%.
B.
Las unidades de bsqueda ultrasnica deber indicar con claridad su frecuencia normal, el
ngulo de refraccin y un punto de referencia del haz.
C.
Las unidades de bsqueda ultrasnica debern estar libres de ruido interno sobre la distancia
de la trayectoria del haz y al ms alto nivel de sensibilidad.utilizado en el examen de soldadura
D.
El codificador interno del mecanismo de exploracin para los datos de posicionamiento deben
ser calibrados segn las recomendaciones del fabricante del equipo. No habr desviaciones
superiores al 5% entre el desplazamiento registrado y el real.
5.2
General
A.
Cada prueba de calibracin debe incluir tanto la imagen de A-scan y TOFD (D-scan) que se
graba digitalmente para la verificacin de la configuracin del equipo. Cada prueba de
calibracin tendr un numero de calibracin y los resultados de cada prueba se guardaran
electrnicamente y sern registrados (por ejemplo CD-ROM), con la hora, fecha y todos los
nmero de etiquetas examinados sucesivamente.
B.
Los estndares de calibracin de bloques se fabricaran a partir del mismo material que la
tubera de polietileno de alta densidad y ser usado para establecer los niveles de sensibilidad,
los efectos de la atenuacin, los requisitos de energa de la sonda, calificar el sistema de
examinacion para la examinacin en campo, y para monitorear el comportamiento del sistema
en forma permanente.
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Los bloques de calibracin debern contener defectos artificiales de difraccin y los reflectores
de calibracin, para verificar los niveles de sensibilidad de los equipos TOFD. Cada bloque de
calibracin deber presentar los siguientes defectos artificiales (Nota: T =Espesor de la Pared):
1.
2.
Orificio perforado al costado, 2mm (0,00790.079) de dimetro, situado a media T (es decir
50% T)
3.
C.
D.
El espesor de la tubera a ser inspeccionado no deber ser inferior a 90% del espesor del
bloque de calibracin.
E.
F.
Referir Tabla 1 para un ejemplo de bloques de calibracin aceptables en funcin del espesor de
la pared de la tubera.
Tabla 1 Seleccin de Matriz, Bloque de Calibracin
Etiqueta
Bloque de
Calibracin
Tamao de la
Tubera Bloque
de Calibracin
Espesor de
Pared Bloque de
Calibracin
Angulo y
Frecuencia
de Sonda
Separacin de
Sonda
Comprobable
Espesor
Tubera
Existente
NPS 24 SDR 17
36 mm (1.412)
55 a 652.25Mhz
68.6 mm (2.7")
20 mm (0.8) a 38
mm (1.5)
NPS 26 SDR 11
60 mm (2.364)
55 a 652.25Mhz
119.4 mm (4.7")
38.1 mm (1.5) a
63.5 mm (2.5)
NPS 28 SDR 9
79 mm (3.11)
55 a 652.25Mhz
175.3 mm (6.9")
63.6 mm (2.5) a
83.9 mm (3.3)
90.5 mm (3.56)
55 a 652.25 Mhz
175.3 mm (6.9")
84 mm (3.3) a
101.5 mm (4)
G.
5.3
Verificacin de Calibracin
La calibracin del equipo TOFD se verificara cada diez (10) exmenes de soldadura, o cada cuatro
(4) horas durante los recesos en el examen, lo que ocurra antes. La calibracin del sistema de
inspeccin debe ser verificada para nuevas tuberas de diferente dimetro nominal y/o espesor.
5.4
Acopladores
A.
El acoplador aprobado por la compaa es el agua potable. El acoplador utilizado para calibrar
debe ser el mismo que se utiliza para realizar pruebas.
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5.5
B.
Un agente humectante ecolgico puede ser necesario para promover el acoplamiento acstico,
sin embargo, despus de que el liquido se haya evaporado ningn residuo permanecer en la
superficie de la tubera.
C.
Un agente anticongelante ecolgico puede ser necesario para asegurar que el acoplador no se
congele cuando se realice al inspeccin a temperaturas inferiores a 0 C. Despus que la
inspeccin se haya completado, el agente anticongelante debe ser retirado de la superficie de la
tubera enjuagando bien con agua potable.
6.
6.2
6.3
Las soldaduras y las superficies adyacentes a las soldaduras que se vayan a probar no estarn
cubiertas, sern accesibles y no recubiertas con cualquier material que pudiera ser perjudicial
para la inspeccin UT-TOFD.
B.
La limpieza en algunas superficies no abrasivas puede ser requerida para proporcionar las
condiciones adecuadas para la inspeccin UT-TOFD.
B.
En caso que sean necesarias reparaciones a las juntas de fusin a tope, el examen ultrasnico
no comenzara sino hasta despus que todas las reparaciones se hayan completado y aceptado
visualmente.
B.
2.
3.
Porosidad*
*la tecnologa de Arreglo de Fase o B-scan ser utilizado para la deteccin de este
defecto. La sensibilidad y la resolucin sern enviadas a 0,5mm o ms.
C.
4.
5.
Inclusiones o Laminacin
Estos resultados o cualquier otra indicacin de mala calidad de material matriz, como se indica
en los criterios de aceptacin de la seccin 7, deben ser sealados y documentados.
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6.5
6.6
A.
B.
El equipo de localizacion de fallas aprobado debe ser utilizado de acuerdo con las instrucciones
de operacin del fabricante del equipo. Para obtener resultados fiables y reproducibles, el
scooter Porta-TOFD o similar aprobado, se utiliza a largo de toda la longitud de la soldadura de
fusin a tope. Si es necesario, el contratista deber modificar la inspeccin scooter Porta-TOFD
o similar aprobado, para que funcione correctamente y con precisin en el material de
polietileno de alta densidad no magntico.
C.
D.
Usando el equipo aprobado TOFD, el D-scan inicial deber cumplir los siguientes requisitos:
1.
Las dos (2) sondas deben estar en una configuracin de emisin y recepcin.
2.
Las sondas de movimiento a largo de la lnea central de la zona de soldadura deber estar
en una sola direccin circunferencial.
3.
4.
5.
E.
Una segunda direccin de exploracin (B-scan) puede ser usada con el transductor movindolo
en la direccin del haz para caracterizar mejor los defectos localizados durante el D-scan
(cuando sea necesario).
F.
La exploracin de sensibilidad debe ser el mismo que se define por la norma del bloque de
calibracin, con una relacin de seal-ruido de 6 dB.
G.
De a cuerdo con BS EN583-6, todas las discontinuidades detectadas por TOFD sern
identificados mediante:
a.
b.
Longitud (x)
c.
d.
Tipo de Discontinuidad:
(1)
Incrustado
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2.
B.
6.7
(2)
(3)
Ruptura Tope-Superficie
(4)
A travs de la Pared
(5)
Punto Reflector
Caracterizacin de Defectos
A.
Con el fin de caracterizar un defecto/imperfeccin una indicacin de resolverse en el D-, A-, Bscan se clasificaran como se describen a continuacin:
1.
Discontinuidades Incrustadas
Una indicacin tanto con difraccin de punta superior y punta inferir que es una distancia
medible lejos de las superficies del tubo interior y exterior.
2.
3.
4.
5.
Punto Reflector
Una indicacin que consta de solo una aparente punta superior sin interrupcin del Eco de
la Pared Posterior o, respectivamente, solo una punta inferior sin interrupcin de la onda
lateral, se etiquetara una imperfeccin sin altura y por lo tanto un punto reflector.
B.
6.8
Compruebe si hay prdida del acoplador cada vez que hay una interrupcin del eco a la pared
posterior o el debilitamiento de la onda lateral. Las indicaciones en la onda lateral o en el eco de
pared posterior puede ser dbil y se debe tener cuidado de no mal interpretar los resultados de
los exmenes TOFD.
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Criterios de Aceptacin
A.
B.
Al comparar los resultados de la categora D-, B-, A-scan a los estndares de Aceptacin, a
continuacin, la unin por soldadura de fusin a tope ser juzgado aceptable o no aceptable.
Sobre la base de la gravedad relativa de los defectos, las soldaduras con defectos tambin se
clasificaran.
C.
El criterio de aceptacin entregado segn ASME B31.3, Tabla A341.3.2 (ver Fig. 2) se utilizaran
cuando se evaluen las soldaduras de fusin a tope: las reas no cubiertas o sin unir en el
empalme no son aceptables.
Toda incrustacin, ruptura fondo- superficie, ruptura tope-superficie o discontinuidad atraves de
pared , se interpreta como falta grave de fusin o penetracin incompleta no son aceptables
independientemente de la longitud.
Las imperfecciones que no son interpretados como zonas de falta grave de fusin o penetracin
incompleta pueden o no ser motivo de rechazo de la soldadura. Cualquier dimensin de un
punto reflector identificado, indicacin, o defecto tipo grieta, no ser mayor que el tamao critico
del defecto.
1.
2.
Para paredes de esposor mayor a 25.4mm (1): el tamao crtico de defecto es de 9.5mm
(0.375).
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CATE 1
1 - 6PR
7PR
X
X
IF
IF+PR
C+PR
PedidaPrdida de LW y/o BE
CATE 2
1.
2.
F.
G.
2.
El tamao de cada poro deber ser de 1mm o menor.
Ambos criterios debern reunirse para que la tubera y los conectores sean aceptados.
7.2
El Contratista de inspeccin deber marcar todas las soldaduras que se hayan examinado por
ultrasonido y aceptado con pintura verde. Todas las soldaduras que requieren reparacin
debern ser marcados con pintura roja, la categora de severidad de soldadura debe ser
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7.3
B.
C.
Un archivo electrnico individual se mantendr para cada soldadura inspeccionada. Todos los
informes de soldadura se almacenan en un CD-ROM y se categorizan de tal amanera que se
pueda hacer referencia a ellos en una fecha posterior. El archivo electrnico de cada soldadura
defectuosa tendr marcadores electrnicos que indican y describen la presencia de cada
defecto identificado.
8.
2.
Fecha
3.
4.
Evaluacin de Resultados
5.
Caracterizacin de Defectos
a.
b.
c.
6.
7.
8.
REQUISITOS DE SEGURIDAD
8.2
B.
Notificacin de Accidentes
A.
B.
Un accidente de tiempo perdido ser seguido por un informe escrito. En este informe se
describe el accidente y las medidas adoptadas para evitar que se repita.
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ANEXOS
Anexo 1
Anexo 2
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DE
INFORME E IMAGEN
TOFD NO.:
NUMERO DE LNEA:
ESPESOR DE TUBO
NPS/ DR :
FECHA:
UBICACIN DE
SOLDADURA:
NORMA
INSPECCIN:
NORMA PARA
ACEPTACIN:
AL
DE
PAGINA 1 OF 1
MODELO DE EQUIPO UT
NO.:
ADITIVOS
ACOPLADOR(S):
TRANSDUCTOR MTG.:
TAMAO
TRANSDUCTOR:
TRANSDUCTOR S/N:
CALIBRACIN
NO.
ETIQUETA
DE
BLOQUE
DE
CALIBRACIN DE REFERENCIA:
A
TEMPERATURA DEL
BLOQUE DE
CALIBRACIN.:
INDICACIN DE
POSICIN
DE
DIMENSIONES
(X, Y, Z, &
profundidad)
BLOQUE
DE
CALIBRACIN NPS,
DR, Y ESPESOR:
PROCEDIMIENTO DE
NDE NO.:
CDIGO DE
DEFECTO
TIPO DE
DEFECT
O
DE
NUMERO DE LOTE:
TIPO DE INSPECCIN:
LADO
AGUJERO
SISTEMA
VERTICAL
FRECUENCIA
DEL
TRANSDUCTOR:
ACEPTA
BLE
MTODO
ESCANEADO:
DETECCIN
DEFECTOS
ESPESOR
TIPO DE REFLECTOR
TEMPERATURA DE
TUBO.:
LA
DE
MUESCA
ANGULO DE INCIDENCIA:
0 DEG.
55 DEG.
65 DEG.
70 DEG.
1.0 MHz
2.25 MHz
OTRO
RECHAZA
DO
CATEGORA DE
SOLDADURA
CDIGO DE DEFECTO
C-
GRIETAS
IP -
PENETRACIN
INCOMPLETA
IF LA -
FUSIN
INCOMPLETA
LAMINACIN
INCRUSTADO
BSB -
PR -
PUNTO REFLECTOR
TW -
RUPTURA
FONDOSUPERFICIE
A TRAVS DE LA
PARED
P
O
-
POROSIDAD
TSB -
RUPTURA
SUPERFICIE
OTRAS
ESPECIFICACIONES
P-014)
TOPE-
ACEPTABLE
RECHAZADO
REGISTRADO
SERVICIOS DE INTERPRETE:
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INFORME
ACEPTADO
COMPAA:
POR
LA
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SOLDAD
URA
LNEA NO.
IPS
NO.
SDR
REA:_______________________
INSPECCIN
VISUAL
BLOQUE DE
CALIBRACIN
NO.
PASA
FALL
A
INSPECCIN
TOFD
PASA
CAT.
SOLDADUR
A
FECHA: _____________________
OBSERVACIONES
FALL
A
INSPECTOR ULTRASNICO-TOFD
FECHA
__________________
REPRESENTANTE DE LA COMPAA
PAGINA
FECHA
DE ___
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