Ultrasonic Thickness Testing Procedure

Refinery Refinery An d Petrochemical Integrated Integrated Development Development (RAPID) Package 2 ULTRASONIC THICKNESS TESTING PROCEDURE

Owner: PRPC Refinery and Crack er SDN.BHD

CONRACTOR CONRACTOR Pro ject No.: M6002-01DD Document No.

Cont ract No :

RAPID/CTC/05-2013-P2 RAPID/CTC/05-2013-P2

Page 1 of 7

RAPID-P0002-0100-PMG-PRC-0001-0011

ULTRASONIC UL TRASONIC THICKNESS THICK NESS TESTING TESTING PROCEDURE PROCEDURE

Document Class: Class :

Z

A

29-Jul-16

IFR – Issued For Review

Rev.

DATE DD-MMM-YY

STATUS – REVISION MEMO

Date

WRITTEN BY (name & signature)

1- not accepted

Vendor Job No.

2- not approved and has comment(s)

Designation : (Eq. Service,if applicable):

3- approved by Purchaser without comment

Vendor Doc. No.

4- approved with minor comment

Requisiton No. :

:

Sign

:

:

:

CHECKED BY (name & signature)

Unit

:

Item No.

:

RAPID-P0002-0100-PMG-PRC-0001-0011

APPROVED BY (name & signature)

Refinery An d Petrochemical Integrated Development (RAPID) Package 2 ULTRASONIC THICKNESS TESTING PROCEDURE CONRACTOR Pro ject No.: M6002-01DD Document No.


Cont ract No :

RAPID-P0002-0100-PMG-PRC-0001-0011

RAPID/CTC/05-2016-P2

Page 2 of 7

Table of Content 1.

GENERAL PRINCIPLES ................................ ................................................................. ........................................... 3

2.

RANGE OF TESTING............................................................ ................................................................. ..................... 3

3.

ACOUSTIC VEL OCITY RANGE OF SEVERAL MATERIAL S ........................................................ ..................... 3

4.

INSTRUMENTS AND PROBES .................................................................................................................... ............. 3

5.

STANDARD TEST BLOCK ....................................................................... ............................................................... ..4

6.

COUPLING .............................................................................................................. ...................................................... 4

7.

INSTRUMENT RECTIFICATION ......................................................................... ...................................................... 4

8.

TESTING PREPARATION ............................................................... ................................................................. .......... 5

9.

METHOD OF MEASUREMENT ................................................................................................ ................................. 5

10. TREATMENT FOR ABNORMAL MEASUREMENT ................................................... ........................................... 5 11. RECORDING AND REPORTING .............................................................................................. ................................ 5 12. COMPLETION DATA ARCHIVE ............................................................................................... ................................ 6 APPENDIX: TESTING REPORT FORMAT ...................................................................................... ................................ 7


1.


Cont ract No :


Page 3 of 7

RAPID-P0002-0100-PMG-PRC-0001-0011

General pri ncip les

1.1 Goals The purpose of making the technological procedure is to improve and guarantee the quality of ultrasonic thickness Testing. Ultrasonic thickness Testing personnel should finish t heir assignment strictly according to requirement in technological procedure. 1.2 The reference for procedure making is ASME BPVC Section V - Nondestructive Examination ASME BPVC Section VIII - Rules for Construction of Pressure Vessels

2.

Range of testing

The procedure is suitable for test thickness of special metal equipment, materials, accessories, machinery parts by digital direct reading ultrasonic thickness instrument or type A pulse reflection ultrasonic flaw detector.

3.

Acous tic velocit y range of several materials

Acoustic velocity of several materials is listed in table1, when using the data of this table, actual acoustic velocity of material should be measured if necessary. Table 1 Acoustic velocity of some main materials: m/s Material

Al um i

names

nium

Steel

Stainles

coope

s steel

r

zirconium

titani

zinc

lead

um

Cas t iron

longitudin al

6300

5900

wave

velocity;

4.

5800

4700

4310

6240

4170

2170

3500 5600

Instrum ents and probes

4.1 The accuracy of ultrasonic thickness instrument should meet the measurement requirements. 4.2 Ultrasonic thickness usually adopts the single crystal straight probe which is type of direct contact, also, single crystal straight probe and double crystal straight probe with deferred piece can be used for testing. 4.3 Testing wall thickness of high temperature workpiece should use the special high temperature probe, casting piece and coarse grained materials should adopt the probe which have large diameter and low frequency. 4.4 Generally, thickness gauge which the accuracy is 0.0 or 0.01 can be used for testing workpiece thickness, thickness gauge with 0.01 accuracy is needed for testing important part or making judgement.


5.

RAPID-P0002-0100-PMG-PRC-0001-0011


Cont ract No :


Page 4 of 7

Standard test bloc k

5.1 Basic requirement and size of test block is shown at ASME standard: The typical ladder block for thickness testing calibration. 5.2 When testing the thickness of curve surface, the same curvature blocks should be used, or amend the standard block for testing.

6.

Coupling

The non-bubble and suitable viscosity coupling agent should be choose according to the surface situation and acoustic impedence of tested workpiece such as engine oil, silica gel, glycerol, sodium silicate and paste. If the workpiece surface is roughness, more viscous coupling agent is needed.

7.

Instrument rectification

7.1

Ultrasonic thickness meter rectification

7.1.1 Digital direct-reading ultrasonic thickness meter Adding the probe on the rectify block of digital direct-reading ultrasonic thickness meter, making the digital shows on the thickness meter screen is the known value of block by adjusting the sound velocity correction button. 7.1.2 Type A pulse reflection ultrasonic flaw detector a. Correction process is done at the thickness value which is near the maximum and minimum value (or half of the maximum value) of thickness which is waiting for testing by ladder blocks. b. Adding probe on the block which is more thick, then, adjust the sound velocity correction button to make the digital shows on the thickness meter screen is the known value of block. c. Adding probe on thinner block, adjusting zero correction button to make the digital shows on the thickness meter screen is near the known value of block. d. Finally, make sure the correct number of both higher and lower sides of measurement is obtained by iterative adjustment, instrument adjusting process is f inish. e. If sound, velocity of material is known, the sound velocity value can be set in advance, then, adjust zero correction button on the block which is the part of instrument to make sure the instrument display is the block thickness. At this time, instrument adjusting process is f inish 7.2 Correction of ultrasonic flaw detector a. Correction process is done at the thickness value which is near the maximum and minimum value ( or half of the maximum value) of thickness which is waiting for testing by ladder blocks. b. Adding probe on the block which is thicker, then, adjust the scanning range button of instrument until bottom echo appear in the corresponding scale position. c. Adding probe on thinner block, adjusting delay scanning button until bottom echo appear in the corresponding scale position.


RAPID-P0002-0100-PMG-PRC-0001-0011


Cont ract No :


Page 5 of 7

d. Finally, make sure the correct bottom echo of both thinner and thicker sides of measurement is obtained by iterative adjustment, instrument adjusting process is finish.

8.

Testin g preparation

Floating rust, scabrities or part of paint film which is disengaged should be clean, proper grinding can be done by grinding wheel if necessary.

9.

Method of measurement

Each position for thickness testing should be tested three times respectively, and recording in time. During test the thickness of pipe, the centre line of the probe and tube shaft centre line should be vertical, and through the pipe axis centre.

10. Treatment for abnormal measurement When using ultrasonic thickness gauge to measure thickness, sometimes the abnormal value would appear which must be properly dealing with. 10.1 There is no display value If the workpiece curvature radius is too small or large number of pitting corrosion is on the back, there is no display value on instrument. At this time, the supplementary testing process should be done by adopting ultrasonic flaw detector. 10.2 The display value is about 2 times of actual thickness When workpiece thickness is less than 3 mm and the back is more smooth, at this time, small distance probe or special probe should be used to avoid the display value is about 2 times of actual thickness. 10.3 The display value smaller than actual thickness When the inner defect is exist, thickness gauge display value is always less than 70% of the nominal thickness, at this time, ultrasonic flaw detector should be used to detect place around the testing point to confirm whether the testing is influenced by defects, the straight probe or angle probe can be used. 10.4 After using carbon block to correct thickness gauge, the display value perhaps would be larger than actual value due to acoustic velocity difference, which should be pay attention to and must correct by corresponding blocks.

11. Record ing and report ing 11.1 Thickness testing personnel must finish original ultrasonic thickness records timely and seriously, if the diagram about thickness testing is needed, the diagram should completely and clearly reflect the actual position for testing. 11.2 The operator should issue report correctly according to the ultrasonic thickness testing recording. Ultrasonic thickness report must be filled completely according to the format prescribed. Report writing must be correct, legible and cannot be altered arbitrarily.


RAPID-P0002-0100-PMG-PRC-0001-0011


Cont ract No :


Page 6 of 7

11.3 Thickness test result should be based on the report, any individual oral data cannot be taken as the basis of construction and completion data, the report should deliver to entrust unit or the client timey. 11.4 Ultrasonic thickness report is only effective which must have the signing by operator and audit and stamped with the special seal for testing.

12. Completion data archive 12.1 Non-destructive testing data of projects under construction should have special person to (personnel duty engineer, evaluation personnel) storage, storage environment shall ensure that data will not be affected with damage and loss. 12.2 Completion data should be transfer to the archivists timely.

Refinery An d Petrochemical Integrated Development (RAPID) Package 2 ULTRASONIC THICKNESS TESTING PROCEDURE


CONRACTOR Pro ject No.: M6002-01DD Document No.

Cont ract No :


Page 7 of 7

RAPID-P0002-0100-PMG-PRC-0001-0011

Appen di x: tes ti ng rep or t f or mat NNo.032-2015

宁波恒信工程检测有限公司 Ningbo Hengxin Engineering Testing Co.,Ltd

Ultrasonic Thickness Measurement Report 报告编号： Report No.

工程名称

委托单号

记录编号

Project name

Entrust No.

委托单位 Entrusted by

Record No.

检件名称

检件编号

Test piece description

Test piece No.

材质

Material

委托日期 Date of entrustment

表面状态

检测场所 Test place

Surface states

检测比例

Test percentage

检测标准 Test criteria

设备型号 Equipment model

标准试块 Standard test coupon

仪器编号

检件规格

测量精度

Equipment No.

Measurement precision

对比试块

耦合剂

公称厚度

thickness Check point No. ominal （mm）

检测：

审核：

Tested by:

Reviewed by:

实测厚度 Actual thickness

（mm）

mm mm

Couplant

Reference block

检测部位(编号) 测点编号 Test position No.

检测部位(编号)测点编号 Test position No.

heck point No.

公称厚度实测厚度 Nominal thickness

（mm）

Actual thickness

（mm）

日期：(印章) Date:

(Seal)

公司地址：浙江宁波镇海俞范东路 811 号. Address:No.811 Yufan east road Zhenhai Ningbo Zhejiang Province 电话、传真 Tel\Fax：0574-86433603 未经公司批准，部分采用本报告无效 .Part adopts is invalid without the approval of the company.  第页共页Page of

Ultrasonic Thickness Testing Procedure

Recommend Documents