Performance Test Protocol for AUT Personnel Qualification

Performance Test Protocol for AUT Personnel Qualification Revision 1.0, 3/30/3009

1. General

The Test Protocol that is to be used by ultrasonic testing (UT) examiners to take the automated ultrasonic testing (AUT) Personnel Qualification Test is described in this document. The Examinee shall be familiarized with this protocol before arriving at the Westhollow Technology Center. Prior to the start of each test session, the Test Administrator will conduct an orientation with all Examinees that will cover any changes made to this document.

Personnel taking the test shall follow his/her employer’s written AUT procedure. The Examinee shall provide a copy of the AUT procedure to the Test Administrator prior to taking the test.

2. Testing Details

The test session is scheduled to be completed in one workday. The testing will start at 8:00 am, with a lunch break at 12:00 - 12:30 - In Room (must bring own lunch). The examination ends at 5:00 pm. Only one Examinee may leave the testing area at a time. The testing will be monitored at all times to prevent compromise of the test samples.

There is only one set of samples that will be scanned by all technicians. The AUT data collection can be done simultaneously by sharing the samples.

Each technician must collect the AUT data from all six samples alone and perform the data analysis without any assistance. Each Examinee shall work independently and is not allowed to discuss sample or examination information during or after the testing.

All paperwork must be completed and turned in to the Test Administrator at the end of the day. Examinees that fail to complete the testing in the allotted time will be considered to be unsuccessful.

No form of data, electronic or otherwise shall be retained by the Examinee after the test is complete.

3. Personnel Requirements

Personnel performing the qualification test should be, as a minimum, certified to UT Level II or III in accordance with their employers written practice.

4. Equipment Requirements

The Examinee is responsible for supplying ALL of the equipment needed for AUT examination. Sharing of equipment will not be allowed during the demonstration. Listed below are recommended equipment and supplies that should be considered for use during the examination:

- Ultrasonic AUT Instrument - Ultrasonic MUT Instrument - Ultrasonic Transducers for AUT and MUT. Search unit frequencies should be between 2.25 and 5.0 MHz. - Ultrasonic cables - Basic Calibration Blocks - Calibration Reference Standards (IIW, DSC, Rompas) - Indication Plotting Device - Rags - Couplant - Pens/Pencils

5. Test Sample Description

The test will consist of six carbon steel samples, 3 plates and 3 pipes. The samples details are as follows:

- 1 inch plate, 15 inches weld length, Single Vee, 37.5 degree bevel (2) - 1/2 inch plate, 15 inches weld length, Single Vee, 37.5 degree bevel (1) - 12" pipe half section, Wall thickness.767", 20" weld length, Single Vee, 37.5 degree bevel (2) - 8" pipe, Wall thickness .343", 25" weld length, Single Vee, 37.5 degree bevel (1)

Each test specimen will be given a unique identification number. The flaw location and actual specimen identification will be concealed to maintain a “blind test”. Any tape or other type of masking shall not be removed from any of the test samples during or after the examination.

6. Description of Potential Flaws

The type of potential flaws includes all flaws listed in the API QUTE plus transverse cracks, both surface connected and non-surface connected. These flaws include:

 Inside surface connected crack (ID Crack)  Outside surface connected crack (OD Crack)  Embedded center line cracking (CL Crack)  Lack of root penetration (LOP)  Lack of side wall fusion (LOF)  Porosity  Slag and Inclusions  Transverse Cracks Specific Test Specimens are not required to contain all of the flaws identified above. At least one test specimen may be unflawed along the entire length.

All Test Specimens are in the as-welded condition and may contain ID or OD mismatch or other typical non-symmetrical welding geometry.

7. Grading Criteria

The Candidate performance will be evaluated in the following categories: a) Detection – Each weld is divided into grading units and each grading unit will be considered as either flawed or unflawed. There will be only defect type in each grading unit. Sufficient data must be provided in order for the Test Administer to determine if the Examinee actually detected the flaw. b) Flaw Characterization – Once a flaw is detected, the Examinee must characterize the flaw to determine the type of flaw, as described in the list in Section 6. The location of the flaw must be accurate with regard to surface connected or volumetric. The flaw must be properly categorized as either being surface connected or subsurface. c) Flaw Length Sizing – The flaw length shall be sized in accordance with the Examinee’s written UT procedure. Over sizing of the flaw length may result in false calls in the adjoining grading unit. d) Flaw Height Sizing – The flaw height shall be sized in accordance with the Examinee’s written UT procedure. e) Flaw Positioning – The flaws that are reported must also be positioned correctly with respect to the weld centerline, upstream (US) or downstream (DS). The grading will include the flaws approximate relationship to the weld centerline. Cross sectional plotting of the indications on the indication data sheet is required to determine the location of the flaw. f) False Calls – A false call is defined as reporting a flaw in a non-flawed grading unit. The Examinee will not know the location of any unflawed grading units.

Each weld is divided into grading units, which are not necessarily of equal length. A single grading unit included both sides of the weld. Grading units are considered unflawed or flawed. Flawed grading units will contain only one flaw.

A successful Examinee must meet the minimum requirements in all categories.

The test results of pass/fail will be reported the Examinee within two weeks after the test is complete. 8. Calibration

Calibration should be performed and recorded prior to the start of any examination or series of examinations. Calibration should include the complete ultrasonic examination system.

The search unit manufacturer and type, exit point, beam angle measurements and other Instrument Settings shall be listed on the provided “Ultrasonic Calibration Data Sheet”. The Primary Reference Sensitivity level and associated distance amplitude correction (DAC) should be established using the inside and outside surface notches in the flowing manner:

 Maximize the signal response from the ID notch at ½ V-Path and set the response at approximately 80% FSH, establishing a flat line DAC at 80% for ½ V-Path examinations. For examinations beyond ½ V-Path continue the DAC curve as defined in the step below  Without changing the gain control established in the step above, determine and mark the maximum signal response obtainable from the OD notch at a full V- Path. Construct the DAC curve from these points.

All Calibration Information shall be listed on the provided “Ultrasonic Calibration Data Sheet”.

9. Examination

The examination volume shall consist of the entire weld volume and base material for a distance of ¼ inch from each weld toe for all weld configurations.

The search unit angles selected for each component should be chosen based upon the configuration of the component and expected flaw mechanism. Variables such as weld design, weld crown width and material thickness should be evaluated prior to selecting the inspection angles(s)

The examination sensitivity (scan gain) should be a minimum of twice (+ 6 dB) the primary reference level.

The scanning speed should not exceed 3” per second.

Scan Direction:  For the examination of reflectors oriented parallel with the weld, the sound beam should be directed essentially perpendicular to the weld axis from both sides of the weld.  For the examination of transverse indications, the sound beam should be directed essentially parallel to the weld axis. MUT may be used for the detection and characterization of transverse indications. Scan Pattern:  The probe movement should consist of a raster type scanning sequence providing adequate beam overlap in the indexing direction. This scanning pattern may be supplemented as needed with localized MUT lateral scanning and probe oscillation to provide information important to indication characterization.  MUT follow-up is allowed for both characterization and sizing after AUT is performed providing that the AUT procedure that is being followed includes that step.

10. Indication Evaluation

All suspected flaw indications shall be plotted on a cross sectional drawing of the weld in order to accurately identify the specific origin of the reflector.

All actual flaw indications, i.e. slag, LOP, LOF cracks, etc. exceeding 20% of the primary reference level shall be reported.

11. Recording and Reporting of Exam Results

The component reference information (datum 0 position, direction of flow) that is marked on each sample shall be used for indication reporting.

All indications shall be reported on the provided “Indication Report Sheets”.

Report of non-relevant indications is not required.

Flaw indications 20% of DAC or greater shall be recorded. The following information shall be recorded on the applicable “Indication Report Sheets” for each reported flaw:  Indication #  Flaw Type  % of DAC  Flaw Start and Stop  Flaw Length  Flaw Location (Upstream/CL/Downstream/Transverse) in relationship to the weld centerline  Flaw Location in relationship to the weld volume (ID surface connected, OD surface connected, Embedded

12. Required Paperwork

All paperwork shall be completed and given to the Test Administrator after the test is completed to maintain Test Sample security. No other paper or materials will be allowed at the testing station. The following forms will be required at the completion of the test: Equipment Inventory List A complete list of all equipment used for the AUT examination shall be inventoried and documented on the provided form. This includes all search units, AUT system and MUT system used for follow-up and sizing. This form must be completed before the start of the qualification test.

Ultrasonic Calibration Data Sheet An Ultrasonic Calibration Sheet shall be completed for each test specimen examined. All information must be completed prior to scanning the test samples and should contain the necessary information to assure compliance to the AUT procedure being used.

Indication Report Sheet An Indication Data Sheet must be completed for each sample. The Examinee is responsible to properly document the flaw location, length, depth sizing, positioning, characterization, surface connected or subsurface, etc. Each indication must be numbered and all data should be clearly recorded and legible. All flaws should be placed on the Sketch area provided on the form.

13. Test Security

The Test Administrator will monitor this AUT Personnel Qualification Test. Continuous test area surveillance will be maintained to ensure test security. Entry into and out of the testing area will be restricted. The test Administrator will be present during the lunch break to allow Examinees additional time for testing if they choose no t to take a lunch break.

Purses, backpacks or briefcases will not be allowed at the Examinees testing stations. No cell phones or pagers will be allowed in the testing area. A secure area will be provided for personal items during the testing session.

At the conclusion of the Qualification Test, the Advance UT Data Storage Card/Device will be turned in to the Test Administrator. The Test Administrator will verify that no data is stored on the internal hard drive.

If a laptop computer is used during the Qualification test for analysis, at the conclusion of the test the Test Administrator will verify that no examination data was inadvertently left on the computer system.