Save Time and Cost for Turnarounds

Using Phased Array Technology

Terry M. Webb
Refining NDE Specialist
BP
Toledo, Ohio
Purpose
 The purpose of this presentation is to explain how to
successfully introduce Ultrasonic Testing Method,
Phased Array Technique (PAUT) into a plant turnaround
(TAR) as an alternative to conventional film
Radiographic Testing for the inspection of pipe girth butt
welds for engineering and maintenance projects.
Content
 Safety
 Inspection Department Initiate Program
– Champion to Drive PAUT Program
 Planning and TAR Scheduling
 NDE Company
 TAR Workforce Training
 Audit PAUT during TAR
 Issue TAR Close out Report
 Closing and Questions
Safety
 Monogoggles
And
Chin Straps
Inspection Department Must Initiate Program

 Move idea into the TAR process and include your TAR contractor
organizations. All must be in agreement to use PAUT.
– Champion to Drive Your PAUT Program
• Corporate NDE Level III, inspection superintendent, inspector
with UT background.
– The idea of replacing film Radiography with Phased Array
Ultrasonic Testing needs to be driven from the Owners point of
view and not the NDE company.
– NDE company will provide a service, they will generally not
educate your workforce for a major change in pipe inspection.
– TAR is fast paced and the Champion will reduce conflict from
historic film radiography to PAUT acceptance of pipe butt welds.
Typical Pipe Weld Chain Scanner
Planning and TAR Scheduling
 Must be included soon as possible in the implementation process.
 Count all pipe girth welds, diameters, pipe materials, and schedules.
Same as using Radiographic Testing, this will be the basis of any
NDE bidding for the TAR contract.
 Bid work on Level II and assistant as primary team and then a back-
up team depending on work load.
 Critical step – Mark weld for reject repairs before the PAUT team
leaves the weld location. Important to the Planners, unique over
historic inspections results provided the next day.
 Level II to inform the welding Foreman the weld is accepted
immediately. Rejected welds go back to office for second opinion.
Issue the NDE report before the end of that shift.
Level II and Assistant
Choose the NDE Company
 Experienced in TARs, capable, qualified personnel, efficient and do
not require experimenting and endless adjustments.
 Automated and/or semi-automated services for pipe inspection -
experience is the key.
 Require a second scanner for small 4” (101mm) and less diameter
pipe.
 Entire weld scan digitally recorded introduces a quality assurance
element not available with past manual UT shear wave testing.
 Do not choose for best rates, hire the NDE company on the ability of
their PAUT Level II’s.
 The physics of ultrasonic testing changes that radiographic porosity
reject rate to a more linear based reject rate – important for critical
services.
Magnetic wheels scanner
Magnetic Wheel Scanner for Large Diameter Pipe
Small Diameter Pipe Scanner
TAR Workforce Training
 Topics for the introductory training presentation by your Champion:
– Why have you been invited to take this introductory PAUT
training?
– Pipe weld fabrication inspection alternative to conventional
Radiography
– What is Ultrasonic Testing Phased Array?
– Introductory Ultrasonic and Phased Array Basics
– Indication / Flaw Interpretation / DAC
– Documentation to expect during TAR
PAUT Pipe Elbow
Acceptable Indication in Four Views
Rejected Weld, A –scan DAC exceeded
Display Views S, A, C and B
Audit PAUT during TAR
 Owner’s Champion perform audits on the NDE Company’s program.
 Start on their first butt weld in the plant.
 Witness the calibration and follow them to butt weld for set-up and
full scan and recording of butt weld scan.
 Discuss any indications or rejects at the weld.
 Overall discuss all rejects during the TAR, Champion to review that
rejected weld scan ASAP.
Issue a Turnaround PAUT Close Out Report
 Do not include every weld inspection.
 Impression overall of how the process worked.
 Comments from others during the TAR.
 Did it save time for the planners/schedulers?
 Discuss reject rate compared to past TAR’s if that data available.
 Perhaps there was an engineering project with numerous welds and
they would have had a reject rate during the TAR on their specific
project.
 Discuss problems and how to solve for next TAR.
Closing and Questions?
Perth, Australia