BR N-1594 D - Non Destructive Testing - Ultrasonic
BR N-1594 D - Non Destructive Testing - Ultrasonic
BR N-1594 D - Non Destructive Testing - Ultrasonic
D ENGLISH AUG / 98
NON-DESTRUCTIVE TESTING
- ULTRASONIC -
Procedure
This Standard replaces and cancels the previous revision .
n Indication of clause, item, table or figure, which has its contents been altered
with respect to the previous revision
The Responsible CONTEC Subcommittee provides guidance on the
interpretation of this Standard when questions arise regarding its contents. The
Department of PETROBRAS that uses this Standard is fully responsible for
adopting and applying the clauses thereof.
Mandatory Requirement: a provision established as being the most adequate
CONTEC and which shall be used strictly in accordance with this Standard. If a decision
Comisso de Normas is taken not to follow the requirement ("non-conformity" to this Standard) it
Tcnicas shall be based on well-founded economic and management reasons, and be
approved and registered by the Department of PETROBRAS that uses this
Standard. It is characterized by the verb forms "shall", "it is necessary...", "is
required to...", "it is required that...", "is to...", "has to...", "only ... is
permitted", and other equivalent expressions having an imperative nature.
Recommended Practice (nonmandatory) a provision that may be adopted
under the conditions of this Standard, but which admits (and draws attention
to) the possibility of there being a more adequate alternative (not written in
this Standard) to the particular application. The alternative adopted shall be
approved and registered by the Department of PETROBRAS that uses this
Standard. It is characterized by the verbal form "should" and equivalent
expressions such as "it is recommended that..." and "ought to..." (verbs of a
nonmandatory nature). It is indicated by the expression: [Recommended
SC - 27 Practice].
Copies of the registered "non-conformities" to this Standard that may
Non-Destructive Testing
contribute to the improvement thereof shall be submitted to the Responsible
CONTEC Subcommittee.
Proposed revisions to this Standard shall be submitted to the Responsible
CONTEC Subcommittee, indicating the alphanumeric identification and
revision of the Standard, the clause(s) to be revised, the proposed text, and
technical/economic justification for revision. The proposals are evaluated
during the work for alteration of this Standard.
The present Standard is exclusive ownership of PETRLEO
BRASILEIRO S.A. - PETROBRAS, for internal use in the company,
and any copy for external use or disclosure, without previous
express authorization, implies unlawful act pursuant the relevant
legislation through which the applicable responsibilities shall be
imputed. The external circulation shall be regulated by a specific
clause of Secrecy and Confidentiality, pursuant the terms of the
intellectual and industrial property law.
Foreword
PETROBRAS technical standards are prepared by Working Groups GTs
(consisting of PETROBRAS specialists and PETROBRAS Subsidiaries specialists), are commented by Local
Representatives (representatives of the Industrial Units, Engineering Projects, Technical Divisions and
PETROBRAS Subsidiaries), are approved by Responsible Subcommittees SCs (consisting of specialists belonging
to the same speciality, representing the various PETROBRAS Departments and PETROBRAS Subsidiaries), and
approved by CONTEC General Assembly (consisting of representatives of the Superintendencies of the
PETROBRAS Departments and PETROBRAS Subsidiaries that use PETROBRAS technical standards). A
PETROBRAS technical standard is subjected to revision at any time by the Responsible Subcommittee and must be
reviewed every five years to be revalidated, revised or cancelled. PETROBRAS technical standards are prepared
in accordance with standard PETROBRAS N - 1. For complete information about PETROBRAS standards
see PETROBRAS Technical Standards Catalog.
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N-1594 REV. D ENGLISH AUG / 98
PREFACE
This Standard is the English version (issued in AUG/98) of Standard PETROBRAS N-1594
REV. D AUG/98.
1 SCOPE
1.1 This Standard establishes the required conditions and recommended practices for
nondestructive testing by ultrasonic method.
n 1.2 This Standard is applied to thickness measurement and plate and weld inspections by
manual and semi-automatic apparatus, using the pulse-echo technique.
n 1.3 This Standard is applied to nondestructive testing by ultrasonic method beginning with its
date of issuance.
n 2 COMPLEMENTARY DOCUMENTS
The following documents are referenced in the text and contain valid rules for this standard.
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3 DEFINITIONS
3.1 Couplant
Any substance (usually liquid or pasty) used between the search unit and the test surface, to
transmit ultrasonic energy vibrations through the mean.
Corrections made in the gain level, to adjust the scanning sensitivity, and thereafter evaluate
discontinuities and make up for coupling differences, sound attenuation, found between the
material to be tested and the reference block.
Piece of material having a specified chemical composition, heat treatment, geometric shape,
and surface finish, by means of which the ultrasonic equipment may be checked and calibrated
for testing of materials having similar sound propagation characteristics.
Piece of the same material or group of material, significant dimensions, and form as those of
the particular object being tested and having same surface treatment. It may or may not contain
natural or artificial discontinuity.
Determination of the gain in dB required for the signal produced by a standard reflector to
reach a given amplitude.
3.6 Plate
Testing which the search unit movement and the position transference occur without help of
mechanical devices.
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The search unit movement is manually effectuate and position transference occur with help of
mechanical devices.
The search unit movement and the position transference occur with help of mechanical devices.
Is the system that the acquisition and datas treatment are made with computation auxiliary.
n 4 GENERAL CONDITIONS
General requirements shall be in accordance with ASME Section V, article V, and with the
following additional information and exceptions to that Standard.
4.1.1 Test results shall be recorded by means of an identification and traceability system that
allows the correlation between the tested area and the report and vice versa.
4.1.2 The system description for recording results should be released to include in the
inspection procedure, at PETROBRAS criteria, if the responsible (PETROBRAS department
or responsible firm) presents a system meeting subclause 4.1.1 in its Quality System.
[Recommended Practice]
4.1.3 The terminology used to designate the discontinuities shall be in accordance with
PETROBRAS N-1738 Standard.
4.2 Materials
The materials to be inspected shall be classified, as shown in the list below, according to their
acoustic characteristics.
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n 4.3 Apparatus
4.3.1 For thickness measurement, a device with a digital display shall be used with a
measurement accuracy of 0,1 mm. The use of a device which is different from the one
described shall require PETROBRAS prior approval.
n 4.3.2 For plate and weld inspection shall be used an adequate apparatus for detection, sizing,
interpretation and results valuation.
4.4.1 The apparatus and the testing materials shall be in conformity with ABNT NBR
ISO 9001 requirement.
4.4.2.1 The integrity, surface roughness, and dimensions shall be in accordance with the
specific standards (Ex.: DIN 54120; BS 2704; ASTM A 609; ASME Section V;
PETROBRAS N-1594 standard). In case there are no specific requirements, Standard
BS 4331 Part. 3, Appendix B, shall be used.
4.4.2.2 The time intervals between checks of the blocks depend on the frequency and
conditions of use. Is recommended that the interval does not exceed 24 months.
[Recommended Practice]
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The checking to be carried out, as well as the methods, tolerances, and time intervals shall be
in accordance with TABLE 2:
US - Semi-
Item to be Checked Method Tolerance US - Manual Automatic
(Notes 3 e 4) and
Automatic
(Notes 3 e 4)
DEVICE: ASTM E 317
BS-4331 Part 1 Weekly Weekly
- Horizontal linearity /BS-4331 Part 1 item 5 (NOTE 1)
item 5
- Control/gain linearity BS-4331 Part 1 Daily Daily
/BS-4331 Part 1
item 7 (NOTE 1)
item 7
SEARCH UNITS:
- Exit point of Sound BS 4331 Part 1 BS 4331 Part 1 Daily Weekly
Beam item 8 item 8
- Real Search Unit Angle BS 4331 Part 1 2 Daily Weekly
item 9
- Sound Beam Profile BS 4331 Part 3 1 in the angle Weekly Monthly
(NOTE 2) item 6 of divergence of (Note 2)
the beam
- Sound Beam Alignment BS 4331 Part 3 2 Monthly Monthly
item 13
- Resolution BS 4331 Part 3 BS 4331 Part 3 Yearly Yearly
items 14 e 15 items 14 e 15
Notes:
1) The use of devices exceeding the tolerance is not permitted;
2) Checking of the ultrasonic beam profile is only required when the height of the
discontinuities is sized;
3) The specified time interval is established for normal working conditions. Such
interval may be altered by mutual agreement with the inspection, according to the
frequency of usage of the equipment; [Recommended Practice]
4) Any repair or maintenance in the apparatus shall require a new check, regardless of
the time interval established.
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4.5 Couplant
The couplant shall have good surface wetting characteristics, being either liquid or pasty. An
oily couplant is not allowed when it affects surface preparation (cleaning) for performance of
another nondestructive test.
n 4.6.1 The test surface shall be suitable so as to allow ultrasonic inspection at the indicated
sensitivity. If necessary, the surfaces may be ground, blasted, brushed, scraped, or prepared
otherwise for testing. The method to be used in the surface preparation shall be mentioned.
Note: The reference block shall have on the contact surface of the search unit and on the
opposite surface, the same surface treatment that the piece in testing.
4.6.2 The surface preparation tools of austenitic stainless steels and nickel alloys shall only be
used for such materials and meet the following requirements:
5 SPECIFIC CONDITIONS
5.1.1.1 This inspection procedure shall contain the following items, in the indicated sequence:
a) objective;
b) reference standards;
c) material, range of thickness to be measured (ex.: carbon steel, thickness of 25 mm
to 30 mm);
d) device, type, manufacturer and model;
e) search unit, type, dimensions, and frequency and thickness and temperature
ranges, mentioning manufacturer and model;
f) calibration method;
g) surface condition, preparation technique and surface temperature;
h) couplant, mentioning temperature range;
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i) supplementary requirements;
j) system adopted for recording results;
l) form for report containing recorded results.
Note: Items c), d), e), f), g), and h) are mentioned in ASME Section V.
5.1.1.2 The name of the issuing entity (PETROBRAS department or responsible firm) shall be
included in the procedure, which shall be numbered and contain indication of the revision.
Calibration shall be performed on a standard block. The device is considered calibrated for
thickness measurement within a range of 25% of the thickness of the standard block (ex.: if
calibration is done on a standard block 100 mm thickness, the device is calibrated to measure a
thickness ranging from 75 mm to 125 mm). For device which have V-Path compensation
inner system, the recommendations of the manufacturer shall be followed. Calibration shall be
performed daily at:
It shall be made of material of the same group of the piece to be measured and its thickness
shall be within 0,05 mm of the nominal thickness.
It shall be performed by taking five readings on standard blocks with thickness within the range
in which the device is considered calibrated. The procedure is considered qualified if the
deviation of each of the reading is equal to or smaller than 0,2 mm, with respect to the
standard.
5.1.5.1 Whenever any of the variables mentioned in 5.1.1.1 are altered, a revision of the
procedure shall be issued.
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5.1.5.2 For temperatures higher than or equal to 50, whenever any of the variable c), d), e),
f), g) and h) mentioned in 5.1.1.1 are altered, the procedure shall be requalified.
5.1. Recording
6 of Results
5. Plate
2 Inspection
5.2. Inspection
1 Procedure
n 5.2.1.1 The inspection procedure shall contain the following items, in the indicated sequence:
a) objective;
b) reference standards;
c) material and range of thickness to be tested (ex.: carbon steel, thickness of 25 mm
to 30 mm);
d) device, type, manufacturer and model;
e) search unit, type, dimensions, and frequency, mentioning manufacturer and
model;
f) method and frequency of checking of apparatus;
g) calibration method;
h) surface condition and preparation technique;
i) couplant;
j) scanning technique;
l) supplementary requirements;
m) criteria for recording and acceptance of discontinuities;
n) sizing method of discontinuities;
o) system adopted for recording results;
p) form for report containing recorded results.
Note: Items c), d), e), g), h), i), and j) are mentioned in ASME Section V.
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5.2.1.2 The procedure shall have the name of the issuing entity (PETROBRAS department or
responsible firm), which shall be numbered and contain indication of the revision.
5.2.1.3 The requirements of the manufacture standard of the product shall prevail in case they
differ from those mentioned in 5.2.2 and 5.2.6.
n 5.2.3.2 Calibration of the distance scale shall be performed by means of standard block VI
and/or V2, as per DIN 54120, and ISO 7963 and on a daily basis at:
5.2.4.1 The plate surface shall be marked according to one of the three options of the
TABLE 3, given below:
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The criteria for recording and acceptance of discontinuities shall be in accordance with the
reference standards and design specifications.
5.2.6.1 It shall be done in a standard containing flat discontinuities located in the middle of the
thickness of the standard.
5.2.6.2 The standard shall have a thickness within 25% of the thickness of the piece,
equipment or piping to be tested and the procedure shall be considered qualified if the
reflectors considered in the standard are property detected and evaluated.
5.2.7.1 Whenever any of variables mentioned in 5.2.1.1 are altered, a revision of the
procedure shall be issued.
5.2.7.2 Whenever any of the variables c), d), e), f) and g) mentioned in 5.2.1 are altered, the
procedure shall be requalified.
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Note: Items c), d), e), h), i), and j) are mentioned in ASME Section V.
n 5.3.1.1 The inspection procedure shall contain the following items, in the indicated sequence:
a) objective;
b) reference standards;
c) material (base metal and filler metal) and thickness;
d) drawing containing dimensional details of the weld;
e) device, type, manufacturer, and model;
f) search unit, type, dimensions, angle, frequency and thickness range used,
mentioning manufacturer and model;
g) technique to be used (ex.: direct contact method, pulse-echo technique);
h) method and frequency of checking apparatus;
i) calibration method;
j) sensitivity adjustment of the device;
l) surface condition and preparation technique;
m) couplant;
n) scanning technique;
o) supplementary requirements (if any);
p) criteria for recording and acceptance of discontinuities;
q) sizing method of discontinuities;
r) system adopted for recording results;
s) form for report containing recorded results;
t) final cleaning.
Notes: 1) Items c), d), e), g), i), l), m), n), r), and t) are mentioned in ASME Section V.
2) In the case of an automated inspection, included in the procedure the items T-522
m) and n) of ASME Section V standard.
5.3.1.2 The procedure shall have the name of the issuing entity (PETROBRAS department or
responsible firm), which shall be numbered and contain indication of the revision.
5.3.2.1 Search units shall be in accordance with the design or equipment construction
standard.
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n 5.3.2.2 When the automatic and semi-automatic system is used, search units.
5.3.2.3 Search units shall not produce excessive grass so as to allow easy identification of
an echo with a height of 10% of the total screen height, in its area of use.
n 5.3.2.4 The search unit angle shall be chosen meeting the following requirements:
n 5.3.3.1 The calibration method shall be in accordance with the standard of design or
equipment construction.
5.3.3.2 If, in tracing the reference curve, the last points are below 20% of screen height, a new
curve shall be constructed from these points referred to as auxiliary reference curve.
5.3.4.1 Correction, due to transfer loss, for straight beam and dual crystal search units, shall
be done as follows:
a) maximize a bottom echo of the reference block and with the aid of the gain
control, set it at 80% of full screen height of the device;
b) with the same gain, place the search unit over the piece to be examined;
c) check the difference in the height of the echo in decibels, this difference being
referred to as transfer loss (PT), which shall be added or reduced in the primary
gain (GP);
d) the resulting gain is referred to as corrected gain (GC = GP PT).
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5.3.4.2 Correction, due to transfer loss, for angle beam search units, shall be done as follows:
a) with the reference block, pilot the curve shown on FIGURE A-1 in ANNEX A,
with two search units having the same angle, frequency, type and manufacturer,
used on the testing, one is the emitter and the other the receiver;
b) the search units shall be positioned as shown on FIGURE A-1 in ANNEX A, so
as to obtain the signal E/R1 being the signal maximized and placed at 80% of
screen height;
c) without altering the gain, signals of positions E/R2 and E/R3 shall mark on the
screen;
d) connect points E/R1 to E/R3 obtaining a curve on the screen;
e) with the same gain, position the search units over the piece to be examined
(see FIGURE A-1 in ANNEX A) in the E/P1 position and, if the height of the
echo of this position is equal to the height of the curve (paragraph b), corrections
are not required;
f) if there are differences, adjust the height found on the material of the piece to the
same height of the curve (paragraph b) and note the number of the decibels (PT)
which shall be added or reduced in the primary gain;
g) the resulting gain is referred to as corrected gain (GC = GP PT).
5.3.4.3 The gain for scanning shall be the corrected gain plus 6 dB.
5.3.4.4 To evaluate the discontinuities, the gain shall be the corrected gain, without the added
6 dB.
5.3. Scanning
5 Technique
5.3.5.1 The area covered by the angle beam search unit shall be sufficient to ensure that the
scanning process shall cover the entire weld and an additional 20 mm of the metal base on each
side of the weld, along the cross section, with the sound beam inciding as perpendicularly as
possible to the connection zone (See FIGURE A-2 in ANNEX A). When possible, the test
shall be performed from both sides of the weld, on the same surface. The physical limits of the
area to be covered by search unit shall be marked, by means of paint, pencil, scriber, magnetic
tape or any other adequate means.
5.3. Criteria
6 for Recording and Acceptance
5.3.6.1 The criteria for recording and acceptance of discontinuities shall be in accordance with
the reference standards.
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5.3.6.2 When the criteria are not defined by reference standards, the following ones shall be
adopted:
a) all longitudinal discontinuities shall be recorded with respect to the weld having a
reflectivity:
- greater than the 50% curve or
- greater than the 20% curve and longer than 20 mm;
b) all discontinuities transverse shall be recorded to the weld having a reflectivity
greater than the 20% curve;
c) discontinuities recorded with a longitudinal position with respect to the weld are
considered defects and shall be repaired if:
- they have a reflectivity greater than the reference curve or
- they have a reflectivity between the 50% and 100% curves (50% curve
reflectivity < 100% curve) and a length greater than 2/3 of the thickness or
15 mm, whichever is greater, or have a reflectivity between 20% and 50%
curves (20% curve reflectivity < 50% curve) and a length greater than 1.5 of
the thickness or 25 mm, whichever is greater;
d) discontinuities recorded with transverse position to the weld, that is, which have
been detected by parallel scanning or approximately parallel to the longitudinal
direction of the weld, are considered defects and shall be repaired.
5.3.6.3 The length of the recordable discontinuities shall be determined by the 6 dB fall
method at the ends of the discontinuities and, when the height of the discontinuities is required
through the most suitable method, applicable to the characteristics of discontinuities.
5.3. Inspection
7 Procedure Qualification
5.3.7.1 It shall be performed on the standard and reference blocks utilized for calibration of
the device, and the procedure is considered qualified if the calibration can be performed in
compliance with the provisions in 5.3.3.1.
n 5.3.7.2 For semi-automated and additionally automated systems to the established on item
5.3.7.1, the procedure shall present satisfactory result in test block representative of the piece
to be tested, containing natural and artificial discontinuities.
n 5.3. Inspection
8 Procedure Revision and/or Requalification
n 5.3.8.1 For Manual Ultrasonic, whenever any of the variables mentioned in 5.3.1.1 are altered,
a revision of the procedure shall be issued.
5.3.8.2 Whenever any of variables c), e), f), g), h), and i) mentioned in 5.3.1.1 are altered, the
procedure shall be requalified.
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n 5.3.8.3 For the semi-automatic/ automatic ultrasonic shall be realized an analysis to check the
necessity of requalify the procedure in order to change any of the variables not mentioned in
5.3.8.2.
Note: Items c), d), e), i), and j) are mentioned in ASME Section V standard.
____________
/ANNEX A
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