TOFD and PAUT For Weld Root Corrosion
TOFD and PAUT For Weld Root Corrosion
TOFD and PAUT For Weld Root Corrosion
CONTENTS
Summary ____________________________________________________________________________________________ 1
1. PAUT REPORT OF PIPE TO PIPE _______________________________________________________________________ 3
2. PIPE TO FITTING (SINGLE SIDE ACCESS) PAUT REPORT OF PARALLEL AND TRANSVERSE DEFECT __________________ 8
3. TOFD REPORT _____________________________________________________________________________________ 9
4. VALIDATION BLOCK DEFECT IMAGE __________________________________________________________________ 15
5. DIMENSION OF CALIBRATION AND VALIDATION REFLECTORS ____________________________________________ 16
6. MOZZAT BLOCK DRAWING _________________________________________________________________________ 17
7. ULTRASONIC TESTING REPORT ________________________________________________________________________ 18
8. RADIOGRAPHIC TESTING REPORT _____________________________________________________________________ 19
9. MATERIAL AUTHENTICATION REPORT BY MOZZAT USING PMI-XRF __________________________________________ 21
10. TECHNIQUE SHEET __________________________________________________________ Error! Bookmark not defined.
Phased Array Ultrasonic Testing ASME SEC V
Page 1 of 37
Report of Sample ID: PRC-20 (UT-308) Sector: Weld
Summary
This verification of preferential root corrosion validation is performed by use of PAUT and TOFD in the
qualification bock with sample ID UT-308 with fabrication weld defect. For validating the tool the
block has been modified with simulated in-service defect in various locations of the weld and
numbered with unique ID as PRC-20.
- Measurement traceability has been established using micrometers and other measuring aids
- Contract ultrasonic testing has been conducted to ensure the lamination type defects and
thickness survey.
- Contact Phased Array Testing using scan plan outlines in the procedure and compared the results
with similar scan plan in the same document and reported accordingly!
- Contact Pulsed Echo Manual Ultrasonic outlines in the approved procedure has been performed
for verification of validation reflector dimension and compared with PAUT results
- Conventional Radiographic Testing is performed to ensure the results of TOFD & PAUT.
- Additional verification of Radiographic Testing Techniques proficiency has been compared with UT
TOFD & PAUT results.
- The material configuration has been verified by using Positive Material Identification (PMI)- X-ray
Fluoroscope Spectrum (XRF)
The relevant document of the respective block has been populated in this unique document to improve
the confidence and traceability.
Signature
Qualification
Date
2. PIPE TO FITTING (SINGLE SIDE ACCESS) PAUT REPORT OF PARALLEL AND TRANSVERSE DEFECT
EQUIPMENT DETAILS
Equipment OMNISCAN MX/MX2 Equipment Software MXU 4.4 rev 05
Probe 4L16-DGS-1 Analysis Software Tomoview 2.10 Rev 25
Wedge Integrated Couplant Water
Scanning Patter One-Line Manual Scanning Scanner Configuration Chain Scanner
PHASED ARRAY GROUP SETTING (SPECIFIC TO EACH GROUP)
Index Focal Wave Element First Last Exit Min. Max.
Skew Angle Steps
Position Law Type Qty Element element Element Angle Angle
90 -20 Sectorial Shear 16 1 16 09 23° 85° 1
270 +20 Sectorial Shear 16 1 16 09 23° 85° 1
60 to 120 + 20 & -20 Sectorial Shear 16 1 16 09 23° 85° 1
Skew-90:Screen Shot
3. TOFD REPORT
Specimen ID PRC-20 (UT-308) Report Number MESB-TOFD-PL-08
Technique UT-TOFD Procedure Number MESB-TOFD-GW-07.Rev.00
Joint Description
Joint Configuration Plate to Plate Martial Configuration Carbon Steel
Bevel Configuration Single-V Dimension 300x300x20 mm
Equipment Description
Equipment Model Olympus OMNISCAN MX-II Scanner HSMT-FLUX
Probe C563-SM Wedge ST-1:N70⁰L
Technical Description
Probe Center Separation 73mm Focus Depth 2/3 time of job thickness
Scan Length in mm 300 Scan Resolution in mm 1
Scan Type Non Parallel Scan (D-Scan) Restricted Access (if any) Not Applicable
DETAILS OF INDICATION
Flaw Position (mm) Flaw Depth (mm)
Height
S.No Type of flaw From Remark
Length Top Bottom mm
Datum
1. Embedded with no measurable Height 33-55 22 3.7 7.6 3.9 NM
2. Root Connected with Measurable height 55-74 15 16 20 4.0 M
3. Root Connected Weld and Off Axis 105-110 05 16 20 4.0 M
4. Embedded with no measurable Height 132-151 19 13 20 6.4 NM
Off-Axis Defect with measurable length and no
5. 158-173 15 18.4 20.0 1.7 M
measurable height & Depth
6. Root Connected with Measurable height 186-201 15 18 20 2.2 M
7. Root Connected with Measurable height 216-221 05 16.5 20 3.3 M
8. Embedded with no measurable Height 265-275 10 5 7.4 2.4 NM
TOFD DATA SCREEN CAPTURED:
Signature
TOFD POST CALIBRATED, LATERAL WAVE SYNCHRONIZED, AND LATERAL WAVE REOVED DATA FILES
D5. Off-axis Defect with no measurable depth ( deducted between Longitudinal and Shear Back Wall)
SIGNATURE
QUALIFICATION
NDT LEVEL
3
530
7 +Y=150
-Y=150
2
2
A 0^ B 0^
6
-16 +16
20.0
INDICATION DETAILS
Distance from Length Depth Angle
S. No Flaw Details Side Remarks
Zero ’0’ Datum In mm In mm Tested
1. Lack of fusion 0-27 25 4.0-6.0 45°,60° A Reject
2. Root Corrosion 0-55 37 17-20 70° A to B Reject
3.
25%,75% &
Round Bottom Hole (3-Set) 0-110 Ø2.5mm 70° A to B Reject
50%
4. Lack of Root Fusion 0-121 34 16-18 45°,60° B Reject
5. Cluster (B-Side) 0-160 15 18-20 70° B Reject
6. Base Metal Corrosion (A-Side) 0-180 30 16-20 60°,70° A Reject
7. Transverse Corrosion (A to B side) 0-215 7 4.0-6.0 45°,60° A to B Reject
8. Porosity 0-250 30 1.0-2.0 60°,70° A Reject
Signature
Date 26-09-2022
DWDI - Double Wall Double Image; DWSI - Double Wall Single Image; SWSI - Single Wall Single Image; RW - Required Wire; VW - Viewing Wire
Indication Summary
Datum in Length in Side of Defect
Sl. No. Defect Characterization Film Segment Remarks
mm mm (A/B)
1. Lack of fusion A 0-27 25 A
2. Root Corrosion A 0-55 37 A to B
3. Round Bottom Hole (3-Set) A 0-110 Ø2.5mm A to B
4. Lack of Root Fusion B 0-121 34 B
5. Cluster (B-Side) B 0-160 15 B
6. Base Metal Corrosion (A-Side) B 0-180 30 A
7. Transverse Corrosion (A to B side) C 0-215 7 A to B
8. Porosity C 0-250 30 A
Name
Signature
Qualification
RT TOP VIEW
Name
Signature
Qualification
Date
PAUT General Scan Plan for Weld Root Corrosion of Varying Scope Configuration
Plate Weld Configuration and Vessel Circumferential Weld Plate Beam Configuration and Scanning Pattern
Nozzle Set-In Weld Configuration Nozzle Set-In Nozzle Beam Configuration and Scanning Pattern
Nozzle Set-On Weld Configuration Nozzle Set-On Nozzle Beam Configuration and Scanning Pattern
Nozzle Tangential (TKY) Weld Configuration TKY-Nozzle Merged Beam Configuration and Scanning Pattern
1) The inspector shall perform site survey and refer to BSP approved Fabrication Weld inspection procedure’s scan plan for scope
configuration and weld overlay based on design specification provided from client.
2) The Focal law configuration shall be referred to this technique sheet for beam coverage over region of interest.
3) Primary scanning shall be carried out close to the weld toe for detection of weld root corrosion and adjacent base material corrosion.
4) Primary sensitivity for weld root corrosion shall be set using 3mm Side Drill hole at the depth equals to scope thickness. Additional
TCG Point shall be added to have even sensitivity over region of interest throughout the depth.
5) Reference dB shall be notified in the inspection report.
6) The weld overlay shall be altered based on site conditions and shall be notified in the final inspection report.
REVIEWED BY: (MOZZAT) APPROVED BY: (MOZZAT) BALAJI
PREPARED BY: (MOZZAT) BALAJI
SIVA PRADEEP ISO-9712 NDT LEVEL-III
ASNT NDT LEVEL-III UT
ASNT NDT LEVEL-III in UT, UT/PAUT
Thickness ranges from 35.0mm to 50.00mm Thickness ranges from 50.0mm to 85.00mm
Note: The angle selection is based on clear discrimination of Lateral wave and Back wall signal. A Close PCS shall be recommended to get
information on root corrosion (i.e. Probe center Separation from weld toe to weld toe) and use of lower refracted angle is good for root focusing
at reduced PCS value, distinct lateral wave and back wall for easy for interpretation. Also, this approach results in less attenuation of weak
lateral wave/ bulk wave traveling over the surface of the scope under inspection.
Non-Parallel Scan shall be used as preliminary method of scanning to detect and locate defects along the weld axis. And Supplementary scans
Non-Parallel Offset scanning shall be performed to locate the base material corrosion close to weld zone.
FOR MOZZAT ENTERPRISE SDN BHD AUTHORIZATION
PREPARED BY REVIEWED BY APPROVED BY
Name BALAJI PAULRAJ SIVA PRADEEP BALAJI PAULRAJ
Signature
ASNT NDT LEVEL-III in UT, ASNT NDT LEVEL-III in UT, ASNT NDT LEVEL-III in UT,
Qualification ISO-9712 NDT LEVEL-III-TOFD PCN Level-III in UT, L-II-PAUT ISO-9712 NDT LEVEL-II-TOFD
Contract Manager Quality Engineer Contract Manager
S
C
A
N
Image of TOFD Non-Parallel Scan (D-Scan) Data Scanning Patter for TOFD
Note:
- For Detection of Weld Root Corrosion, inspector shall set the PCS close to weld toe, if any off-axis defects were observed
during initial scanning in the mode converted shear wave. Then inspector shall perform two additional TOFD scanning using
increased PCS by offsetting the one of transducer close to weld toe of A-Side of weld (Skew-90) and other scan close to weld
toe of B-Side of weld (Skew-270), this approach enables to estimate the base material defect depth accurately.
- Ensure that the Lateral and Back wall signals are well distinct and satisfactory, if not inspector shall perform necessary PCS
adjustment. As an alternat Inspector shall try using lower refracted longitudinal wave wedge (ST-1-N45®L) to get distinct
Lateral and Longitudinal Back wall signal.
- Inspector shall increase or decrease the gain setting during TOFD data collection to maintain the Lateral wave between 40%
to 80% FSH to get required sensitivity.
- Check for data quality requirement prior to naming and saving for further expert’s review/ analysis.
FOR MOZZAT ENTERPRISE SDN BHD AUTHORIZATION
PREPARED BY REVIEWED BY APPROVED BY
Name BALAJI PAULRAJ SIVA PRADEEP BALAJI PAULRAJ
Signature
ASNT NDT LEVEL-III in UT, ASNT NDT LEVEL-III in UT, ASNT NDT LEVEL-III in UT, ISO-
Qualification ISO-9712 NDT LEVEL-III-TOFD PCN Level-III in UT, L-II-PAUT 9712 NDT LEVEL-III-TOFD
Contract Manager Quality Engineer Contract Manager
Signature
ASNT NDT LEVEL-III in UT, ASNT NDT LEVEL-III in UT, ASNT NDT LEVEL-III in UT,
Qualification ISO-9712 NDT LEVEL-III-UT, PAUT PCN Level-III in UT, L-II-PAUT ISO-9712 NDT LEVEL-III-UT, PAUT
Contract Manager Quality Engineer Contract Manager
Date 09-09-2022 09-09-2022 09-09-2022
TOFD POST CALIBRATED, LATERAL WAVE SYNCHRONIZED, AND LATERAL WAVE REOVED DATA FILES
3. Round Bottom Hole (3-Set) In-Service 0-110 Ø2.5mm 25%,75% & 50% 5,15, & 10 90 & 270 A to B M
4. Lack of Root Fusion Fabrication 0-121 34 16-18 2 270 B NM
5. Cluster (B-Side) In-Service 0-160 15 18-20 2 270 B M
6. Base Metal Corrosion In-Service 0-180 30 16-20 4 90 A M
7. Transverse Corrosion In-Service 0-215 7 4.0-6.0 3 90 & 270 A to B M
8. Porosity Fabrication 0-250 30 1.0-2.0 2 90 A NM
Remarks: (if any)
Mandatory Defects: Root Corrosion, Erosion and Cavitation. In-addition. LORF and LOP connected open to the surface shall be reported
as Mandatory. Any crack like signal response shall be reported as mandatory for assessment.
Non-Mandatory Defects: Fabrication Defect (Slag, Porosity, LOF embedded)
Planar: LOF-Lack of Fusion; LORF- Lack of Root Fusion; LOP-Lack of Penetration, CR-Crack; and Volumetric: SL-Slag; PS-Porosity
Skew 90⁰: negative side or A side. Which is along the flow direction; Skew 270⁰: positive Side or B-side. Which is against the flow direction;
FOR MOZZAT ENTERPRISE SDN BHD AUTHORIZATION
INSPECTED BY REVIEWED BY APPROVED BY
Name BALAJI PAULRAJ SIVA PRADEEP BALAJI PAULRAJ
Signature
APPENDIX-F: UT, UTG, PAUT AND TOFD SIGNAL RESPONSE SAMPLES IN-SERVICE DAMAGES
UTG Reading at Scanning Side Wall Loss coated with Paint
Angle probes or Shear Wave Probes Signal Response Examples of screen displays
Reference sensitivity, back wall grass level at 5 – 10% Standard ripple from the half skip distance evident.
full screen height Relatively smooth back surface
Low amplitude signal from the back wall at half skip Significant increase in amplitude from the back wall at
distance. Evidence of rougher inside surface and possibly half skip distance. Evidence of intermediate or
early-stage corrosion. advanced stage corrosion
Note: Manual UT System has poor signal to noise ratio. i.e. 30dB less than PAUT. Hence upon increasing the
sensitivity setting/ gain setting for detection of root corrosion may result in noise/ghost echo during test.
Note: First Three indication are from BSP Production Joint of Vessel-730 dished end with in-service defect, which is not captured in
Manual UT performed by another inspection vendor. After PAUT confirmation, respective indications are being verified by RENNAH,
Wood and BSP. 4th indication is a blister captured in BLNG scope of work
HAZ Corrosion or
- Opposite surface breaking defect
Wall loss Close to weld
- Off axis surface breaking defect
Zone
Non-Detection signal
response with tip
Through Wall Discontinuity
diffraction at start and
end of discontinuity
Real Site Data: BLNG-27MM PIPE DATA OF TOFD WITH ROOT CORROSION
Real Site Data: BLNG-27MM THICKNESS TOFD DATA WITH BLISTERS IN BASE MATERIAL
Tangential Plate Double Side Access Double Side 0.5-inch and above 1.20mm to 70mm
radiography Pipe Double Side Access Double Side 0.5-inch and above 1.20mm to 70mm
Double wall Plate Double Side Access Double Side 0.5-inch and above 1.20mm to 70mm
radiography Pipe Double Side Access Double Side 0.5-inch and above 1.20mm to 70mm
Validation Report Reference Scope Description Description of Report
1. MESB-PAUT-VLC-PRC-06 (PAUT, TOFD & RT) 06.02mm Plate Mozzat In-house Sample
2. MESB-PAUT-VLC-PRC-10 (PAUT, TOFD & RT) 10.00mm Plate Mozzat In-house Sample
3. MESB-PAUT-VLC-PRC-20 (PAUT, TOFD & RT) 20.00mm Plate Mozzat In-house Sample
4. MESB-NDT-CM-1246-BLNG-V1201-A15-1. R-0 At Site Real Corrosion
30mm Single V Piping
(PAUT &TOFD on Base Material for Blisters) (BLNG Scope of work)
5. MESB-NDT-CM-1246-BLNG-V1201-A15-2. R-0 At Site Real Corrosion
30mm Single V Piping
Rev.00(PAUT &TOFD on Weld) (BLNG Scope of work)
6. MESB-BMW-PAUT-INS06-015-R1 (In-Service and Vessel Dish-end Weld At Site Real Corrosion
Fabrication Defects) Confirmed using PAUT 85.00mm Double V (BSP Scope of work)
Note:
- In detection of weld root corrosion over targeted inspection areas (weld root and adjacent base material close to the
weld), a combination of ultrasonic and radiographic techniques shall be employed. The choice of techniques depends on
Joint configuration, thickness, accessibility, and the requirement for comprehensive defect detection.
- In use of PAUT, TOFD, MUT, UTG, and RT inspection by employing a data fusion approach, we shall achieve a more
robust inspection strategy for detecting and characterizing weld root corrosion in Plate, Pipe, Nozzle, and complex
geometries.