ML20239A056

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Operating Procedure OP-17-60-016-0, Ultrasonic Thickness Measurement Piping Using Swri Thickness Data Acquisition Sys
ML20239A056
Person / Time
Site: Calvert Cliffs Constellation icon.png
Issue date: 02/28/1987
From: Diaz H
SOUTHWEST RESEARCH INSTITUTE
To:
Shared Package
ML20238F770 List:
References
NUDOCS 8709170054
Download: ML20239A056 (14)
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i ENCLOSURE 6 1 t' l

SOUT H WEST - RESEARCH INSTITUTE OP-17-60-016-0 OlVISION 87 February 1987 OPER ATING PROCEDURE Page 1 of 13 I /

ULTRASONIC THICKNESS MEASUREMENT PIPING USING THE SwRI THICKNESS DATA ACQUISITION SYSTEM OP-17-60-026 1. PURPOSE l This procedure provides the technical information and detailed steps required to ensure a proper calibration for ultrasonic (UT) thickness mea-surements using the SwRI Thickness Data Acquisition System (TDAS).

Details are also included for data file initiation in the TDAS data storage device (Polycorder).  !

2. SCOPE AND APPLICATION Manual, contact, pulse-echo, straight-beam longitudinal-wave UT calibration for measuring wall thickness with a nominal thickness of 0.05 to 2.5 inch shall be utilized in accordance with this procedure.
3. APPLICABLE DOCUMENTS (1) Southwest Research Institute (SwRI) Nuclear Quality Assurance Program '

Manual, as referenced in this procedure 3.1 Applicable Examination Records SwRI NDTR Form No. Revision Date 17-133 02-19-87

4. RESPONSIBILITY (1) The Director of the Department of Engineering Services, Nondestruc- ,

tive Evaluation Science and Technology Division, shall be responsible i for the preparation, review, approval, and control of this procedure. l (2) The Project Manager shall be responsible for the implementation and control of this procedure.

(3) The examiner shall be responsible for implementing the requirements of this procedure.

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5. PERSONNEL AND EQUIPMENT

'5 1- Personnel Personnel per#otaing UT calibrations and thickness measurements shall be certified I.n accordance with SwRI NQAP 11-1.

5.2 Equipment for Ultrasonic Measurements The following equipment comprises the Thickness Data Acquisition Sys-tem (TDAS):

(1)' Sonic Mark I UT. instrument aligned and displaying a valid align- ,

ment calibration tag as required by NQAP 10-1.  !

(2). TDAS Digital Interface unit shall be attached to the UT instru-ment and~ provide the necessary data signal processing and out-put for recording of thickness measurements.

(3) Polycorder data, storage unit attached to the TDAS Digital Inter-face for recording of thickness data.

(4) R'ecord Command Switch will allow the operator to control the recording of data.

(5) A dual- or single-element search unit shall be used. The search unit wear face shall be flat and straight. If the component carvature prevents contact with the surface, a contoured wear face may be'used.

5.2.1 Step Thickness Blocks Step thickness blocks shall be used for screen distance cali-  ;

bration and verification. The block used for calibration /

-verification shall be of the same basic material, i.e.,

carbon steel, as the material to be measured.

The step thickness block (s) shell provide a minimum of two calibration points within the full screen distance size chosen (see 6.2). When a contoured wear face is used, the ,

step thickness block shall be curved. .l f

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.q Page 3 of 13 5.2.2 Search Unit Search units shall be selected from the following s zes:

1/8" Round ,

1/4" Round 3/8" Round The nominal search unit frequency shall be 5.0 MHz or 2.25 MHz.

NOTE Adequate contact may not be possible on pitted surfaces. Where possible, arrangements shall be made for removal of any surf ace condition which prevents adequate contact. ,

5.3 Couplant (1) USP grade glycerine, water-based Exosen or Sonotrace 40 shall be used when performing UT calibrations and examinations in accordance with this procedure.

(2) USP-grade glycerine, Exosen or Sonotrace 40 shall be certified in accordance with material certification requirements.

(3) Couplant materials used for examinations shall be the same as used for the calibration.

6. TDAS CALIBRATION _ _

6.1 Preliminary UT Instrument Setup The examiner shall assure the " Low Battery" charge indicator light is out during instrument use.

The instrument shall be warmed up a minimum of 10 minutes prior to use.

The controls on the Sonic FTS Mark I shall be set as follows prior to calibration: l I

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DIVISION 17 February 1987 I

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NOTE  !

l The following instrument settings are initial settings. The examiner may require. l different settings for some instrument and search unit combinations. j (1) POWER /0FF switch set to power .

I (2) RANGE switch set as required (3) DELAY coarse switch set to position 1  !

(4) FREQ-MHz switch set to 2 for 2.25-PRz sacch units and to 5 '

3 for 5.0-MHz search units (5) DAMPING switch initially set to MIN (6) Mode switch set to THRU TRANS for dual-element search units and to NORMAL for single-element search units.

I (7) REP RATE switch set to 3K -

i (8) FILTER switch set to HI j (9) VIDEO switch set to DIFF (10) DEC START, if applicable, turned all the way counterclockwise (11) DEC SLOPE, if applicable, turned to 0FF j 1

(12) REJECT CONTROL to be used as necessary to provide a clean  ! I baseline (13) Single search unit cable connected to R jack and dual search unit cables connected to R and T jacks 1 6.2 Sonic MK I Calibration j i

The full screen distance size shall be 0.5, 1.0, 1.0, 2.5, or 1 I

5.0 inches, as applicable. The smallest . screen t.ize which encompasses 1/4t beyond the anticipated thickness shall te used.

The appropriate step thickness block shall be utilized to construct a linear sound path distance as follows:

l l (1) Position the search unit on the thinnent step of the step thick-I ness block. Ad just the signsi amplitude to 80-90% full screen f height (FSH) with the coarse and fine GAIN dB controls. ,

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OlViSl0N -17 February 1987 q OPERATING PROCEDURE Page 5 of 13 1 NOTE L

The left-hand side of the signal should be as straight as possible. Using the l

FREQ-MHZ switch and the REP RATE, VIDEO, and FILTER switches, adjust the posi- i l tions to give the straightest and most vertical leading edge possible.

Adjust the backwall reflection to the appropriate position on

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(2) the screen baseline utilizing the DELAY control.

(3) Position the search unit on the thickest step which is within

.the examination thickness. Adjust the signal amplitude to 80-90% FSH.with.the fine and coarse GAIN dB controls. Adjust the backwall reflection to the appropriate position on the screen baseline utilizing the MAT'L CAL control.

NOTE f.

A calibration may be accomplished using a block or step of one thickness. The thickness used.must provide' multiple' reflections within the screen distance size used. ,

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(4) Repeat steps (1), (2), and (3) until a linear screen distance is obtained. These steps may need to be repeated several' times to obtain proper readings.

(5) Couple the search unit to.coch of the intermediate steps and observe the signal at each location. The signal shall be within t1% of full screen width of the actual reading. Repeat steps (1) through (4) if the screen distance is not within tolerance.

6.3 TDAS Calibration NOTE l

Position the MOVE switch to the " single" (single backwall) position.

6.3.1 Gate Length Adjust the Cate Length as follows:

(1) Turn the TDAS Gate Marker switch to the ON position.

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(2) With the Sonic Range switch set at 2 or a range one position higher than used for thickness measurements, use the Pulse Delay knob on the TDAS to adjust the left side of the gate just off screen or approximately

.200" to the left side'of the signal received from the

. thinnest calibration step.

(3) Using the TDAS Pulse' Width knob, adjust the right side of the gate to approximately .200" past the antici-pated thickness range.

6.3.2 Thresht id Adjust the Threshold as follows:

(1) Reposition the Sonic Range switch to the position used for thickness measurements.

(2) Place the transducer on an appropriate step thickness at the lower end of the calibration range and adjust the amplitude to within the range of 30% to 40% FSH.

The digital display will light up when the signal breaks the threshold level. If the signal is below the threshold, the display will not licht up.

6.3.3 Final Gate Adjustment Make final gate adjustments as follows:

(1) Place. the transducer on the thickness step used for the lower end of the calibration range and adjust the signal amplitude to 80% FSH.

(2) Adjust the lef t side of the gate using the TDAS Pulse Delay knob until the lowest stabilized number appears in the digital display.

NOTE As the gate is adjusted, the numbers in the display will decrease to the point where they begin to flicker and then blank out. The adjustment is correct when the number appearing in the display is as low a value as possible while remain-ing stable.

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t SOUT H WEST RESEARCH lNSTITUTE OP-17-60-016-0 DIVISION 17 February 1987 q OPER A TING PROCEDURE Page; 7 of 13 6.3.4 TDAS Digital Display Calibration Calibrate the Digital Display as follows:

(1)- Place the transducer on the .100" step at 80% FSH and make note of the digital display. Place the transducer on the .300" step at 80% FSH and make note of the digi-

- tal display. Using the TDAS Range control, adjust the-digital display to obtain 200 counts difference between the 100" step and the .300" step.

NOTE Other steps may be used for this calibration providing the display readings are noted and the count differences equal the step differences.

(2) After the count difference la obtained, place the trans-ducer on the .100" step or smallest step used and adjust the TDAS "Zero" control so that the display reads "100" or reading corresponding to the smallest step used.

(3) Verify that all steps produce a readout within t.005".

Each signal should be 80% to 100% FSH.

6.4 Polycorder Programming for Data Collection

. Perform the following steps te, program the Polycorder for data collection:

(1) To assure that a false reading is not recorded in the first line of the Polycorder data file, it is recommended that the TDAS POWER switch be cycled to 0FF and ON before proceeding with Polycorder setup steps.

(2) Turn the Polycorder on by depressing the "0N" key. The display window will show " MODE ?__".

(3) Upon initial use of the Polycorder; i.e. , first site to be measured after the Polycorder memory has been transfered to the computer, the examiner must assure that data is cleared by executing Mode 4-3 as follows:

TECHNICAL P rV IE W DATEl C OGNIZANT DIR E CTO R DAT E SS WRIT T EN SY DATE 3rY%B K4 > A2C -& AS WS SWN4 FORM SS-50-0

SOUTHWEST RESEARCH INSTITUTE OP-17-60-016-0 E

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Display l (a) Press ON " MODE ?"

l. (b) Press 4 " FILE 1, 2, 3 DIR, EXA-FILE, ESA DATA" (c) Press 3 " ERASE DATA TILE (d) Press ENTER "SURE? (Y/N)"

(e) Press SHF, Y " ERASE DATA FILE" l' (f) ESC " MODE 7" (4) Depress the *0" and use the arrow keys to select from the fol-lowing " EXECUTE PROGRAM FILE:" "Pfinal", "Xfer", " Input", and

" Enter". (Input and Enter are not used.) "Xfer" will be used af ter data collection f or downloading of data to the computer.

(5) Select the "Pfinal" option and press the " ENTER" key.

(6) The display window now indicates " FILE CODE =". The File Code will be selected by the Team Supervisor for the specific area to be examined. Press the one-digit key corr,esponding to the desired code, 0-9, and press " ENTER".

(7) The display window now indicates " INPUT STARTING X POSITION _".

Enter the start; Lng "X" position. (The starting position will ,

normally be "0".) Press the " ENTER" key.  !

(8) .The display window now indicates " INPUT ENDING X POSITION _".

Enter the applicable "X" corresponding to the last "X" on the grid pattern. Press the " ENTER" key.

(9) The display window now indicates " INPUT X INCREMENT _". Enter the number corresponding to the grid size in inches (1, 2, 3, ,

or 4) and press the " ENTER" key. l (10) The display window now indicates " INPUT STARTING Y POSITION _".

Enter the appropriate "Y" data following the same steps as (5) through (7) above.

(11) On completion of "Y" data entry, the display will indicate

" INPUT MINIMUM THICKNESS _". Enter the three-digit minimum wall thickness as specified for the area being examined. Press the " ENTER" key.

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, OlVISION 17 February 1987 I q OPERATING PROCEDURE p,g, 9 of 13 The display window now indicates " SCAN DIRECTION l=K 0=Y _".

(12) . -Enter a"1" if the scan direction is in the X direction or enter "0" if the scan .tirection is in the Y direction. Press the " ENTER" key.

. NOTE The Polycorder is now ready to accept data. Prompts will be displayed until the first measurement is recorded.

(13) To turn the Polycorder off, depress " ESC" and then "9" keys.

NOTES At an* time during the above steps (2) through (11), entry errors (errors that are et tered by depressing the " ENTER" key) may be corrected by returning to step (4). To return to step (4), press " ESC".

Key stroke errors that have not yet been entered can normally be corrected by depressing the left hand arrow key.

6.5 Calibration verification Calibration shall be verified:

(1) Prior to a series of measurements (2) At least every 30 mintues during measurements (3) At the completion of a series of measurements (4) With a change in personnel (5) Whenever the validity of the calibration is in doubt 6.6 Recalibration Perform the f ollowing if the distance calibration has changed on the screen more than 15% of full screen width:

(1) Void all measurements performed after the last valid calibra-tion verification.

(2) Correct the calibration.

(3) Remeasure the voided measurement areas.

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7. GRID MARKING'OF EXAMINATION AREAS Areas to be examined will be identified by the customer. The entire. area'-

of. examination will be marked by a grid pattern drawn on the surface of the pipe with'a customer-approved marker. The grid pattern will be sized in accordance with the following:-

(1) Piping nominal diameter' greater than 6 inches, grid size shall be no greater than 2 inches nominal.

(2) Piping nominal diameter equal to or less than 6 inches, grid size shall be.no greater than 1 inch nominal.

. EXCEPTION For large diameter piping, 20 inches nominal diameter anc larger, consideration should be given to increasing grid size to 3 inches or greater.

NOTE Grid marking on fittings such as " Tees" and "Els" will be accomplished as indi-cated above to the extent possible. Due to curvatures and increasing / decreasing-radii, constant line separation (parallel lines) will not be possible. Grid marking allows the return to the same location for additional examination /

relooks when the situation warrants. A clear, well-defined line is of greater importance than constant and equal separation.

After completion of grid marking, the "X" and "Y" starting locations will be identified on the pipe and the direction of measurement marked.. A hand sketch of the component will be made showing the grid pattern, spacing, "X" and "Y" locations, and direction of measurement. The sketch will be included in the data package for reference. Photographs of gridded sites may be used in lieu of sketches.

Customers can create and mark their own grid pattern.

8. EXAMINATION NOTE The total number of examination data points must be considered prior to )

examination. If the total number exceeds 1,720 for a 516B Polycorder or 3,500 for a 516C Polycorder, verify the Polycorder capacity prior to data recording and coordinate the examination requirements with the supervisor.

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The'Polycorder software is designed to terminate data recording just prior to I reaching full capacity. In such a case a "N0 MORE ROOM" message will be dis-  !

played and the TT)AS display will no longer respond to valid UT signals until j execution of the " RECORD" program is' terminated. {

l CAUTION  ;

I The Polycorder must not be disconnected from the TDAS unit while data is being taken or the unit is on. Disconnection of the Polycorder may result in the  ;

loss of data.

(1) Place the TDAS search unit on the pipe at the starting X/Y location.

Obtain a valid backwall signal and digital display reading. Press i the Record Command Switch to enter the data.

(2) Continue taking readings as in (1), advancing Scan Direction as  !

entered in the Polycorder (see 6.4(10)]. l 1

(3) For any location where a measurement cannot be recorded, a "0" thick-ness must be entered into the data file. This is accomplished by {

removing the earch unit from the pipe surface and depressing the l RECORD switch with no signals in the CRT screen. If the TDAS digi-tal display is " flickering" when the RECORD switch is depressed, a random number will be recorded rather than a "0". This can normally be avoided by wiping the excess couplant from the transducer contact surface. j NOTE After the first reading is taken, the Polycorder will indicate the "X" and "Y" f coordinate location, X=0 and Y-0, and the thickness reading recorded. For each j successive data point, the Polycorder will indicate the last coordinate location

.and the thickness recorded.  ;

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9. EVALUATION

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'The thickness measurements taken in accordance with this procedure shall be  !

evaluated by the customer or the customer's representative. j

10. RECORDS Data generated in accordance with this procedure will be in the form of com-puter printouts and shall be stored as specified in the SwRI Project Plan.

The customer shall receive copies of these data in the Examination Report, 1

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unless specified otherwise in the SwRI Project Plan. Additionally, all computer report files (*.RPT) must be recorded on floppy diskettes for future reference. A copy of each diskette will also be made available to 1 j

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