Phased Array UT in Lieu

of RadiographyNDTMA Las Vegas 2018

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January 23,2018

Curtiss-Wright History

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BackgroundCode Case N-831, “Ultrasonic Examination in Lieu of Radiography for Welds in Ferritic Pipe” has been developed to allow the use of UT for weld acceptance

– ASME Board Approved October 20, 2016 and published in the

2017 Edition of Code Cases

Major Benefits over performing RT

– Eliminates exclusion zone and allows work to continue in

adjacent areas

– Eliminates radiation safety concerns of using a source to perform

RT

– Eliminates the unnecessary repair of insignificant fabrication

flaws

– Better detection capabilities for planar flawsProprietary3

Developed PAUT in lieu of RT techniques with clients for B31.1 and ASME Code applications

− ASME Section XI, Repair replacement welds for ferritic piping.− ASME B31.1 piping welds 2004 through 2014 edition with or

without use of B31 Case 189. Examination Acceptance Criteria, Approval date: January 3, 2013

− ASME Section VIII pressure Vessel final closure welds where access does not permit interpretable radiographs, in accordance with UW-11(a)(7) or UT examinations in accordance with UW-51

− Qualified procedures, equipment and personnel to perform PAUT in lieu of RT for ASME Code activities

Overview

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ASME Code Case N-831

Highlights of N-831 Requirements − Applicable to carbon steel welds

− All flaws are considered planar

− Acceptance Standard of Section XI IWB-3000, IWC-3000 or IWD-3000

shall be utilized

− Examination shall be performed utilizing encoded UT system and

recorded to provide that produces an electronic record of the combined

UT data

− The examination procedure, equipment and personnel shall be qualified

by performance demonstration

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The examination volume shall include 100% of the weld volume and the weld-to-base-metal interface

− Angle beam examination of the complete examination volume for fabrication flaws oriented parallel to the weld joint shall be performed

− Angle beam examination for fabrication flaws oriented transverse to the weld joint shall be performed to the extent practical

Encoded ultrasonic examination shall be performed− Where component configuration does not allow for effective

examination for transverse flaws (e.g., pipe-to-valve, tapered weld transition, weld shrinkage), non- encoded ultrasonic examination technology may be used for transverse flaws

Development of N-831 Program

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Procedure and personnel performance demonstrations are based on:

− Type of fabrication flaw (Planar and volumetric)− Flaw location (near/far side and upper, middle, inner− Flaw size (both acceptable and unacceptable)− Min and max diameter and thickness− Surface condition (as demonstrated)− Welding processes

Development of N-831 Program

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UT in lieu of Radiography is now included in the following ASME Codes:

− ASME Section I, Power Boilers− ASME Section VIII, Pressure Vessels− ASME B31.1, Power Piping− ASME B31.3, Process Piping

Applications in Additional ASME Codes

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The examination shall be conducted using encoded techniques

− Examination are shall include the volume of the weld plus the lesser of 1.0” or t adjacent base metal

− Procedure and personnel qualified in accordance with Section V Mandatory Appendices

B31.1 Code

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Qualifications performed in accordance with N-831 exceeds these requirements

The alternative acceptance criteria is similar to N-831 − Uses total flaw height (h) instead of a or 2a of section XI− Flaw length shall not exceed 4t − Most benefits are for t>1.0”− No longer reject/repair for small planar flaws

Procedure and personnel qualified in accordance with Section V Mandatory Appendices

− Qualifications performed in accordance with N-831 exceeds these requirements

B31.1 Code Case 189 (continued)

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Field Experience

The following slides illustrate PAUT field results:

− Sidewall Lack of Fusion detected in a 16” SCH 100 Carbon Steel field weld

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Field Experience

Sidewall Lack of Fusion - 16” SCH 100 Carbon Steel Field Weld

Flaw

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Field Experience

Dye Penetrant examination results after weld removal

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Flaw Specimen: Lack of Fusion (LOF)

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Flaw Specimen: Lack of Fusion (LOF)

Future State

Code Case N-831 is limited to ferritic piping welds made as part of a repair/replacement activity

− Most repair/replacement welds are ferritic materials of various sizes

− To prepare for unplanned weld R/R activities demonstrating a procedure for the full range of possible weld sizes is desirable

− Austenitic weld R/R activities are less common and may be limited in sizes

− It would be advantageous to have the ability to use UT in lieu of RT

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EPRI Research

EPRI performed research to assess the effectiveness of UT to detect

fabrication related flaws for austenitic piping welds

− 3002010297, “Technical Basis for Substituting Ultrasonic Testing

for Radiographic Testing for New, Repaired, and Replacement

Welds for ASME Section XI, Division 1, Stainless Steel

Piping”(publicly available)

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Summary of EPRI Research

− Fabricated stainless steel mockups in accordance with N-831 requirements

− Mockups examined as single side access

− All flaws were detected and sized within N-831 criteria

− Demonstrated PAUT as effective for stainless steel fabrication flaw detection and sizing

This report provides the technical basis for revising N-831 to include austenitic piping

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On-going ASME Code Activity

CC N-831 is being revised to include austenitic materials using EPRI report as the technical basis

Revision to include addition of material through a procedure expansion demonstration

− Through the personnel demonstration process− Specimens must include diameter and thickness range of new

material− Must use same techniques already qualified− All flaws must be detected

If expansion process is unsuccessful, a full demonstration must be performed

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On-going ASME Code Activity

− EPRI research completed and report published -June 2017

− Discussed concept of procedure expansion for austenitic piping at the August 2017 Code meeting

− Draft Code Case revision presented at the November 2017 Code meeting

− Feedback provided by Task Group− Comments incorporated into N-831-1 (draft) and will be presented at

the February 2018 Code meeting− Expect endorsement through NDE Subgroup

− Updated the supporting white paper for the Code Case revision

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Conclusion

Phased Array UT provides a reliable alternative to radiography

− Established and Regulatory accepted protocol for performing PAUT in lieu of RT

− Significant savings have been realized for near critical path activities by utilizing PAUT ILO RT

− PAUT has provided collateral benefit of more realistic acceptance criteria for R/R welds

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