ACUREN Group Inc.

Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

TABLE OF CONTENTS
1.0

SCOPE

2.0

STANDARDS AND SPECIF ICATIONS

3.0

QUALIFICATIONS OF PERSONNEL

4.0

SAFETY

5.0

DEFINITIONS AND TERMINOLOGY

6.0

EQUIPMENT AND APPARA TUS

6.1 Equipment Requirements

6.2 Cleanliness and Handling

6.3 Inspection Materials

6.4 Operational Requirements

7.0

TECHNICAL HAZARDS

8.0

GENERAL PROCEDURE

8.1

Surface Preparation

8.2

Identification of Examination areas

8.3

Examination Coverage

8.4

Examination Process

10

8.5

Interpretation and Evaluation

11

8.6

Defect Sizing

12

8.7

Marking

13

9.0

ACCEPTANCE CRITERIA

14

10.0

POST CLEANING

14

11.0

REPORTS AND RECORDS

14

12.0

NONCOMPLIANCE

15

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October 10, 2007

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ACUREN Group Inc.

Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

1.0

2.0

SCOPE
1.1

This procedure outlines the requirements of an Ultrasonic Thickness

Measurement Survey.

1.2

This procedure also indicates a numbering convention to be followed

during surveys and sets a reporting standard for the final report.

STANDARDS AND SPECIFICATIONS

2.1

This procedure is in conjunction with the following codes:

a) ASME Section V Article 4 and 5
b) ASTM Standard E317.

3.0

4.0

QUALIFICATIONS OF PERSONNEL
3.1

Techniques and procedure for UT corrosion surveys are to be carried out

by technicians with a minimum certification of CGSB or SNT Level I.

3.2

A minimum certification to CGSB and SNT Level II shall carry out all final
interpretation.

SAFETY
4.1

All personnel must follow the Acuren safety policies as outlined in Acurens
Safety Manual.

4.2

All personnel utilizing this procedure must have WHMIS training.

4.3

Take precautions when reaching over Steam Tracer lines. Wrist

protectors are required.

4.4

Some areas where measurements are to be taken may be in high heat

zones. Personnel must take extra precautions when entering these areas.

4.5

Equipment must have secure hand and waist straps to ensure units are
not dropped. Extreme care is to be taken when handling calibration step
blocks, couplant and probes to ensure they are not dropped.

4.6

Disposal or cleanup of waste examination materials shall conform to

Federal, Provincial and Municipal Environmental Regulations and
Company policy.

4.7

Follow all manufacturer instructions and precautionary statements.

4.8

Workplace hazard assessments must identify and/or mitigate the potential

hazards prior to commencing work.

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

5.0

DEFINITIONS & TERMINOLOGY

a) ASTM American Society of Testing Materials.
b) ASME American Society of Mechanical Engineers.
c) CGSB Canadian General Standards Board.
d) FSH Full Screen Height.
e) MHz Megahertz.
f)

NDE Non-destructive Examination.

g) SNT- Society of Non-destructive Testing.

h) Contact Method refers to contact of the transducer with the part.

6.0

i)

Straight Beam where the angle of pulse from the transducer is zero
degrees. Mode of propagation is longitudinal wave.

j)

Search Unit transducer or probe.

EQUIPMENT AND APPARATUS

6.1

Equipment Requirements
a) UT Set

Datalogger capable of A-Scan representation.

Panametrics 36DL+, 37DL+ or equivalent.

b) Probes (Transducers)

Panametrics D790 and D798 or other suitable probes.

c) Calibration Blocks

0.100 to 0.500 Stainless steel and carbon steel with traceable

certification.

0.600 to 1.00 Stainless steel and carbon steel with traceable

certification.

Metric calibration blocks may also be used at the clients request.

d) Couplant

Use the appropriate co uplant for the range of temperature.

e) Supplies

tape measures flexible, heat resistant

Pyromarkers

Squeeze bottles for couplant application.

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

f)

6.2

Scrapers.

Wire brushes.

Clipboards and office supplies.

PPE

Fire-retardant coveralls.

Heavy clothing for winter work.

Suitable hearing protection.

Safety glasses.

Full Face shield when buffing .

Hard Hat, Steel-toed boots, leather gloves.

Wrist protectors.

Calibration
a) Typical for 36DL+ and 37DL+ or equivalent.
b) Determine the pipe nominal thickness and material, then calibrate on a
range of thickness values appropriate to the nominal pipe thickness. A
minimum of two points is required for calibrations. One at the upper
limit and one at the lower limit.
c) The search unit shall be calibrated at a similar temperature as the pipe
to be inspected. This shall be accomplished by placing the calibration
block on the part and allowing the calibration block to achieve the
same temperature as the test piece. Calibrations wi ll be carried out
using a small amount of the same couplant that is to be used during
the procedure.

NOTE
Failure to comply with temperature difference during calibration will result in
measurement errors due to the velocity changes that occur at different
temperatures.
d) Wipe the probe end clean and press [Zero ] often to compensate for
temperature drift.
e) Check the calibration frequently (see tips for improving transducer
longevity).

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

7.0

TECHNICAL HAZARDS
7.1

It is critical to know the material grade and type prior to performing

ultrasonic examination. Velocities and acoustic attenuation change with
types of materials and calibrations must be done on the same material
standards as those being examined. Accuracy is dependent upon actual
dimensional measurements to standards.

7.2

Special attention must be given on curved or contoured surfaces to ensure

consistent ultrasonic beam entry angle and adequate coupling.

7.3

Search units must be periodically checked for characteristics as per ASTM

E164 or the referencing code section. These include beam spread, index
points, angle verification, near field and far field resolution.

7.4

Any damage to the ultrasonic instrument requires re-calibration.

7.5

Steps To Ensure Transducer Longevity

a) UT Set

Always keep the download and recharging port clean and

protected, either by keeping the cap in place when unit is being
used or, if cap becomes lost/damaged, by using electricians tape
to protect the port.

b) High Temperature Applications

Ensure the surface temperature of the test piece does not exceed
the maximum specified temperature for the transducer.

Use couplant rated for the temperature of the test material.

Limit transducer contact time to 5 seconds.

Never let transducer get too hot to hold.

If transducer gets hot:

Allow transducer to air cool or,

Dip transducer in water to cool.

Re-zero transduce r frequently with the tip dry to compensate for

temperature drift.

Avoid dragging transducer cable across hot pipe and/or place a

protective sleeve on the cable. Armored cables are also available
and should be used if possible.

High temperature dual transducers have delay lines made of

thermally tolerant materials, but with continuous exposure to high
temperatures, the inside of the probe will heat to a point where the
bonds will fail, destroying the transducer.

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

c) Surface Conditions

Develop a technique of applying a transducer with the least

possible pressure.

When scanning an area, do so with the lightest pressure possible.

Clean any loose debris (flaking paint, rust, scale, and dirt) from the
specimen with a wire brush or file.

When dealing with a rough surface, an effort should be made to

smooth the surface roughness.

On some rough surfaces, the use of gel or grease rather than a

liquid couplant will help transmit sound energy into the test piece.

NOTE
If a surface is rough and it is difficult to obtain a reading, it is unlikely that
grinding the transducer into the surface will improve the situation. When the
transducer surface becomes worn, the efficiency of the transducer will diminish
due to the fact that thick couplant layers may build up between the delay
elements of the transducer and the surface. Alternatively, the gage may have
difficulty in performing do zero. If these conditions develop, resurfacing of the
transducer face may be necessary.
d) Transducer Positioning/Alignment

8.0

On small diameter cylindrical surfaces, such as pipes, hold the

transducer so that the crystal division bar visible on the probe face
is aligned perpendicular to the centre axis of the pipe.

When scanning an area, data should be taken at increments no

greater than half the diameter of the transducer to insure that
nothing is missed.

GENERAL PROCEDURE
8.1

Supervisor Responsibilities
a) Supplying the required number of technicians, the data clerk and the
lead technician.
b) Understanding the job scope and any previously identified trouble
areas or trends before commencing the survey.
c) Keeping the lines of communication with the Project Supervisor during
the duration of the survey.

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

8.2

Client Requirements
a) The following are tasks to be completed by client representati ves prior
to Acuren Personnel arriving on site.

8.3

Supply isometric drawings for every line to be surveyed.

Identify the line contents and hazard (s) level(s) of each line.

Identify the survey locations on the isometric drawings.

Label the direction of flow on every isometric drawing.

Provide the operating temperature for every line to be surveyed.

Identify any non-standard material types on isometric drawings (i.e.

Hastalloy).

Co-ordinate the scaffolding and insulation removal.

Establish a liaison between the Lead Technician and the

Scaffolding and Insulator Foremen to enable smooth and efficient
co-ordination during inspection.

Personnel
a) The number of Acuren personnel will be based upon the survey scope
and duration.
b) The duties of the data clerk shall inc lude but are not limited to:

Input data as it comes in from the field.

Update or create new drawings as required.

Ensure final report is in proper format at job completion

c) Lead Technician (either CGSB UT Level II or experienced CGSB UT

Level I) shall be responsible for the following:

Ensuring the project runs smoothly including job set-up, equipment

maintenance and supplies.

Obtaining the line contents and hazard(s) level(s) for each line.

Review previous surveys when accessible and familiarize self to

job scope and trends.

Act as liaison with Client Area Inspector(s) and provide daily

updates of progress.

Ensure that the organization system records survey completions,

rework requirements and their progress and that the system is kept
current.

Review all downloaded readings.

Have all questionable readings re-checked and verified.

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

Perform a random audit on 10% of thickness readings for each

technician.

Report thickness readings taken during audit in the final report to

the client.

Sign off completed survey locations.

Review a ll correspondence with Client Area Inspector(s).

Perform ultrasonic thickness testing in field.

Organize daily toolbox meetings.

Ensure all equipment is calibrated.

d) UT Technicians (minimum requirement CGSB UT Level I):

Set up the UT data logger and numbering convention as outlined in

later sections.

Perform ultrasonic thickness testing in field.

Ensure readings are accurate to minimize re-checks.

Perform re -checks of other technicians when requested by Lead

Technician.

Aid in creating, uploading and downloading of data.

Participate in all facets regarding safety program meetings.

e) Supervisor:

8.4

Peer review of final report document before issuing to the Client.

Ensure duties of above personnel are carried out.

Act as a resource for any problems that occur.

Preparation
a) Review all Isometric drawings for flow direction and clear identification
of locations to be surveyed.
b) The Lead Technician shall discuss the following with the client
representative:

Work Permit procedure.

Number of locations.

Criteria for what is considered an area of concern.

Schedule for completion of work and priorities.

When they would like final reports: i.e. as they are completed or at
the end of the job.

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

8.5

At what intervals they would like to receive progress reports.

Data Acquisition
a) Set up the UT set and data numbering convention as explained in this
technique or as requested by the client.
b) Make a drawing of the area ensuring that both the direction of flow and
the numbering convention are identified.
c) Using a data logger perform the initial thickness measurement survey.
d) Review the data on the instrument prior to leaving the location to
ensure that no data points have been missed. If the data appears to
be incomplete, perform additional data logging for any remaining
survey locations.
e) Automated methods of obtaining thickness information (i.e. UT B-Scan
and C-scan) may be employed when requested by the client.

8.6

Data Review and Reporting

a) The Lead technician shall review the data for any low areas or
erroneous data and identify any areas that need to be re -logged or
confirmed.

NOTE
The data must be reviewed within two days of the initial survey or as required
by the client.
b) If any areas are to be rechecked the lead technician will assign a
different technician than the one who performed the initial survey to remeasure the areas of concern.
NOTE
This must be done within 3 days of the initial survey or as required by the client.
c) If the review did not reveal any low areas the field report will be
prepared for each survey site location.
d) A field copy of the survey report shall be printed given to the client
area representative.
NOTE
The final report shall be completed as soon as possible, and it must be within 5
days of the initial survey or as required by the client.
e) All applicable updates and new drawings to the corrosion surveys shall
be carried out by Acuren Group Inc.
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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

8.7

Data Logging
a) Setting up a Matrix

Looking in the direction of flow, the grids start at the upstream side
of the initial circumferential weld and progress alphabetically as the
bands move downstream.

b) Location of Measurement Bands

The second axis for the matrix shall make up the numeric portion
of the alphanumeric grid and is also referenced to the direction of
flow.

Each grid is made up of a series of readings in the center of each

2.54 cm (1) square on the outside of the pipe. The grid placement
may be determined by the client (i.e. top of the pipe, bottom of the
pipe outside of the elbow, inside of the elbow, etc.).

When Acuren is determining the grid locations they shall be:

for pipe start on top at zero

for elbows outside of bend

for tees center of straight side

The client may employ a method of permanently marking the pipe

to ensure consistency, repeatability and accuracy of future
thickness surveys. The method of permanently marking the pipe
shall be the responsibility of the client.

The direction of numbering is determined by the direction of flow.

The grid squares shall be designated alphanumerically as follows:

The grid squares shall be designated along the longitudinal

axis numerically

The grid squares shall be designated circumferentially with

letters of the alphabet.

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

c)

The grid size s will be different for each size of pipe.

For pipe ranging in size from 2.54 cm (1) to 35.56 cm (14) shall
be 2.54 x 2.54 cm (1x 1) squares. The grid shall start 2.54 cm
(1) after the closest upstream weld (see fig.1) and continue for a
longitudinal distance designated by the client.

Figure 1

For pipe ranging from 40.64 cm (16) to 76.2 cm (30), a 5.08 cm

by 5.08 cm (2 x 2) square grid shall used. The grid shall start
2.54 cm (1) after the closest upstream weld (see fig. 2) and
continue for a longitudinal distance designated by the client.

Figure 2

For piping ranging from 86.36 cm (34) to 132.08 cm (52), a 7.62

by 7.62 cm (3 x 3) square grid shall used. The grid shall start
2.54 cm (1) after the closest upstream weld (see fig. 3) and
continue for a longitudinal distance designated by the client.

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

Figure 3
d) Set up a table with the numerical grid designation as column headings
and the alpha designation as row headings. For Example, an NPS 4
standard wall pipe would have a 1 x 12 grid for a total of 12 thickness
readings and the grid would be as shown table 2.
1

10

11

12

Table 2
NOTE
It is important to maintain the above convention for naming both columns
and rows even if a portion of the grid is not accessible. For example, if
there was no access to Column 3 of Table 2, all other areas would be
inspected and no data would be entered in Column 3. Make note in the
report the reason for no data in that location (i.e. A nozzle, B restricted
access, etc.).
8.8

Data Logger ID and Excel File Naming Conventions

a) It is important to follow a logical convention in naming the data logger
files. The name should contain information regarding the plant name,
isometric drawing, and inspection point.
b) The Panametrics matrix maker allows the first 8 characters for naming
the file, using numbers and letters.
c) Following the ID Name, is a delimiter, then the first column, another
delimiter, followed by the first row.
d) Name the file with the plant number, the isometric drawing number,
followed by weld number designated by the client or from existing ISO
drawings.

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

e) Example: In the isometric sketch shown in Figure 4, 15-2 FB-003, 13-1

is the plant number, and FB-003 is the Drawing ID number.
f)

If we surveyed the T location the closest upstream weld is 01, the

data logger file should be 131FB3-01.

g) If for some reason 8 characters are not sufficient to follow this

convention, ensure that the data entry clerk is informed right away so
that the file can be renamed after downloading to conform to the
proper naming convention.

Figure 4
8.9

Care of Equipment
a) In order to ensure accurate thickness measurements and reliable
inspection results, equipment must be properly maintained.
b) Keep the unit clean and protect from the environment.
c) Follow the manufacturers manual for routine care and maintenance.
d) Equipment to be red tagged if unit is not operating properly and
returned to the Acuren Repair Facility in Edmonton.

9.0

ACCEPTANCE CRITERIA
9.1

10.0

The client shall determine the acceptance criteria.

POST CLEANING
10.1 If necessary final cleaning shall be accomplished with an approved
manufacture rs cleaner or a cleaner approved by the referencing code
section or customer specification.

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Technical Procedure No. UT-0030

GENERAL THICKNESS MEASUREMENT SURVEYS

11.0

REPORTS AND RECORDS

11.1 The report of results for each location surveyed shall include but not
limited to the following information:
a) Plant number.
b) Isometric drawing number.
c) Location identifier.
d) Component name (i.e. elbow, tee, reducer, etc.)
e) Diameter of component surveyed.
f)

Nominal wall thickness.

g) Material.
h) Pipe temperature at time of examination.
i)

Operator name and certification number.

j)

Survey date.

k) Data logger serial number.

l)

Calibration due date.

m) Transducer type and serial number, and length of cables.

n) Calibration block material, size and reference serial number.
o) Sketch of the component with direction of flow and location of
thickness grid.
p) The minimum reading and grid location.
q) The maximum reading and grid location.
r) The survey data.
12.0

NONCOMPLIANCE
12.1

All items of non-compliance will be dealt with according to the Acuren

Quality Management System, and a report shall be generated on nonconformance items to address any problems that may occur.

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