Aries Iris Tube Procedure

Procedure for Internal Rotatory Inspection QHSE/ P11/ ANDT/
Date: 03.04.2021
System JP004/ IRIS/Gen
Rev # 03 Page 1 of 25
INTERNAL ROTATORY INSPECTION SYSTEM

INSPECTION PROCEDURE FOR CONDENSER AND
HEAT EXCHANGER TUBE.
Document
Rev Issue Date Prepared by: Reviewed by: Approved by:
No:
Name & Name &
Name & Signature:
Signature: Signature:
Lalith R. Vipin Shetty Ganeshbabu.M
Level-II Level-II Level-III
QHSE/ P11/
ANDT/ JP04/ 03 03.08.2021
IRIS/Gen
Date: 03.08.2021 Date: 03.08.2021 Date: 03.08.2021

Date: 03.04.2021
Table of Contents
Page #
1. Amendment Record------------------------------------------------------------- 3
2. Introduction-------------------------------------------------------------------- 3
3. References--------------------------------------------------------------------- 3
4. Qualification Of Personnel------------------------------------------------ 3
5. Safety----------------------------------------------------------------------------- 4
6. Principle------------------------------------------------------------------------- 4
7. Test Equipment--------------------------------------------------------------- 4
8. Functional Test--------------------------------------------------------------- 4
9. Tube Inspection Procedure----------------------------------------------- 5
a. Pre Inspection Preparations------------------------------------ 5

b. Services Required At The Work Station-------------------- 6
c. Exchanger Inspection--------------------------------------------- 6
10. Restrictions of Test--------------------------------------------------------- 7
11. Limitations of Technique-------------------------------------------------- 7
12. Presentation of Results---------------------------------------------------- 8
a. Reporting Criteria--------------------------------------------------- 8
b. Inspection Report-------------------------------------------------- 8
APPENDIX A – Overview Of Test Instrument ( Ms5800)------------- 9-10
APPENDIX B – Set Up Of Test Instrument ( Ms5800)------------------ 11-25

Date: 03.04.2021
AMENDMENT RECORD
Section / Name
Revision Date of
Checklist Amendment Details
No. Amendment Reviewed Approved
Amended
03 03.04.2021 Sec 11 Report format changed Vipin Shetty Ganesh Babu M
00 18.03.2018 Initial Issue Ajesh V Ganesh Babu M

Date: 03.04.2021
1. INTRODUCTION
The technique described is designed to detect and classify ultrasonic responses

originating from metal loss in ferrous & non-ferrous tubing. It is the purpose of this
procedure to establish the necessary test equipment, equipment operator qualifications,
sequence of steps to be performed during the inspection, and records to be kept. This
procedure shall be applied only when no client procedures are applicable.
Any special requirements for a particular inspection shall be agreed upon prior to
inspection commencement, and will be identified on the Work Request and or Report
Sheet.
2. REFERENCES
· BS EN 473 Qualifications and Certification of Personnel

· SNT-TC-1A Recommended Practice for personnel Qualification and
Certification in Non-destructive Testing.
· BS EN 1330-4 Non-destructive Testing – Terminology.
· Olympus NDT IRIS Operating Manual.
All standards and procedures referenced were the latest issues on the date of writing this
procedure.
3. QUALIFICATION OF PERSONNEL
The team leader engaged in IRIS inspection will have a minimum of
· BS EN 473 PCN Level II or ASNT Level II in Ultrasonic Inspection.

· Comprehensive experience of tube inspection.
· Full comprehension of this procedure, relevant standards and referenced
documents.
4. SAFETY
All inspection related activities shall be carried out in accordance with Health & Safety
requirements in addition to all site related Local Rules and systems of work.
Particular attention shall be paid to the exercising of care whilst using water & electricity
in close proximity as well as good housekeeping in order to minimise trip hazards.
Date: 03.04.2021
5. PRINCIPLE
The IRIS system uses a conventional ultrasonic pulse echo technique with the ultrasonic
beam being scanned around the internal circumference of the tube.
The beam is rotated by directing it at an angled mirror, which is driven at approximately

1800 r.p.m. by a small hydraulic turbine mounted in the inspection head. To transmit the
ultrasound to the tube wall the tube is flooded with water and, by withdrawing the
inspection head from the tube at a pre-determined rate, the ultrasonic beam is made to
describe a helical path. The individual revolutions produce a continuous series of
measurements, which are displayed on the monitor.
A functional test should be carried on the IRIS system before commencing inspection.
The operator should check that all water hose and electrical connections are made good
and that the electronics equipment is protected from spray. During an inspection the
following procedure should be followed:
6. TEST EQUIPMENT
The equipment to be used for the inspection as a minimum requirement comprises of:
· Olympus NDT MS5800 (Or Equivalent) and all required cables, with a valid test
certificate to indicate that it has been calibrated in accordance with an approved
maintenance schedule within the last 12 months.
· PC loaded with the appropriate software, licences & security keys,
· IRIS front end i.e. optimum frequency & focal size probe suitable diameter
turbine & centralisation device with adequate length umbilical for the tube under
examination.
· Water supply via filter and/or optional pump system and all necessary hoses, whip
arresters etc.
· Appropriate reference tube “See below”.
7. FUNCTIONAL TEST
A reference tube of the same dimensions, material and geometry as the tube type to be
inspected shall be machined with artificial defects typically a 50% external groove and
some flat bottomed holes arranged in sets of 4, representing Pitts of 10-50% wall loss, of
varying diameters ranging from 2 – 5mm.
The above reference tube is used to carry out a functional test of the MS5800 system.
The functional testing of the system is to be carried out:
· At the start and finish of each working shift.

· After any change in equipment, cables or operating system.
Date: 03.04.2021
· After any prolonged stoppage of work.

· After damage to the equipment or if any errors are suspected.
The Multi view software is used to call up the correct velocity for the tube being
inspected. The Multi view probe/turbine selection software is used to select the optimum
probe and turbine configuration. After the initial settings have been entered into the Multi
view software wizard or existing settings have been recalled, the turbine is introduced
into the reference tube and an image of the tube wall is obtained. The turbine head is
brought in line with the machined artificial defects and the IRIS image checked that the
wall loss is accurate to within ± 5% (±0.05mm) of the known artefacts (See Appendix A
& B).
8. TUBE INSPECTION PROCEDURE
4.1 Pre-Inspection Preparation
Orientation of the exchanger/tubes in terms of inspection end, row & tube numbering
system together with the extent of the survey, recording level and location of the tubes to
be inspected will be established via a pre-inspection consultation with the Client
(Instructions shall be detailed in the contract document or work request sheet). In the
absence of client instruction the above will be at the discretion of the lead technician,
where anything other than a 100% inspection is required the tubes inspected will give a
good representation of tube condition, particular attention shall be focused on any areas:
· In close proximity to Inlets/Outlets

· Adjacent to impingement plates
· Surrounding previously Plugged/Removed tubes or tubes with known defects.
In addition to selecting tubes to ensure a cross sectional spread of the bundle is inspected.
The propagation and reflection of ultrasound depends largely on the condition of the
interface between adjoining media. A clean, well defined boundary between the flood
water and the inside diameter of the tube produces a sharp, relatively high amplitude front
wall echo.
Any rust, scale or other precipitate on the inside of the tube reduces the reflectivity of the
boundary, producing a less well defined front wall echo and an increase in the threshold
at which the SIGNAL can be readily differentiated from the NOISE. No other factor has a
greater influence on the resolving power of IRIS than the condition of the internal surface
of the tube.
It is recommended that, in the majority cases, the minimum cleaning requirements should
be high pressure water jetting of the inside of the tube using a minimum pressure of
10,000 p.s.i. with a rotating polishing head used as the final cleaning pass.
Date: 03.04.2021
Any inadequacies in tube cleanliness shall be reported to the client’s representative,

where no further cleaning is possible any restrictions to test shall be recorded (See
definitions in section 10.0 RESTRICTIONS OF TEST) also See 11.0 LIMITATIONS OF
TECHNIQUE.
N.B. Prior to use the turbine should be left to run for a minimum of ten minutes to ensure
that all air bubbles have been removed from the water couplant and to stabilise the
couplant temperature.
During the initial set up the earthing cable should be connected between the exchanger
and the test instrument in order to minimise any external interference.
4.2 Services Required at Workstation
The client is requested to provide the following requirements at each workstation:
· AC mains power (Client is to advise as to the voltage i.e. 110/240V and if a non
standard electrical fitting is required)
· A fresh water supply of 50-100 psi or 3-7 bar (Client is to advise of water fitting
type required)
· A habitat to protect personnel & equipment from adverse weather conditions and
to provide the correct viewing conditions for the VDU.
· Where bundles have been removed from the shells, the bundle should be
positioned so that adequate working space is available at the inspection end of the
exchanger and the bundle inclined slightly towards the inspection end.
· In the case of “U” tubes the “U” tubes should be positioned horizontally.
· In the case of vertical exchangers where possible the tubes should be pre flooded.
4.3 Exchanger Inspection.
Prior to inspection each tube must be flooded. To facilitate this far end of the tube is
usually part blocked with a rubber plug or flood hose.
As it is easier to withdraw the Inspection Head Assembly in a controlled manner than to

push it in, it is recommended that the inspection commences with the inspection head
assembly located at the far end of the tube. The end of the tube is indicated by the
collapse of the rectilinear display. As the Inspection Head Assembly is moved away from
the end of the tube the rectilinear display reappears on the screen.
During the inspection the inspection head assembly is gradually pulled along the tube
towards the operator. The rate at which the inspection head assembly is moved along the
tube is dependant on the size of tube being inspected and is calculated by multiplying the
turbine rotation speed (Turns/Sec) by the Probe resolution (Transducer focal point in
mm/Turn). Care must be taken to manually centralise the probe assembly during the last
400mm of the inspection.
Date: 03.04.2021
When the probe exits the tube, data collection is stopped.
When possible analyze the data and record the results immediately after data acquisition.
The repeat level for large defect indications may be varied at the discretion of the lead
technician, taking into consideration the general condition of the tubes, and the
repeatability of the tests.
Push the probe into the next tube to be examined and repeat steps above for each tube.
During analysis each tube is monitored and its condition reported with hard copies taken
if required. Defect location along the tube length if required is facilitated either by the
handling tube being marked off in metre intervals or by the use of an encoder.
An IRIS record for each tube inspected shall be stored showing 360 degrees (Exception
under target pin) over the full length of the tube, any deviation from 100% must be
documented as either a restriction or a limitation.
9. RESTRICTION OF TEST
Tubes not fully inspected will be recorded using the following titles:
· Obstruction (OBS) - Any tube that has not been inspected over its entire length
due to the probe passage being impeded by dirt, dents etc. (If a partly tested tube
is found to contain a reportable defect indication the tube shall be recorded as
having such a defect and the reason for partial inspection reported separately.
· Plugged (PLG) - Any tube no longer in service and fitted with a plug.
· Inaccessible (INA) - Any tube that can not temporarily be inspected i.e. due to
scaffolding etc.
· No ACCESS (No ACC) - Any tube into which the probe cannot be
introduced.
10. LIMITATIONS OF TECHNIQUE
Limitations of standard IRIS technique:
· The minimum defect diameter detectable by IRIS is dependant on the minimum

resolution of the focal point on the tube wall, the turbine revolution speed and
travel speed (The defect needs to be detected 3 times). For small tubes this is
approximately 3mm (Detection of smaller defects is possible down to 1.5mm). For
larger tubes this increases to approximately 6.0mm.
· The high pulse repetition frequency allows 100% coverage of the tube I.D. & O.D.
where wall thickness allows i.e. the minimum resolvable wall thickness of steel is
dependant on the probe frequency (10MHz – 1.2mm, 15MHz – 1.0mm & 20MHz
Date: 03.04.2021
– 0.8mm.This minimum value will vary for each material. N.B. The minimum
resolvable wall thickness detectable on 19.05mm O.D. tube is 1.3mm.
· The maximum I.D. that can be inspected using a conventional centring device is
75mm.
· The maximum wall thickness that can be inspected using a conventional probe
and turbine arrangement is 15mm.
· Bends cannot be inspected using IRIS.
· The first and last 25mm of the tube cannot be inspected using IRIS.
Any areas of the inspection where a signal was not achievable or further limitations must
be detailed in the report i.e. loss of signal due to:
· Loss of centralisation/couplant.
· Loss of signal due to dirt/solid deposit
· Loss of signal due to tube geometry i.e. dents.
11. PRESENTATION OF RESULTS
a. Reporting Criteria
The reporting threshold of percentage wall loss will be established by consultation with
the client, together with a threshold above which hard copy printouts would be required.
In the absence of client instruction all defects above 10% are to be reported giving the
estimated percentage wall loss with defect location in the tube length (Where defects are
not of a random nature) and hard copy printouts showing images of all defects above 50%
wall loss. Defect description codes which accompany the percentage wall loss are used to
describe the defect mechanism:
· OD COR – General corrosion on the OD of the tube wall

· ID COR – General corrosion on the ID of the tube wall
· OD PIT – Isolated pit on the OD of the tube wall
· ID PIT – Isolated pit on the ID of the tube wall
· NDD – No defect detected (Less than 10% wall loss noted)
b. Inspection Report
Date: 03.04.2021
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Appendix A - Overview of ms5800 test instrument using IRIS

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Appendix B - SET UP OF MS5800 test instrument using IRIS

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Procedure for Internal Rotatory Inspection QHSE/ P11/ ANDT/

INTERNAL ROTATORY INSPECTION SYSTEM

Date: 03.08.2021 Date: 03.08.2021 Date: 03.08.2021

9. Tube Inspection Procedure----------------------------------------------- 5

a. Pre Inspection Preparations------------------------------------ 5

10. Restrictions of Test--------------------------------------------------------- 7

11. Limitations of Technique-------------------------------------------------- 7

12. Presentation of Results---------------------------------------------------- 8

APPENDIX A – Overview Of Test Instrument ( Ms5800)------------- 9-10

APPENDIX B – Set Up Of Test Instrument ( Ms5800)------------------ 11-25

00 18.03.2018 Initial Issue Ajesh V Ganesh Babu M

The technique described is designed to detect and classify ultrasonic responses

· BS EN 473 Qualifications and Certification of Personnel

The team leader engaged in IRIS inspection will have a minimum of

· BS EN 473 PCN Level II or ASNT Level II in Ultrasonic Inspection.

The beam is rotated by directing it at an angled mirror, which is driven at approximately

The functional testing of the system is to be carried out:

· At the start and finish of each working shift.

· After any prolonged stoppage of work.

8. TUBE INSPECTION PROCEDURE

4.1 Pre-Inspection Preparation

· In close proximity to Inlets/Outlets

Any inadequacies in tube cleanliness shall be reported to the client’s representative,

4.2 Services Required at Workstation

The client is requested to provide the following requirements at each workstation:

4.3 Exchanger Inspection.

As it is easier to withdraw the Inspection Head Assembly in a controlled manner than to

When the probe exits the tube, data collection is stopped.

10. LIMITATIONS OF TECHNIQUE

Limitations of standard IRIS technique:

· The minimum defect diameter detectable by IRIS is dependant on the minimum

11. PRESENTATION OF RESULTS

· OD COR – General corrosion on the OD of the tube wall

Appendix A - Overview of ms5800 test instrument using IRIS

Appendix B - SET UP OF MS5800 test instrument using IRIS

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