AXIS INSPECTION LTD. No.

: AIC-IRIS-100

OPERATING PROCEDURE Issue : 1

(WORK INSTRUCTION)

INTERNAL ROTARY INSPECTION Rev. : 0

SYSTEM (IRIS)

AXIS INSPECTION LTD.

OPERATING PROCEDURE

INTERNAL ROTARY INSPECTION SYSTEM (IRIS)

FOR HEAT EXCHANGER TUBES

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to a third party without the written consent of Axis Inspection Ltd.
 AXIS INSPECTION LTD. No. : AIC-IRIS-100

OPERATING PROCEDURE Issue : 1

(WORK INSTRUCTION)

INTERNAL ROTARY INSPECTION Rev. : 0

SYSTEM (IRIS)

Table of Contents

S.No. Description Page No.

1.0 Scope 3

2.0 Purpose 3

3.0 Definitions 3

4.0 References 3

5.0 General Requirements: 4

6.0 Surface Preparation 6

7.0 Precautions 6

8.0 Procedure 7

9.0 Calibration Verification 8

10.0 Data Acquisition 9

11.0 Data Interpretation 11

12.0 Data Evaluation 11

13.0 Reporting 12

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 AXIS INSPECTION LTD. No. : AIC-IRIS-100

OPERATING PROCEDURE Issue : 1

(WORK INSTRUCTION)

INTERNAL ROTARY INSPECTION Rev. : 0

SYSTEM (IRIS)

1. Scope:
1.1. This document specifies the application of the Internal Rotary Inspection System (IRIS)
on all Heat Exchanger tubing using Multi Scan test equipment and data capturing
software.
1.2. This procedure allows the detection and location of IRIS responses in the tubes.
1.3. Due to size for IRIS inspection is limited by 0.75 inch due to

2. Purpose:
2.1. This procedure is to provide instruction for the setup/calibration of the IRIS ultrasonic
technique.

3. Definitions:
3.1. Definitions shall be as defined in ASTM E 1316 Terminology for Non- destructive testing,

4. References:
4.1. AIC-CERT-100, Axis Inspection Technologies, Procedure for the Qualification and
Certification of NDT Personnel.
4.2. API Standard 661 Air-Cooled Heat exchanger for General Refinery Services
4.3. The references listed above were used to compile this document and
Insure that the requirements of the above documents were met.
4.4. Client specific requirements e.g. acceptance criteria, will be attached to this document.

5. General Requirements:
5.1. Personnel Qualification:
5.1.1. Personnel performing and or evaluating IRIS examinations shall be qualified and
certified to at least Level II in UT in accordance with AIC-CERT-100, Axis Inspection
Technologies, Procedure for the Qualification and Certification of NDT Personnel
5.1.2. Personnel performing IRIS inspection shall have enough training to perform the
Inspection, Equipment setup, data acquisition, data storage and report preparation

5.2. Equipment and Accessories:

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 AXIS INSPECTION LTD. No. : AIC-IRIS-100

OPERATING PROCEDURE Issue : 1

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SYSTEM (IRIS)

5.2.1. The IRIS equipment shall be TC5700 or MS5800 or equivalent capable of multi-
functional NDT Inspection machine in IRIS Inspection mode.
5.2.2. Electronic instrumentation which used shall be calibrated at least once a year or when
it is apparent that the equipment is malfunctioning or damaged.

5.3. Probes
5.3.1. Unless otherwise specified probes shall be of a frequency of no less than 10 MHZ and
of the immersion type.
5.3.2. Probe may either be manually operated by hand or by means of an automatic pusher
puller.
5.3.3. The probe transverse speed shall under no circumstances exceed 1. 0 meter/ second
during the inspection. The speed of probe insertion is not important but should be
done as fast as possible.

5.4. General Instructions and Information Requirements

5.4.1. The following minimum information is required prior to conducting an inspection:
5.4.1.1. Tube-dimension: outside diameter, wall thickness, length
5.4.1.2. Tube Material: CU/NI/90/10, Brass, stainless steel, etc
5.4.1.3. Tube Characteristics: Finned, U-tube, etc `
5.4.1.4. Scope of inspection: Number of tubes, inspection pattern
5.4.1.5. Service- e.g., Tube side-water/shell side-steam
5.4.1.6. Wastage Mechanism : in any are known
5.4.1.7. Recent tube failures

5.4.2. Work Instructions:

5.4.2.1. Tube material, diameter and wall thickness
5.4.2.2. Inspection and recording equipment
5.4.2.3. Probe transverse speed
5.4.2.4. Calibration Tube standard
5.4.2.5. Calibration procedure
5.4.2.6. Analysis procedure

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5.4.3. Pre Inspection Requirements: Prior to conducting an inspection following items shall
be conducted visually to verify.
5.4.3.1. Unit Identification
5.4.3.2. Location of the tube bundle .i.e. Top, bottom, north south etc
5.4.3.3. Number of passes
5.4.3.4. Inspection conducted from which end
5.4.3.5. Thickness of tube sheet
5.4.3.6. Number of supports, material and thickness
5.4.3.7. Condition of tube sheet
5.4.3.8. Condition of tube externally
5.4.3.9. Tube cleanliness
5.4.3.10. Accuracy of drawing

6. Surface Preparation:
6.1. The inside of the tube must be clean with no obstruction by any suitable means like
Hydro-jetting, Air blower etc.,)
6.2. If it is determined that the tube cleanliness is not sufficient to produce the required quality
it shall be notified to the client for another attempt of cleaning required.

7. Precautions:
7.1. Uninterrupted continuous power supply.
7.2. Confirm the tube no. and identify of the specific tube after every 25 tubes. If there is error
all the tubes from the last confirmed shall be re-tested.
7.3. Tube sheet shall be clearly marked up in such away as to identify individual sections (if
any) and rows. The tube sheet of each heat exchanger shall be marked in the same
manner to ensure traceability of each tube.
7.4. Normal numbering is from top to bottom for row numbers and from left to right for tube
numbers.

8. Procedure:
8.1. Calibration:

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 AXIS INSPECTION LTD. No. : AIC-IRIS-100

OPERATING PROCEDURE Issue : 1

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8.1.1. Prior to use the calibration standard shall be manufactured from length of tubing of the
same material as that to be examined in the heat exchanger. The tubing should be of
the same nominal size and material type as that in the heat exchanger.
8.1.2. The standard should contain a sample/s of the expected damage, natural or artificial,
the minimum degradation to be detected, the plugging limit and the reference required
by the applicable codes.
8.1.3. The Calibration standard used for the IRIS shall have the following discontinuities.

8.1.3.1. A single hole drilled 100% through the wall 0. 052 inch diameter for 0. 750inch
O. D. tubing and smaller and 0. 067 inch diameter for larger tubing.
8.1.3.2. Flat bottomed hole 5/64 inch diameter, 80% through the tube wall from the
O. D.
8.1.3.3. Flat bottomed drill hole 7/64 inch diameter, 60% through the tube wall from the
O. D.
8.1.3.4. Flat bottomed hole, 3/16 inch diameter, 40% through the tube wall from O. D.
8.1.3.5. Four flat bottom holes, 3/16 inch diameter spaced 90 degree apart in a single
plane around the tube circumference, 20% through the tube wall from the O. D.
8.1.3.6. A 1/8 inch wide, 360 degree circumferential groove, 10 to 20% through the tube
wall from the O. D. (optional)
8.1.3.7. A 1/16 inch wide, 360 degree circumferential groove, 10 to 20% through the
tube wall from the I. D. ( optional)
8.1.3.8. Each standard shall be identified by a serial number. The depth of the
calibration discontinuities at their center shall be accurate to within ± 20% if the
specified depth or ± 0. 003 inch, whichever is smaller. All other dimensions
shall be accurate to ± 0. 010 inch.
8.1.3.9. Additional calibration standards other than that used Section 8. 1 may be used
to establish specific sensitivity settings. The use and description of additional
calibration standards shall be documented in the permanent report. However,
the calibration standard used in section 8. 1 must be used with any additional
standard(s) when setting up the primary frequency.

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 AXIS INSPECTION LTD. No. : AIC-IRIS-100

OPERATING PROCEDURE Issue : 1

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SYSTEM (IRIS)

9. Calibration Verification:
9.1 Calibration checks shall include the entire system.
9.2 Calibration shall be made at the beginning and end of each production run of given
diameter and thickness of a given material and data recording device.
9.3 Calibration shall be made if any of the IRIS equipment is replaced. This includes probes,
cable extensions, BNC cables, or any instrumentation.
9.4 The system calibration shall be confirmed every four hour of operation.
9.5 If the system be out of calibration, the system shall be recalibrated.
9.6 The Recalibration of Instrument:
9.6.1 After every four (4) hour.
9.6.2 If once switch off the instrument re-calibrate it after switch on.
9.6.3 In case of changing the probe.
9.6.4 In case of adding any extra hardware or any software installation.
9.6.5 At any point of time when there is a doubt about functioning of the equipment.
9.6.6 If the calibration is disturbed all the tubes tested after the recorded correct calibration
shall be re-tested.

10 Data Acquisition:
10.1 Tube Identification shall be from Bottom half or Top half, Row No and Column No. Row
No’s are counted from the partition plate to outward and Column No’s are counted from
the partition to outward and Column are counted from left to right while facing the tube
sheet.
10.2 After the system is calibrated, the probe will be attached to probe pusher or manually
inserted into tube to be tested.
10.3 At the beginning of each data analysis and collection the following information shall be
recorded.

10.3.1 Name of client,

10.3.2 Plant /site
10.3.3 Heat exchanger and section identification.
10.3.4 Date of examination.
10.3.5 Test Frequency (s)

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10.3.6 Digital data recording type.

10.3.7 Calibration standard identification number.
10.3.8 Operator’s certification level.
10.3.9 Record all calibration setting for each piece of equipment.

10.4 Before the scan is made of each tube, the tube number shall be recorded in electronic
mean.
10.5 During the scan, the operator will monitor all the recording equipment as suggested by
the equipment manufacturers.

11 Data Interpretation:

11.1 Data interpretation will be made using information from initial calibration.
11.2 All tubes with defect signals which indicate defects 20% through wall or greater shall be
reported on the data sheets.

12 Data Evaluation:
12.1 All indication shall be evaluated and recoded in an analysis report. All wall loss indication
shall be classified as follows:

0% - 20% wall loss of nominal tube thickness

21% - 40% wall loss of nominal tube thickness
41% - 60% wall loss of nominal tube thickness
61% - 80% wall loss of nominal tube thickness
61% - 80% wall loss of nominal tube thickness
81% - 100% wall loss of nominal tube thickness

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 AXIS INSPECTION LTD. No. : AIC-IRIS-100

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SYSTEM (IRIS)

12.2 These evaluation categories should be used when no client specified acceptance criteria
are available
12.3 Defected classification shall be accomplished by using curved; Table or software derived
from the inspection frequencies and calibration standard. Where possible visual
conformation of defect must be done.
12.4 Results shall be recorded in report from and each result recorded shall be traceable to the
corresponding tube in the data storage file folder or batch.

13 Reporting:

13.1 Preliminary data shall be given on the job site and a final report shall proceed in dictating
all tubes tested and any final discontinuities. These defects will be defined according to
origin O. D or I. D
13.2 Permanent records will include (as applicable) digital data cartridge, or strip charts and
tabulated results. These records become the owner’s property.
13.3 Final report will include, but not be limited to, the following:

13.3.1 Tube material specification, diameter and wall thickness condition

13.3.2 Probe manufacturer, size and type
13.3.3 Manufacturer, model, serial number of equipment
13.3.4 scanning speed
13.3.5 Contract reference or P. O. number
13.3.6 Personnel operating equipment.
13.3.7 Personnel certifications records.
13.3.8 Instrument(s) used.
13.3.9 Equipment calibration record.
13.3.10Instrument setting (s)
13.3.11Interpretation results and interpreter’s name and level.
13.3.12Procedure number.
13.3.13Date of examination.

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SYSTEM (IRIS)

13.4 A written report shall be submitted within 21 days of completion of work which include an
interpretation of the above tabulated results as to type of defects whether O. D. or I. D.
axial location along tube length, and tube position within the bundle.

Attachment # 1

Data Acquisition of Calibration Tube

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