Standard Operating Procedure IRIS Inspection

Transcription

1 Document Review Record Rev Date Reviewed By Amendment Details SL Initial Issue 1

2 CONTENTS Section Description Page review Record 1 Table of Contents Introduction Scope Preparation 3 & Personnel Site Establishment General Survey Equipment Set Up Data Acquisition 5 & Data Analysis Reporting References 7 2

3 1.0 Introduction 2.0 Scope This document describes the equipment and methods to be utilized by TesTex Inc personnel in conducting an inspection on tubular products, using the Testex Inc developed Helix-XT system. This document is intended to be a generic procedure. The specific equipment calibrations and system setups will be detailed in the job work instructions for the specific tube type. This document details the procedures to be followed during the inspection of ferrous and non-ferrous tubing used in condensers, heat exchangers and similar equipment using an inspection. 3.0 Preparation 3.1 The selection of a turbine, transducer and centering device will be determined from the tube specifications received from the customer. Once the appropriate equipment is selected, it is essential to check the equipment out on a calibration standard of the same spec. as the tubes to be inspected. This will allow you to make sure all equipment is in working order For picking a turbine for an inspection you want to select the largest, but most practical turbine that will fit the ID of the tube that is to be inspected Selecting the transducer for the inspection will be based on the turbine selected and the wall thickness of the tube The centering devices part number correlates to the range of the leg expansion. Select the centering device that best fits the ID of the tube and allows for optimal centering of the turbine Flooding equipment (Flood Gun / Plugs). The appropriate size plugs will be procured once the tube specifications have been reviewed. An adequate flooding mechanism will be selected to insure proper flooding of tube for inspection. 3.2 A full system check will be conducted on all systems to be used on the inspection. If available use a calibration the same or similar to conduct this system check of the equipment. 3.3 All equipment will be packed securely and safely for transportation to site. 3

4 4.0 Personnel Personnel interpreting data collected shall be qualified to UT Level II or higher. Prior to receiving certification, all personnel shall have completed the training program and taken the TesTex written practice. 5.0 Site Establishment 5.1 Contact the client representative. 5.2 Ensure all permits are in order and the condenser or heat exchanger has been checked for entry. (If entry is required) 5.3 Check that suitable power supply, lighting and continuous water source have been provided. 5.4 In the case of power plant condensers, forced air ventilation will be provided. 5.5 Entry to the vessel will be in accordance with the Testex Inc. Confined Space Entry Policy (Section 3 of TesTex, Inc Safety Program). 5.6 Check cleanliness of tubes. 6.0 General Survey 6.1 Note the direction of the tube sheet. Reference this to a geographical compass direction or some permanent landmark. 6.2 Prior to numbering the tubesheet, check with the client representative to determine if there is a preferred numbering scheme. If the client has no preference, analyze the tube sheet configuration and find the most logical way to begin numbering. Plan the numbering scheme that will be the most productive. Then draw tube sheet map of unit. Mark every fifth row of tubes with paint (if permission to do so has been given), if the use of paint is not permitted, use chalk or some other acceptable means. 4

5 7.0 Equipment Set Up 7.1 Unpack and setup the equipment. 7.2 Connect Helix-XT electronics to computer. Turn on Helix, wait for it to boot up. 7.3 Local Area Connection will say connected. If not repair the connection. Open up Helix-XT acquisition software. 7.4 Enter in tube specifications in the Setup window. Speed of sound the material will be needed if not already listed. 7.5 Turn on pump and verify that the turbine is spinning. 7.6 Insert turbine into calibration standard or unit, if calibration standard not available. 7.7 Adjust your settings to see the target pin echo, front wall echo and back wall echo in the A-Scan screen. 7.8 Adjust the actual RPM to the selected RPM in the Setup window. 7.9 Adjust gates to the appropriate settings to insure proper thickness readings Set up folders and files names for inspection 8.0 Data Acquisition 8.1 The data from all tubes tested will be saved to hard drive under appropriate files and directories. 8.2 Plugged tubes, Blocked tubes (Tubes with internal restrictions that do not allow a probe to pass through), Inaccessible tubes (Tubes with restricted access to tube and/or tube sheet, will be logged as such in the data logger feature of the software. 8.3 Pull speed will be at approximately 8ft./minute. Collection can be perform by pulling or pushing the probe through the tube.. 5

6 8.4 Plant and information will be acquired and entered into the Acquisition software. (a) Owner (b) Plant site and unit (c) Heat exchanger identification (d) Data storage unit number (e) Date of examination (f) Serial number of the calibration standard (g) Operator s identification and certification level (h) Mode of operation including instrument sample rate and gain settings (i) Tube specifications (j) Transducer serial number a. Frequency b. Focal Length (k) Turbine type (l) Helix electronics serial number (m) Probe Lead serial number (n) Pump serial number (o) Probe scan direction during data acquisition (p) Application side inlet or outlet, top or bottom, east or west, etc (q) identification and revision 9.0 Data Analysis In addition, all Electronics, Turbines, Transducers, and Calibration Standards shall be TesTex issued equipment with serial numbers and current calibration when applicable. Non-TesTex calibration standards may be used as long as they meet ASME standards and have supporting documentation from the manufacturer. 9.1 Nominal wall will be recorded for each tube. 9.2 Each tube will be analyzed for indications in the tube. All tube data will be saved via the software s data logger function. All indications found in each tube will be entered. 9.3 Data analysis will be performed during acquisition. Any indication will be recorded three (3) times in the same file and the results entered into the dialog box. 9.4 Data from a selection of tubes will be sent back to headquarters for review by the Quality Assurance Manager. 6

7 10.0 Reporting 10.1 A preliminary report will be submitted to the client before departure from the site. The preliminary report will contain the most important information for any remedial work that may be necessary. In most cases, the preliminary report given will be electronic, using the latest version of TesTex, Inc. Tube Sheet Mapping and Automated Reporting Software The final report will be created using the latest version of TesTex, Inc. Tube Sheet Mapping and Automated Reporting Software. The final report will be reviewed and will be forwarded to the client within an agreed time period. The final report will include as a minimum a colored drawing of the tube sheet with flaws clearly marked, an evaluation of the severity shown in color for ease of interpretation, a tabulated report sheet detailing all flaws by tube number and location and at least one printout of typical flaws detected In heat exchangers where no flaws are found, data from a good tube will be included in the report A copy of the final report and working copies will be maintained on file at the TesTex, Inc. offices for a period of not less than five years form the date of completion. In addition an electronic copy of the report will be stored References TesTex Inc.: Helix-XT Manual 7