JRL QAP INS NDT 0001 Eddy Current Examination Procedure

JRL-QAP-INS-NDT-0001- EDDY CURRENT EXAMINATION

JIMCOL RESOURCES LIMITED

Eddy Current Examination Procedure

ISO 9001:2008

OPERTIONS MANAGEMENT SYSTEM MANUAL

PROCEDURES

JRL-QAP-INS-NDT-0001 EDDY CURRENT EXAMINATION

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Rev 0 Revision Date: 01/11/2014


Document Approval

The following signatures are required prior to issue of this document.

Role Name Signature Date

Author Festus Osigheghe 01/11/2014

Reviewer

Gilbert Jeremiah

01/11/2014

Document Owner Josiah Agwere

01/11/2014

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Procedure Usage

Procedure Revision

This Nondestructive Examination Procedure is a controlled document. Suggestions for revision are to be submitted in writing to JIMCOL RESOURCES LIMITED. Attention Mr. Josiah Agwere,

[email protected], Km 3, Olu Obasanjo Drive, Eliozu, Port Harcourt, and Rivers State, Nigeria.

Procedure Storage

To ensure you have the most recent version of this procedure, contact JIMCOL RESOURCESLIMITED at +234 (0) 805 636 0145. This document is not to be issued in electronic form.

Availability

This procedure is available upon request to clients and jurisdictions for review. Formal requests are to be in writing.

This document is intended for the sole use/purpose of JIMCOL RESOURCES. Propriety

information is contained within and is to be considered confidential. Release of this

document does not constitute written permission or consent to copy (in any format) for

distribute.

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Table of Contents

1.0 Purpose............................................................................................. 5

2.0 Scope............................................................................................... 5

3.0 References......................................................................................... 5

4.0 Qualification of Personnel..................................................................... 5

5.0 Equipments……………………………….……………………………………………………………………… 5

5.1 Eddy current instrument……………….………………………………………………………………… 5

5.2 Probes………………………………………………..…………………………………………………………… 6

5.3 Calibration block……………………………………..……………………………………………………… 6

6.0 Calibration......................................................................................... 6

7.0 Sensitivity…………………………................................................................... 6

8.0 Alarm gate……………………………………………………………….……………………………………… 6

9.0 Surface condition................................................................................ 7

10.0 Material Check……………....................................................................... 7

10.1 Equipment Required………………………...................................................... 7

10.2 Connections…………. ........................................................................... 8

10.3 Initial Setting…………………………………………………………………………………………………… 8

10.4 Material check procedure………………………………………………………………………………. 8

11.0 Coating thickness assessment……………………………………………… ……………………. 9

12.0 Weld Inspection………………………………………………………………………… …………………. 10

12.0 Weld Inspection……………………………………………………………………………………………… 10

12.1 Equipment required……………………………………………………………………………………….. 10

12.2 Connections…………………………………………………………………………………………..……….. 10

12.3 Initial setting…………………………………………………………………………………………………… 10

12.4 Calibration procedure…………………………………………………………………………….……….. 10

12.5 Scanning procedure……………………………………………………………………………………….. 11

13.0 Reporting…………………………………………………………………………………………………………. 12

FIG-01 Scanning pattern of heat affected zone……………………………………………… 13

FIG-02 Optimum angle for varying surface conditions…………………………… ……. 14

FIG-03 Transverse/Longitudinal scanning………………………………………………,……… 15

FIG-04 Scanning of stiffener………………………………………………………………….………. 16

FIG-05 Scanning of rat hole………………………………………………………………….………… 17

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1. PURPOSE

This procedure describes how JIMCOL RESOURCES Group technicians perform eddy

current inspections.

2. SCOPE

The techniques specified are related to applications where flaws break the surface of

materials that can be interrogated by eddy currents.

3. REFERENCES

ASME Boiler and Pressure Vessel Code, Section V Nondestructive Examination (2002 Edition) i. Article 1, General Requirements ii. Article 8, Eddy Current Examination iii. Article 26, Eddy Current Standards.

4. PERSONNEL

All personnel qualifications shall meet the minimum requirements stated by the client,

and shall demonstrate their competence in any given technique, if required. If no specific

qualifications are required, personnel considered appropriately qualified by the

Department Manager are used.

Level I personnel shall be supervised by Level 2 personnel. The equipment will be both

amplitude and phase sensitive.

5. EQUIPMENT

The probes used shall be pencil probe types and will be held normal to the surface of the

test piece.

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5.1 Eddy Current Instrument

NORTEC 500 Portable Eddy Current Instrument or other applicable

instrument. The equipment shall have a current, valid calibration certificate

issued by the manufacturers and/or their official agent(s). This calibration

process shall be carried out on an annual basis as a minimum.

5.2 Probes

Weld Inspection

NORTEC 500 probe type WLD-8-55/7L or other applicable probe shall be used.

5.3

Surface Coating Assessment

These probes shall be capable of providing a lift-off signal for the sample at a

frequency of 10 kHz which enables a full screen deflection for 0-2mm coating

thickness to be obtained.

NORTECH 500 probe type NEC-2236/7L shall be used.

5.4 Calibration Block

A standard test block shall be of representative material, and have spark eroded

slots of 0.5, 1.0 and 2.0mm depth, together with simulated surface coatings of

0.5, 1.0 and 1.5mm thickness.

6. CALIBRATION

Calibration shall be carried out immediately prior to and after the inspection, after change of

any equipment, and on observation of a suspected crack indication.

7. SENSITIVITY

As per specification. In the absence of a written specification from the client, sensitivity will

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be such that a reference defect 1mm in depth will produce a vertical defect signal to full

screen height after allowance has been made for surface coating thickness and

composition. The frequency shall be set at 10 kHz or 100 kHz for the coating thickness or

weld inspection respectively. The sensitivity level shall be set to 20dB.

8. ALARM GATE

As per specification. In the absence of a written specification from the client, the alarm will

be switched off, and potential defect signals assessed by the operator as they are

observed.

9. SURFACE CONDITION

Before inspection, the operator will find out the following, where possible:

a. Material specification

b. Weld specification

c. Post weld heat treatment

d. Details of any repairs

e. Coating specification

f. Details of any previous MPI inspection

g. Access and work environment.

9. MATERIAL CHECK

9.1 Equipment Required

NORTECH 500 Portable Eddy Current Unit or other applicable instrument

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Probe type : WLD-8-55/7L or other applicable probe.

Load type : 5A003

Probe Lead : CL/SC/6 or other applicable lead.

Calibration block : NORTECH 500 SRSM61020S/WLD (steel)

with 3 off 0.5mm non-conductive material samples

9.2 Connect splitter lead, load, probe and probe lead. Make sure the batteries in the instrument are charged or that the instrument is connected via a charger to a power supply. Switch on and wait a few minutes for the equipment to warm up.

9.3 Initial Settings Frequency selection control : 10 kHz

Alarm control : OFF

Sensitivity level : 20 dB

Horizontal : 0

Vertical : 0

A.C. coupling : OFF

D.C. coupling : ON

9.4 Material Check Procedure

Hold the probe away from the calibration block or any other or any other ferrous material, and push the balance control. The equipment is electronical1y balanced for air and a cross is displayed on the C.R.T.

Clear the screens by pushing the erase control. A spot should appear on the screen. If the spot does not appear, re-balance and press the erase control again.

Position the spot in the centre of the screen using the horizontal and vertical controls. Lift the probe on and off the (bare) calibration block, and adjust the phase angle control until the movement of the spot is vertical.

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Clear the screen by pushing the erase control. Place the probe on the calibration block in order to obtain a reference signal, and then place it on the material to be inspected. The angle between the signals displayed on the screen for the calibration block and the test material must not exceed 10° for subsequent weld or material inspection to be considered valid.

A calibration block which more closely matches the material or metallurgical condition of the component to be tested is required if the angle between the displayed signals exceeds 10°.

10. COATING THICKNESS ASSESSMENT


NORTECH 500 Portable Eddy Current Unit

10.2 Connect lead, load, probe and probe lead. Make sure that the batteries in the instrument are charged or that the Instrument is connected via a charger to a power supply. Switch on and wait a few minutes for the equipment to warm up.

10.3 Initial Settings

Frequency selection control : 10 kHz Alarm control : OFF Sensitivity level : +20 dB Horizontal : -40 Vertical : -32 A.C. coupling : OFF D.C. coupling : ON

10.4 Calibration Procedure

Place the probe on the calibration block and push the balance control. The equipment is electronically balanced for the steel specimen and a spot displayed on the C.R.T.

Clear the screen by pushing the erase control. A spot should re-appear on the screen. If the spot does not appear, re-balance and press the erase control again.

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Using the horizontal and vertical controls adjust the position of the spot until it is on the left hand side of the screen. Lift the probe on and off the calibration block, and adjust the phase angle control until the movement of the spot is vertical.

The screen is cleared by pushing the erase control. The probe is then placed on the 0.5mm, 1.0mm and 1.5mm thick non-conductive layers positioned over the block in turn. The spot should be moved horizontally between changes in layer thickness.

10.5 The thickness of the coating on the area to be examined can be estimated by interpolation between the signal amplitudes for the known thicknesses. The average and maximum coating thickness will be noted.

10.6 The maximum coating thickness through which inspection will be carried out is 2.5mm.

10.7 System gain will be increased by 6dB for each millimeter of paint coating.

11. WELD INSPECTION (if applicable)


NORTECH 500 Portable Eddy Current Unit

Probe type : WLD-8-55/7L Calibration block : NORTECH 500 SRSM61020S/WLD (steel) with 3 off 0.5mm thick non-conductive material samples

11.2 Connect probe and probe lead. Make sure that the batteries in the instrument are charged or tat the instrument is connected via a charger to a power supply. Switch on and wait a few minutes for the equipment to warm up.

11.3 Initial Settings

Frequency selection control : 100 KHz Alarm Control : OFF Horizontal : 0 Vertical : -21 A.C. coupling : ON

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11.4 Calibration Procedure With the settings detailed in 11.2, place the probe on the calibration block ensuring that it is some distance from any of the slots, and push the balance control. The equipment is electronically balanced for the steel specimen, and a cross is displayed on the screen. Clear the screen by pushing the erase control. A spot should appear on the screen. If the spot does not appear, re-balance and press the erase control again.

Run the probe over the 2mm deep slot. Care should be taken to ensure that the longitudinal axis of the probe is kept parallel to the slot and that the scanning direction is at right angles to the slot. The phase angle control is adjusted until the indication from the slot is in the upward vertical direction. The sensitivity level is adjusted to meet the client’s specification or, in the absence of a client specification, in accordance with paragraph 5 above, i.e. 1mm defect signal to full screen height after allowance has been made for surface coating thickness.

11.5 Scanning Procedure - the inspection consists of the following stages which will be carried out in the given order for full coverage of the weld and adjacent material.

11.5.1 Parent Material - the probe is placed on the component surface in an area 3 times the material thickness from the weld, and the equipment is balanced by pushing the balance control. The material is then scanned using a zig-zag pattern which must touch the weld toe (see Figure 1). This scan is performed on both sides of the weld. Note: The probe has directional sensitivity, and its long edge must be kept parallel to the line of the weld.

11.5.2 Heat Affected Zone - the equipment is balanced with the probe on an area free of defects in the HAZ to establish the normal condition. As a preliminary examination, the weld toe is investigated by a longitudinal scan (see Figure 2a). The area should be re-examined using a zig-zag scan (see Figure 2b). This scan is performed on both sides of the weld.

11.5.3 Weld Metal - the equipment is balanced with the probe on an area free of defects on the weld metal to establish the normal condition. The weld is the scanned using a zig-zag pattern (see figure 3a). Pronounced weld runs may produce an unacceptable noise level if scanned traversely. In this case, each weld must be scanned individually (see Figure 3b). Inter-

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run boundaries are inspected by longitudinal movement of the probe. (See figure 3c).

11.5.4 Rat Holes/Stiffener Tip – Inspection of the weld is as detailed in steps 1 to 3. A second scan is carried out on the rat hole/stiffener tip as shown in figures 4 and 5.

11.5.5 Scanning for Transverse Defects – as with the parent plate scan, the equipment is balanced on an area free from defects on the parent plate. After the initial scans, the weld is then scanned with the weld probe turned 90o to detect transverse defects along the HAZ and weld cap.

11.5.6 Any areas giving defect indications should be cleaned to a suitable surface finish and re-examined using an appropriate MPI method for confirmation of a defect prior to reporting, unless otherwise specified by Freidi Goldman.

12. REPORTING The operator will record at least the following information in addition to that required by paragraph 8 of this procedure using the current revision of controlled form SG-nnn:

a. Customer

b. Contract

c. Order Number

d. Date

e. Job Description

f. Drawing and Line Numbers (if applicable)

g. Weld and Welders Numbers (if applicable)

h. Location, orientation and length of all defects detected

i. Measured average and maximum coating thickness

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Figure 1: Scanning pattern of Heat Affected Zone

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Figure 2: Optimum Angle for Varying Surface Conditions

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Figure 3: Transverse/Longitudinal Scanning

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Figure 5: Scanning of Rat Hole

Figure 4: Scanning of Stiffner

Tip

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Revision History

The following is the latest revision record for this document.

Revision Date Description of changes Requested By

00 08/09/2008 Initial issue Management

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JRL-QAP-INS-NDT-0001

JOB STEPS

HAZARD INITIAL RISK CONTROLS RESIDUAL RISK

Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk

Rating List All Controls Required

Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Task

Preparation Injury or damage due to lack of control

Workforce and site

personnel Major

Possible Medium

Become familiar with company procedures for Rope

Access operations

Review generic risk assessment

Pre-job site survey where appropriate

Project specific risk assessment

Adequate assessment of tasks

Consideration of work methods and equipment and

safer/more appropriate alternatives

Consideration of contractual relationships and

interfaces between organizations involved.

Major Unlikely Medium

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Arrival on

Site Unfamiliar surroundings

Workforce Major Possible

Medium

Client PTW Training

Site Induction

Walk the line – identify response locations; eye wash

station, first aid, GPA etc

Major Remote Low

Task

Preparation Excessive wear Equipment Major

Possible Medium

All equipment to be inspected prior to use.

Equipment to conform to equipment inspection and

maintenance procedure

Major Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Operating

Wind/weather

affecting operations

Operator and site

personnel/pre-rigged

equipment

Major Possible High

Observe weather forecast and do not start unless

conditions are acceptable in line with company and

client guidelines.

Secure equipment and materials to reduce effect of

wind.

Safety watch to monitor weather conditions.

Major Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Operating Falling from worksite

Operator and site

personnel Serious Possible High

Observe company rope access procedures

Use suitable trained in date personnel

For newly qualified technicians: gradually introduce

work, work under direct control of supervisor and once

satisfied capable, work under close supervision of

experienced worker. Check all items of suspension

equipment is secured prior to starting work.

If lead /belay climbing is utilized. Please refer to

company procedures.

Serious Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Operating

Dropped Objects by

technicians

Site Personnel/plant

& equipment Serious Possible High

Barrier areas off below worksite and at maximum

deflected landing radius.

All tools below 8kg to be secured by lanyard

attachment to harness or utility bag.

All items above 8kg to be separate work line attached.

All pockets to be empty, all utility bags to be securely

shut.

Use of man aloft inventory where appropriate

Serious Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Operating Failure of anchor system

Operator and site

personnel Serious Unlikely Medium

An independent anchor system for each rope

deployed is to be installed Serious Remote Low

Operating Abseiling off end of rope

Operator Serious Possible High Knots are to be tied above end of rope to prevent

accelerated descent onto deck level or off end of rope. Serious Remote

Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Operating Reduced visibility

Operator and site

personnel Major Possible High

Appropriate positioning of personnel monitoring

operator.

Adequate lighting.

Primary and agreed secondary means of

communication

Major Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Operating

over water Falling into water

Operator and site

personnel Serious Possible High

Minimum 3 man rope access team.

Buoyancy aids to be worn.

Recovery vessel on station.

Safety watch posted.

Good communication between all parties.

Life belt at hand.

Serious Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Work

positioning

Injury caused by operator unstable work position

Operator and site

personnel Fatal Possible High

Secure position prior to commencing work.

Consider use of access platform aids i.e. seats, MAP.

Major Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Work

positioning

using Rope

Access

Techniques

Rope cut/abrasion Work party Fatal Possible High

Observe specified job procedures and specific risk

assessments.

Deviate ropes away from hot surfaces, open edges,

rough surfaces.

Use of edge rollers.

Use of rope protectors as last option.

Serious Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

General

Worksite

Control

Personal Injury

Workforce and site

personnel Fatal Possible High

Use work area barriers and signs.

No personnel allowed within specified area.

Keep worksite tidy. Good housekeeping.

Use of sufficient personnel to adequately monitor

worksite.

Provision of first aid cover/facilities.

Use of minimum PPE requirements.

Major Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

General

Worksite

Control

Dropped objects from worksites aloft

Workforce and site

personnel Major Possible Medium

Ensure all deck personnel are aware of under deck

operations (Tannoys and barriers).

Barrier off area above worksite if required.

Work permit system in place to ensure no conflicting

operations where required.

All tools, utility bags and materials required at worksite

are secured to prevent dropped object and trip risk.

(look at securing at waist height).

All tools and materials secured within utility bags.

All utility bags to be kept shut.

Consider use of dropped object netting or matting.

Major Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

Maintenance Excessive Wear

Operator and site

personnel Major Possible Medium

A daily user check of all equipment to be conducted

by operators prior to use.

Failed items to be quarantined and returned to base

operations.

Major Remote Low

Ultrasonic

inspection Personal injury Operator Major Possible Medium

Full PPE to be worn and MSDS of all substances

must be in place with permit to work

Continous gas monitoring while inspection is ongoing

Minor Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

MPI

inspection Personal injury Operator Minor Probable Medium

Complete PPE to be worn and MSDS of all

substances must be in place and understood by

operator

Minor Remote Low

Eddy current

inspection Personal injury Operator and site Major Possible Medium

Wearing of appropriate PPE,

Prior and ongoing gas monitoring while inspection is

ongoing

Minor Remote Low

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JOB STEPS


Hazard Description

and Effect

People, Property or

Environment at Risk

Hazard

Consequence

Chance of

Occurrence

Risk


Controlled

Hazard

Consequence

Controlled

Chance of

Occurrence

Residual

Risk

Rating

House

keeping Personal injury

Operator and site

personnel Major Probable Medium

Wearing of appropriate PPE,

Always call for help when there is a need to carry

excessive load or use mechanical means

Cables to be arranged of the floor so no trip hazard

caused all couplants to be cleaned up after use

Major Remote Low

JRL QAP INS NDT 0001 Eddy Current Examination Procedure

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