Flange Inspection Procedure

Scope

This document covers the use of Phased array to inspect Flanges for areas of corrosion.
Flange inspection is an increasingly growing concern for inspection companies and asset
owners. The integrity of these flanges is crucial particularly on high pressure pipe were
failure can be catastrophic. The procedure is based around raised face flanges.

Personnel
Individual requires experience of flange inspection both on artificial and in-service flanges.
This experience enables them to get use to the geometric reflectors and they are then able to
isolate defects.

Training
Training is key as the technique is based around pattern recognition comparing good
samples verses bad samples. Experience is key to know how the scan on the screen relates
to the flange itself and also how considerations such as lack of couplant and surface finish
can affect scan.

Equipment
Omniscan 16:128 was used for inspection with 4L16DGS probe and 5L16-A00 probe. Both
of these probes are sufficient to produce a Sectorial swear wave from 30-75 degrees.

Inspection Method
Historically there are 3 types of scans that can be performed depending on area requiring
coverage and obstacles preventing scanning. Figure 1 shows the 3 scans

The Blue Sectorial scan (40-75 degree inspection) represents a scan from the tampered are
which due to its orientation is covering the corner reflector and gasket surface. Limitation
may require contoured wedges.
The Red sectorial scan (35-75 degree inspection) is scanning in between the bolt heads
focused on the corner reflector and gasket surface. The limitation of this scan is that 100%
coverage is not obtained due to large bolt heads

The Green sectorial scan (-20-30) is a zero degree inspection of the inner bore surface and
is performed with either a contact probe or an N60L wedge to avoid internal reflections from
the wedge.
Each scan has its own advantages and disadvantage, but the standard infield tends to be the
scan working on the Bolt head surface (red scan).

Calibration
Standard Flanges are used which are clean flanges with notches matched in. Initially this
flanges are used to set up the producer were notches are placed in all faces (bore and
gasket face) to verify that the scan is able to pick up these defect. In the inspection these
are used to set up the unit for inspection. Inspectors are able to ensure that know target
reflectors are present on the screen. Cursors can then be set up for each different type of
scan to ensure correct coverage.

Bolt Face inspection

Find attached below screen shots of image from Omniscan used for inspection of Bolt face
the areas of interest have been highlighted.

Area highlighted shows the corner reflector from the gasket to bore face. On the clean
gasket this is a strong reflector that is set to 80% screen height (+6dB for scanning gain).
The line depicts the bore surface any signals which are picked up on this face would relate to
defects in this area.
Area highlighted demonstrates the requirement to raster the probe back and forth to ensure
complete coverage of gasket face. The 2 geometric defects are from the corner and the
raised face reflector any signal that comes between these indications would be a defect of
this face

Tapered Face Inspection

As stated previously the tapered inspection allows complete coverage of the part under test
with no limitations due to the bolts
Area highlighted has 2 strong reflectors on the clean flange. Any defects are related to loss
of these signals or movement of these signals

Outer Rim Inspection

This is more or less viewed as a zero degree inspection and so you are looking for changes
in the thickness of the material any changes will give an indication of material loss in the
bore.

Procedure
*Use an Omniscan MX16:128 (or Manual 16:64), with a 4L16-DGS probe (Tapered and Bolt
face inspection) or 5L16-A10 (For Outer rim inspection).
*Set up unit for inspection
Find below details for Wizard setup
*Using the Wizard software in the Omniscan set up the correct scan
-Group Wizard NEXT
-Operation MODIFY
-Material PLATE (thickness of flange this will enable cursors to show corner reflector clear)
MATERIAL STEEL
-Group PA
-Connection 1
-Probe AUTODETECTION ON
-4L16-DGS
-Position NEXT
-Law Wizard
-Law SECTORIAL
-Wave SW
-Probe type ELEMENT QUANTY 16, FIRST ELEMENT 1
-Set Angle MIN ANGLE 35, MAX ANGLE 60
-Generate Law DONE

Place probe on Flange at know good position (Alternative can use a Cal block with same
thickness and geometry for the corner reflector).
Ensure offset is correct
Adjust UT settings for best signal (FILTER and VIDEO FILTER)
Ensure picking up corner/know reference reflectors
Adjust Range to view corner reflector
Adjust gain to take corner reflector to 100% Screen height (May have to add additional dB for
corroded areas).
Use Turn on cursors DISPLAY OVERLAY CURSOR (ON) OVERLAY (ON)
Overlay should appear along corner reflector and can use cursors to indicate cross point.
When moving probe around flange face corrosion will appear as loss of corner reflector and
additional signals coming before corner signal.
Measurement cursor can then be used for rough sizing of material loss.
A Defect table can be added by selecting MEASUREMENT TABLE DISPLAY TABLE
ADD ENTRY
This will build up a report that can be handed to the customer.

To Note
Scan is not encoded so length of defect is related to speed in which the individual is
scanning, although visualisation of defects tends to be limited to S scan display
Min and Max angle can be adjusted to only view the corner reflector or expanded to enable
viewing of gasket surface.
Both the change in position of reflectors and the geometry (rough, smooth, multi faceted) of
the defect are used to analysis a defect
The use of setting up an overlay in the unit can make the inspection easier

Reporting
Flanges are inspected using inspection sheets (see below), these enable a record to be kept
of area inspected in relation to a know datum. Also defects can be plotted and stored.
Defects are also recorded on the Omniscan which will be used as evidence to extent of
corrosion.

Sizing is performed via cursors on the screen. To date there is accept or reject standard.
Previous Inspection data

Figure below demonstrations the difference between a good and bad reflection in a Raised
face Flange (blue overlay has been added to show geometry of Flange). The left image
shows a clear indication from the corner and also shadows from the inside bore surface. As
opposed to the image on the right were the corner reflector has been lost replaced by a
rough reflection before the corner.

Screwing of the probe and rastering will be required to verify defects

The use of standard flanges can be key as they allow the inspector to become comfortable
with geometric signals that he would expect from a standard. Also artificial defects can be
added to allow the operator to view reflectors in different areas of the flange. The corner
reflector from these standard flange can be used to set for sensitivity taking into account
scanning/ surface condition gain.