Selection of Techniques and Establishment of Acceptance Criteria
What you must know
Selection is a reasoned match between the expected discontinuity (type, orientation, location, size), the geometry and material, and the capability of the method: probability of detection, sizing accuracy, coverage, speed, access and cost.
Selection drivers:
- Orientation - maximum response when the beam or flux is perpendicular to the flaw plane.
- Location - surface vs subsurface, near-surface dead zones, one-sided access.
- Material - conductivity, permeability, grain structure and attenuation.
- Geometry - thickness, curvature, nozzle and weld configuration, cladding.
- Documented requirement - the code, contract or specification may mandate the method.
Acceptance criteria come in two families:
- Workmanship criteria - fixed limits on indication length, amplitude or density, reflecting good practice rather than a calculated margin.
- Fitness-for-service / engineering critical assessment - allowable flaw size derived from fracture mechanics, applied stress and material toughness (as in API 579 or BS 7910).
Traps
- Assuming a code acceptance limit guarantees fitness for purpose - it does not, and vice versa.
- Comparing indications obtained by different techniques, frequencies or reference reflectors as if equivalent.
- Believing a tighter criterion is always better; it can produce excessive repair and rejection without any integrity benefit.
- Forgetting that a criterion is meaningless unless the technique, reference reflector and sizing method are stated with it.
- Ignoring sampling risk when 100 per cent coverage is not achieved.
Worked example
A thick-section nozzle-to-shell weld: through-thickness stress and inclusion stringers suggest planar, plate-parallel flaws, which are badly oriented for angle beams. Select straight-beam scanning plus a complementary surface method, and state acceptance against the contract criterion using the specified reference reflector.
Rule of thumb: if the flaw orientation is unknown, inspect from two directions roughly 90 degrees apart, and never set a criterion without naming the technique and sizing method.