Ansaldo NDT Specifications 22GRKW v1 0

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TABLE OF CONTENT
1. OBJECT
2. FOREWORD
3. NDE SPECIFICATION
- ANNEX A Ultrasonic Examination of Materials
- ANNEX B Ultrasonic Examination of Weldments
- ANNEX C Radiographic Examination
- ANNEX D Liquid Penetrant Examination
- ANNEX E Eddy Current Examination of non-Ferromgnetic Materials
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1. OBJECT
This set of specifications cover the general requirements for the Non-destructive
Examinations (NDE) to be carried out during fabrication of Toroidal Field Case.
The present document contains the NDE methodologies applicable to the
subject component taking into account the geometry, the material, the thickness
range of the raw material and the welded joints.
Therefore, the document gives the rules of the following NDE methodologies.
- Ultrasonic Examination of materials
- Ultrasonic Examination of weld
- Radiographic Examination
- Liquid Penetrant Examination
- Eddy Current Examination of non ferromagnetic materials
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2. FOREWORD
Following requirements are mandatory.
Any deviations to this specification, necessitated by special circumstances, shall
be submitted in writing to ITER (also called the Purchaser in the following
paragraphs) for written disposition.
This document applies only to the fabrication of Toroidal Field Cases
Components.
This document does not apply to maintenance, In-service Inspection, or other
operation not strictly related to fabrication.
Acceptance criteria stated in this document shall be applied only if required by
Component Technical Specification document.
General requirement of this specification may be implemented or superseded
by the requirements of Component Technical Specification document.
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3. NDE SPECIFICATIONS
The Annexes A, B, C, D, and E contain the following Specifications:
- Ultrasonic Examination of materials
- Ultrasonic Examination of weld
- Radiographic Examination
- Liquid Penetrant Examination
- Eddy Current Examination of non ferromagnetic materials
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ANNEX A
ULTRASONIC EXAMINATION OF MATERIALS
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TABLE OF CONTENTS
1.0 SCOPE
2.0 REFERENCE DOCUMENTS
3.0 GENERAL
4.0 EQUIPMENT
5.0 CALIBRATION BLOCKS
6.0 SURFACE PREPARATION
7.0 PERSONNEL QUALIFICATION
8.0 CALIBRATION METHODS
9.0 CALIBRATION AND RECALIBRATION REQUIREMENTS
10.0 SCANNING REQUIREMENTS
11.0 QUALITY LEVEL
12.0 ACCEPTANCE CRITERIA
13.0 REPORTING CRITERIA
14.0 REPAIR AND RETEST
15.0 REPORT
TABLES
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1.0 SCOPE
This specification covers general requirements for the straight and angle beam
ultrasonic examination of plates, bars, forgings, and tubing in austenitic
stainless steel. The requirements herein are intended to supplement those
specified in the ASME Boiler and Pressure Vessel Code.
The applicable Code issue and other requirements will be specified in the
equipment specification or procurement document.
This process specification is intended as a guide to the Supplier to prepare the
NDE procedure specifications. The Supplier specifications shall be approved by
the Purchaser prior any NDE being performed.
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2.1 ASME Boiler and Pressure Vessel Code Section V Non-destructive
Examination.
2.2 EN 473 Qualification and certification of NDT personnel General principles.
July 1993.
2.3 Additional documents that may be referred in design specification, drawings
and/or procurement documents.
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3.0 GENERAL
3.1 ULTRASONIC EXAMINATION PROCEDURE
Before testing begins, the Supplier shall prepare ultrasonic examination
procedures and drawings or sketches detailing the essential variables of the
examination, including equipment calibration and acceptance standards. As a
minimum, the following parameters and requirements shall be detailed in the
procedure.
a. The scope of the examination describing in detail the material to be
inspected, e.g. sizes, geometry, quality level, etc., and the stage or stages
of manufacture at which the examination will be conducted.
b. The degree of surface preparation and description of the finish of the
surfaces to be examined.
c. The mode(s) of sound propagation and test angle(s) to be used.
d. The ultrasonic test System including instrument, transducer types,
materials, and sizes. Beam angle in the material as measured on an IIW
(International Institute of Welding) or equivalent reference block shall be
noted for contact testing methods. For immersion testing methods, the
angle of incidence and the water path distance shall be noted. The angle of
incidence is that included angle between the direction of the transmitted
wave and the normal to the interface at the point of incidence. The water
path distance is that distance travelled by the transmitted wave in water.
e. A detailed description of calibration blocks including types, location, sizes,
and depths of reference reflectors placed in each block. This description
shall be supplemented by a detailed sketch of the calibration block(s).
f. A detailed description of the instrument calibration procedure for each scan
and/or type of test including a sample copy of the calibration data sheet.
g. Type of couplant used and cleaning procedure employed.
h. The direction(s) and extent of scanning. The speed of transducer
movement, the amount of overlap between scans, and the test system
sensibility during scanning shall also be noted.
j. Test frequencies.
k. Qualification and certification of the personnel performing the test.
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i. Specific criteria for acceptance and/or reporting results. A sample copy of
the recording sheet shall also be provided.
l. Automatic alarm, recording equipment, or both, if used.
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4.0 EQUIPMENT
4.1 ULTRASONIC INSTRUMENT
A pulse-echo ultrasonic instrument shall be used for tests covered by this
Specification. The system shall have as a minimum, the capability for examining
at frequencies from 0,5 to 5.0 MHz.
The ultrasonic instrument shall provide a linear vertical presentation (within 5
percent of full screen height) for at least 80 percent of the screen height (sweep
line of screen).
Instrument linearity shall be verified in accordance with ASTM E-317 or an
equivalent. Any set of standard calibration blocks processed in accordance with
the applicable section of ASTM E-317 may be used to establish the above
specified instrument linearity.
The instrument shall contain an attenuator (accurate over its useful range to
10 percent ( 1 dB) of the amplitude ratio) which will allow measurement of
indications beyond the linear range of the instrument,
4.2 SEARCH UNITS
Straight beam search units for contact testing methods shall have a nominal
frequency from 1.0 to 5.0 MHz and an active transducer diameter between 10
mm and 30 mm. Other search unit sizes and/or frequencies are permissible with
prior approval if required for better resolution, penetrability or detectability of
flaw.
Angle beam search unite for contact testing methods shall have a nominal
frequency from 1.0 to 5.0 MHz and an active transducer length and width
dimension of a minimum of 8 and a maximum of 25 mm. Other search unit sizes
and/or frequencies are permissible with prior approval if required for better
resolution, penetrability, or detectability of flaws. Search unit shall be fitted with
wedges to provide a nominal refracted angles between 35 and 80.
For immersion testing methods, the search units shall have a nominal frequency
from 2.0 to 8.0 MHz and a maximum active transducer diameter between 10
mm and 30 mm. Other search units sizes and/or frequencies are permissible
with prior approval if required for better resolution, penetrability and -
detectability of flaws.
Where contact surfaces are curved or contoured, search units shall be fitted
with shoes, which fit the part curvature or contour.
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Transducers shall be used at their rated frequencies.
4.3 COUPLANT
Glycerine or an equivalent shall be used as a couplant in sufficient quantity to
maintain continuous acoustic coupling between the search unit and test piece,
when using the contact method.
If the immersed method is used, the workpiece and the search unit shall be
immersed in a container of couplant (usually water). Couplant for use on
stainless steel shall contain less than 15 ppm chloride, 10 ppm fluoride and 100
ppm sulphur.
Other couplant materials may be used with prior approval, if guarantees of
complete removal after testing are provided. Couplant for use on stainless steel
shall contain less than 15 ppm chloride, 10 ppm fluoride and 100 ppm sulphur.
After testing ends, the workpiece shall be rinsed with water grade in accordance
with cleanliness classification. .
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5.0 CALIBRATION BLOCKS
5.1 GENERAL
The Supplier shall provide the standard calibration blocks necessary to fully
represent the various thickness, geometry, acoustical characteristic, and other
parameters of the production parts.
Calibration test metal distances to reference reflectors shall be sufficient to
assure the calibration criteria extend through the complete volume to be
examined.
5.2 MATERIAL
Standard calibration blocks shall be fabricated from production material, where
possible, or from material of the same specifications, product form, heat-treat
condition, thickness and shape. Whether fabricated from production material or
equivalent material, the blocks shall represent to the extent possible the same:
a. Production form (rolled, forged, cast, etc.).
b. Material condition: composition or grade, heat treatment including
temperatures, times and cycles.
c. Material size, shape, configuration and curvature.
5.3 SURFACE FINISH
The surface finish of the calibration block shall be no better than that of the
parts being examined.
5.4 REFERENCE REFLECTORS
The following reference reflectors shall be placed in calibration blocks or in
production material:
- Drilled Holes - Drilled holes shall be flat bottom holes (FBH) or side drilled
(SDH). Required hole diameters for the various quality levels are given in
Tables 1 through 4.
2
- Notch Standards - Notch standards shall be 60 to 75 degree included angle,
25 mm long V-notches, located at least 25 mm from any edge or comer.
Required notch depths for the various quality levels are given in Table 1
through 4.
2
Contact surfaces shall be free of base scale, dirt, paint, weld spatter, or any
other foreign material that might interfere with the free movement of the search
unit or impair efficient transmission of ultrasonic soundwaves into the test piece.
Surface finish shall be RA = 6.3 micron (250 micro in) or better.
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Personnel performing NDE under this specification shall be certified in
accordance with European Standard EN 473 (see 2.3).
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8.1 STRAIGHT BEAM
8.1.1 Back Reflection
Adjust instrument sensitivity to obtain an 80 percent of full screen height first
back refection from the apposite side of the test specimen in an indication free
area.
8.1.2 Flat Bottom Hole (FBH)
A flat bottomed hole shall be drilled into the workpiece or calibration bock to a
depth of 19 mm or one half the part thickness, whichever is smaller, in materials
up to 150 mm thick and to a depth of 32 mm in materials of a thickness greater
than 150 mm. Adjust the instrument controls to obtain a reflection of 75-80
percent of full screen height from the flat bottomed hole. This is the 100 percent
reference level.
8.1.3. Side Drilled Hole (SDH)
A side drilled hole shall be drilled into the workpiece or a calibration block to a
minimum depth of 75 mm. The test distance to the side drilled hole shall assure
complete volumetric coverage of the part under examination. Adjust the
instrument controls to obtain a reflection of 80 percent of full screen height from
the side drilled hole. This shall be the 100 percent reference level.
8.1.4. Flat Bottom Hole and Side Drilled Hole Distance-Amplitude Correction:
Establish the distance-amplitude curve (DAC), 100 percent reference level
curve through the peak responses from the reference holes placed such that
test distances equal _ T, _ T and _ T (where T = thickness of part), using 80
percent of full screen height from the reference hole producing the largest
reflection as the primary reference point.
8.2 ANGLE BEAM
8.2.1 V-notches
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Establish the distance-amplitude curve (DAC), 100 percent reference line
through the peak responses of the required notches at the hail node and full
node positions using 80 percent of full screen height from the notch resulting in
the largest reflection as the primary reference point.
If the notch at the full node position cannot be detected, the response from the
notch at the half node position shall represent the 100 percent reference level.
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9.1 CALIBRATION REQUIREMENTS
Calibration shall include the complete ultrasonic system (search units,
contoured wedges, cables, couplant, operator, instruments, power supply. or
other component of this system). Any change in this system shall be cause for
re-calibration.
9.2 RECALIBRATION REQUIREMENTS
Calibration shall be checked at regular intervals, four hours maximum,
throughout the inspection period. If during any calibration check, it is determined
that changes in sweep calibration exceeding 10% and/or a decrease in
amplitude exceeding 20% of full screen height or 2 dB have occurred, the
complete ultrasonic system shall be recalibrate and all material examined
subsequent to the last acceptable check and calibration shall be re-examined.
9.3. AUTOMATED TESTING TECHNIQUES
For automated testing techniques calibration of the complete ultrasonic system
shall be done with the calibration standard or search unit or both moving in the
same manner, in the same direction, and at the same speed as will be used
during the examination.
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Scanning shall be performed at a gain setting in the range 2x to 5x calibration
(+ 6 to + 14 dB). Evaluation shall be performed at the calibration reference level.
The scanning rate shall not exceed 125 mm of search unit movement per
second unless calibration is verified at scanning speed.
Scanning shall be conducted aver 100% of the designated test surface or
surfaces unless otherwise specified, e.g., on a grid basis in the contact or
purchase order. All scanning shall be conducted with a minimum of 15% of
transducer overlap.
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11.0. QUALITY LEVEL
Requirements for the various quality levels are listed in Table 1 through 4.
- Quality level A is given in Table 1.
- Quality level B is given in Table 2.
- Quality level C is given in Table 3.
- Thin wall tubing (2.5 mm wall, maximum), quality level D is given in Table
4.
Quality level A, given in Table 1, and Quality level D, given in Table 4 are
mandatory for the TF Coil Cases.
Quality level B, given in Table 2, and Quality level C, given in Table 3 are
applicable when required by Component Technical Specifications.
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12.1 BACK REFLECTION
When calibrated to a back reflection, the part will be rejected if longitudinal
wave examination results in one or more discontinuities which produce a loss of
back reflection to 5 percent or less of full screen height. The exception to this
requirement is a laminar discontinuity in plates where paragraph 12.1.2 is
applicable.
12.1.1 Non parallel surfaces
Any loss of back reflection caused by non-parallel surfaces, changes in part
geometry, and/or surface irregularities shall not be caused for rejection.
However, tests must be conducted and documented to prove the loss of back
reflection is a result of the above causes.
12.1.2 Laminar discontinuities in plates
Laminar discontinuities in plates are subject to rejection if they produce a
continuous total loss of back reflection accompanied by indications on the same
plane that cannot be encompassed with a circle whose diameter is 75 mm or _
the plates thickness whichever is larger, unless specified otherwise in
applicable Purchaser documents.
12.2 FLAT BOTTOM HOLE, SIDE DRILLED HOLE , V-NOTCH
When calibrated to a single flat bottom hole, side drilled hole, or V-notch, any
discontinuity producing an indication amplitude equal To or exceeding that of
the 100 percent reference bevel shall be cause for rejection.
12.3 DISTANCE AMPLITUDE CURVE (DAC)
When calibrated to a distance amplitude curve (FBH, SDH, or V-notch), any
discontinuity producing an indication amplitude equal to or exceeding the
reference curve shall be cause for rejection.
Individual flaws and multiple linearly aligned flaws whose indications equal or
exceed 50 percent of the calibration standard and exhibit the following are
subject to rejection.
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- In the case of individual flaws, any flaw which exhibits length greater than
or equal to _ to the thickness of part being examined or 50 mm. whichever
is larger. The length of the flaw shall be obtained by recording the position
and location as determined by _ the maximum amplitude for each end of
the 2 flaws.
- In the case of linearly aligned multiple flaws, two or more flaws whose total
length exceeds _ T (50 mm maximum) in any 2T length, where 2T length is
taken in the most unfavourable location relative to the indications being
evaluated. The length of the flaws shall be obtained by recording the
position and location as determined by _ the maximum amplitude for each
end of the flaw.
2
All recordable indications as defined below shall be reported per paragraphs
15.1.3 and 15.1.4 of this specification.
In the back reflection technique, any reduction of 50 percent or more of the back
reflection amplitude shall be reported.
In the back reflection technique, any indications equal to or exceeding the
remaining back reflection shall be recorded.
In the back reflection technique, any area where a loss of the back reflection to
5 percent or loss of full screen height occurs shall be recorded. -
All discontinuities producing indication amplitudes equal to or exceeding 50
percent of the 100 percent reference level shall be reported.
All discontinues which produce indications which are continuous on the same
plane regardless of amplitude and found over an area larger than twice the
major axis of the search unit shall be reported. The extent of such an indication
shall be accurately measured and reported along with variation in amplitude.
2
Unless otherwise specified, rejectable defects may be removed and repaired
using a repair procedure approved by the Purchaser, provided that the repaired
area is retested and complies with all provisions of this specification, the
Purchase order, and the appropriate drawings.
2
15.0 REPORT
The Supplier shall prepare a report of all ultrasonic examinations which shall
include at least the following:
- Date of test, operator, NDE personnel certification level, and other pertinent
information of that nature.
- All procedures and equipment shall be identified sufficiently to permit
duplication of the examination. This shall include calibration data and any
significant changes in subsequent re-examination following repair.
- A marked-up drawing or sketch, Including the part or area examined, the
item or piece number and other information including reportable indications
mapped as to location, extent, size, etc. The drawing or sketch shall also
show the reference axes and planes for subsequent relocation purpose.
- A record of the reportable indications showing the maximum amplitude
obtained, the location, extent, and orientation with the part, etc., shall be
presented in sufficient detail to permit evaluation of all discontinuities.
- A record of repaired areas as well as the results of the re-examination of
these areas.
- Items accepted or rejected.
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TABLE 1
QUALITY LEVEL A
Scans Required Reference Standard Reflectors
Product Form Straight Beam Angle Beam Straight Beam Angle Beam Drilled Hole Dia Notch Depth
Plate 100 percent of
one major surface
100 percent in
two directions
perpendicular to
each other on one
major surface
Back reflection or
Flat Bottom Holes
as required by
contract
V Notches 0.4 mm for each 6
mm of the
nominal thickness
of the plate or
fraction thereof to
a max. of 3 mm
3 percent of the
nominal section
thickness to a
maximum of 6
mm
Round Bar and
Forgings
100 percent radial
and 100 percent
axially from both
ends (see
footnote 1)
(see footnote 2) Flat Bottom Holes
or Side Drilled
Holes
mm of the
thickness of the
forgings at the
time of
examination, or
fraction thereof to
a max. of 3 mm
3 percent of the
thickness of the
forgings at the
time of
examination, to a
maximum of 6
mm
Bar and Forgings
(other than round)
100 percent
axially from both
ends and from
two perpendicular
sides (see
footnote 1)
(see footnote 2) Flat Bottom Holes
or Side Drilled
Holes
V Notches

Ring and Hollow
Forgings
Forged and Bored
Tubing over 7.6
mm wall thickness
100 percent radial
from OD, and 100
percent axially
from one end (see
footnote 1)
100 percent in 2
circumferential
directions from
OD and/or ID on a
full or half node
basis as
necessary to
achieve 100
inspection (see
footnote 2)
Flat Bottom Holes
or Side Drilled
Holes
V Notches

Tubing and Pipe
over 2.5 mm wall
thickness
Not required 100 percent
circumferential in
2 directions and
100 percent
axially in two
directions
Not required V Notches Not applicable 5 percent of
nominal wall
thickness or 0.10
mm whichever is
larger
Note (1) Forging having length/diameter or length/thickness ratios greater than 6/1 shall be examined axially from both ends. Forgings
having length/diameter or length/thickness ratios greater than 12/1 shall be examined per footnote 2. Section of forgings having
length/thickness ratios greater than 6 to 1 shall be examined per footnote 2.
Note (2) Forging which cannot be examined axially using a straight beam shall be examined in both axial directions with an angle beam
technique. Use a 60 degrees V Notch(es) for calibration.
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TABLE 2
QUALITY LEVEL B
one major surface
100 percent in
two directions
perpendicular to
each other on one
major surface
Back reflection or
Flat Bottom Holes
as required by
contract
mm of the
nominal thickness
of the plate or
fraction thereof to
a max. of 6 mm
3 percent of the
nominal thickness
of the plate to a
maximum of 6
mm
Round Bar and
Forgings
100 percent radial
and 100 percent
axially from one
end (see footnote
1 of Table 1)
(see footnote 2 of
Table 1)
Flat Bottom Holes
or Side Drilled
Holes
mm of the
thickness of the
forgings at the
time of
examination, or
fraction thereof to
a max. of 6 mm
3 percent of the
thickness of the
forgings at the
time of
examination, to a
maximum of 6
mm
Bar and Forgings
(other than round)
100 percent
axially from one
end and from two
perpendicular
sides (see
footnote 1 of
Table 1)
(see footnote 2 of
Table 1)
Flat Bottom Holes
or Side Drilled
Holes
V Notches

Ring and Hollow
Forgings
Forged and Bored
Tubing over 7.6
mm wall thickness
100 percent radial
from OD, and 100
percent axially
from one end (see
footnote 1 of
Table 1)
100 percent in 2
circumferential
directions from
OD and/or ID on a
full or half node
basis as
necessary to
achieve 100
percent inspection
(see footnote 2 of
Table 1)
Flat Bottom Holes
or Side Drilled
Holes
V Notches

Tubing and Pipe
over 2.5 mm wall
thickness
circumferential in
2 directions and
100 percent
axially in two
directions
nominal wall
thickness or 0.10
mm whichever is
larger
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TABLE 3
QUALITY LEVEL C
one major surface
unless grid
scanning is
specified by
contract
100 percent in
two directions
perpendicular to
each other on one
major surface
unless grid
scanning is
specified by
contract
Back reflection or
Flat Bottom Holes
as required by
contract
V Notches 6 mm for each 25
mm of the
nominal thickness
of the plate or
fraction thereof to
a max. of 12 mm
The lesser of 5
percent of the
nominal thickness
of the plate or 10
mm
Round Bar and
Forgings
100 percent radial
and 100 percent
axially from one
end. (see footnote
1 of Table 1)
(see footnote 2 of
Table 1)
Flat Bottom Holes
or Side Drilled
Holes
V Notches 6 mm for each 25
mm of the
thickness of the
forgings at the
time of
examination, or
fraction thereof to
a max. of 12 mm
The lesser of 5
percent of the
thickness of the
forging at the time
of inspection or
10 mm
Bar and Forgings
(other than round)
100 percent
axially from two
perpendicular
sides
(see footnote 2 of
Table 1)
Back reflection or
Flat Bottom Holes
or Side Drilled
Holes
V Notches

Ring and Hollow
Forgings
Forged and Bored
Tubing over 7.6
mm wall thickness
100 percent radial
from OD, and 100
percent axially
from one end (see
footnote 1 of
Table 1)
100 percent in 1
circumferential
directions from
OD and/or ID on a
full or half node
basis as
necessary to
achieve 100
percent inspection
(see footnote 2 of
Table 1)
Flat Bottom Holes
or Side Drilled
Holes
V Notches

Tubing and Pipe
over 2.5 mm wall
thickness
circumferential in
2 directions
nominal wall
thickness or 0.10
mm whichever is
larger
2
TABLE 4
QUALITY LEVEL D
THIN WALL TUBING (2.5 mm IN WALL THICKNESS, MAXIMUM)
Class 1:
Thin Wall Tubing
(less than 2.5 mm
in wall thickness)
See Note 1
circumferential in
two directions
Not required V Notches Not applicable 5 percent wall
thickness, OD
notch length shall
be equal to 3 mm.
Notch located on
ID may be of any
length greater
than transducer
diameter
Class 2:
Thin Wall Tubing
(less than 2.5 mm
in wall thickness)
circumferential in
two directions.
100 percent
axially in two
directions
Not required V Notches Not applicable 5 percent wall
thickness, OD
notch length shall
be equal to 3 mm.
Notch located on
ID may be of any
length greater
than transducer
diameter
Note (1) Ultrasonic testing must be augmented by Eddy Current Testing
2
ANNEX B
ULTRASONIC EXAMINATION OF WELDMENTS
2
TABLE OF CONTENTS
1.0 SCOPE
3.0 GENERAL
4.0 EQUIPMENT
5.0 REFERENCE BLOCKS
11.0 EVALUATION
2
1.0 SCOPE
The pulse-echo ultrasonic test methods described herein shall be employed as
a complement to radiography in the inspection of welds and heat affected zones
of Toroidal Field Coil Cases. The objective of this specification is to achieve
reliable detection and evaluation for acceptance of metallurgical and other
discontinuities in the welds (WMZ) and heat affected zones (HAZ) of primary
pressure boundary components made in austenitic stainless steel.
2
Examination.
July 1993.
2.3 Handbook on the ultrasonic examination of austenitic welds Compiled by the
COMMISSION V Testing, Measurement, and Control of Welds of The
Intentional Institute of Welding.
2
3.0 GENERAL
3.1 ULTRASONIC EXAMINATION PROCEDURE
Before testing begins, the Supplier shall prepare ultrasonic examination
procedure.
c. The mode(s) of sound propagation and test angle(s) to be used.
d. The ultrasonic test System including instrument, transducer types,
materials, and sizes. Beam angle in the material as measured on an IIW or
equivalent reference block shall be noted for contact testing methods. For
immersion testing methods, the angle of incidence and the water path
distance shall be noted. The angle of incidence is that included angle
between the direction of the transmitted wave and the normal to the
interface at the point of incidence. The water path distance is that distance
travelled by the transmitted wave in water.
g. Type of couplant used and cleaning procedure employed.
h. The direction(s) and extent of scanning. The speed of transducer
movement, the amount of overlap between scans, and the test system
sensibility during scanning shall also be noted.
j. Test frequencies.
k. Qualification and certification of the personnel performing the test.
2
i. Specific criteria for acceptance and/or reporting results. A sample copy of
l. Automatic alarm and recording equipment, or both, if used.
3.2 TIME OF EXAMINATION
The ultrasonic examination of primary pressure boundary welds may be
performed following completion of all manufacturing and fabrication procedures
including final stress relief or other final heat treatment, coincident with final
radiographic inspection.
3.3 EXAMINATION REQUIREMENTS
Ultrasonic examination of the entire volume of the weld and heat affected zones
(HAZ) is required at equivalent detectability levels in at least two (2) directions
perpendicular to the long axis of the weld and in two directions perpendicular
(approximate) to the transverse plane of the weld. Both the shear and
longitudinal (compression) modes of sound propagation and/or a combination of
both may be applied as required by the part size and contour, as well as the
weld shape, location and orientation to achieve the stated objectives. For
evaluation purposes, the weld and HAZ shall be examined in as many ways and
directions as necessary to define the extent and nature of a questioned
(reportable, recordable) condition.
Angled projection of the ultrasonic sound beam shall be considered the primary
methods of examination. The sound beam angles shall be chosen so as to
provide as near-normal incidence as possible to the expected flaw orientations
while maintaining a short probe to flaw distance; see Table 1 for suggested
anglethickness relationships. (Note: for flaw evaluation the same
angularthickness relationships (Table 1) may be applied to heavy wall (e.g.
150 mm to 300 mm) welds by considering the weld thickness in increments or
layers equivalent to the material thickness listed, measured from designated
test surface).
The length of material (test metal distance) examined using either angle or
straight beam procedures in the shear or longitudinal modes shall not exceed
the distance from the search unit to the farthest notch or reference reflector
used in calibration.
See also 4.2.2.
2
TABLE 1
Sound Beam (Shear Wave) Angle Thickness Relationships
Material (Base) Primary Beam Angle Secondary
Thickness (In Material) Beam Angle
6 mm to 75 mm 70 45
75 mm to 150 mm 60 45
150 mm to 225 mm 50 60
Over 225 mm 45 (+ 5 - 0) 60
2
4.0. EQUIPMENT
4.1 ULTRASONIC INSTRUMENT
The ultrasonic test equipment shall be capable of transmitting, receiving and
displaying signals at set frequencies of 1.0 to 5.0 MHz. The test equipment shall
have linear response within 5% for at least 75% of the vertical screen height
and for at least 75% of the horizontal sweep length, determined using either the
methods prescribed in ASTM E 317 or similar methods designed to provide
equivalent data. Signal attenuator, if used, shall be accurate over the range
used to 10% of the nominal attenuation ratio. If the instrument is equipped
with an electronic distance amplitude correction device, the primary reference
response shall be equalised at 75% of the linear screen height over the
distance range to be employed in the longitudinal wave and/or shear cave
examinations.
4.2 SEARCH UNITS
The major variables to be considered when selecting a probe are:
1) wave type;
2) angle;
3) frequency;
4) type of probe;
5) size and geometry of probe and component.
4.2.1 Wave Type
The use of conventional shear wave probes shall always be considered first, if
the signal-to-noise ratio is insufficient for an effective inspection, special probes
like refracted longitudinal angle beam probes, including the surface wave type
need to be used.
4.2.2 Probe Angle
The probe angle shall be selected to be suitable for the expected defect
orientation. This means that if possible, the incident angle shall be chosen to
strike a defect perpendicularly for maximum echo amplitude.
For weld examination, it is therefore necessary to know the weld geometry prior
to and after welding; particularly the details of the weld root if this is not
machined or ground flush (full dressed).
2
The entire volume of weld and fusion zone can be covered with at least two
angles of incidence as shown in Figure 4.1.
Figure 4.1 - Volumetric Examination
However, this approach does not take into account the above consideration of
preferred beam to flaw orientation. Nevertheless, in some cases it may only be
necessary to examine inner and outer surfaces of the weld to demonstrate
fitness-for-purpose from a fracture mechanics point of view. In this case, the
use of an additional surface wave probe may be considered. If optimized flaw
detection over the whole thickness is required, then a range of probe angles
between 60 and 70 should be included to detect lack of sidewall fusion.
2
In some cases, one would also consider using 45 angle probes to inspect the
root area in relatively thick welds. However, if the weld penetration is not ground
flush, geometrical or false echoes may be generated with a 45 probe, and for
that reason, a probe with a larger angle (for instance 60) may be used to
improve the identification of echoes defect. Therefore, the choice of probe angle
largely depends on the weld preparation and weld surface condition, It should
also be remembered that examination at more than half- skip distance is not
very effective due to mode conversion effects at the backwall. To reach the
lower part of the weld with large angle probes requires a long sound path and
this can also reduce the effectiveness of the examination.
This is influenced by the total attenuation and is highly material dependent. If all
these different effects are considered, it can generally be concluded that:
- For thin welds and for the near surface area (at the scanning side) of thick
welds, large angle probes provide the best results.
- For all welds, the weld surface shall be dressed smooth to enable the probe
to be scanned across the weld.
- If the weld is narrow, then surface wave probes can still provide a good
examination of the upper part of the weld.
- Surface wave probes are also well suited for detection of surface breaking
defects and near surface defects in wide welds, provided the welds are full.
As the surface wave probes do not have a significant dead zone, their use can
be considered under all circumstances where the required working depth does
not extend beyond about 10mm.
For detection of deep lying defects in thick welds, steeper angles must be
selected and a compromise found between optimum incidence on flaws and
scanning distance. This may result in the selection of a range of angled probes.
Also, a tandem arrangement of longitudinal wave probes or a combination of a
longitudinal and shear wave probe(s) should be considered as suggested in
Figure 4.2.
As a result of the above approach, thick welds are often considered divided into
thickness zones and examined with different probes whereby each zone is
inspected by the most appropriate probe(s)
2
Figure 4.2 - Tandem Inspection
4.2.3 Probes Frequency
The frequencies used are generally in the range of 1 to 5 MHz. The interaction
between grain-size and wavelength dominates the selection of the best
frequency to optimize signal-to-noise ratio.
Ultimately, the frequency selected is a compromise between the resolution
required and signal to noise ratio. This often leads to the use of probes with a
large bandwidth. In special cases, a selectable bandwidth for the ultrasonic
pulse might be appropriate.
Equipment bandwidth should be appropriate to probe type.
In practice, it is found that for welds over 25mm thickness and cast material,
frequencies of 2 and 1 MHz are predominantly used.
For welds below 25 mm thickness, the frequencies most commonly used are 4
and 2 MHz.
The side drilled holes in the probe characterisation block provide a means for
comparing different probes with respect to signal-to-noise ratios. The signal is
the echo of a side-drilled hole, whereas the noise can be taken as the
maximum level of material grain indications occurring at the same sound path
as the side-drilled hole.
Clearly the signal-to-noise ratio of a probe is not a constant, but dependent on
sound path. The signal-to-noise ratio found on the probe characterisation block
represents the nominal condition and can change considerably in the presence
of a weld, and it should also be determined on the reference block.
2
4.2.4 Probes Type
The main probes in use for austentic weld inspection are:
- single crystal probes;
- twin crystal probes with separate transmitter and receiver crystal (TR).
The selection is often arbitrary.
In order to decrease the number of probes and inspection zones, single crystal
probes are favoured because they do not show so pronounced a distance
amplitude curve as for TR probes.
On the other hand, many single crystal probe designs show a long acoustic
dead zone, which decreases the efficiency of surface and near surface
examination. Occasionally, single crystal point or line-focussing probes can be
are used, particularly where the more conventional probes described above fail.
The use of such purpose built focussing probes is critical because they will
behave only as calculated if all aspects of the examination such as surface
roughness, geometry, and acoustic material properties. etc., are kept within
narrow tolerance limits.
The above remarks are valid for both immersion and contact techniques.
Immersion testing, in particular, requires a very stable and precise mechanical
arrangement because the refractive index is roughly twice that for contact
probes. As a result, small variations in angle of incidence cause considerable
variations in the angle of refraction.
4.2.5 Size and Geometry of Probe and Component
Apart from the beam characteristics necessary for the examination, the probe
shall be of a size which allows manual examination with good acoustic coupling.
Thus, coupling involves an interaction between probe size, roughness, and the
geometry of the component.
If the probe dimension W fails to meet the requirement R < W
2
/ 4 (where A is
the radius of the curved surface under examination and W is the probe
dimension, in length or width), dimensions in mm, or the coupling gap exceeds
0.5 mm, the probe shoe shall be adapted to the geometry of the component.
This can be done by machining or by applying grinding paper on the component
and matching the probe shoe to the component curvature.
2
Care shall be taken when operating from curved surfaces. The probe
performance shall be checked after modification of the probe shoe by trials on
the appropriate reference blocks. The probe index point and/or nominal angle
may change if shoe adaptation is not carried out properly.
4.3 COUPLANT
Liquids couplant such as glycerine or water shall be used to complete the
search unit or probe to the item to be examined. Other couplant materials may
be used with prior approval, if guarantees of complete removal after testing are
provided. Couplant for use on stainless steel shall contain less than 15 ppm
chloride, 10 ppm fluoride and 100 ppm sulphur.
After testing ends, the workpiece shall be rinsed with water grade in accordance
with cleanness classification.
2
5.0. REFERENCE BLOCKS
5.1 GENERAL
Because of the special effects of austenitic weld metal on ultrasound it is
necessary to produce a reference block in order to:
a) develop an examination procedure;
b) set a preliminary sensitivity level;
c) assess the procedure;
d) help to demonstrate the effectiveness of the preliminary examination
procedure before a definitive procedure is written.
The material from which the block is fabricated should have the same
composition as the material being examined, i.e. chemical analysis, product
form, fabrication, procedure, heat treatment, cooling rate.
The weld in the reference block should be similar to the weld being examined
and made using the same welding procedure. All variables should be respected,
including those which may not be considered essential for the welding
procedure qualification test pieces, weld preparation, weld position, heat input,
cooling rate, etc.
The geometry and surface condition of the scanning and reverse side of the
reference block should be considered, both for the base material and for the
weld deposit. The reference block should generally contain known artificial
reflectors, though in some cases, a weld containing real defects may be useful.
5.2 ARTIFICIAL REFLECTORS
Before machining artificial reflectors as described below, the reference block
should be examined by non-destructive methods such as penetrant testing,
ultrasonic testing (straight beam), and radiographic testing to detect possible
unwanted defects which would interfere with its use.
Side drilled holes (in combination with notches) are most commonly used as the
artificial reflectors. Holes shall be drilled at regular depth intervals, e.g. 1/4, _
and 3/4 t (where t is weld thickness) for single crystal probes. For twin crystal
probes, which are effective over a particular depth zone, the holes shall be
located at the zone centre and the zone limits (6 dB). Altematively, when a set
of twin crystal probes is applied, a series of holes distributed over the thickness,
say every 10 mm, may be used.
2
The holes shall be drilled in the fusion zone of the weld to allow comparison of
the sensitivities when the beam passes through the full width of the weld and
through base material only. In some cases, this may not be practicable, and
separate sets of holes at the weld centre line and within the base material may
be more suitable.
Flat bottom holes can also be used with the flat bottom perpendicular to either
the examination surface or to the nominal beam direction. In the latter case, the
holes represent flaw detection by reflection from facets and shall be of small
diameter.
Due to mode conversion (compression into shear) even in fine grain material, a
smooth notch sometimes produces only a small reflection. Hence, when
longitudinal waves are applied with 45 probes, the use of notches (corner
effect) for sensitivity calibration is not advisable.
Figure 5.1 - Reference block with artificial defects situated at the weld centre
line and in the parent metal
In all cases, it is recommended that in addition to the artificial reflectors in the
weld, a similar set of reflectors be machined in the adjacent plate or pipe
material of the reference block, as shown in Figure 5.1. This is important in
2
order to quantify the effects of the weld structure and to give a reference
reflector for the examination of the parent material near the heat-affected zone.
Drilled holes shall be used to establish reference levels and distance -
amplitude correction data. The reference calibration hales shall be drilled
parallel to the contact surface of the reference block.
The locations and diameters of these holes shall be as given in Table 2.
In addition to the drilled hole calibration reflectors, a 75 ( 5) included angle
vee notch shall be provided in the reference block for flaw evaluation purposes.
The vee notch shall have an effective length of 25 mm, maximum and a depth
of 3% of the production weld of test material thickness or 9.5 mm whichever is
smaller. The notch shall be placed in the surface opposite the proposed primary
test surface of the reference block or production material if permitted.
TABLE 2
Material Thickness Hole Diameter (mm) Hole Location
Up to 25 mm Included 2.5 - _ T -
Over 25 mm Through 50 mm 3.0 - _ T -
Over 50 mm Through 100 mm 5.0 _ T _ T _ T
Over 250 mm 11.0 _ T _ T _ T
2
6.0. SURFACE PREPARATION
All test surfaces shall be prepared by machining, grinding and/or polishing for a
distance approximately equal to twice the weld thickness on both sides of the
weld to be examined, or in limited accessibility situations, for a distance
approximately equal to twice the weld thickness on one side of the weld and to
the extent (two search unit width minimum) possible on the other side.
In all cases all the accessible weld metal surface shall be full dressed. Surfaces
finishes shall be of 6,3 micron (250 micro in) or better.
All test surfaces shall be free from loose scale, machining or grinding particles,
paint, other foreign particles and any roughness that will interfere with free
movement of the search unit or probe. All test surfaces shall be sufficiently
smooth and free from waviness to permit a uniform test at the required
sensitivity levels over the required areas; e. g., changes due to surface
conditions, of 15% or less in back refection amplitude when testing through the
base metal thickness using longitudinal wave straight beam techniques are
considered acceptable. Grooves, score marks etc. (for example: valleys
between weld beads) are permitted in the flat surfaces, provided the width
does not exceed 10% of the effective diameter or width of the transducer and
the individual grooves or marks are separated by at least one diameter or width
of the transducer used.
2
7.0 PERSONNEL QUALIFICATIONS
2
8.0 CALIBRATION METHOD
Calibration shall be performed establishing a DAC curve by using a reference
block.
8.1 SENSITIVITY SETTING
For sensitivity setting, the reference block and reference reflectors described in
5.0 shall be used.
After selecting the probes for a particular wall thickness and weld geometry and
determining their characteristics on the probe characterisation block (i.e. the
characterisation blocks described in the Chapter 6 of the document Handbook
on the ultrasonic examination of austenitic welds Compiled by the
COMMISSION V Testing, Measurement, and Control of Welds of The
International Institute of Welding), the examination sensitivity shall be set. This
is done with the aid of the reference blocks shown in Figure 5.1 using side
drilled holes at the fusion face or at the weld centre line.
Where fusion face holes are used, two calibrations are to be performed per
scanning surface:
a) by establishing the echo height of the side drilled holes, with the beam
passing through parent metal only (see Figure 4.1);
b) by establishing their echo height with the beam passing through the weld
metal (see Figure 4.1).
If centre line holes are used (see Figure 5.1), sensitivity setting from both sides
is not required unless dissimilar metals are welded together (e.g. cast and
forged austenitic material).
Within the zone over which a particular probe will be used, the echoes from
each of the available holes is maximised. The highest echo should then be set
to approximately 80% screen height. Then, without altering the gain setting, the
peaks of the echoes of the other holes are marked on the screen, and a DAC-
curve is drawn to connect the points.
This is the 100% Distance Amplitude Correction (DAC) reference line.
In practice, the shape of such a curve can differ considerably from that obtained
on the probe characterisation block; especially when the beam passes through
the weld metal.
2
It may sometimes be found that a different probe combination and/or zone
distribution are required from that previously chosen on the basis of
measurements on the probe characterisation blocks. For this revised probe
selection, a new set of DAC curves should be established on the reference
block.
8.2 RECORDING LEVEL
The recording level is specified in terms of a percentage of the reference
reflector-response or the Distance Amplitude Correction (DAC) curve.
Two additional curves (50% and 20%) shall be drawn.
The recording level in the appropriate depth zone should be at least 6 dB higher
than the maximum noise level in that depth zone.
2
9.1 CALIBRATION REQUIREMENTS
Calibration shall include the complete ultrasonic system (search units,
contoured wedges, cables, couplant, operator, instrument, power supply, or
other component of the system). Any change in this system shall be cause for
recalibration.
9.2 RECALIBRATION REQUIREMENTS
Calibration shall be checked at regular intervals, four hours maximum,
throughout the inspection period. If during any calibration check, it is determined
that changes in sweep calibration exceeding 10% and/or a decrease in
amplitude exceeding 20% of full screen height or 2dB have occurred, the
complete ultrasonic system shall be recalibrated and all material examined
subsequent to the last acceptable check and calibration shall ho re-examined.
9.3 AUTOMATED TESTING TECHNIQUES
For automated testing techniques calibration of the complete ultrasonic system
shall be done with the calibration standard or search unit or both moving in the
same manner, in the same direction, and at the same speed as will be used
during the examination.
2
All scanning shall be conducted at speeds not exceeding 125 mm per second.
Contact and coupling effectiveness during scanning shall be maintained by
monitoring structure noise levels, and reflections or by approved electronic
and/or mechanical devices included in the test equipment.
The area of the base metal through which the sound will travel in the angle
beam examinations shall be completely scanned with a straight beam (0
longitudinal wave) search unit to detect reflectors which might affect the
interpretation of angle beam results. Consideration must be given these
reflectors during interpretation of the weld examination results, but their
detection is not a basis for rejection of the base material. The coarse grain
austenitic materials will require special fixture to accommodate the straight
beam and refracted longitudinal searching combinations needed to accomplish
this interpretative scanning.
10.1 LONGITUDINAL MODE SCANNING - (Straight Beam to 20)
The sections to be examined shall be scanned by moving the search unit along
and across a sufficient area so as to scan the entire volume of weld and heat
affected zones.
Scanning shall be performed at a gain setting in the range 2x to 5x calibration
(+ 6 to + 14 dB). Evaluation shall be performed at the calibration reference level.
Scanning shall be conducted aver 100% of the designated test surface or
surfaces unless otherwise specified, e.g., on a grid basis in the contract or
purchase order. All scanning shall be conducted with a minimum of 15% of
transducer overlap.
Search unit holders, shoes, wedges, guides, etc., shall be used to maintain the
sound beam at the angle designated for the scanning operation.
NOTE: Shoes, wedges, guides, etc., must be included in the calibration.
10.2 ANGLE BEAM (Shear and Longitudinal Mode Scanning)
Place the search unit (properly coupled) on the prepared test surface adjacent
to the weld to be examined with the projected direction of the sound beam
normal to the long axis of the weld. Move the search unit to and from the weld in
a path normal to the axis of the weld.
2
Search unit movement to and from the weld shall not be less than a distance
equal to twice the thickness of the weld with the scan path starting at the toe of
the weld. This scanning procedure shall be repeated, to the extent possible,
from the apposite side of the weld.
Place the search unit (properly coupled) on the prepared test surface adjacent
to the weld to be examined with the projected direction of the sound beam at a
slight angle, see Table 3, with respect to the long axis of the weld.
TABLE 3
Search unit Direction for axial scanning
Scan Angle Weld Thickness
5 6 mm to 25 mm
5 - 10 25 mm to 75 mm
15 75 mm to 150 mm
15 - 20 Over 225 mm
Move the search unit along the weld maintaining the scan angle per Table 3 in
a path parallel to the axis of the weld. With each pass along the weld, index the
search unit away from the weld a distance equal to a maximum of 75% of the
transducer (crystal) width until a width of test surface equivalent to the material
thickness is scanned along the entire length of the weld.
Reverse the projected direction of the sound beam, i.e. direct the sound beam
in the apposite direction to that of previous Paragraph and repeat the angled
scanning procedure on the same side of the weld.
Repeat the previous described angled scanning procedures on the apposite
side of the weld or to the extent possible if accessibility is limited.
2
11.0 EVALUATION
11.1 ANGLE BEAM (Shear and/or Longitudinal Wave Mode)
Angle beam (shear and/or longitudinal wave mode) detected discontinuities
whose indications exceed 20% of the DAC reference line for the particular
thickness being tested shall be evaluated to the extent possible for size
(determining maximum amplitude obtainable), extent, length, orientation,
location, shape and nature using larger and smaller sound beam angles, higher
and/or lower test frequencies and other modes of propagation based on the
side drilled hole and vee notch references in the calibration block.
11.2 STRAIGHT BEAM (Longitudinal Wave Mode)
Longitudinal wave mode detected discontinuities whose indications exceed 20%
of the DAC reference line shall be evaluated in the same manner outlined in
11.1.
2
Acceptance criteria will be as follows.
- All imperfection which produce a response greater than 20% of the
reference level (100% DAC reference level) shall be evaluated as per
11.1, and evaluated in terms of the acceptance standards given in (a) and
(b) below.
(a) Imperfection are unacceptable if the indications exceed the reference
level amplitude and have lengths exceeding:
(1) 6.35 mm for t up to 19 mm inclusive;
(2) 1/3 t for t from 19 mm to 57 mm inclusive;
(3) 19 mm for t over 57 mm.
Where t is the thickness of the weld being examined. If a weld joins
two members having different thicknesses at the weld, t is the thinner
of these two thicknesses.
(b) Indications characterised as cracks, lack of fusion, or incomplete
penetration are unacceptable regardless of length.
2
The Supplier shall prepare a report of the ultrasonic examination which shall
contain the following:
a. All procedures and equipment shall be identified sufficiently to permit
duplication of the examination(s) at a later date. This shall include initial
calibration data and calibration transfer test and dimensional data and any
significant changes in subsequent re-examination following repair. The
procedures shall include at least the following information.
- Weld types and configurations tested including thickness dimensions.
- Automatic defect alarm and recording equipment or both if used.
- Special search units, wedges, guides, or saddles, if used.
- Automatic scanning mechanisms, if used,
- Stage of manufacture when test was made.
- The surface or surface from which the test was performed.
- Surface finish.
- Couplant.
- Mode and method (angles) used.
- Description of the calibration method and method of correlating
indications with defects.
- Scanning directions.
- Type and size of transducer and test frequency.
b. A marked up drawing or sketch indicating the weld(s) examined, the item or
piece number, and other information necessary to identify the weldment.
c. A record of the maximum amplitude, location, orientation, length, extent,
shape and predicted nature of all discontinuities producing indications of
amplitude exceeding 90% of the applicable reference amplitude.
d. A record of the repaired areas as well as the results of the re-examination
of the repaired areas.
2
using a repair produce approved by the Purchaser, provided that the repaired
area is retested and complies with all provisions of this specification, the
Purchase order, and the appropriate drawings.
2
ANNEX C
RADIOGRAPHIC EXAMINATION
2
TABLE OF CONTENTS
1.0 SCOPE
3.0 GENERAL REQUIREMENTS
4.0 EQUIPMENT AND PROCESS
5.0 PREPARATION OF SURFACES TO BE RADIOGRAPHED
7.0 RADIOGRAPHIC INSPECTION SEQUENCE
8.0 TECHNIQUE
9.0 IDENTIFICATION AND MARKING
10.0 RADIOGRAPHIC REPORT
11.0 QUALITY LEVEL
TABLE 1
2
1.0 SCOPE
This process covers procedure to be followed in radiographic testing of
materials for discontinuities as may be required by various Codes or by general
specifications under which the equipment is being designed and manufactured.
The requirements herein are intended to supplement those specified in the
ASME Boiler and Pressure Vessel Code or other governing documents where
applicable.
the Purchaser prior any being performed.
2
Examination.
July 1993.
2
3.0 GENERAL REQUIREMENT
3.1 RADIOGRAPHIC EXAMINATION PROCEDURE
Before testing begins, the Supplier shall prepare radiographic examination
examination, including equipment and acceptance standards. As a minimum,
the following parameters and requirements shall be detailed in the procedure.
of manufactures at which the examination will be conducted.
b. The degree of surface preparation and. description of the finish of the
c. The radiographic test including: instruments, source of radiation, films,
intensifying screen, penetrameters.
d. Qualification and certification of the personnel performing the test.
e. Specific criteria for acceptance and/or reporting results.
2
4.0 EQUIPMENT AND PROCESS
4.1 SOURCES OF RADIATION
Sources of Radiation: Either X-rays or gamma rays may be used. Maximum
voltage of the source of radiation shall be in accordance with the applicable
section of the ASME Code.
4.2. SENSING MEDIUM
4.2.1 Films
Radiographs shall be made only on non-flammable, fine grain (Type 1 or Type
2 of ASTM E-94) and high contrast radiographic film free of inherent flaw that
may interfere with the interpretation of the radiograph except as noted in 8.4.1
(Betatron section).
4.2.2 Intensifying Screens
Metallic intensifying screens of approximately 0.15 mm thick shall be used in
the production of radiographs except that when radiographing various metals
equivalent to 6.35 mm or less of steel, it may be necessary to remove or not
use such screens in order to produce the best radiographs.
Fluorescent type screens are prohibited.
4.2.3 Filters
Objectionable backscatter may be reduced by suitable filtration (filters of greater
atomic number than the material being radiographed).
4.3 PROCESSING
Film shall be processed in accordance with ASTM E-94, Part III.
2
5.0 PREPARATION OF SURFACE TO BE radiographed
5.1 MATERIALS
All surfaces shall conform to applicable material specifications. Additional
conditioning may be applied to assure that surface irregularities cannot mask or
be conformed with discontinuities.
5.2 WELDS
When the ground flushing (full dressing) of the welded joints is not required for
carrying out other NDE (i.e. Ultrasonic Examination), all weld ripples or other
weld surface irregularities of joints, on both the outside and, where applicable,
the inside, shall be removed by suitable mechanical processes to a degree such
that the resulting radiographic contrast due to remaining irregularities cannot
mask or be confused with sub-surface discontinuities. Also, the weld metal shall
merge smoothly into the base metal surface. The finished surface of
reinforcement or butt weld should, have a reasonably uniform crown.
5.3 COMPONENTS
All components shall be free of base sand, oxides, etc. and should have
relatively smooth surfaces free from flash, scale and other surface irregularities
which could obscure internal defects.
NOTE: Any method that induces hot grinding when removing weld ripples
and surface irregularities shall not be used.
2
2
7.0 RADIOGRAPHIC INSPECTION SEQUENCE
Exploratory radiographic examination may be conducted at any point in the
process schedule of a component to determine the presence of defects in areas
usually encountered; such as, at points of high stress, abrupt changes in metal
sections, root of welds, questionable visual surface defects, etc., in order that
the most economical corrective action may be taken to produce a quality
component. After a major defect has been removed, the area should be radio-
graphed in order to determine whether the removal of the defect is complete
before repairing. Repairs shall only be made by welders possessing
qualifications required by contract.
Any repair welds radiographed shall be identified on the radiography by the
letter R.
Specified radiographic examination shall be made on the component in the final
heat treated condition, if such heat treatment consist of solution annealing or
quench hardening. Unless otherwise specified, radiographic examination shall
be made on the component or system in accordance with the time of
examination requirements of the applicable code(a) rules.
2
8.0 TECHNIQUE
8.1 SENSITIVITY
All radiographic examinations shall be performed by a technique capable of
indicating Image Quality Indicators (I.Q.I.) outline, identify numbers, and 2T hole
or the slit. All I.Q.I. thickness shall conform to ASME Boiler and Pressure
Vessel Code requirements.
Required quality level shall be 2% (2-2T) unless another level is agreed upon by
Purchaser and Supplier.
The two-film technique is recommended.
8.2 IMAGE QUALITY INDICATORS (I.Q.I.) DESIGN
I.Q.I. shall have a radiographic density equal to or less than that of the material
to be radiographed.
Hole-Type Image Quality Indicators (according to ASTM E-1025) shall be used.
If necessary, Wire-Type Image Quality Indicators (according to EN 462 Part 1 or
ASTM E-747) may be used, prior Customer written approval.
8.3 POSITION OF I.Q.I.
When possible, I.Q.I. shall be placed on the side nearest the radiation source.
When more than one exposure is made with the film and source, both outside
the parameters shall be located on the inside surface of the component
adjacent to the area which the radiograph represents.
When a number of exposures are to be made with the source outside and the
film inside, the I.Q.I. shall be placed on the outside surface nearest the source.
When radiographing an assembly with the source located inside the component,
the I.Q.I. shall also be located on the inside surface.
In cases where placement of the I.Q.I. on the source side is impractical without
cutting a hole in the wall of the component, the I.Q.I. may be placed on the film
side. (I.Q.I. placement shall be identified as to F for film side and S for
source side).
2
At last two I.Q.I. shall be used, if possible, one at each end of the exposed
length for each exposure. One shall be placed parallel to and the other
perpendicular to the edge of the area under examination, and both shall be
approximately 6.3 mm away from the edge. The I.Q.I. shall be placed at the
point of maximum obliquity between the source of radiation and the object, with
the small 1T holes being positioned at the point of greatest angularity. For
radiographs of welds, the I.Q.I. shall be placed on the base metal (see Figure
8.1).
Figure 8.1 - Positioning of Hole-Type Image Quality Indicators and
identification markers
When the I.Q.I. is placed adjacent to a weld scan and the weld reinforcement is
not removed, a shim of the same radiographic density shall be placed under the
I.Q.I. such that the total thickness being radiographed under the I.Q.I. is the
same as the total thickness through the weld.
Where the thickness of the metal is not uniform, but does not vary by more than
20% of the maximum thickness or by more than 12 mm in section, whichever is
the lesser, over the area covered by a single radiograph, one set of I.Q.I. shall
be required as per Figure 8.1.
If the thickness of the metal covered by a single radiograph varies by more than
20% of the maximum thickness or by more than 12 mm whichever is the lesser,
suitably sets of I.Q.I. shall be placed at the thinnest and thickest portion being
radiographed.
2
8.4 LIMITING DISTANCE
During exposure, the film shall be as close as practicable to the surface of the
object being radiographed.
The focus - film distances shall allow a geometric unsharpness (Ug) which not
exceed the following:
Material Thickness, mm Ug Maximum, mm
under 50 0.50
50 through 75 0.75
over 75 to 100 1.00
greater than 100 1.80
Geometric unsharpness (see Figure 8.2) is given by the equation: Ug = Ft / d
o
Where:
Ug = Geometric Unsharpness Ft / d
o
F = Size of the radiation source
t = specimen thickness, when in contact / d
o
d
o
= source object distance
2
Figure 8.2 - Geometric unsharpness
8.4.1 X - Rays
When using X-rays, the focus-film distance shall be not less than seven times
the thickness of the metal being radiographed, and, in general, the
recommended distance shall not be less than 900 mm except as follows:
When using 140 kV or lower voltage X-ray equipment it may be possible to
obtain satisfactory results with a 600 mm or even shorter focus film distance.
The minimum focus-film distance with 1000 kV X-rays is usually 1800 mm.
However, when very loss currents are being used with the 1000 kV equipment,
the size of the focal spot shall be correspondingly reduced which will permit
2
shorter focus-film distances. Such techniques shall be determined during the
Qualification Test.
When a high energy type machine in the range of 10 to 25 MeV is employed, a
focus-film distance of at least 230 mm is recommended. It is desirable to use
very fine grain film for steed thickness less than 150 mm and fine grain film for
greater thickness.
When radiographing flat surface at 250 kV or less, the focus-film distance shall
be not less than the largest linear dimension of the area being radiographed, but
not less than 900 mm.
For Betatron type machines, the linear dimension of flat surfaces that can be
radiographed is determined by the beam angle and shall be proven by properly
placed I.Q.I. at the extremities and central portion of such area.
For linear accelerator type machines having a 1 mm focal spot size, a focus-film
distance vs. thickness being radiographed relationship as follows is
recommended:
Thickness, mm Optimum ffd, mm Minimum Acceptable ffd, mm
250 1420 710
380 1930 960
500 2440 1220
In those cases where a second radiograph is considered desirable, it will often
be advantageous to alter the position of the source and film in order that the
defect may be registered from a different angle. This will aid in interpretation of
the defect and also determine its exact location. For this type radiograph, the
focal spot should be displaced a distance of approximately 15 to 20% of the
focal-film distance.
8.4.2 Gamma - Rays
When using Gamma-rays from Iridium (192), Cobalt (60) or other isotopes, the
recommended focus-film distance for maximum sensitivity will depend upon the
strength of the gamma-ray source capsule and the thickness of metal being
2
radiographed. The following tabulation shows the shortest focus-film distance
which shall be used in radiographing various sections of steel with different
source strengths:
Source Strength Section Thickness, mm
Ci x g 25 (max) 76 (max) 100 (max) Over 100
25 150 225 380 (1)
100 200 250 430 (1)
250 250 300 510 (1)
500 350 400 580 (1)
(2)
(1) Each application shall be negotiated to determine the source strength and
acceptability standard.
(2) Source strength above 500 Ci x g for any thickness be approved by the
Customer.
8.5 EXP0SURE
All two film radiographic techniques shall consist of two films sandwiched
between sheets of lead in the following order:
Lead-film-lead-film-lead, except the middle lead can be omitted when using
techniques below 125 kV and for the 1.000.000 volt and up machines, and
when film of different speeds are used in the radiographic technique.
Single wall thickness radiography shall be used except as otherwise provided
for in this specification.
When radiographing piping or cylindrical shapes, the OD of which is less than
90 mm, a technique may be used in which radiation passes through two walls
and both walls are viewed for acceptance on the same film (double-wall
viewing). At least four exposures are required around the circumference, the
cassette being placed flat against the outside surface of the pipe and the source
located apposite in such a manner that the rays pass through the pipe at an
2
angle of not less than 15 degrees to a plane passing through the area being
examined. The quadrant area of the portion being radiographed shall be
positioned nearest the film.
When radiographing piping or cylindrical shapes, the OD of which is 90 mm or
greater, the cassettes should be placed inside the pipe, where practical, in order
that the rays shall be required to penetrate a single wall thickness of metal. At
least four exposures should be made in radiographing the full extent of the
circumferential area.
In location where it is impractical to place the cassettes inside the pipe, the
outside of which is 90 mm or greater, the inspection may be conducted as in the
case of pipe which OD is less than 90 mm.
When the diameter of the pipe or cylinder is such that the source of radiation
may be located inside without reducing the focus-film distance below the
requirements of 8.4, the cassettes may be grouped panoramically around the
outer surface of the pipe or cylinder. With such an arrangement it may be
possible to radiograph a complete circumferential area with one exposure. It will
normally be necessary to block holes and edges of components being
radiographed in order to prevent halation and undercutting.
8.6 NEGATIVE REQUIREMENTS
Technique shall be such that normal development of negatives shall yield an
individual film density of 1.5 to 4,0, or a double, composite film density of 2 to
4.0. Each film of a composite set shall have a minimum density of 1.0.
Interpretation shall be made either as single or composite film, whichever is
better suited for interpretation. However, in single film viewing when two film
technique is used, if defects is shown it is necessary to view the second film
before making a decision regarding the defect. Photographic density may be
measured by a densitometer or visually comparison step wedge films.
Densitometers shall be calibrated by calibration step wedge films.
Radiographs of welds shall produce negatives with film density through the weld
of 2.0 minimum for single viewing and 2.6 minimum for composite viewing.
Each film of a composite set shall have minimum density of 1.3.
Where thickness varies in a section sufficiently to cause difficulty in meeting
density requirements ( 8.3) and two I.Q.I. must be used, film density minimum
shall be 1.3 for single viewing and 2.0 for composite viewing. Each film of a
composite set shall have minimum density of 1.0.
All radiographs shall be free from processing or other film defects which would
interfere with proper interpretation of the radiograph. When an apparent defect
2
is indicated by a radiograph which, by comparison with the object being
radiographed, is shown conclusively to be entirely on the surface, the area on
the radiograph shall be encircled by the Inspector and identified ad a surface
imperfection by letter S placed immediately adjacent to the encircled area.
Take great care to ascertain that such markings are due entirely to surface
markings and not partly due to underlying internal defects. Also, particularly
observe the area obscured by the I.Q.I. and lead identification markers for the
presence of underlying defects.
2
9.0 IDENTIFICATION AND MARKING
9.1 IDENTIFICATION MARKERS
Lead identification markers shall be placed on the section being radiographed
so that at least two markers shall be visible on each radiograph to identify the
actual length being examined. These markers shall be placed an the source
side. Whenever identification markers must be placed on the film side, the
technique shall be such that sufficient film overlap is provided to assure
complete coverage of the full sectional thickness due to angularity. There shall
also be an indication on each film showing the shop order, drawing number and
item of the part being radiographed, Suppliers symbol, and date if space
permits.
Otherwise, such information shall be supplied with the radiographs.
The letter R shall be marked on all radiographs of repair welds. All I.Q.I. shall
be identified by permanently attached lead numbers at least 2.6 mm high.
9.2 IDENTIFICATION AND MARKING COMPONENTS
The location of identification markers shall be accurately and permanently
stamped, if permission has been obtained in writing from the Purchaser, on the
metal surfaces of the component, upon completion of radiography by the
radiograph technician in order that the orientation of the radiograph may be
established.
These markings shall be maintained on the component throughout the
fabrication cycle. In cases where this stamping must be removed as a result of
subsequent machining, it shall be re-established by the machinist or person
removing same. Every effort shall be made to restore the mark in the exact
location where removed. Also, the radiograph technician shall mark the exact
location of the identification markers on the appropriate drawing and file the
drawing permanently with the films.
When permanent stamping is prohibited or impractical, temporary marking of
the identification markers shall be made an the metal surfaces of the
component. This type marking shall be maintained until it has been established
that the area under examination is satisfactory. In these cases, it is of the
utmost importance that the radiograph technician prepare the marked print very
clearly and accurately as this will be the only medium with which to establish
identity with the part and the radiograph.
2
It is very important that work on which radiograph examination has been
performed be shipped with proper identification of the radiograph serial number
and the area stencil numbers intact.
2
10.0 RADIOGRAPHIC REPORT
The radiographic technician shall furnish a written report, together with all
radiographs for all of the radiographic examinations performed, to the
Purchaser. The report shall contain all of the technical data, including the
source size and strength, concerning the radiographic process and technique
used, together with a sketch or marked up drawing correlating his technique
including an interpretation of each individual gammagraph or radiograph.
The final interpretation of radiographs shall be the responsibility of the
Purchaser. Interpretation shall be made by comparison to acceptable standards,
as specified on the manufacturing drawing or specification.
2
11.0. QUALITY LEVEL
Requirements for the quality levels from A to C are listed in Table 1.
Quality level A is mandatory for the TF Coil Cases.
Quality level B is applicable when required by Component Technical
Specifications.
2
12.1 CASTINGS

The acceptability of ferrous and non-ferrous casting examined in accordance
with this specification shall be judged, for X-ray or gamma-ray as specified on
the ordering information, by comparison to the following ASTM Specifications.
E-446 Reference Radiographs for Steel Castings up to 51 mm in Tickness.
E-186 Reference Radiographs for Heavy-Walled (51 to 114 mm) Steel
Castings.
E-280 Reference Radiographs for Heavy-Walled (114 to 305 mm) Steel
Castings.
12.2 WROUGHT MATERIALS
The acceptability of wrought materials (other than castings) examined in
accordance with this specification shall be agreed upon between the Supplier
and Purchaser.
12.3 WELDMENTS
Unless otherwise specified, the acceptability of all welds, regardless of the
thickness or throat depth of the weld, examined in accordance with the
requirements of Quality Level A of Table 1.
2
TABLE 1
QUALITY LEVEL A
Material Form Material Thickness Sensitivity Acceptance Criteria
Less than 100 mm 2 1 T Welds
100 mm and greater 1 1 T
Linear, or linearly aligned, flaws are
rejectable. Porosity or inclusions greater
than 1/10 T or 0.8 mm whichever is less
are rejectable
Less than 100 mm 2 1 T Castings
The acceptance Standards of ASTM E-
446 Class I shall apply
QUALITY LEVEL B
Less than 100 mm 2 2 T Welds
Indications characterised as crack or
incomplete fusion or penetration are
rejectable. Other elongated indication
which has a length greater than _ T are
rejectable. Porosity or rounded
inclusions greater than 1/10 T or 3.0 mm,
whichever is less, are rejectable
Less than 100 mm 2 2 T Castings
The acceptance Standards of ASTM E-
446 Class II shall apply
QUALITY LEVEL C
Welds All thickness 2 4 T Cracks are rejectable. Lack of fusion or
lack of penetration greater than 10% of
the section thickness are rejectable
Castings All thickness 2 4 T The acceptance Standards of ASTM E-
446 Class III shall apply
Note: - T = Material thickness.
- For Quality Level A Type 1 or finer grain film is required.
2
ANNEX D
LIQUID PENETRANT EXAMINATION
2
TABLE OF CONTENTS
1.0 SCOPE
3.0 GENERAL RQUIREMENTS
4.0 MATERIALS
7.0 METHODS
8.0 TECHNIQUE REQUIREMENTS
9.0 QUALITY LEVEL
10.0 ACCEPTANCE STANDARD
12.0 POST-EXAMINATION CLEANING
13.0 MARKING AND REPORTING
TABLES
2
1.0 SCOPE
This specification covers the requirements and procedures for the liquid
penetrant examination of materials and welds. The requirements herein are
intended to be both compatible and supplementary to those specified in the
ASME Boiler and Pressure Vessel Code and ASTM-E-165.
This specification should not be interpreted as prohibiting new or improved
techniques, procedures which do not conform in all respects to this specification
must be submitted to the Purchaser in detail. If they qualify as described in
Section III of the ASME Boiler and Pressure Vessel Code, they may be
approved for use. Written approval of such a procedure shall be provided by the
Purchaser prior to its use.
The applicable code issue and other requirements will be specified in the
NDE procedure specifications.
The Supplier specifications shall be approved by the Purchaser prior any NDE
being performed.
2
Examination.
July 1993.
2
3.0 GENERAL REQUIREMENT
Before testing begins, the Supplier shall prepare liquid penetrant examination
procedures detailing the essential variables of the examination. As a minimum,
the following parameters and requirements shall be detailed in the procedure.
inspected, e.g. sizes, geometries, quality level, etc. and the stage or stages
of manufacture at which examination will be conducted.
c. The brand name and specific type (number or letter designation if available)
of penetrant, penetrant remover, emulsifier, and developer shall be
specified.
d. The processing details of method used for pre-examination cleaning and
drying, including the cleaning materials used and the maximum time
allowed for drying shall be specified.
e. The details of the method for penetrant application, the length of time that
the penetrant remains on the surface, and the temperature of the surface
and penetrant during the examination (if not within the 16 C to 52 C
range) shall be specified.
f. The details method for removing excess penetrant from the surface and for
drying the surface before applying the developer shall be specified.
g. The details of the method for applying the developer, and the length of
developing time before examination shall be specified.
h. The details of the method of post-examination cleaning shall be specified.
j. Qualification and certification of the personnel performing the test.
k. Specific criteria for acceptance and/or reporting the results.
2
4.0 MATERIALS
Penetrant material (penetrant, solvents or cleaning agents, developers, etc.,
used in the examination process) must belong to a single family group. Family
group means that all components (penetrants, solvents or cleaning agents,
emulsifiers, and developers) are manufactured by one Supplier and have been
proven to compliment one another.
Penetrant materials shall be certified to contain less than 1% by weight of
halides or sulphides in the remaining dry residue by the method described in the
ASME Code Section V Article 6. This requirement must be met unless
otherwise specified a drawings and/or other applicable specifications.
2
Surfaces to be examined shall be free of loose scale, dirt, paint, weld spatter or
any other foreign material that might obscure surface openings or otherwise
interfere with the examination.
Examinations shall be conducted prior to surface treatments such as blasting
(shot, sand, grit, or pressure), liquid honing, emery cloth, wire brushes, disc
grinding or sanding, metal scrapers, etc., which would peen, smear or otherwise
plug the metal surface and prevent entrance of the penetrant into unacceptable
discontinuities.
2
2
7.0 METHODS
Either a colour contrast penetrant technique or a fluorescent penetrant
technique shall be used. For each technique, one of the following three types of
penetrant systems is acceptable unless surface conditions or environmental
conditions precludes ad adequate examination.
a. Water washable penetrant method.
b. Post-emulsifiable penetrant method.
c. Solvent removable penetrant method.
2
8.0 TECHNIQUE REQUIREMENTS
8.1 PRE-EXAMINATION CLEANING
It is essential that the examination surface be clean. This shall be interpreted to
include the removal of all rust, scale, welding flux, weld spatter, paint, grease,
oily films, water, dirt, etc. from both the examination surface and from any
defects present.
Any surface irregularities, such as rust, scale, slag etc. which prohibit
interpretation of the test method or which could mask indications of
unacceptable discontinuities must be removed by mm approved method.
Traces of dirt and grease must be removed from the examination surface using
a clean, lint-free cloth saturated with an approved cleaning agent.
Metal-removing processes as sanding, lathe cutting, tumble or vibratory
deburring, and abrasive blasting, often used to prepare part surfaces, may
decrease the effectiveness of the penetrant examination and should only be
used when other non-metal removing processes fail to prepare the surfaces
for proper examination.
Approved cleaning materials are the penetrant solvent, acetone, alcohol, or
isopropanol. No cleaning solvents containing over 1% halogens or sulphides by
weight may be used. The use of other cleaning agents or methods requires
written approval of the Purchaser.
After cleaning it is essential that examination surface be completely dried prior
to application of penetrant. Traces of water or cleaning agent remaining in any
discontinuities are unacceptable.
Drying of the examination surfaces may be accomplished by normal
evaporation or with forced hot air.
A minimum period of time shall be established to ensure that this drying process
has been completed prior to application of the penetrant.
8.2 PENETRANT APPLICATION
Penetrant may be applied by dipping, brushing, flooding, or spraying.
Penetrant time is critical. The length of time the penetrant must remain in on the
examination surface to allow proper penetration will be recommended by the
penetrant manufactures. Longer times may be required depending on the
examination situation.
2
Examination of surfaces at temperatures outside a range of 16 C to 52 C shall
not be permitted without qualification and written approval by the Purchaser.
8.3 EXCESS PENETRANT REMOVAL
After the penetration time has elapsed excess penetrant must be removed from
the surface to provide adequate contrast between indications and background.
Care should be exercised not to remove penetrant from discontinuities.
With water-washable penetrants the excess penetrant shall be removed with a
water spray with a pressure of less than 3.5 Kg/cm
2
and a temperature between
16 C to 43 C.
With solvent removable penetrants the excess penetrant shall be removed with
clean, soft, dry, lint-free rags or cloths which may be moistened with a solvent.
An acceptable technique consists of wiping with clean, soft, dry, lint- free cloths
followed by wiping with cloths moistened with a minimum amount of solvent and
then repeating with dry cloths. Suitable absorbent paper towels may be used in
lieu of cloth materials.
Flushing the surface with solvent following the application of the penetrant
and prior to the application of the developer is strictly prohibited.
With post-emulsifying penetrants, an emulsifier is applied by dipping, brushing,
flooding, or spraying. The length of time that the emulsifier is allowed to remain
an the examination surface and in contact with the penetrant is critical. Nominal
emulsification time should be as recommended by the manufactures. The actual
emulsification time for each specific application should be determined
experimentally. Immediately after the emulsification time elapses, the emulsified
penetrant is removed by a water spray as described in the previous paragraphs.
8.4. DRYING
Drying of the examination surface is necessary either following the application
of an aqueous wet developer or following the removal of the excess penetrant
when a dry or non-aqueous developer is used.
If a water washable or post-emulsifying method is used, the drying process shall
be accomplished by using a hot-air recalculating oven, a hat-air blast, or by
exposure to ambient temperature. The examination surface may not exceed 52
C.
2
If solvent removable method is used, the drying process shall be accomplished
by allowing a minimum of five minutes for normal evaporation.
8.5. DEVELOPING
Aqueous wet developers shall be applied to the examination surface
immediately after the excess penetrant has been removed and prior to drying.
Methods of application include spraying, flowing or immersing. Thick application
or puddles of developer is prohibited.
Non-aqueous developer shall be applied to the examination surface
Immediately after the penetrate removal and drying processes. Apply non-
aqueous developers by spray application as recommended by the Supplier.
Dipping or flooding is prohibited.
Dry developers shall be applied to the examination surface immediately after
the penetrant removal and drying processes. Methods of application include
dipping into a container of dry developer, dipping into a fluid bed of dry
developer, or dusting with the powder developer through a hand powder gun.
Any excess developer may be gently blown away from the surface.
The length of time developer is to remain on the examination surface prior to
inspection should not be less - than 7 minutes or greater than 30 minutes.
Longer developer times are permitted if bleed-out does not alter the
examination results. Developing time begins immediately after the application of
the dry powder developer and as soon as the wet developer (aqueous or non-
aqueous) coating is dry.
8.6. INSPECTION
Due to the rapid diffusion of dye in the developer it is recommended that the
examination surface be observed while applying the developer to aid in the
evaluation of indications.
For colour contrast penetrant methods adequate illumination is essential for
proper examination. A minimum light intensity at the examination surface of 350
lux is recommended. A portable light source for dose inspection of the
examination surface is also recommended.
For fluorescent penetrant methods, general illumination must be quite low and a
black light must be provided.
The black light intensity shall be a minimum of 800 W / cm
2
at the examination
surface.
2
The black light shall be filtered ultraviolet radiation of wavelength within the
range of 330 nm to 390 nm.
The bulb shall be allowed to warm-up a minimum of five (5) minutes prior to
inspection.
The Inspector shall be in the darkened room for at last five (5) minutes prior to
the inspection.
2
9.0. QUALITY LEVEL
Requirements for the various quality levels are listed in Table 1 through 4.
- Quality level A is given in Table 1.
- Quality level B is given in Table 2.
- Quality level C is given in Table 3.
- Quality level D is given in Table 4.
Quality level A, given in Table 1, are mandatory for the TF Coil Cases.
Quality level B, given in Table 2, Quality level C, given in Table 3 and Quality
level D, given in Table 4 are applicable when required by Component Technical
Specifications.
2
10.0 ACCEPTANCE STANDARD
10.1 DEFINITIONS
10.1.1 Relevant indications
Relevant indications are indications which result from imperfections.
10.1.2 Linear indications
Linear indications are indications in which the length is more than three times
the width.
10.1.3 Rounded indications
Rounded indications are indications which are circular or elliptical with the
length equal or less than three times then width.
10.2 ACCEPTANCE STANDARD FOR MATERIALS (Plates, Forgings and
Castings) AND WELDS
Acceptance Standards for Materials and Welds are listed in Table 1 through 4.
2
using an approved repair procedure, provided that the repaired area is retested
and complies with all provisions of this specification, the purchase order, and
the appropriate drawings.
Disposition of discrepant and repaired material shall be documented in
accordance with the non-conformance system procedures wherein the
purchaser will recommended acceptance, further repair, or rejection.
2
12.0 POST-EXAMINATION CLEANING
The penetrant materials shall he removed as soon as possible after inspection
by means of water or solvents in accordance with applicable specification
approved by the Purchaser.
2
Following liquid penetrant examination, all acceptable units or bundles shall be
cleanly and temporarily marked in as permanent a fashion as circumstances
permit. Temporary marking materials containing sulphur and low melting points
elements such as lead in other than trace shall not be used on nickel base
alloys. Temporary marking materials containing halides in other than trace
amounts shall not be used an austenitic stainless steels.
Metal stamping may be used only when approved in writing by the Purchaser.
The Supplier shall prepare a report for each lot which shall include at least the
following.
a. Purchase Order Number and Drawing Number.
b. Serial Number or Heat Number of the examined material.
c. Detailed Procedure Number.
d. Date of test, Inspector, NDE personnel certification level, and other
pertinent information of that nature.
e. A record of repaired areas.
f. Items accepted or rejected.
2
TABLE 1
QUALITY LEVEL A
Material Forms Material Thickness Acceptance Criteria
Materials All Thickness No linear or rounded indications permitted
Welds All Thickness No linear or rounded indications permitted
TABLE 2
QUALITY LEVEL B
Surface examined shall be free of any laps, fissures, cracks or linear
indications
No rounded indication with a maximum dimension of T/10 (T= Thickness
of the thinnest section) or 3 mm whichever is less, is permitted
In any most unfavourably selected 3871 mm
2
(minimum dimensions 25
mm) there shall be no more than six rounded indications and whose sum
of maximum dimensions is no greater than 6.3 mm
Materials All Thickness
There shall be no more than three rounded indications in a line separated
by 1.6 mm edge to edge
indications
No rounded indication with a maximum dimension greater than 1.6 mm is
permitted
2
mm) of the weld and adjacent base metal there shall be no more than six
rounded indications and whose sum of maximum dimensions is no greater
than 4.7mm
Welds All Thickness
2
TABLE 3
QUALITY LEVEL C
indications
No rounded indication with a maximum dimension greater than 3 mm is
permitted
2
mm) there shall be no more than ten rounded indications and whose sum
of maximum dimensions is no greater than 15 mm
Materials All Thickness
by 1.6 mm or less edge to edge
Surface examined shall be free of any laps, fissures, cracks or other
relevant linear indications
No rounded indication with a maximum dimension greater than 3.0 mm is
permitted
2
mm) of the weld and adjacent base metal there shall be no more than ten
rounded indications and whose sum of maximum dimensions is no greater
than 15.0 mm
Welds All Thickness
2
TABLE 4
QUALITY LEVEL D
All Thickness Only imperfections producing indications with major dimensions greater
than 1.6 mm shall be considered relevant imperfections
Less than 16 mm Linear indications longer than 1.6 mm are unacceptable
From 16 mm to under
51 mm
Linear indication longer than 3.2 mm are unacceptable
Greater then 51 mm Linear indication longer than 4.8 mm are unacceptable
Less than 16 mm Rounded indications greater than 3.2 mm are unacceptable
16 mm and greater Rounded indication greater than 4.8 mm are unacceptable
There shall be no more than four or more relevant indications in a line
separated by 1.6 mm edge to edge
Materials
All Thickness
2
there shall be no more than
ten rounded indications and whose sum of maximum dimensions is no
greater than 152 mm with the dimensions taken in the most unfavourable
location relative to the indication being evaluated
Only imperfections producing indications with major dimensions greater
than 1.6 mm shall be considered relevant imperfections
Cracks or linear indications are unacceptable
Rounded indications with dimensions greater than 4.8 mm are
unacceptable
There shall be no more than four or more relevant indications in a line
separated by 1.6 mm edge to edge
Welds All Thickness
2
there shall be no more than
ten rounded indications and whose sum of maximum dimensions is no
greater than 152 mm with the dimensions taken in the most unfavourable
location relative to the indication being evaluated
2
ANNEX E
EDDY CURRENT EXAMINATION OF NON FERROMAGNETIC
TUBING
2
TABLE OF CONTENTS
1.0 SCOPE
3.0 GENERAL
4.0 EQUIPMENT
6.0 CALIBRATION STANDARDS
7.0 CALIBRATION PROCEDURE
8.0 LEVEL OF ACCEPTANCE
10.0 REPAIRS AND RETEST
2
1.0 SCOPE
This specification covers the broad requirements and procedures for the
examination of non-ferromagnetic tubing for safety related applications, by the
use of electromagnetic search coils.
All eddy current tests within the scope of this specification may be classified as
to coil configuration, sensing method, scan pattern, readout method, and
discrimination.
The requirements herein are intended to supplement those specified in the
ASME Boiler and Pressure Vessel Code.
2
Examination.
July 1993.
2
3.0 GENERAL
3.1 EDDY CURRENT EXAMINATION PROCEDURE
Before testing begins, the Supplier shall prepare Eddy Current examination
procedure.
a. Type of material and size to which applicable.
b. The scope of the examination describing in detail the material to be
c. The degree of surface preparation and description of the finish of the
d. The E. C. test System including instrument, type of coil or probe (e.g.,
differential coil).
g. The direction(s) and extent of scanning. The speed of coils movement, the
amount of overlap between scans, and the test system sensibility during
scanning shall also be noted.
h. Qualification and certification of the personnel performing the test.
j. Specific criteria for acceptance and/or reporting results. A sample copy of
k. Automatic alarm and recording equipment, or both, if used.
i. Additional information as necessary to permit retesting.
2
4.0 EQUIPMENT
4.1 COIL CONFIGURATION
4.1.1 Encircling Coil
This configuration consists of a toroid through which the workpiece is fed
forming a central core for the coil.
4.1.2 Internal Coil
This configuration consists of a bobbin type coil designed to fit inside a hollow
work piece.
4.1.3 Solenoid Coil (Probe Coil)
This configuration consists of a solenoid wound coil with or without a core. It
adapts to a wider range of shapes and sizes than 4.1.1 or 4.1.2 but is not
widely used for flaw detection.2.1.3
When wide and fiat this configuration is known as a pancake coil and is used for
interrogating comparatively large areas of the workpiece
4.2 SENSING METHOD
4.2.1 Absolute Coil Voltage
This sensing method consists of monitoring voltage across a sensing coil.
Defects are represented as fluctuations in the voltage.
4.2.2 Change in Absolute Coil Voltage
This sensing method consists of balancing out any voltage across a sensing coil.
Flaw are represented as any voltage above or below the balance point.
4.2.3 Primary Coil Impedance Change
2
This sensing method consists of monitoring soma function of primary coil
impedance. Flaw are represented as a fluctuation in this function.
4.2.4 Differential Coil Null
This sensing method consists of connecting two similar coils in series
opposition and monitoring voltage across the coils, Flaws are normally
represented as an excursion in one direction followed by a fluctuation in the
other direction.
4.3 READ OUT
4.3.1 Oscillograph (pen recorder)
This read-out method is characterised by an oscillograph or a recorder which
plots time or distance against voltage. This system produces a graphic record of
flaw location along scanned length.
4.3.2 Pulse Height Discriminator
This device sorts flaw signals into categories by the use of a graduated gate
system. This discriminator may then be caused to trip relays and alarm devices.
4.3.3 Oscilloscope
This read-out device, often coupled with another read-out method, is useful in
determining phase of a signal.
Voltage may be presented as amplitude of an electron trace from screen centre
and phase as rotational direction around the screen.
The more normal oscilloscope presentation of time versus voltage may be also
used.
4.3.4 Voltmeter
This read-out method is characterised by use of a simple voltmeter to read out
test results.
2
4.3.5 Compliance
For production inspection complying with this specification 4.3.1 or 4.3.2
must be used either alone or with another read-out method. The oscillograph is
strongly recommended and is required for critical quality level.
4.4 DISCRIMINATION
4.4.1 Phase Discriminator
This circuit allows for rejection of flaw signals of a given voltage and phase
acceptance of signals of similar voltage but different phase.
4.4.2 Integration
This circuit allows for acceptance of certain high voltage signals if their time
duration is not great.
4.4.3 Differentiation
This circuit allows for rejection based on rate of rise of a signal rather than upon
amplitude alone.
4.4.4 Frequency Discrimination (Fourier Analysis)
This circuit allows for rejection of flaw signals of a given voltage and frequency
and acceptance of certain signals of similar voltage but different frequency.
4.5 SCANS
Scan shall refer to the relative motion between the search coil and the test
piece during the period of tracing the search pattern.
4.5.1 Longitudinal
This scan pattern consists of relative coil motion essentially parallel to the major
axis of the test piece.
2
4.5.2 Helical
This scan pattern consists of relative coil motion an in a helix which is
essentially co-axial with the test piece.
4.5.3 Lateral (Transverse)
This scan pattern consist of relative coil motion essentially perpendicular to the
major axis of the test piece.
4.5.4 Rectangular Grid
This scan pattern shall consist of scanning along grid lines which normally will
be laid out parallel and perpendicular to the major axis of the test piece. Testing
may be only at grid intersection or along the full grid lines.
2
2
6.0 CALIBRATION STANDARDS
6.1 GENERAL
The standard used to adjust the sensitivity of the apparatus shall be free of
interfering discontinuities and of the same nominal alloy, temper, and nominal
dimensions as the lot of material be examined an a production basis. If shall be
of sufficient dimensions to permit the spacing of artificial discontinuities to
provide good signal resolution, and to be mechanically stable while in the
examining position in the apparatus. Artificial discontinuities placed in the tube
shall be of the following types.
6.1.1 Notch
Longitudinal or transverse notches, or both, may be produced by milling, filing,
EDM (Electro Discharge Machine) or other suitable means. Notches may be
placed on the outer, inner, or both surfaces of the reference standard.
Longitudinal notch standards are normally used when testing with rotating probe
systems.
6.1.2 Hole
The holes shall be drilled radially through the tube wall without causing
permanent distortion of the tube wall,
6.1.3 Hole size and notch configuration
Hole size and notch configuration (type, orientation, length, depth, etc.)
influence the eddy-current response. These factors, plus the method and
tolerances in their measurement, shall be as specified in the agreement
between the Supplier and the Purchaser.
2
7.0 CALIBRATION PROCEDURE
7.1 GENERAL
The calibration standard with artificial (or natural) defects shall be tested ten
times (five in each direction) using the identical coil, speed, phase, frequency
and apparatus to those to be used in testing the work pieces. Each defect must
be clearly above the noise level and each must exceed the level of rejection
each of the fan times.
After each significant change of parameters this calibration procedure shall be
repeated.
After minor change two tests in each direction shall be sufficient.
To check against drift, the standard shall be run intermittently at an interval to
be chosen by the vendor. A single standard run is sufficient for this purpose. If
any standard defect signal fails to exceed the rejection level, all work pieces
tested since the last satisfactory run of the standard shall be retested at new
and satisfactory parameters as proved by calibration above paragraphs.
Rotate the reference standard in either 90 or 120 degrees, increments to
determine the location of the electrical centre in the examining coil.
Mechanically adjust the position of the tube within the coil to obtain nearly equal
responses from the artificial discontinuities regardless of their circumferential
orientation.
7.2 END SIGNALS
The length of tubing not examined due to the end effect may be determined by
selecting a tube of low background noise and making a series of calibration
holes or notches of appropriate intervals near the end of this special tube. Pass
the tube through the test set-up of the production test speed with the artificial
discontinuities end first, and then with the artificial discontinuities end last.
Determine the distance from the tube end to the point at which the signal
response from successive discontinuities is uniform with a recording device
such mm a pen recorder or memory oscilloscope. A signal suppression method
(photo relay, mechanical switches, or proximity devices are commonly used)
may be used to permit examination only when the length of tubing exhibiting
uniform signals is within the test coil. The section of tube passing through the
test coil representing the end effect is not examined.
As an option to above the length of tubing representing the end effect may be
determined by selecting a tube of low background noise and making a
2
calibration hole or notch at a point 152 to 203 mm from the tube end. Pass the
tube through the test coil at the production test speed with the artificial
discontinuity end first and then with the artificial discontinuity end last. If the
artificial discontinuity is not defected, make another artificial discontinuity farther
from the end. If it is detected, cut off 12.7 mm increments from the end of the
tube until the artificial discontinuity is no longer detected. The length from the
tube end to the artificial discontinuity that can be detected is that length of
tubing representing the end effect.
2
8.0 LEVELS OF ACCEPTANCE
Quality Level AND Acceptance standards are listed in Table 1.
All imperfection which produce a response greater than the calibration
standards listed in Table 1 shall be rejected.
TABLE 1
QUALITY LEVEL AND ACCEPTANCE STANDARDS
Quality Level Calibration Standard Calibration Standard Dimensions
Notch (see 7.1.1) Length: 25 mm Maximum
Width: 1.6 mm Maximum
Depth: 5% of nominal wall thickness or 0.10 mm whichever is less
A
Hole (see 7.1.2) 1.6 mm Maximum diameter
Depth: 10% of nominal wall thickness or less
B
Hole (see 7.1.2) 40% of nominal wall thickness or less in diameter
Depth: 12. 5% of nominal wall thickness or less
C
Hole (see 7.1.2) 50% of nominal wall thickness or less in diameter
2
Following eddy current testing all acceptable pieces or bundles of pieces shall
be clearly marked in as permanent a fashion as circumstances permit E.C.
O.K.. If the material is rejectable it shall be segregated and marked E.C.
REJ..
Metal stamping may be used only when specifically permitted by the Purchaser..
For each lot tested, a report shall be submitted listing:
a. Number and Drawing number.
b. Date of test
c. Automatic defect alarm and recording equipment or both if used.
d. Special coils and equipment, if used.
e. Automatic scanning mechanisms, if used,
f. Stage of manufacture when test was made.
g. Surface finish.
h. Description of the calibration method and method of correlating indications
with defects.
j. Scanning directions.
k. Type and size of coils and test frequency.
i. Number of tems accepfed
l. Heat number
m. Any unusual conditions noted during the test.
2
10.0 REPAIRS AND RETEST
10.1 REMOVAL
Unless otherwise specified rejectable defects may be removed, provided that
the affected area is thoroughly retested and compiles with all provisions of this
and other applicable specifications.
10.2 REPAIR
Unless otherwise specified, repairs may be made by the vendor to a procedure
approved by the Purchaser provided the repaired area is thoroughly retested
and complies with all provisions of this and other applicable specifications.

Ansaldo NDT Specifications 22GRKW v1 0

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