NDT Procedure - PCN_test1

Oliveira’s NDT – Porto - PORTUGAL

OLIVEIRA’S

Non-Destructive Testing Procedure

NDT

NDT Proc – UT Welds.001 - Ed.00 from 2016/12/10

1 TITLE Procedure Title:

Ultrasonic inspection procedure for the inspection of single sided, single ‘V’ straight butt-welded carbon steel plate in accordance to EN ISO 17640: 2010 – Non-Destructive Testing – Techniques, testing levels and assessment.

Company:

Oliveira’s NDT

Document nr:

NDT Proc – UT Welds.001 - Ed.00

Name:

Issued by:

Approved by:

Authorized by:

Pedro Oliveira

Fausto Águia

Carlos Vaz

EN ISO 9712 – Level 3 Welds


Site Manager

2016/12/09

2016/12/09

2016/12/10

Signature:

Date:

2 CURRENT STATUS Ed.:

00

Description:

Initial draft / all pages

Date of Release:

Issue by:

Approved by:

Authorized by:

2016/12/10

P.Oliveira

F.Águia

C.Vaz

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OLIVEIRA’S

Oliveira’s NDT – Porto - PORTUGAL Non-Destructive Testing Procedure

NDT

NDT Proc – UT Welds.001 - Ed.00 from 2016/12/10

3 INDEX Section

Title

Page

1

Title.......................................................................................................................0

2

Current Status.......................................................................................................0

3

Index.....................................................................................................................1

4

Figures..................................................................................................................2

5

Tables....................................................................................................................2

6

Scope....................................................................................................................3 6.1 Introduction.................................................................................................... 3 6.2 Details of the Component.............................................................................. 3 6.3 Test Area........................................................................................................ 3

7

Standards and References...................................................................................4

8

Definitions and Abbreviations...............................................................................6

9

Safety....................................................................................................................7

10

Personnel..............................................................................................................8

11

Identification and DATUM Points..........................................................................9

11.1 Identification of the component.....................................................................9 11.2 DATUM points................................................................................................. 9 11.3 Retest............................................................................................................. 9

12

Surface................................................................................................................10

13

Extent of Inspection............................................................................................11

14

Equipment Specification.....................................................................................12

15

Equipment Checks / Calibration Setup...............................................................13

15.1 Linearity of time base.................................................................................. 13 15.2 Linearity of the gain/amplitude....................................................................13 15.3 Probe Index Point and Incident Angle...........................................................14 15.4 DAC curve.................................................................................................... 15 15.5 Couplant....................................................................................................... 16 15.6 Transfer Correction....................................................................................... 16 15.7 Scanning Sensitivity..................................................................................... 17

16

Performance of Testing.......................................................................................18 Page 1 of 33

OLIVEIRA’S

Oliveira’s NDT – Porto - PORTUGAL Non-Destructive Testing Procedure

NDT

NDT Proc – UT Welds.001 - Ed.00 from 2016/12/10 16.1 Visual Inspection.......................................................................................... 18 16.2 Parent Material Inspection............................................................................18 16.3 Weld Examination........................................................................................ 18 16.4 Transverse Scanning.................................................................................... 19

17

Evaluation and sizing Defects............................................................................20

18

Reporting............................................................................................................21

19

Post Examination................................................................................................23

20

Non-compliance Statement................................................................................23

21

Attachments........................................................................................................23

4 FIGURES Figure 1 - Weld Cross Section...............................................................................................3 Figure 2 - DAC typical representation.................................................................................15 Figure 3 - Determination of transfer correction....................................................................16

5 TABLES Table 1 - EN 12668-3:2014 Acceptance Values..................................................................14 Table 2 - Acceptance Criteira...............................................................................................21

6 SCOPE Page 2 of 33

OLIVEIRA’S NDT

Oliveira’s NDT – Porto - PORTUGAL Non-Destructive Testing Procedure NDT Proc – UT Welds.001 - Ed.00 from 2016/12/10

6.1

Introduction

This procedure defines the criteria and general requirements to carry out ultrasonic inspection of single sided, single ‘V’ straight butt-weld, carbon steel plate in accordance to EN ISO 17640: 2010 – Non-Destructive Testing – Techniques, testing levels and assessment, to a testing level B in accordance with table A.1.

6.2

Details of the Component

The component to be tested under this procedure shall me made from carbon steel, 18mm thickness with a weld configuration of 60º preparation angle; 2mm root face and 2mm root gap, welded from both sides, using the MMA welding process. The potential discontinuities and defects likely to be detected in this test are lack of side wall and inter run fusion, lack of penetration, slag inclusion, solidification cracking, heat affected zone/weld toe cracking and porosity. Insert weld cross section

Figure 1 - Weld Cross Section

6.3

Test Area

This procedure is for the ultrasonic inspection of the full length of the weld, heat affected zone and parent material for the full volume of material adjacent to the weld over which angle beam scanning will transverse when scanned from both sides of the plate.

The ultrasonic velocities for which this procedure is written are nominally 5960 m/s ± 50 m/s for longitudinal scanning and 3240 m/s ± 30 m/s for shear wave scanning but these shall be verified at the time of inspection and equivalent calibration.

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7 STANDARDS AND REFERENCES The following standards and references shall be applicable to the undertaking of this procedure: 

EN ISO 9712:2012 – Non-destructive testing – Qualification and certification of NDT personnel;



EN 1330-4:2010 – Non-destructive testing – Terminology. Part 4 – Terms used in ultrasonic testing:



EN ISO 17640:2010 - Non-Destructive testing of welds - Ultrasonic Testing – Technique, testing levels and assessment;



EN ISO 11666: 2011 - Non-Destructive testing of welds - Ultrasonic Testing of welded joints - Acceptance level for UT;



EN ISO 23279:2010 – Non-Destructive testing of welds – Characterization of indications in welds;



EN 12688-1:2010 - Non-Destructive testing of welds – Characterization and Verification of Ultrasonic examination. Part 1 – Instruments;



EN 12688-2:2010 - Non-Destructive testing of welds – Characterization and Verification of Ultrasonic examination. Part 2 – Probes;



EN 12688-3:2013 - Non-Destructive testing of welds – Characterization and Verification of Ultrasonic examination. Part 3 – Combined Equipment;



EN ISO 16810:2014 - Non-Destructive testing – Ultrasonic testing. General principles;



EN ISO 12611:2014 - Non-destructive testing. Ultrasonic testing. Sensitivity and range setting;



EN ISO 16823:2014 - Non-destructive testing. Ultrasonic testing. Transmission technique;



EN ISO 16826:2014 - Non-destructive testing. Ultrasonic testing. Examination for discontinuities perpendicular to the surface;



EN ISO 16827:2014 - Non-destructive testing. Ultrasonic testing. Characterization and sizing of discontinuities;



EN ISO 2400:2012 - Non-destructive testing. Ultrasonic testing. Specification for calibration block No. 1;



BS EN ISO 7963:2010 - Non-destructive testing. Ultrasonic testing. Specification for calibration block No. 2;



NDT UT Instruction for the inspection of double ‘V’ straight butt-welded carbon steel plate in accordance to EN ISO 17640: 2010 – Non-Destructive Testing – Techniques, testing levels and assessment, to a testing level B in accordance with table A.1.; Page 4 of 33

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

PCN DOC PSL/44 and other relevant documentation.

NOTE: All standards and referenced documentation are to latest edition issue unless otherwise specified and agreed to prior to the inspection.

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8 DEFINITIONS AND ABBREVIATIONS The specific definitions and abbreviation that shall apply to this procedure are as specified in EN 10330-4 and elsewhere. Nominally they are as follow: Symbol

Description

h

Extension of the defect in depth

l

Length of defect

lx

Length of the defect in x direction

ly

Length of the defect on y direction

lh

Height of the defect in z direction

H0

Scanning sensitivity

H

Indication Amplitude

X

Position of the indication in longitudinal direction

Y

Position of the indication in transverse direction

z

Position of the indication in height

UT

Ultrasonic testing

DAC

Distance Amplitude Correction

SDH

Side drilled holes

FSH

Full screen height

BWE

Back wall echo

SBWE

Second back wall echo

MBPL

Maximum beam path length

HAZ

Heat affected zone

NDT

Non-Destructive testing

PPE

Personal Protective Equipment

MMA

Manuel Metal Arc weld

HSE

Health and Safety Executive

COSHH MSDS PCN S PWHT

Control of Substances Hazardous to Health Material Safety Data Sheets Personal Certification in non-destructive testing Difference between sound path Post Weld Heat Treatment

Other definitions as listed in EN 1330-4 shall apply. There are no non-standard definitions applicable to this procedure.

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9 SAFETY This procedure shall be undertaken in accordance with all relevant safety regulations, local rules and guidelines. Ultrasonic examinations require the use of couplant and cleaning fluids, some of which may be hazardous to health. Specified site PPE shall be worn all times when conducting inspections in accordance to this procedure. As minimum safety glasses, gloves, ear plugs and boots shall be worn.

For further information the following shall be consulted for reference: Health and Safety Executive COSHH Regulations Local Rules Site Specific Rules Company Health and Safety Procedure on NDT Material Safety Data Sheets Manual Handling Procedures

10 PERSONNEL Page 7 of 33

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Personnel performing inspections in accordance to this procedure shall be qualified to a minimum of Level 2, UT welds, in accordance to EN ISO 9712:2012 or equivalent. Shall have a minimum of 12 months experience in similar tests and be familiar with the welding process use. Operator and hold a valid eye-sight certificate to a minimum of Jaeger No.1 or Times New Roman N4.5, and should be able to distinguish and differentiate contrast on Ishihara plates. Evaluation and validation of test results shall be performed by personnel qualified to a minimum of Level 2, UT welds, in accordance to EN ISO 9712:2012 or equivalent.

11 IDENTIFICATION AND DATUM POINTS

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The component is to be uniquely identified using an alphanumeric identification system permanent marked at the DATUM point (Master) side.

11.1 Identification of the component 138D All records shall nominate the relevant unique identification for traceability.

11.2 DATUM points DATUM points are as nominated on the Reporting Diagram, refer to section 21 of this procedure. All reference is to and from the DATUM point (Master) side of the component. The centerline of the weld is to be marked on the component, on each side of the plate, for stand of distance measurement and discontinuity position reference.

11.3 Retest Where a retest is called for, an additional suffix ‘R’ shall be added to the identification to signify that the additional inspection was a retest activity.

12 SURFACE

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Scanning surface shall be even (less than 0.5mm deviation) and free from foreign material or mechanical damage which may impede accurate scanning and assessment of the component (e.g. scale, spatter, paint...). Surface shall permit full and uniform coupling. Surface roughness shall not be greater than 6.3m on the areas transversed by the ultrasonic probes. Component surface temperature shall remain within ±15ºC of the calibration standard used for the calibration setup.

13 EXTENT OF INSPECTION Page 10 of 33

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100% of the weld body, HAZ from each side of the weld (10mm from the weld toe either side), on both side of the component. For the conduct of tests in accordance to this procedure visual inspection shall be carried out on the full length of the weld, HAZ and adjacent parent material from both sides of the weld and both sides of the component, with a width of not less than 5.5t+Probe width dimensions. This visual inspection is intended to detect any discontinuities that may interfere with scanning. Any discontinuities detected shall be recorded as part of this inspection.

14 EQUIPMENT SPECIFICATION The equipment used during this procedure shall be as follow: Page 11 of 33

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A-Scan, Pulse-echo unit (e.g. GE USM35X) compliant with EN 12668-1:2000; Ultrasonic Twin Crystal probe, 0º, 10mm diameter, 5MHz; Ultrasonic Shear Wave probe, 45º, 10mm diameter, 4MHz; Ultrasonic Shear Wave probe, 60º, 10mm diameter, 4MHz; Ultrasonic Shear Wave probe, 70º, 10mm diameter, 4MHz; Ultrasonic Calibration Block, A2 Block, Carbon Steel; Ultrasonic Calibration Block, A4 Block, Carbon Steel; Ultrasonic Calibration Block, A5 Block, Carbon Steel; Ultrasonic Calibration Block, A7 Block, Carbon Steel; Ultrasonic Calibration Block, DAC Block, Carbon Steel Probes Leads/Connectors; Magnetic guides/rulers Marker Pen and Beam plotting Material;

Probes shall comply with the requirements of EN 12668-2:2010. The overall equipment shall comply with EN 12668-3:2000 and hold a valid calibration certificate and calibration status, and this shall be undertaken within the last week or sooner.

15 EQUIPMENT CHECKS / CALIBRATION SETUP The equipment checks and calibrations setup to be applied to this procedure shall be as follow:

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

The equipment shell be verified for completeness and correct operation (physical state) prior to commencement of this procedure.



The ultrasonic test unit shall have current calibration status and this shall have been, if required, due to service or maintenance requirements and or in accordance with EN 12688-3:2013.

Nominally, linearity of time base and gain/amplitude shall be carried out weekly. This shall be undertaken utilizing the A2 block and a 0º probe.

15.1 Linearity of time base a. Place the 0º ultrasonic probe on the 25mm thick section of the A2 block; b. Adjust the range and gain to obtain 10 BWE signals, the first of which shall be raised to 80% FSH; c. Adjust delay control to bring the first BWE to alignment with the first graticule on the time base line; d. Adjust the gain control to bring the sixth BWE to 80% FSH; e. Check horizontal position of sixth BWE relative to the sixth graticule on the time base line; f. Record the variance. Linearity of time base is compliant if the tolerance at the assessed graticule is less than ±2% FSW.

15.2 Linearity of the gain/amplitude a. Place 0º ultrasonic probe on the A2 block above 1.5mm SDH; b. Adjust the range and gain to bring the signal to mid-way along the time base line and to 80% FSH. Note gain setting; c. Adjust gain by 2 dB, confirm signal goes to approximately 101%FSH, and record this actual value of signal amplitude. d. Reduce gain to original value and confirm signal to returns to 80%FSH, reduce the gain for a further 6dB, confirm signal goes to approximately 40%FSH and record this actual value of signal amplitude; e. Reduce gain by a further 6dB, confirm signal goes to approximately 20%FSH and record this actual value of signal amplitude. f. Reduce gain by a further 6dB, confirm signal goes to approximately 10%FSH and record this actual value of signal amplitude.

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g. Reduce gain by a further 6dB, confirm signal goes to approximately 5%FSH and record this actual value of signal amplitude. h. Determine compliance by assessing against the following table as per EN 126683:2014 Gain [dB]

Excepted Screen Height

Limits

+2

101%

>95%FSH

0

80%

80%FSH

-6

40%

37-43%FSH

-12

20%

17-23%FSH

-18

10%

8-12%FSH

-24

5%

< 8%FSH

Table 1 - EN 12668-3:2014 Acceptance Values

Linearity of gain/amplitude is compliant if the tolerance at the assessed screen height and gain setting is within the limits above. The current status of this calibration check shall be entered upon the master equipment record card and the test report format, refer to section 21.

15.3 Probe Index Point and Incident Angle The ultrasonic probes shall have a current verification for angle, ‘0’ index point verification and resolution status and this shall have been undertaken in accordance with and EN 12668-2-2010 prior to and during the performance of this procedure. Nominally this shall be carried out on a daily basis whilst the ultrasonic unit is in service. Probe index point verification shall be undertaken utilizing either the A2 block or the A4 block and each of the angle beam (45º, 60º and 70º) ultrasonic probes. This shall be undertaken by maximizing the signal of the 100mm radius of the A2 block or the 25mm radius of the A4 block. The relative probe position shall be marked upon each probe body, on each side of the probe and the distance from the index point to the front/edge of the probe shall be recorded on the equipment record card. The maximum allowable variation shall be ±1 mm (1 graduation). The incident angle shall be verified for the 45º, 60º and 70º probes, and the probe wear surface ‘reshoed’ and gently lapped to adjust to the correct angle if wear is evident. The correct angle verification shall be undertaken using the Perspex plug on the A2 block as the reflector and the graduated angle scale on the block as the angle confirmation.

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Note: Current status of verification shall be entered upon the test report format, refer to section 21 of this procedure.

15.4 DAC curve A Distance Amplitude Correction curve shall be plotted for each of the angle beam probes to be utilized during this inspection for the varying beam path lengths for the testing of the component. This can be undertaken using the ‘onboard electronic’ programming of the ultrasonic test unit or by using a screen overlay. Nominally this is performed by initially selecting the range to be utilized for the angle beam probes. The probe is then placed in the position to maximizing the signal response from the uppermost SDH in the DAC block and the gain setting is adjusting so that it achieves 80%FSH. This dB setting is recorded/saved and the trace maximum peak either electronically captured or hard marked in the overlay using a permanent marker. The probe is then repositioned to maximize the signal response from the next lower SDH and the trace maximum peak either electronically captured or hard marked. This is repeated on each of the subsequent SDH’s until the full range of the beam path is plotted for DAC correction. This process shall be repeated for each of the others angle beam probes used during this inspection until the full set of probes has been plotted for DAC. Refer below showing a typical DAC curve representation for an angle beam probe.

Figure 2 - DAC typical representation

The ultrasonic calibration blocks used for the initial calibration of the ultrasonic test unit and the ultrasonic probes shall be in accordance with the requirements of EN ISO 2400:2012 for the A2 block and EN ISO 7963:2010 for the A4 block. DAC block shall be in accordance to EN ISO 16811:2014. Page 15 of 33

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15.5 Couplant The couplant utilized during this procedure shall be of sufficient viscosity and inherent wetting ability to ensure good coupling of the probe to the test component and be of low acoustic impedance. Batch numbers shall be maintained on record. The couplant used during this procedure shall be entered upon the test report format, refer to section 20 of this procedure.

15.6 Transfer Correction Transfer correction shall be assessed and any variation between calibration block and component shall be adjusted for and recorded. As you cannot get a BWE with angle probes from a plate or pipe wall, you have to use two probes with the same angle. Place the two probes on the DAC block, first in V-formation, and then in W-formation, and the gain settings required to bring to the same height on the screen are recorded (values VA1 and VA2 respectively). The probes are then similarly positioned on the component, and the procedure repeated (Values VB1 and VB2). The recorded gain values are plotted against the sound path length, and lines drawn through each pair of points. The transfer correction, V, is given by the difference in gain between the two lines at the appropriate sound path length.

Figure 3 - Determination of transfer correction

Note: Transfer loss/coupling loss can significantly influence the assessment of signal response and must be assessed and accounted for. The range from a 2dB up to 12dB can be accounted for by correction. Page 16 of 33

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Any greater losses shall require supervision advice prior to proceeding.

15.7 Scanning Sensitivity Scanning sensitivity shall be 80%FSH on the SBWE at MBPL for the 0º twin crystal probe. Scanning sensitivity for the angle beam probes shall be determined by the DAC gain setting + transfer correction assessed + 2dB. These shall be entered upon the test report format, refer to section 21 of this procedure.

Scanning sensitivity, correction loss and coupling are to be regularly checked and verified at no greater than 4h intervals. Probe near zone limits for discontinuities near to the scanning surface shall be allowed for by scanning at full skip distances or by scanning from other side of the component. Any equipment, which is unserviceable, out of tolerance or is not operating to requirement shall be removed from service, tagged out and sent for assessment/repair by a certify person. Records shall be kept on file for all equipment as the current status shall be entered.

16 PERFORMANCE OF TESTING The performance of the test procedure undertaken in accordance with the specific requirements of the NDT instructions, refer to section 21, and as follow:

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16.1 Visual Inspection The full length of the weld, HAZ and adjacent parent material shall be visually inspected on both sides of the weld, both sides of the component for discontinuities that may impede with the longitudinal and angle beam inspection of the weld, HAZ and parent material. All such discontinuities noted shall be recorded as part of this inspection.

16.2 Parent Material Inspection The full surface of the component shall be longitudinal beam scanned using the twin crystal 0º probe to detect lamination type discontinuities within the parent material, which may impede the accurate angle beam scanning of the weld, and determine component thickness. This shall be performed utilizing the scanning pattern as per section 21 (written instruction) of this procedure. All scanning runs will overlap a minimum of 10% to ensure the full coverage of the scanned area. Inspection extent shall comprehend the full length of the weld and a width of a minimum of 5.5t+probe width on each side of the weld toe. A scanning speed of no greater than 50mm per second shall be used. All discontinuities of greater than 40%FSH on the SBWE noted during this part of the inspection shall be sized for length, breadth and relative position, shall recorded and a statement limiting the validity of the further inspection across this area shall be declared. Supervision advice shall be sought prior to proceeding further with this procedure if discontinuities are identified during scan.

16.3 Weld Examination A critical root scan shall be carried out from both sides of the weld, with at least the 70º probe directed perpendicular to the weld axis so as to distinguish between root variations and the existence of root defects or crack-like defects.

This may be done where practicable with the aid of a magnetic strip ruler placed so that the distance from the probe index will be constant. This distance shall be set to t * tan(70º) + ½ root gap The body and fusion faces of the weld shall be then inspected using a continuous scanning raster from both sides of the weld between the weld toe and full skip plus the cap width using 60º and 45º angle probes. 60 º angle probes are more suitable for detecting side wall defects taken in consideration the preparation angle. The scanning shall be performed at approximate right angles to the weld axis from both sides for the detection of discontinuities parallel to the weld axis. Page 18 of 33

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A scanning speed of no greater than 50mm per second shall be used. For scanning schemes, refer to section 21 (written instruction).

16.4 Transverse Scanning The 45º angle probe shall be used directed essentially parallel to the weld axis and shall be manipulated so that the angle beam passes through the required volumes of weld, HAZ and adjacent parent material in order to detect discontinuities oriented transverse to the weld axis. This operation shall be performed on both sides of the weld and both directions, making a total of 4 scans. A scanning speed of no greater than 50mm per second shall be used. For scanning schemes, refer to section 21 (written instruction).

17 EVALUATION AND SIZING DEFECTS Any discontinuities which cause an indication in excess of -14dB scanning level shall be investigated to the extent that it can be evaluated in terms of the acceptance criteria. The indication shall be investigated to: 

Confirm its existence;



Determine its location with reference to the established DATUM points;

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

Determine its size;



Determine its depth.

For length sizing, 6dB drop technique shall be used. This technique consists by maximize the indication using gain setting until 100%FSH has been achieved. By moving laterally the probe until the signal drops to 50%FSH (-6dB), the front/center of the probe indicates the position of one of the ends of the indication. With gain at the same level, the probe shall be moved laterally in the opposite direction. The signal will increase in height at the screen and when it drops again to 50%FSH (-6dB) at the front/center of the probe it will be the other end of the indication.

For through thickness dimension 20dB drop technique. This technique consists by maximize the indication using gain setting until 100%FSH has been achieved. By moving traversing, towards the weld, until the signal drops 1/10 (-20dB), the stand of to centerline and the corresponded sound path shall be noted. Move the probe in the opposite direction until the signal drops 1/10 (-20dB), take note of stand of and sound path of this signal. Through thickness dimension is assessed by calculating lh=S x cos (probe angle) being S the difference between the sound paths noted.

18 REPORTING Upon completion of the test the operator shall prepare an examination report using the approved report sheet, refer to section 21 for template. All restrictions which limit the effectiveness of the test must be recorded.

Defects shall be stated as acceptable or non-acceptable according to table 2.

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H

l

Acceptable/Non-Acceptable

Gain Assessed [dB]

Length [mm]

H > H0

Any

Non-Acceptable

H ≤ H0

l ≤ 0,5t

Non-Acceptable

H > H0 - 6dB

0,5t > l ≤ t

Non-Acceptable

H > H0 - 10dB

l>t

Non-Acceptable

Table 2 - Acceptance Criteira

All other indications shall be considered acceptable. Recording levels are 4 dB below the corresponding acceptance levels. The report shall contain as minimum: a. identification of the object under test (material and product form, dimensions, location of weld/welded joint examined, reference to the welding procedure, specification and heat treatment, state of manufacture, surface conditions, temperature of the component); b. place and date of testing; c. identification of test organizations and identification and certification of operator; d. maker and type of ultrasonic instrument with identification number; e. maker, type, nominal frequency, size of element and actual angle of incidence of probes used; f. identification of reference blocks used; g. couplant medium; h. testing level(s) and reference to written procedure when used; i. Reference standards j. extent of testing; k. location of the scanning areas; l. reference points and details of coordinate system used; m. identification of probe positions; n. time base range;

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o. method and values used for sensitivity setting (gain setting for reference levels and values used for transfer corrections); p. reference levels; q. result of the parent material test; r. standards for acceptance levels; s. deviations from this International Standard, or contract requirements; t. coordinates of the indication, with details of associated probes and corresponding probe positions; u. maximum echo amplitude and information on the type and size of defect; v. lengths of defects; w. results of evaluation according to specified acceptance levels;

19 POST EXAMINATION All traces of couplant, markings, water or other contaminants are to be removed from component surfaces. Light covering of oil applied prior to storage. Component to be tagged with ‘Inspection Approved’ green label in case of no indications or acceptable indications only are found. Component to be tagged with ‘Inspection Reproved’ red label in case of non-acceptable indications are found. Page 22 of 33

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20 NON-COMPLIANCE STATEMENT If any aspects of this Procedure are contradictory, cannot be interpreted or carried out as intended then this procedure and any associated instructions are top e ceased immediately and supervision approval/advice to be sought prior to recommencing.

All records are to be completed to the point of ceasing the procedure and these are to be supplied to supervision for reference.

The test piece is to be marked as ‘Inspection on hold’, surface preservative applied as/if required and be placed in ‘Quarantine Area’ subject to approval to recommence this inspection procedure.

21 ATTACHMENTS 

Written Instruction



“Ultrasonic Test Report” form



“Equipment Checks / Calibration Setup” form



Drawings and Scanning Patterns

1 TITLE

Document Title:

Ultrasonic inspection written instruction for the inspection of single sided, single ‘V’ straight butt-welded carbon steel plate in accordance to EN ISO 17640: 2010 – Non-Destructive Testing – Techniques, testing levels and assessment.

Company:

Oliveira’s NDT

Page 23 of 33


OLIVEIRA’S

Non-Destructive Testing Procedure

NDT

NDT Proc – UT Welds.001 - Ed.00 from 2016/12/10 Document nr:

Name:

NDT WI – UT Welds.001 - Ed.00

Issued by:

Approved by:

Authorized by:

Pedro Oliveira

Fausto Águia

Carlos Vaz



Site Manager

2016/12/09

2016/12/09

2016/12/10

Signature:

Date:

2 CURRENT STATUS Ed.:

00

Description:

Initial draft / all pages

Date of Release:

Issue by:

Approved by:

Authorized by:

2016/12/10

P.Oliveira

F.Águia

C.Vaz

3 PURPOSE OF TEST

100% examination to find defects in weld body and HAZ carried out in accordance with EN ISO 17640:2010 – Technique 1, testing level 2 and UT Proc. – UT Welds.001 – Ed.00

4 AREA OF TEST

100% of weld body, HAZ and 10mm parent material either side of weld.

5 COMPONENT REFERENCE

138D

6 COMPONENT

18mm carbon steel plate, with 60º preparation angle, a 2mm

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DESCRIPTION

root face and a 2mm root gap, welded by MMA welding process

7 STAGE OF MANUFACTURE

After PWHT

8 SURFACE CONDITION

Scanning surfaces shall be even and free from foreign matter likely to interfere with probe movement or coupling (e.g. rust, scale, spatter...) Scanning surfaces shall permit full and uniform coupling and have a roughness not more than 6,3µm.

9 SAFETY

Care to be taken when lifting components. Company statutory national Health and Safety procedures shall be adhered to. Correct PPE shall be worn all times when conducting inspections according to this written instruction. Refer to section 9 of NDT Proc – UT Welds.001 Ed.00 for further information.

10 PERSONNEL

Refer to section 10 of NDT Proc – UT Welds.001 Ed.00 for further information.

11 EQUIPMENT

A-Scan, Pulse-echo unit (e.g. GE USM35X) compliant with EN 12668-1:2000; Ultrasonic Twin Crystal probe, 0º, 10mm diameter, 5MHz; Ultrasonic Shear Wave probe, 45º, 10mm diameter, 4MHz; Ultrasonic Shear Wave probe, 60º, 10mm diameter, 4MHz; Ultrasonic Shear Wave probe, 70º, 10mm diameter, 4MHz; Ultrasonic Calibration Block, A2 Block, Carbon Steel; Ultrasonic Calibration Block, A4 Block, Carbon Steel; Ultrasonic Calibration Block, DAC Block, Carbon Steel Probes Leads/Connectors; Magnetic guides/rulers Marker Pen and Beam plotting Material; Please refer to section 12 of NDT Proc – UT Welds.001 Ed.00 for equipment compliance

12 COUPLANT

UCA1 – Ultragel or equivalent.

13 TIME BASE

For 0º Compression probes : 0-100mm Page 25 of 33

OLIVEIRA’S NDT


CALIBRATION For 45º angle probe: 0-100mm For 60º and 70º probes: 0-200mm 14 SENSITIVITY SETTINGS

DAC plotted for all angle probes from the 3mm SDH.

15 TRANSFER CORRECTION

Transfer correction to be assessed in accordance to EN ISO 16811:2014, refer to section 15.6 of NDT Proc – UT Welds.001 Ed.00. 0º Compression probe – SBWE at FSH

16 VISUAL INSPECTION

Carry out visual inspection of surface and report irregularities or non-conformance to supervisor

17 EQUIPMENT CHECKS AND CALIBRATION

All equipment to be tested in accordance with EN 12668-3

any

Linearity of time base, Linearity of the gain/amplitude and Probe Index Point and Incident Angle shall be assessed. Refer to section 15 of NDT Proc – UT Welds.001 Ed.00 Records of all checks and calibrations to be kept.

18 SCANNING

Scan 1 – 0º compression wave scan to all surface where ultrasonic examination will be conducted. Scan width shall comprehend HAZ and 5.5t+probe width from the weld toe, on each side of the full length of the weld. Scan 2 – Fixed root scan with 70º angle probe at ½ skip distance + ½ root gap, from the centerline of the weld. Scan 3 – 60º angle probe scan for fusion faces and weld body. Scan 4 – 45º angle probe scan for weld body inclusions and confirmation of any indications detected with previous scan Scan 5 – 45º angle probe for transverse scanning of the weld for the detection of transverse indications. Maximum scanning speed 50 mm/s. Scanning level for 0º probe – SBWE at FSH Scanning level for angle probes – DAC reference level + transfer correction + 2dB, for each probe respectively. Refer to section 16 of NDT Proc – UT Welds.001 Ed.00

19 EVALUATION OF INDICATIONS

All indications equal or exceeding scanning level 114dB shall be evaluated using beam spread geometry technique to Page 26 of 33

OLIVEIRA’S NDT

Oliveira’s NDT – Porto - PORTUGAL Non-Destructive Testing Procedure NDT Proc – UT Welds.001 - Ed.00 from 2016/12/10 establish maximum echo amplitude, length, through wall dimensions and defect characterization. For assessing length 6dB drop technique shall be use. For assessing through wall dimension 20dB drop technique shall be use. Refer to section 17 of NDT Proc – UT Welds.001 Ed.00 for guidance.

20 REPORTING

All inspections to be recorded on approved report format. Identification of the weld following information to be recorded for each defect (length, maximum amplitude, depth, through wall dimension, position with respect to DATUM and defect characterization) shall be recorded. Refer to section 18 of NDT Proc – UT Welds.002 Ed.00 for acceptance criteria and reporting. Sketches to be produce for each defect evaluated giving length, maximum amplitude, depth, through wall dimension, position with respect to DATUM and defect characterization. An overall plan view shall be produced giving all defects positions in respect to DATUM.

21 NONCOMPLIANCE

Any non-conformance in relation to this written instruction shall be brought to the supervisor’s attention immediately. All work shall be stopped and area be safely controlled. Work shall be restart only after non-conformance be solved or instructions being given by supervisor or by him designated.

22 POST EXAMINATION

All traces of couplant, markings, water or other contaminants are to be removed from component surfaces. Light covering of oil applied prior to storage.

0º compression probe scanning

Page 27 of 33

OLIVEIRA’S NDT


Angle probes scanning (cross section)

Page 28 of 33


OLIVEIRA’S

Ultrasonic Examination Report

NDT Client:

Report nr

Component:

Date of Test

Extent of inspection Reference documents: Standard Technique

Testing level

Others:

Item inspected Material

Stage of Manufacture

Surface condition

Dimensions

Equipment Make and Model

Serial number

Probes Make and Model

Angle of Incidence

Frequency [MHz]

Range [mm]

Serial number

Reference Gain [dB]

Couplant Type

Batch no

Test Settings Blocks: Reporting level

Acceptance level

Probe positions

Results Indication

Coordinates

Length

Through

Maximum

Type of

Accept/Reject

OLIVEIRA’S NDT

Oliveira’s NDT – Porto - PORTUGAL Ultrasonic Examination Report

nr

Thickness X

Remarks

Y

Amplitude

Indication

OLIVEIRA’S NDT

Oliveira’s NDT – Porto - PORTUGAL Ultrasonic Equipment Checks Attached to Report nr:_________________

Date:___________

Linearity of time base

Value of FSW: Value read:

Linearity of time base is compliant if the tolerance at the assessed graticule is less than ±2% FSW.

Linearity of the gain/amplitude

Gain [dB]

Excepted Screen Height

Actual Screen Height

+2

101%

>95%FSH

0

80%

80%FSH

-6

40%

37-43%FSH

-12

20%

17-23%FSH

-18

10%

8-12%FSH

-24

5%

< 8%FSH

Limits

Probe Index Point and Incident Angle Make / Model

Serial number

Distance of Index Point to front edge [mm]

Index Marked (Y/N)

Angle of Incidence OK (Y/N)

NDT Procedure - PCN_test1

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