Nde-procedures (rt, Vt, Ut, Pt, Pmi)

Plant

Client

Fertilizer Complex

BFI Brunei BFI Fertilizer Industries

Code

Doc ID Code

Project No.

PDE-EQS-02-DZ-0082

KXEO-00045

NDE-procedures (RT, VT, UT, PT, PMI) Pages attached

34

NDE-Procedures (RT, VT, UT, PT, PMI)

Updated acc. TkIs comments

10.12.18 wnt

10.12.18 sds

10.12.18 dab

00

First Issue

13.11.18 wnt

13.11.18 sds

13.11.18 dab

Rev. Status

Description

Date

Prepared

Date

Checked

Bar code

Date

Approved

2 AC

Category Code

01

Manufacturer:

BBM-Akustik Industrie GmbH, Ziegelweg 7, D-01640 Coswig

Inspector:

Mr. Tilo Sperling

Document number:

AA 17.4

(Rev. 01/2015)

VT- TEST INSTRUCTIONS

Pos.

Contents

Page

1

Application area

2

2

General Requirements

2

3

General

2

4

Technical auxiliary means

2

4.1

Use of gauges and measuring equipment

2

4.2

Use of magnifiers

2

Acceptance standards

2

5.1

Reference Code ASME B31.1-2010

3

5.2

Reference Code DIN EN ISO 5817

3

VT- Test reports

3

5

6

5

Comments added

16.01.2015

T. Sperling

T. Sperling (VT – Level 2)

U. Mütterlein

4

Revision AWS D1.1

01.08.2013

T. Sperling

T. Reuß (VT – Level 2)

T. Sperling

3

Revision

09.10.2013

U. Mütterlein

T. Reuß (VT – Level 2)

U. Mütterlein

2

Final issue

19.09.2012

I. Salvenmoser (VT – Level 2

H. Dittrich (QM)

T. Reuß (VT – Level 2)

1

Revision

31.05.2011

I. Salvenmoser (VT – Level 2

H. Dittrich (QM)

T. Reuß (VT – Level 2)

0

First issue

11.05.2011

I. Salvenmoser (VT – Level 2

H. Dittrich (QM)

T. Reuß (VT – Level 2)

Rev.

Revision

Date

Created

Controlled

Approved

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Page 1 of 3

1

Manufacturer:

BBM-Akustik Industrie GmbH, Ziegelweg 7, D-01640 Coswig

Inspector:

Mr. Tilo Sperling

Document number:

AA 17.4

(Rev. 01/2015)

Application area

This procedure is applicable to the execution of visual inspections of welded joints.

2

General requirements

Personnel charged with the execution of inspections must be qualified and familiar with ASME V Art. 9 and ASME VIII Div. 1 UW 35, UW 36, UW 37 and ASME IX. Furthermore, an annual test of vision carried out by an ophthalmologist / certified optician has to be submitted. The testing instruction is also conform with AWS D1.1. Additional the requirements of ASME B31.1 are fulfilled.

3

General

Inspection is carried out under improved visual conditions (luminance  1000lx, visual angle  30°, nonglaring, sight line). The distance between the inspector’s eye and the object to be examined is 600 mm at maximum. The scope of inspection is 100 %. In case of doubt, a different non-destructive procedure (e. g. MT test) has to be realised.

4

Technical auxiliary means

4.1

Use of gauges and measuring equipment

Measuring equipment and gauges are used to check the size and quality of the fabricated weldseam. To support a proper evaluation the surface of the weldseam has to be cleaned of remainings from the oxidation process, from sputter and other contaminitions. A suitable tool as a brush shall be used to achieve this state.

4.2

Use of magnifiers

For a better classification of surface defects it is possible to use magnifiers (max. enlargement 12x). For this purpose, the area to be examined has to be illuminated very well. Furthermore, control mirrors and the like will be used.

5.

Evaluation

The evaluation has to be done according the acceptance standards of the referencing code sections.

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Manufacturer:

BBM-Akustik Industrie GmbH, Ziegelweg 7, D-01640 Coswig

Inspector:

Mr. Tilo Sperling

Document number:

AA 17.4

5.1

(Rev. 01/2015)

Reference Code ASME B31.1-2010

Is the reference code B 31.1 Visual examination shall be performed in accordance with the methods described in Section V, Article 9, of ASME Boiler and Pressure Vessel Code. The evaluation is defined in B31.1. Section 136.4.2 defines acceptance standards. Unacceptable are: •

Cracks – external surface

•

Undercuts

•

Lack of fusion on surface

•

Incomplete penetration

•

Other linear (l=> 3*width) indications being longer than l > 5mm

•

Circular surface porosity of a single indication of 5 mm or max. 4 indications with 2 mm diameter in an edge to edge direction. Rounded indications (l=< 3*width)

5.2

Reference DIN EN ISO 5817

Under this code the given tables have to be used for the evaluation. Commonly pressure parts need to be evaluated according the criteria’s of class B non-pressure parts as casings of class C.

6

VT test report

A written report of the examination shall contain the following information:

(a) the date of examination; (b) procedure identification and revision used; (c) technique used; + equipment (d) results of the examination; (e) examination personnel identity, and, when required by referencing Code Section, qualification level; (f) identification of the part or component examined; (g) Luminance measured

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ZWP ERNST GmbH - Zerstörungsfreie Werkstoffprüfung Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Magnetic Particle Examination Procedure

1. Purpose These test instructions specify the method of magnetic particle tests using AC-electromagnetic yoke (MT test) of welding seams on ferromagnetic material according to ASME Sect. V Art. 7.

2. Scope The test specification applies to magnetic particle of magnetisable materials and welded connexions. In case of magnetisable steel types, preference should be given to the magnetic particle test instead of the dye penetrant inspection.

3. Regulations

ASME Sec. I, app. A-260, ASME Sec. V, Art. 7, ASME Sec. VIII, Div. 1, app. 6, PES-AD6

Edition 2017 Edition 2017 Edition 2017

4. Staff qualification The personnel shall be qualified and certified in conformity with DIN EN ISO 9712 or SNT-TC-1A. Execution of tests and evaluation of test results: at least level 2 according to DIN EN ISO 9712 or SNT-TC-1A. All testers working in the inspection must have an eye test certificate not older than 12 months.

5. Time and scope of testing The time and scope of testing works shall be taken from the purchaser’s instruction and order documents (drawings, inspection plans). Special attention is to be paid to the inspection time with regard to thermal treatments prescribed. Only thin, one-layer colour coatings are allowed.

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ZWP ERNST GmbH - Zerstörungsfreie Werkstoffprüfung Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Magnetic Particle Examination Procedure

6. Surface preparation Surfaces to be tested and the adjacent area of at least 25 mm, shall be free from rust, scales, spatters, scores or other contaminations impeding the inspection (paint coats see section 5). The test area shall be dry as well as free from grease and oil. Depending on the test equipment, maximum admissible temperatures are to be taken into account. Nonmagnetic (white) surface contrast may be applied by the examiner to uncoated surfaces, only in amounts sufficient to enhance (black) particle contrast. This contrast background must be used from the same test system. 7. Test system The test is performed using wet, no fluorescent ferromagnetic particles with white priming colour. The use of the following test materials is recommended: -

Ferromagnetic particles, wet, no fluorescent: DIFFUTHERM MPS-S White priming colour (background): DIFFUTHERM DPM

Manufakturer: HELMUT KLUMPF · TECHNISCHE CHEMIE KG Industriestrasse 15 45699 Herten

The system may be used, preferably in terms of ready-for-use wet test agent, filled in aerosol tins. This system is satisfied to ASME sec. V, art. 7 and related ASTM-standards.

8. Magnetisation The test sections will always be magnetised with AC-electromagnetic yoke in two magnetisation directions, possibly arranged shifted by 90°. The AC- electromagnetic yoke lifting power must be checked once a year as minimum (or after damage or repair), in accordance with ASME sec.V, art.7, T 762 (lift off with maximum pole spacing at least of 4,5 kg)

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ZWP ERNST GmbH - Zerstörungsfreie Werkstoffprüfung Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Magnetic Particle Examination Procedure

9. Evaluation of the test sections Directly during magnetisation, the test section must complete moistened through spraying the magnetic particles, whereby this area is to be observed for possible patterns. The determination of the pattern size should possibly be done during magnetisation in order to get the whole pattern size. During the examination it is to be guaranteed, that surplus wet inspection device can run off. For the examination with no fluorescent method must be the light intensity at the test area more than 1000 lux. Evaluation of indications: An indication of an imperfection may be larger than the real imperfection. However the size of the indication will be the basis for the acceptance standard. All indications with dimensions larger than 1,5 mm have to be considered relevant. -a: a linear indication is an indication, of which the length is larger than 3 times the width -b: a rounded indication is an indication of circular- and/or elliptical shape with a length equal to or less than 3 times its width. -c: any questionable or doubtful indication shall be re-examined, to determine whether or not they are relevant. Acceptance standard: All surfaces examined shall be free of: -a: relevant linear indications, -b: relevant rounded indications greater than 5 mm -c: four or more relevant indications in a line separated by 1,5 mm or less, measured from edge to edge

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ZWP ERNST GmbH - Zerstörungsfreie Werkstoffprüfung Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Magnetic Particle Examination Procedure

10. Test report The tests evaluated according to the standards used and the admissible tolerances are documented in test reports of Ernst GmbH. Non-complying test sections shall be tested again after repair and be marked in the test report by writing an “R” behind the weld designation. The minimum information’s of the report shall be in accordance to T-793, as follow: a) b) c) d) e) f) g) h)

1

procedure identification and revision; magnetic particle equipment and type of current; magnetic particles (visible or fluorescent, wet or dry) examination personnel identity and if required by referencing Code Section, qualification level; map or record of indications per T-792; material and thickness lighting equipment; and date of examination

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ZWP ERNST GmbH - Zerstörungsfreie Werkstoffprüfung Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Liquid Penetrant Examination Procedure

1. Purpose These test instructions specify the method of liquid penetrant tests of welding seams according to the ASME Sect. V Art. 6. 2. Scope The test specification applies to liquid penetrant tests on materials and welded connections. In case of magnetisable steel types, preference should be given to the magnetic particle test instead of the dye penetrant inspection. 3. Regulations ASME Sec. I, app. A-260, ASME Sec. V, Art. 7, ASME Sec. VIII, Div. 1, app. 6, PES-AD6

Edition 2017 Edition 2017 Edition 2017

4. Staff qualification The personnel shall be qualified and certified in conformity with ISO 9712 (or SNT-TC-1A) Execution of tests: at least level II according to ISO 9712 (or SNT-TC-1A) Evaluation of test results: at least level II according to ISO 9712 (or SNT-TC-1A) All testers working in the inspection must have an eye test certificate not older than 12 months. 5. Time and scope of testing The time and scope of testing works shall be taken from the purchaser’s instruction and order documents (drawings, inspection plans). Special attention is to be paid to the inspection time with regard to thermal treatments prescribed.

6. Surface preparation

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ZWP ERNST GmbH - Zerstörungsfreie Werkstoffprüfung Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Liquid Penetrant Examination Procedure

In general, satisfactory results may be obtained when the surface of the part is in as-welded, asrolled, as-cast, or as-forged condition. Surface preparation by grinding, machining, or other methods may be necessary when surface irregularities could mask indications of unacceptable discontinuities. The surface to be examined and all adjacent areas within at least 25mm must be dry and free of all dirt, grease, lint, welding flux, weld splatter, paint, oil and other extraneous matter that could obscure surface openings interfere with the examination. Before applying the penetrant, the surface to be tested shall be pre-treated with solvent ColorPEN RL 40. The surface may be dried by normal evaporation or forced air. The standard temperature of the penetrant and inspection area shall not be below 5°C and not above 52°C. 7. Test system The use of the following test materials (Family group: ColorPEN) is recommended: -

Penetrant: ColorPEN - PWL1 Solvent: ColorPEN - RL 40 Developer: ColorPEN - DL 20

Manufacturer: Magnaflux GmbH Bahnhofstraße 94-98 73457 Essingen -Germany This non-fluorescent system may be used, preferably in terms of ready-for-use wet test agent, filled in aerosol tins. The ColorPEN-test system is satisfied to ASME sec. V, art. 6 and related ASTMstandards.

8. Examination

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ZWP ERNST GmbH - Zerstörungsfreie Werkstoffprüfung Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Liquid Penetrant Examination Procedure

All test units must take place, with consideration of the respective retention times, directly one behind the other. 8.1 Penetration The penetrant be applied by spraying. At temperature range from 10°C to 52°C the minimum exposure time of the penetrant is 10 minutes. For temperatures from 5°C up to 10°C the minimum penetrant dwell time shall be 20 minutes. 8.2 Method of removing excess surface penetrant After the penetration dwell time elapsed, any penetrant remaining on the surface shall be removed with purifier: ColorPEN RL 40 (ITW Tiede-Ndt GmbH). Excess solvent shall be removed by wiping with a cloth or absorbent paper, repeating the operation until most traces of penetrant have been removed. The remaining traces shall be removed by lightly wiping the surface with cloth or absorbent paper moistened with solvent. To minimize removal of penetrant from discontinuities, care shall be taken to avoid the use of excess solvent. Flushing the surface with solvent, following the application of the penetrant and prior to developing, is prohibited! 8.3 Drying after excess penetrant removal The surface may be dried by normal evaporation or forced air. 8.4 Developing The (non-aqueous) developer shall be applied only to a dry surface. It shall be applied by spraying. Drying shall be by normal evaporation. Developing time for final interpretation begins immediately after the developer is dry. The minimum developing time for temperature range between 10°C to 52°C is 10 minutes. For temperatures from 5°C up to 10°C the minimum developing time shall be 20 minutes. 8.5 Evaluation of indications For the examination with non-fluorescent method must the light intensity at the routing scope more at least 1000 lux. The indication size shall be measured immediately after the end of developing time. Final interpretation shall be made within 10 to 60 minutes after the developing time. If the surface to be examined is large enough to preclude complete examination within the prescribed time, the examination shall be performed in increments. An indication is the evidence of a mechanical imperfection. All indications with major dimensions greater than 1,5 mm shall be considered relevant. Indications of an imperfection may be larger that causes it, however, the size of the indication is the basis for acceptance evaluation.

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ZWP ERNST GmbH - Zerstörungsfreie Werkstoffprüfung Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Liquid Penetrant Examination Procedure

A linear indication is one having a length greater than three times the width. A rounded indication is one of circular or elliptical shape with the length equal or less than three times the width. The following indications are not permissible: - relevant linear indications - relevant rounded indications greater than 5 mm - four or more relevant rounded indications in a line, separated by 1,5 mm or less(edge to edge) - ten or more rounded indications in any 3870 mm² area of surface with the major dimension of this area not exceed 150 mm with the area taken in the most unfavorable location relative to the indications being evaluated. Any questionable or doubtful indications shall be reexamined to determine whether or not they are relevant. 9. Test report The tests evaluated according to the standards used and the admissible tolerances are documented in tests reports of Ernst GmbH. Non-rejectable indications shall be recorded as specified by the referencing Code Section. Rejectable indications shall be recorded, with the type of indications (linear or rounded), location and extent (length, diameter or aligned). Non-complying test sections shall be tested again after repair and be marked in the test report by writing an “R” behind the weld designation. The minimum information of the report shall be in accordance to T-692, as follow: a) procedure identification and revision; b) liquid penetrant type (visible or fluorescent); c) type (number or letter designation) of each penetrant, penetrant remover, emulsifier and developer used; d) examination personnel identity and if required by referencing Code Section, qualification level; e) map or record of indications per T-691; f) material and thickness; g) lighting equipment; h) date of examination; i) ambient temperature

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Ultrasonic Inspections acc. to ASME-Code Written Practice 1. Purpose These test instructions specify the method of ultrasonic inspections (UT) of welds within the operational sphere of Messrs. Ernst GmbH. 2. Scope The test specification applies to ultrasonic inspections of metallic materials and welded joints of a thickness of  6mm through 19 mm. Lifting lugs and the areas where they will be installed on the container must be 100% tested for laminar tears. For smaller wall thicknesses, other test methods shall be preferred (RT, MT or PT tests) or should this be regarded as not possible or not sufficient, the proceedings shall be determined separately with the purchaser before starting the UT inspections. 3. Regulations The following rules and standards apply in their respectively valid version. ASME-Code Sec.V, Subsec.A, Art.4 Edition 2017

Ultrasonic Examination, Methods for welds

ASME Sec. VIII, Div.1, UW 51, 52, 53 Edition 2017

Pressure tanks and vessels

PES-AD6 4. Staff qualification The inspection staff has to be trained according to these test specification. The following conditions apply: - Execution of tests: at least level 1 according to DIN EN ISO 9712 (or SNT-TC-1A) - Evaluation of test results: at least level 2 according to DIN EN ISO 9712 (or SNT-TC-1A) - All testers working in the inspection must have an eye test certificate not older than 12 months.

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Ultrasonic Inspections acc. to ASME-Code Written Practice

5. Time and scope of testing The time and scope of testing works shall be taken from the purchaser’s instruction and order documents (drawings, inspection plans). Special attention is to be paid to the regulations valid at the time of test regarding thermal treatments prescribed. 6. Surface preparation Surfaces to be tested shall be free from rust, scales, spatters, scores or other contaminations impeding the inspection. Uneven surfaces and ripples may only occur to such an extent that the resulting gap of the testing head sole does not exceed 0.5 mm. The width of the test surfaces shall guarantee a complete determination of the test volume. 7. Devices for ultrasonic inspection The UT devices shall comply with the requirements according to DIN EN 12668-1. A calibration certificate to be renewed every year, shall be available. 8. Couplant Paste, UT gel, water (only inspection for laminar-type defects) or oil can be used as a couplant. In this context, corrosion protection questions may have to be cleared up with the purchaser before starting the tests. In general both, adjustment and inspection have to be realised by using the same couplant. 9. Calibration 9.1 Range calibration The range calibration is realised by using the reference blocks K1 and K2, a step wedge or directly on the constructional element, whereby always the echoes of two different known sound paths shall be used.

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Ultrasonic Inspections acc. to ASME-Code Written Practice 9.2 Scanning sensitivity calibration 9.2.1 Distance Amplitude Techniques (DAC method) The calibration reflectors demanded by the standard for material-like calibration block (ASME Sec.V; Fig. T-434.2.1) shall be used to determine a DAC curve. 9.3 Control of adjustments Controls or new calibrations will be necessary: - before starting the test - after 4 hours of testing - after changing the test system (e. g. testing head) - when exchanging the tester - at the end of the test. 10. Evaluation Welds that are shown by ultrasonic examination to have discontinuities that produce an indication greater than 20% of the reference level shall be investigated to the extent that can determine their shape, identity and location. (Instead of drawing a 20% DAC or 20% reference level on the instrument's screen, the gain may be increased 14 dB to make the reference level DAC curve the 20% DAC curve or 20% of the reference level.) Discontinuities evaluated as being cracks, lack of fusion or incomplete penetration are unacceptable regardless of their length. Laminar tears on lifting lug plates and for the welding area portion of silencers are none accepted. Other discontinuities are unacceptable if the indication exceeds the reference level (greater than 20% DAC) and their length exceeds 6 mm.

11. Description of recordable ads Ads are subject to registration by indicating their echo height is exceeded, recording length, depth position (if necessary depth extent), position in the longitudinal and transverse directions to monitor the weld. The respective zero point position must be indicated component-based.

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Ultrasonic Inspections acc. to ASME-Code Written Practice 12. Test report The tests evaluated according to the standards used and the admissible tolerances are documented in tests reports of Ernst GmbH. All necessary data shall be registered. The weld sections shall primarily be marked as indicated in drawings and inspection plans. In case specific weld designations are given, they shall be shown in a sketch, which forms an integral part of the test report. Non-complying test sections shall be tested again after repair and be marked in the test report by writing an “R” behind the weld designation.

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice 1. Purpose These written practice specify the method of radiographic examination of weld seams according to the requirements of the ASME code within the operational sphere of Messrs. Ernst GmbH. 2. Scope The test specifications apply to radiographic examinations of welded joints of ferritic and austenitic steels up to a wall thickness of 76 mm. 3. Regulations ASME-Code Sec.V, Subsec.A, Art.2 and 22 Edition 2017 ASME Sec. VIII, Div.1, UW 51 and 52 Edition 2017 PES-AD6 4. Staff qualification

Inspection technique, radiography of welds Pressure tanks and vessels

The inspection staff has to be trained according to these test specification. The following conditions apply: - Execution of tests and evaluation of test results: at least level 2 according to ISO 9712 or SNT-TC-1A - All testers working in the inspection must have an eye test certificate not older than 12 months. - When realising the radiographic examination, a person in charge of “radiation protection in situ” of Ernst GmbH shall be present. 5. Scope and time of inspection The scope and time of inspection works are shown in the purchaser’s instructions and order documents (drawings, inspection plans). Please note that the radiographic examination has to be performed after the last heat treatment.

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice 6. Surface preparation The surface shall be free from any contaminations, foreign particles or surface damage in the area of the film layer. Appropriate measures shall be taken to avoid scattered radiation. Contour grinding of welds on outside surface shall be performed to the extent that clarity of the radiographic examination is maintained. 7. Demands on the inspection technique 7.1 Selection of radiation source and determination of maximum voltage The following radiation sources will be used: - X-ray systems Eresco MF2 (200 kV, 4.5 mA) - Isotope iridium 192 (size: Ø < 3 mm) When choosing the maximum voltage of the x-ray system, the conditions shown in Figure 1 are to be complied with as a function of the smallest single wall thickness (pay attention to double wall radiography!). Figure 1

Maximalspannung (kV)

Maximalspannung für Röntgenstrahler 200 175 150 125 100 0,05/ 1,3

0,1/ 2,5

0,15/ 3,8

0,2/ 5,1

0,25/ 6,3

einfache Wandstärke (inch/ mm)

When using iridium 192 the single wall thickness may not be inferior to 19 mm.

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice

7.2 Minimum distance radiation source / work piece The minimum distance between radiation source and work piece is determined by the geometric inaccuracy and is calculated as follows:

fmin =

d*s ug

fmin = minimum distance radiation source / work piece d = focal spot size s = thickness of work piece ug = geometric inaccuracy (s: < 51 mm ug = 0,51 mm s: 51 – 76 mm ug = 0,76 mm)

7.3 Shot arrangements Figure 2 shows the shot arrangements possible according to ASME-Code Sec. V, Art.2. If technically possible, the single wall radiography is to be preferred to double wall radiography. In order to minimize distortions as far as possible, the radiation source should be positioned according to shot arrangement A or B (Fig. 2). When applying the double-wall technique, preference is to be given to shot arrangement D or E with evaluation of the wall close to the film. The double-wall radiography according to shot arrangement F or G is only admissible if the outer diameter of the work piece is < 89 mm.

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice

Figure 2: Shot arrangement A to G

7.4. Films and foil combinations Films shall be as mentioned below: - Fine grain film (Class II) for X-Ray. - Ultra-fine grain film (Class I) for gamma ray (Ir 192) Films of AGFA-D5 with lead reinforced foils shall be used. The lead foils shall be chosen with regard to the radiation energy according to Table 1:

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice

Table 1 Energy / isotope up to 125 keV >125 keV – 200 keV

Lead foils: thickness / combination < 0.13 mm / front and rear intensifying screen 0.02 – 0.13 mm / front and rear intensifying screen 0.13 mm / front and rear intensifying screen

Iridium 192 7.5. Proof of image quality, blackening

The proof of the image quality is to be provided by using wire penetrameter sets (SE-747). For each individual shot at least one penetrameter shall be used (for central shots on round seams shot arrangement A = 3 pieces, arranged shifted by 120°). The sensitivity of proof depends on the singlewall thickness as well as on the position of the penetrameter and can be taken from Table 2. The penetrameters shall preferably be positioned on the radiation source side (also applies to ellipse technique and vertical radiography according to shot arrangements F and G). In case it is not possible to place the penetrameters on the radiation source side (shot arrangements D and E), the position close to the film is to be marked with the letter ‘F’ near the penetrameter. Penetrameters of the same material group as the specimen (e. g. steel, copper, aluminium, titanium) shall be used. The image quality is considered to be complied with if the required wire is recognized on a length of 10 mm. The required minimum blackening is 2.0 in the evaluable range. In dependency on the luminance of the light boxes, the blackening level 4 should not be exceeded. Table 2 Single wall thickness inch

mm

< 0.25 >0.25-0.375 >0.375-0.5 >0.5-0.75 >0.75-1.0 >1.0-1.5 >1.5-2.0 >2.0-2.5

< 6.3 >6.3-9.5 >9.5-12.7 >12.7-19.0 >19.0-25.4 >25.4-38,1 >38.1-50.8 >50.8-63.5

Position of the penetrameter radiation source side film side Ø wire No. wire Set Ø wire No. wire (inch) (inch) 0.008 5 A 0.006 4 0.010 6 A/B 0.008 5 0.013 7 B 0.010 6 0.016 8 B 0.013 7 0.020 9 B 0.016 8 0.025 10 B 0.020 9 0.032 11 B/C 0.025 10 0.040 12 C 0.032 11

Set A A A/B B B B B B/C

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice >2.5-3.0

>63.5-76.0

0.050

13

C

0.040

12

C

7.5 Proof of scattered radiation control During exposure, the letter ‘B’ has to be indicated on the rear side of the film / foil combination (see chapter VIII, section 2, T-223). A too strong scattered radiation is proved by a bright appearance of the letter ‚B’ on the film. In this case, the shot shall be repeated after taking adequate measures to reduce scattered radiation. A dark appearance of letter ‘B’ is no reason for rejecting the shot.

8. Identification of film overlay For permanent marking the films, lead figures and lead letters shall be used. The marking of the welds carried out from the inspection plans and drawings of the respective object. Order number, part number and seam number must be mapped to each film. The following information shall appear in the test report: a) b) c) d) e) f) g)

number of equipment, piping or part joint number, in case of welded joint thickness material film identification number date service was performed identification of level from professional

Overlay: > 2 cm, evidence is mainly provided by the lead figure ribbons used during radiography.

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice 9. Admissibility criteria (ASME Sec. VIII, Div.1, UW 51 and Appendix 4) The following indications are non-compliance criteria of the weld sections shown: 9.1 Inadmissible types of indication (The occurrence of such a kind of fault already leads to non-compliance.) -

crack incomplete welding penetration lack of fusion,

9.2 any other elongated indications on the radiograph which has length greater than: -

6 mm for t up to 19 mm 1/3 of the wall thickness for t > 19 mm up to 57 mm 19 mm for t > 57 mm

The letter ‘t’ stands for nominal wall thickness of the thinnest basic material adjacent to the weld seam. The length of oblong indications is at least three times their width. 9.3 Groups of aligned indications, any group of aligned indications that have an aggregate length greater than t in a length of 12 t, except when the distance between the successive imperfections exceeds 6 L where L is the length of the longest imperfection in the group 9.4 Round individual indications Round indications have a maximum length which is smaller than the triplicate of their width. These indications may be circular, elliptical, conical or irregular in shape and may have tails. The indication may be from any imperfection, such as porosity, slag or tungsten. Only those indications shall be considered in the evaluation, the dimensions of which (as a function of the wall thickness) exceed the values shown in Table 3.

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice

Table 3 Nominal wall Maximum Size of Acceptable Rounded Indication Maximum Size of thickness t (mm) Nonrelevant Indication (mm) Random Isolated (0,25*t; < 4 mm) < 3 mm 1/4 t 1/3 t 1/10 t 3 0,79 1,07 0,38 5 1,19 1,60 0,38 6 1,60 2,11 0,38 8 1,98 2,64 0,79 10 2,31 3,18 0,79 11 2,77 3,71 0,79 13 3,18 4,27 0,79 14 3,61 4,78 0,79 16 3,96 5,33 0,79 17 3,96 5,84 0,79 19 to 50 3,96 6,35 0,79 over 50 3,96 9,53 1.60

9.4.1 Aligned Rounded Indications Aligned rounded indications are acceptable when the summation of the diameters of the indications is less than t in a length 12 times the wall thickness (see Fig. 4-1).

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice

The length of groups of aligned rounded indications and the spacing between the groups shall meet the requirements of Fig. 4-2

9.4.2 Rounded Indication Charts The rounded indications characterized as imperfections shall not exceed that shown in the charts. The charts in Figs. 4-3 till 4-7 illustrate various types of assorted, randomly dispersed and clustered rounded indications for different weld thickness > 3 mm. These charts represent the maximum acceptable concentration limits for rounded indications. For weld thickness less than 3 mm the maximum number of relevant rounded indications shall not be exceed 12 in 150 mm length of weld. A proportionally fewer number of indications shall be permitted in welds less than 150 mm length. Clustered indications are four times as many indications in a local area (as shown in Figs. 4-3 till 4-7, each position (c)). The length of an acceptable cluster shall not exceed the lesser of 25 mm or 2*t. Where more than one cluster is present, the sum of the lengths of the clusters shall not be exceeding 25 mm in 150 mm weld length.

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice

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ZWP ERNST GmbH – Non-Destructive Material Testing Bosewitzer Straße 20, 01259 Dresden Tel.: 0351 / 20 38 - 566 - 567 Fax: 0351 / 20 38 - 568 Test Specification for Radiographic Examinations acc. to ASME-Code Written Practice

9.5 Rootcontacavity, when there is an abrupt change in density, as indicated on the radiograph 10. Logging and repairs The evaluations of the tests are outlined in the Ernst GmbH test reports. All necessary data shall be registered. Non-complying test sections shall be tested again after being repaired by radiographic examination using the same parameters. Identification of these films see No.8.

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