S1450401 - Corus - Execution and Inspection of Steel Welding PDF

S1 45 04 01 Corus Standard
Execution and inspection of steel welding

Author: P.W.L. Lensen / V.H.M. Reus

Issue: March 2002

Version 4.0

Intended for location IJmuiden

This is a non-registered document.
In case of future changes, amendments will not be sent to you.
The latest version can be retrieved from Intranet of Corus (project.net).

Information on:
Contents of document P.W.L. Lensen Tel. +31 (0)251-4 95242
V.H.M. Reus Tel. +31 (0)251-4 92911
Standardisation Standardisation office Tel. +31 (0)251-4 97693

Contents:

1. GENERAL STIPULATIONS................................................................................................................................. 3
1.1. GENERAL............................................................................................................................................................... 3
1.1.1. Scope................................................................................................................................................................ 3
1.1.2. Rules ................................................................................................................................................................ 3
1.1.3. Conflicting requirements ................................................................................................................................. 3
1.1.4. Order of priority .............................................................................................................................................. 3
1.2. WELDING INSPECTORATE ...................................................................................................................................... 4
1.3. CLASSIFICATION.................................................................................................................................................... 4
1.3.1. Categories........................................................................................................................................................ 4
1.3.2. Pressure vessels ............................................................................................................................................... 4
1.3.3. Special Corus regulations................................................................................................................................ 4
1.3.4. Classification by the supplier........................................................................................................................... 4
1.4. MATERIAL............................................................................................................................................................. 5
1.5. TESTING ................................................................................................................................................................ 5
1.5.1. Inspection plan................................................................................................................................................. 5
1.5.2. Quality assurance and documents ................................................................................................................... 6
1.5.3. Inspections ....................................................................................................................................................... 6
1.5.4. Non-destructive testing reports........................................................................................................................ 6
1.5.5. Repairs............................................................................................................................................................. 6
1.5.6. R.T.D................................................................................................................................................................ 7
1.5.7. Cost settlement ................................................................................................................................................. 7
1.6. REPAIRS................................................................................................................................................................. 7
1.7. REMOVAL.............................................................................................................................................................. 7
1.8. WORKING CONDITIONS.......................................................................................................................................... 7
1.9. STRESS RELIEVING ANNEALING ............................................................................................................................. 8
1.10. CLAD WELDING ..................................................................................................................................................... 8
1.10.1. Clad welding by means of cladding material equal to the workpiece material properties......................... 8
1.10.2. Clad welding by means of cladding material unequal to the workpiece material properties.................... 8
1.10.3. Welding procedures .................................................................................................................................... 8
1.10.4 Welding method and welders qualifications .............................................................................................. 9
1.10.5. Inspection.................................................................................................................................................... 9
2. WELDING CATEGORY 1 .................................................................................................................................. 10
2.1. EXECUTION ......................................................................................................................................................... 10
2.1.1. Supplier.......................................................................................................................................................... 10
2.1.2. Welders .......................................................................................................................................................... 10
2.1.3. Welding specifications ................................................................................................................................... 10
2.1.4. Welding consumables .................................................................................................................................... 10
2.2. TESTING .............................................................................................................................................................. 11
2.2.1. Scope and nature of the test ........................................................................................................................... 11
2.2.2. Execution of the test ....................................................................................................................................... 11
3.1. EXECUTION ......................................................................................................................................................... 12
3.1.1. Supplier.......................................................................................................................................................... 12
3.1.2. Welders .......................................................................................................................................................... 12
3.1.3. Welding specifications ................................................................................................................................... 12
3.1.4. Welding consumables .................................................................................................................................... 12
3.2. TESTING .............................................................................................................................................................. 13
3.2.1. Scope of the test ............................................................................................................................................. 13
3.2.2. Execution of the test ....................................................................................................................................... 13
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4.1. EXECUTION..........................................................................................................................................................14
4.2. TEST ....................................................................................................................................................................14
4.3. CONDITIONS ........................................................................................................................................................14
5. REQUIREMENTS FOR STAINLESS AND HIGHLY HEAT-RESISTANT STEEL...................................15
5.1. GENERAL.............................................................................................................................................................15
5.1.1. Material storage.............................................................................................................................................15
5.1.2. Workshop accommodation.............................................................................................................................15
5.1.3. Tools...............................................................................................................................................................15
5.1.4. Weld preparation ...........................................................................................................................................15
5.1.5. Welding execution..........................................................................................................................................16
5.1.6. Welding consumables.....................................................................................................................................16
5.2. HEAT TREATMENT ...............................................................................................................................................16
5.3. WELD FINISHING..................................................................................................................................................16
6. LIST OF CLASSIFICATION OF WELDING IN WELDING CATEGORIES .............................................17
6.1. STEEL STRUCTURES .............................................................................................................................................17
6.1.1. Welding category 1 ........................................................................................................................................17
6.2. BOILERS / PRESSURE VESSELS / MACHINERY........................................................................................................17
6.3. MACHINES / INSTRUMENTS ..................................................................................................................................18
6.4. HOISTING AND TRANSPORT EQUIPMENT...............................................................................................................18
6.5. PIPELINES ............................................................................................................................................................19
7. REFERENCES ......................................................................................................................................................20
8. STATEMENT........................................................................................................................................................22
9. APPENDICES: NON-DESTRUCTIVE TESTING PROCEDURES .............................................................23
9.1. UT-97001 PROCEDURE FOR ULTRASONIC EXAMINATION. ...................................................................................23
9.2. UT-97002 PROCEDURE FOR ULTRASONIC EXAMINATION FOR INTERNAL IMPERFECTIONS IN STEEL. ...................23
9.3. MT-97003 PROCEDURE FOR MAGNETIC EXAMINATION. ......................................................................................23
9.4. PT-97004 PROCEDURE FOR PENETRANT EXAMINATION.......................................................................................23
9.5. RT-97005 PROCEDURE FOR RADIOGRAPHIC EXAMINATION.................................................................................23


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1. GENERAL STIPULATIONS
1.1. General
1.1.1. Scope
This Corus Standard stipulates rules for welding and clad welding of machine parts, steel
structures, vessels, equipment and piping of unalloyed, low alloyed and high alloyed steel.
1.1.2. Rules
The welding must always meet legal requirements and the (possible supplementary)
requirements of a third party authority. Moreover, the customer can also set supplementary
requirements in accordance with a third party authority.
The stipulations in this Corus Standard apply to the execution of steel welding, unless
other stipulations are set in the order and related drawings and/or specifications. Any
deviation from this Corus Standard, or the stipulations of the order is not allowed, unless a
written permission has been granted by the customer.
The stipulations of the Corus Standard only apply when their scope is more far-reaching
and not in conflict with legal stipulations and the stipulations of any third party authority.
1.1.3. Conflicting requirements
Conflicting requirements must be brought to the attention of the contractor in writing by
way of explanation. In the event that this is omitted, the most stringent requirements will
apply.
1.1.4. Order of priority
Order of priority of documents stated in the requisition:

Legal requirements
Drawings
Specified requirements
Other specifications


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1.2. Welding inspectorate
Welding inpectorate is defined as follows.
The customers inspector, as well as any other accredited inspection authority appointed
by the customer or an authority pursuant to any legal stipulation.
At any stage the welding inspectorate may determine that the work must be discontinued
before granting its permission. This permission can be made subject to one or more
conditions being met. Article 5 of the Terms & Conditions of Delivery of Corus applies
here.
1.3. Classification
1.3.1. Categories
The customer classifies welding as category 1, 2 or 3 in accordance with Chapter 6. This
classification must be stated on (working) drawings, special regulations, and special
standards or on the order. Besides the general stipulations of these regulations, the
stipulations to be met by the category in question will also apply.
The welding category should preferably be indicated by means of the classification
designation in the suffix of the weld designation in accordance with ISO 2553.
1.3.2. Pressure vessels
Please refer to the rules concerned in the case of systems to which the Rules for Pressure
Vessels (Stoomwezen) [Steam Vessel Inspectorate] apply. In the event that the regulations
of the Gasunie apply, these are determinative.
1.3.3. Special Corus regulations
Please refer to these regulations in the case of systems for which special Corus regulations
have been compiled -- such as ATVK (Mechanical specifications for electric cranes and
bulk handling machines), standard drawings, etc..
1.3.4. Classification by the supplier
If the welding has not been classified as category 1, 2 or 3 on the order, the supplier is
obliged to classify the welding and to submit the proposal to the customer for written
approval. This should be carried out in accordance with Chapter 6 of this Corus Standard.


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1.4. Material
Welded structures must be made of sound and suitable materials. The welding
specifications (see Paragraphs 2.1.3. and 3.1.3.) and consumables (see Paragraphs 2.1.4.
and 3.1.4.) must be in accordance with the welding properties of the selected material.
Please refer to NPR-EGKS 2 for welding fine-grained structural steels.
If otherwise specified, material for welding classified as welding category 1 or 2 must be
delivered with inspection certificate 3.1.B in accordance with EN 20104 mentioning the
mechanical values.

The supplier must ensure the material identification (restamp) is carried out by means of
a procedure approved by the customer.

It is not permitted to make welded joints on surfaces with weld primers. If weld primers
have been used, these must be removed in advance.

Welding classified as welding category 1 and 2 must be subjected to a surface zone
inspection for laminations and/or segregation in accordance with procedure 97002 (see
appendix) prior to welding if this involves welded joints that exert stress towards the
direction of the thickness.
1.5. Testing
1.5.1. Inspection plan
The supplier must have the welding tested by means of non-destructive testing methods
and in accordance with the inspection plan approved by the Corus inspection department.
This inspection plan must include all data required for the welding category in question.
Each test must be performed after a visual check. The visual check must be repeated in the
case of weld seam machining.
The nature and scope of the test is described in greater detail at the welding categories and
in the inspection plan. The procedures involved in non-destructive testing performed by
the RTD are laid down in the appendices of Chapter 9. (Appendices)

In the event that parties other than the RTD perform the non-destructive tests, the same
procedures must be used.

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1.5.2. Quality assurance and documents
Only those organisations with a certified quality assurance system in accordance with ISO
9002 and that meet the requirements of EN 729, classification 2 or 3, may have the non-
destructive test performed by an independent authority qualified in accordance with EN
45001.

Organisations that do not meet the aforementioned requirements, are not permitted to have
a non-destructive test performed by others; they must have this performed by the Corus
Inspection Department.

All inspection documents must be signed and stamped for approval by the customers
welding inspectorate. These documents must be filed in a manufacturing book and
submitted on delivery.
At least the following documents must be included:
Material certificates
Weld method qualifications (PQR)
Weld plan
Inspection and testing plan
Annealing curve (if applicable)
Measuring reports
Welders qualifications
Pressure-test certificates (if applicable)
Non-destructive testing reports
Photo plan
Approved welding procedures (WPS)
1.5.3. Inspections
The welding inspectorate is entitled to indicate the sites to be tested, to be present during
the test and to get full information on the results.
1.5.4. Non-destructive testing reports
The supplier must indicate the places that have been submitted to non-destructive tests on a
drawing. This must also include references to evidence such as radiographic and test
reports applicable to the non-destructive tests.
1.5.5. Repairs
Only the welding inspectorate is qualified to determine on the basis of test results whether
or not repairs are to be carried out.
Surface faults, such as cracks, lack of fusion or lack of penetration, will always lead to
rejection.

Repairs may only be carried out after consultation and approval of the welding
inspectorate.

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1.5.6. R.T.D.
Corus recognises the RTD (Rntgen Technische Dienst) [Radiographic Technical
Department] as the executive authority for non-destructive testing. In case of using another
inspection authority, a written permission of our inspection department for each individual
case is required.
The welding inspectorate remains entitled at all times to have supplementary non-
destructive tests performed by an authority appointed by Corus.
1.5.7. Cost settlement
Unless stipulated otherwise in the contract, all costs involved in non-destructive tests are
for the account of the contractor, except in those cases where the Corus Inspection
Department itself has ordered the performance of non-destructive testing.

Retesting after repairs are always for the account of the contractor. In the event that the
non-destructive test must be extended due to poor results, these costs are also for the
account of the contractor.

1.6. Repairs
If stress relieving has taken place or if the weld has been exposed to a corrosive medium, it
may only be repaired once. In all other cases when the results of the test are unacceptable,
the weld may be repaired twice. Each repair made on these grounds must again be
submitted to a 100% non-destructive test and the end results must meet the original
requirements. If that is not the case, the welds in question must be removed completely.
The customer must be consulted in all cases.
1.7. Removal
Attachments and fixed parts may only be removed by means of grinding. Any other form
of removal will result in immediate rejection.
1.8. Working conditions
Special measures must be taken in the following cases.

If the ambient temperature is lower than 5 C.
If the welding site is exposed to a windforce in excess of 5 Beaufort.


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1.9. Stress relieving annealing
The conditions below must be met when stress relieving annealing is prescribed:

The annealing procedure must be included in the inspection plan in question.
The equipment and measuring instruments used must be calibrated.
The prescribed non-destructive test must be performed after annealing.
The performance of the heat treatment must be recorded by a writing recorder.

For unalloyed construction steel with a yield up to and including 355N/m2, the stress
relieving annealing temperature may not exceed 580C and the heat treatment may not
last more than one hour. This is in accordance with EN 10025: prolonged annealing may
result in decline of mechanical qualities. In case prolonged annealing in higher
temperatures is desirable, this should be agreed upon in the order. The annealing
temperature of refined steel should be at least 50C lower than the discharge temperature
applied by the steel manufacturer. In case of high yielded and low alloyed steel it is not
allowed to go beyond the annealing temperature prescribed by the steel supplier.
1.10. Clad welding
Below mentioned regulations are in addition to the rules of this Standard.
1.10.1. Clad welding by means of cladding material equal to the workpiece material properties.
Unless prescribed otherwise, clad welding should be carried out in at least two layers.
Non-destructive examination of clad welded layers can, after any treatment, be restricted to
some visual tests, followed by penetrant or magnetic tests. To determine the relevant test
method and scope, the Welding Inspectorate should be consulted.

The required weld method and welders qualifications should be drawn up according to
EN 287, EN 288 of EN 1418. Testing can be performed by a blunt weld in a pipe or plate
sample of minimal 12 mm thickness.
1.10.2. Clad welding by means of cladding material unequal to the workpiece material
properties.
This means clad welding of special alloyed parts in order to increase wear resistance
and/or corrosion resistance (except for wear plates).
1.10.3. Welding procedures
Welding procedures should contain at least the following items:
Extent and way of preparation
Surface examination after preparation
Clad welding material

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Required thickness of the cladding layer
Welding order, welding direction and number of cladding layers
Preheating temperature and interlayer temperature (geared to the workpiece material
and
cladding material)
Hardness and surface examination after clad welding and possible treatment
The welding procedures should be offered in advance to the Corus Welding Inspectorate
for approval. Deviation from the prescribed cladding material by Corus IJmuiden is only
permitted after written approval by the customer.
1.10.4 Welding method and welders qualifications
At each application an adjusted welding method and welders qualification are required.
These qualifications should be drawn up in accordance to and after consultation with the
Welding Inspectorate.
In the event of special requirements for hardness and/or chemical composition of the
cladding layer, these aspects should be mentioned in the qualifications.
1.10.5. Inspection
Before starting the work, the scope of inspection as well as the applying non-destructive
testing method should be established in the inspection plan, in consultation with the
Welding
Inspectorate.
In general cracks and visible porous spots will not be accepted. However,in case of some
kinds of hard-cladding alloys, cracks are unavoidable.
For these applications, it is necessary in consultation with the customer to establish in
advance what measure and direction of the cracks are acceptable.
In acquiring the right cladding layer thickness, it might be necessary to do some
pretreatment. After the pretreatment and before starting the clad welding activity, the
relevant measurements should be registered. These measurements should be stated in a
report.

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2. WELDING CATEGORY 1
2.1. Execution
The execution of the welding may not commence until the welding inspectorate has
granted its permission (approval inspection plan).
Statutory regulations and/or regulations of third party authorities (see Paragraph 5.1.5), in
particular regarding the execution, may deviate from those stated below.
2.1.1. Supplier
The supplier must meet the following conditions:

In possession of a valid certificate in accordance with EN 729, classification 2.
In possession of all documents required for the acceptance of all welding methods to be
used in accordance with EN 288.
Conditions set by the welding inspectorate in each particular case.
2.1.2. Welders
The welders must have a valid qualification in accordance with EN 287-1 for manual
welding or EN 1418 for mechanical or automatic welding.
2.1.3. Welding specifications
The supplier must submit a welding plan in advance to the welding inspectorate for
approval.
The welding specifications stated in this welding plan must meet the stipulations of
EN 287-1 and EN 288, parts 1 to 9.
2.1.4. Welding consumables
The welding consumables and basic material must be meticulously matched. Only those
consumables approved by Controlas and listed in the latest issue of the List of certified
welding consumables may be used. Deviation from this stipulation is only permitted with
the written approval of the welding inspectorate.
Electrodes and other consumables must be stored in a secure and dry environment.


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2.2. Testing
2.2.1. Scope and nature of the test
The full length of each weld must be submitted to a non-destructive test. Deviation from
this stipulation is only permitted if standards permit or with the approval of the Corus
Inspection Department.

The nature of the non-destructive test (radiographic, ultrasonic, magnetic, etc.) is laid
down in the welding plan.
All welds must be subjected to a 100% visual inspection. Non-butt welds (with slot) are
subjected to a 100% magnetic or liquid penetration inspection.
Butt welds are subjected to a 100% radiographic or ultrasonic inspection.
Supplementary magnetic or liquid penetration inspection can be prescribed.

2.2.2. Execution of the test
The visual inspection must be executed in accordance with EN 970.
The requirements laid down in EN 25817 classification B must be met.

The remaining non-destructive tests must be performed in accordance with the procedures
laid down in the appendices of Chapter 9.

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3.1. Execution
The execution of the welding may not commence until the welding inspectorate has
granted its permission (approval inspection plan).
Statutory regulations and/or regulations of third party authorities (see Paragraph 5.1.5), in
particular regarding the execution, may deviate from those stated below.
3.1.1. Supplier
The supplier must meet the following conditions:

In possession of a valid certificate in accordance with EN 729 classification 3.
In possession of all documents required for the acceptance of all welding methods to be
used in accordance with EN 288.
3.1.2. Welders
The welders must have a valid qualification in accordance with EN 287-1 for manual
welding or EN 1418 for mechanical or automatic welding.
3.1.3. Welding specifications
The supplier must submit a welding plan in advance to the welding inspectorate for
approval.
The welding specifications stated in this welding plan must meet the stipulations of
EN 287-1 and EN 288, parts 1 to 9.
Electrodes and other consumables must be stored in a secure and dry environment.


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3.2. Testing
3.2.1. Scope of the test
All welds are subjected to a 100% visual inspection.
If other standards are not applicable the scope of the remaining non-destructive tests must
meet the all the points below.

At least one inspection of each type of weld by each welder.
All cruciform welds are to be inspected.
Inspection of points indicated by the welding inspectorate.
In total these tests must include at least 10% of the weld length classified as category 2.

If the welding must take place in both a workshop and at an assembly site, the scope of the
inspection must include 10% of the workshop welding and 10% of the on-site welding.
However, on the basis of experience gained during this inspection, the welding
inspectorate can increase the scope.

The nature of the non-destructive test (radiographic, ultrasonic, magnetic, etc.) is written
down in the welding plan.

Non-butt welds (with slot) are inspected magnetically or by liquid penetration.
Butt welds are inspected by radiography or ultrasound.
Supplementary magnetic or liquid penetration inspection can be prescribed.
3.2.2. Execution of the test
The visual inspection must be executed in accordance with EN 970.
The requirements laid down in EN 25817 classification B must be met.

The remaining non-destructive tests must be performed in accordance with the procedures
laid down in the appendices in Chapter 9.


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4.1. Execution
The material must be welded with the appropriate high-quality welding electrode or
consumable. The seams must be properly prepared and cleaned.
The welding must be carried out by experienced welders.
4.2. Test
A visual inspection must be performed in accordance with EN 970.
The welds are visually assessed in accordance with EN 25817, classification C.
4.3. Conditions
The supplier must meet one of the following conditions:

In possession of a valid certificate in accordance with EN 729, classification 4.


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5. REQUIREMENTS FOR STAINLESS AND HIGHLY HEAT-
RESISTANT STEEL
5.1. General
5.1.1. Material storage
Stainless and high-alloyed heat-resistant steel must be stored separately from other
materials. The supports against which stainless steel semi-finished products are placed may
not be made of carbon steel. Materials such as resin-free or coated wood, hardboard, etc.,
are recommended.
It is essential that materials are given identification markings before being stored. These
marks must all be placed on one side so that they can be checked on the non-processing
side.
5.1.2. Workshop accommodation
Welding must be carried out in a suitable area. The processing of stainless and highly heat-
resistant steel must take place in a separate area. If these conditions cannot be met,
effective measures must be taken to meet the approval of the Corus welding inspectorate.
5.1.3. Tools
Stainless and high-alloyed heat-resistant steel may not come into direct contact with
carbon steel tools, tacking equipment, hoisting equipment, etc.
Only grinding tools such as grinding discs, etc., may be used on stainless and highly heat-
resistant steel.
5.1.4. Weld preparation
Appropriate methods such as those below must be used in the preparation:

Machining
Plasma cutting
Laser cutting

Gouging may only be used in exceptional cases. After gouging the welding edges must
always be smoothly ground. The welding edges and the material adjacent to the weld to a
width of 50 mm, must be thoroughly cleaned.


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5.1.5. Welding execution
The execution of the welding must be part of the welding specifications in advance and
must be approved by the Corus welding inspectorate.

Stainless steel may never be welded using the autogenous method.

It is not permitted to strike the welding arc outside the weld seam.

The application of heat to the basic material must be restricted as much as possible.

The TIG process must be used to weld piping and stainless steel DN < 50.

The root in piping > DN 50 must be welded using the TIG process.

Oxidation of metal surfaces during the welding process must be prevented as much as
possible by means of a shielding gas.

See VM 42 for shielding gases.

The last bead (in the case of several layers) must be made on the corrosion side, if
possible.
Electrodes and other consumables must be stored in a dry environment.
5.2. Heat treatment
For heat treatment, please refer to VM 42, Chapter 10 and Appendix A of EN 10088-3.
5.3. Weld finishing
For weld finishing, please refer to VM 42, Chapter 11.
The seam and area affected by heat must be finished to guarantee the required corrosion
resistance.


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6. LIST OF CLASSIFICATION OF WELDING IN WELDING
CATEGORIES
Please note:
In case welded joints are made between parts that are not classified in the same welding
category, the highest category applies.
6.1. Steel structures
6.1.1. Welding category 1
Crane runways, brake girders, crane runway column heads, brake gantries, rigid gantry
angles, machine foundations, hoisting lugs.

Structures that are subject to fatigue.
Columns, pedestals, trusses, floor beams, secondary beams, structures to support or
suspend boilers, pressure vessels and piping.
Channels and outlet pipes, steel window frames, stairs, platforms, railings, cable racks and
instrument cabinets.
6.2. Boilers / pressure vessels / machinery
If subject to inspection (Stoomwezen-inspection) also subject to Corus Standard
S1 30 04 01.
Joints in pressurised*) components: shells, fronts, walls, pipe fittings with stiffeners, wall
stiffeners, flanges, pipe joints.
Fan blades, annealing hoods, hot-blast stoves, hoisting lugs.

*) Pressurised includes both overpressure and partial vacuum.

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Joints in non-pressurised components that form part of pressure systems. Climbing &
walking irons, insulation brackets, supports, fire tubes in boilers, various pressure vessels.
Welding that is not subject to pressure, outer cladding, screening.

6.3. Machines / instruments
Bearing houses and frames of motors and turbines, wheel constructions, flanges on axles,
machine tool bed structures, hoisting lugs, water-cooled rails in furnaces.
Gear boxes and foundations: stiffeners, consoles, inspection manholes and hatches.
Foundations of various machines.
Handwheels and control levers, light seat frames, protective panels.
6.4. Hoisting and transport equipment
Beams in loading ramps, jibs and cranes, gantries for cranes, equalizers, hoisting drums
multi-sheave blocks, hoisting trestles, bogies, balance beams, conveyor belt drums,
hoisting lugs.
Columns supporting conveyor belt beams, winch drums, frames for winches and drive
systems, stiffeners, gear boxes and track vehicles.
Protective casings, ladders and stairs, feed hoppers for conveyors, platforms and cabins.

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6.5. Pipelines
Steam pipes, oxygen pipes, pipelines for corrosive, flammable and toxic media, pipelines
used at low temperatures.
Gas distribution piping.
Cooling water piping, hydraulic piping.
Hydraulic piping must meet the requirements of the Technical Directives
R1 42 01 02 and R1 42 01 08.

Drinking water piping.


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7. REFERENCES
The following references are made in this Corus Standard:

EN
287-1
288-1 to 9
729
1418
10088-3
10204
25817
45001
970
NPR-EGKS 2

DIN
462
54111-1

ISO
2553
9002

VM 42 Welding stainless and highly heat-resistant steel (latest issue).

or:

EN DIN
287-1 462
288 54111-1
729
1418
25817
45001

NPR-EGKS 2 ISO
2553
9002
Sheet T 0111
Sheet T 0117
Sheet T 0202

IIW Collection of reference radiographics

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Test procedures RTD:
UT 97001 and 97002
MT 97003
PT 97004
RT 97005

ASME Boiler and Pressure vessel Code Sect. I, II en VIII
ASME Boiler and Pressure vessel Code Sect. V art. 5

DVS Katalog, quality classification BS.

ATVK (Mechanical specifications for electric cranes and bulk handling machines)

VM 42 Welding stainless and highly heat-resistant steel (latest issue).

Corus Standard:
S1 30 04 01 Ordering, realisation and inspection for making, repair or
modification of equipment subject to approval of Stoomwezen.

Technical Directive:
R1 42 01 02 Hydraulics-directive for suppliers, erection companies,
managers and users.
Part 2: General
R1 42 01 08 Hydraulics-directive for suppliers, erection companies,
managers and users.
Part 8: Selection piping

RTD: (Rntgen Technische Dienst bv)
Delftweg 144 3046 NC Rotterdam
Tel: +31 (0)10 2088208 Fax: +31 (0)10 4158022

Controlas: (Dutch organisation for specifying welding consumables)
PO box 85745 2508 CK Den Haag
Tel: +31 (0)70 3587301 Fax: +31 (0)70 3502020

Projects &

S1 45 04 01

8. STATEMENT
Version 1.0:
This Corus Standard replaces HO standard 00.45.04.001.

Version 2.0:
Par 1.4 supplement to previous text
Par 1.5.2 supplemented with data on required documents
Par 1.9 supplemented
Par 2.2.2 Execution of the test added
Par 3.2.2 Execution of the test fully amended
Par 4.2 supplemented
Chapter 6 amended in List of classification of welding in welding categories
Chapter 9 Appendices non-destructive testing procedures added

Version 2.1
Logo changed

Version 3.0:
Non-destructive testing procedure UT-97001 version 3 dated jan.22,2001 added.

Version 4.0:
Par.1.1.1: Scope completed.
Par.1.9: Stress relieving extended.
Par.1.10: Clad welding added (including sub paragraphs)

Alterations appendices (non-destructive testing procedures)

UT-97001 point 5.1
Text changed into:The vertical and horizontal linear measures must be checked every three months.

UT-97002
Point 4 changed into:Personnel must be in possession of a valid certificate in accordance with
EN-473, minimal level 1.
Point 6 changed.

MT-97003
Point 3 changed into: Personnel must be in possession of a valid certificate in accordance with EN-
473, level MT-2.

PT-97004
Point 4 changed into: Personnel must be in possession of a valid certificate in accordance with EN
473, level PT-2.

Projects &

S1 45 04 01

9. Appendices:
Non-destructive testing procedures
9.1. UT-97001 Procedure for ultrasonic examination.

9.2. UT-97002 Procedure for ultrasonic examination for internal
imperfections in steel.

9.3. MT-97003 Procedure for magnetic examination.

9.4. PT-97004 Procedure for penetrant examination.

9.5. RT-97005 Procedure for radiographic examination.

Projects &

S1 45 04 01
Number : UT-97001
Revision : 3 ULTRASONIC EXAMINATION PROCEDURE
Date : 22.01.2001
Page : 2 of 14
1 Purpose of examination
This procedure describes the method to be used for ultrasonic weld examination of full
penetration welds in ferritic constructionparts with a wall thickness between 8 and
100 mm. The examination will be in accordance with the EN 1714 examination level B and
the acceptance will be in accordance with level 2 or 3 of the EN 1712, the specific demands
of CORUS regarding method of examination, determination of defect type, the acceptance
and registration were implemented.
2 Extent of examination
Welding category 1 (quality level EN 25817 class B):
The category will be indicated by Corus Weldinspection's or client's instructions
The welding shall be 100% examined in accordance with EN 1714 examination level B
and the welding should meet the requirements of the EN 1712 acceptance level 2, as
indicated in 15.3.
Welding category 2 (quality level EN 25817 class C):
Examined will be all weldcrossings and in addition locations of the remaining
weldlength will be examined as indicated by Corus weldinspection.
These examinations will include at least 10% of the erection welds and 10% of the
prefab welds in category 2 classified welds.
Examination will be executed in accordance with EN 1714 examination level B and the
welding shall meet the requirements of EN 1712 acceptance level 3 as indicated in 15.4.
Welding category 3 (quality level EN 25817 Class C):
On request of Corus' Weldinginspection welds can be indicated for examination.
Examination will be executed in accordance with EN 1714 examination level B and the
welding shall meet the requirements of EN 1712 acceptance level 3 as indicated in 15.4.
3 NDE Personnel
All NDE personnel shall be in possession of a valid certificate according tot EN-473,
level UT-2.
Number : UT-97001
Date : 22.01.2001
Page : 4 of 14
6 Range
Calibration on V1/V2
For lamination check at least two backwall echoes shall be visible
For weld examination the range depends on type of weld connection and
material thickness (see chapter 12 table 1 u/i 5)
7. Transfer correction
When reference blocks or DAC scales are used for establishing reference levels a
measurement shall be made of the transfer differences, between test object and block, at
a representative number of locations. These measurements will be established by placing
two probes opposite from each other and comparing the resulting reflections of equal
sweep range.
If the differences are less than 2 dB, correction is not required.
If the differences are greater than 2 dB but smaller than 12 dB, they shall be compensated
for.
If transfer losses exceed 12 dB, the reason shall be considered and further preparation of
the scanning surfaces shall be carried out, if applicable.
8. Sensitivity
Lamination check
Second backwall echo of the object to be examined shall be set at 80% screen height
Weld examination
The sensitivity for weld examination will be established by constructing a DAC curve
from the reference block in which two or more, equally divided through thickness, holes
have been drilled with a diameter of 3 mm.
In case no blocks are available the RTD/ASME diagrams will be used. In addition by
wallthicknesses over 50 mm the sensitivity will be increased by 2 dB.
The 100% DAC line is the reference level.
Number : UT-97001
Date : 22.01.2001
Page : 5 of 14
9. Test sensitivity
During examination, sensitivity shall be increased by a minimum of 6 dB. Evaluation of
indications shall be carried out at normal sensitivity.
10. Calibration control
A calibration control has to be executed:
- at the start and end of each examination
- after every 4 hours of examination
- when a part of the examination system has been changed
If deviations are found during these checks then the measures shown in the table must be
implemented.
Deviation in
sensitivity
Measure
Deviations < 4 dB The stetting must be corrected for the remainder of the test.
Reduction in the
sensitivity > 4 dB
The setting must be corrected and all tests carried out in the previous period must
be repeated.
Increase in the sensitivity
> 4 dB
The setting must be corrected and all indications recorded must be re-tested and
re-evaluated.
Deviation in
measuring range
Measure
Deviations < 2 %
in the measuring range
The setting must be corrected for the remainder of the test.
Deviations > 2 %
in the measuring range
The setting must be corrected and all tests carried out in the pervious period must
be repeated.
11. Lamination test
The areas next to the weld across which the corner transducer(s) move (see point 12) must
be tested in advance of the weld test using the straight transducer type B2S-N.
If flaws are detected then their influence on the weld test that is to be performed must be
evaluated and, if necessary, the techniques must be adapted accordingly, for example by
testing from the other surfaces. The consequences of the flaws on the test must be reported
to the client.
Number : UT-97001
Date : 22.01.2001
Page : 6 of 14
12. Performing the test, transducer movements and test directions
This chapter deals with testing the different types of welds.
12.1 Welds in plates and pipes
For transducer movement A or B for each stroke a minimum overlap of 10 % of the

crystal width must be taken into account and the transducer must be rotated as it is
moved (approx. 10 degrees).
For movements X, Y, W and Z the angle with weld direction is approximately 15

degrees.
The tests A,X and Y or B, W and Z must be carried out on both sides of the weld. If
it is not possible to perform the test from both sides then perform the test from
direction A,X and Y as well as from and from direction B, W and Z.

Tabel 1
Thickness of
the parent
material
in mm (t)
Transducers
for
longitudinal
flaws
Transducer
positions
Scanning
distance SZW
Transducer
for transverse
flaws
Transducer position
8 < t < 15 MWB 70
4 MHz
A or B 1,25 x skip MWB 70
4 MHz
(X and Y) or (W and Z)
15
! t < 40
MWB 70 and
60 4 MHz
A or B 1,25 x skip MWB 60 4
MHz.
40
! t < 60
WB 60 and 45
2 MHz.
A or B 1,25 x skip WB 60 and 45
2 MHz.
60
! t ! 100
WB 60 and 45
2 MHz.
A or B 1,25 x skip WB 60 and 45
2 MHz.
(C and D) of (E and F)
B
SZW
D
C
A
X
Y
(B)
(
W
)
(
Z
)
(E)
(F)
A
X,Y
W,Z
Number : UT-97001
Date : 22.01.2001
Page : 7 of 14
12.2 T (K)- connections in constructions
For transducer movement A or B for each stroke a minimum overlap of 10 % of the

crystal width must be taken into account and the transducer must be rotated as it is
moved (approx. 10 degrees).
For movements X, Y, W and Z the angle with weld direction is approximately 15

degrees.
When tested with a straight beam probe from position C for t < 15 mm the probe
shall be moved opposite the centre of the weld and for t > 15 mm the probe shall be
moved over distance c.
Tabel 2
Thickness of
the parent
material
in mm (t)
Transducers
for
longitudinal
flaws
Transducer
positions
Scanning
distance SZW
Straight
probe
Transducer
for transverse
flaws
Transducer
position
8
! t < 15
MWB 70
4 MHz
A or B 1,25 x skip MB4S-N MWB 70
4 MHz
(X and Y) or
(W and Z)
15
! t < 40
MWB 60
4 MHz
A and B 1,25 x skip MB4S-N MWB 60
4 MHz
(X and Y) or
(W en Z)
40
! t ! 100
WB 60 en 45
2 MHz.
A and B 0,75 x skip B2S-N WB 60 en 45
2 MHz.
(X and Y) or
(W and Z)
X
(
W
)
Y
(
Z
)
A (B)
B A
C
C
C
Cross-section Side view
Number : UT-97001
Date : 22.01.2001
Page : 8 of 14
12.3 L- connections in constructions
For transducer movement A or B for each stroke a minimum overlap of 10 % of the crystal
width must be taken into account and the transducer must be rotated as it is moved (approx.
10 degrees).
For movements X en Y the angle with weld direction is approximately 15 degrees.
When tested with a straight beam probe from position C the probe shall be moved over
distance c as a minimum.
Tabel 3
Thickness of
the parent
material
in mm (t)
Transducers
for
longitudinal
flaws
Transducer
positions
Scanning
distance
SZW
Straight
probe
Transducer for
transverse flaws
Transducer
position
8
! t < 15
MWB 70
4 MHz
A or B 1,25 x skip MB4S-N MWB 70
4 MHz
X en Y
15
! t < 40
MWB 70 en
60 4 MHz
A or B 1,25 x skip MB4S-N MWB 60 and 45
4 MHz
X en Y
40
! t ! 100
WB 60 en 45
2 MHz.
(H or A)
and B
0,75 x skip B2S-N WB 60 and 45
2 MHz.
D en E
X
Y
B (A)
C
Side view
H
E D
H
C
C
H
A B
t
Cross-section
Number : UT-97001
Date : 22.01.2001
Page : 9 of 14
12.4 Set in nozzle welds
For transducer movement A, B, D and E for each stroke a minimum overlap of 10 % of the
crystal width must be taken into account and the transducer must be rotated as it is moved
(approx. 10 degrees).
For movements X, Y, W and Z the angle with weld direction is approximately 15 degrees.
If possible the examination from inside the nozzle will be carried out, positions C, D and E.
Position C will be moved over distance c and D and E will be moved over distance d and e
respectively.
Tabel 4
Thickness of
the parent
material
in mm (t)
Transducers
for
longitudinal
flaws
Transducer
positions
Scanning
distance SZW
Straight
probe
Transducer
for transverse
flaws
Transducer
position
8
! t < 15
MWB 70
4 MHz
A or
D
1,25 * skip or d MB4S-N MWB 70
4 MHz
X and Y
15
! t < 40
MWB 60
4 MHz
A or
D and E
1,25 * skip or
d + e
MB4S-N MWB 60
4 MHz.
X and Y
40
! t < 60
WB 60
2 MHz.
A or B D
and E
1,25 * skip
d + e
MB4S-N WB 60
2 MHz.
(X and Y) and
(W and Z)
60
! t ! 100
WB 60 en 45
2 MHz.
A and B
D en E
0,5 * skip
d + e
B2S-N WB 60 and 45
2 MHz.
(X and Y) and
(W and Z)
D,E
C
A
(B)
X
(W
)
Y
(Z)
c
e
d
D
C
E
B
A
Cross-section Top view
Shell
Nozzle
Number : UT-97001
Date : 22.01.2001
Page : 10 of 14
12.5 Set-on nozzle welds
For transducer movement A or B for each stroke a minimum overlap of 10 % of the crystal
width must be taken into account and the transducer must be rotated as it is moved (approx.
10 degrees).
For movements X en Y the angle with weld direction is approximately 15 degrees.
The examination from the inside of the nozzle, positions B, X and Y, will be executed if
accessible.
Tabel 5
Thickness of
the parent
material
in mm (t)
Transducers
for
longitudinal
flaws
Transducer
positions
Scanning
distance
SZW
Straight
probe
Transducer
for
transverse
flaws
Transducer
position
8
! t < 15
MWB 70 + 60,
4 MHz
A 1,25 x skip NA MWB 70
4 MHz
X and Y
15
! t < 40
MWB 60 + 70,
4 MHz
A 1,25 x skip MB4S-N MWB 60
4 MHz.
X and Y
40
! t < 60
WB 60 + 45
2 MHz.
A and B 1,25 x skip
0,5 x skip
MB4S-N WB 60 + 45
2 MHz.
X and Y
60
! t ! 100
WB 60 + 45
2 MHz.
A and B 1,25 x skip
0,5 x skip
B2S-N WB 60 + 45
2 MHz.
X and Y
Dwarsdoorsnede Bovenaanzicht
A
B
x,y
A
B
X
Y
Number : UT-97001
Date : 22.01.2001
Page : 11 of 14
13. Onderzoeksvolume
During the test at least the weld and 10 mm on both sides of the weld must be tested.
A
10 mm 10 mm
A = width of the test volume
14. Determination of the length of indications
The length of an indication is determined by recording the distance over which the
amplitude of the echo is above the evaluation level.
The evaluation level is 33% DAC (= -10 dB)
15. Evaluation of indications
15.1 Noise level
During the test the noise level must remain at least 12 dB below the evaluation level (33%
DAC) (in other words a noise level of < 8% DAC). If the noise level is higher then these
areas are to recorded in the report as not tested.
15.2 Evaluation and recording indications
Step 1:
All indications with a level of > 33% DAC must be tested further and then characterised
as flat or volumetric flaws. This means that indications of < 33% DAC are not to be taken
into consideration.
Step 2:
All weld flaws, characterised as flat, are to recorded by their position, length and echo
height. The type of flaw is also to be determined: crack (E), lack of fusion (C) or
incomplete penetration (D).
Step 3:
All volumetric flaws above 50% DAC are to be recorded by their position, length and
echo height for examination with acceptance level 2 and above 80% DAC for examination
with acceptance level 3.
The type of flaw is also to be determined: gas (A), slag (B)
Step 4:
Evaluate the permissibility of all indications that are recorded for acceptance level 2
according to 15.3 and for acceptance level 3 according to 15.4.

Number : UT-97001
Date : 22.01.2001
Page : 12 of 14
15.3 Acceptance level 2
Flat flaws are not permitted, irrespective of their length.
The acceptance for volumetric flaws is shown in the figures below for individual
longitudinal and transverse flaws, in relation to material thickness. For accumulative flaws
and flaws in line see 15.5.
= Acceptance level for volumetric flaws
--------- = Evaluation level
Reference level : 0 dB (=100% DAC)
Registration level for volumetric indications = Reference level 6dB
0
2
-2
-4
-6
-8
4
6
-10
-12
1t 0.5t 1.5t 2t
8 mm =< t =< 15 mm
lengte van de indicaties
r
e
l
a
t
i
e
v
e

e
c
h
o
a
m
p
l
i
t
u
d
e
0
2
-2
-4
-6
-8
4
6
-10
-12
1t 0.5t 1.5t 2t
15 mm =< t =< 100 mm
r
e
l
a
t
i
e
v
e

e
c
h
o
a
m
p
l
i
t
u
d
e
dB
dB
-14
-14
Number : UT-97001
Date : 22.01.2001
Page : 13 of 14
15.4 Acceptance level 3
Flat flaws are not permitted, irrespective of their length.
The acceptance for volumetric flaws is shown in the figures below for individual
longitudinal and transverse flaws, in relation to material thickness. For accumulative flaws
and flaws in line see 15.5.
= Acceptance level for volumetric flaws
--------- = Evaluation level
Reference level : 0 dB (=100% DAC)
Registration level for volumetric indications = Reference level 2dB
0
2
-2
-4
-6
-8
4
6
-10
-12
1t 0.5t 1.5t 2t
8 mm =< t =< 15 mm
r
e
l
a
t
i
e
v
e

e
c
h
o
a
m
p
l
i
t
u
d
e
0
2
-2
-4
-6
-8
4
6
-10
-12
1t 0.5t 1.5t 2t
15 mm =< t =< 100 mm
r
e
l
a
t
i
e
v
e

e
c
h
o
a
m
p
l
i
t
u
d
e
dB
dB
-14
-14
Number : UT-97001
Date : 22.01.2001
Page : 14 of 14
15.5 Clustered indications
The following flaws are not acceptable:
For every length of weld equal to 6 x material thickness, the accumulated length of all
acceptable single indications should not exceed 20% of this length. These flaw will not be
summarised as indications in line.
Example: The maximum acceptable accumulated length of flaws in each 180 mm weld
length with a thickness of 30 mm is 36 mm. Flaws can be located at various depths.
Indications in line shall be treated as one if the distance between them is less then two times
the length of the longest indication. The accumulated length is to be seen as one flaw with
respect to 15.3 or 15.4.
Example: One flaw with a length of 8 mm one with a length of 6 mm should have a
minimum spacing of 2 * 8 = 16 mm. For instance when the spacing between them is 10
mm then the accumulated flaw length is 8+10+6 = 24 mm.
16. Reporting
The report must contain the following information, as a minimum:
a. client name and where the test was performed;
b. the PSP number;
c. procedure number UT-97001 rev. 3;
d. equipment, techniques and transducers used;
e. equipment inspection due date;
f. calibration method (blocks or scales);
g. couplant;
h. object, areas tested, material type, dimensions and temperature;
i. surface condition and test directions;
j. test results:
all areas in the base material with indications that limit the test;
all areas with noise level > 12 dB with regard to the evaluation level;
all non-acceptable indications including the type of flaw;
all acceptable non-flat indications that are recorded, including the type of flaw.
Record the length, position and % with regard to DAC of the indications as well as the
location of the areas;
k. test date;
l. name, level and certificate number of the inspector.
Number : UT-97002
Date : 18.02.2000
Page : 3 of 5
8 Couplant
A waterbased couplant is preferable.
9 Range
The range with a single crystal probe shall be adjusted in such a way that at least two
backwall echoes appear on the screen. With a double crystal probe, at least the minimum
thickness of the steelplate shall be adjusted.
10 Sensitivity
- steelplate examination - Class S3 see table 1
- material edge examination - Class E4 see table 2
Table 1: plate surface
Acceptable clusters of discontinuities Class Area of Unacceptable individual
discontinuity mm
2
Area
1)
mm
2
Maximum density
not greater than
S3 Inclusions which a reflection
> DAC for a cylindrical
hole 8 mm
N3
(between 5 mm
and 8 mm)
10 in the most
populated
1 m x 1 m square
a) Dimensions of each discontinuity within the assessed
Table 2: Material edge
Permissible individual
discontinuity size
Class
Maximum
Dimension
L
max
mm
Maximum
Area
S
max
Mm
2
Minimum
Discontinuity
dimension
Considered
L
min
mm
Permissible
number of
discontinuities
smaller than the
maximum size and
longer than
L
min per
1 m length
E4 20 50 10 2
Number : UT-97002
Date : 18.02.2000
Page : 4 of 5
11 Sensitivity setting weld preparation examination
This examination will only be carried out when the plates already have been
cut and the welds preparations are machined.
- Sensitivity 5 mm ERG according to the A.V.G.-system.
12 Test sensitivity
During examination, sensitivity shall be increased by a minimum of 6 dB. Evaluation of
indications shall be carried out at original sensitivity.
13 Registration level
Plate examination : see table 1.
Weld preparation examination : see table 2.
Corus Weldinspection Department assesses the report for the acceptability of the
discontinuities.
14 Report form
The standard RTD report forms shall be used and be filled out completely.

Number : UT-97002
Date : 18.02.2000
Page : 5 of 5
Statement:
1. See table 2 for the value of the edge zone width
2. Scan line
3. Edge zone
4. Principal rolling direction
5. Flat product
6. Width
7. Length
Dimensions of each discontinuity in the cluster in question
Number : MT-97003
Revision : 2 MAGNETIC PARTICLE EXAMINATION PROCEDURE
Date : 21.02.2000
Page : 3 of 5
4 Surface condition
The object to be examined at the location of the test shall be dry and free of oil, dirt,
weld spatter, rust, loose scale, loose paint or foreign matter that might interfere with
the examination.
If can be necessary to improve the surface condition, for example with sandpaper or
local grinding to allow a secure interpretation of the indications.
The temperature of the surfaces to be examined shall be 60C as a maximum.
5 Equipment and method of examination
5.1 A. Yoke magnet alternating current (AC)
In accordance with CP-31201
B. Prode Magnet unit alternating current (AC) coil method
In accordance with CP-31208
5.2 Accessories
- Inspection ink
Black inspection ink, oil or water based.
The inspection ink has to be in accordance with CP-31203.
- Berthold indicator
The Berthold indicator shall be used to determine the direction of the field. Also the
inspection ink can be assessed for its adequacy.
The NDT technician shall be inpossession of the indicator and shall use the indicator
on a regular basis. In any case once a day and in case of relevant changes in the
examination circumstances.
Number : MT-97003
Date : 21.02.2000
Page : 4 of 5
6 Current to be used
6.1 (A) Examination-technique yoke magnet
Yoke magnets shall have a lifting power capacity of at least 4,5 kg.
6.2 (B) Examination with prodequipment
The amperages to be used shall > 5 A/mm prod spacing.
6.3 Coil technique
The amperages to be used shall be in accordance with following sketch.
N = number of coils
I = amperage
a = distance between the weld and the coil or cable
7 Direction of field
Two independant examinations shall be made in each area being tested.
The second examination shall be made with the lines of magnetic flux approximately
perpendicular to the first examination. The second examination may be carried out
using a different magnetising technique.
Number : MT-97003
Date : 21.02.2000
Page : 5 of 5
8 Examination coverage
The examination shall be carried out with sufficient overlap to assure that all areas to
be examined will be 100% examined with the required sensitivityopi. See following
sketch.
9 Application of test ink (continuous method)
The test ink is applied simultaneously with the appliance of the field and the
appliance will be continued after appliance of the testink to create the forming of the
particles.
10 Evaluation of indications
Not all indications are necessarily relevant indications. Excessive surface roughness,
magnetic permeability variations may produce similar indications.
Each doubtful indication shall be re-examined to determine if relevant
discontinuities are present or not.
11 Acceptance standard for the indications
Dimensions in mm
Acceptance level Type of indication
1
Linear indication
l = length of the indication l 1,5
Not-linear indication
d = dimensions of the primary axis d 2
12 Report form
Number : PT-97004
Revision : 2 LIQUID PENETRANT EXAMINATION PROCEDURE
Date : 21.02.2000
Page : 3 of 5
5 Surface condition
All items to examined shall be free of dirt, oil, paint, weld spatter, rust, scale loose
paint or foreign matter that might interfere with the examination.
6 Penetrant types to be used
Colour contrast, solvent or water removable.
7 Type penetrant
Penetrant materials from the same brand.
8 Temperature of workpiece
Between 10 and 55 celcius.
9 Method of examination
9.1 Pre-cleaning
All surfaces to be examined shall be thoroughly cleaned. In case of inspection of
welds, the weld and both sides of the material to 25 mm shall be well cleaned.
9.2 Application of penetrant
After drying the penetrant may be applied by dipping brushing or spraying. If the
penetrant does not stay in an even layer, then pre-cleaning shall be repeated.
- dwell time minimum 20 minutes.
Warning:
Emphatically we point out that the use of aerosol containers in closed areas is
dangerous and therefor forbidden.
Number : PT-97004
Date : 21.02.2000
Page : 4 of 5
9.3 Removal of penetrant
Excessive penetrant shall be removed sequently as follow:
a. Dry cloths
b. Cloths dampened with solvent or water
c. Dry cloths.
9.4 Application of developer
After drying, apply a very thin even layer.
The surface of the workpiece should be just visible.
- develop time minimum 20 minutes.
9.5 Examination
Start examination when developer has dried and continue until development time has
lapsed (minimum 20 minutes).
10 Evaluation of indications
- Not all indications are necessarily relevant indications, localized surface
irregularities due to machining marks or other surface conditions, may produce
false indications.
- Any questionable or doubtful indications shall be re-examined to determine
whether or not they are relevant.
Number : PT-97004
Date : 21.02.2000
Page : 5 of 5
11 Acceptance levels of indications
Dimensions in mm
Acceptance level Type of indication
1
Linear indication
l = length of the indication l 2
Not-linear indication
d = dimensions of the primary axis d 4
12 Clustered indications
Indications in-line shall be assessed as one, continuing indication, if the distance is
smaller as the marndimension of the smallest indication.
13 Report form
Number : RT-97005
Revision : 2 RADIOGRAPHIC EXAMINATION PROCEDURE
Date : 21.02.2000
Page : 2 of 14
1 Scope of examination
This procedure describes the method and assessment for the radiographic weld
examination.
For the assessment of the radiographs the following numbers of the EN 25817 will be
evaluated: 1, 2, 3, 4, 5, 6, 7, 8 and 9.
2 Extent of examination
The extent of the examination will be established by Hoogovens or the contractor.
The category of welding may be 1, 2, or 3.
Welding category 1:
Percentage of inspection 100%.
Assessment criteria according EN 25817 level B
Welding category 2:
All weld crossings, completed up to at least 10% of the total amount of welds. This
completion must be of the same welding category, 10% erection welds and 10%
prefab welds. The remaining welds will be pointed out by a weld inspector.
Assessment criteria according EN 25817 level C
Welding category 3:
No NDE dictated.
On a request of Hoogovens' Welding inspection welds can be dictated for
examination.
Assessment criteria according EN 25817 level D
Number : RT-97005
Date : 21.02.2000
Page : 3 of 14
3. Equipment
3.1 X-ray equipment, directional type
Make : Balteau, Andrex or Seifert
Energy range : 10 300 keV
Effective focal spot size : 2 4 mm
3.2 X-ray equipment, orthogonal type
Make : Balteau, Andrex or Seifert
Energy range : 160 300 keV
Effective focal spot size : 3 5 mm
3.3 Gamma-ray equipment
Make : Techops
Ir-192 : Effective source size < 2,1 mm
Co-60 : Effective source size between 2 and 4 mm
4. Films, screens, density and diagnostic film length
4.1 Films
The films used are conform EN 584-1: C3 and C4 respectively Agfa D4 and D5.
The films must be free of defects that may disturbed the evaluation of the results.
Such blemishes include but are not limited to:
a. repairs to radiographs owing to processing;
b. scratches and dirtiness;
c. static marks;
d. false indications due to defective screens.
Number : RT-97005
Date : 21.02.2000
Page : 4 of 14
4.2 Screens
Radioactive
source
Screen thickness
front/back
in mm
Material
X-ray
Ir-192
Co-60
0,027
0,125
0,5
Pb
Pb
Cu or SS
The thickness of the screens may be less if the required sensitivity keeps
demonstrable.
4.3 Density
Radiographs shall be within the density limits 2.3 and 3.5.
A tolerance of 0.1 in density shall be used for variations between densitometer
readings. Only films with a maximum fog density of 0.3 shall be used.
4.4 Diagnostic film length
The diagnostic film length will be specified by: the number of exposures, the
demonstrated quality and the density limits.
4.5 Film coverage
The film coverage shall be within the diagnostic film length. If the diagnostic film
length is more than the film size used the coverage shall be at least 20 mm.
Number : RT-97005
Date : 21.02.2000
Page : 5 of 14
5. Image Quality Indicator (IQI)
5.1 IQI conform EN 462-1
Type and wire material of IQI.
Code en type Wire number Wire length
in mm
Wire material Material group
EN 1 Fe
EN 6 Fe
EN 10 Fe
EN 13 Fe
1 to 7
6 to 12
10 to 16
13 to 19
50
50 or 25
50 or25
50 or 25
unalloyed
steel
iron
5.2 Required image quality for the single wall technique (SW)

Single wall technique and the
IQI on source side
Required quality wire diameter
Nominal wall thickness in
mm
Class B mm
1,5
2,5
4
2,5
4
6
W18
W17
W16
0,063
0,080
0,100
6
8
12
8
12
20
W15
W14
W13
0,125
0,16
0,20
20
30
35
30
35
45
W12
W11
W10
0,25
0,32
0,40
45
65
65
120
W9
W8
0,50
0,63

If Iridium 192 is used the required image quality within 12 to 40 mm shall be 1 wire
number lower.
Number : RT-97005
Date : 21.02.2000
Page : 6 of 14
5.3 Required image quality for the double wall double image technique (DW-DI)
Double wall Double image technique
and the IQI on source side
Required quality Wire diameter
Penetrated thickness in mm class B mm
1,5
2,5
4
2,5
4
6
18
17
16
0,063
0,080
0,100
6
8
12
8
12
20
15
14
13
0,125
0,16
0,20
20
30
35
30
35
45
12
11
10
0,25
0,32
0,40
45 65 9 0,50
5.4 Required image quality for the double wall single image technique (DW-SI)
Double wall single image technique and
IQI on film side
Required quality Wire diameter
Penetrated thickness in mm class B mm
1,5
2,5
4
2,5
4
6
18
17
16
0,063
0,080
0,100
6
12
18
12
18
30
15
14
13
0,125
0,16
0,20
30
45
55
45
55
70
12
11
10
0,25
0,32
0,40
Number : RT-97005
Date : 21.02.2000
Page : 7 of 14
5.5 Number of IQI's
Weld in flat plates
At least one IQI across the weld with the thinnest wire in the thickest part to be
examined.
Welds in curved plates
Circumferentional welds examined in one exposure at least three IQI's equally spaced
across the weld. The maximum distance between two IQI's shall be less than 1 m.
Double wall single image technique (DW-SI)
One IQI just within the diagnostic film length.
Double wall double image technique (DW-DI)
With the DW-SI technique and a diameter smaller than 50 mm, one IQI parallel next
to the weld and perpendicular to the pipe axis in such a way that the IQI image will
not be projected in the weld area.
5.6 IQI location
The IQI shall be placed on the source side of the object to be examined.
If the source side is inaccessible the IQI will be placed on film side. A lead letter "F"
will be placed beside or on the IQI.
In general the IQI will be placed across the weld, except if the diameter is smaller than
50 mm.
6. Energy selection
The choice of the radiation source will be stipulated by the object thickness. For a
double wall technique the penetrated thickness is the sum of two walls.
6.1 X-ray up to 300 kV
The maximum kV-setting for steel: 100 kV + 8 kV/mm
The maximum kV-setting shall be raised with a maximum of 50 kV when the
reinforcement or thickening may influence the interpretation of the radiographs.
Number : RT-97005
Date : 21.02.2000
Page : 8 of 14
6.2 Thickness range for radioactive sources
Gamma source Steel
Ir-192 20 to 100 mm
Co-60 60 to 150 mm
The thickness limitation will be reduced when the radiographic techniques used
demonstrate that the required radiographic sensitivity has been obtained
7. Film-focus distance
The minimum film focus distance (Fmin) shall be:
10x the thickness to be inspected. This calculation will be used for a 2 mm radiation
source.
In general : Fmin= B x 5 x (thickness to be inspected)
B = Radiation source size in mm
Fmin = Minimum Film focus distance in mm
8. Film identification and marking
8.1 Film identification
The identification may consist of:
a. order number or object number;
b. weld number;
c. indication after a repair, R1 for first repair, R2 for second repair, etc.
8.2 Marking
In general fixed markers will be used to localise any radiograph. When the shape of
the material doesn't allow marking by hammering other method will be used, e.g.
yellow chalk.
For the radiographic inspection of circumferential welds measuring tape or overlap
ciphers will be used. When measuring tape is used at least one distance indicator shall
be visible on the next radiograph. The start and a direction indicator will be marked on
the object.
Number : RT-97005
Date : 21.02.2000
Page : 9 of 14
9. Radiographic set-ups and techniques
9.1 Direction of radiation
The direction of the central beam of radiation will be centred on the area of interest. If
possible or practical, a single wall technique will be used. When a single wall
technique is not practical a double wall technique shall be applied.
9.2 Single wall technique
9.3 Double wall single image technique (DW-SI)
For the number of exposures for technique 13 see page 11
Number : RT-97005
Date : 21.02.2000
Page : 10 of 14
9.4 Double wall double image technique (DW-DI)
For circumferential welds up to 75 mm diameter, if practical.
Elliptical projection Superimposed
10. Number of exposures
The number of exposures of circular welds in steel are given in the next two tables.
Table 1 for X-ray equipment and table 2 when Iridium 192 is used.
The code 2/3 means: 2 exposures with an elliptical projection (set-up 11) or 3
exposures with the superimposed technique at 60
0
or
120
0
to each other (set-up 12), only when the elliptical
projection is not practical.
The code X/XX means: X exposures with the DW-SI technique or
XX exposures with the DW-DI technique
Number : RT-97005
Date : 21.02.2000
Page : 11 of 14
Number of exposures when an X-ray tube is used
table 1
mm 5S 10S 10 20 30 40S S 40 60 80S XS 80 100 120 140 160 XXS
1/2 21.34 3 3 3 3 3 3 3 3 3 3 1/2
3/4 26.67 3 3 3 3 3 3 3 3 3 3 3 3/4
1 33.40 3 3 3 3 3 3 3 3 3 3 11/6 1
1 1/4 42.16 3 3 3 3 3 3 3 3 3 3 10/6 1 1/4
1 1/2 48.26 3 3 3 3 3 3 3 3 3 3 9/6 1 1/2
2 60.32 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3 8/5 9/5 2
2 1/2 73.02 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3 8/5 9/5 2 1/2
3 1/2 101.60 7 7 7 7 7 7 7 7 7 8 3 1/2
4 114.30 6 6 6 7 7 7 7 7 7 7 7 8 4
5 141.30 6 6 6 6 6 6 6 6 6 7 7 7 5
6 168.27 6 6 6 6 6 6 6 6 6 7 7 6
8 219.07 6 6 6 6 6 6 6 6 6 6 6 6 6 8
10 273.05 6 6 6 6 6 5 5 6 6 6 6 6 6 10
12 323.05 5 5 5 5 5 5 5 6 6 6 6 12
14 355.60 5 5 5 5 5 5 5 5 5 14
16 406.40 5 5 5 5 5 5 5 5 5 16
18 457.20 5 5 5 5 5 5 5 5 5 18
20 508.00 5 5 5 5 5 5 5 5 5 20
22 558.80 5 5 5 5 5 5 5 5 5 22
Number of exposures when Iridium 192 is used
table 2
mm 5S 10S 10 20 30 40S S 40 60 80S XS 80 100 120 140 160 XXS
1/2 21.34 3 3 3 3 3 3 3 3 3 3 1/2
3/4 26.67 3 3 3 3 3 3 3 3 3 3 3 3/4
1 33.40 3 3 3 3 3 3 3 3 3 3 10/6 1
1 1/4 42.16 3 3 3 3 3 3 3 3 3 3 9/6 1 1/4
1 1/2 48.26 3 3 3 3 3 3 3 3 3 3 9/6 1 1/2
2 60.32 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3 7/5 8/5 2
2 1/2 73.02 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3 7/5 8/5 2 1/2
3 1/2 101.60 4 4 4 5 5 5 5 5 5 7 3 1/2
4 114.30 4 4 4 5 5 5 5 5 5 6 6 7 4
5 141.30 4 4 4 4 4 4 5 5 5 5 6 7 5
6 168.27 4 4 4 4 4 5 5 5 5 6 6 6
8 219.07 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 8
10 273.05 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 10
12 323.85 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 12
14 355.60 4 4 4 4 4 4 4 4 4 4 4 5 5 5 14
16 406.40 4 4 4 4 4 4 4 4 4 4 4 4 5 5 16
18 457.20 4 4 4 4 4 4 4 4 4 4 4 4 5 5 18
20 508.00 4 4 4 4 4 4 4 4 4 4 4 4 5 5 20
22 558.80 4 4 4 4 4 4 4 4 4 4 4 4 5 5 22
11. Check for backscatter
As a check for scattered radiation a lead symbol "B" with dimensions not exceeding a
height of 13 mm and a thickness of 1.6 mm will be attached to the back of each film
cassette.
If a lighter image of the "B" appears on a dark background, scattered radiation
prevention is inadequate. Extra lead protection will be applied at the back of film
cassette.
Number : RT-97005
Date : 21.02.2000
Page : 12 of 14
12. Film processing
For film processing the recommendation of manufacturers about films, chemicals and
development equipment will be followed.
All radiographs shall be free of mechanical, chemical or other deviations in the area of
examination because these might be confused with the image of a deviation.
Such deviations include but are not limited to:
a. fog;
b. development errors;
c. loss of sharpness due to screen-film contact;
d. indications attributable to defect screens.
13. Personnel
All NDE personnel shall be qualified and certified conform EN 473.
At least one operator per team has a valid certificate according tot EN-473
level RT-II.
14. Reporting
The following information shall be reported as a minimum:
a) examination department;
b) object/project;
c) weld type, material and material thickness;
d) welding process;
e) examination specification, set-up and class;
f) acceptance criteria;
g) equipment: gamma source, x-ray type and radiation source size;
h) film type. foils and filters;
i) kV-setting, mA-setting or activity;
j) film focus distance and exposure;
k) IQI-type, IQI-location and IQI-sensitivity;
l) density;
m) automatic or hand processing;
n) weld imperfection notation conform EN 26520;
o) result of examination;
p) permitted difference to this standard procedure;
q) name and level of the operators;
r) date of inspection and assessment.
Number : RT-97005
Date : 21.02.2000
Page : 13 of 14
15. Acceptance criteria
EN 25817 level B, C and D. The level depends on the welding category.
Symbols used:
d = diameter of pore
h = height or width of imperfection
s = nominal weld thickness
t = wall thickness
( ) = number of imperfection conform EN 25817
Definitions:
Short imperfections
One or more imperfections of a total length not greater than 25 mm in any 100 mm
length of the weld or a maximum of 25% of the weld length for a weld shorter than
100 mm.
Long imperfection
One or more imperfections of a total length greater than 25 mm in any 100 mm length
of the weld or a minimum of 25% of the weld length for a weld shorter than 100 mm.
Projected area
Area given by length of weld examined multiplied by the maximum width of weld.
Butt weld thickness (s)
Minimum distance from the surface of the part to the bottom of the penetration, which
cannot be greater than the thickness of the thinner of the parts.
Only imperfections demonstrable by radiography are noticed in the next table
Number : RT-97005
Date : 21.02.2000
Page : 14 of 14
Limits for imperfections
Limits for imperfections for
quality levels
Imperfection designation
and ( ) ISO definition
conform EN 26520
Remarks
D C B
1
Cracks (E) All types of cracks, except
crater cracks Not permitted
2 Crater crack (Ec) permitted not permitted
3 Porosity (Aa) size
max. size
Random
d 0.5s
4mm
4%
d 0.4s
4mm
2%
d 0.3s
3mm
1%
4 Localised (clustered)
porosity (An)
concentration
size
max. size
>16%
d 0.5s
4 mm
>8%
d 0.4s
3mm
>4%
d 0.3s
2mm
5 Elongated cavities (Ab) Long imperfections
max. width
Short imperfections
hmax
max. length
h 0.5s
2mm
h 0.5s
4mm
s
not
permitte
d
h 0.4s
3mm
s
not
permitted
h 0.3s
2mm
s
6 Solid inclusions (Ba)
(other than copper)
Long imperfections
max. width
Short imperfections
hmax
max. length
h 0.5s
2mm
h 0.5s
4mm
s
not
permitte
d
h 0.4s
3mm
s
not
permitted
h 0.3s
2mm
s
7 Copper inclusions Not permitted
8 Lack of fusion (C) Not permitted
9 Lack of penetration (D) Not permitted

S1450401 - Corus - Execution and Inspection of Steel Welding PDF

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S1 45 04 01 Corus Standard

Execution and inspection of steel welding

For transducer movement A or B for each stroke a minimum overlap of 10 % of the

For movements X, Y, W and Z the angle with weld direction is approximately 15

For transducer movement A or B for each stroke a minimum overlap of 10 % of the

For movements X, Y, W and Z the angle with weld direction is approximately 15

For movements X en Y the angle with weld direction is approximately 15 degrees.

For movements X en Y the angle with weld direction is approximately 15 degrees.

Flat flaws are not permitted, irrespective of their length.

Flat flaws are not permitted, irrespective of their length.

all non-acceptable indications including the type of flaw;

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