NDE-6407 Rev0

TERMOCHIMICA IMPIANTI Vendor Document No. Rev.
Page
VIA PURICELLI 5 GALLARATE (VA) ITALY 1 of

NDE-6407 0
TEL +39 0331 770068 116
NDT PROCEDURE AND NDE PERSONAL QUALIFICATION
VENDOR DOCUMENT REVIEW
151 NEW GAS TURBINE GENERATOR 1 REVISE AND RESUBMIT

PROJ.: GT5
MOTOR OIL HELLAS - CORINTH 2 TO BE ISSUED AS FINAL PROVIDED
CLIENT: REFINERIES S.A. COMMENTS ARE INCORPORATED
MATERIAL REQUISITION No. 3 NO COMMENT - FINAL ISSUE
FOR INFORMATION ONLY (INTERNAL

151 MR 0 8 4 5 0 1 4
USE)
ITEM: D-7026
MOTOR OIL HELLAS
SR Doc. CODE: B1103
BY: DATE:
NEW GAS TURBINE GENERATOR GT-5

MOTOR OIL (HELLAS) – CORINTH REFINERIES S.A.
Stamp
Requisition Number: MR-0845-01
Purchase Order Number: 151A0005
Equipment / Item Tag: D-7026

Equipment / Item Description: DEAERATOR
Document Number: NDE-6407

Comment given in this document does not relieve vendor of his/her responsibility for
the correct engineering design and fabrication. This equipment or product shall be
Document Category: made as per the codes, requisition, specification, project procedures, and
international standards.
0 14-OCT-2010 AG MB AV
Date Written By Check By Approved By
Rev Status
DD-MMM-YYYY (name) (name) (name)
DOCUMENT COVER SHEET
Document Title:
Visual Examination Procedure

Owner Name : TERMOCHIMICA Job No : 1004915
Project Name : NEW GAS TURBINE GENERATOR Procedure No : TIF/ASME/NDE/VT/001
GT-5 Project, Greece
Mfr’s Sl. No : Doc No : TI/TC/D019
P.O No : 4794-10/SV – Rev.00
Description: Visual Examination Procedure
TERMOCHIMICA
0 11.10.2010 For Approval Renjith. G Sinoj BalasubramaniamS
Rev. Date Description Prepared Checked Approved

Visual Examination Procedure Doc. No TIF/ASME/NDE/VT/001
Revision 02
Date 12.12.2009

VISUAL EXAMINATION PROCEDURE
REVISION RECORD
REVISION DATE DESCRIPTION
00 15.09.2008 Original Issue
01 22.06.2009 ASME BPV 2008 Addenda incorporated.
02 12.12.2009 Addenda 2009 added
Page 2 of 13
Revision 02
Date 12.12.2009

INDEX
Clause
Description of Content Page Ref.
Ref...
1 Scope 4
2 Reference Documents 4
3 Procedure Qualification & Revision 4
4 Performance Demonstration Requirements 5
5 Qualification of Visual testing Personnel 6
6 Equipment and calibration 6
7 Inepection Method and lighting 6
8 Sequence of Inspection 6
9 Surface finish and extent of inspection 7
10 Stages of Application 7
11 Acceptance Criteria 8
12 Appendix – 1 9
13 Attachment – 1: ASME B 31.1 Acceptance Criteria 10
14 Attachment – 2: AWS D 1.1 Acceptance Criteria 11
15 Attachment – 3: ASME Sec VIII Div 2: 2007 Acceptance criteria. 12
Page 3 of 13
Revision 02
Date 12.12.2009

1.0 SCOPE
1.1. This procedure describes minimum requirements to perform Direct Visual Inspection on all
types of welds and components as required by the referencing code sections stated in para
2.0 of this document whenever such type of inspection is applicable by contract
Specification.
1.2 Extent of visual inspection shall be as per applicable document.
2.0 REFERENCE DOCUMENTS
Current editions of the following references shall be applicable.
ASME SEC V, Article 9 Edition 2007; Addenda 2009
ASME Sec VIII Div 2: 2007 Edition, Addenda 2009
ASME SEC IX, 2007; Addenda 2009
ASME SEC I, 2007, Addenda 2009
ASME B-31.1; 2007, Addenda 2009
AWS D 1.1:2008
ASNT SNT TC IA 2001 & 2006 EDITION.
3.0 PROCEDURE QUALIFICATION AND REVISION

3.1 This Procedure is a General NDE document for reference and use by authorized TECH
INTERNATIONAL personnel applicable for the purpose identified in the Scope and
essentially addressing the requirements of ASME Section V
3.2 Relevant TECH INTERNATIONAL personnel are required to be aware of the requirements
of this Procedure and suitably qualified and certified by TECH INTERNATIONAL for
implementation.
3.3 When used by non-TECH INTERNATIONAL Organizations, the necessary agreements

will need to be effected with TECH INTERNATIONAL and a reference to this Procedure
shall be made appropriately by the Organizations.
3.4 This Procedure contains variables, which may need qualification by way of demonstration
required by the referencing Code. Under such situations, any change or deviation to
essential variables will require revision and re-qualification by demonstration of this
Procedure. Such demonstrations shall be on a case-to-case basis and shall be demonstrated
to the Inspector / Client Representative prior to implementation of this procedure on Test
Component. A change or requirement identified as non-essential variable does not require
requalification of the written procedure. However, all such changes of essential or non-
essential variables from those specified within the written procedure shall require revision
or at least addendum to the written procedure. Refer table 3.1 below.
Page 4 of 13
Revision 02
Date 12.12.2009

TABLE 3.1 (Table T-921 of Article 9)

REQUIREMENTS OF A VISUAL EXAMINATION PROCEDURE
Requirement (As Applicable) Non-Essential

Essential Variable
Variable
Change in technique used
Direct to or from translucent X
Direct to remote X
Remote visual aids X
Personnel performance requirements, when required X
Lighting intensity (decrease only) X
Configurations to be examined and base material
X
product forms (pipe, plate, forgings, etc)
Lighting equipment X
Methods or tools used for surface preparation X
Equipment or devices used for a direct technique X
Sequence of examination X
Personnel qualifications X
3.5 This Procedure contains Mandatory and Non-mandatory Annexure. Any revision to this
Procedure or Mandatory Annexure will require revision and re-issue of this Procedure. Any
revision to this Procedure will as a minimum require review and acceptance by the
Appointed NDT Level III and approval by Manager / TECH INTERNATIONAL.
3.6 This Procedure contains sample acceptance standards applicable for welds as per ASME
Sec VIII Div 2, ASME B 31.1 and AWS D 1.1 as Non-mandatory Annexure I. However,
when suitable, this Procedure may be applied for other acceptance standards when such
acceptance criteria are appropriately recorded during examination with reference to this
Procedure, any revision to Non-mandatory annexure will not warrant revision of this
procedure.
3.7 Users of this Procedure shall verify the applicability of this Procedure with respect to
requirements.
4.0 PROCEDURE DEMONSTRATION REQUIREMENT:
4.1 As an evidence of the qualification of the procedure, a report shall be attached with or
referenced to the procedure including all the parameters of the examination. In general a
fine line of 0.8 mm or less in width, an artificial imperfection or a simulated condition
located on the surface or a similar surface to that to be examined, may be considered as a
method for procedure demonstration. The condition or artificial imperfection should be in
the least discernable position of the test surface to validate the procedure.
5.0 QUALIFICATION OF VISUAL TESTING PERSONNEL
Page 5 of 13
Revision 02
Date 12.12.2009

5.1 Personnel conducting visual inspection shall be qualified to minimum NDT level II/III
Certification in accordance with TECH INTERNATIONAL UAE’s written practice No
TIF/WP/NDE/001/08 in compliance with ASNT document SNT-TC-IA.
5.2 Personnel Qualified to AWS QC 1, Standard for Qualification and Certification of Welding
Inspection may be used for Visual examination of welds.
5.3 All personnel responsible for visual testing shall have to undergo annual near distance
acuity test such that they are capable of reading standard J – 1 letters on standard Jaeger test
type chart for near vision.
6.0 EQUIPMENT AND CALIBRATION
An array of devices are available for viewing measuring etc. whenever such a device is deem
necessary by Contractual requirements or Specification, any device requiring calibration shall be
calibrated accordingly and documented.
7.0 INSPECTION METHOD AND LIGHTING
7.1 Inspection Method:
Visual inspection shall be performed without magnification unless specifically required by
the governing document. When magnification is required, evaluation and acceptance shall
be based upon comparison with a reference standard where both magnified and
unmagnified appearance can be determined.
7.2 Direct visual examination:
Direct visual examination may usually be made when access is sufficient to place the eye
within 24 in. (600 mm) of the surface to be examined and at an angle not less than 30 deg.
to the surface to be examined. Mirrors may be used to improve the angle of vision, and aids
such as a magnifying lens may be used to assist examinations. The specific part,
component, vessel, or section thereof, under immediate examination, shall be illuminated, if
necessary with flashlight or other auxiliary lighting, to attain a minimum of 100 foot-
candles (1000 lux) at the examination surface/site.
7.3 Remote Visual Examination
In some cases, remote visual examination may have to be substituted for direct examination.
Remote visual examination may use visual aids such as mirrors, telescopes, Boroscopes,
fiber optics, cameras or other suitable instruments. Such systems shall have a resolution
capability at least equivalent to that obtainable by direct visual observation and prior
approval by authorized inspector.
7.4 Records:
Weld inspection results shall be recorded when required, and maintained as required by the
governing document or contract specifications.
8.0 SEQUENCE OF INSPECTION

8.1 Visual Inspection shall be performed prior, during and after the completion of weldments.
8.2 Visual Inspection should be performed prior to any other Inspection, if the Inspector has
reason to doubt the quality of the item as weldments. The inspector may require additional
Inspection.
8.3 Visual inspection shall be done after PWHT (if any) and shall be done prior to any other
NDE.
Page 6 of 13
Revision 02
Date 12.12.2009

9.0 SURFACE FINISH & EXTENT OF INSPECTION

9.1 Surface finish
Unless otherwise specified, acceptance inspection shall be performed on an item in the final
surface condition and final heat-treated condition. Surfaces to be inspected shall be free
from, paint, scale, slag, and adhering or embedded sand or other extraneous materials. With
the exception of undercuts, which are within specification allowances the contour of welds,
shall blend smoothly and gradually into the base metal. Weld surface irregularities shall be
removed to the extent that they do not interfere with the inspection. Shot peening, sand, grit,
and vapor blasting shall not be performed on surfaces, which are to be liquid penetrant
inspected unless specifically approved by the authorized Inspector.
9.2 Area of interest
The area of inspection for welds shall include as a minimum, the area one inch on either
side of the expected weld width. The area of inspection of other items shall be as specified
in the governing document.
10.0 STAGES OF APPLICATION
a) Prior to welding for
1. Weld and preparation, dimensions and surface finish.
2. Clearance dimensions of backing strips, Backing rings, sockets or consumable inserts.
3. Verification of correct type of material.
4. Verification of cleanliness requirements.
5. Placements of reference lines for socket welds.
b) At fitup for
1. Joint clearances
2. Alignment
c) Condition of tack welds, in accordance with requirements of the specific weld
type.
d) During welding
1. For compliance to proper Welding procedure.
e) After welding for
1. Contour and finish of outside surface.
2. Contour and finish of inside surface when accessible.
3. Size of legs and throat thickness of fillet welds.
4. Degree of undercutting.
5. Evidence of mishandling, from center punch or other impression marking or excessive
grinding.
Page 7 of 13
Revision 02
Date 12.12.2009

11.0 ACCEPTANCE CRITERIA

11.1 Evaluation:
Acceptance standards shall be as required by the governing documents. Discontinuities
shall be classified in accordance with applicable acceptance standards.
Refer attachment 1 acceptance criteria.
11.2 Examination Checklist:

A checklist shall be prepared to ensure that the required visual examinations were
performed. The checklist shall address the minimum requirements for visual examination.
Any additional requirement other than above is not mandatory for including in the checklist
unless specified by client.
Page 8 of 13
Revision 02
Date 12.12.2009

APPENDIX - I
Measuring apparatus and Practical Applications
Attribute Tool
Wall Thickness Ball Micrometer
Bevel Angles Bevel Protractor
Outside Diameter Vernier Caliper, Micrometer
Inside Diameter Vernier Caliper, Micrometer
Scale, Vernier Caliper
Feeler Gauge
Reinforcement Scale / Weld Gauges
Undercut Scale, Depth, Gauge
Surface Finish Surface Comparator
Socket Depth Scale
Fillet Legs or Throat Thickness Scale, Gauge, Template.
Page 9 of 13
Revision 02
Date 12.12.2009

ATTACHMENT 1
ACCEPTANCE CRITERIA – VISUAL TESTING – ASME B31.1
A. Acceptance Standards. The following indications are unacceptable:

(A.1) cracks – external surface;
(A.2) undercut on surface which is greater than 1/32 in. deep;
(A.3) weld reinforcement greater than specified in Table I
(A.4) lack of fusion on surface;
(A.5) incomplete penetration (applies only when inside surface is readily accessible);
(A.6) any other linear indications greater than 3/16 in long;
(A.7) surface porosity with rounded indications having dimensions greater than 3/16
in. or four or more rounded indications separated by 1/16 in. or less edge to
edge in any direction. Rounded indications which, are circular or elliptical with
their length less than three times their width.
TABLE I
REINFORCEMENT OF GIRTH AND LONGITUDINAL BUTT WELDS
Maximum Thickness of Reinforcement

for Des ign Temp erature
Th ickness of Base M etal, in (mm ) > 750 oF 350o F - 750oF < 350oF
(400oC) (175oC - 400o C) (175oC)
in. mm in. mm . In. mm.
Up to 1/8 (3.0), in cl. 1/16 2.0 3/32 2.5 3/16 5.0

Over 1/8 to 3/16 (3.0 to 5.0) incl. 1/16 2.0 1/8 3.0 3/16 5.0
Over 3/16 to ½ (5.0 to 13.0) incl. 1/16 2.0 5/32 4.0 3/16 5.0
Over ½ to 1 (13.0 to 25.0) incl. 3/32 2.5 3/16 5.0 3/16 5.0
Over 1 to 2 (25.0 to 50.0), incl. 1/8 3.0 ¼ 6.0 ¼ 6.0
Over 2 (50.0 ) 5/32 4.0 The greater of ¼ (6mm) or 1/8 times the width of
the weld in inch es (mm)
GENERAL NOTES:
a. For double welded butt joints, this limitation on reinforcement given

above shall apply separately to both inside and outside surfac es of the
joint.
b. For single welded butt joints, the reinforcement limits given above shall
apply to the outs ide s urface of the joint only.
c. The thickness of weld reinforcement shall be based on the thickness of
the thinner of the materials being joined.
d. The weld reinforcement thicknesses shall be determined from the
higher of the abutting surfaces involved.
e. Weld reinforcement may be removed if so desired.
Page 10 of 13
Revision 02
Date 12.12.2009

Attachment – II (AWS D 1.1: 2008)
Page 11 of 13
Revision 02
Date 12.12.2009

Attachment – III (ASME Sec. VIII Div. 2: 2007)
NOTES: Para 6.2.4.1(b)(2): A reduction in thickness due to the welding process is acceptable
provided all of the following conditions are met.
i) The reduction in thickness shall not reduce the material of the adjoining surfaces below the
minimum required thickness at any point.
ii) The reduction in thickness shall not exceed 0.8 mm (1/32 in.) or 10% of the nominal
thickness of the adjoining surface, whichever is less.
Page 12 of 13
Revision 02
Date 12.12.2009

Attachment – III contd. (ASME Sec. VIII Div. 2: 2007; Addenda 2008)
Note to 13: Concavity due to the welding process on the root side of a single welded
circumferential butt weld is permitted when the resulting thickness of the weld is at least equal to
the thickness of the thinner member of the two sections being joined and the contour of the
concavity is smooth.
Page 13 of 13
Document Title:
Magnetic Particle Examination Procedure

Project Name : NEW GAS TURBINE GENERATOR Procedure No : INS/ASME/MT/001
P.O No : 4794-10/SV – Rev.00
Description: Magnetic Particle Examination Procedure
TERMOCHIMICA

INTERNATIONAL INSPECTION SERVICES LTD
MAGNETIC PARTICLE EXAMINATION
PROCEDURE
REVISION CONTROL
Revision Number &
Changes Remarks
Date
00 Issued to address requirements of ASME Section
New Issue
15 February 2003 V Edition 2001 Addenda 2003
01 Issued to address requirements of ASME Section
Sec 5.2, 6.2, 7.2, 10.1, 10.2
15 February 2005 V Edition 2004
02
Sec. 8.1, 10.1, 11.5, 18.1 -
13 September 2005
Sec 1.1 Revised
Sec 1.5 Added
03 Sec 2.1 Revised & ASME Sec V addenda 2005 added
25 January 2006 Sec 4.2 Added
Sec 17.1 Revised
Annexure II Revised
Sec 1.2 Revised Addenda 2006 incorporated.
04
Sec 2.1 Revised
18 February 2007
Sec 12.1.1 Revised
Sec 1.2: Revised. 2007 edition incorporated.
05 Sec 3.4: Fully revised. Table 3.1
th
10 September 2007
added.
06 Sec 14.3.1: Revised. Comments and interpretations.
th
14 February 2008 Sec 14.3.2: Added.
Sec 1.2: Revised.
Sec 2: Revised 2008 Addenda incorporated.
07
rd Sec 3.5: Revised.
3 January 2009
Sec 14.3.3: Newly added.
Sec 17.1: Fully revised.
08 Appendix-I: Revised. ASME Sec VIII Div 2 requirements incorporated.
th
16 February 2009
Sec 2 and 5.1 revised.
Sec 5.2: Newly added. Subsequent
09 paragraphs re-numbered. 2009 edition incorporated.
20th December 2009 Sec 8.4: Newly added.
Sec 14.3.3: Revised.
Report format revised.
Document No. : INS/ASME/MT/001 Rev.: 09 dated 20.12.2009 Page No.: 2 of 15

This document is a property of INSPEC and for use by its authorized personnel only. Use of this Procedure by non-INSPEC
Organizations is by specific agreement. This document is subject for revisions and only the latest revision stands current.
Approved Master Copy of this document is filed and stored under the custody of INSPEC HSEQ manager. This document shall
not be reproduced without the written consent of INSPEC. Controlled Distribution Copy Holders will receive current versions
PROCEDURE
INDEX
Clause
Ref...
1 Scope 4
3 Procedure Qualification & Revision 4
4 Performance Demonstration 6
5 Personnel Qualification 6
6 NDE Method Technique 7
7 Test Equipment 7
8 Test Materials 7
9 Surface Condition and Preparation 8
10 QC of Test Equipment 8
11 Examination 8
12 Contrast Enhancement 9
13 Test Temperature 10
14 Viewing Conditions 10
15 Interpretation of Indications 10
16 Evaluation for Acceptance 11
17 Documentation and Reporting of Results 11
18 Final Cleaning 12
19 Demagnetizing 12
20 Safety 12
NON-MANDATORY ANNEXURE
Annexure I - Sample Acceptance Criteria 14
Annexure II - Sample Report Format 15
SUPPLEMENTS
MT/WELD/001 Attached

PROCEDURE
1. Scope:
1.1 This Non-destructive Examination Procedure details the minimum requirements for conducting
Magnetic Particle Examination by AC Electromagnet or Permanent Magnet with the application of
non-fluorescent particles on the test surface.
1.2 This Magnetic Particle Examination procedure shall be applied for detecting discontinuities, which are
on the surfaces or very near to the surface of ferromagnetic materials (including but not limited to
wrought/cast products and welds).
1.3 The extent of examination shall be as per applicable construction-Code requirements / project
specifications and client directives.
1.4 Typical types of discontinuities that can be detected by this method are cracks, laps, seams, cold shuts,
and laminations.
1.5 This procedure may be applicable to other MPI methods/ techniques subject to satisfactory
demonstration for qualification and revision of the procedure.
2. Reference Documents:
2.1 The following documents are referred:
2.1.1 ASME Section V 2007 ed. Addenda 2009.

2.1.2 ASME Section VIII Division 1& 2 2007 edition, Addenda 2009.
2.1.3 ASME Section I: 2007 edition, Addenda 2009.
2.1.4 ASME B31.1b 2009.
2.1.5 ASNT SNT TC 1A 2001 edition & 2006 edition.
2.1.6 INSPEC Written Practice INSPEC/9/USN/Q1.1994 Rev. 18.
3. Procedure qualification & revision:
3.1 This Procedure is a General NDE document for reference and use by authorized INSPEC personnel
applicable for the purpose identified in the Scope and essentially addressing the requirements of
ASME Section V
3.2 Relevant INSPEC personnel are required to be aware of the requirements of this Procedure and
suitably qualified and certified by INSPEC for implementation.
3.3 When used by non-INSPEC Organizations, the necessary agreements will need to be effected with

PROCEDURE
INSPEC and a reference to this Procedure shall be made appropriately by the Organizations.
3.4 This Procedure contains variables, which may need qualification by way of demonstration required by
the referencing Code. Under such situations, any change deviation to essential variables will require
revision and re-qualification of this Procedure. Such demonstrations shall be on a case-to-case basis
and shall be demonstrated to the Inspector / Client Representative prior to implementation of this
procedure on Test Component. A change of a requirement identified as a nonessential variable does
not warrant re-qualification of the procedure. However, any change in either essential or non-
essential variables shall require revision or at least an addendum/ supplement to this procedure. Refer
to Table – 3.1 for the list of variables.
TABLE – 3.1
Requirements Essential Non-essential
variable variable
Magnetizing technique X
Magnetizing current type or amperage outside range specified by X
Article 7 of ASME Sec V: 2007 or as previously qualified
Surface preparation X
Magnetic Particles (fluorescent/ visible, color, particle size, wet/dry X
etc.)
Method of Particle application X
Method of excess particle removal X
Minimum light intensity X
Existing coatings, greater than the thickness demonstrated X
Non-Magnetic surface contrast enhancement, when utilized X
Performance demonstration, when required X
Examination part surface temperature outside of the temperature X
range recommended by manufacturer of the particles or as
previously qualified.
Shape or size of the examination object X
Equipment of the same type. X
Temperature (within those specified by manufacture or as X
previously qualified).
Demagnetizing technique X
Post examination cleaning technique X
Personnel Qualification requirements X
3.5 Record of variables qualified by demonstration shall be attached as a supplement with this procedure

PROCEDURE
detailing the range of variables qualified and referencing the demonstration record number. The
applicability of this procedure shall be restricted to the variables which have been demonstrated,
qualified and relevant supplements attached with this procedure.
3.6 This Procedure contains Mandatory and Non-mandatory Annexure. Any revision to this Procedure or
Mandatory Annexure will require revision and re-issue of this Procedure. Any revision (either of
essential or non essential variables) to this Procedure will as a minimum require review and
acceptance by the Appointed NDT Level III and approval by Manager / INSPEC
3.7 This Procedure contains sample acceptance standards applicable for welds as per ASME Section VIII
(D 1) as Non-mandatory Annexure I. However, when suitable, this Procedure may be applied for
other acceptance standards. When such acceptance criteria are appropriately recorded during
examination with reference to this Procedure; any revision to Non-mandatory annexure will not
warrant revision of this procedure.
3.8 Users of this Procedure shall verify the applicability of this Procedure with respect to requirements.
4. Performance demonstration:
When required by referencing Code Section or per Client requirements, performance demonstration shall
be carried out and documented as report. Copies of such reports shall be maintained by INSPEC.
Whenever required, a certification statement either incorporated in the Procedure Demonstration Record
or attached separately to the procedure from the client shall be made available to the Authorized
Inspector/ client representative.
5. Personnel Qualification:
5.1. All personnel conducting Magnetic Particle Examinations using this Procedure shall be qualified to a
minimum of Level I. However, personnel evaluating results of such inspection shall be qualified to at
least Level II or Level III (Refer 2.1.6).
5.2. As defined in the Written Practice, a person certified in accordance with the older version of the
written practice shall remain certified until the next scheduled recertification. Recertification shall be
based on Written Practice which refers to current code approved edition of SNT-TC-1A.
Recertification may be based on evidence of continued satisfactory performance or reexamination in
full or part as per the Written Practice.
5.3. Personnel conducting Magnetic Particle Examination shall have vision, with correction if necessary,
to enable to read Jaeger Type No. 2 Standard Chart at a distance of not less than 300mm, and is
capable of distinguishing and differentiating contrast between colors or shades of gray used. Vision
tests shall be conducted annually and be current during examination.

PROCEDURE
5.4. Personnel conducting Magnetic Particle Examination shall be competent in conducting the testing as
described in this Procedure.
5.5. Where required by a specific Code, existing Personnel Qualification shall be verified for applicability
as to the Code conditions.
5.6. Personnel conducting Magnetic Particle Examination should be aware of the safe-practice
requirements during examination. (Refer 20.)
6. NDE Method Technique:
6.1. Wet Continuous Color Contrast Magnetic Particle Examination using AC ElectromagneticYoke
magnetization technique.
6.2. Wet Continuous Color Contrast Magnetic Particle Examination using Permanent magnetic Yoke
magnetization technique.
(All essential variables relevant to this NDE method technique has been included)
7. Test Equipment:
7.1. Alternating Current electromagnetic yoke with adjustable poles shall be used. The minimum and
maximum pole spacing utilized during examination shall be 3 in. and 8 in. respectively.
7.2. Permanent magnetic Yoke with adjustable poles shall be used. The minimum and maximum pole
spacing utilized during examination shall be 3 in. and 8 in. respectively.
7.3. The equipment essentially produces longitudinal magnetization in the component tested.
7.4 The equipment model is Y6 manufactured by Magnaflux for AC Electromagnetic Yoke and
ELYMAG 1 for Permanent Magnetic Yoke.
8. Test Materials:

PROCEDURE
8.1. Test materials as defined in Table 8.1 are used during the examination
Table 8.1
Material Brand Manufacture Group
r
Black Ink (Magnetic Ink) 7 HF Magnaflux MT 1
Non-Magnetic surface Contrast enhancement WCP-2
Black Ink (Magnetic Ink) Supramor-4 Ely MT 2
Non-Magnetic surface Contrast enhancement Code-712
Black Ink (Magnetic Ink) MR 76 MRChemie MT 3
Non-Magnetic surface Contrast enhancement MR 72
8.2. Test materials will be in ready-mix aerosol containers

8.3. Intermixing of test materials from different Groups is not permitted.
8.4. This procedure is valid for only those family or group of materials for which a satisfactory
demonstration has been carried out and documented. Refer to supplements for details.
9. Surface condition & preparation:
9.1. Satisfactory results are usually obtained when the surface of the component is as rolled, as-welded,
as-cast or as-forged condition. Surface preparation may be necessary by grinding, machining or other
methods where surface irregularities could mask indications.
9.2. Prior to magnetic particle examination all areas to be examined and all adjacent areas within in at
least 25 mm shall be dry and free of all dirt, grease, lint, scale, welding flux or slag or spatter, paint,
oil or other extraneous matter that could interfere with the examination.
9.3. Cleaning may be accomplished using detergents, organic solvents, de-scaling solutions, paint
removers, sand or grit blasting.
10. QC of Test Equipment:
10.1. The equipment shall be checked for adequacy of magnetization strength. This can be accomplished
by setting the pole spacing to the required maximum and verify lifting of a 4.5 kg steel weight for AC
Electromagnetic Yoke and 18 kg for Permanent Magnetic Yoke.
10.2. This check shall be done everyday prior to use.
11. Examination:

PROCEDURE
11.1. The test surface shall be magnetized using the yoke. Magnetizing shall be done in such a way that a
complete coverage of the test area is done and discontinuities of all probable orientation can be
detected. This can be accomplished by at least two separate examinations on each area producing
approximately perpendicular directions of magnetic lines. (Turn the yoke by 90º alternately).
11.2. A field indicator will be used to check the adequacy of magnetic field. This can be either a pie type
or Burmah Castrol type flux indicator. The dimensions of Pie Gauge are given in ASME Sec V Art 7.
BC strips contain 3 fine parallel notches of 42mm length and 3mm apart in a sheet of ferromagnetic
material of 50mmx12mm size.
11.3. Adequacy of the magnetic field on the test surface can be verified by the Pie gauge or BC strips by
placing the gauge/ strip on the test surface and applying the test particle while the magnetizing
current is on. The magnetic field (at least 0.72 Tesla for 2400amp/meter) will be satisfactory if all the
three lines are visible on the BC strip or the lines on the pie gauge perpendicular to the flux direction.
11.4. The magnetic ink (Black Ink) shall be applied to the test area by uniform spraying, when the current
is on (i.e. whenever the magnetizing force is applied). The magnetic ink shall be applied to an extent
just sufficient to aid free flow of particles on test surface. Care shall be exercised to avoid excess
application of magnetic ink (since it might lead to excess build up of particles near the legs and mar
the examination).
11.5. Indications will be revealed by retention of magnetic particles.
11.6. For weld examinations, yoke legs should be positioned on either side of weld axis (transverse) and
spacing shall not exceed the spacing used during the lifting-power test and the minimum spacing
should not be less than 75mm (3”) to avoid any excess particle build-up. The maximum spacing
shall not exceed 200mm (8”).
11.7. The examination shall proceed with a minimum of 10% overlap on each progressive area tested.
12. Non-Magnetic Surface Contrast enhancement:
12.1. To enhance particle contrast with the test surface, a uniform thin spray of white contrast
enhancement may be applied (Refer Table 8.1) before start of magnetizing and allowed to have
normal evaporation resulting in a uniform white background.
12.1.1. Such coating should be applied only on uncoated surfaces as required only in amounts
sufficient to enhance particle contrast. When non-magnetic surface contrast enhancement is used,

PROCEDURE
it shall be demonstrated that the indications can still be detected through the coating. Thickness of
coating may be measured with a coating thickness gauge but it is not essential.
12.2. When such enhancement is applied on coated surfaces, it must be demonstrated that indications to
desired level can still be achieved through enhancement coating.
13. Test temperature:
13.1. The temperature of the test surface and the magnetic ink shall not exceed 57 ºC. Where the
manufacturer’s recommendation is more stringent than this temperature limit, the same shall be
followed.
14. Viewing conditions:
14.1. The test area shall be adequately illuminated for proper evaluation of indications revealed on the
test surface.
14.2. A minimum light intensity of 100 fc (1000 lux) is required on the surface to be examined to ensure
adequate sensitivity during the examination and evaluation of indications.
14.3. The light-source technique used (day light or artificial) shall be documented and maintained.
14.3.1 A hand lamp without a focusing curvature hood, with a 100 watt/ 220 volt incandescent bulb
placed at a distance maximum 250 mm from the surface will fulfill the minimum light intensity
requirement (100 fc/ 1000Lx) on the test surface. For a 60 Watt/ 220volt incandescent bulb
without focusing hood the maximum distance will be 180mm.
14.3.2 Alternately, a rechargeable focused torch with quartz halogen bulb (Specification 6V 25W) of 25
watt/ 6 volts equipped with 6V 4AH sealed Lead acid battery placed at a distance of 1000mm from
test surface may fulfill the above requirements.
14.3.3 The light source as described in 14.3.1 & 14.3.2 above, are for example only, actual light level
may vary depending on the background light available, focusing condition and the light source
condition. Hence, the light source, technique and light level verification shall be demonstrated on
case to case basis for each shop/ manufacturer and shall be recorded on file.
14.4. Where required, the area of examination can be viewed under magnification using lenses
(generally at 5x magnification).

PROCEDURE
15. Interpretation of indications:
15.1. The evaluation of indications will be during the period when the magnetic ink is applied and the
current is on.
15.2. Indications will be revealed by retention of magnetic particles. The size of the indication is the
basis for acceptance evaluation.
15.2.1. All such indications are not necessarily imperfections, however, since excessive surface
roughness, magnetic permeability variations (such as at the edge of heat affected zones), etc.,
may produce similar indications.
15.2.2. Broad areas of particle accumulation, which might mask indications from discontinuities, are
prohibited and such areas shall be cleaned and reexamined.
15.3. Relevant indications are those indications, which have any dimension greater than 1/16 in. (1.5
mm).
15.3.1. Linear indication is one having a length greater than three times the width.
15.3.2. Rounded indication is one of circular or elliptical shape with length equal to or less than three
times the width.
15.3.3. Any questionable or doubtful indications shall be explored by visual or other means, and if
necessary, evaluated by a re-examination
16. Evaluation for Acceptance:
16.1. All relevant (including non-relevant or non-rejectable, if necessitated by any referencing

document or client requirement) indications (type of indication – linear or rounded, location,
length or diameter or aligned) shall be recorded as a minimum and interpreted against the
relevant acceptance criteria. Where none specified, all the relevant indications shall be recorded.
16.2. This Procedure contains sample acceptance standards as per ASME Section VIII Division I and
Division 2 (Refer Annexure I)
16.3. Acceptance criteria used shall be documented in the NDE Report (refer Annexure-II).

PROCEDURE
17. Documentation & reporting of results
17.1. For each Magnetic Particle Examination as per this Procedure, the following minimum
information shall be recorded and suitably addressed in the relevant INSPEC Report (Refer
Annexure III):
17.1.1. Client / Project / Job details

17.1.2. Location
17.1.3. Item
17.1.4. Material & thickness
17.1.5. Surface Condition
17.1.6. Procedure Identification & Revision.
17.1.7. Method of initial cleaning*
17.1.8. Test Method / Technique
17.1.9. Equipment & current type.
17.1.10. Test Temperature.
17.1.11. Viewing (lighting) Conditions
17.1.12. MPI Materials’ Group & Batch Ref.
17.1.13. Post-examination cleaning*
17.1.14. Examination personnel & qualification level
17.1.15. Accept / Reject status (as appropriate & applicable)
17.1.16. Examination date.
17.1.17. Map or Record of indications (attach as appropriate)**
*: Optional information and may be included in the report or attached separately.
**: See Para 16.1.
18. Final cleaning:
18.1. When post examination cleaning is required it shall be conducted as soon as practical by using a
process that does not adversely affect the part.
19. Demagnetizing:
19.1. Demagnetizing, if required, shall be done on the following conditions:
19.2. Prior to testing, if the material contains strong remnant magnetic fields from some previous
operation or inspection.
19.3. On completion of Examination, if any existing remnant field could interfere with the removal of

PROCEDURE
magnetic particle while cleaning the part or when necessitated by the component requirement
post-examination.
20. Safety:
20.1. All inspection personnel shall be responsible for compliance with applicable safety rules in the
use of Test materials.
20.2. Test materials are highly volatile, relatively toxic and the liquids may cause skin irritation. Use
adequate ventilation at all times and avoid prolonged skin contact.
20.3. Test materials shall never be heated above the recommended temperature limits prescribed by
the manufacturer.
20.4. Test materials shall never be exposed to open flames
20.5. Keep aerosol cans containing Test materials out of direct sunlight and storage areas in excess of
the recommended temperature limits specified by manufacturer; an excessive heat may cause
aerosol cans to explode.
20.6. The test system has electrical input for the Test equipment and safe practices should be followed
to avoid any electrical shocks.

PROCEDURE
NON-MANDATORY ANNEXURE I
(Note: Information provided in this annexure is for guidance only; users are encouraged to refer the relevant
standards / codes for specific acceptance criteria. These acceptance criteria apply unless other more
restrictive standards are specified for specific materials or applications within the Code Sections / Divisions)
Sample Acceptance Criteria

ASME Section VIII Div 1 Appendix 6 & ASME Section VIII Div 2 Para 7.5.6.2 :
Terminology:
a. Relevant Indications – indications with major dimensions greater than 1.5 mm (1/16 in)
b. Linear Indication – an indication having a length greater than three times the width
c. Rounded Indication – an indication or circular or elliptical shape with the length equal to less than
three times the width
d. Any questionable or doubtful indications shall be explored by visual or other means, and if
necessary, evaluated by a re-examination
Acceptance Standard:
All surfaces to be examined shall be free of:
a. Relevant linear indications
b. Relevant rounded indications greater than 5 mm (3/16 in.)
c. Four or more relevant rounded indications in a line separated by 1.5 mm (1/16 in.) or less edge-to-
edge.
Crack like indications detected, irrespective of surface conditions, are unacceptable.
ASME B 31.1: POWER PIPING

Terminology:
a. Relevant Indications – Those indications which result from mechanical discontinuities with major
dimensions greater than 2 mm (1/16 in)
a. Any Cracks or linear indications.
b. Rounded indications with dimensions greater than 5 mm (3/16 in.).
c. Four or more rounded indications in a line separated by 2 mm (1/16 in.) or less edge-to-edge.
d. Ten or more rounded indications in any 3870 mm2 (6 sq. in.) of surface with the major dimension
of this area not to exceed 150mm (6 in.) with the area taken in the most unfavorable location
relative to the indications being evaluated.

PROCEDURE
NON-MANDATORY ANNEXURE II – SAMPLE REPORT FORM
INTERNATIONAL INSPECTION SERVICES (DUBAI BR) DATE:

P.O. BOX NO. 96535, DUBAI, U.A.E.
REPORT NO.:
TEL. NO.: (9714) 3241955 FAX NO.: (9714) 3241957
E-mail : inspec@emirates.net.ae , Web Site : www.int-inspec.com PAGE OF
IN-OPF-03a Rev.04
MAGNETIC PARTICLE EXAMINATION REPORT

CLIENT: LOCATION:
PROJECT: JOB NO.:
ITEM: MATERIAL & THICKNESS:
SURFACE COND.: TEST TEMP.:
MT. PROC. : TECHNIQUE:
EQUIPMENT:
METHOD:
MODEL No.:
ILLUMINATION: SENSITIVITY:
CONSUMABLES: CLEANER: BACKGROUND: DETECTING MEDIA:
ACCEPTANCE CRITERIA / SPECIFICATION: TEST CALIBRATION DATE:
OBSERVATION & EVALUATION:
TECHNICIAN: CLIENT REP.: AI / TPI.
LEVEL : NAME: NAME:
SIGNATURE : SIGNATURE: SIGNATURE:
DATE : DATE: DATE:

Document Title:
Liquid Penetrant Examination Procedure

Project Name : NEW GAS TURBINE GENERATOR Procedure No : INS/ASME/P5/001
P.O No : 4794-10/SV – Rev.00
Description: Liquid Penetrant Examination Procedure
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Doc No : TI/meTECH/P5/001
meTECH JOBSHOP FZC Revision : 4
Date : 28.12.2009
LIQUID PENETRANT EXAMINIATION Page : 2 of 14
PROCEDURE
TABLE OF CONTENTS
1. Scope ...........................................................................................................3

2. General ........................................................................................................3
3. References...................................................................................................3
4. Procedure Qualification: ..........................................................................3
5. Qualification of Personnel ........................................................................5
6. Extent of Examination: .............................................................................5
7. Surface Preparation ...................................................................................5
8. Equipment and Materials .........................................................................6
9. Examination ...............................................................................................7
10. Viewing Conditions ..................................................................................9
11. Interpretation of Indications ....................................................................9
12. Evaluation for Acceptance status ..........................................................10
13. Post Cleaning ...........................................................................................10
14. Repairs ......................................................................................................10
15. Documentation ........................................................................................11
16. Report Format ..........................................................................................12
Non-Mandatory Annexure I ............................................................................13
Date : 28.12.2009
PROCEDURE
1. Scope
1.1. This procedure shall govern the methods and requirements for liquid penetrant
examination of ferrous, nonferrous and nonporous materials whose shapes and sizes
are suitable for liquid penetrant examination.
2. General
2.1. This general procedure shall be used in conjunction with the applicable code.
2.2. Specific requirements contained in this procedure may be superseded if specified in

the applicable contract documents and is more stringent than this procedure
requirement.
2.3. Variations in the liquid penetrant examination procedure, equipment and acceptance
standards may be used upon agreement between Tech International FZC and the
client. The client shall clearly specify any variations in the Liquid Penetrant
Examination Procedure and this is subject to acceptance of AI for jobs requiring AIA.
3. References
3.1. The current editions of the following documents have been referenced in the
preparation of this procedure and shall be considered a part of this procedure as
applicable.
3.1.1. ASME Section V, Ed. 2007, Add. 2009b, Article 6 – Liquid Penetrant
Examination.
3.1.2. SE-165, Standard practice for Liquid Penetrant Inspection Method
3.1.3. ASME Section VIII Div.1, Ed. 2007, Add. 2009b – Un-fired Pressure Vessels
3.1.4. ASME Section I, Ed. 2007, Add. 2009b – Rules for construction of Power Boilers
3.1.5. ASME/ANSI B31.1, Ed. 2007, Add. 2009b – Power Piping
3.1.6. ASME / ANSI B31.3b, Ed. 2007, 09 – Process Piping
3.1.7. ASNT SNT TC 1A, Ed. 2006.
3.1.8. TIF/WP/NDE/001/08 Rev. 01 Qualification & Certification of Tech
International NDE personnel.
3.1.9. Applicable codes and standards according to client specifications.
4. Procedure Qualification:
The procedure shall be demonstrated and documented to ensure that the examination
procedure is adequate. The essential variable is listed below that is a change in any of these
shall be qualified by demonstration. The qualification shall be demonstrated to the
Authorized Inspector / Client representative prior to implementation of this procedure on
test component. The qualification variables shall be incorporated in the demonstration
record. A change of requirement identified as a non essential variable doesn’t require re-
qualification of the procedure. However any change in the essential or non essential
variable shall require revision to this procedure.
Date : 28.12.2009
PROCEDURE
The following essential variables are applicable to this procedure.
Requirement Essential Variable Non Essential Variable
Identification of and any change in

type or family group of penetrant
X (Para 8.1.3)
materials including developers,
emulsifiers, etc.
Surface preparation (finishing and

cleaning, including type of cleaning X (Para 7)
solvent)
Method of applying penetrant X (Para 9.4.1)
Method of removing excess surface

X (Para 9.5.1)
penetrant
Hydrophilic or lipophilic emulsifier

concentration and dwell time in dip
X (not Applicable)
tanks and agitation time for
hydrophilic emulsifiers
Hydrophilic emulsifier concentration

X (Not Applicable)
in spray applications
Method of applying developer X (Para 9.6.3)
Minimum and maximum time periods

X (Para 9.4 & 9.6.1)
between steps and drying aids
Decrease in penetrant dwell time X (Para 9.4.3)
Increase in developer dwell time

X (Para 11.1)
(Interpretation Time)
Minimum light intensity X (Para 10.2)
Performance demonstration, when

X (Para 4)
required
Date : 28.12.2009
PROCEDURE
Requirement Essential Variable Non Essential Variable
Personal Qualification Requirements X
Materials, Shapes or Sizes to be

examined and the extent of X
examination
Post examination cleaning technique. X
5. Qualification of Personnel
5.1. Personnel performing liquid penetrant examinations shall be qualified and certified
in accordance with Tech International’s Personnel qualification and Certification
Procedure, TIF/WP/NDE/001/08 Rev. 01.
5.2. Personnel performing liquid penetrant examination shall have vision, with correction
if necessary, to enable to read Jaeger Type No. 2 standard chart at a distance of not
less than 30mm, and is capable of distinguishing and differentiating contrast between
colours and shades of grey used. Vision test shall be conducted annually and shall be
current.
5.3. Personnel performing penetrant examination shall have level I certification as a

minimum. However, the results shall be evaluated by level II /Level III certified
personnel only.
6. Extent of Examination:
6.1. The extent of liquid penetrant examination shall be as specified in the applicable code
and contract documents.
6.2. All areas having discontinuities revealed by liquid penetrant examination that
require repair shall be re-examined by liquid penetrant examination after the repair
has been made unless another non-destructive examination method is agreed upon
by Tech International and the client.
7. Surface Preparation
7.1. Surfaces may be in the as-welded, as rolled, as-cast or as forged condition.

Date : 28.12.2009
PROCEDURE
7.2. Surface preparation by grinding, machining, or other methods may be necessary for
at least 25mm adjacent areas of welds, where surface irregularities could mask
indication of unacceptable discontinuities. Cleaning solvent shall meet the
requirements of T-641 of ASME Sec. V.
7.3. The temperature of the test surface shall be between 10º C and 52º C. If there is a
condition when the temperature of the test surface is beyond this range, the
effectiveness of the test system shall be verified by conducting the test at the
temperature concerned on a test piece containing artificial defects.
8. Equipment and Materials
8.1. Penetrant Materials:
8.1.1. The test consumables shall be in accordance with the applicable client’s
specification. This test procedure calls for use of solvent-removable liquid
penetrant type using either visible dye or fluorescent penetrant dye in
combination with a wet solvent-suspended developer.
8.1.2. The penetrant test consumables including cleaning solvents to be used on

Nickel based alloys shall have sulphur content <1% of the residue by weight.
The penetrant test consumables to be used on Austenitic or Duplex stainless
steel and Titanium shall have chlorine plus fluorine (halogen) content <1% of
the residue by weight. Batch Test certificates of conformity shall be kept on
file as part of the quality records in the company.
8.1.3. Consumables shall be used in sets purchased from the same manufacturer.
Brands of dye and developer shall not be mixed. Penetrant / developers &
cleaners Brand approved for use is Magnaflux (Spot check). Other brands may
be used after demonstration of the procedure with new brands to the AI.
8.1.4. Storage of these materials should be as per manufactures recommendation and

should be used within the self life period.
8.1.5. A certification statement from the manufacturer of penetrant material stating

the penetrant material batch nos. and test result obtained for the sulphur and
total chlorine and fluorine content in accordance with mandatory appendix II
of Article 6 of ASME Sec V 2007 addenda 2009b.
8.2. White Light Intensity

8.2.1. When performing penetrant examinations using visible dye, a minimum light
intensity of 100 fc (1000 Lx) is required to ensure adequate sensitivity during
examination and evaluation of indications. The use of a flashlight or drop
Date : 28.12.2009
PROCEDURE
light to illuminate the part surface is permissible in order to meet the lighting
recommendations of this paragraph.
9. Examination
9.1. General: Liquid penetrant examination shall be accomplished by solvent-removable

liquid penetrant type using either visible dye or fluorescent penetrant methods in
accordance with this procedure. The examination method and type shall be as
specified in the contract specification. If the method and type is not specified, the
application used shall be at the discretion of Tech International’s Level III.
9.2. Time of Examination: For final acceptance, liquid penetrant examination shall be
performed when the part is in the final heat treated, machined or otherwise
completed condition, unless otherwise specified in the contract specification.
9.3. Pre cleaning
9.3.1. Prior to liquid penetrant examination the surface to be examined and all
adjacent areas within at least one inch shall be dry and free of any dirt, grease,
lint, scale, welding flux, spatter, oil or other extraneous matter that could
obscure surface opening or otherwise interfere with the examination.
9.3.2. Cleaning may be accomplished by detergents, organic solvents, de scaling

solvent paint removers. Degreasing and ultrasonic cleaning methods may also
be used.
9.3.3. Drying, after cleaning of the surfaces to be examined shall be accomplished by

normal evaporation or with circulating cold or hot air. The temperature of the
part surface shall be in between 10° C to 52° C.
9.3.4. The drying time shall be sufficient to assure that the cleaning solvent has
evaporated prior to apply of penetrant.
9.4. Penetrant Application
9.4.1. The dye penetrant shall be applied to the test surface to provide a thin uniform
coating over the entire area of interest. Care shall be exercised to ensure that
the test surface is free of cleaner after completion of the pre-cleaning operation
before applying the penetrant dye. Typical times allowed for this after
completion of pre-cleaning shall be the greater of 1 minute. Application may
be done means of spraying on of the dye on the test surface and area of
interest. Alternatively application may be done by brushing.
9.4.2. The maximum time between completion of pre-cleaning and application of the
penetrant shall not exceed 30 minutes.
Date : 28.12.2009
PROCEDURE
9.4.3. The minimum penetrant (dwell) time shall be as stated in Table 1 of this
procedure for part temperatures between 50º and 125ºF. When the part is not
within this temperature range, a procedure shall be established using ASME
Section V Article 6 Paragraph T-653, Techniques for Non-Standard
Temperature.
9.5. Excess Penetrant Removal:
9.5.1. Excess penetrant shall be removed by wiping with a lint-free cloth or

absorbent paper, repeating the operation until most traces of penetrant have
been removed. The remaining traces shall be removed by wiping the surface
lightly with cloth or absorbent paper moistened with solvent.
9.5.2. 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 penetrant and prior to developing is prohibited.
9.5.3. The surface may be dried by normal evaporation, blotting, wiping or forced
air.
9.6. Developing
9.6.1. The developer shall be applied as soon as possible after the penetrant removal.
The maximum time between completion of excess dye removal and
application of the developer shall not exceed 10 minutes, to ensure that the
entrapped penetrant is not dried inside the flaws and also to minimize the
collection of dust particles on the test surface.
9.6.2. Application shall aim towards imparting a thin uniform film of developer on
the area of interest. Blotches and drips shall be avoided. Heavy coating of the
developer shall be avoided.
9.6.3. The developer is applied by means of spraying only after removal of excess
dye. (Adequate time shall be provided after removal of excess dye for the
solvent cleaner to evaporate completely from the test surface. Typical time
allowed for this shall be the greater of 1 minute or the time required for the
wetting shadow of the cleaner to disappear from the test surface).
9.6.4. The development time (interpretation time) shall be limited to minimum 10

minutes after the wet developer dray to a maximum of 60 minutes.
Date : 28.12.2009
PROCEDURE
10. Viewing Conditions
10.1. The surface to be evaluated shall be adequately illuminated for proper evaluation.
10.2. A minimum of 100 fc (1000 lux) is required on the surface to be evaluated to ensure
adequate sensitivity.
10.3. The light source technique shall be recorded in the report.
11. Interpretation of Indications
11.1. Development of indications shall be actively observed from the time of application of
the developer for a period of at least up to 10 minutes. Interpretations and evaluation
may be done after this time. In any case observation period in excess of 60 minutes
are not necessary. If the surface to be examined is large enough to preclude complete
examination within the prescribed or established time, the examination shall be
performed in increments.
11.2. Discontinuities at surface will be indicated by bleed-out of penetrant. However,

localized surface irregularities due to machining marks or other surface conditions
may produce false indications.
11.3. Any indication believed to be non-relevant shall be regarded as a defect unless it is

shown by re-examination by the same method or by use of other non-destructive
methods and/or surface re-conditioning that no unacceptable discontinuity is
present.
11.4. Broad areas of fluorescence or pigmentation that could mask indication of

discontinuities are unacceptable, and such areas shall be cleaned and re-examined.
11.5. The interpretation and evaluation of indications shall begin on completion of the
minimum developer-dwell-time of 10 minutes, however with the maximum
developer-dwell-time is limited to 60 minutes. For larger areas, the above functions
shall be performed in increments.
11.6. Discontinuities are indicated by bleed-out of the penetrant in deep red colour staining
the developer (indications).
11.7. Relevant indications are those indications resulting from mechanical discontinuities
on the surface. Linear indication is one having a length having greater than three
times the width. Rounded indication is one of circular or elliptical shape with length
equal to or less than three times the width.
Date : 28.12.2009
PROCEDURE
11.8. Discontinuities due to localized surface imperfections (such as machining marks,

rough weld profile) or attributable directly to some feature of the assembly or
component examined may produce non-relevant indications.
12. Evaluation for Acceptance status
12.1. Indications those have their major dimension greater than 1/16th inch (1.5mm) shall
be considered as relevant.
12.2. An indication from a discontinuity may show size, which is larger than its actual
dimension as seen on the surface; however the size of the indication shall be the basis
for evaluation.
12.3. All relevant (including non-relevant, if necessitated by any referencing document or

client requirement) indications (type of indication – linear or rounded, location,
length or diameter or aligned) shall be recorded as a minimum and interpreted
against the relevant acceptance criteria.
12.4. The acceptance criteria as per ASME Section VIII (D1 & D2) & Section IX are listed in
Non-Mandatory Annexure–1 for reference. Acceptance criteria used shall be
documented in the NDE Report format as per Para 16).
12.5. Broad areas of pigmentation, which could mask indications, are not acceptable and
shall be cleaned and retested in accordance with the method stated in this procedure.
13. Post Cleaning
Upon completion of the penetrant examination, the surface shall be thoroughly cleaned by
wiping with a clean cloth moistened with an approved acetone solvent or cleaner as
required to remove all traces of the examination materials.
14. Repairs
14.1. The examiner shall report all unsatisfactory discontinuities.
14.2. When surface defects are identified, they may be removed by grinding or machining
and not repaired by welding, provided the following requirements are met:
14.2.1. The remaining thickness is not below the minimum acceptable wall thickness.
14.2.2. The area, after defect removal, is blended uniformly into the surrounding
surface.
14.2.3. The area is examined after blending by the Liquid Penetrant method to ensure
that the defect has been removed or reduced to an acceptable limit.
Date : 28.12.2009
PROCEDURE
15. Documentation
15.1. Recording of Indications

15.1.1. Non-rejectable Indications – Non-rejectable indications shall be recorded as
specified by the referencing code section.
15.1.2. Rejectable Indications – Rejectable indications shall be recorded. As a

minimum, the type of indications (linear or rounded), location and extent
(length or diameter or aligned shall be recorded).
15.2. The results of liquid penetrant examination shall be recorded on Liquid Penetrant
Examination Report (Refer report format at the end).
15.3. The original reports shall be kept on file by Tech International.
TABLE 1
Recommended Dwell Times
Dwell Times (A) Minutes

Type of (Minimum)
Material Form
Discontinuity
Penetrant (B) Developer (C)
Cold shuts,
Castings and porosity, lack of
Welds fusion, cracks (all
8 10
Carbon steel,
Low Alloy forms)
Steel, High
Alloy Steel, Wrought
Aluminium materials – Laps, cracks (all
extrusions, forms)
10 10
forgings, plate
(A) - For temperature range from 50ºF to 125ºF (10ºC to 52ºC).

(B) - Minimum penetrant dwell time.
(C) - Development time begins as wet developer coating has dried on surface of parts.
Date : 28.12.2009
PROCEDURE
16. Report Format
LIQUID PENETRANT EXAMINATION REPORT

Project Title : Project Code : Date:
Drg.# / Line# : Report # :
Material : Applicable Code :
Developer : Mfrs. Sl. No :
Test Temperature : Procedure No & Rev. :
TYPE OF SYSTEM TECHNIQUE
Water Washable : Visible :
Solvent Removable : Fluorescent :
Light Equipment used : Visible Light Intensity :
PENETRANT MATERIALS (INCLUDE NUMBER OR LETTER DESIGNATION)
Cleaner : Batch No. :
Penetrant : Batch No. :
Developer : Batch No. :
Penetrant Dwell Time : Extent of Inspection :
SURFACE PREPARATION
As Welded Ground Other Specify
Description Dia.(mm) Thk. (mm) Results Remarks
Remark:
Representative TI Client AI / TPI

Name/Level
Signature
Date/Time of Examination
Date : 28.12.2009
PROCEDURE
NonMandatory Annexure I
(Note: Information provided in this annexure is for guidance only; users are encouraged to refer the relevant
standards / codes for specific acceptance criteria. These acceptance criteria apply unless other more
restrictive standards are specified for specific materials or applications within the Code Sections / Divisions)

I. ASME Section IX (QW-195)
Acceptance Criteria (corrosion resistant overlay welds – performance & procedure qualification)
Terminology:
Indications in excess of the limits specified below are unacceptable:
b. Relevant rounded indications greater than 4.8 mm (3/16 in.)
c. Four or more relevant rounded indications in a line separated by 1.6 mm (1/16 in.) or less edge-to
edge.
II. ASME Section VIII Div 1 Appendix 8 & ASME Section VIII Div 2 Para 7.5.7.2
Terminology:
three times the width.
Any indication, which is believed to be non-relevant, shall be regarded as an imperfection unless it is shown
by re-examination by the same method or by the use of other non-destructive methods and / or by surface
conditioning that no unacceptable imperfection is present.
b. Relevant rounded indications greater than 5 mm (3/16 in.)
c. Four or more relevant rounded indications in a line separated by 1.5 mm (1/16 in.) or less edge-to
edge.
Any crack like indication is unacceptable irrespective of surface conditions.

Date : 28.12.2009
PROCEDURE
III. ASME B 31.1: POWER PIPING

Terminology:
a. Relevant Indications – Those indications which result from mechanical discontinuities with major
dimensions greater than 2 mm (1/16 in)
a. Any Cracks or linear indications.
b. Rounded indications with dimensions greater than 5 mm (3/16 in.).
c. Four or more rounded indications in a line separated by 2 mm (1/16 in.) or less edge-to-edge.
d. Ten or more rounded indications in any 3870 mm2 (6 sq. in.) of surface with the major dimension of
this area not to exceed 150mm (6 in.) with the area taken in the most unfavourable location relative to
the indications being evaluated.
Document Title:
Radiographic Examination Procedure

Project Name : NEW GAS TURBINE GENERATOR Procedure No : INS/ASME/RT/001
P.O No : 4794-10/SV – Rev.00
Description: Radiographic Examination Procedure
TERMOCHIMICA

RADIOGRAPHIC EXAMINATION
PROCEDURE
REVISION CONTROL
Revision Number &

Changes Remarks
Date
Issued to address requirements of
00
New Issue ASME Section V Edition 2001
20 February 2004
Addenda 2003
01 Issued to address requirements of
Sec 5.2
20 February 2005 ASME Section V Edition 2004
Sec.11 and Sec. 12
Sec 1.1 Revised. Sec 5.2: added, subsequent
02
paragraph nos. changed accordingly. -
13 September 2005
Sec 7.4 Revised.
03 Sec 11.7.1 Revised.

January 25, 2006
Sec 3: Paragraph name changed. To incorporate the comments
Sec 4: deleted. Sec 5 renumbered as Sec 4. All made by ASME team leader and
subsequent Paras’ renumbered. Authorized inspector.
04 Sec 6.6 (Previous 7.6): revised.
August 12, 2006 Sec 10.6 (Previous 11.7): revised.
Sec 10.6.1 (Previous 11.7.1): revised.
Sec 11.1 (Previous 12.1): revised.
Sec 2.1: Revised Addenda 2006 added.

05
Sec 9: Revised
February 18, 2007
Sec 5.3: Revised
06 Sec 2.1: Revised. 2007 edition incorporated.
September 10, 2007 Annexure – III: Revised. ASME Sec VIII Div 2: Revised
acceptance criteria added.
Sec 2: Revised. Addenda 2008 incorporated.
07
Para 6.5: Revised.
January 3, 2009
Sec 11.1: Revised.
08 Sec 2: Revised. 2009 addenda incorporated.
th
20 December 2009 Report format: Revised.
Document No. : INS/ASME/RT/001 Rev.: 08 dated 20.12.2009 Page No.: 2 of 21

PROCEDURE
INDEX
Clause
Ref...
1 Scope 4
3 Procedure Demonstration 4
5 Test Equipment and materials 6
6 Film Quality 6
7 Surface Condition 8
8 Scattered Radiation 8
9 Radiographic Film Viewing 8
10 Method 9
11 Documentation / Storage of Films 14
12 Acceptance Criteria 14
MANDATORY
ANNEXURE
Annexure I - Single Wall Technique 15
Annexure II - Double Wall Technique 16
NON-MANDATORY ANNEXURE
Annexure III - Sample Acceptance Criteria 18
Annexure IV - Sample Report Format 20

PROCEDURE
1. Scope:.
Radiographic Examination of full penetration butt-welds in pipelines, structures etc. made of Carbon
steels, Stainless Steel and Low alloy steel up to 90mm wall thickness using either X-Ray or Gamma Ray
as radiation source whenever such type of examination is deemed necessary by applicable codes.
1.3 Typical types of discontinuities that can be detected by this method are cracks, incomplete fusion,
incomplete penetration, misalignment, overlap, porosity, root-concavity, undercut, burn-through,
excessive/ inadequate reinforcement, inclusions, etc.
2.1.1 ASME Section V 2007 Ed. Addenda 2009.

2.1.2 ASME Section VIII Division 1&2; Ed 2007; Addenda 2009.
2.1.3 ASME Section I; Ed 2007; Addenda 2009.
2.1.4 ASME Section IX; Ed 2007; Addenda 2009.
2.1.5 ASME B 31.1b, Ed 2009.
2.1.6 ASNT SNT TC 1A 2001 & 2006 Edition.
2.1.7 INSPEC/9/USN/Q1.1994 Rev 18: Personnel Qualification and Certification for NDT personnel.
3. Procedure Demonstration:
3.1 This Procedure is a General NDE document for reference and use by authorized INSPEC personnel,
applicable for the purpose identified in the Scope and essentially addressing the requirements of ASME
Section V
3.2 Relevant INSPEC personnel are required to be aware of the requirements of this Procedure and suitably
qualified and, certified by INSPEC for implementation.
3.3 When used by non-INSPEC Organizations, the necessary agreements will need to be effected with
INSPEC and a reference to this Procedure shall be made appropriately by the Organizations.

PROCEDURE
3.4 Demonstration of the density and IQI image requirements of the written procedure on production or
technique radiographs shall be considered as satisfactory compliance with the procedure. However,
whenever required or asked by client, a technique sheet with all the parameters mentioned therein shall
be attached to the procedure or a reference to the technique shall be made.
3.5 This Procedure contains Mandatory and Non-mandatory Annexure. Any revision to this Procedure or
Mandatory Annexure will require revision and re-issue of this Procedure.
3.6 Any revision to this Procedure will as a minimum require review and acceptance by the Appointed NDT
Level III and approval by INSPEC.
3.7 This Procedure contains sample acceptance standards applicable for welds as per ASME Section VIII
Div. 1 & 2, Section I, Section IX, B 31.1 as Non-mandatory Annexure III. However, when suitable,
this Procedure may be applied for other Acceptance Standards. Any such Acceptance Criteria are to be
appropriately recorded during examination with reference to this Procedure; any revision to Non-
mandatory appendix will not warrant revision of this procedure.
3.8 Users of this Procedure shall verify the applicability with respect to requirements.
4. Personnel Qualification:
4.1 All INSPEC personnel performing Radiographic Examination using this Procedure shall be qualified to
a minimum of Level II. (Refer 2.1.7).
4.2 Interpretation and evaluation of radiographs shall be done by only Level II certified personnel in
radiography with sufficient experience.
4.3 Personnel performing Examination shall have vision, with correction if necessary, to enable to read
Jaeger Type No. 2 Standard Chart at a distance of not less than 300mm and differentiate the contrast
between the shades of gray, and records of such vision test shall be maintained by INSPEC.
4.4 Personnel conducting Radiographic Examination shall be competent in conducting the testing as
described in this Procedure.
4.5 Where required by a specific Code, existing Personnel Qualification shall be verified for applicability as
to the Code conditions.
4.6 Personnel conducting Radiographic Examination should be aware of the safe-practice requirements
during examination. Radiography personnel shall be "classified" and operate in conjunction with the
INSPEC Radiation Safety Manual. All personnel shall adhere to each Client’s specific safety
requirements and ensure scaffolding, lighting and access is sufficient to perform the work in a safe
manner.

PROCEDURE
5 Test Equipment and materials:
5.1 Equipment:- The equipment utilized by INSPEC is Gamma-ray Remote Control Tech-ops 660 projector
containing Iridium-192 Radioactive Isotope (80 curie max source strength) / 300 kV Directional X-ray
machine. The radiation energy employed for any radiographic technique shall achieve the density and
IQI image requirements of Article-2 of ASME sec V.
5.2 Source Size:- Maximum source size that will be utilized shall be less than the dimensions indicated
below
Active sizes (Dia x h) mm – 3.0 x 3.0 Diagonal (active part) mm – 4.2
Note: Verification of Source Size. The equipment manufacturer’s or supplier’s certification statement,
technical manuals, decay curves, or written statements documenting the actual or maximum source
size or focal spot, shall be acceptable for source size verification.
5.3 Film selection:- Radiographs shall be made using industrial radiographic film. AGFA-D4 / KODAK-
MX 125 and AGFA-D7 / KODAK-AA400 may be used (Table 6-1). Prior to purchase and during
storage at site the film will be stored by the supplier in a temperature controlled building to ensure the
quality of film supplied. After exposure, radiographs shall be kept together with log sheets and marked
up drawings submitted to client for storage. The package shall allow for at least three years shelf life.
Table 6-1
Type Speed Contrast Graininess Example

1 Slow Very Very Fine AGFA D4 (165) / KODAK MX
High 125
2 Medium High Fine AGFA D7 (40) /KODAK AA 400
Screens:- Lead intensifying screens shall be utilized and shall be of good quality to prevent screen
marks on film and be of 0.125 mm thick placed at both the front and back of the film inside the cassette.
6 Film Quality
6.1 Film Processing:-All films shall be processed in accordance with ASTM SE-999 or paragraphs 23
through 26 of standard guide for Radiographic examination SE-94 and or manufacturers
recommendations, with careful attention given to time, temperature and chemical mixtures to ensure
radiograph is free from darkroom induced defects i.e. light fogging. Adequate washing is required to
achieve conditions for maximum storage life.
6.2 Film Handling:- Film shall be handled in such a manner that the emulsion is not damaged and

PROCEDURE
fingerprints or other marks are not caused on the film, before, during and after processing.
6.3 Quality:- All radiographs shall be free of the following defects that may interfere with the satisfactory
interpretation of the weld image.
a) Mechanical damage such as scratches, static tears crimp pressure or similar handling marks.
b) Chemical interference due to fogging, processing marks, stains or the like.
c) Radiographic defects caused by dirty or damaged screens or poor screen contact.
6.4 Interpretation: -Only qualified personnel having valid Level II certificate in Radiography as well as
sufficient practical experience in interpretation and evaluation of radiographs shall interpret
radiographs, such interpretation shall be in accordance with the appropriate applicable specification as
advised by client in writing.
6.5 Viewing Conditions: - Radiographs shall be viewed in subdued background lighting. The viewer shall
have sufficient intensity to view areas of interest on the radiograph with an even diffused light to the
maximum density required and any extraneous areas of illumination shall be masked to avoid glare or
distraction. During viewing film will be handled by the edges to avoid finger marks on the films and
they will be kept in folders to avoid scratches.
Densitometer:- Calibrated densitometer shall be used for density measurement of Radiographs.

Calibration of densitometers shall be performed as per Article 2, T-262.1 of Sec V on national standard
calibrated step tablet or the step wedge film having at least five steps with neutral densities from at least
1.0 thru 4.0, traceable to National Standards. The density steps closest to 1.0, 2.0, 3.0, and 4.0 on the
national standard step tablet or step wedge calibration film shall be read during calibration. Such
calibration shall be performed at least every 90 days during use and documented, but the actual readings
for each step do not have to be recorded. Periodic calibration check shall be performed at the beginning
of each shift, after 8 hr of continuous use, or after change of apertures, whichever comes first. The
densitometer shall be acceptable if the readings are within ±0.05 of the calibration readings determined.
Periodic check need not be documented.

PROCEDURE
7 Surface Condition
Weld to be examined shall be free of irregularities such as weld ripples, spatter, grinding or chipping
marks or other irregularities, which may mask successful interpretation of the radiographs.
8 Scattered Radiation
When performing radiography near to the ground or close to other structures scattered radiation may cause a
reduction in film quality, thus a lead symbol "B" of min. size 1/2" H x 1/16" THK shall be attached to the
back of the film cassette if the white symbol "B" is evident then adequate precautions should be taken by
shielding the cassette with lead sheets. Dark symbol "B" image shall be disregarded, as long as the image
does not mask any indications of weld imperfections.
9 Radiographic Film Viewing & Location Markers:
Location markers, which need to appear as radiographic images on the processed radiograph, shall be
placed on the part and not on the exposure holder or cassette. Their locations shall be permanently marked
on the surface of the part being radiographed or on a map clearly indicating the area of interest such that the
required portions of the weld/ part can be accurately traceable for the retention period of the radiograph.
Evidence shall also be provided on the radiograph that the required coverage of the location under
examination has been obtained. Placement of location markers shall be as per the following:
9.1 Single Wall Viewing

a. Source Side Markers: Location markers shall be placed on the source side when doing radiography of the
following:
1. Flat components or longitudinal joints in cylindrical or conical components.
2. Curved or spherical components whose concave side is toward the source and when the
“source-to-material” distance is less than the inside radius of the component.
3. Curved or spherical components whose convex side is toward the source.
b. Film Side Markers: Location markers shall be placed on the film side when performing radiographs
either curved or spherical components whose concave side is toward the source and when the
“source-to-material” distance is greater than the inside radius.
As an alternative to source side placement in 9.1a Location markers may be placed on the film
side when the radiograph shows coverage beyond the location markers to the extent demonstrated,
and when this alternate is documented.
c. Either Side Markers: - Location markers may be placed on either the source side or film side,
when radio graphing either curved or spherical components whose concave side is toward the
source and the “source-to-material” distance equals the inside radius of the component.

PROCEDURE
9.2 Double-wall viewing: - For double-wall viewing, at least one location marker shall be placed on
the source side surface adjacent to the weld (or on the material in the area of interest) for each
radiograph.
9.3 Radiographic Technique: - A single wall exposure technique shall be used whenever practical. When
it is not possible to use single wall technique a double wall technique shall be used. However adequate
number of exposures shall be made to demonstrate that the required coverage has been obtained.
10. Method
10.1 Procedure Qualification and approval:- Whenever specified by project specification, activities
performing NDT shall develop and maintain a written procedure for each radiographic technique &
Certification statement shall be part of this written procedure and signed by the cognizant examiner.
See attached radiography technique sheet. This procedure is to be performed only before start of any
project.
10.2 Identification of Radiographs:- Subject to no other client’s requirements the following information
shall appear on the radiograph:
a) Client’s symbol / Name

b) Drawing / Line No
c) Pipe Size
d) Weld No
e) Welders No
f) Job No
g) Date
h) Repair Reference e.g. R1,R2 or Rw
i) Location Marker
10.2.1.Each weld shall have a unique identification reference marked in such a manner to permit the
case of identification of individual welds and areas of defects within the weld.
10.2.2 Lead location markers shall be used with approximate height of 6mm and 1.5 mm thick forming
part of a metric number tape marked clearly in intervals covering the whole circumference of the
weld.
a) over 88.9mm O/D to 508mm O/D = every 50mm
b) over 508mm O/D = every 100mm
10.3 Density:- The film density is the degree of blackening and shall be checked using a calibrated

PROCEDURE
densitometer
D = Log (Io/It)
Where D = Density
Io = Light intensity incident on film
It = Light intensity transmitted through the film
The density shall be 1.8 to 4.0 for single film viewing for Radiographs made with X-Ray source and
2.0 to 4.0 for Radiographs made with Gamma Ray source in the area being examined for acceptance.
For composite viewing of multiple film exposures, each film of the composite set shall have a
minimum density of 1.3. The maximum density shall be 4.0 for either single or composite viewing. A
tolerance of 0.05 in density is allowed for variations between densitometer readings. In any case
variations shall not be -15% or +30% of the required density through the area of interest. However if
the density of the radiograph any where through the area of interest varies by more than minus 15% or
plus 30% from density through the body of hole penetrameter or adjacent to designated wire of wire
type penetrameter within the min / max allowable density range, then an additional penetrameter shall
be used for each exceptional area or areas and the radiographs retaken. When calculating the allowable
variation in density, the calculation may be rounded to the nearest 0.1 within the range specified.
10.4 Image Quality Indicators:- ASTM IQI Wire type shall be as per SE 747.
SET A SET B SET C SET D
Wire Dia Wire Dia Wire Dia Wire Dia
Inch (mm) / Wire No Inch (mm) / Wire No Inch (mm) / Wire No Inch (mm) / Wire No
0.0032 (0.08) / 1 0.010 (0.25) / 6 0.032 (0.81) / 11 0.100 (2.54) / 16
0.004 (0.10) / 2 0.013(0.33 ) / 7 0.040 (1.02) / 12 0.126 (3.20) / 17
0.005 (0.13) / 3 0.016 (0.41) / 8 0.050 (1.27) / 13 0.160 (4.06) / 18
0.0063 (0.16) / 4 0.020 (0.51) / 9 0.063 (1..60) / 14 0.200 (5.08) / 19
0.008 (0.20) / 5 0.025 (0.64) /10 0.080 (2.03) / 15 0.250 (6.35) / 20
0.010 (0.25) / 6 0.032 (0.81) / 11 0.100 (2.54) / 16 0.320 (8.13) / 21

11.5 Placement of I.Q.I:- Placement of penetrameter shall be in accordance to the following table II.
TABLE II. Penetrameter place for welds.

PROCEDURE
Weld length Minimum

Configuration
(mm) no. of IQI Penetrameter placement
Welds in curved surfaces At the center of the area of interest
less than 609.6mm in 127 and less 1
diameter
(on one film) Greater than 2 One at the extremity and one at the center
127 of the area of interest/or two at the
extremity.
Welds in flat surfaces and
curved surfaces 609.6mm Less than 254 1 At the center of the area of interest.
and greater diameter
(includes longitudinal
welds in pipes and 254 up to and 2 One placed at each extremity of the area
pressure vessels) including 432 of interest.
(on one film)
Greater than 3 One placed at each extremity and one at

432 the center of the area of interest.
Essential circular (non- Unlimited Approximately 180 degrees apart at the
cylindrical welds on one 2 extremity of the area being inspected.
film)
Cylindrical welds
radiographed Unlimited 4 One in each quadrant
simultaneously using a
series of film or a single
length of roll film
(panoramic exposure)
Repairs in cylindrical
welds initially Unlimited 1 One in each affected quadrant provided
radiographed using the technique used is the same as the
panoramic exposure initial radiography.
technique
Note-1: For techniques refer Annexure I & II
Note-2: Placement of Penetrameters

a. Source Side Penetrameter(s). : The penetrameter(s) shall be placed on the source side of the part being
examined, except for the condition described in (b).

PROCEDURE
When configuration or size prevents placing the penetrameter(s) on the part or weld, the
penetrameter(s) may be placed on a separate block. Separate blocks shall be made of the same or
radiographically similar materials and may be used to facilitate penetrameter positioning. There is no
restriction on the separate block thickness, provided the penetrameters are of density tolerance
requirements.
1. The penetrameter on the source side of the separate block shall be placed no closer to the
film than the source side of the part being radiographed.
2. The separate block shall be placed as close as possible to the part being radiographed.
3. The block dimensions shall exceed the penetrameter dimensions such that the outline of at
least three sides of the penetrameter image shall be visible on the radiograph.
b. Film side penetrameter(s). Where inaccessibility prevents hand placing, the penetrameter(s) shall be
placed on the film side in contact with the part being examined. A lead letter “F”, at least as high as
the penetrameter identification number(s), shall be placed adjacent to or on the penetrameter(s), but
shall not mask the essential hole where hole-type penetrameters are used.
10.5 IQI SELECTION:
Penetrameter (Essential wire)

----------------------------------------------------------------------------------------------------------------------
Nominal Source Side Film Side
Single-Wall ---------------------------------- -----------------------------------
Material Thickness Wire Type Wire Type
Range, mm. Essential wire Essential wire
-----------------------------------------------------------------------------------------------
Up to 6.4, include. 5 4
Over 6.4 through 9.5 6 5
Over 12.7 through 19 8 7
Over 19 through 25.4 9 8
Over 38.1 through 50.8 11 10
Over 50.8 through 63.5 12 11
Over 63.5 through 101.6 13 12
Over 101.6 through 152.4 14 13
10.6 Geometrical Unsharpness:-Geometric unsharpness of the radiograph shall be determined in
accordance with the formula below.
Ug = F x d

PROCEDURE
D
Where
Ug = geometric unsharpness
F = source size: the maximum projected dimension of the radiation source or effective focal spot in
the plane perpendicular to the distance ‘D’ from the weld or object being radio graphed.
D = distance from source of radiation to weld or object being radiographed, mm.
d = distance from source side of weld or object being radiographed to the film, mm.
D & d shall be measured to the approximate center of the area of interest.

Note : Refer to Standard Guide for Radiographic Testing SE-94 for a method of determining
geometric unsharpness. Alternatively a nomograph as shown in standard guide for radiographic
testing SE-94 may be used.
10.6.1 Geometric Unsharpness Limitations:-

According to Sec I and ASME B 31.1, geometric un-sharpness of the radiograph shall not
exceed the 1.78mm irrespective of thickness.
The following table outlines geometric un-sharpness values as recommended in ASME Sec V.
Material Ug
Thickness (mm) Maximum (mm)
Under 50 0.51
50 through 75 0.76
Over 75 through 100 1.02
Greater than 100 1.78
However, according to ASME Sec VIII, Div 1 & 2, the geometric un-sharpness values in the
above table are to be used only as a guide. Final acceptance of the Radiographs shall be based on
the ability to see the prescribed penetrameter image and the specified hole or the designated wire
of a wire penetrameter. Slightly bent (non-straightness) image of IQI wire shall not be a
criterion for rejection of the radiograph.
Note: Material thickness is the thickness on which the penetrameter is based.
10.7 Diagnostic Film Length: - Consideration will be given to each exposure ensuring the thickness of the
material penetrated at the extremities of the readable area of interest which is measured in the direction
of the incident beam at that point, does not exceed 10% of the thickness being examined.
11. Documentation / Storage of Films:
11.1 Report: - Radiography reports shall contain the following as a minimum

PROCEDURE
(a) Client (l) screen type & thickness

(b) Project (m) IQI identity & type
(c) Job Number (n) film manufacture / type / designation
(d) Report Number (o) Radiographic technique
(e) Date of Test (p) Radiographic sensitivity
(f) Test location (q) No. of exposure / No. of film per cassette
(g) Base Material type and Thickness/ (r) source size or focal spot
weld thickness/ reinforcement (s) Isotope type/X-ray voltage
(h) Drawing Number (t) Radiographic density
(i) Weld Number / Welder Number (u) Acceptance criteria
(j) Source to object distance (D: Para 10.6) (v) Name and level of evaluating person / signature.
(k) Distance from Source side of object (w) Evaluation / Disposition of the welds/materials.
to film (d: Para 10.6). (x) List of each radiograph location with observation.
(y) Date of evaluation.
11.2 A complete set of radiographs and records, as described in Para 11.2 above, for each vessel or vessel
part shall be retained by the Manufacturer for at least three years after stamping of the vessel.
11.3 Film storage:- Radiographs shall be stored after acceptance of the Client as per line or drawing
number sequences for easy traceability whenever the need arises, and shall be the responsibility of
the Client.
12. Acceptance Criteria
12.1 Film shall be interpreted and evaluated by qualified Level II or Level III personnel.
12.2 The manufacturer or his representative shall be responsible for the acceptance of the completed
radiographs to assure the compliance with requirements of ASME Sec V Article-2, and the
referencing Code Section
12.3 Refer annexure –III for acceptance / rejection criteria.
Mandatory Annexure Page 1/2

Annexure-I
SINGLE WALL RADIOGRAPHIC TECHNIQUES

PROCEDURE
Pipe Exposure Radiograph Source-Weld-Film Arrangement IQI Penetrameter Location

O. D. Technique Viewing Marker
Placement
End View Side View Selection Placement
Film
T-276 Source Side Either Side

And T-277.1(a) T-275.3
Table T-275.1(c )
Single-Wall : Single –wall T-276
T-271.1
Any
Film Side T-
277.1 (b)
Exposure Arrangement - A
Single-Wall : Single –wall T-276 Source Side Film Side

T-271.1 And T-277.1(a) T-275.1
Table (b) (1)
Any T-276
Film Film Side

Exposure Arrangement - B T-277.1 (b)
Any Single-Wall : Single –wall T-276 Source Side Source Side

T-271.1 And T-277.1(a) T-275.1
Table (a) (3)
T-276
Film
Film Side
T-277.1 (b)
Exposure Arrangement - C
Annexure-II

PROCEDURE
DOUBLE – WALL RADIOGRAPHIC TECHNIQUES

Placement
Optional
Double-Wall Single –wall Source T-276 Source Side Either Side
: Location And Table T-277.1(a) T-275.1
T-271.2 T-276 (b) (1)
(a)
At Least 3
Any Exposures
120° To
Each Other
For Film
Complete Side
Coverage T-277.1(b)
Film
Exposure Arrangement - D
Optional
Double-Wall Single- wall Source T-276 Source Side Either Side
: Location And Table T-277.1(a) T-275.1
Any T-271.2 T-276 (b) (1)
(a)
At Least 3
Exposures
120° To
Each Other
For Film
Complete Side
Coverage T-277.1(b)
Film
Exposure Arrangement - E
Annexure-II

PROCEDURE
DOUBLE – WALL RADIOGRAPHIC TECHNIQUES

Placement
Double-
Wall : Double-Wall Source T-276 Source Side Either side
31/2″ T-271.2 (Ellipse): And Table T-277.1(b) T 275.2
(88mm) (b) (1) Read Offset T-276
or less At Least 2 Source Side
Exposures And Film
At 90° To Side Images
Each
Other For
Complete
Coverage
Film
Exposure Arrangement - F
31/2″ Double- Double-Wall : T-276 Source Side Either Side

(88mm) Wall : Read Super- Source And Table T-277.1(b) T-275.2
or less T-271.2 Imposed
T-276
(B) (2) Source Side
At Least 3 And Film
Exposures Side Images
At 60° Or
120° To
Each
Other For
Complete
Coverage F
Film
Exposure Arrangement - G

PROCEDURE
Non-mandatory Annexure
Annexure-III
RT ACCEPTANCE CRITERIA COMPARISON CHART
Type of ASME B31.1 ASME VIII / ASME VIII / 2 ASME IX ASME 1
Indication 1*
Crack Not permitted Not permitted See note 2 below. Not permitted Not permitted
Lack of Fusion Not permitted Not permitted Not permitted Not permitted
Lack of penetration Not permitted Not permitted Not permitted Not permitted
Elongated a. ¼” for t upto ¾” a. ¼” for t upto a. 1/8” for t upto a. ¼” for t upto
Indication b. t/3 for t from ¾” ¾” 3/8” incl. ¾”
to 2 1/4” b. t/3” for t from b. t/3” for t over b. t/3” for t over
c. ¾” for t over 2 ¼” ¾” to 21/4” 3/8” to 2 ¼” 3/8” to 2 ¼”
c. ¾” for t over c. ¾” for t over c. ¾” for t over
2¼” 2¼” 2¼”
Rounded indication Refer porosity chart Max. Permissible a. Max. Refer Porosity Chart
(Max, permissible Appendix A 250 Sec. 1 size 1/4t or 5/32” Permissible Appendix A-250
size and whichever is dimension shall
distribution) smaller, except that be 20% of t or
on isolated 1/8” whichever is
indication separated smaller.
from an adjacent
b. For t < 1/8”.
indication by 1” or
Max. number
more may be 1/3t or
shall not exceed
¼” whichever is
12 in a 6” length
less. For t >, 2” the
of weld.
max. isolated
Proportionately
indication shall be
fewer no. of
increased to 3/8”
indications shall
be permitted in
Refer Porosity
welds < 6” in
Chart Appendix 4.
length.
c. For t 1/8” or >
Refer Chart
Appendix. 1.
Rounded
Indication less
than 1/32” max.
dia shall not be
considered for
acceptance in
these ranges of
thickness.
Aligned rounded / Any group of indication Any group of Any group of Any group of
elongated indication in line having an indication in line indication in line indication in line
aggregate length greater having an aggregate having an aggregate having an aggregate
than “t” in a length of length greater than length greater than length greater than
12t is unacceptable, “t” in a length of “t” in a length of 12t “t” in a length of 12t
except when the 12t is unacceptable, is unacceptable, is unacceptable,
distance between the except when the except when the except when the
successive indications distance between distance between the distance between the
exceed 6L where “L” is the successive successive successive
the largest indication. indications exceed indications exceed 6L indications exceed 6L
6L where “L” is the where “L” is the where “L” is the
largest indication longest indication largest indication
Radiograph 5 years Until MDR is 3 years Not specified 5 years
retention Time signed
Note 1: “t” is the thickness of the weld
*Chart gives acceptance as per UW-51 for 100% RT

PROCEDURE
For spot RT UW-52 shall be followed
Note 2: Acceptance criteria in accordance with ASME Sec VIII Div 2 2007 edition: -
a) Linear Indications
1) Terminology
Thickness t – the thickness of the weld excluding any allowable reinforcement. For a butt weld joining two members having different thicknesses at the weld, t is
the thinner of these two thicknesses. If a full penetration weld includes a fillet weld, the thickness of the fillet throat shall be included in the calculation of t.
2) Acceptance/Rejection Criteria
i) Any crack or zone of incomplete fusion or lack of penetration
ii) Any other linear indication that has a length greater than:
6 mm (1/4 in) for t less than or equal to 19 mm (3/4 in),
t/3 for t greater than 19 mm (3/4 in) and less than or equal to 57 mm (2 1/4 in),
19 mm (3/4 in) for t greater than 57 mm (2 1/4 in).
iii) Internal root weld conditions are acceptable when the density or image brightness change as indicated in the radiograph is not abrupt. Linear indications on
the radiograph at either edge of such conditions shall be evaluated in accordance with the other sections of this paragraph.
Rounded Indications
1) Terminology
i) Rounded Indications – indications with a maximum length of three times the width or less on the radiograph are defined as rounded indications. These
indications may be circular, elliptical, conical, or irregular in shape.
ii) Aligned Indications – a sequence of four or more rounded indications shall be considered to be aligned when they touch a line parallel to the length of the
weld drawn through the center of the two outer rounded indications.
iii) Thickness t – the thickness of the weld, excluding any allowable reinforcement. For a butt weld joining two members having different thicknesses at the
weld, t is the thinner of these two thicknesses. If a full penetration weld includes a fillet weld, the thickness of the fillet throat shall be included in the calculation of t .
2) Acceptance Criteria
i) Rounded Indication Charts – relevant rounded indications characterized as imperfections shall not exceed those shown in Figures 7.5 through 7.10, which
illustrate various types of assorted, randomly dispersed and clustered rounded indications for different weld thick nesses greater than 3 mm (1/8 in). The charts
for each thickness range represent full-scale 150 mm (6 in) radiographs, and shall not be enlarged or reduced. The distributions shown are not necessarily the
patterns that may appear on the radiograph, but are typical of the concentration and size of indications permitted.
ii) Relevant Indications (see Table 7.7 for examples) – only those rounded indications that exceed the following dimensions shall be considered relevant and
compared to the acceptance charts for disposition.
1. t 10 for t less than 3 mm (1/8 in)
2. 0.4 mm (1/64 in) for t greater than or equal to 3 mm (1/8 in) and less than or equal to 6 mm (1/4 in)
3. 0.8 mm (1/32 in) for t greater than 6 mm (1/4 in) and less than or equal to 50 mm (2 in)
4. 1.5 mm (1/16 in) for t greater than 50 mm (2 in)
5. Maximum Size of Rounded Indication – the maximum permissible size of any indication shall be t 4 or 4 mm (5/32 in), whichever is smaller; except
that an isolated indication separated from an adjacent indication by 25 mm (1 in) or more may be t 3, or 6 mm (1/4 in), whichever is less. For t
greater than 50 mm (2 in) the maximum permissible size of an isolated indication shall be increased to 10 mm (3/8 in).
6. Aligned Rounded Indications – aligned rounded indications are acceptable when the summation of the diameters of the indications is less than t in a
length of 12t. The length of groups of aligned rounded indications and the spacing between the groups shall meet the requirements of Figure 7.4 of
ASME Sec VIII Div 2; 2007.
7. Clustered Indications – the illustrations for clustered indications show up to four times as many indications in a local area, as that shown in the
illustrations for random indications. The length of an acceptable cluster shall not exceed the lesser of 25 mm (1 in) or 2t. Where more than one
cluster is present, the sum of the lengths of the clusters shall not exceed 25 mm (1 in) in a 150 mm (6 in) length weld.
8. Weld Thickness t less than 3 mm (1/8 in) – for t less than 3 mm (1/8 in) the maximum number of rounded indications shall not exceed 12 in a 150
mm (6 in) length of weld. A proportionally fewer number of indications shall be permitted in welds less than 150 mm (6 in) in length.
iii) Image Density – density or image brightness within the image of the indication may vary and is not a criterion for acceptance or rejection.

PROCEDURE
Non-mandatory Annexure Page 1/2

Annexure-IV
INTERNATIONAL INSPECTION SERVICES LTD (DUBAI BR) DATE.:
TEL. NO.: (9714) 3241955 FAX NO.: (9714) 3241957 REPORT NO.:
E-mail : inspec@ int-inspec.com, Website : www.int-inspec.com
Form No. IN-OPF-01 Rev. 07 PAGE OF
RADIOGRAPHIC EXAMINATION REPORT
CLIENT: CONTRACT / JOB No. :
LOCATION: JOB DESCRIPTION:
PROJECT: BASE MATERIAL TYPE:
SPECIFICATION : RT. PROCEDURE No. & Rev :
Source to Source side Film Manufacturer / Type Screens Thk. No. of exposure :
object of object to F : Pb 0.125 mm
distance film B : Pb 0.125 mm No of film per cassette :
RT. Technique & Radiation Source Source / FS Exposure Time: IQI Sensitivity:
Figure Ref.: / X-Ray Voltage size
Welding Process: Dia.: Base Material Thick Optical Density
Welders Results
Weld I.D. Draw No./Line No.
I.D. Location Remarks ACCEPT ACCEPT
RT LEVEL II TECHNICIAN CLIENT REP. AI / TPI.

NAME : NAME: NAME:
SIGN : SIGN: SIGN:
DATE: DATE: DATE:
Abbreviations No Significant Discontinuities NSD Tungsten Inclusion TI
Porosity P Lack of Fusions L/F Elongated Inclusion EI
Slag Inclusions SI Cracks C Excess Penetration E/P
Lack of Penetration L/P Root Undercut R-U/C External Under Cut E-UC
Rooting Cavity RCV Depression DEP Cluster of Porosity C/P

PROCEDURE
Non-mandatory Annexure Page 2/2

Annexure-IV
INTERNATIONAL INSPECTION SERVICES LTD (DUBAI BR) DATE.:
REPORT NO.:
TEL. NO.: (9714) 3241955 FAX NO.: (9714) 3241957
E-mail : inspec@ int-inspec.com, Website : www.int-inspec.com PAGE OF
RADIOGRAPHIC INSPECTION REPORT

(CONTINUATION SHEET)
WELD I.D. WELDERS I.D. DRAW NO./ REMARKS RESULTS

SIZE
ACCEPT REJECT
TECHNICIAN: CLIENT REP.: AI / TPI.:

LEVEL: NAME: NAME:
SIGNATURE: SIGNATURE: SIGNATURE:
DATE: DATE: DATE:

Document Title:
Ultrasonic Examination Procedure

Project Name : NEW GAS TURBINE GENERATOR Procedure No : INS/ASME/UT/001
P.O No : 4794-10/SV – Rev.00
Description: Ultrasonic Examination Procedure
TERMOCHIMICA

ULTRASONIC EXAMINATION PROCEDURE
REVISION CONTROL
Revision Number &

Changes Remarks
Date
Issued to address requirements of
00
New Issue ASME Section V Edition 2001
15 Feb 2004
Addenda 2003
01 Issued to address requirements of
Revised Vision Test Requirements
15 Feb 2005 ASME Section V Edition 2004
02
Sec.5, Sec.7
13 September 2005 -
Sec 1.2; 1.3; 1.4 Revised
Sec 2.1 Revised. Addenda 2005 incorporated.
Sec 3.1 Revised.
Sec 4.2 Added.
Sec 7.2 Revised
03 Sec 8.3 Deleted
25th January 2006 Sec 13.3 Deleted
Sec 16 Name revised
Sec 17 Newly added, subsequent sections
renumbered.
Annexure III; sample report format Revised
Annexure VI Revised
Sec 2 Addenda 2006 incorporated.
04
Sec 10.1 Revised
1st February 2007
Sec 11.1 Revised
Sec 1.2: Revised. 2007 edition incorporated.
05 Sec 3.4: Fully revised. Table 3.1 added.
10th September 2007 Sec 10.1; 10.2: Revised in their entirety.
Sec 2.1.6: revised. 2007 revisions incorporated.

06
Annexure V: Non-piping calibration block:
21st April 2008
Notes to the figure T-434.2.1 revised.
Sec 1.1: Deleted.
07 Sec 1.3: Revised.
11th August 2008 Sec 2.1.2: ASME Sec VIII Div 2 added.
Sec 3.4: Revised.
08 Sec 2: Revised. 2008 Addenda incorporated.
Document No. : INS/ASME/UT/001 Rev.: 10 dated 20.12.2009 Page No.: 2 of 36

3rd January 2009 Sec 14.2: Revised.

Sec 1.3: Revised. Comments and interpretations
09 Sec 2.1: Revised. incorporated.
28th February 2009 Technique sheets 1 – 5: Revised.
Technique sheet 5/6: deleted.
10 Sec 2: Revised. Addenda 2009 Incorporated
20th December 2009

INDEX
Clause
Ref...
1 Scope 4
3 Procedure qualification & revision 4
4 Performance Demonstration 6
6 Testing Method 7
7 Test Equipment and Auxiliaries 7
8 Surface Condition and Preparation 8
9 Couplant 8
10 Calibration Blocks 9
11 QC of Test Equipment 10
12 General Calibration Requirements 10
13 System Calibration 10
14 Calibration Confirmation 12
15 Examination 14
16 Evaluation and discrimination of geometric indications 15
17 Sizing of indications 16
18 Evaluation for Acceptance 16
19 Documentation and Reporting of Results 16
20 Final Cleaning 17
21 Safety 17
MANDATORY ANNEXURE
Annexure I - Linearity Checks 19
NON MANDATORY ANNEXURE
Annexure II - Sample Acceptance Criteria 21
Annexure III - Sample Report Format 22
TECHNIQUE SHEET & CALIBRATION BLOCK
Annexure IV - Technique Sheet 24
Annexure V - Calibration Blocks 35
SUPPLEMENTS
UT/MAN/001 Attached.

1. Scope:
Ultrasonic Examination of welded joints, associated heat affected zone and base metal.
1.2 This Procedure is primarily intended for application on welds and adjacent heat affected zone made of
steel or ferritic materials for detection and dimensioning of indications for comparison with referencing
code section; however, the Procedure may be applied to welds and HAZ made of other materials and
base metal product forms subject to the qualification of the procedure by way of satisfactory
demonstration and revision of the procedure.
1.3 This Procedure can be used on weld thick nesses varying between 5 mm and 150 mm (of steel).
However for use in vessels according to ASME Sec VIII Division 2, this procedure shall only be
applicable for thicknesses 13mm and above.
1.5 Typical types of discontinuities that can be detected by this method are cracks, incomplete fusion,
incomplete penetration, misalignment, overlap, porosity, root-concavity, undercut, burn-through,
excessive/ inadequate reinforcement, laminations, inclusions, etc.
2.1.1 ASME Section V 2007 Edition; Addenda 2009.

2.1.2 ASME Section VIII Division 1 & 2 2007 Edition; Addenda 2009.
2.1.3 ASME B 31.1b 2007 Edition; Addenda 2009.
2.1.4 ASME Section I; Ed 2007, Addenda 2009.
2.1.5 ASNT SNT TC 1A 2001 & 2006 edition.
2.1.6 INSPEC Written Procedure INSPEC/9/USN/Q1.1994 Rev. 18.
3 Procedure qualification & revision:

3.1 This procedure is a general NDE document for reference and use by authorized INSPEC personnel,
applicable for the purpose identified in the scope and essentially addressing the requirements of ASME
Section V, Article 4.
3.2 Relevant INSPEC personnel are required to be aware of the requirements of this procedure and suitably

qualified and, certified by INSPEC for implementation. (Refer 2.1.6)
3.3 When used by non-INSPEC organizations, the necessary agreements will need to be effected with
INSPEC and a reference to this procedure shall be made appropriately by the organizations.
3.4 This procedure contains variables, which may need qualification by way of demonstration required by
the referencing code. Under such situations, any change or deviation to essential variables will require
revision and re-qualification of this procedure. Such demonstrations shall be on a case-to-case basis and
shall be demonstrated to the Authorized Inspector/ Client representative prior to implementation of this
procedure on test component. A change of a requirement identified as a nonessential variable does not
warrant re-qualification of the procedure. However, any change in either essential or non-essential
variables shall require revision or at least an addendum/ supplement to this procedure. Applicability of
this procedure shall be limited to the range of variables qualified and listed as a supplement attached to
this procedure. Such supplements shall be indicated in the index as supplement attachment of the
procedure. Refer to Table – 3.1 for the list of variables.
TABLE – 3.1

variable variable
Weld configurations to be examined, including thickness X
dimensions and base material product form (pipe, plate etc.)
The surfaces from which the examination shall be performed. X
Techniques (Straight beam, angle beam, contact and/or immersion) X
Angles and modes of wave propagation in the material X
Search unit types, frequencies, and element sizes/shapes X
Special search units, wedges, shoes or saddles, when used X
Ultrasonic instrument X
Calibration (calibration blocks and techniques) X
Directions and extent of scanning X
Scanning (manual vs. automatic) X
Method of discriminating geometric from flaw indications X
Method for sizing indications X
Computer enhanced data acquisition, when used X

TABLE – 3.1 (contd.)

variable variable
Scan overlap (decrease only) X
Personnel performance requirements, when required X
Personnel qualification requirements X
Surface condition (examination surface, calibration block) X
Couplant (brand name or type) X
Automatic equipment and/or recording equipment, when applicable X
Records, including minimum calibration data to be recorded (e.g. X
instrument settings)
3.5 This procedure contains mandatory and non mandatory annexure. Any revision to this procedure or
mandatory annexure will require revision and re-issue of the procedure.
3.6 Any revision to the procedure will as a minimum require review and acceptance by the NDT Level III
and approval by general manager/ QA manager of INSPEC.
3.7 This procedure contains sample acceptance standards applicable for welds as per ASME section VIII
div 1 & 2 and ASME B 31.1 as non-mandatory annexure III. However, when suitable, this procedure
may be applied for other acceptance standards. Any such acceptance criteria are to be appropriately
addressed and recorded during examination with reference to this procedure. In any case, a revision,
inclusion or exclusion of non mandatory annexure will not warrant revision of the procedure.
3.8 Users of this procedure shall verify the applicability of this procedure with respect to requirements.
4 Performance demonstration:
4.1 When required by referencing Code Section or per Client requirements, performance demonstration
shall be carried out and documented as report with the variables used. Copies of such reports shall be
maintained by INSPEC.
4.2 A ‘Certification Statement’ stating satisfactory demonstration and qualification of the procedure with
respect to the variables stated therein, either incorporated in procedure demonstration record or as a
separate sheet shall be attached to the procedure.

5 Personnel Qualification:
5.1 All INSPEC personnel performing ultrasonic examination using this procedure shall be qualified to a
minimum of Level II. (Refer 2.1.6)
5.2 Personnel performing Examination shall have vision, with correction if necessary, to enable to read
Jaeger Type No. 2 Standard Chart at a distance of not less than 300mm, and differentiate the contrast
between the colors and shades of gray, and records of such vision test shall be maintained by INSPEC.
Vision tests shall be conducted annually and be current during examination.
5.3 Personnel conducting Ultrasonic Examination shall be competent in conducting the testing as described
in this Procedure.
5.4 Where required by a specific Code, existing Personnel Qualification shall be verified for applicability as
to the Code conditions.
5.5 Personnel conducting Ultrasonic Examination should be aware of the safe-practice requirements during
examination. (Refer 21)
6 Testing Method:
6.1 Manual contact method using pulse-echo-type of ultrasonic instrument with a ‘A’ scan presentation and
with system calibration using Distance Amplitude Techniques, with Normal & Angle Beam Probes
employing Compressional & Shear Waves.
7 Test Equipment and Auxiliaries:
7.1 The pulse-echo type instrument shall be capable of operation at frequencies over the range of at least 1
MHz to 5 MHz and shall be equipped with a stepped gain control in units of 2.0 dB or less.
7.2 The equipment shall have facilities to work with both combined and, separate transmitter/receiver
probes.
7.2.1 The recommended equipment models include USM 35X DAC/ USM 22B manufactured by
KRAUTKRAMER. Application of this procedure for other instrument/ types shall be subject to
qualification and revision of this procedure.
7.3 Search Units (Transducers) shall be either Single Crystal or Twin Crystal types. The nominal frequency
shall be from 1 MHz to 5 MHz

7.4 The search units’ materials & construction shall be capable of producing either longitudinal or shear
waves into the test component. Generally designated normal (0°) probes should be capable of producing
longitudinal waves into test component while angle probes should be capable of producing refracted
shear waves in to test component at angles 45°, 60°, and 70° (in steel).
7.5 The nominal cross-section sizes of normal probes shall be between diameters 10 mm to 25 mm, while
the cross-section sizes of angle probes shall be 8 mm x 9 mm to 20 mm x 22 mm.
7.6 Co-axial cables connecting search units with the equipment shall be of length between 1.5m. & 4m. and
shall have end adapters capable of secured connections at ends; where, required adopters of various
types shall be used to secure connectivity.
7.7 Auxiliary test aids would include tape strips & rulers, calculators, mimic gauges, Perspex slides, plot-
cards, marking aids.
8 Surface condition & preparation:
8.1 Satisfactory results are usually obtained when the surface of the component is in as-rolled, as-welded,
as-cast or as-forged condition. Surface preparation may be necessary by grinding, machining or other
methods, where surface irregularities could affect proper scanning or affect test results by causing
excessive surface reflections or noise.
8.2 Prior to examination, all areas to be scanned shall be free of all dirt, paint, loose particles, loose mill-
scale, temporary attachments or any obstructive materials that could interfere with the examination.
9 Couplant:
9.1 Couplants are liquids or pastes used to eliminate the air gap between the transducer and the test surface
to assure maximum ultrasound transmission. The couplants will normally be a wetting agent (polycel)
in water, liquid soap, sodium CMC or any other suitable couplant medium. Glycerin, light machine
oil or grease may also be used.
9.2 The couplant should be selected so that its viscosity is appropriate for the surface finish of the material
surface to be examined (Examination of rough surfaces generally requires high viscosity couplant).
Temperature of the material surface can change the couplant’s viscosity.
9.3 The couplant, including additives, shall not be detrimental to the material being examined.
9.3.1 Where, during examination, it may come in contact with nickel base alloys, the couplant shall

not contain more than 250 ppm of sulfur. In cases where it may come in contact with stainless
steel or titanium, the couplant shall not contain more than 250 ppm of halides (chlorides plus
fluorides).
9.4 Couplant used for calibration shall be the same proposed for use during examination
10 Calibration Blocks:
10.1 Calibration Reflectors:

Specified reflectors like side drilled holes; flat bottom holes and ID/OD notches shall be used as
reference reflectors to establish the Primary Reference Response of the instrument. Alternative
reflectors may be used provided that the alternative reflectors produce sensitivity at equal to or
greater than the specified reflectors. In such cases side drilled holes may be used in lieu of notches
or flat bottom holes in lieu of side drilled holes etc.
10.2 Block Material:

10.2.1 Similar metal welds: The material from which the block is fabricated shall be of the same
product form and material specification or equivalent P number grouping as with the product
material. P no 1, 3, 4 & 5 materials are considered equivalent in this regard.
10.2.2 Dissimilar metal welds: The material selection shall be based on the material on the side of the
weld from which examination will be conducted. If the examination is to be conducted from
both sides of the weld, the calibration reflectors shall be provided in both materials.
10.3 IIW – V1 Calibration Block, V2 (miniature) Calibration Block shall be used for distance calibration
10.4 IIW / IOW Standard blocks shall be used for equipment checks.
10.5 IIW Block shall be used for evaluating sensitivity, sweep linearity, transducer index point and angle.
10.6 IOW Standard block shall be used for establishing shear wave beam characteristics, profiles, to
check accuracy of beam index and angle obtained for measurements on the large hole of IIW block,
for assessment of the resolution characteristics of instrument-transducer combinations.
10.7 IOW Block or ASME Basic Calibration Block shall be used for Distance Amplitude Correction
(DAC) curves.
10.8 Where specific calibration blocks are mandated by Code or client requirements, the same shall be
used for calibration and instrument set-up.
10.9 Examples of such calibration blocks are the Basic Calibration Blocks as per J-431 of ASME Section

V, Non-Piping Calibration Blocks as per figures T-434.2.1, Calibration Block for Pipe as per T-434.3,
Cladding Calibration Blocks as per T-434.4.1, T-434.4.2.1, T-434.4.2.2, T-434.4.3.
11 QC of Test Equipment:
11.3 Instrument Linearity Checks:
11.3.1 Screen Height Linearity and Amplitude Control Linearity of the equipment shall be periodically
evaluated; such periodicity shall be at intervals not to exceed three months for Analogue type
instruments and one year for Digital type instruments or prior to first use thereafter. Results of
such evaluations shall be recorded and records to be maintained.
11.3.2 The procedures for linearity checks shall be as detailed in Mandatory Annexure I
12 General Calibration Requirements:
12.3 Calibrations shall include the complete ultrasonic system and shall be performed prior to use of the
system in the thickness range under examination
12.4 Calibrations shall be performed from the surface (clad or unclad; convex or concave) corresponding
to the surface of the component from which examination will be performed.
12.5 Same contact wedges to be used during the examination shall be used for calibration.
12.6 Any instrument control, which affects instrument linearity (e.g. filters, reject, or clipping), shall be in
the same position for calibration, calibration checks, instrument linearity checks, and examination.
12.6.1 If the instrument has a damping control, it may be used if it does not reduce sensitivity of
examination.
12.6.2 The reject control shall be in the “off” position for all examinations, unless it can be
demonstrated that it does not affect the linearity of the examination.
12.5 The temperature differential between calibration block and examination surfaces shall be
within 14°C (25°F).
13 System Calibration:
13.3 Angle Beam Calibration:

13.3.1 The Basic Calibration Block (as per ASME V T434.2.1) shall be used. Where necessitated by
Code requirements, appropriate other Calibration blocks shall be used.
13.3.2 The calibration shall provide the following measurements:

13.3.2.1 Distance range calibration
13.3.2.2 Distance-amplitude correction
13.3.2.3 Echo amplitude measurement from the surface notch in the basic calibration block.
13.3.3 Distance Amplitude Correction (DAC) Curves:
13.3.3.1 The Distance Amplitude Correction (DAC) curves shall be constructed by using
amplitude from (minimum three reference) holes of the calibration block as detailed
below:
13.3.3.2 Select the range required to cover the volume of examination. Position the search unit to
produce maximum response from the SDH, which gives the highest amplitude.
13.3.3.3 Adjust the sensitivity (gain) control to provide an indication of 80% (±5%) of full
screen height (FSH). This is the primary reference. Mark the peak of the indication on the
screen.
13.3.3.4 Position the search unit without changing the sensitivity (dB) to produce maximum
response from another SDH and mark the peak of the indication on the screen.
13.3.3.5 Position the search unit for maximum amplitude from third SDH and mark the peak on
the screen.
13.3.3.6 Position the search unit for maximum amplitude from the ¾ T SDH after the beam has
bounced from the opposite surface. The indication should appear near the sweep line 10.
Mark the peak on the screen for the 5/4 T Position.
13.3.3.7 Connect all the screen marks for the SDHs to provide the distance-amplitude curve
(DAC) and this line shall be the primary reference level.
13.3.4 Calibration correction for Perpendicular reflectors at opposite surface:
13.3.4.1 Notch Indication: Position the search unit for maximum amplitude from the notch on the
opposite surface. Mark the peak of the indication with an “X” on the screen.
13.3.4.2 45° vs. 60°: The opposite surface notch may give an indication 2 to 1 above DAC for a
45° shear wave, but only ½ DAC for a 60° shear wave. Therefore, the indications from
the notch shall be considered when evaluating reflectors at the opposite surface.
13.4 Straight (Normal) Beam Calibration:
13.4.1 The calibration shall provide the following measurements:

13.4.1.1 Distance range calibration

13.4.1.2 Distance-amplitude correction
13.4.2 Distance Amplitude Correction (DAC) Curves:
13.4.2.1 The Distance Amplitude Correction (DAC) curves shall be constructed by using
amplitude from (minimum three reference) holes of the calibration block as detailed
below:
13.4.2.1.1 Select the range required to cover the volume of examination.
13.4.2.1.2 Position the search unit to produce maximum response from the SDH, which gives
the highest amplitude.
13.4.2.1.3 Adjust the sensitivity (gain) control to provide an indication of 80% (±5%) of full
screen height (FSH). This is the primary reference. Mark the peak of the indication on
the screen
13.4.2.1.4 Position the search unit without changing the sensitivity (dB) to produce maximum
response from another SDH and mark the peak of the indication on the screen.
13.4.2.1.5 Position the search unit for maximum amplitude from third SDH and mark the peak
on the screen.
13.4.2.1.6 Connect all the screen marks for the SDHs to provide the distance-amplitude curve
(DAC) and this line shall be the primary reference level.
14 Calibration Confirmation:
14.1 System Changes: When any part of the examination system is changed, a calibration check shall
be made on the basic calibration block to verify that distance range points and sensitivity setting(s)
satisfy the requirements in 14.1.1 & 14.1.2. Calibration check shall be on change of operator, after each
30 min. of operation, or on disturbance for electrical circuit. Disturbance to electrical circuit would
include transducer changes, change of co-axial cable, change of battery, change of electrical outlet,
machine “on” / “off”, or power outage.
14.1.1 Distance Range Points: If any distance range point has moved on the sweep line by more than
10% of the distance reading or 5% of full sweep, whichever is greater, correct the distance range
calibration and note the correction in the examination record. All recorded indications since the
last valid calibration or calibration check shall be reexamined and their values shall be changed
on the data sheets or re-recorded.
14.1.2 Sensitivity Settings: If any sensitivity setting has changed by more than 20% or 2 dB of its
amplitude, correct the sensitivity calibration and note the correction in the examination record.
If the sensitivity setting has decreased, all data sheets since the last valid calibration check shall
be marked void and the area covered by the voided data shall be reexamined. If the sensitivity

setting has increased, all recorded indications since the last valid calibration or calibration check
shall be reexamined and their values shall be changed on the data sheets or re-recorded.
14.2 Periodic Examination Checks:
14.2.1 A calibration check on at least one of the basic reflectors in the basic calibration block or a check
using a simulator shall be made:
14.2.1.1 At the finish of each examination or series of similar examination, and
14.2.1.2 When examination personnel (excluding automated equipment) are changed.
14.2.2 The distance range points and sensitivity setting(s) recorded shall satisfy the requirements of
14.1.1 & 14.1.2
14.2.3 In addition to the checks described in 14.2.1, interim calibration checks can be avoided or
performed depending on the necessity to perform such calibration checks e. g. Ultrasonic
instrument’s stability (Analog vs digital), re-examination risks and benefit of avoiding interim
calibration checks etc.
14.3 Simulator Checks:
14.3.1 Any simulator checks that are used shall be correlated with the original calibration on the basic
calibration block during the original calibration.
14.3.2 The simulator checks may use different type of calibration reflectors or blocks (such as IIW)
and/or electronic simulation.
14.3.3 The simulation used shall be identifiable on the calibration sheet(s).
14.3.4 The simulator check shall be made on the entire examination system. The entire system does not
have to be checked in one operation; however, for its check, the search unit shall be connected to
the ultrasonic instrument and checked against a calibration reflector.
14.3.5 Accuracy of the simulator checks shall be confirmed, using the basic calibration block, at the
conclusion of each period of extended use, or every three months, which ever is less.
14.4 Shear wave transducers shall be checked after every 8 hours for correct angle and flat surface
condition.
14.5 The dimension of the search unit shall be such that the distance from the leading edge of search
unit to the index point shall not exceed 25 mm.
14.6 Beam angle in the material being tested shall be determined to an accuracy of ± 2° from the
nominal angles.
14.7 Transducer units, which do not meet necessary requirements, shall be corrected or withdrawn
from service.

15 Examination:
15.1 General Requirements:

15.1.1 The volume to be scanned shall be examined by moving the search unit over the scanning
surface so as to scan the entire examination volume for each required search unit.
15.1.2 Each pass of the search unit shall overlap a minimum of 10% of the active transducer
(piezoelectric element) dimension perpendicular to the direction of scan. Where mandated by
Code requirements, the percent minimum overlap may be increased.
15.1.3 Alternatively, each pass of the search unit may overlap a dimension less than the minimum beam
dimension (beam spread) if the same is already known. Oscillation of the search unit is
permitted provided improved coverage is demonstrated.
15.1.4 The Pulse Repetition Rate shall be small enough to assure that a signal from a reflector located at
the maximum distance in the examination volume will arrive back at the search unit before the
next pulse is placed on the transducer.
15.1.5 The rate of search unit movement (scanning speed) shall not exceed 6 in. /s (152 mm/s).
15.2 Scanning:
15.2.1 The scanning sensitivity level shall be set a minimum of 6 dB higher than the reference level
gain setting.
15.2.2 The temperature differential between the test surface and that of the calibration block shall be
less than 25° F.
15.3 Weld Joint Scanning:

15.3.1 Weld Joints shall be scanned with an angle beam search unit in both parallel and transverse
directions (4 scans) to the weld axis.
15.3.2 Before performing the angle beam examinations, a straight beam examination shall be performed
on the volume of base material through which the angle beams will travel to locate any reflectors
that can limit the ability of the angle beam to examine the weld volume.
15.3.3 Beam Angle: The search unit and beam angle selected shall be appropriate for the configuration
being examined and shall be capable of detecting the calibration reflectors, over the required
angle beam path.
15.3.4 Reflectors Parallel to the Weld Seam: The angle beam shall be directed at approximate right
angles to the weld axis from both sides of the weld (i.e. from two directions) on the same surface
when possible. The search unit shall be manipulated so that the ultrasonic energy passes through
the required volume of weld and adjacent base material.
15.3.5 Reflectors Transverse to the Weld Seam: The angle beam shall be directed essentially parallel to
the weld axis. The search unit shall be manipulated so that the ultrasonic energy passes through
the required volume of weld and adjacent base material. The search unit shall be rotated 180°
and the examination repeated.

15.3.6 Restricted Access Welds: Welds that cannot be fully examined from two directions using the
angle beam technique (e.g. corner and tee joints) shall also be examined, if possible, with a
straight beam technique.
15.3.6.1 These areas of restricted access shall be noted in the examination report.
15.3.7 Inaccessible Welds: Welds that cannot be examined from at least one side (edge) using the angle
beam technique shall be noted in the examination report. For flange welds, the weld may be
examined with a straight beam or low angle longitudinal waves from the flange face provided the
examination volume can be covered.
15.4 Cladding Techniques:
15.4.1 When examination for lack of bond and clad flaw indications are required, 15.4.2 shall be
followed. When examination for lack of bond only is required, 15.4.3 shall be followed.
15.4.2 The examination shall be performed from the clad surface with the plane separating the elements
of the dual element search unit positioned parallel to the axis of the weld bead. The search unit
shall be moved perpendicular to the weld direction.
15.4.3 The examination may be performed from either the clad or unclad surface and the search unit
may be moved either perpendicular or parallel to the weld direction.
16 Evaluation and discrimination of geometric indications:
16.1Generally, certain metallurgical discontinuities and geometric conditions may produce indications that
are not relevant.
16.1.1 Classification of an indication as geometric shall be through the following steps:
16.1.1.1 Interpret the area containing the reflector in accordance with the applicable examination
procedure.
16.1.1.2 Plot and verify the reflector coordinates. Prepare a cross-sectional sketch showing the
reflector position and surface discontinuities such as root and counterbore.
16.1.1.3 Review fabrication or weld preparation drawings.
16.1.1.4 If necessary, other ultrasonic techniques or nondestructive examination methods may be
applied in determining a reflector’s true position, size and orientation.
16.2 All indications greater than 20 % of the reference level shall be investigated to the extent that they
can be evaluated in terms of the acceptance criteria of the referencing Code.
16.3 Reflectors evaluated as laminar reflectors in base material, which interfere with the scanning of
examination volumes, shall require the angle beam examination technique to be modified such that
the maximum feasible volume is examined, and shall be noted in the record of the examination.

16.4 Reflector dimensions exceeding the referencing Code Section requirements may be evaluated to
any alternative standards provided by the referencing Code Section.
16.5 This Procedure contains sample acceptance standards as per ASME Section VIII Division 1 and 2
(Refer Non-Mandatory Annexure IV)
17 Sizing of Indications:
17.1 All indications considered to be record able shall be sized for their length extension by 6 dB drop
(50% amplitude drop) method.
17.2 Other methods of sizing of indications may be used subject to subject to satisfactory demonstration
for qualification and revision of the procedure.
18 Evaluation for Acceptance:
18.1 All non-rejectable indications shall be recorded, as specified by any referencing Code Section or
client requirement.
18.2 Rejectable indications shall be recorded. As a minimum, the type of indication (i.e. crack, non-
fusion, slag, etc.), location, and extent (i.e. length) shall be recorded.
18.3 Acceptance criteria used shall be documented in the NDE Report
19 Documentation & reporting of results
19.1 For each Ultrasonic Examination as per this Procedure, the following minimum information
shall be recorded and suitably addressed in the relevant INSPEC Report (Refer Non-Mandatory
Annexure III):
19.1.1 Client / Project / Job details

19.1.2 Location
19.1.3 Procedure Identification and Revision
19.1.4 Ultrasonic Instrument identification (Make / Serial No.)
19.1.5 Search unit identification
19.1.5.1 Make / Serial No.
19.1.5.2 Frequency
19.1.5.3 Size

19.1.6 Beam Angles Used

19.1.7 Search unit cable, type & length:
19.1.8 Special equipment (like wedges, shoes etc, when used):
19.1.9 Calibration block identification:
19.1.10Simulation blocks identification (when used)
19.1.11Instrument reference level gain
19.1.12Damping and Reject settings (when used):
19.1.13Calibration data (including reference reflectors, indication amplitudes & distance)
19.1.14Data correlating simulation blocks (when used) with initial calibration
19.1.15Weld Configuration, thickness & dimensional details of Base metal
19.1.16Identification and location or weld or volume scanned
19.1.17Couplant brand name or type used:
19.1.18Surface condition of examination location
19.1.19Surface from which examination was conducted
19.1.20Record of rejectable indications detected or areas cleared
19.1.21Record of all reflections from uncorrected areas having responses greater than 50% of the
reference level. (See Annexure II).
19.1.22Areas of restricted access or inaccessible welds
19.1.23Examination personnel identity and qualification level
19.1.24Examination date.
19.1.25Accept / Reject status (as appropriate & applicable)
19.2 Items 19.1.4 through 19.1.14 may be included in a separate calibration record, provided the calibration
record identification is included in the Examination Record.
19.3 A complete set of records, as described in section 19.1 above, for each vessel or vessel part shall
be retained by the Manufacturer/contractor for at least three years (Refer paragraph 2.C.3 of
ASME Sec VIII Div 2). In addition, a record of repaired areas shall be noted as well as the results
of the reexamination of the repaired areas. The Manufacturer/contractor shall also maintain a
record from uncorrected areas having responses that exceed 50% of the reference level. This
record shall locate each area, the response level, the dimensions, the depth below the surface, and
the classification.
20 Final cleaning:
Whenever required, after completion of Examination, couplants such as polycel paste shall be cleaned using
water. Couplants such as glycerin / oil / grease shall be cleaned utilizing suitable solvent remover. Such
cleaning agents shall not produce any detrimental effect to the test component.

21 Safety:
21.1All inspection personnel shall be responsible for compliance with applicable safety rules in the use of
Test materials.
21.2 Some of the Calibration blocks used in Ultrasonic Testing are fairly heavy in weight, having square
edges. They may be become slippery due to usage of couplants and will need to be carefully handled.
21.3Some test materials such as couplants may cause skin irritation. Use adequate ventilation at all times
and avoids prolonged skin contact.
21.4Test materials shall never be heated above the recommended temperature limits prescribed by the
manufacturer.
21.5The test system has electrical input for the Test equipment and safe practices should be followed to
avoid any electrical shocks.

MANDATORY ANNEXURE I
LINEARITY CHECKS
Fig. MA II-1
Screen Height Linearity:
Position an angle beam search unit on a calibration block similar to that shown in Fig. MA II-1 so that indications from both the ½
and ¾ T holes give a 2:1 ratio of amplitudes between the two indications. Adjust the sensitivity (gain) so that the larger indication is
set at 80% of full screen height (FSH). Without moving the search unit, adjust sensitivity (gain) to successively set the larger
indication from 100% to 20% of full screen height, in 10% increments (or 2 dB steps if a fine control is not available), and read the
smaller indication at each setting. The reading shall be 50% of the larger amplitude, within 5% of FSH. The settings and readings
shall be estimated to the nearest 1% of full screen.
Alternatively, a straight beam search unit may be used on any calibration bloc that provides amplitude differences, with sufficient
signal separation to prevent overlapping of the two signals.
Amplitude Control Linearity:
Position an angle beam search unit on a basic calibration block, as shown in Fig. MA II-1 so that the indication from the ½T side-
drilled hole is peaked on the screen. Adjust the sensitivity (gain) as shown in the following table. The indication shall fall within the
specified limits. Alternatively, any other convenient reflector from any calibration block may be used with angle or straight beam
search units. The settings and readings shall be estimated to the nearest 1 % of full screen.

Indication Set at % of Indication Limits % of

dB Control Change
Full Screen Full Screen
80 % -6 dB 32 to 48 %
80 % -12 dB 16 to 24 %
40 % +6 dB 64 to 96 %
20 % +12 dB 64 to 96 %

NON-MANDATORY ANNEXURE II
(Note: Information provided in this annexure is for guidance only; users are encouraged to refer the relevant standards / codes for specific
acceptance criteria. These acceptance criteria apply unless other more restrictive standards are specified for specific materials or applications within
the Code Sections / Divisions)
ASME Section VIII Div. 1 (Appendix 12)

Imperfections, which produce a response greater than 20% of the reference level, shall be investigated to the extent that the operator can determine
the shape, identity, and location of all such imperfections and evaluate them in terms of acceptance standards given below:
Indications characterized as Crack, Lack of Fusion, or Incomplete Penetration are unacceptable regardless of length
Other imperfections whose indications exceed the reference level and which have their length exceeding the following are unacceptable:
¼” (6 mm) for t up to ¾” (19 mm)
t/3” for t from ¾” to 2¼” (19 mm to 57 mm)
¾” for t over 2¼” (57 mm)
where t is the thickness of the weld excluding any allowable reinforcement. For a butt weld joining two members having different thicknesses at the
weld, t is the thinner of these two thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be
included in t.
A record of repaired areas shall be noted as well as the results of the reexamination of the repaired areas. A record of all reflections from uncorrected
areas having responses that exceed 50% of the reference level shall be prepared; such record shall show the location of each area, response level, the
dimensions, the depth below the surface, and the classification in accordance with para. 19.1.21.
ASME Section VIII Div 2 (Part 7: Para 7.5.4)

All imperfections that produce amplitude greater than 20% of the reference level shall be investigated to the extent that the operator can determine
the shape, identity, and location of all such imperfections and evaluate them in terms of the acceptance standards given in (a) and (b) below.
a) Imperfections that are interpreted to be cracks, lack of fusion, or incomplete penetration are unacceptable regardless of length.
b) All other linear type imperfections are unacceptable if the amplitude exceeds the reference level and the length of the imperfection
exceeds the following:
1) 6 mm (1/4 in) for t less than 19 mm (3/4 in)
2) t/3 for t greater than or equal to 19 mm (3/4 in) and less than or equal to 57 mm (2-1/4 in)
3) 19 mm (3/4 in) for t greater than 57 mm (2-1/4 in)
In the above criteria, t is the thickness of the weld, excluding any allowable reinforcement. For a butt weld joining two members having different
thicknesses at the weld, t is the thinner of these two thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the
fillet shall be included in t.
ASME B 31.1: POWER PIPING (Para 136.4.6):
Welds that are shown by ultrasonic examination to have discontinuities, which produce a response greater than 20% of the reference level, shall be
investigated to the extent that the operator can determine their shape, identity & location and evaluate them in terms of acceptance standards given
below:
A1: Discontinuities evaluated as cracks, lack of fusion or incomplete penetrations are unacceptable regardless of length.
Other discontinuities whose indications exceed the reference level and which have their length exceeding the following are unacceptable:
1/4th inch (6mm) for ‘t’ up to 3/4th inch.
t/3 for ‘t’ from 3/4th to 2-1/4th inches (19mm to 57mm)
3/4th inch for ‘t’ over 2-1/4th inches (57mm)
where ‘t’ is the thickness of the weld. For a butt weld joining two members having different thicknesses at the weld, ‘t’ is the thinner of the two
thicknesses.

NON-MANDOTARY ANNEXURE III

SAMPLE REPORT FORMAT
INTERNATIONAL INSPECTION SERVICES (DUBAI BR) DATE OF TEST:

P.O. BOX NO.96535, DUBAI, U.A.E.
REPORT NO.:
TEL.NO. (9714) 3241955 FAX NO.: (9714) 3241957
E-mail : inspec@int-inspec.com, Web Site : www.int-inspec.com
IN-OPF-02a Rev 04 PAGE OF
ULTRASONIC EXAMINATION REPORT

Client: Job no:
Location: Item ID:
Connecting Cable type & length: Project:
Special attachment/ equipment/Blocks:
Calibration Block No. Thickness: Reference Reflectors:
Acceptance criteria:
DAC settings:
Probe Reflector no. %Echo Beam path Reflector no. %Echo Beam path Reflector no. %Echo Beam path
Damping/ reject setting: Weld volume scanned:

PROBE TYPE UT procedure & revision:
Make Technique sheet ref:

Sr. no. Flaw detector:
Serial no.:
Crystal Size/ diameter Calibration certification no.:
Frequency MHz Base metal type & thickness:
Primary Reference dB Weld type/ configuration:
Scanning Sensitivity dB Couplant brand name & type:

Test Range (mm) Scan Face: from both faces of the plate.
Surface condition/
preparation:
Access Limitations (if any):
RESULT :
Technician: Client rep.: AI / TPI.
Level: II Name: Name:
Signature & Date: Signature & Date Signature & Date:

NON-MANDATORY ANNEXURE III

SAMPLE REPORT FORMAT
DATE. OF TEST:
INTERNATIONAL INSPECTION SERVICES (DUBAI BR)
REPORT NO.:
P.O. BOX NO.96535, DUBAI, U.A.E.
TEL.NO. (9714) 3241955 FAX NO.: (9714) 3241957 PAGE OF
E-mail : inspec@int-inspec.com, Web Site : www.int-inspec.com
ULTRASONIC INSPECTION REPORT

(CONTINUATION SHEET)
WELD I.D. WELDERS I.D. DRAW NO./ REMARKS RESULTS

SIZE
ACCEPT REJECT
TECHNICIAN: CLIENT REP.: AI / TPI.:
LEVEL: NAME: NAME:
SIGNATURE: SIGNATURE: SIGNATURE:

DATE: DATE: DATE:

ANNEXURE-IV
Technique sheet -1/5
BUTT WELD – SINGLE “V” PREPARATION
3&4
1 2
3
Note : Position ‘3’ & ‘4’ is for scanning from the weld surface and will be applicable whenever the weld is flush ground with base
metal. Scan shall be along the axial direction of the weld to find any transverse indication.
a. Parent Metal Examination:
Scanning Positions : 1 & 2 over 2.5 times the parent metal
thickness each side of the weld toe.
Scanning Pattern : Overlapping Scans
Sensitivity : 2nd back wall echo at full screen height
Probes : 0° - 2.25 MHz to 5 MHz T/C or S/C
b. Weld Metal Examination:

Scanning Pattern : Overlapping Scans.
Probes Scanning Options Scanning Sensitivity
0° 3 (if required) Reference side drilled hole set to DAC + 6 dB
45° 1&2 Reference side drilled hole set to DAC + 6 dB
60° 1&2 Reference side drilled hole set to DAC + 6 dB
70° 1 & 2 and 3 & 4 Reference side drilled hole set to DAC + 6 dB
Evaluation Sensitivity : In access of 20% D.A.C.
Sizing Technique : 6 dB drop / max amplitude or similar
recognized technique
Note: Scans 3 & 4 may also be necessary with 45° or 60° probes for transverse discontinuities with particular
orientations.

Technique sheet -1/5 (BUTT WELD – SINGLE “V” PREPARATION)

Examination Requirements Qualified range
Weld configurations Butt weld, Single V, without back strip; Type 3*
Thickness range As per procedure demonstration
Base material As per procedure demonstration
Product form (pipe, plate etc.) Plate to pipe (Refer to sketch)
Scan surfaces From vessel OD and/or ID
Technique DAC
Angles and modes of wave propagation 450; 600; 700; shear wave.
Search unit types, Piezo-electric; permanent wedge mounted
Frequency 4 MHz & 2 MHz
element sizes & shape 10mm diameter/ circular
Special search units, wedges, shoes or saddles Nil
Ultrasonic instrument USM 35
Calibration: Calibration block: As per procedure demonstration, refer annex V
Technique: DAC with reference hole.
Directions and extent of scanning Perpendicular to weld axis; 100%.
Scanning (manual/automatic) Manual
Method of discriminating geometric from flaw indications 1:1 sketch and beam plotting.
Method for sizing indications 6 dB drop
Computer enhanced data acquisition: Nil
Scan overlap (decrease only) 10% minimum
Personnel performance: Not required
Personnel qualification: Level II
Surface condition: As rolled
Couplant (brand name/type) Polycell paste or equivalent.
Automatic equipment and/or recording equipment Nil
Records/minimum calibration data/instrument settings: To be recorded
*: Refer to ASME Sec VIII Division 2, Table 4.2.2.

ANNEXURE-IV
BUTT WELD – DOUBLE “V” PREPARATION – COMPLETE PENETRATION

5
1 2
8
7 6
787
3 6 4 7 8
Scanning Positions : 1 & 2 or 3 & 4 over 2.5 times the parent

metal thickness each side of the weld toe.
Sensitivity
Probes
:
:
INSPEC 2nd back wall echo at full screen height
0° - 2.25 MHz to 5 MHz T/C or S/C

0° 5 & 6 (if required) Reference side drilled hole set to DAC + 6 dB
1 & 2 and 3 & 4 and Reference side drilled hole set to DAC + 6 dB
70°
5 & 6 or 7 & 8
Sizing Technique : 6 dB drop / max amplitude or similar recognized technique.
Note: Scans 3 & 4 may also be necessary with 45° or 60° probes for transverse discontinuities with particular
orientations.

Technique sheet -2/5 (BUTT WELD – DOUBLE “V” PREPARATION – COMPLETE PENETRATION)
Weld configurations Butt weld, Double V; Type 1*
Technique DAC

ANNEXURE-IV
BUTT WELD – SET ON (INCLUDING NOZZLES)
Technique sheet -3/5 (BUTT WELD – SET ON (INCLUDING NOZZLES)


Weld configurations Nozzle; Set-on; Type 7*
Technique DAC
Scanning Positions : From vessel/ nozzle OD or ID surface up to the total scan distance for actual probe angle utilized.

Probes Scan positions Scanning sensitivity
0° Scan-1 Reference side drilled hole set to DAC + 6 dB
45° Scan-2 Reference side drilled hole set to DAC + dB
Recording: Indications more than 50%DAC shall be recorded and location, size and classification noted.

ANNEXURE-IV
BUTT WELD – SET THROUGH (INCLUDING NOZZLES)
INSPEC

Technique sheet -4/5 (BUTT WELD – SET THROUGH, INCLUDING NOZZLES)

Weld configurations Nozzle; Set-in; Type 7*
Technique DAC
c. Parent Metal Examination:
d. Weld Metal Examination:


ANNEXURE-IV
TEE BUTT WELD – COMPLETE PENETRATION
1
3
2 4
6 5 7
Note : For Single Bevel Welds also
Scanning Positions : 1 or 3 & 2 or 6 & 4 or 7 & 5 over 2.5 times the
parent metal thickness each side of the weld toe.
Scanning Pattern
Sensitivity
:
:
INSPEC Overlapping Scans
2nd back wall echo at full screen height
0° 5 Reference side drilled hole set to DAC + 6 dB
45° 1 or 3 or 2 & 4 or 6 & 7 Reference side drilled hole set to DAC + 6 dB
60° 1 or 3 or 2 & 4 or 6 & 7 Reference side drilled hole set to DAC + 6 dB
1 or 3 or 2 & 4 or 6 & 7 Reference side drilled hole set to DAC + 6 dB
70°
and 3 & 4
Sizing Technique : 6 dB drop / max amplitude or similar recognized technique.

Technique sheet -5/5 (TEE BUTT WELD – COMPLETE PENETRATION)

Weld configurations Nozzle Set-in/ tee joint; Type 7*
Scan surfaces From vessel/ nozzle OD and/or ID
Technique DAC
e. Parent Metal Examination:
f. Weld Metal Examination:


ANNEXURE-V
BASIC CALIBRATION BLOCK -1/2
Weld Thickness (t) Calibration Block Hole Notch Dimensions

in (mm) Thickness (T) in Diameter in. (mm)
(mm) In (mm)
Up to 1 (25) ¾ (19) or t 3/32 (2.5) Notch Dept = 2% T
Over 1 (25) through 2 (50) 1 ½ (38) or t 1/8 (3) Notch Width = ¼ (6) max
Over 2 (50) through 4 (100) 3 (75) or t 3/16 (5) Notch Length = 1 (25) min
Over 4 (100) T ± 1 (25) **
** For each increase in weld thickness of 2 in (50 mm) or fraction thereof 4 in. (100 mm), the hole diameter shall increase 1/16 in. (1.5mm)
GENERAL NOTES:
a) Holes shall be drilled and reamed 1.5 in (38 mm) deep minimum, essentially parallel to the examination surface.
b) For components equal to or less than 20 in. (500 mm) in diameter, calibration block diameter shall meet the requirements of T-434.1.7.2.
Two sets of calibration reflectors (holes, notches) oriented 90 deg from each other shall be used. Alternatively, two curved calibration
blocks may be used.
c) The tolerance for hole diameter shall be ± 1/32 in. (0.8 mm). The tolerance for hole location through the calibration block thickness (i.e.
distance from the examination surface) shall be ± 1/8 in. (3 mm)
d) For blocks less than 3⁄4 in. (19 mm) in thickness, only the 1⁄2T side-drilled hole and surface notches are required.
e) All holes may be located on the same face (side) of the calibration block, provided care is exercised to locate all the reflectors (holes, notches)
to prevent one reflector from affecting the indication from another reflector during calibration. Notches may also be in the same plane as the
inline holes. A sufficient number of holes shall be provided for both angle and straight beam calibrations at the 1⁄4T, 1⁄2T, and 3⁄4T depths.
Refer figure J431, Appendix J of ASME Sec V: 2007.
f) Minimum notch depth shall be 1.6%T and maximum notch depth shall be 2.2% T plus the thickness of cladding, if present.
g) Maximum notch width is not critical. Notches may be made by EDM or with end mills up to 1⁄4 in. (6.4 mm) in diameter.
h) Weld thickness, t, is the nominal material thickness for welds without reinforcement or, for welds with reinforcement, the nominal material
thickness plus the estimated weld reinforcement not to exceed the maximum permitted by the referencing Code Section. When two or more
base material thicknesses are involved, the calibration block thickness, T, shall be determined by the average thickness of the weld;
alternatively, a calibration block based on the greater base material thickness may be used provided the reference reflector size is based upon
the average weld thickness.
FIG. T-434.2.1 (ASME SEC V) NON-PIPING CALIBRATION BLOCKS

ANNEXURE-V
BASIC CALIBRATION BLOCK-2/2
* Notches shall be located not closer than T or 1 in. (25 mm), whichever is greater, to any block edge or to other notches.
GENERAL NOTES :
a) The minimum calibration block length (L) shall be 8 in. (200 mm), whenever is greater.
b) For OD 4 in. (100 mm) or less, the minimum arc length shall be 270 deg. For OD greater than 4 in. (100mm), the minimum arc length shall be
8 in. (200 mm) or 3 T, whichever is greater.
c) Notch depths shall be from 8% T minimum to 11% T maximum. Notch widths shall be ¼ in. (6.5 mm) maximum. Notch lengths shall be 1 in.
(25 mm) minimum.
d) Notch length shall be sufficient to provide for calibration with a minimum 3 to 1 signal to noise ratio.
FIG T-434.3 (ASME SEC V) CALIBRATION BLOCK FOR PIPE

Document Title:
NDE Inspectors Qualification list & Certificate

Project Name : NEW GAS TURBINE GENERATOR Procedure No : TI-4915-NDE-01
P.O No : 4794-10/SV – Rev.00
Description: NDE Inspectors Qualification list & Certificate
TERMOCHIMICA

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TERMOCHIMICA IMPIANTI Vendor Document No. Rev.

VIA PURICELLI 5 GALLARATE (VA) ITALY 1 of

NDT PROCEDURE AND NDE PERSONAL QUALIFICATION

VENDOR DOCUMENT REVIEW

151 NEW GAS TURBINE GENERATOR 1 REVISE AND RESUBMIT

MATERIAL REQUISITION No. 3 NO COMMENT - FINAL ISSUE

FOR INFORMATION ONLY (INTERNAL

NEW GAS TURBINE GENERATOR GT-5

Purchase Order Number: 151A0005

Equipment / Item Tag: D-7026

Document Number: NDE-6407

Visual Examination Procedure

Description: Visual Examination Procedure

0 11.10.2010 For Approval Renjith. G Sinoj BalasubramaniamS

Rev. Date Description Prepared Checked Approved

VISUAL EXAMINATION PROCEDURE

REVISION DATE DESCRIPTION

00 15.09.2008 Original Issue

01 22.06.2009 ASME BPV 2008 Addenda incorporated.

02 12.12.2009 Addenda 2009 added

3.0 PROCEDURE QUALIFICATION AND REVISION

3.3 When used by non-TECH INTERNATIONAL Organizations, the necessary agreements

TABLE 3.1 (Table T-921 of Article 9)

Requirement (As Applicable) Non-Essential

4.0 PROCEDURE DEMONSTRATION REQUIREMENT:

5.0 QUALIFICATION OF VISUAL TESTING PERSONNEL

8.0 SEQUENCE OF INSPECTION

9.0 SURFACE FINISH & EXTENT OF INSPECTION

11.0 ACCEPTANCE CRITERIA

11.2 Examination Checklist:

Measuring apparatus and Practical Applications

Wall Thickness Ball Micrometer

Bevel Angles Bevel Protractor

Outside Diameter Vernier Caliper, Micrometer

Inside Diameter Vernier Caliper, Micrometer

Scale, Vernier Caliper

Reinforcement Scale / Weld Gauges

Undercut Scale, Depth, Gauge

Surface Finish Surface Comparator

Socket Depth Scale

Fillet Legs or Throat Thickness Scale, Gauge, Template.

ACCEPTANCE CRITERIA – VISUAL TESTING – ASME B31.1

A. Acceptance Standards. The following indications are unacceptable:

REINFORCEMENT OF GIRTH AND LONGITUDINAL BUTT WELDS

Maximum Thickness of Reinforcement

in. mm in. mm . In. mm.

Up to 1/8 (3.0), in cl. 1/16 2.0 3/32 2.5 3/16 5.0

a. For double welded butt joints, this limitation on reinforcement given

Attachment – II (AWS D 1.1: 2008)

Attachment – III (ASME Sec. VIII Div. 2: 2007)

Magnetic Particle Examination Procedure

Description: Magnetic Particle Examination Procedure

0 11.10.2010 For Approval Renjith. G Sinoj BalasubramaniamS

Rev. Date Description Prepared Checked Approved

Document No. : INS/ASME/MT/001 Rev.: 09 dated 20.12.2009 Page No.: 2 of 15

Document No. : INS/ASME/MT/001 Rev.: 09 dated 20.12.2009 Page No.: 3 of 15

2.1 The following documents are referred:

2.1.1 ASME Section V 2007 ed. Addenda 2009.

3. Procedure qualification & revision:

Document No. : INS/ASME/MT/001 Rev.: 09 dated 20.12.2009 Page No.: 4 of 15

Document No. : INS/ASME/MT/001 Rev.: 09 dated 20.12.2009 Page No.: 5 of 15

Document No. : INS/ASME/MT/001 Rev.: 09 dated 20.12.2009 Page No.: 6 of 15

6. NDE Method Technique: