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ENGINEERING STANDARD SPECIFICATION Ontario

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SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – ULTRASONIC INSPECTION GENERAL PROCEDURE FOR WELDS

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Rev Description Approved by Reviewed by Issue Date YYYY/MM/DD

1 Document format and content changed. Previous number 017-00.

PB 2012/01/18

JL 2011/12/22

2012/06/06

2 SPEC Reviewed 2016 – Regional Approvals removed, no other changes

P.Belzile A.Nadeau 2016/12/15


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1.0 PURPOSE

This specification describes the minimum requirements to be followed for the ultrasonic inspection of weld and weldments to ASME Sec. V, Article 4. 2.0 APPLICATION

This specification, applies at any Vale locations indicated with approval on the cover page, with the following exceptions: 2.1 Exceptions

None. 3.0 REFERENCE DOCUMENTATION

The following documents were used in the development of this document or have instructions and procedures applicable to it. They shall be used in their most recent revision. ASME Section V, Article 4 ASTM E 317-06a

4.0 QUALIFICATION OF PERSONNEL

Personnel performing this inspection shall be qualified in accordance with the requirements of C.G.S.B. Standard 48.9712 Level II or III or as required by the referencing code or specification. 5.0 MATERIALS

This procedure shall be used when inspecting welds and weldments. Refer to a specific weld inspection technique which shall be prepared in accordance with this procedure and the applicable reference code. 6.0 EQUIPMENT AND SUPPLIES

6.1 Frequency / Instrument Controls

This examination shall be conducted with a pulse-echo ultrasonic instrument capable of generating frequencies over the range of at least 1 MHz to 5 MHz. Instruments operating at other frequencies may be used if equal or better sensitivity can be


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demonstrated and documented. Any control, which affects instrument linearity (e.g. filters, reject, or clipping), shall be used in the same position for calibration, calibration checks, instrument linearity checks, and examination. 6.2 Screen Height Linearity

The ultrasonic instrument shall provide linear vertical presentation within ± 5% of the full screen height in 10% increments from 20% to 100%, of the calibrated screen height (base line to maximum calibrated screen points). The procedure for evaluating screen height linearity is provided in Appendix I and shall be performed at the beginning of each period of extended use or every three months, whichever is less (Appendix I attached). 6.3 Amplitude Control Linearity

The ultrasonic instrument shall utilize an amplitude control accurate over its useful range to +/- 20% of the nominal amplitude ratio to allow measurement of indications beyond the linear range of the vertical display on the screen. The procedure for evaluating amplitude control linearity is given in Appendix II and shall be performed at the beginning of each period of extended use or every three months, whichever is less (Appendix II attached). 6.4 Checking Equipment and Calibration for Inspection

The proper functioning of the examination equipment shall be checked prior to use. Calibrations shall include the complete ultrasonic system and shall be performed prior to use of the system in the thickness range under examination. The same couplant and contact wedges used during calibration shall be used for the examination. The UT instrument and probes shall be calibrated by the use of the calibration standard (as per the individual weld inspection technique(s)) at the beginning and end of each examination, every 4 hours during the examination, when examination personnel are changed, and at any time that malfunctioning is suspected, as a minimum. If during any check it is determined that the testing equipment is not functioning properly, all of the product that has been tested since the last valid equipment calibration shall be re-examined. 6.5 Search Units / Ultrasonic Instrument

a) Search units may contain either single or dual transducer elements. b) Search units with contoured contact wedges may be used to aid ultrasonic coupling.


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Search units must be periodically checked for characteristics as per ASTM E164 or the referencing code section. These include beam spread, index points, angle verification, near field and far field resolution. The exact type, size, and frequency of search unit shall be as specified in the technique for the particular weld design. Exit points and angles of contoured or standard wedges must be verified prior to use. The actual angle of the wedge shall be within ± 2⁰ of the nominal angle. Standard angles are 45⁰ , 60⁰ and 70⁰ .

The ultrasonic instrument used shall have either a calibrated gain control, or calibrated attenuator capable of discreet 2dB steps over a minimum range of 0 - 70dB. Test equipment shall satisfy the horizontal linearity and resolution functional requirements of ASTM E317-06a. 7.0 CALIBRATION BLOCKS

Time base calibration shall be achieved using the (IIW) International Institute of Welding block or equivalent (eg. Rompas Block). The basic calibration blocks which contain basic calibration reflectors used to establish a primary reference response of the equipment and to construct a distance amplitude correction curve (DAC), shall be used. The material from which the block is fabricated shall be from material of the same specification and acoustically similar as one of the materials being formed. Calibration for sensitivity shall be achieved using the basic calibration block specified in figure T434.2.1 of ASME Section V, Article 4 unless an alternate Calibration Block is designated in specific technique sheets. For T434.2.1 see attached Appendix 3. The calibration block shall receive at least the minimum tempering treatment as required by the material specification for the type and grade. If the calibration block contains welds other than cladding, and the component weld at the time of the examination has been heat treated, the block shall receive the same heat treatment. The calibration and examination surface temperatures shall be within ±25°F (14°C) to avoid large attenuation and velocity differences in the wedge material. This can be accomplished by placing the calibration block on the part and allow it to reach the same temperature prior to calibration. Use of a “corner reflector” for calibration purpose is prohibited.


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8.0 CALIBRATION OF INSTRUMENTATION

8.1 Time Base Calibration The time base shall be calibrated sufficient to display a minimum of two back reflections using compression waves or a minimum of one full skip using shear waves, unless the technique dictates a shorter or longer distance display. 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 rerecorded. 8.2 Calibration for Sensitivity The response from calibration reflector at ¼ or ½ thickness (whichever gives the higher amplitude response) shall be set at 80% ± 5% of full screen height. A distance amplitude correction curve shall be drawn using the 1/4, 1/2, and 3/4 thickness reflectors at this sensitivity. The DAC curve shall have a time base equal to at least one full skip. 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 been 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 rerecorded. 8.3 Transfer Value A correction value known as a Transfer Value shall be applied to the above sensitivity level for the shear wave probe to compensate for the difference in sound attenuation between the calibration block and the test piece in the transmit / receive mode as follows: After the DAC has been constructed, use the probe for the constructed DAC as the transmitter and choose another angle beam probe as the receiver. The probes will be directed at each other on the standard reference block (ASME Basic block that is the same thickness as the part to be tested) at one skip distance, and the signal adjusted to the DAC height. The decibel reading is to be noted. Note: For most weld inspections, there will be 2 DAC curves for 2 different angled

shear wave probes (45⁰ and 60⁰ or 60⁰ and 70⁰). Use the DAC curve for the


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lower angle for the transfer value. The probes will then be positioned on the part to be tested such that the beam travels through the area of interest to provide a signal at one full skip distance. The beam shall be directed at a flat reflecting surface and not a weld protrusion or weld reinforcement area. The reflection amplitude is adjusted to DAC and the resulting dB noted. This ± difference in decibels is then added or subtracted from the reference level and recorded on the report as the Transfer Value. 8.4 Scanning sensitivity shall be 14dB greater than the adjusted reference level. 9.0 SURFACE PREPARATION

Surfaces from which the inspections are to be carried out shall be free of weld spatter, surface irregularities or foreign matter that might interfere with the examination.

10.0 SCANNING

Probe movement shall be in parallel paths with not less than 15% overlap and at a speed not exceeding 6" per second, unless otherwise specified in specific the technique. 10.1 Straight Beam Scanning The volume through which the angle beams will travel shall be first examined by a straight beam technique. Straight beam sensitivity calibration shall be carried out by placing search unit on the item to be tested to obtain a back wall echo (BWE). Adjust the sensitivity to put the BWE at 80% FSH. Carry out examination using the following steps: • Verify adequate penetration by obtaining a reflection from the opposite surface of the material being examined. • Lamination scanning shall be performed at a gain setting of +6 dB relative to the calibration level. • At areas where the back wall signal is reduced by 6 dB or more, or where laminar indications are found that may interfere with the examination, reflectors shall be recorded on the examination report and the subsequent angle beam examination shall be carried out to cover the volume of the area or weld being examined.


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10.2 Angle Beam Scanning Scanning shall be from the outer (OD) surface by the direct contact method unless the area is inaccessible. Beam angle selected shall be as per the technique. An angle beam scan shall be directed at approximately a right angle to the weld axis. Examination to be carried out from two opposite directions to detect any reflectors oriented parallel to the weld or component. The search unit shall be manipulated such that the ultrasonic beam passes through the entire volume of the weld and heat affected zone on both sides of the weld. Wherever feasible, the scanning of the examination volume shall be carried out from both sides of the weld on the same surface. To detect the reflectors oriented transverse to the weld or component, an angle beam scan shall be directed parallel to the weld axis on each side of the weld in two

directions, approximately 180⁰ apart.

The search unit shall be manipulated so that the ultrasonic energy is passed through the whole volume of the part or welds and heat affected zones of the base metals. If component design is such that configurations or adjacent parts of the component do not allow full examination, it shall be recorded on the report. • Restricted weld access– Welds that cannot be fully examined from two directions (e.g. corner and tees) shall also be examined if possible, with a straight beam technique. This shall be noted on the report. • Inaccessable welds– Welds that cannot be examined from at least one side 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 wave from the face provided the examination volume can be covered. 10.3 Technique requirements The written specific technique shall be established and shall include the following information as applicable: • a cross-sectional drawing of the weld type and configuration. The weld preparation, thicknesses of base material and areas of examination are shown. • the surface of surfaces from which the scans are performed. • the angles and mode of wave propagation utilized for the scans • the calibration blocks required • the type of material being inspected • ultrasonic instrument type • the search unit type, frequency and size • special search units, wedges, shoes or saddles and type • the range required for each scan


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• transfer value requirements • scanning sensitivities • recording criteria • couplant to be used (shall meet requirements of ASME V, Article 4, Section T-433 (latest edition)) • any additional information pertaining to the weld inspection • technique identification number 11.0 RECORDING

Recording of all information and indications shall be in accordance with the referencing code. 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 Section. 11.1 Geometric Indications

It is recognized that not all ultrasonic reflectors indicate flaws, since certain metallurgical discontinuities and geometric conditions may produce indications that are not relevant. Included in this category are plate segregates in the heat-affected zone that become reflective after fabrication. Under straight beam examination, these may appear as spot or line indications. Under angle beam examination, indications that are determined to originate from surface conditions (such as weld root geometry) or variations in metallurgical structure in austenitic materials (such as the automatic-to-manual weld clad interface) may be classified as geometric indications. The identity, maximum amplitude, location, and extent of reflector causing a geometric indication shall be recorded. [For example: internal attachment,

200% DAC, 1 in. (25 mm) above weld center line, on the inside surface, from 90⁰ 95 ⁰] The following steps shall be taken to classify an indication as geometric:

(a) Interpret the area containing the reflector in accordance with the applicable examination procedure. (b) Plot and verify the reflector coordinates. Prepare a cross-sectional sketch showing the reflector position and surface discontinuities such as root and counterbore. (c) Review fabrication or weld preparation drawings. Other ultrasonic techniques or nondestructive examination methods may be helpful in determining a reflector’s true position, size, and orientation.


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11.2 Flaw Sizing 11.2.1 Vertical Extent (when required) The orientation, shape and height of the discontinuity shall be determined by using the 6 dB drop technique as follows: • Move the probe and adjust gain to maximize the indication amplitude to 100% of FSH. Record the sound path distance from the time base and make a mark on the part at the beam index point of the probe. • Move the probe forward until the signal response amplitude drops to 50% of

FSH. Record the travel distance and again make a mark on the component.

• Move the probe backward past the 100% FSH until the amplitude again drops to

50% of FSH. Record the travel distance and again make a mark on the part.

• Transfer the distance calculated from the center of the examination area, and

determine the location, height and orientation of the discontinuity. To plot the

vertical extent, utilize a beam spread diagram for the probe being used. The

beam spread drawing is constructed as per B-466 of ASME V, Article 4,

Appendix B.

• Record the discontinuity position on a profile map on the examination report. Report depth, height, and orientation. 11.2.2 Flaw Length The length of a discontinuity shall be determined using the 6 dB drop technique as follows: • Maximize the signal and adjust the amplitude to 100% of FSH.

• Move the probe laterally until the signal response drops to 50% of FSH

amplitude. Record the travel distance and make a mark on the part of the

centerline of the probe.

• Move the probe laterally back past the 100% FSH until the signal response drops

to 50% FSH in the opposite direction. Record the travel distance and again make

a mark on the part.

• Record the discontinuity position on a profile map on the examination report. Report the length.


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12.0 ACCEPTANCE STANDARDS

Acceptance standards shall be in accordance with the referencing code.

13.0 MARKING

a) Upon completion of examination, parts, components and/or assemblies shall be marked in accordance with the applicable code or as directed in the contract or purchase order. b) All relevant indications on the part shall be marked using halogen-free markers or as per client instructions/request.

14.0 REPORTING

The results of all ultrasonic examination shall be recorded. The ultrasonic report shall provide for traceability to the specific part or lot inspected. As a minimum, the report shall include: a) Procedure, technique number, and effective date. b) Ultrasonic Instrument identification and serial number. c) Search unit(s) identification, serial number, frequency, and size. d) Beam angle. e) Couplant used, brand name or type. f) Search unit cables used, type and length. g) Special equipment, (search units, wedges, shoes, scanning equipment, recording equipment. h) Computerized program identification when used. i) Calibration block(s) identification. j) Simulation blocks or electronic simulators when used. k) Instrument reference level gain and if used, damping level. l) Calibration data including reference reflector(s), indication amplitude(s), and distance reading(s). m) Data correlating simulation blocks and electronic simulators when used. n) Identification of parts, components, assemblies and welds examined. o) Surface(s) from which examination was conducted. p) Map or record of all indications and geometric reflectors detected. q) Areas of restricted access or inaccessible welds. r) Examination personnel identity and certification level.


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s) Date and time examinations were conducted (eg PWHT/ completed) t) Areas of welds or volume scanned u) Results of all rejectable and non-rejectable indications shall be recorded. v) Surface condition. w) Transfer value. x) Automatic alarm and recording equipment/ or both if used. y) Rotating revolving or scanning mechanism if used. 14.0 POST CLEANING If necessary final cleaning shall be accomplished with an approved manufacture’s cleaner or a cleaner approved by the referencing code section or customer specification.


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APPENDIX I SCREEN HEIGHT LINEARITY To verify the ability of the ultrasonic instrument to meet the linearity requirement of ASME Section V, Article 4, Appendix I, T-410 and T-440, position an angle beam search unit as shown in Fig.1 (attached) so that indications can be observed from both the 1/2 and 3/4T holes in a basic calibration block. Adjust the search unit position to give a 2:1 ratio of amplitudes between the two indications, with the larger set at 80% of full screen height. Without moving the search unit, adjust sensitivity (gain) to successfully set the larger indication from 100% to 20% of full screen height, in 10% increments (or 2db steps if a fine control is not available), and read the smaller indication at each setting. The reading must be 50% of the larger amplitude, within 5% of full screen height. Alternatively, a straight beam search unit may be used on any calibration block which will provide amplitude differences, with sufficient signal separation to prevent overlapping of the two signals.


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APPENDIX II AMPLITUDE CONTROL LINEARITY To verify the accuracy of the amplitude control of the ultrasonic instrument, as required in ASME Section V, Article 4, Appendix II, II-410 and II-440, position an angle beam search unit as shown in Figure 1 (attached) so that the indication from the 1/2T hole in a basic calibration block is peaked on the screen. With the increases and decreases in attenuation shown in the following table, the indication must fall within the specified limits. Other convenient reflectors from any calibration block may be used with angle or straight beam search units.


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FIGURE 1 - LINEARITY

ASME SECTION V, ARTICLE 4, APPENDIX 1


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APPENDIX III BASIC CALIBRATION BLOCKS


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ASME BASIC CALIBRATION BLOCK FOR WELDS 1” OR LESS THICK (FLAT) Note: This block can be used for welds with a diameter greater than 20”.

NOTES: 1. Notch size to be 2% T = 0.015 deep. 3/16” wide flat bottom. A. Tolerance on notch depth shall be + 10% and – 20%.

B. Tolerance on notch width shall be 1/16”.

C. Perpendicular tolerance on notch reflecting surface shall be 2º. 2. All holes to be drilled & renamed to 3/32” dia.

A. Tolerance for hole diameters shall be 1/32”.

B. Tolerance on hole location through the thickness shall be 1/8”.

C. Center line of all holes shall be perpendicular to the sides 10. 3. Surface finish shall be 125 rms (surfaces with notches only).

A. Dimensional tolerance shall be 1/16” unless otherwise noted.


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Ultrasonic Inspection Report

Job Number:

Client Specifications:

Client Name:

Procedure/Technique:

Work Location:

P.O. or W.O. Number:

Date Of Inspection:

Time:

Scope:

Results:

Scan

Surface Finish

ULTRASONIC EQUIPMENT TRANSDUCER

Make Model S/N Calib. # Angle Size Frequency Serial #

This Certificate or Report is valid only for that work which was specifically requested. The Company is not responsible for any views or opinions expressed by employees performing this work which fall outside the exact terms of reference. All certificates and/or reports are the result of work performed in conformance with applicable specifications and standards to the best of our ability and intent. However, the company will not be responsible for deviations within the normal limits of accuracy in accordance with the standard practices.

INSPECTOR: CERTIFICATION:

CLIENT REPRESENTATIVE FINAL ACCEPTANCE:


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15.0 APPENDICES

Appendix A: Revision and Transition Notes Appendix B: Keywords

Appendix A: Revision and Transition Notes

(Revisions are listed in reverse chronological order with most recent revision at the top. Revision notes describe: what was changed, why it was changed, and the plan to implement the change, including whether changes are retroactive)

Revision 2 SPEC Reviewed 2016 – Regional Approvals removed, no other changes Revision 1 Document format and number changed due to Vale Engineering Document Program changes in 2011. Previous Standard number was 017-00 Rev 0.

Appendix B: Keywords 017-00

Issued By: Jerry Lech Certification: C.G.S.B. 48-9712, UT Level 3, ASNT Level 3 UT

Date: Dec. 22, 2011 Signature:

Approved By Philippe Belzile Certification: P. Eng. (On, Mb, Qc. NF)

Date: January 18th 2012 Signature:

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