5.6 Non-destructive examination of components 5.6.1 General requirements 5.6.1.1 Examination of welds ‘The methods, extent and acceptance levels of non-destructive examination shall bé'in accordance with 5.6 to 5.9 inclusive. Non-destructive examination shall be carried out to written procedures provided by the manufacturer and approved by the Inspecting Authority (see 6.1.31). . ‘The requirements for the non-destructive examination of welded tubewails are contained in Annex J. 5.6.1.2 Qualification of personnel Personnel responsible for non-destructive examination, including interpretation, evaluation and rpportifg, shall have qualifications and experience acceptable to the Inspecting Authority. : Other than for visual examination, all personnel responsible for non-destructive examination, including interpretation, evaluation and reporting, shall be certified in accordance with the general rules of BS EN 473, NOTE. BS EN 473 isnot applicable to visual inspection. Visual examination shall be carried out by suitably” trained and experienced personnel that have sufficient Iniowledge in welding techniques, and a full . comprehension of this standard, to be able to identify and interpret imperfections in the welds, or in the heat affected zones of welds, as specified in tablé 5.92. Radiographs shall be viewed by personne! under the irect supervision of persotinel qualified, as 2 minimum, to level 2 of BS EN 473. ‘Uitrasonic examination shall be performed under the irect supervision of personnel qualified, as a minimum, to level 2 of BS EN 473. Magnetic particle and dye penetrant inspections shall be performed, as a minimum, under the, direct supervision of personnel qualified to level 2 of BS EN 473, 6.6.1.3 Visual examination ‘As a minimum requirement, all welds shall be visually examined for profile defects and surface flaws in accordance with BS EN 970 and the requirements of tables 66.131, 56.132 and 66139. 6.6.1.4 Volumetric examination ‘Volumetric exarnination of welds shall be by ultrasonic techniques, or by radiography, in accordance with the following. 4) Ultrasonic testing. Ultrasonic testing shall be carried out in accordance with the requirements of 5.6.2, to the extent defined in tables 5.6.13-1, 56.132 and 56.133. ) Radiography. Radiographic examination shall be carried out in accordance with the requirements of BS EN 1435, to the extent defined in tables 5.6.1.3, 56.192-and 58133, BS 1113:1999 5.6.15 Surface flaw detection Where surface flaw detection is specified in tables 56.131, 661.92 and 5.61.33, either magnetic or dye penetrant methods shall be used in accordance with the following. a) Magnetic particle inspection shall be caried out in accordance with BS EN 1290/Where probe contacts are used to induce the magnetic field, two mutually perpendicular directions of magnetization shall be employed. Where the current flow (prod) method is used, arcing at the contact points should be avoided and any resulting marks shall be removed by light grinding. b) Dye penetrant inspection shall be carried out in accordance with BS EN 571-1 6.6.1.6 Percentage inspection of welds ‘Where non-destructive examination on 2 percentage basis of 10% is specified in tables 5.6.1.3-1, 5.6.1.32 and 56.1.3, the representative sample of welds for examination shall be agreed with the Inspecting ‘and shall include a sample of each welder’s ‘work, for each welding procedure specification on the ‘component concemed. The number of welds to be fully examined shall then be, as a rainimum, 10% of the total number.of welds performed by that welder ‘using the same welding procedure specification, on the same component. ‘Where this standard specifies percentage examination and the examination reveals imperfections which do not comply with the acceptance levels in tables 3.9.2 and 5.94, or 6.6.2 in the case of ultrasonic examination, the percentage rate of inspection shall be increased. The basis for the extension shall always be related to each individual component, to each welder involved in the manufacture of that component, and to the same type of welds,-Le to the same welding procedure specification. The basis for increased examination shall be as follows. 4) When performing the random examination, {f one ‘weld, or more than one weld, isfare revealed as not being acceptable, the examination shall be extended to two additional welds of the same type, for each rejected weld. ) If all the examined welds of that extension, Le as called for in a) above, are acceptable then the initial rate of 10% may be resumed. : ‘©) When one or more of the welds examined during the extension is/are not acceptable, then the examination shall extend to 10 additional welds for each weld rejected during the first extension, or to all the welds in the component if this is less than 10 in number. ¢) The extension procedure shall be continued on this principle until all the extension welds are acceptable. 2) If the extension procedure continues to reveal unacceptable welds, the extension procedure stall be increased until a rate of 100% is achieved.BS 1113:1999 Section 5 ‘Where this standard specifies non-destructive examination on a percentage basis of the total number of welds and the manufacturer-has demonstrated to the satisfaction of the Inspecting Authority that the welds consistently conform to the standards of acceptance specified in tables 6.9.2 and 5.9.4, 09,5.6.2, a reduction in the percentage rate of examination, to 2 minimum of 5 % shall be permitted by agreement | ~ between the manufacturer and the Inspecting * Authority. 5.6.1.7 Design requirements ‘The designer shall ensure that all non-destructive examination techniques required by this standard can be implemented. NOTE, Particular care is required inthe design of Joints subjectto ultrasonic examination to ensure that sutfeten length of parent material is avalabe adjacent to welds to pect the required! probe reovements ‘The designer shall nominate on the drawings those attachment welds which are to be considered 2s load camrying for the purpose of this specification. 5.6.1.8 Dressing of welds Except where dressing of the welds is specified in this standard, the welds shall be accepted in the undressed condition, unless dressing is necessary to effect satisfactory non-destructive examination. Dressing in the bore of nozzles and branches of drums, headers, tubes and pipes to remove defects revealed by visual or non-destructive examination shall be permitted. Such dressing shall not exceed 10% of the ‘through thickness of the weld, but not more than § mm, provided that the design thickness of the weld is maintained. 5.6.1.9 Timing of NDE ‘The specified non-destructive examination shall be carried out after any required final stress relief or heat treatment, except as permaitted by 4.3.1.1.7 or by this clause. If no final stress relief is required by 4.5, non-destructive examination shall be carried out in the as-welded condition. It shall be permissible to carry out the specified non-destructive examination before any final stress relief or heat treatment in the case of welds in Steél Groups 1, 5.1 and 5.2 only in the following cases: a) butt welds in tubes and integral pipes; b) by agreement between the manufacturer and the Inspecting Authority for the following weld types: 4) butt welds in drums and headers; i) branch, nozzle and stub welds; ii) attachments welds. 5.6.1.10 Steel groups Steels have been grouped together for welding ‘purposes. The groups have been taken from prEN ISO/TR 15608. 5.6.2 Ultrasonic examination 5.6.2.1 General requirements ‘The assessment of defects for acceptance purposes shall be by evaluation methods 1 or 2 as specified in BS EN 1714, ot a combination of these methods. ‘The evaluation and recording levels shall be in accordance with BS EN 1712, Quality Level B. MOTE, Characterization of defects in accordance with BS EN 1719 should ony be implemented a contactual requirement and isnot an esvental feature for conformance to {his standard. Defects requiring repr donot require characteraation. Thre are no special requirements for near surface examination. 5.6.2.2 Special requirements ‘The above ultrasonic standards shall be fully applied to the ultrasonic examinations of welds where specified in tables 5.6.14, 56.132 and5.6.133. However the following special requirements shall be met when options are permitted within those standards. 1) Austenitic steels. Ultrasonic examination of fusion welded joints in Steel Group 9 shall be carried out in accordance with written procedures, approved by the Inspecting Authority. In the event that a satisfactory ultrasonic ‘examination procedure cannot be provided for butt welds, the welds shall, as a minimum, be radiographed. The examination methods to be applied to pressure connection welds shall be by agreement between the manufacturer and the Inspection Authority. NOTE. tis recognized that ultrsonic techniques for the volumetric examination of austenitic but, brancty nezle and tub welds have rot been developed to a stage where ConBdence in the results canbe asoured. Therefore, before ‘manufacture commences, consideration should be given to the Based on this consideration, agreement should be reached beoween the manufacnurer and the inspecting Authority cegarding the valid use of ultrasonic examination nd the ssseasment of results Werefron. 2) Partial penetration welds. Uitrasonic examination of partial penetration welds shall only be carried out in accordance with written procedures, approved by the Inspecting Authority. 3) Examination levels, Examination level B shall be used except where the specific test requirements are not defined in BS EN 1714. In such cases examination level D shail be used in accordance with a written procedure approved by the Inspecting Authority, tating into account the general rules of BSEN i714, 4) Transverse defects. Ultrasonic examination for transverse defects shall be performed: 8) on Steel Group LZ, where the thickness of the base material is =40 may, ) on Steet Groups 2, 3, 4and 5, for all base material thicknesses. pee eee © © ae Ee peetti eetnein eee Cpetenepee GSection 5 5) Tandem examination. The tandem examination technique shall not normally be applied. 6) Probe frequencies. Probes with a frequency of between 15 MHz and 5 MBiz shall be used for normal applications. Specific applications requiring frequencies outside this range shalt be subject to agreement between the manufactarer and the Inspecting Authority. 7) Parent metal examination. If the edge of the parent metal has not been previously scanned before ‘welding, the parent metal in the scanning zone shall be ultrasonically tested with a normal probe before testing commences with an angle probe. 8) Preparation of the surface. Scanning surfaces and surfaces from which the sound beam is, reflected shall be assumed to be satistéctory if the ‘surface roughness is not greater than 12.5 wm. NOTE. Roughness greater than this value may sl be acceptable if ean be demonstrated that effective ultrasonic ‘amination ean be performed. 9) Signal to noise ratio. During the examination of a weld, the noise level, excluding spurious surface indications, shall be at least 12 dB below the required evaluation level 10) Measurement: of the length of defects, The length of reflectors, in either the longitudinal or transverse direction, shall normally be determined using the half amplitude method, Le. the ~6 dB technique. 1) Height measurements. Where BS EN 171. 5 applicable, defect height measurements shall not be necessary. For examinations outside the scope of that standard the examination level, and the acceptance criteria, shall be agreed between the manufacturer and the Inspecting Authority. 12) Application of ultrasonic examinations to thicknesses of 8 mm or less. Uitrasonic examination of fusion welded Joints in materials =8 mm thick shall be conducted in accordance with ‘written procedures approved by the Inspecting Authority. BS 1113:1999 5.6.3 Non-destructive examination reports ‘The following information shall be provided, as a minimum, in the examination reports: = Identification of the water tube boiler components ‘concerned; ~ identification of the welds examined and any ultrasonic scanning pattem used; — the examination procedure reference; =the applicable welding procedure specification; ~ the stress relief or post weld heat treatment condition; = the surface condition prior to the examination, e.g ‘ground, machined, as welded, ete = details of the procedure, eg. type of magnetization, consumables used, type of radiographic source or equipment, etc; ~ reference to the applicable acceptance criteria; = the results of the examination, including details of any repairs; in the case of percentage examination, application of any extension zones of examination and their results; statement of conformity with the requirements of this standard; = the date when the examinations were carried out and the data of the report; = the names, and approvals, of the personne! resporsible for the examination, the evaluation and the interpretation of the results.