ndt.docx

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The cleaner used for the surface cleaning will be an organic chemical such as Acetone or Trichloro-ethylene.

Developer- Non-aqueous suspendable [email protected]

Sulphur content in enetrant materials for Nic!el base alloys testing shall be less than "# of the residue by weight.

$hlorine plus %luorine content shall not e&ceed "# of the residue by weight in enetrantmaterials when used for testing of Stainless steel or Titanium.

%or 'ower temperature range from (° $ to ")° $* the Dwell time shall be two times the time

listed in the table.

%inal interpretation begins as soon as a wet developer coating is dry. The minimumdeveloping time shall be ") minutes and ma&imum time +) minutes.

A minimum light intensity of ")) foot candle ,"))) lu& is required to ensure adequatesensitivity during the e&amination and evaluation of indications* which can be achieved by ahand lamp or torch light positioning at a distance of )) mm.

The temperature of the wet particle suspension and the surface of the part being e&aminedshall not e&ceed (/0$.

METHOD OF EXAMINATION

1&amination shall be made by continuous method.

Dry continuous magneti2ation method

TECHNIQUES

3ne of the following magneti2ation techniques shall be used.$ircular 4agneti2ation-rod Technique'ongitudinal 4agneti2ation- 5o!e Technique

TYPE OF CURRENT FOR MAGNETISATION

Single phase half-wave rectified Direct $urrent shall be employed for testing with prodtechniques.

The amperage required with single-phase 6alf-wave rectified current shall be verifiedby measuring the average current during the conducting half cycle only.

%or yo!es* the current shall be either A$ or 67A$.

1ach alternating current electromagnetic yo!e shall have a lifting power of at least 8.( !g

and each direct current 9 permanent magnetic yo!e shall have a lifting power of ":.) !g* at

the ma&imum pole spacing that will be used. 3r the pole distance shall be the spacing at

which the yo!e lifts the stipulated weight.

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Magnetizing Current

The current shall be ")) to "( ,ma&imum amperes 9 ( mm of prod spacing for sections"; mm thic! or greater.

%or sections less than "; mm thic!* the current shall be ;) to "") amperes9( mm of prodspacing.

Pro S!a"ing

rod spacing shall not be less than /( mm nor e&ceed a ma&imum of )) mm.

YO#E TECHNIQUE

The pole spacing shall be between ")) mm to "() mm. The field indicator will beused to chec! the direction of the part magneti2ation.

$IGHTING

%i&i'(e $ig)t Inten&it*

The e&amination and evaluation of indications shall be performed under minimum lightintensity of "))) lu& ,")) fc at a height of )) mm using a torch light or 6and lamp.

+(a", $ig)t

<lac! light intensity at the e&amination surface shall be not less than "))) micro watt9cmsquare at a height of )) mm. The blac! light intensity shall be measured at least onceevery : hr. and whenever the wor! station is changed.

The e&aminer shall be in the dar!ened area for at least ( minutes prior to performing the

e&amination for eye adaptation.

%i&i'(e $ig)t Inten&it* An intensity of ()) lu& is adequate.

+(a", $ig)t

<lac! light intensity at the e&amination surface shall be not less than "))) microwatt9cm=.

The blac! light shall be warmed up for a minimum period of ( minutes prior to use ormeasurement of the intensity.3ne e&posure shall be made for 6ancoc! 7elds ,Double wall double image technique.

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SE$ECTION OF IQI

>?> shall be selected from either the same material group or grade as identified in S1 - ")(or from a material group or grade with less radiation absorption than the material beingradiographed.

P$ACEMENT OF IQI

Sour"e Sie IQI

7herever possible* the >?> shall be placed on the source side of the part being e&amined.

Fi(- Sie IQI

7here inaccessibility prevents hand placing the >?>,s on the source side* the >?> shall beplaced on the film side in contact with the part being e&amined. A lead letter % shall beplaced adacent to the >?>,s but shall not mas! the essential hole

Raiogra!)i" en&it*

The transmitted film density through the radiographic image of the body of the >?> and thearea of interest shall be ".: minimum for radiographs made with an B-ray source and .)minimum for radiographic made with a gamma ray source.

Any group of aligned indications that have an aggregate length greater thanCtC in a length of

"t e&cept when the distance between successive indication e&ceeds +' where ' is thelongest indication in the group.

+AC# SCATTER

A lead symbol <C of mm thic! and "mm height* shall be !ept at the bac! of each film cassette tochec! the bac! scattering effect and the radiograph is unacceptable if light image of the letter <Cappears on a dar!er bac!ground of the radiograph. A dar! image of E<F on a lighter bac!ground is nota cause for reection.

SYSTEM OF IDENTIFICATION

The following identifications shall be available in the radiograph.

Gob >dentification number9 7or! order Segment identification number Date of HT*%irm code No7eld repair. 9 rewor! status details ,H"* H* HI etc.* HT* JHT or 4HT if applicable*'ocation identification mar!ers'ocation mar!er identification shall be mar!ed 9 stamped on the surface. These identification numbers

shall be placed )mm away from the weld edge.

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MATERIA$ THIC#NESS µg Ma.Uner /0.0 -- 0./1 --

O2er /0.0 to 3/.0 -- 0.34 --

O2er 3/.0 to 100.0-- 1.05 --

Greater t)an 100.0 -- 1.36 --IMAGE QUA$ITY INDICATORS 7IQI8EQUIPMENT

The equipment shall be of pulse - echo type that responds to frequencies " 462 to + 462.Hate of probe movement

The rate of probe movement for e&amination shall be less than "() mm9sec.

S"anning &en&iti2it*

The scanning shall be performed at a gain setting K + d< of the primary reference level.1valuation shall be performed with respect to primary reference level.

PRO+ES

The nominal frequency of the probe shall be 8 462 for thic!ness less than or equivalent to 8) mmand 462 for thic!ness greater than 8) mm.

The crystal dimensions will be : & ; mm or ) & mm and shall be appropriate to the e&aminationsurfaces ensuring adequate contact for transmission of ultrasonic vibrations.

A square notch of si2e " mm & " mm shall be used to adust the sensitivity for detection of flaws in theroot area and to furnish proof of form echoes in welds at root

DEMAGNETISATION OF MATERIA$S

4ethod L D14AJN1T>SAT>3N

Type of 4agneti2ation L '3NJ>TMD>NA'

$urrent Hating L "))) amps 9 ( mm diameter of the

specimen

Type of $urrent L A$

MATERIAL FORMDWELL TIME IN MINUTES

PENETRANT DEVELOPER

STEEL,ALUMINUM,TITANIUMAND HIGH TEMPARATUREALLOYS

CASTINGS AND 5 10

FORGINGS,PLATES 10 10

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Note: For temer!t"re# r!$%e &rom 50°F to 1'5°F (10°C to 5'°C)* Fortemer!t"re# &rom +0°F (5°C) " to 50°F (10°C), m$m"m e$etr!$t

-.e// tme #!// e ' tme# te 2!/"e /#te-*

%or straight beam technique* longitudinal wave probe of frequency 462 or 8 462 with

contact face not e&ceeding (mm ,crystal dia. shall be used.

%or angle beam technique* shear wave probe of frequency 462 or 8 462 with contact

face not e&ceeding ) & )mm shall be used.

Jlycerine* SA1 I) Servoway +:* Servo system 8+ or Servo system +: shall be used as

couplant.

Speed of scanning shall not e&ceed "()mm 9 second.

ACCEPTANCE STANDARD 9E$DS IN A$UMINUM RADIOGRAPHIC QUA$ITY

>n general* the testing procedure shall be as per AS41* Section * Article .

Hadiation source O & rays

%ilm O AST4 class " or * such as Poda! $(* Agfa O Jaevart D/*NDT +(* /) or equivalent.

%ilm density O shall be between ".: to I.).

Hadiographic ?uality level O shall be determined by using AS41 enetrameters or wirepenetrameters to D>N (8"); or >S I+(/.

Note:

>t is mentioned in AS41 section >>> ,";:: pare M' 7 (8

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MINIMUM NDE REQUIREMENTS AS PER I+R

+oi(er an Su!er )eater Tu'e& 7Regu(ation No.1/1 7)88:

<ore* ercenta e of ND1

3ver "/: "))#

3ver ") and upto "/: ") # ,4in. welds per welder

<elow ") (# ,4in. " weld per welder

Pi!e(ine& NDE re;uire-ent:

Description <ore* mmercentage of ND1 for each

7elder

ercentage of cutout oints for visual and bend

test for eachwelder

$'ASS > >1'>N1S

A 7here the completed pipelinesare not subected to hydraulictest

3ver ") "))#

3ver I: andupto including

")

(# ,4in. welds per

welder<elow I: -- # ,Note-"

< 7here the completed pipelinesare subected to hydraulic test

3ver ") ")#,4in. welds per welder

3ver I: andupto including")

# ,4in. " weldper welder

<elow I: -- # ,Note-"

$'ASS >> >1'>N1S

All pipes All si2e # ,Note-"

MINIMUM NDE REQUIREMENTS AS PER ASME +<1.1 7PO9ER PIPING8

Pi!ing &er2i"e "onition&: Te-!erature o2er =00 >C an a(( !re&&ure&.

Type of weld ND1

<utt welds HT for over NS ()

4T or T for NS () and less

%illet* soc!et* attachment Q seal welds 4T or T for all si2es and thic!nesses

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Pi!ing &er2i"e "onition&: Te-!erature& 'et?een 13/ >C in"(u&i2e an =00 >C

in"(u&i2e ?it) a(( !re&&ure& a'o2e 3100 ,Pa 7gauge8

Type of weld ND1

<utt welds HT for over NS () with thic!ness

over ";mm. isual for others

%illet* soc!et* attachment Q seal welds isual for all si2es Q thic!nesses

Minimum NDE Requirements as per ASME SEC.I

,Table 7-""* Hequired Hadiographic and Mltrasonic 1&amination of 7elded butt oints%or drums and shells ,e&cluding pipes* tubes* headers

NS e&ceeding ()mm or wall thic!ness R ;mmL All butt welds shall be radiographed or

ultrasonically tested.

%or pipes* tubes and headers* radiography is not mandatory for the following

conditionsL

%or parts in flue gas path and subect to furnace radiant heatL NS "))mm or wallthic!ness "I mm

%or parts containing waterL NS () mm or wall thic!ness ; mm

%or parts containing steamL NS 8)) mm or wall thic!ness 8"mm

7here radiography is to be performed and geometric un-sharpness cannot be within

".: mm* ultrasonic testing shall be performed.

NoteL NS - Nominal ipe Si2e

PHASE DIAGRAMS AND THEIR IMPORTANT FEATURES

Phase is a constituent that is completely homogenous both physically and chemically,

seperated from the rest of the alloy by definite bounding su r f a c e s .

Alloys can be classified as binary (two component elements), ternary (three component

elements), quaternary alloys (four component elements), and so forth.

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DEFINITION OF ALLOYING

An alloy is a metallic material that contains two or more elements where at least one of

the major elements is a metal. Materials produced by alloying can have improved

corrosion resistance, physical, and mechanical properties.

Mutip!ase Materias " Eute#ti#s

wo liquidus lines are apparent from the upper changes in the slopes of the cooling

curves. he intersection of these liquidus lines is called the !utectic Point. T# o$t rere#e$t# te /o.e#t temer!t"re !t .3 te !//o4 rem!$#

3om/ete/4 /"-*

equii$rium A state of balance between opposing forces.

!%m%&ene%us "niform structure or composition throughout

iqui's ine he temperature at which each alloy composition starts to solidify.

s%i'us ine he temperature at which each alloy composition has 3om/ete/4 #o/-6e-*

CHARACTERISTICS OF THE PHASES IN THE PHASE DIAGRAM

Mi' Stee

Mild steel (appro#imately $.%$ percent carbon) is a multiphase solid at ambient

temperature. &ts microstructure contains the following'

errite (bodycentered cubic), an alloy of carbon dissolved in iron.

Pearlite, a mi#ture of ferrite and cementite (e%*) that e#hibits a lamellar structure. Pearlite

is formed when an alloy containing about $.+% percent carbon is cooled from slightly

above -- * (/%%% ).

Austenite, a solid solution of carbon in iron, is formed above -- * (/%%% ), and

has a facecentered cubic crystal structure.

0illed steels are normally specified when fabricating pressure vessels or heat

e#changers for petroleum or chemical service because the use of these materials

results in equipment of better quality, i.e., the base materials and welds generally

contain fewer defects.

N%nequii$rium C%n'iti%ns (Rapi' C%%in&)

the martensite, are e#tremely hard and brittle. o obtain useful engineering properties, the

martensite and bainite must be tempered (reheated) or stress relieved to reduce hardness

and increase ductility. &t is important to understand that both martensite and bainite are

formed under nonequilibrium cooling conditions, and consequently do not appear on the

phase diagram.

7hen used in post weld heat treatment in sections - 7 I times the plate thic!ness.

%or no22le and other welded attachments - 7 must be wider than the no22le or attachmentor I times the wall thic!ness.

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For Pi!ing:

7 I times the wall thic!ness ,of thic!est part on each side from the centre of the weld

Thermocouples located at a distance of appro&imately ".( times of the wall thic!ness

about the center line of weld.

T)i",ne&& o@ Materia( Mai-u- Heating Rate A'o2e Mai-u- Coo(ing<00>C

Rate U!to <00>C

≤ ( mm )0$9hour )0$9hour

R ( ≤ () mm "")0$9hour "")0$9hour

R ()≤ /( mm /(0$9hour /(0$9hour

R /(mm ((0$9hour ((0$9hour

%or structural - +(0$9 hour ,4a&.

T)er-o"ou!(e $o"ation& :

4inimum

d ".( & t from weld centre

6eating <and + & t

>nsulation <and " & tNote 1 : For SA 104 Gr .C ?it) (e&& t)an 0.5/ "ar'on "ontent .

Note 5 : PreB)eating i& ne"e&&ar* @or t 14--.

Note < : $e&& t)an 0.1/ "ar'on "ontent .

Note = : Cr 1 Mo % Stee( 7 PB1 TB1 8

"; U t ≤ 2( Nil "() +) - +()"Jr for hours

( U t ≤ /( "))"()

+) - +()for hours

t R /( "() "() +) - +()

≤; Nil Nil Nil Nil Nil+) -

Nil

+()

" Jr R;≤"; Nil

+) -Nil

+)-Nil

+) -NilQ SA ")+ Jr $

+() +() +()

+)- +)- +) - "()R"; "() "() "() for

+() +() +()

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hrs

" K I - +) to +()0$

" K 8 - +8) to +/)0$

8 K (A - +:) to /")0$

,%or other Jroup combinations* refer to 1ngineering

P NUM+ER AND GROUP NUM+ER FOR +ASE MATERIA$S

.NoJrou

$ommon Name Tubes ipes lates %orgings $astings %ittingsp No.

SA"; SA")+JH< SAI+ SA++$' SA"+7$ SAI8

$arbonSA")JHA" SA("(JH(( SAI('$

SA("(JH+) SAI('$Steels

" " SA("(JH+(

SA("+JH((

SA("+JH+)

SA("+JH+(

SA")JH$ SA")+JH$ SA("(JH/) SA++$' SA"+7$ SA")(

" $arbon Steels SA("+JH/) SA"+7$ SAI8

SA;; SAI('$

I "$arbon-4oly SA);T" SAII(" SA"/7$

Steels

I "V$rV4o Steels

SA"IT SAII( SAI:/JH

"$rV4o9SA"IT"9 SAII(" SAI:/JH" SA":%" SA"/7$ SAI8

8 " "W$rV4o Steels

SA"IT"" SAII("" SAI:/JH"" SA":%" SAI8

(A "W$r"4o Steels

SA"IT SAII( SAI:/JH SA":% SA"/7$ SAI8

"(;$r"4o Steels

SA"IT;" SAII(;" SAI:/JH;" SA":%;" SAI8

7;"1

":$r-:Ni SteelsSA"ITI)8 SAI/+TI)8 SA8)TI)8 SA":%I SAI("$% SA8)I

SA"ITI)8 SAI/+TI)86 SA8)TI" SA":%I SAI("$%

: "SA"ITI8/ SAI/+TI" SA8)TI8/ SA":%I SAI("$%

SA"ITI8/ SAI/+TI8/ SAII+%I SAI("$%

SA"ITI" SAI/+TI8/6 SAII+%I SAI("$%

SAII+%I SAI("$%

: ($r-)Ni Steel

SA8)TI") SA":%I") SAI("$P,Type I")

)

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Note L >S"I; Q A> (' JH < ipes* >S)+ lates may be treated as No." Jr No."material.

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