520530_A4-P________8 0_EN(1)

General workshop instructions 4

Inspection and final manufacturing

Steel structure and mechanical equipment

Approved date: 25 Mar 2015 Created by: BK Approved by: AO

General workshop instructions 520530 - 8.0

Doc. No.: 520530-8.0

Table of content

4 Inspection and final manufacturing ......................................................................................... 37 4.1 Welding NDT (non-destructive testing) ......................................................................................... 39 4.1.1 Definition and basis for NDT ........................................................................................... 39 4.1.2 Time of inspection ......................................................................................................... 39 4.1.3 Qualification/quality ....................................................................................................... 39 4.1.4 Extent and methods of testing ........................................................................................ 39 4.1.4.1 General notes ......................................................................................................................................... 39 4.1.4.2 Test methods.......................................................................................................................................... 39 4.1.4.3 Inspection lot ......................................................................................................................................... 40 4.1.4.4 Lamination ............................................................................................................................................. 40 4.1.4.5 Inspection of welds ................................................................................................................................. 40 4.1.4.6 Where reasonable suspicion exists ............................................................................................................ 40

4.1.5

Condition for detection and rejection of imperfection.......................................................... 40 4.1.5.1 4.1.5.2 4.1.5.3 4.1.5.4

General requirement................................................................................................................................ 40 Length of imperfection ............................................................................................................................. 41 Short imperfection .................................................................................................................................. 41 Long imperfection ................................................................................................................................... 41

4.1.5.5 Acceptance criteria .................................................................................................................................. 41 4.2 Casting inspection ...................................................................................................................... 42 4.2.1 Surface inspection ......................................................................................................... 42 4.2.1.1 4.2.1.2

4.2.2

NDT, Volume inspection ................................................................................................. 42 4.2.2.1 4.2.2.2

4.3

Visual inspection ..................................................................................................................................... 42 PT and MT test ........................................................................................................................................ 42 Ultrasonic inspection................................................................................................................................ 42 Radiographic inspection ........................................................................................................................... 42

4.2.3 Weld upgrade, UT/PT/MT inspection ................................................................................. 42 Forging inspection...................................................................................................................... 42 4.3.1 Surface inspection ......................................................................................................... 42 4.3.1.1 Visual inspection ..................................................................................................................................... 42 4.3.1.2 PT/MT inspection ..................................................................................................................................... 42

4.3.2

NDT, volume inspection.................................................................................................. 43 4.3.2.1

UT inspection .......................................................................................................................................... 43

4.4 Inspection rate. Casting and forging ............................................................................................. 43 4.5 Imperfection in welding according to EN ISO 5817:2014................................................................. 43 4.6 Checking dimension ................................................................................................................... 49 4.6.1 Qualification ................................................................................................................. 49 4.6.2 General requirement ...................................................................................................... 49 4.6.3 Erection joints ............................................................................................................... 50 4.6.4 Critical dimensions ........................................................................................................ 50 4.6.5 Dimensions on circular shells .......................................................................................... 50 4.6.6 Not trial assembled parts ................................................................................................ 50 4.6.7 Geometrical tolerance .................................................................................................... 50 4.6.8 Checking of planeness, straightness and parallelism .......................................................... 50 4.7 Test and trial-assembly .............................................................................................................. 51 4.7.1 Qualification ................................................................................................................. 51 4.7.2 Functional test .............................................................................................................. 51 4.7.3 Trial-assembly of welded structures/components ............................................................... 51 4.7.4 Damage from shop internal transportation ........................................................................ 51 4.8 Thread dimension ...................................................................................................................... 51 4.9 Hydraulic pressure and leakage test ............................................................................................. 51 4.9.1 Pressure test ................................................................................................................ 51 4.9.2 Leakage test ................................................................................................................. 51 4.10 Corrosion protection ................................................................................................................... 51 4.11 Documentation .......................................................................................................................... 52 4.11.1 Supplier’s / manufacturer’s documentation ....................................................................... 52

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General workshop instructions 520530 - 8.0

4

Inspection and final manufacturing 4.1

Welding NDT (non-destructive testing) 4.1.1

Definition and basis for NDT

NDT includes the following kinds of test: Acoustic emission testing, eddy current testing, infrared thermographic testing, leak testing (hyd. press. test excluded), strain gauge testing, PT, MT, RT, UT and VT (direct unaided visual test and visual tests carried out during the application of another NDT method are excluded) See EN ISO 9712:2013 (Non-destructive testing – Qualification and certification of NDT personnel). Non-destructive testing must be carried out in accordance with an internationally recognised standard. For further instructions, see EN ISO 17635 (Non-destructive testing of welds – General rules for metallic materials). It must be noted that the term VT is used only in connection with inspection of welding work. 4.1.2

Time of inspection

The inspection of welds must only be started after termination of any thermal straightening or heat treatment. Where conditions dictate, inspection can be permitted before the final heat treatment; but permission must be obtained from FLSmidth1). Welds and materials with a latent possibility for the formation of hydrogen cracks or any other delayed crack mechanisms must not be examined until at least 48 hours have passed. In case of doubt, please contact FLSmidth. 4.1.3

Qualification/quality

NDT personnel must be qualified and certified to carry out NDT inspection jobs in accordance with EN ISO 9712:2013 (Non-destructive testing – Qualification and certification of personnel). The operator must be certified to level 2. The operator certificate(s) have to be included in the final certified documentation. Alternative corresponding internationally recognised standard may be agreed upon. The test equipment and method must be suitable for the purpose. Visual inspection may be conducted by inspectors not certified, however qualified. NDT personnel and their qualifications shall be subject to written approval by FLSmidth37). If no quality level reference is made on the drawings, the welding work and the extent of testing must be done in a quality corresponding to quality level QA. See sub-section 2.3.3 and 2.7. 4.1.4

Extent and methods of testing 4.1.4.1

General notes

The quality level and the extent of testing of welds are defined by the quality levels, QA, QB or QC as specified in Table 13. The normal test scope defined in Table 29 is compulsory and must be completed for all deliveries of welded structures to FLSmidth. It is the responsibility of the manufacturer to plan welding and NDT work so that required inspection / examination can take place. Drawings showing NDT locations and extent of testing must be prepared by the manufacturer and be available for the inspection, see sub-section 4.11.1. When inspecting the structure it shall be ascertained that all welds have been completed and that they are located as specified on the drawing(s) and that no welds show indications of excessive defects. 4.1.4.2

Test methods

Leakage test shall if demanded, but not detailed specified be executed by means of water or suitable trace gas. The test methods approved by FLSmidth for the inspection of welds are listed in the Table 28 below. Welded seams must be examined by the use of suitable test methods. The VT and PT/MT testing of raw materials for surface imperfections should precede the use of UT and RT for detecting internal imperfections. Method

1

Abbreviation

Visual test

VT

Magnetic particle inspection (MPI)

MT

Liquid penetrant test

PT

Technical Query, see sub-section 1.3.3.

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General workshop instructions 520530 - 8.0 Radiographic test

RT

Ultrasonic test

UT

Table 28. Test methods and abbreviations, EN ISO 17635:2010.

4.1.4.3

Inspection lot

Welds perpendicular to each other must be included in the test lot. The test lot must include welds, so that all welders on that particular job are represented in the NDT report on welds. 4.1.4.4

Lamination

Lamination in plate edge (flange on profiles included) prepared for QB or QC weld must not exist closer than the greater of 50 mm or 4 x plate thickness. Detection of lamination shall be conducted by mean of UT. 4.1.4.5

Inspection of welds

On drawings where the quality class has not been indicated, the extent of testing can in agreement with the FLSmidth inspection be reduced from the given percentage to include VT only. See sub-section 2.7. If imperfections are found: •

Causing non-compliance with the quality requirements, repairs must be made, and at the same time the extent of testing must be increased from normal test to re-testing of the weld in concern.

•

In cases of non-compliance during re-testing, repairs must be made. At the same time, the extent of testing must be increased to 100 % (repeated) re-test of the weld in concern. • In cases of non-compliance during a 100 % test, repairs must be made and all repaired sections of the welded seams must be examined 100 %.

For welding inspection the following requirements apply: Exam

Quality level FLS / (EN ISO 5817)

Method Weld

VT 38) , 39)

PT

MT

RT/UT 40)

type

Fillet QA / (moderate D), normal test.

0 100

5

0

Butt

0

Fillet

0

QA / (moderate D), re-testing.

-

20

41)

Butt

20

Fillet QA / (moderate D), repeated re-testing.

0 -

100

41)

Butt

100

Fillet

0

QB / (intermediate C), normal test.

100

0

20

Butt

20

Fillet QB / (intermediate C), re-test.

42)

0 -

0

100

Butt

100

Fillet

0

QC / (stringent B), normal test

100

0

Butt

42)

100 100

Table 29. Extent of weld testing. % of length of welded seams.

4.1.4.6 Where reasonable suspicion exists FLSmidth reserves - without cost to FLSmidth - the right to call for an extraordinary increased quality control (according to the choice of FLSmidth) of any item or any subject where reasonable suspicion exist that defects or imperfections are present in the product. This reservation is valid not only for welding; also imperfections in raw materials are covered by this clause (see e.g. sub-section 4.1.4.4). Any imperfections detected during an extraordinary quality control must be evaluated and treated as if they had been detected during a normal test according to Table 29. 4.1.5 Condition for detection and rejection of imperfection 4/6 The information transmitted by this document is the proprietary and confidential property of FLSmidth duplicated, disclosed or utilized without written consent from FLSmidth.

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General workshop instructions 520530 - 8.0 4.1.5.1 General requirement The detection and determination of the sizes of imperfections is highly dependent on inspection methods and the methodology used. Inspection methods and the methodology must be chosen and carried out according to an internationally recognised standard. The methods shall yield the detection, characterization and size of imperfections, which all are required to determine the type of imperfection and the acceptance/rejection mentioned in Table 32, EN ISO 5817:2014 as well as in the standards mentioned in Table 30. 38

VT, visual test ascertains that the welding work has been completed and inspected according to EN ISO 17637:2011.

39 40 41 42

Measuring of weld dimension is included in VT according to EN ISO 5817 and EN ISO 17637/970. Instead of RT the drawing may require UT. Otherwise UT/RT may be chosen optionally with regard to suitable thickness and weld characteristic. Instead of PT the drawing may require MT. In this case the frequency test scope must follow what is required at PT. Otherwise PT/MT may be chosen optionally. UT shall apply 20% / 100% on fillet weld according to drawing requirement and EN ISO 17640:2011 (Non-destructive testing of welds - Ultrasonic testing Techniques, testing levels, and assessment) . Accept from FLSmidth inspection required.

EN ISO 17635:2010 (Non-destructive testing of welds – General rules for metallic materials) is an example of an internationally recognised standard which gives guidance on the choice of inspection methods. EN ISO 17635 links standards concerning acceptance levels for non-destructive testing to EN ISO 5817:2014 (Welding - Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) - Quality levels for imperfections), see Table 32. Simultaneously the NDT inspection shall be conducted so that any type of imperfection described in Table 32 will be detected and the UT shall be performed to detect transverse indications. FLSmidth has the undisputed right to judge the suitability of the NDT method used. 4.1.5.2 Length of imperfection The descriptions of long and short imperfections are in accordance with EN ISO 5817:2014. The distance from an imperfection in a longitudinal seam to the next imperfection of the same type must be equal to or longer than the mean length of the two imperfections in order to hold the two imperfections separate from each other. If so, the length of imperfection is equal to the length of the individual imperfection. If this situation is not satisfactory, the seam is regarded as imperfect over a length corresponding to the distance between the two outer limits of the areas of imperfection. 4.1.5.3 Short imperfection One or more imperfections of a total length not exceeding 25 mm taken from any 100 mm of a weld or maximum 25% of a weld length shorter than 100 mm. 4.1.5.4 Long imperfection One or more imperfections of a total length exceeding 25 mm taken from any 100 mm of a weld or minimum 25% of a weld length shorter than 100 mm. 4.1.5.5 Acceptance criteria The acceptance/reject of imperfections detected by NDT in welded joint and adjacent HAZ shall be in accordance with the quality levels and limits for imperfection defined in Table 32, which is according to EN ISO 5817:2014 (Welding – Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) – Quality levels for imperfections). Furthermore characterisation and acceptance level of imperfections detected by PT, MT, RT or UT is defined in the standards mentioned in Table 30 which shall be considered minimum requirements. Crack or crack like indication will not be accepted.

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General workshop instructions 520530 - 8.0

DSF/FprEN ISO 23278 (Non-destructive testing of welds - Magnetic particle testing of welds - Acceptance levels (ISO/FDIS 23278:2014))exists. DSF/FprEN ISO 23277 (Non-destructive testing of welds - Penetrant testing of welds - Acceptance levels (ISO/FDIS 23277:2014))exists.

Inspection method 43)

Quality level EN ISO 5817, (FLS) B, Stringent, (QC)

VT

EN ISO 17637/970

D, Moderate, (QA)

EN ISO 17637/970

EN ISO 5817 ‘D’

EN ISO 3452-1:2013/EN 571-1

45)

EN ISO 23277/1289

46)

‘2X’

C, Intermediate, (QB)

EN ISO 3452-1:2013/EN 571-1

EN ISO 23277/1289 ‘2X’

D, Moderate, (QA)

EN ISO 3452-1:2013/EN 571-1

EN ISO 23277/1289 ‘3X’

EN ISO 17638/1290

47)

EN ISO 23278/1291

48)

‘2X’

C, Intermediate, (QB)

EN ISO 17638/1290

EN ISO 23278/1291 ‘2X’

D, Moderate, (QA)

EN ISO 17638/1290

EN ISO 23278/1291 ‘3X’

EN ISO 17636-149), EN 1435 level B

C, Intermediate, (QB) D, Moderate, (QA)

43

EN ISO 5817 ‘B’ EN ISO 5817 ‘C’

B, Stringent, (QC) RT

44)

EN ISO 17637/970

B, Stringent, (QC) MT

Acceptance level

C, Intermediate, (QB)

B, Stringent, (QC) PT

Implementation requirements

EN ISO 17636-1, EN 1435 level B

50)

52)

EN ISO 17636-1, EN 1435 level A

EN ISO 10675-1:2013/EN ISO 12517-1

51)

‘1’ EN ISO 10675-1:2013 / EN ISO 12517-1 ‘2’ EN ISO 10675-1:2013 / EN ISO 12517-1 ‘3’

44 45

This table is an excerpt of EN ISO 17635:2010, Non-destructive examination of welds – General rules for metallic materials. Stroked through number indicates (in the entire table) previous in force standard number. EN ISO 17637:2011 (Non-destructive testing of welds - Visual testing of fusion-welded joints) EN ISO 3452-1:2013 (Non-destructive testing - Penetrant testing - Part 1: General principles)

46 47 48 49 50

EN EN EN EN EN

51 52

EN ISO 10675-1:2013 (Non-destructive testing of welds - Acceptance levels for radiographic testing - Part 1: Steel, nickel, titanium and their alloys). 52 Max. area of single exposure must satisfy the requirements of level A, acc. to. EN 1435.

ISO 23277:2009 (Non-destructive testing of welds - Penetrant testing of welds - Acceptance levels). ISO 17638:2013 (Non-destructive testing of welds -- Magnetic particle testing). ISO 23278:2009 (Non-destructive testing of welds - Magnetic particle testing of welds - Acceptance levels). ISO 17636-1:2013 (Non-destructive testing of welds - Radiographic testing - Part 1: X- and gamma-ray techniques). 1435, Non-destructive examination of welds – Radiographic examination of welded joints.

Inspection method 43)

Quality level EN ISO 5817, (FLS)

B, Stringent, (QC)

UT

C, Intermediate, (QB) D, Moderate, (QA)

Implementation requirements

EN ISO 17640/1714 Level B

53)

min.

EN ISO 17640/1714 min. level A EN ISO 17640/1714 - not applicable 52)

Acceptance level EN ISO 11666/1712 54) ‘2’ EN ISO 23279/EN 1713 55) EN ISO 11666/1712 ‘3’ EN ISO 23279 EN 1713 55) not applicable

56)

Table 30. Linking EN ISO 5817:2014 with inspection methods.

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