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KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specification Number
Pipeline Field Welding Non-Sour Service

17 JUN 94

ISSUED AS KOC ENG. GROUP SPEC.

26 FEB 94

ISSUED FOR INVITATION TO BID

Rev

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Section

PE

Client

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CONTENTS
1.0
2.0
3.0
4.0

5.0
6.0
7.0

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
STANDARD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 3
SERVICE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CONTRACTOR'S OBLIGATIONS . . . . . . . . . . . . . . . . . . . . . . . . 5
MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
QUALITY SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WELDING PROCEDURE APPROVAL . . . . . . . . . . . . . . . . . 6 . . .
SCOPE

8.0

QUALIFICATION OF WELDING PROCEDURE


ANDWELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

9.0

WELDING CONSUMABLES

10.0

11.0

............................8
PRODUCTION WELDING . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . .
10.1 Fit-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
10.2 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
10.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 0
HEATTREATMENT- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

12.0 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.2 NDE Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . 11
12.3 Non-Destructive Testing . . . . . . . . . . . . . . . . . . . . . . . . 1 2
12.4 Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2
12.5 Magnetic Particle Inspection . . . . . . . . . . . . . . . . . . . . . . 16
12.6 Liquid Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . 1 7

1.0

2.0

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SCOPE

1.1

This specifications covers the design and manufacture of pipeline field


welding for installation at the Facility in Kuwait.

1.2

The field welding shall fully comply with all relevant contractual
requirements specified in the Scope of Work and Technical Specification
of the Contract.

STANDARD SPECIFICATIONS

2.1

The pipeline field welding shall conform in design, material and


performance, except where otherwise specified, with the current issue
and amendments of the following prevailing on the effective date of the
Contract:
2.1.1 International Standards
In addition to the text of this specification, the following codes
and standards are applicable:
API 1 104

Welding of Pipelines and Related Facilities

ASME Vlll Div 1

Unfired Pressure Vessels

ASME IX

Welding and Brazing Qualification

ASME B31.4

Liquid Transmission Systems for


Hydrocarbons, Liquid Petroleum Gas,
Anhydrous Ammonia, and Alcohols

ASME 831.8

Gas Transmission and Distribution Piping


Systems

ASNT-SNT-TC-1A American Society for Nondestructive Testing


ASTM E747-87

Test Method for Controlling Quality of


Radiographic T e s t i n g Using Wire
Penetrameters

2.1.2 British Standard


BS 5750
Part 2

Quality Systems
Specification for Production and Installation

2.1.3 Engineering Group Specifications


015-AH-1001

Basic Design Criteria

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International Codes and Standards


Pipeline Construction
Pipeline Design
Pipeline Pigging and Hydrostatic Test
Pipeline Dewatering and Drying
Pig LauncherIReceiver
Field Welding
External Coating of Pipeline
Induction Bends
Pipeline Field Joint Coating
Line Pipe Materials
Shop and Field Painting
Cathodic Protection Design Requirements

3.0

2.2

Compliance with this specification shall not relieve the Contractor of its
responsibility t o supply equipment suited t o meet the specified service
conditions and applicable regulations.

2.3

Where conflicts exist between this specification and other Drawing,


standards, codes or specifications, the most stringent shall be applied,
and the Company decision shall be final.

SERVICE CONDITIONS

3.1

The welded pipeline shall be suitable for continuous operation at a desert


location under high ambient temperatures and humidity the atmosphere
at the facility is generally dusty and corrosive and may contain traces of
hydrogen sulphide.

3.2

The welded pipeline shall in all respects be suitable for continuous


operation in service conditions stated in the Engineering Group
Specification entitled "Basic Design Criteria" (Number 0 1 5-AH-1001 ).

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CONTRACTOR'S OBLIGATIONS
4.1

The Contractor shall submit descriptions of all welding equipment,


welding materials to be used, tools, etc. to the Company for approval
prior to starting work.

4.2

This equipment shall consist of at least:


Welding machines, welding generators and gas welding
equipment.
Equipment and machinery for cutting, bevelling, preheating and
postheating.
External and internal line-up clamps.
Welding electrodes, welding wire, fluxes, etc.
Welder's tools.
Tests and asbestos blankets for weather protection of the
welds to be made.
Portable or permanent meters to calibrate machines and
regulate voltage and amperes.

4.3

5.0

6.0

Sufficient equipment for each welding method to be applied shall be


present to ensure a replacement in the event of failure so that operations
can be continued normally.

MATERIAL
5.1

The Contractor shall supply the line pipe in accordance with the
Engineering Group Specification entitled "Pipeline Pigging and
Hydrostatic Test" (Number 015-IH-1004).

5.2

The line pipe supplied by the Contractor with a limitation on the carbon
equivalent as follows:

QUALITY SYSTEMS
6.1

The Contractor shall maintain a Quality System to BS 5750, Part 2.

6.2

The Contractor shall submit to the Company a copy of its Quality


Manual for approval.
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The Contractor shall submit a Quality Plan for the entire work for
Company approval prior to commencement of fabrication.

WELDING PROCEDURE APPROVAL


The Contractor shall submit to the Company for approval written weld
Procedure Proposals (WPPs) to cover the range of materials, thicknesses
and diameters in the work. This shall include a welding repair procedure
(WRP). Upon Company approval, each WRP shall be qualified in
accordance with API 1104. All weld procedure qualification (WPQ)
tests shall be witnessed by the Company's Representative. Following
qualification, the supplier shall prepare a weld procedure specification
(WPS) for use on site.
When testing is completed, the Contractor shall submit the complete
package of WPSs and weld procedure qualification records (WPQRs)for
Company approval.
All welding details required by API 1104, Sec. 2, shall be included in
each WPS and qualified by the corresponding WPQR.
In addition to the requirements of API 1104, the WPSs and WPQRs shall
specify string or weave bead.
The following shall be considered as essential variables in addition to API
1 104:
7.5.1

For filler materiallelectrode and any change


classification.

7.5.2

A change in welding equipment for automatic processes.

7.5.3

Any change in wall thickness or outside diameter (OD) outside


the wall thickness or OD group qualified. Wall thickness and
OD groups are defined in paragraph 3.2.2 of API 1104.

7.5.4

A change in current or voltage range beyond that of the WPQR.

7.5.5

A change in polarity of the electrode.

7.5.6

A change in electrode diameter.

7.5.7

Post-weld heat treatment (PWHT).

7.5.8

Any change in root pass welders.

7.5.9

Any significant change in heat input.

7.5.10 Any change in shield flux manufacturer or brand.

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In addition to the testing requirements of API 1 104, the test welds shall
be visually inspected and radiographed. The acceptance criteria shall be
as per of API 1104, Sec. 6. In addition, a macro etching specimen shall
be produced for both the WPQ and repair. Hardness testing shall also
be made on the etched specimen; hardness impression shall be made at
the weld, heat-affected zone, and base metal hardness value shall not
exceed HVlO 248 BHN 237.
Welding procedures shall be approved by the Company prior to the
commencement of production welding.
Previously qualified procedures may be acceptable provided they comply
fully with the requirements of this specification and API 1 104, and have
been witnessed by a third party.

8.0

QUALIFICATION OF WELDING PROCEDURE AND WELDERS


8.1

The Contractor shall comply with the conditions described in all


applicable specifications. If the Contractor wishes to depart from
specification requirements, this shall be submitted in writing for
Company approval.

8.2 The qualification of the welding procedure and welders/operators shall


be established,
specifications.
8.2.1

inspected and tested as laid down in these

Quality of the Welding Work


a. The Contractor shall at all times be responsible for the good
quality of the welding work.
b. A Quality Plan describing the systematic control of the
construction, inspection and testing required by this
specification, other relevant specifications, codes and
standards and the Contract conditions shall be submitted t o
the Company for approval.
c.

8.2.2

The Contractor shall compile a log identifying by number


each pipe and fitting and indicating the weld numbers
joining them to other items. Each circumferential weld
(whether a field joint or a shop-made weld) shall be
allocated a unique number which shall be used for
reference to the weld in all reports, radiographs and nondestructive testing (NDT) documents.

Performance of Welding Work

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Welded joints in lines of 2 in. and up may be produced by


manual electric are shield welding with a minimum of four
beads.
8.2.3

Welders' Qualification
Welders shall be qualified to API 1104, with testing at the job
site and on Project-specific material. Previously qualified
welders with current certificates may be acceptable to the
Company provided all the requirements of this specification and
API 1104 are met and the qualification tests have been
witnessed by a third party.

9.0

WELDING CONSUMABLES
9.1

The Contractor shall submit a procedure for the storage and handling of
welding consumables for approval by the Company.

9.2

Welding consumables shall be stored in accordance with the Approved


Manufacturer's recommendations in a covered, clean, dry location.

9.3

Heated quivers shall be used for low-hydrogen electrodes.

9.4

9.3.1

The welds shall be made with electrodes or welding wire


suitable for the purpose and approved by the Company. To
obtain this approval, the welds shall be subjected to the tests
described in the section on welding procedure qualification.

9.3.2

Each coil of filler wire, bag of flux and packet of electrodes


shall be clearly marked with its batch number. Batch testing
shall be completed before the start of field welding. Batch
testing may be undertaken by the Approved consumables
Manufacturer, and the test results shall be submitted to the
Company for approval.

9.3.3

The values found in the mechanical tests of the weld metal


shall at least comply with the specified minimum mechanical
requirements of the steel that has been welded.

Welding consumables showing signs of damage or deterioration shall not


be used.

10.0 PRODUCTION WELDING

10.1.1 Internal line-up clamps shall be used for 16-in. pipe and larger
and shall not be removed prior to the completion of the root
pass.

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Where it is not practicable to use internal line-up clamps,


external clamps shall be used. These shall not be removed until
70% minimum of the root pass has been completed and is
evenly distributed around the pipe circumference. Cleats and
brackets shall not be attached to the pipe for alignment.
The pipe on both sides of the joint shall not be raised, lowered
or otherwise moved until both root pass and the hot pass have
been completed.
Where field bevelling is necessary, it shall be effected using
either mechanical or automatic flame- or plasma-cutting
equipment, followed by grinding to remove all oxide, and
preparing the joint surfaces to a clean, bright finish. Bevels shall
comply with the approved welding procedure.
Tack welds shall be made using qualified welders and
procedures qualified in accordance with this specification. At
least four evenly spaced tack welds a minimum of 25 mm long
shall be used. Tack welds to be incorporated into the final weld
shall be ground to a suitable taper at either end to ensure
adequate fusion with the root run. Where heat is required for
the root run, this shall also be applied to the tack welds.
The tolerance on misalignment at butt joints shall be in
accordance with API 1 104. Additionally, any misalignment
shall be reduced to minimum by rotating the pipes to the
optimum position.
Where longitudinally welding pipe is used, the pipe shall be
positioned such that the weld is located in the upper half of the
pipe circumference. The longitudinal or spiral welds of adjacent
pipes shall be offset by the lesser of 90 or a circumferential
distance of 250 mm or on neutral axis of bent sections of pipe.
No welds shall be made on pipe other than the circumferential
welds between the pipe and appurtenances.
Earthing connectors shall not be weld to the pipe, and only
suitable clamps which do not cause arcs shall be used.
Under no circumstances may the arc be struck on the surface
of the pipe outside the weld bevels. If this inadvertently
occurs, the entire weld and the drainage part of the pipe shall
be subject to removal.

10.2 Welding
10.2.1 Welding shall not be carried out on wet steel. Wet steel
surfaces shall be thoroughly dried by the application of heat to

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the entire joint prior to welding commencing. Preheat shall be


based on weldability tests, chemical analysis and welding in
procedure and shall be in accordance with ASME Vlll Div. 1.
The minimum preheat temperature shall be 50 C.
The maximum interpass temperature shall be 250 C.
As far as possible, welds shall not be left in a partially
completed state. However, if this is unavoidable, a minimum
of three passes shall be made prior to cooling. The joint shall
be entirely wrapped in dry, insulating material, with
waterproofed exterior, and cooled in a slow, uniform manner.
Prior to the recommencement of welding, the joint shall be
dried in accordance with paragraph 9.2.
Joints shall not be welded by blocking out individual segments.
The stringer bead technique shall be used when welding with
low hydrogen electrodes.
Adequate weather shielding shall be in place for all welding.
The Company reserves the right to discontinue all welding in
the event of non-fulfillment of welding requirements.
Where the vertical down process is used for welding the root
pass, the time delay before welding the hot-pass shall be
strictly in accordance with the qualified WPS and not in excess
of five minutes.
Only earthing clamps shall be used on the pipes. Arc strikes on
base metal are forbidden. Only arc striking on fusion face shall
be allowed.

A WPS for weld repairs shall be submitted together with a


corresponding WPQR for Company approval prior to the
commencement of the work.
Weld repairs shall be effected in accordance with the
requirements of API 1 104.
Defects shall be removed by arc air gouging followed by
grinding or by grinding alone. Metal surfaces shall be dried in
accordance with paragraph 9.2 prior to any gouging operation.
The Contractor shall maintain a full record of all repairs. Such
record shall show the weld number, type and size of defect,
circumferential location, estimated depth of the defect, number

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or repair, welding procedure, name of repair welder, date of


repair, etc.
All repairs shall be witnessed by the Company Inspector. Root
sealing or single-pass repair deposit shall not be done; only t w o
attempts on the repair are permitted.
Repair length shall be limited t o 3 0 % of the weld if the repair
does not require opening the root. If a repair opens the root,
only 2 0 % of the weld length shall be repaired. If the repair
cannot be implemented within these limitations, the weld shall
be cut out.
The cut end of the pipe shall be re-bevelled, and about
1 0 0 m m on either side of the joint shall be examined by
ultrasonic for laminations. The new bevels shall be magnetic
examined.

11.0 HEAT TREATMENT


11.I The requirement for post-weld stress relief shall be in accordance with
ASME B31.4, paragraph 434.8.9.
11.2 If PWHT is necessary, the Contractor shall submit a detailed procedure
for post-weld stress relief for Company approval. This shall include all
details required by ASME Vlll Div. 1, paragraph UCS 56.
1 1.3 A chart recording of each PWHT shall be produced.

12.0 INSPECTION
12.1 General
Inspection and witnessing by the Company shall not release the
Contractor from its sole responsibility for carrying out the necessary
inspection, testing and non-destructive examination (NDE) required by
the code and by this specification. The Company shall have the right t o
order the removal of any weld for the purpose of carrying out
destructive tests.

12.2 NDE O ~ e r a t o Qualifications


r
12.2.1 NDE operators shall be qualified by a third party t o ASNT-SNTTC-1A Level II or Ill, and of API 1104, sections 5.3 and 5.4.
12.2.2

NDE operators shall have current certification for the work


undertaken, and their qualification certificates shall be subject
t o approval by the Company.

12.3 Non-Destructive Testing


All NDT work shall be the full responsibility of the Contractor.
The Contractor shall submit procedures for all NDT to the
Company for approval prior to work commencing.
NDT radiograph, wire-type image quality indicators shall be in
accordance with ASTM E747. The sensitivity shall be better
than 2.0%.
High-pressure (HP) gas and condensate lines welds shall be
100% radiographed. Nozzles or attachment welds that cannot
be radiographed shall be examined by the wet magnetic crack
detection method.
Low-pressure (LP) gas and crude oil lines shall be 10%
radiographed except at the road crossings, populated areas, tiein points and repair welds, where 100% radiography on welds
shall be made. All fillet welds, nozzle or branch welds and
other attachment welds shall be examined by the wet magnetic
crack detection method.
The first five production welds of each welder or welding group
shall be 100% radiographed.
Two additional welds shall be radiographed for a welder if these
welds do not meet the acceptance criteria as per API 1104
should any or both of the additional radiograph show
unacceptable welds. The entire welds made by that welder or
welding group shall be radiographed at the expense of the
Contractor.
12.4 Radioara~hy
The following defines the minimum requirements for radiography work
to be carried out by the Contractor or the Approved Subcontractor:

12.4.1 Procedure
A detailed procedure and production of images shall be
prepared by the Contractor for Company approval:
a.

Radiation source machine identification.

b. Film Manufacturer and relevant ASTM Class.


c.

Intensifying screen.

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d.

Exposure geometry (double wall, double imageldouble wall,


single imagelor single wall, single image).

e.

Source film distance of focal film distance.

f.

Number of exposures required for radiography of a


complete weld.

g.

Exposure conditions and exposure time.

h. Processing (manual or automatic).


i.

Material thickness range.

j.

Penetrameters (101):type, material and related standard.

k.

Density and sensitivity.

I.

Collimator or field limitation device.

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m. Safety precautions and aids.

12.4.2 Minimum Requirements for Radiographic Examination


X-radiography shall be used for site inspection unless prior
approval is obtained for the use of the isotope iridium 192.

12.4.3 Film Density


The density through the weld metal shall not be less than 1.8
and not more than 3. The Company has the right to check the
Contractor's unexposed films at any time and from any lot of
films intended to be used by the Contractor.

12.4.5 Film Type


a. The following types of industrial radiographic films shall be
used for X-ray and for iridium 192 radiography:
Class 1

Low Speed Film

Fo r M at e r ia I
Thickness < 0.50"

Class 2

Med. Speed Film

For Material
Thickness r 0.50"
but not exceeding 1"

Class 3

High Speed Film

Fo r M at e r ia I
Thickness 1 1"

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b. For X-Ray Radiography:


KV Range

Film Class

Upto 114" inclusive

120- 15 0

Upto 114" inclusive

150-250

> I 1 4 - 112"

120- 15 0

Mat'l Thickness (inch)

12.4.6 Penetrameters (101)


a.

Quality indicator (penetrameter) shall conform t o ASTME747 for wire penetrameter or any alternative standard for
wire penetrameter subject t o Company approval.

b. A t least one penetrameter per radiograph exposed


simultaneously with the specimen shall be used.
12.4.7

Sensitivity
2% or better sensitivity is required.

12.4.8

Exposure Geometry
The double wall, double image technique shall be used for
piping of less than 3 112 in. inclusive. A t least t w o
exposures separated by 90 degrees shall be made for the
radiographic inspection of a complete weld.
One
penetrameter on the source side with its length
perpendicular t o the weld shall be used.
For single wall, single image, at least four penetrameters
spaced approximately equally around the circumference of
the pipe shall be used at source side.
Double wall, single image shall be used for pipe diameter >
3 112 in. The penetrameter shall be placed on source side,
if applicable; otherwise, it shall be placed on film side at
the mid length of the film: an overlap of at least 2 in. is
required between shots.
In radiography of tankage annular plates butt weld, when
backing strip is used or weld reinforcement is high, a shim
plate of the same type of metal as the parent metal shall be

placed under the penetrameter to provide the same


thickness of material under the penetrameter as the
average thickness through the weld.

12.4.9 Identification of Location Markers on Radiographs


Each radiograph shall be identified so that there is a
permanent correlation between the part radiographed and
the film.
The types of identification and method of identification
shall be as per the Contractor procedure unless otherwise
specified by the Company.
The letter "R" should be used to designate a radiograph of
repaired area.
The exact location of location markers should be clearly
marked on the surface being radiographed so that the area
of interest can be identified accurately.
When more than one image is used to inspect a weld,
identification markers shall overlap at a minimum of 2 in.
The last reference marker on each end of the image shall
appear on the appropriate adjacent images in a way that no
part of the weld images could be omitted.
Radiographic Report
The format of radiography results shall be based on this
specification and shall be agreed upon with the Company prior
to implementation of the work.

12.4.11

Interpretation
a.

Prior to any weld repairs, the radiographs shall be


submitted to the radiography report and any relevant
Drawings.

b. The designated length for interpretation shall not contain


any discontinuities whose severity exceeds that allowed in
the related code, standard, specification or Company
limitations.
c. When two or more types of weld defects are present in the
same radiograph whose extent equals the maximum
acceptable limit for both, the weld shall be judged
unacceptable.

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Radiographs showing processing defects, improper density


or sensitivity, or any image that masks the weld or adjacent
base metal shall not be submitted for interpretation.
Record of Radiographic Examination
The Contractor shall produce a record for all films with their
identification marks on a developed shell plate diagram (for
tanks), on isometrics or plans (for piping) and on the
welding key plan (for other equipment).
Upon completion and acceptance of the relevant equipment
or piping and all other related works by the Company, all
radiographic films shall be handed over to the Company in
good condition when they will become the sole property of
the Company and shall be retained for a minimum period of
five years.
Radiography work shall be at the expense of the
Contractor.
Should the Company request additional
radiography, it will be at Company expense unless it does
not meet the Engineering Group specification. The cost of
the rework of these non-conforming conditions, including
that of radiography, shall be to the Contractor's account.

12.5 Maanetic Particle lns~ection


12.5.1

Equipment for magnetization of parts shall be capable of


inducting flux density of sufficient intensity and direction to
perform the required job.

12.5.2

Either AC or DC (full-wave or half-wave rectified) equipment or


permanent magnets shall be used as specified in the Contractor
procedure to produce the required magnetization. Flexible
movable legs of the yoke should be available for work
requirements.

12.5.3 Magnetic particle may be applied wet or dry. Dry particles


should be applied uniformly with a dusting or light blowing
action. Wet particles should be applied by aerosol cans or by
hosing. Provisions should be made available to ensure that the
required amount of particles are in the suspension when the
spray is applied and to periodically check the concentration of
the solution. When fluorescent dyed particles are used,
ultraviolet light (3200 3800 A O ) must be available.
12.5.4 Equipment for demagnetization should be available for
demagnetizing parts to the minimum residual field.

Specification Number

12.6 Liauid Penetrant lns~ection

12.6.1 The Contractor should prepare the necessary apparatus to apply


the penetrant, wash the surface of the part, dry the part and
apply a developer and a properly lighted area in which the part
can be inspected by the Company. The inspection materials
should not adversely affect the parts to be tested. When
fluorescent dyed particles are used, ultraviolet light
(3200- 3800 A O ) must be available.

12.6.2 Only aerosol cans for cleaner, penetrant and developers shall be
used in order to allow for the smooth flow of parts.

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