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Mining Directives Page: 1 of 13


Title:
Instructions for Non-Destructive Testing of Welds

Rev: Dated:
Text pages: 13 Annexes: 3
05 07/2011

Table of contents Page

1. Purpose 2
2. Validity 2
3. Terms and abbreviations 2
4. Execution 3
4.1 Examination supervisors 3
4.2 Inspectors 3
4.3 Testing time 3
4.4 Extent of test 3
4.5 Assessment of external findings 5
4.6 Visual and dimensional examination 5
4.7 Surface crack examination 5
4.8 Ultrasonic examination 7
4.9 Radiographic examination 12
5. Nonconforming parts 13
6. Documentation 13
7. Feedback 13
8. Annexes 13
In the event of any doubt refer to the German version

*)Delete where not Prepared by *) *) *) *)

applicable Inspected/Released Inspected/Released Inspected/Released Inspected/Released

Department MI QM MI QM MI TE

Name Haferkamp Hübner Frericks

Date

Signature

*)Delete where not *) *) *) *) *)

applicable Inspected/Released Inspected/Released Inspected/Released Inspected/Released Inspected/Released

Department

Name

Date

Signature

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1 Purpose
This directive applies to the non-destructive testing and assessment of findings of
welds. Examinations are effected in form of
— visual inspections
— dimensional examinations
— ultrasonic examinations
— surface crack examinations and
— radiographic examinations
and an examination report about the findings of the examinations is made out.

2 Validity
(a) Valid for ThyssenKrupp Fördertechnik GmbH, BU Mining,
(b) To be applied by the manufacturer’s examination staff
(c) Valid as from the “Reviewed and released” date

3 Terms and abbreviations

(a) Abbreviations
TKF ThyssenKrupp Fördertechnik
BU Business Unit
MT Magnetic particle test
PT Penetration test
RT Radiographic test
UT Ultrasonic test
VT Visual inspection
(b) Other applicable standards:
Standard Number Title
DIN EN 1993-1 Steel structures - Design and manufacturer’s qualification
DIN 18800-7 Steel structures - Design and manufacturer’s qualification
DIN 22261-3 Welded joints, type of joints, assessment groups
DIN EN 10025 Hot-rolled structural steel products / unalloyed structural steel
DIN EN 571-1 Non-destructive testing, penetration testing
DIN EN ISO 17638 Non-destructive testing, magnetic particle testing
DIN EN 1435 Non-destructive testing of welded joints, radiographic testing
DIN EN ISO 17640 Non-destructive testing of welded joints, ultrasonic testing
DIN EN 10204 Metal products, type of test certificates
DIN EN 22553 Welded joints, symbols used in drawings
DIN EN ISO 5817 Fusion welded joints on steel, assessment groups
DIN EN ISO 9692 Welding, recommendations relating to the preparation of welds
The contractor undertakes to take into account other standards relating to his scope of supplies and ser-
vices beyond the standards specified in this directive and to meet their requirements when he is fulfilling
his contractual obligations.

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4 Execution
As a rule the specified non-destructive tests must be carried out by the manufacturer.
An examination report has to be prepared about the test carried out and about the test
result.
Examination supervisors and inspectors generally belong to the staff of the
manufacturer fabricating the parts. The manufacturer may call in inspectors from
outside the works to carry out the non-destructive tests. These inspectors, too, must
meet the requirements specified in section 4.2.
4.1 Examination supervisors
Examination supervisors must have the knowledge required to carry out their duties
and have a basic knowledge of welding engineering. They must be able to apply the
specifications of this directive relating to the examinations to be carried out. They must
also ensure that inspectors are properly qualified and that the testing equipment is in
perfect condition. Supervisors specify the details of how the tests must be carried out
conform to this directive, if necessary in consultation with the party ordering the parts,
and will appoint the inspectors. Persons with a level 3 qualification according to DIN EN
473 meet the requirements to be fulfilled by an examination supervisor.
Inspection supervisors sign the test report together with the inspector.
4.2 Inspectors
Inspectors must have an adequate basic technical knowledge and be able to carry out
the required examinations conform to the stipulations contained in this directive. This
must be demonstrated to the examination supervisors. Adequate basic technical know-
ledge can be assumed if the inspector has completed a training course in compliance
with DIN EN 473 and/or DGZfP guidelines.
The test report is prepared by the inspector.

4.3 Testing time

If a heat treatment must be carried out after welding, the non-destructive tests to be
documented must be carried out after the final heat treatment.

4.4 Extent of test

The extent of tests to be carried out conform to DIN EN 1993 on components made of
unalloyed structural steel meeting DIN EN 10025-2 standards is specified in table 1 as
a function of the assessment groups.
When other steel grades are used, the same extent of tests applies.
If a test shows that repair work is necessary, the extent of tests must be doubled (pro-
vided the examination has not already been carried out for 100%). Repaired areas
must be examined 100% using the specified testing methods.
The assessment group relating to the weld design is indicated for the entire component
/ drawing in the drawing’s title block.
If another assessment group applies to a weld, this group is indicated near the symbol
of the welded joint.
If only a percentage of the welds has to be examined, preference should be given to
those non-destructive testing areas which appear to be critical for welding.
All assessment criteria must be fulfilled during the assessment. In case of doubt and/or
in borderline cases supplementary tests need to be carried out.

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Table 1: Extent of tests and examination classes for welded joints
a
Share of length (of reference length ) of welds to be Examination
Type of joint with examined and/or joint surfaces in percent class
respective assessment VT and PT and MT for
group b c
dimensional test surface crack UT RT UT RT
testing
Butt joint through fusion
Both sides One side
DBS DES
0 - 100 100 3 B
1 1 100 100 2 B
2 2 20 20 2 B
3 3 10 10 1 A
4 4 - - - -
T-joint through fusion
Both sides One side
DBT DET
1 1 100 100 2
2 2 20 20 2
All welds must be
3 3 visually inspected 10 10 1
4 4 across the entire - - -
Butt joint T-joint length.
no through fusion Visual inspection
Both sides must be supple-
NBSc, NBS NBTc, NBT mented by a
dimensional exami-
1 1 nation to such extent 100
2 2 that the permissible 20
surface condition
3 3 tolerances and 10
4 4 dimensions specified -
in the assessment
Butt joint T joint
group are met.
no through fusion
One side
NES NET
- - -
2 2 20
3 3 10
4 4 -
Parallel joint Overlap joint
P Ü
1 - 100
2 2 20
3 3 10
4 4 -
a) The reference length is the sum of lengths of the welds produced under identical conditions (shape, method,
filler, position, the same welder) so that the likelihood of defects is the same. Lengths exceeding 10 m must be
divided into reference lengths smaller than 10 m.
b) See section 4.8
c) See section 4.9
S = butt joint
Characteristic letters for T = (double) T joint
type of joints D = Through fusion N = No through fusion
B = Welded on both sides E = Welded on one side
Example: DBS = butt joint with through fusion, welded on both sides
4.5 Assessment of external findings
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The assessment of external findings of welded joints is governed by the requirements
specified in DIN EN ISO 5817. This applies to butt and fillet welds.
Table 2: Assessment criteria for external findings
Assessment group Assessment group conform
conform to this directive to DIN EN ISO 5817
Corresponds to
B
0 With addititonal requirements con-
form to section 4.6 of this directive
1 B
2 C
3 D

4 D x 1,5 *)

*) The limits for the irregularities are increased by 50% with regard to assessment group D.

When selecting the assessment groups for a specific application, the design
conditions, the subsequently applied methods (e.g. surface treatment), the type of
load (e.g. static, dynamic), the operating conditions (e.g. temperature, surroundings)
and the consequences of defects must be taken into account.
The assessment groups have been compiled to allow a broad range of applications to
be employed in the fabrication of welded structures. The limits relating to irregularities
in welded joints are included in table 1 of DIN EN ISO 5817.
Cracks and areas with a lack of fusion must be repaired.

4.6 Visual and dimensional examination (VT)

The visual inspection VT and dimensional examination methods must be specified by
the manufacturer. For each fabrication unit the manufacturer confirms in writing that the
visual and dimensional examination has been carried out prior to and after welding and
that it has revealed no impermissible deviations.
If the examination reveals impermissible deviations, these must be documented
together with the appropriate measures taken to remedy them.
If internal weld discontinuities are believed to exist, the respective area must be
subjected to the appropriate non-destructive examination.
The test results are assessed using the limits specified in DIN EN ISO 5817.
Deviations: Arc strikes are not permitted.
Molten weld spatters are not permitted.
Starting and end craters must be treated like notches.
In assessment groups 2 to 4 pores and slag inclusions on the weld
surface must be assessed conform to assessment group B of
DIN EN ISO 5817 and are not permitted in assessment groups 0 and 1.
Assessment group 0: the following applies in addition to assessment
group 1: weld reinforcements are not permitted,
(flush) weld undercuts are not permitted,
weld concavity max. 5% of weld length

4.7 Surface crack testing (MT, PT)

Surface crack tests can be performed using the magnetic particle and dye penetration
examination methods. Whenever the magnetic particle examination can be applied, it
should be given preference when examining welded joints. Surface crack testing must
be carried out on both sides of the weld provided they are accessible.

As a matter of principle the surface of the areas to be examined must be free of

grease, weld spatters and other impurities.
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Scores, drag lines, notches and similar defects impairing the examination statement
are not permitted.
During the assessment the areas to be examined must be sufficiently illuminated. The
examined area should preferably be coated with a white contrasting colour.

4.7.1 Magnetic particle examination (MT)

The magnetic particle examination method to be applied conforms to the stipulations
contained in DIN EN ISO 17638 Yoke magnetisation is to be preferred.
As a rule the magnetic field should be produced by means of AC magnetisation.
Yoke magnetisation should be given priority.
In order to detect longitudinal and cross defects, magnetisation must be carried out in
two different directions possibly at an angle of 90°.
Dry powder or liquid examination media can be used. The appropriateness of the
examination media must be checked and demonstrated.
The only media which are permitted to be used as carrier liquids for the magnetic flux
are media which do not cause corrosion of the test specimen, not even after they have
acted on it for a long time (e.g. water with a suitable rust inhibitor).

4.7.2 Penetration test (PT)

A penetration examination method conform to DIN EN 571-1 is applied.
An examination system is made up of a penetration medium, an intermediate cleaning
agent and a developer. It must be ensured that these are compatible and that only
systems approved conform to EN 571 are used.

A first assessment should be made when the developer has dried. This makes it easier
to interpret the findings. A final assessment is made at the end of the development
time.

4.7.3 Limits of acceptable discontinuities for the surface crack examination

Indications suggesting cracks or lack of fusion are not permitted.
Indications exceeding 1 mm for the magnetic particle examination and exceeding 2 mm
for the penetration examination are regarded as cracks or lack of fusion and are not
permitted in as far as they are not recognised as being distinct pores or slag inclusions.
Indications up to a length of 6 mm are only permitted when it can be proven that they
are non-metallic inclusions.

Table 3: Acceptable surface defects as a function of the weld assessment group

Permissible length of Permissible dimensions *)
Assessment group linear indications of other indications
in mm in mm
0 1 1,5
1 2 2
2 2 3
3 2 3
*) For PT examination: real dimension, systematic defects are not permitted

Up to 10 acceptable indications are admissible over an area of 10 cm x 10cm.

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Extent of examination
The extent of examination specified on the drawing is indicated in table 1 of this
directive.
Areas where auxiliary welding has been carried out must be subjected to a magnetic
particle or dye penetration test.

4.8 Ultrasonic examination (UT)

The ultrasonic examination must be carried out in compliance with DIN EN ISO 17640
„Non-destructive testing of welds“. This directive includes variations relating to
examination classes and assigned conditions.
Ultrasonic examinations only make sense on throughly fused joints and should be
applied from material thickness of at least 10 mm onward.
Nominal material thicknesses exceeding 60 mm can be split up into 60 mm thick
examination zones. Zone splitting is effected starting from both surfaces, overlaps
being possible.

Table 4: Ultrasonic examination classes

Exam. Assessment
Technical requirements
class group *)

1 Test carried out starting at least from the seam side:

3 Spotting cross defects by inclined acoustic irradiation next to the
seam.
Test carried out from both seam sides (or
from both surfaces):
for material thicknesses ≥ 40 mm acoustic
2 irradiation under 2 different angles which If reflectors are
2 must differ by at least 15°; If acoustic irradiation spotted near the
1 spotting cross defects by inclined acoustic positions cannot be surface, carry out a
irradiation next to the seam in 2 irradiation realised for geometrical surface crack test
directions, each. reasons, make sure that conform to section
T-welds require an additional vertical by selecting appropriate 4.7.
acoustic irradiation. other positions the
Test carried out from both seam sides; for relevant orientations of
material thicknesses > 40 mm acoustic defects are spotted.
0 irradiation with 2 different angles which
3 (machined must differ by at least 15°; spotting cross
flush) defects by coupling to appropriately
prepared cover bead in 2 acoustic
irradiation directions.

*) Table 1 includes no ultrasonic examination for assessment group 4.

Minimum technical requirements

The testing areas that can be selected on the testing device must overlap. Within each
area the time-base sweep must be continuously adjustable and the deviation from the
linearity of the testing area must be smaller than 2 %.

All coupling areas must be free from irregularities which have an adverse effect on the
strength of statement of the test result. Notches, loose scale, weld spatters, scores and
other contaminations affecting the coupling must be removed. When the surface
opposite the coupling area is used as reflection area, this area is subject to the same
requirements. An average peak-to-valley height of Ra = 20 µm must be strived for the
coupling and reflection area.
Taking into account the transfer losses, the amplification of the device must be
adjusted to have the registration limit for the area to be assessed reach at least 40 %
of the screen height.

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The maximum echo height of a reflection point must be indicated as a dB figure in

excess of the echo height of the valid registration limit according to the AVG method in
KSR (KSR being the circular reflector in mm).
Determination of the linear extension for a specified registration limit
The extension of a reflector must be indicated by the displacement stroke of the probe.
This displacement stroke is limited by the fact that the echo height
— falls short of the registration limit for nominal material thicknesses ≤10 mm,
— falls short of the registration limit by 6 dB for nominal material thicknesses
>10 mm to ≤ 40 mm,
— falls short of the registration limit by 12 dB for nominal material thicknesses
>40 mm.

When the echo grass is reached in the process, the registration length up to the
moment when the echo indication disappears in the grass must be indicated.

Registration length ≥10 mm must be measured and recorded, shorter registration

lengths must be recorded as “< 10“.

Form echoes
If echoes have to be classified as being subject to the form, measurements must be
carried out to verify the cause of the echo. For echoes subject to the form this
verification is regarded as being carried out if no echo is indicated from the presumed
reflection point when the acoustic irradiation stems from the other seam side.
Position of reflectors
The longitudinal, transverse and depth coordinates of all indications must be recorded in
an appropriate system. The system applied must be displayed in a sketch. The sketch
must include the dimensions of the reference points on the test specimen and the direc-
tions of coordinates.
Definitions of registration length
Distance of the two test positions where the echo height is reduced by 6 dB compared to
the max. indication of a reflector.
1
Legend:
1 = Reflector
2 = Welding wire
3 = Probe

Single reflector Closely spaced Stretched single reflector with

single reflectors irregular reflection behaviour

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Test position for butt joints

Spotting
longitudinal defects

Spotting
transverse defects

(‘) Test positions on the opposite surface

Table 5: test positions for butt joints

Examination class Test position
Longitudinal defects Transverse defects
1 5, 6
1 or 1´ or 7, 8
or 2 or 5´, 6´
or 2´ or 7´, 8´
2 1, 2 prefe- 5, 6, 7, 8
or 1´, 2´ rably or 5´, 6´, 7´, 8´
3 or 1, 1´ 3, 4
or 2, 2´ or 3´, 4´

Test position for T-joints

Longitudinal defects Transverse defects

(‘) Test positions on the opposite surface
Table 6: test position for T joints
Examination class Test position
Longitudinal defects Transverse defects
1 1 5, 6
or 1´
1, 9 prefe-
2 5, 5´, 6, 6´
or 1´, 9´ rably
or 1, 1´

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Test positions on double T-joints

Longitudinal defects Transverse defects

(‘) Test positions on the opposite surface

Table 7: test positions on double T-joints

Examination class Test position
Longitudinal defects Transverse defects
1 1, 2 5, 6, 7, 8
or 1´, 2´ or 5´, 6´, 7´, 8´
2 5, 5´, 6, 6´
1, 1´, 2, 2´
7, 7´,8, 8´

Table 8: acceptable limits for UT

Limits of acceptable discontinuities for the UT as a function of the material thickness and
assessment group:
Longitudinal defects Transverse defects
Max. Max.
Registra- Perm. rel. Max.perm. Max. perm.
Assessment Material perm. perm.
tion limit disconti- echo registration Perm. no.
group thickness echo registra- nuity height length of of discon-
t Observation height tion length surface
disconti- tinuities *)
threshold of discon-
nuity
tinuity
Parts per
mm KSR KSR mm % KSR mm
m
10 ≤ t ≤ 15 1,0 2,0 15,0 1,5 1,5 10 3
0 15 ≤ t ≤ 20 1,5 3,0 23,0 1,5 2,0 10 3
20 ≤ t ≤ 40 2,0 4,0 30,0 1,5 2,5 10 3
40 ≤ t ≤ 60 3,0 6,0 45,0 1,5 3,5 10 3
10 ≤ t ≤ 15 1,0 2,0 15,0 3,0 1,5 10 3
1 15 ≤ t ≤ 20 1,5 3,0 23,0 3,0 2,0 10 3
20 ≤ t ≤ 40 2,0 4,0 30,0 3,0 2,5 10 3
40 ≤ t ≤ 60 3,0 6,0 45,0 3,0 3,5 10 3
10 ≤ t ≤ 15 1,0 3,0 20,0 4,5 2,0 10 3
2 15 ≤ t ≤ 20 1,5 4,0 30,0 4,5 2,5 10 3
20 ≤ t ≤ 40 2,0 5,0 40,0 4,5 3,0 10 3
40 ≤ t ≤ 60 3,0 7,0 60,0 4,5 4,0 10 3
10 ≤ t ≤ 15 1,0 3,0 25,0 6,0 2,0 10 3
3 15 ≤ t ≤ 20 1,5 4,0 38,0 6,0 2,5 10 3
20 ≤ t ≤ 40 2,0 5,0 50,0 6,0 3,0 10 3
40 ≤ t ≤ 60 3,0 7,0 75,0 6,0 4,0 10 3
*) The indication of the transverse defect test must only be registered when it is at least twice as high as the
indication of the longitudinal defect test on the same discontinuity.

Irregularity area
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The irregularity area is the product of the registration length and the maximum echo
height measured in the KSR (see Fig. 1). The KSR value is used as the thickness
extension rate of the discontinuity. The referred discontinuity area U is the ratio from the
sum of discontinuity areas divided by the seam surface.

The following applies:

KSR1 x I1 + KSR2 x l2+ KSR3 x l3+ …+ KSRn x ln x 100%
U=
txL
in which: U referred irregularity area, in percent
t seam thickness in mm; for butt joints with different material thicknesses the smaller
material thickness, for T joints the material thickness of the connected component,
in mm
L max. 1000 mm continuous seam length section or when the seam is shorter, the
existing seam length in mm
l registration length, in mm
KSR equivalent circular reflector size, in mm (echo height).

Dimensions needed to determine the discontinuity area

- symbolic representation -

Fig. 1

Assessment of examination findings

All echoes of reflectors not subject to form which reach or exceed the appropriate
registration limits of table 8 „Acceptable limits for UT“ must be registered. The distance
of two registered reflectors used in spotting longitudinal defects must at least be:
— either in transverse or thickness direction two times the value of the extension of
the larger discontinuity in transverse and/or thickness direction but not less than
two times the KSR value,
— or in longitudinal direction two times the length of the larger discontinuity.
When the appropriate minimum distance between two discontinuities is not met in
longitudinal and/or in transverse and thickness direction, they must be regarded as a
discontinuity with the inclusion of the gap. When spotting the transverse defects, only
one discontinuity may occur in one cross section provided the echo of the transverse
defect test is twice the echo of the longitudinal defect test of the same discontinuity.
The distance from the surface in thickness direction must at least be identical to the
extension of the discontinuity in thickness direction, but may not be smaller than its
KSR value.

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4.9 Radiographic examination (RT)

The radiographic examination is only provided for throughly fused butt joints. The
technical procedure is based on DIN EN 1435. The examination class must be applied
conform to table 1 as a function of the appropriate assessment group. This requires the
quality of the picture as specified in DIN EN 1435 to be achieved.

The general conditions for examination and additional minimum technical requirements
to be met by the radiographic examination method are specified in DIN EN 444 and
DIN EN 462.
The radiographic examination is carried out conform to DIN EN 1435 and table 9.

Table 9

Picture quality class Examination class

Assessment group as per as per
DIN EN 462-3 DIN EN 444
0 B B
(machined flush with plate)

1 B B

2 A B

3 A A

Examination findings
All visible surface defects and damages affecting the assessment of the film must be
remedied before the radiographic examination is carried out.

Film position plans must be prepared clearly describing the position of the films and the
shooting setup. The films must be clearly marked so that they can be properly
assigned.

Cracks and incomplete edge fusions are inacceptable. Roots which are not throughly
fused in joints which are only welded on one side are not acceptable.
Flat root concavities and flat root notches in as-welded roots of joints which are only
welded on one side are acceptable in places, provided that they are restricted to small
areas.
Incomplete fusion between several passes in welds and inadequate roots in joints
which are welded on both sides are to be treated in the same manner as the inclusions
in table 10.
For multiple pass welds – taking into account the general condition – solid or gaseous
inclusions, linear porosity as well as elongated pores running parallel to the surface
conform to table 10 can be allowed.
Several inclusions in a row meeting the conditions of table 10 can be allowed provided
the sum of their lengths across a joint length of 6 x S (S = material thickness) is
smaller than „S“ and if the flawless weld between two neighbouring discontinuities is at
least twice the length of the larger of the two inclusions. For seam lengths smaller than
6 x S this condition is a proportional one. Elongated pores running normal to the
surface are not acceptable. Over a joint length of 150 mm no area containing pores

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which are recognizable on the radiograph may exceed 1.5 x S (in mm2). The maximum
diameter of such pores may not exceed 0,25 x S, and may not be greater than 3 mm.
Systematic discontinuities marked by high frequency and extent are not acceptable.
In single-pass welds isolated pores are acceptable provided their diameter is < 0,25 x S
and does not exceed a maximum of 3 mm.

Table 10: acceptable lengths of the inclusion-type discontinuities in multi-pass welds

Nominal material
Assessment groups**)
thickness*)
s in mm 0 1 2 3
<10 7 7 7 7
>10 bis 75 2/3 x s 2/3 x s 2/3 x s 1xs

*) In case there are two different material thicknesses that are connected to each other, the
smaller material thickness must be taken as a basis.
**) No RT is provided for assessment group 4 conform to table 1.

5 Nonconformities
Cracks and incomplete fusions are not acceptable.
Impermissible surface defects may be ground out in form of a flat trough. Deeper
surface defects and inacceptable internal findings are professionally remedied by
repairing, welding and re-testing them.
If tests reveal nonconformities which should not be repaired, these must be treated
conform to directive DR 13.01.

6 Documentation

Test reports must be drawn up as included in the annex or other reports must be used
that show the same content.
Reports should be drawn up of all required examinations and of all examinations
carried out conform to this directive. All results must be stated, even if they contain no
indications which are required to be registered.

7 Feedback

A ruling for a feedback of nonconformities is specified in DR 13.01

8 Annexes
Test reports: Annex 1: Radiographic examination
Annex 2: Ultrasonic examination
Annex 3: Surface crack examination

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