LESER WORKS STANDARD Ultrasonic testing procedure

LWN 331-05-EN page 1

Table of contents
Summary........................................................................................................................................... 2 1. General, the principle of ultrasonic testing................................................................................. 2 2. Application ................................................................................................................................. 2 3. Purpose ..................................................................................................................................... 2 4. Testing reference....................................................................................................................... 2 5. Testing technology..................................................................................................................... 3 5.1 Testing instructions............................................................................................................. 3 5.2 Testing depth...................................................................................................................... 3 5.3 Test procedure ................................................................................................................... 3 5.4 Testing equipment and couplant ........................................................................................ 3 5.4.1 Ultrasound device........................................................................................................ 3 5.4.2 Ultrasound testing heads and test frequencies ........................................................... 3 5.4.3 Couplant ...................................................................................................................... 4 5.4.4 Calibration block.......................................................................................................... 4 5.5 Device setup....................................................................................................................... 4 5.6 Preparation of the testing, surface preparation .................................................................. 4 5.7 Testing................................................................................................................................ 4 5.8 Description of irregularities, evaluation............................................................................... 4 6. Acceptance criterion .................................................................................................................. 5 7. Documentation, option code ...................................................................................................... 5 8. Qualifications of the test personnel............................................................................................ 5 9. Standard references .................................................................................................................. 5

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LESER
GmbH & Co. KG

processed: Sa approved: refer to M 103600

edition: 27.11.07 replaces edition: 00.00.00

LESER WORKS STANDARD Ultrasonic testing procedure Summary

LWN 331-05-EN page 2

This procedure summarises the standard requirements and describes the procedure of ultrasonic testing at LESER and its documentation. The issue of a certification about the ultrasonic testing carried out can be ordered using the following option code: Option code H03 M56 Certificate LESER CGA (Certificate for Global Application) Inspection certificate 3.1 according to DIN EN 10204 Inspection certificate 3.1 acc. to DIN EN 10204: Ultrasonic test optional Comments

1. General, the principle of ultrasonic testing

Ultrasonic testing, short UT, is an acoustic procedure to detect internal and external material faults and it is a non-destructive testing method. A couplant is put on the test surface of the work piece (for example plaster, gel, water or oil). The entire surface is scanned with the test head, which emits and receives ultrasound from 0,5 to 25 MHz. A change in the acoustic characteristics at the bordering areas (for example cavities, an enclosure, a fissure or any other separation in the unit) inside the part to be tested reflect the sound impulse and sends it back to the swinger in the test head. Using the measured time difference a picture is generated electronically. In this picture the situation can be determined and the size of the fault can be estimated.

2. Application
Ultrasonic testing at LESER is carried out with magnetised and non-magnetised materials and welding seams.

3. Purpose
This LWN summarises the standard requirements and describes the procedure of ultrasonic testing at LESER and its documentation.

4. Testing reference
The following standards were included at LESER for ultrasonic testing: AD 2000 fact sheet A4, casings of equipment parts, edition October 2004 Chapter 6 Testing before commissioning, Point.6.1 The following testing is required for casings of equipment parts: 6.1 (5) Non-destructive testing of the product moulds for casings of equipment parts and the welding seams on pressure bearing walls and ... ASME BOILER AND PRESSURE VESSEL CODE Section VIII Rules for construction of pressure vessels UG -136 Minimum requirements for pressure relief valves UG-136 (f) Welding and other requirements. All welding, brazing, heat treatment, and non-destructive examination used in the construction of bodies, bonnets and yokes shall be performed in accordance with the applicable requirements of this division.
continues on page 3

LESER
GmbH & Co. KG

processed: Sa approved: refer to M 103600

edition: 27.11.07 replaces edition: 00.00.00

LESER WORKS STANDARD Ultrasonic testing procedure

LWN 331-05-EN page 3

DIN 1690

Technical delivery conditions for moulds made of metallic materials

ASME BOILER AND PRESSURE VESSEL CODE Section V Non-destructive examination Type 5: Ultrasonic examination methods for materials ASME B 16.34 Valves flanged, threaded, and welding end Mandatory Appendices IV- Ultrasonic examination: procedure and acceptance standards Ultrasonic testing, testing at LESER

LWN 221-05

5. Testing technology 5.1 Testing instructions

Written instructions have been recorded for each ultrasonic testing, which at LESER is regulated via the test regulation PV 004. These testing instructions have to comply with the minimum requirements that are recorded in DIN EN 583-1, chapter 11. This requirement should determine the testing parameter in such a way that the testing can be repeated in the same manner.

5.2

Testing depth

The ultrasonic testing at LESER is carried out in accordance with the test schedule or customer requirements.

5.3

Test procedure

The standards EN 583-1, 583-2 and 583-5 are the applicable foundations of ultrasonic testing.

5.4
5.4.1

Testing equipment and couplant

Ultrasound device The ultrasound device has to fulfil the requirements in accordance with DIN EN 12668-1 and have the following characteristics (EN 12680-1): - Setup range, gapless selection, minimum from 2 mm to 2 m, - selectable amplification in max 2-dB stages over a range of at least 80 dB with a measuring exactness of 1 dB; - Linearity of the time axis and vertical linearity below 5 % of the set range on the monitor. - Suitable for minimum nominal frequencies of 1 MHz to 5 MHz in impulse echo technology in transducer and SE operation. At LESER ultrasonic testing is carried out with a digital testing device that complies with the above mentioned specifications and characteristics.

5.4.2

Ultrasound testing heads and test frequencies Testing heads and test frequencies have to comply with the requirements in accordance with DIN EN 12668-2 and EN 12668-3 with the following exceptions (EN 12680-1): o the rated frequencies have to be within the range of 1 MHz to 5 MHz ; o for angle beam scanning angle test heads with angles between 35 and 70 have to be used. The test head selection depends on the purpose of the testing and depends on the following characteristics:
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LESER
GmbH & Co. KG

processed: Sa approved: refer to M 103600

edition: 27.11.07 replaces edition: 00.00.00

LESER WORKS STANDARD Ultrasonic testing procedure

5.4.3

LWN 331-05-EN page 4

material thickness, shape and surface condition; Type and metallurgical condition of the material to be tested; Type, position and orientation of the irregularities to be detected.

Couplant You can use several types of couplants (water, couplant paste, oil, grease etc.). The characteristics of the couplants have to remain constant during checking the devices, setting and testing. The couplant has to moisten the test area to secure a sufficient sound transfer. After completion of the testing the couplant will be removed.

5.4.4

Calibration block The calibration blocks to be used are determined in DIN EN 12223 for calibration block no. 1 and in DIN EN 27963 calibration block no. 2 for the ultrasonic testing of welded connections.

5.5

Device setup

The device setup has to be carried out at the beginning of each test interval. The distance has to be set on the monitor of the test equipment using vertical or angle test heads in accordance with EN 583-2. The setup of the time axis and time shift have to be carried out using a calibration block. The sensitivity has to be setup after the distance setup in accordance with EN 583-2. To show irregularities the amplification has to be turned up that the background noise will become visible on the monitor.

5.6

Preparation of the testing, surface preparation

All test surfaces have to be free of dirt, loose contaminations, weld drops etc. and has to show a sufficient even smoothness and contour to enable a satisfactory coupling. The surface roughness of all mechanically processed and to be tested mould surfaces has to be Ra 12,5 m. (DIN EN 12680-1) Each test object has to be clearly identifiable to enable a clear determination during the recording of irregularities.

5.7

Testing

The testing has to comply with the requirements of the used documents (DIN EN 583-1, test regulation PV 004), which has to contain information about the test area and scanning direction and information about type, dimensions, frequency and scanning direction of the used testing heads.

5.8

Description of irregularities, evaluation

Irregularities will be described using at least the following characteristics: - Its position within the test object (x-, y-, z coordinates); - its reflectivity or the maximum amplitude decline of the let out signals - orientation - Size, determined by the half-amplitude method or by other technologies, where the test head is being moved. - Level or unlevelled type. A detailed description of the irregularities is carried out in DIN EN 583-5. The moulds are evaluated in accordance with DIN EN 12680, DIN 1690 and ASME B16.34.
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LESER
GmbH & Co. KG

processed: Sa approved: refer to M 103600

edition: 27.11.07 replaces edition: 00.00.00

LESER WORKS STANDARD Ultrasonic testing procedure

LWN 331-05-EN page 5

The evaluation of the ultrasonic testing on welding seams is carried out in accordance with the in LWN 287-99, chapter 9.1.3 stated standards and/or regulations.

6. Acceptance criterion
The moulds will be evaluated in accordance with DIN EN 12680, DIN 1690 and ASME B16.34. The evaluation of the ultrasonic testing on welding seams is carried out in accordance with the in LWN 287-99, table 19 stated standards and/or regulations.

7. Documentation, option code

The issue of a certification about the ultrasonic testing can be ordered using the following option code: Option code H03 M56 Certificate LESER CGA (Certificate for Global Application) Inspection certificate 3.1 according to DIN EN 10204 Inspection certificate 3.1 acc. to DIN EN 10204: Ultrasonic test optional Comments

8. Qualifications of the test personnel

The personnel for the ultrasonic testing is qualified and certified in accordance with DIN EN 473 and SNT-TC 1A. The level of qualifications of the personnel for ultrasonic testing at LESER corresponds with ZfP- Training UT Level I and Level II.

9. Standard references
AD 2000 fact sheet A4 DIN EN 583- 1 DIN EN 583- 2 DIN EN 358- 5 DIN EN 12680-1 DIN EN 12680-3 DIN 1690 DIN EN 473 DIN EN 10204 ASME code, Section VIII ASME code Section V ASME B 16.34 SNT-TC 1A PV 004 Casings of equipment parts, edition October 2004 Chapter 6 testing before commissioning Non-destructive testing ultrasonic testing Part 1 General principles Non-destructive testing ultrasonic testing Part 2 sensitivity and distance setup Non-destructive testing ultrasonic testing Part 5 Description and determination of size of irregularities Moulding ultrasonic testing; Part 1: steel moulds for general usage. Moulding ultrasonic testing; Part 3: iron moulds with nodular graphite Technical delivery conditions for moulds made of metallic materials Non-destructive testing- qualification and certification of personnel of the non-destructive testing General principles Metal products, Types of test certificates Rules for Construction of Pressure Vessels, Division 1 Non-destructive examination Valves-Flanged, Threaded, and Welding End Personnel Qualification and Certification in Non-destructive Testing Test regulation ultrasonic testing
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LESER
GmbH & Co. KG

processed: Sa approved: refer to M 103600

edition: 27.11.07 replaces edition: 00.00.00

LESER WORKS STANDARD Ultrasonic testing procedure

LWN 287-99 SVs. LWN 289.01 DIN EN 12668-1 DIN EN 12668-2 DIN EN 12668-3

LWN 331-05-EN page 6

Standard requirements for welding construction groups at LESER Technical delivery conditions for moulds made of metallic materials Non-destructive testing Characteristics and verification of the ultrasonic testing-Testing equipment Part 1: Test equipment Non-destructive testing Characteristics and verification of the ultrasonic testing-Testing equipment Part 2: testing heads Non-destructive testing Characteristics and verification of the ultrasonic testing-Testing equipment Part 3: Complete testing equipment Non-destructive testing ultrasonic testing description of the calibration block no. 1 Welded steel connections calibration block no. 2 for ultrasonic testing von welded connections

DIN EN 12223 DIN EN 27963

End of LWN

LESER
GmbH & Co. KG

processed: Sa approved: refer to M 103600

edition: 27.11.07 replaces edition: 00.00.00

T h e S a fe ty V a lve
Inspection certificate 3.1 according to DIN EN 10204

ULTRASONIC TEST [Option code M56]

LESER GmbH & Co. KG Postfach 26 16 51 20506 Hamburg, Germany

. . .

Customer Order No.: LESER Job No.: LESER-Customers-No.: LESER-Contact: Fon: Fax: eMail:

xxx xxx xxx xxx + 49 (40) 25 165+ 49 (40) 25 165-500 xxx@leser.com

This LESER inspection certificate confirms that the test object was tested according to the undermentioned test references.

1 Test object
xxx xxx xxx
Art.-No. xxxx.xxxx Cold differential test pressure x,x barg LESER Job No. xxx xxx,xx psig Pos.No. xx Option Code: Further SV-Info: xxx xxx Nominal size Inlet xxx xxx xx Outlet xx Pressure rating Inlet xx Outlet xx

Tag No. xxx

Serial No.

Material

Tested component
Pos. 1 Description xxx Material xxx Manufacturer xxx Heat No. / Batch xxx

2 Test reference
Ultrasonic test acc. to: AD 2000-Merkblatt A4, chapter 6 ASME Code, Section VIII Div. 1, UG-136(f) LESER Works Standard LWN 331-05

3 Procedure 4 Equipment
Testing equipment (DIN EN 12688-1): Search units (DIN EN 12688-2): Couplant: Calibration Block Requirements: Qualification of the test personnel: Digital ultrasonic test unit USK 7B MB4F Couplant Calibration Block No. 1 (DIN EN 12223), Calibration Block No. 2 (DIN EN 27963) UT Level I, UT Level II (DIN EN 473 and SNT-TC 1A)

5 Acceptance criteria
The castings will be evaluated in accordance with DIN EN 12680, DIN 1690 and ASME B16.34. The evaluation at the welding seams will be carried out in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99.

6 Test result
The test was realised without any objection. The requirements of the test references are fulfilled. Manfred Orlowski Inspection Representative
This certification is written digitally and requires no handwritten signature. (Acc. to EN 10204, chapter 5)

Hohenwestedt, xx.xx.200x

LESER GmbH & Co. KG Hamburg HRA 82424

GF BoD Joachim Klaus, Martin Leser 20537 Hamburg, Wendenstr. 133 135 20506 Hamburg, P.O. Box 26 16 51 ( )

Fon +49 (40) 251 65-100 Fax +49 (40) 251 65-500 E-Mail sales@leser.com Internet www.leser.com

Bank HypoVereinsbank Hamburg BLZ 200 300 00, Konto Account 3203171 BIC: HYVEDEMM300 IBAN: DE64 2003 0000 0003 2031 71 USt-ID VAT-Reg DE 118840936

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